Duplo DF-999 Service Manual

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SERVICE MANUAL

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DF-999/DF-999A

DF-990/DF-990A

2019/09

Revision 1

DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1

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Summary of Contents for Duplo DF-999

Page 2 Reproduction or reprinting of this document in part or in whole without permission is prohibited. CAUTION Handle this manual with extreme care. In particular, exercise extreme precautions against leakage of technical information. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 3 As it is not possible to list all possible hazards which may occur during servicing, SPs must always pay extreme safety precautions during servicing, apart from the precautions described on the product and in this manual. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 4 This manual does not describe the disassembly and assembly procedures for all parts. For details of parts not described in this manual, refer to the separate “Parts Catalogue.” DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 5 "LED" is used for LED itself and other LEDs on a board. Noise filter Resistor A resistor not mounted on the board. Relay Transformer Temperature fuse Contactor Scanner Inlet Camera SD card DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 6 In this manual, each destination is written in an abbreviated form as follows. JPN: JPN is an abbreviation for Japan. NA is an abbreviation for North America. EU is an abbreviation for European Union. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 7 Sometimes, it may contain a graphic inside to detail the “forbidden action” more specifically. This symbol indicates an “instruction” which must be followed. Sometimes, it may contain a graphic inside to detail the “instruction” more specifically. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 8 Connect the power plug to a socket-outlet which is easily accessible by hand. Failure to disconnect the power plug immediately when the product is working abnormally could result in fire or an electrical shock. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 9 Always disconnect the power plug from the power outlet when the unit is not to be used for an extended period. Failure to do so could result in fire due to leakage current if the insulation should deteriorate. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 10 Disassembling parts for which no technical information, etc. is provided in this manual, parts catalogue, technical information guide, etc. could result in fire, electrical shock, and malfunction. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 viii Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 11 This product also consists of sharp edged parts or sharp pointed parts. Use gloves when touching pointed parts by necessity. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 12 “WARNING” and “CAUTION” labels are pasted or printed on the machine to ensure user safety. Do not remove or change them. If they become dirty or lost, replace with new ones. a. For JPN When DF HAND FEED KIT (option) is attached: DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 13 PREFACE b. For NA and EU For EU For NA When DF HAND FEED KIT (option) is attached: For EU For NA DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 14 In the European Union there are separate collection systems for used batteries and accumulators. Please, dispose of batteries and accumulators correctly at your local community waste collection/recycling centre. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 15 5.1 DF HAND FEED KIT ..........1-22 5.2 DF CROSS FOLD UNIT ........1-22 2.2 Control panel ............3-4 5.3 DF COUNTING UNIT ........1-23 2.2.1 LCD touch panel (PCB102) ......3-4 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 xiii Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 16 Adjusting the feed clutch (CL101) ....5-10 2.2.1 Recommended parts A (Expendables) ....4-3 4.1.3 For adjusting the tension of driving belt ..5-11 2.2.2 Recommended parts B (Functional parts) ..4-3 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 17 Procedures for adjusting folding plate 1 U1000 The top cover is open........7-9 and folding plate 2 .........6-14 U1300 The side cover is open........7-9 3.5.5 Procedures for adjusting switching shaft ..6-14 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 18 Folding misalignment along vertical length of paper ..........7-24 2.2.2 Folding misalignment along sides of paper ..............7-24 2.2.3 When paper is not folded at the normal position ............7-24 2.3 Ejection problems ...........7-25 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 20 ● Auxiliary paper guide (option) is can be used to hold down the edge of paper when using large paper. 1.1.1 Machine configuration Two types of this machine are available, DF-999 (*1) and DF-990 (*2). Main differences Item DF-999/DF-999A DF-990/DF-990A...
Page 21 • Free from air-borne salt • Place without harmful chemicals (*1) Fine quality paper 64 g/m /43.52 lbs (Equivalent to 500 sheets) cross folding shall be 25 mm/0.98 inch or less. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 22 1.55 m/61.03 inches from the floor. Background noise 6 dB below the value of measurement object at least • Noise test EN13023 J.3.1.1 - Grade 3 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 23 (*7) DF COUNTING UNIT (for JPN only) is installed, at maximum paper size loading. (*8) Including accessories (1.0 kg/2.2 lb). (*9) Including accessories (NA, EU: 1.0 kg/2.2 lb, JPN: 0.9 kg/2.0 lb). DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 24 (ream weight) Art paper 84.9 to 127.9 g/m /57.73 to 86.97 lbs(*1) Coated paper (*1) Stacking height on the paper feed plate: 25 mm/0.98 inch or less DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 25 Irregular accordion fold-out Letter fold Accordion-fold Gate fold(*4) Specified cross folding(*5) Other deformed folding(*6) Folding plate 1 stopper position Automatic moving section Folding plate 2 stopper position Stacker roller position DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 26 141.0 to 457.2 Letter fold 5.55 to 18.00 inch 141.0 to 457.2 Accordion-fold 5.55 to 18.00 inch 128.0 to 432.0 Gate fold 5.04 to 17.00 inch DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 27 Paper feed tray skew correction Stacker paper receiving plate (*1) Conditions Paper: fine quality paper 81.4 g/m /55.35 lbs long grain, Paper size: A4, Processing form: single fold DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 28 (*3) The function cannot be set when the refold mode and stopper fixed mode are set to ON. (*4) When an error occurs, the buzzer sounds even if the buzzer sound settings is set to OFF. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 1-10 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 29 Fine quality paper, coated paper Paper quality Sheet Paper type Paper size (W × L) 100.0 × 148.0 to 311.0 × 457.2 3.94 × 5.83 to 12.24 × 18.0 inch DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 1-11 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 30 [4] Power inlet [5] Support paper feed tray [6] Paper feed tray [7] Top cover [8] Folding plate 1 [9] Folding plate 2 [10] Paper set lever (*) DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 1-12 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 31 Paper ejection section [1] Stacker lever [2] Eject section [3] Paper receiving tray [4] Stacker belt [5] Stacker roller [6] Auxiliary paper ejection guide [7] Paper support guide DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 1-13 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 32 This part can be moved by using the [6] Cross fold lever (*1) optional part. [7] Auxiliary paper feed ring (movable) (*2) [8] Paper feed ring [9] Auxiliary paper feed ring [10] Folding roller DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 1-14 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 33 [8] Label, control (*2) ........1 (*2): For JPN [9] Instruction manual......1 (*3): For EU [10] Safety Guide A (*3) (*4) .......1 (*4): For NA [11] DECLARATION OF CONFORMITY (*3) ......1 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 1-15 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 34 [8] Separating pressure adjustment This scale is used when adjusting the separating scale pressure. [9] Paper feed pressure adjustment This scale is used when adjusting the paper feed scale pressure. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 1-16 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 35 4.2.1 Touch panel display [Ready] screen [Ready] screen (custom fold) [2] [3] [10] [10] [Processing] screen [Processing] screen (custom fold) [11] [11] [10] [10] DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 1-17 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 36 [9] Processing speed Displays processing speed currently set. The processing speed is not displayed during [Ejecting Paper]. Setting range: 1- to 6+ (speed) (1-) (thin paper) (6+) (thick paper) DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 1-18 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 37 [11] Processing display Displays current processing content. Testing Processing Idling Ejecting paper (*1) DF-999/999A (*2) DF-990/990A (*3) Option 4.2.2 Touch panel operation section [Ready] screen [Processing] screen [11] [10] DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 1-19 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 38 When the [Language] is set on the custom screen, the custom key is displayed in stopper fixed mode, manual feed mode (*), and counting mode (*). DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 1-20 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 39 (*). However, it is not displayed in custom folding mode. When in standard folding of standard paper (DF- 990/-990A), the [Standard Size] screen is displayed. (*) Option DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 1-21 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 40 [5] Manual feed guide [2] Manual paper feed tray [3] Manual skew correction knob 5.2 DF CROSS FOLD UNIT [1] Cross fold lever [2] T-handle hexagonal wrench DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 1-22 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 41 [5] Knob screw [10] Static removal brush The following options are available. DF ULTRASONIC SENSOR KIT It can be installed on DF-999 (JPN, EU) and DF-999A (NA). Chap. 2 > 3 PAPER FEED SECTION DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 1-23 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 43 AC power supply DC power supply Control signal (Single) Control signal (Multiple) Mechanical drive conveyance DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 44 The functions of this machine can broadly be divided into the following five types. [1] Exterior/control section [2] Paper feed section [3] Drive section [4] Folding section [5] Ejecting section DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 45 Paper sensor PS203 PS204e Feed jam sensor PS204r PS206e Feed timing sensor PS206r (*1): The PS205 is mounted only for the destination of NA. (*2): S201t/S201r are options. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 46 PS305 B sensor Folding plate 2 PS306 home sensor Ejecting Section Stacker index sensor PS401 Stacker roller motor M401 Stacker home sensor PS402 PS403e Eject jam sensor PS403r DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 47 This switch detects the existence or non-existence of the folding plate 1. When the folding plate 1 is removed, an error message is displayed on the LCD, and the relay (RL1) isolate driving power supply (+24 VA). DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 48 Delink the keys used with a high frequency such as start/stop and paper ejection from the LCD touch panel, and transmit the instruction to the PCB101. SD card (SDC101) Mounted in the LCD touch panel to save the image data. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 49 Paper sensor PS204e Feed jam sensor (emitter) PS204r Feed jam sensor (receiver) PS205 Legal size sensor (Mounted on the DF-999 for the destination of NA) PS206e Feed timing sensor (emitter) PS206r Feed timing sensor (receiver) S201t Ultrasonic sensor (transmitter) (Option mounted only on the DF-999/DF-999A)
Page 50 PS203 Paper sensor PS204e Feed jam sensor (emitter) PS204r Feed jam sensor (receiver) PS206e Feed timing sensor (emitter) PS206r Feed timing sensor (receiver) SW201 Paper feed tray switch DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 51 A reflective photointerrupter is used for the PS205, which is mounted on the support paper feed tray of the DF-999 for the destination of NA. It detects the legal size paper. The PS206e detects paper feed timing with photo sensor on the light emitting section, and the PS206r detects paper feed timing with photo sensor on the light receiving section.
Page 52 Timing pulley (S3M-48-08) Center press roll Idler roll [F], [G] Folding roller Index plate Paper feed shaft CL101 Feed clutch M101 Conveyance motor PS101 Conveyance index sensor DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 2-10 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 53 A photointerrupter is used for the PS101. It detects the rotation of the index plate. a. Jam detection Jamming is not detected on the drive section. b. Error detection E2220, E2221 Appendix > 2.3 Error (Exxx) DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 2-11 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 54 Folding plate 1 index A sensor PS302 Folding plate 1 index B sensor PS304 Folding plate 2 index A sensor PS305 Folding plate 2 index B sensor DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 2-12 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 55 Chapter 2 OPERATIONS PS303 PS306 PS303 Folding plate 1 home sensor PS306 Folding plate 2 home sensor DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 2-13 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 56 Index plate M301 Folding plate 1 motor PS301 Folding plate 1 index A sensor PS302 Folding plate 1 index B sensor PS303 Folding plate 1 home sensor DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 2-14 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 57 PS303 detects the home position of the folding stopper 1. a. Jam detection Jam detection is not performed on the folding plate 1. b. Error detection E2410, E2411, E2412, E2419 Appendix > 2.3 Error (Exxx) DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 2-15 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 58 Index plate M302 Folding plate 2 motor PS304 Folding plate 2 index A sensor PS305 Folding plate 2 index B sensor PS306 Folding plate 2 home sensor DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 2-16 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 59 PS306 detects the home position of the folding stopper 2. a. Jam detection Jam detection is not performed on the folding plate 2. b. Error detection E2420, E2421, E2422, E2429 Appendix > 2.3 Error (Exxx) DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 2-17 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 60 Flat belt Paper receiving tray Index plate M101 Conveyance motor PS401 Stacker index sensor PS402 Stacker home sensor PS403e Eject jam sensor (e) PS403r Eject jam sensor (r) DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 2-18 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 61 The paper is ejected by driving the flat belt through the STS belt and paper ejecting drive shaft. a. Jam detection J3002, J6002 Appendix > 2.1 Jam (Jxxx) b. Error detection E2400, E2401, E2402, E2409 Appendix > 2.3 Error (Exxx) DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 2-19 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 64 The wiring of the wire harness and the orientation of the cable clamps may differ on an actual machine. For details on wiring, refer to “DF-999/DF-999A, DF-990/ DF-990A WIRING DIAGRAM MANUAL.”...
Page 65 Chapter 3 DISASSEMBLY/ASSEMBLY 2 EXTERIOR/CONTROL SECTION 2.1 Exterior section 2.1.1 Exterior cover Name Screw Remarks Main cover F Remove the screws from the frame side. Main cover B DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 66 [2] Knob ............1 [3] Connector ..........2 [4] Screw ............2 [5] Cable clamp ..........2 [6] Screw ............6 [7] Nut ............1 [8] Control panel section ........ 1 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 67 [14] Screw ............4 [15] KEY PWB unit (PCB104) ......1 [10] [11] [12] [13] [15] [14] 2.2.2 KEY PWB unit (PCB104) Chap. 3 > 2.2.1 LCD touch panel (PCB102) DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 68 SD card. Insert the SD card backward as far as it clicks into place to attach. • Confirm the version of the program, when changing the panel program of the SD card. Chap. 6 > 3.1 Version check DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 69 • Initial screen setting/custom screen setting • Idling setting/tone setting • LCD bright setting/double-feed detection setting • Number of test sheets setting/manual feed setting/power saving setting • mm/inch setting/alarm setting/custom folding registration <Maintenance Menu> • Language • Mode • Area • Option (M-Feed/Count/U/S) • Offset data DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 70 [A] and then secure it with the screw [1]. If you do not install it securely, you may get an electric shock by touching the live parts through the gaps. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 71 [1] Screw ............4 [2] Paper feed tray lower cover ..... 1 [3] Screw ............1 [4] Connector ..........1 [5] Sensor angle ..........1 [6] Paper sensor(PS203) ........ 1 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 72 DF-999A DF-999A [3] Screw ............1 [4] Cable clamp ..........1 [5] Connector ..........2 [6] Screw ............2 [7] PS PWB unit (PCB201) ......1 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-10 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 73 [7] Cable band ..........1 [8] Connector ..........1 [9] Legal size sensor (PS205) ......1 NOTE When attaching the sensor, use new parts for the cable band. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-11 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 74 [8] Screw ............1 [9] Thrust regulatory plate ......1 [10] Raising and lowering lever section ..1 [11] Collar ............1 [12] Bearing ............1 [11] [12] DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-12 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 75 [15] Screw ............4 [16] Motor bracket ........... 1 [14] [13] [16] [15] [17] Screw ............3 [18] Paper feed tray motor (M201) ....1 [17] [18] [17] DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-13 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 76 Remove in the direction of an arrow. [3] Screw ............2 [4] Sensor cover ..........1 [5] Connector ..........1 [6] Screw ............2 [7] Feed jam sensor (PS204e) ......1 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-14 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 77 [4] Paper feed inlet lower ......1 [5] Connector ..........1 [6] Screw ............1 [7] Sensor bracket .......... 1 [8] Screw ............2 [9] Feed jam sensor (PS204r) ......1 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-15 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 78 Remove the parts in numerical order. [1] Screw ............1 [2] Sensor bracket .......... 1 [3] Connector ..........1 [4] Screw ............1 [5] Feed timing sensor (PS206r) ....1 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-16 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 79 Chapter 3 DISASSEMBLY/ASSEMBLY 3.3.3 Ultrasonic sensor (S201t/S201r) The ultrasonic sensor (S201t/S201r) is an option which can be mounted only on the DF-999/ DF-999A. a. Receiver (S201r) Perform as far as the step 2) removing the [4] sensor cover of “3.3.1 Feed JAM sensor (PS204e/PS204r)”...
Page 80 [2] Paper feed ring unit ......... 1 Remove in the direction of an arrow. [3] FR screw (Loosen) ........2 [4] Screw (only for the DF-999/DF-999A) ..1 DF-999/DF-999A [5] Auxiliary paper feed ring ......2 [6] Screw ............1 [7] Paper feed ring ........
Page 81 [1] E type retaining ring ........ 2 [2] Shaft ............1 [3] Separator assembly ........1 [4] Separator base unit ........1 [5] Paper separator base unit ......1 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-19 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 82 [2] Electrical cover ......... 1 [3] Screw ............1 [4] Cable clamp ..........1 [5] Connector ..........1 [6] Screw ............3 [7] Motor bracket ........... 1 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-20 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 83 [1] Connector ..........1 [2] Screw ............1 [3] Cable clamp ..........1 [4] Screw ............3 [5] Main bracket ..........1 [6] Bearing ............1 [7] Belt ............1 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-21 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 84 • Fit the cutout section [A] of the paper feed clutch in the shaft [B], when attaching the feed clutch. • Adjust the tension of the belt, when attaching it. Chap. 5 > 4.1.3 For adjusting the tension of driving belt • Adjust the play of the feed clutch, when attaching it. Chap. 5 > 4.1.2 Adjusting the feed clutch (CL101) [When attaching] DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-22 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 85 [7] Drive belt ..........1 NOTE Adjust the tension of the drive belt when attaching it. Chap. 5 > 4.1.3 For adjusting the tension of driving belt [1] [2] DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-23 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 86 [9] Fold plate motor assembly ....... 1 [10] Screw ............1 [11] Spur gear ..........1 [12] E type retaining ring ........ 1 [13] Bearing ............1 [13] [11] [12] [10] DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-24 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 87 When attaching the cable band, use new parts and adjust the position of the folding plate 1 motor. Chap. 5 > 5.1.1 Adjusting the folding plate 1 motor (M301) [18] [17] [16] [16] [15] [14] [14] DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-25 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 88 Folding stopper drive belt Remove the parts in numerical order. [1] Screw ............6 [2] Lower cover 1 ..........1 [3] Screw ............4 [4] Folding plate 1 .......... 1 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-26 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 89 [18] Folding stopper drive belt ......1 [16] [16] NOTE Adjust the tension of the belt, when attaching it. Chap. 5 > 5.1.2 Adjusting the STS belt [18] DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-27 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 90 Chap. 5 > 6.1.1 Adjusting the index plate [6] Connector ..........2 [7] Cable band ..........1 [10] [8] Screw ............2 [9] Z collar ............2 [10] Spring T ............ 1 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-28 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 91 When attaching the cable band, use new parts and adjust the position of the folding plate 2 motor. Chap. 5 > 5.2.1 Adjusting the folding plate 2 motor (M302) DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-29 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 92 [4] Plate ............1 [5] E type retaining ring ........ 1 [6] Bearing ............1 [7] Shaft assembly (Slide the shaft assembly in the direction of an arrow) ..........1 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-30 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 93 Chapter 3 DISASSEMBLY/ASSEMBLY [8] Folding stopper drive belt ......1 NOTE Adjust the tension of the belt, when attaching it. Chap. 5 > 5.2.2 Adjusting the STS belt DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-31 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 94 [4] Screw ............2 [5] Index plate ..........1 NOTE Adjust the position of the index plate when attaching it. Chap. 5 > 6.1.1 Adjusting the index plate DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-32 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 95 [10] Shaft unit ..........1 [11] Screw ............4 [12] Stacker plate ..........1 [11] [11] [11] [12] [11] [13] Roller unit ..........2 [14] Eject belt ........... 2 [14] [13] DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-33 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 96 [1] Screw ............2 [2] Lever R ............1 [3] CFR screw ..........1 [4] Connector ..........1 [5] Screw ............2 [6] Motor assembly ........1 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-34 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 97 [7] Eject jam sensor (PS403e) ......1 NOTE Do not move the stacker roller forcibly back and forth by hand. The stacker roller motor may be broken down. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-35 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 98 Remove the parts in numerical order. [1] Screw ............1 [2] Cable clamp ..........1 [3] Connector ..........1 [4] Screw ............1 [5] Eject jam sensor (PS403r) ......1 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 3-36 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 100 1.2 Special tools For the latest part number, refer to the parts catalogue. Name Intended use AUXILIARY GUIDE UNIT For holding down the edges of large sheets of paper. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 101 These are parts which rarely are consumed or wear out in normal use (excluding malfunctions), but may be replaced within the product life. For details, refer to the parts catalogue. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 102 Record the information on the following item if there is no problem. • Counter value Chap. 6 > 3.8 Maintenance counter A periodic maintenance is completed with the above. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 103 Chap. 4 > Step A (*1): Mounted only on the DF-999/DF-999A. (*2): Mounted only when the product is shipped to NA. (*3): Option mounted only on the DF-999/DF-999A. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 104 MOLYKOTE X5-6020 THE ORELUBE Tooth surface of the gear/chain/ CORPORATION G1650 sprocket Screw fixing Henkel For fixing the FR screws on the pulley agent Loctite 242 and sprocket DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 105 See below for each recommended product ([A] through [D] in the illustrations). Chap. 4 > 3.3.1 List of recommendation a. Paper feed tray _ Up and down section DF-999/DF-999A DF-990/DF-990A DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 106 Chapter 4 MAINTENANCE/INSPECTION b. Paper feed tray _ Controlling plate ratchet section c. Separator mechanical section _ Slide bar DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 107 Chapter 4 MAINTENANCE/INSPECTION d. Drive section _ Paper feed clutch e. Fold plate motor _ Worm and worm wheel DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 109 Chapter 4 MAINTENANCE/INSPECTION g. Paper ejecting section _ Drive shaft and roller h. Stacker section _ Drive shaft DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 4-11 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 110 Points to apply screw stopping agent See below for each recommended product ([E] in the illustrations). Chap. 4 > 3.3.1 List of recommendation a. Paper feed plate _ Skew correction knob DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 4-12 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 113 This chapter instructs you the solvents/oils to be used for adjustments of the parts using symbols. For details on the types of solvents/oils used, refer to Chapter 4. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 114 Chap. 6 > 3.4 Sensor check Check that the mechanism section stops at the specified position, after adjusting the home sensors. Chap. 1 > 4.1 Control panel Chap. 6 > 3.3 Motion check DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 115 ON by the actuator. [1] Switch bracket ........1 each [2] Actuator ..........1 each [3] Switch main body ......1 each [A] Clearance: 1.5 mm/0.06 inch SSW101 SSW103 SSW102 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 116 Check that there is no trouble and the separating plate touches the paper feed ring when raising the paper feed tray softly. [6] Paper feed ring ......... 3 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 117 Chapter 5 STANDARDS/ADJUSTMENT 3.2 Driving the paper feed tray 3.2.1 Adjusting the paper feed tray upper limit sensor (PS201) (DF-999/DF- 999A) 3.2.2 Adjusting the paper feed tray lower limit sensor (PS202) (DF-999/DF- 999A) Pull the paper feed tray upper limit and lower limit sensors in the direction of an arrow to attach.
Page 118 [A]. [5] Adjustment plate ........1 [6] Paper feed tray ......... 1 [7] Rib ............. 1 [A] Distance: less than 44 to 48 mm/1.73 to 1.89 inches DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 119 [A]. [2] Adjustment plate ........1 [3] Paper feed tray ......... 1 [4] Rib ............. 1 [A] Distance: less than 44 to 48 mm/1.73 to 1.89 inches DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 120 [6] Paper feed tray switch ......1 Adjust the position of the switch so that the clearance will be [B] with the switch ON. [B] Clearance: 0 to 1 mm/0 to 0.04 inch DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 121 When the sensor is adjusted, the display of [Status] will be changed from [No Adjust] to [Adjusted]. Press the key. The screen returns to the top screen in the maintenance mode. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 122 [A]. [1] Feed clutch (CL101) ......... 1 [2] Bearing ............1 [3] Adjusting washer ........1 [A] Thrust play: 0.1 mm/0.004 inch or less DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 5-10 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 123 [B]. [1] Drive belt ..........1 [2] Motor bracket ........... 1 [B] Amount of deflection: 3 to 5 mm/0.12 to 0.2 inch DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 5-11 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 124 [2] Worm ............1 [3] Worm wheel ..........1 Check the backlash of the worm and worm wheel is [A]. [A] Backlash: 0.1 to 0.2 mm/0.004 to 0.008 inch DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 5-12 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 125 STS belt will be [B]. [1] STS belt ............. 1 [2] Bracket ............1 [B] Amount of deflection: 3 to 5 mm/0.12 to 0.2 inch DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 5-13 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 126 The “Offset” screen will be displayed. Select the [Parallel CK] screen by touching key. Set the paper feed pressure adjustment lever to “0”. [1] Paper feed pressure adjustment lever..1 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 5-14 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 127 [4] Paper feed guide ........1 NOTE Be careful not to leave the paper unstable on the paper feed guide, which may cause sideway misalignment. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 5-15 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 128 [8] Folding stopper 1 ........1 [9] Fixing screw ..........1 13) After adjustment, tighten the fixing screw. 14) Return the top screen in the maintenance mode by pressing the key. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 5-16 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 129 [2] Worm ............1 [3] Worm wheel ..........1 Check the backlash of the worm and worm wheel is [A]. [A] Backlash: 0.1 to 0.2 mm/0.004 to 0.008 inch DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 5-17 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 130 STS belt will be [B]. [1] STS belt ............. 1 [2] Bracket ............1 [B] Amount of deflection: 3 to 5 mm/0.12 to 0.2 inch DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 5-18 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 131 2. [2] Folding stopper 2 ........1 [3] Fixing screw ..........2 After adjustment, tighten the fixing screw. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 5-19 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 132 [2] Switching adjustment plate ..... 1 [3] Folding stopper ......... 1 [A] Square hole of the frame F [B] Distance: 2 ± 0.5 mm/0.08 ± 0.02 inch DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 5-20 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 133 [ – ] or [+] key, and adjust the switching adjustment plate so that the distance between the edge of square hole and edge of switching angle will be [E]. [E] Distance: 0.3 to 0.5 mm/0.012 to 0.02 inch DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 5-21 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 134 The “Offset” screen will be displayed. For the DF-990/DF-990A, take the step 5) next. For the DF-999/DF-999A, the step 5) is not needed. Proceed to the step 7). However, set the standard size, when the paper stack detection is set to OFF by user.
Page 135 If the value does not meet the standard adjustment values of folding size, repeat the steps 5) to 7). 10) Execute “single fold” and check that the folding dimension is within the range of 182 mm ±0.5 mm/7.17 inces ±0.02 inch. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 5-23 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 136 [5] Frame B ............ 1 [6] Shaft ............1 After securing the set collar 120-16-100 to the shaft while keeping the condition of 2), check if the shaft is firmly secured. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 5-24 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 138 The program installed in this machine can be ungraded to a new version. To upgrade the version of the programs, obtain the SD card in which the latest version of the program files is saved. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 139 Press and hold the bottom right of the screen (2 seconds or more). The buzzer sounds, and the password input screen is displayed. Input “753620” on the password input screen, and touch the (enter) key. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 140 Press and hold the cancel key on the top screen in the maintenance mode (2 seconds or more). Exit the maintenance mode, and return to the ready screen. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 141 "APP" stands for the application section, and "Boot" for the program version of the boot section. Page Program Display Remarks 18H***** Bin program Main 18H***** Main program Boot 18H***** FPGA 18H***** FPGA program Panel Panel LC020EA version Ver01.02 Panel program 18H***** image DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 142 [3] To return to the top screen of the maintenance mode. 3.2.2 List Item Details/remarks Simulation • Simulates folding operation without using paper. • To operate cross fold in the folding mode. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 143 Feed Clutch Feed clutch (CL101) Paper Feed Tray Paper feed tray motor (M201) Operation can be performed when Motor the [Mode: 999] is set at “3.6 Various settings”. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 144 Checks that the sensors and switches operate normally. 3.4.1 Operation method Page 1 [1] DF-999/DF-999A: To proceed to the screen on page 5. DF-990/DF-990A: To proceed to the screen on page 4. [2] To proceed to the screen on page 2.
Page 145 Chapter 6 MAINTENANCE MODE Page 5 (Displayed only on the DF-999/DF-999A) [1] DF-999/DF-999A: To return to the screen on page 4. DF-990/DF-990A: No display. [2] DF-999/DF-999A: To proceed to the screen on page 1. DF-990/DF-990A: No display. [3] To return to the top screen of the maintenance mode.
Page 146 [1] To move the folding stopper (folding plate 1 and folding plate 2) and switching shaft without passing paper. To use for adjusting the switching shaft. [2] DF-999/DF-999A: To display the paper size after automatically detected. DF-990/DF-990A: To proceed to the standard paper size selection screen.
Page 147 Chapter 6 MAINTENANCE MODE Light Emit Amt [1] DF-999/DF-999S: To display the paper size after automatically detected. DF-990/DF-990A: To proceed to the standard paper size selection screen. [2] To proceed to the folding mode selection screen. [3] To return to the [Adjust Emission] screen.
Page 148 Value adjusted at the factory setting. Adjust the clearance between the first folding roller and switching shaft to the specified value (0.3 to 0.5 mm/0.012 to 0.02 inch). DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 6-12 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 149 The value is calculated by multiplying by 2.45 the number of pulses detected by the conveyance index sensor (PS101) while the paper is passing the feed jam sensor (PS204e and PS204r). Unit: mm DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 6-13 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 150 Press the start key or test key to move the folding stopper to the specified position. For the DF-999/DF-999A, the paper feed tray is raised. For details of procedures for adjustments, refer to the following. Chap. 5 > 5.1.3 Adjusting the parallelism of the folding stopper 1 Chap.
Page 151 To set to “ON” when the ultrasonic type double-feed detection is used. OFF (*) To set to “OFF” when the ultrasonic type double-feed detection is not used. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 6-15 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 152 [2] To return to the top screen of the maintenance mode. 3.7.2 List Item Language Remarks English English Japanese Español Spanish Deutsch German Français French Italiano Italian Русский Russian Polski Polish Korean Chinese DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 6-16 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 153 [1] To return to the top screen of the maintenance mode. 3.8.2 List Item Value Details/remarks Maintenance 0 to 99999999 The number of total feeding operations after factory counter shipment is displayed. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 6-17 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 154 Maintenance Not used. Details of settings by “User”, language, model, area, option, offset data, mm/inch settings (*1) (*1) The error history and counter are not reset. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 6-18 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 155 [4] To return to error history display screen. Error history reset (in execution) When error history reset is completed, the screen returns to the error history display screen. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 6-19 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 156 In the example shown above, two times of 24-hours elapsed is recorded, and it means that an error (E1902) occurred in 49 hours 23 minutes and 55 seconds after turning on the power. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 6-20 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 157 [1] FPGA program version before change [2] FPGA program version selected currently [3] To return to the main program details screen. [4] To return to the program version selection screen. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 6-21 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 158 Restart after the buzzer sounds. 3.11.2 List Display Remarks 18H8***x Displays the Bin file saved in the “Duplo” folder of the SD card. Will be upgraded after upgrading the version. x: 0 to 9 18H8***x Boot 18H8***x FPGA...
Page 160 [2] To stop adjusting the touch panel. [3] To perform adjusting the touch panel. [4] To return to the top screen of the maintenance mode. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 6-24 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 161 MC unit main program 4.1.3 Obtain the SD card Create the folder named with “Duplo” in the SD card. Copy the program version to be upgraded to “Duplo” folder Chap. 6 > 4.1.2 Types of program DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 6-25 Copyright ©...
Page 162 Insert the SD card into the SD card slot of the MC unit. Insert the SD card softly in the direction of an arrow until it clicks. [A] SD card slot [B] SD card Turning on the power. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 6-26 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 163 14) Turning on the power. 15) Enter the maintenance mode. Chap. 6 > 2.1 Entering the maintenance mode 16) Check the version of the program. Chap. 6 > 3.1 Version check DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 6-27 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 164 10) Turning on the power. 11) Enter the maintenance mode. Chap. 6 > 2.1 Entering the maintenance mode 12) Check the version of the program. Chap. 6 > 3.1 Version check DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 6-28 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 166 If no error information is displayed on the LCD display, you need to check what type of error has occurred. See “TROUBLESHOOTING INDEX (TROUBLE SHOOTING BY SYMPTOM)” on the following page for information on how to deal with each trouble. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 167 E5012 Ext. Comm Error Panel Parity ............................7-21 E5013 Ext. Comm Error Panel Framing ..........................7-21 E5015 Ext. Comm Error Panel ACK ............................7-21 E5770 Ext. Comm Error SD Card ..............................7-21 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 168 Control panel does not respond to key touch ......................7-27 2.4.6 [Paper Empty] is not displayed when starting paper feed ................7-27 2.4.7 Automatic detection of paper size does not operate (DF-999/DF-999A) ...........7-28 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 169 Perform test feeding every time paper is stacked when changed during processing. Yes: Is the problem corrected by cleaning the sensor? Chap. 4 > 3.2 Cleaning points End. Yes: DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 170 Is the state recovered by replacing the sensor? End. Yes: Check the conduction of bound wires from the sensor to MC unit. If there is no problem, replace the MC unit. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 171 Is the state recovered by replacing the sensor? End. Yes: Check the conduction of bound wires from the sensor to MC unit. If there is no problem, replace the MC unit. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 172 Is the state recovered by replacing the sensor? End. Yes: Check the conduction of bound wires from the sensor to MC unit. If there is no problem, replace the MC unit. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 173 Is there continuity from the terminals of the switch when the switch is pressed? Check the conduction of bound wires from the switch to MC unit. Yes: If there is no problem, replace the MC unit. Replace the switch. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 174 MC unit (PCB101) Is test feeding performed? Perform test feeding after changing the settings of paper type, paper size, and double-feed detection during operation. Replace the MC unit. Yes: DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 7-10 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 175 Is the state recovered by replacing the PS PWB unit? End. Yes: Check the conduction of bound wires from the PS PWB unit to MC unit. If there is no problem, replace the MC unit. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 7-11 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 176 Is the state recovered by replacing the switch? End. Yes: Check the conduction of bound wires from the switch to MC unit. If there is no problem, replace the MC unit. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 7-12 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 177 Chap. 6 > 4 VERSION UPGRADING End. Yes: Replace the MC unit. E1903 Download Sec. Broken Main defective parts MC unit (PCB101) Chap. 7 > E1902 Wrong Boot Version DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 7-13 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 178 Update the Bin program. Chap. 6 > 4 VERSION UPGRADING E2002 Motor Err Paper Feed Tray This error is displayed only on the DF-999/DF-999A. Main defective parts Paper feed tray motor (M201) Paper feed tray upper limit sensor (PS201) Paper feed tray lower limit sensor (PS202)
Page 179 Check the conduction of bound wires from the motor to MC unit. If there is no problem, replace the MC unit. E2003 Motor Err Paper Feed Tray This error is displayed only on the DF-999/DF-999A. Chap. 7 > E2002 Motor Err Paper Feed Tray E2005 Motor Err Paper Feed Tray This error is displayed only on the DF-999/DF-999A.
Page 180 Check the conduction of bound wires from the motor to MC unit. If there is no problem, replace the MC unit. E2221 Motor Err Convey Chap. 7 > E2220 Motor Err Convey DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 7-16 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 181 Chap. 7 > E2400 Motor Err Stacker E2402 Motor Err Stacker Chap. 7 > E2400 Motor Err Stacker E2409 Motor Err Stacker Chap. 7 > E2400 Motor Err Stacker DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 7-17 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 182 Chap. 7 > E2410 Motor Err Fold Plate1 E2412 Motor Err Fold Plate1 Chap. 7 > E2410 Motor Err Fold Plate1 E2419 Motor Err Fold Plate1 Chap. 7 > E2410 Motor Err Fold Plate1 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 7-18 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 183 Chap. 7 > E2420 Motor Err Fold Plate2 E2422 Motor Err Fold Plate2 Chap. 7 > E2420 Motor Err Fold Plate2 E2429 Motor Err Fold Plate2 Chap. 7 > E2420 Motor Err Fold Plate2 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 7-19 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 184 Chap. 7 > E4300 Int. Comm Error MC unit FPGA E4302 Int. Comm Error MC unit FPGA Chap. 7 > E4300 Int. Comm Error MC unit FPGA DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 7-20 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 185 Chap. 3 > 2.2.3 SD card (SDC101) Check the SD card program. If there is no problem, replace the LCD touch panel. Yes: Chap. 6 > 3.1 Version check DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 7-21 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 186 Chap. 3 > 4.1.2 Feed clutch (CL101) End. Yes: Check the conduction of bound wires from the feed clutch to MC unit. If there is no problem, replace the MC unit. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 7-22 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 187 Adjust the folding stopper. Chap. 5 > 5.1.3 Adjusting the parallelism of the folding stopper 1 Chap. 5 > 5.2.3 Adjusting the parallelism of the folding stopper 2 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 7-23 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 188 Is the center press roll dirty? Clean or replace the parts. Yes: Refer to “Instruction Manual > Chapter 5 Cleaning the Machine”. Adjust the folding section. Chap. 5 > 5 FOLDING SECTION DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 7-24 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 189 Is the state recovered by replacing the sensor? End. Yes: Check the conduction of bound wires from the sensor to MC unit. If there is no problem, replace the MC unit. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 7-25 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 190 Replace the wire harness. Is the state recovered by replacing the LCD touch panel? Chap. 3 > 2.2.1 LCD touch panel (PCB102) End. Yes: Replace the MC unit. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 7-26 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 191 Chap. 3 > 3.1.1 Paper sensor (PS203) End. Yes: Check the conduction of bound wires from the sensor to MC unit. If there is no problem, replace the MC unit. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 7-27 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 192 Chapter 7 TROUBLESHOOTING 2.4.7 Automatic detection of paper size does not operate (DF-999/DF-999A) Is the standard size is set to OFF in the [Detection] of the mode setting? The paper size is not automatically detected when the standard size is set to OFF.
Page 194 Stacker Home Top Cover Side Cover Convey IDX Stacker IDX Paper Feed Tray Paper Feed Tray Down Paper Size1 Paper Size2 Paper Size3 Paper Size4 Paper Size5 Paper Size6 DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 195 Chap. 6 > 3.10 Error history Code Version upgrading Main Chap. 6 > 3.11 Version upgrading Boot FPGA Touch panel Chap. 6 > 3.12 Touch panel adjustment adjustment DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 196 • The paper length setting is incorrect. U2007 Position Err DF-999: Paper feed The paper feed tray is not set. Paper Feed Tray tray upper limit sensor (PS201) DF-990/DF-990A: Paper feed tray switch (SW201) DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 197 The PS401 could not detect the index (M401) within the specified time although Stacker index sensor the M401 is driven. (PS401) E2409 MC unit (PCB101) The PCB101 detected an error signal inside the IC. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 198 E5015 Ext. Comm Error Panel E5770 Ext. Comm Error SD LCD touch panel The SD card is not attached to the Card (PCB102) PCB102. (*1) Displayed only on the DF-999/DF-999A. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 199 Mounted only on the DF-999/DF-999A. PS303 Folding plate 1 home sensor PS306 Folding plate 2 home sensor PSW001 Power switch Relay SW201 Paper feed tray switch Mounted only on the DF-990/DF-990A. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 200 PS305 Folding plate 2 index B sensor PS401 Stacker index sensor PS402 Stacker home sensor SSW101 Top cover switch SSW102 Side cover L switch SSW103 Folding plate switch DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 201 M101 PCB001 Symbol Name Remarks M101 Conveyance motor M201 Paper feed tray motor Mounted only on the DF-999/ DF-999A. PCB001 Switching power supply PS403r Eject jam sensor (Receiver) DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 202 APPENDIX 3.2.2 Paper ejecting side DF-999/DF-999A, DF-990/DF-990A PS403e Symbol Name Remarks PS403e Eject jam sensor (Emitter) DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 A-10 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 203 PS206r Feed timing sensor (Receiver) S201t Ultrasonic sensor (Transmitter) option Mounted only on the DF-999/ DF-999A. S201r Ultrasonic sensor (Receiver) option Mounted only on the DF-999/ DF-999A. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 A-11 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 204 Paper feed tray DF-999/DF-999A PCB201 PS205 Symbol Name Remarks PCB201 PS PWB unit Mounted only on the DF-999/ DF-999A. PS205 Legal size sensor Mounted only on the DF- 999A. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 A-12 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 205 4 LAYOUT OF BOARDS 4.1 Power supply/safety function 4.1.1 Switching power supply (PCB001) VR51 Symbol Roles Remarks Input connector CN51 Output connector VR51 Readjustment after shipment is prohibited. DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 A-13 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 206 APPENDIX 4.2 Control board 4.2.1 MC unit (PCB101) Symbol Roles Remarks Connector for memory unit SD card slot Relay Chap. 2 > 2.1.2 Safety function DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 A-14 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 207 APPENDIX 4.2.2 LCD touch panel (PCB102) Obverse side Reverse side Symbol Roles Remarks Connector for MC unit Not use SD card slot DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 A-15 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 208 KEY PWB unit (PCB104) Obverse side Reverse side Symbol Roles Remarks Connector for MC unit Lamp (start) key (stop) key (test) key (paper ejection) key (folding plate paper ejection) key DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 A-16 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 209 Photo sensor Photo sensor Photo sensor b. NA Symbol Roles Remarks Connector for MC unit Connector for legal size sensor Photo sensor Photo sensor Photo sensor Photo sensor DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 A-17 Copyright © 2019 Duplo Corporation All Rights Reserved...
Page 211 -Issued- DUPLO CORPORATION 4-1-6 Oyama, Chuo-ku, Sagamihara-shi, Kanagawa, 252-5280, Japan Revision 1 (2019/09) DUPLO DF-999/DF-999A, DF-990/DF-990A 18H-M12D1 Copyright © 2019 Duplo Corporation All Rights Reserved...

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Df-999a Df-990 Df-990a