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CT Service Manual - Copy Finishing Systems

1. 4 18 Electric Eye Assembly NMOHS SV JHL 513 QN3 33T1081N09 ATddNS 33MOd 3HL dYNS Z 9 014 ONISN c 8 ONILNNOW Ol UVY 320718 JHL 1 SNOLLOPIISNI 15 E LI MD NND nn NS E 222253 ER RR D Ol Q338WhN 3 NOLING LND 5318 2 dION31O0S 100 BHHBB LONG OINI diMIS TWNINYAL e c FEES ES 3131dWOO SI ONIMIM N3HM 9 6 e 44 4 0 Schematics amp Parts Lists Electric Eye Assembly K 3030 Sheet 1 Rev B 310d 319 15 dlMIS JVNIWe3L 9292 3 61 2 JHM 1 691 5 81 GH LNG 2 1 X 0 MANOS 70 201 0169 9 1001 LNI OL S3HSVM Old vc L H OOZ 21 135 NIVLYND 21 12313 10 3 L ONOT ZZ MLN 9 8107 JHIM 602 3 voe 9 01 MIW VO 811 jMIM 4 60 3 GZ MIN M Z 7 M 6 OT IZ 981 MIM Y 60Z J4 8 O1 62 VO Lif 7 4 20 3 Z OT 6 VOVL 20 3 9 C 2018 13MOvH8 ANJ L 0202 3 S 6 40018 WNINYSL Se ZB gw E 104100 AvZ AlddNS N3MOd 104100 AL3JVS 4134 1008 3
2. 28 4 0 Schematics amp Parts Lists 50 Hz Power Unit IC 4 6 Hydraul H 477 2 Rev A 4 ONIN O 01 0181 5 91 S ATEN3SSV ISOH 6 2 0 61 Z 9EL1 3 vl 102 1 6901 3 61 3 dVYAL 691 5 21 2 81 91 6 OL 9NIJ 81 91 6 MOS 3 0 LL l ZHOS 4 1 022 01 1 AT18W3SSV 01041 1 9 5 6 1 8 2 dvd GH 13905 2 1 6 X 91 8 829 8169 H 9 4 9 92 WSv 3SOH 2 0 6 2 LAN 1 1621 3 v 1 GAH 18 1355 409 1 0 2 33 4 81 91 6 01 ONIN 81 91 6 H3ldvav 9 2 H 2 9 629 d8 ALO 531 055322 40 NOIlLdl4j2S3 ON 1 29 4 0 Schematics amp Parts Lists 4 7 Hydraulic Manifold Assembly amp Schematic HH 476 1 434 1A 3ATVA 33r134 0 HH l 0 0202 5 l 9 1 3314140 vBr H JAWA GAH NOLSId 02 438 102 6901 3 2 9NIN O 01 0181 S i INWA GIONTIOS 2 002 3WWA 34055384 1 07 H
3. NT 9 3 4 NO PART NO DESCRIPTION OF ACCESSORIES QTY 1 E 967 1 LAMP LINE LIGHT 2 E 1260 1 SOCKET LINE LIGHT 9127 1 SUPPORT LINE LIGHT 4 35048 13 SPRING 5 9126 2 BRACKET LINE LIGHT 6 7 E 1214 47 CONNECTOR FEM FULLY INS QUICK DISC 8 H 6918 410 SCREW 1 4 20 X 1 1 4 SOC HD CAP 9 6910 83203 SCREW 8 32NC X 3 8 BUT HD 10 H 7324 8 WASHER 8 INTERNAL TOOTH 4 0 Schematics amp Parts Lists 4 15 Cut Button Assembly EE 2851 3 Rev A NO PART NO DESCRIPTION OF ACCESSORIES QTY 1 16566 1 BOX PUSHBUTTON 1 2 E 2074 7 SWITCH BODY PUSHBUTTON GREEN 1 3 E 1839 9 CONTACT BLOCK 1 0 SWITCH 1 4 E 1839 10 CONTACT BLOCK 2 SWITCH 1 5 16520 ANTI ROTATION RING 1 6 7 5 1350 15 STRAIN RELIEF CABLE 1 NOTES WHEN SNAPPINC THE CONTACT BLOCKS INTO THE SUPPLIED HOLDERS BE SURE THAT THE CONTACT IS MOUNTED SO THAT IT S PLUNGER IS ON THE INSIDE OF THE HOLDER 41 4 0 Schematics amp Parts Lists 42 4 16 Fuse Value and Function Location Fuse Value Type Circuit Transformer Voltage Dimension F1 2 Backgauge 230 VAC 5mm x 20mm Motor F2 3 1 Pcb output T1 Secondary 5mm x 20mm F3 5A T Line Lights 12 VDC 5mm x 20mm F4 10A T Main Hot 230 VAC 13
4. 1 81 91 MaYOS 806 169 Z6 2 Qv3H ANNON X Op vf MAXIS ZlOvY CZ69 H 9S ONVIS N3 02 HI H3A00 MYL L330vi8 Ha A3409 13 0 8 Lv0 v 25 16 oc 6 ALO S3IJOSS322v 40 59530 ON Lavd NIVYLS 9NIHShH 91 0561 5 8 021 ATAW3SSY NOD H3MOd 2 8112 33 ZH OS A1HW3SSv H3MOd 1 8442 33 4 ZH 09 LIOA 062 18 4355 MOD M3MOd 8442 33 M3ovds 6 4002 9 ATHW3SSV T3Nvd N3MOd 1 69 2 33 vv XNVHOTI3H 980Z XONd aOlvniov 92069 5 1381 11 18 1 5 18 HSNYD T38v1 91 18Z1 S 0 3NIHOVW H3A02 0 6c 21319385 ac 6 i100NviIS 19 2611 3 Le NHfi3H 5 9 14 9 ZH 09 LINN N3MOd ZH 06 082 80 LINN N3MOd 2 44 LAN 2 001 2 M3llOO 2069 2 1 434 1004 Nid Gv 18408405 score 16 M3dWv 13 2W4H 19069 AlBW3SSV H3dWvd 62 M3HOSQV31 X109 82 018 318 2 2 691 5 LZ 2 1 1 440 QNVIS 89 2611 3 92 39nvoxov8 318 1 33402 060
5. 49 222 7 o 220 304 NMOHS LON SW3LI 3 60 22 05 u3 201 1 318VAOW3H LJVHS 1 311201 4 75350484 ONIGNNOYD 04 S310H OINnOMNV WOU LNIVd 3AOW33 310N 2 4 0399 1 XZ TIVOS 318 9 d 318vo 399 1 318 2 86182122 TWOA HOLIMS LOANNOOSIC 16 C 3525 2552271 9014 ay ONmm 2 4 3iVM3d3S 01 59 OND G2 8 T3NVd H3MOd 01 ON ON 38IM 9 17 S SZ v LE 06 _ 1 3IVOS 43000 Sht 1 of 4 Rev 2 re W130 ONILNNOW XOMd 3JIN Ld 20 4 0 Schematics amp Parts Lists Main Assembly Front View 43000 Sht 1 of 4 Rev 4 NiVid t l H3HSVM 1264 4 M3dvl f Nid 812 6699 dVYAL 9691 5 lt 4 51
6. 91 9 uaHsvM 01 ATHW3SSV LHOIT 6112 33 v HLOOL JVNH3INI 1 YaHSVM 8 vZ L H vl HLOOL TVNH3INI OL H3HSVM 1 ZS 9 1108 34JINM B3HSVM 6188 3001 ZIHM v x 91 8 909 689 16 T3Nvd ONINYWM 00 9 Qv3H 133208 v 01 MGYOS 90 201 8169 06 2 ANT 80001 13S LNIOd 2 1 X 2 01 MANOS 980v201 8 69 H 6v XONd NMOQ 3JINX 3 80017 4 114 8 6 X 09 90 5 010 2069 8v 01001 1913 X Ov v 5 21099 2269 v AI8W3SSV HOLY JAINA 6 lt 0711 e Qv3H 1 81 91 6 3425 805 169 9 2 1NONJ 2 20001 6 2 OYAH v X 02 9 1 MANOS 90 169 8 v Qv3H NOLING 8 OZ v MANOS 0v 0169 H 3sva8 1 10001 2 QvaH 1913 v 81 91 6 5 905 6069 v 1 112 9 2 135 LNIOd 402 Z 91 8 6 3825 2 9 8 69 H v 3801 01 Jdid 06 MOTI 4 lt 2 6 22 QV3H 13205 X 91 8 3805 809 8169 H 1v 2 WSv dWv12 28001 v Qv3H 2 1 2 01 MGYOS 0 201 0169 OF 4 9612 3 6 XONd GAH 13 4 2 MS 123 02510 NIVW NOILOSLONd WNIAM3I 9642 3 86 QOJ ALO S3IHOSS3OOV JO NOlLdlJ2S3a ON 18 ON ALO S3IMOSS322V JO NOlLdlJOS3
7. 2 8 1 nET ors 4 Gl O o QUT Fos a EIU an B eT Oa oO HEADER H9 LH i KEYBOARD oa 3l 2 H10 HEADER NO JUMPER H8 LCD HEADER FUSE F2 15 T H11 HEADER E 2330 5 NO JUMPER F3 SA PROGRAMMED EPROM 9330 7 CHECK WITH CMC ENGINEERING FOR PROPER REVISION LEVEL INPUTS OUTPUTS DESCRIPTION IDLE STATUS DESCRIPTION IDLE STATUS IN1 Left Cut Switch when switch is pressed OUT1 Hydraulic Motor On when motor is running IN2 Clamp Up Limit when clomp is up OUT2 Cut Solenoids Off except for downward motion 183 Cylinder Up Limit when hyd are up 0073 Not Usec 1 4 Knife Up Limit when knife is up 0074 Unlocd Solenoid Off when clomp is up INS Right Cut Switch when switch is pressed 0075 Used 1 6 Knife Lctch Switch w pin under knife bor OUT6 Knife Lctch Solenoid Off when knife is up Pump Relcy when pump is running 0077 Used when elec eyes cre blocked Off when knife is down Not Used INQ Knife Down Limit IN10 43 4 0 Schematics amp Parts Lists 303 406 031 08 SI MIA SIHL 01 H30V3H 01 OZ U 9 01 v9 aA X90718 IWNINYAL OL 65 NOLLAG 112 1431 WOW3 veo 318v2 7105 100 WONJ Ver SX2018 TVNIWM3L 01 vv ec tex e Li
8. 5 OvZ01 6069 H 19 c Ing 1 1 X OZ v MAYS 01 0169 09 8 108 2 1 X 2 01 5 0 201 0169 66 01 Qv3H v 91 8 MANOS 909 169 H 8S dvo 505 1 1 X 02 9 1 3825 015 8169 ZG 02 1 0 9 96 2 1 611 3 SS 135344 13 0vu8 1 0 001 2 82 9 1 LAN 80 9 2 2 8 6 9 8Z2v9 H 24 Y HLOOL 8 M3HSVM S PZEL H 16 9 t l MN3HSVM 1264 OG v 8 9 61 4 H 6v e HLOOL t l MN3HSVM 8 2 8 133208 v OZ v M3N0S 90 8169 9 e Qv3H l X 91 8 3 25 809 169 H 9 Y Qv3H v 02 9 1 M3NOS 909 0169 9 Qv3H 8 2 01 5 0 201 0169 l X007 ZIHM v 91 8 MIX S 909 v689 H 2 Qv3H 8 ze 8f 5 02 8 0169 H 2 ALO 5314055322 30 NOIlLdl42S3G LaWd ON 4 QvaH 1v14 2 1 ze 8fb 3805 002 lt 8 6069 19 135 SSvud 1 82 1 5 91 69 0 9 Qv3H 133205 2 91 8 MANOS 9 8169 6 c Qv3H 133005 v g 91 8 M3MOS 909 8169 H 8 2 10N 9 4 21 3 1 9691 5 9 MOOHS 121512313 138 1 08 18 1 5 3dvl 13 104 92
9. NOMhvO 138 1 91 18 1 5 lt lt 9 39nvOMOVH Nid 59001 ze l3S3Hd QNVM 16 2 NOTAN 3 25 1 9961 5 06 2 4 15 090 62 Al8W3SSV 2018 MOTIld 1 4 690 v 82 ISNYHL 2 0061 5 ZZ ISNYHL 5 lt 621 5 92 310011 S 9Z001 SZ Al8W3SSV N3lL3S34d 1 8891 33 2 1 30N9 2 82001 l S3NIHOVN A 062 7274 10A 081 YOLON 991 0091 3 zz N3 00 820 lt 12 3OIOW 1340v38 12069 02 YOLOW A3TIhd 90 61 1138 vYS6L 81 2 3JOQNVIS 09 2611 3 41 INNOW Y3GOON3 31 1 620 v 91 L9v2 3 81 33002N3 9 S0Zv vl 1108 yb X 7 1 Nid 0001 0SZ SIZ H M3HOSOV31 A3TInd 290 5 32018 MOTIld AVIY 890 v 11 1340vu8 2001 01 INN 500 lt 6 42540 31 006 8 3onvoxova 18001 2 2 3 ino3aiss 1 6806 9 ALS 102 991 8 2 XLS 102 4015 822 9 8 v 1NOMJ 3QIn93dIS H1 808 1NONJ 450 2 318 1 S2001 ALO 5314055322 30 9530 ON 1474 25 4 4 Main Assembly Tilt Shield Electric Eyes 4 0 Schematics amp Parts Lists 43000 Sht 4 of 4 Rev C 001 Qv3uHl
10. 3 1231434 102 5 9 Ov v 5 21099 6269 21 TOSWAS 1381 2 1841 5 v NOLING 2 1 X vz Oif 3425 0 201 0169 14 M31100 1 Z Nid 80 1 99 H SS320V 08069 04 3JINM 1438 1H9rl gng 1 496 3 69 M T3AIMS 3155 2 31 691 S 89 18 1355 GNVLS 800 v JAINJ 001 v z9 2 1004 318 2 L Hl4V3 319310849 138 1 6 1821 5 99 NOLLAWD 1391 91 18 1 5 69 193NNOOSIG NIVN HOLIMS 1 9 2 3 31115 d3 Z 9 LAN 9j czv9 H v9 103NNOOSIQ 32 4 HOLIMS S9vZ 3 v 3201 ZIHM 1 2 1 LAN 8 v1v9 H 9 JAINA Nid 79001 8 31115 d3 09 LAN vl ccv9 H 29 2 318 1 s30vds 9S0 l 5 91 8 6 LAN 9 01 9 19 M3ONIIAD 81001 e 31415 434 81 91 6 LAN 6 2 9 09 8 1108 wt 1 0001 062 512 8 31416 day 02 LAN 2 9 66 SIVE INS 0001 4 NiVid OL N3HSVM Oif 1cgz H 86 9 2 1 ONIN ONINIVL3H 06 6611 5 9 HLOOL vf H3HSVM vzeL H 46 2 10001 HLOOL JVNH3INI 9f N3HSVM 9 96 2 ANIT JANA Nid 60001 3201 WNIGaW 8 21 42 lt 4 7ONINOO NSv 310SNOO 0 33 e 3201
11. 3 583010 ISNA OL vc lt 2 71225518 5 31314WOO 01 S3NIM 30 d SQN3 HIO 9 1 diMIS IND OL OND 310N AlddnS 7 9 o 1442 3 3NIHOVW TIF gor 5 d s Er 13S 212313 NI E 3 40 16 JAY ONILNNOW JNIHOVN FHL OL 6c e 5318 S3A3 210419313 3Hl 310N 43JMOd 4340438 534 NO ONITINd 5 0123 dAVIO 38425 NI 9 3801235 S3MIM 71 AJIMH3A 310N A139 1 2 L 1 TIM 41315 VNIWH3I JO 3015 AIHUI Cm an Cis mo M3HIONV SI LVHL TWNINNSL 135012 1 3 3015 3HL OL 09 AQv3NlV NI 53 SVH 3ShVO3H NMOHS WNIWH3L NI Ld 38 LONNYD XIANNN 1NA 40193130 di 31dWVX3 5 JAIM Sv AJANNN IWYS NIWLUND NIVI8ND 1 9 JHL SVH WNIWH3I JHL SV 9NO1 Sv X90719 TVNIWH3I JHL SYSLIND THGOW 404 WVYOVIC 3H3HMANV Q3OVld 38 NVO 541415 VNINH3I JHL S33IM 310N 83114405 N338 3 vH 03033 53 71431 JHL 01 51130 3 1 NI NMOHS SV 13NYd S318vO QION3IO0S 112 WONJ vvf 53 NILSIXI M3MOd JHL NI SIN3NO
12. 50 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 Read and understand all instructions thoroughly before using the machine If questions remain contact the dealer from which you purchased this machine Failure to understand the operating instructions may result in personal injury Only trained and authorized people should operate this machine DO NOT ALTER SAFETY GUARDS OR DEVICES They are for your protection Severe personal injury may result Disconnect power before cleaning or performing maintenance See Section 2 2 Power Lockout Procedure Observe all caution labels on this machine Be sure the cutter is properly grounded Be sure there is sufficient power to operate the cutter properly Observe all caution plates mounted on this cutter Keep foreign objects off table and away from cutter blade BE EXTREMELY CAREFUL when handling and changing the cutter knife Severe lacerations or dismemberment could result from careless handling procedures Keep the floor around the cutter free of trim debris oil and grease When replacing hydraulic parts loosen the connections slowly to release pressure Never loosen connections with the machine running If the cutter sounds or operate
13. 10 3 0 Maintenance Guide Dip Stick Figure 2 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 The hydraulic fluid should be changed AT LEAST ONCE A YEAR or after every 1 000 hours of operation NOTE Failure to change oil when needed can damage seals in the cylinders pump and valves Empty the hydraulic tank and refill with 1 gallon of International Standards Organization Viscosity Grade 100 ISO VG 100 rust oxidation and foam inhibiting hydraulic fluid Challenge part no 5 1991 NOTE NEVER use automatic transmission fluid or brake fluid as a substitute for the correct hydraulic fluid A table of various manufacturers and their equivalents is listed below 3 5 1 Recommended Hydraulic Oils CAUTION Use one of the recommended oils or an ISO VG 100 Hydraulic Fluid equivalent only Oils other than the recommended type will cause seals and O rings to deteriorate Unsafe operating conditions will result Name Distributor Rykon No 100 AMOCO Duro AW Oil 465 Arco AW Machine Oil 100 Chevron Pacemaker XD No 100 Citgo Super Hydraulic 100 Conoco Nuto H 100 Exxon Harmony 100 AW Gulf HO 2A Hydraulic Oil Lubriplate DTE No 18 Mobil Pennzoil AW 100 Pennzoil Magnus A Oil 215 Phillips Tellus 100 Shell Energol HLP 100 Sohio Industro
14. HOIIMS 320 TIH3INI HOLIMS 320 18 3INI 1H9 8 QNVH 1431 15 O13 9 304 INId 336 SA Or 26 4 0 Schematics amp Parts Lists Main Assembly 43000 Sht 4 of 4 Rev C 24 ALO S343 72313 531 055322 40 NOIlLdlJOS3 LIM 0 0 y ON 1 ON Ov v 81 91 6 INN 6 0 9 6 86 91 2 01 LAN 01 6299 ZE 9 vl 01 N3HSVM 01 1 SE v 91 6 H3HSVM OL ZZ L H vc HLOOL 01 5 01 2 lt ZE v HLOOL 8 8f vzcL H 1 v 205 8 6 x 01 MANOS 0 801 0269 OF Y 205 LNG 2 1 X 25 01 MANOS vOZC OL 0269 H 62 t jOOHNd N3dAVI 2 1 X 29 80 M3X S 00 lt 8 8889 82 t 205 8 X OZ v 5 0 0169 72 8 205 GH v X 2 01 MANOS 90 201 0169 92 8 205 GH 18 2 1 X 2 01 3525 707201 0169 SZ 2 205 108 1 X 2 01 5 90v201 0169 H 2 310H 1 9612 3 41 43Ovds 6 2611 3 91 4 8 011 GI 2 Oif 2 691 5 338 X2031NI GOOH HOLIMS 9 46 0 3 2 39NIH 10019 21 3 10NVH 15996 11 l3 2vs
15. 4 R vd YSL ISNI 8SG1 6401 3 Z ANO AO0fZ 802 Ld vi 1 VOL 35 3 9501 5401 3 1 AINO 13 DLW 1 YZ 3503 0 amp 3 48 L AINO A0 2 802 13 OiBI3A 1 vi 3514 ocez 3 91 G H3HSVM 6 12 lt 4 8 2 HLOOL vf H3HSVM vil vzez H 28 HLOOL v 1 H3HSVM 8 9262 18 vl HLOOL 01 J3HSVM Olff vZcz H 08 014 N3HSVM 01 12 lt 6 9 3201 91 6 3 5 01 4264 84 l 8Z v INN 82 9 L D 3201 X314 8Z 99 92 2 09 90 INN 9 6299 S4 2 OZ v INN v ECV9 H 001 314 2 014 LAN 9201 26 4 9 2 01 LAN 0144 2 9 24 9 81 91 8 IAN G Zv9 H 12 z 135 133205 Z 81 91 MAYS 2 8 69 04 69 2 Qv3H NOLING 92 014 MANOS 90 201 0169 89 19 ot Qv3H NOLLDH 2 1 OZ v 1 MGNOS 20 0169 H 99 8 Qv3H NOLING 2 1 1 MANOS vOZCOL OZ69 H G9 91 NOLLhH 2 1 X 2 01 MANOS 0v201 0169 H 9 D 7205 v 1 1 X 02 1 5 01 8169 9 QV3H 137205 1 91 8 5 809 8169 29 22 Qv3H 8 vz Olf M3U2S 0v201 0169 H 19 Qv3H NOLING 9 1 1 02 9 1 5 01 0169 09 2 Qv3H v 81 91 6 M382S 906 0169 6S 2 INXA ANNOY 1 x Of 5 00 269
16. dee ME 4 2 2 Power Lockout Proced re iiec oditaut taa 4 2 3 Warning Label Definitions 5 3 0 Maintenarice Ulde ect tee E ed E Pune ete Oo EE 6 Troubleshootitig 2 2 2 er ptt ceo DU tec pedem pt pieni matrice dtes nudes 7 3 2 Description of Error 065 1 1 1 111111 enhn tenen kan nhs ee as 8 3 3 Sensor Data Abbreviations 9 3 4 Routine Maintenance esed deseada ended 10 RE AMBITIO 10 342 Monthly 10 MB m 10 3 5 Checking Changing the Hydraulic 10 3 5 1 Recommended Hydraulic Oils sess 11 3 6 Oll arid 1 deer ee resa devi der 12 37 Adjustments 2 ice eee dee ee dd deve edo e pa ud eda a nia devi up A ud dd 14 3 7 1 Electric Eye 22 222 44210 00 i nh dnd d tuna nb da 14 3 7 2 Backgauge Gib 15 3 7 3 Squaring the 16 3 7 4 Clamp Pressure 22 2224 17 3 6 18 4 0
17. 2 INNON 110 1 02 13 0Vve8 I ALO 531405530202 JO NOILdINOSAC ON 1 ON 45 4 0 Schematics amp Parts Lists Electric Eye Assembly K 3030 Sheet 2 Rev A a I e 74 m a F 2 c 8 o 5 im 210 ie gu BS Ed wag Eu 58 24 ENS ax 25 gt Zc 256 ae a e 5 S25 of 358 5 6a Ol z z o gt gt 46 RELOCATE CUT BUTTONS TO POSITION SHOWN 4 0 Schematics amp Parts Lists Electric Eye Assembly K 3030 Sheet 2 Rev A 02 61 8 21 v 1 YJHSYM 106 91 v 4201 GSN 1 XJHSYM 8 2 lt 81 01 8 6 M3HSVM 9 106 1 01 8 5 ZL LZEL H 61 8 109 2 1 X 2 01 MANOS 707201 0169 v GH 108 6 X OZ v 3825 90 0169 01 GH 90S X 91 8 6 MANOS 909 8169 H OL Y 2 01 LAN 01 lt 079 6 8 d j3rl3J NIVMIS jlvld MOv8 9 L SNOISN3IX3 318VL 1504405 860 tv G Z NOISN3IX3 319 v6O0cv v L H1 1349v4J8 343 2313 L60 v L HM I3MOvsH8 343 2313 960 v Z 438 LAS NIVIMOO
18. 70313 tl0 3 ALO 5 55399 40 NOlLldl42S3Q LNVd ON 47 4 0 Schematics amp Parts Lists 4 19 Titan 200 Floor Plan 43000 FP 7 4 lt p JES H A 7 7 A LN IN EY Symbol Inch cm 49 0 124 55 0 135 36 0 91 20158 02 147 E 53 0 155 F 58 0 147 4 0 188 Net Wt 755 101342 MACHINE DIMENSIONS AxBxC MACHINE DIMENSIONS WITH SIDE TABLE EXTENTIONS DxBxE OPERATING AREA FxG OVERALL MAINTENANCE AREA FxG 48 4 0 Schematics amp Parts Lists NOTES 49 5 0 Safety Systems Test 50 5 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 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
19. Cheksum Error Bad program chip Replace EEPROM Clamp Up Failure Clamp failed to return to up position within 7 seconds Clamp up sequence valve solenoid cut valve Clamp Down Failure 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 outside the limits of the machine Informational error Motor starter was OFF when it should have been ON Motor Starter Failure 1 Defective motor contact switch Motor starter was ON when it should have been OFF Motor Starter Failure 0 Defective motor contact switch Knife Latch Failure 1 Latch prox ON when it should have been OFF Loose solenoid wire mechanical bind knife up prox Switch out of adjustment defective prox Switch Knife Latch Failure 0 Latch prox OFF when it should have been ON Knife failed to come down within 4 seconds Knife Down Failure Low main pressure low voltage knife down sequence valve Knife failed to return within 1 17 seconds Knife Up Failure Mechanical bind solenoid cut valve Knife at Both Limits Knife up and down prox Switches are on at the same time Prox Switches broken knife bar components 3 0 Maintenance Guide Message Description Test Lubricate Machine Lubricate machine alarm Have mach
20. icm 65 B 12 1 amp 2 JUMPERED NO JUMPERS ON OTHERS 4 0 Schematics amp Parts Lists Electrical Schematic Tilt Shield Machines Continued E 2771 2 Rev B LCD MODULE 2758 1 CONTROLLER BOARD CONTINUED HB 20 PIN HD 20 PIN RIBBON H9 14 H9 14 PIN RIBBON H11 LINK TO 016 PIN 17 POT INPUT AND 20 PIN HEADER LCD BACKLITE 10 CONTROL 20 AED CONTROL CONSOLE KEYBOARD ASM AT EE 2773 1 14 PIN HEADERS o gt NOTE FOR MACHINES WITH 2 HAND CUT BUTTON CONTROL AND HOOD CONTROL USE EE 1766 53 XX SOFTWARE SPECIAL TERMINAL BLOCK SCHEMATIC SHOWS SWITCHES IN POSITION OF THE HOOD OPEN AND CUT BUTTONS NOT INSTRUCTIONS DEPRESSED FOR 208V MACHINES JUMPER TERMINAL BLOCKS NOTE THE PULSE WIDTH P C BOARD EE 2813 16 16A 16B AND THE CLAMP PRESSURE PROXIMITY SWITCH ARE OPTIONAL AND ARE SHOWN FOR 230V MACHINES JUMPER TERMINAL BLOCKS FORT CON Ys 16 16 160 SERVICE NOTE THE LINKS ON H10 AND H11 MUST BE REMOVED FOR THIS BOARD TO BE USED FOR REPAIRS FOR OLD EE 2762 BOARDS 33 4 0 Schematics amp Parts Lists E 2771 1 Rev F 4 10 Electrical Schematic Electric Eye Machines Ton o
21. 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 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 5 0 Safety Systems Test Please enter date and initials for both tests Date Test 1 Test 2 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 51
22. sz 31 318v2 1 5691 5 92 lav 8109 evocr 901 5 83409 1906 22 dNVID aOlvniOv vcore 12 3 5 5 1 H3HSVM 12 4 02 401 X109 1 10069 61 dWVIO 1 2 8i M3 02 01 318v Zi AQOH HOLIMS 02 3 91 Z HOLIMS 32018 LOVLNOD 01 668 3 ci 1 HOLIMS 92018 10291502 6 6681 3 v XOOTHiINI 5 9 4Gv2 3 21 u 01 162 A18W3SSV HOLIMS 6 1682 33 6 39NIH 1001 8 TWNYADG 2 1 ONIN 9NINIVL3H 06 lt 611 5 4 QNVIS 14084 X109 9 i n0843 881 5 6 NAUJA 9NiNdS v 9 14v v NOLVHBIA LNNOW 9100 3NSvHBV 206 z 1004 TWwa3d 1 ALO 5314055322 30 5 ON 14 23 4 3 Main Assembly Table Asm View 43000 Sht 3 of 4 Rev K 4 0 Schematics amp Parts Lists 3NON 31 26 ws 2 AWLAC YACGOON A Fr 231 25 50 3 M3NOS 40 3015 3LISOddO 05 9v LY 22 5 QNhnONO 26 8 NMONB ama ovi8 81 sv 3r 18141 LC ALBIYTO 304 Q3 OW3H 83409 6v 91 9v E
23. 1 55 19 3504 688 3 4 4534 1 1 55 19 3504 21 688 3 92 318 2 691 5 SZ 300718 IWNINYSL 824 NI 9NId 0103NNOO 7 9902 3 2 32018 IWNINYSL 8 NI 9 N0103NNOO 01 9902 3 Z 26 98 ONOT 2 1 440 0 15 0 0611 3 22 21 H3ANOJSNVHL 138 1 26 861 3 12 all H3ASOJSNVHL 138 1 16 5861 3 02 3104 2018 IWNINYSL 390148 10S2 3 61 8 201431 GOOH ATHW3SSV 318 2 2064 33 81 v9 01 HOnONHI A0078 TWNINYSL 8 8902 3 41 X90078 WNINNSL ANI 1 0202 3 91 1390IN LNNOW 3504 6 v4161 3 GL 3snj 55 19 a3aon 3504 0681 3 v 3503 SSv19 INNOW vNIWH3L 52018 3504 v161 3 l 9NO 2 1 9 32018 1 1 7198 81 4461 3 21 318 2 43734 NIVYLS 91 0661 5 11 035 2 91 062 021 YANYOISNVYL 6 2 42 3 01 235 2 21 0 lt 2 802 001 YANYOISNVYL 9 cv42 3 6 dN OrwvnsdAH AT8W3SSV ALIWIXOSd 1 0110 33 8 INNON 13 0 42 3 1 401 9 01 5 8 9812 3 9 9 01 2 1 61 N3A00 1 6142 3 6 2 1 LONG JAM 1 62 1 3 v YOLOVINOD B3laviS 5082 3 H3TIOHINOO ATHN3SSV H O d 1 7082 33 2 1 21 12313 13NYd 1 9006 1 ALO 5314055322 40 1915253 14 Power Panel Assembly EE 2765 1 Rev 37 4 12 Control Console Assembly 4 0 Schematics
24. 32 x 1 1 2 F5 5A T 5V logic T2 Primary 4 1 1 4 preset encoder 15v prox F6 1 25A T 12v 24v Pcb T1 Primary 4 x 1 1 4 outputs F7 10A T Main 230 VAC 13 32 x 1 Neutral 1 2 FL 5A T Backgauge 230 VAC 5mm x 20mm Motor T Time Delay Fuse 4 17 Control P C Assembly 4 0 Schematics amp Parts Lists HEADERS H13 H14 amp H15 JUMPERS FUSE FL SAT FUSE F1 E 2330 7 2A T HEADER H12 E 2330 5 JUMPER PINS 1 amp 2 Rz Lu z s Poe Tee ER 831 soe FL nno i oon aj o LED BACKGAGE DIRECTION o g 1 H 2 On reverse 9 m z T oO IN 1 Dado LED SCR IN2 n n LE On when bockgoge IN3 noo m rt ct motor is on 5 T amp Tto LED BACKGAGE DYNAMIC BRAKE 6 noo Nis 1 On when motor is off ra n t N 8 n Un 17 5 5 uro g n a oo IN 10 8 ooo 8 c L BT P ai ga ooo OUT 1 g aes a n ze 2 11 DB out eas OUT 4 gt L g
25. 8 a 8 8 8 amp 12 35 T1 C r 12V Bv 12v 12v 34 4 34 6 7 8 9 10 11 H7 1 H2 6 7 8 2 9 10 11 9 IN 15 IN 35 36 SA SB Hent 36 H7 2 E 2330 7 e 2 T 1 2 16 35 36 45 1 5 2330 3 EAE MOTOR 2330 7 46 Ne H7 1 55 F2 2 12 NC 47 5 51 15 1 4 10 2330 5 5 35 KNIFE 47 47 ue 6 gt LATCH ate Al Sor zs wy 54220182 35 55 33 H6 7 uS B1 H1 3 H1 4 5 E 53 5 A2 B2 UE 2813 35 PUMP 39 n 1 4 PULSE WIDTH RELAY 9 5 29 tHe 4a PS 99 6 MODULATION PCB 5 1 E 63 35 39 39 15V wat poesie ed 24 4 5 6 7 2A SB 1 2 Al B HBI 54 rn 1 1 5 35 CUT N TR2 51 52 SOL 445 0 0 H6 2 VO 63 1 42 42A gt i IN HYD UP 61 6 1 NC H6 3 5 3 CLAMP 65 PRESSURE VALVE IN 4 KNIFE 60 4 64 H7 4 4 UP KE SATA oes oat t 63 TR4 6 4 wu 6 KNIFE LATCH 59 e H5 6 Hees 218 5 6 MSCE1 yqz H HO 57 AUX 64 No ENS 4 H2 5 5 7 PRESET IN B ds 5 8 iN 9 KNIFE 56 64 H2 35 5 9 DOWN ROTEN 2 4 CONTROLLER BOARD ne ENCODER H2 1 IN 10 65 64 H2 2 H5 10 HI
26. Abbreviations Abbreviations Standby Description Location LEFTCUT 0 Left Cut Button Lower front of table RGHTCUT 0 Right Cut Button Lower front of table KNFLAT 0 Knife Latch Proximity Switch Left side of cutter opening HYDMOT R 4 Motor Starter Relay Status Right side of power panel KNFDWN 1 Knife Down Proximity Switch Inside of cutter opening right side PRESET 1 Preset Sensor Rear of cutter under left side of table CUTSOL 0 Cut Valve Solenoid Valve on left side of manifold UNLOAD 0 Unload Valve Solenoid Valve not in use yet KNLATSOL 0 Knife Latch Solenoid Inside of cutter opening left side 3 0 Maintenance Guide CLAMPUP 1 Clamp up Proximity Switch Inside rear of cutter opening left side HYDUP 1 Hyd Clamp Up Proximity At bottom of clamp cylinder KNFUP 0 Knife Up Proximity Switch Inside of cutter opening left side CUTBTN 0 Cut Button On display console EYES GUARD 1 Electric Eyes OR Front Guard In front of cutter opening HYDMOT O 0 Hydraulic Motor Relay Output Top right side of main pcb N C 0 No Connection LTLINE 1 Line Light Output Inside rear cutter opening left side CBTNLIT 0 Cut Button Light In display console On when pump is running 3 4 Routine Maintenance CAUTION DISCONNECT POWER before making any adjustments or lubricating See page 4 SAFETY PRECAUTIONS for Power Lockout Procedure This m
27. L 3WWA 035 JINA 41 02 23 2 8 002 L 5 dN 9 02 H AID 631 055322 40 5 ON Lavd S310H ONILNNOW 2 90 22 lt 1 9 lt 6 ze Lt 002 NVLIL WINLNDOG 105 1 6901 3 02 1300W 103 lt 1 6901 3 ATHW3SSV SIHL 30 18 SV ON 5 Q3330H0 38 5 5102 1N3W3OV 1d3M 18 v i 310N 32l H3S o M3QNIIAD 341 5 39nv9 30 4 0 Schematics amp Parts Lists 00 NVLIL 994 NVLIL 1841 5 8501 5 01 3 10 11 34 IZo aSe SZ0l J z 688 3 1 93 688 3 1 93 2 Co 21 688 3 Iye 63 71 688 3 GJ T AINO S9Z 8501 54 013 zd 5 4201 34 SN QVO TM3AO C 0E5 m m C s 0ccz 3 1 43 i OIMI3N 1 YZ C DCEZ 1 2 14 lt lt L 0 2 3 714 182 33 SS3Md 5 1VNOlLdO 18 M3T1OMINOO o GUVOE Od 4052 40 GOL 9 2919 800 40 GOL 29 919 SMOTIO
28. SOL t NA 43 42 a IN 2 E NC ug 3 an H5 3 a 1 1 1 IN 4 5 4 PHOTO e H 4 0 2 ELECTRIC we H6 4 ie CONTROL Pa i UNIT a nes ee H5 6 PECU ale jJ S H2 5 5 7 20191817 16 59 S N 9 NOTE ELEC EYE KIT H2 3 5 9 E P N 3030 H2 4 CONTROLLER BOARD 2 s 2807 1 IN 10 H EMITIER H2 1 519 5016 H2 2 DETECTOR di uh EQ M E 3015 H12 1 amp 2 JUMPERED NO JUMPERS ON THE OTHER 34 4 0 Schematics amp Parts Lists Electrical Schematic Electric Eye Machines Continued E 2771 1 Rev F LCD MODULE EE 2758 1 CONTROLLER BOARD EE 2807 H9 14 CONTINUED 29 RIBBON H9 15 H9 12 H9 11 H9 10 H9 9 PA H9 8 H9 H9 7 14 PIN RIBBON H9 6 H11 Hae LINK mE e e S TO U16 PIN 17 ie H9 3 H9 2 POT INPUT AND H9 1 20 PIN HEADER LCD BACKLITE 10 CONTROL 20 KEYBOARD CONTROL CONSOLE KEYBOARD ASM EE 2773 1 N 14 N 13 12 14 PIN N HEADERS 10 9 8 8 8 7 7 7 6 6 6 5 5 5 4 4 4 5 5 3 2 2 2 N 1 1 1 NOTE SCHEMATIC 15 SHOWN IN MACHINE READY STATE gt NOTE FOR MACHINES WITH HOOD CONTROL SWITCHES CONNECTED TO INPUTS 1 amp 5 ARE NORMALLY SPE
29. Schematics amp Parts Lists osse 20 4 1 Main Assembly Front 20 4 2 Main Assembly Right Side 22 4 3 Main Assembly Table 24 4 4 Main Assembly Tilt Shield Electric 26 4 5 Hydraulic Power Unit 60 2 nennen ern nens 28 4 6 Hydraulic Power 5 29 4 7 Hydraulic Manifold Assembly amp 30 4 3 Power Panel Lun anne me cin eaten bt en 31 4 9 Electrical Schematic Tilt Shield 32 4 10 Electrical Schematic Electric Eye Machines sse 34 441 Power Panel Assembly e cin DER die 36 4 12 Control Console 38 4 13 Knife batch Assembly c in Pte 39 4 74 Line Light Assembly nin doter rt eret tieu i rts 40 4 15 Gut Button Assembly rete eer 41 4 16 Fuse Value and FUNCHON nente annt nnns 42 4 47 Control P C Assembly mit eet eret eed 43 4 18 Electric Eye Assembly ninia ara entretenir a anite a 44 4 19 Titan 200 Floor iE eter ete Rt ett be PR ee e nas 48 5 0 Safety Systems TESTy
30. amp Parts Lists EE 3035 Rev A SNI NON 17 1 1 9 121 3 vC LAU 1 81 71 sw of 00 9121 3 ez 1001 9 M3HSVM 9 22 0 9 LAN 94 299 12 8 7205 GH 1 25 98 5 9 0169 02 zz TOSWAS 138 1 18 1 5 61 v 9NOT 1 140 0 15 gS ZS11 3 81 v 26 61 140 QNviS 9 2611 3 Z1 54 6 440 15 46 2411 3 91 6 12 2 9NO1 9 1 1 130 QNVIS 66 2611 3 81 v M3HSVM v981 S vl 1 1 v691 S l Oif 2 691 5 21 l A3Y ON ASV 138 1 7891 3 01 9 1 Z OYNI 1 vo JAIM 6 72 1 6 18 355 14510 1 86 2 33 8 l ANOO 02 AvidSId Wsv 318 2 2 lt 680 33 4 l QNOO v WSv 318v9 NOBHIS 6 5680 33 9 31VW 8 ATHW3SSV Bod 7940 33 6 73Nvd 10 1 2 33 02 19069 v 2 LNNOW AVIdSIG 12069 318 2 Noga 43134 NIVMIS 99067 2 l 310SNOO 71ONINOO 13NYd 20169 ALO 531 0553202 30 NOILdIXOS3A ON Lavd ON 61 01 22 38 4 0 Schematics amp Parts Lists 4 13 Knife Latch Assembly 411
31. dirty or dry lubricate knife guideways Dirt in hydraulic system CLAMP STARTS UP BEFORE KNIFE IS UP Clamp Up Sequence Valve setting incorrect defective CONCAVE CUTTING ENDS WIDE CENTER NARROW Excessive moisture at edges of paper CONCAVE CUTTING VARIATION FROM TOP TO BOTTOM Soft paper not firmly clamped Knife dull or incorrectly grounded ERRATIC OPERATION POWER LOSS Hydraulic fluid low Dirt in hydraulic system Oil bypassing piston in cylinder Voltage supply is low KNIFE DRIFTS DOWN Knife latch not engaging or damaged KNIFE HESITATES OR STALLS Dull knife Main relief valve setting off 3 0 Maintenance Guide 3 0 Maintenance Guide Paper clamped too tight lower clamp pressure reducer setting 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 Cylinder disconnected from bracket Sequence valve misadjusted PUMP MOTOR WON T SHUT OFF Knife Clamp Up Limit switch not activated readjust Motor relay contacts welded 3 2 Description of Error Messages Message Description Test Backgauge Failure Backgauge doesn t move Mechanical bind encoder failure main pcboard blown fuse Backgauge at Limit Backgauge is all the way forward or backward
32. g ee e cL Le o o aan 91 so 20 XZ 31 25 6 4 331103 92 1 15 24 4 0 Schematics amp Parts Lists Main Assembly Table Asm View 43000 Sht 3 of 4 Rev K c 0 3 134005 8 6 91 8 3 25 09 8169 28 l dv9 0 3 205 2 X 91 8 6 MAYS 919 8169 18 l v X 91 1OY 06 0 81 512 08 32018 10169 64 134 OLEY 8 1138 13 0vu8 SGivv L AaTINd LHIIVYLS 10929 92 A3Tihd Q3NMONO 88S v 82 1 ONIN ONINIVL3H 40 61 01 6 4 4 166 CL 4 M3ovds 6 2611 3 74 2018 5 1138 961 12 1138 14199 02 4 anyo 1138 80169 69 2 91 8 9 vZv9 H 89 2 02 1 LAN 0 9 9 2 01 M3HSVM 01 1262 99 01 HLOOL INI 01 M3HSVM 0144 2 69 l 5 205 2 1 X 2 1 MIX S 08 626 v9 4 135 33VhOS X 91 8 M3N0S C9 1 69 H 69 4 135 205 2 1 1 X 08 9 1 3805 0 86 lt 69 29 c 113 8 X 2 01
33. on the right hand pressure gauge It should read 400 p s i If it does not correct by using the up and down arrow keys When finished press soft key C to return to Send Mode or Soft key D to return to Diagnostics 3 8 Cleaning Before cleaning inside machine turn off and lockout power page 4 Hydraulics 1 The vent fan should be wiped off weekly to maintain maximum cooling of the hydraulic System The hydraulic manifold fittings and hoses should be wiped off weekly to maintain maximum cooling Remove then replace panels as necessary 3 0 Maintenance Guide Table 1 The front table should be wiped down periodically Use a non abrasive cleaner along with a protective wax 2 rear table cover and front guard if equipped may be cleaned with glass cleaner or a mild water based detergent Some petroleum based solvents may damage the plexiglass Console 1 The console should be cleaned with a mild water based detergent applied to a damp cloth or paper towel Petroleum based solvents will damage the console Machine Exterior 1 The machine s exterior should be cleaned with a non abrasive water based detergent applied to a damp cloth 2 Always be careful when cleaning around safety warning labels Use limited amounts of cleaners in those areas 19 4 0 Schematics amp Parts Lists ics amp Parts Lists Front View 4 0 Schemat 4 1 Main Assembly 31 25 NGIA 1015 02 P d
34. to be operational 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 the machine disconnect the power and lock it out see SAFETY PRECAUTIONS page 4 unless the directions specifically require the machine to be powered 3 7 1 Electric Eye Alignment If your machine is equipped with electric eyes the alignment can be checked as follows Turn on the power switch and make sure there are no obstructions between the electric eyes e If the green and yellow lights on the electric eyes are on solid then the eyes in proper alignment e red light is on and the yellow light is off or flashing then the eyes either blocked or not aligned properly 14 3 0 Maintenance Guide If alignment is necessary loosen the screws that attach the electric eye brackets to the table extensions Adjust until the green and yellow lights are on solid as described above and tighten Screws 3 7 2 Backgauge Gib Adjustments If the backgauge does not stay squared or jumps up and down when jogging paper against it the backgauge gib screws are probably loose or worn To Adjust 1 Send the backgauge near the rear of the table 2 Turn off the power and disconnect the power cord 3 Remove the leadscrew cover under the table 4 Loosen the two side gib screws and the bottom nylon guide screws Fi
35. 20 3 Rev A 02 S t i 5 82 88211 61 wr OZ v 1 LN gt 9 81 1 1 3201 XTU 02 1 IAN v LvVZG H 41 8 H3HSVM 1 91 INI 8f N3HSVM 8 20 SI XIS 5 205 v 1 1 91 6 3525 016 9626 91 L NOUN 8 6 x gf 825 90Z 8 0889 H 205 IVU 8 6 26 88 MIS 0z 8 6069 H 21 v 205 8 26 81 MINS 02 8 0169 H 11 1 2 7205 2 1 1 X 02 9 1 M382S 219 8169 01 l 31 z siiiy 6 2018 HOIV ATHW3SSV 2 8 JNM 9 4 ANIT 1 66618 9 1 0060 1699 5 H3NIVI3H 9 SANI 0 6 0181 S v 1 NOISNADG 5 4 9 911w 2 GIONTIOS 1 AID 531 056322 30 5 ON 1 ON Q3ZIOM3N3 SI QION310S JHL N3HM NMOHS SW 42018 HSNI SI cid M3YOS JHL LVHL OS NOILO3MIQ SIHL NI 010 3105 LSNrav 231 25 H3NIVL3H X ANNI L 31 25 39 4 0 Schematics amp Parts Lists 40 4 14 Line Light Assembly EE 2779 Rev B
36. 3 28 3104 S WH3l Gd 9 YOLOSNNOO 9902 3 18 32018 WNINYSL 1914 NOlvsvd3s v982 3 08 COiNvIH 39vX2vd Nid 21 11 6681 3 62 001 9 1 M3HSVM 8 82 1nH 2 1 X 02 1 M3NOS 07 0169 ZZ 1 8 1 ONIGNL 5 9 6v1 3 92 318 2 143134 NIVYLS 066 6 GZ c4 OiMI3A 55 19 014 016 3SN4 1 0662 3 v 24 OlMI3W 55 19 018 015 ISNI S occz 3 lt 14 55 10 018 015 3504 0 2 3 21 OlMI3N 353 162 3 14 MLN VO 4 20 3 04 SNO 6 01 LONG 43409 61 6122 3 69 9 01 v 0l 1004 33M GI 62v1 3 89 X09074 WWNINYSL 929 NI 9nd 0103NNOO 8 9902 3 9 8 6 x 2 lt 9 MNOS 50259 0169 99 31044 138 1 1871 5 138v1 v 1841 S v9 OuvHON3nO 9 1 3 HOLIMS 3201431NI ATHW3SSV 318v2 L vL 2 33 79 HOLIMS INI GOOH AT8N3SSV 318 2 1 1062 33 19 ONIN 5 9 NOIO3NNOO 9 v121 3 o9 80 31VW34 SNI ATINA 47 1 30193NNOO 6 121 3 ec TO SNI ATINA 9 1 HOLI93NNOO S i21 3 ONIN SNI 8 HOIO3NNOO 6 v171 3 ZS MLN Sif 602 3 96 MLN 91 H 6v98 3 SNO 320018 VNINH3I 1161 3 9 f ONO
37. B IIHS 90169 OL 3015 H1 WSY H3AOO 1403 886069 6 M3AOO 111 MOCNIM 1 9 0 v 8 3015 HH WSV N3AOO INO3J 66069 2 1006 9 2 S3HOLIMS 15 0 S 2 YOLWNLOV 15069 v anis 11 8 6019 H3A00 HI I3 9v38 9v0 t Y3GNITAD H3AO0 HY 11 0 v90cv 5 HOLIMS HI L3 2viuB 8 0 HOLIMS H3AOO HM I3X0v3u8 0 10 53 055322 JO NOILdhJOS3Q ON LHYd ON 27 4 0 Schematics amp Parts Lists 4 5 Hydraulic Power Unit 60 Hz H 477 1 Rev B 1 c 0 01 0181 5 91 2 9NO1 A18W3SSv ISOH G ZvZ H GI H NINO 2 96 1 3 1 1102 11 6901 3 NOLLVOIHIIN3QI 6 691 5 21 2 3801 81 91 6 OL 81 91 6 moga 0 IL ZH 09 33MOd OMNVYECAH 8 028 01 ATBW3SSV Q103INVW 1 9 6 314 0 2 662 8 2 M3NOS 134005 2 1 6 X 91 8 829 8169 4 9 4 n 9NO1 WSv ISOH 19 2 2 2 IAN 1 7621 3 v YOLON GAH ATHW3SSV 409 1 0 2 33 4 3901 81 91 6 OL ONIN 81 91 6 u3ldvav 9 3o9nv9 629 d8 ALO S3IMOSS3OOv 40 NOIlLdlJ2S3G ON 1BVd ON
38. CIAL TERMINAL BLOCK CLOSED AND USE EE 1766 41 XX SOFTWARE FOR MACHINES WITH 2 HAND CUT BUTTON CONTROL INSTRUCTIONS SWITCHES CONNECTED TO INPUTS 1 amp 5 ARE NORMALLY OPEN AND USE 1766 50 FOR 208V MACHINES JUMPER TERMINAL BLOCKS SOFTWARE 16 16 168 NOTE THE PULSE WIDTH P C BOARD 2813 AND THE CLAMP PRESSURE PROXIMITY FOR 230V MACHINES JUMPER TERMINAL BLOCKS SWITCH ARE OPTIONAL AND ARE SHOWN 16 16 160 FOR REF ONLY SERVICE NOTE THE LINKS ON H10 AND H11 MUST BE REMOVED FOR THIS BOARD TO BE USED FOR REPAIRS FOR OLD EE 2762 BOARDS 35 4 0 Schematics amp Parts Lists 4 11 Power Panel Assembly EE 2765 1 Rev F 0999 5 vase gyi 1 2482 3 33S NOldO 55 5 N03 310N CX V eso pun V STVNINH3I N33ML38 YOLVYVd3S VNIWNH3L LYSSNI Q3au3dwnr Z SNId QTnOHS ZLIH Q343dWnr 38 LON OLH 83Q0V3H 310N G N VU 9 gt 0 5 apoa 0 R ESERE Korda Doraz s Ei sje o 9212 Fit zT bl Aao Olea E slele H SII 93 S4 E Q SIHL
39. J SV JOVLIOA 12444092 H04 d3dNnn WNINYSL 39NVHO AlddNs ASN4A ANY jJAVS AINO 3OVld3M GYVZVH 3414 31 iJNIHOVIN 300A 49 TIM dA MOOH S3MOd LOAYYOONI INVI SLYVd NOILONYLSNI 3HL NI 1005201 83MOd 33S dA JVIN3GdIOOV INdA3Hd OL 100 Ll MOOT 3NIHOVNW NO ONIMHOM 340438 13NVd H3JMOd JHL LV 3 LOANNOOSIC 5 li SDILON ii ONINUVM Y 594 9 002 NVIIL 4 8 Power Panel Label 5 1781 54 Rev C 4 0 Schematics amp Parts Lists 32 4 9 Electrical Schematic Tilt Shield Machines E 2771 2 Rev B LIDE n 22 24 208 230V ppy E 1075 1058 MD 21 L2 BROWN F4 T 208 230v 23 E 1075 1058 21 23 1 24 1 4 15 FILTER 16 23 HYD 32 M 24 Eo BLuE PUMP BROWN n F5 15 1 24 SB 26 F6 E B89 12 15 1 1 4458 227 16A 16C 16B 160 889 B Bl 2 z
40. NIHLIM S32018 i 9 4 MOTT3A 8 m 01 MOTIA 3n18 6 ania 091 q38 32v18 891 134 2 18 92 avia ON 30102 aaa MOTA 291 18 MOTIAZXOvi8 22 ON 30102 411 3002 80102 N3WHOJSNVAL 1 L 1 1 6 m KNFE LATCH 11 9o 1 210 6 LD s 9 G GQ OQO Sr ONY 19 X03 5318 2 Qq3iHs HOVLIV s orgi lt 2 Sun an 5 8 5 3 36 4 0 Schematics amp Parts Lists 1 1 MOIOVINOO vY 941 2
41. Q Lad ON 21 4 0 Schematics amp Parts Lists 4 2 Main Assembly Right Side View 43000 Sht 2 of 4 Rev N XZ 31725 LASNI O 08 v9 oc t 717130 a 5 MOO T183INI QNVH 1431 Va tr W130 SNIMIM HOIIMS MOOTYSINI QNVH 8 14 18 C 19 182 Le fJ Or fJ 19 6 791 2 19 sc 99 85 8 OF 29 9v Or J19 122 0817912 12 89 02 138 1 09 4399 1 318 2 54 08 tt 61 104 95 81 at 4 98 99 28 99 ymo 8 c9 62 ONIH33NION3 38 Ol tt 128 98 8 03119915 W130 W130 HOLIMS MOOTHSINI HOLIMS 520 TH3LNI 8 0 Va QNVH 1431 22 4 0 Schematics amp Parts Lists Main Assembly Right Side View 43000 Sht 2 of 4 Rev SNI NON 2 1 HOLO3NNOO 69 101 3 16 1 ONUSM 52 10 138 1 LLAG 06 ONusn T38v1 16 68 D 135 205 1 X 02 1 M3N2S 917 8 69 88 l 3IEVWAVHOONd WONd3 19 9941 33 8 1389 6 1871 5 98 2 AINO A021
42. Serial Numbers 032425 amp Up TECHNICAL SERVICE AND PARTS MIANUAL TITAN 200 PAPER CUTTING MACHINE Sold and Serviced by The Challenge Machinery Company 6125 NortonCenter Drive Norton Shores MI 49441 6081 USA ChallengeMachinery com F 200 CT August 2003 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 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 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 1 0 Introduction TABLE CONTENTS 1 0 Introductio 2 2 0 5 co sitis fo e dom dt dn LR Lens cc 4 2 4 PreCcautlols
43. T 96 MLN 7 981 8 604 3 MLN vo8If 8 604 3 zc 32018 TWNINYSL 138 1 1 1 96 1 3 16 2018 1387 261 9661 3 06 MIN 034 vogif 4 60 3 6v 145344 18 355 318 2 1 8891 33 89 0018 WAIL 824 NO103NNOO 21 9902 3 HOLV JANA ATHN3SSV 318 2 6472 33 9v dN 18 1355 HOLIMS ALINIXOYd 2 0112 33 Gv 34IN4 ATHW3SSV HOLIMS 07 2 33 vt 3JINM 18 1355 HOLIMS ALIWIXONd 0442 33 ALO 5314055322 40 53 Luvd ON NMOG 3JINX AT8W3SSV HOLIMS ALINIXOYd 0442 33 Zv 43000N3 18 4355 318 2 L v 62 33 19 QION3IOS 112 A1HW3SSV 318 2 6942 33 0 YOLON 39voxOvd ATHW3SSV 318 2 8942 33 6c ONIN SNI NON 1 80193NNOO 9 121 3 86 8 HOLIMS 1 ATHW3SSV 3182 VLLC 33 LE HOLIMS 193NNOOSIQ NIVW AJ8W3SSV 318 2 99 2 33 9 MOOTHLOOL OL u3HSVM OL YZEL H SE 108 8 X 2 01 5 0 201 0169 MOOTHLOOL 8 XIHSYM 8 064 ing 2 1 29 80 5 02 8 0169 MOOTHLOOL 9 XIHSYM 9 vZEL H I 9 LAN 9j czv9 H OF 1n8 8 6 X 9 MANOS 02 9 0169 H 62 13 31 NOISIA3J M38W N 18 4 1387 861 3 82 494 1 1
44. achine should be placed on a regular maintenance schedule A clean lubricated machine will run longer smoother cut more accurately with less downtime and fewer costly repairs Schedule lubrication both early in the day and early in the week This allows the lubricants to work into the machine Lubrication at the end of the day or week allows the lubricants to run off without any benefit to the machine The following guidelines will help you set up a regular maintenance schedule 3 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 operating temperatures which causes premature wear to all hydraulic components Hardware Remove the lower front panel cover rear panel cover and top hood to check all nuts and bolts for tightness Loose hardware is the cause of most component wear and in the electrical area could cause short circuits and or shock Hydraulic Fluid Low fluid level causes excessive heat and wear on the system Check the fluid level as described in section 3 5 below Oil and Grease See section 3 6 3 4 2 Monthly Backgauge Squaring See section 3 7 3 3 4 3 Yearly Change Hydraulic Fluid See section 3 5 3 5 Checking Changing the Hydraulic Fluid The hydraulic fluid level should be checked weekly To check remove the lower rear cover and unscrew the cap on top of the tank Figure 2
45. ave been adjusted at the factory 2 Remove the rear plexiglass table cover 3 Loosen the jam nuts on the backgauge adjusting screws Figure 13 Adjusting Screws with 7 Jam Nuts Figure 13 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 either sequence 6 Replace the rear plexiglass table cover Note Once the backgauge is square restore power to the machine and check the backgauge accuracy see the Titan 200 Operator manual to make sure it is accurate 16 3 0 Maintenance Guide 3 7 4 Clamp Pressure Adjustment Adjust the clamp pressure reducer Figure 14 to the desired setting It is factory preset at 800 psi Read the gauge with the clamp down and as the knife begins to move down Loosen the jam nut on the valve stem With an allen wrench turn the stem clockwise to increase pressure and counter clockwise to decrease pressure Note When cutting pressure sensitive paper you may want to reduce the clamping pressure 400 psi minimum to prevent marking the paper Clamp Pressure Reducer Figure 14 CAUTION DO NOT set the clamp pressure below 400 psi Severe lacerations or dismemberment could result The knife and clamp system loses sequence at settings below 400 psi and the knife could come down before the clamp 3 7 4 1 Optional Ele
46. ctronic Clamp Pressure Control Adjustment The electronic clamping control option allows the convenience of changing the clamp pressure at the control console The pressure is controlled by use of the up and down arrow keys 0 being the lowest 15 the highest and is indicated in the upper right hand corner of the display Note To turn the electronic clamp control option on or off enter the Maintenance Mode and choose Diagnostic Then choose Electric Clamp and select or OFP To adjust the actual clamp pressure maximum and minimum first make sure the Electric Clamp option is set to see above paragraph Enter the Maintenance Mode and choose Diagnostic Then choose Clamp Adjust and the screen on the following page should be displayed 17 18 3 0 Maintenance Guide 5 000 Set Maximum gt Press to Increase Press V to Decrease 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 800 psi If it does not correct by using the up and down arrow keys When finished press soft key D to exit and go to the minimum pressure set up screen shown next 5 000 Set Minumum gt Press to Increase Press V to Decrease A Main C Send B Job D Exit Perform a cut cycle After the clamp has contacted the table and while the knife bar is coming down read the pressure
47. dWOO 01 1332vM8 318 1355 FHL IXM 9 NMOHS SV HOVLIV H3T10HINOO 21910313 IHL OL ALNOY 5318 2 3106 102 WO S3HIM ONLSIX3 TVNIWH31 N3dO OL 66 34M 03114406 JHL Q3HOVIIV NMOHS SV 41415 VNIWH3L 3l0d 319NIS 03114405 OINI JAIM Q3H38WON3MH 1M3SNI ONY SV 3MIM H3ENON3N 6 3AOW3N 7542018 WNIWH3L JHL 01 2v8 S38IM 109 1431 31HVO NOlIn8 102 31 201 6 NMOHS SV LINN OMINOO 3HL NO IVNIAH3I OINI Q34838WQN33 3HL LH3SNI ONY Viv SV 3HIM SIHL HJEWON3H vvf JHL 3AOW3H SM2O1H VNIWH3I 3HL Ol XOVE S3YIM 3HL 30VMl 318 2 0 3105 102 FHL 31v2O v 86 6 4315 5 30 ONINNIO38 JHL 1Y SNOILONYISNI MOTIO4 SM3NOS 3Hl N3IH9IL 13 M3MOd LONG 30 3015 WOLLOS 33 138 13 2 30 S310H Q31101S 9115 SM3N2S 9NIINDOW JHL 35001 12n 1342 8 318W3SSV JHL INnOW OL 1 5 ISN 13 2v48 INNON OL 5 030 34 3AVH LON 5300 T3Nvd 33MOd 3Hl I3Nvd N3MOd OL SdilS ShOlA3Nd JHL WO3J anova Q318W3SSv SN3HSVM ANY SA3H2S 01 5
48. gure 11 next page Gib Screws Screws Figure 11 5 Tighten the bottom nylon guide screws until they just touch the guide Do not overtighten or they could cause the backgauge to bind 6 Similarly turn the side gib screws in until they just touch the guide Lock in position with the jam nuts 7 Run backgauge back and forth the length of the table using the backgauge glide control Check for any binding Readjust if necessary NOTE The screws should be tightened to hold the backgauge square against the guide rail Excessive tightening will cause the backgauge to bind and cause premature wear of all components 15 3 0 Maintenance Guide 3 7 3 Squaring the Backgauge a eae a e x mo Ogee ee Figure 12 To test if the backgauge is square place a small lift of paper against the left side of the backgauge but not against the side guide and make a cut Now leave the backgauge in the same position flip the lift over and push it against the right side of the backgauge but not against the side guide Make another cut to see if any of the paper will trim off Run two checks one starting on the left and moving to the right the other moving from the right to the left If paper is trimmed in either sequence the backgauge is out of square 1 Make sure the backgauge gibs are set properly see section 3 7 2 NOTE Gib adjustments are not necessary on initial machine set up as gibs h
49. ine lubricated Memory Failed A memory error occurred during test Encoder wires 9 amp 10 are reversed Should only occur during initial assembly otherwise is an encoder error Replace encoder Memory Locked Tried to change a locked channel Next Channel Locked Tried to link two channels together and the linked channel is locked Number Outside of Limit Selected cut position beyond limits of machine Operator error false clamp limit Positioning Error Backgauge failed to move to programmed position within 005 failure main pcboard leadscrew thrust washers loose gibs loose Remove Obstruction Obstruction is blocking electric eyes or electric eyes are not functioning properly Remove obstruction check alignment of eyes check all electric eye connections Result is Negative When a math operation yields a negative number Send Cancelled Console key was pressed while backgauge was moving Operator error key board failure Sequence Error Timing error in either up or down cycled Low main pressure any sequence valve Sharpen Knife Sharpen knife alarm Have knife sharpened Shorted Key Error Console Key shorted Operator error defective keyboard f error codes cannot be reset by depressing the clear key the power will have to be turned OFF and 3 3 Sensor Data
50. n 100 Std Oil Indiana Boron Sunvis 851 WR Sun Oil Co Rando HD 100 Texaco Unax AW 100 Union Oil Co 11 3 0 Maintenance Guide 3 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 figures Figure 3 through Figure 10 starting on page 12 for oil and grease locations Figure 3 through Figure 5 require the knife and clamp be in the up position Figure 6 through Figure 10 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 Cil Figure 3 Knife Bar Link L H Side Upper Figure 4 Knife Bar Link R H Side Upper 12 3 0 Maintenance Guide Figure 5 Knife Bar Figure 6 Knife Bar Link L H Side Lower Figure 7 Knife Bar Link R S Lower Knife Bar Knife Cylinder Bracket Upper 13 3 0 Maintenance Guide Figure 8 amp Figure 9 Clamp Guides Figure 10 Leadscrew and Backgauge Guide 3 7 Adjustments CAUTION Several of the following tests require the machine
51. s 2 MA d 2 GRN YEL gt BROWN F4 10 T 208 250 25 1075 1058 21 15 FILTER 23 M 31 HYD 32 BLuE PUMP BROWN F5 15 1 2 SB 26 889 12 15 1 1 44 SB 27 16A 16 0 r 3 889 35 gI T1 TeV 24v on Y 12 8v 8v 12V 12v 34 34 33 6 7 9 10 n 7 1 2 6 7 8 2 9 10 11 F5 2 5 IN 15VAC IN 35 Y 36 5A SB LIGHT 36 7 2 E 2330 7 O o 5 2330 7 55 51 35 55 33 1 3 1 4 1 RIGHT 53 2813 64 PULSE WIDTH MODULATION PCB 63 FB 2A SB 2 CLAMP I 51 52 HYD UP CLAMP PRESSURE KNIFE VALVE UP KNIFE LATCH 59 57 M AUX T NC F2 Tu H2 12 pus 3 158 H4 10 KNIFE 259 55 1 35 47 47 ug 6 T LATCH 12 a 2 1 7 NC H5 1 i 2 3 35 39 PECU 1 QI 1 Bs Nya 94079 4 4 E 3 l 35 41 9 Opes 4 5 6 7 49 24 0 D ADS eS CUT PECU 44 8 2 CAMIS u5 2 T
52. s 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 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 Do not alter safety guards or devices they are for your protection Replace all guards Do not operate with any guards removed SHOCK HAZARD Disconnect power before removing cover Replace cover before operation SHOCK HAZARD Disconnect power before removing cover Replace cover before operation SINGLE OPERATOR Do not operate with more than one person 3 0 Maintenance Guide 3 0 Maintenance Guide NOTICE A The instructions on the following pages are for the use of trained service per
53. sonnel only Attempting to perform repair and replacement procedures without proper training may cause machine damage or operator injury PARTS CUSTOMERS 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 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 modification or alteration of any Challenge product will void any remaining warranty 3 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 CUT BUTTONS PUSHED WON T CUT Check error codes page 8 Obstruction between electric eyes if equipped Guard open if equipped Guard hasn t been opened since last cut if equipped Hydraulic fluid low Main relief valve setting off Sequence pressure set wrong Cut button defective Motor relay defective Knife latch solenoid defective Knife down coil defective Defective directional valve Cylinder disconnected from cylinder bracket Knife bar

CT Service Manual - Copy Finishing Systems

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