Challenge TITAN 200BC - User Manual

F.200BC-T
March 2018
TITAN 200BC
Serial Numbers:
110001 through 159999,
200BC-A-150000 and up
Sold and Serviced by
The Challenge Machinery Company
6125 Norton Center Drive
Norton Shores, MI 49441-6081 USA
ChallengeMachinery.com
The Challenge Machinery Company provides owner's manuals on its
products solely as a courtesy to its customers. See the information below
before using this manual.
These manuals are for reference only. These manuals include products which are noncurrent,
unsupported or no longer produced by The Challenge Machinery Company, and are provided solely as
an accommodation to our customers. By providing these manuals, The Challenge Machinery Company
makes no representation or warranty as to the products, their current condition, or their suitability or fitness
for use in any particular application, which are the sole and independent responsibility of the product
owner and user.
Older products may not comply with current safety procedures, guidelines or regulations, and it
is the product owner's and user's responsibility to evaluate the suitability and fitness of the
products in their current use and application. The Challenge Machinery Company makes no
representation, warranty or recommendation regarding any modifications which may be required
on non-current or unsupported products. The Challenge Machinery Company assumes no liability
for any modification or alteration to any Challenge product, and any such modification or
alteration to any Challenge product is not authorized by The Challenge Machinery Company. The
availability of these manuals is solely for the purpose of providing reference information for the products.
This manual may not be complete in all aspects of product maintenance and repair. All products should
be used only by qualified and properly trained personnel, following proper safety procedures. All
products should be regularly inspected and maintained, and their condition, application and use should
be periodically evaluated by qualified personnel. Only qualified and properly trained technicians should
perform maintenance, repair and replacement procedures. Attempting these procedures without proper
training may cause machine damage or operator injury!
Products may be unsupported by The Challenge Machinery Company due to age or the unavailability of
parts from their original manufacturer. No parts or product support will be available to repair or maintain
unsupported products. Older products may not be UL listed (if the product does not have a UL label it is
not a listed product), and may not comply with applicable installation or other regulations or requirements
if relocated to a new facility. Many municipalities require a product to be UL listed before an electrician
will connect power to them. Often the cost of updating an older product to comply with current safety
regulations is greater than the value of the product.

Summary

1.0 Introduction

Safety Alert and Parts Information

Highlights safety warnings and provides information on obtaining parts and service for the machine.

2.0 Safety

General Safety Precautions

Essential safety guidelines for machine operation, maintenance, and user responsibility.

Power Lockout Procedure

Procedure for safely disconnecting electrical power before performing adjustments or repairs.

Warning Label Definitions

Explanation of various warning symbols and labels found on the machine for user safety.

3.0 Maintenance Guide

User and Parts Disclaimers

Disclaimers regarding manual accuracy, product condition, and warranty voiding due to modifications.

Routine Maintenance

Guidelines for weekly, monthly, and yearly maintenance tasks to ensure optimal machine performance.

Hydraulic Fluid Maintenance

Instructions for checking, changing, and recommended hydraulic oils to maintain system integrity.

Lubrication Procedures

Details on lubricating machine parts, identifying oil and grease points, and proper application methods.

Backgauge Gib Adjustments

Procedure for adjusting backgauge gib screws to ensure squareness and smooth operation.

Squaring the Backgauge

Steps to align the backgauge for accurate perpendicular cuts, ensuring proper squareness.

Lead Screw Collar and Readout

Adjusting the lead screw collar for play and resetting the backgauge position readout for accuracy.

Backgauge Accuracy Adjustment

Procedure to check and adjust the backgauge position readout accuracy using preset sensors.

Knife Latch Adjustment

Steps to adjust the knife latch mechanism for proper machine cycling and safety interlocks.

Hydraulic Adjustments

Procedures for adjusting various hydraulic system pressures for optimal machine performance.

Hydraulic Pressure Settings

Specific pressure values for main relief, knife down, clamp up sequences, and clamp pressure reducer.

Cleaning Procedures

Guidelines for cleaning hydraulic components, table, console, and machine exterior for maintenance.

4.0 Schematics & Parts Lists

70000 Main Assembly - Knife;Clamp Schematic

Diagram of the 70000 Main Assembly Knife/Clamp, showing component layout and part identification.

70000 Main Assembly - Arch Schematic

Diagram of the 70000 Main Assembly Arch, detailing its structural and component layout.

70000 Main Assembly - Table Schematic

Diagram of the 70000 Main Assembly Table, illustrating its parts and assembly configuration.

70000 Main Assembly - Knife Latch Schematic

Diagram of the 70000 Main Assembly Knife Latch, showing its mechanical components and connections.

70000 Main Assembly - Console;Tilt Shield Schematic

Diagram of the 70000 Main Assembly Console and Tilt Shield, detailing their components and assembly.

70000 Main Assembly - Stand Schematic

Diagram of the 70000 Main Assembly Stand, illustrating its structural parts and mounting points.

70000 Main Assembly - Covers Schematic

Diagram of the 70000 Main Assembly Covers, showing how panels and shields are fitted.

70000 Main Assembly - Short Table Option Schematic

Diagram for the 70000 Main Assembly with the Short Table Option, detailing its components.

70000 Main Assembly - Foot Pedal Option Schematic

Diagram for the 70000 Main Assembly with the Foot Pedal Option, showing pedal and related parts.

Hydraulic Power Unit Schematic

Schematic and parts list for the Hydraulic Power Unit, including voltage and frequency options.

HH-467-1 Hydraulic Manifold Assembly & Schematic

Detailed schematic and assembly of the HH-467-1 Hydraulic Manifold, showing valves and connections.

Power Panel Assembly W;HOOD (120 V) Schematic

Wiring diagram for the 120V Power Panel Assembly equipped with a hood, detailing electrical connections.

Power Panel Assembly W;EYES (120 V) Schematic

Wiring diagram for the 120V Power Panel Assembly equipped with eyes, detailing electrical connections.

Interconnection Diagrams

Diagrams illustrating electrical interconnections for machines with hoods and eyes.

Basic Machine Schematic (E-3421)

Electrical schematic for the basic machine configuration, showing power, control, and component circuits.

Knife Latch Assembly Schematic (41120-4)

Schematic and parts breakdown for the 41120-4 Knife Latch Assembly.

Power Panel Labels

Details of labels for power panels on machines with hoods and eyes, including wiring and voltage settings.

K-70027 Foot Pedal Kit Schematic

Diagram illustrating the components and assembly of the K-70027 Foot Pedal Kit.

K-70027 Foot Pedal Kit Installation

Step-by-step instructions for installing the K-70027 Foot Pedal Kit onto the machine.

K-3412 Light Curtain Kit Schematics

Diagrams showing components, mounting, and wiring for the K-3412 Light Curtain Kit (3 sheets).

K-3412 Light Curtain Kit Installation

Instructions for installing the K-3412 Light Curtain Kit, including shield removal and wiring.

K-3412 Light Curtain Kit Parts List

List of parts required for the K-3412 Light Curtain Kit installation.

K-3431 Cut Switch Upgrade Option Schematic

Diagram detailing the wiring and components for the K-3431 Cut Switch Upgrade Option.

K-3431 Cut Switch Upgrade Option Installation

Instructions for installing the K-3431 Cut Switch Upgrade Option, including wiring and mounting.

Titan 200 BC Floor Plans

Dimensional layouts for the Titan 200BC with standard and short table options.

5.0 Safety Systems Test

Safety Test #1 - Front Guard Open

Procedure to verify the machine does not operate when the front guard is open.

Safety Test #2 - Guard Interruption

Procedure to verify the machine stops safely if the front guard is opened during a cut cycle.

Challenge TITAN 200BC Specifications

General

Blade Material	High-carbon steel
Dimensions	41" x 40" x 50"
Weight	975 lbs
Clamp Type	Hydraulic
Base Material	Steel