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!