Scott Scotty 5000 Instruction Manual

Copy No.:

Instruction Manual

Model No. : Scotty 5000.................

Year of Manufacture : 2006.......

Manufactured by :..........

Document Number : F--9999--8........

Issue : 1.....................

Date of Issue : August 2006..............

ISSUE NOTE

This is Issue 1; Date of Issue: August 2006

Copyright 2006

I

F--9999--8 Issue 1

TABLE OF CONTENTS

1 INTRODUCTION AND SAFETY 1--1........................................................

1.1 Introduction 1--3....................................................................

1.1.1 Scotty 5000 Machine Specifications and Utility Requirements 1--4.......................

1.2 General Safety Guidelines 1--6.......................................................

1.3 Safety Features 1--7.................................................................

1.3.1 Emergency Stop 1--7.............................................................

1.3.2 Stop and Safe 1--7...............................................................

1.3.3 Main Power Switch 1--8...........................................................

1.3.4 Compressed Air Valve 1--8........................................................

1.3.5 Guards and Covers 1--9...........................................................

1.3.6 Safety Devices 1--9...............................................................

1.4 Warnings, Cautions & Notes 1--10.....................................................

1.4.1 Warnings 1--10....................................................................

1.4.2 Cautions 1--10....................................................................

1.4.3 Notes 1--10.......................................................................

1.5 Warnings 1--11.......................................................................

1.5.1 Heat Hazards 1--11................................................................

1.5.2 Electrical Shock Hazards 1--11......................................................

1.6 Safety Procedures 1--12..............................................................

1.6.1 Compressed Air Valve 1--12........................................................

1.6.2 Safety Devices 1--12...............................................................

1.6.3 Appropriate Dress 1--12............................................................

1.6.4 Keep Area Clean 1--13.............................................................

1.6.5 Grease and Oil 1--13..............................................................

1.6.6 Manual Usage 1--13...............................................................

2 INSTALLATION 2--1......................................................................

2.1 Installation Requirements 2--3........................................................

2.1.1 Pre-Installation Requirements 2--4..................................................

2.1.2 Uncrating & Placement 2--5........................................................

3 OPERATION 3--1.........................................................................

3.1 General Information 3--3.............................................................

3.1.1 Before Operating the Machine 3--3.................................................

3.2 Operating Controls and Indicators Descriptions 3--4...................................

3.2.1 Operator’s Control Panel Layout 3--4................................................

3.2.2 Machine Stopping Device 3--4.....................................................

3.2.3 Main Operator’s Panel Control Descriptions 3--5......................................

3.2.4 Scotty 5000 with Telemecanique PLC Control 3--12....................................

3.3 Preliminary Inspection and Start-Up Procedure 3--13....................................

3.3.1 Preliminary Set-Up 3--13...........................................................

3.3.2 Adjust Hub Roller 3--26............................................................

3.3.3 Adjust Drive Roller 3--26...........................................................

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3.3.4 Side Guide Set--Up 3--27...........................................................

3.3.5 Kick Out Solenoid Set--Up 3--28.....................................................

3.3.6 Sheet Hold Down Straps 3--28......................................................

3.3.7 Set Up For Production 3--29........................................................

3.3.8 Run Production 3--30..............................................................

3.4 Handwheel and Tab Set-Up 3-34..........................................................

3.4.1 Hand Wheel and Tab Set-Up Definitions 3-35.........................................

HANDWHEEL SET-UPS FOR 5” SHEET WITH 3/16” MARGINS 3-36...............................

HANDWHEEL SET-UPS FOR 6” SHEET WITH 3/16” MARGINS 3-37...............................

HANDWHEEL SET-UPS FOR 7-1/4” SHEET WITH 3/16” MARGINS 3-38...........................

HANDWHEEL SET-UPS FOR 7-1/4” SHEET WITH 1/4” MARGINS 3-39.............................

HANDWHEEL SET-UPS FOR 7-3/4” SHEET WITH 3/16” MARGINS 3-40...........................

HANDWHEEL SET-UPS FOR 7-3/4” SHEET WITH 1/4” MARGINS 3-41.............................

HANDWHEEL SET-UPS FOR 8” SHEET WITH 3/16” MARGINS 3-42...............................

HANDWHEEL SET-UPS FOR 8-1/2” SHEET WITH 3/16” MARGINS 3-43...........................

HANDWHEEL SET-UPS FOR 8-1/2” SHEET WITH 1/4” MARGINS 3-44.............................

HANDWHEEL SET-UPS FOR 8-1/2” SHEET WITH 1/2” MARGINS 3-45.............................

HANDWHEEL SET-UPS FOR 9” SHEET WITH 3/16” MARGINS 3-46...............................

HANDWHEEL SET-UPS FOR 9-1/2” SHEET WITH 3/16” MARGINS 3-47...........................

HANDWHEEL SET-UPS FOR 9-1/2” SHEET WITH 1/4” MARGINS 3-48.............................

HANDWHEEL SET-UPS FOR 9-1/2” SHEET WITH 1/2” MARGINS 3-49.............................

HANDWHEEL SET-UPS FOR 11” SHEET WITH 1/8” MARGINS 3-50...............................

HANDWHEEL SET-UPS FOR 11” SHEET WITH 3/16” MARGINS 3-51..............................

HANDWHEEL SET-UPS FOR 11” SHEET WITH 1/4” MARGINS 3-52...............................

HANDWHEEL SET-UPS FOR 11” SHEET WITH 1/2” MARGINS 3-53...............................

HANDWHEEL SET-UPS FOR 12” SHEET WITH 3/16” MARGINS 3-54..............................

HANDWHEEL SET-UPS FOR 12” SHEET WITH 1/4” MARGINS 3-55...............................

HANDWHEEL SET-UPS FOR 12” SHEET WITH 1/2” MARGINS 3-56...............................

HANDWHEEL SET-UPS FOR 14” SHEET WITH 3/16” MARGINS 3-57..............................

HANDWHEEL SET-UPS FOR 14” SHEET WITH 1/4” MARGINS 3-58...............................

HANDWHEEL SET-UPS FOR 14” SHEET WITH 1/2” MARGINS 3-59...............................

METRIC HANDWHEEL SET-UPS FOR A4 (297mm x 210mm) TAB SIDE: 297 MM MARGIN: 0 MM 3-60
METRIC HANDWHEEL SET-UPS FOR A4 (297mm x 210mm) TAB SIDE: 210 MM MARGIN: 0 MM 3-61
METRIC HANDWHEEL SET-UPS FOR A4 (297mm x 210mm) TAB SIDE: 297 MM MARGIN: 1 MM 3-62
METRIC HANDWHEEL SET-UPS FOR A4 (297mm x 210mm) TAB SIDE: 210 MM MARGIN: 1 MM 3-63

4 MAINTENANCE 4--1......................................................................

4.1 Maintenance 4--3....................................................................

4.1.1 Machine Lubrication 4--3..........................................................

4.1.2 Vacuum Pump Maintenance 4--6...................................................

4.1.3 Machine Timing 4--8..............................................................

4.1.4 Preparation for Timing Procedures 4--10..............................................

4.1.5 Timing Procedures 4--11...........................................................

4.1.5.2 Plastic Feed & Cut Operating Arm 4--12..............................................

4.1.6 Reinstall Chains 4--15..............................................................

4.2 Calibration 4--16.....................................................................

4.2.1 Preparation for Calibration Procedures 4--16..........................................

4.2.2 Handwheel Settings 4--17..........................................................

4.2.3 Handwheel Calibration Procedures 4--18.............................................

4.2.4 Pile Feeder 4--22

..................................................................

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F--9999--8 Issue 1

4.2.5 Paper Stocks 4--26................................................................

4.2.6 Procedure To Set Tab Cutting Knives 4--28............................................

4.2.7 Set Tab Cut Cylinder 4--30..........................................................

4.2.8 Kick Out Solenoid Set Up 4--30......................................................

4.2.9 Plastic Tip Die 4--32...............................................................

4.2.10 Paper Stop Adjustment 4--34........................................................

4.2.1 1 Plastic Reel Holder Adjustment Procedure 4--36.......................................

4.3 Fiber Optics 4--37....................................................................

4.3.1 Fiber Optic Sensor Locations 4--37..................................................

4.3.2 Fiber Optic Adjustment 4--38........................................................

4.3.3 Fiber Optic Sensor Cleaning 4--40...................................................

4 MAINTENANCE 4--1......................................................................

4.1 Maintenance 4--3....................................................................

4.1.1 Machine Lubrication 4--3..........................................................

4.1.2 Vacuum Pump Maintenance 4--6...................................................

4.1.3 Machine Timing 4--8..............................................................

4.1.4 Preparation for Timing Procedures 4--10..............................................

4.1.5 Timing Procedures 4--11...........................................................

4.1.5.2 Plastic Feed & Cut Operating Arm 4--12..............................................

4.1.6 Reinstall Chains 4--15..............................................................

4.2 Calibration 4--16.....................................................................

4.2.1 Preparation for Calibration Procedures 4--16..........................................

4.2.2 Handwheel Settings 4--17..........................................................

4.2.3 Handwheel Calibration Procedures 4--18.............................................

4.2.4 Pile Feeder 4--22..................................................................

4.2.5 Paper Stocks 4--26................................................................

4.2.6 Procedure To Set Tab Cutting Knives 4--28............................................

4.2.7 Set Tab Cut Cylinder 4--30..........................................................

4.2.8 Kick Out Solenoid Set Up 4--30......................................................

4.2.9 Plastic Tip Die 4--32...............................................................

4.2.10 Paper Stop Adjustment 4--34........................................................

4.2.1 1 Plastic Reel Holder Adjustment Procedure 4--36.......................................

4.3 Fiber Optics 4--37....................................................................

4.3.1 Fiber Optic Sensor Locations 4--37..................................................

4.3.2 Fiber Optic Adjustment 4--38........................................................

4.3.3 Fiber Optic Sensor Cleaning 4--40...................................................

4.4 Machine Cleaning 4--41...............................................................

4.4.1 Clean Platen Unit 4--41............................................................

5 SCOTTY 5000 PARTS 5-1.................................................................

5.1 ASSEMBLY LOCATOR 5-4...............................................................

5.2 PILE FEED - REGISTER BOARD ADJUSTMENT 5-6........................................

5.3 PILE FEED - DRIVE ROLLER ASSEMBLY 5-8

..............................................

5.4 PILE FEED DRIVE 5-10...................................................................

5.5 PILE FEED DRIVE & TENSIONER 5-12.....................................................

5.6 PILE FEED - VACUUM BAR DRIVE 5-14....................................................

5.7 PILE FEED - VACUUM BAR 5-16..........................................................

5.8 PILE FEED - PAPER GUIDE 5-18..........................................................

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5.9 PILE FEED - OPTIC MOUNTING 5-20......................................................

5.10 PILE HEIGHT ASSEMBLY 5-22...........................................................

5.11 PILE LIFT DRIVE 5-24...................................................................

5.12 PILE LIFT FRAME 5-26..................................................................

5.13 PILE LIFT HANDWHEEL 5-28............................................................

5.14 PILE FEED - SHEET SEPARATOR 5-30...................................................

5.15 PILE FEED -- STACK GUIDE 5-32.........................................................

5.16 PILE FEED - PNEUMATIC FITTINGS 5-34.................................................

5.17 PILE FEED - GUARDS, COVERS 5-36....................................................

5.18 PILE FEED - OPTIC MOUNTING 5-38.....................................................

5.19 PILE FEED - PNEUMATIC CONTROLS “A” 5-40............................................

5.20 PILE FEED - PNEUMATIC CONTROLS “B” 5-42............................................

5.21 PILE FEED - BELT & CHAIN LAYOUT 5-44.................................................

5.22 PLATEN UNIT 5-46.....................................................................

5.23 REGISTER BOARD - HOLD DOWN PLATE 5-48............................................

5.24 REGISTER BOARD - CONVEYOR 5-50...................................................

5.25 MIDDLE REGISTER - HOLD DOWN PLATE 5-52...........................................

5.26 MIDDLE REGISTER - CONVEYOR 5-54...................................................

5.27 MIDDLE REGISTER BOARD UNIT 5-56...................................................

5.28 MIDDLE REGISTER BOARD DRIVE (A) 5-58...............................................

5.29 MIDDLE REGISTER BOARD DRIVE (B) 5-60...............................................

5.30 TAB CUTTER - KNIFE CARRIER (L.H.) 5-62...............................................

5.31 TAB CUTTER - KNIFE CARRIER (R.H.) 5-64...............................................

5.32 TAB CUTTER (A) 5-66...................................................................

5.33 TAB CUTTER (B) 5-68...................................................................

5.34 TAB CUTTER DRIVE LINKAGE 5-70......................................................

5.35 TIP DIE UNIT 5-72......................................................................

5.36 HANDWHEEL UNIT/ PLASTIC POSITION/ TAB POSITION 5-74..............................

5.37 HANDWHEEL UNIT/ PLASTIC SIZE 5-76..................................................

5.38 HANDWHEEL UNIT/ TAB SIZE 5-78.......................................................

5.39 HANDWHEEL LOCATOR 5-80............................................................

5.40 PLASTIC FEED UNIT ASSEMBLY (A) 5-82.................................................

5.41 PLASTIC FEED UNIT ASSEMBLY (B) 5-84.................................................

5.42 PLASTIC FEED ASSEMBL Y (C) 5-86......................................................

5.43 PLASTIC FEED UNIT - ROLLERS 5-88....................................................

5.44 PLASTIC FEED - SLIDE 5-90.............................................................

5.45 PLASTIC FEED - DRIVE 5-92............................................................

5.46 PLASTIC FEED - COVERS & GUARDS 5-94...............................................

5.47 PLASTIC CUT - BASE 5-96..............................................................

5.48 PLASTIC CUT ASSEMBLY 5-98..........................................................

5.49 PLASTIC REEL HOLDER 5-100...........................................................

5.50 PNEUMATIC CONTROLS --1 5-102........................................................

5.51 PNEUMATIC CONTROLS --2 5-104........................................................

5.52 PAPER TRAY ASSEMBLY 5-106...........................................................

5.53 GUARDS & COVERS

5-108...............................................................

5.54 BASE & DRIVE 5-110....................................................................

5.55 MAIN MOTOR & VACUUM PUMP 5-112....................................................

5.56 HOLD DOWN BAR 5-114.................................................................

5.57 DRIVE BELT & CHAIN ASSEMBLY 5-116...................................................

5.58 CHIP REMOVAL VACUUM 5-118..........................................................

V

F--9999--8 Issue 1

6 ELECTRICAL AND PNEUMATICS 6-1...

1 Introduction and Safety

1--1

F--9999--8 Build 8 Issue 1

1 INTRODUCTION AND SAFETY

1 Introduction and Safety

1--2

F--9999--8 Build 8 Issue 1

Important Warranty Information

All Scott machines require clean, dry air. The warranty does not cover damage to machines due to
impurities or water in the air supply system. An optional coalescing filter with auto drain is available.

Contact your Scott representative for details.

1 Introduction and Safety

1--3

F--9999--8 Build 8 Issue 1

1.1 Introduction

Fig. 1-1. Scotty 5000t

The Scotty 5000t uses a vacuum feeder for accuracy with many stocks, a platen mylar applicator which
only heats the tab extension, tab cutting knives, and efficient receiving stacker for hands--off operation.
Tab sizes range from 1/2 inch to 5 inches (12.7 mm to 127 mm) by simply rotating the Tab Size handwheel.
The extra long tool steel knives quickly and easily cut a one inch (25.4 mm) tab in the first position on a 14
inch (355.6 mm) long sheet. As the tab widens, or the tab position moves toward the center of the sheet, the
sheet size capability increases accordingly.

1 Introduction and Safety

1--4

F--9999--8 Build 8 Issue 1

1.1.1 Scotty 5000 Machine Specifications and Utility Requirements

Model Scotty 5000t

Speed

Up to 5000 tabs cut per hour
Up to 4200 tabs laminated and cut per hour

Sheet Size

355.6 mm x 342.9 mm (14” x 13--1/2”) maximum
127 mm x 111.1 mm (5” x 4--3/8”) minimum

Plastic Size

139.7 mm (5--1/2”) maximum

25.4 mm (1”) minimum

Tab Cut Size

127 mm (5”) maximum

12.7 mm (1/2”) minimum

Paper Load

Approximately 2000 sheets

Counter

1 -- 999999

Motor

1HorsePower

Electrical Requirements

30 Amps, 220VAC single phase, 50 or 60 Hz

Air Requirements

6 ScFm @ 80 P.S.I. (170LPM @ 5.3 bar)

Air Quality

Clean Dry Air filtered to 5 micron

Decibel Rating

94db

Dimensions

L--85” W--52” H--63” (L--2159mm W--1320.8mm H--1600.2mm)

Shipping Weight

2000 lbs (910 Kg)

Warranty

One year against defects in parts and workmanship

Note ! All Scott Machines require clean, dry air.

Optional air filters are available, contact your Scott representative for more details.

1 Introduction and Safety

1--5

F--9999--8 Build 8 Issue 1

PAPER

SUPPORT

PAP ER

CATCHER

OPERATORS

PAN EL

PILE

FEEDER

TIP DIE

TAB

CUTTER

ELECTRICAL

BOX

PAPER LIFT

HANDWHEEL

PLASTIC

POSITION

HANDWHEEL

PLASTIC SIZE

HANDWHEEL

TAB POSITION

HANDWHEEL

TAB S IZE

HANDWHEEL

Fig. 1-2. Machine Front View

FILM

GUIDES

VACUUM

UNIT

TRANSFORMER

MAIN POWER

SWITCH

REEL HOLDER

PLASTIC
FEEDER

VACUUM

GAGE

DRIVE

MOTOR

AREA

AIR INLET

VALV E

TAB CUTTER OFF

Fig. 1-3. Machine Back View

1 Introduction and Safety

1--6

F--9999--8 Build 8 Issue 1

1.2 General Safety Guidelines

Providing a safe working environment for operating your machine is the responsibility of the user. The
suggested precautions, material safety data and other suggestions that follow do not have preference over
the user’s own plant practices, regulations or safety committee recommendations.

Personal injury and equipment damage can be avoided by the continued adherence to the safety features
provided with this machine and in keeping with the necessary governmental requirements. The guarding
and interlocking safety switches have been installed on the machine for the operator’s safety. These items
should be maintained in good working order by the user.

It is assumed that the user’s safety department has established a safety program that is in keeping with a
complete analysis of industrial hazards. Before installing and operating or performing maintenance and
clean--up procedures on the machine, it is suggested that the safety program be reviewed to ensure that it
covers the possible hazards that might occur with the operation of this machine.

Due consideration must be given to those hazards which arise from the presence of electrical power, high
temperature, and cleaning materials used in the operational areas of the machine. Proper installation and
care of protective devices and over--pressure protective equipment should be considered an essential part of
any safety program.

Special lock--out features are to prevent the possibility of applying power to the equipment at any time when
maintenance work is in progress.

In general, personnel should be guided by all basic rules of safety associated with the equipment and the
process. It should be further understood that information contained in this manual does not relieve operating
and maintenance personnel of the responsibility of exercising normal good judgment in operating and care of
the machine and its attendant equipment.

1 Introduction and Safety

1--7

F--9999--8 Build 8 Issue 1

1.3 Safety Features

EMERGENCY

STOP

MAIN POWER

SWITCH

KEY SWITCH

STOP

PUSHBUTTON

Fig. 1-4. Safety Feature Locations

E--STOP

Fig. 1-5. Know Where Emergency Stop Button
is Located

These safety features are to be used in conjunction
with the installation, operation and maintenance
instructions contained in this manual.

1.3.1 Emergency Stop

Stops machine drive immediately. This pushbutton
must be manually pulled out to reset.

RUN

SAFE

STOP

Fig. 1-6. Know How to Stop Machine & Set Key
Switch to SAFE

1.3.2 Stop and Safe

The machine operator, clean--up and maintenance
personnel MUST be shown how to stop the
machine and place the KEY SWITCH on the
operator’s CONTROL PANEL in the SAFE mode
whenever machine is accessed or clean--up
operations are performed.

1 Introduction and Safety

1--8

F--9999--8 Build 8 Issue 1

Fig. 1-7. Turn Machine Off Before Making
Adjustments

1.3.3 Main Power Switch

If machine is to be shut down for adjustments or
repairs, turn the power supply to the machine off.

VALV E

CONTROL

PLANT

AIR

SUPPLY

Fig. 1-8. Compressed Air Can Be Turned Off.

1.3.4 Compressed Air Valve

The compressed air line at the main AIR IN
features a ON/OFF valve for safety. The valve is
constructed to lockout down stream air pressure
when in the OFF position.

● The valve shuts off plant supplied compressed

air to the machine.

● Place the valve in the closed position when the

machine is not in use and prior to washing or
servicing the machine.

1 Introduction and Safety

1--9

F--9999--8 Build 8 Issue 1

Fig. 1-9. Cover Warnings

1.3.5 Guards and Covers

All safety guards, protective screens and covers
MUST be in place and securely fastened before
operating the machine.

Observe Danger warnings. Use extra care around
moving cutting blades.

SAFETY
SWITCH

Fig. 1-10. Safety Devices

1.3.6 Safety Devices

The covers of the machine are connected to safety
devices for your protection.

1 Introduction and Safety

1--10

F--9999--8 Build 8 Issue 1

WARNING!

Fig. 1-11. Warnings Indicate Personal Danger

1.4 Warnings, Cautions & Notes

In order to emphasize certain areas in the interest
of personal safety and a properly operated and
maintained machine, you will encounter the words

WARNING, CAUTION, and NOTE.

1.4.1 Warnings

AN OPERATING PROCEDURE,
PRACTICE, ETC. WHICH IF NOT
CORRECTLY FOLLOWED, COULD
RESULT IN PERSONAL INJURY OR
LOSS OF LIFE.

WARNING!

CAUTION!

Fig. 1-12. Cautions Indicate Potential Damage
to Equipment

1.4.2 Cautions

AN OPERATING PROCEDURE,
PRACTICE, ETC. WHICH, IF NOT
STRICTLY OBSERVED, COULD RESULT
IN DAMAGE TO OR DESTRUCTION OF
EQUIPMENT.

CAUTION!

Note !

Fig. 1-13. Notes Indicate Essential Information

1.4.3 Notes

An Operating Procedure, Condition,
etc. Which is Essential To Highlight.

Note !

1 Introduction and Safety

1--11

F--9999--8 Build 8 Issue 1

Fig. 1-14. Heat Hazard

1.5 Warnings

1.5.1 Heat Hazards

Forexample,thereisHOTSURFACEsignontop
of the Plastic Press assembly. Look for warning
signs throughout the machine. They are there to
alert you to hazards.

Fig. 1-15. Electrical Shock Hazard

1.5.2 Electrical Shock Hazards

Look for warning signs on electrical cabinets and
circuit breaker boxes. They are there to alert you
to hazards of electrical shock.

1 Introduction and Safety

1--12

F--9999--8 Build 8 Issue 1

VALV E

CONTROL

PLANT

AIR

SUPPLY

Fig. 1-16. Compressed Air Valve.

1.6 Safety Procedures

1.6.1 Compressed Air Valve

Assemblies which are air actuated may have
pressure remaining in the air lines. Turn OFF
valve before working on pneumatic circuits to
release air trapped in the system.

DRAIN LINES OF COMPRESSED AIR TO
PREVENT ACCIDENTAL ACTIVATION OF
AIR DRIVEN ASSEMBLIES.

WARNING!

SAFETY
SWITCH

Fig. 1-17. Do Not Disable Safety Devices

1.6.2 Safety Devices

Tampering with safety mechanisms in order to
disable them should not be tolerated.

IT IS EXTREMELY DANGEROUS TO ACCESS
MACHINE WHEN IT IS OPERATING OR
CAPABLE O F OPERATING.

WARNING!

Fig. 1-18. Wear Proper Clothing

1.6.3 Appropriate Dress

Personnel working in the machine operation area
must remove jewelry and neckties. Personnel
must wear clothing appropriate for the work area.

1 Introduction and Safety

1--13

F--9999--8 Build 8 Issue 1

Fig. 1-19. Keep Work Area Clean and Neat

1.6.4 Keep Area Clean

Loose materials, tools and equipment, not
essential to the operation of the machine, must be
removed from the machine work area.

Fig. 1-20. Clean Up Oil and Grease Spills

1.6.5 Grease and Oil

Clean up all oil and grease spills around the
machine work area.

Fig. 1-21. Read Manuals First

1.6.6 Manual Usage

Read and understand the instructions in the
manual before operating, adjusting or servicing
machine.

2 Installation

2--1

F--9999--8 Build 8 Issue 1

2 INSTALLATION

2 Installation

2--2

F--9999--8 Build 8 Issue 1

2 Installation

2--3

F--9999--8 Build 8 Issue 1

2.1 Installation Requirements

Fig. 2-1. Scotty 5000

All procedures in this section provide advance planning and site preparation data for installation of the Scotty

5000. Environmental requirements, unpacking instructions, and electrical and physical specifications are
included. This information should be used as a reference during the development of site preparation plans
before you install your machine.

If any questions arise while performing any of the following procedures, contact

Training is available from Scott Office Systems at / eight hour day, plus all travel expenses.

Note ! A forklift is required to lift the machine off the shipping skid and place it on the floor.

2 Installation

2--4

F--9999--8 Build 8 Issue 1

2.1.1 Pre-Installation Requirements

The environmental requirements of the Scotty 5000 must be considered well in advance of the actual
installation. Providing a well suited operating environment will help ensure a trouble free installation process.
Consideration should be given to the following items:

● Power, location and rating of outlets

● Floor strength

● Level floor

● Adequate space must be provided around all four sides of the machine to permit normal operation and

maintenance procedures. The figure shows the minimum space required.

12’--0” (3657mm)

2’--4”

3’--0”6’--8”

4’--4”

2’--4” (711mm)

2’--6”

7’--9”

(711mm)

(2032mm)

(914mm)

(762mm)

(2362mm)

Fig. 2-2. Space Requirements

● Space should be allocated near the feeder for a small table that can be used for jogging stock, small jobs,

samples, etc.

● Provide plenty of space In front of the machine so large jobs can be easily moved in and out with skids or

carts.

2 Installation

2--5

F--9999--8 Build 8 Issue 1

2.1.2 Uncrating & Placement

The machine will arrive crated. Inspect the external condition of the crate for visible signs of damage before
opening. If damage is noticeable, notify the carrier or Scott before proceeding with the installation.

VACUUM

UNIT

PLASTIC

POSITION

HANDWHEEL

SHIPPING

SKID

MAIN

MACHINE

RAISE FROM

THIS SIDE

OF SKID

Fig. 2-3. Scotty 5000 on Shipping Skid

Step: 1. Remove shrink wrap enclosing the machine.

REMOVE SUPPORT BOARD BEFORE
PROCEEDING FUTHER. CARE MUST
BE TAKEN WHEN MOVING THE
MACHINE SO AS NOT TO DAMAGE IT.

CAUTION!

EXTREME CAUTION MUST BE
EXERCISED WHEN MOVING MACHINE
TO INSTALLATION LOCATION TO
PREVENT DAMAGE.

CAUTION!

Step: 2. With fork lift, place shipping skid near designated floor area of operation.
Step: 3. Remove vacuum unit from skid.
Step: 4. Remove four lag screws holding machine to shipping skid.
Step: 5. Raise main machine with fork lift, remove shipping skid assembly from under machine.
Step: 6. Lower main machine to floor.

2 Installation

2--6

F--9999--8 Build 8 Issue 1

Fig. 2-4. Remove Foam and Tie Wraps

Step: 7. Remove the foam and tie wraps that were protecting the machine during shipping.

Fig. 2-5. Remove Parts from Vacuum Canister

Step: 8. Once the machine is in place, open the

vacuum canister and remove packaged
parts.

LARGE BALL

BEARING POCKETS

SMALL BALL

BEARING POCKETS

Fig. 2-6. Install Ball Bearings

Step: 9. Install ball bearings in the correct

pockets.

2 Installation

2--7

F--9999--8 Build 8 Issue 1

PAPER

CATCHER

Fig. 2-7. Install Paper Catcher

Step: 10.Install paper catcher parts.

VACUUM

CANISTER

HOSE

Fig. 2-8. Release Hose

Step: 11.Crank the Plastic Position handwheel to

release the vacuum canister hose. (See
Fig. 2-3. for Plastic Position Handwheel
location)

DRIVE ROLLER

HUB ROLLER

Fig. 2-9. Install Drive Roller

Step: 12.Install Drive Roller. Align drive roller to

the center of the hub roller on platen unit.
This is used to assist short sheets into
the platen unit.

2 Installation

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VACUUM

VALV E

Fig. 2-10. Install Vacuum Valve

Step: 13.Install vacuum adjustment valve.

THREADED

LEVELING

HOLES (2 FRONT)

LEVELING SCREWS

Fig. 2-11. Leveling Rod Installation

Step: 14.The machine must be on a level surface. However, If machine is to be placed on an abnormally

uneven floor, machine may be leveled in the following manner:

● Install 3/4 in.--#10 threaded rods through four threaded holes In machine weldment. (See Fig. 2-11. )

● Threaded rods can then be used to level machine. Use appropriately sized jam nuts to maintain level

position when attained.

2 Installation

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DANGER: ELECTRICAL CONNECTIONS
MUST BE MADE BY A QUALIFIED
ELECTRICIAN FAMILIAR WITH
APPLICABLE ELECTRICAL CODES
AND REGULATIONS. ELECTRICAL
CONNECTIONS MUST THEN BE MADE
ONLY AFTER REVIEWING AND
UNDERSTANDING THE ELECTRICAL
SCHEMATICS SUPPLIED WITH
MACHINE AND SAFETY SECTION OF
THIS MANUAL, FAILURE TO EXERCISE
NECESSARY SAFETY PRECAUTIONS
CAN RESULT IN SERIOUS BODILY
INJURY OR DEATH.

WARNING!

2.2 Utility Connections

2.2.1 Electrical Connections

1. The machine requires No. 10, 3 wire cable

including ground for 220 volt, single phase
electrical power.

Note ! Electrical cables going to machine

should be routed overhead and be of
sufficient height to allow personnel to
travel around entire machine without
interference. The figure below shows
recommended installation
configuration.

GROUND

TERMINAL

1L1

TERMINAL

5L3

TERMINAL

Fig. 2-12. Installation Wiring Route

2. Route main power electrical cable through the conduit opening in the back of the control cabinet.

3. Connect two “hot” leads onto terminals 1L1 and 5L3 on main power relay. Connect neutral lead to

ground terminal.

2 Installation

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Fig. 2-13. Connect Air Supply

2.2.2 Connect Air Supply

1. Supply a 1/4 NPT air line with 6 ScFm @

80psi (170LPM @ 5.3bar)to the air shut off
valve located at the back of the machine.

Note ! The compressed air line at the main

AIR IN features a ON/OFF valve for
safety. Place the valve in the closed
position when connecting the
machine to the plant air supply.

Fig. 2-14. Air Supply Gage

Set the Regulator to 60psi (4.0bar).

3 Operation

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3 OPERATION

3 Operation

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3 Operation

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3.1 General Information

3.1.1 Before Operating the Machine

AVOID SERIOUS INJURY OR EQUIPMENT
DAMAGE. RESTRICT OPERATION OF THIS
MACHINE TO TRAINED, QUALIFIED
PERSONNEL ONLY.

WARNING!

EACH OPERATOR SHOULD KNOW THE
LOCATION AND FUNCTION OF ALL
MACHINE STOPPING CONTROLS.
REVIEW MANUAL FOR EMERGENCY
STOP BUTTON LOCATION.

WARNING!

Do not attempt to operate the machine before reading and understanding the manual. Pay close attention to
all WARNINGS, CAUTIONS and NOTES. Failure to do so may cause serious injury and extensive machine
damage.

Read through the inspection and pre--start procedures before starting the machine. Make these checks part
of your routine to insure efficiency and quality during the production run.

3 Operation

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3.2 Operating Controls and Indicators Descriptions

3.2.1 Operator’s Control Panel Layout

UPPER

HEAT

LOWER

HEAT

STOP

PAP ER

FEED

START

RUN/SAFE

RESET

FEED

DELAY

HEATER

SEAL

TIME

PLASTIC

FEED

COUNT

REACHED

EMERGENCY

STOP

OUT OF

PLASTIC

COUNTER

ON/OFF

COUNTER

PLATEN

CLOSE

PLASTIC

ADVANCE

DRIVE

SPEED

TAB CUTTER OFF (SIDE OF MACHINE)

Fig. 3-1. Control Panel

E--STOP

Fig. 3-2. Emergency Stop Pushbutton

3.2.2 Machine Stopping Device

3.2.2.1 EMERGENCY STOP -- Red Pushbutton

Stops the machine drive immediately. The
Emergency Stop Button is on the front of the
machine. After a stop, the button must be
manually pulled out and the Reset button pushed
before cycling can resume.

3 Operation

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3.2.3 Main Operator’s Panel Control Descriptions

The following is a list of each control on the operator’s panel and a description of the functions performed at
each setting.

TAB CUTTER

OFF

Fig. 3-3. Tab Cutter Off

3.2.3.1 TAB CUTTER OFF -- Red Illuminated
Pushbutton

The Tab Cutter Off Button located on the left side
of the operator’s box and is used to disable the
cutting knives when running production that
involves laminating tabs only (not tab cutting).

OFF-- When pushed this button disables the tab
cutting knives so that sheets are not cut.

ON -- When pushed, knives are raised into position
so that tabs will be cut.

COUNTER

Fig. 3-4. Counter On/Off -- Illuminated
Pushbutton

3.2.3.2 COUNTER ON / OFF -­White Illuminated Pushbutton

When the counter button is pushed, the button
illuminates indicating that the counter is on.

This will allow the operator to off the counter to run
make overs without losing the current count.

COUNT

REACHED

Fig. 3-5. Count Reached Lamp

3.2.3.3 COUNTER REACHED -­Amber Indicator Lamp

This lamp will illuminate when the machine has
produced the amount predetermined by the
counter. Once the count has been reached, the
paper feed vacuum pump will shut off so that paper
feed will stop. Also, if plastic is being applied to
the paper stock, the plastic chip removal vacuum
will shut off. Both units will resume operation once
the counter has been reset.

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RUN

SAFE

Fig. 3-6. Run/Safe Key Switch

3.2.3.4 SAFE / RUN -- Key Switch

RUN -- The machine drive cycles continuously.

This is the normal switch position for production.

SAFE -- No machine cycle is possible.

If conditions are safe, pushing RESET will allow
the machine to operate.

OUT OF

PLASTIC

Fig. 3-7. Out of Plastic Lamp

3.2.3.5 OUT OF PLASTIC -- LAMP

Lamp will illuminate when upon pushing the Plastic
Feed button, the proximity switch on the plastic
feed does not sense plastic at the feeder
discharge. The plastic chip removal vacuum and
the paper feed vacuum pump will also be disabled
until the plastic spool is refilled.

START

Fig. 3-8. Start Pushbutton

3.2.3.6 START -- Green Pushbutton

Turns on main drive motor to begin machine
cycling.

This means:

● The safety switches indicate all the guards are

in place.

● The EMERGENCY STOP buttons are reset.

● The RESET button is pushed.

● The pushbutton turns on the main drive motor

for continuous machine cycling with the KEY
switch in RUN position.

PAPER

FEED

Fig. 3-9. Paper Feed Pushbutton

3.2.3.7 PAPER FEED -- White Illuminated
Pushbutton

Starts the vacuum pump for the pile feeder vacuum
nozzles.

3 Operation

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STOP

Fig. 3-10. Stop Drive Pushbutton

3.2.3.8 STOP -- Red Pushbutton

The pushbutton stops the machine drive. This is a
“soft” stop and is intended for planned stops, not
emergencies.

FEED

DELAY

Fig. 3-11. Feed Delay -- Illuminated Pushbutton

3.2.3.9 FEED DELAY -- White Illuminated
Pushbutton

Shuts off the vacuum to the paper pick--up vacuum
nozzles to prevent a new sheet from being fed into
the machine until the preceding sheet has cleared
the press assembly. The amount of time that the
paper is in the press will depend on the time that is
preset in the Seal Time unit.

HEATER

Fig. 3-12. Heaters Illuminated Pushbutton

3.2.3.10 HEATERS ON / OFF --

ON -- When pushed, the button illuminates,

indicating upper and lower heaters are turned ON.

OFF -- When pushed again, the heaters are turned
OFF.

Approximate warm up time for heaters is between
10--15 minutes.

NOTE: See additional information under Heater
Temperature Controller write--up.

PLASTIC

FEED

Fig. 3-13. Plastic Feed Pushbutton

3.2.3.11 PLASTIC FEED -- White Illuminated
Pushbutton

Turns on the chip removal vacuum and allows
plastic to enter the Tip Die, if the reel is threaded
onto the machine. The plastic chip removal
vacuum operates only when Plastic Feed is on,
machine is in Run mode and machine is running.

3 Operation

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RESET

Fig. 3-14. Reset Pushbutton

3.2.3.12 RESET -- Blue Pushbutton

Resets machine, and verifies it is safe to run after
an emergency stop.

Press this button when changing the Run/Safe
switch from Safe position to Run.

PLATEN

CLOSE

Fig. 3-15. Platen Close Pushbutton

3.2.3.13 PLATEN CLOSE -- Black Pushbutton

Activates plastic press air cylinder for cleaning
purposes.

PLASTIC

ADVANCE

Fig. 3-16. Plastic Advance Pushbutton

3.2.3.14 PLASTIC ADVANCE -- Black
Pushbutton

It brings plastic into the Tip Die when the machine
is in Run position. It is used when loading a new
reel of film and must be held in.

3 Operation

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DRIVE SPEED

Fig. 3-17. Main Drive Feed

3.2.3.15 SPEED -- Adjustment Control

Adjusts main drive motor speed. The dial is turned
clockwise to increase, and counterclockwise to
decrease the machine drive speed.

Note ! Drive speeds too low or too high will

cause improper machine operation.

COUNT RESET

COUNT SET

NUMBER

OF

SHEETS

RAN

COUNT SET

Fig. 3-18. Feeder Counter

3.2.3.16 FEEDER COUNTER

Activating the Feeder Counter, allows operator to
specify an exact number of sheets to be run. The
feeder shuts off after the requirement has been
met.

The counter only counts when the machine is in
RUN mode and the Counter button is ON. The
digital counter counts forwards to the number
specified, then shuts feeder and vacuum OFF
when that number is reached.

● Do not change setting while counter is running.

3 Operation

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Fig. 3-19. Heater Temperature Control

3.2.3.17 Heater Temperature Control

Controls upper and lower platen temperatures by
cycling power to the heaters. The setpoint
temperature is adjusted by using the buttons below
the indicator display.

Note ! The heat controllers will automatically

turn off if the machine is not run for
two hours. The heat button will stay
illuminated but the controllers will go
dark and the platen will loose heat.
To restart the machine:

Press the start
button while the heater button is still
on and the machine will start to heat
again.

1. PV:Processing value indicator(Red color)

2. SV:Setting value indicator(Green color)

3. ARROWS(3): Key shifting the display.

4. Information for operation mode.

5. AT Key: The mode key to execute Auto tuning

function.

6. MD Key: The mode key to change the items to
be set, such as alarm value, etc.

7. EV2: EVENT2 Output signal lamp. (Not Used)

8. EV1: EVENT1 Output signal lamp. (Not Used)

9. OUT: Output signal lamp.

10.AT: The signal lamp flickers while Auto tuning is

being executed.

11. SV2: Signal lamp for SV2 operation. (Not Used)

3 Operation

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SEAL TIME

Fig. 3-20. Seal Timer

3.2.3.18 Seal Timer

Operate the pushbuttons to select the desired
settings.

1. Display Window

2. Operator Pushbuttons

3. Time Unit Display Window

● Set on 0.1s always.

4. Rated Time Display Window

● Do not set all three digits to zero.

5. Operation Mode Display Window

● Always on “E”

3 Operation

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3.2.4 Scotty 5000 with Telemecanique PLC Control

The Scotty 5000 incorporates two Telemecanique TSX07 Programmable Logic Controllers. Each controller
has a series of LEDs indicating the on/off status of its inputs and outputs. Separate LEDs also verify
communication between controllers. Check Electrical Sheets 8 and 8A for a listing of the devices that are
attached to the controller and to which location (input/output), the device is attached.

When a device is active, the green LED is lit. The yellow com LED should always be lit. The second smaller
PLC will have a blinking red LED in the error position which is normal. The larger primary PLC error lamp
should not be lit.

3 Operation

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3.3 Preliminary Inspection and Start-Up Procedure

VALV E

CONTROL

Fig. 3-21. Air Valve Control

3.3.1 Preliminary Set-Up

Step: 1. SlidethevalvecontroluptotheON

position.

MAIN

POWER

SWITCH

Fig. 3-22. Circuit Breaker Switch (ON)

Step: 2. Main Power Switch ON.

HEATER

Fig. 3-23. Warm Up Heater

To laminate plastic to paper:

Step: 3. Press HEATER pushbutton.
Step: 4. Set temperature controllers to

220--230_F as a starting point.

Note ! Starting Heaters now will allow

heaters to reach operating
temperature while the rest of the
machine is being set up.

3 Operation

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ADJUSTMENT KNOB

Fig. 3-24. Loosen Guide Roller Adjustment
Knob

Reel Holder

Step: 1. Loosen adjustment knob on the bottom

roller guide.

ROLLER

ROLLER GUIDES

3 FILM THICKNESS

Fig. 3-25. Set Gap Between Plastic Feed Roller
Guides to 3 Film Thickness

Step: 2. Set the gap between the plastic feed

roller guides to 3 film thickness by
moving the lower roller guide.

Step: 3. Tighten the adjustment knob.

3 Operation

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FILM

REEL

FILM

SPOOL

FILM

GUIDES

Fig. 3-26. Loading the Film

Step: 4. Load film reel on the reel holder.
Step: 5. Thread film through the film guides as

shown.

Fig. 3-27. Refer to Decal for Film Loading

3 Operation

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PLASTIC

FEEDER

Fig. 3-28. Hand Feed Film into Machine

Step: 6. Hand feed film into the plastic feed

mechanism.

RUN

SAFE

Fig. 3-29. Key Switch

Step: 7. Turn key switch to RUN

RESET

Fig. 3-30. Reset Pushbutton

Step: 8. Press RESET pushbutton.

3 Operation

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DRIVE SPEED

Fig. 3-31. Adjust Drive Speed

Step: 9. Adjust drive speed to 7.

START

Fig. 3-32. Start Pushbutton

Step: 10.Press START pushbutton.

PLASTIC

ADVANCE

Fig. 3-33. Plastic Advance Pushbutton

Step: 11.Press and hold PLASTIC ADVANCE

pushbutton till plastic enters the Tip Die.

STOP

Fig. 3-34. Stop Drive Pushbutton

Step: 12.Press STOP pushbutton.

3 Operation

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1/32”

FILM

TIP DIE

FILM STOP

FILM STOP

FILM STOP
ADJUSTMENT SCREW

WINDOW ASSEMBLY

Fig. 3-35. Remove Film Scrap from Tip Die Area

Step: 13.Lift the window assembly to expose the

Tip Die.

Step: 14.Loosen the film stop adjustment screw.
Step: 15.Set film stop to 1/32” from edge of film

after plastic size handwheel has been
set.

Step: 16.Retighten the film stop adjustment screw.
Step: 17.Remove film from Tip Die.
Step: 18.Lower the window assembly.

ROLLERS GUIDES

DRIVE ROLLERS

Fig. 3-36. Inspect Plastic Feed Area

Step: 19.Inspect the folded plastic that has been

fed through the roller guides and into the
drive roller assembly.

3 Operation

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DRAG
ROLLER
KNOB

MYLAR

FOLD
UNEVEN
EDGE

MYLAR FILM

TOP VIEW

ROLLER GUIDE

ROLLER

Fig. 3-37. Move Drag Roller Left If Mylar is
Tracking Unevenly

Step: 20.If the plastic (Mylar) fold is uneven, move

roller to the left as shown in Fig. 3-37.

3 Operation

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DRAG ROLLER KNOB

MYLAR FILM

TOP VIEW

ROLLER GUIDE

ROLLER

FRONT VIEW

ROLLER

MYLAR

ROLLER GUIDE

MYLAR

Fig. 3-38. Inspect Plastic Feed Tracking

Step: 21.If Mylar is tracking behind the fold and drive rollers, move roller to the right as shown in Fig. 3-38.

3 Operation

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PAPER LIFT

HANDWHEEL

PAPER

SUPPORTS

Fig. 3-39. Set Paper Lift

Loader Set--Up.

Step: 1. Pull out the paper lift handwheel and

lower the paper lift.

Step: 2. Set paper supports to fit paper.

Note ! Make sure left support is not

underneath left guide rail.

3 Operation

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PAPER LIFT

HANDWHEEL

PAP ER STOC K

PAPER

GUIDES

MIDDLE

FRONT
GUIDE

Fig. 3-40. Load Stock

Step: 3. Load paper stock.
Step: 4. Push handwheel in and raise the paper

lift till the paper is level with top screw of
the middle front guide.

Note ! Make sure paper lift handwheel is fully

engaged. If not, the stack may fall
without warning.

Step: 5. Adjust paper guides (length & width).

PILE HEIGHT

ADJUSTMENT

KNOB

Fig. 3-41. Adjustment Knob

Step: 6. Depending on the curl and weight of the

stock, adjust the pile height with the
adjustment knob.

1. Up for heavier or downward curl stock.

2. Middle for normal and straight stock.

3. Down for lighter or upward curl stock.

SPRING

HEX
NUT

VACUUM

GAGE

PLUNGER

Fig. 3-42. Vacuum Setting

Step: 7. Adjust Vacuum.

Note ! The vacuum starting point is 10 inch

pounds for standard index stock. The
vacuum can be adjusted by turning
the hex nut to tighten or loosen the
spring, while keeping the plunger
stationary.

3 Operation

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RESET

PAPER

FEED

Fig. 3-43. Start Up Air Valves

3.3.1.1 Set Sheet Separators and Separator
Air Valves

Adjust valves according to the size and weight of
the paper. The following steps will start the Blower,
so that the system can be adjusted.

Step: 1. Push RESET button.
Step: 2. Push PAPER FEED button.
Step: 3. If the vacuum nozzles are not in an

upward position, index machine to place
them there.

AIR BLOW NOZZLES

Fig. 3-44. Blow --Air System

3.3.1.2 Blow-Air System

The blow-air system performs several functions.
First, it separates the sheets so the effect of the
vacuum bleeding through the paper is less critical.
Also, with the second sheet separated from the
first sheet, it allows air to get in between the sheets
when the top sheet is removed from the stack. This
prevents the first sheet from sucking up the second
sheet. Another function of the blow--air is to lift the
top few sheets until the top sheet is up against the
sheet separator finger. This establishes a uniform
height for the top sheet so that it will be in the
proper position when the nozzles come down for
the pick--up.

The feeder is equipped with four blow nozzles.
Two of these blow in from the edges of the stack
and two blow in from the front of the stack.

VACUUM NOZZLES

CAP

Fig. 3-45. Two Vacuum Nozzles in Place

3.3.1.3 Vacuum Nozzle Set--Up

It is necessary to use different quantities of
vacuum nozzles to run different types of
production. Vacuum nozzles may have to be
moved horizontally to accommodate different sheet
sizes.

Use two nozzles (one per block) for 4200
laminated and cut tabs per hour.

Note ! It is not possible to run 5,000 tab cut

and laminated sheets per hour.

3 Operation

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TWO NOZZLES

PER BLOCK

THUMB SCREW

Fig. 3-46. Vacuum Nozzle Set Up

Use four nozzles (two per block) when running
5,000 cut only

(not laminated) tabs per hour.

To Install/remove: Loosen the thumb screw and
insert/remove vacuum nozzle and rubber plug.
Gently retighten thumb screws.

Fig. 3-47. Side Air Blow Nozzles

Blow air nozzle height is pre--set at the factory and
should not need to be adjusted. If they need
adjusting, the side nozzles are adjusted in height
by screwing them either up or down. The front
nozzles can be adjusted in height by first tilting
them toward the stack and then screwing them
either up or down.

To adjust direction of air nozzle, rotate nozzle to
desired location.

3 Operation

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EXHAUST VALVE

Fig. 3-48. Adjust the Air Blow At the Exhaust
Val ve

The amount of blow--air from the nozzles can be
adjusted by use of the exhaust valve located on
the feeder guards.

The right exhaust valve controls the RH side air
blow nozzle and RH top air blow nozzle. The left
exhaust valve controls the LH side and top air
nozzles.

DO NOT RESTRICT THE BLOW AIR TO
THE POINT WHERE IT OVERLOADS
THE VACUUM PUMP. THIS CAN CAUSE
THE MOTOR TO BE DAMAGED.

CAUTION!

Step: 1. Use exhaust valve to adjust over all blow air for all four blow air nozzles.

● The higher the vacuum, the more closed this valve will need to be.

● Heavier stocks will need more blow air, lighter stock will need less blow air.

● The higher the vacuum is set, the less blow air is available.

Step: 2. Open valves until the stock touches the separator fingers. Adjust the air valves according to size

and weight of the stock.

THUMB SCREW

WINDOW ASSEMBLY

Fig. 3-49. Plastic Feed Window Adjustment

3.3.1.4 Plastic Feed Window Adjustment

The plastic feed window holds the Mylar in its
proper open position.

To adjust the window:

Step: 1. Loosen the jam nut on the plastic thumb

screw.

Step: 2. Rotate the thumb screw

counter--clockwise until the window
assembly is touching the tip die and the
plastic feed tunnel.

Step: 3. Lift up the window assembly and place a

piece of index stock (from current
production run) and place it over the tip
die area.

Step: 4. Set the window assembly down on top of

the index stock and slowly turn the thumb
screw clockwise until the index stock can
be slide back and forth easily without any
resistance.

Step: 5. Gently retighten the jam nut.

3 Operation

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INDEX STOCK

SET SCREW

HUB ROLLER

Fig. 3-50. Adjust Hub Roller Assembly

3.3.2 Adjust Hub Roller

The hub roller preforms a couple of tasks. It drives
the index stock with the Mylar into the platen press
assembly where it is kept tight against the paper
stop until the platen press seals the Mylar to the
stock and then drives it out of the platen press
assembly.

To adjust the Hub Assembly:

Step: 1. Lift the plastic window assembly.
Step: 2. Take a strip of stock that will be used

during production and cut a small strip.

Step: 3. Set the machine drive to half speed.
Step: 4. Insert the strip of stock between the black

rubber o--ring on the hub roller and the
nylon in--feed roller. You should feel a
slight tug on the stock.

Note ! If there is too much tension, the

rollers could leave marks on some
stocks. If there is not enough tension,
the stock will not leave the platen
press assembly in time for the next
piece of stock to enter.

To adjust tension:

Step: 1. Remove cover.
Step: 2. Turn the set screw clockwise for more

tension and counter--clockwise for less.
The roller must have equal tension on
both sides.

Step: 3. Replace cover.
Step: 4. Reset Machine.
Step: 5. Test tension again. Repeat if necessary.

DRIVE ROLLER

THUMB SCREW

SPRING PLATE

Fig. 3-51. Adjust Roller Drive

3.3.3 Adjust Drive Roller

To Adjust Roller Drive:

Step: 1. Loosen the the thumb screw that holds

the drive roller assembly to the mounting
bar.

Step: 2. Lightly apply pressure to the spring plate

with your fingers.

Step: 3. Retighten thumb screw.

3 Operation

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SIDE GUIDE

THUMB SCREW

MOUNTING BRACKET

Fig. 3-52. Side Guide Set--Up

3.3.4 Side Guide Set--Up

To adjust the Side Sheet Guide:

Step: 1. Slowly jog one piece of sheet stock

(without Mylar) up to the tab cutter.
Lower knife blade and stop the sheet.

Step: 2. Loosen the side guide thumb nut and

screw.

Step: 3. Loosen the thumb screw on the mounting

bracket and position the assembly close
to the sheet stock.

Step: 4. Tighten mounting bracket thumb screw.
Step: 5. Slowly turn the thumb screw until the side

guide just touches the side of the sheet
stock.

Note ! If the side guide is positioned too

tightly against the sheet stock it will
stop the sheet as it passes through
the conveyor. If it is positioned too far
from the sheet stock it will cause the
sheet to twist as it passed through.

Step: 6. Tighten the thumb nut on the guide.

3 Operation

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THUMB SCREW

KICK OUT SOLENOID
MOUNTING BRACKET

Fig. 3-53. Kick Out Solenoid Adjustment

3.3.5 Kick Out Solenoid Set--Up

Step: 1. Loosen the thumb screw on the solenoid

mounting plate.

KICK OUT SOLENOID
MOUNTING BRACKET

TAB LOC ATIO N

Fig. 3-54. Align Kick O ut Solenoid to Tab
Location

Step: 2. Position the solenoid assembly inline with

the tab location.

Step: 3. Tighten the thumb screw.

THUMB SCREW

HOLD DOWN STRAPS

Fig. 3-55. Hold Down Straps

3.3.6 Sheet Hold Down Straps

Step: 1. Loosen the thumb screws on the hold

down straps mounting block.

Step: 2. Position the straps so they are equally

divided between the end of the sheet
and the kick out solenoid.

Note ! Ifthesheetshavea“curl”tothem,

position the straps as close to the curl
as possible.

Step: 3. Tilt the straps down until they just touch

the sheet.
Too much down pressure will stop the
sheet from passing through.

Step: 4. Tighten the thumb screw.
Step: 5. Remove the sheet from the machine.

3 Operation

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3.3.7 Set Up For Production

PLASTIC SIZE

HANDWHEEL

PLASTIC POSITION

HANDWHEEL

TAB S IZE

HANDWHEEL

TAB POSITION

HANDWHEEL

PILE LIFT

HANDWHEEL

Fig. 3-56. Set Handwheels for Tabs

Step: 1. Use the charts in the back of this section to set the machine up for the desired tabs.

Fig. 3-57. Heater Controls

Step: 2. If laminating plastic to paper, check heat

controls to see if they have reached their
operating temperature.

Note ! The starting point for the heaters is

220- 230

_

F. This may need to be
changed depending on thickness of
stock and the length or type of plastic.

BAD CUT

HIGH

TOPPING

Fig. 3-58. Test Sheets

Step: 3. Run at least 6 test sheets of stock.

Check each sheet for:

High Topping.

● Roller tension.

● Steel ball placement.

Cut (tab and edge of stock)

● Knife blade adjustment

● Dull knives

3 Operation

3--30

F--9999--8 Build 8 Issue 1

BAD FILM

SEAL

Fig. 3-59. Film Seal

Film Seal (adhesion to stock)

● Heat or seal time

● Bad film

● Bad paper stock

If needed make necessary adjustments and repeat
till problem is corrected.

Note ! The film may not adhere to some

coated stocks. Aqueous and
Varnished stocks tend to release gas
when laminated and cause bubbles in
the film. Also, coated stocks tend to
isolate the film from the paper not
allowing the plastic to adhere to the
paper fibers.

COUNTER

Fig. 3-60. Feeder Counter

3.3.8 Run Production

Step: 1. Set counter to desired quantity of sheets

to be run.

Step: 2. Push Counter On/Off button to start

counting.

RUN

SAFE

Fig. 3-61. Key Switch

Step: 3. Turn key switch to RUN.

RESET

Fig. 3-62. Reset Pushbutton

Step: 4. Press RESET pushbutton.

3 Operation

3--31

F--9999--8 Build 8 Issue 1

START

Fig. 3-63. Start Pushbutton

Step: 5. Press START pushbutton.

PLASTIC

FEED

Fig. 3-64. Plastic Feed Pushbutton

Note ! If tabs are to be laminated, include

this Step. If not, skip this Step.

Step: 6. Press PLASTIC FEED pushbutton to turn

ON.

PAPER

FEED

Fig. 3-65. Paper Feed Pushbutton

Step: 7. Press PAPER FEED pushbutton to turn

ON machine for the run.

Fig. 3-66. Remove Finished Tabs

Step: 8. Adjust paper catcher to collect outgoing

stock.

Step: 9. Remove finished tabs as necessary to

prevent over filling the basket.

3 Operation

3--32

F--9999--8 Build 8 Issue 1

3-33

F--9999-- 8 Issue 1

3.4 Handwheel and Tab Set-Up

3-34

F--9999-- 8 Issue 1

3.4.1 Hand Wheel and Tab Set-Up Definitions

11”

SHEET LENGTH

1/2”

MARGIN MARGIN

1 2 3

1/2”

TAB BANK

PLASTIC

SIZE

TAB
SIZE

Fig. 3-67. Chart Diagram (Example: English Measurement 3 Tab Bank, 11” Sheet Length, 1/2” Margin)

Use the definitions in the above diagram to determine hand wheel set ups.

Margin: The dimension from the top or bottom edge of the sheet to the outwardmost flat edge of the first or last tab on the page.

The top and bottom margins will be the same dimension.
Sheet Length: The overall length of the sheet of tab stock paper.
Tab Blank: The quantity of tab divisions desired on page.
Plastic Size: Dimension of plastic film applied to tab area prior to cutting.

3-35

F--9999-- 8 Issue 1

Note ! Page intentionally left blank.

3-36

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 5” SHEET WITH3/16” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB BANK TAB S IZ E TABS PLASTIC

LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC

LENGTH

PLASTIC & TAB POSITIONS

3 1.54 1&3 2.15 1.03 .96 2.29

2

2.50

4 1.16 1&4 1.77 .84 .77 1.91

2 3

1.92 1.92

5 .93 1&5 1.54 .72 .65 1.68

2 3 4

1.57 2.50 1.57

6 .77 1&6 1.48 .64 .57 1.52

2 3 4 5

1.34 2.11 2.11 1.34

3-37

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 6” SHEET WITH3/16” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB BANK TAB S IZ E T ABS PLASTIC

LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC

LENGTH

PLASTIC & TAB POSITIONS

3 1.88 1&3 2.49 1.19 1.12 2.63 2

3.00

4 1.41 1&4 2.02 .96 .89 2.16 2 3

2.30 2.30

5 1.13 1&5 1.74 .82 .75 1.88 2 3 4

1.87 3.00 1.87

6 .94 1&6 1.55 .73 .66 1.69

2 3 4 5

1.59 2.53 2.53 1.59

3-38

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 7-1/4” SHEET WITH3/16” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB

BANK

TAB

SIZE

TABS

PLASTIC
LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC
LENGTH

PLASTIC & TAB POSITION

3 2.29 1&3 2.83 1.43 1.33 3.04 2

3.63

4 1.72 1&4 2.26 1.15 1.05 2.47 2 3

2.76 2.76

5 1.38 1&5 1.92 .93 .88 2.13 2 3 4

2.25 3.63 2.25

6 1.15 1&6 1.69 .86 .76 1.90 2 3 4 5

1.90 3.05 3.05 1.90

7 .98 1&7 1.52 .78 .68 1.73 2 3 4 5 6

1.66 2.64 3.63 2.64 1.66

8 .86 1&8 1.40 .72 .62 1.61 2 3 4 5 6 7

1.48 2.33 3.19 3.19 2.33 1.48

9 .76 1&9 1.30 .67 .57 1.51 2 3 4 5 6 7 8

1.33 2.09 2.86 3.63 2.86 2.09 1.33

10 .69 1&10 1.23 .63 .53 1.44 2 3 4 5 6 7 8 9

1.22 1.90 2.59 3.28 3.28 2.59 1.90 1.22

11 .63 1&11 1.17 .60 .50 1.38 2 3 4 5 6 7 8 9 10

1.13 1.75 2.38 3.00 3.63 3.00 2.38 1.75 1.13

12 .57 1&12 1.10 .57 .47 1.32 2 3 4 5 6 7 8 9 10 11

1.05 1.62 2.19 2.76 3.33 3.33 2.76 2.19 1.62 1.05

13 .53 1&13 1.07 .55 .45 1.28 2 3 4 5 6 7 8 9 10 11 12

.98 1.51 2.04 2.56 3.09 3.63 3.09 2.56 2.04 1.51 .98

3-39

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 7-1/4” SHEET WITH1/4” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB

BANK

TAB
SIZE

TABS

PLASTIC
LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC
LENGTH

PLASTIC & TAB POSITION

3 2.25 1&3 2.86 1.45 1.38 3.00 2

3.63

4 1.69 1&4 2.30 1.16 1.09 2.44 2 3

2.78 2.78

5 1.35 1&5 1.96 1.00 .93 2.10 2 3 4

2.28 3.63 2.28

6 1.13 1&6 1.74 .88 .81 1.88 2 3 4 5

1.94 3.06 3.06 1.94

7 .96 1&7 1.57 .80 .73 1.71 2 3 4 5 6

1.70 2.66 3.63 2.66 1.70

8 .84 1&8 1.45 .74 .67 1.59 2 3 4 5 6 7

1.51 2.36 3.20 3.20 2.36 1.51

9 .75 1&9 1.36 .70 .63 1.50 2 3 4 5 6 7 8

1.37 2.13 2.88 3.63 2.88 2.13 1.37

10 .68

1&10

1.29 .66 .59 1.43 2 3 4 5 6 7 8 9

1.26 1.94 2.61 3.29 3.29 2.61 1.94 1.26

11 .61

1&11

1.22 .63 .56 1.36 2 3 4 5 6 7 8 9 10

1.17 1.78 2.40 3.01 3.63 3.01 2.40 1.78 1.17

12 .56

1&12

1.17 .60 .53 1.31 2 3 4 5 6 7 8 9 10 11

1.09 1.66 2.22 2.78 3.34 3.34 2.78 2.22 1.66 1.09

13 .52

1&13

1.13 .58 .51 1.27 2 3 4 5 6 7 8 9 10 11 12

1.03 1.55 2.07 2.59 3.10 2.63 3.10 2.59 2.07 1.55 1.03

3-40

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 7-3/4” SHEET WITH3/16” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB

BANK

TAB
SIZE

TABS

PLASTIC
LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC
LENGTH

PLASTIC & TAB POSITION

3 2.46 1&3 3.00 1.52 1.42 3.21

2

3.88

4 1.84 1&4 2.38 1.21 1.11 2.59

2 3

2.95 2.95

5 1.47 1&5 2.01 1.02 .92 2.20

2 3 4

2.40 3.88 2.40

6 1.23 1&6 1.77 .90 .80 1.98

2 3 4 5

2.03 3.26 3.26 2.03

7 1.05 1&7 1.59 81 .71 1.80

2 3 4 5 6

1.77 2.82 3.88 2.82 1.77

8 .92 1&8 1.46 .75 .65 1.67

2 3 4 5 6 7

1.57 2.49 3.41 3.41 2.49 1.57

9 .82 1&9 1.36 .70 .60 1.57

2 3 4 5 6 7 8

1.42 2.23 3.05 3.88 3.05 2.23 1.42

10 .74

1&10

1.28 .66 .56 1.49

2 3 4 5 6 7 8 9

1.29 2.03 2.77 3.50 3.50 2.77 2.03 1.29

11 .67

1&11

1.21 .62 .52 1.42

2 3 4 5 6 7 8 9 10

1.19 1.86 2.53 3.20 3.88 3.20 2.53 1.86 1.19

12 .61

1&12

1.15 .59 .49 1.36

2 3 4 5 6 7 8 9 10 11

1.11 1.72 2.34 2.95 3.56 3.56 2.95 2.34 1.72 1.11

13 .57

1&13

1.11 .57 .47 1.32

2 3 4 5 6 7 8 9 10 11 12

1.04 1.60 2.17 2.74 3.31 3.88 3.31 2.74 2.17 1.60 1.04

14 .53

1&14

1.07 .55 .45 1.28

2 3 4 5 6 7 8 9 10 11 12 13

.98 1.50 2.03 2.55 3.08 3.61 3.61 3.08 2.55 2.03 1.50 .98

15 .50

1&15

1.04 .53 .43 1.25

2 3 4 5 6 7 8 9 10 11 12 13 14

.92 1.41 1.90 2.40 2.89 3.38 3.88 3.38 2.89 2.40 1.90 1.41 .92

3-41

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 7-3/4” SHEET WITH1/4” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB

BANK

TAB
SIZE

TABS

PLASTIC
LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC
LENGTH

PLASTIC & TAB POSITION

3 2.42

1&3

3.03 1.53 1.46 3.17

2

3.88

4 1.81

1&4

2.42 1.23 1.16 2.56

2 3

2.97 2.97

5 1.45

1&5

2.06 1.05 .98 2.20

2 3 4

2.43 3.88 2.43

6 1.21

1&6

1.82 .92 .85 1.96

2 3 4 5

2.06 3.27 3.27 2.06

7 1.04

1&7

1.65 .84 .77 1.79

2 3 4 5 6

1.80 2.84 3.88 2.84 1.80

8 .91

1&8

1.52 .77 .70 1.66

2 3 4 5 6 7

1.61 2.52 3.42 3.42 2.52 1.61

9 .81

1&9

1.42 .72 .65 1.56

2 3 4 5 6 7 8

1.46 2.26 3.07 3.88 3.07 2.26 1.46

10 .73

1&10

1.34 .68 .61 1.48

2 3 4 5 6 7 8 9

1.34 2.06 2.79 3.51 3.51 2.79 2.06 1.34

11 .66

1&11

1.27 .65 .58 1.41

2 3 4 5 6 7 8 9 10

1.24 1.90 2.56 3.22 3.88 3.22 2.56 1.90 1.24

12 .60

1&12

1.21 .62 .55 1.35

2 3 4 5 6 7 8 9 10 11

1.16 1.76 2.36 2.97 3.57 3.57 2.97 2.36 1.76 1.16

13 .56

1&13

1.17 .60 .53 1.31

2 3 4 5 6 7 8 9 10 11 12

1.09 1.64 2.20 2.76 3.31 3.88 3.31 2.76 2.20 1.64 1.09

14 .52

1&14

1.13 .58 .51 1.27

2 3 4 5 6 7 8 9 10 11 12 13

1.03 1.54 2.06 2.58 3.09 3.61 3.61 3.09 2.58 2.06 1.54 1.03

15 .48

1&15

1.09 .56 .49 1.23

2 3 4 5 6 7 8 9 10 11 12 13 14

.97 1.46 1.94 2.42 2.91 3.39 3.88 3.39 2.91 2.42 1.94 1.46 .97

3-42

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 8” SHEET WITH3/16” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB BANK TAB SI ZE TABS PLASTIC

LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC
LENGTH

PLASTIC & TAB POSITION

3 2.54 1&3 3.15 1.53 1.46 3.29 2

4.00

4 1.91 1&4 2.52 1.21 1.14 2.66 2 3

3.05 3.05

5 1.53 1&5 2.14 1.02 .95 2.28 2 3 4

2.47 4.00 2.47

6 1.27 1&6 1.88 .89 .82 2.02 2 3 4 5

2.09 3.36 3.36 2.09

3-43

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 8-1/2” SHEET WITH3/16” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB

BANK

TAB
SIZE

TABS

PLASTIC
LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC
LENGTH

PLASTIC & TAB POSITION

3 2.71

1&3

3.25 1.64 1.54 3.46

2

4.25

4 2.03

1&4

2.57 1.30 1.20 2.78

2 3

3.23 3.23

5 1.63

1&5

2.17 1.10 1.00 2.38

2 3 4

2.62 4.25 2.62

6 1.35

1&6

1.89 .96 .86 2.10

2 3 4 5

2.22 3.57 3.57 2.22

7 1.16

1&7

1.70 .87 .77 1.91

2 3 4 5 6

1.93 3.09 4.25 3.09 1.93

8 1.01

1&8

1.55 .79 .69 1.76

2 3 4 5 6 7

1.71 2.72 3.74 3.74 2.72 1.71

9 .90

1&9

1.44 .74 .64 1.65

2 3 4 5 6 7 8

1.54 2.44 3.34 4.25 3.34 2.44 1.54

10 .81

1&10

1.35 .69 .59 1.56

2 3 4 5 6 7 8 9

1.41 2.22 3.03 3.84 3.84 3.03 2.22 1.41

11 .74

1&11

1.28 .66 .56 1.49

2 3 4 5 6 7 8 9 10

1.29 2.03 2.77 3.51 4.25 3.51 2.77 2.03 1.29

12 .68

1&12

1.22 .63 .53 1.43

2 3 4 5 6 7 8 9 10 11

1.20 1.88 2.56 3.23 3.91 3.91 3.23 2.56 1.88 1.20

13 .63

1&13

1.17 .60 .50 1.38

2 3 4 5 6 7 8 9 10 11 12

1.13 1.75 2.38 3.00 3.62 4.25 3.62 3.00 2.38 1.75 1.13

14 .58

1&14

1.12 .58 .48 1.33

2 3 4 5 6 7 8 9 10 11 12 13

1.06 1.64 2.22 2.80 3.38 3.96 3.96 3.38 2.80 2.22 1.64 1.06

15 .54

1&15

1.08 .56 .46 1.29

2 3 4 5 6 7 8 9 10 11 12 13 14

1.00 1.54 2.08 2.62 3.16 3.70 4.25 3.70 3.16 2.62 2.08 1.54 1.00

3-44

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 8-1/2” SHEET WITH1/4” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB

BANK

TAB
SIZE

TABS

PLASTIC
LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC
LENGTH

PLASTIC & TAB POSITION

3 2.67

1&3

3.28 1.65 1.58 3.42

2

4.25

4 2.00

1&4

2.61 1.32 1.25 2.75

2 3

3.25 3.25

5 1.60

1&5

2.21 1.12 1.05 2.35

2 3 4

2.65 4.25 2.65

6 1.33

1&6

1.94 .99 .92 2.08

2 3 4 5

2.25 3.58 3.58 2.25

7 1.14

1&7

1.75 .89 .82 1.89

2 3 4 5 6

1.96 3.10 4.25 3.10 1.96

8 1.00

1&8

1.61 .82 .75 1.75

2 3 4 5 6 7

1.75 2.75 3.75 3.75 2.75 1.75

9 .89

1&9

1.50 .76 .69 1.64

2 3 4 5 6 7 8

1.58 2.47 3.36 4.25 3.36 2.47 1.58

10 .80

1&10

1.41 .72 .65 1.55

2 3 4 5 6 7 8 9

1.45 2.25 3.05 3.85 3.85 3.05 2.25 1.45

11 .73

1&11

1.34 .68 .61 1.48

2 3 4 5 6 7 8 9 10

1.34 2.07 2.79 3.52 4.25 3.52 2.79 2.07 1.34

12 .67

1&12

1.28 .65 .58 1.42

2 3 4 5 6 7 8 9 10 11

1.25 1.92 2.58 3.25 3.91 3.91 3.25 2.58 1.92 1.25

13 .62

1&13

1.23 .73 .56 1.37

2 3 4 5 6 7 8 9 10 11 12

1.17 1.79 2.40 3.02 3.63 4.25 3.63 3.02 2.40 1.79 1.17

14 .57

1&14

1.18 .61 .54 1.32

2 3 4 5 6 7 8 9 10 11 12 13

1.11 1.68 2.25 2.82 3.39 3.96 3.96 3.39 2.82 2.25 1.68 1.11

15 .53

1&15

1.14 .59 .52 1.28

2 3 4 5 6 7 8 9 10 11 12 13 14

1.05 1.58 2.12 2.65 3.18 3.71 4.25 3.71 3.18 2.65 2.12 1.58 1.05

3-45

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 8-1/2” SHEET WITH1/2” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

PLASTIC POSITIONS & TAB POSITION

TAB

BANK

TAB

SIZE

PLASTIC

SIZE

PLASTICPOSITIONS&TABPOSITIO

N

HANDWHEEL DIMENSION

2 3.75 4.50

1 2

2.38 2.38

3 2.50 3.25

1 2 3

1.75 4.25 1.75

4 1.88 2.63

1 2 3 4

1.44 3.31 3.31 1.44

5 1.50 2.25

1 2 3 4 5

1.25 2.75 4.25 2.75 1.25

6 1.25 2.00

1 2 3 4 5 6

1.13 2.38 3.63 3.63 2.38 1.13

7 1.07 1.82

1 2 3 4 5 6 7

1.04 2.11 3.18 4.25 3.18 2.11 1.04

8 .94 1.69

1 2 3 4 5 6 7 8

.97 1.91 2.84 3.78 3.78 2.84 1.91 .97

9 .83 1.58

1 2 3 4 5 6 7 8 9

.92 1.75 2.58 3.42 4.25 3.42 2.58 1.75 .92

10 .75 1.50

1 2 3 4 5 6 7 8 9 10

.88 1.63 2.38 3.13 3.88 3.88 3.13 2.38 1.63 .88

11 .68 1.43

1 2 3 4 5 6 7 8 9 10 11

.84 1.52 2.20 2.88 3.56 4.25 3.56 2.88 2.20 1.52 .84

12 .63 1.38

1 2 3 4 5 6 7 8 9 10 11 12

.81 1.44 2.06 2.69 3.31 3.94 3.94 3.31 2.69 2.06 1.44 .81

13 .58 1.33

1 2 3 4 5 6 7 8 9 10 11 12 13

.79 1.36 1.94 2.52 3.09 3.67 4.25 3.67 3.09 2.52 1.94 1.36 .79

14 .54 1.29

1 2 3 4 5 6 7 8 9 10 11 12 13 14

.77 1.30 1.84 2.37 2.91 3.44 3.98 3.98 3.44 2.91 2.37 1.84 1.30 .77

15 .50 1.25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

.75 1.25 1.75 2.25 2.75 3.25 3.75 4.25 3.75 3.25 2.75 2.25 1.75 1.25 .75

3-46

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 9” SHEET WITH3/16” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB BANK TAB SI ZE TABS PLASTIC

LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC
LENGTH

PLASTIC & TAB POSITION

3 2.88 1&3 3.49 1.70 1.63 3.63 2

4.50

4 2.16 1&4 2.77 1.34 1.27 2.91 2 3

3.42 3.42

5 1.73 1&5 2.34 1.12 1.05 2.48 2 3 4

2.75 4.50 2.75

6 1.44 1&6 2.05 .98 .91 2.19 2 3 4 5

2.34 3.78 3.78 2.34

3-47

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 9-1/2” SHEET WITH3/16” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB

BANK

TAB
SIZE

TABS

PLASTIC
LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC
LENGTH

PLASTIC & TAB POSITION

3 3.04

1&3

3.58 1.81 1.71 3.79

2

4.75

4 2.28

1&4

2.82 1.43 1.33 3.03

2 3

3.61 3.61

5 1.83

1&5

2.37 1.20 1.10 2.58

2 3 4

2.92 4.75 2.92

6 1.52

1&6

2.06 1.05 .95 2.27

2 3 4 5

2.47 3.99 3.99 2.47

7 1.30

1&7

1.84 .94 .84 2.05

2 3 4 5 6

2.14 3.44 4.75 3.44 2.14

8 1.14

1&8

1.68 .86 .76 1.89

2 3 4 5 6 7

1.90 3.04 4.18 4.18 3.04 1.90

9 1.01

1&9

1.55 .79 .69 1.76

2 3 4 5 6 7 8

1.71 2.72 3.73 4.75 3.73 2.72 1.71

10 .91

1&10

1.45 .74 .64 1.66

2 3 4 5 6 7 8 9

1.56 2.47 3.38 4.29 4.29 3.38 2.47 1.56

11 .83

1&11

1.37 .70 .60 1.58

2 3 4 5 6 7 8 9 10

1.43 2.26 3.09 3.92 4.75 3.92 3.09 2.26 1.43

12 .76

1&12

1.30 .67 .57 1.51

2 3 4 5 6 7 8 9 10 11

1.33 2.09 2.85 3.61 4.37 4.37 3.61 2.85 2.09 1.33

13 .70

1&13

1.24 .64 .54 1.45

2 3 4 5 6 7 8 9 10 11 12

1.24 1.94 2.64 3.34 4.04 4.75 4.04 3.34 2.64 1.94 1.24

14 .65

1&14

1.19 .61 .51 1.40

2 3 4 5 6 7 8 9 10 11 12 13

1.16 1.81 2.47 3.12 3.77 4.42 4.42 3.77 3.12 2.47 1.81 1.16

15 .61

1&15

1.15 .59 .49 1.36

2 3 4 5 6 7 8 9 10 11 12 13 14

1.10 1.71 2.32 2.92 3.53 4.14 4.75 4.14 3.53 2.92 2.32 1.71 1.10

3-48

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 9-1/2” SHEET WITH1/4” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB

BANK

TAB
SIZE

TABS

PLASTIC
LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC
LENGTH

PLASTIC & TAB POSITION

3 3.00

1&3

3.61 1.83 1.75 3.75

2

4.75

4 2.25

1&4

2.86 1.46 1.38 3.00

2 3

3.63 3.63

5 1.80

1&5

2.41 1.23 1.15 2.55

2 3 4

2.95 4.75 2.95

6 1.50

1&6

2.11 1.08 1.00 2.25

2 3 4 5

2.50 4.00 4.00 2.50

7 1.29

1&7

1.90 .97 .89 2.04

2 3 4 5 6

2.18 3.46 4.75 3.46 2.18

8 1.13

1&8

1.74 .89 .81 1.89

2 3 4 5 6 7

1.94 3.06 4.19 4.19 3.06 1.94

9 1.00

1&9

1.61 .83 .75 1.75

2 3 4 5 6 7 8

1.75 2.75 3.75 4.75 3.75 2.75 1.75

10 .90

1&10

1.51 .78 .70 1.65

2 3 4 5 6 7 8 9

1.60 2.50 3.40 4.30 4.30 3.40 2.50 1.60

11 .82

1&11

1.43 .73 .66 1.57

2 3 4 5 6 7 8 9 10

1.48 2.30 3.11 3.93 4.75 3.93 3.11 2.30 1.48

12 .75

1&12

1.36 .70 .62 1.50

2 3 4 5 6 7 8 9 10 11

1.38 2.13 2.88 3.63 4.38 4.38 3.63 2.88 2.13 1.38

13 .69

1&13

1.30 .68 .60 1.44

2 3 4 5 6 7 8 9 10 11 12

1.29 1.98 2.67 3.36 4.06 4.75 4.06 3.36 2.67 1.98 1.29

14 .64

1&14

1.25 .65 .57 1.39

2 3 4 5 6 7 8 9 10 11 12 13

1.21 1.86 2.50 3.14 3.78 4.42 4.42 3.78 3.14 2.50 1.86 1.21

15 .60

1&15

1.21 .63 .55 1.35

2 3 4 5 6 7 8 9 10 11 12 13 14

1.15 1.75 2.35 2.95 3.55 4.15 4.75 4.15 3.55 2.95 2.35 1.75 1.15

3-49

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 9-1/2” SHEET WITH1/2” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

TAB

TAB

PLASTIC

PLASTIC POSITIONS & TAB POSITION

BANKSIZE SIZE

PLASTICPOSITIONS&TABPOSITIO

N

HANDWHEEL DIMENSION

2 4.25 5.00

1 2

2.63 2.63

3 2.83 3.58

1 2 3

1.92 4.75 1.92

4 2.13 2.88

1 2 3 4

1.56 3.68 3.68 1.56

5 1.70 2.45

1 2 3 4 5

1.35 3.05 4.75 3.05 1.35

6 1.42 2.17

1 2 3 4 5 6

1.21 2.63 4.04 4.04 2.63 1.21

7 1.21 1.96

1 2 3 4 5 6 7

1.11 2.32 3.54 4.75 3.54 2.32 1.11

8 1.06 1.81

1 2 3 4 5 6 7 8

1.03 2.09 3.16 4.22 4.22 3.16 2.09 1.03

9 .94 1.69

1 2 3 4 5 6 7 8 9

.97 1.92 2.86 3.80 4.75 3.80 2.86 1.92 .97

10 .85 1.60

1 2 3 4 5 6 7 8 9 10

.93 1.78 2.63 3.48 4.33 4.33 3.48 2.63 1.78 .93

11 .77 1.52

1 2 3 4 5 6 7 8 9 10 11

.89 1.66 2.43 3.20 3.97 4.75 3.97 3.20 2.43 1.66 .89

12 .71 1.46

1 2 3 4 5 6 7 8 9 10 11 12

.85 1.56 2.27 2.98 3.69 4.39 4.39 3.69 2.98 2.27 1.56 .85

13 .65 1.40

1 2 3 4 5 6 7 8 9 10 11 12 13

.83 1.48 2.13 2.79 3.44 4.09 4.75 4.09 3.44 2.79 2.13 1.48 .83

14 .61 1.36

1 2 3 4 5 6 7 8 9 10 11 12 13 14

.80 1.41 2.02 2.62 3.23 3.84 4.45 4.45 3.84 3.23 2.62 2.02 1.41 .80

15 .57 1.32

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

.78 1.35 1.92 2.48 3.05 3.61 4.18 4.75 4.18 3.61 3.05 2.48 1.92 1.35 .78

3-50

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 11” SHEET WITH1/8” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB

BANK

TAB
SIZE

TABS

PLASTIC
LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC
LENGTH

PLASTIC & TAB POSITIONS

3 3.58 1&3 4.08 2.06 1.91 4.33

2

5.50

4 2.69 1&4 3.19 1.61 1.47 3.44

2 3

4.16 4.16

5 2.15 1&5 2.65 1.35 1.20 2.90

2 3 4

3.35 5.50 3.35

6 1.79 1&6 2.29 1.17 1.02 2.54

2 3 4 5

2.81 4.60 4.60 2.81

7 1.54 1&7 2.04 1.04 .89 2.29

2 3 4 5 6

2.43 3.97 5.50 3.97 2.43

8 1.34 1&8 1.84 .94 .79 2.09

2 3 4 5 6 7

2.14 3.49 4.84 4.84 3.49 2.14

9 1.19 1&9 1.69 .87 .72 1.94

2 3 4 5 6 7 8

1.91 3.10 4.30 5.50 4.30 3.10 1.91

10 1.07 1&10 1.57 .80 .66 1.82

2 3 4 5 6 7 8 9

1.74 2.81 3.89 4.96 4.96 3.89 2.81 1.74

11 .98 1&11 1.48 .76 .60 1.73

2 3 4 5 6 7 8 9 10

1.58 2.56 3.54 4.52 5.50 4.52 3.54 2.56 1.58

12 .90 1&12 1.40 .72 .56 1.65

2 3 4 5 6 7 8 9 10 11

1.46 2.36 3.26 4.16 5.06 5.06 4.16 3.26 2.36 1.46

13 .83 1&13 1.33 .69 .53 1.58

2 3 4 5 6 7 8 9 10 11 12

1.36 2.19 3.02 3.85 4.68 5.50 4.68 3.85 3.02 2.19 1.36

14 .77 1&14 1.27 .66 .50 1.52

2 3 4 5 6 7 8 9 10 11 12 13

1.27 2.04 2.81 3.58 4.35 5.12 5.12 4.35 3.58 2.81 2.04 1.27

15 .72 1&15 1.22 .63 .47 1.47

2 3 4 5 6 7 8 9 10 11 12 13 14

1.19 1.91 2.63 3.35 4.07 4.79 5.50 4.79 4.07 3.35 2.63 1.91 1.19

3-51

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 11” SHEET WITH3/16” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB

BANK

TAB
SIZE

TABS

PLASTIC
LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC
LENGTH

PLASTIC & TAB POSITION

3 3.54

1&3

4.08 2.05 1.95 4.29

2

5.50

4 2.66

1&4

3.20 1.61 1.51 3.41

2 3

4.17 4.17

5 2.13

1&5

2.67 1.35 1.25 2.88

2 3 4

3.36 5.50 3.36

6 1.77

1&6

2.31 1.17 1.07 2.52

2 3 4 5

2.84 4.61 4.61 2.84

7 1.52

1&7

2.06 1.04 .94 2.27

2 3 4 5 6

2.46 3.98 5.50 3.98 2.46

8 1.33

1&8

1.87 .94 .84 2.08

2 3 4 5 6 7

2.17 3.50 4.83 4.83 3.50 2.17

9 1.18

1&9

1.72 .87 .77 1.93

2 3 4 5 6 7 8

1.95 3.13 4.31 5.50 4.31 3.13 1.95

10 1.06

1&10

1.60 .82 .72 1.81

2 3 4 5 6 7 8 9

1.78 2.84 3.90 4.96 4.96 3.90 2.84 1.78

11 .97

1&11

1.51 .76 .66 1.72

2 3 4 5 6 7 8 9 10

1.62 2.59 3.56 4.54 5.50 4.54 3.56 2.59 1.62

12 .89

1&12

1.43 .73 .63 1.64

2 3 4 5 6 7 8 9 10 11

1.52 2.41 3.30 4.18 5.06 5.06 4.18 3.30 2.41 1.52

13 .82

1&13

1.36 .69 .59 1.57

2 3 4 5 6 7 8 9 10 11 12

1.41 2.23 3.05 3.87 4.69 5.50 4.69 3.87 3.05 2.23 1.41

14 .76

1&14

1.30 .66 .56 1.51

2 3 4 5 6 7 8 9 10 11 12 13

1.32 2.08 2.84 3.60 4.36 5.12 5.12 4.36 3.60 2.84 2.08 1.32

15 .71

1&15

1.25 .64 .54 1.46

2 3 4 5 6 7 8 9 10 11 12 13 14

1.25 1.96 2.67 3.38 4.09 4.80 5.50 4.80 4.09 3.38 2.67 1.96 1.25

3-52

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 11” SHEET WITH1/4” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB

BANK

TAB
SIZE

TABS

PLASTIC
LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC
LENGTH

PLASTIC & TAB POSITION

3 3.50

1&3

4.11 2.07 2.00 4.25

2

5.50

4 2.62

1&4

3.23 1.63 1.56 3.37

2 3

4.18 4.18

5 2.10

1&5

2.71 1.37 1.30 2.85

2 3 4

3.40 5.50 3.40

6 1.75

1&6

2.36 1.19 1.12 2.50

2 3 4 5

2.87 4.62 4.62 2.87

7 1.50

1&7

2.11 1.07 1.00 2.25

2 3 4 5 6

2.50 4.00 5.50 4.00 2.50

8 1.31

1&8

1.92 .97 .90 2.06

2 3 4 5 6 7

2.21 3.52 4.83 4.83 3.52 2.21

9 1.17

1&9

1.78 .90 .83 1.92

2 3 4 5 6 7 8

2.00 3.17 4.34 5.50 4.34 3.17 2.00

10 1.05

1&10

1.66 .84 .77 1.80

2 3 4 5 6 7 8 9

1.82 2.87 3.92 4.97 4.97 3.92 2.87 1.82

11 .95

1&11

1.56 .79 .72 1.70

2 3 4 5 6 7 8 9 10

1.67 2.62 3.58 4.54 5.50 4.54 3.58 2.62 1.67

12 .87

1&12

1.48 .75 .68 1.62

2 3 4 5 6 7 8 9 10 11

1.55 2.42 3.30 4.18 5.06 5.06 4.18 3.30 2.42 1.55

13 .80

1&13

1.41 .72 .65 1.55

2 3 4 5 6 7 8 9 10 11 12

1.46 2.27 3.08 3.89 4.70 5.50 4.70 3.89 3.08 2.27 1.46

14 .75

1&14

1.36 .69 .62 1.50

2 3 4 5 6 7 8 9 10 11 12 13

1.38 2.12 2.88 3.62 4.37 5.12 5.12 4.37 3.62 2.88 2.12 1.38

15 .70

1&15

1.31 .67 .60 1.45

2 3 4 5 6 7 8 9 10 11 12 13 14

1.30 2.00 2.70 3.40 4.10 4.80 5.50 4.80 4.10 3.40 2.70 2.00 1.30

3-53

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 11” SHEET WITH1/2” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

TAB

TAB

PLASTIC

PLASTIC POSITIONS & TAB POSITION

BANKSIZE SIZE

PLASTICPOSITIONS&TABPOSITIO

N

HANDWHEEL DIMENSION

2 5.00 5.75

1 2

25.005.75

3.00 3.00

3 3.34 4.08

1 2 3

33.344.08

2.17 5.50 2.17

4 2.50 3.25

1 2 3 4

42.503.25

1.75 4.25 4.25 1.75

5 2.00 2.75

1 2 3 4 5

52.002.75

1.50 3.50 5.50 3.50 1.50

6 1.66 2.41

1 2 3 4 5 6

61.662.41

1.33 3.00 4.66 4.66 3.00 1.33

7 1.43 2.18

1 2 3 4 5 6 7

71.432.18

1.21 2.64 4.07 5.50 4.07 2.64 1.21

8 1.25 2.00

1 2 3 4 5 6 7 8

81.252.00

1.13 2.38 3.63 4.88 4.88 3.63 2.38 1.13

9 1.11 1.86

1 2 3 4 5 6 7 8 9

91.111.86

1.06 2.17 3.28 4.39 5.50 4.39 3.28 2.17 1.06

10 1.00 1.75

1 2 3 4 5 6 7 8 9 10

101.001.7

5

1.00 2.00 3.00 4.00 5.00 5.00 4.00 3.00 2.00 1.00

.91 1.66

1 2 3 4 5 6 7 8 9 10 11

11.911.66

.96 1.87 2.78 3.69 4.60 5.50 4.60 3.69 2.78 1.87 .96

12 .83 1.58

1 2 3 4 5 6 7 8 9 10 11 12

12.831.58

.92 1.75 2.58 3.41 4.24 5.07 5.07 4.24 3.41 2.58 1.75 .92

13 .77 1.52

1 2 3 4 5 6 7 8 9 10 11 12 13

13.771.52

.89 1.66 2.43 3.20 3.97 4.74 5.50 4.74 3.97 3.20 2.43 1.66 .89

14 .71 1.46

1 2 3 4 5 6 7 8 9 10 11 12 13 14

14.711.46

.85 1.57 2.28 2.99 3.70 4.41 5.12 5.12 4.41 3.70 2.99 2.28 1.57 .85

15 .67 1.42

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

15.671.42

.82 1.49 2.16 2.83 3.50 4.17 4.84 5.50 4.84 4.17 3.50 2.83 2.16 1.49 .82

3-54

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 12” SHEET WITH3/16” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB

BANK

TAB
SIZE

TABS

PLASTIC
LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC
LENGTH

PLASTIC & TAB POSITION

3 3.87

1&3

4.41 2.22 2.12 4.62

2

6.00

4 2.91

1&4

3.45 1.74 1.64 3.66

2 3

4.55 4.55

5 2.33

1&5

2.87 1.45 1.35 3.08

2 3 4

3.67 6.00 3.67

6 1.94

1&6

2.48 1.26 1.16 2.69

2 3 4 5

3.09 5.03 5.03 3.09

7 1.66

1&7

2.20 1.12 1.02 2.41

2 3 4 5 6

2.68 4.34 6.00 4.34 2.68

8 1.45

1&8

1.99 1.01 .91 2.20

2 3 4 5 6 7

2.37 3.82 5.27 5.27 3.82 2.37

9 1.29

1&9

1.83 .93 .83 2.04

2 3 4 5 6 7 8

2.12 3.41 4.70 6.00 4.70 3.41 2.12

10 1.16

1&10

1.70 .87 .77 1.91

2 3 4 5 6 7 8 9

1.93 3.09 4.25 5.42 5.42 4.25 3.09 1.93

11 1.06

1&11

1.60 .81 .71 1.81

2 3 4 5 6 7 8 9 10

1.77 2.83 3.88 4.94 6.00 4.94 3.88 2.83 1.77

12 .97

1&12

1.51 .77 .67 1.72

2 3 4 5 6 7 8 9 10 11

1.64 2.61 3.58 4.54 5.51 5.51 4.54 3.58 2.61 1.64

13 .89

1&13

1.43 .73 .63 1.64

2 3 4 5 6 7 8 9 10 11 12

1.53 2.42 3.32 4.21 5.10 6.00 5.10 4.21 3.32 2.42 1.53

14 .83

1&14

1.37 .70 .60 1.58

2 3 4 5 6 7 8 9 10 11 12 13

1.43 2.26 3.09 3.92 4.75 5.58 5.58 4.75 3.92 3.09 2.26 1.43

15 .77

1&15

1.31 .67 .57 1.52

2 3 4 5 6 7 8 9 10 11 12 13 14

1.35 2.12 2.90 3.67 4.45 5.22 6.00 5.22 4.45 3.67 2.90 2.12 1.35

3-55

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 12” SHEET WITH1/4” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB

BANK

TAB
SIZE

TABS

PLASTIC
LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC
LENGTH

PLASTIC & TAB POSITION

3 3.83

1&3

4.44 2.24 2.17 4.58

2

6.00

4 2.87

1&4

3.48 1.75 1.68 3.62

2 3

4.56 4.56

5 2.30

1&5

2.91 1.47 1.40 3.05

2 3 4

3.70 6.00 3.70

6 1.92

1&6

2.53 1.28 1.21 2.67

2 3 4 5

3.12 5.04 5.04 3.12

7 1.64

1&7

2.25 1.14 1.07 2.39

2 3 4 5 6

2.71 4.36 6.00 4.36 2.71

8 1.44

1&8

2.05 .96 .97 2.19

2 3 4 5 6 7

2.41 3.84 5.28 5.28 3.84 2.41

9 1.28

1&9

1.89 .94 .89 2.03

2 3 4 5 6 7 8

2.17 3.44 4.72 6.00 4.72 3.44 2.17

10 1.15

1&10

1.76 .90 .83 1.90

2 3 4 5 6 7 8 9

1.98 3.13 4.28 5.43 5.43 4.28 3.13 1.98

11 1.04

1&11

1.65 .84 .77 1.79

2 3 4 5 6 7 8 9 10

1.82 2.86 3.91 4.95 6.00 4.95 3.91 2.86 1.82

12 .96

1&12

1.57 .80 .73 1.71

2 3 4 5 6 7 8 9 10 11

1.69 2.65 3.60 4.56 5.52 5.52 4.56 3.60 2.65 1.69

13 .88

1&13

1.49 .76 .69 1.63

2 3 4 5 6 7 8 9 10 11 12

1.58 2.46 3.34 4.23 5.11 6.00 5.11 4.23 3.34 2.46 1.58

14 .82

1&14

1.43 .73 .66 1.57

2 3 4 5 6 7 8 9 10 11 12 13

1.48 2.30 3.12 3.94 4.77 5.59 5.59 4.77 3.94 3.12 2.30 1.48

15 .77

1&15

1.38 .70 .63 1.52

2 3 4 5 6 7 8 9 10 11 12 13 14

1.40 2.17 2.93 3.70 4.46 5.23 6.00 5.23 4.46 3.70 2.93 2.17 1.40

3-56

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 12” SHEET WITH1/2” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

TAB

TAB

PLASTIC

PLASTIC POSITIONS & TAB POSITION

BANKSIZE SIZE

HANDWHEEL DIMENSION

3 3.66 4.41

1 2 3

2.33 6.00 2.33

4 2.75 3.50

1 2 3 4

1.88 4.63 4.63 1.88

5 2.20 2.95

1 2 3 4 5

1.60 3.80 6.00 3.80 1.60

6 1.83 2.58

1 2 3 4 5 6

1.42 3.25 5.08 5.08 3.25 1.42

7 1.57 2.32

1 2 3 4 5 6 7

1.29 2.86 4.43 6.00 4.43 2.86 1.29

8 1.38 2.13

1 2 3 4 5 6 7 8

1.19 2.56 3.94 5.31 5.31 3.94 2.56 1.19

9 1.22 1.97

1 2 3 4 5 6 7 8 9

1.11 2.33 3.55 4.78 6.00 4.78 3.55 2.33 1.11

10 1.10 1.85

1 2 3 4 5 6 7 8 9 10

1.05 2.15 3.25 4.35 5.45 5.45 4.35 3.25 2.15 1.05

11 1.00 1.75

1 2 3 4 5 6 7 8 9 10 11

1.00 2.00 3.00 4.00 5.00 6.00 5.00 4.00 3.00 2.00 1.00

12 .92 1.67

1 2 3 4 5 6 7 8 9 10 11 12

.96 1.88 2.79 3.71 4.62 5.54 5.54 4.62 3.71 2.79 1.88 .96

13 .85 1.60

1 2 3 4 5 6 7 8 9 10 11 12 13

.92 1.77 2.61 3.46 4.31 5.15 6.00 5.15 4.31 3.46 2.61 1.77 .92

14 .79 1.54

1 2 3 4 5 6 7 8 9 10 11 12 13 14

.89 1.68 2.46 3.25 4.03 4.82 5.60 5.60 4.82 4.03 3.25 2.46 1.68 .89

15 .73 1.48

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

.87 1.60 2.33 3.07 3.80 4.53 5.26 6.00 5.26 4.53 3.80 3.07 2.33 1.60 .87

3-57

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 14” SHEET WITH3/16” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB

BANK

TAB
SIZE

TABS

PLASTIC
LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC
LENGTH

PLASTIC & TAB POSITION

3 4.54

1&3

5.08 2.55 2.45 5.29

2

7.00

4 3.41

1&4

3.95 1.99 1.89 4.16

2 3

5.30 5.30

5 2.73

1&5

3.27 1.65 1.55 3.48

2 3 4

4.28 7.00 4.28

6 2.27

1&6

2.81 1.42 1.32 3.02

2 3 4 5

3.59 5.86 5.86 3.59

7 1.95

1&7

2.49 1.26 1.16 2.70

2 3 4 5 6

3.11 5.06 7.00 5.06 3.11

8 1.70

1&8

2.24 1.13 1.03 2.45

2 3 4 5 6 7

2.73 4.43 6.13 6.13 4.43 2.73

9 1.51

1&9

2.05 1.04 .94 2.26

2 3 4 5 6 7 8

2.45 3.96 5.48 7.00 5.48 3.96 2.45

10 1.36

1&10

1.90 .97 .87 2.11

2 3 4 5 6 7 8 9

2.23 3.59 4.95 6.31 6.31 4.95 3.59 2.23

11 1.24

1&11

1.78 .91 .81 1.99

2 3 4 5 6 7 8 9 10

2.05 3.29 4.53 5.77 7.00 5.77 4.53 3.29 2.05

12 1.13

1&12

1.67 .85 .75 1.88

2 3 4 5 6 7 8 9 10 11

1.89 3.02 4.16 5.29 6.43 6.43 5.29 4.16 3.02 1.89

13 1.05

1&13

1.59 .81 .71 1.80

2 3 4 5 6 7 8 9 10 11 12

1.76 2.81 3.86 4.90 5.95 7.00 5.95 4.90 3.86 2.81 1.76

14 .97

1&14

1.51 .77 .67 1.72

2 3 4 5 6 7 8 9 10 11 12 13

1.65 2.62 3.59 4.56 5.54 6.51 6.51 5.54 4.56 3.59 2.62 1.65

15 .91

1&15

1.45 .74 .64 1.66

2 3 4 5 6 7 8 9 10 11 12 13 14

1.55 2.46 3.36 4.27 5.18 6.09 7.0 6.09 5.18 4.27 3.36 2.46 1.55

3-58

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 14” SHEET WITH1/4” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB

BANK

TAB
SIZE

TABS

PLASTIC
LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC
LENGTH

PLASTIC & TAB POSITION

3 4.50

1&3

5.11 2.57 2.50 5.25

2

7.00

4 3.37

1&4

3.98 2.01 1.94 4.12

2 3

5.31 5.31

5 2.70

1&5

3.31 1.67 1.60 3.45

2 3 4

4.30 7.00 4.30

6 2.25

1&6

2.86 1.44 1.37 3.00

2 3 4 5

3.62 5.87 5.87 3.62

7 1.93

1&7

2.54 1.28 1.21 2.68

2 3 4 5 6

3.14 5.07 7.00 5.07 3.14

8 1.69

1&8

2.30 1.16 1.09 2.44

2 3 4 5 6 7

2.78 4.47 6.15 6.15 4.47 2.78

9 1.50

1&9

2.11 1.07 1.00 2.25

2 3 4 5 6 7 8

2.50 4.00 5.50 7.00 5.50 4.00 2.50

10 1.35

1&10

1.96 1.00 .93 2.10

2 3 4 5 6 7 8 9

2.75 3.62 4.98 6.33 6.33 4.98 3.62 2.75

11 1.23

1&11

1.84 .93 .86 1.98

2 3 4 5 6 7 8 9 10

2.09 3.32 4.54 5.77 7.00 5.77 4.54 3.32 2.09

12 1.12

1&12

1.73 .88 .81 1.87

2 3 4 5 6 7 8 9 10 11

1.94 3.06 4.19 5.31 6.44 6.44 5.31 4.19 3.06 1.94

13 1.04

1&13

1.65 .84 .77 1.79

2 3 4 5 6 7 8 9 10 11 12

1.81 2.85 3.88 4.92 5.96 7.00 5.96 4.92 3.88 2.85 1.81

14 .96

1&14

1.57 .80 .73 1.71

2 3 4 5 6 7 8 9 10 11 12 13

1.70 2.66 3.62 4.59 5.55 6.52 6.52 5.55 4.59 3.62 2.66 1.70

15 .90

1&15

1.51 .77 .70 1.65

2 3 4 5 6 7 8 9 10 11 12 13 14

1.60 2.50 3.40 4.30 5.20 6.10 7.00 6.10 5.20 4.30 3.40 2.50 1.60

3-59

F--9999-- 8 Issue 1

HANDWHEEL SET-UPS FOR 14” SHEET WITH1/2” MARGINS

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

TAB

TAB

PLASTIC

PLASTIC POSITIONS & TAB POSITION

BANKSIZE SIZE

PLASTICPOSITIONS&TABPOSITIO

N

HANDWHEEL DIMENSION

3 4.33 5.08

1 2 3

2.67 7.00 2.67

4 3.25 4.00

1 2 3 4

2.13 5.38 5.38 2.13

5 2.60 3.35

1 2 3 4 5

1.80 4.40 7.00 4.40 1.80

6 2.17 2.92

1 2 3 4 5 6

1.58 3.75 5.92 5.92 3.75 1.58

7 1.86 2.61

1 2 3 4 5 6 7

1.43 3.29 5.14 7.00 5.14 3.29 1.43

8 1.63 2.38

1 2 3 4 5 6 7 8

1.31 2.94 4.56 6.19 6.19 4.56 2.94 1.31

9 1.44 2.19

1 2 3 4 5 6 7 8 9

1.22 2.67 4.11 5.55 7.00 5.55 4.11 2.67 1.22

10 1.30 2.05

1 2 3 4 5 6 7 8 9 10

1.15 2.45 3.75 5.05 6.35 6.35 5.05 3.75 2.45 1.15

11 1.18 1.93

1 2 3 4 5 6 7 8 9 10 11

1.09 2.27 3.45 4.63 5.81 7.00 5.81 4.63 3.45 2.27 1.09

12 1.08 1.83

1 2 3 4 5 6 7 8 9 10 11 12

1.04 2.13 3.21 4.29 5.37 6.46 6.46 5.37 4.29 3.21 2.13 1.04

13 1.00 1.75

1 2 3 4 5 6 7 8 9 10 11 12 13

1.00 2.00 3.00 4.00 5.00 6.00 7.00 6.00 5.00 4.00 3.00 2.00 1.00

14 .93 1.68

1 2 3 4 5 6 7 8 9 10 11 12 13 14

.96 1.89 2.82 3.75 4.68 5.60 6.53 6.53 5.60 4.68 3.75 2.82 1.89 .96

15 .87 1.62

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

.93 1.80 2.67 3.53 4.40 5.26 6.13 7.00 6.13 5.26 4.40 3.53 2.67 1.80 .93

3-60

F--9999-- 8 Issue 1

METRIC HANDWHEEL SET-UPS FOR A4 (297mm x 210mm) TAB SIDE: 297 MM MARGIN: 0 MM

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB

BANK

TABS TAB

SIZE

PLASTIC

LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC

LENGTH

POSITION

DIMENSION

2 -- 148.50 158.50 84.25 74.25 --

3 1&3 99.00 109.00 59.50 49.50 118.00 2

148.50

4 1&4 74.25 84.25 47.00 37.00 93.25 2 3

111.25 111.2 5

5 1&5 59.25 69.25 39.50 29.50 78.25 2 3 4

89.25 148.50 89.25

6 1&6 49.50 59.50 34.75 24.75 68.50 2 3 4 5

74.25 123.75 123.75 74.25

7 1&7 42.25 52.25 31.00 21.00 61.25 2 3 4 5 6

64.00 106.25 148.50 106.25 64.00

8 1&8 37.00 47.00 28.50 18.50 56.00 2 3 4 5 6 7

55.50 92.50 129.50 129.50 92.50 55.50

9 1&9 33.00 43.00 26.50 16.50 52.00 2 3 4 5 6 7 8

49.50 82.50 115.50 148.50 115.50 82.50 49.50

10 1&10 29.50 39.50 24.75 14.75 48.50 2 3 4 5 6 7 8 9

44.25 73.75 113.25 138.00 138.00 113.25 73.75 44.25

11 1&11 27.00 37.00 23.50 13.50 46.00 2 3 4 5 6 7 8 9 10

40.50 67.50 94.50 121.50 148.50 121.50 94.50 67.50 40.50

12 1&12 24.75 34.75 22.25 12.25 43.75 2 3 4 5 6 7 8 9 10 11

37.00 61.75 86.50 111.2 5 136.00 136.00 111.25 86.50 61.75 37.00

13 1&13 22.75 32.75 21.25 11.25 41.75 2 3 4 5 6 7 8 9 10 11 12

34.75 57.50 80.25 103.00 125.75 148.50 125.75 103.00 80.25 57.50 34.75

14 1&14 21.00 31.00 20.50 10.50 40.00 2 3 4 5 6 7 8 9 10 11 12 13

31.50 52.50 73.50 94.50 115.50 136.50 136.50 115.50 94.50 73.50 52.50 31.50

15 1&15 19.75 29.75 19.75 9.75 38.75 2 3 4 5 6 7 8 9 10 11 12 13 14

30.00 49.75 69.50 89.25 109.00 128.75 148.50 128.75 109.00 89.25 69.50 49.75 30.00

3-61

F--9999-- 8 Issue 1

METRIC HANDWHEEL SET-UPS FOR A4 (297mm x 210mm) TAB SIDE: 210 MM MARGIN: 0 MM

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB

BANK

TABS TAB

SIZE

PLASTIC

LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC

LENGTH

POSITION

DIMENSION

2 -- 105.00 115.00 62.50 52.50 --

3 1&3 70.00 80.00 45.00 35.00 89.00 2

105.00

4 1&4 52.50 62.50 36.25 26.25 71.50 2 3

78.75 78.75

5 1&5 42.00 52.00 31.00 21.00 61.00 2 3 4

63.00 105.00 63.00

6 1&6 35.00 45.00 27.50 17.50 54.00 2 3 4 5

52.50 87.50 87.50 52.50

7 1&7 30.00 40.00 25.00 15.00 49.00 2 3 4 5 6

45.00 75.00 105.00 75.00 45.00

8 1&8 26.25 36.25 23.00 13.00 45.25 2 3 4 5 6 7

39.25 65.50 91.75 91.75 65.50 39.25

9 1&9 23.25 33.25 21.50 11.5 0 45.25 2 3 4 5 6 7 8

35.25 58.50 81.75 105.00 81.75 58.50 35.25

10 1&10 21.00 31.00 20.50 10.50 40.00 2 3 4 5 6 7 8 9

31.50 52.50 83.50 104.00 104.00 83.50 52.50 31.50

11 1&11 19.00 29.00 19.50 9.50 38.00 2 3 4 5 6 7 8 9 10

29.00 48.00 67.00 86.00 105.00 86.00 67.00 48.00 29.00

12 1&12 17.50 27.50 18.75 8.75 36.50 2 3 4 5 6 7 8 9 10 11

26.25 43.75 61.25 78.75 96.25 96.25 78.75 61.25 43.75 26.25

13 1&13 16.00 26.00 18.00 8.00 35.00 2 3 4 5 6 7 8 9 10 11 12

25.00 41.00 57.00 73.00 89.00 105.00 89.00 73.00 57.00 41.00 25.00

14 1&14 15.00 25.00 17.25 7.50 34.00 2 3 4 5 6 7 8 9 10 11 12 13

22.50 37.50 52.50 67.50 82.50 97.50 97.50 82.50 67.50 52.50 37.50 22.50

15 1&15 14.00 24.00 17.00 7.00 33.00 2 3 4 5 6 7 8 9 10 11 12 13 14

21.00 35.00 49.00 63.00 77.00 91.00 105.00 91.00 77.00 63.00 49.00 35.00 21.00

3-62

F--9999-- 8 Issue 1

METRIC HANDWHEEL SET-UPS FOR A4 (297mm x 210mm) TAB SIDE: 297 MM MARGIN: 1 MM

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB

BANK

TABS TAB

SIZE

PLASTIC

LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC

LENGTH

POSITION

DIMENSION

2 -- 147.00 157.50 80.75 74.75 --

3 1&3 98.00 108.25 56.00 50.00 117.25 2

148.50

4 1&4 73.75 83.75 43.75 37.75 92.75 2 3

111.50 111.5 0

5 1&5 59.00 69.00 36.50 30.50 78.00 2 3 4

89.50 148.50 89.50

6 1&6 49.00 59.00 31.50 25.50 68.00 2 3 4 5

74.50 123.50 123.50 74.50

7 1&7 42.00 52.00 28.00 22.00 61.00 2 3 4 5 6

64.50 106.50 148.50 106.50 64.00

8 1&8 36.75 46.75 25.25 19.25 55.75 2 3 4 5 6 7

56.00 92.75 129.50 129.50 92.75 56.00

9 1&9 32.75 42.75 23.25 17.25 51.75 2 3 4 5 6 7 8

50.25 83.00 115.75 148.50 115.75 83.00 50.25

10 1&10 29.50 39.50 21.75 15.75 48.50 2 3 4 5 6 7 8 9

45.25 74.75 114.25 136.00 136.00 114.25 74.75 45.25

11 1&11 26.75 36.75 20.25 14.25 45.75 2 3 4 5 6 7 8 9 10

41.50 68.25 95.00 121.75 148.50 121.75 95.00 68.25 41.50

12 1&12 24.50 34.50 19.25 13.25 43.50 2 3 4 5 6 7 8 9 10 11

37.50 62.25 86.75 111.2 5 135.75 135.75 111.25 86.75 62.25 37.50

13 1&13 22.50 32.50 16.25 12.25 41.50 2 3 4 5 6 7 8 9 10 11 12

36.00 58.50 81.00 103.50 126.00 148.50 126.00 103.50 81.00 58.50 36.00

14 1&14 21.00 31.00 17.50 11.50 40.00 2 3 4 5 6 7 8 9 10 11 12 13

32.50 53.50 74.50 95.50 116.50 137.50 137.50 116.50 95.50 74.50 53.50 32.50

15 1&15 19.50 29.50 16.75 10.75 38.50 2 3 4 5 6 7 8 9 10 11 12 13 14

31.50 51.00 70.50 90.00 109.50 129.00 148.50 129.00 109.50 90.00 70.50 51.00 31.50

3-63

F--9999-- 8 Issue 1

METRIC HANDWHEEL SET-UPS FOR A4 (297mm x 210mm) TAB SIDE: 210 MM MARGIN: 1 MM

NOTE: SHADED AREAS ARE ACHIEVED BY TURNING THE STOCK UPSIDE DOWN. THE MIDDLE TAB IS JUST TO THE LEFT OF THE SHADED AREA.

END TAB POSITIONS ONL Y ALL OTHER TAB POSITIONS

TAB

BANK

TABS TAB

SIZE

PLASTIC

LENGTH

PLASTIC

POSITION

TAB

POSITION

PLASTIC

LENGTH

POSITION

DIMENSION

2 -- 104.00 114.00 59.00 53.00 --

3 1&3 69.25 79.25 41.50 35.50 88.25 2

105.00

4 1&4 52.00 62.00 33.00 27.00 71.00 2 3

79.00 79.00

5 1&5 41.50 51.50 27.75 21.75 60.50 2 3 4

63.50 105.00 63.50

6 1&6 34.50 44.50 24.25 18.25 53.50 2 3 4 5

52.75 87.25 87.25 52.75

7 1&7 29.50 39.50 21.75 15.75 48.50 2 3 4 5 6

46.00 75.50 105.00 75.50 46.00

8 1&8 26.00 36.00 20.00 14.00 45.00 2 3 4 5 6 7

40.00 66.00 92.00 92.00 66.00 40.00

9 1&9 23.00 33.00 18.50 12.50 42.00 2 3 4 5 6 7 8

36.00 59.00 82.00 105.00 82.00 59.00 36.00

10 1&10 20.75 30.75 17.25 11.25 39.75 2 3 4 5 6 7 8 9

32.00 52.75 83.50 100.75 100.75 83.50 52.75 32.00

11 1&11 18.75 28.75 16.25 10.25 37.75 2 3 4 5 6 7 8 9 10

30.00 48.75 67.50 86.25 105.00 86.25 67.50 48.75 30.00

12 1&12 17.25 27.25 15.50 9.50 36.25 2 3 4 5 6 7 8 9 10 11

26.75 44.00 61.25 78.50 95.75 95.75 78.50 61.25 44.00 26.75

13 1&13 16.00 26.00 15.00 9.00 35.00 2 3 4 5 6 7 8 9 10 11 12

25.00 41.00 57.00 73.00 89.00 105.00 89.00 73.00 57.00 41.00 25.00

14 1&14 14.75 24.75 14.25 8.25 33.75 2 3 4 5 6 7 8 9 10 11 12 13

23.00 37.75 52.50 67.25 82.00 96.75 96.75 82.00 67.25 52.50 37.75 23.00

15 1&15 13.75 23.75 13.75 7.75 32.75 2 3 4 5 6 7 8 9 10 11 12 13 14

22.50 36.25 50.00 63.75 77.50 91.25 105.00 91.25 77.50 63.75 50.00 36.25 22.50

4 Maintenance

4--1

F--9999--8 Build 8 Issue 1

4 MAINTENANCE

4 Maintenance

4--2

F--9999--8 Build 8 Issue 1

4 Maintenance

4--3

F--9999--8 Build 8 Issue 1

4.1 Maintenance

4.1.1 Machine Lubrication

CHAIN

REDUCER

Fig. 4-1. Main Drive Gear

4.1.1.1 Main Drive

The Dodge Tigear reducer incorporates the unique
Relialube system which eliminates the lengthy
preparation normally required to put a reducer into
service. The Dodge Tigear reducer is properly filled
at the factory with sufficient lubricant for all
mounting positions.

The lubricant is Mobil SHC--634, a synthesized
hydrocarbon formulated for extremely long life. Do
not add or remove oil at installation or change oil
after break--in. Change oil only when

performing

maintenance that requires

gearbox

disassembly

.

Note ! If oil must be replaced, use only Mobil

SHC- 634 or Ultrachem Chemlube 140.
Do not confuse Mobil SHC - 634 with
Mobilgear 634. Mobilgear 634 is an EP
type gear oil NOT suitable for use in
the Relialube system.

CHAIN

CHAIN

PILE FEEDER GEARS

Fig. 4-2. Drive Chains

4.1.1.2 Chain Lubrication

Use chain lubrication CRC 03050 or Superior Graphite 35201G. Apply Lubricant to chain with machine set
to 2 or 3 on the speed adjustment control. Lubricant should be applied before chain is dry, once a month

or

about every 200 operating hours. Also apply lithium grease to Pile Feed gears.

Note ! Use CRC 03050 or Superior Graphite 35201G for Chain Lubrication.

Use White Lithium Grease for Pile Feed Gear Lubrication.

4 Maintenance

4--4

F--9999--8 Build 8 Issue 1

GREASE FITTINGS

(2 BACK SIDE)

Fig. 4-3. Grease Fittings on Vacuum Bar

4.1.1.3 Feeder Area Hand Fittings

Note ! Use White Lithium Grease for paper

feeder lubrication.

There are four hand grease fittings

in the paper

feeder area.

All fittings should be greased every 200 operating
hours or once a month. One shot of grease is all
that is necessary.

Two fittings are located on the ends of the vacuum
bar. To lubricate, remove the access covers.

GREASE FITTING

(1 FRONT)

Fig. 4-4. Grease Fitting -- Pile Lift Shaft

One hand grease fitting is located on the Pile Lift
Shaft.

GREASE FITTING

Fig. 4-5. Grease Fitting -- Inside Pile Feeder

One hand grease fitting is located inside the pile
feeder.

4 Maintenance

4--5

F--9999--8 Build 8 Issue 1

GREASE FITTING

Fig. 4-6. Plastic Feed Slide

4.1.1.4 Plastic Feed Slide

There is one grease fitting located on the plastic
feed slide inside the cover on the plastic feed
mechanism. This fitting should be lubricated

once

every month.

One shot of grease is all that is

necessary.

Note ! Use White Lithium Grease for Plastic

Feed Slide Lubrication.

ASSEMBLY UNIT / VENDOR UNITS INTERVAL LUBE SPECIFICATION

REDUCER (DODGE TIGEAR)

RELIALUBE SYSTEM

-- -- -- -- -- -- -- -- -- -- -- -- MOBIL SHC--634 OR ULTRACHEM
CHEMLUBE 140
(Change oil only when performing
maintenance that requires gearbox
disassembly.)

CHAINS 3 CHAINS 200 HOURS CRC 03050 or Superior Graphite

35201G

FEEDER (3 OUTSIDE, 1 INSIDE) 4 FITTINGS 200 HOURS White Lithium Grease

PLASTIC FEED SLIDE 1 FITTING 200 HOURS White Lithium Grease

Table 4-1. HAND LUBE LOCATIONS AND INTERVALS Part 1 of 1

4 Maintenance

4--6

F--9999--8 Build 8 Issue 1

Fig. 4-7. Gast Vacuum Pump Model
1023--101Q--G608X

4.1.2 Vacuum Pump Maintenance

Regular inspection can prevent unnecessary
damage and repairs. Intake and exhaust filters
require periodic inspection and replacement. Initial
inspection is suggested at 500 hours. After that,
user should determine the frequency. Keeping filter
clean can prevent most problems. Dirty filter
decrease unit performance and service life.

WARNING -- Muffler box may become very hot
during operation. Do not touch these parts until unit
has been turned off and allowed to cool.

Vacuum Pump Service Kit: HW --47110

Includes:
Van es ( 4)
Gasket (1)
ORing(2)
Felt (2)

VACUUM PUMP TROUBLESHOOTING GUIDE

REASON FOR PROBLEM LOW HIGH PUMP

-

MOTOR

-

VACUUM PRESSURE VACUUM PRESSURE

OVE

R

-

HEATING

OVE

R

-

LOAD

FILTER DIRTY X X AT P UMP X X

MUFFLER DIRTY X AT PUM P X X

VACUUM LINE COLLAPSED X AT PUM P X X

RELIEF VALVE SET TOO HIGH X X X

RELIEF VALVE SET TOO LOW X X

PLUGGED VACUUM / PRESSURE LINE X X AT PU MP AT P UMP X X

VANES STICKING X X

RUNNING AT TOO HIGH RPM X X X X

VANES WORN (REPLACE) X X

SHAFT SEAL WORN (REPLACE) X X

DUST OR OFFSET POWDER IN PUMP X X X X

MOTOR NOT WIRED CORRECTLY X X X

4 Maintenance

4--7

F--9999--8 Build 8 Issue 1

FELT

FILTER/MUFFLER

BODY

VANE

SHROUD

END PLATE

GASKET

MUFFLER BOX

END CAP
ASSEMBLY

END CAP

O--RING

Fig. 4-8. Gast Vacuum Pump Model 1023--101Q --G608X

4.1.2.1 Filter Inspection and Replacement

Step: 1. Make sure all power is turned off and all

pressure and vacuum is released from
the unit.

Step: 2. Remove filters and inspect.
Step: 3. Check for rips, tears, cuts, brittleness and

excessive foreign matter.

Replace immediately if any of the above
conditions exist.
If not, precede to the next step.

Step: 4. Clean with compressed air if filter looks

serviceable. Recheck for above

conditions.

Step: 5. Inspect filter/muffler for compacted

debris. Replace immediately if present.

Step: 6. Check o--ring for softness and pliability.

Replace if not.

Step: 7. Remove muffler box and inspect.
Step: 8. Clean out debris.
Step: 9. Check for cracks and tears in gasket.

Replace if necessary.

Step: 10.Reassemble muffler box.
Step: 11.Install filters and end cap.

Flushing

Should excessive dirt, foreign particles, moisture,or
oil be permitted to enter unit, vanes will act
sluggish or even break. Flushing unit should
remove these materials.
Caution -- Do not use kerosene or other
combustible solvents to flush unit. Use only Gast
AH225B flushing solvent or equivalent.