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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, 1433
Fulton Avenue

•

Grand Haven

•

MI 49417-1594.

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

•

1433 Fulton Ave.

•

Grand Haven MI 49417

Copyright© 1999 by The Challenge Machinery Company. All rights reserved. Printed in the U.S.A

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Содержание Titan 265

Страница 1: ...Provided By http www MyBinding com http www MyBindingBlog com CHALLENGE TITAN 265 PAPER CUTTER Instruction Manual Serial Numbers 001314 Up...

Страница 2: ...000 TITAN 265 PAPER CUTTING MACHINE Sold and Serviced by The Challenge Machinery Company 1433 Fulton Avenue Grand Haven MI 49417 1594 USA ChallengeMachinery com Serial Numbers 001314 Up INSTRUCTION AN...

Страница 3: ...le 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 re...

Страница 4: ...20 6 1 Power Main Switch 20 6 2 Start Up 20 6 3 Making a Cut Using Two hand cut buttons 21 6 4 Making a Cut Using Front guard 21 6 5 Jogging Aid 21 6 6 Knife Change Alarm and Lubrication Alarm 22 6 7...

Страница 5: ...ne Maintenance 45 8 4 1 Weekly 45 8 4 2 Monthly 45 8 4 3 Yearly 45 8 5 Checking Changing the Hydraulic Fluid 45 8 5 1 Recommended Hydraulic Oils 46 8 6 Oil and Grease 48 8 7 Adjustments 48 8 7 1 Backg...

Страница 6: ...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...

Страница 7: ...nted 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 car...

Страница 8: ...EA 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 gu...

Страница 9: ...das 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 puede...

Страница 10: ...321 6 Washer 3 8 Plain 8 S 1859 1 Shim 005 12 S 1088 5 Wood Screw 10 x 5 8 8 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 S 1245 5...

Страница 11: ...lbs 861 kg Electrical 208 230 Volts 10 30 Amps 1 Phase 60 Hz AC Service size 40 Amps Sound Emission A weighted sound pressure level measured in an enclosed room at operator level 6 feet 183 cm Machine...

Страница 12: ...earance 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 str...

Страница 13: ...nt guard and foot treadle removed it will fit through a 32 81 3 cm opening 5 5 Removing the table Make sure the knife has been removed from the machine and that the knife and clamp are in the up posit...

Страница 14: ...tor junction box cover and disconnect the wires to the motor Figure 4 Remove the leadscrew cover and the nylon tyraps that are attached to the bottom of the table The motor wires and encoder wires sho...

Страница 15: ...disconnected With the lower front cover removed use an open end wrench to remove the two cables attached to the base at the foot treadle These cables hold the foot treadle up Remove the long bracket...

Страница 16: ...st be readjusted see the Accuracy Adjust section on page 27 and the Squaring the Backguage section on page 49 5 9 Installing Extension Tables NOTE The power should be connected to the machine before i...

Страница 17: ...e 11 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 Recommended Oils sec...

Страница 18: ...Up For satisfactory operation be sure that your cutter is wired for the correct phase and voltage and has adequate power The correct electrical specifications are shown on the machine s serial number...

Страница 19: ...t hand corner of the machine rear Secure it with a conduit connector 4 Use a wire nut to join the incoming ground wire with the green yellow or green wire found in the junction box 5 Use wire nuts to...

Страница 20: ...AZARD 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 6 Bulb replacement 1 Make sure power is off a...

Страница 21: ...de section on page 26 To restore power to the display and line lights press any button on the keyboard or press any cut button or lift up the front guard if equipped 6 2 Start Up Once power has been t...

Страница 22: ...place the paper against the backgauge and left side guide If the cut will leave strips of paper less than 2 1 8 wide place the paper against the right side guide This will prevent the strips from get...

Страница 23: ...To reset either alarm or to change the knife alarm value see the Knife Count section on page 27 The lube alarm value is factory set at 2 500 cuts and cannot be changed NOTE The alarms do not prevent n...

Страница 24: ...position and programmed send values in inches e g 5 250 inch fractions to the nearest 1 64 e g 5_1 4 or millimeters e g 133 3 6 9 3 Send Key The SEND key is used to send the backgauge to any valid po...

Страница 25: ...led as A B C and D The definition for these keys change depending on the operating mode The function of the key can be found on the bottom of the display screen 6 9 9 Arrow Keys The four arrow keys ca...

Страница 26: ...nd the backgauge 2 forward from its current position just press 2 and SEND The send mode screen can also be used for doing math calculations that are larger than the backgauge s reverse limit In this...

Страница 27: ...ameter 6 12 2 1 False Clamp The false clamp plate is an optional attachment which reduces the creasing of paper caused by the clamp The disadvantage of using the false clamp plate is that it limits th...

Страница 28: ...ar count to reset the knife counter when a knife change has been performed Select Knife Alarm to enter or change the knife stroke alarm value When this value is reached the display will alert you to c...

Страница 29: ...n page 48 6 12 4 Language In the language screen use the up and down arrow keys to toggle to the desired language and press ENTER All messages will be displayed in the selected language 6 13 Job Mode...

Страница 30: ...S or NO YES will erase the job NO will leave the job unchanged NOTE locked jobs can be erased 6 13 4 Creating a New Job To create a new job type in a number that is not already assigned to a job and p...

Страница 31: ...into one job providing up to 70 198 on s n 001276 and up cut values This is done automatically when a job is at 35 cuts 99 on s n 001276 and up and an attempt is made to add another value At this poin...

Страница 32: ...Exit to exit to send mode Or you may use the job for cutting since it is already open 6 13 5 3 Inserting Send Values To insert a send value press the soft key A Insert This moves all send values down...

Страница 33: ...e an existing job with the new job first erase the existing job by moving the cursor to it and press the soft key C Erase Now type in the new number and press ENTER In this example job s 1 2 5 and 6 a...

Страница 34: ...n Place the paper to be cut against the backgauge close the front guard and press the cut button Once the cut cycle is complete the backgauge will push out the paper and move to the next send value 11...

Страница 35: ...re the first cuts are with these guide edges against the backgauge Measure printed paper to check for shrinkage or expansion of the paper from humidity You may have to disregard the printed cut lines...

Страница 36: ...The knife changing equipment shown in Figure 18 is included in the cutter tool kit The following instructions show how to remove and install a new or re sharpened knife Read through these instructions...

Страница 37: ...ard on the table Remove the scabbard s knife retaining screws 5 Grasp the knife lifters firmly and at the same time turn them counterclockwise to release the knife from the knife bar Figure 21 on page...

Страница 38: ...tainer screw from the new blade and screw the knife lifters into the new blade Screw the lifters all the way in and then back them out a 3 4 turn 5 Remove the other scabbard retainer screw 6 Double ch...

Страница 39: ...n the power cord and turn the power on Make a test cut through a full lift of paper and make minor adjustments if necessary by repeating steps 9 through 17 NOTE If the knife ends cut but the middle do...

Страница 40: ...es called draw Cut marks appear on the cut face of the paper The profile of the cut side view is not perpendicular to the table The cut does not appear straight when viewed from the top The knife make...

Страница 41: ...ng the life of your machine and reduce maintenance 7 3 5 Knife Care To prevent corrosion knives are coated with light oil It should be REMOVED WITH CARE While removing or installing a knife be careful...

Страница 42: ...Parts with the express understanding that they are to replace parts found missing or no longer serviceable on equipment designed and or manufactured at Challenge The Challenge Machinery Company assum...

Страница 43: ...nife latch solenoid defective Knife down coil defective Defective directional valve Cylinder disconnected from cylinder bracket Knife bar dirty or dry lubricate knife guideways Dirt in hydraulic syste...

Страница 44: ...ailure Clamp failed to come down Solenoid valves low voltage low pressure Clamp or Knife Down Clamp or knife stayed down No main pressure stuck solenoid valve DATA IS OUT OF RANGE The number is outsid...

Страница 45: ...harpen Knife Sharpen knife alarm Have knife sharpened Shorted Key Error Console Key shorted Operator error defective keyboard If error codes cannot be reset by depressing the clear key the power will...

Страница 46: ...ar maintenance schedule 8 4 1 Weekly Clean Clean off old dirty excess grease Remove the lower front panel cover and clean accumulated dust off valves hoses and connections Built up dust increases oper...

Страница 47: ...46 rust oxidation and foam inhibiting hydraulic fluid Challenge part no S 1991 3 NOTE NEVER use automatic transmission fluid or brake fluid as a substitute for the correct hydraulic fluid A table of v...

Страница 48: ...ure 24 Figure 25 Clamp Gibs and Rack Pinion Figure 26 Leadscrew and Backgauge Guide Oil Knife Link Grease Knife Bar Oil Knife Cylinder Pins Grease Thrust Washers Oil Knife Link Grease Knife Bar Grease...

Страница 49: ...l for checking and adjusting Be very careful that tools and other people are clear of moving parts and that the cutter is not accidentally operated while adjustments are being made Whenever working on...

Страница 50: ...t not against the side guide and make a cut Now leave the backgauge in the same position flip the lift over and against the right side of the backgauge but not against the side guide Make another cut...

Страница 51: ...4 without false clamp plate 3 3 4 with false clamp plate from the table surface on each end of the clamp then it should be adjusted for optimal cutting performance Clamp Height Adjustment Procedure 1...

Страница 52: ...wer See page 6 2 Remove the bottom front cover and the top rear cover 3 Loosen one end of the rack and pinion shaft coupling pg 50 fig 30 4 Loosen the clamp rod bottom nut on the side of the clamp tha...

Страница 53: ...by loosening the two mounting screws and sliding the switch closer to the knife bar The gap between the proximity switch and the knife bar should be 1 32 1 16 0 5mm 1 5mm Turn the power back on and g...

Страница 54: ...bar should be 1 32 1 16 0 5mm 1 5mm Turn the power back on and when the knife is in it s full up position the proximity should not be on If it is lower the switch until it goes off Figure 34 8 7 4 4 H...

Страница 55: ...e Visual 4 Clamp Pressure Reducer 400 900 psi Adjustment Procedure Note On all valves turning in clockwise increases pressure out counter clockwise decreases pressure 1 Remove the lower front cover pa...

Страница 56: ...t the knife sequence valve Figure 37 to obtain the proper reading Figure 37 4 CLAMP UP SEQUENCE PRESSURE Activate a cut cycle and visually inspect the motion of the knife and clamp The clamp should re...

Страница 57: ...n should be displayed Now perform a cut cycle After the clamp has contacted the table and while the knife bar is coming down read the pressure on the right hand pressure gauge It should read 900 psi I...

Страница 58: ...on abrasive cleaner along with a protective wax 2 The rear table cover and optional front guard may be cleaned with glass cleaner or a mild water based detergent Some petroleum based solvents may dama...

Страница 59: ...9 0 Parts List Sequence of Operations 58 9 0 Parts List Sequence of Operations 9 1 Main Assembly Front View 44000 Sht 1 Rev E...

Страница 60: ...9 0 Parts List Sequence of Operations 59 9 2 Main Assembly Side View 44000 Sht 2 Rev J...

Страница 61: ...9 0 Parts List Sequence of Operations 60 9 3 Main Assembly Rear View 44000 Sht 3 Rev E...

Страница 62: ...9 0 Parts List Sequence of Operations 61 9 4 Main Assembly Table View 44000 Sht 4 Rev E...

Страница 63: ...9 0 Parts List Sequence of Operations 62 9 5 Main Assembly Parts List 44000 Sht 5 Rev S...

Страница 64: ...9 0 Parts List Sequence of Operations 63 Main Assembly Parts List continued 44000 Sht 6 Rev N...

Страница 65: ...9 0 Parts List Sequence of Operations 64 9 6 Main Assembly Cut Buttons 44000 Sht 7 Rev H...

Страница 66: ...9 0 Parts List Sequence of Operations 65 9 7 Main Assembly Front Shield 44000 Sht 7 Rev H...

Страница 67: ...9 0 Parts List Sequence of Operations 66 9 8 Electrical Panel Assembly EE 2879 Rev H...

Страница 68: ...9 0 Parts List Sequence of Operations 67 Electrical Panel Assembly continued EE 2879 Rev H...

Страница 69: ...9 0 Parts List Sequence of Operations 68 Electrical Panel Assembly continued EE 2879 Rev H...

Страница 70: ...will rise Pressure in the clamp down line will level off to the setting of the pressure reducing valve The system pressure will continue to rise until the knife sequence pressure valve opens allowing...

Страница 71: ...9 0 Parts List Sequence of Operations 70 9 10 Hydraulic Power Unit Assembly H 507 Rev E...

Страница 72: ...9 0 Parts List Sequence of Operations 71 Hydraulic Power Unit Assembly continued H 507 Rev E...

Страница 73: ...9 0 Parts List Sequence of Operations 72 9 11 Manifold Assembly H 516 Sheet 1 Rev C...

Страница 74: ...9 0 Parts List Sequence of Operations 73 9 12 Hydraulic Schematic H 516 Sheet 2 Rev B...

Страница 75: ...9 0 Parts List Sequence of Operations 74 9 13 Manifold Sub Plate Assembly H 517...

Страница 76: ...9 0 Parts List Sequence of Operations 75 9 14 Sequence Check Valve Assembly H 551 Rev A...

Страница 77: ...9 0 Parts List Sequence of Operations 76 9 15 Basic Machine Schematic E 2853 Rev C...

Страница 78: ...9 0 Parts List Sequence of Operations 77 Basic Machine Schematic continued E 2853 Rev C...

Страница 79: ...backgauge information see C below C Backgauge control via keyboard The backgauge glide control on the keyboard is used to manually control the backgauge position The speed of the backgauge motor will...

Страница 80: ...9 0 Parts List Sequence of Operations 79 9 17 Cut Button Assembly EE 2851 1...

Страница 81: ...9 0 Parts List Sequence of Operations 80 9 18 Control Console Assembly EE 2773 1 Rev C...

Страница 82: ...9 0 Parts List Sequence of Operations 81 9 19 Control P C Assembly EE 2807 1...

Страница 83: ...9 0 Parts List Sequence of Operations 82 9 20 Power Panel Label S 1781 54 Rev C...

Страница 84: ...5 F3 5A T Line lights 12 VDC 5mmx 20mm E 2330 7 F4 3A T Main Hot 230 VAC 13 32 x 1 E 1075 3SB F5 1 2A T 5V logic preset encoder 15v prox T2 Primary x 1 E 889 12 F6 1 25A T 12v 24v Pcb outputs T1 Prim...

Страница 85: ...9 0 Parts List Sequence of Operations 84 9 22 Knife Latch Assembly 47568 Rev C...

Страница 86: ...9 0 Parts List Sequence of Operations 85 9 23 Line Light Assembly EE 2779 Rev B...

Страница 87: ...__ ______ ______ ______ ______ Test 2 ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ Date ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ Tes...

Страница 88: ...10 0 Safety Systems Test 87 NOTES...

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