Model 3800AP and 3800FC Installation, Maintenance, and Operating Instructions

Model 3800AP and 3800FC Installation, Maintenance, and Operating Instructions
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Model 3800AP and 3800FC
Installation, Maintenance, and Operating Instructions
Model 3800 Specifications
Feed Speed
3800AP……………………………………...Variable to 15,800 sheets per hour
3800FC…….……………………………......Variable to 12,000 sheets per hour
Paper Length….…………………..…………3-1/2” min to 22” max
Paper Width…….…………………..……….3-7/8” min to 18” max
Paper Weight……………………….………16# bond to 150# card
Continuous Feed Load Capacity…………...1-3/8” of paper
Standard Accessories
3800FC (2) 7-tooth per inch. Perforating wheels. (1) Slitting Wheel. (3) Backup Hubs. (2)
Exit Straps.
3800AP (1) 10-tooth per inch. Perforating Wheel. (2) Scoring Wheels. (1) Stripper. (4)
Backup Hubs. (2) Exit Straps.
Electrical………………………………….115 V 60 Hz (220 V 50 Hz available)
3.5 amp Circuit Breaker
Working Dimensions…………………..….36” x 27-1/2” x 13-1/4”
Shipping Weight………..………………….87 lbs.
Options…………………………….………960 Machine Stand, Perforating Wheels, Scoring
Wheels, Slitting
Introduction
Thank you for selecting the Martin Yale Model 3800. This unit has been designed for fast, easy
operation and will give you years of trouble-free service.
These instructions are applicable to both the 3800 AutoPerf (AP) and the 3800 Forms Cutter (FC).
Operational and setup procedures are the same for each machine. Since the standard accessories
differ, not all accessory setup procedures will apply to each model. The 3800AP is equipped with
a 10-tooth slot type perforating wheel, two scoring wheels, a stripper and four backup hubs. The
3800FC is equipped with two 7-tooth slit type perforating wheels, one slitting wheel and three
backup hubs.
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Please review this publication in its entirety before attempting to setup or operate you new 3800.
Thorough understanding of this information will help eliminate most operator-associated errors
and ensure years of trouble-free performance.
Warning – Never connect power to the machine until you are ready to setup and operate.
Installation
Carefully unpack the 3800. Do not throw out the hardware bag. Carefully inspect the carton
contents for damage. If damage is apparent, immediately notify the freight carrier and then your
dealer. Save the shipping carton in the event the 3800 requires relocation. If no damage is
apparent, place the 3800 on a flat, level surface such as the Martin Yale 960 Machine Stand.
Allow sufficient space around the 3800 for comfortable operation.
To orient you to the 3800 controls and various terms used, we will refer to the front of the
machine as the side where paper feeds into the machine. The rear of the machine is the area where
the paper exits the machine. The left (operator) side of the machine contains the hand wheel and
the other controls. The right side is the side opposite the operator side
I.
Assembly (Figure 1 and 1a)
Check to make sure all four rubber feet are in place. Note – If one or more of the feet are
missing, do not attempt to operate the machine. Call your dealer.
The following tools are required for assembly and setup: #2 Philips Screwdriver, 11/32” box or
open end wrench, 3/32” “T” handle Allen wrench (supplied).
Your machine was fully assembled and tested at the factory to ensure proper operation. Some
components were removed for shipping purposes. The following assembly is required:
Slide the feed table assembly (1) beneath the left and right paper guide supports (3) to engage the
four feed table notches (1a) onto the four index pins (1b). After engaging the front feed table
notches on the inner pins, apply a slight inward and downward pressure to engage the feed table
side notches onto the other set o f index pins.
Loosen the adjustment locking knobs and position the guide supports (3) 2” from the left and right
side frame. Check both the left and right paper guides (2) to make sure there is 1/16” clearance
between left sprint (at the front of each guide) and the top surface of the paper guide. If there is no
clearance, loosen the leaf spring assembly locking knob on the side of the paper guide. Set the
correct clearance and retighten the locking knob.
Attach the left and right paper guides (2) to the guide supports (3) with the screws and nuts that
are packed in the hardware bag. Tighten each screw securely by using a #2 Philips screwdriver
and 11/32” wrench. Squareness of the guides is critical to proper operation. The paper guides
should lay flat on the feed table.
The receiving tray (12) is installed by engaging the top two brackets notches (12a) onto the top
index pins (12b) on the exit side of the machine. The lower part of the bracket rests against the
lower index pin.
Install the exit straps (9) by opening the safety cover (13) and removing the locking knobs from
two guide fingers. Insert one exit strap (hole side toward the machine) between the top of the exit
tray and the bottom of the safety cover. Align the hole in the exit strap with the threaded hole in
the guide finger. Replace the locking knob and relock the guide finger(s). The exit straps should
now suspend loosely between the locking knob and the back end of the guide finger. The retarder
housing is factory preset to 83º and should require no further adjusting.
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II.
Functional Test
Before attempting to process forms with the 3800, perform the following functional test. Make
sure the power switch is in the off position and set the depth control indicator (7) to “Open” (at the
Open” position, the upper cutter shaft should be at the highest point). To adjust the depth
control, loosen the depth control locking knob (6). Turn the depth control knob counterclockwise
until the knob indicator aligns with the zero on the depth control scale. Retighten the depth
control locking knob.
Open the safety cover (13) and inspect the accessories on the upper shaft. Make sure none of the
accessories are contacting the backup hubs on the lower shaft. Close the safety cover (13). Plug
in the machine and turn the speed control (7) clockwise until the machine just begins to run.
Increase the feed speed by continuing to turn the knob clockwise. Open the safety cove (13). The
machine should stop. Turn the speed control (7) to the off position. The 3800 is now ready for
operation setups for perforating, scoring, or slitting.
Setup and Operation
Set of the 3800 is based on paper side, paper weight and operation to be performed. Scoring,
perforating and slitting operations may be done individually or simultaneously except the
perforating and score combination. The operator is required to position each component and
adjust for paper stock and operation depth. The speed of the machine is variable and must be
adjusted to suit the paper stock and operation being performed. This machine incorporates a dual
bottom feed system that provides positive feed. Paper stock can be added without interrupting
operation. Note – Always test a new setup by hand operation prior to applying the power.
This wi ll prevent damage to the perforator components.
I.
Feed Table Setup (Figure 1)
Loosen the four paper guide locking knobs and position the guides (2) slightly wider than the
paper stock to be processed. Place a piece of paper stock on the feed table (1) with the center of
the paper aligned approximately with the orange feed tire. Next, position the paper guides (2) so
that each guide touches the corresponding side of the paper. Tighten the four locking knobs. Note
– Paper guide position may be fine tuned by using the fine tuning adjustment knob. The
guides can be moved independently or at the same time. Loosen the locking knobs on the guide(s)
to be moved. Lock both knobs if the guide does not need to be moved.
II.
Retarder
Place one sheet of the paper to be run between the retarder and feed roller. Hold the sheet by
the tail end and adjust the retard until you feel a slight drag on the paper. The retarder roller is
raised and lowered via the knob (8) on top of the retarded housing. Utilizing the hand wheel
(5), manually operate (cycle) the machine for one complete revolution of the feed roller. If
you do not feel an even pull throughout the entire cycle, readjust the retarder. Note – Apply
only enough pressure on the retarder for positive feeding. Too much pressure will cause
excessive wear of the feed roller and retarder.
III.
Slot Perforator Setup (Figure 1 and 3)
Mark a sheet of the paper to be processed at the leading edge of the position(s) of the desired
perforation(s). Place the sheet onto the feed table (1) with the marked edge closest to the
infeed roller. Adjust the paper guides (2) so the sheet slides freely down between the guides
without excessive side play. Check the feed system for proper adjustment.
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Loosen the depth control locking knob (6) and turn the control knob (7) so the indicator aligns
with “Open” on the depth control scale plate. The two accessory shafts should now be at their
maximum open position.
Raise the acrylic safety cover (13) to gain access to the perforator wheels and backup hubs
(figure 3). Move or remove the aluminum stripper fingers by loosening the locking knobs.
Note – A safety interlock switch will prevent the machine from operating while the
acrylic safety cover is open.
Using the “T” handle Allen wrench, loosen the perforator set screw (upper shaft) and the two
backup hub set screws (lower shaft).
Turn the hand wheel (5) and advance the marked sheet of paper into the machine until the
leading edge meets the backup hubs (figure 3). Align the inside edge of one backup hub with
the mark on the paper stock. Tighten the backup hub set screw. Note – When lowering the
depth control, make sure the perforator cannot come in connect with the backup hubs.
Set the depth control knob (7) indicator to No. 3 on the depth control scale and lock into
position with the locking knob (6). Slide the 10 tooth perforator against the preset backup hub
and lock into position. Also slide the stripper blade against the backup hub. Move the second
backup hub against the other side of the perforator blade and lock into position.
Caution – For the stripper blade to function correctly, the blade must be positioned as
illustrated in figure 3. The stripper point should be behind the lower exit roller and in
front of the 1 / 4” tie rod. Failure to position the stripper correctly can damage the
lower intake roller.
Set the guide fingers (see Exploded Parts Diagram, Item 38) according to the following
procedure. Place the first and second guides fingers one each in line with the left and right
paper guides (2). The third guide finger should be placed about 1/16” away from the
perforator blade, opposite the blade hub. The fourth guide finger should be placed about 1/8”
away from the hub of the perforator blade. To order additional guide fingers, contact your
dealer.
Close the acrylic safety cover (13). With the hand wheel, advance the sheet of the paper
through the machine until it exits onto the receiver tray (12). Set the two long paper guides
(11) so the vertical sides of the guides are about 1/8” from the sheet. Set the backstop (10) so
there is about 1” between the vertical side of the stop and the sheet.
Load stock to be perforated onto the feed table (1). Turn the speed control (4) to minimum
speed and feed several sheets through. Stop the machine and check perforation.
If the position of the perforation is incorrect, make paper guide adjustments as follows:
a.
b.
c.
d.
e.
f.
Lock the left and right guide support knobs (3) into position on the fine adjustment shaft.
Loosen the locking knobs that hold the left and right guides in position on the tie rod.
Rotate the fine adjustment knob clockwise or counterclockwise to correct perforation
position. (The fine adjustment moves the paper guides laterally.)
Test run sheets and check position of the perforation.
Repeat fine adjustment and test run until perforation is in proper position
Lock the guide support locking knobs into position on the tie rod.
If the perforation blade cuts through the stock, make adjustments according to the following
procedure:
a.
Loosen the depth control locking knob (6).
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b.
c.
d.
Rotate the depth control knob (7) counterclockwise one line on the depth control scale.
Tighten the depth control locking knob (6).
Turn the speed control on low and run a few test sheets through the machine.
Check and repeat steps 2 and 3 if necessary until correct perforation is achieved.
Setting the depth control perforation is too shallow:
a.
b.
c.
Loosen the depth control lock knob
Rotate the depth control knob clockwise one line at a time on the depth control scale and
test each time control is moved until proper perforation is achieved.
Re-tighten depth control lock knob.
Caution – After the setup is made, do not disengage or re-engage the perforator from
between the backup hubs when machine is in operation mode. This action could cause
severe damage to the perforator blade. To re-engage perforator follow Section III “Slot
Perforator Setup” instruction.
IV.
Slit Perforator Setup (Figure 4)
The setup for slit perforating is the same as the setup for slot perforating, with the following
exception:
Only one backup hub is required. (The sharp edge of the hub should tightly contact the
perforator blade teeth.) The stripper blade is required.
V.
Scoring Wheel Setup (Figure 1 and 5)
Note – The backup hub has two grooves, a wide groove for heavy stock and a narrow
groove for light weight stock. Select the groove that provides the desired scoring width
for the stock being run.
Loosen the depth control locking knob (6) and set the depth control (7) to the maximum open
position.
Mark a piece of stock at the position to be scored and place it on the feed table (1) with the
marked edge toward the scoring wheel. Set paper guide as described in Section I and set
retarder as described in Section II.
Loosen the scoring wheel (upper shaft) and backup hub (lower shaft) set screws. Align the
scoring wheel blade and appropriate backup hub groove to the mark on the paper. Tighten the
backup hub set screw. Using the depth control, lower the scoring wheel into the appropriate
backup hub groove. Align the scoring wheel blade in the center of the backup hub groove and
tighten the scoring wheel set screw (figure 5).
Place a sheet of paper stock onto the feed table (1). Rotate the hand wheel (5) to feed the
paper. Use the depth control adjusting knob (7) to set the proper scoring depth. Tighten the
depth control locking knob (6) when properly set. Set the guide fingers into position.
If the score position is incorrect, follow the paper guides adjustment in Section III.
VI.
Slitter Setup (Figure 4)
Slitter setup is identical to the Slit Perforator Setup.
VII.
Shaft Removal (Figure 1 and 2)
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Note – Each accessory shaft can be removed from the machine so accessories can be
added, removed, or changed. The upper shaft and guide fingers must be removed prior
to removing the lower shaft.
Loosen the depth control lock knob (6) and turn the depth control knob (7) to the maximum
open position.
Raise the acrylic safety cover (13). Note – A safety interlock switch will prevent the
machine from running while the acrylic safety cover is raised.
Rotate the hand wheel (5) until the set screw at the operator end of the upper shaft is
accessible (figure 2). Loose the set screw using the “T” handle Allen wrench supplied with
machine.
Grasp the upper shaft and slide it toward the non-operating side of the machine until it is
disengaged from the shaft journal (figure 2). Lift the free end up and pull the shaft from the
swivel bearing at the opposite end.
If the lower shaft is to be removed, repeat this procedure. Note – Do not attempt to
interchange the shafts. When reinstalling shafts, install bottom shaft first.
To reinstall a shaft, first slide the shaft into the swivel bearing on the non-operator side of the
machine. Slide the other end of the shaft into the operator side shaft journal. Note – Be sure
that you align the dimple on the accessory shaft with the set screw hole in the shaft
journal. Tighten the shaft journal set screw using the “T” handle Allen wrench. Note – If
the lower shaft contains a stripper, make sure the bottom point is placed between the
exit roller and the tie rod.
Troubleshooting
The 3800 will not run
Check to make sure power is flowing to the machine. Reset the internal circuit breaker. Have a
qualified electrician check the machine wiring. See wiring diagram.
Scoring, Perforating or Slitting
Adjust the paper guides. Ensure the paper guides are parallel not straight.
Not feeding or feeding more than a single sheet
Adjust the retarder for proper feed roller tension or replace the feed rollers or replace the retard
roller. Note – It may be necessary to rotate the retarder to a new surface if a large flat
surface has developed on the retarder. See section Maintenance III.
Perforating Scoring, Slitting depth inconsistent.
Readjust the depth control. Loosen the perforator set screw, and rotate the perforator hub 90º, and
retighten the set screw. Check the condition of the perforator.
Maintenance
Main Rubber Rollers
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Caution – Never use detergent or soap and water on the main rubber (black) rollers as it will
ruin the rollers and void your warranty.
During normal operation, the main rubber rollers will become coated with ink, toner, lint and
various other contaminants. Contaminated rollers can cause a variety of performance problems.
Regular cleaning will ensure optimum performance and add years of life to the rollers. We
recommend cleaning the rollers after every job, according to the following procedure.
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