FREE ENGLISH DUPLO DF-999A (01) PDF USER GUIDE
FREE ENGLISH DUPLO DF-999A (01) PDF USER MANUAL
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FREE ENGLISH DUPLO DF-999A (01) PDF OWNER MANUAL
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FREE ENGLISH DUPLO DF-999A (01) PDF REFERENCE MANUAL
FREE ENGLISH DUPLO DF-999A (01) PDF INSTRUCTION MANUAL
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What do the symbols in the manual mean?
In this manual, several symbols are used to indicate important warnings. These symbols 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.
Lightbulb Icon: Indicates supplementary or useful information.
Book Icon: Describes names of related items and supplementary instructions.
What are the power supply requirements?
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: 100 W
Rated current: 1.0 to 0.5 A
What is the required operating environment for this unit?
Operate this unit in the following environment:
where the temperature range is between 5 and 35°C/41 and 95°F (−10 to 50°C/14 to 122°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
where the unit is kept away from air-borne salt
where the unit is kept away from harmful chemicals
where the unit is not exposed to water
What should I do if the WARNING or CAUTION labels on the machine become dirty or lost?
“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.
What are the main features of this machine?
This machine is designed to fold paper into six popular folding modes: Single fold, Double fold, Irregular accordion fold-out, Letter fold, Accordion-fold, and Gate fold.
Use the cross fold lever to fold single folded paper further into standard folding.
Use the DF HAND FEED KIT (option) to bind and fold at maximum three sheets of paper simultaneously.
What precautions should be taken before installation?
Do not fall down the folding plates. Make sure the folding plates are not subject to shock. Otherwise, the folding plates may damage, resulting in poor folding accuracy.
The machine may make loud sounds while operating according to the processing speed and paper used due to its paper-folding mechanism.
Be sure to move this machine with the bottom surface of this machine held by two persons.
What accessories are included with the machine?
| No. | Name | QTY DF-999/DF-999A | QTY DF-990/DF-990A | Function |
|---|---|---|---|---|
| [1] | Cross fold lever | 1 | 1 | For holding down the folded paper when cross fold. |
| [2] | Auxiliary paper ejection guide | 1 | 1 | Attached to the stacker roller at the ejecting section. |
| [3] | Folding plate 1 | 1 | 1 | Attached to the upper right section on the operator’s side. |
| [4] | Folding plate 2 | 1 | 1 | Attached to the lower left section on the operator’s side. |
| [5] | Paper support guide | 1 | 1 | Attach it to the paper receiving tray from the paper ejecting section. A4/LT size fine quality paper of 64 g/m²/43.52 lbs, 81.4 g/m²/55.35 lbs will be well in alignment by using this paper support guide at the time of paper ejection for letter fold or accordion fold. |
| [6] | T-handle hexagonal wrench | 1 | 1 | Used when moving the auxiliary paper feed ring. Do not use the T-handle hexagonal wrench for a purpose other than handling the auxiliary paper feed ring as instructed in this manual. |
| [7] | Scale label | 1 | 1 | Used to measure non-standard size paper. Attach the scale. |
| [8] | Instruction manual | 1 | 1 | This manual |
| [9] | Safety Guide A | 1 | 1 | Contains information for correct and safe use of this machine. |
| [10] | DECLARATION OF CONFORMITY | 1 | 1 | For EU |
| [11] | WEEE Statement | 1 | 1 | For EU |
| [12] | Statement of Electromagnetic Compatibility (EMC) | 1 | 1 | For NA |
| [13] | Power cord | 1 | 1 | For EU |
| [14] | Power cord | 1 | 1 | For NA |
How do I perform the initial setup and installation?
1. Open the side cover.
2. Remove the tape fixing the lever. Be sure to remove this tape, otherwise the machine cannot detect the presence of folding plate 2.
3. Check that the folding stopper does not protrude from the cover on the paper feeding side of the folding plate 2. If it does, rotate the gear in the direction of the arrow to move the folding stopper to the inner section. Do not hold the belt section of folding plate 2, as this can cause a malfunction.
4. Hold folding plate 2 by the labeled areas and insert it into the machine. Insert it with its rollers [A] moving along the rails [B] of the machine. Ensure it is attached properly.
5. Store the T-shape hexagonal wrench accessory in its designated position inside the machine.
6. Close the side cover.
7. Open the support paper feed tray to the left side from the operator’s viewpoint.
8. Insert folding plate 1 into the main body of the machine along with the set guide. Hold it with both hands. If it’s not easy to attach, check that the gear on the reverse side rotates in the front-back direction.
9. Open the top cover gently to avoid injury.
10. Rotate the jam correction handle to check that the folding roller rotates smoothly.
11. Place the cross fold lever in its specified place and direction. Failure to do so may result in damage to the folding roller.
12. Close the top cover.
13. Open the paper receiving tray to the right side from the operator’s viewpoint.
14. Attach the auxiliary paper ejection guide to the stacker roller.
How do I connect the power cord?
1. Install the power cord to the machine.
2. Connect the power plug to the outlet.
WARNING: Do not touch the power plug with wet hands. Otherwise electric hazards may occur.
What should I consider when checking the machine’s operations?
Use the paper that will be actually used when checking operations.
The folding position may be subtly different from the shipment settings due to the thickness and stiffness of the paper. The position may also vary depending on the purchase season of the paper, even if it’s the same size.
What are the external parts of the machine and their functions?
| No. | Name | Function |
|---|---|---|
| [1] | Control panel | Use this panel to enter information to operate the machine. |
| [2] | Power switch | Turns the machine on and off. |
| [3] | Side cover | Safety cover to prevent the user from touching the moving parts. |
| [4] | Power inlet | Connector for the power cord. |
| [5] | Support paper feed tray | For ensuring paper are stacked on the paper feed tray properly. |
| [6] | Paper feed tray | For stacking the paper to be folded. |
| [7] | Top cover | Safety cover to prevent the user from touching the moving parts. The top cover keeps hands or fingers from being caught and injured by braking the opening or closing motion. |
| [8] | Folding plate 1 | Guide plate for deciding the paper folding position. |
| [9] | Folding plate 2 | Guide plate for deciding the paper folding position. |
| [10] | Paper set lever (DF-990/DF-990A) | This lever is used to move the paper feed tray up and down when stacking paper. |
What are the internal parts of the paper ejecting section and their functions?
| No. | Name | Function |
|---|---|---|
| [1] | Stacker lever | This is the lever that supports the stacker roller. The height of the roller can be adjusted. |
| [2] | Ejecting section | For receiving folded paper ejected out. |
| [3] | Paper receiving tray | For stacking ejected paper. |
| [4] | Stacker belt | For ejecting folded paper. |
| [5] | Stacker roller | It holds down the ejected paper and supports conveyance of paper. |
| [6] | Auxiliary paper ejection guide | Used to hold the ejected paper. |
| [7] | Paper support guide | A4/LT size fine quality paper of 64 g/m²/43.52 lbs, 81.4 g/m²/55.35 lbs will be well in alignment by using this paper support guide at the time of paper ejection for letter fold or accordion fold. |
What are the internal parts under the top cover and their functions?
| No. | Name | Function |
|---|---|---|
| [1] | Feeding pressure adjustment lever | For adjustment the paper feed pressure. |
| [2] | Guide fixing screw | For securing the paper feed guide. |
| [3] | Skew correction knob | For correcting skewed paper feed. |
| [4] | Paper feed guide | For holding paper stacked on the paper feed tray firmly. |
| [5] | Paper separator | Located underneath the paper feed ring, and prevents double-feed (feeding of multiple sheets of paper at a time). |
| [6] | Cross fold lever | For holding down the folded paper when cross fold. |
| [7] | Auxiliary paper feed ring (movable) | Functions in the same way as the auxiliary paper feed ring. The position can be adjusted in accordance with paper size in cross fold. |
| [8] | Paper feed ring | The main paper feed ring. Ensures smooth feeding of paper in combination with the paper separator. |
| [9] | Auxiliary paper feed ring | For holding down curled paper for reliable paper feed. |
| [10] | Folding roller | These rollers are used to fold paper. This machine is equipped with four rollers to make six types of folding. |
| [11] | Jam correction knob | For rotating the folding rollers when paper has jammed inside the machine or when cleaning the machine. |
| [12] | Separating pressure adjustment dial | For adjustment the paper separating pressure. |
What are the parts and functions of the optional DF HAND FEED KIT?
| No. | Name | Function |
|---|---|---|
| [1] | Manual feed top cover | Safety cover to prevent the user from touching the moving parts. The top cover keeps hands or fingers from being caught and injured by braking the opening or closing motion. |
| [2] | Manual paper feed tray | Stack paper to be fed manually and folded. |
| [3] | Manual skew correction knob | For correcting skewed paper feed. |
| [4] | Auxiliary feed guide | Subordinately guides sheets so that the paper will be fed properly. (magnet type). |
| [5] | Manual feed guide | Guides sheets so that the paper will be fed properly. |
What are the functions of the keys and indicators on the Control Panel?
| No. | Name | Function |
|---|---|---|
| [1] | LCD touch panel | Menu and error messages are displayed. Touch to operate. |
| [2] | Folding plate paper ejection key | Press and hold to forcibly eject paper from inside the folding plate. |
| [3] | Lamp | When the machine is in the power saving mode, the lamp blinks slowly. When a message requiring service personnel is displayed, the lamp blinks faster. |
| [4] | (start) key | Press to start paper folding. |
| [5] | (stop) key | Press to stop paper folding. |
| [6] | (test) key | Press to test fold. By testing the paper feed, the machine will remember the thickness of the paper. |
| [7] | Paper ejection key | Press and hold to forcibly eject paper from inside the machine. |
| [8] | Separating pressure adjustment scale | This scale is used when adjusting the separating pressure. |
| [9] | Paper feed pressure adjustment scale | This scale is used when adjusting the paper feed pressure. |
What are the cautions for using the touch panel?
The touch panel is designed to touch lightly with a finger or a pen (its tip radius is 0.8 or smaller). Do not press the panel strongly with a finger or push it with any sharp objects (such as a fingernail, ball-point pen, and pin).
If you perform the following operations, the touch panel may not work even though you are touching it. Additionally, note that such operations may cause malfunction of the machine.
Operation with the tip of a nail
Operation with a foreign object placed on the touch panel
Operation with a protective sheet or sticker applied on the touch panel
Operation with the touch panel being wet
Operation with a finger wet with sweat or water
What do the different buzzer sounds indicate?
In this machine the buzzer sounds in confirmation when setting on the control panel or paper runs out on the paper feed tray. Classification of the sounds is as follows.
“pi”: Operational sound at the time of normal key operation
“pipi”: Warning alarm at the time of mis-operation, mis-feed of paper, or paper empty
“pii”: At the start of folding operation or end of normal folding operation. Saves changes in various settings. The time when you set the alarm has come.
“piipii”: At the occurrence of an error such as paper jam
“piipiipiipii”: At the occurrence of an error to be asked for Duplo dealer’s assistance
What paper types and sizes can be used with this machine?
Paper type: Fine quality paper: 46.5 to 157 g/m² / 31.62 to 106.76 lbs. Rough paper, Stencil paper, Recycle paper, Specific art paper, Specific coated paper
Paper size
Standard Paper: The standard paper can be used only when it is stacked in the machine direction. A3/B4/A4/B5/A5/B6 (For EU), LGR/LGL/LTR/STMT/INV (For NA)
Non-standard paper:
[a] 74 to 311 mm/2.91 to 12.24 inches (Width)
[b] 105.0 to 457.2 mm/4.13 to 18.0 inches (Length)
Some limitations in setting and paper quality may be applied depending on paper size. The A6, A7, or B7 paper can be used as non-standard paper (For EU).
What paper cannot be used with this machine?
Paper out of specifications
Curled paper
Wavy paper
What precautions should be taken when handling paper?
Paper used:
Make sure that the printing ink on the paper has dried completely prior to use.
Wet ink or ink that is not completely dried may stain the folding roller causing trouble such as smearing on paper.
Use of paper printed with special types of ink may cause the folding roller to swell or deform, and folding misalignment may occur.
Paper may not be fed smoothly into the folding plate or deformed folding may occur depending on different environmental factors (temperature, humidity), paper ream weight, paper type, paper grain direction if curled paper is used. Make sure to flatten curled paper or paper with folded lines before use.
Separate the sheets of paper well before stacking them.
Precautions on stacking paper:
[a] Do not stack the sheets of paper on the paper feed tray with the sides of sheets unaligned or some sheets protruding from the stack. This machine has an automatic standard paper size detection function. It automatically detects paper size at the paper feed guides. Therefore, if paper is protruding out from the left or right side, it is unable to detect paper size accurately and may determine standard paper as non-standard. (DF-999/DF-999A)
[b] Do not stack paper on the paper feed tray with the lead and trail edges unaligned or some sheets protruding out.
Processing with sheets unaligned on the right or left side may cause such trouble as folding misalignment and jamming.
Processing with sheets unaligned on the lead and trail edges may lead to unstable feed causing such trouble as mis-feed and double-feed.
What is the basic operational workflow?
The flowchart below illustrates the flow of basic operation.
1. Connect the power cord.
2. Turning on the power.
3. Stacking paper.
4. Basic settings.
5. Paper size setting (DF-990/DF-990A).
6. Folding mode selection.
7. Adjustment of feed pressure/separating pressure.
8. Processing speed setting.
9. Positioning of paper receiving tray.
10. Test folding.
11. Counter setting.
12. Process start.
13. Process end.
14. Turning off the power.
15. Disconnect the power cord.
How do I turn the machine on and off?
Turning on power:
Make sure the power plug is connected to the wall socket. Set the power switch to the “I” side.
WARNING: Do not touch the power switch with wet hands. Otherwise electric hazards may occur.
Turning off power:
Set the power switch to the “O“ side.
How do I stack paper in the machine?
CAUTION: Do not put fingers inside during operation. Keep away long hair, ties, jewelry and loose clothing. It could cause injury.
Note: Steps 1 and 6 are not necessary with the DF-999/DF-999A. Move on to steps 2 to 5.
1. Raise the paper set lever. The paper feed stand will come down to the paper stacking position.
2. Loosen the guide fixing screw.
3. Stack paper on the paper feed tray. Push in the paper until the lead edge touches the paper feed inlet lightly. Maximum paper stacking height: 46 mm/1.81 inches.
4. Adjust the paper feed guide to match the paper size. Set the paper feed guide so that it touches the paper lightly. Do not press too strongly. For DF-999/DF-999A, if the guides are positioned incorrectly, the automatic paper size detection function will not work.
5. Tighten the guide fixing screws on both right and left sides. If not fixed, the guide may move during operation, causing misalignment.
6. Lower the paper set lever. The paper feed stand will go up to the paper feeding position. For DF-990/DF-990A, if the tray is not set at the feed position, an error will be displayed and operation will not start.
Automatic rise/descent of the paper feed tray (DF-999/DF-999A):
When paper is stacked, the paper feed guides are set, and the start or test key is pressed, the paper feed tray rises automatically. When using large or heavy paper, the tray may become over-stacked and not rise due to weight. In such cases, stack less paper.
The paper feed tray descends automatically when paper is removed or runs out. If the [Detection] setting is turned off, the tray will descend automatically when operation stops, even if paper is still on the tray.
How do I perform a standard fold on standard paper?
This procedure is for folding standard paper using the pre-set standard folding modes. An example using A4 paper and “Single Fold” is described.
CAUTION: Do not put fingers inside during operation. Keep away long hair, ties, jewelry and loose clothing.
1. Touch the “Basic Settings” key (four squares icon) on the [Ready] screen.
2. Touch the [Standard Fold] key.
* For DF-999/DF-999A: The Folding Mode setting screen is displayed. Proceed to step 4. If paper size isn’t displayed, the paper feed guide is positioned incorrectly.
* For DF-990/DF-990A: The Standard Paper Size setting screen is displayed.
3. (DF-990/DF-990A only) Touch the key for your paper size (e.g., [A4]).
4. Touch the key for the desired folding mode (e.g., single fold icon). Return to the Ready screen.
5. Set the feeding pressure adjustment lever to [0]. As the scale value increases, the pressure increases. If mis-feed occurs, increase pressure to [1]. If double-feed occurs, lower pressure to [-1].
6. Set the separating pressure adjustment dial to [0]. As the scale value increases, separating pressure increases. If double-feed occurs, increase the pressure by 0.5 on the scale.
7. Touch the processing speed keys (◄◄- or ►►+) to set the speed. If processing thick paper, use a slower speed (“Thick paper mode”). If using thin paper, use a slower speed (“Thin paper mode”).
8. Adjust the position of the paper receiving tray. Set to [A] to stack diagonally or [B] to stack straight.
9. If applicable, attach the paper support guide [A] to the paper receiving tray.
10. Press the (test) key. Test folded paper is not counted.
* For DF-999/DF-999A: If the machine does not start, check that the paper feed guide is set correctly.
* For DF-990/DF-990A: If the machine does not start, check that the paper set lever is lowered.
11. Check the finish of the test fold for any misalignment.
12. Touch the (No. of Sheet setting) key to display the number of sheets input screen.
* Count up: Touch the key. After setting the counter to [0], start operation. If you press start without setting to [0], it increments from the current value.
* Count down: Using the numeric keypad, enter the number of sheets to be folded, then touch the return key. The machine will stop after folding the set number of sheets.
13. Press the (start) key to start folding. Press the (stop) key to interrupt or stop. If paper runs out, the machine will go on standby; after restacking, press the start key to continue.
How do I properly store the machine when it is not in use?
1. Turn off the power switch. WARNING: Do not touch the power switch with wet hands.
2. Disconnect the power plug from the outlet. WARNING: Do not touch the power plug with wet hands.
3. Remove the power cord from this machine.
4. Close the support paper feed tray.
5. Remove the auxiliary paper ejection guide and paper support guide. Store them with caution to avoid losing them.
6. Return the height of the stacker roller to the standard position.
7. Hang the hook section of the paper receiving tray.
8. Hang the auxiliary paper ejection guide on the paper receiving tray.
How do I correct folding misalignment in the right and left direction?
When the folded paper is misaligned along the sides, correct it using the skew correction knob of the paper feed tray.
1. Check that the paper feed guides are set correctly. Gaps can cause misalignment.
2. Remove the paper stacked on the paper feed tray.
3. Rotate the skew correction knob to adjust:
* For misalignment A (right side feeds late): Rotate the knob clockwise. The leading edge on the right side will be fed earlier.
* For misalignment B (left side feeds late): Rotate the knob counterclockwise. The leading edge on the left side will be fed earlier.
4. Stack paper on the paper feed tray again, touching the guide plate lightly.
5. Tighten the guide fixing screw on the paper feed guide.
6. Perform a test folding to check the correction.
7. After completing folding operations, return the skew correction knob to the standard position (pin in round hole).
How do I correct folding misalignment in the up and down direction (along the vertical length)?
When the folded paper is misaligned along the vertical length, adjust the positions of the folding stoppers of folding plates 1 and 2.
Adjustment Method:
1. Touch the (Adjustment) key on the [Ready] screen. The [Fold Position] screen is displayed.
2. Use the adjustment keys for Folding A (plate 1) and Folding B (plate 2) to correct the position:
* The folding stopper moves 0.1 mm/0.004 inch each time you press the adjustment key.
* Press and hold the key to change the value continuously within the setting range.
* You can also touch the value display (e.g., [A:x.x mm]) to input a value manually with the numeric keypad.
3. The changed value is cleared when power is turned off. To save it for future use:
* For standard folding of standard paper: touch the (Save) key, then press and hold the (Save) key again to save the adjustment value.
* For standard folding of non-standard paper or custom folding: touch the (Save) key, then touch the (Custom folding) key, then select and save to a custom fold data number.
What should I do if the paper is folded deformably?
The paper may not be folded properly due to the characteristics of paper. In such cases, check the following points:
Do not use paper outside the specifications. Particularly, deformed folding occurs frequently with thin, flimsy paper.
Lower the processing speed when deformed folding occurs for thin and flimsy paper.
Separate paper well prior to stacking.
Stack paper on the paper feed tray after aligning well, and set the paper feed guides at the correct positions. Also tighten the fixing screws of the paper feed guides firmly.
How do I perform a standard fold on non-standard paper?
This method allows you to perform standard fold types on paper sizes that are not pre-programmed by inputting the paper length.
Example: Performing a letter fold on 300.0 mm length paper.
1. Touch the (Basic settings) key on the [Ready] screen, then touch [Standard Fold for Non-Standard Size].
2. Using the numeric keypad, enter the paper length [300] and touch the (Return) key.
3. Touch the (letter fold) key. You will return to the [Ready] screen with the settings applied.
Note: Standard paper stacked in the long edge feeding direction is considered non-standard paper.
How do I perform a custom fold?
Custom folding allows you to fold paper at any position by specifying the folding lengths for folding plates 1 and 2.
1. Prepare a folding sample manually using the paper to be folded.
2. Measure the length of each fold on the sample (length A and length B).
3. On the [Ready] screen, touch the (Basic settings) key, then the (Custom folding) key.
4. Touch the (Paper size) key. For DF-999/DF-999A, the [Create New Custom Fold] screen appears; proceed to step 6. For DF-990/DF-990A, the [Size] screen appears.
5. (DF-990/DF-990A only) Select the paper size or input the paper length manually.
6. On the [Create New Custom Fold] screen, you can touch the (Folding mode selection) key to select a standard fold as a base, or input values manually.
7. Touch the [A: xxxx.x mm] key, use the numeric keypad to enter the measured folding A length, and touch the return key.
8. Touch the [B: xxxx.x mm] key, use the numeric keypad to enter the measured folding B length, and touch the return key.
9. To save the custom fold setting, touch the (Save) key. The [Save] screen will be displayed. Proceed to step 10. To continue without saving, touch the (Return) key.
10. On the [Save] screen, select an open data slot and touch the (Save) key again. The input value is saved, and the display returns to the [Ready] screen.
How do I edit, use, lock, or delete saved custom fold data?
Editing Saved Data:
1. From the [Ready] screen, navigate to the [Custom Fold] saved data selection screen.
2. Select the data number you want to edit and touch the (Edit) key.
3. On the edit screen, you can change the paper length or the folding A/B dimensions.
4. After making changes, save the data as you would a new custom fold.
Using Saved Data:
1. From the [Ready] screen, navigate to the [Custom Fold] saved data selection screen.
2. Touch the data number you want to use (e.g., [06]), then touch the (Open) key. The saved data is loaded, and the display returns to the [Ready] screen.
Locking Saved Data:
1. From the [Ready] screen, navigate to the [Custom Fold] saved data selection screen.
2. Select the data number you want to lock and touch the (Lock/Unlock) key. A lock icon will appear. To unlock, press and hold the key again.
Deleting Saved Data:
1. Locked data cannot be deleted. Unlock it first.
2. From the [Ready] screen, navigate to the [Custom Fold] saved data selection screen and touch the (Switch to save screen) key.
3. Select the data number you want to delete and press and hold the (Delete) key. The data will be deleted.
How do I perform a cross fold on standard paper?
Cross fold is folding a single-folded paper a second time. The maximum paper thickness is fine quality paper 104.7 g/m²/71.20 lbs.
Stacking Paper for Cross Fold:
1. Perform a single fold on standard paper following the standard procedure.
2. Press the folded line of the single-folded paper firmly with your fingertip.
3. (DF-990/DF-990A only) Raise the paper set lever.
4. Loosen the guide fixing screw.
5. Stack the single-folded paper on the paper feed tray with the folded line toward the non-operator’s side. Stack about half the height of the paper feed guide (approx. 25 mm/0.98 inch).
6. Attach the paper feed guide lightly to the side of the paper and tighten the fixing screws.
7. (DF-990/DF-990A only) Lower the paper set lever.
Adjustment of Parts:
1. Turn off the power switch.
2. Disconnect the power plug and take the T-handle hexagonal wrench.
3. Open the top cover.
4. Loosen the screw of the auxiliary paper feed ring (for moving) using the T-handle wrench.
5. Move the auxiliary paper feed ring so that it will be on the folding line of the paper.
6. Tighten the screw. Store the T-handle wrench in its original position.
Operation:
1. Set the separating pressure adjustment dial to [0].
2. Set the feeding pressure adjustment lever to [3] (within the range of [3] to [5]).
3. Take out the cross fold lever.
4. Attach the cross fold lever to the paper feed guide on the left side, so the weight roller is on the folding line.
5. Close the top cover and turn on the power.
6. Set the machine for the second fold (e.g., single fold again).
7. Press the test key to execute a test fold and check the result.
How do I handle special paper like art, coated, rough, or recycled paper?
Art paper, coated paper:
These papers often stick together, leading to double-feeds. Follow this procedure:
1. Separate the paper well.
2. Align the paper.
3. Stack the paper on the feed tray, but do not stack too many sheets (approx. half the height of the feed guide, 25 mm/0.98 inch).
4. Attach the paper feed guide.
5. Set the feeding pressure adjustment lever to [3] (or [4] or [5] if mis-feeds occur).
6. Set the separating pressure adjustment dial to [2.5]. If double-feed occurs, increase by [0.5] at a time.
7. Press the test key and check the finish. If folding is abnormal, decrease the processing speed.
8. After finishing, return the paper feeding and separating pressures to [0].
Rough paper, recycled paper:
These papers can be thin, flimsy, and curl easily. Pay attention to the following:
Separate the paper well before stacking.
Set the processing speed as low as possible to avoid wrinkles or deformed folding.
Set the paper feed pressure as low as possible to avoid double-feeds.
Set the paper separating pressure as low as possible. If set too high, the lead edge may be scratched or turned over.
How do I adjust the stacker roller height and position?
Changing stacker roller height:
Some thick and stiff paper may not eject smoothly because it opens after folding. Change the stacker roller height to widen the space.
1. Remove the auxiliary paper ejection guide and paper support guide.
2. Lift the stacker roller and hold it with your hand to move it to the raised [A] position shown in the figure.
Important: After completing folding operations, be sure to return the stacker roller to the standard position. Leaving it raised will result in poor alignment of ejected paper.
Adjusting stacker roller position:
During cross folding or when folding thick paper, adjust the position of the stacker roller if the paper opens upon ejection, causing misalignment or a jam.
1. Touch the (Stacker roller) key on the [Ready] screen. The [Stacker Roller] screen is displayed.
2. Using the [+]/[-] keys, adjust the position. The smaller the value, the more the roller moves to the internal side. The higher the value, the more it moves to the outer side. [0] is used when a paper jam occurs during cross folding, which also slows the processing speed.
3. Touch the (Test) key to check the result.
4. Touch the (Return) key to return to the previous screen.
How do I use the various function settings?
Navigate to the [Function Settings] screen from the [Ready] screen.
Thick paper mode: For double folding B4 or larger, or thick (104.7 g/m² or more) paper. On the [Ready] screen, use the (Processing speed up) key to change the speed to the highest setting (6+). To clear, use the (Processing speed down) key.
Thin paper mode: For thin, flimsy paper like rough or recycled paper. On the top screen, use the (Processing speed down) key to change the speed to the lowest setting (1-). To clear, use the (Processing speed up) key.
Interval function: To pause folding after a set number of sheets. In Function Settings, select [Interval]. Set the number of sheets (1-999) and the pause duration in seconds (3-30).
Double-feed detection: In Function Settings, select [D-Feed Detect]. Choose OFF, optical sensor, or ultrasonic sensor (if installed). For the optical sensor, set the paper as [Thin] or [Thick]. Test folding is required when the optical sensor is enabled.
Detection: In Function Settings, select [Detection]. Turn [Load] (paper stack detection) and [Standard Size] (auto size detection) on or off as needed.
Initial (When Turned On): In Function Settings, select [When Turned On]. Set the machine to start up in [Normal] mode, with the [Last Fold] settings, or in [Stopper Fixed] mode.
Idling: In Function Settings, select [Idling]. Turn on to keep the machine’s conveyance drive running during short pauses to prevent stopping operations.
Tone (Buzzer): In Function Settings, select [Tone] to turn the key operation sound on or off.
mm/inch: In Function Settings, select [mm/inch] to switch the unit of measurement.
LCD bright: In Function Settings, select [LCD Bright] to adjust screen brightness from 1 to 5.
Number of test sheets: In Function Settings, select [Test Sheets] to set the number of sheets fed during a test fold (1 to 3).
Language: In Function Settings, select [Language] to change the display language.
Power saving: In Function Settings, select [Power Save] to set a time (1-120 minutes) after which the LCD backlight will turn off.
Alarm (DF-999/DF-999A): In Function Settings, select [Alarm] to set a time (5-120 minutes) after which a buzzer will sound if the machine remains unused while powered on.
How do I use the optional DF HAND FEED KIT?
The DF HAND FEED KIT allows a maximum of three sheets to be folded together simultaneously.
Applicable Paper and Folding:
Paper size: A4, B5 (For EU)/LTR (For NA)
Thickness: 52.3 to 81.4 g/m²
Number of sheets: Max three sheets of fine quality short grain paper (64 g/m² or less), art paper, or two sheets of coated paper.
Folding modes: Single fold, Letter fold, Accordion-fold.
Using with Stapled Paper:
Use a flat type stapler. The staple should be a standard No. 10, with a width of 8.4 mm and height of 5.0 mm. After stapling, the height should be 1.5 mm or less. Stitch the paper in parallel, within 20mm of the edge.
Operation:
1. Open the paper receiving tray and attach the auxiliary paper ejection guide.
2. Set [Manual Feed Mode] in the Function Settings. Adjust Timing and Size as needed. When running thick sheets, set speed to higher levels.
3. Set the paper to the hand feed paper feed guide on the tray.
4. Set the auxiliary guide to the paper side, leaving a small clearance.
5. Insert a sheet of paper to perform a test fold. Compress the paper inside the machine to insert it into the inlet. If it jams, press the paper ejection key.
6. Check the finish and adjust misalignment if necessary.
7. Select the counter method (Count Up or Count Down).
8. Insert paper to start folding. Do not insert the next paper until the machine stops.
How do I clean the machine?
CAUTION: Make sure you disconnect the power cord from the wall outlet before cleaning. Before use after cleaning, ensure the surface is completely dry. Do not use flammable sprays and solvents.
Cleaning paper feed rings and folding rollers:
1. Open the top cover.
2. For the Paper feed ring, clean with a cloth moistened with alcohol while rotating the ring by hand.
3. For the Folding roller, remove folding plate 1. Then, clean with a cloth moistened with alcohol while rotating the jam correction knob.
Cleaning sensors:
Use a non-flammable air duster. Read cautions for use.
1. Paper feed timing sensor, paper sensor, double-feed detection sensor: Open the top cover and remove dust with an air duster.
2. Paper ejection jam sensor upper: Remove dust with an air duster.
3. Paper ejection jam sensor lower: Open the side cover, remove folding plate 2, and remove dust with an air duster or wipe with a dry cloth.
Cleaning LCD touch panel:
Gently wipe the LCD touch panel of the control panel with a dry cloth.
Cleaning stacker belt:
1. Remove the auxiliary paper ejection guide.
2. Wipe the stacker belt with a cloth moistened with alcohol while rotating it by hand.
Cleaning paper separator:
If the paper separator is dirty, mis-feed or double-feed may occur. For cleaning the paper separator, contact your dealer.
How do I troubleshoot error codes?
Check the error code or message and solve the problem by following the guide displayed on the screen or by referring to the list below. If the C key is displayed, touch it to release the error. If not, follow the guide content.
Warning Errors
| Error Code | Cause | Solution |
|---|---|---|
| U1000 | The top cover is open. | Close the top cover. |
| U1300 | The side cover is open. | Close the side cover after attaching the folding plate 2 correctly. |
| U1500 | Folding plate 1 is not attached. | Attach the folding plate 1 correctly. |
| U1602 (*1) | The test key is pressed when test paper feeding is not performed while the optical sensor is set for double feed detection. | Perform a test feed. |
| U2001 | Paper is not stacked in the paper feed tray. | Load paper in the paper feed tray. Touch the C key to release the error. |
| U2005 (*1) | The direction of paper stacked on the paper feed tray is incorrect. | Load paper in the correct direction. Check if the paper size setting is correctly set. Touch the C key to release the error. |
| U2007 (*2) | The paper feed tray is not set. | Raise the paper feed tray. Touch the C key to release the error. |
Motor Errors
| Error Code | Cause | Solution |
|---|---|---|
| E2002, E2003, E2005 (*) | Abnormal stack on the motor for raising and lowering paper feed plates due to paper jamming, etc. | Remove jammed paper and touch the C key to release the error. |
| E2220, E2221 | Abnormal stack on the motor due to paper jamming, etc. | Remove jammed paper and touch the C key to release the error. |
| E2400, E2401, E2402 | Abnormal stack on the stacker roller motor due to paper jamming, etc. | Remove jammed paper and touch the C key to release the error. |
| E2410 | Folding plate 1 is not attached properly. | Make sure that folding plate 1 is attached properly. |
| E2411, E2412, E2419 | Motor for moving the folding stopper is not functioning due to paper jamming, etc. | Remove jammed paper and touch the C key to release the error. |
| E2420 | Folding plate 2 is not attached properly. | Make sure that folding plate 2 is attached properly. |
| E2421, E2422, E2429 | Motor for moving the folding stopper is not functioning due to paper jamming, etc. | Remove jammed paper and touch the C key to release the error. |
Paper Jam Errors
| Error Code | Cause | Solution |
|---|---|---|
| J1000 | Miss-feed on the paper feed tray. | Align the paper again. |
| J1001 | Double-feed occurs at the paper feed section. | Remove the double-fed paper. |
| J1006 | Paper jamming at paper feed section. | Remove the jammed paper. |
| J3002 | Paper jamming inside the machine. | Remove the jammed paper. Clear the error by referring to forcible ejection or opening and closing the top cover. |
| J6002 | Paper jamming at paper ejecting section. | Remove the jammed paper. |
Other Errors
| Error Code | Cause | Solution |
|---|---|---|
| E1903 | An incorrect program is included. | Touch the C key to release the error. |
| E1904 | Incorrect data is included in the SD card. | Touch the C key to release the error. |
(*1) DF-999/DF-999A
(*2) DF-990/DF-990A
What should I do if a paper jam occurs?
CAUTION: Do not put fingers inside during operation. Keep away long hair, ties, jewelry and loose clothing. It could cause injury.
WARNING: Open or close the top cover gently. Hands or fingers may be caught in the cover section.
Jam in Paper feed ring:
1. Open the top cover.
2. Slowly remove the jammed paper near the paper feed ring. If it cannot be pulled out easily, first remove all paper from the feed tray and then pull out the jammed paper.
3. Close the top cover.
Jam in Folding roller:
1. Take out folding plate 1.
2. Open the side cover.
3. Take out folding plate 2.
4. Open the top cover.
5. Pull out the paper by rotating the jam correction knob.
6. Close the top cover.
7. Insert folding plate 1 and folding plate 2.
8. Close the side cover.
Jam in Folding plate:
Press the folding plate paper ejection key to forcibly eject the paper. If paper is not removed, check the position of the jam and remove it by taking out the relevant folding plate (1 or 2).
Jam in Ejecting section:
Press the paper ejection key. The paper is ejected forcibly as long as the key is held down.
What are some common problems and their solutions?
| Condition | Cause | Solution |
|---|---|---|
| Power is not turned on. | The power cord is not connected. | Connect the power cord. |
| The power switch is not turned on. | Turn on the power switch. | |
| The machine does not start operation when the start key is pressed. | Paper is not stacked. | Stacking paper on the paper feed tray. |
| The paper switch is not responding. | Stacking paper in correct position so that the paper switch responds. | |
| Paper has jammed. | Remove jammed paper. | |
| The top cover and side cover are open. | Close the covers which are open. (The side cover will not be closed if folding plate 2 is not attached correctly.) | |
| Non-standard paper is used in standard paper settings. (DF-999/DF-999A) | Change the settings to match non-standard paper. | |
| The paper feed guide is off the paper size detection area. (DF-999/DF-999A) | Secure the paper feed guide correctly. | |
| The paper set lever is not lowered. (DF-990/DF-990A) | Lower the paper set lever. | |
| [D-Feed Detect] is turned on but test folding was not performed. (DF-999/DF-999A) | Perform test folding. | |
| Paper is not folded at the normal folding position. | The folding plates 1 and 2 are not set properly. | Set the folding plates 1 and 2 properly. |
| Static electricity is built up on paper. | Use a commercially available static electricity removal spray. Separate the paper well. Humidify with a humidifier as required. | |
| Double-feed of paper has occurred. | Paper feed pressure is too high. | Decrease the paper feed pressure. |
| Paper separating pressure is too low. | Increase the paper separating pressure. | |
| Mis-feed of paper has occurred. | Paper feed pressure is too low. | Increase the paper feed pressure. |
| Paper separating pressure is too high. | Decrease the paper separating pressure. | |
| Folding misalignment along the vertical length of the paper occurs. | Processing speed was changed midway through operation. | Adjust the folding stopper positions of folding plates 1 and 2. |
| Folding misalignment along the sides of the paper occurs. | The paper feed guides are not set properly. | Set the paper feed guides properly. |
| The fixing screws of the paper feed guides got loose and the paper feed guide slipped out of position. | Tighten the fixing screws of the paper feed guides. | |
| Paper is not cut properly. | Correct the folding misalignment along the sides of the paper using the skew correction knob. | |
| Continuous-feeding occurs with small paper. | Paper feed pressure is too high. | Decrease the paper feed pressure. |
| Single-folded thick paper jams at the folding rollers. | The processing speed is too slow. | Increase the processing speed. |
| When large paper is stacked, the tray does not rise. | Heavy paper is used. | Increase the paper feed pressure. |
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