Duplo DF-920, DF-915 Maintenance Manual

PAPER FOLDER

DF-920/915

MAINTENANCE MANUAL

12H-M12M0-0309-0

TABLE OF CONTENTS

CHAPTER 1 MECHANISM

1. Outline of Machine ..........................................1-2

2. Outline of Mechanisms and Adjustments........1-6

3. Periodic Inspections........................................1-50

4. Troubleshooting Guide

(Mechanical Causes) ......................................1-52

CHAPTER 2 ELECTRICAL

COMPONENTS

1. Block Diagram of Structure and Outline of

Each Block ......................................................2-2

2. Errors and Causes ..........................................2-10

3. Maintenance Mode .........................................2-15

4. Backup Data Form ..........................................2-28

5. Initializing the Memory ....................................2-30

6. Precautions on Replacing the MC Unit ...........2-31

7. Upgrading the Program Version .....................2-32

8. Overall Schematic Diagram (DF-920).............2-33

9. Overall Schematic Diagram (DF-915).............2-34

10. Wiring Diagram 1/2 (DF-920)..........................2-35

11. Wiring Diagram 2/2 (DF-920)..........................2-36

12. Wiring Diagram 1/2 (DF-915)..........................2-37

13. Wiring Diagram 2/2 (DF-915)..........................2-38

About This Manual

This maintenance manual is intended for those familiar with maintenance work of the Duplo paper folder DF-500
series. Sections found in the maintenance manual of the DF-520N have been omitted. Refer to the maintenance
manual for DF-520N for these sections.

Precautions on Maintenance

Disconnect the power cord from the outlet to ensure safety when implementing maintenance work.
Use a non-flammable type air spray. Read the instructions on use carefully and be sure to observe them.
Notify users who have remodeled this unit that they are required to ensure safety at their own responsibility.

Consumables Used for Maintenance (Grease, etc.)

This manual lists the standard products and specifications for consumables used in maintenance such as grease, etc.
If these products are not available, use products that comply with the specifications indicated.

“MOLY KOTE” is either the trademark or registered trademark of U.S. Dow Corning Corporation, “Loctite” that of U.S. Henkel Loctite Corporation,
“NITOFLON” that of Japan NITTO DENKO Corporation, and “Three Bond” that of Japan Three Bond Co., Ltd. Other company and product names
in the manual may be the trademark or registered trademark of their respective countries.

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12H-M12M0-0309-0

CHAPTER 1

MECHANISM

1. Outline of Machine......................................... 1-2

1-1. Names of Parts ....................................... 1-2

1-2. Layout of Folding Plates and

Folded Size by Folding Mode ................. 1-4

2. Outline of Mechanisms and Adjustments ...1-6

2-1.

Folding Section and Drive Mechanism ....

1-6

2-2. Paper Feed Tray.....................................1-15

2-3. Separating Mechanism........................... 1-23

2-4. Paper Feed Inlet .....................................1-24

2-5. Paper Ejection Mechanism..................... 1-26

2-6. Folding Plates .........................................1-29

2-7. Exterior and Detection Switches.............1-47

3. Periodic Inspections...................................... 1-50

3-1. Inspection Points and Procedure............1-50

3-2. Other General Precautions..................... 1-50

4. Troubleshooting Guide

(Mechanical Causes) .....................................1-52

4-1. When Paper is Conveyed Skewed .........1-52

4-2. When Paper Wrinkles............................. 1-52

4-3. When Abnormal Sounds (Metal Sliding

Sounds) are Produced During Rotation

of Folding Rollers.................................... 1-52

4-4. When Stacker Belt Rotates Heavily........1-52

4-5. Stopping Position of Paper Lead Edge

Does Not Stabilize During Paper Feed,

and Paper Jams Near Paper Feed Inlet

Sensor ....................................................1-53

4-6. When Paper Slips Frequently................. 1-53

4-7. When Continuous-feed Occurs

Frequently with Small Paper

(B7, INV, etc.) ......................................... 1-53

4-8. When Stacker Belt Slips .........................1-53

4-9. When Folding Stopper Moves

Abnormally Slow .....................................1-53

4-10. When Folding Misalignment Along

Vertical Length of Paper is Large ...........1-54

4-11. When Folding Misalignment Along

Sides of Paper is Large ..........................1-54

4-12. Paper Jams at Folding Unit or

Flattening of Folded Line Occurs During
Single Folding and When Thick Paper is
Used, or Folding Wrinkle Line is Formed

at Folded Line with Thin Paper ...............1-54

4-13. Paper Jams at Folding Unit or

Flattening of Folded Line Occurs
During Folding Modes Other Than
Single Folding and When Thick Paper

is Used....................................................1-54

4-14. When Motor Lock of Folding Plate 2

Occurs ....................................................1-54

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1. OUTLINE OF MACHINE

1-1. Names of Parts

DF-920

Front view (Operating side)

Rear view (Drive side)

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12H-M12M0-0309-0

DF-915

Front view (Operating side)

Rear view (Drive side)

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1

2

3
4

A

A

B

B

Paper
ejection
section

Folding stopper

Folding rollers 1 to 4

Paper feed ring

Paper feed tray

Folding plate 1

Stacker roller

Folding stopper

Folding plate 2

Flow of paper

1-2. Layout of Folding Plates and Folded Size by Folding Mode

The DF-900 series is equipped with folding plates to ensure smooth paper conveyance from paper feed to ejection.
This section describes the layout of folding plates and folded size by folding plates 1 and 2 in each folding mode.

1-2-1. Layout of folding plates

As seen from the control panel side, the paper feed section is located at the top left, folding plate 1 at the top right,
folding plate 2 at the bottom left, and paper ejection section at the bottom right.
This layout subjects paper to the least stress from paper feed to ejection. However, because folding plate 2 is located
at the lower side of the paper feed section, this makes adjustment of the folded size by hand difficult, and all folded
size adjustments must be performed on the control panel.

Adjusting the folded size (folding position)

Folded size (folding position) is adjusted by moving the folding stopper using the folding stopper adjusting keys of
folding plates 1 and 2 on the control panel.
Each time the key is pressed, the folding stoppers move by 0.125 mm (0.005"). The window shows the distance
moved. At this point, the folding stoppers do not move. They move when the start or test key is pressed.
Pressing the “+” key moves the folding stoppers of folding plates 1 and 2 in direction A shown in the figure. Pressing
the “–” key moves them in direction B.

A4 +3.O/-1.O
STAND BY

Folding plate 1
folding stopper adjusting key

Folding plate 2
folding stopper adjusting key

LTR +.O3O/-.O4O
STAND BY

DF-920 UK DF-920 USA

DF-915 UK DF-915 USA

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1-2-2. Folded size by folding plates 1 and 2 in each folding mode (theory)

The values in the table below are theoretical values. In actual use, folded size is finely adjusted according to the
folding mode to prevent dog ears and curling of paper.

Folding mode

Single

fold

Folded size by folding plate 1
(Ratio to paper length)

Folded size by folding plate 2
(Ratio to paper length)

1/2

0

Double

fold

1/2

1/4

Irregular

accordion

fold

1/4

1/4

Letter

fold

2/3

1/3

Accordion

fold

1/3

1/3

Brochure

fold

3/4

1/4

Example: Letter folding A4 (Letter) paper

A4 (Letter) paper length: 297 mm (11")

Folded size by folding plate 1: 199 mm (7.37") (About 2/3 of paper length)
Folded size by folding plate 2: 100 mm (3.70") (About 1/3 of paper length)

∗ Measure the folded size at the center of the paper.

Folded size by folding plate 1

199 mm (7.37")

Measuring point

(Center)

99 mm

(3.67")

98 mm
(3.63")

Folded size by folding plate 2

100 mm (3.70")

Paper feed direction

∗ ( ) shows the folded size for letter size paper.

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2. OUTLINE OF MECHANISMS AND ADJUSTMENTS

2-1. Folding Section and Drive Mechanism

The folding section is the most basic paper folding mechanism. It is composed of folding rollers, press lever, reference
stoppers, etc.
The drive mechanism distributes driving force from the main motor to the folding rollers, paper feed mechanism, and
stacker mechanism.

2-1-1. Cleaning the folding rollers

Clean off dirt on the surface of the idler roller, center press roller, and folding rollers 1 and 2 with alcohol. Use of other
solvents may deform the surface of the rubber roller.

2-1-2. Replacing folding rollers

(1) Removing/attaching order of folding rollers

Remove in the order of idler roller, center press roller, folding roller 1, and folding roller 2.
Attach in the reverse order of the above.

As the center press roller is incorporated with a switching shaft unit, be careful not to deform the
switching angle during removal.
As the folding rollers are incorporated with keys, collars, and flat pins for securing the drive gears (helical
gears), be careful not to lose these during removal.
Make sure that there is no grease or oil on the side of the switching shaft passed by paper.

NoteNote

(2) Attaching the press lever

Apply a small amount of oil to the area where the
press reference pillar and press lever are
connected.
(Orelube G90-140: Equivalent to ISO #460)

(3) Attaching the reference stoppers

The reference stoppers minimize deformation of
the rubber roller (nip), maintain appropriate
distance between the folding roller shafts, and
maintain backlash of the drive gear (helical
gear).

Secure the reference stoppers in the order of
idler roller, folding roller 1, and folding roller 2
with the folding rollers in contact.

Always turn off the power when cleaning. Also take precautions against fire and ensure ventilation when using
alcohol.

NoteNote

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12H-M12M0-0309-0

(4) Attaching the drive gear (helical gear) of folding

roller

Attach the press spring T and regulated stopper
after attaching the drive gear. This helps
facilitate attaching of the drive gear.

Attach the key, flat pin, and deceleration pulley
for securing the drive gear to the center press
roller.

Attach the key, collar, timing pulley, and thrust
regulated washer for securing the drive gear to
the idler roller.

Attach the key, collar, and thrust regulated
washer for securing the drive gear to folding
rollers 1 and 2.

The teeth of the helical gear is subject to force in
the thrust direction during rotation. When
securing the thrust regulated washer with
screws, check that the helical gear does not
move in the thrust direction.
Using gears in the thrust play state may cause
abnormal wear on the gear teeth side and
wrinkles of the paper due to paper slipping.

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12H-M12M0-0309-0

After attaching the drive gear, apply press force to all folding rollers, and check the following points.

• Rotate the folding rollers for one round, and check that there is uniform roller nip (surface hollowing
amount of rubber roller) in all directions (left, right, center) between all folding rollers.

• Make sure that gear engagement is ample, and the rollers rotate smoothly.

At this time, if the nip amount on the left and right differs between folding rollers, paper may slip.

• Roller nip : 0.1 mm (0.004") (folding roller shaft distance: 35.9 mm (1.41"))

• Folding roller drive gear backlash: 0.1 to 0.2 mm (0.004" to 0.008") for above distance between folding

roller shafts

Check the gear backlash with the folding roller key removed.

Apply grease to the whole circumference of the drive gear. (Orelube G1650: Equivalent to NLGI #1)

(5) Attaching the regulated stopper

The regulated stopper helps prevent inference between teeth resulting from excess distance between the
drive gears (helical gears), maintaining proper engagement all the time, and regulating force in the thrust
direction imposed on the helical gear.

The regulated stopper is secured at the position indicated in the figure.
The regulated movement amount of each folding roller is as follows.

Idler roller : 0.8 mm (0.03") (1.5°)
Folding roller 1: 0.8 mm (0.03") (1.5°)
Folding roller 2: 1.1 mm (0.04") (2°)

Regulated movement amount of idler roller

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12H-M12M0-0309-0

(6) Attaching the press spring T

q Secure the spring hook at the position shown in

the figure, and attach the press spring T.
(Primary adjustment in the assembly stage)

Spring T inner dimensions of idler roller:
45 mm (1.77")
(Spring pressure: 23.5 N ±8.5%)

Spring T inner dimensions of folding roller 1:
50 mm (1.97")
(Spring pressure: 38.8 N ±8.5%)

Spring T inner dimensions of folding roller 2:

49.5 mm (1.95")
(Spring pressure: 37.2 N ±8.5%)

w Perform test folding, and if wrinkles or extreme

folding misalignment along the sides of the paper
occur, check the balance between the left and
right pressure, and adjust by changing the spring
hooking direction. (Secondary adjustment by
passing paper)

(7) Attaching the plate spring (grounding conduction)

The plate spring helps static electricity accumulated in folding rollers to escape to the chassis.

q Attach so that the center drill mark of the folding roller edge and throttle of the plate spring contact.

Check that no anticorrosive coating is applied to the contact area of the folding roller edge.

w Apply conductive grease to the plate spring. (Dow Corning MOLY KOTE 41)

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12H-M12M0-0309-0

(8) Adjusting the tension of the paper ejection

drive timing belt

Inappropriate tension of the belt may cause such
problems as noise, slips, etc.

Using a tension gauge of 5 N (510 gf), apply
pressure of 3 N (306 gf) to the belt, and check
that the belt slacks by 3 to 5 mm (0.12" to 0.20").

(9) Adjusting the tension of the drive belt for the

jam correction knob

The jam correction knob rotates the folding rollers
during jam correction and cleaning of folding rollers
to facilitate work.

q Check that when the jam correction knob is

rotated, the folding rollers rotate smoothly.

w Using a tension gauge of 5 N (510 gf), apply

pressure of 3 N (306 gf) to the belt, and check
that the belt slacks by 3 to 5 mm (0.12" to 0.20").

(10) Attaching the main pulley of the center press

roller, and jam correction knob drive pulley of
the idler roller

q While pressing the main pulley against the frame

B side so that there is no thrust play of the helical
gear, attach it to the center press roller.

w While pressing the knob drive pulley against the

frame B side so that there is no thrust play of the
helical gear, attach it to the idler roller.

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12H-M12M0-0309-0

q Set the drive belt on the paper feed clutch unit, and

secure the bracket.

“2-1-6. Attaching the paper feed clutch unit”

w Loosen the two screws securing the main motor and

adjust the tension of the belt so that it slacks by 3 to 5
mm (0.12" to 0.20") when a pressure of 3 N (306 gf) is
applied to the belt using a 5 N (510 gf) tension gauge.

2-1-3. Adjusting the tension of the main drive timing belt

Inappropriate tension of the belt may cause such problems as noise, slips, etc.

SeeSee

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12H-M12M0-0309-0

2-1-4. Paper ejection drive shaft

The stacker belt is driven at high speed intermittently using the electromagnetic clutch to enhance stacking
performance and processing speed.

Replace the paper ejection clutch using the following
procedure.

q Check the accessories provided with the paper

ejection clutch unit.

Shim (adjusting washer, t = 0.1): 3
Collar: 1

w Check for thrust play of the paper ejection drive shaft

at frame F side. At shipment, a shim (adjusting
washer) is inserted between the paper ejection drive
shaft and bearing to control thrust play to below 0.1
mm (0.004").
Check that thrust play is not minus (pressed state).

e While ensuring the w state, attach and secure the

clutch rotor at frame B side.

r Attach the collar, shim, armature (STS pulley)

provided with the paper ejection clutch unit as a set to
the drive shaft.

As the paper ejection clutch unit is adjusted
to an air gap (0.15 mm (0.006")) at shipment,
always attach the above parts to the
machine as a set.
Do not apply oil to the contacting area of the
clutch rotor and armature.

NoteNote

t Using the shim provided, adjust so that thrust play of

the collar and E ring outside the armature becomes
less than 0.1 mm (0.004").

y Check that the armature rotates smoothly.

Also check that paper ejection drive shaft does not
rotate when the armature rotates.

u Apply a very small amount of oil to the area where the

drive shaft and bearing are connected.
(Orelube G90-140)

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12H-M12M0-0309-0

2-1-5. Attaching the motor pulley

If the motor pulley is not attached at the proper position, slipping of the drive belt and abnormal wear may result.
Replace the main motor using the following procedure.

q Attach the motor pulley to the main motor at the

position shown in the figure.

w After attaching, rotate the main motor and check that

the belt does not slip.

2-1-6. Attaching the paper feed clutch unit

With the DF-900 series, an electromagnetic clutch is used as a paper feed clutch to enhance processing speed and
stabilize paper feed performance.

Replace the paper feed clutch using the following procedure.

q Check for thrust play of the paper feed clutch drive shaft at the clutch bracket side. At shipment, a shim (adjusting

washer) is inserted between the paper feed clutch drive shaft and bearing to control thrust play to below 0.1 mm
(0.004").
Check that thrust play is not minus (pressed state).

w While ensuring the q state, insert the bearing at the main bracket side, and secure the paper feed clutch unit.

e Apply a very small amount of oil to the area where the drive shaft and bearing are connected. (Orelube G90-140)

r Check that the paper feed drive gear (42T) and paper feed clutch gear (33T) are engaged appropriately along the

whole circumference (backlash: 0.1 to 0.2 mm (0.004" to 0.008")), and that they rotate smoothly.
Adjust the backlash by changing the clutch bracket position.

t Apply grease to the whole circumference of the gear teeth. (Orelube G1650)

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12H-M12M0-0309-0

2-1-7. Attaching the brake unit

The brake unit reduces inconsistency in the stopping position of the paper lead edge during paper feed, and stabilizes
the jam detection timing and number of sheets processed.

q To prevent abnormal sounds due to the use of the

friction brake mechanism, apply a very small amount
of grease to the urethane area of the brake unit and
attach. (Orelube G1650)

w After attaching the brake unit, check that the rotating

torque of the paper feed shaft unit is 0.0147 to 0.0245
Nm (0.15 to 0.25 kgf • cm) with the paper separator
and paper feed ring not in contact.
However, even if the rotating torque does not meet
the above value, if the stopping position of the paper
lead edge is stable without touching the paper feed
inlet sensor it means that paper feed is stable and no
re-adjustments are required.

e Apply a very small amount of oil to the area where the

paper feed shaft joint and bearing are connected.
(Orelube G90-140)

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12H-M12M0-0309-0

2-2. Paper Feed Tray

As the paper feed tray mechanism is more or less the same as the DF-520N, only the differences are described in this
section.

2-2-1. Automatic paper size detection

Photosensors are located at the standard paper size positions. Paper size is detected when the shield attached to the
paper feed guide blocks a sensor.
For USA models, the auxiliary paper feed tray is also provided with a photosensor to differentiate between legal size
and letter size.
The automatic detection range is within ±7 mm (0.28") from standard paper size.
The paper feed guides move together left and right from the center of the paper feed tray.

Standard paper size which can be automatically detected

UK model : A3, B4, A4, B5, A5, B6 (6 types)
USA model: LGR, LGL, LTR, STMT, INV (5 types)

2-2-2. Paper size which can be stacked

Distance moved by paper feed guide: Maximum 310 mm (12.2")

: Minimum 76 mm (3.0")

Paper width which can be fed : Maximum 305 mm (12.0") ∗ 297 mm (11.7") in specifications: Width of A3 paper

: Minimum 76 mm (3.0") ∗ Width of B7 paper

Paper length which can be fed: Maximum 432 mm (17.0")

: Minimum 128 mm (5.1") ∗ Length of B7 paper

The above values are design specifications. In actual use, values given in instruction manual apply because they are
restricted by the length of the folding plate and paper receiving allowance of the paper ejection section.

Maximum paper size: 297 (width) × 432 (length) mm (11.7" × 17.0")
Minimum paper size : 128 (width) × 182 (length) mm (5.1" × 7.2")

∗ B7 and A6 paper can be folded under certain conditions.

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12H-M12M0-0309-0

2-2-3. Attaching the paper feed tray assembly

Take note when attaching the paper feed tray assembly because the direction of the set collar differs between the
DF-920 and DF-915 according to whether the paper feed tray up/down lever is provided or not.

Secure the set collar with some thrust play (0.1 to 0.2 mm (0.004" to 0.008")). Otherwise, load increases when the
paper feed tray rises, resulting in insufficient paper feed pressure even if the pressure is adjusted, and paper slips
occur easily.

Apply a very small amount of oil to the area where the fixed plate bearing and hinge rod are connected.
(Orelube G90-140)

Enlargement of section A

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2-2-4. Adjusting the paper feed pressure

Adjust to the reference paper feed pressure to prevent double-feeding and slipping of paper.
q Attach the paper feed tray lower cover, raise the

paper feed tray, and set the paper feed pressure
adjusting lever to the reference position “0”.

w Press a 30 N (3.06 kgf) tension gauge against the

notch of the operating side of the paper feed tray, and
gradually increase the pressure until the paper feed
shaft and tension gauge contact.
Rotate the adjusting screw so that the tension gauge
value becomes 6 ± 0.18 N (612 ± 18 gf) in this state.
The clearance between the bracket and fine
adjustment lever should be around 10 to 13 mm
(0.39" to 0.51").

e After adjusting, tighten the fixing nut and fixing screw

to secure the fine adjustment lever.

r Set the paper feed pressure adjusting lever to “–1”.

Check that the paper feed tray can be pushed down
smoothly by hand, and check that when the paper
feed tray is raised gently, the paper separator at the
tip of the paper feed tray touches the paper feed ring.

t Check that the paper feed tray moves up and down

smoothly.

y Apply a very small amount of grease to the regulating

plate ratchet. (Orelube G1650)

Notch of paper feed tray

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12H-M12M0-0309-0

2-2-5. Automatic up/down mechanism of paper feed tray (DF-920 only)

If this mechanism has been removed during motor replacement, attach it using the following procedure.
q Attach a pulley to the drive motor at the position

shown in the figure.

w Apply a very small amount of thread locking to the set

screw. (Loctite 242: Medium strength/for screws)

e Check for thrust play of the drive shaft assembly. At

shipment, a shim (adjusting washer) is inserted
between the collar and bearing (outer ring) at frame F
side to control thrust play to below 0.1 mm (0.004").
Check that thrust play is not minus (pressed state).

r While ensuring the e state, insert the bearing and

collar at the bracket side, and secure the bracket.

t Apply a very small amount of oil to the area where the

drive shaft and bearing are connected.
(Orelube G90-140)

y Attach the plate and rack so that their surfaces touch

and slide.

u Adjust the points on the eccentric shaft and rack, and

secure temporarily. (Primary adjustment)

i Move the rack up and down, and check that there is

appropriate backlash (0.1 to 0.2 mm (0.004" to

0.008")) where the rack and gear engage, and the
rack moves smoothly. Do not tighten the set screw of
the gear just yet. Tighten after completing the
adjustment of “2-2-7”.
The rack fulcrum Z (0Z4-08022) is designated as a
semi-durable part. Replace it appropriately after
50000 times of up/down movements of the paper
feed tray.

o Apply grease to the following parts. (Orelube G1650)

Contacting area between the up/down lever and
bearing outer ring
Connected area and sliding area of the eccentric
shaft and rack long hole
Connected area and sliding area of the Z part and
rack long hole
Sliding area of the plate and rack
Engaged area of the rack and gear

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2-2-6. Adjusting the tension of the paper feed tray automatic up/down drive timing belt

(DF-920 only)

If the tension of the belt is not appropriate, problems
such as faulty drive and jumping of the belt will occur.

Move the tension idler and adjust the tension of the
belt so that it slacks by 3 to 5 mm (0.12" to 0.20")
when a pressure of 3 N (306 gf) is applied to the belt
using a 5 N (510 gf) tension gauge.

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2-2-7. Adjusting the stopping position of the paper feed tray when rising/descending and paper

stacking amount

DF-920

To ensure paper stacking amount which can satisfy specifications, adjust the stopping position (motor drive range) of
the paper feed tray during automatic up/down.
Perform adjustments as follows without the paper feed tray automatic up/down drive gear of section “2-2-5” secured.

q Move the switch bracket for the length of the long

hole and adjust so that when the up/down lever is
pressed down to the lower limit, the actuator of the
lower limit detection microswitch turns ON the switch,
and a clearance of 0.7 ± 0.1 mm (0.028" ± 0.004") is
formed at the position shown in the figure.

w Move the switch bracket for the length of the long

hole and adjust so that when the up/down lever is
pressed up to the upper limit, the actuator of the
upper limit detection microswitch turns ON the switch,
and a clearance of 0.8 ± 0.1 mm (0.031" ± 0.004") is
formed at the position shown in the figure.

e Tighten the set screw of the drive gear D cut, and

lower the paper feed tray to the lower limit position
from the control panel.

r Rotate the eccentric shaft and adjust so that the

paper feed tray stops at a depth of 45 ± 1 mm (1.77" ±

0.04") from the bent part of the lower paper feed inlet.
The paper stacking amount given in specifications is
500 sheets (approximately 44 mm (1.73")) for fine
quality paper 64 g/m2 (16 lb).

When the paper feed tray descends

When the paper feed tray rises

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t After adjusting the paper stacking amount, raise and lower the paper feed tray from the control panel, and check the

following.
To raise the paper feed tray from the control panel, press the “+” key of the folding plate 1 folding stopper adjusting
key while pressing the stop key.
To lower the paper feed tray, press the “–” key of the folding plate 1 folding stopper adjusting key while pressing the
stop key.
The paper feed tray can also be raised and lowered using the maintenance mode “Code No.24: Paper feed tray up/
down motor test”.

“3. MAINTENANCE MODE” in CHAPTER 2 ELECTRICAL COMPONENTS

SeeSee

When the paper feed tray descends

The actuator of the lower limit detection
microswitch should not be pressing the switch
completely, and no load should be applied on Z at
the rack long hole upper edge from overrun of the
drive motor.
(When load is applied to Z, the slack of the
opposite tension idler side of the drive belt
changes.)

The paper feed tray stops at the specified position
of the paper stacking amount (approximately 44
mm (1.73")).

When the paper feed tray rises

When the paper feed pressure setting is “–1”, the paper separator at the tip of the paper feed tray touches the
paper feed ring to maintain appropriate paper feed pressure.

The actuator of the upper limit detection microswitch must not be pressing the switch completely, and there
should be a clearance between the rack long hole lower edge and Z.

When the paper feed pressure setting is “6”, there should be a clearance between the up/down lever and bearing
outer ring so that the paper feed pressure set is not affected.

When the paper feed tray descends

When the paper feed tray rises

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12H-M12M0-0309-0

y Secure the set screw of the drive gear, and apply a

very small amount of thread locking to the set screw.
(Loctite 242: Medium strength)

DF-915

Adjust the paper feed tray stopping position so that the paper stacking amount satisfies the specifications, and the
position of the tray is detected accurately when the tray is raised/lowered manually.

q Move the roller unit of the hinge lever up and down and adjust so that when the paper feed tray up/down lever is

raised and the paper feed tray is lowered, the hinge lever touches the stopper, and the paper feed tray stops at a
depth of 45 ± 1 mm (1.77" ± 0.04") from the bent part of the lower paper feed inlet.
The paper stacking amount given in specifications is 500 sheets (approximately 44 mm (1.73")) for fine quality
paper 64 g/m2 (16 lb).

When the paper feed tray rises

When the paper feed tray descends

w Move the switch angle and adjust so that when the

paper feed tray up/down lever is lowered and the
paper feed tray is raised, the actuator of the
microswitch turns ON the switch and a clearance of

0.5 to 0.7 mm (0.02" to 0.03") is formed at the position
shown in the figure.

e After completing the adjustment in w, check that the

R hinge of the actuator and the actuator press of the
paper feed tray up/down lever do not press the
actuator by continuous point contact and cause
damage.
The switch angle is provided with a stopper to prevent
damage of the switch by the damage of the actuator.

1-23

12H-M12M0-0309-0

2-3. Separating Mechanism

The separating mechanism is more or less the same as the DF-520N.

The separating pressure can be set in seven steps from 0 to 6 to handle special coated paper. For this reason, the
separator base is located on the tilted plate to which it is connected by the link mechanism. When the separating
pressure adjusting dial is rotated, the tilted plate moves and forced pressure is applied to the separator base.

When the separating pressure scale value is standard “0”, the forced pressure is released, and only pressure of
spring C (approximately 120 g) is applied to the separator base.

When the separating pressure adjusting dial is rotated, forced pressure is applied to the separator base if the scale
value is within 3.5 (design value is 2.5).

Setting the separating pressure

When using normal paper, set the separating pressure to standard “0”, and increase 0.5 at a time if double-feed
occurs. For coated paper, set the separating pressure to “2.5 to 3.5”. However, first set to “2.5” and increase 0.5 at a
time if double-feed occurs.
Using at a high separating pressure from the beginning causes problems such as paper jam at the separator and
abnormal wear of the paper feed ring.

1-24

12H-M12M0-0309-0

2-4. Paper Feed Inlet

The following changes have been made in the paper feed inlet mechanism from the DF-520N.

The curvature of the rib shape has been changed so that paper is fed properly to the very last sheet even in multiple
paper feed (500 sheets) of small size paper (B6, INV, etc.) by automatic rise/descent of the paper feed tray.

To enhance the processing speed, a transmissive sensor (paper feed inlet sensor) is provided at the paper feed
inlet.
By changing the delay time based on the paper feed inlet sensor for all paper sizes and folding modes, paper can
be fed at the optimum paper feed timing.

To eliminate static electricity, a static eliminator brush is provided at the paper feed inlet sensor (light-receiving).

2-4-1. Replacing the paper feed inlet unit

When replacing the paper feed inlet unit, take note of the following points.

After replacing the paper feed inlet sensor, check that one sheet of 52.4 g/m2 (14 lb) paper is detected properly.

The static eliminator brush is made of carbon fiber with high non-contact static elimination effects. When replacing
the static eliminator brush, attach it at the position shown in the figure so that it does not touch the center press
roller.

1-25

12H-M12M0-0309-0

2-4-2. Cleaning the paper feed inlet sensor

The paper feed inlet sensor will not function if adhered with printing powder and paper dust, and an error message will
be displayed.
The LCD of the DF-920 displays “JAM FEED SECT” while the right window of the DF-915 displays “J1-2”.
When these messages appear, clean the sensor.

q Remove the two fixing screws, and remove the

sensor cover attached to the paper feed inlet upper
guide.

Sensor cover

Fixing screws

w Use a cloth or cotton swab to remove powder or paper dust adhered to the paper feed inlet sensor (light-emitting).

e Remove the paper feed inlet sensor (light-emitting), insert a cotton swab into the hole to remove powder or paper

dust adhered to the paper feed inlet sensor (light-receiving).

If the sensor is very dirty, remove the paper feed inlet upper guide to clean.

NoteNote

r Reinstall the paper feed inlet sensor (light-emitting) and sensor cover back to their original positions.

Be sure to perform this cleaning together with the “2-5-6. Cleaning the paper ejection outlet sensor” described
later as a set when visiting users for maintenance work.

NoteNote

2-4-3. Providing instructions on cleaning the paper feed inlet sensor to users

“21. CLEANING THE UNIT” in the instruction manual (chapter 20 in the case of the DF-915) describes the method
of cleaning using an Air Duster (a commercially available air spray for eliminating dust). Explain the details carefully to
users and instruct them on use.
With this method, the nozzle of the Air Duster is inserted into the hole of the sensor cover and paper feed inlet and
sprayed briefly.

Hole of sensor cover

Paper feed inlet

1-26

12H-M12M0-0309-0

2-5. Paper Ejection Mechanism

To enhance paper ejection stack performance and processing speed, the paper ejection drive mechanism is
intermittently driven by the electromagnetic clutch. To improve operability, the movement of the stacker roller has
been made automatic.

2-5-1. Replacing the stacker belt

Take note of the following points when replacing the belt.

Belt front/back : The green side is the front.
Rotating direction of the belt: The rotating direction is indicated by an arrow on the belt back (black side).

2-5-2. Adjusting the tension of the stacker belt

Perform the following check and adjustment if the stacker belt slips while rotating.
Normally, the belt slips due to the change in the frictional coefficient between the stacker plate and belt back from the
load of the stacker roller.

q If the belt slips with the stacker roller and belt not

contacting (the stacker roller is raised), perform step
w.
If the belt does not slip in this state, perform step e.

w Generally, the ST shaft assembly is fixed at the

topmost position of the frame long hole. This state is
the recommended stretch rate of the belt. (Stretch
rate: 4%)
If the belt slips, loosen the screw fixing the ST shaft
assembly, and adjust the tension of the belt by
moving the assembly.
The adjusting range is within 2 mm (0.08").

e The area where the stacker plate and belt back

contact each other is pasted with a Teflon tape to
reduce the frictional coefficient. The belt may start to
slip when the effects of the tape drop. In such cases,
paste a new tape.
(NITTO DENKO NITOFLON tape No.973UL t0.13 ×
W15)

Enlargement of section A

1-27

12H-M12M0-0309-0

2-5-3. Paper ejection roller lever unit

The basic configuration of this unit is more or less the same as the DF-520N.

If the paper ejection roller lever unit has been removed during the replacement of the drive motor, attach it using the
following procedure.

q Apply a very small amount of oil to the area where the

drive shaft of the paper ejection roller lever unit and
bearing are connected. (Orelube G90-140)

w Check that there is appropriate backlash (0.1 to 0.2

mm (0.004" to 0.008")) at the area where the drive
gear of the paper ejection roller lever unit and pinion
are engaged, and that they rotate smoothly.

e Apply grease to the engaged gear teeth.

(Orelube G1650)

r Secure the set screw of the drive gear, and apply a

very small amount of thread locking to the set screw.
(Loctite 242: Medium strength)

2-5-4. Adjusting and checking the stacker roller home sensor

The stopping position of the stacker roller moves automatically in six steps according to the folded paper length.
The moving distance is controlled by the moving duration from the home sensor.

q When the switch lever is at the home position, secure

the sensor bracket with a clearance of 2.0 to 2.5 mm
(0.08" to 0.10") between the switch lever shield and
home sensor.

w After adjusting, check that the home sensor turns ON

and OFF properly in the maintenance mode.

“3. MAINTENANCE MODE” in CHAPTER 2
ELECTRICAL COMPONENTS

SeeSee

1-28

12H-M12M0-0309-0

2-5-5. Replacing the paper ejection outlet sensor

To detect jams in the paper ejection section, a transmissive sensor (paper ejection outlet sensor) is provided at the
main reinforcement base and stacker plate. To eliminate static electricity of the paper ejected, a static eliminator brush
(stainless fiber) is provided on the upper paper ejection guide.

Take note of the following points when replacing the paper ejection outlet sensor.

After replacing the paper ejection outlet sensor, check that one sheet of 52.4 g/m2 (14 lb) paper is detected
properly.

To prevent accumulation of paper dust on the sensor surface, the paper ejection outlet sensor (light-receiving)
protection cover is pasted with a polyester film.

2-5-6. Cleaning the paper ejection outlet sensor

The power supply cover has a φ13 mm hole to simplify cleaning of accumulated paper dust, etc. by blowing an Air
Duster (a commercially available air spray for eliminating dust) from this hole. Remove folding plate 2, insert the spray
nozzle facing down at 5° into the cover hole and blow air.

1-29

12H-M12M0-0309-0

2-6. Folding Plates

As the folding plate mechanism is more or less the same as the DF-520N, only important differences are described in
this section.

Overall view of folding plate mechanism

(1) Movement control of folding stopper

A slit plate (index plate) divided into 12 parts (pulses) is mounted to a screw shaft with a pitch of 1.5 mm (0.06").
The number of slits (pulses) is counted by two photointerrupters (index sensor) to control the moving distance
and direction of the folding stopper.
The minimum distance moved by the stopper is 0.125 mm (0.005") of one pulse of the above index plate.
The restricted value of each folding plate is shown below.

Limitations of length of folded plane

Maximum distance moved by

folding stopper from home position

Folding plate 1 288.5 mm (11.36")
Folding plate 2 180.5 mm (7.11")

Maximum folded

plane length

Folding plate 1 325 mm (12.79") 42 mm (1.65")
Folding plate 2 217 mm (8.54") 47 mm (1.85")

Minimum folded

plane length

Moving distance of folding stopper

1-30

12H-M12M0-0309-0

(3) Shape of paper inlet of folding plate

The lower guide of folding plate 1 is tapered to facilitate entrance and exit of paper to and from the folding roller.
The upper guide of folding plate 2 is extruded (deep drawing) to reduce the local clearance of the conveyance
route in the aim to reduce W dent and dog ears.

(2) Adjusting the home position of the folding

stopper

The home position of the folding stopper is the
basic position where the shield plate blocks the
home sensor added with the correction value set in
the following maintenance mode.

“3. MAINTENANCE MODE” in CHAPTER 2
ELECTRICAL COMPONENTS

Correction value of folding plate 1 home position
(Maintenance mode code No.1)

Correction value of folding plate 2 home position
(Maintenance mode code No.2)

Correction value of switching shaft home
position (Maintenance mode code No.3)

SeeSee

Folding plate 1 Folding plate 2

1-31

12H-M12M0-0309-0

(4) Structure of folding stopper

To reduce the collision sound when the lead edge of the paper collides with the folding stopper, a double-stopper
structure where a slide stopper is mounted onto the folding stopper is provided.
The side of the slide stopper which collides with the paper is also pasted with urethane to simultaneously reduce
the collision sound and paper bending.

Folding stopper structure

2-6-1. Adjusting the clearance of the conveyance route of the folding plate

To prevent paper jamming at the folding plate, check that the clearance of the conveyance route of the folding plate
satisfies the following values within the 120 mm (4.72") range from the center of the folding plate.

Folding plate 1: 1.6 mm (0.063" )
Folding plate 2: 0.8 + 0.3 mm (0.031" + 0.012")

Folding plate 1

+0.3
–0.1

Bottom regulated position

Top regulated position

Folding plate 2

+0.012"
–0.004"

1-32

12H-M12M0-0309-0

2-6-2. Checking and adjusting the thrust play of the screw shaft unit

Check the following points when folding misalignment along the vertical length of the paper and folding plate motor
lock occurs.

Check that a shim is inserted between the chassis and bearing at the folding plate motor side so that the thrust play
of the screw shaft unit becomes 0.1 to less than 0.15 mm (0.004" to less than 0.006"), and that the unit moves lightly
and smoothly.

Apply a very small amount of oil to the area where the screw shaft and bearing are connected. (Orelube G90-140)

To prevent folding plate motor lock, never apply oil or grease to the sliding area where the screw shaft, full nut, and
guide block bush are connected.

2-6-3. Replacing the full nut

If the female screw of the full nut (resin) wears due to extended use, thrust play between the screw shaft and full nut
increases, resulting in reduced folding stopper stop accuracy and increased folding misalignment along the vertical
length of the paper due to play of the folding stopper itself.
When these problems occur, replace the full nut.
The full nut cannot be replaced by merely pulling it upwards because the screw is cut on the whole block
circumference for higher durability. Rotate the screw shaft as shown in the figure, move in the right direction, and pull
the full nut downwards.

1-33

12H-M12M0-0309-0

2-6-4. Motor deceleration pulley assembly

If the tension of the belt is not appropriate, problems such as folding plate motor lock and jumping of the belt occur.
q Tighten the set screw with a torque of 0.69 Nm (7.0

kgf • cm), and secure the motor pulley at the position
shown in the figure.

w Check that a shim is inserted between the idler pulley

and E ring so that the thrust play becomes 0.1 to 0.3
mm (0.004" to 0.012").

e Apply a very small amount of oil to the area where the

idler pulley and fulcrum pillar are connected.
(Orelube G90-140)

r Apply a pressure of 3 N (306 gf) to deceleration

timing belt 1 using a tension gauge of 5 N (510 gf),
and check that the belt slacks by 2 to 3 mm (0.08" to

0.12").

t Apply a pressure of 3 N (306 gf) to deceleration

timing belt 2 using a tension gauge of 5 N (510 gf),
then move the motor deceleration pulley assembly
and adjust the tension of the belt so that it slacks by 2
to 3 mm (0.08" to 0.12").

1-34

12H-M12M0-0309-0

2-6-5. Adjusting the position of the folding stopper and slide stopper

q Tighten the M3 screw with a torque of 0.64 Nm (6.5 kgf • cm) and secure the collar.

w Check that when a pressure of 0.25 N (25 gf) is applied to the slide stopper using a tension gauge of 1 N (102 gf),

the slide stopper moves smoothly to the bottom regulated position, and when the tension gauge is removed, it
returns promptly to the top regulated position.
The distance moved by the slide stopper is 1 mm (0.04").

e Apply a very small amount of thread locking to the collar fixing screw from the back of the folding stopper.

(Three Bond 1401B: For preventing loosening)

Top regulated position

2-6-6. Folding stopper slide pin

A slide pin is provided at both ends of the folding stopper
so that the folding stopper moves horizontally, thus
preventing abnormal low speed movements due to load
changes and abnormal noise.

q Check that the two photointerrupters are attached

parallel to each other.

w When the screw shaft is rotated by hand, check that

the two sensors turn ON and OFF properly in the
maintenance mode.

“3. MAINTENANCE MODE” in CHAPTER 2
ELECTRICAL COMPONENTS

e Check that the folding stopper moves away from the

home position when the “+” key of the folding stopper
adjusting key on the control panel is pressed, and
towards the home position when the “–” key is
pressed.

SeeSee

2-6-7. Checking the operations of the index sensor

Bottom regulated position

1-35

12H-M12M0-0309-0

Check that the home sensor turns ON and OFF properly
in the maintenance mode.

“3. MAINTENANCE MODE” in CHAPTER 2
ELECTRICAL COMPONENTS

SeeSee

2-6-9. Fixed position of the switching adjusting plate of folding plate 2 folding stopper

Adjusting plate for setting the switching shaft to the regulated stopping position in single folding.

q Secure the switching adjusting plate at the position (7.0 mm (0.28")) shown in the figure while paying attention to

the left and right parallelity.

w Apply a very small amount of thread locking to the fixing screw of the switching adjusting plate.

(Loctite 242: Medium strength)

2-6-8. Checking the operations of the home sensor

1-36

12H-M12M0-0309-0

2-6-10. Adjusting the parallelity of the folding stoppers

Adjust the parallelity of the lead edge of paper fed and folding stoppers of folding plates 1 and 2 to reduce folding
misalignment along the sides of the paper.

q Remove the paper feed tray lower cover, and adjust

the skew correction knob of the paper feed tray to the
standard position.
Adjust both the paper feed pressure and paper
separating pressure to “0” on the scale.

w Stack well aligned 80 g/m2 (20 lb) fine quality paper

(vertical grain) on the paper feed tray, adjust the
paper feed guides to the paper width properly, and
secure them.
If the paper feed guides are not adjusted to the paper
width, folding misalignment along the sides of the
paper occurs.

e Select “Code No.28: Folding stopper parallelity

mode” of the maintenance mode, and press the start
key.

“3. MAINTENANCE MODE” in CHAPTER 2
ELECTRICAL COMPONENTS

For DF-920, selecting this mode and pressing the
start key causes the paper feed tray to rise
automatically, and the folding stoppers of folding
plates 1 and 2 move to the set position.
For DF-915, selecting this mode and pressing the
start key after lowering the paper feed tray up/down
lever and raising the paper feed tray moves the
folding stoppers to the set position.

SeeSee

Skew correction knob

Pin

<Standard

position>

Round hole

Idler roller

Jam correction knob

Paper feed ring

r Rotate the paper feed ring by hand, and feed the lead

edge of the paper to the idler roller.

t Rotate the jam correction knob, and move the lead

edge of the paper near the slide stopper of folding
plate 1.

Paper feed tray lower cover

Adjusting method when the folding mode is set to brochure fold

When adjusting the parallelity of the folding stoppers, there is a need to move the folding stoppers away from the
home position. When the folding mode is set to brochure fold, as the folding stoppers are set away from the home
position, parallelity deviation can be seen more clearly.
Set the folding mode to brochure fold after step w, and proceed to step e.

1-37

12H-M12M0-0309-0

y Loosen the fixing screws of the folding stopper, and

adjust so that the folding stopper becomes parallel to
the lead edge of the paper, and then tighten the fixing
screws.

u If paper slips during conveyance in t, check the left

and right roller nips of the idler roller.

“2-1-2. (4) Attaching the drive gear (helical
gear) of folding roller”

SeeSee

i Rotate the jam correction knob, and move the lead

edge of the paper near the slide stopper of folding
plate 2.

o Loosen the fixing screws of the folding stopper, and

adjust so that the folding stopper becomes parallel to
the lead edge of the paper, and then tighten the fixing
screws.

Enlargement of section A

Enlargement of section B

Section A

Fixing screws

Folding stopper

Slide stoppers

Fixing screws

Folding stopper

Slide stoppers

Section B

1-38

12H-M12M0-0309-0

2-6-11. Adjusting the home position of the switching shaft (stopping position) in single folding

The switching shaft switches the paper conveyance route between single folding and other folding modes.

To adjust the home position of the switching shaft, adjust the clearance between folding roller 1 and tip of the
switching shaft to 0.2 to 0.4 mm (0.008" to 0.016") when the folding stopper of folding plate 2 is stopping at the
home position.
If this adjustment is not carried out appropriately, problems may occur in folding which may cause conveyed paper
to become thick such as the single folding of thick paper and cross folding. These problems include flattening of the
lead edge of folded paper and paper jam at the folding roller.
In the single folding of thin paper, one folding wrinkle line occurs near the 15 mm (0.59") position from the folded
line.

The correction value of the switching shaft home position adjustment in the maintenance mode does not affect the
folding size.

Enlargement of section A

1-39

12H-M12M0-0309-0

q For DF-920, select “Code No.3: Switching shaft home position adjustment” of the maintenance mode with all

interlock switches (top cover, side cover, folding plate 1, folding plate 2 detection switches) and paper ejection
cover detection sensor ON.
For DF-915, select “Code No.3: Switching shaft home position adjustment” of the maintenance mode with all
interlock switches (top cover, folding plate 1, folding plate 2 detection switches) ON.

“3. MAINTENANCE MODE” in CHAPTER 2 ELECTRICAL COMPONENTS

SeeSee

1-40

12H-M12M0-0309-0

w Pressing the clear key while pressing the stop key initializes the folding stopper, and moves the folding stopper of

folding plate 2 to the home position.

e Open the top cover (leave the detection switch ON), and check that there is clearance between the protrusion of the

switching angle and stopper (M4).
If there is no clearance, it means that the switching adjusting plate is pushing the switching shaft excessively, and
this may cause the urethane sheet of the switching shaft to peel off or motor lock.

r With the top cover opened (detection switch in the

ON state), press the speed key and adjust the
clearance between the protrusion of the switching
angle at the left and right frames and stopper (M4) to

0.1 to 0.3 mm (0.004" to 0.012").

Adjusting method

Pressing the “+” speed key increases the correction
value by 1, and moves the folding stopper of folding
plate 2 by 0.125 mm (0.005") in the opposite
direction of the home position.
(The clearance between folding roller 1 and
switching shaft tip widens.)

Pressing the “–” speed key decreases the
correction value by 1, and moves the folding
stopper of folding plate 2 by 0.125 mm (0.005") in
the direction of the home position.
(The clearance between folding roller 1 and
switching shaft tip becomes smaller.)

The settable correction values range from “–20” to
“+5”. The position of the folding stopper ranges
from –2.5 to +0.625 mm (–0.10" to +0.02") with the
home position as 0 mm (0").

t After adjusting the clearance, single fold thick and

thin paper, and check for problems of the folded line.
If the clearance is too narrow, paper jams during
single folding of thick paper, resulting in scratches
and wrinkles near the folded line.
If the clearance is too broad, one folding wrinkle line
occurs near the 15 mm (0.59") position from the
folded line during single folding of thin paper.

1-41

12H-M12M0-0309-0

Relation between home position of switching shaft (stopping position) and
stopping position of folding stopper (Reference)

Both folding plates 1 and 2 in electrical design
(theory) are set so that the clearance between the tip
of the folding stopper and folding plate chassis
becomes 3.0 mm (0.12") when the shield blocks the
home sensor.
In mechanical design, this clearance is set to 1.5 mm
(0.06") (–12 pulses).
This is to easily make the inconsistencies of the home
position (stopping position) of the switching shaft
occurring due to the accumulation of parts tolerance
even by electrical correction.

When the folding stopper is stopping at the reference
position, the reference dimensions of the switching
adjusting plate is 7.0 mm (0.28").

When the folding stopper and switching adjusting
plate are stopping at their reference positions, the
reference dimensions of the switching shaft stopping
position is 0.2 mm (0.008").

When the switching shaft stopping position is the
reference dimension, the correction value of the
switching shaft home position is “–12”.

Switching shaft home position (stopping position)

in electrical design (Theory)

Switching shaft home position (stopping position)

in mechanical design

1-42

12H-M12M0-0309-0

2-6-12. Stopping position of switching shaft in folding modes other than single folding

The stopping position of the switching shaft in folding
modes other than single folding is set near the folding
roller so that the collar for reducing defects such as
double dent and dog ears of brochure folding serves as
the stopper of the switching shaft. As a result, the ridge
of the switching shaft is used as the holder of the paper
ejected from folding plate 2.
At this time, as the conveyance route for paper coming
into folding plate 2 becomes narrow, defects such as
flattening of the first folded line may occur in the double
folding of some thick paper (157 g/m2 (40 lb)).
Perform the following solutions for such defects.

(1) Setting the thick paper mode (Can be

performed by users.)

Increase the rotational speed of the folding roller
temporarily.

Setting method

Press the “+” speed key and set the maximum
processing speed, and press it again for another
two seconds. The maximum speed lamp blinks,
indicating that the thick paper mode has been set.

Clearing the setting

Press the “–” speed key. The maximum speed lamp
stops blinking and lights up, indicating that the thick
paper mode has been cleared.
This setting will also be cleared when the power is
turned off.

Blinking (Thick paper mode)

1-43

12H-M12M0-0309-0

(2) Removing the stopper (collar) of the switching shaft (Can not be performed by users.)

If the defects in (1) thick paper mode cannot be corrected, or when use of brochure folding is minimum, remove
the switching shaft stopper (collar).

q Remove folding plate 2 from the unit.

w Remove the resin collar (white) from inside the frame (two on the left and right of the switching shaft).

e Tighten the screw of the resin collar from outside the frame.

As the diameter of the stopper of the switching shaft changes from φ12 mm to φ4 mm, the stopping position of the
switching shaft moves back, the conveyance route broadens, allowing thick paper to enter folding plate 2.

Stopping position of switching shaft
in standard use (with φ12 mm collar)

Stopping position of switching shaft

when φ12 mm collar is removed

1-44

12H-M12M0-0309-0

2-6-13. Switching shaft cushion (urethane sheet)

To reduce noise during single folding, a cushion (urethane sheet) is attached to the switching shaft so that the
switching shaft and switching adjusting plate do not touch.
Cleaning the urethane sheet surface with alcohol during cleaning of the folding rollers increases the frictional
coefficient of the urethane surface excessively to exceed the allowed torque of the folding stopper drive motor in some
rare cases. As a result, folding plate 2 may motor lock during initialization (returning of folding stopper to home
position) immediately after power ON.
For this reason, do not clean the urethane sheet surface of the switching shaft with alcohol.

When folding plate 2 motor locks

Wipe the cushion (urethane sheet) surface of the switching shaft with a cloth moistened with grease or oil
(Orelube G90-140), then wipe immediately with a clean dry cloth to reduce the frictional coefficient of the urethane
surface. If no grease or oil is available, move the hand across the urethane surface once.

1-45

12H-M12M0-0309-0

2-6-14. Adjusting folded size

When performing folding operations under the following conditions, adjust so that the folded size becomes the
specified value when folded using the folding stoppers of folding plates 1 and 2. Adjust the folded size after completing
all other adjustments.

Paper conveyance conditions in adjustment of folded size are described below.

Paper : A4 (Letter) 80 g/m2 (20 lb) fine quality paper (vertical grain)
Folding mode : Letter fold Processing speed : Level 5 (MAX)
Paper feed pressure: 0 (Standard) Paper separating pressure: 0 (Standard)
Skew correction : 0 (Standard) Folding stopper : Parallel

The standard folded sizes under the above conditions are shown in the figure.

∗ ( ) shows the folded size for letter size paper.

Folded size by folding plate 1

199 mm (7.37")

Measuring point

(Center)

99 mm

(3.67")

98 mm
(3.63")

Folded size by folding plate 2

100 mm (3.70")

Paper feed direction

(1) Adjusting folded size by folding plate 1

For DF-920

q Turn on the power while pressing both the start and stop keys to enter the maintenance mode.

“3. MAINTENANCE MODE” in CHAPTER 2 ELECTRICAL COMPONENTS

SeeSee

e Press the clear key while pressing the stop key to initialize the folding stopper of folding plate 1.

r Press the test key to perform test folding.

t Measure the folded size of the second sheet ejected, and enter the adjustment value using the “+” or “–” key of

the speed key so that this folded size becomes the specified value.
Each time the “+” key is pressed, the folded size increases by 0.125 mm (0.005").
Each time the “–” key is pressed, the folded size decreases by 0.125 mm (0.005").
The settable adjustment values range from “–20” to “+20”. The folded size ranges from –2.5 to +2.5 mm
(–0.10" to +0.10").

y After setting, check the finish again by test folding.

u Repeat the above procedure until the folded size becomes the specified value.

w Select “Code No.1: STOP1 DEFAULT”, check

the default adjustment value displayed on the
LCD and note it down.

1.STOP1 DEFAULT

∗∗∗

Adjustment value

1-46

12H-M12M0-0309-0

For DF-915

q Turn on the power while pressing both the start and stop keys to enter the maintenance mode.

“3. MAINTENANCE MODE” in CHAPTER 2 ELECTRICAL COMPONENTS

w Select “Code No.1: Folding plate 1 home position adjustment”, check the default adjustment value displayed

on the right 7-segment window and note it down.

e Press the clear key while pressing the stop key to initialize the folding stopper of folding plate 1.

r Press the test key to perform test folding.

t Measure the folded size of the second sheet ejected, and enter the adjustment value using the “+” or “–” key of

the speed key so that this folded size becomes the specified value.
Each time the “+” key is pressed, the folded size increases by 0.125 mm (0.005").
Each time the “–” key is pressed, the folded size decreases by 0.125 mm (0.005").
The settable adjustment values range from “–20” to “+20”. The folded size ranges from –2.5 to +2.5 mm
(–0.10" to +0.10").

y After setting, check the finish again by test folding.

u Repeat the above procedure until the folded size becomes the specified value.

(2) Adjusting folded size by folding plate 2

For DF-920

q Turn on the power while pressing both the start and stop keys to enter the maintenance mode.

SeeSee

w Select “Code No.2: STOP2 DEFAULT”, check

the default adjustment value displayed on the
LCD and note it down.

2.STOP2 DEFAULT

∗∗∗

Adjustment value

e The following procedure is the same as “(1) Adjusting folded size by folding plate 1”.

For DF-915

q Turn on the power while pressing both the start and stop keys to enter the maintenance mode.

w Select “Code No.2: Folding plate 2 home position adjustment”, check the default adjustment value displayed

on the right 7-segment window and note it down.

e The following procedure is the same as “(1) Adjusting folded size by folding plate 1”.

1-47

12H-M12M0-0309-0

q Open and close the top cover and check that it is

moderately tight and remains open without falling
from its weight at an open/close angle of 60°.

w Move the switch bracket for the length of the long

hole and adjust so that when the top cover is closed,
the actuator of the microswitch turns ON the switch,
and a clearance of 1.0 ± 0.2 mm (0.039" ± 0.008")
forms at the position shown in the figure.

e After adjustment, check that the detection switch is

able to detect the open/close of the top cover in the
maintenance mode.

“3. MAINTENANCE MODE” in CHAPTER 2
ELECTRICAL COMPONENTS

2-7. Exterior and Detection Switches

2-7-1. Adjusting the top cover and detection switch (interlock)

SeeSee

2-7-2. Adjusting the side cover and detection switch (interlock) (DF-920 only)

q Open and close the side cover and check that it is

moderately tight.

w If abnormal sounds are produced (as if the cushion is

being rubbed) when the side cover is opened and
closed, apply a very small amount of oil to the frame
of the cushion contact, and wipe away immediately
with a dry cloth.

e Move the switch bracket for the length of the long

hole and adjust so that when the side cover is closed,
the actuator of the microswitch turns ON the switch,
and a clearance of 1.0 ± 0.2 mm (0.039" ± 0.008")
forms at the position shown in the figure.

r After adjustment, check that the detection switch is

able to detect the open/close of the side cover in the
maintenance mode.

“3. MAINTENANCE MODE” in CHAPTER 2
ELECTRICAL COMPONENTS

t Move and adjust the catch bracket so that the side

cover is suctioned and maintained by the magnet
catcher at the stopping position of the stopper.

SeeSee

1-48

12H-M12M0-0309-0

2-7-3. Adjusting folding plate 1 and detection switch (interlock)

2-7-4. Adjusting folding plate 2 and detection switch (interlock)

q Move the switch bracket for the length of the long hole and adjust so that when folding plate 2 is attached to the unit

at the reference position (position of mark “1 ( )” on the label), the actuator of the microswitch turns ON the switch
according to the displacement of the detection lever, and a clearance of 0.7 to 0.9 mm (0.03" to 0.04") forms at the
position shown in the figure.

w Check that when folding plate 2 is moved to the drop prevention position (position of mark “2 ( )” on the label), the

microswitch goes OFF.

e After adjustment, check that the detection switch is able to detect that folding plate 2 has been attached to the unit

in the maintenance mode.

“3. MAINTENANCE MODE” in CHAPTER 2 ELECTRICAL COMPONENTS

q Move the switch bracket for the length of the long

hole and adjust so that when folding plate 1 is
attached to the unit, the actuator of the microswitch
turns ON the switch according to the displacement of
the detection lever, and a clearance of 0.5 to 0.7 mm
(0.02" to 0.03") forms at the position shown in the
figure.

w After adjustment, check that the detection switch is

able to detect that folding plate 1 has been attached
to the unit in the maintenance mode.

“3. MAINTENANCE MODE” in CHAPTER 2
ELECTRICAL COMPONENTS

SeeSee

SeeSee

Folding plate 2 reference position Folding plate 2 drop prevention position

1-49

12H-M12M0-0309-0

2-7-5. Adjusting the paper ejection cover and detection sensor (DF-920 only)

q Open and close the paper ejection cover and check that it is moderately tight.

w If abnormal sounds are produced (as if the cushion is being rubbed) when the paper ejection cover is opened and

closed, apply a very small amount of oil to the frame of the cushion contact, and wipe away immediately with a dry
cloth.

e Move and adjust the sensor bracket so that when the paper ejection cover is closed, the clearance between the

switch lever shield and paper ejection cover detection sensor becomes 2.5 to 3.0 mm (0.10" to 0.12").

r After adjustment, check that the detection sensor is able to detect the open/close of the paper ejection cover in the

maintenance mode.

“3. MAINTENANCE MODE” in CHAPTER 2 ELECTRICAL COMPONENTS

t Move and adjust the catch bracket so that the paper ejection cover is suctioned and maintained by the magnet

catcher at the stopping position of the stopper.

SeeSee

1-50

12H-M12M0-0309-0

3. PERIODIC INSPECTIONS

3-1. Inspection Points and Procedure

In order to maintain stable paper folding performance and quality, perform periodic inspection every time the machine
has processed 200,000 sheets or every six months, whichever is faster.

Inspection point Inspection Procedure

Paper feed ring,
paper separator

Folding roller
Stacker roller moving

mechanism
Jam correction knob
Paper feed tray automatic up/

down mechanism
Paper feed inlet,

paper ejection outlet sensors

Folding stopper

Folding plate screw shaft

Cleaning

Cleaning

Oiling

Oiling

Greasing,

inspection

Cleaning

Inspection

Cleaning, oiling

Remove paper dust, and clean with alcohol.

Remove paper dust, and clean with alcohol.
Apply oil the sintered bearing.

Apply oil the sintered bearing.
Apply grease the gear surface and rack. (DF-920 only)

Check the wear state of the Z collar.

“2-4-2. Cleaning the paper feed inlet sensor”
“2-5-6. Cleaning the paper ejection outlet
sensor”

Check that the fixing screw of the Z collar of the slide
stopper is not loose.

Remove paper dust near the female screw groove on
the screw shaft and the home sensor, and apply a small
amount of oil to the bearing.
The area where the screw shaft and the full nut are
connected cannot be applied with oil or grease.

3-2. Other General Precautions

3-2-1. Oiling

Apply the specified oil to the following locations.

Area where shaft and bearing are connected (sintered bearing)
Specified oil: Orelube G90-140 (Equivalent to ISO #460)

Make sure no oil adhered to the contact surfaces of the armature and rotor of the electromagnetic clutch,
and area where the screw shaft and full nut are connected.

NoteNote

3-2-2. Greasing

Apply the specified grease to the following parts.

Gear teeth, paper feed tray automatic up/down drive rack related parts, etc.
Specified grease: Orelube G1650 (Equivalent to NLGI #1)

Plate spring for grounding conduction of folding roller
Specified grease: Dow Corning MOLY KOTE 41 (Conductive grease)

Make sure no grease adhered to the contact surfaces of the armature and rotor of the electromagnetic
clutch, and area where the screw shaft and full nut are connected.

NoteNote

SeeSee

1-51

12H-M12M0-0309-0

3-2-3. Preventing screws from loosening

If the following screws have been removed, apply a very small amount of the specified thread locking.

Set screw of drive gear for automatic up/down of paper feed tray
Set screw of drive gear for stacker roller
Fixing screw of folding pate 2 switching adjusting plate

Specified thread locking: Loctite 242 (Medium strength/for screws)
Fixing screw of slide stopper Z collar

Specified thread locking: Three Bond 1401B (For preventing loosening)

3-2-4. Others

Make sure that no oil and grease adheres to the timing belt and drive pulley grooves.

Fill maintenance data (folded size correction data, etc.) changed during machine adjustments in the backup data
form pasted to the back of the main cover F.

1-52

12H-M12M0-0309-0

4. TROUBLESHOOTING GUIDE (MECHANICAL CAUSES)

4-1. When Paper is Conveyed Skewed

Cause Solution

The left and right nip amount
differs between the folding rollers.

The thrust play of the folding roller
drive gear is large.

The press pressure of the folding
roller is not balanced between the
left and right sides.

The folding roller is deformed.

Check the attached state of the reference stopper, and make the roller nip
the same.

“2-1-2. (3) Attaching the reference stoppers”
“2-1-2. (4) Attaching the drive gear (helical gear) of folding roller”

Adjust so that there is no thrust play.

“2-1-2. (4) Attaching the drive gear (helical gear) of folding roller”

Adjust the press pressure.

“2-1-2. (6) Attaching the press spring T”

Replace the folding roller.

“2-1-2. Replacing folding rollers”

Cause Solution

The press pressure of the folding
roller is strong.

The folding roller is deformed.

Adjust the press pressure.
Especially set the press pressure of folding roller 1 weak. (About 45 to 46 mm
(1.77" to 1.81"))

“2-1-2. (6) Attaching the press spring T”

Replace the folding roller.

“2-1-2. Replacing folding rollers”

Cause Solution

The plate spring for grounding
conduction has worn out.

Apply conductive grease or replace the plate spring.

“2-1-2. (7) Attaching the plate spring (grounding conduction)”

Cause Solution

The thrust play of the paper
ejection drive shaft and paper
ejection clutch is not appropriate.

Adjust so that the thrust play is less than 0.1 mm (0.004").

“2-1-4. Paper ejection drive shaft”

SeeSee

SeeSee

SeeSee

SeeSee

4-2. When Paper Wrinkles

SeeSee

SeeSee

4-3. When Abnormal Sounds (Metal Sliding Sounds) are Produced During

Rotation of Folding Rollers

SeeSee

4-4. When Stacker Belt Rotates Heavily

SeeSee

1-53

12H-M12M0-0309-0

4-5. Stopping Position of Paper Lead Edge Does Not Stabilize During Paper Feed,

and Paper Jams Near Paper Feed Inlet Sensor

Cause Solution

As the rotating load is too light
during paper feed drive, paper
continuous-feeds.

Wipe off a small amount of grease from the brake unit of the paper feed
clutch to decrease the amount.
If the brake unit has worn out, replace it.

“2-1-7. Attaching the brake unit”

4-6. When Paper Slips Frequently

Cause Solution

Contact resistance occurs when
the paper feed tray rises, and the
reference paper feed pressure is
insufficient.

The paper feed pressure
adjustment is inappropriate.

The up/down lever and bearing are
touching, and the reference paper
feed pressure is insufficient.
(DF-920 only)

When attaching the paper feed tray to the unit, ensure that thrust play is
appropriate.

“2-2-3. Attaching the paper feed tray assembly”

Re-adjust the reference paper feed pressure.

“2-2-4. Adjusting the paper feed pressure”

Adjust the microswitch detection position when the paper feed tray rises.

“2-2-7. Adjusting the stopping position of the paper feed tray
when rising/descending and paper stacking amount”

4-7. When Continuous-feed Occurs Frequently with Small Paper (B7, INV, etc.)

Cause Solution

The processing speed is too fast or
the paper feed pressure is too
high.

Set the processing speed to less than “4” and the paper feed pressure to “0”
or “–1”.

4-8. When Stacker Belt Slips

Cause Solution

The tension of the stacker belt is
too weak, or tension differs
between the left and right sides.

The Teflon tape on the stacker
plate has worn out.

Adjust the tension of the stacker belt.

“2-5-2. Adjusting the tension of the stacker belt”

Replace the Teflon tape.

“2-5-2. Adjusting the tension of the stacker belt”

4-9. When Folding Stopper Moves Abnormally Slow

Cause Solution

No thrust play of the screw shaft
unit.

The tension of the drive belt of the
screw shaft is too strong.

Adjust so that the thrust play becomes 0.1 to less than 0.15 mm (0.004" to
less than 0.006").

“2-6-2. Checking and adjusting the thrust play of the screw shaft
unit”

Adjust so that the belt slacks by the specified amount.

“2-6-4. Motor deceleration pulley assembly”

SeeSee

SeeSee

SeeSee

SeeSee

SeeSee

SeeSee

SeeSee

SeeSee

1-54

12H-M12M0-0309-0

4-10. When Folding Misalignment Along Vertical Length of Paper is Large

Cause Solution

Thrust play of the screw shaft unit
is large.

The full nut has worn out, and the
thrust play of the area connected
the screw shaft is large.

Adjust so that the thrust play becomes 0.1 to less than 0.15 mm (0.004" to
less than 0.006").

“2-6-2. Checking and adjusting the thrust play of the screw shaft
unit”

Replace the full nut.

“2-6-3. Replacing the full nut”

4-11. When Folding Misalignment Along Sides of Paper is Large

Cause Solution

Paper is conveyed skewed.
Paper lead edge and folding

stopper are not parallel.

Perform “4-1. When Paper is Conveyed Skewed”.
Adjust the parallelity of the folding stopper.

“2-6-10. Adjusting the parallelity of the folding stoppers”

4-12. Paper Jams at Folding Unit or Flattening of Folded Line Occurs During

Single Folding and When Thick Paper is Used, or Folding Wrinkle Line is
Formed at Folded Line with Thin Paper

Cause Solution

The clearance between the folding
roller and switching shaft is too
large.

Adjust the clearance.

“2-6-11. Adjusting the home position of the switching shaft
(stopping position) in single folding”

4-13. Paper Jams at Folding Unit or Flattening of Folded Line Occurs During

Folding Modes Other Than Single Folding and When Thick Paper is Used

Cause Solution

As the conveyance route is too
narrow, the thick paper does not
enter the folding rollers easily.

Increase the processing speed.

“2-6-12. (1) Setting the thick paper mode”

Change the stopping position of the switching shaft, and widen the
conveyance route.

“2-6-12. (2) Removing the stopper (collar) of the switching shaft”

4-14. When Motor Lock of Folding Plate 2 Occurs

Cause Solution

The frictional coefficient of the
cushion (urethane sheet) surface
of the switching shaft is high,
exceeding the allowed current
during motor drive.

Decrease the frictional coefficient.

“2-6-13. Switching shaft cushion (urethane sheet)”

SeeSee

SeeSee

SeeSee

SeeSee

SeeSee

SeeSee

SeeSee

2-1

12H-M12M0-0309-0

CHAPTER 2

ELECTRICAL COMPONENTS

1. Block Diagram of Structure and Outline of

Each Block...................................................... 2-2

1-1. MC Unit...................................................2-6

1-2. Control Panel ..........................................2-6

1-3. Paper Feed Inlet Sensor.........................2-6

1-4. Paper Ejection Outlet Sensor .................2-6

1-5. Paper Switch...........................................2-6

1-6. Top Cover Switch ...................................2-6

1-7. Side Cover Switch (DF-920 only) ...........2-7

1-8. Paper Ejection Cover Sensor

(DF-920 only)..........................................2-7

1-9. Paper Feed Tray Upper Limit Detection

Switch (DF-920 only) .............................. 2-7

1-10. Paper Feed Tray Lower Limit Detection

Switch (DF-920 only) .............................. 2-7

1-11. Folding Plate 1 Set Switch ......................2-7

1-12. Folding Plate 2 Set Switch ......................2-7

1-13. Folding Plate 1 Index Sensor A/B ...........2-7

1-14. Folding Plate 2 Index Sensor A/B ...........2-7

1-15. Folding Plate 1 Home Sensor .................2-8

1-16. Folding Plate 2 Home Sensor .................2-8

1-17. Main Motor ..............................................2-8

1-18. Paper Feed Tray Up/Down Motor

(DF-920 only)..........................................2-8

1-19. Folding Plate 1 Motor..............................2-8

1-20. Folding Plate 2 Motor..............................2-8

1-21. Stacker Roller Moving Motor ..................2-8

1-22. Stacker Roller Home Sensor ..................2-8

1-23. Paper Feed Clutch ..................................2-8

1-24. Paper Ejection Clutch .............................2-9

1-25. Main Motor Index Sensor........................2-9

1-26. PS P.W.B. Unit .......................................2-9

1-27. Paper Feed Tray Set Switch

(DF-915 only)..........................................2-9

1-28. Switching Power Supply .........................2-9

1-29. Power Switch ..........................................2-9

1-30. Power Inlet ..............................................2-9

1-31. Power Cord .............................................2-9

2. Errors and Causes .........................................2-10

2-1. When Paper Jams Occur........................ 2-10

2-2. Troubleshooting ...................................... 2-10

2-3. Other Condition Messages .....................2-12

2-4. Emergency Measures When the Paper

Switch Damages.....................................2-14

3. Maintenance Mode......................................... 2-15

3-1. Entering the Maintenance Mode .............2-15

3-2. Setting the Maintenance Mode ............... 2-15

3-3. List of Maintenance Modes .....................2-16

3-4. Precautions for Setting Folding Stopper

Fixed Mode (DF-920 only) ......................2-27

4. Backup Data Form ......................................... 2-28

5. Initializing the Memory .................................. 2-30

6. Precautions on Replacing the MC Unit........ 2-31

7. Upgrading the Program Version................... 2-32

8. Overall Schematic Diagram (DF-920) ...........2-33

9. Overall Schematic Diagram (DF-915) ...........2-34

10. Wiring Diagram 1/2 (DF-920)......................... 2-35

11. Wiring Diagram 2/2 (DF-920)......................... 2-36

12. Wiring Diagram 1/2 (DF-915)......................... 2-37

13. Wiring Diagram 2/2 (DF-915)......................... 2-38

2-2

12H-M12M0-0309-0

1. BLOCK DIAGRAM OF STRUCTURE AND OUTLINE OF EACH BLOCK

DF-920 block diagram

1-1. MC unit

1-17. Main motor

1-2. Control panel

1-22. Stacker roller home sensor

1-18. Paper feed tray up/down motor

1-9. Paper feed tray upper limit

detection switch

1-10. Paper feed tray lower limit

detection switch

Legal paper detection sensor
(USA model only)

1-26. PS P.W.B. unit

1-23. Paper feed clutch

1-24. Paper ejection clutch

1-3. Paper feed inlet sensor

1-4. Paper ejection outlet sensor

1-5. Paper switch

1-6. Top cover switch

1-7. Side cover switch

1-8. Paper ejection cover sensor

1-11. Folding plate 1 set switch

1-19. Folding plate 1 motor

1-13. Folding plate 1 index sensor A

1-13. Folding plate 1 index sensor B

1-15. Folding plate 1 home sensor

1-12. Folding plate 2 set switch

1-20. Folding plate 2 motor

1-14. Folding plate 2 index sensor A

1-14. Folding plate 2 index sensor B

1-16. Folding plate 2 home sensor

1-28. Switching power supply

1-25. Main motor index sensor

1-21. Stacker roller moving motor

1-29. Power switch

: Primary cable

1-30. Power inlet

1-31. Power cord

: Secondary cable

2-3

12H-M12M0-0309-0

1-9

1-2

1-22

1-7

1-29

1-10

1-1

1-8

1-11

1-6

1-23

1-24

1-12

1-30

1-19

1-13

1-15

1-20

1-14

1-16

1-21

1-4

1-26

1-17

1-28

1-18

1-3

1-5

1-26

(USA model only)

2-4

12H-M12M0-0309-0

DF-915 block diagram

1-1. MC unit

1-17. Main motor

1-2. Control panel

1-22. Stacker roller home sensor

1-27. Paper feed tray set switch

Legal paper detection sensor
(USA model only)

1-26. PS P.W.B. unit

1-23. Paper feed clutch

1-24. Paper ejection clutch

1-3. Paper feed inlet sensor

1-4. Paper ejection outlet sensor

1-5. Paper switch

1-6. Top cover switch

1-11. Folding plate 1 set switch

1-19. Folding plate 1 motor

1-13. Folding plate 1 index sensor A

1-13. Folding plate 1 index sensor B

1-15. Folding plate 1 home sensor

1-12. Folding plate 2 set switch

1-20. Folding plate 2 motor

1-14. Folding plate 2 index sensor A

1-14. Folding plate 2 index sensor B

1-16. Folding plate 2 home sensor

1-28. Switching power supply

1-25. Main motor index sensor

1-21. Stacker roller moving motor

1-29. Power switch

: Primary cable

1-30. Power inlet

1-31. Power cord

: Secondary cable

2-5

12H-M12M0-0309-0

1-2

1-29

1-1

1-27

1-22

1-11

1-6

1-23

1-12

1-30

1-21

1-4

1-26

1-17

1-28

1-19

1-13

1-15

1-20

1-14

1-16

1-3

1-5

1-26

(USA model only)

1-24

2-6

12H-M12M0-0309-0

1-1. MC Unit

[Part No.: 12H-8003X (DF-920), 12H-8602X (DF-915) Part name: Main unit]

Located inside the operating side cover (below the control panel) and functions to control the whole unit. Mounted with
a 1M-byte ROM in the microprocessor which performs control of the whole unit. This board is also mounted with one
256-byte EEPROM, as well as the driving circuits for the DC motor and clutch.
Converts DC +24 V power input from the switching power supply to +5 V, +6.3 V, and +12 V.

The power supply used by this unit is DC +5 V and DC +6.3 V (panel displays) for the control system (ICs,
sensors, etc.), and DC +24 V for the load system (motors, clutches).

NoteNote

1-2. Control Panel

[Part No.: 12H-9011X (DF-920), 12H-9052X (DF-915) Part name: Control panel unit]

Composed of key switches, 16-character × 2-line LCD (DF-920 only), 7-segment display, and various display LEDs
required for operating this unit.

1-3. Paper Feed Inlet Sensor

[Part No.: 11G-8052X (Light-emitting), 11G-8051X (Light-receiving) Part name: Photosensor]

Uses a separation type photointerrupter. Located about 60 mm (2.36") inside from the paper feed ring to detect paper
fed.
If the sensor is not blocked even though the paper feed clutch has been driving for more than a certain distance
(number of pulses) after it turned ON, it is determined as paper feed error. Likewise, if the sensor continues to be
blocked even though the paper feed clutch has been driving for more than a certain distance (number of pulses) after
it was blocked, it is determined as paper jam.

As the paper folder processing speed can be changed, the sensor ON/OFF timing is based on distance (number
of pulses) and not time.

NoteNote

1-4. Paper Ejection Outlet Sensor

[Part No.: 11G-8052X (Light-emitting), 11G-8051X (Light-receiving) Part name: Photosensor]

Uses a separation type photointerrupter. Located about 50 mm (1.97") inside from the stacker roller home position to
detect paper ejection.
If the sensor is not blocked even at the timing for the paper to be ejected, or continues to be blocked even though the
paper ejection clutch has been driving for more than a certain distance (number of pulses) after it was blocked, it is
determined as paper jam.

1-5. Paper Switch

[Part No.: 054-10326 Part name: Paper switch]

Uses a photointerrupter. Incorporated inside the paper feed tray to detect the presence of paper.

1-6. Top Cover Switch

[Part No.: 054-10248 Part name: Microswitch]

Uses the normal open microswitch. Incorporated inside the non-operating side frame. The contact is established
when the cover is closed.
Connected to the relay mounted on the MC unit. As the relay contact is established to the DC +24 V supplied to each
motor, when the contact of the cover switch or folding plate set switch is opened, power supply to each motor is cut off.
Therefore if the top cover is open, the unit cannot start. The unit also stops suddenly when the cover is opened while
operating.

2-7

12H-M12M0-0309-0

1-7. Side Cover Switch (DF-920 only)

[Part No.: 054-10115 Part name: Microswitch]

Uses the normal open microswitch. Incorporated inside the operating side frame. The contact is established when the
cover is closed.
If the cover is open, the unit cannot start. The unit also stops suddenly when the cover is opened while operating.

1-8. Paper Ejection Cover Sensor (DF-920 only)

[Part No.: 98R-8023X Part name: Photosensor]

Uses a photointerrupter. Incorporated in the non-operating side frame. The optical axis is blocked when the cover is
closed.
When the cover is open, controls so that folding is not carried out. If the cover is opened during folding operations, the
unit stops feeding paper and stops operations after paper ejection.

1-9. Paper Feed Tray Upper Limit Detection Switch (DF-920 only)

[Part No.: 054-10248 Part name: Microswitch]

Uses a contact switch. Incorporated in the operating side frame to detect the upper limit position of the level bar.
Detects when the level bar rises by the rotation of the paper feed tray up/down motor and reaches the upper limit
position.

1-10. Paper Feed Tray Lower Limit Detection Switch (DF-920 only)

[Part No.: 054-10248 Part name: Microswitch]

Uses a contact switch. Incorporated in the operating side frame to detect the lower limit position of the level bar.
Detects when the level bar descends by the rotation of the paper feed tray up/down motor and reaches the lower limit
position.

1-11. Folding Plate 1 Set Switch

[Part No.: 054-10115 Part name: Microswitch]

Uses the normal open microswitch. Incorporated in the non-operating side frame. The contact is established when
folding plate 1 is set. When not set, the unit cannot start.

1-12. Folding Plate 2 Set Switch

[Part No.: 054-10115 Part name: Microswitch]

Uses the normal open microswitch. Incorporated in the non-operating side frame. The contact is established when
folding plate 2 is set. When not set, the unit cannot start.

1-13. Folding Plate 1 Index Sensor A/B

[Part No.: 98R-8023X Part name: Photosensor]

Uses two photointerrupters. Located at the side of the folding stopper moving motor inside folding plate 1 to detect the
rotation of the motor.

1-14. Folding Plate 2 Index Sensor A/B

[Part No.: 98R-8023X Part name: Photosensor]

Uses two photointerrupters. Located at the side of the folding stopper moving motor inside folding plate 2 to detect the
rotation of the motor.

2-8

12H-M12M0-0309-0

1-15. Folding Plate 1 Home Sensor

[Part No.: 062-10782 Part name: Photosensor]

Uses a photointerrupter. Located inside folding plate 1 to detect the home position of the folding stopper.

1-16. Folding Plate 2 Home Sensor

[Part No.: 062-10782 Part name: Photosensor]

Uses a photointerrupter. Located inside folding plate 2 to detect the home position of the folding stopper.

1-17. Main Motor

[Part No.: 12H-8101X Part name: DC motor]

DC +24 V power supply, output 60 W brushless DC motor. For driving the conveyance section.

1-18. Paper Feed Tray Up/Down Motor (DF-920 only)

[Part No.: 97J-8505X Part name: DC motor unit]

DC +24 V power supply geared motor. For driving the level bar which raises/lowers the paper feed tray.

1-19. Folding Plate 1 Motor

[Part No.: 12H-8111X Part name: DC motor unit]

DC +24 V power supply DC motor. Located inside folding plate 1 for driving the folding stopper.

1-20. Folding Plate 2 Motor

[Part No.: 12H-8111X Part name: DC motor unit]

DC +24 V power supply DC motor. Located inside folding plate 2 for driving the folding stopper.

1-21. Stacker Roller Moving Motor

[Part No.: 96V-8146X Part name: DC motor]

DC +24 V power supply geared motor. Located inside the paper ejection section. For driving the arm for moving the
stacker roller.

1-22. Stacker Roller Home Sensor

[Part No.: 98R-8023X Part name: Photosensor]

Uses a photointerrupter. Located inside the non-operating side frame. For detecting the home position of the stacker
roller.

1-23. Paper Feed Clutch

[Part No.: 12H-8120X Part name: Paper feed clutch unit]

Uses a DC +24 V electromagnetic clutch (250 mA, coil resistance 96Ω). Located inside the non-operating side frame.
Drives for 130 msec (about one rotation) when paper feed is started and feeds paper to the folding roller.

2-9

12H-M12M0-0309-0

1-24. Paper Ejection Clutch

[Part No.: 12H-8168X Part name: Delivery clutch unit]

Uses a DC +24 V electromagnetic clutch (250 mA, coil resistance 96Ω). Located inside the non-operating side frame.
When the folded paper blocks the paper ejection outlet sensor, operates for 130 msec (about one rotation) at the
appropriate timing with the stacker roller position to feed paper to the space between the stacker roller and stacker
belt.
When paper on the paper feed tray runs out, or when paper feed is stopped using the stop key, after the last sheet of
paper reaches the paper ejection outlet sensor, ON/OFF is repeated intermittently until the paper is ejected
completely.

1-25. Main Motor Index Sensor

Uses the index inside the main motor for detecting motor rotation. When the motor rotates, outputs pulses at a certain
cycle.

1-26. PS P.W.B. Unit

[Part No.: 96V-8016X (UK), 96V-8026X (USA) Part name: PS P.W.B. unit]

When the shield plate below the paper feed guide blocks the sensor of the PS P.W.B. unit, detects the paper size.
For USA models, the auxiliary paper feed tray is also provided with a photosensor to differentiate between legal size
and letter size.
For UK models, six paper sizes can be detected : A3, B4, A4, B5, A5, and B6.
For USA models, five paper sizes can be detected: LGR, LGL, LTR, STMT, and INV.

1-27. Paper Feed Tray Set Switch (DF-915 only)

[Part No.: 054-00396 Part name: Microswitch]

Uses a contact switch. Detects whether the paper feed tray is set or not. The contact is established when the paper
feed tray up/down lever is lowered (paper feed tray is set).

1-28. Switching Power Supply

[Part No.: 057-10033 Part name: Power supply unit]

Outputs DC +24 V (5 A, 10 A at peak) power. Mounted with a 6.3 A fuse (not replaceable).
Used also for 100 V, 120 V, 220 to 240 V, and 50/60 Hz (switching not required).

1-29. Power Switch

[Part No.: 054-10308 Part name: Power switch]

For turning ON/OFF the power supply to the unit.

1-30. Power Inlet

[Part No.: 056-10357 Part name: Inlet]

For connecting the power cord.

1-31. Power Cord

[Part No.: 055-10212 (UK), 055-10209 (USA) Part name: Power cord unit]

For supplying primary power to the unit. Use only the power cord provided with the unit.

2-10

12H-M12M0-0309-0

2. ERRORS AND CAUSES

2-1. When Paper Jams Occur

When paper jams during processing or the unit is started with paper jammed inside the sensor, a warning buzzer
sounds and a message to indicate the error appears on the control panel display (see table below).
The DF-920 LCD shows the error messages on the second line, while DF-915 shows at the 7-segment window on the
right side.
When an error message is displayed, inspect near the paper feed inlet sensor or the paper ejection outlet sensor, and
remove the jammed paper.

LCD

(DF-920)

Description

JAM FEED SECT

JAM INSIDE

JAM EXIT

The paper feed inlet sensor is blocked for more than the
specified distance (number of pulses) during processing.
Attempted to start with the paper feed inlet sensor blocked.

The paper ejection outlet sensor did not turn ON even though
the unit drove for the specified distance (number of pulses) after
the paper feed inlet sensor turned OFF during processing.

The paper ejection outlet sensor is blocked for more than the
specified distance (number of pulses) during processing.
Attempted to start with the paper ejection outlet sensor
blocked.

7-segment window

(DF-915)

LCD

(DF-920)

Description

MOTOR ERROR 1

7-segment window

(DF-915)

The pulse output of the main motor index sensor is not normal.

<Causes>

The folding mechanism cannot operate due to paper jams,
etc.
Faulty connection between the main motor and MC unit
Malfunction of the MC unit
Malfunction of the main motor

---------------------------------------------------------------------------

(Alternately displayed)

The following causes may be suspected if error messages are displayed even though no paper jam has actually
occurred.

The paper feed inlet sensor or paper ejection outlet sensor is not secured properly.
The paper feed inlet sensor or paper ejection outlet sensor is faulty.
The connection between a paper feed inlet sensor or a paper ejection outlet sensor and MC unit is faulty.
The MC unit is faulty.

NoteNote

2-2. Troubleshooting

The DF-920 LCD shows the error messages on the second line, while DF-915 shows at the 7-segment window on the
right side (see table below).

2-11

12H-M12M0-0309-0

LCD

(DF-920)

Description

MOTOR ERROR 4

MOTOR ERROR 5

MOTOR ERROR 3

MOTOR ERROR 2

7-segment window

(DF-915)

The pulse output of the folding plate 1 index sensor is not normal.

<Causes>

The folding mechanism cannot operate due to paper jam
inside folding plate 1.
Foreign objects jammed in the detecting section of the folding
plate 1 index sensor.
Faulty connection between the folding plate 1 index sensor
and MC unit
Malfunction of the folding plate 1 index sensor
Faulty connection between the folding plate 1 motor and MC
unit
Malfunction of the MC unit
Malfunction of the folding plate 1 motor
Improper adjustments of the folding plate 1 mechanism (idling
of shaft, etc.)

The pulse output of the folding plate 2 index sensor is not normal.

<Causes>

The folding mechanism cannot operate due to paper jam
inside folding plate 2.
Foreign objects jammed in the detecting section of the folding
plate 2 index sensor.
Faulty connection between the folding plate 2 index sensor
and MC unit
Malfunction of the folding plate 2 index sensor
Faulty connection between the folding plate 2 motor and MC
unit
Malfunction of the MC unit
Malfunction of the folding plate 2 motor
Improper adjustments of the folding plate 2 mechanism (idling
of shaft, etc.)

The stacker roller home sensor does not turn ON/OFF within the
specified time after the stacker roller moving motor turned ON.

<Causes>

The stacker roller mechanism cannot operate due to paper
jams, etc.
Foreign objects jammed in the detecting section of the stacker
roller home sensor.
Faulty connection between the stacker roller home sensor
and MC unit
Malfunction of the stacker roller home sensor
Faulty connection between the stacker roller moving motor
and MC unit
Malfunction of the MC unit
Malfunction of the stacker roller moving motor
Improper adjustments of the stacker roller mechanism (idling
of shaft, etc.)

The paper feed tray upper limit detection switch or paper feed
tray lower limit detection switch does not turn ON/OFF within the
specified time after the paper feed tray up/down motor turned
ON. (DF-920 only)

<Causes>

The paper feed tray up/down mechanism cannot operate due
to paper jams, etc.
Faulty connection between the upper limit detection switch or
the lower limit detection switch and MC unit
Malfunction of the upper limit detection switch or the lower
limit detection switch
Faulty connection between the paper feed tray up/down motor
and MC unit
Malfunction of the MC unit
Malfunction of the paper feed tray up/down motor
Improper adjustments of the paper feed tray up/down
mechanism (idling of shaft, etc.)

---------------------------------------------------------------------------

---------------------------------------------------------------------------

---------------------------------------------------------------------------

---------------------------------------------------------------------------

(Alternately displayed)

(Alternately displayed)

(Alternately displayed)

—

2-12

12H-M12M0-0309-0

2-3. Other Condition Messages

When covers are open or when folding plates are not set, the control panel display shows the conditions of the unit.
The DF-920 LCD shows the error messages on the second line, while DF-915 shows at the 7-segment window on the
left and right sides.
In some cases, if the message and actual condition differ such as when “TOP COVER OPEN” is displayed despite the
cover being closed, other errors may be suspected. The following table shows details.

LCD

(DF-920)

Description

TOP COVER OPEN

SIDE COVER OPEN

DELIVERY COVER

F.PLAT-1 SET ERR

F.PLAT-2 SET ERR

7-segment window

(DF-915)

The contact of the top cover switch is open.

<Causes>

The top cover is not closed completely.
The top cover switch is not secured properly.
The top cover switch is broken or has malfunctioned.
Faulty connection between the top cover switch and MC unit
(Disconnection of bundled wires, improper insertion of
connectors)
Malfunction of the MC unit

The contact of the side cover switch is open. (DF-920 only)

<Causes>

The side cover is not closed completely.
The side cover switch is not secured properly.
Malfunction of the side cover switch
Faulty connection between the side cover switch and MC unit
(Disconnection of bundled wires, improper insertion of
connectors)
Malfunction of the MC unit

The paper ejection cover sensor is OFF. (DF-920 only)
∗ This message is normally displayed when the start key or test

key is pressed with the paper ejection cover open. It is not
displayed at the instant the paper ejection cover is open.

<Causes>

The paper ejection cover is not closed completely.
The paper ejection cover sensor is not secured properly.
Malfunction of the paper ejection cover sensor
Faulty connection between the paper ejection cover sensor
and MC unit
(Disconnection of bundled wires, improper insertion of
connectors)
Malfunction of the MC unit

The contact of the folding plate 1 set switch is open.

<Causes>

The folding plate 1 is not set properly.
The folding plate 1 set switch is not secured properly.
Malfunction of the folding plate 1 set switch
Faulty connection between the folding plate 1 set switch and
MC unit
(Disconnection of bundled wires, improper insertion of
connectors)
Malfunction of the MC unit

The contact of the folding plate 2 set switch is open.

<Causes>

The folding plate 2 is not set properly.
The folding plate 2 set switch is not secured properly.
Malfunction of the folding plate 2 set switch
Faulty connection between the folding plate 2 set switch and
MC unit
(Disconnection of bundled wires, improper insertion of
connectors)
Malfunction of the MC unit

---------------------------------------------------------------------------

---------------------------------------------------------------------------

---------------------------------------------------------------------------

---------------------------------------------------------------------------

—

—

---------------------------------------------------------------------------

2-13

12H-M12M0-0309-0

LCD

(DF-920)

Description

FEED ERROR

NO PAPER

—

PAPER SIZE ERROR

7-segment window

(DF-915)

The paper feed inlet sensor does not turn ON even though the
paper feed clutch has driven for the specified distance (number
of pulses) after it turned ON.

<Causes>

The paper stacking method on the paper feed tray is not
correct.
Paper has slipped, etc. due to insufficient paper feed
pressure, and paper is not fed correctly.
The paper separating pressure is too high.
Malfunction of the paper feed inlet sensor
Malfunction of the paper feed clutch
Faulty connection between the paper feed inlet sensor and
MC unit
(Disconnection of bundled wires, improper insertion of
connectors)
Malfunction of the MC unit

The paper switch of the paper feed tray turned OFF during
processing or attempts were made to start the unit with the
paper switch OFF.

<Causes>

Paper has run out on the paper feed tray.
Malfunction of the paper switch
Faulty connection between the paper switch and MC unit
(Disconnection of bundled wires, improper insertion of
connectors)
Malfunction of the MC unit

The paper feed tray set switch is OFF. (DF-915 only)

<Causes>

The paper feed tray is not set.
The paper feed tray set switch is not secured properly.
Malfunction of the paper feed tray set switch
Faulty connection between the paper feed tray set switch and
MC unit
(Disconnection of bundled wires, improper insertion of
connectors)
Improper adjustments of the paper feed tray mechanism
Malfunction of the MC unit

Paper less than half of the paper size set was fed.

<Causes>

Paper of different lengths are stacked together.
The stacking direction of the paper on the paper feed tray is
different.
The paper length has been registered incorrectly.
Malfunction of the paper size detection sensor
Faulty connection between the paper size detection sensor
and MC unit
(Disconnection of bundled wires, improper insertion of
connectors)
Improper adjustments of the paper feed tray mechanism
Malfunction of the MC unit

---------------------------------------------------------------------------

---------------------------------------------------------------------------

---------------------------------------------------------------------------

---------------------------------------------------------------------------

2-14

12H-M12M0-0309-0

2-4. Emergency Measures When the Paper Switch Damages

When the paper switch damages, folding operations can be performed ignoring the paper switch as an emergency
measure until the switch is replaced.
This function is available from the following ROM versions.

DF-920: 12H-80072 and later
DF-915: 12H-86041 and later

Method

Turn ON the power while pressing the stop and No. of sheets/Paper length keys simultaneously.
This enables folding operations to be carried out because the unit takes that paper is stacked even though the paper
switch is not working.

When the paper switch malfunctions, as the “no paper state” cannot be detected even though paper has run
out on the paper feed tray during folding operations, the unit proceeds feeding the next sheet of paper, after
which the whole unit stops due to paper feed error. For this reason, the folded paper is not ejected out
completed but stops near the stacker roller.
To continue paper folding in this state, replenish paper and resume operations. To end paper folding
operations, remove the folded paper near the stacker roller by hand. The folded paper can also be ejected by
pressing the test key while pressing the stop key.
As settings of this function cannot be registered in the memory, it is cleared when the power of the unit is
turned OFF.

NoteNote

DF-920 DF-915

2-15

12H-M12M0-0309-0

3. MAINTENANCE MODE

3-1. Entering the Maintenance Mode

DF-920

q To enter the maintenance mode, turn ON the power while pressing both the start and stop keys. Or enter “920”

using the numerical keys of the initial screen displayed on the control panel (even if an error message is displayed
on the second line), and press the folding mode key while pressing the stop key.
Upon entering the maintenance mode, “MAINTENANCE MENU” is displayed on the first line of the LCD.

w Enter the one-digit or two-digit maintenance code using the numerical keys (refer to “3-3. List of Maintenance

Modes”), and press the folding mode key to enter the desired maintenance mode. If the maintenance code is not

known, press custom folding registration key 1 or 2 to select the maintenance mode. (Pressing the key
continuously switches the mode continuously.)

DF-915

q To enter the maintenance mode, turn ON the power while pressing both the start and stop keys. Or press the

adjustment registration key while pressing both the stop key and No. of sheets/Paper length key while the unit is in
the standby state (press the adjustment registration key last).
Upon entering the maintenance mode, “– –” is displayed at the 7-segment window on the left side.

w Press the “+” or “–” key of the Paper length/Stacker roller position key and select the desired maintenance mode.

One-digit or two-digit code No. is displayed at the 7-segment window on the left side. (Pressing the key
continuously switches the mode continuously.)

3-2. Setting the Maintenance Mode

Select the desired maintenance mode, and change the settings using the “+” or “–” speed key.
To set another mode, select the maintenance mode to be set.

2-16

12H-M12M0-0309-0

3-3. List of Maintenance Modes

DF-920

The following table lists the maintenance modes of DF-920.

Code

Setting

1
2
3
4
5
6
7
8

9
10
11
12
13
14
15
16
17
18
21
22
23
24
25
26
27
28
31
32
33
34
36

1st line of LCD

2nd line of LCD

(Setting at shipment)

Folding plate 1 home position adjustment
Folding plate 2 home position adjustment
Switching shaft home position adjustment
Destination setting
mm/inch display setting
Language setting
No. of test folding sheets setting
Backlight automatic OFF setting
Buzzer ON/OFF setting
Power still ON alert setting
Speed 1 adjustment
Processing speed adjustment
Operation mode setting
Total counter
MC ROM version display
OP ROM version display
Paper ejection cover detection ON/OFF setting
Program version up mode
Main motor test
Folding plate motor test
Stacker roller moving motor test
Paper feed tray up/down motor test
Paper feed clutch test
Paper ejection clutch test
Simulation mode
Folding stopper parallelity mode
Sensor/switch check
Paper size detection sensor check
Main motor index sensor check
Folding plate index sensor check
Panel check mode

Note 1
Note 2
Note 3

UK (USA)
MILLIMETER (INCH)
ENGLISH
2 SHEETS
30 SEC
ON
OFF
NORMAL
NORMAL
OFF
0000000
12H-8∗∗∗∗
12∗8∗∗∗∗
ON

RUN W/O PAPER

ABCDEFGHIJKLM
– – – – –
0000
1:0000 / 2:0000

1.STOP1 DEFAULT

2.STOP2 DEFAULT

3.SW BAR ADJUST

4.AREAS

5.SET MM/INCH

6.LANGUAGES

7.TEST FOLD QTY

8.BACK LIGHT OFF

9.BUZZ ON/OFF

10.POWER ON BUZZ

11.SPEED1 ADJUST

12.SPEED ADJUST

13.SET FUNCTION

14.TOTAL COUNTER

15.MC ROM VER

16.PANEL ROM VER

17.DEL CVR SNSR

18.PROG VER UP

21.MAIN MTR TEST

22.F.PLATE MOTOR

23.STACK ROL MTR

24.FEED TRAY MTR

25.FEED CLUTCH

26.DLVRY CLUTCH

27.SIMULATION

28.ALIGNMENT

31.CHK SENSOR SW

32.CHK SIZE SNSR

33.MAIN MTR INDX

34.F.PLATE INDEX

36.PANEL CHECK

Code No.19, 20, 29, 30, and 35 are currently not used.
The Note 1 to 3 settings differ by machine because they are finely adjusted at shipment.

NoteNote

2-17

12H-M12M0-0309-0

(1) Folding plate 1 home position adjustment (Code No.1)

Mode for adjusting the home position of folding plate 1.

“2-6-14. (1) Adjusting folded size by folding plate 1” in CHAPTER 1 MECHANISM

SeeSee

This setting differs by machine because it is finely adjusted at shipment.
The setting at shipment is indicated on the backup data form inside the operating side cover.
To change the setting, first note down the current value. After changing the setting, fill in the new value in
the backup data form.

NoteNote

(2) Folding plate 2 home position adjustment (Code No.2)

Mode for adjusting the home position of folding plate 2.

“2-6-14. (2) Adjusting folded size by folding plate 2” in CHAPTER 1 MECHANISM

SeeSee

This setting differs by machine because it is finely adjusted at shipment.
The setting at shipment is indicated on the backup data form inside the operating side cover.
To change the setting, first note down the current value. After changing the setting, fill in the new value in
the backup data form.

NoteNote

(3) Switching shaft home position adjustment (Code No.3)

Mode for adjusting the home position of the switching shaft.

“2-6-11. Adjusting the home position of the switching shaft (stopping position) in single folding” in
CHAPTER 1 MECHANISM

SeeSee

This setting differs by machine because it is finely adjusted at shipment.
The setting at shipment is indicated on the backup data form inside the operating side cover.
To change the setting, first note down the current value. After changing the setting, fill in the new value in
the backup data form.

NoteNote

(4) Destination setting (Code No.4)

Mode for setting the destination. Can be set to “JAPAN”, “USA”, or “UK”.
At shipment, this is set according to the destination of the unit.
When the EEPROM is initialized, it is set to “JAPAN”.

Changing the destination setting does not change the (5) mm/inch display setting and (6) language setting.
These settings must be changed separately.

NoteNote

(5) mm/inch display setting (Code No.5)

Mode for setting the unit of the size displayed on the LCD or 7-segment window. Can be set to “MILLIMETER” or
“INCH”.

At shipment, this is set to mm for Japanese and UK models and to inch for USA model.
When the EEPROM is initialized, it is set to “MILLIMETER”.

(6) Language setting (Code No.6)

Mode for setting the language of the messages displayed on the LCD. Can be set to “JAPANESE” or “ENGLISH”.
At shipment, this is set to “JAPANESE” for Japanese model and to “ENGLISH” for USA and UK models.
When the EEPROM is initialized, it is set to “ENGLISH”.

(7) No. of test folding sheets setting (Code No.7)

Mode for setting the number of sheets to be test folded. Can be set within 1 to 3 sheets.
At shipment, this is set to “2 SHEETS”.

(8) Backlight automatic OFF setting (Code No.8)

Mode for setting the time for the LCD backlight to go OFF automatically when not using the unit. Can be set to “15
SEC”, “30 SEC”, “60 SEC”, or “KEEP LIGHT ON” (always ON).
At shipment, this is set to “30 SEC”.

2-18

12H-M12M0-0309-0

(9) Buzzer ON/OFF setting (Code No.9)

Mode for setting ON/OFF the buzzer which sounds during key operations, when a process ends, or when errors
occur. Can be set to “ON” or “OFF”.
At shipment, this is set to “ON”.

A warning buzzer sounds when motor problems occur even if this setting is set to “OFF”. (It will not sound
when errors such as paper jams, etc. occur.)

NoteNote

(10) Power still ON alert setting (Code No.10)

Mode for setting the time to sounding a buzzer to alert that the power is still ON when the unit is not used. Can be
set to “OFF” (buzzer not sounded), “5 MIN”, “15 MIN”, or “30 MIN”.
At shipment, this is set to “OFF”.

(11) Speed 1 adjustment (Code No.11)

Mode for setting the folding roller speed when processing speed is set to 1. Can be set to “NORMAL” or “SLOW”.
At shipment, this is set to “NORMAL”.
When folding thin and flimsy paper, folding problems may occur if the processing speed is set to 1. In such cases,
set to “SLOW”.

The speed of processing speed 1 when set to “NORMAL” is about 460 mm/s. Setting to “SLOW” lowers
the speed to about 290 mm/s.
When set to “SLOW”, the processing speed 1 LED blinks.
When set to “SLOW” and firm paper is used, the main motor may lock due to load.

NoteNote

(12)Processing speed adjustment (Code No.12)

Mode for finely adjusting the speed when the processing speed does not satisfy the specifications
(200 sheets/minute in single folding of B4 paper, 255 sheets/minute in single folding of letter size paper
for USA). Can be set to “NORMAL”, “FAST”, or “SLOW”.
At shipment, this is set to “NORMAL”.
When the EEPROM is initialized, it is set to “NORMAL”.

(13) Operation mode setting (Code No.13)

Mode for setting the operation mode of the unit. Can be set to “OFF”, “LAST TIME FOLD”, or “STOPPER FIXED”.
At shipment, this is set to “OFF”.

+5%
–1%

+5%
–1%

When set to “STOPPER FIXED”, after exiting the maintenance mode, be sure to press the clear key while
pressing the stop key to perform initialization. Initialization is not carried out even if the power is turned
OFF and then ON again. Using the unit without performing initialization may result in incorrect
operations.
The operation mode can be set without entering the maintenance mode. (Refer to the instruction manual.)

NoteNote

(14) Total counter (Code No.14)

Displays the total number of sheets fed into the machine.

(15) MC ROM version display (Code No.15)

Displays the program version of the microprocessor of the MC unit.

(16) OP ROM version display (Code No.16)

Displays the version of the OP unit.

(17) Paper ejection cover detection ON/OFF setting (Code No.17)

Mode for turning the paper ejection cover detection ON/OFF. Can be set to “ON” or “OFF”.
At shipment, this is set to “ON”.

(18) Program version up mode (Code No.18)

Mode for upgrading the program version.

“7. UPGRADING THE PROGRAM VERSION”

SeeSee

2-19

12H-M12M0-0309-0

(19) Main motor test (Code No.21)

Mode for checking the operations of the main motor.
The main motor rotates when the start key is pressed, and stops when the stop key is pressed.
The rotating speed can also be changed using the speed key.

The motor will not rotate if any one interlock switch is not closed.

NoteNote

(20) Folding plate motor test (Code No.22)

Mode for checking operations of the motor for moving the folding stoppers of folding plate 1 and 2.
Pressing the “+” key of the folding plate 1 folding stopper adjusting key rotates the folding plate 1 motor, and
moves the folding stopper in the reverse home position direction. Pressing the “–” key rotates the folding plate 1
motor, and moves the folding stopper in the home position direction.
Pressing the “+” key of the folding plate 2 folding stopper adjusting key rotates the folding plate 2 motor, and
moves the folding stopper in the reverse home position direction. Pressing the “–” key rotates the folding plate 2
motor, and moves the folding stopper in the home position direction.
The motor rotates while the key is pressed, and stops when the key is released.

As the motor rotates regardless of the limit detection by the home sensor and index sensor, make sure
that the folding stopper does not clash into the limit section of the folding plate.
The motor will not rotate if any one interlock switch is not closed.

NoteNote

(21) Stacker roller moving motor test (Code No.23)

Mode for checking operations of the stacker roller moving motor.
Pressing the “+” key of the folding plate 2 folding stopper adjusting key rotates the stacker roller moving motor,
and moves the stacker roller outside. Pressing the “–” key rotates the stacker roller moving motor, and moves the
stacker roller inside.
The motor rotates while the key is pressed, and stops when the key is released.

Pressing the “+” key continuously moves the stacker roller outside the unit and locks the motor.
The motor will not rotate if any one interlock switch is not closed.

NoteNote

(22) Paper feed tray up/down motor test (Code No.24)

Mode for checking operations of the paper feed tray up/down motor.
Pressing the “+” key of the folding plate 1 folding stopper adjusting key rotates the paper feed tray up/down motor,
and raises the paper feed tray. Pressing the “–” key rotates the paper feed tray up/down motor, and lowers the
paper feed tray.
The motor rotates while the key is pressed, and stops when the key is released.

The motor will not rotate if any one interlock switch is not closed.

NoteNote

(23) Paper feed clutch test (Code No.25)

Mode for checking the operations of the paper feed clutch.
The paper feed clutch operates when the start key is pressed, and stops when the stop key is pressed.

Do not leave the unit with the clutch operating. Otherwise, the clutch will overheat, resulting in malfunction.

NoteNote

(24) Paper ejection clutch test (Code No.26)

Mode for checking the operations of the paper ejection clutch.
The paper ejection clutch operates when the start key is pressed, and stops when the stop key is pressed.

Do not leave the unit with the clutch operating. Otherwise, the clutch will overheat, resulting in malfunction.

NoteNote

2-20

12H-M12M0-0309-0

(26) Folding stopper parallelity mode (Code No.28)

Mode for making the folding stoppers of folding plates 1 and 2 parallel.

“2-6-10. Adjusting the parallelity of the folding stoppers” in CHAPTER 1 MECHANISM

(27) Sensor/switch check (Code No.31)

Mode for checking the states of sensors and switches.
Sensors and switches which are ON are displayed in alphabet at the second line of the LCD. Those which are
OFF are displayed as “–”.
The displays correspond to sensors and switches from the left side in the following order.

[A] Paper feed inlet sensor → [B] Paper ejection outlet sensor → [C] Paper switch →
[D] Stacker roller home sensor → [E] Folding plate 1 home sensor →
[F] Folding plate 2 home sensor → [G] Paper feed tray upper limit detection switch →
[H] Paper feed tray lower limit detection switch → [I] Paper ejection cover sensor →
[J] Top cover switch → [K] Side cover switch → [L] Folding plate 1 set switch →
[M] Folding plate 2 set switch

Turning sensors and switches ON/OFF changes the corresponding display (alphabet or “–”), and a buzzer
sounds.

(28) Paper size detection sensor check (Code No.32)

Mode for checking the state of the paper size detection sensor.
Sensors which are ON are displayed as “ ” at the second line of the LCD, and those which are OFF are
displayed as “–”. UK model displays correspond to the B6, A5, B5, A4, B4, and A3 paper size detection sensors
from the left side in order.
For USA models, “ ” is displayed at the leftmost side, and the second display onwards corresponds to the INV,
STMT, LTR, LGR, and LGL paper size detection sensors in order.
The displays change when the paper feed guides are moved, and a buzzer sounds.

SeeSee

The LGL detection sensor is the opposite to other sensors, in that “–” is displayed when it is ON, and “ ”
when OFF.

NoteNote

(29) Main motor index sensor check (Code No.33)

Mode for checking the index sensor inside the main motor.
When the main motor shaft is rotated by rotating the jam correction knob or center press roller, pulse input is
performed, and the number of pulses is counted up and displayed at the second line of the LCD.
When the main motor shaft is rotated once, and the number of pulses should be added with 15.

The number of pulses displayed is reset to 0 when the power is turned OFF.
The number of pulses is counted up even if the main motor shaft is rotated in the normal or reverse
directions.

NoteNote

(30) Folding plate index sensor check (Code No.34)

Mode for checking the index sensor of folding plates 1 and 2.
Check the changes in the states of each sensor by looking at the changes in the number of pulses displayed at
the second line of the LCD.
Pressing the “+” key of the folding plate 1 folding stopper adjusting key counts up the number of pulses displayed
at the left side of the second line of the LCD, and pressing the “–” key counts down the display.
Pressing the “+” key of the folding plate 2 folding stopper adjusting key counts up the number of pulses displayed
at the right side of the second line of the LCD, and pressing the “–” key counts down the display.

If the direction which changes the number of pulses is opposite to the above, check if the connectors of
index sensors A and B of the corresponding folding plate are connected reverse.

NoteNote

(25) Simulation mode (Code No.27)

Mode for operating each mechanism without using paper.
The simulation mode operates when the start key is pressed, and stops when the stop key is pressed.

If operating the unit in the simulation mode, be sure to remove the paper feed ring.

NoteNote

2-21

12H-M12M0-0309-0

(31) Panel check mode (Code No.36)

Mode for checking the LEDs and 7-segment of the control panel.
Pressing the start key lights up the whole 7-segment, and pressing the stop key lights up all LEDs. (Some LEDs
may blink depending on the other settings of the maintenance mode.)

2-22

12H-M12M0-0309-0

Code No.8, 10, 13, 17, 19, 20, 24, 29, and 30 are currently not used.
The Note 1 to 3 settings differ by machine because they are finely adjusted at shipment.

NoteNote

Code

Setting

1

2

3

4

5

6

7

9
11
12
14
15
16
18
21
22
23
25
26
27
28
31
32
33
34
35
36
37

7-segment window

(Left side, 2 digits)

7-segment window

(Right side, 4 digits)

(Setting at shipment)

Folding plate 1 home position adjustment
Folding plate 2 home position adjustment
Switching shaft home position adjustment
Model setting
Destination setting
mm/inch display setting
No. of test folding sheets setting
Buzzer ON/OFF setting
Speed 1 adjustment
Processing speed adjustment
Total counter
MC ROM version display
OP ROM version display
Program version up mode
Main motor test
Folding plate motor test
Stacker roller moving motor test
Paper feed clutch test
Paper ejection clutch test
Simulation mode
Folding stopper parallelity mode
Sensor check (1)
Sensor check (2)
Switch check
Paper size detection sensor check (1)
Paper size detection sensor check (2)
Panel check mode
Motor index sensor check

Note 1
Note 2
Note 3

()

()

∗∗∗ ⇔ ∗∗∗∗

⇔ ∗∗∗∗

∗ ⇔ ∗∗∗∗

∗∗∗∗
∗∗∗
∗∗∗
∗∗∗∗
∗∗

∗∗∗∗

DF-915

The following table lists the maintenance modes of DF-915.

2-23

12H-M12M0-0309-0

(1) Folding plate 1 home position adjustment (Code No.1)

Mode for adjusting the home position of folding plate 1.

“2-6-14. (1) Adjusting folded size by folding plate 1” in CHAPTER 1 MECHANISM

SeeSee

This setting differs by machine because it is finely adjusted at shipment.
The setting at shipment is indicated on the backup data form inside the operating side cover.
To change the setting, first note down the current value. After changing the setting, fill in the new value in
the backup data form.

NoteNote

(2) Folding plate 2 home position adjustment (Code No.2)

Mode for adjusting the home position of folding plate 2.

“2-6-14. (2) Adjusting folded size by folding plate 2” in CHAPTER 1 MECHANISM

SeeSee

This setting differs by machine because it is finely adjusted at shipment.
The setting at shipment is indicated on the backup data form inside the operating side cover.
To change the setting, first note down the current value. After changing the setting, fill in the new value in
the backup data form.

NoteNote

(3) Switching shaft home position adjustment (Code No.3)

Mode for adjusting the home position of the switching shaft.

“2-6-11. Adjusting the home position of the switching shaft (stopping position) in single folding” in
CHAPTER 1 MECHANISM

SeeSee

This setting differs by machine because it is finely adjusted at shipment.
The setting at shipment is indicated on the backup data form inside the operating side cover.
To change the setting, first note down the current value. After changing the setting, fill in the new value in
the backup data form.

NoteNote

(5) Destination setting (Code No.5)

Mode for setting the destination. Can be set to “JPN” (JAPAN), “USA”, or “Euro” (UK).
At shipment, this is set according to the destination of the unit.
When the EEPROM is initialized, it is set to “JPN”.

Changing the destination setting does not change the (4) Model setting and (6) mm/inch display setting.
These settings must be changed separately.

NoteNote

(6) mm/inch display setting (Code No.6)

Mode for setting the unit of the size displayed on the 7-segment window. Can be set to “NN” (mm) or “INCH”.
At shipment, this is set to mm for Japanese and UK models and to inch for USA model.
When the EEPROM is initialized, it is set to “NN”.

(7) No. of test folding sheets setting (Code No.7)

Mode for setting the number of sheets to be test folded. Can be set within 1 to 3 sheets.
At shipment, this is set to “2”.

(4) Model setting (Code No.4)

Mode for setting the model.
Can be set to “915” (DF-915) or “910” (DF-910).
At shipment, Japanese model is set to “910” and UK, USA models are set to “915”.
When the EEPROM is initialized, it is set to “915”.

Changing the model setting does not change the (5) Destination setting and (6) mm/inch display setting.
These settings must be changed separately.

NoteNote

2-24

12H-M12M0-0309-0

(8) Buzzer ON/OFF setting (Code No.9)

Mode for setting ON/OFF the buzzer which sounds during key operations, when a process ends, or when errors
occur. Can be set to “ON” or “OFF”.
At shipment, this is set to “ON”.

A warning buzzer sounds when motor problems occur even if this setting is set to “OFF”. (It will not sound
when errors such as paper jams, etc. occur.)

NoteNote

(9) Speed 1 adjustment (Code No.11)

Mode for setting the folding roller speed when processing speed is set to 1. Can be set to “0” (NORMAL) or “–1”
(SLOW).
At shipment, this is set to “0”.
When folding thin and flimsy paper, folding problems may occur if the processing speed is set to 1. In such cases,
set to “–1”.

The speed of processing speed 1 when set to “0” is about 460 mm/s. Setting to “–1” lowers the speed to
about 290 mm/s.
When set to “–1”, the processing speed 1 LED blinks.
When set to “–1” and firm paper is used, the main motor may lock due to load.

NoteNote

(10)Processing speed adjustment (Code No.12)

Mode for finely adjusting the speed when the processing speed does not satisfy the specifications
(200 sheets/minute in single folding of B4 paper, 255 sheets/minute in single folding of letter size paper
for USA). Can be set to “0” (NORMAL), “1” (FAST), or “–1” (SLOW).
At shipment, this is set to “0”.
When the EEPROM is initialized, it is set to “0”.

(11) Total counter (Code No.14)

Displays the total number of sheets fed into the machine. (7 digits)
At the 7-segment window on the right side, the first three digits “C.∗∗∗” and last four digits “∗∗∗∗” are displayed
alternately for one second each.

Example) “C.123” and “4567” are displayed alternately for one second each.

→ This means that the total number of sheets fed into the machine is 1234567.

(12) MC ROM version display (Code No.15)

Displays the program version of the microprocessor of the MC unit.
The program version is “12H-8∗∗∗∗”, but at the 7-segment window on the right side, the first four digits “12H8”
and last four digits “∗∗∗∗” are displayed alternately for one second each.

(13) OP ROM version display (Code No.16)

Displays the version of the OP unit.
At the 7-segment window on the right side, the first four digits “12∗8” and last four digits “∗∗∗∗” are displayed
alternately for one second each.

(14) Program version up mode (Code No.18)

Mode for upgrading the program version.

“7. UPGRADING THE PROGRAM VERSION”

(15) Main motor test (Code No.21)

Mode for checking the operations of the main motor.
The main motor rotates when the start key is pressed, and stops when the stop key is pressed.
The rotating speed can also be changed using the speed key.

+5%
–1%

+5%
–1%

SeeSee

The motor will not rotate if any one interlock switch is not closed.

NoteNote

2-25

12H-M12M0-0309-0

(16) Folding plate motor test (Code No.22)

Mode for checking operations of the motor for moving the folding stoppers of folding plate 1 and 2.
Pressing the “+” key of the folding plate 1 folding stopper adjusting key rotates the folding plate 1 motor, and
moves the folding stopper in the reverse home position direction. Pressing the “–” key rotates the folding plate 1
motor, and moves the folding stopper in the home position direction.
Pressing the “+” key of the folding plate 2 folding stopper adjusting key rotates the folding plate 2 motor, and
moves the folding stopper in the reverse home position direction. Pressing the “–” key rotates the folding plate 2
motor, and moves the folding stopper in the home position direction.
The motor rotates while the key is pressed, and stops when the key is released.

As the motor rotates regardless of the limit detection by the home sensor and index sensor, make sure
that the folding stopper does not clash into the limit section of the folding plate.
The motor will not rotate if any one interlock switch is not closed.

NoteNote

(17) Stacker roller moving motor test (Code No.23)

Mode for checking operations of the stacker roller moving motor.
Pressing the “+” key of the folding plate 2 folding stopper adjusting key rotates the stacker roller moving motor,
and moves the stacker roller outside. Pressing the “–” key rotates the stacker roller moving motor, and moves the
stacker roller inside.
The motor rotates while the key is pressed, and stops when the key is released.

Pressing the “+” key continuously moves the stacker roller outside the unit and locks the motor.
The motor will not rotate if any one interlock switch is not closed.

NoteNote

(18) Paper feed clutch test (Code No.25)

Mode for checking the operations of the paper feed clutch.
The paper feed clutch operates when the start key is pressed, and stops when the stop key is pressed.

Do not leave the unit with the clutch operating. Otherwise, the clutch will overheat, resulting in malfunction.

NoteNote

(19) Paper ejection clutch test (Code No.26)

Mode for checking the operations of the paper ejection clutch.
The paper ejection clutch operates when the start key is pressed, and stops when the stop key is pressed.

Do not leave the unit with the clutch operating. Otherwise, the clutch will overheat, resulting in malfunction.

NoteNote

(20) Simulation mode (Code No.27)

Mode for operating each mechanism without using paper.
The simulation mode operates when the start key is pressed, and stops when the stop key is pressed.

If operating the unit in the simulation mode, be sure to remove the paper feed ring.

NoteNote

(21) Folding stopper parallelity mode (Code No.28)

Mode for making the folding stoppers of folding plates 1 and 2 parallel.

“2-6-10. Adjusting the parallelity of the folding stoppers” in CHAPTER 1 MECHANISM

(22) Sensor check (1) (Code No.31)

Mode for checking the states of each sensor.
At the 7-segment window on the right side, sensors which are ON are displayed as “1” and those which are OFF
are displayed as “0”.
The display corresponds to each sensor in the following order.

Paper feed inlet sensor → Paper ejection outlet sensor → Paper switch → Paper feed tray set switch

Turning ON/OFF the sensors changes the corresponding display (“1” or “0”) and a buzzer sounds.

SeeSee

2-26

12H-M12M0-0309-0

(23) Sensor check (2) (Code No.32)

Mode for checking the states of each sensor.
At the 7-segment window on the right side, sensors which are ON are displayed as “1” and those which are OFF
are displayed as “0”.
The display corresponds to each sensor in the following order.

Stacker roller home sensor → Folding plate 1 home sensor → Folding plate 2 home sensor

Turning ON/OFF the sensors changes the corresponding display (“1” or “0”) and a buzzer sounds.

(24) Switch check (Code No.33)

Mode for checking the states of each switch.
At the 7-segment window on the right side, switches which are ON are displayed as “1” and those which are OFF
are displayed as “0”.
The display corresponds to each switch in the following order.

Top cover switch → Folding plate 1 set switch → Folding plate 2 set switch

Turning ON/OFF the switches changes the corresponding display (“1” or “0”) and a buzzer sounds.

(25) Paper size detection sensor check (1) (Code No.34)

Mode for checking the state of the paper size detection sensor.
At the 7-segment window on the right side, sensors which are ON are displayed as “1” and those which are OFF
are displayed as “0”. UK model displays correspond to the B6, A5, B5, and A4 paper size detection sensors from
the left side in order.
For USA models, “1” is displayed at the leftmost side, and the second display onwards corresponds to the INV,
STMT, and LTR paper size detection sensors in order.
The displays change when the paper feed guides are moved, and a buzzer sounds.

(26) Paper size detection sensor check (2) (Code No.35)

Mode for checking the state of the paper size detection sensor.
At the 7-segment window on the right side, sensors which are ON are displayed as “1” and those which are OFF
are displayed as “0”. UK model displays correspond to the B4 and A3 paper size detection sensors from the left
side in order.
USA model displays correspond to the LGR and LGL paper size detection sensors from the left side in order.
The displays change when the paper feed guides are moved, and a buzzer sounds.

The LGL detection sensor is the opposite to other sensors, in that “0” is displayed when it is ON, and “1”
when OFF.

NoteNote

(27) Panel check mode (Code No.36)

Mode for checking the LEDs and 7-segment window of the control panel.
Pressing the start key lights up the whole 4-digit 7-segment window on the right side, and pressing the stop key
lights up the 2-digit 7-segment window on the left side and all LEDs. (Some LEDs may blink depending on the
other settings of the maintenance mode.)

2-27

12H-M12M0-0309-0

(28) Motor index sensor check (Code No.37)

Mode for checking the index sensors in the main motor and index sensors of folding plates 1 and 2.

Checking the main motor index sensor

When the main motor shaft is rotated by rotating the jam correction knob or center press roller, pulse input is
performed, and the number of pulses is counted up and displayed at the 7-segment window on the right side.
When the main motor shaft is rotated once, and the number of pulses should be added with 15.

The number of pulses displayed is reset to 0 when the power is turned OFF.
The number of pulses is counted up even if the main motor shaft is rotated in the normal or reverse
directions.

NoteNote

Checking the folding plate 1, 2 index sensor

Check the changes in the states of each sensor by looking at the changes in the number of pulses displayed at
the 7-segment window on the right side.
Pressing the “+” key of the folding plate 1 folding stopper adjusting key counts up the number of pulses displayed,
and pressing the “–” key counts down the display.
Pressing the “+” key of the folding plate 2 folding stopper adjusting key counts up the number of pulses displayed,
and pressing the “–” key counts down the display.

If the direction which changes the number of pulses is opposite to the above, check if the connectors of
index sensors A and B of the corresponding folding plate are connected reverse.

NoteNote

3-4. Precautions for Setting Folding Stopper Fixed Mode (DF-920 only)

When the operation mode is set to the folding stopper fixed mode, if moving the position of the folding stopper for
folding plate motor tests or folding plate index sensor check, be sure to turn OFF the power once, and then turn it ON
again to perform initialization before starting folding operations, and re-check the positions of the folding stoppers.
Starting without performing initialization will result in folding operations at the incorrect stopper position.
Perform initialization by pressing the clear key while pressing the stop key after turning ON the power.

Initialization will be performed automatically when the clear key is pressed twice from the maintenance mode to
return to the normal mode.

NoteNote

2-28

12H-M12M0-0309-0

4. BACKUP DATA FORM

A backup data form is pasted on the inside of the main cover F (control panel side) for noting down various setting
data such as home position adjustment data of folding plates and switching shaft.
If the corresponding setting data has been changed in the maintenance mode, be sure to fill in the changed data in this
backup data form.

Code

Function

STOP1 DEFAULT

SER.No.

120V, 60Hz

220–240V, 50Hz

DF-920

STOP2 DEFAULT

SW BAR ADJUST

AREAS

SET MM/INCH

LANGUAGES

TEST FOLD QTY

BACK LIGHT OFF

BUZZ ON/OFF

POWER ON BUZZ

SPEED1 ADJUST

SPEED ADJUST

SET FUNCTION

TOTAL COUNTER

MC ROM VER

DEL CVR SNSR

∗

Code numbers are derived from the code numbers in the maintenance mode table.

When changing data, follow the maintenance manual.

NOTE: Changing data at code numbers 1 – 3 may cause a degradation in fold accuracy.

Default

Correction Range

DA TE

INIT 1 2 3 4 5

1 0 –20 – +20

0 –20 – +20

–4 –20 – +5

JAPAN

JAPAN, USA, UK

ON ONON ⇔ OFF

ON ON

ON ⇔ OFF

OFF OFF

5, 15, 30 MIN,

OFF

OFF OFF

0000000 0000000

LAST TIME FOLD
STOPPER FIXED

OFF

MM MM, INCH

NORMAL NORMAL

SLOW, NORMAL

12H-8007X

NORMAL NORMAL

SLOW, NORMAL,
FAST

221–3 SHEETS

30 SEC 30 SEC

15, 30, 60 SEC,
KEEP LIGHT ON

ENGLISH ENGLISH

JAPANESE

ENGLISH

2

3

4

5

6

7

8

9

10

11

12

13

14

15

17

Part Number : 12H-9132X

2-29

12H-M12M0-0309-0

Code

Function

STOP1 DEFAULT

SER.No.

120V, 60Hz

220–240V, 50Hz

DF-915

STOP2 DEFAULT

SW BAR ADJUST

AREAS

SET MM/INCH

TEST FOLD QTY

BUZZ ON/OFF

SPEED1 ADJUST

SPEED ADJUST

TOTAL COUNTER

MC ROM VER

∗Code numbers are derived from the code numbers in the maintenance mode table.

When changing data, follow the maintenance manual.
NOTE: Changing data at code numbers 1 – 3 may cause a degradation in fold accuracy.

Default

Correction Range

DA TE

INIT 1 2 3 4 5

10–20 – +20

0 –20 – +20

–4 –20 – +5

JPN

JPN, USA, Euro

ON ONON ⇔ OFF

00

C. 0000000 C. 0000000

NN NN, INCH

00

0–1: NORMAL

: SLOW

1
0

–1

: FAST
: NORMAL
: SLOW

12H-8604X

221 – 3

2

3

5

MODEL CODE 915 915915, 9104

6

7

9

11

12

14

15

Part Number : 12H-9133X

2-30

12H-M12M0-0309-0

5. INITIALIZING THE MEMORY

If for some reason, the EEPROM (nonvolatile memory) data becomes lost and the display does not function normally,
initialize and recover the data using the following procedure.

Initializing the memory

q While pressing the start key, stop key, and test key together, turn ON the power. This initializes data except for the

total count registered in the EEPROM of the MC unit. A buzzer sounds three times when the memory is initialized.

w As the data except for the total count was initialized, reset data such as home position adjustment data of folding

plates and switching shaft in the maintenance mode while checking the backup data form pasted on the inside of

the main cover F.

If data cannot be recovered by the above method, turn ON the power while pressing the start key, stop key,
and clear key together (This initializes all data including the total count). Never perform this method except
when problems have occurred.
Turning ON the power while pressing the test key erases only standard folding adjustment registration and
custom folding registration data.

NoteNote

2-31

12H-M12M0-0309-0

6. PRECAUTIONS ON REPLACING THE MC UNIT

Various data such as home position adjustment data of folding plates and switching shaft and total count memorized
by the unit even when the power has been turned OFF are registered in the EEPROM (nonvolatile memory) of the MC
unit (board). Therefore if the MC unit has been replaced, attach the EEPROM of the old MC board to the new board if
possible.

If board replacement can only be done as a whole together with the EEPROM, note down various settings and total
count data before replacement on the backup data form pasted on the inside of the main cover F, perform the next
step after replacement, and check the data.

(1) Initializing the memory

While pressing the start key, stop key, and clear key together, turn ON the power. This initializes data registered
in the EEPROM of the MC unit. A buzzer sounds three times when the memory is initialized.

(2) Setting various data

Reset data such as home position adjustment data of folding plates and switching shaft in the maintenance mode
as required.

When attaching the EEPROM, take note of the socket direction.

NoteNote

2-32

12H-M12M0-0309-0

7. UPGRADING THE PROGRAM VERSION

When upgrading the control program version, prepare a 1M-byte EPROM written with the new version program
(Equivalent to STMicroelectronics M27C1001-12F1), and rewrite using the following procedure.

q Insert the EPROM written with the new version program into the IC socket of the MC unit (board) with the power

OFF.

w While pressing the start key and stop key, turn ON the power. (To enter the maintenance mode)

e For DF-920, enter the code No. “18” of the maintenance mode using the numerical keys, and press the folding

mode key. (To enter the program version up mode)

For DF-910, select code No. “18” using the Paper length/Stacker roller position key. (Do not use the folding mode

key.)

r Press the start key. (The buzzer will not sound even when the start key is pressed, but this is not a fault.)

When attaching the EPROM, take note of the socket direction.

NoteNote

Never turn OFF the power until rewriting has been completed.
If rewriting is started normally, all keys will be ineffective until rewriting completes. This is not a fault.
If the buzzer sounds “pi.pi.pi” when the start key is pressed, it indicates the ID error of the program. The
following reasons are possible.

• The EPROM is not inserted in the socket correctly

• The program is not written in the EPROM correctly.

• A program with a different ID is written in the EPROM.

NoteNote

t After 15 to 20 seconds later, rewriting completes normally, and the new program starts running automatically.

(The same operations are performed when the power is turned ON normally.)

As motors will operate if all interlock switches are turned ON even if the operation is carried out with the
cabinet cover removed, do not touch the driving parts.

NoteNote

y Check that the maintenance mode “Code No.15: MC ROM version display” is set and the new version is displayed.

u Turn OFF the power, and remove the EPROM from the IC socket.

12H-M12M0-0309-0

2-33

8. OVERALL SCHEMATIC DIAGRAM (DF-920)

FE1

FE5

FE2

FE1

FE1

FE4

FE3

FE1
FE2
FE3
FE4
FE5

(2turn) : Toroidal clamp core 052-10065

(2turn) : Clamp filter 052-10052

(1turn) : Ferrite core 052-10027

(1turn) : Ferrite core 052-10035
(1turn) : Ferrite core 052-10035

F1 to F5 on a circuit diagram are one piece, respectively

FE1

Attach a PWB shielding cover

507 PURPLE
508 GRAY

510 GRAY

COM

N.O.

054-10115

COM

N.O.

054-10248

COM

N.O.

054-10248

514 GRAY

98R-8023

3

ANODE

2

GND

COLLECTOR

1

FRONT COVER SW

98R-8023

3

ANODE

2

GND

COLLECTOR

1

305 BLUE

301 YELLOW

303 PINK

DELIVERY LIMIT SENSOR

1
2
3
4
5
6
7
8
9
10
11
12

J 01

PHD12T

TCK
GND
TDO

TMS
TXD
RXD

TDI
GND
MD1

FOR WRITING ON FPGA FLASH MEMORY

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

J03

PHD30T

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

J 04

20
21
22
23
24
25
26

ORIBAN1-INDEX1
ORIBAN1-INDEX2

GND
GND
ORIBAN2-INDEX1
ORIBAN2-INDEX2

GND
P-SEN1

P-SEN2
P-SEN3
P-SEN4
P-SEN5
P-SEN6
GND
ACSE2
REAR C

GND
GND

ORIKOMIBAN2-LIM

OUT-PA-SEN
OUT-PA-SEN
IN-PA-SEN
IN-PA-SEN

HAISIKORO-LIM
KYUDAI-PA-SEN

ORIKOMIBAN1-LIM

GND
GND

GND

GND

GND
GND

GND
GND

ACSE1

PHD26T

1
2
3
4
5
6
7
8
9
10

J 05

11
12
13
14

ORI1SET-1
ORI1SET-1
ORI1SET-2
ORI1SET-2
TOP C
TOP C
FRONT C
FRONT C

ACSE 3
KYUSI-SET
AUTO-LOW

EH14T

501 PURPLE
502 GRAY
503 SKYBLUE
504 GRAY
505 YELLOW
506 GRAY
507 PURPLE
508 GRAY

510 GRAY

514 GRAY

301 YELLOW
302 SKYBLUE
303 PINK

305 BLUE
306 BLUE

310 PINK
312 BLUE

315 PINK
317 BLUE

321 PINK
323 BLUE

324 BLUE
327 PINK

329 BLUE
330 BLUE

313 YELLOW

308 SKYBLUE

GND
GND
GND

N.C.

N.C.

+5V
+5V

+5V

AUTOMATIC-UP-SEN
+5V

+5V
GND

N.C.
+5V
+5V

GND
+5V

N.C.
+5V

+5V
+5V

+5V
GND

+5V
+5V

+5V
+5V

322 YELLOW

328 SKYBLUE

401 YELLOW
402 SKYBLUE
403 PINK
404 PINK
405 BLUE
406 BLUE
407 GRAY

409 PINK
410 PINK
411 BLUE
412 BLUE
413 PINK
414 YELLOW

416 GRAY

415 SKYBLUE

408 PURPLE

417 PURPLE
418 YELLOW
419 SKYBLUE
420 BLUE

422 SKYBLUE

426 BLUE

STARTING POINT SENSOR (UP)

STARTING POINT SENSOR (DOWN)

1
2
3
4

+24V
+24V

FG

VH05T

J 06

5

601 BROWN
603 BLUE

GND
GND

1
2
3
4
5
6
7
8

SDA

XH08T

SCL

GND
GND

GND

J 02

202 BLUE
204 BLUE

207 ORANGE
208 BLUE

201 PURPLE
203 GRAY

1
2
3
4
5
6
7
8

CN1
SDA

GND

202 BLUE
204 BLUE

207 ORANGE
208 BLUE

201 PURPLE
203 GRAY

12H-8006

OP UNIT

12H-8032

OP CIRCUIT DIAGRAM

J 09

1
2
3

1
2
3
4
5

J 07

GND

HW
HU

HV

VH03T

EH05T

22

131

3

901 GRAY
902 PURPLE

701 PINK
702 BLUE
703 PURPLE
704 YELLOW
705 SKYBLUE

MOT1

4
5
6
7
8

4
5
6
7
8

22

131

3

4
5
6
7

4
5
6
7

22

131

3

24V 3.8A

MOT4

96V-8146

121

2

BLUE
PURPLE
GRAY
YELLOW
GREEN

RED
ORANGE

99

U
V
W

GND
HE1
HE2
HE3

GRAY
SKYBLUE

PINK
BLUE

YELLOW

PURPLE

24V 83mA

Vcc

12H-8101

1
2
3
4
5
6
7
8
9
10
11
12
13
14

M2+

M2–

M3+

M3–

M4+

M4–

COUNTER

CLH1
CLH2

MOT5

1
2

1
2

J 08

3
4
5
6
7
8

3
4
5
6
7
8

99
1212

3
4
5
6
7
8

3
4
5
6
7
8

99

1212

3

ANODE

98R-8023

1

COLLECTOR

2

GND

3

ANODE

98R-8023

1

COLLECTOR

2

GND

ANODE

1

COLLECTOR
GND

EH14T

811 BROWN
812 SKYBLUE
813 BROWN

3

ANODE

98R-8023

1

COLLECTOR

2

GND

3

ANODE

98R-8023

1

COLLECTOR

2

GND

ANODE

1

COLLECTOR
GND

802 SKYBLUE
804 YELLOW
806 PURPLE
808 GRAY

814 YELLOW

062-10782

062-10782

802 SKYBLUE

804 YELLOW

2
3

2
3

ORANGE
YELLOW
GREEN
BLUE
PURPLE
GRAY
WHITE

SKYBLUE

121

2

YELLOW
ORANGE
GREEN

PURPLE
BLUE
GRAY

WHITE

121

2

YELLOW
ORANGE
GREEN

PURPLE
BLUE
GRAY

WHITE

97J-8505
24V 230mA

10
11

1
2

BLACK
PINK

RED

ORANGE
YELLOW
GREEN
BLUE
PURPLE
GRAY
WHITE

SKYBLUE

BLACK
PINK

RED

10
11

121

2

10
11

1
2

10
11

WHITE

RED

RED

BLACK

BLACK

FG

PURPLE

BROWN

BROWN
BLACK

BROWN

BROWN

BROWN
RED

BROWN

+24V
+24V

+5V

M1U
M1V

M1W

+6.5V

SCL
GND

GND

+6.5V

GND

N.C.

DC BL MOTOR

RED

801 YELLOW

YELLOW

803 PURPLE
805 GRAY
807 SKYBLUE

807 SKYBLUE
808 GRAY

801 YELLOW

803 PURPLE

12H-8111

12H-8111

24V 160mA

24V 160mA

SKYBLUE

SKYBLUE

M5+

M5–

+24V

401 YELLOW
403 PINK
405 BLUE
402 SKYBLUE
404 PINK
406 BLUE
308 SKYBLUE
310 PINK
312 BLUE

407 GRAY
409 PINK
411 BLUE
408 PURPLE
410 PINK

313 YELLOW
315 PINK
317 BLUE

412 BLUE

HOME SENSOR

HOME SENSOR

DC MOTOR

DC MOTOR

PAPER FEED PLATE MOTOR

12H-8003

MC UNIT

12H-8301

MC CIRCUIT DIAGRAM

413 PINK
414 YELLOW
415 SKYBLUE
416 GRAY
417 PURPLE
418 YELLOW
419 SKYBLUE
420 BLUE

STOPPER MOVEMENT SENSOR (ENCODER) A

STOPPER MOVEMENT SENSOR (ENCODER) B

STOPPER MOVEMENT SENSOR (ENCODER) A

STOPPER MOVEMENT SENSOR (ENCODER) B

BROWN

MOTOR FOR MOVING STACKER ROLLER

319 GRAY

325 YELLOW

121

2

CLH1

811 BROWN
812 SKYBLUE

BLUE
BLUE

FEEDING CLUTCH

121

2

813 BROWN
814 YELLOW

BLUE
BLUE

CLH2

DELIVERY CLUTCH

24V 250mA 96Ω

24V 250mA 96Ω

SECOND FOLDING PLATE

FIRST FOLDING PLATE

MOT2

MOT3

424 PINK

SIDE COVER SW

424 PINK
422 SKYBLUE
426 BLUE

AC (N)

5

4

3

2

1

FG

SWITCHING POWER SUPPLY

CN1

057-10033

AC (L)

FG

CN2

4

+24V

3

+24V

2

GND

1

GND

BLACK
WHITE

GREEN/YELLOW

054-10308

BLACK
WHITE

POWER SW

AC (L)
AC (N)

FG

230V 10A

INLET
056-10357

AC220 to 240V 50/60Hz : 055-10212

POWER CORD

AC120V 60Hz : 055-10209

COM

N.O.

501 PURPLE
502 GRAY

503 SKYBLUE
504 GRAY

505 YELLOW
506 GRAY

054-10115

COM

N.O.

054-10115

COM

N.O.

054-10115

TOP COVER SW

FOLDING PLATE SW1

FOLDING PLATE SW2

1
2

GND

1
2
3
4
5
6
7
8

SEN1

+5V

SEN2
SEN3
SEN4
SEN5
SEN6

96V-8016
96V-8018

PS P.W.B. UNIT
PS CIRCUIT DIAGRAM

UK Spec.

GND

1
2
3
4
5
6
7
8

SEN1

+5V

SEN2
SEN3
SEN4
SEN5
SEN6

96V-8026
96V-8028

PS P.W.B. UNIT
PS CIRCUIT DIAGRAM

USA Spec.

It changes by Spec.

1
2
3

96V-8110

PAPER SENSOR

ANODE

GND

PINK
WHITE
BLUE

+5V
PS1
CATHODE

EMITTER

4
5
6
7
8

2

1
3

1
2

GND

SIG (N.O.)

054-10326 PAPER SENSOR

1
2

121

2

3

1
2
3

11G-8052

11G-8052

BLUE

324 BLUE

FEED SENSOR

FEED SENSOR

DELIVERY SENSOR

DELIVERY SENSOR

PINK
BLUE

PINK
BLUE

11G-8051

1
2
3GND

Vcc

VOUT

C.V.C

11G-8051

1
2
3GND

Vcc

VOUT

C.V.C

ANODE
ANODE

ANODE
ANODE

CATHODE

CATHODE

SKYBLUE

330 BLUE

328 SKYBLUE

322 YELLOW

1
2
3

1
2
3

1
2332

1

GRAY

321 PINK
323 BLUE

319 GRAY

YELLOW

327 PINK
329 BLUE

325 YELLOW

PINK
YELLOW
SKYBLUE
GRAY
PURPLE
YELLOW
SKYBLUE
BLUE

BLUE

SKYBLUE

SKYBLUE
BLUE

3
4
5
6
7
8
9
10

302 SKYBLUE
306 BLUE

509 BLUE

513 BLUE

509 BLUE

513 BLUE

903 SKYBLUE

SKYBLUE

PURPLE

12H-85101

12H-8120

12H-8168

12H-M12M0-0309-0

2-34

9. OVERALL SCHEMATIC DIAGRAM (DF-915)

FE1
FE2
FE3
FE4
FE5

FE1

FE5

FE2

FE1

FE1

FE4

FE3

FE1

(2turn) : Toroidal clamp core 052-10065

(2turn) : Clamp filter 052-10052

(1turn) : Ferrite core 052-10027

(1turn) : Ferrite core 052-10035
(1turn) : Ferrite core 052-10035

F1 to F5 on a circuit diagram are one piece, respectively

Attach a PWB shielding cover

COM

N.O.

98R-8023

3

ANODE

2

GND

COLLECTOR

1

305 BLUE

301 YELLOW

303 PINK

DELIVERY LIMIT SENSOR

1
2
3
4
5
6
7
8
9
10
11
12

J 01

PHD12T

TCK
GND
TDO

TMS
TXD
RXD

TDI
GND
MD1

FOR WRITING ON FPGA FLASH MEMORY

1
2
3
4
5
6
7
8

9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

J03

PHD30T

1

2

3

4

5

6

7

8

9
10
11
12
13
14
15
16
17
18
19

J 04

20
21
22
23
24
25
26

ORIBAN1-INDEX1
ORIBAN1-INDEX2

GND
GND
ORIBAN2-INDEX1
ORIBAN2-INDEX2

GND
P-SEN1

P-SEN2
P-SEN3
P-SEN4
P-SEN5
P-SEN6
GND
ACSE2
REAR C

GND
GND

ORIKOMIBAN2-LIM

OUT-PA-SEN
OUT-PA-SEN
IN-PA-SEN
IN-PA-SEN

HAISIKORO-LIM
KYUDAI-PA-SEN

ORIKOMIBAN1-LIM

GND
GND

GND

GND

GND
GND

GND
GND

ACSE1

PHD26T

1
2
3
4
5
6
7
8
9
10

J 05

11
12
13
14

ORI1SET-1
ORI1SET-1
ORI1SET-2
ORI1SET-2
TOP C
TOP C
FRONT C
FRONT C

ACSE 3
KYUSI-SET
AUTO-LOW

EH14T

501 PURPLE
502 GRAY
503 SKYBLUE
504 GRAY
505 YELLOW
506 GRAY

301 YELLOW
302 SKYBLUE
303 PINK

305 BLUE
306 BLUE

310 PINK
312 BLUE

315 PINK
317 BLUE

321 PINK
323 BLUE

324 BLUE
327 PINK

329 BLUE
330 BLUE

313 YELLOW

308 SKYBLUE

GND
GND
GND

N.C.

N.C.

+5V
+5V

+5V

AUTOMATIC-UP-SEN
+5V

+5V
GND

N.C.
+5V
+5V

GND
+5V

N.C.
+5V

+5V
+5V

+5V
GND

+5V
+5V

+5V
+5V

322 YELLOW

328 SKYBLUE

401 YELLOW
402 SKYBLUE
403 PINK
404 PINK
405 BLUE
406 BLUE
407 GRAY

409 PINK
410 PINK
411 BLUE
412 BLUE
413 PINK
414 YELLOW

416 GRAY

415 SKYBLUE

408 PURPLE

417 PURPLE
418 YELLOW
419 SKYBLUE
420 BLUE

1
2
3
4

+24V
+24V

FG

VH05T

J 06

5

601 BROWN
603 BLUE

GND
GND

1
2
3
4
5
6
7
8

SDA

XH08T

SCL

GND
GND

GND

J 02

202 BLUE
204 BLUE

207 ORANGE
208 BLUE

201 PURPLE
203 GRAY

1
2
3
4
5
6
7
8

CN1
SDA

GND

202 BLUE
204 BLUE

207 ORANGE
208 BLUE

201 PURPLE
203 GRAY

12H-8006

OP UNIT

12H-8032

OP CIRCUIT DIAGRAM

J 09

1
2
3

1
2
3
4
5

J 07

GND

HW

HU

HV

VH03T

EH05T

2 2

131

3

901 GRAY
902 PURPLE

701 PINK
702 BLUE
703 PURPLE
704 YELLOW
705 SKYBLUE

MOT1

4
5
6
7
8

4
5
6
7
8

2 2

131

3

4
5
6
7

4
5
6
7

2 2

131

3

24V 3.8A

MOT4

96V-8146

121

2

BLUE
PURPLE
GRAY
YELLOW
GREEN

RED
ORANGE

99

U
V
W

GND
HE1
HE2
HE3

GRAY
SKYBLUE

PURPLE

24V 83mA

Vcc

12H-8101

1
2
3
4
5
6
7
8

9
10
11
12
13
14

M2+

M2–

M3+

M3–

M4+

M4–

COUNTER

CLH1
CLH2

J 08

3
4
5
6
7
8

3
4
5
6
7
8

99
1212

3
4
5
6
7
8

3
4
5
6
7
8

99
1212

3

ANODE

98R-8023

1

COLLECTOR

2

GND

3

ANODE

98R-8023

1

COLLECTOR

2

GND

ANODE

1

COLLECTOR
GND

EH14T

811 BROWN
812 SKYBLUE

3

ANODE

98R-8023

1

COLLECTOR

2

GND

3

ANODE

98R-8023

1

COLLECTOR

2

GND

ANODE

1

COLLECTOR
GND

802 SKYBLUE
804 YELLOW
806 PURPLE

062-10782

062-10782

802 SKYBLUE

804 YELLOW

2
3

2
3

ORANGE
YELLOW
GREEN
BLUE
PURPLE
GRAY
WHITE

SKYBLUE

121

2

YELLOW
ORANGE
GREEN

PURPLE
BLUE
GRAY

WHITE

121

2

YELLOW
ORANGE
GREEN

PURPLE
BLUE
GRAY

WHITE

10
11

1
2

BLACK
PINK

RED

ORANGE
YELLOW
GREEN
BLUE
PURPLE
GRAY
WHITE

SKYBLUE

BLACK
PINK

RED

10
11

121

2

10
11

1
2

10
11

RED

RED

BLACK

BLACK

FG

PURPLE

BROWN

BROWN
BLACK

BROWN

BROWN
RED

BROWN

+24V
+24V

+5V

M1U
M1V

M1W

+6.5V

SCL
GND

GND

+6.5V

GND

N.C.

DC BL MOTOR

RED

801 YELLOW

YELLOW

803 PURPLE
805 GRAY

801 YELLOW

803 PURPLE

12H-8111

12H-8111

24V 160mA

24V 160mA

SKYBLUE

SKYBLUE

M5+

M5–

+24V

401 YELLOW
403 PINK
405 BLUE
402 SKYBLUE
404 PINK
406 BLUE
308 SKYBLUE
310 PINK
312 BLUE

407 GRAY
409 PINK
411 BLUE
408 PURPLE
410 PINK

313 YELLOW
315 PINK
317 BLUE

412 BLUE

HOME SENSOR

HOME SENSOR

DC MOTOR

DC MOTOR

12H-8003

MC UNIT

12H-8301

MC CIRCUIT DIAGRAM

413 PINK
414 YELLOW
415 SKYBLUE
416 GRAY
417 PURPLE
418 YELLOW
419 SKYBLUE
420 BLUE

STOPPER MOVEMENT SENSOR (ENCODER) A

STOPPER MOVEMENT SENSOR (ENCODER) B

STOPPER MOVEMENT SENSOR (ENCODER) A

STOPPER MOVEMENT SENSOR (ENCODER) B

BROWN

MOTOR FOR MOVING STACKER ROLLER

319 GRAY

325 YELLOW

121

2

CLH1

811 BROWN
812 SKYBLUE

BLUE
BLUE

FEEDING CLUTCH

24V 250mA 96Ω

GRAY

813 BROWN
814 YELLOW

121

2

813 BROWN
814 YELLOW

BLUE
BLUE

CLH2

DELIVERY CLUTCH

24V 250mA 96Ω

512 GRAY

512 GRAY

054-00396

PAPER FEED PLATE SET SW

12H-8120

12H-8168

1
2

121

2

3

1
2
3

11G-8052

11G-8052

BLUE

324 BLUE

FEED SENSOR

FEED SENSOR

DELIVERY SENSOR

PINK
BLUE

PINK
BLUE

11G-8051

1
2
3

GND

Vcc

VOUT

C.V.C

11G-8051

1
2
3

GND

Vcc

VOUT

C.V.C

ANODE
ANODE

ANODE
ANODE

CATHODE

CATHODE

SKYBLUE

330 BLUE

328 SKYBLUE

322 YELLOW

1
2
3

1
2
3

1
2332

1

GRAY

321 PINK
323 BLUE

319 GRAY

YELLOW

327 PINK
329 BLUE

325 YELLOW

DELIVERY SENSOR

1
2

GND

SIG (N.O.)

054-10326 PAPER SENSOR

GND

1
2
3
4
5
6
7
8

SEN1

+5V

SEN2
SEN3
SEN4
SEN5
SEN6

96V-8016
96V-8018

PS P.W.B. UNIT
PS CIRCUIT DIAGRAM

UK Spec.

GND

1
2
3
4
5
6
7
8

SEN1

+5V

SEN2
SEN3
SEN4
SEN5
SEN6

96V-8026
96V-8028

PS P.W.B. UNIT
PS CIRCUIT DIAGRAM

USA Spec.

It changes by Spec.

1
2
3

96V-8110

PAPER SENSOR

PINK
WHITE
BLUE

+5V
PS1
CATHODE

ANODE

GND

EMITTER

1
2
3

4
5
6
7
8

2

1
3

PINK
YELLOW
SKYBLUE
GRAY
PURPLE
YELLOW
SKYBLUE
BLUE

BLUE

SKYBLUE

1
2

302 SKYBLUE
306 BLUE

3
4
5
6
7
8
9
10

903 YELLOW

PINK
BLUE

YELLOW
SKYBLUE

PURPLE

FIRST FOLDING PLATE

SECOND FOLDING PLATE

MOT3

MOT2

AC (N)

5

4

3

2

1

FG

SWITCHING POWER SUPPLY

CN1

057-10033

AC (L)

FG

CN2

4

+24V

3

+24V

2

GND

1

GND

BLACK
WHITE

054-10308

BLACK
WHITE

POWER SW

AC (L)
AC (N)

FG

230V 10A

INLET
056-10357

AC220 to 240V 50/60Hz : 055-10212

POWER CORD

AC120V 60Hz : 055-10209

COM

N.O.

501 PURPLE
502 GRAY

503 SKYBLUE
504 GRAY

505 YELLOW
506 GRAY

054-10115

COM

N.O.

054-10115

COM

N.O.

054-10115

TOP COVER SW

FOLDING PLATE SW1

FOLDING PLATE SW2

GREEN/YELLOW

SKYBLUE
BLUE

511 BLUE

511 BLUE

12H-85201

12H-M12M0-0309-0

2-35

10. WIRING DIAGRAM 1/2 (DF-920)

Brass screw
M4 toothed lock washer

View of A

2 turns

052-10052
Clamp filter

Details for F

056-00778
Bush

056-00779
Collar

12H-8101
Brushless DC motor

Brass screw
M4 toothed
lock washer

Details for E

12H-8208
Bundled wire unit 8

12H-8201
920 bundled
wire unit 1

12H-8206
Bundled wire
unit 6

12H-8207
Bundled wire
unit 7

056-00003
Bushing
(OCB-500)

5N

Purple

Yellow

056-00876
SK binder

056-00876
SK binder

View of G

12H-8605
OP P.W.B. unit

Gray

Gray

056-00003
Bushing
(OCB-500)

056-00644
Bushing
(OCB-875)

Light blue
Gray

054-10248
Microswitch

5N

3N

4N

4N

2N

2N

3N

6N

5N

5N

054-10248
Microswitch

Main frame F

12H-5003
Main frame F

056-00876
SK binder

12D-8703
Universal bush

11G-8051
Separation type photointerrupter

12H-8206
Bundled wire unit 6

2N2N

12H-4004
Stacker plate

054-10115
Microswitch

054-10308
Power switch

056-00003
Bushing
(OCB-500)

6N

056-00778
Bush x 3

12H-5008
Main frame B

Main frame B

054-10115
Microswitch

3N

2N

98R-8023
Photointerrupter

12H-8120
Paper feed
clutch unit

3N

056-00644
Bushing
(OCB-875)

7N

Purple

4N

056-00876
SK binder

Gray

Light blue

Gray

054-10115
Microswitch

056-00779
Collar x 3

6N

12H-8003
MC unit

5N

Cable clamp

2N 056-09001 3302
3N 056-09002 3303
4N 056-09003 3304
5N 056-09004 3305
6N 056-09005 3306
7N 056-09006 3307

Cable clip

Middle 056-07008 1197

L

Green/Yellow Black

White

N

E

12H-8212
Bundled wire unit 11

056-10357
Inlet

12H-8211
Bundled wire unit 10

1 turn

052-10035
Ferrite core

12H-8205
Bundled wire unit 5

1 turn

12H-8003
MC unit

052-10027
Ferrite core

2N

12H-2533
Lower sensor angle

2N

2N

2N

4N

4N

3N

2N

2N

12H-8168
Paper ejection
clutch unit

Yellow

Gray

12H-5333
Switch angle T

054-10248
Microswitch

3N

056-10100
Spacer

3N

2N 2N

12H-2525
Paper feed inlet upper guide

11G-8052
Separation type photointerrupter

11G-8051
Separation type photointerrupter

12H-8208
Bundled wire unit 8

Details for H

12H-8207
Bundled wire unit 7

Fix the ferrite core with

the binder provided.
056-00876
SK binder

6N

056-00876
SK binder

B

i

h

g

k

d

E

F

c

e

f

j

l

i

j

h

A

G

TDK

MEC

a

b

H

TDK

12H-85010 (1/2)

12H-8201
920 bundled wire unit 1

Brass screw
M4 toothed lock washer

24

3

Insulating sleeve (Blue)

Insulating sleeve (Green)

White

White

View of B

Black
Black

1

12H-M12M0-0309-0

2-36

11. WIRING DIAGRAM 2/2 (DF-920)

12H-8201
920 bundled
wire unit 1

054-10326
Detection switch

12H-8211
Bundled wire unit 10

12H-8201
920 bundled
wire unit 1

052-10065
Toroidal clamp
core

056-00876
SK binder

052-10035
Ferrite core

2 turns

12H-5065
Power supply base

12H-8101
Brushless DC motor

12H-8205
Bundled wire unit 5

1 turn

056-00876
SK binder

12H-2004
Paper feed tray

5N 5N

96V-8026
PS P.W.B. unit

11G-8052
Separation type photointerrupter

056-00003
Bushing
(OCB-500)

5N

5N5N

2N

2N

056-00644
Bushing
(OCB-875)

056-00644
Bushing
(OCB-875)

056-00876
SK binder

2N

View of I

3N

12H-9074
Paper feed tray lower cover

12H-2004
Paper feed tray

12H-5003
Main frame F

12H-3003
Folding plate 1

062-10782
Photointerrupter

056-00003
Bushing
(OCB-500)

98R-8023
Photointerrupter

12H-8111
DC motor unit

12H-8202
Bundled wire unit 2

12H-8111
DC motor unit

98R-8023
Photointerrupter

056-00003
Bushing
(OCB-500)

12H-8203
Bundled wire unit 3

062-10782
Photointerrupter

12H-3203
Folding plate 2

056-00876
SK binder

054-10326
Detection switch

12H-8211
Bundled wire unit 10

12H-2004
Paper feed tray

5N

5N

96V-8016
PS P.W.B. unit

USA specifications

UK specifications

12H-8209
Bundled
wire unit 9

Middle

Middle

96V-8146
DC motor

2N

056-00003
Bushing
(OCB-500)

97J-8505
DC motor unit

12H-5008
Main frame B

057-10033
Switching power supply

12H-2404
Auxiliary paper feed tray

96V-8110
Photointerrupter

12H-9034
Bracket

12H-9034
Bracket

056-10322
Bushing
(OCB-562)

3N

056-10322
Bushing
(OCB-562)

3N

12H-8209
Bundled wire unit 9

Blue/Purple/GrayOrange/Yellow/Green

98R-8023
Photointerrupter

View of C D

056-10100
Spacer x 5

Middle

12H-8204
Bundled wire unit 4

Middle

12H-5016
Reinforcement plate L

Middle

Middle

Middle

12H-8209
Bundled wire unit 9

c

k

m

l

a

d

m

n

D

C

I

n

c

e

f

g

n

n

b

MEC

12H-85010 (2/2)

Brass screw
M4 toothed lock washer

Brass screw
M4 toothed lock washer

USA specifications

USA specifications

Main reinforcement
base
12H-5024

12H-M12M0-0309-0

2-37

12. WIRING DIAGRAM 1/2 (DF-915)

12H-8004
OP P.W.B. unit

052-10052

Clamp filter

Brass screw
M4 toothed
lock washer

12H-8208
Bundled wire unit 8

12H-8221
91X bundled
wire unit 1

2N

B

2 turns

h

g

f

12H-8206
Bundled
wire unit 6

12H-8207
Bundled
wire unit 7

056-00779
Collar x 3

056-00003
Bushing
(OCB-500)

j

5N

056-00876
SK binder

056-00778
Bush x 3

d

Gray

056-00003

Bushing
(OCB-500)

056-00644
Bushing
(OCB-875)

c

e

i

k

5N

3N

3N

4N

2N

2N

3N

6N

5N

5N

Main frame F

12H-5003
Main frame F

054-10308
Power switch

Brass screw
M4 toothed lock washer

7N

6N

6N

12D-8703
Universal bush

Purple

054-10115
Microswitch

12H-5008
Main frame B

Main frame B

054-10115
Microswitch

98R-8023
Photointerrupter

12H-8120
Paper feed
clutch unit

3N

056-00644
Bushing
(OCB-875)

4N

056-00876
SK binder

Light blue

Gray

12H-8205
Bundled wire unit 5

12H-8101
Brushless DC motor

056-10100
Spacer

056-00876
SK binder

E

056-10357
Inlet

2N

2N

2N

4N

4N

3N

2N

2N

2N

3N

12H-8168
Paper ejection
clutch unit

Yellow

Gray

a

b

12H-5333
Switch angle T

054-10248
Microswitch

052-10027
Ferrite core

6N

5N

3N

12H-8602
MC unit

052-10035
Ferrite core

1 turn

1 turn

12H-8211
Bundled wire unit 10

054-00396
Microswitch

056-00876
SK binder

12H-8212
Bundled wire unit 11

056-00876
SK binder

056-11299
Hole plug

3N

Blue

Gray

A

F

TDK

MEC

Brass screw
M4 toothed lock washer

12H-8221
91X bundled wire unit 1

Cable clamp

056-00778
Bush

056-00779
Collar

View of E

L

24

3

12H-8602
MC unit

Insulating sleeve (Blue)

Insulating sleeve (Green)

White

Green/Yellow

White

View of A

View of B

Black

White

Black

N

E

1

Black

2N 056-09001 3302
3N 056-09002 3303
4N 056-09003 3304
5N 056-09004 3305
6N 056-09005 3306
7N 056-09006 3307

Cable clip

Middle 056-07008 1197

12H-8207
Bundled wire unit 7

12H-8208
Bundled wire unit 8

11G-8051
Separation type photointerrupter

11G-8052
Separation type photointerrupter

12H-2525
Paper feed inlet upper guide

2N

2N

11G-8051
Separation type photointerrupter

12H-8206
Bundled wire unit 6

2N2N

12H-4004
Stacker plate

12H-2533
Lower sensor angle

2N

i

h

g

12H-85020 (1/2)

Fix the ferrite core with
the binder provided.

Details for F

TDK

12H-M12M0-0309-0

2-38

13. WIRING DIAGRAM 2/2 (DF-915)

Brass screw
M4 toothed lock washer

12H-8221
91X bundled
wire unit 1

12H-8221
91X bundled
wire unit 1

052-10065
Toroidal clamp
core

056-00876
SK binder

12H-5065
Power supply base

12H-8101
Brushless DC motor

12H-8205
Bundled wire unit 5

1 turn

11G-8052
Separation type photointerrupter

Main reinforcement
base
12H-5024

056-00003
Bushing
(OCB-500)

5N

5N

5N

2N

2N

056-00644
Bushing
(OCB-875)

056-00644
Bushing
(OCB-875)

056-00876
SK binder

2N

2N

98R-8023
Photointerrupter

12H-5003
Main frame F

12H-3003
Folding plate 1

062-10782
Photointerrupter

056-00003
Bushing
(OCB-500)

98R-8023
Photointerrupter

12H-8111
DC motor unit

12H-8202
Bundled wire unit 2

Brass screw
M4 toothed lock washer

12H-8111
DC motor unit

98R-8023
Photointerrupter

056-00003
Bushing
(OCB-500)

12H-8203
Bundled wire unit 3

062-10782
Photointerrupter

12H-3203
Folding plate 2

056-00876
SK binder

056-00876
SK binder

2 turns

Middle

Middle

96V-8146
DC motor

12H-5008
Main frame B

057-10033
Switching power supply

056-10100
Spacer x 5

Middle

12H-8204
Bundled wire unit 4

Middle

12H-5016
Reinforcement plate L

Middle

Middle

Middle

052-10035
Ferrite core

j

l

k

a

d

l

D

C

e

f

b

MEC

12H-85020 (2/2)

12H-9034

056-10322
Bushing
(OCB-562)

054-10326
Detection switch

3N

056-10322
Bushing
(OCB-562)

Bracket

12H-9034
Bracket

12H-2004
Paper feed tray

5N

5N

96V-8026 (USA), 96V-8016 (UK)
PS P.W.B. unit

96V-8110
Photointerrupter

12H-2404
Auxiliary paper feed tray

3N (USA)

12H-9074
Paper feed tray lower cover

12H-2004
Paper feed tray

USA specifications

12H-8211
Bundled wire unit 10

12H-8209 (USA)
Bundled wire unit 9

12H-8209
Bundled
wire unit 9

12H-8209 (USA)
Bundled wire unit 9

3N (USA)

m

m

c

m

G

m

Blue/Purple/GrayOrange/Yellow/Green

View of C D

View of G

12H-M12M0