Duplo Folder
DF-505N
Instruction Manual
DUPLO CORPORATION
[120V]
Please let our service people install the machine.
This page is a blank page.
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CONTENTS
1. Safety Precautions............................... 2
2. Usage Precautions............................... 4
2-1. Power Supply............................................. 4
2-2. Operating Environment.............................. 4
2-3. Storage Conditions .................................... 4
2-4. Maintenance .............................................. 4
3. Installing the Unit................................. 5
3-1. Removing the Press Release Lever .......... 5
3-2. Component Parts....................................... 6
3-3. Bearing support levers............................... 6
3-4. Attaching the Parts .................................... 7
4. Names of the Parts .............................. 8
5. Names and Functions of the
Control Panel Parts.............................. 9
6. Precautions before Use..................... 10
6-1. Paper to Be Used .................................... 10
6-2. Precautions for Stacking Paper ............... 10
7. Operation Procedures ....................... 12
7-1. Fixed Folding of Fixed Paper................... 12
7-2. Single-Folding Paper Neatly .................... 17
7-3. Single-Folding Hard Paper Neatly ........... 19
7-4. Double Folding Thick Paper .................... 20
7-5. Folding 5 (W) x 7 (L) Medium
Thickness Paper (Below 81.4 g/m2)......... 23
7-6. Specil Folding of Fixed Paper.................. 26
8. Folding Adjustments ......................... 29
8-1. Adjusting the Folding Slippage in the
Vertical Direction...................................... 29
8-2. Adjusting the Folding Slippage in the
Horizontal Direction ................................. 31
9. Using Non-Fixed Paper...................... 32
9-1. Fixed Folding Procedures........................ 32
10.Cross Folding ..................................... 34
10-1. Precautions upon Use ............................. 34
10-2. Cross Folding of Fixed Paper .................. 34
10-3. Cross Folding of Non-Fixed Paper .......... 37
11.Troubleshooting................................. 42
11-1. Paper has Jammed near the Paper
Feed Ring ................................................ 42
11-2. Paper has Slipped near the Paper Feed
Section..................................................... 42
11-3. Paper has Coiled around the Rubber Roll
inside the Unit .......................................... 43
11-4. Paper has Jammed at the First Folding
Plate.........................................................43
11-5. Paper has Jammed at the
Second Folding Plate...............................44
11-6. Paper has Jammed near the Stacker ...... 45
12.Emergency Stops............................... 46
13.Troubleshooting Guide...................... 47
14.Cleaning the Unit................................ 50
14-1. Cleaning the Rubber Roll......................... 50
14-2. Cleaning the Paper Feed Ring ................ 51
15.Specifications..................................... 52
INTRODUCTION
Thank you for your purchase. To ensure correct usage, please read this instruction manual
thoroughly, especially the section Safety Precautions. After reading, please store this instruction
manual in a safe place for future reference.
2
1. SAFETY PRECAUTIONS
WARNING:
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 fire or electrical shock.
Do not insert any metal or easily-combustible object inside this unit. This could result in
fire or electrical shock.
Do not touch or insert foreign objects into any rotating part during operation. This could
result in injury.
Do not remove the cover or back panel. This unit contains high-voltage components that
could cause electrical shock.
Do not disassemble, modify or repair this unit. There is a danger of fire, electrical shock
or injury. Contact your dealer when repairs are necessary.
Use only the power supply voltage specified on the main nameplate. Using other
voltages could result in fire or electrical shock.
Keep this unit and the power cord away from heaters and heater vents. Excessive heat
could melt the cover or power cord covering, and result in fire or electrical shock.
Always observe the cautions and warnings given below to prevent personal injury or property
damage.
The degree of danger and damage that could occur is indicated on two levels by the
following marks.
WARNING: Ignoring this mark could result in the possibility of serious injury
or even death.
CAUTION: Ignoring this mark could result in the possibility of injury or
physical damage.
The following graphic symbols indicate the various types of action to be performed
or avoided.
This graphic symbol indicates a forbidden action.
means “Do not disassemble.”
means “Do not touch.”
This graphic symbol indicates actions that must be performed.
means “Disconnect the power plug.”
This graphic symbol indicates a “Caution” that must be observed.
means “Caution: high temperature.”
3
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.
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 fire.
Remove any dust that accumulates on the power plug prongs and the surface of the plug
from which the prongs extend. Accumulated dust can result in fire.
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 fire or electrical shock. Contact your dealer immediately.
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, fire or electrical shock.
Always grip the plug when disconnecting the power plug from the power outlet. Pulling
on the power cord could cause damage, resulting in fire or electrical shock.
Do not handle the power plug with wet hands. This could result in 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.
CAUTION:
Always disconnect the power plug from the power outlet when the unit is not to be used
for an extended period. Failure to do so could result in fire due to leakage current if the
insulation should deteriorate.
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.
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, fire or electrical shock.
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.
1. Safety Precautions
4
2. USAGE PRECAUTIONS
2-1. Power supply
• This equipment shall be installed near the socket-outlet where the plug on the power supply
cord is easily accessible.
• Make sure the power supply used is always within the following range.
120V AC, 60Hz
• When you power other appliances from the same AC outlet, make sure that the combined
power consumption does not exceed the power supply capacity.
Rated power of this equipment : 1.5A
2-2. Operating environment
Operate this unit in the following environment:
• where the temperature range is between
5 and 35°C,
• where the humidity range is between 20
and 85%RH (no dew condensation),
• which is not subject to direct sunlight,
• which is subject to little or no vibration,
2-3. Storage conditions
Store this unit in the following environment:
• where the temperature range is between
–10 and 50°C, (no dew condensation)
• where the humidity range is between 10
and 90%RH (no dew condensation),
• which is not subject to direct sunlight,
• which is subject to little or no vibration,
2-4. Maintenance
To protect the special features of this unit, the customer should never apply oil or grease to
the parts (except when the customer is specifically requested to do so in this instruction
manual).
Please contact your dealer in case of any problem.
• where there are no harmful chemicals,
• which is reasonably free from dust,
• which is free from air-borne salt, and
• where the equipment will not be exposed
to water.
• where there are no harmful chemicals,
• which is reasonably free from dust,
• which is free from air-borne salt, and
• where the equipment will not be exposed
to water.
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3. INSTALLING THE UNIT
3-1. REMOVING THE PRESS RELEASE LEVE
This press release level is attached to the unit at shipment to prevent the rubber roll from
becoming distorted.
Be sure to remove it when installing the unit.
Take note that the unit will be damaged if it is used without removing the lever.
Remember to remove it in the following order when installing the unit.
1 Two press release levers are inserted in the left and right shaft edges of the rubber
roll.
2 First remove press release lever(A).
• To remove, push inwards and pull out the press release lever (A), as shown in the figure.
Also remove that of the operating side in the same way.
• Next, pull out press release lever(B) as shown in the figure.
Also remove that of the operating side in the same way.
Press release lever (A)
Press release lever (B)
Press release lever (A)
Press release lever (B)
Press release lever (A)
Press release lever (A)
Press release lever (B)
Press release lever (B)
<Operating side>
<Non-operating side>
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3. INSTALLING THE UNIT
After checking that you have following parts, attach them to the unit.
3-2. COMPONENT PARTS
No.
Name
Qty. No.
Name
Qty.
First folding plate
Second folding plate
Cross folding lever
Instruction Manual
Guide plate unit
1
2
3
4
5
1
1
1
1
1
12
3
54
3-3. BEARING SUPPORT LEVERS
Bearing support lever
Bearing support lever
Support the bearing with the two bearing support levers.
• Rotate the lever in the arrow direction and support the bearing.
<Operating side>
<Non-operating side>
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3. INSTALLING THE UNIT
1 First, attach the second folding plate.
• Before starting, push the lock lever at the side of
the folding plate to “UNLOCK”.
• Next, insert the folding plate into the unit.
• After inserting it properly, push the lock lever to
“LOCK”.
2 Attach the first folding plate in the
same way.
* As the first folding plate is not provided with a lock
lever, it only needs to be inserted into the unit.
* If paper jams inside the folding plate, turn off the
power, push the lock lever to "UNLOCK", and
remove the folding plate. (Only for second folding
plate.)
3-4. ATTACHING THE PARTS
3 Attach the cross folding lever at its
proper place.
<Parts Used>
Cross folding lever .................................................. 1
Second folding plate
First folding plate
Cross folding lever
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4. NAMES OF THE PARTS
First folding plate
Control panel
Second folding plate
Power switch
Paper set lever
Paper receiving tray
Paper receiving
stopper
Stacker roller
Auxiliary paper
feed plate
Paper feed table
Guide
Top cover
Rubber roll
Paper feed ring
(For moving)
Paper feed ring
Paper feed pressure
adjusting knob
Slant correction
paper feed knob
9
1
2
3
4
5
6
5. NAMES AND FUNCTIONS OF THE
CONTROL PANEL PARTS
Reset button
Counter
Table of Stacker
Roller Positions
Start button
START
Stop button
STOP
Power supply
lamp
The counter is reset to "0" when the reset button is pressed.
Counts and shows the number of sheets that have been folded.
The stacker rollers of the paper discharge section are positioned differently according
to the paper size and folding style.
Refer to this table for the appropriate positions.
When this button is pressed, the unit starts-up and folding operations can be carried out.
When this button is pressed, the unit stops.
Lights up when the power switch is ON.
No.
Name Function
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6. PRECAUTIONS BEFORE USE
• Straighten folded or curled paper before use.
• Make sure that the ink on the paper has dried up properly
before use.
If the ink has not dried properly, it may dirty the
machine, and cause other problems such as dirtying the
folded surface with ink.
• If curled paper is used, depending on the environmental
condition(temperature, humidity), paper quantity, paper
type, paper couch condition, folding speed, etc. it may
not flow smoothly into the folding plate or may not be
folded properly.
• Should such problems occur, reduce the folding speed or
straighten the paper before continuing use.
6-1. PAPER TO BE USED
6-2. PRECAUTIONS FOR STACKING PAPER
• Problems such as folding slippage and paper jam etc.
will ariseif the paper is not stacked neatly on the paper
feed table. Therefore, be sure to stack the paper neatly.
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6. PRECAUTIONS BEFORE USE
• If the paper is not stacked properly lengthwise, mis-feed
or chain feed may occur.
• When stacking just a few sheets of paper on the paper
feed table, lower the paper set lever while pressing the
back edge of the paper.
• Adjust so that the front part of the paper touches the
paper feed ring in front lightly.(Arrow)
• The paper will be folded as shown in the figure if placed
with the printed surface up on the paper feed table.
• For “accordion fold” and “irregular accordion fold”, the
printed surface of some paper will be folded outwards.
Paper
Guide plate
Paper set lever
Paper
Paper feed rings
Single fold Double fold Letter fold Brochure foldIrregular accordion fold Accordion fold
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Start the various fixed folding operations for fixed paper as follows.
7. OPERATION PROCEDURES
7-1. FIXED FOLDING OF FIXED PAPER
1 Insert the power cord in the electrical
outlet and turn on the power.
• Press “ I ” to turn on the power.
• Press “O” to turn off the power.
2 Raise the paper set lever and place
some paper on the paper feed table.
• Loosen the fixing screws of the guide, and move
the guide slightly with a space lift between the
guide and the paper.
• Loosen the paper and stack them neatly at the
center of the paper feed table.
• Insert the paper until its front part touches the front
guide plate lightly.
3 After pressing the guide to the side of
the paper lightly, tighten the screws
to secure the guide.
Paper can be stacked to a height of
approximately 2 inch at one time. Do not stack
too many sheets of paper.
4 Lower the paper set lever.
Power switch
Paper set lever
Paper
Guide
Fixing screw
Fixing
screw
Guide
Guide
Fixing screw
Fixing screw
Paper set lever
13
5 Adjust the rough adjustment knob of
the folding plates to the mark of any
folding mode.
• Adjust the rough adjustment knobs of first and
second folding plates to the desired marks
according to the style in which the paper is to be
folded.
• The rough adjustment knob can be moved freely
by pulling it up.
Although the rough adjustment knob can be
moved up and down, it cannot be rotated.
• After adjusting the position of this knob, be sure to
rotate the fine adjustment knob several times.
6 Set the paper feed pressure adjusting
knob to “thin paper”.
* If the paper slips, and no paper is conveyed, raise
the paper feed pressure from “thin paper” to “thick
paper”.
7. OPERATION PROCEDURES
Rough adjustment knob Rough adjustment knob
Second folding plate First folding plate
Rough adjustment knob
Rough adjustment knob
Fine adjustment knobFine adjustment knob
Second folding plate First folding plate
Paper feed pressure adjusting knob
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7 Set the position of the stacker rollers.
• Referring to the table of stacker roller positions,
position the stacker rollers.
As the figures in this table of stacker roller
positions are approximations, select the best
position taking into consideration the folding
speed and paper quality.
7. OPERATION PROCEDURES
Table of Stacker Rollers Positions
Length of Paper Fold
7 — 8-1/2 inch
6 — 7 inch
5 — 6 inch
4 — 5 inch
1-5/8 — 4 inch
Folding Mode
LD : Single Fold, Irregular Accordion Fold, Brochure Fold
Single fold of paper bigger than LD.
LG : Irregular Accordion Fold, Brochure Fold
LT : Single Fold, Irregular Accordion Fold, Brochure Fold
LD : Letter Fold, Accordion Fold
LG : Letter Fold, Accordion Fold
LD : Double Fold
LT : Double Fold, Letter Fold, Accordion Fold
LG : Double Fold
Number
1
2
3
4
5
Stacker rollers
15
7. OPERATION PROCEDURES
8 Press the start button to test the
folding.
Set the paper on the paper feed table, and with the
paper set lever raised, press the start button. The
paper feed ring slips and the machine stops. Press
the start button after lowering the paper set lever.
• The paper will be folded properly if it is folded after
it has reached the stopper inside the folding plate.
• In some cases, the paper flowing into the folding
plate may be folded before it reaches the stopper due
to conditions such as environmental conditions
(temperature, humidity), its quantity, its type, paper
couch conditions, folding speed, etc., and therefore
not be folded properly.
• In some cases, the paper may also coil around the
rubber roll and cause problems.
• This phenomenon may occur when different paper
quantity, type, and couch conditions are used.
• Check that the paper has been folded properly.
Check from the second piece of paper folded.
<The paper will be folded properly>
<The paper not be folded properly>
Paper for testing folding
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