PTM Print to Mail Endeavour User manual

Operator’s Manual

ii

iii
Table of Contents
Operator Safety............................................................................................1
Introduction..................................................................................................2
Unpacking and Setup ..................................................................................3
Unpacking ................................................................................................3
Setup ........................................................................................................4
ENDEAVOUR Overview ...............................................................................5
ENDEAVOUR Diagram.............................................................................5
Capabilities...............................................................................................5
ENDEAVOUR Operation ..............................................................................6
Identifying Your Fold.................................................................................6
Feed Table Setup .....................................................................................6
Setting the Paper Guide Width..............................................................6
Setting the Feed Gauge........................................................................7
Loading the Feed Table ...........................................................................8
Setting the Fold Plates..............................................................................9
To set a fold plate: ................................................................................9
Fold Plates..............................................................................................10
Maintenance...............................................................................................11
Troubleshooting .........................................................................................12
Automatically Clearing a Paper Jam ......................................................12
Manually Clearing a Paper Jam..............................................................12
Diagnosing the Paper Jam.....................................................................13
Misaligned Folds ....................................................................................13
Paper Feed Problems.............................................................................14
Double Feeds......................................................................................14
Won’t Feed..........................................................................................14
ENDEAVOURWon’t Run ........................................................................14

iv

1
Operator Safety
Please review and follow all the safety precautions to ensure safe
equipment operation. The user is responsible for safe operating
conditions. Read all operating instructions prior to operating the
ENDEAVOUR.
Warning: Do not attempt to handle the equipment alone. It requires
two people to handle and lift the equipment out of the packaging.
Warning: This unit contains moving parts. Watch for Caution,
Warning, and Electrical stickers detailing proper operating conditions
and user safety.
Never remove guards or product safety switches. Removal of
guards or switches will cause the unit to run improperly and can result
in personal injury.
Keep all hands, fingers and objects away from moving parts.
Never attempt to reach into the ENDEAVOUR while the power is on.
Turn off the ENDEAVOUR and disconnect the power cord before
cleaning or servicing the ENDEAVOUR, and before removing either
fold plate. Injury may occur if proper operating procedure is not
followed.
Plug the power cord into 115 VAC 60 Hz outlet only. Voltage up to
120 volts will not damage the ENDEAVOUR.
The Power Cord and Plug must be accessible at all times for
disconnection.
This unit is equipped with a 3-Wire grounded electrical cord. If the cord
becomes damaged and needs to be replaced, it must be replaced with
an authorized part available through the manufacturer or an authorized
service agent.
All ENDEAVOUR maintenance should be performed only by factory
authorized service personnel using factory authorized replacement
parts. Contact PTM Document Systems for more information.
Keep product away from extreme heat & moisture.
Never operate ENDEAVOUR while tired, drowsy, or under the
influence of medication, drugs, or alcohol. Failure to do so can result in
personal injury.
Never operate unit with loose clothing or jewelry. Contain all long hair
and neck ties prior to operating ENDEAVOUR. Failure to do so could
result in clothing, jewelry, or hair becoming entangled in moving parts.

2
Introduction
The ENDEAVOUR is designed to fold and seal up to 3000 documents per
hour. Patented folding & sealing technologies ensure a good seal on every
form and a clean fold every time whether the paper is perforated or plain.
The adjustable fold plates allow the ENDEAVOUR to meet your changing
document processing requirements. Below are the detailed ENDEAVOUR
specs.
Feed System Bottom Feed Friction Belt
Drive System A.C. Fixed
Electrical 115V AC, 60 Hz, 3A
Paper Sizes Length up to 14”, width up to 8.5”
Fold Patterns 11” Half (V)
11” Letter C
11” Z
14” Half (V)
14” C
14” Return Envelope (EC)
14” Z
14” ECC Z
Speed 3000 Documents Per Hour Fixed Continuous
Dimensions Height 12”, Width 20”, Depth 16.5”
Weight 55 Lbs.

3
Unpacking and Setup
Unpacking
When opening the ENDEAVOUR packaging, inspect it for any shipping
damage. The shipper should be notified at once and the packing materials
saved if there is any serious damage. IMPORTANT- Please retain your
shipping carton and packaging material.
Warning: Do not attempt to remove the equipment from the packaging
alone. Two people are required at all times to move the equipment.
Ensure that the following items are
present in the packaging:
1. This manual (1)
2. ENDEAVOUR (1)
3. AC Power Cord (1)
4. Upper & Lower Fold Plates (1
each)
5. Left and right paper guides
6. Tool Kit
a. Breaker bar & 7/16” Socket
b. 3/16” T-Handle Hex Driver
If any items are missing please
contact PTM Document Systems
before continuing.
Figure 1: Upper Fold Plate
Figure 2: Lower Fold Plate
Figure 3: ENDEAVOUR

4
Setup
Warning: Do not attempt to remove the equipment from the packaging
alone. Two people are required at all times to move the equipment.
Place the ENDEAVOUR on a sturdy table or cart. Check to verify that both
fold plates are properly installed [see Figures 4 & 5]. Both fold plates should
rest snugly on the placement pins.
Figure 4: Upper Fold Plate in
Proper Position
Figure 5: Lower Fold Plate in
Proper Position
Insert the power cord into the ENDEAVOUR first, and then into a standard
115V AC 60 Hz outlet.
The power cord must be accessible for disconnect.

5
ENDEAVOUR Overview
ENDEAVOUR Diagram
Figure 6: ENDEAVOUR Diagram
Capabilities
Your ENDEAVOUR is designed from the ground up to be a versatile
folding and sealing ENDEAVOUR. Its capabilities include:
Folding plain paper and forms from 20 lb paper to 80 lb stock.
Folding all standard fold patterns [see Table 1].
Single fold capability: when the bottom fold plate is in the half fold
position, the upper fold plate can be set to lengths other than the
standard V Fold depending on your special needs.
Feed Tabl
e
Feed Gauge
Cover
Lower Fold
Plat
e
Catch Tray
Control Panel
Switch
On / Off
Paper Guides
Upper Fold
Plate
Reverse
Electrical
Panel

6
ENDEAVOUR Operation
Identifying Your Fold
1. Identify your paper size. 11” forms are the standard letter size; 14”
forms are the standard legal size. Measure the form if necessary.
2. Identify the fold shape from Table 1. Note that ECC Z (EZ) Folds are a
similar shape as the standard Z Fold, but the lengths of the folds are
not equal.
C Fold Z Fold EZ Fold V Fold
Table 1: Fold Types
Feed Table Setup
Setting the Paper Guide Width
Figure 7: Feed Table Diagram
To set the width of the Feed Table Paper Guides [see Figure 9]:
Thumbscrews (4) Power Switch
(by power plug)
Breaker

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1. Loosen the red Paper Guide adjustment knobs. Don’t fully remove
them. 1-2 turns clockwise will loosen them.
2. Place a ½” stack of the form to be run on the feed table.
3. Line the paper stack up against the stationery paper guide.
4. Push the moveable paper guide up against the paper stack so that all
the paper is aligned and the paper guide is snug against the side of the
stack.
5. Hold the moveable guide in place with one hand and tighten the
adjustment knobs with the other.
Setting the Feed Gauge
Figure 8: Feed Gauge Cross Section View
To properly set the Feed Gauge System [see Figure 8]:
Make sure that the power switch is in the Off position.
1. Remove all paper from the feed table.
Feed Gauge
Adjustment Screw
Move Feed Belt In This Direction With
Y
ou
r H
a
n
d
T
o
F
eed
Th
e
F
o
rm In.
Feed Gauge
Roll
(Sampl
e
Form)
Feed Belt

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2. Insert the provided 3/16” T-Handle Hex Driver into Feed Gauge
Adjustment Screw.
3. Turn the T-Handle Hex Driver ¼ turn clockwise to loosen the Feed
Gauge Roll.
4. Place one form on the feed table and hand feed the form about 2
inches into the ENDEAVOUR by moving the feed belt with your hand.
5. Turn the T-Handle Hex Driver ¼ turn counter-clockwise.
6. Pull the paper out of the machine. You should feel resistance, but not
too much. Repeat Steps 4-6 until there is a moderate amount of
resistance when pulling the form out. If it feels too tight, turn the T-
Handle Hex Driver ¼ turn clockwise.
7. Return the T-Handle Hex Driver to the toolkit.
Loading the Feed Table
Before loading the feed table, square up the stack of paper you are going to
load by placing it on edge on a flat surface. Place the stack onto the table
so that the front of the stack butts up against the feed gauge cover [do not
push hard].
The proper orientation of the paper when loaded onto the feed table
depends on the type of fold you are using and the layout of your form.
Table 2 shows the order in which folds will be performed when run through
the machine with the right hand paper edge being loaded into the machine
first (red arrow shows paper path).
All forms should be loaded with glue on the leading edge facing up (the
glue is usually visible as yellow, blue or red stripes around the edge of the
form). With Z& EZ Folds you have multiple ways to load the form and still
have glue on the leading edge facing up, either one will work. With EZ
Folds, though, care must be taken to ensure that the upper fold plate is set
to the proper length for the leading fold (the bottom fold plate setting
remains the same either way).
Feed Table Capacities
11” Forms: 150 Sheets
14” Forms: 100 Sheets

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C Folds
Z Fold
EZ Folds
V Folds
C Folds Table 2: Paper Loading & Fold Order
Setting the Fold Plates
To set a fold plate:
1. Remove the fold plate from the machine.
2. Loosen the thumb screws by turning counter-clockwise
3. Line up the tips on both sides of the paper stop with the appropriate
line on the scale so that the appropriate white line on the scale is just
visible [see Figure 9].
a. If you are doing a V Fold, you do not have to set the paper
stop on the Lower Fold Plate.
4. Make sure that the paper stop is setup square by double-checking that
the scales on both sides show the same fold selected or the same inch
reading.
1
2
2
1
1

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5. Tighten the thumb screws, being careful that the paper stop does not
slide out of square.
6. Return the Fold Plate to the machine, making sure that it is resting
properly on the placement pins [see Setup Procedure].
a. If you are using a V Fold, replace the Lower Fold Plate
backwards, so that the flat face is facing in and the slot is
facing out.
Figure 9: Paper Stop Alignment
For a custom form, the fold plate scales measure distance in inches from
the fold, so the paper stop can be set to the appropriate measurement. If
you are unclear about the figures to use, you can measure the lengths of
the folds on your form (the distance from the perforations or fold marks to
the edge of the paper) or contact your form supplier for more information.
Fold Plates
The ENDEAVOUR is equipped with adjustable fold plates. The red thumb
screws can be loosened to allow you to move the paper stop to the correct
position for your form and then tightened to hold the stop in place. All
standard folds are marked on the scales of both the upper and lower fold
plates. Set both fold plates to the desired setting (i.e. 11” Z) in order to
perform that fold. See ENDEAVOUR Operation for more information.
Paper Stop Indicator
Point

11
Maintenance
Regular maintenance on the ENDEAVOUR will ensure that it continues to
function properly and will extend the life of the ENDEAVOUR. Perform the
following steps every 10,000 forms or once a month:
1. Disconnect the power cord from the ENDEAVOUR.
2. Remove both fold plates.
3. Vacuum any paper dust or toner that has accumulated on the feed
table and on the rollers.
Make sure that the power cord has been disconnected before
continuing!
4. Open the access panel in the side cover opposite the control panel.
5. Insert the 7/16” socket at the end of the breaker bar over the hex
shaped end on the #3 roller. This bar can now be used to rotate the
rollers.
6. Clean the stainless steel rollers with a household cleaner such as
Oops in order to remove any accumulated toner. As you clean, use the
breaker bar to rotate the rollers so that the entire roller surface is
cleaned.
7. Clean the rubber rollers and the feed belts using a rubber roll
rejuvenator [available at your local office supply store]. Use the
breaker bar to rotate the rolls and feed belt as you clean so that all the
rubber surfaces are cleaned.
8. Return the breaker bar to the tool kit and replace the access panel.
9. Replace the fold plates.
10. Make sure that the power switch is in the Off position.
11. Connect the power cord to the ENDEAVOUR.

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Troubleshooting
Automatically Clearing a Paper Jam
If paper becomes jammed in the ENDEAVOUR:
1. Remove all paper from the Feed Table.
2. If the Power Switch Breaker has tripped (light is off) then flip into the
on (lighted) position.
3. Remove the Lower Fold Plate.
4. Press the Reverse button.
5. The paper should exit from the back (where the Lower Fold Plate
normally sits). If it does not, try pressing the Reverse button again. If
the paper is not moving or you cannot see it, then you need to
manually clear the jam [see next section].
6. Replace the Lower Fold Plate.
Manually Clearing a Paper Jam
1. Disconnect the power cord from the ENDEAVOUR.
Make sure that the power cord has been disconnected before
continuing!
2. Remove all paper from the Feed Table.
3. Remove the Lower Fold Plate from the ENDEAVOUR.
4. Remove the access panel in the side cover.
5. Place the Breaker Bar socket over the hex end of the #3.
6. Rotate the breaker bar clockwise until the jammed form is out of the
ENDEAVOUR.
7. Replace the Lower Fold Plate.
8. Replace the paper on the Feed Table.
9. Return the breaker bar to the toolkit.
10. Replace the side cover access panel.
11. Make sure that the power switch is in the Off position.
12. Connect the power cord to the ENDEAVOUR.

13
Diagnosing the Paper Jam
Table 3 outlines the different problems that cause paper jams and the
symptoms that will help you to identify the cause.
Problem Double Feed Buckled Form Bad Fold
Symptom Unfold the form
that caused the
jam, you will find
that it is actually
two forms folded
together.
There will be an
extra fold in form
near the correct
fold location.
The form which
caused the jam
will be folded
crooked.
Causes • Bad Feed
Gauge Setting
• Too much
paper on the
feed table
• Wrong fold
plate setting • Feed Table Paper Guide
set improperly
• Fold Plates
set improperly
Solution
• ¼ Turn CCW
on feed gauge
adjust screw
• Check both fold
plates. Make
sure they are
set to the
correct mark on
the scale.
• Check both
fold plates.
Make sure
that both
paper stops
are square.
Table 3: Paper Jam Diagnostics
Misaligned Folds
If your forms are running through the machine OK but they’re folding a little
bit crooked or are not folding right on the perforation, you need to adjust the
fold plate settings. The location of perforations on forms may fluctuates by
as much as 1/16” in either direction. Because of this fluctuation, it is
sometimes necessary to fine tune the placement of the paper stop on one
of the fold plates.
The first step is to identify which fold plate is misaligned. Watch the form as
it is fed into the machine, and then compare it to the finished form. If you’re
having trouble visualizing which fold is off, refer to the section Loading the
Feed Table above.
Once you’ve identified which fold plate needs to be adjusted, remove it
from the ENDEAVOUR. If the fold is crooked, check to make sure that the
paper stop is parallel to the front edge of the fold plate. Check that the
indicator points on the paper stop indicate the same reading on the two
scales of the fold plate. Also check the feed table to make sure that paper
guides are snug against the paper stack. If the fold is just a bit off of the
perforation, adjust the paper stop by the amount that the fold is off. If the

14
fold is above the perforation, then move the paper stop away from the open
end of the fold plate. If the fold is below the perforation, then move the
paper stop towards the open end of the fold plate.
Paper Feed Problems
Double Feeds
If you’re having problems with two forms feeding at once:
1. Turn the Feed Gauge Adjustment Screw [see Figure 8] ¼ turn
counter-clockwise.
2. Try running the forms again.
3. If the problem persists:
a. Try another ¼ turn on the Feed Gauge Adjustment Screw.
b. Try reducing the size of the paper stack on the Feed Table.
c. Try resetting the Feed Gauge.
Won’t Feed
If the ENDEAVOUR won’t feed forms through:
1. Try reducing the size of the paper stack on the Feed Table.
2. Try resetting the Feed Gauge.
ENDEAVOUR Won’t Run
If the ENDEAVOUR won’t run when the On-Off switch is operated:
1. Check that the ENDEAVOUR Power Switch Breaker, located by the
power plug, is not in the tripped (out) position. If it is, press it in. If the
breaker button will not stay pressed in, wait a minute and try again.
2. Check that the Access Panel on the side cover opposite the control
panel is properly in place.
3. Make sure the power switch by the power cord is in the On position.
4. Double-check that the power cord is properly connected to the machine
and an appropriate socket [see Setup].
5. Check that the wall socket which the machine is connected to is
functioning properly.

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Sales [phone]
Service [phone]