User Manual
Contents
1. 23 uinea fei _ 24 6 12 Maintenance MOGE m T P 24 EAR M qa oe AGOS ee eee 24 A E 24 WHITAKER 800 243 9226 W 1 0 Introduction ALE recipe neh anti coe E E en ninavn 26 ARR roan ious yin te mU 27 ARL ARRE 27 6 13 T LOCK UMOCKNO A 000 NER 27 0 132 ONO A JOD 27 S Era 27 6 13 4 Creating New JOD 28 5 13 5 Edling ail EXISUAG 29 6 13 6 Running Programmed 30 ARS E 30 6 14 An Example JOD 30 6 19 Operating 32 6 16 Note to 32 6 16 1 Entering the Dealer Name and Phone 32 7 0 Knife Installation Changing 33 7 1 Knife HEMOV Al NETTE 33 7 2 Knife Installation 35 FO MAAS 36 recu Anie Blade2. 1 8 S 2 9 9 s 9 E 9 21 amp amp 3 z Qo 20 14 5 9 Line Light The Titan 200 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 The light from each bulb reaches the table after passing between the knife and clamp Each light is focused with a socket head capscrew Figure 15 on page 17 OW WHITAKER 800 243 9226 5 0 Installation Setup Line Light Adjustment Screw j Figure 15 5 9 1 Adjustment 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 If the screw turns all the way in before a line appears begin turning the screw counterclockwise 3 Similarly turn the adjustment screw of the other bulb until one continuous beam is seen across the cut stick 5 9 2 Bulb Replacement 1 Make sure power is off and unplug the machine see Power Lockout Procedure page 5 2 Open the front guard if equipped 3 Remove the old bulb by lightly pushing the bulb into the socket and turning it counterclockwise CAUTION If the bulb is still hot allow a few minutes for it to cool 4 I
3. complete floor plan layout see page 43 With table front guard or elec eyes and foot treadle removed can be fit through a 28 71 cm door opening Challenge reserves the right to make changes to any product or specification without notice and without incurring responsibility to existing units 8 W WHITAKER 800 243 9226 5 0 Installation amp Setup 5 0 Installation amp 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 7 Make sure there are no missing items 5 2 Uncrating The Titan 200 weighs approximately 755 lbs 342kg 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 skid is designed to allow the machine to be rolled off without any special lifting equipment The machine is held in place by two 2x4 braces lag bolted to the skid All accessories are shipped inside of the machine Remove the carton by removing
4. 15 220 OWS Hook UD rolla 16 NS HON PR E 16 SOM EA 17 5 9 2 BUID AC TU TTL 17 a ee 18 6 1 uocum ___________ 18 obra 18 6 3 Making a Cut Machines With Electric 5 19 6 4 Making a Cut Machines With Front Guard 19 5 0 0 16 11219 FG RR CRI 19 6 6 Knife Change Alarm and Lubrication Alarm 0000 nnne 20 6 7 Manual Clamping Using the Foot nnne 20 21 naar ii 21 6 9 1 Variable Speed Pinpoint Backgauge Control 21 I E 21 LISI 21 6 9 4 Push Out Key Hold To Run Backgauge 22 22 TC PR EA 22 69 7 Ada OO 22 YS asec cece 22 BOW 22 6 9 10 Contrast Control Serial Numbers 083330 and 22 6 9 11 Contrast Control Serial Numbers 083331 and Above 22 6 10 Manual Backgauge 23 6 10 1 Backgauge Glide Control 23 6 10 2 onirica 23 cim a A 23 2 gt
5. 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 Machines with Front Guards Test 1 With the front guard open press the cut buttons Nothing should happen If the knife and or clamp come down with the front guard open do not use the machine Repair or adjustment is needed Test 2 Close the front guard and press the cut buttons While the clamp or knife is coming down open the front guard The knife and clamp should immediately return to the up position If they do not do not use the machine Repair or adjustment is needed Machines with Electric Eyes Test 1 Wave a test object 12mm in diameter between the electric eye beams The indicator lights should indicate the eyes are blocked If they do not do not use the machine Repair or adjustment is needed Test 2 If machine equipped with electric eyes while making a cut lean into the electric eye beams The knife and clamp should immediately return to the up position If they do not do not use the machine Repair or adjustment is needed WMHIAKER 800 243 9226 10 0 Safety Systems Test Please enter date and initials for both tests Date Date Test 1 Test 2 Date Test 1 Test 2 Date Test 1 Test 2 Date Test 1 Test 2 Initials of Repairs Repairer Date 45 WHITAKER 800 243 9226 W
6. and the shroud as the left end is brought clear of the left guide frame Move the knife to the right then bring the knife out of the cutter left end first Put the blade in the scabbard immediately and secure the knife retainer screws Figure 24 WHITAKER 800 243 9226 34 W W 7 0 Knife Installation Changing 7 2 Knife Installation CAUTION 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 sure the knife and clamp are the up position If they are not turn on the power using the red and yellow main power switch close the front guard if equipped and press the CLEAR button This will preset the backgauge and send the knife and clamp up Turn off the machine and unplug the power cord Pull out the cutting stick using the cut stick removal tool and turn it to a new surface If the cutting Stick is not level or flush with the table 1 2 strips of paper can be placed in the table slot under the cutting stick to shim tt Remove the left retainer screw from the new blade and screw the knife lifter assembly into the new blade Screw the lifters all the way in and then back them out a 3 4 turn Remove the other scabbard retainer screw Double check to make sure the knife adjusting screws have been backed out all
7. arrow keys to toggle between characters of the alphabet Numbers can be entered directly by using the number keys Pressing CLEAR clears the current character When finished you may either go to the current job by pressing ENTER or go to a different job or exit job mode 6 13 5 2 Editing Send Values To edit send values of an existing job start by opening the desired job from the job mode screen A job is opened by one of two methods pointing at the desired job with the cursor and pressing ENTER or by entering the job number with the keypad and pressing ENTER Once a job has been opened the current job number will be displayed in the upper right corner Note If the job is locked it cannot be edited Send values can now be edited by moving the cursor up or down to the desired send value and then typing over the existing value When finished editing the job you may exit the current job by pressing soft key B Job to go back to the job mode screen or soft key D 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 and provides a blank line after the current send value If more than 99 send values are needed the job can be linked see Channel Linking under the Creating a New Job section on page 28 6 13 5 4 Erasing Send Values To erase a send value press the soft
8. display should now look similar to the one shown next 5 000 1 _ 4 To enter the first send value of 8 5 simply type 8 5 and press ENTER The cursor will move to the second line Now type 11 and press enter 5 000 1 8 500 2 11 000 o gt At this point you could exit and save the job by pressing the soft key D Exit to exit to send mode or the soft key B Job to exit back to the job mode screen However lets use this job to cut paper 5 Press the down arrow key once This will remove the blank line 3 and move the cursor to the first send value 8 5 Now press SEND This will move the backgauge to the 8 5 position 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 Now position the paper again close the guard and make another cut After the cut is 31 WHITAKER 800 243 9226 W 6 0 Operation made the backgauge will push out the stock and return to the first cut position ready to repeat the current job 6 Now lets lock the current job so it cannot be edited First exit back to job mode by pressing soft key B Job Now move the cursor down to the new job using the down arrow key Now press the soft key A Lock to lock the job An asterisk will appear indicating the job has been locked 7 To exit back
9. existing job and press ENTER If the new job is locked the copy will not be allowed NOTE if the new job is not locked but contains data the old data WILL BE LOST 6 13 3 Erasing a Job select a job to erase by moving the cursor to the desired job Press the soft key C Erase Clear channel will be displayed followed by YES or NO Use the up and down arrow keys to toggle to YES or NO YES will erase the job NO will leave the job unchanged NOTE locked jobs can be erased 27 WHITAKER 800 243 9226 W 6 0 Operation 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 press ENTER entering a job number greater than 99 will create job 99 The cursor will move to the line corresponding to the number you typed in prompting you for a job name no job name is desired simply press ENTER again to begin entering send values see below To name the job press the right arrow key to move the cursor to the first character position Enter a character of the alphabet by using the up and down arrow keys to toggle to the desired character The numeric keys can be used to enter numbers directly into the job name When the desired character is in place use the right arrow key to move to the next character position The job name can be up to 10 characters long A letter can be removed from the job name by moving the cursor to the undesired character and pressing the CLE
10. in position Lift the table from the front and set the two front spacers in place Insert the front two socket head screws but do not tighten Lift the table from the rear and set the two rear spacers in place Start the rear two socket head screws Reinsert the two taper pins and tap into position so they are below bottom of the slot Tighten all four screws Attach the right and left side guides Figure 7 amp Figure 8 on page 12 the presetter board assembly Figure 6 on page 12 the motor and encoder wires Figure 4 amp Figure 5 on page 11 and all other items that were removed Once the table is installed the backgauge squareness and accuracy will have to be reset See the Titan 200 Technical Service and Parts manual for information on how to do this 13 WHITAKER 800 243 9226 W 5 0 Installation amp Setup 5 5 Installing Optional Extension Tables Front Guard Machines Only Using the wood screws provided attach a back plate to each extension table Using 4 3 8 16 capscrews attach the table support to the under side of the main table as shown in Figure 11 Route each cut button wire through the slots in the bracket and relocate the cut buttons to the extension tables as shown Place the provided flat washers on the table support above each slot receiving a screw to mount the extension table on the support Lay the table extension on top of the Spacers and insert the screws Slide the table extension tight to the ta
11. indicate the presence of the false clamp plate and press ENTER OW WHITAKER 800 243 9226 6 0 Operation 6 12 2 2 Time out The time out parameter allows the operator to set the amount of idle time before the display and line lights turn off The choices are 2 5 10 20 and 30 minutes In the time out screen use the up and down arrow keys to toggle to the desired time out and press ENTER 6 12 2 3 Push out Normally whenever the backgauge is sent to a larger dimension a five inch 127mm push out is performed to aid the operator in accessing the paper In some situations it may be necessary to turn this feature off It is recommended that this feature be left on whenever possible In the push out screen use the up and down arrow keys to toggle to the on or off status as desired and press ENTER 6 12 2 4 Accuracy Adjust This parameter provides a means for adjusting the accuracy of the backgauge To change the accuracy send the backgauge to 2 inches 50 8mm and cut some paper Measure the paper and type in what you actually measure The computer will calculate the amount of error and will compensate 6 12 2 5 Knife Count The knife count parameter allows the operator to reset the knife alarm and the lube alarm The knife alarm displays a message that notifies the operator to change the knife The lube alarm displays a message that notifies the operator to have the machine lubricated The lube alarm will also display the n
12. 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 6 W WHITAKER 800 243 9226 3 0 Packing List 3 0 Packing List Part No Description Qty A 10034 4166 200 12608 2 20 2150 2 6918 608 8815 5064 43108 W 130 3 16 Allen Wrench W 137 W 164 W 170 9 16 x gt Wrench SU 10 113 Optional Items Part No Description Qty AA 10061 False Clamp Plate 5 7 M361 Backgauge Book Guides 4166 Cutting Stick A 10034 1 High Speed Steel Knife W WHITAKER 800 243 9226 4 0 Specifications 4 0 Specifications Description Inch Units Metric Units Cutting Width Minimum Clamp Opening Table Space Front 1594 Back 20 Table Height Overall Height Overall Length 80016 Overall Width Approx Net Weight 800 105 Approx Shipping Weight 920 lbs 208 230 Volts 12 Amps 1 Phase 60 Hz AC Service size 15 Amps Recommended Recepticle 208 230 Volt NEMA 6 15R NEMA 6 20R UL cUL Listed Sound Emission A weighted sound pressure level measured in an enclosed room at operator level 6 feet 183 cm Machine cutting a full lift of paper 77 dB With false clamp plate attached minimum cut is 1 7 8 48 mm
13. stick removal tool Locate the two taper pins in the cut stick slot These must be tapped out from under the base through the table slot and removed Then remove the four screws that mount the table to the base NOTE The table assembly is very heavy and requires two people to remove Pull the table out from the back of the machine Locate the four round spacers that were between the table and the base you will need them later for mounting the table 11 WHITAKER 800 243 9226 W 5 0 Installation Setup _ Presetter Board Assembly 4 7 Cut Stick J Cut Stick Stop Right Side Guide AS Figure 8 12 W WHITAKER 800 243 9226 5 0 Installation amp Setup 5 4 2 Removing the Foot Treadle Make sure the power is off and the power cord is disconnected Remove the lower front cover Use an open end wrench to remove the two cables attached to the base which hold up the foot treadle Carefully remove the springs Now remove the pins at the rear pivot points of the foot treadle Remove the treadle 5 4 3 Removing the Front Guard If Equipped Make sure the power is off and disconnect the power cord Open the front guard Remove the cylinder bracket screws Figure 9 Figure 9 Then open the top hood and remove one set of hinge screws Figure 10 Slide the front guard out of the other hinge Hinge Screws Figure 10 5 4 4 Reattaching the Table Set the table
14. 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 all lag screws from the skid Remove the lower front cover of the Titan 200 and remove the two lag screws in the base Remove the accessories Using the rear bumper board pry one side of the machine up and slide out the top layer of the support riser Figure 2 Do the same on the other side Figure 2 Use the flat board provided as a ramp and position as shown in Figure on page 10 Hold the ramp place with the nails provided Make sure the casters not locked and very carefully roll the machine down the ramp The cutter may now be rolled into position WHITAKER 800 243 9226 W 5 0 Installation amp Setup Figure 3 5 3 Cleaning After unpacking wipe down all machine panels and clean the table surface 5 4 Fitting Through Narrow Door The Titan 200 cutter will not fit through an opening less than 36 91 cm without the table being removed With the table removed the Titan 200 will fit through a 35 89 cm opening With the table front guard and foot treadle removed it will fit through a 28 71 cm opening 5 4 1 Removing the Table Make sure the knife and clamp are in the up position If they are not read the Power Hookup section page 16 to connect powe
15. to send mode press the soft key D Exit 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 If an accurate cut is necessary for close register work you MUST have sharp blade in the cutter dull blade will pull or draw the paper and cause uneven cutting Increased clamp pressure will not eliminate draw caused by a dull knife The correct clamping pressure varies from paper to paper The general rule is that you should have enough pressure to hold the paper securely but not so much that it marks the surface of the paper excessively Excessive pressure causes pile distortion and inaccurate cuts Mark the gripper edge and the guide edge of printed paper and make sure 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 and make your own When cutting business cards or narrow strips of paper place lifts of equal height on opposite sides of the table to prevent wear of the clamp guides 6 16 Note to Dealer 6 16 1 Entering the Dealer Name and Phone Number To enter or change the dealer name and phone number that will be displayed when the lubrication a
16. used to make two cuts one at 8 5 and one at 11 1 Turn on the machine and press CLEAR to preset the backgauge Press the soft key Job to go to job mode 2 Type in a new job number and press ENTER Note It must be a number that does not correspond to an existing job All existing jobs will be displayed on the screen you may have to scroll through them to see them all If you wish to replace an existing job with the new job first erase the existing job by moving the cursor to it and press the soft key Erase Now type the new number and press ENTER In this example job 5 1 2 5 and 6 already exist We will use job 7 for our new job Press 7 and ENTER 3 cursor will move down to the new job number At this point press the right arrow key once to move the cursor to the first character position Now name the job 8 5 11 To do this press 8 on the number key pad Then press the decimal key and so on To enter the spaces and the letter X use the up and down arrow keys to toggle through the alphabet and press the right arrow key to move to the next character position When the last character has been typed in the display should look similar to the one shown below 1 gt 1 2 gt TESTJOB 5 gt BOBS JOB 6 gt 7 gt 8 5 11_ A Lock B Copy OW WHITAKER 800 243 9226 6 0 Operation Now press ENTER to begin programming the job
17. 10 0 Safety Systems Test WMHTAKER 800 243 9226
18. 36 FERMA Se SERERE 37 7 3 3 Bevel 37 7 3 4 Helpful 5 37 SS OGA 37 2 ise E 40 2 FOO tcl CT et ee 43 MOV SAM RN TEE SET T X 44 W HITAKER 800 243 9226 2 0 Safety 2 0 Safety 2 1 Precautions e This machine is designed for one person operation Never operate the machine with more than one person e Safe use of this machine is the responsibility of the operator Use good judgment and common sense when working with and around this machine e 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 e Only trained and authorized people should operate this machine e DO ALTER SAFETY GUARDS OR DEVICES They are for your protection Severe personal injury may result e 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 ta
19. A ChallengeMachinery com August 2003 WHITAKER 800 243 9226 1 0 Introduction 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 CAUTION 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 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 e 6125 Norton Center Drive Norton Shores 49417 1594 ti 2 DEALER NAME amp CITY O 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 Wa
20. AR key When finished press ENTER to save the name and to begin entering send values The screen should now look similar to the one shown next 5 000 1 _ 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 feature as described below When finished entering send values you may exit the current job by pressing soft key B Job to go back to the job mode screen or soft key D Exit to exit to send mode Or you may use the current job for cutting by pressing the down arrow at the last line and following the instructions in the Running a Job section page 30 6 13 4 2 Cut and Record To use this feature send the backgauge to a desired position using the backgauge glide control or by using SEND then make a cut The current backgauge position will automatically be entered into the job as a send value This can be very convenient for setting up a program when the actual cut positions are not known 6 13 4 3 Channel Linking If more than 99 cut values are needed 2 channels can be linked together into one job providing up to 198 cut values This is done automatically when a job is at 99 cuts and an attempt is made to add another value At this point a screen is displayed asking do you want to link to t
21. ame 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 There are three functions within the knife count parameter Clear Count Knife Alarm and Clear Lube Select the desired function and press ENTER See the following descriptions for an explanation of each function Select Clear 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 change the knife and reset the knife counter Knife alarm values for the Titan 200 are factory set at 2 500 cuts However you may want to change this value based on your specific machine applications See 7 3 Knife Care Tips page 36 for help in choosing a knife alarm value for your machine Select Clear lube to reset the lube alarm after performing the lubrication requirements as shown in the Titan 200 Technical Service and Parts manual Note The number of cuts needed to set off the alarm is programmed at the factory and cannot be changed 6 12 2 6 Machine count The number displayed is the total number of cuts made by the machine 25 WHITAKER 800 243 9226 W 6 0 Operation 6 12 3 Diagnostic The diagnostic area can be very helpful in locating a problem in the event of a machine malfunction Use the up and down arrow keys to toggle to the desired s
22. an also enter an equation which begins with the current backgauge position For example if you want to send 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 case you must press ENTER to have the result displayed on the screen 6 11 1 Entering Math In the simple send mode the Titan 200 is capable of calculating an entire math string such as 10 5 5 6 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 23 WHITAKER 800 243 9226 W 6 0 Operation 6 11 2 Entering Fractions Fractions are entered with the priority add key X Y The symbol displayed when this key is pressed is the underline symbol _ This instructs the computer to add the fractional portion of the entry before performing the remaining math This key is useful when entering a formula as follows 3x2_ 3 4 8 1 4 If a simple plus had been used instead the result would be as follows 3x2 3 4 6 3 4 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 From the Send Screen Figure 20 on page 23 e
23. ble Shim the extension tables as necessary to make the tables flush using the provided shims VIEW FROM UNDERNEATH TABLE CAPSCREW BACK PLATE TABLE SUPPORT CAPSCREW WASHER amp SHIMS Figure 11 5 6 Hydraulic System Check The cutting clamping mechanism of the Titan 200 is powered by a hydraulic system consisting of an electric motor coupled directly to a hydraulic pump The hydraulic reservoir holds 4 quarts 1 gallon of hydraulic fluid It is filled with Rykon 100 hydraulic fluid at the factory but should be checked before operation Remove the lower rear panel cover and unscrew the cap on top of the tank Figure 12 on page 15 Fluid level should be at 1 8 from the end of the dip stick check with dip stick cap screwed in Add fluid if necessary but avoid overfilling as this could cause leakage when hot Replace the rear panel when finished For more information about checking and changing the hydraulic fluid including a cross reference chart of approved fluids see the Titan200 Technical Service and Parts manual The hydraulic fluid should be checked weekly and changed AT LEAST ONCE A YEAR or after every 1 000 hours of operation WHITAKER 800 243 9226 5 0 Installation amp Setup Dip Stick w c a Figure 12 5 7 False Clamp Plate Optional To prevent marking on pressure sensitive jobs a false clamp plate is available as an optional item for your machine This plate attaches t
24. ble 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 e When replacing hydraulic parts loosen the connections slowly to release pressure Never loosen connections with the machine running e If the cutter sounds or operates unusually turn it off and consult the troubleshooting section of this manual If the problem cannot be corrected have it checked by a qualified service person CRUSH HAZARD keep hand and fingers from under the clamp when clamping paper Use Jogging Aid to load paper and use the backgauge to push paper out before unloading DO NOT REACH UNDER THE KNIFE AND CLAMP AREA 2 2 Power Lockout Procedure For maximum safety while making adjustments or repairs to your machine be sure to disconnect power to the machine Disconnect the power plug from its socket Figure 1 Main Power Disconnect WHITAKER 800 243 9226 W 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 47 Disconnect power before cleaning servicing making adjustments not requiring N power Do not alter safety guards or devices they are for your
25. ear error messages and the current entry line 6 9 6 Enter Key The ENTER key selects items in the maintenance mode and processes data that has been entered in the other modes 6 9 7 Priority Add X Y Key The priority add key is used for entering fractions when they are combined with whole numbers The symbol displayed when this key is pressed is the underline symbol _ An example of a number entered using the priority add key is 1_ 1 2 see 6 11 2 Entering Fractions page 24 6 9 8 Soft Keys The soft keys are labeled 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 can be used in almost all screens The arrow keys are primarily used for moving the cursor around on the screen or to toggle between highlighted selections In some screens the left arrow key acts as a backspace key 6 9 10 Contrast Control Serial Numbers 083330 and Below The contrast of the display can be adjusted by using the contrast control knob which is located directly behind the display panel sticking out of the display panel cover To access open the front guard reach in with your left hand until you feel the knob and adjust the contrast as necessary 6 9 11 Contrast Control Serial Numbers 083331 and Above The contrast of the display can be adjusted by first pressing the hidden button on the contro
26. election and press ENTER See the following descriptions for an explanation of each 5 000 DIAGNOSTIC Error Code Sensor Data Clear Memory Electric Clamp Clamp Adjust A Maint C Send B Job D Exit 6 12 3 1 Error Code The Error Code function simply recalls the last five error messages that were displayed This can be very useful in cases when the malfunction cannot be reproduced in the presence of the service technician 6 12 3 2 Sensor Data The Sensor Data function provides a list of computer inputs and outputs proximity switches etc along with their status 0 for open 1 for closed This function allows a service technician to check the status of a switch without removing any covers Cuts and backgauge movements are allowed in this screen so that the technician may observe the status of the inputs and outputs during machine operation 6 12 3 3 Clear Memory The Clear Memory function resets the memory to a known state All cut positions will be erased during this operation 6 12 3 4 Electric Clamp This function turns the optional electric clamp pressure control on or off 6 12 3 5 Clamp Adjust This function allows for the adjustment of the electric clamp function 26 vy WHITAKER 800 243 9226 6 0 Operation 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 M
27. f 3 knives one in the machine one as a back up and one at the grinder e f the machine seems to strain but the cut quality is still good reduce the pile height You may also carefully apply glycerin to the bevel when cutting hard coated paper Tie a cloth to the end of a stick dip the stick in glycerin and apply Never apply by hand In lieu of glycerin you may lightly rub white bar soap along the bevel Lubrication will prolong the life of your machine and reduce maintenance 7 3 5 Knife Care e To prevent corrosion knives are coated with light oil It should be REMOVED WITH CARE e While removing or installing a knife be careful not to allow the edge to bump against the machine Nicks will result 37 WHITAKER 800 243 9226 W 7 0 Knife Installation Changing e lf aknife bolt is damaged replace it e Always keep knife bolts securely tightened e 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 e Store knives dry environment to prevent corrosion Never attempt to service a knife in any way W WHITAKER 800 243 9226 7 0 Knife Installation Changing NOTES 39 W WHITAKER 800 243 9226 8 0 and Grease 8 0 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 pai
28. he Challenge dealer from which the machine was purchased To reset either alarm or to change the knife alarm value see 6 12 2 5 Knife Count page 25 NOTE The alarms do not prevent normal operation they are simply reminders 6 7 Manual Clamping Using the Foot Treadle The Titan 200 is equipped with a manual clamping feature which allows the operator to manually clamp paper before beginning the cut cycle To use this feature press down on the foot treadle until the clamp comes down on the paper While holding the foot treadle down close the guard if equipped and press both cut buttons Release the foot treadle once the cut has been completed WHITAKER 800 243 9226 20 6 0 Operation 6 8 Display Panel Push Out key IN MM key 1 32 1 16 3 32 1 8 5 32 Variable Speed Pinpoint Backgauge Control Soft Keys Hidden key Arrow Keys A 3B ES Priority Add L cen X Y key ENTER key Figure 19 6 9 Definition of Keys 6 9 1 Variable Speed Pinpoint Backgauge Control The backgauge control is used to manually position the backgauge The speed of the backgauge will depend upon where the act
29. he next channel Use the up or down arrow key to select yes or no If no is selected the last cut will be discarded and 28 vy WHITAKER 800 243 9226 6 0 Operation the new value will be inserted If yes is selected the last cut will be pushed into the first value of the next channel although it will be displayed as value 100 of the current channel If the next channel is locked linking will not be allowed NOTE If the next channel is not locked but contains data the old data WILL BE LOST After 2 jobs have been linked the linked job will be displayed as and will be locked To unlink a job use the up or down arrow key to point to the linked job name and press soft key C Erase When finished entering send values you may exit the current job by pressing soft key B Job to go back to the job mode screen or soft key D Exit to exit to send mode Or you may use the current job for cutting by pressing the down arrow at the last line and following the instructions in the Running a Programmed Job section 6 13 6 below 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 Then press the right arrow key to move the cursor to the desired character position and edit the character by pressing the up or down
30. key C Erase This will remove the cut value currently being pointed to by the cursor To backspace over the current send value without removing the line press the left arrow key 29 WHITAKER 800 243 9226 W 6 0 Operation 6 13 6 Running a Programmed Job To use an existing job for cutting you must first open it by using one of two methods move the cursor to the desired job with the arrow keys and press ENTER or enter the job number with the keypad and press ENTER Once a job has been opened the current job number will be displayed in the upper right corner Now press SEND to move the backgauge to the first programmed position or send value Close the front guard and make a cut Once the cut is made the backgauge will automatically push out the paper if push out is enabled and move to the next programmed position After the last cut in the job is made the backgauge will move to the first cut position of the current job Pressing SEND at any time during the job will send the backgauge to its next programmed position without making a cut A plus sign will be displayed at the bottom of the screen if more cuts remain in the current job 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
31. l console face plate and then using the left or right arrow buttons press as needed to fine tune the screen s contrast OW WHITAKER 800 243 9226 6 0 Operation 6 10 Manual Backgauge Control 6 10 1 Backgauge Glide Control The backgauge can be moved manually by use of the backgauge glide control Press towards the operator for forward travel and away from the operator for reverse travel The further away from center that the actuator is pushed the faster the backgauge will travel 6 10 2 Backlash Indicator To insure accurate cuts the backgauge must be brought to the cut position from the rear of the table In the display to the right of the backgauge position there is a small arrow to indicate reverse travel Figure 20 This arrow should be off when making a cut Moving back past your cut position then forward to it compensates for any play in the backgauge nut and leadscrew 6 11 Send Mode 5 000 in A Reverse Indicator Arrow Figure 20 The send mode is the first screen displayed after the backgauge is preset From this screen the backgauge can be positioned with the backgauge pinpoint control or by entering a value and pressing the SEND key If the send value is less than approximately 4 either the hood must remain down or the push out button held in for the backgauge to continue to the send position A mathematical expression can also be entered as a send value Simply type the expression and press SEND You c
32. larm is displayed and when the upgrade screen is displayed you must first enter the Dealer Mode screen Todo this turn off the power and then simultaneously hold the left and right arrow keys while turning on the power Continue to hold the arrow keys for a few seconds after the machine turns on Now enter the desired dealer information by using the up and down arrow keys to toggle through the characters similar to naming a job Use the right arrow key to move to the next character and to move to the 2nd line When finished turn off the power W WHITAKER 800 243 9226 7 0 Knife Installation Changing 7 0 Knife Installation Changing CAUTION 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 Clear off cutter table before removing knife Have scabbard on cutter table and insert knife immediately Warn people of any unprotected knife Knife changing is ONE PERSON OPERATION Having more than one person trying to change knives invites accidents 5 16 T Wrench Knife Lifter Asm 3 16 Hex Allen Wrench B 5 Cut Stick N Removal Tool Figure 21 Knife Changing Equipment The knife changing equipment shown in Figure 21 is included in the cutter tool kit The following instructions sho
33. lectrical codes It is the customer s responsibility to provide a properly grounded receptacle that meets the power requirements specified on the nameplate of this machine as well as all local electrical codes Have a qualified electrician install one if your location is not so equipped Check incoming voltage and position the voltage selection jumper in the proper location as shown below 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 Connect the power cord into a grounded 3 prong receptacle only Recommended receptacle 208 230 Volt NEMA 6 15R or NEMA 6 20 208 V 250 V Ci Fo N M FS S F6 TS F6 TS o M 0 ja o o lollo 2 O 9 gt a gt gt lt TERMINAL amp 7 9 ZO 9 BLOCK si OZ 2 7 8 JUMPER BLOCK o 1 8
34. n the CLEAR key is pressed the clamp and knife will move up if they are not already in the up position provided the front guard is closed if equipped Then the backgauge will move to coordinate the true position into the computer When finished the machine will be in Send Mode and the display will appear similar to the display shown on top of the next page OW WHITAKER 800 243 9226 6 0 Operation backgauge may now be sent to desired position by simply typing the dimension and pressing SEND see the Send Mode section page 23 for more details 6 3 Making a Cut Machines With Electric Eyes Place the paper against the backgauge and left side guide Note If the cut will leave strips of paper less than 1 2 wide place the paper against the right side guide This will prevent the strips from getting caught in the small opening near the left side guide To make a cut make sure there are no obstructions between the electric eyes and press both cut buttons located beneath the front face of the table within 1 2 second of each other Hold the buttons in until the knife reaches the table Releasing the cut buttons at any time during the cut cycle will immediately send the knife and clamp to the up position 6 4 Making a Cut Machines With Front Guard Open the front guard and place the paper against the backgauge and left side guide Note if the cut will leave strips of paper less than 1 2 wide place the
35. nsert the new bulb into the socket and twist it clockwise until the bulb locks into place 5 Reconnect power and turn the main power switch on Readjust the line if necessary 17 WHITAKER 800 243 9226 W 6 0 Operation 6 0 Operation CAUTION IMPORTANT DO NOT ATTEMPT TO OPERATE THE CUTTER UNTIL YOU HAVE THOROUGHLY READ AND UNDERSTAND ALL OF THE FOLLOWING INSTRUCTIONS CALL YOUR AUTHORIZED CHALLENGE DEALER IF YOU STILL HAVE ANY QUESTIONS 6 1 Power Main Switch Power is brought to the machine when the main power switch 15 turned to the ON position Figure 16 The display and line lights are turned on at this time The hydraulic motor will not be activated until a cut cycle is initiated and it will shut off after the completion of the cut cycle I OFF ON Figure 16 Power On Off Switches The display and line lights will shut off after 5 minutes without any activity This shut off time can be changed in the Parameters screen of the Maintenance Mode section 6 12 2 on page 24 To restore power to the display and line lights press any button on the keyboard or lift up the front guard if equipped 6 2 Start Up Once power has been turned on the Titan 200 will show the following display 55 000 Backgauge must move to be preset Please clear the table and close guard Warning Clamp and Knife may move Revision 1 0 Press clear to start A Maint B Job Whe
36. nt See figures Figure 26 through Figure 33 starting on page 40 for oil and grease locations Figure 26 through Figure 28 require the Knife and clamp be in the up position Figure 29 through Figure 33 require the knife and clamp be down Wipe off any old or excess grease Use any brand name type of grease or light oil to lubricate It may be necessary to use the supplied grease brush to access some locations Note the leadscrew may be lubricated with grease or oil Oil has a tendency to run off and must be lubricated more frequently grease tends to collect paper dust and must be cleaned off periodically Grease Oil Figure 27 Knife Bar Link R H Side Upper WHITAKER 800 243 9226 40 W 8 0 and Grease Figure 30 Knife Bar Link R S Lower Knife Bar Knife Cylinder Bracket Upper 41 WHITAKER 800 243 9226 W 8 0 and Grease Figure 33 Leadscrew Backgauge Guide WHITAKER 800 243 9226 42 W 9 0 Titan 200 Floor Plan 9 0 Titan 200 Floor Plan 43000 FP LU A Net Wt 755 61342 MACHINE DIMENSIONS AxBxC MACHINE DIMENSIONS WITH SIDE TABLE EXTENTIONS DxBxE OPERATING AREA FxC OVERALL MAINTENANCE AREA FxC 43 WHITAKER 800 243 9226 10 0 Safety Systems Test 10 0 Safety Systems Test Machine manufacturer CHALLENGE Model TITAN 200 Serial Number Frequency of test THESE TESTS SHOULD BE PERFORMED AT THE BEGINNING OF EACH WORK DAY
37. nter A to go to the Maintenance Screen 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 5 000 MAINT MENU KNIFE ADJUST PARAMETERS DIAGNOSTIC LANGUAGE B Job C Send D Exit 6 12 1 Knife Adjust The knife adjust function provides a way for the service technician to adjust change the knife In the Knife Adjust screen use the up and down arrow keys to toggle to the up or down status as desired and press ENTER Close the front guard if equipped and press the cut buttons to send the knife to the desired position in the down mode hold the cut buttons until the motor turns off NOTE To exit the knife down screen and return to the main menu screen press D exit 6 12 2 Parameters In the parameter screen use the up and down arrow keys to toggle to the desired parameter and press ENTER See the descriptions that follow for an explanation of each parameter 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 the smallest cut dimension The computer must know when the false clamp plate is installed on the machine to prevent the backgauge from crashing into it In the false clamp screen use the up and down arrow keys to toggle between ON or OFF to
38. o the bottom of the clamp It is secured with wing nuts on studs that pass through the top 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 close the front guard and press the CLEAR button This will preset the backgauge and send the knife and clamp up 2 Turn the power off and disconnect the power cord Open the front guard if equipped and slide the false clamp plate under the knife and clamp Figure 13 and slide the plate up into position with the locator pins toward the front of the machine The locator pins insert into holes in the bottom front of the clamp 4 Hold the plate in position and secure with the wing nuts provided 5 Change the false clamp setting of the machine to ON to prevent the backgauge from crashing into the false clamp plate This is done in the Maintenance Mode Parameters False Clamp screen For more details on how to do this see page 24 NOTE The minimum cut with the false clamp plate attached is 1 3 4 Locator Figure 13 15 WHITAKER 800 243 9226 W 5 0 Installation amp Setup 5 8 Power Hook Up CAUTION SHOCK HAZARD NEVER CUT THE GROUND PLUG from a three prong plug to fit a two prong socket Possible shock could cause personal injury or death Hire a qualified electrician to provide a power source that meets electrical requirements and all local e
39. ode The Titan 200 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 Each job can hold up to 99 send values If 2 channels are linked up to 198 send values can be accessed from one job When the job mode is entered all previously programmed jobs will be displayed along with their name and lock status Locked jobs will be indicated by an asterisk A plus sign at the bottom of the screen indicates there are more jobs programmed than what are displayed An example of a job mode screen display is shown below gt 1 gt 1 2 gt TESTJOB 5 gt 6 gt BOBS JOB 7 gt 8 5 X 11 9 gt 10 gt 4 A Lock B Copy 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 If a job is locked an asterisk will be displayed to the right of the job name change the lock status of a job simply move the cursor to the desired job using the up and down arrow keys and press the soft key A Lock Unlock 6 13 2 Copying a Job First select a job to copy by moving the cursor up or down to the desired job number and press the soft key Copy Select Copy to will be displayed at the bottom of the screen Enter a job number for the new job or move the cursor to an
40. of the dangers but others may not be Never attempt to hone polish or service the knife in any way Failure to follow safety procedures may result in severe lacerations or dismemberment 7 3 1 Knife Blade Life Knife blade life or the time between sharpenings can be affected by many factors One important factor is the type of paper being cut Abrasive paper such as recycled paper soft paper such as newsprint paper and bound books can all significantly shorten knife blade life Also if the knife depth is set too deep the knife will cut too deep into the cutting stick and can dull the knife blade A knife can last between 2 000 and 5 000 cuts before it needs to be sharpened Cutting soft paper such as newsprint paper or paper with high post consumer recycled content can cause the knife to need sharpening after only 2 000 to 3 000 cuts Cutting pure paper such as bond paper with no recycled content or hard paper can allow the knife to be used for as many as 5 000 cuts before it needs to be sharpened In all cases the operator should continually check the quality of the cut to WHITAKER 800 243 9226 36 W 7 0 Knife Installation Changing determine when the knife blade needs to be sharpened Some characteristics that indicate a blade needs sharpening are e The knife hesitates or stalls while making a cut e The sheets are not all cut to the same length usually the top few sheets are longer than the rest of the sheets
41. paper against the right side guide This will prevent the strips from getting caught in the small opening near the left side guide To make the cut close the front guard and press both cut buttons located beneath the front face of the table within 1 2 second of each other Hold the buttons in until the knife reaches the table Releasing the cut buttons or raising the guard at any time during the cut cycle will immediately send the knife and clamp to the up position Note The guard must be opened and closed each time a new cut is made 6 5 Jogging Aid CAUTION Always remove the jogging aid from the table before making a cut A jogging aid is included as standard equipment with the Titan 200 This tool allows the operator to load and align paper without the need to place hands or arms under the knife or clamp To use load the paper against the side and backgauge using the jogging aid Figure 17 amp Figure 18 Remove the jogging aid from the table close the guard and make the cut 19 WHITAKER 800 243 9226 W 6 0 Operation Figure 18 6 6 Knife Change Alarm and Lubrication Alarm The Titan 200 has two built in alarms that will be displayed after a certain number of cuts The knife alarm displays a message that notifies the operator to change the knife The lube alarm displays a message that notifies the operator to have the machine lubricated The lube alarm will also display the name and phone number of t
42. r to the machine Turn on the power using the red and yellow main power switch close the front guard and press the CLEAR button This will preset the backgauge and send the knife and clamp up Turn off the machine and unplug the power cord If equipped with electric eyes remove the electric eye mounting brackets the small side tables and the side table mounting bracket from bottom of table Remove the cut buttons from the bottom of the table Remove the Plexiglas cover and the three sheet metal covers on the rear of the table Remove the backgauge motor cover the rear table support leg 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 4 on page 11 WHITAKER 800 243 9226 10 5 0 Installation amp Setup Encoder Plug Rear Support Figure 4 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 From the rear of the machine remove the presetter board assembly from the table Figure 6 on page 12 Open the front guard if equipped open the top cover and remove the left and right side guides and the cut stick stops as shown in Figure 7 amp Figure 8 on page 12 Next remove the cut stick from the table using the cut
43. rranty 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 Companye 6125 Norton Center Drive e Norton Shores 49441 6081 Copyright 2003 by The Challenge Machinery Company All rights reserved Printed in the U S A 2 Meme 800 243 9226 1 0 Introduction TABLE OF CONTENTS 2 AMS UY __ _ 5 D _ _ __ _ __ 5 2 2 OWEN LOCKOUP Proc dure ___ _ _ __ 5 2 3 Warning Label STINE OU 6 SOPKO MN IER TET eine 7 aa aiii era aiaei 8 5 0 MSTA O 9 5 1 Inspecting erica 9 BPCO m Tm 9 AE ERO 10 5 4 Fitting Through Narrow Door 10 5 4 1 Removing the narrans 10 5 4 2 Removing the Foot 9 13 5 4 3 Removing the Front Guard If 13 5 4 4 Reattaching the nennen nnne nnn nnns 13 5 5 Installing Optional Extension Tables Front Guard Machines Only 14 5 6 Hydraulic System IB Rari 14 5 7 False Clamp Plate
44. the knife cuts through the bottom sheet of paper the entire length of the cutting stick Figure 25 Turning the screws down evenly prevents uneven wear on the knife and cutting stick WHITAKER 800 243 9226 35 7 0 Knife Installation Changing Figure 25 14 Plug in the power cord and turn the power on 15 Close the front guard if equipped and press CLEAR This will raise the knife and clamp to the up position 16 Turn the power off and disconnect the machine power cord 17 Tighten all knife bolts securely 18 Plug in 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 doesn t you could have dips or uneven spots in the knife and or cutting stick These can be eliminated by placing 1 2 strips of paper in the table slot beneath the cutting stick to shim it 19 Send the dull knife to a knife grinder Do not attempt to sharpen your own knives See the Knife Care Tips Section below to determine the knife bevel angle 7 3 Knife Care Tips CAUTION KNIFE SAFETY Knives are DANGEROUS They are heavy and very sharp even after use Keep the edge away from your body and keep the area clear of others when handling knives Never touch the cutting edge To prevent personal injury and damage to the knife always keep knives in their holders with screws tightened You are aware
45. the way step 2 Knife removal Lift the blade and insert it into the knife bar slot Guide the blade right edge first into the space between the shroud and the knife bar guide frames Tip to clear the table side guides then move the left end of the blade into the knife bar slot dropping the left end as the right end is brought around the right knife bar guide frame and up into the knife bar slot Raise the knife into the knife bar slot as high as it will go and tighten the lifters NOTE If the blade will not go in either the lifters are screwed into the blade too far or the end of the blade is hitting the cylinder bracket at the right end of the knife slot In this case drop the left end when inserting the knife 7 8 9 10 11 12 13 Insert the knife bolts with washers and snug to hold the knife but don t tighten them yet Remove the knife lifter assembly and replace with bolts and washers Place a few sheets of paper over the cut stick covering the stick end to end Plug in the power cord and turn the power on Go to the MAINTENANCE screen and choose KNIFE ADJUST Choose KNIFE DOWN close the guard if equipped and press the cut buttons to send the knife to the down position hold the cut buttons until the motor turns off for more details on how to do this see page 24 Knife Adjustment Turn the power off and disconnect the machine power cord Turn the knife adjusters down evenly a little at a time until
46. this is sometimes called draw e Cut marks appear on the cut face of the paper e The profile of the cut side view is not perpendicular to the table e The cut does not appear straight when viewed from the top e The knife makes a rougher sound as it passes through paper e Nicks are visible on the cutting edge of the knife 7 3 2 Cutting Stick A worn cutting stick can affect the cut quality of the bottom sheets When this happens the cut stick can be rotated Usually the stick should be rotated one or two times between knife sharpenings There are 8 possible cut stick positions The stick can be rotated 4 times and then turned end to end and rotated 4 times again 7 3 3 Bevel Angle Challenge recommends that bevel angles for the Titan 200 knives be the range of 21 to 23 In general 21 bevel angle will provide better cut quality when cutting soft paper such as newsprint recycled paper or bound books However 21 angle knives can become dull sooner than 23 knives which results in shorter knife blade life A knife with a 23 bevel angle on the other hand will no t dull as easily and can provide satisfactory results when cutting most types of paper Knives shipped with the Titan 200 from the factory have a bevel angle of 23 7 3 4 Helpful Suggestions e f your establishment is large enough to purchase more than one set of knives have one set beveled at 21 and the other at 23 Note A set consists o
47. ual 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 W WHITAKER 800 243 9226 Serial Numbers 032425 Up OPERATION MANUAL TITAN 200 PAPER CUT TING MACHINE Sold and Serviced by The Challenge Machinery Company 6125 NortonCenter Drive Norton Shores 49441 6081 US
48. uator is pressed Press farther from center for a faster soeed Press toward the operator for forward direction and away from the operator for reverse direction 6 9 2 IN MM Key This key toggles the display to show the position and programmed send values in inches e g 5 250 inch fractions to the nearest 1 64 e g 5_ or millimeters e g 133 3 6 9 3 Send Key The SEND key 15 used to send the backgauge to any valid position If an attempt is made to send the backgauge to an illegal position an error message will be displayed at the bottom of the screen stating Number outside limit In the Job mode the SEND key will also advance the backgauge to the next sequential cut position before performing the cut WHITAKER 800 243 9226 W 6 0 Operation 6 9 4 Push Out Key Hold To Run Backgauge Key This key has 2 functions It is used to 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 It also allows backgauge to move forward under program control if the electric eyes are blocked or front guard is raised for dimensions less than 3 5 inches 8 9 cm CAUTION Never place hands in the clamp and knife area Use the push out key or the backgauge glide control to move the paper to an area where it can be reached 6 9 5 Clear Key The CLEAR key is used to cl
49. w how to remove and install a new or re sharpened knife Read through these instructions AT LEAST ONCE before attempting to actually change or install any blades 7 1 Knife Removal 1 Make sure the knife and clamp are in the up position Turn the main power switch to the OFF position and disconnect the machine power cord to prevent accidental power up while servicing the cutter 2 Back off the knife adjusting screws on top of the knife bar several turns Figure 22 A new knife will cut deeper than one that has been ground several times Failure to back off the screws could damage the knife and or the cutting stick 33 WHITAKER 800 243 9226 W 7 0 Knife Installation Changing Knife Adjusting Screws Figure 22 3 Remove the knife bolts from the two slotted knife bar holes and replace with the knife lifter assembly Figure 23 Tighten the lifters to hold the knife in place and then remove the remaining two knife bolts Figure 23 4 Clear the table surfaces and place the empty knife scabbard 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 24 Lower the left end first then lower the right end as you shift the knife sideways to the left Bring the right end of the knife around the knife bar guide frame Maneuver the right end into the space between the guide frame
50. www WhitakerBrothers 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 non current unsupported or no longer produced by The Challenge Machinery Company and are provided solely as an accomodation 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 man
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