Challenge Titan 200 User manual

TITAN200
PAPERCUTTER
TM. 200-A
MARCH 2000
The Challenge Machinery Company
1433 Fulton Avenue
Grand Haven, MI 49417-1594 USA
Phone: [phone]
Fax: [phone]
ChallengeMachinery.com
TECHNICALMANUAL

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INTRODUCTION The information contained in this document is intended solely for Challenge
trained service technicians. There may be situations that are not covered by this manual. The
information contained in this manual is to guide a technician to possible repair solutions. This
manual is to be used in conjunction with the TITAN 200 instruction and parts manual P/N F-200 (A).
TABLE OF CONTENTS
TABLE OF CONTENTS................................................................................................2
GENERAL INFORMATION.........................................................................................................................5
ELECTRICAL SPECIFICATIONS ...........................................................................................................5
MACHINE DIMENSIONS ........................................................................................................................5
MACHINE REVISIONS................................................................................................................................6
TITAN MAIN BOARD REVISIONS........................................................................................................6
CLAMP DAMPENER ASSEMBLY MOUNT REVISION.......................................................................6
MANUAL MISPRINT ...............................................................................................................................6
SINGLE CUT BUTTON REVISION.........................................................................................................6
HYDRAULIC PUMP REVISION..............................................................................................................6
MANIFOLD SEAL REVISION.................................................................................................................6
BACKGAUGE FUSE REVISION.............................................................................................................6
FRONT GUARD INTERLOCK SWITCH REVISION.............................................................................6
GENERAL HYDRAULIC INFORMATION.................................................................................................7
HYDRAULIC FLUID CHANGE...............................................................................................................7
PRESSURE GAGE.....................................................................................................................................7
OPERATOR SETTING CLAMP PRESSURE ..........................................................................................7
PRELIMINARY VALVE SETTING.........................................................................................................7
VALVE INFORMATION..........................................................................................................................7
SOFTWARE REVISIONS.............................................................................................................................8
ERROR CODES DESCRIPTIONS..............................................................................................................10
ERROR MESSAGES THAT DON’T REQUIRE A FLOW CHART......................................................10
ERROR MESSAGES THAT REQUIRE A FLOW CHART...................................................................11
SENSOR DATA ABBREVIATIONS AND MEANINGS.......................................................................12
TITAN 200 TEST & ADJUSTMENT PROCEDURES...............................................................................13
TESTING DOWN VALVE COIL MAGNETISM...................................................................................13
TESTING ANY HYDRAULIC VALVE SPOOL OPERATION............................................................13
SEQUENCE OF ADJUSTING HYDRAULIC PRESSURES .................................................................13
TESTING AND ADJUSTING PROX SENSOR .....................................................................................13
MANUALLY ACTIVATING THE HYDRAULIC MOTOR..................................................................14
TESTING AND REPAIR OF BACKGAUGE BRAKE RESISTOR.......................................................14
TESTING ENCODER..............................................................................................................................14
TESTING ENCODER/BACKGAGE ACCURACY................................................................................14
TESTING ENCODER CABLE................................................................................................................15
TESTING INPUTS ON MAIN CIRCUIT BOARD.................................................................................15
TESTING MAIN BOARD OUTPUT and OUTPUT DEVICES .............................................................15
INSTALLATION AND ADJUSTMENTS FOR OF THE KNIFE LATCH ASSEMBLY:.....................16
TEST BACKGUAGE ARMATURE........................................................................................................16
FRONT GUARD INTERLOCK SWITCH ADJUSTMENT ...................................................................16
DISASSEMBLY OF SOLENOID COIL CABLE CONNECTOR..........................................................17
TESTING AND MANUALLY ACTIVATING KEYBOARD................................................................17
EE-2807 MAIN BOARD..............................................................................................................................18
BASIC MACHINE SCHEMATIC...............................................................................................................19
EE-2807-1.....................................................................................................................................................20
Basic hydraulic schematic.............................................................................................................................21
CHAMPION and TITAN CONSOLE PROGRAM MAP............................................................................23
Hydraulic Motor didn’t start.........................................................................................................................24
Positioning error ...........................................................................................................................................25
Clamp/Knife down........................................................................................................................................26

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Clamp stuck down ........................................................................................................................................27
Slow backgauge movement to end of table...................................................................................................28
Hydraulic up failure......................................................................................................................................29
Knife down failure........................................................................................................................................30
Sequence error ..............................................................................................................................................31
Knife at both limits.......................................................................................................................................32
Clamp down failure ......................................................................................................................................33
Backgauge failure .........................................................................................................................................34
Shorted key error ..........................................................................................................................................35
“Encoder wires 9 and 10 are reversed” or “Backgauge direction reversed”................................................36
Knife latch failure 1......................................................................................................................................37
Knife latch failure 0......................................................................................................................................38
Hydraulic latch error 1..................................................................................................................................39

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SINGLE OPERATOR
Do not operate with more than one person.
SHOCK HAZARD
Disconnect power before removing cover.
Replace cover before operation
SHOCK HAZARD
Disconnect power before removing cover.
Replace cover before operation
HAZARD 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.

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GENERAL INFORMATION
ELECTRICAL SPECIFICATIONS
The cutter requires a 208/230vac 15-amp service. The cutter has a power cord, which requires a NEMA
6-15R or 6-20R receptacle. The proper way to test voltage is from before power up through a complete
cycle. The voltage must be tested at the
main fuse holders. The meter used must
have a reaction time of at least 100ms or a
low voltage record function. A low quality
meter will not respond fast enough to give
a true minimum voltage reading. Low
voltage to the cutter will blow the main
fuses. When the voltage drops, the 24vac
(solenoids) and 5vdc (computer) will have
problems. The low limit is 190 vac using
the above test. The high limit is 245 vac.
The voltage for the power panel can be
matched to the measured incoming
voltage. Reposition the jumper located in
the center of the terminal strip. Do not
remove any wires.
All Titan 200 s/n 981388 and down are 230vac only. If the voltage drop are 210vac or below during a
cut, a buck/boost transformer, p/n K-2834, is required. Note: The buck/boost can also be rewired to buck
voltage 250vac down. Call Challenge for rewiring. Always check the serial number tag to determine the
proper voltage range.
MACHINE DIMENSIONS
The Net weight is 755 LB (342kg). The height is 53”(135cm), length is 49” (124cm), and width is 36”
(91cm). Removal of the table, front guard and treadle will allow the machine to go through a 31 1/4”
(79.4cm) door way.

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MACHINE REVISIONS
TITAN MAIN BOARD REVISIONS
The main circuit board, EE-2762, was changed to EE-2762-1. When using an EE-2762-1, the H-10 and
H-11 must not be connected.
Titan 200 cutters above s/n 971103 use EE-2807, the LCD display is no longer back lit. On EE-2807, the
H-10 jumper must be connected and H-11 jumper must not be connected. Both black plastic jumpers are
located near the F3 fuse. The EE-2807 can not be used for replacement a EE-2762 and EE-2762-1.
The EE-2807-1 is a direct replacement for the EE-2807. The H-10 jumper must be connected and the H-
11, 12, 13, 14 must not be connected.
CLAMP DAMPENER ASSEMBLY MOUNT REVISION
The upper mounting stud for the clamp-dampened cylinder has been changed to a three-piece mounting.
The first production Titan with the change is s/n 981319, (July-98). The part numbers are H-6938-416
(1/4x20x1"set screw), E-1152-68 (1/4x20x1"hex spacer), H-6918-412 (1/4x20x1½" cap screw). If the stud
is broken, it can be removed with an "screw extractor ". Install the set screw so ½" is extended out from the
frame. Tighten the spacer onto the setscrew. Slide the cap screw into the top hole of the dampened then
tighten screw and damper to the spacer. The fluid in the damper is 100# hydraulic fluid, which is used in
the reservoir of the pump.
MANUAL MISPRINT
Titans s/n 971103 and up main board yellow IN7 input, for hydraulic latch will never light. The Sensor
Data input “HYDLAT” will function. Titans s/n 971102 and down the hydraulic latch relay was located on
a separate relay board.
SINGLE CUT BUTTON REVISION
The green light button was changed to a heavier duty non-lighting style. This heavy duty button was used
beginning with serial number 981342. Early machines require conversion kit K-2874.
HYDRAULIC PUMP REVISION
The first machine with the revised motor/pump is s/n 971157 (Dec 97). Replacement pump/motor
number is H-220-5. Replacement motor/pump units have a different mounting bolt pattern. It is acceptable
to use only two mounting bolts. Parts are not interchangeable from earlier to later units. The manifold and
valves are not affected.
MANIFOLD SEAL REVISION
Hydraulic manifolds stamped with an “-A” in the top corner use a 7/8 ” O- ring. The two O- rings are
located between the manifold and the pump. The machines affected are s/n 981271 (Sept-98) to s/n
991570 (Mar-99).
BACKGAUGE FUSE REVISION
A kit is available to keep the “F1” fuse from blowing. The kit number is K-2908. A 5A (SB) fuse is
being added. The first Titan 200 with the new fuse is s/n 991734, August 99. It is located on the revised
circuit board (EE-2807-1) and is labeled “FL”.
FRONT GUARD INTERLOCK SWITCH REVISION
The interlock switch mounted on either side of the front opening was changed by the manufacturer. The
first machines affected were built late April 2000. The replacement switch is part number E-2457-6, also
six E-1214-65, ¼ “ quick disconnects are needed (per switch).

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GENERAL HYDRAULIC INFORMATION
HYDRAULIC FLUID CHANGE
The oil should be changed every 1000 hours or once a year. Use 100 weight (ISO VG 100) hydraulic oil
only. An electric hand drill pump can be used to remove the oil from reservoir through the filler hole. The
hydraulic pump does have a strainer and magnet. It is recommended as part of the regular oil change that
the reservoir be removed to wipe the interior of the tank clean. The O- ring seal may be reused if it is not
damaged (p/n is S-1810-37).
PRESSURE GAGE
The gage supplied with the Titan is filled with clear glycerin. If the gauge liquid turns yellow, hydraulic
fluid has leaked into the gauge and it must be replaced. If the rubber top seal leaks, replace the gauge (p/n
8P-629-3).
OPERATOR SETTING CLAMP PRESSURE
The clamping pressure range is 400 to 800 psi. Turning the clamp pressure reducer cartridge cw increases
pressure and ccw decreases pressure. One turn of the adjustment screw equals approximately 75 psi. Don’t
adjust below 400 psi. the because clamp and knife will be out of sequence.
PRELIMINARY VALVE SETTING
The four adjustable cartridge valves in the hydraulic system can be preset manually to an approximate
setting. These adjustments should be done only as a last resort. The valves are not interchangeable. Each
valve is to be turned in all the way (cw) then turned out (ccw) a specific amount of turns. Main pressure
cartridge 4 turns. Knife down sequence 3 turns. Clamp up sequence 1 turn. Clamp pressure reducer
(adjustable by the operator) 4 turns (800 psi). Use the hydraulic pressure setting section in the manual for
final adjustment.
VALVE INFORMATION
Listed is general information for testing and checking.
VALVE CHALLENGE MANUFACTURES SPRING INNER SPOOL
NUMBER NUMBER TENSION MOVEMENT
MAIN SYSTEM HH-304-1 RV1-10-S-0-18/ HEAVY ¼” (6MM)
DOWN VALVE H-200-2 SV1-10-4-0-00 LIGHT 1/8” (3MM)
CL. UP SEQ. H-203-6 RV3-10-S-0-36/ MEDIUM ¼” (6MM)
CLAMP PRESS H-203-13 PRV1-10-S-0-12/ MEDIUM ¼” (6MM)
KN. DN. SEQ.* H-203-7 PSV2-10-S-0-12/ MEDIUM 1/8” (3MM)
PSV4-10-S-0-12/ MEDIUM 1/8” (3MM)
ELEC. CL.** H-203-33 EPRV1-5824-14 LIGHT 3/16” (5MM)
* KN. DN. SEQ. Used two different valves
** Cartridge comes with coil E-1069-19

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SOFTWARE REVISIONS
Titan 200 with front guard using EE-2762 circuit board and EE-1766-41 software.
1.0 Original software.
1.1 Increased knife latch timing.
1.2 False Camp Plate limit was 1.750; changed it to 1.875.
1.3 This revision contains all of the languages. In fraction mode corrected positioning problem.
1.4 Increased timing between scr and brake turning on an off. This is performed at the beginning
of each zero cross.
1.5 Enables the Preset interrupt during the zero-cross. Allowed maintenance mode access during
preset screen. Changed send routine for better positioning accuracy.
1.6 Added noise protection to prevent erroneous backgauge control touch pad movement. This
error causes the machine to show actual backgauge position instead of the "sent to" value.
1.7 Allow accuracy adjust to be set in mm. Fixed a backgauge creep problem that would occur if
the foot pedal was pressed during a send. Note: This is the highest possible revision software
the for EE-2762 circuit board.
New Board, EE-2807 Starting at s/n 971102
1.9 Added a delay in the backgauge routine to prevent fuses from being blown in the back-
gauge circuit when using the slide pot in the center or bottom edge.
2.0 A) Added Challenge logo to sleep screen.
B) Added electric clamp option in the “diagnostic” menu.
C) Immediately position to 5” after preset.
2.1 Changed reverse limit from 20.050 to 20.030 to prevent bumping in the back.
2.2 A) Electronic clamp pressures range adjustable in the DIAGNOSTIC menu.
B) REPOSITIONING is added as an option in the parameters menu. This allows the
machine to reposition automatically from a sent position if the back gauge moves back
.005” or more.
C) When entering data in a job, if a math function key is pressed, the operation assumes the
previous data, not the backgauge position.
2.3 Forced PUSHOUT if the forward movement is < .005”.
2.4 Allow ELECTRIC CLAMP option to be on.
2.5 If the backgauge is moving at a high speed, the brake is applied near the front and
back to prevent bumping.
2.6 A) Added auto memory initialization for new boards.
B) Added memory test to initialization routine.
C) Correct translation errors.
2.7 A) Improved positioning time by shortening the slow down distances and making the
slow down distance self-adjusting between .2” and .75”.
B) Added input status to the end of several error messages.
Knife Latch Failure 1 = Latch disengaged when it should be engaged
Knife Latch Failure 0 = Latch engaged when it should be disengaged
Hyd Latch failure 1 = Latch Relay is off When it should be on.
Hyd Latch failure 0 = Latch Relay is on when it should be off.
2.8 A) Adjust for new 1/8 hp back gauge motor
B) Service message reads “Lubricate Machine”
C) Lubricate alarm frequency twice knife alarm count
D) Attempt to reduce F1 blowing computer responds quicker to the backgauge movement
Commands
2.9 Improved electronic clamp pressure routine to reducing changing “CP” number.

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Titan 200 with cut buttons (N.C.) using EE-2807 circuit board and EE-1766-42 software
The revision descriptions for 2.0 and on is the same as EE-1766-41
Titan 200 with cut buttons (N.O.) using EE-2807 circuit board and EE-1766-50 software
2.3 Original software.
2.5 If the backgauge is moving at a high speed, the brake is applied near the front and back to
prevent bumping.
2.6 A) Added auto memory initialization for new boards.
B) Added memory test to initialization routine.
C) Correct translation errors.
2.7 A) Improved positioning time by shortening the slow down distances and making the
slow down distance self-adjusting between .2” and .75”.
B) Added input status to the end of several error messages.
Knife Latch Failure 1 = Latch disengaged when it should be engaged
Knife Latch Failure 0 = Latch engaged when it should be disengaged
Hyd Latch failure 1 = Latch Relay is off When it should be on.
Hyd Latch failure 0 = Latch Relay is on when it should be off.

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ERROR CODES DESCRIPTIONS
ERROR MESSAGES THAT DON’T REQUIRE A FLOW CHART
ERROR EXPLANATION PROCEDURE
Result is Negative Math operation result was negative Press Clear key
Data out of Range Send position beyond forward or reverse Press Clear key
limits
Send Canceled Back gauge in motion and a console key Press Clear key then Send
was pressed key to complete
movement
Number Outside Limit Send position beyond forward or reverse Press Clear key
Limits
Back gauge at Limit Back gauge position at either end of table Move back gauge in
opposite direction
Memory Locked Tried to change a locked channel Press Clear key
Next Channel Locked Linked channel locked Press Clear key. Move
locked channel to another.
location
Sharpen Knife Operator sets knife count for sharpening Clear message:
Enter Maintenance,
Enter Parameters,
Enter Knife count
Enter clear count.
Press exit 4 times
Change knife count
EnterKnifeCount
EnterKnifeAlarm.
Enter number of cycles
Press exit 4 times
Lubricate Machine The relubrication message has been Clear message:
activated Enter Maintenance
Enter Parameters,
Enter Knife count
Enter clear lube.
Press exit 4 times.
Checksum Error Defective EPROM chip. Replace chip
Memory Failed Memory failured Replace main board .
Hyd latch error 0 Board mounted relay failed to turn off Replace main board
Sensor data, “hydlat” didn’t change from 0 to 1 EE-2807-1
Occurs when pump motor turns off

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ERRORS (NO MESSAGE) THAT REQUIRE A FLOW CHART
ERROR EXPLANATION PROCEDURE
Clamp stuck down Upward movement of spring return clamp See flow chart page 27
Did not overcome mechanical bind.
Slow backgauge Main board is sensing the preset is always See flow chart page 28
movement to end of table activated.
Hydraulic motor didn’t Motor didn’t start at the beginning of a cut See flow chart page 24
start
A continious beeping Press CLEAR to stop alarm See Positioning Error.
ERROR MESSAGES THAT REQUIRE A FLOW CHART
ERROR EXPLANATION TEST PROCEDURE
Hyd up failure Clamp failed to return up after 4 sec. See flow chart page 29
Knife down failure Knife failed to go down after 4 sec. See flow chart page 30
Knife up failure See Sequence Error or Knife at both limits
Sequence error Knife came down before clamp See flow chart page 31
or Clamp came up before knife.
Clamp up prox made while
knife up prox unmade.
Knife at both limits Knife up or knife down proximity sensor See flow chart page 32
not switching or switching at the wrong time
Positioning error Back gauge missed programmed position See flow chart page 25
by .005”. Back gauge accuracy off by .010”
when wand goes through preset sensor,
Clamp/Knife down When in a program or send mode See flow chart page 26
(Not manual backgauge mode)
knife or clamp not up
Clamp down failure Clamp did not come down at the start of a cycle See flow chart page 33
Backgauge failure Backgauge did not move after presetting See flow chart page 34
Shorted key error Any key (except backgauge slide)held on See flow chart page 35
for longer than 90 seconds
Encoder wires 9 and Encoder wire pulse wire are backwards or See flow chart page 36
10 are reversed or backgage power wires are backwards.
Backgage direction Typically this happens only on a table out
Reversed installation.

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Knife latch failure 1 Prox sensor on when should be off. See flow chart page 37
The pin should be in the disengaged position
i.e. pulled out from under knife bar.
Knife latch failure 0 Prox sensor off when should be on. See flow chart page 38
The pin should be in the engaged position
i.e. pushed under knife bar.
Hyd latch error 1 Board mounted relay failed to turn on See flow chart page 39
Motor will not start
Sensor data, “hydlat” didn’t change from 1 to 0
SENSOR DATA ABBREVIATIONS AND MEANINGS
The knife and clamp are at top of stroke with the hydraulic motor off and line light on.
INPUTS/OUTPUTS IDLE DESCRIPTION LOCATION
RHSAFE (in) 0 R. H. safety switch or cut button Inside right font cover
LHSAFE (in) 0 L.H. safety switch or cut button Inside left front cover
KNFLAT (in) 1 Knife latch proximity sensor Left side of cutter opening
KYDLAT (out) 1 hydraulic latch relay Main board
KNFDWN (in) 1 Knife down proximity sensor Lower right corner of knife bar
PRESET (in) 1 Preset sensor Under left side of table
CUTSOL (out) 0 Cut Down valve Solenoid on left side of hyd. manifold
UNLOAD (out) 0 Not used
KNLATSOL (out) 0 Knife latch solenoid Left side of cutter opening
CLAMPUP (in) 1 Clamp up proximity Top right corner of clamp (rear view)
HYDUP (in) 1 Clamp cylinder up proximity Bottom of clamp cylinder
KNFUP (in) 1 Knife up proximity Top left corner of knife bar
CUTBTN (in) 0 Single cut button Green button on console
N.C. 0 not used
HYDMOT (out) 0 hydraulic motor relay Right of main board
N.C. 0 Not used
LTLINE (out) 1 Line/table light Two light bulbs above knife bar
CBTNLIT (out) 0 Not used

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TITAN 200 TEST & ADJUSTMENT PROCEDURES
TESTING DOWN VALVE COIL MAGNETISM
1. Remove the ¾" nut holding the coil to the valve.
2. Slide the coil away from the base of the valve ¼".
3. The coil should move easily on the valve stem.
4. Make a cut.
5. If there is voltage and the coil is good, magnetism will move it back the ¼" to the base of the valve.
If a screw driver blade is placed inside the center of the coil then cycle the cutter. If magnetism is felt
the coil, cable and main board is good tested.
TESTING ANY HYDRAULIC VALVE SPOOL OPERATION
1. Remove the valve from the manifold. There isn’t trapped hydraulic pressure, some fluid will flow out.
Always use a 1” box end wrench or deep well socket only on the hex on the valve. Never use an
adjustable wrench or pliers to remove or install a valve.
2. Use a small rod to push in on the end of the valve that was in the manifold. The spool inside the valve
must move smoothly in both directions. Each valve type has a different spring tension and some do
not have springs at all. On adjustable valves, the spring tension can be lessened to help in testing spool
movement. Loosen the jam nut then turn the allen screw CCW to reduce spring pressure. See General
Hydraulic Information, ie Valve information for spring tension.
3. Check for damaged black “O” rings or white split Teflon spacers.
4. Check the manifold cavity for loose particles
5. Reinstall valve. It does not require excessive force to retighten the valve. Do not tighten over 40 FT
LB of torque.
6. Typically, a valve that cannot adjust its pressure range is defective.
SEQUENCE OF ADJUSTING HYDRAULIC PRESSURES
Turn adjuster clockwise to increase pressure, counter clock wise to reduce pressure. Reference
F. 200 parts manual hydraulic schematic page for cartridge location.
1. Turn the clamp reducer valve (item 4), located on front face of blue manifold block, CW all the way.
2. Read main system pressure when clamp and knife are at the bottom of stroke. Adjust valve (item 11)
on front of black pump to 1400psi.
3. Read knife down sequence pressure when clamp is at the table and the knife is moving down. Adjust
front valve (item3) located on right face of manifold block to 900psi.
4. Read clamp up sequence when the knife is at top of stroke and the clamp is moving up. Adjust rear
valve (item 1) located on right face of manifold block to 600psi.
5. Adjust clamp reducer valve, item 4, to a range of 400 to 800psi when clamp and knife are at the bottom
of stroke.
TESTING AND ADJUSTING PROX SENSOR
1. Access the “SENSOR DATA “ menu in the console. The zero and ones to the right of the abbreviations
will indicate changed status as the prox is activated.
2. Place a thin metal strip in front of sensor. The target area has four red squares in a block pattern.
When the strip is placed in front of the sensor the red LED should turn on and the sensor data
indicator should change.
3. The distance from the rectangular prox sensor to a moving part is typically .01” to .06”. The distance
from the round prox sensor to a moving part is typically .01” to .125”.

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MANUALLY ACTIVATING THE HYDRAULIC MOTOR
Pressing the manual pin on the motor relay will activate the motor. This will raise the clamp and knife to
the full up position. The relay is located on the right side center of the electrical panel. Do not push the
relay for longer than 3 seconds, the main fuses may blow!
1. S/N 971102 and down the relay is 1.5” x 3” and brown/black with a small button on the long side.
2. S./N 971103 and up the relay is 3” x 3” and black in color. Press the top white plastic piece down.
TESTING AND REPAIR OF BACKGAUGE BRAKE RESISTOR
1. Resistor is white, 2” long by 3/8” square (may be two side by side), located on the right end of main
board EE-2807-1. The resistor is next to the BRK, SCR, and DIR red LED’s
2. Measure resistance from one lead to the other. A reading of 5 ohms means the resistor is good. A
reading of infinity means the resistor is open and must be replaced.
3. A pair of 10 ohm, 10watt resistors can be purchased from Radio Shack, # 271-132.
4. Cut the defective resistor leads at the end of the resistor. This will leave a lead from the board to solder
too.
5. Apply silicon sealant to the bottom of the new resistor
6. Lay the new resistors side by side (with silicone sealant in between) then wrap one lead around the
other lead and solder.
7. Place new resistor on the board then cut the leads to overlap the leads on the board by 3/8”.
8. Solder resistor leads to board leads.
TESTING ENCODER
Measure voltages on the screw heads of the EE-2807-1 header. If the voltages are correct, the EE-2807 is
defective. The test gives a general condition of the encoder as it impossible to count all encoder pulses.
If the voltages are not correct, see “TESTING CABLE”. If cable is good, the encoder is defective. Turn
motor pulley very, very slowly when testing A and B pulse.
Cable connector Header Function Voltage
18 (black) H2-4 common common
20 (red) H2-3 “+” voltage 5 vdc, power
17 (white) H2-1 “A” pulses toggles 5 & 0 vdc
19 (green) H2-2 “B” pulses toggles 5 & 0 vdc
TESTING ENCODER/BACKGAGE ACCURACY
This test is preformed when the accuracy alarm is activated or there is a question of backgage point to
point accuracy.
1. Remove the backgauge pulley cover.
2. Turn off the REPOSITIONING option in the parameter menu.
3. Move the backgage to rear of the table. Manually turn the leadscrew pulley back til the backgage
stops. Write down the dimension shown on the display.
4. Move the backgage only with the manual slide control to at least 6 different positions, never coming
forward of 7 ” (178mm).
5. Repeat step 3. The two numbers should match within (+ or -) .002.
6. If the numbers match the accuray problem is in the loading of the paper, backgage squaring or
accuracy adjutment. If the numbers do not match the encoder, encoder cable or main board may be
defective.

15
TESTING ENCODER CABLE
1. Unplug the cable connector at encoder. Measure voltages at the cable connector.
2. If voltages are correct, cable (E-2534-1) and main board (EE-2807) are good.
If voltages are not correct, go to step 3.
3. With the cable connector still unpluggged at encoder, measure the voltage at the header screws.
If voltage is correct the main board is good and the cable is defective.
Cable connector Header Function Voltage
18 (black) H2-4 common common
20 (red) H2-3 “+” voltage 5 vdc
17 (white) H2-1 “A” pulses 5 vdc
19 (green) H2-2 “B” pulses 5 vdc
REPLACEMENT EE-2807 & EE-2807-1 CIRCUIT BOARDS
1. Transfer all fuses from the original board to the new board. The FL fuse (EE-2807-1 only) will not have
to be transferred. Fuse clips may have to be tightened (squeezed togethre) before reinstalling a fuse.
2. Transfer the EPROM from original board to the new board. Tip: Before removing old EPROM note
position of locating notch on the chip.
3. The H-10 link must be connected, otherwise “Hydraulic Latch Error” will be displayed. The H-11 link
must not be connected, otherwise the display and keyboard will not work.
On EE-2807-1 links H-12, H-13, H-14 should not be made.
4. Test and adjust the back gauge accuracy.
TESTING INPUTS ON MAIN CIRCUIT BOARD
Inputs on the main board, EE-2807-1, can be manually activated. If the LED does not light nor the sensor
data input change, the main board EE-2807 is defective. The sensor data menus are based on the the power
on, knife/clamp in the up position and the hydraulic motor off.
1. Remove wire for the input to be tested from green header.
2. Touch one end of 12” insulated jumper wire to any 64 wire terminal.
3. Touch the other end of the jumper wire to the screw head where the input wire was attached.
4. If yellow LED lights, then the sensor or wiring is defective. If the yellow LED or the sensor data
input doesn’t change the main board, EE-2807, is defective.
TESTING MAIN BOARD OUTPUT and OUTPUT DEVICES
Outputs can be manually activated, except for the backgauge motor. The red output LED’s only indicates
computer commands, not actual operation of the output device.
Connect an insulated jumper wire from the 24vac supply (wire #33) then touch the other end of the wire to
the to the screw head where output device wire is attached. The desired output device should turn on i.e.,
solenoid, relay or light. (Note: An error may be displayed). If the device turns on manually, the main
board, EE-2807 is defective. If the device does not turn on, the device, wiring or F2, F3 is defective.
Output voltage can be measured. Check the voltage between at the main board output wire (?) and wire
#35 when the machine is activated. NOTE: An unloaded output will measure a static voltage. The voltage
will disappear or change when a load is applied.

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TESTING AND LEVELING THE CLAMP
1. Remove the cut stick, false plate clamp if installed. Clean the bottom of the clamp.
2. Place a 2 1” x 22” strips of paper lengthwise from under the clamp (right and left), to the front edge of
the table.
3. Close guard, if equipped, and make a cut.
4. When the clamp is at the table and the knife is swinging down, pull on the paper strips.
5. If the clamp is parallel, both strips will be held. If one of the strips is loose the clamp will have to be
adjusted.
6. The adjustment is made by turning the nuts on the top and bottom of the pull clamp pull down rods.
Adjust the side that does not hold the strip. Make only 1/8-turn adjustments. Loosen the upper nut.
Tighten the lower nut to lower the high side.
7. Repeat steps 1 through 7 until both strips are held.
INSTALLATION AND ADJUSTMENTS FOR OF THE KNIFE LATCH ASSEMBLY:
1. The retracted position of the knife latch pin is adjusted before installation. The end of the pin should be
flush with the face of the block that it slides through (the plastic screw head does not matter). Check the
position of the pin by pushing in the solenoid plunger (not the lever) to bottom of its travel.
a). Loosen the mounting screws of the solenoid.
b). Push in the solenoid plunger to bottom of its travel.
c). On the 41120-1 version slide the solenoid with plunger pushed in so the knife latch pin end is flush
with the block. On the 41120-3 version slide the solenoid with plunger pushed in so the plastic
screw on end of the latch pin is flush with the block.
d). Retighten the solenoid mounting screws.
2. The latch assembly mounting plate should be visually parallel to the knife bar.
3. The top of the knife latch pin should be 1/64” (0.3mm) to 1/32” (0.5mm) below the knife bar. This
clearance is set only when the knife is in the full up position (see manually section “Activating the
hydraulic motor”). The latch plate mounting screws will have to be loosened slightly. The height adjusting
screw is located at the bottom of the plate. Turn the screw CW to raise and CCW to lower the plate then
tighten the jam nut. Tighten the mounting plate screws.
INSTALLATION TIP: The top cover of the cutter should be tilted forward and the left front table side
guide should be removed for easier access. Table side guide mounting screws can be removed through
the two side left access hole covers using the knife bolt wrench.
4. The proximity sensor should be 1/64” (0.5mm) to 1/32” (1.5mm) from the solenoid lever arm. The
sensor has a red four-point target for activation.
TEST BACKGUAGE ARMATURE (Procedure measuring backgauge motor for opens and shorts)
1. Turn power off.
2. Unplug the H1connector on the main board and remove motor cover. Measure the resistance between
wire 45 and 46. Rotate motor pulley in small increments (one complete turn) while reading the
resistance at each incremental stop. The nominal resistance should be 12 ohms. Values above 12
indicate open and values below indicate a short in the armature.
3. Unplug the H1connector on the main board. Measure the resistance between wire 45 and 46 to the
unpainted part of the motor case. A reading of infinity (open) is correct. A reading less than infinity
indicates a short.
FRONT GUARD INTERLOCK SWITCH ADJUSTMENT
1. Remove the interlock switch bracket assembly from the top cover.
2. Bend the strap, near the mounting screws, so it is parallel to the face of the interlock switch and has
.015” clearance to the tip of the plunger.
3. Reinstall the bracket on the top cover. Open the front guard then adjust the interlock switch bracket
assembly so the strap is flat against the cover but not depressing the plunger.

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DISASSEMBLY OF SOLENOID COIL CABLE CONNECTOR
1. Remove screw completely from the center of square connector then remove connector from coil.
2. Unscrew cable strain relief nut.
3. Turn connector upside down. Place a small screwdriver in the narrow slot in one of the corners of the
red center piece then pry it out. The cable will need to be pushed in.
4. Voltage can then be measured between the wires.
TESTING THE DISPLAY CONTRAST
The LCD display uses 19 Volts DC for the contrast adjustment. The voltage is produced on the main
circuit board, EE-2807. The contrast voltage on the main board can be measured from header H2 pin 7, to
the non-line end (anode) of the diode located next to the H8 header. Use the left drawing below for (d)
diode location.
EE-2807-1 EE-2764
H8 Header
The level of contrast is adjusted by a potentiometer located on the back of the console. The voltage is
measured on the keyboard interface board located under the console cover. Use the above right drawing
for reference. Use the left end of the resistor (shown with a "C") as the common. The voltage at leg 3 on
the potentiometer should read -19vdc. The voltage at "2" on the potentiometer will have a range of 9vdc to
19vdc. Nominal operational voltage is approximately 12vdc.
Conclusions: No voltage between diode and H7-2, defective EE-2807.
No voltage between "C" and # 3, defective ribbon cable EE-2855-2.
No voltage between "C" and # 2, defective EE-2764.
All voltages good, defective LCD display, defective EE-2758-1.
TESTING AND MANUALLY ACTIVATING KEYBOARD
1. Remove the metal cover behind the console.
2. Disconnect blue tipped ribbon cable from interface board.
3. Turn power on.
4. Use a jumper wire shorting the exposed pins to manually activate a key function. Use the diagram
and key list below.
5. If the console shows activity by manually jumping the pins, the keyboard is defective, 43002.
KEY PIN KEY PIN Backgauge Slide Key Interface board
Clear 5 to 11 Send 5 to 13 Pin 1 to 3 1K ohms fixed
# 1 9 to 13 # 2 8 to 13 Pin 1 to 2 1 K ohms variable*
# 3 7 to 13 # 4 9 to 12 Pin 2 to 3 1 K ohms variable*
# 5 8 to 12 *when pressing guide
# 6 7 to 12
# 7 9 to 11 # 8 8 to 11
# 9 7 to 11 # 0 8 to 10

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EE-2807 MAIN BOARD

19
BASIC MACHINE SCHEMATIC

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EE-2807-1