6204 Series Low-Volume Inserter

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1 204 Series Low-Volume Inserter /2012 MAINTENANCE MANUAL

2 Mechanical description Mechanical description...51 General...52 Covers and plates...52 Electrical components...57 Feeder modules...0 Document feed...4 Collating area...74 Collating area...74 Folder...7 Main drive mechanism...89 Envelope hopper...97 Upper unit Envelope transport Envelope sealing and ejection Detectors Adjustments Service Guide 51

3 Collating area (Dis)assembly - Vertical transport 03.1 Service Guide To get access to several parts of the vertical transport track, remove the vertical transport cover as described in Section Covers upper unit on page 5 73

4 Collating area Disassembling the collating area 03.1 Service Guide The parts which are described in this section are located in the upper arm of the collating area. It is recommended to remove the complete collating arm. 1. Remove the collator area covers as described in Section Top cover feeders, covers collator area, power supply cover on page Disconnect the wiring of the collator motor. 74

5 3. Loosen the set screw () on the bush (7) as shown in the following figure. 4. Pull the motor outside the frame 5. Support the collating arm.. Remove the screws (1) as shown in the previous figure (two at the left-hand side and two at the right-hand side). 7. Carefully remove the collating arm Transportation belts 03.1 Service Guide The transportation belts are only available as a set. If a belt is worn, all the belts should be replaced. 1. Remove roller (1) from the axle. 2. Slide the axle to the left-hand side out of the bearings. Take care of the tensioner (2), it is spring loaded. 3. Remove the tensioner (2). 75

6 4. Remove the plate (3). 5. Remove the axles (4 and 5). The middle transportation belt can now be replaced. Guide rollers The guide rollers (8 and 10) are spring loaded. 1. Remove the accompanying spring clips and washers 2. Slide the guide rollers of the axles 3. Remove the screw of the axle of the guide roller (9). 4. Slide the axle to the left-hand side 5. Remove the spring clip at the right-hand side of the guide roller.. Slide the roller of the axle 03.1 Service Guide Folder Right-hand drive mechanism- Lower folder section Belts The removal of the drive belt (1) as described in Section Drive mechanism right-hand - Belts and pulleys on page 1. 7

7 Pulleys 1. Remove the drive belt (1). 2. Remove the accompanying spring clip 3. Remove the clamping ring 4. Slide pulley 2 and 3 of the axles Gears The gears, number 4 (refer picture in section Right-hand drive mechanism on page 7) and number 1 ( following picture), can easily be slid of the axles. Take care of the cyl. pins when removing the gears Service Guide 77

8 Right-hand drive mechanism- Upper folder section Belts 03.1 Service Guide 1. Slacken the two screws (2) of the belt tensioner (1) 2. Remove the belt (4 )from the pulleys (3) and (5) Pulleys 1. Remove the belt (4) as described in the previous section 2. Remove the spring clip and the bush of the pulley (3) 3. Slide the pulley (3) of the axle 4. Slide the pulley (5) of the axle Gears and 8 1. Remove the spring clip, clamping ring and washers 2. Remove the gears ( and 8). When removing gear, take care of the cyl. pin Gear 7 1. Remove the belt (4) 2. Remove the pulley (5) 3. Remove gear (7) 78

9 Left-hand drive mechanism Gears 03.1 Service Guide To remove the gears of the lower folder section (1 to 5) at the left-hand side of the machine 1. Remove the circuit board 2. Remove the spring clips, clamping rings and washers. Take care of the cyl. pin of the gears 1, 3 and 5 and the spacers of the gears 2 and 4 3. Remove the gears (1 to 5) 79

10 Fold mechanism 03.1 Service Guide The fold plates (1 and 5) are driven via the curved gears (7, four in total) and two gears (3), activated by the two clutches (2) on the drive axle (4). 80

11 Gears 32T, drive axle 1. Remove the belt (13), pulleys (12 and 14) and freewheel clutch (11) 2. Remove the locking plate (10) securing the bearing of the drive axle (4) 3. Carefully move the axle (4) to the right-hand side until the bearing clears the frame 4. Carefully lift the axle assembly as far upwards as possible. Take care of the wiring of the clutches on the axle and the plastic bearing on the left-hand side 5. Remove the bearing, spacer, washers and the spring clip of the left-hand side of the drive axle assembly. Slide the gear (1) of the axle. To remove the gear (4) and clutches (2 and 3): 1. Cut the wire straps at the connectors of the clutches 2. Slide the clutch (2) to the left-hand side of the axle. Take care of the cyl. pin of the clutch 3. Remove all the components between the clutches, including the cyl. pin of the clutch (3) 4. Slide the clutch (3) to the left-hand side of the axle 5. Remove the gear (4) from the drive axle 03.1 Service Guide Ensure on replacement to secure the wiring of the clutches again and that both clutches are retained by the locking plate. Also ensure that the clutches clockwise and counterclockwise are placed in the proper position. 81

Gears 32T,drive axle- Curved folder gears 03.1 Service Guide 1. Remove the drive axle assembly as described in section Gears 32T, drive axle on page 81 (refer to the picture on the same page). 2.

12 Gears 32T,drive axle- Curved folder gears 03.1 Service Guide 1. Remove the drive axle assembly as described in section Gears 32T, drive axle on page 81 (refer to the picture on the same page). 2. Remove the bearings (9) from the axles () 3. Remove the brake discs (15, spring loaded), the springs, the brake strip (1) and the bearings (17) from the axles (8) 4. Remove the levers for the flap actuators, the bearings, etc. (1 up to ) from the axles (12). Pin has to be loosened by a set screw, to be accessed at axle end (12) 5. Remove the brackets (7) with the sensors. Remove the brake discs with the bearings (20 up to 22) from the axles (13) 7. Remove the screws at the left and right-hand side of the guide plate (9) 8. Unhook the guide plate and remove it 9. Remove the screws at the left and right-hand side by which the brackets (10) are mounted to the upper frames 10. Carefully lift each complete fold assembly upwards and withdraw it 82

13 Gears 32T- First curved folder gears 03.1 Service Guide To remove the curved gears 1. Remove the two screws () 2. Slide both hinge plates (5 and 7) together with the fold plate (4) of the axle 3. Pull the curved gears (2 and 8) of the axle 83

14 Gears 32T- Second curved folder gears Refer to the figure on section "First curved folder gears on page 83" 1. Remove the hinge plates (15 and 17) in the same way as described previously 2. Pull the curved gears (9 and 10) of the axle Ensure on replacement that the curved gears and the curved discs are replaced correctly onto the axle (refer to the following figure). Secure the wiring of the clutches again. The right hand curved gear is marked with an R and the left-hand curved gear is marked with an L 03.1 Service Guide After replacing and securing the complete fold assembly, check the adjustment of the paper guides (3 and 11, refer to the figure on section "First curved folder gears on page 83"). See section "Paper guide on page 132". 84

15 Input rollers Remove the drive belt as described in section "Drive mechanism right-hand - Belts and pulleys on page 1". To remove the input rollers 1. Remove the pulley, the gears of the upper input rollers (1) and the gears of the lower input rollers (2) as described in section "Right-hand drive mechanism on page 7" Service Guide 85

16 2. Remove the bearing locking plate (3) 03.1 Service Guide 3. Remove the gear 7 of the lower input roller () 4. Remove the bearing locking plate (5) 5. Remove the guide strip (4) and the guide bracket below it.. Move the upper input roller (2) to the right-hand side until the left-hand bearing is free of the left-hand inside frame 7. Lift the left-hand side of the roller upwards and withdraw the roller out of the right-hand inside frame 8. Move the lower input roller () to the right-hand side until the left-hand bearing is free of the left-hand inside frame 9. Lift the left-hand side of the roller upwards and withdraw the roller out of the right-hand inside frame 8

17 Lower fold rollers 03.1 Service Guide 1. Remove the gears (8, refer to the figure on section "Input rollers on page 85"). 2. Loosen the two hexagonal head screws (3) 3. Push down the solenoid (4) to get access to the screw (2) 4. Remove the screws (2) 5. Remove the bearing plate (1). Move the roller to the right-hand side until the left-hand bearing is free of the left-hand inside frame 7. Lift the left-hand side of the roller upwards and withdraw the roller out of the right-hand inside frame After replacing the lower fold rollers, check the adjustment of the solenoid. See section "Solenoids on page 133". 87

Upper fold rollers 03.1 Service Guide To remove the upper fold rollers 1. Remove the belt with the pulley (5) and the three gears (4) at the right-hand side 2. Remove the guide strip (2).

18 Upper fold rollers 03.1 Service Guide To remove the upper fold rollers 1. Remove the belt with the pulley (5) and the three gears (4) at the right-hand side 2. Remove the guide strip (2). This is necessary for the removal of the first fold roller 3. Remove the bearing locking plates (3) on both sides 4. Move roller 1 to the right-hand side until the left-hand bearing is free of the left-hand frame 5. Move the left-hand side of the roller downwards and withdraw the roller out of the right- hand frame For belt adjustments, see section "Drive belt upper folder section on page 131". 88

19 Main drive mechanism (Dis)assembling the main drive mechanism inserter The main motor 8 provides the mechanical power to the 03.1, with exception of the collating area Service Guide 89

PJ-belt For removal of the PJ-belt (2): 1. Disassemble the main drive belt for the feeder and folder section. See section "Drive mechanism right-hand - Belts and pulleys on page 1". 2.

20 PJ-belt For removal of the PJ-belt (2): 1. Disassemble the main drive belt for the feeder and folder section. See section "Drive mechanism right-hand - Belts and pulleys on page 1". 2. Loosen the two hexagonal head screws (4) of the tensioner (5) 3. Remove the belt (2) from the main pulley (1) and the motor pulley (3) Drive belt inserter 03.1 Service Guide All moving components of the inserter part are driven by belt 10. To remove belt Loosen the two hexagonal head screws of the tensioner (1) 2. Remove the belt from the pulleys 90

21 Belt envelope feed To remove the belt envelope feed 1. Remove the support plate (11) by which the intermediate axle (13) is supported. Take care of the bearings and the washers 2. Remove the belt (5) from the pulley on the intermediate axle and from the pulley on the envelope feed axle (3) 03.1 Service Guide Pulleys Pulleys 5 and 9 Refer to the figure on section"drive belt inserter on page 90". 1. Remove the pulleys (5 and 9) 2. Remove the spring clips of the pulleys (5 and 9) Pulley Remove the main pulley (Refer to section"drive mechanism right-hand - Belts and pulleys on page 1"). 2. Remove the pulley (11) Pulley 8 1. Remove the mounting plate () with the adjustment plate and the pulse disc sensor 2. Remove the pulse disc (7) 3. Slide the pulley (8) of the axle. Take care of the spacer After replacement of the pulse disc sensor be sure that it clears the pulse disc on both sides 91

22 Pulley 9 Refer to the figure on section "Belt envelope feed on page 91". 1. Remove the belt (5) as described in Belt envelope feed 2. Remove the accompanying spring clip and washer from the pulley (9) 3. Slide the pulley (9) of the envelope feed axle (3). Pulley Remove the bearings, washers and gears from the intermediate axle (13) 2. Tap the tension pin from the intermediate axle 3. Slide the pulley (14) of the axle Gears 03.1 Service Guide Gears 3 (sealing rollers) Refer to the figure on section "Drive belt inserter on page 90 " {cr} 1. Remove the pulley (5). 2. Remove the spring clips and washers 3. Slide the gears (3) of the axles Gear 2 The gear (2) is mounted to the axle by a tension pin. To remove the gear (2): 1. Remove the tension springs of the bearings of the axle. 2. Remove the spring clip with washer and bearing at the left-hand side of the axle. 3. Slide the two rollers to the right-hand side 4. Remove the cyl. pin from the axle 5. Slide the axle with the gear (2) to the right-hand side out of the right-hand inside frame.. Tap the tension pin to remove the gear (2). Gear 4 The gear (4) is mounted to the pulse disc axle (14) by a tension pin. To remove the gear (4): 1. Remove the pulse disc (7) and the pulley (8). 2. Remove the spring clip at the left-hand side of the axle. 3. Slacken the set screws of the two rollers. 4. Remove the locking plate (13). 5. Slide the pulse disc axle (14) to the right-hand side out of the right-hand inside frame. While doing this: remove the bearing, the washer, and the two rollers.. Tap the tension pin 7. Dissemble the gear Gear 12 Refer to the picture "Main drive mechanism inserter - Belt on page 91" 1. Remove pulley (9) 2. Slide the gear (12) of the axle Gears 8, 10, 15, 1, 18, 20 and 22 Refer to the figure on section "Belt envelope feed on page 91". 1. Remove the spring clips and washers 2. Remove the gears (8, 10, 15, 1, 18, 20 and 22). Gear Remove the nuts. Take care of the tension spring. 92

23 2. Slide all the parts of the brake rod 3. Remove the gear (21). For adjustment of the friction brake, see section "Friction brake on page 13". Gear 1. Remove the gear (8). 2. Dissemble the clutch (7). 3. Remove the support plate (11). 4. Disconnect the wiring of the clutch 5. Slide the clutch of the axle. Remove gear Gears 4 and Remove the support plate (11) to free the intermediate axle (13) with its components. 2. Remove the bearings, washers and spring clip from the axle. 3. Slide the gears (4 and 12) from the axle. Gear Remove the insert table to get access to the transportation axle. 2. Remove the spring clip, washer and bearing at the left-side of the transportation axle (2). 3. Move the axle a little to the right-hand side 4. Slide the gear (17) to the left-hand side 5. Remove the cyl. pin.. Slide the gear (17) of the axle Gear 19 The gear (19) is mounted to the transportation axle (1) by a tension pin. To remove this gear: 1. Remove the insert table 2. Remove the spring clip, washer and bearing from the left-hand side of the axle. 3. Slide the rollers to the right-hand side to remove the cyl. pins. 4. Slide the axle to the right-hand side out of the right-hand inside frame. Take care of the two rollers. 5. Tap the tension pin. Remove the gear (19) from the axle Clutches 03.1 Service Guide Slip clutch envelope feed axle Refer to the figure on section "Belt envelope feed on page 91". 1. Remove the metal ring of the pulley (9). 2. Slide the belt (5) of the pulley (9). 3. Remove the pulley from the axle 4. Slide the slip clutch of the axle Clutch CW When the machine is switched on the gear () it is constantly driven. By activating the clutch (7) all the gears shown in the figure on section "Belt envelope feed on page 91" and the accompanying axles and rollers of the envelope feed and envelope track will be driven. So to feed, open and place an envelope on the insert table the clutch (7) is activated. To remove the clutch (7): 1. Remove the support plate (11) and the gear (8). 2. Disconnect the wiring of the clutch 3. Slide the clutch (7) of the axle. 93

24 Power supply assy. and main motor (M2) Power supply assy The main fuse can be replaced without removal of the covers. In the switch mode power supply () an extra fuse is present Service Guide To remove the power supply assy.: 1. Remove the main lead 2. Remove the power supply cover (2). 3. Disconnect all wiring 94

4. Cut the wire straps 5. Remove the two countersunk head screws (4) and the two round head screws (7) securing the power supply assy.. Pull the power supply assy. out of the machine.

25 4. Cut the wire straps 5. Remove the two countersunk head screws (4) and the two round head screws (7) securing the power supply assy.. Pull the power supply assy. out of the machine. When replacing the power supply assy., ensure that the guide plates 1 are fitted correctly in the guide rollers. Also take care to fit the microswitch correctly and ensure the correct functioning Service Guide 95

26 Main motor M Service Guide To remove the main motor: 1. Release the belt tensioner (5) 2. Remove the belt (2). 3. Remove the bottom plate of the machine 4. Remove the four screws () and the washers (7). 5. Withdraw the motor (8) from the machine. Take care of the wiring. For belt adjustment, see section "Main drive PJ-belt on page 127", and section "Main drive belt inserter on page 129". 9

ILLUSTRATED PARTS LIST

FPi 5000 Inserting System SERVICE MANUAL ILLUSTRATED PARTS LIST FPI 5000 I ollator rev. 0.0-0/00 Contents Section Page General 50.00- Process description 50.0- Mechanical description 50.0- Electrical description