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
10
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**