Challenge Titan 200 Technical reference manual

The Challenge Machinery Company provides owner's
manuals on its products solely as a courtesy to its customers.
See the information below before using this manual.
These manuals are for reference only. These manuals include products which are non-
current, unsupported or no longer produced by The Challenge Machinery Company, and are
provided solely as an accomodation to our customers. By providing these manuals, The
Challenge Machinery Company makes no representation or warranty as to the products,
their current condition, or their suitability or fitness for use in any particular application, which
are the sole and independent responsibility of the product owner and user.
Older products may not comply with current safety procedures, guidelines or regulations,
and it is the product owner's and user's responsibility to evaluate the suitability and fitness of
the products in their current use and application. The Challenge Machinery Company makes
no representation, warranty or recommendation regarding any modifications which may be
required on non-current or unsupported products. The Challenge Machinery Company
assumes no liability for any modification or alteration to any Challenge product, and any such
modification or alteration to any Challenge product is not authorized by The Challenge
Machinery Company. The availability of these manuals is solely for the purpose of providing
reference information for the products.
This manual may not be complete in all aspects of product maintenance and repair. All
products should be used only by qualified and properly trained personnel, following proper
safety procedures. All products should be regularly inspected and maintained, and their condition,
application and use should be periodically evaluated by qualified personnel. Only qualified and
properly trained technicians should perform maintenance, repair and replacement
procedures. Attempting t hese 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.

Instruction and
Parts Manual
TITAN 200
Paper Cutting
Machine
Power Backgauge &
Programmable Models
This manual covers serial numbers 961001 & up.
ALWAYS GIVE THE SERIAL NUMBER OF YOUR MACHINE WHEN WRITING.
Sold and serviced by
SERIAL NO-
UPGRADE CODE-
THE CHALLENGE MACHINERY COMPANY
1433 Fulton Avenue/Grand Haven, Michigan 49417-1594 U.S.A. • Phone: [phone] • Fax: [phone] F.200
This safety alert symbol means CAUTION OR WARNING-PERSONAL SAFETY
INSTRUCTION. Personalinjury mayresult ifsafety precautionsare notcarefully readbefore
attempting to operate or repair this machine. See SAFETY PRECAUTIONS, pg. 7.
•ThismachineisdesignedforONE PERSON OPERATION ONLY!
•AlwaysDISCONNECT THE POWER before workingonthis machine.
•DO NOT OPERATE WITHANYGUARDS REMOVED! Replaceall guardsbeforeoperating.
•CUT/CRUSH HAZARD -Keep handsfrom underpaper clampand knife.
SAFETY ALERT
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

F.200/TITAN 200/MAR 97
2
INTRODUCTION
WELCOMEto thefamilyof Challenge®users. Challengehas beendeveloping and manufacturingGraphics Arts
Equipmentforover 100yearsand istodayone oftheworld’s leading producersand distributors ofPaper Cutters,
Paper Drills and Bindery Equipment.
THE CHALLENGE REPUTATIONis importanttoyou as auserfor thecontinuous,ready availability ofpartsand
service.
THIS MANUALis designedtohelp yougetthe mostfromyour Challengeequipment. Keepthis manualina safe,
convenient place for quick reference by operators and service personnel.
SAFETYALERT! This symbol meansCAUTION OR WARNING: Personal safety instructions! Pay
special attention to the instructions in bold type. Personal injury may result if the precautions are not
readand followed.
READ THIS MANUAL BEFORE OPERATING! Follow precautions and instructions given and you should have
yearsof trouble-freeoperation. Ifafterreadingthe manualquestionsstillremain,contact yourAuthorizedChallenge
Dealer or the Challenge Service Department. For the dealer nearest you or for service questions call (616)-842-
8300.
FOR PARTS AND SERVICEcontact theAuthorizedChallenge Dealerfromwhom you purchasedyour machine.
Use the illustrations and parts lists at the back of this manual to identify the correct parts needed. Always give
the SERIAL NUMBER and MODELof yourmachineto insurethatthe correctpartsare sentassoon aspossible.
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 this manual and return it
DIRECT 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, 1433 Fulton Avenue, Grand
Haven, MI 49417-1594. Fax [phone]. Phone [phone].
CHALLENGE MODEL SERIAL NUMBER
ATTN COMPANY
ADDRESS
CITY STATE ZIP
PHONE DATE INSTALLED
DEALER’S NAME AND CITY
PLEASE REVIEW THE ENCLOSED WARRANTY SHEET!
It is very important that you read and understand the conditions outlined in the Warranty Information Sheet
included with the manual information package.
The Warranty Information Sheet must be filled out completely, returned, and beON-FILE at THE CHALLENGE
MACHINERY COMPANY in order for the warranty to be issued for this machine.
WARRANTY INFORMATION
Challenge® is a registered trademark of The Challenge Machinery Company. 1433 Fulton Avenue, Grand Haven, MI 49417.
Copyright © 1997 by The Challenge Machinery Company. All rights reserved. Printed in the U.S.A.
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

3
F.200/TITAN 200/MAR 97
PACKING LIST
Part No. Description Qty.
A-10034 Knife..................................................................................... 2
4166 Cutting Stick (in addition to one installed in machine) .......... 3
F.200 Instruction and Parts 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
S-1245-5 Knife Lifters ................................................................... 2
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 1/2” 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 Sticks (in addition to one installed in machine)
20-2150-3 Optional Tool Kit
8815 Knife Washers, Special.................................................. 6
H-6918-608 Knife Bolts, 3/8-16 x 1” .................................................. 6
W-131 5/16” Allen Wrench ........................................................ 1
W-134 7/32” Allen Wrench ........................................................ 1
W-154 3/32” Allen Wrench ........................................................ 1
W-170 1/2” x 9/16” Wrench ....................................................... 1
5064 Cutting Stick Puller ........................................................ 1
SU-10-113 Grease Brush ................................................................ 1
E-1075-10SB 10 amp slo-blo fuse (230 V)........................................... 2
E-1075-15SB 15 Amp slo-blo fuse (120 V) .......................................... 2
E-889-12 1/2 Amp slo-blo fuse...................................................... 1
E-889 1-1/4 Amp slo-blo fuse................................................... 1
E-2330 1 Amp T (metric 230 V) ................................................. 1
E-2330-3 2 Amp T (metric 120 V) ................................................. 1
E-2330-5 3.15 Amp T (metric)....................................................... 3
E-2789 Cut button replacement lamp......................................... 1
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

F.200/TITAN 200/MAR 97
4
SPECIFICATIONS
CuttingDimensions
Cutting Width 20” (508 mm)
Minimum Cut* ½” (13 mm)
Clamp Opening 3¼” (83 mm)
Table Space
Front: 16” (406 mm)
Back: 20” (508 mm)
Machine Dimensions
Table Height 36” (91 cm)
Overall Height 53” (135 cm)
Overall Length** 49” (124 cm)
Overall Width 36” (91 cm)
Net Weight (Approximate) 755 lbs (342 kg)
Shipping Weight (Approximate) 950 lbs (431 kg)
Electrical
120 Volts (±10%)/16Amps, 1 Phase 60 Hz, AC. Service size 20Amps
120 Volts (±10%)/16Amps, 1 Phase 50 Hz, AC. Service size 20Amps
208-230 Volts (±10%)/12Amps, 1 Phase, 60 Hz,AC. Service size 15Amps
208-230 Volts (±10%)/12Amps, 1 Phase, 50 Hz,AC. Service size 15Amps
Recommended Recepticle: 120 Volt, NEMA5-20R
RecommendedRecepticle:208-230 Volt, NEMA6-15R, NEMA6-20R
SoundEmission
A-weightedsound pressurelevelmeasuredinan enclosedroom atoperatorlevel(6feet/
183cm):
Machine cutting a full lift of paper: 77 dB
*With false clamp plate attached, minimum cut is 1-7/8” (48 mm).
**With table, front guard, and foot treadle removed, can be fit through a 28” (71 cm) door opening.
Challenge reserves the right to make changes to any product or specification without notice and without
incurring responsibility to existing units.
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

5
F.200/TITAN 200/MAR 97
TABLE OF CONTENTS
INTRODUCTION........................................................................................................ 2
PACKING LIST........................................................................................................... 3
OPTIONAL ITEMS ..................................................................................................... 3
SPECIFICATIONS...................................................................................................... 4
SAFETY PRECAUTIONS........................................................................................... 7
CAUTION: POWER LOCK-OUT PROCEDURE........................................................ 7
¡OJO!.......................................................................................................................... 8
WARNING LABEL DEFINITIONS .............................................................................. 9
INSTALLATION & SETUP........................................................................................ 10
Uncrating ..................................................................................................... 10
Cleaning ...................................................................................................... 10
Removing the Table (to fit through a narrow door opening) ......................... 10
Removing the Foot Treadle ......................................................................... 11
Removing the Front Guard .......................................................................... 12
Reattaching the Table.................................................................................. 12
Hydraulic System Check.............................................................................. 12
Power Hook-Up ........................................................................................... 12
KnifeInstallation/Changing .......................................................................... 13
Knife Removal....................................................................................... 13
KnifeInstallation .................................................................................... 14
False Clamp Plate (Optional)....................................................................... 15
Line Light ..................................................................................................... 15
OPERATING CONTROLS ....................................................................................... 16
USING THE MACHINE ...................................................................................... 16
Power - Main Power Switch ......................................................................... 16
Start Up ....................................................................................................... 16
Making a Cut ............................................................................................... 16
Jogging Aid.................................................................................................. 17
Knife Change Alarm and Lubrication Alarm ................................................. 17
Manual Clamping (Using the Foot Treadle) ................................................. 17
DEFINITION OF KEYS ...................................................................................... 18
Backgauge Glide Control ............................................................................. 18
IN/MM Key................................................................................................... 18
SEND Key ................................................................................................... 18
Push-Out Key .............................................................................................. 18
Clear Key..................................................................................................... 18
Enter Key..................................................................................................... 18
Priority Add (X/Y) Key.................................................................................. 19
Soft-Keys..................................................................................................... 19
Arrow Keys .................................................................................................. 19
Contrast Control .......................................................................................... 19
SEND MODE ..................................................................................................... 19
Entering Math .............................................................................................. 19
Entering Fractions........................................................................................ 19
Upgrading Power Backgauge Models to Programmable Models ................. 19
MAINTENANCE MODE ..................................................................................... 20
Language..................................................................................................... 20
Parameters .................................................................................................. 20
False Clamp .......................................................................................... 20
Time-out ................................................................................................ 20
Push-out................................................................................................ 20
Accuracy Adjust .................................................................................... 20
Knife count ............................................................................................ 20
Machine count....................................................................................... 21
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

F.200/TITAN 200/MAR 97
6
MAINTENANCE MODE (cont.)
Diagnostic.................................................................................................... 21
Error Code ............................................................................................ 21
Sensor Data .......................................................................................... 21
Clear Memory........................................................................................ 21
Knife Adjust ................................................................................................. 21
JOB MODE ........................................................................................................ 21
Lock/Unlocking a Job................................................................................... 21
Copying a Job.............................................................................................. 21
Erasing a Job............................................................................................... 22
Creating a New Job ..................................................................................... 22
Entering Send Values............................................................................ 22
Cut and Record ..................................................................................... 22
Channel Linking..................................................................................... 22
Editing an Existing Job ................................................................................ 22
Running a Programmed Job ........................................................................ 23
Exiting a Job ................................................................................................ 23
AN EXAMPLE JOB ............................................................................................ 23
OPERATING TIPS ................................................................................................... 24
KNIFE TIPS.............................................................................................................. 24
Knife Blade Life............................................................................................ 25
Cutting Stick ................................................................................................ 25
Bevel Angle ................................................................................................. 25
HelpfulSuggestions..................................................................................... 25
Knife Care.................................................................................................... 25
NOTE TO DEALER .................................................................................................. 26
TECHNICAL SECTION FOR TRAINED PERSONNEL ONLY
NOTICE.................................................................................................................... 27
TROUBLESHOOTING ............................................................................................. 28
MAINTENANCE ....................................................................................................... 28
Recommended Oils ..................................................................................... 30
ADJUSTMENTS ....................................................................................................... 31
Backgauge Gib Adjustments........................................................................ 31
Squaring the Backgauge.............................................................................. 31
Proximity Switches ...................................................................................... 32
Hydraulic Valve Adjustments ....................................................................... 33
Pressure Settings:................................................................................. 33
Procedure: ............................................................................................ 33
MAIN ASSEMBLY - FRONT VIEW........................................................................... 34
MAIN ASSEMBLY - RIGHT SIDE VIEW................................................................... 36
MAIN ASSEMBLY - TABLE ASM. VIEW .................................................................. 38
BASIC MACHINE SCHEMATIC ............................................................................... 40
ELECTRICAL SEQUENCE OF OPERATION .......................................................... 41
HYDRAULIC POWER UNIT ..................................................................................... 42
HYDRAULIC SEQUENCE OF OPERATION............................................................ 43
POWER PANEL ASSEMBLY ................................................................................... 44
CONTROL PC ASSEMBLY...................................................................................... 46
CONTROL CONSOLE ASSEMBLY ......................................................................... 47
KNIFE LATCH ASSEMBLY ...................................................................................... 48
LINE LIGHT ASSEMBLY.......................................................................................... 49
POWER PANEL LABEL ........................................................................................... 50
SAFETY SYSTEM TESTS ....................................................................................... 51
TABLE OF CONTENTS (cont.)
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

7
F.200/TITAN 200/MAR 97
•This machine is designed and safeguarded for ONE PERSON operation. NEVER operate the cutter with more
than one person.
•Safety is the responsibility of the user of this machine. Use good judgement and common sense when working
with and around this machine.
•READ and understand all instructions thoroughly before using the cutter. If questions still remain, call your
Authorized Challenge Dealer - fingers and hands are too valuable to risk experimentation.
•Only trained and authorized persons should operate the cutter.
•DO NOT ALTER SAFETY MECHANISMS, they are for your protection and should not be altered or removed.
Severe lacerations or dismemberment could result.
•DISCONNECT POWER before cleaning, lubricating, servicing or making adjustments not requiring power. Turn
the main disconnect switch to the off position and disconnect the power plug, see Disconnect Procedure
below.
•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!
SAFETY PRECAUTIONS
For maximum safety and to prevent unauthorized
use, turn the power switch to the off position and
disconnect the power cord whenever adjusting, lu-
bricating, or making repairs to the machine.
CAUTION: POWER LOCK-OUT PROCEDURE
(fig. 1)
Thissafety symbolmeans CAUTION/WARNING -PERSONALSAFETYINSTRUCTION.Read the
instructions because it has to do with safety. Failure to comply with the following instructions
may result in personal injury.
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

F.200/TITAN 200/MAR 97
8
• Esta maquina, junto con sus mecanismos de seguridad, esta disenada para ser manejada por
UNA SOLA PERSONA a la vez. Jamas debe ser manejada por mas de una persona al mismo
tiempo.
• La seguridad es la responsabilidad del operario que usa esta maquina.
• LEADETENIDAMENTEelmanualdeinstruccionesylasPRECAUCIONESDESEGURIDADantesdeponer afuncionar
la cortadora. Pidale a su supervisor una copia.
• El manejo de la guillotina debe estar exclusivamente a cargo de personal entrenado y autorizado para ello.
• NO MODIFIQUE LOS MECANISMOS DE SEGURIDAD, estan ahi para su proteccion no deben ni modificarse ni
quitarse.
• DESCONECTE LA CORRIENTE ELECTRICA antes de proceder a hacerle servicio de limpieza, engrasar, o de
haceradjustes que no requieren corriente. Trabe el interruptor en la posicion OFF(apagado); vea “Procedimiento
para cortar la corriente electrica” al pie de esta pagina.
• Eche llave a la guillotina y quite la llave cuando la maquina no esta en operacion; vea “Corriente electrica”.
• Asegurese de que la guillotina este debidamente a tierra. Vea “Conexion de la fuerza electrica”.
• Verifique el voltaje y asegurese de que este sea suficiente para el debido funcionamiento de la guillotina.
• Preste atencion a todas las placas con advertencias instaladas en esta guillotina.
• No permita que objetos estranos esten en la mesa o cerca de la cuchilla cortadora.
• TENGA SUMO CUIDADO al tocar y cambiar la cuchilla. Heridas severas y hasta desmembramiento pueden
resultar del manejo sin cuidado o negligente.
• El suelo alrededor de la guillotina debe mantenerse despejado y libre de recortes, desperdicios, aceite y grasa.
• Al haber la necesidad de reemplazar partes hidraulicas, afloje todas las conexiones poco a poco para dejar
escapar la presion. Jamas debe aflojarse conexiones mientras la maquina este
andando.
• Si la guillotina empezara a sonar o trabajar diferentemente a lo acostumbrado, desconectela y consulte la
seccion “Troubleshooting” (Reparador) de este manual. Si no es posible corregir el problema, llame a su
servicio autorizado para que le examinen la maquina.
• PELIGRO DE MACHUQUE - Mantenga manos y dedos fuera de la agarradera mientras sujeta el papel. Use el
calibrador trasero y su rueda de mano para empujar el papel cortado. NO PONGA SUS MANOS BAJOLA
CUCHILLA O AREA DE LA AGARRADERA.
• NO OPERE SIN LAS GUARDAS PROTECTORAS!
¡ OJO ! PRECAUCION - Como proceder para desconectar
la corriente electrica.
Para maxima seguridad durante ajustes y reparaciones de su maquina, verifique bien que el interruptor principal de control
de corriente al cual la maquina esta conectada, este desconectado. El interruptor deba ser puesto en la posicion “OFF”
(desconectado) y se debe poner un candado en la anilla. La llave del candado debe ser guardada por la persona que
estara efectuando los trabajos de servicio o de reparacion en la guillotina.
Desconecte la corriente electrica antes de proceder a hacer cualquier ajuste o reparacion o de efectuar el engrase en
cualquier maquina.
¡OJO!
This Este simbolo de alerta de seguridad significa ¡ OJO ! - INSTRUCCIONES DE
SEGURIDADPERSONAL. Lea las instrucciones porque se refieren a su seguridad personal.
Fall de obedecer las instrucciones que siguen podria resultar en lesiones corporales.
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

9
F.200/TITAN 200/MAR 97
SINGLE OPERATOR
SHOCK HAZARD
SHOCK HAZARD
HAZARDOUS AREA
Do not operate with more than one person.
Disconnect power before removing cover. Replace
cover before operation.
Disconnect power before removing cover. Replace
cover before operation.
Disconnectpower beforecleaning,servicing,ormaking
adjustments not requiring power. Do not alter safety
guardsordevices,theyare foryourprotection. Replace
all guards, do not operate with any guards removed.
WARNING LABEL DEFINITIONS
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

F.200/TITAN 200/MAR 97
10
INSTALLATION & SETUP
Uncrating
Your cutter has been carefully packaged to prevent
damageduring shipping. Inspectallshipmentsassoon
as they are received. Note any damage on the freight
billand notifythe claimsdepartment ofthecarrierwithin
15 days. All claims for damage are the responsibility
of the receiver, so remember to inspect promptly.
Check the contents of the crate against the packing
list at the front of this manual.
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 packed in a separate
box which is shipped inside the machine.
Remove the carton by removing the nails or staples
holdingit totheskidandliftitstraight upover thecutter.
If you don’t have the ceiling clearance to do this,
carefullyslitthe cartondownthe sideandthen unwrap
it from around the cutter.
Remove the accessory box. 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.
Using the rear bumper board, pry one side of the
machine up, and slide out the top layer of the support
riser (fig. 2). Do the same on the other side.
Use the flat board provided as a ramp and position as
shown in fig 3. 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.
Cleaning
Afterunpacking,wipedownallmachinepanelsandclean
thetablesurface.
Removing the Table (to fit through a narrow door
opening)
TheTitan200 cutterwillnot fitthrough an openingless
than36” (91cm) withoutthe tablebeing removed. With
the table removed, the Titan 200 will fit through a 35”
(89 cm) opening. With the table, front guard, and foot
treadleremoved,itwillfit througha28”(71 cm)opening.
To remove table:
Makesurethe knife andclampare inthe“up” position.
Ifthey arenot,readthePower Hookupsection onpage
12to connectpower tothemachine. Turnonthepower
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.
Removethe plexiglasscoverandthethreesheetmetal
coverson therear ofthe table. Removethe backgauge
motor cover, the rear table support leg, the lower back
panel, and the lower front cover of the machine.
(fig. 3)
(fig. 2)
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

11
F.200/TITAN 200/MAR 97
Unplug the cable to the motor encoder at the back of
the machine (fig. 4).
Remove the motor junction box cover and disconnect
the wires to the motor (fig. 5). Remove the leadscrew
cover and the nylon tyraps that are attached to the
bottomof thetable. The motorwiresandencoderwires
should now be free from the table.
From the front of the machine, remove the presetter
board assembly from the table (fig. 6).
Open the front guard, open the top cover and remove
the left and right side guides and the cut stick stops as
shown in figures 7 and 8.
Next, remove the cut stick from the table using the cut
stick removal tool and tap out the two taper pins from
the bottom side of the table. 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.
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
Motor Junction
Box Cover
(fig. 5)
Presetter Board
Assembly
(fig. 6)
Left Side
Guide
(fig. 7)
Cut Stick Stop
(fig. 8)
Right Side
Guide
Cut Stick
Encoder Plug
Rear Support Leg
(fig. 4)
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

F.200/TITAN 200/MAR 97
12
tothe basewhich holdup thefoot treadle. Nowremove
the pins at the rear pivot points of the foot treadle.
Remove the treadle.
Removing the Front Guard
Make sure the power is off and disconnect the power
cord. Open the front guard. Remove the cylinder
bracket screws (fig. 9).
Then open the top hood and remove one set of hinge
screws (fig. 10). Slide the front guard out of the other
hinge.
Reattaching the Table
Setthetable in position. Liftup the tablefromthe front
and set the front two spacers in place. Then start the
front two socket head screws. Then lift the table from
the rear and set the rear two spacers in place. Start
the rear two socket head screws. Replace the two
taperpins,then tightenall fourscrews. Attachthe right
and left side guides (fig. 7 & 8), the presetter board
assembly(fig.6), the motorand encoder wires(fig’s.4
& 5), and all guards and panels.
Once the table is installed, the backgauge accuracy
willhave tobereadjusted. Todothis,seethe “Operator
Controls/Maintenance Mode/Parameters/Accuracy
Adjust” section of this manual.
Hydraulic System Check
The Titan 200 is powered by a hydraulic system
consisting of an electric motor coupled directly to a
hydraulic pump. The pump is a gear type pump with a
fixed output of 1.5 gallons-per-minute at 1200 psi at
1725 RPM.
Thebiggestadvantage ofahydraulic systemissafety.
The knife and clamp immediately return to the up
position should the front guard be raised at any time
during a cut cycle.
The hydraulic reservoir holds 4 quarts (1 gallon) of
hydraulicfluid. Itis filledwith Rykon100hydraulic fluid
at the factory but should be checked before operation.
A cross reference chart of approved fluids is provided
in the Maintenance section of this manual (pg. 28).
Remove the front panel cover and unscrew the
hydraulic plug on top of the tank (fig. 11). Fluid level
should be at 1/8” from the end of the dip stick (check
withdipstick cap screwedin). Topoff ifnecessarybut
avoidoverfillingas thiscouldcause leakagewhenhot.
Replacethefrontpanel.
The hydraulic fluid should be checked weekly and
changed AT LEAST ONCE-A-YEAR or after every
1,000 hours of operation.
Power Hook-Up
Hinge
Screws
(fig. 10)
Bracket
Screws
(fig. 9)
Dipstick
(fig. 11)
CAUTION: NEVERCUT THEGROUND
LUG OFF of a 3-prong plug to fit a 2-
prong socket! You run the risk of
electrical shock which could cause personal
injury or death.
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

13
F.200/TITAN 200/MAR 97
It is the customer’s responsibility to provide a properly
groundedreceptaclethat meetsthepowerrequirements
specifiedonthe nameplateof this machine,as well as
all local electrical codes. Have a qualified electrician
install one if your location is not so equipped.
Connect the power cord into a grounded, 3-prong
receptacle only! (Recommended receptacle: 120volt,
NEMA5-20R.208-230volt, NEMA 6-15R,orNEMA 6-
20R.
Knife Installation/Changing
Theknifechangingequipmentshowninfig.12isincluded
in the cutter tool kit. The following instructions show
howtoremove and install anewor resharpened knife.
ReadthroughtheseinstructionsATLEASTONCEbefore
attempting to actually change or install any blades.
Knife Removal
1. Makesuretheknifeandclampareinthe“up”position.
Turn the main power switch to the “OFF” position and
disconnectthemachinepowercordtopreventaccidental
power-upwhile servicingthecutter.
2.Back offtheknifeadjustingscrewsontopoftheknife
bar several turns (fig. 13). A new knife will cut deeper
thanone thathasbeengroundseveraltimes. Failureto
back off the screws could damage the knife and/or the
cutting stick.
3. Removetheknifeboltsfromthetwoslottedknifebar
holesandreplacewiththe knifelifters (fig.14). Tighten
the lifters to hold the knife in place, then remove the
remainingknifebolts.
4. Clear the table surfaces and place the empty knife
scabbard on the table. Remove the scabbard’s knife
Knife Adjusting Screws
(fig. 13)
(fig. 14)
(fig. 12)
5/16”
T-Wrench
Knife Lifters
Cut Stick
Removal Tool
3/16”
Hex Allen
Wrench
CAUTION: Changing knives can be
very dangerous unless safety
precautions are observed and
extreme care is taken when handling knives.
•Make sure knife lifters are properly
installed, see instructions following.
•Keep handling of unprotected knives to an
absolute minimum.
•Clear off cutter table before removing
knife.
•Have scabbard on cutter table and insert
knife immediately.
•Warn people of any unprotected knife.
•Knife changing is a ONE PERSON
OPERATION. Having more than one
person trying to change knives invites
accidents.
CAUTION: Knives are heavy and
always very sharp! Be sure to keep
the edge away from your body and
keep other people out of the area while
handling the blade. Severe lacerations or
dismemberment could result from careless
handling procedures.
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F.200/TITAN 200/MAR 97
14
retainingscrews.
5. Grasp the knife lifters firmly and, at the same time,
turn them counterclockwise to release the knife from
theknife bar(fig.15). Lowertheleftendfirst, thenlower
the right end as you shift the knife sideways to the left.
Bringtherightend oftheknifearoundtheknifebarguide
frame. Maneuvertheright endinto the spacebetween
theguideframeandtheshroudastheleftendisbrought
clearofthe leftguide frame. Move theknife totheright
then bring the knife out of the cutter, left end first. Put
the blade in the scabbard immediately and secure the
kniferetainerscrews.
Knife Installation
1. Makesure theknife andclamp arein theupposition.
If they are not, turn on the power using the red and
yellow main power switch, close the front guard, and
presstheCLEARbutton. Thiswillpresetthebackgauge
and send the knife and clamp up.
2. Turn off the machine and unplug the power cord.
3. Pull out the cutting stick using the cut stick removal
tool and turn it to a new surface. If the cutting stick is
notlevelor flushwiththe table, 1/2”stripsof papercan
be placed in the table slot under the cutting stick to
shim it.
4. Remove the left retainer screw from the new blade
and screw the knife lifters into the new blade. Screw
the lifters all the way in and then back them out 3/4
turn).
5. Remove the other scabbard retainer screw.
6. Double check to make sure the knife adjusting
screws have been backed out all the way (step #2,
Kniferemoval). Liftthe bladeand insert itinto theknife
barslot. Guide theblade, rightedgefirst,intothespace
between the shroud and the knife bar guide frames.
Tip to clear the table side guides, then move the left
endoftheblade into the knifebarslot dropping the left
end as the right end is brought around the right knife
bar guide frame and up into the knife bar slot. Raise
the knife into the knife bar slot as high as it will go and
tighten the lifters.
NOTE: If the blade will not go in, either the lifters are
screwed into the blade too far, or the end of the blade
is hitting the cylinder bracket at the right end of the
knifeslot.In this case, droptheleft end when inserting
the knife.
7. Insert the knife bolts with washers and snug to hold
the knife, but don’t tighten them yet.
8. Remove the knife lifters one at a time and replace
with bolts and washers.
9. Place a few sheets of paper over the cut stick,
covering the stick end-to-end.
10. Plug in the power cord and turn the power on.
11. Go to the MAINTENANCE screen and choose
KNIFE ADJUST. Choose KNIFE DOWN, close the
guard,andpress thecutbutton to sendtheknife tothe
down position (for more details on how to do this, see
the “Operator Controls/Maintenance/Knife Adjust”
section, pg. 21).
12. Turn the power off and disconnect the machine
power cord.
13. Turn the knife adjusters down evenly, a little at a
time, until the knife cuts through the bottom sheet of
paper the entire length of the cutting stick (fig. 16).
Turningthe screwsdown evenlyprevents unevenwear
on the knife and cutting stick.
14. Plug in the power cord and turn the power on.
(fig. 16)
(fig. 15)
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15
F.200/TITAN 200/MAR 97
15. Close the front guard and press CLEAR. This will
raise the knife and clamp to the up position.
16. Turn the power off and disconnect the machine
power cord.
17. Tighten all knife bolts securely.
18. Plug in the power cord and turn the power on.
Make a test cut through a full lift of paper and make
minor adjustments if necessary by repeating steps 9
through17. NOTE: Ifthe knifeendscut butthe middle
doesn’t, you could have dips or uneven spots in the
knife and/or cutting stick. These can be eliminated by
placing 1/2” strips of paper in the table slot beneath
the cutting stick to shim it.
19. Sendthedullknifetoaknifegrinder. Donotattempt
tosharpen yourown knives! Seethe KnifeTips section
(pg. 23) to determine the knife bevel angle.
False Clamp Plate (Optional)
Topreventmarking on pressuresensitivejobs, afalse
clamp plate is available as an optional item for your
machine. This plate attaches to the bottom of the
clamp. It is secured with wing nuts on studs that pass
through the top of the clamp.
To install:
1. Makesure theknife andclamp arein theupposition.
If they are not, 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.
2. Turn the power off and disconnect the power cord.
3. Openthefront guardandslide thefalse clamp plate
under the knife and clamp (fig. 17), and slide the plate
upintoposition withthelocator pins towardthe front of
the machine. The locator pins insert into holes in the
bottom front of the clamp.
4. Hold the plate in position and secure with the wing
nuts provided.
5. Change the false clamp setting of the machine to
ON to prevent the backgauge from crashing into
thefalse clampplate. ThisisdoneintheMaintenance
Mode/Parameters/False Clamp screen. For more
details on how to do this, see the Operating Controls/
Maintenance Mode/Parameters section (pg. 20).
NOTE: The minimum cut with the false clamp plate
attached is 1-3/4”
Line Light
TheTitan 200isequippedwithtwo lightswhich provide
a line of light on the paper in the approximate location
ofwhere thepaper willbe cut.Thelightscomeonwhen
powertothemachineis turnedon. Thelight fromeach
bulbreachesthe table afterpassingbetween the knife
and clamp. Each light is focused with a socket head
capscrew (fig. 18).
To Adjust:
1. Place a wide sheet of paper on the cut stick to view
the line light.
2. Using a 3/16” hex allen wrench, turn one of the cap
screws until you see a 1/16-1/8” beam. Note: it is best
to start by turning the screw clockwise. If the screw
turnsallthe wayinbefore aline appears, beginturning
the screw counterclockwise.
3. Similarly, turn the adjustment screw of the other
(fig. 18)
Line Light
Adjustment
Screw
(fig. 17)
Locator Pins
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F.200/TITAN 200/MAR 97
16
bulb,untilone continuous beamis seen acrossthecut
stick.
Bulbreplacement:
1. Make sure power is off and unplug the machine
(see power lockout procedure, pg. 7).
2. Open the front guard.
3. Removetheold bulbbylightly pushing thebulbinto
thesocket andturning itcounterclockwise. CAUTION!-
If the bulb is still hot, allow a few minutes for it to cool.
4. Insert the new bulb into the socket and twist it
clockwise until the bulb locks into place.
5. Reconnect power and turn the main power switch
on. Readjust the line if necessary.
OPERATING CONTROLS
IMPORTANT: DO NOT ATTEMPT TO OPERATE
THE CUTTER UNTIL YOU HAVE THOROUGHLY
READ AND UNDERSTAND ALL OF THE
FOLLOWING INSTRUCTIONS. CALL YOUR
AUTHORIZED CHALLENGE DEALER IF YOU STILL
HAVE ANY QUESTIONS.
USING THE MACHINE
Power - Main Power Switch
Powerisbrought tothemachine whenthemain power
switchisturnedtothe“ON”position(fig.19). Thedisplay
andlinelights areturnedon atthistime. The hydraulic
motor will not be activated until a cut cycle is initiated,
and it will shut off after the completion of the cut cycle.
The display and line lights will shut off after 5 minutes
withoutanyactivity. This shut-offtime canbechanged
in the Parameters screen of the Maintenance Mode
(see the “Operating Controls/Maintenance Mode/
Parameters/Time Out” section, pg. 20). To restore
power to the display and line lights, press any button
on the keyboard or lift up the front guard.
Start Up
Once power has been turned on, the Titan 200 will
show the following display:
When the CLEAR key is pressed the clamp and knife
will move up if they are not already in the up position
(providedthefrontguardisclosed). Thenthebackgauge
will move to coordinate the true position into the
computer. When finished,the machinewillbein“Send
Mode”andthe displaywill appear similarto thedisplay
shownbelow.
The backgauge may now be sent to a desired position
by simply typing the dimension and pressing SEND
(seethe “SendMode”section,pg.19,formoredetails).
Making a Cut
Open the front guard and place the paper against the
backgauge and left side guide. Note: if the cut will
leavestripsofpaperlessthan1/2”wide,placethepaper
againsttheright sideguide. Thiswill preventthe strips
from getting caught in the small opening near the left
side guide.
55.000in
Backgaugemustmove tobe preset.
Please clear the table and close
guard.
Warning! Clamp and Knife may
move.
Revision 1.0
Press clear to start
A) Maint
B) Job
5.000in
>_
A) Maint
B) Job
ON
OFF
(fig. 19)
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17
F.200/TITAN 200/MAR 97
CAUTION: Always remove the
jogging aid from the table before
making a cut.
(fig. 20)
(fig. 21)
To make the cut, close the front guard and press the
cutbutton. Iftheguard is raised atanytime during the
cut cycle, the knife and clamp will immediately return
to the up position.
Note: The guard must be opened and closed each
time a new cut is made. The cut button will light up to
indicate that the machine is ready to make a cut.
Jogging Aid
A jogging aid is included as standard equipment with
theTitan200. This toolallows theoperatorto loadand
align paper without the need to place hands or arms
undertheknife or clamp.
Touse, loadthepaperagainstthe sideand backgauge
using the jogging aid (fig’s. 20 & 21). Remove the
jogging aid from the table, close the guard, and make
the cut.
Knife Change Alarm and Lubrication Alarm
Titan 200 has two built in alarms that will be displayed
aftera certainnumber ofcuts. Theknifealarmdisplays
amessageto remind theoperatorto change theknife.
The lube alarm displays a message to remind the
operator to have the machine lubricated. The lube
alarm will also display the name and phone number of
the Challenge dealer from which the machine was
purchased. To reset either alarm, or to change the
knife alarm value, see the “Operating Controls/
Maintenance Mode/Parameters/ Knife Count” section
(pg. 20). The lube alarm value is factory set at 2,500
cuts and cannot be changed.
Manual Clamping (Using the Foot Treadle)
The Titan 200 is equipped with a manual clamping
feature which allows the operator to manually clamp
paper before beginning the cut cycle. To use this
feature, press down on the foot treadle until the clamp
comes down on the paper. While holding the foot
treadledown,closetheguard andpress thecut button.
Release the foot treadle once the cut has been
completed.
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F.200/TITAN 200/MAR 97
18
DEFINITION OF KEYS
Variable Speed Pinpoint Backgauge Control
Thebackgauge controlisusedtomanuallypositionthe
backgauge. The speed of the backgauge will depend
uponwhere theactuatorispressed. Pressfarther from
centerfor afaster speed. Presstowardtheoperatorfor
forwarddirectionandaway fromtheoperatorforreverse
direction.
IN/MM Key
This key toggles the display to show the position and
programmed send values in inches (e.g. 5.250), inch
fractionstothe nearest1/64”(e.g. 5_1/4),or millimeters
(e.g. 133.3).
SEND Key
The SEND key is used to send the backgauge to any
valid position. If an attempt is made to send the
backgaugetoan illegal position,an error messagewill
be displayed at the bottom of the screen stating
“Number outside limit”. In the Job mode, the SEND
key will also advance the backgauge to the next
sequential cut position before performing the cut.
Push-Out Key
The push-out key will move the backgauge forward 5
inches(ortothemost forwardposition)andthenreturn
it to its previous position. This allows paper to be
removed from the cutter without putting hands under
the knife and clamp.
Clear Key
The CLEAR key is used to clear error messages and
the current entry line.
Enter Key
TheENTERkeyselectsitemsinthemaintenancemode
andprocessesdata that hasbeenentered in theother
modes.
CAUTION! Never place hands in the
clamp and knife area. Use the push-
out key or the backgauge glide
control to move the paper to an area where it
can be reached.
CutButton
SENDKey IN/MM Key
Soft Keys
Push-Out Key
Arrow Keys
CLEARKeyENTERKey
PriorityAdd(X/Y) Key
Display
TITAN 200 DISPLAY PANEL
(fig. 22)
Variable Speed
Pinpoint Backgauge
Control
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19
F.200/TITAN 200/MAR 97
5.000in /\
>_
A) Maint
B) Job
Priority Add (X/Y) Key
Thepriorityadd keyis usedforentering fractionswhen
they are combined with whole numbers. The symbol
displayed when this key is pressed is the underline
symbol “_”. An example of a number entered using
the priority add key is 1_1/2.
Soft-Keys
The soft-keys are labeled as A, B, C, and D. The
definition for these keys change depending on the
operating mode. The function of the key can be found
on the bottom of the display screen.
Arrow Keys
Thefourarrow keyscanbe used inalmost all screens.
Thearrow keysareprimarilyusedformovingthe cursor
aroundonthe screen,or totogglebetween highlighted
selections. In some screens, the left arrow key acts
as a backspace key.
ContrastControl
The contrast of the display can be adjusted by using
the contrast control knob, which is located directly
behind the display panel, sticking out of the display
panelcover. Toaccess, openthefront guard,reachin
with your left hand until you feel the knob, and adjust
the contrast as necessary.
MANUAL BACKGAUGE CONTROL
Backgauge Glide Control
The backgauge can be moved manually by use of the
backgaugeglide control.Presstowardstheoperatorfor
foward travel and away from the operator for reverse
travel.Thefurtherawayfrom centerthattheactuatoris
pushed,thefaster thebackgaugewill travel.
Backlash Indicator
Toinsureaccuratecuts, thebackgaugemustbebrought
tothecutpositionfromtherearofthetable.Inthedisplay,
to the right of the backgauge positon, there is a small
arrowtoindicatereversetravel.(fig.1a) Thisarrowshould
be off when making a cut. Moving back past your cut
position,then forwardtoit,compensatesfor anyplay in
thebackgaugenut andleadscrew.
SEND MODE
(fig. 1A)
The send mode is the first screen displayed after the
backgaugeispreset. From thisscreenthe backgauge
can be positioned with the backgauge pinpoint control
or by entering a value and pressing the SEND key. A
mathematicalexpressioncanalsobe enteredasasend
value. Simply type the expression and press SEND.
You can also enter an equation which begins with the
current backgauge position. For example, if you want
to send the backgauge 2” forward from its current
position, just press [-] [2] and SEND.
Thesend modescreencanalsobeusedfor doingmath
calculationsthatarelargerthanthebackgauge’sreverse
limit. In this case, you must press ENTER to have the
result displayed on the screen.
Entering Math
In the simple send mode, the Titan 200 is capable of
calculatinganentiremathstringsuchas,10-5+5x6+2_3/
4. However, the result is limited to 29999.000 and the
resultcannot beanegativevalue. Inthejobmode, and
duringasend,theresult ofthecalculation mustbe less
than the backgauge limit of 20.000 inches.
Entering Fractions
Fractionsareentered withthe priorityaddkey X/Y.The
symbol displayed when this key is pressed is the
underline symbol “_”. This instructs the computer to
addthe fractionalportionoftheentrybeforeperforming
theremainingmath. Thiskeyis usefulwhen enteringa
formula as follows: 3x2_3/4 = 8_1/4. If a simple plus
hadbeenused instead, the resultwouldbe as follows:
3x2+3/4 = 6_3/4.
reverse
indicator
arrow
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