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DF-1000 Service Manual

1. DUPLO DF 1000 12T M12M0 0602 0 3 3 1 EXTERNAL COVER CONTROL SECTION b Procedure 1 Remove the main cover F 2 Disconnect all connectors 10 on the MC unit and remove the MC unit A OTE 4 2 MC unit 1 4 Power Supply Drive 1 4 1 Removing the switching power supply 1 Remove the main cover F 2 Disconnect two connectors on the switching power supply and remove the switching power supply A events 4 2 Switching power supply 1 4 2 Removing the main motor MOT1 1 Remove the main cover B 2 Remove the stacker unit CF Refer to 4 1 1 Removing the stacker unit 3 Remove the partitioning plate four screws 4 Loosen the fixing screws of the main motor and remove the timing belt 1 Fixing screw Loosen ocooonccnoccconnnonnncnnncnns 2 2 Timing Deltssissc cassciecas sicascesesansieesieas issues 1 NOTE When installing the timing belt adjust the belt tension CY Refer to Chapter 5 STANDARDS ADJUSTMENTS gt 2 2 1 Adjusting the tention of the timing belt 3 4 DUPLO DF 1000 12T M12M0 0602 0 1 EXTERNAL COVER CONTROL SECTION 5 Remove the main motor 1 Fixing screw Remove cccoocccocccnoncnonnnnnnon 2 3 Connector 4 Main motor 1 4 3 Removing the paper feed tray motor 1 Remove the main cover B 2 Remove the stacker unit C Refer to 4 1 1 Removing the stacker unit 3 Remove the partitioning plate four screws
2. fi 12T 8205 Bundled wire unit 5 12T 1429 Fixed plate 062 11006 A n Thai Separation type photointerrupter light emitting side 127 4021 Paper ejection stay 127 4023 Sensor bracket 062 11095 Bundled wire unit 1 121 8201 o 303 el aN Separation type photointerrupter light receiving side 12T 8201 Bundled wire unit 1 DC motor unit gt 12H 3062 062 10964 Photointerrupter E 12H 3075 Sensor bracket H E Sensor bracket IN 12H 3279 o o T l o AA i o 96V 8146 FN 056 00876 DC motor N SK binder ll pl C u I 1 FS 127 4203 Stacker plate 127 4263 Front cover 062 11006 Separation type photointerrupter light emitting side 127 4260 Bundled wire bridge 062 10917 pe e y 3 Photointerrupter Na l 3303 Z gt Esp
3. Contents Remarks Mode for checking the operations of the following motors NOTE The motor will not operate if any one interlock switch is not closed Main motor MOT1 O Start key Main motor starts rotating O Stop key Main motor stops O Speed key Main motor rotating speed changes Paper feed tray motor MOT4 O Folding plate 1 folding stopper adjusting key Paper feed tray rises O Folding plate 1 folding stopper adjusting key Paper feed tray descends Stacker roller moving motor MOT5 O Folding plate 2 folding stopper adjusting key Stacker roller moves outside away from paper ejection section NOTE If the stacker roller is fed too outside the motor locks O Folding plate 2 folding stopper adjusting key Stacker roller moves inside home position side DUPLO DF 1000 12T M12M0 0602 0 3 MENUS AND FUNCTIONS Maintenance menu Setting 1st line display 2nd line display 22 F PLATE MOTOR 1 2 Contents Remarks Mode for checking the operations of the stopper motors of folding plates 1 and 2 The motor rotates while the key is pressed and stops when the key is released NOTE e The motor will not operate if any one interlock switch is not closed O As the motor rotates regardless of the limit detection by the home sensor and index sensor make sure that the folding stopper does not clash into the limit section of the folding plate Folding plate 1 stopp
4. 1 OUTLINE 7 Cover detection section C7 Refer to 2 EXTERNAL COVER CONTROL SECTION 8 Paper feed section C7 Refer to 3 PAPER FEED SECTION 9 Folding section CF Refer to 4 FOLDING SECTION 10 Paper ejection section CF Refer to 5 PAPER EJECTION SECTION DUPLO DF 1000 12T M12M0 0602 0 2 5 1 OUTLINE 1 3 Basic Operations 1 3 1 Operations at power ON 1 Power switch ON 2 Reading of memory data 3 Initialization of each part e Detection of folding plate 1 folding stopper home position e Detection of folding plate 2 folding stopper home position e Detection of stacker roller home position e Detection of paper on paper feed tray e Detection of paper feed position of paper feed tray 4 Standby status 1 3 2 Operations at power OFF This unit does not perform processing such as memory backup etc when the power switch is OFF When the power switch is turned OFF AC supply to the switching power is cut off immediately 1 3 3 Operation during processing 1 Press the start key or test key Implementation of settings 2 The MC unit calculates the targeted set position of each part based on the following conditions e Paper size e Folding mode e Correction value 3 The MC unit compares the targeted set position of each part and the current stopping position and moves the parts as required e Movement of folding plate 1 folding stopper e Movement of folding plate 2 folding stop
5. Chapter 7 TROUBLESHOOTING 1 OUTLINE 1 OUTLINE The problems of this unit can broadly be divided into the following three types 1 Abnormal processing results The unit operates but the desired processing results cannot be obtained Example O Mis feed O Double feed O Folding misalignment If these phenomena occur refer to the following and perform the appropriate measure C7 Refer to 2 TROUBLESHOOTING BY PHENOMENON 2 Operational problems Error message is displayed on the control panel The following four types of messages are displayed on the control panel Message type O Paper jam message O Error message O Trouble message O Other messages No paper cover open etc If these messages are displayed refer to the following and perform the appropriate measure CF Refer to 3 TROUBLESHOOTING BY MESSAGE DISPLAYED 3 Operational problems No error message is displayed on the control panel Example O Power does not turn ON O Nothing is displayed on control panel O Key operations are disabled If these phenomena occur refer to the following and perform the appropriate measure C Refer to 4 TROUBLESHOOTING FOR OPERATION FAILURES DUPLO DF 1000 12T M12M0 0602 0 2 TROUBLESHOOTING BY PHENOMENON 2 TROUBLESHOOTING BY PHENOMENON 2 1 Paper Feed Problems 2 1 1 Mis feed 1 Is the separating air too weak Yes Increase the separating air using the separating air adjusti
6. DUPLO DF 1000 12T M12M0 0602 0 2 LAYOUT OF ELECTRICAL PARTS 2 4 Paper Feed Section PS P W B unit Remarks Parts differ between UK model and USA model Paper feed tray sensor 1 Paper sensor Light emitting side Paper sensor Light receiving side Paper feed tray sensor 2 Legal paper detection sensor DUPLO DF 1000 12T M12M0 0602 0 USA model only A 7 2 LAYOUT OF ELECTRICAL PARTS 2 5 Folding Plate Section PS2 Folding plate 1 stopper motor Remarks Folding plate 2 stopper motor Folding plate 1 index sensor A Folding plate 1 index sensor B Folding plate 1 home sensor Folding plate 2 index sensor A Folding plate 2 index sensor B Folding plate 2 home sensor DUPLO DF 1000 12T M12M0 0602 0 2 LAYOUT OF ELECTRICAL PARTS 2 6 Paper Ejection Section PS12a MOT5 Remarks Stacker roller moving motor Stacker roller home sensor Paper ejection outlet sensor Light emitting side DUPLO DF 1000 12T M12M0 0602 0 A 9 3 LAYOUT OF BOARDS 3 LAYOUT OF BOARDS 3 1 MC Unit 00000000000000000 00000000000000000 A 10 DUPLO DF 1000 12T M12M0 0602 0 3 LAYOUT OF BOARDS 3 2 Control Pan
7. touch metal tools that are properly grounded to eliminate static electricity accumulated in the human body Static electricity may accumulate in the human body during contact with clothing This static electricity may damage electrical devices or change the electrical characteristics of devices vi DUPLO DF 1000 12T M12M0 0602 0 PREFACE 2 4 Warning and Caution Label Locations NOTE The warning and caution labels are pasted or printed on the unit to ensure the safety of users Do not remove nor change them If these labels become dirty or damaged replace with new ones A A CAUTION A jit ZA Do not put fingers inside during operation 2a hich A BicM aFPCBEANALCCESLY Keep away long hair ties jewelry BODE 994 RAR RMSE and loose clothing EDERT It could cause injury BEWDENTTHETFSEANMRHVET Caution Label for SP CAUTION FOR CONTINUED PROTECTION AGAINST RISK OF FIRE REPLACE ONLY WITH SAME TYPE AND RATING OF FUSE DUPLO DF 1000 12T M12M0 0602 0 vii PREFACE 3 ENVIRONMENTAL PRESERVATION 3 1 Collection of This Unit Please collect disassemble recycle or dispose unwanted products in accordance with the requirements of each country and region 3 2 Collection of Consumables and Parts Please collect disassemble recycle or dispose unwanted consumables and parts in accordance with the requirements of each country and region Please handle the following parts with particular care as they a
8. 0 Left and right two each 2 Install the shutter and paper feed tray so that they are 90 to each other Reference Steps 1 and 2 can be adjusted easily by using a level 3 Adjust the attaching position of arm L so that the actuator of the paper feed tray home switch SW4 and rack do not interfere Pl Arm dins Left and right one each Adjusting screw Left and right two each 4 Adjust the height from the top surface of the paper feed tray to the stacking upper limit mark A on the side guides At this time check that the clearance between the stopper plate and arm is 1 5 to 3 5 mm lt Adjustment value gt 100 to 102 mm 3 Stopper plate 5 Adjust the attaching position so that the paper feed tray home switch SW4 turns ON at step 4 4 Fixing screw Loosen 2 5 Sensor bracket 5 6 DUPLO DF 1000 12T M12M0 0602 0 3 PAPER FEED SECTION lt A 100 to 102 mm o DUPLO DF 1000 12T M12M0 0602 0 5 7 3 PAPER FEED SECTION 3 1 2 Adjusting the side guide 1 Adjust the position of the plate so that the following conditions are met and secure The left and right side guides should be symmetrical to the center of the two frames The left and right side guides should be parallel to each other an
9. Pressing the start key or test key raises the paper feed tray until the paper feed tray sensor 2 PS9 detects paper 2 When the paper feed tray sensor 2 PS9 detects paper the blower fan FAN1 and suction fan FAN2 turn ON The unit stands by for two seconds in this state and then separates paper with the air from the blower fan FAN1 3 The paper feed tray sensor 1 PS7 detects the topmost paper lifted up by air If it fails to detect the paper feed tray will rise until this paper is detected 4 After some time from the detection of paper by the paper feed tray sensor 1 PS7 paper feed starts Paper feed operations 5 After completion of paper feed tray setting operations the suction solenoid SOL1 turns ON and sucks the topmost paper lifted up by air to the suction belt 6 After a certain period of time the paper feed clutch CLH1 turns ON and paper is fed If the second sheet of paper is fed together with the topmost paper the second sheet is dropped by the separator 7 If paper is fed continuously when the paper feed inlet sensor PS10 detects the trail edge of the paper feeding of the next paper starts Reference In the following processing conditions paper feed interval is controlled to enhance processing speed e Standard paper e Processing speed 5 or 5 e Single fold double fold letter fold CF Refer to 3 3 4 Conveyance section gt c Paper feed interval control Skew correction 8 Paper is
10. 1 Preparing the rewriting tool EPROM Write the program in the EPROM and create the rewriting tool EPROM type No Equivalent to STMicroelectronics M27C1001 12F1 4 2 Upgrading the Version 4 2 1 Upgrading the program version 1 Turn OFF the power switch 2 Attach the rewriting tool EPROM to the IC socket U11 on the MC unit 3 Enter the maintenance mode While pressing the start key and stop key turn ON the power 4 Select 18 PROG VER UP Enter 18 using the numerical keys and press the folding mode key 5 Press the start key and start rewriting The time required for rewriting is about 20 seconds When rewriting ends normally the new version program starts automatically NOTE O During rewriting never turn OFF the power During rewriting all key operations will be disabled Nothing will be displayed on the LCD O f 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 O The EPROM is not inserted in the socket correctly O The program is not written in the EPROM correctly OA program with a different ID is written in the EPROM 6 Enter the maintenance mode select 15 MC ROM VER and check that the new version is displayed on the LCD 7 Turn OFF the power and remove the EPROM DUPLO DF 1000 12T M12M0 0602 0 6 11 5 DATA INITIALIZATION 5 DATA INITIALIZATION 5 1 Erasing Standard Folding Corr
11. 12T 85031 2 2 DUPLO DF 1000 12T M12M0 0602 0 DUPLO CORPORATION Duplo building 1 6 Oyama 4 chome Sagamihara Kanagawa 229 1180 Japan Revision O Feb 2006 DUPLO DF 1000 12T M12M0 0602 0 Duplo 12T M12M0 DUPLO DF 1000 12T M12M0 0602 0
12. 2 folding stopper adjusting key Folded plane 2 is short Press the key of the folding plate 2 folding stopper adjusting key Irregular accordion Folded plane 1 is long Press the key of the folding plate 1 fold folding stopper adjusting key Folded plane 1 is short Press the key of the folding plate 1 folding stopper adjusting key Folded plane 2 is long Press the key of the folding plate 2 folding stopper adjusting key Folded plane 2 is short Press the key of the folding plate 2 folding stopper adjusting key Letter fold Folded plane 1 is long Press the key of the folding plate 1 folding stopper adjusting key Folded plane 1 is short Press the key of the folding plate 1 folding stopper adjusting key Folded plane 2 is long Press the key of the folding plate 2 folding stopper adjusting key Folded plane 2 is short Press the key of the folding plate 2 folding stopper adjusting key Folded plane 1 is long Press the key of the folding plate 1 folding stopper adjusting key Folded plane 1 is short Press the key of the folding plate 1 folding stopper adjusting key Folded plane 2 is long Press the key of the folding plate 2 folding stopper adjusting key Folded plane 2 is short Press the key of the folding plate 2 folding stopper adjusting key DUPLO DF 1000 12T M12M0 0602 0 1 15 5 USER ADJUSTMENTS 4 Correcti
13. 4 Loosen the fixing screws of the paper feed tray motor and remove the timing belt 1 Fixing screw Loosen 4 2 Timing belt ee eeceeseeeecereceeeeteeneeneees 1 NOTE When installing the timing belt adjust the belt tension Cr Refer to Chapter 5 STANDARDS ADJUSTMENTS gt 2 2 1 Adjusting the tention of the timing belt 1 1 2 5 Remove the paper feed tray motor 8 4 1 Fixing screw Remove occccooccccoocccnconncn no 4 3 Connector 4 Paper feed tray motor DUPLO DF 1000 12T M12M0 0602 0 3 5 2 PAPER FEED SECTION 2 PAPER FEED SECTION 2 1 Paper Feed Tray Section 2 1 1 Removing the PS P W B unit 1 Remove the paper feed reinforcement plate 2 cover 2 Disconnect all connectors on the PS P W B unit and remove the PS P W B unit 2 PS P W B unit 1 2 2 Suction Conveyance Section 2 2 1 Removing the suction conveyance unit 1 Remove the main cover B 2 Remove the cable clamp and disconnect the connectors of the suction fan FAN2 and paper feed tray sensor 1 PS7 3 Open the top cover L and remove the screws of the paper feed shaft coupling 4 Move the suction conveyance unit to the non operating side and remove the bearing at frame of operating side 5 Remove the suction conveyance unit Using the holes on the bearing removed in step 4 remove the paper feed shaft while tilting it NOTE When installing the suction conveyance unit perform
14. 5 mm The number of slits pulses is counted by two photointerrupters index sensors to control the moving distance and direction of the folding stopper The minimum distance moved by the stopper is 0 125 mm of one pulse of the above index plate c Maximum moving distance of folding stopper Folding plate 1 288 5 mm from home position Folding plate 2 180 5 mm from home position d Length of folded plane Max Min Folding plate 1 325mm 42mm Folding plate 2 217mm 47mm e 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 e Code No 1 Correction value of folding plate 1 home position e Code No 2 Correction value of folding plate 2 home position e Code No 3 Correction value of switching shaft home position CF Refer to Chapter 6 MAINTENANCE MODE gt 3 MENUS AND FUNCTIONS DUPLO DF 1000 12T M12M0 0602 0 2 27 4 FOLDING SECTION 4 3 Folding Roller Section 4 3 1 Configuration Reference The basic structure is the same as DF 920 915 we Symbol Part name Symbol Part name Idler roller 1 Folding roller 1 Center press roller Folding roller 2 Folding roller 3 2 28 DUPLO DF 1000 12T M12M0 0602 0 5 PAPER EJE
15. 60 Hz UK model Rated current Rated power 2 to 1 A 140 W N WARNING O Use only the power supply voltage specified on the main nameplate Using other voltages could result in a fire or an electrical shock Make sure that the combined power consumption of the appliances to be connected does not exceed the capacity rating of the power outlets or plug receptacles Exceeding the capacity rating could cause the power outlets plug receptacles or power extension cords to overheat and catch a fire DUPLO DF 1000 12T M12M0 0602 0 iii PREFACE CAUTION Do not place anything around the socket outlet to ensure that the power plug can be disconnected anytime If the power plug cannot be disconnected immediately when product failure occurs it could result in fire or an electric shock This unit shall be installed near the socket outlet where the plug on the power supply cord is easily accessible If the power plug cannot be disconnected immediately when product failure occurs it could result in fire or an electric shock 2 2 Operating Environment Operate this unit in the following environment O where the temperature range is between 5 and 35 C 10 to 50 C in storage where the humidity range is between 20 and 80 RH 10 to 90 RH in storage however no condensation Keep this unit and the power cord away from heaters and heater vents Excessive heat could melt the cover or power cord covering and r
16. Adjusting the home position of the switching shaft 2 Note down the current user menu function setting mode and then change the user menu settings to shipment settings C Refer to Chapter 1 INTRODUCTION gt 4 2 User Menu Function Setting Mode 3 Set paper passage conditions as follows item USA model UK model Paper size 8 5 x 11 LTR Paper type Fine quality paper 81 4 g m Paper grain direction Vertical direction Processing speed 5 Maximum speed Side guide Adjust to paper width Side guide adjusting knob Standard position Skew correction knob Standard position Thin paper feed button ON 4 Set the folding mode to letter fold and press the test key 5 Measure the center of the ejected paper second sheet and adjust so that the following reference values are satisfied Reference value of Folded plane length A Folded plane length B C Refer to 4 1 3 Adjusting the home position of the folding stopper 6 Set the folding mode to single fold and press the test key 7 Measure the center of the ejected paper second sheet and adjust so that the following reference values are satisfied Reference value of folded plane length Eanes Pe ee Folded plane length C plane Folded plane length C C 189 5 0 5mm 5 0 5 mm 1485 0 5mm 5 0 5 mm lt lt conveyance 7 direction lt lt conveyance direction a I 5 2 D
17. Gray Clutch unit 8 8 ES wae Details of back 3302 94X 8021 Brown Gray Cable clamp 056 09001 3302 056 09002 3303 056 09003 3304 056 09004 3305 056 09006 3307 056 09007 3308 056 09009 3330 DUPLO DF 1000 12T M12M0 0602 0 DC solenoid 127 4601 O E Drive bracket 3303 127 4643 O Paper ejection clutch bracket 3302 054 10248 Microswitch 054 10208_ 1 Mi itch NO Yellow COM Purple SN icroswitel 12T 5371 we D MS bracket 12H 8101 30 Brushless DC motor 127 2047 SW bracket unit USA model AAA A A A iP F 121 8210 l l 127 9036 fl i i 42T 8209 Bundled wire unit 10 i i Pa feed ia ets Bundled wire unit 9 i l pi y i i le a b EN i i i i View of 1 i Hay ID I wi N i l Black Green i I o6v 8110 127 8209 on Whit
18. NOTE After completing the adjustment check that each switch is able to detect the open close of the top cover normally 3 Turn ON the power and set the paper passage conditions as follows Items not included in the following table will not affect this adjustment item USA model UK model Paper size 8 5 x 11 LTR Paper type Fine quality paper 81 4 g m Paper grain direction Vertical direction Separator adjusting knob 5 Side guide Adjust to paper width Side guide adjusting knob Standard position Skew correction knob Standard position 4 Align paper neatly and stack on the paper feed tray and adjust the side guides to the paper width NOTE If the side guides are not adjusted to the paper width folding misalignment along the sides of the paper will occur 5 Select 28 ALIGNMENT of the maintenance mode and press the start key C Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List The paper feed tray rises and the folding plate 1 folding stopper and folding plate 2 folding stopper move to their home positions 6 Insert one sheet of paper on the paper feed tray into the unit by hand Insert until the paper lead edge touches the conveyance roller 7 Rotate the conveyance roller by hand to convey the paper Convey until the paper lead edge touches the registration secondary roller 8 Rotate the registration secondary roller by hand to convey the paper Convey until the
19. and start blinking Set this when paper feed error occurs frequently with recycled paper Folding plate 1 folding stopper adjusting key Press to adjust the position folding position of the folding stopper of folding plate 1 Folding plate 2 folding stopper adjusting key Adjustment registration key Press to adjust the position folding position of the folding stopper of folding plate 2 If the position of the folding stopper has been finely adjusted in standard folding operations the adjustment value can be registered with this key Custom folding registration key Custom folding registration lamp Press to register the position of the folding stopper and stacker roller which have been moved when using custom folding modes When this lamp is lit it means that the custom folding mode is registered Folding mode key Standard folding lamp Press to select the folding mode from five standard folding modes When a folding mode registered with the folding stopper position adjustment value is selected the corresponding lamp blinks Liquid crystal display LCD Displays the size of standard paper stacked on the paper feed tray paper length registered and error messages 1 10 Numerical display Counter When using the add count mode displays the number of sheets processed When using the subtract count mode displays the number of sheets left to be processed DUPLO DF 1000 12T M12
20. clutch CLH3 2 Remove the registration brake BRK1 3 Remove the E ring at frame B 4 Remove the bearing holder from inside the frame and pull out the registration roller DUPLO DF 1000 12T M12M0 0602 0 3 7 3 FOLDING SECTION 3 FOLDING SECTION 3 1 Folding Plate Section 3 1 1 Removing the folding stoppers 1 Disconnect the folding plate connector and remove the folding plate 2 Remove the folding plate lock lever 3 Remove the folding plate upper cover and folding plate lower cover 4 Disconnect the connectors of folding plate 1 unit and folding plate 2 unit 5 Remove the fixing screws of the connecting plate at folding plate 1 unit and remove the folding plate 1 unit NOTE Do not remove the fixing screws of the connecting plate at folding plate 2 unit and remove the connecting plate As the connecting plate is adjusted by tool at assembly it cannot be adjusted on the market 6 Remove each folding stopper NOTE When installing the folding stopper perform the following adjustments C7 Refer to Chapter 5 STANDARDS ADJUSTMENTS gt 4 1 1 Adjusting the parallelity of the folding stopper CF Refer to Chapter 5 STANDARDS ADJUSTMENTS gt 4 1 7 Adjusting the folding stopper section 3 1 2 Removing the folding plate stopper motors MOT2 MOT3 1 Disconnect the folding plate connector and remove the folding plate 2 Remove the folding plate lock lever 3 Remove the folding pl
21. cover 3 2 1 2 Control Panel Section 3 3 1 2 1 Removing the control panel MS Board ia ai 1 3 1 Removing the MC unit eee 3 3 1 4 Power Supply Drive 00 0 0 3 4 1 4 1 Removing the switching power SUP PLY iaa ia 3 4 1 4 2 Removing the main motor MOT1 3 4 1 4 3 Removing the paper feed tray motor 3 5 2 Paper Feed Section nsss 3 6 2 1 Paper Feed Tray Section i 2 1 1 Removing the PS P W B unit 2 3 Registration Section 2 3 1 Removing the registration clutch C LH NE 3 7 Removing the registration brake A O 3 7 Removing the registration secondary rolas 2 3 4 Removing the registration roller 3 Folding Section 3 1 Folding Plate Section j 3 1 1 Removing the folding stoppers 3 1 2 Removing the folding plate stopper motors MOT2 MOB ecnonininnnininicinnnn 3 8 2 3 2 2 3 3 3 1 3 Removing the folding plate index sensors PS1 PS2 PS4 PS5 3 8 3 1 4 Removing the folding plate home sensors PS3 PS6 3 9 3 2 Folding Roller Section 3 9 3 2 1 Removing the folding rollers 3 9 4 Paper Ejection Section 3 11 4 1 Stacker Unit si 4 1 1 Removing the stacker unit 3 11 4 1 2 Removing the stacker roller home sensor PS11 occ ii 3 11 4 1 3 Removing the stacker roller moving Motor MOTOS ics scsscesssacedsseesssssevevexcesevees 3 11 4 1 4 Removing the stacker b
22. feed interval control is as follows Paper feed interval control Paper feed Remarks start time A Quick The paper feed start time A to D differs according to the size of standard paper Paper feed interval setting Processing speed D Slow 2 20 DUPLO DF 1000 12T M12M0 0602 0 3 PAPER FEED SECTION 3 4 Registration Section 3 4 1 Outline The following shows the structure of the registration section o o_o Skew roller fixing knob id correction knob Skew roller fixing knob Skew roller spring pressure adjusting knob A i Fulcrum 7 i A 1 Secondary registration roller Registration roller 3 4 2 Registration control Skew correction a Outline Skew is corrected by touching the lead edge of paper fed against the registration roller to slack the paper slightly The registration roller conveys skew corrected paper to the folding section PS10 Secondary registration roller Registration roller E NOTE Adjust the tilt of the secondary registration roller using the skew correction knob as necessary C Refer to Chapter 1 INTRODUCTION gt 5 2 2 Skew correction by skew correction knob DUPLO DF 1000 12T M12M0 0602 0 2 21 3 PAPER FEED SECTION b Operations 1st sheet 1 2
23. is display dui aaa 7 5 3 1 2 When JAM INSIDE is displayed 7 5 3 1 3 When JAM EXIT is displayed 7 5 3 2 Error Messages hiis rie 7 6 3 2 1 When F PLATE SET ERR is displayed esnai iiaii 7 6 3 2 2 When FEED ERROR is displayed 7 6 3 3 Trouble Messages niisiis 7 7 3 3 1 When MOTOR ERROR 1 is display dico apa 7 7 3 3 2 When MOTOR ERROR 4 is A 7 7 3 3 3 When MOTOR ERROR 5 is displasia i n 7 7 3 3 4 When MOTOR ERROR 3 is displayed ooooccccccnononcononnonooncnnonornnononncnnons 7 8 3 3 5 When MOTOR ERROR 2 is split 7 8 3 3 6 When TRAY UP ERROR is displayed ars mauina 7 9 3 3 7 When TRAY DOWN ERROR is displayed vinos dai 7 9 3 4 Other Messages ccocoocioicncnncccccccnnncncnnncnnons 7 10 3 4 1 When NO PAPER is displayed 7 10 3 4 2 When TOP COVER L OPEN is displayed ccccccsceescssessesessesesseeseseeeees 7 10 3 4 3 When TOP COVER R OPEN is displayed reor ieri o aE Ei 7 10 3 4 4 When SIDE COVER OPEN is displaye dracs isos 7 10 4 Troubleshooting for Operation FAQ UTOS coco cocineros sesenta 7 11 xii 4 1 Power Does Not Turn ON 7 11 4 2 Nothing is Displayed on Control Panel 7 11 4 3 Key Operations are Disabled on Control Palo 7 12 4 4 Misdetection of Standard Paper Sizes OCCUIS ici a 7 12 Appendix 1 List of Displayed Messages A 2 1 1 NO Papel is coin 1 2 Key
24. may be difficult to set on the main body of the unit In this case adjust as follows 1 Remove the folding plate and loosen fixing screws B1 and B2 B1 Fixing screw eee One each in front and rear B2 Fixing screw eee One each in front and rear NOTE While the B1 and B2 fixing screws are loosened never loosen fixing screws A1 and A2 A2 B1 82 2 Inthe state of step 1 attach the folding plate to the main body of the unit 3 Tighten the fixing screw B2 Secure with the folding plate attached to the main body 4 Remove the folding plate and tighten fixing screw B1 DUPLO DF 1000 12T M12M0 0602 0 5 21 5 PAPER EJECTION SECTION 5 PAPER EJECTION SECTION 5 1 Stacker Belt Section 5 1 1 Adjusting the tention of the stacker belt lt Adjustment value gt Tighten the belt so that the skew of the belt and repeated deviation of the belt to the left and right sides are within 2 mm 1 Fixing screw Loosen 2 Standard position 5 2 Stacker Roller Section 5 2 1 Adjusting the tention of the timing belt lt Adjustment value gt Gap A between shafts is 39 7 0 5 mm 1 Adjusting screw seses 2 2 Motor bracket 5 2 2 Adjusting the stacker roller o home sensor PS11 position 3 lt Adjustment value gt Secure at top of long hole 8 Adjusting SCreW ocoonoccconccoonccnncconnccancconnnono 2 4 Sensor angl
25. paper lead edge touches the idler roller 5 12 DUPLO DF 1000 12T M12M0 0602 0 4 FOLDING SECTION 9 Rotate the jam correction knob to convey the paper Convey to the position just before the paper lead edge touches the slide stopper 1 of the folding plate 1 folding stopper NOTE If paper skews during conveyance check the nip amount of the idler roller C Refer to 4 2 3 Checking the folding roller nip 10 Adjust the attaching position of the folding plate 1 folding stopper 2 so that it is parallel to the paper lead edge 2 Folding plate 1 folding stopper 3 PS SOLOW iio 2 11 Rotate the jam correction knob to convey the paper Convey to the position just before the paper lead edge touches the slide stopper of the folding plate 2 folding stopper 12 Check the parallelity of the folding plate 2 folding stopper and paper lead edge 13 Turn OFF the power and remove the folding plate 1 unit C7 Refer to Chapter 3 DISASSEMBLY ASSEMBLY gt 3 1 1 Removing the folding stoppers 14 Adjust the attaching position of the folding plate 2 folding stopper The adjustment method is the same as the folding plate 1 folding stopper 15 Install the folding plate 1 unit and install the folding plate to the main body 16 Perform from step 3 and check that the parallel adjustment of each folding stopper has been completed appropriately DUPLO DF 1000 12T M12M0 0602 0 5 13 4 FOLDING SECTION 4 1 2 Adjusting
26. plate 1 home sensor PS3 Folding plate 2 home sensor PS6 Paper feed tray sensor 2 PS9 Paper feed tray home switch SW4 Top cover R switch SW1 Top cover L switch SW5 Side cover switch SW2 Folding plate switch SW3 Paper feed tray upper limit switch SW6 Paper feed tray sensor 1 PS7 Tray down button SW8 Safety lever switch SW7 Display of OFF state Displayed as at the bottom of the LCD A B C D E F G H I J K L M N O P 32 CHK SIZE SNSR DUPLO DF 1000 12T M12M0 0602 0 Mode for checking the operations of the PS P W B unit paper size sensor The display changes when the side guide moves and the buzzer sounds The sensor state is displayed as follows at the bottom of the LCD Hi displayed Sensor which is ON displayed Sensor which is OFF Available paper sizes for UK model from left B6 A5 B5 A4 B4 A3 Available paper sizes for USA model from left INV STMT LTR LGR LGL 3 MENUS AND FUNCTIONS Maintenance menu Setting 1st line display 2nd line display 33 MAIN MTR INDX 0000 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 the number of pulses is counted up and displayed at the bottom of the LCD When the main motor shaft is rotated once the number of pulses added is 15 NOTE The number of pulses displa
27. processing speed Sound collection microphone position when measuring acoustic pressure level Sound is collected at 1 0 m from measured surface 1 5 m height indoor below 30 dB scale A and FAST operation characteristics Dimensions W x D x H In use 1 277 x 534 x 590 mm 50 28 x 21 02 x 23 23 In storage 912 x 534 x 590 mm 35 91 x 21 02 x 23 23 Mass Weight 71 kg 156 5 lb 2 4 2 Error detection functions Item Contents Paper feed error detection function Mis feed continuous feed paper jam Other detection functions DUPLO DF 1000 12T M12M0 0602 0 Opening closing of top cover L R and side cover With without folding plate Paper feed tray UP DOWN error Safety lever ON OFF 3 NAMES OF PARTS 3 NAMES OF PARTS 3 1 External Parts Folding plate Top cover L Top cover R Skew correction knob Side guide adjusting knob Side guide Paper feed tray Auxiliary paper feed tray Rear guide 10 Power cord inlet 11 Power switch OO ON DON FWD 1 8 12 Level sensor adjusting lever 13 Tray down button 14 Separating air adjusting knob 15 Separator adjusting knob 16 Safety lever 17 Separating air duct 18 Separator 19 Suction belt 20 Shutter 21 Level sensor 22 Paper switch USA model only DUPLO DF 1000 12T M12M0 0602 0 3 NAMES OF PARTS 23 24 25 26 27 28 29 30 31 32 Side guide d
28. roller 1 12 Remove the timing pulley of the jam correction knob and remove the timing belt 13 Remove the timing pulley and helical gear at frame B NOTE When installing the helical gear install from the center press roller Remember also to insert the key amp 7 9 DUPLO DF 1000 12T M12M0 0602 0 3 FOLDING SECTION 14 Remove the key and collar 15 Remove the stopper at frame B remaining one NOTE When removing the stopper do not remove the stopper of folding roller 1 If removed adjust the gap with the center press roller CF Refer to Chapter 5 STANDARDS ADJUSTMENTS gt 4 2 2 Adjusting the gap of folding roller 1 16 Remove the plates levers at both frames F and B 17 Remove the idler roller 18 Remove folding roller 2 19 Remove folding roller 3 20 Remove the hook of spring T from the M3 screw 21 Remove spring T from the switching angle and remove the switching shaft from the switching angle 22 Remove the bearing of folding roller 1 23 Remove the portion fixing the paper ejection stay and main body together frame B side 24 Remove folding roller 1 Remove while widening the clearance between the frames slightly 25 Remove the bearing holder and remove the center press roller 3 10 DUPLO DF 1000 12T M12M0 0602 0 4 PAPER EJECTION SECTION 4 PAPER EJECTION SECTION 4 1 Stacker Unit 4 1 1 Removing the stacker unit 1 Remove the stacker side c
29. segerna 2 3 Paper Feed Section sassen 2 1 3 1 Outline 2 1 3 1 1 Configuration 3 1 2 Paper feed operations 3 2 Paper Feed Tray Section 3 2 1 Outline sisenes 3 2 2 Side guide section 3 2 3 Tray up down section 3 3 Suction Conveyance Section 2 1 A A 3 3 2 Separator section 3 3 3 Suction sectiON coccion 1 3 3 4 Conveyance section coccion 2 20 3 4 Registration Section 341 Outline reconnais na 3 4 2 Registration control Skew correction oconcocininicininononinonononos 2 21 4 Folding Section 4 1 Outline 4 1 1 Configuration 4 1 2 Folding operations 4 2 Folding Plate Section 2 26 ADV Dil cas 2 26 4 2 2 Folding stopper sections of folding plates Tand Zrniar 2 26 ix CONTENTS 4 3 Folding Roller Section ooooocin 2 28 4 3 1 Configuration 5 Paper Ejection Section ST OUUINC areas 5 1 1 Configuration 2 29 5 1 2 Paper ejection operations 2 29 5 2 Stacker Belt Section cece 2 30 5 2 1 Configuration i 5 2 2 Stacker belt drive ooocininininininininmmm 2 30 5 3 Stacker Roller Secti0N o ooco 2 31 5 3 1 Configuration 5 3 2 Lever unit drive oooccciononnoconcononcnncnninannos 2 31 Chapter 3 DISASSEMBLY ASSEMBLY 1 External Cover Control Section 3 2 1 1 External Cover Section 3 2 1 1 1 External
30. switch SW4 does not turn ON within the specified time TRAY UP ERROR The paper feed tray upper limit switch SW6 turns ON TRAY DOWN ERROR DUPLO DF 1000 12T M12M0 0602 0 The safety lever switch SW7 turns ON 2 LAYOUT OF ELECTRICAL PARTS 2 LAYOUT OF ELECTRICAL PARTS 2 1 Front of Unit Registration brake Remarks MC unit Control panel Switching power supply Power switch Safety lever switch Safety function parts Tray down button Thin paper feed button Suction solenoid switch DUPLO DF 1000 12T M12M0 0602 0 2 LAYOUT OF ELECTRICAL PARTS 2 2 Back of Unit MOT1 Main motor SW5 SW6 SOL1 MOT4 Remarks Paper feed tray motor Paper feed clutch Stacker belt clutch Registration clutch Suction solenoid Top cover R switch Safety function parts Side cover switch Safety function parts Folding plate switch Paper feed tray home switch Safety function parts Top cover L switch Safety function parts Paper feed tray upper limit switch DUPLO DF 1000 12T M12M0 0602 0 Safety function parts 2 LAYOUT OF ELECTRICAL PARTS 2 3 Inside Unit FAN2 Blower fan Remarks Suction fan Paper feed inlet sensor Light emitting side Paper feed inlet sensor Light receiving side Paper ejection outlet sensor A 6 Light receiving side
31. the following adjustments C Refer to Chapter 5 STANDARDS ADJUSTMENTS gt 3 2 3 Adjusting the suction conveyance unit position 2 2 2 Removing the suction belts 1 Remove the secondary roller of the suction conveyance unit 2 Remove the set collar and bearing on the paper feed shaft and remove the paper feed shaft 3 Remove the flat belts 3 6 DUPLO DF 1000 12T M12M0 0602 0 2 PAPER FEED SECTION 2 3 Registration Section 2 3 1 Removing the registration clutch CLH3 Remove the main cover B 2 Remove the drive bracket and remove the bearing 3 Remove the two E rings and remove the timing belt 4 Loosen the set screws FR of the registration clutch CLH3 Loosen the two set screws securing the rotor to the registration roller 5 Remove the cable clamp and remove the registration clutch CLH3 2 3 2 Removing the registration brake BRK1 1 Remove the main cover F 2 Remove the stacker unit CF Refer to 4 1 1 Removing the stacker unit 3 Remove the partitioning plate four screws 4 Loosen the nut brake side and remove the registration brake BRK1 When loosening the nut hold the registration roller with the hand to stop it from rotating 2 3 3 Removing the registration secondary roller 1 Remove the main covers F and B 2 Remove the lever at frame B 3 Remove the registration secondary roller 2 3 4 Removing the registration roller Remove the registration
32. the home position of the switching shaft In the single fold mode folding is not carried out by folding plate 2 The switching shaft restricts paper conveyance so that paper does not enter the folding plate 2 unit in the single fold mode Reference If this adjustment is not carried out appropriately problems may occur in the single fold mode These problems include paper jam at the folding roller and flattening of the lead edge of folded paper In the single folding of thin paper one folding wrinkle line occurs near the 15 mm position from the folded line 1 Check or adjust the attaching position of the switching adjusting plate CF7 Refer to 4 1 8 Adjusting the attaching position of the switching adjusting plate 2 Enter the maintenance mode 3 Check that the 3 SW BAR ADJUST correction value of the maintenance mode is the same as backup data form value C Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List 4 Press the clear key while pressing the stop key The folding stopper executes initial operations and the folding plate 2 folding stopper moves to the home position of the switching shaft 5 Press the speed key and correct the home position of the switching shaft With the folding plate 2 folding stopper at the home position of the switching shaft perform the following correction lt Adjustment value gt When the switching shaft 1 is gently pressed by finger the switching shaft sh
33. the paper feed inlet sensor PS10 detects the trail edge of the paper Reference The following is carried out for paper jams occurring after the paper feed inlet sensor PS10 detects the trail edge of the paper Internal jam The total count becomes 1 at the point of detection O Paper ejection section jam The total count remains 1 even if jam is detected DUPLO DF 1000 12T M12M0 0602 0 2 11 3 PAPER FEED SECTION 3 PAPER FEED SECTION 3 1 Outline 3 1 1 Configuration The functions of the paper feed section can broadly be divided into the paper feed tray section suction conveyance section and resistration section Paper feed tray Suction conveyance Registration section section section 1 1 3 4 1 Paper sensor PS8 lt DC 5 V photosensor light emitting and receiving separation type gt Detects the presence of paper on the paper feed tray 2 Paper feed tray sensor 1 PS7 lt DC 5 V photosensor gt Detects whether paper is at the paper feedable position 3 Paper feed tray sensor 2 PS9 lt DC 5 V photosensor gt Detects paper feed tray height 4 Paper feed inlet sensor PS10 lt DC 5 V photosensor light emitting and receiving separation type gt Detects paper feed state 2 12 DUPLO DF 1000 12T M12M0 0602 0 3 PAPER FEED SECTION 3 1 2 Paper feed operations Paper feed tray setting operations 1
34. the sensor is stacked on the tray NOTE Paper length is not detected Paper size is detected if paper is stacked in the short edge feeding direction d Side guide correction Side guide L Shield plate 15 Loosening the side guide adjusting knob enables fine adjustment of the fixing position of the side guide and skew correction of paper on the paper feed tray Side guide L Side guide adjusting knob Fulcrum A E m i 10 7 1 mm sO E m Side guide R Side guide adjusting knob Fulcrum DUPLO DF 1000 12T M12M0 0602 0 2 15 3 PAPER FEED SECTION 3 2 3 Tray up down section a Configuration Paper feed tray 1 Pinion 2 Rack Pinion Timing belt Pin screw spacer 1 Paper feed tray motor MOT4 lt DC 24 V DC motor gt Raises and lowers the paper feed tray 2 Paper feed tray home switch SW4 lt DC 24 V microswitch gt Detects the home position of the paper feed tray b Rise descent of paper feed tray The paper feed tray is raised and lowered by the paper feed tray motor MOT4 This motor raises and lowers the paper feed tray via the timing belt pinion and rack The rising position of the paper feed tray is detected by the paper feed tray sensor 1 PS7 and paper feed tray sensor 2 PS9 CF Refer to 3 1 2 Paper feed operations The home position of the paper feed tray is detected when the pin screw spac
35. to 1 and tighten the set screw 1 OO DUPLO DF 1000 12T M12M0 0602 0 5 9 3 PAPER FEED SECTION 3 2 3 Adjusting the suction conveyance unit position 1 Touch the angle 3 against the duct 4 so that the top surface 1 of the paper feed tray and suction belt surface 2 become parallel and then secure the angle 2 When the suction conveyance unit is lifted secure so that there is a clearance of about 1 mm between the paper feed tray upper limit switch SW6 and switch lever SW6 e peed OO TOTO 1 3 2 4 Adjusting paper feed tray sensor 1 PS7 position 1 Loosen the fixing screws of the plate 1 2 Move the level sensor adjusting lever 2 and adjust the distance between the top surface of the paper feed tray 3 and paper feed bracket 4 as shown in the figure Raise the paper feed tray in the maintenance mode CF Refer to Chapter 6 MAINTENANCE MODE gt 3 MENUS AND FUNCTIONS 3 Adjust the attaching position of the plate 1 so that the level sensor adjusting lever 2 does not exceed the distance in step 2 5 10 DUPLO DF 1000 12T M12M0 0602 0 3 PAPER FEED SECTION 3 2 5 Adjusting the suction solenoid SOL1 position Adjust the attaching position of solenoid base 1
36. troubleshooting methods when expected processing results are not obtained error messages and methods for resolving malfunctions Appendix Contains menu maps electrical parts layout board layout overall schematic diagrams and wiring diagrams This manual does not describe disassembly assembly procedures for all parts For details on parts not listed in this manual please refer to the separate Parts Catalog ii DUPLO DF 1000 12T M12M0 0602 0 PREFACE 2 SAFETY PRECAUTIONS In this manual operations and handling of the unit which are hazardous are described using the following marks to prevent personal injury or property damage to the user and others Ignoring this mark could result in the possibility of serious WARNING injury or even death CAUTION Ignoring this mark could result in the possibility of injury or physical damage A graphic may be shown inside the mark to describe the warning or caution more specifically This mark indicates a Warning or Caution This mark indicates a forbidden action O A graphic may be shown inside the mark to describe the forbidden action more specifically A graphic may be shown inside the mark to describe the action to be performed O This mark indicates actions that must be performed more specifically 2 1 Power Supply Make sure the power supply used is always within the following range O Power supply AC 120 V 60 Hz USA model AC 220 to 240 V 50
37. type Paper size Width x Length Max 297 x 432 mm Min 120 x 182 mm Standard size lt UK model gt A3 B4 A4 B5 A5 B6 lt USA model gt 11 x 17 LGR 8 5 x 14 LGL 8 5 x 11 LTR 7 x 8 5 STMT 5 5 x 8 5 INV Paper quality Paper weight Fine quality paper recycled paper art paper coated paper Fine quality paper recycled paper 52 3 to 157 g m Art paper coated paper 73 3 to 157 g m x However when single folding art paper or coated paper width less than 216 mm paper up to 209 4 g m can be used Curl amount The upper and lower curl amount should be above 130 mm in radius R the curl height H should be less than 5 mm without corrugation NOTE When using paper curled more than the above correct the curl DUPLO DF 1000 12T M12M0 0602 0 2 SPECIFICATIONS 2 4 Others 2 4 1 Power supply dimensions mass weight Item Contents Operating environment Storage environment 5 to 35 C 20 to 80 RH 10 to 50 C 10 to 90 RH x However no condensation Power supply USA model AC 120 V 10 60Hz 10 UK model AC 220 to 240 V 10 50 60 Hz 10 Current consumption Max 2 to 1 A 140 W Standby mode 14 W Acoustic noise Max 88 dB A Measuring method Machine installation conditions Install the unit on a desk of 600 mm in height Paper feed conditions B4 fine quality paper 64 g m double folding maximum
38. 0 0602 0 1 17 5 USER ADJUSTMENTS 5 4 2 Changing the stacker roller height If paper jams frequently at the stacker roller in the use of thick paper change the height of the stacker roller 1 Lift up the stacker roller 1 2 Turn down the lever 2 of the stacker support in the arrow direction NOTE After completing folding operations be sure to return the stacker roller to the original position 1 18 DUPLO DF 1000 12T M12M0 0602 0 6 USER MAINTENANCE 6 USER MAINTENANCE 6 1 List of Maintenance Items Maintenance Frequency Remarks Lower paper sensor Cleaning Paper dusts etc adhered near the sensor PS8 may cause misdetection Paper feed inlet Cleaning CF Refer to 6 2 1 Cleaning the sensors sensor PS10 Paper ejection outlet Cleaning upper sensor PS12 Paper ejection outlet Cleaning lower sensor PS12 Suction belt Cleaning If dirty folding misalignment and paper feed problems can occur Cy Refer to 6 2 2 Cleaning the suction belts Folding roller Cleaning If dirty folding misalignment and folding problems can occur C7 Refer to 6 2 3 Cleaning the folding rollers Stacker belt Cleaning If dirty paper ejection problems such as poor paper alignment etc can occur C7 Refer to 6 2 4 Cleaning the stacker belts 6 2 Cleaning by User NOTE Prior to cleaning be sure to turn off the power switch and disconnect the power cord plug from th
39. 0 2 25 4 FOLDING SECTION 4 2 Folding Plate Section 4 2 1 Outline The functions of the folding plate section can broadly be divided into the folding plate 1 folding stopper section and folding plate 2 folding stopper section Reference The basic structure is the same as DF 920 915 1 Folding plate 1 folding stopper section Performs the first folding position control 2 Folding plate 2 folding stopper section Performs the second folding position control 4 2 2 Folding stopper sections of folding plates 1 and 2 a Configuration Folding plate 1 folding stopper section 5 1 Folding plate 2 folding stopper section 1 Folding plate 1 stopper motor MOT2 5 Folding plate 2 stopper motor MOT3 lt DC 24 V DC motor gt Moves the folding stopper 2 Folding plate 1 index sensor A PS1 3 Folding plate 1 index sensor B PS2 6 Folding plate 2 index sensor A PS4 7 Folding plate 2 index sensor B PS5 lt DC 5 V photosensor gt Detects the index plate attached to the folding plate stopper motor and the distance moved by the folding stopper 4 Folding plate 1 home sensor PS3 8 Folding plate 2 home sensor PS6 lt DC 5 V photosensor gt Detects the home position of the folding stopper 2 26 DUPLO DF 1000 12T M12M0 0602 0 4 FOLDING SECTION b 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
40. 1 Stacker belt clutch CLH2 lt DC 24 V electromagnetic clutch gt Transmits drive from the main motor to the stacker belt 2 30 DUPLO DF 1000 12T M12M0 0602 0 5 PAPER EJECTION SECTION 5 3 Stacker Roller Section 5 3 1 Configuration Reference The basic structure is the same as DF 920 915 Stacker roller Lever unit If Lever unit J driving section 5 3 2 Lever unit drive When the folded size is set on the control panel the lever unit drives and the stacker roller moves automatically according to the finished size 1 Stacker roller home sensor PS11 lt DC 5 V photosensor gt Detects the home position of the stacker roller 2 Stacker roller moving motor MOT5 lt DC 24 V DC motor gt Motor for moving the stacker roller Controls the distance moved by the stacker roller together with the stacker roller home sensor PS11 DUPLO DF 1000 12T M12M0 0602 0 2 31 Memo 2 32 DUPLO DF 1000 12T M12M0 0602 0 Chapter 3 DISASSEMBLY ASSEMBL Y 1 EXTERNAL COVER CONTROL SECTION 1 EXTERNAL COVER CONTROL SECTION 1 1 External Cover Section 1 1 1 External cover 4 Main cover F No of screws for Remarks Paper feed lower cover Paper feed reinforcement plate cover Top cover L Top cover R Stacker side cover Main cover B Side cover Folding plate upper cover lela Ale rml e Folding plate lower cove
41. 3 4 5 6 7 When the paper feed inlet sensor PS10 detects the paper lead edge the MC unit starts the pulse count of the main motor MOT1 The paper lead edge touches the registration roller and the paper slacks When the pulse count becomes constant the registration clutch CLH3 turns ON to rotate the registration roller The skew of the paper is corrected by the rebounding force generated by the slack and the paper is pulled into the registration roller When the paper lead edge reaches the folding roller section the registration clutch CLH3 goes OFF and the registration roller idles The paper is pulled into the folding section by the folding roller The registration brake BRK1 turns ON after a certain period of time has passed from the detection of the paper trail edge by the paper feed inlet sensor PS10 and the registration roller stops rotating 2nd sheet onwards 8 9 When the paper feed inlet sensor PS10 detects the paper lead edge the registration brake BRK1 goes OFF Hereafter steps 2 to 7 are repeated 10 After processing the set number of sheets the main motor MOT1 stops and at the same 2 22 time the registration brake BRK1 goes OFF DUPLO DF 1000 12T M12M0 0602 0 4 FOLDING SECTION 4 FOLDING SECTION 4 1 Outline 4 1 1 Configuration The functions of the folding section can broadly be divided into the folding plate section and folding roller section Fol
42. 3 2 3 Adjusting the suction conveyance unit POST sereins naa 5 10 3 2 4 Adjusting paper feed tray sensor 1 PST pOsitiON aria 5 10 3 2 5 Adjusting the suction solenoid SOL1 A O E ETE 5 11 3 2 6 Adjusting paper feed tray sensor 2 PS9 position sass duaanaia 5 11 4 Folding Section 5 12 4 1 Folding Plate Section 5 12 4 1 1 Adjusting the parallelity of the folding A rro aatar EARS E 5 12 4 1 2 Adjusting the home position of the switching shaft coccion 5 14 4 1 3 Adjusting the home position of the folding stopper 5 15 4 1 4 Checking the conveyance path gap of folding plate areon 5 16 4 1 5 Adjusting the gap of the screw shaft Wii 5 16 4 1 6 Adjusting the motor deceleration pulley A r Er AEA 5 17 4 1 7 Adjusting the folding stopper section 5 18 4 1 8 Adjusting the attaching position of the switching adjusting plate 4 2 Folding Roller Section 00 cece DUPLO DF 1000 12T M12M0 0602 0 4 2 1 Adjusting the attaching position of the press spring T se 5 19 4 2 2 Adjusting the gap of folding roller 1 5 19 4 2 3 Checking the folding roller nip 5 20 4 2 4 Adjusting the attaching position of the conveyance plate oes 5 21 4 2 5 Adjusting the connecting plate 5 21 5 Paper Ejection Section ws 5 22 5 1 Stacker Belt Section saccisi osorssrrras 5 22 5 1 1 Adjusting the tention of the stacker A nates 5 22 5 2 Stacker Roller Section 0 0 0 5 22 5 2 1 Adjusting the tentio
43. 501 Troidal Clamp Core 2turn FE3 1122_YELLOW 1126_SKYBLUE Y SE 6001 YELLOW Stacker Roller Home Sensor 005_PURPLE PS11 x Up Doun a 7 BROWN 7 8007 SKYBLUE 7 5008 3 6004_SKYBLI 008 PURA z Weight Wheel T 2 HOTS 052 1031 961 3146 DC24v 143m4 PS12b PS12a Peper Ejection Sensor Paper Eject ion Sensor 4 OVERALL SCHEMATIC DIAGRAM 6001_ YELLOW 002_BLUE T 2 3 062 11095 062 11006 5007_BROUN CLH2 00087 PCB3 aa Power supply PSW Troidal Clemp Corel2turn Apel Intet 12178168 ZMSISOPAF 24 J Powersey een po n ocedv 250nA A AMO Brack o BLACK FEI AD Al Register Clutch iE Vo Swine db 12T 85022 A 13 Memo A 14 DUPLO DF 1000 12T M12M0 0602 0 5 WIRING DIAGRAM 127 5008 056 00876 i 054 10116 ae 05410248 Microswitch 056 00876 05410248 Microswitch aa SK binder Frame B 3302 Microswitch 3303 COM Light blue O NO Light blue zx 10 O a ea Oe o gt Me 3302 N 121 8210 D 12H 5333 E i i 7 COM Gray ET 12H 5333 COM Purple Ne Bundled wire unit 10 3304 witch angle Switch angle T Yellow are 12T 8016 SW angl O O O cluich unit e angle NO 054 10248 127 2462 056 00876 Light blue Microswitch T N Solenoid base unit SK binder 12H 5333 O Switch angle T COM
44. 8202 Bundled wire unit 2 057 10054 Switching power supply 2 2 Q a or 3303 J10 J11 3303 o o 9 N os6 10101 056 0876 1 Spacer x 4 SK binder s 3304 3304 a 1 056 00876 SK binder Note Secure the section so that bundled wires are not slacking 127 2439 Suction duct C 12T 8208 Bundled wire unit 8 Suction duct A DN 127 8101 127 2442 Fan bracket 127 8208 Fan motor unit Bundled wire unit 8 127 8208 Bundled wire unit 8 12T 2438 Suction duct B 052 10031 Toroidal clamp core USA model 127 8201 Bundled wire unit 1 96Y 8007 PR P W B unit 056 10499 Spacer x 2 96V 8026 PS P W B unit 3305 8 _ va e Paper feed reinforcement plate Bundled wire a 3304 e 3304 127 5013 127 8210 unit 10 UK model ES 127 8201 Bundled wi
45. CTION SECTION 5 PAPER EJECTION SECTION 5 1 Outline 5 1 1 Configuration The functions of the paper ejection section can broadly be divided into the stacker belt section and stacker roller section 2 Stacker roller section oe aegis ant Po o q 2 1 uu cy Stecker belt section 1 Stacker roller home sensor PS11 CF Refer to 5 3 2 Lever unit drive 2 Paper ejection outlet sensor PS12 lt DC 5 V photosensor light emitting and receiving separation type gt Detects paper ejection 5 1 2 Paper ejection operations 1 Folded paper is ejected by folding roller 3 and ejection roller 2 Ejected paper is conveyed to the paper receiving tray by the stacker roller and stacker belt DUPLO DF 1000 12T M12M0 0602 0 2 29 5 PAPER EJECTION SECTION 5 2 Stacker Belt Section 5 2 1 Configuration Reference The basic structure is the same as DF 920 915 Shaft coupling Stacker belts 5 2 2 Stacker belt drive This unit intermittently drives the stacker belt to enhance stacking performance and processing speed The drive of the stacker belt is transmitted from the main motor via the stacker belt clutch CLH2 and shaft coupling AOS Whee pos we A lr o O Stacker belts Timing belt N 1 1 1 1 l Main motor MOT1 1 1 N
46. Detects the open close of the top cover R TOP COVER R OPEN When the top cover R is detected as open this message appears on the control panel 7 Side cover switch SW2 lt DC 24 V microswitch gt Detects the open close of the side cover SIDE COVER OPEN When the side cover is detected as open this message appears on the control panel 2 8 DUPLO DF 1000 12T M12M0 0602 0 2 EXTERNAL COVER CONTROL SECTION 8 Folding plate switch SW3 lt DC 24 V microswitch gt Detects the presence of the folding plate F PLATE SET ERROR When the folding plate cannot be detected this message appears on the control panel 9 Top cover L switch SW5 lt DC 24 V microswitch gt Detects the open close of the top cover L TOP COVER L OPEN When the top cover L is detected as open this message appears on the control panel 10 Paper feed tray upper limit switch SW6 lt DC 24 V microswitch gt Detects the upper limit position of the paper feed tray TRAY UP ERROR When the upper limit position of the paper feed tray is detected this message appears on the control panel 11 Safety lever switch SW7 lt DC 24 V microswitch gt Detects the ON OFF of the safety lever TRAY DOWN ERROR When the safety lever turns ON this message appears on the control panel b Operations One of the following switches activate SW1 SW2 SW3 SW5 or SW6 2 The interlock relay RL1 on the MC unit goes
47. ERROR is displayed 1 Are there foreign particles between the paper feed tray and safety lever Yes Remove the foreign particles 2 Is the attaching position of the safety lever switch SW7 appropriate CF7 Refer to Chapter 5 STANDARDS ADJUSTMENTS gt 2 1 1 Adjusting the interlock switch position No Adjust 3 Is the safety lever switch SW7 normal CF Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the switch Yes Replace the MC unit DUPLO DF 1000 12T M12M0 0602 0 7 9 3 TROUBLESHOOTING BY MESSAGE DISPLAYED 3 4 Other Messages 3 4 1 When NO PAPER is displayed 1 Is the paper sensor PS8 normal C Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the sensor Yes Replace the MC unit 3 4 2 When TOP COVER L OPEN is displayed 1 Is the attaching position of the top cover L switch SW5 appropriate C Refer to Chapter 5 STANDARDS ADJUSTMENTS gt 2 1 1 Adjusting the interlock switch position No Adjust 2 Is the top cover L switch SW5 normal C7 Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled w
48. Input Error si 1 3 Cover Ope usd 1 4 Paper Jam ErTO kitsai A 2 10 UroUbDlS acti 2 Layout of Electrical Parts 2 1 Frontof Unit sissies 2 2 Back of Unit cid 2 3 Inside Unicorn 2 4 Paper Feed SectiON occccicnniicinnnnnimmmm 2 5 Folding Plate Section He 2 6 Paper Ejection Section oococcii 3 Layout of Boards sesers 3 1 MC Unit i 3 2 Control Pane l 3 3 Switching Power Supply ai 3 4 PS PWB Unico rai pios A 11 4 Overall Schematic Diagram A 13 5 Wiring Diagram sesers A 15 DUPLO DF 1000 12T M12M0 0602 0 Chapter 1 INTRODUCTION 1 FEATURES 1 FEATURES 1 Supports five types of standard folding modes and custom folding mode Standard folding Single fold double fold irregular accordion fold letter fold accordion fold Custom folding Two types can be registered as keys 2 Maximum processing speed is 200 sheets minute A4 single fold Maximum processing speed for 8 5 x 11 LTR single fold is 207 sheets minute 3 Supports wide types of art and coated paper 4 Holds large volume of paper More than 1 000 sheets of paper can be stacked on the paper feed tray 5 Adopts the air suction paper feed method Stable and high speed paper feed is realized by the adoption of the air suction paper feed method used in the collator system 6 Skew correction Use of skew rollers registration rollers corrects skewing of paper 7 Opera
49. Key Operations are Disabled on Control Panel 1 2 3 4 Is there any key which remains pressed Yes Unpress it and check for key input problems Are the following connectors connected normally e MC unit J6 e Control panel CN1 No Re connect the connectors Are the bundled wires between the connectors of step 2 disconnected or short circuited Yes Replace the bundled wires Check for problems in the electric parts of the part connected to and replace if faulty Is the problem resolved by replacing the control panel Yes End No Replace the MC unit 4 4 Misdetection of Standard Paper Sizes Occurs 1 Is the PS P W B unit PCB4 normal Cy Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List 7 12 If the PS P W B unit PCB4 does not operate the paper size may be detected as B6 or INV after power ON For USA model when stacking 8 5 x 11 LTR size paper on the paper feed tray if the rear guide etc is pressing against the legal paper detection sensor PS13 the paper will be incorrectly detected as 8 5 x 14 LGL size paper Take note that this unit does not detect PS P W B unit PCB4 problems No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the PS P W B unit Yes Replace the MC unit DUPLO DF 1000 12T M12M0 0602 0 Appendix DUPLO DF 1000 12T M12
50. M 2 S PUT SuN 062 10917 G PUT_SW_COM TIULIN SH NC PS8a PS8b 8 ULIM_SW COH S PSET_SW_NO 16 PSET_SH_COM MIR Cc SW_NO 12R_C SH_COM EMi2T Paper Set Sensor Vee Paper Set Sensor Main Motor ytl z PHOTO 10 Y T 4009_PURPLE 40 KYBL oc MOTOR MOTA 36 8007 0301 PINK 24V 60W 12H 8101 AQ17_PINK 018_SKYBLU Down Limit SW M 054 10243 4023 PURPLE 024 BL SW4 Blower Fen FANT 051 10172 I24V 1 34 Top Cover Left SW SW5 9054 10248 Feed Tray Upper Limit SW SW6 Suct ion Fan 054 10406 Paper Feed Tray Sensor 2 3 1 2 FAN2 Shox Register Brake 0 T e240 3A Z Stop Bar Under Feed Trey 116 8230 CNI UK model PCB4 F 7l 4017 PINK 4017_PINK con No OC24V 197mA PSI 2 2019 PURPLE i SW e TSE ese 32 YELL 4020 PS P W B UNIT PS3 ADA 7 gt 9 96V 8016 PS4 S A022 SETETE Doun Button PSs 023 PORE PS CIRCUIT DIAGRAM ess Tagea BLUE dl e Y PHOST SA USA model PCB4 PS crea DIAGRAM 6V 8028 Feed Tray Motor Solenoid SW T 2 T CE ION RED 4017_PINK 0408 PURPLE 2 BLACK MOT4 SW9 114 8038 DC24V 380mA 121 8302 PS10a PS10b Paper Feed Sensor Paper Feed Sensor 1116_SKYBLUE f z 3 Main Circuit Diagram 127 8
51. M0 0602 0 1 LIST OF DISPLAYED MESSAGES 1 LIST OF DISPLAYED MESSAGES 1 1 No Paper Detection details NO PAPER The paper sensor PS8 detected no paper on the paper feed tray 1 2 Key Input Error TOO SHORT Enter value outside specifications for Setting Non standard Paper TOO LONG Length Registering Custom Folding or Correction Registration OUT OF CORRECT 1 3 Cover Open TOP COVER L OPEN The top cover L switch SW5 detected that the top cover L is open TOP COVER R OPEN The top cover R switch SW1 detected that the top cover R is open SIDE COVER OPEN The side cover switch SW2 detected that the side cover is open 1 4 Paper Jam Error Detection details The folding plate switch SW3 cannot detect the folding plate FEED ERROR Mis feed The paper feed inlet sensor PS10 does not detect the paper lead edge even after some time from the ON of the paper feed clutch CLH1 JAM FEED SECT Continuous feed The paper feed inlet sensor PS10 does not detect the paper trail edge even after paper size set certain time after the sensor detected the paper lead edge Paper feed section paper jam The paper feed inlet sensor PS10 does not detect the paper trail edge even after some time from the detection of continuous feed JAM INSIDE The paper ejection outlet sensor PS12 does not detect the paper lead edge within a certain period of time 1 after detection of the paper lead edge
52. M0 0602 0 4 CONTROL PANEL 4 2 User Menu Function Setting Mode This section summarizes the information provided in the instruction manual For details refer to the instruction manual The in the Setting 2nd line display column indicates setting at shipment Selection of function Mode key Selection of setting Speed key Input of values Numerical keys Confirmation of settings Stop key Function Setting 1st line display 2nd line display SAO ae OFF Set and register the paper length when standard 182 to 432 mm folding non standard paper NOTE To insure the quality of the fold when paper width is 120 mm it is recommend not to exceed 240 mm in length The paper length data registered is erased when the power is turned off To save the registered data set the operation mode to the last time fold mode NORMAL Setting for shortening the operation procedure LAST TIME FOLD Normal mode STOPPER FIXED There is a need to perform various settings in each use The unit will perform initialization operations when the power is turned ON Last time fold mode Function which starts the unit at the settings used the last time when the power is turned ON When set to this mode the following will be set automatically at power ON O Folding mode O Stacker roller position O Processing speed Folding stopper fixed mode When set to this mode the following settings will be fixed Theref
53. OFF 3 The 24 VA supplied to the motor driver from RL1 goes OFF 4 All motors MOT1 to 4 stop DUPLO DF 1000 12T M12M0 0602 0 2 9 2 EXTERNAL COVER CONTROL SECTION 2 2 Main Motor Control 2 2 1 Outline cc gt MC unit Index signal r r Driving signal tr 1 Main motor MOT1 lt Input DC 24 V output 60 W brushless motor gt During processing this motor rotates constantly to drive each part 2 2 2 Operations The processing speed of this unit is controlled by varying the rotational speed of the main motor based on the control signal from the MC unit The processing speed can be switched in five steps using the speed key on the control panel Reference Actual value measured Condition When 64 g m fine quality paper is single folded Processing speed sheets minute A3 8 5 x 11 LTR 11 x 17 LGR Speed key setting 5 Fast 1 Slow 2 10 DUPLO DF 1000 12T M12M0 0602 0 2 EXTERNAL COVER CONTROL SECTION 2 3 Counter 2 3 1 Outline This unit does not have an electromagnetic counter Total counting for maintenance is performed on the program and recorded in the EEPROM U1 on the MC unit The total count recorded in the EEPROM U1 can be checked in the maintenance mode CF Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List 2 3 2 Operations The total count increases when
54. SERVICE MANUAL DF 1000 Duplo Feb 2006 Revision 0 Purpose This manual describes technical specifications of the product for service persons to understand the operational principles of the product so that they can carry out appropriate maintenance and repair work on the market This manual provides information applying to all countries in which the product is sold as well as information which may not apply to certain countries Revision The information contained in this manual is subject to change due to product improvement etc When information is changed this manual will also be revised Please check with quality service information issued as required until the manual is revised Trademark The product name and company name used in this manual are the trademark or registered trademark of the respective companies Note This manual must be handled with extreme caution particularly ensure against leakage of technical details DUPLO DF 1000 12T M12M0 0602 0 PREFACE PREFACE Most accidents occur due to the failure to observe basic safety rules and precautions To prevent accidents it is important to prevent their causes Service persons of this product hereafter referred to as SP must therefore attend servicing skill seminars before carrying out servicing and read this manual thoroughly to fully understand safety precautions appropriate servicing procedures and methods Failure to do so will result in unexpecte
55. T 1 Ww 127 8206 127 3203 Folding plate 2 Motor bracket 98R 8023 Photointerrupter 12H 3076 Bundled wire unit 6 127 4255 Sensor bracket 127 4248 Motor bracke 5 F a 4 12T 3002 Folding plate 1 unit o 12H 8111 motor unit 062 10964 056 00876 3302 Ga E o o Photointerrupter SK binder 12H 3075 al Sensor bracket H sas 12H 3062 Motor bracket 98R 8023 Photointerrupter 12H 3076 Sensor bracket ole 124 3079 056 00876 SK binder Bundled wire bridge 056 00003 Bushing OCB 500 127 8207 Bundled wire unit 7 if F el Bundled wire bridge 1 o o 056 00003 Bushing OCB 500 056 00876 SK binder Gray Light blue Pink EE View of Yellow Light blue Pink Light blue Purple l 98R 8023 Photointerrupter L gt 121 8203 Bundled wire unit 3
56. UPLO DF 1000 12T M12M0 0602 0 2 EXTERNAL COVER CONTROL SECTION 2 EXTERNAL COVER CONTROL SECTION 2 1 External Cover Section 2 1 1 Adjusting the interlock switch position a Top cover R switch SW1 Side cover switch SW2 Top cover L switch SW5 lt Adjustment value gt When each cover is closed the clearance A should be 1 0 0 2 mm 1 Fixing screw Loosen 2 2 Sensor bracket b Folding plate switch SW3 lt Adjustment value gt When the folding plate is set the clearance A should be 1 0 0 5 mm 1 Fixing screw Loosen cooocccooncnonnnonnc nnanono 2 2 Sensor bracket c Safety lever switch SW7 lt Adjustment value gt When the paper feed tray is at the lower limit position the clearance B should be 0 7 0 2 mm 1 Fixing screw Loosen ocococccnonccococonncnnnnnono 2 2 Sensor bracket DUPLO DF 1000 12T M12M0 0602 0 5 3 2 EXTERNAL COVER CONTROL SECTION 2 2 Drive Section 2 2 1 Adjusting the tention of the timing belt 20O a Drive belt of main motor section lt Adjustment value gt When a load of 3 N is applied vertically to the belt at measuring point A the slack should be 2 to 4 mm 1 M
57. USER ADJUSTMENTS 5 USER ADJUSTMENTS 5 1 List of Adjustments Adjustment contents Remarks Skew correction C3 Refer to 5 2 1 Skew correction by side guide adjusting knob Correction of folding Correction method when paper trimming misalignment misalignment along sides occurs of paper C Refer to 5 2 2 Skew correction by skew correction knob Correction method when folding misalignment is inconsistent and this is thought to be caused by paper thickness C7 Refer to 5 2 3 Using the skew roller spring pressure adjusting knob Folding position correction C Refer to 5 3 1 Folding position correction by folding mode Correction of folding misalignment along vertical length of paper Change of stacker roller Adjustment method when paper alignment on the paper position receiving tray is poor C Refer to 5 4 1 Changing the stacker roller position Change of stacker roller Adjustment method when paper jams frequently at the height stacker roller in the use of thick paper etc CF Refer to 5 4 2 Changing the stacker roller height 5 2 Paper Feed Adjustments 5 2 1 Skew correction by side guide adjusting knob Before correcting check that the skew roller 11 spring pressure adjusting knobs are set at the same position for the left and right sides If their positions differ folding misalignment may occur CF7 Refer to 5 2 3 Using the skew roller spring pre
58. YBLUE 0402 PURPLE 9483 YELL 015 SK 001_SKY sail 1002 PURPLE 5024 PURPLE 2024 PURPLE 1913_Sk 1014P af RI ae Clamp Filter 2turn 9601 SKYBLUE 0601_SKYBLUE Top Cover Right SW oa con n5001 YELLOW 05410248 5002 GRAY 0703_ YELLOW swt 1019 PINK OP CIRCUIT DIAGRAM 12H 8302 0607 ORANGE 0607_ORANGI 014 3014_BLUE ac SKY 500 BROWN 908_PURPL Right Lower Door SW COR no 5003_YELLOW E 5004_ PURPLE 052 10052 10248 sw2 Infeed Clutch BLUE BLUE 5011_ BROWN Q14_GRAY T 2 CLH1 1 5005 BROWN 7 5006_SkYBLU 121 8017 DC 4V 250n4 Stacker Belt Clutch BLUE AC120V 60Hz AC220 240V 50Hz Detachable Power Supply Cord 055 10209 1055 10212 BLUE Elle 7 3099_BROWN CLH3 i m 054 10308 Ac250w 154 rae k k 05270031 E DABA 20ra NPSN Suct ion On OFF E IO GREEN YELLOW fg GND YELLOW 911 SOL YELLOW 5012_GRAY 056 10357 94X 8021 DC24V 330mA Paper Stop Box SW com no 5013_SKYBLUE 0541828 ora Ray For Writing On FPGA Flash Memory Sw3 J TOP 1_NO 9701_PURPLE KYI A TOP2_COM Peper Feed Tray Sensor 3 PS7 4001 SKYBLUE 4 10P2_CO
59. ain motor Adjusting SCTOW cocconoccnccoonnnncnnnnnnonnnonncnnno 2 b Drive belt of registration roller folding roller paper ejection section lt Adjustment value gt When a load of 3 N is applied vertically to the belt at measuring point B the slack should be 4 to 6 mm 2 Idler roller Adjusting SCrew essees 2 c Drive belt of tray up down section lt Adjustment value gt When a load of 3 N is applied vertically to the belt at measuring point C the slack should be 3 to 5 mm 3 Paper feed tray motor Adj sting SCT Wosessisnorainanii 4 d Other drive belts lt Adjustment value gt Do not tauten the drive belts D E and F excessively 5 4 DUPLO DF 1000 12T M12M0 0602 0 2 EXTERNAL COVER CONTROL SECTION 2 2 2 Attaching position of motor pulley a Main motor MOT1 Attach the motor pulley as shown in the 2 figure 1 Motor pulley m S 2 Frame B EB _ i f 37 mm 62 0 5 mm b Paper feed tray motor MOT4 Attach the motor pulley as shown in the 7 figure 1 Motor pulley 4 14 ron i ld a DUPLO DF 1000 12T M12M0 0602 0 3 PAPER FEED SECTION 3 PAPER FEED SECTION 3 1 Paper Feed Tray Section 3 1 1 Adjusting the paper feed tray position 1 Adjust the attaching position of the left and right racks and set the paper feed tray horizontally Ul Rack insano Left and right one each Adjusting screw
60. ate upper cover and folding plate lower cover 4 Remove the fixing screws of the connecting plate at folding plate 1 unit and remove the folding plate 1 unit NOTE Do not remove the fixing screws of the connecting plate at folding plate 2 unit and remove the connecting plate As the connecting plate is adjusted by tool at assembly it cannot be adjusted on the market 5 Remove the motor bracket 6 Remove the timing belt 7 Remove the folding plate stopper motor 3 1 3 Removing the folding plate index sensors PS1 PS2 PS4 PS5 1 Disconnect the folding plate connector and remove the folding plate 2 Remove the folding plate lock lever 3 Remove the folding plate upper cover and folding plate lower cover 4 Remove the fixing screws of the connecting plate at folding plate 1 unit and remove the folding plate 1 unit NOTE Do not remove the fixing screws of the connecting plate at folding plate 2 unit and remove the connecting plate As the connecting plate is adjusted by tool at assembly it cannot be adjusted on the market 5 Remove the sensor bracket 6 Remove the connector 7 Remove the folding plate index sensor 3 8 DUPLO DF 1000 12T M12M0 0602 0 3 FOLDING SECTION 3 1 4 Removing the folding plate home sensors PS3 PS6 Disconnect the folding plate connector and remove the folding plate 2 Remove the folding plate lock lever 3 Remove the folding plate upper cover and folding plate
61. bility features and additional functions succeeded from DF 920 1 2 DUPLO DF 1000 12T M12M0 0602 0 2 SPECIFICATIONS 2 SPECIFICATIONS Specifications and dimensions are subject to change without prior notice for improvements 2 1 Type and Method Item Contents Type Desktop paper folder Paper feed method Belt suction method by fan Air suction paper feed method Folding method Paper ejection section conveyance method Press roller folding stopper method Stacker roller flat belt conveyance method 2 2 Performance and Functions 2 2 1 Processing performance Item Contents Paper feed tray capacity Maximum stacking height 100 mm 1000 sheets fine quality paper 81 4 g m 1250 sheets fine quality paper 64 g m Folding mode Standard folding single fold double fold irregular accordion fold letter fold accordion fold custom folding Maximum UK model processing 200 sheets minute A4 140 sheets minute A3 x When 81 4 g m fine quality paper is single folded speed USA model 207 sheets minute 8 5 x 11 x When 81 4 g m 20 lb fine quality paper is single folded Folding misalignment A 1 0 mm or less B 0 5 mm or less C 1 5 mm or less A A OS DUPLO DF 1000 12T M12M0 0602 0 D 0 5 mm or less 2 SPECIFICATIONS a Folding mode condition 1 For single fold art paper or coated paper up to 209 4 g m can be u
62. by the paper feed inlet sensor PS10 JAM EXIT The paper ejection outlet sensor PS12 does not detect the paper trail edge even after finished size certain time after the sensor detected the paper lead edge 1 Calculated from conveyance distance inside the unit The conveyance distance inside the unit changes according to the positions of the folding stoppers A 2 DUPLO DF 1000 12T M12M0 0602 0 1 LIST OF DISPLAYED MESSAGES 1 5 Trouble Message Detection details MOTOR ERROR 1 The index sensor in the main motor cannot detect the main motor MOT1 rotation MOTOR ERROR 4 The folding plate 1 index sensor A PS1 folding plate 1 index sensor B PS2 cannot detect the rotation of the folding plate 1 stopper motor MOT2 MOTOR ERROR 5 MOTOR ERROR 3 The folding plate 2 index sensor A PS4 folding plate 2 index sensor B PS5 cannot detect the rotation of the folding plate 2 stopper motor MOTS3 During detection of the stacker roller home position the stacker roller home sensor PS11 does not turn ON within the specified time While the stacker roller is moving the stacker roller home sensor PS11 does not turn OFF within the specified time MOTOR ERROR 2 While the paper feed tray is rising the paper feed tray sensor 1 PS7 and paper feed tray sensor 2 PS9 do not turn ON within the specified time While the paper feed tray is descending the paper feed tray home
63. conveyed to the registration section by the conveyance roller and hits the stationary registration roller skew correction 9 The registration roller rotates registration brake OFF registration clutch ON and paper is conveyed to the folding roller DUPLO DF 1000 12T M12M0 0602 0 2 13 3 PAPER FEED SECTION 3 2 Paper Feed Tray Section 3 2 1 Outline The functions of the paper feed tray section can broadly be divided into the side guide section and tray up down section 1 Side guide section Aligns the width of paper stacked on the paper feed tray and also detects paper size 2 Tray up down section Rises and descends to the paper feed position according to the volume of paper on the paper feed tray 3 2 2 Side guide section a Configuration Shield plate Side guide adjusting knobs Left side pulleys Side guide Side guide Right side pulleys timing belts timing belts 1 PS P W B unit PCB4 Detects paper width Composed of photosensors 2 14 DUPLO DF 1000 12T M12M0 0602 0 3 PAPER FEED SECTION b Movement of side guide Rotating the side guide dial moves the side guide via the pulley and timing belt on the dial shaft c Paper size detection The side guide L bracket is mounted with a shield plate which also moves along the paper width when the side guide L moves When this shield plate blocks the sensor on the PS P W B unit this unit detects that paper of the width corresponding to
64. ctrical shock be used for an extended period Failure to do so could result in a fire due to leakage current if the insulation should deteriorate Always disconnect the power plug from the power outlet when the unit is not to 2 3 Maintenance etc N WARNING Do not damage the power cord or power plug Do not scratch alter bend twist pull or place heavy objects on the power cord or power plug This could result in damage a fire or an electrical shock Do not handle the power plug with wet hands This could result in an electrical shock Do not use flammable sprays inside or near the unit e g when cleaning the unit Such flammable gas may ignite and cause a fire or combustion Take precautions against fire and ensure ventilation when using alcohol and store the alcohol in a safe place after use Also note that use of other solvents can damage the rubber rollers and resin inside the unit resulting in malfunctions If any foreign object such as metal or liquid should enter this unit immediately turn the unit off at the power switch and disconnect the power plug from the power outlet Failure to do so could result in a fire or an electrical shock Before cleaning this unit turn the unit off at the power switch and disconnect the power plug from the power outlet Accidental operation of the unit during cleaning could result in injury Before beginning servicing work turn the unit off at the
65. d accidents Since it is not possible to list all imaginable dangers which may occur during servicing the SP must carry out servicing with extreme care to ensure safety at all times in addition to observing the precautions labeled on the product and indicated in this manual DUPLO DF 1000 12T M12M0 0602 0 PREFACE 1 ORGANIZATION OF THIS MANUAL This manual describes information required for carrying out servicing work of this product in the following chapters Chapter 1 INTRODUCTION Provides information for the user such as system configuration features specifications names of parts user menu user maintenance etc Chapter 2 OPERATIONS Describes the mechanism control methods of the whole product and each part Chapter 3 DISASSEMBLY ASSEMBLY Describes the parts to be replaced regularly consumables recommended spare parts boards and disassembly assembly procedures of main units Chapter 4 MAINTENANCE INSPECTION Lists tools solvents lubricants required for servicing work lists parts to be replaced regularly consumables and recommended spare parts and describes periodic servicing methods Chapter 5 STANDARDS ADJUSTMENTS Describes mechanical and electrical adjustment methods and standard values Chapter 6 MAINTENANCE MODE Describes check menus for servicing work simulation modes procedures for checking operations of electrical parts procedures for upgrading version etc Chapter 7 TROUBLESHOOTING Describes
66. d at the same time vertical to the paper feed tray 2 To adjust the tension of the belt for moving position and secure the timing pulley so that when a load of 1 N 102 gf is applied near the belt center A with a 5 N 510 gf tension gauge the belt slackens by 3 to 5 mm 360 mm gt a gt O tz 000000 Bi U o gt E 73 mm 210 mm 73 mm o ie 5 8 DUPLO DF 1000 12T M12M0 0602 0 3 PAPER FEED SECTION 3 2 Suction Conveyance Section 3 2 1 Adjusting the separating air adjusting knob position 1 Loosen the set screw of the separating air adjusting knob 1 Separating air adjusting knob Set screw 2 Slide the shutter in the arrow direction until it stops 2 Shutter 3 Adjust the separating air adjusting knob to 1 and tighten the set screw lt 21 rt U PA o III RS fee S A a zo 3 2 2 Adjusting the separator adjusting knob position 1 Loosen the set screw of the separator adjusting knob 1 Separator adjusting knob Set screw 2 Slide the bracket in the arrow direction until it stops 2 Bracket 3 Adjust the separator adjusting knob
67. ding roller Folding plate section section 1 Part name Part name Folding plate 1 Folding roller 1 Folding plate 2 Folding roller 2 Idler roller Folding roller 3 Center press roller 4 1 2 Folding operations a Outline First folding 1 Paper conveyed from the registration roller is conveyed by the idler roller and center press roller and touches the folding stopper of folding plate 1 2 The paper is continuously fed touching the folding stopper of folding plate 1 and slacks 3 The slackened part of the paper is sandwiched between the center press roller and folding roller 1 First folding Second folding 4 The paper is conveyed by the center press roller and folding roller 1 and touches the folding stopper of folding plate 2 For single fold paper is conveyed to the paper ejection section by folding rollers 2 and 3 5 The paper is continuously fed touching the folding stopper of folding plate 2 and slacks 6 The slackened part of the paper is sandwiched between folding roller 2 and folding roller 3 Second folding Paper ejection 7 Paper is conveyed to the paper ejection section by folding rollers 2 and 3 DUPLO DF 1000 12T M12M0 0602 0 2 23 4 FOLDING SECTION b Single fold 2 24 DUPLO DF 1000 12T M12M0 0602 0 4 FOLDING SECTION e Letter fold DUPLO DF 1000 12T M12M0 0602
68. e 5 22 DUPLO DF 1000 12T M12M0 0602 0 Chapter 6 MAINTENANCE MODE 1 OUTLINE 1 OUTLINE This unit has the following functions to ensure smooth servicing work O Maintenance menu O Data initialization The maintenance menu of this unit can broadly be divided into the following four types Data initialization is used for erasing data in the EEPROM U1 when problems occur a Adjustment Menu for adjusting each part Code No 1 to 3 11 12 28 b Settings Menu for performing function settings such as destination display unit display language settings changing standard settings of the user menu checking the total counter checking the program version etc Code No 4 to 10 14 to 16 c Version upgrade Menu for upgrading the program version Code No 18 d Test checks Menu for checking operations such as LEDs 7 segment window switches sensors motors clutches etc Code No 21 to 27 31 to 36 6 2 DUPLO DF 1000 12T M12M0 0602 0 2 MAINTENANCE MODE OPERATIONS 2 MAINTENANCE MODE OPERATIONS 2 1 Entering the Maintenance Mode There are two ways of entering the maintenance mode a Method 1 1 Turn off the power switch 2 While pressing the start and stop keys together turn ON the power switch Upon entering the maintenance mode MAINTENANCE MENU will appear on the LCD b Method 2 1 Enter 920 using the numerical keys while the initial screen or error message i
69. e Yelow Ka a A Photointerrupter Bundled wire unit 9 I 1 Nos H 3303 3303 3303 4 Ir e et Uh i g e D 127 2428 So 1 View of 2 SW bracket ot q M A y l To nc inlet i White Black e 96V 9039 er My To switching Ap LS To switching Bracket Paper feed tray f j power supply 3 power supply i bottom cover i l E I rif I ae I TE ll iy ll ies l ll 1 it l i pa i iy 127 2437 I i l h i eae f i ll il A paa ee ee ee ee eee eo E 12T 5073 SW bracket 12T 8301 Switch unit 056 10078 Inlet 054 10308 _ Power switch E A 12H 5501 Switch unit Frame F OPS AAA et ee a E SE AE Ie ES Perl ros E ETA om MY 5 EE gt 0 N 056 00876 1 SK binder 12H 8605 3303 A 3302 OP P W B unit 052 10052 C Clamp filter C O 2 turns 3303 E aL led wire unit 1 O O O Bushing 3304 3304 OCB 1375 T 056 10216 054 10116 Light blue 3330 W Spacer x 4 Microswitch o 2 Ea es A J4 C O 4 5 COM Purple 3302 12T 8001 12H 5061 o MC unit SW bracket B 127
70. e outlet After cleaning make sure that the areas that were cleaned are completely dry before connecting the power cord AX WARNING Do not use flammable sprays inside or near the unit e g when cleaning the unit Such flammable gas may ignite and cause a fire or combustion Take precautions against fire and ensure ventilation when using alcohol and store the alcohol in a safe place after use Also note that use of other solvents can damage the rubber rollers and resin inside the unit resulting in malfunctions 6 2 1 Cleaning the sensors a Lower paper sensor PS8 1 Clean the protection film 1 of the paper 1 sensor PS8 under the paper feed tray with a 57 dry and soft cloth DUPLO DF 1000 12T M12M0 0602 0 1 19 6 USER MAINTENANCE b Paper feed inlet sensor PS10 1 Open the top cover L 2 Insert the nozzle of the dust removal spray canned air into the cut away on the sensor cover vertically and blow air 3 Close the top cover L c Paper ejection outlet upper sensor PS12 1 Remove the folding plate and open the top cover R 2 Insert the nozzle of the dust removal spray canned air into the cut away on the sensor cover and blow air 3 Return the folding plate to its original position 4 Close the top cover R d Paper ejection outlet lower sensor PS12 1 Loosen the two knob screws and remove the paper ejection guide Center 2 Insert the nozzle of the dust rem
71. eaning Approximate cleaning time Cleaning part Upper paper sensor PS8 Every six Lower paper sensor PS8 months or Paper feed inlet sensor PS10 SOOO ase Paper ejection outlet upper sensor PS12 Paper ejection outlet lower sensor PS12 Suction belt Folding roller Stacker belt 1 Also designated as user maintenance part 3 3 Oiling oe Approximate Olinger oiling time Overall Whole circumference of gear Every six months or 100 000 uses Area where shaft and bearing are connected Paper feed Sliding part of the separator section unit bracket Side guide up down slide shaft Folding Area where folding roller section center press roller and bearing are connected Area where press reference pillar and press bar are connected Plate spring of folding roller end Defect due to dirt Paper jam misdetection Oil grease used Equivalent to Orelube G1650 grease Equivalent to Orelube G90 140 oil Equivalent to Kyodoyushi unilube No 2 grease Equivalent to Orelube G90 140 oil Equivalent to Dow Corning MOLY KOTE 41 grease DUPLO DF 1000 12T M12M0 0602 0 Chapter 5 STANDARDS ADJUSTMENTS 1 BASIC ADJUSTMENT PROCEDURES 1 BASIC ADJUSTMENT PROCEDURES 1 Perform the following checks and adjustments E Refer to 4 1 1 Adjusting the parallelity of the folding stopper CF Refer to 4 1 2
72. ection Custom Folding Data Standard folding correction registration and custom folding registration data only can be collectively erased by the following procedure 1 Turn OFF the power switch 2 While pressing the test key turn ON the power switch 5 2 Initializing the EEPROM If the setting data in the EEPROM U1 is lost due to some reason the display will not function normally In this case initialize the EEPROM U1 by the following procedure a Procedure for initializing with current total count remaining 1 Turn OFF the power switch 2 While pressing the start key stop key and test key together turn ON the power switch The initialization of the EEPROM U1 starts and when it ends the buzzer sounds three times This indicates initialization of all data except the total count registered in the EEPROM U1 3 While checking the BACKUP DATA FORM pasted inside cover F register each setting data NOTE The following procedure erases total count important for the maintenance of the unit Therefore it should never be performed unless failures which cannot be resolved by the above procedure have occurred Procedure for initializing total count at the same time 1 Turn OFF the power switch 2 While pressing the start key stop key and clear key together turn ON the power switch All data in the EEPROM U1 including the total count is initialized 6 12 DUPLO DF 1000 12T M12M0 0602 0
73. el O 99090090 0 LD07 LDO6LD05 LD04 _LD03 LD02 LD01 O swo7 SW08 SW09 SW10 SW11 o a Wi W14 S Wis S O ol ol 3 4 PS P W B Unit a UK model b USA model PH3 HL A5 PHA 5 PH3 A4 PH2 B4 DUPLO DF 1000 12T M12M0 0602 0 Memo A 12 DUPLO DF 1000 12T M12M0 0602 0 4 OVERALL SCHEMATIC DIAGRAM Stopper Movement Sensor Encoder 1A 7 PS1 2 Stopper Movement Sensor Encoder 1B Paper Stop Motor Upper SKYBLUE 12H 8111 DC24V 200mA Stopper Movement Sensor Encoder 2A 7002_PINK PS4 00 t 1 z S8R 8023 Stopper Hovenent Sensor Encodgr gt 28 3 PS5 1 2 98R 8023 Stopper Movement Home Sensor 2 7 008_PINK PS6 T 3 0 4 Paper Stop Motor Lower SKYBLUE py 2 1 MOT3 12H 8111 DC24V 200mA Legal Sensor PS13 T z E DUPLO DF 1000 12T M12M0 0602 0 PS2 2 98R 8023 Stopper Movement Home sensor st 2 PS3 3 062 10964 T AHA 3 T SKYBLUE YELLOW 01 K 3013P INK O14 BL INK 3009 WHITE 3003_ORANGE PCB1 Unit Main Control 12T 8001 0401 SK
74. elts 3 11 Chapter 4 MAINTENANCE INSPECTION 1 List of Maintenance Tools 000 4 2 1 1 General Tools 1 2 Special Tools 2 Product Lifespan Parts Lifespan 4 3 2 1 Product LifeSpamtvicrccecserercesssanereceeesnd 4 3 2 2 Parts LITO PM cian cias isc 4 3 2 2 1 Recommended spare parts A Consumables cossis 4 3 2 2 2 Recommended spare parts B Function paftS sciesrsscsssisssireersisssssssari 4 3 2 2 3 Recommended spare parts C Drive parts iia ini 4 3 2 2 4 Recommended spare parts D Semi durable parts 4 8 3 Periodic Maintenance 4 4 3 1 Basic Maintenance oocccicicnnnnninicnnnnnimm 4 4 3 2 Cl orcas 4 4 O 4 4 DUPLO DF 1000 12T M12M0 0602 0 CONTENTS Chapter 5 STANDARDS ADJUSTMENTS 1 Basic Adjustment Procedures 5 2 2 External Cover Control Section 5 3 2 1 External Cover Section ee 5 3 2 1 1 Adjusting the interlock switch POSO resaca ic 5 3 2 2 Drive SCHON ssiri 5 4 2 2 1 Adjusting the tention of the timing A aserotents T 2 2 2 Attaching position of motor pulley 5 3 Paper Feed Section sssrin 3 1 Paper Feed Tray Section 3 1 1 Adjusting the paper feed tray POSTON as ie 5 6 3 1 2 Adjusting the side guide co 5 8 3 2 Suction Conveyance Section 5 9 3 2 1 Adjusting the separating air adjusting knob position aia 5 9 3 2 2 Adjusting the separator adjusting knob A AE A EET 5 9
75. enoid valve is open The air suctioned in from the suction duct becomes weak c Thin paper control When fine quality paper less than 81 9 g m is used press the thin paper feed button SW9 to process as thin paper When this button is pressed paper will be fed with the suction solenoid SOL1 in the OFF state valve open state DUPLO DF 1000 12T M12M0 0602 0 2 19 3 PAPER FEED SECTION 3 3 4 Conveyance section a Configuration Conveyance roller 9 O SO a LI a 1 Paper feed inlet sensor PS10 C Refer to 3 1 Outline b Paper conveyance The conveyance roller is rotated by the drive of the main motor MOT1 Paper fed into the unit by the suction section is conveyed to the registration section by the conveyance roller c Paper feed interval control During continuous paper feed feed operations of the following paper start after the paper feed inlet sensor PS10 has detected the paper trail edge However in the case of the following processing conditions to enhance processing speed the next paper feed operations are started after a certain period of time has passed from the detection of the paper lead edge by the paper feed inlet sensor PS10 e Standard paper e Processing speed 5 or 5 e Single fold double fold letter fold The relation between the paper feed interval setting of the user menu function setting mode and paper
76. er attached on the rack at the frame B side turns OFF the paper feed tray home switch SW4 2 16 DUPLO DF 1000 12T M12M0 0602 0 3 PAPER FEED SECTION 3 3 Suction Conveyance Section 3 3 1 Outline The functions of the suction conveyance section can broadly be divided into the suction section separator section and conveyance section 1 Separator section Blows air on paper stacked on the paper feed tray to separate paper 2 Suction section Suctions paper stacked on the paper feed tray to the suction belt and feeds paper inside 3 Conveyance section Conveys paper fed into the unit 3 3 2 Separator section a Configuration Separating air adjusting knob Separator adjusting knob Shutter Ducts Separator Separator 1 Blower fan FAN1 lt DC 24 V fan motor gt Supplies air for paper separation b Paper separation by air When the blower fan FAN1 rotates air is blown out of the duct to separate paper on the paper feed tray Rotating the separating air adjusting knob slides the shutter and changes the duct opening amount When the duct opening amount is large The separating air is strong When the duct opening amount is small The separating air is weak c Separator When several sheets of paper are being fed by the suction belt the separator drops the second sheet of paper onwards Rotating the separator adjusting knob moves the separator up and down NOTE Adjust the separator height accordin
77. er motor MOT2 O Folding plate 1 folding stopper adjusting key Folding stopper moves in opposite direction of the home position O Folding plate 1 folding stopper adjusting key Folding stopper moves in the home position direction Folding plate 2 stopper motor MOT3 O Folding plate 2 folding stopper adjusting key Folding stopper moves in opposite direction of the home position O Folding plate 2 folding stopper adjusting key Folding stopper moves in the home position direction 23 CLUTCH TEST IN OUT REGIST Mode for checking the operations of the following clutches The clutch operates while the key is pressed and stops when the key is released NOTE The clutch will not operate if any one interlock switch is not closed Do not leave the unit with the clutch operating Otherwise the clutch will overheat resulting in malfunction Paper feed clutch CLH1 Operates with the start key Stacker belt clutch CLH2 Operates with the stop key Registration clutch CLH3 DUPLO DF 1000 12T M12M0 0602 0 Operates with the test key 3 MENUS AND FUNCTIONS Maintenance menu 1st line display 24 FAN SOL TEST Setting 2nd line display Contents Remarks Mode for checking the operations of the following fans and solenoids The fan or solenoid operates while the key is pressed and stops when the key is released NOTE The fan or solenoid will not operate if any one inte
78. esult in a fire or an electrical shock Do not place metal objects or vessels containing liquids on top of the unit The entry of any metal object or liquid could result in a fire or an electrical shock Do not insert any metal or easily combustible object inside this unit This could result in a fire or an electrical shock Do not install the unit in the following environment Otherwise it may cause fire or an electric shock O where the temperature is high O where the unit will be subject to direct sunlight O near fire O where it is considerably dusty O where there is considerable vibration O where there is considerable air borne salt O where there are harmful chemicals Do not install this unit in a location where there is excessive humidity or where contact with water is possible Poor choice of location could result in deterioration of the insulation a fire or an electrical shock Do not install the unit near devices which emit strong magnetic force and in magnetic fields Otherwise incorrect operations and malfunctions may occur iv Install this unit on a level stable stand or floor with sufficient space around it Failure to do so could result in the unit overturning and causing injury DUPLO DF 1000 12T M12M0 0602 0 PREFACE N CAUTION Disconnect the power plug from the power outlet before attempting to move this unit Failure to do so could result in power cord damage a fire or an ele
79. f this unit paper feed folding paper ejection The control program is written in the microprocessor b 12 V 6 5 V 5 V generation Stepped down from the 24 V input power supply 5 V is used as the power supply for the input system and board circuits 12 V and 6 5 V are used as the power for board circuits c Memory backup Incorporates one EEPROM U1 to backup the various settings when the power switch is OFF d Version up Upgrades the control program version x The separate 128K byte 1M bit EPROM is required CF Refer to Chapter 6 MAINTENANCE MODE gt 4 UPGRADING THE PROGRAM VERSION 2 Control panel PCB2 Performs various settings such as processing speed number of sheets processed etc Composed of the LCD 7 segment window LED and push switches 3 Tray down button SW8 lt DC 24 V push switch gt The paper feed tray descends while this button is pressed 4 Main motor MOT1 C Refer to 2 2 Main Motor Control 5 Power switch PSW For turning ON OFF the AC input to the switching power supply PCB3 6 Switching power supply PCB3 lt Input AC 100 V output DC 24 V overcurrent overvoltage protection circuit incorporated gt Used for generating DC 24 V If the protection circuit operates due to some reason the DC output will go OFF To recover from this state turn OFF the power switch wait for more than three minutes and turn ON the power switch 2 4 DUPLO DF 1000 12T M12M0 0602 0
80. fied value gt Tightening torque of screw is 0 69 Nm MI Collet tia 2 SOLOW airneisi ires eritar AEAEE L REENEN 2 Apply a very small amount of thread locking to the collar fixing screw from the back of the lt Bottom regulated position gt folding stopper Equivalent to Three Bond 1401B 1mm b Checking the operations of the slide stopper When the measuring point A is pressed with a load of 0 25 N the slide stopper should move smoothly to the bottom regulated position When the load is removed the slide stopper should return to the top regulated position immediately 2 Slide stopper 8 Folding stopper lt Top regulated position gt 4 1 8 Adjusting the attaching position of the switching adjusting plate Secure the switching adjusting plate of the folding plate 2 folding stopper pushed towards the arrow direction in the figure paying attention to the parallelity of the left and right sides 1 Switching adjusting plate trat NEE 2 NOTE Apply a very small amount of thread locking to the fixing screw of the switching adjusting plate Equivalent to Loctite 242 Medium strength 5 18 DUPLO DF 1000 12T M12M0 0602 0 4 FOLDING SECTION 4 2 Folding Roller Section 4 2 1 Adjusting the attaching position of the press spring T lt Adjustment value gt Secure the spring hook at the position shown in
81. g to the paper thickness and type DUPLO DF 1000 12T M12M0 0602 0 2 17 3 PAPER FEED SECTION 3 3 3 Suction section a Configuration Suction belts Suction ducts 2 Actuator 1 Suction fan FAN2 lt DC 24 V fan motor gt Suction source for suctioning paper Controls the suction of paper on the paper feed tray together with the suction solenoid SOL1 2 Paper feed tray sensor 1 PS7 C Refer to 3 1 Outline 3 Suction solenoid SOL1 lt DC 24 V solenoid gt Opens closes the suction duct valve 4 Paper feed clutch CLH1 lt DC 24 V electromagnetic clutch gt Transmits the drive of the main motor to the suction belt via the conveyance roller 5 Thin paper feed button SW9 lt DC 5 V push switch with built in LED gt Turns ON OFF the operations of the suction solenoid SOL1 2 18 DUPLO DF 1000 12T M12M0 0602 0 3 PAPER FEED SECTION b Paper suction When the valve is closed while the suction fan FAN2 is rotating air is suctioned in from the suction duct and paper is suctioned to the suction belt The valve is opened closed by the solenoid SOL1 Normally the valve is open and controlled to close only when the paper feed clutch CLH1 is ON The pin white rod works to stabilize the movements of paper especially thin paper suctioned to the suction belt Suctioned state When solenoid valve is closed The air suctioned in from the suction duct becomes strong Open state When sol
82. gt 1 BASIC ADJUSTMENT PROCEDURES DUPLO DF 1000 12T M12M0 0602 0 7 3 2 TROUBLESHOOTING BY PHENOMENON 2 2 2 Folding misalignment along sides of paper 1 Is there clearance between the side guides and paper Yes Align paper neatly and stack then push the side guides lightly against the paper 2 Is the side guide adjusting knob loose Yes Tighten the knob firmly 3 Is the paper trimmed precisely No Ifthe trimming misalignment of the paper lead edge is large it cannot be corrected using the side guide adjusting knob and skew correction knob alone Have the user use paper with little trimming misalignment 4 Are the left and right skew roller spring pressure adjusting knobs set at the same position No Set at the same position 5 Is the folding roller dirty Yes Clean with a cloth moistened with alcohol 6 Is the registration brake BRK1 normal CF Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List If the registration brake BRK1 does not operate folding misalignment may have occurred along the sides of the paper Remove the main cover F and check the operations of the registration brake BRK1 No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the brake Yes Replace the MC unit 2 2 3 When paper is not folded at the normal position 1 Is folding plate set properly No Set the fold
83. he sensor 2b Is the paper feed tray home switch SW4 normal C Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the switch 3 Is the paper feed tray motor MOT4 normal C Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the motor Yes Replace the MC unit 7 8 DUPLO DF 1000 12T M12M0 0602 0 3 TROUBLESHOOTING BY MESSAGE DISPLAYED 3 3 6 When TRAY UP ERROR is displayed 1 Are there foreign particles between the paper feed tray and suction belt Yes Remove the foreign particles 2 Is the stacked paper lead edge touching the shutter No Stack the paper again 3 Is the attaching position of the paper feed tray sensor 2 PS9 appropriate CF Refer to Chapter 5 STANDARDS ADJUSTMENTS gt 3 2 6 Adjusting paper feed tray sensor 2 PS9 position No Adjust 4 Is the paper feed tray upper limit switch SW6 normal CF7 Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the switch Yes Replace the MC unit 3 3 7 When TRAY DOWN
84. ial Control panel Skew roller spring pressure adjusting knob Skew roller fixing knob Jam correction knob Folding plate connector Stacker unit connector Stacker unit Stacker roller Stacker belt DUPLO DF 1000 12T M12M0 0602 0 33 Stacker support 34 Lever 35 Auxiliary paper ejection guide 86 Paper ejection guide 37 Paper receiving tray 38 Side cover 39 Thin paper feed button 1 9 4 CONTROL PANEL 4 CONTROL PANEL 4 1 Control Panel 8 Start key 5 41 3 Operation Press to start paper folding Stop key Press to stop paper folding Test key Press to test fold two sheets of paper Mode key Press to switch the function setting mode Clear key Press to clear the value entered with the numerical keys Numerical keys 0 to 9 Press to enter the number of sheets to be processed or paper length Speed key Speed lamp Press to select the processing speed from five levels Speed 1 to 5 Every time the key is pressed the speed increases Every time the key is pressed the speed decreases O Speed 5 With the speed 5 lamp lit press and hold the key for more than three seconds and the lamp will stop lighting and start blinking Set this when paper jamming occurs frequently with thick paper O Speed 1 With the speed 1 lamp lit press and hold the key for more than three seconds and the lamp will stop lighting
85. ing Knob eee 1 18 5 2 2 Skew correction by skew correction A o 14 5 2 3 Using the skew roller spring pressure adjusting Knobuvarianinacion cias 14 5 3 Folding Position Adjustments 1 15 5 3 1 Folding position correction by folding E sts 15 5 4 Paper Ejection Adjustments 1 17 5 4 1 Changing the stacker roller position 1 17 5 4 2 Changing the stacker roller height 18 6 User Maintenance coccinininnnnnnncnnnnanannores 1 19 6 1 List of Maintenance Items 1 19 6 2 Cleaning by User 1 19 6 2 1 Cleaning the sensors mls 6 2 2 Cleaning the suction belts 1 21 DUPLO DF 1000 12T M12M0 0602 0 6 2 3 Cleaning the folding rollers 1 21 6 2 4 Cleaning the stacker belts 6 3 Replacement by User Chapter 2 OPERATIONS 1 Outline 1 1 Function Configuration 1 2 Block Diagram of Structure 1 3 Basic Operations cocoocconccicinnncmmcinion 1 3 1 Operations at power ON eee 1 3 2 Operations at power OFF 1 3 3 Operation during processing 2 6 1 3 4 Stopping operations when problems A ET 2 7 2 External Cover Control Section 2 8 2 1 Power Supply cocoocicooncccciccccnccncnos 2 8 2 1 1 Outline 2 8 2 1 2 Safety fUnction ccceccsseceeeeenees 2 8 2 2 Main Motor Control oo eee 2 10 2 2 1 Outline 2 22 2 OPE sortida 2 2 9 COIN Orientada 2 3 1 Outline 2 2 3 2 Operations
86. ing knob Switch the knob position if paper passage appears unstable such as the folding misalignment amount differs with each folded paper 1 Open the top cover L 2 Switch the position of the adjusting knob according to the paper thickness Top position A Above 127 9 g m Bottom position B Less than 127 9 g m NOTE Be sure to set the left and right knobs at the same position 3 Close the top cover L 1 14 DUPLO DF 1000 12T M12M0 0602 0 5 USER ADJUSTMENTS 5 3 Folding Position Adjustments 5 3 1 Folding position correction by folding mode Correct folding misalignment using the folding stopper adjusting keys of folding plates 1 and 2 referring to the following table The correction range of standard folding is within 5 mm to folding misalignment of 10 mm Folding mode State of folded plane Correction method Single fold Folded plane 1 is long Press the key of the folding plate 1 folding stopper adjusting key 1 Folded plane 1 is short Press the key of the folding plate 1 folding stopper adjusting key Mm There is no folded plane 2 in the case of single folding Folding plate 2 is not used Double fold Folded plane 1 is long Press the key of the folding plate 1 folding stopper adjusting key Folded plane 1 is short Press the key of the folding plate 1 folding stopper adjusting key Folded plane 2 is long Press the key of the folding plate
87. ing plate properly 2 Has static electricity occurred in the paper Yes Fan the paper well and decrease the processing speed 3 Is non standard paper with the same width but different length from standard paper used For USA model when stacking 8 5 x 11 LTR size paper on the paper feed tray if the rear guide etc is pressing against the legal paper detection sensor PS13 the paper will be incorrectly detected as 8 5 x 14 LGL size paper Yes Follow the procedure for non standard paper 4 Are the left and right skew roller spring pressure adjusting knobs set at the same position No Set at the same position Yes Adjust each part according to the basic adjustment procedure E Refer to Chapter 5 STANDARDS ADJUSTMENTS gt 1 BASIC ADJUSTMENT PROCEDURES 7 4 DUPLO DF 1000 12T M12M0 0602 0 3 TROUBLESHOOTING BY MESSAGE DISPLAYED 3 TROUBLESHOOTING BY MESSAGE DISPLAYED 3 1 Paper Jam Messages 3 1 1 When JAM FEED SECT is displayed 1 Are there foreign particles such as paper dusts and paper chips sticking to the light receiving light emitting sensors of the paper feed inlet sensor PS10 Yes Clean the sensors to remove the paper dusts and paper chips 2 Is the paper feed inlet sensor PS10 normal CF Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the optical axis connection of connectors and if bundled wires have disconnected or short circuited and if they are fou
88. ires have disconnected or short circuited and if they are found to be normal replace the switch Yes Replace the MC unit 3 4 3 When TOP COVER R OPEN is displayed 1 Is the attaching position of the top cover R switch SW1 appropriate C Refer to Chapter 5 STANDARDS ADJUSTMENTS gt 2 1 1 Adjusting the interlock switch position No Adjust 2 Is the top cover R switch SW1 normal E Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the switch Yes Replace the MC unit 3 4 4 When SIDE COVER OPEN is displayed 1 Is the attaching position of the side cover switch SW2 appropriate C Refer to Chapter 5 STANDARDS ADJUSTMENTS gt 2 1 1 Adjusting the interlock switch position No Adjust 2 Is the side cover switch SW2 normal C Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the switch Yes Replace the MC unit 7 10 DUPLO DF 1000 12T M12M0 0602 0 4 TROUBLESHOOTING FOR OPERATION FAILURES 4 TROUBLESHOOTING FOR OPERATION FAILURES 4 1 Power Does Not Turn ON 1 2 Is the power plug inserted into the power outlet properly No Insert Are the follo
89. ively high risk of incidental malfunctions and large electrical parts For details refer to the parts catalog 2 2 3 Recommended spare parts C Drive parts These consist of mechanical parts with comparatively low risk of incidental malfunctions and electrical parts For details refer to the parts catalog 2 2 4 Recommended spare parts D Semi durable parts The following shows parts which may need to be replaced within the product lifespan though they rarely are consumed or wear out in normal use excluding malfunctions Approximate lifespan Part name million sheets Part used Remarks 1 2 3 Bearing 013 10024 Paper feed section drive section Bearing 013 10031 Bearing 013 10036 Bearing 013 10039 Bearing 013 10051 Link 11A 10200 Flat belt 11A 11393 Spring C 12H 30470 Pulley unit 12H 40390 Valve head unit 12T 24480 Spring T 12T 24690 Spring T 12T 26280 Flat belt 12T 42190 Paper ejection section Folding section Paper feed section Drive section Paper feed section Folding section Paper ejection section Paper feed section OJOJOJOJOJO JOJOJOJOJO Oja Paper ejection section DUPLO DF 1000 12T M12M0 0602 0 4 3 3 PERIODIC MAINTENANCE 3 PERIODIC MAINTENANCE 3 1 Basic Maintenance To maintain the quality of this product perform inspections at the following cycle e One month after installation e Every six months or 100 000 uses 3 2 Cl
90. lower cover 4 Remove the fixing screws of the connecting plate at folding plate 1 unit and remove the folding plate 1 unit NOTE Do not remove the fixing screws of the connecting plate at folding plate 2 unit and remove the connecting plate As the connecting plate is adjusted by tool at assembly it cannot be adjusted on the market 5 Remove the sensor bracket 6 Remove the connector 7 Remove the folding plate home sensor 3 2 Folding Roller Section 3 2 1 Removing the folding rollers 1 Remove the folding plate 2 Remove the main covers F and B 3 Remove the stacker unit CF Refer to 4 1 1 Removing the stacker unit A Remove the partitioning plate four screws al Remove the paper ejection conveyance plate unit N O Loosen the fixing screws of the main motor and remove the timing belt Remove the timing pulley of the main motor Loosen the idler unit and remove the timing belt driving the paper feed section and paper ejection section 9 Remove the spring hook hooking the spring T for the folding roller four each at frames F and B 10 Remove the four conductive plates at frame F 11 Remove the stoppers eight at frame F and seven at frame B NOTE When removing the stopper do not remove the stopper of folding roller 1 If removed adjust the gap with the center press roller C7 Refer to Chapter 5 STANDARDS ADJUSTMENTS gt 4 2 2 Adjusting the gap of folding
91. lt SW5 i Paper feed tray sensor reel i g i g 2 PS9 i 9 Folding section i Paper feed inlet sensor gt Folding plate 1 index PS10 i sensor A PS1 Paper feed tray home gt A N Folding plate 1 index i switch SW4 sensor B PS2 Paper feed tray upper gt a Folding plate 1 home l limit switch SW6 1 1 sensor PS3 Safety lever switch 1 f Folding plate 1 stopper SW7 motor MOT2 1 1 Thin paper feed button gt a Folding plate 2 index SW9 i i sensor A PS4 i Paper feed tray motor t Folding plate 2 index MOT4 sensor B PS5 i Registration brake Folding plate 2 home BRK1 Das sensor PS6 1 1 i Blower fan Folding plate 2 stopper FAN1 motor MOT3 Suction fan i Folding plate switch FAN2 f i SW3 l 1 1 5 3 e Paper feed clutch 4 CLH1 i 10 Paper ejection section Registration clutch Stacker belt clutch CLH3 CLH2 f 1 Suction solenoid Stacker roller moving SOL1 l motor MOT5 1 PS P W B unit gt Stacker roller home PCB4 i sensor PS11 4 a I Paper ejection outlet Legal paper detection sensor PS12 i sensor PS13 1 i USA model only 7 j DUPLO DF 1000 12T M12M0 0602 0 2 3 1 OUTLINE 1 MC unit PCB1 Incorporates a 32 bit microprocessor for controlling the overall operations of this unit The following are main functions a Overall control Incorporates a 32 bit microprocessor for controlling the overall operations o
92. n adjustment registration Custom folding registration 2 ways Non standard paper length registration Interval Last time fold Folding stopper fixed Thick paper supported Forced paper ejection Forced paper ejection in folding plate Stacker belt continuous rotation LCD backlight automatic OFF energy saving function 1 Details of folding stopper position adjustment registration custom folding registration and non standard paper length registration Folding stopper position adjustment registration Remarks Minimum adjustment unit 0 125 mm 0 005 inch x The display unit on the control panel is 0 01 inch NOTE O The folded size by folding plate 2 cannot be corrected for single folding O The folded size by folding plate 2 can be corrected between 0 to 5 0 mm for double folding of B6 paper O The folded size by folding plate 2 can be corrected between 0 to 5 0 mm for irregular accordion folding of B6 paper O l paper length is registered the correction range may be limited 5 0 to 5 0 mm 20 2 to 0 2 inch Custom folding Folded size by folding plate 1 42 to 325 mm 1 65 to 12 79 inch registration Folded size by folding plate 2 47 to 217 mm 1 85 to 8 54 inch 0 mm for single folding Non standard paper length registration DUPLO DF 1000 12T M12M0 0602 0 182 to 432 mm 7 2 to 17 inch 2 SPECIFICATIONS 2 3 Paper Item Contents Paper
93. n of the timing A TI TL 5 22 5 2 2 Adjusting the stacker roller home sensor PS11 position 5 22 Chapter 6 A 6 2 2 Maintenance Mode Operations 6 3 2 1 Entering the Maintenance Mode 6 3 2 2 Exiting the Maintenance Mode 16 3 3 Menus and Functions 3 1 Menu List 18 4 3 2 Other FUNCIONS vices iscisssicaseticssaiecescicesaiens 6 10 3 2 1 Setting the paper feed tray sensor 2 PS9 to Func 6 10 4 Upgrading the Program Version 6 11 AD A 6 11 4 1 1 Preparing the rewriting tool EPROM ieran eena 6 11 4 2 Upgrading the Version 6 11 4 2 1 Upgrading the program version 6 11 5 Data Initialization oococonnionn cmmmm 6 12 5 1 Erasing Standard Folding Correction Custom Folding Data ooccccincinc 6 12 5 2 Initializing the EEPROM eee 6 12 xi CONTENTS Chapter 7 TROUBLESHOOTING 1 OUTING os 7 2 2 Troubleshooting by Phenomenon 7 3 2 1 Paper Feed Problems 7 3 2 1 1 Mis feed ee 1 3 2 1 2 Continuous feed 1 3 22 Folding Problems omisonncirici 7 3 2 2 1 Folding misalignment along vertical length of paper 7 3 2 2 2 Folding misalignment along sides of DADO siii 7 4 2 2 3 When paper is not folded at the normal A ness 7 4 3 Troubleshooting by Message DISPLAY OG aia tecceiscccecsncscseeserszetecteesszcestsers 7 5 3 1 Paper Jam Messages 7 5 3 1 1 When JAM FEED SECT
94. nd to be normal replace the sensor 3 Is the registration clutch CLH3 normal C7 Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the clutch Yes Replace the MC unit 3 1 2 When JAM INSIDE is displayed 1 Is the paper ejection outlet sensor PS12 normal CF Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the optical axis connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the sensor 2 Is the registration clutch CLH3 normal C7 Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the clutch Yes Replace the MC unit 3 1 3 When JAM EXIT is displayed 1 Are there foreign particles such as paper dusts and paper chips sticking to the light receiving light emitting sensors of the paper ejection outlet sensor PS12 Yes Clean the sensors to remove the paper dusts and paper chips 2 Is the paper ejection outlet sensor PS12 normal C Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the optical axis connection of connectors and if bundled wires have disconnected or short circui
95. ng knob 2 Is the separator height too high Yes Lower the separator using the separator adjusting knob 3 Is the level sensor height too low Yes Raise the level sensor using the level sensor adjusting lever 4 Is the suction belt dirty or are there foreign particles on it Yes Clean the suction belt If it cannot be cleaned properly or it is damaged replace the suction belt 5 Are abnormal sounds produced from the suction conveyor Yes Check the rotating portion of the suction conveyor and if abnormal replace it 2 1 2 Continuous feed 1 Is the separating air too strong Yes Weaken the separating air using the separating air adjusting knob 2 Is the separator height too low Yes Raise the separator using the separator adjusting knob 3 Is the level sensor height too high Yes Lower the level sensor using the level sensor adjusting lever 2 2 Folding Problems 2 2 1 Folding misalignment along vertical length of paper 1 Was the processing speed changed halfway through Yes Set back the previous speed If the speed has been changed the folding stopper position must be corrected 2 Was the paper type paper quality thickness changed halfway through Yes Use the original paper before change If paper has been changed the folding stopper position must be corrected No Adjust each part according to the basic adjustment procedure C Refer to Chapter 5 STANDARDS ADJUSTMENTS
96. of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the motor 4 Is the problem resolved by replacing the folding plate 1 index sensor A PS1 or B PS2 Yes End No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the MC unit 3 3 3 When MOTOR ERROR 5 is displayed 1 Has the folding plate 2 folding stopper locked Yes Rotate the screw shaft unit with a flat screwdriver etc to release the lock If the folding stopper has locked the index sensor may very likely be malfunctioned so replace folding plate 2 index sensors A PS4 and B PS5 2 Is the folding plate 2 home sensor PS6 normal CF7 Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the sensor 3 Is the folding plate 2 stopper motor MOT3 normal CF Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the motor 4 Is the problem resolved by replacing the folding plate 2 index sensor A PS4 or B PS5 Yes End No Check the connection of connectors and if bundled wires have disconnected or
97. on range restrictions For double fold and irregular accordion fold the correction range may be restricted and cannot be corrected for some paper lengths Restricted folded plane Folded plane 2 for double fold Paper length mm Inch 182 to 187 7 21 to 7 4 Correction range restrictions Correction using the key is not possible 188 to 207 7 5 to 8 1 208 to 432 8 2 to 17 0 The values which can be corrected vary in the 0 1 to 4 8 mm 0 004 to 0 19 range according to the paper length No restriction Folded plane 1 for irregular accordion fold 182 to 426 7 2 to 16 7 No restriction 427 to 432 16 8 to 17 0 The values which can be corrected vary in the 0 6 to 4 3 mm 0 02 to 0 17 range according to the paper length Folded plane 2 for irregular accordion fold 1 16 182 to 189 7 2 to 7 4 Correction using the key is not possible 190 to 208 7 5 to 8 2 The values which can be corrected vary in the 0 2 to 4 7 mm 0 008 to 0 19 range according to the paper length 209 to 432 8 3 to 17 0 No restriction DUPLO DF 1000 12T M12M0 0602 0 5 USER ADJUSTMENTS 5 4 Paper Ejection Adjustments 5 4 1 Changing the stacker roller position The position of the stacker roller is automatically set according to the folded paper length in standard folding In the case of custom folding if alignment of
98. ore initial settings of the unit will be omitted when the power is turned ON enabling folding to be started immediately O Folding stopper position O Stacker roller position O Processing speed SET INTERVAL Setting this setting to ON repeatedly pauses operations for every specified number of sheets and restarts operations after several seconds NOTE The setting is erased when the power is turned OFF AIR POWER Function for adjusting the air amount for separating paper DUPLO DF 1000 12T M12M0 0602 0 1 11 4 CONTROL PANEL Function 1st line display FEED SPEED Setting 2nd line display Contents Remarks Function for changing the processing speed when single folding double folding or letter folding standard paper QUANTITY Function which changes the amount of paper stacked on the paper feed tray Reference The number of sheets stacked for each setting is as follows for fine quality paper 81 4 g m or equivalent HIGH 1000 sheets O NORMAL 600 sheets LOW 800 sheets STACKER BELT NORMAL CONTINUOUS Function for changing the operation mode of the stacker belt NORMAL The stacker belt operates according to the paper ejection timing CONTINUOUS The stacker belt operates continuously THICK PAPER 1 12 NOT CORRECTED CORRECTED The correction value of the folding stopper positions can be changed for thick paper DUPLO DF 1000 12T M12M0 0602 0 5
99. oss Spanner M4 7 0 mm across General Box wrench M3 Box wrench M4 General Box wrench M5 For removing motors etc Hexagonal wrench 1 5 mm across Set collar of adjusting knobs etc Hexagonal wrench 2 0 mm across Set collar of adjusting knobs etc Thread locking Equivalent to Three Bond 1401B For fixing screws Thread locking Equivalent to Loctite 242 Medium strength For fixing screws Thickness gauge Gap adjustments Level 1 2 Special Tools There are no special tools for this unit For adjusting the paper feed tray position C7 Refer to Chapter 5 STANDARDS ADJUSTMENTS gt 3 1 1 Adjusting the paper feed tray position DUPLO DF 1000 12T M12M0 0602 0 2 PRODUCT LIFESPAN PARTS LIFESPAN 2 PRODUCT LIFESPAN PARTS LIFESPAN 2 1 Product Lifespan Five years or 5 million sheets 2 2 Parts Lifespan This section describes parts recommended to be stocked at each service center recommended parts to maintain the product quality and reduce the down time 2 2 1 Recommended spare parts A Consumables The following shows parts which need to be replaced more than once within the product lifespan due to consumption and wear in normal use excluding malfunctions Approximate lifespan Part name million sheets Part used Remarks 1 2 3 5 2 2 2 Recommended spare parts B Function parts These consist of mechanical parts with comparat
100. ould move slightly clearance between switching shaft tip and folding roller 2 should be 0 2 to 0 4 mm Speed key Pressing the key once distances the switching shaft from folding roller 2 by 0 125 mm Speed key Pressing the key once moves the switching shaft nearer to folding roller 2 by 0 125 mm NOTE If the switching shaft is touching folding roller 2 the switching shaft does not move even when pressed gently by finger folding roller 2 may get damaged 6 Press the clear key while pressing the stop key The folding stopper executes initial operations and the folding plate 2 folding stopper moves to the home position of the switching shaft 5 14 DUPLO DF 1000 12T M12M0 0602 0 4 FOLDING SECTION 4 1 3 Adjusting the home position of the folding stopper 1 2 Enter the maintenance mode Check that the following correction value is the same as backup data form value CF Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List Folding plate 1 folding stopper Check the correction value of 1 STOP1 DEFAULT Folding plate 2 folding stopper Check the correction value of 2 STOP2 DEFAULT Press the clear key while pressing the stop key to execute initial operations of the folding stopper Press the test key to execute test folding Measure the folded plane length of the ejected paper second sheet Press the speed key and correct the folded plane length Speed ke
101. oval spray canned air into the cut away on the sensor cover and blow air 3 Reinstall the paper ejection guide to its original position 1 20 DUPLO DF 1000 12T M12M0 0602 0 6 USER MAINTENANCE 6 2 2 Cleaning the suction belts ON A 5 6 6 Move the side guides out to the sides and lower the paper feed tray Turn off the power switch and disconnect the power cord plug from the outlet Open the top cover L 1 Rotate the suction belts 3 by rotating the paper feed shaft 2 by hand Clean them with a cloth moistened with alcohol Close the top cover L 2 3 Cleaning the folding rollers Remove the folding plate 11 2 Open the top cover R 1 While rotating the folding rollers with the jam correction knob 2 clean them with a cloth moistened with alcohol Return the folding plate to its original position Check that the jam correction knob rotates smoothly NOTE If the folding plate is not secured at the correct position the knob will not only feel heavy but the folding rollers and folding plate may get damaged Close the top cover R DUPLO DF 1000 12T M12M0 0602 0 1 21 6 USER MAINTENANCE 6 2 4 Cleaning the stacker belts 1 Lift up the stacker roller 1 and turn down the lever 2 of the stacker support in the arrow direction 2 While rotating the stacker belts 3 by hand clean them with a cloth moistened with alcohol 3 Retu
102. over and paper ejection guide 2 Open the side cover and disconnect the connector 3 Remove attaching angles F and B and remove the stacker unit 4 1 2 Removing the stacker roller home sensor PS11 1 Remove the stacker unit 2 Remove the cover at the paper receiving tray 3 Remove the stacker roller home sensor together with the sensor bracket 4 1 3 Removing the stacker roller moving motor MOT5 1 Remove the stacker unit 2 Remove the cover at the paper receiving tray 3 Disconnect the connector and remove the motor bracket and timing pulley 4 Remove the stacker roller moving motor 4 1 4 Removing the stacker belts Remove the stacker roller home sensor 2 Remove the stacker roller moving motor 3 Remove the lever unit roller and joint etc 4 Remove the stacker belts NOTE When installing the stacker belt install according to the instructions on the rotating direction printed inside the belt DUPLO DF 1000 12T M12M0 0602 0 3 11 Memo 3 12 DUPLO DF 1000 12T M12M0 0602 0 Chapter 4 MAINTENANCE INSPECTION 1 LIST OF MAINTENANCE TOOLS 1 LIST OF MAINTENANCE TOOLS 1 1 General Tools Tool name Main purpose Phillips screwdriver Phillips screwdriver Long Phillips screwdriver Stubby General Flat screwdriver Small For removing E rings etc Long nose plier Plier For install E rings removing installing springs etc Spanner M3 5 5 mm acr
103. paper ejected to the paper receiving tray is poor change the stacker roller position Reference When standard folding non standard paper the stacker roller will automatically be set according to the folded paper length calculated from folding mode and paper length 1 While pressing the stop key press a numerical key between 1 and 7 Changing the folding mode returns the position to the default setting Default setting of stacker roller position Standard paper size The numbers in the table are numerical key numbers UK model USA model Folding mode 11 x 17 8 5 x 14 18 5 x 11 7 x 8 5 5 5 x 8 5 LGR LGL LTR STMT Single fold Double fold Irregular accordion fold Letter fold Accordion fold Custom fold 1 Set in the range of 4 to 6 according to the folding stopper position however there is a need to check the folded paper length and adjust accordingly Refer to the following table Reference for stacker roller position Custom folding i i Folded r length nes Contents Numerical Folden paper lengt Pressing the 0 key while To 80 To 3 15 pressing the stop key returns the 81 to 110 3 16 to 4 33 111to140 4 34 to 5 51 Use the 1 key if paper jams at 141 to 170 5 52 to 6 69 the 2 position 171 to 210 6 70 to 8 27 211 to 250 8 28 to 9 84 position to the default setting DUPLO DF 1000 12T M12M
104. per e Movement of stacker roller e Paper feed preparations After paper detection the blower fan FAN1 and suction fan FAN2 are turned ON and the unit stands by for about two seconds Folding operations 4 Paper feed 5 After paper is folded using the folding plate and folding roller paper is ejected onto the stacker unit C7 Refer to 4 1 2 Folding operations 2 6 DUPLO DF 1000 12T M12M0 0602 0 1 OUTLINE 1 3 4 Stopping operations when problems occur The stopping operations of this unit differ according to the error detection and key operations a Normal stopping of unit Operations stop after paper in the unit is ejected The unit will set into the normal stopping state in the following cases e When the stop key is pressed e When NO PAPER is displayed e When JAM FEED SECT continuous paper feed is detected is displayed When single folding double folding or letter folding standard paper at processing speed 5 as the paper feed interval is short the unit will stop immediately e When paper size error length of paper fed is shorter than setting occurs Automatic paper ejection If paper causing paper size error is not ejected but remains in the unit this unit will perform initialization of the folding stopper as well as rotate the folding roller and stacker belt at low speed to eject the paper automatically b Immediate stopping of unit The unit will stop immediately Paper currently being
105. plate 2 CF Refer to Chapter 5 STANDARDS ADJUSTMENTS gt 4 1 3 Adjusting the home position of the folding stopper 3 SW BAR ADJUST 20 to 5 0 Mode for adjusting the home position of the switching shaft CF Refer to Chapter 5 STANDARDS ADJUSTMENTS gt 4 1 2 Adjusting the home position of the switching shaft 4 AREAS JAPAN USA UK Mode for setting the destination At shipment this is set according to the destination of the unit NOTE If this setting has been changed be sure to change the following setting as well if required 5 SET MM INCH O 6 LANGUAGES 5 SET MM INCH MILLIMETER INCH Mode for setting the unit of the size displayed on the LCD At shipment this is set according to the destination of the unit Japanese model MILLIMETER USA model INCH UK model MILLIMETER DUPLO DF 1000 12T M12M0 0602 0 3 MENUS AND FUNCTIONS Maintenance menu 1st line display 6 LANGUAGES Setting 2nd line display JAPANESE ENGLISH Contents Remarks Mode for setting the language of the messages displayed on the LCD At shipment this is set according to the destination of the unit Japanese model JAPANESE USA model ENGLISH UK model ENGLISH 7 TEST FOLD QTY 1 to 3 SHEETS 2 SHEETS Mode for setting the number of sheets to be test folded 8 BACK LIGHT OFF 15 SEC 30 SEC 60 SEC KEEP LIGHT ON Mode for set
106. power switch and disconnect the power plug from the power outlet Accidental operation of the unit during servicing could result in injury If removing covers to check operations be very careful to ensure that hands and clothing are not drawn into movable parts Remove any dust that accumulates on the power plug prongs and the surface of the plug from which the prongs extend Accumulated dust could result in a fire Always grip the plug when disconnecting the power plug from the power outlet Forcibly pulling on the power cord could cause damage resulting in a fire or an electrical shock DUPLO DF 1000 12T M12M0 0602 0 PREFACE N WARNING Do not disassemble the product unnecessarily Disassembly of parts not specified in this manual parts catalog and technical information may cause fire electric shock injury incorrect operations and malfunctions Do not disable the product safety function Safety functions are provided to protect the user and product Do not remodel the product so as to disable the safety functions Do not touch or insert foreign objects into any rotating part during operation This could result in injury CAUTION Q Prior to servicing be sure to read this manual and all technical information Q Perform servicing work in safety working wear and using the specified tools solvents and lubricants To prevent static electric damage of electrical parts prior to servicing
107. press roller 1 Folding roller 1 2 Folding roller 2 8 Folding roller 3 NOTE If the nip amount is not uniform it may cause folding misalignment along the sides of the paper and wrinkling of the folded line In this case adjustment attaching position of press spring T of the concerned roller and adjust the nip amount uniform CF7 Refer to 4 2 1 Adjusting the attaching position of the press spring T 5 20 DUPLO DF 1000 12T M12M0 0602 0 4 FOLDING SECTION 4 2 4 Adjusting the attaching position of the conveyance plate Press the conveyance plate in the arrow direction shown in the figure and secure lt Specified value gt Gap between the conveyance plate and folding roller 1 is 0 2 mm 1 Letter fold of A3 or 11 x 17 LGR fine quality paper 157 g m 2 Sandwich the paper made in step 1 between the conveyance plate and folding roller and secure the conveyance plate 1 Conveyance plate Screw Two each in front and rear 4 2 5 Adjusting the connecting plate NOTE Do not remove the fixing screws of the connecting plate at folding plate 2 unit and remove the connecting plate As the connecting plate is adjusted by tool at assembly it cannot be adjusted on the market If the folding plate has been replaced the new folding plate
108. processed will all be jammed The unit will set into the immediate stopping state in the following cases e After detecting continuous paper feed if the paper feed inlet sensor PS10 continues to detect paper even after a certain period of time When internal paper jam is detected Automatic paper ejection is carried out when paper size error is also detected at the same time When paper ejection section paper jam is detected The paper ejection outlet sensor PS12 does not turn OFF even after a certain period of time e When the top cover L top cover R or side cover is open e When folding plate set errors paper feed tray UP errors paper feed tray DOWN errors motor problems of each part are detected DUPLO DF 1000 12T M12M0 0602 0 2 7 2 EXTERNAL COVER CONTROL SECTION 2 EXTERNAL COVER CONTROL SECTION 2 1 Power Supply 2 1 1 Outline 1 MC unit PCB1 DC 12 V 24 V 14 Switching power generator supply PCB3 DC 6 5 V Overcurrent overvoltage generator protection circuit DC5V generator 3 Power switch PSW Motor driver Detector 6 Top cover R switch SW1 7 Side cover switch SW2 8 Folding plate switch SW3 9 Top cover L switch SW5 10 Paper feed tray upper limit switch SW6 11 Safety lever switch SW7 To each motor 2 1 2 Safety function a Configuration 6 Top cover R switch SW1 lt DC 24 V microswitch gt
109. r 3 2 Secure together with folding plate upper cover DUPLO DF 1000 12T M12M0 0602 0 1 EXTERNAL COVER CONTROL SECTION 1 2 Control Panel Section 1 2 1 Removing the control panel 1 Remove the main cover F 2 Disconnect the connector of the control panel and remove the control panel MR AAA A 2 2 Control panel 1 3 Board 1 3 1 Removing the MC unit a Precautions upon replacement Settings are saved in the EEPROM U1 of the MC unit When replacing the MC unit remove the EEPROM U1 from the MC unit and reinstall it in the new MC unit NOTE If replacing the MC unit without reinstalling the EEPROM in the new one record settings and the total count before the replacement on a backup data form pasted inside main cover F and perform the following after replacement 1 Initializing the memory While pressing the start stop and clear keys together turn ON the power This initializes all data registered in the EEPROM of the MC unit C Refer to Chapter 6 MAINTENANCE MODE gt 5 DATA INITIALIZATION 2 Setting data Reset various data in the maintenance mode as necessary such as home position adjustment of folding plates and switching shaft etc 00000000000000000 00000000000000000
110. re subject to regulations of each country and are difficult to sort complex materials by material O Batteries eLCD O Boards O Power cords I F cables cables such as bundled wire units O Electrical parts such as sensors switches motors clutches solenoids etc viii DUPLO DF 1000 12T M12M0 0602 0 CONTENTS Preface niisiis i 1 Organization of This Manual ii 2 Safety Precautions eessen 2 1 Power Supply cell 2 2 Operating Environment iv 2 3 Maintenance etc 00 0 cceceeeeeeeeeeeees v 2 4 Warning and Caution Label Locations vii 3 Environmental Preservation viii 3 1 Collection of This Unit viii 3 2 Collection of Consumables and Parts viii Chapter 1 INTRODUCTION 1 Features iciiccssiesicacccceseccccscencestssecciavennteite 2 Specifications 0 0 cesses 2 1 Type and Method j 2 2 Performance and Functions 1 3 2 2 1 Processing performance 1 3 2 2 2 Functions eo 2 9 Pcia A 2 4 1 Power supply dimensions mass WEIGHE maraca alaaa 1 7 2 4 2 Error detection functions 1 7 3 Names of Parts 3 1 External Parts 4 Control Panel sa 4 1 Control Panels 4 2 User Menu Function Setting Mode 1 11 5 User Adjustments 5 1 List of Adjustments oococcincniccininnnincncnco 1 13 5 2 Paper Feed Adjustments cceee 1 13 5 2 1 Skew correction by side guide adjust
111. re unit 1 A Y 3305 8 127 5013 Paper feed reinforcement pl 96Y 8007 PR P W B unit e 127 8210 056 10499 e Bundled wire Spacer x 2 unit 10 e 96V 8016 A D PS P W B unit lt I I 3304 3304 a ate 5 WIRING DIAGRAM 12T 85031 1 2 A 15 5 WIRING DIAGRAM 127 5027 Bottom plate 052 10031 Toroidal clamp core 2208 3 biniot 3203 ae 0 Dey o 9 De 1 a ET 127 5003 Frame F 056 11137 2 turns E O 98Y 8017 LED P W B unit 3302 3302 127 8211 OS Bundled wire unit 11 12T 8205 127 8201 Bundled wire uni Bundled Mr Upa To photointerrupter 11A 8038 Motor unit To separation type photointerrupter light receiving side 3307 o 5307 D gt 051 10132 Gear head 127 8201 Bundled wire unit 1 gt L 1 12T 8206 Bundled wire unit 6 12H 8101 Brushless DC motor 062 10917 062 11095 Photointerrupter Para Separation type photointerrupter i light receiving side 12T 2624 Sensor bracket 12T 2603 pE an ae 051 10172 DC fan motor NS 12T 2619 Fan bracket 3302 E
112. rlock switch is not closed Blower fan FAN1 Operates with the start key Suction fan FAN2 Operates with the stop key Suction solenoid SOL1 Operates with the test key 25 RG BRAKE TEST Mode for checking the operations of the registration brake The registration brake operates while the key is pressed and stops when the key is released Registration brake BRK1 Operates with the start key 27 SIMULATION RUN W O PAPER Mode for operating each mechanism without using paper O Simulation starts with the start key O Simulation stops with the stop key 28 ALIGNMENT Mode for making the folding stoppers of folding plates 1 and 2 parallel C7 Refer to Chapter 5 STANDARDS ADJUSTMENTS gt 4 1 1 Adjusting the parallelity of the folding stopper NOTE The folding stopper will not operate if any one interlock switch is not closed DUPLO DF 1000 12T M12M0 0602 0 3 MENUS AND FUNCTIONS Maintenance menu Setting 1st line display 2nd line display 31 CHK SENSOR SW ABCDEFGHIJKLMNOP Contents Remarks Mode for checking the status of each sensor and switch When a sensor or switch is turned ON OFF the corresponding display changes and the buzzer sounds Display of ON state Displayed in alphabets at the bottom of the LCD Paper feed inlet sensor PS10 Paper ejection outlet sensor PS12 Paper sensor PS8 Stacker roller home sensor PS11 Folding
113. rn the stacker roller to its original position 6 3 Replacement by User In normal use excluding malfunctions there are no parts requiring replacement by the user to maintain product performance and work quality 1 22 DUPLO DF 1000 12T M12M0 0602 0 Chapter 2 OPERATIONS 1 OUTLINE 1 OUTLINE 1 1 Function Configuration The functions of this unit can broadly be divided into the paper feed section folding section and paper ejection section Paper feed section co Folding section 88 Paper ejection section q DUPLO DF 1000 12T M12M0 0602 0 1 OUTLINE 1 2 Block Diagram of Structure 2 Control panel 5 Power switch lt H PCB2 lt gt 1 PSW E MC unit 34V 3 Tray down button PCB1 _24 V__ 6 Switching power supply SW8 PCB3 4 Main motor gt gt MOT 7 Cover detection section a i Top cover R switch i SW1 8 Paper feed section i ji Paper feed tray sensor Side cover switch 1 PS7 s Sw2 Paper sensor i Top cover L switch PS8
114. s displayed 2 While pressing the stop key press the folding mode key Upon entering the maintenance mode MAINTENANCE MENU will appear on the LCD 2 2 Exiting the Maintenance Mode a Method 1 1 Turn off the power switch b Method 2 1 Press the clear key two times continuously DUPLO DF 1000 12T M12M0 0602 0 6 3 3 MENUS AND FUNCTIONS 3 MENUS AND FUNCTIONS 3 1 Menu List The first two digits of the menu name indicate the code number when entering a menu from the maintenance mode The in the Setting 2nd line display column of the table below indicates the value when initializing the EEPROM Input of code number Confirmation of code number Selection of setting Switching to the next screen Numerical keys Folding mode key Speed key Custom folding registration 1 key Switching to the previous screen Custom folding registration 2 key Reference If the code number is unknown press the custom folding registration key 1 or 2 to display it in the order of the code number Maintenance menu 1st line display 1 STOP1 DEFAULT Setting 2nd line display 20 to 20 0 Contents Remarks Mode for adjusting the home position of folding plate ll CF7 Refer to Chapter 5 STANDARDS ADJUSTMENTS gt 4 1 3 Adjusting the home position of the folding stopper 2 STOP2 DEFAULT 20 to 20 0 Mode for adjusting the home position of folding
115. sed 2 Use fine quality paper of 64 g m set the processing speed above speed 4 and set the folded plane length of folding plate 2 to more than 47 mm lt UK model gt Paper size Folding mode Irregular accordion fold Letter fold Accordion fold Custom fold Folded paper length within 250 mm lt USA model gt Paper size Folding mode 41 x17 8 5 x 14 8 5 x 11 7 x 8 5 5 5 x 8 5 LGR LGL LTR STMT INV Single fold Double fold Irregular accordion fold Letter fold Accordion fold Custom fold Folded paper length within 250 mm 1 4 DUPLO DF 1000 12T M12M0 0602 0 2 SPECIFICATIONS 2 2 2 Functions Paper size detection Contents Automatic detection of standard paper sizes fed by short edge feeding lt UK model gt A3 B4 A4 B5 A5 B6 lt USA model gt 11 x 17 LGR 8 5 x 14 LGL 8 5 x 11 LTR 7 x 8 5 STMT 5 5 x 8 5 INV Paper feed tray control Paper presence detection automatic rise descent manual raising lowering also possible Movement of folding stopper Automatic setting Manual setting also possible Movement of stacker roller Automatic setting Manual setting also possible Liquid crystal display LCD Counter Paper size folding stopper position operation error message 4 digit selection of add or subtract count method Other functions Folding stopper positio
116. short circuited and if they are found to be normal replace the MC unit DUPLO DF 1000 12T M12M0 0602 0 7 7 3 TROUBLESHOOTING BY MESSAGE DISPLAYED 3 3 4 When MOTOR ERROR 3 is displayed 1 Are there foreign particles such as paper dusts and paper chips sticking to the light receiving light emitting sensors of the stacker roller home sensor PS11 Yes Clean the sensors to remove the paper dusts and paper chips 2 Is the stacker roller home sensor PS11 normal C7 Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the sensor 3 Is the stacker roller moving motor MOT5 normal C Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the motor Yes Replace the MC unit 3 3 5 When MOTOR ERROR 2 is displayed 1 Is this message displayed when the paper feed tray rises Yes Check from step 2a onwards No Check from step 2b onwards 2a Is the paper feed tray sensor 1 PS7 or 2 PS9 normal EF Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace t
117. so that when the suction solenoid SOL1 is ON the following state is set lt Adjustment value gt O Clearance A between the solenoid and plunger is 0 to 0 5 mm O The valve head 2 is completely blocking the suction box 3 square hole 1 Solenoid base py AAA po 2 Valve head 3 Suction box 3 2 6 Adjusting paper feed tray sensor 2 PS9 position lt Adjustment value gt Adjust so that when the lever protrusion amount A from the shutter is 1 0 2 mm it is detected by the sensor 3 1 Shutter 2 Lever 3 Sensor bracket Adjusting SCTOW cccooonooccconoconccconcconnnonncnnno DUPLO DF 1000 12T M12M0 0602 0 5 11 4 FOLDING SECTION 4 FOLDING SECTION 4 1 Folding Plate Section 4 1 1 Adjusting the parallelity of the folding stopper Adjust the parallelity of the lead edge of paper and folding stoppers of folding plates 1 and 2 to reduce folding misalignment along the sides of the paper 1 Remove the folding plate from the main body and remove the folding plate upper cover and folding plate lower cover Install the folding plate to the main body with the covers removed 2 Open the top covers L and R Place paper etc between the top cover L switch SW5 and top cover R switch SW1 detector and set each switch to ON
118. solenoid SOL1 normal C Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the solenoid Yes Replace the MC unit 7 6 DUPLO DF 1000 12T M12M0 0602 0 3 TROUBLESHOOTING BY MESSAGE DISPLAYED 3 3 Trouble Messages 3 3 1 When MOTOR ERROR 1 is displayed 1 Is the main motor MOT1 normal CF Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the motor Yes Replace the MC unit 3 3 2 When MOTOR ERROR 4 is displayed 1 Has the folding plate 1 folding stopper locked Yes Rotate the screw shaft unit with a flat screwdriver etc to release the lock If the folding stopper has locked the index sensor may very likely be malfunctioned so replace folding plate 1 index sensors A PS1 and B PS2 2 Is the folding plate 1 home sensor PS3 normal CF7 Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the sensor 3 Is the folding plate 1 stopper motor MOT2 normal CF Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection
119. ssure adjusting knob 1 Loosen the side guide adjusting knobs 1 2 Move the side guides 2 by hand according to the folding misalignment direction Refer to the position of the adjusting knob needle A for the adjusting amount NOTE Always move the left and right side guides in the same direction Folding 3 Tighten the side guide adjusting knobs and misalignment A misalignment B secure the side guides 4 Perform test folding and check that the folding hd misalignment has improved Moving direction of side guide Example of adjusting knob needle position DUPLO DF 1000 12T M12M0 0602 0 1 13 5 USER ADJUSTMENTS 5 2 2 Skew correction by skew correction knob Perform this skew correction if folding misalignment occurs due to trimming misalignment of the paper 1 Loosen the skew roller fixing knobs 1 2 Open the top cover L 2 3 Rotate the skew correction knob 3 according to the folding misalignment direction Refer to the position of the check window needle A shown in the figure for the adjusting amount Folding Folding T a lt Adjusting amount check window gt misalignment C misalignment D Rotating direction of knob Example of check window needle position 4 Close the top cover L 5 Tighten the skew roller fixing knobs 6 Perform test folding and check that the folding misalignment has improved 5 2 3 Using the skew roller spring pressure adjust
120. ted and if they are found to be normal replace the sensor Yes Replace the MC unit DUPLO DF 1000 12T M12M0 0602 0 7 5 3 TROUBLESHOOTING BY MESSAGE DISPLAYED 3 2 Error Messages 3 2 1 When F PLATE SET ERR is displayed 1 Is the folding plate switch SW3 normal EF Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the switch Yes Replace the MC unit 3 2 2 When FEED ERROR is displayed 1 Check 2 1 1 Mis feed first 2 Is the paper feed inlet sensor PS10 normal C Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the optical axis connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the sensor 3 Is the paper feed clutch CLH1 normal C Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the clutch 4 Is the blower fan FAN1 or suction fan FAN2 normal C Refer to Chapter 6 MAINTENANCE MODE gt 3 1 Menu List No Check the connection of connectors and if bundled wires have disconnected or short circuited and if they are found to be normal replace the fan 5 Is the suction
121. ted but not 0 15 5 16 DUPLO DF 1000 12T M12M0 0602 0 4 FOLDING SECTION 4 1 6 Adjusting the motor deceleration pulley section a Gap adjustment Insert a shim in the space A between the idler pulley 1 and E ring 2 and adjust the thrust play to the following value lt Adjustment value gt 0 1 to 0 3 mm b Adjusting the tention of deceleration timing belts 1 and 2 lt Adjustment value gt When a load of 3 N is applied to the timing belt at measuring points B and C the respective slack should be 2 to 3 mm 3 Deceleration timing belt 1 4 Deceleration timing belt 2 5 Motor deceleration pulley De p gt r CO a O 9 I Pee E A O DUPLO DF 1000 12T M12M0 0602 0 5 17 4 FOLDING SECTION 4 1 7 Adjusting the folding stopper section a Fixing the collar 1 2 3 lt Speci
122. the figure and attach the press spring T 1 Spring hook actes Four each in front and rear 2 Press spring Tonino Four each in front and rear 3 Idler roller Eight each in front and rear Reference If extreme folding misalignment along the sides of the paper occur check the balance between the front and rear pressure and adjust by changing the spring hooking direction lt Rear gt lt Front gt 4 2 2 Adjusting the gap of folding roller 1 Adjust the gap in all directions centering around folding roller 1 and center press roller so that when a sheet of fine quality paper 81 4 g m is inserted and removed gently two sheets are properly gripped one over the other Reference value Gap between 0 1 to 0 2 mm 1 Adjusting screw 2 Folding roller 1 3 Center press roller eR MI o lo IN OS IN N S N DUPLO DF 1000 12T M12M0 0602 0 5 19 4 FOLDING SECTION 4 2 3 Checking the folding roller nip 1 Apply press force to all folding rollers 2 Rotate the folding rollers for one round 3 Check that the following value is satisfied between the folding rollers excluding folding roller 1 lt Adjustment value gt O Nip amount A left center right should be uniform at three locations O Backlash B on the whole circumference of the drive gear should be 0 1 to 0 2 mm i Idler roller c Center
123. ting the time for the LCD backlight to go OFF automatically when not using the unit 9 BUZZ ON OFF ON OFF Mode for setting ON OFF the buzzer which sounds during key operations when a process ends or when errors occur excluding motor problems 10 POWER ON BUZZ OFF 5 MIN 15 MIN 30 MIN 9 to 17P 13P Mode for setting the time to sounding a buzzer to alert that the power is still ON when the unit is not used Mode for adjusting the slack of the paper at the registration roller When the pulse count of the main motor becomes the designated setting value after the lead edge of the paper passes the paper feed inlet sensor PS10 the registration clutch CLH3 turns ON The greater the setting value the larger the paper slack will be 12 TRAY DOWN DOWN STAY Mode for setting whether to lower the paper feed tray when this unit detects no paper during standby 14 TOTAL COUNTER 0000000 Displays the total number of sheets fed into the machine max 9999999 15 MC ROM VER 127T 84HHtt Displays the program version of the MC unit 16 PANEL ROM VER 124844444 Displays the program version of the control panel 18 PROG VER UP DUPLO DF 1000 12T M12M0 0602 0 Mode for upgrading the program version Cr Refer to 4 UPGRADING THE PROGRAM VERSION 3 MENUS AND FUNCTIONS Maintenance menu 1st line display 21 MOTOR TEST Setting 2nd line display
124. wing connectors connected normally e MC unit J2 e Switching power supply CN1 CN51 No Re connect the connectors Are the bundled wires between the connectors of step 2 disconnected or short circuited Yes Replace the bundled wires Check for problems in the electric parts of the part connected to and replace if faulty Is rated power supplied to the outlet No Explain to the user that the unit is not faulty When the power switch is turned ON is power conducted to it No Replace the power switch When the power switch is turned ON is AC power supplied to the switching power supply No Replace the bundled wires from the power switch to the switching power supply Check for problems in the electric parts of the part connected to and replace if faulty Yes Replace the switching power supply 4 2 Nothing is Displayed on Control Panel 1 2 Check 4 1 Power Does Not Turn ON first Are the following connectors connected normally e MC unit J6 e Control panel CN1 No Re connect the connectors Are the bundled wires between the connectors of step 2 disconnected or short circuited Yes Replace the bundled wires Check for problems in the electric parts of the part connected to and replace if faulty Is the problem resolved by replacing the control panel Yes End No Replace the MC unit DUPLO DF 1000 12T M12M0 0602 0 7 11 4 TROUBLESHOOTING FOR OPERATION FAILURES 4 3
125. y Pressing the key once increases the folded plane length by 0 125 mm Speed key Pressing the key once decreases the folded plane length by 0 125 mm Repeat steps 3 to 6 until the respective folded plane length becomes the reference value DUPLO DF 1000 12T M12M0 0602 0 5 15 4 FOLDING SECTION 4 1 4 Checking the conveyance path gap of folding plate If the conveyance path gap of the folding plate does not meet the specified value a part may be deformed Continuing use in this state can result in paper jams and folding problems Be sure to change the concerned part lt Specified value gt The conveyance path gap within the 120 mm range from the center of the folding plate should be the following value A Folding plate 1 1 6 mm 7 mm B Folding plate 2 1 6 mm Gay mm wt Stell t o T 120 mm cT t t t t t t t no ca i ms m B l i o o E 4 1 5 Adjusting the gap of the screw shaft unit When attaching the screw shaft unit 1 to the folding plate insert a shim in the space A between the chassis 2 motor side and bearing 3 and adjust the thrust play to the following value lt Adjustment value gt More than 0 1 mm but less than 0 15 mm Thickness gauge of 0 1 can be inser
126. yed is reset to 0 when the power is turned OFF O The number of pulses is counted up even if the main motor shaft is rotated in the normal or reverse directions Contents Remarks 34 THIN KEY CHK Mode for displaying the status of thin paper feed button SW9 36 PANEL CHECK Mode for checking the LEDs and 7 segment of the control panel O Start key The whole 7 segment lights up O Stop key All the LEDs light up 3 2 Other Functions 3 2 1 Setting the paper feed tray sensor 2 PS9 to OFF a Outline When the paper feed tray sensor 2 PS9 is malfunctioning as an emergency measure the detection function can be set to OFF disabled in the use of this unit If required explain the following procedure to users Reference When the paper feed tray sensor 2 PS9 is disabled the paper feed tray sensor 1 PS7 will perform substitute control For this reason the up down operations of the paper feed tray will become slower than normally and the overall processing speed will drop b Operations 1 Turn ON the power switch while pressing the stop and mode keys NOTE This setting is cleared when the power switch is turned OFF 6 10 DUPLO DF 1000 12T M12M0 0602 0 4 UPGRADING THE PROGRAM VERSION 4 UPGRADING THE PROGRAM VERSION 4 1 Outline The version of the program of the MC unit can be upgraded To upgrade the version prepare an EPROM written with the program of the new version 4 1

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