Formax FD 6100 Service Manual Download

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Formax 6100

Paper Folder/Inserter

Service Manual

Summary of Contents for FD 6100

Page 1: ...Provided By http www MyBinding com http www MyBindingBlog com Formax 6100 Paper Folder Inserter Service Manual ...

Page 2: ...ISSUE 21 09 2003 FD 6100 MAINTENANCE MANUAL REVISION 2 1 SECTION CONTENTS PAGE 1 FD 6100 ...

Page 3: ...ISSUE 21 09 2003 FD 6100 MAINTENANCE MANUAL REVISION 2 1 SECTION CONTENTS PAGE 2 CONTENTS REVISIONS SECTION 1 MAINTENANCE ...

Page 4: ...ISSUE 21 09 2003 FD 6100 MAINTENANCE MANUAL REVISION 2 1 SECTION CONTENTS PAGE 3 SECTION 2 PARTS LIST SECTION 3 UNPACKING ...

Page 5: ... Reference soft Section Page DESCRIPTION 1 4 10 07 03 1 11 ALL Launch Version S1 FR 5 23 25 31 32 48 50 S1 ENG Pages 5 6 7 11 23 25 31 32 40 48 50 have been modified S2 ALL 2 0 01 09 03 1 15 S4 ALL S1 ENG 31 Adding of US terminology S1 ENG 46 49 Splitting of the USA and Europe specifications 2 1 21 09 03 1 15 S3 3 5 Removing of the empty chapters ...

Page 6: ...ANCE KITS DETAILS 23 3 SOFTWARE UPGRADE AND CPU BOARD REPLACEMENT 39 3 1 SOFTWARE UPGRADE 39 3 2 CPU BOARD REPLACEMENT 39 4 DIAGNOSTICS TOOL 40 4 1 ERROR MESSAGE LIST 40 4 2 FUNCTIONAL FAULTS 42 4 3 FUNCTIONAL TESTS 43 5 DISASSEMBLING RE ASSEMBLING AND ADJUSTMENTS 51 5 1 TOOLS 51 5 2 DISASSEMBLING 51 5 3 RE ASSEMBLING AND ADJUSTMENTS 52 5 4 DISASSEMBLING AND RE ASSEMBLING SUMMARY 53 6 THEORY OF OP...

Page 7: ...use compressed air for cleaning and maintenance Never grease ball bearings It is strongly advised to use only the recommended grease synthetic grease as other types of grease may damage the mechanisms of the machine Empty the water tank before transporting the machine MAINTENANCE PRODUCTS Grease MOLYCOTE PLASTISLIP PG75 plastic parts ESSO MULTIPURPOSE 4746 bearing output roller ...

Page 8: ...on 1 Chapter 1 4 1 Sensors DD KEY See description in Section 1 Chapter 1 4 1 Sensors DOC LOADED See description in Section 1 Chapter 1 4 1 Sensors DOCUMENT FEEDER CLUTCH See description in Section 1 Chapter 1 4 2 Clutches and Motors END SEPARATION A See description in Section 1 Chapter 1 4 1 Sensors END SEPARATION B See description in Section 1 Chapter 1 4 1 Sensors END SEPARATION C See descriptio...

Page 9: ...rs Type E sensor Electrodes Type F sensor Flag sensor Type H sensor Hall effect sensor Type PP motor stepper motor Type R sensor Reed bulb activation of a mechanical switch under a magnet effect Type S switch Mechanical Switch Icons Fix Job memorized Blinking Job modified Job secured locked Type of folds Single fold C fold or letter fold Double parallel fold ...

Page 10: ...09 03 FD 6100 MAINTENANCE MANUAL REVISION 2 1 SECTION 01 PAGE 9 CONTENTS 1 3 GENERAL OVERVIEW 1 3 1 FEEDER A B SENSORS AND SWITCH VIEW DD A END SEPARATION B END SEPARATION A DD KEY DD B B EMPTY A EMPTY AUTOSTART ...

Page 11: ...TENANCE MANUAL REVISION 2 1 SECTION 01 PAGE 10 CONTENTS 1 3 2 BASE SENSORS AND SWITCH VIEW MACHINE OPEN ENV EXIT ZERO CAME REF ENV LETTER OUTP C CLOSED DD BAC C END AND SEPARATION C DOC LOADED C EMPTY INSERT STOP FOLDING PLATE 2 ...

Page 12: ...INTENANCE MANUAL REVISION 2 1 SECTION 01 PAGE 11 CONTENTS 1 3 3 BASE SENSORS AND SWITCH VIEW MACHINE OPEN INSERT STOP ENV REFERENCE ENV EXIT LETTER OUTPUT DOC LOADED CAM ZERO INSERT SIGNAL END SEP R TION C C EMPTY C CLOSED DD C ...

Page 13: ...9 03 FD 6100 MAINTENANCE MANUAL REVISION 2 1 SECTION 01 PAGE 12 CONTENTS 1 3 5 CLUTCHES VIEW C SELECTION CLUTCH DOCUMENT FEEDER CLUTCH C TRANSPORT CLUTCH B SELECTION CLUTCH A SELECTION CLUTCH MANUAL FEEDING MOTOR ...

Page 14: ... 09 03 FD 6100 MAINTENANCE MANUAL REVISION 2 1 SECTION 01 PAGE 13 CONTENTS 1 3 6 MOTORS VIEW HOPPER MOTOR ENV TRANSPORT MOTOR BOTTOM FOLDER MOTOR TOP FOLDER MOTOR MAIN MOTOR CAM MOTOR SINGLE FOLD MOTOR EUR only ...

Page 15: ...ISSUE 21 09 03 FD 6100 MAINTENANCE MANUAL REVISION 2 1 SECTION 01 PAGE 14 CONTENTS 1 3 7 PAPER PATH VIEW DOCUMENT PATH ENVELOPE PATH ...

Page 16: ... or BRE Envelope Exit LETTER OUTPUT Letter output check Envelope Ref ENV REFERENCE Reference for the envelope inserting position Cam zero CAM ZERO Cam home position SERVICE TEST COMPONENT NAME FUNCTION Document in feeder A A EMPTY AUTOSTART No document in feeder A AUTOISTART Document in feeder B B EMPTY No document in feeder B End separation A END SEPARATION A A SEPARATION CLUTCH drive End separat...

Page 17: ...s Activate document transportation until folding rollers SERVICE TEST COMPONENT NAME FUNCTION Not available TOP FOLDER MOTOR Drives Top folder adjustment Not available BOTTOM FOLDER MOTOR Drives Bottom folder adjustment Not available MAIN MOTOR Drives the folding rollers Documents feeding Insert BRE feeding Not available CAM MOTOR Drives the cam inserting area Not available ENV TRANSPORT MOTOR Dri...

Page 18: ...ISSUE 21 09 03 FD 6100 MAINTENANCE MANUAL REVISION 2 1 SECTION 01 PAGE 17 CONTENTS 1 5 PCB INTERCONNECTION DIAGRAM 1 5 1 MAIN PCB PART 1 1 5 2 ...

Page 19: ...ISSUE 21 09 03 FD 6100 MAINTENANCE MANUAL REVISION 2 1 SECTION 01 PAGE 18 CONTENTS 1 5 3 MAIN PCB PART 2 1 5 4 ...

Page 20: ...ISSUE 21 09 03 FD 6100 MAINTENANCE MANUAL REVISION 2 1 SECTION 01 PAGE 19 CONTENTS 1 5 5 FEEDER PCB 1 5 6 ...

Page 21: ...ISSUE 21 09 03 FD 6100 MAINTENANCE MANUAL REVISION 2 1 SECTION 01 PAGE 20 CONTENTS 1 6 PROTOCOL AND HARDWARE CONFIGURATION LEFT INTENTIONALLY BLANK ...

Page 22: ...to the machine specifications What is the total number of cycles What is the rate of clogging up of the machine does the user apply the recommended cleaning procedures 2 2 END OF SERVICE CALL CHECK LIST Clean the transportation and folding rollers Inform the user about the origin of the fault and show how to avoid it in the future Test the job in process process at least thirty documents Rinse the...

Page 23: ...581N X X X X X End of Life Inserting fingers and rollers replacement 4124587U EUR 4124831Y US X End of Life Feeder C maintenance 4124590X X End of Life Feeder E maintenance 4124591Y X X End of Life C path maintenance 4124592Z X X End of Life Doc Transport Maintenance 4124594B X End of Life Exit rollers maintenance 4124603L X X End of Life Feeder AB replacement swap 4120482T X End of Life Regular c...

Page 24: ...nveloppe Tongue left YES 11PIC015 6 1 Languette droite ouverture enveloppe Tongue right YES 11PIC022 0 2 Languette arrêt enveloppe Tongue envelope stop YES 21PIA000 1 1 Contre rouleau arrêt enveloppe Pressure roller envelope stop YES 21PIA003 4 1 Rouleau arrêt enveloppe Drive roller Envelope stop YES 21PIA003 5 1 Ejection enveloppe Ejection roller Envelope stop NO 4122298K 1 Capteur arrêt envelopp...

Page 25: ...rieur droite right cam Sensors 4124583Q NO 4121929A 1 Ens DD C DD C assembly NO 4122298K 5 Zero came chargement Arrêt env sortie env Sensors NO 4122982X 5 Ens capteur chemin encart Insert path sensor assembly NO 4123041J 1 Ens capteur sortie env LETTER OUTPUT sensor assembly NO 4123044 M 1 Ens capteur ref selection env ENV REFERENCE sensor assembly ...

Page 26: ...e cde bac C Bin C belt Clutches 4124585S YES 14PIC000 2 3 1 bac C 1 transport C 1 pliage Clutch Pocket A closing Europe use only 4124586T YES 11BFA24 02 1 Pignon intermédiaire fermeture poche Gear intermediate closing bar YES 11PIC007 5 2 Palier barette de fermeture poche Bearing pocket closing bar YES 11PIC009 1 1 Pignon cde levier gauche Gear left lever drive YES 11PIC009 2 1 Levier pivot droit ...

Page 27: ... chargement Pulley inserting roller YES 4123028V 1 Ensemble doigts d insertion Europe équipé Insert fingers assembly Europe YES 11PIA032 6 1 poulie rouleau chargement Pulley inserting roller YES 12PIA000 6 1 Courroie de chargement Belt inserting YES 21PIA005 3 1 Poulie cde courroie chargement Pulley inserting belt YES 21PIC002 6 1 Rouleau d insertion équipé Inserting roller assembly ...

Page 28: ...t Pulley inserting belt YES 21PIC002 6 1 Rouleau d insertion équipé Inserting roller assembly Tongues 4124588V YES 11PIA009 3 4 patins amortissants pieds Shock absorber feet YES 11PIC008 9 1 Languette gauche ouverture enveloppe Left tongue envelope pre opening YES 11PIC015 6 1 Languette droite ouverture enveloppe Right tongue envelope pre opening YES 11PIC022 0 2 Languette arrêt enveloppe Tongue e...

Page 29: ...28 Feeder C maintenance 4124590X YES 11PIA000 1 4 Palier Bearing YES 11PID013 9 2 Rouleau de sélection Selection roller feeder C YES 21PIC008 6 2 Ensemble filière Europe Separation assembly Feeder C Europe YES 4122975Q 2 Ensemble filière US Separation assembly Feeder C US ...

Page 30: ...n brush Feeder E YES 21PIA001 7 1 Rouleau plein transport env Transportation roller full Feeder E YES 21PIA008 1 2 Galets libres bac E Roller free Feeder E YES 21PIA014 3 1 Contre rouleau transport doc Pressure roller YES 21PIA015 6 1 Ensemble rouleau 5 gommes bac E Roller 5 rubbers Feeder E YES 21PIA015 7 1 Ensemble rouleau 5 gommes mixtes bac E Roller 5 mixed rubbers Feeder E YES 21PIA015 8 1 En...

Page 31: ...N 3 Folding roller 3 YES 11PIDO15 5 1 Rouleau pliage N 4 Folding roller 4 Doc Transport Maintenance 4124594B YES 11PID005 2 1 Rouleau arrière entrée doc Entry roller rear Document path YES 21PIA014 3 1 Contre rouleau transport env Pressure roller YES 11PIA000 1 6 Palier Bearing YES 21PIC001 8 1 Rouleau avant entrée doc Entry Roller front Document path YES 21PID001 1 1 rouleau inf transport doc Low...

Page 32: ...ES 11PID008 8 1 Chemin C Gear Feeder C path YES 11PID011 3 2 poulie chemin C Pulley Feeder C YES 4122039Q 2 Pignon crémaillère Rack gear Feeder C YES 4122040R 1 Pignon bac C Gear Feeder C YES 4122098B 1 Pignon bac C Gear Feeder C Feeder E gears 4124596D YES 11PIA002 5 1 Pignon intermédiaire Intermediate gear Feeder E YES 11PIA010 4 1 Pignon moteur bac E Motor gear Feeder E YES 11PIA014 1 1 monté e...

Page 33: ...ECTION 01 PAGE 32 YES 11PIB000 7 1 Commande de came Cam drive Inserting YES 11PIB003 8 1 pignon cde came Cam drive gear Inserting YES 11PIC021 3 1 Pignon cde came Cam drive gear Inserting YES 21PIA005 3 1 Poulie cde courroie chargement Pulley inserting belt ...

Page 34: ...nt entrée doc Gear front entry roller Document path YES 11PID004 1 1 pignon embrayage entrée doc Gear entry doc clutch Document path YES 11PID004 2 1 Pignon intermédiaire Intermetiate gear Document path YES 11PID004 4 2 Pignon intermédiaire Intermetiate gear Document path YES 11PID007 1 2 Pignon intermédiaire Intermetiate gear Document path YES 11PID010 9 1 Pignon intermédiaire Intermetiate gear D...

Page 35: ...er drive YES 11PIC007 4 1 Pignon moteur transport enveloppe Motor gear Envelope motor YES 21PIA005 9 1 Pignon poulie chemin enveloppe Gear pulley Envelope path YES 21PIC000 1 1 Pignon poulie transport enveloppe Gear pulley Envelope transportation YES 21PIC005 1 1 Pignon chemin enveloppe tarington clutch Gear Tarington clutch Envelope path ...

Page 36: ...C YES 11PIA022 3 2 Ressort deflecteur mouillage Spring Moistening deflector YES 11PIA022 5 2 Ressort levier cde mouillage Spring moistening drive lever YES 11PIA022 9 2 Ressort rappel verrou machine Spring machine locking YES 11PIA023 1 2 Ressort contre rouleau arrêt enveloppe Spring Envelope stop pressure roller YES 11PIA023 1 2 Ressort contre rouleau transport doc Spring Document transportation ...

Page 37: ...vant entrée doc Spring left front entry doc YES 11PIC013 8 1 Ressort deflecteur env Spring envelope deflector YES 11PIC019 2 2 Ressort préselection enveloppe Spring envelope pre separation YES 11PIC024 7 1 Ressort déflecteur sortie Spring exit deflector YES 11PID002 1 2 bac C Spring bin C YES 11PID005 4 1 Ressort droit barette entrée doc Spring right document entry bar YES 11PID005 5 1 Ressort gau...

Page 38: ...8T 1 Câble capteur ouverture machine sortie enveloppe ref env et selection env Cable machine opening envelope exit envelope reference and envelope separation sensors NO 4121900V 1 câble capteur zero came et doc chargé Cable Zero cam and document loaded sensors NO 4121887G 1 Cable DD C Cable DD C NO 4122782P 1 cable document chargé Cable Document loaded sensor NO 4121902X 1 câble embrayages bac C P...

Page 39: ...ISSUE 21 09 03 FD 6100 MAINTENANCE MANUAL REVISION 2 1 SECTION 01 PAGE 38 YES 4122955U 1 Capot cellule autostart équipé Feeder AB Front cover equiped ...

Page 40: ...he machine 3 2 CPU BOARD REPLACEMENT When the LOGIC PCB is replaced all the data stored into the RAM are lost The following settings have then to be done Perform a RAM Reset Set the machine serial number Service Mode Set the total counter Service Mode Set the Authorisation code Customize the language Advanced CONTENTS language Customize the envelopes format Advanced CONTENTS set format Check the e...

Page 41: ... sides feeder and main board CLOSE THE MACHINE Sensor MACHINE CLOSED faulty or badly located Check the sensor in the service mode and eventually adjust its positioning DETECTION OF DUPLICATE DOCUMENT IN TRAYS A B Faulty DD x sensor Check the faulty sensor in the service mode DETECTION OF DUPLICATE DOCUMENT IN TRAY C Faulty DD x sensor Check the faulty sensor in the service mode SWITCH THE MACHINE ...

Page 42: ...r AB clutches badly set Check the feeders sensors in the service mode Check the setting of the feeder AB clutches REMOVE DOCUMENTS FROM TRAY A The AUTOSTART sensor is faulty Check the sensor in the service mode DUPLICATE DETECTION CHECK CONTENTS OF ENVELOPE Faulty DD x sensor Check the faulty sensor in the service mode CHECK PAPER PATH OF TRAY C Rollers clogged up Path C sensor faulty Clean the ro...

Page 43: ...Envelope not bad closed Set of document to be inserted too thick Try with a thinner set Job miss setting Check that the moistening is set in the job selected Exit roller wet Clean the exit roller Bad no moistening Envelope flap out of specification Check the envelope flap shape and high in the specification Offset between documents from feeders A and B Bad setting of the clutches Check the setting...

Page 44: ...ween the drive rollers Start a manual cycle holding the piece of cardboard Wait for the machine to stop open it and with a fine pencil mark the envelope along the edge of the upper deflector 21PIC0028 while pushing up the top inserting plate and measure dimensions A The A nominal value must be If the envelope height is 105 mm 4 13 in Æ A 6mm 3mm 0 23 in 0 12 in If the envelope height is 152 mm 6 i...

Page 45: ...ISSUE 21 09 03 FD 6100 MAINTENANCE MANUAL REVISION 2 1 SECTION 01 PAGE 44 ...

Page 46: ...ocuments by the base and of misalignment with a second document ADJUSTMENT PROCEDURE To control the stop position for the feeder A B it is necessary to select a job which uses the envelope feeder as well as feeder A or B Load feeder A with only one document but without any envelope in the feeder E Start the job push the START key Rotate the feeder A B without disconnect it in order to look at the ...

Page 47: ... key UP the following screen will appear Use the arrow key to select the line job number and select job from1 9 with the key UP and valid with the key MEM Select clutch A set the value and valid with the key MEM Use the same process for clutch B Note the value reference is written underneath the feeder A B e Exit this screen using the key ESC to return to user mode Reference ...

Page 48: ...m Undo securing screw 1 which adjusts the cam belt Introduce two 3 mm diameter rods 0 12 in through the left rear and left front cams and the machine bottom side plate If necessary move one of the cams in relation to the toothed belt Tighten the belt adjustment fixing screw NOTE Incorrect synchronisation of the cams causes machine operating fault sealing and ejection faults Incorrect belt tension ...

Page 49: ...late 3 if it has been removed Place cam 4 in the position shown in the figure opposite Rotate inserting roller 5 a few turns by its rubber rollers in the direction of operation in order to tension the belt correctly Tighten screw 1 NOTE Incorrect adjustment of the insertion belt tension may give rise to noise skewed insertion envelope feed faults or rapid wear of the loading roller Do not rotate t...

Page 50: ...the tensionner in order to release it Drive the belt in the 2 directions by turning manually the pulley and gear wheel 3 While turning the pulley tighten screw 2 in the tensionner lower position Fit again the motor gear wheel NOTE An incorrect adjustment of the belt tension will result in difficulties in the envelope feeding as well as in insertion closing and ejection defect These defects will be...

Page 51: ...RIZE DOWN and START Open the machine see page 6 Switch the top cover security MACHINE OPEN with a screwdriver in order to have no risk to forget the shortcut of this security With the keyboard select Advanced parameters Select Pocket life cycle Press START to begin the test cycle Feeder A stop bar selection between automatic and daily mode Pocket A deflector only for the European machines Folding ...

Page 52: ...ver 2 screws underneath the front and 2 screws on the top at the rear Do not forget to remove the metallic cable holder above the display unit 2 Remove the side covers fitted in the lower part 3 screws for each 3 Remove the lower cover 4 screws underneath the machine through the 4 feet 5 2 2 DISASSEMBLING MAIN PCB 1 Remove the top cover refer to description chapter 5 2 1 2 Disconnect the cables fr...

Page 53: ...E ASSEMBLING AND ADJUSTMENTS 5 3 1 REASSEMBLING TOP COVER When putting back the top cover onto the machine be careful to put the hopper side guides locking knob in regard of the locking lever set both to the locked position otherwise the locking system will be out of order Locked position ...

Page 54: ...EEDER E TOP PLATE SIDE GUIDE LOCKING BRACKET FEEDER E SEPARATION PLATE FEEDER E FRONT FEEDER E GEERS MAIN PCB FEEDER E GEARS FLASH MEMORY JACKS INSERTING ROLLER ASSEMBLY FOLD ROLLERS 2 3 LOWER COVER POCKET B ASSEMBLY POWER SUPPLY CAMS INSER TING GEARS INSERT SIGNAL SENSOR ASSEMBLY ALUMINIUM FOLD ROLLER 1 TOP TABS GUIDING THE POCKET A ASSEMBLY WHEN PIVOTING SPRING HOLDERS WHICH PULL THE POCKET A AS...

Page 55: ...e machine initialisation To lock or unlock a job In the ready screen select the job and press ESC and while pressing ESC press MEMORIZE To set the feeder A B clutches timing In the ready screen press ESC and while pressing ESC press UP Information screen access In the ready screen press ESC and while pressing ESC press DOWN RAM reset EEPROM initialisation Press the keys START MEMORIZE and keep pus...

Page 56: ...A B C AUTO A B AUTO A AUTO A B C AUTO A C AUTO C USA LETTER 11 LEGAL 14 SPECIAL EUROPE A4 12 A5 SPECIAL USA SPECIAL SEAL SPECIAL NO SEAL C FOLD ONLY 10 SEAL 10 NO SEAL EUROPE SPECIAL SEAL SPECIAL NO SEAL C FOLD ONLY SINGLE FOLD ONLY C6 5 DL SEAL C6 5 DL NO SEAL C5 SEAL C5 NO SEAL MOVE THE ADDRESS UPWARD MOVE THE EDDRESS DOWNWARD START ESC MEM MACHINE TURNED ON This step appears until the Authoriza...

Page 57: ...AGE SET ENV DOC SELECT THE ENVELOPE FORMAT SET STANDART ENVELOPE SET SPECIAL ENVELOPE SET SPECIAL DOCUMENT HEIGHT ENV POSITION MOIST POSITION SIZE DOUBLE DETECTION BIN C ENABLE DISABLE THE DOUBLE DETECTION FRANCAIS ENGLISH DEUTSH ITALIANO NEDERLANDS ESPANOL SVENSKA DANSK PORTUGUES POLSKI HEIGHT ENV POSITION MOIST POSITION MEM MEM MEM MEM EXIT ESC ESC DURING INIT ...

Page 58: ...ARATION C C EMPTY DOC LOADED INSERT STOP INSERT SIGNAL LETTER OUTPUT ENV REFERENCE CAM ZERO A EMPTY B EMPTY END SEPARATION A END SEPARATION B DD KEY KEYS TEST SET TOTAL COUNTER TOTAL COUNTER SETUP SET ADVANCED PARAMETERS SERVICE DOUBLE DETECTION SERVICE LIFE CYCLE SET CONTINENT YES NO YES NO EUROPE USA SELECT UP MEM DOWN START START START START START START START START KEYBOARD TEST EXIT OFF POCKET...

Page 59: ...UENCES OF SOFTWARE FUNCTIONS MACHINE OFF THICKNESS SENSORS INITIALIZATION BOTTOM FOLDER INITIALIZATION TOP FOLDER INITIALIZATION CAM INITIALIZATION MACHINE INITIALIZED MACHINE SWITCHED ON THICKNESS SENSORS INITIALIZED BOTTOM FOLDER INITIALIZED TOP FOLDER INITIALIZED CAM AT THE HOME POSITION ...

Page 60: ...y of main document feeder bin A bin B 100 sheets 80 g 100 sheets 80 g Capacity of insert feeder bin C Reply envelopes 100 Inserts 250 g 200 Catch tray capacity 100 letters inserted with 2 A4 sheets 80g letter fold Water tank capacity about 1 000 letters Types of folds single fold Letter fold Double parallel fold Capacity of folds insertion Single double fold Parallel fold Insertion without fold fr...

Page 61: ...minary test can be required This paper quality may require frequent pick up rollers and fold rollers cleaning Long size annex inserts manual entry and bin B width height 142 to 226 mm 80 to 150 mm Paper quality auxiliary inserts Printers Listings Photocopiers Offset Selfcopier Glossy paper advertisement 80 to 90 g m 70 to 90 g m 90 to 120 g m A preliminary test can be required This paper quality m...

Page 62: ...ain document feeder bin A bin B 100 sheets 20 Lb Bond 100 sheets 20 Lb Bond Capacity of insert feeder bin C Reply envelopes 100 65 lbs Inserts 200 Catch tray capacity 100 letters inserted with 2x 20 Lb Bond Letters sheets Water tank capacity About 1 000 letters Types of folds Letter fold and Double parallel fold Capacity of folds insertion Letter fold Double parallel fold Insertion without fold fr...

Page 63: ...b Bond in automatic feeding mode 24 to 32 Lb Bond in manual feeding mode A preliminary test can be required This paper quality may require frequent pick up rollers and fold rollers cleaning Long size annex inserts manual entry and bin B Width Height 5 6 in to 8 9 in 142 to 226 mm 3 15 in to 5 9 in 80 to 150 mm Paper quality auxiliary inserts Printers Listings Photocopiers Offset Self copying NCR G...

Page 64: ...SECTION 01 PAGE 63 advertisement Glossy paper Pre fold Business Reply Envelopes BRE 19 to 45 Lb Bond 19 to 24 Lb Bond with or without window A preliminary test can be required This paper quality may require frequent pick up rollers and fold rollers cleaning ...

Page 65: ...C008 2 YES Tôle insertion Inserting plate 10 18 11PIC017 8 YES Déflecteur sortie enveloppe Deflector Letter exit 30 54 11PID007 5 YES Rouleau pliage N 1 ALU Folding roller alu 2 3 6 12PIC000 6 YES Vérin Jack 100 180 4105487Y YES Guide arrière gauche bac E Hopper rear guide left 10 18 4105488Z YES Guide arrière droit bac E Hopper rear guide right 10 18 4105489A NO Flasque droit bac C Cover bin C ri...

Page 66: ...PCB 10 18 4121956D NO Capot afficheur Cover Display 10 18 4122058K NO Capot support guides arrières bac E Cover Hopper rear guides bracket 5 9 4122061N YES Margeur gauche bac E Hopper side guide left 5 9 4122062P YES Margeur droit bac E Hopper side guide right 5 9 4122113S NO carte principale Main PCB 20 36 4122148D NO Plateau magasin env Hopper plate 5 9 4122525W NO Platine avant bac E Hopper fro...

Page 67: ...89E NO Ensemble tôle inférieure poche A équipée Pocket A Lower plate assembly 1 1 8 4122990F YES Ensemble chemin encart sup Inf Insert path assembly upper lower 1 1 8 4122993J NO Ensemble tôle inférieure poche B équipée Pocket B Lower plate assembly 1 1 8 4122999Q YES ensemble bac mouilleur Moistener tank assembly 15 27 4124580M YES Kit ensemble arrêt enveloppe Kit Envelope stop assembly 5 9 41245...

Page 68: ...ues 30 54 4124589W YES Kit leviers defleteur sortie envelopes Kit Envelope exit lever deflector 25 45 4124590X YES Kit maintenance bac C Kit Feeder C maintenance 25 45 4124591Y YES Kit maintenance bac E Kit Feeder E maintenance 30 54 4124592Z YES Kit maintenance chemin encarts Kit Inserts path maintenance 10 18 ...

Page 69: ...ars 50 90 4124599G YES Kit pignons transport documents Kit Documents transportation gears 100 180 4124600H YES Kit pignon transport envelopes Kit Envelope transport kit 50 90 4124602K YES Kit ressorts Kit Springs 50 90 4124603L YES Kit maintenance rouleaux de sortie Kit Exit rollers maintenance 10 18 4124604M NO Kit câbles Kit Cables 15 27 4124648P YES Kit boutons alimenteur AB Kit Feeder AB knobs...

Page 70: ...4590X 88 FEEDER E MAINTENANCE 4124591Y 89 INSERTS PATH MAINTENANCE 4124592Z 90 FOLDING MAINTENANCE 4124593A 91 DOC TRANSPORT MAINTENANCE 4124594B 92 FEEDER C GEARS 4124595C 93 FEEDER E GEARS 4124596D 94 INSERTING GEARS 4124598F 95 DOC TRANSPORT GEARS 4124599G 96 ENV TRANSPORT GEARS 4124600H 97 EXIT ROLLERS MAINTENANCE 4124603L 98 CABLE 4124604M 99 FEEDER AB KNOBS 4124648P 100 SPRINGS 4124602K 101 ...

Page 71: ... comp at French description English description 4122058K NO Capot support guides arrières bac E Cover Hopper rear guides bracket 4122061N YE S Margeur gauche bac E Hopper side guide left 4122062P YE S Margeur droit bac E Hopper side guide right 4122525W NO Platine avant bac E Hopper front plate 4122525W 4122061N 4122062P 4122058K ...

Page 72: ...mpoule reed C FERME Reed sensor assembly C CLOSED 4105487Y YE S Guide arrière gauche bac E Hopper rear guide left 4105488Z YE S Guide arrière droit bac E Hopper rear guide right 4122972M YE S Ensemble bac C équipé Europe Bin C assembly for Europe 4122973N YE S Ensemble bac C équipé US Bin C assembly for USA 4105488Z 4122972M EUR 4122973N US 11BFA1105 4105487Y ...

Page 73: ...escription English description 4105489A NO Flasque droit bac C Cover bin C right 4105490B NO Flasque gauche bac C Cover bin C left 4105492D YE S Bouton verrouillage bac E Hopper side guides locking knob 4125899L NO Ensemble alimenteur AB Feeder AB assembly 4105490B Picture not available 4105489A 4105492D 4125899L ...

Page 74: ...French description English description 11PID0075 YE S Rouleau pliage N 1 ALU Folding roller alu 12PIC0006 YE S Vérin Jack 4122748D NO alimentation Power supply assembly 4122990F YE S Ensemble chemin encart sup Inf Insert path assembly upper lower 4122748D 4122990F Picture not available 11PID0075 12PIC0006 ...

Page 75: ...ECTION 02 PAGE 74 CONTENTS Part number S1 comp at French description English description 4121955C NO Ensemble ecran clavier User interface assembly display unit keyboard PCB 4121956D NO Capot afficheur Cover Display 4121956D Picture not available 4121955C ...

Page 76: ...ie enveloppe Deflector Letter exit 4122993J NO Ensemble tôle inférieure poche B équipée Pocket B lower plate assembly 4121897S NO Moteur équipé Env Came Env Cam transport motor 4122745A NO Limande afficheur Cable display PCB 4122999Q YE S ensemble bac mouilleur Moistener tank assembly 4122999Q 4121897S Picture not available 4122745A 4122993J Picture not available 11PIC0178 ...

Page 77: ...ption English description 11PIC0082 YE S Tôle insertion Inserting plate 4105505S NO Capot sortie inf Cover Letter exit lower part 4122113S NO carte principale Main PCB 4122989E NO Ensemble tôle inférieure poche A équipée Pocket A Lower plate assembly 4122989E Picture not available 11PIC0082 4105505S 1 1 4122113 S 1 2 ...

Page 78: ...EUR Hopper separation plate EUR 11PIC0202 YE S Barette selection bac E US Hopper separation plate US 4121894P NO Moteur bac E équipé Hopper motor 4121907C NO Moteur transport doc équipé Main motor 4122113S NO carte principale Main PCB 4122148D NO Plateau magasin env Hopper plate 4122748D NO alimentation Power supply assembly 4121907C 4122148D 4121894P 11PIA101 EUROPE 11PIC0202 USA ...

Page 79: ...enveloppe Envelope flap deflector 4 YES 11PIC0089 1 Languette gauche ouverture enveloppe Tongue left 5 YES 11PIC0156 1 Languette droite ouverture enveloppe Tongue right 6 YES 11PIC0220 2 Languette arrêt enveloppe Tongue envelope stop 7 YES 21PIA0001 1 Contre rouleau arrêt enveloppe Pressure roller envelope stop 8 YES 21PIA0034 1 Rouleau arrêt enveloppe Drive roller Envelope stop 9 YES 21PIA0035 1 ...

Page 80: ...D 6100 SERVICE MANUAL REVISION 2 1 SECTION 02 PAGE 79 CONTENTS 9 2 BRUSH 4124581N Item Series 1 compat Part number Qt y French description English description 1 YES 21PIA0027 3 Brosses de mouillage Moistening brush 1 1 1 ...

Page 81: ...Part number Qt y French description English description 1 YES 11PIA0122 1 disque zéro came Cam disc 2 YES 11PIC0127 1 Came sortie droite Right exit cam 3 YES 11PIC0128 1 Came sortie gauche Left exit cam 4 YES 11PIC0213 1 Came intérieur gauche left cam 5 YES 11PIC0214 1 Came intérieur droite right cam 1 2 3 5 4 1 4 3 2 5 ...

Page 82: ...ion English description 1 NO 4121929A 1 Ens DD C DD C assembly 2 NO 4122298K 5 Zero came chargement Arrêt env sortie env Sensors 3 NO 4122982X 5 Ens capteur chemin encart Insert path sensor assembly 4 NO 4123041J 1 Ens capteur sortie env LETTER OUTPUT sensor assembly 5 NO 4123044M 1 Ens capteur ref selection env ENV REFERENCE sensor assembly 1 5 4 3 2 ...

Page 83: ...escription English description 1 YES 12NCA000 4 1 Courroie Chemin inf C Insert lower path belt 2 YES 12PIA0003 1 Courroie moteur env Envelope motor belt 3 YES 12PIA0006 1 Courroie de chargement Inserting belt 4 YES 12PIA0007 1 Cde came Cam belt 5 YES 12PIB0002 1 poche A B Pocket A B belt 6 YES 12PID0001 1 Courroie cde bac C Bin C belt 1 2 4 3 6 5 ...

Page 84: ...6100 SERVICE MANUAL REVISION 2 1 SECTION 02 PAGE 83 CONTENTS 9 5 CLUTCHES 4124585S Item Series 1 compat Part number Qt y French description English description 1 YES 14PIC0002 3 1 bac C 1 transport C 1 pliage Clutch 1 1 1 ...

Page 85: ...re poche Bearing pocket closing bar 3 YES 11PIC0091 1 Pignon cde levier gauche Gear left lever drive 4 YES 11PIC0092 1 Levier pivot droit fermeture de poche Right lever 5 YES 11PID0093 2 Levier de cde fermeture poche Pocket closing drive lever 6 YES 11PID0106 1 Barette fermeture poche Closing bar 7 YES 21PID0032 1 Support gauche barrette de fermeture poche Left bracket 8 YES 21PID0033 1 Support dr...

Page 86: ...123028V 1 Ensemble doigts d insertion Europe équipé Insert fingers assembly Europe 3 YES 11PIA0326 1 poulie rouleau chargement Pulley inserting roller 4 YES 12PIA0006 1 Courroie de chargement Belt inserting 5 YES 21PIA0053 1 Poulie cde courroie chargement Pulley inserting belt 6 YES 21PIC0026 1 Rouleau d insertion équipé Inserting roller assembly 7 YES 4123029W 1 Ensemble doigts d insertion US équ...

Page 87: ...ber feet 2 YES 11PIC0089 1 Languette gauche ouverture enveloppe Left tongue envelope pre opening 3 YES 11PIC0156 1 Languette droite ouverture enveloppe Right tongue envelope pre opening 4 YES 11PIC0220 2 Languette arrêt enveloppe Tongue envelope stop 5 YES 11PIC0223 1 languette bac E Tongue bin E 6 YES 11PID0125 1 Languette entrée chemin C Tongue path C entrance 7 YES 11PID0126 2 Cache fil Tongue ...

Page 88: ...87 CONTENTS 9 9 EXIT LEVER DEFLECTOR 4124589W Item Series 1 compat Part number Qt y French description English description 1 YES 21PIA0117 1 Levier pré mouillage droit Lever pre moistening right 2 YES 21PIA0118 1 Levier pré mouillage gauche Lever pre moistening left 2 1 ...

Page 89: ...eries 1 compat Part number Qt y French description English description 1 YES 11PIA0001 4 Palier Bearing 2 YES 11PID0139 2 Rouleau de sélection Selection roller feeder C 3 YES 21PIC0086 2 Ensemble filière Europe Separation assembly Feeder C Europe 4 YES 4122975Q 2 Ensemble filière US Separation assembly Feeder C US 4 1 2 3 ...

Page 90: ...187 2 Patins de sélection bac E Separation pad Feeder E YES 12PIA0002 1 Brosse préselection bac E Separation brush Feeder E YES 21PIA0017 1 Rouleau plein transport env Transportation roller full Feeder E YES 21PIA0081 2 Galets libres bac E Roller free Feeder E YES 21PIA0143 1 Contre rouleau transport doc Pressure roller YES 21PIA0156 1 Ensemble rouleau 5 gommes bac E Roller 5 rubbers Feeder E YES ...

Page 91: ...4592Z Item Series 1 compat Part number Qt y French description English description 1 YES 11PIA0001 12 Palier Bearing 2 YES 11PID0013 2 Rouleau Chemin inf axe court Lower roller short Path C 3 YES 21PID0001 1 Rouleau Chemin inf axe long Lower roller long Path C 4 YES 21PID0003 3 Chemin sup Upper path Path C 2 1 3 4 ...

Page 92: ...NTENANCE 4124593A Item Series 1 compat Part number Qt y French description English description 1 YES 11PIA0001 12 Palier Bearing 2 YES 11PID0154 1 Rouleau pliage N 2 Folding roller 2 3 YES 11PID0156 1 Rouleau pliage N 3 Folding roller 3 4 YES 11PIDO155 1 Rouleau pliage N 4 Folding roller 4 1 4 3 2 ...

Page 93: ...ch description English description 1 YES 11PID0052 1 Rouleau arrière entrée doc Entry roller rear Document path 2 YES 21PIA0143 1 Contre rouleau transport env Pressure roller 3 YES 11PIA0001 6 Palier Bearing 4 YES 21PIC0018 1 Rouleau avant entrée doc Entry Roller front Document path 5 YES 21PID0011 1 rouleau inf transport doc Lower roller Document path 2 3 4 1 5 ...

Page 94: ...C 3 YES 11PIA104 1 Pignon intermédiaire cde bac C Inter gear Feeder C drive 4 YES 11PID0044 1 Pignon bac C Gear Feeder C 5 YES 11PID0068 1 Pignon embrayage transport C Gear Feeder C trans clutch 6 YES 11PID0088 1 Chemin C Gear Feeder C path 7 YES 11PID0113 2 poulie chemin C Pulley Feeder C 8 YES 4122039Q 2 Pignon crémaillère Rack gear Feeder C 9 YES 4122040R 1 Pignon bac C Gear Feeder C 10 YES 412...

Page 95: ... English description 1 YES 11PIA0025 1 Pignon intermédiaire Intermediate gear Feeder E 2 YES 11PIA0104 1 Pignon moteur bac E Motor gear Feeder E 3 YES 11PIA0141 1 monté en pignon double Double gear Feeder E 4 YES 11PIC0125 1 monté en pignon double Double gear Feeder E 5 YES 21PIA0052 3 Pignon intermédiaire Intermediate gear Feeder E 1 3 2 4 1 5 5 4 3 2 3 2 5 5 1 5 4 ...

Page 96: ...1PIA0053 1 poulie rouleau chargement Pulley Inserting roller 2 YES 11PIA0326 1 poulie rouleau chargement Pulley Inserting roller 3 YES 11PIB0007 1 Commande de came Cam drive Inserting 4 YES 11PIB0038 1 pignon cde came Cam drive gear Inserting 5 YES 11PIC0213 1 Pignon cde came Cam drive gear Inserting 6 YES 21PIA0053 1 Poulie cde courroie chargement Pulley inserting belt 1 5 6 2 1 4 6 5 4 3 2 3 ...

Page 97: ...Gear rear entry roller Doc path 4 YES 11PIC0140 1 Pignon rouleau avant entrée doc Gear front entry roller Doc path 5 YES 11PID0041 1 pignon embrayage entrée doc Gear entry doc clutch Doc path 6 YES 11PID0042 1 Pignon intermédiaire Intermetiate gear Doc path 7 YES 11PID0044 2 Pignon intermédiaire Intermetiate gear Doc path 8 YES 11PID0071 2 Pignon intermédiaire Intermetiate gear Doc path 9 YES 11PI...

Page 98: ...pe Pulley Exit roller 3 YES 11PIA0027 1 Pignon rouleau ejection env Gear Exit roller 4 YES 11PIB0043 1 Poulie cde rouleau de sortie Pulley Exit roller drive 5 YES 11PIC0074 1 Pignon moteur transport env Motor gear Envelope motor 6 YES 21PIA0059 1 Pignon poulie chemin enveloppe Gear pulley Envelope path 7 YES 21PIC0001 1 Pignon poulie transport env Gear pulley Env transportation 8 YES 21PIC0051 1 P...

Page 99: ...L Item Series 1 compat Part number Qt y French description English description 1 YES 11PIA0001 3 Palier Bearing 2 YES 21PIA0024 1 Rouleau de sortie inf Lower exit roller 3 YES 21PIA0055 1 Palier gauche rouleau de sortie sup Bearing left upper exit roller 4 YES 4122861W 1 Rouleau de sortie sup Upper exit roller 4 2 3 1 ...

Page 100: ...on env Cable machine opening envelope exit envelope reference and envelope separation sensors 4 NO 4121900V 1 câble capteur zero came et doc chargé Cable Zero cam and document loaded sensors 5 NO 4121887G 1 Cable DD C Cable DD C 6 NO 4122782P 1 cable document chargé Cable Document loaded sensor 7 NO 4121902X 1 câble embrayages bac C Pliage et transport doc Cable Feeder C folding and document trans...

Page 101: ...eries 1 compat Part number Qt y French description English description 1 YES 4105509W 2 Bouton de dévérouillage bacs AB Bin A B unlocking knob 2 YES 4105508V 2 Levier de dévérouillage guides bacs AB Feeder A B side guides locking lever 3 YES 4122955U 1 Capot cellule autostart équipé Feeder AB Front cover equiped 3 1 2 ...

Page 102: ...ument transportation pressure roller YES 11PIA0232 4 Ressort rouleau pliage Spring folding roller YES 11PIA0257 1 Ressort courroie transport env Spring Envelope transportation belt YES 11PIA0258 1 Ressort rappel ens arrêt env Spring Envelope stop assembly YES 11PIA0307 1 Ressort tendeur courroie came Spring belt cam YES 11PIA0325 1 ressort tendeur courroie chargement Spring inserting belt YES 11PI...

Page 103: ...ide guides locking knob 4105505S NO Capot sortie inf Cover Letter exit lower part 4125899L NO Ensemble alimenteur AB Feeder AB assembly 4121894P NO Moteur bac E équipé Hopper motor 4121897S NO Moteur équipé Env Came Env Cam transport motor 4121907C NO Moteur transport doc équipé Main motor 4121955C NO Ensemble ecran clavier User interface assembly display unit keyboard PCB 4121956D NO Capot affich...

Page 104: ...commande de butée de poche Pocket stop drive assembly 4122989E NO Ensemble tôle inférieure poche A équipée Pocket A Lower plate assembly 4122990F YE S Ensemble chemin encart sup Inf Insert path assembly upper lower 4122993J NO Ensemble tôle inférieure poche B équipée Pocket B Lower plate assembly ...

Page 105: ...ngues 4124589W YE S Kit leviers defleteur sortie envelopes Kit Envelope exit lever deflector 4124590X YE S Kit maintenance bac C Kit Feeder C maintenance 4124591Y YE S Kit maintenance bac E Kit Feeder E maintenance 4124592Z YE S Kit maintenance chemin encarts Kit Inserts path maintenance 4124593A YE S Kit maintenance pliage Kit Folding maintenance 4124594B YE S Kit maintenance transport documents ...

Page 106: ...imenteur AB Kit Feeder AB knobs 4124831Y YE S Kit insertion US Kit Inserting US Le capteur 4122298K inclu dans ce kit n est pas compatible S1 The sensor 4122298K included in this kit is not compatible with S1 Le moteur 4121971U inclus dans ce kit n est pas compatible S1 The motor 4121971U included in this kit is tot compatible with S1 ...

Page 107: ...CTION 02 PAGE 106 CONTENTS 4 SINGLE PART ILLUSTRATIONS 11PID0075 12PIC0006 11BFA1105 BACK TO THE ILLUSTRATED BACK TO THE ILLUSTRATED BACK TO THE ILLUSTRATED 4121894P BACK TO THE ILLUSTRATED BACK TO THE ILLUSTRATED 4105489A 11PIC0178 BACK TO THE ILLUSTRATED ...

Page 108: ... PAGE 107 CONTENTS 4122061N 4122525W 4122058K 4122062P BACK TO THE ILLUSTRATED BACK TO THE ILLUSTRATED BACK TO THE ILLUSTRATED BACK TO THE ILLUSTRATED 4105488Z 4105492D 4105487Y BACK TO THE ILLUSTRATED VIEW BACK TO THE ILLUSTRATED VIEW BACK TO THE ILLUSTRATED VIEW ...

Page 109: ...21 09 2003 FD 6100 SERVICE MANUAL REVISION 2 1 SECTION 02 PAGE 108 CONTENTS 4122748D 4121955C 4122999Q BACK TO THE ILLUSTRATED BACK TO THE ILLUSTRATED BACK TO THE ILLUSTRATED 4122113S BACK TO THE ILLUSTRATED ...

Page 110: ...0 SERVICE MANUAL REVISION 2 1 SECTION 02 PAGE 109 CONTENTS 11PIA0101 4122745A 11PIC0082 4105505S 4121907C BACK TO THE ILLUSTRATED BACK TO THE ILLUSTRATED BACK TO THE ILLUSTRATED BACK TO THE ILLUSTRATED BACK TO THE ILLUSTRATED ...

Page 111: ...ISSUE 21 09 2003 FD 6100 SERVICE MANUAL REVISION 2 1 SECTION 02 PAGE 110 CONTENTS 4122148D BACK TO THE ILLUSTRATED 4125899L BACK TO THE ILLUSTRATED ...

Page 112: ...ISSUE 21 09 2003 FD 6100 SERVICE MANUAL REVISION 2 1 SECTION 03 PAGE 111 MANUAL CONTENTS SECTION 3 COUNTRY SPECIFIC 1 INSTALLATION 112 1 1 UNPACKING THE MACHINE 112 ...

Page 113: ... 1 SECTION 03 PAGE 112 CONTENTS 10 INSTALLATION 10 1 UNPACKING THE MACHINE To unpack the machine process according the following steps WARNING THE HANDLING OF THE MACHINE REQUIRES 2 PERSONS NOW REFER TO THE GETTING STARTED GUIDE TO INSTALL THE MACHINE ...

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Formax FD 6100, Service Manual

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