DC-645 Creaser, Cutter, Slitter Service Manual

Duplo DC-645 (Slitter / Cutter / Creaser)
SERVICE MANUAL Ver. 1.0 / December 2006
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.
P9-Y1100
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
instructions 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.
1
■ HOW TO USE THIS SERVICE MANUAL
• This service manual includes the structural and functional descriptions for the major areas of DC-645,
along with the descriptions of procedures for disassembly and assembly, design standard and adjustment,
maintenance and service requirements, and actions to be taken in the case of malfunctions. These are the
information as of December, 2006.
The parts and components used are subject to change for the quality and performance improvements, or
for safety reasons. In such cases, please note that certain part of the descriptions and/or illustrations
contained in this manual may differ from the actual product.
• The marking listed below accompanied by indicates the instructions of particular importance for
safety reasons. Never fail to comply with them.
● Safety instructions
Indicates a high degree of potential danger. If the warning is
WARNING
ignored, death or serious injury may result.
Indicates a medium degree of potential danger. If the caution is

CAUTION
ignored, medium injury or damage to property may result.
[Examples of Pictorial Symbols]

symbol is to note that the instruction calls for close attention
(including danger and warning).
Specific hazard to be careful about is indicated in the drawing
(e.g. warning for electric shock in the case of illustration on the
left).
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 disassem-
bly.)
A black disc indicates an instruction, or sometimes a prohib-

ited 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.”)
● For maintenance operation

Failure to comply with the instruction will result in the problematic
IMPORTANT:
performance and poor quality of the machine.
This is the information related to the know-how and key points for the
TIP:
effective service work.
2
Safety instructions
1. Cautions regarding the installation location
Safety instructions
Installation environment
● 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
malfunction 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.
● Avoid 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 : 10 - 30 ˚C
Ambient humidity : 40 % - 70 %
Optimum temperature and humidity : 20, 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.
● Avoid 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.
● Avoid installing the machine in poorly ventilated places.
● Avoid installing the machine in dusty places.
• The 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.)
● Do 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.
3
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 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.
→ Otherwise, 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.
Power supply voltage Connect to outlet of 120V AC,60Hz,at least 15A
With no load* No more than 130V AC Use power supply meeting these
At full load At least 110V AC requirements
During operation:90W
Power consumption
In standby:15W
* Under no-load condition: The machine is in the standby condition with the power kept ON.
At full load: Power consumption comes to the maximum.
● To prevent any hazard, the grounding wire shall always be connected to the object
of grounding.
The object of grounding includes:
• Grounding terminal of the plug outlet.
• Grounding terminal that is provided by the proper installation work (the first to third categories).
* Never connect the grounding terminal to the gas pipes.
● 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 120V AC model: 130V, at least 15A, length not exceeding 5m.
• For a 230V AC 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.
4
CAUTION
● Install the machine in accordance with the installation procedure appended to this
manual.
● Lock the casters after the machine is installed.
→ Otherwise, the machine could move or fall over, causing injury.
3. Cautions for maintenance, inspection and servicing
Warning
● Precautions for safe servicing
• Always remove the power cord plug from the outlet before starting work.
→ Otherwise, 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.
→ Otherwise, 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 or roller is
rotating.
→ Otherwise, your hands/fingers could get caught and crushed between the drum and rollers.
In addition, when you remove paper clogged up or work on the machine, be very careful not to roll
up a tie and/or a necklace by the machine.
● Working clothes
• Wear clothing than enables you to work safely.
CAUTION
● Tools
• Use tools that are appropriate for the work.
5
❒ Warning Sticker
Keep the WARNING stickers clean at all times. If stickers become damaged or come off, replace them
with new ones.
2 2
1
1 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
2 WARNING
DO NOT put hands inside machine
while it is operating.
Hands could get caught up

or crushed.
M7-T3030
No. Parts No. Name Q’ty
1 L8-T1080 Warning Sticker 1 2
2 M7-T3030 Warning Sticker 1 2
6
Introduction 1
Operation in General
2
Mechanism
3
Adjustment
4
Maintenance Checks
5
Troubleshooting 6
HELP Mode 7
Others
8
7
8
CONTENTS
Introduction ........................................................... 1 Margin jam detecting section ............................ 164

■HOW TO USE THIS SERVICE MANUAL ..... 2
Safety instructions ................................................. 3
❒Warning Sticker ................................................. 6 Chapter 4 Adjustment
Exterior of the machine ..................................... 169
Chapter 1 Introduction Paper Feed Section ............................................ 170
Skew Adjust Section ......................................... 173
Specifications ...................................................... 12 Double-Feed Detection Section ........................ 174
Part Names and Their Functions ......................... 14 Reject Section ................................................... 175
Dimensions ......................................................... 19 Margin Slitter Section ....................................... 177
Center Slitter Section ........................................ 178
Slitter Drive Section ......................................... 180
Chapter 2 Operation in General Gutter Section ................................................... 181
Cutter Section ................................................... 182
Paper Feed Section .............................................. 23
Creaser Section ................................................. 183
Skew Adjust Section ........................................... 30
Main Drive Section ........................................... 184
Double-Feed Detection Section .......................... 32
Margin jam detecting section ............................ 186
Reject Section ..................................................... 34
Margin Slitter Section ......................................... 38
Center Slitter Section .......................................... 41 Chapter 5 Maintenance Checks
Slitter Drive Section ............................................ 47
Gutter Section ..................................................... 48 Guaranteeing maintenance cycle ...................... 188
Cutter Section ..................................................... 51 Cleaning and Oiling .......................................... 188
Creaser Section ................................................... 53 Periodic Maintenance Check List ..................... 189
Optional Section ................................................. 57
Main Drive Section ............................................. 61
Exit Tray ............................................................. 62 Chapter 6 Troubleshooting
BAR CODE ........................................................ 63
Troubleshooting ................................................ 194
REG. Mark .......................................................... 65
Conditions for the Error Detection ................... 203
Margin jam detecting section .............................. 68
Major Cause and Preventive Action for the
Paper Jam in DC-645 ........................................ 205
Chapter 3 Mechanism
Exterior of the Machine ...................................... 73 Chapter 7 HELP Mode
Paper Feed Section .............................................. 80
HELP Mode List ............................................... 208
Skew Adjust Section ........................................... 96
Accessing the HELP Mode ............................... 211
Double-Feed Detection Section ........................ 101
Looking into Each “HELP Mode” .................... 211
Reject Section ................................................... 103
Accessing the Serviceman JOB ........................ 212
Margin Slitter Section ....................................... 112
HELP Mode description ................................... 213
Center Slitter Section ........................................ 118
Slitter Drive Section .......................................... 129
Gutter Section ................................................... 132 Chapter 8 Others
Cutter Section ................................................... 137
Creaser Section ................................................. 140 Position and Function of Electronic Parts ......... 280
Optional Section ............................................... 146 Overall Wiring Diagram ................................... 286
Main Drive Section ........................................... 152 Serviceman JOBs .............................................. 290
Electrical System Section ................................. 157
9
10
Chapter 1 Introduction 1
Specifications............................................................................................. 12
Part Names and Their Functions............................................................... 14 2
1 Appearance....................................................................................................... 14
2 Modules............................................................................................................ 16
3 Control Panel.................................................................................................... 17
4 LCD Panel ........................................................................................................ 18 3
Dimensions ................................................................................................ 19
11
1 Specifications
● DC-645 Specifications
Product name / Model No. DC-645
Machine type Slit / Cut / Creaser Floor Stand Model
Width: 210 mm – 370 mm [8.26” – 14.56”]
Document size
Length:210 mm – 650 mm [8.26” – 25.59”]
Min.: 110 gsm [30 lb Bond]
Document weight
Max.: 350 gsm [130 lb Cover] <Tolerance for curl: +/–3 mm>
Document type Non coated paper, Coated paper, Laminated paper
Finishing document size Min.: 48 mm (Width) x 85 mm (Length) <Business card size>
6 rotary slitters
Slitters
(2 margin slitters in 1 module x 1, 2 center slitters in 1 module x 2)
Slit accuracy +/–0.2 mm on finished size (+/–0.3 mm for business cards)
Margin slit width 3.2 mm – 40.0 mm from paper edge
5 mm – 15 mm (Gutter strips wider than 15 mm are output on the
Gutter slit width
stacker tray.)
Cuts/document Max. 15 cuts
Lead edge cut: 3.2 mm
Min. cut length Gutter cut: 4.0 mm
Trail edge cut: 5.0 mm
+/–0.2 mm on finished size
Cut accuracy (+/–0.3 mm for business cards)
(May vary depending on crease number and crease depth.)
Crease / document Max. 10 creases
+/–0.2 mm on finished size
Crease accuracy
(May vary depending on crease number and crease depth.)
Gutter deflector / document Max. 2 gutter cuts
Crease depth adjustment 3 steps (MAX., MID, MIN.)
Feeding method Belt suction
Feed tray capacity 100 mm
Stacker Drop type
Stacker tray capacity 140 mm
Control panel 16 letters x 2 lines LCD, LED Error indication
LCD languages English, Japanese, French, German, Italian, Spanish
USB2.0 compliance (B type connector)
OS: Windows XP / 2000, Macintosh OS9.1~ OS10.1~
Job program interface
(Cable length must be within 3m.)
(The cable and computer should be prepared by customer.)
12
Chapter 1 Introduction Specifications
Max 80 job program memory

Proof feed mode (process 1 sheet)
Job program interface
Air knife
Skew adjustment
Standard features
Double feed detection and reject
Image shift compensation with REG. mark
Automatic setup with barcode
Gutter deflector
Image shrinkage compensation 1
Business card module (Customer replaceable module), Perforator unit,
Optional module
Vertical crease unit
100V +/– 10%, 50/60 Hz
Power supply 120VAC +/– 10%, 50/60 Hz
230VAC +/– 10%, 50/60 Hz
2
100 V 3.85 A 325 W
Power consumption 120 V 3.3 A 320 W
230 V 1.6 A 300 W
Operating temperature 10 – 30 degree (Celcius) / 50 – 86 degree (Fahrenheit) 3
Operating humidity 40% – 70%
Opened: 2240 mm (W) x 750 mm (D) x 1115 mm (H)
[89.6” x 30” x 44.6”]
Machine dimensions
*(When using the additional feed
(with max document: 2530 mm (W) x 750 mm (D) x 1115 mm (H)
[96.6” x 30” x 44.6”]
4
tray)
Folded: 1630 mm (W) x 750 mm (D) x 1115 mm (H)
[65.2” x 30” x 44.6”]
Machine weight 360 kg [793 lb.] (approx)
5
Paper Curl
Due to the automated slitter function design, the paper path of the DC-645 is sensitive to paper curl.
If paper curl is causing paper jams the following are suggestions for remedying the problem: 6
1. Adjust the printing devices de-curler (if available)
2. Manually de-curl the stock before loading in the feed tray
3. Turn the paper over (reprogramming the job may be necessary)
4. Use different paper stock
7
Specifications and descriptions in this manual are for information purposes only. Duplo Seiko Corp. reserves the right
to change or modify products or specifications at any time without prior notice.
13
2 Part Names and Their Functions
1 Appearance
5 8 7 6
9
4
10
11
3 2 1 13 12
No. Name Function
1 Control panel Displays operations and statuses.
2 Waste box Receives pieces of waste paper.
3 Front cover Open to remove pieces of paper in the waste box.
4 Stacker tray Receives the finished document.
5 Scale. This measures the cut and slit position, and the finish of the document
Open this to move the upper guide or to remove the paper jam from the feed
6 Top cover 1
unit.
7 Top cover 2 Open this to remove the paper jam from the slitter module.
Open this to remove the paper jam from the cutter/crease/optional module or
8 Top cover 3
to replace the optional module.
9 Feed tray The original document is placed here.
10 USB terminal Insert a USB cable here to connect the computer and this machine.
11 AC inlet Connect the power cord.

This is where the document comes when it is rejected due to double feed, bar-
12 Reject tray
code error, REG. Mark error, etc.
13 Power switch Press to switch the power on and off.
14
Chapter 1 Introduction Part Names and Their Functions
17
16
3
6
14 15
7
No. Name Function
14 Airflow adjustment knob This adjusts the airflow level.
15
Separator adjustment
knob
This adjusts the distance between the separator and document. 8
16 Level adjustment knob This adjusts the elevator height.
17 Skew adjustment wheel This adjusts the feed angle of the document.
15
2 Modules
7 6 5
3 2 1
4
No. Name Function

Slitter Module
1 Cuts off the blank-area of the further-side and front-side.
(Margin slitter Module)
2 Slitter Module
Cuts parallel in the paper feed direction.
3 Slitter Module
4 Gutter Deflector The blank-area cut off by the slitter is dropped in the waste box.
5 Cutter Module Cuts in a right angle in the paper feed direction.
6 Creaser Module Creases parallely in the paper feed direction.
Transport Module
7 Transports the paper to the stacker tray.
(or Optional Module)
IMPORTANT: When removing various modules of this device, always re-set the module in the sequential
order indicated in the illustration above. It is especially that the slitter module is properly
assembled, when setting slitter module again.
16
Chapter 1 Introduction Part Names and Their Functions
3 Control Panel
1 2 3
7 10 11 4 5 6 3
8 9 12 13 6
No. Name Function
1 OK Monitor The LED of the Error area flashes when detecting an Error.
Displays the status of the machine.
7
2 LCD panel
Displays the message when an error or paper jam occurs.
3 < + / – > key Select setting of function.
4 <F> key Switches to function selecting display. 8

Switches modes. (operating mode, JOB selection mode, JOB
5 <MODE> key
inputting mode)
6 <SET> key Press to confirm selection / entry.
7 POWER lamp Lights up when the power is switched on.
8 <CLEAR> key Press to clear the count. Press to cancel manual programming.
Press to enter print numbers and enter values during manual pro-
9 <Number> key
gramming.
17
Press to eject the document from the machine when paper jam
10 • <JOG> keys
occurred.
11 <TEST> key One (sheet) document is processed to test the current JOB details.
Press this to start processing the document. The <START> key light
turns green when the machine is ready to process the document
12 <START> key in this machine. The <START> key can be activated when the LED
on the key is green. The <START> key is inactive when the light is
red. In this case DC-645 may be running or having an error.
Press to stop automatic feeding after the current sheet is pro-
13 <STOP> key
cessed.
4 LCD Panel
1 2
∗∗:∗∗∗∗∗∗∗∗∗∗∗∗∗
BC REG AC ∗∗∗
3 4 5 6
No. Name Function
1 JOB No. Displays the JOB No. currently selected.
2 JOB name Displays name of the JOB currently selected.
3 BARCODE BC is displayed when barcode reading is ON.
4 REGISTER MARK REG is displayed when REG. Mark reading is ON.
5 AUTO CUT AC is displayed when AUTO CUT is ON.

The number of document sheets processed with the JOB currently
6 COUNTER
set, is displayed.
18
Chapter 1 Introduction Dimensions
3 Dimensions
750 mm 1
2
620 mm
3
2530 mm
2240 mm
1630 mm
4
335 mm 470 mm 390 mm 5
6
1115 mm
19
20
Chapter 2 Operation in General 1
Paper Feed Section.................................................................................... 23
1 Description ....................................................................................................... 23
2 Operation.......................................................................................................... 23
2
3 Operation of Each Part ..................................................................................... 23
4 Operation Sequence ......................................................................................... 29
Skew Adjust Section .................................................................................. 30
1 General Description ......................................................................................... 30
3
2 Operation.......................................................................................................... 30
Double-Feed Detection Section ................................................................ 32 4
2 Operation.......................................................................................................... 32
Reject Section ............................................................................................ 34 5
2 Operation.......................................................................................................... 34
4 Operation sequence .......................................................................................... 37 6
Margin Slitter Section ............................................................................... 38
2 Operation.......................................................................................................... 38
3 Slitter Blade...................................................................................................... 38
7
Center Slitter Section ................................................................................ 41
2 Operation.......................................................................................................... 41
8
3 Slitter blade ...................................................................................................... 41
Slitter Drive Section .................................................................................. 47
Gutter Section ........................................................................................... 48
21
2 Operation.......................................................................................................... 48
Cutter Section............................................................................................ 51
2 Operation.......................................................................................................... 51
3 Operation of Each Unit .................................................................................... 52
Creaser Section.......................................................................................... 53
2 Operation.......................................................................................................... 53
Optional Section........................................................................................ 57
Main Drive Section .................................................................................... 61
1 Operation.......................................................................................................... 61
Exit Tray..................................................................................................... 62
BAR CODE.................................................................................................. 63
REG. Mark .................................................................................................. 65
Margin jam detecting section ................................................................... 68
1 Description ....................................................................................................... 68
2 Operation.......................................................................................................... 68
22
Chapter 2 Operation in General Paper Feed Section
1 Paper Feed Section

1 Description
Paper feed section feeds the paper into the
machine after separating each sheet of paper by
air knife. This is done through the operation of
the air suction mechanism and the air blow duct 1
mechanism.
2 Operation
Air blow duct mechanism blows the compressed
2
air to the paper from the front side to create
some gap between the papers. The separated
paper is transferred when the shutter solenoid
and the feed motor provided in the air suction 3
mechanism are turned ON.
3 Operation of Each Part

6
I. Paper Level Sensor
<Operation>
• Detect the top of the paper on the feed tray
When the feed plate rises to the extent that the
7
shut-off plate is lifted up by the paper, the sensor
comes to the “light blocked” state.
Once the topmost sheet of paper is detected, the
rising motion of the feed plate is stopped. 8
• Detect the low level of paper
The shut-off plate comes down as the paper
level gets low until the sensor comes to the “light
through” state. Once the sensor comes to the
“light through” state, the feed plate rises until the
sensor comes to the “light blocked” state. “E8”
(elevator error) appears on the display if the
topmost paper sensor does not switch to the
“light blocked” state within 10 seconds after the
23
transmission of feed plate go-up command.
state within 10 seconds after the transmission of
feed plate go-up command.
<Circuit diagram>
Main P.C.B Unit

5V
RED RED RED CN18-1 5V

1 1 9
YELLOW YELLOW YELLOW 2

2 2 10
BLUE BLUE BLUE 3

3 3 11
Light not transmitted: 5V

Light transmitted: 0V
II. Elevator Upper Limit Switch

<Operation>
If the topmost sheet of paper cannot be detected,
and the paper feed plate continues to go up, the
air suction module is pulled away from the
elevator upper limit switch to come to the
“CLOSE” state.
The elevator upper limit switch stops the
machine operation immediately once it comes to
the “CLOSE” state.
<Circuit diagram>
Main P.C.B Unit
5V
NO
COM ORANGE PURPLE CN18-8
14
ORANGE PURPLE 10 ON : 5V
15 OFF: 0V
NC
24
III. Elevator Lower Limit Switch

<Operation>
As the feed plate goes up, the screw is pulled
away from the elevator lower limit switch to come
to the “CLOSE” state. As the feed plate does
down to reach the lower limit, the screw pushes
the switch actuator to trigger the “OPEN” state.
“E8” (elevator error) appears on the display if the
screw does not push the elevator lower limit 1
switch actuator within 10 seconds after the
transmission of the feed plate go-down
command.
<Circuit diagram>
2
Main P.C.B Unit 3

5V
NO
COM PURPLE ORANGE CN18-5
NC
PURPLE
12
ORANGE 6
4
13
ON: 5V
OFF: 0V
5
IV. Elevator down Switch
<Operation>
Normally the feed plate goes up and down
6
automatically. However, it may be lowered by the
elevator down switch as required, including the
case of paper jam.
7
25
<Circuit diagram>
Main P.C.B Unit
5V
NO
NC GRAY GRAY ORANGE ON: 0V
1 16
OFF: 5V
GRAY GRAY BLUE
2 17
V. Shutter Solenoid
<Operation>
The shutter solenoid is turned ON as the level
sensor is turned ON and the paper feed is ready.
Then, the valve opens to suck up the paper.
The valve is closed by the timer after the
transferred paper passes through the PPS2.
<Circuit diagram>
DC-DRV
24V
RIGHT RIGHT
RED RED BLUE BLUE CN2-7
1 1 1 13
RIGHT RIGHT
RED YELLOW BLUE BLUE 8
2 2 2 14
26
VI. Paper Separator Eliminating Solenoid

<Operation>
• When the adjustment is set at 1 through 7, the
paper separator is raised by turning on the
solenoid until the paper end passes through
the separator position to prevent the double
feed. After the paper passes through, the
separator is lowered so that it will not hinder
the paper transfer. 1
• When the adjustment is set over 7 (i.e. When it
is turned clockwise to the maximum), the screw
pushes the actuator of the solenoid switch to
cancel the paper separator function.
• Paper separator solenoid is also canceled
2
when the paper jam takes place.
<Circuit diagram>
3
DC-DRV
Solenoid
RED
15
RED CN2-9
24V
ON: 24V
4
OFF: 0V
NC
RED RED 10
16
NO SW
5
VII. PPS1
<Operation> 6
While the light goes through at the PPS sensor,
LED on the control panel and the start key light
up in red. “PLEASE SET PAPER” appears on
the display as the start key is pressed.
While the light is blocked at the PPS sensor, the
7
start key lights up in green.
* Wipe off the dirt or contamination, if any, on the
PPS sensor with by some rag.
8
27
<Circuit diagram>
RED WHITE
1 1 3
Transmitting RIGHT
BLUE PEACH
3 2 4 RED Main P.C.B Unit
5V
GREEN RED CN3-8 5V

1 8
WHITE WHITE 7
2 7
Receiving
BLUE BLUE 6
3 6
RED RED 5
4 5
5V Light transmitted: 0V
VIII. Paper Separator Cancel Switch

<Operation>
Paper separator height can be altered by turning
the paper separator dial from 1 (max.) to 7
(min.). When the dial is turned beyond 7, the
paper separator stops its function and goes
down to the lowest position.
<Circuit diagram>
DC-DRV
24V
Solenoid
RED RED CN2-9 ON: 24V
15
OFF: 0V
NC
RED RED 10
16
NO SW
28
4 Operation Sequence
feed start feed end next paper feed start
PPS2
PPS3
1
transfer motor
air blow fan
shutter solenoid
skew adjust module 2
: sensor light blocked
: motor & solenoid ON
: motor & solenoid OFF/sensor light through
3
29
2 Skew Adjust Section
1 General Description
The paper, separated by air suction mechanism,
is transmitted in the corrected angular position,
since it is abutted to the frame by the slantingly
arranged conveyer belts as it is sent the next
process.
2 Operation
In the skew adjust section, the fan starts to rotate
as the start key is turned ON. The conveyer belt
starts to rotate just as the air suction module belt
starts its rotation. It is stopped by the timer.
30
Chapter 2 Operation in General Skew Adjust Section

I. PPS2
<Operation>
The light from the photo-emitting PCB of the PPS
sensor is received by the photo-detecting PCB of
the PPS sensor. The presence or non-presence
of paper is determined by the amount of light
received. Then, mis-feed or paper jam is
1
detected by the skew adjust section.
If the light path between the PPS sensors is
blocked by the paper (or by the dirt on the PPS
sensor) when the power supply is turned ON, 2
“J1” (REJECT PAPER) appears on the display.
* Wipe off the dirt or contamination, if any, on the
PPS sensor by some rag.
<Circuit diagram>
3
Main P.C.B Unit

5V
4
BROWN RED CN3-12
1
Transmitting
BLUE
3
BLUE 13
5
WHITE WHITE 14
1
Receiving
BLUE BLUE 15
2 Light not transmitted: 5V
5V
6
31
3 Double-Feed Detection Section
The double-feed detection sensor is provided
between the air suction module and the skew
adjust section (beside the PPS2).
An ultrasonic sensor is used, which can deal with
wider range of paper types compared with
conventional mechanical sensor or photo-micro
sensor. Also, no adjustment for fitting it to the
particular type of paper, and no input of the
paper thickness are required in the ultrasonic
sensor.
2 Operation
Whenever the ultrasonic sensor detects double-
feed, the rejection bar opens to send out the
double-fed paper to the reject tray.
When the double-feed is repeated for a preset
number of times, E-11 “DOUBLE FEED” appears
on the display, and the machine stops the
operation.
32
Chapter 2 Operation in General Double-Feed Detection

I. Double-Feed Detection Sensor
<Operation>
Whenever the ultrasonic sensor detects double-
feed, the rejection bar opens to send out the
double-fed paper to the reject tray. The double-
feed is detected not by the paper thickness, but
by the number of sheets.
1
In addition, if the double-feed is repeated for a
preset number of times, E-11 “DOUBLE FEED”
appears on the display, and the machine stops
the operation. 2
<Circuit diagram>
3
Main P.C.B Unit
CN12-2 4
WHITE BLUE 4
CN2-1 2
Receiving Switching power supply
BROWN V +
5
RED RED CN1-1 CN3-2
2
BLACK WHITE 2 4 BLUE V-
1
Receive P.C.B Unit
6
Transmit
Switching power supply
RED
2
RED CN2-1 CN1-2 BROWN V + 7
BLACK YELLOW 2 4 BLUE V-
1
Transmit P.C.B Unit
33
4 Reject Section
If the CCD reading error of the barcode or
register mark, or the double-feed takes place,
paper transfer guide in front of the slitter module
opens to drop the paper into the rejection
section.
2 Operation
Normally, the home position sensor is in the
“light blocked” state, and the topmost paper
sensor is in the “light through” state. The
rejection bar opens once the “barcode, REG.
mark reading error” or “double feed” takes place.
The topmost paper sensor comes to the “light
blocked” state by the sensor plate directly
attached to the rejection bar, and brings the
rejection motor to halt.
When the rejection bar returns to the home
position, the motor rotates in reverse until the
home position sensor comes to the “light
blocked” state.

I. Rejection Home Position Sensor
<Operation>
The rejection home position sensor detects the
position of the rejection bar while it returns to the
home position.
34
Chapter 2 Operation in General Reject Section
<Circuit diagram>
Main P.C.B Unit

5V
RED CN13-19 5V
1
WHITE 20
2
3
BLUE 21 1
II. Rejection Limit Sensor

2
<Operation>
The rejection limit sensor detects the topmost
paper while the rejection bar is open. 3
<Circuit diagram> 5
Main P.C.B Unit
1
RED CN13-16
5V
5V
6
RIGHT GREEN 17
2
3
BLUE 18

7
35
III. PPS3
<Operation>
• The light from the PPS photo-emitting PCB is
received by the PPS photo-detecting PCB. The
presence or non-presence of paper is
determined by the receiving amount.
• When REG. mark or barcode is used, PPS3
works to assure the correct CCD reading by
temporarily stopping the paper and making it
proceed for the given amount of pulse.
• In the operation without REG. mark or barcode,
PPS 3 detects the passing paper.
<Circuit diagram>
Main P.C.B Unit
5V
BROWN RED CN18-12

1
Transmitting
BLUE BLUE 13
3
WHITE WHITE 14
1
Receiving Light not transmitted: 5V
BLUE BLUE 15
2 Light transmitted: 0V
5V
IV. PPS8
<Operation>
received by the PPS photo-detecting PCB. The
presence or non-presence of paper is
• PPS8 detects the paper jam in the reject area.
36
Chapter 2 Operation in General Reject Section
<Circuit diagram>
Main P.C.B Unit

5V
BROWN RED CN18-20

1
BLUE
3
BLUE 21
1
WHITE WHITE 22
1
BLUE BLUE 23 Light transmitted: 0V
2
5V
2
4 Operation sequence
3
paper feed error detected rejection bar open rejection bar close
4
CCD
double feed detection
PPS3
rejection HP 5
rejection LM
rejection motor
PPS8
rejection driving motor
6
CW (motor normal rotation) CCW (motor reverse rotation)
: sensor light blocked

: motor & solenoid ON 7
: motor & solenoid OFF/sensor light through
37
5 Margin Slitter Section
The margin slitter is provided one each on both
sides to cut the paper along the traveling
direction by means of the rotary blade.
The cut-off margin is dropped into the waste box.
2 Operation
The lead screw is turned by means of the
stepping motor to cause the margin slitter to
move from the home position by the specified
amount of pulse.
3 Slitter Blade
The slitter blades are constructed so that the
lower blade of the slitter is tilted relative to the
paper feed direction. This makes the upper and
lower slitter blades contact at only one point to
maintain the clean cut even after the slitter blade
has worn out.
38
Chapter 2 Operation in General Margin Slitter Section

I. Margin Slitter Module Fit-on Sensor
<Operation>
The margin slitter module fit-on sensor detects
the presence or non-presence of the margin
slitter module by sensing a part of the module by
the photo-micro sensor. 1
2
<Circuit diagram>
3
Main P.C.B Unit
5V
RED RED CN10-1 5V

1 1
2
YELLOW
2
YELLOW 2 4
BLUE BLUE 3
3 3
5
II. Margin Slitter 1 Home Position Sensor
<Operation>
Margin slitter 1 HP sensor detects the home
6
position of the margin slitter 1 by the photo-micro
sensor, and controls the margin slitter 1 position
based on the amount of pulse from the home
position. 7
39
<Circuit diagram>
Main P.C.B Unit
BLUE BLUE CN1-6 5V

1 9
YELLOW YELLOW 5
2 8
RED RED 4 5V
3 7
III. Margin Slitter 2 Home Position Sensor

<Operation>
Margin slitter 2 HP sensor detects the home
position of the margin slitter 2 by the photo-micro
sensor, and controls the margin slitter 2 position
position.
<Circuit diagram>
Main P.C.B Unit
BLUE BLUE CN1-3 5V

1 6
WHITE WHITE 2
2 5
RED RED 1 5V
3 4
40
Chapter 2 Operation in General Center Slitter Section
6 Center Slitter Section

Two center slitters are provided each on both
sides to cut the paper in the traveling direction by
means of the rotary blades arranged vertically
side by side. 1
2 Operation
stepping motor to cause the center slitters to
2
move from the home position by the specified
amount of pulse.
3 Slitter blade 3
The slitter blades are constructed so that the
lower blade of the slitter is tilted relative to the
paper feed direction. This makes the upper and
lower slitter blades contact at only one point to
4
maintain the clean cut even after the slitter blade
has worn out.
5
I. Center Slitter 3/4 Module Fit-on Sensor
6
<Operation>
The center slitter 3/4 module fit-on sensor
detects the presence or non-presence of the
center slitter 3/4 module by sensing a part of the
7
module by the photo-micro sensor.
41
<Circuit diagram>
Main P.C.B Unit

5V
RED RED CN10-7 5V

1 1
PEACH PEACH 8
2 2
BLUE BLUE 9
3 3
II. Center Slitter 3 Home Position Sensor

<Operation>
Center slitter 3 HP sensor detects the home
position of the center slitter 3 by the photo-micro
sensor, and controls the center slitter 3 position
position.
<Circuit diagram>
Main P.C.B Unit
BLUE BLUE CN1-12 5V

1 9
ORANGE ORANGE 11
2 8
RED RED 10 5V
3 7
42
III. Center Slitter 4 Home Position Sensor

<Operation>
received by the PPS photo-detecting PCB.
The presence or non-presence of paper is
• PPS4 detects the passing paper and the paper
jam in the slitter area. (In the case of PPS 4,
photo-emitting PCB is in the lower position, 1
and the photo-detecting PCB is in the upper
position.)
<Circuit diagram>
2
Main P.C.B Unit
5V
3
BLUE BLUE CN1-9
1 6
PEACH PEACH 8
2 5
3
RED
4
RED 7 5V

4
IV. PPS4 5
<Operation>
43
<Circuit diagram>
RIGHT BLUE Main P.C.B Unit

1 4
BLUE BLUE CN3-14 5V

2 3
Transmitting
YELLOW YELLOW 15
3 2
RED RED 13
4 1
5V
RED RED 16
1 10
Receiving
RIGHT BLUE Light not transmitted: 5V
3 11 5V Light transmitted: 0V
RIGHT BLUE
V. Center Slitter 5/6 Module Fit-on Sensor

<Operation>
The center slitter 5/6 module fit-on sensor
detects the presence or non-presence of the
center slitter 5/6 module by sensing a part of the
module by the photo-micro sensor.
<Circuit diagram>
Main P.C.B Unit

5V
RED RED CN10-13 5V

1 1
PURPLE PURPLE 14
2 2
BLUE BLUE 15
3 3
44
VI. Center Slitter 5 Home Position Sensor

<Operation>
sensor, and controls the center slitter 5 position
position.
1
<Circuit diagram>
2
Main P.C.B Unit
BLUE BLUE CN1-18 5V

3
1 9
PURPLE PURPLE 17
2 8
3
RED
7
RED 16 5V

4
VII. Center Slitter 6 Home Position Sensor 5

<Operation>
sensor, and controls the center slitter 6 position 6
position.
45
<Circuit diagram>
Main P.C.B Unit
BLUE BLUE CN1-15 5V

1 6
GREEN GREEN 14
2 5
RED RED 13 5V
3 4
46
Chapter 2 Operation in General Slitter Drive Section
7 Slitter Drive Section

I. Encoder Sensor (for driving the slitter)
<Operation>
Encoder sensor (for driving the slitter) controls 1
the revolution of the slitter module by sensing the
slit on the encoder attached directly to the motor
by means of the photo-micro sensor.
2
3
<Circuit diagram>
5V
DC-DRV 4
RED CN6-1 5V
1
YELLOW 2
2
BLUE 3
5
3
47
8 Gutter Section
The gutter section works to drop the gutter area
of the paper cut off by the center slitter into the
waste box.
2 Operation
stepping motor to cause the gutter to move from
the home position by the specified amount of
pulse.

I. Gutter (R) Home Position Sensor
<Operation>
Gutter (R) HP sensor detects the right gutter
home position by the photo-micro sensor, and
controls the right gutter position based on the
amount of pulse from the home position.
48
Chapter 2 Operation in General Gutter Section
<Circuit diagram>
Main P.C.B Unit
BLUE CN1-24 5V
1
GREEN 23
2
3
RED 22 5V 1
II. Gutter (L) Home Position Sensor

2
<Operation>
Gutter (L) HP sensor detects the left gutter home
position by the photo-micro sensor, and controls
the left gutter position based on the amount of
3
pulse from the home position.
<Circuit diagram> 5
Main P.C.B Unit
1
BLUE CN1-21 5V
6
BLACK 20
2
RED 19 5V
3
7
49
III. PPS5
<Operation>
jam in the gutter area.
<Circuit diagram>
Main P.C.B Unit

5V
BROWN BROWN CN18-16

1
Transmitting
BLUE BLUE 17 5V
3
WHITE PEACH 18
1
Receiving
BLUE BLUE 19
50
Chapter 2 Operation in General Cutter Section
9 Cutter Section
The “Guillotine type” cutter module is provided in
which the lower blade is fixed while the upper
blade moves up and down to cut the paper
perpendicularly to the traveling direction. 1
2 Operation
The rotating motion of the DC motor is
transformed into the reciprocating motion of the
2
upper blade by means of the excentric shaft.
A sensor is provided at the top dead center of
the blade stroke, which works to apply the brake
on the blade movement at every reciprocating 3
cycle to make it stop.
51
3 Operation of Each Unit
I. Cutter Home Position Sensor
<Operation>
Cutter HP sensor detects the blade positions by
sensing the light-blocking plate linked to the
movement of rotary blade by means of the
photo-micro sensor.
<Circuit diagram>
Main P.C.B Unit

5V
YELLOW RED CN6-1 5V

1 1
RIGHT GREEN YELLOW 2

2 2
RIGHT BLUE BLUE 3

3 3
52
Chapter 2 Operation in General Creaser Section
0 Creaser Section
Creaser module contains the lower blade having
a concave (recessed) section and the upper
blade having a convex (projected) section. The
creaser unit works to crease the paper 1
perpendicularly to its traveling direction.
2 Operation
The sensor plate provided coaxially with the cam
2
detects the top dead center of the upper blade to
control the DC motor.The lower blade also can
move up and down by a cam. The height of the
lower blade is set by the DC motor with an 3
encoder, and is specified relative to the lower
blade’s bottom dead center at which the sensor
plate is provided. The crease depth is
determined in this way.
4
5
I. Crease Lower Blade Home Position Sensor
6
<Operation>
53
<Circuit diagram>
Main P.C.B Unit

5V
RED WHITE RED CN6-7 5V

1 1 4
RIGHT RIGHT
GREEN BLUE GRAY 8
2 2 5
BLUE WHITE BLUE 9

3 3 6
II. Creaser Home Position Sensor

<Operation>
Creaser home position sensor detects the top
dead center of the creaser upper blade by
sensing the light-blocking plate attached to the
creaser upper blade driving cam shaft by means
of the photo-micro sensor.
<Circuit diagram>
Main P.C.B Unit

5V
RED YELLOW RED CN6-4 5V

1 4 1
GRAY WHITE GREEN 5

2 5 2
RIGHT
BLUE GREEN BLUE 6
3 6 3
54
Chapter 2 Operation in General Creaser Section
III. Creaser Lower Blade Encoder Sensor

<Operation>
Creaser lower blade encoder sensor adjusts the
crease depth in 3 levels from the lower limit
position by reading out the encoder attached to
the crease depth adjustment motor by means of
the photo-micro sensor.
1
<Circuit diagram>
2
Main P.C.B Unit
RED CN6-22
5V
5V
3
1
WHITE 23
2
3
BLUE 24

4
55
IV. PPS6
<Operation>
jam in the cutter and creaser areas.
<Circuit diagram>
Main P.C.B Unit

5V
BROWN RED CN18-24

1
Transmitting
BLUE BLUE 25
3
WHITE PEACH 26
1
Receiving Light not transmitted: 5V
BLUE BLUE 27 Light transmitted: 0V
2
5V
56
Chapter 2 Operation in General Optional Section
A Optional Section
Optional Section is used to meet the special
cutting requirements which cannot be dealt with
by the cutter module or by the slitter module.
(Transfer module is attached to the standard 1
type machine.)
5
I. Optional Section Detecting Sensor 1 6
<Operation>
Option detecting sensor identifies the type of
optional module by one of the detecting sensors
1, 2, or 3, or by the combination of these sensors
to implement the control required for the
7
particular optional module attached.
57
<Circuit diagram>
Main P.C.B Unit

5V
RED RED CN10-19 5V

1 1
YELLOW YELLOW 20
2 2
BLUE BLUE 21
3 3
II. Optional Section Detecting Sensor 2

<Operation>
<Circuit diagram>
Main P.C.B Unit

5V
RED RED CN10-22 5V

1 4
WHITE WHITE 23
2 5
BLUE BLUE 24
3 6
58
Chapter 2 Operation in General Optional Section
III. Optional Section Detecting Sensor 3

<Operation>
<Circuit diagram> 1
2
Main P.C.B Unit
5V
1
RED
7
RED CN10-25 5V 3
PEACH PEACH 26
2 8
BLUE BLUE 27
3 9
4
IV. Optional Module Home Position Sensor

<Operation>
5
Option HP sensor detects the home position of
the optional module by the photo-micro sensor,
and controls the module position based on the
amount of pulse from the home position. 6
59
<Circuit diagram>
Main P.C.B Unit

5V
RED BLUE CN1-25 5V

3 13
RIGHT BLUE RIGHT BLUE 26

2 14
BLUE BLUE 27
1 15
V. PPS7
<Operation>
jam in the stacker area.
<Circuit diagram>
Main P.C.B Unit

5V
BROWN BROWN CN3-17

1
BLUE BLUE 18
3
WHITE WHITE 19
1
BLUE BLUE 20
60
Chapter 2 Operation in General Main Drive Section
B Main Drive Section

1 Operation
Stepping motors are used for activating
components related to the paper cutting
dimensions, paper transfer, each slitter,
transversal position of the gutter. The movement 1
of other DC motors are also controlled by the
encoder attached to the motor as required.
61
C Exit Tray
Exit tray is for receiving the finished paper
discharged from the machine.
The exit tray can be set at 3 (three) different
heights. Normally the tray is set at the middle
height position. Upper position is to install the
business card stack tray. Lower position is for
the papers with strong static electricity.
62
Chapter 2 Operation in General BAR CODE
D BAR CODE
By adding barcode which indicates job number
on each document, DC-645 automatically set up Paper feed direction
the machine and start the job. Operator can
press the START key and leave. Even if multiple 1
types of jobs are loaded on the feed tray at one
time, DC-645 recognizes barcode on documents
also with the built-in CCD and automatically
switch setup and finish the jobs.
To use this function, each documents must have 2
BARCODE printed on them. Please refer to
following instructions for specifications and
position of BARCODE.
3
I. Specifications
Barcode type : CODE-39
Start and Stop code : Required 4
Minimum resolving power : 0.254 mm
Thin bar: Thick bar : 1: 2.5
Bar height : 4 mm or more
Use barcode generator function equipped on

5
your software application or use barcode
generator software.
IMPORTANT: Do not enter the check digit as it

can cause improper operations to
6
the machine.
63
II. Position
Paper feed direction: The whole BARCODE
should be within 3
mm~ 20 mm from the
lead edge.
Paper width direction: The whole BARCODE
should be within 25
mm~60 mm from the
right edge (See below) 1 2 3 4
1 is the start code designator for CODE-39. (*)
2 is the 10’s digit data of the JOB number.
(Example: When the JOB number is 21, the
data is “2”.)
3 is the 1’s digit data of the JOB number.
(Example: When the JOB number is 21, the
data is “1”.)
4 is stop code of CODE-39. (*)
* Barcode should be entered between 1 and 80.
Do not enter the check digit.
(It can cause improper operation.)
60mm or less
35mm 25mm
3mm
20mm
Barcode
Position Range
Barcode
Paper feed direction
64
Chapter 2 Operation in General REG. Mark
E REG. Mark
1 General Description Paper feed direction

DC-645 automatically compensate for image
drift, one of the common problems on digital
printers. It detects the image drift caused on 1
each page by reading REG. mark with built-in
CCD and adjust the cut / slit / crease position
accordingly. Side mark
Lead mark Correct for image drift
To use this function, each documents must have
REG, mark printed on them. Please refer to
Correct for image drift
in this direction
in this direction
2
following instructions for specifications and
position of REG. mark.
I. Specifications
REG. mark consists of 2 straight & perpendicular
3
lines.
line length : 5 mm or more / each
line thickness : 0.4 mm or more / each
Use pen tool etc. of your software application to 4
draw 2 straight & perpendicular lines.
II. Position
Paper feed direction: The whole REG. mark
should be within 3 mm ~ 3mm
5
20 mm from the lead 3mm
edge.
5mm or more
Paper width direction: The whole REG. mark
should be within 3 mm ~ 6
20 mm from the right 5mm
or more
20mm
edge.
REG. Mark
0.4mm or more
REG. Mark
Position Range 7
65
IMPORTANT: The appropriate correction of the 20mm
paper position may not be Fine Printing area
3mm
attained if there is any stain or
flaw within the specified REG. 3mm
mark printing area.
6mm
20mm
6mm
III. Printing both REG. mark and barcode
60mm or less
35mm 25mm
3mm
20mm
Barcode
Position Range
Barcode
Paper feed direction
TIP: REG. marks or barcodes located out of the specified printing area cannot be detected properly by
DC-645.
Take account of the possible variation in the printed position of REG. marks and barcodes when
they are arranged on the paper.
66
Chapter 2 Operation in General REG. Mark
IV. Non-printable area for REG. marks and barcodes
35mm 5mm 20mm
3mm or more
Non-printable area 1
20mm
3mm
2
or more 3mm
or more
3
Barcode REG. Mark
Paper feed direction 4
IMPORTANT: • Any part of the image to be printed shall not enter into the gray-colored area.
• No other printings than REG. mark and barcode shall enter into the gray-colored area. 5
67
F Margin jam detecting section
1 Description
The margin jam detecting system detects
whether shreds cut by a margin slitter remain in
a machine, and this system stops the machine
before margin jam occurs, and displays a
message.
2 Operation
The system displays a message and stops the
machine when a sensor can’t detect light for
more than fixed period of time during machine
runs.
68
Chapter 3 Mechanism 1
Exterior of the Machine ............................................................................ 73
1 Removing the Feed Cover L Unit .................................................................... 74
2 Removing the Upper Cover L .......................................................................... 74
2
3 Removing the Under Cover R1........................................................................ 74
4 Removing the Feed Cover................................................................................ 75
5 Removing the Upper Cover R.......................................................................... 75
6 Removing the Under Cover L1 ........................................................................ 75
3
7 Removing the Under Cover R2........................................................................ 76
8 Removing the Top Cover 1 .............................................................................. 76
4
A Removing the Top Cover 1 Interlock Switch .................................................. 77
B Removing the Top Cover 2•3 Interlock Switch ............................................... 78
C Removing the Front Cover Interlock Switch ................................................... 79
Paper Feed Section.................................................................................... 80
5
1 Removing the Belt Suction Unit ...................................................................... 80
2 Removing the Field Belt Driving Motor and the Belt...................................... 82
3 Removing the Air Blow Duct .......................................................................... 82
4 Removing the Paper Separator Cancel Switch................................................. 85
6
5 Removing the Suction Fan ............................................................................... 86
6 Removing the Compressor ............................................................................... 86
7 Removing the SSR ........................................................................................... 87
8 Removing the Paper Level Sensor ................................................................... 88
7
9 Removing the Elevator Upper Limit Switch.................................................... 89
0 Removing the Elevator Lower Limit Switch ................................................... 90
A Removing the Elevator Go-down Switch ........................................................ 90
B Removing the Elevator Motor and Driving Chain ........................................... 91
8
C Removing the Elevator Chain (on control panel side) ..................................... 92
D Removing the Elevator Chain (on the opposite side to the control panel)....... 93
E Removing the PPS1.......................................................................................... 94
69
Skew Adjust Section .................................................................................. 96
1 Removing the Skew Adjust Module ................................................................ 96
2 Removing the Skew Adjust Fan....................................................................... 98
3 Removing the Skew Adjusting Dial and the Belt ............................................ 98
4 Removing the PPS2.......................................................................................... 99
Double-Feed Detection Section .............................................................. 101
1 Removing the Ultrasonic Sensor (receiving side).......................................... 101
2 Removing the Ultrasonic Sensor (transmitting side) ..................................... 101
Reject Section .......................................................................................... 103
1 Removing the Reject Open/Close Motor ....................................................... 103
2 Removing the Reject Delivery Module.......................................................... 103
3 Removing the Rejection Home Position Sensor ............................................ 106
4 Removing the Rejection Limit Sensor ........................................................... 106
5 Removing the CCD ........................................................................................ 107
6 Removing the PPS3........................................................................................ 108
7 Removing the PPS8........................................................................................ 110
Margin Slitter Section ............................................................................. 112
1 Removing the Margin Slitter Module ............................................................ 112
2 Removing the Margin Slitter 1 Position Motor.............................................. 114
3 Removing the Margin Slitter 2 Position Motor.............................................. 114
4 Removing the Margin Slitter 1 Home Position Sensor .................................. 115
5 Removing the Margin Slitter 2 Home Position Sensor .................................. 116
6 Removing the Margin Slitter Module Fit-on Sensor...................................... 117
Center Slitter Section .............................................................................. 118
1 Removing the Center Slitter 3/4•5/6 Module................................................. 118
2 Removing the Center Slitter 3 Position Motor............................................... 120
4 Removing the Center Slitter 3 Home Position Sensor ................................... 120
6 Removing the Center Slitter 3/4 Module Fit-on Sensor................................. 122
7 Removing the PPS4........................................................................................ 124
A Removing the Center Slitter 6 Home Position Sensor ................................... 127
B Removing the Center Slitter 5/6 Module Fit-on Sensor................................. 128
Slitter Drive Section ................................................................................ 129
1 Removing the Encoder Sensor (Slitter Driving Motor) ................................. 129
2 Removing the slitter driving motor and the belt ............................................ 129
70
Chapter 3 Mechanism
Gutter Section ......................................................................................... 132

1 Removing the gutter module (R) position motor ........................................... 132
2 Removing the gutter module (L) position motor ........................................... 132
3 Removing the Gutter Module......................................................................... 133
4 Removing the Gutter Home Position Sensors (R) ......................................... 134
5 Removing the Gutter Home Position Sensors (L).......................................... 134
6 Removing the PPS5........................................................................................ 135
Cutter Section.......................................................................................... 137 1
1 Removing the Cutter Module......................................................................... 137
2 Removing the Cutter Home Position Sensor ................................................. 137
3 Removing the Cutter Motor and the Belt ....................................................... 138
Creaser Section........................................................................................ 140
2
1 Removing the Creaser Module....................................................................... 140
2 Removing the Creaser Motor and the Belt..................................................... 141
3 Removing the Creaser Lower Blade Motor ................................................... 142
4 Removing the Creaser Lower Blade Encoder Sensor .................................... 143 3
5 Removing the PPS6........................................................................................ 144
Optional Section...................................................................................... 146
1 Removing the Option Module........................................................................ 146
2 Removing the Option Position Motor ............................................................ 146
4
3 Removing the Option Detecting Sensor 1...................................................... 147
6 Removing the Option Home Position Sensor ................................................ 149
5
7 PPS 7 .............................................................................................................. 150
Main Drive Section .................................................................................. 152
1 Removing the Main Motor 1 and the Drive Belt ........................................... 152
2 Removing the Main Motor 2 and the Drive Belt ........................................... 153
6
3 Removing the Driving Roller (upper) ............................................................ 155
4 Removing the Driving Roller (lower) ............................................................ 156
7
71
Electrical System Section......................................................................... 157
1 Removing the Control Panel .......................................................................... 157
2 Removing the Fuse......................................................................................... 157
3 Removing the DC Power Supply Unit ........................................................... 158
4 Removing the Power Supply PCB Unit ......................................................... 158
5 Removing the Main PCB Unit ....................................................................... 159
6 Removing the DC Drive PCB Unit ................................................................ 159
7 Removing the Stepping Drive PCB Unit ....................................................... 160
8 Removing the Stepping Drive PCB Unit ....................................................... 161
9 Removing the Battery Circuit Board Unit ..................................................... 161
0 Removing the Receive PCB unit.................................................................... 162
A Removing the Oscillation PCB unit ............................................................... 163
B Removing the USB PCB unit......................................................................... 163
Margin jam detecting section ............................................................ 164
1 Removing the margin jam detecting sensor ................................................... 164
72
Chapter 3 Mechanism Exterior of the Machine
1 Exterior of the Machine
73
1 Removing the Feed Cover L Unit
1 Open the top cover 1.
2 Remove the feed cover L unit after by taking
out the 4 screws.
2 Removing the Upper Cover L

1 Open the top cover 2 and 3.
2 Remove the upper cover L by taking out the 8
screws.
3 Removing the Under Cover R1

1 Remove the under cover R1 by taking out the 4
screws.
74
4 Removing the Feed Cover

2 Remove the feed cover L by taking out the 5
screws.
2
5 Removing the Upper Cover R
1 Open the top cover 2 and 3.
2 Remove the option module. (See p.146)
3
3 Remove the upper cover R by taking out the 8
screws.
6 Removing the Under Cover L1

1 Remove the under cover L1 by taking out the 4
6
screws.
75
7 Removing the Under Cover R2
1 Remove the under cover R2 by taking out the 4
screws.
8 Removing the Top Cover 1

2Take out the 2 screws and the screw plate, and
remove the top cover 1 from the hinge.
3 Remove the top cover 1 by taking out the 2
screws and sliding the pin.

2 Take out the 2 screws and the screw plate, and
76

2 Take out the 2 screws and the screw plate, and
2
A Removing the Top Cover 1 Interlock Switch
2 Take out the two (2) screws, and remove the
3
top cover 1 interlock switch with the cover.
5
3 Pull out the bullet connector.
4 Remove the top cover 1 interlock switch by
taking out the 2 screws.
* See page 169 for the adjustments required at
6
the time of installation.
77
B Removing the Top Cover 2•3 Interlock Switch
1 Open the top covers 2 and 3.
2 Take out the 2 screws, and remove the cover.

4 Remove the top cover interlock switch by
78
C Removing the Front Cover Interlock Switch

1 Open the front cover.
2 Take out the 2 screws, and remove the front
cover interlock switch with the bracket.
2
4 Remove the front cover interlock switch by
taking out the 2 screws and the screw plate.
3
79
1 Removing the Belt Suction Unit
2 Remove the shutter solenoid cover after taking
out the 2 screws.
3 Disengage the shutter solenoid connector.
4 Take out the 2 screws at the shaft joint area,

and let the joint slide in the arrowhead
direction.
5 Remove the suction unit while pushing it-in
toward the arrowhead direction.
* After the installation, perform the unit
operation check in HELP Mode: 19 and 25.
80
Chapter 3 Mechanism Paper Feed Section
I. Removing the Feed Belt

1 Loosen the belt adjusting screw.
2 Remove the suction belt.
2
II. Removing the Shutter Solenoid
1 Disengage the connector.
2 Take out the 2 screws, and remove the shutter
solenoid with the bracket. 3
3 Remove the shutter solenoid after taking out

5
the 3 screws.
6
81
2 Removing the Field Belt Driving Motor and the Belt
1 Remove the feed cover L unit. (See p.74)
2 Loosen the 2 screws and let the motor slide in
the arrowhead direction.
3 Remove the belt.
5 Take out the 2 screws, and remove the motor

with the bracket.
6 Remove the motor after taking out the 2
screws.
3 Removing the Air Blow Duct

1 Set the feed tray in the lowered position.
2 Remove the feed cover L unit and the under
guide R1. (See p.74)
3 Loosen the set screw to remove the pinion gear
and the washer. (2 places)
82
4 Pull out the rod in the arrowhead direction.
5 Disengage the connector. (3 places)

2
4
6 Take out a screw after drawing out the lower
rack, and remove the lower rack.
7 Remove the air blow duct module after taking

out the 4 screws. 7
83
8 Get the air blow duct module out of the under
guide R1.
I. Removing the Air Knife Eliminating Solenoid

1 Take out the 2 screws, and remove the air knife
eliminating solenoid with the bracket.
2 Remove the air knife eliminating solenoid after

* Make sure that the screws are positioned in the
center at the time of installation.
* After the installation, perform the operation
check in HELP Mode: 21.
84
II. Removing the Blower Fan

1 Remove the blower fan (2 places) after taking
out the 6 screws.
2
4 Removing the Paper Separator Cancel Switch
1 Remove the feed cover L unit.
2 Take out the 2 screws, and remove the paper 3
separator cancel switch with the bracket.
5
4 Take out the 2 screws, and remove the paper
separator cancel switch from the bracket.
* See page 171 for the adjustments required at 6
85
5 Removing the Suction Fan
2 Take out the 3 screws, and remove the suction
fan with the bracket.
3 Remove the suction fan after taking out the 3

screws.
6 Removing the Compressor

1 Remove the feed cover L unit, the feed cover,
the under guide R1, and the under guide L1,
respectively. (See p.74, 75)
2 Make sure that the air blow duct is removed.
(See p.82)
3 Take out the 2 screws (on the control panel
side and on the opposite side), and remove the
brackets on both sides.
86
4 Take out the 2 screws (on the control panel

side and on the opposite side), and draw out
the compressor downwards together with the
bracket.
5 Disengage the connector, and the hose.

2
4
6 Remove the compressor after taking out the 4
screws.
* After the installation, perform the compressor
operation check in HELP Mode: 20. 5
7 Removing the SSR

7
1 Remove the feed cover L unit.(See p.74)
2 Disengage the bullet connectors (2 places) and
the couplers (2 places).
3 Take out the 2 screws, and remove the SSR
8
with the bracket.
87
4 Take out another 2 screws, and remove the
SSR from the bracket.
8 Removing the Paper Level Sensor

1 Remove the feed cover. (See p.75)

level sensor with the bracket.
4 Remove the shaft assembly after taking out

one screw.
level sensor with the bracket.
88
6 Remove the paper level sensor from the

bracket.
* After the installation, perform the sensor
operation check in HELP Mode: 12.
* Make sure that the pinion shaft and the cable
tube does not interfere with other after the
installation.
9 Removing the Elevator Upper Limit Switch 2

1 Make sure that the belt suction unit is
removed. (See p.80)
2 Take out the 2 screws, and remove the elevator
upper limit switch with the bracket.
3
3 Disengage the bullet connectors (2 places). 5

4 Remove the elevator upper limit switch after
6
89
0 Removing the Elevator Lower Limit Switch
2 Disengage the bullet connectors (2 places).
lower limit switch with the bracket.
4 Remove the elevator lower limit switch after

A Removing the Elevator Go-down Switch

go-down switch with the bracket.
90
4 Pull out the button.

5 Remove the elevator go-down switch after
taking out the ring nut.
* Make sure that the button is positioned in the
center of the frame aperture at the time of
installation.
B Removing the Elevator Motor and Driving Chain 2

1 Remove the feed cover L unit, the feed cover,
and the under guide R1, respectively. (See
p.74, 75)
2 Remove the control panel. (See p.157)
3
3 Remove the elevator lower limit switch. (See
p.90)
4 Remove both springs mounted on the control
panel side and on the opposite side. 4
5 Loosen the 4 screws and let the motor slide in 5

7
6 Loosen the 2 worm screw, and remove the
driving chain with the sprocket wheel.
7 Disengage the connector. 8
91
8 Remove the elevator motor from the rejection
side after taking out the 4 screws.
C Removing the Elevator Chain (on control panel side)

1 Make sure that the elevator motor chain is
removed. (See p.92)
2 Remove the sprocket wheel cover after taking
out the 2 screws.
3 Remove the chain guide after taking out the 2

screws.
4 Remove the elevator chain after taking out the

2 cap bolts.
* Install the chain guide after aligning the height
on both sides.
* After the installation, perform the paper feed
elevator operation check in HELP Mode: 17.
92
D Removing the Elevator Chain (on the opposite side

to the control panel)
1 Make sure that the springs mounted on the
control panel side and on the opposite side of
the elevator driving section are both removed.
2 Remove the sprocket wheel cover after taking
out the 3 screws.
1
2
3 Remove the sprocket wheel after taking out
one screw.
3
4 Remove the chain guide after taking out the 2 5

screws.
7
5 Remove the elevator chain after taking out the
2 cap bolts.
* Install the chain guide after aligning the height 8
on both sides.
* After the installation, perform the paper feed
elevator operation check in HELP Mode: 17.
93
E Removing the PPS1
• Photo-emission Sensor
2 Remove the photo-emission sensor after taking
out one screw.
• Photo-detecting sensor
1 Remove the suction module. (See p.80)
3 Remove the back panel after taking out the 4

screws.
94
4 Take out the 2 screws, and remove the photo-

detecting sensor with the bracket.
5 Remove the photo-detecting sensor after taking

out one screw. 2
95
1 Removing the Skew Adjust Module
1 Make sure that the belt suction unit is
removed. (See p.80)
2 Remove the stay after taking out the 2 screws.
3 Remove the sensor cover after taking out one

screw.
4 Remove the guide plate after taking out the 2
screws.
5 Remove the guide (2 places) after taking out

the 6 screws.
96
Chapter 3 Mechanism Skew Adjust Section
6 Remove the skew adjust module after taking

out the 3 screws and disengaging the
connector.
I. Removing the Skew Adjust Belt Driving Motor 2

1 Take out the 2 screws, and remove the skew
adjust belt driving motor with the bracket.
2 Loosen the set screw to remove the pulley.

3 Remove the skew adjust belt driving motor 5
after taking out the 2 screws.
97
II. Removing the Skew Adjust Belt
1 Pull the skew adjust belt until it is dismounted.
2 Removing the Skew Adjust Fan

1 Make sure that the skew adjust module is
removed. (See p.96)
3 Remove the skew adjust fan after taking out
the 3 screws.
3 Removing the Skew Adjusting Dial and the Belt

2 Loosen the 2 screws and let the stay slide in
98
Chapter 3 Mechanism Skew Adjust Section
3 Loosen the set screw at the 2 places on the

dial.
4 Remove one screw.
5 Pull out the shaft, and remove the belt.

2
4
4 Removing the PPS2
• Photo-emission Sensor 5
3 Remove the photo-emission sensor on the
opposite side to the control panel after taking
out one screw.
6
99
3 Remove the photo-detecting sensor on the
opposite side to the control panel after taking
out one screw.
100
Chapter 3 Mechanism Double-Feed Detection Section

1 Removing the Ultrasonic Sensor (receiving side)
removed. (See p.96)
1
3 Remove the ultrasonic sensor after taking out

the 2 screws.
3
2 Removing the Ultrasonic Sensor (transmitting side)

6
removed. (See p.96)
101
3 Remove the ultrasonic sensor assembly after
taking out one screw.
4 Remove the ultrasonic sensor after taking out
one screw.
operation check in HELP Mode 15:.
102
Chapter 3 Mechanism Reject Section
5 Reject Section
1 Removing the Reject Open/Close Motor
3 Take out the 4 screws, and remove the reject
open/close motor with the bracket. 1
4 Remove the reject open/close motor after

3
* At the time of installation, make sure that the
sensor plate is located in between the home
position sensor and the limit sensor.
* After the installation, perform the rejection bar
4
2 Removing the Reject Delivery Module

6
1 Remove the under guide L1 and R1. (See p.74,
75)
2 Remove the 2 screws.
3 Loosen the 2 screws.
7
103
4 Disengage the connectors at 3 places.
5 Remove the reject delivery module by sliding

it in the arrowhead direction.
I. Removing the Motor and the Belt

1 Loosen the tensioner screw and let it slide in
2 Remove the belt.
3 Loosen the set screw to remove the pulley.

4 Remove the motor by taking out the 3 screws.
104
II. Removing the Roller (upper)

1 Take out the springs. (on the control panel side
and on the opposite side)
2 Take out the E ring and remove the bearings.
(on the control panel side and on the opposite
side)
3 Remove the rollers.
2
III. Removing the Roller (lower)
1 Loosen the set screw to remove the pulley. (on
the control panel side)
3
2 Remove the lock plate for the bearings after

5
taking out the 2 screws. (on the control panel
side and on the opposite side)
3 Remove the bearings. (on the control panel
side and on the opposite side) 6
4 Remove the rollers. (on the control panel side
105
3 Removing the Rejection Home Position Sensor
1 Remove the upper cover R. (See p.75)
2 Take out the 2 screws, and remove the sensor
with the bracket.

4 Remove the rejection home position sensor.
* If the sensor plate is removed, it must be
reassembled so that the rejection bar lies
horizontally when detected by the home
position sensor.
4 Removing the Rejection Limit Sensor

with the bracket.
106

4 Remove the rejection limit sensor.
* If the sensor plate is removed, it must be
reassembled so that the rejecting bar lies
horizontally when detected by the limit sensor.
5 Removing the CCD 2

2 Remove the upper cover R and under guide
R2. (See p.75, 76)
3 Disengage the connector from the CN5 of the
3
main PCB unit.
4 Take out the 2 screws, and remove the CCD 5

module assembly.
6
107
6 Removing the PPS3
emission sensor assembly.

emission sensor with the angle.

photo-emission sensor from the angle.
108
removed. (See p.96)
3 Loosen the 2 screws, let the angle slide in the
arrowhead direction, and remove the photo-
detecting sensor with the angle.
4
5 Remove the photo-detecting sensor from the
angle after taking out the 2 screws.
109
7 Removing the PPS8
1 Remove the under guide R1. (See p.74)
2 Remove the under guide L1. (See p.75)
4 Take out the 2 nuts, and remove the photo-
emission sensor with the bracket.
5 Remove the photo-emission sensor from the

bracket after taking out the 2 screws.
110
3 Open the front cover.

4 Take out the 2 nuts, and remove the photo-
detecting sensor with the bracket.

bracket after taking out the 2 screws. 2
111
1 Removing the Margin Slitter Module
2 Loosen the setscrews, and remove the margin
slitter module by pulling it up.
I. Removing the Margin Slitter 1/2

* Do not remove the upper plate and the frame.
* The slitter module sensor plate cannot be
disassembled.
1 Remove the detection plate after taking out the
4 screws.
2 Take out the 4 screws, and remove the back
plate.
3 Remove the bearing presser for the driving

shaft after taking out the 2 screws.
4 Pull out the driving shaft.
* Do not drop the key placed in the groove.
112
Chapter 3 Mechanism Margin Slitter Section
5 Loosen the set screw to remove the stopper

and the gear.
6 Remove the bearings after taking out the 4

screws. 2
* Take note of the correct orientation at the time
of installation.
7 Pull out the Lead screw while turning it
around.
3
4
8 Loosen the 6 screws and leave them in the
temporary-fastened condition.
9 Take out the 2 screws and remove the shaft.

0 Take out the 4 screws and remove the margin 7
slitter 1/2 with the shaft.
A Remove the margin slitter 1/2.
* Place the slitter at the end when it is re-
assembled. 8
* Do not tighten up the shaft and the bearings
until the smooth movement of the slitter is
verified.
* After the installation, perform the slitter
113
2 Removing the Margin Slitter 1 Position Motor
1 Make sure that the margin slitter module is
removed. (See p.112)
4 Remove the margin slitter 1 position motor
* After the installation, perform the motor
3 Removing the Margin Slitter 2 Position Motor

2 Remove the upper cover L. (See p.74)
4 Remove the margin slitter 2 position motor
114
4 Removing the Margin Slitter 1 Home Position Sensor

2 Remove the cable cover after taking out the 2
screws.
2
3 Remove the sensor guard after taking out the 2
screws.
3
4 Remove the margin slitter 1 home position

5
sensor after taking out one screw.
the time of installation. 6
115
5 Removing the Margin Slitter 2 Home Position Sensor
screws.

screws.
4 Remove the margin slitter 2 home position

sensor after taking out one screw.
116
6 Removing the Margin Slitter Module Fit-on Sensor

2
screws.
3 Remove the margin slitter module fit-on
sensor.
* After installation, perform the sensor operation
117
1 Removing the Center Slitter 3/4•5/6 Module
2 Loosen the setscrew, and remove the center
slitter module 3/4•5/6 by pulling it up.
* Make sure that the center slitter module 3/4•5/
6 are re-assembled in the original positions at
I. Removing the Center Slitter 3/4•5/6

* Do not remove the upper plate and the frame.
* The slitter module sensor plate cannot be
disassembled.
1 Remove the detection plate after taking out the
4 screws.
2 Take out the 4 screws, and remove the back
plate.
3 Remove the bearing presser for the driving

shaft after taking out the 2 screws.
4 Pull out the driving shaft.
* Do not drop the key placed in the groove.
118
Chapter 3 Mechanism Center Slitter Section
5 Loosen the set screw to remove the stopper

and the gear.

screws. 2
* Take note of the correct orientation at the time
of installation.
7 Pull out the Lead screw while turning it
around.
3
4
8 Loosen the 6 screws and leave them in the
temporary-fastened condition.
9 Take out the 4 screws and remove the shaft.

0 Take out the 4 screws and remove the center 7
slitter 3/4•5/6 with the shaft.
A Remove the center slitters 3/4•5/6 .
* Place the slitter at the end when it is re-
assembled. 8
* Do not tighten up the shaft and the bearing
until the smooth movement of the slitter is
verified.
* After the installation, perform the slitter
119
2 Removing the Center Slitter 3 Position Motor
1 Make sure that the center slitter module is
4 Remove the center slitter 3 position motor after

taking out the 2 screws. (left / right)
4 Removing the Center Slitter 3 Home Position Sensor

screws.
120

screws.
4 Remove the sensor after taking out one screw.

4
1 Make sure that the center slitter module is 5
screws.
121
screws.

6 Removing the Center Slitter 3/4 Module Fit-on Sensor


screws.
122
3 Remove the center slitter 3/4 fit-on sensor.

123
7 Removing the PPS4
3 Remove the cover after taking out the 2
screws.

out one screw.
* * After installation, perform the sensor
3 Remove the 4 screws and reverse the plate in
the lower part of the center slitter 3/4 to put it
inside out.
124
4 Remove the emission sensor after taking out

one screw.
8 Removing the Center Slitter 5 Position Motor 2

3
operation check in HELP Mode: 35. 4
5
6
* After the installation, perform the motor 7
125
screws.

screws.

126
A Removing the Center Slitter 6 Home Position Sensor

screws.
2
screws.

127
B Removing the Center Slitter 5/6 Module Fit-on Sensor
screws.
3 Remove the center slitter 5/6 module fit-on

sensor.
128
Chapter 3 Mechanism Slitter Drive Section

1 Removing the Encoder Sensor (Slitter Driving Motor)
3 Remove the encoder sensor by taking out the 2
screws. 1
3
2 Removing the slitter driving motor and the belt
1 Remove the encoder sensor. (See above)
removed. (See p.112) 4
3 Make sure that the center slitter module 3/4 is
4 Make sure that the center slitter module 5/6 is
5 Take out one screw, and remove the gear.
5
6 Take out the set screws, and remove the gear.
6
screws.
129
8 Remove the pulley with the belt on the
foreside.
9 Loosen the set screw to remove the encoder.
0 Loosen the 3 nuts and let the motor slide in the

arrowhead direction.
A Remove the belt.
B Loosen the screws, slide the tensioner in the

arrowhead direction, and remove the belt.
C Remove the entire slitter module. (Reference)

D Remove the 4 screws and slide the under plate
of the center slitter 5/6 module.
130
Chapter 3 Mechanism Slitter Drive Section
E Disengage the connector.
F Take out the 4 screws and remove the motor

from the top. 2
131
9 Gutter Section
1 Removing the gutter module (R) position motor
3 Take out the 3 screws, and remove the gutter
module (R) position motor with the bracket.
4 Remove the gutter module (R) position motor

2 Removing the gutter module (L) position motor

3 Take out the 3 screws, and remove the gutter
module (L) position motor with the bracket.
132
Chapter 3 Mechanism Gutter Section
4 Remove the gutter module position (L) motor

3 Removing the Gutter Module 2

2 Remove the gutter module position motors.
(See p.132)
3 Take out the 2 screws, and remove the lock
3
plate of the bearing. (on the control panel side
4 Pull out the lead screw while turning it around, 5

and remove the gutter module.
7
5 Take out one screw on the control panel side.
133
6 Let the shaft slide to set it aside, and remove
the gutter module.
* After the installation, perform the gutter
module operation check in HELP Mode 37,
and 38.
4 Removing the Gutter Home Position Sensors (R)

1 Make sure that the gutter module is removed.
(See p.133)
2 Remove the gutter home position sensor after
5 Removing the Gutter Home Position Sensors (L)

(See p.133)
2 Remove the gutter home position sensor after
134
Chapter 3 Mechanism Gutter Section
6 Removing the PPS5

emission sensor with the cover.
1
2
5 Take out one screw, and remove the photo-
3
135
(See p.133)
3 Remove the cable bridge after taking out the 2
screws and disengaging the connector at 2
places.
4 Take out the 2 screws, and remove the angle

and the photo-detecting sensor with the
bracket.

detecting sensor from the bracket together with
the angle.
136
Chapter 3 Mechanism Cutter Section
0 Cutter Section
1 Removing the Cutter Module
3 Remove the cutter module after installing the

cover for removal.
3
* Cutter module cannot be disassembled.
2 Removing the Cutter Home Position Sensor

6
1 Make sure that the cutter module is removed.
(See above)
2 Take out one screw, and remove the cutter
home position sensor with the bracket.
7
137
3 Take out one screw, and remove the cutter
home position sensor.
3 Removing the Cutter Motor and the Belt

1 Make sure that the creaser lower blade
adjusting motor is removed. (See p.142)
2 Remove the under guide L. (See p.74)
3 Open the top cover.
4 Loosen the 4 screws and let the motor slide in

6 Take out the 2 screws, and remove the cutter
motor with the bracket.
7 Remove the cutter motor after taking out the 4

screws.
138
Chapter 3 Mechanism Cutter Section
8 Remove the inner bracket (2 places) after

taking out the 3 screws and one flat head
screw.
9 Remove the cutter drive belt.
139
A Creaser Section
1 Removing the Creaser Module
2 Disengage the connector of the creaser home
position sensor.
3 Loosen the setscrew, and remove the creaser
module by pulling it up.
* Creaser module cannot be disassembled.
I. Removing the Creaser Lower Blade Home Position Sensor

1 Remove the creaser lower blade home position
sensor.
II. Removing the Creaser Home Position Sensor

screws.
140
Chapter 3 Mechanism Creaser Section
2 Disengage the connector, and remove the

creaser blade top dead center sensor.
2 Removing the Creaser Motor and the Belt 2

screws.
3
3 Loosen the 4 screws and let the motor slide in 5

4 Remove the belt with gear assemblies.
7
141
6 Open the front cover and draw out the creaser
motor downwards.
3 Removing the Creaser Lower Blade Motor

1 Remove the upper cover R. (See p. 75)
3 Take out the 2 screws, and remove the creaser
lower blade motor with the bracket.

creaser lower blade encoder sensor.
5 Loosen the set screw at two places to remove

the encoder and the pinion gear.
142

lower blade adjustment motor from the
bracket.
4 Removing the Creaser Lower Blade Encoder Sensor 2

lower blade encoder sensor with the bracket.
3 Remove the creaser lower blade encoder
3
sensor.
4
143
5 Removing the PPS6
2 Remove the upper cover R.
emission sensor with the cover.

2 Make sure that the creaser module is removed.
(See p.140)
3 Remove the tensioner spring.
4 Remove the bearings.
144
6 Push-in the cables except for the photo-

emission sensor in the direction of arrowhead. 2
4
7 Take out the 2 screws, and remove the angle
and the photo-detecting sensor with the
bracket.
5

detecting sensor from the bracket together with 7
the angle.
8
145
B Optional Section
1 Removing the Option Module
2 Loosen the set screw, and remove the option
module by pulling it up.
2 Removing the Option Position Motor

3 Remove the option position motor after taking
out the 2 screws.
146
Chapter 3 Mechanism Optional Section
3 Removing the Option Detecting Sensor 1

1 Make sure that the option module is removed.
(See p.146)
screws.
2
3 Remove the option detecting sensor 1.
3
147
(See p.146)
screws.


(See p.146)
screws.
148

6 Removing the Option Home Position Sensor 2

(See p.146)
screws.
3
3 Remove the option home position sensor after 5

6
149
7 PPS 7
(See p.146)
screws.

emission sensor with the bracket.
150
6 Remove the emission sensor after taking out

the 2 screws.
1 Make sure that the option module is removed. 2
(See p.146)
3
4
detecting sensor with the cover and the
bracket. 5

7
out the 2 screws.
8
151
C Main Drive Section
1 Removing the Main Motor 1 and the Drive Belt
screws.
4 Loosen the 4 screws and slide the main motor

1 in the arrowhead direction.
5 Remove the belt on the foreside together with
the counter gear.
6 Remove the timing belt.
7 Pull out the connector for the stepping drive

PCB unit.
152
Chapter 3 Mechanism Main Drive Section
8 Take out the 4 screws, and remove the main

motor 1 with the bracket.
9 Remove the main motor 1 after taking out the

4 screws. 2
4
2 Removing the Main Motor 2 and the Drive Belt
1 Remove the upper cover R. (See p.75) 5
screws.
7
4 Loosen the 4 screws and slide the main motor
2 in the arrowhead direction.
5 Remove the belt with the pulley assembly. 8
153
6 Pull out the connector for the stepping drive
PCB unit.
7 Take out the 4 screws, and remove the main

motor 2 with the bracket.
8 Remove the main motor 2 after taking out the

4 screws.
9 Remove the bracket after taking out the 3

screws and the E rings.
154
Chapter 3 Mechanism Main Drive Section
0 Remove the cable bridge after taking out the 2

screws and the connector (2 places).
A Remove the timing belt.
3 Removing the Driving Roller (upper) 2

1 Make sure that the timing belt is removed. (See
p.152, 153)
2 Remove the upper cover L, and the upper
cover R. (See p.74, 75)
3
3 For a roller with a spring (See the right
illustration), loosen the 2 screws and remove
the springs.
4
4 Remove the E-rings. (on the control panel side 5

screws. (on the control panel side and on the
opposite side)
6 Remove the rollers. 6
* Do not drop the washer inserted for
adjustment.
155
4 Removing the Driving Roller (lower)
1 Make sure that the driving roller (upper) is
2 Loosen the set screw to remove the pulley. (on
the opposite side of the control panel)
3 Take out the screws, and remove the lock

plate. (on the control panel side and on the
opposite side)
4 Remove the bearings. (on the control panel
side and on the opposite side)
5 Remove the rollers.
156
Chapter 3 Mechanism Electrical System Section
D Electrical System Section

1 Removing the Control Panel
2 Remove the feed cover L unit (See p.74)
3 Disengage the connector (2 places)
1
4 Remove the control panel after taking out the 4

screws.
3
2 Removing the Fuse

6
1 Remove the under guide R1 (See p.74)
2 Open the cover and remove the fuse.
157
3 Removing the DC Power Supply Unit
2 Loosen the screw to remove all the cables with
circular terminal.
3 Remove the DC power supply unit after taking

out the 4 screws.
* Pay attention to the terminals at the time of
installation to prevent them from touching with
each other.
4 Removing the Power Supply PCB Unit

3 Take out the 2 screws, and remove the power
supply PCB unit.
158
5 Removing the Main PCB Unit

2
3 Remove the main PCB unit after taking out the
6 screws.
6 Removing the DC Drive PCB Unit 5

6
159
3 Remove the DC drive PCB unit after taking
out the 6 screws.
7 Removing the Stepping Drive PCB Unit

3 Remove the stepping drive PCB unit after

160
8 Removing the Stepping Drive PCB Unit

2
3 Remove the stepping drive PCB unit after
NOTE: Never touch the VR on the circuit
boards.
3
5
9 Removing the Battery Circuit Board Unit
6
161
3 Remove the battery circuit board unit after
NOTE: Input the value on the HELP label after
the replacement.
0 Removing the Receive PCB unit

2 Disengage the connectors (3 places).
3 Take out the 4 screws, and remove the receive

PCB unit.
162
A Removing the Oscillation PCB unit

2 Disengage the connectors (2 places).
2
3 Take out the 4 screws, and remove the
oscillation PCB unit.
B Removing the USB PCB unit 5

3 Take out the 4 screws, and remove the USB
PCB unit. 6
163
E Margin jam detecting section
1 Removing the margin jam detecting sensor
1 Remove the under cover L2. (See p.76)
2 Disconnect the sensor connector.
3 Remove the margin slitter unit. (See p.112)
164
Chapter 3 Mechanism Margin jam detecting section

bracket.
5 Take out the 2 screws, and remove the photo

sensor. 2
165
166
Chapter 4 Adjustment 1
Exterior of the machine........................................................................... 169
1 Top cover 1 interlock switch adjustment ....................................................... 169
2
4 Front cover interlock switch adjustment ........................................................ 169
Paper Feed Section.................................................................................. 170
1 Suction belt adjustment .................................................................................. 170
3
2 Shutter solenoid adjustment ........................................................................... 170
3 Feed belt driving motor and belt adjustment.................................................. 170
4 Airflow adjustment knob adjustment ............................................................. 171
5 Separator adjustment knob adjustment .......................................................... 171
4
6 Paper separator cancel switch adjustment...................................................... 171
7 Elevator upper limit switch adjustment.......................................................... 172
8 Elevator lower limit switch ............................................................................ 172
9 Elevator motor and driving chain adjustment ................................................ 172
5
Skew Adjust Section ................................................................................ 173
1 Skew adjusting dial and the belt adjustment .................................................. 173
Double-Feed Detection Section .............................................................. 174 6
1 Ultrasonic sensor adjustment ......................................................................... 174
Reject Section .......................................................................................... 175
1 Reject delivery module motor and belt adjustment........................................ 175
2 Rejection home position sensor adjustment ................................................... 175
7
3 Reject limit sensor adjustment ....................................................................... 175
4 CCD................................................................................................................ 176
5 PPS3 ............................................................................................................... 176
Margin Slitter Section ............................................................................. 177
8
1 Margin slitter 1 home position sensor adjustment ......................................... 177
2 Margin slitter 2 home position sensor adjustment ......................................... 177
Center Slitter Section .............................................................................. 178
1 Center slitter 3 home position sensor adjustment .......................................... 178
167
Slitter Drive Section ................................................................................ 180
1 Encoder sensor (slitter driving motor) adjustment......................................... 180
2 Slitter blade driving motor and belt adjustment ............................................. 180
Gutter Section ......................................................................................... 181
1 Gutter home position sensor (R) adjustment.................................................. 181
2 Gutter home position sensor (L) adjustment .................................................. 181
Cutter Section.......................................................................................... 182
1 Cutter motor and belt adjustment ................................................................... 182
2 Cutter home position sensor adjustment ........................................................ 182
Creaser Section........................................................................................ 183
1 Creaser motor and belt adjustment................................................................. 183
2 Creaser lower blade encoder sensor adjustment ............................................ 183
3 Creaser lower blade home position sensor..................................................... 183
4 Creaser home position sensor......................................................................... 183
Main Drive Section .................................................................................. 184
1 Main motor 1 drive belt adjustment ............................................................... 184
2 Main motor 2 drive belt adjustment ............................................................... 184
Margin jam detecting section ................................................................. 186
1 Adjust the margin jam detecting sensor. ........................................................ 186
168
Chapter 4 Adjustment Exterior of the machine
1 Exterior of the machine

1 Top cover 1 interlock switch adjustment
2 Top cover 2 interlock switch adjustment 1

3 Top cover 3 interlock switch adjustment
4 Front cover interlock switch adjustment 2

i Adjust “a” to be 0.5mm while the switch is
turned ON.
3
"a"
169
1 Suction belt adjustment
i Adjust the belt tension to 20mm / 2.5 – 3.0N
by the adjusting screw.
ii After the adjustment, perform the operation
check in HELP Mode:19, 25.
2 Shutter solenoid
adjustment
"a"
i Adjust the throttle opening angle “a” at 80 – 90
degrees when the solenoid is turned ON.
3 Feed belt driving motor

and belt adjustment
i Slide the motor in the arrowhead direction and
adjust the belt tension to 3mm / 2N.
check in HELP Mode: 19, 25.
170
Chapter 4 Adjustment Paper Feed Section
4 Airflow adjustment knob

adjustment
i Adjust the knob so that the lack comes to the
innermost position when the dial is set at 7. 7
ii After the adjustment, check if the duct window
opens and closes smoothly.
5 Separator adjustment
knob adjustment 2
i Adjust the knob so that the lack comes to the
innermost position when the dial is set at 7.
7
3
4
ii Loosen the screw and keep the separator
plate in the raised position. Then, make an
adjustment so that the suction belt lightly
touches the upper end of the separator plate.
iii After the adjustment, perform the operation
5
check in HELP Mode:21.
"a"
6
6 Paper separator cancel

switch adjustment
7
turned ON. "a"
8
171
7 Elevator upper limit
switch adjustment
turned ON. "a"
8 Elevator lower limit

switch
i Make an adjustment so that the switch is
turned ON when “a” comes to 105 mm.
"a"
ii Adjust “b” to be 0.5mm while the switch is

turned ON.
iii After the adjustment, perform the operation
check in HELP Mode: 12, 17.
"b"
9 Elevator motor and

driving chain adjustment
i Let the motor slide in the arrowhead direction,
and adjust the chain to have 3-5mm slack.
check in HELP Mode:17.
172
Chapter 4 Adjustment Skew Adjust Section

1 Skew adjusting dial and
the belt adjustment
i Let the frame slide in the arrowhead direction,
and adjust the belt tension to 2mm / 2N.
1
173
1 Ultrasonic sensor
adjustment
i Adjust “a” on the ultrasonic sensor (receiving
side) to be 4mm. "a"
174
Chapter 4 Adjustment Reject Section
5 Reject Section
1 Reject delivery module
motor and belt
adjustment
i Slide the tensioner in the arrowhead direction, 1
and adjust the belt tension to 5 mm / 2N.
2
2 Rejection home position
sensor adjustment
"a"
3
i Adjust the distance between the sensor plate
and the sensor “a” to 2.5mm.
check in HELP Mode12, 23.
4
3 Reject limit sensor 5

adjustment
"a"
Adjust the distance between the sensor plate
and the sensor “a” to 2.5mm.
After the adjustment, perform the operation
6
175
4 CCD
i Fix CCD in about the center of a long hole.
ii Perform REG. mark read out position
adjustment in HELP Mode: 45.
5 PPS3
i Perform REG. mark read out position
adjustment in HELP Mode: 45.
ii Perform the operation check in HELP Mode:
12.
176
Chapter 4 Adjustment Margin Slitter Section

1 Margin slitter 1 home
position sensor
adjustment
i Check the sensor operation in HELP Mode:12, 1
26.
ii Feed the test paper through the machine
applying the Serviceman JOB.
iii Adjust the home position setting in HELP
Mode: 49. 2
2 Margin slitter 2 home
position sensor
adjustment
3
i Check the sensor operation in HELP Mode:
12.
4
ii Adjust the home position setting in HELP
Mode: 49.
177
1 Center slitter 3 home
position sensor
adjustment
12, 26.
Mode: 49.

position sensor
adjustment
12, 26.
Mode: 49.

position sensor
adjustment
12, 26.
Mode: 49.
178
Chapter 4 Adjustment Center Slitter Section

position sensor
adjustment
12, 26.
iii Adjust the home position setting in HELP 1
Mode: 49.
179
1 Encoder sensor (slitter
driving motor)
adjustment
Adjust the distance between the encoder and the
sensor “a” to 2.5mm.
"a"
2 Slitter blade driving

motor and belt
adjustment
* Belt “A”
Move the tensioner in the arrowhead direction,
* Belt “B”
Let the motor slide in the arrowhead direction,
180
Chapter 4 Adjustment Gutter Section
9 Gutter Section
1 Gutter home position
sensor (R) adjustment
12.
ii Feed the test paper through the machine 1
Mode: 50.
2
2 Gutter home position
sensor (L) adjustment
3
12.
iii Adjust the home position setting in HELP 4
Mode: 50.
181
0 Cutter Section
1 Cutter motor and belt
adjustment
ii Perform the operation check in HELP Mode:
29.
iii Feed the test paper through the machine
iv Adjust the cutting position in HELP Mode: 46.
2 Cutter home position

sensor adjustment
i Perform the sensor operation check in HELP
Mode: 12.
iii Adjust the cutting position in HELP Mode: 46.
182
Chapter 4 Adjustment Creaser Section
A Creaser Section
1 Creaser motor and belt
adjustment
ii Perform the operation check in HELP Mode: 27. 1
iv Adjust the crease position and depth in HELP
Mode: 47, 48. 2
2 Creaser lower blade
encoder sensor adjustment
3
i Adjust the distance between the encoder and
the sensor “a” to 2.5mm.
ii Perform the operation check in HELP Mode: 28.
applying the Serviceman JOB. 4
iv Adjust the crease position and depth in HELP
Mode: 47,48.
"a"
3 Creaser lower blade 5

home position sensor
Mode: 12.
6
iii Adjust the crease position and depth in HELP
Mode: 47, 48.
7
4 Creaser home position
sensor 8
Mode: 12.
iii Adjust the crease position and depth in HELP
Mode: 47, 48.
183
B Main Drive Section
1 Main motor 1 drive belt
adjustment
* Belt “A”
i Adjust with the eccentric shaft to set the
distance between the belt outer surface and
the center of the tension lever shaft “a” at
10mm.
"a"
* Belt “B”
2 Main motor 2 drive belt

adjustment
* Belt “A”
i Adjust with the eccentric shaft to set the
distance between the belt outer surface and
the center of the tension lever shaft “a” at
10mm.
"a"
184
Chapter 4 Adjustment Main Drive Section
* Belt “B”
185
C Margin jam detecting section
1 Adjust the margin jam
detecting sensor.
i Adjust the sensor detecting time in HELP
mode 59.
186
Chapter 5 Maintenance Checks 1
Guaranteeing maintenance cycle ........................................................... 188
Cleaning and Oiling ................................................................................ 188 2
1 Cleaning ......................................................................................................... 188
2 Oiling.............................................................................................................. 188
Periodic Maintenance Check List ............................................................ 189
3
187
1 Guaranteeing maintenance cycle
After the delivered item, visit customer periodically and guide the DC-645 operation.
2 Cleaning and Oiling

1 Cleaning
I Paper shreds
Clean with a brush or a dry cloth.
2 Oiling
I Bearings
Apply a small amount of oil to the end face and axel while turning the levers and rollers.
II Gears and Rails

Apply grease after cleaning the paper dust off of the gears.
188
Chapter 5 Maintenance Checks Periodic Maintenance
3 Periodic Maintenance Check List

6-month Periodic Checks
Section to be checked Description Inspection standard

PPS1
PPS2 1
PPS3
PPS4 Use a brush to clean any paper dust,etc.from the
Cleaning
PPS5 upper and lower sensors.
PPS6
2
PPS7
PPS8
Timing Belts Checking

Inspect Belts for signs of wear or loss of tension.
Replace any cracked or worm belts, and retension as
3
required.
Roller Bearings Oiling Oil (70P95)
Slitter Oiling Oil (70P95) 4
Cutter Oiling Oil (70P95)
Photo Sensor Cleaning Use a brush to clean any paper dust, etc.
Flat Belts Cleaning Use a brush to clean any paper dust, etc.
Gears Greasing 5
189
Criteria for Replacing Primary Parts
No. Section Part No. Part name MTBF

1 Paper feed P9-A1050-01 Belt -
2 AJ085 Super torque timing belt -
3 AK029 Roller chain -
7 N4-K2122 Paper separator plate -
8 Skew adjust AJ208 Super torque timing belt -
9 P9-B1260 Flat belt -
10 Reject AJ209 Super torque timing belt -
11 P9-E3060-03 Rubber roll -
12 P9-E3080-02 Rubber roll -
13 Slitter P9-F1041-01 Upper blade 2,000,000 sheets
14 P9-F1070 Lower blade unit 2,000,000 sheets
15 P9-F1211 Nut -
16 P9-F1280 Support roller -
21 Cutter AJ210 Super torque timing belt -
22 P9-J1010 Cutter unit 1,000,000 times
23 Crease P9-K1021-02 Crease upper blade -
24 P9-K1031-03 Crease lower blade -
26 Drive AJ081 Super torque timing belt -
30 P9-N1110-02 Driving roller -
31 P9-N1131 Sponge roll -
32 P9-N1330-02 Driving roller -
Delivery
33 P9-P1010-02 Driving roller -
module
34 P9-P1030-02 Sponge roll -
190
Chapter 5 Maintenance Checks Periodic Maintenance
2,000,000 sheets
35 Each module S-0001 Slitter A module
(A3 size, fine quality 230gsm)
2,000,000 sheets
36 S-0002 Slitter 1
2,000,000 sheets
37 S-0003 Slitter 2
2,000,000 sheets
38 S-0004 Slitter B, C module
(A3 size, fine quality 230gsm) 1
2,000,000 sheets
39 S-0005 Slitter 3, 5
2,000,000 sheets
40 S-0006 Slitter 4, 6
2
1,000,000 sheets
41 S-0007 Cutter module
1,000,000 sheets
42 S-0008 Crease module
43 S-0009 Delivery module

-
3
250,000 sheets
44 Option PFR-04 Perforator unit
(A4 portrait, fine quality 230gsm)
45 RSM-01 Vertical crease unit

250,000 sheets
4
1,000,000 cuts
46 BCM-55 Business card unit
47
Electrical
parts
BZ008 Stepping motor driver - 5
48 CA021 Photo micro sensor -
49 CA031 Photo interrupter -
50 CA035 Ultrasonic wave sensor - 6
53 DA005 Grommet G -
54 LA005 Micro switch - 7
55 LA038 Micro switch -
56 PD014 SSR -
57 TG021 LC module - 8
58 UA042 Switching power supply -
59 UD028 Power relay -
60 UI025 Fuse -
61 L1-X1080 Motor/Press -
62 M7-V3060 Memory P.C.B unit -
63 M7-X1020 Motor -
64 M7-X1040 Motor -
191
65 N4-V3022 Power P.C.B unit -
66 N4-W1320 LC unit -
67 N4-X1000 Solenoid -
68 N4-X1030 CCD -
69 N4-X1050 Fan motor -
70 N4-W1081 Photo-receiving P.C.B unit 1 -
71 N4-W1091 Photo-receiving P.C.B unit 1 -
72 N5-X1030-01 Exit motor -
73 N5-X1111 Motor -
74 P6-X1000 DC motor -
75 P6-X1010 DC solenoid -
76 P9-V3011 Main P.C.B unit -
77 P9-V3030-01 Oscillation P.C.B unit -
78 P9-V3050-01 Receive P.C.B unit -
79 P9-V3070 Panel P.C.B unit 1 -
80 P9-V3090-02 Panel P.C.B unit 2 -
81 P9-V3130-01 Stepping drive P.C.B unit -
82 P9-V3150 USB P.C.B unit -
83 P9-V3170 DC drive P.C.B unit -
84 P9-W2192-01 Cut HP relay cable unit -
85 P9-W2202-01 Crease HP relay cable unit -
86 P9-X1010 Stepping motor -
87 P9-X1020 Stepping motor -
88 P9-X1030 Compressor -
89 P9-X1060 Main motor -
*It is reference in the replacement time mentioned above. Please understand that there can
be different by actual usage environment and condition.
192
Chapter 6 Troubleshooting 1
Troubleshooting ...................................................................................... 194
1 When “J2 FEED JAM” is Displayed ............................................................. 194
2 When “J3 CENTER JAM” is Displayed........................................................ 194
2
3 When “J4 CUTTER OR CREASE” is displayed........................................... 195
4 When “J5 OPTION AREA JAM” is Displayed............................................. 195
5 When “J6 STACKER JAM” is Displayed ..................................................... 196
6 When “J7 OVER CAPACITY” is Displayed ................................................ 196
3
7 When “J8 REJECT AREA JAM” is Displayed ............................................. 197
8 When “E2 RS232C ERROR” is Displayed ................................................... 197
9 When “E3 BARCODE ERROR” is Displayed .............................................. 197
0 When “E4 REG. MARK ERROR” is Displayed ........................................... 198
4
A When “E5 SLITTER ERROR” is Displayed ................................................. 198
B When “E6 DATA ERROR” is Displayed ...................................................... 199
C When “E7 CUTTER ERROR” is Displayed. ................................................ 199
D When “E8 ELEVATOR ERROR” is Displayed ............................................ 199 5
E When “E9 CREASE ERROR” is Displayed.................................................. 200
F When “E12 REJECT ERROR” is Displayed................................................. 200
G When “E14 GUTTER ERROR R” is Displayed............................................ 201
H When “E15 GUTTER ERROR L” is Displayed............................................ 201 6
I When “E16 BC & REG ERROR” is Displayed............................................. 202
J When “E17 TRIM ERROR/SLITTER DRIVE ERROR” is Displayed ........ 202
Conditions for the Error Detection ......................................................... 203
7
Major Cause and Preventive Action for the Paper Jam in DC-645......... 205
193
1 Troubleshooting
1 When “J2 FEED JAM” is Displayed
see
step cause/failed area check item if action
page
Remove the paper left in the

Paper jam in the machine YES machine. —
1 inside the machine
(feed tray or transfer path).
NO Go to step 2. —
Do PPS2 and PPS3 work YES Go to step 3. —

2 PPS2, PPS3 properly when checked in • Clean the sensor. 99,
HELP Mode:11? NO
• Replace the sensor. 107
Incomplete plug-in at #3 Plug-in the connector prop-

YES —
3 main PCB and #18 connectors of main erly. Done.
PCB? NO Replace the main PCB. 159
HELP Mode:11 → p.223
2 When “J3 CENTER JAM” is Displayed

see
page

Paper jam in the machine YES —
1 inside the machine machine.
(reject, slitter, or gutter).
YES Go to step 3. —
Do PPS3, PPS4, and PPS5
2 PPS3, PPS4, PPS5 work properly when 108,
• Clean the sensor.
checked in HELP Mode:11? NO 124,
• Replace the sensor.
135

YES —
194
Chapter 6 Troubleshooting Troubleshooting
3 When “J4 CUTTER OR CREASE” is displayed

see
page

(cutter or creaser).
NO
YES
Go to step 2.
Go to step 3.
—
—
1
Do PPS5 and PPS6 work
2 PPS5, PPS6 properly when checked in • Clean the sensor. 135,
HELP Mode:11? NO
• Replace the sensor. 144
Incomplete plug-in at #18 YES

Plug-in the connector prop-
erly. Done.
—
2
3 main PCB
connector of main PCB?
NO Replace the main PCB. 159

3
4 When “J5 OPTION AREA JAM” is Displayed

see
page
4
(option module)
NO Go to step 2. — 5
Do PPS6 and PPS7 work YES Go to step 3. —
2 PPS6, PPS7 properly when checked in • Clean the sensor.
HELP Mode:11? NO —
6
Incomplete plug-in at #3 YES —
HELP Mode:11 → p.223 7
195
5 When “J6 STACKER JAM” is Displayed
see
page

(exit tray)
Does PPS7 work properly YES Go to step 3. —

2 PPS7 when checked in HELP • Clean the sensor.
Mode:11? NO 150

3 main PCB erly. Done.
6 When “J7 OVER CAPACITY” is Displayed

see
page
Does PPS7 work properly YES Go to step 2. —

1 paper level sensor when checked in HELP • Clean the sensor.
Mode:12? NO 88
elevator upper Does actuator move YES Go to step 3. —

2
limit sensor smoothly? NO Replace the actuator. 89
elevator lower limit Does elevator lower limit
3 • Replace the elevator lower
switch switch work properly? NO 90
limit switch.

4 main PCB erly. Done.
196
7 When “J8 REJECT AREA JAM” is Displayed

see
page

YES —
1 inside the machine Paper jam at reject area. machine.
NO
YES
Go to step 2.
Go to step 3.
—
—
1
Does PPS8 work properly
2 PPS8 when checked in HELP • Clean the sensor.
Mode:11? NO 110
Incomplete plug-in at #18 YES

erly. Done.
—
2
3 main PCB

3
8 When “E2 RS232C ERROR” is Displayed

see
page
4
Try reading out the adjust- Replace the main PCB, or 107,
1 CCD module Failed
ment test paper. replace the CCD. 159
5
9 When “E3 BARCODE ERROR” is Displayed
see
page 6
1 paper Is a barcode provided? Use an appropriate paper
NO 64
with barcode.
7
Appropriate printing qual-
2 paper
ity of the barcode? NO Re-print the barcode. 64
Adequate type of barcode YES Go to step 4. —

3 paper
used (among 1 - 80)? NO Print the adequate barcode. 64
8
4 CCD module Failed
197
0 When “E4 REG. MARK ERROR” is Displayed
see
page
1 paper Is a REG. mark provided? Use an appropriate paper
NO 66
with REG. mark.
Appropriate printing qual- YES Go to step 3. —

2 paper
ity of the REG. mark? NO Re-print the Reg. mark. 66
Is the REG. mark in confor-
3 paper Print the adequate REG.
mity to the specifications? NO 66
mark.
4 CCD module Failed
A When “E5 SLITTER ERROR” is Displayed

* Check the slitter number displayed with the error message
see
page
YES Go to step A-2. —

Does the HP sensor for slit-
A-1 slitter HP sensor ter work properly when 115–
checked in HELP Mode:12? NO 127

A-2 main PCB erly. Done.
Stepping motor Check the motor operation OK Done. —

B-1
for the lead screw in HELP Mode: 31 - 36. Failed Go to step B-2. —
OK Replace the stepping motor. 129

Check the adequate 24V
B-2 Stepper drive PCB output power at the CN2 - Replace the stepper drive.
158,
10 brown terminals. Failed Replace the power supply
160
PCB.

198
B When “E6 DATA ERROR” is Displayed

see
page
Try the input of settings

OK —
Values input to the Check if the input value again.
1
JOB Creator meets the specifications.
Failed
Change the settings to meet
the specifications.
— 1
C When “E7 CUTTER ERROR” is Displayed.
see
2
page
Does the cutter HP sensor YES Go to step 2. —

1 Cutter HP sensor work properly when
checked in HELP Mode:12? NO
137
3
OK Replace the cutter motor. 138

Replace the DC drive PCB.
2 DC drive PCB output power at the CN11 -
#1 and 2 terminals. Failed Replace the power source
158,
159
4
PCB.
D When “E8 ELEVATOR ERROR” is Displayed

5
see
page
6
Does the paper level sensor YES Go to step 2. —
1 Paper level sensor work properly when • Clean the sensor.
Does the elevator lower YES Go to step 3. — 7

Elevator lower limit limit switch work properly
2
switch when checked in HELP NO Replace the switch. 90
Mode:12?

OK Replace the elevator motor. 91
8
3 DC drive PCB output power at the CN5 - Replace the DC drive PCB.
158,
#1 and 2 terminals. Failed Replace the power source
159
PCB.
199
E When “E9 CREASE ERROR” is Displayed.
see
page
Does the creaser HP sensor YES Go to step A-2. —

A-1 Creaser HP sensor work properly when • Clean the sensor.
Check the adequate 24V YES Replace the creaser motor. 141
A-2 DC drive PCB output power at the CN11 -
#3 and 4 terminals. NO Replace the DC drive PCB. 159
Does the creaser lower YES Go to step B-2. —

Creaser lower blade HP sensor work prop-
B-1 • Clean the sensor.
blade HP sensor erly when checked in HELP NO 140
Mode:12? • Replace the sensor.
Replace the creaser lower 142,

YES
Check the adequate 24V blade motor. 159
B-2 DC drive PCB output power at the CN5 - Replace the DC drive PCB.
#7 and 8 terminals. 158,
NO Replace the power source
159
PCB.
F When “E12 REJECT ERROR” is Displayed.

see
page
Does the rejection HP sensor YES Go to step 2. —

Rejection HP sen-
1 work properly when • Clean the sensor.
sor NO 106
checked in HELP Mode:12? • Replace the sensor.
Does the rejection LM sen- YES Go to step 3. —

Rejection LM sen-
2 sor work properly when • Clean the sensor.
sor NO 106
checked in HELP Mode:12? • Replace the sensor.
YES Replace the rejection motor. 103

3 DC drive PCB output power at the CN3 - Replace the DC drive PCB.
106,
#7 and 8 terminals. NO Replace the power source
159
PCB.
200
G When “E14 GUTTER ERROR R” is Displayed

see
page
Does the gutter HP sensor YES Go to step A-2. —

A-1 Gutter HP sensor work properly when • Clean the sensor.

1
B-1
Stepping motor Check the motor operation OK Done. — 2
for the lead screw in HELP Mode: 37 and 38. Failed Go to step B-2. —
OK Replace the stepping motor. 161

B-2 Stepper drive PCB output power at the CN8
and 9 brown terminals. Failed
Replace the stepper drive.
Replace the power supply 160
3
PCB.

HELP Mode:38 → p.251 4
H When “E15 GUTTER ERROR L” is Displayed
see
5
page
Does the option HP sensor YES Go to step A-2. —

A-1 Option HP sensor work properly when
checked in HELP Mode:12? NO
149
6
NO Replace the main PCB. 159 7
Stepping motor Check the motor operation OK Done. —
B-1
for the lead screw in HELP Mode: 39. Failed Go to step B-2. —

OK Replace the stepping motor. 161 8
B-2 Stepper drive PCB output power at the CN7 Replace the stepper drive.
brown terminal. Failed Replace the power supply 160
PCB.

201
I When “E16 BC & REG ERROR” is Displayed
see
page
1 paper Is a barcode provided? Use an appropriate paper
NO 64
with barcode.

2 paper
ity of the barcode? NO Re-print the barcode. 64
Adequate type of barcode YES Go to step 4. —

3 paper
used (among 1 - 80)? NO Print the adequate barcode. 64
4 paper Is a REG. mark provided? Use an appropriate paper
NO 159
with REG. mark.

5 paper
ity of the REG. mark? NO Re-print the REG. mark. 159
6 paper paper Print the adequate REG.
NO 159
mark.
Try reading out the adjust- Replace the main PCB, 107,
7 CCD module Failed
ment test paper. or replace the CCD. 159
J When “E17 TRIM ERROR/SLITTER DRIVE ERROR” is

Displayed
see
page

YES —
1 inside the machine Paper jam in the waste box machine.
Does margin jam sensor YES Go to step 3. —

2 Margin jam sensor work properly when • Clean the sensor.

YES —
202
Chapter 6 Troubleshooting Conditions for the Error Detection
2 Conditions for the Error Detection

J1 (REJECT PAPER)
When paper remains in the machine.
(To be checked when; the power is turned on, “cover open” is canceled, and the machine
starts operation.)
J2 (FEED JAM) 1
When the paper does not reach the PPS2 after 3 times retry of the feeding operation, or
when the paper does not reach the PPS3 after passing through the PPS2.
J3 (CENTER JAM)
When the PPS4 is kept in the "light through" state after passing through the PPS3, or when
the PPS3 is kept in the “light blocked” state.
2
When the PPS5 is kept in the "light through" state after passing through the PPS4, or when
the PPS4 is kept in the “light blocked” state.
J4 (CUTTER OF CREASE)
When the paper does not reach the PPS6 after passing through the PPS5, or when the
3
PPS5 is kept in the “light blocked” state.
J5 (OPTION AREA JAM)
When the paper does not reach the PPS7 after passing through the PPS6, or when the
PPS6 is kept in the “light blocked” state.
4
J6 (STACKER JAM)
When the PPS7 is kept in the “light blocked” state.
J7 (OVER CAPACITY) 5
When the elevator lower limit switch, the elevator upper limit switch, and the paper level
sensor are all turned ON.
J8 (REJECT AREA JAM)
When the paper does not reach the PPS7 after passing through the PPS8.
When the paper does not reach the PPS8 after machine reject operation.
6
E2 (RS232C ERROR)
When communication error takes place in the barcode scanner operation.
E3 (BARCODE ERROR) 7
When the machine does not recognize the barcode after the paper passes through the
PPS3 and transferred for a certain distance.
(on condition that the barcode rejection setting is OFF.)
E4 (REG. MARK ERROR) 8
When the machine does not recognize the REG. mark after the paper passes through the
PPS3 and transferred for a certain distance.
(on condition that the REG. mark setting is ON and the barcode rejection setting is OFF.)
E5 (SLITTER ERROR)
When the slitter does not reach the home position within 12 seconds after the slitter driving
signal is sent out, or when the slitter does not move from the home position after it reaches
there.
(Detection duration: 12 seconds)
203
E6 (DATA ERROR)
The present data settings do not comply with the specifications of DC-645.
E7 (CUTTER ERROR)
When the home position cannot be detected in the course of cutter operation.
(Detection duration: 900ms)
E8 (ELEVATOR ERROR)
In the course of elevator operation, reach to either the upper limit sensor, the paper level
sensor, or the lower limit sensor cannot be recognized within 10 seconds after the elevator
driving signal is sent out.
(Detection duration: 10 seconds)
E9 (CREASE ERROR)
When the home positions for creaser upper blade and/or lower blade cannot be detected in
the course of creaser operation.
When the home positions for crease upper blade and/or lower blade cannot be detected
within 0.8 seconds after the creaser driving signal is sent out.
(Detection duration: 900ms)
E11 (DOUBLE FEED)
When the sensor threshold value is exceeded after the paper passes through the PPS2
and before it reaches the PPS3.
(on condition that the rejection setting is OFF.)
E12 (REJECT ERROR)
When the sensor detection state does not change after the rejection bar operation
command is sent out.
E14 (GUTTER ERROR)
When the gutter module does not reach its home position,
or when the gutter module does not move from the home position after it reaches there.
E15 (OPTION ERROR)
When the option module does not reach its home position, or when the option module
does not move from the home position after it reaches there.
E16 (BARCODE & REG. MARK ERROR)
When both the barcode and the REG. mark cannot be recognized by CCD, although these
functions are both turned ON.
E17
When the light of Margin jam sensor is continuously blocked beyond the time setting.
COVER OPEN
When the covers of the machine are open.
CHANGE MODULE
When the module required for the JOB selected is different from the module actually
installed on the machine.
SET SLIT MODULE
When the slitter module is not installed.
USB – IF SUSPENDED
When USB communication error takes place.
BLANK DATA
When there is no data input that is necessary for the selected JOB.
204
Chapter 6 Troubleshooting Major Cause and Preventive Action for the Paper Jam in DC-645
3 Major Cause and Preventive Action for

the Paper Jam in DC-645
Avoid the use of the following types of paper:
• Torn paper or papers with large holes.
• Stapled or clipped paper.
• Substantially curled, wavy, or partly folded paper. 1
• Carbon paper and the like.
• Paper of high transparency such as OHP films.
• Paper with punched holes for filing.
• Paper containing cut-and-paste areas.
• Laminated paper of improper adhesion 2
• Paper with projected edges on the cutting face.
205
206
Chapter 7 HELP Mode 1
HELP Mode List........................................................................................ 208
Accessing the HELP Mode ....................................................................... 211 2
Looking into Each “HELP Mode” ............................................................ 211
Accessing the Serviceman JOB ................................................................ 212
HELP Mode description ........................................................................... 213
3
207
1 HELP Mode List
No. function category page
(1) Display the ROM version. ROM version display 213

00
(2) Version-up the ROM version-up 213
(1) Display the total cut count 215

01 counter
(2) Reset the User Mode total cut count 215
(1) Display the total paper feed count 216

02 counter
(2) Reset the User Mode total paper feed count 216
(1) Display the total creasing count 217

03 counter
(2) Reset the User Mode total creasing count 217
04 (1) Check on the paper jam count 1 counter 218
05 (1) Check on the paper jam count 2 counter 219
07 (1) Check on the error count 1 counter 220
08 (1) Check on the error count 2 counter 221
09 (1) Check on the slitter error count counter 222
(1) PPS sensor check 223

11 sensor check
(2) PPS sensor display in analog format 223
12 (1) Sensor and switch check sensor / switch check 225
13 (1) DIP switch check switch check 227
15 (1) Double feed detection check check 228
16 (1) LED function check display / check 229
17 (1) Paper feed elevator operation test operation test 230
18 (1) Fan motor operation test operation test 231
19 (1) Solenoid and feeding operation test operation test 232
20 (1) Compressor operation test operation test 233
21 (1) Paper separator plate solenoid operation test operation test 234
22 (1) Feed belt motor operation test operation test 235
23 (1) Rejection bar operation test operation test 236
24 (1) Rejection motor operation test operation test 237
25 (1) Feed RUN test operation test 238
(1) Slitter RUN test 239

26 operation test
(2) Slitter home position check 239
208
Chapter 7 HELP Mode HELP Mode List
27 (1) Creaser motor operation test operation test 240
28 (1) Creaser lower blade motor operation test operation test 241
29 (1) Cutter motor operation test operation test 242
(1) Putting the slitter speed on the display 243

30 display / adjustment
(2) Adjusting the slitter speed 243 1
31 (1) Slitter 1 motor operation test operation test 244
33 (1) Slitter 3 motor operation test operation test 246 2


3
37 (1) Gutter R motor operation test operation test 250
38 (1) Gutter L motor operation test operation test 251
39
41
(1) Option slitter motor operation test
(1) Main motor 1 (paper feed end) operation test

operation test
operation test
252
253
4
42 (1) Main motor 2 (paper exit end) operation test operation test 254
43 (1) Clear the JOB clear the JOB memory 255
44 Setting CCD ADJUST value display / adjustment 256

5
45 (1) REG. mark read out position adjustment adjustment 257
46 (1) Cutting position adjustment adjustment 258
47 (1) Creasing position adjustment adjustment 259 6

48 (1) Creasing depth adjustment adjustment 260
49 (1) Margin slitter and center slitter positions adjustment adjustment 261
50 (1) Gutter positions adjustment adjustment 262 7

51 (1) Position adjustment for option (business card module) adjustment 263
52 (1) Main motor transfer distance adjustment adjustment 264
53 (1) Provision or elimination of the gutter function setting 265 8

55 (1) Setting the number of times for rejection setting 266
56 (1) Setting the paper feed rate from PPS2 to PPS3 adjustment 267
(1) Display the skew adjust fan speed 268

(2) Adjust the skew adjust fan speed 268
(1) Display the margin jam detecting sensor 269

(2) Adjust the margin jam detecting sensor 269
209
(1) Cancel Limit of the cutting direction 270

60 display / change
(2) Cancel Limit of slitter position 270
(1) Display the setting of the machine 271

61 display / change
(2) Change the setting of the machine 271
(1) Display the setting of the paper feed interval 272

(2) Adjust the paper feed interval 272
(1) Display the JOG REVERSE setting 273

67 display / change
(2) Change the JOG REVERSE setting 273
(1) Display details of the REG mark errors 274

(2) Clear the REG mark error counter 274
(1) Display the screen setting for the gutter less business
278
card unit
69 display / change
(2) Change the screen setting for the gutter less business
278
card unit
210
Chapter 7 HELP Mode Accessing the HELP Mode
2 Accessing the HELP Mode

1 When the machine is in use, put it in the standby mode and turn
OFF the power switch before accessing the HELP Mode.
2 Turn ON the power switch while pressing the <JOG> and
<JOG> keys at the same time. In about 2 seconds, “00: ROM
VERSION” appears on the display with the bleeping sound.
3 Input the relevant “HELP Mode No.” that you want to check or 1
change by the ten key.
e.g.: To access the HELP Mode “H-11”, input the number by
pressing “1”, “1".
TIP: “HELP Mode No.” may be selected using <+> and <->
keys. 2
4 Press the START key. The “HELP Mode” specified in 3 above is
displayed.Follow the procedure described under the corresponding
“HELP Mode No.”.
3 Looking into Each “HELP Mode” 4
HELP Mode No.

5
HELP Mode: 00
Main Functions I. Function

6
(1) Display the ROM version.
DC-645
¥ THE ROM version of the Main PCB is displayed.
LCD Display
Ver. x. xx
(2) Version-up the ROM
¥ The Main PCB ROM (U10) version is updated.
Procedure for
each function
II
(1)
Operating Procedure
Display the ROM version.
7
1 Access the HELP Mode, press <START> key while “00: ROM
VERSION” is on the display. ROM version is displayed.
2 Press the <STOP> key. It will return to the HELP Mode selection U10
screen. SW1
To quit the “HELP Mode”
8
............Turn OFF the power switch.
To move to other “HELP Mode”
............Input the new “HELP Mode No.” by the ten key.
211
4 Accessing the Serviceman JOB
OFF the power switch before accessing the HELP Mode.
2 Turn ON the power switch while pressing the <+> key and the <C>
in the ten key at the same time. The machine is put in the standby
mode with the “pip” sound.
3 Input the “Serviceman JOB No.” to be checked by the ten key.
e.g.: to access the Serviceman JOB “81”,
Input the number by pressing “8”, “1".
4 Press the <TEST> key, and the JOB will be implemented.
212
Chapter 7 HELP Mode HELP Mode description
5 HELP Mode description
HELP Mode: 00
I. Function
1
• THE ROM version of the Main PCB is displayed. DC-645
Ver. x. xx
(2) Version-up the ROM
• The Main PCB ROM (U10) version is updated. 2
II Operating Procedure
1 Access the HELP Mode, press <START> key while “00: ROM
3
VERSION” is on the display. ROM version is displayed.
2 Press the <STOP> key. It will return to the HELP Mode selection U10
screen. SW1
→ To quit the “HELP Mode”
4
........... Turn OFF the power switch.
→ To move to other “HELP Mode”
........... Input the new “HELP Mode No.” by the ten key.
(2) Version-up the ROM 5

OFF the power before accessing the HELP Mode.
Turn ON only the “No. 1 of the SW1” on the main PCB.
IMPORTANT: Never touch other switches than “No. 1 of the
SW1”.
6
2 Insert the “Master ROM” into the ROM “U10” socket on the main
PCB.
3 Turn ON the power while pressing the <JOG> and <JOG>
keys at the same time. 7
4 Input the numbers “0”, “0” by the ten key. (HELP Mode: 00)
5 Press the <START> key.
6 Press the <SET> key, and “COPY …” appears on the LCD panel.
The copying process is initiated.
It takes 30 seconds before the copying process is completed. Once
8
completed, “FINISH!!” appears on the LCD panel.
IMPORTANT: Do not turn OFF the power switch while “COPY...”
is displayed on the panel. If it is turned OFF, please
repeat the copying process from the beginning
7 Turn OFF the power switch.
213
8 Pull out the “Master ROM” set in the ROM “U10” socket on the
main PCB.
9 Turn OFF the “No. 1 of the SW1” on the main PCB.
214
HELP Mode: 01
I. Function
(1) Display the total cut count
• Total number of cuts is displayed in 8 digits numeral. xxxxxxxx
(2) Reset the User Mode total cut count xxxxxxxx 1
• The User Mode total cut count is reset.
2. Operating Procedure
(1) Display the total cut count
2
1 Access the HELP Mode “01”, and press the <START> key.
The “total cut count” is shown in the upper part, and the “User
Mode total cut count” is shown in the lower part.
2 Press the <STOP> key. It will return to the HELP Mode selection 3
screen.

4
(2) Reset the User Mode total cut count
1 Access the HELP Mode “01”, and press the <START> key. 5
2 Continuously press the <C> in the ten key for about 3 seconds, and
the total cut count will be reset with the bleeping sound.
3 Press the <STOP> key. It will return to the HELP Mode selection
screen.
6
7
215
HELP Mode: 02
I. Function
(1) Display the total paper feed count
• Total number of paper feed is displayed in 8 digits numeral.
(2) Reset the User Mode total paper feed count

• The User Mode total paper feed count is reset.
II. Operating Procedure

(1) Display the total paper feed count
The “total paper feed count” is shown in the upper part, and the
“User Mode total paper feed count” is shown in the lower part.
screen.

(2) Reset the User Mode total paper feed count

the total paper feed count will be reset with the bleeping sound.
screen.

216
HELP Mode: 03
I. Function
(1) Display the total creasing count
• Total number of creasing done is displayed in 8 digits xxxxxxxx
numeral. xxxxxxxx 1
(2) Reset the User Mode total creasing count
• The User Mode total creasing count is reset.
II. Operating Procedure 2

(1) Display the total creasing count
The “total creasing count” is shown in the upper part, and the “User
Mode total creasing count” is shown in the lower part. 3
screen.

........... Turn OFF the power switch. 4
(2) Reset the User Mode total creasing count

the total creasing count will be reset with the bleeping sound.
screen.
6
7
217
HELP Mode: 04
I. Function
(1) Check on the paper jam count 1
• The following items are displayed: J2:xxxx J3:xxxx
J2: FEED JAM J4:xxxx J5:xxxx
J3: CENTER JAM
J4: CUTTER OR CREASE
J5: OPTION AREA JAM

Types of the paper jam
• Number of times that JAM 2, 3, 4, and 5 took place is
displayed.
“J2 - FEED JAM” : Paper jam at the paper feed
“J3 – CENTER JAM” : Paper jam at the central area
“J4 – CUTTER OR CREASE”: Paper jam at the cutter or the
creaser
“J5 - OPTION AREA JAM” : Paper jam at the option area
all the paper jam counts will be reset with the bleeping sound.
screen.

218
HELP Mode: 05
I. Function
• The following items are displayed: J6:xxxx J8:xxxx
J6: STACKER JAM
J8: REJECT AREA JAM
1
(1) Check on the paper jam count 2 2
Types of the paper jam
• Number of times that JAM 6 and 8 took place is displayed.
“J6 – STACKER JAM” : Paper jam at the stacker
“J8 – REJECT AREA JAM” : Paper jam at the reject area
3
all the paper jam counts will be reset with the bleeping sound.
screen. 4
........... Input the new “HELP Mode No.” by the ten key. 5
219
HELP Mode: 07
I. Function
(1) Check on the error count 1
• The following items are displayed: E3:xxxx E4:xxxx
E3: BARCODE ERROR E11:xxxx
E4: REG.DMARK ERROR
E11: DOUBLE FEED
E16: BC & REG ERROR

Types of the Error
• Number of times that ERROR 3, 4, and 11 were detected is
displayed.
“E3 – BARCODE ERROR” : Barcode reading error
“E4 – REG MARK ERROR” : REG. mark (position adjustment
mark) reading error
“E11 – DOUBLE FEED” : Double feed error (double error
was detected.)
“E16 – BC & REG ERROR” : Barcode and REG. mark error
all the error counts will be reset with the bleeping sound.
screen.

220
HELP Mode: 08
I. Function
• The following items are displayed: E7:xxxx E8:xxxx
E7: CUTTER ERROR
E8: ELEVATOR ERROR
E9:xxxx E12:xxxx 1
E9: CREASE ERROR
E12: REJECT ERROR

Types of the Error
• Number of times that ERROR 7, 8, 9, and 12 were detected is 3
displayed.
“E7 – CUTTER ERROR” : Error in the cutter
“E8 – ELEVATOR ERROR” : Error in the elevator
“E9 - CREASE ERROR”
“E12 – REJECT ERROR”
: Error in the creaser module
: Error in the reject area
4
screen. 5
6
221
HELP Mode: 09
I. Function
(1) Check on the slitter error count
• The following items are displayed (press the <SET> key to S1:xxxx S2:xxxx
display the next item). S3:xxxx S4:xxxx
S1: SLITTER 1 ERROR
S2: SLITTER 2 ERROR
S3: SLITTER 3 ERROR
S4: SLITTER 4 ERROR
S5: SLITTER 5 ERROR
S6: SLITTER 6 ERROR
GR: GUTTER RIGHT ERROR
GL: GUTTER LEFT ERROR
OP: OPTION ERROR
OP1: OPTION1 ERROR
OP2: OPTION2 ERROR

(1) Check on the slitter error count
Types of the Error
• The number of errors detected for each slitter are displayed
(Press <SET> key to display the next item.)
“S1 – SLITTER 1 ERROR” : Error in the slitter 1
“S2 – SLITTER 2_ERROR” : Error in the slitter 2
“GR – GUTTER RIGHT ERROR”: Error in the gutter right
“GL – GUTTER LEFT ERROR” : Error in the gutter light
OP : BUSINESS CARD UNIT ERROR
OP1 : VERTICAL CREASE, PERFORATOR
Error of the motor in the control panel side
OP2 : VERTICAL CREASE, PERFORATOR
Error of the motor in the opposite side of control panel
screen.

222
HELP Mode: 11
I. Function
(1) PPS sensor check
abcdefgh
1
• Status of the following sensors is displayed.
No. Sensor Display Location
a PPS1 0: light through 1: light blocked feed tray

2
b PPS2 0: light through 1: light blocked double feed
c PPS3 0: light through 1: light blocked CCD
d PPS4 0: light through 1: light blocked center slitter

3
e PPS5 0: light through 1: light blocked in front of the cutter
f PPS6 0: light through 1: light blocked in the rear of the creaser
g PPS7 0: light through 1: light blocked paper dropping position

4
h PPS8 0: light through 1: light blocked rejection point
(2) PPS sensor display in analog format 5

• The display is made in analog format for the sensors No. b, c,
e, f, and g listed above.
A threshold of each sensor
PPS4
PPS2,3,6,7,8
: 51 or less
: 128 or less 6
(1) PPS sensor check
7
screen.

8
223
(2) PPS sensor display in analog format
2 Then, press the <SET> key, and the display will be made in analog
format for the relevant sensors.
screen.

224
HELP Mode: 12
I. Function
(1) Sensor switch check
abcdefghijklmnop
ABCDEFGHIJKLMNOP 1
• Status of the following sensor switches is displayed.
No. Sensor Switch Display
a Margin slitter module detection sensor 0: light through 1: light blocked

2
b not used not used
c Center slitter 1 module detection sensor 0: light through 1: light blocked
d not used not used

3
e Center slitter 2 module detection sensor 0: light through 1: light blocked
f not used not used
g Option module detection sensor 1 0: light through 1: light blocked

4
h Option module detection sensor 2 0: light through 1: light blocked
i Option module detection sensor 3 0: light through 1: light blocked
j not used not used 5

k Cutter home position sensor 0: light through 1: light blocked
l Creaser home position sensor 0: light through 1: light blocked
m Creaser lower blade home position sensor 0: light through 1: light blocked 6
n Reject home position sensor 0: light through 1: light blocked
o Reject upper limit sensor 0: light through 1: light blocked
p Elevator go-down switch 0: ON 1: OFF 7
225
No. Sensor Switch Display
A Slitter 1 home position sensor 0: light through 1: light blocked
B Slitter 2 home position sensor 0: light through 1: light blocked
C Slitter 3 home position sensor 0: light through 1: light blocked
D Slitter 4 home position sensor 0: light through 1: light blocked
E Slitter 5 home position sensor 0: light through 1: light blocked
F Slitter 6 home position sensor 0: light through 1: light blocked
G Gutter R home position sensor 0: light through 1: light blocked
H Gutter L home position sensor 0: light through 1: light blocked
I not used not used
J Option home position sensor 0: light through 1: light blocked
K Paper level sensor 0: light through 1: light blocked
L Elevator upper limit switch 0: ON 1: OFF
M Elevator lower limit switch 0: ON 1: OFF
O Cover switch 0: ON 1: OFF

(1) Sensor switch check
screen.

226
HELP Mode: 13
I. Function
(1) DIP switch check
• Status of the DIP switch is displayed. xxxxxxxx
1
(1) DIP switch check 2
screen.

3
227
HELP Mode: 15
I. Function
(1) Double feed detection check
• Double feed detection adjustment is verified. 15:DOUBLEFEED CK
xxx

(1) Double feed detection check
• The double feed detection value is displayed:
0-80 : one sheet of paper
160 – 255 : Two sheets of paper or more
screen.

228
HELP Mode: 16
I. Function
(1) LED function check
• Check that the LED on the control panel lights up correctly. 16:LED CHECK
1
(1) LED function check 2
• All the LED on the control panel lights up.
screen. 3
4
229
HELP Mode: 17
I. Function
(1) Paper feed elevator operation test
• The correct operation of the paper feed elevator is verified. +KEY:ELEV. UP
-KEY:ELEV.DWN

(1) Paper feed elevator operation test
2 Run the elevator by pressing the <+> and <-> keys.
screen.

230
HELP Mode: 18
I. Function
(1) Fan motor operation test
• The proper function of each fan motor is verified. +:FAN1 -:FAN2
<:FAN3 >:FAN4 1
(1) Fan motor operation test 2
2 Run the fan motor to be tested after selecting it by the applicable
key listed below.
<+> key
<-> key
FAN 1 – blower fan 1
FAN 2 – blower fan 2
3
<JOG> key FAN 3 – suction fan
<JOG> key FAN 4 – skew adjustment fan
screen. 4
5
231
HELP Mode: 19
I. Function
(1) Solenoid and feeding operation test
• The proper function of the shutter solenoid is verified. +KEY:SOL. ON
• The proper function of the feed motor is verified. -KEY:FEED ON

(1) Shutter solenoid operation test
2 Run the shutter solenoid by pressing the <+> key.
screen.

(2) Feed motor operation test

2 Run the feed motor by pressing the <-> key.
screen.

232
HELP Mode: 20
I. Function
(1) Compressor operation test
• The proper function of the compressor is verified. 20:COMPRESSOR CK
+KEY:COMP. ON 1
(1) Compressor operation test 2
2 Run the compressor by pressing the <+> key.
screen. 3
4
233
HELP Mode: 21
I. Function
(1) Paper separator plate solenoid operation test
• The proper function of the paper separator plate solenoid is 21:SEP. SOL.
verified. +KEY:SOL. OFF

(1) Paper separator plate solenoid operation test
2 Run the paper separator plate solenoid by pressing the <+> key.
screen.

234
HELP Mode: 22
I. Function
(1) Feed belt motor operation test
• The proper function of the feed belt motor is verified. 22:FEED BELT CK
+KEY:BELT ON 1
(1) Feed belt motor operation test 2
2 Run the feed belt motor by pressing the <+> key.
screen. 3
4
235
HELP Mode: 23
I. Function
(1) Rejection bar operation test
• The proper function of the rejection bar is verified. +KEY:REJ. UP
-KEY:REJ. DOWN

(1) Rejection bar operation test
2 Activate the rejection bar by pressing the <+> and <-> keys.
screen.

236
HELP Mode: 24
I. Function
(1) Rejection motor operation test
• The proper function of the rejection motor is verified. 24:REJ. DRV. CK
+,-KEY:MOT. ON 1
(1) Rejection motor operation test 2
2 Run the rejection motor by pressing the <+> and <-> keys.
screen. 3
4
237
HELP Mode: 25
I. Function
(1) Feed RUN test
• The proper function is verified regarding a series of operation +KEY:ELEV. UP
indicated below. -KEY:ELEV. DOWN
1. fan motor
2. shutter solenoid
3. feed motor
4. compressor
• Besides the functions listed above, the proper operation of
the paper feed elevator is verified.

(1) Feed RUN test
2 Run the paper feed elevator by pressing the <+> and <-> keys.
screen.

238
HELP Mode: 26
I. Function
(1) Slitter RUN test
• The proper function is verified regarding a series of slitter
operation. 1
(2) Slitter home position check
• Move the slitter to its home position.

(1) Slitter RUN test
2 Run all the slitters by pressing the <START> key.
3
screen.

→ To move to other “HELP Mode” 4
(2) Slitter home position check

2 Move all the slitters to their home positions by pressing the
5
<START> key.
screen.
→ To quit the “HELP Mode” 6

239
HELP Mode: 27
I. Function
(1) Creaser motor operation test
• The proper function of the creaser motor is verified. 27:CREASE CHECK
+,-KEY:CRE. ON

(1) Creaser motor operation test
2 Run the creaser motor by pressing the <+> and <-> keys.
screen.

240
HELP Mode: 28
I. Function
(1) Creaser lower blade motor operation test
• The proper function of the creaser lower blade motor is 28:CRE.LOW CK
verified. +,-KEY:MOT. ON 1
(1) Creaser lower blade motor operation test 2
2 Activate the creaser lower blade motor by pressing the <+> and <->
keys.
screen.

4
241
HELP Mode: 29
I. Function
(1) Cutter motor operation test
• The proper function of the cutter motor is verified. 29:CUTTER CHECK
+,-KEY:CUT ON

(1) Cutter motor operation test
2 Activate the creaser motor by pressing the <+> and <-> keys.
screen.

242
HELP Mode: 30
I. Function
(1) Putting the slitter speed on the display
• The slitter speed is indicated. 30:SLIT CHECK
(2) Adjusting the slitter speed XXXX XXXX 1
• The Slitter speed is adjusted.

(1) Putting the slitter speed on the display
2
2 The slitter speed for “Margin slitter / center slitter module” is
indicated on the right.
screen.

(2) Adjusting the slitter speed

2 The slitter speed for “Margin slitter / center slitter module” is 5
indicated on the right.
3 Adjust the VR2 on the DC drive PCB so that the slitter speed is set
within the following range.
VR2 – margin slitter / center slitter module: 2580–2600
6
screen.

243
HELP Mode: 31
I. Function
(1) Slitter 1 motor operation test
• The proper function of the slitter 1 motor is verified. +KEY:GOTO RIGHT
-KEY:GOTO LEFT

2 Move the slitter 1 to the right by pressing the <+> key, and move it
to the left by pressing the <-> key.
screen.

244
HELP Mode: 32
I. Function
-KEY:GOTO LEFT 1
(1) Slitter 2 motor operation test 2
screen.

4
245
HELP Mode: 33
I. Function
-KEY:GOTO LEFT

screen.

246
HELP Mode: 34
I. Function
-KEY:GOTO LEFT 1
screen.

4
247
HELP Mode: 35
I. Function
-KEY:GOTO LEFT

screen.

248
HELP Mode: 36
I. Function
-KEY:GOTO LEFT 1
screen.

4
249
HELP Mode: 37
I. Function
(1) Gutter R motor operation test
• The proper function of the gutter R motor is verified. +KEY:GOTO RIGHT
-KEY:GOTO LEFT

(1) Gutter R motor operation test
2 Move the gutter R to the right by pressing the <+> key, and move it
screen.

250
HELP Mode: 38
I. Function
(1) Gutter L motor operation test
• The proper function of the gutter L motor is verified. +KEY:GOTO RIGHT
-KEY:GOTO LEFT 1
(1) Gutter L motor operation test 2
2 Move the gutter L to the right by pressing the <+> key, and move it
screen.

4
251
HELP Mode: 39
I. Function
• The proper function of the option slitter motor is verified. +KEY:GOTO RIGHT
-KEY:GOTO LEFT

2 Move the option slitter to the right by pressing the <+> key, and
move it to the left by pressing the <-> key.
screen.

252
HELP Mode: 41
I. Function
(1) Main motor 1 (paper feed end) operation test
• The proper function of the main motor 1 is verified. 41:MAIN MOT. 1 CK
1
+,-KEY:MOT. ON

(1) Main motor 1 operation test
2 Activate the main motor 1 by pressing the <+> and <-> keys. 3
screen.

4
253
HELP Mode: 42
I. Function
(1) Main motor 2 (paper exit end) operation test
• The proper function of the main motor 2 is verified. 42:MAIN MOT. 2 CK
+,-KEY:MOT. ON

(1) Main motor 2 operation test
2 Activate the main motor 2 by pressing the <+> and <-> keys.
screen.

254
HELP Mode: 43
I. Function
(1) Clear the JOB
• All contents of the JOB (01 – 80) is initialized. (Note that the 43:JOB CLEAR
contents of the HELP are not cleared.) ALL:MODE, SET 1
(1) Clear the JOB 2
2 Press the <MODE> key and the <SET> key simultaneously.
“Please Wait” appears on the LED panel, and the JOB initialization
is commenced. It takes 30 seconds before the initializing process is
completed. Once completed, “FINISH!!” appears on the LCD
3
panel.
IMPORTANT: Do not turn OFF the power switch while “Please
Wait” is displayed on the panel. If it is turned
OFF, please repeat the initialization process
from the beginning
4
screen.

5
255
HELP Mode: 44
CCD ADJUST set value: 60.8

The value 60.8: The standard value for CCD read-out is fixed
at 60.8 to meet the design requirement. Do not alter the set
value.
256
HELP Mode: 45
I. Function
(1) REG. mark read out position adjustment
• REG. mark read-out position is adjusted. 45:PPS3 - CCD DIST.
S:XXX L:XXX 1
(1) REG. mark read out position adjustment 2
1 Prepare a sheet of paper used for the adjustment (adjustment paper).
2 Cut the adjustment paper applying the Serviceman JOB 87.
3 After cutting the adjustment paper, measure the lead margin and the
side margin on it. 3
4 Access H-45 and press the <START> key.
5 Move the * mark to “S” or “L” by the <SET> key. Change the “S”
value for adjusting the side margin, and change the “L” value for
adjusting the lead margin so that the value is set at 8mm to
correspond to the JOB setting. (Reduction of the indicated value by 4
1.0 will result in the expansion of the margin width by 1.0 mm.
approximately for both “S” and “L”.)
6 Cut the adjustment paper applying the Serviceman JOB 87 again.
7 The adjustment process is completed if the measurement from cut
end to REG. mark is 2mm ±0.2mm. Otherwise, repeat the
5
adjustment process from the step 4.
257
HELP Mode: 46
I. Function
(1) Cutting position adjustment
• The cutting position is adjusted. 46:PPS5-CUT DIST.
DISTANCE: XXX

(1) Cutting position adjustment
• Apply Serviceman JOB: 83 for checking the cutting position.
1 Set the skew adjusting dial at “0”.
3 Cutting position adjustment value appears on the display.
4 Change the cutting position adjustment value by pressing the <+>
key or the <-> key.
The cutting position moves by 0.1mm when the adjustment value is
changed by 1.
Press the <+> key to make the cutting length longer, and press the
<-> key to make it shorter.
IMPORTANT: Cutting position change will automatically result
in the creasing position change. Always readjust
the creasing position after the cutting position
change (HELP: 47).
TIP: Cutting position is reset to the default value by
continuously pressing the <MODE> key. (This is not a
factory setting.)
5 Press the <STOP> key, and it returns to the HELP Mode selection
screen after storing the adjustment information in the memory.

258
HELP Mode: 47
I. Function
(1) Creasing position adjustment
• The creasing position is adjusted. 47:CUT-CRE DIST.
DISTANCE: XXX 1
(1) Creasing position adjustment 2
• Apply Serviceman JOB: 83 for checking the creasing position.
3 Creasing position adjustment value appears on the display. 3
4 Change the creasing position adjustment value by pressing the <+>
key or the <-> key.
The creasing position moves by 0.1mm when the adjustment value
is changed by 1.
Press the <+> key to make the creasing length longer, and press the
4
<-> key to make it shorter.
TIP: Creasing position is reset to the default value by
factory setting.)
5

259
HELP Mode: 48
I. Function
(1) Creasing depth adjustment
• The creasing depth is adjusted. HIGH MID LOW
XXX XXX XXX

(1) Creasing depth adjustment
• Apply Serviceman JOB: 83 for checking the creasing depth.
2 Depth adjustment values for levels HIGH, MID, and LOW are
shown on the display.
3 Press the <SET> key to move the * mark to the position of desired
depth level.
4 Change the depth adjustment value (0 – 150) by pressing the <+>
key or the <-> key.
Press the <+> key for creasing deeper, and press the <-> key to
make it shallower.
IMPORTANT: The creasing depth is adjustable in 3-levels.
Thus the adjustment values shall be set to be
HIGH > MID > LOW.
Reference depth: Total thickness - max. 0.4 -
0.45 (at 230 gsm sheet).
TIP: Creasing depth is reset to the default value by
factory setting.) Also, by continuously pressing the <F>
key, MID level is set and -40 relative to the value for
HIGH level, and LOW depth is set at -60 relative to the
same.

260
HELP Mode: 49
I. Function
(1) Margin slitter and center slitter positions adjustment
• Positions of each margin slitter (S1, S2) and center slitter (S3 S5 S3 S1
– S6) are adjusted. S6 S4 S2 1
(1) Margin slitter and center slitter positions adjustment 2
• Apply Serviceman JOB: 84 for checking the slitter position.
3 Slitter position adjustment values appear on the display. 3
4 Press the <SET> key to move the * mark to the position of the
slitter to be adjusted.
5 Change the slitter position adjustment value (0 – 255) by pressing
the <+> key or the <-> key.
The slitter position moves by 0.1mm when the adjustment value is
4
changed by 1.
Press the <+> key to move it farther from the home position, and
press the <-> key to move it closer to the home position.
IMPORTANT: The home position for the slitters 1, 3, and 5 is
on the opposite side of the control panel, while
5
the home position for the slitters 2,4, and 6 is on
the control panel side. Further, gutter position
readjustment is required whenever the slitter
position is changed. (HELP: 50)
6

261
HELP Mode: 50
I. Function
(1) Gutter positions adjustment
• Positions of the gutter R and gutter L are adjusted. *RIGHT:110
LEFT:110

(1) Gutter positions adjustment
• Apply Serviceman JOB: 85 for checking the gutter position.
2 Position adjustment values for each gutter appear on the display.
3 Press the <SET> key to move the * mark to the position of the
gutter to be adjusted.
4 Change the gutter position adjustment value (0 – 255) by pressing
The gutter position moves by 0.1mm when the adjustment value is
changed by 1.
IMPORTANT: The home position for the gutter R is on the
opposite side of the control panel, while the
home position for the gutter L is on the control
panel side.

262
HELP Mode: 51
I. Function
(1) Position adjustment for the option (business card
module) 51:OPTION ADJ.
• Slitter position for the business card module are adjusted.
OPTION XXX 1
(1) Option (business card module) slitter position 2
adjustment
• Apply Serviceman JOB: 89 and 90 for checking the slitter
position.
2 Position adjustment value for the slitter appears on the display.
3 Change the slitter position adjustment value (0 – 255) by pressing
The slitter position moves by 0.1mm when the adjustment value is
changed by 1.
4
IMPORTANT: The home position for the business card module
is on the opposite side of the control panel.
5

263
HELP Mode: 52
I. Function
(1) Main motor transfer distance adjustment
• Transfer distance of the main motor is adjusted. 52:MAIN MOTOR ADJ.
XXX. XX

(1) Main motor transfer distance adjustment
• Apply Serviceman JOB: 82 or 91 for checking the transfer
distance.
2 Adjustment value for the transfer distance appears on the display.
3 Change the transfer distance adjustment value by pressing the <+>
key or the <-> key.
The transfer distance will get shorter as the adjustment value
becomes smaller.
The transfer distance will get longer as the adjustment value
becomes larger.

264
HELP Mode: 53
I. Function
(1) Provision or elimination of the gutter function
• Setting is made for providing or eliminating the gutter 53:GUTTER ON/OFF
function. *ON OFF 1
(1) Provision or elimination of the gutter function 2
2 Make the setting by moving the * mark with the <+> key or the <->
key.
ON: The gutter function is activated when the JOB has 5 –
15mm distance between the center slitters.
3
OFF: The gutter function is not used.

4
5
265
HELP Mode: 55
I. Function
(1) Setting the number of times for rejection
• Set the number of times the rejection will be made when an 55:REJECT
error takes place continuously. X

(1) Setting the number of times for rejection
2 Set the number of times for rejection using the <+> key or the <->
key.
TIP: When the number of times for rejection is set at “3”, the
machine will stop operation without rejecting the paper
when the fourth error took place in series.

266
HELP Mode: 56
I. Function
(1) Setting the paper feed rate from PPS2 to PPS3.
56: FEED TIMING
XXX 1
Check the 3-digit numeral shown at the lower right.
2 Set the numeral at “080” using the <+> key and the <-> key.
267
HELP Mode: 58
I. Function
(1) Display the skew adjust fan speed.
(2) Adjust the skew adjust fan speed. HIGH MID LOW
*100 050 035

(1) Display the skew adjust fan speed.
2 The each value of “HIGH”, “MID”, “LOW” will be shown on the
screen.
screen.
(2) Adjust the skew adjust fan speed.
2 When the each values of “HIGH”, “MID”, “LOW” are shown, press
the <SET> key to select the item you want to change.
3 Press the <+> or <-> key to adjust the value of each item.
screen.
268
HELP Mode: 59
I. Function
(1) Display the margin jam detecting sensor.
(2) Adjust the margin jam detecting sensor. 59:TRIM SENSOR
1
TRIM AREA SENSOR
*ON OFF 2
TRIM AREA SENSOR
0100mSec 3
(1) Display the margin jam detecting sensor.
4
2 The mark * will be shown in front of either “ON” or “OFF” on the
screen.
screen. 5
(2) Adjust the margin jam detecting sensor.
2 The mark * will be shown in front of either “ON” or “OFF” on the
screen. 6
3 Press the <+> or <-> key to move the mark *.
4 When the mark * is in front of “ON”, press the <SET> key. The
sensor detecting time will appear on the screen.
5 Press the <+> or <-> key to adjust the sensor detecting time. 7
screen.
269
HELP Mode: 60
I. Function
(1) Cancel Limit of the cutting direction.
(2) Cancel Limit of slitter position. 60:CANCEL LIMIT
*YES NO

(1) Display the Cancel Limit.
2 The status of Cancel Limit of the machine will appear on the screen.
screen.
(2) Change the Cancel Limit.
2 The status of Cancel Limit of the machine will appear on the screen.
3 Press the <+> or <-> key to select “YES (limit)” or “NO (cancel)”.
screen.
IMPORTANT: When Cancel Limit is deactivated and the cut
dimension is set to 4.0 mm or less, a paper jam
may occur because a paper piece gets
entangled in cutters.
IMPORTANT: The margin slitter can be set to 40mm or more
from a paper edge by deactivating Cancel Limit.
However, when the margin slitter 1 is set in
position more than 45 mm from a paper edge,
the paper will be undetectable by PPS4 since
the part of paper may fall as a margin.
Therefore, use the slitter 3 when setting the
slitter in position more than 45mm from a paper
edge.
270
HELP Mode: 61
I. Function
(1) Display the setting of the machine.
(2) Change the setting of the machine. 61:MEMORY SW
00000000 1
(1) Display the MEMORY SW. 2
2 The status of the setting of the machine will appear on the screen.
(2) Change the MEMORY SW.
3 The number at the left-side end is the first column, and at the right-
side end is the eighth column.
When changing the numerical value of the first column, push the
ten-key “1”, and push the ten-key “8” likewise when changing the
4
eighth column.
Types of MEMORY SW setting
First column: HELP62 INTERVAL setting “1” ON, “0” OFF
Unused after the Second column
5
screen.
271
HELP Mode: 62
I. Function
(1) Display the setting of the paper feed interval.
(2) Adjust the paper feed interval. 62:INTERVAL
0

(1) Display the INTERVAL setting.
(2) Change the INTERVAL setting.
2 A numeric value that shows paper feed intervals displays on the
right-side end of the screen.
3 Press the <+> or <-> key to change the numeric value. A higher
value sets more paper feed intervals.
REFERENCE: This setting is effective only when the left-side
end of the HELP61 MEMORY SW setting is “1”.
screen.
272
HELP Mode: 67
I. Function
(1) Display the JOG REVERSE setting.
(2) Change the JOG REVERSE setting. 67:JOG REVERSE
ENABLE *DISABLE 1
(1) Display the JOG REVERSE setting. 2
(2) Change the JOG REVERSE setting.
2 Press the <+> or <-> key to change the numeric value.
REFERENCE: When “DISABLE” is selected, and the paper is
fed more than 100 mm advanced from PPS3,
the JOG KEY can prevent a paper from going
back, and thus, the Lumiror film attached to a
4
margin slitter is protected.
screen.
5
273
HELP Mode: 68
I. Function
(1) Display details of the REG mark errors.
(2) Clear the REG mark error counter. 68:E4 COUNT

reg 1-1 ****
(1) Display details of the REG mark errors.
reg 1-2 ****
2 The number of errors in each condition is displayed on the screen.
3 Press the <+> or <-> key to change the display.
(2) Clear the REG mark error counter.
20mm
2 The number of errors in each condition is displayed on the screen.
3 If the <C> key is pressed for long, all error counts in each condition
will be cleared. Lead mark
screen.
20mm
Error conditions
reg1-1: When there is no margin on the right side of the REG
mark. Side mark
REG mark
e.g. When the REG mark starts from the right-side end.
20mm
20mm
274
reg1-2: When there is dust that is not a dot and recognized as a

line, during recognition of a lead mark, or a right angle
of the lead mark is not recognized.
e.g. When dust settled on the edge of a paper is recognized
as a start position of the lead mark.
e.g. When a right angle of the lead mark is not recognized.
20mm
dust settled 1
20mm
3
reg1-3: When the lead mark is recognized more than 17mm.
20mm
(The REG mark defines that the lead mark has to be at
least 3mm away from the end of a paper)
e.g. When the distance between the lead mark and the end of
a paper exists no more than 3mm, and the length of the
Lead mark 4
lead mark is more than 17mm.
20mm
5
18mm
275
reg1-4: When the lead mark exists within 20mm from the end of
a paper, and is not recognized more than 5mm long.
e.g. When the lead mark doesn’t reach a length of 5mm.
When the lead mark doesn’t reach a length of 5mm in
total due to uncertainty of the lead line.
20mm
4mm 10mm
4mm 20mm
reg1-5: When the lead mark is no more than 5mm long and
can’t be read within 20mm from the end of a paper.
(Out-of-bounds)
20mm
10mm
4mm
20mm
4mm
reg1-6: When the REG mark can’t be recognized

20mm
20mm
REG mark can’t be recognized
276
reg2: When the side mark isn’t parallel. (The inclination of

the side mark has to be within ± 1.3 degree to paper
feed direction.)
20mm
20mm 1
2
reg3: When the REG mark’s correction causes slitter’s
position to be out of specification.
REFERENCE: The same contents are including in reg1-2, 1-4, 3
1-5, and the count point changes depend on the
program stage where the error is detected.
REFERENCE: When a paper has uneven or gloss coated
surface, the REG mark may not be read
correctly and thus errors may be recognized. 4
277
HELP Mode: 69
I. Function
(1) Display the screen setting for the gutter less
business card unit. 69:BCM NO GUTTER
(2) Change the screen setting for the gutter less *ENABLE DISABLE
business card unit.

(1) Displaying the screen setting for the gutter less
business card unit.
(2) Changing the screen setting for the gutter less
business card unit.
3 Press <+> or <-> key to change the setting.
screen.
278
Chapter 8 Others 1
Position and Function of Electronic Parts ............................................... 280
1 Switches and Solenoids.................................................................................. 280
2 PPS sensors .................................................................................................... 281
2
3 Sensors ........................................................................................................... 282
4 Motors ............................................................................................................ 284
Overall Wiring Diagram .......................................................................... 286 3
Serviceman JOBs...................................................................................... 290
279
1 Position and Function of Electronic
Parts
1 Switches and Solenoids
1
2
10
3
5
8
7
9
1 Top Cover 1 Interlock Switch
4 Front Cover Lock Switch
5 Shutter solenoid
6 Paper Separator Eliminating Solenoid
7 Paper Separator Cancel Switch
8 Elevator Upper Limit Switch
9 Elevator Lower Limit Switch
10 Elevator Down Switch
280
Chapter 8 Others Position and Function of Electronic Parts
2 PPS sensors
2
1
3
8
6
5
4
1
7
1 PPS1 6
2 PPS2
3 PPS3
4 PPS4
7
5 PPS5
6 PPS6
8
PPS7
PPS8
8
281
3 Sensors
2
5 1
3
26
17
20
18
9 6
19 12 8
16
21
25 11
13 7
22 26
10
15
23 14
24
1 Paper Level Sensor
2 Ultrasonic Sensor
3 Rejection Home Position Sensor
4 Rejection Limit Sensor
5 CCD
6 Margin Slitter 1 Home Position Sensor
7 Margin Slitter 2 Home Position Sensor
8 Margin Slitter Module Fit-on Sensor
9 Center Slitter 3 Home Position Sensor
11 Center Slitter 3/4 Module Fit-on Sensor
14 Center Slitter 5/6 Module Fit-on Sensor
282
2
5 1
3
26
20
17
1
18
9 6
19 12 8
16
2
21
25 11
22
13
10
26
7
3
15
23 14
24
4
5
15 Encoder Sensor (for driving the slitter)
16 Gutter (L) Home Position Sensor

6
17 Gutter (R) Home Position Sensor
18 Cutter Home Position Sensor
19 Crease Lower Blade Home Position Sensor

7
20 Creaser Home Position Sensor
21 Creaser Lower Blade Encoder Sensor
22 Optional Section Detecting Sensor 1

8
25 Optional Module Home Position Sensor
26 Margin Jam Detecting Sensor
283
4 Motors
3
2
11
6
8
10
14
15
17
1
5
20
4
7
9
19 12
13
16
18
1 Feed Belt Driving Motor
2 Elevator Motor
3 Skew Adjust Belt Driving Motor
4 Reject Open/Close Motor
5 Reject Transport Motor
6 Margin Slitter 1 Position Motor
7 Margin Slitter 2 Position Motor
8 Center Slitter 3 Position Motor
12 Slitter Driving Motor
13 Gutter Diflector (L) Position Motor
284
3
2
11
6
8
14
10 1
15
17
1
20
5 3
4
7
9
19 12
18
16
13
4
14 Gutter Diflector (R) Position Motor 6

15 Cutter Motor
16 Creaser Motor
17 Creaser Lower Blade Motor

7
18 Option Position Motor
19 Main Motor 1
20 Main Motor 2
8
285
2 Overall Wiring Diagram
AC POWER
100-230V AC
CN1
SLITTER2 HP
1 RED 3
GND
100-230V AC
100-230V AC
CN6
1 RED 1 2 WHITE 2
CUTTER HP
2 YELLOW 2 3 BLUE 1
3 BLUE 3 4 RED 3
1 RED 4 5 YELLOW 2
SLITTER1 HP
2 GREEN 5 6 BLUE 1
3 BLUE 6 7 RED 3
CREASE HP
1 RED 7 8 PINK 2
SLITTER4 HP
2 GLAY 8 9 BLUE 1
CREASE LOW HP
3
2
1
3 BLUE 9 10 RED 3
10 11 ORANGE 2
GREEN
SLITTER3 HP
11 12 BLUE 1
12 13 RED 3
100-230V
100-230V
13 14 YELLOW GREEN 2
SLITTER6 HP
14 15 BLUE 1
15 16 RED 3
16 17 PURPLE 2
SLITTER5 HP
17 18 BLUE 1
WHITE
BLACK
18 19 RED 3
19 20 BLACK 2
SLITTER8 HP
20 21 RED 1
21 22 BLUE 3
CREASE LOW ENCODER
1 RED 22 23 GREEN 2
SLITTER7 HP
2 WHITE 23 24 RED 1
3 BLUE 24 25 BLUE 3
Option HP
25 26 SKY BLUE 2
Power Swich
26 27 RED 1
28
29
30
E
CN2
CN1
RED
1 1
CN2
YELLOW 1 WHITE
2 2
CN10
1 RED WHITE 2 WHITE

1 3 3
P9-V307*
PANEL PCB 1
MARGIN SLITTER UNIT CHECK
LCD UNIT
2 YELLOW ORANGE 3 WHITE
BLUE 2 4 PURAPLE 4
3 3 5 5 4 WHITE
YELLOW GREEN 5 WHITE
4 6 GREEN 6
5 7 7 6 WHITE
BLACK 7 WHITE
6 8 8
CENTRE SLITTER UNIT1 CHECK
1 RED SKY BLUE 8 WHITE

PINK 7 9 PINK 9
2 8 10 10 9 WHITE
3 BLUE GRAY 10WHITE
9 11 YELLOW 11
10 12 12 11WHITE
WHITE 12WHITE
11 13 13
GREEN
WHITE
BLACK
ORANGE 13WHITE
12 14 14
CENTRE SLITTER UNIT2 CHECK
1 RED PURPLE 14WHITE

PURPLE 13 15 YELLOW GREEN 15
2 14 16 16 15WHITE
3 BLUE GREEN 16WHITE
15 17 BLUE 17
16 18 18
17
RED 18
1
FG
N
L
19
OPTION UNIT CHECK1
2 YELLOW
BLUE 20
3 21
MAIN PCB P9-V301*
CN3
1 RED
22
OPTION UNIT CHECK2
2 WHITE
UA042
SWITTING POWER SUPPLY
BLUE 23
3 24
1 RED
25
OPTION UNIT CHECK3
2 PINK
26
CN4
3 BLUE
14
13
12
11
10
9
8
7
6
5
4
3
2
1
27 1
28 2
29 3
30 4
31 5
32 6
14
13
12
11
10
7
9
8
7
6
5
4
3
2
1
8
CN1
9
10
11
P9-V309*
PANEL PCB 2
CN13
1
ELEVATOR DOWN SW
2
3
4
M7-V3070
EEPROM PCB
5
6
V+
V+
V+
V+
V-
V-
V-
V-
7
CN9
CN1
8 RED
1 WHITE 1
9 2 2
10 YELLOW
3 3
GND
GND
GND
GND
24V
24V
24V
24V
11 WHITE
NC 4 BLUE 4
12 5 5
COM 13 6
BLUE
BLUE
BLUE
BLUE
BROWN
BROWN
BROWN
BROWN
NO ORANGE 14
BLUE
A
15
1 RED 16
REJECT LM
2 YELLOW GREEN 17
3 BLUE 18
1 RED 19
PPS2
2 WHITE 20
REJECT HP
3 BLUE 21
22
B
BLUE
BROWN
BLUE
BROWN
CN3
1 RED
2 BLUE
PPS1(PAPER SENSOR)
3 YELLOW
4 RED
RED
G
5 1
6 BLUE
WHITE 2
7 3
8 RED
5
4
3
2
1
CN1
5
4
3
2
1
CN3
4
P9-V305*
OSCILLATION PCB
9
4
3
2
1
CN1
N4-V302*
POWER PCB
P9-V305*
RECIEVE PCB
CN12
1 10
WHITE 11
1 2
2 3 12
BLUE 13 RED
4 1
CN2
14 BLUE
YELLOW 2
15 3
16 RED
17 BROWN
CN1
18 BLUE
19 WHITE
CN2
CN2
3
2
1
20 BLUE
6
5
4
3
2
1
3
2
1
PPS4(SLITTER)
WHITE
RED
1
YELLOW
RED
2
GND
GND
5V
5V
CA035
Double Feed Sensor(Oscillation)
3
CA035
Double Feed Sensor(Receive)
4
BLUE
BLUE
RED
RED
1
C
2
3
PPS7(STACKER)
CN12
1
2
3
4
5
D
CN5
N4-X103 *
1 BLACK
2 RED
CCD
3 BLUE
4 GREEN
5 GRAY
6 WHITE
7 BROWN
8 ORANGE
9 PURPLE
10 YELLOW
CN7
1
2
3
4
5
286
Chapter 8 Others Overall Wiring Diagram
MAIN PCB P9-V301*
ELEVATOR UPPER SWITCH
ELEVATOR LOWWER SWITCH

LEVEL SENSOR
CN18
1 RED 1
2 YELLOW 2
3 BLUE 3 NO
4 COM
2
5 ORANGE NC
6 ORANGE
7 NO
8 PURPLE COM
9 NC
10 PURPLE
11
12 RED
PPS3(CCD)
13 BLUE
14 WHITE
15 BLUE
16 BROWN
17 BLUE
18 PINK
19 BLUE
20 RED
21 BLUE
22 WHITE
PPS5(CUT)
23 BLUE
24 RED
25 BLUE
26 PINK
27 BLUE
3
P9-V315*
USB PCB
28
PPS8(REJECT)
CN3
CN21
ORANGE
1 1
CN1
ORANGE
1 2 GRAY 2
2 3 GRAY 3
3 4 4
4 5 5
6
7
8
PPS6(CREASE)
4
5
CN15
CN6
1 WHITE 1
6
CN4
CN19
1 BLACK 1 2 WHITE 2
2 BLACK 2 3 WHITE 3
3 BLACK 3 4 WHITE 4
4 BLACK 4 5 WHITE 5
5 WHITE 5 6 WHITE 6
6 WHITE 6 7 WHITE 7
7 WHITE 7 8 WHITE 8
8 WHITE 8 9 WHITE 9
9 WHITE 9 10 WHITE 10
P9-V313*
STEP DRV. PCB
P9-V311*
DC DRV. PCB
7
32 WHITE 32
33 WHITE 33
34 WHITE 34
35 WHITE 35
36 WHITE 36
37 WHITE 37
38 WHITE 38
39 WHITE 39
40 WHITE 40
41 WHITE 41
42 WHITE 42
43 WHITE 43
44 WHITE 44
45 WHITE 45
46 WHITE 46
47 WHITE 47
8
48 WHITE 48
49 WHITE 49
50 WHITE 50
287
SKEW ADJUSTMOTOR
N5-X111 1 E
COMPRE SSOR
SEPARATOR SOLENOID
P9-X1030( 100V)
REJECT DRV. MOTOR P9-X1040( 120V)
NO
NC
N4-X10 00 SOLENOID ON/OFF SW

L1-X108 0 4
3
4
3 P9-X1050( 230V)
REJECT MOTOR 2
1
2
1
M7-X102 0 250V 2A
NC NC NC
COM COM COM
NO NO NO
COVER SWITCH COVER SWITCH COVER SWITCH
(COVER) (COVER) (COVER)
1
3 U5
~
+
SSR PD014 COVER SWITCH
4
NO
NC
-
~
(DUST)
SHUTTER SOLENOID
STEP DRV. PCB
2
P6-X101 0 FEED BELT MOTOR

N5-X103 0-01
EXHAUST FAN MOTOR *2
N4-X10 50
INTAKE
FAN POWER R
ERAY
P9-V313*
VD025 CN5
MOTO R
N4-X10 50 CONVEYOR FAN MOTOR ENCODER(SLITTER DRV.)
ENCODER(OPTION DRV.)
10
11
1
2
3
4
5
6
7
8
9
N4-X10 50
BROWN 24V
BROWN
G
1
2
3
1
2
3
BLUE 24V
BLACK
BLACK
BLACK
YELLOW
PINK
RED
RED
RED
ORANGE
WHITE
BLUE
BLUE
BLUE
BROWN
YELLOW
RED
RED
SKY BLUE
SKY BLUE
PURPLE
PURPLE
BLUE
BLACK
YELLOW
ORANGE
RED
RED
RED
RED
WHITE
WHITE
GREEN
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
1
2
3
4
5
6
7
8
9
10
11
12
13
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9
10
24V
CN8
CN2 CN3 CN6 CN10 CN7
DC DRV. PCB P9-V311*
CN5 CN11 CN1 CN12
CN4
1
2
3
4
5
6
7
8
1
2
3
4
1
2
3
4
1
2
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
1
2
3
4
5
6
7
8
9
RED
BLUE
BLUE
BLACK
YELLOW
RED
RED
WHITE
BLACK
RED
BROWN
GND
GND
WHITE
5V
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
GND
24V
24V
BLUE
BLUE
BLUE
RED
BROWN
BROWN
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
CREASE LOW
1
2
3
4
5
6
7
8
9
MOTOR
M7-X1040 CN19
ELEVATOR MOTOR
P6-X100 0
MAIN PCB
SLITTER DRV.
OPTION DRV. A C
P9-V301*
MOTOR CUTTER MOTOR CREASE MOTOR
MOTOR
Q4-X10 10 Q4-X10 10 Q4-X101 0
Q4-X101 0
288
Chapter 8 Others Overall Wiring Diagram
P9-X10 10
SLITTER3 MOTOR
BZ008
MAIN STEP1 D RV .PWB
CN1
CN4
CN2
BROWN ORANGE
1 1 1
P9-X102 0
MAIN MOTOR1 (FRONT)
BLUE BROWN
2 RED 2 2 WHITE
BLUE 3 3 ORANGE
4 4
NC3
BLUE YELLOW BROWN
1
1 5 5
NC2
PINK SKY BLUE WHITE

2 1 6 6
P9-X10 10
SLITTER1 MOTOR
ORANGE BLACK SKY BLUE
GREEN 3 2 GRAY 7 7 BROWN
BLACK 4 3 ORANGE 8 8 GREEN
5 4 9 9 SKY BLUE
5 10 10 BROWN
6 11 GREEN
7 12
8
P9-X10 10
MOTOR
OPTION SLITTER
1
CN7
RED
1 BROWN
2
2
P9-V313*
STEP DRV. PWCB
PINK
3 RED
4 BROWN
5
P9-X102 0
MAIN MOTOR2 (REAR)
BZ008
MAIN STEP2 D RV .PWB
PINK
6
7
8
CN1
CN3
BROWN
1 BLUE 1 9
2 RED 2 10
BLUE 3 11
4 12
CN3
BLUE YELLOW
1 5
CN2
PINK SKY BLUE

ORANGE 2 1 BLACK 6
GREEN 3 2 GRAY 7
BLACK 4 3 ORANGE 8
5 4 9
P9-X10 10
SLITTER7 MOTOR
5
6
7
8
3
CN9
PINK
1 BROWN
2 GRAY
3 PINK
4 GRAY
5 YELLOW
6
P9-X101 0
SLITTER5 MOTOR
BLACK
7 BROWN
8 PURPLE
9 BLACK
10 BROWN
11 PURPLE
12
13
P9-X101 0
SLITTER8 MOTOR
4
D B
CN1
RED 5V
1
CN8
BROWN 24V RED

BLUE GND 2 1 BROWN
BLUE GND 3 2 YELLOW
4 3 RED
4 BROWN
5 YELLOW
6
P9-X10 10
SLITTER6 MOTOR
SKY BLUE
7 BROWN
8 GRENN
9 SKY BLUE
10 BROWN
11 GREEN
12
13
14
P9-X10 10
SLITTER4 MOTOR
5
CN10
BLUE
1 BROWN
2 WHITE
3 BLUE
4 BROWN
5 WHITE
6
P9-X101 0
SLITTER2 MOTOR
PURPLE
7 BROWN
8 ORANGE
9 PURPLE
10 BROWN
11 ORANGE
12
13
14
15
6
CN6
CN15
1 BLACK 1
2 BLACK 2
3 BLACK 3
4 BLACK 4
5 WHITE 5
6 WHITE 6
7 WHITE 7
8 WHITE 8
P9-V311*
DC DRV. PCB
9 WHITE 9
10 WHITE 10
P9-V301*
MAIN PCB
11 WHITE 11
12 WHITE 12
13 WHITE 13
WHITE
7
14 14
15 WHITE 15
16 WHITE 16
17 WHITE 17
18 WHITE 18
19 WHITE 19
20 WHITE 20
21 WHITE 21
22 WHITE 22
23 WHITE 23
24 WHITE 24
25 WHITE 25
26 WHITE 26
27 WHITE 27
28 WHITE 28
CN7
CN5
WHITE 29 WHITE 29
1 WHITE 1 WHITE
2 2 30 30
WHITE 31 WHITE 31
3 WHITE 3 WHITE
4 4 32 32
WHITE 33 WHITE 33
5 WHITE 5 WHITE
6 6 34 34
WHITE 35 WHITE 35
7 WHITE 7 WHITE
8 8 36 36
WHITE WHITE
8
9 9 37 37
WHITE 38 WHITE 38
10 10 WHITE
11 39 39
40 WHITE 40
41 WHITE 41
42 WHITE 42
43 WHITE 43
44 WHITE 44
45 WHITE 45
46 WHITE 46
47 WHITE 47
48 WHITE 48
49 WHITE 49
50 WHITE 50
289
3 Serviceman JOBs
Use to check the Use to adjust the H-46: Use to cut. H-49: Use to adjust H-50: Use to adjust
parallelity of the vertical enlarge- H-47: Use to adjust slit position. the position of the
right margin. ment (magnifica- the parallelity and gutter deflector
tion) of H-52. distance of the guide.
(using 650 exclu- crease.
sive paper) H-48: Use to adjust
the depth of the
crease.
JOB Name MARGIN CK H-52 CK1 CUT&CRE CK SLIT CK GUTTER CK
Paper Size 310 x 460 650 310 x 460 310 x 460 310 x 460
JOB No. 81 82 83 84 85
OPTION STANDARD STANDARD STANDARD STANDARD STANDARD
TOTAL LENGTH 460 650 460 460 460
PAPER WIDTH 310 366 310 310 310
Side Mark 0 0 0 0 0
Lead Mark 0 0 0 0 0
SLIT1 25 0 0 25 5
SLIT2 295 0 0 275 300
SLIT3 0 0 0 75 100
SLIT4 0 0 0 175 205
SLIT5 0 0 0 125 105
SLIT6 0 0 0 225 200
CUT01 0 25 25 0 0
CUT02 0 575 0 0 0
CUT03 0 0 0 0 0
CUT04 0 0 0 0 0
CUT05 0 0 0 0 0
CUT06 0 0 0 0 0
CUT07 0 0 0 0 0
CUT08 0 0 0 0 0
CUT09 0 0 0 0 0
CUT10 0 0 0 0 0
CUT11 0 0 0 0 0
CUT12 0 0 0 0 0
CUT13 0 0 0 0 0
CUT14 0 0 0 0 0
CUT15 0 0 0 0 0
CRE.01 0 0 125 0 0
CRE.02 0 0 0 0 0
CRE.03 0 0 0 0 0
CRE.04 0 0 0 0 0
CRE.05 0 0 0 0 0
CRE.06 0 0 0 0 0
CRE.07 0 0 0 0 0
CRE.08 0 0 0 0 0
CRE.09 0 0 0 0 0
CRE.10 0 0 0 0 0
OPTION1 0 0 0 0 0
OPTION2 0 0 0 0 0
AIR KNIFE OFF OFF OFF OFF OFF
FAN REG. ON ON ON ON ON
REG. MARK OFF OFF OFF OFF OFF
SLIT GUIDE ON ON ON ON ON
AUTO CUT ON ON ON ON ON
CREASE DEPTH MID MID HIGH MID MID
SPEED HIGH HIGH HIGH HIGH HIGH
290
Chapter 8 Others
Use to check Use to check the Use to check the H-51 Use to check Use to adjust Use to adjust
plain paper. REG. Mark func- REG. Mark func- Use to adjust business card the vertical the position of
Use to adjust tion (OK if the tion (OK if the the position of accuracy. enlargement the perforator
double-feed finish of JOB87 finish of JOB87 the business (magnification) unit.
sensor. and JOB88 are and JOB88 are card module. of H-52.
the same) the same) (using SRA3
exclusive paper)
FEED CK
310 x 460
REG. CK1
310 x 460
REG. CK2
310 x 460
BC MOD. CK
310 x 460
50 x 85
310 x 460
H-52 CK2
310 x 60
PERF MOD.
310 x 460
1
86 87 88 89 90 91 92
STANDARD STANDARD STANDARD BUSINESS CARD STANDARD STANDARD PERFORATOR
460 460 460 460 460 460 460
310
0
310
10
310
14
310
0
310
0
310
0
310
0 2
0 10 14 0 0 0 0
0 8 12 0 25 0 10
0 290 294 0 275 0 287
0 0 0 0 75 0 0
0
0
0
0
0
0
0
0
175
125
0
0
0
0
3
0 0 0 0 225 0 0
0 8 12 5 5 5 15
0 0 0 90 90 405 445
0
0
0
0
0
0
95
180
95
180
0
0
0
0
4
0 0 0 185 185 0 0
0 0 0 270 270 0 0
0 0 0 275 275 0 0
0 0 0 360 360 0 0
0 0 0 365 365 0 0 5
0 0 0 450 450 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
6
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 7
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
8
0
0
0
0
0
20
8
0 0 0 0 0 0 277
OFF OFF OFF OFF OFF OFF OFF
ON ON ON ON ON ON ON
OFF ON ON OFF OFF OFF OFF
MID MID MID MID MID MID MID
HIGH HIGH HIGH HIGH HIGH HIGH HIGH
291
This is used to Use to check per- Use to adjust the Use to adjust the Use to adjust the
check the barcode formance. position of the per- position of the ver- position of the ver-
reading and to forator unit. tical crease unit. tical crease unit.
reset the setting to
the factory preset
state. (Can only be
used in the Service
JOB Mode)
JOB Name BARCODE CK DEEP BLUE 6UP PERF MOD2. SCORE MOD. SCORE MOD2.
Paper Size 310 x 460 320 x 450 310 x 457 310 x 460 310 x 457
JOB No. 93 94 95 96 97
OPTION STANDARD STANDARD PERFORATOR ROTARY SCR ROTARY SCR
TOTAL LENGTH 460 450 457 460 457
PAPER WIDTH 310 320 310 310 310
Side Mark 0 10 0 0 0
Lead Mark 0 10 0 0 0
SLIT1 0 10 6.5 10 6.5
SLIT2 0 300 303.5 287 303.5
SLIT3 0 100 0 0 0
SLIT4 0 210 0 0 0
SLIT5 0 110 0 0 0
SLIT6 0 200 0 0 0
CUT01 0 22 7 15 7
CUT02 0 225 217 445 217
CUT03 0 235 227 0 227
CUT04 0 438 437 0 437
CUT05 0 0 0 0 0
CUT06 0 0 0 0 0
CUT07 0 0 0 0 0
CUT08 0 0 0 0 0
CUT09 0 0 0 0 0
CUT10 0 0 0 0 0
CUT11 0 0 0 0 0
CUT12 0 0 0 0 0
CUT13 0 0 0 0 0
CUT14 0 0 0 0 0
CUT15 0 0 0 0 0
CRE.01 0 147 0 0 0
CRE.02 0 360 0 0 0
CRE.03 0 0 0 0 0
CRE.04 0 0 0 0 0
CRE.05 0 0 0 0 0
CRE.06 0 0 0 0 0
CRE.07 0 0 0 0 0
CRE.08 0 0 0 0 0
CRE.09 0 0 0 0 0
CRE.10 0 0 0 0 0
OPTION1 0 0 16.5 20 16.5
OPTION2 0 0 293.5 277 293.5
AIR KNIFE OFF OFF OFF OFF OFF
FAN REG. ON ON ON ON ON
REG. MARK OFF OFF OFF OFF OFF
SLIT GUIDE ON OFF ON ON ON
AUTO CUT ON ON ON ON ON
CREASE DEPTH MID MID MID MID MID
SPEED HIGH HIGH HIGH HIGH HIGH
292
Duplo DC-645 (Slitter / Cutter / Creaser)
DC-645 SERVICE MANUAL

SERVICE MANUAL Version. 1.0 / March 2005
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.
P9-Y1100

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DC-645 Creaser, Cutter, Slitter Service Manual

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Duplo DC-645 (Slitter / Cutter / Creaser)

SERVICE MANUAL Ver. 1.0 / December 2006

Be sure to read this manual carefully, so that you

Indicates a medium degree of potential danger. If the caution is

[Examples of Pictorial Symbols]

A circle with a line through it indicates a prohibited action.

A black disc indicates an instruction, or sometimes a prohib-

● For maintenance operation

Power supply voltage Connect to outlet of 120V AC,60Hz,at least 15A

3. Cautions for maintenance, inspection and servicing

1 WARNING Cutters and movable parts are inside this cover.

Hands could get caught up

No. Parts No. Name Q’ty

1 L8-T1080 Warning Sticker 1 2

2 M7-T3030 Warning Sticker 1 2

Introduction ........................................................... 1 Margin jam detecting section ............................ 164

Max 80 job program memory

2 Waste box Receives pieces of waste paper.

3 Front cover Open to remove pieces of paper in the waste box.

4 Stacker tray Receives the finished document.

11 AC inlet Connect the power cord.

No. Name Function

5 Cutter Module Cuts in a right angle in the paper feed direction.

6 Creaser Module Creases parallely in the paper feed direction.

4 <F> key Switches to function selecting display. 8

7 POWER lamp Lights up when the power is switched on.

2 JOB name Displays name of the JOB currently selected.

3 BARCODE BC is displayed when barcode reading is ON.

4 REGISTER MARK REG is displayed when REG. Mark reading is ON.

5 AUTO CUT AC is displayed when AUTO CUT is ON.

335 mm 470 mm 390 mm 5

1 Paper Feed Section

3 Operation of Each Part

Main P.C.B Unit

RED RED RED CN18-1 5V

YELLOW YELLOW YELLOW 2

BLUE BLUE BLUE 3

Light not transmitted: 5V

II. Elevator Upper Limit Switch

Main P.C.B Unit

III. Elevator Lower Limit Switch

Main P.C.B Unit 3

Main P.C.B Unit

VI. Paper Separator Eliminating Solenoid

GREEN RED CN3-8 5V

VIII. Paper Separator Cancel Switch

feed start feed end next paper feed start

3 Operation of Each Part

Main P.C.B Unit

3 Operation of Each Part

3 Operation of Each Part

Main P.C.B Unit

II. Rejection Limit Sensor

Light not transmitted: 5V

Main P.C.B Unit

BROWN RED CN18-12

Main P.C.B Unit

BROWN RED CN18-20