Duplo DC-616 Service Manual Download Page 52

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S2-Y1540

9 Main Drive Section

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(1) Removing the Main Motor and the Drive Belt

(2) Removing the Driving Roller (Upper)

(3) Removing the Driving Roller (Lower)

(4) Removing the Perforation Tool

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10 Electrical System Section

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(1) Removing the Control Panel

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(2) Removing the Power Supply Unit

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(3) Removing the Main PCB Unit

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(4) Removing the Drive PCB Unit

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(5) Removing the Main Drive PCB Unit

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(6) Removing the Double Feed Detection PCB Unit

(7) Removing the USB PCB Unit

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Summary of Contents for DC-616

Page 1: ...SLITTER CUTTER CREASER DC 616 Apr 2014 Revision 0 DUPLO DC 616 S2 Y1540...

Page 2: ......

Page 3: ...ving the safety instructions marked in this manual and on the machine s labels service person should be safety conscious and take other safety precautions as necessary When performing repair or servic...

Page 4: ...may lead to injury or damage to property symbol is to note that the instruction calls for close attention including danger and warning Specific hazard to be careful about is indicated in the drawing...

Page 5: ...y ranges are Ambient temperature 10 C 30 C Ambient humidity 40 70 Optimum temperature and humidity 20 C 65 If the machine is installed near to faucets water heaters or humidifiers or in cool sunless p...

Page 6: ...cord that is provided with the accessories Insert the power cord plug firmly into the socket so that proper electrical contact is made Use of any other power cord could result in imperfect grounding I...

Page 7: ...ions of related equipment and take great care not to put your hands or fingers into moving parts The cutter unit slitter unit and perforation unit contain sharp tools blades which may cause danger Exe...

Page 8: ...6 S2 Y1540 Warning Labels No Part No Name Q ty 1 L1 T108 L1 T111 EU WARNING LABEL 2 2 S2 T105 WARNING LABEL 6 3 M7 T303 M7 T307 EU WARNING LABEL 2 4 S2 T115 WARNING LABEL 2 0...

Page 9: ...7 S2 Y1540 5 0 No Part No Name Q ty 5 R7 T115 WARNING LABEL 1...

Page 10: ...8 S2 Y1540 0 No Part No Name Q ty 6 L8 T109 L8 T112 EU WARNING LABEL 1...

Page 11: ...1 2 3 4 5 6 7 8 9 10 Introduction Operation in General Mechanism Adjustment Maintenance Checks Troubleshooting HELP Mode Others PC Controller...

Page 12: ...s Service Manual 2 Safety Instructions 3 Warning Labels 6 Introduction 1 Specifications 12 2 Part Names and Their Functions 14 3 Dimensions 20 Operation in General 1 Paper Feed Section 22 2 Double Fee...

Page 13: ...Specifications 12 2 Part Names and Their Functions 14 1 Appearance 14 2 Ejection Side 15 3 Appearance Ejection side 16 4 Inside 17 5 Control Panel 18 6 LCD Panel 19 3 Dimensions 20 Chapter 1 Introduct...

Page 14: ...rgin slit spec 3 2 55 0 mm from document side edges Gutter slit width 5 0 15 0 mm Gutter slits wider than above are exited onto the exit tray Gutter deflector Max 2 gutter slits can be deflected Numbe...

Page 15: ...Asia Oceania model Perforation unit optional on 115V and 230V Asia Oceania models Long paper tray PC am mount standard on 115V PRO model PC controller software standard on 115V PRO model USB B TYPE C...

Page 16: ...shed products 3 Waste box Receives pieces of waste paper 4 Front cover Open this to remove the waste box 5 Feed tray Original document is placed here 6 Scale Measures the cut and slit position and the...

Page 17: ...d Side 3 2 1 4 No Name Function 1 Airflow adjustment knob Adjusts airflow level 2 Separator adjustment knob Adjusts the distance between the separator and conveyance belt 3 Skew adjustment knob Adjust...

Page 18: ...rforates parallel to the document feed direction 2 Side guide Receives the processed documents 3 Back guide Receives the processed documents 4 USB terminal Used for the connection to your computer on...

Page 19: ...on 3 Slitter module 1 2 Cuts side margins parallel to the document feed direction 4 Slitter module 3 4 Cuts parallel to the document feed direction 5 Slitter module 5 6 6 Gutter deflector Drops the ma...

Page 20: ...ursor in a lower or an upper direction 6 SET key Press to set selection entry 7 JOG Forward Backward key Press to eject the document from the machine when paper jam occurred 8 TEST key One sheet docum...

Page 21: ...JOB Setting Setting Cleaning mode Return 1 2 3 4 5 3 0 1 2 4 3 No Name Function 1 JOB No Displays the JOB number currently selected 2 JOB Name Displays the JOB name currently selected 3 Counter Displa...

Page 22: ...Chapter 1 3 Dimensions S2 Y1540 20 Unit mm 3 Dimensions 0...

Page 23: ...2 Operation 28 3 Slitter Blade 28 4 Operation of Each Part 28 5 Center Slitter Section 30 1 Description 30 2 Operation 30 3 Slitter Blade 30 4 Operation of Each Part 30 6 Cutter Section 33 1 Descripti...

Page 24: ...1 Level Sensor Operation Detect the top of the paper on the feed tray When the feed tray rises to the extent that the actuator is lifted up by the paper the sensor comes to the light blocked state On...

Page 25: ...not be detected and the feed tray continues to go up the air suction unit is pulled away from the elevator upper limit switch to come to the OFF state The elevator upper limit switch stops the machine...

Page 26: ...y if the angle does not push the elevator lower limit switch actuator within 30 seconds after the transmission of the feed tray go down command ON 0V OFF 5V 5V 4 5 1 2 CN3 19 0 2 5V ON 0V OFF 5V CN2 2...

Page 27: ...r passes through the PPS2 Circuit diagram Circuit diagram Shutter solenoid Red Yellow Red Yellow Drive PCB unit 7 PPS1 Operation While the light goes through at PPS1 LED on the control panel lights up...

Page 28: ...double feed the machine stops the operation Transmitting Transmitting Receiving Receiving 3 Operation of Each Part 1 Double Feed Sensor Operation Whenever the ultrasonic sensor detects double feed th...

Page 29: ...ading 1 PPS2 Operation PPS detects the presence or non presence of paper by the light through or the light bloced state of the PPS photo receiving sensor by means of receiving from the PPS photo emitt...

Page 30: ...d amount of pulse 3 Slitter Blade The slitter blades are constructed so that the lower blade of the slitter is tilted relative to the paper feed direction This makes the upper and lower slitter blades...

Page 31: ...ed Light not transmitted 5V Light transmitted 0V 2 Margin Jam Sensor Operation The system stops the machine when a sensor cannot detect light for more than fixed period of time during machine runs Cir...

Page 32: ...y the specified amount of pulse 3 Slitter Blade The slitter blades are constructed so that the lower blade of the slitter is tilted relative to the paper feed direction This makes the upper and lower...

Page 33: ...3 8 9 7 Slitter HP3 sensor Slitter HP4 sensor Slitter HP5 sensor Slitter HP6 sensor Purple Red Blue Gray Blue Red Yellow Blue Red Yellow Blue Red Light not transmitted 5V Light transmitted 0V Main PCB...

Page 34: ...sensor and in case the gutter is not needed Gutter Released is displayed Circuit diagram 5V 1 2 3 4 5V 18 20 CN4 21 19 1 3 2 1 17 16 4 3 2 1 Gutter ON OFF sensor Receiving Emitting Light not transmit...

Page 35: ...ans of the eccentric shaft A sensor is provided at the top dead center of the blade stroke which works to apply the brake on the blade movement at every reciprocating cycle to make it stop 3 Operation...

Page 36: ...Chapter 2 6 Cutter Section S2 Y1540 Circuit diagram 2 Cutter Motor Operation Cutter motor controls the upper blade up and down operation CN6 3 4 M 1 2 Cutter motor Red Black Drive PCB unit Red Black...

Page 37: ...o its traveling direction 2 Operation The sensor plate provided coaxially with the cam detects the top dead center of the upper blade to control the DC motor The lower blade also can move up and down...

Page 38: ...t diagram 5V 5V 1 2 3 4 5 6 CN3 13 14 15 CREASE LOW HP sensor Red Light green Main PCB unit Blue 2 Crease Home Position Sensor Operation This sensor detects the crease home position by sensing the sen...

Page 39: ...2 3 7 8 9 CN3 16 17 18 CREASE ENCODER Red Purple Main PCB unit Blue 4 PPS4 Operation The light from the PPS photo emitting PCB is received by the PPS photo detecting PCB The presence or non presence o...

Page 40: ...tor rotates the encoder attached in the crease lower motor to adjust the crease depth in three steps Circuit diagram CN5 4 5 M 1 2 CREASE LOW MOTOR Black Black Brown Brown Drive PCB unit 0 7 Perforati...

Page 41: ...motors are used for activating components related to the paper cutting dimensions paper transfer each slitter transversal position of the gutter The movement of other DC motors are also controlled by...

Page 42: ...he finished paper discharged from the machine The exit tray can be set at four different heights Normally the tray is set at the middle height position Upper position is to install the Card Stacker Lo...

Page 43: ...er interlock switch detects the opening and closing of the front cover The machine stops immediately when the cover is opened during operations When the cover is closed the cover presses the switch Wh...

Page 44: ...rior S2 Y1540 Circuit diagram CN14 1 2 CN7 2 1 2 3 Front cover interlock switch Top cover interlock switch Drive PCB unit Main PCB unit Relay Brown Brown Brown Brown Brown Brown Brown Brown Rear cover...

Page 45: ...nction each documents must have BARCODE printed on them Please refer to following instructions for specifications and position of BARCODE Paper feed direction 1 Specifications Barcode type CODE 39 Sta...

Page 46: ...m the right edge Here is the example barcode CODE39 21 See below 1 2 3 4 60 mm or less 35 mm 25 mm 3 mm 20 mm Paper feed direction Barcode Barcode Position Range 1 is the start code designator for COD...

Page 47: ...is 1 4 is stop code of CODE 39 4 Calculation procedure of check digit 1 Convert all the data characters to the numeric number referring the table 1 Except start and stop code 21 2 1 2 Add the each co...

Page 48: ...raw 2 straight and perpendicular lines 2 Position Paper feed direction The whole REG mark should be within 3 to 20 mm from the lead edge Paper width direction The whole REG mark should be within 3 to...

Page 49: ...printing area cannot be detected properly by DC 616 Take account of the possible variation in the printed position of REG marks and barcodes when they are arranged on the paper IMPORTANT 60 mm or sho...

Page 50: ...nto the gray colored area No other printings than REG mark and barcode shall enter into the gray colored area 35 mm 5 mm 20 mm 20 mm Barcode Paper feed direction 3 mm or more 3 mm or more 3 mm or more...

Page 51: ...r 58 4 Removing the Suction Fan 58 5 Removing the Compressor 59 6 Removing the Compressor Fuse 60 7 Removing the Paper Level Sensor 61 8 Removing the Elevator Upper Limit Switch 62 9 Removing the Elev...

Page 52: ...ving Roller Lower 92 4 Removing the Perforation Tool 92 10 Electrical System Section 96 1 Removing the Control Panel 96 2 Removing the Power Supply Unit 96 3 Removing the Main PCB Unit 97 4 Removing t...

Page 53: ...r 3 S2 Y1540 1 Exterior of the Machine 0 10 Front cover interlock switch 9 Top cover interlock switch 1 Cover F 7 Top cover 2 Cover F2 unit 3 Cover R2 5 Cover R 6 Plate 8 Cover Power supply 4 Cover 11...

Page 54: ...3 Removing the Cover R2 1 Open the top cover 2 Take out the three screws and remove the cover F 1 Open the top cover 2 Remove the cover F 3 Take out the three screws and remove the cover F2 unit 1 Ope...

Page 55: ...ake out the seven screws and remove the plate 1 Open the top cover 2 Take out the two screws and the screw plate and remove the hinge 3 Take out the two screws each and remove the top cover with the h...

Page 56: ...the cover Be sure to work with thepower cord removed 1 Open the top cover 2 Take out the two screws and remove the micro switch with the bracket 3 Disconnect the connector 4 Take out the two screws an...

Page 57: ...After the installation adjust the interlock switch 11 Removing the Exit Interlock Switch 1 Open the Top cover 2 Take out the three screws and remove the cover R 3 Take out the two screws and remove t...

Page 58: ...nd one screw and remove the belt suction unit 2 Removing the Belt Suction Unit 1 Open the top cover 2 Remove the cover F2 unit 3 Remove the feed motor connector and the suction fan connector 4 Take ou...

Page 59: ...n 3 S2 Y1540 Removing the Shutter Solenoid 1 Disconnect the connector 2 Take out the two screws and remove the shutter solenoid with the bracket 3 Take out the two screws and remove the shutter soleno...

Page 60: ...s and remove the feed motor After the installation perform the motor operation check in HELP Mode 19 4 Removing the Suction Fan 1 Remove the cover F2 unit 2 Disconnect the fan motor connector 3 Take o...

Page 61: ...or Secured from the backside 5 Draw the compressor toward you and remove the wiring and air tube See P 52 See P 53 After the installation perform the compressor operation check in HELP Mode 20 Removin...

Page 62: ...Open the cover and remove the fuse Be sure to work with the power cord removed Rating of compressor fuse 250 V 2 A CAUTION Be sure to remove the power cord plug from the outlet before starting the wor...

Page 63: ...ove the shaft ASSY 5 Take out the two screws and remove the sensor with the bracket 6 Remove the sensor from the bracket After the installation perform the sensor operation check in HELP Mode 11 Make...

Page 64: ...the cover R2 2 Disconnect the connector 3 Take out the nut and remove the elevator upper limit switch with the bracket See P 52 9 Removing the Elevator Lower Limit Switch 1 Remove the cover F2 unit 2...

Page 65: ...4 Remove the banding band See P 52 6 Loosen the hexagon socket set screw and remove the gear 7 Take out the three screws and remove the motor After the installation perform the paper feed elevator op...

Page 66: ...elevator to the upper limit HELP Mode 17 and turn off the power 2 Take out one screw and remove the sensor with the bracket 3 Take out one screw and remove the sensor After the installation perform t...

Page 67: ...p cover 2 Remove the cover F2 unit and cover R2 3 Disconnect the following connectors Elevator down switch Elevator lower limit switch Suction fan Feed motor Shutter solenoid Blow fan Paper level sens...

Page 68: ...nector and remove the paper feed unit Adjust the indicator to 0 at the time of installation 1 Remove the paper feed unit Be sure to work with the power cord removed 2 Take out the three screws and rem...

Page 69: ...e the cover R2 2 Disconnect the five connectors and remove the two ground wires 3 Take out the three screws and remove the ultrasonic sensor unit 4 Take out the two screws and remove the ultrasonic se...

Page 70: ...d at the time of installation 1 Remove the cover power supply and cover R Be sure to work with the power cord removed 2 Disconnect the connector CN8 Make sure that the terminals do not interfere each...

Page 71: ...o emission sensor 1 Open the top cover 2 Take out the three screws and remove the hinge of the top cover 3 Take out the two screws and remove the sensor with the bracket Adjustment required at the tim...

Page 72: ...the motor fixing screws and remove the timing belts Do not drop the key placed in the groove 5 Take out the screw and remove the upper guide plate three places See P 53 See P 52 7 Take out the screw a...

Page 73: ...areful that there are two kinds of shaft with different depth of D cutting 10 Take out the screw and remove the bearing pressers two places Take note of the orientation to attach at the time of instal...

Page 74: ...two screws each and remove the lids two places right and left 5 Take out the two screws each and remove the lids two places 3 Pull out the upper blade unit 6 Pull out the shaft and remove the lower b...

Page 75: ...Motor Belt 1 Open the front cover 2 Disconnect the two motor connectors 3 Remove the cover R 4 Remove the timing belt 5 Take out the four screws and remove the motor After the installation perform the...

Page 76: ...er Home Position Sensor 1 Remove the cover F 2 Remove the cover R 3 Take out one screw each and remove the sensor with the bracket 4 Take out one screw each and remove the sensor from the bracket Adju...

Page 77: ...4 Removing the Margin Jam Sensor Photo emission sensor 1 Remove the cover F 2 Take out one screw and remove the sensor with the bracket See P 52 Photo detecting sensor 3 Remove the cover R 4 Take out...

Page 78: ...ng shafts and the timing belts Do not drop the key placed in the groove See P 53 See P 52 6 Take out the screw and remove the bearing presser 7 Pull out the slitter driving shaft with its groove facin...

Page 79: ...on be careful that there are two kinds of shaft with different depth of D cutting 9 Take out the screw and remove the bearing pressers two places 10 Pull out the two driving shafts while turning them...

Page 80: ...e plate 6 Draw out the upper blade unit Slitter 3 and slitter 4 upper blade unit Slitter 5 and slitter 6 lower blade unit 7 Take out the two screws and remove the guide 4 Take out the two screw and re...

Page 81: ...ids two places Take note of the correct orientation of the eccentric shaft at the time of installation 10 Draw out the lower blade unit with the shaft 2 Removing the Center Slitter Position Motor 1 Op...

Page 82: ...operation check in HELP Mode 31 1 Remove the cover F 3 Removing the Center Slitter Home Position Sensor 2 Remove the cover R 3 Take out one screw each and remove the photointerrupter with the bracket...

Page 83: ...or with the bracket 5 Take out the screw and remove the sensor from the bracket After installation perform the sensor operation check in HELP Mode 11 Photo detecting sensor 1 Take out the two screws a...

Page 84: ...over R 3 Disconnect the sensor connector 4 Take out the screw and remove the sensor with the bracket See P 52 See P 53 HELP Mode 11 P 137 5 Take out the two screws and remove the sensor After the inst...

Page 85: ...the cutter module Adjustment required at the time of installation See P 105 Removing the Slitter Blade Module 1 Take out the two screws and remove the lock plate unit 2 Take out the four screws and r...

Page 86: ...Remove the cover R 2 Take out the two screws and remove the sensor with the bracket 3 Take out one screw and remove the sensor Adjustment required at the time of installation See P 107 2 Removing the...

Page 87: ...Sensor 4 Take out the two screws and draw out the motor with the bracket 5 Take out the three screws and remove the gear cover and timing belt Adjustment required at the time of installation 1 Remove...

Page 88: ...5 Remove the belt and the pulley unit 6 Take out one screw and remove the eccentric gear 7 Take out one screw and remove the bearing presser 8 Draw out the eccentric shaft and the two bearings 9 Draw...

Page 89: ...cket 5 Removing the Crease Lower Blade Motor 4 Removing the Crease Lower Blade Home Position Sensor 3 Remove the sensor from the bracket Adjustment required at the time of installation Gear 3 Loosen t...

Page 90: ...Remove the cover F 2 Take out the screw and remove the sensor with the bracket 6 Removing the Creaser Lower Blade Encoder Sensor 3 Remove the sensor from the bracket Adjustment required at the time o...

Page 91: ...remove the sensor After the installation perform the sensor operation check in HELP Mode 11 1 Take out the four screws and remove the plate 2 Take out one screw and remove the sensor After the instal...

Page 92: ...nd remove the pulley cover 4 Remove the timing belt 1 Remove the cover F 2 Take out the two screws and loosen the pulley bracket 9 Main Drive Section 1 Removing the Main Motor and the Drive Belt 5 Dis...

Page 93: ...installation 2 Removing the Driving Roller Upper 6 Take out the four screws and remove the motor with bracket 1 Remove the covers F R 2 Remove the bush presser spring 3 Take out the E ring and remove...

Page 94: ...e timing belt 5 Take out the screw and remove the bearing presser 6 Draw out the roller See P 53 See P 52 See P 90 4 Removing the Perforation Tool 1 Take out the two black thumbscrews and remove the p...

Page 95: ...ent screws approx 3 mm First loosen the nut and then loosen the screws 4 Raise the perforation tools on both sides up to the upper limit position with the depth adjustment screws Turn the depth adjust...

Page 96: ...step 5 in the direction of the arrow and remove the shaft upper from the unit 7 Replace the upper tool assy with a new one Upper tool assy Roll assy When attaching the upper tool assy to the shaft ta...

Page 97: ...e upper tools with the perforation depth adjustment thumbscrews 10 When the perforation tool is raised up to the upper limit position adjust the screw for the upper limit stopper to secure at the posi...

Page 98: ...ve the control panel 1 Remove the cover 5 Take out the ten screws and remove the panel PCB unit 2 Removing the Power Supply Unit Always remove the power cord plug from the outlet before replacing a PC...

Page 99: ...Removing the Main PCB Unit 4 Removing the Drive PCB Unit CN 1 CN 2 CN 8 CN 3 CN 7 CN 5 CN 6 CN 10 CN 11 CN 9 CN 4 F6 F206 F205 F207 F202 F201 F204 F203 F6 250V 10A TLC10AN4 Always remove the power co...

Page 100: ...ake out the two screws and remove the PCB unit 6 Removing the Double Feed Detection PCB Unit 1 Remove the cover R2 2 Disconnect five connectors 3 Take out the eight screws and remove the PCB unit Alwa...

Page 101: ...in slitter home position sensor adjustment 103 2 Margin jam detecting sensor adjustment 103 3 Slitter position motor and belt adjustment 103 5 Center Slitter Section 104 1 Center slitter home position...

Page 102: ...rior of the Machine 1 Top cover interlock switch adjustment 1 Adjust a to be 0 5 mm while the switch is turned ON 2 Perform the operation check in HELP Mode 11 2 Front Cover interlock switch adjustmen...

Page 103: ...orm the operation check in HELP Mode 19 D a a 1 Adjust a to be 0 5 mm while the switch is turned ON 3 Elevator lower limit switch 1 Make an adjustment so that the switch is turned ON when the distance...

Page 104: ...Section 0 3 CCD Section 1 Fix CCD in about the center of a long hole 2 Perform REG mark read out position adjustment in HELP Mode 45 1 CCD 1 Perform the operation check in HELP Mode 11 2 PPS2 HELP Mod...

Page 105: ...in slitter home position sensor adjustment 2 Margin jam detecting sensor adjustment 1 Adjust the sensor detecting time in HELP Mode 59 2 Check the sensor operation in HELP Mode 11 3 Slitter position m...

Page 106: ...lying the Service person JOB 3 Adjust the home position setting in HELP Mode 49 1 Center slitter home position sensor adjustment 1 Adjust the belt tension to 3 mm 10N by moving the motor installation...

Page 107: ...person JOB 3 Adjust the slide installation position skew 4 Adjust the cutting position in HELP Mode 46 1 Cutter motor adjustment 1 Feed the test paper through the machine applying the Service person...

Page 108: ...ncoder sensor adjustment 1 Adjust the distance between the encoder and the sensor a to 2 5 mm 2 Perform the operation check in HELP Mode 28 3 Feed the test paper through the machine applying the Servi...

Page 109: ...home position sensor 1 Perform the operation check in HELP Mode 27 2 Feed the test paper through the machine applying the Service person JOB 3 Adjust the crease position and depth in HELP Mode 47 48 H...

Page 110: ...ction 0 8 Main Drive Section 1 Main motor drive belt adjustment 1 Move the pulley bracket installation position and adjust the belt tension to 10 mm 10N 2 After the adjustment perform the operation ch...

Page 111: ...5 Maintenance Checks Chapter 5 1 Guaranteeing Maintenance Cycle 110 2 Cleaning and Oiling 110 1 Cleaning 110 2 Oiling 110 3 Periodic Maintenance Check List 111 4 Recommended Parts List 112...

Page 112: ...or a dry cloth 2 Oiling 1 Bearings Apply a small amount of oil to the end face and axel while turning the levers and rollers 2 Gears and Rails Apply grease after cleaning the paper dust off of the ge...

Page 113: ...e a brush to clean any paper dust etc Timing belt Checking Inspect Belts for signs of wear or loss of tension Replace any cracked or worn belts and retention as required Cutter Oiling Use a brush to c...

Page 114: ...LT 13 AJ044 TIMING BELT 14 AJ301 TIMING BELT 15 AJ146 TIMING BELT 16 AJ230 TIMING BELT 17 AJ231 TIMING BELT 18 S2 N101 DRIVING ROLLER 1 million sheets Coated paper 230 gsm 19 S2 N102 ROLLER CHAIN 1 mi...

Page 115: ...P9 X101 STEPPING MOTOR 44 P9 X102 STEPPING MOTOR 45 S2 X101 MOTOR 46 S2 X103 STEPPING MOTOR 47 LA051 MICRO SWITCH 1 000 000 times 48 N4 X103 CCD 49 UI028 FUSE 50 S2 X105 AIR POMP 115 V 51 S2 X106 AIR...

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Page 117: ...Panel is displayed 118 8 When E01 CCD is displayed 118 9 When E02 Elevator is Displayed 119 10 When E03 Crease lower is Displayed 119 11 When E04 06 Memory error is Displayed 119 12 When E07 Connect...

Page 118: ...main PCB YES Reconnect properly NO Replace the main PCB Unit 97 2 When J2 FEED JAM is Displayed step cause failed area check item if action see page 1 Paper Level sensor Check that the paper level se...

Page 119: ...l out gutter guides 2 Inside the machine Paper jam inside the machine slitter unit YES Remove the paper inside the machine NO Go to step 3 3 PPS3 Check that the PPS3 sensor works properly in HELP Mode...

Page 120: ...o 4 connector of the main PCB properly YES Reconnect properly NO Replace the main PCB Unit 97 7 E00 Main Panel is displayed step cause failed area check item if action see page 1 Main PCB control pane...

Page 121: ...ge 1 Creaser lower blade HP sensor Check that the creaser lower blade sensor works properly in HELP Mode 28 YES Go to step 2 NO Clean the sensor Replace the sensor 87 2 Creaser lower blade ENC sensor...

Page 122: ...is displayed step cause failed area check item if action see page 1 Main PCB Check that an error message is displayed even if the power is turned on again YES Replace the main PCB Unit 97 14 When BC R...

Page 123: ...1 Document Is the REG mark printed on the document YES Go to step 2 NO Change the document to the proper one 2 Document Is the REG mark bad printing YES Go to step 3 NO Print REG mark again 3 Documen...

Page 124: ...aper length 300 mm during processing J7 Waste box The margin jam sensor is in the light blocked state for the configured period 800 ms during processing E00 Main Panel The main panel does not respond...

Page 125: ...ned off when processing is started or during processing Double feed The ultrasonic sensor exceeds the threshold value JOB error An unsupported job is registered USB error A USB communication error occ...

Page 126: ...f paper Torn paper or paper with large holes Paper held together with a clip or staples Substantially curled wavy or partially folded paper Carbon paper and the like Paper of high transparency such as...

Page 127: ...n In Case of Center Slitter 3 Example 1 Move the center slitters to the center of the module 2 Loosen the hexagon socket head cap screw securing the lid of the slitter with the intersecting blade The...

Page 128: ...shaft in without sliding the lid may damage the upper blade and the lower blade The right figure shows that the blade intersection is corrected and the blades are in the normal position 5 Tighten the...

Page 129: ...HELP Mode List 128 2 Accessing the HELP Mode 129 3 Finishing the HELP Mode 129 4 Setting the Other HELP Mode No 129 5 Accessing the Service Person JOB 129 6 HELP Mode Description 130 HELP Mode Chapte...

Page 130: ...HELP28 1 Creaser lower blade motor operation test operation test 147 HELP29 1 Cutter motor operation test operation test 148 HELP31 1 Slitter operation test 1 6 operation test 149 HELP41 1 Main motor...

Page 131: ...tch before accessing the HELP Mode 2 Turn on the power switch while pressing the CURSOR Up key and the CLEAR key simultaneously The machine is put in the standby mode with the pip sound 3 Input the Se...

Page 132: ...anel PCB is displayed Press the DOWN cursor key FPGA FPGA is displayed 2 Press the STOP key It will return to the HELP Mode selection screen 2 ROM version upgrade 2 1 DDL 1 DDL 2 version upgrade Upgra...

Page 133: ...Serial Converter is not available in Macintosh 1 When the machine is in use put it in the standby mode and turn off the power 2 Connect your computer and the DC 616 with the USB cable 3 Turn on the p...

Page 134: ...USB and click OK 8 Click OPEN 9 Select a file and click OPEN 10 Normal is selected Click Start Upgrading starts 11 When the download completes the message Complete appears Click OK 12 Turn off the pow...

Page 135: ...XX Reset XXXXXXXX H02 Total count Cut count Total XXXXXXXX Reset XXXXXXXX H02 Total count Crease count Total XXXXXXXX Reset XXXXXXXX H02 Total count Operating count Total XXXXhXXm Reset XXXXhXXm Total...

Page 136: ...Total Total count is shown 3 Press the STOP key It will return to the HELP Mode selection screen 2 Reset the count 1 Access the HELP Mode 02 2 Continuously press the C in the NUMERIC key for about 3 s...

Page 137: ...k Slit 2 lock Slit 3 lock Slit 4 lock Slit 5 lock Slit 6 lock BC error 1 BC error 2 BC error 3 Reg error 1 Reg error 2 Reg error 3 Reg error 4 Double feed Cutter lock Creaser lock 3 Continuously press...

Page 138: ...item 1 Display the error count 1 Access the HELP Mode 07 and press the START key 2 Press the UP DOWN cursor key to switch pages E01 CCD error E02 Elve error E03 Cre lower 3 Continuously press the C i...

Page 139: ...PPS1 0 light blocked 1 light through PPS2 0 light through 1 light blocked PPS3 Page 2 PPS4 0 light through 1 light blocked Slit 1 hp Slit 2 hp Page 3 Slit 3 hp 0 light through 1 light blocked Slit 4 h...

Page 140: ...is displayed Because DIP SW1 is used for version up it cannot be verified in HELP Mode 13 1 DIP switch check 1 Access the HELP Mode 13 and press the START key Status of the DIP switch ON OFF is displ...

Page 141: ...ed detection result is verified 1 Double feed detection check 1 Access the HELP Mode 15 and press the START key The double feed detection result is displayed 0 one sheets of paper 1 two sheets of pape...

Page 142: ...anel sounds correctly Check that the LEDs on the LED PCB function correctly 1 Control panel check 1 Access the HELP Mode 16 and press the START key 2 Press the NUMERIC keys A buzzer sounds 3 The LCD p...

Page 143: ...evator operation test 1 Access the HELP Mode 17 and press the START key 2 Run the elevator by pressing the CURSOR Up Down keys 3 Press the CURSOR Right Left keys to turn the pages 4 The status of the...

Page 144: ...ified The proper function of blower motor is verified 1 Fan motor operation test 1 Access the HELP Mode 18 and press the START key 2 Press the UP DOWN cursor key and operate the fan motor UP cursor ke...

Page 145: ...st 1 Access the HELP Mode 19 and press the START key 2 Press the JOG key and operate the feed motor 3 Press the STOP key It will return to the HELP Mode selection screen 2 Shutter solenoid operation t...

Page 146: ...dure 1 Compressor operation test Operate the compressor 1 Compressor operation test 1 Access the HELP Mode 20 and press the START key 2 Press the UP cursor key and operate the compressor 3 Press the S...

Page 147: ...he slitter operation is verified 1 Slitter home position check 1 Access the HELP Mode 26 and press the START key 2 Press the UP DOWN cursor key and move the slitter UP cursor key Move to home position...

Page 148: ...per blade home position sensor is verified 1 Creaser upper blade motor operation test 1 Access the HELP Mode 27 and press the START key 2 Press the UP DOWN cursor key and operate the motor UP cursor k...

Page 149: ...e home position is verified 1 Creaser lower blade motor operation test 1 Access the HELP Mode 28 and press the START key 2 Press the UP DOWN cursor key and operate the motor UP cursor key normal rotat...

Page 150: ...operation test 1 Access the HELP Mode 29 and press the START key 2 Press the UP DOWN cursor key and operate the motor UP cursor key normal rotation DOWN cursor key reverse rotation 3 Check that the se...

Page 151: ...on test 1 Access the HELP Mode 31 and press the START key 2 Select the slitter by pressing the RIGHT LEFT cursor key 3 Move the selected slitter by pressing the UP DOWN cursor key UP cursor key Move t...

Page 152: ...ation test The proper function of the main motor is verified 1 Main motor operation test 1 Access the HELP Mode 41 and press the START key 2 Activate the main motor by pressing the JOG and JOG keys 3...

Page 153: ...JOB Please Wait appears on the LED panel and the JOB initialization is commenced It takes 30 seconds before the initializing process is completed Once completed FINISH appears on the LCD panel H43 Ini...

Page 154: ...Service person JOB 87 4 Load a check sheet on the feed tray and press the TEST key 5 Enter numerical value into S and L so that a cut position of 2 mm 0 2 mm from the lead mark side mark is set Enter...

Page 155: ...ter the adjustment value by pressing the NUMERIC key The cutting position moves by 0 1 mm when the adjustment value is changed by 1 H46 PPS3 Cut dist Distance XXX SET Save Cutting position change will...

Page 156: ...er is cut applying the Service person JOB83 4 Measure the finished creasing position 5 Enter the adjustment value by pressing the NUMERIC key The creasing position moves by 0 1 mm when the adjustment...

Page 157: ...desired depth by pressing the UP DOWN cursor key 6 Enter the adjustment value by pressing the NUMERIC key 0 150 The slitter position moves by 0 1 mm when the adjustment value is changed by 1 H48 Creas...

Page 158: ...The paper is cut applying the Service person JOB84 4 Measure the cut paper width 5 Enter the adjustment value by pressing the NUMERIC key The slitter position moves by 0 1 mm when the adjustment value...

Page 159: ...EST key The test RUN is proceeded by the setting of Service person JOB84 4 Measure the processed slit positions 5 Press the STOP key The HELP mode 49 will exit 6 Access the HELP Mode 50 and press the...

Page 160: ...ers run following the adjustment values properly The setting of Service person JOB84 MSL 25 mm 1 50 mm 2 50 mm 3 50 mm 4 50 mm 5 50 mm If the slitter position is still incorrect go back to the step 7...

Page 161: ...ng the Service person JOB 91 4 Measure the cut paper width 5 Enter the adjustment value by pressing the NUMERIC key H52 Main motor adj XXX XX SET Save REFERENCE The transfer distance will get shorter...

Page 162: ...ss the HELP Mode 58 and press the START key 2 Select the desired air volume by pressing the RIGHT LEFT cursor key 3 Enter the adjustment value by pressing the NUMERIC key 4 Press the SET key and store...

Page 163: ...y 2 Press the UP DOWN cursor key to adjust the sensor detecting time Each time the cursor key is pressed the detecting time will increase or decrease by 20 msec C quick press sensor OFF C continuous p...

Page 164: ...function setting 1 Access the HELP Mode 60 and press the START key 2 Select the desired option by pressing UP DOWN cursor key 3 Change the setting by pressing the NUMERIC key 0 Invalid 1 Valid 4 Pres...

Page 165: ...number is set 1 Serial number setting 1 Access the HELP Mode 61 and press the START key 2 Enter the serial number by pressing the NUMERIC key 3 Press the SET key and store the serial number in the me...

Page 166: ...est 3 errors 1 Display the error record 1 Access the HELP Mode 62 and press the START key 2 Change the error contents by pressing the UP DOWN cursor key Error No Number of the error JOB No JOB number...

Page 167: ...ssing the CURSOR Right Left keys CURSOR Right addition CURSOR Left subtraction The LCD panel becomes darker in color as the value increases Setting range 12 to 40 REFERENCE Adjustment value is reset t...

Page 168: ...off cancellation of slit position limit WidthLim 330 5 cancellation of paper width limit There is another limit which is mechanical limit of the feed guide and conditions of use for the slitter 2 3 S...

Page 169: ...Function of Electronic Parts 168 1 Switches 168 2 PPS sensors 169 3 Sensors 170 4 Motors Fan Solenoid 171 5 PCB Units Power Supply 172 6 Others 173 8 Connector VR Fuse Layout 174 2 Service Person JOB...

Page 170: ...40 1 Switches 1 Position and Function of Electronic Parts No Part Name 1 Elevator Lower Limit Switch 2 Interlock switch 3 Top cover Interlock switch 4 Cover switch 5 Elevator Lower Limit Switch 6 Elev...

Page 171: ...d Function of Electronic Parts 8 S2 Y1540 2 PPS sensors No Part Name 1 PPS1 2 PPS2 Photo emission 3 PPS2 Photo detecting 4 PPS3 Photo emission 5 PPS3 Photo detecting 6 PPS4 Photo emission 7 PPS4 Photo...

Page 172: ...ensor 8 Center Slitter 5 Home Position Sensor 9 Cutter Home Position Sensor 10 Creaser Lower Blade Encoder Sensor 11 Creaser Lower Blade Home Position Sensor 12 Creaser Upper Blade Home Position Senso...

Page 173: ...id 5 Blow out fan 6 Elevator Motor 7 Margin Slitter 1 Position Motor 8 Margin Slitter 2 Position Motor 9 Center Slitter 3 Position Motor 10 Center Slitter 4 Position Motor 11 Center Slitter 5 Position...

Page 174: ...n of Electronic Parts S2 Y1540 5 PCB Units Power Supply No Part Name 1 Panel PCB unit 2 Receive PCB 3 Oscillation PCB 4 USB connector board 5 Drive PCB Unit 6 Power supply unit 7 Main PCB unit 8 Main...

Page 175: ...173 Chapter 8 1 Position and Function of Electronic Parts 8 S2 Y1540 6 Others No Part Name 1 SSR 2 Fuse 3 Compressor 4 Relay PCB UNIT 5 Appliance inlet 6 Varistor 7 Terminal blocks 5 1 4 6 3 2 7 8 0...

Page 176: ...174 Chapter 8 1 Position and Function of Electronic Parts S2 Y1540 8 Connector VR Fuse Layout 2 Panel PCB Unit S2 V311 1 Main PCB Unit S2 V500 CN1 CN2 CN4 CN3 CN5 CN7 CN6 CN9 CN14 CN8 CN1 0...

Page 177: ...175 Chapter 8 1 Position and Function of Electronic Parts 8 S2 Y1540 3 DRIVE PCB Unit S2 V321 CN7 CN11 CN10 CN6 CN9 CN4 CN3 CN5 CN2 CN1 CN8 CN3 CN2 CN1 4 Main Motor Drive PCB Unit BZ008 0...

Page 178: ...Position and Function of Electronic Parts S2 Y1540 5 Power Supply Unit 24V UA040 CN51 CN1 CN3 CN2 CN1 CN2 CN1 6 Double Feed Detect PCB Unit Oscillation PCB Receive PCB 0 Oscillation PCB P9 V303 Recei...

Page 179: ...8 1 Position and Function of Electronic Parts 8 S2 Y1540 7 USB PCB Unit R8 V347 8 Fuse 0216002XP CAUTION Fuse Use the proper type of fuse when replacing Otherwise fire may occur CN2 CN1 0 Rating of fu...

Page 180: ...k 0 0 0 0 0 Lead Mark 0 0 0 0 0 SLIT1 25 0 25 25 5 SLIT2 285 0 285 275 285 SLIT3 0 0 0 75 95 SLIT4 0 0 0 225 195 SLIT5 0 0 0 125 100 SLIT6 0 0 0 175 190 CUT01 0 20 20 0 0 CUT02 0 570 0 0 0 CUT03 0 0 0...

Page 181: ...SLIT4 0 0 0 0 225 SLIT5 0 0 0 0 125 SLIT6 0 0 0 0 175 CUT01 0 8 12 0 5 CUT02 0 0 0 0 90 CUT03 0 0 0 0 100 CUT04 0 0 0 0 185 CUT05 0 0 0 0 195 CUT06 0 0 0 0 280 CUT07 0 0 0 0 290 CUT08 0 0 0 0 375 CUT...

Page 182: ...0 10 10 55 SLIT2 0 0 300 300 285 SLIT3 0 0 100 100 0 SLIT4 0 0 210 210 0 SLIT5 0 0 110 110 0 SLIT6 0 0 200 200 0 CUT01 5 0 22 10 0 CUT02 405 0 225 325 0 CUT03 0 0 235 640 0 CUT04 0 0 438 0 0 CUT05 0...

Page 183: ...SLIT2 293 2 SLIT3 61 2 SLIT4 235 2 SLIT5 119 2 SLIT6 177 2 CUT01 20 CUT02 105 CUT03 115 CUT04 200 CUT05 210 CUT06 295 CUT07 305 CUT08 390 CUT09 0 CUT10 0 CUT11 0 CUT12 0 CUT13 0 CUT14 0 CUT15 0 CUT16...

Page 184: ...Red White Blue 6 Blue Red 4 Blue Red Red Blue 1 9 Blue Orange Blue 2 White Red 1 Red Red 3 6 Blue Pink White d e R 1 y a r G 2 e u l B 3 d e R 1 3 3 d e R 1 Orange 2 3 e u l B 3 d e R 1 2 Red Blue Bl...

Page 185: ...ht blue Pink Green Light green White Purple Pink Yellow Light blue Black Gray Orange 2 k c a l B 1 n w o l B Blown Black Red Black 1 d e R 2 k c a l B Red Black Yellow 1 Black Red 1 Red 2 Red Black Re...

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Page 187: ...Folder 191 4 Maintenance 192 1 Confirming Saved Maintenance Data 192 2 Uploading the Maintenance Data of DC 616 194 3 Setting Up the Machine to Be Connected 195 4 Set Up Language to Be Used 196 5 Set...

Page 188: ...he dimensions are already finalized 3 UPLOAD Read the JOB from the DC 616 and save in computer 4 SETTING This is used to set the default values of the PC Controller 5 MAINTENANCE For service person us...

Page 189: ...ADJUST ALL This sets Apply Shrinkage and Adjust All 17 Stacker Setup Select the Stacker Setup check box and click Test to process only one sheet and stop it at the document ejecting position Then clic...

Page 190: ...540 2 Maintenance Menu 1 Maintenance Data No Item Function 1 Open Maintenance Data File To confirm the maintenance data saved in computer 2 Upload Maintenance Data from DC 616 To load the maintenance...

Page 191: ...9 Chapter 9 2 Maintenance Menu 189 S2 Y1540 2 Option Module No Item Function 1 Setting of connected device Check the box of the optional modules 0 1...

Page 192: ...ng No Item Function 1 LANGUAGE Set the language to be used on the screen 2 EDIT Edit the messages 3 IMPORT Import the message files 4 DELETE Delete the message files 5 SELECT Name of the message file...

Page 193: ...file of French LanguageGr ini Language file of German LanguageIt ini Language file of Italian LanguageJp ini Language file of Japanese LanguagePl ini Language file of Polish LanguageRs ini Language fi...

Page 194: ...MAINTENANCE 2 Enter the password 630304 and click YES If you click NO the screen will return to the one on step 1 If you enter the wrong password and click YES the maintenance screen will not appear...

Page 195: ...maintenance data appears Click Save as CSV file The imported data will be saved as CSV file in the computer If you click END the screen returns to the one in step 3 6 Enter the file name of the create...

Page 196: ...screen returns to the previ ous one 3 The message Upload maintenance data appears Click Yes to start uploading the data If you click No the screen returns to the previous one 4 Select the location you...

Page 197: ...in the Confirming the mainte nance data 2 Click OPTION MODULE tab 3 Check the box of option modules which is installed in DC 616 Click OK after confirmation of the check box If you click CANCEL the c...

Page 198: ...Japanese Polish Russian Spanish and other Click OK after the selection If you click CANCEL the selected one is canceled And the screen returns to the main menu 4 The message Do you want to change the...

Page 199: ...ate the txt file of new message IMPORT Upload the txt file of message you want to use DELETE Delete the txt file displayed in the select box Click EDIT 4 The screen shown on the right figure appears C...

Page 200: ...h KEY 4 3 Click the text box on the lower screen Enter the message in other language corresponding to the one in English Click Apply to define the entered message The defined message will be entered i...

Page 201: ...the file name of the new data you edited and save the message file Save the message file in text format txt Click Save If you click Cancel the screen returns to the one in step 4 without saving operat...

Page 202: ...ox 10 If you select the existing file the message This file name already exists Do you want to overwrite appears Click YES if you want to overwrite it Click NO if you do not overwrite it The screen re...

Page 203: ...ly Restart the PC controller And it runs with the set language you have changed Clicking Cancel returns to the screen of step 11 6 Deleting the Message File 1 Select Other 2 Select a message file to d...

Page 204: ...needs up version when adding the optional equipment on DC 616 2 Duplo seiko corp usbdc616 USB driver It does not need up version normally Confirming the version of PC Controller Run the PC Controller...

Page 205: ...9 5 Confirming the Version 203 S2 Y1540 Windows 7 Vista 1 Click Start and then click Control Panel in the menu The Control Panel appears 2 Click Hardware and Sound 2 Click Control panel 3 Click Device...

Page 206: ...ce Manager dialog The part of USB DC 616 is the version of driver After the confirmation close the window Windows XP 1 Click Start on the task bar Click Control Panel in the menu 2 Click Performance a...

Page 207: ...m Properties dialog appears Double click Hardware tab and then click De vice Manager 5 USB DC 616 is registered in Universal Serial Bus controller of Device Manager dialog The part of USB DC 616 is th...

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