OWNER’S MANUAL FSC (Fletcher Substrate Cutter) The Fletcher-Terry Company 65 Spring Lane • Farmington, CT USA 06032-3311 Tel 860.677.7331 • Toll-Free 888.888.5165 • Fax 860.676.8858 • customerservice@fletcher-terry.com • www.fletcher-terry.
FSC OWNER’S MANUAL – TABLE OF CONTENTS Section Page # INTRODUCTION……………………………………………………iii PRODUCT WARRANTY…………………………………………..iii SAFETY FIRST……………………………………………………..iv 1.0 ASSEMBLY 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 2.0 SET UP AND CALIBRATION 2.1 2.2 2.3 3.0 Squaring the FSC……………………………………………………..14 Setting the Scales…………………………………………………….15 Adjusting the Clamp Assembly…………………………………….16 CUTTING TOOLS AND SUBSTRATES 3.1 3.2 3.3 4.0 Unpacking the FSC……………………………………………………..
Section (cont.) 5.0 LASER INSTALLATION 5.1 5.2 5.3 5.4 5.5 6.0 Page # Setting up the Laser Sight Attachment………………….……….26 Mounting the Laser………………………………………….……….26 Dual-Position Laser………………………………………….………27 A. Wheel Cutting Position………………………………………....27 B. Blade Cutting Position…………………………………...……..27 Creating Score Lines for Laser Calibration……………………..27 Aligning the Laser to Cut/Score Line Positions………...……...28 MAINTENANCE, ADJUSTMENTS, TROUBLESHOOTING, FAQs 6.1 6.2 6.3 6.
Introduction Thank you for purchasing the Fletcher Substrate Cutter (FSC). Our history of quality, our reputation for innovation, and our superior customer service combined with this amazing product, is designed to make your business more profitable than you ever imagined. We want your experience using the FSC to be exceptional, so for maximum safety and productivity, please read and understand this manual thoroughly before you operate your new Fletcher Substrate Cutter.
SAFETY FIRST! Please read through this manual before operating the Fletcher Substrate Cutter (FSC). If after reviewing these pages you still have questions about using the machine, contact our Customer Service Department toll-free at 1.800.843.3826 in the United States. Outside the United States, call ++860.677.7331 or email: customerservice@fletcher-terry.com. ¾ It is the employer’s responsibility to enforce compliance with these safety warnings and procedures by all who use the FSC.
1 ASSEMBLY ♦ Important Notes: 1.1 • To assemble the FSC, you will need a clear workspace of approximately 10'x10'. • All views mentioned for the assembly of the FSC are from the perspective of the customer facing the standing machine. • All bolts are inserted from left-to-right, or from front-to-back. Unpacking the FSC Check the exterior of the shipment carton to make sure there is no visible damage. After unpacking the unit, check to make sure all the parts listed below are present and undamaged.
1 1.4 ASSEMBLY Tools Required for Assembly a. 2.5mm , 3mm, 4mm, 5mm, and 6mm Hex Keys (included with Box #3, shown at right) b. 8mm, 10mm, 13mm, and two (2), 17mm Wrenches c. Philips Head Screwdriver d. Drill (wall-mounted unit only) a. e. Carpenter’s Level (wall-mounted unit only) 1.5 Frame Parts List 1. 2. 3. 4. Large Face Plate Center Adjustable Leg Left Leg Bottom Right Leg Bottom 5. 6. 7. 8.
1 ASSEMBLY 1.6 Hardware List N All items shown here are contained in Hardware Box #4 D C R I F E O B Note: Please keep all hardware items in their separate bags until ready for assembly. Each bag will be called for next to the caption photo of the corresponding step. G J A P V U S Q Hardware Size / Description L M K T H Item A B C D E F G H I J Qty.
1 ASSEMBLY Preparation a. Remove the Vertical Track assembly from the shipping carton with assistance from at least one other person. Set the assembly onto two of the foam packing inserts so that the cutting head is facing up (Figure a). b. Slide the cutting head upward to the approximate midpoint on the track, and lock it into position with the locking knob (Figures a and b). Set on Foam Packing inserts Figure a Figure b 1.7 1.
1 ASSEMBLY 2. Attach the Small (triangular) Face Plate (item #8) with seven (7) more M6 x 20 flat head screws (K). (Figure 2) Figure 2 3. Attach the Large Face Plate (item #1), with the remaining six (6) M6 x 20 flat head screws (K). Tighten all of the flat head screws now with a 5mm hex/Allen key (Figure 3). Figure 3 Hardware bag a Figure 4 4. Locate the Horizontal Material Bar (item #5), and slide it over and through the Vertical Track Assembly from right to left, as shown (Figure 4). 5.
1 ASSEMBLY Hardware bag b 6. Insert the Pivot shoulder bolt (M) through the Horizontal Material Bar and into the hole in the Vertical Track assembly, just to the right of the main extrusion (Figure 6). Make certain that the shoulder of the bolt has been inserted correctly, and then tighten securely with a 6mm hex key. Important! Insert this Pivot bolt FIRST. Figure 6 7.
1 ASSEMBLY Hardware bag c 10. Attach the left leg to the Horizontal Brace Channel using two (2) M8 x 50 button head screws (Q), flat washers (O), and lock washers (T). Insert the screws into the threaded holes on the rear of the channel plate, and tighten securely with a 5mm hex key (Figure 9). Figure 9 11. Locate the right leg (left side of machine, now facing downward). Slide the right lower leg section (item 4) into the main right leg section (Figure 10a).
1 ASSEMBLY 13. Place the Horizontal Brace (item 6) spanning across the left and right leg Figure 13a sections, aligned with the leg mounting holes at each end (Figure 13a). Insert an M8 x 80 socket head screw (U) with flat washer (O) from the underside and through each leg and the corresponding hole at the each end of the Horizontal Brace. See detail: Fig. 13b Use a flat washer (O) and a locknut (R) with each screw. Tighten both fasteners securely now. (Figures 13b and c). See detail: Fig.
1 ASSEMBLY 15. Fold the lower rear center leg and supports up and away from the Vertical Track Assembly (Fig. 15a). Pivot the upper center leg section rearward, align its bottom end with the upper end of the lower section, and insert the lower section into the upper one (Figure 15b). Insert two M8 x 70 button head screws (S), one flat washer (O) at each end, and one locknut (R). Tighten both securely with a 5mm hex key and 13mm wrench (Figure 15c).
1 ASSEMBLY Hardware bag h 17. Join the rear sides of the Large and Small face Plates (items #1 and #8) together using two (2) M6 x 12 button head screws (H), two (2) M6 Flat washers each (J), and M6 hex nuts (I). Use a 4mm hex key and 10mm wrench to tighten (Figure 17). Figure 17 18. Attach the Large Face Plate (item 1) to the Left leg using the Large Face Plate Bracket assembly (P). Follow the steps below: (See Figure 18) a. Remove both of the M5 nuts and screws from the angle bracket. b.
1 ASSEMBLY 1.8 Wall-Mounting Option Remove bolt, fold braces up Removing the Rear Leg Assembly for Wall-Mounting 19. Using two 17mm wrenches, remove the M10 bolt, washers, and locknut joining the rear braces to the center rear leg (Figure 19). Pivot the two braces upward against the rear of the Vertical Track, and set the bolt, washers, and nut aside for now. Figure 19 Remove 20. Remove the two (2) M10 bolts from the top end of the Rear leg with a 17mm wrench.
1 ASSEMBLY 22. Wall Mounting the Rear Center Leg Follow these steps to correctly mount the rear center leg to the wall: Note: Find a wall location where there will be plenty of room on either side of the wall stud to feed in and remove the sheet material. If you cannot find a vertical structural stud, or your wall construction is of a solid material (i.e. masonry, concrete, etc.), you will need to install the appropriate wall anchors for the Lag Bolts. a.
1 ASSEMBLY Free-Standing Option (continued from Step 18): 24. With assistance, lift the assembled machine upright onto the legs, and move it to the approximate location where it will be used. Figure 25 Final Assembly, Both Mounting Options 25. Adjust the Center Adjustable Leg by unscrewing the round foot until it makes firm contact with the floor surface. Tighten the locking nut after proper floor contact is achieved (Figure 25). 1.9 Tool Caddy Attachment 26.
2 2.1 Set Up & Calibration Squaring the FSC Follow these steps to assure that the Vertical Track / cutting head is square (perpendicular) to the Horizontal Material Bar’s top surface. 1. Take a ¼" thick piece of PVC or foamboard (approx. 32"H x 40"W) and place the straight edge on the Horizontal Material Bar so that roughly half the board is on either side of the cutting head/Vertical Track. 2. Insert the 1/2" Blade Holder (with blade, see sections 3.2 and 4.1) into the Cutting Head.
2 Set Up & Calibration 4. If the cuts you made on the front and back of the board do not align, the machine is not square yet. The Horizontal Material Bar must be repositioned. If the third cut you made (the one made at the top on the back of the board) is to the left of the first cut you made (at the top of the board from the front), the Horizontal Material Bar must be lowered by making a Squaring ramp adjustment on the left side of the machine.
2 2.3 Set Up & Calibration 4. When setting the Horizontal Scales, start with the left one. Take your board and slide it into the machine until the 6" marking lines up with the blade, and clamp into place. Slide the measuring scale so that it aligns precisely with the left edge of the material. Apply doublesided tape behind the left Horizontal Scale to make sure it doesn’t move. 5.
2 Set Up & Calibration 9. Lower the Clamp Lever fully so that the stationary part and the moveable clamp are firmly together. 10. Turn the eccentric left or right while attempting to remove the paper from between the stationary part and the moveable clamp. 11. To verify clamping, attempt to remove the folded paper. When the paper cannot be removed, the eccentric is providing proper clamping. Tighten the M6 Screw so that the eccentric will not turn. 12.
3 3.1 Cutting Tools and Substrates Cutting Tool Holder Types ♦ Note: Always use the Blade Holder that is appropriate for the thickness of your material to help minimize the possibility of blade deflection. Standard Blade Holders - Included A. ½" (13mm) Blade Holder A This blade holder is used for foamboard, gatorboard, PVC and corrugated plastic. Use this one for materials up to ½" (13mm) thick. B B.
3 Cutting Tools and Substrates 3.2 Installing New Cutting Blades/Wheels/Scoring Tips into Holders CAUTION: Blades are extremely sharp. Handle with care. A. ½" (13mm) or ¼" (7mm) Blade Holders 1. Loosen the Blade Clamp Screw on the Blade Holder using a Phillips-head Screwdriver. 2. Slide the notched end of the Cutting Blade into the holder so it nests on the Blade Stop Pin. 3. Tighten the screw securely. ♦ Note: Make sure the Blade is fully inserted into the Blade Holder. B.
3 Cutting Tools and Substrates D. Glass Scoring Wheel 1. Position the new Glass Scoring Wheel in the gap so the notch is positioned inward. 2. Gently rock it back-and-forth until it is firmly seated into place. 3.3 Cutting Techniques for Various Substrates Each material you will use has its own unique characteristics. Whether it is brittle, soft, thick, or ridged in nature, you will need to choose the proper Cutting Blade/Wheel and technique to get the best results.
3 Cutting Tools and Substrates ♦ Notes: • Production Stop(s) should be used if making multiple pieces of the same size. • Thinner materials can be cut with one pass, but thicker materials may take more than one pass to cut completely through the material. C. Scoring and Breaking Techniques for Fracture-Sensitive Material ♦ Note: It is not necessary to remove the acrylic’s protective film prior to cutting. Scoring Fracture-Sensitive Material and Polycarbonate 1. 2. 3. 4.
3 Cutting Tools and Substrates E. Proper Glass Scoring and Breaking Techniques CAUTION: ; Always wear eye protection, gloves, and protective clothing when handling glass. ; Always load glass from the left side of the machine. ; Glass should not extend beyond the edges of the Horizontal Material Bar. ; Always score in a downward stroke. Scoring Glass ♦ Notes: • • • 1. 2. 3. 4. 5. 6. 7. Never score glass more than once on the same line. A light, continuous score line is best.
4 Operating the FSC Operating the FSC 4.1 Inserting Cutting Tool Holders in the Cutting Head 1. 2. 3. 4. Raise the Cutting Head to a comfortable level by grabbing either the Dual Handle Bar, or the black Handle. Hold the Cutting Tool so the Blade Screw is to your right. Insert the Blade Holder so the small tab on the left side of the Blade Holder is positioned in the notch of the Cutting Head above the Dual Handle Bar. Secure the Holder by tightening the Holder Securing Knob.
4 4.3 Operating the FSC Positioning the Substrate 1. Place the material on the Horizontal Material Bar and slide it under the Vertical Track Assembly. ♦ Note: It is preferable to load the material from the left to right direction. 2. Position the material so that the left edge of the board aligns with the desired cutting dimension. 3.
4 4.5 Operating the FSC Making a Cut or Score Line with the FSC Please refer to “Cutting Tools and Substrates,” beginning on page 18 for specific information on the substrate you are cutting. ♦ Note: All cutting and scoring is done with a smooth downward stroke. A. Creating a Cut Line 1. Grasp the handle of the Cutting Head. 2. Depress the Thumb Lever to raise the “Knife” Blade. 3. Pull the Cutting Head up above your material. 4.
5 Laser Installation Tools Needed 10mm, 16mm, 17mm Wrenches 2mm, 2.5mm, 4mm, & 1/8" Hex Keys Installing the Laser 5.1 Setting up the Laser 1. Loosen the black Handle by turning it counterclockwise. 2. Slide the Laser all the way to the left along the Laser Shaft. 3. Ensure the brass-tipped Set Screw on the Laser Assembly is tight against the Laser Mount, and retighten the Handle. 4. Hold the Laser in the palm of your hand so the four (4) black Set Screws on the left side of the Laser are facing you.
5 5.3 Laser Installation Dual-Position Laser ♦Note: The FSC cutting tool holders are sized for cutting performance. The “wheeled” tools are larger and provide an off-set cut line compared to the blade tool. The Laser Assembly is designed with a Dual Position feature giving you the ease of positioning the Laser Sight-Line to correspond to the cutting tool in use. A. Positioning the Laser for use with the Blade (SILVER Tools) (PVC, Foamboard, Coroplast, Acrylic) 1.
5 5.5 Laser Installation Calibrating the Alignment of Laser to Cut Lines CAUTION: Use Laser Safety Glasses before turning on the Laser. A. Creating a Continuous Laser Beam 1. Turn on the Laser. The switch is located on the right side of the Laser. Slide the On/Off switch down to the On position. 2. If Laser Beam is visible from the top of the substrate to the bottom, skip to the next section: “Setting the Angle of the Laser Beam,”. 3.
5 Laser Installation ♦ Note: Slight adjustments may be required for correct alignment. Beam is diagonal to score line Tightening back Set Screw moves beam clockwise Tightening bottom Set Screw moves beam right If the beam falls across your substrate from top right to bottom left, use a 2mm Hex Key to: 1. Tighten the top Set Screw and the beam will move to the left. When it is positioned over the top of the score line, stop tightening. 2.
5 Laser Installation 3. If the beam is to the left of the Aluminum Composite Wheel Cut line, perform steps a and b above, but loosen (turn counter-clockwise) the Nylock bolt instead.
6 Maintenance, Adjustments, Troubleshooting & FAQs Maintenance, Adjustments, Troubleshooting & FAQ 6.1 General Maintenance Tips Cleaning With care and frequent cleaning, the FSC will remain in proper working order and will perform well indefinitely, as designed. 1. Clean the Horizontal Material Support’s top surface. If debris collects on the Bar, the substrate will not sit properly, and the machine will not cut squarely. 2. Always use sharp cutting tools.
6 Maintenance, Adjustments, Troubleshooting & FAQs B. Adjusting the Rocker Arm Pressure The Rocker Arm pressure adjustment knob increases or decreases the amount of pressure applied to the material surface. This is especially important when scoring glass, as too much or too little pressure will create an ineffective score, making the break out difficult. 1. Locate the knurled Rocker Arm Adjusting knob (gold color) under the dual handle bar. 2.
6 Maintenance, Adjustments, Troubleshooting & FAQs D. Replacing the Cutting Head Bearings If adjusting the bearings doesn’t work, you will need to replace two (2) round-shaped bearings at the back, and two (2) V-shaped bearings at the front of the Cutting Head Assembly. The chances of this are low, so try the above adjustment (C) before you replace the bearings. ♦ Note: Remove any Blade/Wheel Holders before you remove the Cutting Head. E. Removing the Cutting Head 1.
6 Maintenance, Adjustments, Troubleshooting & FAQs 6.3 Troubleshooting Your FSC If this Troubleshooting Guide or the Frequently Asked Questions listed below does not answer your questions, call our Customer Service Department at 1.800.843.3826 (within the United States) or outside the United States, call ++800.843.3826, visit our website (www.fletcher-terry.com) or send an email to customerservice@fletcher-terry.com.
6 Maintenance, Adjustments, Troubleshooting & FAQs 6.4 Frequently Asked Questions A. Materials Q: What is the best way to cut corrugated plastic? A: When cutting across corrugated plastic flutes, cut in a single pass. When cutting in the direction of the flutes, position the blade between the flutes to avoid blade deflection. Use the Rocker Arm Locking Pin to help avoid deflection. Note: Thicker material may require multiple passes.
6 Maintenance, Adjustments, Troubleshooting & FAQs B. Cutting Q: What is the FSC’s cut capacity? A: The FSC has a vertical height cut capacity of 65" and can cut up to ½" thick materials. Q: Why are the Production Stops color-coded? A: The red stops are for sheet aluminum and aluminum composite material, and the silver stops are for all other material (see page 24). Q: How long do the blades and wheels last? A: All Fletcher cutting blades and wheels are “Extended Life” blades/wheels.
Replacement Parts List And Schematics VI. Replacement Parts List & Schematics NOTE: Our Replacement Parts List and Schematics are in the final stages and will be posted on our website (www.fletcher-terry.com) when they become available. In the meantime, if you need technical support, contact our customer service department at: 800.843.3828 (in the United States) ++860.677.7331 (outside the United States) email - customerservice@fletcher-terry.
