Duplo DF-505N Instruction Manual

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Duplo Folder

DF-505N

Instruction Manual

DUPLO CORPORATION

[120V]

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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.

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.”

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

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.

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 (B)

<Non-operating side>

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 1 1

1 1

3-3. BEARING SUPPORT LEVERS

Bearing support lever

Support the bearing with the two bearing support levers.

• Rotate the lever in the arrow direction and support the bearing.

<Non-operating side>

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.

Cross folding lever .................................................. 1

Second folding plate

First folding plate

Cross folding lever

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

1 2 3

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

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.

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

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

Guide

Fixing screw

Paper set lever

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

Fine adjustment knobFine adjustment knob

Second folding plate First folding plate

Paper feed pressure adjusting knob

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

2 3

Stacker rollers

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.

Paper for testing folding

• If the sheets of paper have not been folded satisfactorily, refer to the following steps.

1 If there is folding slippage in the vertical direction,

rotate the fine adjustment knob and correct the folding slippage. Refer to “8-1. Adjusting the folding slippage in the vertical direction”.

2 If the folding has slipped in the horizontal

direction: Rotate the “slant correction knob” and adjust the folding slippage. Refer to “8-2. Adjusting the folding slippage in the horizontal direction”.

Check the folding slippage in the horizontal direction with the second sheet of test fold sample.

9 After completing all preparations,

start operation.

• Press the start button.

10 The unit stops automatically when

there is no more paper on the paper feed table.

7. OPERATION PROCEDURES

Fine adjustment knobFine adjustment knob

Second folding plate First folding plate

Slant correction knob

7. OPERATION PROCEDURES

11 To interrupt or to stop operation,

press the stop button.

1 While looking at the scale, roughly adjust the stopper of first folding plate to the

paper size.

1 Slide the rough adjustment knob of first folding plate while lifting it up, move the stopper to the single-folding

position for the paper size, and set the stopper.

2 After adjusting the position of the rough adjustment knob, be sure to rotate the fine adjustment knob to the left and

right several times and make sure that they are engaged properly.

7-2. SINGLE-FOLDING PAPER NEATLY

In DF-505N, paper is single-folded by folding plate 1. The rough adjustment knob of folding plate 2 must therefore be set to ''Press" position as shown in the figure.

To single-fold paper, perform the following procedure.

Rough adjustment knob

Fine adjustment knob

7. OPERATION PROCEDURES

2 Adjust the stopper of second folding plate.

1 While lifting the rough adjustment knob of second folding plate, slide it to the ''Press" position shown in the figure

and set it there.

2 Rotate the fine adjustment knob to the left until the rough adjustment knob presses against it lightly but completely.

Note : Rotating the fine adjustment knob excessively will result in paper jamming, improper folding, and other

mechanical malfunctions.

3 Start folding operations hereafter using the normal procedure.

If the above problem occurs, it means that the stopping position of the stopper is too apart. Rotate the fine adjustment knob to the left until the folding stopper lightly but completely presses against it.

WHAT TO DO WHEN :

When single-folding paper, if the folding stopper (rough adjustment knob) of second folding plate is not at the correct position, the following problems may occur according to the type of paper used (thickness, paper quality, etc.)

If the paper is thin (no hardness) ........ A crease about 0.59 inch from the folded line of the paper parallel to it will be formed.

Rough adjustment knob

Fine adjustment knob

Second folding plate

0.59inch

7. OPERATION PROCEDURES

When single-folding drawing paper or fine quality thick paper (127g/m2), the edge of the folding line of the paper or a part near the center may bend due to environmental conditions (temperature, humidity), paper size, paper jamming, paper size, paper fiber direction, etc. and not because the unit has malfunctioned. In such cases, perform the following procedure.

7-3. SINGLE-FOLDING HARD PAPER NEATLY

1 The stopping position of the stopper

is too close. Rotate the fine adjustment knob of folding plate 2 to the right by 1/4 turn so that the stopper is appropriately apart from it.

2 Press the START button and start

folding operations. If folding problems occur again during operations, press the STOP button to stop the unit. Once the unit has stopped completely, rotate the fine adjustment knob of second folding plate to the right by 1/4 turn so that the stopper is appropriately apart from it. Resume operations again.

Bent at edge

Bent near center

Fine adjustment knob

Second folding plate

7. OPERATION PROCEDURES

3 After completing the single-folding

operations for hard paper, rotate the fine adjustment knob to the left until the stopper presses against it lightly but completely.

Note : If thin paper is single-folded with the folding stopper of second folding plate moved to the position for thick paper, the thin paper will not be folded neatly, Therefore, after completing single-folding operations for thick paper, be sure to move the stopper back to its original normal position.

7-4. DOUBLE FOLDING THICK PAPER

• When thick paper(above 104.7g/m2) such as fine quality paper, etc. is folded into fours, its thickness may cause its folding section to open when ejected to the stacker, which consequently will prevent it from being able to pass through the stacker rollers and result in paper jam.

Do not use thick paper (127.9/m2) folded into fours as paper ejection problems may occur.

• In such cases, proceed in the following steps.

1 Place the paper on the paper feed

table, lower the paper set lever, and raise the paper feed table.

Fine adjustment knob

Folding plate 2

Lever

Stacker rollers

Stacker lever

Lever

Belts

Paper

Paper set lever

2 Adjust the stacker rollers to “5”.

3 Next, while lifting up the stacker

rollers with your hand, pull the levers (left and right) attached to the stacker lever in the direction of the arrow, and adjust so that the stacker rollers are above the belt.

4 Press the start button and test the

folding.

• Check if the paper is ejected smoothly.

5 If the paper is not ejected smoothly,

change the position of the stacker rollers.

7. OPERATION PROCEDURES

Stacker rollers

Stacker roller

Lever

Belt

Stacker lever

Stacker rollers

7. OPERATION PROCEDURES

6 If folding slippage occurs, rotate the

fine adjustment knob of the folding plate 1 or 2 and correct the folding slippage.

7 After completing all adjustments,

press the “reset button” of the counter.

8 Press the start button and begin

operations.

9 After the operations have completed,

be sure to lower the left and right levers attached to the stacker lever in the direction of the arrow.

• If the stacker rollers are left lifted up, problems will occur when the normal paper size is used.

Fine adjustment knob

Fine adjustment knob

Reset button Counter

Stacker rollers

Lever

Belts

Stacker lever

7. OPERATION PROCEDURES

7-5. FOLDING 5(W) X 7 (L) MEDIUM THICKNESS PAPER (BELOW 81.4 g/m

)

Paper jam may occur when folding 5(W) X 7(L) size medium thickness paper such as fine paper (below 81.4g/m2) into fours. If this occurs, attach the guide plate unit provided.

1. Attach the guide plate unit at the

innermost center of the two belts of the paper ejection plate.

2. Set the stacker roller at “4”.

3. Press the start button and test-fold

the paper.

* Check if the paper can be ejected smoothly.

Paper ejection plate

Belt

Guide plate unit

Guide plate unit Stacker roller

Stacker rollers

4. If the paper is not ejected out

smoothly, change the position of the stacker roller.

5. If the paper slips when folded, rotate

the fine adjustment knob of the first folding plate or second folding plate, and adjust the folding slippage.

6. After all adjustments, press the

“Reset” button of the counter.

7. Press the start button to start

operations.

7. OPERATION PROCEDURES

Stacker rollers

Fine adjustment knob

Fine adjustment knob

Reset button Counter

8. After completing the work, be sure to

remove the guide plate unit.

* Take note that leaving the guide plate unit

attached may result in problems when other types of paper are used.

Note : When folding 52.3 g/m2 paper in fours, do not use

the guide plate unit.

Store the guide plate unit removed in the DF-505N as shown in the figure.

7. OPERATION PROCEDURES

Guide plate unit

7. OPERATION PROCEDURES

7-6. SPECIAL FOLDING OF FIXED PAPER

1 Stack some paper on the paper feed

table.

2 Fold the paper as desired and

measure the folded paper. Adjust the setting position of the rough adjustment knob of the folding plate accordingly.

3 Adjust the rough adjustment knob of

the first folding plate to the mark corresponding to measurement A.

• 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.

Paper

Accordion fold

Rough adjustment knob

Fine adjustment knob

4 Adjust the rough adjustment knob of

the second folding plate to the mark corresponding to measurement B.

• When carrying out special folding, folding sizes should be within the following ranges. Folding range (A) for the first folding plate:

1-5/8 to 12-7/8 inch

Folding range (B) for the second folding plate:

1-5/8 to 8-1/2 inch

Max. paper length (C) when folded:

8-1/2 inch

5 Adjust the position of the stacker

rollers.

• Referring to the table of stacke 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

Length of Paper Fold

7 — 8-1/2 inch

6 — 7 inch 5 — 6 inch

4 — 5 inch

1-5/8 — 4 inch

Number

2 3

Rough adjustment knob

Stacker rollers

6 Press the start button to test the

folding.

• Check that the paper has been folded properly.

Check the second piece of paper folded first.

• If the sheets of paper have not been folded satisfactorily, refer to the following steps.

1 If there is folding slippage in the vertical direction,

rotate the fine adjustment knob and correct the folding slippage. Refer to “8-1. Adjusting the folding slippage in the vertical direction”.

2 If the folding has slipped in the horizontal

direction: Rotate the “slant correction knob” and adjust the folding slippage. Refer to “8-2. Adjusting the folding slippage in the horizontal direction”.

Check the folding slippage in the horizontal direction with the second sheet of test fold sample.

7. OPERATION PROCEDURES

Paper for testing folding

Fine adjustment knob

Fine adjustment knob

Slant correction knob

8. FOLDING ADJUSTMENTS

8-1. ADJUSTING THE FOLDING SLIPPAGE IN THE VERTICAL DIRECTION

To adjust the folding slippage in the vertical direction, rotate the fine adjustment knob of first folding plate.

Folding Style

Fold Surface A Adjustment

First Folding Plate

Fine Adjustment Knob

Single Fold

Double Fold

Letter Fold

Accordion Fold

Brochure Fold

Irregular

Accordion Fold

When A

is longer

When A

is shorter

When A

is longer

When A

is shorter

When A

is longer

When A

is shorter

When A

is longer

When A

is shorter

When A

is longer

When A

is shorter

When A

is longer

When A

is shorter

Rotate the fine adjustment knob counterclockwise

Rotate the fine adjustment knob clockwise.

Rotate the fine adjustment knob counterclockwise

Rotate the fine adjustment knob clockwise.

Rotate the fine adjustment knob counterclockwise

Rotate the fine adjustment knob clockwise.

Folding Style

Fold Surface B Adjustment

Second Folding Plate

Fine Adjustment Knob

Double Fold

Letter Fold

Accordion Fold

Brochure Fold

Irregular

Accordion Fold

When B

is longer

When B

is shorter

When B

is longer

When B

is shorter

When B

is longer

When B

is shorter

When B

is longer

When B

is shorter

When B

is longer

When B

is shorter

8. FOLDING ADJUSTMENTS

Rotate the fine adjustment knob counterclockwise

Rotate the fine adjustment knob clockwise.

Rotate the fine adjustment knob counterclockwise

Rotate the fine adjustment knob clockwise.

Rotate the fine adjustment knob counterclockwise

Rotate the fine adjustment knob clockwise.

Rotate the fine adjustment knob counterclockwise

Rotate the fine adjustment knob clockwise.

Rotate the fine adjustment knob counterclockwise

8-2. ADJUSTING THE FOLDING SLIPPAGE IN THE HORIZONTAL DIRECTION

• If folding slips as shown in the figure because the paper is not cut straight, rotate the “slant correction” knob to adjust the folding slippage.

1 Rotate the “slant correction” knob to

adjust the folding slippage.

• If folding slippage is as shown in Fig. A, rotate the knob in the direction of the arrow.

• If folding slippage is as shown in Fig. B, rotate the knob in the direction of the arrow.

2 After adjustment, be sure to rotate the

“slant correction” knob to adjust the round holes of the paper feed table to the pin.

• The position at which the round hole meets the pin is the standard position.

8. FOLDING ADJUSTMENTS

Slant correction knob

Round hole

Slant correction knob

9. USING NON-FIXED PAPER

9-1. FIXED FOLDING PROCEDURES

Start fixed folding operations for non-fixed paper according to the following procedures. The procedures are described by taking an example of folding a sheet of 12 inch paper.

1 Measure the length of the paper.

• Use measuring instruments that are in 1 inch

2 Refer to the table of rough adjustment

knob positions and position the rough adjustment knobs of first and second folding plates.

• Calculating from the table, the position of the knob of first folding plate should be set at 6 inch. 12÷2=6 inch

• Adjust the rough adjustment knob of the second folding plate to “End”.

Folding Style Single Fold Double Fold Irregular Letter Fold Accordion Fold Brochure Fold

Accordion Fold First Folding Plate L/2 L/2 3L/4 L/3 2L/3 L/4 Second Folding Plate END L/4 L/4 L/3 L/3 L/2

L= Length of paper

Rough adjustment knob

3 Adjust the position of the stacker

rollers.

• As the length of the paper fold is 6 inch, adjust the position of the stacker rollers to “2”. Reference: Refer to “Table of Stacker Roller

Positions”.

4 Place the paper on the paper feed

table.

• Refer to “7. Operation Procedures” and begin operations.

9. USING NON-FIXED PAPER

To fold the paper in styles (special folding) other than fixed-folding, carry out the procedures in “7-6. Special Folding of Fixed Paper”.

Stacker rollers

Paper

Paper set lever

• As shown in the figure, cross folding means folding single folded paper again.

• Paper can be cross folded into various shapes depending on use.

10-1. PRECAUTIONS UPON USE

(1) The maximum paper thickness is 104.7g/m2. However, this thickness may differ slightly

according to various conditions such as environmental conditions (temperature, humidity), paper size, type of paper, paper couch conditions, and printed surface conditions.

10-2. CROSS FOLDING OF FIXED PAPER

• The following describes the cross folding shown in the figure and the procedures for it.

• Start cross folding according to the following procedures.

1 First, adjust the rough adjustment

knob of first folding plate to the mark for single fold.

• After adjusting the position of this knob, be sure to

rotate the fine adjustment knob several times.

Although the rough adjustment knob can be moved up and down, it cannot be rotated.

2 Next, adjust the rough adjustment

knob of the second folding plate to “End”.

(2) When the paper is cross folded, Σ shape

folding, folding slippage in the horizontal direction may occur due to conditions such as environmental conditions (temperature, humidity), paper thickness, paper size, type of paper, paper couch conditions. Therefore do not suspect a fault.

Folded

Cross single folding

Cross letter folding

shape folding

Rough adjustment knob

10. CROSS FOLDING

3 Adjust 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.

4 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".

5 Press the start button to test the

folding.

• Check that the paper is folded properly.

Check the second piece of paper folded first.

6 To prevent the paper from slipping in

the horizontal direction when folded and bending of the paper, press the folded line of the paper folded into twos.

10. CROSS FOLDING (Optional-Cross Folding kit is required)

Stacker rollers

Paper feed pressure adjusting knob

7 Set the single fold paper on the paper

feed table. Place the paper with the folded edge to the back of the unit as shown in the figure.

• To prevent folding slippage in the horizontal direction and misfeeding, press the folded edge of the paper with your hand firmly.

The amount of paper that can be folded is approximately 2/3 (approx. 1-1/2 inch) of the height of the guide at the folded side.

8 Open the top cover and move the

paper feed ring at the far end to the folded edge of the paper.

• Loosen the set screw and move the paper feed ring.

• After moving the paper feed ring, tighten the set screw properly.

9 Close the top cover and adjust the

cross folding lever to the guide.

• Place the weight rollers at the tip of the lever on top of the folded edge.

10 Set the paper feed pressure adjusting

knob to “thin paper”.

• If the paper slips, and no paper is conveyed, set the paper feed pressure to “thick paper”.

10. CROSS FOLDING (Optional-Cross Folding kit is required)

Paper

Set knob

Paper feed ring (For moving)

Top cover

Cross folding lever

Weight roller

Paper feed pressure adjusting knob

11 From here, refer to “7. Operation

Procedures”.

• When replenishing paper, raise the cross folding lever as shown in the figure first.

Cross folding consists of not only the single folding of LD, double folding of LT, but the letter folding of LT.

12 After use, store the cross folding

lever as shown in the figure.

10-3. CROSS FOLDING OF NON-FIXED PAPER

• The following describes the procedures for single cross folding.

• Start single cross folding of non-fixed paper according to the following procedure.

1 Adjust the rough adjustment knob of

first folding plate to the mark which has a value half of this length.

• Adjust the rough adjustment knob of the second

folding plate to “End”.

Cross folding lever

Rough adjustment knob Rough adjustment knob

Second folding plate First folding plate

10. CROSS FOLDING (Optional-Cross Folding kit is required)

2 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”.

3 Adjust the position of the stacker

rollers.

Reference: Refer to “7. Operation Procedures”.

4 Press the start button to test the

folding.

• Check that the paper is folded properly.

• Check the second piece of paper folded first.

If the paper has not been folded properly, correct the problem first before proceeding onto the next step.

5 Press the start button to begin

operations.

Paper feed pressure adjusting knob

Stacker rollers

Paper for testing folding

10. CROSS FOLDING (Optional-Cross Folding kit is required)

6 Adjust the rough adjustment knob of

first folding plate to the mark which has a value half of this length.

• Adjust the rough adjustment knob of the second folding plate to “End”.

7 To prevent folding slippage in the

horizontal direction and misfeeding, press the folded edge of the paper with your hand firmly.

Set the single fold paper on the paper feed table. Place the paper with the folded edge to the back of the unit as shown in the figure.

The amount of paper that can be folded is approximately 2/3 (approx. 1-1/2 inch) of the height of the guide at the folded side.

9 Open the top cover and move the

paper feed ring at the far end to the folded edge of the paper.

• Loosen the set screw and move the paper feed ring.

• After moving the paper feed ring, tighten the set screw properly.

Rough adjustment knob Rough adjustment knob

Second folding plate First folding plate

Paper

Set knob

Paper feed ring (For moving)

10. CROSS FOLDING (Optional-Cross Folding kit is required)

10 Lower the paper set lever.

While pressing the back edges of the paper.

• Adjust so that the front part of the paper touches the paper feed ring in front lightly.

11 Close the top cover and adjust the

cross folding lever to the guide.

• Place the weight rollers at the tip of the lever on top of the folded edge.

12 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”.

13 Press the start button to test the

folding.

• Check that the paper is folded properly.

• Check the second piece of paper folded first.

If the paper has not been folded properly, correct the problem first before proceeding onto the next step.

Paper

Paper set lever

Top cover

Cross folding lever

Weight roller

Paper feed pressure adjusting knob

Paper for test folding

10. CROSS FOLDING (Optional-Cross Folding kit is required)

14 Press the start button to begin

operations.

15 When replenishing paper, raise the

cross folding lever as shown in the figure first.

Cross folding consists of not only the single folding of LD, double folding of LT, but the letter folding of LT.

• From here, refer to “7. Operation Procedures”.

16 After use, store the cross folding

lever at the place shown in the figure.

Cross folding lever

10. CROSS FOLDING (Optional-Cross Folding kit is required)

11. TROUBLESHOOTING

11-1. PAPER HAS JAMMED NEAR THE PAPER FEED RING

1 If paper has jammed near the paper

feed ring, raise the paper set lever and lower the paper feed table downwards.

2 Pull the jammed paper towards you.

11-2. PAPER HAS SLIPPED NEAR THE PAPER FEED SECTION

• If the paper stops at the paper feed section when thick paper is used (127.9 g/m2) and no paper is fed, set the paper feed pressure to “thick paper”.

Note : Move the lever as shown in the right figure until

the lever stops.

Paper feed table

Paper

Paper set lever

Paper feed pressure adjusting knob

11. TROUBLESHOOTING

11-3. PAPER HAS COILED AROUND THE RUBBER ROLL INSIDE THE UNIT

11-4. PAPER HAS JAMMED AT THE FIRST FOLDING PLATE

1 Remove first folding plate from the

unit.

2 Open the top cover and pull the

jammed paper towards you to remove.

• Open the top cover, pull the wound paper towards you and remove it.

• If the paper does not come out easily, insert a ruler,etc. at the tip of the paper wound around the lower rubber roll from the gap between the rubber rolls and remove the paper.

Turn off the power switch first before performing the above. Remove the first folding plate from the unit.

Paper

Rubber roll

First folding plate

3 After removing the paper, return the

folding plate and top cover to their original positions.

Check that the folding plate has been set correctly. Always remove and return folding plates with both hands.

11. TROUBLESHOOTING

11-5. PAPER HAS JAMMED AT THE SECOND FOLDING PLATE

1 Release the lock of the second

folding plate and remove this plate from the unit.

2 Pull the jammed paper towards you to

remove.

3 After removing the paper, slide the

folding plate down the slider, return it to the unit, and lock the lock lever.

Make sure that the folding plate has been set correctly. Always remove and return folding plates with both hands.

First folding plate

Second folding plate

Slider

11. TROUBLESHOOTING

• Remove the paper stuck in the stacker section towards you.

11-6. PAPER HAS JAMMED NEAR THE STACKER

Paper

12. EMERGENCY STOPS

An emergency stop device to ensure safety has been installed to the top cover of this unit. Take note that this emergency stop device will function as follows.

(1) If the top cover is open while the unit

is operating, the unit will stop promptly.

(2) If the “start” button is pressed with

the top cover open, the unit will not start.

(3) The emergency stop condition will be

released when the top cover is closed.

Top cover

(2) When the start button is

pressed, the paper feed ring rotates but no paper is fed.

13. TROUBLESHOOTING GUIDE

Problem

Check

Correct

(1)The unit does not start when

the start button is pressed.

• Insert the power cord properly into the outlet.

1 Is the power cord

disconnected ?

3 Is there paper on the paper

feed plate?

• Load some sheets of paper.

2 Is the power switch on ?

• Turn on the switch.

• Set the paper properly.

4 Is the paper on the paper feed

table set properly on the paper switch?

5 Is the paper stuck? • Remove the paper.

6 Is the top cover open?

• Close the top cover.

• Contact your serviceman.

7 Has a problem occurred

inside the unit?

* The motor will continue to rotate for about five seconds after the paper stacked

on the paper feed table has run out before.

1 Is the paper feed plate

lowered?

• Lower the paper set lever and

raise the paper feed plate.

(3)The main motor does not

rotate.

1 Is the top cover open?

• Close the top cover.

2 Has a problem occurred

inside the unit?

• Contact your serviceman.

(4)The paper is not folded at the

proper folding position.

1 Is the folding plate set

properly?

• Position the folding plate

properly.

2 Environmental conditions

such as static electricity, etc. may be the cause.

• Change the paper type.

‰

1 Is the paper feed pressure too

high?

(5)Double feed occurs frequently.

• Lower the paper feed pressure gradually until the optimum pressure is obtained.

13. TROUBLESHOOTING GUIDE

Problem

Check

Correct

‰

2 Is the paper separator dirty?

• Clean with neutral detergent or alcohol.

• Loosen the paper properly and load on the paper feed table.

‰

3 Are the sheets of paper stuck to

each other and cannot be separated?

‰

4 Is paper outside the specified

sizes used?

• Do not use such a kind of paper as they will cause problems.

5 Has a problem occurred inside

the unit?

• Contact your serviceman.

(6)Paper slips frequently.

1 Is the paper feed pressure too

low?

• Raise the separator pressure gradually until the optimum pressure is obtained.

2 Is the paper feed ring dirty?

• Clean with neutral detergent or alcohol.

3 Are the sheets of paper sticking

to each other and cannot be separated.

• Loosen the paper properly and load on the paper feed table.

4 Is paper outside the specified

sizes used?

• Do not use such paper as they will cause problems.

5 Has a problem occurred inside

the unit?

• Contact your serviceman.

1 Is the rubber roll dirty?

• Clean with neutral detergent or alcohol.

(7)Paper jams frequently.

• Check inside the unit and remove any paper shreds.

2 Are paper shreds stuck inside

the paper conveyance passage?

3 The stacker roller position is not

correct.

• Re-set the position of the stacker roller.

4 Is the paper curled?

• Straighten the curl before use.

5 Is the guide plate unit left

attached to the paper ejection plate?

6 Due to static electricity.

• Use an anti-static electricity spray available on the market.

• Remove the guide plate unit.

‰

Problem

Check

(8)When paper slips in the

vertical direction.

• Adjust each folding stopper finely.

13. TROUBLESHOOTING GUIDE

Correct

1 Was the paper type (quality,

amount) changed halfway?

• Adjust each folding stopper finely again.

(9)When paper slips in the

horizontal direction when folded.

1 Is the paper stacked

unevenly?

• Stack the paper neatly on the paper feed table.

• Adjust the guide firmly against the paper.

2 Is there space between the

paper and guide?

• Rotate the slant correction knob and correct the folding slippage.

(10) Paper jam at the rubber roll

when thick paper or cross folded thick paper is folded into two.

1 Is paper outside the specified

sizes used?

• Do not use such paper as they will cause problems.

2 Is the space inside the internal

paper conveyance passage narrow?

• Rotate the fine adjustment knob of second folding plate to the right one round and move the folding stopper.

(11)

Small paper is fed continuously.

(Chain-feed).

1 Is small paper outside the

specified sizes used?

• Do not use such a paper as they will cause problems.

2 Is the paper feed pressure

too high?

• Set the paper feed pressure from “thick paper” to “thin paper”.

‰

14. CLEANING THE UNIT

• As paper shreds, ink of printed paper on the rubber roll and paper feed ring will cause problems, clean these parts according to the following procedures.

• To ensure safety, always turn off the power of the unit first before cleaning.

14-1. CLEANING THE RUBBER ROLL

1 Open the top cover.

2 Remove the first and second folding

plates completely as shown in the figure.

3 Rotate the rubber roll, and clean off

the dirt with a cloth moistened with neutral detergent or alcohol.

Top cover

Second folding plate

First folding plate

Rubber roll

14. CLEANING THE UNIT

14-2. CLEANING THE PAPER FEED RING

1 Open the top cover.

2 While rotating the paper feed ring

with your hand in the direction of the arrow, clean it with a cloth moistened with neutral detergent or alcohol.

Take note that the paper feed ring can only be rotated in one direction.

Top cover

Paper feed ring

15. SPECIFICATIONS

Model

Type

Paper size that can be folded

Max.

Min.

Paper quality

Folding mode

Paper thickness

Processing speed

Paper feed method

Office use, desktop

11 (W) x 17 (L) inch

5 (W) x 7 (L) inch Rough paper, fine quality paper, stencil paper, recycled paper,

drawing paper. Single fold, double fold, irregular accordion fold, letter fold,

accordion fold, brochure fold, special cross fold (paper thickness:

52.3 to 127 g/m 2), other special folds

Loading capacity of paper feed table

120 sheets/min. (For single folding 64 g/m 2 of fine quality LG paper)

3 rings, automatic paper separation method, slant correction device

52.3 to 127 g/m

However, 127 g/m 2 cannot be double folded. 500 sheets (Fine quality paper, 64 g/m 2)

Moving the stacker roller

Manual setting (5 steps)

Counter

4-figure adding counter display

Moving the folding stopper Manual setting

Power

Dimensions

In storage

In use

Weight

120V 60Hz

31 (W) x 19-5/16 (D) x 20-11/16 (H) inch

36-3/16 (W) x 19-5/16 (D) x 20-11/16 (H) inch (MAX)

Other detections

Top cover open/close detection.

70.77 lb

Specifications and dimensions are subject to change without prior notice.

DF-505N

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Duplo DF-505N Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual