I have trouble keeping the machine running consistently, is it me or the machine?

It is hard to say without seeing the equipment firsthand. But I would ask how much operator training you received when you got your machine, and your overall feel for the machine. Most any inserter requires periodic service, a noticeable reduction in production, many jam ups will undoubtedly knock some cam or portion of the machine out of time.As long as you feel comfortable with how the machine works, most problems can be solved fairly easily. If you get in over your head, stop and call for service.

The vacuum on my machine is weak, help!

A very common problem occurs after filters are cleaned. The rubber gasket can fall out and cause nothing but leaks. Also check filters at the pump as well as open station valves (manual valves) Never oil the plastic slide valves as they will swell and bind. remove hose at pump and check for vacuum at the source. Replace old vacuum hose and disassemble elbows and fittings to backflush with compressed air.

How do I stop misfeeds and doubles?

The bane of every operator! Proper suction cup choice is important! Thin stock requires a tan suction cup which being very porous, allows vacuum to escape. And Tee plate positioning also important. However most mailers encounter jobs in which the inserts are horrible (warped,nested,poorly packed) a common solution is a Feeder which eliminates these very problems.

How fast will a production swing arm inserter run?

The first requirement of this is what model inserter you have. If you have a ratchet drive machine it is rated for either 5000 to 7200 cycles per hour.

Conjugate cam inserters will cycle at 10,000/hr. Much of the ability to run at 9,200 pieces per hour is dependent on the material. Envelopes have dimensional requirements that allow higher speeds,and should be ordered with specifications that they are to be run on automatic inserting machines.

A number 9 envelope into a number 10 envelope can easily be inserted at 9200 per hour(In a tight, maintained inserter) by an experienced operator. However it should be noted that warped,curled stock will greatly constrict thru-put. Glossy thin stock can be a challenge(unfolded especially). One technique for this material is to "sandwich" this insert between the BRE and the data piece.Additional inserts will reduce overall speed. The best means for production is to take the time to correctly set up the machine for the job. Run the machine at low speed initally,carefully observing all aspects of the operation. If all looks right,increase speed while running until the material starts to crash. At this point you may have more set up adjustments to run consistently.Or this may be over the speed threshold for the given material and machine.Production is going to be higher when the machine runs with minimal stops. Training for operators will always pay for itself,especially in machine life, overall reduction in frustration with operation of the inserter, and thru-put, and spoilage.

How often should I oil the machine?

It all depends on how often the machine is run,a typical 8 hour a day machine should be oiled every other day with non detergent oil. Canister trigger oilers should be avoided,the preferential oiler should be a long flex hand squeeze oiler,used with a long skinny screwdriver to access oil cups. Many oil spots are marked in red.Many are not. If the location has friction with another component chances are it needs oil. It could be easily argued that that you can't oil too often. It is also advisable to wipe the machine down cleaning excess oil from the deck. Oiling of the chains should be discouraged.

What is the difference between the colored suction cups?

There are many variations, but the common distinction is regular (bell shaped) and bellows. Tan cups are porous, which makes these ideal for thin material,in that they "bleed" vacuum allowing one insert to be pulled. One trick for stubborn inserts (the inability to pull just one insert) is to take a regular tan cup and turn it inside out (a 5/32 allen works well) this reduces the surface coverage, and this coupled with angle adjustment, will put that problem to bed.

The green and blues are for heavier stock and are longer lasting.Urethane cups are more expensive but are very handy to have on hand. Old suction cups are questionable,many becoming hard and sometimes brittle.Common mistakes with suction cups is in installation. The envelope hopper is an area where all three cups must be fully seated,as well as the upper sucker bar. 86 all torn or worn cups.

What is preventative maintenance?

The most overlooked procedure. Open the covers to your machine and witness many processes occuring in harmony and all of this is due to proper timing and adjustment. PM's are insurance against easily repairable problems,especially conflict in timing issues. These can be very expensive in the short run. We are factory trained with over 23 years in the industry. For those who view this as being akin to taking your car to the dealership and asking them to find problems, I share your feelings. Bad move, chump! Regular pm's can be divided into subsections and are more cost effective than running them hard and wait for the real problems. Peace of mind is a frequent guest when machines are inspected on a semi regular basis.