Challenge Titan 265 Instruction Manual
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Challenge Titan 265 Instruction Manual

Challenge Titan 265 Instruction Manual

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CHALLENGE
TITAN 265
PAPER CUTTER
Instruction Manual
Serial Numbers 001314 & Up
Provided By
http://www.MyBinding.com
http://www.MyBindingBlog.com

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  • Page 1 CHALLENGE TITAN 265 PAPER CUTTER Instruction Manual Serial Numbers 001314 & Up Provided By http://www.MyBinding.com http://www.MyBindingBlog.com...
  • Page 2 Serial Numbers 001314 & Up NSTRUCTION AND ARTS ANUAL TITAN 265 PAPER CUTTING MACHINE Sold and Serviced by The Challenge Machinery Company 1433 Fulton Avenue Grand Haven, MI 49417-1594 USA ChallengeMachinery.com F.265-B Sept. 2000...

  • Page 3: Introduction

    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, 1433 Fulton Avenue •...

  • Page 4: Table Of Contents

    1.0 Introduction TABLE OF CONTENTS 1.0 Introduction ..........................2 2.0 Safety............................6 2.1 Precautions ..........................6 2.2 Power Lockout Procedure ....................... 6 2.3 Warning Label Definitions......................7 3.0 Packing List..........................9 Optional Items ..........................9 4.0 Specifications ..........................10 5.0 Installation & Setup........................11 5.1 Inspecting Shipment......................
  • Page 5 1.0 Introduction 6.13 Job Mode..........................28 6.13.1 Lock/Unlocking a Job ....................29 6.13.2 Copying a Job......................29 6.13.3 Erasing a Job....................... 29 6.13.4 Creating a New Job...................... 29 6.13.5 Editing an Existing Job....................31 6.13.6 Running a Programmed Job..................31 6.13.7 Exiting a Job ........................
  • Page 6 1.0 Introduction 9.16 Electrical Sequence of Operation..................78 9.17 Cut Button Assembly......................79 9.18 Control Console Assembly ....................80 9.19 Control P.C. Assembly ......................81 9.20 Power Panel Label ......................82 9.21 Fuse Value and Function..................... 83 9.22 Knife Latch Assembly......................84 9.23 Line Light Assembly ......................

  • Page 7: Safety

    2.0 Safety 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.

  • Page 8: Warning Label Definitions

    2.0 Safety 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.
  • Page 9 2.0 Safety !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. •...

  • Page 10: Packing List

    3.0 Packing List 3.0 Packing List Part No. Description Qty. 2263-2 Knife 4165 Cutting Stick (in addition to one installed in machine) F.265-B Instruction and Parts Manual A-12608-4 Jogging Aid 44116 Table Extensions 44090 Support Bracket 44093 Back Plate H-6918-606 Screw –...

  • Page 11: Specifications

    *With false clamp plate attached, minimum cut is 1-7/8” (48 mm). ***With table, front guard, and foot treadle removed, can be fit through a 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.

  • Page 12: Installation & Setup

    5.2 Uncrating The Titan 265 weighs approximately 1680 lbs (762kg). 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.

  • Page 13: Cleaning

    5.4 Fitting Through Narrow Door The Titan 265 cutter will not fit through an opening less than 46-1/4” (117 cm) without the table being removed. With the table, front guard, and foot treadle removed, it will fit through a 32” (81.3 cm) opening.
  • Page 14 5.0 Installation & Setup Remove the front tilt cover (if installed) and 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. Also remove the table extensions and 2-hand button controls (if equipped). Unplug the cable to the encoder at the back of the machine (Figure 4).

  • Page 15: Removing The Foot Treadle

    5.0 Installation & Setup Left Side Guide Side Guide Support Screw Figure 6 Right Side Guide Figure 7 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.

  • Page 16: Reattaching The Table

    5.0 Installation & Setup Bracket Screws Figure 8 Then open the top hood and remove one set of hinge screws (Figure 9). Slide the front guard out of the other hinge. Hinge Screws Figure 9 5.8 Reattaching the Table Set the table in position, and start its front two mounting screws. Then start the rear two mounting screws.

  • Page 17: Hydraulic System Check

    Figure 10 5.10 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 Rykon 46 hydraulic fluid at the factory but should be checked before operation.

  • Page 18: Power Hook-Up

    IMPORTANT! An adequate circuit size with properly sized wires is crucial. The circuit size should be a minimum of 20% greater than amperage rating listed on the serial number plate. If a wire is run over 75 feet (23m), the next size wire should be used. Electrical Specifications for the Titan 265: Voltage Amperage Circuit Size Wire Size Single Ph.: 230 V...

  • Page 19: Line Light

    5.13 Line Light The Titan 265 is equipped with two lights, which provide a line of light on the paper in the approximate location of where the paper will be cut. The lights come on when power to the machine is turned on.
  • Page 20 5.0 Installation & Setup Line Light Adj. Screws Figure 13 To Adjust: 1. Place a wide sheet of paper on the cut stick to view the line light. 2. Using a 3/16” hex allen wrench, turn one of the cap screws until you see a 1/16-1/8” beam. NOTE: it is best to start by turning the screw clockwise.

  • Page 21: Operation

    (if equipped). 6.2 Start Up Once power has been turned on, the Titan 265 will show the following display: 55.000 Backgauge must move to be preset.

  • Page 22: Making A Cut (Using Two-Hand Cut Buttons)

    Always remove the jogging aid from the table before making a cut. A jogging aid is included as standard equipment with the Titan 265. This tool allows the operator to load and align paper without the need to place hands or arms under the knife or clamp.

  • Page 23: Knife Change Alarm And Lubrication Alarm

    6.6 Knife Change Alarm and Lubrication Alarm The Titan 265 has two built in alarms that will be displayed after a certain number of cuts. The knife alarm displays a message to remind the operator to change the knife. The lube alarm displays a message to remind the operator to have the machine lubricated.

  • Page 24: Display Panel

    6.0 Operation 6.8 Display Panel Display SEND Key IN/MM Key Variable Speed Pinpoint Backgauge Control Soft Button Keys Push-Out Key Arrow Keys Priority Add ENTER Key CLEAR Key (X/Y) Key 6.9 Definition of Keys 6.9.1 Variable Speed Pinpoint Backgauge Control The backgauge control is used to manually position the backgauge.

  • Page 25: Push-Out Key

    6.0 Operation 6.9.4 Push-Out Key The push-out key will move the backgauge forward 5 inches (or to the most forward position) and then return it to its previous position. This allows paper to be removed from the cutter without putting hands under the knife and clamp.

  • Page 26: Backlash Indicator

    6.11.1 Entering Math In the simple send mode, the Titan 265 is capable of calculating an entire math string such as, 10- 5+5x6+2_3/4. However, the result is limited to 29999.000 and the result cannot be a negative value. In the job mode, and during a send, the result of the calculation must be less than the backgauge limit of 20.000 inches.

  • Page 27: Maintenance Mode

    6.0 Operation 6.12 Maintenance Mode The maintenance mode is an area where many machine functions can be set or modified. The four principle functions are: Language, Parameters, Diagnostic, and Knife Adjust. To select a particular function, use the up and down arrow keys to toggle to the desired function and press ENTER. See the following descriptions for an explanation of each function.

  • Page 28: Diagnostic

    The lube alarm will also display the name and phone number of the Challenge dealer from which the machine was purchased. NOTE: The alarms do not prevent normal operation they are simply reminders.

  • Page 29: Language

    6.13 Job Mode The Titan 265 can be programmed for up to 99 different jobs or channels. A job is used for making a sequence of cuts using the send (or cut) values of the job as the backgauge positions for each cut.

  • Page 30: Lock/Unlocking A Job

    6.0 Operation > 1> JOB 1 2> TESTJOB 5> 6> BOBS JOB * 7> 8.5 X 11 * 9> 10> A) Lock C) Erase B) Copy D) Exit 6.13.1 Lock/Unlocking a Job In the Job Mode screen, the soft-key “A” will display “Lock” or “Unlock” depending on the current status of the job.
  • Page 31 6.0 Operation 5.000 1> A) Insert C) Erase B) Job D) Exit 6.13.4.1 Entering Send Values Now enter send values by using any of the following methods: 1) Type in the desired value and press ENTER, 2) Press ENTER at a blank line - this will enter the current position of the backgauge as a send value, or 3) Use the “Cut and Record”...

  • Page 32: Editing An Existing Job

    6.0 Operation 6.13.5 Editing an Existing Job 6.13.5.1 Editing the Job Name The job name can be edited (or added if an existing job does not have a name) in the job mode screen. To edit the name, move the cursor down to the desired job number by pressing the down arrow key.

  • Page 33: Exiting A Job

    6.0 Operation 6.13.7 Exiting a Job To exit an open job, press the soft-key “B” (Job) to return to the job mode screen, or press the soft- key “D” (Exit) to exit to the send mode screen. 6.14 An Example Job The following is an example of how to program a job, which will be used to make two cuts: one at 8.5”...
  • Page 34 6.0 Operation Now press ENTER to begin programming the job. The display should now look similar to the one shown next: 5.000 1> A) Insert C) Erase B) Job D) Exit 4. To enter the first send value of 8.5”, simply type in 8.5 and press ENTER. The cursor will move to the second line.

  • Page 35: Operating Tips

    6.0 Operation 6.15 Operating Tips Carefully lay out each sheet before you start cutting. Find the best cut pattern to give you the most pieces out of the sheet. If the sheet will be folded, be sure grain of the paper is running in the same direction as the fold or you will get a rough edge on the fold.

  • Page 36: Knife Installation/Changing

    7.0 Knife Installation/Changing 7.0 Knife Installation/Changing Changing knives can be very dangerous unless safety precautions are observed and extreme care is taken when handling knives. • Make sure knife lifters are properly installed, see instructions following. • Keep handling of unprotected knives to an absolute minimum. •...
  • Page 37 7.0 Knife Installation/Changing Knife Adjusting Screws Figure 19 3. Remove the knife bolts from the two slotted knife bar holes and replace with the knife lifters (Figure 20). Tighten the lifters to hold the knife in place, and then remove the remaining knife bolts.

  • Page 38: Knife Installation

    7.0 Knife Installation/Changing Figure 21 7.2 Knife Installation Knives are heavy and always very sharp! Be sure to keep the edge away from your body and keep other people out of the area while handling the blade. Severe lacerations or dismemberment could result from careless handling procedures.

  • Page 39: Knife Care Tips

    7.0 Knife Installation/Changing 10. Plug in the power cord and turn the power on. 11. Go to the MAINTENANCE screen and choose KNIFE ADJUST. Choose KNIFE DOWN, close the guard, and press the cut button to send the knife to the down position (for more details on how to do this, see page 26, Knife Adjustment).

  • Page 40: Knife Blade Life

    4 times again. 7.3.3 Bevel Angle Challenge recommends that bevel angles for the Titan 265 knives be in the range of 21° to 23°. In general, a 21° bevel angle will provide better cut quality when cutting soft paper (such as newsprint), recycled paper, or bound books.

  • Page 41: Knife Care

    • Always keep knife bolts securely tightened. • Always use the heavy-duty knife bolt washers provided by Challenge. Failure to do so could result in scratching or marring of the clamp face. • Store knives in a dry environment to prevent corrosion.

  • Page 42: Maintenance Guide

    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...

  • Page 43: Troubleshooting

    8.0 Maintenance Guide 8.1 Troubleshooting WON’T START Fuse Blown. 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.

  • Page 44: Description Of Error Messages

    8.0 Maintenance Guide Cylinder seals worn - leaking pressure. 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.

  • Page 45: Sensor Data Abbreviations

    8.0 Maintenance Guide Message Description Test Memory Failed A memory error occurred during test Encoder wires 9 & 10 are Should only occur during initial Replace encoder reversed assembly otherwise is an encoder error Memory Locked Tried to change a locked channel Next Channel Locked Tried to link two channels...

  • Page 46: Routine Maintenance

    8.0 Maintenance Guide N.C. No Connection HYDMOT Hydraulic Motor Relay Top right side of main pcb LTLINE Line Light Output Inside rear cutter opening, left side CBTNLIT Cut Button Light In display console *On when pump is running. 8.4 Routine Maintenance DISCONNECT POWER before making any adjustments or lubricating.

  • Page 47: Recommended Hydraulic Oils

    Pump out the hydraulic tank and refill with 5 gallons of International Standards Organization Viscosity Grade 46 (ISO VG 46) rust, oxidation and foam inhibiting hydraulic fluid (Challenge part no. S-1991- NOTE: NEVER use automatic transmission fluid or brake fluid as a substitute for the correct hydraulic fluid.
  • Page 48 8.0 Maintenance Guide Oil Knife Link Oil Knife Link Grease Knife Bar Grease Knife Bar Oil Knife Cylinder Pins Grease Thrust Washers Figure 24 Grease Grease Grease Grease Figure 25 – Clamp Gibs and Rack & Pinion Grease Figure 26 – Leadscrew and Backgauge Guide...

  • Page 49: Oil And Grease

    8.0 Maintenance Guide 8.6 Oil and Grease Turn the power off and disconnect the power cord. Open the front guard (if equipped) and open the top hood for access. Parts requiring oiling are marked with red paint. See Figure 24, Figure 25, and Figure 26 on page 47, for oil and grease locations.

  • Page 50: Squaring The Backgauge

    8.0 Maintenance Guide 6. Turn the side gib screws in until they just touch the guide. The backgauge should not be able to rock side to side. Lock in position with the jam nuts. 7. Run the backgauge back and forth the length of the table using the backgauge glide control. Check for any binding.

  • Page 51: Clamp Height And Level Adjustment

    8.0 Maintenance Guide 4. Back off the adjusting screw on the side that the trim occurred and tighten the other. 5. With the squaring screws tight, make another test. Continue to adjust and test until no trim occurs when testing in either sequence. 6.

  • Page 52: Proximity Switches

    8.0 Maintenance Guide 8. Recheck the clamp height in case tightening the linkage moved it out of adjustment. If the clamp has moved out of adjustment, repeat steps 3 through 7 as necessary. 9. Once a satisfactory setting has been obtained, replace all covers and unlock the power source.
  • Page 53 8.0 Maintenance Guide will be listed, along with their status (0 for open, 1 for closed). The four proximity switches should have the following status during the various knife and clamp positions: Knife Up Knife Up Knife Up Clamp Down Clamp Down Knife Down Clamp Up...
  • Page 54 8.0 Maintenance Guide Clamp Up Proximity Bracket Figure 33 8.7.4.3 Knife Up Proximity Switch (Knfup) Go to the Maintenance Mode and select Knife Adjust, the Knife Down. Press and hold both cut buttons until the knife and clamp are on the table and the hydraulics shut off. Turn the power switch off and lockout power, page 6.

  • Page 55: Hydraulic Adjustments

    8.0 Maintenance Guide Hose Clamp Mounting Actuator Plate Plate Figure 35 8.7.5 Hydraulic Adjustments Note: When adjusting valves, first loosen the jam nut around the stem, then use a hex allen wrench to turn the stem clockwise to increase pressure, or counterclockwise to decrease pressure. Pressure Settings: 1.
  • Page 56 8.0 Maintenance Guide Main System Clamp Pressure Gauge Gauge Clamp Up Sequence Valve Main System Relief Valve Figure 36 3. KNIFE DOWN SEQUENCE PRESSURE: Begin a cut cycle and read the knife sequence pressure from the main system pressure gauge as the knife is traveling down (after the clamp reaches the table).
  • Page 57 8.0 Maintenance Guide 5. CLAMP PRESSURE: The clamp pressure is adjusted remotely from the console with the up and down arrow keys. It is shown in the upper left corner of the display, on a scale of 0 to 15, with 0 being the lightest pressure and 15 the highest.

  • Page 58: Cleaning

    8.0 Maintenance Guide 8.8 Cleaning Before cleaning inside machine turn off and lockout power, page 6. Hydraulics 1. The vent fan should be wiped off weekly to maintain maximum cooling of the hydraulic system. 2. The hydraulic manifold, fittings, and hoses should be wiped off weekly to maintain maximum cooling.

  • Page 59: Parts List & Sequence Of Operations

    9.0 Parts List & Sequence of Operations 9.0 Parts List & Sequence of Operations 9.1 Main Assembly – Front View 44000 Sht. 1 Rev. E...

  • Page 60: Main Assembly - Side View

    9.0 Parts List & Sequence of Operations 9.2 Main Assembly – Side View 44000 Sht. 2 Rev. J...

  • Page 61: Main Assembly - Rear View

    9.0 Parts List & Sequence of Operations 9.3 Main Assembly – Rear View 44000 Sht. 3 Rev. E...

  • Page 62: Main Assembly - Table View

    9.0 Parts List & Sequence of Operations 9.4 Main Assembly – Table View 44000 Sht. 4 Rev. E...

  • Page 63: Main Assembly - Parts List

    9.0 Parts List & Sequence of Operations 9.5 Main Assembly – Parts List 44000 Sht. 5 Rev. S...
  • Page 64 9.0 Parts List & Sequence of Operations Main Assembly – Parts List (continued) 44000 Sht. 6 Rev. N...

  • Page 65: Main Assembly - Cut Buttons

    9.0 Parts List & Sequence of Operations 9.6 Main Assembly – Cut Buttons 44000 Sht. 7 Rev. H...

  • Page 66: Main Assembly - Front Shield

    9.0 Parts List & Sequence of Operations 9.7 Main Assembly – Front Shield 44000 Sht. 7 Rev. H...

  • Page 67: Electrical Panel Assembly

    9.0 Parts List & Sequence of Operations 9.8 Electrical Panel Assembly EE-2879 Rev. H...
  • Page 68 9.0 Parts List & Sequence of Operations Electrical Panel Assembly (continued) EE-2879 Rev. H...
  • Page 69 9.0 Parts List & Sequence of Operations Electrical Panel Assembly (continued) EE-2879, Rev. H...

  • Page 70: Hydraulic Sequence Of Operation

    9.0 Parts List & Sequence of Operations 9.9 Hydraulic Sequence of Operation NOTE: Please see the section on electrical sequence of operation for more details. Hydraulic Sequence of Operation Hydraulic Schematic References Drawing Number: H-516 Sheet 2 A. Dump solenoid de-energized (open) while The hydraulic motor drives the pump outside cut cycle.

  • Page 71: Hydraulic Power Unit Assembly

    9.0 Parts List & Sequence of Operations 9.10 Hydraulic Power Unit Assembly H-507-( ) Rev. E...
  • Page 72 9.0 Parts List & Sequence of Operations Hydraulic Power Unit Assembly (continued) H-507-( ) Rev. E...

  • Page 73: Manifold Assembly

    9.0 Parts List & Sequence of Operations 9.11 Manifold Assembly H-516 Sheet 1 Rev. C...

  • Page 74: Hydraulic Schematic

    9.0 Parts List & Sequence of Operations 9.12 Hydraulic Schematic H-516 Sheet 2 Rev. B...

  • Page 75: Manifold Sub-Plate Assembly

    9.0 Parts List & Sequence of Operations 9.13 Manifold Sub-Plate Assembly H-517...

  • Page 76: Sequence/Check Valve Assembly

    9.0 Parts List & Sequence of Operations 9.14 Sequence/Check Valve Assembly H-551 Rev. A...

  • Page 77: Basic Machine Schematic

    9.0 Parts List & Sequence of Operations 9.15 Basic Machine Schematic E-2853 Rev. C...
  • Page 78 9.0 Parts List & Sequence of Operations Basic Machine Schematic (continued) E-2853 Rev. C...

  • Page 79: Electrical Sequence Of Operation

    9.0 Parts List & Sequence of Operations 9.16 Electrical Sequence of Operation NOTE: Please see the section on Hydraulic Sequence of Operation for more details. Electrical Sequence of Operation Electrical Schematic References Schematic Drawing Number: E-2853 A. Turn Main Disconnect switch to “on” position. If fuses F7 and F4 are conductive, power is brought to the main control board (EE-2807-1).

  • Page 80: Cut Button Assembly

    9.0 Parts List & Sequence of Operations 9.17 Cut Button Assembly EE-2851-1...

  • Page 81: Control Console Assembly

    9.0 Parts List & Sequence of Operations 9.18 Control Console Assembly EE-2773-1 Rev. C...

  • Page 82: Control P.c. Assembly

    9.0 Parts List & Sequence of Operations 9.19 Control P.C. Assembly EE-2807-1...

  • Page 83: Power Panel Label

    9.0 Parts List & Sequence of Operations 9.20 Power Panel Label S-1781-54 Rev. C...

  • Page 84: Fuse Value And Function

    9.0 Parts List & Sequence of Operations 9.21 Fuse Value and Function Location Value/Type Circuit Transformer/ Dimension Part Number Voltage 2A-T Backgauge motor 230 VAC 5mm x 20mm E-2330-3 3.15A-T Pcb output T1. Secondary 5mm x 20mm E-2330-5 5A-T Line lights 12 VDC 5mmx 20mm E-2330-7...

  • Page 85: Knife Latch Assembly

    9.0 Parts List & Sequence of Operations 9.22 Knife Latch Assembly 47568 Rev. C...

  • Page 86: Line Light Assembly

    9.0 Parts List & Sequence of Operations 9.23 Line Light Assembly EE-2779 Rev. B...

  • Page 87: Safety Systems Test

    10.0 Safety Systems Test Machine manufacturer CHALLENGE Model TITAN 265 Serial Number __________________ Frequency of test: THESE TESTS SHOULD BE PERFORMED AT THE BEGINNING OF EACH WORK DAY. Turn the power on and press CLEAR to preset the backgauge. Make sure the knife and clamp are in the up position (if they are not, follow the instructions in this manual to send them up).
  • Page 88 10.0 Safety Systems Test NOTES...

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