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Duplo DF-915, Maintenance Manual

The Duplo DF-915 is a high-quality, user-friendly document folder equipped with advanced features. To maximize your experience with this reliable machine, make sure to refer to the comprehensive Instruction Manual available for free download at manualshive.com. Easily access detailed instructions and optimize your productivity with ease.

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12H-M12M0-0309-0

2-34

9. OVERALL SCHEMATIC DIAGRAM (DF-915)

FE1

FE2

FE3

FE4

FE5

FE1

FE5

FE2

FE1

FE1

FE4

FE3

FE1

(2turn) : Toroidal clamp core 052-10065

(2turn) : Clamp filter

052-10052

(1turn) : Ferrite core

052-10027

(1turn) : Ferrite core

052-10035

(1turn) : Ferrite core

052-10035

F1 to F5 on a circuit diagram are one piece, respectively

Attach a PWB shielding cover

COM

N.O.

98R-8023

3

ANODE

2

GND

COLLECTOR 1

305   BLUE

301   YELLOW

303   PINK

DELIVERY LIMIT SENSOR

1

2

3

4

5

6

7

8

9

10

11

12

J 01

PHD12T

TCK

GND

TDO

TMS

TXD

RXD

TDI

GND

MD1

FOR WRITING ON FPGA FLASH MEMORY

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

J03

PHD30T

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

J 04

20

21

22

23

24

25

26

ORIBAN1-INDEX1

ORIBAN1-INDEX2

GND

GND

ORIBAN2-INDEX1

ORIBAN2-INDEX2

GND

P-SEN1

P-SEN2

P-SEN3

P-SEN4

P-SEN5

P-SEN6

GND

ACSE2

REAR C

GND

GND

ORIKOMIBAN2-LIM

OUT-PA-SEN

OUT-PA-SEN

IN-PA-SEN

IN-PA-SEN

HAISIKORO-LIM

KYUDAI-PA-SEN

ORIKOMIBAN1-LIM

GND

GND

GND

GND

GND

GND

GND

GND

ACSE1

PHD26T

1

2

3

4

5

6

7

8

9

10

J 05

11

12

13

14

ORI1SET-1

ORI1SET-1

ORI1SET-2

ORI1SET-2

TOP C

TOP C

FRONT C

FRONT C

ACSE 3

KYUSI-SET

AUTO-LOW
EH14T

501   PURPLE

502   GRAY

503   SKYBLUE

504   GRAY

505   YELLOW

506   GRAY

301   YELLOW

302   SKYBLUE

303   PINK

305   BLUE

306   BLUE

310   PINK

312   BLUE

315   PINK

317   BLUE

321   PINK

323   BLUE

324   BLUE

327   PINK

329   BLUE

330   BLUE

313   YELLOW

308   SKYBLUE

GND

GND

GND

N.C.

N.C.

+5V

+5V

+5V

AUTOMATIC-UP-SEN

+5V

+5V

GND

N.C.

+5V

+5V

GND

+5V

N.C.

+5V

+5V

+5V

+5V

GND

+5V

+5V

+5V

+5V

322   YELLOW

328   SKYBLUE

401   YELLOW

402   SKYBLUE

403   PINK

404   PINK

405   BLUE

406   BLUE

407   GRAY

409   PINK

410   PINK

411   BLUE

412   BLUE

413   PINK

414   YELLOW

416   GRAY

415   SKYBLUE

408   PURPLE

417   PURPLE

418   YELLOW

419   SKYBLUE

420   BLUE

1

2

3

4

+24V

+24V

FG

VH05T

J 06

5

601   BROWN

603   BLUE

GND

GND

1

2

3

4

5

6

7

8

SDA

XH08T

SCL

GND

GND

GND

J 02

202   BLUE

204   BLUE

207   ORANGE

208   BLUE

201   PURPLE

203   GRAY

1

2

3

4

5

6

7

8

CN1

SDA

GND

202   BLUE

204   BLUE

207   ORANGE

208   BLUE

201   PURPLE

203   GRAY

12H-8006

OP UNIT

12H-8032

OP CIRCUIT DIAGRAM

J 09

1

2

3

1

2

3

4

5

J 07

GND

HW

HU

HV

VH03T

EH05T

2 2

1

3

1

3

901   GRAY

902   PURPLE

701   PINK

702   BLUE

703   PURPLE

704   YELLOW

705   SKYBLUE

MOT1

4

5

6

7

8

4

5

6

7

8

2 2

1

3

1

3

4

5

6

7

4

5

6

7

2 2

1

3

1

3

24V  3.8A

MOT4

96V-8146

1

2

1

2

BLUE

PURPLE

GRAY

YELLOW

GREEN

RED

ORANGE

9

9

U

V

W

GND

HE1

HE2

HE3

GRAY

SKYBLUE

PURPLE

24V  83mA

Vcc

12H-8101

1

2

3

4

5

6

7

8

9

10

11

12

13

14

M2+

M2–

M3+

M3–

M4+

M4–

COUNTER

CLH1

CLH2

J 08

3

4

5

6

7

8

3

4

5

6

7

8

9

9

12

12

3

4

5

6

7

8

3

4

5

6

7

8

9

9

12

12

3 ANODE

98R-8023

1 COLLECTOR

2 GND

3 ANODE

98R-8023

1 COLLECTOR

2 GND

ANODE

1 COLLECTOR

GND

EH14T

811   BROWN

812   SKYBLUE

3 ANODE

98R-8023

1 COLLECTOR

2 GND

3 ANODE

98R-8023

1 COLLECTOR

2 GND

ANODE

1 COLLECTOR

GND

802   SKYBLUE

804   YELLOW

806   PURPLE

062-10782

062-10782

802   SKYBLUE

804   YELLOW

2

3

2

3

ORANGE

YELLOW

GREEN

BLUE

PURPLE

GRAY

WHITE

SKYBLUE

1

2

1

2

YELLOW

ORANGE

GREEN

PURPLE

BLUE

GRAY

WHITE

1

2

1

2

YELLOW

ORANGE

GREEN

PURPLE

BLUE

GRAY

WHITE

10

11

1

2

BLACK

PINK

RED

ORANGE

YELLOW

GREEN

BLUE

PURPLE

GRAY

WHITE

SKYBLUE

BLACK

PINK

RED

10

11

1

2

1

2

10

11

1

2

10

11

RED

RED

BLACK

BLACK

FG

PURPLE

BROWN

BROWN

BLACK

BROWN

BROWN

RED

BROWN

+24V

+24V

+5V

M1U

M1V

M1W

+6.5V

SCL

GND

GND

+6.5V

GND

N.C.

DC BL MOTOR

RED

801   YELLOW

YELLOW

803   PURPLE

805   GRAY

801   YELLOW

803   PURPLE

12H-8111

12H-8111

24V  160mA

24V  160mA

SKYBLUE

SKYBLUE

M5+

M5–

+24V

401   YELLOW

403   PINK

405   BLUE

402   SKYBLUE

404   PINK

406   BLUE

308   SKYBLUE

310   PINK

312   BLUE

407   GRAY

409   PINK

411   BLUE

408   PURPLE

410   PINK

313   YELLOW

315   PINK

317   BLUE

412   BLUE

HOME SENSOR

HOME SENSOR

DC MOTOR

DC MOTOR

12H-8003

MC UNIT

12H-8301

MC CIRCUIT DIAGRAM

413   PINK

414   YELLOW

415   SKYBLUE

416   GRAY

417   PURPLE

418   YELLOW

419   SKYBLUE

420   BLUE

STOPPER MOVEMENT SENSOR (ENCODER) A

STOPPER MOVEMENT SENSOR (ENCODER) B

STOPPER MOVEMENT SENSOR (ENCODER) A

STOPPER MOVEMENT SENSOR (ENCODER) B

BROWN

MOTOR FOR MOVING STACKER ROLLER

319   GRAY

325   YELLOW

1

2

1

2

CLH1

811   BROWN

812   SKYBLUE

BLUE

BLUE

FEEDING CLUTCH

24V  250mA  96

Ω

GRAY

813   BROWN

814   YELLOW

1

2

1

2

813   BROWN

814   YELLOW

BLUE

BLUE

CLH2

DELIVERY CLUTCH

24V  250mA  96

Ω

512   GRAY

512   GRAY

054-00396

PAPER FEED PLATE SET SW

12H-8120

12H-8168

1

2

1

2

1

2

3

1

2

3

11G-8052

11G-8052

BLUE

324   BLUE

FEED SENSOR

FEED SENSOR

DELIVERY SENSOR

PINK

BLUE

PINK

BLUE

11G-8051

1

2

3

GND

Vcc

VOUT

C.V.C

11G-8051

1

2

3

GND

Vcc

VOUT

C.V.C

ANODE

ANODE

ANODE

ANODE

CATHODE

CATHODE

SKYBLUE

330   BLUE

328   SKYBLUE

322   YELLOW

1

2

3

1

2

3

1

2

3 3

2

1

GRAY

321   PINK

323   BLUE

319   GRAY

YELLOW

327   PINK

329   BLUE

325   YELLOW

DELIVERY SENSOR

1

2

GND

SIG (N.O.)

054-10326 PAPER SENSOR

GND

1

2

3

4

5

6

7

8

SEN1

+5V

SEN2

SEN3

SEN4

SEN5

SEN6

96V-8016

96V-8018

PS P.W.B. UNIT

PS CIRCUIT DIAGRAM

UK Spec.

GND

1

2

3

4

5

6

7

8

SEN1

+5V

SEN2

SEN3

SEN4

SEN5

SEN6

96V-8026

96V-8028

PS P.W.B. UNIT

PS CIRCUIT DIAGRAM

USA Spec.

It changes by Spec.

1

2

3

96V-8110

PAPER SENSOR

PINK

WHITE

BLUE

+5V

PS1

CATHODE

ANODE

GND

EMITTER

1

2

3

4

5

6

7

8

2

1

3

PINK

YELLOW

SKYBLUE

GRAY

PURPLE

YELLOW

SKYBLUE

BLUE

BLUE

SKYBLUE 1

2

302   SKYBLUE

306   BLUE

3

4

5

6

7

8

9

10

903   YELLOW

PINK

BLUE

YELLOW

SKYBLUE

PURPLE

FIRST FOLDING PLATE

SECOND FOLDING PLATE

MOT3

MOT2

AC (N)

5

4

3

2

1

FG

SWITCHING POWER SUPPLY

CN1

057-10033

AC (L)

FG

CN2

4 +24V

3 +24V

2 GND

1 GND

BLACK

WHITE

054-10308

BLACK

WHITE

POWER SW

AC (L)

AC (N)

FG

230V  10A

INLET
056-10357

AC220 to 240V  50/60Hz : 055-10212

POWER CORD

AC120V  60Hz

: 055-10209

COM

N.O.

501   PURPLE

502   GRAY

503   SKYBLUE

504   GRAY

505   YELLOW

506   GRAY

054-10115

COM

N.O.

054-10115

COM

N.O.

054-10115

TOP COVER SW

FOLDING PLATE SW1

FOLDING PLATE SW2

GREEN/YELLOW

SKYBLUE

BLUE

511   BLUE

511   BLUE

12H-85201

Summary of Contents for DF-915

Page 1: ...PAPER FOLDER DF 920 915 MAINTENANCE MANUAL ...

Page 2: ...aintenance manual of the DF 520N have been omitted Refer to the maintenance manual for DF 520N for these sections Precautions on Maintenance Disconnect the power cord from the outlet to ensure safety when implementing maintenance work Use a non flammable type air spray Read the instructions on use carefully and be sure to observe them Notify users who have remodeled this unit that they are require...

Page 3: ...Folding Rollers 1 52 4 4 When Stacker Belt Rotates Heavily 1 52 4 5 Stopping Position of Paper Lead Edge Does Not Stabilize During Paper Feed and Paper Jams Near Paper Feed Inlet Sensor 1 53 4 6 When Paper Slips Frequently 1 53 4 7 When Continuous feed Occurs Frequently with Small Paper B7 INV etc 1 53 4 8 When Stacker Belt Slips 1 53 4 9 When Folding Stopper Moves Abnormally Slow 1 53 4 10 When F...

Page 4: ...1 2 12H M12M0 0309 0 1 OUTLINE OF MACHINE 1 1 Names of Parts DF 920 Front view Operating side Rear view Drive side ...

Page 5: ...1 3 12H M12M0 0309 0 DF 915 Front view Operating side Rear view Drive side ...

Page 6: ...s from paper feed to ejection However because folding plate 2 is located at the lower side of the paper feed section this makes adjustment of the folded size by hand difficult and all folded size adjustments must be performed on the control panel Adjusting the folded size folding position Folded size folding position is adjusted by moving the folding stopper using the folding stopper adjusting key...

Page 7: ...length 1 2 0 Double fold 1 2 1 4 Irregular accordion fold 1 4 1 4 Letter fold 2 3 1 3 Accordion fold 1 3 1 3 Brochure fold 3 4 1 4 Example Letter folding A4 Letter paper A4 Letter paper length 297 mm 11 Folded size by folding plate 1 199 mm 7 37 About 2 3 of paper length Folded size by folding plate 2 100 mm 3 70 About 1 3 of paper length Measure the folded size at the center of the paper Folded s...

Page 8: ...r is incorporated with a switching shaft unit be careful not to deform the switching angle during removal As the folding rollers are incorporated with keys collars and flat pins for securing the drive gears helical gears be careful not to lose these during removal Make sure that there is no grease or oil on the side of the switching shaft passed by paper Note Note 2 Attaching the press lever Apply...

Page 9: ...iming pulley and thrust regulated washer for securing the drive gear to the idler roller Attach the key collar and thrust regulated washer for securing the drive gear to folding rollers 1 and 2 The teeth of the helical gear is subject to force in the thrust direction during rotation When securing the thrust regulated washer with screws check that the helical gear does not move in the thrust direct...

Page 10: ...sh 0 1 to 0 2 mm 0 004 to 0 008 for above distance between folding roller shafts Check the gear backlash with the folding roller key removed Apply grease to the whole circumference of the drive gear Orelube G1650 Equivalent to NLGI 1 5 Attaching the regulated stopper The regulated stopper helps prevent inference between teeth resulting from excess distance between the drive gears helical gears mai...

Page 11: ...lding and if wrinkles or extreme folding misalignment along the sides of the paper occur check the balance between the left and right pressure and adjust by changing the spring hooking direction Secondary adjustment by passing paper 7 Attaching the plate spring grounding conduction The plate spring helps static electricity accumulated in folding rollers to escape to the chassis qAttach so that the...

Page 12: ...olding rollers to facilitate work qCheck that when the jam correction knob is rotated the folding rollers rotate smoothly wUsing a tension gauge of 5 N 510 gf apply pressure of 3 N 306 gf to the belt and check that the belt slacks by 3 to 5 mm 0 12 to 0 20 10 Attaching the main pulley of the center press roller and jam correction knob drive pulley of the idler roller qWhile pressing the main pulle...

Page 13: ... the two screws securing the main motor and adjust the tension of the belt so that it slacks by 3 to 5 mm 0 12 to 0 20 when a pressure of 3 N 306 gf is applied to the belt using a 5 N 510 gf tension gauge 2 1 3 Adjusting the tension of the main drive timing belt Inappropriate tension of the belt may cause such problems as noise slips etc See See ...

Page 14: ...s not minus pressed state eWhile ensuring the w state attach and secure the clutch rotor at frame B side rAttach the collar shim armature STS pulley provided with the paper ejection clutch unit as a set to the drive shaft As the paper ejection clutch unit is adjusted to an air gap 0 15 mm 0 006 at shipment always attach the above parts to the machine as a set Do not apply oil to the contacting are...

Page 15: ...heck for thrust play of the paper feed clutch drive shaft at the clutch bracket side At shipment a shim adjusting washer is inserted between the paper feed clutch drive shaft and bearing to control thrust play to below 0 1 mm 0 004 Check that thrust play is not minus pressed state wWhile ensuring the q state insert the bearing at the main bracket side and secure the paper feed clutch unit eApply a...

Page 16: ...and attach Orelube G1650 wAfter attaching the brake unit check that the rotating torque of the paper feed shaft unit is 0 0147 to 0 0245 Nm 0 15 to 0 25 kgf cm with the paper separator and paper feed ring not in contact However even if the rotating torque does not meet the above value if the stopping position of the paper lead edge is stable without touching the paper feed inlet sensor it means th...

Page 17: ... tray Standard paper size which can be automatically detected UK model A3 B4 A4 B5 A5 B6 6 types USA model LGR LGL LTR STMT INV 5 types 2 2 2 Paper size which can be stacked Distance moved by paper feed guide Maximum 310 mm 12 2 Minimum 76 mm 3 0 Paper width which can be fed Maximum 305 mm 12 0 297 mm 11 7 in specifications Width of A3 paper Minimum 76 mm 3 0 Width of B7 paper Paper length which c...

Page 18: ...per feed tray up down lever is provided or not Secure the set collar with some thrust play 0 1 to 0 2 mm 0 004 to 0 008 Otherwise load increases when the paper feed tray rises resulting in insufficient paper feed pressure even if the pressure is adjusted and paper slips occur easily Apply a very small amount of oil to the area where the fixed plate bearing and hinge rod are connected Orelube G90 1...

Page 19: ...sting screw so that the tension gauge value becomes 6 0 18 N 612 18 gf in this state The clearance between the bracket and fine adjustment lever should be around 10 to 13 mm 0 39 to 0 51 eAfter adjusting tighten the fixing nut and fixing screw to secure the fine adjustment lever rSet the paper feed pressure adjusting lever to 1 Check that the paper feed tray can be pushed down smoothly by hand and...

Page 20: ... where the drive shaft and bearing are connected Orelube G90 140 yAttach the plate and rack so that their surfaces touch and slide uAdjust the points on the eccentric shaft and rack and secure temporarily Primary adjustment iMove the rack up and down and check that there is appropriate backlash 0 1 to 0 2 mm 0 004 to 0 008 where the rack and gear engage and the rack moves smoothly Do not tighten t...

Page 21: ...DF 920 only If the tension of the belt is not appropriate problems such as faulty drive and jumping of the belt will occur Move the tension idler and adjust the tension of the belt so that it slacks by 3 to 5 mm 0 12 to 0 20 when a pressure of 3 N 306 gf is applied to the belt using a 5 N 510 gf tension gauge ...

Page 22: ...of 0 7 0 1 mm 0 028 0 004 is formed at the position shown in the figure wMove the switch bracket for the length of the long hole and adjust so that when the up down lever is pressed up to the upper limit the actuator of the upper limit detection microswitch turns ON the switch and a clearance of 0 8 0 1 mm 0 031 0 004 is formed at the position shown in the figure eTighten the set screw of the driv...

Page 23: ...tch completely and no load should be applied on Z at the rack long hole upper edge from overrun of the drive motor When load is applied to Z the slack of the opposite tension idler side of the drive belt changes The paper feed tray stops at the specified position of the paper stacking amount approximately 44 mm 1 73 When the paper feed tray rises When the paper feed pressure setting is 1 the paper...

Page 24: ...om the bent part of the lower paper feed inlet The paper stacking amount given in specifications is 500 sheets approximately 44 mm 1 73 for fine quality paper 64 g m2 16 lb When the paper feed tray rises When the paper feed tray descends wMove the switch angle and adjust so that when the paper feed tray up down lever is lowered and the paper feed tray is raised the actuator of the microswitch turn...

Page 25: ...d 0 the forced pressure is released and only pressure of spring C approximately 120 g is applied to the separator base When the separating pressure adjusting dial is rotated forced pressure is applied to the separator base if the scale value is within 3 5 design value is 2 5 Setting the separating pressure When using normal paper set the separating pressure to standard 0 and increase 0 5 at a time...

Page 26: ... the paper feed inlet sensor for all paper sizes and folding modes paper can be fed at the optimum paper feed timing To eliminate static electricity a static eliminator brush is provided at the paper feed inlet sensor light receiving 2 4 1 Replacing the paper feed inlet unit When replacing the paper feed inlet unit take note of the following points After replacing the paper feed inlet sensor check...

Page 27: ... paper feed inlet sensor light receiving If the sensor is very dirty remove the paper feed inlet upper guide to clean Note Note rReinstall the paper feed inlet sensor light emitting and sensor cover back to their original positions Be sure to perform this cleaning together with the 2 5 6 Cleaning the paper ejection outlet sensor described later as a set when visiting users for maintenance work Not...

Page 28: ...e change in the frictional coefficient between the stacker plate and belt back from the load of the stacker roller qIf the belt slips with the stacker roller and belt not contacting the stacker roller is raised perform step w If the belt does not slip in this state perform step e wGenerally the ST shaft assembly is fixed at the topmost position of the frame long hole This state is the recommended ...

Page 29: ...d and that they rotate smoothly eApply grease to the engaged gear teeth Orelube G1650 rSecure the set screw of the drive gear and apply a very small amount of thread locking to the set screw Loctite 242 Medium strength 2 5 4 Adjusting and checking the stacker roller home sensor The stopping position of the stacker roller moves automatically in six steps according to the folded paper length The mov...

Page 30: ...ejection outlet sensor After replacing the paper ejection outlet sensor check that one sheet of 52 4 g m2 14 lb paper is detected properly To prevent accumulation of paper dust on the sensor surface the paper ejection outlet sensor light receiving protection cover is pasted with a polyester film 2 5 6 Cleaning the paper ejection outlet sensor The power supply cover has a φ13 mm hole to simplify cl...

Page 31: ...ed by two photointerrupters index sensor to control the moving distance and direction of the folding stopper The minimum distance moved by the stopper is 0 125 mm 0 005 of one pulse of the above index plate The restricted value of each folding plate is shown below Limitations of length of folded plane Maximum distance moved by folding stopper from home position Folding plate 1 288 5 mm 11 36 Foldi...

Page 32: ...g the home position of the folding stopper The home position of the folding stopper is the basic position where the shield plate blocks the home sensor added with the correction value set in the following maintenance mode 3 MAINTENANCE MODE in CHAPTER 2 ELECTRICAL COMPONENTS Correction value of folding plate 1 home position Maintenance mode code No 1 Correction value of folding plate 2 home positi...

Page 33: ...imultaneously reduce the collision sound and paper bending Folding stopper structure 2 6 1 Adjusting the clearance of the conveyance route of the folding plate To prevent paper jamming at the folding plate check that the clearance of the conveyance route of the folding plate satisfies the following values within the 120 mm 4 72 range from the center of the folding plate Folding plate 1 1 6 mm 0 06...

Page 34: ... 140 To prevent folding plate motor lock never apply oil or grease to the sliding area where the screw shaft full nut and guide block bush are connected 2 6 3 Replacing the full nut If the female screw of the full nut resin wears due to extended use thrust play between the screw shaft and full nut increases resulting in reduced folding stopper stop accuracy and increased folding misalignment along...

Page 35: ...E ring so that the thrust play becomes 0 1 to 0 3 mm 0 004 to 0 012 eApply a very small amount of oil to the area where the idler pulley and fulcrum pillar are connected Orelube G90 140 rApply a pressure of 3 N 306 gf to deceleration timing belt 1 using a tension gauge of 5 N 510 gf and check that the belt slacks by 2 to 3 mm 0 08 to 0 12 tApply a pressure of 3 N 306 gf to deceleration timing belt...

Page 36: ...nd 1401B For preventing loosening Top regulated position 2 6 6 Folding stopper slide pin A slide pin is provided at both ends of the folding stopper so that the folding stopper moves horizontally thus preventing abnormal low speed movements due to load changes and abnormal noise qCheck that the two photointerrupters are attached parallel to each other wWhen the screw shaft is rotated by hand check...

Page 37: ... folding stopper Adjusting plate for setting the switching shaft to the regulated stopping position in single folding qSecure the switching adjusting plate at the position 7 0 mm 0 28 shown in the figure while paying attention to the left and right parallelity wApply a very small amount of thread locking to the fixing screw of the switching adjusting plate Loctite 242 Medium strength 2 6 8 Checkin...

Page 38: ...this mode and pressing the start key causes the paper feed tray to rise automatically and the folding stoppers of folding plates 1 and 2 move to the set position For DF 915 selecting this mode and pressing the start key after lowering the paper feed tray up down lever and raising the paper feed tray moves the folding stoppers to the set position See See Skew correction knob Pin Standard position R...

Page 39: ...aching the drive gear helical gear of folding roller See See iRotate the jam correction knob and move the lead edge of the paper near the slide stopper of folding plate 2 oLoosen the fixing screws of the folding stopper and adjust so that the folding stopper becomes parallel to the lead edge of the paper and then tighten the fixing screws Enlargement of section A Enlargement of section B Section A...

Page 40: ...folding plate 2 is stopping at the home position If this adjustment is not carried out appropriately problems may occur in folding which may cause conveyed paper to become thick such as the single folding of thick paper and cross folding These problems include flattening of the lead edge of folded paper and paper jam at the folding roller In the single folding of thin paper one folding wrinkle lin...

Page 41: ... side cover folding plate 1 folding plate 2 detection switches and paper ejection cover detection sensor ON For DF 915 select Code No 3 Switching shaft home position adjustment of the maintenance mode with all interlock switches top cover folding plate 1 folding plate 2 detection switches ON 3 MAINTENANCE MODE in CHAPTER 2 ELECTRICAL COMPONENTS See See ...

Page 42: ...e correction value by 1 and moves the folding stopper of folding plate 2 by 0 125 mm 0 005 in the opposite direction of the home position The clearance between folding roller 1 and switching shaft tip widens Pressing the speed key decreases the correction value by 1 and moves the folding stopper of folding plate 2 by 0 125 mm 0 005 in the direction of the home position The clearance between foldin...

Page 43: ...n of the switching shaft occurring due to the accumulation of parts tolerance even by electrical correction When the folding stopper is stopping at the reference position the reference dimensions of the switching adjusting plate is 7 0 mm 0 28 When the folding stopper and switching adjusting plate are stopping at their reference positions the reference dimensions of the switching shaft stopping po...

Page 44: ... plate 2 becomes narrow defects such as flattening of the first folded line may occur in the double folding of some thick paper 157 g m2 40 lb Perform the following solutions for such defects 1 Setting the thick paper mode Can be performed by users Increase the rotational speed of the folding roller temporarily Setting method Press the speed key and set the maximum processing speed and press it ag...

Page 45: ...in collar white from inside the frame two on the left and right of the switching shaft eTighten the screw of the resin collar from outside the frame As the diameter of the stopper of the switching shaft changes from φ12 mm to φ4 mm the stopping position of the switching shaft moves back the conveyance route broadens allowing thick paper to enter folding plate 2 Stopping position of switching shaft...

Page 46: ...ue of the folding stopper drive motor in some rare cases As a result folding plate 2 may motor lock during initialization returning of folding stopper to home position immediately after power ON For this reason do not clean the urethane sheet surface of the switching shaft with alcohol When folding plate 2 motor locks Wipe the cushion urethane sheet surface of the switching shaft with a cloth mois...

Page 47: ...0 Paper feed direction 1 Adjusting folded size by folding plate 1 For DF 920 qTurn on the power while pressing both the start and stop keys to enter the maintenance mode 3 MAINTENANCE MODE in CHAPTER 2 ELECTRICAL COMPONENTS See See ePress the clear key while pressing the stop key to initialize the folding stopper of folding plate 1 rPress the test key to perform test folding tMeasure the folded si...

Page 48: ...ses by 0 125 mm 0 005 The settable adjustment values range from 20 to 20 The folded size ranges from 2 5 to 2 5 mm 0 10 to 0 10 yAfter setting check the finish again by test folding uRepeat the above procedure until the folded size becomes the specified value 2 Adjusting folded size by folding plate 2 For DF 920 qTurn on the power while pressing both the start and stop keys to enter the maintenanc...

Page 49: ...e cover and detection switch interlock DF 920 only qOpen and close the side cover and check that it is moderately tight wIf abnormal sounds are produced as if the cushion is being rubbed when the side cover is opened and closed apply a very small amount of oil to the frame of the cushion contact and wipe away immediately with a dry cloth eMove the switch bracket for the length of the long hole and...

Page 50: ...l the microswitch goes OFF eAfter adjustment check that the detection switch is able to detect that folding plate 2 has been attached to the unit in the maintenance mode 3 MAINTENANCE MODE in CHAPTER 2 ELECTRICAL COMPONENTS qMove the switch bracket for the length of the long hole and adjust so that when folding plate 1 is attached to the unit the actuator of the microswitch turns ON the switch acc...

Page 51: ...ately with a dry cloth eMove and adjust the sensor bracket so that when the paper ejection cover is closed the clearance between the switch lever shield and paper ejection cover detection sensor becomes 2 5 to 3 0 mm 0 10 to 0 12 rAfter adjustment check that the detection sensor is able to detect the open close of the paper ejection cover in the maintenance mode 3 MAINTENANCE MODE in CHAPTER 2 ELE...

Page 52: ...fixing screw of the Z collar of the slide stopper is not loose Remove paper dust near the female screw groove on the screw shaft and the home sensor and apply a small amount of oil to the bearing The area where the screw shaft and the full nut are connected cannot be applied with oil or grease 3 2 Other General Precautions 3 2 1 Oiling Apply the specified oil to the following locations Area where ...

Page 53: ...ing screw of folding pate 2 switching adjusting plate Specified thread locking Loctite 242 Medium strength for screws Fixing screw of slide stopper Z collar Specified thread locking Three Bond 1401B For preventing loosening 3 2 4 Others Make sure that no oil and grease adheres to the timing belt and drive pulley grooves Fill maintenance data folded size correction data etc changed during machine a...

Page 54: ... 2 1 2 Replacing folding rollers Cause Solution The press pressure of the folding roller is strong The folding roller is deformed Adjust the press pressure Especially set the press pressure of folding roller 1 weak About 45 to 46 mm 1 77 to 1 81 2 1 2 6 Attaching the press spring T Replace the folding roller 2 1 2 Replacing folding rollers Cause Solution The plate spring for grounding conduction h...

Page 55: ... when the paper feed tray rises 2 2 7 Adjusting the stopping position of the paper feed tray when rising descending and paper stacking amount 4 7 When Continuous feed Occurs Frequently with Small Paper B7 INV etc Cause Solution The processing speed is too fast or the paper feed pressure is too high Set the processing speed to less than 4 and the paper feed pressure to 0 or 1 4 8 When Stacker Belt ...

Page 56: ...Folding Wrinkle Line is Formed at Folded Line with Thin Paper Cause Solution The clearance between the folding roller and switching shaft is too large Adjust the clearance 2 6 11 Adjusting the home position of the switching shaft stopping position in single folding 4 13 Paper Jams at Folding Unit or Flattening of Folded Line Occurs During Folding Modes Other Than Single Folding and When Thick Pape...

Page 57: ...cker Roller Moving Motor 2 8 1 22 Stacker Roller Home Sensor 2 8 1 23 Paper Feed Clutch 2 8 1 24 Paper Ejection Clutch 2 9 1 25 Main Motor Index Sensor 2 9 1 26 PS P W B Unit 2 9 1 27 Paper Feed Tray Set Switch DF 915 only 2 9 1 28 Switching Power Supply 2 9 1 29 Power Switch 2 9 1 30 Power Inlet 2 9 1 31 Power Cord 2 9 2 Errors and Causes 2 10 2 1 When Paper Jams Occur 2 10 2 2 Troubleshooting 2 ...

Page 58: ... inlet sensor 1 4 Paper ejection outlet sensor 1 5 Paper switch 1 6 Top cover switch 1 7 Side cover switch 1 8 Paper ejection cover sensor 1 11 Folding plate 1 set switch 1 19 Folding plate 1 motor 1 13 Folding plate 1 index sensor A 1 13 Folding plate 1 index sensor B 1 15 Folding plate 1 home sensor 1 12 Folding plate 2 set switch 1 20 Folding plate 2 motor 1 14 Folding plate 2 index sensor A 1 ...

Page 59: ...2 3 12H M12M0 0309 0 1 9 1 2 1 22 1 7 1 29 1 10 1 1 1 8 1 11 1 6 1 23 1 24 1 12 1 30 1 19 1 13 1 15 1 20 1 14 1 16 1 21 1 4 1 26 1 17 1 28 1 18 1 3 1 5 1 26 USA model only ...

Page 60: ...Paper switch 1 6 Top cover switch 1 11 Folding plate 1 set switch 1 19 Folding plate 1 motor 1 13 Folding plate 1 index sensor A 1 13 Folding plate 1 index sensor B 1 15 Folding plate 1 home sensor 1 12 Folding plate 2 set switch 1 20 Folding plate 2 motor 1 14 Folding plate 2 index sensor A 1 14 Folding plate 2 index sensor B 1 16 Folding plate 2 home sensor 1 28 Switching power supply 1 25 Main ...

Page 61: ...2 5 12H M12M0 0309 0 1 2 1 29 1 1 1 27 1 22 1 11 1 6 1 23 1 12 1 30 1 21 1 4 1 26 1 17 1 28 1 19 1 13 1 15 1 20 1 14 1 16 1 3 1 5 1 26 USA model only 1 24 ...

Page 62: ...es to be blocked even though the paper feed clutch has been driving for more than a certain distance number of pulses after it was blocked it is determined as paper jam As the paper folder processing speed can be changed the sensor ON OFF timing is based on distance number of pulses and not time Note Note 1 4 Paper Ejection Outlet Sensor Part No 11G 8052X Light emitting 11G 8051X Light receiving P...

Page 63: ...tion 1 10 Paper Feed Tray Lower Limit Detection Switch DF 920 only Part No 054 10248 Part name Microswitch Uses a contact switch Incorporated in the operating side frame to detect the lower limit position of the level bar Detects when the level bar descends by the rotation of the paper feed tray up down motor and reaches the lower limit position 1 11 Folding Plate 1 Set Switch Part No 054 10115 Pa...

Page 64: ...Part name DC motor unit DC 24 V power supply DC motor Located inside folding plate 1 for driving the folding stopper 1 20 Folding Plate 2 Motor Part No 12H 8111X Part name DC motor unit DC 24 V power supply DC motor Located inside folding plate 2 for driving the folding stopper 1 21 Stacker Roller Moving Motor Part No 96V 8146X Part name DC motor DC 24 V power supply geared motor Located inside th...

Page 65: ...e sensor of the PS P W B unit detects the paper size For USA models the auxiliary paper feed tray is also provided with a photosensor to differentiate between legal size and letter size For UK models six paper sizes can be detected A3 B4 A4 B5 A5 and B6 For USA models five paper sizes can be detected LGR LGL LTR STMT and INV 1 27 Paper Feed Tray Set Switch DF 915 only Part No 054 00396 Part name M...

Page 66: ...turned OFF during processing The paper ejection outlet sensor is blocked for more than the specified distance number of pulses during processing Attempted to start with the paper ejection outlet sensor blocked 7 segment window DF 915 LCD DF 920 Description MOTOR ERROR 1 7 segment window DF 915 The pulse output of the main motor index sensor is not normal Causes The folding mechanism cannot operate...

Page 67: ...mechanism idling of shaft etc The stacker roller home sensor does not turn ON OFF within the specified time after the stacker roller moving motor turned ON Causes The stacker roller mechanism cannot operate due to paper jams etc Foreign objects jammed in the detecting section of the stacker roller home sensor Faulty connection between the stacker roller home sensor and MC unit Malfunction of the s...

Page 68: ...witch and MC unit Disconnection of bundled wires improper insertion of connectors Malfunction of the MC unit The paper ejection cover sensor is OFF DF 920 only This message is normally displayed when the start key or test key is pressed with the paper ejection cover open It is not displayed at the instant the paper ejection cover is open Causes The paper ejection cover is not closed completely The...

Page 69: ...eed tray Malfunction of the paper switch Faulty connection between the paper switch and MC unit Disconnection of bundled wires improper insertion of connectors Malfunction of the MC unit The paper feed tray set switch is OFF DF 915 only Causes The paper feed tray is not set The paper feed tray set switch is not secured properly Malfunction of the paper feed tray set switch Faulty connection betwee...

Page 70: ...working When the paper switch malfunctions as the no paper state cannot be detected even though paper has run out on the paper feed tray during folding operations the unit proceeds feeding the next sheet of paper after which the whole unit stops due to paper feed error For this reason the folded paper is not ejected out completed but stops near the stacker roller To continue paper folding in this ...

Page 71: ...registration key 1 or 2 to select the maintenance mode Pressing the key continuously switches the mode continuously DF 915 qTo enter the maintenance mode turn ON the power while pressing both the start and stop keys Or press the adjustment registration key while pressing both the stop key and No of sheets Paper length key while the unit is in the standby state press the adjustment registration key...

Page 72: ...d tray up down motor test Paper feed clutch test Paper ejection clutch test Simulation mode Folding stopper parallelity mode Sensor switch check Paper size detection sensor check Main motor index sensor check Folding plate index sensor check Panel check mode Note 1 Note 2 Note 3 UK USA MILLIMETER INCH ENGLISH 2 SHEETS 30 SEC ON OFF NORMAL NORMAL OFF 0000000 12H 8 12 8 ON RUN W O PAPER ABCDEFGHIJKL...

Page 73: ...ipment is indicated on the backup data form inside the operating side cover To change the setting first note down the current value After changing the setting fill in the new value in the backup data form Note Note 4 Destination setting Code No 4 Mode for setting the destination Can be set to JAPAN USA or UK At shipment this is set according to the destination of the unit When the EEPROM is initia...

Page 74: ...eed when the processing speed does not satisfy the specifications 200 sheets minute in single folding of B4 paper 255 sheets minute in single folding of letter size paper for USA Can be set to NORMAL FAST or SLOW At shipment this is set to NORMAL When the EEPROM is initialized it is set to NORMAL 13 Operation mode setting Code No 13 Mode for setting the operation mode of the unit Can be set to OFF...

Page 75: ...the stacker roller moving motor Pressing the key of the folding plate 2 folding stopper adjusting key rotates the stacker roller moving motor and moves the stacker roller outside Pressing the key rotates the stacker roller moving motor and moves the stacker roller inside The motor rotates while the key is pressed and stops when the key is released Pressing the key continuously moves the stacker ro...

Page 76: ... sensor is the opposite to other sensors in that is displayed when it is ON and when OFF Note Note 29 Main motor index sensor check Code No 33 Mode for checking the index sensor inside the main motor When the main motor shaft is rotated by rotating the jam correction knob or center press roller pulse input is performed and the number of pulses is counted up and displayed at the second line of the ...

Page 77: ...ode No 36 Mode for checking the LEDs and 7 segment of the control panel Pressing the start key lights up the whole 7 segment and pressing the stop key lights up all LEDs Some LEDs may blink depending on the other settings of the maintenance mode ...

Page 78: ...on adjustment Model setting Destination setting mm inch display setting No of test folding sheets setting Buzzer ON OFF setting Speed 1 adjustment Processing speed adjustment Total counter MC ROM version display OP ROM version display Program version up mode Main motor test Folding plate motor test Stacker roller moving motor test Paper feed clutch test Paper ejection clutch test Simulation mode F...

Page 79: ...tting differs by machine because it is finely adjusted at shipment The setting at shipment is indicated on the backup data form inside the operating side cover To change the setting first note down the current value After changing the setting fill in the new value in the backup data form Note Note 5 Destination setting Code No 5 Mode for setting the destination Can be set to JPN JAPAN USA or Euro ...

Page 80: ...MAL 1 FAST or 1 SLOW At shipment this is set to 0 When the EEPROM is initialized it is set to 0 11 Total counter Code No 14 Displays the total number of sheets fed into the machine 7 digits At the 7 segment window on the right side the first three digits C and last four digits are displayed alternately for one second each Example C 123 and 4567 are displayed alternately for one second each This me...

Page 81: ...ey continuously moves the stacker roller outside the unit and locks the motor The motor will not rotate if any one interlock switch is not closed Note Note 18 Paper feed clutch test Code No 25 Mode for checking the operations of the paper feed clutch The paper feed clutch operates when the start key is pressed and stops when the stop key is pressed Do not leave the unit with the clutch operating O...

Page 82: ...ys correspond to the B6 A5 B5 and A4 paper size detection sensors from the left side in order For USA models 1 is displayed at the leftmost side and the second display onwards corresponds to the INV STMT and LTR paper size detection sensors in order The displays change when the paper feed guides are moved and a buzzer sounds 26 Paper size detection sensor check 2 Code No 35 Mode for checking the s...

Page 83: ...lses displayed and pressing the key counts down the display Pressing the key of the folding plate 2 folding stopper adjusting key counts up the number of pulses displayed and pressing the key counts down the display If the direction which changes the number of pulses is opposite to the above check if the connectors of index sensors A and B of the corresponding folding plate are connected reverse N...

Page 84: ...Z ON OFF POWER ON BUZZ SPEED1 ADJUST SPEED ADJUST SET FUNCTION TOTAL COUNTER MC ROM VER DEL CVR SNSR Code numbers are derived from the code numbers in the maintenance mode table When changing data follow the maintenance manual NOTE Changing data at code numbers 1 3 may cause a degradation in fold accuracy Default Correction Range DATE INIT 1 2 3 4 5 1 0 20 20 0 20 20 4 20 5 JAPAN JAPAN USA UK ON O...

Page 85: ...he code numbers in the maintenance mode table When changing data follow the maintenance manual NOTE Changing data at code numbers 1 3 may cause a degradation in fold accuracy Default Correction Range DATE INIT 1 2 3 4 5 1 0 20 20 0 20 20 4 20 5 JPN JPN USA Euro ON ON ON OFF 0 0 C 0000000 C 0000000 NN NN INCH 0 0 0 1 NORMAL SLOW 1 0 1 FAST NORMAL SLOW 12H 8604X 2 2 1 3 2 3 5 MODEL CODE 915 915 915 ...

Page 86: ...mory is initialized wAs the data except for the total count was initialized reset data such as home position adjustment data of folding plates and switching shaft in the maintenance mode while checking the backup data form pasted on the inside of the main cover F If data cannot be recovered by the above method turn ON the power while pressing the start key stop key and clear key together This init...

Page 87: ...together with the EEPROM note down various settings and total count data before replacement on the backup data form pasted on the inside of the main cover F perform the next step after replacement and check the data 1 Initializing the memory While pressing the start key stop key and clear key together turn ON the power This initializes data registered in the EEPROM of the MC unit A buzzer sounds t...

Page 88: ...he EPROM take note of the socket direction Note Note Never turn OFF the power until rewriting has been completed If rewriting is started normally all keys will be ineffective until rewriting completes This is not a fault If the buzzer sounds pi pi pi when the start key is pressed it indicates the ID error of the program The following reasons are possible The EPROM is not inserted in the socket cor...

Page 89: ...CTOR GND EH14T 811 BROWN 812 SKYBLUE 813 BROWN 3 ANODE 98R 8023 1 COLLECTOR 2 GND 3 ANODE 98R 8023 1 COLLECTOR 2 GND ANODE 1 COLLECTOR GND 802 SKYBLUE 804 YELLOW 806 PURPLE 808 GRAY 814 YELLOW 062 10782 062 10782 802 SKYBLUE 804 YELLOW 2 3 2 3 ORANGE YELLOW GREEN BLUE PURPLE GRAY WHITE SKYBLUE 1 2 1 2 YELLOW ORANGE GREEN PURPLE BLUE GRAY WHITE 1 2 1 2 YELLOW ORANGE GREEN PURPLE BLUE GRAY WHITE 97J...

Page 90: ...LECTOR 2 GND ANODE 1 COLLECTOR GND 802 SKYBLUE 804 YELLOW 806 PURPLE 062 10782 062 10782 802 SKYBLUE 804 YELLOW 2 3 2 3 ORANGE YELLOW GREEN BLUE PURPLE GRAY WHITE SKYBLUE 1 2 1 2 YELLOW ORANGE GREEN PURPLE BLUE GRAY WHITE 1 2 1 2 YELLOW ORANGE GREEN PURPLE BLUE GRAY WHITE 10 11 1 2 BLACK PINK RED ORANGE YELLOW GREEN BLUE PURPLE GRAY WHITE SKYBLUE BLACK PINK RED 10 11 1 2 1 2 10 11 1 2 10 11 RED RE...

Page 91: ...eed clutch unit 3N 056 00644 Bushing OCB 875 7N Purple 4N 056 00876 SK binder Gray Light blue Gray 054 10115 Microswitch 056 00779 Collar x 3 6N 12H 8003 MC unit 5N Cable clamp 2N 056 09001 3302 3N 056 09002 3303 4N 056 09003 3304 5N 056 09004 3305 6N 056 09005 3306 7N 056 09006 3307 Cable clip Middle 056 07008 1197 L Green Yellow Black White N E 12H 8212 Bundled wire unit 11 056 10357 Inlet 12H 8...

Page 92: ...23 Photointerrupter 056 00003 Bushing OCB 500 12H 8203 Bundled wire unit 3 062 10782 Photointerrupter 12H 3203 Folding plate 2 056 00876 SK binder 054 10326 Detection switch 12H 8211 Bundled wire unit 10 12H 2004 Paper feed tray 5N 5N 96V 8016 PS P W B unit USA specifications UK specifications 12H 8209 Bundled wire unit 9 Middle Middle 96V 8146 DC motor 2N 056 00003 Bushing OCB 500 97J 8505 DC mot...

Page 93: ...aper ejection clutch unit Yellow Gray a b 12H 5333 Switch angle T 054 10248 Microswitch 052 10027 Ferrite core 6N 5N 3N 12H 8602 MC unit 052 10035 Ferrite core 1 turn 1 turn 12H 8211 Bundled wire unit 10 054 00396 Microswitch 056 00876 SK binder 12H 8212 Bundled wire unit 11 056 00876 SK binder 056 11299 Hole plug 3N Blue Gray A F TDK MEC Brass screw M4 toothed lock washer 12H 8221 91X bundled wir...

Page 94: ...errupter 056 00003 Bushing OCB 500 12H 8203 Bundled wire unit 3 062 10782 Photointerrupter 12H 3203 Folding plate 2 056 00876 SK binder 056 00876 SK binder 2 turns Middle Middle 96V 8146 DC motor 12H 5008 Main frame B 057 10033 Switching power supply 056 10100 Spacer x 5 Middle 12H 8204 Bundled wire unit 4 Middle 12H 5016 Reinforcement plate L Middle Middle Middle 052 10035 Ferrite core j l k a d ...

Page 95: ...12H M12M0 ...

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