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SERVICE MANUAL

Ver.1

DOCU CUTTER

DC-545HC

DUPLO SEIKO CORP.

Be sure to read this manual carefully, so that you
repair and service this machine safely and correctly.
Do not begin work until you have thoroughly
understood the contents of this manual.
Repairing or servicing the machine with insuffeicient
knowledge about it could lead to unforeseen
accidents or falls in the machine's performance or
quality.

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Summary of Contents for DC-545HC

Page 1: ...Provided By http www MyBinding com http www MyBindingBlog com Duplo Docu Cutter DC 545HC Service Manual...

Page 2: ...hat you repair and service this machine safely and correctly Do not begin work until you have thoroughly understood the contents of this manual Repairing or servicing the machine with insuffeicient kn...

Page 3: ......

Page 4: ...chine with insufficient knowledge about it could lead to unforeseen accidents It is not possible to anticipate and describe in a manual such as this every possible hazard that could arise in the cours...

Page 5: ...nt temperature 5 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 parts of a building...

Page 6: ...could make it fall over With no load when the machine is on standby At full load when the machine is running at maximum power consumption Use only the power cord that is provided among the accessories...

Page 7: ...vated so be aware of the conditions and positions of related equipment and take great care not to put your hands or fingers into moving parts The cutter unit and slitter unit contain hazardous sharp b...

Page 8: ...ged or come off have your service representative replace them WARNING Cutters and movable parts are inside this cover Before opening the cover to work unplug the power cord Use caution when working ne...

Page 9: ...6 Safety instructions...

Page 10: ...pter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 Introduction Description of Operation Mechanical Standard Adjustments Maintenance Checks Troubleshooting HELP Mode Miscalla...

Page 11: ...85 Chapter 4 Standard Adjustments z LCD Panel 94 x Slitter Position 95 c Cutter Registration 98 v Creaser Calibration 100 b CCD Horizontal Line Alignment 102 n Adjusting Crease Depth 104 m Feed Solen...

Page 12: ...9 z Specifications 10 x Dimensions 11 c Part Names and Functions 12 1 Appearance 12 2 Operation Panel 14 v Work Flow 15 1 Operations 15 b Options 16 Chapter 1 Introduction 1...

Page 13: ...ease Trim Crease tolerance 0 03 0 762 mm With paper cutting length not exceeding 18 Media type Range Regular copy paper to coated heavy weight paper Feeding method Automatic Feeding Air suction method...

Page 14: ...11 x Dimensions Chap 1 x Dimensions...

Page 15: ...t Names and Functions c Part Names and Functions 1 Appearance Feeder Cover Cover front Cover rear Exit Tray Operation Panel Door Caster Stand Separator ADJ Knob Guide Plate Feed Tray Blower Air ADJ Kn...

Page 16: ...Part Names and Functions Feeding Section Flat Belt Separator Guide Plate Separator ADJ Knob Skew ADJ Knob Feed Tray Blower Air ADJ Knob Level ADJ Lever CCD Margin Slitter Center Slitter Creaser Cutter...

Page 17: ...n t STOP key Press to stop automatic feeding after the current sheet is processed Press to clear jam indication after the paper is cleared y Key pad Press to enter print numbers and enter values durin...

Page 18: ...o create job programs When to use register marks When to use bar codes When to use AUTO CUT Various Settings 1 INPUT BAR CODE REGISTER MARK AUTO CUT Start Key 4 Finish 5 Setting the paper 2 Select the...

Page 19: ...Options Setting the Optional Slitter 2 MODE switching is shown next RUN P 04 MODE KEY SELECT P 04 MODE KEY INPUT INPUT SET MODE KEY BARCODE ON OFF SET KEY MODE KEY MODE KEY REGISTER MARK ON OFF SET KE...

Page 20: ...tection Sensor 27 10 Feed Solenoid 28 11 Feed Stepping Motor 29 x CCD Mechanism 30 1 Description 30 2 Operation 30 c Margin Slitter 32 1 Description 32 2 Operation 33 v Guillotine Cutter Unit 34 1 Des...

Page 21: ...r Elevator Upper SW Elevator Lower SW Level Sensor 2 Operation 1 Processing starts processing does not start if there is no paper The fan blower and the fan suction start running 2 The feed tray start...

Page 22: ...n be increased by turning the knob so the numbers increase The gap between the shutter and the fan increases which increases the air intake and therefore increases the amount of air blown out The blow...

Page 23: ...the right side of the AF 100 The fan suction is usually running during processing Circuit diagram Fan Suction Chap 2 z Paper Feed Unit RED BLACK CN3 1 24V FAN Intake GND GND 24V CN1 1 CN1 1 2 12 CN11...

Page 24: ...etween the suction belt and the paper To increase the force of the suction move the adjustment lever towards w to decrease the gap between the suction belt and the paper Turn the lever towards q if th...

Page 25: ...unit The feed motor starts running about 0 3 seconds after the shutter solenoid turns on and the suction belt turns and transfers the paper to the DC 545 Circuit diagram Shutter inner Shutter Solenoid...

Page 26: ...path This gap is regulated by turning the knob to raise and lower the separator Turn the knob so that the numbers increase to make the gap narrower The separator rises and the gap narrows Turn the kn...

Page 27: ...ed retry operation the feed tray continues to lower until the paper level sensor goes off light is transmitted for a period Then the feed tray rises until the paper level sensor goes on light is not t...

Page 28: ...y turns the micro switch on The feed tray is determined to be at its upper limit when the micro switch is on and the feed tray will not rise any higher Circuit diagram Elevator Upper SW PURPLE PURPLE...

Page 29: ...tch is on and the feed tray will not go any lower If the elevator lower switch is on because there is too much paper loaded on the feed tray and the paper level sensor is on light is not transmitted t...

Page 30: ...nd stops When there is not paper light is transmitted the LED PAPER on the operation panel blinks Status Output Paper is present 5V light is not transmitted Paper is not present 0V light is transmitte...

Page 31: ...hen feeding paper As the feed solenoid turns on the roller driven by the feed stepping motor presses the paper onto the press roller and sends it to the main paper path Circuit diagram Feed Solenoid C...

Page 32: ...Stepping Motor Description Paper that reaches PPS1 is transferred to the main paper path Circuit diagram Feed Stepping Motor CN3 3 8 FEED STEPPING MOTOR M7 X111 Main P W B unit N4 V300 M Chap 2 z Pape...

Page 33: ...bar code has been read If when reading starts the paper is transferred 50 mm but the bar code could not be read then E3 BARCODE ERROR is displayed and the machine stops See page 135 3 The job is set...

Page 34: ...31 Chap 2 x CCD Mechanism CN5 1 CN5 10 Main P W B unit N4 V300 CCD unit N4 X103 Circuit diagram...

Page 35: ...oved to the designated position These slitters are used for removing the left and right margins to the waste tray Right Margin Slitter Left Margin Slitter Sensor Right Margin Slitter Sensor Left Margi...

Page 36: ...for the job if the margin slitter moves 8 mm and light is still not being transmitted at the slitter sensor then E5 SLITTER ERROR is displayed and the machine stops See page 136 Possible range for eac...

Page 37: ...The cutter motor starts and cutting begins 3 The cutter motor stops when the cutter position sensor goes from off to on and the main transfer starts again If the cutter position sensor does not change...

Page 38: ...temporarily when the paper reaches the crease position 2 The creaser motor starts and cutting begins 3 The creaser motor stops when the creaser position sensor goes from off to on and the main transfe...

Page 39: ...36 Circuit diagram Chap 2 b Creaser Unit RED BLUE YELLOW 1 3 2 CN8 1 2 3 Main P W B unit N4 V300 RED BLACK CN3 15 16 CREASER MOTOR N4 X102 CREASER SENSOR CA021 M...

Page 40: ...d e After the machine stops due to an error r There is no paper in the feed tray after paper is loaded in the feed tray again t After the job has been changed 2 When the margin slitter moves from the...

Page 41: ...ptional slitter When the OP1 is set at 110 0 mm settings from 160 0 mm are possible Circuit diagram CN6 9 9 8 CN8 7 3 2 1 BLUE PEACH RED 18 CN7 13 10 Main P W B unit N4 V300 26 25 CN4 24 3 2 1 BLUE OR...

Page 42: ...scription Paper that is ejected from the DC 545 is collected here It is possible to adjust the paper being ejected into two levels Refer to the image below for the installation position Position A Eje...

Page 43: ...the rollers driven by the feed stepping motor use two timing belts driven by the main motor Chap 2 Main Drive Main Motor Main Motor Driver PPS4 Photo Diode PPS4 Photo Transistor PPS3 Photo Diode PPS2...

Page 44: ...in Drive q When paper does not reach PPS3 PPS3 is not transmitting light although the paper has transferred 100 mm from after the front edge of the paper has reached PPS2 PPS2 is not transmitting ligh...

Page 45: ...er reached PPS3 Has the paper reached PPS4 Has the paper been transferred 500 mm No No No Yes Yes Yes J4 SLITTER OR STACK Start processing Count start Go to the next path Has the paper reached PPS4 Ha...

Page 46: ...iption If the paper is skewed while processing use the adjustment knob to adjust the guide and straighten paper Adjustment procedure q w Turning the knob Turning the knob clockwise counterclockwise An...

Page 47: ...545 can use this bar code if it is converted to CODE 39 If the bar code comes in the following range the CCD automatically replaces the data and sends the data pre set no to the DC 545 START STOP bit...

Page 48: ...e edge is the same for 4 5 mm the value for the mark is the average of the values of the 10 values for the reference clock in the buffer in the CCD MARK1 MARK2 10 mm The clock count within 10 mm in th...

Page 49: ...ore a b Positioning REGISTER MARK and BAR CODE 5 mm BAR CODE REG MARK a b REG MARK Position range 60 mm or less 35 mm or less 10 mm or more 5 mm 30 mm 8 mm 8 mm 40 mm 0 4 mm or more 5 mm or more 5 mm...

Page 50: ...Motor 61 4 Removing the Right Margin Slitter Sensor 62 5 Removing the Left Margin Slitter Sensor 62 6 Removing the Right Margin Slitter 63 7 Removing the Left Margin Slitter 64 8 Removing the Margin...

Page 51: ...oving the 8th Roller Lower 84 Electric Section 85 1 Removing the PPS1 Phototransistor 85 2 Removing the Panel PWB Unit 85 3 Removing the Motor Driver 86 4 Removing the PPS2 Phototransistor and PPS3 Ph...

Page 52: ...e the cover R unit 2 Removing the AF 100 Cover L Unit q Remove the AF 100 from the stand See page 52 w Take out the 4 screws and remove the cover L unit 3 Removing the DC 545 Cover R Unit q Remove the...

Page 53: ...h q Remove the cover R unit from the DC 545 See page 49 w Remove the cutter motor See page 67 e Remove the connector for the switch 2 positions r Take out the 2 screws and remove the front cover switc...

Page 54: ...move the cover R unit from the DC 545 See page 49 w Remove the cutter motor See page 67 e Remove the connector 1 position r Take out the 2 screws and remove the rear cover switch Reinstallation IMPORT...

Page 55: ...two screws NOTE The machine made to U S specifications has no screws w Remove the DC 545 and AF 100 connector IMPORTANT Be sure to remove the power cord from the electric outlet before starting work N...

Page 56: ...emove the suction assembly See page 53 w Slide the flat belts off to remove them 4 Removing the Fan Motor Blower q Remove the AF 100 cover L unit See page 49 w Remove the connector for the fan motor 1...

Page 57: ...emove the separator 7 Removing the Elevator Upper Switch q Remove the AF 100 cover L unit See page 49 w Remove the connector for the upper switch 1 position e Take out the 2 screws and remove the angl...

Page 58: ...TANT Adjust the position in which to install the lower switch See page 111 9 Removing the Paper Level Sensor q Open the cover of the AF 100 w Remove the connector from the inside of the frame 1 positi...

Page 59: ...s and remove the bracket r Loosen the set screws and remove the pulley unit t Take out the 3 screws and remove the feed motor 11 Removing the Shutter Solenoid q Remove the suction assembly See page 53...

Page 60: ...id Reinstallation IMPORTANT Adjust the shutter position when install the shutter solenoid See page 113 12 Removing the Shutter q Remove the Shutter Solenoid See page 56 w Take out the 4 screws and rem...

Page 61: ...Removing the Elevator Motor q Remove the AF 100 cover R unit See page 49 w Loosen the set screws and remove the motor gear e Take out the 3 screws and remove the motor r Remove the connector from insi...

Page 62: ...ion r Cut the tie wraps 4 positions NOTE Do not cut any other bundles of wires t Remove the code band 6 positions y Cut the tie wraps 7 positions NOTE Do not cut any other bundles of wires u Take out...

Page 63: ...ition y Take out the set screw and remove the pulley unit u Take out the 3 screws and remove the margin slitter driving motor 2 Removing the Right Margin Slitter Position Motor q Remove the cover R un...

Page 64: ...rews and remove the lid See page 50 e Open the door in the stand and remove the waste tray r Take out the 2 screws and remove the cover t Undo the thumb screws and remove the guide unit y Remove the c...

Page 65: ...right margin slitter sensor Sensor Angle Connector Feed Direction Optional 1 Slitter Sensor Optional 2 Slitter Sensor Center Left Slitter Sensor Center Right Slitter Sensor Left Margin Slitter Sensor...

Page 66: ...positions NOTE Do not drop the bearings from opposite the operation side into the machinery 2 posi tions Do not drop the left or right margin slitter key into the machinery 4 positions t Remove the t...

Page 67: ...n the operation side 2 positions NOTE Do not drop the bearings from opposite the operation side into the machinery 2 posi tions Do not drop the left or right margin slitter key into the machinery 4 po...

Page 68: ...pper assembly e Take out the 2 screws from the upper assembly and remove the lid 2 positions r Remove the bearings 2 positions t Remove the upper blade assembly NOTE Be careful not to cut yourself on...

Page 69: ...t the 2 screws and remove the lower assembly e Take out the screws from the lower assembly and remove the guide plate r Take out the 2 screws and remove the lid 2 positions t Remove the bearing 2 posi...

Page 70: ...and remove the cutter assembly Reinstallation IMPORTANT Make adjustments after installing the cutter assembly See page 98 107 2 Removing the Cutter Motor q Remove the cutter assembly See page 67 w Ta...

Page 71: ...the cutter motor wires e Remove the connector for the switch and the motor 2 positions NOTE Switch wires are yellow and yellow Motor wires are red and black r Take out the 2 screws and remove the cutt...

Page 72: ...e t Remove the motor connector and Power Supply PCB connector y Loosen the set screws and remove the pulley unit u Take out the 4 screws and remove the creaser motor assembly 2 Removing the Creaser Se...

Page 73: ...ews and remove the creaser belt u Take out the screw and remove the pillar from the main rear drive i Remove the timing belt o Take out the screws and remove the sensor plate 0 Take out the 4 screws f...

Page 74: ...ioning motor assembly e Remove the connector from the motor 1 position r Take out the 4 screws and remove the center right slitter positioning motor 3 Removing the Center Left Slitter Posi tioning Mot...

Page 75: ...en it is not installed r Take out the 4 screws and remove the optional slitter 1 positioning motor 5 Removing the Optional Slitter 2 Posi tioning Motor q Remove the cover L unit from the DC 545 See pa...

Page 76: ...Right Slitter Sensor q Open the cover rear of the DC 545 w Remove the connector for the sensor 1 position e Remove the sensor from the angle Reinstallation IMPORTANT Make adjustments after installing...

Page 77: ...nal Slitter 1 Sensor q Open the cover rear of the DC 545 w Remove the connector for the sensor 1 position e Remove the sensor from the angle Reinstallation IMPORTANT Make adjustments after installing...

Page 78: ...nto the machinery 2 positions Do not drop the center right slitter or center left slitter keys into the machinery 4 positions y Take out the 2 screws and remove the lead screw 2 positions NOTE Do not...

Page 79: ...r 1 or the optional slitter 2 into the machinery 4 positions y Loosen the 4 screws on the motor plate on optional slitter 1 and optional slitter 2 and remove the position belt 2 positions u Take out t...

Page 80: ...page 75 76 w Take out the 3 screws and remove the lid unit R e Remove the bearing 2 positions r Take out the 2 screws and remove the lid t Remove the upper blade assembly NOTE Be careful not to cut y...

Page 81: ...enter slitter See page 75 76 w Take out the 3 screws and remove the lid e Remove the bearing r Take out the 2 screws and remove the lid t Remove the lower blade assembly NOTE Be careful not to cut you...

Page 82: ...er driver PWB CN2 1 position t Take out the 3 screws and remove the main motor 2 Removing the Feed Stepper q Remove the cover L unit from the DC 545 See page 50 w Take out the 2 screws on the motor pl...

Page 83: ...llers Lower q Remove the cover R unit from the DC 545 See page 49 w Remove the cover L unit from the DC 545 See page 50 e Take out the screw and remove the pillar r Remove the main belt front t Loosen...

Page 84: ...crews and remove the pulley unit y Open the cover front on the DC 545 u Take out the 2 screws and remove the plate i Remove the spring 2 positions o Remove the E ring from the 4th roller upper 0 Remov...

Page 85: ...main drive belt rear t Loosen the set screws and remove the pulley unit y Open the cover rear on the DC 545 u Remove the spring 2 positions i Remove the E rings from the 5th roller upper 2 positions o...

Page 86: ...set screws and remove the pulley unit y Open the cover rear on the DC 545 u Remove the spring 2 positions i Remove the E rings from the 6th and 7th rollers upper 2 positions o Remove the 6th and 7th...

Page 87: ...y Open the cover rear on the DC 545 u Take out the 4 screws and remove the rear plate i Remove the connector for the rear plate 1 position o Remove the spring 2 positions 0 Remove the E rings from th...

Page 88: ...ps 2 positions y Take out the 2 screws and remove the phototransistor Ref Photodiode Brown blue Phototransistor White blue 2 Removing the Panel PWB Unit q Remove the cover R unit from the DC 545 See p...

Page 89: ...the connector 1 position e Cut the tie wrap 1 position r Take out the screw and remove the code band 3 positions t Take out the 2 screws and remove the bracket y Take out the 2 screws and remove the p...

Page 90: ...the bush 0 Remove the square shaft 1 Remove the connector for the PPS1 phototransistor 1 position 2 Take out the 2 screws and remove the guide plate unit NOTE You need to make adjustments during insta...

Page 91: ...e r Take out the 4 screws and remove the lid t Remove the connector from the inside of the frame 1 position NOTE There are three connectors in a row They are in order from the feeder the PPS1 photo di...

Page 92: ...d remove the Z collar r Take out the 2 screws and remove the bracket t Take out the 3 screws and remove the feed solenoid 8 Removing the Gate Solenoid Without using the DC 545HC q Remove the cover L u...

Page 93: ...ging the main P W B H 09 H 24 H 26 H 27 See page 140 Enter the values that you noted after replacing the main P W B 10 Removing the Power Supply Power Board and Memory Board q Remove the DC 545 cover...

Page 94: ...d and memory board Reinstallation IMPORTANT Jobs that the user has stored are erased when the Memory board is changed When a new Memory board is installed it has no memory perform H 25 INITIAL IZE RAM...

Page 95: ...92 Chap 3 Electric Section MEMO...

Page 96: ...113 5 Creaser Sensor Plate Adjustment 118 1 Objective 118 2 How to make adjustments 118 Chapter 4 Standard Adjustments 4 z LCD Panel 94 1 Objective 94 2 How to make adjustments 94 x Slitter Position...

Page 97: ...ght Turn VR1 to adjust the backlight Turn VR1 clockwise to make the backlight darker Turn VR1 counterclockwise to make the backlight brighter w Adjusting the LCD contrast Turn VR2 to adjust the contra...

Page 98: ...tep t to make adjustments t Access H 24 HELP mode H 24 see p 147 y Adjust H 24 so that the width of the left margin is within a range of 10 0 mm 0 762 mm Increase the numbers to make the width of the...

Page 99: ...NOTE Use a JOB that has the LEFT SL set to 10 0 mm and the RIGHT SL set to 218 0 mm 270 0 mm and the C L SL set to 62 0 mm the C R SL set to 166 0 mm 218 0 mm the OP 1 SL set to 114 0 mm and the OP 2...

Page 100: ...sensor Decrease the numbers to move the center slitter closer to the slitter sensor 6 Repeat Steps 3 to 5 until the width of the paper is within the correct range Left Center Slitter Sensor Left Cent...

Page 101: ...72 77 8 5 mm 0 762 LE T SL P1 L P 73 104 m 762 C L SL O 1 SL P 77 8 2mm 76 EFT SL OP2 SL P 76 1 6m 7 2 P1 L C R SL P 77 5 mm 0 762 P1 L OP2 SL P 78 5 mm 0 762 L FT L C R SL 74 20 mm 0 762 C R SL IGHT...

Page 102: ...ents of 0 2 mm for each step Reduce the number to make the cut shorter and increase the numbers to make the cut longer Access H 09 to confirm the value that is currently set HELP mode H 09 see p 143 y...

Page 103: ...nts q Select P 79 Turn off both bar code and reg mark NOTE Use a JOB that has the Cut 1 set to 10 0 mm and SCR 1 set to 114 0 mm when the preset program P 79 have been overwritten See page 155 w Run o...

Page 104: ...gth 0 1 mm and decreasing the value by 1 makes the length 0 1 mm If the distance from the lead edge to SCR 1 is 103 3 mm or less increase the value If the distance from the lead edge to SCR 1 is 104 7...

Page 105: ...have been overwrit ten See page 155 r Turn off bar code turn on reg mark and then turn off AUTO CUT t Turn off the power y Turn on the power while pressing the SET key u Paper can be fed in the follow...

Page 106: ...gle Adjust the CCD towards A increase the angle if the value for a is greater than 124 Adjust the CCD towards B decrease the angle if the value for a is less than 120 0 Repeat Steps t to o until the v...

Page 107: ...ually rotating the creaser unit pulley q Place the Creaser Assembly in the upright position normal operating orientation on a stable surface w Loosen the two lock nuts as shown in Figure e Rotate the...

Page 108: ...distance between the 1st roller upper and the 1st roller lower so that it is between 1 mm and 2 mm Also make sure the end play of the square shaft is 0 2 mm e Adjust the distance between the E clip o...

Page 109: ...he center of the slotted holes on the solenoid bracket e Loosen the set screw and adjust the gate position so it is between 4 5 mm to 5 0 mm above the plate Note the lever should be pulled up by the s...

Page 110: ...e 98 Creaser Calibration Adjustment See page 100 2 How to make adjustments q Prepare some paper that is either 81 2 x 11 A4 size or use the adjustment sheet w Turn on the power e Select P 79 Turn off...

Page 111: ...er perpendicu larity and creaser calibration after adjusting the sensor plate See page 100 2 How to make adjustments q Prepare some paper that is either 81 2 x 11 A4 size or use the adjustment sheet w...

Page 112: ...F BC OFF AF 100 to DC 545 Mounting Aligme t With O 2 SL P 79 REG OFF BC OFF Lead Edge Lehgth Score Position P 79 REG ON BC OFF Image Sh ft Chec 1 P 80 REG ON BC OFF Image S ift Chec 2 104mm 762 N4 Y20...

Page 113: ...tical Line Alignment Chap 4 CNT 70 KEY CCD ON u Loosen the screws of the CCD and adjust its position so that the CNT value is 70 1 i Tighten the screws so that the CNT value is within a range of 70 1...

Page 114: ...levator Switch See page 54 55 2 How to make adjustments Upper Limit Switch adjustment q Access H 29 HELP mode H 29 see p 148 w Press the key to adjust the movement of the Upper Limit Switch LA028 with...

Page 115: ...e cover switch Removing the Cover Switch See page 50 51 58 2 How to make adjustments q Turn the power off and disconnect the power cord w Adjust the cover switch so that the micro switch goes on when...

Page 116: ...the direction of the arrow as possible Attach the solenoid assembly to the duct Set the solenoid assembly as far in the direction of the arrow as possible w Turn the shaft counterclockwise until the s...

Page 117: ...pass it through the hole in the spindle t Pull the wire to remove any slack in the wire Check again that the shutter is closed y Wrap the wire counterclockwise as shown by the arrow Wrap the wire tow...

Page 118: ...115 u Attach the wire unit to spring T i Fasten the set screw so that the shutter is in the closed position L Wrench 4 Shutter Solenoid Chap 4...

Page 119: ...t by hand In the case of diagram 3 adjust the angle of the open shutter so that it is between 70 to 80 by moving the plate in the direction of the arrow as shown in the image below See the illustratio...

Page 120: ...117 1 Access H 31 HELP mode H 31 see p 149 2 Press the key to make sure that the shutter moves smoothly Plate Angle 4 Shutter Solenoid Chap 4...

Page 121: ...to adjust the sensor plate after installing the creaser assembly See page 108 You need to adjust the creaser perpendicu larity and creaser calibration after adjusting the sensor plate See page 100 2...

Page 122: ...119 z Cleaning and Oiling 120 1 Cleaning 120 2 Oiling 120 x Periodic Maintenance Check List 120 1 6 month Periodic Checks 120 2 Criteria for Replacing Primary Parts 121 Chapter 5 Maitenance Checks 5...

Page 123: ...3 Cleaning Use a brush to clean any paper dust etc from the upper and lower sensors PPS4 Cleaning Use a brush to clean any paper dust etc from the upper and lower sensors Timing Belts Checking Inspect...

Page 124: ...X1110 Stepping motor slitter position 1 200 000 sheets N4 X1020 Gear motor 2 000 000 cycles N4 X1000 Paper feed solenoid 1 8 000 hours N4 X1010 Paper feed solenoid 2 8 000 hours Main board unit 40 000...

Page 125: ...122 Chap 5 x Periodic Maintenance Check List MEMO...

Page 126: ...TACK 126 5 J5 OVER CAPACITY 127 6 J7 CUTTER LOCK 127 7 J8 CREASE LOCK 128 8 E1 COVER OPEN 128 9 E2 RS232C ERROR 128 10 E3 BARCODE ERROR 129 11 E4 REG MARK ERROR 129 12 E5 SLITTER ERROR 130 13 E6 DATA...

Page 127: ...e cleared by setting the suction appropriately Is the trouble cleared by correcting the position of the paper level sensor Does it operate in HELP mode H 31 Is the connector for the feed motor firmly...

Page 128: ...eed solenoid is operating Does it operate normally if you open a gap between the Front Plate N4 A1190 and Plate N4 A1210 Is the trouble cleared by replacing the feed PCB unit Fan suction Paper level s...

Page 129: ...ked HELP mode H 11 see p 144 HELP mode H 20 see p 145 4 J4 SLITTER OR STACK Pro ce dure Is the paper on which the trouble occurred at least 50 mm longer than the JOB data Is the paper getting stuck on...

Page 130: ...s it normal when checked in HELP mode H 08 Is the connector for the main PWB unit 6 firmly plugged in Does the blade go up and down when checked in HELP mode H 19 While the power is turned off remove...

Page 131: ...unning check that the screw holding the pulley is tight If the motor is not running replace the creaser motor Replace the main PWB unit Items to be checked HELP mode H 08 see p 143 HELP mode H 18 see...

Page 132: ...he specified range Plug the connector in firmly Replace the main PWB unit Replace the CCD Items to be checked 11 E4 REG MARK ERROR Pro ce dure Is the REG MARK printed Is the area where the REG MARK is...

Page 133: ...lace faulty slitter sensors Plug the connector in firmly Replace the main PWB unit Replace faulty slitter positioning motors Adjust the belt tension Tighten the pulley screw Replace the main PWB unit...

Page 134: ...ed in HELP mode H 08 Does the feed tray go up and down when checked in HELP mode H 29 Are the chain and pulley normal Is the voltage measured with a tester between CN2 5 and CN2 6 on the feed PCB unit...

Page 135: ...was pressed while the machine was stopped and paper was in the AF 100 Only when using DC 545HC J 2 FEED JAM Cause Paper does not meet specifications Separator gap is too narrow AF 100 Fan blower airfl...

Page 136: ...ons The length of the job data and the paper are different The stacker is full and paper can not be ejected Problem detected 1 The leading edge of the paper was not detected at PPS4 even though the sp...

Page 137: ...E LOCK Cause Paper does not meet specifications Creaser motor is defective Creaser sensor is defective Main PWB unit is defective Problem detected 1 There was no response from the creaser sensor even...

Page 138: ...Main PWB unit is defective Problem detected 1 The bar code could not be read even after the paper fed the specified length 50 mm after the bar code reading operation started E 4 REG MARK ERROR Cause R...

Page 139: ...ded from light and the command to move the slitter was issued 2 The slitter did not return to the predetermined position within the specified time period refer to the table below after the command to...

Page 140: ...st cut There are 0 AUTO CUTs from the last cut to the trailing edge of the paper The number of cuts scores and AUTO CUTs is 10 4 0 14 The total is less than 17 resulting in no error x Error Display Ch...

Page 141: ...s defective Elevator motor is defective Paper level sensor is defective Feed PCB unit is defective Main PWB unit is defective Problem detected 1 Elevator was not detected at elevator upper switch elev...

Page 142: ...139 z HELP Mode List 140 x Functions and operation procedures for each HELP mode 141 1 Accessing HELP mode 141 c HELP Description 142 v Select Language for Displays 150 Chapter 7 HELP Mode 7...

Page 143: ...check Function testing H 16 OP1 slitter check Function testing H 17 Main motor check Function testing H 18 Score check Function testing H 19 Cutter check Function testing H 20 Slitter blade drive chec...

Page 144: ...it in standby and then turn OFF the power switch 2 Turn the power switch ON while pressing the Stop key The HELP mode is displayed 3 Select the HELP mode no setting that you want to change by pressin...

Page 145: ...ounter can be cleared by pressing the CLEAR key for 3 seconds or more H 03 PPS1 check The level of the PPS of the paper supply is displayed PPS level is below 30 when there is no paper at PPS H 04 PPS...

Page 146: ...OP2 Light transmitted 0 Light not transmitted 1 p Not used q Connection check option Connected 0 Not connected 1 r Elevator upper limit switch Option ON 0 OFF 1 s Elevator lower limit switch Option O...

Page 147: ...Slitter moves to the left opposite the operation panel when the key is pressed Slitter moves to the right toward the operation panel when the key is pressed H 14 Left center slitter Left center slitt...

Page 148: ...test function test Motor runs forward when the key is pressed Motor runs backward when the key is pressed H 19 Cutter stepping mode Cutter motor function test function test Motor runs forward when the...

Page 149: ...emain lit until the power is turned off after it has been turned on once When the check is finished turn off the power X mm CNT 1 15 1 2 21 1 3 27 1 4 33 1 5 40 1 6 46 1 7 52 1 8 58 1 9 64 1 10 70 1 1...

Page 150: ...P Description Chap 7 Left Margin Slitter Right Margin Slitter Left Center Slitter Right Center Slitter Optional Slitter1 Optional Slitter2 100 100 100 100 100 100 Distance Value moved input mm 0 1 1 0...

Page 151: ...he Main P W B unit Compensates for mechanical differences between the PPS2 and the CCD Use the key and the key to adjust the score position and then register it with the STOP key The processing cuttin...

Page 152: ...tter control method when REG MARK is ON control method ON Slitter moves just the amount of drift as the REG MARK scan indicates It returns to the home position under the following conditions OFF Slitt...

Page 153: ...rn the power ON while pressing the F key and the CLEAR key The message shown below is displayed e Select a language with the key and the key The language is stored when it is switched 1 ENGLISH 2 FREN...

Page 154: ...Position and Function of Electronic Parts 156 1 Schematic drawing of electronic parts 156 2 Connector VR and LED layout 159 c Overall Wiring Diagram 161 1 DC 545 161 2 AF 100 162 3 Connector 163 8 Cha...

Page 155: ...2 184 2 0 0 184 2 0 0 142 9 139 7 108 0 139 7 144 1 0 0 144 1 139 7 25 4 19 1 22 2 15 2 17 1 28 6 19 1 0 190 3 108 0 111 1 101 6 106 0 130 2 196 9 0 0 114 3 123 8 188 0 114 9 149 2 0 0 0 203 2 212 7 2...

Page 156: ...269 9 0 101 6 0 136 4 0 57 2 108 0 0 0 0 0 0 184 2 158 8 0 0 0 114 3 0 142 9 0 108 0 0 0 17 1 19 1 12 7 12 7 28 6 6 4 12 7 16 9 271 1 266 7 266 7 419 1 130 2 95 3 139 7 415 9 0 0 0 0 149 2 184 2 266 7...

Page 157: ...1 3 0 0 0 0 238 1 0 0 0 0 0 0 108 0 0 0 0 0 0 0 0 0 0 0 0 25 4 93 1 139 7 0 0 406 4 186 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 153 4 0 0 139 7 94 1 280...

Page 158: ...76 70 10 0 10 0 166 0 10 0 206 0 216 0 77 70 10 0 10 0 218 0 62 0 166 0 114 0 10 0 206 0 216 0 79 70 10 0 10 0 200 0 10 0 270 0 114 0 297 0 80 82 8 0 12 0 202 0 8 0 268 0 112 0 297 0 78 70 10 0 10 0...

Page 159: ...156 x Position and Function of Electronic Parts 1 Schematic drawing of electronic parts 2 6 10 12 5 11 6 9 6 6 7 17 15 4 13 3 14 1 16 8 6 DC 545 x Position and Function of Electronic Parts Chap 8...

Page 160: ...For detecting cutter motor interlock and whether the cover is open or closed Home position for the left margin slitter Home position for the right margin slitter Home position for the left center slit...

Page 161: ...enoid for opening and closing the shutter Intake fan Exhaust fan For detecting whether the top cover is open or closed For detecting paper level For detecting the upper limit of the elevator For detec...

Page 162: ...B Unit N4 V300 CN10 CN2 CN5 CN8 CN1 CN4 CN9 CN14 CN13 CN12 CN11 CN3 CN7 CN6 U32 ROM SW1 SW2 2 Panel P W B Unit N4 V301 CN1 CN2 Buzzer VR1 VR2 3 Power P W B Unit N4 V302 FUSE 250 V 8 A CN2 CN1 x Posit...

Page 163: ...160 4 Memory P W B Unit K9 V212 CN1 5 Switching Power Supply UA023 CN1 CN2 6 Motor Driver L8 X101 CN1 CN2 7 Feed P C B Unit N4 V303 CN2 CN3 CN1 CN4 x Position and Function of Electronic Parts Chap 8...

Page 164: ...ANGE BLACK BROWN YELLOW WHITE BROWN ORANGE BLACK BROWN YELLOW WHITE BROWN ORANGE BLACK BROWN YELLOW W W W W WHITE BROWN ORANGE BLACK BROWN YELLOW RED PURPLE BLUE WHITE YELLOW ORANGE BLUE GREEN RIGHT B...

Page 165: ...19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 1 2 3 RED BLACK BROWN WHITE WHITE GREEN GREEN GRAY BLACK RIGHT BLUE Y...

Page 166: ...UE 5V 5V GND GND CN1 CN2 CN2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 c Overall Wiring Diagram Chap 8 3 Connector 1 Main P W...

Page 167: ...EED STEPPING M M2 X101 4 Main P W B CN4 BROWN BLUE BROWN BLUE WHITE BLUE BROWN BLUE WHITE BLUE BROWN BLUE WHITE BLUE WHITE BLUE N4 W107 N4 W108 N4 W108 N4 W109 N4 W109 N4 W123 N4 W110 N4 W111 GND GND...

Page 168: ...ER UNIT L8 X1090 FEED LED RED RED YELLOW WHITE GND YELLOW WHITE RED BLACK YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW RED BLUE N4 W112 N4 W113 N4 W119 N4 W120 N4 X101 L8 X1010 L8 X1010 24V 24V GND 24V R...

Page 169: ...3 14 15 16 17 18 RIGHT SLIT LEFT CENTER RIGHT CENTER CN7 c Overall Wiring Diagram Chap 8 7 Main P W B CN7 8 Main P W B CN8 MAIN PWB N4 W115 N4 W119 N4 W120 RED YELLOW BLUE RED PEACH BLUE RED GREEN BLU...

Page 170: ...16 24V 24V 5V GND WHITE BROWN ORANGE BLACK BROWN YELLOW RED PURPLE BLUE 1 2 3 4 5 6 7 8 9 1 2 3 CN9 OPTION SEN OPTION SLT 1 MAIN PWB MEMORY PWB K9 V212 N4 W117 WHITE YELLOW ORANGE BLUE GREEN RIGHT BLU...

Page 171: ...Wiring Diagram Chap 8 11 Main P W B CN13 12 Main P W B CN14 MAIN PWB INRET WITH NOISE FILTER POWER PWB N4 V302 POWER SUPPLY BLACK WHITE WHITE BLACK GREEN YELLOW BLUE BLUE BROWN BROWN 24V 24V 5V 5V GN...

Page 172: ...Y BLACK RIGHT BLUE YELLOW PINK RED BLUE PURPLE ORANGE YELLOW GREEN WHITE BLUE BROWN 24V 5V GND GND 24V BROWN ORANGE WHITE GREEN BLUE RIGHT BLUE YELLOW YELLOW PURPLE ORANGE RED BLACK WHITE YELLOW PINK...

Page 173: ...LEVATOR LOWER SW LA028 COVER SW N4 W207 ELEVATOR SENSOR CA021 FEED PPS RECEIVE N4 W206 SOLENOIDO N4 X101 N4 W204 N4 W205 N4 W202 N4 W209 CN4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 ORANGE ORANGE PUR...

Page 174: ......

Page 175: ...Reproduction prohibited 1st printing February 2003 Issued by DUPLO SEIKO CORPORATION PRINTED IN JAPAN...

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