SLITTER / CUTTER / CREASER

DC-616

Apr. 2014 Revision 0

DUPLO DC-616 S2-Y1540
 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 person 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.

Trademarks
• Microsoft, Windows, Windows NT, and Windows Vista are either registered trademarks or
trademarks of Microsoft Corporation in the United States and/or other countries.
All other company names and product names shown in this manual are trademarks or
registered trademarks of their respective companies.

PLEASE NOTE
In the interests of upgrading our product, specifications and other data given in this manual are
subject to change without notice.
If the manual contains anything that you do not understand, contact the dealer for clarification.

S2-Y1540 -0 1
■ How to Use This Service Manual
• This service manual includes the structural and functional descriptions for the major areas
of DC-616, 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 April, 2014. 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 instruction of particular
importance for safety reasons. Never fail to comply with them.

●Safety instructions
WARNING Indicates a high degree of potential danger. Failure to heed the warning
may lead to death or serious injury.

CAUTION Indicates a medium degree of potential danger. Failure to heed the

caution may lead to injury or damage to property.

[Examples of Pictorial Symbols]

Δ 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 disassembly.)

● A black disc indicates an instruction, or sometimes a prohibited action.

The instruction itself is indicated by pictorial symbols drawn in white on
the disc. (In the example shown here, the instruction is “Remove the
plug from the outlet”.)

●For maintenance operation

IMPORTANT : Introduces instructions for correct operation of the machine.

If these instructions are ignored, the machine may not be able to
operate at optimum performance or may break down.

Introduces information that is useful for operation and maintenance of

REFERENCE the machine, or information about the machine’s performance, etc.

2 S2-Y1540-0
 Safety Instructions
1. Cautions regarding the installation location

CAUTION
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°C–30°C
Ambient humidity : 40%–70%
Optimum temperature and humidity : 20°C, 65%
• If the machine is installed near to faucets, water heaters or humidifiers, or in cool (sunless)
parts of a building or in the vicinity of water sources, the paper could absorb moisture and curl,
leading to misfeeds.
● 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 5 mm in the front-rear
direction, and 5 mm 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.

S2-Y1540 -0 3
2. Cautions for installation work

WARNING

● The machine’s power supply voltage and power consumption are given in the table
below. The machine's power supply voltage is indicated on the identification plate on
machine; 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 whole, including optional equipment.

Power supply 115 VAC ±10%, 60Hz 230 VAC ±10%, 50/60 Hz
Power consumption 1.5 A,190 W 0.7 A,190 W
Standby energy 0.25 A, 26 W 0.22 A,26 W
● Use only the power cord that is provided with the accessories. Insert the power cord
plug firmly into the socket, so that proper electrical contact is made. Use of any other
power cord could result in imperfect grounding. If grounding is imperfect and
electrical leakage occurs, fire or electric shock could result.
● 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 120 VAC model: 130 V, at least 15 A, length not exceeding 5 m
• For a 230 VAC model: 250 V, at least 8 A, length not exceeding 5 m
● Never tread on the power cord or pinch it between other objects, or accidents could
result.

CAUTION
● Install the machine in accordance with the Installation Manual supplied.
● Lock the casters after the machine is installed.
→ Otherwise, the machine could move or fall over, causing injury.

4 S2-Y1540-0
3. Cautions for maintenance, inspection and servicing

WARNING
● Always remove the power cord plug from the outlet before starting work.
→ Otherwise, your hands/fingers could get damaged beside electrical shock.
• 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, slitter unit, and perforation unit contain sharp tools (blades) which may
cause danger. Exercise great care when inspecting these units or replacing them or
their parts.
→ Otherwise, your hands/fingers could get caught and injured.
● Do not put your hands or fingers inside the machine while it is operating and while
you are pressing the JOG key.
→ Otherwise, your hands/fingers could get caught and injured.
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 that enables you to work safely.
Work clothing should be close-fitting.

CAUTION
● Tools
• Use tools that are appropriate for the work.

S2-Y1540 -0 5
■ Warning Labels

No. Part No. Name Q'ty

L1-T108*
1 WARNING LABEL 2
L1-T111* (EU)
2 S2-T105* WARNING LABEL 6
M7-T303*
3 WARNING LABEL 2
M7-T307* (EU)
4 S2-T115* WARNING LABEL 2

6 S2-Y1540-0
5

No. Part No. Name Q'ty

5 R7-T115* WARNING LABEL 1

S2-Y1540 -0 7
 No. Part No. Name Q'ty
L8-T109*
6 WARNING LABEL 1
L8-T112* (EU)

8 S2-Y1540-0
Introduction
1

Operation in General
2

Mechanism
3

Adjustment
4

Maintenance Checks
5

Troubleshooting
6

HELP Mode
7

Others
8

PC Controller
9

10
Contents

Contents

Introduction .......................................... 1 Chapter 5 Maintenance Checks

■ How to Use This Service Manual ............. 2
Safety Instructions .............................. 3 1 Guaranteeing Maintenance Cycle .......... 110
■ Warning Labels .................................. 6 2 Cleaning and Oiling ........................... 110
3 Periodic Maintenance Check List ........... 111
Chapter 1 Introduction 4 Recommended Parts List .................... 112

1 Specifications .................................... 12 Chapter 6 Troubleshooting

2 Part Names and Their Functions............. 14
3 Dimensions ...................................... 20 1 Troubleshooting ................................ 116
2 Conditions for the Error Detection ......... 122
Chapter 2 Operation in General 3 Major Cause and Preventive Action for the Paper Jam . 124
4 Slitter Blade Intersection Correction ....... 125
1 Paper Feed Section ............................ 22
2 Double Feed Detection Section (Option) ... 26 Chapter 7 HELP Mode
3 CCD Section ..................................... 27
4 Margin Slitter Section .......................... 28 1 HELP Mode List ............................... 128
5 Center Slitter Section .......................... 30 2 Accessing the HELP Mode .................. 129
6 Cutter Section ................................... 33 3 Finishing the HELP Mode ................... 129
7 Creaser Section ................................. 35 4 Setting the Other HELP Mode No. ......... 129
8 Main Drive Section ............................. 39 5 Accessing the Service Person JOB ....... 129
9 Exit Tray .......................................... 40 6 HELP Mode Description ..................... 130
10 Exterior .......................................... 41
11 Barcode .......................................... 43 Chapter 8 Others
12 REG Mark ....................................... 46
1 Position and Function of Electronic Parts .. 168
Chapter 3 Mechanism 2 Service Person JOBs ........................ 178
3 Overall Wiring Layout ........................ 182
1 Exterior of the Machine ........................ 51
2 Paper Feed Section ............................ 56 Chapter 9 PC Controller
3 Double Feed Detection Section (Option) ... 67
4 CCD Section (Option) .......................... 68 1 Main Menu of PC Controller ................ 186
5 Margin Slitter Section .......................... 70 2 Maintenance Menu ........................... 188
6 Center Slitter Section .......................... 76 3 Data Folder .................................... 191
7 Cutter Section ................................... 83 4 Maintenance ................................... 192
8 Creaser Section ................................. 85 5 Confirming the Version....................... 202
9 Main Drive Section ............................. 90
10 Electrical System Section .................... 96

Chapter 4 Adjustment
1 Exterior of the Machine ...................... 100
2 Paper Feed Section .......................... 101
3 CCD Section ................................... 102
4 Margin Slitter Section ........................ 103
5 Center Slitter Section ........................ 104
6 Cutter Section ................................. 105
7 Creaser Section ............................... 106
8 Main Drive Section ........................... 108

10 W5-Y1030 -0
 1

Chapter 1 Introduction
1 Specifications .................................. 12
2 Part Names and Their Functions ........... 14
1. Appearance ................................. 14
2. Ejection Side................................ 15
3. Appearance (Ejection side) .............. 16
4. Inside ........................................ 17
5. Control Panel ............................... 18
6. LCD Panel .................................. 19
3 Dimensions ..................................... 20
Chapter 1 1 Specifications

1 Specifications
Model name DC-616
Product type Slitter/Cutter/Creaser Floor stand model
Feeding method Belt suction
Infeed document size Width: 210–320 mm
Length: 210–670 mm*
* The standard feed tray takes up to 460 mm. For longer sheet, the
optional long paper tray is available.
Minimum finishing size Width: 48 mm (1.89 in)
Length: 50 mm (1.97 in)*
The distance between the lead edge of the last card and the trail edge
of the parent sheet should be 67 mm or more.
Document type Uncoated, coated, laminated*
* Laminated document is not included in the specifications of the
perforation unit.)
Document weight 110 gsm–350 gsm

Paper curl Within 5 mm

Feeder capacity 100 mm
Speed 10 ppm (A4 SEF, 2 cuts, 1 crease)
Number of slits Max 6 slits per document (2 margin slitters and 4 center slitters)
Margin slit spec 3.2–55.0 mm from document side edges
Gutter slit width 5.0–15.0 mm
Gutter slits wider than above are exited onto the exit tray.
Gutter deflector Max 2 gutter slits can be deflected.
Number of cuts Max 25 per document
Cut position spec Lead edge: min. 3.0 mm
Gutter cut: min. 3.0 mm
Trail edge: min. 5.0 mm
Number of creases Max 20 per document
Crease depth adjustment 3 steps (from control panel)
Tolerance +/-0.3 mm from programmed positions
(+/-0.4 mm with business cards)
When creasing, it may fluctuate depending on the number of creases
and their depths.
Stacker capacity 100 mm (with card stacker: 40 mm)
Control panel 64×128 dots LCD
LCD languages Japanese, English, French, German, Italian, Spanish, Polish, Russian
Software update DDL-01, DDL-02
Perforation unit Operator replaceable unit
Max 2 perforations parallel to the feeding direction
Manual positioning
Perforation position Minimum distance from the card side edge: 5 mm
Minimum distance between 2 perforations: 48 mm
Perforation tool spec Cut: 0.84 mm Tie: 0.84 mm

12 S2-Y1540-0
 Chapter 1 1 Specifications

Model name DC-616

Functions 80 job memory
Test feed
Skew adjustment
Slitter guide
1
Auto cut
Apply shrinkage
Adjust all
Cleaning mode
Automatic job setup by reading barcode (CCD is optional on “115V”
and “230V Asia Oceania” models.)
Image shift compensation by reading REG mark (CCD is optional on
“115V” and “230V Asia Oceania” models.)
Options Air knife (optional on “230V Asia Oceania” model)
Double feed detection (optional on “115V” and “230V Asia Oceania”
models)
CCD (standard on “115V PRO” and “230V EMEA” models)
Card stacker (optional on “230V Asia Oceania” model)
Perforation unit (optional on “115V” and “230V Asia Oceania” models)
Long paper tray
PC am mount (standard on “115V PRO” model)
PC controller software (standard on “115V PRO” model)
USB (B TYPE CONNECTOR)
Compatible OS:
Windows XP Professional/Home edition (x86 32bit only)
Windows Vista Ultimate/Business/Home basic/Home premium
Windows 7 Ultimate/Professional/Home premium
Windows 8 Professional/Enterprise
Power supply 115 VAC, 60 Hz 230 VAC, 50/60 Hz
Power consumption 115 V: current consumption 1.5 A (standby: 0.25 A)
power consumption 190 W (standby: 26 W)
230 V: current consumption 0.7 A (standby: 0.22 A)
power consumption 190 W (standby: 26 W)
Dimensions In use: 1610 (W) × 625 (D) × 1060 (H) mm
In use with max paper: 2025 (W) × 625 (D) × 1060 (H) mm
Stored: 975 (W) × 625 (D) × 1060 (H) mm
Packed: 1140 (W) × 770 (D) × 1360 (H) mm
Machine weight 115 V: 145 kg (Gross weight: 178 kg)
115 V PRO: 155 kg (Gross weight: 188 kg)
230 V EMEA: 150 kg (Gross weight: 183 kg)
230 V Asia Oceania: 140 kg (Gross weight: 173 kg)
Operating temperature 10–30 degrees (Celsius) (50-80 degrees (F))
Operating humidity 40%–70% RH (No condensation)
Storing temperature 5–35 degrees (Celsius)
Storing humidity 20%–70% RH (No condensation, No exposure to salt)
Operating altitude Max 1000 m ALT
Safety standard UL, CE, VCCI

The specifications are subject to change without prior notice.

Paper Curl
Due to the automated slitter function, the paper path of the DC-616 is sensitive to paper curl.
If paper curl is causing paper jams, the following are suggestions for remedying the problem:
1. Adjust the printing devices de-curler (if available).
2. Manually de-curl the stock before loading in the fe tray.
3. Turn the paper over (reprogramming the job may be necessary).
4. Use different paper stock.

S2-Y1540 -0 13
Chapter 1 2 Part Names and Their Functions

2 Part Names and Their Functions

1. Appearance

1
7
6

No. Name Function

1 Control panel Displays operations and status.
2 Exit tray Receives the finished products.
3 Waste box Receives pieces of waste paper.
4 Front cover Open this to remove the waste box.
5 Feed tray Original document is placed here.
6 Scale Measures the cut and slit position, and the finished product.
7 Top cover Open this to remove paper jam from inside of the machine.

14 S2-Y1540-0
 Chapter 1 2 Part Names and Their Functions

2. Appearance (Feed Side)

1
4

No. Name Function

1 Airflow adjustment knob Adjusts airflow level.
2 Separator adjustment Adjusts the distance between the separator and conveyance belt.
knob
3 Skew adjustment knob Adjusts the document skew.
4 Level adjustment knob Adjusts the elevator height.

S2-Y1540 -0 15
Chapter 1 2 Part Names and Their Functions

3. Appearance (Ejection side)

2
1

6
4

No. Name Function

1 Perforation unit Perforates parallel to the document feed direction.
2 Side guide Receives the processed documents.
3 Back guide Receives the processed documents.
4 USB terminal Used for the connection to your computer on PC Controller using.
5 AC inlet Connect the power cord here.
6 Power switch Press to switch the power on and off.

16 S2-Y1540-0
 Chapter 1 2 Part Names and Their Functions

4. Inside

8 7 6 5 4 2 1
1
3

5 4 3

No. Name Function

1 Double feed detection Detects double feed by the ultrasonic sensor. (Option)
section
2 CCD section Reads out REG Mark/Barcode. (Option)
3 Slitter module 1,2 Cuts side margins parallel to the document feed direction.
4 Slitter module 3,4
Cuts parallel to the document feed direction.
5 Slitter module 5,6
6 Gutter deflector Drops the margin cut off by the slitters into the waste box.
7 Cutter module Cuts perpendicularly to the document feed direction.
8 Creaser module Creases perpendicularly to the document feed direction.

S2-Y1540 -0 17
Chapter 1 2 Part Names and Their Functions

5. Control Panel
1 4 7 8

2 3 5 6 9 10

No. Name Function

1 LCD panel Displays the status of the machine.
Displays the message when an error or paper jam occurs.
2 F key Switches to function selecting screen.
3 RETURN key Switches to the previous screen.
4 CURSOR (Left/ Press to move the cursor to the left or right.
Right) key
5 CURSOR (Up/ Press to the cursor in a lower or an upper direction.
Down) key
6 SET key Press to set selection/entry.
7 JOG (Forward/ Press to eject the document from the machine when paper jam
Backward) key occurred.
One (sheet) document is processed to test to the current JOB
details. When the card stacker is installed, if you press and hold the
8 TEST key TEST key for guide adjustment, the processed document temporarily
stops. Then, when you press the START key or the TEST key, the
processed document is ejected.
Press to start processing documents. The START key light turns
9 START key green when when the machine is ready to process the document in
this machine. The machine is inactive when the light is red. In this
case, the machine may be running or having an error.
10 STOP key Press to return the current screen to the main screen or to stop
processing

1
1

3 2

No. Name Function

1 NUMERIC key Press to enter JOB/values during manual programming.
2 SET key Press to set selection/entry.
3 CLEAR key Press to clear the count. Press to cancel manual programming.

18 S2-Y1540-0
 Chapter 1 2 Part Names and Their Functions

6. LCD Panel

● Standby screen
1
2

3
4

No. Name Function

1 JOB No. Displays the JOB number currently selected.
2 JOB Name Displays the JOB name currently selected.
Displays the number of document sheets processed with the JOB
3 Counter
currently set.
Function setting
AC: Auto cut AC is displayed when “Auto cut” is enabled.
REG: REG mark REG is displayed when “REG mark reading” is enabled.
BC: BARCODE BC is displayed when “Barcode reading” is enabled.
4
% % is displayed when “Apply shrinkage” is enabled.
is displayed when “Adjust all” is enabled.

is displayed when the PC Controller is online.

● “Select menu” screen

Select menu Select menu

1 Retrieve JOB 3 Setting
2 Enter JOB 4 Cleaning mode
3 Setting 5 Return

No. Name Function

1 Retrieve JOB Retrieves saved JOB.
2 Enter JOB Enters and changes JOB.
3 Setting Changes functions of the machine.
4 Cleaning mode Retrieves Cleaning mode to clean conveyance belt / conveyance
roller.
5 Return Returns to standby screen.

S2-Y1540 -0 19
Chapter 1 3 Dimensions

3 Dimensions
Unit: mm













         


20 S2-Y1540-0
Chapter 2 Operation in General 2
1 Paper Feed Section ........................... 22
1. Description .................................. 22
2. Operation.................................... 22
3. Operation of Each Part ................... 22
2 Double Feed Detection Section (Option).. 26
1. Description .................................. 26
2. Operation.................................... 26
3. Operation of Each Part ................... 26
3 CCD Section ................................... 27
1. Description .................................. 27
2. Operation.................................... 27
3. Operation of Each Part ................... 27
4 Margin Slitter Section ......................... 28
1. Description .................................. 28
2. Operation.................................... 28
3. Slitter Blade ................................. 28
4. Operation of Each Part ................... 28
5 Center Slitter Section ......................... 30
1. Description .................................. 30
2. Operation.................................... 30
3. Slitter Blade ................................. 30
4. Operation of Each Part ................... 30
6 Cutter Section .................................. 33
1. Description .................................. 33
2. Operation.................................... 33
3. Operation of Each Part ................... 33
7 Creaser Section ............................... 35
1. Description .................................. 35
2. Operation.................................... 35
3. Operation of Each Part ................... 36
8 Main Drive Section ............................ 39
1. Description .................................. 39
9 Exit Tray ......................................... 40
1. Description .................................. 40
10 Exterior ......................................... 41
1. Description .................................. 41
2. Operation.................................... 41
3. Operation of Each Part ................... 41
11 Barcode ........................................ 43
1. Description .................................. 43
12 REG Mark ..................................... 46
1. Description .................................. 46
Chapter 2 1 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 mechanism.

2. Operation
Air blow duct mechanism blows the compressed
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 mechanism are
turned ON.

3. Operation of Each Part

1. Level Sensor
<Operation>
• Detect the top of the paper on the feed tray
When the feed tray rises to the extent that the
actuator 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 tray is stopped.
• Detect the low level of paper
The actuator 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 tray rises until the sensor comes
to the “light blocked” state. “E02” (elevator error)
appears on the display if the topmost paper sensor
does not switch to the “light blocked” state within 10
seconds after the transmission of feed tray go-up
command.

22 S2-Y1540-0
 Chapter 2 1 Paper Feed Section

<Circuit diagram>

Main PCB unit

Level sensor
5V
Red Red CN2-10 5V
1 6
Yellow Yellow 11
2 7

3
Blue
8
Blue 12
2
Light not transmitted: 5V
Light transmitted: 0V

2. Elevator Upper Limit Switch

<Operation>
If the topmost sheet of paper cannot be detected, and
the feed tray continues to go up, the air suction unit
is pulled away from the elevator upper limit switch to
come to the “OFF” state.
The elevator upper limit switch stops the machine
operation immediately once it comes to the “OFF”
state.

3. Elevator Motor
<Operation>
Elevator motor rotation lets the feed tray move up and
down.

<Circuit diagram>

Elevator upper limit switch

Brown
2

Drive PCB unit

Brown 1
Elevator motor
Brown Brown
1
Brown CN5-2

M
Black Black 1
2

S2-Y1540 -0 23
Chapter 2 1 Paper Feed Section

4. Elevator Lower Switch

<Operation>
As the feed tray goes up, the angle is pulled away
from the elevator lower limit switch to come to the
“OFF” state. As the feed tray goes down to reach the
lower limit, the angle pushes the switch actuator to
trigger the “ON” state. “E02” (elevator error) appears
on the display if the angle does not push the elevator
lower limit switch actuator within 30 seconds after the
transmission of the feed tray go-down command.

<Circuit diagram>

Elevator lower switch Main PCB unit

5V

Purple Purple CN3-19

1 4
Purple Purple 20
2 5
ON : 0V
OFF : 5V

5. Perforation unit Sensor

<Operation>
Normally the feed tray goes up and down
automatically. However, it may be lowered by the
elevator down switch as required, including the case
of paper jam.

<Circuit diagram>

Elevator down switch Main PCB unit

5V

Light green Light green CN2-25


Light green Light green 26

ON : 0V
OFF : 5V

24 S2-Y1540-0
 Chapter 2 1 Paper Feed Section

6. Shutter Solenoid
<Operation>
The suction 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.

2
<Circuit diagram>

Shutter solenoid Drive PCB unit

24V
Red Red
CN2-7
1
Yellow Yellow
8
2

7. PPS1
<Operation>
While the light goes through at PPS1, LED on the
control panel lights up in red. “NO PAPER” appears
on the display as the start key is pressed. While the
light is blocked at the PPS1, the start key lights up in
green.
* Wipe off the dirt or contamination, if any, on the
PPS sensor with a rag.

<Circuit diagram>

Main PCB unit

Paper sensor
Red Red
5V
CN4-1
1 1
Emitting
Orange Orange 2
3 2

5V
Red Red 3 5V
1 1
Receiving Gray Gray 4
2 2
Blue Blue 5
3 3
Light not transmitted: 5V
Light transmitted: 0V

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Chapter 2 2 Double-Feed Detection Section (Option)

2 Double Feed Detection Section (Option)

1. Description
The double feed detection sensor is provided at the
ejection side of feed belt.
An ultrasonic sensor is used, and no adjustment for
fitting it to the particular type of paper, and no input of
the paper thickness are required.

2. Operation
Whenever the ultrasonic sensor detects double feed,
the machine stops the operation.

3. Operation of Each Part

1. Double Feed Sensor
<Operation> Receiving

Whenever the ultrasonic sensor detects double feed,

the machine stops the operation. The double feed is
detected not by the paper thickness, but by the number
of sheets.

Transmitting

<Circuit diagram>

Main PCB unit

CN9-2 4

White Blue

Double feed sensor 1 2

24V Power supply unit

Red 1 2 Brown V+
Receiving 2 4 Blue V-
White
Receive PCB

Red 1 2
Transmitting Yellow 2 4
Transmit PCB

26 S2-Y1540-0
 Chapter 2 3 CCD Section

3 CCD Section
1. Description
This section reads the barcode and REG mark by
CCD.

2. Operation
On the JOB using REG mark or barcode, PPS2 works
to assure the correct CCD reading by temporarily
stopping the paper run at the place of PPS2 and slows
it. The paper conveyance speed will be accelerated
after the CCD reading.

3. Operation of Each Part

1. PPS2
<Operation>
• PPS detects the presence or non-presence of paper
by the “light-through” or the “light-bloced” state of the
PPS photo-receiving sensor by means of receiving
from the PPS photo-emitting sensor.
• In the operation without REG mark or barcode,
PPS2 detects the timing of passing paper.
<Circuit diagram>

PPS2
Main PCB unit
5V
Red Red CN4-6
1 1
Emitting
Orange Orange 7
3 2

Red Red
5V
8 5V
1 1
Gray Gray 9
Receiving 2 2
Blue Blue 10
3 3 Light not transmitted: 5V
Light transmitted: 0V

S2-Y1540 -0 27
Chapter 2 4 Margin Slitter Section

4 Margin Slitter Section

1. Description
The margin slitter is provided (slitter 1, 2) on both
sides to cut the paper along the traveling direction
by means of the rotary blades. 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.

4. Operation of Each Part

1. Margin Slitter Home Position Sensor
<Operation>
Margin slitter HP sensor detects the home position
of the margin slitter by the photo-micro sensor, and
controls the margin slitter position based on the
amount of pulse from the home position.

28 S2-Y1540-0
 Chapter 2 4 Margin Slitter Section

<Circuit diagram>

Slitter HP1 sensor

Main PCB unit

Blue CN2-3 5V
1 2

2
White
3
2 2
Red 1 5V
3 1

Slitter HP2 sensor

Blue CN3-3 5V
1 2
Pink 2
2 3
Red 1 5V
3 1 Light not transmitted: 5V
Light transmitted: 0V

2. Margin Jam Sensor

<Operation>
The system stops the machine when a sensor cannot
detect light for more than fixed period of time during
machine runs.

<Circuit diagram>

Margin jam sensor

Main PCB unit
Black CN4-27
1 4 5V
White 26
2 3
Receiving
Orange 25
3 2
5V
Red 24
4 1

Black 23
1 2
Emitting Orange Light not transmitted: 5V
3 1 22 Light transmitted: 0V

S2-Y1540 -0 29
Chapter 2 5 Center Slitter Section

5 Center Slitter Section

1. Description
Two pairs of center slitters (slitter 3–6) are provided to
cut the paper in the traveling direction by mean of the
rotary blades arranged vertically side by side.

2. Operation
The lead screw is turned by means of the stepping
motor to cause the center slitters 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.

4. Operation of Each Part

1. Center Slitter Home Position Sensor
<Operation>
Center slitter HP sensor detects the home position
of the center slitter by the photo-micro sensor, and
controls the center slitter position based on the
amount of pulse from the home position.

30 S2-Y1540-0
 Chapter 2 5 Center Slitter Section

<Circuit diagram>

Main PCB unit

Slitter HP3 sensor 5V

Purple CN2-5
1
Blue 6
2
2
Red 4 5V
3 Light not transmitted: 5V
Light transmitted: 0V
Slitter HP4 sensor 5V

Gray CN3-5
1
Blue 6
2
Red 4 5V
3 Light not transmitted: 5V
Light transmitted: 0V
5V
Slitter HP5 sensor
Yellow CN2-8
1
Blue 9
2
Red 7 5V
3 Light not transmitted: 5V
Light transmitted: 0V

5V
Slitter HP6 sensor
Yellow CN3-8
1
Blue 9
2
Red 7 5V
3 Light not transmitted: 5V
Light transmitted: 0V

S2-Y1540 -0 31
Chapter 2 5 Center Slitter Section

2. PPS3
<Operation>
• PPS detects the presence or non-presence of paper
by the “light-through” or the “light-bloced” state of the
PPS photo-receiving sensor by means of receiving
from the PPS photo-emitting sensor.
• PPS3 detects the passing paper and paper jam in
the slitter area.

<Circuit diagram>

PPS3
Main PCB unit

Red Red CN4-11 5V

1 1
Receiving Orange Orange
3 2 12

Red Red 13 5V 5V
1 1
Gray Gray 14
Emitting 2 2
Blue Blue 15
3 3
Light not transmitted: 5V
Light transmitted: 0V

3. Gutter ON/OFF Sensor

<Operation>
The gutter ON/OFF sensor detects the gutter guide
position by the photo sensor, and in case the gutter is
not needed, “Gutter Released” is displayed.

<Circuit diagram>

Gutter ON/OFF sensor

Main PCB unit
Black CN4-21
1 4 5V
White 20
2 3
Receiving
Orange 19
3 2
Red 18 5V
4 1

Black 17
1 2
Emitting Light not transmitted: 5V
Orange 16
3 1 Light transmitted: 0V

32 S2-Y1540-0
 Chapter 2 6 Cutter Section

6 Cutter Section
1. Description
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. 2

2. Operation
The rotating motion of the DC motor is transformed
into the reciprocating motion of the upper blade by
means of the eccentric 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 cycle to make
it stop.

3. Operation of Each Part

1. 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>

Cutter HP sensor
Main PCB unit

Blue Blue CN2-18 5V

1 3
Yellow Yellow 17
2 2
Red Red 16 5V
3 1
Light not transmitted: 5V
Light transmitted: 0V

S2-Y1540 -0 33
Chapter 2 6 Cutter Section

2. Cutter Motor
<Operation>
Cutter motor controls the upper blade up and down
operation.

<Circuit diagram>

Cutter motor

Red Red CN6-3 Drive PCB unit

1

M
Black Black 4
2

34 S2-Y1540-0
 Chapter 2 7 Creaser Section

7 Creaser Section
1. Description
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 perpendicularly to its 2
traveling direction.

2. Operation
The sensor plate provided coaxially with the cam
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 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.

S2-Y1540 -0 35
Chapter 2 7 Creaser Section

3. Operation of Each Part

1. Crease Lower Blade Home Position Sensor
<Operation>
This sensor detects the crease home position by
sensing the sensor plate attached to the eccentric
shaft by means of the photo-micro sensor.

<Circuit diagram>

CREASE LOW HP sensor

Main PCB unit

5V
Red CN3-13 5V
1 4
Light green 14
2 5
Blue 15
3 6 Light not transmitted: 5V
Light transmitted: 0V

2. Crease Home Position Sensor

<Operation>
This sensor detects the crease home position by
sensing the sensor plate attached to the eccentric
shaft by means of the photo-micro sensor.

<Circuit diagram>

CREASE HP sensor
Main PCB unit
5V
Red CN3-10 5V
1 1
White 11
2 2
Blue 12
3 3 Light not transmitted: 5V
Light transmitted: 0V

36 S2-Y1540-0
 Chapter 2 7 Creaser Section

3. Creaser Lower Blade Encoder Sensor

<Operation>
Creaser lower blade encoder sensor adjusts the crease
depth in three 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.

<Circuit diagram>
2
CREASE ENCODER Main PCB unit
5V
Red CN3-16 5V
1 7
Purple 17
2 8
Blue 18
3 9
Light not transmitted: 5V
Light transmitted: 0V

4. PPS4
<Operation>
The light from the PPS photo-emitting PCB is
received by the PPS photo-detecting PCB. The
presence or non-presence of the paper is determined
by the receiving amount.
PPS4 detects the passing paper and paper jam in the
cutter and crease areas.

<Circuit diagram>

PPS4
Main PCB unit

Red CN4-13 5V 5V
1 1
Gray 14
2 2
Blue 15
3 3

Red
5V
11
1 1
Orange 12
3 2 Light not transmitted: 5V
Light transmitted: 0V

S2-Y1540 -0 37
Chapter 2 7 Creaser Section

5. Crease Motor
<Operation>
Crease motor controls the crease upper blade up and
down operation.

<Circuit diagram>

CREASE MOTOR

Red Red CN6-1 Drive PCB unit

1

M
Black Black 2
2

6. Crease Low Motor

<Operation>
Crease low motor rotates the encoder attached in the
crease lower motor to adjust the crease depth in three
steps.

<Circuit diagram>

CREASE LOW MOTOR

Drive PCB unit

Brown Brown CN5-4
1

M
Black Black 5
2

7. Perforation Unit Sensor

<Operation>
Perforation unit sensor detects whether the perforation unit is installed or not.

<Circuit diagram>

Perforation Unit Sensor Main PCB unit

5V
Red CN2-19 5V
1 1
White 23
2 2
Blue 24
3 3 Light not transmitted: 5V
Light transmitted: 0V

38 S2-Y1540-0
 Chapter 2 8 Main Drive Section

8 Main Drive Section

1. Description
Stepping motors are used for activating components
related to the paper cutting dimensions, paper
transfer, each slitter, transversal position of the gutter.
The movement of other DC motors are also controlled
by the encoder attached to the motor as required. 2

S2-Y1540 -0 39
Chapter 2 9 Exit Tray

9 Exit Tray
1. Description
Exit tray is for receiving the finished paper discharged
from the machine.
The exit tray can be set at four different heights.
Normally the tray is set at the middle height position.
Upper position is to install the Card Stacker.
Lower position is for the papers with strong static
electricity.

40 S2-Y1540-0
 Chapter 2 10 Exterior

10 Exterior
1. Description
Exterior section detects the opening and closing of
each cover. The machine stops immediately when the
cover is opened during operations.
2
2. Operation
The machine stops immediately when opening of the
cover is detected during operations.

3. Operation of Each Part

1. Top Cover Interlock Switch
<Operation>
Top cover interlock switch detects the opening
and closing of the top cover. The machine stops
immediately when the cover is opened during
operations.
When the cover is closed, the cover presses the
switch.
When the cover is opened, the cover is off the switch.

2. Front Cover Interlock Switch

<Operation>
Front cover interlock switch detects the opening
and closing of the front cover. The machine stops
immediately when the cover is opened during
operations.
When the cover is closed, the cover presses the
switch.
When the cover is opened, the cover is off the switch.

S2-Y1540 -0 41
Chapter 2 10 Exterior

<Circuit diagram>

Front cover interlock switch Main PCB unit

Brown Brown CN7-2


Brown Brown 3

Rear cover interlock switch

 1 Relay

2


Top cover interlock switch Drive PCB unit

CN14-1
Brown Brown

Brown Brown 2


42 S2-Y1540-0
 Chapter 2 11 Barcode

11 Barcode
1. Description
By adding barcode which indicates job number on Paper feed direction
each document, DC-616 automatically set up the
machine and start the job. Operator can press the
START key and leave. Even if multiple types of jobs
are loaded on the feed tray at one time, DC-616
2
recognizes barcode on documents also with the built-
in CCD reading and automatically switch setup and
finish the jobs.
To use this function, each documents must have
BARCODE printed on them. Please refer to following
instructions for specifications and position of
BARCODE.

1. Specifications
Barcode type : CODE-39
Start and Stop code : Required
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 your

software application or use barcode generator
software.

REFERENCE
Barcode may not be read even it is within the
specifications depending on the print quality of printer
and document type. If this is the case, enlarging the
barcode may enable it to be read.

S2-Y1540 -0 43
Chapter 2 11 Barcode

2. Position of barcode
Paper feed direction: The whole BARCODE should be within
3 to 20 mm from the lead edge.
Paper width direction: The whole BARCODE should be
within 25 to 60 mm from the right edge.
* Here is the example barcode: CODE39 (*21*).
(See below)

60 mm or less
35 mm 25 mm

3 mm

20 mm

Barcode
Position Range

Barcode

Paper feed direction

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. (*)
1 2 3 4

44 S2-Y1540-0
 Chapter 2 11 Barcode

3. Position of check digit

Modulus43 is the calculational procedure of check

digit specified for CODE39. Each of 43 character types
available to CODE39 are allocated each Numeric
Number to be calculated after converting them to the
numeric number. Here is the example calculation of
check digit (*21*) in CODE39.
1 2 3 4 5
1. is the start code designator for CODE-39. (*) 2
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. (*)

4. Calculation procedure of check digit

1. Convert all the data characters to the numeric number

referring the table 1.
(Except start '*' and stop '*' code.) 21→2,1

2. Add the each converted number.

2+1 =3
3. Divide the number of calculated in step 2 by 43, and
find out the remainder.
3÷43 = Remainder 3

4. Convert the remainder 3 calculated in step 3 to the

character referring the table 1.
3→3

Therefore, the check digit is 3, and the data will be 213*'.

Table 1 Modulus43 Check Digit Calculation List

Character 0 1 2 3 4 5 6 7 8 9 A B C D E
Value 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Character F G H I J K L M N O P Q R S T
Value 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

Character U V W X Y Z - • $ / + %
Value 30 31 32 33 34 35 36 37 38 39 40 41 42

S2-Y1540 -0 45
Chapter 2 12 REG Mark

12 REG Mark
1. Description
DC-616 automatically compensate for image drift, one
of the common problems on digital printers. It detects Paper feed direction
the image drift caused on each page by reading REG
mark with built-in CCD and adjust the cut/slit/crease
position accordingly.
To use this function, each documents must have
REG mark printed on them. Please refer to following Side mark
Lead mark Correct for image drift
instructions for specifications and position of REG Correct for in this direction
mark. image drift
in this direction

1. Specifications 20 mm
REG mark consists of two straight and perpendicular 3 mm
lines.
Line length: 5 mm or more / each 3 mm
Line thickness: 0.4 mm or more / each 5 mm or more
Use pen tool etc. of your software application to draw
2 straight and perpendicular lines.
5 mm
or more 20 mm
2. Position
Paper feed direction: The whole REG mark should be 0.4 mm or more
within 3 to 20 mm from the lead REG Mark
edge. Position Range

Paper width direction: The whole REG mark should be REG Mark
within 3 to 20 mm from the right
edge.

REFERENCE 20 mm

Right figure shows optimum position of REG mark. 3 mm

3 mm

6 mm

20 mm

6 mm

IMPORTANT
When there are scratches or stains in the printing range of the REG mark, the position may
not be corrected.
When the read side of the document is rough and glossy, the CCD scanner may not be able
to read REG mark and barcode. (The document may diffusely reflect light.)

46 S2-Y1540-0
 Chapter 2 12 REG Mark

3. Printing both REG mark and barcode

60 mm or shorter

35 mm 5 mm 20 mm
3 mm

3mm
5 mm or more
3 mm
2
5 mm
or more 20 mm

0.4 mm or more

Barcode REG Mark

Paper feed direction

IMPORTANT
REG marks or barcodes located out of the specified printing area cannot be detected
properly by DC-616.
Take account of the possible variation in the printed position of REG marks and barcodes
when they are arranged on the paper.

S2-Y1540 -0 47
Chapter 2 12 REG Mark

4. Non-printable area for REG marks and barcodes

35 mm 5 mm 20 mm
3 mm or more

Non-Printing Area

20 mm

3 mm 3 mm
or or
more more

Barcode REG Mark

Paper feed direction

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.

48 S2-Y1540-0
 Chapter 3 Mechanism
1 Exterior of the Machine ....................... 51 3 Double Feed Detection Section (Option).. 67
(1) Removing the Cover F (on control panel side) .. 52 (1) Removing the Ultrasonic Sensor Unit. 67
(2) Removing the Cover F2 Unit (on control panel side) . 52 4 CCD Section (Option) ........................ 68 3
(3) Removing the Cover R2 ................. 52 (1) Removing the CCD....................... 68
(4) Removing the Cover ..................... 53 (2) Removing the PPS2 ..................... 69
(5) Removing the Cover R .................. 53 5 Margin Slitter Section ......................... 70
(6) Removing the Plate ...................... 53 (1) Removing the Margin Slitter Module .. 70
(7) Removing the Top Cover ................ 53 (2) Removing the Margin Slitter Position Motor/Belt . 73
(8) Removing the Cover (Power supply) . 54 (3) Removing the Margin Slitter Home Position Sensor . 74
(9) Removing the Top Cover Interlock Switch .. 54 (4) Removing the Margin Jam Sensor .... 75
(10) Removing the Front Cover Interlock Switch . 55 6 Center Slitter Section ......................... 76
(11) Removing the Exit Interlock Switch .. 55 (1) Removing the Center Slitter Module .. 76
2 Paper Feed Section ........................... 56 (2) Removing the Center Slitter Position Motor . 79
(1) Removing the Paper Separation Plate 56 (3) Removing the Center Slitter Home Position Sensor . 80
(2) Removing the Belt Suction Unit ........ 56 (4) Removing the PPS3 ..................... 81
(3) Removing the Feed Motor .............. 58 (5) Removing the Gutter ON/OFF Sensor 82
(4) Removing the Suction Fan.............. 58 7 Cutter Section .................................. 83
(5) Removing the Compressor ............. 59 (1) Removing the Cutter Module ........... 83
(6) Removing the Compressor Fuse ...... 60 (2) Removing the Cutter Home Position Sensor .. 84
(7) Removing the Paper Level Sensor .... 61 8 Creaser Section ............................... 85
(8) Removing the Elevator Upper Limit Switch .. 62 (1) Removing the Creaser Motor and the Belt.. 85
(9) Removing the Elevator Lower Limit Switch .. 62 (2) Removing the Creaser Home Position Sensor . 85
(10) Removing the Elevator Motor ......... 63 (3) Removing the Crease Blade............ 86
(11) Removing the PPS1 .................... 64 (4) Removing the Crease Lower Blade Home Position Sensor . 87
(12) Removing the Elevator Down Switch . 65 (5) Removing the Crease Lower Blade Motor . 87
(13) Removing the Paper Feed Unit....... 65 (6) Removing the Creaser Lower Blade Encoder Sensor . 88
(14) Removing the Blow Fan ............... 66 (7) Removing the PPS4 ..................... 89

CAUTION
•Always remove the power cord plug from the outlet before starting work.

•Cautions Regarding Disassembly and Assembly

•In principle, do not operate this machine with parts removed.
•When assembling:
•Unless specified otherwise, perform the disassembly procedure in reverse.
•Make sure that screw types (radius, length) and locations are correct.
•Be sure to use rosette washers when they are specified.
(Rosette washers are used with installation screws to prevent static electricity.)
•To ensure electrical current, a rosette washer is used with the installation screw on
the ground wire. Be sure to use the rosette washer during assembly.
9 Main Drive Section ............................ 90
(1) Removing the Main Motor and the Drive Belt . 90
(2) Removing the Driving Roller (Upper) . 91
(3) Removing the Driving Roller (Lower) . 92
(4) Removing the Perforation Tool ......... 92
10 Electrical System Section .................. 96
(1) Removing the Control Panel............ 96
(2) Removing the Power Supply Unit ..... 96
(3) Removing the Main PCB Unit .......... 97
(4) Removing the Drive PCB Unit .......... 97
(5) Removing the Main Drive PCB Unit ... 98
(6) Removing the Double Feed Detection PCB Unit .. 98
(7) Removing the USB PCB Unit .......... 98

50 S2-Y1540-0
 Chapter 3 1 Exterior

1 Exterior of the Machine

(9) Top cover interlock switch

(7) Top cover

(1) Cover F
3
(2) Cover F2 unit

(10) Front cover

interlock switch

(11) Exit interlock switch

(3) Cover R2

(5) Cover R (4) Cover

(6) Plate

(8) Cover
(Power supply)

S2-Y1540 -0 51
Chapter 3 1 Exterior

(1) Removing the Cover F (on control panel side)

1. Open the top cover. Screw
2. Take out the three screws, and remove the cover F.

Screw Screw

(2) Removing the Cover F2 Unit (on control panel side)

1. Open the top cover.
2. Remove the cover F.
3. Take out the three screws, and remove the cover
Screw
F2 unit.
Screw

Screw

(3) Removing the Cover R2

1. Open the top cover. Screw
2. Take out the three screws, and remove the cover R2
unit.
Screw

Screw

52 S2-Y1540-0
 Chapter 3 1 Exterior

(4) Removing the Cover

1. Loosen the thumbscrew, and remove the cover.

Thumbscrew

(5) Removing the Cover R

3
1. Open the top cover.
2. Take out the three screws, and remove the cover R.

Screw
Screw

Screw

(6) Removing the Plate

1. Take out the seven screws, and remove the plate.

Screw
Screw
Screw

Screw
Screw Screw

Screw

(7) Removing the Top Cover

1. Open the top cover.
2. Take out the two screws and the screw plate, and Screw
remove the hinge.
3. Take out the two screws (each), and remove the
Screw
top cover with the hinges (two places).
Screw

S2-Y1540 -0 53
Chapter 3 1 Exterior

(8) Removing the Cover (Power supply)

1. Take out the six screws, and pull out the cover.
* Be sure to work with thepower cord removed. Screw
Screw

Screw
Screw
Screw

Screw

(9) Removing the Top Cover Interlock Switch

1. Open the top cover.
2. Take out the two screws, and remove the micro
switch with the bracket.

Screw Screw

3. Disconnect the connector.

4. Take out the two screws, and remove the micro
switch.
* After the installation, adjust the interlock switch.
Screw
(See→P.103)

Screw

54 S2-Y1540-0
 Chapter 3 1 Exterior

(10) Removing the Front Cover Interlock Switch

1. Open the front cover.
2. Take out the two screws, and remove the front
cover interlock switch with the bracket.
Screw

Screw

3. Remove the two faston terminals.

4. Take out the two screws, and remove the switch.
3
Screw

* After the installation, adjust the interlock switch.

(See→P.100)
Screw
Faston terminal

(11) Removing the Exit Interlock Switch

1. Open the Top cover.
2. Take out the three screws, and remove the cover R.
3. Take out the two screws, and remove the exit
interlock switch with the bracket.
Screw

4. Remove the two faston terminals.

5. Take out the two screws, and remove the switch. Screw

* After the installation, adjust the interlock switch.

(See→P.100) Screw

Faston terminal

S2-Y1540 -0 55
Chapter 3 2 Paper Feed Section

2 Paper Feed Section

(1) Removing the Paper Separation Plate
1. Take out the two screws, and remove the paper
separation plate with the unit.

Screw

Screw

(2) Removing the Belt Suction Unit

1. Open the top cover.
2. Remove the cover F2 unit. (See→P.52)
3. Remove the feed motor connector and the suction Screw Screw
fan connector. (See→P.58) Screw
4. Take out the three screws, and remove the shutter
solenoid cover.

5. Disconnect the shutter solenoid connector. Connector

6. Take out the two nuts and one screw, and remove
the belt suction unit.

* After the installation, perform the unit operation

check in HELP Mode: 19.
(HELP Mode : 19→P.143)

56 S2-Y1540-0
 Chapter 3 2 Paper Feed Section

● Removing the Shutter Solenoid

1. Disconnect the connector.
2. Take out the two screws, and remove the shutter Connector
solenoid with the bracket.

Screw
Screw

3. Take out the two screws, and remove the shutter

solenoid. 3

Screw

S2-Y1540 -0 57
Chapter 3 2 Paper Feed Section

(3) Removing the Feed Motor

1. Open the top cover.
2. Remove the cover F2 unit. (See→P.52)
3. Disconnect the connector from the motor.
4. Remove the belt suction unit. (See→P.56)

Connector

5. Take out the two screws, and remove the feed

motor.
* After the installation, perform the motor operation
check in HELP Mode: 19.
(HELP Mode : 19→P.143)
Screw

Screw

(4) Removing the Suction Fan

1. Remove the cover F2 unit. (See→P.52)
2. Disconnect the fan motor connector.
3. Take out the two screws, and remove the suction
fan.
* After the installation, perform the fan motor
operation check in HELP Mode: 18.
(HELP Mode : 18→P.142) Screw

Screw

Connector

58 S2-Y1540-0
 Chapter 3 2 Paper Feed Section

(5) Removing the Compressor

1. Remove the power cord plug.
2. Take out the three screws, and remove the cover R2.
(See→P.52)
3. Remove the plate. (See→P.53)
4. Take out the four screws securing the compressor.
(Secured from the backside.)

5. Draw the compressor toward you, and remove the

wiring and air tube.
3
* After the installation, perform the compressor
operation check in HELP Mode: 20.
(HELP Mode : 20→P.144)

● Removing the SSR

1. Remove the power cord plug.
2. Remove the plate. (See→P.53)
Screw Screw Screw
3. Take out the four screws, and remove the wirings.
4. Take out the two screws, and remove the SSR.

Screw Screw
Screw

S2-Y1540 -0 59
Chapter 3 2 Paper Feed Section

(6) Removing the Compressor Fuse

CAUTION
● Be sure to remove the power cord plug from the outlet before starting the work.
● Replace the compressor fuse for exclusive use of the rating that showed in the label.
Otherwise, fire could result.

1. Remove the power cord plug.

2. Remove the plate. (See→P.53)
3. Open the cover, and remove the fuse.
* Be sure to work with the power cord removed.
* Rating of compressor fuse: 250 V, 2 A

9
$+

60 S2-Y1540-0
 Chapter 3 2 Paper Feed Section

(7) Removing the Paper Level Sensor

1. Remove the cover R2. (See→P.52)
2. Disconnect the sensor connector.
Connector

3. Take out the two screws, and remove the paper

level sensor.
3
Screw

Screw

4. Take out one screw, and remove the shaft ASSY.

5. Take out the two screws, and remove the sensor
with the bracket.
* Install the sensor bracket at the lowest point
aligned with volume 1.
Screw

Screw

Screw

6. Remove the sensor from the bracket.

* After the installation, perform the sensor
operation check in HELP Mode: 11.
(HELP Mode : 11→P.137)
* Make sure that the pinion shaft and the cable
tube do not interfere with other at the time of
installation.

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Chapter 3 2 Paper Feed Section

(8) Removing the Elevator Upper Limit Switch

1. Remove the cover R2. (See→P.52)
2. Disconnect the connector.
3. Take out the nut, and remove the elevator upper
limit switch with the bracket.

Nut

4. Take out the two screws, and remove the elevator

upper limit switch.
* Adjustment required at the time of installation Screw
(See→P.100)

Screw

(9) Removing the Elevator Lower Limit Switch

1. Remove the cover F2 unit. (See→P.52)
2. Disconnect the two faston terminals.
3. Take out the two screws, and remove the elevator
lower limit switch. Screw
* Adjustment required at the time of installation
(See→P.100)
Screw

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 Chapter 3 2 Paper Feed Section

(10) Removing the Elevator Motor

1. Move the elevator to the upper limit, and turn off the
power.
2. Remove the cover R2. (See→P.52)
Banding band
3. Disconnect the motor connector.
4. Remove the banding band. Screw

Connector

5. Take out the two screws and nut, and remove the
motor with the bracket.
Screw 3

Nut

6. Loosen the hexagon socket set screw, and remove

the gear.
7. Take out the three screws, and remove the motor. Screw
Screw
* After the installation, perform the paper feed
elevator operation check in HELP Mode: 17.
(HELP Mode : 17→P.141)
Screw

Hexagon
socket set
screw

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Chapter 3 2 Paper Feed Section

(11) Removing the PPS1

1. Move the elevator to the upper limit (HELP Mode:
17), and turn off the power.

2. Take out one screw, and remove the sensor with

the bracket.
Screw

3. Take out one screw, and remove the sensor.

* After the installation, perform the sensor operation

check in HELP Mode: 11.
(HELP Mode : 11→P.137)

Screw

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 Chapter 3 2 Paper Feed Section

(12) Removing the Elevator Down Switch

1. Remove the cover F2 unit. (See→P.52)
2. Disconnect the switch connector. Screw
3. Take out the two screws, and remove the elevator
down switch with the angle.
Screw

Connector

4. Push the part indicated by the arrow, and remove

the elevator down switch.
3

(13) Removing the Paper Feed Unit

1. Open the top cover.
2. Remove the cover F2 unit and cover R2.
(See→P.52)
3. Disconnect the following connectors.
• Elevator down switch (See→P.65)
• Elevator lower limit switch (See→P.62)
• Suction fan (See→P.58)
• Feed motor (See→P.58)
• Shutter solenoid (See→P.57)
• Blow fan (See→P.66)

• Paper level sensor (See→P.61)

• Elevator motor (See→P.63)
• Optional ultrasonic sensor (See→P.67)

* After the installation, perform the sensor and motor

operation check in HELP Mode: 11, 15, 17, 18, 19.

(HELP Mode : 11→P.137)

(HELP Mode : 15→P.139)
(HELP Mode : 17→P.141)
(HELP Mode : 18→P.142)
(HELP Mode : 19→P.143)

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Chapter 3 2 Paper Feed Section

4. Take out the four screws securing the paper feed

unit.
* Do not loose the collars and washers.
Screw Screw

Screw Screw

5. Disconnect the PPS1 connector, and remove the

paper feed unit.
* Adjust the indicator to "0" at the time of installation
(See→P.101)

Connector

(14) Removing the Blow Fan

1. Remove the paper feed unit. (See→P.65)
* Be sure to work with the power cord removed.
2. Take out the three screws, and remove the fan
motor. Screw

* After the installation, perform the fan motor

operation check in HELP Mode: 18.
(HELP Mode : 18→P.142)
Screw
Screw

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 Chapter 3 3 Double Feed Detection Section

3 Double Feed Detection Section (Option)

(1) Removing the Ultrasonic Sensor Unit
* The ultrasonic sensor unit cannot be disassembled.
(Sensor installation angle is a factory setting.)
Screw Screw

1. Remove the cover R2. (See→P.52)

2. Disconnect the five connectors and remove the two
ground wires. Connector
3. Take out the three screws, and remove the
ultrasonic sensor unit.
3

Connector

Screw

4. Take out the two screws, and remove the ultrasonic Screw
sensor.
* After the installation, perform the sensor operation
check in HELP Mode: 15.
(HELP Mode : 15→P.139)

Screw

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Chapter 3 4 CCD Section

4 CCD Section (Option)

(1) Removing the CCD
1. Remove the cover (power supply) and cover R.
(See→P.53)
* Be sure to work with the power cord removed.
2. Disconnect the connector (CN8).
CN8
* Make sure that the terminals do not interfere each
other at the time of installation.

3. Open the top cover.

4. Take out the three screws, and remove the hinge of
the top cover.

Screw
Screw

Screw

5. Take out the two screws, and remove the CCD unit.
* Adjustment required at the time of installation
(See→P.102)

Screw
Screw

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 Chapter 3 4 CCD Section

(2) Removing the PPS2

● Photo-emission sensor
1. Open the top cover.
2. Take out the three screws, and remove the hinge of
the top cover. Screw

Screw

Screw

3. Take out the two screws, and remove the sensor

3
with the bracket.

Screw

Screw

4. Take out one screw, and remove the sensor.

* Adjustment required at the time of installation
(See→P.102)

Screw

● Photo-detecting sensor
1. Open the front cover.
2. Remove the shutter.
3. Take out the screw, and remove the sensor.
* Adjustment required at the time of installation
(See→P.102) Screw

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Chapter 3 5 Margin Slitter Section

5 Margin Slitter Section

(1) Removing the Margin Slitter Module
1. Open the top cover.
2. Remove the cover R and cover F. (See→P.52)
(See→P.53)
3. Remove the timing belt of the two lead shafts.
4. Loosen the motor fixing screws, and remove the
timing belts.

5. Take out the screw, and remove the upper guide

plate. (three places)

6. Take out the screw, and remove the lower guide

plate. (three places)

7. Take out the screw, and remove the bearing

presser.
8. Pull out the slitter driving shaft with its groove
facing down.
* Do not drop the key placed in the groove.

Screw

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 Chapter 3 5 Margin Slitter Section

9. Take out the screw, and pull out the two slide
shafts.
* Do not damage the ball bearings at the time of
installation.
* Take note of the orientation of the D cutting in the
shaft point at the time of installation.
* Before installation, be careful that there are two
kinds of shaft with different depth of D cutting.

10. Take out the screw, and remove the bearing

pressers. (two places)
* Take note of the orientation to attach at the time of
installation.
3
11. Pull out the lead shafts while turning them around.

● Removing the Slitter Blade

* To install the upper and lower blade housing, the
jig for parallel is necessary.
* Do not lose the key.

1. Take out the six screws, and separate the housing. Screw
Screw
Screw
Screw

Screw Screw

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Chapter 3 5 Margin Slitter Section

2. Take out the two screws (each), and remove the Screw
lids (two places, right and left).
Screw

3. Pull out the upper blade unit.

4. Remove the spring T.

Spring T

5. Take out the two screws (each), and remove the

lids (two places). Screw
Screw

6. Pull out the shaft, and remove the lower blade.

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 Chapter 3 5 Margin Slitter Section

(2) Removing the Margin Slitter Position Motor/Belt

1. Open the front cover.
2. Disconnect the two motor connectors.

Connector
Connector

3. Remove the cover R.

4. Remove the timing belt.
(See→P.53)
3
5. Take out the four screws, and remove the motor.
* After the installation, perform the motor operation
check in HELP Mode: 31.
(HELP Mode : 31→P.149)

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Chapter 3 5 Margin Slitter Section

(3) Removing the Margin Slitter Home Position Sensor

1. Remove the cover F. (See→P.52)

2. Remove the cover R. (See→P.53)

3. Take out one screw (each), and remove the sensor
with the bracket.
4. Take out one screw (each), and remove the sensor
from the bracket.
* Adjustment required at the time of installation
(See→P.103)

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(4) Removing the Margin Jam Sensor

• Photo-emission sensor
1. Remove the cover F. (See→P.52)
2. Take out one screw, and remove the sensor with the
bracket.

Screw

• Photo-detecting sensor
3. Remove the cover R. (See→P.53)
3
4. Take out one screw, and remove the sensor with the
bracket.
5. Disconnect the sensor connectors.

6. Take out the two screws (each), and remove the Photo-emission sensor
sensors.
Screw
* After the installation, perform the sensor operation
check in HELP Mode: 11.
(HELP Mode : 11→P.137)

Photo-detecting sensor

Screw

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Chapter 3 6 Center Slitter Section

6 Center Slitter Section

(1) Removing the Center Slitter Module
1. Open the top cover.
2. Remove the cover R and cover F. (See→P.52)
(See→P.53)
3. Remove the two slitter driving shafts and the timing
belts.

4. Take out the screw, and remove the upper guide

plate. (three places)

5. Take out the screw, and remove the lower guide

plate. (three places)

6. Take out the screw, and remove the bearing

presser.
7. Pull out the slitter driving shaft with its groove
facing down.
* Do not drop the key placed in the groove.

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 Chapter 3 6 Center Slitter Section

8. Take out the screw, and pull out the two slide
shafts.
* Do not damage the ball bearings at the time of
installation.
* Take note of the orientation of the D cutting in the
shaft point at the time of installation.
* Before installation, be careful that there are two
kinds of shaft with different depth of D cutting.

9. Take out the screw, and remove the bearing

pressers. (two places)
10. Pull out the two driving shafts while turning them
around.
3

● Removing the Slitter Blade

* When removing the slitter blade of center slitters
(5 and 6), remove the gutter guide.
* To install the upper and lower blade housing, the
jig for parallel is necessary.
* Do not lose the key.

1. Remove the tape and expose the two screws.

Screw

Screw

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Chapter 3 6 Center Slitter Section

2. Take out the two screw, and separate the housing. Screw Screw
3. Take out the two screw, and remove the plate.

4.Take out the two screw, and remove the guide. Screw
Screw

5.Take out the two screws, and remove the lids (2 places, Screw
right and left) . 
Screw

6. Draw out the upper blade unit.

(Slitter 3 and slitter 4: upper blade unit
Slitter 5 and slitter 6: lower blade unit)

7. Take out the two screws, and remove the guide.

Screw

Screw

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 Chapter 3 6 Center Slitter Section

8. Remove the spring T.

Spring T

9. Take out the two screw (each), and remove the lids Screw
(two places).
* Take note of the correct orientation of the
eccentric shaft at the time of installation.
Screw 3

10. Draw out the lower blade unit with the shaft.

(2) Removing the Center Slitter Position Motor

1. Open the font cover.
2. Disconnect the motor connector.

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Chapter 3 6 Center Slitter Section

3. Remove the cover R. (See→P.53)

4. Remove the timing belt.
5. Take out the four screws, and remove the motor.
* After the installation, perform the motor operation
check in HELP Mode: 31.

(HELP Mode : 31→P.149)

(3) Removing the Center Slitter Home Position Sensor

1. Remove the cover F. (See→P.52)

2. Remove the cover R. (See→P.53)

3. Take out one screw (each), and remove the
photointerrupter with the bracket.
4. Take out one screw (each), and remove the
photointerrupter from the bracket .
* Adjustment required at the time of installation
(See→P.104)

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 Chapter 3 6 Center Slitter Section

(4) Removing the PPS3

● Photo-emission sensor
1. Open the top cover.
2. Remove the cover R. Screw Screw
3. Take out the two screws, and remove the sensor
cover.

4. Take out the two screws, and remove the sensor

with the bracket.
3

5. Take out the screw, and remove the sensor from the
bracket.
* After installation, perform the sensor operation check
in HELP Mode: 11. (HELP Mode : 11→P.137) Screw

● Photo-detecting sensor
1. Take out the two screws, and remove the sensor
with the bracket.

2. Take out the screw, and remove the sensor from

the bracket.
* After installation, perform the sensor operation
check in HELP Mode: 11. Screw
(HELP Mode : 11→P.137)

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Chapter 3 6 Center Slitter Section

(5) Removing the Gutter ON/OFF Sensor

1. Remove the cover F. (See→P.52)

2. Remove the cover R. (See→P.53)

3. Disconnect the sensor connector.
4. Take out the screw, and remove the sensor with the
bracket.

5. Take out the two screws , and remove the sensor. Photo-emission sensor
* After the installation, perform the sensor operation
check in HELP Mode: 11. Screw
(HELP Mode : 11→P.137)

Photo-detecting sensor

Screw

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 Chapter 3 7 Cutter Section

7 Cutter Section
(1) Removing the Cutter Module
1. Open the top cover.
2. Remove the covers F, R. (See→P.52) (See→P.53)
3. Disconnect the motor connector. Screw
4. Take out one screw, and draw out the home
position sensor bracket. (See→P.87)

Connector

3
5. Take out the five screws, and draw out the cutter
Screw
module.
* Adjustment required at the time of installation
(See→P.105)
Screw

Screw
Screw Screw

● Removing the Slitter Blade Module

1. Take out the two screws, and remove the lock plate
unit. Screw

Screw

2. Take out the four screws, and remove the under Screw
guide. Screw
* Align the top of the under guide with the top of the Screw
blade at the time of installation. Screw

3. Take out the three screws, and remove the bracket.

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Chapter 3 7 Cutter Section

(2) Removing the Cutter Home Position Sensor

1. Remove the cover R. (See→P.53)
2. Take out the two screws, and remove the sensor
with the bracket.
3. Take out one screw, and remove the sensor.
* Adjustment required at the time of installation
(See→P.107)

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 Chapter 3 8 Creaser Section

8 Creaser Section
(1) Removing the Creaser Motor and the Belt
1. Remove the covers F, R. (See→P.52) (See→P.53)
2. Disconnect the motor connector. Screw
3. Loosen the motor fixing screws, and remove the
timing belt.

3
Connector

4. Take out the two screws, and draw out the motor Screw
 Screw
with the bracket.
5. Take out the three screws, and remove the gear
cover and timing belt.
* Adjustment required at the time of installation
(See→P.106) Screw

(2) Removing the Creaser Home Position Sensor

1. Remove the cover F. (See→P.52) 
2. Take out the two screws, and remove the photo
micro sensor with the bracket.

3. Remove the sensor from the bracket.

* Adjustment required at the time of installation

(See→P.107)

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Chapter 3 8 Creaser Section

(3) Removing the Crease Blade

1. Remove the covers F, R. (See→P.52) (See→P.53) Screw
2. Take out one screw, and remove the sensor plate.
3. Take out one screw, and remove the bearing presser. Screw

4. Take out the three screws, and remove the gear 

Screw
cover. Screw
5. Remove the belt and the pulley unit.

Screw

6. Take out one screw, and remove the eccentric gear. Screw
7. Take out one screw, and remove the bearing presser.

8. Draw out the eccentric shaft and the two bearings.

9. Draw out the upper blade.
10. Draw out the two springs and the lower blade.
* Apply the grease to the slider metal at the time of
installation.
* Adjustment required at the time of installation
(See→P.104)

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 Chapter 3 8 Creaser Section

(4) Removing the Crease Lower Blade Home Position Sensor

1. Remove the cover F. (See→P.52)
2. Take out the two screws, and remove the sensor
with the bracket.

3. Remove the sensor from the bracket. 3

* Adjustment required at the time of installation
(See→P.106)

(5) Removing the Crease Lower Blade Motor

1. Remove the cover F. (See→P.52)

2. Take out the two screws, and remove the motor with
the bracket.

3. Loosen the hexagon socket set screw, and remove

the gear.
4. Take out the three screws, and remove the motor
from the bracket. Gear
* Adjustment required at the time of installation
(See→P.108) Screw

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Chapter 3 8 Creaser Section

(6) Removing the Creaser Lower Blade Encoder Sensor

1. Remove the cover F. (See→P.52)
2. Take out the screw, and remove the sensor with the
bracket.

Screw

3. Remove the sensor from the bracket.

* Adjustment required at the time of installation
(See→P.106)

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 Chapter 3 8 Creaser Section

(7) Removing the PPS4

● Photo-emission sensor
1. Remove the covers F, R. (See→P.52) (See→P.53) Screw Screw
2. Take out the five screws, and remove the
reinforcing plate. Screw

Screw

Screw

3. Take out one screw, and remove the sensor.

3
* After the installation, perform the sensor operation Screw
check in HELP Mode: 11.
(HELP Mode : 11→P.137)

• Photo-detecting sensor
1. Take out the four screws, and remove the plate.

Screw

Screw

2. Take out one screw, and remove the sensor.

* After the installation, perform the sensor operation
Screw
check in HELP Mode: 11.
(HELP Mode : 11→P.137)

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Chapter 3 9 Main Drive Section

9 Main Drive Section

(1) Removing the Main Motor and the Drive Belt
1. Remove the cover F. (See→P.52)
2. Take out the two screws, and loosen the pulley
bracket.

Screw

3. Take out the three screws, and remove the pulley

cover.
4. Remove the timing belt.

Screw

Screw

Screw

5. Disconnect the motor connector.

Connector

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 Chapter 3 9 Main Drive Section

6. Take out the four screws, and remove the motor with
bracket.
Screw Screw

Screw

Screw

7.Loosen the hexagon socket set screw, and remove Hexagon

the gear.
* Adjustment required at the time of installation
socket set
screw 3
(See→P.108)

(2) Removing the Driving Roller (Upper)

1. Remove the covers F, R. (See→P.52) (See→P.53)
2. Remove the bush presser spring.
3. Take out the E-ring, and remove the bush.
4. Draw out the roller from the control panel side.

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Chapter 3 9 Main Drive Section

(3) Removing the Driving Roller (Lower)

1. Remove the covers F, R. (See→P.52) (See→P.53)
2. Remove the two slitter driving belts.
3. Loosen the screw to remove the pulley.
4. Draw out the roller from the control panel side.

4. Loosen the timing belt. (See→P.90)

5. Take out the screw, and remove the bearing
presser.
6. Draw out the roller.

(4) Removing the Perforation Tool

1. Take out the two black thumbscrews, and remove

Thumbscrew
the perforation unit from the DC-616.

2. Loosen the two white thumbscrews on the rear side Thumbscrew

of the perforation unit.

REFERENCE Thumbscrew
The white thumbscrews should be loosened only. Do
not remove them from the perforation unit.

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 Chapter 3 9 Main Drive Section

3. Loosen the two screws securing the stoppers of the

perforation tool depth adjustment screws. (approx. 1. Loosen the nut.
3 mm)
First loosen the nut, and then loosen the screws.

2. Loosen the screw.

4. Raise the perforation tools on both sides up to

the upper limit position with the depth adjustment Depth adjustment screw
screws. 3

REFERENCE
Turn the depth adjustment screws until they stop.

REFERENCE
Make sure that the rubber roller of the upper tool is
apart from the lower tool.
If not, loosen the screws securing the stoppers in step
3 more.

Should be apart from the lower tool

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Chapter 3 9 Main Drive Section

5. Take out the two screws of the joint securing the

shaft (upper).

Screw

6. Slide the joint in step 5 in the direction of the arrow,

and remove the shaft (upper) from the unit.

Joint

7. Replace the upper tool assy with a new one.

Upper tool assy Roll assy

REFERENCE
When attaching the upper tool assy to the shaft, take
note of the orientation to attach the upper assy and
roll assy.

Loosen the hexagon socket set screws which suit the

supplied hexagon wrench size.

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 Chapter 3 9 Main Drive Section

8. Attach the shaft (upper) to the unit in the reverse

order to steps 5 and 6.

Screw

9. Move the upper tools so that the both right and left
perforation tools fit in the grooves of the lower tools,
and move the roll assys to hold the paper.
Then lower the upper tools with the perforation
3
depth adjustment thumbscrews.

10. When the perforation tool is raised up to the

upper limit position, adjust the screw for the upper
limit stopper to secure at the position where the
perforation tool is inside of the groove of the lower
tool.

11. Secure the perforation tool and the lower tool at

the preferred position with a hexagon socket set
screw.

12. Secure the perforation tool and the lower tool at

the preferred position with a hexagon socket set
screw.

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Chapter 3 10 Electrical System Section

10 Electrical System Section

(1) Removing the Control Panel
WARNING
● Always remove the power cord plug from
the outlet before replacing a PCB Unit.

1. Open the top cover.

Connector
2. Remove the cover F. (See→P.52)
3. Disconnect the connector.

4. Take out the two screw, and remove the control

panel.

Screw

Screw

5. Take out the ten screws, and remove the panel

Screw
PCB unit .

Screw

(2) Removing the Power Supply Unit

WARNING Screw Screw
● Always remove the power cord plug from
the outlet before replacing a PCB Unit.
Connector Connector

1. Remove the cover. (See→P.54)

2. Disconnect all connectors.
3. Take out the four screws, and remove the PCB unit.
* Pay attention to the terminals at the time of Screw
Screw
installation to prevent them from touching with
each other.

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(3) Removing the Main PCB Unit

WARNING Screw Connector
Screw

● Always remove the power cord plug from

the outlet before replacing a PCB Unit.

1. Remove the cover. (See→P.54) Connector

2. Disconnect 10 connectors.
3. Take out the four screws, and remove the PCB unit.
* Pay attention to the terminals at the time of
installation to prevent them from touching with each
other.
3
Connector
Screw Screw

(4) Removing the Drive PCB Unit

WARNING Screw Screw

● Always remove the power cord plug from

the outlet before replacing a PCB unit.

1. Remove the cover. (See→P.54) Screw Screw

2. Disconnect 11 connectors.
3. Take out the six screws, and remove the drive PCB
unit.
* Pay attention to the terminals at the time of
installation to prevent them from touching with each
other. Screw Screw

CAUTION F205 F207

CN 6 CN 10 CN 11
Fuse: F6
F202
● For continued protection against fire hazard, F206
CN 8

replace only with the same type and rating fuse.

F204 F201
CN 9

CAUTION F203
CN 5

CN 4

Fuse: F201 - F207

CN 2

● When the fuse of the drive PCB unit was

damaged, replace the drive PCB unit.
CN 3

CN 1 F6 CN 7

F6:250V 10A
TLC10AN4

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Chapter 3 10 Electrical System Section

(5) Removing the Main Drive PCB Unit

WARNING
● Always remove the power cord plug from
the outlet before replacing a PCB Unit. Screw

1. Remove the cover F. (See→P.52)

2. Disconnect three connectors.
3. Take out the two screws, and remove the PCB unit.
Screw Connector
Connector Connector

(6) Removing the Double Feed Detection PCB Unit

Screw Screw
WARNING
● Always remove the power cord plug from Connector
the outlet before replacing a PCB Unit. Screw
Screw

1. Remove the cover R2. (See→P.52) Screw

Screw
2. Disconnect five connectors.
3. Take out the eight screws, and remove the PCB unit.
Screw
Screw Connector

(7) Removing the USB PCB Unit

WARNING Screw

● Always remove the power cord plug from Connector

the outlet before replacing a PCB Unit.

1. Remove the cover. (See→P.54)

2. Disconnect one connector. Screw
3. Take out the screw, and remove the PCB unit. Screw

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Chapter 4 Adjustment
1 Exterior of the Machine ..................... 100
(1)Top cover interlock switch adjustment 100
(2)Front Cover interlock switch adjustment . 100
(3)Exit interlock switch adjustment ...... 100
2 Paper Feed Section ......................... 101
(1)Shutter solenoid adjustment ........... 101
(2)Elevator upper limit switch adjustment ... 101
(3)Elevator lower limit switch ............. 101
(4)Paper Feed Unit 0 Adjustment ........ 101
4
3 CCD Section ................................. 102
(1)CCD........................................ 102
(2)PPS2 ...................................... 102
4 Margin Slitter Section ....................... 103
(1)Margin slitter home position sensor adjustment . 103
(2) Margin jam detecting sensor adjustment . 103
(3) Slitter position motor and belt adjustment . 103
5 Center Slitter Section ....................... 104
(1)Center slitter home position sensor adjustment . 104
(2)Slitter position motor and belt adjustment . 104
6 Cutter Section ................................ 105
(1)Cutter motor adjustment ............... 105
(2)Cutter home position sensor adjustment . 105
7 Creaser Section ............................. 106
(1)Creaser motor and belt adjustment .. 106
(2)Creaser lower blade encoder sensor adjustment. 106
(3)Creaser lower blade home position sensor .. 106
(4)Creaser home position sensor ........ 107
8 Main Drive Section .......................... 108
(1)Main motor drive belt adjustment ..... 108
Chapter 4 1 Exterior of the Machine

1 Exterior of the Machine

(1)Top cover interlock switch adjustment

(2)Front Cover interlock switch adjustment

(3)Exit interlock switch adjustment

1. Adjust “a” to be 0.5 mm while the switch is turned ON.

2. Perform the operation check in HELP Mode:11.
(HELP Mode : 11→P.137)
"a"

100 S2-Y1540-0
 Chapter 4 2 Paper Feed Section

2 Paper Feed Section

(1)Shutter solenoid adjustment
1. Adjust the bracket installation position, so that the
throttle opening “a” is at 80-90 degrees when the
solenoid is turned ON.
2. Install the bracket parallel so that the actuator moves D
smoothly.
3. After the adjustment, perform the operation check in
HELP Mode: 19.
(HELP Mode : 19→P.143)

(2)Elevator upper limit switch adjustment

1. Adjust “a” to be 0.5 mm while the switch is turned ON. 4
"a"

(3)Elevator lower limit switch

1. Make an adjustment so that the switch is turned ON
when the distance between paper feed plate and MAX
comes to 100 mm or more.
2. Adjust “a” to be 0.5 mm while the switch is turned ON. "a"
3. After the adjustment, perform the operation check in
HELP Mode:11, 17.
(HELP Mode : 11→P.137)
(HELP Mode : 17→P.141)

(4)Paper Feed Unit 0 Adjustment

1. Adjust the indicator to “0”.
2. After the adjustment, check the parallel of the right
margin.

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Chapter 4 3 CCD Section

3 CCD Section
(1)CCD
1. Fix CCD in about the center of a long hole.
2. Perform REG. mark read out position adjustment in
HELP Mode: 45. (HELP Mode : 45→P.152)

(2)PPS2
1. Perform the operation check in HELP Mode:11.
(HELP Mode : 11→P.137)

102 S2-Y1540-0
 Chapter 4 4 Margin Slitter Section

4 Margin Slitter Section

(1)Margin slitter home position sensor adjustment
1. Check the sensor operation in HELP Mode:11,26.
2. Feed the test paper through the machine applying the
Service person JOB. (HELP Mode : 11→P.137)
(HELP Mode : 26→P.145)
3. Adjust the home position setting in HELP Mode: 49.
(HELP Mode : 49→P.156)

(2) Margin jam detecting sensor adjustment

1. Adjust the sensor detecting time in HELP Mode: 59. 4
2. Check the sensor operation in HELP Mode:11.
(HELP Mode : 11→P.137)
(HELP Mode : 59→P.161)

(3) Slitter position motor and belt adjustment

1. Adjust the belt tension to 6 mm/10N by moving the
motor installation position.
2. Check the operation in HELP Mode: 26.
(HELP Mode : 26→P.145)

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Chapter 4 5 Center Slitter Section

5 Center Slitter Section

(1)Center slitter home position sensor adjustment
1. Check the sensor operation in HELP Mode:11, 26.
2. Feed the test paper through the machine applying the
Service person JOB. (HELP Mode : 11→P.137)
(HELP Mode : 26→P.145)
3. Adjust the home position setting in HELP Mode: 49.
(HELP Mode : 49→P.156)

(2)Slitter position motor and belt adjustment

1. Adjust the belt tension to 3 mm/10N by moving the
motor installation position.
2. Check the operation in HELP Mode: 26.
(HELP Mode : 26→P.145)

104 S2-Y1540-0
 Chapter 4 6 Cutter Section

6 Cutter Section
(1)Cutter motor adjustment
1. Perform the operation check in HELP Mode: 29.
(HELP Mode : 29→P.148)
2. Feed the test paper through the machine applying the
Service person JOB.
3. Adjust the slide installation position (skew).
4. Adjust the cutting position in HELP Mode: 46.
(HELP Mode : 46→P.153)

(2)Cutter home position sensor adjustment

1.Feed the test paper through the machine applying the 4
Service person JOB.
2. Check the sensor operation in HELP Mode:11, 26.
(HELP Mode : 11→P.137)
(HELP Mode : 26→P.145)

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Chapter 4 7 Creaser Section

7 Creaser Section
(1)Creaser motor and belt adjustment
1. Move the motor installation position, and adjust the belt
tension to 6 mm/10N.

2. Perform the operation check in HELP Mode: 27.

(HELP Mode : 27→P.146)
3. Feed the test paper through the machine applying the
Service person JOB.
4. Adjust the crease position and depth in HELP Mode: 47,
48. (HELP Mode : 47→P.154)
(HELP Mode : 48→P.155)
REFERENCE
When the creaser depth is in MAX setting, creaser height
is within 0.4 - 0.45 mm.

(2)Creaser lower blade encoder sensor adjustment

1. Adjust the distance between the encoder and the sensor
“a” to 2.5 mm.
2. Perform the operation check in HELP Mode: 28.
(HELP Mode : 28→P.147)
3. Feed the test paper through the machine applying the
Service person JOB.
4. Adjust the crease position and depth in HELP Mode: 47, D
48. (HELP Mode : 47→P.154)
(HELP Mode : 48→P.155)

(3)Creaser lower blade home position sensor

1. Perform the operation check in HELP Mode: 28.
(HELP Mode : 28→P.147)
2.Feed the test paper through the machine applying the
Service person JOB.

3.Adjust the crease position and depth in HELP Mode: 47,

48. (HELP Mode : 47→P.154)
(HELP Mode : 48→P.155)

106 S2-Y1540-0
 Chapter 4 7 Creaser Section

(4)Creaser home position sensor

1. Perform the operation check in HELP Mode: 27.
(HELP Mode : 27→P.146)
2.Feed the test paper through the machine applying the
Service person JOB.
3.Adjust the crease position and depth in HELP Mode: 47,
48. (HELP Mode : 47→P.154)
(HELP Mode : 48→P.155)

S2-Y1540 -0 107
Chapter 4 8 Main Drive Section

8 Main Drive Section

(1)Main motor drive belt adjustment
1. Move the pulley bracket installation position, and adjust
the belt tension to 10 mm/10N.
2. After the adjustment, perform the operation check in
HELP Mode: 41.
(HELP Mode : 41→P.150)

108 S2-Y1540-0
Chapter 5 Maintenance Checks
1 Guaranteeing Maintenance Cycle .........110
2 Cleaning and Oiling ..........................110
(1) Cleaning ...................................110
(2) Oiling .......................................110
3 Periodic Maintenance Check List.......... 111
4 Recommended Parts List ...................112

5
Chapter 5 1 Guaranteeing Maintenance Cycle 2 Cleaning and Oiling

1 Guaranteeing Maintenance Cycle

After the delivered item, visit customer periodically and guide the DC-616 operation.

2 Cleaning and Oiling

(1) Cleaning

1. Slitter section and cutter section

Clean with a brush or a dry cloth.

(2) Oiling

1. Bearings
Apply a small amount of oil to the end face and axel while turning the levers and rollers.

2. Gears and Rails

Apply grease after cleaning the paper dust off of the gears.

110 S2-Y1540-0
 Chapter 5 3 Periodic Maintenance Check List

3 Periodic Maintenance Check List

6-month Periodic Checks

Section to be checked Description Description

Sensors Cleaning Use a brush to clean any paper dust, etc.

Timing belt Checking Inspect Belts for signs of wear or loss of tension.
Replace any cracked or worn belts, and retention as
required.
Cutter Oiling Use a brush to clean any paper dust, etc.
Feed Belts Cleaning Use a brush to clean any paper dust, etc.
Gears Greasing
Springs Greasing
Slider Greasing

S2-Y1540 -0 111
Chapter 5 4 Recommended Parts List

4 Recommended Parts List

No. Part No. Part name MTBF Remarks
1 S2-A114* BELT 1 million sheets Coated paper/230 gsm
2 AJ233 TIMING BELT -
3 AK049 ROLLER CHAIN -
4 N4-K212* SEPARATER PLATE -
5 P9-F104* UPPER BLADE 2 million sheets Coated paper/230 gsm
6 P9-F107* LOWER BLADE UNIT 2 million sheets Coated paper/230 gsm
7 P9-F121* NUT -
8 P9-F128* ROLLER -
9 S2-J210* CUTTER UNIT 1 million sheets Coated paper/230 gsm
10 S2-K111* CREASER UPPER BLADE 1 million sheets Coated paper/230 gsm
11 S2-K102* CREASER LOWER BLADE 1 million sheets Coated paper/230 gsm
12 AJ232 TIMING BELT -
13 AJ044 TIMING BELT -
14 AJ301 TIMING BELT -
15 AJ146 TIMING BELT -
16 AJ230 TIMING BELT -
17 AJ231 TIMING BELT -
18 S2-N101* DRIVING ROLLER 1 million sheets Coated paper/230 gsm
19 S2-N102* ROLLER CHAIN 1 million sheets Coated paper/230 gsm
20 U7-Q515* PERFORATION BLADE 250,000 times high-quality paper(230 sm)
21 BZ008 MOTOR DRIVER -
22 CA021 PHOTO MICROSENSOR -
23 CA032 REFLECTIVE SENSOR -
24 CA033 PHOTOINTERRUPTER -
25 CA046 PHOTO MICROSENSOR -
26 CA059 PHOTOINTERRUPTER -
27 LA048 MICRO SWITCH 500,000 times
28 UA040 SWITCHING POWER SUPPLY 100,000 times
29 UD028 RELAY -
30 UJ040 RELAY -
31 P9-X107* PHOTOINTERRUPTER -
32 L5-X104* MOTOR -
33 M7-X104* MOTOR -
34 U7-X101* DC BLOW -
35 S2-X107* DC BLOWER -
36 P6-X101* DC SOLENOID -
37 S2-V500* MAIN PCB UNIT -
38 S2-V311* PANEL PCB UNIT -
39 S2-V321* DRIVING PCB UNIT -
40 R8-V341* USB PCB Unit -

112 S2-Y1540-0
 Chapter 5 4 Recommended Parts List

No. Part No. Part name MTBF Remarks

41 R8-W122* CABLE UNIT:SW1 -
42 S2-W233* BUNDLED CABLE UNIT SWITCH -
43 P9-X101* STEPPING MOTOR -
44 P9-X102* STEPPING MOTOR -
45 S2-X101* MOTOR -
46 S2-X103* STEPPING MOTOR -
47 LA051 MICRO SWITCH 1,000,000 times
48 N4-X103* CCD -
49 UI028 FUSE -
50 S2-X105* AIR POMP - 115 V
51 S2-X106* AIR POMP - 230 V

Please note that the replacement timing mentioned above is reference and may differ depending
on actual usage environment and conditions.

S2-Y1540 -0 113
Chapter 6 Troubleshooting
1 Troubleshooting...............................116
(1) When “NO DOCUMENT” is Displayed ...116
(2) When “J2 FEED JAM” is Displayed ..116
(3) When “J3 FEED ERROR” is Displayed ..117
(4) When “J4 Slitter” is displayed .........117
(5) When “J5 Cut.crease” is displayed ...117
(6) When “J6 Exit tray” is displayed ......118
(7) “E00 Main-Panel” is displayed ........118
(8) When “E01 CCD” is displayed ........118
(9) When “E02 Elevator” is Displayed ....119
(10) When “E03 Crease lower” is Displayed .119
(11) When “E04-06 Memory error” is Displayed.119
(12) When “E07 Connect error” is displayed .. 120
(13) “E08 FPGA ERROR” is displayed.. 120
(14) When “BC READ ERROR” is displayed .. 120
(15) When “REG MARK ERROR” is displayed .. 121
2 Conditions for the Error Detection ........ 122
3 Major Cause and Preventive Action for the Paper Jam . 124
4 Slitter Blade Intersection Correction ..... 125 6
Chapter 6 1 Troubleshooting

1 Troubleshooting
(1) When “NO DOCUMENT” is Displayed
step cause/failed check item if action see
area page
YES Go to step 2. -
Are any documents on the
1 Feed tray Load the documents on the
feed tray? NO -
feed tray.
Check the setting of the YES Go to step 3. -
paper tray sensor in HELP
2 Paper tray sensor mode 11 for the paper • Clean the sensor.
absence: 1,and the paper NO 64
• Replace the sensor.
presence: 0.
Connector, Incomplete plug-in at #4 YES Reconnect properly. -
3
Main PCB unit connectors of main PCB? NO Replace the main PCB Unit. 97

(HELP Mode : 11→P.137)

(2) When “J2 FEED JAM” is Displayed

step cause/failed check item if action see
area page
Check that the paper level YES Go to step 2. -
1 Paper Level sensor sensor works properly in • Clean the sensor.
HELP Mode: 11. NO 61
• Replace the sensor.
Check that the elevator YES Go to step 3. -
Elevator upper/ upper/lower limit switch
2
lower limit switch works properly in HELP
Mode: 11. NO Replace the switch. 62

Check that the connection YES Reconnect properly. -

between the paper level
Connector, sensor, elevator lower
3
Main PCB unit limit switch and #2, #3
connectors of main PCB are NO Replace the main PCB Unit. 97
correct.

(HELP Mode : 11→P.137)

116 S2-Y1540-0
 Chapter 6 1 Troubleshooting

(3) When “J3 FEED ERROR” is Displayed

step cause/failed check item if action see
area page
• Remove the paper inside
• Paper jam in the machine the machine.
Inside the (feed tray unit). YES -
1 • Check that the paper
machine • Error in the paper feed feeds properly
mechanism.
NO Go to step 2. -
Check that the PPS2 sensor YES Go to step 3. -
2 works properly in HELP • Clean the sensor.
PPS2 NO 69
Mode: 11. • Replace the sensor.
Check that the PPS2 is YES Reconnect properly. -
Connector,
3 connected to #4 connector
Main PCB unit NO Replace the main PCB Unit. 97
of the main PCB properly.

(HELP Mode : 11→P.137)

(4) When “J4 Slitter” is displayed

step cause/failed check item if action see
area page
Does not PPS3 detect Reset slit position or pull
1 JOB setting YES -
gutter slit (blank-area)? out gutter guides.
Remove the paper inside
Inside the Paper jam inside the YES -
2 the machine.
machine machine (slitter unit).
NO Go to step 3. -
Check that the PPS3 sensor YES Go to step 4. -
3 PPS3 works properly in HELP • Clean the sensor.
6
Mode: 11. NO 81
• Replace the sensor.
Check that the PPS3 is YES Reconnect properly. -
Connector,
4 connected to #4 connector
Main PCB unit NO Replace the main PCB Unit. 97
of the main PCB properly.

(HELP Mode : 11→P.137)

(5) When “J5 Cut.crease” is displayed

step cause/failed check item if action see
area page
Remove the paper inside
Inside the Paper jam in the machine YES -
1 the machine.
machine (cutter unit or creaser unit).
NO Go to step 2. -
Check that the PPS4 YES Go to step 3. -
2 PPS4 sensor works properly in • Clean the sensor.
HELP Mode: 11. NO 89
• Replace the sensor.
Check that the PPS4 is YES Reconnect properly. -
Connector,
3 connected to #4 connector
Main PCB unit NO Replace the main PCB Unit. 97
of the main PCB properly.

(HELP Mode : 11→P.137)

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Chapter 6 1 Troubleshooting

(6) When “J6 Exit tray” is displayed

step cause/failed check item if action see
area page
Paper jam in the machine Remove the paper inside
Inside the YES -
1 (stacker tray unit or waste the machine.
machine
box unit) NO Go to step 2. -
Check that the margin jam YES Go to step 3. -
PPS4/Margin jam
2 sensor and PPS4 work • Clean the sensor.
sensor
properly in HELP Mode: 11. NO • Replace the sensor. 89

Check that the PPS4 and YES Reconnect properly. -

Connector, margin jam sensor are
3
Main PCB unit connected to #4 connector of
the main PCB properly. NO Replace the main PCB Unit. 97

(HELP Mode : 11→P.137)

(7) “E00 Main-Panel” is displayed

step cause/failed check item if action see
area page
Check that the connection
between the main PCB YES Reconnect properly. -
Main PCB/
1 (CN6) and the board of
control panel
control panel (CN3) is NO Go to step 2. -
correct.
Check that the LED works YES Replace the main PCB Unit. 97
Main PCB/
2 properly on the control
control panel NO Replace the panel PCB Unit 96
panel in HELP Mode:16.

(HELP Mode : 16→P.140)

(8) When “E01 CCD” is displayed

step cause/failed check item if action see
area page
Try reading out the Replace the main PCB or 97
1 CCD NG
adjustment test paper. CCD. 68

118 S2-Y1540-0
-0
 Chapter 6 1 Troubleshooting

(9) When “E02 Elevator” is Displayed

step cause/failed check item if action see
area page
Check that the elevator YES Go to step 2. -
Elevator lower
1 lower switch works properly
limit switch NO Replace the switch. 62
in HELP Mode: 17.
Check that the elevator YES Go to step 3. -
Elevator upper
2 upper limit switch works
limit switch NO Replace the switch. 62
properly.
Check the adequate 24 V YES Replace the elevator motor. 63
3 Drive PCB output power at #1 and 2 Replace the drive/power 96
terminal of CN5. NO
source PCB. 97

(HELP Mode : 17→P.141)

(10) When “E03 Crease lower” is Displayed

step cause/failed check item if action see
area page
YES Go to step 2. -
Creaser lower Check that the creaser
1 blade HP lower blade sensor works • Clean the sensor.
sensor properly in HELP Mode: 28. NO • Replace the sensor. 87

Check that the creaser YES Go to step 3. -

Creaser lower lower blade ENC sensor
2 • Clean the sensor.
blade ENC sensor works properly in HELP NO 88
Mode: 28. • Replace the sensor.
Check that the creaser
Connector, drive lower blade HP sensor is
YES Reconnect properly. - 6
3
PCB connected to #3 connector NO Replace the main PCB Unit.
of the main PCB properly. 97

(HELP Mode : 28→P.147)

(11) When “E04-06 Memory error” is Displayed

step cause/failed check item if action see
area page
Check that an error
message is displayed
1 Main PCB YES Replace the main PCB Unit. 97
even if the power is turned
on again.

S2-Y1540-0
-0 119
Chapter 6 1 Troubleshooting

(12) When “E07 Connect error” is displayed

step cause/failed check item if action see

area page
Check that the connection YES Reconnect properly. -
Main PCB/Drive between the main PCB
1
PCB (CN6) and the drive PCB
(CN3) is correct. NO Go to step 2. -

Check that the Drive PCB YES Replace the main PCB. 97
Main PCB/Drive
2 works properly in HELP
PCB NO Replace the Drive PCB. 97
Mode: 16.

(HELP Mode : 16→P.140)

(13) “E08 FPGA ERROR” is displayed

step cause/failed check item if action see

area page
Check that an error
message is displayed
1 Main PCB YES Replace the main PCB Unit. 97
even if the power is turned
on again.

(14) When “BC READ ERROR” is displayed

step cause/failed check item if action see
area page
YES Go to step 2. -
Is the barcode printed on
1 Document Change the document to
the document? NO -
the proper one.
YES Go to step 3. -
2 Document Is the barcode bad printing?
NO Print barcode again. -
Is the barcode valid? (1 to YES Go to step 4. -
3 Document
80) NO Print valid barcode. -
Attempt to read the test
4 CCD NG Replace the CCD unit. 68
sheet.

120 S2-Y1540-0
 Chapter 6 1 Troubleshooting

(15) When “REG MARK ERROR” is displayed

step cause/failed check item if action see
area page
YES Go to step 2. -
Is the REG mark printed on
1 Document Change the document to
the document? NO -
the proper one.
Is the REG mark bad YES Go to step 3. -
2 Document
printing? NO Print REG mark again. -
YES Go to step 4. -
3 Document Is the REG mark valid?
NO Print valid REG mark. -
Attempt to read the test
4 CCD NG Replace the CCD unit. 68
sheet.

S2-Y1540 -0 121
Chapter 6 2 Conditions for the Error Detection

2 Conditions for the Error Detection

No paper
PPS1 is in the “light through” state when the <START> or <TEST> key is pressed.
J2 Feed tray
Both the elevator lower/upper limit switches are turned on.
J3 Feed error
The paper does not reach the PPS2 even if the feeding operation is performed for three times.
J4 Slitter
The paper does not reach the PPS3 even if it is fed by 400 mm after passing through the
PPS2.
J5 Cut.crease
The PPS3 is kept in the “light blocked” state even if the paper is fed by 820 mm after the cut
and crease process being completed.
The paper does not reach the PPS4 even if it is fed by 75 mm after the cut and crease process
being completed.
J6 Exit tray
The PPS4 is kept in the “light blocked” state even if the paper is fed by “registration paper
length + 300 mm” during processing.
J7 Waste box
The margin jam sensor is in the “light blocked” state for the configured period (800 ms) during
processing.
E00 Main-Panel
The main panel does not respond to the inquiry from the control panel within 6 seconds.
E01 CCD
A communication error occurs in the barcode scanner operation.
E02 Elevator
After the driving signal of the elevator is output, it dose not reach either the upper or lower
sensor within 10 seconds.
E03 Crease lower
The encoder output does not change (H/L) even if the creaser lower blade motor is started.
The HP of the lower blade cannot be detected within 10 seconds after the creaser-driving
signal is output.
E04-06 Memory error
There is no response from the memory (write/read error)
E07 Connect error
The connection between the main PCB and drive PCB is incorrect.
The input to the main PCB from the drive PCB cannot be confirmed.

E08 FPGA ERROR

Program writing is not successful.

122 S2-Y1540-0
 Chapter 6 2 Conditions for the Error Detection

Slitter 1-6 lock

Within 12 seconds after the slitter driving signal is output, the slitter does not reach the HP or it
does not move from the HP after reaching the HP (detection period: 12 seconds).
Cutter lock
Within 2 seconds after the cutter driving signal is output, the cutter does not reach the HP or it
does not move from the HP after reaching the HP.
Crease lock
Within 2 seconds after the creaser upper blade driving signal is output, the creaser upper
blade does not reach the HP or it does not move from the HP after reaching the HP.
Document in machine
In the standby mode, the PPS2 to PPS4 and margin jam sensor are in the “light blocked” state.
Cover open
The interlock switch is turned off when processing is started or during processing.
Double feed
The ultrasonic sensor exceeds the threshold value.
JOB error
An unsupported job is registered.
USB error
A USB communication error occurs.
Gutter deflector
The Gutter sensor is turned on when a job that does not need “Gutter” is registered.
BC error 1
Barcode reading is not successful.
BC error 2
The job printed in the barcode is not registered.
BC error 3
The check digit is not correct.
REG error 1
Particles of dirt adhere to the paper, or the lead mark cannot be read properly.
6
REG error 2
The REG mark cannot be read (not printed).
REG error 3
The side mark cannot be read properly.
REG error 4
The correction using REG mark causes the slitter to go beyond the limited area.
CCD read error
Both the barcode and REG mark cannot be identified using CCD while they are turned on.
Document in waste box
The margin jam sensor is in the “light blocked” state for more than the configured period.

S2-Y1540 -0 123
Chapter 6 3 Major Cause and Preventive Action for the Paper Jam

3 Major Cause and Preventive Action for the Paper Jam

Avoid using the following types of paper:
• Torn paper or paper with large holes
• Paper held together with a clip or staples
• Substantially curled, wavy, or partially folded paper
• 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 inadequate adhesion
• Paper with edges on the cutting surface

124 S2-Y1540-0
 Chapter 6 4 Slitter Blade Intersection Correction

4 Slitter Blade Intersection Correction

When a heavy weight document is jammed in the margin slitter area and the center slitter area, if
you pull out the document by force, the slitter upper blade and the lower blade may intersect each
other. Also, when the document cannot be slit or conveyed, the blades may have intersected.
In this case, follow the procedures below to correct the upper blade or lower blade position.

● In Case of Center Slitter 3 (Example)

1. Move the center slitters to the center of the module.

Slitter

2. Loosen the hexagon socket head cap screw

securing the lid of the slitter with the intersecting
blade. (The right figure shows the slitter 3.)
Lid
REFERENCE
• Do not remove the screw of the lid securing the
eccentric pin. Hexagon socket
6
• Do not loosen the hexagon socket head cap screw head cap screw
excessively. The screw will drop off.

3. Insert the shaft into the hole of the lid while sliding
the lid upward.

REFERENCE
Shaft
• Margin slitters 1 and 2:
Slide the lid of the lower blade downward.
• Center slitters 3 and 4: Lid
Slide the lid of the upper blade upward.
• Center slitters 5 and 6:
Slide the lid of the lower blade downward.

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Chapter 6 4 Slitter Blade Intersection Correction

4. Push the shaft in the direction of the arrow to

correct the intersecting upper blade.

REFERENCE
The right figure shows that the upper blade and the
lower blade intersect.
Pushing the shaft in without sliding the lid may
damage the upper blade and the lower blade.

REFERENCE
The right figure shows that the blade intersection is
corrected and the blades are in the normal position.

5. Tighten the hexagon socket head cap screw to

secure the lid.

Lid

Hexagon socket
head cap screw

6. Move the slitter which blade intersection has been

corrected to its home position in HELP mode: 31.

7. Check that the slitter home position is detected

correctly in HELP mode: 11.

126 S2-Y1540-0
Chapter 7 HELP Mode
1 HELP Mode List ...................................... 128
2 Accessing the HELP Mode ..................... 129
3 Finishing the HELP Mode ....................... 129
4 Setting the Other HELP Mode No........... 129
5 Accessing the Service Person JOB ........ 129
6 HELP Mode Description ......................... 130

7
Chapter 7 1 HELP Mode List

1 HELP Mode List

No. Function Category Page
(1) Display the ROM (FPGA) version. ROM version display
HELP00 130
(2) ROM version upgrade ROM version upgrade
(1) Display the count
HELP02 counter 133
(2) Reset the count
HELP04 (1) Display the jam count (reset) counter 135
HELP07 (1) Display the error count (reset) counter 136
HELP11 (1) Sensor switch check sensor switch check 137
HELP13 (1) DIP switch check switch check 138
HELP15 (1) Double feed detection check sensor check 139
HELP16 (1) Control panel check check 140
HELP17 (1) Paper feed elevator operation testv operation test 141
HELP18 (1) Fan motor operation test operation test 142
(1) Feed motor operation test
HELP19 operation test 143
(2) Shutter solenoid operation test
HELP20 (1) Compressor operation test operation test 144
HELP26 (1) Slitter operation test operation test 145
HELP27 (1) Creaser upper blade motor operation test operation test 146
HELP28 (1) Creaser lower blade motor operation test operation test 147
HELP29 (1) Cutter motor operation test operation test 148
HELP31 (1) Slitter operation test (1~ 6) operation test 149
HELP41 (1) Main motor operation test operation test 150
HELP43 (1) Clear the JOB, counter clear the memory 151
HELP45 (1) REG. mark read out position adjustment adjustment 152
HELP46 (1) Cutting position adjustment adjustment 153
HELP47 (1) Creasing position adjustment adjustment 154
HELP48 (1) Creasing depth adjustment adjustment 155
HELP49 (1) Margin and center slitter positions adjustment adjustment 156
HELP50 (1) Slit positions auto adjustment adjustment 157
HELP52 (1) Main motor transfer distance adjustment adjustment 159
HELP58 (1) Adjust the suction fan air volume adjustment 160
HELP59 (1) Adjust the margin jam detecting sensor adjustment 161
HELP60 (1) Optional function setting setting 162
HELP61 (1) Serial number setting setting 163
HELP62 (1) Display the error record display 164
LCD panel contrast
HELP62 (1) LCD panel contrast adjustment 165
adjustment
(User customize
HELP98 (1) Special setting 166
function)

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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, and hold down the (Left) and (Right) JOG keys simultaneously.
In about 10 seconds, “00: ROM VERSION” appears on the display with the beep sound.

3. Input the relevant “HELP Mode No.” that you want to check or change by the NUMERIC keys.
e.g.: To access the HELP Mode “H-11”, input the number by pressing “1”, “1”.

Alternatively, “HELP Mode No.” is selected by using the Cursor (Up/Down) key. Holding down
the key can select HELP Mode automatically as well.

4. Press the <START> key. The “HELP Mode” specified in 3 above is displayed.
Follow the procedure described under the corresponding “HELP Mode No.”

Continuously pressing the RETURN key and the CURSOR (Down) key simultaneously can
reset the machine to the standby mode.

3 Finishing the HELP Mode

Turn off the power switch to finish the HELP mode.

4 Setting the Other HELP Mode No.

Press the STOP key to return to the selection screen of the HELP mode.
Input the “HELP Mode No.” that you want to check or change by the NUMERIC keys.

7
5 Accessing the Service Person JOB
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 CURSOR (Up) key and the CLEAR key
simultaneously.
The machine is put in the standby mode with the “pip” sound.

3. Input the “Service person JOB No.” to be checked by using the NUMERIC keys.
e.g.: To access the Service person JOB “81”, input the number by pressing “8”, “1”.

4. Press the TEST key, and the JOB will be implemented.

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6 HELP Mode Description

HELP Mode: 00

1. Function
(1) ROM version display
• Main: The ROM version of the Main PCB is displayed. H00 Version ck.▼
• Panel: The ROM version of the control panel PCB is displayed. Main:V X.XX
Panel:V X.XX
SET:Update

(2) ROM version upgrade

2-1. DDL-1/DDL-2 version upgrade
2-2. USB version upgrade
• The main PCB and the panel PCB are upgraded.

2. Operating Procedure
(1) ROM version display
1. Access the HELP Mode, and press the <START> key . H00 Version ck.▼
Main: The ROM version of the Main PCB is displayed. Main:V X.XX
Panel: The ROM version of the control panel PCB is displayed.
Press the DOWN cursor key. Panel:V X.XX
FPGA: FPGA is displayed. SET:Update
2. Press the STOP key. It will return to the HELP Mode selection
screen.

(2) ROM version upgrade

2-1. DDL-1/DDL-2 version upgrade

Upgrading the ROM needs the downloader. (DDL-1/DDL-2)

1. When the machine is in use, put it in the standby mode and turn
off the power.
2. Loosen the screw, and remove the connector cover specified for
version upgrade.
3. Connect the connector of downloader to the connector specified
for version upgrade.
4. Turn on the power switch.
5. Hold down the (left) and (right) JOG keys simultaneously.
“H00 : Version ck” appears on the LCD panel with beeping sound.
6. Press the SET key. The machine enters standby mode of “ROM
version upgrade”.

For more details, see the instruction manual of the downloader.

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2-2. USB version upgrade

The USB Serial Converter is a software necessary for upgrading product via computer.
Operating system: Windows 8 (32bit/64bit)
Windows 7 (32bit/64bit)
Windows VISTA (32bit/64bit)
Windows XP Professional/Home Edition
Windows 2000 Professional
Interface: USB port (USB2.0/1.1)
The USB Serial Converter is not available in Macintosh.

1. When the machine is in use, put it in the standby mode and turn
off the power.

2. Connect your computer and the DC-616 with the USB cable.

3. Turn on the power switch.

Hold down the (Left) and (Right) JOG keys simultaneously. H00 Version ck.▼
“H00 : Version ck” appears on the LCD panel with beeping sound. Version ck

4. Press the <START> key to check the version of the main PCB
unit and the panel PCB unit. H00 Version ck.▼
Main:V XX.XX
Total:V XX.XX
Reset: XXXXXXXX

5. Press the SET key to enter upgrading mode. 7

REFERENCE
Preparing for
Click [Cancel] if “Completing the device driver installation
wizard” dialog appears on your computer. software update

6. Click [Duplo download utility] folder, and double-click [Duplo

download utility. exe].

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7. Select [USB] and click [OK].

8. Click [OPEN].

9. Select a file, and click [OPEN].

10. [Normal] is selected.

Click [Start]. Upgrading starts.

11. When the download completes, the message [Complete]

appears.
Click [OK].

12. Turn off the power of DC-616, then turn on the power again.

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HELP Mode: 02
1. Function
(1) Display the count
• Total number of paper feed is displayed in 8 digits numeral. H02 Total count▼
Paper count
Total: XXXXXXXX
Reset: XXXXXXXX

• Total number of cutting is displayed in 8 digits numeral.

H02 Total count▼
Cut count
Total: XXXXXXXX
Reset: XXXXXXXX

• Total number of crease is displayed in 8 digits numeral. H02 Total count▼

Crease count
Total: XXXXXXXX
Reset: XXXXXXXX

• Paper feed time is displayed. H02 Total count▼

Operating count
Total: XXXXhXXm
Reset: XXXXhXXm
7
(2) Reset the count
• The reset count is reset.

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2. Operating Procedure
(1) Display the count

1. Access the HELP Mode “02”, and press the <START> key.

2. Press the UP/DOWN cursor key to switch pages.

Total: Total count is shown.

3. Press the <STOP> key. It will return to the HELP Mode selection
screen.

(2) Reset the count

1. Access the HELP Mode “02”.

2. Continuously press the <C> in the NUMERIC key for about

3 seconds, and the reset count will be reset with the beeping
sound.

REFERENCE
Total count cannot be reset.

3. Press the <STOP> key. It will return to the HELP Mode selection
screen.

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HELP Mode : 04
1. Function
(1) Display on the jam count
• Display the jam count of each item. H04 Jam count ▼

J4 Slitter
XXXX

2. Operating Procedure
(1) Check on the paper jam count

1. Access the HELP Mode “04”, and press the <START> key.

2. Press the UP/DOWN cursor key to switch pages.

J4 Slitter
J5 Cut.crease
J6 Exit tray
J7 Waste box
Slit 1 lock
Slit 2 lock
Slit 3 lock
Slit 4 lock
Slit 5 lock
Slit 6 lock
BC error 1
BC error 2
BC error 3
Reg error 1 7
Reg error 2
Reg error 3
Reg error 4
Double feed
Cutter lock
Creaser lock

3. Continuously press the <C> in the NUMERIC key for about 3

seconds, and selected error count will be reset with the beeping
sound.

4. Press the <STOP> key. It will return to the HELP Mode selection
screen.

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HELP Mode : 07
1. Function
(1) Display the error count
• Display the error count of each item.
H07 Error count▼
E01 CCD error
XXXX

2. Operating Procedure
(1) Display the error count

1. Access the HELP Mode “07”, and press the <START> key.

2. Press the UP/DOWN cursor key to switch pages.

E01 CCD error
E02 Elve. error
E03 Cre. lower

3. Continuously press the <C> in the NUMERIC key for about 3

seconds, and selected error count will be reset with the bleeping
sound.

4. Press the <STOP> key. It will return to the HELP Mode selection
screen.

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HELP Mode : 11
1. Function
(1) Sensor switch check
• Status of the sensor switch ON: 0 / OFF: 1 is displayed. H11 Sens. ck. ▼

PPS1 X
PPS2 X
PPS3 X

2. Operating Procedure
(1) Sensor switch check

1. Access the HELP Mode “11”, and press the <START> key.

2. Press the UP/DOWN cursor key to switch pages.

3. Press the <STOP> key. It will return to the HELP Mode selection
screen.

Page Sensor Display

Page 1 PPS1 0: light blocked 1: light through
PPS2
0: light through 1: light blocked
PPS3
Page 2 PPS4
Slit 1 hp 0: light through 1: light blocked
Slit 2 hp
Page 3 Slit 3 hp
Slit 4 hp
Slit 5 hp
0: light through 1: light blocked 7
Page 4 Slit 6 hp
Cut hp 0: light through 1: light blocked
Crease up hp
Page 5 Crease low. hp
0: light through 1: light blocked
Crease enc
Elev. dw. SW 0: ON 1: OFF
Page 6 Elev. low. SW 0: OFF 1: ON
Level sensor 0: light through 1: light blocked
Cover SW 0: OFF 1: ON
Page 7 Gutter on/off
Trim waste 0: light through 1: light blocked
Perf Sensor

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HELP Mode : 13
1. Function
(1) DIP switch check
• Status of the DIP switch is displayed. H13 Dip sw ck. ▼

• Because DIP SW1 is used for version-up, it cannot be verified Dip sw:1 2 3 4
in HELP Mode “13”.
X X X X

2. Operating Procedure
(1) DIP switch check

1. Access the HELP Mode “13”, and press the <START> key.
• Status of the DIP switch ON/OFF is displayed.
1: ON
2: OFF

2. Press the <STOP> key. It will return to the HELP Mode selection
screen.

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HELP Mode : 15
1. Function
(1) Double feed detection check
• Double feed detection result is verified. H15 D feed check
Value: X
0:1sheet
1: more

2. Operating Procedure
(1) Double feed detection check

1. Access the HELP Mode “15”, and press the <START> key.
• The double feed detection result is displayed:
0: one sheets of paper
1: two sheets of paper or more

2. Press the <STOP> key. It will return to the HELP Mode selection
screen.

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HELP Mode : 16
1. Function
(1) Control panel check
• Check that the NUMERIC keys on the control panel work H16 Panel check
correctly. Key:Buzzer on
• Check that the buzzer of the keys on the control panel sounds
correctly. SET:LCD LED on
• Check that the LEDs on the LED PCB function correctly.

2. Operating Procedure
(1) Control panel check

1. Access the HELP Mode “16”, and press the <START> key.

2. Press the NUMERIC keys. A buzzer sounds.

3. The LCD panel will be black while pressing the SET key.
The LED on the control panel and on the LED PCB blinks.

4. Press the <STOP> key. It will return to the HELP Mode selection
screen.

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HELP Mode : 17
1. Function
(1) Paper feed elevator operation test
• The correct operation of the paper feed elevator is verified. H17 Elevator ck.
• The status of the paper level sensor and the elevator lower Level sen. : X
limit switch are verified.
Low sw : X
↑↓:Up,dw

2. Operating Procedure
(1) Paper feed elevator operation test

1. Access the HELP Mode “17”, and press the <START> key.

2. Run the elevator by pressing the CURSOR (Up/Down) keys.

3. Press the CURSOR (Right/Left) keys to turn the pages.

4. The status of the sensor while the elevator is operating is verified.

5. Press the <STOP> key. It will return to the HELP Mode selection
screen.

Sensor switch Elevator Elevator

upper limit lower limit
Level sen. 1: light blocked 0: light through
Low SW 0: OFF 1: ON
7

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HELP Mode : 18
1. Function
(1) Fan motor operation test
• The proper function of suction motor is verified. H18 Air check
• The proper function of blower motor is verified. ↑: Suction fan
↓:Blow out fan

2. Operating Procedure
(1) Fan motor operation test

1. Access the HELP Mode “18”, and press the <START> key.

2. Press the UP/DOWN cursor key, and operate the fan motor.
• UP cursor key: Suction fan
• DOWN cursor key: Blower fan

3. Press the <STOP> key. It will return to the HELP Mode selection
screen.

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HELP Mode : 19
1. Function
(1) Feed motor operation test
• Operate the feed motor. H19 Feed check
(2) Shutter solenoid operation test :Feed belt on
• Operate the shutter solenoid.
↓:Sol. on

2. Operating Procedure
(1) Feed motor operation test

1. Access the HELP Mode “19”, and press the <START> key.

2. Press the <JOG> key, and operate the feed motor.

3. Press the <STOP> key. It will return to the HELP Mode selection
screen.

(2) Shutter solenoid operation test

1. Access the HELP Mode “19”, and press the <START> key.

2. Press the DOWN cursor key, and operate the shutter solenoid.

3. Press the <STOP> key. It will return to the HELP Mode selection
screen.

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HELP Mode : 20
1. Function
(1) Compressor operation test
• Operate the compressor. H20 Air knife
↑:On

2. Operating Procedure
(1) Compressor operation test

1. Access the HELP Mode “20”, and press the <START> key.

2. Press the UP cursor key, and operate the compressor.

3. Press the <STOP> key. It will return to the HELP Mode selection
screen.

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HELP Mode : 26
1. Function
(1) Slitter operation test
• Move the slitter to its home position. H26
• The proper function of the slitter operation is verified. Slitter run ck.
↑:Hp ck.
↓:Run test

2. Operating Procedure
(1) Slitter home position check

1. Access the HELP Mode “26”, and press the <START> key.

2. Press the UP/DOWN cursor key, and move the slitter.

UP cursor key : Move to home position.

DOWN cursor key: Move to the right or the left.
(10 back and forth)

3. Press the <STOP> key. It will return to the HELP Mode selection
screen.

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HELP Mode : 27
1. Function
(1) Creaser upper blade motor operation test
• The proper function of the creaser upper blade motor is verified. H27 Cre. mot ck
• The proper function of the creaser upper blade home position Cre. hp sen: X
sensor is verified.

↑↓:cre. mot on

2. Operating Procedure
(1) Creaser upper blade motor operation test

1. Access the HELP Mode “27”, and press the <START> key.

2. Press the UP/DOWN cursor key, and operate the motor.

UP cursor key: normal rotation
DOWN cursor key: reverse rotation

3. Verify if the sensor detects.

0: light through
1: light blocked

4. Press the <STOP> key. It will return to the HELP Mode selection
screen.

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HELP Mode : 28
1. Function
(1) Creaser lower blade motor operation test
• The proper function of the creaser lower blade motor is verified. H28 Cre. low ck.
• The proper function of the creaser lower blade home position is Cre. low.sen. : X
verified.
Cre. enc.sen. : X
↑↓:cre. mot. on

2. Operating Procedure
(1) Creaser lower blade motor operation test

1. Access the HELP Mode “28”, and press the <START> key.

2. Press the UP/DOWN cursor key, and operate the motor.

UP cursor key: normal rotation

DOWN cursor key: reverse rotation

3. Check that the sensors detect properly.

0: light through
1: light blocked

4. Press the <STOP> key. It will return to the HELP Mode selection
screen.

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HELP Mode : 29
1. Function
(1) Cutter motor operation test
• The proper function of the cutter motor is verified. H29 Cut mot ck.
Cut hp.sen. : X
Cut enc.sen. : X
↑↓:Cut mot. on

2. Operating Procedure
(1) Cutter motor operation test

1. Access the HELP Mode “29”, and press the <START> key.

2. Press the UP/DOWN cursor key, and operate the motor.

UP cursor key: normal rotation

DOWN cursor key: reverse rotation

3. Check that the sensors detect properly.

0: light through
1: light blocked

4. Press the <STOP> key. It will return to the HELP Mode selection
screen.

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HELP Mode : 31
1. Function
(1) Slitter operation test (1~6)
• The proper function of the slitter motor is verified. H31 MSL&SLOT mot
Slit: 1 2 3 4 5 6
←→:Select
↑↓ : Slit on

2. Operating Procedure
(1) Slitter motor operation test

1. Access the HELP Mode “31”, and press the <START> key.

2. Select the slitter by pressing the RIGHT/LEFT cursor key.

3. Move the selected slitter by pressing the UP/DOWN cursor key.

UP cursor key: Move to the opposite side.
DOWN cursor key: Move to the control panel side.

4. Press the <STOP> key. It will return to the HELP Mode selection
screen.

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HELP Mode : 41
1. Function
(1) Main motor operation test
• The proper function of the main motor is verified. H41 Main mot.ck.
:Main mot.on

2. Operating Procedure
(1) Main motor operation test

1. Access the HELP Mode “41”, and press the <START> key.

2. Activate the main motor by pressing the <JOG> and <JOG>

keys.

3. Press the <STOP> key. It will return to the HELP Mode selection
screen.

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HELP Mode : 43
1. Function
(1) Clear the JOB, counter
• The contents and history of the JOB (01-80) and the reset H43 Initialize
counter are reset. ↑+↓:All clear
• The contents and history of the JOB (01-80) is reset.
SET+C:JOB clear

2. Operating Procedure
(1) Clear the counter

1. Access the HELP Mode “43”, and press the <START> key.

2. Press the <SET> key and the <C> key simultaneously to reset
the JOB. “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 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

3. Press the UP/DOWN cursor key simultaneously to reset the JOB

and the counter.
7
4. “Initialize now!!” appears on the LCD panel and the HELP Mode “43”
exits automatically.

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HELP Mode : 45
1. Function
(1) REG. mark read out position adjustment
• REG. mark read-out position is adjusted. H45
PPS2 CCD dist.
S: XX . X L: XX . X
JOB: XX

2. Operating Procedure
(1) REG. mark read out position adjustment
H45
1. Access the HELP Mode “45”, and press the <START> key. PPS2 CCD dist.
2. Select “JOB” by pressing the UP/DOWN cursor key. S: XX . X L: XX . X
JOB: XX
3. Press the “1” key, and select the Service person JOB 87.

4. Load a check sheet on the feed tray, and press the <TEST>
key. H45
PPS2 CCD dist.
5. Enter numerical value into “S” and “L” so that a cut position of
S: XX . X L: XX . X
2 mm (+/- 0.2 mm) from the lead mark/side mark is set.
JOB:87
REFERENCE
Entering “-1.0” causes the cut position to be shifted by 1.0
2mm
6. Press the <SET> key , and store the adjustment information in
the memory. 2mm

7. Press the <STOP> key. It will return to the HELP Mode

selection screen.

REFERENCE
Perform the following procedures when you replace the CCD.
1. Access the HELP Mode “H45”, and press the <START> key.
2. Select “CCD read” by pressing the UP/DOWN cursor key.
3. Load a check sheet on the feed tray, and press the <TEST>
key. Check the values of “S” and “L” are 10.0.

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HELP Mode : 46
1. Function
(1) Cutting position adjustment
• The cutting position is adjusted. H46
PPS3 -Cut dist.
Distance: XXX
SET:Save

2. Operating Procedure
(1) Cutting position adjustment

1. Set the skew adjusting dial at “0”.

2. Access the HELP Mode “46”, and press the <START> key.

3. Cut the adjustment paper (S2-Y1040) by pressing the <TEST>

key.
* The paper is cut applying the Service person JOB83.

4. Measure the cut paper length.

5. Enter the adjustment value by pressing the NUMERIC key.

The cutting position moves by 0.1 mm when the adjustment value
is changed by 1.

IMPORTANT
Cutting position change will automatically result in the creasing
position change. Always readjust the creasing position after the
7
cutting position
change (HELP: 47).

IMPORTANT
Cutting position is reset to the default value by continuously
pressing the <C> key. (This is not a factory setting.)

6. Press the <SET> key, and store the adjustment information in the
memory.

7. Press the <STOP> key. It will return to the HELP Mode

selection screen.

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HELP Mode : 47
1. Function
(1) Creasing position adjustment
• The creasing position is adjusted. H47
Cut-Crease dist.
Distance: XXX
SET:Save

2. Operating Procedure
(1) Creasing position adjustment

1. Set the skew adjusting dial at “0”.

2. Access the HELP Mode “47”, and press the <START> key.

3. Cut the adjustment paper (S2-Y1040) by pressing the <TEST>

key.
* The paper is cut applying the Service person JOB83.

4. Measure the finished creasing position.

5. Enter the adjustment value by pressing the NUMERIC key.

The creasing position moves by 0.1 mm when the adjustment
value is changed by 1.

REFERENCE
Creasing position is reset to the default value by continuously
pressing the <C> key. (This is not a factory setting.)

6. Press the <SET> key, and store the adjustment information in the
memory.

7. Press the <STOP> key. It will return to the HELP Mode selection
screen.

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HELP Mode : 48
1. Function
(1) Creasing depth adjustment
• The creasing depth is adjusted. H48 Crease depth
High Mid Low
XXX XXX XXX
SET:Save

2. Operating Procedure
(1) Creasing depth adjustment

1. Set the skew adjusting dial at “0”.

2. Access the HELP Mode “48”, and press the <START> key.

3. Cut the adjustment paper by pressing the <TEST> key.

* The paper is cut applying the Service person JOB83.

4. Measure the finished creasing depth.

5. Select the desired depth by pressing the UP/DOWN cursor key.

6. Enter the adjustment value by pressing the NUMERIC key.

(0-150)
The slitter position moves by 0.1 mm when the adjustment value
is changed by 1.

IMPORTANT
7
The creasing depth is adjustable in 3-levels.
Thus the adjustment values shall be set to be HIGH > MID > LOW.

IMPORTANT
Reference depth: Total thickness - max. 0.4 - 0.45 (at 230gsm
sheet).
Creasing depth is reset to the default value by continuously
pressing the <C> key. (This is not a factory setting.)

7. Press the <STOP> key. It will return to the HELP Mode

selection screen.

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HELP Mode : 49
1. Function
(1) Margin and center slitter positions adjustment
• Positions of each margin (S1, S2) and center slitter (S3 – S6) H49 Slit adjust
are adjusted. XXX XXX XXX
XXX XXX XXX

JOB:MSL,SLOT3,4

2. Operating Procedure
(1) Margin and center slitter positions adjustment

1. Set the skew adjusting dial at “0”.

2. Access the HELP Mode “49”, and press the <START> key.

3. Cut the adjustment paper (S2-Y1040) by pressing the <TEST>

key.
* The paper is cut applying the Service person JOB84.

4. Measure the cut paper width.

5. Enter the adjustment value by pressing the NUMERIC key.

The slitter position moves by 0.1 mm when the adjustment value
is changed by 1.
IMPORTANT
The home position for the slitters 1, 3, and 5 is on the opposite side
of the control panel, while the home position for the slitters 2, 4, and
6 is on the control panel side.

6. Press the <SET> key, and store the adjustment information in the
memory.

7. Press the <STOP> key. It will return to the HELP Mode election
screen.

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HELP Mode : 50
1. Function
(1) Slit positions auto adjustment
• Positions of each margin (S1, S2) and center slitter (S3 – S6) are H50 Sl.auto adj.
adjusted automatically. MSL : XX . XX mm
The entered values on HELP Mode “49” are adjusted automatically.
1: XX . XX mm
2: XX . XX mm

2. Operating Procedure
(1) Slit auto adjustment
• Apply Service JOB: 84 for checking the slit auto adjustment.

1. Set the skew adjusting dial at “0”.

2. Access the HELP Mode “49”, and press the <START> key.

3. Load a check sheet on the feed tray, and press the <TEST> key.
* The test RUN is proceeded by the setting of Service person
JOB84.

4. Measure the processed slit positions.

5. Press the <STOP> key. The HELP mode “49” will exit.

6. Access the HELP Mode “50” and press the <START> key.

7. Press the UP/DOWN cursor key, and input the values of each
finished paper width. 7
MSL:xx.xx mm MSL:xx.xxmm
Paper run
1:xx.xx mm 1:xx.xxmm
direction
2:xx.xx mm 2:xx.xxmm
3:xx.xx mm 3:xx.xxmm Slit positions
4:xx.xx mm 4:xx.xxmm
5:xx.xx mm 5:xx.xxmm

8. Press the <SET> key , then DC-616 calculates the magnification

automatically for working out the adjustment values of HELP
Mode “50”. And also the values are input on HELP Mode “49”.

S2-Y1540 -0 157
Chapter 7 6 HELP Mode

9. Proceed the Service person JOB84 again to check for slitters run
following the adjustment values properly.

The setting of Service person JOB84

MSL: 25 mm
1: 50 mm
2: 50 mm
3: 50 mm
4: 50 mm
5: 50 mm
* If the slitter position is still incorrect, go back to the step 7 and
attempt to re-adjust.

10. Press the <STOP> key. It will return to the HELP Mode selection
screen.

158 S2-Y1540-0
 Chapter 7 6 HELP Mode

HELP Mode : 52
1. Function
(1) Main motor transfer distance adjustment
• Transfer distance of the main motor is adjusted. H52
Main motor adj.
XXX . XX
SET:Save

2. Operating Procedure
(1) Main motor transfer distance adjustment

1. Set the skew adjusting dial at “0”.

2. Access the HELP Mode “52”, and press the <START> key.

3. Cut the adjustment paper by pressing the <START> key.

* The paper is cut applying the Service person JOB 91.

4. Measure the cut paper width.

5. Enter the adjustment value by pressing the NUMERIC key.

REFERENCE
The transfer distance will get shorter as the adjustment value
becomes smaller.
The transfer distance will get longer as the adjustment value
becomes larger.
7
Adjustment value is reset to the default value by continuously
pressing the CLEAR key.
(This is not a factory setting.)

6. Press the <SET> key, and store the adjustment information in the
memory.

7. Press the <STOP> key. It will return to the HELP Mode selection
screen.

S2-Y1540 -0 159
Chapter 7 6 HELP Mode

HELP Mode : 58
1. Function
(1) Adjust the suction fan air volume.
H58 Fan duty
Max Mid Min
XXX XXX XXX
SET:Save

2. Operating Procedure
(1) Adjust the suction fan air volume.

1. Access the HELP Mode “58”, and press the <START> key.

2. Select the desired air volume by pressing the RIGHT/LEFT

cursor key.

3. Enter the adjustment value by pressing the NUMERIC key.

4. Press the <SET> key, and store the adjustment information in the
memory.

5. Press the <STOP> key. It will return to the HELP Mode selection
screen.

160 S2-Y1540-0
 Chapter 7 6 HELP Mode

HELP Mode : 59
1. Function
(1) Adjust the margin jam detecting sensor.
H59
J7 Time Set
XXXXmsec
Set:Save

2. Operating Procedure
(1) Adjust the margin jam detecting sensor.

1. Access the HELP Mode “59”, and press the <START> key.

2. Press the UP / DOWN cursor key to adjust the sensor detecting

time.
Each time the cursor key is pressed, the detecting time will increase
or decrease by 20 msec.
<C> quick press: sensor OFF
<C> continuous press: return to the default (800 msec)

3. Press the <SET> key, and store the adjustment information in the
memory.

5. Press the <STOP> key. It will return to the HELP Mode selection
screen.

S2-Y1540 -0 161
Chapter 7 6 HELP Mode

HELP Mode : 60
1. Function
(1) Optional function setting
• Air knife H60 Option
• Double feed detecting sensor Air knife X
• CCD
• Perforation unit Dl.feed sen X
CCD X

2. Operating Procedure
(1) Optional function setting
1. Access the HELP Mode “60”, and press the <START> key.

2. Select the desired option by pressing UP/DOWN cursor key.

3. Change the setting by pressing the NUMERIC key.

0: Invalid
1: Valid

4. Press the <SET> key, and store the adjustment information in the
memory.

5. Press the <STOP> key. It will return to the HELP Mode selection
screen.

162 S2-Y1540-0
 Chapter 7 6 HELP Mode

HELP Mode : 61
1. Function
(1) Serial number setting
• Serial number is set. H61
Set serial no.
XXXXXXXXX
SET:Save

2. Operating Procedure
(1) Serial number setting

1. Access the HELP Mode “61”, and press the <START> key.

2. Enter the serial number by pressing the NUMERIC key.

3. Press the SET key, and store the serial number in the memory.

4. Press the <STOP> key. It will return to the HELP Mode selection
screen.

S2-Y1540 -0 163
Chapter 7 6 HELP Mode

HELP Mode : 62
1. Function
(1) Display the error record.
• Error record is displayed in order. H62 Err record ▼
(Latest 3 errors) Latest
Error No: 0006-DA
JOB No:01

2. Operating Procedure
(1) Display the error record.

1. Access the HELP Mode “62”, and press the <START> key.

2. Change the error contents by pressing the UP/DOWN cursor key.

Error No: Number of the error

JOB No: JOB number which the error occurred

3. Press the <STOP> key. It will return to the HELP Mode selection
screen.

164 S2-Y1540-0
 Chapter 7 6 HELP Mode

HELP Mode : 63
1. Function
(1) LCD panel contrast adjustment
• LCD panel contrast is adjusted. H63
LCD contrast
XX
SET:Save

2. Operating Procedure
(1) LCD panel contrast adjustment

1. Access the HELP Mode “63”, and press the <START> key.

2. Change the adjustment value by pressing the CURSOR (Right/

Left) keys.
CURSOR (Right): addition
CURSOR (Left): subtraction
The LCD panel becomes darker in color as the value increases.
Setting range: 12 to 40

REFERENCE
Adjustment value is reset to the default value (24) by continuously
pressing the CLEAR key.
(This is not a factory setting.)

3. Press the SET key, and store the adjustment information in the
memory. 7
4. Press the <STOP> key. It will return to the HELP Mode selection
screen.

S2-Y1540 -0 165
Chapter 7 6 HELP Mode

HELP Mode : 98
1. Function
(1) Special setting ▼
H98 Special

▼
● Cancelling limits of slit position, cut position, and paper width ▼

Cut limit off X

Slit limit off X

WidthLim.330.5 X

2. Operating Procedure
(1) Special setting
1. Access the HELP Mode “98”, and press the <START> key.

2. Select the item to be set by pressing the UP/DOWN cursor key.

Cut limit off: cancellation of cut position limit
Slit limit off: cancellation of slit position limit
WidthLim.330.5: cancellation of paper width limit (There is another
limit, which is mechanical limit of the feed guide, and conditions of use
for the slitter 2.)

3. Select and switch the function status by pressing the NUMERIC keys.
0 : limit enabled
1 : limit disabled

IMPORTANT
Even though “Slit limit off” is disabled, the following limits remain.
• Margin slit position: 55 mm or less from the edge of paper
• Distance between slitter 3 and slitter 4: 48 mm or more
Distance between slitter 5 and slitter 6: 48 mm or more

4. Press the <STOP> key. It will return to the HELP Mode selection
screen.

166 S2-Y1540-0
Chapter 8 Others
1 Position and Function of Electronic Parts.. 168
1. Switches .................................. 168
2. PPS sensors .............................. 169
3. Sensors .................................... 170
4. Motors, Fan, Solenoid .................. 171
5. PCB Units • Power Supply ............. 172
6. Others...................................... 173
8. Connector VR/Fuse Layout ........... 174
2 Service Person JOBs ....................... 178
3 Overall Wiring Layout ....................... 182

8
Chapter 8 1 Position and Function of Electronic Parts

1 Position and Function of Electronic Parts

1. Switches
5

4
7
2

No. Part Name

1 Elevator Lower Limit Switch
2 Interlock switch
3 Top cover Interlock switch
4 Cover switch
5 Elevator Lower Limit Switch
6 Elevator Upper Limit Switch
7 Exit Interlock switch

168 S2-Y1540-0
 Chapter 8 1 Position and Function of Electronic Parts

2. PPS sensors

2
1

5 7

No. Part Name

1 PPS1
2 PPS2 (Photo-emission)
3 PPS2 (Photo-detecting)
4 PPS3 (Photo-emission)
5 PPS3 (Photo-detecting)
8
6 PPS4 (Photo-emission)
7 PPS4 (Photo-detecting)

S2-Y1540 -0 169
Chapter 8 1 Position and Function of Electronic Parts

3. Sensors

2 17 13
16
3
15

12
14
4 18

7 11
5
10

8
9

No. Part Name

1 CCD
2 Ultrasonic Sensor
3 Paper Level Sensor
4 Margin Slitter 1 Home Position Sensor
5 Margin Slitter 2 Home Position Sensor
6 Margin Jam Detecting Sensor
7 Gutter ON / OFF sensor
8 Center Slitter 5 Home Position Sensor
9 Cutter Home Position Sensor
10 Creaser Lower Blade Encoder Sensor
11 Creaser Lower Blade Home Position Sensor
12 Creaser Upper Blade Home Position Sensor
13 Gutter ON / OFF sensor
14 Margin Jam Detecting Sensor
15 Center Slitter 6 Home Position Sensor
16 Center Slitter 4 Home Position Sensor
17 Center Slitter 2 Home Position Sensor
18 Perforation Unit Detecting Sensor

170 S2-Y1540-0
 Chapter 8 1 Position and Function of Electronic Parts

4. Motors, Fan,Solenoid

1
5
6
7
8
14
9
10

11

12

13

No. Part Name

1 Main Motor Driver
2 Feed Motor
3 Suction fan
4 Shutter Solenoid
5 Blow out fan
6 Elevator Motor 8
7 Margin Slitter 1 Position Motor
8 Margin Slitter 2 Position Motor
9 Center Slitter 3 Position Motor
10 Center Slitter 4 Position Motor
11 Center Slitter 5 Position Motor
12 Center Slitter 6 Position Motor
13 Creaser Motor
14 Creaser Lower Blade Motor

S2-Y1540 -0 171
Chapter 8 1 Position and Function of Electronic Parts

5. PCB Units • Power Supply

2
3

7
4

No. Part Name

1 Panel PCB unit
2 Receive PCB
3 Oscillation PCB
4 USB connector board
5 Drive PCB Unit
6 Power supply unit
7 Main PCB unit
8 Main motor drive PCB unit

172 S2-Y1540-0
 Chapter 8 1 Position and Function of Electronic Parts

6. Others

8
1
2

7
4
6

No. Part Name

1 SSR
2 Fuse
3 Compressor 8
4 Relay PCB UNIT
5 Appliance inlet
6 Varistor
7 Terminal blocks

S2-Y1540 -0 173
Chapter 8 1 Position and Function of Electronic Parts

8. Connector VR/Fuse Layout

1. Main PCB Unit (S2-V500*)

CN3 CN4 CN2

CN9

CN5
CN8
CN7
CN6

CN14 CN1

2. Panel PCB Unit (S2-V311*)

CN1

174 S2-Y1540-0
 Chapter 8 1 Position and Function of Electronic Parts

3. DRIVE PCB Unit (S2-V321*)

CN6 CN10 CN11

CN8
CN9
CN4
CN5

CN3
CN2

CN1 CN7

4. Main Motor Drive PCB Unit (BZ008)

8
CN3

CN1 CN2

S2-Y1540 -0 175
Chapter 8 1 Position and Function of Electronic Parts

5. Power Supply Unit 24V (UA040)

CN51
CN1

6. Double Feed Detect PCB Unit

Oscillation PCB (P9-V303*) Receive PCB (P9-V305*)

Oscillation PCB

CN2

CN1

Receive PCB

CN1
CN3

CN2

176 S2-Y1540-0
 Chapter 8 1 Position and Function of Electronic Parts

7. USB PCB Unit (R8-V347*)

CN1

CN2
8. Fuse (0216002XP)
Rating of fuse : 250 V, 2 A

CAUTION
8
Fuse : Use the proper type of fuse when replacing. Otherwise, fire may occur.

S2-Y1540 -0 177
Chapter 8 2 Service Person JOBs

2 Service Person 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 enlargement H-47: Use to adjust the slit position. the position of the
right margin. (magnification) the parallelity and gutter deflector
distance of the crease. guide.
of H-52.
H-48: Use to adjust the
(using 650 exclusive depth of the crease.
paper)
JOB Name MARGIN CK H-52 CK1 CUT&CRE CK SLIT CK GUTTER CK
Paper size 297×420(A3) 320 x 650 297×420(A3) 297×420(A3) 297×420(A3)
JOB number 81 82 83 84 85
PAPER WIDTH 297 320 297 297 297
TOTAL LENGTH 420 650 420 420 420
Side Mark 0 0 0 0 0
Lead Mark 0 0 0 0 0
SLIT1 25 0 25 25 5
SLIT2 285 0 285 275 285
SLIT3 0 0 0 75 95
SLIT4 0 0 0 225 195
SLIT5 0 0 0 125 100
SLIT6 0 0 0 175 190
CUT01 0 20 20 0 0
CUT02 0 570 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
CUT16-25 0 0 0 0 0
CRE.01 0 0 120 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
CRE.11-20 0 0 0 0 0
PERF1 0 0 0 0 0
PERF2 0 0 0 0 0
AIR KNIFE OFF OFF OFF OFF OFF
SUCTION POWER MAX MAX MAX MAX MAX
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 FAST FAST FAST FAST

178 S2-Y1540-0
 Chapter 8 2 Service Person JOBs

Use to check plain Use to check Use to check Use to check Use to check
paper. REG. Mark REG. Mark skew of processing
Use to adjust function function perforation unit accuracy of
double-feed sensor. business cards.

JOB Name FEED CK REG. CK1 REG. CK2 PERF CK 50×85

Paper size 297×420(A3) 297×420(A3) 297×420(A3) 297×420 297×420(A3)
JOB number 86 87 88 89 90
PAPER WIDTH 297 297 297 297 297
TOTAL LENGTH 420 420 420 420 420
Side Mark 0 10 14 0 0
Lead Mark 0 10 14 0 0
SLIT1 0 8 12 10 25
SLIT2 0 285 289 290 275
SLIT3 0 0 0 0 75
SLIT4 0 0 0 0 225
SLIT5 0 0 0 0 125
SLIT6 0 0 0 0 175
CUT01 0 8 12 0 5
CUT02 0 0 0 0 90
CUT03 0 0 0 0 100
CUT04 0 0 0 0 185
CUT05 0 0 0 0 195
CUT06 0 0 0 0 280
CUT07 0 0 0 0 290
CUT08 0 0 0 0 375
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
CUT16-25 0 0 0 0 0
CRE.01 0 0 0 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
CRE.06
0
0
0
0
0
0
0
0
0
0
8
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
CRE.11-20 0 0 0 0 0
PERF1 0 0 0 30 0
PERF2 0 0 0 270 0
AIR KNIFE OFF OFF OFF OFF OFF
SUCTION POWER MAX MAX MAX MID MAX
REG. MARK OFF ON ON OFF OFF
SLIT GUIDE ON ON ON ON ON
AUTO CUT ON ON ON ON ON
CREASE DEPTH MID MID MID MAX MID
SPEED FAST FAST FAST FAST FAST

S2-Y1540 -0 179
Chapter 8 2 Service Person JOBs

Use to adjust the This is used to check Use to check Use to adjust the Use to check the
vertical enlargement the barcode reading performance. gutter deflector . 55 mm margin.
magnification) of and to reset the
H-52. (using SRA3 setting to the factory
exclusive paper) preset state.(Can only
be used in the service
JOB Mode)
JOB Name H-52 CK2 BARCODE CK DEEP BLUE 6UP GUTTER TEST MARGIN55 CK
Paper size 297×420(A3) 297×420(A3) 320×450 320×650 297×420
JOB number 91 93 94 95 96
PAPER WIDTH 297 297 320 320 297
TOTAL LENGTH 420 420 450 650 420
Side Mark 0 0 10 0 0
Lead Mark 0 0 10 0 0
SLIT1 0 0 10 10 55
SLIT2 0 0 300 300 285
SLIT3 0 0 100 100 0
SLIT4 0 0 210 210 0
SLIT5 0 0 110 110 0
SLIT6 0 0 200 200 0
CUT01 5 0 22 10 0
CUT02 405 0 225 325 0
CUT03 0 0 235 640 0
CUT04 0 0 438 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
CUT16-25 0 0 0 0 0
CRE.01 0 0 147 0 0
CRE.02 0 0 360 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
CRE.11-20 0 0 0 0 0
PERF1 0 0 0 0 0
PERF2 0 0 0 0 0
AIR KNIFE OFF OFF OFF OFF OFF
SUCTION POWER MAX MAX MAX MIN MAX
REG. MARK OFF OFF OFF OFF OFF
SLIT GUIDE ON ON OFF OFF ON
AUTO CUT ON ON ON ON ON
CREASE DEPTH MID MID MID MID MID
SPEED FAST FAST FAST SLOW FAST

180 S2-Y1540-0
 Chapter 8 2 Service Person JOBs

Use to check
center
crease on the
business
cards produced
from A3
paper.
JOB Name A3 58×85 CCR
Paper size 297×420
JOB number 98
PAPER WIDTH 297
TOTAL LENGTH 420
Side Mark 0
Lead Mark 0
SLIT1 3.2
SLIT2 293.2
SLIT3 61.2
SLIT4 235.2
SLIT5 119.2
SLIT6 177.2
CUT01 20
CUT02 105
CUT03 115
CUT04 200
CUT05 210
CUT06 295
CUT07 305
CUT08 390
CUT09 0
CUT10 0
CUT11 0
CUT12 0
CUT13 0
CUT14 0
CUT15 0
CUT16-25 0
CRE.01 62.5
CRE.02 157.5
CRE.03 252.5
CRE.04 347.5
CRE.05 0
CRE.06 0
CRE.07 0 8
CRE.08 0
CRE.09 0
CRE.10 0
CRE.11-20 0
PERF1 0
PERF2 0
AIR KNIFE OFF
SUCTION POWER MAX
REG. MARK OFF
SLIT GUIDE ON
AUTO CUT ON
CREASE DEPTH MAX
SPEED FAST

S2-Y1540 -0 181
 Chapter 8 3 Overall Wiring Layout

3 Overall Wiring Layout Overall Wiring Layout 1/2

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Model:DC-616

VX-52-1A3
Light green 1
ELEVATOR Light green 2
DOWN SW Option

Red 1 &1
3
White 2
Blue 3 $$%% 1
SLITTER HP3 2 Red 4 2
1 Purple 5 3
Blue 6 4
3
Red 7
&1 5 CCD
SLITTER HP5 2
Yellow 8
Blue 9 &1 6
7 1;
1 Red 10 8
Yellow 11 9

Red 1
Blue 12
Red 13 &1 10
3 White 2 Light blue 14
SLITTER HP1 2 Blue 3 Blue 15
1 Red 16
Yellow 17
1 Red 6 Blue 18
LEVEL 2 Yellow 7 Red 1 Red 19
3 Blue 8 CUTTER 3 Yellow 2 Green 20
2
1
Black
Black
1
2
Red
Light blue
9
10
HP 1
Blue 3 Green 21
22 Option
KYUSHI 2 Black 3 Blue 11 White 23
3 Blue 24
OPTION 3
Red Light green 25 RECIEVE PCB
SENSOR 2
1
Yellow
Blue
Light green 26
39
3
SLITTER HP4 2 Red
1 1 White
Red 1 2
3 Pink 2 3
SLITTER HP6 2 Blue 3
1 Red 4
Red 1 Gray 5
1

1
2
3
4
5
White 2 Blue 6
CREASE HP 2 Blue 3 Red 7 Double Feed Sensor
3 Red 4 Yellow 8
CREASE LOW HP
1
2
Light green 5 Blue 9 CA035
Blue 6 Red 10
3 Red 7 White 11
1 Purple 8 Blue 12
CREASE 2
ENCODER 3
Blue 9 Red
Light green
13
14 &1 C
Blown
Blue
Blue
Red
15
16 0$,13&%8QLW
SLITTER 3
Purple
Blue
17
18 69
Purple 19
HP2 2
1
Red 1 Purple 20 Double Feed Sensor
Pink 2 21
ELEVATOR Blue 3 22 CA035

1
2
3
4
5
Purple 1 Purple 4 23
LOWER SW Purple 2 Purple 5 24

Red 1 1 White Red

2 1
1
Orange 2
&1 3 Blue 1 2
White
4 2 3
3
Red 1
PPS1 Gray 2
1 Blue 3
2 Red 1
3 Orange 2 RECIEVE PCB
Red
Gray
3
4 39
Blue 5
1 Red 1 Red 6 Control panel PCB Unit
3
Orange 2 Orange 7
Red 8 69
Gray 9
PPS2 Blue 10
1 Red 1 Red 11
2 Gray 2 Orange 12
3 Blue 3 Red 13
Gray 14 1 Orange 1
Blue 15 2 Orange 2
Orange 16 3 Gray 3
Blue 17 4 Gray 4
1 Red 1 Red 18
&1 5 White 5
Orange 2 Orange 19 6 White 6
&1
3 White 20
Blue 21 &1 7
8
Yellow
Yellow
7
8
PPS3 Orange 22 9 Pink 9
1 Red 1 Blue 23 10 Pink 10
2 Gray 2 Red 24 11
3 Blue 3 Orange 25 12
White 26
Blue 27
28
29
30 Blown
1
Orange 1
31
32 &1 2
Black D
3 Black 2 3
2
1

DOBU GUIDE 1
Blown

SENSOR Red 1 &1 2

Blue B
4 Orange 2
3 white 3
2 Black 4
1

&1
Orange 1
3
1
2
3
4
5

Black 2
2
1 8
7
MARGIN JAM Gray 6

SENSOR 4
Red 1
Gray
Orange
5
4 86%&211(&725
3
2
Orange
white
2
3
Orange 3
2 %2$5'
1
Black 4 1
59

S2-Y1540 -0
 Chapter 8 3 Overall Wiring Layout

Overall Wiring Layout 2/2

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Model:DC-616
ELEVATER
UPPER LIMIT
Brown 2 Brown
Brown 1 Brown SWITCH

ELEVATER
1 Blown Brown 1 Brown
2 Black Black 2 Black MOTOR
Red 1
Black 2
Red
Black A /;

1 Red BLOW FAN SUCTION

2 Black
&1 FAN
1;
$$%% 1 6;
2 Red
3 Black
4 Red 1 Red
13 5
12 &1 6
Black
Red
2
3
Light blue
Black
11 7 Yellow
10
9
8
9
Red SHUTTER
Black 1 Red
8
7 &1
10
11
Light blue 2 Yellow SOL
Purple
6
Blown
White 5 3;
Pink 4 1 Red CREASE
SLITTER MOTOR5 Blown 3 2 Black
2 MOTOR
6; Yellow
1

1
2
Red
Black 6;
&1 3
Red
Black
1
2
Red
Black
4
CUTTER
MOTOR
SLITTER MOTOR3 15
14 6;
6; Pink 13
12 1
Black
Blown Blown
11 2
Purple
10 &1 3 CREASELOW
Light green Blown 1 Blown
Blown 9 4 Black 2 Black
Light blue 8
7 &1
5 MOTOR
Green
6
Blown
Yellow 5
4
0;
Gray
SLITTER MOTOR1 Blown 3
2
6; White
1 0DLQ0RWRU'ULYHU8QLW
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2 &1 2
3 Main motor
SLITTER MOTOR4 14
13 1
Blown 4
5 3;
6; Pink
Blown 12
11
2
3
Blue
Red 1
2
Purple Blue
Light green 10 4 3
9 &1 5
Yellow
4
Blown
8 6
Light blue
5 &1
Light blue
Green 7 &1 7
Black
Gray 6
Blown 6 8 Orange 7
Yellow 5 9 8
Gray 4
SLITTER MOTOR2 Blown 3
2
6; White
1 Black
D Blown
5(/$<
Black
Blown
2
1 8'
3 Blown
Blown 4
Blown
1 Blown
KYUSHI 2
3
Blown Blue

3; Green
Blown 12 &1 4 Blown B
White 11 5 Blue
Light blue 10 6
Blown 9
Gray 8
7
Purple
Blown 6 &1 Blue

White 5
4
7
6
Blown C
Pink
SLITTER MOTOR6 Blown 3
2
5
4
6; Yellow
&1 Blown

Blown
Blown
Blown
Blown
1 3

Blue
Blue
Blue
Blue
Blown
2
1
Terminal
OFD-02N-2P-187

1
2
3
4
5
6
7
8
Black Black
1 Black
2 1 AC IN1
White Yellow/Green
A 3 White White 2 EARTH
VX-52-1A3 3RZHU6XSSO\ࠉ8QLW8$
4
5
3 AC IN2

=:63$)-
DUST BOX Blown 2 Blown Power Switch Appliance Inlet
Blown 1 Blown
SWITCH LLK35C65 AC-P01CF01

Option
VX-52-1A3
REARCOVER Compressor Fuse(2A)
3

Blown 2 Blown
Blown 1 Blown
SWITCH Fuse Holder F-400-01A2
IN+

IN-

Black 1 Black 1 2 Black Black

White 2 White LOAD LOAD

VX-52-1A3
AQA-211VL
COVER Blown 2 Blown
Blown 1 Blown
SWITCH

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Chapter 9 PC Controller

1 Main Menu of PC Controller .................. 186

2 Maintenance Menu ............................. 188
1. Maintenance Data .......................... 188
2. Option Module ............................... 189
3. Language Setting ........................... 190
3 Data Folder ...................................... 191
1. Contents of Data Folder ................... 191
4 Maintenance..................................... 192
1. Confirming Saved Maintenance Data ... 192
2. Uploading the Maintenance Data of DC-616 .. 194
3. Setting Up the Machine to Be Connected .. 195
4. Set Up Language to Be Used ............ 196
5. Set Up the Other Language Than Existing Ones to Be Used . 197
6. Deleting the Message File ................ 201
5 Confirming the Version ........................ 202
1. Descriptions ................................. 202

9
Chapter 9 1 Main Menu of PC Controller

1 Main Menu of PC Controller

The following screen appears when PC Controller is run.
Select each sub menu to be set from this main menu screen.

24 6 7 8 12 13
14
10 11
9
15 16 17
1 18
25
2
3
4
5

19

20
21
22
23

No. Item Function

Create a JOB in Wizard format.
1 WIZARD A preview of the JOB being created is displayed. Create the JOB
while checking the input details.
Directly input the number value to create a JOB.
2 DIRECT Use this to create a JOB rather than “WIZARD” when the
dimensions are already finalized.
3 UPLOAD Read the JOB from the DC-616 and save in computer.
4 SETTING This is used to set the default values of the PC Controller.
For service person use only. This is used for setting the machine
5 MAINTENANCE
etc. Password is required to access.
6 SELECT This reads the saved JOBs on the DC-616. Select one from them.
7 Job Detail Input JOB details are displayed.
8 DOWNLOAD This sends the JOB saved on the computer to the DC-616.
9 OPEN This opens the saved JOB on the computer.
10 Preset Count This presets the number of sheets to be processed for the JOB.

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No. Item Function

11 Clear This clears the number of preset count.
Click [Start] to perform the process.
12 Start button This lights up in green in the standby mode. This will be invalid
while the machine is running or having an error.
13 Test button Click [Test] to process only one sheet.
14 Stop button Click [Stop] to stop the running process.
This sets Slitter Guide, Auto Trail Cut, Air Knife, Read Barcode,
15 SETTING Double Feed Detection, Suction fan,Crease Depth,Speed and
Read REG. Mark,
16 ADJUST ALL This sets Apply Shrinkage and Adjust All.
Select the [Stacker Setup] check box and click [Test] to process
only one sheet and stop it at the document ejecting position.
17 Stacker Setup Then click [Stop] or [Test] to eject it to the Exit tray. At that time,
if you click [Start], the DC-616 ejects it to the exit tray and then
continues the JOB.
Select the [Connect] check box to control function limit of the
18 Connect
control panel on the DC-616.
Select the [Advanced Mode] check box to put the machine in
19 Advanced Mode Advanced Mode.
Clear the check box to put the machine in Simple Mode.
The JOBs processed by the PC Controller (JOBs processed by
clicking [Start] or [Test]) are saved in the computer as logs. Up to
20 JOB Log
50 lately processed JOBs can be saved. If the number of saved
JOBs exceeds 50, they will be deleted in chronological order.
This displays JOB log programmed and saved by the PC
21 Saved Job log
Controller.
22 Job log. Details This displays the details of a JOB in the JOB log.
23 Select Job log. Click to download the JOB being selected from the JOB log.
24 Status This displays the current machine status by letters.
This displays the current machine status by picture (icon and
25 System
color).

REFERENCE
Note when opening the JOBs
When you click [SETTING] and select the [Enable re-editing Wizard JOB data] check
box on the [DEFAULT] tab, the retrieved JOB data that was created with the “WIZARD
program” is displayed on the “WIZARD” screen.
When you created a JOB with the “DIRECT program,” the JOB data is displayed on the 9
“DIRECT” screen.
However, if you re-enter the data, which was created with the “WIZARD program,” on the
“DIRECT” screen, it is also displayed on the “DIRECT” screen.

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Chapter 9 2 Maintenance Menu

2 Maintenance Menu
1. Maintenance Data

No. Item Function

Open Maintenance
1 To confirm the maintenance data saved in computer.
Data File
Upload Maintenance
2 To load the maintenance data saved in DC-616 into the PC.
Data from DC-616

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2. Option Module

No. Item Function

Setting of connected
1 Check the box of the optional modules.
device

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Chapter 9 2 Maintenance Menu

3. Language Setting

2 3 4

No. Item Function

1 LANGUAGE Set the language to be used on the screen.
2 EDIT Edit the messages.
3 IMPORT Import the message files.
4 DELETE Delete the message files.
5 SELECT Name of the message file.
6 Language Displays the current set language.

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 Chapter 9 3 Data Folder

3 Data Folder
1. Contents of Data Folder

Folder Name File/Folder Name Function

*.res File of icon data.
Duplo.exe Application software.
HistoryJob.H616 File of processed history data.
HistoryJob.S616 File of JOB entering history data.
LanguageEn.ini Language file of English.
LanguageFr.ini Language file of French.
LanguageGr.ini Language file of German.
LanguageIt.ini Language file of Italian.
LanguageJp.ini Language file of Japanese.
DC-616_PC _
LanguagePl.ini Language file of Polish.
Controller V*.**
LanguageRs.ini Language file of Russian.
LanguageSp.ini Language file of Spanish.
*.tmp Data of the language file administration.
PC_Contoller.ini File of setting data including the default setting.
MSIMG32.dll Software library povided by Microsoft.
usb645.dll File of data required for executing applications.
*.M616 File of maintenance data.
*.A616 File of ‘All JOB’ data.
*.J616 File of JOB data.

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Chapter 9 4 Maintenance

4 Maintenance
1. Confirming Saved Maintenance Data

Open the saved file in computer to confirm the maintenance data.

1. The main menu screen appears.

Click [MAINTENANCE].

2. Enter the password ‘630304’, and click [YES].

If you click [NO], the screen will return to the one on

step 1.

IMPORTANT
If you enter the wrong password and click [YES], the
maintenance screen will not appear.
The entering password screen will be stayed.
Click [NO] to return to the main menu screen, and try
it again.

3. The maintenance menu screen appears.

Click [Open Maintenance Data File].

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4. Select the file name and file type.

Click [Open].

5. The contents of maintenance data appears.

Click [Save as .CSV file.]. The imported data will be

saved as CSV file in the computer.

If you click [END], the screen returns to the one in

step 3.

6. Enter the file name of the created data.

Click [Save].

If you click [Cancel], the screen returns to the one in

step 5 without saving operation.

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Chapter 9 4 Maintenance

2. Uploading the Maintenance Data of DC-616

1. Process the step 1 to 2 in the “Confirming the mainte-

nance data”.

2. Select [Upload Maintenance Data from DC-616],

and click [OK].

If you click [Cancel], the screen returns to the previ-

ous one.

3. The message ‘Upload maintenance data?’ appears.

Click [Yes] to start uploading the data.

If you click [No], the screen returns to the previous

one.

4. Select the location you want to save the data in.

Right figure shows an example of selecting ‘My Docu-

ments’.

Click [OK] to save the data.

If you click [Cancel], the message ‘Don’t Save the

service file.’ appears.

Click [OK].

The screen returns to the one in step 2.

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5. The message ‘Save the service file.’ appears.

Click [OK].

3. Setting Up the Machine to Be Connected

1. Process the step 1 to 2 in the “Confirming the mainte-

nance data”.

2. Click [OPTION MODULE] tab.

3. Check the box of option modules which is installed in

DC-616.

Click [OK] after confirmation of the check box.

If you click [CANCEL], the checked option modules

are canceled. And the screen returns to the main
menu.

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Chapter 9 4 Maintenance

4. Set Up Language to Be Used

Set the language to be displayed on PC Controller.

1. Proceed along the step 1 to 2 in the “Confirming the

maintenance data”.

2. Click [LANGUAGE] tab.

3. Click to display the language list, and select one

language you want to use.

(English, French, German, Italian, Japanese, Polish,

Russian, Spanish, and other)

Click [OK] after the selection.

If you click [CANCEL], the selected one is canceled.

And the screen returns to the main menu.

4. The message ‘Do you want to change the settings?'

appears.

Click [YES].

If you click [NO], the screen returns to the one in step 3.

5. The message ‘Restart the application.' appears.

Click [OK].
PC controller is finished automatically.
Restart the PC controller.
And it runs with the set language you have changed.

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5. Set Up the Other Language Than Existing Ones to Be Used

1. Proceed along the step 1 to 2 in the “Setting Up

Language to Be Used” when you require to use the
other language than existing languages.

2. Select [Other].

3. [Other Language]

· EDIT : Create the txt file of new message.

· IMPORT : Upload the txt file of message you want

to use.

· DELETE : Delete the txt file displayed in the select

box.

Click [EDIT].

4. The screen shown on the right figure appears.

: Create New Language

You can create a new txt file of message.

: Open File
Opens saved txt file.

: Save File
You can save data you created as new txt
file.

: Undo
Deletes the current entered edit. Returns
to the previous edit state by each one click.
9
You can click here up to 20 times.

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Chapter 9 4 Maintenance

Here are the descriptions how to create a new message file.

4-1. Click .

4-2. Click a low you want to edit.

(Right figure shows the topmost low as an example.)

KEY : Shows “KEY” (Symbol for administration)

which is allocated on each messages.

Resource : Shows the edited language when

you open existing file.
Shows nothing when you click new
document.

English : Shows the message in English

corresponding to each “KEY”.

4-3. Click the text box on the lower screen.

Enter the message in other language

corresponding to the one in English.
Click [Apply] to define the entered message.

The defined message will be entered in the low

you selected in step 4-2.

IMPORTANT
Entering number of characters should be
referred the English message character.
Though number of characters is not set out,
the letters out of the display range will be left
out and displayed in “···”.
Displayable letter form will depend on OS nor-
mal font.

IMPORTANT
Raw data will be displayed in English.

4-4. Repeat the sequences of step 4-2 to 4-3 until

you finish editing each messages.

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5. After edit complete, click .

6. Enter the file name of the new data you edited, and
save the message file.

IMPORTANT
Save the message file in text format (*.txt).

Click [Save].

If you click [Cancel], the screen returns to the one in

step 4 without saving operation.

7. Close this window.

8. The right screen appears.

Click [IMPORT].

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Chapter 9 4 Maintenance

9. Select the file saved in step 6, and click [OPEN].

(The right figure shows an example of selecting “duplo” file.)

The message file will be imported in the PC controller,

and the file name will be added in the list of the other
language selecting box.

10. If you select the existing file, the message ‘This

file name already exists. Do you want to overwrite?'
appears.

Click [YES] if you want to overwrite it.

Click [NO] if you do not overwrite it.

The screen returns to the one in step 8, and re-enter
the file name.

11. Click [OK].

Clicking [CANCEL] returns to the screen of main

menu.
(Reference → See P.192)

12. The message ‘Do you want to change the settings?’

appears.

Click [YES].

Clicking [NO] returns to the screen of step 11 without

saving operation.

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13. The message ‘Restart the application.' appears.

Click [OK].
Application is finished automatically.
Restart the PC controller.
And it runs with the set language you have changed.

Clicking [Cancel] returns to the screen of step 11.

6. Deleting the Message File

1. Select ‘Other’.

2. Select a message file to delete from the list of

[SELECT] box.

3. Click [DELETE].
The selected message file will be deleted from the
folder specified to storage.
9

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Chapter 9 5 Confirming the Version

5 Confirming the Version

1. Descriptions

The following programs need up-version when it is required.

1. DC-616 PC Controller V*.**

It needs up-version when adding the optional equipment on DC-616.

2. Duplo seiko corp. (usbdc616) USB ***** driver

It does not need up-version normally.

Confirming the version of PC Controller

Run the PC Controller.

Look at the upper of the screen. ‘Duplo DC-616 PC

Controller V*.**' is displayed.

‘V*.**’ is the version of PC controller.

Confirming the version of driver

• Windows 8

1. Click [Settings] charm.

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 Chapter 9 5 Confirming the Version

2. Click [Control panel].

• Windows 7 / Vista

1. Click [Start], and then click [Control Panel] in

the menu.

The ‘Control Panel’ appears.

2. Click [Hardware and Sound].

3. Click [Device Manager].

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Chapter 9 5 Confirming the Version

4. ‘USB DC-616 *.*' is registered in 'Universal Serial

Bus controller' of 'Device Manager' dialog.

The part ‘*.*' of 'USB DC-616 *.*' is the version of

driver.

After the confirmation, close the window.

• Windows XP

1. Click [Start] on the task bar.

Click [Control Panel] in the menu.

2. Click [Performance and Maintenance].

REFERENCE
The display of screen is different from the one
in classic display setting.

3. Click [System].

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4. The ‘System Properties’ dialog appears.

Double-click [Hardware] tab, and then click [De-
vice Manager].

5. ‘USB DC-616 *.*’ is registered in ‘Universal

Serial Bus controller’ of ‘Device Manager’ dialog.

The part ‘*.*’ of ‘USB DC-616 *.*’ is the version of

driver.

After the confirmation, close the window.

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