Service manual

ManualsBrandsDuplo ManualsBusiness equipmentDF-755

DUPLO DF-755 86V-M12D0-0

May 2008

Duplo Folder

DF-755

SERVICE MANUAL

Revision 0

Summary of content (126 pages)

PAGE 1
SERVICE MANUAL Duplo Folder DF-755 May 2008 DUPLO DF-755 86V-M12D0-0 Revision 0
PAGE 2
Purpose This manual describes technical details of the product for service engineers to understand the operational principles of the product so that they can provide appropriate maintenance and repair services on the market. As this manual provides information for all regions in which the product is sold in, it may contain information which may not apply to certain regions. Revision The information contained in this manual may be subject to change due to product improvement.
PAGE 3
PREFACE PREFACE Most accidents occur due to failure to observe basic safety rules and precautions. To prevent accidents, it is important to prevent causes of accidents. Engineers performing the servicing of this product on the market (hereafter referred to as SPs) must attend service skill classes prior to providing servicing, as well as read this manual thoroughly to fully understand safety precautions and appropriate servicing procedures.
PAGE 4
PREFACE 1 OUTLINE OF THIS MANUAL 1.1 Components of This Manual The information contained in this manual on servicing work for this product is divided into the following chapters. PREFACE Describes how to read this manual, safety warning for handling this machine, and environmental considerations. CHAPTER 1 INTRODUCTION Mainly describes details to be explained to users such as system conﬁguration, features, speciﬁcations, names of parts, user menus, user maintenance, etc.
PAGE 5
PREFACE 1.2 Electrical Parts Electrical parts are indicated with “symbol + number (two or three digits)” in this manual. While most parts are shown with a sequence number, some parts are organized by categories of functions and units. When only one part exists in a category, the part is indicated only by a symbol without a number. Note “Layout of Electrical Parts” in the Parts Catalog uses the same symbols as used in this manual.
PAGE 6
PREFACE 2 SAFETY PRECAUTIONS This manual indicates and describes operations and uses which are accompanied by safety risks to prevent injuries to users and others as well as damage to property using the following symbols. Ignoring this mark could result in the possibility of serious injury or even death. Ignoring this mark could result in the possibility of injury or physical damage. This symbol indicates “warning” or “caution”.
PAGE 7
PREFACE Do not place anything around the socket-outlet to ensure that the power plug can be disconnected anytime. Failure to disconnect the power plug immediately when the product is working abnormally could result in ﬁre or an electrical shock. Connect the power plug to a socket-outlet which is easily accessible by hand. Failure to disconnect the power plug immediately when the product is working abnormally could result in ﬁre or an electrical shock. 2.
PAGE 8
PREFACE Do not install the product near equipment generating strong magnetic force or in magnetic ﬁelds. Doing so could result in misoperations and malfunctions. 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. Disconnect the power plug from the power outlet before attempting to move this unit. Failure to do so could result in power cord damage, ﬁre or electrical shock.
PAGE 9
PREFACE Prior to beginning servicing work, be sure to turn off the power switch and disconnect the power plug from the socket-outlet. Accidentally operating the product during servicing work could result in injuries. When checking operations with covers removed, be careful not to let hands and clothing get caught in movable parts, etc. 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.
PAGE 10
PREFACE 2.4 WARNING / CAUTION Labels NOTE "WARNING" and "CAUTION" labels are pasted or printed on the machine to ensure user safety. Do not remove or change them. If they become dirty or lost, replace with new ones. USA UK When changing a huse, make sure that the fuse rating is same as that indicated on this label.
PAGE 11
PREFACE 3 ENVIRONMENT CONSIDERATION 3.1 Recovery of Products Recover/disassemble and recycle or dispose products which are no longer required in accordance with the regulations of respective countries and regions. 3.2 Recovery of Consumables/Parts Recover/disassemble and recycle or dispose consumables/parts which are no longer required in accordance with the regulations of respective countries and regions.
PAGE 12
CONTENTS PREFACE............................................... i 1 OUTLINE OF THIS MANUAL .......... ii 1.1 Components of This Manual ...................ii 1.2 Electrical Parts ....................................... iii 2 SAFETY PRECAUTIONS ................ iv 2.1 2.2 2.3 2.4 Power Supply .........................................iv Operating ................................................v Maintenance/Others ..............................vi WARNING / CAUTION Labels .............
PAGE 13
CONTENTS Chapter 3 DISASSEMBLY/ASSEMBLY 1 EXTERNAL COVER/CONTROL SECTION ....................................... 3-2 1.1 1.1.1 1.2 1.2.1 1.2.2 1.3 1.3.1 1.4 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6 1.4.7 1.4.8 1.4.9 External Cover Section ....................... 3-2 External cover .................................................3-2 Control Panel Section ......................... 3-3 Removing the control panel unit ....................3-3 Removing the panel base ................................3-3 Board .....
PAGE 14
CONTENTS 2.2 Adjusting the Folding Plate ................5-11 2.2.1 Adjusting the height of the folding stopper ...........................................................5-11 2.2.2 Attaching the rough adjustment knob .........5-12 2.2.3 Adjusting the ﬁne adjustment knob .............5-12 2.2.4 Adjusting clearance around the switching shaft ...............................................................5-13 2.2.5 Adjusting the parallelity of the folding stopper ..............................................
PAGE 15
Chapter 1 INTRODUCTION DUPLO DF-755 86V-M12D0-0
PAGE 16
1 Features 1 FEATURES 1. Supports six types of standard folding The DF-755 is designed to fold paper into six standard folding patterns. Single fold Double fold Irregular accordion fold Letter fold Accordion fold Gate fold 2. Supports cross folding The DF-755 supports cross single fold and cross letter fold as shown in the ﬁgure.
PAGE 17
2 SPECIFICATIONS 2 SPECIFICATIONS Speciﬁcations and dimensions are subject to change without prior notice for improvements. 2.1 Type and Method Item Type Paper feed method Folding method Paper ejection section conveyance method Contents Desktop paper folder Auto paper separation method Press roll + folding stopper method Stacker roller + ﬂat belt conveyance method 2.2 Performance and Functions 2.2.
PAGE 18
2 SPECIFICATIONS 2.2.2 Functions Item Paper feed tray control Movement of folding stopper Movement of stacker roller Liquid crystal display (LCD) Counter Contents Paper presence detection, manual rise/descent Manual setting Manual setting Processed number of paper, error message 4-digit, count up 2.3 Paper Item Paper type Paper size (Width × Length) Paper quality Paper weight Curl amount H R Contents Sheet Max: 297 × 432 mm (11.0 × 17.0 inches) Min: 128 × 182 mm (5.0 × 7.
PAGE 19
2 SPECIFICATIONS 2.4 Others 2.4.1 Power supply/dimensions/mass (weight) Item Operating environment (Storage environment) Power supply Current consumption Acoustic noise Dimensions (W×D×H) Mass (Weight) 2.4.2 Contents 5 to 35°C (41 to 95°F), 20 to 85%RH (–10% to 50%, 10% to 90%RH) *No condensation USA model:AC120 V–10% 60 Hz UK model: AC220–10%240 V+6% 50 Hz USA model: 0.85A UK model: 0.4A Max: 79dB (A) Machine installation conditions ; Install the unit on a desk of 600 mm (23.62 inches) in height.
PAGE 20
3 NAMES OF PARTS 3 NAMES OF PARTS 3.
PAGE 21
3 NAMES OF PARTS 3.
PAGE 22
4 NAME/FUNCTION OF CONTROL PANEL 4 NAME/FUNCTION OF CONTROL PANEL 4.1 CONTROL PANEL [1] [5] [4] [3] [2] [3] [2] [1] [4] No. 1-8 Name Functions [1] Counter/Liquid crystal display Displays the number of folded sheets (count up) and error messages. Up to four ﬁgures are displayed. When a count number has reached "9999," the count will return to "0" and start counting up again. [2] Stop button Press to stop paper folding.
PAGE 23
5 USER MENU 5 USER MENU 5.1 List Adjustment Remarks Adjusting paper feed pressure Switch the position of the paper feed pressure adjustment knob between "Thin" and "Thick," depending on the paper thickness and feeding conditions. Correcting folding Refer to "5.2.1 Correcting folding misalignment along misalignment along sides of sides of paper." paper Correcting folding Refer to "5.2.2 Correcting folding misalignment along misalignment along vertical vertical length of paper.
PAGE 24
5 USER MENU 5.2 Paper Feed Adjustments 5.2.1 Correcting folding misalignment along sides of paper When folded paper is misaligned along the sides of paper as shown in the ﬁgure, turn the slant correction knob [1] to correct the misalignment. The correction range is within ±0.5 mm (0.02 inch). [1] 1) Turn the slant correction knob [1] to adjust the folding slippage. If folding slippage is as shown in Figure A, turn the knob in the direction of the arrow.
PAGE 25
5 USER MENU 5.2.2 Correcting folding misalignment along vertical length of paper When folded paper is misaligned along the vertical length as shown in the ﬁgure, turn the ﬁne adjustment knob to correct the misalignment. Adjusting Fine Adjustment Knob of the First Folding Plate Folding Style Feeding direction Fold Surface A Adjustment Fine adjustment knob When A is Turn the ﬁne adjustment knob longer counterclockwise. Single fold When A is Turn the ﬁne adjustment knob shorter clockwise.
PAGE 26
5 USER MENU Folding Style Feeding direction Fold Surface A Fine adjustment knob Adjustment When A is Turn the ﬁne adjustment knob longer counterclockwise. Gate fold When A is Turn the ﬁne adjustment knob shorter clockwise.
PAGE 27
5 USER MENU Adjusting Fine Adjustment Knob of the Second Folding Plate Folding Style Fold Surface A Adjustment Fine adjustment knob Single fold The second folding plate is not used in single folding. Feeding direction When B is Turn the ﬁne adjustment knob longer counterclockwise. Double fold When B is Turn the ﬁne adjustment knob shorter clockwise. Irregular accordion fold Letter fold Feeding direction When B is Turn the ﬁne adjustment knob longer counterclockwise.
PAGE 28
5 USER MENU 5.3 Paper Ejection Adjustments 5.3.1 Changing Stacker Rollers Position Refer to the table of stacker rollers position to check the appropriate position of the stacker rollers [1]. [1] Table of Stacker Rollers Position Stacker Rollers Length of Folded Paper Folding Pattern Position 1 182 to 216 mm A3: single fold, irregular accordion fold, gate fold B4 : single fold Single fold larger than A3 size 2 148.5 to 182 mm B4: Irregular accordion, gate fold 3 128.5 to 148.
PAGE 29
6 USER MAINTENANCE Table of Stacker Rollers Position Stacker Rollers Length of Folded Paper Folding Pattern Position 1 7.0 to 8.5 inches LD: single fold, irregular accordion fold, gate fold Single folded paper larger than LD 2 6.0 to 7.0 inches LG: Irregular accordion, gate fold 3 5.0 to 6.0 inches LT: single fold, irregular accordion fold, gate fold LD: letter fold, accordion fold 4 4.0 to 5.0 inches LG: letter fold, accordion fold LD: double fold 5 1.6 to 4.
PAGE 30
6 USER MAINTENANCE 6 USER MAINTENANCE 6.1 List of Maintenance Items Part Rubber roll Paper feed ring Maintenance Frequency Cleaning Once a week Cleaning Once a week Paper separator Cleaning Once a week Paper sensor Ejection gate sensor Ejection belt Cleaning Cleaning Once a week Once a week Cleaning Once a week Remarks If dirty, folding misalignment and paper feed problems can occur. "6.2.1 Cleaning Rubber Rolls and Paper Feed Rings." If dirty, paper is double-fed frequently. "6.2.
PAGE 31
6 USER MAINTENANCE 6.2.1 Cleaning Rubber Rolls and Paper Feed Rings a. Rubber roll 1) Open the top cover. 2) Remove the ﬁrst folding plate and second folding plate from the machine. 3) While rotating the rubber roll [1], clean off the dirt with a cloth moistened with alcohol. [1] b. Paper feed ring 1) Open the top cover. 2) While rotating the rubber roll [2], clean off the dirt with a cloth moistened with alcohol. 6.2.2 1) 2) 3) [2] Cleaning the Paper Separator Open the top cover.
PAGE 32
6 USER MAINTENANCE b. Paper sensor (PS2) Clean PS2e and PS2r, located on the back of the stacker rollers using an air duster. PS2r PS2e 6.2.4 1) Cleaning the Paper Ejection Belts Move the stacker rollers [1] to “5.” [1] 2) 3) 4) While lifting up the stacker rollers [1] with your hand, pull the levers [3] (left and right) attached to the stacker lever [2] in the direction of the arrow so that the stacker rollers [1] are lifted up from the belt [4].
PAGE 33
6 USER MAINTENANCE 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.
PAGE 34
Memo DUPLO DF-755 86V-M12D0-0
PAGE 35
Chapter 2 OPERATIONS DUPLO DF-755 86V-M12D0-0
PAGE 36
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.
PAGE 37
1 OUTLINE 1.2 Block Diagram of Structure [2] Control panel (PCB2) [1] MC unit (PCB1) +20.
PAGE 38
1 OUTLINE [1] MC unit (PCB1) Incorporates a ﬂash ROM for controlling the overall operations of this unit. The followings are main functions. a. Overall control The control program written to the ﬂash ROM controls the overall operations of this unit (paper feed, folding, paper ejection). The control program is written in the microprocessor. b. 5VDC, 24VDC generation 24VDC is used as the power supply for loading and micro switches. 5VDC is used as the power supply for the controlling system and photo sensors.
PAGE 39
1 OUTLINE [11] Top cover switch (SW1) Refer to “2.1.2 Safety function." [12] First folding plate switch (SW2) Refer to “2.1.2 Safety function." [13] Second folding plate switch (SW3) Refer to “2.1.2 Safety function." [14] Paper feed solenoid (SL1) Transmits the drive of the AC motor (M1) to the paper feed ring.
PAGE 40
1 OUTLINE 1.3 Basic Operations 1.3.1 Operations at power On 1.3.2 Operations at power Off 1.3.3 Operation during processing 1) 2) Power switch on Standby status 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) Press the Start button.
PAGE 41
2 EXTERNAL COVER/CONTROL SECTION 2 EXTERNAL COVER/CONTROL SECTION 2.1 Power Supply 2.1.1 Outline [1] MC unit (PCB1) 20.
PAGE 42
2 EXTERNAL COVER/CONTROL SECTION 2.1.2 Safety function a. Conﬁguration [7] Top cover switch (SW1) Detects the open/close of the top cover. “COVER OPEN”; When the top cover is detected as open, this message appears on the control panel. [8] First folding plate switch (SW2) Detects the presence of the ﬁrst folding plate. "PRAT-1 SET ERR"; When the ﬁrst folding plate switch cannot detect the ﬁrst folding plate, this message appears on the control panel.
PAGE 43
2 EXTERNAL COVER/CONTROL SECTION 2.2 Main Motor Control 2.2.1 Outline Main motor (M1) USA: 120VAC/60Hz/60W UK: 230VAC/50Hz/60W 2.2.2 1) 2) 3) M1 Operations The microcomputer controls the AC motor relay in the MC unit. When the AC motor locks during operations for some reason, the microcomputer detects it and shuts down the relay to interrupt electrical supply.
PAGE 44
2 EXTERNAL COVER/CONTROL SECTION 2.3 Counter 2.3.1 Outline 2.3.2 Operations Total counting for maintenance is performed on the program and recorded in the EEPROM (U2) on the MC unit. The total count recorded in the EEPROM (U2) can be checked in the maintenance mode. Refer to “Chapter 6 > 3 MENUS AND FUNCTIONS." The total count increases when paper has passed the ejection gate sensor (PS2e, PS2r).
PAGE 45
3 PAPER FEED SECTION/CONVEYANCE SECTION 3 PAPER FEED SECTION/CONVEYANCE SECTION 3.1 Outline 3.1.1 Conﬁguration The functions of the paper feed section can broadly be divided into the paper feed table section and conveyance section. [1] [2] [1] Paper feed table section [2] Conveyance section 3.1.2 Paper feed pressure adjustment knob A user can switch a paper feed pressure between "Thick" and "Thin" using the knob.
PAGE 46
3 PAPER FEED SECTION/CONVEYANCE SECTION 3.1.3 Paper feed table setting operations 3.1.4 Conveyance section operations A user manually adjusts the position of the feed guides and raises or lowers the paper feed table. 1) When paper is placed on the paper feed table, the paper sensor (PS1) detects the presence of paper. 2) When the Start button is pressed, the paper feed rings feed a sheet of paper to the inside the machine.
PAGE 47
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.
PAGE 48
4 FOLDING SECTION 4.1.2 Folding operations a. Outline First folding 1) Paper conveyed by the idler roller and center press roll touches the folding stopper of the ﬁrst folding plate. 2) The paper is continuously fed touching the folding stopper of the ﬁrst folding plate and slacks. 3) The slackened part of the paper is sandwiched between the center press roll and ﬁrst press roll.
PAGE 49
4 FOLDING SECTION b. Single fold (1) (1) i i C C (2) (2) c. Double fold (1) i C (1) (1) i i C C (2) (2) (2) d.
PAGE 50
4 FOLDING SECTION e. Letter fold (1) i C (1) (1) i i C C (2) (2) (2) f. Accordion fold (1) i C (1) (1) i i C C (2) (2) (2) g.
PAGE 51
4 FOLDING SECTION 4.2 Folding Roller Section 4.2.
PAGE 52
5 PAPER EJECTION SECTION 5 PAPER EJECTION SECTION 5.1 Outline 5.1.1 Conﬁguration The functions of the ejection section can broadly be divided into the ejection belt section and stacker roller section. [2] [1] [1] Ejection belt section [2] Stacker roller section 5.1.2 Paper ejection operations Folded paper is ejected by the stacker roller and ejection belt. 5.2 Ejection belt section 5.2.1 Conﬁguration The AC motor (M1) drives the stacker rollers to turn the ejection belt. 5.
PAGE 53
Chapter 3 DISASSEMBLY/ASSEMBLY DUPLO DF-755 86V-M12D0-0
PAGE 54
1 EXTERNAL COVER/CONTROL SECTION 1 EXTERNAL COVER/CONTROL SECTION 1.1 External Cover Section 1.1.1 External cover [1] [3] [2] 3-2 No.
PAGE 55
1 EXTERNAL COVER/CONTROL SECTION 1.2 Control Panel Section 1.2.1 1) 2) Removing the control panel unit Remove the cover R. Disconnect the connector of the control panel, and remove the control panel. [1] Connector .................................................. 1 [2] Screw ......................................................... 4 [3] Control panel [3] [1] [2] 1.2.2 1) Removing the panel base Remove the control panel unit. Refer to "1.2.1 Removing the control panel unit.
PAGE 56
1 EXTERNAL COVER/CONTROL SECTION 1.4 Power Supply/Drive/Others 1.4.1 1) 2) [1] [2] Removing the cover for electric components Remove the second folding plate. Remove the cover for electronic components. Screw ......................................................... 5 Cover for electric components [2] [1] 1.4.2 1) 2) Removing the AC motor drive unit (PCB3) Remove the second folding plate. Remove the cover for electronic components. Refer to "1.4.1 Removing the cover for electronic components.
PAGE 57
1 EXTERNAL COVER/CONTROL SECTION 1.4.3 1) 2) [1] 3) [2] 4) [3] Removing the MB belt Remove the cover L. Loosen the screws of the tension pulley. Screw ......................................................... 2 Displace the tension pulley. Tension pulley Remove the MB belt. MB belt Note When attaching the MB belt, adjust its tension. Refer to “Chapter 5>1.7 Adjusting the MB belt Tension." [3] 1.4.4 1) 2) [2] [1] Removing the AC motor (M1) Remove the cover L.
PAGE 58
1 EXTERNAL COVER/CONTROL SECTION 4) [3] [4] [5] 5) Remove the connector. Connector .................................................. 2 SK binder .................................................. 1 Bushing ..................................................... 1 [3] [5] [3] Remove the MB belt. Refer to "1.4.3 Removing the MB belt." Note When attaching the MB belt, adjust its tension. Refer to “Chapter 5>1.7 Adjusting the MB belt Tension." [4] 6) Remove the nut securing the AC motor (M1) to the frame.
PAGE 59
1 EXTERNAL COVER/CONTROL SECTION 1.4.6 Removing the tension spring 1.4.7 Removing the paper feed clutch 1) Remove the cover L. 2) Remove the tension spring using a plier. [1] Tension spring 1) Remove the MB belt. Refer to "1.4.3 Removing the MB belt." 2) Remove the nut of the paper feed clutch unit from the inside the frame. [1] Nut ............................................................ 1 [2] Spring washer...........................................
PAGE 60
1 EXTERNAL COVER/CONTROL SECTION 1.4.8 1) 2) [1] 3) 4) [2] [3] [4] Removing the top cover microswitch (SW1) Remove the cover R. Disconnect the connector of the microswitch. Connector .................................................. 1 Cut the SK binder using a nipper. Remove the top cover microswitch. SK binder .................................................. 2 Screw ......................................................... 2 SW1 [4] [3] [2] [1] 1.4.
PAGE 61
2 PAPER FEED SECTION 2 PAPER FEED SECTION 2.1 Paper Feed Table Section 2.1.1 Removing the paper feed shaft unit 2.1.2 Removing the paper feed rings 1) Remove the paper feed shaft unit. [1] Screw ......................................................... 1 1) Remove the paper feed rings. Refer to "2.1.1 Removing the paper feed shaft unit." 2) Remove the set screw. [1a] Set screw ................................................... 1 [1b] Washer ......................................................
PAGE 62
2 PAPER FEED SECTION 2.1.3 1) Removing the paper separator plate Remove the paper feed shaft unit. Refer to "2.1.1 Removing the paper feed shaft unit." 2) Remove the paper feed gate. [1] Screws ....................................................... 2 [2] Paper feed gate unit 3) Remove one of the E ring from the paper separator plate. [3] E ring ........................................................ 1 4) Remove the shaft. [4] Shaft ..........................................................
PAGE 63
3 FOLDING SECTION 3 FOLDING SECTION 3.1 Folding Roller Section 3.1.1 Removing the P roll cover [2] 1) Remove the P roll cover. [1] Screw ......................................................... 2 [2] P roll cover 3.1.2 Removing the idler roller 1) [1] [2] [3] [1] Remove the idler roller. E ring .......................................... 1 each Square metal .............................. 1 each Spring ..........................................
PAGE 64
3 FOLDING SECTION 3.1.3 Removing the press rolls 1) Remove the pulley of the center press roll. (non-operator's side) [1] Screw ........................................... 1 [2] Pulley .......................................... 1 2) [3] [4] [5] Remove the press levers from the ﬁrst press roll. Tension spring ..................................1 each E ring ................................................1 each Press lever ........................................
PAGE 65
3 FOLDING SECTION 3) [6] [7] [8] Remove the bearing of the ﬁrst press roll. Bearing screw ...................................1 each Bearing..............................................1 each Screw (securing the ﬁrst press roll bearing) ......................................1 each [9] First press roll bearing.....................1 each 4) Remove the ﬁrst press roll and switching shaft. [10] Spring ................................................
PAGE 66
3 FOLDING SECTION 5) Remove the tension spring of the paper feed table. [14] Tension spring 6) Remove the second press roll. [15]Tension spring...................................1 each [16] Screw of the press lever ...................1 each [17] E ring ................................................1 each [18]Press lever .........................................1 each [19] Second press roll bearing .................1 each [20] Second press roll [14] 7) Remove the center press roll.
PAGE 67
3 FOLDING SECTION 3.2 Folding Plate Section 3.2.1 1) 2) [1] [2] Removing the half nut of the ﬁrst folding plate Remove the ﬁrst folding plate. Remove the rough adjustment knob. FR screw ..................................... 2 Rough adjustment knob 3) Remove the top cover. [3] Screw ......................................................... 5 [4] Top cover 4) [5] [6] [7] Remove the ﬁne adjustment knob and bearing from the ﬁrst folding plate. FR screw ...................................................
PAGE 68
3 FOLDING SECTION 3.2.2 1) 2) [1] [2] Removing the half nut of the second folding plate Remove the second folding plate. Remove the rough adjustment knob using the L-type wrench. FR screw ................................................... 2 Rough adjustment knob 3) Remove the lock lever. [3] Screw [4] Lock lever 4) Remove the top cover. [5] Screw .........................................................
PAGE 69
3 FOLDING SECTION [3] [4] [2] [7] [5] [8] [1] [5] [9] [6] [5] [11] [13] [14] [10] [12] DUPLO DF-755 86V-M12D0-0 3-17
PAGE 70
3 FOLDING SECTION 3.2.3 1) [1] [2] [3] 2) [4] [5] Removing the ﬁrst folding plate micro switch (SW2) Remove the connector of the ﬁrst folding plate. Connector .................................................. 1 Screw ......................................................... 1 Clamp ........................................................ 1 Remove SW2. Screw ......................................................... 2 SW2 3.2.
PAGE 71
4 PAPER EJECTION SECTION 4 PAPER EJECTION SECTION 4.1 Stacker Section 4.1.1 1) Removing the stacker roller Remove the upper screw (non-operator's side). 2) Loosen the lower screw (non-operator's side). 3) Remove the stacker roller. [1] Upper screw .............................................. 1 [2] Lower screw .............................................. 1 [3] Stacker roller [1] [2] [3] 4.1.2 Removing the ejection belt 1) [1] [2] [3] [4] [5] Remove the paper receiving tray.
PAGE 72
4 PAPER EJECTION SECTION 4) Remove the shaft unit. [7] Screw .................................................1 each [8] Shaft unit [8] [7] 5) Remove the ST shaft. [9] E ring ........................................................ 2 [10] Pulley ........................................................ 1 [11] Gear ........................................................... 3 [12] E ring ........................................................ 2 [13] E ring .................................................
PAGE 73
4 PAPER EJECTION SECTION 6) Remove the ejection belt and stacker plate. Note When attaching the MB belt, adjust its tension. Refer to "Chapter 5>1.8 Adjusting the Ejection Belt Tension." 4.2 Ejection Gate Sensor 4.2.1 1) 2) Removing the Ejection Gate Sensor (PS2e, PS2r) Remove the ﬁrst folding plate and second folding plate. Remove the cover for electronic components. Refer to "1.4.1 Removing the cover for electronic components." 3) Remove the lower paper feed gate. [1] Screw ..........................
PAGE 74
4 PAPER EJECTION SECTION 5) Remove the reinforcement plate. [5] Screw ......................................................... 4 [6] Reinforcement plate [6] [5] [5] 6) Disconnect the connector of the rejected guide unit. [7] Screw ......................................................... 1 [8] Clamp ........................................................ 1 [9] Connector .................................................. 1 7) Remove the rejected guide unit. [10] Screw .................................
PAGE 75
4 PAPER EJECTION SECTION 8) Remove the ejection gate sensor (PS2r) from the rejected guide unit. [12] Nut ............................................................ 2 [13] PS2r [14] Connector .................................................. 1 9) Remove the guide plate unit from the rejected guide unit. [15] Screw ......................................................... 2 [16] Guide plate unit........................................
PAGE 76
4 PAPER EJECTION SECTION 11) Remove the ejection gate sensor (PS2e) from the ejection gate sensor bracket. [20] Screw .........................................................
PAGE 77
Chapter 4 MAINTENANCE/INSPECTION DUPLO DF-755 86V-M12D0-0
PAGE 78
1 LIST OF MAINTENANCE TOOLS 1 LIST OF MAINTENANCE TOOLS 1.1 General Tools Tool name Phillips screwdriver Phillips screwdriver (Long) Phillips screwdriver (Short) Flat screwdriver (Large) Flat screwdriver (Small) Long nose plier Plier Spanner M3 (5.5 mm across) Spanner M4 (7.0 mm across) Spanner M5 (8.0 mm across) Spanner M6 (10.0 mm across) Hexagonal wrench (1.5 mm across) Hexagonal wrench (2.0 mm across) Hexagonal wrench (2.
PAGE 79
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).
PAGE 80
3 PERIODIC MAINTENANCE 3 PERIODIC MAINTENANCE 3.1 Basic Maintenance To maintain the quality of this product, perform inspections at the following cycle. •One month after installation •Every six months or 200,000 uses 3.
PAGE 81
Chapter 5 STANDARDS/ADJUSTMENTS DUPLO DF-755 86V-M12D0-0
PAGE 82
1 PAPER FEED SECTION 1 PAPER FEED SECTION 1.1 Adjusting the Paper Feed Table To ensure the loading capacity of 500 sheets (64 g/m², 17 lb.), adjust the position of the hinge lever roller unit by moving it up or down. • Adjust the position of the hinge lever roller until the hinge lever touches the stopper when you raise the paper set lever to lower the paper feed table. • Adjust the position of the hinge lever roller until the the paper feed table stops at the depth of 45 mm (1.
PAGE 83
1 PAPER FEED SECTION 1.2 Adjusting the Paper Feed Pressure 1) 2) 3) [1] [2] [3] [4] [A] 4) [5] [6] Lower the paper set lever. Switch the paper feed pressure adjustment knob to "thin paper." Hold the tension gauge of 2 kg against the notch located on the tip of the paper feed table (operator's side), and press it down 15 mm (0.59 inch) from the corner of the paper feed gate unit. Notch Tension gauge Lower paper feed gate unit Paper feed table 15 mm (0.
PAGE 84
1 PAPER FEED SECTION 1.3 Checking the Paper Feed Gear and Back Lash If there is no appropriate backlash between the paper feed gear and clutch gear, it may cause a noise or wear-out and damage to the parts. 1) Check that a backlash of between 0.1 mm (0.004 inch) and 0.2 mm (0.008 inch) exists between the paper feed gear and clutch gear. [1] Paper feed gear [2] Clutch gear [A] Backlash: 0.1 to 0.2 mm (0.004 to 0.008 inch) 2) Check that grease is applied around the gear. [1] [A] [2] 1.
PAGE 85
1 PAPER FEED SECTION 4) Make the solenoid on and press the plunger against the solenoid ﬁrmly to lower the solenoid lever completely. [1] Solenoid [2] Plunger [5] Solenoid lever 5) [1] [3] [4] [5] [6] [C] When the solenoid lever has reached its lowest position, adjust the position of the solenoid and secure it to the solenoid bracket so that the clearance between the protruding part and the tip of the solenoid lever is [C]. Solenoid Clutch case Protruding part Solenoid lever Solenoid bracket 1 to 1.
PAGE 86
1 PAPER FEED SECTION 1.5 Checking the Backlash of the Stacker Gear and Idler Gear If there is no appropriate backlash between the stacker gear and idler gear, it may cause a noise or wear-out and damage to the parts. 1) Check that a backlash [A] exists between the stacker gear and each idler gear. [1] Gear [A] Backlash: 0.1 to 0.2 mm (0.004 to 0.008 inch) 2) Check that grease is applied around the gear.
PAGE 87
1 PAPER FEED SECTION 1.6 Checking the Position of the Motor Pulley If the motor pulley is not in the correct position, the MB belt may get entangled or run off. 1) Check that the distance between the motor pulley and the frame is [A]. [1] Motor pully [2] Frame [A] 35 mm (1.
PAGE 88
1 PAPER FEED SECTION 1.7 Adjusting the MB belt Tension If the tension of the MB belt is not enough, a feed error or folding error due to a noise or slippage may occur. 1) Apply pressure on the MB belt with a tension gauge of 2 kg. Apply the tension gauge to the middle point between the motor pulley and paper feed clutch pulley.
PAGE 89
1 PAPER FEED SECTION 1.8 Adjusting the Ejection Belt Tension If the tension of the ejection belt is not enough, poor alignment of paper or paper jam may occur due to slippage. If these phenomena occur, adjust them as follows. 1) 2) [1] [2] 3) 4) Loosen the screw securing the shaft unit. Move the shaft unit to strain the belt. Shaft unit Ejection belt Check that the tension is equal between the left and right belts. Tighten the screw. Secure the shaft unit at the top of the long hole.
PAGE 90
2 FOLDING SECTION 2 FOLDING SECTION 2.1 Checking and Adjusting Press Force If the press force between left and right is extremely different, horizontal folding misalignment may occur or paper may get wrinkled. If extreme folding misalignment along the sides of the paper occur, check the balance between the left and right pressure. 1) [1] [2] [3] 2) [4] [5] [6] 3) [7] Hang a tension gauge of 5 kg on the bearing holder of the press lever and pull the gauge little by little.
PAGE 91
2 FOLDING SECTION 2.2 Adjusting the Folding Plate Before adjusting the folding plate, remove the top cover of the folding plate. Refer to "Chapter 3>3.2 Folding Plate Section." 2.2.1 Adjusting the height of the folding stopper Adjusting the vertical swing of the folding stopper will reduce a vibration and noise caused by motion of the stopper, and will stabilize the folding accuracy. 1) Loosen the M3 screws and nuts located on either side of the folding stopper. [1] Screw ...............................
PAGE 92
2 FOLDING SECTION 2.2.2 1) [1] [2] 2) [3] [4] [A] 3) [5] [6] Attaching the rough adjustment knob Make the half nut mesh with the screw shaft. Half nut Screw shaft Attach the rough adjustment knob so that the clearance between the top cover and the rough adjustment knob is [A]. Top cover Rough adjustment knob Clearance: 1.5 mm (0.06 inch) Align the indicator of the scale nameplate with that of the pull nameplate. Scale label Adjustor nameplate [6] [4] [3] [A] [1] [2] [5] 2.2.
PAGE 93
2 FOLDING SECTION 2.2.4 Adjusting clearance around the switching shaft If the clearance between the switching shaft and center press roll is not enough, a paper jam may occur during cross folding or single folding operations, causing damage to the center press roll. 1) Screw down the ﬂap adjust plate so that the clearance between the folding stopper and the back end of the ﬂap adjust plate is [A]. [1] Folding stopper [2] Flap adjust plate [A] Clearance: 6 mm (0.
PAGE 94
2 FOLDING SECTION Note Although there is no problem with the ﬁnish when the clearance [B] between the switching shaft and center press roll is 0.5 mm (0.02 inch), a noise during operation (single folding) will be larger with the clearance of 0.5 mm (0.02 inch) than with that of 0.3 mm (0.012 inch). [4] Cushion [5] [4] First press roll First press roll [2] [5] Second press roll Second press roll Cushion [A] [B] [1] [3] 2.2.
PAGE 95
2 FOLDING SECTION 3) Lower the paper set lever to raise the paper feed table. 4) Rotate the paper feed rings to send the paper to the idler roller. [5] Paper feed ring [6] Idler roller 5) Rotate the idler roller to send the paper to the ﬁrst folding plate. [6] Idler roller [5] [6] Leading edge of the paper and the folding stopper should be parallel to each other. 6) Send the paper until the paper lead edge touches the folding stopper of the ﬁrst folding plate.
PAGE 96
2 FOLDING SECTION 2.3 Adjusting the Bearing Support Lever The bearing support lever increases the power of conveyance and reduces conveyance failures of thick paper. 2.3.1 Adjusting the bearing support lever after replacing the bearing 1) 2) [1] [2] 3) Remove the top cover. Secure the bracket R (or bracket L) temporarily. Bracket R Bracket L Press down the bracket R (or bracket L) downward as shown in the ﬁgure and tighten the securing screw.
PAGE 97
3 EXTERNAL COVER SECTION 3 EXTERNAL COVER SECTION 3.1 Adjusting the interlock switch position a. Top cover switch (SW1) 1) Open the top cover. 2) Make the following adjustments so that the switch is activated when the top cover is closed. • Secure the switch bracket at a position where the lever on the back of the top cover presses down the actuator of the interlock switch to activate the switch.
PAGE 98
3 EXTERNAL COVER SECTION b. First folding plate switch (SW2), second folding plate switch (SW3) 1) Remove the ﬁrst folding plate and the second folding plate from the machine. 2) Make the following adjustment so that the SW2 and SW3 are activated when the ﬁrst folding plate and the second folding plate are installed to the machine. • Secure the switch bracket at a position where the side of the folding plate presses down the actuator of the interlock switch to activate the switch.
PAGE 99
Chapter 6 MAINTENANCE MODE DUPLO DF-755 86V-M12D0-0
PAGE 100
1 OUTLINE 1 OUTLINE This unit has the following functions to ensure smooth servicing work.
PAGE 101
2 MAINTENANCE MODE OPERATIONS 2 MAINTENANCE MODE OPERATIONS 2.1 Entering the Maintenance Mode 1) With the paper sensor (PS1) on the paper feed table interrupted, turn on the power switch while pressing down the Start button and Stop button. "TEST MODE" sill be displayed on the LCD display. 2.2 Exiting the Maintenance Mode 1) Turn off the power switch. When turned on again, the user menu will be displayed on the LCD display.
PAGE 102
3 MENUS AND FUNCTIONS 3 MENUS AND FUNCTIONS Maintenance menu TEST MODE ******* (number display) Functions Simulation run Total count (total number of folded paper since the ﬁrst use of the machine) TEST MODE or Swithing of language (English<=>Japanese) Remarks Press the Start button. Press the C button for two seconds.While pressing it, the total count is displayed. When you release the button, "TEST MODE" is displayed. Pressing the Stop button for ﬁve seconds switches the languge displayed.
PAGE 103
Chapter 7 TROUBLESHOOTING DUPLO DF-755 86V-M12D0-0
PAGE 104
1 OUTLINE 1 OUTLINE The problems of this machine 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; ○ Paper feeding problem ○ Folding problem ○ Discharging problem If these phenomena occur, refer to the following and perform the appropriate measure. Refer to “2 TROUBLESHOOTING BY PHENOMENON.” 2.
PAGE 105
2 TROUBLESHOOTING BY PHENOMENON 2 TROUBLESHOOTING BY PHENOMENON 2.1 Paper Feed Problem 2.1.1 Mis-feed 1) Is the paper feed pressure adjustment knob set to "Thin paper?" No: Set the paper feed pressure adjustment knob to "Thick paper." 2) Is the paper bend because it is hardly pressed against the side guide? Yes: Press the side guide to each side of the paper lightly. 3) Are the paper feed rings dirty? Yes: Clean them. Refer to "Chapter 1 > 6 USER MAINTENANCE.
PAGE 106
2 TROUBLESHOOTING BY PHENOMENON 2.1.2 Double-feed 1) Is the paper feed pressure adjustment knob set to "Thick paper?" Yes: Set the paper feed pressure adjustment knob to "Thin paper." 2) Is the paper separator dirty? Yes: Clean it. Refer to "Chapter 1 > 6 USER MAINTENANCE." 3) Has the paper separator reached its end of life? Refer to "Chapter 4> 2.2.1 Recommended spare parts A (Consumables)." Yes: Replace the paper separator. Refer to "Chapter 3 >2.1.3 Removing the paper separator plate.
PAGE 107
2 TROUBLESHOOTING BY PHENOMENON Yes: Replace the paper feed rings. Refer to "Chapter 3 >2.1.2 Removing the paper feed rings." No: 2.1.5 Adjust the folding stopper. Refer to "Chapter 5 > 2.2.5 Adjusting the parallelity of the folding stopper." When the second paper is not fed after the ﬁrst paper is discharged 1) Is the paper mis-fed? Yes: Refer to "2.1.1 Mis-feed." 2) Does the ejection gate sensor (PS2e, PS2r) function properly? Yes: Replace the MC unit (PCB1).
PAGE 108
3 TROUBLESHOOTING BY MESSAGE DISPLAYED 2.2.3 When paper is not folded at the normal position 1) Is folding plate set properly? No: Set the folding plate properly. 2) Has static electricity occurred in the paper? Yes: Fan the paper well. 3) Is the press roll dirty ? Yes: Clean or replace it. Refer to "Chapter 1 > 6 USER MAINTENANCE." No: Adjust the folding section. Refer to "Chapter 5 > 2 FOLDING SECTION." 2.3 Discharging Problem 2.3.
PAGE 109
3 TROUBLESHOOTING BY MESSAGE DISPLAYED 3 TROUBLESHOOTING BY MESSAGE DISPLAYED NO PAPER 1) Is paper on the paper feed table? No: Stack paper on the paper feed table. 2) Does the paper reach the end of the paper feed tray? No: Push paper all the way in so that the paper reaches the end of the paper feed table. 3) Is the paper sensor (PS1) dirty? Yes: Clean it. Refer to "Chapter 1 > 6 USER MAINTENANCE." 4) Does the paper sensor (PS1) function properly? Yes: Replace the MC unit (PCB1).
PAGE 110
3 TROUBLESHOOTING BY MESSAGE DISPLAYED PRAT-1 SET ERR 1) Is the attaching position of the ﬁrst folding plate switch (SW2) appropriate? No: Adjust the position. Refer to "Chapter 5 > 3.1 Adjusting the interlock switch position." 2) Are there foreign particles on the detection part of the ﬁrst folding plate switch (SW2) or is it broken or deformed? Yes: Clean the part or replace the ﬁrst folding plate switch (SW2).
PAGE 111
4 TROUBLESHOOTING FOR OPERATION FAILURES 4 TROUBLESHOOTING FOR OPERATION FAILURES 4.1 Power 4.1.1 Power does not turn on 1) Is the power plug inserted into the power outlet properly? No: Insert it properly. 2) Is the fuse (F1) burned out? Yes: Replace the fuse (F1). 3) Are the following connectors connected properly? •AC motor drive unit: J1, J4 •MC unit (PCB1): J6 No: Connect them properly.
PAGE 112
4 TROUBLESHOOTING FOR OPERATION FAILURES 4.2.2 Button operations are disabled on the control panel 1) Is there any button which remains pressed? Yes: Release the button and check for button input. 2) Are the following connectors connected normally? •MC unit (PCB1): J3 •Control panel: J2 No: Connect them properly. 3) Are the bundled wires between the connectors of step 2) disconnected or short-circuited? Yes: Replace the bundled wires.
PAGE 113
APPENDIX DUPLO DF-755 86V-M12D0-0
PAGE 114
1 LIST OF DISPLAYED MESSAGES 1 LIST OF DISPLAYED MESSAGES 1.1 No Paper Message NO PAPER Detection details The paper sensor (PS1) detected no paper on the paper feed table. 1.2 NO PAPER and the number of folded paper blinks alternately Message NO PAPER/ ****(the number of folded paper) Detection details The paper sensor (PS1) detected no paper on the paper feed table. When paper is stacked, the number of folded paper is displayed. 1.
PAGE 115
2 LAYOUT OF ELECTRICAL PARTS 2 LAYOUT OF ELECTRICAL PARTS 2.
PAGE 116
2 LAYOUT OF ELECTRICAL PARTS 2.
PAGE 117
2 LAYOUT OF ELECTRICAL PARTS 2.
PAGE 118
2 LAYOUT OF ELECTRICAL PARTS 2.
PAGE 119
2 LAYOUT OF ELECTRICAL PARTS 2.
PAGE 120
3 LAYOUT OF BOARDS 3 LAYOUT OF BOARDS 3.
PAGE 121
3 LAYOUT OF BOARDS J3 J4 J5 J1 J2 J6 J7 DUPLO DF-755 86V-M12D0-0 A-9
PAGE 122
3 LAYOUT OF BOARDS 3.
PAGE 123
3 LAYOUT OF BOARDS 3.
PAGE 124
4 SCHEMATIC DIAGRAMS (PS2e/r) Paper Ejection Sensor Yellow/Green 47 (F1) Fuse (PS1) Power Plug Orange Purple Paper Exit Sensor GND IRout 2 Brown 3 1 2 Fuse Holder Stop 2P Connector 1 1 2 Red White (PS2e) 1 GND 2 PM2 IR Sender 1 VCC 2 GND IR Receiver Control Panel 2 4 6 8 10 12 14 16 18 20 1 3 5 7 9 11 13 15 17 19 (PS2r) (SW3) NC Blue Brown 2 (SW2) NO NC First Folding Plate Switch Second Folding Plate Switch NC C NO NO C Yellow C Yellow AC1 AC2 1 2 1
PAGE 125
-Issued- DUPLO CORPORATION Duplo building, 1-6, Oyama 4 chome, Sagamihara, Kanagawa 229-1180, Japan Revision 0 (May 2008) DUPLO DF-755 86V-M12D0-0
PAGE 126
86V-M12D0 DUPLO DF-755 86V-M12D0-0