SLITTER/CUTTER/CREASER

DC-616
 Safety Precautions
Warning Terminology
The following warning terminology is used in this installation manual.

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>

A circle with a line through it indicates a prohibited action.
The particular act prohibited is indicated by a picture inside the circle.
(In the example shown here, the prohibited act is disassembly.)

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

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

● The precautions below are vital for safety and must be taken.

WARNING
● Use only the power cord that is provided among the accessories.
Insert the power cord plug firmly into the socket, so that proper electrical contact is effected.
→ Use of any other power cord could result in imperfect grounding.
If grounding is imperfect and electrical leakage occurs, fire or electric shock could result.
● Do not use a source voltage other than that specified. Do not connect two or more loads to a
single outlet. → Doing so may result in fire or electric shock.
● Do not place the machine in a humid or dusty area. → Doing so may result in fire or electric
shock.

CAUTION
● Do not place the machine in an unstable position, such as on an unsteady support or sloping
area.
→ If the machine is dropped or falls over, this could result in personal injury.

● Once the machine is in position, secure in place using the casters.

→ If the machine falls over, this could result in personal injury.

1
1. Unpacking Checks
1. Check the product name on the package.
Product name: DC-616

2. Unpack the package.

IMPORTANT
Carry out unpacking in a place that is safe for the work.

3. Check the contents.

No. Name Part No. Q'ty Remarks

1 Power cord E1-8108* 1 115V model
L1-W126* 1 230V model
2 Side guide 3
3 Back guide 1
4 Guide 1
5 Hexagon wrench driver XZ046 1
6 Tweezers DZ058 1
7 Check sheets S2-Y104* 6
8 Waste box 1
9 Flexible press roller 2
10 Warning label M7-T307* 2 230V model
11 Warning label L8-T111* 1 230V model
12 Warning label sheet L8-T112* 2 230V model
13 Warning label L8-T113* 1 230V model
14 Warning label sheet S2-T109* 6 230V model
15 Installation Manual S2-Y152* 1
16 Instruction Manual S2-Y150* 1

1 2 3

4 5 7

8 9 10

2
 11 12 13

14 15 16

Card stacker (Option)

No. Name Part No. Q'ty Remarks
1 Card stacker assy 1
2 Back guide assy 1

1 2

Perforation unit (Option)

No. Name Part No. Q'ty Remarks
1 Perforation unit 1
2 Thumbscrew DA293 1

1 2

PC arm mount assy (Option)

No. Name Part No. Q'ty Remarks
1 PC arm W5-M287* 1
2 Block U7-M783* 1
3 Screw (M5×12) 5

1 2 3

3
 2. Installation
Follow the procedures below for installation of 5. Remove the two screws securing the exit
the machine. tray.

WARNING
This machine is heavy-weight equipment.
When moving it by using the casters, two or
more persons are required.
Pay extra attention to slopes when trans-
porting.

1. Lock the casters on the operator’s side when

you reach the place to install the machine.
Screws
2. Remove all the tapes from the machine.

3. Remove the four screws to remove the two 6. Open the front cover and remove the four
grip brackets. screws to remove the angle.

4. Remove the four screws securing the fixing 7. Take out the included items in the waste box
angles at the top and bottom of the front and check for any missing parts.
cover. Open the front cover and remove the
four screws on the rear side of the fixing
angles to remove them.
Fixing angle

Fixing angle

4
 10. Attach each “flexible press roller” in front of
• Attaching the Flexible Press Rollers
and behind the cutter unit:

8. Open the top cover. 10-1. Attach one side with the hexagon
socket set screw loosened to the
attachment position.

9. Loosen the hexagon socket set screw

securing the “block” on one side of the 10-2. Attach the other side with the “block”
“flexible press rollers” to slide the “block” secured to the attachment position.
inward.
Flexible press roller
IMPORTANT
Attach the “flexible press roller” with
Block Block
the hexagon socket set screws in the
“blocks” upward.

Press roller

10-3. Secure the hexagon socket set screw

in the “block” with the hexagon wrench
driver.

5
 10-4. Attach the second flexible press roller
in a similar way.

11. Close the “top cover”.

6
 3. Selecting Language
1. Make sure that the power is off. 3. Turn on the power while simultaneously
Connect the female plug of the supplied pressing the F key and C key.
power cord to the inlet of the DC-616.

Inlet
Female plug of
the power cord

4. Press the CURSOR (Up/Down) key to select

language, and press the SET key.

2. Insert the male plug of the power cord into

the outlet.

Male plug of
the power cord
Select one from the following eight
languages.
Outlet REFERENCE
English, French, Italian, German, Spanish,
Japanese, Polish, and Russian

5. Turn off the power.

WARNING
Insert the power cord plug securely so that 6. Turn on the power.
proper electrical contact is made. If The LCD display appears in the language set
grounding is imperfect, and electrical in step 4.
leakage occurs, fire or electrical shock
could result.

WARNING
Unplug the power cord when emergency
situation.

CAUTION
Use a access-friendly outlet so that an
operator easily plugs and unplugs the
power cord after installation.

7
 4. Operation Check

• Checking the Operation of the PPS Sensor • Adjusting the Cutting Position

1. Turn on the power while simultaneously 1. Set the skew adjustment knob to “0”.
pressing the Right/Left JOG keys on the
control panel to enter the HELP mode.

2. Access HELP-11, and press the START key

to check the operation of the sensor.
The sensor name and its status are
displayed on the LCD screen in order.
Check for the operation of the “PPS3 sensor”
by testing it with a piece of paper to let the
sensor be in the status of “Light-through” or
“Light-blocked”.
(0 : Light-blocked/ 1 : Light-through) 2. Access HELP-46, and the press START key.
(See → HELP Mode 11 in the Service
Manual) 3. Load the document (297×420 mm) on the
feed tray, and press the TEST key.
H11 Sens.ck The machine processes the document
PPS1 0 following the contents of service person
JOB83. (To see the details→Table of JOB83)
PPS2 0
PPS3 0 4. Measure the cutting position of the finished
product with a vernier caliper.

3. Press the STOP key to return to the HELP 5. Enter adjustment value using the NUMERIC
mode selection display. keys.
Increasing the value by 1:
Moves the cutting position 0.1 mm
forward to the document feed direction.
Decreasing the value by 1:
Moves the cutting position 0.1 mm
backward from the document feed
direction.

IMPORTANT
Cutting position change will automatically
result in the creasing position change.
Always readjust the creasing position after
the cutting position change.

REFERENCE
The adjustment value can be reset to the
default by continuously pressing the C key.
(This is not a value of factory setting.)

6. Press the SET key to store the adjustment

value.

7. Press the STOP key to return to the HELP

mode selection display.

8
 • Adjusting the Ceasing Position • Operation Check

1. Set the Skew adjustment knob to “0”. Perform operation check using the service
person JOBs.
2. Access HELP-47, and press the START key.
1. Turn on the power while simultaneously
3. Load the document (297×420 mm) on the pressing the CURSOR (Up) key and the
feed tray, and press the TEST key. CLEAR key.
The machine processes the document
following the contents of service person
JOB83. (To see the details→Table of JOB83)

4. Measure the creasing position of the finished

product with a vernier caliper.

5. Enter adjustment value using the NUMERIC

keys. 2. Select service person JOB and perform
Increasing the value by 1: operation check.
Moves the creasing position 0.1 mm
forward to the document feed direction. REFERENCE
Decreasing the value by 1: • When a CCD (option) is installed, perform
Moves the creasing position 0.1 mm operation check using service person
backward from the document feed JOB74, JOB88, and JOB93.
direction. • When a perforation unit (option) is installed,
perform operation check using service
REFERENCE person JOB89.
The adjustment value can be reset to the
default by continuously pressing the C key.
(This is not a value of factory setting.)

6. Press the SET key to store the adjusting

value.

7. Press the STOP key to return to the HELP

mode selection display.

9
 Use to check the H-46: Use to cut. H-49: Use to H-50: Use to Use to check
parallelity of the H-47: Use to adjust adjust the slit adjust the plain paper.
right margin. the parallelity and position. position of the Use to adjust
distance of the crease. gutter deflector double-feed
H-48: Use to adjust guide. sensor.
the depth of the
crease.
JOB Name MARGIN CK CUT&CRE CK SLIT CK GUTTER CK FEED CK
Paper size 297×420(A3) 297×420(A3) 297×420(A3) 297×420(A3) 297×420(A3)
JOB number 81 83 84 85 86
PAPER WIDTH 297 297 297 297 297
TOTAL LENGTH 420 420 420 420 420
Side Mark 0 0 0 0 0
Lead Mark 0 0 0 0 0
SLIT1 25 25 25 5 0
SLIT2 285 285 275 285 0
SLIT3 0 0 75 95 0
SLIT4 0 0 225 195 0
SLIT5 0 0 125 100 0
SLIT6 0 0 175 190 0
CUT01 0 20 0 0 0
CUT02 0 0 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 0 120 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 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 HIGH MID MID MID
SPEED FAST FAST FAST FAST FAST

10
 Use to check Use to check Use to check Use to checkUse to adjust This is used to check
REG. Mark REG. Mark skew of processing the vertical the barcode reading
function function perforation accuracy of enlargement and to reset the
unit business magnification) of setting to the factory
cards. H-52. (using preset state.(Can
SRA3 exclusive only be used in the
paper) service JOB Mode)
JOB Name REG. CK1 REG. CK2 PERF CK 50×85 H-52 CK2 BARCODE CK
Paper size 297×420(A3) 297×420(A3) 297×420 297×420(A3) 297×420(A3) 297×420(A3)
JOB number 87 88 89 90 91 93
PAPER WIDTH 297 297 297 297 297 297
TOTAL LENGTH 420 420 420 420 420 420
Side Mark 10 14 0 0 0 0
Lead Mark 10 14 0 0 0 0
SLIT1 8 12 10 25 0 0
SLIT2 285 289 290 275 0 0
SLIT3 0 0 0 75 0 0
SLIT4 0 0 0 225 0 0
SLIT5 0 0 0 125 0 0
SLIT6 0 0 0 175 0 0
CUT01 8 12 0 5 5 0
CUT02 0 0 0 90 405 0
CUT03 0 0 0 100 0 0
CUT04 0 0 0 185 0 0
CUT05 0 0 0 195 0 0
CUT06 0 0 0 280 0 0
CUT07 0 0 0 290 0 0
CUT08 0 0 0 375 0 0
CUT09 0 0 0 0 0 0
CUT10 0 0 0 0 0 0
CUT11 0 0 0 0 0 0
CUT12 0 0 0 0 0 0
CUT13 0 0 0 0 0 0
CUT14 0 0 0 0 0 0
CUT15 0 0 0 0 0 0
CUT16-25 0 0 0 0 0 0
CRE.01 0 0 0 0 0 0
CRE.02 0 0 0 0 0 0
CRE.03 0 0 0 0 0 0
CRE.04 0 0 0 0 0 0
CRE.05 0 0 0 0 0 0
CRE.06 0 0 0 0 0 0
CRE.07 0 0 0 0 0 0
CRE.08 0 0 0 0 0 0
CRE.09 0 0 0 0 0 0
CRE.10 0 0 0 0 0 0
CRE.11-20 0 0 0 0 0 0
PERF1 0 0 30 0 0 0
PERF2 0 0 270 0 0 0
AIR KNIFE OFF OFF OFF OFF OFF OFF
SUCTION POWER MAX MAX MID MAX MAX MAX
REG. MARK ON ON OFF OFF OFF OFF
SLIT GUIDE ON ON ON ON ON ON
AUTO CUT ON ON ON ON ON ON
CREASE DEPTH MID MID MAX MID MID MID
SPEED FAST FAST FAST FAST FAST FAST

11
 5. Installation (Option)
• Installing the Perforation Unit
6. Tighten the two “perforation unit installing
screws” to install the “perforation unit” on the
1. Loosen the “thumbscrew” to remove the ejection side of the DC-616.
“cover” on the ejection side of the DC-616.

Non-operator's
side on the
ejection side

7. Select a JOB containing perforation process

2. Loosen the two “thumbscrews” on both sides and perform a test run for one sheet.
of the “perforation unit”.
8. Check the processed positions on the
finished product. When you want to change
the perforation positions, repeat steps 2 to 7
and perform a test run for one sheet.

3. Move the perforation tool.

(→P.13 “• Changing the Perforation Tool
Position”)

4. Adjust the perforation tool depth.

(→P.15 “• Changing the Depth of the
Perforation Tool”)

5. Tighten the two “thumbscrews” loosened in

step 2.

12
 • Removing the Perforation Unit • Changing the Perforation Tool Position

1. Loosen the two “perforation unit installing 1. Loosen the two “thumbscrews” on both sides
screws” to remove the “perforation unit”. of the “perforation unit”.

2. (Inside of the perforation unit)

2. Tighten the thumbscrew to attach the “cover” Loosen the two hexagon socket set screws
to the ejection side of DC-616. (upper tool: 1, lower tool: 1) each of the
“perforation tool assys” (right and left).
Non-operator's
side on ejection
side
Perforation tool assy
Upper tool

Lower tool

3. Document feed side

Install the “perforation unit” at the installation IMPORTANT
position under the feed tray, and tighten the Take note of the position of the loosened
two “thumbscrews”. hexagon socket set screw of the upper
tool.
Correct

Incorrect

13
 5. Tighten the two “thumbscrews” loosened in
REFERENCE step 1.
When the hexagon socket set screw does
not face toward you, rotate the shaft as
shown below to change the direction.

3. Move each “perforation tool assy” to the

position where you want to perforate with
your fingers.

WARNING
Do not touch the perforation tools.
This could result in injury.

4. Tighten the four hexagon socket set screws

loosened in step 2.

Perforation tool assy

Upper tool

Lower tool

14
 • Changing the Depth of the Perforation Tool • Attaching the Card Stacker

1. Loosen the two “thumbscrews” on both sides 1. Make the exit tray level.
of the “perforation unit”.

2. Adjust the perforation tool depth by turning

the “depth adjustment screw” on the
“perforation unit”.
Turn the depth adjustment screw clockwise:
The upper tool raises.
Turn the depth adjustment screw
counterclockwise: The upper tool lowers.
Adjust the depth of the perforation tools on
both sides.
Perform a test run to check the depth of the
upper tools on the finished product.
2. Place the card stacker on the exit tray along
the ejection side.

Depth adjustment screw

3. Tighten the two “thumbscrews” loosened in

step 1.
REFERENCE
When the perforation unit is installed, place
the card stacker along the perforation unit.

15
 • How to Adjust the Guide of the Card Stacker REFERENCE
The number of the side guides of the card
1. Select a JOB, and press and hold the TEST stacker can be changed.
key. The finished product stops at the exit
Loosen the
before being ejected. Adjust the guide so that thumbscrew to
the side edge of the finished product comes slide the stopper.
into contact with the side guide.

REFERENCE
The above adjustment can stack the short
finished products properly.

2. Press the STOP key to eject the document

and adjust the back guide (for card stacker)
according to the finished size of the
document.

16
 • Attaching the PC Arm Mount Assy

1. Take out the block (with the screws attached

to the packaging materials) and the PC arm
unit from the waste box.

2. Attach the block to the PC arm mount unit

and secure with the screw.

3. Attach the PC arm mount assy in step 2 on

the non-operator’s side of the DC-616 with
the four screws.
S2-Y1520
2014.04