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FD 6100 - MAINTENANCE MANUAL


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FD 6100

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CONTENTS
REVISIONS
SECTION 1: MAINTENANCE

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FD 6100 - MAINTENANCE MANUAL

SECTION 2: PARTS LIST


SECTION 3: UNPACKING

PAGE 3

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CONTENTS

MODIFICATIONS FOLLOW-UP
Revision

Date

Reference
soft.

1.4
2.0

10/07/03
01/09/03

1.11
1.15

2.1

21/09/03

1.15

Main modifications
Section
ALL
S1 FR
S1 ENG
S2
S4
S1 ENG
S1 ENG
S3

Page

DESCRIPTION
Launch Version
5, 23, 25, 31, 32, 48, 50
Pages 5, 6, 7, 11, 23, 25, 31, 32, 40, 48, 50 have been modified.

ALL
ALL
31 Adding of US terminology
46-49 Splitting of the USA and Europe specifications
3-5 Removing of the empty chapters

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MANUAL CONTENTS

SECTION 1: MAINTENANCE
1

INTRODUCTION ..................................................................................................6
1.1
1.2
1.3
1.4
1.5
1.6

PRECAUTION ............................................................................................................................. 6
TERMINOLOGY .......................................................................................................................... 7
GENERAL OVERVIEW............................................................................................................... 9
SENSORS/SWITCHES, MOTORS AND CLUTCHES.............................................................. 15
PCB INTERCONNECTION DIAGRAM..................................................................................... 17
PROTOCOL AND HARDWARE CONFIGURATION ............................................................... 20

SERVICE CALL CHECK LISTS.........................................................................21


2.1
2.2
2.3
2.4

Click
page

START OF SERVICE CALL CHECK LIST .............................................................................. 21


END OF SERVICE CALL CHECK LIST ................................................................................... 21
PREVENTIVE MAINTENANCE ................................................................................................ 22
MAINTENANCE KITS DETAILS .............................................................................................. 23

SOFTWARE UPGRADE AND CPU BOARD REPLACEMENT .........................39


3.1 SOFTWARE UPGRADE ........................................................................................................... 39
3.2 CPU BOARD REPLACEMENT ................................................................................................ 39

DIAGNOSTICS TOOL ........................................................................................40


4.1 ERROR MESSAGE LIST.......................................................................................................... 40
4.2 FUNCTIONAL FAULTS ............................................................................................................ 42
4.3 FUNCTIONAL TESTS............................................................................................................... 43

DISASSEMBLING, RE-ASSEMBLING AND ADJUSTMENTS..........................51


5.1
5.2
5.3
5.4

TOOLS ...................................................................................................................................... 51
DISASSEMBLING..................................................................................................................... 51
RE-ASSEMBLING AND ADJUSTMENTS ............................................................................... 52
DISASSEMBLING AND RE-ASSEMBLING SUMMARY......................................................... 53

THEORY OF OPERATION.................................................................................54
6.1
6.2
6.3
6.4
6.5

KEY CODES.............................................................................................................................. 54
USER MODE DIAGRAM........................................................................................................... 55
SETTING MODE DIAGRAM (ADVANCED USER MODE) ...................................................... 56
BASE SERVICE MODE ............................................................................................................ 57
SEQUENCES OF SOFTWARE FUNCTIONS .......................................................................... 58

EUROPE SPECIFICATIONS..............................................................................59

USA SPECIFICATIONS .....................................................................................61

RECOMMENDED SPARE PARTS LIST............................................................64

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CONTENTS

1
1.1

INTRODUCTION
PRECAUTION

Actuators : never grease or lubricate plastic parts in movement . Only 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)

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CONTENTS
1.2

TERMINOLOGY

A SELECTION
CLUTCH
A, feeder A
A-EMPTY
B SELECTION
CLUTCH
B, feeder B
B-EMPTY
BOTTOM FOLDER
MOTOR
C SELECTION
CLUTCH
C TRANSPORT
CLUTCH
C, feeder C
CAM MOTOR
CAM-ZERO
C-CLOSED
C-EMPTY
DD-A
DD-B
DD-C
DD-KEY
DOC-LOADED
DOCUMENT FEEDER
CLUTCH
END-SEPARATION-A
END-SEPARATION-B
END-SEPARATION-C
ENV TRANSPORT
MOTOR
ENV-EXIT
ENV-REFERENCE
Flash
Hopper
HOPPER MOTOR
INSERT-SIGNAL
INSERT-STOP
LETTER-OUTPUT
MACHINE-OPEN
MAIN MOTOR
MANUAL FEEDING
MOTOR
MMI
MULTI
SINGLE FOLD
MOTOR

See description in Section 1, Chapter 1.4.1 "Sensors"


Front manual and automatic feeder for documents
See description in Section 1, Chapter 1.4.1 "Sensors"
See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
Rear automatic feeder for documents
See description in Section 1, Chapter 1.4.1 "Sensors"
See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
Automatic feeder for inserts or BRE
See description in Section 1, Chapter 1.4.1 "Sensors"
See description in Section 1, Chapter 1.4.1 "Sensors"
See description in Section 1, Chapter 1.4.1 "Sensors"
See description in Section 1, Chapter 1.4.1 "Sensors"
See description in Section 1, Chapter 1.4.1 "Sensors"
See description in Section 1, Chapter 1.4.1 "Sensors"
See description in Section 1, Chapter 1.4.1 "Sensors"
See description in Section 1, Chapter 1.4.1 "Sensors"
See description in Section 1, Chapter 1.4.1 "Sensors"
See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
See description in Section 1, Chapter 1.4.1 "Sensors"
See description in Section 1, Chapter 1.4.1 "Sensors"
See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
See description in Section 1, Chapter 1.4.1 "Sensors"
See description in Section 1, Chapter 1.4.1 "Sensors"
Memory including the software
Envelope feeder
See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
See description in Section 1, Chapter 1.4.1 "Sensors"
See description in Section 1, Chapter 1.4.1 "Sensors"
See description in Section 1, Chapter 1.4.1 "Sensors"
See description in Section 1, Chapter 1.4.1 "Sensors"
See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
Man Machine Interface
Multimeter in ohmmeter position.
See description in Section 1, Chapter 1.4.2 "Clutches and Motors"

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CONTENTS
TOP FOLDER MOTOR
Type E sensor
Type F sensor
Type H sensor
Type PP motor
Type R sensor
Type S switch

See description in Section 1, Chapter 1.4.2 "Clutches and Motors"


Electrodes
Flag sensor
Hall effect sensor
stepper motor
Reed bulb (activation of a mechanical switch under a magnet effect)
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

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PAGE 9

CONTENTS
1.3

1.3.1

GENERAL OVERVIEW

FEEDER A-B SENSORS AND SWITCH VIEW

DD-A

DD-B

END SEPARATION - B

END-SEPARATION-A

B-EMPTY

DD-KEY

A-EMPTY / AUTOSTART

B-EMPTY

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CONTENTS
1.3.2

BASE SENSORS AND SWITCH VIEW

C.EMPTY
LETTER.OUTP
ENV.EXIT

MACHINE
OPEN
C.CLOSED
END AND
SEPARATION C

DD.BAC.C
REF.ENV
INSERT.STOP
FOLDING
PLATE 2
DOC.LOADED
ZERO.CAME

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CONTENTS
1.3.3

BASE SENSORS AND SWITCH VIEW

MACHINE-OPEN
1.3.4
LETTER-OUTPUT
DD-C
ENV-EXIT

ENV-REFERENCE
ENDSEPARATION C
INSERT-STOP
C-EMPTY

C-CLOSED
CAM-ZERO

DOC-LOADED

INSERT-SIGNAL

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CONTENTS
1.3.5

CLUTCHES VIEW

B SELECTION
CLUTCH

MANUAL
FEEDING MOTOR

A SELECTION
CLUTCH

C SELECTION CLUTCH

C TRANSPORT CLUTCH

DOCUMENT FEEDER
CLUTCH

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CONTENTS
1.3.6

MOTORS VIEW

HOPPER
MOTOR

MAIN MOTOR

ENV
TRANSPORT
MOTOR

SINGLE FOLD
MOTOR
(EUR only)

TOP FOLDER
MOTOR

BOTTOM
FOLDER
MOTOR

CAM MOTOR

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CONTENTS
1.3.7

PAPER PATH VIEW

DOCUMENT PATH

ENVELOPE PATH

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CONTENTS
1.4

SENSORS/SWITCHES, MOTORS AND CLUTCHES

1.4.1

SENSORS

SERVICE TEST
Bin C path closed
Exit env. feeder
Machine open
End separation C
Document in feeder C
Document loaded
Stop insert
SERVICE TEST
Insert signal
Envelope Exit
Envelope Ref.
Cam zero
SERVICE TEST
Document in feeder A
Document in feeder B
End separation A
End separation B
Double detection key
SERVICE TEST
Entry doc A sensor
Entry doc B sensor
Entry doc C sensor

MACHINE SENSORS (PART 1)


COMPONENT NAME
FUNCTION
C-CLOSED
Checks if feeder C path is closed
ENV-EXIT
Checks if the envelope has left the envelope hopper
MACHINE-OPEN
Checks if the machine is open
END-SEPARATION-C C SEPARATION CLUTCH drive
C-EMPTY
No inserts in the feeder C
DOC-LOADED
inserting check
INSERT-STOP
Insert (or BRE) stop position
MACHINE SENSORS (PART 2)
COMPONENT NAME
FUNCTION
INSERT-SIGNAL
Synchronization document / Insert (or BRE)
LETTER-OUTPUT
Letter output check
ENV-REFERENCE
Reference for the envelope inserting position
CAM-ZERO
Cam home position
FEEDER A-B SENSORS
COMPONENT NAME
FUNCTION
A-EMPTY / AUTOSTART
No document in feeder A / AUTOISTART
B-EMPTY
No document in feeder B
END-SEPARATION-A A SEPARATION CLUTCH drive
END-SEPARATION-B B SEPARATION CLUTCH drive
DD-KEY
Enable or disable DD-A and DD-B
DOUBLE DETECTION (Thickness detection)
COMPONENT NAME
FUNCTION
DD-A
Voltage delivered by the feeder A duplicate detector
DD-B
Voltage delivered by the feeder B duplicate detector
DD-C
Voltage delivered by the feeder C duplicate detector

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CONTENTS
1.4.2

MOTORS AND CLUTCHES

SERVICE TEST
Not available
Not available
Not available

FEEDERS CLUTCHES
COMPONENT NAME
FUNCTION
A SELECTION CLUTCH
Activate feeder A selection rollers
B SELECTION CLUTCH
Activate feeder B selection rollers
C SELECTION CLUTCH
Activate feeder C selection rollers

SERVICE TEST
Not available

MACHINE CLUTCHES
COMPONENT NAME
FUNCTION
C TRANSPORT CLUTCH
Activate the transport C rollers.

Not available

DOCUMENT FEEDER CLUTCH

SERVICE TEST
Not available
Not available
Not available
Not available
Not available
Not available
Not available
Not available

- Transfer mechanical power to document feeders


- Activate document transportation until folding rollers.

MOTORS
COMPONENT NAME
FUNCTION
TOP FOLDER MOTOR
Drives Top folder adjustment
BOTTOM FOLDER MOTOR
Drives Bottom folder adjustment
- Drives the folding rollers.
MAIN MOTOR
- Documents feeding.
- Insert/BRE feeding
CAM MOTOR
Drives the cam (inserting area)
Drives envelope from the hopper exit until the exit of
ENV TRANSPORT MOTOR
the machine
HOPPER MOTOR
Drives the envelope until the hopper exit.
SINGLE FOLD MOTOR
Drives the pocket A closing bar (Europe only)
MANUAL FEEDING MOTOR
Opens the feeder A path in order to perform daily mail

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CONTENTS
1.5

1.5.1
1.5.2

PCB INTERCONNECTION DIAGRAM

MAIN PCB (PART 1)

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CONTENTS
1.5.3
1.5.4

MAIN PCB (PART 2)

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CONTENTS
1.5.5
1.5.6

FEEDER PCB

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CONTENTS
1.6

PROTOCOL AND HARDWARE CONFIGURATION

LEFT INTENTIONALLY BLANK

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CONTENTS
2

2.1

SERVICE CALL CHECK LISTS

START OF SERVICE CALL CHECK LIST

Check the user has been trained on the machine.


Check the application corresponds with the job in process.
Check the properties of the job correspond 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 wetting brushes under warm water.
Check the moistening quality.
Check the water level in the tank.

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PAGE 22
CONTENTS

2.3

PREVENTIVE MAINTENANCE

SPARE / KIT
PN

REGULA
"HIGH VOLUME" CUSTOMER
R
CUSTOM
ER
30000 or 60000 90000 120000 150000 180000
once a year
End of
Rollers cleaning
X
X
X
X
X
Life
4124581N
End of
Moistening brushes replacement
X
X
X
X
X
Life
4124587U (EUR)
End of
Inserting fingers and rollers
X
4124831Y (US)
Life
replacement
4124590X
End of
Feeder C maintenance
X
Life
4124591Y
End of
Feeder E maintenance
X
X
Life
4124592Z
End of
C path maintenance
X
X
Life
4124594B
End of
Doc. Transport. Maintenance
X
Life
4124603L
End of
Exit rollers maintenance
X
X
Life
End of
4120482T
Feeder AB replacement (swap)
X
Life
Regular customer: 1000 cycles per month / 5 years
"Hi Volume" customer: up to 3000 cycles per month / 5 years

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PAGE 23

CONTENTS
2.4

MAINTENANCE KITS DETAILS

Kit description

Series 1
compatibilit
y

Envelope stop
4124580M

YES
YES
YES
YES
YES
YES
YES
YES
YES

Brush
4124581N
Cam
4124582P

NO
YES
YES
YES
YES

Part Quantit
French description
number
y
11PIA000
6 Paliers
1
11PIA002
2 Support arrt enveloppe
0
11PIC008
1 Dflecteur volet enveloppe
5
11PIC008
1 Languette gauche ouverture
9
enveloppe
11PIC015
1 Languette droite ouverture
6
enveloppe
11PIC022
2 Languette arrt enveloppe
0
21PIA000
1 Contre rouleau arrt enveloppe
1
21PIA003
1 Rouleau arrt enveloppe
4
21PIA003
1 Ejection enveloppe
5
4122298K
1 Capteur arrt enveloppe
21PIA002
3 Brosses de mouillage
7
11PIA012
1 disque zro came
2
11PIC012
1 Came sortie droite
7
11PIC012
1 Came sortie gauche
8

English description
Bearings
Enveloppe stop bracket
Envelope flap deflector
Tongue - left
Tongue - right
Tongue - envelope stop
Pressure roller - envelope stop
Drive roller - Envelope stop
Ejection roller - Envelope stop
Sensor - Envelope stop
Moistening brush
Cam disc
Right exit cam
Left exit cam

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YES

PAGE 24

1 Came intrieur gauche

left cam

1 Came intrieur droite

right cam

NO

11PIC021
3
11PIC021
4
4121929A

1 Ens DD-C

DD-C assembly

NO

4122298K

Sensors

NO
NO

4122982X
4123041J

5 Zero came - chargement - Arrt


env - sortie env
5 Ens capteur chemin encart
1 Ens capteur sortie env

NO

4123044
M

YES
Sensors
4124583Q

FD 6100 MAINTENANCE MANUAL

1 Ens capteur ref selection env.

Insert path sensor assembly


LETTER-OUTPUT sensor
assembly
ENV-REFERENCE sensor
assembly

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KITS DETAILS (FOLLOW UP)


CONTENTS
Series
1
Kit description compatibilit
Part Quantit
French description
English description
number
y
y
Belts
YES 12NCA00
1 Courroie Chemin inf C
Insert lower path belt
4124584R
04
YES 12PIA000
1 Courroie moteur env
Envelope motor belt
3
YES 12PIA000
1 Courroie de chargement
Inserting belt
6
YES 12PIA000
1 Cde came
Cam belt
7
YES 12PIB000
1 poche A
Pocket A belt
2
YES 12PID000
1 Courroie cde bac C
Bin C belt
1
Clutches
YES 14PIC000
3 1 bac C, 1 transport C, 1 pliage
Clutch
4124585S
2
Pocket A closing
YES 11BFA24
1 Pignon intermdiaire fermeture
Gear (intermediate) - closing bar
(Europe use only)
02
poche
4124586T
YES 11PIC007
2 Palier barette de fermeture poche Bearing - pocket closing bar
5
YES 11PIC009
1 Pignon cde levier gauche
Gear - left lever drive
1
YES 11PIC009
1 Levier pivot droit (fermeture de
Right lever
2
poche)
YES 11PID009
2 Levier de cde fermeture poche
Pocket closing drive lever
3
YES 11PID010
1 Barette fermeture poche
Closing bar
6
YES 21PID003
1 Support gauche barrette de
Left bracket
2
fermeture poche
YES 21PID003
1 Support droit barrette de fermeture Right bracket

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Inserting (Europe)
4124587U

NO
YES
YES
YES
YES
YES
YES

FD 6100 MAINTENANCE MANUAL


PAGE 26

3
4121971U
11PIA005
3
4123028V
11PIA032
6
12PIA000
6
21PIA005
3
21PIC002
6

poche
1 Moteur pas a pas
1 poulie rouleau chargement

Stepper motor
Pulley - inserting roller

1 Ensemble doigts d'insertion


Europe quip
1 poulie rouleau chargement

Insert fingers assembly (Europe)


Pulley - inserting roller

1 Courroie de chargement

Belt - inserting

1 Poulie cde courroie chargement

Pulley - inserting belt

1 Rouleau d'insertion quip

Inserting roller assembly

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KITS DETAILS (FOLLOW UP)


Series 1
Kit description compatibilit
Part Quantit
French description
number
y
y
Inserting (US)
YES 11PIA005
1 poulie rouleau chargement
4124831Y
3
YES 4123029
1 Ensemble doigts d'insertion US
W
quip
YES 11PIA032
1 poulie rouleau chargement
6
YES 12PIA000
1 Courroie de chargement
6
YES 21PIA005
1 Poulie cde courroie chargement
3
YES 21PIC002
1 Rouleau d'insertion quip
6
Tongues
YES 11PIA009
4 patins amortissants pieds
4124588V
3
YES 11PIC008
1 Languette gauche ouverture
9
enveloppe
YES 11PIC015
1 Languette droite ouverture
6
enveloppe
YES 11PIC022
2 Languette arrt enveloppe
0
YES 11PIC022
1 languette bac E
3
YES 11PID012
1 Languette entre chemin C
5
YES 11PID012
2 Cache fil
6
Exit lever deflector YES 21PIA011
1 Levier pr-mouillage droit
4124589W
7
YES 21PIA011
1 Levier pr-mouillage gauche
8

PAGE 27
CONTENTS

English description
Pulley - inserting roller
Insert fingers assembly (US)
Pulley - inserting roller
Belt - inserting
Pulley - inserting belt
Inserting roller assembly
Shock absorber - feet
Left tongue - envelope preopening
Right tongue - envelope preopening
Tongue - envelope stop
Tongue - bin E
Tongue - path C entrance
Tongue - Cable protection
Lever - pre-moistening (right)
Lever - pre-moistening (left)

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4124590X

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PAGE 28

YES

11PIA000
1

4 Palier

Bearing

YES

11PID013
9
21PIC008
6
4122975Q

2 Rouleau de slection

Selection roller - feeder C

2 Ensemble filire Europe

Separation assembly - Feeder C


Europe
Separation assembly - Feeder C
US

YES
YES

2 Ensemble filire US

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KITS DETAILS (FOLLOW UP)


Series 1
Kit description compatibilit
Part Quantit
French description
number
y
y
Feeder E
YES 11PIA038
2 Bute filire
maintenance
6
4124591Y
YES 11PIC016
2 Revtement pour patin slection
7
bac E
YES 11PIC018
2 Patins de slection bac E
7
YES 12PIA000
1 Brosse prselection bac E
2
YES 21PIA001
1 Rouleau plein transport env
7
YES 21PIA008
2 Galets libres bac E
1
YES 21PIA014
1 Contre rouleau transport doc
3
YES 21PIA015
1 Ensemble rouleau 5 gommes bac
6
E
YES 21PIA015
1 Ensemble rouleau 5 gommes
7
mixtes bac E
YES 21PIA015
1 Ensemble rouleau 3 gommes bac
8
E
Inserts path
YES 11PIA000
12 Palier
maintenance
1
4124592Z
YES 11PID001
2 Rouleau Chemin inf - axe court
3
YES 21PID000
1 Rouleau Chemin inf - axe long
1
YES 21PID000
3 Chemin sup
3

PAGE 29
CONTENTS

English description
Separation assembly stop - Feeder
E
Separation pad covering - Feeder
E
Separation pad - Feeder E
Separation brush - Feeder E
Transportation roller (full) Feeder E
Roller (free) - Feeder E
Pressure roller
Roller (5 rubbers) - Feeder E
Roller (5 mixed rubbers) - Feeder
E
Roller (3 rubbers) - Feeder E
Bearing

Lower roller (short) - Path C


Lower roller (long) - Path C
Upper path - Path C

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maintenance
4124593A

PAGE 30

YES

11PIA000
1

YES

11PID015
4
11PID015
6
11PIDO15
5
11PID005
2

YES
YES
Doc. Transport.
Maintenance
4124594B

FD 6100 MAINTENANCE MANUAL

YES

YES
YES
YES
YES

21PIA014
3
11PIA000
1
21PIC001
8
21PID001
1

12 Palier

Bearing

1 Rouleau pliage N2

Folding roller (#2)

1 Rouleau pliage N3

Folding roller (#3)

1 Rouleau pliage N4

Folding roller (#4)

1 Rouleau arrire entre doc

Entry roller (rear) - Document


path

1 Contre rouleau transport env

Pressure roller

6 Palier

Bearing

1 Rouleau avant entre doc

Entry Roller (front) - Document


path
Lower roller - Document path

1 rouleau inf transport doc

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KITS DETAILS (FOLLOW UP)


Series 1
Kit description compatibilit
Part Quantit
French description
number
y
y
Feeder C gears
YES 11BFA32
1 Pignon bac C
4124595C
82
YES 11PIA000
1 Pignon bac C
4
YES 11PIA104
1 Pignon intermdiaire cde bac C
YES 11PID004
1 Pignon bac C
4
YES 11PID006
1 Pignon embrayage transport C
8
YES 11PID008
1 Chemin C
8
YES 11PID011
2 poulie chemin C
3
YES 4122039Q
2 Pignon crmaillre
YES 4122040R
1 Pignon bac C
YES 4122098B
1 Pignon bac C
Feeder E gears
YES 11PIA002
1 Pignon intermdiaire
4124596D
5
YES 11PIA010
1 Pignon moteur bac E
4
YES 11PIA014
1 mont en pignon double
1
YES 11PIC012
1 mont en pignon double
5
YES 21PIA005
3 Pignon intermdiaire
2
Inserting gears
YES 11PIA005
1 poulie rouleau chargement
4124598F
3
YES 11PIA032
1 poulie rouleau chargement
6

PAGE 31
CONTENTS

English description
Gear - Feeder C
Gear - Feeder C
Intermediate gear - Feeder C drive
Gear - Feeder C
Gear - Feeder C transport clutch
Gear - Feeder C (path)
Pulley - Feeder C
Rack gear - Feeder C
Gear - Feeder C
Gear - Feeder C
Intermediate gear - Feeder E
Motor gear - Feeder E
Double gear - Feeder E
Double gear - Feeder E
Intermediate gear - Feeder E
Pulley - Inserting roller
Pulley - Inserting roller

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YES
YES
YES

FD 6100 MAINTENANCE MANUAL


PAGE 32

11PIB000
7
11PIB003
8
11PIC021
3
21PIA005
3

1 Commande de came

Cam drive - Inserting

1 pignon cde came

Cam drive gear - Inserting

1 Pignon cde came

Cam drive gear - Inserting

1 Poulie cde courroie chargement

Pulley - inserting belt

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PAGE 33

KITS DETAILS (FOLLOW UP)


Series 1
Kit description compatibilit
Part Quantit
French description
number
y
y
Doc. Transport.
YES 11PIA008
2 Pignon rouleaux pliage N3 et 4
Gears
2
4124599G
YES 11PIA008
1 Pignon rouleau pliage N1
2
YES 11PIA010
1 Pignon intermdiaire transport doc
4
YES 11PIC013
1 Pignon rouleau arrire entre doc
9
YES 11PIC014
1 Pignon rouleau avant entre doc
0
YES 11PID004
1 pignon embrayage entre doc
1
YES 11PID004
1 Pignon intermdiaire
2
YES 11PID004
2 Pignon intermdiaire
4
YES 11PID007
2 Pignon intermdiaire
1
YES 11PID010
1 Pignon intermdiaire
9
YES 11PID014
1 Pignon moteur transport doc
6
YES 4122220D
1 Pignon rouleau pliage N2
Env. transport.
YES 11PIA002
1 Pignon rouleau arrt enveloppe
Gears
5
4124600H
YES 11PIA002
1 Poulie rouleau jection enveloppe
6
YES 11PIA002
1 Pignon rouleau ejection enveloppe

CONTENTS

English description
Gear - Folding rollers # 3 & 4

Gear - Folding roller # 1


Intermetiate gear - Document path
Gear (rear entry roller) Document path
Gear (front entry roller) Document path
Gear (entry doc clutch) Document path
Intermetiate gear - Document path
Intermetiate gear - Document path
Intermetiate gear - Document path
Intermetiate gear - Document path
Motor gear - Document path
Gear - Folding roller # 2
Gear - Envelope stop roller

Pulley - Exit roller


Gear - Exit roller

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YES
YES
YES
YES

FD 6100 MAINTENANCE MANUAL


PAGE 34

7
11PIB004
3
11PIC007
4
21PIA005
9
21PIC000
1
21PIC005
1

1 Poulie cde rouleau de sortie

Pulley - Exit roller drive

1 Pignon moteur transport


enveloppe
1 Pignon/poulie chemin enveloppe

Motor gear - Envelope motor


Gear / pulley - Envelope path

1 Pignon/poulie transport enveloppe Gear / pulley - Envelope


transportation
1 Pignon chemin enveloppe
Gear (Tarington clutch) (tarington clutch)
Envelope path

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KITS DETAILS (FOLLOW UP)


Series 1
Kit description compatibilit
Part Quantit
French description
number
y
y
Springs
YES 11PIA023
4 Ressort Chemin sup C (2eme et
4124602K
1
3eme)
YES 11PIA045
2 Ressort Chemin sup C (1er )
6
YES 11PIA013
1 Ressort droit chemin C
2
YES 11PIA019
1 Ressort verrouillage margeurs bac
8
E
YES 11PIA022
2 Ressort bac C
3
YES 11PIA022
2 Ressort deflecteur mouillage
3
YES 11PIA022
2 Ressort levier cde mouillage
5
YES 11PIA022
2 Ressort rappel verrou machine
9
YES 11PIA023
2 Ressort contre rouleau arrt
1
enveloppe
YES 11PIA023
2 Ressort contre rouleau transport
1
doc
YES 11PIA023
4 Ressort rouleau pliage
2
YES 11PIA025
1 Ressort courroie transport env.
7
YES 11PIA025
1 Ressort rappel ens arrt env
8
YES 11PIA030
1 Ressort tendeur courroie came
7
YES 11PIA032
1 ressort tendeur courroie
5
chargement

PAGE 35
CONTENTS

English description
Spring - Upper path (2nd and 3rd)
- Path C
Spring - Upper path (1st) - Path C
Spring - path C (right)
Spring - Feeder E side guides
locking
Spring - bin C
Spring - Moistening deflector
Spring - moistening drive lever
Spring - machine locking
Spring - Envelope stop pressure
roller
Spring - Document transportation
pressure roller
Spring - folding roller
Spring - Envelope transportation
belt
Spring - Envelope stop assembly
Spring - belt cam
Spring - inserting belt

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YES
YES
YES
YES
YES
YES
YES
YES
YES

FD 6100 MAINTENANCE MANUAL


PAGE 36

11PIA045
6
11PIC002
8
11PIC006
5
11PIC013
8
11PIC019
2
11PIC024
7
11PID002
1
11PID005
4
11PID005
5
11PID012
8

2 Ressort contre rouleau transport


env
1 Ressort droit rouleau avant entre
doc
1 Ressort gauche rouleau avant
entre doc
1 Ressort deflecteur env.

Spring - Envelope transportation


pressure roller
Spring (right) - front entry doc

Spring - envelope deflector

2 Ressort prselection enveloppe

Spring - envelope pre-separation

1 Ressort dflecteur sortie

Spring - exit deflector

2 bac C

Spring - bin C

Spring (left) - front entry doc

1 Ressort droit barette entre doc

Spring (right) - document entry


bar
1 Ressort gauche barette entre doc Spring (left) - document entry bar
1 Chemin inf C

Spring - lower path C

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PAGE 37

KITS DETAILS (FOLLOW UP)


CONTENTS
Series
1
Kit description compatibilit
Part Quantit
French description
English description
number
y
y
Exit rollers
YES 11PIA000
3 Palier
Bearing
maintenance
1
4124603L
YES 21PIA002
1 Rouleau de sortie inf
Lower exit roller
4
YES 21PIA005
1 Palier gauche rouleau de sortie sup Bearing (left) - upper exit roller
5
YES 4122861
1 Rouleau de sortie sup
Upper exit roller
W
Cable
NO 4121904Z
1 cble base/alimenteur
Cable - base/Feeder AB cnx
4124604M
NO 4121901
1 Cble capteur bac C
Cable - feeder C sensor
W
NO 4121898T
1 Cble capteur ouverture machine, Cable - machine opening,
sortie enveloppe, ref env et
envelope exit, envelope reference
selection env
and envelope separation sensors
NO 4121900V
1 cble capteur zero came et doc
Cable - Zero cam and document
charg
loaded sensors
NO 4121887G
1 Cable DD-C
Cable - DD-C
NO 4122782P
1 cable document charg
Cable - Document loaded sensor
NO 4121902X
1 cble embrayages bac C, Pliage et Cable - Feeder C, folding and
transport doc
document transportation clutches
NO 4121916
1 cable encart precharg
Cable - insert preloaded sensor
M
NO 4121906B
1 cble moteur transport doc
Cable - document transportation
motor
Feeder AB knobs
YES 4105509
2 Bouton de dvrouillage bacs AB Bin A&B unlocking knob
4124846P
W
YES 4105508V
2 Levier de dvrouillage guides
Feeder A&B side guides locking
bacs AB
lever

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FD 6100 MAINTENANCE MANUAL


PAGE 38

4122955U

1 Capot cellule autostart quip

Feeder AB Front cover equiped

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PAGE 39

CONTENTS
3
3.1

SOFTWARE UPGRADE AND CPU BOARD REPLACEMENT


SOFTWARE UPGRADE

Note: the use of an anti-static bracelet is recommended for the handling of PCBs
1
2
3
4
5
6
7
8

Switch off and unplug the machine


Remove the top cover
Disconnect the top connectors on the MAIN PCB
Unscrew ( see section 1 chapter 5.2.2) and pivot the MAIN PCB
Replace the flash
Fit the MAIN PCB back and reconnect the cables
Put the top cover back
Plug and switch on the machine

Flash Memory

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 envelope inserting position for kind of envelope (Advanced CONTENTS)
Check the envelope moistening position (Advanced CONTENTS).
Set the jobs according to the applications (User CONTENTS).
Adjust the offset between documents of feeders A and B for each job using these combinations of feeders (Advanced
CONTENTS).

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PAGE 40

CONTENTS
4
4.1

DIAGNOSTICS TOOL
ERROR MESSAGE LIST

Message displayed
CHECK THE
ENVELOPE TRAY

Likely Cause

No envelopes in the hopper.


Envelope miss-feeding
Envelope out of specification
Envelope path jammed
CHECK THE DOCUMENT The document did not exit
from the feeder
PATH
Document out of
specification
Document path jammed
(piece of paper)
CHECK THE CONNECTION AB feeder connector
OF THE PAPER TRAYS Disconnected.
CLOSE THE MACHINE

Sensor "MACHINECLOSED" faulty or badly


located

Remedy

Reinsert envelopes.
Adjust the side .guides
Check the specifications
Check the envelope path
Check the setting of the
feeder AB clutches
Check the Specifications
Check the feeder and the
document path
Check the connections on
both sides (feeder and main
board)
Check the sensor in the
service mode and eventually
adjust its positioning.

DETECTION OF DUPLICATE Faulty "DD-x" sensor


DOCUMENT IN TRAYS A-B

Check the faulty sensor in


the service mode

DETECTION OF DUPLICATE Faulty "DD-x" sensor


DOCUMENT IN TRAY C

Check the faulty sensor in


the service mode

SWITCH THE MACHINE OFF AB feeder connector


AND THEN ON AGAIN
Disconnected.

OPEN THE MACHINE AND


CLOSE IT AGAIN
KEYBOARD FAULT

CHECK THE
ENVELOPE PATH

Check the connections on


both sides (feeder and main
Feeder AB PCB faulty
board)
Request a feeder swap.
The machine was unable to Check all the paper path and
run through its normal cycle. perform a power cycle
(OFF/ON)
When powered up one or
Check the keyboard in the
more keys on the keyboard service mode
are depressed.
Envelope jammed in
Open the machine
The machine.
and check the
Envelope path.

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PAGE 41

CONTENTS

Message displayed
Likely Cause
REMOVE THE DOCUMENTS Document Jam
FROM THE ENTRY OF
TRAYS A + B
Clutch badly set
NO DOCUMENT IN THE
TRAY(S)

Sensors faulty

CHECK THAT DOCUMENTS


Sensors faulty or feeder AB
ARE MOVING CORRECTLY OUT clutches badly set
OF TRAYS A,B or C

REMOVE DOCUMENTS
FROM TRAY A
DUPLICATE DETECTION,
CHECK CONTENTS OF
ENVELOPE
CHECK PAPER PATH OF
TRAY C
CLOSE TRAY C
OPEN THEN CLOSE THE
MACHINE

The AUTOSTART sensor is


faulty
Faulty "DD-x" sensor
Rollers clogged up.
Path C sensor faulty

Remedy

Clear the paper path in the


feeder.
Check the setting of the
feeder AB clutches
Check the sensors in the
service mode.
Check the feeders sensors
in the service mode.
Check the setting of the
feeder AB clutches
Check the sensor in the
service mode.
Check the faulty sensor in
the service mode

Clean the rollers


Check the sensor in the
service mode
Sensor faulty
Check the sensor in the
service mode.
The machine was unable to Check all the paper path and
run through its normal cycle. perform a power cycle
(OFF/ON)

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PAGE 42

CONTENTS
4.2

FUNCTIONAL FAULTS

SYMPTOMS
The machine pre-load feed the
documents from AB to the pre-loaded
position then stop
After 3000 cycles, the machine get
blocked
Envelope not/bad closed

Likely Cause

Check the setting of the


feeder AB clutches

The authorization code was not entered

Set the authorization code

Inadequate moistening
Job mis-setting

Set the moistening position


Check that the moistening is set in the job
selected
Check that the fold length / envelope high
are consistent
Check the envelope stop position. Clean
the inserting rollers.
Try with a thinner set.
Check that the moistening is set in the job
selected
Clean the exit roller
Check the envelope flap shape and high in
the specification

Bad fold lengths


Bad inserting of the document

Bad/no moistening

Set of document to be inserted too thick


Job miss-setting
Exit roller wet
Envelope flap out of specification

Offset between documents from feeders


A and B

Remedy

Bad setting of the clutches

Bad setting of the clutches

The envelope height doesn't match with


Document set ejected below the
the job setting
envelope
Document set ejected after the envelope Envelope not placed properly in the feeder
E
Sensor "REF-ENVELOPE" faulty
Inserting rollers clogged up
Paper jams
Bad envelope inserting position

Check the setting of the


feeder AB clutches
Check the job and the envelope
Check the envelope orientation in the
feeder E
Check sensor in the service mode
Clean the inserting rollers
Adjust the envelope inserting position.

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PAGE 43

CONTENTS

FUNCTIONAL TESTS

4.3

4.3.1

ENVELOPE STOP POSITION

Remove the upper cover.


Check for presence of envelopes in the stacker.
Actuate the AUTOSTART detector with a piece of cardboard stiff enough and hold it
firmly in order to not be gripped between 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.) A = 6mm 3mm (0,23 in. 0,12
in.)
If the envelope height is 152 mm (6 in.) A = 10mm 3mm (0,39 in. 0,12 in.)
For the other envelopes A = 8mm 3mm. (0,31 in. 0,12 in.)

TOP INSERTING
PLATE

UPPER DEFLECTOR
EDGE

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PAGE 44

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PAGE 45

CONTENTS

4.3.2

FEEDER AB CLUTCHES SETTING

PURPOSE: To ensure the correct document pre-loading position and to ensure as well the proper
synchronisation between feeders A and B:
A too low stopping position (clutch delay too long) causes deformation of
thin and medium-thickness documents by the stop and consequently misalignment
from both bins.
A Too high stopping position (clutch delay too short) includes risks of
gripping defaults of thick documents 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 document stop position.
If the position isnt correct (see the picture below), it is necessary to apply the A & B
CLUTCHES SETTING procedure to adjust the timing value.
Perform again this adjustment until the stop position is correct, then apply the same procedure
for the feeder B

ALLOWED STOP POSITION


ALLOWED VARIATION

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PAGE 46

A & B CLUTCHES SETTING PROCEDURE:

From the user CONTENTS, press ESC

and keep it pressed while pressing the 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

Reference
reference value

Exit this screen using the key ESC

to return to user mode.

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PAGE 47

CONTENTS

4.3.3

CAM POSITION AND CAM BELT TENSION

PURPOSE: To synchronise the position of the cams to ensure the correct tension of the cam belt.
ADJUSTMENT PROCEDURE:
- Ensure that the position of the RH cams is symmetrical to that of the LH cam
- 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 gives rise to abnormal operating noise and may cause the cams to
become out of synchronisation and machine to stop.

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PAGE 48

CONTENTS

4.3.4

INSERTER BELT TENSION

PURPOSE: To ensure that the belt tension is correct.


ADJUSTMENT PROCEDURE:
- The machine must be off and open with the covers removed.
- Undo screw (1) by one or two turns to release lever (2).
- Replace document support plate (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 the inserting roller by folding roller (6) (incorrect adjustment).
Take care not to soil or get grease on the inserting roller.

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PAGE 49

CONTENTS

4.3.5

ENVELOPE BELT TENSION

PURPOSE: Make sure that the belt tension is correct.


ADJUSTMENT PROCEDURE:
- Remove gear wheel (1) from the envelope feed motor.
- Undo screw (2) fixing 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 accompanied by a typical
knocking noise in the motor.

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PAGE 50

CONTENTS

4.3.6

FOLDING PLATES TEST

SUBJECT: Check the Folding plates management.


-

PROCEDURE:

Service CONTENTS access (see page 39) :

Press START key


the machine on.

and the UP key

, and keep pushing both keys while turning

Enter the access code:

SELECTION
-

, UP

, MEMORIZE

, 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 plate stopper cycle test.

- At the end of the test, dont forget to remove the tool you have used to restore the top cover
security.

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PAGE 51

CONTENTS
5
5.1

DISASSEMBLING, RE-ASSEMBLING AND ADJUSTMENTS


TOOLS

DESIGNATION
SEPARATION ASSEMBLY TOOL
GREASE OF SYNTHESIS
MULTIMETER
T10 TORX
T20 TORX
Philips screwdriver
POSIDRIVE screwdriver
SPRING HOOK
VARNISH

5.2

REF.
FUNCTION
4103791G Separation assembly adjustment.
Ohmmeter
Screwdriver
Screwdriver
Screwdriver
Screwdriver

DISASSEMBLING

5.2.1

DISASSEMBLING BASE COVERS

1- Remove the top cover (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 from the PCB
3- Remove the protection plate below the MAIN PCB (1 screw on the right)
4- Remove the MAIN PCB: 1 screw on the left in the middle of the board, 2 screws on the right side fixing the cooler). The bottom
one has just to be loosened.

PCB screws

Screw
Protection
plate

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PAGE 52

CONTENTS
5.3

5.3.1

RE-ASSEMBLING AND ADJUSTMENTS

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

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PAGE 53

CONTENTS
5.4

DISASSEMBLING AND REASSEMBLING SUMMARY

COMPLETE
BASE
TOP COVER

RIBBON
CABLE
HOLDER

MAIN PCB

FEEDER E
GEARS
FLASH
MEMORY

FEEDER E
GEERS
SIDE COVERS
FEEDER E
FRONT

LEFT
METALLIC

LETTER
OUTPUT
SENSOR ASS.

DOCUMENT
TRANSPORT
PATH GEARS

FOLD
ROLLERS "2"
& "3"

CAMS&INSER
TING GEARS

POWER
SUPPLY

INSERTING
PLATE

FINGER
SHAFT

ENV-EXIT
SENSOR
ASSEMBLY

JACKS
FEEDER E
SEPARATION

SIDE COVERS

INSERTING
ROLLER
ASSEMBLY

LOWER COVER

PLATE

SIDE GUIDE
LOCKING
BRACKET

FEEDER E
TOP PLATE

SIDE COVERS

DISCONNECT
THE JACKS

POCKET B
ASSEMBLY

FOLD
ROLLER 3

INSERT
SIGNAL
SENSOR
ASSEMBLY

POCKET A
UPPER PLATE

FEEDER E
ROLLERS

ALUMINIUM
FOLD
ROLLER 1

POCKET A &
PATH C
ASSEMBLY

SPRING HOLDERS
WHICH PULL THE
POCKET A
ASSEMBLY WHEN
OPENNING

TOP TABS
GUIDING THE
POCKET A
ASSEMBLY WHEN
PIVOTING

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PAGE 54

CONTENTS
6
6.1

THEORY OF OPERATION
KEY CODES

UP

DOWN

SELECT

MEMORIZE

ESC

START

Service mode access:


Press the keys START and UP and keep pushing both keys while turning the machine on.
The access in code is: SELECT, UP, MEMORIZE, DOWN and START

Advanced CONTENTS access (user):


Press ESC during the 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 pushing both keys while turning the machine on, press START and while pressing
START, press MEMORIZE.

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PAGE 55

CONTENTS
6.2

USER MODE DIAGRAM

MACHINE
OFF
MACHINE TURNED ON
AUTHORIZATION
CODE SETUP

This step appears until the


Authorization code has not been set

USER MENU

SET TO ZERO

COUNTER

JOB NUMBER

START
ESC + MEM

FEEDER

DOCUMENT

TEST CYCLE
LOCK / UNLOCK

MANUAL A / MANUAL A+B / MANUAL


A+C /MANUAL 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

NOTE:
USA/EUROPE is set in
Service mode (ADVANCED
PARAMETERS)

USA: SPECIAL SEAL / SPECIAL NO SEAL / C FOLD ONLY /


#10 SEAL / #10 NO SEAL

ENVELOPE

ADDRESS
HEIGHT

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

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PAGE 56

CONTENTS
6.3

SETTING MODE DIAGRAM (ADVANCED USER MODE)

MACHINE
OFF
ESC DURING INIT

MACHINE SETUP MENU

LANGUAGE

SET ENV / DOC MEM

ESC

FRANCAIS / ENGLISH / DEUTSH / ITALIANO / NEDERLANDS /


ESPANOL / SVENSKA / DANSK / PORTUGUES / POLSKI

SELECT THE
ENVELOPE
FORMAT

SET
STANDART
ENVELOPE

MEM

- HEIGHT
- ENV POSITION
- MOIST. POSITION

SET
SPECIAL
ENVELOPE

MEM

- HEIGHT
- ENV POSITION
- MOIST. POSITION

SET
SPECIAL
DOCUMENT

DOUBLE
DETECTION
BIN C

EXIT

MEM

ENABLE / DISABLE THE DOUBLE DETECTION

SIZE

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PAGE 57

CONTENTS
6.4

BASE SERVICE MODE

MACHINE
OFF
START + UP WHILE TURNING MACHINE ON

SET SERVICE
PIN CODE
SELECT - UP - MEM - DOWN - START

SERVICE MENU

SET MACHINE
NUMBER

SENSORS
TEST

START

START

EXIT = OFF

SERIAL
NUMBER
SETUP

START

MACHINE
SENSORS PART 2

START

INSERT-SIGNAL,
LETTER-OUTPUT,
ENV-REFERENCE, CAM-ZERO

FEEDER AB
SENSORS

START

A-EMPTY, B-EMPTY,
END-SEPARATION-A,
END-SEPARATION-B, DD-KEY

KEYBOARD TEST START


SET TOTAL
COUNTER

SET
ADVANCED
PARAMETERS

START

KEYS TEST

TOTAL COUNTER
SETUP

SERVICE DOUBLE
DETECTION

YES/NO

SERVICE LIFE
CYCLE

YES/NO

SET CONTINENT

POCKET LIFE
CYCLE
SOFTWARE REFERENCE: 1.09

C-CLOSED, ENV-EXIT,
MACHINE-OPEN,
EN-SEPARATION-C, C-EMPTY,
DOC-LOADED, INSERT-STOP

MACHINE
SENSORS PART 1

DOUBLE
DETECTION TEST

EUROPE/USA

START

CYCLE TEST FOR THE FEEDER A


STOP BAR, POCKET A
DEFLECTOR, AND POCKET STOP
BAR

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CONTENTS
6.5

SEQUENCES OF SOFTWARE FUNCTIONS

MACHINE OFF

- MACHINE SWITCHED ON

THICKNESS SENSORS
INITIALIZATION

- THICKNESS SENSORS INITIALIZED

BOTTOM FOLDER
INITIALIZATION

- BOTTOM FOLDER INITIALIZED

TOP FOLDER INITIALIZATION

- TOP FOLDER INITIALIZED

CAM INITIALIZATION

- CAM AT THE "HOME" POSITION

MACHINE INITIALIZED

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CONTENTS
7

EUROPE SPECIFICATIONS
Maximum speed
automatic mode, opened or closed letter,
C6/5 env. and A4 document
Operating life
Regular monthly volume
Maximum monthly use
Maximum daily volume
Maximum theoretical service life
MCBF (Mean Cycle Between Failures)
BVPY (Breakdown Visit Per Year)
MTTR (Mean Time To Repair)
Selection rollers durability
Rollers cleaning in normal use
Capacity of main document feeder
- bin A
- bin B
Capacity of insert feeder
- bin C
Catch tray capacity :
Water tank capacity
Types of folds

Capacity of folds/insertion
- Single/double fold
- Parallel fold
- Insertion without fold (from bin C)

1 350 envelopes/hour

180 000 envelopes


1000 envelopes
3 000 envelopes
3 000 envelopes
5 years
12 000 (failure = breakdown)
1 VPY for 1 000 cycles average monthly use
Maximum: 1h00
120 000 cycles
1 per year (Service operation)

100 sheets, 80 g
100 sheets 80 g
Reply envelopes:
100
Inserts 250 g :
200
100 letters (inserted with 2 A4 sheets, 80g, letter fold)
about 1 000 letters
- single fold
- Letter fold
- Double parallel fold
weight 70 to 85 g/m
1 to 5 sheets
weight 86 to 120 g/m (1)
1 to 3 sheets
weight 70 to 85 g/m
1 to 3 sheets
weight 86 to 120 g/m (1)
1 to 2 sheets
weight 80 to 250 g/m
1 sheet
up to 150 g/m for glossy paper in manual insertion.

Remark : Insert counts as one page in the fold and insertion capacity.
Dimensions of fold
- Single fold:

min.
max.

- Double and parallel fold:


1st fold (A) :
min.
max.
2nd fold (B) :
min.
max.

Tolerance on fold dimension 3 mm


60 mm
155 mm

65 mm
155 mm
60 mm
155 mm

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SPECIFICATION (FOLLOW UP)


Envelopes with and without windows

Width

Height
small

Large (Europe only)

Quality/thickness
These dimensions allow to process C6/5, DL, C5 envelopes
Documents (bins A and B)

Basic document:

Other dimensions : width


height
Paper quality - main document, single and double fold
Printers, Listings, Photocopiers, Offset
Self-copier

PAGE 60

CONTENTS
224 to 240 mm
105 to 125 mm
152 to 165 mm
75 to 90 g/m

Europe: A4 (210 x 297 mm), 2/3 A4 (210 x 198 mm) and


A4(210 x 148.5 mm)
142 to 226 mm
178 to 356 mm

70 to 120 g/m (automatic and manual feeding)


70 to 120 g/m (1st sheet of self-copying stack automatic and
manual feeding)

Glossy paper (advertisement) ()


90 to 120 g/m in automatic feeding mode
90 to 150 g/m 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 :
142 to 226 mm

height :
80 to 150 mm
Paper quality - auxiliary inserts
80 to 90 g/m

Printers, Listings, Photocopiers, Offset


70 to 90 g/m

Selfcopier
90 to 120 g/m

Glossy paper (advertisement) ()


() A preliminary test can be required. This paper quality may require frequent pick-up rollers and fold rollers cleaning.
Auxiliary insert must be positioned behind a document and cannot therefore be seen through the envelope window.
Short size annex insert (bin C)
Dimensions :

width

height
Paper quality - Inserts
Printers, Listings, Photocopiers
Offset, Bristol board, Glossy paper (advertisement) ()
Glossy paper (), Pre-fold
Business Reply envelopes (BRE)
()

142 to 226 mm
80 to 150 mm

80 to 120 g/m
80 to 250 g/m

90 to 170 g/m
70 to 90 g/m (with or without window)
A preliminary test can be required. This paper quality may require frequent pick-up rollers and fold rollers cleaning

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USA SPECIFICATIONS
Maximum speed

1 350 envelopes/hour

Automatic mode, opened or closed


letter,

# 10 env. and 8 1/2"x 11" document


Operating life
Regular monthly volume
Maximum monthly use
Maximum daily volume
Maximum theoretical service life
MCBF (Mean Cycle Between
Failures)
BVPY (Breakdown Visit Per Year)
MTTR (Mean Time To Repair)
Selection rollers durability
Rollers cleaning interval in normal
use
Capacity of main document feeder
- bin A
- bin B
Capacity of insert feeder
- bin C
Catch tray capacity
Water tank capacity
Types of folds
Capacity of folds/insertion
- Letter fold

180 000 envelopes


1000 envelopes
3 000 envelopes
3 000 envelopes
5 years
12 000 (failure = breakdown)
1 BVPY for 1 000 cycles average monthly use
Maximum: 1h00
120 000 cycles
1 per year (Service operation)

100 sheets, 20 Lb Bond


100 sheets, 20 Lb Bond
Reply envelopes:
100
65 lbs Inserts:
200
100 letters (inserted with 2x 20 Lb Bond Letters sheets)
About 1 000 letters
- Letter fold and Double parallel fold

From 20 to 22 Lb Bond
1 to 5 sheets
From 24 to 32 Lb Bond
1 to 3 sheets
From 20 to 22 Lb Bond
1 to 3 sheets
- Double parallel fold
From 24 to 32 Lb Bond (1) 1 to 2 sheets
1 sheet
- Insertion without fold (from bin From 20 to 66 Lb Bond
Up to 39 lbs for glossy paper with manual feeding.
C)
Remark : Insert counts as one page in the fold and insertion capacity.
Dimensions of fold
- Double and parallel fold:
1st fold (A) : min.
max.
2nd fold (B) : min.
max.

Tolerance on fold dimension 0,12 In. ( 3mm)


2,56 in. (65 mm)
6,10 in. (155 mm)
2,36 in. (60 mm)
6,10 in. (155 mm)

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SPECIFICATION (FOLLOW UP)


Envelopes with and without windows
Width
Height
Quality/thickness

8,82 in. to 9,45 in. (224 to 240 mm)


4,13 in. to 4,92 in. (105 to 125 mm)
20 to 24 Lb Bond

These dimensions allow to process #10 envelopes and higher.


Documents (bins A and B)
Letter US ( 8 " x 11"), 8 " x 8" and 8 " x 5
Regular documents:
" for US.

Other dimensions: Width


Height

5,6 in. to 8,9 in. (142 to 226 mm)


3,15 in. to 14 in. (80 to 356 mm)

Paper quality - main document, single


and double fold
20 to 32 Lb Bond (automatic and manual
Printers, Listings, Photocopiers, Offset
feeding)
Self-copier
20 to 32 Lb Bond (1st sheet of self-copying stack
automatic and manual feeding)
Glossy paper (advertisement) ()
24 to 32 Lb 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)
5,6 in. to 8,9 in. (142 to 226 mm)
Width
3,15 in. to 5,9 in. (80 to 150 mm)
Height
Paper quality - auxiliary inserts
Printers, Listings, Photocopiers, Offset 20 to 24 Lb Bond
19 to 24 Lb Bond
Self-copying (NCR)
24 to 32 Lb Bond
Glossy paper (advertisement) ()
- () A preliminary test can be required. This paper quality may require frequent pick-up rollers
and fold rollers cleaning.
- Auxiliary insert must be positioned behind a document and cannot therefore be seen through
the envelope window.
Short size annex insert (bin C)
Dimensions:
Width
Height
Paper quality - Inserts
Printers, Listings, Photocopiers
Offset,
Bristol
board,
Glossy

5,6 in. to 8,9 in. (142 to 226 mm)


3,15 in. to 5,9 in. (80 to 150 mm)

20 to 32 Lb Bond
paper 20 to 66 Lb Bond

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(advertisement) ()
Glossy paper (), Pre-fold
Business Reply Envelopes (BRE)

FD 6100 MAINTENANCE MANUAL


PAGE 63

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

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PAGE 64

CONTENTS
9

RECOMMENDED SPARE PARTS LIST

Part
number

11BFA110
5
11PIA010
1
11PIC020
2
11PIC008
2
11PIC017
8
11PID007
5
12PIC000
6
4105487Y
4105488Z
4105489A
4105490B
4105492D
4105505S
4121894P
4121897S

S1
compat.

French description

YES Ampoule reed (C-FERME)

English description

YES Barette selection bac E (Europe)

Reed sensor assembly (CCLOSED)


Hopper separation plate (Europe)

YES Barette selection bac E (US)

Qty / 1000 machines /


year
High
Regular
volume
cust. (1000
cust. (3000
cycles /
cycles /
month/ 5
month/ 5
Years)
Years)
2
3,6
2

3,6

Hopper separation plate (US)

3,6

YES Tle insertion

Inserting plate

10

18

YES Dflecteur sortie enveloppe

Deflector - Letter exit

30

54

YES Rouleau pliage N1 (ALU)

Folding roller (alu)

3,6

YES Vrin

Jack

100

180

YES
YES
NO
NO
YES
NO
NO
NO

Hopper rear guide (left)


Hopper rear guide (right)
Cover - bin C (right)
Cover - bin C (left)
Hopper side guides locking knob
Cover - Letter exit (lower part)
Hopper motor
Env / Cam transport motor

10
10
10
10
10
5
5
5

18
18
18
18
18
9
9
9

Guide arrire gauche bac E


Guide arrire droit bac E
Flasque droit bac C
Flasque gauche bac C
Bouton verrouillage bac E
Capot sortie inf
Moteur bac E quip
Moteur quip Env / Came

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4121907C
4121955C
4121956D
4122058K

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NO Moteur transport doc quip


NO Ensemble ecran clavier

NO Capot afficheur
NO Capot support guides arrires bac
E
4122061N YES Margeur gauche bac E
4122062P YES Margeur droit bac E
4122113S NO carte principale
4122148D NO Plateau magasin env.
4122525W NO Platine avant bac E

PAGE 65

Main motor
User interface assembly (display
unit + keyboard + PCB)
Cover - Display
Cover - Hopper rear guides bracket

5
10

9
18

10
5

18
9

Hopper side guide (left)


Hopper side guide (right)
Main PCB
Hopper plate
Hopper front plate

5
5
20
5
5

9
9
36
9
9

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CONTENTS

Part
number

S1
compat.

4122745A
4122748D
4122972M
4122973N
4122988D

NO
NO
YES
YES
NO

4122989E
4122990F
4122993J
4122999Q
4124580M
4124581N
4124582P
4124583Q
4124584R
4124585S
4124586T
4124587U

French description

Limande afficheur
alimentation
Ensemble bac C quip Europe
Ensemble bac C quip US
Ensemble commande de bute de
poche
NO Ensemble tle infrieure poche A
quipe
YES Ensemble chemin encart (sup +
Inf)
NO Ensemble tle infrieure poche B
quipe
YES ensemble bac mouilleur
YES* Kit ensemble arrt enveloppe
YES Kit 3 brosses de mouillage
YES Kit cames
NO Kit capteurs
YES Kit courroies
YES Kit embrayages
YES* Kit fermeture poche A (Europe
* seulement)
YES Kit insertion (Europe)

English description

Cable (display PCB)


Power supply assembly
Bin C assembly for Europe
Bin C assembly for USA
Pocket stop drive assembly

Qty / 1000 machines /


year
High
Regular
volume
cust. (1000
cust. (3000
cycles /
cycles /
month/ 5
month/ 5
Years)
Years)
100
180
5
9
1
1,8
1
1,8
1
1,8

Pocket A Lower plate assembly

1,8

Insert path assembly (upper +


lower)
Pocket B Lower plate assembly

1,8

1,8

Moistener tank assembly


Kit - Envelope stop assembly
Kit - 3 moinsting brushes
Kit - cams
Kit - sensors
Kit - belts
Kit - clutches
Kit - Pocket A closing (Europe
only)
Kit - Inserting (Europe)

15
5
15
5
80
5
10
3

27
9
27
9
144
9
18
5,4

5,4

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4124588V YES Kit languettes


4124589W YES Kit leviers defleteur sortie
envelopes
4124590X YES Kit maintenance bac C
4124591Y YES Kit maintenance bac E
4124592Z YES Kit maintenance chemin encarts

PAGE 67

Kit - tongues
Kit - Envelope exit lever deflector

30
25

54
45

Kit - Feeder C maintenance


Kit - Feeder E maintenance
Kit - Inserts path maintenance

25
30
10

45
54
18

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CONTENTS

Part
number

S1
compat.

French description

4124593A YES Kit maintenance pliage


4124594B YES Kit maintenance transport
documents
4124595C YES Kit pignons bac C
4124596D YES Kit pignons bac E
4124598F YES Kit pignons insertion
4124599G YES Kit pignons transport documents
4124600H
4124602K
4124603L
4124604M
4124648P
4124831Y
4125899L

YES
YES
YES
NO
YES
YES
NO
*

English description

Kit - Folding maintenance


Kit - Documents transportation
maintenance
Kit - Feeder C gears
Kit - Feeder E gears
Kit - Inserting gears
Kit - Documents transportation
gears
Kit pignon transport envelopes
Kit - Envelope transport kit
Kit ressorts
Kit - Springs
Kit maintenance rouleaux de sortie Kit - Exit rollers maintenance
Kit cbles
Kit - Cables
Kit boutons alimenteur AB
Kit - Feeder AB knobs
Kit insertion (US)
Kit - Inserting (US)
Ensemble alimenteur AB
Feeder AB assembly

Le capteur 4122298K inclu dans


ce kit n'est pas compatible S1
** Le moteur 4121971U inclus dans
ce kit n'est pas compatible S1

Qty / 1000 machines /


year
High
Regular
volume
cust. (1000
cust. (3000
cycles /
cycles /
month/ 5
month/ 5
Years)
Years)
3
5,4
10
18
50
50
50
100

90
90
90
180

50
50
10
15
100
5
30

90
90
18
27
180
9
54

The sensor 4122298K included in this kit is not compatible


with S1
The motor 4121971U included in this kit is tot compatible
with S1

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PAGE 69

MANUAL CONTENTS

SECTION 2: PARTS LISTS

1.

SINGLE PARTS & SUB-ASSEMBLIES VIEW...................................................70


For Sensors, Rollers, Clutches, tongues, gears, springs, cams, belts and any other parts
not showed in this chapter, please refer to the next chapter ("Kit details")

2.

KIT DETAILS .....................................................................................................78


ENVELOPE STOP:4124580M .......................................................................................................... 78
BRUSH: 4124581N ........................................................................................................................... 79
CAM:4124582P................................................................................................................................. 80
BELTS: 4124584R ............................................................................................................................ 82
CLUTCHES:4124585S ..................................................................................................................... 83
POCKET A CLOSING (EUROPE USE ONLY): 4124586T.............................................................. 84
INSERTING (EUROPE): 4124587U & (US): 4124831Y................................................................... 85
TONGUES: 4124588V ...................................................................................................................... 86
EXIT LEVER DEFLECTOR: 4124589W........................................................................................... 87
FEEDER C MAINTENANCE: 4124590X .......................................................................................... 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

3.

ALPHANUMERICAL PARTS LIST .................................................................102

4.

SINGLE PART ILLUSTRATIONS ...................................................................106

Click
page

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PAGE 70

CONTENTS

1.

SINGLE PARTS & SUB-ASSEMBLIES VIEW

4122525W

4122061N

4122062P

4122058K

Part
number
4122058K

S1
comp
at.

French description

NO Capot support guides arrires


bac E
4122061N YE Margeur gauche bac E
S
4122062P YE Margeur droit bac E
S
4122525W NO Platine avant bac E

English description
Cover - Hopper rear guides
bracket
Hopper side guide (left)
Hopper side guide (right)
Hopper front plate

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CONTENTS

4105487Y

4105488Z

4122972M (EUR)
4122973N (US)
11BFA1105

S1
Part
comp
number
at.
11BFA1105 YE
S
4105487Y YE
S
4105488Z YE
S
4122972M YE
S
4122973N YE
S

French description
Ampoule reed (C-FERME)

English description

Guide arrire gauche bac E

Reed sensor assembly (CCLOSED)


Hopper rear guide (left)

Guide arrire droit bac E

Hopper rear guide (right)

Ensemble bac C quip Europe

Bin C assembly for Europe

Ensemble bac C quip US

Bin C assembly for USA

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4105490B
Picture not
available

4125899L

4105489A

4105492D

Part
number
4105489A
4105490B
4105492D
4125899L

S1
comp
at.

French description

NO
NO
YE
S
NO

Flasque droit bac C


Flasque gauche bac C
Bouton verrouillage bac E

Cover - bin C (right)


Cover - bin C (left)
Hopper side guides locking knob

Ensemble alimenteur AB

Feeder AB assembly

English description

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11PID0075

4122990F
Picture not
available

12PIC0006

4122748D

S1
Part
comp
number
at.
11PID0075 YE
S
12PIC0006 YE
S
4122748D NO
4122990F YE
S

French description

English description

Rouleau pliage N1 (ALU)

Folding roller (alu)

Vrin

Jack

alimentation
Ensemble chemin encart (sup +
Inf)

Power supply assembly


Insert path assembly (upper +
lower)

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4121955C

4121956D
Picture not available

Part
number
4121955C

S1
comp
at.

4121956D

NO Capot afficheur

French description

NO Ensemble ecran clavier

English description
User interface assembly (display
unit + keyboard + PCB)
Cover - Display

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4122745A

4121897S
Picture not available

4122993J
Picture not available

4122999Q

11PIC0178

S1
Part
French description
comp
number
at.
11PIC0178 YE Dflecteur sortie enveloppe
S
4122993J
NO Ensemble tle infrieure poche B
quipe
4121897S
NO Moteur quip Env / Came
4122745A NO Limande afficheur
4122999Q YE ensemble bac mouilleur
S

English description
Deflector - Letter exit
Pocket B lower plate assembly
Env / Cam transport motor
Cable (display PCB)
Moistener tank assembly

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CONTENTS

1.1

4122113
S
1.2

4122989E
Picture not available

11PIC0082

4105505S

S1
Part
comp
number
at.
11PIC0082 YE
S
4105505S
NO
4122113S
NO
4122989E NO

French description
Tle insertion

English description
Inserting plate

Capot sortie inf


Cover - Letter exit (lower part)
carte principale
Main PCB
Ensemble tle infrieure poche A Pocket A Lower plate assembly
quipe

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CONTENTS

4122148D

11PIA101 (EUROPE)
11PIC0202 (USA)

4121894P

4121907C

S1
Part
comp
number
at.
11PIA0101 YE
S
11PIC0202 YE
S
4121894P NO
4121907C NO
4122113S
NO
4122148D NO
4122748D NO

French description

English description

Barette selection bac E (EUR)

Hopper separation plate (EUR)

Barette selection bac E (US)

Hopper separation plate (US)

Moteur bac E quip


Moteur transport doc quip
carte principale
Plateau magasin env.
alimentation

Hopper motor
Main motor
Main PCB
Hopper plate
Power supply assembly

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CONTENTS

2.

KIT DETAILS

9.1

ENVELOPE STOP:4124580M

ITEM

Series 1
compat.

1
2
3
4

YES
YES
YES
YES

Part
number
11PIA0001
11PIA0020
11PIC0085
11PIC0089

Qt
y
6
2
1
1

YES

11PIC0156

6
7
8
9
10

YES
YES
YES
YES
NO

11PIC0220
21PIA0001
21PIA0034
21PIA0035
4122298K

2
1
1
1
1

French description

English description

Paliers
Support arrt enveloppe
Dflecteur volet enveloppe
Languette gauche ouverture
enveloppe
Languette droite ouverture
enveloppe
Languette arrt enveloppe
Contre rouleau arrt enveloppe
Rouleau arrt enveloppe
Ejection enveloppe
Capteur arrt enveloppe

Bearings
Enveloppe stop bracket
Envelope flap deflector
Tongue - left
Tongue - right
Tongue - envelope stop
Pressure roller - envelope stop
Drive roller - Envelope stop
Ejection roller - Envelope stop
Sensor - Envelope stop

2
6
1

6
10
7
9
8

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CONTENTS
9.2

BRUSH: 4124581N

Item

Series 1
compat.

YES

Part
Qt
number
y
21PIA0027 3

French description

English description

Brosses de mouillage

Moistening brush

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CONTENTS
9.3

CAM:4124582P

Item

Series 1
compat.

1
2
3
4
5

YES
YES
YES
YES
YES

Part
number
11PIA0122
11PIC0127
11PIC0128
11PIC0213
11PIC0214

Qt
y
1
1
1
1
1

French description
disque zro came
Came sortie droite
Came sortie gauche
Came intrieur gauche
Came intrieur droite

English description
Cam disc
Right exit cam
Left exit cam
left cam
right cam

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CONTENTS

Sensors: 4124583Q
Series 1
Item
compat.
1
2

NO
NO

3
4

NO
NO

Part
Qt
French description
number
y
4121929A 1 Ens DD-C
4122298K 5 Zero came - chargement - Arrt
env - sortie env
4122982X 5 Ens capteur chemin encart
4123041J 1 Ens capteur sortie env

NO

4123044M

1 Ens capteur ref selection env.

English description
DD-C assembly
Sensors
Insert path sensor assembly
LETTER-OUTPUT sensor
assembly
ENV-REFERENCE sensor
assembly

5
4

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CONTENTS
9.4

BELTS: 4124584R

Item

Series 1
compat.

YES

2
3
4
5
6

YES
YES
YES
YES
YES

Part
number
12NCA000
4
12PIA0003
12PIA0006
12PIA0007
12PIB0002
12PID0001

Qt
French description
y
1 Courroie Chemin inf C
1
1
1
1
1

English description
Insert lower path belt

Courroie moteur env


Courroie de chargement
Cde came
poche A/B
Courroie cde bac C

Envelope motor belt


Inserting belt
Cam belt
Pocket A/B belt
Bin C belt

4
1

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CONTENTS
9.5

CLUTCHES:4124585S

Item

Series 1
compat.

YES

Part
Qt
number
y
14PIC0002 3

French description

English description

1 bac C, 1 transport C, 1 pliage

Clutch

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CONTENTS
9.6

POCKET A CLOSING (EUROPE USE ONLY): 4124586T

Kit
description
1
2
3
4
5
6
7
8
Not
Illustrated

Series 1
compat.

Part
Qt
French description
number
y
YES 11BFA2402 1 Pignon intermdiaire fermeture
poche
YES 11PIC0075 2 Palier barette de fermeture poche
YES 11PIC0091 1 Pignon cde levier gauche
YES 11PIC0092 1 Levier pivot droit (fermeture de
poche)
YES 11PID0093 2 Levier de cde fermeture poche
YES 11PID0106 1 Barette fermeture poche
YES 21PID0032 1 Support gauche barrette de
fermeture poche
YES 21PID0033 1 Support droit barrette de fermeture
poche (Point rouge)
NO 4121971U 1 Moteur pas a pas

English description
Gear (intermediate) closing bar
Bearing - pocket closing bar
Gear - left lever drive
Right lever
Pocket closing drive lever
Closing bar
Left bracket
Right bracket (Red point)
Stepper motor

5
6

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CONTENTS
9.7

INSERTING (EUROPE): 4124587U & (US): 4124831Y

Item

Series 1
compat.

1
2

YES
YES

Part
number
11PIA0053
4123028V

3
4
5
6
7

YES
YES
YES
YES
YES

11PIA0326
12PIA0006
21PIA0053
21PIC0026
4123029W

Qt
French description
y
1 poulie rouleau chargement
1 Ensemble doigts d'insertion
Europe quip
1 poulie rouleau chargement
1 Courroie de chargement
1 Poulie cde courroie chargement
1 Rouleau d'insertion quip
1 Ensemble doigts d'insertion US
quip
5

English description
Pulley - inserting roller
Insert fingers assembly
(Europe)
Pulley - inserting roller
Belt - inserting
Pulley - inserting belt
Inserting roller assembly
Insert fingers assembly (US)

4
6

4
6

4124587U

4124831Y

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CONTENTS
9.8

TONGUES: 4124588V

Item

Series 1
compat.

1
2

YES
YES

Part
number
11PIA0093
11PIC0089

YES

11PIC0156

4
5
6
7

YES
YES
YES
YES

11PIC0220
11PIC0223
11PID0125
11PID0126

Qt
French description
y
4 patins amortissants pieds
1 Languette gauche ouverture
enveloppe
1 Languette droite ouverture
enveloppe
2 Languette arrt enveloppe
1 languette bac E
1 Languette entre chemin C
2 Cache fil

English description
Shock absorber - feet
Left tongue - envelope preopening
Right tongue - envelope preopening
Tongue - envelope stop
Tongue - bin E
Tongue - path C entrance
Tongue - Cable protection

6
4

7
2
5

1
3
4

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CONTENTS
9.9

EXIT LEVER DEFLECTOR: 4124589W

Item

Series 1
compat.

1
2

YES
YES

Part
number
21PIA0117
21PIA0118

Qt
French description
y
1 Levier pr-mouillage droit
1 Levier pr-mouillage gauche

English description
Lever - pre-moistening (right)
Lever - pre-moistening (left)

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CONTENTS
9.10 FEEDER C MAINTENANCE: 4124590X

Item

Series 1
compat.

1
2
3

YES
YES
YES

Part
number
11PIA0001
11PID0139
21PIC0086

YES

4122975Q

Qt
French description
y
4 Palier
2 Rouleau de slection
2 Ensemble filire Europe
2 Ensemble filire US

1
2

English description
Bearing
Selection roller - feeder C
Separation assembly - Feeder C
Europe
Separation assembly - Feeder C
US

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CONTENTS
9.11 FEEDER E MAINTENANCE: 4124591Y

Item

Series 1
compat.

YES

Part
Qt
French description
number
y
11PIA0386 2 Bute filire

YES

11PIC0167

YES
YES
YES

11PIC0187 2
12PIA0002 1
21PIA0017 1

YES
YES
YES

21PIA0081 2
21PIA0143 1
21PIA0156 1

YES

21PIA0157 1

YES

21PIA0158 1

English description

Separation assembly stop Feeder E


Revtement pour patin slection Separation pad covering bac E
Feeder E
Patins de slection bac E
Separation pad - Feeder E
Brosse prselection bac E
Separation brush - Feeder E
Rouleau plein transport env
Transportation roller (full) Feeder E
Galets libres bac E
Roller (free) - Feeder E
Contre rouleau transport doc
Pressure roller
Ensemble rouleau 5 gommes bac Roller (5 rubbers) - Feeder E
E
Ensemble rouleau 5 gommes
Roller (5 mixed rubbers) mixtes bac E
Feeder E
Ensemble rouleau 3 gommes bac Roller (3 rubbers) - Feeder E
E

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CONTENTS
9.12 INSERTS PATH MAINTENANCE: 4124592Z

Item

Series 1
compat.

1
2
3
4

YES
YES
YES
YES

Part
number
11PIA0001
11PID0013
21PID0001
21PID0003

Qt
y
12
2
1
3

French description
Palier
Rouleau Chemin inf - axe court
Rouleau Chemin inf - axe long
Chemin sup

English description
Bearing
Lower roller (short) - Path C
Lower roller (long) - Path C
Upper path - Path C

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CONTENTS
9.13 FOLDING MAINTENANCE: 4124593A

Item

Series 1
compat.

1
2
3
4

YES
YES
YES
YES

Part
number
11PIA0001
11PID0154
11PID0156
11PIDO155

1
2

Qt
y
12
1
1
1

French description
Palier
Rouleau pliage N2
Rouleau pliage N3
Rouleau pliage N4

English description
Bearing
Folding roller (#2)
Folding roller (#3)
Folding roller (#4)

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CONTENTS
9.14 DOC. TRANSPORT. MAINTENANCE: 4124594B

Item

Series 1
compat.

YES

Part
Qt
French description
number
y
11PID0052 1 Rouleau arrire entre doc

2
3
4

YES
YES
YES

21PIA0143 1 Contre rouleau transport env


11PIA0001 6 Palier
21PIC0018 1 Rouleau avant entre doc

YES

21PID0011 1 rouleau inf transport doc

3
2
5
1

English description
Entry roller (rear) - Document
path
Pressure roller
Bearing
Entry Roller (front) Document path
Lower roller - Document path

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CONTENTS
9.15 FEEDER C GEARS: 4124595C

Item

Series 1
compat.

1
2
3
4
5
6
7
8
9
10

YES
YES
YES
YES
YES
YES
YES
YES
YES
YES

Part
number
11BFA3282
11PIA0004
11PIA104
11PID0044
11PID0068
11PID0088
11PID0113
4122039Q
4122040R
4122098B

Qt
y
1
1
1
1
1
1
2
2
1
1

French description
Pignon bac C
Pignon bac C
Pignon intermdiaire cde bac C
Pignon bac C
Pignon embrayage transport C
Chemin C
poulie chemin C
Pignon crmaillre
Pignon bac C
Pignon bac C

English description
Gear - Feeder C
Gear - Feeder C
Inter. gear - Feeder C drive
Gear - Feeder C
Gear - Feeder C trans. clutch
Gear - Feeder C (path)
Pulley - Feeder C
Rack gear - Feeder C
Gear - Feeder C
Gear - Feeder C

8
PICTURE NOT
AVAILABLE

10

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CONTENTS
9.16 FEEDER E GEARS: 4124596D

Item

Series 1
compat.

1
2
3
4
5

YES
YES
YES
YES
YES
1

Part
number
11PIA0025
11PIA0104
11PIA0141
11PIC0125
21PIA0052

Qt
y
1
1
1
1
3

French description
Pignon intermdiaire
Pignon moteur bac E
mont en pignon double
mont en pignon double
Pignon intermdiaire

Intermediate gear - Feeder E


Motor gear - Feeder E
Double gear - Feeder E
Double gear - Feeder E
Intermediate gear - Feeder E

1
4

English description

4
3
1

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CONTENTS
9.17 INSERTING GEARS: 4124598F

Item

Series 1
compat.

1
2
3
4
5
6

YES
YES
YES
YES
YES
YES

Part
number
11PIA0053
11PIA0326
11PIB0007
11PIB0038
11PIC0213
21PIA0053

Qt
y
1
1
1
1
1
1

French description

English description

poulie rouleau chargement


poulie rouleau chargement
Commande de came
pignon cde came
Pignon cde came
Poulie cde courroie chargement

6
5
3

Pulley - Inserting roller


Pulley - Inserting roller
Cam drive - Inserting
Cam drive gear - Inserting
Cam drive gear - Inserting
Pulley - inserting belt

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CONTENTS

9.18 DOC. TRANSPORT. GEARS: 4124599G

Item

Series 1
compat.

1
1
2
3
4
5
6
7
8
9
10
11

YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES

Part number Qty


11PIA0082
11PIA0082
11PIA0104
11PIC0139
11PIC0140
11PID0041
11PID0042
11PID0044
11PID0071
11PID0109
11PID0146
4122220D

French description

English description

Pignon rouleaux pliage N3 et 4


Pignon rouleau pliage N1
Pignon intermdiaire trans. doc
Pignon rouleau arrire entre doc
Pignon rouleau avant entre doc
pignon embrayage entre doc
Pignon intermdiaire
Pignon intermdiaire
Pignon intermdiaire
Pignon intermdiaire
Pignon moteur transport doc
Pignon rouleau pliage N2

2
1
1
1
1
1
1
2
2
1
1
1

Gear - Folding rollers # 3 & 4


Gear - Folding roller # 1
Intermetiate gear - Document path
Gear (rear entry roller) - Doc. path
Gear (front entry roller) - Doc. path
Gear (entry doc clutch) - Doc. path
Intermetiate gear - Doc. path
Intermetiate gear - Doc. path
Intermetiate gear - Doc. path
Intermetiate gear - Doc. path
Motor gear - Document path
Gear - Folding roller # 2

10
10

8
9

7
1

11

7
2

10

11

4
3

8
1

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CONTENTS

9.19 ENV. TRANSPORT. GEARS: 4124600H

Item

Series 1
compat.

1
2
3
4
5
6
7

YES
YES
YES
YES
YES
YES
YES

11PIA0025
11PIA0026
11PIA0027
11PIB0043
11PIC0074
21PIA0059
21PIC0001

YES

21PIC0051

Part number Qty

French description

English description

1
1
1
1
1
1
1

Pignon rouleau arrt enveloppe


Poulie rouleau jection enveloppe
Pignon rouleau ejection env.
Poulie cde rouleau de sortie
Pignon moteur transport env.
Pignon/poulie chemin enveloppe
Pignon/poulie transport env.

Pignon chemin env. (tarington


clutch)

Gear - Envelope stop roller


Pulley - Exit roller
Gear - Exit roller
Pulley - Exit roller drive
Motor gear - Envelope motor
Gear / pulley - Envelope path
Gear / pulley - Env.
transportation
Gear (Tarington clutch) Envelope path
7

5
6
2

4
2
1

3
8
5

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CONTENTS
9.20 EXIT ROLLERS MAINTENANCE: 4124603L

Item

Series 1
compat.

1
2
3

YES
YES
YES

YES

Part
number
11PIA0001
21PIA0024
21PIA0055

Qt
French description
y
3 Palier
1 Rouleau de sortie inf
1 Palier gauche rouleau de sortie
sup
4122861W 1 Rouleau de sortie sup

2
1

English description
Bearing
Lower exit roller
Bearing (left) - upper exit roller
Upper exit roller

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CONTENTS

9.21 CABLE: 4124604M

Item

Series 1
compat.

1
2
3

NO
NO
NO

Part
Qt
French description
English description
number
y
Cable - base/Feeder AB cnx
4121904Z 1 cble base/alimenteur
Cable - feeder C sensor
4121901W 1 Cble capteur bac C
4121898T 1 Cble capteur ouverture machine, sortie Cable - machine opening, envelope
enveloppe, ref env et selection env

NO

4121900V

1 cble capteur zero came et doc charg

5
6
7

NO
NO
NO

4121887G
4122782P
4121902X

1 Cable DD-C
1 cable document charg
1 cble embrayages bac C, Pliage et

4121916M
4121906B

transport doc
1 cable encart precharg
1 cble moteur transport doc

8
9

NO
NO

exit, envelope reference and envelope


separation sensors
Cable - Zero cam and document
loaded sensors
Cable - DD-C
Cable - Document loaded sensor
Cable - Feeder C, folding and
document transportation clutches
Cable - insert preloaded sensor
Cable - document transportation
motor

7
6

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PAGE 100
CONTENTS

9.22 FEEDER AB KNOBS: 4124648P

Item

Series 1
compat.

YES

YES

YES

Part
Qt
French description
number
y
4105509W 2 Bouton de dvrouillage bacs
AB
4105508V 2 Levier de dvrouillage guides
bacs AB
4122955U 1 Capot cellule autostart quip

English description
Bin A&B unlocking knob
Feeder A&B side guides
locking lever
Feeder AB Front cover equiped

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CONTENTS

9.23 SPRINGS: 4124602K

Not
Illustrated

Series 1
compat.

YES

Part
Qt
French description
English description
number
y
11PIA0231 4 Ressort Chemin sup C (2eme et 3eme) Upper path spring (2nd and 3rd) -

YES
YES
YES
YES
YES
YES
YES
YES
YES

11PIA0456
11PIA0132
11PIA0198
11PIA0223
11PIA0223
11PIA0225
11PIA0229
11PIA0231
11PIA0231

2
1
1
2
2
2
2
2
2

Ressort Chemin sup C (1er )


Ressort droit chemin C
Ressort verrouillage margeurs bac E
Ressort bac C
Ressort deflecteur mouillage
Ressort levier cde mouillage
Ressort rappel verrou machine
Ressort contre rouleau arrt enveloppe
Ressort contre rouleau transport doc

YES
YES
YES
YES
YES
YES

11PIA0232
11PIA0257
11PIA0258
11PIA0307
11PIA0325
11PIA0456

4
1
1
1
1
2

Ressort rouleau pliage


Ressort courroie transport env.
Ressort rappel ens arrt env
Ressort tendeur courroie came
ressort tendeur courroie chargement
Ressort contre rouleau transport env

YES
YES

11PIC0028
11PIC0065

1 Ressort droit rouleau avant entre doc


1 Ressort gauche rouleau avant entre

YES
YES
YES
YES
YES
YES
YES

11PIC0138
11PIC0192
11PIC0247
11PID0021
11PID0054
11PID0055
11PID0128

1
2
1
2
1
1
1

doc
Ressort deflecteur env.
Ressort prselection enveloppe
Ressort dflecteur sortie
bac C
Ressort droit barette entre doc
Ressort gauche barette entre doc

Chemin inf C

Path C
Upper path spring (1st) - Path C
Spring - path C (right)
Spring - Feeder E side guides locking
Spring - bin C
Spring - Moistening deflector
Spring - moistening drive lever
Spring - machine locking
Spring - Envelope stop pressure roller
Spring - Document transportation
pressure roller
Spring - folding roller
Spring - Envelope transportation belt
Spring - Envelope stop assembly
Spring - belt cam
Spring - inserting belt
Spring - Envelope transportation
pressure roller
Spring (right) - front entry doc
Spring (left) - front entry doc
Spring - envelope deflector
Spring - envelope pre-separation
Spring - exit deflector
Spring - bin C
Spring (right) - document entry bar
Spring (left) - document entry bar

Spring - lower path C

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CONTENTS

3.

ALPHANUMERICAL PARTS LIST


Part
number

S1
comp
at.

French description

11BFA1105

YE
S
YE
S
YE
S
YE
S
YE
S
YE
S
YE
S
YE
S
NO
NO
YE
S
NO
NO
NO
NO
NO
NO

Ampoule reed (C-FERME)

11PIA0101
11PIC0082
11PIC0178
11PID0075
12PIC0006
4105487Y
4105488Z
4105489A

4105490B
4105492D
4105505S
4125899L
4121894P

4121897S
4121907C
4121955C

4121956D
4122058K
4122061N
4122062P
4122113S
4122148D
4122525W
4122745A
4122748D

4122972M
4122973N

English description

Barette selection bac E

Reed sensor assembly (CCLOSED)


Hopper separation plate

Tle insertion

Inserting plate

Dflecteur sortie enveloppe

Deflector - Letter exit

Rouleau pliage N1 (ALU)

Folding roller (alu)

Vrin

Jack

Guide arrire gauche bac E

Hopper rear guide (left)

Guide arrire droit bac E

Hopper rear guide (right)

Flasque droit bac C


Flasque gauche bac C
Bouton verrouillage bac E

Cover - bin C (right)


Cover - bin C (left)
Hopper side guides locking knob

Capot sortie inf


Ensemble alimenteur AB
Moteur bac E quip
Moteur quip Env / Came
Moteur transport doc quip
Ensemble ecran clavier

Cover - Letter exit (lower part)


Feeder AB assembly
Hopper motor
Env / Cam transport motor
Main motor
User interface assembly (display
unit + keyboard + PCB)
Cover - Display
Cover - Hopper rear guides bracket

NO Capot afficheur
NO Capot support guides arrires bac
E
YE Margeur gauche bac E
S
YE Margeur droit bac E
S
NO carte principale
NO Plateau magasin env.
NO Platine avant bac E
NO Limande afficheur
NO alimentation
YE Ensemble bac C quip Europe
S
YE Ensemble bac C quip US

Hopper side guide (left)


Hopper side guide (right)
Main PCB
Hopper plate
Hopper front plate
Cable (display PCB)
Power supply assembly
Bin C assembly for Europe
Bin C assembly for USA

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4122989E
4122990F
4122993J

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FD 6100 - SERVICE MANUAL

S
NO Ensemble commande de bute de
poche
NO Ensemble tle infrieure poche A
quipe
YE Ensemble chemin encart (sup +
S Inf)
NO Ensemble tle infrieure poche B
quipe

PAGE 103

Pocket stop drive assembly


Pocket A Lower plate assembly
Insert path assembly (upper +
lower)
Pocket B Lower plate assembly

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CONTENTS

Part
number
4122999Q
4124580M
4124581N
4124582P
4124583Q
4124584R
4124585S
4124586T
4124587U
4124588V
4124589W
4124590X
4124591Y
4124592Z
4124593A
4124594B
4124595C
4124596D
4124598F
4124599G
4124600H
4124602K
4124603L

S1
comp
at.

YE
S
YE
S*
YE
S
YE
S
NO
YE
S
YE
S
YE
S**
YE
S
YE
S
YE
S
YE
S
YE
S
YE
S
YE
S
YE
S
YE
S
YE
S
YE
S
YE
S
YE
S
YE
S
YE
S

French description

English description

ensemble bac mouilleur

Moistener tank assembly

Kit ensemble arrt enveloppe

Kit - Envelope stop assembly

Kit 3 brosses de mouillage

Kit - 3 moinsting brushes

Kit cames

Kit - cams

Kit capteurs
Kit courroies

Kit - sensors
Kit - belts

Kit embrayages

Kit - clutches

Kit fermeture poche A (Europe


seulement)
Kit insertion (Europe)

Kit - Pocket A closing (Europe


only)
Kit - Inserting (Europe)

Kit languettes

Kit - tongues

Kit leviers defleteur sortie


envelopes
Kit maintenance bac C

Kit - Envelope exit lever deflector

Kit maintenance bac E

Kit - Feeder E maintenance

Kit maintenance chemin encarts

Kit - Inserts path maintenance

Kit maintenance pliage

Kit - Folding maintenance

Kit maintenance transport


documents
Kit pignons bac C

Kit - Documents transportation


maintenance
Kit - Feeder C gears

Kit pignons bac E

Kit - Feeder E gears

Kit pignons insertion

Kit - Inserting gears

Kit pignons transport documents


Kit pignon transport envelopes

Kit - Documents transportation


gears
Kit - Envelope transport kit

Kit ressorts

Kit - Springs

Kit - Feeder C maintenance

Kit maintenance rouleaux de sortie Kit - Exit rollers maintenance

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4124604M
4124648P
4124831Y

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FD 6100 - SERVICE MANUAL

NO Kit cbles
YE Kit boutons alimenteur AB
S
YE Kit insertion (US)
S
* Le capteur 4122298K inclu dans
ce kit n'est pas compatible S1
** Le moteur 4121971U inclus dans
ce kit n'est pas compatible S1

PAGE 105

Kit - Cables
Kit - Feeder AB knobs
Kit - Inserting (US)

The sensor 4122298K included in


this kit is not compatible with S1
The motor 4121971U included in
this kit is tot compatible with S1

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PAGE 106

CONTENTS

4.

SINGLE PART ILLUSTRATIONS

11PID0075

11BFA1105

12PIC0006

BACK TO THE ILLUSTRATED

BACK TO THE ILLUSTRATED

BACK TO THE ILLUSTRATED

4121894P

4105489A
BACK TO THE ILLUSTRATED

BACK TO THE ILLUSTRATED

11PIC0178

BACK TO THE ILLUSTRATED

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BACK TO THE ILLUSTRATED

4122525W

4122058K
BACK TO THE ILLUSTRATED
4122061N

BACK TO THE ILLUSTRATED

4122062P

BACK TO THE ILLUSTRATED

4105492D

4105487Y
BACK TO THE ILLUSTRATED VIEW

4105488Z
BACK TO THE ILLUSTRATED VIEW

BACK TO THE ILLUSTRATED VIEW

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CONTENTS

4121955C

4122748D
BACK TO THE ILLUSTRATED

4122999Q

4122113S

BACK TO THE ILLUSTRATED

BACK TO THE ILLUSTRATED

BACK TO THE ILLUSTRATED

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CONTENTS

4122745A

4121907C
BACK TO THE ILLUSTRATED

11PIC0082

BACK TO THE ILLUSTRATED

BACK TO THE ILLUSTRATED

4105505S
BACK TO THE ILLUSTRATED

11PIA0101
BACK TO THE ILLUSTRATED

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CONTENTS

4122148D

BACK TO THE ILLUSTRATED

4125899L

BACK TO THE ILLUSTRATED

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PAGE 111

MANUAL CONTENTS

SECTION 3: COUNTRY SPECIFIC

INSTALLATION................................................................................................112
1.1 UNPACKING THE MACHINE................................................................................................. 112

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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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