Challenge Titan 265 User manual

F.265XT-EO
January 2014
TITAN 265 XT
Operator’s Manual
Serial Numbers 071755 & 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.
READ THIS MANUAL BEFORE OPERATING! Follow precautions and instructions given and you
should have years of trouble-free operation. If after reading the manual questions still remain, contact
your Authorized Challenge Dealer.
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.
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
your machine and return it DIRECTLY 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, Norton
Center Drive •Norton Shores •MI 49441-6081.
CHALLENGE MODEL SERIAL NUMBER
ATTN COMPANY
ADDRESS
CITY STATE/PROVINCE ZIP
PHONE DATE INSTALLED
DEALER NAME & CITY
* WARRANTY INFORMATION *
It is very important that you read and understand the conditions outlined in the Warranty Information
Sheet attached to the outside of the shipping container of your machine.
The Warranty Information Sheet must be filled out completely and returned to THE CHALLENGE
MACHINERY COMPANY in order for the warranty to be issued for this machine.
Challenge® is a registered trademark of The Challenge Machinery Company•6125 Norton Center Drive •Norton Shores, MI
49441-6081
Copyright© 2007-2013 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 Packing List.................................................................................................................................8
Optional Items ..............................................................................................................................8
4.0 Specifications..............................................................................................................................9
5.0 Installation & Setup ...................................................................................................................10
5.1 Inspecting Shipment.............................................................................................................. 10
5.2 Uncrating.............................................................................................................................. 10
5.3 Cleaning ...............................................................................................................................11
5.4 Fitting Through Narrow Door................................................................................................. 11
5.4.1 Removing the Extension Tables..................................................................................... 11
5.4.2 Removing the Table.......................................................................................................12
5.4.3 Removing the Electric Eyes............................................................................................14
5.4.4 Removing the Footswitch...............................................................................................14
5.4.5 Attaching the Table........................................................................................................ 14
5.4.6 Attaching the Extension Tables...................................................................................... 14
5.4.7 Attaching the Electric Eyes............................................................................................. 15
5.4.8 Attaching the Footswitch................................................................................................ 15
5.5 Hydraulic System Check....................................................................................................... 15
5.6 Optional False Clamp Plate................................................................................................... 16
5.7 Power Hook-Up (208/230 50/60Hz)...................................................................................... 17
5.7.1 Single Phase Hook-Up................................................................................................... 18
5.7.2 Three Phase Hook-Up ................................................................................................... 18
5.8 Power Hook-Up (380/400/415V 50Hz) – also applies for (460V 60Hz).................................. 19
5.8.1 Three Phase Hook-Up ................................................................................................... 20
5.9 Line Light..............................................................................................................................21
6.0 Operation.................................................................................................................................. 23
6.1 Main Power and Start Up...................................................................................................... 23
6.2 Making a Cut......................................................................................................................... 23
6.3 Air Table Option.................................................................................................................... 24
6.4 Jogging Aid........................................................................................................................... 24
6.5 Adjusting the Clamp Pressure...............................................................................................24
6.6 Pre-Clamping........................................................................................................................ 24
6.7 Electric Eyes......................................................................................................................... 25
6.8 False Clamp Plate................................................................................................................. 25
6.9 Sleep Mode........................................................................................................................... 25
6.10 Display Panel...................................................................................................................... 25
6.11 Definition of Keys................................................................................................................25
6.11.1 Touch Screen ..............................................................................................................25
6.11.2 Backgauge Glide Control ............................................................................................. 26
6.11.3 IN/MM Key................................................................................................................... 26
6.11.4 Air Table ON/OFF Key................................................................................................. 26
6.11.5 CANCEL Key...............................................................................................................26
6.11.6 SEND Key ................................................................................................................... 26
6.11.7 Push-Out Key .............................................................................................................. 26
6.11.8 CLEAR Key.................................................................................................................. 27
6.11.9 ENTER Key ................................................................................................................. 27
6.11.10 Priority Add (X/Y) Key ................................................................................................ 27
6.11.11 Arrow Keys ................................................................................................................ 27
6.11.12 PAGE Keys................................................................................................................ 27

1.0 Introduction
4
6.12 Interface ..............................................................................................................................28
6.12.1 Icons.............................................................................................................................28
6.12.2 Main Window................................................................................................................29
6.12.3 Job Statistics................................................................................................................30
6.13 Jobs.....................................................................................................................................31
6.13.1 Programming a Job.......................................................................................................31
6.13.2 Opening a Previously Saved Job ..................................................................................33
6.13.3 Editing an Open Job .....................................................................................................33
6.13.4 Saving an Open Job .....................................................................................................34
6.13.5 Delete a Previously Saved Job......................................................................................34
6.13.6 Copy a Job To/From a USB Storage Device..................................................................34
6.13.7 Locking/Unlocking a Job...............................................................................................34
6.14 Safety Systems....................................................................................................................34
6.14.1 False Clamp Plate........................................................................................................34
6.14.2 Safety Eyes..................................................................................................................34
6.15 Maintenance........................................................................................................................35
6.15.1 Maintenance.................................................................................................................35
6.16 Upgrade...............................................................................................................................38
6.16.1 Calculator.....................................................................................................................39
6.17 Diagnostic............................................................................................................................39
6.17.1 Sensor Data..................................................................................................................39
6.17.2 Last Error Code ............................................................................................................40
7.0 Knife Installation/Changing.........................................................................................................41
7.1 Knife Removal.......................................................................................................................41
7.2 Knife Installation ....................................................................................................................43
7.3 Knife Care Tips......................................................................................................................44
7.3.1 Knife Blade Life ..............................................................................................................44
7.3.2 Cutting Stick...................................................................................................................45
7.3.3 Bevel Angle....................................................................................................................45
7.3.4 Helpful Suggestions........................................................................................................45
7.3.5 Knife Care......................................................................................................................45
8.0 Oil and Grease...........................................................................................................................48
9.0 Safety Systems Test..................................................................................................................50

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 when making adjustments or repairs to your machine, be sure to lock out the
main power control switch to which the machine is connected. The switch should be moved to the
OFF position and a padlock placed in the loop. The key should be held by the person servicing the
machine.
Figure 1

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.

2.0 Safety
7
!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.
•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.
•LEA DETENIDAMENTE el manual de instrucciones y las PRECAUCIONES DE SEGURIDAD
antes de poner a funcionar 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 hacer adjustes 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.

3.0 Packing List
8
3.0 Packing List
Part No. Description Qty.
2263-2 Knife 2
4165 Cutting Stick (in addition to one installed in machine) 3
F.265XT-EO Operator’s Manual 1
A-12608-4 Jogging Aid 1
20-2150-4 Tool Kit 1
H-6918-608 Knife Bolts, 3/8 – 16 x 1” 6
8815 Knife Washers, Special 6
5064 Cutting Stick Puller 1
44183 Knife Lifter Assembly 1
W-141 1/8” Allen Wrench 1
W-137 5/32” Allen Wrench 1
W-164 5/16” Hex ‘T’ Wrench 1
W-158 3/8 x 5/16” Wrench 1
Optional Items
Part No. Description Qty.
44027 False Clamp Plate
4165 Cutting Stick
2263-3 High Speed Steel Knife
41058 Waste Wagon

4.0 Specifications
9
4.0 Specifications
Description Inch Units Metric Units
Cutting Width 26 ½” 67.3 cm
Minimum Cut* 5/8” 16 mm
Clamp Opening 4” 10.2 cm
Table Space
Front:
Back:
24 ¼”
28”
62 cm
71 cm
Dimensions
Table Height 36” 91 cm
Overall Height 59” 150 cm
Overall Length** 69 ½” 176.5 cm
Overall Width 54” 137.2 cm
Approx. Net Weight 1780 lbs 807 kg
Approx. Shipping Weight 2020 lbs 916 kg
Floor Loading 22 PSI 14.9 kPa
Electrical
208/230 Volts, 25 Amps, 3 Phase, 60 Hz, AC. Service size 30 Amps
Optional:
208/230 Volts, 30 Amps, 1 Phase, 60 Hz, AC. Service size 40 Amps
208/230 Volts, 30 Amps, 1 Phase, 50 Hz, AC. Service size 40 Amps
380/415 Volts, 15 Amps, 3 Phase, 50 Hz, AC. Service size 20 Amps
Sound Emission
A-weighted sound pressure level measured in an enclosed room at operator level
(6 feet/183 cm):
Machine in idle state: 60 dB
Machine cycling without cutting paper: 70 dB
*With false clamp plate attached, minimum cut is 1-7/8” (48 mm).
**With table, electric eyes, and footswitch removed, can be fit through a 32” (81.3 cm) door
opening.
Challenge reserves the right to make changes to any product or specification without notice and
without incurring responsibility to existing units.

5.0 Installation & Setup
10
5.0 Installation & Setup
5.1 Inspecting Shipment
This machine has been carefully packed to prevent damage during shipment. However, claims for
damage or loss are the responsibility of the recipient. Inspect all shipments as soon as they are
received. If there is any noticeable damage, note it on the freight bill. Visual and/or hidden damage
must be reported to the claims department of the carrier within 15 days. Contact your dealer if you
need any assistance. Check the contents of the box against the packing list on page 8. Make sure
there are no missing items.
5.2 Uncrating
The Titan 265 weighs approximately 1780 lbs (807kg). DO NOT risk personal injury or damage by
attempting to move machinery with makeshift equipment or inadequate manpower. This machine is
shipped on a wooden skid and enclosed in a protective, corrugated top. The machine is secured in
place with (4) lag screws. All accessories are packed in a separate box.
Remove the carton by removing the nails or staples holding it to the skid and lift it straight up over the
cutter. If you don’t have the ceiling clearance to do this, carefully slit the carton down the side and
then unwrap it from around the cutter. Remove the accessory box. Remove the lag screws that
secure the machine to the skid. Cut shipping straps on the hydraulic reservoir and remove wood
spacer from under reservoir.
The machine may then be removed from the skid. A fork-lift may be used if the forks will extend to
the back of the machine base. Raise the machine enough to create a small clearance between the
skid and machine. Make sure the forks engage the fork pockets found beneath the base. Remove
the skid.
DO NOT place hands under machine at any time during skid removal.
Place the machine on the ground and readjust placement of the forks for safe transport to its
destination.
Alternately, the following method may be used to lift the machine from the skid. Remove the table
extensions (page 11) and the lower front cover. Using lifting straps rated at 2000 lbs. or more, wrap
the straps around the machine base from front to back on each side of the table as shown in Figure 2
& Figure 3. Hoist the machine and remove its skid.
IMPORTANT! Do not lift the machine by any portion of the table. The aluminum table may pull
from the base and strip its mounting threads. Injury may result.

5.0 Installation & Setup
11
Figure 2
Figure 3
5.3 Cleaning
After unpacking, wipe down all machine panels and clean the table surface. The touch screen and
control console should be cleaned using a mild water-based soap solution. DO NOT use petroleum
or oil based solvents as they will damage the touch screen and control console.
5.4 Fitting Through Narrow Door
As shipped, the Titan 265 cutter will not fit through an opening less than 57” (137 cm). With the
extension tables removed, it will fit through a 46-1/2” (118 cm) opening. With the table and electric
eyes removed, it will fit through a 32” (81.3 cm) opening.
5.4.1 Removing the Extension Tables
Make sure power is disconnected from the machine. Remove the front table plate (Figure 4) by
removing the hex nuts. Remove the extension table hardware and remove extension tables.
NOTE: There may be shims located between the extension tables and the extension table brackets.
These are used for leveling the extension tables at the factory. Take note as to where they are
located so they can be placed in the proper position when reattaching the extension tables later.

5.0 Installation & Setup
12
Now remove the two extension table support brackets (Figure 4).
View from underneath table
Figure 4
5.4.2 Removing the Table
Make sure the knife has been removed from the machine and that the knife and clamp are in the “up”
position. If they are not, read the Power Hookup Section (page 17) to connect power to the machine.
Turn on the power using the red and yellow main power switch, and press the CLEAR button. This
will preset the backgauge and send the knife and clamp up.
Turn off the machine and disconnect the power.
Make sure the extension tables have been removed (page 11). Remove the 2-hand button controls.
Remove the sheet metal covers from the rear of the table. Remove the backgauge motor cover, the
lower back panel, and the lower front cover of the machine.
Unplug the cable to the encoder at the back of the machine (Figure 5). Remove the motor junction
box cover and disconnect the wires to the motor (Figure 5). Remove the leadscrew cover and the
nylon tyraps that are attached to the bottom of the table. The motor wires and encoder wires should
now be free from the table.
Figure 5
Motor
Junction
Box
Encoder
Plu
g

5.0 Installation & Setup
13
Remove the preset board assembly from the bottom of table (Figure 6).
Figure 6
Open the top hood and loosen the jam nut on left hand side guide support screw and turn it in a few
turns for clearance, then remove the left and right side guides as shown in Figure 7 & Figure 8.
Figure 7
Figure 8
Remove the two taper pins from the bottom side of the table by tightening the jam nut on the taper
pin. Then remove the four screws that mount the table to the base. CAUTION: the table assembly
is very heavy and requires at least four people to remove.Pull the table out towards the back of
the machine.
Preset Board
Assembly
Left Side
Guide
Right Side
Guide
Side Guide
Support Screw

5.0 Installation & Setup
14
5.4.3 Removing the Electric Eyes
Make sure power is disconnected from the machine. Open top cover. Remove the four hex-head
screws for each electric eye assembly from the inside of the machine. By sliding some of the slack in
the cable through the side of the machine, the eye assemblies can be set on the machine. If it is
necessary to completely remove the eyes from the machine, the wires must be disconnected from the
power panel.
5.4.4 Removing the Footswitch
Make sure power is disconnected from the machine. Remove lower front cover. Remove the two
screws that mount the footswitch bracket (Figure 9). Lay footswitch assembly inside the machine.
Figure 9
5.4.5 Attaching the Table
Set the table in position, and start its front two mounting screws. Then start the rear two mounting
screws. Replace the two taper pins (must be snug to seat the table), and then tighten all four screws.
Attach the right and left side guides then re-adjust the left hand side guide support screw until it
contacts the side guide and tighten the jam nut. (Figure 7 &Figure 8 on page 13), the preset board
assembly (Figure 6 on page 13), the motor and encoder wire (Figure 5 on page 12) and all guards
and panels.
Once the table is installed, the backgauge squareness and accuracy must be readjusted. See the
Titan 265 Technical Service and Parts manual for information on how to do this.
5.4.6 Attaching the Extension Tables
Attach the extension table support brackets to the under side of the main table as shown in Figure 10,
but do not tighten screws completely. Route each cut button wire through the slots in the brackets
while attaching them. Next, place any shims that were installed at the factory in the position they
were in when the extension tables were removed. Lay the table extensions in place and insert the
screws. Align the front edges of the tables and tighten screws. Attach the front table plate.
Mounting
Screws

5.0 Installation & Setup
15
Figure 10
5.4.7 Attaching the Electric Eyes
Make sure power is disconnected from the machine. If necessary, connect the wires to the power
panel. Attach electric eye assemblies with provided hardware, making sure that the bottom of the
electric eye housings are parallel to the table. Once power is hooked up, the electric eyes should be
checked for alignment. See the Titan 265 Technical Service and Parts manual for information on how
to do this.
5.4.8 Attaching the Footswitch
Make sure power is disconnected from the machine. Attach the footswitch bracket using the
mounting hardware (Figure 9, page 14).
5.5 Hydraulic System Check
The Titan 265 is powered by a hydraulic system consisting of an electric motor coupled directly to a
hydraulic pump.
The hydraulic reservoir holds 5 gallons of hydraulic fluid. It is filled with Tellus #46 hydraulic fluid at
the factory but should be checked before operation. Remove the lower rear panel cover. Check the
sight gauge on the rear side of the hydraulic tank. Fluid should just be visible in the sight gauge
(Figure 11, next page). Add fluid if necessary, but avoid overfilling. For more information about
checking and changing the hydraulic fluid, including a cross-reference chart of approved fluids, See
the Titan 265 Technical Service and Parts manual. When finished, replace the panel.

5.0 Installation & Setup
16
Figure 11
The hydraulic fluid should be checked weekly and changed AT LEAST ONCE-PER-YEAR or after
every 1,000 hours of operation.
5.6 Optional False Clamp Plate
To prevent marking on pressure sensitive jobs, a false clamp plate is available as an optional item for
your machine. This plate attaches to the bottom of the clamp. It is secured with (3) setscrews
located in holes on the lower front face of the clamp.
To install:
1. Make sure the knife and clamp are in the up position. If they are not, turn on the power using
the red and yellow main power switch. Press the CLEAR button. This will preset the
backgauge and send the knife and clamp up.
2. REMOVE KNIFE. See Section 7.1 Knife Removal, page 41.
3. Turn the power off and disconnect the power cord.
4. Slide the false clamp plate under the clamp and slide the plate up into position.
5. Hold the plate in position and secure with the (3) setscrews located in the lower front face of
the clamp, Figure 12.
6. A sensor detects that the false clamp is installed and the computer setting will automatically
be set to ON.
NOTE: The minimum cut with the false clamp plate attached is 1-7/8”.
Figure 12
Sight
Gauge
False Clam
p
Plate Set Screws

5.0 Installation & Setup
17
5.7 Power Hook-Up (208/230 50/60Hz)
For satisfactory operation, be sure that your cutter is wired for the correct phase and voltage and has
adequate power. The correct electrical specifications for your machine are shown on the serial plate.
Check the machine serial plate before connecting the power. For future reference, transfer this
information to the front cover of this manual.
Watch Setup Voltage- Inadequate power to the cutter can be a major source of problems. Too
many machines on the same circuit will reduce the power to each machine. Inadequate voltage will
frequently cause overheating, loss of power, and in extreme cases, failure to operate. Test your
voltage when the shop is at actual working levels. Challenge recommends a dedicated line with a
lockable disconnect to provide adequate power for this machine.
CAUTION: SHOCK HAZARD! Always disconnect power at main
power panel before working on the cutter. Lock it out to prevent accidental power up. (See
Power Lockout Procedure page 5).
Important: You must have an adequate size circuit and heavy enough wiring for this machine. The
circuit size should be a minimum of 20% greater than the amperage rating on the machine
nameplate. If a wire is run over 75 feet (23 meters), the next size wire should be used. Check local
electrical codes.
Electrical Specifications for the Titan 265:
Voltage Amperage Circuit Size Wire Size
Three Ph.: 208/230 V 25 A 30 A #10 AWG
Voltage Amperage Circuit Size Wire Size
Single Ph.: 208/230 V 30 A 40 A #8 AWG
‘XT’ models – there are two places that must be set for the proper incoming voltage. The first is the
terminal blocks found in the power panel. Check incoming voltage and position the Terminal Block
Jumper for the proper voltage selection location as shown in Figure 13.
Figure 13

5.0 Installation & Setup
18
NOTE: The terminal block jumper must be set to the correct location according to the supply voltage
of the machine. Failure to set the terminal block jumper will cause damage to the machine!
The second place that must be set for the proper incoming voltage is the transformer terminal strip
behind the control console. Check the incoming voltage and move wire #21 to the proper terminal as
shown in Figure 14
Figure 14
NOTE: The terminal block jumper must be set to the correct location according to the supply voltage
of the machine. Failure to move wire #21 to the proper terminal will cause damage to the
machine!
The power source is connected to the cutter at in the junction box located at the rear, right hand side
of the machine.
5.7.1 Single Phase Hook-Up
1. Disconnect the power at the main power panel and lock it out to prevent accidental power-up.
See Power Lock-Out procedure, page 5.
2. Thread the power cord through the knock-out hole in the junction box located near the floor in
the lower left hand corner of the machine rear. Secure it with a conduit connector.
3. Fasten the ground lead to the ground terminal lug found in the junction box.
4. Use wire nuts to join the two power leads to the L1 and L2 leads found in the junction box.
5. Close all doors and guards, unlock the main power and switch it on. The machine should
now have power.
5.7.2 Three Phase Hook-Up
1. Disconnect the power at the main power panel and lock it out to prevent accidental power-up.
See Power Lock-Out procedure, page 5.
2. Thread the power cord through the knock-out hole in the junction box located near the floor in
the lower left hand corner of the machine rear. Secure it with a conduit connector.
3. Fasten the ground lead to the ground terminal lug found in the junction box.

5.0 Installation & Setup
19
4. Use wire nuts to join the three power leads to the L1, L2 and L3 leads found in the junction
box.
5. Close all doors and guards, unlock the main power and switch it on. The machine should
now have power.
6. Press both cut buttons simultaneously to activate the motor and check to make sure it is
turning the same direction as the arrow on the motor casing. If it isn’t, disconnect the power
and simply exchange any two leads of the power cord as in Figure 15. The motor will now
turn the correct direction. Double check to make sure.
Figure 15
5.8 Power Hook-Up (380/400/415V 50Hz) – also applies for (460V
60Hz)
For satisfactory operation, be sure that your cutter is wired for the correct phase and voltage and has
adequate power. The correct electrical specifications for your machine are shown on the serial plate.
Check the machine serial plate before connecting the power. For future reference, transfer this
information to the front cover of this manual.
Watch Setup Voltage- Inadequate power to the cutter can be a major source of problems. Too
many machines on the same circuit will reduce the power to each machine. Inadequate voltage will
frequently cause overheating, loss of power, and in extreme cases, failure to operate. Test your
voltage when the shop is at actual working levels. Challenge recommends a dedicated line with a
lockable disconnect to provide adequate power for this machine.
CAUTION: SHOCK HAZARD! Always disconnect power at main
power panel before working on the cutter. Lock it out to prevent accidental power up. (See
Power Lockout Procedure page 5).
Important: You must have an adequate size circuit and heavy enough wiring for this machine. The
circuit size should be a minimum of 20% greater than the amperage rating on the machine
nameplate. If a wire is run over 75 feet (23 meters), the next size wire should be used. Check local
electrical codes.
Electrical Specifications for the Titan 265:
Voltage Amperage Circuit Size Wire Size
Three Ph.: 380/400/415V 50Hz 15 A 30 A #10 AWG
460V 60Hz 11.5A 25 A #10 AWG
1
2
31 2
3

5.0 Installation & Setup
20
Check the incoming voltage – if it is different from the factory set 415V, the tap on the main
transformer must be changed to match the incoming voltage - see Figure 16 below for the procedure
The following also applies for 460V 60Hz Hook-ups – use taps H4 and H1.
Figure 16
The power source is connected to the cutter at in the junction box located at the rear, right hand side
of the machine. The power is then run up to the main transformer mounted to the side of the machine,
under the top hood.
5.8.1 Three Phase Hook-Up
7. Disconnect the power at the main power panel and lock it out to prevent accidental power-up.
See Power Lock-Out procedure, page 5.
8. Thread the power cord through the knock-out hole in the junction box located near the floor in
the lower left hand corner of the machine rear. Secure it with a conduit connector.
9. Fasten the ground lead to the ground terminal lug found in the junction box.
10. Use wire nuts to join the three power leads to the L1, L2 and L3 leads found in the junction
box.