Rhin-O-Tuff OD4012 User manual

Instruction Book
for the OD4012,
OD4000 and OD4800

OD4012, OD4000 and OD4800
Setup & Operator Manual
Issue 3 June 09
Performance Design LLC.
These punches have been designed to punch most any job that may
pass through your office. No matter what type of binding you need to
carry out, these punches can handle the job. The maximum single
punching length for the OD4012, OD4000 and OD4800 is a 11” (297mm)
format. The OD4012 and the OD4000 are electrically operated punches
and the OD4800 is manually operated. All three machines utilize a
simple two knob die lock system to retain the die punch assemblies.
2
OD4012
OD4000 OD4800

OD4012 Contents S/N:____________
___Punch (1) ___Instruction Book (1)
___Oil (1) ___Brush (1)
___Foot Pedal (1) ___Power Cord (1)
___Reversing Tool (1)
Inspected by: __________________
OD4800 Contents S/N:____________
___Punch (1) ___Instruction Book (1)
___Knob Kit (1) ___Handle with bolt (1)
a) ¼-20x1½”Knob (2) ___Oil (1)
___Brush (1)
Inspected by: __________________
OD4000 Contents S/N:____________
___Punch (1) ___Instruction Book (1)
___Knob Kit (1) ___Oil (1)
a) ¼-20x1½”Knob (2) ___Brush (1)
___Foot Pedal (1) ___Power Cord (1)
Inspected by: __________________

Table of Contents
Topic: Page Number:
3
Safety Alert Symbols
Safe operating guidelines
Proper machine placement
Attach OD4800 Handle
Providing electric power
Die installation / Maintenance
Setting the paper stop/guide
Punching paper
Removing paper waste
Paper jam
Troubleshooting
4
4
5
6
7
7-9
10
10
10
11-12
13

Safety Alert Symbols
uThe OD4012 and OD4000 need to be plugged into a wall outlet that
provides a 15-amp, 120 volt service (16-amp, 220 volt for European
installations) and is protected by a fuse or circuit breaker at the main
electrical panel.
uIf machine cycles on its own, turn off power switch, unplug machine
from the wall outlet and call your dealer immediately for service.
uMake sure you read this section very carefully! Learn to recognize
these The OD4012, OD4000 and OD4800
have been designed to provide a high level of protection to an
operator. Follow the guidelines below while installing, operating and
maintaining your machine.
Safety Alert Symbols.
4
!DANGER
!WARNING
Safe Operating Guidelines
!CAUTION CAUTION: Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury. It may also be used without the safety alert symbol as
an alternative to "Notice".
WARNING: Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
DANGER: Indicates a hazardous situation which, if not avoided, will result in
death or serious injury. This signal word is to be limited to the most extreme
situations.
Trip Hazard
Two Person LIft
Electric Shock
Crushing Hazard
uAlways replace any fuse with the same type and
amperage fuse as indicated on the machine.
Hazardous voltage
inside.
Disconnect power
before servicing.
!WARNING
Cutting Hazard
Hint or Suggestion
uAlways keep this instruction manual with the machine for reference to
safe operating guidelines and correct operation of the machine.

5
Placing your machine in the proper location:
uBefore lifting machine, turn power off and
remove the power cord from the wall outlet.
The machine is very heavy! Never attempt to lift
the machine by yourself. Two people will be
needed to lift the machine.
uPlace the machine on a hard level surface, place the foot pedal on the
floor in front of the machine. Ensure the placement of machine allows
for ergonomic work flow (separate locations for un-punched books and
punched books).
u
u
Connect the foot-pedal into the foot-pedal
receptacle on the back of the machine, do not
attempt to connect foot-pedal into anything other
than the foot-pedal receptacle.
paper activated switches are available
for these punches. These switches replace the foot-pedal and plug
into the foot-pedal receptacle on the back of the machine.
Optional
Lifting Hazard
Single person
lift could result
in injury.
Two person lift required.
!CAUTION
uTurn power switch off before maintaining or
changing die assembly.
!WARNING
Crush hazard.
Keep hands away
from moving parts.
Lockout and disconnect
power before servicing.
!CAUTION
Cutting Hazard
Injury to fingers
and hands.
Use hand protection
uUse of appropriate hand protection should be
utilized to avoid injury from handling of materials.
uFollow all recommended workplace procedures for repetitive activities.
!CAUTION
Tripping Hazard
Bodily injury could
occur from fall.
Route cables away
from walkways

6
Attach Handle to OD4800:
uThe OD4800 manual punch is shipped with the handle removed from
the punch. You will need two 3/8” wrenches (not supplied) to tighten
the handle bolt.
Diagram 1 (Image of OD4800)
?

?


?
Locate the handle and remove the nut, washer and bolt from the
handle.
Orientate the handle so the black handle grip extends to the right of
the machine as seen on front cover of this book.
Slide handle onto exposed crankshaft of machine and align the holes
in the handle with the hole in the crankshaft.
Insert the bolt completely through the handle and install the washer
and nylock nut. See photo below left.
Tighten the nut securely so there is not play between the handle and
the crankshaft.
Open the top grey lid of the punch and remove the styrofoam block.
See photo below right.
Remove Styrofoam
Handle Crankshaft
Front of
Machine
Bolt

7
Providing power to the machine:
uPower cord shall be certified for the country
where the machine will be installed. Plug one
end of the power cord into the power cord
receptacle on the back of the machine. The
other end goes into the wall outlet.
Die Installation:
u
u
u
u
u
OD4012 Make sure the machine
is turned off before installing the die
Diagram 2.
.
Make sure there is no paper dust or paper chips
in the machine die slot before installing the die.
Install the die by sliding it into the opening
located on the left hand side of the machine. Make sure the punch pin
retainer slides into the slot on the backside of the opening.
Install die until right side of die is flush to exterior of right side of
machine.
Thread both retained die lock knobs into the die and tighten evenly
until the die can not move.
Diagram 2. (Image of OD4012)
!DANGER
Hazardous voltage.
Use only approved
power cord
assemblies.
!WARNING
Crush hazard.
Keep hands away
from moving parts.
Lockout and disconnect
power before servicing.
Die Lock Knob
Punch Pin
Retainer

8
u
u
u
u
u
Install the die by sliding it into the opening of the machine located on
the left hand side of the machine. Make sure the punch pin retainer
slides into the slot of the pusher bar.
Thread both die lock knobs into die
assembly and tighten evenly until die assembly can not move.
OD4000/OD4800: Diagram 3.
Make sure there is no paper dust or paper chips
in the machine die slot before installing the die.
Install die until right side of die is flush to exterior of right side of
machine.
Locate the two supplied die lock knobs and insert them into the left
and right sides of the machine.
Make sure the
machine is turned off before installing the
die.
Diagram 3. (Image of OD4000)
Comb Die Backspace (Margin) Adjustment
uThe comb die assemblies for the OD4012, OD4000, and OD4800
have a four position adjustable backspace. The positions are changed
by pulling the adjustor bar to the left for deeper settings (commonly
used for average to thicker sized books) and pushing the adjustor bar
to the right for shallower settings (commonly used for thinner sized
books).
!WARNING
Crush hazard.
Keep hands away
from moving parts.
Lockout and disconnect
power before servicing.
Die Lock Knob
Punch Pin
Retainer

9
Removing Punch Pins
?Turn machine power off and remove die assembly from the machine.
On the opposite side of the die assembly from the die handle, push
Remove the desired punch
pin or pins.
Replace the pin capture by pressing down on the pin retainer and
placing the pin capture back into place.
?Install die assembly into machine as described earlier and turn
machine power back on.
uDie maintenance should be performed with the die removed from the
machine. To perform the die maintenance, remove the die assembly
from the machine (see die installation section). Apply enough oil to
lightly coat each pin.
Remove any excess oil with a disposable cloth. After oiling, always
punch some scrap paper to remove excess oil.
u
Saturate a small section of a cloth with oil and using that
portion of the cloth, wipe the punch pins to apply a light coating
of oil.
Die Maintenance
?Pull the pin capture away from the pin retainer to expose the punch
pins.

10
Setting the paper stop/guide:
u
u
OD4012, OD4000 and OD4800 -
Locate the paper stop on the front cover of the machine. Loosen the
knob counterclockwise, so that the guide can be adjusted to the left or
the right.
until the punch pattern is centered on
the paper.
The OD4012, OD4000 and OD4800 punch machines allow for viewing of
the common size paper position markings on the die assemblies.
Aligning the paper stop with these marks will result in the punch pattern
being centered on the paper and need only small adjustments if
at all.
Move the paper stop until the desired position is reached
and tighten the knob clockwise until tight to lock the paper stop in
place. Repeat this procedure
Punching Paper:
uSelect an appropriate number of sheets to be punched and slide the
sheets down vertically into the opening of the die assembly. When the
paper is fully inserted, slide it to the left so it comes in contact with the
paper stop. Make sure all the edges of the sheets are flush by tapping
the top and the right hand sides of the sheets then activate the punch
by depressing the foot-pedal. OD4800 users pull handle toward front
of machine.
If a paper activated switch is being used, tap the sheets flush
before sliding the paper to the paper stop.
Removing Paper Waste:
uThe paper waste drawer is located conveniently on the front of the
punch. The paper waste drawer is removed by lifting up on the front
and pulling out away from the machine. This drawer should be
checked frequently while punching and emptied as necessary.
Paper Stop

11
Paper Jam:
uThe OD4012 and OD4000 punches use a circuit board for controlling
the punch cycle, this circuit board also has the ability to automatically
reverse the pusher bar and punch pins to their starting position if the
machine takes too much time to complete a punch cycle. This
condition could happen if too much material has been attempted to be
punched at one time. If this condition occurs, allow the machine to
attempt to reset itself back to its home position.
uIf the punch does not reset itself back to its home position, the punch
will need to be reversed manually.
!WARNING
Crush hazard.
Keep hands away
from moving parts.
Lockout and disconnect
power before servicing.
uTurn the machine power switch off and
remove some or all of the material in the
punch.
It is easier to remove one or two sheets at a time from the
backside of the material in the punch.
uOD4012 Manual Reverse utilizes a reversing
tool supplied with the punch.
Locate the
silver plug on the rear of the left side panel of
the machine. Remove the silver plug by prying it out gently with a
small flat tool. Insert the end of the reversing tool into the open hole
and engage the tool with the end of the motor shaft. Rotate the tool
counterclockwise 5-10 revolutions, until the punch pins have been
retracted back to the starting position. Remove most or all of the
material from the punch. Remove the reversing tool from the punch
and replace the small silver plug. Plug the power cord back into the
wall outlet and turn the power switch on. Test cycle the machine by
punching with no material in the punch, the machine will reset itself
back to its home position. Reduce the amount of material being
punched and continue working.
Turn the
machine power switch off and unplug
the power cord from the wall.
!WARNING
Crush hazard.
Keep hands away
from moving parts.
Lockout and disconnect
power before servicing.

12
uOD4000 Manual Reverse
Locate the silver plug
on the rear of the left side panel of the
machine. Remove the silver plug by prying it
out gently with a small flat tool. Insert the end of a large flat blade
screwdriver into the open hole and engage with the end of the motor
shaft. Rotate the screwdriver counterclockwise 5-10 revolutions, until
the punch pins have been retracted back to the starting position.
Remove most or all of the material from the punch. Remove the
screwdriver from the punch and replace the small silver plug. Plug
the power cord back into the wall outlet and turn the power switch on.
Test cycle the machine by punching with no material in the punch, the
machine will reset itself back to its home position. Reduce the
amount of material being punched and continue working.
Turn the machine
power switch off and unplug the power
cord from the wall.
!WARNING
Crush hazard.
Keep hands away
from moving parts.
Lockout and disconnect
power before servicing.
It is easier to remove one or two sheets at a time from the
backside of the material in the punch.

13
Machine does not cycle
Symptom Possible Cause Action
Troubleshooting
Die does not go into machine
1) Machine is off
2) Machine is not plugged in
3) Foot-pedal is not plugged into
machine
4) Die lock handle is not locked
5) Reversing tool is in machine
1) Pin retainer interference
2) Punch is stopped in mid cycle
3) Die lock handle is in lock position
1) Check power switch
2) Check both ends of power cord
3) Make sure foot-pedal cable is
attached to machine.
4) Lock the die lock handle
5) Remove reversing tool and
store properly
1) Make sure pin retainer enters slot
in pusher-bar.
2) Restart machine by turning power
off and back on
3) Move handle to unlock position
Only qualified personnel should attempt to
work on this equipment. There are no user
serviceable parts inside of the machine.
Your machine has been designed for years of trouble free operation. The
following is a troubleshooting guide to help you through some of the
problems that may be encountered.
The OD4012 has earned the UL Listing Mark. E179574.
The OD4012 and OD4000 have been tested with a
duty cycle of 25 cycles per minute with a 1 minute
rest period after 2 minutes of run time. Operating outside of these limits
could result in machine damage.
!DANGER
Hazardous voltage
inside.
Disconnect power
before servicing.
!NOTICE

Be sure to fill out and return your Product
Warranty Registration Card or Register online
at:
www.Rhin-O-Tuff.com/warranty_registration.asp
Part Number 001172 Rev. 3 Aug 2010
IMPORTANT
!