6204 Maint Manual 6e-Adjustments.pdf - Formax

6204 Series
Low-Volume Inserter
6/2012
MAINTENANCE MANUAL

6
Mechanical
description
6 Mechanical description ...................................................................................51
General ............................................................................................52
Covers and plates ............................................................................52
Electrical components ......................................................................57
Feeder modules ...............................................................................60
Document feed ................................................................................64
Collating area ..................................................................................74
Collating area ..................................................................................74
Folder ..............................................................................................76
Main drive mechanism .....................................................................89
Envelope hopper ..............................................................................97
Upper unit .....................................................................................103
Envelope transport ........................................................................109
Envelope sealing and ejection .......................................................111
Detectors .......................................................................................112
Adjustments ..................................................................................127
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063.1 Service Guide

Adjustments
Mechanical description
Adjusting the main drive PJ-belt
The maximum movement of the drive belt at the indicated position is 10 mm (0.4 inch).
To adjust:
1. Slacken the two screws (1) securing the belt tensioner (2).
2. Shift the belt tensioner to adjust the correct belt movement.
3. Hold the belt tensioner in position and retighten the two screws.
4. Check the adjustment and readjust if necessary.
Do not adjust the drive belt too tight.
When adjustment of the belt tensioner is not sufficient, re-adjust the motor position.
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Adjusting the main drive belt feeders /folder
The maximum movement of the drive belt at the indicated position is 10 mm (0.4 inch).
To adjust:
1. Slacken the two screws (1) securing the belt tensioner (2).
2. Shift the belt tensioner to adjust the correct belt movement.
3. Hold the belt tensioner in position and retighten the two screws.
4. Check the adjustment and readjust if necessary.
Do not adjust the drive belt too tight.

Adjusting the main drive belt inserter
The maximum movement of the drive belt at the indicated position is 10 mm (0.4 inch).
To adjust:
1. Slacken the two screws (1) securing the belt tensioner (2).
2. Shift the belt tensioner to adjust the correct belt movement.
3. Hold the belt tensioner in position and retighten the two screws.
4. Check the adjustment and readjust if necessary.
Do not adjust the drive belt too tight.
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Adjusting the RH drive belts
The adjustment of the lower and upper drive belt is similar.
The maximum movement of the drive belts (1) at the indicated position is 5 mm (0.2 inch).
To adjust:
1. Slacken the hexagonal head screw (3) securing the belt tensioner (2).
2. Shift the belt tensioner to adjust the correct belt movement.
3. Hold the belt tensioner and retighten the hexagonal head screw.
4. Check the adjustment and readjust if necessary.
Do not adjust the drive belt too tight.

Adjusting the drive belt upper folder section
The maximum movement of the drive belts at the indicated position is 5 mm (0.2 inch).
To adjust:
1. Slacken the hexagonal head screw (1) securing the belt tensioner (2).
2. Shift the belt tensioner to adjust the correct belt movement.
3. Hold the belt tensioner and retighten the hexagonal head screw.
4. Check the adjustment and readjust if necessary.
Do not adjust the drive belt too tight.
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Adjusting the paper guide
There must be a small gap between the fixed guide plate (3) and the fold roller (2). The fold roller should just
run free.
To adjust:
1. Slacken the two round head screws (1) to move the guide plate (3) further away from the fold roller (2).
2. Tighten it to move it closer

Adjusting the solenoids
The adjustment procedure for all solenoids is described below. Only for the finger solenoids
a different procedure is necessary.
Whenever a solenoid is actuated the plunger is pulled into the solenoid coil. To make sure that the pulling
power of the solenoid coil on the plunger is maximal, the plunger should not touch the bottom of the solenoid
coil whenever the solenoid is actuated.
To set this requirement:
1. Slacken the two screws (3) securing the solenoid coil (4).
2. Push the plunger (2) together, with the linkage (1) attached to it, as far as it will go in the direction towards the
solenoid coil.
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3. Hold the plunger in this position and then slide the solenoid coil towards the plunger until the plunger bottoms
the solenoid coil.
4. Move the solenoid coil back by approximately 1 mm (0.04 inch).
5. Retighten the two screws. Ensure the solenoid coil and the plunger are aligned in a straight line.
Adjusting the finger solenoid
To adjust the finger solenoid:
1. Slacken the two screws (2) securing the solenoid coil (1).
2. Push the plunger (3) down into the lowest position.
3. Move the solenoid coil (with the plunger in the lowest position) so that the middle fingers (slide in) is adjusted
approximately 2 mm (0.07 inch) (max.) above the insert table.
4. Retighten the two screws

Adjusting the separation roller
Because the separation roller does not reverse, a 'flat' gradually wears on the roller surface. This can be the cause
of irregular feeding of the envelopes. Should this occur, carry out the following adjustment:
1. Use (3) to set the separation gap to the maximum.
2. Slacken the set screws (1) securing the separation roller.
3. Rotate the separation roller (2) about 30 degrees in the direction indicated, so that the unworn portion of the
separation roller faces the feed roller.
4. Retighten the set screw (1) and re-adjust the separation gap.
After rotating the separation roller over 330 degrees it is necessary to replace it.
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Adjusting the friction brake
The friction brake is correctly adjusted when the distance between the inner faces of the two friction discs (3),
i.e. the overall pressure spring length, is 20 mm (0.79 inch).
To adjust:
1. Remove the outer nut (1) securing the inner nut (2).
2. Turn the inner nut to adjust the correct distance.
3. Replace the outer nut and check the adjustment.
Adjusting the flap scraper
An increased variation of the envelope stop position can be caused by excessive play in
the lower gear train. A slight reduction in the distance (increasing the pressure) may give
the required result.
The flap scraper (3) must be positioned so that its lower edge is aligned with the lower edge of the envelope
guide (1).
To adjust:
1. Slacken the two hexagonal head screws (2) securing the flap scraper (3) on both sides.

2. Move the flapscraper to adjust the correct position.
3. Retighten the two hexagonal head screws and check the adjustment.
Depending on the envelope type and flap shape, a different setting may be necessary.
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