Duplo DF-920 Maintenance Manual
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Duplo DF-920 Maintenance Manual

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PAPER FOLDER
DF-920/915
MAINTENANCE MANUAL

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Summary of Contents for Duplo DF-920

  • Page 1 PAPER FOLDER DF-920/915 MAINTENANCE MANUAL...

  • Page 2: Table Of Contents

    About This Manual This maintenance manual is intended for those familiar with maintenance work of the Duplo paper folder DF-500 series. Sections found in the maintenance manual of the DF-520N have been omitted. Refer to the maintenance manual for DF-520N for these sections.
  • Page 3 CHAPTER 1 MECHANISM 1. Outline of Machine ......... 1-2 4-8. When Stacker Belt Slips ......1-53 1-1. Names of Parts ........1-2 4-9. When Folding Stopper Moves 1-2. Layout of Folding Plates and Abnormally Slow ........1-53 Folded Size by Folding Mode ....1-4 4-10.

  • Page 4: Outline Of Machine

    1. OUTLINE OF MACHINE 1-1. Names of Parts DF-920 Front view (Operating side) Rear view (Drive side) 12H-M12M0-0309-0...
  • Page 5 DF-915 Front view (Operating side) Rear view (Drive side) 12H-M12M0-0309-0...

  • Page 6: Layout Of Folding Plates And Folded Size By Folding Mode

    Folding plate 1 Folding plate 2 folding stopper adjusting key Paper feed tray Stacker roller Folding stopper +3.O/-1.O +.O3O/-.O4O STAND BY STAND BY Paper ejection section DF-920 UK DF-920 USA Folding plate 2 Flow of paper DF-915 UK DF-915 USA 12H-M12M0-0309-0...
  • Page 7 1-2-2. Folded size by folding plates 1 and 2 in each folding mode (theory) The values in the table below are theoretical values. In actual use, folded size is finely adjusted according to the folding mode to prevent dog ears and curling of paper. Irregular Single Double...

  • Page 8: Outline Of Mechanisms And Adjustments

    2. OUTLINE OF MECHANISMS AND ADJUSTMENTS 2-1. Folding Section and Drive Mechanism The folding section is the most basic paper folding mechanism. It is composed of folding rollers, press lever, reference stoppers, etc. The drive mechanism distributes driving force from the main motor to the folding rollers, paper feed mechanism, and stacker mechanism.
  • Page 9 (4) Attaching the drive gear (helical gear) of folding roller Attach the press spring T and regulated stopper after attaching the drive gear. This helps facilitate attaching of the drive gear. Attach the key, flat pin, and deceleration pulley for securing the drive gear to the center press roller.
  • Page 10 After attaching the drive gear, apply press force to all folding rollers, and check the following points. • Rotate the folding rollers for one round, and check that there is uniform roller nip (surface hollowing amount of rubber roller) in all directions (left, right, center) between all folding rollers. •...
  • Page 11 (6) Attaching the press spring T q Secure the spring hook at the position shown in the figure, and attach the press spring T. (Primary adjustment in the assembly stage) Spring T inner dimensions of idler roller: 45 mm (1.77") (Spring pressure: 23.5 N ±8.5%) Spring T inner dimensions of folding roller 1: 50 mm (1.97")
  • Page 12 (8) Adjusting the tension of the paper ejection drive timing belt Inappropriate tension of the belt may cause such problems as noise, slips, etc. Using 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"...
  • Page 13 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. q Set the drive belt on the paper feed clutch unit, and secure the bracket. “2-1-6. Attaching the paper feed clutch unit” w Loosen 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"...
  • Page 14 2-1-4. Paper ejection drive shaft The stacker belt is driven at high speed intermittently using the electromagnetic clutch to enhance stacking performance and processing speed. Replace the paper ejection clutch using the following procedure. q Check the accessories provided with the paper ejection clutch unit.
  • Page 15 2-1-5. Attaching the motor pulley If the motor pulley is not attached at the proper position, slipping of the drive belt and abnormal wear may result. Replace the main motor using the following procedure. q Attach the motor pulley to the main motor at the position shown in the figure.
  • Page 16 2-1-7. Attaching the brake unit The brake unit reduces inconsistency in the stopping position of the paper lead edge during paper feed, and stabilizes the jam detection timing and number of sheets processed. q To prevent abnormal sounds due to the use of the friction brake mechanism, apply a very small amount of grease to the urethane area of the brake unit and attach.

  • Page 17: Paper Feed Tray

    2-2. Paper Feed Tray As the paper feed tray mechanism is more or less the same as the DF-520N, only the differences are described in this section. 2-2-1. Automatic paper size detection Photosensors are located at the standard paper size positions. Paper size is detected when the shield attached to the paper feed guide blocks a sensor.
  • Page 18 Take note when attaching the paper feed tray assembly because the direction of the set collar differs between the DF-920 and DF-915 according to whether the paper 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.
  • Page 19 2-2-4. Adjusting the paper feed pressure Adjust to the reference paper feed pressure to prevent double-feeding and slipping of paper. q Attach the paper feed tray lower cover, raise the paper feed tray, and set the paper feed pressure adjusting lever to the reference position “0”. w Press a 30 N (3.06 kgf) tension gauge against the notch of the operating side of the paper feed tray, and gradually increase the pressure until the paper feed...
  • Page 20 2-2-5. Automatic up/down mechanism of paper feed tray (DF-920 only) If this mechanism has been removed during motor replacement, attach it using the following procedure. q Attach a pulley to the drive motor at the position shown in the figure.
  • Page 21 2-2-6. Adjusting the tension of the paper feed tray automatic up/down drive timing belt (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"...
  • Page 22 2-2-7. Adjusting the stopping position of the paper feed tray when rising/descending and paper stacking amount DF-920 To ensure paper stacking amount which can satisfy specifications, adjust the stopping position (motor drive range) of the paper feed tray during automatic up/down.
  • Page 23 t After adjusting the paper stacking amount, raise and lower the paper feed tray from the control panel, and check the following. To raise the paper feed tray from the control panel, press the “+” key of the folding plate 1 folding stopper adjusting key while pressing the stop key.
  • Page 24 y Secure the set screw of the drive gear, and apply a very small amount of thread locking to the set screw. (Loctite 242: Medium strength) DF-915 Adjust the paper feed tray stopping position so that the paper stacking amount satisfies the specifications, and the position of the tray is detected accurately when the tray is raised/lowered manually.

  • Page 25: Separating Mechanism

    2-3. Separating Mechanism The separating mechanism is more or less the same as the DF-520N. The separating pressure can be set in seven steps from 0 to 6 to handle special coated paper. For this reason, the separator base is located on the tilted plate to which it is connected by the link mechanism. When the separating pressure adjusting dial is rotated, the tilted plate moves and forced pressure is applied to the separator base.

  • Page 26: Paper Feed Inlet

    2-4. Paper Feed Inlet The following changes have been made in the paper feed inlet mechanism from the DF-520N. The curvature of the rib shape has been changed so that paper is fed properly to the very last sheet even in multiple paper feed (500 sheets) of small size paper (B6, INV, etc.) by automatic rise/descent of the paper feed tray.
  • Page 27 The paper feed inlet sensor will not function if adhered with printing powder and paper dust, and an error message will be displayed. The LCD of the DF-920 displays “JAM FEED SECT” while the right window of the DF-915 displays “J1-2”. When these messages appear, clean the sensor.

  • Page 28: Paper Ejection Mechanism

    2-5. Paper Ejection Mechanism To enhance paper ejection stack performance and processing speed, the paper ejection drive mechanism is intermittently driven by the electromagnetic clutch. To improve operability, the movement of the stacker roller has been made automatic. 2-5-1. Replacing the stacker belt Take note of the following points when replacing the belt.
  • Page 29 2-5-3. Paper ejection roller lever unit The basic configuration of this unit is more or less the same as the DF-520N. If the paper ejection roller lever unit has been removed during the replacement of the drive motor, attach it using the following procedure.
  • Page 30 2-5-5. Replacing the paper ejection outlet sensor To detect jams in the paper ejection section, a transmissive sensor (paper ejection outlet sensor) is provided at the main reinforcement base and stacker plate. To eliminate static electricity of the paper ejected, a static eliminator brush (stainless fiber) is provided on the upper paper ejection guide.

  • Page 31: Folding Plates

    2-6. Folding Plates As the folding plate mechanism is more or less the same as the DF-520N, only important differences are described in this section. Overall view of folding plate mechanism (1) Movement control of folding stopper A slit plate (index plate) divided into 12 parts (pulses) is mounted to a screw shaft with a pitch of 1.5 mm (0.06"). The number of slits (pulses) is counted by two photointerrupters (index sensor) to control the moving distance and direction of the folding stopper.
  • Page 32 (2) Adjusting 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)
  • Page 33 (4) Structure of folding stopper To reduce the collision sound when the lead edge of the paper collides with the folding stopper, a double-stopper structure where a slide stopper is mounted onto the folding stopper is provided. The side of the slide stopper which collides with the paper is also pasted with urethane to simultaneously reduce the collision sound and paper bending.
  • Page 34 2-6-2. Checking and adjusting the thrust play of the screw shaft unit Check the following points when folding misalignment along the vertical length of the paper and folding plate motor lock occurs. Check that a shim is inserted between the chassis and bearing at the folding plate motor side so that the thrust play of the screw shaft unit becomes 0.1 to less than 0.15 mm (0.004"...
  • Page 35 2-6-4. Motor deceleration pulley assembly If the tension of the belt is not appropriate, problems such as folding plate motor lock and jumping of the belt occur. q Tighten the set screw with a torque of 0.69 Nm (7.0 kgf • cm), and secure the motor pulley at the position shown in the figure.
  • Page 36 2-6-5. Adjusting the position of the folding stopper and slide stopper q Tighten the M3 screw with a torque of 0.64 Nm (6.5 kgf • cm) and secure the collar. w Check that when a pressure of 0.25 N (25 gf) is applied to the slide stopper using a tension gauge of 1 N (102 gf), the slide stopper moves smoothly to the bottom regulated position, and when the tension gauge is removed, it returns promptly to the top regulated position.
  • Page 37 2-6-8. Checking the operations of the home sensor Check that the home sensor turns ON and OFF properly in the maintenance mode. “3. MAINTENANCE MODE” in CHAPTER 2 ELECTRICAL COMPONENTS 2-6-9. Fixed position of the switching adjusting plate of folding plate 2 folding stopper Adjusting plate for setting the switching shaft to the regulated stopping position in single folding.
  • Page 38 “3. MAINTENANCE MODE” in CHAPTER 2 ELECTRICAL COMPONENTS For DF-920, selecting this mode and pressing the Skew correction knob 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.
  • Page 39 y Loosen the fixing screws of the folding stopper, and Section A adjust so that the folding stopper becomes parallel to the lead edge of the paper, and then tighten the fixing screws. u If paper slips during conveyance in t, check the left and right roller nips of the idler roller.
  • Page 40 2-6-11. Adjusting the home position of the switching shaft (stopping position) in single folding The switching shaft switches the paper conveyance route between single folding and other folding modes. To adjust the home position of the switching shaft, adjust the clearance between folding roller 1 and tip of the switching shaft to 0.2 to 0.4 mm (0.008"...
  • Page 41 For DF-920, select “Code No.3: Switching shaft home position adjustment” of the maintenance mode with all interlock switches (top cover, 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.
  • Page 42 w Pressing the clear key while pressing the stop key initializes the folding stopper, and moves the folding stopper of folding plate 2 to the home position. e Open the top cover (leave the detection switch ON), and check that there is clearance between the protrusion of the switching angle and stopper (M4).
  • Page 43 Relation between home position of switching shaft (stopping position) and stopping position of folding stopper (Reference) Both folding plates 1 and 2 in electrical design (theory) are set so that the clearance between the tip of the folding stopper and folding plate chassis becomes 3.0 mm (0.12") when the shield blocks the home sensor.
  • Page 44 2-6-12. Stopping position of switching shaft in folding modes other than single folding The stopping position of the switching shaft in folding modes other than single folding is set near the folding roller so that the collar for reducing defects such as double dent and dog ears of brochure folding serves as the stopper of the switching shaft.
  • Page 45 (2) Removing the stopper (collar) of the switching shaft (Can not be performed by users.) If the defects in (1) thick paper mode cannot be corrected, or when use of brochure folding is minimum, remove the switching shaft stopper (collar). q Remove folding plate 2 from the unit.
  • Page 46 2-6-13. Switching shaft cushion (urethane sheet) To reduce noise during single folding, a cushion (urethane sheet) is attached to the switching shaft so that the switching shaft and switching adjusting plate do not touch. Cleaning the urethane sheet surface with alcohol during cleaning of the folding rollers increases the frictional coefficient of the urethane surface excessively to exceed the allowed torque of the folding stopper drive motor in some rare cases.
  • Page 47 ∗ ( ) shows the folded size for letter size paper. (1) Adjusting folded size by folding plate 1 For DF-920 q Turn on the power while pressing both the start and stop keys to enter the maintenance mode. “3. MAINTENANCE MODE” in CHAPTER 2 ELECTRICAL COMPONENTS w Select “Code No.1: STOP1 DEFAULT”, check...
  • Page 48 Repeat the above procedure until the folded size becomes the specified value. (2) Adjusting folded size by folding plate 2 For DF-920 q Turn on the power while pressing both the start and stop keys to enter the maintenance mode.

  • Page 49: Exterior And Detection Switches

    “3. MAINTENANCE MODE” in CHAPTER 2 ELECTRICAL COMPONENTS 2-7-2. Adjusting the side cover and detection switch (interlock) (DF-920 only) q Open and close the side cover and check that it is moderately tight. w If abnormal sounds are produced (as if the cushion is...
  • Page 50 2-7-3. Adjusting folding plate 1 and detection switch (interlock) q Move 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 according to the displacement of the detection lever, and a clearance of 0.5 to 0.7 mm (0.02"...
  • Page 51 2-7-5. Adjusting the paper ejection cover and detection sensor (DF-920 only) q Open and close the paper ejection cover and check that it is moderately tight. w If abnormal sounds are produced (as if the cushion is being rubbed) when the paper ejection 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.

  • Page 52: Periodic Inspections

    Jam correction knob Oiling Apply oil the sintered bearing. Paper feed tray automatic up/ Greasing, Apply grease the gear surface and rack. (DF-920 only) down mechanism inspection Check the wear state of the Z collar. Paper feed inlet, Cleaning “2-4-2.
  • Page 53 3-2-3. Preventing screws from loosening If the following screws have been removed, apply a very small amount of the specified thread locking. Set screw of drive gear for automatic up/down of paper feed tray Set screw of drive gear for stacker roller Fixing screw of folding pate 2 switching adjusting plate Specified thread locking: Loctite 242 (Medium strength/for screws) Fixing screw of slide stopper Z collar...

  • Page 54: Troubleshooting Guide (Mechanical Causes)

    4. TROUBLESHOOTING GUIDE (MECHANICAL CAUSES) 4-1. When Paper is Conveyed Skewed Cause Solution The left and right nip amount Check the attached state of the reference stopper, and make the roller nip differs between the folding rollers. the same. “2-1-2. (3) Attaching the reference stoppers” “2-1-2.

  • Page 55: Stopping Position Of Paper Lead Edge Does Not Stabilize During Paper Feed, And Paper Jams Near Paper Feed Inlet Sensor

    “2-2-7. Adjusting the stopping position of the paper feed tray feed pressure is insufficient. when rising/descending and paper stacking amount” (DF-920 only) 4-7. When Continuous-feed Occurs Frequently with Small Paper (B7, INV, etc.) Cause Solution The processing speed is too fast or Set the processing speed to less than “4”...

  • Page 56: When Folding Misalignment Along Vertical Length Of Paper Is Large

    4-10. When Folding Misalignment Along Vertical Length of Paper is Large Cause Solution Thrust play of the screw shaft unit Adjust so that the thrust play becomes 0.1 to less than 0.15 mm (0.004" to is large. less than 0.006"). “2-6-2.
  • Page 57 1-5. Paper Switch ........... 2-6 2-2. Troubleshooting ........2-10 1-6. Top Cover Switch ........2-6 2-3. Other Condition Messages ..... 2-12 1-7. Side Cover Switch (DF-920 only) ... 2-7 2-4. Emergency Measures When the Paper 1-8. Paper Ejection Cover Sensor Switch Damages ........2-14 (DF-920 only) ..........

  • Page 58: Block Diagram Of Structure And Outline Of Each Block

    1. BLOCK DIAGRAM OF STRUCTURE AND OUTLINE OF EACH BLOCK DF-920 block diagram 1-2. Control panel 1-22. Stacker roller home sensor 1-3. Paper feed inlet sensor 1-17. Main motor 1-4. Paper ejection outlet sensor 1-25. Main motor index sensor 1-18. Paper feed tray up/down motor 1-5.
  • Page 59 1-13 1-19 1-15 1-29 1-10 1-14 1-20 1-11 1-23 1-16 1-30 1-22 1-12 1-24 1-21 1-26 1-26 (USA model only) 1-17 1-28 1-18 12H-M12M0-0309-0...
  • Page 60 DF-915 block diagram 1-22. Stacker roller home sensor 1-2. Control panel 1-3. Paper feed inlet sensor 1-17. Main motor 1-4. Paper ejection outlet sensor 1-25. Main motor index sensor 1-5. Paper switch 1-27. Paper feed tray set switch 1-6. Top cover switch 1-26.
  • Page 61 1-13 1-19 1-27 1-29 1-15 1-14 1-20 1-11 1-23 1-16 1-30 1-22 1-24 1-12 1-21 1-26 1-26 (USA model only) 1-17 1-28 12H-M12M0-0309-0...

  • Page 62: Mc Unit

    1-2. Control Panel [Part No.: 12H-9011X (DF-920), 12H-9052X (DF-915) Part name: Control panel unit] Composed of key switches, 16-character × 2-line LCD (DF-920 only), 7-segment display, and various display LEDs required for operating this unit. 1-3. Paper Feed Inlet Sensor [Part No.: 11G-8052X (Light-emitting), 11G-8051X (Light-receiving) Part name: Photosensor]...

  • Page 63: Side Cover Switch (Df-920 Only)

    When the cover is open, controls so that folding is not carried out. If the cover is opened during folding operations, the unit stops feeding paper and stops operations after paper ejection. 1-9. Paper Feed Tray Upper Limit Detection Switch (DF-920 only) [Part No.: 054-10248 Part name: Microswitch] Uses a contact switch.

  • Page 64: Folding Plate 1 Home Sensor

    [Part No.: 12H-8101X Part name: DC motor] DC +24 V power supply, output 60 W brushless DC motor. For driving the conveyance section. 1-18. Paper Feed Tray Up/Down Motor (DF-920 only) [Part No.: 97J-8505X Part name: DC motor unit] DC +24 V power supply geared motor. For driving the level bar which raises/lowers the paper feed tray.

  • Page 65: Paper Ejection Clutch

    1-24. Paper Ejection Clutch [Part No.: 12H-8168X Part name: Delivery clutch unit] Uses a DC +24 V electromagnetic clutch (250 mA, coil resistance 96Ω). Located inside the non-operating side frame. When the folded paper blocks the paper ejection outlet sensor, operates for 130 msec (about one rotation) at the appropriate timing with the stacker roller position to feed paper to the space between the stacker roller and stacker belt.

  • Page 66: Errors And Causes

    When paper jams during processing or the unit is started with paper jammed inside the sensor, a warning buzzer sounds and a message to indicate the error appears on the control panel display (see table below). The DF-920 LCD shows the error messages on the second line, while DF-915 shows at the 7-segment window on the right side.
  • Page 67 The paper feed tray upper limit detection switch or paper feed tray lower limit detection switch does not turn ON/OFF within the specified time after the paper feed tray up/down motor turned ON. (DF-920 only) --------------------------------------------------------------------------- <Causes> The paper feed tray up/down mechanism cannot operate due to paper jams, etc.

  • Page 68: Other Condition Messages

    When covers are open or when folding plates are not set, the control panel display shows the conditions of the unit. The DF-920 LCD shows the error messages on the second line, while DF-915 shows at the 7-segment window on the left and right sides.
  • Page 69 7-segment window Description (DF-920) (DF-915) FEED ERROR The paper feed inlet sensor does not turn ON even though the paper feed clutch has driven for the specified distance (number of pulses) after it turned ON. --------------------------------------------------------------------------- <Causes> The paper stacking method on the paper feed tray is not correct.

  • Page 70: Emergency Measures When The Paper Switch Damages

    When the paper switch damages, folding operations can be performed ignoring the paper switch as an emergency measure until the switch is replaced. This function is available from the following ROM versions. DF-920: 12H-80072 and later DF-915: 12H-86041 and later Method Turn ON the power while pressing the stop and No.

  • Page 71: Maintenance Mode

    3. MAINTENANCE MODE 3-1. Entering the Maintenance Mode DF-920 q To enter the maintenance mode, turn ON the power while pressing both the start and stop keys. Or enter “920” using the numerical keys of the initial screen displayed on the control panel (even if an error message is displayed on the second line), and press the folding mode key while pressing the stop key.

  • Page 72: List Of Maintenance Modes

    3-3. List of Maintenance Modes DF-920 The following table lists the maintenance modes of DF-920. 2nd line of LCD Code Setting 1st line of LCD (Setting at shipment) Folding plate 1 home position adjustment 1.STOP1 DEFAULT Note 1 Folding plate 2 home position adjustment 2.STOP2 DEFAULT...
  • Page 73 (1) Folding plate 1 home position adjustment (Code No.1) Mode for adjusting the home position of folding plate 1. “2-6-14. (1) Adjusting folded size by folding plate 1” in CHAPTER 1 MECHANISM This setting differs by machine because it is finely adjusted at shipment. Note Note The setting at shipment is indicated on the backup data form inside the operating side cover.
  • Page 74 (9) Buzzer ON/OFF setting (Code No.9) Mode for setting ON/OFF the buzzer which sounds during key operations, when a process ends, or when errors occur. Can be set to “ON” or “OFF”. At shipment, this is set to “ON”. A warning buzzer sounds when motor problems occur even if this setting is set to “OFF”. (It will not sound Note Note when errors such as paper jams, etc.
  • Page 75 (19) Main motor test (Code No.21) Mode for checking the operations of the main motor. The main motor rotates when the start key is pressed, and stops when the stop key is pressed. The rotating speed can also be changed using the speed key. Note Note The motor will not rotate if any one interlock switch is not closed.
  • Page 76 (25) Simulation mode (Code No.27) Mode for operating each mechanism without using paper. The simulation mode operates when the start key is pressed, and stops when the stop key is pressed. Note Note If operating the unit in the simulation mode, be sure to remove the paper feed ring. (26) Folding stopper parallelity mode (Code No.28) Mode for making the folding stoppers of folding plates 1 and 2 parallel.
  • Page 77 (31) Panel check mode (Code 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.) 2-21 12H-M12M0-0309-0...
  • Page 78 DF-915 The following table lists the maintenance modes of DF-915. 7-segment window 7-segment window (Right side, 4 digits) Code Setting (Left side, 2 digits) (Setting at shipment) Folding plate 1 home position adjustment Note 1 Folding plate 2 home position adjustment Note 2 Switching shaft home position adjustment Note 3...
  • Page 79 (1) Folding plate 1 home position adjustment (Code No.1) Mode for adjusting the home position of folding plate 1. “2-6-14. (1) Adjusting folded size by folding plate 1” in CHAPTER 1 MECHANISM This setting differs by machine because it is finely adjusted at shipment. Note Note The setting at shipment is indicated on the backup data form inside the operating side cover.
  • Page 80 (8) Buzzer ON/OFF setting (Code No.9) Mode for setting ON/OFF the buzzer which sounds during key operations, when a process ends, or when errors occur. Can be set to “ON” or “OFF”. At shipment, this is set to “ON”. A warning buzzer sounds when motor problems occur even if this setting is set to “OFF”. (It will not sound Note Note when errors such as paper jams, etc.
  • Page 81 (16) Folding plate motor test (Code No.22) Mode for checking operations of the motor for moving the folding stoppers of folding plate 1 and 2. Pressing the “+” key of the folding plate 1 folding stopper adjusting key rotates the folding plate 1 motor, and moves the folding stopper in the reverse home position direction.
  • Page 82 (23) Sensor check (2) (Code No.32) Mode for checking the states of each sensor. At the 7-segment window on the right side, sensors which are ON are displayed as “1” and those which are OFF are displayed as “0”. The display corresponds to each sensor in the following order. Stacker roller home sensor →...

  • Page 83: Precautions For Setting Folding Stopper Fixed Mode (Df-920 Only)

    A and B of the corresponding folding plate are connected reverse. 3-4. Precautions for Setting Folding Stopper Fixed Mode (DF-920 only) When the operation mode is set to the folding stopper fixed mode, if moving the position of the folding stopper for folding plate motor tests or folding plate index sensor check, be sure to turn OFF the power once, and then turn it ON again to perform initialization before starting folding operations, and re-check the positions of the folding stoppers.

  • Page 84: Backup Data Form

    If the corresponding setting data has been changed in the maintenance mode, be sure to fill in the changed data in this backup data form. DF-920 120V, 60Hz SER.No.
  • Page 85 DF-915 120V, 60Hz SER.No. 220–240V, 50Hz DATE INIT Code Function Default Correction Range STOP1 DEFAULT –20 – +20 STOP2 DEFAULT –20 – +20 SW BAR ADJUST –4 –20 – +5 MODEL CODE 915, 910 AREAS JPN, USA, Euro SET MM/INCH NN, INCH TEST FOLD QTY 1 –...

  • Page 86: Initializing The Memory

    5. INITIALIZING THE MEMORY If for some reason, the EEPROM (nonvolatile memory) data becomes lost and the display does not function normally, initialize and recover the data using the following procedure. Initializing the memory q While pressing the start key, stop key, and test key together, turn ON the power. This initializes data except for the total count registered in the EEPROM of the MC unit.

  • Page 87: Precautions On Replacing The Mc Unit

    6. PRECAUTIONS ON REPLACING THE MC UNIT Various data such as home position adjustment data of folding plates and switching shaft and total count memorized by the unit even when the power has been turned OFF are registered in the EEPROM (nonvolatile memory) of the MC unit (board).

  • Page 88: Upgrading The Program Version

    While pressing the start key and stop key, turn ON the power. (To enter the maintenance mode) e For DF-920, enter the code No. “18” of the maintenance mode using the numerical keys, and press the folding mode key. (To enter the program version up mode) For DF-910, select code No.

  • Page 89: Overall Schematic Diagram (Df-920)

    8. OVERALL SCHEMATIC DIAGRAM (DF-920) INLET FOLDING PLATE SW1 056-10357 (2turn) : Toroidal clamp core 052-10065 N.O. 501 PURPLE POWER SW 502 GRAY 230V 10A (1turn) : Ferrite core 052-10027 054-10308 SWITCHING POWER SUPPLY (2turn) : Clamp filter 052-10052 054-10115...

  • Page 90: Overall Schematic Diagram (Df-915)

    9. OVERALL SCHEMATIC DIAGRAM (DF-915) INLET FOLDING PLATE SW1 056-10357 (2turn) : Toroidal clamp core 052-10065 N.O. 501 PURPLE POWER SW 502 GRAY 230V 10A (1turn) : Ferrite core 052-10027 SWITCHING POWER SUPPLY 054-10308 (2turn) : Clamp filter 052-10052 054-10115 057-10033 (1turn) : Ferrite core 052-10035...

  • Page 91: Wiring Diagram 1/2 (Df-920)

    10. WIRING DIAGRAM 1/2 (DF-920) Main frame B Main frame F 12H-5333 056-00644 056-00876 Switch angle T 12H-8605 Bushing SK binder OP P.W.B. unit (OCB-875) 054-10248 12H-5008 Brass screw Yellow Microswitch Main frame B 052-10052 M4 toothed lock washer Clamp filter...

  • Page 92: Wiring Diagram 2/2 (Df-920)

    11. WIRING DIAGRAM 2/2 (DF-920) UK specifications 12H-5016 12H-5008 12H-5003 Reinforcement plate L Main frame B Main frame F 12H-3203 062-10782 12H-2004 96V-8016 Photointerrupter Folding plate 2 Paper feed tray PS P.W.B. unit Middle Middle Middle 97J-8505 12H-8211 DC motor unit...

  • Page 93: Wiring Diagram 1/2 (Df-915)

    12. WIRING DIAGRAM 1/2 (DF-915) Main frame B Main frame F 056-00644 12H-5333 056-00876 12H-8004 Bushing Switch angle T SK binder (OCB-875) OP P.W.B. unit 054-10248 12H-5008 Yellow Microswitch Brass screw Main frame B 052-10052 M4 toothed lock washer Clamp filter 056-00644 12H-5003 056-00003...

  • Page 94: Wiring Diagram 2/2 (Df-915)

    13. WIRING DIAGRAM 2/2 (DF-915) 12H-5016 12H-5008 12H-5003 Reinforcement plate L Main frame B Main frame F 12H-3203 062-10782 Photointerrupter Folding plate 2 Middle Middle Middle 12H-8205 12H-8101 Bundled wire unit 5 Brushless DC motor 056-00876 SK binder 056-00876 SK binder Middle 057-10033 Switching power supply...
  • Page 95 12H-M12M0...

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Df-915

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