Rhin-O-Tuff OD4000 User manual

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RhinoTuff OD
3500/4000 Binding
Machine
Instruction Manual

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OD 4000 W/BINDING MODULES
OD 4000 PUNCH
OD 4000 PUNCH WITH COMB OPENER
OD 4000 PUNCH WITH WIRE CLOSER
“-.’ ,
L
OD 4000 PUNCH WITH WIRE CLOSER
AND COIL INSERTER
OD 3500 W/BINDING MODULES
OD 3500 COMBO BINDING STATION WITH
COMB OPENER AND COIL INSERTER
OD 3500 COMBO BINDING STATION WITH
W/RE CLOSER AND COIL INSERTER

OD 4000 PUNCH and OD 3500 COMBO BINDING STATION
Setup
& Operator Manual
Issue 2 April, 99
Performance Design Inc.
The Office Duty (OD 4000) electric punch, shown on opposite page, has been designed to
punch most any job that may pass through your office. No matter what type of binding you
need to carry out, the OD 4000 can punch the job. It will punch up to
17 sheets of 2Olb
(80gsm) copy paper at one time while maintaining perfect alignment. The maximum punching
length is
11” or A4 European format. Any sheet smaller can be punched for the minimum size.
Combo Binding Station
The Combo Binding Station is a base unit that supports three differ-
ent binding modules. Each module attaches in a matter of minutes,
The attachment procedure will be located in the module instructional
section of this manual.
There are three optional attachments (modules) for the OD 4000 Punch and OD 3500 Combo
Binding Station.
These are:
Coil Inserter
The plastic spiral inserter will bind books up to
1-1/8" (28.6mm) thick
using coil diameter up to
1-1/4" (30mm). The unit attaches to the
right side of the Combo Binding Station or OD 4000 Punch using
two wing nuts for easy installation.
Wire
C/oser
The wire closer is capable of binding books up to 1-1/8" (28.6mm)
thick. It uses wire sizes from 3/16" to 1-1/4". It has an adjustable
closing bar for the different size wires. Each end can be adjusted
independently to obtain a perfect close. The unit attaches to the rear
of the Combo Binding Station or OD 4000 Punch using four knobs.
Comb Opener
The comb opener will bind books up to 2” (51 mm) thick. The opener
has an adjustable ring opener control for exact book placement. The
unit attaches to the rear of the Combo Binding Station or OD 4000
Punch using four knobs.
All of the above modules can be ordered when ordering the OD 4000 Punch or the OD 3500
Combo Binding Station. Individual units can also be ordered at a latter date. Each unit can be
installed in a matter of minutes. The coil inserter can be attached and kept on the machine per
manently. If the Wire closer module is installed on the machine and the comb opener module
is required; the wire closer will have to be removed so that the comb opener can be installed.
The opposite is also true. It only takes a few minutes to detach any one of the modules to
install any other one.

Topic:
Table of Contents
OD 4000 PUNCH
Page Number:
1) Important safety notices
2) Placing your machine in the proper location
3) Providing power to the machine
4) Die installation
+ Removing punch pins
+ Die maintenance
5) Setting the paper guide
6) Punching paper
7) Removing paper waste
8) Paper jam (Reverse knob)
3
4
4
4
4
5
5
6
6
6
Optional Modules &Accessories
9) Attaching Coil Inserter module
Setup Instructions
11
a) Determine the correct size coil 12
b) Determine the correct size mandrel
12
c) Installing the mandrel on the machine 12
d) Adjusting the Mandrel bracket 12
e) Adjusting the paper stop 13
f) Adjusting the front table / lexan guide 13
g) Forward / off /reverse switch 14
h) Inserting a coil 14
i) Drive wheel stop screw
15
j) Cutting a coil 15
10) Attaching Wire Closer module
Setup Instructions
18
a) Determine the correctwire size
b) Inserting the wire into the book
c) Setting the closing bar height
d) Closing the book
19
19
20
21
11) Attaching Comb Opener module
Setup Instructions
I
22
a) Determine the correct comb size
23
b) Placing the comb onto the rake 23
c) Setting the comb opener stop
23
d) Placing the book onto the comb
24
e) Margin settings
24

Topic: Page Number:
12) Attaching the Versa Switch to OD 4000
25
Setup Illustrations
Diagram 1 Punch
Diagram 2
Punch
Diagram 3
Punch
Diagram 4 Coil inserter
Diagram 5a Coil inserter
Diagram 5b
Coil inserter
Diagram
5c Coil inserter
Diagram 5d Coil inserter
Diagram
5e Coil inserter
Diagram 6 Wire closer
Diagram 7a Wire closer
Diagram 7b Wire closer
Diagram
7c Wire closer
Diagram 7d Wire closer
Diagram 6 Comb Opener
Diagram 9 Versa Switch
Troubleshooting
OD 4000
Troubleshooting Coil Inserter Module
Electrical schematic
OD 4000
Electrical schematic Coil Inserter Module
Die
list
4
5
7
11
13
13
14
15
16
18
20
20
21
21
22
25
8
16
8
17
9&10
1) important Safety Notice!
Make sure you read this section very carefully! Learn
to recognize
!
this Safety Alert Symbol.
The
OD 4000 has been designed to provide a very high level of
protection
to an operator. Follow the guidelines below while
installing, operating and maintaining your machine.
+ Plug the machine into an outlet that provides a 15-amp service that is
protected at
the customers circuit box.
+ Always replace fuses with the correct amperage and type fuse.
+ If machine cycles on its own, call dealer immediately for service.
+ Never bypass top cover switch.
+ Turn power switch off before removing a die.

2) Placing your machine in the proper location:
Place the machine on a hard level surface placing the foot pedal on the floor in
front of the machine. Set aside some room for the books that have to be punched
and also some room for the books that had already been punched.
3) Providing
power to the machine:
Plug one end of the power cord into the back of the machine. The other end goes
into the
wall outlet. Install the foot pedal plug into the receptacle, which is located
on the left side of the machine. The optional Versa switch can be plugged into
the same receptacle if this option is to be used.
4) Die installation: Diagram 1
Make
sure the machine is turned off before installing die. Install the die (1) by
sliding it into the opening of the machine located
on the left-hand side of the
machine, Make sure the punch pin retainer (2) slides into the slot of the pusher
bar. Using the two
fluted knobs (3) provided with the machine, install each
handle into the hole located in the front of the die and
turn them clockwise to
tighten. Make sure there is
no paper dust in the machine die slot before installing
the die.
Diagram 1
+ To remove a punch pin from the die:
Make
sure the machine is turned off before removing the die. To remove a punch
pin from the die, remove both fluted knobs and slide the die to the left just

enough so the punch pin can be removed. Pull the pin straight up through the die
retainer. Reinstall the die using die installation procedure.
+ Die maintenance:
Die maintenance can be performed with the die installed in the machine. To
perform the die maintenance, loosen the safety screw (4) on the top front cover
and raise it
up so it stays open. Using the oil provided with the machine, squeeze
the plastic bottle over the oil slot that runs the entire length of the die. To much oil
can
run onto the paper being punched. After oiling, always punch scrap paper
to remove excess oil.
5)
Setting the paper guides: Diagram 2
The paper guide (1) is located on the top hinged cover. By loosening the knob
(2) counterclockwise, the guide can be adjusted to the left or the right so the
holes can be centered within the paper being punched. For
11” sheets, the right-
hand portion of the guide can be set at the 11” mark (3) (thick vertical line).
This patented feature will allow all the
11” sheet sizes to be perfectly centered in
the sheet no matter which punch pattern is being used. When using different
length sheets, the paper guide will have to be moved to a different position,
Diagram 2

Comb dies are the only kind to have an adjustable backstop. These are specia/
order dies and are not standard. To change the position of the hole placement
(margin) to the back edge of the sheet, first install the die into the OD 4000.
Pull
on the black handle, which is part of the die. There are four placement positions.
Choose the position best suited for your job. Push
the handle towards the right
for
the larger combs and pull it out to the left for smaller combs. The exact
position will be left up to the operator’s preference.
1) Punching Paper:
Position the paper that needs to be punched either to the left, right or on top of
the machine. This is up to the individual operator. Remove 10 to
15 sheets (2Olb
bond copy paper) from the pile and slide it down vertically into the opening of the
die. When the paper is fully down, slide it to the left so it comes in contact with
the paper guide. Make sure all the edges of the sheets are flush by tapping the
top and the right hand side of the sheets before pressing the foot pedal. After
punching the sheets, place the paper on the punched pile making sure the
sheets remain in exact order.
2) Removing paper waste: Diagram 3
The paper waste is removed by pulling towards you the paper
waste drawer (3).
It is located directly below the die. This should be checked frequently while
punching not to allow it to fill up and spill into the machine.
3) Paper Jam: (Reverse knob) Diagram 3
Unplug and turn the power oft to the machine before proceeding. The reverse
knob is only utilized if a paper jam occurs in the die or if the die is installed
incorrectly. When a paper jam occurs, the fuse protecting the motor may have to
be replaced. This is normal and allows maximum protection for the punch motor.
+ Push in and turn the reverse knob (1) counter clockwise about 8-10 times so
the punch pins (2) start to move
out of the paper in which it had jammed.
This should be enough to allow the paper to become free of the die. (This
knob is normally tight and requires a firm grip to turn it the small amount
necessary to remove the paper from the die.)
+ Plug the machine back into the wall outlet and turn the main power switch on
+ Press the foot pedal to see if the machine operates. If yes, reinstall the die
and continue punching the job. If the machine does not function, see
replacing the fuses in the troubleshooting section of this manual.

Diagram 3

Only qualified personal should attempt to work on this equipment.
There is not much to go wrong with the OD 4000 punch. Most of the
problems are due to setup error. There are two fuses located at the rear of the
punch that can be replaced by the customer. Here is a small troubleshooting
guide to help
you through some of the problems that may be encountered.
Symptom
Machine does notcycle.
Troubleshooting
I
Possible Cause
I
Action
1) Machine is off. 1) Check power switch.
2) Machine not plugged in. 2) Check both ends of power
Foot
pedal notplugged
into machine.
Top Cover Switch.
Blown fuse.
Pin retainer interference.
Punch stopped in mid
cycle.
Pins not flush with pin
retainer.
cord.
3) Make sure foot pedal cable is
attached to machine.
4) Close top
cover.
5) Check Fuse1 (5A).
slot in pusher bar. (see
2) Check fuses and
restart
Make sure that all the pins are
OD 4000 Electrical Schematic
This product has earned the UL Listing Mark and the UL Listing Mark for
Canada.
E179574. The OD 4000 has been tested with a duty cycle of 20 cycles
per minute with a 2 minute rest period after 30 seconds of
run time.

SIIO
@,25@
Die list:
This is a list of the
most common dies
manufactured by
Performance
Design. Special
dies are available.
m
<
Askyourdealerfor 2 To 1 Round
more information.
Drawings are to
,3333
0,172
scale.
III
3 To 1 Round
,250
0.172
II I
To 7 Round
-_
5 To1 Roun.d (5mm)

-- t- 6mm
6MM Round
4,250 ~
3 Hole X 5/16
Drawings are to

Drawings are to
scale.
- .500 -
,250 Sq
2 To 1 Square
7 t .3333 i- ,156 Sq
3To I Square

Coil Inserter Module
1) Installation Instructions: Diagram 4
Procedure to attach the coil inserter onto the OD 4000 punch
Unplug the main power cord from the OD 4000.
Loosen the safety screw and open the top cover on the OD 4000.
Align the two threaded studs (1) that protrude from the coil inserter option
into the two holes located on the right side of the OD 4000.
Use the two wing nuts provided with the coil inserter to attach the unit. Hand
tighten the two wing nuts.
Attach the paper stop bracket (2) to the right side of the OD 4000 using the
two black thumb knobs (3) provided.
Attach the paper stop (4) to the paper stop bracket by sliding the square nut
into the slot of the paper stop bracket. This can be positioned and tightened
by the knob (5) at a latter time when setting the guides to the paper.
Use two black thumb knobs (6) to attach the book table / lexancoil guide to
the OD 4000. (The book table /
lexan guide has been removed to view the
diagram, see diagram 5b to view the book table / lexan guide in position)
Plug one end of the power cord into the back of the coil option and the other
end into the wall outlet. Both the OD 4000 and the coil option have power
cords.

Setup Instructions: Diagram 5a, 5b, 5c, 5d & 5e
a)
Determine the correct size coil.
Use a coil that is at least 3/32" (2.5mm) larger than the book thickness for
coil sizes up to 3/4" (2Omm). After 3/4”, use a coil size of at least 1/8" over
the book size. The larger the coil compared to the book, inserting will
become much easier.
b)
Determine the correct size mandrel
There are a total of nine mandrels, which are used for coil sizes 3/16”
(5mm) up to 1-1/4" (30mm). Use the below table to choose the correct
mandrel size to coil size.
Mandrel size Inch Coil size mm
3/16”
3/1 6" to 1/4" (5mm-6mm)
1/4"
5/16" (7mm-8mm)
5/16"
3/8"
(9mm-1Omm)
3/8"
7/16" to 1/2" (llmm~i2mm)
1/2"
9/1 6"
(13mm-16mm)
5/8"
3/4"
(17mm-19mm)
3/4"
7/8"
(2Omm-23mm)
7/8"
1 ” (24mm-27mm)
1”
1-1/8" to 1-1/4" (28mm-30mm)
Installing the mandrel on the machine.
+ Place the mandrel (1) into the mandrel holder bracket (2) making
sure the beveled edge of the mandrel is facing the right side of the
machine. Both guide pins located on the mandrel need to line up with
both slots on the mandrel bracket. Use the black knob (3) to tighten
the mandrel in place.
+ Adjust the height of the mandrel so the center of the mandrel is the
same height as the center of the book.
d)
Adjusting the mandrel bracket
+ The mandrel assembly-adjustment knob (4) is located on the right
side of the coil inserter. Move the mandrel bracket assembly towards
the drive wheel for small mandrels and away from the drive wheel for
the larger mandrels.
+ The mandrel holder bracket-adjustment knob (5) can be adjusted to
the left or the right so the leading edge of the coil lines up with the first
hole of the book.

Diagram 5a
Adjusting the paper stop.
Place the book on the top cover of the punch with the right side of the
book against the paper stop bracket. Adjust the paperstop (6) so the
holes of the book hang over the edge of the front cover on the OD 4000
punch. The holes should hang over the edge just enough for the coil
to clear the cover.Tighten the knob located on the paper stop bracket. It
may be necessary to fine-tune this after a few books are bound for exact
placement.
f)
Adjusting the front table / lexan guide
The front table/lexan guide (7,7a, L? 7b) has two purposes.(FIRST):
When the lexan is in the closed position, rotated on top of the coil (7a),
it will assist the coil to insert smoothly into the book. You should use the
lexan guide with all books regardless of thickness. (SECOND): With the
lexan guide (plastic) in the open position,rotated away from the
machine, it acts as asupport table 7b) for large books. For books over
9/16" thick, it may be necessary at times to start the coil into the book,
then split the book in half using the table to support one half of the book,
then finish the inserting of the coil. This method improves productivity.
Diagram 5b
,

cd
Forward /off / reverse switch
The forward I off I reverse (8) switch has three positions. The center
position of this switch is the off position and should be placed in this
position when not using the machine. Press the left side (forward) of the
switch and the coil will rotate into the book. Press the right side (reverse)
of the switch and the coil will exit the book. The reverse feature allows the
coil to be removed from the book. Sometimes this will be necessary when
the leading edge of the coil misses a hole of a single sheet.
Inserting a coil.
Diagram 5c
Place the coil on the mandrel by sliding the open end of the coil onto the
beveled end of the mandrel. Turn the coil so it threads onto the mandrel
post (9) and is in front of the drive wheel by one coil. Make sure the
forward /reverse switch is in the forward position. Pull the handle (10)
down to start the motor and engage the drive wheel (11) to the coil.
Rotate the coil so it comes close to the edge of the book, but not past the
book. With your right hand, hold the leading edge of the coil and thread it
through the first two holes of the book. This helps align the holes of the
book. Rotate the lexan guide on top of the coil. Pull the handle down
gently at first making sure the coil is rotating into the book without missing
holes in the sheets or covers. Continue until the coil is past the left side of
the book by about one or two coils.

Drive wheel stop screw,
The drive wheel stop screw (12) will prevent the wheel from pressing to
hard on the mandrel. it is very important not to have too much pressure on
the mandrel when inserting the larger coils. If the leading edge of the coil
stops on a miss-aligned sheet, the coil wants to tie itself into a knot
between the book and the end of the mandrel. Setting the stop screw will
prevent this from happening most of the time. To set the stop screw, turn it
clockwise to push the wheel away from the mandrel. Load the coil onto the
mandrel and turn the stop screw counter clockwise while holding down on
the motor handle (10) until the drive wheel touches the coil. Try a few
books and readjust if necessary.
If the mandrel bracket is adjusted after the stop screw has been
adjusted, it will be necessary to readjust the stop screw
Cutting the coil
There are special cutter crimper pliers (ordered separately) that are used
to terminate the ends of the coil After the coil is cut, the sharp end of the
coil will tuck itself under the inside of the coil opening. To use the cutter,
make sure the red dot (13) is facing up. Place the cutter on the edge of
the right hand side of the book. Open the cutter enough so that the end of
the cutter enters the coil by about
1/4". Make sure the cutter is level
with the book before you cut. As you squeezethe cutters you may
notice the coil wants to twist. You can supporl the coil with your fingers as
you cut to help stabilize the coil. Turn the book over and repeat these
steps on the opposite end of the book. Always make sure to close
crimping cutters completely.

13
0
AT
Diagram 5e
Only qualified personal should attempt to work on this equipment.
There is very little that can go wrong with the Coil Inserter Module.
Most
of the problems are due to setup error. There is one fuse located at the rear of
the inserter that can be replaced by
the customer. Here is a small
troubleshooting guide
to help you through some of the problems that may be
encountered.
Troubleshooting
Symptom
Possible Cause
Action
Drive wheel does not rotate.
1))Machine is off. (switch is I) Place switch in either
(There is athermal
overload in center position) Forward or Reverse
built inside of the motor. Wait 2)Machine not plugged
in, posibon.
several minutes
below
3) Blown Fuse. 2)
checkingthe fuse) Check both ends of
power
cord.
3) Check Fuse
1. (5amp)
Coil tightens onthe mandrel 1) Mandrel is too small for
when inserting.
I) Select proper size
coil.
mandrel. (see page 12)
Coil stops before it is
completely through the book.
1) The holes in the book are I) This is normal. Try moving
misaligned. the book around so the
2) The coil is beyond drive coil rotates in the holes.
wheel. 2) Coil length may need to
be longer for that
particular book. Note:
On
larger coils, they can wind
themselves open so that