DUPLO DF-870 (01) PDF MANUAL

The symbols used in this manual have the following meanings:

Exclamation Point Icon: Describes instructions which must be followed in use. Be sure to read the instructions to avoid problems due to incorrect operations.

Open Book Icon: Indicates supplementary or useful information. Describes names of related items and supplementary instructions.

Make sure the power supply used is always within the following range:

Power supply: 100 to 240 V AC, 50/60 Hz

When you power other appliances from the same AC outlet, make sure that the combined power consumption does not exceed the power supply capacity.

Rated power: 125 W

Rated current: 1.3 to 0.65 A

Operate this unit in the following environment:

where the temperature range is between 5 and 35°C/41 and 95°F (-5 to 45°C/23 to 113°F in storage)

where the humidity range is between 20 and 80% RH (10 to 90% RH in storage, however no condensation)

which is not subject to direct sunlight

where the outside light does not exceed 1,500 lx

which is subject to little or no vibration

which is free from air-borne salt

where there are no harmful chemicals

where the unit is not exposed to water

“WARNING” and “CAUTION” labels are pasted on the machine to ensure user safety. Do not remove or change them. When the labels become dirty or are lost, be sure to contact your dealer for a new one.

This device can be used to fold paper into the following six shapes:

Single fold

Double fold

Irregular accordion fold-out

Letter fold

Accordion fold

Gate fold

By using the cross folding lever, it is also possible to create cross single fold and cross letter fold. Note that the finish of cross folding is not as accurate as that of the six folding modes mentioned above.

1. Remove the press release levers:

The press release levers are attached at shipment to prevent the rubber roll from becoming distorted. The machine will be damaged if used without removing them.

1. To remove press release lever [A] on the non-operator’s side, push it inwards and pull it out.

2. To remove press release lever [A] on the operator’s side, push it inwards and pull it out.

3. To remove press release lever [B] on the non-operator’s side, push it inwards and pull it out.

4. To remove press release lever [B] on the operator’s side, push it inwards and pull it out.

2. Attach the folding plates:

Always hold the folding plate in both hands when attaching or removing.

1. Lower the folding plate 2 lock lever.

2. Attach folding plate 2 to the machine, aligning it with the slider and frame pillars.

3. Lower the lock lever to fix folding plate 2.

4. For DF-870, lower the folding plate 1 lock lever. (The DF-850 does not have this lever).

5. Attach folding plate 1 to the machine. Align it with the frame pillars and insert the U-shaped groove at its tip into the pillar at the back of the frame.

6. For DF-870, lower the lock lever to fix folding plate 1.

3. Connect control cables (DF-870 only):

Be sure to turn off the power before connecting or disconnecting the control cable. Be careful not to connect the cable to the wrong connector.

1. Connect control cable 1 of folding plate 1 to connector 1.

2. Connect control cable 2 of folding plate 2 to connector 2.

4. Store the guide plate unit and cross folding lever:

1. Open the top cover gently.

2. Store the guide plate unit on the magnet inside.

3. Store the cross folding lever by inserting it into the storage pillar.

5. Connect the power cord:

WARNING: Do not touch the power plug with wet hands.

1. Install the power cord to the machine’s power inlet.

2. Connect the power plug to the outlet.

External Parts:

(*) DF-850 only

Inside Top Cover:

(*) DF-870 only

Paper Feed Section:

(*) DF-870 only

Ejecting Section:

The control panel consists of an LCD display and various keys to operate the machine.

(*1) DF-870 only

Paper Condition:

Make sure that the printing ink on the paper has dried completely prior to use. If used while wet, the folding roller or paper may become dirty. Paper with special ink may cause swelling of rubber rolls, leading to misalignment.

If curled paper is used, it may not feed smoothly or fold properly. Flatten the paper prior to use.

When folding B6 size paper or less (EU), fine quality paper of 64 g/m²/17.1 lb or thicker may not eject properly.

Fan paper well prior to use.

Stacking Precautions:

Do not stack paper on the feed tray with the left and right sides unaligned or with some sheets protruding. This can cause folding misalignment and jamming.

Do not stack paper with the lead and tail edges unaligned. This will result in unstable feeding, paper feed errors, and folding misalignment.

When stacking just a few sheets, lower the paper set lever while pressing the lead edge of the paper against the guide plate.

For model DF-850:

1. Connect the power cord.

2. Turn on the power.

3. Stack the paper.

4. Position the rough/fine adjustment knobs for Folding Plate 1 and 2.

5. Position the paper feed pressure adjustment lever.

6. Position the stacker roller.

7. Perform a test fold.

8. Set the counter.

9. Start the process.

10. When the process ends, turn off the power.

11. Disconnect the power cord.

For model DF-870:

1. Connect the power cord.

2. Turn on the power.

3. Stack the paper.

4. Select the paper size.

5. Select the folding mode.

6. Position the paper feed pressure adjustment lever.

7. Position the separation pressure adjustment dial.

8. Perform a test fold.

9. Set the counter.

10. Start the process.

11. When the process ends, turn off the power.

12. Disconnect the power cord.

1. Turning Power On/Off

Make sure the power plug is connected. WARNING: Do not touch the plug with wet hands.

To turn ON: Set the power switch to the “I” side. The machine will start an initial operation.

To turn OFF: Set the power switch to the “O” side.

2. Stacking Paper

CAUTION: Do not put fingers inside during operation. Keep away long hair, ties, jewelry and loose clothing.

1. Open the paper reception plate.

2. Open the support paper feed plate. (Always open the reception plate first to avoid damage).

3. Loosen the guide fixing screws.

4. Open the paper feed guides.

5. Lift the paper set lever.

6. Stack paper (max height 46 mm/1.8 inches) in the center of the feed tray. Insert it until it lightly bumps the guide plate.

7. Align the paper feed guides to lightly bump the sides of the paper. Do not press too hard.

8. Tighten the guide fixing screws on both sides.

9. Lower the paper set lever to raise the paper tray. Always lower this lever before starting.

3. Selecting Paper Size and Fold Mode

For DF-850: Manually adjust the rough and fine adjustment knobs on folding plate 1 and 2 to the scale markings for your paper size and desired fold type.

For DF-870: Use the (custom folding) key to cycle through paper sizes ([A3] → [B4] → etc.) and the (folding mode) key to cycle through fold types ([SingleFold] → [DoubleFold] → etc.) on the LCD display.

4. Adjusting Paper Feed Pressure

DF-850: Set the lever to ≡ (thin paper). If paper mis-feeds, move it towards the thick paper setting.

DF-870: Set the lever to [0]. If paper mis-feeds, move it to [1]. If paper overlaps, move it to [-1].

5. Aligning Stacker Roller and Separation Pressure (DF-870)

The stacker roller position is set automatically on the DF-870. You can fine-tune it via the control panel if paper ejects poorly.

For separation pressure, open the top cover and set the dial to [0.]. If multiple sheets feed (double-feed), increase the pressure gradually towards [1] or [2.].

6. Performing a Test Fold

Press the (test) key. Two sheets of test-folded paper will be ejected. Confirm the fold is correct. If not, refer to “Adjusting Misalignment”.

7. Setting the Counter and Starting the Operation

Press the (count) key to set a number for subtract count mode, or leave it at 0000 for add count mode.

Press the (start) key to begin folding. Press the (stop) key to pause, and (start) again to resume. The machine stops automatically when the paper runs out or the subtract count is reached.

Using the Bearing Support Lever for Thick Paper:

When using thick paper, use the bearing support lever to hold down the bearing, which prevents the rubber roller from floating up.

1. Open the top cover.

2. Rotate the bearing support levers (on both operations and reverse operations sides) in the direction of the arrow to hold the bearing down.

3. Close the top cover. Remember to remove the lever support after processing is finished.

Double Folding of Thick Paper (e.g., fine quality paper 104.7 g/m²/27.9 lb):

1. Perform the standard paper stacking and pressure adjustment steps.

2. Lift up the stacker roller by hand and lift the levers (two locations) to let the stacker roller float above the belt surface.

3. Set the stacker roller position to [5] (or adjust to [4] or [3] if ejection is not smooth).

4. Perform a test fold and confirm smooth ejection.

5. Perform the full folding operation. The recommended processing speed is slower.

6. After the operation is ended, return the stacker roller to position [1] and lower the levers.

Double Folding of B6 Size Paper:

When B6 paper (64.0 g/m² to 81.4 g/m²) jams during double-folding, use the attached guide plate unit.

1. Open the top cover.

2. Remove the guide plate unit from its storage location.

3. Attach the guide plate unit in the position shown in the manual’s diagram.

4. Follow standard folding procedures, setting the stacker roller position to [4] (or [5] if ejection is not smooth).

5. After operation, store the guide plate unit in its original location.

Custom Folding of Standard Size Paper:

This allows you to specify custom fold positions.

1. Manually prepare a folding sample with the paper you intend to use.

2. Measure the folding position dimensions of your sample: Dimension A (for folding plate 1) and Dimension B (for folding plate 2).

3. Set up the machine:

DF-850: While pulling up the rough adjustment knob, align it to the scale mark corresponding to your measured Dimension A. Repeat for folding plate 2 with Dimension B.

DF-870: Press the key to set the paper size to [CF] (Custom Fold). Enter your measured Dimension A and B values using the control panel keys.

4. Align the stacker roller position according to the finished size of your folded paper (refer to the table in the manual).

5. Perform a test fold and then run the operation.

Standard Folding of Non-Standard Size Paper:

1. Measure the length (L) of your non-standard paper.

2. Stack the paper.

3. Set up the machine:

DF-850: Use the “Rough adjustment knob set position table” in the manual to calculate the required knob position based on the paper length (e.g., for a letter fold, plate 1 is L/3, plate 2 is L/3). Align the knobs to the calculated scale value.

DF-870: Press the key to set paper size to [LP] (Non-standard). Press the key to select the desired standard fold type (e.g., LetterFold). Enter the measured paper length using the control panel.

4. Proceed with test folding and operation as normal.

Cross folding is when a single fold or letter fold is performed, and then the paper is folded again. The paper size for cross folding is A3, B4, A4, B5 (EU) / LGR, LGL, LTR, STMT, INV (NA). Paper cannot be stacked lengthwise.

1. First, perform a single fold on your stack of paper according to the standard folding procedures.

2. Take the stack of single-folded paper and firmly press down the folding line with your fingertips to ensure it is crushed flat.

3. Stack the single-folded paper back in the paper feed tray. The stacking height should be about half the normal amount (25 mm/0.98 inch). The fold line side should point toward the reverse operation side.

4. Set the paper size and folding mode for the second fold (a single fold). Refer to the “Paper size setting table” in the manual for the correct settings (e.g., for a B4 cross single fold, the machine setting is a B5 single fold).

5. Position the auxiliary paper feed ring. Open the top cover, use the L-shaped hex wrench to loosen the screws on the auxiliary paper feed ring, move the ring so it is on the paper folding line, and tighten the screws.

6. Attach the cross folding lever. Attach it to the pillar on the paper feed guide so that the weight roller on its tip is on the fold line.

7. Perform a test fold and then run the full operation.

8. After the operation is ended, store the cross folding lever and return the auxiliary paper feed ring to their original positions.

Art Paper / Coated Paper:

This paper can stick together, causing two-sheet feeds.

Carefully separate and arrange the paper before stacking.

Stack a smaller volume of paper in the feed tray (about half the height of the guides).

Adjust paper feed pressure: DF-870 set to [3] or higher; DF-850 set to the thick paper setting.

Adjust separation pressure (DF-870 only): Set to [2.5] and increase by 0.5 if two-sheet feed persists.

If mis-feeds continue, set [Feed Time] to [Long] in the menu. Remember to restore all settings to normal after finishing the job.

Rough Paper / Recycled Paper:

This paper may lack stiffness.

Carefully separate the paper before stacking.

Set the processing speed to low to avoid wrinkling.

Set the paper feed pressure to low to avoid two-sheet feeds.

B7, A6 Size Paper (For EU):

These can only be processed under specific conditions:

Paper stacking orientation: Vertical stacking

Folding form: Single fold

Keep the processing speed as low as possible to prevent chaining (hooked feeds).

Correcting Up/Down Misalignment (Vertical):

This is corrected by making fine adjustments to the folding stopper position.

Use the tables in the manual (Chapter 3, section 6-1) to determine the correct adjustment. For example, for a single fold where the top surface (A) is too long:

DF-850: Rotate the Fine adjustment knob for folding plate 1.

DF-870: Press the (folding stopper 1 adjustment) key, select [F1 Adjust], and press the down arrow key.

Follow the same logic for other fold types and for folding plate 2, as detailed in the manual’s tables.

Correcting Left/Right Misalignment (Horizontal):

This is corrected using the slant correction knob.

1. Check the folded paper to see which way it is misaligned (e.g., slanted to the left or right).

2. Rotate the slant correction knob in the direction of the arrow shown in the diagram to adjust the alignment.

3. After the operation is finished, return the slant correction knob to its original position, where the pin aligns with the round hole in the paper feed tray.

Make sure you disconnect the power cord before cleaning. Do not use flammable sprays or solvents.

Cleaning Rubber Roll:

1. Remove the folding plates.

2. Open the top cover.

3. While rotating the rubber roller by hand (or with the jam correction knob on DF-870), wipe it down with an alcohol-saturated cloth.

Cleaning Paper Feed Rings:

1. Open the top cover.

2. While rotating the paper feed ring by hand, wipe it down with an alcohol-saturated cloth.

Cleaning Paper Separator:

1. Open the top cover.

2. Insert an alcohol-saturated cloth between the center paper feed ring and the paper separator.

3. Rotate the paper feed ring to clean the separator.

Cleaning Sensors:

If the detection function fails, the sensors may be dirty. Use a dust removal spray to clean the paper sensor and the paper exit sensor.

Cleaning Paper Ejection Belts:

1. Lift up the stacker roller by hand and lift the levers to let it float.

2. Slowly push the stacker roller to the [6] position.

3. While rotating the paper ejection belts by hand, wipe them with an alcohol-saturated cloth.

4. Return the stacker roller to its original position.

Error Relating to Cover and Folding Plate:

Paper Jam Error:

If paper jam errors persist, clean the sensors.

Motor Error:

Other Errors:

(*) DF-870 only

Errors Requiring a Service Call:

If the following error codes are displayed, turn the power off and on. If the error is not solved, contact your dealer: E2220, E2400 (*), E2401 (*), E2410 (*), E2411 (*), E2420 (*), E2421 (*), E4210.

Jam at Paper Feed Ring:

1. Raise the paper set lever to lower the paper feed tray.

2. Pull the jammed paper towards you.

Paper Coiled Around a Rubber Roller:

1. Open the top cover.

2. If the bearing support lever is engaged, rotate it to release the bearing.

3. Pull the coiled paper towards you to remove it. For DF-850, if it doesn’t come out, use both hands to rotate the roller while removing the paper. For DF-870, turn the jam correction knob while removing the paper.

4. Return the bearing support levers to their original position.

Jam in Folding Plates (DF-850):

1. Turn off the power.

2. Remove the affected folding plate (1 or 2).

3. Remove the jammed paper.

4. Re-attach the folding plate and ensure it is correctly attached.

Jam in Folding Plates (DF-870):

With the (stop) key pressed down, press the C key to forcibly eject the paper. If this does not work, follow the DF-850 procedure above.

Jam in Ejecting Section:

With the (stop) key pressed down, press the (start) key to forcibly eject the paper. If paper still cannot be obtained, locate and remove the jammed paper by hand.

Handling of Abnormal Fold:

If paper does not fold correctly:

Do not use paper outside of specifications, especially thin paper lacking stiffness.

When abnormal folding occurs, lower the processing speed.

Carefully separate the paper before stacking it.

Check that the folding plate is correctly attached.

If static electricity is suspected, use a commercially available static electricity removal spray on the rubber roller.

Handling of Mis-Feed:

A mis-feed is when paper fails to feed into the machine.

Increase the paper feed pressure. Check the paper feed state and raise the paper feed pressure adjustment lever one step at a time.

Before stacking, carefully separate the paper.

Reduce the paper stacking volume.

Handling of Chaining (Hooked Feeds):

Chaining is when the next sheet of paper feeds linked to the previous one.

Increase the separating pressure (DF-870 only).

Check the paper feed state and adjust pressure levers as needed.

Before stacking, carefully separate the paper.

Reduce the paper stacking volume.

Basic Specifications:

(*1) Fine quality paper 64 g/m²/17.1 lb (Equivalent to 500 sheets)
(*2) Including accessories

Media Specifications:

(*) For paper less than 182 mm/7.16 inches long, only single fold is applicable on specific paper weights.

Performance and Functions:

(*1) Limits on folding form depend on paper quality and size.
(*2) Speed for A4 fine quality paper (long paper) of 81.4 g/m², single fold.
(*3) 52.3 g/m² or less Y grain paper cannot be used.
(*4) Rough paper Y grain is outside specifications.
(*5) Fine quality paper 52.3 to 104.7 g/m².
(*6) Maximum finish length is 216 mm/8.50 inches or less.