Duplo DC-646 User manual

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<Examples of Pictorial Symbols>
A circle with a line through it indicates a prohibited action.
The particular act prohibited is indicated by a picture inside the circle.
(In the example shown here, the prohibited act is disassembly.)
A black disc indicates an instruction, or sometimes a prohibited action.
The instruction itself is indicated by pictorial symbols drawn in white on the disc.
(In the example shown here, the instruction is “Remove the plug from the outlet”.)
●The precautions below are vital for safety and must be taken.
Warning Terminology
The following warning terminology is used in this installation manual.
Indicates a high degree of potential danger. Failure to heed the warning may lead to death or
serious injury.
Safety Precautions
WARNING
Indicates a medium degree of potential danger. Failure to heed the caution may lead to injury or
damage to property.
CAUTION
WARNING
●Use only the power cord that is provided among the accessories.
Insert the power cord plug firmly into the socket, so that proper electrical contact is effected.
→Use of any other power cord could result in imperfect grounding.
If grounding is imperfect and electrical leakage occurs, fire or electric shock could result.
●Do not use a source voltage other than that specified. Do not connect two or more loads to a
single outlet. →Doing so may result in fire or electric shock.
●Do not place the machine in a humid or dusty area. →Doing so may result in fire or electric
shock.
CAUTION
●Do not place the machine in an unstable position, such as on an unsteady support or sloping
area.
→If the machine is dropped or falls over, this could result in personal injury.
●Once the machine is in position, secure in place using the casters.
→If the machine falls over, this could result in personal injury.

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WARNING
Use this machine correctly in accordance with the instructions. Great care must be taken to
ensure person safety while installing, operating, checking, and maintaining this machine.
The maintenance including dangerous work, transportation or installation should be carried out
by a person with sufficient knowledge and experience of this machine and system.
CAUTION
Never lay the machine on its side.
WARNING
This machine is heavy-weight equipment.
When moving it by using the casters, two or more persons are required. Pay extra attention to
slopes when transporting.
WARNING
Do not place the machine outside.
Rain drops, water, or dust may result in electric fire, electric shock or malfunction.
CAUTION
Horizontally place the machine on a flat hard floor that bears the weight of the machine, and
take actions for the machine not to fall over. Imperfect installation could result in dropping or
falling, causing personal injury .
WARNING
Do not touch the tools contained in each module.
Injury may result.
WARNING
Turn off the power before uninstalling, adjusting and installing the modules.

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Operating temperature 10°C–30°C
Operating humidity 40%–70%
Storage temperature 0°C–50°C, no condensation
Storage humidity 10%–80%, no condensation
●Installation environment
Be sure to offer training in replacement of the tool, adjustment, and safety precautions to
customers who are in charge of maintenance when the machine is installed.
Instruct customers that replacement of the tool must be performed only by the trained person
in charge of maintenance.
Be sure to offer training in pressing and releasing the back-up rollers to customers who
are in charge of maintenance.
Procedures for contacting back-up rollers is described in this manual. Have customers keep
this manual at hand.
Duplo is not responsible for damage, injury, or any other troubles due to failure to observe
the description in this manual.
To All Dealers/Distributors

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1. Unpacking Checks
1. Check the product name on the package.
Product name: DC-646
(The DC-646 includes 115V model, 230V model, ASIA model.)
2. Unpack the package.
Carry out unpacking in a place that is safe for the work.
3. Check the contents.
IMPORTANT
No. Name Part No. Q'ty Remarks
1 Power cord E1-8108* 1 115V model
2 Power cord L1-W126* 1 230V model , ASIAmodel
3 PC controller CD W5-Y198* 1
4 Card stacker 1
5 Support guide (for card stacker) W5-L232* 4
6 Guide assy (for card stacker) Y2-L208* 1
7 Side guide (for exit tray) 2
8 Side guide (for feed tray) 1
9 Upper guide 1
10 Back guide (for exit tray) 1
11 Back guide (for feed tray) 1
12 Back guide weight (for feed tray) 5
13 Plate (for PC) U7-M722* 1 115V (USA) model, 230V model
14 PC arm mount assy 1 115V (USA) model, 230V model
15 Screw (HSKW5×12) 7115V (USA) model, 230V model
16 Hexagon wrench XZ057 1
17 Shaft (tool) W5-G138* 1
18 Check sheet S2-Y104* 6
19 Coated paper
320×450 mm (230 gsm) 5
Used for pressure adjustment
when the driving roller and the
press roller are replaced. See the
service manual for adjustment
procedure.
20 Warning label K9-T140* 3 230V model
21 Warning label M7-T307* 2 230V model
22 Warning label sheet L8-T112* 4 230V model
23 Warning label W5-T135* 1 230V model
24 Warning label sheet P9-T301* 1 230V model
25 Label sheet U3-T114* 1 230V model
26 Label U3-T112* 1
27 Installation Manual W5-Y206* 1
28 Instruction Manual W5-Y204* 1

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1
2
3
4
5
6
7
8
9
10

6
11
13
12
14
15
16
17
18
19
20

7
21
ACHTUNG
P9-T3010g
NOTA
P9-T3010s
ATTENTION
P9-T3010f
ATTENZIONE
P9-T3010i
P9-T3010r
P9-T3010
22
23
24
26
27
28
25

8
2510mm
2310mm
2570mm
1650mm
1110mm
(1745mm)
1540mm
1505mm
765mm
745mm
800mm800mm
2650mm
800mm
1000mm
(240mm)
800mm800mm
3250mm
800mm
2. Machine Dimensions and Required Space for Operation
Dimensions in ( ): DC-646 230V model,
DC-646 115V model

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3. Installation
Lock
Release
2. Lock the casters when you reach the place
to install the machine.
3. Adjust the six adjuster feet on the bottom of
the machine to bring into contact with the
floor.
4. Adjust each adjuster foot until the casters
come to the position apart from the floor.
5. Use a level gauge to make sure that the
machine has been setup horizontally. If it
hasn’t been setup horizontally, then adjust
the adjuster feet again so that it is setup
horizontally.
1. Release the four caster locks on the
operator’s side, and slowly move the DC-646
by pushing it to the place to be installed.
WARNING
This machine is heavy-weight equipment.
When moving it by using the casters, two or
more persons are required.
Pay extra attention to slopes when trans-
porting.

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6. Tighten the nuts to secure the adjuster feet.
7. Remove the plastic cover from the DC-646.
8. Remove all the tapes and cushioning
materials from the machine.
Document feed side (tapes)
Ejection side (tapes, cushioning materials)
Top cover 1 (tape)
Inside the top cover 1 (tapes)

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10. Remove the screws (two each) securing
the two angles for securing the front cover.
Inside the top covers 2 and 3 (tapes securing
the fixing screws on each module)
Open the front cover, and remove the two
screws to remove the angle securing the
front cover from the DC-646.
Open the front cover, and remove the screws
(two each) to remove the two fixing angles
securing the front cover.
Top cover 2 and top cover 3
(tapes, cushioning materials)
9. Remove the five screws to remove the fixing
angle under the feed tray.
Inside the front cover

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Inside the front cover
11. Take out the included items in the waste
box and check for any missing parts.
REFERENCE REFERENCE
Keep the removed fixing angles and the fixing
screws for when the machine is moved.
Non-operator’s side
●Attaching the PC arm mount assy
(115V model, 230V model)
1. Attach the PC arm mount assy to the
indicated place below.
2. While holding the PC arm mount assy with
both hands, secure it with the four included
screws (M5×12) from the upper ones.
Lastly retighten the screws (M5×12) with a
wrench.

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1. Temporarily attach the included two screws
(M5×12) to the places (indicated in the
following figure) on the non-operator’s side.
3. Use the included screw (M5×12) to secure
the screw hole in the middle of the PC tray.
Tighten the two temporarily attached screws.
REFERENCE
●Attaching the PC tray
(115V model, 230V model)
2. Attach the PC tray by inserting the temporarily
attached two screws in the gourd-shaped holes
of the PC tray.
Gourd-shaped hole
●Affixing the warning label
1. Affix the warning label (U3-T112*) to the
indicated place.
Align with the line.
2 cm
When the display language of the machine is
other than English, affix the warning label (U3-
T114*) corresponding to each destination.

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●Affixing the warning label on the
existing label (Only when the display
language is other than English)
1. Affix the warning labels (K9-T140*)
corresponding to destination on the existing
labels at the three places in the following
figure.
2. Affix the warning labels (M7-T307*)
corresponding to destination on the existing
labels at the two places in the following
figure.
Document feed side
Ejection side
Operator’s side
3. Affix the warning labels (L8-T112*)
corresponding to destination on the existing
labels at the four places in the following
figure.
4. Affix the warning label (W5-T135*)
corresponding to destination on the existing
label at the indicated place in the following
figure.
Non-operator’s side

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Slitter module
Margin slitter module
Slitter module
5. Affix the warning label (P9-T301*)
corresponding to destination on the existing
label at the indicated place in the following
figure.
6. Affix the warning labels (S5-T109*)
corresponding to destination on the existing
labels at the six places in the following figure.

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4. Removing the Stopper of the Press Roller
Non-operator’s side
Operator’s side
Document
feed side
Ejection
side
1245 37 6891012
Press roller
Frame
Back-up roller
Stopper
Press roller
Frame
Back-up roller
Driving roller
Driving roller
●At shipment, the press rollers are not in contact with the driving rollers. Remove the stopper
by removing the blue tape with hand to bring the press roller and the driving roller into contact
with each other at the time of unpacking. The stoppers releasing the contact of the press rollers
and the drive rollers are located at 12 places on the non-operator’s side in the above picture.
Remove all of the modules before removing the stoppers.
Store the stoppers that have been removed for when the machine is not used for a long
period.
11
Stopper
REFERENCE

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1. Open the top cover 2 and the top cover 3.
2. Remove all of the modules.
1. Removing the stoppers of 1–11
1. Remove the blue tape with hand to remove
the stoppers of 1–11 inside the machine
(non-operator’s side). (The following picture
shows 1–3.)
Inside machine
Stopper
1
2
3
2. Removing the stopper of 12
Stopper
Ejection side
2. Install all of the modules.
1. Remove the blue tape by hand to remove
the stopper of 12 from the ejection side (non-
operator’s side).

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Driving roller
5. Pressing the Back-Up Roller
Non-operator’s side
Operator’s side
Document feed sideEjection side
1245 37 6891011
Press roller
Frame
Back-up roller
Nut
Press roller
Frame
Back-up roller
Hexagon socket
head cap screw
Nut
IMPORTANT
Driving roller
●At shipment, the press rollers are not in contact with the back-up rollers. Turn the hexagon
socket head cap screws to bring the press rollers and the back-rollers into contact with each
other at the time of unpacking. The hexagon socket head cap screws bringing the back-up rollers
into contact with the press rollers are located at the 11 places (both on operator’s side and non-
operator’s side) in the above picture.
At the time of shipment, the 20 hexagon
socket head cap screws (one each on the
operator’s side and non-operator’s side) of
1–8 and 10–11 are loosened. Turn them
clockwise to bring the back-up rollers into
contact with the press rollers when installing
the machine.
The hexagon socket head cap screws
(one each on the operator’s side and non-
operator’s side) of 9are tightened. Turn
them counterclockwise to bring the back-up
roller into contact with the press roller when
installing the machine.
If the press rollers and the back-up rollers are in contact with each other for a long period,
the press rollers will get dented. When the machine is not used for a long period, release
the roller pressure. When using the machine after a long unused period, be sure to bring the
rollers into contact with each other.
Contact release angle
Contact release angle
Hexagon socket
head cap screw