Challenge Titan 230 Guide

F.230-BT
Oct. 2017
TITAN 230
Technical Service and Parts Manual
Serial Numbers:
120249 through 159999,
230-B-150000 and up
Sold and Serviced by
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.

1.0 Introduction
2
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.
FOR PARTS AND SERVICE contact the Authorized Challenge Dealer from whom you purchased
your 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 MODEL of your machine to insure the correct
parts are sent as soon as possible.
Challenge® is a registered trademark of The Challenge Machinery Company6125 Norton Center Drive Norton Shores, MI
49441-6081 Copyright© 2013 by The Challenge Machinery Company. All rights reserved. Printed in the U.S.A

1.0 Introduction
3
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 Maintenance Guide...........................................................................................................................7
3.1 Troubleshooting............................................................................................................................8
3.2 Description of Error Messages .....................................................................................................9
3.3 Sensor Data Abbreviations........................................................................................................ 11
3.4 Routine Maintenance................................................................................................................. 11
3.4.1 Weekly................................................................................................................................ 11
3.4.2 Monthly............................................................................................................................... 12
3.4.3 Yearly ................................................................................................................................. 12
3.5 Checking/Changing the Hydraulic Fluid .................................................................................... 12
3.5.1 Recommended Hydraulic Oils............................................................................................ 12
3.6 Oil and Grease........................................................................................................................... 13
3.7 Adjustments............................................................................................................................... 15
3.7.1 Electric Eye Alignment ....................................................................................................... 15
3.7.2 Backgauge Gib Adjustments.............................................................................................. 16
3.7.3 Squaring the Backgauge.................................................................................................... 17
3.7.4 Proximity Switches ............................................................................................................. 18
3.7.5 Hydraulic Adjustments........................................................................................................ 20
3.7.6 Line Light Adjustment......................................................................................................... 22
3.8 Cleaning..................................................................................................................................... 23
4.0 Schematics & Parts Lists ............................................................................................................... 24
4.1 Main Assembly –Knife.............................................................................................................. 24
4.2 Main Assembly –Clamp............................................................................................................ 26
4.3 Main Assembly –Knife Latch .................................................................................................... 29
4.4 Main Assembly- Power Panel.................................................................................................... 30
4.5 Main Assembly- Table Bottom................................................................................................... 32
4.6 Main Assembly- Table Bottom................................................................................................... 34
4.7 Main Assembly- Table Top........................................................................................................ 36
4.8 Main Assembly- Stand............................................................................................................... 38
4.9 Main Assembly- Foot Pedal....................................................................................................... 40
4.10 Main Assembly- Side Tables................................................................................................... 42
4.11 Main Assembly- Electric Eyes ................................................................................................. 44
4.12 Main Assembly- Covers........................................................................................................... 46
4.13 Main Assembly- Air Table........................................................................................................ 48
4.14 Main Assembly- Air Table - Electrical...................................................................................... 49
4.15 Hydraulic Power Unit –60 Hz (s/n 130352 and below)........................................................... 50
4.16 Hydraulic Power Unit –60 Hz (s/n 130353 and above) .......................................................... 51
4.17 Hydraulic Power Unit –50 Hz (s/n 130352 and below)........................................................... 52
4.18 Hydraulic Power Unit –50 Hz (s/n 130353 and above) .......................................................... 53
4.19 Hyd. Manifold Asm. & Schematic (s/n 130352 and below) ..................................................... 54
4.20 Hyd. Manifold Asm. & Schematic (s/n 130353 & Above) ........................................................ 55
4.21 Blower Assembly –Air Table Option....................................................................................... 56
4.22 Power Panel Assembly (s/n 130352 and below)..................................................................... 58
4.23 Power Panel Assembly (s/n 130353 and above) .................................................................... 62
4.30 P.C. Board Assembly - control ................................................................................................ 75
4.31 Control Console Assembly –Standard, Back Lit Display........................................................ 76
4.32 Knife Latch Assembly.............................................................................................................. 77
4.33 ‘TC’ Upgrade (Optional)........................................................................................................... 78
4.34.1 Electrical Schematic –Basic Machine, ‘TC’ Upgrade ..................................................... 86
4.34.4 Console Assembly, ‘TC’ Upgrade (Optional) .................................................................. 89

1.0 Introduction
4
4.35 Power Panel Label w/fuses......................................................................................................90
5.0 Safety Systems Test.......................................................................................................................92

2.0 Safety
5
2.0 Safety
2.1 Precautions
This machine is designed for one-person operation. Never operate the machine with more than
one person.
Safe use of this machine is the responsibility of the operator. Use good judgment and common
sense when working with and around this machine.
Read and understand all instructions thoroughly before using the machine. If questions remain,
contact the dealer from which you purchased this machine. Failure to understand the operating
instructions may result in personal injury.
Only trained and authorized people should operate this machine.
DO NOT ALTER SAFETY GUARDS OR DEVICES. They are for your protection. Severe
personal injury may result.
Disconnect power before cleaning or performing maintenance. See Section 2.2 Power Lockout
Procedure.
Observe all caution labels on this machine.
Be sure the cutter is properly grounded.
Be sure there is sufficient power to operate the cutter properly.
Observe all caution plates mounted on this cutter.
Keep foreign objects off table and away from cutter blade.
BE EXTREMELY CAREFUL when handling and changing the cutter knife. Severe lacerations or
dismemberment could result from careless handling procedures.
Keep the floor around the cutter free of trim, debris, oil and grease.
When replacing hydraulic parts, loosen the connections slowly to release pressure. Never loosen
connections with the machine running.
If the cutter sounds or operates unusually, turn it off and consult the troubleshooting section of
this manual. If the problem cannot be corrected, have it checked by a qualified service person.
CRUSH HAZARD, keep hand and fingers from under the clamp when clamping paper. Use
Jogging Aid to load paper, and use the backgauge to push paper out before unloading. DO NOT
REACH UNDER THE KNIFE AND CLAMP AREA!
2.2 Power Lockout Procedure
For maximum safety while making adjustments or repairs to your machine, be sure to disconnect
power to the machine. Disconnect the power plug from its socket
Figure 1 - Main Power Disconnect

2.0 Safety
6
2.3 Warning Label Definitions
The following warning labels are found at various locations on your machine. Read and understand
the meaning of each symbol. If a label is lost from the machine, it should be replaced.
HAZARDOUS AREA
Disconnect power before cleaning, servicing, or making adjustments not requiring
power. Do not alter safety guards or devices; they are for your protection. Replace
all guards. Do not operate with any guards removed.
SHOCK HAZARD
Disconnect power before removing cover. Replace cover before operation.
SHOCK HAZARD
Disconnect power before removing cover. Replace cover before operation.
SINGLE OPERATOR
Do not operate with more than one person.

3.0 Maintenance Guide
7
3.0 Maintenance Guide
NOTICE
The instructions on the following
pages are for the use of trained
service personnel only!
Attempting to perform repair and
replacement procedures without
proper training may cause
machine damage or operator
injury!
PARTS CUSTOMERS: Parts with the express understanding that they are to replace parts
found missing or no longer serviceable on equipment designed and/or manufactured at
Challenge. The Challenge Machinery Company assumes no liability for any modification or
alteration to any Challenge products, and any such modification or alteration to any
Challenge product is not authorized by The Challenge Machinery Company. Any
modification or alteration of any Challenge product will void any remaining warranty.

3.0 Maintenance Guide
8
3.1 Troubleshooting
WON’T START
Fuse Blown/ Circuit Breaker tripped
Power cord disconnected.
Main power switch not turned on.
BACKGAUGE DISPLAY INACCURATE
Preset circuit board malfunction.
Encoder malfunction.
Main circuit board malfunction.
BACKGAUGE DISPLAY INACCURATE - BY CONSTANT AMOUNT
Backgauge needs accuracy adjustment.
Presetter malfunction.
CUT BUTTONS PUSHED - WON’T CUT
Check error codes (page 9).
Obstruction between electric eyes.
Hydraulic fluid low.
Main relief valve setting off.
Sequence pressure set wrong.
Cut button defective.
Motor relay defective.
Knife latch solenoid defective.
Knife down coil defective.
Defective directional valve.
Cylinder disconnected from cylinder bracket.
Knife bar dirty or dry, lubricate knife guideways.
Dirt in hydraulic system.
CLAMP STARTS UP BEFORE KNIFE IS UP
Clamp Up Sequence Valve setting incorrect/defective.
CONCAVE CUTTING - ENDS WIDE, CENTER NARROW
Excessive moisture at edges of paper.
CONCAVE CUTTING - VARIATION FROM TOP TO BOTTOM
Soft paper not firmly clamped.
Knife dull or incorrectly grounded.
ERRATIC OPERATION-POWER LOSS
Hydraulic fluid low.
Dirt in hydraulic system.
Oil bypassing piston in cylinder .
Voltage supply is low.
KNIFE DRIFTS DOWN
Knife latch not engaging or damaged.
KNIFE HESITATES OR STALLS
Dull knife.
Main relief valve setting off.
Paper clamped too tight - lower clamp pressure reducer setting.
Cylinder seals worn - leaking pressure.

3.0 Maintenance Guide
9
Hydraulic fluid low.
Voltage supply is low.
KNIFE STARTS DOWN BEFORE CLAMP REACHES TABLE
Knife down sequence valve setting incorrect.
Clamp pressure set too low.
KNIFE WON’T RETURN UP
Solenoid defective.
Limit switch out of adjustment.
Cylinder disconnected from bracket.
Sequence valve misadjusted.
PUMP-MOTOR WON’T SHUT OFF
Knife/Clamp Up Limit switch not activated - readjust.
Motor relay contacts welded.
3.2 Description of Error Messages
Message
Description
Test
Backgauge Failure
Backgauge doesn’t move
Mechanical bind; encoder
failure; main pcboard; blown
fuse/circuit breaker tripped
Backgauge at Limit
Backgauge is all the way
forward or backward
Cheksum Error
Bad program chip
Replace EEPROM
Clamp Up Failure
Clamp failed to return to up
position within 7 seconds
Clamp up sequence valve;
solenoid (cut) valve
Clamp Down Failure
Clamp failed to come down
Solenoid valves; low voltage,
low pressure
Clamp or Knife Down
Clamp or knife stayed down
No main pressure; stuck
solenoid valve
DATA IS OUT OF RANGE
The number is outside the limits
of the machine
Informational error
Motor Starter Failure 1
Motor starter was OFF when it
should have been ON
Defective motor contact switch
Motor Starter Failure 0
Motor starter was ON when it
should have been OFF
Defective motor contact switch
Knife Latch Failure 1
Latch prox. ON when it should
have been OFF
Loose solenoid wire;
mechanical bind; knife up prox.
Switch out of adjustment;
defective prox. Switch
Knife Latch Failure 0
Latch prox. OFF when it should
have been ON
Knife Down Failure
Knife failed to come down
within 4 seconds
Low main pressure; low
voltage; knife down sequence
valve
Knife Up Failure
Knife failed to return within 1.17
seconds
Mechanical bind; solenoid (cut)
valve
Knife at Both Limits
Knife up and down prox.
Switches are on at the same
time
Prox. Switches; broken knife
bar components

3.0 Maintenance Guide
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Message
Description
Test
Lubricate Machine
Lubricate machine alarm
Have machine lubricated
Memory Failed
A memory error occurred during
test
Encoder wires 9 & 10 are
reversed
Should only occur during initial
assembly otherwise is an
encoder error
Replace encoder
Memory Locked
Tried to change a locked
channel
Next Channel Locked
Tried to link two channels
together and the linked channel
is locked
Number Outside of Limit
Selected cut position beyond
limits of machine
Operator error; false clamp limit
Positioning Error
Backgauge failed to move to
programmed position within +/-
.oo5
Mechanical bind; encoder
failure; main pcboard;
leadscrew thrust washers loose;
gibs loose
Remove Obstruction
Obstruction is blocking electric
eyes, or electric eyes are not
functioning properly
Remove obstruction, check
alignment of eyes, check all
electric eye connections
Result is Negative
When a math operation yields a
negative number
Send Cancelled
Console key was pressed while
backgauge was moving
Operator error; key board
failure
Sequence Error
Timing error in either up or
down cycled
Low main pressure; any
sequence valve
Sharpen Knife
Sharpen knife alarm
Have knife sharpened
Shorted Key Error
Console Key shorted
Operator error; defective
keyboard
** If error codes cannot be reset by depressing the clear key, the power will have to be turned OFF
and ON**

3.0 Maintenance Guide
11
3.3 Sensor Data Abbreviations
Abbreviations
Standby
Description
Location
LEFTCUT
0
Left Cut Button
Lower front of table
RGHTCUT
0
Right Cut Button
Lower front of table
KNFLAT
1
Knife Latch Proximity Switch
Left side of cutter opening
HYDLAT
1
Motor Starter Relay Status
Right side of power panel
KNFDWN
1
Knife Down Proximity Switch
Inside of cutter opening,
right side
PRESET
0
Preset Sensor
Rear of cutter, under left
side of table
CUTSOL
0
Cut Valve
Solenoid Valve on left side
of manifold
UNLOAD
0
Unload Valve
Solenoid Valve* (not in use
yet)
KNLATSOL
0
Knife Latch Solenoid
Inside of cutter opening,
left side
CLAMPUP
1
Clamp up Proximity Switch
Inside rear of cutter
opening, left side
HYDUP
1
Hyd. Clamp Up Proximity
At bottom of clamp
cylinder
KNFUP
1
Knife Up Proximity Switch
Inside of cutter opening,
left side
CUTBTN
0
Cut Button
On display console
EYES
1
Electric Eyes
In front of cutter opening.
HYDMOT
0
Hydraulic Motor Relay Output
Top right side of main pcb
N.C.
0
No Connection
LTLINE
0
Line Light Output
Inside rear cutter opening,
left side
CBTNLIT
0
Cut Button Light
In display console
3.4 Routine Maintenance
DISCONNECT POWER before making any adjustments or lubricating.
See page 5, SAFETY PRECAUTIONS, for Power Lockout Procedure.
This machine should be placed on a regular maintenance schedule. A clean, lubricated machine will
run longer, smoother, cut more accurately, with less downtime and fewer costly repairs. Schedule
lubrication both early in the day and early in the week. This allows the lubricants to work into the
machine. Lubrication at the end of the day or week allows the lubricants to run off without any benefit
to the machine. The following guidelines will help you set up a regular maintenance schedule:
3.4.1 Weekly
Clean —Clean off old, dirty excess grease. Remove the lower front panel cover and clean
accumulated dust off valves, hoses and connections. Built-up dust increases operating temperatures,
which causes premature wear to all hydraulic components.
Hardware —Remove the lower front panel cover, rear panel cover, and top hood to check all nuts
and bolts for tightness. Loose hardware is the cause of most component wear and in the electrical
area could cause short circuits and/or shock.

3.0 Maintenance Guide
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Hydraulic Fluid —Low fluid level causes excessive heat and wear on the system. Check the fluid
level as described in section 3.5 below.
Oil and Grease —See section 3.6
3.4.2 Monthly
Backgauge Squaring —See section 3.7.3
3.4.3 Yearly
Change Hydraulic Fluid —See section 3.5
3.5 Checking/Changing the Hydraulic Fluid
The hydraulic fluid level should be checked weekly. To check, remove the lower rear cover and
unscrew the cap on top of the tank (Figure 2).
Figure 2
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.
The hydraulic fluid should be changed AT LEAST ONCE-A-YEAR or after every 1,000 hours of
operation. NOTE: Failure to change oil when needed can damage seals in the cylinders, pump, and
valves.
Empty the hydraulic tank and refill with 1 gallon of International Standards Organization Viscosity
Grade 100 (ISO VG 100) rust, oxidation, and foam inhibiting hydraulic fluid (Challenge part no.:
S-1991).
NOTE: NEVER use automatic transmission fluid or brake fluid as a substitute for the correct
hydraulic fluid. A table of various manufacturers and their equivalents is listed below.
3.5.1 Recommended Hydraulic Oils
Use ISO VG 100 Hydraulic Fluid equivalent only. Oils other than the
recommended type will cause seals and O-rings to deteriorate. Unsafe operating conditions will
result.
Dip Stick

3.0 Maintenance Guide
13
3.6 Oil and Grease
Turn the power off and disconnect the power cord. Open the top hood for access. Parts requiring
oiling are marked with red paint. See figures Figure 3 through Figure 10 starting on page 13 for oil
and grease locations. Figure 3 through Figure 5 require the knife and clamp be in the up position.
Figure 6 through Figure 10 require the knife and clamp be down. Wipe off any old or excess grease.
Use any brand-name type of grease or light oil to lubricate. It may be necessary to use the supplied
grease brush to access some locations. Note: the lead screw may be lubricated with grease or oil.
Oil has a tendency to run off and must be lubricated more frequently; grease tends to collect paper
dust and must be cleaned off periodically.
Figure 3 –Knife Bar Link –L.H. Side, Upper
Figure 4 –Knife Bar Link –R.H. Side, Upper
Grease
Oil

3.0 Maintenance Guide
14
Figure 5 –Knife Bar
Figure 6 –Knife Bar Link –L.H. Side, Lower
Figure 7 –Knife Bar Link –R.S., Lower
Knife Bar
Knife Cylinder Bracket, Upper

3.0 Maintenance Guide
15
Figure 8 & Figure 9 –Clamp Guides
Figure 10 –Lead Screw and Backgauge Guide
3.7 Adjustments
Several of the following tests require the machine to be operational
for checking and adjusting. Be very careful that tools and other people are clear of moving
parts and that the cutter is not accidentally operated while adjustments are being made.
Whenever working on the machine, disconnect the power and lock it out (see SAFETY
PRECAUTIONS, page 5) unless the directions specifically require the machine to be powered.
3.7.1 Electric Eye Alignment
If your machine is equipped with electric eyes, the alignment can be checked as follows:
Switch on power and make sure there are no obstructions between the electric eyes.
On the Receiver - If the “beam status” and the “Status Indicator” are all green, the Eyes are
aligned and working properly. If any of these lights are red then the Eyes are blocked or mis-
aligned.
On the Emitter - If the “Status Indicator” is green the Emitter unit is working properly. If the
“Status Indicator” light is red then the Emitter unit is faulty and must be replaced.

3.0 Maintenance Guide
16
If alignment is necessary, loosen the screws that attach the electric eye brackets to the table
extensions. Adjust until the “Beam Status” and the Status Indicator” are green then tighten the
screws.
3.7.2 Backgauge Gib Adjustments
If the backgauge does not stay squared or jumps up and down when jogging paper against it, the
backgauge gib screws are probably loose or worn.
To Adjust:
1. Send the backgauge near the rear of the table.
2. Turn off the power and disconnect the power cord.
3. Remove the lead screw cover under the table.
4. Loosen the two side gib screws and the bottom nylon guide screws (Figure 11).
Figure 11
5. Tighten the bottom, nylon guide screws until they just touch the guide. Do not over tighten or
they could cause the backgauge to bind.
6. Similarly, turn the side gib screws in until they just touch the guide. Lock in position with the
jam nuts.
Gib Screws
Nylon Guide
Screws

3.0 Maintenance Guide
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7. Run the backgauge back and forth the length of the table using the backgauge glide control.
Check for any binding. Readjust if necessary.
NOTE: The screws should be tightened to hold the backgauge square against the guide rail.
Excessive tightening will cause the backgauge to bind and cause premature wear of all components.
3.7.3 Squaring the Backgauge
Figure 12
To test if the backgauge is square, place a small lift of paper against the left side of the backgauge
(but not against the side guide) and make a cut. Now, leave the backgauge in the same position, flip
the lift over and push it against the right side of the backgauge (but not against the side guide). Make
another cut to see if any of the paper will trim off. Run two checks, one starting on the left and
moving to the right; the other, moving from the right to the left. If paper is trimmed in either sequence,
the backgauge is out of square.
1. Make sure the backgauge gibs are set properly (see section 3.7.2 Backgauge Gib
Adjustments).
NOTE: Gib adjustments are not necessary on initial machine set-up as gibs have been
adjusted at the factory.
2. Remove the rear Plexiglas table cover.
3. Loosen the jam nuts on the backgauge adjusting screws (Figure 13).
Figure 13
4. Back off the adjusting screw on the side that the trim occurred and tighten the other.
5. With the squaring screws tight, make another test. Continue to adjust and test until no trim
occurs when testing either sequence.
6. Replace the rear Plexiglas table cover.
Adjusting
Screws with
Jam Nuts

3.0 Maintenance Guide
18
Note: Once the backgauge is square, restore power to the machine and check the backgauge
accuracy (see the Titan 230 Operator manual) to make sure it is accurate.
3.7.4 Proximity Switches
Proximity switches are used to inform the computer of the up and down positions of the knife and
clamp. They do not determine the stopping positions of the knife and clamp, and therefore rarely
need to be adjusted. However, if a proximity switch is not sensing the knife
or clamp position correctly, it may need adjustment.
To check if the four proximity switches are sensing correctly, go to Maintenance Mode and select
Diagnostic. Then select Sensor Data, and a list of abbreviations for several inputs and outputs will be
listed, along with their status (0 for open, 1 for closed). The four proximity switches should have the
following status during the various knife and clamp positions:
Knife Up Knife Up
Knife Up Clamp Down Clamp Down Knife Moving Down Knife Down
Clamp Up (Manually) (Hydraulically) Clamp Down Clamp Down
Knfdwn 1 1 1 1 0
Clampup 1 0 0 0 0
Knfup 1 1 1 0 0
Hydup 1 1 0 0 0
If any of the four proximity switches has a status of 0 when it should be 1, adjust the switch as
described below:
3.7.4.1 Knife Down Proximity Switch (Knfdwn)
Make sure the clamp and knife are in the up position. Turn the power switch off and disconnect the
power cord. Remove the top front cover.
Figure 14
Adjust the knife down proximity switch (Figure 14) by loosening the two mounting screws and sliding
the switch closer to the knife bar. The gap between the proximity switch and the knife bar should be
1/32” to 1/16” (0.5 to 1.5 mm). No vertical adjustment is necessary.

3.0 Maintenance Guide
19
3.7.4.2 Clamp Up Proximity Switch (Clampup)
Make sure the clamp and knife are in the up position. Turn the power switch off and disconnect the
power cord. Remove the top front cover and the upper rear cover.
Figure 15
Adjust the clamp up proximity switch by loosening the two actuator mounting screws (Figure 15) and
sliding the actuator up or down. The gap between the actuator and the proximity switch should be
1/32” to 1/16” (0.5 to 1.5 mm).
3.7.4.3 Knife Up Proximity Switch (Knfup)
Make sure the clamp and knife are in the up position. Turn the power switch off and disconnect the
power cord. Remove the top front cover.
Figure 16
Adjust the knife up proximity switch (Figure 16) by loosening the two mounting screws and sliding the
actuator up or down. The switch should be adjusted such that it senses the knife bar at the very top of
its stroke only. The gap between the switch and the knife bar should be 1/32” to 1/16” (0.5 to 1.5
mm).

3.0 Maintenance Guide
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3.7.4.4 Hydraulic Clamp Up Proximity Switch (Hydup)
Make sure the clamp and knife are in the up position. Turn the power switch off and disconnect the
power cord. Remove the lower front panel.
Figure 17
Adjust the hydraulic clamp up proximity switch (Figure 17) by loosening the two hose clamp screws
and sliding the switch plate up or down. The gap between the switch and the actuator plate should be
1/32” to 1/16” (0.5 to 1.5 mm).
3.7.5 Hydraulic Adjustments
Pressure Settings:
1. Main System Relief Pressure —1,300 psi. –Then in 1-1/2 turns.
2. Knife Down Sequence Pressure —900 psi.
3. Clamp/Knife up Sequence Pressure —600 psi.
4. Clamp Pressure Reducer —400-800 psi.
Notes:
To access hydraulic gauges and valves, remove the lower front cover panel.
To adjust valves, loosen hex jam nut, then make adjustments by turning the adjusting
screw with a hex wrench.
On all valves, turning in (clockwise) increases pressure; out (counter-clockwise)
decreases pressure.