Chapter 1 Safety, Introduction, Characteristics

and Application Descriptions of Machine

1-1 Safety
● Themain electric power supply requires the below specification.
Main Power : 220V 1ψ AC 60/50HZ

● The machine should be installed qualified clean and dry operation

environment

● After installed in operation area, the machine should be fully fixed

on the floor to keep machine levelness.

● Machine main power must be shut down before execute adjustment

and maintenance procedures.

● Any unauthorized machine modification is strictly forbidden by

Alpha Pack. Any machine modification requires further
authorization from Alpha Pack.

● Compressed air usage must comply with standard design applicable

pressure range.

● Any unauthorized person is forbidden to enter machine operation

area when machine is running.

● After operation procedure is finished, machine main power shut

down confirmation is required.

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1-2 General Introduction
The major products transmission method is applying starwheel rotating to
deliver products to each designed station.

The machine contains major parts in the following

1. Main Frame
2. Transmission
3. Starwheel
4. Carton in-feeding mechanism
5. Flap folding mechanism 1
6. Flap folding mechanism 2
7. Carton out-feeding mechanism.

7. Carton out-feeding 6. Flap folding

mechanism 4. Carton in-feeding mechanism 2
mechanism
3. Starwheel

5. Flap folding
mechanism 1

1.Main
Frame
2. Transmission

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  Operation procedure
The standard machine operation procedures are shown as the blow
drawing.

6
1
11
12 10 5
1 9

2 8 4

2 3 7
4 6
5

3
- Carton in-feeding applies vacuum suction to uniform and set carton
into molds.
- Uniformed carton delivers to embossing station to print required
information on box. Information can be “Batch/Lot Number”,
“Manufacturing Date”, “Expired Date”.
- Printed carton delivers to leaflet station. Leaflet can be inserted
automatically by pneumatic cylinder.
- After leaflet inserting procedure is completed, carton delivers to
product inserting station. Operator is required to put products manually
and check if there is any missing leaflet in the carton.
- After product is placed into the carton, it delivers to closing station.
Both upper/lower flaps are closed automatically by pneumatic cylinder.
- After carton is closed, it delivers to out-feed station. Finished carton
is pushed out by pneumatic cylinder.
-

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1-3 Machine application

 For different size carton, the change parts contain carton molds,
carton bending /inserting parts. In general, the change over time is
approximately 20~25 minutes according to the operator’s familiarity.

 This vertical type cartoning machine is suitable for low productivity

but various size cartons.

 The major machine material is anodized aluminum to make more

durable, antirust and easy cleaning.

 The machine is continuous carton folding and sealing. It is also

adopted with speed adjustor to make the machine complied with
operator’s productivity.

 This machine is applicable to various square cartons for

pharmaceutical, food and cosmetics products.

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 Chapter 2 General Machine Specification
2-1 Dimension

1650
1062 1400

2-2 Specification

Model CSC-50
Min. carton dimension 60X20X20m/m
Max. carton dimension 200x80x80m/m
Production speed 20-60 per/min
Power 220V 1ψ; 50/60HZ
Horse power of motor 1/4HP 30:1
Compressed air
150L/min
consumption
Dimension of machine 1400LX1062WX1650H
Weight of machine 350Kg
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 Chapter 3 Moving and Installation
3-1 Moving
Wooden case packed machine must be moved by a forklift. During
packed moving, a secured path and protection is strongly
recommended.

3-2 Machine Installation

 The fixed foot stands are moving wheel and fixed stand multi
function designed to make machine moving and installation easily.

 Machine must be installed on the flat ground. Once the machine

has moved to installed area, fully machine fixed is required. The
fixed procedure is shown as following instruction.

foot base
foot base
elongation

foot base rotating knob

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 Chapter 4 Machine Operation
4-1 Preparation
(1) Connect the machine with specified power source.
(2) Turn on the master power switch (shown as the below drawing)
(3) Compressed air source should be 6kg/c ㎡.Machine is not able
to be operated with insufficient air pressure.
(4) Place the carton at in-feeding storage device.
(5) Check printing characters are as required.
(6) Set up printing machine operation temperature at 95~100 ℃
(shown as the below drawing).

temperature adjusting knob

electrical doo r

Rotating outer master power switch

fram can adjust
temperature

°C
100
50 150

0 200

AT48

Temperature adjustor Open safety door is Open Safety Door is

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allowed when main forbidden when
power is off. main power is on .
 緊急停止 主機寸動 主機停止 批號 說明書
關 開 關 開

4-2 Control Panel

UNPOSITION SPEED ADJ. START VACUUM POWER

OFF ON OFF ON

EMG STOP JOG STOP EMBOSSING LEAFLET

OFF ON OFF ON

 Power On ( Main Power On): Machine in Standby mode. Carton Suction cylinder
is activated.
 Machine Start (Machine Start): Machine start operation.
 Machine Stop (Machine Stop): Machine Stop operation. Carton suction cylinder is
inactivated.
 Vacuum Switch (Vacuum System On/Off) : Vacuum system is able to be activated
while machine is under normal operation status. Vacuum system is applied to
carton in-feed suction and leaflet suction procedure.
 Leaflet Switch (Leaflet System On/Off): Leaflet system is able to be activated while
machine is under normal operation status and carton has detected by leaflet
sensor.
 Batch Printing Switch (Batch Printing System On/Off) : Batch printing system is
able to be activated while machine is under normal operation and carton has
detected by batch printer sensor.
 Speed Adjustor(Operation Speed Adjustment): While machine is running, the
operation speed is adjustable according to the speed adjustor.
 Jog Knob( Jog Function): While main power is on , and machine stay at stand-by
mode, the jog function is activated. Jog function is for machine adjustment and
testing.
 Emergency Stop: Machine fully stops.
 Batch Printer Temperature Controller (Batch Printing system operation
temperature control) : Set batch printer required temperature. When reached
setting temperature, the green light is on. The suggested operation temperature is
between 95 ℃~100 ℃

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 Chapter 5 Machine Maintenance And Trouble
Shooting
5-1 Maintenance
The following table contains the routine maintenance items and details
Items Recommend Maintenance Comment
Main gear reducer Lubricant Oil: 1. First three months
operation, lubricant oil
-Brand: Kou-Kuang
change is required
-Model:HD-220
2. Every six month
operation, lubricant oil
change is required
Cam Lubricant Oil: 1. First three months
operation, lubricant oil
-Brand: Kou-Kuang
change is required
-Model:HD-220
2. Every six month
operation, lubricant oil
change is required
Gears N/A Routine check. Suggested
frequency is every month.

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5-2 Trouble Shooting
Because of operator’s inappropriate operation will cause the machine in
abnormal status. The following table shows the most common abnormal
condition and suggested solution:

Condition Solution

Machine can not be started normally. Please refer to Chapter 4. Section 1.

Carton in-feed mechanism fail Replace Spring

carrying carton forward. Please refer to Chapter 6. Section 22.

Printed characters are not clear or Print System proper adjustment

overlapped. Please refer to Chapter 6. Section 27

Proximate switch function - Clean the proximate switch

incorrectness - Replace the proximate switch
Starwheel incorrect rotating / not
stop at correct position/ Shaking Torques limiter adjustment.
during operation. Please refer to Chapter 6. Section 23
.

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 Chapter 6 Machine Adjustment and Parts Change
Attention：Main Power Must Be “Off” before executes machine adjustment
and parts change procedure.
6-1 Carton Storage Device and In-Feed Mechanism Width
Adjustment.
(A)Condition: Carton size is changed(Different Carton)/Carton
inappropriate in-feeding.
(B)Adjustment Position: Carton storage and in-feed
mechanism.(Shown as below drawing)
(C)Adjustment Method:
1.Right auxiliary :
The horizontal distance should be equal with the carton mold
inner edge.
2.Left auxiliary:. The horizontal position distance must be 2mm
greater than carton size. After adjustment is completed, device
should be fixed. (Shown as the below drawing).

The inner edge of the

carton guide rod aligns Loosening fixing
with the inner edge of handle can adjust
the mold. left and right position

Mold

Carton feeding
mechanism
Carton shall be away
from the guide rod
within 2mm

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6-2 Carton Supporting Rod and Guide Rod Vertical
Position Adjustment
(A) Condition : Carton size is changed (Different carton )
(B) Adjustment Position: Carton storage and in-feed
mechanism.(Shown as below drawing)
(C)Adjustment Method:
1.Carton supporting rod:
(a) Height Adjustment- The standard height is 5mm distance
between carton lower folding cut line and carton mold.
(shown as the below drawing)
.
(b) Horizontal -. The suitable space is based on the
supporting rod is able to touch carton small flap center.
(Shown as the below drawing)

Loosening screw
can adjust supporting
after carton is pushed
rod to left and right
out, lower folding line
position
shall be away from the
mold by 5mm

Loosening screw can

adjust supporting rod
to left and right position

Loosing screw can adjust Adjust the left and

supporting rod to up and right of the supporting
down position rod to the extent that
it hits the center of small
flap

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 2. Carton guide rod: Put carton in storage area, the guide rod
position should be at 1/4 carton height ( carton height measure
from lower folding cut line till upper folding cut line).
(Shown as below drawing)

loosening all screws over

here can adjust the distance
between upper and lower
carton guide rod

The distance
between upper
carton guide rod
and upper folding
line is 1/4 height
of the carton
H/4
H

The distance between

H/4

lower carton guide rod

and lower folding line
is 1/4 height of the carton

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6-3 Vacuum Suction Pad Position Adjustment
(A) Condition: Carton size is changed or incompletely carton vacuum
suction. .
(B) Adjustment position: Carton suction device (Suction pad holder)
(Shown as the below drawing)
(C) Adjustment method:
1.Height – The suction pad should be at carton center.

2Horizontial - The suction pad horizontal position should at

1/3 of carton width (Shown as the below drawing)

Loosening screw can

adjust up/down height Carton folding line

Vacuum carton sucking device

Moving rightward
away from the carton
folding line for a
distance of 1/3 carton
Loosening fixing handle width is the position for
can adjust left and right carton sucking
position
W/3
W

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6-4 Lower Side Flap Folding Cylinder Position
Adjustment

(A) Condition: Carton size is changed.

(B) Adjustment Position: The cylinder underneath vacuum carton
suction device. (shown as the below drawing)
(C) Adjustment Method:
1.Height – Check the height when cylinder is activated (cylinder
shaft is extended). The cylinder shaft end point should be
slight higher than the bottom plate 1~1.5mm
2.Horizentoal – Check the horizontal position when cylinder is
activated (cylinder shaft is extended). The cylinder shaft end
point and carton left side flap should be 1mm~1.5mm gap.
3.Front and rear - Check the fron/rear position when cylinder is
activated (cylinder shaft is extended). The cylinder shaft end
point should be at the carton center.
4. Angle – Check the angle when cylinder is activated(cylinder
shaft is extended). The cylinder angle should make side flap
folded smoothly.
(Shown as the below drawing)

After cylinder is extended

out, its end shall slightly be
higher than the bottom plate
by 1-1.5mm

Loosening this screw

can adjust up and down
position of the cylinder

Loosening these two

screws can adjust left
and right position of the
cylinder

Loosening this screw can

Loosening this screw make a rotation to adjust
can adjust front and the protruding angle of
rear position of the cylinder the cylinder

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6-5 Vacuum Suction Device Activate Timing Adjustment
(A) Condition: Vacuum suction incorrect activates timing.
(B) Adjustment Position: proximate switch below suction cylinder.
(shown as the below drawing).
(C) Correct Activate timing: Vacuum suction should be terminated
once carton is fixed in the mold.
(D)Adjustment Method:
1. Proximate Switch Adjustment – Proximate switch control
vacuum suction activate and deactivate timing. The vacuum
suction should be deactivate according to suction pad is away
from carton mold 5mm.
(Shown as the below drawing).

Proximate switch
5mm

stabilized
shaft
loosening screw can
adjust the front and
rear position of the
proximate switch
Proximate
switch

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 2. Vacuum Suction Function Control Cam Adjustment :
Vacuum suction function control cam controls vacuum suction
activate and deactivate timing.
a. Cam 1 controls vacuum suction deactivate timing. If
vacuum suction is not deactivate at set timing in section
1(Vacuum suction delay deactivate), adjust cam and micro
switch (limit switch) contact timing. (Shown as the below
drawing)
b. Cam 2 controls vacuum suction activate timing. Adjust cam
and micro switch (limit switch) timing to determinate
vacuum suction activate timing.( Shown as the below
drawing)

Loosen cam 1 & 2 Vacuum generator

set screw to adjust micro switch
recess angle position

When cam 1 contact When cam 2 not contact

micro switch , micro switch, vacuum
vacuum stop actuated

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6-6 Vacuum Suction Moving Cylinder Timing Adjustment
(A) Condition: Incorrect Vacuum suction moving cylinder activate
timing.
(B) Adjustment Position: Moving cylinder control cam behind index.
(shown as the below drawing.)
(C) Correct Activate timing: Vacuum suction cylinder shaft is
retracted (deactivate) and begin sucking carton while main
starwheel is rotating. Afterwards, when main starwheel
system stops, vacuum suction cylinder shaft is extended
(activate) to carry carton into mold
(D) Adjustment Method:
Cam 1: Control moving cylinder extended (Activated). Adjust cam 1
and micro switch (limit switch) contact timing to
determinate moving cylinder activate timing.
Cam 2 : Control moving cylinder retracted (deactivate). Adjust cam 2
and micro switch (limit switch) contact timing to
determinate moving cylinder deactivate timing.
(Shown as the following drawing)

Loosen set screw to

adjust recess angle Carton sucking
position between air cylinder micro
cam 1 & 2 switch

When cam 2 not

When cam 1 touch
the limit switch, touch the limit
switch, air cylinder
air cylinder extend
retract.
out

Vacuum carton
sucking device

Air cylinder

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 6-7 Main Starwheel Height Adjustment
(A)Condition: carton size is changed
(B) Adjustment Position: Hand wheel on the star wheel and bottom
plate adjust rod. (shown as the below drawing)
(C) Adjustment Method :
1. Star wheel bottom plate – The gap between Starwheel
bottom plate and mold should be 5mm (Shown as the below
drawing)
2. Star wheel – Adjust the Starwheel to make the gap between
mold and carton small flap folding cutting line is 5mm (Shown
as the below drawing)

up
down

Hand wheel

Loosening handle can

rotate the hand wheel
for height adjustment.

Adjust rod

The gap between

mold and small flap
folding line is 5mm

Loosen set screw to

adjust star wheel The gap between
bottom plate height mold and star wheel
bottom plate is 5mm

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6-8 Starwheel Guard Strip Vertical Position Adjustment

(A) Condition: Carton size is changed.

(B) Adjustment Position: Guard Strip beside Starwheel. (Shown as the
below drawing).
(C)Standard position:
1. Space between the low edge of top guard strip and up edge of top
carton mold is 15mm.
2. Space between the up edge of bottom guard strip and low edge of
bottom carton mold is 15mm
(D) Adjustment Method:
1. Top guard strip position – Adjust the space between low edge
of top guard strip and up edge of top carton mold to 15mm
(Shown as the below drawing)

2. Bottom guard strip position – Adjust the space between up

edge of bottom guard strip and low edge of bottom carton mold
is 15mm.(Shown as the below drawing)

loosening screw can

adjust up down position
of guard strip

the bottom of guard

strip is away from
the upper edge of the
mold by approximately
15mm

The upper edge of

guard strip is away
from the bottom of
the mold by
approximately
15mm

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6-9 Carton Stop Block Adjustment
(A) Condition: Carton size is changed.
(B) Adjustment position: Carton folding station 1, in front of the
carton mold (shown as the below drawing).
(C) Adjustment Method : The gap between carton stop block and
mold inner edge is 2mm (Shown as the below drawing)

loosening screw can

adjust the left and
right position of
carton stop block

Carton stop
block

Carton stop
block is away
from the inner
edge of the mold
by 2mm

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6-10 Flap Folding Mechanism (1) Position Adjustment
(A) Condition:
 Carton size is changed.
 Inappropriately top side flap folding operation.
(B) Adjustment Position: The FESTO rotary cylinder installed at
carton folding station 8.(shown as the below drawing)
(C)Adjustment Method :
1. Height – Adjust the gap between side flap bar bottom edge
and mold about 7mm (shown as the below drawing)
2. Horizontal – Adjust the flap folding bar at the center of the
carton mold (shown as the below drawing)
3. Front, rear –Adjust the flap folding bat at the center of the
carton side flap. (shown as the below drawing) Loosen stop
screw of flap folding bar fixing

loosening this screw

can adjust up/down
position of the cylinder
loosening screw can
adjust left/right loosening screw can
position of cylinder adjust front and rear
position of flap
folding bar

The gap between flap

folding bar and mold
is 7mm

loosening screw can

adjust up/down position
of flap folding bar Adjust flap folding bar
to align with the mold
at center and slightly to
the right position

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6-11 Carton Top Side Flap Pressing Rod (1)Adjustment
(A) Condition : Carton size is changed
(B) Adjustment Position : The flap pressing rod behind the flap
folding bar(shown as the below drawing).
(C) Adjustment Method:
1. Height - Adjust the gap between side flap pressing rod bottom
edge and mold about 7mm (shown as the below drawing)
2. Horizontal - Adjust the side flap pressing rod 1mm away
from carton top right side flap (the flap is folded) (shown as the
below drawing)
3. Front, rear – Adjust the flap pressing rod at the center of
carton top side flap (Shown as the below drawing)

Loosening screw can

adjust the left and
right position of
Loosening stop screw
flap pressing rod
can adjust the height
of flap pressing rod The gap between
Loosening screw can flap pressing rod
adjust the front and and mold is 7mm
rear position of
flap pressing rod

When small flap is depressed, a fix gap

shall be maintained between small flap
and flap pressing rod

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6-12 Carton Top Side Flap Folding Cylinder Operation
Timing Adjustment
The appropriate carton top side flap folding cylinder timing should be
synchronous with carton in-feeding cylinder.

(A) Condition: After machine annual maintenance or incorrect

operation timing.
(B) Adjustment Position: The driving cam behind index (Shown as the
below drawing).
(C) Standard Operation Timing: When machine main Starwheel stops,
the carton side flap folding cylinder should activate once
(rotate once), on the contrary, when machine main
Starwheel moves, the carton top side flap folding cylinder
is inactivated (stay at stand-by position)
(D) Adjustment Method: When the machine main starwheel stops,
adjust cam 2 contact with limit switch to make rotating
cylinder activated (fold carton top side flap). Adjust cam 1
contact with limit switch to make rotating cylinder
inactivated when the machine main starwheel moves.
(Shown as the below drawing)
Loosen set screw of Rotary cylinder
cam 1 & cam 2 to adjust micro switch
recess angle position

Upon
Not touch cam 2,
touch
air cylinder rotate
cam 1, air
90°
cylinder
rotate back Rotary air cylinder

Flap folding
cylinder in
feeding area

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 6-13 Carton Top Side Flap Folding Cylinder Rotating
Angle Adjustment
(A)Condition: Cylinder incorrect rotating angle
(B)Adjustment Position: the rotary cylinder above carton top side flap
folding mechanism (shown as the below drawing).
(C)Adjustment Method: Adjust the stop block to make fold bar is able
to fold carton top side flap when rotating cylinder is
activated (cylinder rotates 90 degree). (Shown as the
below drawing)

move angle adjusting

stop block to adjust
cylinder rotating angle

Loosening screw can

move angle adjusting
stop block

Rotary cylinder

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 6-14 Flap Folding Mechanism (2) Position Adjustment
(A) Condition: Carton dimension is changed or main flap cannot be
folded smoothly
(B) Adjustment Position: Station 9, Main flap Folding Station.
(Shown as the below drawing)
(C) Adjustment Method:
1. Height – Adjust the gap between cylinder and flap folding
block is 4mm when folding cylinder extends (activated). (Shown
as the below drawing)
2. Front, rear – Adjust cylinder shaft to contact with carton inner
wall when cylinder extends (activated) (Shown as the below
drawing)

adjust the position of

cylinder to the extent Loosening screw can
that after the cylinder adjust up/down Cylinder
extends out, the flap flap folding
position of cylinder
folding block just mechanism 2
contacts the inboard of
the carton Loosening screw can
adjust up/down
position of cylinder
Adjusting nut
Loosening fixing handle
can rotate the adjusting
After cylinder extends out, nut to adjust front, rear
the gap between cylinder position
and mold shall be 4mm.

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6-15 Carton Top Side Flap Pressing Rod 2 Adjustment
(A) Condition: Carton size is changed or inappropriate main flap folding
angel
(B) Adjustment position Main flap pressing rod above carton mold at
carton folding station 9 (shown as the below drawing)
(C) Adjustment Method: Adjust pressing rod to make carton top
main flap at suitable position (at middle) between flap
block and flap blocking rod (cylinder spindle) (Show as
the below drawing)

flap folding
block
flap pressing
rod

Flap blocking
rod
adjust flap pressing rod
to the extent that the larger
flap of carton is between
flap folding block
and flap blocking rod

flap folding
mechanism 2 Loosening screw can
adjust front and rear
position of flap
pressing rod

Flap pressing rod

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6-16 Flap Block Cylinder Operation Timing Adjustment
(A) Condition: After annual maintenance or incorrect cylinder
operation timing.
(B) Adjustment: operation cam behind index. (Shown as the below
drawing).
(C) Standard Operation Timing: The flap block cylinder operation is
part of main flap inserting procedure. The flap inserting
procedure is flap block cylinder activated main flap
pressing flap block cylinder deactivated flap inserting.
The flap block cylinder standard operation timing is when
main starwheel starts carrying carton to flap inserting
station (starwheel starts moving).
(D)Adjustment Method: Adjust cam 1 contact with micro switch
(limit switch) to make block cylinder activated (cylinder
shaft extends) when main starwheel starts moving. Adjust
cam2 contact with micro switch (limit switch) to make
cylinder deactivated (cylinder shaft retracted) while main
flap pressing procedure is completed. (Shown as the
below drawing)

Flap blocking air

Loosen set screw
cylinder micro switch
of cam 1 & cam 2
to adjust recess
angle position

Air cylinder extrude

out when cam 2 not
Air cylinder retract touch the micro
back when cam 1 switch
touch the micro
switch flap folding
mechanism 2

flap blocking
air cylinder

28
6-17 Flap Folding Cylinder Operation Timing Adjustment

(A) Condition: After annual maintenance or incorrect cylinder

operation timing.
(B) Adjustment Position: operation cam behind index. (Shown as the
below drawing).
(C) Standard operation timing: The flap folding cylinder operation is
part of main flap inserting procedure. The flap inserting
procedure is flap block cylinder activated main flap
pressingflap block cylinder deactivated flap inserting.
The flap folding cylinder standard operation timing is
when main starwheel carries carton to flap inserting
station, flap block cylinder is activated (shaft extends) and
starwheel stops. (Shown as the below drawing)

(D) Adjustment Method: Adjust cam 1 contact with micro switch

(limit switch) to activate flap press cylinder (first cylinder)
when flap blocking cylinder is activated. Adjust cam 2
contact with micro switch to activate flap inserting
cylinder (second cylinder) while flap block cylinder is
deactivated (cylinder shaft extracted). (Shown as the
below drawing)

loosening stop screw

of cam 1, cam 2 can
adjust indentation angle
of the cam

Air cylinder extrude Flap folding cylinder

Air cylinder retract out when cam 2 not micro switch
back when cam 1 touch the micro switch
touch the micro
switch

flap folding flap folding

mechanism 2 air cylinder

29
6-18 Carton Main Flap Pressing Cylinder Operation
Timing Adjustment
(A) Condition: After annual maintenance or incorrect cylinder
operation timing.
(B) Adjustment Position: Operation cam behind index. (Shown as the
below drawing).
(C) Standard Operation Timing: The main flap press cylinder
operation is part of main flap inserting procedure. The flap
inserting procedure is flap block cylinder activated
main flap pressingflap block cylinder deactivated
flap inserting. The main flap pressing cylinder standard
operation timing is when main starwheel carries carton to
flap inserting station, flap block cylinder is activated
(shaft extends) and starwheel stops. (Shown as the below
drawing)
(D) Adjustment Method: Adjust cam 2 contact with micro switch
(limit switch) to activate flap pressing cylinder (cylinder
shaft extends) while starwheel stop and flap cylinder is
activated. Adjust cam 1 contact with micro switch (limit
switch) to deactivated flap pressing cylinder (cylinder
shaft retracts) before starwheel moves.(Shown as the
below drawing)

loosening stop screw

of cam 1, cam 2 can
adjust indentation angle
of the cam Flap pressing cylinder
micro switch

Air cylinder extrude

Air cylinder out when cam 2 not
retract back touch the micro switch
when cam 1 touch
the micro switch

flap folding flap pressing

mechanism 2 cylinder

30
6-19 Carton Out-feed Mechanism Adjustment
(A) Condition: Carton dimension is changed or carton out-feed
movement is not smooth.
(B) Adjustment Position: The fixed handle below carton out-feed
mechanism (Shown as the below drawing)

(C) Adjustment Method:

1. Height – Adjust guard plate to suitable height (Slightly
contact with carton). (Shown as the below drawing)
2. Horizontal –
Left guard plate: Adjust the left guard plate aligns with carton
mold inner edge.(Shown as the below drawing)
Right guard plate: Adjust right guard plate (plate with brush)
slightly contact with carton ( do not extrude cartons). (Shown
as the below drawing)

loosening fixing carton push-out

screw can adjust the mechanism
height of guard plate

Loosening fixing
handle can adjust
the left and right
width of guard
plate

Adjust guard plate mold

to align with the
inner edge of the
mold Guard plate

31
6-20 Carton Out-feed Cylinder Height Adjustment
(A) Condition: Carton size is changed.
(B) Adjustment Position: Cylinder fixed block beside carton guard
plate (shown as the below drawing).
(C) Adjustment Method: Adjust suitable height. (During cylinder
operation, the out-feed support plate will not contact with
carton mold outer edge). (Shown as the below drawing)

carton push-out
mechanism

cylinder
cylinder fixing
base

(rear view of cylinder fixing base)

loosening fixing screw

can adjust up/down
position of cylinder

32
6-21 Carton Out-Feed Cylinder Operation Timing
Adjustment
(A) Condition: After annual maintenance or incorrect cylinder
operation timing.
(B) Adjustment Position: Operation cam behind index (Shown as the
below drawing).
(C) Standard Operation Timing: The carton out-feed cylinder should
be operation once while starwheel carries the carton to
out-feed station and starwheel stops. (Operation once
means cylinder extends and retracts once)
(D) Adjustment Method: Adjust cam 2 contact with micro switch
(limit switch) to activate (cylinder shaft extends) carton
out-feed cylinder when main starwheel stops. Adjust cam
1 contact with micro switch (limit switch) to deactivate
(cylinder shaft retracts) carton out-feed cylinder before
main starwheel moves. (Shown as the below drawing)

Loosen cam 1 &

2 set screw to carton push-out
adjust recess angle cylinder micro
position switch

Air cylinder
extrude out
Air cylinder retract
when cam 1 touch
back when cam 2 not
micro switch
touch micro switch

carton push-out
mechanism
cylinder

33
6-22 Wire Reeling Spring Replacement and Tightness
Adjustment
(A) Condition: Reeling Spring Broken/Damaged or insufficient
tightness to drive carton in-feed device
(B) Adjustment Position: wire reeling box below carton feeding
mechanism.
(C) Replacement and Adjustment Method.
1. Removal:
a. Remove reeling wire and collect in reeling wire round box
b. Remove the wire reeling spring from wire collect round box
2. Installation:
- Round hook part of spring need to be fixed at the cotter pin in wire
collect box
- The flat plate portion must be fixed at the insertion slot center of spring
fixed block
- The installation procedure is according to reversed removal sequence
(shown as the below drawing )

Spring fixing
Pin
block
re
mo
wive r Guard cover of
re ee
Reeling wire sp lin reeling wire box
ri g
box ng

Reeling wire screwdriver

spring tighten
Loosening screw can
remove guard cover
Loosening nut
of reeling wire box
Carton press plate
Slide block

Loosening screw
remove reeling wire

reeling wire

34
6-23 Starwheel Torque Limiter Adjustment
(A) Condition: Machine displays “Unposition” abnormal status
frequently or keeps breaking object in the carton.
(B) Adjustment Position: The torque limiter above index.
(C) Adjustment method:
- Counterclockwise Adjustment: To increase affordable torque ( eg:
machine displays “Unposition” status frequently)
-Clockwise Adjustment: To decrease affordable torque (eg: keeps
breaking object in the carton, but machine keeps running)

Note: 1. The initial affordable torque setting is 30Nt/m

2 . Please check with the manufacturer if adjustment is necessary
needed.

Torque increases by
turning counter clockwise
3 holes

Torque decreases
by turning clockwise

Adjusting ring

Loosen set 3 screw to

turn the adjusting ring
to adjust the torque

35
6-24 Starwheel Mislocation Troubleshooting
(A) Condition: When machine is under “Unposition” abnormal status,
and starwheel is stuck by carton..
(B) Excluded Position: Starwheel (shown as the below drawing).
(C) Excluded Method:
- Turn off the machine main power and main power .
- Disconnect main compressed air connection.
- Turn starwheel back to correct position ( Turn counterclockwise
direction , and it will a “Click” sound appear)
(Shown as the below drawing)

clockwise rotate
the star wheel
can restore the
torgue limiter

36
6-25 Change Parts For Different Cartons
(A) Carton In-Feed Mechanism:
Carton In-Feed plate: Change the carton
corresponding in-feed plate (Shown as the below
drawing).

carton push-in plate

A-direction view

loosening these
screws can replace
the push-in plate

37
(B) Carton Mold :
1. Carton Mold: Change the new carton corresponding
mold on main starwheel . (Shown as the below
drawing)

Pull out

Mold

38
 2.Carton In-Feed Guiding Block: Change the carton
corresponding in-feed guiding block, and keep the gap
between carton and guiding block approximately
1mm~1.5mm (Shown as the below drawing)

space between
correction block
and carton is
1~1.5mm
correction block

loosening screw
can replace correction
block

39
 (C) Flap folding mechanism 2:
Flap Pressing Plate and Flap Inserting Plate:
Change the carton corresponding flap pressing plate and flap
inserting plate (total 4 pieces). (Shown as the below drawing)

Loosening these two

screws can remove flap
folding block and flap
pressing block

flap pressing block

Flap folding remove flap folding

block block and flap
pressing block

40
(D) Carton Out-Feed mechanism:
Carton Out-Feed Guard Plate: Adjust the guard plate
at the middle of new carton. (Shown as the below
drawing)

carton push-out
mechanism
carton output
guard plate

loosening guard
plate fixing screw
can remove the
guard plate

loosening screw can

adjust left and right
position of guard plate

41
6-26 Compressed Air Regulator Maintenance
(A) Recommend Compressed Air Pressure Setting: Set compressed air
inlet pressure between 5 kg/cm2 ~6 kg/cm2.
(B) Regulator Setting: Pull up the pressure adjustor.
Turn Clockwise Direction: Increase air inlet pressure
Turn Counterclockwise Direction: Decrease air inlet pressure.

(C) Water Discharge: Check water filter before operated machine to

check if there is too much water.

Decrease

Pressure-adjusting valve

Increase
Pressure g switch

Air shut off valve

Pressure gage

Filter

Drainage valve

42
6-27 Lot Printer Adjustment (optional Device)
(A) Condition: Carton size is changed or printed result is not as clear
as expected.
(B)Adjustment Position: Lot printer (station 3).(Shown as the below
drawing )
(C) Adjustment Method:
1. Position: Adjust the printer to suitable position ( Suitable
position is based on carton printed zone)
2. Printing force: Adjust printing force by air regulator
- Clockwise : Decrease Printing Force
- Counterclockwise: Increase Printing Force

Adjust printing
force by this
requlator

Adjust retract speed

by this requlator

loosening fixing handle can adjust

the height of printing machine

Loosening two fixing screws can adjust the

left or right position of the printing machine

43
6-28 Lot Printer Operation Timing Adjustment (Optional
Device)
(A) Condition: After machine annual maintenance or incorrect printer
operation timing.
(B) Adjustment Position: Operation cam behind index (Shown as the
below drawing).
(C) Standard Operation Timing: Carton detect sensor will check if
there is any carton, then the lot printer will be activated
once the carton is detected.
(D) Adjustment Method: Adjust cam 2 contact with micro switch
(limit switch) to make lot printer cylinder activated
(cylinder shaft extends). Adjust cam 1 contact with micro
switch (limit switch) to make lot printer cylinder
deactivated (cylinder shaft retracts) (Shown as the below
drawing)

Loosening stop screw

of cam 1 and cam 2 printing machine
can adjust the
indentation angle of cam

Air cylinder will Air cylinder will

retract when extrude out when
cam 1 touch the cam 2 not touch the
micro switch micro switch

printing
machine

44
6-29 Lot Printer Characters Replacement (Optional
Device )
(A) Condition: Carton dimension is changed or printed characters
need to be changed.
(B) Replacement Position: The character holder on the printing
machine (Shown as the below drawing).
(C) Replacement Method:
1. Removal:
(1) Press the knob to make knob blocking shaft extend.
(Shown as the below drawing)
(2) Rotate the knob blocking shaft 90 degree to remove it
(Shown as the below drawing)
(3) Remove characters fixed block and characters
(Shown as the below drawing).

2. Installation: Please reverse removal sequence. .

Note: Fine tuning printer position if necessary.

rotating knob
depressing rotating knob

rotate the knob

lot number type

rotating knob
blocking rod

t er
ou
a w hold
dr pe
ty
type fixing block

type holder

6-30 Leaflet Magazine Adjustment (Optional Device)

45
(A) Condition: Leaflet size is changed.
(B) Adjustment Position: Leaflet magazine.
(C)Adjustment Method:
1. Length: Adjust slide chute position corresponding with new
leaflet length..
2. Width: Adjust slide chute position corresponding with new
leaflet width,
3. Suction pad should be at the leaflet center.
(Shown as the below drawing)
W

Leaflet slide chute

MSR-12-15

Suction pad

Leaflet
Stop pin
Loosen set screw to
adjust to proper length
Loosen set screw to
adjust to proper width

4. Blocking pin: Adjust the leaflet blocking pin at suitable

46
 position (Keep leaflet in the magazine without falling).
(Shown as the below drawing)

Leaflet slide chute

MSR-12-15

Suction pad
Leaflet

Adjust the extend of extrude

of stop pin for easy take out
but will not fall down

6-31 Leaflet Suction Pad Angle Adjustment (optional

Device)
47
(A) Condition: Leaflet can not be correctly carried.
(B) Adjustment Position: Below leaflet magazine.
(C)Adjustment Method :
(1) Position: Adjust the suction pad to align with leaflet and keep
leaflet on it.

Suction pad adjust plate

Suction pad
Loosen lock nut,turn the
bolt till suction pad just
touch leaflet when it swing up.

(2) Suction pad swing angle: Adjust the suction cylinder to

suitable position ( move cylinder close to swing arm fixed
point to decrease swing angle, and away to increase ) (Shown
48
 as the below drawing)

Loosen set screw to

move the air cylinder
to adjust swing angle

Increase

Decrease

Suction pad
Lever point swing arm

6-32 Leaflet Inserting Plate Adjustment (Optional Device)

(A) Condition: Leaflet size is changed.
(B) Adjustment Position: Beside leaflet magazine.
(C) Adjustment Method: Adjust the inserting plate length to make
leaflet can be put into carton smoothly.
49
 Fixing plate

Loosen set screw,

adjust stroke

Insert plate

6-33 Torque Limiter Disassemble and Installation

Note: Check the correct installed position between torque limiter and
index before disassemble.
(A) Disassemble Procedure:
(1) Loosen set screw approximately 4-5mm for both top and
bottom keyless shaft sleeve.
(a) Top keyless shaft sleeve: Use 3 lift screw and then
50
 counter clockwise evenly rotate these 3 lift screw to
lift the flange of keyless shaft sleeve to loosen tight
clamp between keyless shaft sleeve and shaft
(b) Bottom keyless shaft sleeve: Take out 3 set screw,
insert these 3 set screw to the other three thread hole
and evenly tighten these 3 set screw to loosen tight
clamp between keyless shaft sleeve and shaft.
(2) Remove starwheel.
(3) Remove shaft and bearing housing.
(4) Remove torque limiter, change a new one.
(Shown as the below drawing)

Loosen set
1 screw 4-5mm
3 lift screw 4 Torque limiter

Adjust ring
of torque

2
Star wheel
Upper keyless
shaft sleeve
3
Lower keyless
shaft shaft sleeve

2
Bearing housing

(B) Installation Procedure:

1. Fixed top keyless shaft sleeve 3 screws.
2. Fixed bottom keyless shaft 3 screws.
3. Install starwheel Shaftbearing housingtorque limiter to
original position ( check if the position is same as before.)
4. Check the distance between torque limiter and index as it was,
diagonally and evenly tighten 6 set screw of lower keyless
shaft sleeve.
51
 5. Turn the star wheel to its original position. (The original
position means that one of the carton mold is parallel to
machine frame. )
6. Diagonally and evenly tighten 6 set screw of top keyless shaft
sleeve.
(Shown as the below drawing)
Note: DO NOT ATTEMPT TO REMOVE INDEX.

Torque limiter

Adjust ring
of torque

Lower keyless
Upper keyless
Star wheel shaft sleeve
shaft sleeve

shaft

Bearing housing

6-34 Torque Limiter Center Regulated

(A)Condition: After machine annual maintenance or torque limiter
misalignment.
(B) Alignment Position: Under Starwheel.
(C) Alignment Method :
1. Loosen fasten bolts at Index bottom.
2. Put the align sleeve on Index output shaft.
3. Put the align tool into Bearing housing and align sleeve.
4. Confirm the align tool, bearing housing, align sleeve and
52
 index output shaft are in one line and accurately aligned.
5. Tighten fasten bolts at Index bottom.

Align tool

Bearing housing
Don't loosen these
fasten bolts

Align sleeve

Index output shaft

Loosen fasten bolts, after alignment

tighten fasten bolts

6-35 Side Flap Pressing Rod Adjustment (Hot melt glue)

(A) Condition: Carton size is changed.
(B) Adjustment Position: Side flap pressing rod(Shown as the below
drawing)
(C) Adjustment Method :
1.Side flap pressing rod:
a.Height: Adjust the rod bottom edge below 7mm of carton
mold. (Shown as the below drawing)
b.Left/Right position: Adjust the rod left/right to suitable
position ( side flap pressing rod 1mm away from side flap
53
 when it is folded). (Shown as the below drawing)
c.Front/Rear: Adjust the side flap pressing rod at the side
flap center. (Shown as the below drawing)

small flap
press rod
box meld

Loosen set screw to 7mm clearance between

adjust small flap press small flap press rod
rod's lateral position and box mold
Loosen set screw to
Loosen set screw to adjust small flap press
adjust small flap press rod's longitude position
rod height

flap folding rod

small flap The folding small flap

press rod not touch with small
flap press

2. Main Flap Pressing Rod Adjustment:

(a) Height: Adjust the pressing rod to suitable position ( The
pressing rod bottom edge is away 7mm away from carton mold)
(Shown as the below drawing)
(b) Front/Rear: Adjust the pressing rod to the position where
pressing rod front edge is 5mm away from carton front edge
(Shown as the below drawing).

Loosen set screw 54 Loosen set screw

to adjust press rod's to adjust press rod
longitude position height and angle
6-36 Hot Melt Glue Spray Nozzle Adjustment (Hot Melt
Glue)
(A) Condition: Carton Size is changed.
(B) Adjustment Position: Glue spraying station (station #9)
(C) Adjustment Method :
1. Front/Rare Adjustment: Adjust the spray nozzle to suitable
position (shown as the below drawing)
2. Spray Nozzle Adjustment : Adjust the spray nozzle position
3mm away from the carton center. (shown as the below
drawing)
2. Main Flap Pressing Rod Adjustment : Adjust the pressing
rod to suitable position ( The pressing rod bottom edge is
55
 away 7mm away from carton mold) (Shown as the below
drawing)
1. Photo Sensor Adjustment: Adjust the photo sensor to suitable
position. (The sensor position determinates spray nozzle
activate timing)

Loosen set screw to

adjust nozzle's longitude
Hot melt jet
position and height
mechanism
Loosen set screw and fasten
Loosen set screw to screw to adjust photo sensor
adjust large flap press height and lateral position
rod height and longitude
position
Loosen lock knob to Adjust knob
adjust longitude
position

Keep certain distance

between box and large 3mm clearance
flap press rod front Box mold between nozzle and
a box top

7mm clearance
between box mold
Large flap press rod and press rod

6-37 Carton Out-Feed Mechanism Adjustment (Hot Melt

Glue)
(A) Condition :Carton size is changed. .
(B) Adjustment Position: Carton out-feed area (station #11).
(C) Adjustment Method :
1. Pressing Rod Adjustment:
a.Height: Adjust 1mm~2mm gap between pressing rod and
cartons.(shown as the below drawing)
b. Front /Rear : Adjust the pressing rod at the middle of
carton. (Shown as the below drawing)

Loosen set screw 56

adjust press rod Loosen set screw
height adjust press rod's
longitude position
 a. 2. Pressing plate height adjustment : Adjust 1mm~2mm
gap between pressing plate and cartons.(shown as the
below drawing)

Loosen set screw to

adjust height
Loosen set screw to
change pless plate

Box discharge
mechanism

57

1-2mm clearance
between press plate
6-38 Leaflet Inserting Operation Timing adjustment
(A) Standard Operation Timing:
1. Only Carton is detected by leaflet sensor, the leaflet system
will be activated.
2. Vacuum suction device is activated to carry leaflet to the
position and ready to be clamped
3. Leaflet clamp cylinder is activated to carry leaflet to the
position and ready to be inserted.
4. When the carton arrives leaflet station and starwheel stios, the
inserting cylinder is activated to insert leaflet into carton
(B) Condition: After annual maintenance or incorrect leaflet inserting
timing.
(C)Adjustment Position: the operation cam behind index.
(B) Adjustment Method :
1. Leaflet suction cylinder: Adjust cam 1 contact with micro
switch (limit switch) to activate leaflet suction
58
 cylinder( Cylinder shaft extends). Adjust cam 2 contact with
micro switch (limit switch ) to deactivate leaflet suction cylinder
(Cylinder shaft retracts). (Shown as the below drawing)
.

loosen cam 1&2 set

screw to adjust recess suck leaflet air
angle position cylinder micro
switch

air cylinder extrnde

out when cam 2 not
air cylinder retract
touch micro switch
dack when cam 1
touch micro switch

suck leaflet
air cylinder

2. Leaflet Clamp Cylinder: Adjust cam 1 contact with micro

switch (limit switch) to activate cylinder ( cylinder shaft
extends). Adjust cam 2 contact with micro switch ( limit switch )
to deactivate cylinder ( cylinder shaft retracts) ( Shown as the
below drawing).
3. Leaflet Pulling Cylinder: Adjust cam 1 contact with micro
switch (limit switch) to activate cylinder ( cylinder shaft
extends). Adjust cam 2 contact with micro switch ( limit switch )
to deactivate cylinder ( cylinder shaft retracts) ( Shown as the
below drawing).
4. Leaflet Inserting Cylinder: Adjust cam 1 contact with micro
switch (limit switch) to activate cylinder ( cylinder shaft
extends). Adjust cam 2 contact with micro switch ( limit switch )
to deactivate cylinder ( cylinder shaft retracts) ( Shown as the
below drawing).
5. insert leaflet air
loosen cam 1&2 set
screw to adjust recess cylinder micro
59 switch
angle position

clamp leaflet air

cylinder micro
switch
 6. Leaflet Vacuum Suction: Adjust cam1 contact with micro
switch(limit switch) to activate vacuum generator ( vacuum
suction begins). Adjust cam2 contact with micro switch ( limit
switch) to deactivate vacuum generator (vacuum suction
terminates ). (Shown as the below drawing)

loosen cam 1&2 set sack leaflet vacuum

screw to adjust recess generator micro
angle position switct

when cam 2 not contact

micro switch , vacuum
when cam 1 contact actuated
micro switch
vacuum stop

60