Duplo Docu Cutter

DC-545HC

Service Manual

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 SERVICE MANUAL

Ver.1 DOCU CUTTER

DC-545HC

Be sure to read this manual carefully, so that you

repair and service this machine safely and correctly.
Do not begin work until you have thoroughly
understood the contents of this manual.
Repairing or servicing the machine with insuffeicient
knowledge about it could lead to unforeseen
accidents or falls in the machine's performance or
quality.

DUPLO SEIKO CORP.

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 Introduction

The cause of most accidents is failure to adhere to basic safety rules and observe safety
instructions. It is important to prevent potential causes of accidents from occurring. In
order to do so, read this manual carefully, and be sure to understand all the safety instruc-
tions and correct inspection and servicing procedures that it provides before beginning
repair or servicing work.
Repairing or servicing the machine with insufficient knowledge about it could lead to
unforeseen accidents.
It is not possible to anticipate and describe in a manual such as this every possible
hazard that could arise in the course of repair and servicing. Therefore, besides observing
the safety instructions marked in this manual and on the machine's labels, service
personnel should be safety-conscious and take other safety precautions as necessary. When
performing repair or service work not covered by this manual, you should obtain safety
guidance from an appropriately knowledgeable person.

Copyright © 2003
DUPLO SEIKO CORPORATION
All Rights Reserved

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 Safety instructions

Safety instructions
1.Cautions regarding the installation location

Safety instructions
Installation environment
s 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 mal-
function of the control system.
• Sunlight could cause misoperation of the sensors.
• The heat of direct sunlight could cause deformation of the machine’s plastic parts.
* Also avoid installation near to a ground glass window; light and heat penetrate such windows
although they are opaque.

s 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: 5˚C–30˚C
Ambient humidity: 40%–70%
Optimum temperature and humidity: 20˚C, 65%
• If the machine is installed near to faucets, water heaters or humidifiers, or in cool (sunless) parts
of a building or in the vicinity of water sources, the paper could absorb moisture and curl,
leading to misfeeds or poor image quality.

s 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.
s Avoid installing the machine in poorly ventilated places.
s Avoid installing the machine in dusty places.

s The machine should not be tilting when it is used.

• Install the machine so that it is level.
(The machine should be level to within 5mm in the front-rear direction, and 5mm in the lateral
direction.)

s 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.

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 Safety instructions

2. Cautions for installation work

Warning
• The machine’s power supply voltage and power consumption depend on the model. Details of this
are given in the tables below. The power supply voltage and power consumption for the machine
are given in the table below. The machine’s power supply voltage is indicated on the identification
plate located on the machine’s left side; the machine must be connected to a power supply of the
voltage indicated.
a Otherwise, fire or electric shock could result.
If the power supply voltage is unstable or if the power supply has insufficient capacity, the
machine may not operate normally.
Make sure that the power supply has sufficient capacity for the system as a whole, including
optional equipment.
* 120V AC model
Power supply voltage Connect to outlet of 120V AC, 60Hz, at least 15A

With no load*
At full load
No more than 130V AC
At least 110V AC } Use power supply meeting these requirements
During operation : 90W
Power consumption
In standby : 15W

* 230V AC model
Power supply voltage Connect to outlet of 230V AC, 50Hz, at least 8A

With no load*
At full load
No more than 250V AC
At least 210V AC } Use power supply meeting these requirements
During operation : 90W
Power consumption
In standby : 15W

* “With no load” - when the machine is on standby.

* “At full load” - when the machine is running at maximum power consumption.

• Use only the power cord that is provided among the accessories.
Insert the power cord plug firmly into the socket, so that proper electrical contact is effected.
• Install the machine close to its power supply. The outlet used should be exclusively for the
machine, and have no other equipment connected to it.
If an extension cord is necessary, it should have a ground terminal, and be of the following ratings:
* For a 120V AC model: 130V, at least 15A, length not exceeding 5m.
* For a 230V AC model: 250V, at least 8A, length not exceeding 5m.
• Never tread on the power cord or pinch it between other objects, or accidents could result.

CAUTION
• Install the machine in accordance with the installation procedure appended to this manual.
Using the stand
• Lock the casters after the machine is installed.
a Otherwise, the machine could move or fall over, causing injury.
• To move the machine, push it by its mounting base.
a Pushing the DC-545 could make it fall over.

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 Safety instructions

3. Cautions for maintenance, inspection and servicing

Warning
Precautions for safe servicing
• Always remove the power cord plug from the outlet before starting work.
aOtherwise, you could get a shock or your hands/fingers could be injured.
• However, the plug must be left connected to the outlet when performing function checks (of
individual motors, a given series of operations, or electrical circuits). When motors are operated
alone in function checks, interlocks are deactivated, so be aware of the conditions and positions of
related equipment, and take great care not to put your hands or fingers into moving parts.
• The cutter unit and slitter unit contain hazardous sharp blades. Exercise great care when inspecting
the cutter unit or replacing it or its parts.
aOtherwise, your hands/fingers could be injured.

• Do not touch the drum or rollers after turning on the jog switch.
• Do not put your hands or fingers inside the machine while the drum is rotating.
aOtherwise, your hands/fingers could get caught and crushed between the drum and rollers.

Working clothes
• Wear clothing than enables you to work safely.

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

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 Safety instructions

Warning Sticker
Keep the WARNING stickers clean at all times. If labels become damaged or come off, have your service
representative replace them.

q
Do not touch blade!
WARNING To remove jammed paper,
use the tweezers. L8-T1100

e
WARNING

Use caution when working

near movable parts.
Disconnect power before
servicing.
L8 T1090

w
WARNING Cutters and movable parts are inside this cover.
Before opening the cover to work,
unplug the power cord.
Use caution when working near cutters
and movable parts.
L8-T1080

No. Parts No. Name Q’ty

q L8-T1100 Warning Sticker 1 1
w L8-T1080 Warning Sticker 2 3
e L8-T1090 Label Caution 2

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 Safety instructions

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 Chapter 1
Introduction

Chapter 2
Description of Operation

Chapter 3
Mechanical

Chapter 4
Standard Adjustments

Chapter 5
Maintenance Checks

Chapter 6
Troubleshooting

Chapter 7
HELP Mode

Chapter 8
Miscallaneous

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 Table of Contents

Introduction ....................................................... 1
Chapter 4 Standard Adjustments
Safety instructions ............................................ 2
1. Cautions regarding the installation z LCD Panel .................................................... 94
location .......................................................... 2 x Slitter Position ............................................ 95
2. Cautions for installation work ...................... 3 c Cutter Registration ..................................... 98
3. Cautions for maintenance, inspection and v Creaser Calibration .................................. 100
servicing ........................................................ 4 b CCD Horizontal Line Alignment .............. 102
Warning Sticker ................................................. 5 n Adjusting Crease Depth ........................... 104
m Feed Solenoid Adjustment ...................... 105
Chapter 1 Introduction , Gate Solenoid Adjustment (Without the
DC-545HC) ................................................. 106
z Specifications ............................................. 10
. Cutter Assembly Perpendicularity
x Dimensions ................................................. 11
Adjustment ................................................ 107
c Part Names and Functions ........................ 12
⁄0 Creaser Perpendicularity Adjustment .... 108
v Work Flow .................................................... 15
⁄1 CCD Vertical Line Alignment ................... 109
b Options ........................................................ 16
⁄2 Elevator Switch Height Adjustment ........ 111
⁄3 Cover Switch (AF-100 : 1 position,
Chapter 2 Description of Operation DC-545 : 2 positions) ................................ 112
⁄4 Shutter Solenoid ....................................... 113
z Paper Feed Unit .......................................... 18
⁄5 Creaser Sensor Plate Adjustment ........... 118
x CCD Mechanism ......................................... 30
c Margin Slitter ............................................... 32
v Guillotine Cutter Unit ................................. 34 Chapter 5 Maintenance Checks
b Creaser Unit ................................................ 35 z Cleaning and Oiling .................................. 120
n Center Slitter ............................................... 37 x Periodic Maintenance Check List ............ 120
m Paper Eject Tray .......................................... 39
, Main Drive ................................................... 40 Chapter 6 Troubleshooting
. Skew Adjustment Mechanism ................... 43
⁄0 BAR CODE .................................................. 44 z Troubleshooting Guide ............................. 124
⁄1 REGISTER MARK ....................................... 45 x Error Display ............................................. 132

Chapter 3 Mechanical Chapter 7 Help Mode

z Exterior ........................................................ 49 z HELP Mode List ........................................ 140

x Feed Section ............................................... 52 x Functions and operation procedures for
each HELP mode ...................................... 141
c CCD Section ................................................ 59
c HELP Description ..................................... 142
v Margin Slitter Section ................................. 60
v Select Language for Displays ................. 150
b Cutter Section ............................................. 67
n Creaser Section .......................................... 69
Chapter 8 Miscallaneous
m Center Slitter Section ................................. 71
, Driving Section ........................................... 79 z Job List ...................................................... 152
. Electric Section ........................................... 85 x Position and Function of Electronic Parts .. 156
c Overall Wiring Diagram ............................ 161

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 Chapter 1 Introduction 1
z Specifications ............................................ 10

x Dimensions ................................................ 11

c Part Names and Functions ....................... 12

1. Appearance ........................................... 12
2. Operation Panel .................................... 14

v Work Flow ................................................... 15

1. Operations ............................................ 15

b Options ....................................................... 16

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 Chap.1 z Specifications

z Specifications

Product name/Model No. DC-545 with HC AUTO FEEDER

Input paper size Min.: 8.5” x 11”/A4
Max.: 12.6” x 18”/A3
Input paper weight Min.: 110 gsm, Max.: 230 gsm <No curl in the paper>
Finishing size Min.: 2” (Width) x 3.5” (Length) <Business card size>
Lead edge trim Min.: 0.125” (3.2 mm)
Trail edge trim Min.: 0.125” (3.2 mm)
Side edge trim Min.: 0.125” (3.2 mm), Max.: 4.5” (114 mm)
Speed Max.: 9 ppm (A4 lengthwise, 4-side trim, 1 crease)
Trim/Crease tolerance ± 0.03” (± 0.762 mm)
<With paper cutting length not exceeding 18”>
Media type Range: Regular copy paper to coated heavy weight paper
Feeding method Automatic Feeding (Air suction method)
Feed tray capacity 100 mm
Stacker Drop type
Power supply AC 120 V ±10%, 50/60 Hz, 1.0 A
AC 230 V ±10%, 50/60 Hz, 0.6 A
Machine dimensions (mm) 1376 (W) x 576 (D) x 948 (H)
Machine weight (kg) 109.6 (Main body 56.4, Feeder 20.4, Stand 32.8)
1. Four creases perpendicular to the feed direction.
Other Features 2. Up to ten cuts perpendicular to the feed direction.
3. Automatic setting of slit, cut and crease position.

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 Chap.1 x Dimensions

x Dimensions

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 Chap.1 c Part Names and Functions

c Part Names and Functions

1. Appearance

Guide Plate Cover (rear)

Cover (front)
Feeder Cover
Exit Tray
Blower Air ADJ Knob

Feed Tray

Guide Plate Operation Panel

Separator ADJ Knob

Stand

Door

Caster

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 Chap.1 c Part Names and Functions

Feeding Section

Separator
Flat Belt
Level ADJ Lever
Guide Plate

Blower Air ADJ Knob

Separator ADJ Knob

Feed Tray Skew ADJ Knob

CCD Margin Slitter Center Slitter

Creaser
2nd Roller Cutter

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 Chap.1 c Part Names and Functions

2. Operation Panel
q w e r

POWER START
+
1 2 3

– 4 5 6
7 8 9
COVER
STOP
F MODE SET
JAM C 0
PAPER

!1 !0 o i u y t

No. Name Function

q LCD panel Displays the status of the machine.

Displays messages when an error or paper jam occurs.
w <+> key Press to eject the document from the machine at the time of paper jam.
<-> key Press to eject the document from the machine at the time of paper jam. During
programming mode enables backward movement through the program steps.
e POWER lamp Lights up when the power is switched on.
r <START> key Not used when the DC-545 is operated without the autofeeder - AF-100. Press
to start processing when the AF-100 is attached.
START lamp Normally lights up in green. Lights up in red when the front cover or the rear
cover is open.
t <STOP> key Press to stop automatic feeding after the current sheet is processed.
Press to clear jam indication after the paper is cleared.
y Key pad Press to enter print numbers and enter values during manual programming.
u <CLEAR> key Press to clear the count. Press to cancel manual programming.
i <SET> key Press to confirm selection/entry. Used to test process a single sheet. (for
systems with the AF-100 only)
o <MODE> key Press to change the mode.
!0 <F> key The AF-100 Feed Tray lowers while the <F> + <-> keys are being pressed.
!1 COVER lamp Blinks when the front cover or the rear cover is open.
JAM lamp Blinks when a paper jam has occurred.
PAPER lamp Blinks when paper runs out. (systems with the AF-100 only)

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 Chap.1 v Work Flow

v Work Flow
1. Operations
1 Various Settings

INPUT .....................................How to create job programs

BAR CODE ........................ When to use bar codes

REGISTER MARK ............When to use register marks

AUTO CUT ...........................When to use AUTO CUT

2 Setting the paper

Select the Program

3
Except when bar code is on.

4 <Start> Key

5 Finish

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 Chap.1 v Work Flow b Options

MODE switching is shown next.

[RUN] P–04

<MODE> KEY

[SELECT] P–04

<MODE> KEY

[INPUT]
INPUT––>SET
<MODE> KEY

<MODE> KEY
BARCODE
*ON OFF
<SET> KEY

<MODE> KEY
REGISTER MARK
*ON OFF
<SET> KEY

<MODE> KEY
AUTO CUT
*ON OFF
<SET> KEY

b Options
Setting the Optional Slitter 2

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 Chapter 2 Description of Operation

z Paper Feed Unit ......................................... 18 m Paper Eject Tray ......................................... 39

1. Description ............................................ 18
2. Operation .............................................. 18
3. Operation of each unit ......................... 19
1. Description ............................................ 39

, Main Drive ................................................... 40

2
(1) Fan (Blower) ............................................ 19 1. Description ............................................ 40
(2) Fan (Suction) ............................................ 20 2. Operation .............................................. 41
(3) Paper Level Sensor .................................. 21
(4) Suction Unit and Feed Motor ................... 22
. Skew Adjustment Mechanism .................. 43
(5) Separator Gap .......................................... 23
1. Description ............................................ 43
(6) Elevator Motor ......................................... 24
(7) Elevator Upper Switch ............................. 25
(8) Elevator Lower Switch ............................ 26 ⁄0 BAR CODE .................................................. 44
(9) Paper Detection Sensor ............................ 27 1. Description ............................................ 44
(10) Feed Solenoid ........................................ 28
(11) Feed Stepping Motor .............................. 29 ⁄1 REGISTER MARK ....................................... 45

x CCD Mechanism ........................................ 30

1. Description ............................................ 30
2. Operation .............................................. 30

c Margin Slitter .............................................. 32

1. Description ............................................ 32
2. Operation .............................................. 33

v Guillotine Cutter Unit ................................. 34

1. Description ............................................ 34
2. Operation .............................................. 34

b Creaser Unit ............................................... 35

1. Description ............................................ 35
2. Operation .............................................. 35

n Center Slitter .............................................. 37

1. Description ............................................ 37
2. Operation .............................................. 37

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 Chap.2 z Paper Feed Unit

z Paper Feed Unit

1. Description
The paper loaded on the feed tray is raised by the Suction Assembly Feed Motor
elevator motor. When the paper is in the required Elevator Motor
position, a jet of air from a fan in front of the paper
causes several sheets of paper to rise up. The suction
unit pulls up the top sheet only, and then the feed motor
drives the suction belt to transfer the paper.
When the paper from the AF-100 reaches the PPS1 in
the DC-545, the paper is transferred to the paper path by
the press roller and the feed stepping motor.
A separator mechanism is used to prevent two or more Feed Tray Fan (Suction)
sheets from being transferred at one time.

Level Sensor
Elevator
Lower SW

Elevator
Upper SW

Fan (Blower)

2. Operation
1) Processing starts (processing does not start if there is no paper).
The fan (blower) and the fan (suction) start running.
2) The feed tray starts rising.
3) The feed tray stops when the paper level sensor turns on (light is not transmitted).
4) The shutter solenoid operates and the shutter opens and the paper is sucked onto the suction unit.
5) The feed motor starts and the suction belt begins turning to transfer the paper.
6) The feed motor stops when the paper reaches PPS1 (light is not transmitted).
If paper does not reach PPS1 within about 2.5 seconds, the elevator falls repeating operations 3) to 5) until
the paper level sensor turns off (light is transmitted). If the operation is repeated three times before the paper
reaches PPS1, a J2: FEED JAM error occurs and the machine stops.
\See page 132

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 Chap.2 z Paper Feed Unit

3. Operation of each unit

(1) Fan (blower)

Description
Paper on the feed tray is transferred to the blower and several sheets are floated up.
The airflow of the blower is adjusted by changing the position of the shutter and fan unit.
The level the paper is floated up is adjusted by changing the airflow of the blower and the paper level sensor.
The fan (blower) is usually running during processing.

Fan (Blower)

Knob

Shutter

Operation
The blower airflow can be increased by turning the knob so the numbers increase.
The gap between the shutter and the fan increases, which increases the air intake and therefore increases the
amount of air blown out.
The blower airflow can be decreased by turning the knob so the numbers decrease.
The gap between the shutter and the fan decreases, which decreases the air intake and therefore decreases the
amount of air blown out.

Circuit diagram

FAN(Blower) Feed P.W.B. unit N4-V303*

N4-X105*
CN2-3
RED
M
-4
BLACK
CN1-1
-3
-12
-17
-18
FAN(Exhaust)
GND
GND
24V

24V
CN1-1
-3
-12
CN11-10
-19

Main P.W.B. unit N4-V300*

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 Chap.2 z Paper Feed Unit

(2) Fan (Suction)

Description
Air near the suction belt is sucked in, and then blown
Fan(Suction)
out on the right side of the AF-100.
The fan (suction) is usually running during processing.

Circuit diagram
FAN(Suction) Feed P.W.B. unit N4-V303*
N4-X105*
CN3-1
RED
M
-3
BLACK
CN1-1
-2
-12
-17
-18
FAN(Intake)
GND
GND
24V

24V
CN1-1
-2
-12
CN11-10
-19

Main P.W.B. unit N4-V300*

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 Chap.2 z Paper Feed Unit

(3) Paper Level Sensor

Description
The paper level sensor controls the elevator motor to
Level
determine the position of the feed tray by detecting the
Sensor
position of the topmost sheet of paper on the feed tray.
q
Status Output
Light not transmitted 5V
Light transmitted 0V
w
To reduce the force of the suction, move the adjustment Level Sensor
lever towards q to increase the gap between the suction Adjustment Lever
belt and the paper.
To increase the force of the suction, move the
adjustment lever towards w to decrease the gap
between the suction belt and the paper.

Turn the lever towards q if the paper is double feed.

Turn the lever towards w if the paper is not being
sucked on to the suction unit.

Circuit diagram
Level Sensor
Feed P.W.B. unit N4-V303*
CA021
CN4-11
1 RED
-12
2 YELLOW
-13
CN1-11
-12
-14
-17

3 BLUE
Level Sensor
GND

GND
5V
CN1-11
-12
-14
CN11-10

Main P.W.B. unit N4-V300*

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 Chap.2 z Paper Feed Unit

(4) Suction Unit and Feed Motor

Description
Shutter Solenoid
Because the fan (suction) is running during processing,
when the shutter solenoid is on, the topmost sheet of
paper on the feed tray is sucked on to the suction unit.
The feed motor starts running about 0.3 seconds after
the shutter solenoid turns on, and the suction belt turns
and transfers the paper to the DC-545.

Shutter (inner)

Circuit diagram

Shutter Solenoid Feed P.W.B. unit N4-V303*

N4-X101*
CN2-7
RED RIGHT
SOL BLUE
-8
RED RIGHT
BLUE
CN2-9
BROWN
M
CN1-1
-6
-7
-12
-17
-18

-10
BLACK
FEED MOTOR
N4-X104*
solenoid
Feed
GND
GND
24V

24V
CN1-1
-6
-7
CN11-10
-19

Main P.W.B. unit N4-V300*

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 Chap.2 z Paper Feed Unit

(5) Separator Gap

Description
The separator gap is a mechanism between the separator
and the suction belt that allows paper that is sucked on
to the suction unit to be transferred one sheet at a time
to the paper path.
This gap is regulated by turning the knob to raise and
lower the separator.

Separator

Separator Adjustment Knob

Turn the knob so that the numbers increase to make the

gap narrower. The separator rises and the gap narrows.
Turn the knob so that the numbers decrease to make the
gap wider. The separator falls and the gap widens.

Raise the separator if the paper being transferred is

double feed.
Lower the separator if paper is mis-feeding.

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 Chap.2 z Paper Feed Unit

(6) Elevator Motor

Description
Elevator Motor
The elevator motor raises and lowers the feed tray.
When there is no paper on the feed tray, the feed tray
lowers until it triggers the elevator lower SW.
However, if paper is loaded on the feed tray while it is
lowering (paper sensor is not transmitting light), the
elevator motor stops and the feed tray stops lowering.
The feed tray rises until the paper level sensor is on
(light is not transmitted) while paper is being fed.
During a paper feed retry operation, the feed tray
continues to lower until the paper level sensor goes off
(light is transmitted) for a period. Then the feed tray
rises until the paper level sensor goes on (light is not
transmitted).
If paper does not reach the elevator upper switch,
elevator lower switch, or paper level sensor after a set
time (*) after the elevator operation, an E8: ELEVATOR
ERROR occurs.
* 10 seconds when rising at start, 3.5 seconds during
paper feed operations, 9 seconds when lowering at
stop
\See page 138

Circuit diagram
Elevator Motor Feed P.W.B. unit N4-V303*
N4-X106*
CN2-5
BROWN
M
-6
BLACK
CN1-1
-4
-5
-17
-18
ELEVATOR1
ELEVATOR2
GND
GND
24V

24V
CN1-1
-4
-5
CN11-10
-19

Main P.W.B. unit N4-V300*

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 Chap.2 z Paper Feed Unit

(7) Elevator Upper Switch

Description
The feed tray stops when the angle that is attached to Elevator Upper SW
the chain that raises and lowers the feed tray turns the
micro switch on.
The feed tray is determined to be at its upper limit when
the micro switch is on, and the feed tray will not rise
any higher.

Circuit diagram
ELEVATOR UPPER SW
Feed P.W.B. unit N4-V303*
LA028

PURPLE CN4-3

PURPLE -4

CN1-9
-11
-12
-17
Elevator Upper SW

GND
GND
5V
CN1-9
-11
-12
CN11-10

5V

5V ON:0V
0 OFF:5V
Main P.W.B. unit N4-V300*

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 Chap.2 z Paper Feed Unit

(8) Elevator Lower Switch

Description
The feed tray stops when the screw that is attached to Elevator Lower SW
the chain that raises and lowers the feed tray turns the
micro switch on.
The feed tray is determined to be at its lower limit when
the micro switch is on, and the feed tray will not go any
lower.
If the elevator lower switch is on because there is too
much paper loaded on the feed tray, and the paper level
sensor is on (light is not transmitted), then a J5: OVER
CAPACITY error occurs.
\See page 133

Circuit diagram
ELEVATOR LOWER SW
Feed P.W.B. unit N4-V303*
LA028

ORANGE CN4-1
CN1-10
-11
-12
-17
ORANGE -2
CN1-10 Elevator Lower SW

GND
GND
-11 5V
-12
CN11-10

5V

5V ON:0V
0 OFF:5V
Main P.W.B. unit N4-V300*

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 Chap.2 z Paper Feed Unit

(9) Paper Detection Sensor

Description
The paper detection sensor detects whether or not there
is paper on the feed tray.
Feed PPS Photo
If there is no paper, the elevator goes to its lower level
Transistor
and stops.
When there is not paper (light is transmitted) the LED
(PAPER) on the operation panel blinks.

Status Output Feed PPS Photo

Paper is present Diode
(light is not transmitted) 5V
Paper is not present
(light is transmitted) 0V

Circuit diagram

Feed P.W.B. unit N4-V303*

5V
Feed PPS Photo Diode
N4-W109*

BROWN CN4-7 5V
BLUE -8

WHITE CN4-9
CN1-11
-12
-13
-17

BLUE -10
Feed PPS Photo Transistor
N4-W206*
-13 Feed PPS
GND

GND
CN1-11 5V
-12

CN11-10

5V Paper is present :5V

0 Paper is not present :0V
Main P.W.B. unit N4-V300*

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 Chap.2 z Paper Feed Unit

(10) Feed Solenoid

Description
Paper that reaches PPS1 is transferred to the paper path
when feeding paper.
As the feed solenoid turns on, the roller driven by the
feed stepping motor presses the paper onto the press
roller and sends it to the main paper path.

Feed Solenoid

Circuit diagram

Feed Solenoid
Main P.W.B. unit N4-V300*
N4-X101*
CN6-1
RED
SOL
-2
RED

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 Chap.2 z Paper Feed Unit

(11) Feed Stepping Motor

Description
Paper that reaches PPS1 is transferred to the main paper
path.

Feed Stepping Motor

Circuit diagram
FEED STEPPING MOTOR
Main P.W.B. unit N4-V300*
M7-X111*
CN3-3
M
-8

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 Chap.2 x CCD Mechanism

x CCD Mechanism
1. Description
The CCD mechanism reads the bar code and register
mark on the paper that is being processed and transfers
the data to the main P.W.B. unit.
The job is automatically selected according to the bar CCD Unit
code (code 39) and the register mark compensates for
incorrect printing positioning.

2. Operation
1) When the paper feeding operation is finished, the
CCD starts reading the bar code.
If the data transfer between the CCD and the main
P.W.B. is not done correctly, then E2: RS232C
ERROR is displayed and the machine stops.
If bar code is off go to Step 4.
\See page 135
2) Data is transferred to the main P.W.B. after the bar
code has been read.
If, when reading starts, the paper is transferred
50 mm but the bar code could not be read, then E3:
BARCODE ERROR is displayed and the machine
stops.
\See page 135
3) The job is set based on the data in the bar code.
4) The machine is in standby until each slitter has been
moved.
If register mark is turned off go to Step 9.
5) The front edge of the paper backs up to PPS2
temporarily.
6) The CCD starts to read the register mark.
7) The amount of compensation is calculated after the
register mark has been read.
If the register mark can not be read even though the
paper has been transferred 40 mm after reading has
started, then E4: REG. MARK ERROR is displayed
and the machine stops.
\See page 135
8) The position of each slitter, cutter and scorer is
adjusted.
9) The CCD processing is finished.

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 Chap.2 x CCD Mechanism

Circuit diagram

CCD unit N4-X103*

CN5-1

CN5-10
~

Main P.W.B. unit N4-V300*

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 Chap.2 c Margin Slitter

c Margin Slitter
1. Description
The margin slitter position motor starts, turning the lead Left Margin Slitter Right Margin Slitter
screw, and the margin slitter is moved to the designated Sensor Sensor
position.
These slitters are used for removing the left and right
margins to the waste tray.

Left Margin Slitter Right Margin Slitter

Left Margin Slitter Position Motor

Left Margin Slitter Slitter Driving Motor

Position Motor

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 Chap.2 c Margin Slitter

2. Operation
1) After paper feeding has finished (after the feed
stepping motor stops) the margin slitter returns to the
home position under the following conditions.
q The first process after the power was turned on.
w After all the covers have been opened.
e After the machine stops due to an error.
r There is no paper in the feed tray, after paper is
loaded in the feed tray again.
t After the job has been changed.
2) When the margin slitter moves from the home
position to the position indicated for the job, if the
margin slitter moves 8 mm and light is still not being
transmitted at the slitter sensor, then E5: SLITTER
ERROR is displayed and the machine stops.
\See page 136

Possible range for each slitter

Name Possible range
Left Margin Slitter 0 to 120 mm
Right Margin Slitter 200 to 320 mm

NOTE :
• 3.2 mm is the smallest possible margin
width.

Circuit diagram

CN4-21
Left Margin Slitter Sensor 1 RED
-22
CA003 2 PEACH
3 BLUE -23

Left Margin Slitter Position Motor CN3-9

M
~

M7-X111* -14

Right Margin Slitter Position Motor CN7-1 Main P.W.B. unit

M
~

M7-X111* N4-V300*
-6

Right Margin Slitter Sensor 1 RED CN8-1

2 YELLOW -2
CA003 -3
3 BLUE

Slitter Driving Motor CN6-3

L8-X1010
M
-4

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 Chap.2 v Guillotine Cutter Unit

v Guillotine Cutter Unit

1. Description
The paper is cut vertically in relation to the direction the
paper is moving. Cutter Motor
Turning on the power starts the cutter motor in standby
in the home position.
One cut can be done in approximately 0.3 seconds.

Cutter Position
Cutter Switch

2. Operation
1) Main transfer stops temporarily when the paper
reaches the cutting position.
2) The cutter motor starts and cutting begins.
3) The cutter motor stops when the cutter position
sensor goes from off to on, and the main transfer
starts again. If the cutter position sensor does not
change (if its on then it stays on) 0.6 seconds after
the cutter motor starts running, then J7: CUTTER
LOCK is displayed and the machine stops.
\See page 134

Circuit diagram
CUTTER UNIT
L8-X109*

CUTTER M.

POSITION SW
BLACK
RED

YELLOW
YELLOW

COVER SW
YELLOW
N4-W119*
YELLOW

YELLOW
COVER SW
N4-W120*
YELLOW
YELLOW
YELLOW
BLACK
RED
CN6-5
-6
-7
-8

Main P.W.B. unit N4-V300*

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 Chap.2 b Creaser Unit

b Creaser Unit
1. Description
The paper is creased vertically in relation to the direction the paper is moving.
One crease can be done in approximately 1.5 seconds.
Turning on the power starts the creaser motor in standby in the home position.

Creaser Position Sensor Creaser Unit

Creaser Motor
Creaser Unit

2. Operation
1) Main transfer stops temporarily when the paper reaches the crease position.
2) The creaser motor starts and cutting begins.
3) The creaser motor stops when the creaser position sensor goes from off to on, and the main transfer starts
again. If the creaser position sensor does not change (if light is transmitted then it continues to transmit) 2.0
seconds after the creaser motor starts running, then J8: CREASE LOCK is displayed and the machine stops.
\See page 134

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 Chap.2 b Creaser Unit

Circuit diagram

CN8-1
CREASER SENSOR 1 RED
-2
CA021 2 YELLOW
-3
3 BLUE

CN3-15
CREASER MOTOR RED
M
N4-X102*
-16
BLACK

Main P.W.B. unit N4-V300*

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 Chap.2 n Center Slitter

n Center Slitter
1. Description
The slitter position motor starts, turning the lead screw, and the center slitter is moved to the designated
position and the paper is cut horizontally in reference to the direction the paper is moving.
A maximum of 4 center slitters can be installed.

Right Center Slitter Left Center Slitter

Right Center Slitter Sensor Left Center Slitter Sensor

OP2 Slitter Sensor OP1 Slitter Sensor

OP2 Slitter OP1 Slitter

OP1 Slitter OP2 Slitter Left Center Slitter Right Center Slitter
Position Motor Position Motor Position Motor Position Motor

Slitter Driving Motor

2. Operation
1) After paper feeding has finished (after the feed stepping motor stops) the center slitter returns to the home
position under the following conditions.
q The first process after the power was turned on.
w After all the covers have been opened.
e After the machine stops due to an error.
r There is no paper in the feed tray, after paper is loaded in the feed tray again.
t After the job has been changed.
2) When the margin slitter moves from the home position to the position indicated for the job, if the margin
slitter moves 8 mm and light is still not being transmitted at the slitter sensor, then E5: SLITTER ERROR is
displayed and the machine stops.
\See page 136

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 Chap.2 n Center Slitter

Possible range for each slitter

Name Possible range Comments
Left center slitter 0 to 160 mm Example:
Right center slitter Left center slitter position +50 mm to 320 mm When the left center slitter is set
at 120.2 mm, settings from
170.2 are possible.
OP1 slitter 0 to 320 mm (when OP2 is not installed.)
0 to 160 mm (OP2 is installed)
OP2 slitter OP1 position +50 mm to 320 mm Example:
(This is an optional slitter) When the OP1 is set at 110.0
mm, settings from 160.0 mm are
possible.

Circuit diagram

CN4-24
Left Center Slitter Sensor 1 RED
-25
CA003 2 ORANGE
3 BLUE -26

Left Center Slitter Position Motor CN7-7

M

~
M7-X111* -12

Right Center Slitter Position Motor CN7-13

M7-X111* M ~
-18

Right Center Slitter Sensor 1 RED CN8-7

2 PEACH -8
CA003 -9
3 BLUE

Slitter Driving Motor CN6-9 Main P.W.B. unit

L8-X1010
M N4-V300*
-10

CN9-7
OP1 Slitter Sensor 1 RED
-8
CA003 2 PURPLE
3 BLUE -9

OP1 Slitter Position Motor CN9-1

M
~

M7-X111* -6

OP2 Slitter Position Motor CN14-1

M
~

M7-X111* -6

CN14-7
OP2 Slitter Sensor 1 RED
-8
CA003 2 PURPLE
3 BLUE -9

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 Chap.2 m Paper Eject Tray

m Paper Eject Tray

1. Description
Paper that is ejected from the DC-545 is collected here.
It is possible to adjust the paper being ejected into two
levels. Refer to the image below for the installation
position.

Position
A
Ejected
A amount.......too small
Ejected B
B amount.......too large

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 Chap.2 , Main Drive

, Main Drive
1. Description
The paper is transferred by the main motor.
All the rollers except the rollers driven by the feed
stepping motor use two timing belts driven by the main
motor.

Main Motor Driver Main Motor

PPS3 Photo Diode PPS2 Photo PPS1 Photo

Transistor Transistor

PPS3 Photo PPS2 Photo

PPS1 Photo Diode
Transistor Diode

PPS4 Photo Transistor

PPS4 Photo Diode

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 Chap.2 , Main Drive

2. Operation
1) After paper stops being fed (after the Feed Stepping Motor stops) the Main Motor starts running and the
paper is transferred to the paper path section.
2) The paper stops temporarily at the CCD and then continues being transferred. If read BAR CODE
(REGISTER MARK) has been set, then the paper continues being transferred after the BAR CODE
(REGISTER MARK) has been read.
3) Main motor stops temporarily when cutting and scoring. When cutting and scoring have finished, transfer
starts again, and stops a short period after the paper is ejected.
The below two conditions cause J3: CENTER JAM to be displayed, and the machine to stop.
\See page 133

q When paper does not reach PPS3 (PPS3 is not w When paper is not extracted from PPS3 (PPS3 is
transmitting light) although the paper has not transmitting light) although the total length of
transferred 100 mm from after the front edge of the paper +30 mm has been transferred from after
the paper has reached PPS2 (PPS2 is not the front edge of the paper has reached PPS3
transmitting light). (PPS3 is not transmitting light).

Start Processing Start processing

No Has the paper reached No Has the paper reached

PPS2? PPS3?
Yes Yes

Count start Count start

Has the paper reached Yes Has the paper Yes

Go to the next path Go to the next path
PPS3? separated from PPS3?
No No

No Has the paper been No Has the paper being

transferred 100 mm? processed been tranferred
a distance more than the
Yes total length of the paper
plus 30 mm?
Yes
J3:CENTER JAM

J3:CENTER JAM

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 Chap.2 , Main Drive

The below two conditions cause J4: SLITTER OR STACK to be displayed, and the machine to stop.
\See page 133
q When paper does not reach PPS4 (PPS4 is not w When paper is not extracted from PPS4 (PPS4 is
transmitting light) although the paper has not transmitting light) although the total length of
transferred 500 mm from after the front edge of the paper +50 mm has been transferred from after
the paper has reached PPS3 (PPS3 is not the front edge of the paper has reached PPS4
transmitting light). (PPS4 is not transmitting light).

Start processing Start processing

No Has the paper reached No Has the paper reached

PPS3? PPS4?
Yes Yes

Count start Count start

Has the paper reached Yes Has the paper Yes

Go to the next path Go to the next path
PPS4? separated from PPS4?
No No

No Has the paper been No Has the paper being

transferred 500 mm? processed been tranferred
a distance more than the
Yes total length of the paper
plus 50 mm?
Yes
J4:SLITTER OR STACK

J4:SLITTER OR STACK

Circuit diagram STEPPING DRIVER

L8-X1080

CN2-1 CN1-1 CN1-1 Main P.W.B. unit

MAIN MOTOR M
~

N4-V300*
M2-X1010 -5 -12 -11

PPS1 LED BROWN CN4-1

5V 5V
N4-W109*
BLUE -2

PPS1 Photo Transistor WHITE -3

N4-W108*
BLUE -4

PPS2 LED BROWN CN4-5

5V 5V
N4-W109*
BLUE -6

PPS2 Photo Transistor WHITE -7

N4-W110*
BLUE -8

PPS3 LED BROWN CN4-9

5V 5V
N4-W110*
BLUE -10

PPS3 Photo Transistor WHITE -11

N4-W111*
BLUE -12

PPS4 LED BROWN CN4-13

5V 5V
N4-W123*
BLUE -14

PPS4 Photo Transistor WHITE -15

N4-W108*
BLUE -16

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 Chap.2 . Skew Adjustment Mechanism

. Skew Adjustment Mechanism

1. Description
If the paper is skewed while processing , use the adjustment knob to adjust the guide and straighten paper.

Angle

Adjustment procedure
q w
Turning the knob Turning the knob clockwise
counterclockwise

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 Chap.2 ⁄0 BAR CODE

⁄0 BAR CODE
1. Description
This machine uses code 39 bar code.

Example: The bar code for P-11 is shown below.

START/STOP bit

* 1 1 2
Preset no.
*
Check digit

The DC-545 can use this bar code if it is converted to CODE-39.

If the bar code comes in the following range, the CCD automatically replaces the data and sends the data (pre-
set no.) to the DC-545.

8 mm

Code-39
BAR CODE Within 35 mm

Paper feeding Direction

60 mm

8 mm

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 Chap.2 ⁄1 REGISTER MARK

⁄1 REGISTER MARK

MARK2

MARK1

Mark 1
1) The paper is transferred in increments of 0.1 mm
from PPS2, and the mark is read by the CCD. The clock count within 10 mm in
Basic clock this space is 70.
2) When the edge of the reg. mark is detected, the in the CCD
reference clock count in the CCD is stored in the
buffer in the microcomputer.
3) After another 0.1 mm is transferred, it is compared
with the clock count before the position of the edge is
detected, and if it is within a fixed range, the count is
then +1, and the reference clock in the CCD is stored Read data
in the microcomputer buffer (up to 10 items). The in the CCD
count is cleared if it is outside the range.
4) When the counter reaches 45 (the edge is the same
10 mm
for 4.5 mm) the value for the mark is the average of Paper Feeding
the values of the 10 values for the reference clock in Direction
the buffer in the CCD.
CCD Reading Range

Mark 2
1) The edge of the REGISTER MARK is detected.
REG.MARK Edge
2) The paper is transferred in increments of 0.1 mm, and
the mark is read by the CCD. If the REGISTER
MARK has the position of the detected edge (it is
OK even if it is not the edge), if the counter is not +1,
the counter goes to 0 and returns to Step 1.
3) The position of mark 2 is determined as 1.0 mm 0.1 mm
before the position when a continuous count of 10
(1.0 mm) is read for the REGISTER MARK. 1.0 mm

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 Chap.2 ⁄1 REGISTER MARK

Positioning REGISTER MARK and BAR CODE

REG. MARK
BAR CODE

30 mm
*a
8 mm
*b 5 mm

8 mm 8 mm or
5 mm or more more
35 mm or less

5 mm
or more
40 mm

* 0.4 mm or
more
10 mm or more

REG. MARK Position range

60 mm or less

5 mm

* The width of Reg. Mark line is 0.4 mm or more.

* a<=b

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 Chapter 3 Mechanical
z Exterior ....................................................... 49 (6) Removing the Right Margin Slitter ................ 63
(1) Removing the AF 100 Cover R Unit ............. 49 (7) Removing the Left Margin Slitter .................. 64
(2) Removing the AF 100 Cover L Unit ............. 49 (8) Removing the Margin Slitter’s
(3) Removing the DC 545 Cover R Unit ............ 49 Upper Blade ................................................... 65
(4) Removing the DC 545 Cover L Unit ............. 50 (9) Removing the Margin Slitter’s
(5) Removing the Lid .......................................... 50 Lower Blade ................................................... 66

3
(6) Removing the Front Cover Switch ................ 50
(7) Removing the Rear Cover Switch ................. 51 b Cutter Section ............................................ 67
(1) Removing the Cutter Assembly ..................... 67
x Feed Section .............................................. 52 (2) Removing the Cutter Motor ........................... 67
(1) Removing the AF 100 .................................... 52 (3) Removing the Cutter Position Switch ............ 68
(2) Removing the Suction Assembly ................... 53
(3) Removing the Flat Belts ................................ 53 n Creaser Section ......................................... 69
(4) Removing the Fan Motor (Blower) ............... 53 (1) Removing the Creaser Motor ......................... 69
(5) Removing the Feed PCB Unit ....................... 54 (2) Removing the Creaser Sensor ........................ 69
(6) Removing the Separator ................................. 54 (3) Removing the Creaser Assembly ................... 70
(7) Removing the Elevator Upper Switch ........... 54
(8) Removing the Elevator Lower Switch ........... 55 m Center Slitter Section ................................ 71
(9) Removing the Paper Level Sensor ................. 55 (1) Removing the Center Slitter
(10) Removing the Feed Motor ........................... 56 Drive Motor ................................................... 71
(11) Removing the Shutter Solenoid ................... 56 (2) Removing the Center Right Slitter
(12) Removing the Shutter .................................. 57 Positioning Motor .......................................... 71
(13) Removing the AF 100 Cover Switch ........... 58 (3) Removing the Center Left Slitter
(14) Removing the Elevator Motor ..................... 58 Positioning Motor .......................................... 71
(15) Removing the Fan Motor (Suction) ............. 58 (4) Removing the Optional Slitter 1
Positioning Motor .......................................... 72
(5) Removing the Optional Slitter 2
c CCD Section ............................................... 59
Positioning Motor .......................................... 72
(1) Removing the CCD Sensor ............................ 59
(6) Removing the Center Right
Slitter Sensor .................................................. 73
v Margin Slitter Section ................................ 60 (7) Removing the Center Left Slitter Sensor ....... 73
(1) Removing the Margin Slitter (8) Removing the Optional Slitter 1 Sensor ........ 74
Driving Motor ................................................ 60 (9) Removing the Optional Slitter 2 Sensor ........ 74
(2) Removing the Right Margin Slitter Position (10) Removing the Center Right Slitter and the
Motor ............................................................. 60 Center Left Slitter ........................................ 75
(3) Removing the Left Margin Slitter Position (11) Removing the Optional Slitter 1 and the
Motor ............................................................. 61 Optional Slitter 2 .......................................... 76
(4) Removing the Right Margin (12) Removing the Center Slitter’s
Slitter Sensor .................................................. 62 Upper Blade ................................................. 77
(5) Removing the Left Margin (13) Removing the Center Slitter’s Lower Blade ... 78
Slitter Sensor .................................................. 62

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 , Driving Section .......................................... 79
(1) Removing the Main Motor ............................ 79
(2) Removing the Feed Stepper ........................... 79
(3) Removing the 1st Roller (Lower) .................. 80
(4) Removing the 2nd and 3rd Rollers
(Lower) .......................................................... 80
(5) Removing the 4th Roller (Lower) .................. 81
(6) Removing the 5th Roller (Lower) .................. 82
(7) Removing the 6th and 7th Rollers
(Lower) .......................................................... 83
(8) Removing the 8th Roller (Lower) .................. 84

. Electric Section .......................................... 85

(1) Removing the PPS1 Phototransistor .............. 85
(2) Removing the Panel PWB Unit ..................... 85
(3) Removing the Motor Driver .......................... 86
(4) Removing the PPS2 Phototransistor and
PPS3 Photodiode ........................................... 86
(5) Removing the PPS1 and PPS2
Photodiode ..................................................... 87
(6) Removing the PPS3 Phototransistor .............. 88
(7) Removing the Feed Solenoid ......................... 89
(8) Removing the Gate Solenoid
(Without using the DC 545HC) .................... 89
(9) Removing the Main P.W.B. Unit ................... 90
(10) Removing the Power Supply, Power Board,
and Memory Board ...................................... 90

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 Chap.3 z Exterior

z Exterior

(1) Removing the AF-100 Cover R Unit

q Remove the AF-100 from the stand. Cover L Unit Cover R Unit
\See page 52

w Take out the 4 screws, and remove the cover R unit.

Screws Screws

(2) Removing the AF-100 Cover L Unit

q Remove the AF-100 from the stand.

\See page 52

w Take out the 4 screws, and remove the cover L unit.

(3) Removing the DC-545 Cover R Unit

q Remove the AF-100 from the stand. Auxiliary Plate

\See page 52

w Take out the 4 screws, and remove the auxiliary

plate.

e Take out the 4 screws, and remove the cover R unit. Screws
NOTE :
• Be sure to attach the auxiliary plate after
attaching the cover.

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 Chap.3 z Exterior

(4) Removing the DC-545 Cover L Unit

q Remove the AF-100 from the stand.

Screws Screws
\See page 52
Cover Cover
w Take out the 4 screws, and remove the cover L unit. L Unit R Unit

Screws
Screws

(5) Removing the Lid

q Take out the 6 screws, and remove the lid.

Lid

Screws

(6) Removing the Front Cover Switch

q Remove the cover R unit from the DC-545.

\See page 49

w Remove the cutter motor.

\See page 67

e Remove the connector for the switch. (2 positions)

Front Cover Rear Cover
r Take out the 2 screws, and remove the front cover Switch Screws Switch Screws
switch.

Reinstallation

IMPORTANT:
• Adjust the position in which to install the
cover switch.
\See page 112

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 Chap.3 z Exterior

(7) Removing the Rear Cover Switch

q Remove the cover R unit from the DC-545.

\See page 49

w Remove the cutter motor.

\See page 67

e Remove the connector. (1 position)

Front Cover Rear Cover
r Take out the 2 screws, and remove the rear cover Switch Screws Switch Screws
switch.

Reinstallation

IMPORTANT:
• Adjust the position in which to install the
cover switch.
\See page 112

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 Chap.3 x Feed Section

x Feed Section

(1) Removing the AF-100

q Take out the two screws.

NOTE :
• The machine made to U.S. specifications has
no screws.

Screws

w Remove the DC-545 and AF-100 connector.

IMPORTANT:
• Be sure to remove the power cord from the
electric outlet before starting work. Not
doing so may damage the main P.W.B. unit. WARN NG

e Remove the AF-100.

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 Chap.3 x Feed Section

(2) Removing the Suction Assembly

q Take out the 2 screws, and remove the joint.

Joint & Screws

w Remove the thumb screw and connector. (1 each)

e Remove the suction assembly. Thumb Screw

Connector

(3) Removing the Flat Belts

q Remove the suction assembly.

\See page 53

w Slide the flat belts off to remove them.

Flat Belts

(4) Removing the Fan Motor (Blower)

q Remove the AF-100 cover L unit. Screws

\See page 49 Connector

w Remove the connector for the fan motor. (1 position). Fan Motor
Shutter
e Remove the spring.
Screws Screws
r Take out the 2 screws, and remove the shutter.
t Remove the 4 screws, and remove the fan motor Spring
(blower).
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 Chap.3 x Feed Section

(5) Removing the Feed PCB Unit

q Remove the AF-100 cover R unit.

\See page 49

w Remove the connector for the feed PCB unit.

(4 positions)

e Take out the 4 screws, and remove the feed PCB

unit.
Screws

(6) Removing the Separator

q Remove the suction assembly. Separator

\See page 53

w Take out the 2 screws, and remove the separator.

Screws

(7) Removing the Elevator Upper Switch

q Remove the AF-100 cover L unit. Lower Angle

\See page 49 & Screws

w Remove the connector for the upper switch.

(1 position) Upper Angle Connector
& Screws
e Take out the 2 screws, and remove the angle.
Elevator Lower
r Take out the 2 screws, and remove the elevator Connector
Switch
upper switch.

Reinstallation

IMPORTANT:
• Adjust the position in which to install the
upper switch.
\See page 111

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 Chap.3 x Feed Section

(8) Removing the Elevator Lower Switch

q Remove the AF-100 cover L unit. Lower Angle

\See page 49 & Screws

w Remove the connector for the lower switch.

(1 position). Upper Angle Connector
& Screws
e Take out the 2 screws, and remove the angle.
Elevator Lower
r Take out the 2 screws, and remove the elevator Connector
Switch
lower switch.

Reinstallation

IMPORTANT:
• Adjust the position in which to install the
lower switch.
\See page 111

(9) Removing the Paper Level Sensor

q Open the cover of the AF-100.

w Remove the connector from the inside of the frame.
Connector
(1 position)

e Take out the 3 screws, and remove the plate unit.

r Remove the connector for the sensor, and then
remove the paper level sensor.
Screws

Connector

Sensor

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 Chap.3 x Feed Section

(10) Removing the Feed Motor

q Remove the AF-100 cover R unit. Blacket & Screws

\See page 49

w Remove the connector for the motor. (1 position)

e Take out the 4 screws, and remove the bracket.

Connector Blacket & Screws

r Loosen the set screws, and remove the pulley unit.

t Take out the 3 screws, and remove the feed motor.
Screws

Pulley Unit & Set Screw

(11) Removing the Shutter Solenoid

q Remove the suction assembly.

Lid
\See page 53

w Take out the 2 screws, and remove the lid.

Screws

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 Chap.3 x Feed Section

e Remove the connector for the solenoid. (1 position) Screws

r Remove the wire unit from the spring.

t Loosen the set screws on the shaft, and remove the Shaft & Shutter
wire unit. Set Screw Solenoid

y Take out the 2 screws, and remove the shutter

solenoid.
Wire Unit Spring Connector
Reinstallation

IMPORTANT:
• Adjust the shutter position when install
the shutter solenoid.
\See page 113

(12) Removing the Shutter

q Remove the Shutter Solenoid. Lid & Screws Plate & Screws
\See page 56

w Take out the 4 screws, and remove the plate.

e Take out the 8 screws, and remove the lid.

Lid & Screws

r Take out the 2 screws, and remove the shutter.

Reinstallation

IMPORTANT:
• Adjust the shutter position when install
the shutter solenoid.
\See page 113
Shutter Screws

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 Chap.3 x Feed Section

(13) Removing the AF-100 Cover Switch

q Remove the AF-100 cover L unit.

\See page 49

w Remove the connector for the switch. (1 position) Connector

Screws
e Take out the 2 screws, and remove the AF-100 cover
switch.

Reinstallation

IMPORTANT:
• Adjust the position in which to install the
AF-100 cover switch.
\See page 112

(14) Removing the Elevator Motor

q Remove the AF-100 cover R unit. Screws Connector

\See page 49

w Loosen the set screws, and remove the motor gear.

e Take out the 3 screws, and remove the motor.
r Remove the connector from inside the frame.
(1 position)
Set Screw

(15) Removing the Fan Motor (Suction)

q Remove the AF-100 cover R unit.

\See page 49
Screws Fan Motor
w Remove the connector for the fan motor. (1 position)
e Take out the 3 screws, and remove the fan motor.

Connector

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 Chap.3 c CCD Section

c CCD Section

(1) Removing the CCD Sensor

q Remove the cover L unit from the DC-545.

\See page 50

w Take out the 6 screws, and remove the lid.

\See page 50

e Remove the connector for the main PWB CN5.

(1 position)
Tie Wrap
r Cut the tie wraps. (4 positions)
NOTE :
• Do not cut any other bundles of wires.

t Remove the code band. (6 positions) Tie Wrap

y Cut the tie wraps. (7 positions)

NOTE :
• Do not cut any other bundles of wires. Tie Wrap

Tie Wrap

u Take out the 2 screws, and remove the CCD sensor. CCD
Reinstallation

IMPORTANT:
• Make adjustments after installing the
CCD sensor.
\See page 102, 109

Screws Paper

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 Chap.3 v Margin Slitter Section

v Margin Slitter Section

(1) Removing the Margin Slitter Driving Motor

q Remove the cover R unit from the DC-545.

\See page 49
Timing Belt
w Take out the 2 screws, and remove the bundled cable
plate.

e Take out the 4 screws, and remove the margin slitter Screws
driving motor.
Bundled Cable Plate
r Remove the timing belt.
t Extract the motor, and remove the connector. Margin Slitter Driving Motor Assembly
(1 position)

y Take out the set screw, and remove the pulley unit.
u Take out the 3 screws, and remove the margin slitter
driving motor.
Screws

Pulley Unit & Set Screw

(2) Removing the Right Margin Slitter

Position Motor

q Remove the cover R unit from the DC-545. Screws Control Plate Assembly
\See page 49

w Take out the 4 screws, and remove the panel bracket.

Connector
e Take out the 4 screws, and remove the right margin
slitter position motor.

r Remove the connector for the motor. (1 position)

Screws

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 Chap.3 v Margin Slitter Section

(3) Removing the Left Margin Slitter

Position Motor

q Remove the cover L unit from the DC-545.

\See page 50

w Take out the 6 screws, and remove the lid.

\See page 50

e Open the door in the stand, and remove the waste

Guide Unit Guide
tray.
Thumb Screws Cover
Screws
r Take out the 2 screws, and remove the cover.
t Undo the thumb screws, and remove the guide unit.
y Remove the connector for the motor. (1 position)
u Take out the 4 screws, and remove the left margin
slitter position motor.

Screws

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 Chap.3 v Margin Slitter Section

(4) Removing the Right Margin Slitter

Sensor

q Open the cover (front) of the DC-545. Angle

w Remove the connector for the sensor. (1 position) Sensor

e Remove the right margin slitter sensor from the

angle.

Reinstallation
Connector
IMPORTANT:
This image shows the right margin slitter sensor.
• Make adjustments after installing the
sensor.
\See page 95

Optional 1 Slitter Sensor Optional 2 Slitter Sensor

Center Left Slitter Sensor Center Right Slitter Sensor

Left Margin Slitter Sensor Right Margin Slitter Sensor

Feed Direction

DC-545 Position Sensor Layout

(5) Removing the Left Margin Slitter

Sensor

q Open the cover (front) of the DC-545.

w Remove the connector for the sensor. (1 position)
e Remove the left margin slitter sensor from the angle.
Reinstallation

IMPORTANT:
• Make adjustments after installing the
sensor.
\See page 95

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 Chap.3 v Margin Slitter Section

(6) Removing the Right Margin Slitter

q Remove the cover R unit from the DC-545. Timing Belt Screws

\See page 49 Lead

Screw
w Take out the screw, and remove the clamper.
(2 positions)
Shafts
e Loosen the 4 screws and slide the motor plate Motor
towards the exit tray. Plate

r Face the key groove on the shaft downwards, and Clamper & Screws
pull it out on the operation side. (2 positions)

NOTE :
• Do not drop the bearings from opposite the
operation side into the machinery. (2 posi-
tions)
• Do not drop the left or right margin slitter key
into the machinery. (4 positions)

t Remove the timing belt.

y Take out the 2 screws, and remove the lead screw.
NOTE :
• Do not drop the bush that is on the lead
screw into the machinery.
Reinstallation

IMPORTANT:
• Make adjustments after installing the
slitter.
\See page 95

• Adjust the play in the Lead Screw to be

less than 0.1 mm.

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 Chap.3 v Margin Slitter Section

(7) Removing the Left Margin Slitter

q Remove the cover R unit from the DC-545. Timing Belt Screws

\See page 49 Lead

Screw
w Remove the cover L unit from the DC-545.
\See page 50
Shafts
e Take out the 1 screw, and remove the clamper on the Motor
Plate
operation side. (2 positions)
Clamper & Screws
r Loosen the 4 screws and slide the motor plate
towards the feeder.
Screws
t Face the key groove on the shaft downwards, and
pull it out on the operation side. (2 positions) Lead Screw

NOTE :
• Do not drop the bearings from opposite the
operation side into the machinery. (2 posi- Timing Belt
tions)
• Do not drop the left or right margin slitter key
into the machinery. (4 positions)

y Remove the timing belt.

u Take out the 2 screws, and remove the lead screw.
NOTE :
• Do not drop the bush that is on the lead
screw into the machinery.
Reinstallation

IMPORTANT:
• Make adjustments after installing the
slitter.
\See page 95

• Adjust the play in the Lead Screw to be

less than 0.1 mm.

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 Chap.3 v Margin Slitter Section

(8) Removing the Margin Slitter’s Upper

Blade

q Remove the right margin slitter, left margin slitter.

\See page 63, 64

w Take out the 4 screws, and remove the upper

assembly. Screws

e Take out the 2 screws from the upper assembly, and Upper Assembly Lid Upper Blade
remove the lid. (2 positions) Assembly

r Remove the bearings. (2 positions)

t Remove the upper blade assembly. Screws

NOTE :
• Be careful not to cut yourself on the edge of
the blade. Bearings

y Remove the C-clip, and then remove the disk,

spring, and the upper blade. C-Clip Upper Blade

Spring Boss

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 Chap.3 v Margin Slitter Section

(9) Removing the Margin Slitter’s Lower

Blade

q Remove the right margin slitter and the left margin Screws
slitter.
\See page 63, 64

w Take out the 2 screws, and remove the lower

assembly.

e Take out the screws from the lower assembly, and Lower Assembly Lower Blade Unit
remove the guide plate.

r Take out the 2 screws, and remove the lid. Guide Plate
(2 positions)

t Remove the bearing. (2 positions)

y Remove the lower blade unit.
Screws Lid & Screws
NOTE :
• Be careful not to cut yourself on the edge of
the blade.

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 Chap.3 b Cutter Section

b Cutter Section

(1) Removing the Cutter Assembly

q Remove the cover R unit from the DC-545.

\See page 49

w Remove the cover L unit from the DC-545. Screw

\See page 50

e Remove the connector for the motor. (1 position)

r Take out the 2 screws, and remove the cutter Connector
assembly.

Reinstallation

IMPORTANT:
• Make adjustments after installing the
cutter assembly.
\See page 98, 107

Screw

(2) Removing the Cutter Motor

q Remove the cutter assembly. Screw Cutter Motor Assembly

\See page 67

w Take out the 2 screws, and remove the cutter motor

Tie Wrap
assembly.

e Loosen the set screws, and remove the eccentric

shaft.

r Take out the 3 screws, and remove the cutter motor. Screw

Set Screw

Eccentric Shaft

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 Chap.3 b Cutter Section

(3) Removing the Cutter Position Switch

q Remove the cover R unit from the DC-545. Screws

\See page 49

w Cut the tie wrap on the cutter motor wires.

Hole for
e Remove the connector for the switch and the motor. access
(2 positions) to screws

NOTE : Tie Wrap

• Switch wires are yellow and yellow. Motor
wires are red and black.

r Take out the 2 screws, and remove the cutter

position switch.

Motor Connector

Switch Connector

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 Chap.3 n Creaser Section

n Creaser Section

(1) Removing the Creaser Motor

q Remove the cover L unit from the DC-545.

\See page 50

w Take out the 6 screws, and remove the lid.

\See page 50

e Remove the main P.W.B.

\See page 90 Screws

r Take out the 3 screws, and remove the plate.

t Remove the motor connector and Power Supply

PCB connector.

Connector

y Loosen the set screws, and remove the pulley unit.

u Take out the 4 screws, and remove the creaser motor
assembly.

Pulley Unit & Set Screw

(2) Removing the Creaser Sensor

q Remove the cover R unit from the DC-545.

Connector
\See page 49

w Remove the connector for the sensor. (1 position) Sensor

e Remove the creaser sensor from the sensor angle.

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 Chap.3 n Creaser Section

(3) Removing the Creaser Assembly

q Remove the cover R unit from the DC-545. Cover (Rear) Upper Cover & Screws Cover (Front)
& Screw & Screw
\See page 49
Creaser
w Remove the cover L unit from the DC-545. Assembly

\See page 50

e Take out the screw, and remove the cover (front).

r Take out the screw, and remove the cover (rear). Pillar & Screw Screws Timing Belt

t Take out the 4 screws, and remove the upper cover.

y Take out the 4 screws, and remove the creaser belt.
u Take out the screw, and remove the pillar from the
main rear drive.

i Remove the timing belt.

o Take out the screws, and remove the sensor plate.
Screw

Sensor
Plate

!0 Take out the 4 screws from the auxiliary plate Screws

(upper).

!1 Pull the creaser assembly out opposite the operation

side.

Reinstallation

IMPORTANT:
• Make adjustments after installing the Auxiliary Plate (Upper)
creaser assembly.
\See page 108

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 Chap.3 m Center Slitter Section

m Center Slitter Section

(1) Removing the Center Slitter Drive

Motor

q Remove the cover R unit from the DC-545. Pulley Unit

\See page 49 Center Slitter
Drive Motor
w Take out the 4 screws, and remove the center slitter Assembly
drive motor assembly.

e Remove the connector for the motor. (1 position)

r Loosen the set screws, and remove the pulley unit.
Screws
t Take out the 3 screws, and remove the center slitter
drive motor.

(2) Removing the Center Right Slitter

Positioning Motor

q Remove the cover R unit from the DC-545. Center Left Slitter Positioning Motor

\See page 49

w Take out the 2 screws, and remove the center right

slitter positioning motor assembly. Center Right
Slitter Positioning
e Remove the connector from the motor. (1 position) Motor

r Take out the 4 screws, and remove the center right

slitter positioning motor. Screws Screws

(3) Removing the Center Left Slitter Posi-

tioning Motor

q Remove the cover R unit from the DC-545. Center Left Slitter Positioning Motor

\See page 49

w Take out the 2 screws, and remove the center left

slitter positioning motor assembly. Center Right
Slitter Positioning
e Remove the connector from the motor. (1 position) Motor

r Take out the 4 screws, and remove the center left

slitter positioning motor. Screws Screws

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 Chap.3 m Center Slitter Section

(4) Removing the Optional Slitter 1 Posi-

tioning Motor

q Remove the cover L unit from the DC-545. Optional Slitter 1 Positioning Motor
\See page 50

w Take out the 4 screws, and remove the optional

slitter positioning motor assembly.

e Remove the connector from the motor. Optional Slitter 2

Positioning Motor
NOTE :
• There are two connectors when the optional Screws
slitter 2 positioning motor is installed, but
only one connector when it is not installed.

r Take out the 4 screws, and remove the optional

slitter 1 positioning motor.

(5) Removing the Optional Slitter 2 Posi-

tioning Motor

q Remove the cover L unit from the DC-545. Optional Slitter 1 Positioning Motor
\See page 50

w Take out the 4 screws, and remove the optional

slitter positioning motor assembly.

e Remove the connector from the motor. (2 positions) Optional Slitter 2

Positioning Motor
r Take out the 4 screws, and remove the optional
slitter 2 positioning motor. Screws

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 Chap.3 m Center Slitter Section

(6) Removing the Center Right Slitter

Sensor
Angle Connector
q Open the cover (rear) of the DC-545.
w Remove the connector for the sensor. (1 position) Sensor

e Remove the sensor from the angle.

Reinstallation

IMPORTANT: This image shows the optional 1 slitter sensor.

• Make adjustments after installing the
slitter.
\See page 95

Optional 1 Slitter Sensor Optional 2 Slitter Sensor

Center Left Slitter Sensor Center Right Slitter Sensor

Left Margin Slitter Sensor Right Margin Slitter Sensor

Feed Direction

DC-545 Position Sensor Layout

(7) Removing the Center Left Slitter Sen-

sor

q Open the cover (rear) of the DC-545.

w Remove the connector for the sensor. (1 position)
e Remove the sensor from the angle.
Reinstallation

IMPORTANT:
• Make adjustments after installing the
slitter.
\See page 95

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 Chap.3 m Center Slitter Section

(8) Removing the Optional Slitter 1 Sensor

q Open the cover (rear) of the DC-545. Angle Connector

w Remove the connector for the sensor. (1 position)
Sensor
e Remove the sensor from the angle.
Reinstallation

IMPORTANT:
• Make adjustments after installing the This image shows the optional 1 slitter sensor.
slitter.
\See page 95

Optional 1 Slitter Sensor Optional 2 Slitter Sensor

Center Left Slitter Sensor Center Right Slitter Sensor

Left Margin Slitter Sensor Right Margin Slitter Sensor

Feed Direction

DC-545 Position Sensor Layout

(9) Removing the Optional Slitter 2 Sensor

q Open the cover (rear) of the DC-545.

w Remove the connector for the sensor. (1 position)
e Remove the sensor from the angle.
Reinstallation

IMPORTANT:
• Make adjustments after installing the
slitter.
\See page 95

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 Chap.3 m Center Slitter Section

(10) Removing the Center Right Slitter and

Center Left Slitter

q Remove the cover R unit from the DC-545. Screws Lead Screw Clampers & Screws
Shafts
\See page 49
Position Belt
w Loosen the 2 screws on the center right (left) slitter
Position
motor plate, and remove the position belt. Belt
Timing Belt
(2 positions) Center Right
Slitter Motor
e Loosen the 4 screws on the motor plate, and remove Center Left Plate
the timing belt. (1 position) Slitter Motor
Plate Screws Motor Plate Screws
r Take out the screw, and remove the clamper.
(2 positions)

t Face the key groove on the shaft downwards, and

pull it out on the operation side.
(2 positions)

NOTE :
• Do not drop the bearings from opposite the
operation side into the machinery.
(2 positions)
• Do not drop the center right slitter or center
left slitter keys into the machinery.
(4 positions)

y Take out the 2 screws, and remove the lead screw.

(2 positions)

NOTE :
• Do not drop the collar or disc that are on the
lead screw into the machinery.
• Do not install the center right slitter and the
center left slitter in the wrong positions
during assembly.
Reinstallation

IMPORTANT:
• Make adjustments after installing the
slitter.
\See page 95

• Adjust the play in the Lead Screw to be

less than 0.1 mm.

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 Chap.3 m Center Slitter Section

(11) Removing the Optional Slitter 1 and

the Optional Slitter 2

q Remove the cover R unit from the DC-545. Shafts

\See page 49
Clampers
w Remove the cover L unit from the DC-545. & Screws

\See page 50

e Loosen the 4 screws on the motor plate, and remove

the timing belt. (1 position)
Timing Belt Motor Plate
r Take out the screw, and remove the clamper.
(2 positions)

t Face the key groove on the shaft downwards, and

pull it out on the operation side. (2 positions)

NOTE :
• Do not drop the bearings from opposite the
operation side into the machinery.
(2 positions)
• Do not drop the optional slitter 1 or the
Lead Screws Screws
optional slitter 2 into the machinery. Screws
(4 positions)

y Loosen the 4 screws on the motor plate on optional

slitter 1 and optional slitter 2, and remove the
position belt. (2 positions) Position
Position Belt Belt
u Take out the 3 screws, and remove the lead screw.
(2 Positions)
Screws Motor Plate
NOTE :
• Do not drop the collar or disc that are on the
lead screw into the machinery.
• Do not install the optional slitter 1 and the
optional slitter 2 in the wrong positions
during assembly.
Reinstallation

IMPORTANT:
• Make adjustments after installing the
slitter.
\See page 95

• Adjust the play in the Lead Screw to be

less than 0.1 mm.

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 Chap.3 m Center Slitter Section

(12) Removing the Center Slitter’s Upper

Blade

NOTE :
• The center left slitter, and the optional slitter
2 as well as the center right slitter and the
optional slitter 1 are made in the same
configuration.

q Remove the center slitter.

\See page 75, 76
Lid & Screws
Screws
w Take out the 3 screws, and remove the lid unit R.
Bearings
e Remove the bearing. (2 positions)
r Take out the 2 screws, and remove the lid.

t Remove the upper blade assembly.

Spacer Upper Blade
NOTE : Assembly & Screws
• Be careful not to cut yourself on the edge of
the blade.
• Be careful not to lose the wave washer and
spacer.

y Take out the 2 screws, and remove the blade.

Wave Washer

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 Chap.3 m Center Slitter Section

(13) Removing the Center Slitter’s Lower

Blade

NOTE :
• The center left slitter, and the optional slitter
2 as well as the center right slitter and the
optional slitter 1 are made in the same
configuration.

q Remove the center slitter.

\See page 75, 76

w Take out the 3 screws, and remove the lid. Lid

e Remove the bearing. Lid & Screws

r Take out the 2 screws, and remove the lid. Screws

Bearing

t Remove the lower blade assembly.

Lower Blade Assembly & Screws
NOTE :
• Be careful not to cut yourself on the edge of
the blade.
• Be careful not to lose the wave washer and
spacer.

y Take out the 2 screws, and remove the blade.

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 Chap.3 , Driving Section

, Driving Section

(1) Removing the Main Motor

q Remove the cover L unit from the DC-545.

Pillar & Screw Main Belt
\See page 50

w Take out the screw, and remove the pillar.

e Remove the main belt.
Screws
r Remove the connector for the stepper driver PWB
CN2. (1 position)

t Take out the 3 screws, and remove the main motor.

(2) Removing the Feed Stepper

q Remove the cover L unit from the DC-545.

\See page 50
Timing Belt
w Take out the 2 screws on the motor plate, and
remove the timing belt.

e Remove the connector for the motor. (1 position) Screw

r Take out the 4 screws, and remove the feed stepper.

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 Chap.3 , Driving Section

(3) Removing the 1st Roller (Lower)

q Remove the cover R unit from the DC-545. Pulley Unit & Set Screw
1st Roller
\See page 49 & Bearings

w Remove the cover L unit from the DC-545. Clamper & Screw

\See page 50 Timing Belt

e Take out the 2 screws, and remove the motor plate. Motor Plate
& Screws
r Remove the belt.
t Loosen the set screws, and remove the pulley unit.
Screws
y Take out the 4 screws, and remove the auxiliary
plate.

u Take out the 4 screws, and remove the lid.

i Take out the screw, and remove the clamper. Screws
(2 positions)

o Remove the bearings. (2 positions) Lid Auxiliary Plate

!0 Remove the 1st roller.

(4) Removing the 2nd and 3rd Rollers (Lower)

q Remove the cover R unit from the DC-545. 3rd Roller Pulley Units
& Bearings & Set Screws
\See page 49
2nd Roller
w Remove the cover L unit from the DC-545. & Bearings

\See page 50 Pillar

Clampers
e Take out the screw, and remove the pillar. & Screws
Main Belt
r Remove the main belt (front).
t Loosen the set screws, and remove the pulley unit.
y Take out the 4 screws, and remove the auxiliary plate.
u Take out the 4 screws, and remove the lid.
i Take out the screw, and remove the clamper.
(2 positions)

o Remove the bearings. (4 positions)

!0 Remove the 2nd and 3rd Roller.

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 Chap.3 , Driving Section

(5) Removing the 4th Roller (Lower)

NOTE :
• Do not cut yourself on the cutter unit.

q Remove the cover R unit from the DC-545.

Screws
\See page 49

w Remove the cover L unit from the DC-545.

\See page 50

e Take out the screw, and remove the pillar. Plate

r Remove the main drive belt (front).

t Loosen the set screws, and remove the pulley unit.
Springs, E-Rings, Bushes Pulley Unit
y Open the cover (front) on the DC-545. & Set Screw
4th Roller
u Take out the 2 screws, and remove the plate. & Bearings

i Remove the spring. (2 positions) Clampers

& Screws
o Remove the E ring from the 4th roller (upper). Pillar

!0 Remove the 4th roller (upper). Main Belt (Front)

!1 Take out the screw, and remove the clampers.

(2 positions)

!2 Remove the bearings. (2 positions)

!3 Remove the 4th roller (lower).

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 Chap.3 , Driving Section

(6) Removing the 5th Roller (Lower)

q Remove the cover R unit from the DC-545. Springs, E-Rings, Bushes 5th Roller

\See page 49

w Remove the cover L unit from the DC-545.

\See page 50

e Take out the screw, and remove the pillars.

(2 positions)
Remove the main drive belt (front). Main Belt (Rear) Pillar Main Belt (Front)

r Remove the main drive belt (rear).

t Loosen the set screws, and remove the pulley unit.
y Open the cover (rear) on the DC-545.
u Remove the spring. (2 positions)
i Remove the E rings from the 5th roller (upper).
(2 positions)

o Remove the 5th roller (upper).

!0 Take out the screw, and remove the clampers.
(2 positions)

!1 Remove the bearings. (2 positions)

!2 Remove the 5th roller (lower).

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 Chap.3 , Driving Section

(7) Removing the 6th and 7th Rollers

(Lower)

q Remove the cover R unit from the DC-545. Springs, E-Rings, Bushes
\See page 49
6th Roller
w Remove the cover L unit from the DC-545. & Bearings

\See page 50
7th Roller
e Take out the screw, and remove the pillar. & Bearings Pillar
(1 position)
Main Belt (Rear)
r Remove the main drive belt (rear).
t Loosen the set screws, and remove the pulley unit.
y Open the cover (rear) on the DC-545.
u Remove the spring. (2 positions)
i Remove the E rings from the 6th and 7th rollers
(upper). (2 positions)

o Remove the 6th and 7th rollers (upper).

!0 Take out the screw, and remove the clampers.
(2 positions)

!1 Remove the bearings. (2 positions)

!2 Remove the 6th and 7th rollers (lower).

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 Chap.3 , Driving Section

(8) Removing the 8th Roller (Lower)

q Remove the cover R unit from the DC-545. Springs & E-Rings & Bushes
Screws
\See page 49

w Remove the cover L unit from the DC-545.

\See page 50 Piller
8th Roller
e Remove the belt tensioner from the main drive belt & Bearings
(rear).
Clampers & Screws
r Remove the main drive belt (rear).
t Loosen the set screws, and remove the pulley unit.
y Open the cover (rear) on the DC-545.
Connector
u Take out the 4 screws, and remove the rear plate.
i Remove the connector for the rear plate. (1 position)
o Remove the spring. (2 positions)
Rear Plate
!0 Remove the E rings from the 8th roller (upper).
!1 Remove the 8th roller (upper).
!2 Take out the screw, and remove the clamper.
(2 positions)

!3 Remove the bearings. (2 positions)

!4 Remove the 8th roller. (lower)

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 Chap.3 . Electric Section

. Electric Section

(1) Removing the PPS1 Phototransistor

q Remove the cover L unit from the DC-545. Screws

\See page 50

w Open the cover (front) on the DC-545. Connector

e Remove the connector for the guide plate unit.

(1position)

r Take out the 2 screws, and remove the guide plate Guide Plate Unit Tie Wrap
unit.

t Cut the tie wraps. (2 positions)

y Take out the 2 screws, and remove the
phototransistor.
Ref. Photodiode: Brown, blue
Phototransistor: White, blue

(2) Removing the Panel PWB Unit

q Remove the cover R unit from the DC-545. Screws Control Plate Assembly
\See page 49
Nuts
w Remove the connector. (1 position)
Panel PWB
Unit
e Take out the 4 screws, and remove the control plate
assembly.

r Undo the 8 nuts, and remove the panel PWB unit. Connector

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 Chap.3 . Electric Section

(3) Removing the Motor Driver

q Remove the cover L unit from the DC-545.

\See page 50
Motor
w Remove the connector for the motor driver. Driver
(2 positions) Screws
Connector
e Take out the 4 screws, and remove the motor driver.

(4) Removing the PPS2 Phototransistor

and PPS3 Photodiode

q Remove the cover L unit from the DC-545. Tie Wrap Connector
\See page 50

w Remove the connector. (1 position)

Code Band
e Cut the tie wrap. (1 position)
r Take out the screw, and remove the code band.
(3 positions)

t Take out the 2 screws, and remove the bracket.

Code Band Phototransistor PPS3
y Take out the 2 screws, and remove the
phototransistor PPS2.
Bracket(PPS3)
& Screws
u Take out the 2 screws, and remove the bracket
(PPS3).

i Take out the 2 screws, and remove the

phototransistor PPS3. Bracket(PPS2)
Ref. Photodiode: Brown, blue & Screws
Phototransistor PPS2
Phototransistor: White, blue

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 Chap.3 . Electric Section

(5) Removing the PPS1 and PPS2 Photo-

diode

q Remove the cover R unit from the DC-545. 2nd Roller Right Margin Slitter
Position motor
\See page 49
Plate
w Remove the cover L unit from the DC-545.
\See page 50
PPS1
e Remove the right margin slitter position motor. Phototransistor
Connector
\See page 60
Guide Plate Unit Front Plate
r Take out the 4 screws, and remove the auxiliary
plate.
Feed Lamp Screws
t Take out the 4 screws, and remove the lid.
(1 position)

y Remove the connector for the feed lamp. Front Plate

u Take out the 4 screws, and remove the front plate. Screws

i Loosen the set screws on the lever unit on the Screws Lid Auxiliary Plate
operation side.

o Remove the E ring opposite the operation side, and Connector (PPS3)
remove the bush.

!0 Remove the square shaft.

!1 Remove the connector for the PPS1 phototransistor.
(1 position)
Connector (PPS1) Connector (PPS2)
!2 Take out the 2 screws, and remove the guide plate
unit.
Lever Unit & Set Screw
NOTE :
• You need to make adjustments during
installation.

!3 Remove the connector from the inside of the frame. Square Shaft
(1 position)

NOTE :
• There are three connectors in a row. They are
in order from the feeder, the PPS1 photo-
diode, the PPS2 photodiode, and the PPS3
Phototransistor.Do not install them in the
wrong position.

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 Chap.3 . Electric Section

!4 Remove the spring from the 2nd roller (upper). 2nd Roller Right Margin Slitter
(2 positions) Position motor

!5 Remove the E rings from the 2nd roller (upper), Plate

and remove the bushes. (2 positions each)

!6 Remove the 2nd roller (upper). PPS1

Phototransistor
Connector
!7 Take out the 6 screws, and remove the plate.
Guide Plate Unit Front Plate
!8 Take out the 2 screws, and remove the photodiode
PPS1 and PPS2.
Ref. Photodiode: Brown, blue
Phototransistor: White, blue

(6) Removing the PPS3 Phototransistor

q Remove the cover R unit from the DC-545. Screws

\See page 49

w Remove the cover L unit from the DC-545.

\See page 50

e Take out the 4 screws, and remove the auxiliary Screws

plate.
Lid Auxiliary Plate
r Take out the 4 screws, and remove the lid.
t Remove the connector from the inside of the frame. Connector (PPS3)
(1 position)

NOTE :
• There are three connectors in a row. They are
in order from the feeder, the PPS1 photo-
diode, the PPS2 photodiode, and the PPS3
phototransistor. Do not install them in the
wrong position.
Connector (PPS1) Connector (PPS2)
y Remove the cable cramp. (2 positions)
u Remove the margin slitter L. Cable Cramp
\See page 64

i Open the cover of the DC-545.

o Take out the 2 screws, and remove the plate.
!0 Remove the springs from the 4th roller (upper).
(2 positions)

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 Chap.3 . Electric Section

!1 Remove the E rings from the 4th roller (upper).

Center Plate PPS3 Phototransistor
(2 positions)
Plate
!2 Remove the 4th roller (upper).
!3 Take out the 4 screws, and remove the center plate. Screws

!4 Take out the 2 screws, and remove the PPS3

phototransistor.
Ref. Photodiode: Brown, blue
Phototransistor: white, blue

(7) Removing the Feed Solenoid

q Remove the cover R unit from the DC-545. Z Collar & Screw

\See page 49

w Remove the connector for the solenoid. (1 position)

e Take out the screw, and remove the Z collar. Bracket

r Take out the 2 screws, and remove the bracket.

Connector
t Take out the 3 screws, and remove the feed solenoid.

(8) Removing the Gate Solenoid (Without

using the DC-545HC)

q Remove the cover L unit from the DC-545. Z Collar & Screw
\See page 50

w Remove the connector for the solenoid. (1 position)

e Take out the 2 screws, and remove the bridge. Bracket
& Screws
r Take out the screw, and remove the Z collar.
Bridge
t Take out the 2 screws, and remove the bracket.
y Take out the 3 screws, and remove the feed solenoid.

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 Chap.3 . Electric Section

(9) Removing the Main P.W.B. Unit

q Remove the lid.

\See page 50 Main P.W.B unit

w Remove all of the connectors from the Main P.W.B.

unit. (There are 13 positions when the OP2 is not
installed, and 14 positions when it is installed).

e Take out the 6 screws, and remove the main P.W.B.

unit.
Screws
Reinstallation

IMPORTANT:
• Note the values on the following Help
before changing the main P.W.B.
H-09, H-24, H-26, H-27
\See page 140
• Enter the values that you noted after
replacing the main P.W.B.

(10) Removing the Power Supply, Power

Board, and Memory Board

q Remove the DC-545 cover R unit.

\See page 49

w Remove the center slitter drive motor.

\See page 71

e Remove the lid.

\See page 50 Screws
r Remove all of the connectors from the Main P.W.B.
unit.

t Remove the 3 screws and take off the plate and then
remove the cable cramp. Cable Cramp

NOTE :
• The main board, power supply, power board
and memory board are attached to the Plate.

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 Chap.3 . Electric Section

y Remove the screws and then take off the power Power Supply Power Board
supply, power board, and memory board.

Reinstallation Screws

IMPORTANT:
Memory
• Jobs that the user has stored are erased Board
when the Memory board is changed. Screws
• When a new Memory board is installed it
has no memory, perform H-25: INITIAL-
Screws Screws
IZE RAM.
HELP mode H-25 \see p. 148

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 Chap.3 . Electric Section

MEMO

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 Chapter 4 Standard Adjustments
z LCD Panel ................................................... 94 . Cutter Assembly Perpendicularity
1. Objective ............................................... 94 Adjustment ............................................... 107
2. How to make adjustments ................... 94 1. Objective ............................................. 107
2. How to make adjustments ................. 107
x Slitter Position ........................................... 95
1. Objective ............................................... 95 ⁄0 Creaser Perpendicularity Adjustment .... 108
2. How to make adjustments ................... 95 1. Objective ............................................. 108
2. How to make adjustments ................. 108
c Cutter Registration .................................... 98
1. Objective ............................................... 98 ⁄1 CCD Vertical Line Alignment ................... 109
2. How to make adjustments ................... 98 1. Objective ............................................. 109

v Creaser Calibration .................................. 100

2. How to make adjustments ................. 109
4
1. Objective ............................................. 100 ⁄2 Elevator Switch Height Adjustment ......... 111
2. How to make adjustments ................. 100 1. Objective .............................................. 111
2. How to make adjustments .................. 111
b CCD Horizontal Line Alignment.............. 102
1. Objective ............................................. 102 ⁄3 Cover Switch (AF-100: 1 position,
DC-545: 2 positions) ................................ 112
2. How to make adjustments ................. 102
1. Objective ............................................. 112
2. How to make adjustments ................. 112
n Adjusting Crease Depth .......................... 104
1. Objective ............................................. 104
⁄4 Shutter Solenoid ....................................... 113
2. How to make adjustments ................. 104
1. Objective ............................................. 113
2. How to make adjustments ................. 113
m Feed Solenoid Adjustment...................... 105
1. Objective ............................................. 105
⁄5 Creaser Sensor Plate Adjustment ........... 118
2. How to make adjustments ................. 105
1. Objective ............................................. 118
2. How to make adjustments ................. 118
, Gate Solenoid Adjustment
(Without the DC-545HC) .......................... 106
1. Objective ............................................. 106
2. How to make adjustments ................. 106

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 Chap.4 z LCD Panel

z LCD Panel
1. Objective
Adjusting the brightness and contrast of the LCD
backlight.

2. How to make adjustments

q Adjusting the LCD backlight
Turn VR1 to adjust the backlight.
• Turn VR1 clockwise to make the backlight darker.
• Turn VR1 counterclockwise to make the backlight
brighter.

VR1
VR2

Panel PWB unit

w Adjusting the LCD contrast

Turn VR2 to adjust the contrast.
• Turn VR2 clockwise to make the text darker.
• Turn VR2 counterclockwise to make the text lighter.

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 Chap.4 x Slitter Position

x Slitter Position
1. Objective
Adjusting the position of each slitter.

2. How to make adjustments

q Prepare some paper that is either 81/2” x 11”, A4
size, or use the adjustment sheet.

w Turn on the power.

e Select P-75. Turn off both bar code and reg. mark.
NOTE :
• Use a JOB that has the LEFT. SL set to 10.0
mm and the RIGHT. SL set to 270.0 mm when
the preset program P-75 have been
overwitten.
\See page 155

r Run one sheet of paper, and measure the width of the

left margin. If the margin is within a range of 10.0
mm +/- 0.762 mm, go to Step i. If it is not in that
range, go to Step t to make adjustments.

t Access H-24.
HELP mode H-24 \ see p.147
∗100 100 100
100 100 100
Left Margin Slitter Left Center Slitter Optional Slitter1
Right Margin Slitter Right Center Slitter Optional Slitter2
y Adjust H-24 so that the width of the left margin is
within a range of 10.0 mm +/- 0.762 mm.
• Increase the numbers to make the width of the left
margin larger.
• Decrease the numbers to make the width of the left
margin smaller.

u Repeat Steps r to y until the width of the left

margin is within the correct range.

i Run one sheet of paper and measure the width of the

piece of paper that comes out in the exit tray. If the
width is within a range of 260.0 mm +/- 0.762 mm
go to Step !2. If it is not in that range go to Step o,
to make adjustments.

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 Chap.4 x Slitter Position

o Access H-24.

!0 Adjust H-24 so that the width of the paper is within

a range of 260.0 mm +/- 0.762 mm.
• Increase the numbers to make the width of the paper
larger.
• Decrease the numbers to make the width of the paper
smaller.

!1 Repeat Steps i to !0 until the width of the paper is

within the correct range.

!2 Select P-77 (P-78 when OP2 is installed).

Turn off both bar code and reg. mark.
NOTE :
• Use a JOB that has the LEFT. SL set to 10.0
mm and the RIGHT. SL set to 218.0 mm
(270.0 mm), and the C.L. SL set to 62.0 mm,
the C.R. SL set to 166.0 mm (218.0 mm), the
OP 1 SL set to 114.0 mm, and the OP 2 SL set
to (166.0 mm) when the preset program P-78
(P-78 when OP 2 is attached) have been
overwritten.
\See page 155

!3 Run one sheet of paper and measure the width of the

piece of paper that comes out in the exit tray. If the
width is within a range of 52.0 mm +/- 0.762 mm
finish the job. If it is not in that range go to Step !4,
to make adjustments.

!4 Access H-24.

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 Chap.4 x Slitter Position

!5 Adjust H-24 so that the width of the paper is within

a range of 52.0 mm +/- 0.762 mm.
• Increase the numbers to move the center slitter away
from the slitter sensor.
• Decrease the numbers to move the center slitter closer to
the slitter sensor.

Right Center Slitter Left Center Slitter

Right Center Slitter Sensor

Left Center Slitter Sensor

OP2 Slitter Sensor OP1 Slitter Sensor

OP2 Slitter OP1 Slitter

!6 Repeat Steps !3 to !5 until the width of the paper is

within the correct range.

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 Chap.4 c Cutter Registration

c Cutter Registration
1. Objective
Adjusting the feed from PPS3 to the cutter.

2. How to make adjustments

q Select P-79. Turn off both bar code and reg. mark.
NOTE :
• Use a JOB that has the Cut 1 set to 10.0 mm
when the preset program P-79 have been
overwritten.
\See page 155
• Do not lose the leading edge of the waste
paper that falls into the waste tray so that
you can measure it.

w Run one sheet of paper that is either 81/2” x 11”, A4

size, or use the adjustment sheet.

e Measure the pieces of waste paper. If the width of

the waste paper is within a range of 10.0 mm +/-
0.762 mm, finish the job. If it is not in that range, go
to Step r to make adjustments.

Lead Ed e P 79 L ft arg n P 8 1 mm 0 762

5 mm 0 762
( -72 77 8
L FT L ~ C L

P-79 P-80
Feed direction
L

P 2 75 REG OFF BC OFF AF 100 to DC 45 oun ing Al gme t(O e By O e)

(P 77 8
C L SL ~ O 1 SL
(P 73 104 m
LE T SL ~ P1

P 6 R G O F BC O F AF 100 to DC 545 Mou ting A igm nt( ne y O e ith OP2 SL)

P 7 R G O F C O F AF 100 to DC 545 Mou ting A igm nt
P 8 R G O F C O F AF 100 to DC 545 Mou ting A igm nt( ith OP2 SL)
P 9 R G O F C O F L ad dge Le gth & S ore Po iti n
2mm

P 9 R G ON C O F I age Shi t hec 1

P 0 R G ON C O F I age Shi t hec 2

10mm+/-0.762
762
L
76

Sco e P siti n P 79 104m 62

Feed direction

(P-78 5 mm 0 762

(P-77 5 mm 0 762

(P-76 1 6m
P1 L ~ OP2 SL

P1 L ~ C R SL

EFT SL ~ OP2 SL
P-72~78

Feed Direction
7 2
( -78 52 m 0 762
O 2 SL ~ C R L
( -77 52 m 0 762
C R SL ~ IGHT SL
( -74 20 mm 0 762
L FT L ~ C R SL

DC-545
Adjustment Sheet

Lead Edge
(P- 8
C R SL ~ RI HT L

(P- 5
LEFT SL ~ R GHT SL
2m

60m

Duplo
7 2

62

N4 2061

r Remove the rear lid (N4-G1250).

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 Chap.4 c Cutter Registration

t Adjust the rotary DIP SW (SW2) on the main P.W.B.

Adjustments are made in increments of 0.2 mm for Main P.W.B unit
each step. Reduce the number to make the cut
shorter, and increase the numbers to make the cut
longer. Access H-09 to confirm the value that is ROM
currently set.
HELP mode H-09 \ see p.143
4 56
23

7 8 9A
01
EF
BCD

Rotary DIP SW
y Repeat Steps w to t until the width of the leading
edge of the waste paper is within the range of 10.0
mm +/- 0.762 mm.

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 Chap.4 v Creaser Calibration

v Creaser Calibration
• Removing the Creaser Assembly
\See page 70
NOTE :
• You need to adjust the sensor plate after
installing the creaser assembly.
\See page 118
• You need to adjust the creaser perpendicu-
larity and creaser calibration after adjusting
the sensor plate.
\See page 108

1. Objective
Adjusting the distance between the cutter and the
creaser.

2. How to make adjustments

q Select P-79. Turn off both bar code and reg. mark.
NOTE :
• Use a JOB that has the Cut 1 set to 10.0 mm
and SCR 1 set to 114.0 mm when the preset
program P-79 have been overwritten.
\See page 155

w Run one sheet of paper that is either 81/2” x 11”, A4

size, or use the adjustment sheet.

e Measure the distance from the leading edge of the

paper that was fed and the SCR.1. If the distance is
within a range of 104.0 mm +/- 0.762 mm finish the
job. If it is not in that range go to Step r, to make
adjustments.

104.0 mm 0.762 mm
Lead Edge

SCR.1
Feed Direction

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 Chap.4 v Creaser Calibration

r Access H-26.
HELP mode H-26 \ see p.148

t Adjust the distance between the lead edge of the

paper and SCR.1 with the <+> and <-> keys.
(Increasing the value by 1 makes the length 0.1 mm,
and decreasing the value by 1 makes the length 0.1
mm.)
• If the distance from the lead edge to SCR.1 is 103.3 mm
or less, increase the value.
• If the distance from the lead edge to SCR.1 is 104.7mm
or greater, decrease the value.

y Repeat Steps w to t until the width of the distance

from the leading edge to SCR.1 is 104.0 mm +/-
0.762 mm.

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 Chap.4 b CCD Horizontal Line Alignment

b CCD Horizontal Line Alignment

1. Objective
Adjusting the installation angle of the CCD.

2. How to make adjustments

q Prepare an adjustment sheet or make the markings
shown below on a piece of white paper.

10 10

10

10

w Turn on the power.

e Select P-77.
NOTE :
• Use a JOB that has the MARK 1 set to
70.0mm and MARK 2 set to 10.0 mm when
the preset program P-77 have been overwrit-
ten.
\See page 155

r Turn off bar code, turn on reg. mark, and then turn
off AUTO CUT.

t Turn off the power.

y Turn on the power while pressing the <SET> key.

u Paper can be fed in the following ways depending on

the type of machine.

<For DC-545HC>
• Place the sample paper that was prepared in Step 1 on
the feed tray, and then press the <START> key to start
feeding.

<For DC-545>
• Place the sample on the feed tray to start feeding.

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 Chap.4 b CCD Horizontal Line Alignment

i When the machine stops, the following appears on

the LCD display panel. Confirm the value that is
shown at “a” in the diagram. If the value is greater ∗∗ ∗∗∗∗∗∗∗∗∗∗∗∗ a
than 119 and less than 125, finish the job. If the
value for “a” is less than 120, or greater than 124, go
∗∗∗∗∗∗∗∗ 122 ∗∗∗
to Step o to make adjustments.

o Loosen the four screws holding the CCD, and then

adjust the angle.
• Adjust the CCD towards A (increase the angle), if the
value for “a” is greater than 124.
• Adjust the CCD towards B (decrease the angle), if the
value for “a” is less than 120.
A B
!0 Repeat Steps t to o until the value for “a” is
between 120 and 124.
IMPORTANT:
• Do not make adjustments while in the HELP
mode (H-27).
NOTE :
• You can check the value in HELP mode (H-
27), but the value is shown as 27:CCD DIST.
H-27 = [145-“a”]
You need to make adjustments if this value is DISTANCE: 23
not in a range of 23 +/- 2.
HELP mode H-27 \ see p.148

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 Chap.4 n Adjusting Crease Depth

n Adjusting Crease Depth

1. Objective
Adjusting the depth of the crease.
• Removing the Creaser Assembly
\See page 70
NOTE :
• You need to adjust the sensor plate after
installing the creaser assembly.
• You need to adjust the creaser perpendicu-
larity and creaser calibration after adjusting
the sensor plate.

• Creaser Sensor Plate Adjustment

\See page 118
• Creaser Perpendicularity Adjustment
\See page 108
• Creaser Calibration
\See page 100

2. How to make adjustments

NOTE :
• A test sheet may be creased by inserting it in
the creaser gap and manually rotating the
creaser unit pulley.

q Place the Creaser Assembly in the “upright” position

(normal operating orientation) on a stable surface.

w Loosen the two lock nuts, as shown in Figure.

e Rotate the Creaser Assembly pulley unit the eccen-

tric shaft has reached it lowest point. Eccentric Shaft

r Place a 0.6 mm feeler gauge between the Creaser

Blades, making certain the gauge does not interfere
with the raised area on the male creaser blade.
Rotate each adjusting bolt clockwise to increase the Pulley Unit
Lock Nuts
gap size (or counterclockwise to decrease the gap Upper Blade
size).

t Tighten each lock nut while holding the respective

adjusting bolt.

y Verify the gap size and readjust if necessary.

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 Chap.4 m Feed Solenoid Adjustment

m Feed Solenoid Adjustment

1. Objective
Adjusting the clearance between the 1st roller (upper)
and the 1st roller (lower).
• Removing the Feed Solenoid
\See page 89

2. How to make adjustments

q Position the solenoid bracket so the set screws are
located in the center of the slotted holes on the
solenoid bracket.

w Loosen the set screw and adjust the distance between

the 1st roller (upper) and the 1st roller (lower) so
that it is between 1 mm and 2 mm. Also make sure
the end play of the square shaft is 0.2 mm.

e Adjust the distance between the E-clip on the

solenoid's plunger and the rubber so that it is
between 3 mm and 4 mm so that the 1st rollers,
upper and lower, contact.

r Access H-11.
HELP mode H-11 \ see p.144

t Press the <+> key to confirm if the solenoid oper-

ates.

y If the distance between the two rollers is not correct,

adjust the solenoid bracket position.

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 Chap.4 , Gate Solenoid Adjustment (Without the DC-545HC)

, Gate Solenoid Adjustment

(Without the DC-545HC)
1. Objective
Adjust the height of the gate solenoid.
• Removing the Gate Solenoid
\See page 89

2. How to make adjustments

q Turn off the power to the machine and disconnect
the power cord.

w Position the solenoid bracket so the set screws are

located in the center of the slotted holes on the
solenoid bracket.

e Loosen the set screw and adjust the gate position so

it is between 4.5 mm to 5.0 mm above the plate.
Note the lever should be pulled up by the spring.
Also make sure the end play of the shaft is 0.2 mm.

r Access H-11.
HELP mode H-11 \ see p.144

t Press the <+> key to confirm if the solenoid oper-

ates.

y If the gate position is not correct, adjust the solenoid

bracket to obtain the proper position.

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 Chap.4 . Cutter Assembly Perpendicularity Adjustment

. Cutter Assembly Perpendicularity Adjustment

1. Objective
Adjusting the perpendicularity of the cutter assembly.
• Removing the Cutter Assembly
\See page 67
NOTE :
• Do this procedure first before you install the
cutter assembly, and then adjust the cutter
registration and the creaser calibration.

• Cutter Registration Adjustment

\See page 98
• Creaser Calibration Adjustment
\See page 100

2. How to make adjustments

q Prepare some paper that is either 81/2” x 11”, A4
size, or use the adjustment sheet.

w Turn on the power.

e Select P-79. Turn off both bar code and reg. mark.
NOTE : Main Belt (Front)
• Use a JOB that has the Cut 1 set to 10.0 mm
when the preset program P-79 have been
overwritten.
\See page 155
• Put a mark on the leading edge of the paper
that falls into the waste tray for confirmation
when you can measure it.

r Adjust the cutter assembly screws so that the cut off Screw
leading edges are parallel. (2 positions) Pillar

t Adjust the cutter registration after installation.

\See page 98

Screw

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 Chap.4 ⁄0 Creaser Perpendicularity Adjustment

⁄0 Creaser Perpendicularity Adjustment

1. Objective
Adjusting the perpendicularity of the creaser assembly.
• Removing the Creaser Assembly
\See page 70
NOTE :
• You need to adjust the sensor plate after
installing the creaser assembly.
\See page 118
• You need to adjust the creaser perpendicu-
larity and creaser calibration after adjusting
the sensor plate.
\See page 100

2. How to make adjustments

q Prepare some paper that is either 81/2” x 11”, A4
size, or use the adjustment sheet.

w Turn on the power.

e Select P-79. Turn off both bar code and reg. mark.
NOTE :
• Use a JOB that has the Cut 1 set to 10.0 mm
and SCR 1 set to 114.0 mm when the preset
program P-79 have been overwritten.
\See page 155

r Adjust the creaser assembly screws so it is parallel

with the leading edge of the paper. (4 positions) Screws

108
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 Chap.4 ⁄1 CCD Vertical Line Alignment

⁄1 CCD Vertical Line Alignment

1. Objective
Adjusting the installation of the CCD so that it is level.

2. How to make adjustments

q Prepare some paper that is either 81/2” x 11” or A4
size paper, on which a straight line has been drawn
10 mm from the leading edge of the paper, or use the 10mm
adjustment sheet.

w Turn on the power, set the paper you prepared in Feeding

Step q on the feed tray. direction

e Paper can be fed in the following ways depending on

the type of machine.

<For DC-545HC>
• Press the <START> key to start feeding the paper.
Lead Ed e P 79 Left Margin P 78 10mm 0 762

<For DC-545>

52m
(P-72 77,78)
LEFT L ~ C.L SL
.762
P 79 P 80
Feed direction

• Start feeding the paper. P 72 75 REG OFF BC: FF AF 100 to DC 45 Moun ing Ali ment(One By One)

P-77,78) 52mm 0. 62
.L.SL ~ P1 SL
P-73) 10 mm
EFT SL ~ OP
P 76 REG:OFF BC:OFF AF 100 to DC 545 Mounting Aligme t(One By One with OP2 SL)
P 77 REG:OFF BC:OFF AF 100 to DC 545 Mounting Aligme t
P 78 REG:OFF BC:OFF AF 100 to DC 545 Mounting Aligme t(With O 2 SL)
P 79 REG:OFF BC:OFF Lead Edge Lehgth & Score Position
P 79 REG:ON BC:OFF Image Sh ft Chec 1

r Open the cover when the paper approaches the CCD.

P 80 REG:ON BC:OFF Image S ift Chec 2

.762
SL
Score Posi ion P 79 104mm 762

Feed direction

(P-78) 52mm 0 762

OP1 SL ~ OP2 L
(P-77) 52mm 0 762
OP1 SL ~ C.R. L
(P-76) 156m
LEFT L ~ OP
P-72~78
The message E1: COVER OPEN is displayed, and

.762
SL
the machine stops.
( -78) 52m
O 2 SL ~ C R.SL
( -77) 52m
C R.SL ~ R GHT SL
( -74) 208 m .762
L FT SL ~ . .SL
DC-545
Adjustment Sheet .762

.762

t Turn off the power.

(P-78) 2mm 0.7 2
C.R.SL ~ RIGHT L

(P-75) 60mm 0. 62
LEFT SL ~ RI HT SL

Duplo
y Access H-22.
N4 Y2061

HELP mode H-22 \ see p.146

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 Chap.4 ⁄1 CCD Vertical Line Alignment

u Loosen the screws of the CCD and adjust its position

so that the CNT value is 70 +/- 1. CCD

i Tighten the screws so that the CNT value is within a

range of 70 +/- 1.

o Remove the paper and finish.

Screws Paper

+KEY:CCD ON
CNT:70

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 Chap.4 ⁄2 Elevator Switch Height Adjustment

⁄2 Elevator Switch Height Adjustment

1. Objective
Adjusting the upper and lower limits of the elevator.
• Removing the Elevator Switch
\See page 54, 55

2. How to make adjustments

• Upper Limit Switch adjustment

q Access H-29.
HELP mode H-29 \ see p.148

w Press the <+> key to adjust the movement of the

Upper Limit Switch (LA028) within the range Upper
shown below. Switch

4 to
5mm

• Lower Limit Switch adjustment

q Access H-29.
HELP mode H-29 \ see p.148

w Press the <-> key to adjust the movement of the

Lower Limit Switch (LA028) within the range
shown below.

5 to
6mm

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 Chap.4 ⁄3 Cover Switch (AF-100: 1 position, DC-545: 2 positions)

⁄3 Cover Switch (AF-100: 1 position, DC-545: 2 positions)

1.Objective
Adjusting the operating position of the cover switch.
• Removing the Cover Switch
\See page 50, 51, 58

2. How to make adjustments

q Turn the power off and disconnect the power cord.

w Adjust the cover switch so that the micro switch

goes on when the cover has been opened from 6 to
10 mm.
6 to 10mm
e After finishing the adjustments, access H-08 and
confirm that the status of “m” and “w” are operating
correctly.
HELP mode H-08 \ see p.143

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 Chap.4 ⁄4 Shutter Solenoid

⁄4 Shutter Solenoid
1. Objective
Adjusting the shutter operation.
• Removing the Shutter Solenoid
\See page 56

2. How to make adjustments

Solenoid Assembly
q Attach the angle and plate to the solenoid. Set the Plate
plate as far in the direction of the arrow as possible.
Attach the solenoid assembly to the duct. Set the
solenoid assembly as far in the direction of the arrow
as possible.

Angle

w Turn the shaft counterclockwise until the shutter is

closed.
Pull the wire unit to move the plunger in the
direction of the arrow.

Wire Unit

e While pulling on the wire unit give it a 3/4 wrap.

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 Chap.4 ⁄4 Shutter Solenoid

r Hold the wire unit so that it doesn't become loose

and pass it through the hole in the spindle.

t Pull the wire to remove any slack in the wire.

Check again that the shutter is closed.

y Wrap the wire counterclockwise as shown by the

arrow.
Wrap the wire towards the top as shown in the
image.

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 Chap.4 ⁄4 Shutter Solenoid

u Attach the wire unit to spring T.

i Fasten the set screw so that the shutter is in the

closed position.
L Wrench

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 Chap.4 ⁄4 Shutter Solenoid

o Make sure that the shutter is closed when the

solenoid is off.
In the case of diagram 1, move the plate or angle in
the direction of the arrow until the shutter closes.
See the illustration of the following page.

Diagram 1, an incorrect example of

when the solenoid is off

Diagram 2, a correct example of

when the solenoid is off

!0 Make sure that the shutter is at 70˚ or 80˚ when the

solenoid is on (pulling it by hand).
In the case of diagram 3, adjust the angle of the open
shutter so that it is between 70 to 80 by moving the
plate in the direction of the arrow as shown in the
image below.
See the illustration of the following page.

Diagram 3, an incorrect example of

when the solenoid is on.

From 70˚ to 80˚

Diagram 4, a correct example of

116 when the solenoid is on
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 Chap.4 ⁄4 Shutter Solenoid

Plate

Angle

!1 Access H-31.
HELP mode H-31 \ see p.149

!2 Press the <+> key to make sure that the shutter

moves smoothly.

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 Chap.4 ⁄5 Creaser Sensor Plate Adjustment

⁄5 Creaser Sensor Plate Adjustment

1. Objective
Adjusting the standby position of the creaser’s upper
blade.
• Removing the Creaser Assembly
\See page 70
NOTE :
• You need to adjust the sensor plate after
installing the creaser assembly.
\See page 108
• You need to adjust the creaser perpendicu-
larity and creaser calibration after adjusting
the sensor plate.
\See page 100

2. How to make adjustments

q Access H-18.
HELP mode H-18 \ see p.145

w Stop the upper and lower blades with the <+> key so
that the space between them is wide.

e Use one screw to position the sensor plate so that its

left edge touches the middle of the sensor.

Sensor Plate & Screw

Sensor Plate Left Edge

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 Chapter 5 Maitenance Checks
z Cleaning and Oiling ................................. 120
(1) Cleaning ....................................................... 120
(2) Oiling ........................................................... 120

x Periodic Maintenance Check List ........... 120

(1) 6 month Periodic Checks ............................. 120
(2) Criteria for Replacing Primary Parts ........... 121

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 Chap.5 z Cleaning and Oiling x Periodic Maintenance Check List

z Cleaning and Oiling

(1)Cleaning

1.Paper shreds
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.

x Periodic Maintenance Check List

(1) 6-month Periodic Checks

1. DC-545
Section to be checked Description Inspection standard
PPS1 Cleaning Use a brush to clean any paper dust, etc. from the
upper and lower sensors.
PPS2 Cleaning Use a brush to clean any paper dust, etc. from the
upper and lower sensors.
PPS3 Cleaning Use a brush to clean any paper dust, etc. from the
upper and lower sensors.
PPS4 Cleaning Use a brush to clean any paper dust, etc. from the
upper and lower sensors.
Timing Belts Checking Inspect Belts for signs of wear or loss of tension.
Replace any cracked or worm belts, and retension as
required.
Rollers Cleaning Use a lint-free cloth moistened with water to clean the
rollers.
Roller Bearings Oiling Oil (70P95)
Slitter Oiling Oil (70P95)
Cutter Oiling Oil (70P95)

2. AF-100
Photo Emitting Sensor (N4-W1091) Cleaning Use a brush to clean any paper dust, etc.
Photo Receiving Sensor (N4-W2061) Cleaning Use a brush to clean any paper dust, etc.
Flat Belts Cleaning Use a brush to clean any paper dust, etc.
Gears Greasing

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 Chap.5 x Periodic Maintenance Check List

(2) Criteria for Replacing Primary Parts

1. DC-545
PARTS No. DESCRIPTION MTBF
L8-X1110 Cutter motor 2,000,000 times
L8-B1112 Upper blade (margin slitter) 1,500,000 sheets
L8-B2060 Lower blade (margin slitter) 1,500,000 sheets
N4-D2100 Upper blade (center slitter) 1,500,000 sheets
N4-D2230 Lower blade (center slitter) 1,500,000 sheets
N4-E1010 Creaser unit (female) 1,500,000 times
N4-E1080 Creaser unit (male) 1,500,000 times
L8-C1061 Rubber roller 1,500,000 sheets
AJ * * * Timing belt 1,500,000 sheets
M2-X1010 Stepping motor (main) 1,200,000 sheets
L8-X1010 Gear motor (slitter drive) 1,200,000 sheets
M7-X1110 Stepping motor (slitter position) 1,200,000 sheets
N4-X1020 Gear motor 2,000,000 cycles
N4-X1000 Paper feed solenoid 1 8,000 hours
N4-X1010 Paper feed solenoid 2 8,000 hours
Main board unit 40,000 hours
Panel board unit 40,000 hours
Memory board unit 40,000 hours

2. AF-100
PARTS No. DESCRIPTION MTBF
N4-K1021 Flat belt 300,000 to 500,000 sheets
N4-K2122 Separator 300,000 to 500,000 sheets
AJ036 Timing belt 1,500,000 sheets
N4-V3031 Feed PCB unit 40,000 hours
N4-W1091 Photo-emitting PCB 40,000 hours
N4-W2061 Photo-receiving PCB 40,000 hours
N4-W2070 Wiring/Inter lock 30,000,000 times
N4-X1010 Solenoid 8,000 hours
N4-X1040 Gear motor 3,000 hours
N4-X1050 Fan motor 10,000 hours
N4-X1060 Gear motor 500 hours
CA021 Photo interrupter 40,000 hours
LA028 Micro switch 200,000 times
N4-K4550 Actuator 300,000 to 500,000 sheets

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 Chap.5 x Periodic Maintenance Check List

MEMO

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 Chapter 6 Troubleshooting
z Troubleshooting Guide ........................... 124
(1) J1: REJECT PAPER .................................... 124
(2) J2: FEED JAM ............................................. 124
(3) J3: CENTER JAM ....................................... 126
(4) J4: SLITTER OR STACK ............................ 126
(5) J5: OVER CAPACITY ................................. 127
(6) J7: CUTTER LOCK .................................... 127
(7) J8: CREASE LOCK ..................................... 128
(8) E1: COVER OPEN ...................................... 128
(9) E2: RS232C ERROR ................................... 128
(10) E3: BARCODE ERROR ............................ 129
(11) E4: REG.MARK ERROR .......................... 129
(12) E5: SLITTER ERROR ............................... 130
(13) E6: DATA ERROR ..................................... 130
(14) E7: CONNECTION ERROR ..................... 131
(15) E8: ELEVATOR ERROR ........................... 131

x Error Display ............................................ 132

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 Chap.6 z Troubleshooting Guide

z Troubleshooting Guide

(1) J1: REJECT PAPER

Pro- Cause/Defective part Items to be checked Result Countermeasure

ce-
dure
1 In the machine Is there some paper in the Yes Remove the paper from inside the
machine? machine.
2 PPS Is the sensor normal when Yes Finish.
checked in HELP mode (H-
08)?
3 Was the sensor level check No Clean the relevant sensors. If this
done at HELP mode (H-03, 04, does not solve the trouble, replace
05, and 06) correct? the sensors.
4 Main PWB unit Is the main PWB unit connec- No Plug the connector in firmly. Plug
tor CN4 plugged in? the connector in firmly.
Yes Replace the faulty sensor.

HELP mode H-08 \ see p.143

(2) J2: FEED JAM

Pro- Cause/Defective part Items to be checked Result Countermeasure

ce-
dure
1 Paper Does the paper meet specifica- No Use paper that meets specifica-
tions? tions.
2 Separator Is the trouble cleared by Yes Finish
adjusting the space between the
separator and the suction belt?
3 Suction fan Is the trouble cleared by setting Yes Finish
the suction appropriately?
4 Paper level sensor Is the trouble cleared by Yes Finish
correcting the position of the
paper level sensor?
5 Feed motor Does it operate in HELP mode Yes Go to procedure 8.
(H-31)?
6 Is the connector for the feed No Plug the connector in firmly.
motor firmly plugged in?
7 Is the voltage measured with a Yes Replace the feed motor.
tester between CN2-9 (+) and
CN2-10 (GND) on the feed No Go to procedure 21.
PCB unit +24 V (DC) while the
feed motor is operating?
8 Fan (blower) Does it operate in HELP mode Yes Go to procedure 11.
(H-30)?
9 Is the connector for the fan No Plug the connector in firmly.
(blower) firmly plugged in?
10 Is the voltage measured with a Yes Replace the fan (blower).
tester between CN2-3 (+) and
CN2-4 (GND) on the feed PCB No Go to procedure 21.
unit +24 V (DC) while the fan
(blower) is operating?
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 Chap.6 z Troubleshooting Guide

Pro- Cause/Defective part Items to be checked Result Countermeasure

ce-
dure
11 Fan (suction) Does it operate in HELP mode Yes Go to procedure 14.
(H-30)?
12 Is the connector for the fan No Plug the connector in firmly.
(suction) firmly plugged in?
13 Is the voltage measured with a Yes Replace the fan (blower).
tester between CN2-3 (+) and
CN2-4 (GND) on the feed PCB No Go to procedure 18.
unit +24 V (DC) while the fan
(blower) is operating?
14 Paper level sensor Is it normal when checked in Yes Go to procedure 16.
HELP mode (H-08)?
15 Is the voltage measured with a No Replace the sensor.
tester between CN4-12 (+) and
CN4-13 (GND) on the feed No Go to procedure 21.
PCB unit +5 V (DC), is it 0 V
(DC) during light transmission?
16 Connections Are the AF-100 and the DC- No Connect them firmly.
545 firmly connected?
17 Feed motor Is it normal when checked in No Replace the feed motor.
HELP mode (H-10)?
18 Feed solenoid Does it operate when in HELP Yes Go to procedure 20.
mode (H-11)?
19 Is the voltage measured with a Yes Replace the feed solenoid.
tester between CN6-1 (+) and
CN6-2 (GND) on the main No Replace the main PWB unit.
PWB unit +24 V (DC) while the
feed solenoid is operating?
20 Is the press pressure too weak Yes Adjust the press pressure.
when the feed solenoid is
operating?
21 Front Plate Does it operate normally if you Yes Finish
open a gap between the Front
Plate (N4-A1190) and Plate
(N4-A1210)?
22 Feed PCB unit Is the trouble cleared by Yes Finish
replacing the feed PCB unit? No Check the wire bundles and the
connectors, and if there are not
problems, replace the main PWB
unit.

HELP mode H-08 \ see p.143

HELP mode H-10 \ see p.143
HELP mode H-11 \ see p.144
HELP mode H-30 \ see p.149
HELP mode H-31 \ see p.149

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 Chap.6 z Troubleshooting Guide

(3) J3: CENTER JAM

Pro- Cause/Defective part Items to be checked Result Countermeasure

ce-
dure
1 Paper length Is the paper on which the Yes Use paper that matches the JOB
trouble occurred at least 30 data, or rewrite the JOB data.
mm longer than the JOB data?
2 Main motor Is it normal when checked in No Replace the stepper driver PWB.
HELP mode (H-11)? If that does not clear the trouble,
then replace the main motor.
3 Margin slitter drive Is it normal when checked in Yes Replace the main PWB unit.
motor HELP mode (H-20)?
4 Margin slitter drive Is the belt tension too high? Yes Adjust the belt tension.
motor belt tension
5 Margin slitter drive Is the connector for the margin No Plug the connector in firmly.
motor slitter drive motor firmly
plugged in?
6 Main PWB unit Is the voltage measured with a Yes Replace the margin slitter drive
tester between CN6-3 (+) and motor.
CN6-4 (GND) on the main No Replace the main PWB unit.
PWB unit +24 V (DC) while the
slitter drive motor is operating?
HELP mode H-11 \ see p.144
HELP mode H-20 \ see p.145

(4) J4: SLITTER OR STACK

Pro- Cause/Defective part Items to be checked Result Countermeasure

ce-
dure
1 Paper length Is the paper on which the Yes Use paper that matches the JOB
trouble occurred at least 50 data, or rewrite the JOB data.
mm longer than the JOB data?
2 Paper curl Is the paper getting stuck on Yes Eliminate any curl from the paper.
the paper path because it is
curled?
3 Main motor Is it normal when checked in No Replace the stepper driver PWB.
HELP mode (H-11)? If that does not clear the trouble,
then replace the main motor.
4 Center slitter drive Is it normal when checked in Yes Replace the main PWB unit.
motor HELP mode (H-20)?
5 Center slitter drive Is the belt tension too high? Yes Adjust the belt tension.
motor belt tension
6 Center slitter drive Is the connector for center No Plug the connector in firmly.
motor slitter drive motor firmly
plugged in?
7 Main PWB unit Is the voltage measured with a Yes Replace the center slitter driver
tester between CN6-9 (+) and motor.
CN6-10 (GND) on the main
PWB unit +24 V (DC) while the No Replace the main PWB unit.
center slitter drive motor is
operating?
HELP mode H-11 \ see p.144
HELP mode H-20 \ see p.145
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 Chap.6 z Troubleshooting Guide

(5) J5: OVER CAPACITY

Pro- Cause/Defective part Items to be checked Result Countermeasure

ce-
dure
1 Amount of paper Is paper loaded over the MAX? Yes Reduce the paper so that it is
loaded below MAX.
2 Paper level sensor Is the actuator stuck? Yes Adjust the actuator so that is
moves smoothly.
3 Is the trouble cleared by Yes Finish
adjusting the paper level
sensor?
4 Is it normal when checked in Yes Go to procedure 6.
HELP mode (H-08)?
5 Is it normal when checked in No Plug the connector in firmly.
HELP mode (H-08)? No Replace the paper level sensor.
6 Elevator lower Is it normal when checked in No Replace the elevator lower switch.
switch HELP mode (H-08)? No Replace the main PWB unit.

HELP mode H-08 \ see p.143

(6) J7: CUTTER LOCK

Pro- Cause/Defective part Items to be checked Result Countermeasure

ce-
dure
1 Paper Does the paper meet specifica- No Use paper that meets specifica-
tions? tions.
2 Cutter position Is it normal when checked in Yes Go to procedure 4.
switch HELP mode (H-08)?
3 Main PWB unit Is the connector for the main No Plug the connector in firmly.
PWB unit 6 firmly plugged in? Yes Replace the cutter position switch.
4 Cutter motor Does the blade go up and No If the motor is running, check that
down when checked in HELP the hollow screw on the cutter
mode (H-19)? drive is tight. If the motor is not
running, replace the cutter motor.
5 Interlock While the power is turned off, No Check the interlock SW wires, if
remove CN6 from the main they are normal, replace the
PWB unit and measure the switch.
resistance between CN6-5 and
CN6-6. Is the resistance equal
to some amount of ohms (W) Yes Replace the main PWB unit.
when all the covers are
closed? Or is the resistance
infinite ohms ( W) when one
of the covers is open?

HELP mode H-08 \ see p.143

HELP mode H-19 \ see p.145

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 Chap.6 z Troubleshooting Guide

(7) J8: CREASE LOCK

Pro- Cause/Defective part Items to be checked Result Countermeasure

ce-
dure
1 Paper Does the paper meet specifica- No Use paper that meets specifica-
tions? tions.
2 Creaser sensor Is it normal when checked in Yes Go to procedure 4.
HELP mode (H-08)?
3 Main PWB unit Are the connectors for the No Plug the connector in firmly.
Main PWB unit CN3 (creaser
motor) and CN8 (creaser Yes Replace the crease sensor.
sensor) firmly plugged in?
4 Creaser motor Does the creaser's upper No If the motor is running, check that
blade go up and down when the screw holding the pulley is
checked in HELP mode (H- tight. If the motor is not running,
10)? replace the creaser motor.
Yes Replace the main PWB unit.

HELP mode H-08 \ see p.143

HELP mode H-18 \ see p.145

(8) E1: COVER OPEN

Pro- Cause/Defective part Items to be checked Result Countermeasure

ce-
dure
1 Cover Is it normal when checked in Yes Replace the main PWB unit.
HELP mode (H-08)?
2 Main PWB unit Is the connector for the main No Plug the connector in firmly.
PWB unit CN8 firmly plugged in? Yes Replace the interlock switch.

HELP mode H-08 \ see p.143

(9) E2: RS232C ERROR

Pro- Cause/Defective part Items to be checked Result Countermeasure

ce-
dure
1 CCD Is the CCD firmly connected? No Plug the connector in firmly.
(Main PWB unit CN5) Yes Replace the main PWB unit.
Replace the CCD.

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 Chap.6 z Troubleshooting Guide

(10) E3: BARCODE ERROR

Pro- Cause/Defective part Items to be checked Result Countermeasure

ce-
dure
1 BAR CODE Is the BAR CODE printed? No Turn the BAR CODE off, or print a
BAR CODE.
2 BAR CODE Is the area where the BAR Yes Use paper that is not dirty.
CODE is printed dirty?
3 BAR CODE Is the BAR CODE printed No Print the BAR CODE within the
within the specified range? specified range.
4 CCD Is the CCD firmly connected? No Plug the connector in firmly.
(Main PWB unit CN5) Yes Replace the main PWB unit.
Replace the CCD.

(11) E4: REG. MARK ERROR

Pro- Cause/Defective part Items to be checked Result Countermeasure

ce-
dure
1 REG. MARK Is the REG. MARK printed? No Turn the REG. MARK off, or print
a REG. MARK.
2 REG. MARK Is the area where the REG. Yes Use paper that is not dirty.
MARK is printed dirty?
3 REG. MARK Is the REG. MARK printed No Print the REG. MARK within the
within the specified range? specified range.
4 CCD Is the CCD firmly connected? No Plug the connector in firmly.
(Main PWB unit CN5) Yes Replace the main PWB unit.
Replace the CCD.

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 Chap.6 z Troubleshooting Guide

(12) E5: SLITTER ERROR

Pro- Cause/Defective part Items to be checked Result Countermeasure

ce-
dure
1 Slitter sensor Is it normal when checked in Yes Go to procedure 3.
HELP mode (H-08)?
2 Slitter positioning Is the connector firmly plugged Yes Replace faulty slitter sensors.
motor in to the sensor? No Plug the connector in firmly.
3 Is it normal when checked in Yes Replace the main PWB unit.
HELP mode (H-12, 13, 14, 15,
16, 28)?
4 Is the slitter positioning motor No Replace faulty slitter positioning
running? motors.
5 Is the belt tension too high? Yes Adjust the belt tension.
6 Is the lead screw attached to No Tighten the pulley screw.
the pulley firmly set? Yes Replace the main PWB unit.

HELP mode H-08 \ see p.143

HELP mode H-12 \ see p.144
HELP mode H-13 \ see p.144
HELP mode H-14 \ see p.144
HELP mode H-15 \ see p.144
HELP mode H-16 \ see p.145
HELP mode H-28 \ see p.148

(13) E6: DATA ERROR

Pro- Cause/Defective part Items to be checked Result Countermeasure

ce-
dure
1 Cuts and scores Are the number of cuts and Yes Turn off AUTO CUT or reduce the
scores greater than 17 when number of cuts and scores.
calculated from table 1? No Replace the main PWB unit.

\See page 137

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 Chap.6 z Troubleshooting Guide

(14) E7: CONNECTION ERROR

Pro- Cause/Defective part Items to be checked Result Countermeasure

ce-
dure
1 Connector Is the * displayed on the upper No Firmly connect the AF-100 and the
right edge of the LCD? DC-545.
(Indicates that AF-100 and DC-
545 are connected.)
2 Feed PCB unit Is the trouble cleared by Yes Finish
replacing the feed PCB unit? No Replace the main PWB unit.

(15) E8: ELEVATOR ERROR

Pro- Cause/Defective part Items to be checked Result Countermeasure

ce-
dure
1 Elevator upper/ Is it normal when checked in No Replace the faulty switch.
lower/switch HELP mode (H-08)?
2 Elevator motor Does the feed tray go up and Yes Go to procedure 5.
down when checked in HELP
mode (H-29)?
3 Feed tray Are the chain and pulley No Adjust any malfunctions.
normal?
4 Feed PCB unit Is the voltage measured with a Yes Replace the elevator motor.
tester between CN2-5 and
CN2-6 on the feed PCB unit
+24 V (DC) while the elevator
motor is operating?
5 Is the trouble cleared by Yes Finish
replacing the feed PCB unit? No Replace the main PWB unit.

HELP mode H-08 \ see p.143

HELP mode H-29 \ see p.148

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 Chap.6 x Error Display

x Error Display
This machine has a self-diagnosis function that displays an error message on the control panel when it deter-
mines a problem has occurred. The following shows the error message, possible causes and a description of the
problem that was detected.

––– J 1 –––
REJECT PAPER
Cause
• Paper is still in the machine
• One of the sensors (PPS1, PPS2, PPS3, or PPS4) is defective

Problem detected
1. Light did not transmit through all of the sensors (PPS1, PPS2, PPS3, and PPS4) when the power was
turned on.
2. Light did not transmit through all of the sensors PPS1, PPS2, PPS3, and PPS4 when the start switch was
pressed while the machine was stopped and paper was in the AF-100. (Only when using DC-545HC)

––– J 2 –––
FEED JAM
Cause
• Paper does not meet specifications
• Separator gap is too narrow(AF-100)
• Fan (blower) airflow is insufficient (AF-100)
• Feed solenoid incorrect adjustment
• Feed solenoid is defective
• Feed motor is defective
• Shutter solenoid is defective(AF-100)
• Feed motor is defective(AF-100)
• Fan (suction or blower) is defective(AF-100)

Problem detected
1. Paper was not detected at PPS2 even though it was longer than the set length of the paper (30 mm) and it
was detected at PPS1.
2. Paper was not detected at PPS1 after the specified time (about 2.5 seconds) after paper feed operation
started, therefore paper feed operations were started again. Error occurs if the feed operation starts three
times and paper is not detected at PPS1.

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 Chap.6 x Error Display

––– J 3 –––
CENTER JAM
Cause
• Paper does not meet specifications
• The length of the JOB data and the paper are different.

Problem detected
1. The leading edge of the paper was not detected at PPS3 even though the specified length (100 mm) had
passed PPS2.
2. Paper was not released from PPS3 even though the preset registered paper length + 30 mm had passed
PPS3.

––– J 4 –––
SLITTER OR STACK
Cause
• Paper does not meet specifications
• The length of the job data and the paper are different.
• The stacker is full and paper can not be ejected.

Problem detected
1. The leading edge of the paper was not detected at PPS4 even though the specified length (500 mm) had
passed PPS3.
2. Paper was not released from PPS4 even though the preset registered paper length + 50 mm had passed
PPS4.

––– J 5 –––
OVER CAPACITY
Cause
• There is too much paper loaded on the AF-100 feed tray.
• Paper level sensor is defective
• Actuator malfunction
• Main PWB unit is defective

Problem detected
1. Elevator lower switch was pressed after paper feed was started at DC-545HC while the paper level sensor
was on.

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 Chap.6 x Error Display

––– J 7 –––
CUTTER LOCK
Cause
• Paper does not meet specifications
• Cutter motor is defective
• Cutter position switch is defective
• Main PWB unit is defective

Problem detected
1. There was no response from the cutter position switch even though the specified time (0.6 seconds)
elapsed after cutting started.

––– J 8 –––
CREASE LOCK
Cause
• Paper does not meet specifications
• Creaser motor is defective
• Creaser sensor is defective
• Main PWB unit is defective

Problem detected
1. There was no response from the creaser sensor even though the specified time (2.0 seconds) elapsed after
scoring started.

––– E 1 –––
COVER OPEN
Cause
• Actuator (N4-L224*&N4-225*) installation is incorrect
• Interlock is defective
• Main PWB unit is defective

Problem detected
1. One of the covers was open while the machine was operating.
2. One of the covers was open when the start button was pushed.

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 Chap.6 x Error Display

––– E 2 –––
RS232C ERROR
Cause
• CCD is defective
• Main PWB unit is defective

Problem detected
1. There was an abnormal transmission between the CCD and the DC-545.

––– E 3 –––
BARCODE ERROR
Cause
• Bar code being used does not meet specifications
• CCD is defective
• Main PWB unit is defective

Problem detected
1. The bar code could not be read even after the paper fed the specified length (50 mm) after the bar code
reading operation started.

––– E 4 –––
REG.MARK ERROR
Cause
• Reg. mark being used does not meet specifications
• CCD is defective
• Main PWB unit is defective

Problem detected
1. The reg. mark could not be read even after the paper fed the specified length (40 mm) after the reg. mark
reading operation started.
2. Mark 1 was less than 4.5 mm.

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 Chap.6 x Error Display

––– E 5 –––
SLITTER ERROR
Cause
• Slitter sensor is defective
• Slitter positioning motor is defective
• Main PWB unit is defective

Problem detected
1. Light did not transmit to the slitter sensor when temporarily shifting inward 8 mm to detect the home
position while the slitter sensor was shielded from light and the command to move the slitter was issued.
2. The slitter did not return to the predetermined position within the specified time period (refer to the table
below) after the command to move the slitter was issued.

Time until detection

Left margin slitter 4.5 S
Right margin slitter 5.5 S
Left center slitter 6.0 S
Right center slitter 6.0 S
OP1 slitter 12.0S 6.0S
(OP2: When not installed) (OP2: When installed)
OP2 slitter 6.0S (Only when OP2 is installed.)

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 Chap.6 x Error Display

––– E 6 –––
DATA ERROR

Cause
• Preset data is not registered
• Memory PWB unit is defective

Problem detected
1. Preset data was accessed that exceeds a total of 17 AUTO CUTs (see table below), JOB cuts and scores
while AUTO CUT is being used.
2. There was no information in the preset data that was accessed.
Table 1: List of AUTO CUT counts
Distance from the Distance from the
leading edge of the AUTO CUT count last cut to the trailing AUTO CUT count
paper to the first cut edge of the paper
0.0 to 16.9 mm 0 0.0 to 20.9 mm 0
17.0 to 32.9 mm 1 21.0 to 36.9 mm 2
33.0 to 48.9 mm 2 37.0 to 51.9 mm 3
49.0 to 64.9 mm 3 52.0 to 66.9 mm 4
65.0 to 80.9 mm 4 67.0 to 81.9 mm 5
81.0 to 96.9 mm 5 82.0 to 96.9 mm 6
97.0 to 112.9 mm 6 97.0 to 111.9 mm 7
113.0 to 128.9 mm 7 112.0 to 126..9 mm 8
129.0 to 144.9 mm 8 127.0 to 141.9 mm 9
145.0 to 160.9 mm 9 142.0 to 156.9 mm 10
161.0 to 176.9 mm 10 157.0 to 171.9 mm 11
177.0 to 192.9 mm 11 172.0 to 186.9 mm 12
193.0 to 208.9 mm 12 187.0 to 201.9 mm 13
209.0 to 224.9 mm 13 202.0 to 216.9 mm 14
225.0 to 240.9 mm 14 217.0 to 231.9 mm 15
241.0 to 256.9 mm 15 232.0 to 246.9 mm 16
257.0 to 272.9 mm 16 247.0 to 261.9 mm 17
273.0 to 288.9 mm 17

Example:
1. Cuts: 5 Scores: 2 First cut: 98.0 mm
Length from the last cut to the trailing edge of the paper: 65.0 mm
According to the table: There are 6 AUTO CUTs from the leading edge of the paper to the first cut.
There are 4 AUTO CUTs from the last cut to the trailing edge of the paper.
The number of cuts, scores, and AUTO CUTs is 5 + 2 + 6 + 4 = 17.
The total is more than 17, resulting in E6: DATA ERROR.

2. Cuts: 10 Scores: 4 First cut: 10.0 mm

Length from the last cut to the trailing edge of the paper: 20.0 mm
According to the table: There are 0 AUTO CUTs from the leading edge of the paper to the first cut.
There are 0 AUTO CUTs from the last cut to the trailing edge of the paper.
The number of cuts, scores, and AUTO CUTs is 10 + 4 + 0 = 14.
The total is less than 17, resulting in no error.

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 Chap.6 x Error Display

––– E 7 –––
CONNECTION ERROR
Cause
• Bad connection between AF-100 and DC-545
• Feed PCB unit is defective
• Main PWB unit is defective

Problem detected
1. Can not confirm connection between AF-100 and DC-545 while machine is operating.
IMPORTANT:
• Be sure to turn off the power before you connect or disconnect the connectors.

––– E 8 –––
ELEVATOR ERROR
Cause
• Elevator upper switch is defective
• Elevator lower switch is defective
• Elevator motor is defective
• Paper level sensor is defective
• Feed PCB unit is defective
• Main PWB unit is defective

Problem detected
1. Elevator was not detected at elevator upper switch, elevator lower switch, or paper level sensor after the
specified time (* seconds) after the command to operator the elevator was issued.
* 10 seconds when rising at start-up, 3.5 seconds when paper is being fed, 9 seconds when going down at
shut-down
NOTE :
• When this error occurs there is a possibility that the screws pressing on the spring, or the
elevator up and down switch are damaged.

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 Chapter 7 HELP Mode
z HELP Mode List ....................................... 140

x Functions and operation procedures for

each HELP mode ..................................... 141
(1) Accessing HELP mode ................................ 141

c HELP Description .................................... 142

v Select Language for Displays ................. 150

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 Chap.7 z HELP Mode List

z HELP Mode List

HELP
Mode No. Description Classification
H-00 ROM version indication ROM version display
H-01 Total cut counter Total counts
H-02 Total feed counter Total counts
H-03 PPS1 check Sensor condition display
H-04 PPS2 check Sensor condition display
H-05 PPS3 check Sensor condition display
H-06 PPS4 check Sensor condition display
H-07 PPS5 check Sensor condition display
H-08 Sensor & switch check Sensor/switch condition display
H-09 DIP SW status check Dipswitch condition display
H-10 Feed motor check Function testing
H-11 Feed solenoid check Function testing
H-12 Left margin slitter check Function testing
H-13 Right margin slitter check Function testing
H-14 Left center slitter check Function testing
H-15 Right center slitter check Function testing
H-16 OP1 slitter check Function testing
H-17 Main motor check Function testing
H-18 Score check Function testing
H-19 Cutter check Function testing
H-20 Slitter blade drive check Function testing
H-21 LED check Function testing
H-22 CCD performance check Adjustment/specification setting
H-23 Total score counter Total counts
H-24 Slitter position adj. Adjustment/specification setting
H-25 RAM initialize Initialize
H-26 Cutter & score distance adj. Adjustment/specification setting
H-27 PPS2 & CCD distance adj. Adjustment/specification setting
H-28 OP2 slitter check (Option slitter 2) Function testing
H-29 Elevator check (Optional AF-100) Function testing
H-30 Fan Check (Optional AF-100) Function testing
H-31 Solenoid & Feed check (Optional AF-100) Function testing
H-32 Feeder Total check (Optional AF-100) Function testing
H-33 SPEED UP Adjustment/specification setting
H-34 CCD Adjustment/specification setting

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 Chap.7 x Functions and operation procedures for each HELP mode

x Functions and operation procedures for each HELP

mode

(1) Accessing HELP mode

1) When the machine is in use, put it in standby and then turn “OFF” the power switch.

2) Turn the power switch “ON” while pressing the <Stop> key. The “HELP mode” is displayed.

3) Select the “HELP mode no.” setting that you want to change by pressing the <+> key and the <-> key.

4) Press the <Start> key.

Enter the “HELP mode” that you selected in Step 3.
Follow the procedure for each of the various “HELP modes” described below.

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 Chap.7 c HELP Description

c HELP Description
HELP No. Adjustments and checks Contents and descriptions
H-00 ROM version indication The version of the ROM that is mounted on the main PWB
(U32) is displayed.

H-00:ROM VERSION
Ver.-∗ .∗ ∗
H-01 Total cut counter display The number of cuts the cutter has done is displayed.
The top counter can not be cleared.
The bottom counter can be cleared by pressing the <CLEAR>
key for 3 seconds or more.

∗∗∗∗∗∗∗∗
∗∗∗∗∗∗∗∗
H-02 Total feed counter display The number of pages that the machine has fed is displayed.
The top counter can not be cleared.
The bottom counter can be cleared by pressing the <CLEAR>
key for 3 seconds or more.

∗∗∗∗∗∗∗∗
∗∗∗∗∗∗∗∗
H-03 PPS1 check The level of the PPS of the paper supply is displayed.
PPS level is below 30 when there is no paper at PPS.

03:PPS1CHECK
PPS1(0-255):∗ ∗ ∗
H-04 PPS2 check Displays the level of the PPS located after roller 1.
PPS level is below 30 when there is no paper at PPS.

04:PPS2CHECK
PPS2(0-255):∗ ∗ ∗
H-05 PPS3 check Displays the level of the PPS located before the cutter.
PPS level is below 60 when there is no paper at PPS.

05:PPS3CHECK
PPS3(0-255):∗ ∗ ∗
H-06 PPS4 check Displays the level of the PPS at the exit tray.
PPS level is below 30 when there is no paper at PPS.

06:PPS4CHECK
PPS4(0-255):∗ ∗ ∗
H-07 Not used Not used

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HELP No. Adjustments and checks Contents and descriptions

H-08 Sensor & switch status Displays the status of each sensor and switch.
display
abcdefghijklmnop
qrstuvw
a ... PPS1 No paper (0) Paper (1)
b ... PPS2 No paper (0) Paper (1)
c ... PPS3 No paper (0) Paper (1)
d ... PPS4 No paper (0) Paper (1)
e ... Not used
f .... Slitter sensor (left margin) Light transmitted (0)
Light not transmitted (1)
g ... Slitter sensor (right margin) Light transmitted (0)
Light not transmitted (1)
h ... Slitter sensor (left center) Light transmitted (0)
Light not transmitted (1)
I .... Slitter sensor (right center) Light transmitted (0)
Light not transmitted (1)
j .... Slitter sensor (OP1) Light transmitted (0)
Light not transmitted (1)
k ... Score position sensor Light transmitted (0)
Light not transmitted (1)
L ... Cutter position switch ON (0) OFF (1)
m .. Cover switch OPEN (0) CLOSE (1)
n ... Not used
o ... Slitter sensor (OP2) Light transmitted (0)
Light not transmitted (1)
p ... Not used
q ... Connection check (option) Connected (0) Not connected (1)
r .... Elevator upper limit switch (Option) ON(0) OFF (1)
s ... Elevator lower limit switch (Option) ON (0) OFF (1)
t .... Not used
u ... PPS paper supply level (option) No paper(0) Paper (1)
v ... Elevator sensor (option) Light not transmitted (0)
Light transmitted (1)
w ... Feeder cover switch (option) CLOSE(0) OPEN (1)
H-09 DIP SW status display Displays the status of the DIP SW on the main PWB.

09:DIP SW CHECK
DIP:1234 RDIP:∗
DIP SW1 .... (OFF) Use memory board
(ON) Do not use memory board
2 .... Not used
3 .... (OFF) HC model (ON) Not used
4 .... (OFF) Normal operation
(ON) Slitter always returns to home position
RDIP (Rotary dipswitch)
Compensates for mechanical differences between PPS3 and
the cutter.
It is set as a factory default. The display is 0 to 9 and A to F.
H-10 Feed motor function test Feed motor (stepping motor) function test.
Motor runs when the <+> key is pressed.

10:FEED STEP CK

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HELP No. Adjustments and checks Contents and descriptions

H-11 Feed solenoid function test Feed solenoid function test
Pre-solenoid operates when the <+> key is pressed.
Gate solenoid operates when the <-> key is pressed.
NOTE :
• Pressing the key for more than 2 seconds may
damage the solenoid.

+KEY:PRESS SOL.
-KEY:GATE SOL.
H-12 Left margin slitter Left margin slitter positioning motor (stepping motor) function
(stepping motor) function test test
Slitter moves to the left (opposite the operation panel) when the
<+> key is pressed.
Slitter moves to the right (toward the operation panel) when the
<-> key is pressed.

+KEY:GOTO LEFT
-KEY:GOTO RIGHT
H-13 Right margin slitter Right margin slitter positioning motor (stepping motor) function
(stepping motor) function test test
Slitter moves to the left (opposite the operation panel) when the
<+> key is pressed.
Slitter moves to the right (toward the operation panel) when the
<-> key is pressed.

+KEY:GOTO LEFT
-KEY:GOTO RIGHT
H-14 Left center slitter Left center slitter positioning motor (stepping motor) function
(stepping motor) function test test
Slitter moves to the left (opposite the operation panel) when the
<+> key is presseds.
Slitter moves to the right (toward the operation panel) when the
<-> key is pressed.

+KEY:GOTO LEFT
-KEY:GOTO RIGHT
H-15 Right center slitter Right center slitter positioning motor (stepping motor) function
(stepping motor) function test test
Slitter moves to the left (opposite the operation panel) when the
<+> key is pressed.
Slitter moves to the right (toward the operation panel) when the
<-> key is pressed.

+KEY:GOTO LEFT
-KEY:GOTO RIGHT

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HELP No. Adjustments and checks Contents and descriptions

H-16 OP1 slitter (stepping motor) OP1 slitter positioning motor (stepping motor) function test
function test Slitter moves to the left (opposite the operation panel) when the
<+> key is pressed.
Slitter moves to the right (toward the operation panel) when the
<-> key is pressed.

+KEY:GOTO LEFT
-KEY:GOTO RIGHT
H-17 Main motor (stepping motor) Main motor function test
function test Motor runs when the <Start> key is pressed.
Motor stops when the <Stop> key is pressed.

17:MAIN MOTOR CK

H-18 Score (stepping mode) Score motor function test

function test Motor runs forward when the <+> key is pressed.
Motor runs backward when the <-> key is pressed.

+,-KEY:SCORE ON

H-19 Cutter (stepping mode) Cutter motor function test

function test Motor runs forward when the <+> key is pressed.
Motor runs backward when the <-> key is pressed.

+,-KEY:CUT ON

H-20 Slitter blade drive Slitter drive motor function test

(stepping mode) function test Slitter drive motor (forward) runs when the <+> key is pressed.
Slitter drive motor (backward) runs when the <-> key is pressed.

+,-KEY:SLIT ON

H-21 LED function test The LEDs shown below flash

COVER, JAM, PAPER, and START on the operation panel
PAPER, FEED, and LED on the paper supply

21:LED CHECK

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HELP No. Adjustments and checks Contents and descriptions

H-22 CCD performance (stepping Confirms CCD scanner functions
mode) function test CCD lights read and the counter (CNT) is displayed.
When the vertical line located 10 mm from the left edge of the
paper is read, the CNT value is 70 +/- 1.
NOTE :
• The CCD may remain lit until the power is turned
off after it has been turned on once.
When the check is finished, turn off the power.

+KEY:CCD ON
CNT:∗ ∗ ∗ ∗
X mm

X(mm) CNT
1 15±1
2 21±1
3 27±1
4 33±1
5 40±1
6 46±1
7 52±1
8 58±1
9 64±1
10 70±1
11 76±1
12 82±1
13 88±1
14 94±1
15 101±1
16 107±1
17 113±1
18 119±1
19 126±1
20 132±1

H-23 Total score counter display Displays the total number of scores.
The top counter can not be cleared.
The bottom counter can be cleared by pressing the <CLEAR>
key for 3 seconds or more.

∗∗∗∗∗∗∗∗
∗∗∗∗∗∗∗∗

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 Chap.7 c HELP Description

HELP No. Adjustments and checks Contents and descriptions

H-24 Position adjustment for each Adjust the slit position of each slitter.
slitter
∗100 100 100
100 100 100
Left Margin Slitter Left Center Slitter Optional Slitter1
Right Margin Slitter Right Center Slitter Optional Slitter2

q The “*” mark moves each time the <SET> key is pressed.
Move the “*” mark to the left side of the value of the slitter
that you want to set.
w Change the values with the <+> and <-> keys to make
adjustments.(Refer to the table below for distance moved.)
• The slitter position moves 0.08 mm when the value
changes by 1.
• The slitter shifts inwards (opposite the inner side) when the
value increases.
• The slitter shifts outwards (to the inner side) when the value
decreases.
e Register the adjusted value that you decided on by pressing
the <STOP> key.

Distance Value Distance Value Distance Value Distance Value

moved input moved input moved input moved input
(mm) (mm) (mm) (mm)
0.1 1 2.1 26 4.1 51 6.1 76
0.2 2 2.2 27 4.2 52 6.2 77
0.3 4 2.3 29 4.3 54 6.3 79
0.4 5 2.4 30 4.4 55 6.4 80
0.5 6 2.4 30 4.5 56 6.5 81
0.6 7 2.6 32 4.6 57 6.6 82
0.7 9 2.7 34 4.7 59 6.7 84
0.8 10 2.8 35 4.8 60 6.8 85
0.9 11 2.9 36 4.9 61 6.9 86
1.0 12 3.0 37 5.0 62 7.0 87
1.1 14 3.1 39 5.1 64 7.1 89
1.2 15 3.2 40 5.2 65 7.2 90
1.3 16 3.3 41 5.3 66 7.3 91
1.4 17 3.4 42 5.4 67 7.4 92
1.5 19 3.5 44 5.5 69 7.5 94
1.6 20 3.6 45 5.6 70 7.6 95
1.7 21 3.7 46 5.7 71 7.7 96
1.8 22 3.8 47 5.8 72 7.8 97
1.9 24 3.9 49 5.9 74 7.9 99
2.0 25 4.0 50 6.0 75 8.0 100
Table of distance moved (H-24)

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HELP No. Adjustments and checks Contents and descriptions

H-25 Initialization of RAM Initialize the RAM.
The entire RAM memory (including the pre-set data) is
initialized by pressing the <MODE> key and the <SET> key.
(It takes about 10 seconds.) Initialize the RAM memory except
for the pre-set data by pressing the <+> key and the <-> key.
(It takes about 2 seconds.)
NOTE :
• Do not touch the operation panel when “FINISH!!” is
displayed. Also, do not turn off the power.
H-26 Cutter & score distance Compensates for mechanical differences between the cutter
adjustment and the scorer.
Use the <+> key and the <-> key to adjust the score position,
and then register it with the <STOP> key.

26:SCORE DIST.
DISTANCE:∗ ∗ ∗
H-27 PPS2 & CCD distance NOTE :
adjustment • Do not do the following operations except when
changing the Main P.W.B. unit.
Compensates for mechanical differences between the PPS2
and the CCD.
Use the <+> key and the <-> key to adjust the score position,
and then register it with the <STOP> key.
The processing (cutting or scoring) position moves 0.1 mm
when the value changes by 1. However, this is only enabled
when REG. MARK is ON.

27:CCD DIST.
DISTANCE:∗ ∗ ∗
H-28 OP2 positioning motor check OP2 positioning motor (stepping) function test (when the option
(When the optional slitter 2 is installed)
is attached.) Motor moves to the left (opposite the operation panel) when the
<+> key is pressed.
Motor moves to the right (toward the operation panel) when the
<-> key is pressed.

+KEY:GOTO LEFT
-KEY:GOTO RIGHT
H-29 Elevator check Elevator function test (when the option is installed)
(Optional AF-100) Elevator moves up when the <+> key is pressed. (The upper
limit switch stops the elevator.)
Elevator moves down when the <+> key is pressed. (The lower
limit switch stops the elevator.)

+KEY:ELEV.UP
-KEY:ELEV.DWN

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HELP No. Adjustments and checks Contents and descriptions

H-30 Fan check Fan motor function test (when the option is installed)
(Optional AF-100) Suction fan operates when the <+> key is pressed.
Blower fan operates when the <-> key is pressed.

+KEY:FAN1 ON
-KEY:FAN2 ON
H-31 Solenoid and feed check Shutter solenoid and feed motor function test (when the option
(Optional AF-100) is installed)
The shutter solenoid operates when the <+> key is pressed.
The feed motor operates when the <-> key is pressed.
NOTE :
• Do not press the <+> for more than 2 seconds.
Doing so may damage the solenoid.

+KEY:SOL.ON
-KEY:FEED ON
H-32 Feeder function test Optional feeder sequential function test (when the option is
(Optional AF-100) attached)
Elevator moves up when the <+> key is pressed. (The upper
limit switch stops the elevator.)
Elevator moves down when the <+> key is pressed. (The lower
limit switch stops the elevator.)

+KEY:ELEV.UP
-KEY:ELEV.DWN
H-33 Specify slitter movement Switch the slitter control method when REG. MARK is ON.
control method ON : Slitter moves just the amount of drift as the REG.
MARK scan indicates. (It returns to the home position
under the following conditions.)
OFF : Slitter returns to the home position as the REG.
MARK is scanned.
<Conditions under which the slitter returns to the home position
when REG. MARK is ON>
q When processing immediately after the power is turned on.
w When processing after an error.
e When processing after paper was cut.
r When processing after opening a cover.
t When the job changes.
H-34 CCD Change the method to adjust the main motor when reading the
Reg. Mark.
Select CCD2 if a E4 : REG. MARK ERROR occurs whether or
not the Reg. Mark are printed correctly. Usually CCD1 is used.
CCD1 : Turn on the main motor’s magnetization when
reading Reg. Marks.
CCD2 : Turn off the main motor’s magnetization when
reading Reg. Marks.
NOTE :
• A sound occurs when reading Reg. Marks when
CCD2 is selected, but this in not a malfunction.

CCD SCAN.
∗CCD1 CCD2

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 Chap.7 v Select Language for Displays

v Select Language for Displays

q When operating the machine, put it in standby mode, and then turn the power “OFF”.
w Turn the power “ON” while pressing the <F> key and the <CLEAR> key.
The message shown below is displayed.

Language?(+,-)
ENGLISH
e Select a language with the <+> key and the <-> key. (The language is stored when it is switched.)
1. ENGLISH
2. FRENCH
3. JAPANESE
4. GERMAN
5. SPANISH
6. ENGLISH(ICON)

r Turn off the power to finish.

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 Chapter 8 Miscallaneous
z Job List ..................................................... 152

x Position and Function of

Electronic Parts ....................................... 156
1. Schematic drawing of
electronic parts ................................... 156
2. Connector, VR and LED layout ......... 159

c Overall Wiring Diagram ........................... 161

1. DC-545 ................................................. 161
2. AF-100 ................................................. 162
3. Connector ........................................... 163

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 Chap.8 z Job List

z Job List

PROGRAM
NUMBER #1* #2 #3 #4 #5 #6 #7 #8
Trading Trading
Job Type Cut in half SM CARD 8up letter 8up ledger WALLET 3.5 x 5 4x6 5x7
MARK 1 47 47 47 47 47 47 47 47

MARK 2 9.2 9.2 9.2 9.2 9.2 9.2 9.2 9.2

LEFT SL 0 9.5 12.7 31.8 12.7 8.3 31.8 8.3

RGHT SL 0 269.9 266.7 247.7 203.2 271.1 0 271.1

C.L. SL 0 136.5 76.2 95.3 76.2 135.3 0 135.3

C.R. SL 0 0 203.2 184.2 0 0 184.2 0

OP1 SL 0 142.9 139.7 108.0 139.7 144.1 0.0 144.1

OP2 SL

CUT1 139.7 25.4 19.1 22.2 15.2 17.1 28.6 19.1

CUT2 0 190.3 108.0 111.1 101.6 106.0 130.2 196.9

CUT3 0 0 114.3 123.8 188.0 114.9 149.2 0

CUT4 0 0 203.2 212.7 274.3 203.8 250.8 0

CUT5 0 0 0 225.4 0 0 0 0

CUT6 0 0 0 314.3 0 0 0 0

CUT7 0 0 0 327.0 0 0 0 0

CUT8 0 0 0 415.9 0 0 0 0

CUT9 0 0 0 0 0 0 0 0

CUT10 0 0 0 0 0 0 0 0

SCR. 1 0 107.4 0 0 0 0 0 0

SCR. 2 0 0 0 0 0 0 0 0

SCR. 3 0 0 0 0 0 0 0 0

SCR. 4 0 0 0 0 0 0 0 0
TOTAL LENGTH 279.4 215.9 215.9 431.8 279.4 215.9 279.4 215.9

NOTES
THESE VALUES ARE CURRENT AS OF OCTOBER 2002
ALL DIMENSIONS ARE IN MILLIMETERS
8.5 X 11 inches = 215.9 X 279.4 millimeters
11 X 17 inches = 279.4 X 431.8 millimeters

*Be sure to turn off AUTO CUT.

152
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 Chap.8 z Job List

PROGRAM
NUMBER #9 #10 #11 #12 #13 #14 #15 #16
11up 4up
1up Lg 2up 2up Business Business Large
Job Type 8 x 10 Pan Card Scrapbook Postcard Card Postcard Brochure
MARK 1 47 47 47 47 47 47 47 47

MARK 2 9.2 9.2 9.2 9.2 9.2 9.2 9.2 9.2

LEFT SL 6.4 12.7 13.5 6.4 31.8 6.4 6.4 9.5

RGHT SL 209.6 203.2 202.4 272.9 0 209.6 209.6 269.9

C.L. SL 0 101.6 0 136.4 0 57.2 108.0 0

C.R. SL 0 0 0 0 184.2 158.8 0 0

OP1 SL 0 114.3 0 142.9 0 108.0 0 0

OP2 SL
CUT1 17.1 19.1 12.7 12.7 28.6 6.4 12.7 16.9

CUT2 271.1 266.7 266.7 419.1 130.2 95.3 139.7 415.9

CUT3 0 0 0 0 149.2 184.2 266.7 0

CUT4 0 0 0 0 250.8 273.1 0 0

CUT5 0 0 0 0 0 0 0 0

CUT6 0 0 0 0 0 0 0 0

CUT7 0 0 0 0 0 0 0 0

CUT8 0 0 0 0 0 0 0 0

CUT9 0 0 0 0 0 0 0 0

CUT10 0 0 0 0 0 0 0 0

SCR. 1 0 0 139.2 215.4 0 0 0 215.9

SCR. 2 0 0 0 0 0 0 0 0

SCR. 3 0 0 0 0 0 0 0 0

SCR. 4 0 0 0 0 0 0 0 0

TOTAL LENGTH 279.4 279.4 279.4 431.8 279.4 279.4 279.4 431.8

NOTES
THESE VALUES ARE CURRENT AS OF OCTOBER 2002
ALL DIMENSIONS ARE IN MILLIMETERS
8.5 X 11 inches = 215.9 X 279.4 millimeters
11 X 17 inches = 279.4 X 431.8 millimeters

153
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 Chap.8 z Job List

PROGRAM
NUMBER #17 #18* #19* #20 #21
3-Fold
Job Type Brochure Tri-Cut Fourths Fold in Half Tri-Fold
MARK 1 47 47 47 47 47

MARK 2 9.2 9.2 9.2 9.2 9.2

LEFT SL 41.3 0 0 0 0

RGHT SL 238.1 0 0 0 0

C.L. SL 0 0 108 0 0

C.R. SL 0 0 0 0 0

OP1 SL 0 0 0 0 0

OP2 SL

CUT1 25.4 93.1 139.7 0 0

CUT2 406.4 186.2 0 0 0

CUT3 0 0 0 0 0

CUT4 0 0 0 0 0

CUT5 0 0 0 0 0

CUT6 0 0 0 0 0

CUT7 0 0 0 0 0

CUT8 0 0 0 0 0

CUT9 0 0 0 0 0

CUT10 0 0 0 0 0

SCR. 1 153.4 0 0 139.7 94.1

SCR. 2 280.4 0 0 0 187.2

SCR. 3 0 0 0 0 0

SCR. 4 0 0 0 0 0

TOTAL LENGTH 431.8 279.4 279.4 279.4 279.4

NOTES
THESE VALUES ARE CURRENT AS OF OCTOBER 2002
ALL DIMENSIONS ARE IN MILLIMETERS
8.5 X 11 inches = 215.9 X 279.4 millimeters
11 X 17 inches = 279.4 X 431.8 millimeters

*Be sure to turn off AUTO CUT.

154
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 Chap.8 z Job List

Job during installation

Job while installing the AF-100
STEP21: P-77 (REG off + BC off): AF-100 to DC-545 Mounting Alignment
STEP21: P-78 (REG off + BC off): AF-100 to DC-545 Mounting Alignment (With OP2 SL)
STEP22: P-79 (REG off + BC off): Lead Edge Length & Score Position

No. 72 73 74 75 76 77 78 79 80
Job Type

MARK 1 70 70 70 70 70 70 70 70 82
MARK 2 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 8.0
LEFT SL 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 12.0
RGHT SL 270.0 218.0 270.0 200.0 202.0
C.L. SL 62.0 62.0 62.0
C.R. SL 218.0 166.0 218.0
OP1 SL 114.0 114.0 114.0
OP2 SL 166.0 166.0
CUT1 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 8.0
CUT2 206.0 206.0 206.0 206.0 206.0 206.0 206.0 270.0 268.0
CUT3

CUT4

CUT5

CUT6

CUT7

CUT8

CUT9
CUT10

SCR. 1 114.0 112.0

SCR. 2

SCR. 3

SCR. 4

TOTAL LENGTH 216.0 216.0 216.0 216.0 216.0 216.0 216.0 297.0 297.0

155
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 Chap.8 x Position and Function of Electronic Parts

x Position and Function of Electronic Parts

(1) Schematic drawing of electronic parts

DC-545
6
11
5
12

3
13 14

17

15
2
6
7
4

6
9
6

1
6
8
16

10

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 Chap.8 x Position and Function of Electronic Parts

19 21 23
18

24

18(Interior)
20 22

Part name Number Function

Panel P.W.B. unit 1 Operation panel and display
Power switch 2 Switch to turn on the power
Switching power supply 3 DC power supply (AC 100 to 240 V DC 24 V)
Stepping motor 4 Main motor
Motor driver 5 Driver for the main motor
6 Slitter drive motor
Stepping motor
7 Feed stepping motor
8 Margin slitter drive motor
Gear motor
9 Center slitter drive motor
DC Gear motor 10 Cutter drive motor
DC Gear motor 11 Score drive motor
CCD sensor 12 For reading the bar codes and reg. marks
Memory P.W.B. unit 13 For saving job data
Main P.W.B. unit 14 For controlling the DC-545
Solenoid 15 For controlling the gate (not used by DC-545HC)
Solenoid 16 Paper feed solenoid
Power P.W.B. unit 17 Printed wiring board for the power supply (DC 24 V DC 5 V & 24 V)
Micro Switch 18 For detecting cutter motor interlock and whether the cover is open or closed
19 Home position for the left margin slitter
20 Home position for the right margin slitter
Photo Micro Switch 21 Home position for the left center slitter
22 Home position for the right center slitter
23 Home position for the OP1 slitter
24 Home position for the OP2 slitter

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 Chap.8 x Position and Function of Electronic Parts

AF-100 29 30

34
27
32

28

33

31 26

25

Part name Number Function

Feed PCB unit 25 AF-100 drive
Gear motor 26 Paper feed belt drive
Solenoid 27 Solenoid for opening and closing the shutter
28 Intake fan
Fan motor
29 Exhaust fan
Micro switch 30 For detecting whether the top cover is open or closed
Photo micro sensor 31 For detecting paper level
32 For detecting the upper limit of the elevator
Micro switch
33 For detecting the lower limit of the elevator
Gear motor 34 Elevator drive motor

158
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 Chap.8 x Position and Function of Electronic Parts

(2) Connector, VR and LED layout

1) Main P.W.B. Unit N4-V300*

CN10 CN2 CN5 CN8 CN1 CN4 CN9 CN14

CN13
CN12

U32

SW1 ROM
SW2

CN11 CN3 CN7 CN6

2) Panel P.W.B. Unit N4-V301*

Buzzer
CN2

VR1 CN1
VR2

3) Power P.W.B. Unit N4-V302*

FUSE (250 V 8 A)
CN2
CN1

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 Chap.8 x Position and Function of Electronic Parts

4) Memory P.W.B. Unit K9-V212*

CN1

5) Switching Power Supply UA023

CN2
CN1

6) Motor Driver L8-X101*

CN2
CN1

7) Feed P.C.B. Unit N4-V303*

CN2 CN3
CN4

CN1

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 W
W
W
W
1 RED 1 1 WHITE
1 2 WHITE 2 WHITE

CN2
CN1
CN2
2
2 3 YELLOW 3 3 WHITE

JAE16
3 4 ORANGE 4 4 WHITE
5 PEACH 5 5 WHITE

RIGHT
6 PURPLE 6 WHITE

HIROSE16
HIROSE16
6

EN.SEN.
7 GREEN 7 7 WHITE
8 RIGHT BLUE 8 WHITE

N4-W120*
N4-W119*
8
9 GRAY 9 9 WHITE
10 BLACK 10 WHITE

COVER SW
COVER SW
10

N4-W104*
11 RIGHT GREEN 11 WHITE

N4-W121*
11
12 WHITE 12 12 WHITE

LCD UNIT
WHITE 1 13 RED 13 13 WHITE
BROWN 2 14 BLUE 14 WHITE

CN9
14

N4-V301*
ORANGE 3 15 YELLOW 15 15 WHITE
BLACK 4 16 BLUE 16 16 WHITE
BROWN

PANEL PWB

SLT.1
5

NH9(JST)
YELLOW

OPTION
6
RED

g Diagram
7

N4-W116*
PURPLE 8 N4-X100*
BLUE 9 RED RED
1 RED RED

CN3
2 WHITE
1 3
2 4 BROWN
3 WHITE 1 ORANGE
1 YELLOW 5 BLACK

SEN.
2

NH16(JST)

CN1
2 6

GATE SOL.
ORANGE 3 BROWN

CN10

OPTION
3 BLUE 7
4 YELLOW

N4-W106*
4 GREEN 8
5 9 WHITE
5

NH8(JST)
RIGHT BLUE 6 BROWN

HIROSE18
6 RED 10
7 11 ORANGE
7 RED 8 BLACK
8 12

K9-V2120
9 13 BROWN
10 14 YELLOW

MEMORY PWB
11 15 RED
12 16 BLACK
13
14
15

FEED STEPPING M.
16

N4-W117*
17
18

LEFT SLIT.
RED

SLT.2
N4-X102*

OPTION
WHITE 1 BLACK
BROWN 2
ORANGE

CN14
BLACK 3
4
BROWN 1 BROWN BROWN N4-W109*

SCORE M.
5
YELLOW 2 BLUE

NH10(JST)
6

CN4
RED 7 3 WHITE BLUE
1 PURPLE 4 BLUE

N4-W118*
2 8
BLUE 9 5 BROWN
3 6 BLUE WHITE

SEN.
HIROSE26
PPS1
10
7 WHITE BLUE

OPTION
8 BLUE N4-W108*
1 9 BROWN BROWN N4-W109*
2 10 BLUE
3 11 WHITE BLUE

CN11
4 12 BLUE
5 13 BROWN
6 14 BLUE

HIROSE24
7 15 WHITE WHITE

PPS2

N4-W107*
8 16 BLUE BLUE
9 17 BROWN N4-W110*
10 18 BLUE
11 19
12 20
13 21 RED
14 22 WHITE WHITE

PPS3
15 23 BLUE BLUE
16 24 RED N4-W111*
17 25 ORANGE
18 26 BLUE BROWN N4-W123*
19 BLUE
20
21
22
23 WHITE N4-W108*

PPS4
24 BLUE

1 1
2 2

CN12
3 3

SEN.
SLIT.
LEFT
4
5

NH14(JST)
N4-V300*
6

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7
8 1

MAIN PWB
9 2
10 3

CEN.
SEN.
LEFT
11
12
13
14
1 BLACK
2 RED

CN5
3 BLUE
4 GREEN
5
6

N4-W102*
BROWN WHITE

HIROSE10
1 1

CCD
BROWN 2 7 BROWN

CN2
1 2

N4-X103*
RED 8 ORANGE

CN13
3

CN1
2 3 9
3 4 RED 4 PURPLE
BLUE 5 10 YELLOW
4 5

VH6(JST)
VH6(JST)
6 BLUE 6

VH4(JST)
RED N4-X101*

N4-W122*
RED

BLUE
BLUE
N4-V302*

BROWN
BROWN
L8-X1010
YELLOW
WHITE

4
3
2
1
SOL. M.1
ROLL SLIT

POWER PWB
RED
1 RED

CN6
2 WHITE

VH4(JST)
3 YELLOW
4 RED RED
5 BLACK BLACK BLACK BLACK

NH12(JST)
6 YELLOW YELLOW
7 YELLOW YELLOW

N4-W112*
8 WHITE
9 YELLOW
10 RED
11 BLUE
12
L8-X1110
L8-X1090

CUTTER M.

YELLOW
YELLOW
YELLOW
YELLOW

N4-W120*
N4-W119*
CUTTER UNIT

POWER SUPPLY
L8-X1100
POSITION SW

VH5(JST)
5
4
3
2
1
COVER SW
COVER SW

L8-X1010
YELLOW
WHITE

WHITE
BLACK

161
M.2
SLIT

N4-W113*
RED
BLUE
LED

N4-W101*
FEED

POWER SW
SLIT.
RIGHT

1 WHITE
2 BROWN
CN7

3 ORANGE
4 BLACK
5 BROWN

N4-W100*
YELLOW
NH18(JST)

6
7 WHITE
N4-W114*

8 BROWN
9 ORANGE
10 BLACK
11 BROWN
LEFT

YELLOW

GREEN/YELLOW
BLACK
WHITE
12
Chap.8

13 WHITE
CENTER.

14 BROWN
15 ORANGE
16 BLACK
17 BROWN
18 YELLOW

INRET WITH
NOISE FILTER
RIGHT
CENTER.
c Overall Wiring Diagram
 Chap.8 c Overall Wiring Diagram

FAN(BLOWER) ELEVATOR FEED MOTOR FAN(SUCTION)

DC-545 N4-X105* N4-X106* N4-X104* N4-X105* AF-100
BROWN

BROWN
BLACK

BLACK

BLACK

BLACK
RED

RED
BROWN
BLACK

DC-545
RIGHT BLUE
RIGHT BLUE
BROWN

BROWN

MAIN P.W.B.
BLACK

BLACK

BLACK

BLACK
RED

RED

N4-V300* SHUTTER
N4-W204* SOLENOIDO
1
2
3
4
5
6
7
8
9
10

1
2
3
4
5

RIGHT BLUE RED N4-X101*

N12 N4-W124* CN1 CN2 CN3
RIGHT BLUE
WHITE
RED
WHITE
BROWN BROWN N4-W202* N4-W203* BLUE BLUE
1
2
3
WHITE
WHITE
ORANGE
WHITE
1
2
3
NH10 NH5 FEED PPS
GREEN GREEN
4
5
6
GREEN
GRAY
BLUE
RIGHT BLUE
4
5
6
PHOTO
BLACK YELLOW
7
8 RIGHT BLUE YELLOW
7
8 TRANSISTOR
9
10
11
YELLOW
PINK
RED
PURPLE
ORANGE
RED
9
10
11
N4-W201* FEED P.W.B. N4-W206*
BLUE BLACK
12
13 PURPLE WHITE
12
13
N4-V303*
14 ORANGE YELLOW 14
PINK 15
GREEN
(JST) BLUE
16
17 CN4
BROWN 18
NH15 N4-W202*
NH18
N11
10
11
12
13
14
15
1
2
3
4
5
6
7
8
9

1
2
3
4
ORANGE
ORANGE

5
YELLOW
PURPLE
PURPLE

GREEN
GREEN
WHITE

6
BLUE

BLUE

BLUE
RED

RED

7
8 YELLOW GREEN
9 WHITE
10 BLUE
11
12
13
14
15
16
17
18
19 BROWN
20
21
22
23
ORANGE
ORANGE

YELLOW

24
BROWN
GREEN
GREEN
BLUE

BLUE

N4-W209* N4-W205*
RED

SE24
1
2
3

ELEVATOR ELEVATOR PAPER LEVEL COVER SW FEED PPS

LOWER SW UPPER SW SENSOR N4-W207* PHOTO DIODE
LA028 LA028 CA021 N4-W109*

162

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 Chap.8 c Overall Wiring Diagram

(3) Connector
1) Main P.W.B. CN1
MAIN MOTOR
M2-X1010

ORANGE
GREEN
BLACK
BLUE
RED
1
2
3
4
5
STEPPING DRIVER
L8-X1080

10
11
12
1
2
3
4
5
6
7
8
9
ORANGE
PURPLE
BROWN
BROWN

GREEN
BLACK
WHITE
BLUE
BLUE
BLUE
RED
GND
GND
GND

GND
24V
24V

5V
1
2
3
4
5
6
7
8
9
10
11

N4-W103*
CN1

MAIN PWB

2) Main P.W.B. CN2

CN2 1 5V RED 1 CN1 CN2 1 GND WHITE

2 WHITE 2 2 5V WHITE
3 YELLOW 3 3 WHITE
4 ORANGE 4 4 WHITE
5 PEACH 5 5 GND WHITE
6 PURPLE 6 6 WHITE
MAIN 7
8
GREEN
RIGHT BLUE
7
8
PANEL 7 WHITE
WHITE
LCD
8
9 GRAY 9 WHITE
PWB 10 BLACK 10 PWB 9
10 WHITE UNIT
N4-W104* 11 RIGHT GREEN 11 N4-V301* 11 WHITE N4-W121*
12 WHITE 12 12 WHITE
13 5V RED 13 13 WHITE
14 BLUE 14 14 WHITE
15 GND YELLOW 15 15 GND WHITE
16 GND BLUE 16 16 WHITE

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 Chap.8

1 BROWN BROWN N4-W109*

4) Main P.W.B. CN4

3) Main P.W.B. CN3

2 GND BLUE

CN4
3 WHITE BLUE
4 GND BLUE
5 BROWN
6 GND BLUE WHITE

PPS1
c Overall Wiring Diagram

7 WHITE BLUE
8 GND BLUE N4-W108*

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9 BROWN BROWN N4-W109*
10 GND BLUE
11 WHITE BLUE
12 GND BLUE
13 BROWN 24V RED RED
1 RED RED
14 GND BLUE

CN3
2 WHITE
15 WHITE WHITE

PPS2
3

N4-W107*
16 GND BLUE BLUE 4 24V BROWN
N4-X100*

17 BROWN N4-W110* 5 ORANGE

18 BLUE 6 BLACK
GATE SOL.

19 7 24V BROWN
20 YELLOW

N4-W106*
8
21 5V 9 WHITE
22 WHITE 24V BROWN

PPS3
10
23 GND BLUE 11 ORANGE
24 5V N4-W111* 12 BLACK
25 24V BROWN

MAIN PWB
13
M2-X101*

26 GND BROWN N4-W123* YELLOW

164
14
BLUE 15 RED

MAIN PWB
16 BLACK

RED
RED
WHITE N4-W108*

BLUE
BLUE
FEED STEPPING M.

PPS4

WHITE
BLUE
M2-X101*

ORANGE
LEFT SLIT.

RED

BLACK
1
2
N4-X102*

SEN.
SCORE M.

1 LEFT SLIT.
2
3 SEN.
LEFT CEN.
 Chap.8 c Overall Wiring Diagram

5) Main P.W.B. CN5

CCD
N4-X103*

ORANGE
YELLOW
PURPLE
BROWN
GREEN
BLACK

WHITE
GRAY
BLUE
RED
GND
5V

10
1
2
3
4
5
6
7
8
9

CN5

MAIN PWB

6) Main P.W.B. CN6

ROLL SOL. SLIT M.1 CUTTER UNIT SLIT M.2 FEED LED
L8-X1090
24V 24V 24V

CUTTER M.
L8-X1110
N4-W113*
L8-X1010
N4-X101*

L8-X1010

POSITON SW
GND

YELLOW
YELLOW

YELLOW
YELLOW

WHITE
BLACK
WHITE

BLUE
RED
RED
RED

RED

COVER SW
BLACK

N4-W119*
YELLOW
YELLOW
BLACK

COVER SW
N4-W120*
YELLOW
YELLOW
YELLOW

YELLOW
YELLOW
YELLOW
BLACK
WHITE

WHITE

BLUE
RED
RED

RED

RED
GND
24V
24V

24V
1
2
3
4
5
6
7
8
9
10
11
12

N4-W112*
CN6

MAIN PWB

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 Chap.8 c Overall Wiring Diagram

7) Main P.W.B. CN7

RIGHT SLIT. LEFT CENTER. RIGHT CENTER.

ORANGE

ORANGE

ORANGE
YELLOW

YELLOW

YELLOW
BROWN

BROWN

BROWN

BROWN

BROWN

BROWN
BLACK

BLACK

BLACK
WHITE

WHITE

WHITE
24V

24V

24V

24V

24V

24V
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
N4-W114*
CN7

MAIN PWB

8) Main P.W.B. CN8

MAIN PWB
CN8 N4-W115*
1
2
3
4
5
6
7
8
9
10
11
12
13
14
GND

GND

GND
GND
5V

5V

5V
YELLOW

YELLOW
YELLOW
GREEN

COVER SW
PEACH
BLUE

BLUE

BLUE
RED

RED

RED

YELLOW
YELLOW
N4-W119*
YELLOW

COVER SW
YELLOW
YELLOW
N4-W120*
1
2
3

1
2
3

1
2
3

SCORE RIGHT RIGHT

SEN. SLI.SEN. CEN.SEN.

166
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 Chap.8 c Overall Wiring Diagram

9) Main P.W.B. CN9

MAIN PWB
CN9

N4-W116*

1
2
3
4
5
6
7
8
9 GND
24V

24V
5V
ORANGE

YELLOW
PURPLE
BROWN

BROWN
BLACK
WHITE

BLUE
RED

1
2
3
OPTION OPTION
SLT.1 SEN.

10) Main P.W.B. CN10

MAIN PWB
CN10 N4-W117*
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
GND

5V
RIGHT BLUE
ORANGE
YELLOW

GREEN
WHITE

BLUE

RED
RED
1
2
3
4
5
6
7
8

CN1

MEMORY PWB
K9-V212*

167
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 Chap.8 c Overall Wiring Diagram

11) Main P.W.B. CN13

MAIN PWB
CN13
1
2
3
4
5
6
GND
GND
24V
24V
5V
5V

N4-W122*
BROWN
BROWN

BLUE
BLUE
RED
RED
1
2
3
4
5
6

CN2
POWER PWB
CN1 N4-V302*
1
2
3
4
GND
GND

POWER SW
24V
24V

N4-W101* N4-W100*
BLACK WHITE
BLUE
BLUE
1
2
1
2
INRET WITH
BROWN 3 POWER 3
WHITE BLACK
NOISE
N4-W102* BROWN 4 4 GREEN/YELLOW
SUPPLY 5 FILTER

12) Main P.W.B. CN14

MAIN PWB
CN14
N4-W118*
10
1
2
3
4
5
6
7
8
9 GND
24V

24V
5V
ORANGE

YELLOW
PURPLE
BROWN

BROWN
BLACK
WHITE

BLUE
RED
1
2
3

OPTION OPTION
SLT.2 SEN.

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 Chap.8 c Overall Wiring Diagram

13) Main P.W.B. CN11,12 & Feed P.W.B. CN1

DC-545 MAIN P.W.B.

N4-V300*
CN12 N4-W124* CN1
24V BROWN BROWN 24V 1
1 WHITE ORANGE
2 2
3 WHITE WHITE 3
4 GREEN GREEN 4
5 GREEN BLUE 5
6 GRAY
BLACK
RIGHT BLUE
YELLOW
6 FEED P.W.B.
7 7
8 RIGHT BLUE YELLOW 8 N4-V303*
9 YELLOW PURPLE 9
10 PINK ORANGE 10
11 5V RED RED 5V 11
12 GND BLUE BLACK GND 12
13 PURPLE WHITE 13
14 ORANGE YELLOW 14
PINK 15
GREEN 16
BLUE GND 17
CN11 BROWN 24V 18
1
2
3 N4-W209*
4
5
6
7
8 YELLOW-GREEN
9 WHITE
10 GND BLUE
11
12
13
14
15
16
17
18
19 24V BROWN
20
21
22
23
24

14) Feed P.W.B. CN2

FAN ELEVATOR FEED
(EXHAUST) MOTOR MOTOR
N4-X105* N4-X106* N4-X104*
24V

SOLENOIDO
BROWN

BROWN

N4-X101*
BLACK

BLACK

BLACK
RED

24V
BROWN
BLACK

RIGHT BLUE RED

RIGHT BLUE RED
WHITE WHITE
BLUE BLUE
RIGHT BLUE
RIGHT BLUE

N4-W204*
BROWN

BROWN
BLACK
BLACK

BLACK
RED

to CN4
24V

24V

FEED PPS
RECEIVE
1
2
3
4
5
6
7
8
9
10

N4-W206*
CN2 N4-W202*

FEED P.W.B.
N4-V303*

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 Chap.8 c Overall Wiring Diagram

15) Feed P.W.B. CN3

FAN(INTAKE)
N4-X105*

24V

BLACK
RED

BLACK
RED
24V
1
2
3
4
5

CN3 N4-W203*

FEED P.W.B
N4-V303*

16) Feed P.W.B. CN4

to CN2 SOLENOIDO
N4-X101*
FEED P.W.B.
N4-V303*

CN4 N4-W202*

RIGHT BLUE RED

10
11
12
13
14
15
1
2
3
4
5
6
7
8
9

RIGHT BLUE RED

WHITE WHITE
BLUE BLUE
GND
GND

GND
GND

GND
GND
5V

N4-W204*
GND
ORANGE
ORANGE

YELLOW
PURPLE
PURPLE

GREEN
GREEN
WHITE
BLUE
BLUE

BLUE
RED

RED

FEED PPS
RECEIVE
N4-W206*
ORANGE
ORANGE

YELLOW

BROWN
GREEN
GREEN
BLUE

BLUE
RED

N4-W209* N4-W205*
GND
5V

GND

GND
GND

GND

1
2
3

ELEVATOR ELEVATOR ELEVATOR COVER FEED

LOWER SW UPPER SW SENSOR SW PPS LED
LA028 LA028 CA021 N4-W207* N4-W109*

170
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 Reproduction prohibited

1st printing : February 2003

Issued by : DUPLO SEIKO CORPORATION

PRINTED IN JAPAN

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