Docu Cutter
DC-545 HC/DC-545 HCEX
Instruction Manual
Version. 1.0 / November 2003
Correct operation and periodic maintenance are
essential for ensuring safe use of this machine.
Thoroughly read this manual before using this
machine.
Store this manual so that it can be retrieved whenever needed.
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Introduction
DC-545 HC
Thank you for your purchase of the Docu Cutter DC-545 HC.
To ensure safe and efficient prolonged use of this machine, read and thoroughly understand this manual before
using this machine. After using this manual, be sure to keep it in a place to handy reference.
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PLEASE NOTE
In the interest of upgrading our products, specifications and other data given in this manual are subject to
change without notice. If the manual contains anything that you do not understand, contact the manufacturer for clarification.
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DC-545 HCEX
Thank you for your purchase of the Docu Cutter DC-545 HCEX.
To ensure safe and efficient prolonged use of this machine, read and thoroughly understand this manual before
using this machine. After using this manual, be sure to keep it in a handy place to Reference.
OVERVIEW
The DC-545 HCEX was created to produce high-quality, customized products; greeting cards, postcards,
brochures, business cards, and resized photographs. It does this by combining a number of devices that set up
automatically to slit, cut, and crease a sheet of paper into the desired format with no operator intervention.
Initially, the DC-545 HCEX is manually programmed with the required positions of the slits, cuts and creases
and the values are stored in a memory for future recall. A CCD sensor reads the job number encoded in a
barcode on the unfinished sheet. Then, the DC-545 HCEX recalls the values from memory, sets up the slitter
positions, activates the cutter for lead, trail, and any intermediate cuts and any required creases.
In addition, when a small 90-degree angle register mark has been printed adjacent to the barcode, the position
is measured against the intended position stored in the job memory. As this mark is part of the original image,
any error in its location can be compared with the stored value and used to correct the setup positions of the
devices by applying a horizontal offset to the cut and crease positions, and a vertical offset to the slit positions
to maintain precise finishing every time.
PLEASE NOTE
In the interest of upgrading our products, specifications and other data given in this manual are subject to
change without notice. If the manual contains anything that you do not understand, contact the dealer for
clarification.
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Contents
Introduction ......................................................................................................................... 1
DC-545 HC ................................................................................................................. 1
DC-545 HCEX ............................................................................................................ 2
Notes on Safety (Please Read and Observe) ................................................................... 5
Safety Precautions ............................................................................................... 5
Warning Sticker .......................................................................................................... 8
Positioning the Machine ............................................................................................. 9
Maintenance ............................................................................................................. 10
Conventions Used in This Manual............................................................................ 11
Chapter 1 Operating Instraction - DC-545 HC
Part names and their functions................................................................................. 12
Loading the paper .................................................................................................... 13
Selecting/operating/stopping a job ........................................................................... 14
Adjustments.............................................................................................................. 15
Troubleshooting table ............................................................................................... 17
Specifications ........................................................................................................... 17
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Chapter 2 Before Using This Machine - DC-545 HCEX
Confirming the Packaged Materials ................................................................................ 18
How to Set up the System ............................................................................................... 19
Part Names and Their Functions .................................................................................... 21
Appearance .............................................................................................................. 21
Control Panel ............................................................................................................ 23
LCD Panel ................................................................................................................ 24
Turning Power ON/OFF .................................................................................................... 25
Turning ON the Power.............................................................................................. 25
Turning OFF the Power ............................................................................................ 25
Chapter 3 Operating Instructions - DC-545 HCEX
Automatic Cutting Using Bar Codes and Register Marks ............................................ 26
About the Waste Tray ....................................................................................................... 29
Chapter 4 Troubleshooting - DC-545 HCEX
Troubleshooting Flow Chart ............................................................................................ 30
Power Does Not Turn ON......................................................................................... 30
Cutting is Not Possible ............................................................................................. 31
Error Messages ................................................................................................................. 32
When a Paper Jam Has Occurred ................................................................................... 39
When “REJECT PAPER” is Displayed ..................................................................... 39
When “FEED JAM” is Displayed .............................................................................. 41
When “CENTER JAM” is Displayed ......................................................................... 43
Procedure of Removing Front and Rear Creaser Guides ........................................ 45
When “SLITTER JAM” is Displayed ......................................................................... 47
When “CUTTER LOCK” is Displayed ....................................................................... 49
When “CREASE LOCK” is Displayed....................................................................... 51
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Contents
Chapter 5 Manual Programming - DC-545 HCEX
Prior to Programming a Job ............................................................................................ 53
Definition of Programming Terms ................................................................................... 54
Customer Programmed Jobs .......................................................................................... 60
Factory Preset Jobs ......................................................................................................... 61
How to Manually Program a Job ..................................................................................... 64
Appendix - DC-545 HC / DC-545 HCEX
Specifications ................................................................................................................... 70
DC-545 with HC AUTO FEEDER Specifications ...................................................... 70
DC-545 with HCEX AUTO FEEDER Specifications ................................................. 71
Specifications of Reg. Mark and Bar Code .............................................................. 72
How to do AUTO CUT .............................................................................................. 82
Index .................................................................................................................................. 83
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Notes on Safety (Please Read and Observe)
Safety Precautions
Various symbols and pictures are used in this manual and on the stickers affixed to the machine. These symbols and
pictures provide warnings and instructions to prevent danger to you or other personnel, and to prevent damage to office
property. The meanings of these symbols and pictures are explained below.
WARNING
Indicates a high degree of potential danger. If the warning is ignored, death or serious
injury may result.
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CAUTION
[Examples of Pictorial Symbols]
• These are particularly important safety points and should always be observed.
If the machine is used after foreign matter (metal fragments, water, or liquid) has entered the
machine, this may result in fire or electric shock.
• Turn the main unit’s power switch OFF, and then remove the power plug from the outlet. Contact
Indicates a medium degree of potential danger. If the caution is ignored, medium injury or
damage to property may result.
A circle with a line through it indicates a prohibited action. The particular act prohibited is indicated by a picture inside the circle. (In the example shown here, the prohibited
act is disassembly.)
A black disc indicates an instruction, or sometimes a prohibited action. The instruction
itself is indicated by pictorial symbols drawn in white on the disc. (In the example shown
here, the instruction is “Remove the plug from the outlet.”)
WARNING
the sales distributor.
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If the machine is used after heat, smoke, strange smell, or other abnormality is detected, this may
result in fire or electric shock.
• Turn the main unit’s power switch OFF, and then remove the power plug from the outlet. Contact
the sales distributor.
Use only the power cord that is provided among the accessories.
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Notes on Safety (Please Read and Observe)
WARNING
Do not modify the machine.
• Doing so may result in fire or electric shock.
Do not remove the rear lid, cabinet, or covers from the machine.
• The inside of the machine contains high-voltage parts, which may cause electric shock.
Do not remove or insert the power plug with wet hands.
• Doing so may result in electric shock.
Do not damage, break, or modify the power cord.
• Do not place heavy objects on, tug, or unnecessarily bend the power cord. Doing so may result in
fire or electric shock.
Do not insert or drop metal, flammable material, or other matter through the ventilation holes into
the machine interior.
• Doing so may result in fire or electric shock.
Do not place flower vases, flowerpots, cups, or water containers (including metal containers) on top
of the machine.
• Fire or electric shock may result if liquid spills inside the machine.
Do not use a source voltage other than that specified. Do not connect two or more loads to a single
outlet.
• Doing so may result in fire or electric shock.
Do not place the machine in a humid or dusty area.
• Doing so may result in fire or electric shock.
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Notes on Safety (Please Read and Observe)
CAUTION
Before moving the machine, remove the power plug from the outlet.
• If the cord is damaged, this may result in fire or electric shock.
Remove the power plug itself, not the cord.
• Tugging the cord may damage it (expose conductors, or cause disconnections, etc.), resulting in
fire or electric shock.
Do not place the machine in an unstable position, such as on an unsteady support or sloping area.
• If the machine is dropped or falls over, this could result in personal injury.
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Notes on Safety (Please Read and Observe)
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
w
WARNING
No. Parts No. Name Q’ty
q L8-T1100 Warning Sticker 1 1
w L8-T1080 Warning Sticker 2 3
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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
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Notes on Safety (Please Read and Observe)
Positioning the Machine
Installing the machine on a flat, stable surface.
Avoid installing the machine in a dusty area.
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Avoid installing the machine in the direct sunlight or heat,
such as near a stove. The machine may indicate errors due
to overheating caused by sunlight. Also avoid hot, cold, or
humid areas since paper may absorb moisture, causing
paper jams or wrinkles.
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Notes on Safety (Please Read and Observe)
Maintenance
Clean the exterior of the machine as described below.
Tightly wring a soft cloth that has been moistened with
water or neutral detergent, and wipe dirt from the machine’s surface.
Never use alcohol or organic solvents. Doing so may
discolor or damage the machine exterior.
Dust and clean the machine at least once a week to avoid
breakdowns.
Before cleaning, turn the power switch OFF, and then
remove the power plug from the outlet.
WARNING
• Before cleaning, remove the power plug from the outlet.
Failure to do so may result in an electrical shock or a fire hazard.
• Prevent water and neutral cleansers from getting inside the machine. If liquids spill inside the machine,
contact your agent immediately. Using the machine with water spilled inside may result in an electrical
shock or a fire hazard.
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Notes on Safety (Please Read and Observe)
Conventions Used in This Manual
Each page of descriptions in this manual of how to operate the DC-545 is set up as follows.
Chapter
Title
1
2
Description of operational steps
Each step is described in detail.
Illustrations
The illustrations provide a visual
reference to which keys to operate
and other related conditions.
■ Pictorial Symbols and Other Notations Used in This Manual
IMPORTANT : Introduces instructions for correct operation of the machine. If these instructions are ignored,
the machine may not be able to operate at optimum performance or may break down.
Tip : Introduces information that is useful for operation and maintenance of the machine, or
information about the machine’s performance, etc.
Continue Page
(a P.00 “xxxx”) : Indicates the page number and item containing related information.
•••
: Indicates that the description of the operating sequence is continued on the next page.
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Chapter 1
Operating Instraction - DC545 HC
Part names and their functions
q
e
t
r
w
No. Name Function
q Level adjustment lever For adjusting the level of the elevator 6
w Separator adjustment knob For adjusting the amount of space between sheets of paper 6
e Airflow adjustment knob For adjusting the amount of airflow 7
r Skew adjustment knob For adjusting the skew of the paper 7
t Stoppers For holding the rear edge of the paper stack 5
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Reference
Page
Loading the paper
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Fan the edge of the paper stack to separate the
paper.
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Set the paper stack on the feed tray.
Part Names and Their Functions
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Operating Instraction - DC545 HC
2
3
Note
• The height of the paper stack should not exceed
the "MAX" level.
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Turn the feed guide knob to loosen, then adjust
the feed guide.
MAX
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Part Names and Their Functions
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Tighten the knob to fix the position of the guide.
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Set the stoppers.
Selecting/operating/stopping a job
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Follow the instructions in the DC-545 manual to
select the type of job that you want to perform,
and then press START.
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To stop the machine, press STOP.
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4
7
C
1
4
7
C
POWER
POWER
START
2
3
5
6
8
9
STOP
0
START
2
3
5
6
8
9
STOP
0
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Adjustments
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Elevator level ( Feed tray)
The elevator level should be adjusted in the
following cases.
a. The machine does not feed.
→ Lower the lever. The level of the elevator is
raised.
b. The machine feeds multiple sheets at once.
(double feed)
→
Raise the lever. The level of the elevator is
lowered.
Part Names and Their Functions
1
1
2
Figure 1-1: Close-up of the level adjustment lever
3
Operating Instraction - DC545 HC
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Separator
The height of the separator should be adjusted in
the following cases:
a. The machine does not feed.
→
Turn the knob in the clockwise direction (to a
smaller number). The position of the separator is
lowered.
b. The machine feeds multiple sheets at once.
(double feed)
→
Turn the knob in the anti-clockwise direction (to
a larger number). The position of the separator is
raised.
Figure 1-2: Location of the level adjustment lever
Figure 2-1: Close-up of the separator
adjustment knob
Cutters and movable parts are inside this cover.
WARNING
Before opening the cover to work,
unplug the power cord.
Use caution when working near cutters
and movable parts.
L8-T1080
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Figure 2-2: Location of the separator
adjustment knob
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Part Names and Their Functions
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Adjusting the airflow
The amount of airflow should be adjusted in the
following cases:
a. The machine does not feed.
→
Turn the knob in the anti-clockwise direction (to
a larger number). The amount of airflow is
increased.
b. The machine feeds multiple sheets at once.
(double feed)
→
Turn the knob in the clockwise direction (to a
smaller number). The amount of airflow is
decreased.
Figure 3-1: Close-up of the airflow adjustment knob
Figure 3-2: Location of the airflow adjustment knob
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Adjusting the amount of skew
Paper may be cut at an angle if a skew in the paper
arises during feeding. When this happens, correct
the problem by changing the angle of the feed
guide.
Figure 4-1: Skew adjustment knob
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Part Names and Their Functions
Troubleshooting table
Symptom Possible Cause Remedy
The machine
does not feed
paper.
The machine
double feeds
paper.
The paper is cut
at an angle or
not fed straight.
Paper level is too low.
Paper separators are too high.
Not enough airflow.
Paper level is too high.
Paper separators are too low.
Too much airflow.
The paper is skewed.
Specifications
Raise the elevator height by pushing the level adjustment
lever downward. (See Figure 1-1)
Lower the paper separators by turning the separator adjustment knob clockwise, towards a lower number. (See Figure 2-1)
Increase the airflow by turning the airflow adjustment knob
counter-clockwise. (See Figure 3-1)
Lower the elevator height by pushing the level adjustment
lever upward. (See Figure 1-1)
Raise the paper separators by turning the separator adjustment
knob counter-clockwise, towards a higher number. (See Figure
2-1)
Decrease the airflow by turning the airflow adjustment knob
clockwise, towards a lower number. (See Figure 3-1)
1. Remove the paper from the feed tray.
2. Turn the skew adjustment knob according to the instructions on the label to adjust the angle of the feed guide.
1
1
Operating Instraction - DC545 HC
2
3
No. Item AF-100
1 Model Floor Model
2 Model No. AF-100
3 Input paper size Min.8.5” x 11” / A4
Max.12.6” x 18” / A3
<no curl in the paper>
4 Input paper weight Min.110gsm (29.3LB)
Max.230gsm (85LB)
5 Media type Range: Regular copy paper to coated heavy weight paper
6 Feeding method Automatic (Air suction method)
7 Feed tray capacity 3.9” (100mm)
8 Power supply DC5V, DC24V is supplied from DC-545 main body
9 Machine dimensions 43.4” (W) x 22.7” (D) x 37.8” (H)
1102mm (W) x 576mm (D) x 960mm (H)
10 Machine weight 117.1LB (Feeder : 44.9LB, Stand : 72.2LB)
53.2kg (Feeder : 20.4kg, Stand : 32.8kg)
11 Operating temperature 41-86F (5-30°C)
12 Operating Humidity 40-70% (no condensation within this range)
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Chapter 2
Before Using This Machine - DC545 HCEX
This chapter contains essential information you should understand such as the materials packaged with
this machine, how to set up the system, the names of the machine parts, etc.
Confirming the Packaged Materials
This product contains the following materials packaged together. If any material is missing, please contact your dealer.
qwe
r t
No. Name Q’ty
q Power cord 1
w Instruction Manual 1
e Tweezers 1
r Screw Driver 1
t Hex L-wrench 1
18
How to Set up the System
This section describes the cautions and the procedure when you set up this machine.
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Take out the machine from the package and place the machine on a flat and stable
table.
WARNING
• Do not try to lift the machine by yourself. Two or more people are required to prevent
injury and/or damage to the machine.
• When you open the box, be sure not to injure yourself or others with a cutter or the like.
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Detach the shipping bracket.
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Before Using This Machine - DC545 HCEX
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Attach the feed tray to the main body.
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Attach the paper tray to the main body.
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Continue Page
•••
19
How to set up the System
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Connect the power cord to the Docu Cutter and
a wall outlet.
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20
Part Names and Their Functions
Appearance
uyt
1
2
Before Using This Machine - DC545 HCEX
2
qwer
No. Name Function
q Control panel Displays operations and statuses.
w Waste tray cover Open to remove pieces of paper left in the machine.
e Waste tray Receives pieces of waste paper.
r Feed tray The original document is placed here.
t Feed guides Slide to match the width of the document.
y Feed lamp Indicates ready condition. Turns off during cutting or when the front cover or
the rear cover is opened.
u Front cover Open to remove jammed paper.
Reference
page
15
20
19, 20
10, 11, 18
18
18
23, 25
3
21
Part Names and Their Functions
i
No. Name Function
i Rear cover Open to remove jammed paper.
o Paper tray Receives the finished document.
!0 Power switch Press to switch the power on and off.
o!0
Reference
page
23, 25
10,11
17
22
Control Panel
Part Names and Their Functions
US
Europe
COVER
JAM
PAPER
w e rq
POWER
+
–
F
MODE SET
1
4
7
C
2
5
8
0
!0!1 o i u ty
w e rq
+
–
F
1
4
7
C
2
5
8
0
START
3
6
9
STOP
1
2
Before Using This Machine - DC545 HCEX
2
3
6
9
3
!0!1 o i u ty
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. Also
make this the last sentence. 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 Not used.
!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)
Reference
page
16, 23,
25
25
25
23, 27
25
23
Part Names and Their Functions
LCD Panel
q
[ RUN ] P–79
BC REG AC
r
No. Name Function
q Status Displays the current status or operating mode.
w Preset number Displays the preset Program (P) number.
e OPTION An "*" is displayed if the AF-100 is attached.
r BAR CODE When bar code reading is enabled "BC" is displayed; "- -" is displayed when
bar code reading is disabled.
t REGISTER MARK When using register marks reading is enabled "REG" is displayed; "- - -" is
displayed when register mark reading is disabled.
y AUTO CUT When using AUTO CUT is enabled "AC" is displayed; "- -" is displayed
when AUTO CUT is disabled.
u COUNTER Displays the number of pages processed.
w e
∗
∗ ∗ ∗
yt u
Reference
page
15, 48
19
18
24
Turning Power ON/OFF
This section describes the operating sequence from turning ON the power switch until the machine is ready to operate,
and how to turn OFF the power.
Turning ON the Power
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Press the “ | ” side of the power switch.
The power turns ON.
The illustration on the right shows what is displayed on the
LCD panel.
** denotes a preset number (01-80).
[
RUN ] P
-
BC ––– AC
∗∗
∗
∗
1
2
Before Using This Machine - DC545 HCEX
2
3
The illustration on the right shows that paper remains in the
machine. If this screen is displayed, remove them.
(a P.25, “When “REJECT PAPER” is Displayed”)
––– J 1 –––
REJECT PAPER
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Turning OFF the Power
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Press the “
The power turns OFF.
KK
K ” side of the power switch.
KK
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25
Chapter 3
Operating Instructions - DC545 HCEX
This chapter describes the operating sequence from turning ON the power switch until completing
cutting.
Automatic Cutting Using Bar Codes and Register Marks
This machine can read bar codes and reg. marks enabling automatic cutting and creasing.
The procedure is described below.
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Turn ON the power. (
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Set the feed tray.
aa
a P.17, “Turning ON the Power”)
aa
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Slide the feed guides to match the document
size.
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Set the document in the feed tray with the
surface where bar codes and reg. marks are
printed facing upwards.
The feed lamp turns off and a beep sounds.
In a few seconds, the document is fed into the machine.
Tip
• Set the document in the direction shown in the
illustration.
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26
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