Duplo DF-1000 Service Manual


Accurate and concise text, combined with detailed illustrations, lists of error code, instruction and diagrams, guide you through procedure of repair, remediate, maintenance and adjustments your Duplo Air Suction Paper Folder.
Present service manual Duplo DF-1000 contain clear instructions and procedures on how to fix the problems occurring in your equipment.
Format of the manual: PDF, makes it easy to navigate, instant download and print. English language.
Table of contents:

Preface
1 Organization of This Manual
2 Safety Precautions
2.1 Power Supply
2.2 Operating Environment
2.3 Maintenance, etc
2.4 Warning and Caution Label Locations
3 Environmental Preservation
3.1 Collection of This Unit
3.2 Collection of Consumables and Parts

Chapter 1. INTRODUCTION
1 Features
2 Specifications
2.1 Type and Method
2.2 Performance and Functions
2.2.1 Processing performance
2.2.2 Functions
2.3 Paper
2.4 Others
2.4.1 Power supply/dimensions/mass (weight)
2.4.2 Error detection functions
3 Names of Parts
3.1 External Parts
4 Control Panel
4.1 Control Panel
4.2 User Menu (Function Setting Mode)
5 User Adjustments
5.1 List of Adjustments
5.2 Paper Feed Adjustments
5.2.1 Skew correction by side guide adjusting knob
5.2.2 Skew correction by skew correction knob
5.2.3 Using the skew roller spring pressure adjusting knob
5.3 Folding Position Adjustments
5.3.1 Folding position correction by folding mode
5.4 Paper Ejection Adjustments
5.4.1 Changing the stacker roller position
5.4.2 Changing the stacker roller height
6 User Maintenance
6.1 List of Maintenance Items
6.2 Cleaning by User
6.2.1 Cleaning the sensors
6.2.2 Cleaning the suction belts
6.2.3 Cleaning the folding rollers
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
1.3.1 Operations at power ON
1.3.2 Operations at power OFF
1.3.3 Operation during processing
1.3.4 Stopping operations when problems occur
2 External Cover/Control Section
2.1 Power Supply
2.1.1 Outline
2.1.2 Safety function
2.2 Main Motor Control
2.2.1 Outline
2.2.2 Operations
2.3 Counter
2.3.1 Outline
2.3.2 Operations
3 Paper Feed Section
3.1 Outline
3.1.1 Configuration
3.1.2 Paper feed operations
3.2 Paper Feed Tray Section
3.2.1 Outline
3.2.2 Side guide section
3.2.3 Tray up/down section
3.3 Suction Conveyance Section
3.3.1 Outline
3.3.2 Separator section
3.3.3 Suction section
3.3.4 Conveyance section
3.4 Registration Section
3.4.1 Outline
3.4.2 Registration control (Skew correction)
4 Folding Section
4.1 Outline
4.1.1 Configuration
4.1.2 Folding operations
4.2 Folding Plate Section
4.2.1 Outline
4.2.2 Folding stopper sections of folding plates 1 and 2
4.3 Folding Roller Section
4.3.1 Configuration
5 Paper Ejection Section
5.1 Outline
5.1.1 Configuration
5.1.2 Paper ejection operations
5.2 Stacker Belt Section
5.2.1 Configuration
5.2.2 Stacker belt drive
5.3 Stacker Roller Section
5.3.1 Configuration
5.3.2 Lever unit drive

Chapter 3. DISASSEMBLY/ASSEMBLY
1 External Cover/Control Section
1.1 External Cover Section
1.1.1 External cover
1.2 Control Panel Section
1.2.1 Removing the control panel
1.3 Board
1.3.1 Removing the MC unit
1.4 Power Supply/Drive
1.4.1 Removing the switching power supply
1.4.2 Removing the main motor (MOT1)
1.4.3 Removing the paper feed tray motor
2 Paper Feed Section
2.1 Paper Feed Tray Section
2.1.1 Removing the PS P.W.B. unit
2.2 Suction Conveyance Section
2.2.1 Removing the suction conveyance unit
2.2.2 Removing the suction belts
2.3 Registration Section
2.3.1 Removing the registration clutch (CLH3)
2.3.2 Removing the registration brake (BRK1)
2.3.3 Removing the registration secondary roller
2.3.4 Removing the registration roller
3 Folding Section
3.1 Folding Plate Section
3.1.1 Removing the folding stoppers
3.1.2 Removing the folding plate stopper motors (MOT2, MOT3)
3.1.3 Removing the folding plate index sensors (PS1, PS2, PS4, PS5)
3.1.4 Removing the folding plate home sensors (PS3, PS6)
3.2 Folding Roller Section
3.2.1 Removing the folding rollers
4 Paper Ejection Section
4.1 Stacker Unit
4.1.1 Removing the stacker unit
4.1.2 Removing the stacker roller home sensor (PS11)
4.1.3 Removing the stacker roller moving motor (MOT5)
4.1.4 Removing the stacker belts

Chapter 4. MAINTENANCE/INSPECTION
1 List of Maintenance Tools
1.1 General Tools
1.2 Special Tools
2 Product Lifespan/Parts Lifespan
2.1 Product Lifespan
2.2 Parts Lifespan
2.2.1 Recommended spare parts A
(Consumables)
2.2.2 Recommended spare parts B
(Function parts)
2.2.3 Recommended spare parts C
(Drive parts)
2.2.4 Recommended spare parts D
(Semi-durable parts)
3 Periodic Maintenance
3.1 Basic Maintenance
3.2 Cleaning
3.3 Oiling

Chapter 5. STANDARDS/ADJUSTMENTS
1 Basic Adjustment Procedures
2 External Cover/Control Section
2.1 External Cover Section
2.1.1 Adjusting the interlock switch position
2.2 Drive Section
2.2.1 Adjusting the tention of the timing belt
2.2.2 Attaching position of motor pulley
3 Paper Feed Section
3.1 Paper Feed Tray Section
3.1.1 Adjusting the paper feed tray position
3.1.2 Adjusting the side guide
3.2 Suction Conveyance Section
3.2.1 Adjusting the separating air adjusting knob position
3.2.2 Adjusting the separator adjusting knob position
3.2.3 Adjusting the suction conveyance unit position
3.2.4 Adjusting paper feed tray sensor 1 (PS7) position
3.2.5 Adjusting the suction solenoid (SOL1) position
3.2.6 Adjusting paper feed tray sensor 2 (PS9) position
4 Folding Section
4.1 Folding Plate Section
4.1.1 Adjusting the parallelity of the folding stopper
4.1.2 Adjusting the home position of the switching shaft
4.1.3 Adjusting the home position of the folding stopper
4.1.4 Checking the conveyance path gap of folding plate
4.1.5 Adjusting the gap of the screw shaft unit
4.1.6 Adjusting the motor deceleration pulley section
4.1.7 Adjusting the folding stopper section
4.1.8 Adjusting the attaching position of the switching adjusting plate
4.2 Folding Roller Section
4.2.1 Adjusting the attaching position of the press spring T
4.2.2 Adjusting the gap of folding roller 1
4.2.3 Checking the folding roller nip
4.2.4 Adjusting the attaching position of the conveyance plate
4.2.5 Adjusting the connecting plate
5 Paper Ejection Section
5.1 Stacker Belt Section
5.1.1 Adjusting the tention of the stacker belt
5.2 Stacker Roller Section
5.2.1 Adjusting the tention of the timing belt
5.2.2 Adjusting the stacker roller home sensor (PS11) position

Chapter 6. MAINTENANCE MODE
1 Outline
2 Maintenance Mode Operations
2.1 Entering the Maintenance Mode
2.2 Exiting the Maintenance Mode
3 Menus and Functions
3.1 Menu List
3.2 Other Functions
3.2.1 Setting the paper feed tray sensor 2 (PS9) to OFF
4 Upgrading the Program Version
4.1 Outline
4.1.1 Preparing the rewriting tool (EPROM)
4.2 Upgrading the Version
4.2.1 Upgrading the program version
5 Data Initialization
5.1 Erasing Standard Folding Correction/Custom Folding Data
5.2 Initializing the EEPROM

Chapter 7. TROUBLESHOOTING
1 Outline
2 Troubleshooting by Phenomenon
2.1 Paper Feed Problems
2.1.1 Mis-feed
2.1.2 Continuous-feed
2.2 Folding Problems
2.2.1 Folding misalignment along vertical length of paper
2.2.2 Folding misalignment along sides of paper
2.2.3 When paper is not folded at the normal position
3 Troubleshooting by Message Displayed
3.1 Paper Jam Messages
3.1.1 When “JAM FEED SECT” is displayed
3.1.2 When “JAM INSIDE” is displayed
3.1.3 When “JAM EXIT” is displayed
3.2 Error Messages
3.2.1 When “F.PLATE SET ERR” is displayed
3.2.2 When “FEED ERROR” is displayed
3.3 Trouble Messages
3.3.1 When “MOTOR ERROR 1” is displayed
3.3.2 When “MOTOR ERROR 4” is displayed
3.3.3 When “MOTOR ERROR 5” is displayed
3.3.4 When “MOTOR ERROR 3” is displayed
3.3.5 When “MOTOR ERROR 2” is displayed
3.3.6 When “TRAY UP ERROR” is displayed
3.3.7 When “TRAY DOWN ERROR” is displayed
3.4 Other Messages
3.4.1 When “NO PAPER” is displayed
3.4.2 When “TOP COVER-L OPEN” is displayed
3.4.3 When “TOP COVER-R OPEN” displayed
3.4.4 When “SIDE COVER OPEN” displayed
4 Troubleshooting for Operation Failures
4.1 Power Does Not Turn ON
4.2 Nothing is Displayed on Control Panel
4.3 Key Operations are Disabled on Control Panel
4.4 Misdetection of Standard Paper Sizes Occurs

Appendix
1 List of Displayed Messages
1.1 No Paper
1.2 Key Input Error
1.3 Cover Open
1.4 Paper Jam/Error
1.5 Trouble
2 Layout of Electrical Parts
2.1 Front of Unit
2.2 Back of Unit
2.3 Inside Unit
2.4 Paper Feed Section
2.5 Folding Plate Section
2.6 Paper Ejection Section
3 Layout of Boards
3.1 MC Unit
3.2 Control Panel
3.3 Switching Power Supply
3.4 PS P.W.B. Unit
4 Overall Schematic Diagram
5 Wiring Diagram

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