Formax FD 6100 Service Manual
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Formax FD 6100 Service Manual

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  • Page 1 Formax 6100 Paper Folder/Inserter Service Manual Provided By http://www.MyBinding.com http://www.MyBindingBlog.com...
  • Page 2 ISSUE 21/09/2003 FD 6100 - MAINTENANCE MANUAL REVISION : SECTION CONTENTS PAGE FD 6100...
  • Page 3 ISSUE 21/09/2003 FD 6100 - MAINTENANCE MANUAL REVISION : SECTION CONTENTS PAGE CONTENTS REVISIONS SECTION 1: MAINTENANCE...
  • Page 4 ISSUE 21/09/2003 FD 6100 - MAINTENANCE MANUAL REVISION : SECTION CONTENTS PAGE SECTION 2: PARTS LIST SECTION 3: UNPACKING...
  • Page 5 ISSUE 21/09/2003 FD 6100 MAINTENANCE MANUAL REVISION : SECTION : CONTENTS PAGE CONTENTS MODIFICATIONS FOLLOW-UP Reference Main modifications Revision Date soft. Section Page DESCRIPTION 10/07/03 1.11 Launch Version 01/09/03 1.15 S1 FR 5, 23, 25, 31, 32, 48, 50 S1 ENG Pages 5, 6, 7, 11, 23, 25, 31, 32, 40, 48, 50 have been modified.

  • Page 6: Table Of Contents

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 5 MANUAL CONTENTS Click SECTION 1: MAINTENANCE page INTRODUCTION ....................6 1.1 PRECAUTION ..........................6 1.2 TERMINOLOGY .......................... 7 1.3 GENERAL OVERVIEW....................... 9 1.4 SENSORS/SWITCHES, MOTORS AND CLUTCHES.............. 15 1.5 PCB INTERCONNECTION DIAGRAM..................17 1.6 PROTOCOL AND HARDWARE CONFIGURATION ...............

  • Page 7: Introduction

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 6 CONTENTS 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.

  • Page 8: Terminology

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 7 CONTENTS TERMINOLOGY See description in Section 1, Chapter 1.4.1 "Sensors" A SELECTION CLUTCH A, feeder A Front manual and automatic feeder for documents A-EMPTY See description in Section 1, Chapter 1.4.1 "Sensors"...
  • Page 9 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 8 CONTENTS TOP FOLDER MOTOR See description in Section 1, Chapter 1.4.2 "Clutches and Motors" Type E sensor Electrodes Type F sensor Flag sensor Type H sensor Hall effect sensor Type PP motor...

  • Page 10: General Overview

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 9 CONTENTS GENERAL OVERVIEW 1.3.1 FEEDER A-B SENSORS AND SWITCH VIEW DD-A END SEPARATION - B END-SEPARATION-A DD-B DD-KEY A-EMPTY / AUTOSTART B-EMPTY...
  • Page 11 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 10 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...
  • Page 12 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 11 CONTENTS 1.3.3 BASE SENSORS AND SWITCH VIEW MACHINE-OPEN LETTER-OUTPUT DD-C ENV-EXIT ENV-REFERENCE END- SEP R TION C INSERT-STOP C-EMPTY C-CLOSED CAM-ZERO DOC-LOADED INSERT-SIGNAL...
  • Page 13 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 12 CONTENTS 1.3.5 CLUTCHES VIEW B SELECTION CLUTCH MANUAL FEEDING MOTOR A SELECTION CLUTCH C SELECTION CLUTCH C TRANSPORT CLUTCH DOCUMENT FEEDER CLUTCH...
  • Page 14 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 13 CONTENTS 1.3.6 MOTORS VIEW HOPPER MAIN MOTOR MOTOR TRANSPORT MOTOR SINGLE FOLD TOP FOLDER MOTOR MOTOR (EUR only) BOTTOM FOLDER MOTOR CAM MOTOR...
  • Page 15 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 14 CONTENTS 1.3.7 PAPER PATH VIEW DOCUMENT PATH ENVELOPE PATH...

  • Page 16: Sensors/Switches, Motors And Clutches

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 15 CONTENTS SENSORS/SWITCHES, MOTORS AND CLUTCHES 1.4.1 SENSORS MACHINE SENSORS (PART 1) SERVICE TEST COMPONENT NAME FUNCTION Bin C path closed C-CLOSED Checks if feeder C path is closed Exit env. feeder...
  • Page 17 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 16 CONTENTS 1.4.2 MOTORS AND CLUTCHES FEEDERS CLUTCHES SERVICE TEST COMPONENT NAME FUNCTION Not available A SELECTION CLUTCH Activate feeder A selection rollers Not available B SELECTION CLUTCH Activate feeder B selection rollers...

  • Page 18: Pcb Interconnection Diagram

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 17 CONTENTS PCB INTERCONNECTION DIAGRAM 1.5.1 MAIN PCB (PART 1) 1.5.2...
  • Page 19 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 18 CONTENTS 1.5.3 MAIN PCB (PART 2) 1.5.4...
  • Page 20 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 19 CONTENTS 1.5.5 FEEDER PCB 1.5.6...

  • Page 21: Protocol And Hardware Configuration

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 20 CONTENTS PROTOCOL AND HARDWARE CONFIGURATION LEFT INTENTIONALLY BLANK...

  • Page 22: Service Call Check Lists

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 21 CONTENTS 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.

  • Page 23: Preventive Maintenance

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 22 CONTENTS PREVENTIVE MAINTENANCE SPARE / KIT REGULA "HIGH VOLUME" CUSTOMER CUSTOM 30000 or 60000 90000 120000 150000 180000 once a year Rollers cleaning End of Life Moistening brushes replacement 4124581N...

  • Page 24: Maintenance Kits Details

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 23 CONTENTS MAINTENANCE KITS DETAILS Series 1 Kit description Part Quantit French description English description compatibilit number Envelope stop 11PIA000 6 Paliers Bearings 4124580M 11PIA002 2 Support arrêt enveloppe Enveloppe stop bracket 11PIC008 1 Déflecteur volet enveloppe...
  • Page 25 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 24 11PIC021 1 Came intérieur gauche left cam 11PIC021 1 Came intérieur droite right cam Sensors 4121929A 1 Ens DD-C DD-C assembly 4124583Q 4122298K 5 Zero came - chargement - Arrêt...
  • Page 26 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 25 KITS DETAILS (FOLLOW UP) CONTENTS Series 1 Kit description Part Quantit French description English description compatibilit number Belts 12NCA00 1 Courroie Chemin inf C Insert lower path belt 4124584R 12PIA000...
  • Page 27 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 26 poche 4121971U 1 Moteur pas a pas Stepper motor Inserting (Europe) 11PIA005 1 poulie rouleau chargement Pulley - inserting roller 4124587U 4123028V 1 Ensemble doigts d'insertion Insert fingers assembly (Europe) Europe équipé...
  • Page 28 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 27 KITS DETAILS (FOLLOW UP) CONTENTS Series 1 Kit description Part Quantit French description English description compatibilit number Inserting (US) 11PIA005 1 poulie rouleau chargement Pulley - inserting roller 4124831Y 4123029...
  • Page 29 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 28 Feeder C 11PIA000 4 Palier Bearing maintenance 4124590X 11PID013 2 Rouleau de sélection Selection roller - feeder C 21PIC008 2 Ensemble filière Europe Separation assembly - Feeder C Europe 4122975Q 2 Ensemble filière US...
  • Page 30 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 29 KITS DETAILS (FOLLOW UP) CONTENTS Series 1 Kit description Part Quantit French description English description compatibilit number Feeder E 11PIA038 2 Butée filière Separation assembly stop - Feeder maintenance 4124591Y 11PIC016 2 Revêtement pour patin sélection...
  • Page 31 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 30 Folding 11PIA000 12 Palier Bearing maintenance 4124593A 11PID015 1 Rouleau pliage N°2 Folding roller (#2) 11PID015 1 Rouleau pliage N°3 Folding roller (#3) 11PIDO15 1 Rouleau pliage N°4 Folding roller (#4) Doc.
  • Page 32 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 31 KITS DETAILS (FOLLOW UP) CONTENTS Series 1 Kit description Part Quantit French description English description compatibilit number Feeder C gears 11BFA32 1 Pignon bac C Gear - Feeder C 4124595C...
  • Page 33 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 32 11PIB000 1 Commande de came Cam drive - Inserting 11PIB003 1 pignon cde came Cam drive gear - Inserting 11PIC021 1 Pignon cde came Cam drive gear - Inserting 21PIA005...
  • Page 34 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 33 KITS DETAILS (FOLLOW UP) CONTENTS Series 1 Kit description Part Quantit French description English description compatibilit number Doc. Transport. 11PIA008 2 Pignon rouleaux pliage N°3 et 4 Gear - Folding rollers # 3 & 4...
  • Page 35 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 34 11PIB004 1 Poulie cde rouleau de sortie Pulley - Exit roller drive 11PIC007 1 Pignon moteur transport Motor gear - Envelope motor enveloppe 21PIA005 1 Pignon/poulie chemin enveloppe Gear / pulley - Envelope path...
  • Page 36 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 35 KITS DETAILS (FOLLOW UP) CONTENTS Series 1 Kit description Part Quantit French description English description compatibilit number Springs 11PIA023 4 Ressort Chemin sup C (2eme et Spring - Upper path (2nd and 3rd)
  • Page 37 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 36 11PIA045 2 Ressort contre rouleau transport Spring - Envelope transportation pressure roller 11PIC002 1 Ressort droit rouleau avant entrée Spring (right) - front entry doc 11PIC006 1 Ressort gauche rouleau avant Spring (left) - front entry doc entrée doc...
  • Page 38 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 37 KITS DETAILS (FOLLOW UP) CONTENTS Series 1 Kit description Part Quantit French description English description compatibilit number Exit rollers 11PIA000 3 Palier Bearing maintenance 4124603L 21PIA002 1 Rouleau de sortie inf...
  • Page 39 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 38 4122955U 1 Capot cellule autostart équipé Feeder AB Front cover equiped...

  • Page 40: Software Upgrade And Cpu Board Replacement

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 39 CONTENTS SOFTWARE UPGRADE AND CPU BOARD REPLACEMENT SOFTWARE UPGRADE Note: the use of an anti-static bracelet is recommended for the handling of PCBs 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)

  • Page 41: Diagnostics Tool

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 40 CONTENTS DIAGNOSTICS TOOL ERROR MESSAGE LIST Message displayed Likely Cause Remedy CHECK THE No envelopes in the hopper. Reinsert envelopes. ENVELOPE TRAY Envelope miss-feeding Adjust the side .guides Envelope out of specification...
  • Page 42 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 41 CONTENTS Message displayed Likely Cause Remedy REMOVE THE DOCUMENTS Document Jam Clear the paper path in the FROM THE ENTRY OF feeder. TRAYS A + B Clutch badly set Check the setting of the...

  • Page 43: Functional Faults

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 42 CONTENTS FUNCTIONAL FAULTS SYMPTOMS Likely Cause Remedy The machine pre-load feed the Bad setting of the clutches Check the setting of the documents from AB to the pre-loaded feeder AB clutches...

  • Page 44: Functional Tests

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 43 CONTENTS FUNCTIONAL TESTS 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.
  • Page 45 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 44...
  • Page 46 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION 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.
  • Page 47 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION 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”,...
  • Page 48 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION 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.
  • Page 49 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION 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).
  • Page 50 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION 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).
  • Page 51 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION 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 and the UP key , and keep pushing both keys while turning the machine on.

  • Page 52: Disassembling, Re-Assembling And Adjustments

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 51 CONTENTS DISASSEMBLING, RE-ASSEMBLING AND ADJUSTMENTS TOOLS DESIGNATION REF. FUNCTION SEPARATION ASSEMBLY TOOL 4103791G Separation assembly adjustment. GREASE OF SYNTHESIS MULTIMETER Ohmmeter T10 TORX Screwdriver T20 TORX Screwdriver Philips screwdriver Screwdriver...

  • Page 53: Re-Assembling And Adjustments

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 52 CONTENTS RE-ASSEMBLING AND ADJUSTMENTS 5.3.1 REASSEMBLING TOP COVER When putting back the top cover onto the machine, be careful to put the hopper side guides locking knob in regard of the locking lever (set both to the locked position) otherwise the locking system will be out of order.

  • Page 54: Disassembling And Reassembling Summary

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 53 CONTENTS DISASSEMBLING AND REASSEMBLING SUMMARY COMPLETE BASE TOP COVER SIDE COVERS RIBBON CABLE FEEDER E LEFT LETTER INSERTING HOLDER GEARS METALLIC OUTPUT PLATE SENSOR ASS. FLASH MAIN PCB DOCUMENT MEMORY...

  • Page 55: Theory Of Operation

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 54 CONTENTS THEORY OF OPERATION KEY CODES DOWN SELECT MEMORIZE 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...

  • Page 56: User Mode Diagram

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 55 CONTENTS USER MODE DIAGRAM MACHINE MACHINE TURNED ON This step appears until the AUTHORIZATION Authorization code has not been set CODE SETUP USER MENU SET TO ZERO COUNTER JOB NUMBER...

  • Page 57: Setting Mode Diagram (Advanced User Mode)

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 56 CONTENTS SETTING MODE DIAGRAM (ADVANCED USER MODE) MACHINE ESC DURING INIT MACHINE SETUP MENU EXIT FRANCAIS / ENGLISH / DEUTSH / ITALIANO / NEDERLANDS / LANGUAGE ESPANOL / SVENSKA / DANSK / PORTUGUES / POLSKI...

  • Page 58: Base Service Mode

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 57 CONTENTS BASE SERVICE MODE MACHINE START + UP WHILE TURNING MACHINE ON SET SERVICE PIN CODE SELECT - UP - MEM - DOWN - START SERVICE MENU EXIT = OFF...

  • Page 59: Sequences Of Software Functions

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 58 CONTENTS 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"...

  • Page 60: Europe Specifications

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 59 CONTENTS EUROPE SPECIFICATIONS Maximum speed 1 350 envelopes/hour automatic mode, opened or closed letter, C6/5 env. and A4 document Operating life 180 000 envelopes Regular monthly volume 1000 envelopes Maximum monthly use...
  • Page 61 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 60 SPECIFICATION (FOLLOW UP) CONTENTS Envelopes with and without windows • 224 to 240 mm Width • 105 to 125 mm Height small • 152 to 165 mm Large (Europe only) •...

  • Page 62: Usa Specifications

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 61 USA SPECIFICATIONS 1 350 envelopes/hour Maximum speed Automatic mode, opened or closed letter, # 10 env. and 8 1/2"x 11" document Operating life 180 000 envelopes Regular monthly volume 1000 envelopes...
  • Page 63 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 62 SPECIFICATION (FOLLOW UP) Envelopes with and without windows • 8,82 in. to 9,45 in. (224 to 240 mm) Width • 4,13 in. to 4,92 in. (105 to 125 mm) Height •...
  • Page 64 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 63 (advertisement) ( ) Glossy paper ( ), Pre-fold 19 to 45 Lb Bond Business Reply Envelopes (BRE) 19 to 24 Lb Bond (with or without window) A preliminary test can be required. This paper quality may require frequent pick-up rollers...

  • Page 65: Recommended Spare Parts List

    FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 64 CONTENTS RECOMMENDED SPARE PARTS LIST Qty / 1000 machines / year High Regular Part volume French description English description cust. (1000 compat. number cust. (3000 cycles / cycles / month/ 5...
  • Page 66 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 65 4121907C NO Moteur transport doc équipé Main motor 4121955C NO Ensemble ecran clavier User interface assembly (display unit + keyboard + PCB) 4121956D NO Capot afficheur Cover - Display 4122058K NO Capot support guides arrières bac...
  • Page 67 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 66 CONTENTS Qty / 1000 machines / year High Regular Part volume French description English description cust. (1000 compat. number cust. (3000 cycles / cycles / month/ 5 month/ 5 Years)
  • Page 68 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 67 4124588V YES Kit languettes Kit - tongues 4124589W YES Kit leviers defleteur sortie Kit - Envelope exit lever deflector envelopes 4124590X YES Kit maintenance bac C Kit - Feeder C maintenance...
  • Page 69 FD 6100 MAINTENANCE ISSUE 21/09/03 MANUAL REVISION SECTION PAGE 68 CONTENTS Qty / 1000 machines / year High Regular Part volume French description English description cust. (1000 compat. number cust. (3000 cycles / cycles / month/ 5 month/ 5 Years)
  • Page 70 ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 69 MANUAL CONTENTS SECTION 2: PARTS LISTS Click page 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.

  • Page 71: Single Parts & Sub-Assemblies View

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 70 CONTENTS SINGLE PARTS & SUB-ASSEMBLIES VIEW 4122525W 4122061N 4122062P 4122058K Part French description English description comp number 4122058K NO Capot support guides arrières Cover - Hopper rear guides bac E...
  • Page 72 ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 71 CONTENTS 4105487Y 4105488Z 4122972M (EUR) 4122973N (US) 11BFA1105 Part French description English description comp number 11BFA1105 YE Ampoule reed (C-FERME) Reed sensor assembly (C- CLOSED) 4105487Y Guide arrière gauche bac E...
  • Page 73 ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 72 CONTENTS 4105490B Picture not available 4125899L 4105489A 4105492D Part French description English description comp number 4105489A NO Flasque droit bac C Cover - bin C (right) 4105490B NO Flasque gauche bac C...
  • Page 74 ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 73 CONTENTS 11PID0075 4122990F Picture not available 12PIC0006 4122748D Part French description English description comp number 11PID0075 YE Rouleau pliage N°1 (ALU) Folding roller (alu) 12PIC0006 YE Vérin Jack 4122748D...
  • Page 75 ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 74 CONTENTS 4121955C 4121956D Picture not available Part French description English description comp number 4121955C NO Ensemble ecran clavier User interface assembly (display unit + keyboard + PCB) 4121956D NO Capot afficheur...
  • Page 76 ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 75 CONTENTS 4122745A 4121897S Picture not available 4122993J Picture not available 4122999Q 11PIC0178 Part French description English description comp number 11PIC0178 YE Déflecteur sortie enveloppe Deflector - Letter exit 4122993J NO Ensemble tôle inférieure poche B...
  • Page 77 ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 76 CONTENTS 4122113 4122989E Picture not available 11PIC0082 4105505S Part French description English description comp number 11PIC0082 YE Tôle insertion Inserting plate 4105505S NO Capot sortie inf Cover - Letter exit (lower part)
  • Page 78 ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 77 CONTENTS 4122148D 11PIA101 (EUROPE) 11PIC0202 (USA) 4121894P 4121907C Part French description English description comp number 11PIA0101 YE Barette selection bac E (EUR) Hopper separation plate (EUR) 11PIC0202 YE Barette selection bac E (US)

  • Page 79: Kit Details

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 78 CONTENTS KIT DETAILS ENVELOPE STOP:4124580M Series 1 ITEM Part French description English description compat. number YES 11PIA0001 6 Paliers Bearings YES 11PIA0020 2 Support arrêt enveloppe Enveloppe stop bracket YES 11PIC0085 1 Déflecteur volet enveloppe...

  • Page 80: Brush: 4124581N

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 79 CONTENTS BRUSH: 4124581N Series 1 Item Part French description English description compat. number YES 21PIA0027 3 Brosses de mouillage Moistening brush...

  • Page 81: Cam:4124582P

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 80 CONTENTS CAM:4124582P Series 1 Item Part French description English description compat. number YES 11PIA0122 1 disque zéro came Cam disc YES 11PIC0127 1 Came sortie droite Right exit cam...
  • Page 82 ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 81 CONTENTS Sensors: 4124583Q Series 1 Item Part French description English description compat. number 4121929A 1 Ens DD-C DD-C assembly 4122298K 5 Zero came - chargement - Arrêt Sensors env - sortie env...

  • Page 83: Belts: 4124584R

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 82 CONTENTS BELTS: 4124584R Series 1 Item Part French description English description compat. number YES 12NCA000 1 Courroie Chemin inf C Insert lower path belt YES 12PIA0003 1 Courroie moteur env...

  • Page 84: Clutches:4124585S

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 83 CONTENTS CLUTCHES:4124585S Series 1 Item Part French description English description compat. number YES 14PIC0002 3 1 bac C, 1 transport C, 1 pliage Clutch...

  • Page 85: Pocket A Closing (Europe Use Only): 4124586T

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 84 CONTENTS POCKET A CLOSING (EUROPE USE ONLY): 4124586T Series 1 Part French description English description compat. description number YES 11BFA2402 1 Pignon intermédiaire fermeture Gear (intermediate) - poche closing bar...

  • Page 86: Inserting (Europe): 4124587U & (Us): 4124831Y

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 85 CONTENTS INSERTING (EUROPE): 4124587U & (US): 4124831Y Series 1 Item Part French description English description compat. number YES 11PIA0053 1 poulie rouleau chargement Pulley - inserting roller 4123028V 1 Ensemble doigts d'insertion Insert fingers assembly Europe équipé...

  • Page 87: Tongues: 4124588V

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 86 CONTENTS TONGUES: 4124588V Series 1 Item Part French description English description compat. number YES 11PIA0093 4 patins amortissants pieds Shock absorber - feet YES 11PIC0089 1 Languette gauche ouverture...

  • Page 88: Exit Lever Deflector: 4124589W

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 87 CONTENTS EXIT LEVER DEFLECTOR: 4124589W Series 1 Item Part French description English description compat. number YES 21PIA0117 1 Levier pré-mouillage droit Lever - pre-moistening (right) YES 21PIA0118 1 Levier pré-mouillage gauche...

  • Page 89: Feeder C Maintenance: 4124590X

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 88 CONTENTS 9.10 FEEDER C MAINTENANCE: 4124590X Series 1 Item Part French description English description compat. number YES 11PIA0001 4 Palier Bearing YES 11PID0139 2 Rouleau de sélection Selection roller - feeder C YES 21PIC0086 2 Ensemble filière Europe...

  • Page 90: Feeder E Maintenance: 4124591Y

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 89 CONTENTS 9.11 FEEDER E MAINTENANCE: 4124591Y Series 1 Item Part French description English description compat. number YES 11PIA0386 2 Butée filière Separation assembly stop - Feeder E YES 11PIC0167 2 Revêtement pour patin sélection...

  • Page 91: Inserts Path Maintenance: 4124592Z

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 90 CONTENTS 9.12 INSERTS PATH MAINTENANCE: 4124592Z Series 1 Item Part French description English description compat. number YES 11PIA0001 12 Palier Bearing YES 11PID0013 2 Rouleau Chemin inf - axe court Lower roller (short) - Path C...

  • Page 92: Folding Maintenance: 4124593A

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 91 CONTENTS 9.13 FOLDING MAINTENANCE: 4124593A Series 1 Item Part French description English description compat. number YES 11PIA0001 12 Palier Bearing YES 11PID0154 1 Rouleau pliage N°2 Folding roller (#2) YES 11PID0156 1 Rouleau pliage N°3...

  • Page 93: Doc. Transport. Maintenance: 4124594B

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 92 CONTENTS 9.14 DOC. TRANSPORT. MAINTENANCE: 4124594B Series 1 Item Part French description English description compat. number YES 11PID0052 1 Rouleau arrière entrée doc Entry roller (rear) - Document path...

  • Page 94: Feeder C Gears: 4124595C

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 93 CONTENTS 9.15 FEEDER C GEARS: 4124595C Series 1 Item Part French description English description compat. number YES 11BFA3282 1 Pignon bac C Gear - Feeder C YES 11PIA0004 1 Pignon bac C...

  • Page 95: Feeder E Gears: 4124596D

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 94 CONTENTS 9.16 FEEDER E GEARS: 4124596D Series 1 Item Part French description English description compat. number YES 11PIA0025 1 Pignon intermédiaire Intermediate gear - Feeder E YES 11PIA0104 1 Pignon moteur bac E Motor gear - Feeder E YES 11PIA0141 1 monté...

  • Page 96: Inserting Gears: 4124598F

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 95 CONTENTS 9.17 INSERTING GEARS: 4124598F Series 1 Item Part French description English description compat. number YES 11PIA0053 1 poulie rouleau chargement Pulley - Inserting roller YES 11PIA0326 1 poulie rouleau chargement...

  • Page 97: Doc. Transport. Gears: 4124599G

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 96 CONTENTS 9.18 DOC. TRANSPORT. GEARS: 4124599G Series 1 Item Part number Qty French description English description compat. 11PIA0082 Pignon rouleaux pliage N°3 et 4 Gear - Folding rollers # 3 & 4 Pignon rouleau pliage N°1...

  • Page 98: Env. Transport. Gears: 4124600H

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 97 CONTENTS 9.19 ENV. TRANSPORT. GEARS: 4124600H Series 1 Item Part number Qty French description English description compat. 11PIA0025 Pignon rouleau arrêt enveloppe Gear - Envelope stop roller 11PIA0026 Poulie rouleau éjection enveloppe Pulley - Exit roller 11PIA0027 Pignon rouleau ejection env.

  • Page 99: Exit Rollers Maintenance: 4124603L

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 98 CONTENTS 9.20 EXIT ROLLERS MAINTENANCE: 4124603L Series 1 Item Part French description English description compat. number YES 11PIA0001 3 Palier Bearing YES 21PIA0024 1 Rouleau de sortie inf Lower exit roller...

  • Page 100: Cable: 4124604M

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 99 CONTENTS 9.21 CABLE: 4124604M Series 1 Item Part French description English description compat. number 4121904Z câble base/alimenteur Cable - base/Feeder AB cnx Câble capteur bac C Cable - feeder C sensor 4121901W Câble capteur ouverture machine, sortie...

  • Page 101: Feeder Ab Knobs: 4124648P

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 100 CONTENTS 9.22 FEEDER AB KNOBS: 4124648P Series 1 Item Part French description English description compat. number 4105509W 2 Bouton de dévérouillage bacs Bin A&B unlocking knob 4105508V 2 Levier de dévérouillage guides Feeder A&B side guides...

  • Page 102: Springs: 4124602K

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 101 CONTENTS 9.23 SPRINGS: 4124602K Series 1 Part French description English description compat. Illustrated number YES 11PIA0231 4 Ressort Chemin sup C (2eme et 3eme) Upper path spring (2nd and 3rd) -...

  • Page 103: Alphanumerical Parts List

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 102 CONTENTS ALPHANUMERICAL PARTS LIST Part French description English description comp number 11BFA1105 Ampoule reed (C-FERME) Reed sensor assembly (C- CLOSED) 11PIA0101 Barette selection bac E Hopper separation plate 11PIC0082 Tôle insertion...
  • Page 104 ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 103 4122988D NO Ensemble commande de butée de Pocket stop drive assembly poche 4122989E NO Ensemble tôle inférieure poche A Pocket A Lower plate assembly équipée 4122990F Ensemble chemin encart (sup +...
  • Page 105 ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 104 CONTENTS Part French description English description comp number 4122999Q ensemble bac mouilleur Moistener tank assembly 4124580M Kit ensemble arrêt enveloppe Kit - Envelope stop assembly 4124581N Kit 3 brosses de mouillage...
  • Page 106 ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 105 4124604M NO Kit câbles Kit - Cables 4124648P Kit boutons alimenteur AB Kit - Feeder AB knobs 4124831Y Kit insertion (US) Kit - Inserting (US) * Le capteur 4122298K inclu dans...

  • Page 107: Single Part Illustrations

    ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 106 CONTENTS SINGLE PART ILLUSTRATIONS BACK TO THE ILLUSTRATED 11PID0075 11BFA1105 BACK TO THE ILLUSTRATED 12PIC0006 BACK TO THE ILLUSTRATED 4121894P 4105489A BACK TO THE ILLUSTRATED BACK TO THE ILLUSTRATED...
  • Page 108 ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 107 CONTENTS BACK TO THE ILLUSTRATED 4122525W 4122058K BACK TO THE ILLUSTRATED 4122061N 4122062P BACK TO THE ILLUSTRATED BACK TO THE ILLUSTRATED 4105492D 4105487Y 4105488Z BACK TO THE ILLUSTRATED VIEW...
  • Page 109 ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 108 CONTENTS 4121955C 4122748D BACK TO THE ILLUSTRATED BACK TO THE ILLUSTRATED 4122999Q BACK TO THE ILLUSTRATED 4122113S BACK TO THE ILLUSTRATED...
  • Page 110 ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 109 CONTENTS 4122745A 4121907C BACK TO THE ILLUSTRATED BACK TO THE ILLUSTRATED 11PIC0082 BACK TO THE ILLUSTRATED 4105505S BACK TO THE ILLUSTRATED 11PIA0101 BACK TO THE ILLUSTRATED...
  • Page 111 ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION SECTION PAGE 110 CONTENTS 4122148D BACK TO THE ILLUSTRATED 4125899L BACK TO THE ILLUSTRATED...
  • Page 112 ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION : SECTION PAGE MANUAL CONTENTS SECTION 3: COUNTRY SPECIFIC INSTALLATION....................112 1.1 UNPACKING THE MACHINE....................112...
  • Page 113 ISSUE 21/09/2003 FD 6100 - SERVICE MANUAL REVISION : SECTION PAGE 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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