MyBinding DC-545HC User manual

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Duplo Docu Cutter
DC-545HC
Service Manual

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.

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.
Repairing or servicing the machine 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 course of repair and servicing. Therefore, besides observing
the safety instructions marked in this manual and on the machine's labels, service
personnel should be safety-conscious and take other safety precautions as necessary.When
performing repair or service work not covered by this manual, you should obtain safety
guidance from an appropriately knowledgeable person.
Copyright © 2003
DUPLO SEIKO CORPORATION
All Rights Reserved
1

2
Safety instructions
Safety instructions
1.Cautions regarding the installation location
Installation environment
sAvoid 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.
• Sunlight could cause misoperation of the sensors.
• The heat of direct sunlight could cause deformation of the machine’s plastic parts.
*Also avoid installation near to a ground glass window; light and heat penetrate such windows
although they are opaque.
sAvoid installing the machine in places subject to high or low temperature or humidity.
• High or low temperature or humidity could cause the machine to operate abnormally.
Suitable temperature and humidity ranges are:
Ambient 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 or in the vicinity of water sources, the paper could absorb moisture and curl,
leading to misfeeds or poor image quality.
sAvoid installing the machine in places with open flames, or where reflected heat or other hot air
currents (from stoves, etc), or cold air currents from coolers, etc will strike it directly.
sAvoid installing the machine in poorly ventilated places.
sAvoid installing the machine in dusty places.
sThe machine should not be tilting when it is used.
• Install the machine so that it is level.
(The machine should be level to within 5mm in the front-rear direction, and 5mm in the lateral
direction.)
sDo not install the machine on shaky, sloping or otherwise unstable surfaces.
• The machine could fall over on such surfaces, or fall off them, causing injury.
Safety instructions

3
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. The machine’s power supply voltage is indicated on the identification
plate located on the machine’s left side; the machine must be connected to a power supply of the
voltage indicated.
aOtherwise, fire or electric shock could result.
If the power supply voltage is unstable or if the power supply has insufficient capacity, the
machine may not operate normally.
Make sure that the power supply has sufficient capacity for the system as a whole, including
optional equipment.
CAUTION
• Install the machine in accordance with the installation procedure appended to this manual.
Using the stand
• Lock the casters after the machine is installed.
aOtherwise, the machine could move or fall over, causing injury.
• To move the machine, push it by its mounting base.
aPushing the DC-545 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.
Insert the power cord plug firmly into the socket, so that proper electrical contact is effected.
• Install the machine close to its power supply. The outlet used should be exclusively for the
machine, and have no other equipment connected to it.
If an extension cord is necessary, it should have a ground terminal, and be of the following ratings:
* For a 120VAC model: 130V, at least 15A, length not exceeding 5m.
* For a 230VAC model: 250V, at least 8A, length not exceeding 5m.
• Never tread on the power cord or pinch it between other objects, or accidents could result.
Connect to outlet of 120V AC, 60Hz, at least 15A
With no load*
At full load
Power consumption
No more than 130V AC
At least 110V AC
During operation : 90W
In standby : 15W
During operation : 90W
In standby : 15W
Power supply voltage
}
Use power supply meeting these requirements
Connect to outlet of 230V AC, 50Hz, at least 8A
With no load*
At full load
Power consumption
No more than 250V AC
At least 210V AC
Power supply voltage
}
Use power supply meeting these requirements
* 120V AC model
* 230V AC model

4
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). When motors are operated
alone in function checks, interlocks are deactivated, 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 blades. Exercise great care when inspecting
the cutter unit or replacing it or its parts.
aOtherwise, your hands/fingers could be injured.
• Do not touch the drum or rollers after turning on the jog switch.
• Do not put your hands or fingers inside the machine while the drum is rotating.
aOtherwise, your hands/fingers could get caught and crushed between the drum and rollers.
Working clothes
• Wear clothing than enables you to work safely.
CAUTION
Tools
• Use tools that are appropriate for the work.

5
Safety instructions
No. Parts No. Name Q’ty
qL8-T1100 Warning Sticker 1 1
wL8-T1080 Warning Sticker 2 3
eL8-T1090 Label Caution 2
Warning Sticker
Keep the WARNING stickers clean at all times. If labels become damaged 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 near cutters
and movable parts. L8-T1080
WARNING
Do not touch blade!
To remove jammed paper,
use the tweezers. L8-T1100
q
w
e
WARNING
Use caution when working
near movable parts.
Disconnect power before
servicing.
L8 T1090

6
Safety instructions

7
Chapter 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
Miscallaneous

8
Table of Contents
Introduction ....................................................... 1
Safety instructions............................................ 2
1. Cautions regarding the installation
location .......................................................... 2
2. Cautions for installation work...................... 3
3. Cautions for maintenance, inspection and
servicing ........................................................ 4
Warning Sticker ................................................. 5
Chapter 1 Introduction
zSpecifications ............................................. 10
xDimensions ................................................. 11
cPart Names and Functions ........................ 12
vWork Flow .................................................... 15
bOptions ........................................................ 16
Chapter 2 Description of Operation
zPaper Feed Unit .......................................... 18
xCCD Mechanism ......................................... 30
cMargin Slitter............................................... 32
vGuillotine Cutter Unit ................................. 34
bCreaser Unit ................................................ 35
nCenter Slitter ............................................... 37
mPaper EjectTray .......................................... 39
,Main Drive ................................................... 40
.Skew Adjustment Mechanism ................... 43
⁄0 BAR CODE .................................................. 44
⁄1 REGISTER MARK ....................................... 45
Chapter 3 Mechanical
zExterior ........................................................ 49
xFeed Section ............................................... 52
cCCD Section................................................ 59
vMargin Slitter Section................................. 60
bCutter Section ............................................. 67
nCreaser Section .......................................... 69
mCenter Slitter Section ................................. 71
,Driving Section ........................................... 79
.Electric Section........................................... 85
Chapter 4 Standard Adjustments
zLCD Panel.................................................... 94
xSlitter Position ............................................ 95
cCutter Registration ..................................... 98
vCreaser Calibration .................................. 100
bCCD Horizontal Line Alignment .............. 102
nAdjusting Crease Depth........................... 104
mFeed Solenoid Adjustment ...................... 105
,Gate Solenoid Adjustment (Without the
DC-545HC)................................................. 106
.Cutter Assembly Perpendicularity
Adjustment................................................ 107
⁄0 Creaser Perpendicularity Adjustment .... 108
⁄1 CCDVertical Line Alignment ................... 109
⁄2 Elevator Switch Height Adjustment........ 111
⁄3 Cover Switch (AF-100 : 1 position,
DC-545 : 2 positions)................................ 112
⁄4 Shutter Solenoid....................................... 113
⁄5 Creaser Sensor Plate Adjustment........... 118
Chapter 5 Maintenance Checks
zCleaning and Oiling.................................. 120
xPeriodic Maintenance Check List............ 120
Chapter 6 Troubleshooting
zTroubleshooting Guide............................. 124
xError Display ............................................. 132
Chapter 7 Help Mode
zHELP Mode List ........................................ 140
xFunctions and operation procedures for
each HELP mode ...................................... 141
cHELP Description ..................................... 142
vSelect Language for Displays ................. 150
Chapter 8 Miscallaneous
zJob List...................................................... 152
x Position and Function of Electronic Parts .. 156
cOverallWiring Diagram ............................ 161

9
zSpecifications ............................................ 10
xDimensions ................................................ 11
cPart Names and Functions ....................... 12
1. Appearance........................................... 12
2. Operation Panel.................................... 14
vWork Flow................................................... 15
1. Operations ............................................ 15
bOptions ....................................................... 16
Chapter 1 Introduction 1

10
zSpecifications
Chap.1
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” (Width) x 3.5” (Length) <Business card size>
Lead edge trim Min.: 0.125” (3.2 mm)
Trail edge trim Min.: 0.125” (3.2 mm)
Side edge trim Min.: 0.125” (3.2 mm), Max.: 4.5” (114 mm)
Speed Max.: 9 ppm (A4 lengthwise, 4-side trim, 1 crease)
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)
Feed tray capacity 100 mm
Stacker Drop type
Power supply AC 120 V ±10%, 50/60 Hz, 1.0A
AC 230 V ±10%, 50/60 Hz, 0.6A
Machine dimensions (mm) 1376 (W) x 576 (D) x 948 (H)
Machine weight (kg) 109.6 (Main body 56.4, Feeder 20.4, Stand 32.8)
1. Four creases perpendicular to the feed direction.
Other Features 2. Up to ten cuts perpendicular to the feed direction.
3. Automatic setting of slit, cut and crease position.
zSpecifications

11
xDimensions
Chap.1 xDimensions

12
Chap.1 cPart Names and Functions
cPart 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 Knob
Guide Plate

13
Chap.1 cPart 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
2nd Roller

14
No. Name Function
qLCD panel Displays the status of the machine.
Displays messages when an error or paper jam occurs.
w<+> key Press to eject the document from the machine at the time of paper jam.
<-> key Press to eject the document from the machine at the time of paper jam. During
programming mode enables backward movement through the program steps.
ePOWER lamp Lights up when the power is switched on.
r<START> key Not used when the DC-545 is operated without the autofeeder - AF-100. Press
to start processing when the AF-100 is attached.
START lamp Normally lights up in green. Lights up in red when the front cover or the rear
cover is open.
t<STOP> key Press to stop automatic feeding after the current sheet is processed.
Press to clear jam indication after the paper is cleared.
yKey pad Press to enter print numbers and enter values during manual programming.
u<CLEAR> key Press to clear the count. Press to cancel manual programming.
i<SET> key Press to confirm selection/entry. Used to test process a single sheet. (for
systems with the AF-100 only)
o<MODE> key Press to change the mode.
!0 <F> key The AF-100 Feed Tray lowers while the <F> + <-> keys are being pressed.
!1 COVER lamp Blinks when the front cover or the rear cover is open.
JAM lamp Blinks when a paper jam has occurred.
PAPER lamp Blinks when paper runs out. (systems with the AF-100 only)
2. Operation Panel
COVER
JAM F
PAPER
MODE SET
+
–
1
4
7
C
2
5
8
0
3
6
9
POWER
START
STOP
!0!1 o i u ty
w e rq
Chap.1 cPart Names and Functions

15
vWork Flow
1. Operations
vWork Flow
.....................................How to 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 Program
Except when bar code is on.
3
Chap.1

16
Chap.1 vWork Flow bOptions
bOptions
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> KEY
<MODE> KEY
AUTO CUT
*ON OFF
<SET> KEY

17
Chapter 2 Description of Operation
zPaper Feed Unit ......................................... 18
1. Description............................................ 18
2. Operation .............................................. 18
3. Operation of each unit ......................... 19
(1) Fan (Blower) ............................................ 19
(2) Fan (Suction)............................................ 20
(3) Paper Level Sensor .................................. 21
(4) Suction Unit and Feed Motor................... 22
(5) Separator Gap .......................................... 23
(6) Elevator Motor ......................................... 24
(7) Elevator Upper Switch............................. 25
(8) Elevator Lower Switch ............................ 26
(9) Paper Detection Sensor ............................ 27
(10) Feed Solenoid ........................................ 28
(11) Feed Stepping Motor.............................. 29
xCCD Mechanism ........................................ 30
1. Description............................................ 30
2. Operation .............................................. 30
cMargin Slitter.............................................. 32
1. Description............................................ 32
2. Operation .............................................. 33
vGuillotine Cutter Unit................................. 34
1. Description............................................ 34
2. Operation .............................................. 34
bCreaser Unit ............................................... 35
1. Description............................................ 35
2. Operation .............................................. 35
nCenter Slitter .............................................. 37
1. Description............................................ 37
2. Operation .............................................. 37
mPaper Eject Tray......................................... 39
1. Description............................................ 39
,Main Drive................................................... 40
1. Description............................................ 40
2. Operation .............................................. 41
.Skew Adjustment Mechanism .................. 43
1. Description............................................ 43
⁄0 BAR CODE.................................................. 44
1. Description............................................ 44
⁄1 REGISTER MARK....................................... 45
2