instruction manual older folder models

Baumfolder Corporation

Instruction Manual Older Folder Models

These instructions are written as a generic instruction manual for all older folders. If you have a Mark 2 or any other folder that has fixed right angle(s), where all sections are fastened together, ignore information where it mentions height of unit or movement of any section. The main difference of the fixed frame units is that you must remove the cross carrier to add the stacker after each unit.

Before working on the folder, DISCONNECT ALL ELECTRICAL POWER SUPPLY TO THE FOLDER to prevent the accidental start of the folder. Check to be sure you have the correct tools to complete the job.

For reasons of safety, long hair must be tied back or otherwise secured, garments must be close fitting and no jewelry, such as rings or necklaces, may be worn while adjusting or setting up equipment. Injury may result from being caught up in the machinery or jewelry catching in moving parts.

Good luck and good folding. You have a piece of equipment that was built with pride, quality parts and quality people.

Baumfolder Corporation 1660 Campbell Rd. Sidney, OH 45365 Copyright © 2002

Ph: 1-800-543-6107 Fax: 937-492-7280 email: [email protected]

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CONTENTS

THEORY OF OPERATION 3

REGISTER TABLE ADJUSTMENT 4

REGISTER TAPES AND TUCK IN SHOES 5

PROCEDURE FOR SETTING UP A MECHANICAL PILE FEEDER 6

OPERATING A FRICTION FEED BAUMFOLDER 11

SETTING UP A JOB

SETTING UP THE FOLDER 13 CALIBRATION OF THE ZERO BAUMSET 15 STACKER AND STACKER PAN 17 FIRST RIGHT ANGLE / EIGHT-PAGE SECTION 18 USING SLITTER SHAFT ACCESSORIES 20

CENTER TRIM OUT 21 RUN AND CUT MULTIPLE SHEETS AT ONCE 23 SCORING 24 PERFORATING 26 END TRIMS 28 KNOCKOUT PERFORATIONS 29

APPENDIX A – CALIBRATING CALIPERS 30 APPENDIX B – CALIBRATING PILE HIGH CONTROL 31



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THEORY OF OPERATION

Buckle Folding

As the sheet of stock leaves the register section, it is picked up by the #1 idler roll and main drive roll and is driven toward the paper stop in the fold plate. (See figure 1).

When the sheet of stock advances to the point where it strikes the fold plate paper stop (See figure 2). The leading edge stops but the remainder of the sheet is still gripped and being driven by the rollers. Since the sheet of stock is confined in the fold plates, it buckles in the space between the main drive roll and the #2 idler roll. As the sheet continues to advance, the buckle gets longer and is finally picked up between the main drive roll and the #2 idler roll and is pulled down between them, forming the fold.

The number of folds to be made is determined by the job requirements, but the sequence in which the folds are made is decided by the machine operator. Folding problems may require stripping and printing changes. Review the Baumfolder Imposition Manual for additional information on job layout.

Certain types of folds require that the grain of the stock be “weakened” along the proposed fold line to ensure a consistently accurate finished piece. This weakening or breaking down of the paper grain can be done in a number of ways, with scoring, perforating and wetting being the most common.

Fold Plates The numbering of the fold plates is shown in Figure 3.

The two up plates are #1 and #3 and the two down plates are #2 and #4.



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Register Table Adjustment

When setting up the initial job on your folder it is necessary to start with the adjustment of the register table.

TO POSITION THE SIDE GUIDE (see figure 4)

Loosen the MICRO-ADJUSTING KNOBS. Turn them to the center of the adjusting range.

Loosen the thumbscrews (underneath the left side of the register board) holding the SIDE GUIDE. Position the SIDE GUIDE so the end closest to fold rollers is about ¼ inch to the right of the left end of the knurl of the rollers.

Place a sheet of paper to be run firmly against the innermost edge of the SIDE GUIDE. Slide the sheet toward the rollers until it is approximately 2 inches from the fold rollers. Lift the first fold plate out and lay it in a safe place. Turn the hand wheel until the sheet of paper comes out of the first set of rollers. Watch the sheet to see if it comes out square, or if one corner comes out before the other. If one corner comes out before the other, move the MICRO ADJUSTMENT KNOB closest to the feeder in or out to square the sheet to the rollers. THE SIDE GUIDE SHOULD BE AT A 90 DEGREE ANGLE WITH THE ROLLERS.

Retighten the side guide thumbscrews.

The MARBLE RACK should be positioned with the end closest to the fold rollers approximately ¼ inch from the SIDE GUIDE and the other end approximately ¾ inch from the SIDE GUIDE.

The marble closest to the fold rollers should be directly over the TAPE ROLL.

Use mostly glass marbles in the MARBLE RACK except for heavy paper. For heavy paper, use mostly steel marbles. The purpose of the marbles is to hold the paper against the guide but not roll up in the guide when running.



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REGISTER TAPES

Register Tapes carry the sheets from the feeder to the fold rolls. As many tapes as possible should be positioned under the sheets carried to the fold rollers, with the left tape directly under the MARBLE RACK.

Unused tapes should be moved to the extreme right side of the register table.

Wooden spools located beneath the register table control the tape position. To position tapes loosen the thumbscrew holding the guide spool bracket. Slide the bracket right or left to the position desired. Tighten the thumbscrew.

To keep the sheet flat as it travels down the register table, place the HOLDDOWN ROD approximately 1 inch in from the right edge of the paper. TUCK- IN SHOES At least three TUCK-IN SHOES are recommended to hold the paper sheets flat for proper entry into the fold rollers. Place one over each edge and one in the middle of the sheet as shown.

Additional TUCK-IN SHOES will be required for larger sheets of paper.

Adjust the height of the TUCK-IN SHOES for enough clearance between the shoes and the paper to eliminate any drag on the paper but still hold it flat.



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Procedure for Setting up a Mechanical Pile Feeder

1. Place a strip of paper approximately 2” wide and at least 11” long under the marble holder and against the register side guide. Move the strip of paper toward the feeder keeping it against the side guide until it is a couple of inches past the blow bar into the feeder.

2. Set the left-hand vertical (angle type) pile guide one-eighth to one quarter of an inch closer to the center of the feeder than the strip of paper is to the register.

3. Place a sheet of the stock to be

folded on the pile feed table, using the corner guide to locate the sheet on the feed table.

4. Space the remainder of the vertical front pile guides across the width of the sheet. Be sure not to cover any of the openings on the blow bar.

5. Two paper support clips are provided to help support

the paper over the left-hand corner notch in the feed table.

(continued on next page)



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Procedure for Setting up a Mechanical Pile Feeder (Continued) 6. Loosen the thumbscrew on the air bracket

and blow bar; raise the blow bar as high as possible. Tighten the thumbscrew.

7. Loosen the two bolts on the air bracket and

move it toward the register table as close as possible without the blow bar rubbing the pull out roll. Tighten the two bolts.

8. Adjust the lever

on the blow tube to a straight up position so it can be moved forward or backward in the future. Now adjust the circular clips at a 45-degree angle toward the feeder. Adjust the circular clips on the right and left front edge of the sheet of paper to be at 90-degree angle.




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Procedure for Setting up a Mechanical Pile Feeder (Continued)

9. Now load about five inches of the stock you are to run on the feed table against the corner front vertical guide and the front vertical guides. The stock should be properly fanned and jogged before loading on the feeder. Keep the stock as flat as possible. Now raise the load with the hand crank until it is about 1-½ inches below the sucker feed wheel.

10. Install and adjust both the

right and left horizontal pile angle guides on the right and left edge of the sheets close enough to trap the air but not close enough to bind the sheets as they leave the feeder.

11. Two backstops are provided that mount on the horizontal pile angle guides at the tail of

the sheets. This is to prevent the sheets from being blown back from the top of the pile. 12. Loosen the setscrews on the feed wheel and the collar that compresses the spring that

holds the brass plate against the feed wheel and move them until the feed wheel is slightly off center toward the left side of the folder (operator side). Tighten the setscrew on the feed wheel. Apply just enough pressure on the collar against the spring and the brass plate to hold it to the feed wheel, and tighten the setscrew in the collar. The vacuum when the folder is running will hold the brass plate against the feed wheel, so the purpose of the spring is to have the brass plate against the feed wheel when the vacuum is turned on.




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13. Center the caliper in front of the feed

wheel. To move the caliper, first trip the throw off wheel so it will move side to side then reset the caliper and adjust it to allow one sheet to travel under the throw off wheel but not allow two sheets to pass. This is accomplished by turning the knob at the top of the caliper clockwise to raise the throw off wheel and counterclockwise to lower the throw off wheel. (For additional information on the caliper, see Appendix A, information on calipers.)

14. To set the pile height control adjustment,

the adjustment rod screw with the rubber cone should be aligned behind the feed wheel, approximately ¼ “ from the trailing edge of the sheet. Make sure square bars and connections do not bind when lifted and lowered. It must operate freely.

15. See Appendix B for the instructions on calibrating the pile high control and information on raising the pile 1,2,or 3 teeth at a time. This calibration should be made before setting up the feeder or folder and should not change unless something comes loose. For normal runs, the pile should be set to lift 2 teeth at a time.

16. There are additional shoes and fly rods to mount over the pile to prevent the sheets from “ bellying “ up. Use as many as necessary to keep the sheets fairly flat when feeder is feeding sheets The hold-downs should also hold the leading edge of the sheet down as it leaves the feeder and goes under the marble holder. Also, hold downs on the register and the shoe on the caliper help direct the paper through the path without catching.

17. Adjust the adjusting rod screw down as far as it goes by turning it clockwise. Make sure nothing is on the register or binds the folder by turning the hand wheel several times. If all clear, turn on the folder and allow the pile to raise. The pile should stop about and inch below the feed wheel. If the pile height control is NOT on the stock in the pile feeder, the feed board will continue to come up against the feed wheel and damage the folder. Be sure to watch the lift and if it comes close to the feed wheel, STOP THE FOLDER. Once the stock has stopped about an inch below the feed wheel, turn the pile height control screw counterclockwise to raise the stock until it is about three fourths to five eight below the feed wheel then tighten the locking nut on the pile height screw. Turn off the folder.




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18. Turn on the pump control and move the lever on the

blow bar so that the top 5 to 8 or 9 sheets of the stock are separating. Open the butterfly valve that controls the blow from the pump and then slowly begin closing it until sufficient amount separate the sheets about ¾ of the length of the sheet.

19. If the job is set up on the folder, open the butterfly that

controls the vacuum all the way and slowly close it until the sheets feed at a regular and steady rate.

20. When loading the feeder, use wedges to cause the top sheets to be level if necessary.

** End of Topic - Procedure for setting up a Mechanical Pile Feeder **



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Operating a Friction Feed Baumfolder

To position the LEFT FEED GUIDE, loosen the wing nuts (underneath the feed table). Position the guide approximately ¼ inch to the right of the register table SIDE GUIDE, and parallel to the left edge of the FEED TABLE. Tighten the wing nuts. Place a sheet of paper to be run against the LEFT FEED GUIDE. Loosen the wing nuts on the RIGHT FEED GUIDE and move it against the sheet. Leave enough clearance so the sheet falls freely from the top of the feeder to the PAPER FEED WHEEL. Tighten the wing nuts. The angle of the FEED TABLE affects of the fall of the paper as you load it. A normal setting for most jobs is with the TABLE BRACES set in the third notch from the top. Some of the feeders have brackets to move the feed table in or out by relocating the screw in the different holes in the bracket (see picture). The best location is the third hole back from the retarder adjustment screw. Position the RETARDER ROLL by loosening the thumbscrew and moving it to the center or slightly left of center of the sheet in the feeder. Move the FEED WHEEL directly over the retarder roll. Check to insure the setscrew in the retarder roll is tight and the retarder roll does not turn. Tighten the setscrew in the feed wheel so it is secured to the feed wheel shaft. Mount the PAPER GUIDES on the left and right edge of the sheet. These will go between the feed board and the FEED PLATE. Mount the FEED PLATE FORK on the round bar, with the fork straddling the retarder roll. (continued on next page)



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Operating a Friction Feed Baumfolder (Continued)

To correctly position the FEED PLATE FORK, the inside edge should be ¾ inch in front of the FEED PLATE, as shown here. ADJUSTING FOR PAPER FEEDING Adjust the Retarder Roll to allow a sheet of paper to go between the feed wheel and the retarder roll by moving the ADJUSTING SCREW KNOB up or down by turning it clockwise or counter clockwise. Turn the hand wheel on the folder several times to insure there is no bind or reason not to start the folder. Install the feed wheel cover over the feed wheel. If everything is all right, turn on the folder. Insert the sheet of paper you will run between the feed wheel and the retarder roll holding it loosely so not to pull your fingers into the feed wheel cover, turn the ADJUSTING SCREW KNOB clockwise slowly until you feel the sheet pulling out of your fingers. While the folder is running, paper dust will build up on the feed wheel. Stop the folder and clean the feed wheel if the sheets begin to feed erratically.

Turn off the folder

The PAPER GUIDE FLAP slides into the top slot of the PAPER FEED TABLE as shown here. The Paper Feed Flap prevents the sheet from “stumbling” on the feed table slot.

TUCK-IN ASSEMBLIES are mounted on the SQUARE BAR. One Tuck-in assembly mounts over the left side of the paper to guide the paper under the Marble Rack and the side guide. The other Tuck-in Assembly is mounted over the right side of the paper to guide it under the Hold-down rod.

The adjustment between the Feed Wheel and the Retarder roll feeds the sheet but also acts as a caliper. If you are pulling double sheets when feeding, tighten the Retarder Roll slowly until it feeds single sheets. ** End of Topic - Operating a Friction Feed Baumfolder **



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Setting up a Job

Before you set up any job, check the sample fold. The folder operator should make sure they have enough fold plates in the folder you will be using.

For an example: If you have a four-panel wrap around fold, you would need three up plates. That would mean you would either need a six-plate folder in the parallel or an eight-page unit (second section) to run in tandem. The four-panel wrap around would fold up in the number one fold plate then deflect past the number two, three, and four fold plates. Instead of having the eight-page unit at a right angle to the parallel, it would be running parallel with the parallel unit. The signature would go straight into the eight-page unit and make the last two folds in the number one and three fold plates. The purpose of not making two folds in the parallel unit and one in the eight-page unit is to allow a longer sheet/signature against the guide in the eight-page unit.

Space will not permit to go through all of the examples of the different folds. Baum has copies of a book titled “Imposition Manual”. Please call 800-543-6107 for your copy.

** Before starting to set up the job, DISCONNECT THE POWER SUPPLY **

SETTING UP THE FOLDER

1. We will describe setting up a Letter Fold on a three or four plate folder. Remove the first and third fold plates and lay them in a safe place where they will not get damaged.

2. We will use the number one and three fold plates, going up into the number one fold plate, deflect past number two fold plate then into number three plate deflecting the number four fold plate. We will go up one third in number one fold plate, setting the first fold roller with one thickness of paper. Two thickness will go through number two roll but the trailing one third will still be one thickness, so the number two roller will also be set at one thickness. (Always set the roller for the trailing thickness). The paper will deflect number two-fold plate and go through number three roller, again for one thickness. It still is one thickness for the last one third of the paper/sheet. The paper goes up in the number three fold plate one third, now we have three thickness into the number four roller so, set it for three thickness. We will deflect the number four-fold plate; so number five roller will be set at three thicknesses. And out the slitter shaft.

3. Cut two strips of paper approximately two inches wide and twelve inches long. Place a strip of paper, one on the left end of the roller and one on the right end of the roller. The strips should be approximately one inch from the each end of the roller. Using the hand wheel, back the strips of paper between the number one roller and the main drive roller about two or three inches, then rock the hand wheel the other direction to set the rollers. When turning the fold rollers backwards the rolls separate slightly. If you test the rollers before turning them forward, you would get a false setting. After rocking the rollers forward, pull on both (continued on next page)

Baumfolder Corporation 1660 Campbell Rd. Sidney, OH 45365 Copyright © 2002 Ph: 1-800-543-6107 Fax: 937-492-7280 email: [email protected]

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Setting up a Job (Continued)

( step 3 continued )

strips of paper. (The thickness of paper you are going to run). You want a drag as you pull the strips. If you have a folder with STANDARD TENSION SCREW ROLLER ADJUSTMENT, loosen the TENSION LOCKING NUT and turn the ADJUSTING KNOB clockwise to add tension on the strip of paper or counter clockwise to reduce tension on the strip of paper. Once you get an even drag on both strips of paper, tighten the Tension Locking Nut so the adjustment doesn’t change. Set the second roller with one thickness the same as you did the first roller except when you turn the strip of paper in the second roll, the rollers are turning forward so you do not have to rock it backwards. The third roller will be set with one thickness the same way as the number one roller. The number four and five rollers will be set with three strips, on top of each other, or three thicknesses using the same procedure as with the number one and two rollers. When setting the number five rollers, you should turn the sheets into the rollers and rock it forward to bring the rollers back together after backing the strips of paper into the rollers.

4. If you have Baumsets on your folder, read the next section on how to calibrate the Baumsets. Once they are calibrated, then all you have to do is put one thickness of paper in the right and left baumsets on the number one, two, and three rollers and three thickness of paper in the right and left baumsets on the four and five roller.

5. Now replace the number one and three fold plates, leave the deflectors up because the paper will go into both of these plates. Lower the number two fold plate and lower the deflector. We will be deflecting the number two-plate. Raise the number two-plate back into position.

6. Repeat the above procedure with the number four fold plate. You may have a three-plate folder and have a “dummy” deflector in the number four position. If so leave it as it is.

7. The FOLD PLATE STOP is equipped with THUMBSCREWS for major adjustments, and MICROMETER adjustment for close adjustments. Set the Fold Plate Stops at three and nine sixteenth and tighten the

(continued on next page) Setting up a Job (Continued)



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thumbscrews. Set the number three FOLD PLATE STOP at three and five eight’s. Tighten the Thumbscrews.

8. Turn one sheet through the folder until it leaves the folder and is ready to enter the

SLITTER SHAFTS. Place a PULL OUT TIRE approximately one inch from the left side of the sheet on the top shaft and one PULL OUT TIRE approximately one inch from the right side of the sheet. Turn the hand wheel to allow the folded sheet to leave the Slitter Shaft. Place two Pull Out tires directly the ones on the top shaft. Be sure to lock the brass point set screws in the pull out tires so they do not move.

9. Now turn the hand wheel several times to be sure nothing is loose and everything is in it’s

proper position, that hands, hair and all body parts are clear of the folder and that all guards are in the proper location. Now, start the folder and air pump (if applicable). Run one sheet and check the fold. Use the micrometer adjustments for the minor adjustments.

CALIBRATION OF THE ZERO BAUMSET DEVICE

Before the automatic roll setting feature can be used, it is necessary to calibrate it to ensure that the fold rolls are suspended the proper amount when paper is inserted into the Baumset tension screws. To calibrate the Zero Baumset, you should do the following:

1. Tear or cut some strips of paper approximately ½” x 1” in length. It is best to use 50-60# offset stock or equivalent, but some other weight can be used providing the same stock is used for all the adjustments.

2. Push down on the lever for the #1 Baumset on the left hand side of the folder. Insert a single thickness of one of the paper strips, prepared in step #1, in the Baumset tension screw. Gently push up on the Baumset lever to make sure it is seated.

3. Loosen the Baumset knob assembly, which locks the tension screw in place.

4. Insert a single thickness of paper stock, of the same weight as used in the Zero Baumset device, between the #1 fold roll and the stationary fold roll. Be sure the paper is free of tears or folds. The strip of paper should be inserted approximately 1” from the left hand roll band or between the first rubber segment of the combination fold roll. To insert the strip of paper, turn the handwheel

(continued on next page) Setting up a Job – Calibration of the zero Baumset (Continued)



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counterclockwise, rocking back and forth to be sure the rollers are seated. (Note: When setting the #3 and #5 Baumsets, it will be necessary to turn the handwheel clockwise to roll the strip in place.)

5. Adjust the micro adjustment knob until you can pull the strip of paper out from

between the #1 and stationary roll using a steady, light pull. You should feel an even drag of the sheet.

6. Tighten the Baumset lock knob. Remove the pull strips. 7. Repeat the procedure outlined in steps #2 through #6 for the #1 RH Baumset. 8. Check the adjustment on both the LH and RH sides of the fold rolls to ensure an even

pull on each side. 9. Repeat the process outlined in steps #2 through #8 for the #2, #3, #4 and #5

Baumsets. Be sure to use the same thickness of paper throughout the calibration. To set the Zero Baumset dial, remove all the strips of paper from the Baumset adjustment gap and:

Locate the micro adjustment knob so that the top is level with the top of the lever. The Zero Baumset dial should be seated on the stem lock nut. It will be necessary to loosen the stem lock nut and screw the micro adjustment knob up or down if it is not level with the top of the dial.

At this time, align the triangle on the lever and the triangle on the Zero Baumset dial. (See triangle alignment illustration on the previous page) Make certain the Baumset lock knob is tight so the tension screw doesn’t turn while the micro adjustment knob is adjusted up or down. Recheck the calibration to be sure the tension screw did not turn. Retighten the stem lock nut. NOTE: The micro adjustment knob must be level with the lever to ensure a proper reference point for the triangle alignment in case the micro adjustment knob is turned 360 degrees up or down. If it is not level indicates that the micro adjustment knob should be readjusted.

Now the Zero Baumset is calibrated. To set up a job, refer to the operation of the Baumset. (continued on next page)



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Setting up a Job – Calibration of the zero Baumset (Continued)

Once the Baumset has been calibrated or zeroed-in the fold rollers can be set automatically with a designated amount of paper in each Baumset or each roller can be set manually. To calibrate rolls:

1. Be sure all rolls are closed (together). Turn tension screw until washer (A ) is just touching Roll Brg ( B ).

2. Insert one thickness paper (small) into each Baumset ( C ) lift lever ( D ) to insert.

3. Using same type paper, cut two strips of paper 2” x 10” and insert into rolls starting with #1 roller and proceed with same procedure through #5. (Baumset is number 1,2,3,4,5) Insert strips on right and left side by lifting lever ( D ) and inserting strips, or with power off, turn sheets into rolls by turning hand wheel. NOTE: If turning rollers backward inserting paper, rock them in forward motion to set the gears to insure rolls together.

4. With lock screw ( E ) loose, turn tension screw counter clockwise and pull on strip of paper at the same time until you can feel it starting to move. Repeat same motion on other end of fold roller. Recheck to be sure both ends of the roll has a snug drag (equal). Lock the tension setting with lock screw ( E ). Recheck again to insure you still have same setting.

5. Repeat on the #2 then #3 and etc… STACKER AND STACKER PAN 1. The STACKER can be placed after any of the folding sections depending on the type of

the fold being made.

2. The STACKER WHEELS are adjustable back and forth for different length sheets. Lay the folded sheet/signature on the stacker with the trailing edge against the pull out tires on the slitter shaft, move the stacker wheels at the leading edge of the sheet/signature and lock them in place with the thumbscrews. Two flat STACKER SPRINGS are provided to fasten on the square bar above the slitter shafts. These should be bent so they hold the



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Setting up a Job – Stacker and Stacker Pan (Continued)


trailing edge of the sheet/signature down so as the next sheet/signature comes out, it does not strike the previous sheet/signature. The Stacker Springs can be bent so they apply enough pressure to hold the sheet/signature in place until the next sheet/signature comes out. This is used when you don’t want to use the Stacker Wheels. A map fold is an example of when you would not use the stacker wheels. The bulk of the folds cause the maps to jam up at the stacker wheels.

3. There are adjustment screws at the rear of the stacker frame to tighten or loosen the Stacker Belt, to allow it to track straight. If the stacker belt is moving to the left of the stacker, tighten the left adjustment. Allow several minutes to allow the belt to respond before you make another adjustment.

4. Install the STACKER PAN. Now you are ready to run. FIRST RIGHT ANGLE/ EIGHT-PAGE SECTION ( This instruction can be used for any other rollaway units.) 1. Height adjustment may vary depending on the job you run. For an example, if you want

the sheet/signature to overlap (a sheet leaving the parallel at the same time the previous sheet/signature is in the cross carrier guide moving toward the fold rollers), you would have the height of the unit lower. Normal height would be that the top of the cross carrier would be at the bottom of the lower slitter shaft.

2. The purpose of the cross carrier is to accept the sheet/signature out of the previous unit

and instead of stacking, direct the sheet/signature into the next set of rollers. This can be in tandem (Straight in line with the previous unit) or at a right angle with the previous unit.

3. Lay the sheet/signature as it leaves the

previous unit on the cross carrier with the trailing edge at the edge of the left side of the cross carrier rolls. Hold the sheet/signature so it doesn’t move and bring the cross carrier guide so it is against the sheet/signature. Turn the hand wheel until the sheet enters the number one fold plate. If the sheet/signature jams, move the guide back toward the right side. If this change has to be made, you have one of the earlier models Baumfolders.




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Setting up a Job – First Right Angle (Continued)

4. Square the guide the same way you squared the register side guide. On older Baumfolders, there are two bolts on each side of the thumbscrew. Loosen the bolts to move the guide. On the newer Baumfolder, they have micro adjustments. Once the guide is squared (90 degrees) with the fold rollers, tighten the bolts.

5. Put two steel marbles in the MARBLE HOLDER in the center where the sheet/signature enters the Marble Guide and one or two steel marbles in the end of the MARBLE GUIDE just before the sheet/signature enters the fold rolls. Put glass marbles in the rest of the Marble Holder. Replace the MARBLE HOLD DOWN. Once you are running, you may have to change some of the marbles to keep the sheets/signatures against the guide. This depends on the material you are running. The suggestion given about the marbles is a starting point.

6. The fold rollers and the fold plates are adjusted the same as the first unit. Refer to the FOLDER instructions. The STACKER instruction is the same.

7. Always score or perforate in the parallel section before going into the eight page section (first right angle unit). Scoring is not as important when folding the sixteen-page unit (second right angle unit). You perforate to allow the air to escape. It might be a good habit to always score or perforate if you are folding even in the sixteen or thirty-two page unit.

** End of Topic – Setting up a Job **



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Using Slitter Shaft Accessories

You can perforate, score, take out trim outs (gutter trim), and end trim on your folder. Once you know how to use them and what they do, the more profitable your folder becomes. Each will be described separately but you can use a combination of any or all them together. Baum produces an Imposition Manuel to show 144 different types of folds and which fold plates to use for each one, plus the layouts. You can write to Baum for your copy. We hope this will be of value to you and help to increase your present folder value by producing more in profits for you. Our ultimate goal is to sell new equipment, but we also realize our responsibility to you and to the many others who have bought our equipment in the past. Let us know how we can help you. Please call 1-800-543-6107 for part numbers not listed. Different folders have different part numbers required. The pictures below represent some of the accessories discussed next in this manual.


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Center Trim Out on your Baumfolder

The purpose of the center trim, sometimes called gutter trim, is to be able to print signatures two up and trim out the center on the folder and chase on the cross carrier into the second fold section. This allows you to have two signatures at the same time and doubles your production.

This is accomplished by mounting four slitter blades on four blade holders. The two top blades and blade holders are mounted with the sharp cutting edge toward the blade holders. For ¼ inch trim out, butt the blades together. For a wider trim out, separate the slitter blades the width you want to trim out. The bottom slitter blades are mounted with the sharp cutting edge away from the blade holder. This allows the scissor action of both blades to push the trim down between the two bottom slitter blades. That means you have to have a stripper to deflect the trim down and away from the bottom slitter blades. You can use the stripper shown in figure 1 that fastens on the bar under the slitter shafts. If the folder you are using doesn’t have this bar, you can use the brass ring, shown in figure 2, and a wire around it and let the end of the wire hang in front of the end frame of the folder. This carries the trim down between the first section of the folder and the second section to the floor. There are other times when you can use the gutter trims. You can run multiple numbers of religious tracts, or other types of brochures then cut out trims between them and cutting end trims off the left and right sides. You can run from two up on a sheet up to five or six up, depending upon the size of the folder and the size of the tracts or brochures.

Figure 3 shows the center trim out being deflected down to the floor. (continued on next page)


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Center Trim Out (Continued) When mounting the blade to the blade holder, leave the screws loose, then slide the blade holder and the blade on the slitter shaft before you tighten the screws. This aligns the blade and the blade holder so they slide onto the slitter shaft. The parts and the part numbers are listed below. For 7/8 slitter shafts Blade Holder 06411or 06413 Slitter blades (Counter sink beveled side) 06378 Slitter blades (Counter sink flat side) 06804 Screw slitter blade (two per blade) 07728 Center stripper (picture one) 1/8 wide 15701 Center stripper (for wider trim out) ¼ wide 15700 Wire stripper-center brass (picture 2) 1/8 263-781-BG-01 Wire stripper-center brass (wider trim outs) 263-780-BG-01 For 1 1/8 slitter shafts Blade holder assembly S52083 Slitter blade 93209 Screw slitter blades (three per blade) 07728 Wire stripper brass (all 1 1/8 shafts) 1/8” 267-662-BG-01 Wire stripper brass (all 1 1/8 shafts) ¼” 267-663-BG-01 ** End of Topic – Center Trim Out **



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Run and cut multiple sheets at the same time

There are times when you have a small sheet to run such as small religious tracks and it would be better if you could run them three or four up. That’s no problem. If you want to slit with no trim out, just install a slitter blade mounted on a blade holder on the top slitter shaft and one on the bottom slitter shaft with the flat sides together as shown in the picture. Since there is no trim out, you do not have to be concerned which blade is on the inside and which blade is on the outside. You do not have a trim out to worry about. If you want to take end trims and take trims out, read the topics for center trims and end trims. Remember when you mount the slitter blades on the blade holder, start the screws through the slitter blade into the blade holder then slide the collar on the slitter shaft before you tighten the screws. This aligns the slitter blade and the blade holder. Part numbers for 7/8 inch slitter shaft Slitter blades (1of each per cut) 06378 & 06804 Blade holder (2 per cut) 06413 Screw-filstr (4 per cut) 07728 ** End of Topic – Run and cut multiple sheets **



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S coring on your Baumfolder

The folder can be used to score a sheet and deliver flat, or score a sheet after a fold or folds have been made.

To ensure accuracy in making right angle folds, always score the sheet where the fold or folds are to be made. This applies in all instances when a perforator cannot be used. A rule to remember is to fold up (fold in # 1 or / and #3 fold plate), score down. To fold down (#3 or/and #4 fold plate), score up. There are some, which claim the opposite is correct. Both opinions are presented so you can try them both and make your own decision. Most of the folder operators have the first opinion and the paper manufacturers have the second opinion.

There are different types of score blades. The narrow or light score blade is used most of the time. The heavy score blade or wide score blade is used when folding bulk or several sheets. You can score against a rubber collar, score between scoring collars, or a scoring die. To mount the Score Blade on the Blade Holder, place the two screw into the collar through the score blade. Do not tighten them until the collar and blade are put on the slitter shaft. Then tighten the two screws.

Scoring against a scoring die gives a press type score. This is the best type score for hand folds later or folding in the next fold section. This type score is only used with folders that have an adjustable slitter shaft. The score blade runs in the groove in the scoring die. It is important to center the score blade in the groove. Adjust the score blade so there is space between the score blade and the scoring die. Adjust the slitter shaft to get the best score.

Scoring between two slitter collars is probable the best for folders without adjustable slitter shafts. The scoring collars have a rounded side and a beveled side on each collar. The purpose for this is to create different types of scores. The two rounded edges toward the score blade create a softer score. The two beveled edges toward the score blade create a sharper score. Moving the scoring collars closer to or away from the score blade increases or decrease the depth of the score. If you use the scoring collars with one beveled side and one rounded side toward the score blade, the score will be crooked. As a helpful hint, use the rounded edges toward the score blade. Take regular cloth tape like you use in first aid, and place ½ on one collar and ½ on the other collar. The tape will span from one collar to the other. Turn the hand wheel of the folder until you came to where you started and cut the tape. This will give you a soft surface to score against. You can still move the collars in and out without changing the tape.




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Scoring (Continued)

Scoring against the rubber collar gives you a nice score. For this application, the score blade and the scoring collar is mounted on one shaft and the scoring rubber with metal scoring collar on each side of the scoring rubber on the other slitter shaft. To create a deeper score, squeeze the collars together against the scoring rubber as shown in the bottom picture. The one draw back to this type score is that the more you squeeze the scoring rubber, the less control you have after the sheet leaves the fold rollers. When you apply pressure to the score blade to create a deeper score, the less pressure you have on the pull out tires. The last 7/8-inch of the score sometimes trails off. This can give you problems in your fold in the second fold unit. ** End of Topic – Scoring **



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Perforating on your Baumfolder

The purpose in using a perforator is to allow air to escape. With certain types of folds such as wrap around folds, it pockets air and it is not allowed to escape. This causes ripples or “crows feet”. This is not acceptable in quality printing. The cuts in the perforation allow the air to escape. Normally the perforation is in a trimmed area. You can use commercial perforators for coupons or tear off to return for value, but it leaves a push out on the back of the paper. This is acceptable in most Mailings. The perforator holds the sheet and would wrap around the shaft. The stripper is mounted on the bar above the slitter shaft and between the top and bottom slitter shaft to strip the sheet off the perforator blade. You can mount it beside the perforator blade and it is less likely to get caught in the perforator blade. When fastening the blade to the collar, do not tighten the screws until you slide the collar and blade onto the slitter shaft. Tighten the two screws and then locate the perforator where you want it. Mount the perforator collar under the blade with the blade in the wide groove of the perforator collar. Move the sharp edge of the perforator blade against the edge of the groove in the perforator collar and tighten the brass point set screw to lock it in place. Then install the stripper assembly. If you visualize the bevel of the perforator blade as an arrow, the arrow should point to the next fold section. The parts and the part numbers are listed below.

For 7/8” slitter shaft

Collar Blade Holder 06411 or 06413 Screw-filstr 10-24x3/8 20312 (two required) Perforator collar 06799 Perforator blades (Reference the chart on the next page) For 1-1/8 slitter shafts

Collar Blade holder 52092 (Always mount on the slitter shaft so that as the shaft turns the normal direction, the knurled nut tightens)

Collar-perforator 10360 Perforator blades (Reference the chart on the next page)

*See your parts book for the part number for the stripper assembly or call BAUM or your local Baumfolder Dealer. There are several different types of strippers for different model folders.




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Perforating (Continued)

BAUMFOLDER Perforator Blade Chart

Perforator Blades for Baumfolders with 7/8” Slitter Shafts

Perforator Blades for Baumfolders with 1-1/8” Slitter Shafts

Solid Blades

Split Blades

For more information or to order contact your local Baumfolder Dealer or call or fax the Baum Parts Department at

Phone: 800 / 543-6107 Fax: 800 / 452-0947

** End of Topic – Perforating **



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End Trims on your Baumfolder

Taking off END TRIMS has too many advantages to list here. If you have a printed sheet that you want to trim off both sides, you can mount the end trims on the folder and save the operation of the paper cutter. The cut is made on one or both sides and the trim is deflected onto the floor under the folder. To be successful you should have a trim of at least ¼ inch. Some have taken a smaller trim, less than ¼ inch, and are successful but most of the time it’s difficult. Mount two slitter blades on the blade holder with the sharp side toward the blade holder. Remember to slide the blade and the blade holder onto the slitter shaft before you tighten it. Use flat head screws to mount the slitter blade. Mount two slitter blades with the bevel side of the slitter blade toward the blade holder. Mount the slitter blade and blade holder with the slitter blade with the beveled edge toward the blade holder on the top shaft, with the blade holder toward the slitter shaft boxing. Then mount the slitter blade with the sharp edge toward the blade holder on the bottom slitter shaft, with the blade holder toward the slitter shaft boxing on the right side of the folder. Locate the blade assembly on the top shaft where you want the out side trim and tighten the set screw. Slide the slitter shaft blade assembly on the bottom slitter shaft until the sharp edge of the slitter blade is against the sharp edge of the top slitter blade and lock it in place. Place a pullout tire assembly against the slitter blade on the bottom slitter shaft and one on the top slitter shaft directly over the one on the bottom slitter shaft. Space several pullout assemblies to control the sheet as it leaves the fold rollers. REVERSE the procedures for the slitter blades on the operator side. Both of the top slitter blades should be on the outside. This will cause the trim to turn down as it is cut, making it easier to deflect down. Mount the stripper deflectors as illustrated in the pictures ** End of Topic – End Trims **



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Knock out Perforator Assembly

A special Knock-out Perforator is available for improved perfect-binding operations and saddle stitching on your Baumfolder. When signatures are brought from the folder, they are vacuum fed on most types of binders and stitches. With some perforations, the vacuum can pull the sheets apart at the perforations, causing problems with the feeding. By substituting the knock-out perforator, the signatures hold together, thus reducing the problems on the binders and the stitchers. The time you save on the finishing equipment will pay for the knock-out perforator. The knock-out perforator also allows the air to escape when folding all bookwork, and provides an improved adhesive surface for perfect binding. When using the Knock-out Perforator, the punched out pieces are separated and stripped from the folded pieces. The initial price of the Knock-out Perforator may be more expensive, but the life of the assembly is probably two or three times long than an standard perforator, plus consider the labor and down time you save. When mounting the perforator blade, the longer part of the tooth contacts the paper first then the short part of the tooth knocks the knock-out out of the paper, (signature). The blade holder should be mounted on the shaft so that the knurled knob tightens as the slitter shaft turns the forward direction. The perforator should be on the top slitter shaft so the pieces of paper knocked out falls on the floor.

** End of Topic – Knock our Perforator assembly **



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Appendix A - To Calibrate Caliper

Turn Caliper Adj. knob counter clockwise and push down until Throw off wheel contact the Feed Roll. Loosen set screw ( A ) – insert a Dime (10¢ piece) between Caliper squaring block and Throw off wheel setting lever. Make sure Draw roll latch is latched on to caliper reset pin. Apply light pressure down on Caliper adj. knob and tighten set screw ( A ). Remove dime and adjust caliper by turning Caliper adjust knob clockwise until one (1) sheet of material you are running moves free between Throw off wheel and the feed roll but not two (2) sheets. The set screw with the ½” nut on the left side of the Caliper squaring block should be set so the block slides up and down free but doesn’t rock back and forth. ** End of Appendix A – Calibrating Caliper **



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Appendix B - Calibrate Pile High Control

Provision is made for raising the pile more or less quickly to compensate for various sizes and thickness of stock. The ratchet mechanism used to raise the pile can be adjusted to provide a 1/32”, 1/16” or 3/32” rise per engagement of the ratchet.

To time the feeder for 1/32” or 1/16” rise, remove the cover; position the crank gear and lift operating arm as shown above. With the lift operating arm in hole A, the ratchet pawl will move the ratchet two teeth and raise the pawl 1/16”. Be sure the pile height screw is not in contact with the stock. Adjust the lift stem adjusting nut so the latch pin is just 1/32” above the pawl lever latch. Loosen the latch pin adjusting screw and position the latch pin 1/32” away from the pawl lever latch as shown.

When the latch is in the proper position, tighten the latch pin adjusting screw.

A bent wire is mounted on the casting next to the ratchet pawl (not shown). This wire may be positioned so the free end is under the pawl. With the wire under the pawl, only one tooth of the ratchet will be engaged, providing only 1/32” rise or vice versa, entails merely moving the wire. No other adjustments are necessary. An operator may have previously bent this wire up or down, but by operating the machine a short time with the feeder empty or with the pile lowered, you will quickly see how the wire must be adjusted to properly perform its function. (continued on next page)



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Appendix B - Calibrate Pile High Control (Continued)

To time the feeder for a 3/32” pile rise, rotate the crank great 180 degrees from what is shown in the picture on the previous page. This will reverse the positions of holes A and B. Install the lift operating arm in hole B and adjust the latch pin the same as described for the 1/32 - 1/16 rise adjustment. If heavy stock such as cover stock is being run and the pile doesn’t seem to come up fast enough, set the feeder to rise 3/32” per ratchet engagement (three ratchet teeth). When running very light paper, possibly 1/32” (one tooth) will be sufficient. For the usual run of paper, having the pile rise frequently in shorter strokes attains more uniform separation. By watching the operation, one can tell what amount of rise to use. When the correct pile height as been sensed, the latch pin should engage the pawl lever latch by approximately 1/32” on contact. (See figure at right) This is set by adjusting the engagement adjusting screw under the latch pin. ** End of Appendix B – Calibrating Pile High Control ** ** End of Document **



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