Formax FD 342 User manual

FD 342
Document Folder
OPERATOR MANUAL
FIRST EDITION
6/2010

TABLE OF CONTENTS
SUBJECT PAGE
DESCRIPTION 1
SPECIFICATIONS 1
UNPACKING 2
SETUP 2
CONTROL PANEL 3
OPERATION 4
SETTING CUSTOM FOLDS 5
BATCH COUNTING 5
MULTI-SHEET FEEDING (OPTIONAL) 6
CROSS FOLDING 7
STACKER WHEEL POSITIONING CHART 7
STACKER WHEEL SETUP FOR THICK PAPER 8
REMOVING OUTFEED COVER 8
REMOVING INFEED TIRES 9
OPERATOR MAINTENANCE 9
TROUBLE-SHOOTING 10

DESCRIPTION
1
Upper Fold Table
Telescoping
Outfeed Stacker
Self Centering Paper
Side Guides
Infeed Tray
Infeed Tray
Extension
Infeed Tray
Lever
Lower Fold
PlateTable
Non-Operator Side
Operator Side
FUNCTION
The FD 342 Folder is designed to perform a wide variety of folds using a variety of paper weights. The fold plates are
manually adjusted for standard folds and custom folds. Batch counting, self-centering side guides, and the capability to
cross-fold are added features. The folder will automatically stop after the last document has been folded.
SPECIFICATIONS
Speed: Standard Mode: Up to 15,500/hour, depending on fold type
Hopper Capacity: Up to 500 sheets of 20# paper (75gsm)
Paper size: Min: 3.5” X 5” (88.9 W x 127 L mm)
Max: 12.25” X 18” (311 W x 457 L mm)
Pre-Marked fold types: Letter , Zig-Zag , Single , Gate , Fold Out ,
Double Parallel
Pre-Marked Paper Sizes: FD Model: 11”, 14”, 17”
FE Model: A5, A4, A3, B6, B5, B4
Dimensions Closed: 33” L x 20” W x 19” H (84 L x 51 W x 48 H cm)
Fully Extended: 60”L x 20” W x 19” H. (152 L x 51 W x 48 H cm)
Weight: 67 lbs (30 kg)
Power: FD Model: 120 volts A.C., 50/60 Hz, 2.5 amps.
FE Model: 220 volts A.C., 50/60 Hz, 2 amps
Safety Certications: UL & CE Applied For
Control Panel

Fig. 1b Locating Pins
2
Lower Fold Table Pins
Fig. 1a Locating Pins
Upper Fold Table Pins
UNPACKING & SETUP
1. Check package for shipping damage. If there is shipping damage, do not discard the box.
2. Remove the machine and packed components from the box. The fold plates, telescoping stacker, Optional Multi
Sheet Feeder if ordered, power cord and cross-fold guide are wrapped separately in the box.
NOTE: Two people must lift the machine from the box.
3. Place the folder on a solid stand.
Install upper and lower fold plates, telescoping conveyor
multi-sheet feeder and power cord
1. Be sure the plates are set rmly on the locating pins
(Fig 1a & 1b). Slide each fold plate in until it meets the
rst locating pin then push down to set in place.
2. Repeat the same steps for the lower fold plate.
3. Insert the telescoping extension tray into the end of the
outfeed conveyor (Fig. 2).
Fig. 2 Telescoping extension tray

4. If equiped, insert the optional Multi-Sheet Feeder into the
four slots located on the top cover (Fig 3).
5. Make sure the power switch is in the “OFF” position.
Plug the power cord into the power inlet and the wall
outlet.
Fig. 3
4 Slots
3
No. NAME FUNCTION
1 Paper out indicator Lights up when paper needs to be loaded
2 Cover open indicator Lights up when top cover is open
1 Counter Display Shows the number of documents processed. When power is turned on it displays
“F-01”.
2 Start Button Press to start the folder.
3 Stop Button Press to stop the folder.
4 Test Button Test folds one document.
5 Fault Indicator Lights Stops the operation and indicates the problem area, check for paper in the areas
indicated, clear paper and press the “C” button to turn off the “Fault detect” lights.
6 Batch Counting Button Select the batch counting function.
7 “-“ and “+” buttons Select the number of documents to be batch folded.
8 Clear / Reset Button Resets the fault detect circuit and the counter.
CAUTION: when a fault occurs, only press the button one time. If pressed a second
time, the counter will be reset.
CONTROL PANEL
3
8
4
5
6
7
10
9
21

OPERATION
1. Place power switch in the “ON” position.
2. To set the fold plate stop position, squeeze the
stop plate lever and move the stop plate to the
desired location on the upper and lower fold plates
(Fig 4). Align the pointed part of the stop plate with
the desired marks on the decal and release the lever.
Fine adjustments can be made with the adjustment
knob at the end of the plate (Fig 5).
NOTE: When doing a “Single” fold, be sure to move
the lower fold plate stop all the way to the front of
the plate. The plate must be rmly reinstalled on the
locating pins.
3. Move the stacker wheels to the proper position for
the paper size (Fig 6) ( Refer to chart on page 7).
4. Extend the telescoping conveyor stacker as required.
5. Lift the in-feed tray extension into position.
6. Raise the in-feed tray lever.
7. Set the paper side guides for the paper you’re using
and lock in position.
8. Neatly stack paper on the in-feed tray.
9. Lower the in-feed tray lever.
10. Press the “Test” button on the control panel to check
the folds. Adjust as needed.
11. If the fold is skewed use the skew adjustment knob
to make corrections (Fig.7).
12. When you’re satised with the test folds, press the
“Start” button to operate the machine.
Fig.7
Fig. 6
Fig. 5
4
Stacker Wheels
Stacker Wheel Positions A, B & C
Skew Adjuster
Fig. 4

SETTING CUSTOM FOLDS
BATCH COUNTING
The batch counter can be set from “0” to “999”. Press the
“Batch Counting” button to illuminate the “Batch Counting” light.
Press the “-“ or “+” buttons to select the number of documents
to be folded (Fig 8). Press the “ ” button. When the counter
gets to “0” the machine will stop.
NOTE: The batch counting program will remain on after turning
the power off. You must press the Batch Counting button to
turn off the light and cancel the batch count setting.
Example 1: Uneven “Z”
1. Measure the length of panel “A”
2. Adjust the upper fold plate so that the stop plate lines
up with the measurements of the panel “A” i.e. if panel
“A” is 5 1/4” long slide the stop plate up or down so that
it lines up with the 5 1/4” mark on the fold plate.
3. Measure the length of panel “B”
4. Adjust the lower fold plate so that the stop plate lines
up with the measurement of panel “B”
5. Load forms and press test. If folds are too long or too
short adjust accordingly.
1. Measure the length of panel “A” & “B”
2. Adjust the upper fold plate so that the stop plate lines up
with the measurements of panel “A” & “B”. i.e. if panel
“A” & “B” are 10 1/2” long slide the stop plate up or
down so that it lines up with the 10 1/2” mark on the fold
plate.
3. Measure the length of panel “B”
4. Adjust the lower fold plate so that the stop plate lines up
with the measurement of panel “B
5. Load forms and press test. If folds are too long or too
short adjust accordingly.
Example 2: Uneven “C”
5
Panel A
Panel B
Panel A
Panel B
Batch Count Button Batch Count Indicator Light
Fig. 8

6
MULTI-SHEET FEEDING (OPTIONAL)
The multi-sheet feeder is designed to fold pre-collated stapled or unstapled sets of up to four 20 # (75gsm)sheets of pa-
per.
1. Adjust the side guides on the milti-sheet feeder for the
proper paper size. Loosen the brass thumb screw, ad-
just the guides to t the paper width and re-tighten the
thumbscrew (Fig 9a).
2. Slide the pre-collated paper set into the multi-sheet
feeder. When feeding stapled sets the documents
should be placed with the staple on the operator’s side
and leading (Fig 9b).
3. The sheets of paper will be automatically pulled into the
folder (there is a one-second delay after the paper is
placed in the feeder).
4. If the fold is skewed, turn the skew adjustment knob
located on the back of the feeder left or right to make
corrections (Fig 9c).
5. To remove the multi-sheet feeder depress the release
levers located on either side of the lower back side of
the feeder (Fig. 9d), tilt the feeder forward and lift. To
reinstall depress the levers and reinsert.
Staple
Fig. 9b
Fig. 9a
Fig 9c
Brass thumbscrew
Skew Adjuster
Release Levers
Fig. 9d

7
CROSS FOLDING
Cross folding refers to folding a document in one pass and
then running it through the folder a second time to be folded
again.
Common Application: Folding a 11” x 17” document in half
and then letter folding it to t in a standard #10 envelope.
1. Load folded paper into the feed tray with the fold
crease facing the non-operator side of the folder
(Fig 10a).
Note: For best results, rmly run your hand over the
fold crease to help atten the paper before loading.
2. Attach the cross fold paper guide onto the feed tray
paper guide (Fig. 10b) and lower guide.
Note: Cross folding ability will vary based on the paper
weight and type. If the paper is too heavy it may not
be able to be cross folded.
Note: The guide can be convientlly stored under the
lower fold table when not in use (Fig 10c).
Tab “B” Tab “A”
Slot “B” Slot “A”
Fig. 10b
To install cross fold guide hook tab “A” into slot “A” and
then lower tab “B” into slot “B”
Fig. 10a
Fold Crease Cross Fold Guide
STACKER WHEEL POSITIONING GUIDE
8.5" x 11" 8.5" x 14" 11" x 17"
Letter
Zig-Zag
Single
Gate
Fold Out
Double ll
A
A
B
A
B
A
A or B
A or B
B
B
C
A
B
B
C
C
C
A or B
Move the stacker wheels to the proper position indicated on the chart based on the fold and paper size (Fig 11a and 11b).
Stacker Wheels
Fig. 11b
Fig. 11a
Stacker wheels decal
Fig. 10c Cross fold guide storage

Thicker paper from 28 # up to 65 # may require special stacker
wheel setup moving the stacker wheels closer than the position
“A” slot.
If stacking is inconsistent move the stacker wheels from the
standard position #1 (Fig. 12a) to the thick paper weight posi-
tion #2 (Fig. 12b) as indicated in the pictures below, position # 2
may also be good for small folded documents.
Fig. 12a - Standard Stacker Wheel Position
Fig. 12b - Thick Paper Weight Position
Position 1
Position 2
8
STACKER WHEEL SETUP FOR THICK PAPER
REMOVING OUTFEED COVER
The outfeed cover can be removed to access the exit roller.
To remove, unscrew thumbscrews that hold the cover in place
(Fig. 13)
Outfeed cover
Thumbscrews
Fig. 13

REMOVING INFEED TIRES
The infeed tires can easily be removed for cleaning and replace-
ment. Remove the Allen screw located on the left side of the feed
tire shaft (Fig. 14a). Slide the shaft to the right to release from the
side frame and remove (Fig. 14b).
Allen Screw
Fig. 14a
Fig. 14b
9
OPERATOR MAINTENANCE
1. It is recommended to let forms cool for one-half hour, from the laser printer, before folding. This allows toner to set
on the forms and static electricity to discharge. The FD 402 Jogger is recommended for best results. The Jogger
squares the forms and dissipates heat and static electricity created by laser printers.
2. Clean in-feed tires and fold rollers with Formax recommended roller cleaner & rejuvenator to remove paper dust and
toner. A Formax Cleaner Kit is available from your dealer. A damp cloth with water is the best alternative.
CAUTION: Do not use any chemicals other than the roller cleaner & rejuvenator or water.
Fig. 15 Fold Rollers
1. Make sure machine is turned off and unplugged. All folders
have four (4) rubber rollers (Fig. 15).
2. Remove the upper and lower fold plates.
3. Using Formax roller cleaner, spray a new cotton cloth until
the cloth is saturated. Wipe the wet cloth in a back and forth
motion making sure to clean the entire surface of the fold and
seal rollers. Next use a dry cloth and wipe off excess toner.
The cloth should be covered with black toner surplus from
cleaning the rollers.
4. Run 10-15 sheets of blank copy paper through the folder to
ensure all cleaner has been removed from the fold rollers.
Running blank sheets will remove any excess residue of
cleaner on the rollers.
CLEANING PROCEDURES:

TROUBLE-SHOOTING
TROUBLE POSSIBLE CAUSE REMEDY
Control panel lights are
not illuminated.
No power at the wall outlet.
No power to the machine inlet.
No power to the control panel.
Internal electrical failure
Check wall outlet.
Check power cord for frayed/broken
wires.
Press the button on the circuit breaker.
Call for service
“Cover Open” light is on. Cover open
Magnetic switch is broken.
Close cover
Call for service
“Paper out “ light is on. In-feed tray is empty. Place documents on the in-feed tray.
“Fault detect” light is on. Paper misfeed
Paper jammed at exit of folder.
Reload paper and press “Reset”.
Remove paper and press “Reset”.
Black marks on the folded
paper.
In-feed tires, separator, and/or
fold rollers are dirty.
Clean the parts with approved roller
cleaner and rejuvenator.
Fold is skewed. In-feed tray is out of
adjustment.
Turn skew adjuster knob to remove the
skew.
Stacker belts do not turn. Broken drive belt, worn drive
gear.
Call for service
Documents are wrinkled
or crunched.
Fold plates are not inserted
correctly.
Piece of paper or other material
is stuck in the fold plate.
Remove and reinstall fold plates. Be
sure they’re properly positioned.
Remove object from the fold plate.
In-feed tray lever does
not work
Broken spring Call for service
Double feeding forms Documents stuck together
Feed tire or separator worn
Jog forms to remove static electricity.
Call for service
Not feeding documents Feed tire dirty
Feed tire or separator worn
Clean feed tire
Call for Service
10