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Resolving material insertion issues on the DI900 or DI950 FastPac Inserter

Updated: April 27, 2018

This page resolves issues that can occur in your machine's material insert area. For troubleshooting tips, find your problem in the following list.

TIP: Jams and crooked folds may start in a different area of the machine than where the issue is initially discovered. It is a good practice to check that the side guides are set properly when these issues occur.

PROBLEM - Envelope side collision with straight or correct fold.

Possible causes and solutions:

  • Misaligned envelope side guides - The guides keeps the envelope straight as it travels through the system. Over time, the guides may shift and impede insertion. How to load the high capacity envelope feeder on the DI900 and DI950 (video). 
  • Material handling - Good material condition can help avoid paper stoppages. Aerate and neatly stack your paper to facilitate separation when feeding. Remove material with warped or flared edges, as it can produce misfeeds and jams.
  • Poor material condition - Envelopes stored for long periods of time or stored in damp environments may curl or stick. Before loading, check the box of envelopes for damaged pieces, extra glue, or envelopes sticking together.
  • Poor roller condition - Toner buildup or worn edges can diminish the roller's ability to grasp or drive the material correctly. Visually inspect the roller and clean or replace if necessary.

PROBLEM - Envelope side collision with crooked insert fold.

Possible causes and solutions:

  • Misaligned sheet feeder side guides - The guides keep insert material straight as it travels through the system. Over time, the guides may shift and impede insertion. How to load an insert feeder on the DI900 and DI950 (video).
  • Material specifications - Material specifications and recommendations must be followed for the system to run properly and for material to run smoothly through the machine. Crinkled, wrinkled and curled paper can cause crooked folds.
  • Poor roller condition - Toner buildup or worn edges can diminish the roller's ability to grasp or drive the material correctly. Visually inspect the roller and clean or replace if necessary.

PROBLEM - Material not inserted and sitting on top of envelope.

Possible causes and solutions:

  • Envelopes flaps are not opening - Open the flap of the envelope manually before loading. 
  • Poor material condition - Envelopes stored for long periods of time or stored in damp environments may curl or stick. Before loading, check the box of envelopes for damaged pieces, extra glue, or envelopes sticking together.

PROBLEM - Material catches on or "splits" throat of envelope.

Possible causes and solutions:

  • Poor material condition - Envelopes stored for long periods of time or stored in damp environments may curl or stick. Before loading, check the box of envelopes for damaged pieces, extra glue, or envelopes sticking together. Best practices for material storage and safe handling (video).
  • Envelopes flaps are not opening - Open the flap of the envelope manually (or pre-flap) before loading
  • Envelope specifications - Envelope specifications must be followed for the system to run properly. Machinable envelopes with proper depth and flap shape are required. 
  • Envelope testing - Try a different type of envelope (within specification). If the problem improves, it may be the envelope. If the problem does not improve, it could be one of the other causes described here.
  • Poor roller condition - Toner buildup or worn edges can diminish the roller's ability to grasp or drive the material correctly. Visually inspect the roller and clean or replace if necessary.