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MyBinding DC-545HC Service Manual

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DC-545HC
Service Manual
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  • Page 1 Duplo Docu Cutter DC-545HC Service Manual Provided By http://www.MyBinding.com http://www.MyBindingBlog.com...
  • Page 2 SERVICE MANUAL DOCU CUTTER Ver.1 DC-545HC 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...

  • Page 4: Introduction

    Introduction The cause of most accidents is failure to adhere to basic safety rules and observe safety instructions. It is important to prevent potential causes of accidents from occurring. In order to do so, read this manual carefully, and be sure to understand all the safety instruc- tions and correct inspection and servicing procedures that it provides before beginning repair or servicing work.

  • Page 5: Safety Instructions

    Safety instructions Safety instructions 1.Cautions regarding the installation location Safety instructions Installation environment s Avoid installing the machine in places exposed to direct sunlight. • Sunlight will cause the temperature in the machine’s interior to rise, possibly leading to mal- function of the control system.

  • Page 6: Cautions For Installation Work

    Safety instructions 2. Cautions for installation work Warning • The machine’s power supply voltage and power consumption depend on the model. Details of this are given in the tables below. The power supply voltage and power consumption for the machine are given in the table below.

  • Page 7: Cautions For Maintenance, Inspection And Servicing

    Safety instructions 3. Cautions for maintenance, inspection and servicing Warning Precautions for safe servicing • Always remove the power cord plug from the outlet before starting work. aOtherwise, you could get a shock or your hands/fingers could be injured. • However, the plug must be left connected to the outlet when performing function checks (of individual motors, a given series of operations, or electrical circuits).

  • Page 8: Warning Sticker

    Safety instructions Warning Sticker Keep the WARNING stickers clean at all times. If labels become damaged or come off, have your service representative replace them. Do not touch blade! WARNING To remove jammed paper, use the tweezers. L8-T1100 WARNING Use caution when working near movable parts.
  • Page 9 Safety instructions...

  • Page 10: Introduction

    Chapter 1 Introduction Chapter 2 Description of Operation Chapter 3 Mechanical Chapter 4 Standard Adjustments Chapter 5 Maintenance Checks Chapter 6 Troubleshooting Chapter 7 HELP Mode Chapter 8 Miscallaneous...

  • Page 11: Table Of Contents

    Adjusting Crease Depth ......104 m Feed Solenoid Adjustment ...... 105 Chapter 1 Introduction , Gate Solenoid Adjustment (Without the DC-545HC) ..........106 z Specifications ..........10 . Cutter Assembly Perpendicularity x Dimensions ..........11 Adjustment ..........107 c Part Names and Functions ......12 ⁄0 Creaser Perpendicularity Adjustment ..
  • Page 12 Chapter 1 Introduction 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...

  • Page 13: Specifications

    z Specifications Chap.1 z Specifications Product name/Model No. DC-545 with HC AUTO FEEDER Input paper size Min.: 8.5” x 11”/A4 Max.: 12.6” x 18”/A3 Input paper weight Min.: 110 gsm, Max.: 230 gsm <No curl in the paper> Finishing size Min.: 2”...

  • Page 14: Dimensions

    x Dimensions Chap.1 x Dimensions...

  • Page 15: Part Names And Functions

    c Part Names and Functions Chap.1 c Part Names and Functions 1. Appearance Guide Plate Cover (rear) Cover (front) Feeder Cover Exit Tray Blower Air ADJ Knob Feed Tray Operation Panel Guide Plate Separator ADJ Knob Stand Door Caster...
  • Page 16 c Part Names and Functions Chap.1 Feeding Section Separator Flat Belt Level ADJ Lever Guide Plate Blower Air ADJ Knob Separator ADJ Knob Feed Tray Skew ADJ Knob Center Slitter Margin Slitter Creaser 2nd Roller Cutter...

  • Page 17: Operation Panel

    c Part Names and Functions Chap.1 2. Operation Panel START POWER – STOP COVER MODE PAPER Name Function LCD panel Displays the status of the machine. Displays messages when an error or paper jam occurs. <+> key Press to eject the document from the machine at the time of paper jam. <->...

  • Page 18: Work Flow

    v Work Flow Chap.1 v Work Flow 1. Operations Various Settings INPUT ........How to create job programs BAR CODE ......When to use bar codes REGISTER MARK ....When to use register marks AUTO CUT ......When to use AUTO CUT Setting the paper Select the Program Except when bar code is on.

  • Page 19: Options

    v Work Flow b Options Chap.1 MODE switching is shown next. [RUN] P – 04 <MODE> KEY [SELECT] P – 04 <MODE> KEY [INPUT] INPUT –– >SET <MODE> KEY <MODE> KEY BARCODE <SET> KEY <MODE> KEY REGISTER MARK <SET> KEY <MODE>...
  • Page 20 Chapter 2 Description of Operation z Paper Feed Unit ......... 18 m Paper Eject Tray ......... 39 1. Description ..........18 1. Description ..........39 2. Operation ..........18 , Main Drive ........... 40 3. Operation of each unit ......19 (1) Fan (Blower) ..........

  • Page 21: Paper Feed Unit

    z Paper Feed Unit Chap.2 z Paper Feed Unit 1. Description The paper loaded on the feed tray is raised by the Feed Motor Suction Assembly elevator motor. When the paper is in the required Elevator Motor position, a jet of air from a fan in front of the paper causes several sheets of paper to rise up.

  • Page 22: Operation Of Each Unit

    z Paper Feed Unit Chap.2 3. Operation of each unit (1) Fan (blower) Description Paper on the feed tray is transferred to the blower and several sheets are floated up. The airflow of the blower is adjusted by changing the position of the shutter and fan unit. The level the paper is floated up is adjusted by changing the airflow of the blower and the paper level sensor.

  • Page 23: Fan (Suction)

    z Paper Feed Unit Chap.2 (2) Fan (Suction) Description Air near the suction belt is sucked in, and then blown Fan(Suction) out on the right side of the AF-100. The fan (suction) is usually running during processing. Circuit diagram FAN(Suction) Feed P.W.B.

  • Page 24: Paper Level Sensor

    z Paper Feed Unit Chap.2 (3) Paper Level Sensor Description The paper level sensor controls the elevator motor to Level determine the position of the feed tray by detecting the Sensor position of the topmost sheet of paper on the feed tray. Status Output Light not transmitted...

  • Page 25: Suction Unit And Feed Motor

    z Paper Feed Unit Chap.2 (4) Suction Unit and Feed Motor Description Shutter Solenoid Because the fan (suction) is running during processing, when the shutter solenoid is on, the topmost sheet of paper on the feed tray is sucked on to the suction 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.

  • Page 26: Separator Gap

    z Paper Feed Unit Chap.2 (5) Separator Gap Description The separator gap is a mechanism between the separator and the suction belt that allows paper that is sucked on to the suction unit to be transferred one sheet at a time to the paper path.

  • Page 27: Elevator Motor

    z Paper Feed Unit Chap.2 (6) Elevator Motor Description Elevator Motor The elevator motor raises and lowers the feed tray. When there is no paper on the feed tray, the feed tray lowers until it triggers the elevator lower SW. However, if paper is loaded on the feed tray while it is lowering (paper sensor is not transmitting light), the elevator motor stops and the feed tray stops lowering.

  • Page 28: Elevator Upper Switch

    z Paper Feed Unit Chap.2 (7) Elevator Upper Switch Description Elevator Upper SW The feed tray stops when the angle that is attached to the chain that raises and lowers the feed tray 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.

  • Page 29: Elevator Lower Switch

    z Paper Feed Unit Chap.2 (8) Elevator Lower Switch Description The feed tray stops when the screw that is attached to Elevator Lower SW the chain that raises and lowers the feed tray turns the micro switch on. The feed tray is determined to be at its lower limit when the micro switch is on, and the feed tray will not go any lower.

  • Page 30: Paper Detection Sensor

    z Paper Feed Unit Chap.2 (9) Paper Detection Sensor Description The paper detection sensor detects whether or not there is paper on the feed tray. Feed PPS Photo Feed PPS Photo If there is no paper, the elevator goes to its lower level Transistor Transistor and stops.

  • Page 31: Feed Solenoid

    z Paper Feed Unit Chap.2 (10) Feed Solenoid Description Paper that reaches PPS1 is transferred to the paper path when 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.

  • Page 32: Feed Stepping Motor

    z Paper Feed Unit Chap.2 (11) Feed Stepping Motor Description Paper that reaches PPS1 is transferred to the main paper path. Feed Stepping Motor Circuit diagram FEED STEPPING MOTOR Main P.W.B. unit N4-V300* M7-X111* CN3-3...

  • Page 33: Ccd Mechanism

    x CCD Mechanism Chap.2 x CCD Mechanism 1. Description The CCD mechanism reads the bar code and register mark on the paper that is being processed and transfers the data to the main P.W.B. unit. The job is automatically selected according to the bar CCD Unit code (code 39) and the register mark compensates for incorrect printing positioning.
  • Page 34 x CCD Mechanism Chap.2 Circuit diagram CCD unit N4-X103* Main P.W.B. unit N4-V300*...

  • Page 35: Margin Slitter

    c Margin Slitter Chap.2 c Margin Slitter 1. Description The margin slitter position motor starts, turning the lead Right Margin Slitter Left Margin Slitter screw, and the margin slitter is moved to the designated Sensor Sensor position. These slitters are used for removing the left and right margins to the waste tray.

  • Page 36: Operation

    c Margin Slitter Chap.2 2. Operation 1) After paper feeding has finished (after the feed stepping motor stops) the margin slitter returns to the home position under the following conditions. q The first process after the power was turned on. w After all the covers have been opened.

  • Page 37: Guillotine Cutter Unit

    v Guillotine Cutter Unit Chap.2 v Guillotine Cutter Unit 1. Description The paper is cut vertically in relation to the direction the paper is moving. Cutter Motor Turning on the power starts the cutter motor in standby in the home position. One cut can be done in approximately 0.3 seconds.

  • Page 38: Creaser Unit

    b Creaser Unit Chap.2 b Creaser Unit 1. Description The paper is creased vertically in relation to the direction the paper is moving. One crease can be done in approximately 1.5 seconds. Turning on the power starts the creaser motor in standby in the home position. Creaser Unit Creaser Position Sensor Creaser Motor...
  • Page 39 b Creaser Unit Chap.2 Circuit diagram CN8-1 CREASER SENSOR YELLOW CA021 BLUE CN3-15 CREASER MOTOR N4-X102* BLACK Main P.W.B. unit N4-V300*...

  • Page 40: Center Slitter

    n Center Slitter Chap.2 n Center Slitter 1. Description The slitter position motor starts, turning the lead screw, and the center slitter is moved to the designated position and the paper is cut horizontally in reference to the direction the paper is moving. A maximum of 4 center slitters can be installed.
  • Page 41 n Center Slitter Chap.2 Possible range for each slitter Name Possible range Comments Left center slitter 0 to 160 mm Example: Right center slitter Left center slitter position +50 mm to 320 mm When the left center slitter is set at 120.2 mm, settings from 170.2 are possible.

  • Page 42: Paper Eject Tray

    m Paper Eject Tray Chap.2 m Paper Eject Tray 1. Description 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.

  • Page 43: Main Drive

    , Main Drive Chap.2 , Main Drive 1. Description The paper is transferred by the main motor. All the rollers except the rollers driven by the feed stepping motor use two timing belts driven by the main motor. Main Motor Driver Main Motor PPS3 Photo Diode PPS2 Photo PPS1 Photo...

  • Page 44: Operation

    , Main Drive Chap.2 2. Operation 1) After paper stops being fed (after the Feed Stepping Motor stops) the Main Motor starts running and the paper is transferred to the paper path section. 2) The paper stops temporarily at the CCD and then continues being transferred. If read BAR CODE (REGISTER MARK) has been set, then the paper continues being transferred after the BAR CODE (REGISTER MARK) has been read.
  • Page 45 , Main Drive Chap.2 The below two conditions cause J4: SLITTER OR STACK to be displayed, and the machine to stop. \See page 133 q When paper does not reach PPS4 (PPS4 is not w When paper is not extracted from PPS4 (PPS4 is transmitting light) although the paper has not transmitting light) although the total length of transferred 500 mm from after the front edge of...

  • Page 46: Skew Adjustment Mechanism

    . Skew Adjustment Mechanism Chap.2 . Skew Adjustment Mechanism 1. Description If the paper is skewed while processing , use the adjustment knob to adjust the guide and straighten paper. Angle Adjustment procedure Turning the knob Turning the knob clockwise counterclockwise...

  • Page 47: Bar Code

    ⁄0 BAR CODE Chap.2 ⁄0 BAR CODE 1. Description This machine uses code 39 bar code. Example: The bar code for P-11 is shown below. START/STOP bit 1 1 2 Preset no. Check digit The DC-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.

  • Page 48: Register Mark

    ⁄1 REGISTER MARK Chap.2 ⁄1 REGISTER MARK MARK2 MARK1 Mark 1 1) The paper is transferred in increments of 0.1 mm The clock count within 10 mm in from PPS2, and the mark is read by the CCD. this space is 70. Basic clock 2) When the edge of the reg.
  • Page 49 ⁄1 REGISTER MARK Chap.2 Positioning REGISTER MARK and BAR CODE REG. MARK BAR CODE 30 mm 8 mm 5 mm 8 mm 8 mm or more 5 mm or more 35 mm or less 5 mm or more 40 mm * 0.4 mm or more 10 mm or more...

  • Page 50: Mechanical

    Chapter 3 Mechanical z Exterior ............49 (6) Removing the Right Margin Slitter ....63 (1) Removing the AF 100 Cover R Unit ..... 49 (7) Removing the Left Margin Slitter ....64 (2) Removing the AF 100 Cover L Unit ..... 49 (8) Removing the Margin Slitter’s Upper Blade ...........
  • Page 51 , Driving Section .......... 79 (1) Removing the Main Motor ......79 (2) Removing the Feed Stepper ......79 (3) Removing the 1st Roller (Lower) ....80 (4) Removing the 2nd and 3rd Rollers (Lower) ............80 (5) Removing the 4th Roller (Lower) ....81 (6) Removing the 5th Roller (Lower) ....

  • Page 52: Exterior

    z Exterior Chap.3 z Exterior (1) Removing the AF-100 Cover R Unit Remove the AF-100 from the stand. Cover L Unit Cover R Unit \See page 52 Take out the 4 screws, and remove the cover R unit. Screws Screws (2) Removing the AF-100 Cover L Unit Remove the AF-100 from the stand.

  • Page 53: Removing The Dc 545 Cover L Unit

    z Exterior Chap.3 (4) Removing the DC-545 Cover L Unit Remove the AF-100 from the stand. Screws Screws \See page 52 Cover Cover R Unit Take out the 4 screws, and remove the cover L unit. L Unit Screws Screws (5) Removing the Lid Take out the 6 screws, and remove the lid.

  • Page 54: Removing The Rear Cover Switch

    z Exterior Chap.3 (7) Removing the Rear Cover Switch Remove the cover R unit from the DC-545. \See page 49 Remove the cutter motor. \See page 67 Remove the connector. (1 position) Front Cover Rear Cover Take out the 2 screws, and remove the rear cover Switch Screws Switch Screws switch.

  • Page 55: Feed Section

    x Feed Section Chap.3 x Feed Section (1) Removing the AF-100 Take out the two screws. NOTE : • The machine made to U.S. specifications has no screws. Screws Remove the DC-545 and AF-100 connector. IMPORTANT: • Be sure to remove the power cord from the electric outlet before starting work.

  • Page 56: Removing The Suction Assembly

    x Feed Section Chap.3 (2) Removing the Suction Assembly Take out the 2 screws, and remove the joint. Joint & Screws Remove the thumb screw and connector. (1 each) Thumb Screw Remove the suction assembly. Connector (3) Removing the Flat Belts Remove the suction assembly.

  • Page 57: Removing The Feed Pcb Unit

    x Feed Section Chap.3 (5) Removing the Feed PCB Unit Remove the AF-100 cover R unit. \See page 49 Remove the connector for the feed PCB unit. (4 positions) Take out the 4 screws, and remove the feed PCB unit. Screws (6) Removing the Separator Remove the suction assembly.

  • Page 58: Removing The Elevator Lower Switch

    x Feed Section Chap.3 (8) Removing the Elevator Lower Switch Remove the AF-100 cover L unit. Lower Angle & Screws \See page 49 Remove the connector for the lower switch. Upper Angle Connector (1 position). & Screws Take out the 2 screws, and remove the angle. Elevator Lower Switch Take out the 2 screws, and remove the elevator...

  • Page 59: Removing The Feed Motor

    x Feed Section Chap.3 (10) Removing the Feed Motor Remove the AF-100 cover R unit. Blacket & Screws \See page 49 Remove the connector for the motor. (1 position) Take out the 4 screws, and remove the bracket. Connector Blacket & Screws Loosen the set screws, and remove the pulley unit.

  • Page 60: Removing The Shutter

    x Feed Section Chap.3 Remove the connector for the solenoid. (1 position) Screws Remove the wire unit from the spring. Loosen the set screws on the shaft, and remove the Shaft & Shutter Set Screw Solenoid wire unit. Take out the 2 screws, and remove the shutter solenoid.

  • Page 61: Removing The Af 100 Cover Switch

    x Feed Section Chap.3 (13) Removing the AF-100 Cover Switch Remove the AF-100 cover L unit. \See page 49 Remove the connector for the switch. (1 position) Connector Screws Take out the 2 screws, and remove the AF-100 cover switch. Reinstallation IMPORTANT: •...

  • Page 62: Ccd Section

    c CCD Section Chap.3 c CCD Section (1) Removing the CCD Sensor Remove the cover L unit from the DC-545. \See page 50 Take out the 6 screws, and remove the lid. \See page 50 Remove the connector for the main PWB CN5. (1 position) Tie Wrap Cut the tie wraps.

  • Page 63: Margin Slitter Section

    v Margin Slitter Section Chap.3 v Margin Slitter Section (1) Removing the Margin Slitter Driving Motor Remove the cover R unit from the DC-545. \See page 49 Timing Belt Take out the 2 screws, and remove the bundled cable plate. Screws Take out the 4 screws, and remove the margin slitter driving motor.

  • Page 64: Removing The Left Margin Slitter Position Motor

    v Margin Slitter Section Chap.3 (3) Removing the Left Margin Slitter Position Motor Remove the cover L unit from the DC-545. \See page 50 Take out the 6 screws, and remove the lid. \See page 50 Open the door in the stand, and remove the waste Guide Guide Unit tray.

  • Page 65: Removing The Right Margin Slitter Sensor

    v Margin Slitter Section Chap.3 (4) Removing the Right Margin Slitter Sensor Open the cover (front) of the DC-545. Angle Remove the connector for the sensor. (1 position) Sensor Remove the right margin slitter sensor from the angle. Reinstallation Connector IMPORTANT: This image shows the right margin slitter sensor.

  • Page 66: Removing The Right Margin Slitter

    v Margin Slitter Section Chap.3 (6) Removing the Right Margin Slitter Remove the cover R unit from the DC-545. Timing Belt Screws \See page 49 Lead Screw Take out the screw, and remove the clamper. (2 positions) Shafts Loosen the 4 screws and slide the motor plate Motor Plate towards the exit tray.

  • Page 67: Removing The Left Margin Slitter

    v Margin Slitter Section Chap.3 (7) Removing the Left Margin Slitter Timing Belt Screws Remove the cover R unit from the DC-545. \See page 49 Lead Screw Remove the cover L unit from the DC-545. \See page 50 Shafts Motor Take out the 1 screw, and remove the clamper on the Plate operation side.

  • Page 68: Removing The Margin Slitter's Upper Blade

    v Margin Slitter Section Chap.3 (8) Removing the Margin Slitter’s Upper Blade Remove the right margin slitter, left margin slitter. \See page 63, 64 Take out the 4 screws, and remove the upper Screws assembly. Take out the 2 screws from the upper assembly, and Upper Assembly Upper Blade Assembly...

  • Page 69: Removing The Margin Slitter's Lower Blade

    v Margin Slitter Section Chap.3 (9) Removing the Margin Slitter’s Lower Blade Remove the right margin slitter and the left margin Screws slitter. \See page 63, 64 Take out the 2 screws, and remove the lower assembly. Take out the screws from the lower assembly, and Lower Assembly Lower Blade Unit remove the guide plate.

  • Page 70: Cutter Section

    b Cutter Section Chap.3 b Cutter Section (1) Removing the Cutter Assembly Remove the cover R unit from the DC-545. \See page 49 Remove the cover L unit from the DC-545. Screw \See page 50 Remove the connector for the motor. (1 position) Connector Take out the 2 screws, and remove the cutter assembly.

  • Page 71: Removing The Cutter Position Switch

    b Cutter Section Chap.3 (3) Removing the Cutter Position Switch Remove the cover R unit from the DC-545. Screws \See page 49 Cut the tie wrap on the cutter motor wires. Hole for Remove the connector for the switch and the motor. access to screws (2 positions)

  • Page 72: Creaser Section

    n Creaser Section Chap.3 n Creaser Section (1) Removing the Creaser Motor Remove the cover L unit from the DC-545. \See page 50 Take out the 6 screws, and remove the lid. \See page 50 Remove the main P.W.B. \See page 90 Screws Take out the 3 screws, and remove the plate.

  • Page 73: Removing The Creaser Assembly

    n Creaser Section Chap.3 (3) Removing the Creaser Assembly Remove the cover R unit from the DC-545. Cover (Rear) Upper Cover & Screws Cover (Front) & Screw & Screw \See page 49 Creaser Assembly Remove the cover L unit from the DC-545. \See page 50 Take out the screw, and remove the cover (front).

  • Page 74: Center Slitter Section

    m Center Slitter Section Chap.3 m Center Slitter Section (1) Removing the Center Slitter Drive Motor Remove the cover R unit from the DC-545. Pulley Unit \See page 49 Center Slitter Drive Motor Take out the 4 screws, and remove the center slitter Assembly drive motor assembly.

  • Page 75: Removing The Optional Slitter 1 Positioning Motor

    m Center Slitter Section Chap.3 (4) Removing the Optional Slitter 1 Posi- tioning Motor Remove the cover L unit from the DC-545. Optional Slitter 1 Positioning Motor \See page 50 Take out the 4 screws, and remove the optional slitter positioning motor assembly. Remove the connector from the motor.

  • Page 76: Removing The Center Right Slitter Sensor

    m Center Slitter Section Chap.3 (6) Removing the Center Right Slitter Sensor Angle Connector Open the cover (rear) of the DC-545. Remove the connector for the sensor. (1 position) Sensor Remove the sensor from the angle. Reinstallation IMPORTANT: This image shows the optional 1 slitter sensor. •...

  • Page 77: Removing The Optional Slitter 1 Sensor

    m Center Slitter Section Chap.3 (8) Removing the Optional Slitter 1 Sensor Open the cover (rear) of the DC-545. Angle Connector Remove the connector for the sensor. (1 position) Sensor Remove the sensor from the angle. Reinstallation IMPORTANT: • Make adjustments after installing the This image shows the optional 1 slitter sensor.

  • Page 78: Center Left Slitter

    m Center Slitter Section Chap.3 (10) Removing the Center Right Slitter and Center Left Slitter Screws Remove the cover R unit from the DC-545. Lead Screw Clampers & Screws Shafts \See page 49 Position Belt Loosen the 2 screws on the center right (left) slitter Position motor plate, and remove the position belt.

  • Page 79: Removing The Optional Slitter 1 And The Optional Slitter 2

    m Center Slitter Section Chap.3 (11) Removing the Optional Slitter 1 and the Optional Slitter 2 Remove the cover R unit from the DC-545. Shafts \See page 49 Clampers Remove the cover L unit from the DC-545. & Screws \See page 50 Loosen the 4 screws on the motor plate, and remove the timing belt.

  • Page 80: Removing The Center Slitter's Upper Blade

    m Center Slitter Section Chap.3 (12) Removing the Center Slitter’s Upper Blade NOTE : • The center left slitter, and the optional slitter 2 as well as the center right slitter and the optional slitter 1 are made in the same configuration.

  • Page 81: Removing The Center Slitter's Lower Blade

    m Center Slitter Section Chap.3 (13) Removing the Center Slitter’s Lower Blade NOTE : • The center left slitter, and the optional slitter 2 as well as the center right slitter and the optional slitter 1 are made in the same configuration.

  • Page 82: Driving Section

    , Driving Section Chap.3 , Driving Section (1) Removing the Main Motor Remove the cover L unit from the DC-545. Pillar & Screw Main Belt \See page 50 Take out the screw, and remove the pillar. Remove the main belt. Screws Remove the connector for the stepper driver PWB CN2.

  • Page 83: Removing The 1St Roller (Lower)

    , Driving Section Chap.3 (3) Removing the 1st Roller (Lower) Remove the cover R unit from the DC-545. Pulley Unit & Set Screw 1st Roller \See page 49 & Bearings Clamper & Screw Remove the cover L unit from the DC-545. \See page 50 Timing Belt Take out the 2 screws, and remove the motor plate.

  • Page 84: Removing The 4Th Roller (Lower)

    , Driving Section Chap.3 (5) Removing the 4th Roller (Lower) NOTE : • Do not cut yourself on the cutter unit. Remove the cover R unit from the DC-545. Screws \See page 49 Remove the cover L unit from the DC-545. \See page 50 Plate Take out the screw, and remove the pillar.

  • Page 85: Removing The 5Th Roller (Lower)

    , Driving Section Chap.3 (6) Removing the 5th Roller (Lower) Springs, E-Rings, Bushes 5th Roller Remove the cover R unit from the DC-545. \See page 49 Remove the cover L unit from the DC-545. \See page 50 Take out the screw, and remove the pillars. (2 positions) Remove the main drive belt (front).

  • Page 86: Removing The 6Th And 7Th Rollers (Lower)

    , Driving Section Chap.3 (7) Removing the 6th and 7th Rollers (Lower) Remove the cover R unit from the DC-545. Springs, E-Rings, Bushes \See page 49 6th Roller & Bearings Remove the cover L unit from the DC-545. \See page 50 7th Roller &...

  • Page 87: Removing The 8Th Roller (Lower)

    , Driving Section Chap.3 (8) Removing the 8th Roller (Lower) Remove the cover R unit from the DC-545. Springs & E-Rings & Bushes Screws \See page 49 Remove the cover L unit from the DC-545. \See page 50 Piller 8th Roller &...

  • Page 88: Electric Section

    . Electric Section Chap.3 . Electric Section (1) Removing the PPS1 Phototransistor Remove the cover L unit from the DC-545. Screws \See page 50 Open the cover (front) on the DC-545. Connector Remove the connector for the guide plate unit. (1position) Take out the 2 screws, and remove the guide plate Guide Plate Unit...

  • Page 89: Removing The Motor Driver

    . Electric Section Chap.3 (3) Removing the Motor Driver Remove the cover L unit from the DC-545. \See page 50 Motor Driver Remove the connector for the motor driver. Screws (2 positions) Connector Take out the 4 screws, and remove the motor driver. (4) Removing the PPS2 Phototransistor and PPS3 Photodiode Remove the cover L unit from the DC-545.

  • Page 90: Removing The Pps1 And Pps2 Photodiode

    . Electric Section Chap.3 (5) Removing the PPS1 and PPS2 Photo- diode Remove the cover R unit from the DC-545. 2nd Roller Right Margin Slitter Position motor \See page 49 Plate Remove the cover L unit from the DC-545. \See page 50 PPS1 Remove the right margin slitter position motor.

  • Page 91: Removing The Pps3 Phototransistor

    . Electric Section Chap.3 Remove the spring from the 2nd roller (upper). 2nd Roller Right Margin Slitter (2 positions) Position motor Plate Remove the E rings from the 2nd roller (upper), and remove the bushes. (2 positions each) Remove the 2nd roller (upper). PPS1 Phototransistor Connector...

  • Page 92: Removing The Feed Solenoid

    Take out the 2 screws, and remove the bracket. Connector Take out the 3 screws, and remove the feed solenoid. (8) Removing the Gate Solenoid (Without using the DC-545HC) Remove the cover L unit from the DC-545. Z Collar & Screw \See page 50 Remove the connector for the solenoid.

  • Page 93: Removing The Main P.w.b. Unit

    . Electric Section Chap.3 (9) Removing the Main P.W.B. Unit Remove the lid. Main P.W.B unit \See page 50 Remove all of the connectors from the Main P.W.B. unit. (There are 13 positions when the OP2 is not installed, and 14 positions when it is installed). Take out the 6 screws, and remove the main P.W.B.
  • Page 94 . Electric Section Chap.3 Remove the screws and then take off the power Power Supply Power Board supply, power board, and memory board. Screws Reinstallation IMPORTANT: Memory • Jobs that the user has stored are erased Board when the Memory board is changed. Screws •...
  • Page 95 . Electric Section Chap.3 MEMO...
  • Page 96 ⁄5 Creaser Sensor Plate Adjustment ... 118 2. How to make adjustments ....105 1. Objective ..........118 2. How to make adjustments ....118 , Gate Solenoid Adjustment (Without the DC-545HC) ......106 1. Objective ..........106 2. How to make adjustments ....106...

  • Page 97: Lcd Panel

    z LCD Panel Chap.4 z LCD Panel 1. Objective Adjusting the brightness and contrast of the LCD backlight. 2. How to make adjustments Adjusting the LCD backlight Turn VR1 to adjust the backlight. • Turn VR1 clockwise to make the backlight darker. •...

  • Page 98: Slitter Position

    x Slitter Position Chap.4 x Slitter Position 1. Objective Adjusting the position of each slitter. 2. How to make adjustments Prepare some paper that is either 8 ” x 11”, A4 size, or use the adjustment sheet. Turn on the power. Select P-75.
  • Page 99 x Slitter Position Chap.4 Access H-24. Adjust H-24 so that the width of the paper is within a range of 260.0 mm +/- 0.762 mm. • Increase the numbers to make the width of the paper larger. • Decrease the numbers to make the width of the paper smaller.
  • Page 100 x Slitter Position Chap.4 Chap.4 Adjust H-24 so that the width of the paper is within a range of 52.0 mm +/- 0.762 mm. • Increase the numbers to move the center slitter away from the slitter sensor. • Decrease the numbers to move the center slitter closer to the slitter sensor.

  • Page 101: Cutter Registration

    Chap.4 c Cutter Registration c Cutter Registration 1. Objective Adjusting the feed from PPS3 to the cutter. 2. How to make adjustments 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 when the preset program P-79 have been overwritten.
  • Page 102 c Cutter Registration Chap.4 Adjust the rotary DIP SW (SW2) on the main P.W.B. Adjustments are made in increments of 0.2 mm for Main P.W.B unit each step. Reduce the number to make the cut shorter, and increase the numbers to make the cut longer.

  • Page 103: Creaser Calibration

    v Creaser Calibration Chap.4 v Creaser Calibration • Removing the Creaser Assembly \See page 70 NOTE : • You need to adjust the sensor plate after installing the creaser assembly. \See page 118 • You need to adjust the creaser perpendicu- larity and creaser calibration after adjusting the sensor plate.
  • Page 104 v Creaser Calibration Chap.4 Access H-26. HELP mode H-26 \ see p.148 Adjust the distance between the lead edge of the paper and SCR.1 with the <+> and <-> keys. (Increasing the value by 1 makes the length 0.1 mm, and decreasing the value by 1 makes the length 0.1 mm.) •...

  • Page 105: Ccd Horizontal Line Alignment

    Turn on the power while pressing the <SET> key. Paper can be fed in the following ways depending on the type of machine. <For DC-545HC> • Place the sample paper that was prepared in Step 1 on the feed tray, and then press the <START> key to start feeding.
  • Page 106 b CCD Horizontal Line Alignment Chap.4 When the machine stops, the following appears on ∗∗ ∗∗∗∗∗∗∗∗∗∗∗∗ the LCD display panel. Confirm the value that is shown at “a” in the diagram. If the value is greater ∗∗∗∗∗∗∗∗ ∗∗∗ than 119 and less than 125, finish the job. If the value for “a”...

  • Page 107: Adjusting Crease Depth

    n Adjusting Crease Depth Chap.4 n Adjusting Crease Depth 1. Objective Adjusting the depth of the crease. • Removing the Creaser Assembly \See page 70 NOTE : • You need to adjust the sensor plate after installing the creaser assembly. •...

  • Page 108: Feed Solenoid Adjustment

    m Feed Solenoid Adjustment Chap.4 m Feed Solenoid Adjustment 1. Objective Adjusting the clearance between the 1st roller (upper) and the 1st roller (lower). • Removing the Feed Solenoid \See page 89 2. How to make adjustments Position the solenoid bracket so the set screws are located in the center of the slotted holes on the solenoid bracket.

  • Page 109: Gate Solenoid Adjustment (Without The Dc-545Hc)

    , Gate Solenoid Adjustment (Without the DC-545HC) Chap.4 , Gate Solenoid Adjustment (Without the DC-545HC) 1. Objective Adjust the height of the gate solenoid. • Removing the Gate Solenoid \See page 89 2. How to make adjustments Turn off the power to the machine and disconnect the power cord.

  • Page 110: Cutter Assembly Perpendicularity Adjustment

    Chap.4 . Cutter Assembly Perpendicularity Adjustment . Cutter Assembly Perpendicularity Adjustment 1. Objective Adjusting the perpendicularity of the cutter assembly. • Removing the Cutter Assembly \See page 67 NOTE : • Do this procedure first before you install the cutter assembly, and then adjust the cutter registration and the creaser calibration.

  • Page 111: Creaser Perpendicularity Adjustment

    ⁄0 Creaser Perpendicularity Adjustment Chap.4 ⁄0 Creaser Perpendicularity Adjustment 1. Objective Adjusting the perpendicularity of the creaser assembly. • Removing the Creaser Assembly \See page 70 NOTE : • You need to adjust the sensor plate after installing the creaser assembly. \See page 118 •...

  • Page 112: Ccd Vertical Line Alignment

    Step q on the feed tray. Paper can be fed in the following ways depending on the type of machine. <For DC-545HC> • Press the <START> key to start feeding the paper. Lead Ed e P 79 Left Margin P 78 10mm 0 762 <For DC-545>...
  • Page 113 ⁄1 CCD Vertical Line Alignment Chap.4 Loosen the screws of the CCD and adjust its position so that the CNT value is 70 +/- 1. Tighten the screws so that the CNT value is within a range of 70 +/- 1. Remove the paper and finish.

  • Page 114: Elevator Switch Height Adjustment

    ⁄2 Elevator Switch Height Adjustment Chap.4 ⁄2 Elevator Switch Height Adjustment 1. Objective Adjusting the upper and lower limits of the elevator. • Removing the Elevator Switch \See page 54, 55 2. How to make adjustments • Upper Limit Switch adjustment Access H-29.

  • Page 115: Cover Switch (Af-100: 1 Position, Dc-545: 2 Positions)

    ⁄3 Cover Switch (AF-100: 1 position, DC-545: 2 positions) Chap.4 ⁄3 Cover Switch (AF-100: 1 position, DC-545: 2 positions) 1.Objective Adjusting the operating position of the cover switch. • Removing the Cover Switch \See page 50, 51, 58 2. How to make adjustments Turn the power off and disconnect the power cord.

  • Page 116: Shutter Solenoid

    ⁄4 Shutter Solenoid Chap.4 ⁄4 Shutter Solenoid 1. Objective Adjusting the shutter operation. • Removing the Shutter Solenoid \See page 56 2. How to make adjustments Solenoid Assembly Attach the angle and plate to the solenoid. Set the Plate plate as far in the direction of the arrow as possible. Attach the solenoid assembly to the duct.
  • Page 117 ⁄4 Shutter Solenoid Chap.4 Hold the wire unit so that it doesn't become loose and pass it through the hole in the spindle. Pull the wire to remove any slack in the wire. Check again that the shutter is closed. Wrap the wire counterclockwise as shown by the arrow.
  • Page 118 ⁄4 Shutter Solenoid Chap.4 Attach the wire unit to spring T. Fasten the set screw so that the shutter is in the closed position. L Wrench...
  • Page 119 ⁄4 Shutter Solenoid Chap.4 Make sure that the shutter is closed when the solenoid is off. In the case of diagram 1, move the plate or angle in the direction of the arrow until the shutter closes. See the illustration of the following page. Diagram 1, an incorrect example of when the solenoid is off Diagram 2, a correct example of...
  • Page 120 ⁄4 Shutter Solenoid Chap.4 Plate Angle Access H-31. HELP mode H-31 \ see p.149 Press the <+> key to make sure that the shutter moves smoothly.

  • Page 121: Creaser Sensor Plate Adjustment

    ⁄5 Creaser Sensor Plate Adjustment Chap.4 ⁄5 Creaser Sensor Plate Adjustment 1. Objective Adjusting the standby position of the creaser’s upper blade. • Removing the Creaser Assembly \See page 70 NOTE : • You need to adjust the sensor plate after installing the creaser assembly.
  • Page 122 Chapter 5 Maitenance Checks 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...

  • Page 123: Cleaning And Oiling

    z Cleaning and Oiling x Periodic Maintenance Check List Chap.5 z Cleaning and Oiling (1)Cleaning 1.Paper shreds Clean with a brush 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 gears.
  • Page 124 x Periodic Maintenance Check List Chap.5 (2) Criteria for Replacing Primary Parts 1. DC-545 PARTS No. DESCRIPTION MTBF L8-X1110 Cutter motor 2,000,000 times L8-B1112 Upper blade (margin slitter) 1,500,000 sheets L8-B2060 Lower blade (margin slitter) 1,500,000 sheets N4-D2100 Upper blade (center slitter) 1,500,000 sheets N4-D2230 Lower blade (center slitter)
  • Page 125 x Periodic Maintenance Check List Chap.5 MEMO...

  • Page 126: Chapter 6 Troubleshooting

    Chapter 6 Troubleshooting z Troubleshooting Guide ......124 (1) J1: REJECT PAPER ........124 (2) J2: FEED JAM ..........124 (3) J3: CENTER JAM ........126 (4) J4: SLITTER OR STACK ......126 (5) J5: OVER CAPACITY ......... 127 (6) J7: CUTTER LOCK ........127 (7) J8: CREASE LOCK ........

  • Page 127: Troubleshooting Guide

    z Troubleshooting Guide Chap.6 z Troubleshooting Guide (1) J1: REJECT PAPER Pro- Cause/Defective part Items to be checked Result Countermeasure dure In the machine Is there some paper in the Remove the paper from inside the machine? machine. Is the sensor normal when Finish.
  • Page 128 z Troubleshooting Guide Chap.6 Result Pro- Cause/Defective part Items to be checked Countermeasure dure Fan (suction) Does it operate in HELP mode Go to procedure 14. (H-30)? Is the connector for the fan Plug the connector in firmly. (suction) firmly plugged in? Is the voltage measured with a Replace the fan (blower).

  • Page 129: J3: Center Jam

    z Troubleshooting Guide Chap.6 (3) J3: CENTER JAM Pro- Cause/Defective part Items to be checked Result Countermeasure dure Paper length Is the paper on which the Use paper that matches the JOB trouble occurred at least 30 data, or rewrite the JOB data. mm longer than the JOB data? Main motor Is it normal when checked in...

  • Page 130: J5: Over Capacity

    z Troubleshooting Guide Chap.6 (5) J5: OVER CAPACITY Pro- Cause/Defective part Items to be checked Result Countermeasure dure Amount of paper Is paper loaded over the MAX? Reduce the paper so that it is loaded below MAX. Paper level sensor Is the actuator stuck? Adjust the actuator so that is moves smoothly.

  • Page 131: J8: Crease Lock

    z Troubleshooting Guide Chap.6 (7) J8: CREASE LOCK Pro- Cause/Defective part Items to be checked Result Countermeasure dure Paper Does the paper meet specifica- Use paper that meets specifica- tions? tions. Creaser sensor Is it normal when checked in Go to procedure 4. HELP mode (H-08)? Main PWB unit Are the connectors for the...

  • Page 132: E3: Barcode Error

    z Troubleshooting Guide Chap.6 (10) E3: BARCODE ERROR Pro- Cause/Defective part Items to be checked Result Countermeasure dure BAR CODE Is the BAR CODE printed? Turn the BAR CODE off, or print a BAR CODE. BAR CODE Is the area where the BAR Use paper that is not dirty.

  • Page 133: E5: Slitter Error

    z Troubleshooting Guide Chap.6 (12) E5: SLITTER ERROR Pro- Cause/Defective part Items to be checked Result Countermeasure dure Slitter sensor Is it normal when checked in Go to procedure 3. HELP mode (H-08)? Slitter positioning Is the connector firmly plugged Replace faulty slitter sensors.

  • Page 134: E7: Connection Error

    z Troubleshooting Guide Chap.6 (14) E7: CONNECTION ERROR Pro- Cause/Defective part Items to be checked Result Countermeasure dure Connector Is the * displayed on the upper Firmly connect the AF-100 and the right edge of the LCD? DC-545. (Indicates that AF-100 and DC- 545 are connected.) Feed PCB unit Is the trouble cleared by...

  • Page 135: Error Display

    2. Light did not transmit through all of the sensors PPS1, PPS2, PPS3, and PPS4 when the start switch was pressed while the machine was stopped and paper was in the AF-100. (Only when using DC-545HC) ––– J 2 –––...
  • Page 136 There is too much paper loaded on the AF-100 feed tray. • Paper level sensor is defective • Actuator malfunction • Main PWB unit is defective Problem detected 1. Elevator lower switch was pressed after paper feed was started at DC-545HC while the paper level sensor was on.
  • Page 137 x Error Display Chap.6 ––– J 7 ––– CUTTER LOCK Cause • Paper does not meet specifications • Cutter motor is defective • Cutter position switch is defective • Main PWB unit is defective Problem detected 1. There was no response from the cutter position switch even though the specified time (0.6 seconds) elapsed after cutting started.
  • Page 138 x Error Display Chap.6 ––– E 2 ––– RS232C ERROR Cause • CCD is defective • Main PWB unit is defective Problem detected 1. There was an abnormal transmission between the CCD and the DC-545. ––– E 3 ––– BARCODE ERROR Cause •...
  • Page 139 x Error Display Chap.6 ––– E 5 ––– SLITTER ERROR Cause • Slitter sensor is defective • Slitter positioning motor is defective • Main PWB unit is defective Problem detected 1. Light did not transmit to the slitter sensor when temporarily shifting inward 8 mm to detect the home position while the slitter sensor was shielded from light and the command to move the slitter was issued.
  • Page 140 x Error Display Chap.6 ––– E 6 ––– DATA ERROR Cause • Preset data is not registered • Memory PWB unit is defective Problem detected 1. Preset data was accessed that exceeds a total of 17 AUTO CUTs (see table below), JOB cuts and scores while AUTO CUT is being used.
  • Page 141 x Error Display Chap.6 ––– E 7 ––– CONNECTION ERROR Cause • Bad connection between AF-100 and DC-545 • Feed PCB unit is defective • Main PWB unit is defective Problem detected 1. Can not confirm connection between AF-100 and DC-545 while machine is operating. IMPORTANT: •...

  • Page 142: Chapter 7 Help Mode

    Chapter 7 HELP Mode 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...

  • Page 143: Help Mode List

    z HELP Mode List Chap.7 z HELP Mode List HELP Description Classification Mode No. H-00 ROM version indication ROM version display H-01 Total cut counter Total counts H-02 Total feed counter Total counts H-03 PPS1 check Sensor condition display H-04 PPS2 check Sensor condition display H-05...

  • Page 144: Functions And Operation Procedures For Each Help Mode

    x Functions and operation procedures for each HELP mode Chap.7 x Functions and operation procedures for each HELP mode (1) Accessing HELP mode 1) When the machine is in use, put it in standby and then turn “OFF” the power switch. 2) Turn the power switch “ON”...

  • Page 145: Help Description

    c HELP Description Chap.7 c HELP Description HELP No. Adjustments and checks Contents and descriptions H-00 ROM version indication The version of the ROM that is mounted on the main PWB (U32) is displayed. H-00:ROM VERSION ∗ ∗ ∗ Ver.- H-01 Total cut counter display The number of cuts the cutter has done is displayed.
  • Page 146 c HELP Description Chap.7 HELP No. Adjustments and checks Contents and descriptions H-08 Sensor & switch status Displays the status of each sensor and switch. display abcdefghijklmnop qrstuvw a ... PPS1 No paper (0) Paper (1) b ... PPS2 No paper (0) Paper (1) c ...
  • Page 147 c HELP Description Chap.7 HELP No. Adjustments and checks Contents and descriptions H-11 Feed solenoid function test Feed solenoid function test Pre-solenoid operates when the <+> key is pressed. Gate solenoid operates when the <-> key is pressed. NOTE : •...
  • Page 148 c HELP Description Chap.7 HELP No. Adjustments and checks Contents and descriptions H-16 OP1 slitter (stepping motor) OP1 slitter positioning motor (stepping motor) function test function test 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 <->...
  • Page 149 c HELP Description Chap.7 HELP No. Adjustments and checks Contents and descriptions H-22 CCD performance (stepping Confirms CCD scanner functions mode) function test CCD lights read and the counter (CNT) is displayed. When the vertical line located 10 mm from the left edge of the paper is read, the CNT value is 70 +/- 1.
  • Page 150 c HELP Description Chap.7 HELP No. Adjustments and checks Contents and descriptions H-24 Position adjustment for each Adjust the slit position of each slitter. slitter ∗ Left Margin Slitter Left Center Slitter Optional Slitter1 Right Margin Slitter Right Center Slitter Optional Slitter2 q The “...
  • Page 151 c HELP Description Chap.7 HELP No. Adjustments and checks Contents and descriptions H-25 Initialization of RAM Initialize the RAM. The entire RAM memory (including the pre-set data) is initialized by pressing the <MODE> key and the <SET> key. (It takes about 10 seconds.) Initialize the RAM memory except for the pre-set data by pressing the <+>...
  • Page 152 c HELP Description Chap.7 HELP No. Adjustments and checks Contents and descriptions H-30 Fan check Fan motor function test (when the option is installed) (Optional AF-100) Suction fan operates when the <+> key is pressed. Blower fan operates when the <-> key is pressed. +KEY:FAN1 ON -KEY:FAN2 ON H-31...

  • Page 153: Select Language For Displays

    v Select Language for Displays Chap.7 v Select Language for Displays When operating the machine, put it in standby mode, and then turn the power “OFF”. Turn the power “ON” while pressing the <F> key and the <CLEAR> key. The message shown below is displayed. Language?(+,-) ENGLISH Select a language with the <+>...

  • Page 154: Chapter 8 Miscallaneous

    Chapter 8 Miscallaneous z Job List ............. 152 x 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.

  • Page 155: Job List

    z Job List Chap.8 z Job List PROGRAM NUMBER Trading Trading Job Type Cut in half SM CARD 8up letter 8up ledger WALLET 3.5 x 5 4 x 6 5 x 7 MARK 1 MARK 2 LEFT SL 12.7 31.8 12.7 31.8 RGHT SL...
  • Page 156 z Job List Chap.8 PROGRAM NUMBER 11up 1up Lg Business Business Large Job Type 8 x 10 Card Scrapbook Postcard Card Postcard Brochure MARK 1 MARK 2 LEFT SL 12.7 13.5 31.8 RGHT SL 209.6 203.2 202.4 272.9 209.6 209.6 269.9 C.L.
  • Page 157 z Job List Chap.8 PROGRAM NUMBER #18* #19* 3-Fold Job Type Brochure Tri-Cut Fourths Fold in Half Tri-Fold MARK 1 MARK 2 LEFT SL 41.3 RGHT SL 238.1 C.L. SL C.R. SL OP1 SL OP2 SL CUT1 25.4 93.1 139.7 CUT2 406.4 186.2...
  • Page 158 z Job List Chap.8 Job during installation Job while installing the AF-100 STEP21: P-77 (REG off + BC off): AF-100 to DC-545 Mounting Alignment STEP21: P-78 (REG off + BC off): AF-100 to DC-545 Mounting Alignment (With OP2 SL) STEP22: P-79 (REG off + BC off): Lead Edge Length & Score Position Job Type MARK 1 MARK 2...

  • Page 159: Position And Function Of Electronic Parts

    x Position and Function of Electronic Parts Chap.8 x Position and Function of Electronic Parts (1) Schematic drawing of electronic parts DC-545...
  • Page 160 Memory P.W.B. unit For saving job data Main P.W.B. unit For controlling the DC-545 Solenoid For controlling the gate (not used by DC-545HC) Solenoid Paper feed solenoid Power P.W.B. unit Printed wiring board for the power supply (DC 24 V DC 5 V &...
  • Page 161 x Position and Function of Electronic Parts Chap.8 AF-100 Part name Number Function Feed PCB unit AF-100 drive Gear motor Paper feed belt drive Solenoid Solenoid for opening and closing the shutter Intake fan Fan motor Exhaust fan Micro switch For detecting whether the top cover is open or closed Photo micro sensor For detecting paper level...
  • Page 162 x Position and Function of Electronic Parts Chap.8 (2) Connector, VR and LED layout 1) Main P.W.B. Unit N4-V300* CN10 CN14 CN11 2) Panel P.W.B. Unit N4-V301* Buzzer 3) Power P.W.B. Unit N4-V302* FUSE (250 V 8 A)
  • Page 163 x Position and Function of Electronic Parts Chap.8 4) Memory P.W.B. Unit K9-V212* 5) Switching Power Supply UA023 6) Motor Driver L8-X101* 7) Feed P.C.B. Unit N4-V303*...

  • Page 164: Overall Wiring Diagram

    c Overall Wiring Diagram Chap.8 c Overall Wiring Diagram (1) DC-545 FEED STEPPING M. SCORE M. LEFT LEFT ROLL SLIT CUTTER UNIT SLIT FEED L8-X1090 SLIT. CEN. SOL. RIGHT LEFT RIGHT N4-W121* GATE SOL. MAIN MOTOR LEFT SLIT. SEN. SEN. SLIT.
  • Page 165 c Overall Wiring Diagram Chap.8 (2) AF-100 FAN(BLOWER) ELEVATOR FEED MOTOR FAN(SUCTION) DC-545 AF-100 N4-X105* N4-X106* N4-X104* N4-X105* DC-545 MAIN P.W.B. SHUTTER N4-V300* SOLENOIDO N4-W204* N4-X101* RIGHT BLUE N4-W124* CN12 RIGHT BLUE WHITE WHITE N4-W202* N4-W203* BROWN BROWN BLUE BLUE FEED PPS NH10 WHITE...
  • Page 166 c Overall Wiring Diagram Chap.8 (3) Connector 1) Main P.W.B. CN1 MAIN MOTOR M2-X1010 STEPPING DRIVER L8-X1080 N4-W103* MAIN PWB 2) Main P.W.B. CN2 WHITE WHITE WHITE YELLOW WHITE ORANGE WHITE PEACH WHITE PURPLE WHITE MAIN PANEL GREEN WHITE RIGHT BLUE WHITE GRAY WHITE...
  • Page 167 c Overall Wiring Diagram Chap.8 3) Main P.W.B. CN3 FEED STEPPING M. SCORE M. M2-X101* N4-X102* GATE SOL. N4-X100* LEFT SLIT. M2-X101* N4-W106* MAIN PWB 4) Main P.W.B. CN4 LEFT SLIT. LEFT CEN. PPS1 PPS2 PPS3 PPS4 SEN. SEN. WHITE BLUE ORANGE BLUE...
  • Page 168 c Overall Wiring Diagram Chap.8 5) Main P.W.B. CN5 N4-X103* MAIN PWB 6) Main P.W.B. CN6 ROLL SOL. SLIT M.1 CUTTER UNIT SLIT M.2 FEED LED L8-X1090 CUTTER M. L8-X1110 POSITON SW COVER SW N4-W119* YELLOW YELLOW COVER SW N4-W120* YELLOW YELLOW N4-W112*...
  • Page 169 c Overall Wiring Diagram Chap.8 7) Main P.W.B. CN7 RIGHT SLIT. LEFT CENTER. RIGHT CENTER. N4-W114* MAIN PWB 8) Main P.W.B. CN8 MAIN PWB N4-W115* COVER SW YELLOW YELLOW N4-W119* COVER SW YELLOW YELLOW N4-W120* SCORE RIGHT RIGHT SEN. SLI.SEN. CEN.SEN.
  • Page 170 c Overall Wiring Diagram Chap.8 9) Main P.W.B. CN9 MAIN PWB N4-W116* OPTION OPTION SLT.1 SEN. 10) Main P.W.B. CN10 MAIN PWB CN10 N4-W117* MEMORY PWB K9-V212*...
  • Page 171 c Overall Wiring Diagram Chap.8 11) Main P.W.B. CN13 MAIN PWB CN13 N4-W122* POWER PWB N4-V302* POWER SW N4-W101* N4-W100* WHITE BLACK INRET WITH BLUE BLUE POWER BLACK WHITE BROWN NOISE N4-W102* BROWN GREEN/YELLOW SUPPLY FILTER 12) Main P.W.B. CN14 MAIN PWB CN14 N4-W118*...
  • Page 172 c Overall Wiring Diagram Chap.8 13) Main P.W.B. CN11,12 & Feed P.W.B. CN1 DC-545 MAIN P.W.B. N4-V300* CN12 N4-W124* BROWN BROWN WHITE ORANGE WHITE WHITE GREEN GREEN GREEN BLUE FEED P.W.B. GRAY RIGHT BLUE BLACK YELLOW N4-V303* RIGHT BLUE YELLOW YELLOW PURPLE PINK...
  • Page 173 c Overall Wiring Diagram Chap.8 15) Feed P.W.B. CN3 FAN(INTAKE) N4-X105* N4-W203* FEED P.W.B N4-V303* 16) Feed P.W.B. CN4 SOLENOIDO to CN2 N4-X101* FEED P.W.B. N4-V303* N4-W202* RIGHT BLUE RIGHT BLUE WHITE WHITE BLUE BLUE N4-W204* FEED PPS RECEIVE N4-W206* N4-W209* N4-W205* ELEVATOR...
  • Page 175 Reproduction prohibited 1st printing : February 2003 Issued by : DUPLO SEIKO CORPORATION PRINTED IN JAPAN...

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