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Francotyp-Postalia KS 4000 OL Operator's Manual

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Operator Manual
Inserting system KS 4000 OL / OLC
About your new inserting system
This operator manual is designed for users who have been instructed in
the operation of the Inserting System KS 4000 OL/OLC.
This operator manual is one part of the complete documentation available
for the Inserting System KS 4000 OL/OLC. It describes typical operating
procedures for configurations
– with a single-sheet feeder
– with a single-sheet feeder and supplement feeder
– with automatic cutter (for processing continuous-feed paper)
– with automatic cutter and supplement feeder
– with automatic cutter and cross-fold function (for processing
continueous-feed A3 and broadsheet formats)
– with automatic cutter, cross-fold function and supplement feeder.
Detailed descriptions (about functions, technical data, installation,
maintenance, programming) of individual components can be found in the
"Instruction Manual Inserting System 4000" and in the for "Operating
Instructions Cut-Sheet-Feeder" and/or "Operating Instructions Automatic
Forms Cutter" (depending on the configuration of your system).
Keep this operator manual readily available and near the machine.
The following symbols and cautions represent important safety warnings
in this manual:
Warning! indicates a potential hazard which may result in injury.
Caution! indicates a potential hazard that may result in damage to
your inserting system or which may impair the processing of
documents.
Tips marked in this way offer advice and suggestions on the effi-
cient and troublefree use of the inserting system.
2

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Summary of Contents for Francotyp-Postalia KS 4000 OL

  • Page 1 This operator manual is designed for users who have been instructed in the operation of the Inserting System KS 4000 OL/OLC. This operator manual is one part of the complete documentation available for the Inserting System KS 4000 OL/OLC. It describes typical operating procedures for configurations – with a single-sheet feeder –...
  • Page 2 KS 4000 OL (with automatic cutter) The control panel Single-sheet feeder / automatic cutter Diverter Delivery device Display 1 Display 2 Automatic cutter Control panel Toggle between Start feeder program selection and parameter Catch tray Display information Stop feeder Sealer...

  • Page 3: Table Of Contents

    Contents 1 Safety information ____________________________________________________________________________________________________________ 2 Useful information about the KS 4000 Online __________________________________________________ 3 Inserting System KS 4000 OL with single-sheet feeder _______________________________ Insert stacked material ___________________________________________________________________________________ 3.1.1 Starting operation ________________________________________________________________________________________________ 3.1.2 Stop automatic operation __________________________________________________________________________________ 3.1.3 Reload paper _________________________________________________________________________________________________________ 3.1.4 Conclude job and shut system down...
  • Page 4 Inserting from a single station _________________________________________________________________________ Inserting from multiple stations _______________________________________________________________________ Conclude job and shut system down ___________________________________________________________ 7 Inserting system KS 4000 OL / OLC modules ___________________________________________________ Single-sheet feeder __________________________________________________________________________________________ 7.1.1 Operating and adjustment controls _______________________________________________________________ 7.1.2 Adjust paper guides ____________________________________________________________________________________________ 7.1.3 Adjust separator sluice...
  • Page 5 Contents Conveyor _______________________________________________________________________________________________________________ 7.7.1 Adjust paper guides ____________________________________________________________________________________________ 7.7.2 Adjust paper stops (only on KS 4000 OL-systems) ______________________________________________________________________ Feeder / folding feeder ___________________________________________________________________________________ 7.8.1 Controls ___________________________________________________________________________________________________________________ 7.8.2 Adjust paper guides ____________________________________________________________________________________________ 7.8.3 Adjust separator gate _________________________________________________________________________________________ 7.8.4 Load paper _____________________________________________________________________________________________________________...
  • Page 6 Operator Manual KS 4000 OL / OLC...

  • Page 7: Safety Information

    • The system may be installed and moved only by service technicians who have been trained and authorized by Francotyp-Postalia. • The Inserting System KS 4000 OL/OLC may be used only by staff who have been instructed in the system’s operation.
  • Page 8 Operator Manual KS 4000 OL / OLC...

  • Page 9: Useful Information About The Ks 4000 Online

    Useful information about the KS 4000 OL / OLC Useful information about the KS 4000 OL / OLC The KS 4000 OL/OLC is a sophisticated mail processing system for finishing computer- generated mass mailings. The system can collect material, divert office duplicates, fold, insert and seal material in a finished envelope.
  • Page 10 Operator Manual KS 4000 OL / OLC Available options include: – Optical marks recognition (OMR). Code marks printed on each sheet being processed instruct the system to collect and check material addressed to a single address and / or to divert material that should not be mailed.

  • Page 11: Inserting System Ks 4000 Ol With Single-Sheet Feeder

    Inserting System KS 4000 OL with single-sheet feeder Inserting System KS 4000 OL with single-sheet feeder Insert stacked material 3.1.1 Starting operation Detailed instructions on configuring the inserting system for a job can be found in Chapter 7 in descriptions of individual modules and in the “Instruction Manual...
  • Page 12 Operator Manual KS 4000 OL / OLC • Check settings of the single-sheet sheet separator sluice. The single-sheet separator sluice is adjusted correctly when both red marks for automatic operation are visible. Markings (red) • Adjust the optical marks reading head...
  • Page 13 Inserting System KS 4000 OL with single-sheet feeder • If you wish to change the program, use the Program number (blinking) – function keys to select the desired program number. F1 – Set programm “00”. F2 – To reduce by “1” the shown program number.
  • Page 14 Operator Manual KS 4000 OL / OLC If the document set on the conveyor is complete, you can start automatic operation. How you do this depends on the inserter model used in the system. Systems with type VA inserter • Press the black button on the hand-held...

  • Page 15: Stop Automatic Operation

    Inserting System KS 4000 OL with single-sheet feeder 3.1.2 Stop automatic operation You can interrupt automatic operation at any time. • Press the button on the inserter Stop system • Press the button on the control panel of the single-sheet feeder.

  • Page 16: Reload Paper

    Operator Manual KS 4000 OL / OLC 3.1.3 Reload paper The system stops. An error message at the single-sheet feeder indicates that stacked supply of single sheets has been exhausted. • Fan out a stack of material and load it into the single-sheet feeder.

  • Page 17: Insert Stacked Material With Supplement

    Inserting System KS 4000 OL with single-sheet feeder Insert stacked material with supplement 3.2.1 Starting operation Detailed instructions on configuring the inserting system for a job (loading paper, setting paper guides, adjusting reading head, etc.) can be found in Chapter 7 in descriptions of individual modules and in the “Instruction...
  • Page 18 Operator Manual KS 4000 OL / OLC • Check settings of the single-sheet separator. The single-sheet separator sluice is adjusted correctly when both red marks for automatic operation are visible. Marks (red) • Adjust the optical reading head when using...
  • Page 19 Inserting System KS 4000 OL with single-sheet feeder • If you wish to change the program, use the Program number (blinking) – function keys to select the desired program number. F1 – Set program “00”. F2 – To reduce by “1” the shown program number.
  • Page 20 Operator Manual KS 4000 OL / OLC Station / Supp. 1 Additional stations (feeder / folding feeder) may be present on the conveyor. These can Station / Supp. 2 add supplementary sheets to each set. How you use any supplement station depends on how the system is configured and the job being processed.
  • Page 21 Inserting System KS 4000 OL with single-sheet feeder When the first set is complete on the con- veyor and includes all supplements, you can start automatic operation. How you do this depends on the inserter model used in the system (type A oder type VA inserter).

  • Page 22: Stop Automatic Operation

    Operator Manual KS 4000 OL / OLC If supplements are drawn into the inserter with Regulate speed too much force and slam into the chute, use the speed setting wheel to reduce speed so that supplements are gently delivered to the inserter.

  • Page 23: Replenish Paper Supply

    Inserting System KS 4000 OL with single-sheet feeder If the Station STOP was pressed indicator lamp is ON): • Press button on the station. If the control panel STOP has been pressed (the lower display shows STOP and SPEED PAUSE alternately): •...

  • Page 24: Conclude Job And Shut System Down

    Operator Manual KS 4000 OL / OLC 3.2.4 Conclude job and shut system down When the last sheet has been fed from the single-sheet feeder and the last complete set is on the conveyor, the system stops. • Check that the last set is complete and correct.

  • Page 25: Inserting System Ks 4000 Ol With Automatic Cutter

    Inserting System KS 4000 OL with automatic cutter Inserting System KS 4000 OL with automatic cutter Cut and insert continuous-feed paper 4.1.1 Starting operation Detailed instructions on configuring the inserting system for a job (setting up the cutter, adjusting the reading head, etc) can be found in Chapter 7 in descriptions of individual modules and in the “Instruction Manual...
  • Page 26 Operator Manual KS 4000 OL / OLC Load continuous-feed material in the automatic cutter’s tractor drive: Tractor covers Paper holder • Lift transparent hood on the automatic cutter. • Open both tractor drive covers. • Loosen both set screws. • Load the continuous-feed material. Match the holes in the paper’s side strips with the...
  • Page 27 Inserting System KS 4000 OL with automatic cutter Power switch automatic cutter • Turn automatic cutter power switch ON. The red signal buttons on the individual modules will light up briefly. The conveyor will move to its starting position. The red signal button on the Black Box blinks.
  • Page 28 Operator Manual KS 4000 OL / OLC If a program for optical marks reading is With OMR selected, the lower display will show the mes- sage ADJUST! after the program has been started. Then: • Adjust the reading head. The reading head is positioned correctly when the adjustment line (the first printed optical mark) can be seen in the reading head’s...
  • Page 29 Inserting System KS 4000 OL with automatic cutter Systems using type VA inserter • Press the black button on the hand-held conveyor control repeatedly until the first set enters the inserter and automatic operation begins. Systems using type A inserter •...

  • Page 30: Stop Automatic Operation

    Operator Manual KS 4000 OL / OLC 4.1.2 Stop automatic operation You can interrupt automatic operation at any time. • Press the button on the inserter. System stop • Press the button on the control panel of the automatic forms cutter.

  • Page 31: Conclude Job And Shut System Down

    Inserting System KS 4000 OL with automatic cutter 4.1.3 Conclude job and shut system down When the automatic cutter reaches the end of the continuous-feed paper, the lower display in the cutter control panel will show the mes- sage PAPER ??? and the system will stop.

  • Page 32: Process Continuous-Feed Paper And Add Supplement

    Operator Manual KS 4000 OL / OLC Process continuous-feed paper and add supplement 4.2.1 Starting operation Detailed instructions on configuring the inserting system for a job (loading paper, setting paper guides, adjusting reading head, etc.) can be found in Chapter 7 in descriptions of individual modules and in the “Instruction...
  • Page 33 Inserting System KS 4000 OL with automatic cutter Paper holder • Align paper to the middle the of the machine. Paper center line = Centered to paper center paper guide. • Tighten set screws to lock both tractors into position.
  • Page 34 Operator Manual KS 4000 OL / OLC Power switch automatic cutter • Turn automatic cutter power switch ON. The red signal buttons on the individual modules will light up briefly. The conveyor will move to its starting position. The red signal button on the Black Box blinks.
  • Page 35 Inserting System KS 4000 OL with automatic cutter The reading head is positioned correctly when the adjustment line (the first printed optical mark) can be seen in the reading head’s notch. Notch 1st mark Without OMR If programs without optical marks reading...
  • Page 36 Operator Manual KS 4000 OL / OLC At the station (first supplement): • Press button. • Set up station and load with supplement Station ON material. Field occupied • Press button. Start • Press button. One supplement will be fed to determine reference value.
  • Page 37 Inserting System KS 4000 OL with automatic cutter Systems with type A inserters • When the first document set is complete in the inserter machine, press the Insert button. The first set will be folded and inserted into an envelope. The system then stops.

  • Page 38: Stop Automatic Operation

    Operator Manual KS 4000 OL / OLC 4.2.2 Stop automatic operation There are several different ways to stop automatic operation. Inserter • Press the button on the inserter. Feeder/Folding feeder • Press the button on the supplement feeder station. Automatic cutter •...

  • Page 39: Conclude Job And Shut System Down

    Inserting System KS 4000 OL with automatic cutter 4.2.3 Conclude job and shut system down When the automatic cutter reaches the end of the continuous-feed paper, the lower display in the cutter control panel will show the mes- sage PAPER??? and the system will stop.

  • Page 40: Reload Paper

    Operator Manual KS 4000 OL / OLC • Press the button to turn OFF the feeder / folding feeder. Station OFF Inserter OFF • Press the button on the inserter. • Turn OFF the power switch on the inserter machine.

  • Page 41: Supplement

    Inserting System KS 4000 OL with automatic cutter • Load new continuous-feed paper into the Resume operation automatic cutter. • Press the button on the control panel. • When running OMR programs, adjust the reading head if necessary. • Press the button to resume automatic operation.
  • Page 42 Operator Manual KS 4000 OL / OLC...

  • Page 43: Inserting System Ks 4000 Olc With Automatic Cutter

    Inserting System KS 4000 OLC with automatic cutter Inserting system KS 4000 OLC with automatic cutter Cut and insert continuous-feed paper 5.1.1 Starting operation Detailed instructions on configuring the inserting system for a job (setting up the cutter, adjusting the reading head, etc) can be found in Chapter 7 in descriptions of individual modules and in the “Instruction Manual Inserting System 4000“.
  • Page 44 Operator Manual KS 4000 OL / OLC Load continuous-feed material in the automatic cutter’s tractor drive: Tractor covers Paper holder • Lift transparent hood on the automatic cutter. • Open both tractor drive covers. • Loosen both set screws. • Load the continuous-feed material. Match the holes in the paper’s side strips with the...
  • Page 45 Inserting System KS 4000 OLC with automatic cutter Power switch automatic cutter • Turn automatic cutter power switch ON. The red signal buttons on the individual modules will light up briefly. The conveyor will move to its starting position. The red signal button on the Black Box blinks.
  • Page 46 Operator Manual KS 4000 OL / OLC With OMR If a program for optical marks reading is selected, the lower display will show the mes- sage ADJUST! after the program has been started. Then: • Adjust the reading head. The reading head is positioned correctly when the adjustment line (the first printed optical mark) can be seen in the reading head’s...
  • Page 47 Inserting System KS 4000 OLC with automatic cutter Systems with type VA inserter • Press the black button on the hand-held conveyor control repeatedly until the first set enters the inserter and automatic operation begins. Systems with type A inserter •...

  • Page 48: Stop Automatic Operation

    Operator Manual KS 4000 OL / OLC 5.1.2 Stop automatic operation You can interrupt automatic operation at any time. Inserter • Press the button on the inserter. Automatic cutter • Press the button on the control panel of the automatic forms cutter.

  • Page 49: Conclude Job And Shut System Down

    Inserting System KS 4000 OLC with automatic cutter 5.1.3 Conclude job and shut system down When the automatic cutter reaches the end of the continuous-feed paper, the lower display in the cutter control panel will show the mes- sage PAPER ??? and the system will stop. To replenish with paper and continue the job, please refer to Chapter 4.3.

  • Page 50: Process Continuous-Feed Paper And Add Supplement

    Operator Manual KS 4000 OL / OLC “Last envelope” button • Press the “last envelope” button on the sealer. The sealer delivers the last sealed envelope. Inserter OFF • Press the button on the inserter. • Turn OFF the power switch on the inserter.
  • Page 51 Inserting System KS 4000 OLC with automatic cutter • Load envelopes. Inserter Power ON / OFF • Switch inserter power to ON. • Press button on the inserter. The inserter ON button lights up. The inserting system tests all interfaces. Inserter ON Load continuous-feed material in the automatic cutter’s tractor drive:...
  • Page 52 Operator Manual KS 4000 OL / OLC Knurled screws for edge blade fine Adjust edge blades: adjustment • Loosen edge blade locks. Edge blade locking screw Edge blade housing • Set edge blades left and right by sliding the trimmer housing to the desired position.
  • Page 53 Inserting System KS 4000 OLC with automatic cutter Please read the „Instruction Manual Inserting System 4000 “ and the „Operating Instructions Automatic Forms Cutter“ for instructions on changing a program or creating a program for a new job. • Press the button on the control panel.
  • Page 54 Operator Manual KS 4000 OL / OLC • Check to make sure the first set on the Station / Supp.1 conveyor is complete and correct. Station / Supp.2 Additional stations (feeder / folding feeder) may be present on the conveyor. These can add supplementary sheets to each set.
  • Page 55 Inserting System KS 4000 OLC with automatic cutter When the first set is complete on the con- veyor and includes all supplements, you can start automatic operation. How you do this depends on the inserter model used in the system (type A oder type VA inserter). Systems with type VA inserter •...

  • Page 56: Stop Automatic Operation

    Operator Manual KS 4000 OL / OLC 5.2.2 Stop automatic operation There are several different ways to stop automatic operation. Inserter • Press the button on the inserter. Feeder/Folding feeder • Press the button on the supplement feeder station. Automatic cutter •...

  • Page 57: Conclude Job And Shut System Down

    Inserting System KS 4000 OLC with automatic cutter If the red signal button on the lateral conveyor / sequenzer was pressed to stop the system (signal button blinks steadily): • Again press the signal button. The signal button light will go out. 5.2.3 Conclude job and shut system down When the automatic cutter reaches the end of the continuous-feed paper, the lower display...

  • Page 58: Reload Paper

    Operator Manual KS 4000 OL / OLC “Last envelope” button • Press the “last envelope” button on the sealer. The sealer delivers the last sealed envelope. • Press the button on the inserter. Station OFF Inserter OFF • Turn OFF the power switch on the inserter.

  • Page 59: Inserting From Stations (Feeder/Folding Feeder)

    Inserting from Stations (feeder / folding feeder) Inserting from Stations (feeder / folding feeder) Detailed instructions on configuring the inserting system for a job can be found in Chapter 7 in descriptions of individual modules and in the “Instruction manual Inserting system 4000”.
  • Page 60 Operator Manual KS 4000 OL / OLC Lever • Swing the separator head upward until it Separator Address snaps out of the way. location • Load the prepared fanned stack into the paper bin and move it close to the separating head.

  • Page 61: Inserting From Multiple Stations

    Inserting from Stations (feeder / folding feeder) Inserting from multiple stations When processing material from two or more Station 2 stations, the page that bears the receiver’s Station 1 address must always be loaded into Station 1. Caution! Make sure that no material from the previously run job remains in the machine.
  • Page 62 Operator Manual KS 4000 OL / OLC Lever • Swing the separator head upward until it snaps out of the way. Separator • Load the fanned stack into the paper bin and move it close to the separating head. • Lower the separating head by press the lever upward.
  • Page 63 Inserting from Stations (feeder / folding feeder) • Press the button. • Press the button. One sheet (page) will be drawn from the stack to generate a Field occupied reference value. Start • Verify that only a single sheet was drawn. •...

  • Page 64: Conclude Job And Shut System Down

    Operator Manual KS 4000 OL / OLC Conclude job and shut system down • Turn off the feeder / folding feeder station(s) by pressing the button(s). • Make sure the last set is complete and Station OFF correct. “Last envelope” button •...

  • Page 65: Inserting System Ks 4000 Ol / Olc Modules

    Inserting System KS 4000 OL / OLC modules Inserting system KS 4000 OL / OLC modules This chapter introduces each of the modules available for configuring specialized KS 4000 inserting systems. The operation and adjustment possibilities for each module will be briefly described.

  • Page 66: Single-Sheet Feeder

    Operator Manual KS 4000 OL / OLC Single-sheet feeder 7.1.1 Operating and adjustment controls...
  • Page 67 Modules – Single-sheet Feeder n i t o i t o i t t a l i u l i u l s t i o i t g i l t a l i u l i u l s t i o i t i u l...

  • Page 68: Adjust Paper Guides

    Operator Manual KS 4000 OL / OLC 7.1.2 Adjust paper guides Caution! The paper guides must always be aligned to the center to make sure paper is Paper guide locks separated and transported flawlessly. • Loosen paper guide locks so that the paper guildes can easily be moved.

  • Page 69: Load Paper

    Modules – Single-sheet Feeder • Push a sample sheet between the two separator rollers in the separator sluice assembly. • Turn the setting wheel in the + direction (sets sluice “wider”). • Then turn the setting wheel in the other ( - ) direction until the separator drums start pulling on the sample sheet.

  • Page 70: Adjust Reading Head

    Operator Manual KS 4000 OL / OLC • Make sure the pre-sluice separator gate is Pre-sluice lowered into its normal position. Fanned stack (leading wedge) • Lay the prepared stack of paper into the paper tray. Make sure the address location is correct.
  • Page 71 Modules – Single-sheet Feeder • Slide on page with optical marks under the reading head. • Loosen the locking screw on the reading head. The reading head can be moved laterally. • Slide the reading head so that the red markings on the reading head align with the middle of the optical marks on the sheet of paper.

  • Page 72: Automatic Cutter

    Operator Manual KS 4000 OL / OLC Automatic cutter 7.2.1 Operator controls...
  • Page 73 Modules – Automatic cutter e l l c i t g i l i r r t i s t i s t i s t i s t i s c i t...

  • Page 74: Load Continuous-Feed Paper

    Operator Manual KS 4000 OL / OLC 7.2.2 Load continuous-feed paper • Open both transport tractor covers. • Loosen locking screws on both transport tractors (turn counter-clockwise) so that the tractors can be moved laterally. • Set transport tractors to paper width.

  • Page 75: Adjust Edge Cut Position

    Modules – Automatic cutter 7.2.3 Adjust edge cut position • Load paper as described in Chapter 7.2.2. • Loosen the edge blade housing locking screws so that the blade housing can be moved laterally. Locking screw • Slide the edge blade housing so that the blue mark is aligned to the desired cutting position.

  • Page 76: Adjust Reading Head

    Operator Manual KS 4000 OL / OLC 7.2.4 Adjust reading head Optical marks recognition programs include a reading head adjustment step during the start- routine. The automatic cutter positions the adjustment line to the reading head. The lower display will...
  • Page 77 Modules – Automatic cutter When Reading from below: • Before loading the piece of continuous-feed paper, use a punch pliers to mark the location of the adjustment line. • Adjust the reading head as described above. The marking hole must be visible in the reading head notch.

  • Page 78: Lateral Conveyor

    Operator Manual KS 4000 OL / OLC Lateral conveyor 7.3.1 Controls l l o e l f o i t...

  • Page 79: Adjust Paper Transport Guides

    Modules – Lateral Transport 7.3.2 Adjust paper transport guides • Loosen locking screws on both sides. • Swing transport roller brace into its open position and place a sample sheet of paper on the machine. • Position the paper stop about 1 mm from the bottom edge of the page.

  • Page 80: Sequencer And Delivery Device

    Operator Manual KS 4000 OL / OLC Sequencer and Delivery device 7.4.1 Controls n i t l a i l l o i l e o i t i l e...

  • Page 81: Adjust Paper Guide

    Modules – Sequencer and Delivery device 7.4.2 Adjust paper guide • Swing the sequencer’s upper body all the way open. • Swing transport roller brace open and hold in place. • Lay a sample sheet of paper flush to the edge.

  • Page 82: Folder

    Betriebsanleitung KS 4000 OL / OLC Folder...
  • Page 83 Modules – Folder l l a It is not necessary to manually adjust or set folding location, or to close the folding pocket if no fold is desired. Job program parameters provided by the material source (single-sheet feeder or automatic cutter) include these set- tings.

  • Page 84: Diverter Unit

    Operator Manual KS 4000 OL / OLC Diverter unit 7.6.1 Diverter for KS 4000 OL 2 (on rear side) d i l l l o Adjust paper length • Use the slider on the rear of the receptacle to adjust the paper stop to the material length.

  • Page 85: The Catch Tray (Ks 4000 Olc)

    Modules – Diverter 7.6.2 The catch tray (KS 4000 OLC) l l o l a i ) c i Adjust catch tray • Align the magnetic receptacle sides so that ejected material is neatly caught. Make sure the ejected pages do not bump against the receptacle sides on the side.

  • Page 86: Conveyor

    Operator Manual KS 4000 OL / OLC Conveyor...
  • Page 87 Modules – Conveyor s l i l l o n i t n i t e i f n i t n i t o i t n i l...

  • Page 88: Adjust Paper Guides

    Operator Manual KS 4000 OL / OLC 7.7.1 Adjust paper guides • Slide paper guide rails to leave a 2 mm gap on both sides of a sample sheet (scales show half of the paper’s width plus 2 mm). Scales left and right are provided at both ends of the conveyor, with “0”...

  • Page 89: Adjust Paper Stops (Only On Ks 4000 Ol-Systems)

    Modules – Conveyor 7.7.2 Adjust paper stops (only on KS 4000 OL-systems) • To adjust the conveyor to material length, turn the inserter power ON and press the inserter button. The conveyor moves to its starting (or “zero”) position. • Place a sample sheet at the front of the conveyor.

  • Page 90: Feeder / Folding Feeder

    Operator Manual KS 4000 OL / OLC Feeder / folding feeder 7.8.1 Controls Control panel...
  • Page 91 Modules – Feeder / Folding feeder s l i s l i , s t n i t v i t n i t n i t n i t o i t o i t p i t e i f e i f “...

  • Page 92: Adjust Paper Guides

    Operator Manual KS 4000 OL / OLC 7.8.2 Adjust paper guides • Loosen knurled nuts on the guide rails. Knurled screws • Adjust the rails to a setting that is half the paper’s width + c. 2 mm. The correct setting can be read from the scale at the end of the paper tray.

  • Page 93: Load Paper

    Modules – Feeder / Folding feeder 7.8.4 Load paper • Fan out a stack of max. 500 documents so that the sides are evenly straight and the leading edge of the top sheet is at the point of a wedge. Lever Separating •...

  • Page 94: Inserter

    Operator Manual KS 4000 OL / OLC Inserter 7.9.1 Controls - type A inserter (interior) 7.9.2 Controls - type VA inserter (interior)
  • Page 95 Modules – Inserter s l i n i l , s t l a i s l i l a i o i t o i t . i ( c i t o i t t i n t i h g i l c i t t i h...

  • Page 96: Adjust Paper Guides

    Operator Manual KS 4000 OL / OLC 7.9.3 Adjust paper guides • Swing cover open. • Place a sample sheet inside the inserter. • Use the “material width” knob to set the paper guide rails to the correct setting. The rails should leave a 2 mm gap on both sides of the stack.

  • Page 97: Load Envelopes

    Modules – Inserter 7.9.4 Load envelopes Note: – All envelopes in the envelope hopper must be oriented the same way. – The edges and corners of the envelopes must be clean and flat. – Unpack envelopes 24 hours earlier for best results.

  • Page 98: Sealer

    Operator Manual KS 4000 OL / OLC 7.10 Sealer...
  • Page 99 Modules – Sealer , t r L “ ” e i n i e l t l i a l i a l i a t a l t l e a l f l i a h t i a l f...
  • Page 100 Operator Manual KS 4000 OL / OLC Opening the cover • Push the latch as shown to release. • Raise cover upwards. Closing the cover • Lower cover to normal position. • Push the latch as shown with one hand while pressing the cover gently downward.

  • Page 101: Trouble-Shooting Tips

    FP will not be held liable for any resulting damages. In the event of a fault or problem, the Inserting System KS 4000 OL/OLC stops. With the assistance of the system’s error signaling system you can locate the problem and iden- tify causes.
  • Page 102 Operator Manual KS 4000 OL / OLC If a crash or paper jam occurs when processing jobs that use OMR (optical marks recognition) or a preset-counter, we recommend that all the material for the addressee involved in the crash be removed by hand and completed manually.

  • Page 103: Single-Sheet Feeder Faults

    Trouble-shooting tips – Single-sheet feeder Single-sheet feeder faults Error messages The inserting system signals a fault in the single-sheet feeder with: – an error message in the display and / or – blinking red signal button on the Black Box. Clearing error messages After remedying the source of the fault, clear the error message:...
  • Page 104 Operator Manual KS 4000 OL / OLC , t c , y r n i t n i t . t r , t c , y r n i t n i t . t c n i t...

  • Page 105: Automatic Cutter Faults

    Trouble-shooting tips – Automatic cutter Automatic cutter faults Error messages The inserting system signals a fault in the automatic cutter with: – an error message in the display and / or – blinking red signal button on the Black Box. Clearing error messages After remedying the source of the fault, clear the error message:...
  • Page 106 Operator Manual KS 4000 OL / OLC n i t . ) r n i t c i t g i l . y t n i t c i t g i l h t i g i l...

  • Page 107: Lateral Conveyor Faults

    Trouble-shooting tips – Lateral transport Lateral conveyor faults Error messages A fault in the lateral conveyor is indicated when the lateral conveyor’s red signal button is blinking. The red signal button on the Black Box may also blink. Clearing error messages After remedying the source of the fault, clear the error message: •...

  • Page 108: Delivery Device Faults

    Operator Manual KS 4000 OL / OLC t a l t a l n i l h t i . y r : y l Delivery device faults Faults in the delivery device are indicated when the red signal button on the Black Box is blinking.

  • Page 109: Sequencer Faults

    Trouble-shooting tips – Delivery device / Sequencer • Lower the upper part. • Press the upper part gently down until the latch catches. • Press the Black Box signal button to clear the error message. The signal button will stop blinking and the system is ready to resume operation.

  • Page 110: Folding Machine Faults

    Operator Manual KS 4000 OL / OLC Warning! Danger of injury! Use caution when closing the sequencer. Never reach between the roller mounting and the sequencer’s upper part. Fingers may be crushed if the top slams closed. • Carefully lower the sequencer upper part.
  • Page 111 Trouble-shooting tips – Folder Power switch automatic cutter • Turn online-feeder (cutter or single-sheet feeder) power switch OFF and then turn back ON. The Black Box signal button will blink. The folding device folding pocket will move to its “zero” or starting position. The folder’s sig- nal button will blink until the folding pocket reaches this position.
  • Page 112 Operator Manual KS 4000 OL / OLC • Carefully remove jammed papers. • Reattach the folding pocket covering and tighten the knurled nuts. Warning! Danger of injury! When switching the online feeder ON the folding drums will briefly be set in motion. Keep fingers, hair, scarves and jewelry safely away from the folder.
  • Page 113 Trouble-shooting tips – Folder n i l y l t o l l l l a . f l – – y l t n i t – v i l e l i “ v i t . ) ” i l b i l b n i t...

  • Page 114: Diverter Unit Faults

    Operator Manual KS 4000 OL / OLC Diverter unit faults y l t n i l . l l . y t n i t n i t...

  • Page 115: Feeder / Folding Feeder Faults

    Trouble-shooting tips – Diverter & Feeder / Folding feeder Feeder / folding feeder faults The two-place error code in the feeder / folding feeder display provides information about the source of the error. Display i t c g i l i l b g i l g i l...
  • Page 116 Operator Manual KS 4000 OL / OLC – o i t . y t – l a i t a l – i u l . t s y l t g i l i r r g i l...
  • Page 117 Trouble-shooting tips – Feeder / Folding feeder n i t o i t n i t i t c o i t o i t : y l n i t o i t : e l l a t...

  • Page 118: Inserter Faults

    Operator Manual KS 4000 OL / OLC 8.10 Inserter faults . y t n i t o i t t i l y l t l l a . y l o i t e l i t i n...
  • Page 119 Trouble-shooting tips – Inserter y l t . y l not pressed. – c i t g i l . s t o i t – g i l . s t y l t . t i l – g i l .

  • Page 120: Sealing Unit Faults

    Operator Manual KS 4000 OL / OLC 8.11 Sealing unit faults t i n . t l n i t n i l t i n y l t . y r . l a o i t . l i...
  • Page 121 KS 4000 OLC (crossfold configuration with automatic cutter) Declaration Of Conformity Sequencer Folder Delivery device Feeder / Folding feeder Catch tray (diverter) Inserter Black Box * Sealing unit Control panel Catch tray Conveyor Automatic cutter * Location may very depending on configuration...

  • Page 122: Service

    Service Service Every KS 4000 OL/OLC inserting system is assembled in the factory and thoroughly tested before delivery. In the event of a fault becoming apparent despite our best quality control measures, please contact your customer service representative. FP authorized dealer Francotyp-Postalia AG &...

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