D&K Expression 42 User manual

D&K Expression 42
Pouch Laminator
Instruction Manual

EXP 42” Pouch Laminator
Owner’s Manual
MADE IN U.S.A.

1
Table of Contents
About the Manual...............................................................................................................................................................................2
Introduction...............................................................................................................................................................................................3
Safety Precautions................................................................................................................................................................................4
Understanding Your Laminator..................................................................................................................................................5
Unpacking, Setup and Installation..........................................................................................................................................5
Control Panel...........................................................................................................................................................................................6
Nip Adjusters...........................................................................................................................................................................................7
Mounting Using a SuperStick® Pouch Mounting System......................................................................................8
Mounting Using a Superstick® Mounting Board .......................................................................................................9
Mounting and Laminating Using a SuperStick® Pouch Board.........................................................................10
Encapsulating with a SuperStick® Flexible Pouch or Release Board...........................................................11
Cleaning Your EXP 42” Pouch Laminator...........................................................................................................................12
Specifications...........................................................................................................................................................................................12
Terms & Conditions.............................................................................................................................................................................13
Parts List.......................................................................................................................................................................................................14-16

2
About this Manual:
READ ME FIRST!
This manual contains all the information you need to properly unpack, operate and maintain your
Laminator. Before unpacking your laminator we suggest you read and follow the manual step by step. It
contains essential information about each and every facet of your laminator. Pay special attention to the
work environment and safety precautions necessary for your laminating unit.
Please pay special attention to particular notes and caution statements. These comments alert you to
information that we feel essential to operator Safety and damage prevention to the laminator.
Copyright Information:
IMPORTANT: This manual is copyright protected by D&K Group Inc. in accordance with the laws and
requirements of the United States Government. Any reproduction of this manual, in part or in full, without
the written permission of D&K Group Inc. constitutes a violation of the U.S. copyright laws and is subject to
prosecution.

3
Introduction
Thank you for purchasing a EXP 42” Pouch laminator. We have designed the EXP 42” Pouch to give you
years of reliable service. As you become familiar with the EXP 42” Pouch, you will appreciate the high
quality of its production and the excellence in its engineering design.
By following the guidelines outlined in this manual for proper care and use of the EXP 42” Pouch
laminator, you can depend on many years of trouble-free profitability from your investment.
The purpose of this manual is to outline the materials and process when using SuperStick® supplies with
your laminator to create signs, displays, and flexible graphics with professional results. The manual
includes instructions of various laminating procedures, which are meant to give you comprehensive
information needed for the efficient use of your laminator.
Statement of Intended Use
The EXP 42” Pouch laminator has been designed to be used with SuperStick® Pouch Boards and
SuperStick® Flexible Pouches. When used with these products, you are able to mount, mount and
laminate, and encapsulate prints in one step.

4
Safety Precautions
WARNING: Please review the following safety precautions before unpacking your new laminator.
When using electrical appliances, basic precautions should always be taken to reduce the risk of
electrical shock and injury to persons, including the following:
Read all instructions before connecting or operating this unit.
Retain this Owners Manual for future reference. For technical assistance beyond what is covered in
this manual contact Technical Service.
SAVE YOUR CARTON! EXP 42” Pouch laminators are shipped in special cartons that protect them
from damage. Please store your carton in case your Laminator should ever require service or need
to be transported. (
see warranty limitation s)
Do not use the laminator for anything other than its intended use.
The laminator case may be cleaned with a lint-free cloth, lightly dampened with a mild soap and
water solution. Do not use spray-on cleaners.
Do not immerse any part of the laminator in water or any other liquid.
This unit should be situated away from heat sources such as heat registers or stoves.
The laminator’s location or position should not interfere with its proper ventilation. Do not install or
place in a built-in enclosure such as a bookcase.
Do not operate the laminator with a damaged cord or plug, or after the laminator has been
dropped or damaged in any manner. Return the laminator to your dealer for examination, repair
or adjustment.
Do not let the cord hang over the edge of a counter or touch hot surfaces.
Always unplug the laminator when it will not be in use for a long period.
A socket-outlet shall be installed near the equipment and shall be easily accessible.
Save these instructions

5
Understanding Your Laminator
The EXP 42” Pouch Laminator is a professional laminator designed for ease of use. The process
temperature has been preset to eliminate operator guesswork. The factory settings will facilitate good
quality results using SuperStick® brand Flexible Pouches and Pouch boards. The EXP 42” Pouch can
handle Flexible Pouches and Pouch boards up to 42 inches wide and ½” thick.
Unpacking, Setup and Installation
1. Open the box and lift the machine out (at least two persons necessary!). Grasp the machine 8-10”
(200mm-250mm) from either side.
2. Place the machine on the work area described in the previous page.
3. Remove the protective sheet, placed between the rollers. To do this: pull the knob fully outward
(located on the left side of the machine) and rotate clockwise.
4. Inspect the machine for any physical damage (if damage does exist, report this to the Freight
Company or Dealer to file a claim.)
5. Plug the power cable into the grounded outlet with appropriate service as described in the previous
page.
6. Wait 10-15 minutes to allow the unit to achieved operating temperature.
7. When the (heat) LED is blinking, you are ready to use your EXP 42” Pouch laminator.
NOTE: Set the nip to a position other than fully closed when not in use.
NOTE: The laminator may emit steam the first few times it is used. There is no need for alarm. This is
normal (relates to the lubrication system) and will cease after several minutes of use.

6
Control Panel
LED Design
The LED light indicates the status of heat on or off and whether the machine is at the appropriate
temperature. Please see below for the definitions of the LED status lights.
Switch Design
The switch controls whether heat is on or off and the direction the rolls turn. Please see below for detailed
instructions.
Temperature Ready
when blinking
LED Indicator
Speed Control
Heat (ON/OFF)
Control Switch
Roller Direction
Control Switch

7
Nip Adjusters
The Nip Adjusters are Located on the left hand side of the laminator and is operated from the front of the
machine.
The Nip Adjusters are used to adjust the height of the rollers.
To Operate the Nip Adjusters:
Grasp it with your left hand and pull out approximately 1/4” (6mm) to the left.
Once the knob has disengaged from the stop, it may be rotated forward or backward (clockwise or
counter-clockwise, as viewed from the left hand side of the unit).
To Set the Height of the Rollers:
Continue to rotate the Nip Adjusters until the desired measurement corresponds with the indicator of
the knob.
Select the measurement that indicates the thickness of the material you will be using with the machine.
Release the knob so that it moves back to the right and clicks into place, this will set the rollers for use.
The measurements on the knob, ½”, ¼” (6mm), 3/16” (5mm), 1/8” (3mm) and 1/16” (1.5mm) correspond
to board thickness’.
For additional pressure, stop control knob between indicated thicknesses. There is also a fully closed
stop, 0” (0mm) for film pouch applications.

8
Mounting using SuperStick Pouch Mounting System
Step One
Insert your print into the SuperStick Mounting & Laminating Pouch.
Step Two
Place the SuperStick Pouch on the surface of virtually any rigid
substrate or foam board – NO ADHESIVE NECESSARY!
Step Three
Pass the SuperStick pouch and board combination through the
SuperStick heated roll laminator. It comes out done!
Step Four
Display your finished product. That’s it!

9
Mounting using a Superstick® Mounting Board:
1. Refer to the instruction sheet packed with each box of SuperStick® Mounting Boards for specific
instructions on mounting with a SuperStick® board.
2. Also, refer to the instruction sheet for information on Compatible Media, Process Conditions, and
Technical information.
3. Place the image to be mounted on the adhesive coated side of the mounting board (dull side of the
board). Cover your print with the “cover sheet” as marked (included with each box of SuperStick®
Mounting Boards). Please be sure that the board is completely covered by this sheet
4. Insert the board into the inlet opening. Ensure the board will enter centered and straight. A gentle
push may be required to start the board into the machine. Hold the edges of the board until it is
engaged in the unit and the laminator begins pulling the board on its own.
The board will feed through the laminator and automatically exit at the rear of the unit. THE BOARD WILL
BE HOT!
Allow it to lie flat while cooling.

10
Mounting and Laminating using a SuperStick® pouch board:
1. Refer to the instruction sheet packed with each box of SuperStick® pouch boards for specific
instructions on mounting/laminating with a SuperStick® board.
2. Also, refer to the instruction sheet for information on Compatible Media, Process Conditions, and
Technical Information.
3. A SuperStick® Pouch Board consists of a foam mounting board with a piece of film on top. The film is
sealed to the board along one side of the shorter sides.
4. Carefully examine the board, determine which edge is sealed. There is a 1/8” tape edge on the
sealed end.
5. Starting at one of the corners opposite the sealed edge, gently lift and peel back the film. Care
should be taken not to break the sealed hinge.
6. Center the image to be laminated on the board and lay the film back over it.
7. Cover your print with the cover sheet packed in each box as marked. This is required on thick papers
to prevent adhesive from sticking to the rolls.
8. Set the control knob to the correct setting that matches the pouch board thickness.
9. Slowly insert the pouch board into the inlet opening. Ensure that the pouch board will enter centered
and straight. A gentle push may be required to start the board into the machine. Hold the edges of
the pouch board until it is engaged and the laminator begins pulling on its own.
10. The pouch board will feed through the laminator and automatically exit at the rear of the unit.
11. Support board as it exits the machine to keep heated board from curling down.
12. THE POUCH BOARD WILL BE HOT! Allow it to lie flat while cooling.
13. If there is any dirt or adhesive on the surface of the board, it can be removed by dampening a lint
free cloth with Poly-Off and wiping the surface.

11
Encapsulating with a SuperStick® Flexible Pouch using a SuperStick® Sled or release
board:
1. Refer to the instruction sheet packed with each box of SuperStick® Flexible pouches for specific
instructions on encapsulating.
2. Also, refer to the instruction sheet for information on Compatible Media, Process Conditions, and
Technical Information.
3. The Flexible Pouch consists of two pieces of film that are hinged at one end, along a short side.
Separate the two pieces starting at the end opposite the hinge. Take care not to break the hinged
seal.
4. Insert the article to be laminated in the pouch so there is at least a 1/8” (3mm) border around each of
the sides. This ensures that moisture never reaches the image.
5. Place the pouch with the image on the release carrier board included with the flexible pouches or
SuperStick® sled carrier. The SuperStick® sled is carrier board to assist in the handling of large Flexible
Pouches. It is made of materials that will not damage or cause excessive wear to the EXP 42” Pouch
Laminator). Smooth out any wrinkles with the side of the hand or a soft, flexible squeegee.
6. Better results may be achieved by taping the leading edge of the pouch to the sled using masking
tape.
7. Adjust the Control Knob to the 3/16” setting for the SuperStick® Sled or 1/16” for the release carrier
board to accommodate its thickness. Be sure that the heat is on, the middle LED indicator is on and
the bottom LED is constantly on.
8. Slowly insert the sled or release carrier board with the Flexible Pouch on top into the inlet opening.
Ensure that the sled or release board is centered and straight. A gentle push may be required to start
the sled or release board into the machine. Hold the edge of the sled or release board until it is
engaged and the laminator begins pulling it on its own.
9. The sled or release board will feed through the laminator and automatically exit at the rear of the
machine.
10. THE SLED or RELEASE BOARD WILL BE HOT! Allow it to lie flat and cool before removing the tape.
11.If there is any dirt or adhesive on the surface of the board, it can be removed by dampening a lint free
cloth with ISO Propyl Alcohol (IPA) and wiping the surface.

12
Cleaning Your EXP 42” Pouch Laminator
The laminator may be cleaned with a lint free cloth, lightly dampened with a mild soap and water
solution. Do not use spray-on cleaners. Do not immerse any part of the laminator in water or other liquid.
Cleaning the rollers with Poly-Off Cleaners & Erasure
1. Remove Poly-Off kit from Packaging.
2. Place Latex gloves over hands for
protection.
3. Pour required amount of Poly-Off to
sponge and/or abrasive brush.
4. Scrub affected area until all debris has
loosened.
5. Wipe clean with towel or cloth material.
6. Place Poly-Off kit back in packaging for
storage.
Note: The poly-off cleaning kit is not standard with the laminator. Order part# 221065
Specifications
Capacity..............................................................42”
Height...................................................................15”
Width.....................................................................57”
Length...................................................................16”
Net Weight.......................................................125 lbs.
Shipping Weight............................................175 lbs.
Electrical..............................................................110v 20A
Technical Service:
There are no end user serviceable parts in the EXP 42” Pouch Laminator! If the machine does not reach
temperature or you do not get the results you desire, please contact D&K Group Inc. Your machine is
covered by a Full One-Year Warranty as described in this manual. Contact D&K Group Inc. for warranty
and chemical related questions.

13
Terms & Conditions
Dealer, warrants to the original consumer purchaser that each new SuperStick 62” Plus Laminator which
proves defective in materials or workmanship within the applicable warranty period will be repaired or, at
our option, replaced without charge upon its return as outlined below. The applicable warranty shall be
one year from date of purchase with 12 months parts, 6 months labor and 3 months limited warranty on
the rollers. “Original consumer purchaser” means the purchaser who first purchased the product covered
by this warranty other than for purpose of resale.
Liability for breach of any warranty express or implied shall be limited to the repair or replacement, at
dealer, option, of the defective item. Dealer shall not be liable for damages arising out of, or in
connection with the use or performance of any SuperStick® product. Any implied warranty shall be
limited in duration to the duration of this warranty. Some states do not allow limitations on how long an
implied warranty lasts for the exclusion or limitation of consequential damages, so the above limitation
may not apply to you.
There are no consumer serviceable parts in the EXP 42” Pouch Laminator. If you require service under this
Warranty, contact your dealer to obtain Return Authorization (RA), pack the product in its original
packaging (or request the same from Technical Service when requesting the RA), and include a description
of the malfunction and proof of date of purchase. Technical Service will arrange for the EXP 42” Pouch
Laminator to be picked up by a freight company. Failure to return in original packaging could void this
warranty.
The Warranty extends to and is enforceable only by the original consumer purchaser, and only for the
period which the product remains in the possession of the original equipment purchaser. This Warranty
does not cover any defect or malfunction due to the use of faulty non-SuperStick® 42” Pouch Laminator
materials, unreasonable use or abuse of the machine, or failure to provide reasonable and necessary
maintenance. This Warranty gives you specific legal rights and you may have other rights, which vary,
from state to state.

14
Parts List for the EXP 42” Pouch Laminator
Part Number Description line 1 Description line 2 Qty Req'd.
A4510 10-32 X 1" SOCKET CAP SHOULDER SCREW 2
A5511 2002DIGITAL DRIVE SWITCH-BEZEL 2
BSH0290 Brass Washer TT504 1/4"ID x 1/2"OD x 1/16" 0.00001
ELC0870 KNOB - POT 1
EXP287 Label Pinch Point 9295602 1
EXP288 Label Disconnect Power 9295671 1
EXP290 Label Hot 9295596 1
GRD0530 Handle - Guard 1
HTE0150 TRIAC 1
LSW0250 Holder Lap Switch LED 1
600045 SCREW,10-32 X 3/8 SHC 1
600080 SCREW,10-32 X 1-1/4 SHC 2
600194 SCREW, 5/16-18 X 3 3/4 SHC 4
600345 SCREW,10-32 X 1/4,SET CONE PT 1
600422 SCREW,5/16X1/2,SHOULDER,1/4-20 2
600630 SCREW,8-32X1/2 BUTTON HEAD 2
600715 10 X 1/2 PAN PHIL. T/S-B(ZINC) 17
600716 10 X 3/8 PAN PHIL. T/S-B(ZINC) 5
600745 SCREW,1/4-20X1/2 BUTTON HEAD 8
600964 SCREW,1/4-20X2-1/4 SHCS 1
600967 SCREW,1/4-20X1-1/4 BH HEX 4
601100 SCREW,6-32X1/4 PAN HEAD 2
601115 SCREW,8-32X1/4 PAN HEAD 6
601130 SCREW,8-32X5/8 PAN HEAD 4
601156 10-32X1/4 PH ZINC PLATED 8
601215 SCREW,4-40X1/4 PAN HEAD, PHILLIPS W/PATCH 2
604410 DOME HEAD RIVET,1/8X.299X.25H 44
604430 RIVET GSMD44S POP SD44BS 6
604465 RIVET,SD64BS,"POP" BRAND 10
610411 1/8 KEYSTOCK 1" LG 1
610700 CUSTOM BRACKET 8-32 20
610701 LOWER GUARD MOUNTING BRACKET 2
611020 SCREW,6-32X3/8" W/PATCH PHIL PAN HEAD 1
611054 SCREW,6-32X5/8 MACH.PAN PHILLI PS HEAD 2
620112 STRAIN RELIEF,HEYCO 3213/3 1
652822 OPERATION MANUAL,EXP42POUCH LATEST REVISION IS 01 1
652983 Box, Expressions 42 Pouch 65x22x22 1
652988 Skid Expressions 42 Puoch 72 x 30 1
654086 BUSH 1/2X3/4X1/2 FLANGE BRONZE 2
707210 SOLID STATE RELAY MOUNTING PLT EXP42POUCH 3/16 X 2 ALUM 1
707340 CAM, 1.750 EXP42PRO PLUS 1.750 CAM STEEL 2
707341 CAMSHAFT, EXP42PRO PLUS FOR 1.750 CAM 1
707343 GAP ADJUSTMENT HANDLES 1
707344 GAP ADJUSTMENT GEAR 1
707347 STOP RACK GAP ADJUSTER 1
707348 STOP RACK MOUNT 1
707554 BASE CHANNEL SUPPORT,40" INDRL 4
707590 42" 3" OD EXTRUDED RUBBER ROLL USE 707591 EXTRUSION FOR CORE 2
707599 LOWER HOUSING EXP42POUCH 1
707600 UPPER REAR GUARD EXP42POUCH 1

15
707601 UPPER FEED GUARD EXP42POUCH 1
707606 LOWER FEED GUARD EXP42POUCH 1
707608 SWITCH MOUNT PLATE EXP42POUCH 1
707638 LEFT SIDE COVER EXP42PRO POUCH EXP42 POUCH LEFT COVER 1
707639 RIGHT SIDE COVER EXP42 POUCH EXP42 POUCH COVER RIGHT SIDE 1
707691 LOWER CONNECTOR, FRONT 3" ROLL EXP42 PRO PLUS FRONT LOWER 2
707692 UPPER CONNECTOR FRONT 42 PLUS 2
707707 SIDEPANEL,COMMON EXP42POUCH 2
707708 1/2" SPACER FEED GUARD 4
707709 GUARD PIVOT SHAFT 1
707910 REINFORCING BAR, 40"INDUSTRIAL 2
708147 CLIP, BUSHING RETAINER 2
708149 CLIP, RETAINING RING 1" Dia 2
709540 GAP INDICATOR POINTER 1
709541 GAP INDICATOR RING ALUM RING FOR LABEL MOUNT 1
709542 GAP INDICATOR LABEL MOUNTS ON 709541 1
709545 CONTROL LABEL EXP42POUCH LABEL FOR 707608 PLATE 1
801232 SPROCKET 25B12 .312ID one #8ss exp42pouch raw mat = 801224 1
801233 SPROCKET,48 TOOTH #25, 1" BORE WITH TWO 1/4-20 SS MAT SPK1540 1
801923 MOTOR CONTROL, KBIC-11PMCL 1
801939 POWER CORDS 16-3 MILLER #E9006 1
801958 THERMAL CUTOUT,G5A01 216C 2
801987 FUSE HOLDER,PANEL MNT,.25" QCK CONN TERM 1
801988 FUSEHOLDER, MOLDED BASE 1
802015 HEATER,EXP42POUCH 1400W 120V 1
802102 MOTOR V01925AD83 90V DC 1
802133 BUSH 1X1 1/8X 1 FLANGE 2
802145 PRESSURE SPRING,57 LBS/IN,.48" 4
802166 Phonlic Bush,Rota Elec. THERMO 2
802171 BUSH 1X1 1/8X1/2 FLANGE 2
802176 THERMO END COVER 3" ROLLER HIGH TEMP INSULATOR 3" ROLLER 4
802180 SPRING, FOR GAP ADJUSTER 1
802247 ROTATING ELECTRICAL CONNECTOR 2
802301 TERMINAL BLOCK 812-4KT73KT74 1
802338 PRESSURE SPRING 71536S 4
802357 THERMOCOUPLE, EXP32/42 1
802448 FUSE,.8A/250V SLO BLO 1
802452 FUSE 20 AMP@250V,1.5"Lx13/32DI 1
908021 CHAIN,EXP42POUCH DRIVE CHAIN 1
911127 TEMP. CONTROLLER EXP42POUCH 1
920029 WIRE ASS'Y,6",BLACK,SEAL 1
920060 WIRE ASS'Y,7",BLACK 5
920063 WIRE ASS'Y,9",BLACK 3
920132 WIRE ASS'Y,19",WHITE,PB-MC 2
920133 WIRE ASS'Y,19",BLACK,PB-MC 1
920150 WIRE ASS'Y,48" BLACK MOTOR 1
920151 WIRE ASS'Y,48" RED MOTOR 1
920152 WIRE ASS'Y,58",BLK 1
920153 WIRE ASS'Y,58", RED FOR SSR 1
920154 WIRE ASS'Y,THERMOCOUPLE EXT 12 1
920161 WIRE ASS'Y,62", BROWN HEAT 1
920162 WIRE ASS'Y,60" BROWN WIRE 1

16
920163 LED ASSY EXP42POUCH 1
920164 WIRE ASS'Y,WITH 6.8 K RESISTOR 1