DUPLO DBM-5000 In-Line Bookletmaker Service Manual

Duplo DBM-5000 In-line Bookletmaker
Service Manual
Contents at a Glance
Introduction ....................................................................... i
Section 1 Service Call Procedures .............................. 1-1
Section 2 Repair Analysis Procedures .........................2-1
Section 3 Booklet Quality .............................................3-1
Section 4 Replacement and Adjustment ......................4-1
Section 5 Parts Lists ....................................................5-1
Section 6 General Procedures .....................................6-1
Section 7 Wiring Data .................................................. 7-1
Section 8 Installation ....................................................8-1
Section 9 Information ...................................................9-1
iGen3-M12D0-0612-0
Introduction
Contents
Warnings and Symbols............................................... ii
Tool/Oil/Grease ......................................................... iii
Page i Introduction
Warnings and Symbols Symbol of Electric parts
Electrical parts used for this system is indicated in specific symbols in this
manual.
Warning, Caution, and Note Using this symbol would make it easier for you to search and find an
electrical part that appears in the text, Parts Lists and Wiring Data.
WARNING Example:
WARNING indicates a potentially hazardous situation which could result in M301 “M” is the type of an electrical part, “3” is the type of a product, “01” is a
death or serious injury if not avoided. sequence number.
PS501 “PS” is the type of an electrical part, “5” is the type of a product, “01” is
a sequence number.
CAUTION SSW601 “SSW” is the type of an electrical part, “6” is the type of a product,
“01” is a sequence number.
CAUTION indicates a potentially hazardous situation which may result in
minor or moderate personal injury or property damage if not avoided.
Also, this sign can indicate the possible loss of important data. Trademark
SpineMaster™used in this manual is a trademark of Watkiss Automation
Note: Note provides you with the information helpful to handle the machine.
Ltd.
Italic and Monospace All other product names and brand names used in this manual are
trademarks or registered trademarks of their respective owners.
Italic indicates exact terminology or cross references.
Monospace indicates messages, menus, or options displayed on a screen
or display.
Flags
Flag signs ( ) indicate reference points in electrical circuits.
Page ii Introduction
Tool/Oil/Grease OIL/GREASE NAME REMARKS
30WT Motor Oil
Litium grease
You need the following tools, oil and grease to provide service for this Orelube Corporation, G90/140
system.
TOOL NAME REMARKS
Phillips screwdriver
Phillips screwdriver (Long)
Phillips screwdriver (Short)
Flat-blade screwdriver
Flat-blade screwdriver (Small)
Long-nose pliers
Spanner (opposite side 5.0)
Spanner M3 (opposite side 5.5)
Spanner (opposite side 23/24)
Hexagonal wrench (opposite side 1.5)
Hammer
Plastic hammer
Pin removal tool (φ5)
Snap ring pliers
Tension gauge 1 kgm (10N)
Tension gauge 3 kgm (30N)
Spanner (opposite side 23/24) *Supplied with DBM-500
(see Section8, Checking Accessories)
Hexagonal wrench (opposite side 4.0) *Supplied with DBM-500
Screw (CFR5x20) *Supplied with DBM-500T (2 pcs.)
Screw (HS6x25) + Nut (N6) *Supplied with DBM-500T (1 set)
Screw (HS6x100) *Supplied with DBM-500T (2 pcs.)
Page iii Introduction

Section 1
Service Call Procedures
Contents
Section 1 Service Call Procedures .............................. 1-1
Initial Actions ...........................................................1-2
Preventive Maintenance of TR-DP ..........................1-3
Preventive Maintenance of SCC ............................ 1-4
Preventive Maintenance of
DBM-500/DBM-500BR ..........................1-5
Preventive Maintenance of DBM-500T ...................1-8
Preventive Maintenance of DBM-LS1/DBM-K ........1-9
Preventive Maintenance of SpineMaster............... 1-10
Final Actions .......................................................... 1-11
1-1
iGen3-M12D0-0612-0
Initial Actions RS-232C
PC
Duplo DBM-5000 is a bookletmaking system that is managed by the Inline

Controller. If Duplo DBM-5000 does not work, check the Inline Controller Interface box
and the system configuration.
Inline Controller
To see if the Inline Controller is working, follow these steps:
1. If nothing is displayed on the Inline Controller or Controller is not Interface box SCC DBM-500 DBM-500T
functioning, go to Section 2, RAP0.1 Fault Entry RAP. OEM PORT E-PORT E-PORT E-PORT
2. Turn off the bookletmaking system. iGen3 1 1 1 1
3. Wait for about ten seconds to make sure that the booklet system is
deenergized. PC 2 2 2 2
TR-DP DCM Kit
4. Check that the computer and the bookletmaking system is correctly
D-PORT D-PORT D-PORT D-PORT D-PORT D-PORT
connected, and all communication cables to all machines are connected.
1 1 1 1 1 1
5. Restart the Inline Controller Application.
6. Turn on the bookletmaking system. 2
2 2 2 2 2
7. Wait until all machines finish initialization.
3
Note: While a machine is getting ready, you will see or hear some components
moving. : E-port cable
4
8. Look for a message on the Inline Controller. If an error message is : D-port cable
: Other cable
displayed for a specific machine, troubleshoot any error message or
code on that machine’s control panel first. 5 : LED (green)
See Section 2 Fault Entry RAP for questionable machine. �� : LED (orange)
If the only error message is displayed on Inline Controller, see Section 2,

RAP0.1 Fault Entry RAP.
1-2 Section 1—Service Call Procedures

Initial Actions
Preventive Maintenance of TR-DP
Perform a maintenance check approximately every six months or every

50,000 sheets.
Cleaning and Inspection

Clean and inspect components as often as reasonably possible.
• Rollers
• Belts
• Sensors (PL2.6)

Preventive Maintenance of TR-DP
Preventive Maintenance of SCC Oiling Cutter Upper Blade
Lubricate the Upper Blades and Lower Blades periodically. Use the
following oil:
50,000 sheets. • 30WT Motor Oil
Oil the blades one time or more before 500,000 sheets of paper are cut. Oil
Oiling Slitter Upper Blades the blades once in 6 months or more frequently. Note, however, that excess
oil can stain paper. If oil stains paper, remove oil from the blades by using a
Each Slitter has a piece of felt. This felt lubricates the Upper Blade. The felt
dry cloth.
is pressed onto the Blade by a spring. You must oil the felt one time or more
before 500,000 sheets of paper are transported by way of the Process Path.
Note: Excess oil can stain paper. If oil stains paper, replace the felt (see Replacing
Upper Blade), or remove oil from the felt by using dry cloth or paper.
Paper feed
Cutter Motor
(M304) Cutter
Cover
Fan
(FM301)
Spring
Felt
Upper Blade
1. Open the Cover. The Cutter can cut 750,000 sheets of paper (in the quality of 64g/m²). Note
2. Oil the felt. To oil the felt, use the following oil: that the Cutter operates two times to cut one sheet of paper. To cut 750,000
sheets of paper, the Cutter operates 1,500,000 times. When the blades are
• 30WT Motor Oil
not sharp enough, replace the Cutter Unit (PL3.9). You cannot resharpen
the blades.

Preventive Maintenance of SCC
Preventive Maintenance of DBM-500/DBM-500BR • The shafts of the clinchers
Clincher
Perform a maintenance check approximately every six months or every Shaft
50,000 sheets.
Clincher
Lubrication (1)
For the following components, use litium grease or its equivalent.
• The shafts of the stitcher heads
Stitcher head
Shaft
A
Shaft
B
Shaft C
Shaft
• The cams that drive the clinchers
A
B
C
Cam

Preventive Maintenance of DBM-500
• The stitcher drivers and their housings • The stopper angle adjuster
• The sliding bars Adjuster
• The shoe tongues

Sliding bar
Housing
Driver
• All gears and racks

Shoe tongue • All chains
Lubrication (2)
For the following components, use 30WT Oil (not WD40) or its equivalent.
• Bearings (excluding ball bearings)
• Solenoid link mechanism
• The cams and followers that adjust roller gaps
• Moving conveyance roller unit sliding parts (apply thin layer)
• The pins and collars
• The surface between brackets
Lubrication (3)
Press roller
Cam
Follower
For the following components, use Orelube Corporation, G-90/140 or its
equivalent.
• Apply at fitted areas of folding rollers
• Apply at fitted areas of press rollers
Cam
Pin Follower
Follower
Bracket
Folding roller
Surface
Collar
Bracket Bracket Press roller
Folding roller
Viewed from upstream

• Stitcher heads
• Fold rollers
• Press rollers
• Nonmetallic rollers
• Belts
• Sensors (PL5c.2)

Preventive Maintenance of DBM-500T

50,000 sheets.
Lubrication
Lubricate components once in six months or more frequently. For the
following components, use 30WT Oil (not WD40) or its equivalent.
• Bushings and bearings
• Gears, sprockets, and chains
CAUTION
Use extreme caution while inspecting the upper blade, lower blade, or
waste gate. If you touch the upper blade, you may be severely injured.

• Upper and lower blades
• Waste gate mechanism (below the upper blade)
• Nonmetallic rollers
• Belts
• Sensors (PL6.22)

Preventive Maintenance of DBM-500T
Preventive Maintenance of DBM-LS1/DBM-K

50,000 sheets.

• DBM-LS1 belt

Preventive Maintenance of DBM-LS1/DBM-K
Preventive Maintenance of SpineMaster 2. Take a maximum thickness (6.5mm) A4 size booklet, and wrap a sheet
of paper around the outside. Alternatively, take about 30 sheets of A3
80gsm paper and fold into an A4 size booklet.
Perform a maintenance check approximately every six months.
USA Users:
Lubrication 6.5mm is 1/4”
For A4, use 81/2 x 11”
Lubricate drive chains using chain lubricant.
For A3, use 11 x 17”
CAUTION 80gsm is 20# bond
DO NOT lubricate the transverse chain. 3. Apply a thin coating of a suitable cleaning product to the spine of the
booklet.
Note: Suitable cleaning products include alcohol (isopropanol), offset litho
Cleaning and Inspection blanket wash or RS Solvent Cleaner Aerosol (Watkiss Part No. 951-097). Always
observe any health and safety information supplied with cleaning products.
• Belts WARNING
• Stop Cleaning solvents are flammable. DO NOT spray them directly into the
• Carriage Roller (See below) SpineMaster.
Cleaning the Carriage Roller and Stop

4. Hand feed the booklet into the SpineMaster in the normal way. Re-insert
Once a week, or as required, clean the carriage roller as explained below. the booklet and reprocess about 5 times.
1. Set the operating mode to Double Pass, and the Book Thickness 5. Remove the outer sheet, to give a fresh clean surface, and repeat step 4.
Adjustment to maximum.
CAUTION
Do not attempt to use a cloth to clean the carriage roller. This may leave
loose fibres or debris inside the machine.
Double Pass Max.
Min.
Operating Modes Book Thickness Adjustment

Preventive Maintenance of SpineMaster
Final Actions
To see if the booklet makings system works properly, follow the steps below.
When you have a machine energized, go to Stopping the System. When you
do not have any machine energized, go to Starting the System.
Stopping the System

To stop the system, follow these steps:
1. Quit the Inline Controller application.
2. Turn off the bookletmaking system.
3. Shut down the computer.
4. Wait for about ten seconds to make sure that the booklet system is
deenergized. Make sure that no LEDs are on.
Starting the System

Before trying the steps below, stop the bookletmaking system first (see
Stopping the System). To start the bookletmaking system, follow these steps:
1. Check that all cables—including D-port cables, E-port cables and power
cords—are correctly connected.
2. Check that all power-related switches—including Remote Switches and
Main Power Switches—are correctly set.
Note: For correct settings, see section 8.
3. Start the computer.
4. Turn on the bookletmaking system.
5. Wait until all machines finish initialization.
Note: While a machine is getting ready, you see or hear some components
moving.
6. Start the Inline Controller.
7. See the message on the Inline Controller. If an error message is
displayed, solve the problem (see Inline Controller Instruction Manual).
When no error message is displayed, make some booklets.
Making Booklets
To make booklets, see Inline Controller Instruction Manual.

Final Actions
Section 2
Repair Analysis Procedures
Contents
RAP0 System (Inline Controller) Section 2 Repair Analysis Procedures .........................2-1 RAP5.2 Generic RAPs...................................... 2-54
RAP0.1 Fault Entry RAP ......................................2-2 RAP5.3 Power Distribution RAP ....................... 2-55
RAP1 Interface Box
RAP0.2 Generic RAPs.........................................2-3 RAP5.4 Control Panel RAP ...............................2-57
RAP2 TR-DP RAP0.3a PC RAP (For north America) ................ 2-4 RAP5.5 Fault Code RAPs ..................................2-59
RAP0.3b PC RAP (Except north America) ............2-5 RAP5.6 Panel Version Error ..............................2-61
RAP3 SCC
RAP0.4 Fault Message RAPs..............................2-6 RAP5.7 CXX—Cover Open .............................. 2-62
RAP4 DCM Kit RAP0.5 System Power Distribution .....................2-7 RAP5.8 EXX—Hardware-Related Errors ......... 2-64
RAP1.1 Fault Entry RAP ......................................2-8 RAP5.9 JXX—Paper Jams ............................... 2-85
RAP5 DBM-500/DBM-500BR
RAP1.2 Generic RAPs.........................................2-9 RAP5.10 SXX—Emergency Stop ....................... 2-90
RAP6 DBM-500T/DBM-LS1/DBM-K RAP1.3 Power Distribution RAP ........................ 2-10 RAP5.11 TXX—Software-related Troubles .........2-91
RAP1.4 Alarm RAPs .......................................... 2-12 RAP6.1 Fault Entry RAP ....................................2-95
RAP8 SpineMaster
RAP2.1 Fault Entry RAP .................................... 2-13 RAP6.2 Generic RAPs...................................... 2-96
RAP2.2 Generic RAPs....................................... 2-14 RAP6.3 Power Distribution RAP ........................2-97
RAP2.3 Power Distribution RAP ........................ 2-15 RAP6.4 Control Panel RAP .............................. 2-99
RAP2.4 Alarm RAPs .......................................... 2-17 RAP6.5 Main motor RAP .................................2-100
RAP2.5 Cover Open RAP ..................................2-21 RAP6.6 Fault Code RAPs ................................ 2-101
RAP3.1 Fault Entry RAP ....................................2-22 RAP6.7 Paper Jam .......................................... 2-102
RAP3.2 Generic RAPs.......................................2-23 RAP6.8 Malfunction .........................................2-105
RAP3.3 Power Distribution RAP ........................2-24 RAP6.9 Emergency Stop ................................. 2-112
RAP3.4 Control Panel RAP ...............................2-26 RAP6.10 Cover open Messages ....................... 2-113
RAP3.5 Servo motor control unit RAP ..............2-27 RAP6.11 Other Messages ................................. 2-114
RAP3.6 Fault Code RAPs ..................................2-28 RAP6.12 DBM-LS1 RAP ................................... 2-116
RAP3.7 Paper Jam ............................................2-29 RAP8.1 Fault Entry RAP .................................. 2-117
RAP3.8 Malfunction ...........................................2-33 RAP8.2 AC Mains RAP.................................... 2-118
RAP3.9 Emergency stop Messages ................. 2-45 RAP8.3 Error Indicator RAP ............................ 2-119
RAP3.10 Cover open Messages ........................ 2-46 RAP8.4 Jammed Booklet RAP ........................ 2-120
RAP3.11 Other Messages .................................. 2-48 RAP8.5 Carriage Motor and
RAP4.1 Generic RAPs...................................... 2-50 Transverse Chain RAP ....................... 2-121
RAP4.2 Power Distribution RAP ........................2-51
RAP5.1 Fault Entry RAP ................................... 2-53
2-1
iGen3-M12D0-0612-0
System (Inline Controller)
RAP0.1 Fault Entry RAP
Do you see an error message on the Inline Controller?

Y N
| Go to Generic RAPs (RAP0.2).
Go to Fault Message RAPs (RAP0.4).
2-2 Section 2—Repair Analysis Procedures Inline Controller

RAP0.2 Generic RAPs
To solve the problem of the Inline Controller, follow the procedures below.
In the table below, find a symptom that is similar to the machine’s trouble.
Go to the section in See….
Symptom See…
The graphical user interface seems to be DUPLO Inline Controller Instruction Manual,
disorganised. “4-1-8. Incorrect Display”
The problem cannot be solved by following Fault Message RAPs (R AP0.4)
the procedures in DUPLO Inline Controller
Instruction Manual.
The Inline Controller does not work properly PC RAP (R AP0.3)
or its operation is very slow.

RAP0.2 Generic RAPs
RAP0.3a PC RAP (For north America)
This RAP describes locating and solving problems that you may encounter
while using the PT-5500.
Initial Actions
To confirm the problem, follow the procedures below.
1. Make sure that there is no damage on the serial cable and that the PC
is properly connected to the Interface Box (See Section 8, Connecting
Cables).
2. Make sure that there is no failure on each machine (See Section 2).
Checking the PC
Is the power cord connected with the outlet?
Y N
| Check that power cord is connected with outlet.
Does the power lamp (green) light when the power switch is turned on?
Y N
| Replace the PC (PL9.1).
Does the display light?
Y N
| Replace the PC (PL9.1).
Does Inline Controller launch?
Y N
| Are you running an application other than the Inline Controller
| on the PC?
| Y N
| | Replace the PC (PL9.1).
| Close all the applications except the Inline Controller.
| The operation of resident software or data download via a wire/wireless
| LAN may burden the CUP, resulting in the slow operation of the
| Inline Controller.
Remove the Inline Controller application from the PC and install it again.
(Even after removing the Inline Controller application, the setting file and
job data will not be deleted from the PC.)

RAP0.3a PC RAP (For north America)
RAP0.3b PC RAP (Except north America)
Refer to “Dell Business Support contact details.pdf” and “Dell OptiPlex 745
System User Guide.pdf”.

RAP0.3b PC RAP
RAP0.4 Fault Message RAPs Paper Jam
Message See…
Paper Jam - TR-DP ! RAP2.4 Alarm RAPs
When an error message is displayed on the Inline Controller, see the
Paper Jam - SCC ! RAP3.7 Paper Jam
control panel of a dysfunctional machine for details.
Paper Jam - DBM-500 ! RAP5.9 JXX—Paper Jams
In the table below, find a symptom that is similar to the machine’s trouble. Paper Jam - DBM-500T ! RAP6.7 Paper Jam

Reboot
Message See…
Cover Open Check TR-DP ! RAP2.4 Alarm RAPs
Check SCC ! RAP3.8 Malfunction
Message See… Check DBM-500 ! RAP5.4 Control Panel RAP
Cover Open - TR-DP ! RAP2.5 Cover Open RAPs
RAP5.8 EXX—Hardware-related Error
Cover Open - SCC ! RAP3.10 Cover open Messages
RAP5.11 TXX—Software-related Troubles
Cover Open - DBM-500 ! RAP5.7 CXX—Cover Open
Check DBM-500T ! RAP6.8 Malfunction
Cover Open - DBM-500T ! RAP6.10 Cover open Messages
Others
Emergency Stop
Message See…
Message See…
Turn off and on the system. RAP0.5 System Power Distribution
Emergency Stop - SCC ! RAP3.9 Emergency stop Messages
System Error - SpineMaster ! RAP8.1 Entry RAP
Emergency Stop - DBM-500 ! RAP5.10 SXX—Emergency Stop
System Communication Error! RAP1.4 Alarm RAPs
Emergency Stop - DBM-500T! RAP6.9 Emergency Stop
Failed to communicate with TR-DP RAP2.3 Power Distribution RAP
Failed to communicate with SCC RAP3.3 Power Distribution RAP
Failed to communicate with DCM Kit RAP4.2 Power Distribution RAP
Empty Failed to communicate with DBM-500 RAP5.3 Power Distribution RAP
Failed to communicate with DBM-500T RAP6.3 Power Distribution RAP
Message See…
Failed to communicate with Kicker “No Kicker” in RAP6.11 Other Messages
Staple Empty - DBM-500 “E01, E02 / E03, E04” in
RAP5.8 EXX—Hardware-related Error
Full
Message See…
Scrap Box Full - SCC RAP3.11 Other Messages
Stacker Full - DBM-500 RAP5.8 EXX—Hardware-related Error
Scrap Box Full - DBM-500T RAP6.11 Other Messages

RAP0.4 Fault Message RAPs
RAP0.5 System Power Distribution Figure 1 <Connecting Cables & LED’s>
Initial Actions
To confirm the problem, follow the procedures below.
1. Make sure that there is no damage on the D-port cables and that the
each machine is properly connected to other machine (see Figure 1,
Connecting Cables & LED’s).
Interface box SCC DBM-500 DBM-500T
2. Check that there is no damage to the power cord of each machine and OEM PORT E-PORT E-PORT E-PORT
that it connects to the machine and the wall outlet. iGen3 1 1 1 1
Note: This will avoid plugging machines into each other Example, Plugging the
Power cord of the DBM-500T into the DBM-500. PC 2 2 2 2
TR-DP DCM Kit
3. Check that the Main Power Switches and Power Switches are set D-PORT D-PORT D-PORT D-PORT D-PORT D-PORT
properly (see Figure 2, Setting of Power Switches). 1 1 1 1 1 1
4. Check that the voltage of the wall outlet is appropriate for the machine. 2
2 2 2 2 2
5. Turn off the System Power Switch of the Duplo DBM-5000 (the Main 3
Power Switch of the Interface Box). Wait for about ten seconds. Turn on
the System Power Switch again. 4 : E-port cable
: D-port cable
: LED (green) is ON.
: LED (orange) is ON.
: Other cable : LED is OFF.
5
Checking the Duplo DBM-5000 ��
Check that the LED of each machine is on as shown in the figure Figure 2 <Setting of Power Switches>
“Connecting Cables & LED’s.” Is each LED on? Remote switch Main power Main power switch Remote switch
switch DBM-500T
Y N
| Refer to the RAP of the machine concerned.
SpineMaster
End of the RAP. There is no problem with power distribution.
Machine Name Information on LED DCM Kit DBM-500
Green Orange
Interface Box DC power lamp
TR-DP Response lamp of a remote signal Main power
SCC from the upstream unit (asking switch
power-on of the Interface Box, TR-
DP or SCC) SCC Remote switch Main power
switch
DCM Kit Response lamp of a remote signal DBM-500
from the upstream unit (asking
power-on of the DCM Kit)
DBM-500 DC power lamp Response lamp of a remote signal Interface Box TR-DP
Main power
DBM-500T from the upstream unit (asking Remote switch
switch
power-on of DBM-500 or DBM-
500T)
SpineMaster
Main power switch Main power switch
(Duplo DBM-5000 System Power Switch)

RAP0.5 System Power Distribution
Interface Box
LED19 (Red)
Do you hear an alarm sound and/or see error lamp (LED19) flash on the
Interface Box?
Y N
Go to Alarm RAPs (RAP1.4).
2-8 Section 2—Repair Analysis Procedures Interface Box

Interface Box
RAP1.2 Generic RAPs
LED19 (Red)
While another machine in the system failed, the Interface Box does not
operate. But Interface Box does not show any explicit symptom. If Interface
Box does not operate without any particular reason, check other machines
in the system.
To analyze Interface Box, follow these steps:
In the table below, find a symptom that is similar to machine’s trouble.
Symptom See…
You cannot energize the machine. Power Distribution RAP (R AP1.3)
LED19 lights up. Alarm RAPs (R AP1.4)

RAP1.2 Generic RAPs
Interface Box
RAP1.3 Power Distribution RAP
LED02 (green)
Initial Actions
To confirm the problem, follow these steps:
1. Check the Duplo DBM-5000 (RAP0.5).
2. Turn off the Main Power Switch. Wait for about ten seconds. Turn on the
Main Power Switch.
3. Check that the green LEDs (LED02, LED18) used for checking power
distribution are not on.
4. Turn off the Main Power Switch. LED18 (green)
Continue with RAP on next page.

Interface Box
Checking the Switching Power Supply
INLET
WARNING 250V 10A

SWITCHING POWER SUPPLY
Disconnect the power cord before removing an exterior cover. The POWER SW
Switching Power Supply can cause a shock if touched. CN1 BLACK BLACK AC(L)
1 AC(L)
2
CN2 WHITE WHITE AC(N)
Check that the fuse on the Switching Power Supply is not damaged. BROWN 4 +24V 3 AC(N)
4 POWER CORD
3 +24V
Is the fuse defected? BLUE 2 GND 5 FG
Y N 1 GND AC120V 60Hz
2 FG AC220-240V 50/60Hz
| Disconnect all connectors connecting between the 1
FG GREEN/YELLOW
| Switching Power Supply and the Interface unit.

| Is the problem solved?
| Y N
| | Check the harness between the Switching Power Supply and the
| | Interface unit. Is it intact?
| | Y N
| | | Replace the harness (PL1.1, Bundled Wire Unit 1).
| | Measure the voltage between the CN2-4 (+24V) and CN2-2 (GND)
| | of the Switching Power Supply.
| | Did you confirm the output of +24VDC?
| | Y N
| | | Replace the Switching Power Supply (PL1.1).
| | Replace the Interface unit.
| Measure the voltage (120VAC or 230VAC) at CN1-1 and CN1-3.
| Is it normal?
| Y N
| | Check the continuity through the Power SW.
| End of the RAP. The Switching Power Supply is free of defects.
Replace the Switching Power Supply (PL1.1).

Interface Box
RAP1.4 Alarm RAPs Number of
buzzer sounds Error Solution
8 Downstream unit connection 1. Recheck the connection of each
error: cable.
Error lamp (LED19) lights up and the buzzer sounds when the Interface A machine in the system is offline. 2. Replace the D-port cable.
Box detects errors. 3. Replace the IF unit.
The following table shows details. 10 PC I/F error (framing) 1. Recheck the connection of PC cable.
2. Replace the PC cable.
Number of Error Solution
buzzer sounds 3. Replace the IF unit.
1 Downstream unit I/F ACK error: 1. Recheck the connection of the
D-port cable.
A communication error has
occurred between the downstream 2. Replace the D-port cable.
unit and the IF Unit.
3. Replace the IF unit.
2 Downstream unit I/F CRC error: 1. Recheck the connection of the
D-port cable.
A communication error has
occurred between the downstream 2. Replace the D-port cable.
unit and the IF Unit.
3. Recheck the connection PC to
Interface Box.
3 System initial error 1: 1. Replace the D-port cable.
The communication buffer is full 2. Replace the IF unit.
when the system is started by
power ON (data transmission is
disabled).
4 System initial error 2: 1. Recheck the connection of the
D-port cable.
Data cannot be received from the
slave when the system is started 2. Replace the D-port cable.
by power ON.
5 System initial error 3: 1. Check the power supply state of the
machine in the system.
The power of a machine in the
system is ON when the system is 2. Replace the D-port cable.
started by power ON.
6 System initial error 4: 1. Recheck the connection of the
D-port cable.
The downstream unit cannot be
identified (not connected) when 2. Check the power supply state of the
the system is started by power ON. machine in the system.
3. Replace the D-port cable.
7 System initial error 5: 1. Replace the D-port cable.
Data of the downstream unit 2. Replace the IF unit.
cannot be received when the
system is started by power ON.

RAP1.4 Alarm RAPs
TR-DP
Do you hear an alarm sound?

Y N
Go to Alarm RAPs (RAP2.4).
2-13 Section 2—Repair Analysis Procedures TR-DP

TR-DP
RAP2.2 Generic RAPs
While another machine in the system is in trouble, the motor of TR-DP does
not operate. But TR-DP does not show any explicit symptom. If TR-DP does
not operate without any particular reason, check other machines in the
system.
To analyze TR-DP, follow these steps:
1. In the table below, find a symptom that is similar to machine’s trouble.
2. If the machine does not go back to the normal status, the machine might
have failed to output an error code and or error message due to defective
sensors. To check sensors, see GP2.2, Checking the Paper Sensor.
Symptom See…
LED is not on.

RAP2.2 Generic RAPs
TR-DP
Initial Actions
2. Turn off the System Power Switch of the Duplo DBM-5000.
3. Turn on the Remote Switch of the TR-DP.
4. Check that the LED (green) is on.
5. Turn off the Remote Switch.
LED (orange)
LED (green)
Remote switch Main power Main power switch Remote switch

switch DBM-500T
SpineMaster
DCM Kit DBM-500
Main power
switch
SCC Remote switch Main power

switch
DBM-500
Interface Box TR-DP

Main power
switch
Remote switch

(Duplo DBM-5000 System Power Switch) <Setting of Power Switches>

TR-DP
Checking the Switching Power Supply RM UNIT
WARNING
Disconnect the power cord before removing an exterior cover. The
Switching Power Supply and Relay Board can cause a shock if touched.
Check that the fuse on the RM Unit is not damaged.

Is the fuse defected?
Y N
| Disconnect all connectors connecting between the RM Unit and the 1
| MC unit and reconnect them. 2
| Y N
| | Check the harness between the RM Unit and the MC Unit.
| | Is it intact? Note: The input voltage is AC120V or AC220-240V. The output voltage is
| | Y N AC200V regardless of the input voltage.
| | | Replace the harness (PL2.7).
| | Measure the voltage between the J5-2 (+6V) and J5-3 (GND) of
| | the RM Unit.
| | Y N
| | | Replace the RM Unit (PL2.6).
| Measure the voltage (120VAC or 230VAC) at J1-1 and J1-3.
| Is it normal?
| Y N
| | Check the power cord.
| End of the RAP. The RM Unit is free of defects.
Replace the RM Unit (PL2.6).

TR-DP
RAP2.4 Alarm RAPs Paper Jam
A short single alarm indicates paper jams. Solve the problem by following
these steps:
TR-DP sounds several types of alarm tones:
● Remove the jammed paper.
● When the alarm tone goes Single Beep, see Paper Jam.
● See if the upstream machine has failed to transport the paper to TR-DP.
● When the alarm tone goes Double Beep, see Motor Error.
● Check the condition of Belt.
● When the alarm tone goes Triple Beep, see Communication Error.
● See if something is between the sensors, interrupting the light between
● To disable the alarm, see Disabling Alarm. them.
● To enable the alarm, see Enabling Alarm. ● Reconnect the sensor connector.
● Check the paper sensor (GP2.2, Checking the Paper Sensor).
● Replace the MC Unit (PL2.6).

RAP2.4 Alarm RAPs
TR-DP
Motor Error Figure 1
Two consecutive alarm tones indicate motor errors. Solve the problem by 1
21
22
+6.5V
GND MC Unit
following these steps: 0824 BLUE
23
24 GND
0825 PINK
Conveyance Motor 0826
25
PURPLE 26
+5V
HU
FGOUT 1 0827 GRAY 27 HV
0825 PINK
Check the driving path of the Conveyance Motor. DC5V
HU
2
3
0826 PURPLE
0828 SKYBLUE 28 HW
Is it free of defects? HV 4
0827
0828
GRAY
SKYBLUE
DC Motor HW 5
Y N GND 6
0824
0201
BLUE
PURPLE 0201 PURPLE 1 U
J02
| Remove a foreign object or replace or adjust parts. UCOIL
VCOIL
7
8
0202 YELLOW
1
2
1
2
0202 YELLOW 2 V
0203 SKYBLUE 0203 SKYBLUE 3 W
Check the connecting all connectors. WCOIL 9 3 3
Measure the voltage between the J08-25 (+5V) and J01-3(GND) of the MC 24V 37.4W
J01
Unit. 0101 BROWN
1 +24V
Did you confirm the output of +5VDC? 0103 BLUE 2
3
+24V
GND
Y N 4
5
GND
FG
| Replace the MC Unit (PL2.6). 2
Remove the J02, then measure the registor of motor. (see Figure 1)
Is it normal? Measurement point Normal output voltage
Y N Connector - Pin (Signal) Not in operation In operation
J08-25 (+5V) J01-3 (GND) approx. 5VDC approx. 5VDC
| Replace the MC Unit (PL2.6).
Check if each connector is properly connected between the Conveyance
Measurement point Registor of motor
Motor and the MC Unit and if the harness is properly connected between
Connector - Pin (Signal) Not in operation In operation
them. If there is no problem with the connections, replace the MC Unit
J02-1 (UCOIL) J02-2 (VCOIL) approx. 0.8Ω
(PL2.6).
J02-2 (VCOIL) J02-3 (WCOIL) approx. 0.8Ω
J02-3 (WCOIL) J02-1 (UCOIL) approx. 0.8Ω
Note: Remove the J02, and measure the connector of motor side.

RAP2.4 Alarm RAPs
TR-DP
Communication Error Disabling Alarm
Three consecutive alarm tones indicate errors in D Port communication. You can disable the alarm—TR-DP does not sound alarm tones during
Solve the problem by following these steps: regular operation.
● Reconnect the D-port cables. Note: During the Maintenance Mode, TR-DP sounds alarm tones.
● Avoid crosstalk by distancing the D-port cables from other cables. 1. Turn off ( ) the Main Power Switch.
● Check the communication-related sections of other machines.
Unexpected signals can cause communication errors.
● Replace the MC Unit (PL2.6).
Remote Switch Main Power Switch
2. Remove the Cover F (REP2.1).

3. Set the switch on the MC Unit as shown in the table.
1 2 3 4 5 6
Upper Upper Upper Upper Upper Upper
position position position position position position
MC Unit
1 2 3 4 5 6
Switch
4. Replace the covers.

RAP2.4 Alarm RAPs
TR-DP
Enabling Alarm
TR-DP does not sound alarm tones if the alarm function is turned off. To
enable the alarm function, set the switch on the MC Unit as shown in the
table.
1 2 3 4 5 6
Lower Lower Lower Lower Lower Lower
MC Unit
1 2 3 4 5 6
Switch

RAP2.4 Alarm RAPs
TR-DP
RAP2.5 Cover Open RAP
Cover Open - TR-DP ! (Displayed on Inline Controller)

Is the cover completely closed?
Y N
| Close the cover.
Are the Cover Magnet Switch and the Magnet secured to the machine and
the cover, respectively?
Y N
| Secure the Cover Magnet Switch and the Magnet to the machine and
| the cover, respectively.
Check if the cover magnet switch works properly in the Maintenance Mode.
(GP2.2, Checking the Cover Switch).
Does it work properly?
Y N
| Check if each connector is properly connected between the Cover
| Magnet Switch and MC Unit and if the harness is properly
| connected between them.
| Are they connected properly (WD1.2, WD3.2)?
| Y N
| | Reconnect the connectors or replace the harness.
| Replace the switch.
After restarting the Inline Controller, does the message disappear?
Y N
| Replace the MC Unit.
The end of RAP. Each part appears to be functioning.
If this message appears frequently, replace the MC Unit.

RAP2.5 Cover Open RAP
SCC
Do you see an error code and/or error message on the Inline Controller or
the SCC control panel LED?
Y N
Go to Fault Code RAPs (RAP3.6).
2-22 Section 2—Repair Analysis Procedures SCC

SCC
RAP3.2 Generic RAPs
To analyze SCC, follow these steps:

sensors. To check sensors, see GP2.3, Sensor Check.
Symptom See…
LED is not on.
Nothing is displayed on the Control Panel. Control Panel RAP (R AP3.4)

RAP3.2 Generic RAPs
SCC
Initial Actions
3. Turn on the Remote Switch of the SCC.
4. Check that the LED (green) is on.
5. Check that nothing appears on the display. LED (green)
6. Turn off the Remote Switch. LED (orange)

switch DBM-500T
SpineMaster
DCM Kit DBM-500
Main power
switch

switch
DBM-500
Interface Box TR-DP

Main power
switch
Remote switch


SCC REMOTE SWITCH
Checking the Switching Power Supply SWITCHING POWER SUPPLY (PSW302)
ORANGE 3001 CN52 CN2 PURPLE 2 3
BLUE 3002 1 +R 1 +R GRAY INLET
2 -R 2 -R
WARNING BLUE
XH02
CN51
XH02
CN1 BLACK 3 4 3T BLACK L
BLUE 1 GND 1 AC(L)
Disconnect the power cord before removing an exterior cover. The 2 GND
3 GND
2
3 AC(N) WHITE 1 2 WHITE N
BROWN 4 +24V 4 GREEN/YELLOW E
Switching Power Supply (PCB304) and Relay Board (PCB305) can cause a BROWN 5 +24V
6 +24V
5 FG
VH05T MAIN POWER SWITCH
VH06T (PSW301) FERRITE CORE
shock if touched. 1
FG
ZCAT3035-1330
2
Check that the fuse on the Switching Power Supply (PCB304) is not
damaged.
Y N
| Disconnect all connectors connecting between the
| Switching Power Supply (PCB304) and the MC Unit (PCB301) and
| reconnect them. Is the problem solved?
| Y N
| | Check the harness between the Switching Power Supply (PCB304)
| | and the MC Unit (PCB301). Is it intact?
| | Y N
| | Measure the voltage between the CN51-6 (+24V) and
| | CN51-2 (GND) of the Switching Power Supply (PCB304).
| | Y N
| | | Replace the Switching Power Supply (PCB304) (PL3.21).
| Is it normal?
| Y N
| | Check the continuity through the Main Power Switch (PSW301).
| End of the RAP.
| The Switching Power Supply (PCB304) is free of defects.
Replace the Switching Power Supply (PCB304) (PL3.21).

SCC
RAP3.4 Control Panel RAP
Initial Actions
1. Turn off the Remote Switch. Wait for about ten seconds. Turn on the
Remote Switch.
2. See if anything is shown on the display.
Checking the Control Panel
WARNING
Switching Power Supply (PCB304) and Relay Board (PCB305) can cause a
shock if touched.
Reconnect the Control Panel (PCB302) and MC Unit (PCB301).

Is the problem solved?
Y N
| Check the cable between the Control Panel (PCB302) and
| MC Unit (PCB301). Is it intact?
| Y N
| | Replace the cable (PL3.20).
| Reconnect the MC Unit (PCB301) and
| Switching Power Supply (PCB304).
| Y N
| | Check the cable between the MC Unit (PCB301) and
| | Switching Power Supply (PCB304). Is it intact?
| | Y N
| | | Replace the cable.
| | Check the Switching Power Supply (PCB304) (RAP3.3).
| | Is it intact?
| | Y N
| | Check the Servo Motor Control Unit (PCB303) (RAP3.5).
| | Is it intact?
| | Y N
| | | Replace the Servo Motor Control Unit (PCB303) (PL3.21).
| | Replace the Control Panel (PCB302) (PL3.21).
End of the RAP. The Control Panel (PCB302) appears to be functioning.

SCC
RAP3.5 Servo motor control unit RAP 1
2
XH08T EH08T
See WD1.3 and WD3.3. 8 1 8 VH04T
1
4 1
6
PH06T
Fuse
WARNING
1
Touching the heat sink on the Servo Motor Control Unit (PCB303) may
5
cause severe burn injury.
PH05T VH03T
Layout of
Check the fuse connection of the Servo Motor Control Unit (PCB303). Servo Motor Control Unit (PCB303)
1
3
Is the fuse blown out?
Y N
1
| Reconnect all the connectors between the Servo Motor Control Unit
| (PCB303) and the MC Unit (PCB301).
| Y N
| | Check the harness between the Servo Motor Control Unit (PCB303)
| | and the MC Unit (PCB301).
| | Is it intact?
| | Y N
| | Check the voltage between the VH04T-1 (+24V) and the
| | VH04T-3 (GND) of the Servo Motor Control Unit (PCB303).
| | Y N
| | | Replace the MC Unit (PCB301) (PL3.21).
| | Replace the Servo Motor Control Unit (PCB303) (PL3.21).
| The end of RAP.
Replace the Servo Motor Control Unit (PCB303) (PL3.21).

RAP3.5 Servo motor control unit RAP
SCC
RAP3.6 Fault Code RAPs
Follow the procedures below.

In the table below, find a symptom that is similar to machine’s trouble. Go
to the section in See….
Message See…
Paper jam RAP3.7 Paper Jam
Malfunction RAP3.8 Malfunction
(Emergency stop) RAP3.9 Emergency stop Messages
(Cover open) RAP3.10 Cover open Messages
Side Cover Not Attached RAP3.11 Other Messages
Scrap box Full
Scrap box Not Attached
Operation Error Mark Reading Error
Operation Error Ref. Y Length Input Error
Operation Error Ref. X Length Input Error
Operation Error Mark Reading is set to ON
Operation Error Feed Test Sheet

SCC
RAP3.7 Paper Jam
Bypass Sensor
(PS306)
Initial Actions
Bypass
To confirm the problem, follow the procedures below: Paper feed
1. Check operator settings (Paper size and/or etc.) of iGen3 and Inline
Controller. If settings are not same, match settings. Entrance Sensor
(PS305)
2. Open the covers and remove the jammed paper.
Note: Pressing the Function Button will transport the jammed paper to the Conveyer Motor 1
downstream unit. To remove the jammed paper transported to the downstream (M301)
unit, open the covers of the downstream unit.
Stopper Sensor
(PS308) Process Path
Servo Motor
(M303)
Stopper Rear Sensor
(PS309)
Cutter Front Sensor
(PS311)
Function button Jog dial
Creaser Front Sensor
(PS312)
3. Close the covers.
Delivery Sensor
4. Check if the message has disappeared. If the message is still displayed, (PS307)
Conveyer Motor 2
follow the procedures below according to each message. See WD1.3 and (M302)
WD3.3 as well.
Viewing Jam Code

You will see the message Paper Jam on the first line of the display. The
second line shows where the jam has occurred. Turn the Jog Dial to display
a jammed code.

RAP3.7 Paper Jam
SCC
Entrance 01 (J0) Stopper 01 (J2)
Is there any foreign object or deformed/damaged parts on the paper path Is there any foreign object or deformed/damaged parts on the paper path
between the Paper Sensor of the TR-DP and the Entrance Sensor (PS305)? between the Entrance Sensor (PS305) and the Stopper Sensor (PS308)?
Y N Y N
| Check if the Entrance Sensor (PS305) works properly in the | Check if the Stopper Sensor (PS308) works properly in the
| Maintenance Mode (GP2.3, Sensor Check). | Maintenance Mode (GP2.3, Sensor Check).
| Does the sensor work properly? | Does the sensor work properly?
| Y N | Y N
| | Check if each connector is properly connected between the | | Check if each connector is properly connected between the
| | Entrance Sensor (PS305) and the MC Unit (PCB301) and if | | Stopper Sensor (PS308) and the MC Unit (PCB301) and if
| | the harness is properly connected between them. If there is | | the harness is properly connected between them. If there is
| | no problem with the connections, replace the sensor (PL3.21). | | no problem with the connections, replace the sensor (PL3.21).
| Replace the MC Unit (PCB301). | Replace the MC Unit (PCB301).
Remove the foreign object or replace the deformed/damaged parts. Remove the foreign object or replace the deformed/damaged parts.
Lower Conveyance (J3)

Entrance 02 (J1) Check the Stopper Sensor (PS308) and the Stopper Rear Sensor (PS309).
Check the Entrance Sensor (PS305). Is there any foreign object attached to it?
Is there any foreign object attached to it? Y N
Y N | Check if the Stopper Sensor (PS308) and the Stopper Rear Sensor
| Check if the Entrance Sensor (PS305) works properly in the | (PS309) work properly in the Maintenance Mode
| Maintenance Mode (GP2.3, Sensor Check). | (GP2.3, Sensor Check).
| Does the sensor work properly? | Do they work properly?
| Y N | Y N
| | Entrance Sensor (PS305) and the MC Unit (PCB301) and if | | dysfunctional sensor and the MC Unit (PCB301) and if the harness is
| | the harness is properly connected between them. If there is | | properly connected between them. If there is no problem with
| | no problem with the connections, replace the sensor (PL3.21). | | the connections, replace the sensor (PL3.21).

RAP3.7 Paper Jam
SCC
Delivery 01 (J6) Bypass Front (J12)
between the Stopper Sensor (PS308) and the Delivery Sensor (PS307)? between the Entrance Sensor (PS305) and the Bypass Sensor (PS306)?
Y N Y N
| Check if the Delivery Sensor (PS307) works properly in the | Check if the Bypass Sensor (PS306) works properly in the
| Y N | Y N
| | Delivery Sensor (PS307) and the MC Unit (PCB301) and if the | | Bypass Sensor (PS306) and the MC Unit (PCB301) and if the
| | harness is properly connected between them. If there is no problem | | harness is properly connected between them. If there is no problem
| | with the connections, replace the sensor (PL3.21). | | with the connections, replace the sensor (PL3.21).
Delivery 02 (J7) Bypass Center (J13)

Check the Delivery Sensor (PS307). Check the Bypass Sensor (PS306)
Is there any foreign object attached to it? Is there any foreign object attached to it?
Y N Y N
| Check if the Delivery Sensor (PS307) works properly in the | Check if the Bypass Sensor (PS306) works properly in the
| Y N | Y N
| | Delivery Sensor (PS307) and the MC Unit (PCB301) and if the | | Bypass Sensor (PS306) and the MC Unit (PCB301) and if the
| | with the connections, replace the sensor (PL3.21). | | with the connections, replace the sensor (PL3.21).

RAP3.7 Paper Jam
SCC
Bypass Rear (J14)
Is there any foreign object or deformed/damaged parts on the paper path
between the Bypass Sensor (PS306) and the Delivery Sensor (PS307)?
Y N
| Check the Delivery Sensor (PS307) in the Maintenance Mode
| (GP2.3, Sensor Check).
| Does the sensor work properly?
| Y N
| | Check if each connector is properly connected between the
| | Delivery Sensor (PS307) and the MC Unit (PCB301) and if the
| | harness is properly connected between them. If there is no problem
| | with the connections, replace the sensor (PL3.21).
| Replace the MC Unit (PCB301).
Remove the foreign object or replace the deformed/damaged parts.

RAP3.7 Paper Jam
SCC
RAP3.8 Malfunction Figure 1
MC Unit
(PCB301)
Malfunction is displayed on the first line of the LCD. The second line shows Conveyance motor 1 (M301)
the name of the problem.
2
Refer to WD1.3 and WD3.3 as well when following the procedures below.
Conveyance motor 1 locked

Conveyance motor 2 locked
Check the driving path of the Conveyance motor X (M301/M302). 1
Is it free of defects? 1 2
Y N 1
Conveyance motor 2 (M302)
| Remove a foreign object, replace parts or adjust the belt tension
| (ADJ3.2).
Measure the output voltage between the MC Unit (PCB301) and the
1
Conveyance Motor X (M301/M302). (see Figure 1) 1
Is it normal output voltage? 1
Y N
Conveyance Motor 1 (M301)
Check if each connector is properly connected between the Conveyance
Motor X (M301/M302) and the MC Unit (PCB301) and if the harness Measurement point Normal output voltage
is properly connected between them. If there is no problem with the Connector - Pin (Signal) Not in operation In operation
connections, replace the motor (PL3.21). J09-1 (M3U) J06-8 (GND) approx. 0VDC approx. 5.5VDC
J09-2 (M3V) J06-8 (GND) approx. 0VDC approx. 5.5VDC
J09-3 (M3W) J06-8 (GND) approx. 0VDC approx. 5.5VDC
Conveyance Motor 2 (M302)

Measurement point Normal output voltage
J09-4 (M4U) J06-12 (GND) approx. 0VDC approx. 5.5VDC
J09-5 (M4V) J06-12 (GND) approx. 0VDC approx. 5.5VDC
J09-6 (M4W) J06-12 (GND) approx. 0VDC approx. 5.5VDC

RAP3.8 Malfunction
SCC
Cutter motor Error Figure 1
Check the Cutter Sensor (SW301). MC Unit
Is it free of defects? (PCB301)
Y N
2
| Remove a foreign object or replace parts. 1
Check if the Cutter Sensor (SW301) works properly in the Maintenance
Mode (GP2.3, Cutter in “Sensor Check”). Cutter Motor
RED
WHT
Does it work properly? (M304)
Y N
| Check if each connector is properly connected between the
| Cutter Sensor (SW301) and the MC Unit (PCB301) and if the harness is
| properly connected between them. If there is no problem with
| the connections, replace the sensor (PL3.21).
Check the driving path of the Cutter Motor (M304). Measurement point Normal output voltage
Is it free of defects? Connector - Pin (Signal) Not in operation In operation
Y N J09-7 (+M) J09-8 (-M) approx. 0VDC approx. 23.5VDC
| Remove a foreign object or replace parts.
Measure the output voltage between the MC Unit (PCB301) and the Cutter
Motor (M304). (see Figure 1)
Is it normal output voltagel?
Y N
Check if each connector is properly connected between the Cutter Motor
(M304) and the MC Unit (PCB301) and if the harness is properly connected
between them. If there is no problem with the connections, replace the
motor (PL3.21).
Note: The Cutter Sensor (SW301) is a part of the Cutter Unit. When you replace
the Cutter Sensor (SW301), replace the whole Cutter Unit.

RAP3.8 Malfunction
SCC
Creaser motor Error Figure 1
Check the Creaser Sensor (PS301). 2 MC Unit
Is there any foreign object attached to it? 1 (PCB301)
Y N WHT
| Check the Flag, Sensor and Sensor Bracket. Creaser Motor
(M305)
BLK
| Are they free of defects?

| Y N Measurement point Normal output voltage
| | Replace deformed/damaged parts. Connector - Pin (Signal) Not in operation In operation
| Check if the Creaser Sensor (PS301) works properly in the J08-1 (+M) J08-2 (-M) approx. 0VDC approx. 23.5VDC
| Maintenance Mode (GP2.3, Creaser in “Sensor Check”).
| Y N
| | Creaser Sensor (PS301) and the MC Unit (PCB301) and if the
| | harness is properly connected between them (PL3.21).
| | If there is no problem with the connections, replace the sensor
| | (PL3.21).
| Check the driving path of the Creaser Motor (M305).
| Is it free of defects?
| Y N
| | Remove a foreign object or replace parts.
| Measure the output voltage between the MC Unit (PCB301) and the
| Creaser Motor (M305). (see Figure 1)
| Is it normal output voltagel?
| Y N
| | Replace the MC Unit (PCB301).
| Creaser Motor (M305) and the MC Unit (PCB301) and if the
| harness is properly connected between them (PL3.21).
| If there is no problem with the connections, replace the motor (PL3.21).
Remove the foreign object.

RAP3.8 Malfunction
SCC
M.Body motor home-in Figure 1
M.Body motor home-out MC Unit
M.Body motor counter-in (PCB301)
Check the Main Body Sensor (PS314).
Is there any foreign object attached to it?
Y N
| Check the Flag, Sensor and Sensor Bracket.
| Y N
| | Replace deformed/damaged parts.
| Check if the Main Body Sensor (PS314) works properly in the
| Maintenance Mode (GP2.3, Main Body in “Sensor Check”).
| Does the sensor work properly? Main Body Motor
| Y N (M310)
| | Main Body Sensor (PS314) and the MC Unit (PCB301) and if the
| | harness is properly connected between them.
| | (PL3.21).
| Check the driving path of the Main Body Motor (M310).
| Y N
2
| | Remove a foreign object or replace parts. 1
| Main Body Motor (M310). (see Figure 1)
| Is it normal output voltagel?
| | Replace the MC Unit (PCB301). Connector - Pin (Signal) Not in operation In operation
| Check if each connector is properly connected between the J09-9 (+A) J09-10 (-A) approx. 0VDC approx. 20 to 30VDC
| Main Body Motor (M310) and the MC Unit (PCB301) and if the
| harness is properly connected between them (PL3.21).

RAP3.8 Malfunction
SCC
Side jog 1 motor home-in Figure 1
Side jog 1 motor home-out
MC Unit
Side jog 1 motor home out-in (PCB301)
Side jog 1 motor counter Error
Check the S-J1 home sensor (PS302). 2
Y N
| Y N
| Check if the S-J1 home sensor (PS302) works properly in the 1
1
| Maintenance Mode (GP2.3, S•J1 Home in “Sensor Check”). Side Jogger 1 Motor
1
(M306)
| Does the sensor work properly? 1
| Y N 1
1
| | S-J1 Home Sensor (PS302) and the MC Unit (PCB301) and if the
| | harness is properly connected between them (PL3.21).
| | (PL3.21).
| Check the driving path of the Side Jogger 1 Motor (M306).
| Y N
| Measure the output voltage between the MC Unit (PCB301) and the Measurement point Normal output voltage
| Side Jogger 1 Motor (M306). (see Figure 1) Connector - Pin (Signal) Not in operation In operation
| Is it normal output voltagel? J10-17 (A-) J01-7 (GND) approx. 24VDC approx. 22.7 to 23.0VDC
| Y N J10-18 (+24V) J01-7 (GND) approx. 24VDC approx. 24VDC
| | Replace the MC Unit (PCB301). J10-19 (A+) J01-7 (GND) approx. 24VDC approx. 22.7 to 23.0VDC
| Check if each connector is properly connected between the J10-21 (B+) J01-7 (GND) approx. 24VDC approx. 22.7 to 23.0VDC
| Side jogger 1 motor (M306) and the MC Unit (PCB301) and if the J10-22 (+24V) J01-7 (GND) approx. 24VDC approx. 24VDC
| harness is properly connected between them (PL3.21). J10-23 (B-) J01-7 (GND) approx. 24VDC approx. 22.7 to 23.0VDC
Note: There are signal name difference between motor and MC unit. It’s correct.

RAP3.8 Malfunction
SCC
Side jog 2 motor home-in Figure 1
Side jog 2 motor home-out
MC Unit
Side jog 2 motor home out-in (PCB301)
Side jog 2 motor counter Error
Check the S-J2 Home Sensor (PS303). 2
Y N
| Y N
| Check if the S-J2 Home Sensor (PS303) works properly in the
| Maintenance Mode (GP2.3, S•J2 Home in “Sensor Check”).
| Y N
1
| | Check if each connector is properly connected between the 1
| | S-J2 Home Sensor (PS303) and the MC Unit (PCB301) and if the Side Jogger 2 Motor 1
| | harness is properly connected between them (PL3.21). (M307) 1
1
| | If there is no problem with the connections, replace the sensor 1
| | (PL3.21).
| Check the driving path of the Side Jogger 2 Motor (M307).
| Y N
| Side Jogger 2 Motor (M307). (see Figure 1) Connector - Pin (Signal) Not in operation In operation
| Is it normal output voltagel? J10-25 (A-) J01-7 (GND) approx. 24VDC approx. 22.7 to 23.0VDC
| Side jogger 2 motor (M307) and the MC Unit (PCB301) and if the J10-30 (+24V) J01-7 (GND) approx. 24VDC approx. 24VDC
| harness is properly connected between them (PL3.21). J10-31 (B-) J01-7 (GND) approx. 24VDC approx. 22.7 to 23.0VDC

RAP3.8 Malfunction
SCC
Slitter motor home-in Figure 1
Slitter motor home-out
MC Unit
Slitter motor home out-in (PCB301)
Slitter motor counter Error
Check the Slitter sensor (PS310). 2
Y N
| Check the Flag, Sensor and Sensor Bracket. 1
1
| Are they free of defects? Slitter Motor
1
| Y N (M309)
1
| | Replace deformed/damaged parts. 1
| Check if the Slitter sensor (PS310) works properly in the Maintenance 1
| Mode (GP2.3, Slitter in “Sensor Check”).

| Y N
| | Slitter Sensor (PS310) and the MC Unit (PCB301) and if the
| | with the connections, replace the sensor (PL3.21).
| Check the driving path of the Slitter Motor (M309).
| Y N
| | Remove a foreign object or replace or adjust parts.
| Slitter Motor (M309). (see Figure 1) Measurement point Normal output voltage
| Is it normal output voltage? Connector - Pin (Signal) Not in operation In operation
| Y N J10-9 (A-) J01-7 (GND) approx. 24VDC approx. 22.7 to 23.0VDC
| | Replace the MC Unit (PCB301). J10-10 (+24V) J01-7 (GND) approx. 24VDC approx. 24VDC
| Check if each connector is properly connected between the J10-11 (A+) J01-7 (GND) approx. 24VDC approx. 22.7 to 23.0VDC
| Slitter Motor (M309) and the MC Unit (PCB301) and if the harness J10-13 (B+) J01-7 (GND) approx. 24VDC approx. 22.7 to 23.0VDC
| is properly connected between them. If there is no problem with J10-14 (+24V) J01-7 (GND) approx. 24VDC approx. 24VDC
| the connections, replace the motor (PL3.21). J10-15 (B-) J01-7 (GND) approx. 24VDC approx. 22.7 to 23.0VDC
Remove a foreign object.

RAP3.8 Malfunction
SCC
Back jog motor home-in Figure 1
Back jog motor home-out
MC Unit
Back jog motor home out-in (PCB301)
Back jog motor counter Error
Check the Back Jogger Sensor (PS304). 2
Y N
| Check the Flag, Sensor and Sensor Bracket. Back Jogger Motor
| Are they free of defects? (M308)
| Y N
| Check if the Back Jogger Sensor (PS304) works properly in the
| Maintenance Mode (GP2.3, Back Jogger in “Sensor Check”). 1
1
| Y N 1
| | Check if each connector is properly connected between the 1
| | Back Jogger Sensor (PS304) and the MC Unit (PCB301) and if the 1
| | harness is properly connected between them. If there is
| | no problem with the connections, replace the sensor (PL3.21).
| |
| Check the driving path of the Back Jogger Motor (M308).
| Y N
| | Remove a foreign object or replace or adjust parts.
| Back Jogger Motor (M308). (see Figure 1) Connector - Pin (Signal) Not in operation In operation
| Is it normal output voltage? J10-1 (A-) J01-7 (GND) approx. 24VDC approx. 22.7 to 23.0VDC
| Back Jogger Motor (M308) and the MC Unit (PCB301) and if the J10-6 (+24V) J01-7 (GND) approx. 24VDC approx. 24VDC
| harness is properly connected between them. If there is no problem J10-7 (B-) J01-7 (GND) approx. 24VDC approx. 22.7 to 23.0VDC
| with the connections, replace the motor (PL3.21).

RAP3.8 Malfunction
SCC
Side jog Error Servo driver MPU CRC Error
Servo driver MPU ACK Error
This message is not supposed to appear on the Duplo DBM-5000.
See RAP3.5 Servo motor control unit RAP.
Turn off the Remote Switch. Wait for about ten seconds.
When you turn on the Remote Switch again, does the message disappear?
Y N
End of the RAP. If this message appears frequently, replace the MC Unit
(PCB301).

RAP3.8 Malfunction
SCC
Servo driver over load Error Figure 1
Servo driver over power Error Servo Motor
Servo driver over speed Error Control Unit
Servo driver position Error 2
(PCB303)
Servo driver position sensor Error BROWN 0104 1 +24VA
2 +24VA
Servo driver limit sensor Error BLUE 0105 3 GND
Sarvo Motor
Servo driver over run Error (M303)
4 GND
VH04T
Servo driver low voltage Error RED RED
Servo driver high voltage Error BLACK BLACK
1 +5V
2 GND
Servo driver initialize Error BLUE
YELLOW
BLUE
YELLOW
3 A
Servo driver over temp. Error WHITE WHITE
4 B
5 THERMISTOR
Servo motor over time Error 6 N.C.
PH06T XH08T EH08T VH04T
Check the driving path of the Servo Motor (M303). 8 1 8 1
MOT BROWN BROWN 4 1
6
1 +5V
PH06T
Is it free of defects? BLUE BLUE
Fuse
2 GND
YELLOW YELLOW
Y N
1
3 C3
GREEN GREEN
4 C2
5
| Remove a foreign object, replace parts or adjust the belt tension ORANGE ORANGE
PH05T VH03T
5 C1 Layout of
| (ADJ3.10). PH05T
Servo Motor Control Unit (PCB303)
1
3
Measure the output voltage between the Servo Motor Control Unit RED
WHITE
RED
WHITE
1 W3
1
(PCB303) and the Servo Motor (M303). (see Figure 1) BLACK BLACK
2 W2
3 W1
Is it normal output voltage? VH03T
1
Y N 1
| Go to RAP3.5 Servo motor control unit RAP. 1
Check if each connector is properly connected between the Servo Motor
(M303) and the Servo Motor Control Unit (PCB303) and if the harness is Measurement point Normal output voltage
properly connected between them. Connector - Pin (Signal) Not in operation In operation
Are they connected properly? VHT03T-1 (W3) VH04T-3 (GND) approx. 10VDC approx. 11VDC
VHT03T-2 (W2) VH04T-3 (GND) approx. 10VDC approx. 11VDC
Y N
VHT03T-3 (W1) VH04T-3 (GND) approx. 10VDC approx. 11VDC
| Reconnect the connector or replace the harness (PL3.21).
Is the problem solved after replacing the Servo Motor (M303)?
Y N
| Go to RAP3.5 Servo motor control unit RAP.
End of the RAP.

RAP3.8 Malfunction
SCC
Panel MPU CRC Error Memory Data Error
Panel MPU ACK Error Memory Write ACK Error
Turn off the Remote Switch. Wait for about ten seconds. DA converter ACK Error
When you turn on the Remote Switch again, does the message disappear? Turn off the Remote Switch. Wait for about ten seconds.
Y N When you turn on the Remote Switch again, does the message disappear?
| Can you enter the Maintenance Mode (GP2.3)? Y N
| Y N | Is the EEPROM (U38) properly attached?
| Check if each connector is properly connected between the | Y N
| OP Unit (PCB302) and the MC Unit (PCB301) and if the harness is | | Attach the EEPROM (U38) properly.
| properly connected between them. | Is the problem solved after replacing the MC Unit (PCB301)?
| Are they connected properly? | Y N
| Y N | | Replace the EEPROM (U38) (REP3.1).
| | Reconnect the connector or replace the harness (PL3.21). | End of the RAP.
| Check if each connector is properly connected between the End of the RAP. If this problem occurs frequently, replace the MC Unit
| Servo Motor Control Unit (PCB303) and the MC Unit (PCB301) and (PCB301).
| if the harness is properly connected between them.
| Are they connected properly?
| Y N
| | Reconnect the connector or replace the harness (PL3.21).
| Is the problem solved after replacing the OP Unit (PCB302)?
| Y N
End of the RAP.
Interface MPU CRC Error

Interface MPU ACK Error
Y N
End of the RAP. If this message appears frequently, replace the MC Unit
(PCB301).

RAP3.8 Malfunction
SCC
RL Relay Problem Emergency Cable Problem 1
Are the settings of a slide switch on each Relay Board of this machine, Emergency Cable Problem 2
DBM-500 and DBM-500T correct? Emergency Cable Problem 3
Y N Emergency Cable Problem 4
| Set each slide switch correctly (See Figure 1). These messages are displayed only for BG configration whitch is not used
Check if each connector is properly connected between the Relay Board in north America.
(PCB305) and the following parts and if the harness is properly connected
between them.
•Emergency Stop Switch (SSW301) Is the E-port cable properly connected to the machine?
•Top Cover-F Sensor (SSW302) Y N
•Top Cover-R Sensor (SSW303) | Reconnect the cable (See Section 8, Connecting Cables).
•Slitter Cover Sensor (SSW304) Is the E-port Cable electrically connected to the machine?
Are they connected properly? Y N
Y N | Replace the E-port Cable (PL3.17).
| Replace the harness. Check if each connector is properly connected between the
Is the problem solved after replacing the Relay Board (PCB305)? MC Unit (PCB301) and the Relay Board (PCB305) and if the harness is
Y N properly connected between them.
| Replace the MC Unit (PCB301). Are they connected properly?
End of the RAP. Y N
| Reconnect the connectors or replace the harness (PL3.21).
Is the problem solved after replacing the Relay Board (PCB305)?
Figure 1 Y N
<BG/non BG Setting> | Replace the MC Unit (PCB301).
DBM-500T
SCC
End of the RAP.
< Relay Board (PCB604) >
< Relay Board (PCB305) > non BG SW1 SW2
non BG SW1 SW2 ON ON
ON ON
BG SW1 SW2
BG SW1 SW2 ON
ON
OFF
OFF DBM-500
non BG SW1 SW2
ON ON
BG SW1 SW2
OFF OFF

RAP3.8 Malfunction
SCC
RAP3.9 Emergency stop Messages Emergency Stop Upstream Unit
This message is not supposed to appear on the Duplo DBM-5000.
See WD1.3 and WD3.3 as well while the following the procedures below. Turn off the Remote Switch. Wait for about ten seconds.
Y N
Emergency Stop SCC Unit
| Does the message disappear after replacing the Relay Board (PCB305)?
Is the Emergency Stop Switch pressed? | Y N
Y N | | Replace the MC Unit (PCB301).
| When the Emergency Stop Switch (SSW301) is released, are the | End of the RAP.
| pin1 and pin2 electrically connected to each other? End of the RAP. If this message appears frequently, replace the Relay Board
| Y N (PCB305) and the MC Unit (PCB301).
| | Replace the Emergency Stop Switch (SSW301) (PL3.21).
| Emergency Stop Switch (SSW301) and the Relay P.W.B (PCB305) and Emergency Stop Down-stream Unit
Is the message related to the emergency stop displayed on the control panel
of the downstream unit?
| Y N
Y N
| Does the message disappear after replacing the Relay Board (PCB305)?
| Y N
| Relay Board (PCB305) and the MC Unit (PCB301) and if the harness
| is properly connected between them.
| End of the RAP.
Refer to the RAP of the downstream unit.
| Y N
| Is the problem solved after replacing the Relay Board (PCB305)?
| Y N
| End of the RAP.
End of the RAP. Each part appears to be functioning.
Release the Emergency Stop Switch (SSW301).

RAP3.9 Emergency stop Messages
SCC
| |
RAP3.10 Cover open Messages | End of the RAP.
See WD1.3 and WD3.3 as well while the following the procedures below. If the message is still displayed, replace the MC Unit (PCB301).
Top Cover Front Open

Is the Front Top Cover closed completely?
Y N
| Close the Front Top Cover.
Check the sliding part of the Top Cover-F Sensor (SSW302).
Is it free of defects?
Y N
| Replace the Top Cover-F Sensor (SSW302) (PL3.21).
Is the Top Cover-F Sensor (SSW302) adjusted properly?
Y N
| Adjust the Top Cover-F Sensor (SSW302) (ADJ3.17).
Check if the Top Cover-F Sensor (SSW302) works properly in the
Maintenance Mode (GP2.3, Top Cover-F in “Sensor Check”).
Does the switch work properly?
Y N
| When setting the Top Cover-F Sensor (SSW302) to ON, are the pin1
| and pin2, and pin3 and pin4 of the sensor electrically connected to
| each other?
| Y N
| | Replace the Top Cover-F Sensor (SSW302) (PL3.21).
| Top Cover-F Sensor (SSW302) and Relay Board (PCB305) and if
| the harness is properly connected between them.
| Y N
| Top Cover-F Sensor (SSW302) and MC Unit (PCB301) and if the
| harness is properly connected between them.
| Y N
| Y N
| |
| |
RAP3.10 Cover open Messages
SCC
Top Cover Rear Open Slitter Under Cover Open
Is the Rear Top Cover closed completely? Is the Bottom Cover of the Slitter secured to the machine properly?
Y N Y N
| Close the Rear Top Cover. | Secure the Bottom Cover to the machine.
Check the sliding part of the Top Cover-R Sensor (SSW303). Is the Slitter Cover Sensor (SSW304) properly adjusted?
Is it free of defects? Y N
Y N | Readjust the Slitter Cover Sensor (SSW304) (ADJ3.12).
| Replace the Top Cover-R Sensor (SSW303) (PL3.21). Check if the Slitter Cover Sensor (SSW304) works properly in the
Is the Top Cover-R Sensor (SSW303) adjusted properly? Maintenance Mode (GP2.3, Slitter Cov in “Sensor Check”).
Y N Does the switch work properly?
| Adjust the Top Cover-R Sensor (SSW303) (ADJ3.17). Y N
Check if the Top Cover-R Sensor (SSW303) works properly in the | When setting the Slitter Cover Sensor (SSW304) to ON, are the pin1
Maintenance Mode (GP2.3, Top Cover-R in “Sensor Check”). | and pin2, and pin3 and pin4 of the sensor electrically connected to
Does the switch work properly? | each other?
Y N | Y N
| When setting the Top Cover-R Sensor (SSW303) to ON, are the pin1 | | Replace the Slitter Cover Sensor (SSW304) (PL3.21).
| and pin2, and pin3 and pin4 of the sensor electrically connected to | | Check if each connector is properly connected between the
| each other? | | Slitter Cover Sensor (SSW304) and the MC Unit (PCB301) and if
| Y N | | the harness is properly connected between them.
| | Replace the Top Cover-R Sensor (SSW303) (PL3.21). | | Are the connected properly?
| Check if each connector is properly connected between the | Y N
| Top Cover-R Sensor (SSW303) and Relay Board (PCB305) and | | Reconnect the connectors or replace the harness.
| if the harness is properly connected between them. | Replace the MC Unit (PCB301).
| Are they connected properly? End of the RAP. Each part appears to be functioning.
| Y N If the message is still displayed, replace the MC Unit (PCB301).
| Top Cover-R Sensor (SSW303) and MC Unit (PCB301) and if the
| Y N
| Y N
| End of the RAP.
If the message is still displayed, replace the MC Unit (PCB301).

SCC
RAP3.11 Other Messages Scrap box Full
Is the Scrap Box full?
Y N
See WD1.3 and WD3.3 as well while the following the procedures below. | Check the D-box Full Sensor (PS313).
| Is there any foreign object attached to it?
Side Cover Not Attached | Y N
Is each side cover secured to the machine properly? | | Check if the light axis of the D-box Full Sensor (PS313) is displaced.
Y N | | Is it placed properly?
| Secure each side cover to the machine. | | Y N
Does the actuator of each side cover switch (SSW305, SSW306) work | | | Replace deformed/damaged parts (PL3.12).
properly? | | Check if the D-box full sensor (PS313) works properly in the
Y N | | Maintenance Mode (GP2.3, D-box full in “Sensor Check”).
| Replace the switch (PL3.21). | | Does the sensor work properly?
Check if the Side Cover Switch (SSW305, SSW306) works properly in the | | Y N
Maintenance Mode. | | | Check if each connector is properly connected between the
(GP2.3, Side Cover in “Sensor Check”) | | | D-box full sensor (PS313) and the MC Unit (PCB301) and if
Does the switch work properly? | | | the harness is properly connected between them. If they are
Y N | | | properly connected, replace the sensor (PL3.21).
| When setting the Side Cover Switch (SSW305, SSW306) to ON, do the | | End of the RAP. Each part appears to be functioning.
| terminals of the switch electrically connected to each other? | | If the message is still displayed, replace the MC Unit (PCB301).
| Y N | Remove the foreign object.
| | Replace the switch (PL3.21). Open the Scrap Box, and empty it.
Note: If the operator removes the scrap through the Slide Cover, the “Scrap box
| Check if each connector is properly connected between the Full” message will not go away. The Scrap Box must be opened then Re-set in
| Side Cover Switch (SSW305, SSW306) and MC Unit (PCB301) and order for the “Scrap box Full” message to go away.
| Y N

RAP3.11 Other Messages
SCC
Scrap box Not Attached Operation Error Mark Reading Error
Is the Scrap Box properly attached to the machine? Operation Error Ref. Y Length Input Error
Y N Operation Error Ref. X Length Input Error
| Attach the Scrap Box properly. Operation Error Mark Reading is set to ON
Does the actuator of the Scrap Box work properly? Operation Error Feed Test Sheet
Y N This message is not supposed to appear on the Duplo DBM-5000.
| Replace the Actuator (PL3.12).
Check if the D-box Position Sensor (SW302) work properly in the
Maintenance Mode (GP2.3, D-box Pstn in “Sensor Check”). Turn off the Remote Switch. Wait for about ten seconds.
Does the switch work properly? When you turn on the Remote Switch again, does the message disappear?
Y N Y N
| When setting the D-box Position Sensor (SW302) to ON, are the | | Replace the MC Unit (PCB301).
| terminals of the switch electrically connected to each other? | End of the RAP.
| Y N End of the RAP. If this message appears frequently, replace the MC Unit
| | Replace the D-box Position Sensor (SW302). (PCB301).
| D-box Position Sensor (SW302) and MC Unit (PCB301) and if the
| Y N

DCM Kit
RAP4.1 Generic RAPs
While another machine in the system failed, DCM Kit does not operate. But
DCM Kit does not show any explicit symptom. If DCM Kit does not operate
without any particular reason, check other machines in the system.
To analyze DCM Kit, follow these steps:
In the table below, find a symptom that is similar to machine’s trouble.
Symptom See…
2-50 Section 2—Repair Analysis Procedures DCM Kit

RAP4.1 Generic RAPs
DCM Kit
LED (green)
Initial Actions
3. Turn off the Main Power Switch of the DCM Kit.

DCM Kit
Checking the RM Unit
WARNING
Disconnect the power cord before removing an exterior cover. The RM Unit
Switching Power Supply can cause a shock if touched.
Check that the fuse on the RM Unit is not damaged.

Y N
| Disconnect all connectors connecting between the RM Unit and the
| Interface unit and reconnect them. Is the problem solved?
| Y N
| | Check the harness between the RM Unit and the Interface unit.
| | Is it intact?
| | Y N
| | Measure the voltage of the RM Unit as shown in the diagram to the
| | right. Output from the RM Unit
| | Is it normal?
| | Y N Connector Pin Output Voltage
| | | Replace the RM Unit (PL4.3). J2 3 5 200VAC
| Measure the voltage (120VAC or 230VAC) at J1-1 and J1-3. J3 1 4 200VAC
| Is it normal? J5 2 (+6V) 3 (GND) +6VDC
| Y N
| | Check the power cord. Note: The input voltage is 120VAC or 220-240VAC. The output voltage is
| End of the RAP. The RM Unit is free of defects. 200VAC regardless of the input voltage.
| Check that there is no problem with the upstream unit (RAP3.3).
Replace the RM Unit (PL4.3).

DBM-500/DBM-500BR
the DBM-500 control panel LED?
Y N
2-53 Section 2—Repair Analysis Procedures DBM-500/DBM-500BR

DBM-500/DBM-500BR
RAP5.2 Generic RAPs
Follow these steps:

sensors. To check sensors, see GP2.5, Sensor.
Symptom See…
LED is not on.
Panel version error... Panel Version Error (R AP5.6)

RAP5.2 Generic RAPs
DBM-500/DBM-500BR
Initial Actions
3. Turn on the Remote Switch of the DBM-500. LED (green)
LED (orange)
4. Check that the LED (green) is on. Remote switch Main power Main power switch Remote switch
5. Check that nothing appears on the display. switch DBM-500T
6. Turn off the Remote Switch of the DBM-500.

SpineMaster
DCM Kit DBM-500
Main power
switch

switch
DBM-500
Interface Box TR-DP

Main power
switch
Remote switch


DBM-500/DBM-500BR
Checking the Switching Power Supply Fan Noise Filter
3610KL-05W-B50-LD0 GT-210J Ferrite core
DC24V 0.2A AC/DC 250V 10A TDK ZCAT 3035-1330 Power cord
WARNING 5108 BRN
5104 BLU
1
2
RED
BLK
WHT
BLK
WHT
BLK
WHT
BLK
Disconnect the power cord before removing an exterior cover. The YEL GRN/YEL
Circuit protector
Switching Power Supply (PCB504) and Relay Board (PCB503) can cause a Switching Power Supply
ETA 3120-F521-P7T1-W02D-10A
Ferrite core ZWS240PAF-24/J
shock if touched. GRY MSFC10KEX CN51 CN1 YEL
1 GND 5 FG
0608 BLU 2 GND
0B03 BLU WHT
Check that the fuse on the Switching Power Supply (PCB504) is not 5104 BLU
3
4
GND
GND
3 N
0601 BRN BLK
damaged. BRN
5
6
+24V
+24V
1 L
0B07 BRN Switch
Is the fuse defected? 5108 BRN
7
8
+24V
+24V CN2
Purple 1 Purple JW-L12RKK-K1N
Y N CN52
1 +R
2 -R GRY 2 GRY
0A01 ORG
| Disconnect all connectors between the 0A02 BLU
1 +R
2 -R
| Switching Power Supply (PCB504) and the MC Unit (PCB501) and
1
| reconnect them. Is the problem solved? 2
| Y N
| | Y N
| | | Replace the harness (PL5c.5).
| | Measure the voltage between the CN51-5 (+24V) and CN51-2(GND)
| | of the Switching Power Supply (PCB504).
| | Y N
| | | Replace the Switching Power Supply (PCB504) (PL5c.4).
| Is it normal?
| Y N
| | Check the continuity through the noise filter. And check the braker
| | of Main Power Switch.
| End of the RAP.
| The Switching Power Supply (PCB504) appears to be functioning.
Replace the Switching Power Supply (PCB504) (PL5c.4).

DBM-500/DBM-500BR
Minus keys Plus keys
Initial Actions
1. Turn off the Remote Switch. Wait for about ten seconds. Turn on the
Remote Switch.
2. Check the brightness and contrast of the Control Panel.
If the LCD looks pale, adjust the LCD brightness and contrast. To adjust
the brightness and contrast, select the OPTION tab and touch the LCD
LCD setting key OK key
Setting Key. On the “GOT setup:..:Brightness/contrast” screen, touch
the Plus/Minus Keys. When the adjustment is finished, touch the OK
Key.

DBM-500/DBM-500BR
Checking the Control Panel | |
| Reconnect the Control Panel and MC Unit (PCB501).
WARNING | Is the problem solved?
| Y N
| | Check the cable between the Control Panel and MC Unit (PCB501).
| | Is it intact?
shock if touched.
| | Y N
When turning on the Remote Switch of the machine, does the Control Panel | | | Replace the cable (PL5c.5).
remain off? | | |
Y N | | Replace the Control Panel (PL5a.24).
| Is there anything unusual displayed on the Control Panel? End of the RAP. The Control Panel appears to be functioning.
| Y N
| | End of the RAP. The Control Panel appears to be functioning.
| Reconnect the Control Panel and the MC Unit (PCB501)
| (WD1.5, WD3.5).
| The two connectors for Control Panel to MC Unit are attached on
| the frame. One is for L side Control Panel and the other is R side
| Control Panel. In this case, connect R side connector to MC Unit
| (Section 8, Installing DBM-500, Step 8).
| Y N
| | Check the harness is properly connected (PL5c.5).
| End of the RAP.
Reconnect the Control Panel and Switching Power Supply (PCB504).
Check for loose connections between the Switching Power Supply
(PCB504), MC Unit (PCB501) and Control Panel.
Is the problem solved?
Y N
| Check the cable between the Control Panel and
| Is it intact?
| Y N
| | Replace the cable (PL5c.5).
| Check the Switching Power Supply (PCB504) (RAP5.3).
| Check the connection between the
| CN52 of Switching Power Supply (PCB504) and J02 of DPIF PWB Unit.
| Is it intact?
| Y N
| | Replace the Switching Power Supply (PCB504) (PL5c.4).
| |
| |
| |

DBM-500/DBM-500BR
RAP5.5 Fault Code RAPs Code
E31
Message
Motor error (saddle stopper HO)
See…
RAP5.8 EXX—Hardware-related
E32 Motor error (saddle stopper HI2) Errors
E33 Motor error (saddle stopper HC)
Follow these steps:
E34 Motor error (saddle stopper HI3)
Find the error code and message in the table below. Go to the RAP for that E35 Motor error (back stopper HI1)
code in See…. E36 Motor error (back stopper HO)
Note: That no code is displayed in the case of Panel Version Error. E37 Motor error (back stopper HI2)
E38 Motor error (back stopper HC)
Code Message See… E39 Motor error (back stopper HI3)
— Panel version error… RAP5.6 Panel Version Error E40 Motor error (folding guide HI1)
C01 Safety cover (front) RAP5.7 CXX—Cover Open E41 Motor error (folding guide HO)
C02 Safety cover (back) E42 Motor error (folding guide HI2)
C03 Side cover (right) E43 Motor error (folding guide HC)
C04 Side cover (left) E44 Motor error (folding guide HI3)
C05 Shutter E45 Motor error (folding stopper HI1)
E01 Wire feed sensor (L1) RAP5.8 EXX—Hardware-related E46 Motor error (folding stopper HO)
E02 Wire feed sensor (R1) Errors
E47 Motor error (folding stopper HI2)
E03 Wire feed sensor (L2) E48 Motor error (folding stopper HC)
E04 Wire feed sensor (R2) E49 Motor error (folding stopper HI3)
E05 Tray full E50 Motor error (non-fold HI1)
E07 Downstream unit error E51 Motor error (non-fold HO)
E08 RL VP error E52 Motor error (non-fold HI2)
E10 Motor error (main IX) E53 Motor error (non-fold HC)
E11 Motor error (jog conveyance IX) E54 Motor error (non-fold HI3)
E12 Motor error (base IX) E55 Motor error (fold gap1 HI1)
E13 Motor error (base HO) E56 Motor error (fold gap1 HO)
E14 Motor error (base HI) E57 Motor error (fold gap1 HI2)
E15 Motor error (jog unit HI1) E58 Motor error (fold gap1 HC)
E16 Motor error (jog unit HO) E59 Motor error (fold gap1 HI3)
E17 Motor error (jog unit HI2) E60 Motor error (fold gap2 HI1)
E18 Motor error (jog unit HC) E61 Motor error (fold gap2 HIO)
E19 Motor error (jog unit HI3) E62 Motor error (fold gap2 HI2)
E20 Motor error (back jog HI1) E63 Motor error (fold gap2 HC)
E21 Motor error (back jog HO) E64 Motor error (fold gap2 HI3)
E22 Motor error (back jog HI2) E65 Motor error (stitcher HI1)
E23 Motor error (back jog HC) E66 Motor error (stitcher HO)
E24 Motor error (back jog HI3) E67 Motor error (stitcher HI2)
E25 Motor error (side jog HI1) E68 Motor error (stitcher HC)
E26 Motor error (side jog HO) E69 Motor error (stitcher HI3)
E27 Motor error (side jog HI2) E70 Motor error (jog conveyance OV)
E28 Motor error (side jog HC) E71 Motor error (side jog OV)
E29 Motor error (side jog HI3) E72 Stitching error HI
E30 Motor error (saddle stopper HI1) E73 Stitching error HO

DBM-500/DBM-500BR
Code Message See… Code Message See…
E74 Folding error HI RAP5.8 EXX—Hardware-related T25 Emergency stop cable trouble 2 RAP5.11 TXX—Software-related
E75 Folding error HO Errors T26 Emergency stop cable trouble 3 Troubles
J01 Jam (fed-in sensor) RAP5.9 JXX—Paper Jams T27 Emergency stop cable trouble 4
J02 Jam (fed-remain sensor)
J03 Jam (jog-in sensor)
J04 Jam (jog-remain sensor)
J05 Jam (stitch-in sensor)
J06 Jam (stitch-remain sensor)
J07 Jam (side stitch-in sensor)
J08 Jam (side stitch-remain sensor)
J09 Jam (fold-in sensor)
J10 Jam (fold-remain sensor)
J11 Jam (discharge-in sensor)
J12 Jam (discharge-remain sensor)
J13 Jam 13
J14 Jam 14
S01 Emergency stop RAP5.10 SXX—Emergency Stop
S02 Emergency stop (upstream unit)
S03 Emergency stop (downstream unit)
T01 Inverter error RAP5.11TXX—Software-related
T02 Internal comm ACK error (D/A) Troubles
T03 Internal comm ACK error (EPROM)
T04 Memory data error
T05 Internal comm ACK error (SPM1)
T06 Internal comm CRC error (SPM1)
T17 Internal comm Bus busy
T18 Panel comm error (overrun)
T19 Panel comm error (framing)
T20 Panel comm error (parity)
T21 External comm ACK error
T22 External comm CRC error
T23 RL-relay trouble
T24 Emergency stop cable trouble 1

DBM-500/DBM-500BR
RAP5.6 Panel Version Error
The message “Panel version error…” indicates that the Control Panel and
the main program of the MC Unit (PCB501) are inconsistent. To solve the
problem, update programs (GP3.5).

RAP5.7 Panel Version Error
DBM-500/DBM-500BR
RAP5.7 CXX—Cover Open C02
When you close the Rear Top Cover, does the Actuator engage with the
switch?
Y N
Initial Actions
| Is the Actuator deformed/damaged?
To confirm the problem, follow these steps: | Y N
1. Open the appropriate cover and close it completely. | | Adjust the position of the Actuator (ADJ5.46).
| Replace the Actuator.
2. Check if the message has disappeared. If the message is still displayed,
Check if the Top Cover Switch (Back) (SSW505) works properly in the
follow the procedures below according to each message. See WD1.5 and
Maintenance Mode (GP2.5, Sensor).
WD3.5 as well.
Does the switch work properly?
Y N
C01 | Check if each connector is properly connected between the
When you close the Front Top Cover, does the Actuator engage with the | Top Cover switch (Back) (SSW505) and the MC Unit (PCB501) and
switch? | if the harness is properly connected between them.
Y N | If there is no problem with the connections, replace the switch (PL5c.4).
| Is the Actuator deformed/damaged? Replace the MC Unit (PCB501).
| Y N
| | Adjust the position of the Actuator (ADJ5.46). C03
| Replace the Actuator. Is the Side Cover (Right) secured to the machine?
Check if the Top Cover Switch (Front) (SSW504) works properly in the Y N
Maintenance Mode (GP2.5, Sensor). | Secure the cover to the machine.
Does the switch work properly? Are the Side Cover Switch (Right) (SSW501) secured to the machine and
Y N the magnet to the inside of the cover?
| Check if each connector is properly connected between the Y N
| Top Cover switch (Front) (SSW504) and the MC Unit (PCB501) and | Secure the switch and the magnet.
| if the harness is properly connected between them. Check if the Side Cover Switch (Right) (SSW501) works properly in the
| If there is no problem with the connections, replace the switch (PL5c.4). Maintenance Mode (GP2.5, Sensor).
Replace the MC Unit (PCB501). Does the switch work properly?
Y N
| Side Cover Switch (Right) (SSW501) and the MC Unit (PCB501) and
| If there is no problem with the connections, replace the switch (PL5c.2).
Replace the MC Unit (PCB501).

RAP5.7 CXX—Cover Open
DBM-500/DBM-500BR
C04 C05
Is the Side Cover (Left) (SSW502) secured to the machine? Check if there is any foreign object or deformed/damaged part on the
Y N sliding surface of the Shutter.
| Secure the cover to the machine. Is it free of defects?
Are the Side Cover Switch (Left) (SSW502) secured to the machine and the Y N
magnet to the inside the cover? | Remove the foreign object or replace deformed/damaged parts on the
Y N | sliding surface of the Shutter (PL5a.23).
| Secure the switch and the magnet. Check if the Shutter Switch (SSW506) works properly in the Maintenance
Check if the Side Cover Switch (Left) (SSW502) works properly in the Mode (GP2.5, Sensor).
Maintenance Mode (GP2.5, Sensor). Does the switch work properly?
Does the switch work properly? Y N
Y N | Are the Shutter Switch (SSW506) and the MC Unit (PCB501)
| Check if each connector is properly connected between the | connected to each other properly?
| Side Cover Switch (Left) (SSW502) and the MC Unit (PCB501) and | Y N
| if the harness is properly connected between them. | | Reconnect them properly.
| If there is no problem with the connections, replace the switch (PL5c.2). | When the Shutter Switch (SSW506) is on, are they connected to
Replace the MC Unit (PCB501). | each other?
| Y N
| | Replace the switch (PL5c.4).
| Shutter Switch (SSW506) and the MC Unit (PCB501) and if the
| If there is no problem with the connections, replace the switch (PL5c.4).

RAP5.7 CXX—Cover Open
DBM-500/DBM-500BR
RAP5.8 EXX—Hardware-Related Errors E03, E04
Is the two-head selected in the Maintenance Mode?
(GP2.5, Various Settings)
To confirm the problem, follow these steps, depending on the message. Y N
See WD1.5 and WD3.5 as well. | Select two-head on the Various Settings.
E01, E02
Is there a stitching wire left? E05
Y N
Remove booklets on the side-stitching stacker.
| Install new stitching wires (see DBM-500 Instruction Manual,
Has the message disappeared?
| “12-5. Removing Wire” and “12-3. Feeding the Wire”).
Y N
Does the wire diameter meet the specifications?
| Is there any foreign object attached to the Stacker Full Sensor (PS516)?
Y N
| Y N
| Use the wire that meets the specifications.
| | Check if the Stacker Full Sensor (PS516) works properly in the
Are the wires installed properly?
| | Maintenance Mode (GP2.5, Sensor).
Y N
| | Does the sensor work properly?
| Re-install the wires (see DBM-500 Instruction Manual,
| | Y N
| “12-5. Removing Wire” and “12-3. Feeding the Wire”).
| | | Check if each connector is properly connected between the
| Check if there is any problem with the movement of encorder disk to
| | | Stacker Full Sensor (PS516) and the MC Unit (PCB501) and
| wire feed detection unit.
| | | if the harness is properly connected between them. If there is
Check if the Wire Feed Sensor (PS523/PS524) works properly in the
| | | no problem with the connections, replace the sensor (PL5c.2).
Maintenance Mode (GP2.5, Sensor).
Does the sensor work properly?
| Remove the foreign substance.
Y N
End of the RAP.
If the booklets are stacked curled, adjust the guides of the side-stitching
| Wire Feed Sensor (PS523/PS524) and the MC Unit (PCB501) and
stacker (see DBM-500 Instruction Manual, “9-5. Adjusting the Saddle
Stitching Guide/Side Stitching Guide”).
| If there is no problem with the connections, replace the sensor (PL5c.2).

RAP5.8 EXX—Hardware-Related Errors
DBM-500/DBM-500BR
E07 E08
Is there any error in the downstream unit? Is the Slide Switch of the Relay Board (PCB503) set correctly?
Y N Y N
| Is the D-port cable properly connected? | Turn off the power and set the Slide Switch again (See Section 8).
| Y N Check if the Slide Switch on the Relay Board (PCB503) is properly set .
| | Replace the D-port cable (PL5a.27). (GP2.5, “Dip SW 1” or “Dip SW 2” in Sensor).
| Check if each connector is properly connected between the Does the setting displayed on the LCD match the setting of the Slide
| MC Unit (PCB501) and the DPIF P.W.B unit and if the harness is Switch?
| properly connected between them. Y N
| Y N | Check if each connector is properly connected between the
| | Replace the harness (PL5c.5). | Relay Board (PCB503) and the following parts and if the
| Has the problem been solved after replacing the DPIF P.W.B unit? | harnesses are properly connected between them. If there is no problem
| Y N | with the connections, replace Relay Board (PCB503) (PL5c.4).
| | Replace the MC Unit (PCB501). | •Emergency Stop Switch (SSW503)
| End of the RAP. | •Top Cover Switch (Front) (SSW504)
Solve the error in the downstream unit. | •Top Cover Switch (Back) (SSW505)
| •Shutter Switch (SSW506)
| •MC Unit (PCB501)

DBM-500/DBM-500BR
E10 | |
| Measure the output voltage between the Inverter and the
Check the Feed Motor Index Sensor (PS519) (PL5c.2).
| Main Drive Motor (M514) (see Figure 1).
| Is it normal output voltage?
Y N
| Y N
| Check the Index Plate, Sensor and Sensor Bracket.
| | Inverter and the Isolation Board (PCB502), Isolation Board (PCB502)
| Y N
| | and MC Unit, if the harness is properly connected between them.
| | Is the problem solved?
| | Y N
| Are they secured to the machine?
| | | Replace the Isolation Board (PCB502). Is the problem solved?
| Y N
| | | Y N
| | Secure them to the machine.
| | | | Replace the Inverter. Is the problem solved?
| Check the driving path of the Main Drive Motor (M514).
| | | | Y N
| | | | | Replace the MC Unit (PCB501).
| Y N
| | End of the RAP.
| | Remove a foreign object, replace parts or adjust the belt tension
| | (ADJ5.47).
| Inverter and the Main Drive Motor (M514) and if the harness is
| Check if the Feed Motor Index Sensor (PS519) works properly in the
| properly connected between them. If there is no problem with the
| Maintenance Mode (GP2.5, Sensor). Does the sensor work properly?
| connections, replace the Main Drive Motor (M514).
| Y N
| | Feed Motor Index Sensor (PS519) and the MC Unit (PCB501) and
| | if the harness is properly connected between them. If there is
Figure 1
| | no problem with the connections, replace the sensor (PL5c.2).
| Did you turn on the Inverter (PL5c.4, Motor Driver)? Ferrite core
2T
| (See light of the display on Inverter.) 8BRN 1
CN1
24V 1
CN2
P15
RED
Pink
2T
P15 S/L2 BLK
WHT
BLK 1 BLK
2 WHT
WHT 1 BLK
| Y N
7GRY WHT 2 BLK
2 Fin 2 P5 P5 R/L1
1YEL GRY E YEL
3 I1 3 Vout(V1)
2Purple YEL
4 I2 4 I1(F) F Reactor unit
| | Check if the Relay Board (PCB503) works properly in the 3Sky-BLU 7
5
6
I3
I4
5
6
I2(R)
I3(S1)
Purple
R Ferrite core
| | Maintenance Mode (GP2.5, Sensor). 4BLU

8
9
I5
I6
G1
7
8
9
I4(S2)
I5
I6
Sky-BLU S1
S2
| | Does the Relay Board (PCB503) work properly? 5Purple
10
11
NC
O1
10
11
G1(CC)
NC
BLU
Purple
CC
2T
| | Y N 12 O2 12 O1(OUT) FM/OUT
6BLU 13 G2 13 O2
RED 1 RED 1 RED 1 RED
BLU U/T1
CC WHT 2 WHT 2 WHT 2 WHT
14 G2 V/T2
| | | Refer to “E08.” W/T3
BLK 3 BLK 3 BLK 3 BLK
Ferrite core
| | Is the problem solved after replacing the reactor? ISOLATION BOARD Inverter
| | Y N
GRN/YEL
(PCB502)
| | | Check if each connector is properly connected between the Main drive motor
(M514)
| | | Relay Board (PCB503) and reactor, the reactor and the
| | | Inverter (PL5c.4, Motor Driver)and if the harness is properly Measurement point Normal output voltage
| | | connected between them. If there is no problem with the Connector - Pin (Signal) Not in operation In operation
| | | connections, replace the Inverter (PL5c.4, Motor Driver). 1 (U/T1) 2 (V/T2) approx. 0VAC approx. 170 to 200VAC
| | End of the RAP. 2 (V/T2) 3 (W/T3) approx. 0VAC approx. 170 to 200VAC
| | 3 (W/T3) 1 (U/T1) approx. 0VAC approx. 170 to 200VAC
| |

DBM-500/DBM-500BR
E11 Figure 1
Check the driving path of the Jog Belt Drive Motor (M503). MC Unit (PCB501)
Is it free of defects? BI
J04
Y N BLK
RED
1
2
BLU
YEL
7
8
BLU
YEL
1 GND
2 HU
| Remove a foreign object, replace parts or adjust the belt tension WHT 3 GRY 9 GRY
3 HV
BLU 4 Sky-BLU 10 Sky-BLU
| (ADJ5.13). BRN 5 Purple 11 Purple
4
5
HW
RE
Measure the output voltage between the MC Unit (PCB501) and the Jog YEL 6 RED 12 RED
6 +12V
Belt Drive Motor (M503). (see Figure 1) J09
ORN 7 YEL 13 YEL 1
Is it normal output voltage? GRY 8 GRY 14 GRY 2
U
V
Y N Sky-BLU 9 Sky-BLU 15 Sky-BLU 3 W
| Replace the MC Unit (PCB501). 1 J06
DC 24V DC 0.6A 1 +24V
Check if each connector is properly connected between the Jog Belt Drive 1
2 +24V
Jog Belt 1
Motor (M503) and the MC Unit (PCB501) and if the harness is properly Drive motor (M503)
3 +24V
4 +24VA
connected between them. If there is no problem with the connections, 5 +24VA
6 GND
replace the motor (PL5c.1). 2 7 GND
8 GND
9 FG

J09-1 (U) J06-7 (GND) approx. 0VDC approx. 8.5VDC
J09-2 (V) J06-7 (GND) approx. 0VDC approx. 8.5VDC
J09-3 (W) J06-7 (GND) approx. 0VDC approx. 8.5VDC

DBM-500/DBM-500BR
E12 Figure 1
Check the Moving Base Index Sensor (PS528) (PL5c.2). 1 MC Unit (PCB501)
2
Is there any foreign object attached to it? 1 GRY
AX
7 GRY
J10
Y N Base Moving Motor (M513) 2 YEL 8 YEL
1
2
MT1o+
MTo1-
| Check the Index Plate, Sensor and Sensor Bracket. DC24V 2.0A
| Y N
J10-1 (MT1o+) J10-2 (MTo1-) approx. 0VDC approx. 24VDC
| Are they secured to the machine? Note: The output voltage will be DC+ or DC-, depending on the rotation direction
| Y N of the motor.
| | Secure them to the machine.
| Check the driving path of the Base Moving Motor (M513).
| Y N
| | Remove a foreign object, replace parts or adjust the belt tension.
| Check if the Moving Base Index Sensor (PS528) works properly in the
| Maintenance Mode (GP2.5, Sensor).
| Y N
| | Moving Base Index Sensor (PS528) and the MC Unit (PCB501)
| | and if the harness is properly connected between them. If there is
| Base Moving Motor (M513). (see Figure 1)
| Y N
| Base Moving Motor (M513) and the MC Unit (PCB501) and if the
| harness is properly connected between them. If there is
| no problem with the connections, replace the motor (PL5c.1).

DBM-500/DBM-500BR
E13, E14 Figure 1
Check the Moving Base Home Sensor (PS527) (PL5c.2). 1 MC Unit (PCB501)
2
Is there any foreign object attached to it? 1 GRY
AX
7 GRY
J10
Y N Base Moving Motor (M513) 2 YEL 8 YEL
1
2
MT1o+
MTo1-
| Check the Flag, Sensor and Sensor Bracket. DC24V 2.0A
| Y N
J10-1 (MT1o+) J10-2 (MTo1-) approx. 0VDC approx. 24VDC
| Is the sensor plate attached properly?
| Y N Note: The output voltage will be DC+ or DC-, depending on the rotation direction
| | Adjust the position of the Flag (ADJ5.2). of the motor.
| Check the driving path of the Base Moving Motor (M513).
| Y N
| | Remove a foreign object, replace parts or adjust the home position.
| | Check if the Moving Base Index Sensor (PS528) works properly
| | in the Maintenance Mode (GP2.5, Sensor).
| Y N
| | Moving Base Home Sensor (PS527) and the MC Unit (PCB501)
| Base Moving Motor (M513). (see Figure 1)
| Y N
| Base Moving Motor (M513) and the MC Unit (PCB501) and
| if the harness is properly connected between them. If there is

DBM-500/DBM-500BR
E15, E16, E17, E18, E19 Figure 1
Check the Jogger Unit Home Sensor (PS503) (PL5c.2). MC Unit
Is there any foreign object attached to it? (PCB501)
Y N J12
BRN 1 BLK
2
+24VA
+24VA
BRN 2
4
WHT
ORN Jog Unit Moving
| Are they free of defects? 3 PM1A-
GRY
Purple
3
5
BRN
RED Motor (M501)
4 PM1A+ 6 YEL
| Y N 5 PM1B+
Sky-BLU
YEL
DC 3.0V 2.0A
6 PM1B-
| | Replace deformed/damaged parts. 7 +24VA
| Is the sensor plate attached properly? 8
9
+24VA
PM2A- 1
| Y N 10 PM2A+
1
11 PM2B+
| | Adjust the position of the Flag. 12 PM2B- 1
| Check the driving path of the Jog Unit Moving Motor (M501). 13 1
1
| Is it free of defects? J06
1
| Y N 1
2
+24V
+24V
| | Remove a foreign object, replace parts or adjust the home position. 3
4
+24V
+24VA
| | Check if the Jogger Unit Home Sensor (PS503) works properly in the 5 +24VA
6 GND
| | Maintenance Mode (GP2.5, Sensor). 7 GND 2
9
GND
FG
| Y N
| | Check if each connector is properly connected between the Measurement point Normal output voltage
| | Jogger Unit Home Sensor (PS503) and the MC Unit (PCB501) and Connector - Pin (Signal) Not in operation In operation
| | if the harness is properly connected between them. If there is J12-1 (+24VA) J06-7 (GND) approx. 24VDC approx. 24VDC
| | no problem with the connections, replace the sensor (PL5c.2). J12-2 (+24VA) J06-7 (GND) approx. 24VDC approx. 24VDC
| Measure the output voltage between the MC Unit (PCB501) and the J12-3 (PM1A-) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Jog Unit Moving Motor (M501). (see Figure 1) J12-4 (PM1A+) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Is it normal output voltage? J12-5 (PM1B+) J06-7 (GND) approx. 24VDC approx. 23.5VDC
J12-6 (PM1B-) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Y N
| | Replace the MC Unit (PCB501). Note: The output voltage at between J12-3 to J12-6 will be lower by approximately
| Check if each connector is properly connected between the 0.5V when the motor is in operation.
| Jog Unit Moving Motor (M501) and the MC Unit (PCB501) and
| if the harness is properlyconnected between them. If there is

DBM-500/DBM-500BR
E20, E21, E22, E23, E24 Figure 1
Check the Back Jogger Home Sensor (PS504) (PL5c.2). MC Unit 1
Is there any foreign object attached to it? (PCB501) 1
Y N J12 1
1
2
+24VA
+24VA 1
1
4 PM1A+
| Y N 5 PM1B+
6 PM1B-
BRN
BRN BI
| Check the driving path of the Back Jog Moving Motor (M502). 8 +24VA
GRY 1 BRN 1 BLK
9 PM2A- 2 BRN 2 WHT Back Jog Moving
| Is it free of defects? 10 PM2A+
Purple
Sky-BLU
4
3
GRY
Purple
4
3
ORN
BRN Motor (M502)
11 PM2B+ 5 Sky-BLU 5 RED
| Y N 12 PM2B-
YEL 6 YEL 6 YEL
DC 3.6V 2.0A
| | Remove a foreign object or replace parts. 13
J06
| Check if the Back Jogger Home Sensor (PS504) works properly in the 1 +24V
2 +24V
| Maintenance Mode (GP2.5, Sensor). 3 +24V
4 +24VA
| Does the sensor work properly? 5 +24VA
| Y N 6
7
GND
GND 2
| | Check if each connector is properly connected between the 8 GND
9 FG
| | Back Jogger Home Sensor (PS504) and the MC Unit (PCB501) and
| | if the harness is properly connected between them. If there is Measurement point Normal output voltage
| | no problem with the connections, replace the sensor (PL5c.2). Connector - Pin (Signal) Not in operation In operation
| Measure the output voltage between the MC Unit (PCB501) and the J12-7 (+24VA) J06-7 (GND) approx. 24VDC approx. 24VDC
| Back Jog Moving Motor (M502). (see Figure 1) J12-8 (+24VA) J06-7 (GND) approx. 24VDC approx. 24VDC
| Is it normal output voltage? J12-9 (PM2A-) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Y N J12-10 (PM2A+) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| | Replace the MC Unit (PCB501). J12-11 (PM2B+) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Check if each connector is properly connected between the J12-12 (PM2B-) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Back Jog Moving Motor (M502) and the MC Unit (PCB501) and Note: The output voltage at between J12-9 to J12-12 will be lower by
| if the harness is properly connected between them. If there is approximately 0.5V when the motor is in operation.

DBM-500/DBM-500BR
E25, E26, E27, E28, E29 Figure 1
Check the Side Jogger Home Sensor (PS505) (PL5c.2). MC Unit
Y N 1
1
J18
+24V
| Check the Flag, Sensor and Sensor Bracket. 2 SOL1
14 CL3
| Is there no problem with them? Side Jogger Brake
ORN
ORN
1 +24V
2 BR3
1815 BRN
1816 Purple
15 +24V
| Y N (BRK501)
16
17
BR3
+24V
| | Replace deformed/damaged parts. 24V,122Ω,0.199A,4.7W 18 CO1
19 +24V
| Check the driving path of the Side Jog Moving Motor (M504). 20 CO2
| Y N Connector - Pin (Signal) Not in operation In operation
| | Remove a foreign object or replace parts. J18-15 (+24V) J18-16 (BR3) DC 0V DC 24V
| Check if the Side Jogger Home Sensor (PS505) works properly in the
| Does the sensor work properly? Figure 2
| Y N MC Unit
| | Check if each connector is properly connected between the (PCB501)
| | Side Jogger Home Sensor (PS505) and the MC Unit (PCB501) and J13
BRN 1 BLK
1 +24VA
| | if the harness is properly connected between them. If there is 2 +24VA
BRN 2
4
WHT
ORN Side Jog Moving
| | no problem with the connections, replace the sensor (PL5c.2). 3 PM3A-
GRY
Purple
3
5
BRN
RED Motor (M504)
4 PM3A+ 6 YEL
Sky-BLU
| Measure the output voltage between the MC Unit (PCB501) and the 5 PM3B+
YEL
DC 3.6V 2.0A
6 PM3B-
| Side Jogger Brake (BRK501). (see Figure 1) 7 +24VA
| Is it normal? 8
9
+24VA
PM4A- 1
| Y N 10 PM4A+
1
11 PM4B+
| | Replace the MC Unit (PCB501). 12 PM4B- 1
| Check if each connector is properly connected between the J06 1
1 +24V 1
| Side Jogger Brake (BRK501) and the MC Unit (PCB501) and 2 +24V
1
3 +24V
| if the harness is properly connected between them. If there is 4 +24VA
| no problem with the connections, replace the brake (PL5c.3). 5
6
+24VA
GND
| Is the problem solved? 7 GND 2
8 GND
| Y N 9 FG
| | Measure the output voltage between the MC Unit (PCB501) and the
| | Side Jog Moving Motor (M504). (see Figure 2) Measurement point Normal output voltage
| | Is it normal output voltage? Connector - Pin (Signal) Not in operation In operation
| | Y N J13-1 (+24VA) J06-7 (GND) approx. 24VDC approx. 24VDC
J13-2 (+24VA) J06-7 (GND) approx. 24VDC approx. 24VDC
| | | Replace the MC Unit (PCB501).
J13-3 (PM3A-) J06-7 (GND) approx. 24VDC approx. 23.5VDC
J13-4 (PM3A+) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| | Side Jog Moving Motor (M504) and the MC Unit (PCB501) and
J13-5 (PM3B+) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| | no problem with the connections, replace the motor (PL5c.1).
| End of the RAP. Note: The output voltage at between J13-3 to J13-6 will be lower by approximately
Remove the foreign object. 0.5V when the motor is in operation.

DBM-500/DBM-500BR
E30, E31, E32, E33, E34 Figure 1
Check the Saddle Stopper Home Sensor (PS507) (PL5c.2). MC Unit 1
1
Y N 1
J13
+24VA 1
| Check the Flag, Sensor and Sensor Bracket. 2 +24VA 1
3 PM3A-
| Are they free of defects? 4 PM3A+ 1
| Y N 5
6
PM3B+
PM3B-
BRN
BRN
8 +24VA 1 BLK
| Is the position of the Sensor Plate appropriate? 9 PM4A-
GRY
Purple
2
4
WHT
ORN Saddle Stop Moving
| Y N 10
11
PM4A+
PM4B+
Sky-BLU 3
5
BRN
RED Motor (M505)
YEL 6 YEL
| | Adjust the position of the Sensor Plate. 12 PM4B- DC 3.0V 2.0A
J06
| Check the driving path of the Saddle Stop Moving Motor (M505). 1 +24V
| Is it free of defects? 2
3
+24V
+24V
| Y N 4 +24VA
5 +24VA
| | Remove a foreign object, replace parts or adjust the home position. 6 GND
| | Check if the Saddle Stopper Home Sensor (PS507) works properly 7
8
GND
GND
2
| | in the Maintenance Mode (GP2.5, Sensor). 9 FG

| Y N
| | Check if each connector is properly connected between the J13-7 (+24VA) J06-7 (GND) approx. 24VDC approx. 24VDC
| | Saddle Stopper Home Sensor (PS507) and the MC Unit (PCB501) J13-8 (+24VA) J06-7 (GND) approx. 24VDC approx. 24VDC
| | and if the harness is properly connected between them. If there is J13-9 (PM4A-) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| | no problem with the connections, replace the sensor (PL5c.2). J13-10 (PM4A+) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Measure the output voltage between the MC Unit (PCB501) and the J13-11 (PM4B+) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Saddle Stop Moving Motor (M505). (see Figure 1) J13-12 (PM4B-) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Y N Note: The output voltage at between J13-9 to J13-12 will be lower by
approximately 0.5V when the motor is in operation.
| Saddle Stop Moving Motor (M505) and the MC Unit (PCB501) and

DBM-500/DBM-500BR
E35, E36, E37, E38, E39 Figure 1
Check the Back Stopper Home Sensor (PS510) (PL5c.2). MC Unit
Y N 1
J14
+24VA
BRN 1 BLK
2 WHT
| Check the Flag, Sensor and Sensor Bracket. 2 +24VA
BRN 4 ORN Back Stop Moving
GRY 3 BRN
3 PM5A-
Purple 5
6
RED
YEL
Motor (M507)
4 PM5A+
Sky-BLU DC 3.0V 2.0A
| Y N 5
6
PM5B+
PM5B-
YEL
8 +24VA
| Is the position of the Sensor Plate appropriate? 9 PM6A- 1
| Y N 10
11
PM6A+
PM6B+ 1
| | Adjust the position of the Sensor Plate. 12 PM6B- 1
13 1
| Check the driving path of the Back Stop Moving Motor (M507). J06 1
| Is it free of defects? 1 +24V
1
2 +24V
| Y N 3 +24V
4 +24VA
| | Remove a foreign object, replace parts or adjust the belt tension 5 +24VA
| | (ADJ5.34). 6
7
GND
GND 2
| Check if the Back Stopper Home Sensor (PS510) works properly in the 8 GND
9 FG
| Does the sensor work properly? Measurement point Normal output voltage
| | Back Stopper Home Sensor (PS510) and the MC Unit (PCB501) J14-2 (+24VA) J06-7 (GND) approx. 24VDC approx. 24VDC
| Back Stop Moving Motor (M507). (see Figure 1) J14-6 (PM5B-) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Is it normal output voltage? Note: The output voltage at between J14-3 to J14-6 will be lower by approximately
| Y N 0.5V when the motor is in operation.
| Back Stop Moving Motor (M507) and the MC Unit (PCB501) and

DBM-500/DBM-500BR
E40, E41, E42, E43, E44 Figure 1
Check the Folding Guide Home Sensor (PS514) (PL5c.2). MC Unit 1
1
Y N 1
J14
+24VA 1
3 PM5A-
| Y N 5
6
PM5B+
PM5B-
BRN
BRN
8 +24VA 1 BLK
| Check the Folding Side Guide Motor (M510). 9 PM6A-
GRY
Purple
2
4
WHT
ORN Fold Side Guide
| Is it in good condition? 10
11
PM6A+
PM6B+
Sky-BLU 3
5
BRN
RED Motor (M510)
YEL 6 YEL
| Y N 12 PM6B- DC 3.0V 2.0A
13
| | Remove a foreign object, replace parts or adjust each part (ADJ5.33). J06
| | Check if the Folding Guide Home Sensor (PS514) works properly 1 +24V
2 +24V
| | in the Maintenance Mode (GP2.5, Sensor). 3 +24V
4 +24VA
| Does the sensor work properly? 5 +24VA
| Y N 6
7
GND
GND 2
| | Check if each connector is properly connected between the 8 GND
9 FG
| | Folding Guide Home Sensor (PS514) and the MC Unit (PCB501)
| | and if the harness is properly connected between them. If there is Measurement point Normal output voltage
| Measure the output voltage between the MC Unit (PCB501) and the J14-7 (+24VA) J06-7 (GND) approx. 24VDC approx. 24VDC
| Folding Side Guide Motor (M501). (see Figure 1) J14-8 (+24VA) J06-7 (GND) approx. 24VDC approx. 24VDC
| Is it normal output voltage? J14-9 (PM6A-) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Y N J14-10 (PM6A+) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| | Replace the MC Unit (PCB501). J14-11 (PM6B+) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Check if each connector is properly connected between the J14-12 (PM6B-) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Folding Side Guide Motor (M510) and the MC Unit (PCB501) and Note: The output voltage at between J14-9 to J14-12 will be lower by
| if the harness is properly connected between them. If there is approximately 0.5V when the motor is in operation.

DBM-500/DBM-500BR
E45, E46, E47, E48, E49 Figure 1
Check the Folding Unit Home Sensor (PS511) (PL5c.2). MC Unit
Y N 1
J15
+24VA
BRN 1 BRN 1 BRN 1 BLK
2 BRN 2 BRN 2 WHT
BRN 4 GRY 4 GRY 4 ORN Folding Stop Moving
GRY 3 Purple 3 Purple 3 BRN
Purple 5 Sky-BLU 5 Sky-BLU 5 RED Motor (M508)
4 PM7A+ 6 YEL 6 YEL 6 YEL
Sky-BLU DC 3.0V 2.0A
| Y N 5
6
PM7B+
PM7B-
YEL
8 +24VA
| Y N 10
11
PM8A+
PM8B+
1
1
| Check the driving path of the Folding Stop Moving Motor (M508). 1
J06
+24V 1
| Is it free of defects? 2 +24V 1
3 +24V
| Y N 4 +24VA
5 +24VA
| | Check if the Folding Unit Home Sensor (PS511) works properly 7
8
GND
GND
2
| Y N
| | Folding Unit Home Sensor (PS511) and the MC Unit (PCB501) and
| | if the harness is properly connected between them. If there is J15-3 (PM7A-) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Folding Stop Moving Motor (M508). (see Figure 1) J15-6 (PM7B-) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Y N Note: The output voltage at between J15-3 to J15-6 will be lower by approximately
0.5V when the motor is in operation.
| Folding Stop Moving Motor (M508) and the MC Unit (PCB501)
| and if the harness is properly connected between them. If there is

DBM-500/DBM-500BR
E50, E51, E52, E53, E54 Figure 1
Check the Non-fold Home Sensor (PS513) (PL5c.2). MC Unit 1
Y N 1
J15
+24VA
1
1
3 PM7A-
| Y N 5
6
PM7B+
PM7B-
BRN
BRN
8 +24VA 7 BRN 1 BLK
| Is the position of the Sensor Plate appropriate? 9 PM8A-
GRY 8 BRN 2 WHT
Purple 10 GRY 4 ORN Non-fold Delivery
| Y N 10
11
PM8A+
PM8B+
Sky-BLU 9
11
Purple
Sky-BLU
3
5
BRN
RED Motor (M509)
YEL 12 YEL 6 YEL
| | Adjust the position of the Sensor Plate. 12 PM8B- DC 3.0V 2.0A
| Check the driving path of the Non-fold Delivery Motor (M509). 1
J06
+24V
3 +24V
| Y N 4 +24VA
5 +24VA
| | Check if the Non-fold Home Sensor (PS513) works properly in the 7
8
GND
GND
2
| | Maintenance Mode (GP2.5, Sensor). 9 FG
| Y N
| | Non-fold Home Sensor (PS513) and the MC Unit (PCB501) and
| | if the harness is properly connected between them. If there is J15-9 (PM8A-) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Non-fold Delivery Motor (M509). (see Figure 1) J15-12 (PM8B-) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Non-fold Delivery Motor (M509) and the MC Unit (PCB501) and

DBM-500/DBM-500BR
E55, E56, E57, E58, E59 Figure 1
Check the Folding Rollers Gap-1 Home Sensor (PS520) (PL5c.2). MC Unit
Y N 1
J16
+24VA
BRN 1 BLK
2 WHT
BRN
GRY
4
3
ORN
BRN Fold Rollers Gap 1
| Are they free of defects? 3
4
PM9A-
PM9A+
Purple 5
6
RED
YEL Motor (M511)
Sky-BLU
| Y N 5
6
PM9B+
PM9B-
YEL DC 3.0V 2.0A

8 +24VA
| Y N 10
11
PM10A+
PM10B+ 1
13 1
| Check the driving path of the Fold Rollers Gap 1 Motor (M511). J06 1
1
2 +24V
| Y N 3 +24V
4 +24VA
| | Remove a foreign object, replace parts or adjust the home position. 5 +24VA
| | Check if the Folding Rollers Gap-1 Home Sensor (PS520) works 6 GND
7 GND 2
| | properly in the Maintenance Mode (GP2.5, Sensor). 8 GND
9 FG
| | Check if each connector is properly connected between the Connector - Pin (Signal) Not in operation In operation
| | Folding Rollers Gap-1 Home Sensor (PS520) and the J16-1 (+24VA) J06-7 (GND) approx. 24VDC approx. 24VDC
| | MC Unit (PCB501) and if the harness is properly connected J16-2 (+24VA) J06-7 (GND) approx. 24VDC approx. 24VDC
| | between them. If there is no problem with the connections, J16-3 (PM9A-) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| | replace the sensor (PL5c.2). J16-4 (PM9A+) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Fold Rollers Gap 1 Motor (M511). (see Figure 1) J16-6 (PM9B-) J06-7 (GND) approx. 24VDC approx. 23.5VDC
Note: The output voltage at between J16-3 to J16-6 will be lower by approximately
| Y N 0.5V when the motor is in operation.
| Fold Rollers Gap 1 Motor (M511) and the MC Unit (PCB501) and

DBM-500/DBM-500BR
E60, E61, E62, E63, E64 Figure 1
Check the Folding Rollers Gap-2 Home Sensor (PS521) (PL5c.2). MC Unit
1
1
Y N J16 1
2
+24VA
+24VA
1
1
| Is there no problem with them? 3 PM9A-
1
4 PM9A+
| Y N 5 PM9B+
7
PM9B-
+24VA
BRN
BRN
| Is the position of the Sensor Plate appropriate? 8 +24VA
GRY 1
2
BLK
WHT
9 PM10A-
| Y N 10 PM10A+
Purple
Sky-BLU
4
3
ORN
BRN Fold Rollers Gap 2
| | Adjust the position of the Sensor Plate. 11 PM10B+
YEL
5
6
RED
YEL Motor (M512)
12 PM10B-
| Check the driving path of the Fold Rollers Gap 2 Motor (M512). 13 DC 3.0V 2.0A
J06
| Y N 2
3
+24V
+24V
| | Remove a foreign object, replace parts or adjust the home position. 4 +24VA
5 +24VA
| | Check if the Folding Rollers Gap-2 Home Sensor (PS521) works 6 GND
| | properly in the Maintenance Mode (GP2.5, Sensor). 7
8
GND
GND
2
| Does the sensor work properly? 9 FG
| Y N
| | Folding Rollers Gap-2 Home Sensor (PS521) and the
| | MC Unit (PCB501) and if the harness is properly connected J16-8 (+24VA) J06-7 (GND) approx. 24VDC approx. 24VDC
| | between them. If there is no problem with the connections, J16-9 (PM10A-) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| | replace the sensor (PL5c.2). J16-10 (PM10A+) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Fold Rollers Gap 2 Motor (M512). (see Figure 1) J16-12 (PM10B-) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Fold Rollers Gap 2 Motor (M512) and the MC Unit (PCB501) and

DBM-500/DBM-500BR
E65, E66, E67, E68, E69 Figure 1
Check the Stitching Head Home Sensor (PS509) (PL5c.2). MC Unit
Y N 1
J17
+24VA
BRN 1 BLK
BRN 2 WHT
GRY
4
3
ORN
BRN Stitcher Moving
| Are they free of defects? 3
4
PM11A-
PM11A+
Purple 5
6
RED
YEL Motor (M506)
Sky-BLU
| Y N 5
6
PM11B+
PM11B-
YEL
DC 3.0V 2.0A

8
| Is the position of the Sensor Plate appropriate? 9 1
| Y N 10
11 1
| | Adjust the position of the Sensor Plate. 12 1
J06 1
| Check the driving path of the Stitcher Moving Motor (M506). 1 +24V 1
1
3 +24V
| Y N 4 +24VA
5 +24VA
| | Check if the Stitching Head Home Sensor (PS509) works properly 7
8
GND
GND
2
| Y N
| | Stitching Head Home Sensor (PS509) and the MC Unit (PCB501) J17-2 (+24VA) J06-7 (GND) approx. 24VDC approx. 24VDC
| Stitcher Moving Motor (M506). (see Figure 1) J17-6 (PM11B-) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| Y N Note: The output voltage at between J17-3 to J17-6 will be lower by approximately
| Stitcher Moving Motor (M506) and the MC Unit (PCB501) and

DBM-500/DBM-500BR
E70 Figure 1
Check the driving path of the Jog Belt Drive Motor (M503). MC Unit (PCB501)
Is it free of defects? BI
J04
Y N BLK
RED
1
2
BLU
YEL
7
8
BLU
YEL
1 GND
2 HU
| Remove a foreign object, replace parts or adjust the belt tension WHT 3 GRY 9 GRY
3 HV
BLU 4 Sky-BLU 10 Sky-BLU
| (ADJ5.13). BRN 5 Purple 11 Purple
4
5
HW
RE
Measure the output voltage between the MC Unit (PCB501) and the Jog YEL 6 RED 12 RED
6 +12V
Belt Drive Motor (M503). (see Figure 1) J09
ORN 7 YEL 13 YEL 1
Is it normal output voltage? GRY 8 GRY 14 GRY 2
U
V
Y N Sky-BLU 9 Sky-BLU 15 Sky-BLU 3 W
| Replace the MC Unit (PCB501). 1 J06
DC 24V DC 0.6A 1 +24V
Check if each connector is properly connected between the Jog Belt Drive 1
2 +24V
Jog Belt 1
Motor (M503) and the MC Unit (PCB501) and if the harness is properly Drive motor (M503)
3 +24V
4 +24VA
connected between them. If there is no problem with the connections, 5 +24VA
6 GND
replace the motor (PL5c.1). 2 7 GND
8 GND
9 FG


DBM-500/DBM-500BR
E71 Figure 1
Check the driving path of the Side Jog Moving Motor (M504). MC Unit
Is it free of defects? 2 (PCB501)
Y N 1
1
J18
+24V
| Remove a foreign object or replace parts. 2 SOL1
14 CL3
| Check the Index plate and the Sensor Bracket. Side Jogger Brake
ORN
ORN
1 +24V
2 BR3
1815 BRN
1816 Purple
15 +24V
16 BR3
| Are they free of defects? (BRK501) 17 +24V
Y N 24V,122Ω,0.199A,4.7W 18 CO1
19 +24V
| Replace deformed/damaged parts. 20 CO2
Check if the Step Motor Over Sensor (PS506) works properly in the
Maintenance Mode (GP2.5, Sensor). Connector - Pin (Signal) Not in operation In operation
Does the sensor work properly? J18-15 (+24V) J18-16 (BR3) approx. 0VDC approx. 24VDC
Y N
| Step Motor Over Sensor (PS506) and the MC Unit (PCB501) and Figure 2
| if the harness is properly connected between them. If there is MC Unit
| no problem with the connections, replace the sensor (PL5c.2). (PCB501)
Measure the output voltage between the MC Unit (PCB501) and the Side J13
BRN 1 BLK
1 +24VA
Jogger Brake (BRK501). (see Figure 1) 2 +24VA
BRN 2
4
WHT
ORN Side Jog Moving
Is it normal output voltage? 3 PM3A-
GRY
Purple
3
5
BRN
RED Motor (M504)
4 PM3A+ 6 YEL
Y N 5 PM3B+
Sky-BLU
YEL
DC 3.6V 2.0A
6 PM3B-
| Replace the MC Unit (PCB501). 7 +24VA
Check if each connector is properly connected between the Side Jogger 8
9
+24VA
PM4A- 1
Brake (BRK501) and the MC Unit (PCB501) and if the harness is properly 10 PM4A+
1
11 PM4B+
connected between them. If there is no problem with the connections, 12 PM4B- 1
replace the brake (PL5c.3). J06 1
1 +24V 1
Is the problem solved? 2 +24V
1
Y N 3
4
+24V
+24VA
| Measure the output voltage between the MC Unit (PCB501) and the 5
6
+24VA
GND
| Side Jog Moving Motor (M504). (see Figure 2) 7 GND 2
8 GND
| Is it normal output voltage? 9 FG
| Y N
| | Replace the MC Unit (PCB501). Measurement point Normal output voltage
| Check if each connector is properly connected between the Connector - Pin (Signal) Not in operation In operation
| Side Jog Moving Motor (M504) and the MC Unit (PCB501) and J13-1 (+24VA) J06-7 (GND) approx. 24VDC approx. 24VDC
| connected between them. If there is no problem with the connections,
J13-3 (PM3A-) J06-7 (GND) approx. 24VDC approx. 23.5VDC
| replace the motor (PL5c.1).
J13-4 (PM3A+) J06-7 (GND) approx. 24VDC approx. 23.5VDC
End of the RAP.
J13-5 (PM3B+) J06-7 (GND) approx. 24VDC approx. 23.5VDC
Note: The output voltage at between J13-3 to J13-6 will be lower by approximately

DBM-500/DBM-500BR
E72, E73 Figure 1
Check the Stitcher Driver Home Sensor (PS517) (PL5c.2). 2 MC Unit
Y N GRY 1 +24V 1901 BRN
J19
| Check the Flag, Sensor and Sensor Bracket. Stitching clutch GRY 2 CL1 1902 YEL
1 +24V
(CL502) 1903 BRN
2 CL1
| Are they free of defects? 24V,23Ω,1.09A,25W 1904 GRY
3 +24V
4 BR1
| Y N 5 +24V
6 CL2
| | Replace deformed/damaged parts. 2 7 +24V
| Check the driving path of the binding mechanism. 1 8 BR2
| Is it free of defects? GRY 1 +24V

Stitching brake
| Y N (BRK502)
GRY 2 BR1
| | Remove a foreign object or replace or adjust parts. 24V,38Ω,0.63A,15W

| Check if the Stitcher Driver Home Sensor (PS517) works properly
| in the Maintenance Mode (GP2.5, Sensor).
| Does the sensor work properly? J19-1 (+24V) J19-2 (CL1) approx. 0VDC approx. 24VDC
| Y N J19-3 (+24V) J19-4 (BR1) approx. 0VDC approx. 24VDC
| | Stitcher Drive Home Sensor (PS517) and the MC Unit (PCB501)
| Stitching Clutch (CL502). (see Figure 1)
| Y N
| Stitching Clutch (CL502) and the MC Unit (PCB501) and if the
| harness is properly connected between them. If there is no problem
| with the connections, replace the clutch (PL5c.3).
| Y N
| | Stitching Brake (BRK502). (see Figure 1)
| | Is it normal?
| | Y N
| | Stitching Brake (BRK502) and the MC Unit (PCB501) and
| | no problem with the connections, replace the brake (PL5c.3).
| End of the RAP.

DBM-500/DBM-500BR
E74, E75 | | |
Check the “Finely adjust the distance between folding rollers” in ADJUST
| | Folding Brake (BRK503) and the MC Unit (PCB501) and if the
menu. If fold rollers gap is too loose. You can get this error.
Is fold rollers gap correct?
| | with the connections, replace the brake (PL5c.3).
Y N
| End of the RAP.
| Adjust the setting.
Check the Folder Drive Home Sensor (PS518) (PL5c.2).
Y N
Figure 1
| Are they free of defects? MC Unit
| Y N (PCB501)
J19
1 +24V
| Check the driving path of the folding mechanism. 1 2 CL1
3 +24V
| Is it free of defects? 4 BR1
GRY 1 +24V 1905 BRN
| Y N Folding Clutch GRY 2 CL2 1906 Sky-BLU
5 +24V
6 CL2
| | Remove a foreign object or replace or adjust parts. (CL503) 24V,38Ω,0.63A,15W
1907 BRN
7 +24V
1908 Purple
8 BR2
| Check if the Folder Drive Home Sensor (PS518) works properly in the 2
| Maintenance Mode (GP2.5, Sensor). 1
GRY 1 +24V
| Y N Folding Brake GRY 2 BR2
| | Check if each connector is properly connected between the (BRK503) 24V,38Ω,0.63A,15W
| | Folder Drive Home Sensor (PS518) and the MC Unit (PCB501) and
| | if the harness is properly connected between them. If there is Measurement point Normal output voltage
J19-1 (+24V) J19-2 (CL1) approx. 0VDC approx. 24VDC
J19-3 (+24V) J19-4 (BR1) approx. 0VDC approx. 24VDC
| Folding Clutch (CL503). (see Figure 1)
| Y N
| Folding Clutch (CL503) and the MC Unit (PCB501) and if the
| harness is properly connected between them. If there is no problem
| with the connections, replace the clutch (PL5c.3).
| Y N
| | Folding Brake (BRK503). (see Figure 1)
| | Is it normal?
| | Y N
| | |

DBM-500/DBM-500BR
RAP5.9 JXX—Paper Jams
Initial Actions
Jog Key
To confirm the problem, follow the procedures below:
1. Check operator settings (Paper size and/or etc.) of iGen3 and Inline
Controller. If settings are not same, match settings.
2. Remove the jammed paper. You can use the Jog Key to eject the jammed
paper out of the machine.
The figure shows the locations of the paper sensors.
3. Close the cover. If you have not opened any cover, open a cover and close Paper feed
it.
4. Check if the message has disappeared. If the message is still displayed, Infeed sensor Stitch sensor
follow the procedures below according to each message. See WD1.5 and (PS501) (PS508)
WD3.5 as well. Jogger sensor
(PS502)
Side stitch outfeed sensor
(PS515)
Fold outfeed sensor
(PS522)
Fold sensor
(PS512)
Actuator Stacker full sensor

(PS516)

DBM-500/DBM-500BR
J01 J03
Is there any foreign object or deformed/damaged parts on the paper path Is there any foreign object or deformed/damaged parts on the paper
between the paper exit of the SCC and the Infeed Sensor (PS501) (PL5c.2)? path between the Infeed Sensor (PS501) and the Jogger Sensor (PS502)
Y N (PL5c.2)?
| Are the SCC and the DBM-500 positioned alignment properly? Y N
| Y N | Check if the Jogger Sensor (PS502) works properly in the
| | Adjust the position (See Section 8 Aligning Paper Path). | Maintenance Mode (GP2.5, Sensor).
| Check if the Infeed Sensor (PS501) works properly in the | Does the sensor work properly?
| Maintenance Mode (GP2.5, Sensor). | Y N
| Does the sensor work properly? | | Check if each connector is properly connected between the
| Y N | | Jogger Sensor (PS502) and the MC Unit (PCB501) and if the
| | Check if each connector is properly connected between the | | harness is properly connected between them. If there is no problem
| | Infeed Sensor (PS501) and the MC Unit (PCB501) and if the | | with the connections, replace the sensor (PL5c.2).
| | harness is properly connected between them. If there is no problem | Is the sensitivity of the Jogger Sensor (PS502) appropriate?
| | with the connections, replace the sensor (PL5c.2). | Y N
| Is the sensitivity of the Infeed Sensor (PS501) appropriate? | | Adjust the sensitivity of the sensor (ADJ5.1).
| Y N | Replace the MC Unit (PCB501).
| | Adjust the sensitivity of the Sensor (ADJ5.1). Remove the foreign object or deformed/damaged parts.
Remove the foreign object or deformed/damaged parts.
J04
Check the Jogger Sensor (PS502) (PL5c.2).
J02 Is there any foreign object attached to it?
Check the Infeed Sensor (PS501) (PL5c.2). Y N
Is there any foreign object attached to it? | Check if the Jogger Sensor (PS502) works properly in the
Y N | Maintenance Mode (GP2.5, Sensor).
| Check if the Infeed Sensor (PS501) works properly in the | Does the sensor work properly?
| Maintenance Mode (GP2.5, Sensor). | Y N
| Does the sensor work properly? | | Check if each connector is properly connected between the
| Y N | | Jogger Sensor (PS502) and the MC Unit (PCB501) and if the
| | Check if each connector is properly connected between the | | harness is properly connected between them. If there is no problem
| | Infeed Sensor (PS501) and the MC Unit (PCB501) and if the | | with the connections, replace the sensor (PL5c.2).
| | harness is properly connected between them. If there is no problem | Is the sensitivity of the Jogger Sensor (PS502) appropriate?
| | with the connections, replace the sensor (PL5c.2). | Y N
| Is the sensitivity of the Infeed Sensor (PS501) appropriate? | | Adjust the sensitivity of the sensor (ADJ5.1).
| Y N | Replace the MC Unit (PCB501).
| | Adjust the sensitivity of the sensor (ADJ5.1). Remove the foreign object or deformed/damaged parts.

DBM-500/DBM-500BR
J05 J07
Is there any foreign object or deformed/damaged parts on the paper Is there any foreign object or deformed/damaged parts on the paper path
path between the Jogger Sensor (PS502) and the Stitch Sensor (PS508) between the Stitch Sensor and the Side Stitch Outfeed Sensor (PS515)
(PL5c.2)? (PL5c.2)?
Y N Y N
| Check if the Stitch Sensor (PS508) works properly in the | Check if the Side Stitch Outfeed Sensor (PS515) works properly in the
| Maintenance Mode (GP2.5, Sensor). | Maintenance Mode (GP2.5, Sensor).
| Y N | Does the sensor work properly?
| | Check if each connector is properly connected between the | Y N
| | Stitch Sensor (PS508) and the MC Unit (PCB501) and if the | | Check if each connector is properly connected between the
| | harness is properly connected between them. If there is no problem | | Side Stitch Outfeed Sensor (PS515) and the MC Unit (PCB501)
| | with the connections, replace the sensor (PL5c.2). | | and if the harness is properly connected between them. If there is
| Is the sensitivity of the Jogger Sensor (PS502) appropriate? | | no problem with the connections, replace the sensor (PL5c.2).
| Y N | Is the sensitivity of the Side Stitch Outfeed Sensor (PS515) appropriate?
| | Adjust the sensitivity of the sensor (ADJ5.1). | Y N
| Replace the MC Unit (PCB501). | | Adjust the sensitivity of the sensor (ADJ5.1).
Remove the foreign object or deformed/damaged parts. | Replace the MC Unit (PCB501).
J06
Check the Stitch Sensor (PS508) (PL5c.2). J08
Is there any foreign object attached to it? Check the Side Stitch Outfeed Sensor (PS515) (PL5c.2).
Y N Is there any foreign object attached to it?
| Check if the Stitch Sensor (PS508) works properly in the Y N
| Maintenance Mode (GP2.5, Sensor). | Check if the Side Stitch Outfeed Sensor (PS515) works properly in the
| Does the sensor work properly? | Maintenance Mode (GP2.5, Sensor).
| Y N | Does the sensor work properly?
| | Check if each connector is properly connected between the | Y N
| | Stitch Sensor (PS508) and the MC Unit (PCB501) and if the | | Check if each connector is properly connected between the
| | harness is properly connected between them. If there is no problem | | Side Stitch Outfeed Sensor (PS515) and the MC Unit (PCB501)
| | with the connections, replace the sensor (PL5c.2). | | and if the harness is properly connected between them. If there is
| Is the sensitivity of the Stitch Sensor (PS508) appropriate? | | no problem with the connections, replace the sensor (PL5c.2).
| Y N | Is the sensitivity of the Side Stitch Outfeed Sensor (PS515) appropriate?
| | Adjust the sensitivity of the sensor (ADJ5.1). | Y N
| Replace the MC Unit (PCB501). | | Adjust the sensitivity of the sensor (ADJ5.1).
Remove the foreign object or deformed/damaged parts. | Replace the MC Unit (PCB501).

DBM-500/DBM-500BR
J09 J11
between the Side Stitch Outfeed Sensor (PS515) and the Fold Sensor between the Fold Sensor (PS512) and the Fold Outfeed Sensor (PS522)
(PS512) (PL5c.2)? (PL5c.2)?
Y N Y N
| Check if the Fold Sensor (PS512) works properly in the | Check if the Fold Outfeed Sensor (PS522) works properly in the
| Y N | Y N
| | Fold Sensor (PS512) and the MC Unit (PCB501) and if the | | Fold Outfeed Sensor (PS522) and the MC Unit (PCB501) and if the
| | with the connections, replace the sensor (PL5c.2). | | with the connections, replace the sensor (PL5c.2).
| Is the sensitivity of the Fold Sensor (PS512) appropriate? | Is the sensitivity of the Fold Outfeed Sensor (PS522) appropriate?
| Y N | Y N
| | Adjust the sensitivity of the sensor (ADJ5.1). | | Adjust the sensitivity of the sensor (ADJ5.1).
Remove the foreign object or deformed/damaged parts. Remove the foreign object or deformed/damaged parts.
J10 J12
Check the Fold Sensor (PS512) (PL5c.2). Check the Fold Outfeed Sensor (PS522) (PL5c.2).
Is there any foreign object attached to it? Is there any foreign object attached to it?
Y N Y N
| Check if the Fold Sensor (PS512) works properly in the | Check if the Fold Outfeed Sensor (PS522) works properly in the
| Y N | Y N
| | Fold Sensor (PS512) and the MC Unit (PCB501) and if the | | Fold Outfeed Sensor (PS522) and the MC Unit (PCB501) and if the
| | with the connections, replace the sensor (PL5c.2). | | with the connections, replace the sensor (PL5c.2).
| Is the sensitivity of the Fold Sensor (PS512) appropriate? | Is the sensitivity of the Fold Outfeed Sensor (PS522) appropriate?
| Y N | Y N
| | Adjust the sensitivity of the sensor (ADJ5.1). | | Adjust the sensitivity of the sensor (ADJ5.1).
Remove the foreign object. Remove the foreign object.

DBM-500/DBM-500BR
J13
Check the Infeed Sensor (PS501) (PL5c.2).
Y N
| Is the Delivery Sensor (PS307) of the SCC appropriate?
| Y N
| | Go to RAP3.7
| Check if the Infeed Sensor (PS501) works properly in the
| | Infeed Sensor (PS501) and the MC Unit (PCB501) and if the
| | with the connections, replace the sensor (PL5c.2).
| Is the sensitivity of the Infeed Sensor (PS501) appropriate?
| Y N
| | Adjust the sensitivity of the sensor (ADJ5.1).
J14
Check the Jogger Sensor (PS502) (PL5c.2).
Y N
| Check if the Infeed Sensor (PS501) and the Jogger Sensor (PS502)
| work properly in the Maintenance Mode (GP2.5, Sensor).
| Does each sensor work properly?
| Y N
| | problematic sensor and the MC Unit (PCB501) and if the
| | with the connections, replace the sensor (PL5c.2).
| Is the sensitivity of the Infeed Sensor (PS501) and the
| Jogger Sensor (PS502) appropriate?
| Y N
| | Adjust the sensitivity of the sensor (ADJ5.1).

DBM-500/DBM-500BR
RAP5.10 SXX—Emergency Stop S02
Is there any message displayed about the Emergency Stop Switch (SSW503)
on the control panel of the SCC?
Y N
Initial Actions
The table lists error messages, error codes, and conditions. To solve | Y N
problems, follow these steps: | | Replace the MC Unit (PCB501).
1. Reset the Emergency Stop Switch. | End of the RAP.
Refer to RAPs of the SCC (RAP3.10).
2. If the same message is still displayed, turn off the Remote Switch. Wait
for about ten seconds. Turn on the Remote Switch.
3. Check if the message has disappeared. If the message is still displayed, S03
Is there any message displayed about the Emergency Stop Switch (SSW503)
WD3.5 as well.
on the control panel of the DBM-500T?
Y N
S01 | Is the problem solved after replacing the Relay Board (PCB503)?
Check if the Emergency Stop Switch (SSW503) works properly in the | Y N
Maintenance Mode (GP2.5, Sensor). | | Replace the MC Unit (PCB501).
Does the switch work properly? | End of the RAP.
Y N Refer to RAPs of the DBM-500T (RAP6.9).
| Check if the Emergency Stop Switch (SSW503) is properly connected.
| Is the switch properly connected?
| Y N
| | Replace the Emergency Stop Switch (SSW503) (PL5c.4).
| Emergency Stop Switch (SSW503) and the Relay Board (PCB503),
| and the Relay Board (PCB503) and the MC Unit (PCB501) and if the
| If there is no problem with the connections, replace the
| Relay Board (PCB503) (PL5c.4).

RAP5.10 SXX—Emergency Stop
DBM-500/DBM-500BR
RAP5.11 TXX—Software-related Troubles T03, T04
Y N
Initial Actions
| Is the EEPROM (U10) properly attached?
To solve problems, follow these steps: | Y N
1. Turn off the Remote Switch. Wait for about ten seconds. Turn on the | | Attach the EEPROM (U10) properly.
Remote Switch. | Replace the MC Unit (PCB501).
2. Check if the message has disappeared. If the message is still displayed, End of the RAP. If this problem often occurs, replace the MC Unit (PCB501).
WD3.5 as well.
T05, T06
T01 Turn off the Remote Switch. Wait for about ten seconds.
Check the driving path of the Main Drive Motor (M514). When you turn on the Remote Switch again, does the message disappear?
Is there any problem with it? Y N
Y N | Is the IC (U04) properly attached?
| Remove a foreign substance or replace parts. | Y N
Is voltage specified in the specifications available at the wall outlet? | | Attach the IC (U04) properly.
Y N | Replace the MC Unit (PCB501).
| It is not a malfunction of the machine. End of the RAP. If this problem often occurs, replace the MC Unit (PCB501).
Is the problem solved after replacing the inverter?
Y N
| Is the problem solved after replacing the isolation board (PCB502)? T07, T08
| Y N Turn off the Remote Switch. Wait for about ten seconds.
| | Replace the MC Unit (PCB501). When you turn on the Remote Switch again, does the message disappear?
| End of the RAP. Y N
End of the RAP. | Is the IC (U05) properly attached?
| Y N
| | Attach the IC (U05) properly.
T02 | Replace the MC Unit (PCB501).
Turn off the Remote Switch. Wait for about ten seconds. End of the RAP. If this problem often occurs, replace the MC Unit (PCB501).
Y N
End of the RAP. If this problem often occurs, replace the MC Unit (PCB501).

DBM-500/DBM-500BR
T09, T10 T15, T16
Turn off the Remote Switch. Wait for about ten seconds. Turn off the Remote Switch. Wait for about ten seconds.
When you turn on the Remote Switch again, does the message disappear? When you turn on the Remote Switch again, does the message disappear?
Y N Y N
| Is the IC (U06) properly attached? | Is the IC (U09) properly attached?
| Y N | Y N
| | Attach the IC (U06) properly. | | Attach the IC (U09) properly.
End of the RAP. If this problem often occurs, replace the MC Unit (PCB501). End of the RAP. If this problem often occurs, replace the MC Unit (PCB501).
T11, T12 T17

Turn off the Remote Switch. Wait for about ten seconds. Turn off the Remote Switch. Wait for about ten seconds.
When you turn on the Remote Switch again, does the message disappear? When you turn on the Remote Switch again, does the message disappear?
Y N Y N
| Is the IC (U07) properly attached? | Replace the MC Unit (PCB501).
| Y N End of the RAP. If this problem often occurs, replace the MC Unit (PCB501).
| | Attach the IC (U07) properly.
End of the RAP. If this problem often occurs, replace the MC Unit (PCB501). T18, T19, T20
T13, T14 Y N
Turn off the Remote Switch. Wait for about ten seconds. | Can you enter the Maintenance Mode?
When you turn on the Remote Switch again, does the message disappear? | Y N
Y N | | Check if each connector is properly connected between the
| Is the IC (U08) properly attached? | | MC Unit (PCB501) and the touch panel and if the harness is
| Y N | | properly connected between them.
| | Attach the IC (U08) properly. | | If there is no problem with the connections, replace the
| Replace the MC Unit (PCB501). | | touch panel (PL5a.24, Operation Terminal).
End of the RAP. If this problem often occurs, replace the MC Unit (PCB501). | Replace the MC Unit (PCB501).
End of the RAP.

DBM-500/DBM-500BR
T21, T22 T23
Is the D-port cable properly connected to the machine? Is each Slide Switch on the Relay Board (PCB503) of this machine, the SCC
Y N and the DBM-500T set correctly?
| Reconnect the D-port cable (See Section 8, Connecting Cables). Y N
Is the D-port cable electrically connected? | Set each Slide Switch again (See Figure 1).
Y N Check if each connector is properly connected between the Relay board
| Replace the D-port cable (PL5a.27). (PCB5xx) and the following parts and if the harness is properly connected
Check if each connector is properly connected between the DPIF P.W.B between them.
unit and the MC Unit (PCB501) and if the harness is properly connected • Emergency Stop Switch (SSW503)
between them. • Top Cover Switch (Front) (SSW504)
Is it free of defects? • Top Cover Switch (Back) (SSW505)
Y N • Shutter Switch (SSW506)
| Replace the harness (PL5c.5). Are they connected properly?
Is the problem solved after replacing the DPIF P.W.B unit (PL5c.4)? Y N
Y N | Replace the harness.
| Replace the MC Unit (PCB501). Is the problem solved after replacing the Relay Board (PCB503)?
End of the RAP. Y N
End of the RAP.
Figure 1
<BG/non BG Setting>
DBM-500T
SCC < Relay Board (PCB604) >
ON ON
BG SW1 SW2
BG SW1 SW2 ON
ON
OFF
OFF DBM-500
non BG SW1 SW2
ON ON
BG SW1 SW2
OFF OFF

DBM-500/DBM-500BR
T24, T25, T26, T27
These messages are displayed only for BG configration whitch is not used
in north America.
Is the E-port cable properly connected to the machine?

Y N
| Reconnect the E-port cable (See Section 8, Connecting Cables).
Is the E-port cable electrically connected?
Y N
| Replace the E-port cable (PL5a.27).
Check if each connector is properly connected between the DPIF P.W.B
unit and the MC Unit (PCB501) and if the harness is properly connected
between them.
Are they connected properly?
Y N
| Replace the harness (PL5c.5).
Is the problem solved after replacing the DPIF P.W.B unit (PL5c.4)?
Y N
End of the RAP.

DBM-500T/DBM-LS-1/DBM-K
DBM-500T control panel LCD?
Y N
2-95 Section 2—Repair Analysis Procedures DBM-500T

RAP6.2 Generic RAPs
To analyze the problem on the DBM-500T, follow the procedures below.

1. In the table below, find a symptom that is similar to the machine’s
trouble. Go to the section in See….
have failed to output an error code/or error message due to defective
sensors. To check sensors, see GP2.6, Sensors Check.
Symptom See…
LED is not on.

RAP6.2 Generic RAPs
Initial Actions
To confirm the problem, follow the procedures below:
2. Turn off the System Power Switch of the Duplo DBM-5000. LED (orange)
3. Turn on the Remote Switch of the DBM-500T. Remote switch
LED (green)
4. Check that the LED (green) is on. Main power switch
5. Check that nothing appears on the display.

6. Turn off the Remote Switch of the DBM-500T. Remote switch Main power Main power switch Remote switch
switch DBM-500T
SpineMaster
DCM Kit DBM-500
Main power
switch

switch
DBM-500
Interface Box TR-DP

Main power
switch
Remote switch


Checking the Switching Power Supply Noise Filter Circuit protector
AC/DC 250V 10A ETA3120-F521-P7T1-W02D-10A Power Cord
455 BLK 184 BLK BLK
WARNING
1 456 WHT 185 WHT WHT
Disconnect the power cord before removing an exterior cover. The 2 Switching Power Supply 902 GRN/YEL
GRN/YEL
Switching Power Supply (PCB603) and Relay Board can cause a shock if 414 BLU CN51 CN1 155 BLK 2 1
1 GND 1 L
touched. 150 BLU 2 GND
151 BLU 3 GND 3 N 156 WHT
409 BRN 4 +24V
153 BRN 154 YEL
Check that the fuse on the Switching Power Supply (PCB603) is not 152 BRN
5 +24V 5 FG
6 +24V
damaged.
CN2 Switch
Is the fuse defected? 1 +R 157 Purple 2 457 Purple
158 GRY 1 458 GRY
Y N 438 ORN CN52 2 -R
1 +R
| Disconnect all connectors between the 439 BLU 2 -R
| Switching Power Supply (PCB603) and the MC Unit (PCB601).
| Y N
| | Y N
| | Measure the voltage between the CN51-6 (+24V) and CN51-1 (GND)
| | of the Switching Power Supply (PCB603).
| | Y N
| Is it normal?
| Y N
| | Check the continualy through the noise filter. And check the braker
| | of Main Power Switch.
| End of the RAP. The Switching Power Supply (PCB603) appears to
| be functioning.
Replace the Switching Power Supply (PCB603) (PL6.22).

Initial Actions
2. Wait for about ten seconds. Turn on the Remote Switch.
Checking the Control Panel
WARNING
Switching Power Supply (PCB603) and Relay Board can cause a shock if
touched.
Reconnect the Control Panel (PCB602) and Switching Power Supply

(PCB603). Is the problem solved?
Y N
| Check the harness between the Control Panel (PCB602) and
| Is it intact?
| Y N
| | Replace the harness (PL6.24).
| Check the Switching Power Supply (PCB603) (RAP6.3).
| Is it intact?
| Y N
| | Replace the Switching Power Supply (PCB603) (PL6.22).
| Reconnect the connectors of the Control Panel (PCB602) and
| MC Unit (PCB601).
| Y N
| | Check the harness between the Control Panel (PCB602) and
| | MC Unit (PCB601).
| | Is it intact?
| | Y N
| | Replace the Control Panel (PCB602) (PL6.19).
End of the RAP. The Control Panel (PCB602) appears to be functioning.

RAP6.5 Main motor RAP
MC Unit
1 (PCB601)
2
J06
49 BRN
1 +24VA
50 Purple
2 CL1
51 BRN
3 +24VA
52 Sky-BLU
4 BR1
53 BRN
5 +24VA
Checking the Main Motor

54 YEL
6 MOTPRL 41 BRN 1 241 BRN
55 BRN
7 +24VA 42 Purple 2 242 Purple
56 GRY
8 BLTPRL 53 BRN 3 253 BRN
9 54 YEL 4 254 YEL
58 BRN
When supplying drive power to the Main motor (M601) in the Maintenance 59 Purple
10
11
SOL3V
SOL3
55 BRN
56 GRY
5
6
255 BRN
256 GRY
Mode (GP2.6, Main Drive-Relay in “Motor, Sol Test”), measure the

voltage of each part. 253 BRN
254 YEL
Did you confirm the output of 24VDC between the J06-5 (+) and J06-6 (-) on (RL601) Magnetic relay
DC24V For noth America (120V)
the MC Unit (PCB601)? 475 BLK COM NO
178 BLK 1 478 WHT 1 WHT
476 WHT 2 576 GRY 576 GRY 2 GRY
Y N 0.1μF+120Ω Spark 480 BLU
481 BLK
4
3
BLU
BLK
Quencher
| Replace the MC Unit (PCB601). 682 RED
882 YEL
6
5
RED
YEL
GRN/YEL
Did you confirm the output of DC24V between the connector pin1 (+) and Magnetic relay Magnetic relay (M601)
DC24V DC24V Knife motor
the connector pin2 (-) of the Main Motor Drive Relay (RL601)? 241 BRN 1 341 BRN 179 GRY 3 576 GRY
242 Purple 2 342 GRY 180 Sky-BLU 4 φ1 120V 60Hz 5.0A 0.4kW
181 BLK 2
Y N (RL602a)
NC180 Sky-BLU
(RL602b)
NC179 GRY
182 ORN 1 482 ORN 582 WHT
125WVAC 200μF
| Reconnect the connectors between the MC Unit (PCB601) and the
COM COM
NO179 GRY NO180 Sky-BLU
782 GRY
| Main Motor Drive Relay (RL601). 0.1μF+120Ω
250WVAC 40μF

0.1μF+120Ω
0.1μF+120Ω 0.1μF+120Ω
| Y N Spark Quencher
| | Replace the harness (PL6.24).
| End of the RAP.
MC Unit
Did you confirm the rated AC voltage between the connector pin1 (WHT) 1 (PCB601)
and the connector pin2 (GRY) of the Main Motor (M601)? 49 BRN
2
J06
Y N
1 +24VA
50 Purple
2 CL1
51 BRN
3 +24VA
| Check if each connector is properly connected and the harness is
52 Sky-BLU
4 BR1
53 BRN
5 +24VA
54 YEL
| electrically connected between the Main Motor (M601) and each part. 55 BRN
56 GRY
6
7
8
MOTPRL
+24VA
BLTPRL
41 BRN
42 Purple
1
2
241 BRN
242 Purple

53 BRN 3 253 BRN
9 54 YEL 4 254 YEL
58 BRN
10 SOL3V 55 BRN 5 255 BRN
59 Purple
Replace the Main Motor Drive Relay (RL601) (PL6.21). 11 SOL3 56 GRY 6 256 GRY
253 BRN
254 YEL
(RL601) Magnetic relay

DC24V (220-240V)
475 BLK COM NO
178 BLK 1 478 WHT 1 WHT
476 WHT 2 576 GRY 576 GRY 2 GRY
0.1μF+120Ω Spark GRY 480 BLU 4 BLU
681 RED 6 RED
Quencher 5 YEL
3
GRN/YEL
Magnetic relay 179 GRY 3
Knife motor (M601)
180 Sky-BLU 2
241 BRN 1 341 BRN DC24V 181 RED 1 481 ORN ORN 581 WHT φ1 240V 50Hz 2.6A 0.4kW
242 Purple 2 342 GRY
125WVAC 400μF
(RL602) X2
NC179 GRY ORN
COM 781 YEL
181 RED
NO180 Sky-BLU
250WVAC 40μF
0.1μF+120Ω
0.1μF+120Ω
Spark Quencher

RAP6.5 Main motor RAP
Follow these steps:

In the table below, find a symptom that is similar to machine’s trouble. Go
to the section in See….
Message See…
Paper Jam RAP6.7 Paper Jam
Malfunction RAP6.8 Malfunction
Emergency Stop RAP6.9 Emergency Stop
(Cover open) RAP6.10 Cover open Messages
See Scrap Box RAP6.11 Other Messages
Scrap Box Full
Guide roller
No Kicker
RL VP1 error
SpineMaster Error

RAP6.7 Paper Jam Jam-01 Delivery
Is there any foreign object or deformed/damaged parts on the paper
path between the Stopper Unit Sensor (PS605) and Delivery Unit Sensor
(PS606)?
Initial Actions Y N
To confirm the problem, follow the procedures below: | Check if the Delivery Unit Sensor (PS606) works properly in the
| Maintenance Mode (GP2.6 Paper-OUT in “Sensor Check”).
1. Check operator settings (Paper size and/or etc.) of iGen3 and Inline | Does it work properly?
Controller. If settings are not same, match settings. | Y N
2. Open the cover and remove the jammed paper. | | Check if each connector is properly connected and the harness is
Note: You can use the Eject Key to eject the jammed paper from the machine. | | electrically connected between the Delivery Unit Sensor (PS606)
| | and the MC Unit (PCB601). If there is no problem with the
3. Close the cover. | | connections, replace the sensor (PL6.22).
4. Check that the error message is not displayed. If the message is still | Is the sensitivity of the Delivery Unit Sensor (PS606) appropriate?
displayed, follow the procedures below according to each message. See | Y N
WD1.6 and WD3.6 as well. | | Adjust the sensitivity (ADJ5.1).
Remove the foreign object or replace deformed/damaged parts.

RAP6.8 Paper Jam
Jam-02 Entrance Figure 1
Check the detecting part of the Stopper Unit Sensor (PS605). MC Unit
(PCB601)
2
Is any foreign object attached to it? 1 J05
1 +24V
Y N (CL602) 2 CL2
BLU 1 35 BRN
| Check if the Stopper Unit Sensor (PS605) works properly in the Conveyance clutch BLU 2 36 YEL
3
4
+24V
CL3
| Maintenance Mode (GP2.6, Paper-IN in “Sensor Check”). 24V,41Ω,1/1,0.585A 5 +24V
16 FAN2
| Does it work properly?
| Y N
| | Check if each connector is properly connected and the harness is Measurement point Normal output voltage
| | electrically connected between the Stopper Unit Sensor (PS605) and Connector - Pin (Signal) Not in operation In operation
| | the MC Unit (PCB601). If there is no problem with the connections, J05-3 (+24V) J05-4 (CL3) applox. 0VDC applox. 24VDC
| | replace the sensor (PL6.22).
| Measure the output voltage between the MC Unit (PCB601) and
| Conveyance Clutch (CL602). (see Figure 1)
| Y N
| Check if each connector is properly connected and the
| harness is electrically connected between the Conveyance Clutch
| (CL602) and the MC Unit (PCB601). If there is no problem with
| the connections, replace the clutch (PL6.21).
| Y N
| | Is the sensitivity of the Stopper Unit Sensor (PS605) appropriate?
| | Y N
| | | Adjust the sensitivity (ADJ5.1).
| End of the RAP.

RAP6.8 Paper Jam
Jam-02 Delivery Figure 1
Check the detecting part of the Delivery Unit Sensor (PS606). MC Unit
Is any foreign object attached to it? (PCB601)
2
Y N 1 J05
| Check for correct alignment for SpineMaster. (CL602)
1 +24V
2 CL2
| (see Section 8, Installing SpineMaster) Conveyance clutch
BLU 1 35 BRN
3 +24V
BLU 2 36 YEL
| Check if the Delivery Unit Sensor (PS606) works properly in the 24V,41Ω,1/1,0.585A
4
5
CL3
+24V
| Maintenance Mode (GP2.6, Paper-OUT in “Sensor Check”). 16 FAN2
| | Check if each connector is properly connected between the Connector - Pin (Signal) Not in operation In operation
| | Delivery Unit Sensor (PS606) and the MC Unit (PCB601) and if the J05-3 (+24V) J05-4 (CL3) applox. 0VDC applox. 24VDC
| | harness is electrically connected between them. If there is no
| | problem with the connections, replace the sensor (PL6.22).
| Conveyance Clutch (CL602). (see Figure 1)
| Y N
| electrically connected between the Conveyance Clutch (CL602)
| and the MC Unit (PCB601). If there is no problem with the
| connections, replace the clutch (PL6.21).
| Y N
| | Is the sensitivity of the Delivery Unit Sensor (PS606) appropriate?
| | Y N
| | | Adjust the sensitivity of the sensor (ADJ5.1).
| End of the RAP.

RAP6.8 Paper Jam
RAP6.8 Malfunction Interface CRC Error
Is there any error in the upstream unit?
Y N
Malfunction is displayed on the first line of the LCD. The second line | Is the D-port cable properly connected?
shows the name of the problem. Details are described in the following table. | Y N
| | Reconnect the D-port cable (See Section 8, Connecting Cables).
Refer to WD1.6 and WD3.6 as well when following the procedures below. | Does the D-port cable work properly?
| Y N
Motor MPU CRC Error, | | Replace the D-port cable (PL6.20).
Motor MPU ACK Error | Check if each connector is properly connected between the MC Unit
Turn off the Remote Switch. Wait for about ten seconds. Turn on the Remote | (PCB601) and DPIF P.W.B (PCB605) unit and if the harness is
Switch. Does the message disappear? | electrically connected between them. Are they connected properly?
Y N | Y N
| Replace the MC Unit (PCB601). | | Replace the harness (PL6.24).
End of the RAP. If this problem often occurs, replace the MC Unit (PCB601). | Is the problem solved after replacing the DPIF P.W.B unit (PCB605)?
| Y N
| End of the RAP.
Panel MPU CRC Error, Clear the error of the upstream unit.
Panel MPU ACK Error
Turn off the Remote Switch. Wait for about ten seconds. Turn on the Remote
Switch. Does the message disappear?
Y N
| Can you enter the Maintenance Mode (GP2.6)?
| Y N
| | Check if each connector is properly connected and the harness is
| | electrically connected between the MC Unit (PCB601) and the
| | Control Panel (PCB602). If there is no problem with
| | the connections, replace the Control Panel (PL6.22).
End of the RAP.

RAP6.8 Malfunction
Memory Data Error, Knife index trouble
Memory Write ACK Error, Check the detecting part of the Upper Blade Index Sensor (PS602).
DA Convertor ACK Error Is there any foreign object attached to it?
Turn off the Remote Switch. Wait for about ten seconds. Turn on the Remote Y N
Switch. Does the message disappear? | Check the Index Plate, Sensor and Sensor Bracket.
Y N | Are they free of defects?
| Is the EEPROM (U05) properly attached? | Y N
| Y N | | Replace deformed/damaged parts (PL6.22).
| | Attach the EEPROM (U5) properly. | Check the driving path between the Main Motor (M601) and the Index
| Is the problem solved after replacing the MC Unit (PCB601)? | Plate.
| Y N | Is it free of defects?
| | Replace the EEPROM (U05) (REP6.1). | Y N
| End of the RAP. | | Remove a foreign object, replace parts or adjust the belt tension
End of the RAP. If this problem often occurs, replace the MC Unit (PCB601). | | (ADJ6.12, ADJ6.13).
| Check the Upper Blade Index Sensor (PS602) in the Maintenance Mode
| (GP2.6, Knife index in “Sensor Check”).
| Y N
| | electrically connected between the Upper Index Sensor (PS602)
| | and the MC Unit (PCB601). If there is no problem with the
| | connections, replace the sensor (PL6.22).
| Go to RAP6.5 Main motor RAP.

RAP6.8 Malfunction
Knife home-in trouble Figure 1
Knife brake trouble
2 MC Unit
Check the detecting part of the Upper Blade Home Sensor (PS601). 1 (PCB601)
Is there any foreign object attached to it? (CL/BRK)
J06
GRY 1 49 BRN
Y N Upper Blade Clutch GRY 2 50 Purple
1
2
+24VA
CL1
51 BRN
| Check the Flag, Sensor and Sensor Bracket. 24V,38Ω,0.63A,15W
52 Sky-BLU
3 +24VA
4 BR1
| Are they free of defects? 5 +24VA
GRY 1
| Y N Upper Blade Brake GRY 2
6
7
MOTPRL
+24VA
| | Replace deformed/damaged parts. 24V,25.6Ω,0.94A,22.5W 8 BLTPRL
| Check the driving path between the Main Motor (M601) and the Index 2
9
10 SOL3V
| Plate. 1 11 SOL3
| Y N
| | Remove a foreign object, replace parts or adjust the chain/belt
| | tension (ADJ6.12, ADJ6.13). J06-1 (+24VA) J06-2 (CL1) approx. 0VDC approx. 24VDC
| Check the Upper Blade Home Sensor (PS601) in the Maintenance Mode J06-3 (+24VA) J06-4 (BR1) approx. 0VDC approx. 24VDC
| (GP2.6, Knife Home in “Sensor Check”).
| Y N
| | Check if each connector is properly connected and the
| | harness is electrically connected between the Upper
| | Blade Home Sensor (PS601) and the MC Unit (PCB601). If there is
| | no problem with the connections, replace the sensor (PL6.22).
| Upper Blade Clutch (CL/BRK) and between the MC Unit (PCB601)
| and Upper Blade Brake (CL/BRK). (see Figure 1)
| Y N
| electrically connected between the Upper Blade Clutch/Brake
| (CL/BRK) and the MC Unit (PCB601).
| If there is no problem with the connections, replace the clutch/brake
| (PL6.21).

RAP6.8 Malfunction
Main motor overloaded trouble Conveyance motor locked,
Check the detecting part of the Upper Blade Index Sensor (PS602). Conveyance motor overloaded
Is there any foreign object attached to it? Check the driving path of the Conveyance Motor (M602).
Y N Is it free of defects?
| Check the Index Plate, Sensor and Sensor Bracket. Y N
| (only when cluth moves) | Remove a foreign object, replace parts or adjust the belt tension
| Are they free of defects? | (ADJ6.14).
| Y N Measure the output voltage between the MC Unit (PCB601) and
| | Replace deformed/damaged parts. Conveyance Motor (M602). (see Figure 1)
| Check the driving path between the Main Motor (M601) and the Index Is it normal output voltage?
| Plate. Y N
| Is it free of defects? | Replace the MC Unit (PCB601).
| Y N Check if each connector is properly connected and the harness is
| | Remove a foreign object, replace parts or adjust the belt tension electrically connected between the Conveyance Motor (M602)
| | (ADJ6.12, ADJ6.13). and the MC Unit (PCB601). If there is no problem with the
| Check the Upper Blade Index Sensor (PS602) in the Maintenance Mode connections, replace the motor (PL6.21).
| (GP2.6, Knife index in “Sensor Check”).
| Y N Figure 1
1
| | electrically connected between the Upper Blade Index Sensor MC Unit 1
| | (PS602) and the MC Unit (PCB601). (PCB601) 1
| | If there is no problem with the connections, replace the sensor J03
88 Sky-BLU 1 BLU
1 U
89 Purple 2 Purple Conveyance Motor
| | (PL6.22). 2 V
90 GRY 3 GRY DC24V 3.8A
3 W
| Go to RAP6.5 Main motor RAP.
Remove the foreign object. 1
J02
GND
91 BLU 4 YEL (M602)
92 YEL 5 GRN
2 HU
93 Sky-BLU 6 BRN
3 HV
94 Purple 7 RED
4 HW
8 ORN
5
96 RED 9
6 +12V
J04
109 BRN
1 +24V
2 +24V
3 +24V
112 BRN
4 +24VA
5 +24VA
114 BLU
6 GND
7 GND 2
8 GND
9 FG


RAP6.8 Malfunction
RL relay problem Emergency cable problem 1,
Emergency cable problem 2,
Are the settings of the Slide Switch on each Relay Board of each machine Emergency cable problem 3,
correct? Emergency cable problem 4
Y N These messages are displayed only for BG configration whitch is not used
| Set each Slide Switch correctly. (See Figure 1) in north America.
Check if the Slide Switch on the Relay Board (PCB604) is properly set .
(GP2.6, Dip-SW1 or Dip-SW2 in “Sensor Check”).
Does the setting displayed on the LCD match the setting of the Slide Is the E-port cable properly connected to the machine?
Switch? Y N
Y N | Reconnect it (See Section 8, Connecting Cables).
| Check if each connector is properly connected and the harness is Does the E-port cable work properly?
| electrically connected between the Relay Board (PCB604) and Y N
| the following parts . | Replace the E-port cable (PL6.20).
| If there is no problem with the connections, replace the Check if each connector is properly connected and the harness is
| Relay Board (PCB604) (PL6.22). electrically connected between the MC Unit (PCB601) and the Relay Board
| • Stop Emergency Switch (SSW601) (PCB604). Are they properly connected?
| • Top Cover Switch (SSW602) Y N
| • Dust Box Switch (SSW603) | Reconnect or replace the harness (PL6.24).
End of the RAP. Each part appears to be functioning. Is the problem solved after replacing the Relay Board (PCB604)? (PL6.22)
If the message is still displayed, replace the MC Unit (PCB601). Y N
End of the RAP.
Figure 1
<BG/non BG Setting>
DBM-500T
ON ON
BG SW1 SW2
BG SW1 SW2 ON
ON
OFF
OFF DBM-500
non BG SW1 SW2
ON ON
BG SW1 SW2
OFF OFF

RAP6.8 Malfunction
Moving motor home-in Figure 1
Moving motor home-out
Moving motor home out-in MC Unit
(PCB601)
Moving motor counter-out Ferrite core
J07
Moving motor counter-in 1 +24VA
97 BRN
98 BRN
1
2
BLK
WHT
Moving motor counter-over 2
3
+24VA
PM1A-
99 YEL
4
3
ORN
BRN Stopper Unit Motor
100 GRY 5 RED
4 PM1A+ 6 YEL
Check the detecting part of the Stopper Unit Home Sensor (PS604). 5 PM1B+
101 Sky-BLU DC3.0V 2.0A
102 Purple (M604)
Is there any foreign object attached to it? 6 PM1B-
7 +24VA
Y N 8 +24VA
| Check the Flag, Sensor and Sensor Bracket (PL6.22). 9
10
PM2A-
PM2A+
1
| Are they free of defects? 11 PM2B+ 1
1
| Y N 12 PM2B-
1
J04
| | Replace deformed/damaged parts. 1 +24V
109 BRN
1
| Check the driving path on the Stopper Unit Motor (M604). 2
3
+24V
+24V
1
| Is it free of defects? 4 +24VA
112 BRN
| Y N 5
6
+24VA
GND
114 BLU
| | Remove a foreign object, replace parts or adjust the belt tension 7 GND 2
8 GND
| Check the Stopper Unit Motor (M604) in the Maintenance Mode 9 FG
| (GP2.6, MV Mot Home in “Sensor Check”).
| Check if Stopper Unit Sensor (PS605) works properly in the Measurement point Normal output voltage
| Maintenance Mode (GP2.6, Paper-IN in “Sensor Check”). Connector - Pin (Signal) Not in operation In operation
| Y N J07-1 (+24VA) J04-7 (GND) approx. 24VDC approx. 24VDC
| | Check if each connector is properly connected and the harness is J07-2 (+24VA) J04-7 (GND) approx. 24VDC approx. 24VDC
| | electrically connected between the Stopper Unit Home Sensor J07-3 (PM1A-) J04-7 (GND) approx. 24.3 or 23.6VDC approx. 23.5VDC
| | (M604) and the MC Unit (PCB601). If there is no problem with J07-4 (PM1A+) J04-7 (GND) approx. 24.3 or 23.6VDC approx. 23.5VDC
| | the connections, replace the sensor (PL6.22). J07-5 (PM1B+) J04-7 (GND) approx. 24.3 or 23.6VDC approx. 23.5VDC
| Measure the output voltage between the MC Unit (PCB601) and J07-6 (PM1B-) J04-7 (GND) approx. 24.3 or 23.6VDC approx. 23.5VDC
| Stopper Unit Motor (M604). (see Figure 1) Note: The output voltage at between J07-3 to J07-6 will be lower by approximately
| Is it normal output voltage? 0.5V when the motor is in operation.
| Y N
| | Replace the MC Unit (PCB601). Note: When the motor is not in operation, the output voltage at between J07-3 to
| Check if each connector is properly connected and the harness J07-6 varies depending on the brake position of the motor.
| is electrically connected between the Stopper Unit Motor
| Sensor (M604) and the MC Unit (PCB601). If there is no problem
| with the connections, replace the motor (PL6.21).

RAP6.8 Malfunction
Conveyance gap motor home-in Figure 1
Conveyance gap motor home-out
Conveyance gap motor home out-in MC Unit 1
(PCB601) 1
Conveyance gap motor counter-out 1
J07
Conveyance gap motor counter-in 1 +24VA 1
Conveyance gap motor counter-over 2
3
+24VA
PM1A-
1
4 PM1A+ 1
Check the Conveyance Gap Home Sensor (PS603). 5 PM1B+
Is there any foreign object attached to it? 6 PM1B-
103 BRN 5 403 BRN
7 +24VA 5
Y N 8 +24VA
104 BRN 2 404 BRN
2
105 YEL 6 405 YEL Conveyance Gap
10
PM2A-
PM2A+
106 GRY 4 406 GRY
6
4 Motor (M603)
| Are they free of defects? 11 PM2B+
107 Sky-BLU
108 Purple
3
1
407 Sky-BLU
408 Purple
3
| Y N 12 PM2B-
7
1
DC7.3V 0.5A
J04 8
| | Replace deformed/damaged parts. 1 +24V
109 BRN Ferrite core
9
| Check the driving path on the Conveyance Gap Motor (PS603). 2
3
+24V
+24V
| Is it free of defects? 4 +24VA
112 BRN
| Y N 5
6
+24VA
GND
114 BLU
| | Remove a foreign object, replace parts or adjust the belt tension. 7 GND 2
8 GND
| Check the Conveyance Gap Home Sensor (PS603) in the Maintenance 9 FG
| Mode (GP2.6, GAP Mot Home in “Sensor Check”).
| Does the sensor work properly? Measurement point Normal output voltage
| | Check if each connector is properly connected and the harness J07-7 (+24VA) J04-7 (GND) approx. 24VDC approx. 24VDC
| | is electrically connected between the Conveyance Gap Home J07-8 (+24VA) J04-7 (GND) approx. 24VDC approx. 24VDC
| | Sensor (PS603) and the MC Unit (PCB601). J07-9 (PM2A-) J04-7 (GND) approx. 24.3 or 23.6VDC approx. 23.5VDC
| | If there is no problem with the connections, replace the J07-10 (PM2A+) J04-7 (GND) approx. 24.3 or 23.6VDC approx. 23.5VDC
| | sensor (PL6.22). J07-11 (PM2B+) J04-7 (GND) approx. 24.3 or 23.6VDC approx. 23.5VDC
| Measure the output voltage between the MC Unit (PCB601) and J07-12 (PM2B-) J04-7 (GND) approx. 24.3 or 23.6VDC approx. 23.5VDC
| Conveyance Gap Motor (M603). (see Figure 1) Note: The output voltage at between J07-9 to J07-12 will be lower by
| Is it normal output voltage? approximately 0.5V when the motor is in operation.
| Y N
| | Replace the MC Unit (PCB601). Note: When the motor is not in operation, the output voltage at between J07-9 to
| Check if each connector is properly connected and the harness J07-12 varies depending on the brake position of the motor.
| is electrically connected between the Conveyance Gap Motor (M603)
| and the MC Unit (PCB601).

RAP6.8 Malfunction
RAP6.9 Emergency Stop Upstream
Is there any message related to an emergency stop on the Control Panel of
the upstream unit?
Y N
Initial Actions | Is the problem solved after replacing the Relay Board (PCB604)?
To solve problems, follow the procedures below. | (PL6.22)
| Y N
1. Release the Emergency Stop Switch. | | Replace the MC Unit (PCB601).
2. If the same message is still displayed, turn off the Remote Switch. Wait | End of the RAP.
for about ten seconds. Turn on the Remote Switch. See if the same Refer to the RAPS of the upstream unit.
message is displayed.
3. Check if the message has disappeared. If the message is still displayed,
follow the procedures below according to each message. See WD1.6 and See Scrap Box
WD3.6 as well. See RAP6.11, See Scrap Box.
Trimmer
Is the Emergency Stop Switch pressed?
Y N
| Check if the Emergency Stop Switch (SSW601) works properly in the
| Maintenance Mode (GP2.6, Emergency SW in “Sensor Check”).
| Does the switch work properly?
| Y N
| | Reconnect each connector or replace the harness.
| When the Emergency Stop Switch (SSW601) is released, is the pin1
| electrically connected to the pin2 ?
| Y N
| | Replace the Emergency Stop Switch (SSW601) (PL6.23).
| Is each connector properly connected and is the harness
| electrically connected between the Emergency Stop Switch (SSW601)
| and Relay Board (PCB604) ?
| Y N
| Is each connector properly connected and is the harness electrically
| connected between the Relay Board (PCB604) and the
| MC Unit (PCB601)?
| Y N
| Y N
| End of the RAP. The Switching Power Supply appears to be functioning.
Release the Emergency Stop Switch.

RAP6.9 Emergency Stop
RAP6.10 Cover open Messages Cover L is open,
Cover R is open,
Cover B is open
Refer to WD1.6 and WD3.6 when following the procedures below. Is each cover properly attached?
Y N
Top Cover Open | Reattach each cover.
Does the Actuator of each cover switch (SSW604, SSW605, SSW606) work
Is the Top Cover completely closed? properly?
Y N Y N
| Close the Top Cover. | Replace the switch (PL6.23).
Check the sliding part of the Top Cover Switch (SSW602). Check if each cover switch works properly in the Maintenance Mode
Is it normal? (GP2.6, Cover-x in “Sensor Check”).
Y N Does it work properly?
| Replace the Top Cover Switch (SSW602) (PL6.23). Y N
Is the Top Cover Switch (SSW602) properly adjusted? | When each cover switch (SSW604, SSW605, SSW606) is set to ON, is
Y N | each connector electrically connected?
| Readjust the Top Cover Switch (SSW602) (ADJ6.16). | Y N
| Check if the Top Cover Switch (SSW602) works properly in the | | Replace the switch (PL6.23).
| Maintenance Mode (GP2.6, Top cover SW in “Sensor Check”). | Check if each connector is connected and the harness is
| Does it work properly? | electrically connected between each cover (SSW604, SSW605, SSW606)
Y N | and the MC Unit (PCB601).
| Is each connector properly connected and is the harness electrically | Y N
| connected between the Top Cover Switch (SSW602) and the | | Reconnect a connector or replace the harness.
| Relay Board (PCB604) ? | Replace the MC Unit (PCB601).
| Y N End of the RAP. Each part appears to be functioning. If the message
| | Reconnect a connector or replace the harness. is still displayed, replace the MC Unit (PCB601).
| Is each connector properly connected and is the harness electrically
| connected between the Relay Board (PCB604) and the MC Unit
| (PCB601) ?
| Y N
| | Reconnect a connector or replace the harness.
| Y N
| End of the RAP.
End of the RAP. Each part appears to be functioning. If the message
is still displayed, replace the MC Unit (PCB601).

RAP6.11 Other Messages Scrap Box Full
Is the Scrap Box full?
Y N
Refer to WD1.6 and WD3.6 when following the procedures below. | Check the detecting part of the Waste Bin Full Sensor (PS607).
| Is there any foreign object attached to it?
See Scrap Box | Y N
| | Check if the light axis of the Waste Bin Full Sensor (PS607)
Is the Scrap Box properly set? | | is displaced.
Y N | | Is it placed properly?
| Set the Scrap Box correctly. | | Y N
Does the Actuator of the Scrap Box work properly? | | | Replace deformed/damaged parts.
Y N | | Check if the Waste Bin Full Sensor (PS607) works properly in the
| Replace the Actuator (PL6.23). | | Maintenance Mode (GP2.6, D-box full in “Sensor Check”).
Check the Dust Box Switch (SSW603) in the Maintenance Mode | | Does the sensor work properly?
(GP2.6, Dust box SW in “Sensor Check”). | | Y N
Does it work properly? | | | Check if each connector is properly connected and the
Y N | | | harness is electrically connected between the
| Check if each connector is properly connected and the harness is | | | Waste Bin Full Sensor (PS607) and the MC Unit (PCB601).
| electrically connected between the Dust Box Switch (SSW603) (PL6.23) | | | If there is no problem with the connections, replace the
| and the MC Unit (PCB601). | | | sensor (PL6.22).
End of the RAP. Each part appears to be functioning. | | End of the RAP. Each part appears to be functioning. If the message
If the message is still displayed, replace the MC Unit. | | is still displayed, replace the MC Unit (PCB601).
| Remove the foreign object.
Empty the Dust Box.

Guide roller No Kicker
Is the machine connected to the DBM-LS1? Is the machine connected to the DBM-K?
Y N Y N
| Replace the MC Unit (PCB601). | Is the “Kicker Settings” of the Inline Controller set to OFF?
Is the Stacker Roller correctly installed? | (see DBM-500 Instruction Manual, “9-3. Accessory Menus”)
Y N | Y N
| Reinstall the Stacker Roller. | | Set the “Kicker Settings” to OFF.
Check the detecting part of the Paper Guide Wheel Limit Sensor (PS701). | Replace the MC Unit (PCB601).
Is there any foreign object attached to it? Is the connecting cable of the DBM-K properly connected to the machine?
Y N Y N
| Check the Flag, Sensor and Sensor Bracket. | Reconnect the cable.
| Are they free of defects? Check if the Kicker Solenoid (SL701) works properly in the Maintenance
| Y N Mode (GP2.6, Kicker in “Sensor Check”).
| | Replace the deformed/damaged parts. Does the solenoid work properly?
| Check the driving path of the Stacker Roller. Y N
| Is it free of defects? | Check if each connector is properly connected and the harness is
| Y N | electrically connected between the Kicker Solenoid (SL701) and
| | Remove a foreign object, replace parts or adjust the belt tension. | the MC Unit (PCB601). If there is no problem with the connections,
| Check if the Paper Guide Wheel Limit Sensor (PS701) works properly in | replace the solenoid (PL7.2).
| the Maintenance Mode (GP2.6, Roller Limit in “Sensor Check”). End of the RAP. Each part appears to be functioning.
| Does the sensor work properly? If the message is still displayed, replace the MC Unit (PCB601).
| Y N
| | Check if each connector is properly connected and the harness
| | is electrically connected between the Paper Guide Wheel RL VP1 error
| | Limit Sensor (PS701) and the MC Unit (PCB601).
| | If there is no problem with the connections, replace the Are the settings of the Slide Switch on the Relay Board of each machine
| | sensor (PL6.22). correct?
| End of the RAP. Each part appears to be functioning. If the message Y N
| is still displayed, replace the MC Unit (PCB601). | Set the Slide Switch correctly (See Section 8).
Remove the foreign object. Check if the Slide Switch on the Relay Board (PCB604) works properly
(GP2.6, Dip-SW1 or Dip-SW2 in “Sensor Check”).
Does the message match the setting?
Y N
| electrically connected between the Relay Board (PCB604) and
| the MC Unit (PCB601). If there is no problem with the connections,
| replace the Relay Board (PCB604) (PL6.22).
SpineMaster Error
Refer to the RAP of the SpineMaster.

RAP6.12 DBM-LS1 RAP Checking the DBM-500T
When supplying driving power to the Stacker Motor (M701) in the
Maintenance Mode (GP2.6, StackerMot Relay in “Motor, Sol Test”), can
During the booklet-making process, the Stacker Motor (M701) needs to be you confirm the output of the rated AC voltage between the L (BLK) and
moving. the N (WHT) of the Stacker Outlet ?
Y N
See WD1.6, WD1.7, WD3.6 and WD3.7 when following the procedures | Reconnect each connector between the Stacker and SSR, the Stacker
below. | Outlet and the Relay Board (PCB604).
Is the power cord correctly connected to the wall outlet and to the machine? | Y N
Y N | | Check if the harnesses between the Stacker Outlet and SSR, the
| Reconnect it. | | Stacker Outlet and the Relay Board (PCB604) are electrically
Check the driving path between the Stacker Motor (M701) and the | | connected. Are they connected?
Conveyance Belt. | | Y N
Is it free of defects? | | | Replace the harness.
Y N | | When supplying driving power to the Stacker Motor (M701) in the
| Remove a foreign object or replace parts. | | Maintenance Mode (GP2.6, StackerMot Relay in
When supplying driving power to the Stacker Motor (M701) in the | | “Motor, Sol Test”), can you confirm the voltage of DC24V
Maintenance Mode (GP2.6, StackerMot Relay in “Motor, Sol Test”), can | | between the J06-7(+) and J06-8 (-) on the MC Unit (PCB601)?
you confirm the output of the rated AC voltage between the connector pin 1 | | Y N
(BLU) and the connector pin 2 (BRN) of the Stacker Motor (M701)? | | | Replace the MC Unit (PCB601).
Y N | | Check if each connector is properly connected and the harness
| Reconnect each connector between the Stacker Motor (M701) and the | | is electrically connected between the SSR and the MC Unit (PCB601).
| power cord. Is the problem solved? | End of the RAP.
| Y N Replace the power cord (PL7.1) of the DBM-LS1.
| | Go to Checking the DBM-500T.
| End of the RAP.
Replace the Stacker Motor (M701) (PL7.1).

RAP6.12 DBM-LS1 RAP
SpineMaster
Is the Main Power Switch illuminated?

Y N
| Go to AC Mains RAP (RAP8.2).
Is the Error Indicator Light illuminated? LED13
Y N
| Is LED1 on the Transformer Input PCB illuminated?
| Y N
| | Check the Transformer Fuse (WD1.8.2).
| Is LED13 on PCB 900-197 flashing? (see Fig.1)
| Y N
| | Replace PCB 900-197.
| Does LED1 on PCB 900-141 illuminate when a start signal is present?
| (see Fig.2)
| Y N
| | Check the F3 fuse on PCB 900-141. (see Fig.2)
| Does the Main Motor rotate when a start signal is present?
| Y N
| | Check the Wiring/Motor. Fig. 1 PCB 900-197
| Check Drive Chains (REP8.7).
Is the Stacker Support triggering the Stacker Full Sensor? LED1
Y N
| Go to Error Indicator RAP (RAP8.3).
Reset Stacker Support.
Fig.2 PCB 900-141

F3
2-117 Section 2—Repair Analysis Procedures SpineMaster

RAP8.1 Entry RAP
SpineMaster
RAP8.2 AC Mains RAP PCB 900-141
PL1
SK1
Purple
Purple
The mains switch is not illuminated.
ORN
ORN
WHT
WHT
BRN
SP1
Is there mains power to the Mains Lead end? GRN/YEL

Check incorrect voltage.
Y N
Purple
| Is there voltage at fuse block? Transformer
Transformer Input PCB
GRN/YEL
905-351
GRN/YEL Motor
| Y N Assembly
Sky BLU Sky BLU
905-354
| | Is the fuse* in the plug OK? 905-154 SK3 BRN
| | Y N Purple
| | | Reinsert the fuse*. GRN/YEL GRN/YEL Fan 710-058
710-057
| | Check mains supply. Sky BLU
| Is the fuse* in the Input Socket OK?

Plug
| Y N with Fuse (250V/10A)
| | Replace fuse*. BRN BRN
BLU BLU
Replace complete Input Socket. NF
GRN/YEL
GRN/YEL
720-019
*Fuses (WD1.8.2). 640-076

RAP8.2 AC Mains RAP
SpineMaster
RAP8.3 Error Indicator RAP
LED9
The machine will not run and the Error Indicator Light is illuminated.
Are the Guards properly closed?
Y N LED11
| Close the Guards.
Is LED9 (Guard) illuminated? (see Fig.1)
Y N
| Check the Guard Switch and wiring.
Is there a booklet jammed inside the SpineMaster?
Y N
| Does LED11 illuminate when a booklet is pushed into the Infeed?
| (see Fig.1)
| Y N
| | Check/replace Infeed Sensor (REP8.19). LED15
| Does LED15 illuminate when a booklet is on the Clamp Stop?
| (see Fig.1)
| Y N
| | Check/replace Clamp Optical Sensor (ADJ8.4).
| Check/Replace PCB 900-197. Fig. 1 PCB 900-197
Remove the jammed booklet. If the problem persists, go to the Jammed
Booklet RAP (RAP8.4).

RAP8.3 Error Indicator RAP
SpineMaster
RAP8.4 Jammed Booklet RAP
Initial Actions
1. Check all drive components, including belts, gears, chains and pulleys,
for damage.
Is the booklet jammed before the Clamp?

Y N
| Is the booklet jammed in the Clamp?
| Y N
| | Is the booklet jammed in the Upfeed Conveyor?
| | Y N
| | | End of the RAP. Each part appears to be functioning.
| | | If the message is still displayed, replace the
| | | SpineMaster control PCB.
| | Is the booklet thin, with only a few pages?
| | Y N
| | | Check Conveyor Belts are correctly positioned and not worn.
| | Clean the Conveyor Belts and check that the spine is not being over
| | crushed.
| Switch the power off then on.
| Does the Clamp open and release the booklet?
| Y N
| | Refer to Clearing a Paper Jam procedure (see Section4, 8.0b).
| Remove jammed booklet and continue operation. Is all OK?
| Y N
| | Clear jam again. Has the jammed booklet spine been formed?
| | Y N
| | | Check Carriage Motor and Transverse Chain (RAP8.5).
| | Is the booklet thin, with only a few pages?
| | Y N
| | | Check Paper Stop Holding Magnet (REP8.1).
| | Go to Thin Booklet RAP (see Section3, RAP8.a).
| No fault found.
Is the booklet thin, with only a few sheets?
Y N
| Clean the conveyor belts, ensure the booklet feeds in square
| and that it is folded as tightly as possible.
Clean the conveyor belts, ensure the booklet feeds in square and it is not
folded too tightly.
RAP8.4 Jammed Booklet RAP
SpineMaster
RAP8.5 Carriage Motor and Transverse Chain
RAP
Is the Transverse Chain in place?

Y N
| Is the Chain Broken?
| Y N
| | Re-fit Chain to Sprockets and tension (ADJ8.1).
| Replace/repair Chain (REP8.6).
Is the Chain correctly tensioned? (ADJ8.1).
Y N
| Tension Chain (ADJ8.1).
Does the Carriage Motor run?
Y N
| Does LED15 on PCB 900-197 illuminate when booklet is on Stop? LED15
| (see Fig.1)
| Y N
| | Check/replace Clamp Optical Sensor (REP8.20).
| Is the resistance across the Motor Balast Resistor correct
| (68 Ohms +/-5%)? Fig. 1 PCB 900-197
| Y N
| | Replace Resistor (REP8.4).
| Is the Drive Motor faulty?
| Y N
| | Replace PCB 900-197.
| Replace Drive Motor (REP8.16).
Is there drive from the Motor to the Carriage?
Y N
| Tighten Trantorque Bush on Drive Sprocket (REP8.12).
Is the Roller Assembly jammed?
Y N
| No fault found.
Free Roller Assembly (see Section4, 8.0c).

RAP8.5 Carriage Motor and Transverse Chain RAP
Section 3
Booklet Quality
Contents
Section 3 Booklet Quality .............................................3-1
Generic RAPs..........................................................3-2
RAP0.a Cleaning................................................. 3-3
RAP3.a SCC ....................................................... 3-4
RAP3.b Blade...................................................... 3-6
RAP5.a Paper Arrangement ................................3-7
RAP5.b Wire ....................................................... 3-9
RAP5.c Folding Skew ........................................3-12
RAP5.d Folding Position ....................................3-13
RAP6.a Trimming Skew .....................................3-14
RAP6.b Trimming Position .................................3-15
RAP8.a Spine.....................................................3-16
3-1
iGen3-M12D0-0612-0
Generic RAPs
Crease
Stitch
Fold
To analyze booklet trouble, follow these steps:

In the table below, find a symptom that is similar to booklet making Figure 1a Figure 1b
trouble. Go to the section in See…. L
Symptom See…
There is damage or dirt on the print side. RAP0.a Cleaning
The print side is skewed. RAP3.a SCC Figure 2 Figure 9

(see Figure 2)
The finished size is not correct after the fore- RAP6.b Trimming Position
edge is trimmed.
(see Figure 3)
The trimming on the head and tail edge is Slitter Blade of RAP3.b Blade
rough. (when using the slitter) Figure 3 Figure 10
(see Figure 4) L
The trimming on the fore-edge is rough. Trimming Knife of RAP3.b Blade
(see Figure 5) (when trimming fore-edge)
Cutter Blade of RAP3.b Blade
(When you set cutting without fore-edge
trimming) Figure 4 Figure 11
The fore-edge is trimmed skewed. RAP6.a Trimming Skew
(see Figure 6)
The booklet is folded skewed. RAP5.c Folding Skew
(see Figure 7 )
The widths of the front and back covers are RAP5.d Folding Position
not same. Figure 5 Figure 12
(see Figure 8)
Stitches are oblique. RAP5.a Paper Arrangement
(see Figure 9)
Only the stitching position is not correct. RAP5.d Folding Position
(see Figure 10)
Only the fold position is not correct. RAP5.d Folding Position Figure 6 Figure 13
(see Figure 11)
The fold position, stitching position and RAP5.d Folding Position
crease position do not match.
(see Figure 12)
A staple is not applied to the booklet. RAP5.b Wire
There is a problem with the length of a stitch Figure 7 Figure 14
and its form.
(see Figure 13)
Paper is not aligned. RAP5.a Paper Arrangement
(see Figure 14)
Figure 8
3-2 Section 3—Booklet Quality

Generic RAPs
RAP0.a Cleaning
Is there any foreign substance or dirt on each paper path?

Y N
| Is there any damage or deformation on the parts of each paper path?
| Y N
| | End of the RAP. The machine works properly.
| Replace the questionable parts.
Clean the paper path. (see each Instruction Manual)

RAP0.a Cleaning
RAP3.a SCC
W
Figure 1
Common Check
L
Does a sheet pass through the center of the paper path?
Y N
| Fine-tune the main body position.
| (see SCC Instruction Manual, “6-4 Main Body Position”)
Is the height of the stopper appropriate?
Y N
| Adjust the height of the stopper (ADJ3.4).
Is the height of the back jogger appropriate?
Y N
| Adjust the height of the back jogger (ADJ3.5).
Is the side jogger parallel to the side edge of a sheet?
Y N
| Make the side jogger parallel to the side edge of a sheet (ADJ3.6).
Are the angles of the side joggers correct? (see Figure 1)
Y N
| Adjust the angles with the side jogger adjuster.
| (see SCC Instruction Manual, “6-10 Side Jogger Angle”)
Is the distance between a sheet and the side joggers appropriate?
Y N
| Fine-tune the position of the side jogger.
| (see SCC Instruction Manual, “6-2 Side Jog Position”)
Is the distance between the tail edge of a sheet and the side joggers
appropriate?
Y N
| Fine-tune the position of the back jogger.
| (see SCC Instruction Manual, “6-3 Back Jog Position”)
Is the timing of the side jogger correct?
Y N
| Adjust the timing of the back jogger.
| (see SCC Instruction Manual, “6-9 Back Jog Delay”)
Go to Slit, Cut or Crease Check

RAP3.a SCC
Slit Check (see Figure 2)
Are the slitters attached to the right place?
W
Y N
| Adjust the attached position of the slitters (ADJ3.8). Figure 2
Is the slitter position appropriate for a sheet?

Y N
| Adjust the slitter position.
| (see SCC Instruction Manual, “6-5 Finished Size”)
Is the paper dust stacked in the slitters? Figure 3
Y N
| End of the RAP.
Remove paper dust from the slitters (REP3.4).
Figure 4
Cut Check (see Figure 3)
Is the cutter angle correct?
Y N
| Adjust the cutter angle (ADJ3.13).
End of the RAP. Figure 5
Crease Check
Is the crease line parallel between the lead edge and the tail edge of a
sheet? (see Figure 4) Figure 6
Y N
| Adjust the angle of the creaser by using the crease dial adjuster.
| (see SCC Instruction Manual, “6-11 Crease Angle”)
Is the crease position correct? (see Figure 5)
Y N
| Adjust the crease position.
| (see SCC Instruction Manual, “6-7 Crease Position”)
Is the crease depth correct? (see Figure 6)
Y N
| Adjust the crease depth using the crease depth dial.
| (see SCC Instruction Manual, “6-12 Crease Depth”)
End of the RAP.
If the crease position, stitching position and fold position do not match, see
Folding Position (RAP5.d).

RAP3.a SCC
RAP3.b Blade Trimming Knife
Did you replace the trimming knife after cutting specified number of
sheets?
Y N
Slitter Blade
| Is the upper or lower Trimming knife deformed or damaged?
Did you replace the slitter blades after cutting specified number of sheets? | Y N
Y N | | Is there dirt or any paper dust or foreign substance on the
| Is the upper blade or lower slitter blade deformed or damaged? | | upper blade or lower trimming knife?
| Y N | | Y N
| | Is there dirt or any paper dust or foreign substance on the | | | End of the RAP. The trimming knives work properly.
| | upper blade or lower slitter blade? | | Clean the upper and lower trimming knives.
| | Y N Grind or replace the upper and lower trimming knives (REP6.2).
| | | Is there enough oil on the felts of the slitter blades?
| | | Y N
| | | | Lubricate the felts.
| | | | (see Section 1, Preventive Maintenance of SCC)
| | | Is the angle of the upper slitter blades correct?
| | | Y N
| | | | Adjust the angle of the upper blade (ADJ3.11).
| | | End of the RAP. The slitter blades work properly.
| | Clean the upper blade and lower slitter blades.
Replace the upper and lower slitter blades (REP3.4).
Cutter Blade
Did you replace the cutter blade after cutting specified number of sheets?
Y N
| Is the upper blade or lower cutter blade deformed or damaged?
| Y N
| | Is there dirt or any paper dust or foreign substance on the
| | upper blade or lower cutter blade?
| | Y N
| | | Did you lubricate the cutter blade periodically?
| | | Y N
| | | | Lubricate the cutter blade.
| | | | (see Section 1, Preventive Maintenance of SCC)
| | | End of the RAP. The cutter blades work properly.
| | Clean the upper and lower cutter blades.
Replace the cutter blade. (see Exploded view of the Parts Catalog)

RAP3.b Blade
RAP5.a Paper Arrangement
Figure 1
Common Check 1
Does paper pass through the center of the paper path?
Y N
| Fine-tune the main body position.
| (see DBM-500 Instruction Manual, “9-1. Fine Adjustment Menu, Figure 2
| Other setting position fine adjustment screen”)

Go to Saddle Stitching or Side/Corner Stitching.
Saddle Stitching
Is the saddle stitching stopper parallel to the lead edge of a sheet?
(see Figure 1)
Y N
| Make the saddle stitching stopper parallel to the lead edge of a sheet
| (ADJ5.9).
Is the position of the saddle stitching stopper correct? (see Figure 2)
Y N
| Adjust the position of the saddle stitching stopper (ADJ5.7).
Go to Common Check 2.
Side/Corner Stitching
Is the side stitching stopper parallel to the lead edge of a sheet?
Y N
| Make the side stitching stopper parallel to the lead edge of a sheet
| (ADJ5.5).
Is the position of the side stitching stopper correct?
Y N
| Adjust the position of the side stitching stopper (ADJ5.6).
Is the position of the paper holder correct?
Y N
| Adjust the position of the side stitching guide.
| (see DBM-500 Instruction Manual,
| “9-5. Adjusting the Saddle Stitching Guide/Side Stitching Guide”)
Go to Common Check 2.

Common Check 2
Is the side jogger parallel to the lead edge of a sheet?
Y N Figure 3
| Make the side jogger parallel to the lead edge of a sheet
| (ADJ5.15,ADJ5.16).
Is the back jogger parallel to the tail edge of a sheet?
Y N
| Make the back jogger parallel to the tail edge of a sheet
| (ADJ5.10, ADJ5.11). Figure 4
Is the distance between the lead edge of a paper and the side joggers
appropriate? (see Figure 3)
Y N
| Fine-tune the distance in the Step Mode.
| “5-3. Settings, Adjustments using the step mode”)
Is the distance between the tail edge of a paper and the back joggers
appropriate? (see Figure 4)
Y N
End of the RAP.

RAP5.b Wire Length and Form
Find a similar symptom in Symptom and see Causes and Corrective Actions
to solve the problem.
A staple is not applied to the booklet. Symptom Causes and Corrective Actions
Is “E01” or “E02” displayed on the Control Panel? Different leg lengths • Different leg lengths—See Adjusting Leg Length (ADJ5.25).
Y N
| Is the staple stuck between the Feed Wheel and the Wire Tube?
| Y N
| | During the stitching process, is the Clamp on the Main Slide of the The back of the staple • Weak or soft wire—Use appropriate wire. (Spec)
| | Stitcher? is bent in a banana
• Wire not aligned—See Adjusting Wire Angle (ADJ5.23).
| | Y N shape.
| | | Adjust the position of the Clamp. • Circular or flat knife worn—Replace the circular knife and/or flat
knife (REP5.8).
| | | (see DBM-500 Instruction Manual,
| | | “7-2. Changing Size, Corner-stitching”) • Shoe tongue pressure too weak—Remove obstructing wire pieces
or replace pressure spring in shoe tongue.
| | Check that the following parts are properly attached to the Stitcher.
• The wire groove in the bender is soiled, worn or damaged—
| | • Former (REP5.5) Remove the bender, clean the bender groove or replace the bender
| | • Bender Stop (REP5.6) (REP5.7).
| | • Bender (REP5.7) The back of the staple is • Staples are not pressed sufficiently—Set stitching unit to stitch
| | • Knives (REP5.8) not securely positioned. thickness.
| Go to Others
See RAP5.8.
Stitch legs are not • Staples are not pressed sufficiently—Set stitching unit to stitch
sufficiently clinched. thickness.
• Clincher not coming up far enough—Adjust clincher lift pressure
on stitching unit (ADJ5.27).
The back of stitch is not • Staples are not sufficiently pressed—Set stitching unit to stitch
securely positioned and thickness.
is sagging in a saddle
shape. • Weak or soft wire—Use appropriate wire. (Spec)
• The Shoe tongue pressure too weak—See if something is
obstructing the action of the Shoe Tongue. Replace the bender
(REP5.7).
• Check function of the SpineMaster.
The staple legs are • Weak or soft wire—Use appropriate wire. (Spec)
buckled and are not
properly clinched. • Wire not aligned—See Adjusting Wire Angle (ADJ5.23).
• The Clincher box not aligned—See Aligning Stitcher and Clincher
Position (ADJ5.21), and Aligning Clincher Position (ADJ5.20).
• Overall wire piece too short—See Adjusting Wire Length
(ADJ5.24).
• The Circular or Flat Knife worn—Replace the Circular Knife
and/or Flat Knife (REP5.8).

RAP5.b Wire
Symptom Causes and Corrective Actions Symptom Causes and Corrective Actions
Wire is not penetrating, • Weak or soft wire—Use appropriate wire. (Spec) The legs are clinched • Wire not aligned—See Adjusting Wire Angle (ADJ5.23).
resulting in loop obliquely to the same
formation. • Wire out of the Bender Grooves—See Adjusting Wire Position side. • The Clincher not functioning—See if something is obstructing
(ADJ5.26). See if something is obstructing the Bender Grooves. the Clincher. See if the Clincher is damaged. See if the Clincher is
correctly mounted.
• The Circular or the Flat Knife worn—Replace the Circular Knife
• Wire out of the bender groove—Clean the bender groove, or
replace the bender (REP5.7).
• Shoe tongue pressure too weak—See if something is obstructing
the action of the Shoe Tongue. Replace the bender (REP5.7).
• The Clincher box not aligned—See Aligning Stitcher Position
(ADJ5.19), Aligning Clincher (ADJ5.20), and Stitcher and Clincher
Position (ADJ5.21).
The staple legs break • Bender Lock defective—Replace the Bender (REP5.7).
off.
• Wire too brittle—Use appropriate wire. (Spec)
• Former not functioning—See if something is obstructing the
Former (REP5.5).
• The Former defective—See if something is obstructing the action
of the Former (REP5.5).
• Wire thickness not suitable for the wire guiding parts (bender)—
Use appropriate wire. (Spec)
• The Former out of position—See if something is obstructing the
Former (ADJ5.26).
A hump is seen at a • Weak or soft wire—Use appropriate wire. (Spec)
corner.
• The Driver not functioning—See if the Driver is damaged.
• The Circular or Flat Knife worn—Replace the Circular Knife
The staple legs contract • Wire not aligned—See Adjusting Wire Angle (ADJ5.23).
or diverge.
• The Clincher box not aligned—See Aligning Stitcher Position
Position (ADJ5.21).
The leg ends are • Wire not aligned—See Adjusting Wire Angle (ADJ5.23).
clinched the wrong way
round. • The Clincher box not aligned—See Aligning Stitcher Position
Position (ADJ5.21).
One or both legs are • Weak or soft wire—Use appropriate wire. (Spec)
clinched obliquely.
• The Circular or the Flat Knife worn—Replace the Circular Knife
• The Clincher not functioning—See if something is obstructing
the Clincher. See if the Clincher is damaged. See if the Clincher is
correctly mounted.

RAP5.b Wire
Others
Symptom Causes and Corrective Actions
Straight wire pieces fall • The Leaf Spring on Former cover not functioning—See if the Leaf
out. Spring is correctly set. See if the Leaf Spring is damaged.
• The Former not functioning—See if the Former is correctly set.
See if something is obstructing the Former. See if the Former is
damaged.
Lightly bent wire pieces • Wire not aligned—See Adjusting Wire Angle (ADJ5.23).
fall out.
• Bender defective—Replace the Bender (REP5.7).
• The Bender not functioning—See if something is obstructing the
Bender. See if the Bender is damaged.
Wire loops are between • Wire not aligned—See Adjusting Wire Angle (ADJ5.23).
the wheels and wire
guidance tube. • The Circular Knife not functioning—See if the Circular Knife can
move. See if something is obstructing the Circular Knife. See if the
Circular or Flat Knife is damaged.
• The Wire Return Rock not functioning—See if something is
obstructing the Wire Return Rock. See if the Wire Return Rock is
damaged.
• The lower wire tube in the cutting block out of position—See if
the lower wire tube is correctly set.
• The Former not functioning—See if the Former is correctly set.
See if something is obstructing the Former. See if the Former is
damaged.

RAP5.b Wire
RAP5.c Folding Skew
Is only the folding position skewed? (see Figure 1) Figure 1

Y N
| If both the crease and folding positions are skewed, adjust the crease
| position first. (Go to RAP3.a SCC)
Is the folding guide parallel to the edge of a sheet?
Y N
| Make the folding side guide parallel to the edge of a sheet (ADJ5.32).
Is the block parallel to the tail edge of a sheet?
Y N
| Make the block parallel to the tail edge of a sheet (ADJ5.35).
Are the stitches positioned inside the stitching prohibited area?
Y N
| Change the stitching pitch so that the stitches are out of the stitching
| prohibited area.
| (see DBM-500 Instruction Manual, “5-2. Operations,
| Stitch prohibited area”).
Is the folding stopper parallel to the edge of a sheet? (see Figure 1)
Y N
| Make the folding stopper and the edge of a sheet parallel using the
| folding stopper adjustment dial.
| “6-4. Checking the Finished Set, When folded skewed /
| 8-4. Checking the Finished Set, When folding deviates skewed”)
Is the distance between the edge of a sheet and the folding side guide
appropriate?
Y N
Is the distance between the tail edge of a sheet and the folding back guide
appropriate?
Y N
The skew of the fold is appropriate.

RAP5.c Folding Skew
RAP5.d Folding Position
Is the crease position correct? (see Figure 1) Figure 1

Y N
| Adjust the crease position. (Go to RAP3.a SCC)
Do the stitching position and folding position match? (see Figure 2)
Y N
| Is the stitch position appropriate? (see Figure 3) Figure 2
| Y N
| | Match the stitching position with the crease position.
| | (see DBM-500 Instruction Manual, “9-1. Fine Adjustment Menu,
| | Stitching position fine adjustment screen”)
| Match the folding position with the crease and stitching positions.
Figure 3
| (see DBM-500 Instruction Manual, “9-1. Fine Adjustment Menu,
| Folding position fine adjustment screen”)
Match the crease position with the stitching and folding positions.
(see DBM-500 Instruction Manual,
“9-1. Fine Adjustment Menu, Stitching/folding fine adjustment screen”)

RAP5.d Folding Position
RAP6.a Trimming Skew
When trimming, does the paper come under the Stopper?

Y N
| Does the paper touch the stopper completely?
| Y N
| | When you set the conveyance belt driving time longer on the
| | accessory menu, is the skew adjusted?
| | (see DBM-500 Instruction Manual,
| | “9-3. Accessory Menus, Trimmer Settings 2”)
| | Y N
| | | Widen the gap between the Conveyance Rollers on the Accessory
| | | Menu (see DBM-500 Instruction Manual,
| | | “9-3. Accessory Menus, Trimmer Settings 2”).
| | End of the RAP.
| Adjust the angle of the stopper. (ADJ6.5)
Adjust the position of the stopper. (ADJ6.6)

RAP6.a Trimming Skew
RAP6.b Trimming Position
After the booklet is trimmed, is the only front cover longer than other
L L L
sheets?
Y N
| When trimming, does the paper come under the Stopper?
| Y N
| | Does the paper touch the stopper completely?
| | Y N
| | | After lengthening the driving time of the conveyance belt on
| | | the Accessory Menu, is the problem solved?
| | | (see DBM-500 Instruction Manual,
| | | “9-3. Accessory Menus, Trimmer Settings 2”)
| | | Y N
| | | | Widen the gap between the Conveyance Rollers on the
| | | | Accessory Menu.
| | | | (see DBM-500 Instruction Manual,
| | | | “9-3. Accessory Menus, Trimmer Settings 2”)
| | | End of the RAP.
| | Is the position of the size change unit appropriate?
| | Y N
| | | Adjust the position of the size change unit. (ADJ6.3)
| | Adjust the trimming on the Trimmer Setting 1 screen of the
| | accessory menu. (see DBM-500 Instruction Manual,
| | “9-3. Accessory Menus, Trimmer Settings 1”)
| Adjust the position of the stopper. (ADJ6.6)
After shortening the driving time of the conveyance belt on the Accessory
Menu, is the problem solved? (see DBM-500 Instruction Manual,
“9-3. Accessory Menus, Trimmer Settings 2”)
Y N
| Adjust the infeed roller unit.
| (see DBM-500T Instruction Manual,
| “9-2. If a booklet finishes with the cover wider than inner sheets”)
End of the RAP.

RAP6.b Trimming Position
RAP8.a Spine
Spine Forming
Correct:
This is how a well formed spine should look.
Incorrect:
The spine has not been formed sufficiently.
Increase the Book Thickness Adjustment

and/or use Double Pass Mode.
SCC Crease Setting:

Try Crease all sheets.
Incorrect:
The spine has been over-formed resulting in
damage or creasing on the cover.
Decrease the Book Thickness Adjustment

and/or use Single Pass Mode.
SCC Crease Setting:

Try Crease Cover and Inner.
Inspect formed booklets and adjust the ‘Book Thickness Adjustment’

control (ADJ8.10) and/or the ‘Operating Mode’ control as required
(ADJ8.11).
If the spine is well formed at only one end of the booklet, Double Pass Mode
should be used. Some stocks may require Double Pass Mode to achieve an
even result.
If booklet spines are being formed unevenly, check that the Stop is parallel
with the Clamp, and that the minimum depth is correctly set (ADJ8.7).

RAP8a Spine
Thin Booklet
The specified booklet thickness for the SpineMaster is a minimum of 1 mm
(0.04 inch) and a maximum of 6.5 mm (0.25 inch). This is approximately 30
sheets of 80gsm (20# bond) folded into a 120 page booklet.
When operating with thin booklets always question whether the use of
Square-Backing is of any benefit to the finished product. Thin booklets are
flexible and have a tendency to curl upwards at the spine, (the larger the
booklet height and width, the worse the problem). Occasionally they can
‘collapse’ on the Clamp Stop, forcing the spine between the edge of the Stop
and the Anvil Clamp.
Remedial Action
If the customer reports this problem, ascertain whether the booklets are
within the machine specifications. If not, it is recommended that they are
not square-backed.
If within specifications, turn the booklet so that the ‘curl’ faces the Bolster
Clamp rather than the Anvil Clamp - it is not possible for the booklet to drop
below the edge of the Stop on this side. However, when running online with
a digital printer, this would mean inserting the booklets by hand after they
have been made.
Set the ‘Book Thickness Adjustment’ control to the lowest setting. This
control alters the height of the Stop (the higher the setting the lower the
Stop, opening more of a gap between the Stop and the Anvil). If the problem
persists on minimum setting, adjust the Stop (ADJ8.7).
If the Stop oscillates excessively, there is a risk that the following booklet
may fall down between the edge of the Stop and the Anvil. To prevent this
adjust the Stop damping (ADJ8.8).

RAP8a Spine
Damaged booklet
If booklets are damaged, check their condition before processing through
the SpineMaster, i.e. are they clean, correctly cut, well stitched etc.
If the damage is occuring during processing, take the following remedial

action:
Dirty marks on spine:

● Clean carriage.
● Check stitch heads are not over lubricated.
● Check ink is dry and toner properly fused.
Dirty marks on cover:

● Check/clean belts. Use cloth dampened with soapy water or alcohol
(iso-propanol). DO NOT use blanket wash.
● Check ink is dry and toner properly fused.
Damage/marks near spine:

● Bolster/anvil damaged (ADJ8.9).
Torn Spine:
● Check the damage is not caused by poor trimming.
● Booklet is over-formed (see Spine Forming).
Creasing on spine:
● Booklet is over-formed (see Spine Forming).

RAP8a Spine
Poor Stacking 3. Very Thin booklets
Stack flat (as Bypass Mode) and do not allow the Stacker to become too full.
Booklets are stacked, spine uppermost, in the stacker. The stacker support
automatically recedes to accommodate the increasing stack.
4. Thick Booklets
Check the Control Springs are not in use (see 1. Small Booklets).
If the booklets do not stack tidily, advise the operator to take the following
remedial action:
1. Small Booklets
The booklet control springs should be used. Open the front cover of
the SpineMaster and release the two springs by pulling them out from
underneath the shaft. When the springs are not required, they should be
tucked back under the shaft.
Shaft
Spring
Booklet Control Springs
2. Bypass Mode
The booklets bypass the SquareBacking process and will be delivered
straight to the stacker, where they may stack better lying flat. Slide the
stacker support away from the outfeed, taking care not to trigger the
stacker full sensor.
Stacker Support
Stacker Release Lever
Stacker Full Sensor
Stacker

RAP8a Spine
Section 4
Replacement and Adjustment
Contents
REP1 and ADJ1 Interface Box Section 4 Replacement and Adjustment ......................4-1 REP3.20 Side Jogger 2 Motor (M307) ............... 4-33
REP1.1 Precautions on Replacing the REP3.21 Back Jogger Motor (M308).................. 4-34
REP2 and ADJ2 TR-DP
Interface Unit ......................................... 4-4 REP3.22 Back Jogger Solenoid (SL304) ........... 4-38
REP3 and ADJ3 SCC REP1.2 Exterior Cover ....................................... 4-4 REP3.23 Main Body Motor (M310) ..................... 4-39
REP2.1 Exterior Covers ...................................... 4-5 REP3.24 Delivery Sensor (PS307) ..................... 4-40
REP4 and ADJ4 DCM Kit
REP2.2 MC Unit .................................................. 4-5 REP3.25 Cutter Front Sensor (PS311) ............... 4-42
REP5 and ADJ5 DBM-500 REP2.3 Power Supply Unit ................................. 4-6 REP3.26 Power Switch Unit ............................... 4-43
REP2.4 RM Unit .................................................. 4-6 REP3.27 Center Conveyance Belt...................... 4-44
REP6 and ADJ6 DBM-500T
REP2.5 Conveyance Motor .................................4-7 REP3.28 Bypass Conveyance Belt..................... 4-47
REP7 and ADJ7 DBM-LS1/DBM-K REP2.6 Interlock Switch ......................................4-7 REP3.29 Entrance Sensor (PS305) ................... 4-50
REP2.7 Paper Jam Sensor ................................. 4-8 ADJ3.1 Main Body Position .............................. 4-52
REP8 and ADJ8 SpineMaster
ADJ2.1 Paper Path ............................................. 4-9 ADJ3.2 Belt Tension on Conveyer Motor 1 ...... 4-53
REP3.1 MC Unit (PCB301) ................................4-10 ADJ3.3 Adjusting the Flap Solenoid ................. 4-53
REP3.2 EEPROM .............................................. 4-11 ADJ3.4 Stopper Solenoid ................................. 4-54
REP3.3 Switching Power Supply (PCB304) ......4-12 ADJ3.5 Back Jogger......................................... 4-55
REP3.5 OP Unit (PCB302) ................................4-13 ADJ3.6 Side Joggers........................................ 4-56
REP3.6 Servo Motor Control Unit (PCB303).....4-13 ADJ3.7 Adjusting the Idle Roller Solenoid ....... 4-57
REP3.7 Slitter Upper Blades .............................4-14 ADJ3.8 Slitters.................................................. 4-58
REP3.8 Slitter Lower Blade ...............................4-16 ADJ3.9 Belt Tension of Slitter Motor ................ 4-59
REP3.9 Cutter Unit ............................................4-21 ADJ3.10 Belt Tension of Servo Motor ................ 4-60
REP3.10 Creaser Unit .........................................4-24 ADJ3.11 Upper Blade Angle .............................. 4-61
REP3.11 Exterior Covers .....................................4-27 ADJ3.12 Slitter Cover Sensor ............................ 4-62
REP3.12 Clutch (CL301)......................................4-27 ADJ3.13 Cutter ................................................... 4-63
REP3.13 Conveyer Motor 1 (M301) ....................4-28 ADJ3.14 Creaser ................................................ 4-64
REP3.14 Conveyer Motor 2 (M302) ...................4-28 ADJ3.15 Belt Tension of Creaser Motor ............. 4-64
REP3.15 Servo Motor (M303) ............................ 4-29 ADJ3.16 Post-creaser Transport ........................ 4-65
REP3.16 Flap Solenoid (SL301) ..........................4-31 ADJ3.17 Top Cover Sensors .............................. 4-66
REP3.17 Stopper Solenoid (SL302) ....................4-31 REP4.1 Exterior Cover ..................................... 4-67
REP3.18 Idler Roller Solenoid (SL303) .............. 4-32 REP4.2 Static Eliminator................................... 4-68
REP3.19 Side Jogger 1 Motor (M306) ............... 4-32 REP5.1 MC Unit (PCB501) ............................... 4-69
4-1
iGen3-M12D0-0612-0
REP5.2 Sensors ................................................4-70 REP5.41 Base Moving Motor (M513) ................ 4-114
REP5.3 Stitcher Head ........................................4-71 REP5.42 Infeed Section..................................... 4-115 ADJ5.36 Solenoid Position of
REP5.4 Removing Wire .....................................4-71 REP5.43 Folding Side Guide Unit...................... 4-117 Folding Back Guide ............................4-149
REP5.5 Former ..................................................4-72 REP5.44 Transport Belts ................................... 4-119 ADJ5.37 Block Position of
REP5.6 Bender Stop ..........................................4-72 ADJ5.1 Sensors ..............................................4-126 Folding Back Guide ............................4-149
REP5.7 Bender ..................................................4-73 ADJ5.2 Home Positions of Main Body ............4-126 ADJ5.38 Folding Stopper ..................................4-150
REP5.8 Knives ...................................................4-74 ADJ5.3 Chain Tension .....................................4-127 ADJ5.39 Lift Action ............................................4-150
REP5.9 Clincher ................................................4-76 ADJ5.4 Conveyance Belt Tension ...................4-127 ADJ5.40 Side Stitch Ejection Roller .................. 4-151
REP5.10 Fold Roller/Press Roller .......................4-77 ADJ5.5 Aligning the Side Stitching Stopper ....4-128 ADJ5.41 Stacker Full Sensor ............................ 4-151
REP5.11 Exterior Covers .................................... 4-83 ADJ5.6 Positions of Side Stitching Stopper ....4-128 ADJ5.42 Blade Position.....................................4-152
REP5.12 Switching Power Supply (PCB504) ..... 4-85 ADJ5.7 Solenoid Position of ADJ5.43 Folding Rollers ....................................4-153
REP5.13 Relay Board (PCB503) ........................ 4-85 Saddle Stitching Stopper ....................4-129 ADJ5.44 Press Rollers ......................................4-154
REP5.14 Control Panel ......................................... 4-86 ADJ5.8 Belt Tension of ADJ5.45 Press Roller Adjusters ........................4-155
REP5.15 Inverter ................................................ 4-86 Saddle Stitching Stopper ....................4-129 ADJ5.46 Top Cover Switches............................4-155
REP5.16 Main Drive Motor (M514) ..................... 4-87 ADJ5.9 Stopper Angle ....................................4-130 ADJ5.47 Main Drive System .............................4-156
REP5.17 Jog Unit Moving Motor (M501) ............ 4-87 ADJ5.10 Aligning the Back Joggers ..................4-130 ADJ5.48 Side Jogger Brake ..............................4-157
REP5.18 Back Jog Moving Motor (M502) .......... 4-88 ADJ5.11 Aligning the Back Jog Unit ................. 4-131 ADJ5.49 Stitching Brake/Stitching Clutch .........4-157
REP5.19 Jog Belt Drive Motor (M503) ............... 4-89 ADJ5.12 Timing Belt Tension ............................ 4-131 ADJ5.50 Folding Brake/Folding Clutch .............4-158
REP5.20 Side Jogger Unit .................................. 4-90 ADJ5.13 Drive Belt Tension ..............................4-132 REP6.1 MC Unit (PCB601) ..............................4-159
REP5.21 Side Jog Moving Motor (M504) ........... 4-92 ADJ5.14 Conveyance Belt Tension ...................4-132 REP6.2 Upper/Lower Blade.............................4-161
REP5.22 Side Jogger Brake (BRK501) .............. 4-92 ADJ5.15 Aligning the Side Joggers...................4-133 REP6.3 Exterior Covers ...................................4-167
REP5.23 Saddle Stop Moving Motor (M505) ..... 4-93 ADJ5.16 Aligning Middle Guides.......................4-133 REP6.4 Guide Plate of Waste Bin....................4-167
REP5.24 Saddle Stitch Stop Solenoid (SL501) .. 4-93 ADJ5.17 Side Jogger Drive ...............................4-134 REP6.5 Switching Power Supply (PCB603) ....4-168
REP5.25 Stitch Delivery 1 Solenoid (SL503) ..... 4-94 ADJ5.18 Adjusting Stitchers ..............................4-135 REP6.6 Relay Board (PCB604) .......................4-168
REP5.26 Stitch Delivery2 Solenoid (SL504) ...... 4-94 ADJ5.19 Aligning Stitcher Position....................4-138 REP6.7 Control Panel ......................................4-169
REP5.27 Stitcher Moving Motor (M506) ............. 4-95 ADJ5.20 Aligning Clincher Position...................4-138 REP6.8 Main Motor (M601) ............................. 4-170
REP5.28 Jogger Unit .......................................... 4-96 ADJ5.21 Stitcher and Clincher Positions ..........4-139 REP6.9 Conveyance Motor (M602) ................. 4-171
REP5.29 Back Stop Moving Motor (M507) ......... 4-98 ADJ5.22 Home Position of Stitcher ...................4-139 REP6.10 Upper Blade Clutch/Brake (CL/BRK). 4-172
REP5.30 Back Stopper Solenoid (SL505) .......... 4-98 ADJ5.23 Wire Angle ..........................................4-140 REP6.11 Conveyance Clutch (CL601) .............. 4-175
REP5.31 Folding Stop Moving Motor (M508) ..... 4-99 ADJ5.24 Wire Length ........................................ 4-141 REP6.12 Delivery Clutch (CL602) ..................... 4-176
REP5.32 Non-fold Delivery Motor Unit ..............4-100 ADJ5.25 Leg Length ..........................................4-142 REP6.13 Stopper Solenoid (SL601) ..................4-177
REP5.33 Folding Side Guide Motor (M510) ......4-100 ADJ5.26 Wire Position ......................................4-143 REP6.14 Flap Solenoid (SL602)........................ 4-178
REP5.34 Fold Delivery Clutch (CL501) .............4-101 ADJ5.27 Wire Clinch .........................................4-143 ADJ6.1 Conveyance Gap Unit ........................4-180
REP5.35 Side Stitch Delivery Solenoid ADJ5.28 Bender Stop ........................................4-144 ADJ6.2 Waste Gate .........................................4-180
(SL506) ...............................................4-103 ADJ5.29 Disc Knife ...........................................4-144 ADJ6.3 Position of the Size Change Unit ........ 4-181
REP5.36 Stitching Clutch (CL502) ....................4-104 ADJ5.30 Eject Roller 1 ......................................4-145 ADJ6.4 Move Motor (M604) ............................ 4-181
REP5.37 Stitching Brake (BRK502) ..................4-107 ADJ5.31 Eject Roller 2 ......................................4-145 ADJ6.5 Trimming Positions .............................4-182
REP5.38 Folding Clutch (CL503)/ ADJ5.32 Aligning the Folding Side Guides .......4-146 ADJ6.6 Stopper Solenoid (SL601) ..................4-182
Folding Brake (BRK503) ....................4-108 ADJ5.33 Folding Guide Drive ............................ 4-147 ADJ6.7 Timing of Press Bar ............................4-183
REP5.39 Fold Rollers Gap 1 Motor (M511) ....... 4-113 ADJ5.34 Belt Tension of Folding Back Guide ...4-148 ADJ6.8 Height of Press Bar ............................4-184
REP5.40 Fold Rollers Gap 2 Motor (M512) ....... 4-113 ADJ5.35 Aligning Blocks of ADJ6.9 Lower Blade Position ..........................4-185
Folding Back Guide ............................4-148 ADJ6.10 Home Position of Cutter Blade ...........4-186
4-2
ADJ6.11 Uppermost Position ............................4-186
ADJ6.12 Chain Tension .....................................4-187 ADJ8.1 Adjusting the
ADJ6.13 V Belt ..................................................4-187 Transverse Chain Tension ................. 4-225
ADJ6.14 Belt Tension of Paper Feed ................4-188 ADJ8.2 Adjusting LH & RH Limit Sensors...... 4-226
ADJ6.15 Clutches ..............................................4-189 ADJ8.3 Adjusting the Clamp Open Sensor .... 4-228
ADJ6.16 Top Cover Switch ...............................4-189 ADJ8.4 Adjusting Clamp Optical Sensor........ 4-229
REP7.1 DBM-LS1—Bottom cover ...................4-190 ADJ8.5 Adjusting the Clutch Control Collar ... 4-230
REP7.2 DBM-LS1—Stacker motor..................4-191 ADJ8.6 Setting the Solenoid ...........................4-231
REP7.3 DBM-K—Exterior cover .....................4-192 ADJ8.7 Adjusting the Stop ............................. 4-232
REP7.4 DBM-K—Kicker solenoid ...................4-192 ADJ8.8 Adjusting the Stop Damping .............. 4-233
ADJ7.1 DBM-LS1—Chain tension ..................4-193 ADJ8.9 De-burring the Bolster ....................... 4-234
ADJ7.2 DBM-K—Solenoid position ................4-193 ADJ8.10 Book Thickness Adjustment .............. 4-235
8.0a Introduction (for REP8 & ADJ8) .........4-194 ADJ8.11 Operating Modes ............................... 4-236
8.0b Clearing a Paper Jam .........................4-195
8.0c Freeing a Carriage Roller Jam ...........4-196
8.0d Removing Components ......................4-197
REP8.1 Replacing the Holding Magnet ...........4-199
REP8.2 Replacing the Power Interface PCB .. 4-200
REP8.3 Replacing the Transformer .................4-201
REP8.4 Replacing the
Carriage Motor Ballast Resistor ........ 4-202
REP8.5 Replacing the Cam Links................... 4-203
Transverse Drive Chain ..................... 4-204
REP8.7 Replacing the Main Drive Chain and
the Drive Transfer Chain.................... 4-205
REP8.8 Replacing the Final Drive Chain ........ 4-206
REP8.9 Replacing the Clutch Sprockets and/or
Intermediate Drive Sprocket ...............4-207
Main Drive Motor Sprocket ................ 4-208
REP8.11 Replacing the Final Drive Sprocket ... 4-209
REP8.12 Replacing the 24V Motor ....................4-210
REP8.13 Replacing the Cooling Fan ................. 4-211
REP8.14 Replacing the Clutch ..........................4-212
REP8.15 Replacing the Clutch Solenoid ...........4-213
REP8.16 Replacing the Drive Motor ..................4-214
REP8.17 Replacing the Bolster and/or
Anvil Clamp Bar ..................................4-215
REP8.18 Replacing the Stop Assembly ........... 4-220
REP8.19 Replacing the Upper Infeed Sensor ...4-221
REP8.20 Replacing the Clamp Optical Sensor 4-222
4-3
Interface Box
REP1.1 Precautions on Replacing the Interface REP1.2 Exterior Cover
Unit
WARNING
CAUTION Disconnect the power cord before removing an exterior cover. The
Even if the power is turned OFF, various settings will be registered in the Switching Power Supply can cause a shock if touched.
EEPROM (nonvolatile memory) in the interface unit (board). [U08] (See the
figure below.) 1. Remove the screws to remove the exterior cover.
To transfer these settings directly, remove the EEPROM from the current
interface unit board and install it in the new interface unit board after
replacement.
Interface unit
Exterior cover
U18 U19
DSW1
U08
U05
U07
4-4 Section 4—Replacement and Adjustment Interface Box

REP1.1 Precautions on Replacing the Interface Unit
TR-DP
REP2.1 Exterior Covers REP2.2 MC Unit
1. Remove the Cover F (REP2.1).

WARNING 2. Remove the connector and screws on the MC Unit to replace the unit.
Switching Power Supply and Relay Board can cause a shock if touched.
1. Remove the Cable Cover 1 and Cable Cover 2.
Cable cover 1
Screw Screw
Cable cover 2
2. Remove the screw, and detach the exterior covers.

Cover B
MC unit
When you attach the parts removed in the above steps, follow the reverse
procedures.
Cover R
Cover F
procedures.
4-5 Section 4—Replacement and Adjustment TR-DP

REP2.1, REP2.2
TR-DP
REP2.3 Power Supply Unit REP2.4 RM Unit
1. Remove the Cover R (REP2.1). 1. Remove the Cover R (REP2.1).

2. Remove the connector and screw on the Power Supply Unit to replace 2. Remove the connector on the RM Unit.
the unit. 3. Remove the screw and Cable Cover.
Screw
4. Replace the RM Unit.
RM Unit
Screw
Cable cover
Power Supply Unit

Screw
When you attach the parts removed in the above steps, follow the reverse When you attach the parts removed in the above steps, follow the reverse
procedures. procedures.

REP2.3, REP2.4
TR-DP
REP2.5 Conveyance Motor REP2.6 Interlock Switch
1. Remove the Cover B and Cover R (REP2.1). 1. Remove the Cover F (REP2.1).
2. Loosen the nuts to remove the belt. 2. Remove the connector and screws to replace the Interlock Switch.
3. Replace the connector, nuts, and screws to replace the Conveyance Interlock Switch
Motor.
Conveyance Motor
Nut
Screw
Connector
Nut Belt procedures.
4. Temporarily tighten the nuts and attach the belt.
5. Stretch the belt using the motor’s weight and tighten the nuts.
procedures.

REP2.5, REP2.6
TR-DP
REP2.7 Paper Jam Sensor Light emitting side
1. Remove the screw A or B and loosen the other one, then turn the Plate.
Note: Do not remove both screws. If you remove the screws A and B, there will
Light receiving side be a gap between the bracket for the sensor and the machine, and the screw will
not be properly inserted into the bracket when you put back the plate. If you have
1. Remove the Cover R (REP2.1). removed both screws, insert the stick such as a screwdriver into the detection hole
2. Remove the connector and screw to replace the Paper Jam Sensor (light of the conveyance section and screw down the plate holding down the bracket
receiving side). with the stick.
Paper Jam Sensor Screw Plate
Screw B
Screw A
SCC side
2. Remove the connector and screw to replace the Paper Jam Sensor (light
Connector
emitting side).
Paper Jam Sensor (LED)
procedures.
Screw
SCC side Connector
procedures.

REP2.7
TR-DP
ADJ2.1 Paper Path
You can adjust the height of the paper entrance:

1. Remove the Cover F and Cover B (REP2.1). Feed roller unit
2. Loosen the four screws on the Feed Roller Unit.
Idle roller unit
Feed roller unit
Feed roller unit
3. Adjust the position of the Feed Roller Unit. Idle roller unit
4. If you cannot move the Feed Roller Unit because of the Idle Roller Unit,
remove the Idle Roller Unit. And mount the Idle Roller Unit below the
MC unit
Feed Roller Unit.
Note: Located here under the Feed Roller Unit, the Idle Roller Unit does not help
transfer paper at all. This place is, as it were, the storage of the Idle Roller Unit.
5. Make sure both sides of the Feed Roller Unit are at the same height.
Tighten the four screws on the Feed Roller Unit.
procedures.

ADJ2.1
SCC
REP3.1 MC Unit (PCB301) 1. If possible, view Adjustment 1 and Adjustment 2 of the User Mode
and Fine Adjustment in the Maintenance Mode and take notes.
MC Unit and EEPROM 3. Remove the Cover L (REP3.11).
4. Replace the MC Unit (PCB301).
The user settings (Adjustment 1 and Adjustment 2) and initial
settings (GP2.3, Conducting Fine-adjustment) are saved in the EEPROM on 5. Remove the EEPROM from the old MC Unit (PCB301). The EEPROM is
the MC Unit (PCB301). When replacing the MC Unit (PCB301), you should on U38. Attach the EEPROM to the new MC Unit (PCB301).
remove the EEPROM from the old MC Unit (PCB301) and attach it on the 6. Turn on the Remote Switch.
new MC Unit (PCB301) if possible. Or, you should take notes and keep a 7. View Adjustment 1 and Adjustment 2 of the User Mode and Fine
record of these settings before replacing the MC Unit (PCB301) if possible. Adjustment in the Maintenance Mode to check the settings are intact.
Note, however, that you do not have to keep a record of the settings in When the settings are correct, go to step 8. If the settings are not
Adjustment 1 or Adjustment 2 when FineAdjust Value is set to correct, go to step 7.
Not Save (GP2.3, Saving or Not Saving Adjustment).
8. Specify the settings manually.
9. Push the Escape Button several times until you go back to the Initial
How to Replace MC Unit
Screen.
Note that you do not have to keep a record of the settings in Adjustment When you put back the removed parts, follow the reverse procedures.
1 or Adjustment 2 when FineAdjust Value is set to Not Save (GP2.3,
Saving or Not Saving Adjustment). Checking Settings
To check you have made correct settings, follow these steps:
1. Turn off the Remote Switch. Wait for about ten seconds.
2. Turn on the Remote Switch.
3. View Adjustment 1 and Adjustment 2 of the User Mode and
U38
Fine Adjustment in the Maintenance Mode to check the settings are
correct. If they are not correct, it is possible that the EEPROM or the
MC Unit (PCB301) is defective.
4. Push the Escape Button several times until you go back to the normal
operation mode.
4-10 Section 4—Replacement and Adjustment SCC

REP3.1
SCC
REP3.2 EEPROM 1. If possible, view Adjustment 1 and Adjustment 2 of the User Mode
and Fine Adjustment in the Maintenance Mode and take notes.
Define EEPROM 3. Remove the Cover L (REP3.11).
4. Replace the EEPROM in U38 on the MC Unit (PCB301).
The user settings (Adjustment 1 and Adjustment 2) and initial
settings (GP2.3, Conducting Fine-adjustment) are saved in the EEPROM 5. Turn on the Remote Switch.
on the MC Unit (PCB301). Before replacing the EEPROM, you should take 6. See your notes and specify the settings manually. (If you could not take
notes and keep a record of these settings if possible. When you cannot take notes, you must check the operations of SCC and adjust these settings.)
notes, you must adjust these settings after replacing the EEPROM. Note, 7. Push the Escape Button several times until you go back to the Initial
however, that you do not have to adjust the settings in Adjustment 1 or Screen.
Adjustment 2 when FineAdjust Value is set to Not Save (GP2.3,
Saving or Not Saving Adjustment).
How to Replace EEPROM 10. View Adjustment 1 and Adjustment 2 of the User Mode and
Fine Adjustment in the Maintenance Mode to check the settings are
Note that you do not have to keep a record of the settings in Adjustment correct. If they are not correct, it is possible that the EEPROM or the
1 or Adjustment 2 when FineAdjust Value is set to Not Save (GP2.3, MC Unit (PCB301) is defective.
Saving or Not Saving Adjustment). When you put back the removed parts, follow the reverse procedures.
U38

REP3.2
SCC
REP3.3 Switching Power Supply (PCB304) REP3.4 Relay Board (PCB305)
Replacement Procedure Replacement Procedure

1. Remove the Cover L (REP3.11). 1. Remove the Cover L (REP3.11).
2. Disconnect all the connectors on the Switching Power Supply (PCB304). 2. Disconnect all the connectors on the Relay Board (PCB305).
3. Remove the four screws securing the Switching Power Supply (PCB304) 3. Remove the four screws to remove the Relay Board (PCB305) together
to the machine. with the collars.
Switching Power Supply
Note: The collars are attached to the both sides of the Relay Board (PCB305).
Relay Board
Collar
Collar
When you put back the removed parts, follow the reverse procedures.

REP3.3, REP3.4
SCC
REP3.5 OP Unit (PCB302) REP3.6 Servo Motor Control Unit (PCB303)

1. Remove the Cover R (REP3.11). 1. Remove the Cover L (REP3.11).
2. Remove the screw and cable clamp. 2. Disconnect all the connectors on the Servo Motor Control Unit
3. Disconnect the connector. (PCB303).
4. Remove the four screws securing the OP Unit.(PCB302) 3. Remove the four screws securing the Servo Motor Control Unit
OP Unit (PCB303) to the machine.
Cable Clamp
Connector
Servo Motor Control Unit

REP3.5, REP3.6
SCC
REP3.7 Slitter Upper Blades Replacement Procedure
1. Turn off the Main Power Switch.
2. Open the Top Cover.
3. Turn the shaft by hand to the direction of the arrow and move the two
Upper Blades to the center.
Slitter Upper Blade Block
The Upper Blades and Lower Blades can cut 1,500,000 sheets of paper (in
the quality of 64g/m 2). To replace Upper Blades, you do not have to remove
the Slitters from SCC. See Replacing Upper Blade. To replace Lower
Blades, you have to remove the Slitters from SCC.
Note: The Slitters include multiple parts; some of them are very small. To make
locating dropped parts easier, you should empty the Scrap Box—or remove the
Scrap Box out of SCC—before you remove any parts of Slitters.
Cover
Shaft screw
Spring Cover
4. Remove the screw securing the Cover.
Felt Spring
Plate
Felt
Cover
Screw
Upper Blade
Washer
Boss
Upper Blade
Spring
Shaft

REP3.7
SCC
5. Remove the screw securing the plate. 7. Hold down the gear attached to the Upper Blade with a longnose pliers
Note: The spring will be removed together with the Spring Cover. and pull out the shaft from the gear.
Note: The washer will be removed together with the shaft.
8. Remove the two screws securing the blade and take out the Blade.
Shaft Upper Blade
Washer
Felt Spring Spring Cover
6. Remove the two screws securing the plate. Blade
Note: The spring will be removed together with the plate.
When you put back the removed parts, follow the reverse procedures and
adjust the following part.
• Upper Blade Angle (ADJ3.11)
Spring
Plate

REP3.7
SCC
REP3.8 Slitter Lower Blade 6. Remove the two screws on the bottom of the machine to remove the
bracket.
Screw
Replacement Procedure
2. Take out the Scrap Box.
3. Remove the Cover R and Cover L (REP3.11).
4. Loosen the FR screw on the R side to remove the collar.
Bottom Side Screw Bracket

Collar
7. Loosen the screw on the L side, then remove the belt.
Screw Bracket
R side
5. Remove the one screw on the R side.

Belt
Screw

REP3.8
SCC
8. Remove the two screws securing the Roller Unit to the machine. 10. Loosen the screw and remove the belt and pulley.
Roller Unit
Screw
Belt (short) Belt
11. Loosen the FR screw to remove the pulley.

9. Remove the two screws and bracket.
Bracket
Belt
Pulley

REP3.8
SCC
14. Remove the two screws and pull out the Slitter Unit upward.
12. Remove the two screws, holder and shaft.
Note: Rotating the Slitter Unit 90 degrees will make it easier for you to remove
the Slitter Unit.
Screw
Screw
Screw
Shaft
Holder
Slitter Unit
13. Remove the two screws, plate and shaft.

15. Remove the nine screws and plate.
Note : The bearing and roller unit will be removed together with the plate.
Bearing Plate
Screw Screw
Plate Bearing
Bearing
Screw
Roller Unit
Screw

REP3.8
SCC
18. Remove the screw and pulley.
16. Remove the screw from the opposite plate, then remove the shaft.
Remove the other screw and bracket unit.
Bracket Unit
Screw
Pulley
Shaft
19. Remove the two screws.

17. Remove the two screws securing the Guide.
Guide
Screw
Key 4-12
Screw

REP3.8
SCC
20. Remove the three screws, then remove the plate securing the bearing. 22. Remove the two screws securing the Lower Blade.
Lower Blade
Plate
Screw
Blade
21. Remove the bearing and pull out the shaft.

adjust the following parts.
• Slitters (ADJ3.8)
Bearing
• Belt Tension of Slitter Motor (ADJ3.9)
• Belt Tension of Servo Motor (ADJ3.10)
• Upper Blade Angle (ADJ3.11)
Shaft

REP3.8
SCC
REP3.9 Cutter Unit 5. Remove the two screws on the inside of the frame of each side.
Screw
Screw
6. Remove the two screws from the bottom of the machine to remove the
Replacement Procedure bracket.
1. Remove the Cover R (REP3.11).
2. Remove the Scrap Box.
3. Remove the two cable clamps.
4. Disconnect the two motor connectors.
Cable clamp
Cable clamp
Connector Bottom Side Bracket
7. Remove the three screws from the bottom of the machine to remove the
bracket.
Connector
Bracket

REP3.9
SCC
8. Remove the two screws from the bottom of the machine to remove the 10. Remove the two screws securing the Bracket.
plate.
Plate
Bottom Side Bottom Side Bracket
Screws
9. Remove the two screws on the left side of the frame to remove the 11. Remove the two screws from the Cutter Unit to remove the plate.
bracket.
Screw
Bracket
Screw
Screws

REP3.9
SCC
12. Loosen the screw to remove the Z collar.
13. Remove the two screws on each side and remove the Cutter Unit from
the R side.
Z Collar Cutter Unit
• Cutter (ADJ3.13)

REP3.9
SCC
REP3.10 Creaser Unit 3. Remove the bracket.
Bracket
4. Remove the screw, then remove the pulley and belt.
1. Remove the Cover L (REP3.11).
5. Remove the connector.
2. Remove the cap and the two knobs.
Connector
Cap
Pulley Belt
Knob
Knob

REP3.10
SCC
6. Remove the four screws securing the motor and then the belt. 8. Remove the two screws securing the plate, then remove the knob.
Belt
Plate
Knob
7. Remove the two screws securing the guide to the machine. 9. Remove the screw and Z collar.
10. While holding down the Creaser Unit, remove the two knobs.
Knob
Z Collar
Guide
Knob

REP3.10
SCC
11. Pull out the Creaser Unit to the L side.
Creaser Unit
• Creaser (ADJ3.14)
• Post-creaser Transport (ADJ3.16)

REP3.10
SCC
REP3.11 Exterior Covers REP3.12 Clutch (CL301)
1. Remove the screws securing the Cover R, Cover L, Side Cover F and
Side Cover B to the machine.
Cover R Side Cover F
2. Disconnect the connector.
3. Remove the two screws securing the Clutch (CL301) to the machine.
Cover L
Side Cover B
Connector Clutch

REP3.11, REP3.12
SCC
REP3.13 Conveyer Motor 1 (M301) REP3.14 Conveyer Motor 2 (M302)

2. Disconnect the connector. 2. Disconnect the connector.
3. Remove the two screws securing the Conveyer Motor 1 (M301) to the 3. Remove the two screws securing the Conveyer Motor 2 (M302) to the
machine. machine.
Connector
Connector
Conveyance Motor 2
Conveyance Motor 1
• Belt Tension on Conveyer Motor 1 (ADJ3.2)
• Belt Tension on Conveyer Motor 1 (ADJ3.2)

REP3.13, REP3.14
SCC
REP3.15 Servo Motor (M303) 4. Loosen the glove screw and remove the collar.
Glove screw
Collar
5. Loosen the screw and remove the belt and pulley.

Replacement Procedure 6. Remove the belt (short).
2. Remove the two screws securing each tension unit.
3. Remove the two screws securing the bracket to the machine.
Tension Roller Unit Bracket
Belt (short) Belt

REP3.15
SCC
7. Loosen the screw. 9. Remove the four screws securing the Servo Motor (M303).
10. Remove the cable clip.
Belt
Cable clip
8. Disconnect the three connectors (CN5, CN6, CN7) from the Servo
Motor Control Unit (PCB303).
11. Pull out the Servo Motor (M303) to the L side .
Connector(CN7)
Connector(CN6)
Connector(CN5)
Servo Motor
• Belt Tension of Servo Motor (ADJ3.10)

REP3.15
SCC
REP3.16 Flap Solenoid (SL301) REP3.17 Stopper Solenoid (SL302)

2. Remove the two crimp contacts. 2. Remove the two crimp contacts.
3. Remove the screw and Z collar. 3. Remove the screw and Z collar.
4. Remove the two screws securing the Flap Solenoid (SL301) to the 4. Remove the two screws securing the Stopper Solenoid (SL302) to the
machine. machine.
Z Collar
Crimp Contact
Flap Solenoid
Stopper Solenoid
Z Collar Crimp Contact
adjust the following part. When you put back the removed parts, follow the reverse procedures and
• Adjusting the Flap solenoid (ADJ3.3) adjust the following part.
• Stopper Solenoid (ADJ3.4)

REP3.16, REP3.17
SCC
REP3.18 Idler Roller Solenoid (SL303) REP3.19 Side Jogger 1 Motor (M306)

2. Remove the two crimp contacts. 2. Disconnect the connector.
3. Remove the screw and Z collar. 3. Remove the four screws securing the Side Jogger 1 Motor (M306) to the
4. Remove the two screws securing the Idler Roller Solenoid (SL303) to machine.
the machine.
Idler Solenoid Connector
Crimp Contact
Z Collar
Side Jogger Motor 1

• Adjusting the Idle Roller solenoid (ADJ3.7)

REP3.18, REP3.19
SCC
REP3.20 Side Jogger 2 Motor (M307)
3. Remove the four screws securing the Side Jogger 2 Motor (M307) to the
machine.
Connector
Side Jogger Motor 2

REP3.20
SCC
REP3.21 Back Jogger Motor (M308) 6. Remove the pillar on the R side, then remove the pulley- attached Guide
Unit.
Guide Unit
Pillar
1. Disconnect the power plug from the wall outlet.
7. Remove the three screws from the infeed side.
3. Remove the Scrap Box.
Infeed Side
5. Remove the two screws from the Side Jog Guide on the L side.
Note: The eccentric collar will be removed together with the Side Jog Guide.
Eccentric Collar
L Side
Screw

REP3.21
SCC
8. Remove the two screws from the L side. 10. Remove the screw from the bottom of the machine and pull out the long
shaft upward.
Screw Screw
Shaft
Top Side
Screw
L Side L Side
9. Remove the screw, then remove the Guide L.
Guide L
Bottom Side
11. Move the Back Jogger Unit to the center of the main body.
Worm Gear
Approx. 250mm
Back Jogger Unit

REP3.21
SCC
14. Displace the Back Jogger Unit to remove the bracket and belt.
12. Remove the screw and guide.
Bracket
Belt
Screw
Back Jogger Unit

Guide Outfeed Side
15. Disconnect the connector from the Back Jogger Motor.

13. Remove the four screws from the bottom of the machine.
16. Disconnect the two connectors from the Back Jogger Solenoid.
Connector
Screw
Belt
Screw
Back Jogger Unit
Bottom Side

REP3.21
SCC
17. Remove the Back Jogger Unit from the main body.
18. Remove the three screws then remove the Back Jogger Motor (M308).
Screw Rear Side Screw
Back Jogger Unit
• Back Jogger (ADJ3.5)
• Side Jogger (ADJ3.6)

REP3.21
SCC
REP3.22 Back Jogger Solenoid (SL304) adjust the following part.
• Back Jogger (ADJ3.5)
1. Remove the Back Jogger Motor (M308) (REP3.21).
2. Remove the six screws securing the Back Jogger Solenoid (SL304) to
the machine.
Back Jogger Solenoid
Back Jogger Unit

REP3.22,
SCC
REP3.23 Main Body Motor (M310) 4. Loosen the FR screws to remove the joint from the Main Body Motor
(M310).
Joint
Replacement Procedure • Main Body Position (ADJ3.1)
1. Remove the Cover L and Side Cover F (REP3.11).
3. Remove the two screws securing the Main Body Motor (M310) to the
bracket.
Main Body Motor
Connector
Main Body Motor

REP3.23
SCC
REP3.24 Delivery Sensor (PS307) 3. Disconnect the connector.
Connector
4. Remove the two screws on the outfeed side and remove the bracket from
the inside of the machine.
2. Remove the Static Eliminator.
Static Eliminator
Bracket
Connector

REP3.24
SCC
6. Remove the seven screws securing the bracket to the machine, then
remove the bracket together with the Delivery Sensor (PS307).
Bracket
Bracket

REP3.24
SCC
REP3.25 Cutter Front Sensor (PS311) 4. Remove the screw and disconnect the connector to remove the sensor
(lower).
Connector Sensor
When you put back the removed parts, follow the reverse procedures
1. Open the Top.
2. Remove the two screws and move the sensor (upper) to the position
shown in the figure.
3. Disconnect the connector and remove the screw securing the sensor.
Connector Sensor

REP3.25
SCC
REP3.26 Power Switch Unit
2. Disconnect all the connectors on the Power Switch Unit.
3. Remove the four screws securing the Power Switch Unit to the machine.
Power Switch Unit Power Switch Unit

REP3.26
SCC
REP3.27 Center Conveyance Belt 6. Remove the three screws from the infeed side.
Infeed Side
2. Remove the Cover L and Cover R(REP3.11).
4. Remove the two screws from the Side Jog Guide on the L side.
Note: The eccentric collar will be removed together with the Side Jog Guide.
Eccentric Collar
L Side
Screw
7. Remove the two screws from the L side.
Screw Screw
5. Remove the pillar on the R side, then remove the pulley- attached guide
unit.
Guide Unit
Pillar
L Side L Side

REP3.27
SCC
8. Remove the screw, then remove the Guide L. 10. Remove the screw and guide.
Guide L
Screw
Guide Outfeed Side
9. Move the Back Jogger Unit to the center of the main body. 11. Remove the two screws to remove the Back Jog Section from the Back
Jogger Unit.
Back Jogger
Screw
Worm Gear
Approx. 250mm
Screw
Back Jogger Unit
Back Jogger Unit

REP3.27
SCC
12. Remove the two screws to remove the roller Unit. 14. Tilt the shaft to remove the belt.
Shaft
Belt
Roller Unit
Screw
13. Remove the E-Ring and the bearing. When you put back the removed parts, follow the reverse procedures.
Collar
E-Ring
R Side

REP3.27
SCC
REP3.28 Bypass Conveyance Belt 6. Remove the two screws securing the gear unit.
Replacement Procedure Screw Gear unit

2. Remove the Cover L and Cover R (REP3.11).
4. Remove the pillar on the R side, then remove the pulley- attached Guide
Unit.
Guide Unit
Pillar
L Side
7. Remove the three screws securing the bushing R and bushing L.
R Side
L Side
Screw
5. Remove the two screws securing the damper R and damper L to the
Bypass.
Bushing R Bushing L
Screw
Damper

REP3.28
SCC
8. Remove the Bypass. 10. Remove the four screws securing the Guides L and R.
Bypass Screw
Guide Plate R
Screw
Guide Plate L
9. Remove the four screws securing the guide unit with pulley. 11. Remove the three screws securing the Guide Plate.
Screw
Screw
Guide Plate
Screw
Guide Unit (attached Pulley)

REP3.28
SCC
12. Remove the belt.
Belt
Belt

REP3.28
SCC
REP3.29 Entrance Sensor (PS305) 6. Remove the two screws on the infeed side and remove the bracket from
the inside of the machine.
Bracket
Screw
1. Remove the TR-DP (Section 8, Installing TR-DP, Step 4).
2. Remove the Upper Horizontal Bracket and Lower Horizontal Bracket
(Section 8, Installing TR-DP, Step 2).
3. Remove the Vertical Brackets (Section 8, Installing TR-DP, Step 2). 7. Remove the screw and cable clamp.
4. Remove the Cover L (REP3.11). 8. Disconnect the connectors.
Connector
Screw
Cable clamp
Connector
Connector

REP3.29
SCC
9. Remove the six screws on the infeed side.
Screw Screw
10. Remove the bracket together with Entrance Sensor (PS305).
Bracket

REP3.29
SCC
ADJ3.1 Main Body Position Home Position
When the home position is not correct, adjust it by following these steps:
User Menu 2. Turn on the Remote Switch. Wait for SCC to get ready.
3. See the Main Body and the Base Unit from the L side. When the Main
Body and the Base Unit are aligned, you do not have to adjust the home
position. If they are not aligned, go on to the next step.
Escape button Jog dial
6. Loosen the screws on the actuator.
M. BODY Position is in the user menu. You can specify a number from –30 • When the Base Unit is nearer to you than the Main Body is, move the
to 30, where one step equals 0.5 mm. actuator toward you.
1. Turn the Jog Dial to select Adjustment 1. Push the Jog Dial. • When the Base Unit is farther from you than the Main Body is, move the
actuator away from you.
2. Turn the Jog Dial to select M.BODY Position. Push the Jog Dial.
Main body sensor (PS314) Rack
3. Turn the Jog Dial to specify a number. You can specify a number from –
30 to 30. Push the Jog Dial to enter the number. Make sure the specified
number is not blinking. If the specified number is blinking, push the Jog
Dial.
Screen. Screws
Maintenance Menu
The Main Body Pstn menu is in the Maintenance Mode. Use this menu if Actuator Gear
the actual position of the Main Body is different from the position specified
Top view
from the Control Panel (GP2.3).
Base Unit
Main Body
7. Tighten the screws on the actuator.

8. Attach the Cover L (REP3.11).
9. Turn on the Remote Switch. Wait for SCC to get ready.
10. When the Main Body and the Base Unit are aligned, you do not have
to adjust the home position any more. If they are not aligned, adjust the
home position once again.

ADJ3.1
SCC
ADJ3.2 Belt Tension on Conveyer Motor 1 ADJ3.3 Adjusting the Flap Solenoid
Paper feed Flap Solenoid
(SL301)
Paper feed
Flap
Drive belt
Conveyer motor 1
(M301)
To adjust the tension of the drive belt, follow these steps: To adjust the position of the Flap Solenoid (SL301), follow these steps.
1. Remove the Cover L (REP3.11). 1. Remove the Cover R (REP3.11).
2. Loosen the screws on the bracket of Conveyer Motor 1 (M301). 2. Loosen the screws on the solenoid base.
3. Adjust the position of the bracket so that the belt tension is within the 3. Adjust the positions of the solenoid base and the plate so that the flap
following range: moves in the following range:
• 9 to 11 mm (0.35 to 0.43 inch) slack in 98 gm using a tension gauge. • When the solenoid is on (GP2.3), the flap is above the paper. (The
bottom side of the flap should be 2 mm (0.079 inch) from the top side of
the paper path.)
• When the solenoid is off, the tip of the flap is below the paper path and
Belt able to guide the paper to the bypass. (The tip of the flap should be 1.5
mm (0.059 inch) from the bottom side of the paper path.)
Screws Screws
Solenoid Base Solenoid Base Screws
Plate Plate
Conveyer motor 1 (M301) Paper path Paper path

Bracket
1.5mm Flap 2mm
(0.079”) Flap
(0.059”)
4. Tighten the screws. Attach the Cover L (REP3.11).
4. Tighten the screws. Attach the Cover R (REP3.11).

ADJ3.2, ADJ3.3
SCC
ADJ3.4 Stopper Solenoid
Paper Paper travel
1mm
(0.039”)
Paper path Stopper
Spring
Stopper Solenoid
Lever Screws (SL302)
Stopper Solenoid
(SL302)
Stopper
Solenoid Base Plate
To adjust the position of the Stopper Solenoid (SL302), follow these steps.
2. Loosen the screws on the solenoid base.
3. Adjust the positions of the solenoid base and the plate so that the stopper
moves within the following range:
• When the Stopper Solenoid (SL302) is on (GP2.3), the stopper and the
paper meets at the right angles to each other.
• When the Stopper Solenoid (SL302) is off, the top of the stopper is 1 mm
(0.039 inch) lower than the paper path.

ADJ3.4
SCC
ADJ3.5 Back Jogger
Paper feed
Back Jogger
Back jogger
Back jogger
solenoid (SL304)
Screws
Back jogger
solenoid (SL304)
Lever
Spring
Plate Plate
Height of Back Jogger Gear

Top view
To adjust the height of the Back Jogger, follow these steps.
2. Loosen the screws on the Back Jogger Solenoid (SL304). Maintenance Menu
3. Adjust the positions of the two plates so that the Back Jogger moves in
Use the Back Jogger menu if the actual position of the Back Jogger is
the following range:
different from the position of the tail edge of the paper (GP2.3).
• When the Back Jogger Solenoid (SL304) is on, the Back Jogger and the
paper meets at the right angles to each other.
• When the Back Jogger Solenoid (SL304) is off, the Back Jogger is lower
than the paper path.

ADJ3.5
SCC
ADJ3.6 Side Joggers 3. Measure the distance between the Side Jogger and the frame of SCC.
When the distance is 9±1 mm (0.35±0.04 inch), you do not need to adjust
the home position. If the distance is out of this range, go on to the next
step.
Angle of Each Side Jogger Side Jogger 2 Frame of SCC
When one of the Side Joggers is not parallel with the paper path, adjust the
position by following these steps. 9+1mm
(0.35+0.04”)
1. Activate the Maintenance Mode. Select Motor-Sol Test (GP2.3).
2. Move the Side Jogger to a position so that you can easily measure the
distance between the Side Jogger and the frame of SCC (see the next
step).
S-J2 Home Sensor
3. Loosen the screw on the Side Jogger.
4. Move the Adjuster so that the following two distances are the same: Screw Actuator
Paper feed
• The distance between the upstream edge and the frame
• The distance between the downstream edge and the frame 4. Turn off the Remote Switch.
5. Tighten the screws. 5. Loosen the screw on the actuator.
6. If the Side Jogger is too close to the frame, move the actuator closer to
Home Position the frame. If the Side Jogger is too far from the frame, move the actuator
Frame of SCC away from the frame.
7. Tighten the screw.
9. Measure the distance between the Side Jogger and the frame of SCC.
Downstream edge Upstream edge When the distance is 9±1 mm (0.35±0.04 inch), you do not need to adjust
and frame and frame
the home position any more. If the distance is out of this range, adjust
the position once again.
Screw Adjuster Screw
Paper feed Maintenance Menu
Side Jogger 2
Use Side Jogger 1 or Side Jogger 2 if the actual position of a Side
When the home position is not correct, adjust it by following these steps: Jogger is different from the position specified from the Control Panel. See
GP2.3, Conducting Fine-adjustment.

ADJ3.6
SCC
ADJ3.7 Adjusting the Idle Roller Solenoid
Idler Roller Solenoid Solenoid Base
(SL303) Screws
Plate
Idler roller solenoid Paper feed
(SL303)
0.5 to 1 mm
Lever Idler roller (0.020 to 0.039”)
Idler Roller
2 to 3 mm
(0.08 to 0.12”)
Servo motor Drive Roller
To adjust the position of the Idler Roller, follow these steps:

3. Loosen the screws on the solenoid base.
4. Adjust the position of the solenoid base and plate so that the Idler Roller
moves in the following range:
• When the Idler Roller Solenoid is on, the Idler Roller keeps pressing the
paper on the drive roller. (When the core of the Idler Roller Solenoid
(SL303) is 0.5 to 1.0 mm (0.020 to 0.039 inch) away from its topmost
position, the Idler Roller should reach the drive roller.)
• When the Idler Roller Solenoid (SL303) is off, the Idler Roller does not
touch the paper. (When the Idler Roller Solenoid (SL303) is off, the Idler
Roller is 2 to 3 mm (0.08 to 0.12 inch) away from the Drive Roller.)

ADJ3.7
SCC
ADJ3.8 Slitters Mechanically Adjusting Slit Positions
Paper feed
User Menu Slitter Plate

Angle
Bracket
Shaft
Escape Button Jog Dial
Finished Size is in the user menu. You can adjust the positions of the
two Slitters.
1. Make sure no sheet remains in SCC.
2. On the Control Panel, turn the Jog Dial to select Adjustment 2. Push Slitter
the Jog Dial.

3. Turn the Jog Dial to select Finished Size. Push the Jog Dial.
4. Turn the Jog Dial to select Width. Push the Jog Dial.
Note: When necessary, you can adjust cut positions by using Length.
5. Turn the Jog Dial to specify a number. You can specify a number from
–30 to 30. Push the Jog Dial. Make sure the specified number is not
blinking.
Note: If the specified number is blinking, push the Jog Dial.
You can mechanically adjust silt positions.
Screen. 1. Remove the four screws on and beside the bracket.
2. Remove the plate and angle.
Maintenance Menu 3. Move the bracket so that the bracket does not obstruct the Slitter (see
the next step).
Use the Slitter Position menu (GP2.3, Conducting Fine-adjustment) if the
actual positions of the Slitters are different from the positions specified 4. Adjust the position of the Slitter.
from the Control Panel. 5. Attach the bracket, angle, and plate. Tighten the screws.

ADJ3.8
SCC
ADJ3.9 Belt Tension of Slitter Motor
To adjust the belt tension, follow these steps:

2. Loosen the screws on the bracket that holds the Slitter Motor (M309).
3. Adjust the position of the bracket so that the belt tension is within the
following range:
• 9 to 11 mm (0.35 to 0.43 inch) slack in 98 gm using a tension gauge.
Belt Screw Bracket Slitter Motor (M309)

ADJ3.9
SCC
You can adjust the tension of the drive belt that transmits the drive power
ADJ3.10 Belt Tension of Servo Motor horizontally.
You can adjust the tension of the two drive belts that transmit the drive 2. Loosen the screw on the collar.
power vertically.
3. Adjust the position of the collar so that the belt tension is within the
1. Remove the Cover L (REP3.11). following range:
2. Loosen the screw on the Collar. • 4 to 6 mm (0.16 to 0.24 inch) slack in 1020 gm using a tension gauge.
3. Adjust the position of the Collar so that the belt tension is within the
following range:
Collar
Screws
Bracket
Screw

Servo Motor Collar
(M303)

ADJ3.10
SCC
ADJ3.11 Upper Blade Angle
Eccentric Screw
B
30°
Upper Blade
Collar
Belt
The two Upper Blades of the two slitters are not parallel. If you could
view these Blades from above, the distance between the upstream ends is
shorter than the distance between the downstream ends. To set this angle,
each Slitter has an eccentric screw. This eccentric screw is at an angle of
30 degrees by default. However, if you have changed the angle accidentally,
set it back to 30 degrees. When the line A and B are perpendicular to each
other as shown in the figure above, the angle is correct.
Belt Tension
The tension of the belt inside each Slitter is adjusted by a collar. The belt
tension needs to be within the following range:

ADJ3.11
SCC
ADJ3.12 Slitter Cover Sensor 4. Loosen the screws on the bracket that holds the Slitter Cover Sensor
(SSW304). Adjust the position of the bracket so that the sensor works as
follows:
Bottom cover open Bottom cover closed
Actuator
• When the arc of the actuator pushes the roller of the sensor, the lever
moves and the sensor changes state.
5. Tighten the screws.
6. Close the Bottom Cover of the Slitter.
7. Loosen the screws on the actuator. Adjust the position of the actuator so
that the actuator works as follows:
• The right end of the actuator keeps touching the roller of the sensor.
Slitter cover sensor
(SSW304) 8. Tighten the screws.
9. Open the Bottom Cover. Make sure the sensor changes state. If the
sensor does not work actuate, adjust the position of the bracket once
again.
Paper feed
10. Close the Bottom Cover. Make sure the sensor changes state. If the
sensor does not work in the same manner, adjust the position of the
actuator once again.
Bottom cover closed Bottom cover open
Arc
Arc
Bottom cover Slitter cover sensor Slitter cover sensor

(SSW304) (SSW304)
Actuator Actuator
To adjust the positions of the Slitter Cover Sensor (SSW304) and lever,
follow these steps:
2. Remove the Scrap Box out of SCC. Screws Roller Lever Screws Screws Roller Screws
3. Open the Bottom Cover.
11. Set the Scrap Box back in the original position.
12. Attach the Cover R (REP3.11).

ADJ3.12
SCC
ADJ3.13 Cutter 6. Conduct a Test Feeding (see SCC Instruction Manual, “4-5 Test
Feeding”). Make sure the length of the finished size is shorter than the
length of the paper size.
Creaser Cutter
7. Start a Test Feeding. Check the cut angles.
Crease Angle
Dial 8. When the cut angles are correct, remove the Crease Angle Adjuster
from the Cutter. If the cut angles are not correct, adjust the position of
the Cutter once again.
9. Attach the Crease Angel Adjuster and the bracket to their original
Position Mark
Screws places.
Paper feed
Crease Angle
Dial Screws
Cutter Motor
(M304) Cutter
Crease Angle Bracket Fan

Adjuster (FM301)
When the Cutter is not at right angles (90 degrees) with the paper path,
adjust the position of the Cutter by following these steps:
1. Make sure the Crease Angle Dials are fastened.
2. Remove the bracket that holds the Crease Angle Adjuster.
3. Remove the Crease Angle Adjuster. Attach the Crease Angle Adjuster to
the Cutter.
4. Loosen the screws on the Cutter.
5. Turn the Crease Angle Adjuster to adjust the position of the Cutter. As
you turn the Crease Angle Adjuster, the Position Mark moves. Tighten
the screws.

ADJ3.13
SCC
ADJ3.14 Creaser ADJ3.15 Belt Tension of Creaser Motor
Paper feed
To adjust the belt tension, follow these steps:
2. Loosen the screws on the bracket that holds the Creaser Motor (M305).
3. Adjust the position of the bracket so that the belt tension is within the
following range:
Creaser • 4 to 6 mm (0.16 to 0.24 inch) slack in 1020 gm using a tension gauge.
Belt
Creaser Motor
(M305)
Bracket
Creaser Motor
(M305)
Creaser
User Menu Screws
You can adjust the Crease Position by using the Crease Position menu in the 4. Tighten the screws on the bracket.
Adjustment 2 menu (see SCC Instruction Manual, “6-7 Crease Position”).
5. Attach the Cover L (REP3.11).
Crease Angle Adjuster
You can adjust the Crease Angle by using the Crease Angle Adjuster (see
SCC Instruction Manual, “6-11 Crease Angle”).
Crease Depth Adjuster

You can adjust the Crease Depth by using the Crease Depth Adjuster (see
SCC Instruction Manual, “6-12 Crease Depth”).

ADJ3.14, ADJ3.15
SCC
ADJ3.16 Post-creaser Transport
Paper feed
Servo Motor
(M303)

2. Loosen the screws on each bracket that holds a roller for adjustment.
3. Adjust the position of each bracket so that the belt tension is within the
following range:
Screws
Screws
Belts

ADJ3.16
SCC
ADJ3.17 Top Cover Sensors
Actuator Lever Sensor
Top Cover-F Sensor

(SSW302)
Top Covers (upstream)
Paper feed
Top Covers (downstream)
Top Cover-R Sensor

(SSW303)
Screws
Top Cover
Bypass Top of exterior cover
To adjust the positions of the Top Cover-F Sensor (SSW302) and Top
Cover-R Sensor (SSW303), follow these steps:
2. Close the bypass and Top Covers.
3. Loosen the screws on the bracket that holds the Top Cover Sensor.
4. Loosen the screw on the actuator that actuates the Top Cover Sensor.
5. Adjust the positions of the bracket and actuator so that the sensor works
as follows:
• The Top Cover Sensor is actuated when the bottom edge of the bypass is
on the same level as the top of the exterior cover.

ADJ3.17
DCM Kit
REP4.1 Exterior Cover 4. Remove the screw, and detach the exterior cover.
WARNING
Switching Power Supply can cause a shock if touched.
1. Remove the screw, and detach the cover R.

2. Remove the screw, and detach the cover L.
3. Disconnect the connectors of connecting cable.
Cover R
Exterior cover
Cover L
Connecting cable
4. Remove the screw, and detach the cable cover.

Cable cover
Connector
4-67 Section 4—Replacement and Adjustment DCM Kit

REP4.1
DCM Kit
REP4.2 Static Eliminator
1. Remove the screw, and detach the cable cover.

Cable cover
Connector
3. Remove the screws and collars to remove the Static Eliminator.

Static Eliminator
4-68 Section 4—Replacement and Adjustment DCM Kit

REP4.2
DBM-500
REP5.1 MC Unit (PCB501) Replacement Procedure
2. Remove all the connectors on the MC Unit (PCB501).
Replacing the EEPROM (Memory) 3. Remove the six screws securing the MC Unit (PCB501) to the machine.
The EEPROM, nonvolatile memory, in U10 on the MC Unit (PCB501)
stores the settings you and the user have made. When replacing the MC
Unit (PCB501), choose one of the following procedures:
● Remove the currently used EEPROM out of the old MC Unit (PCB501),
and install it on the new MC Unit (PCB501).
MC unit
● Manually restore all the settings by typing necessary keys on the Screw
Control Panel. If you are to restore these settings manually, do not

forget, among others, the Offset Data (GP2.5).
U10
Screw
Put back the removed parts in the reverse procedures.

MC unit
Alarm Tone
You may hear an alarm tone when you turn on the Remote Switch for the
first time after you install a new EEPROM. Just wait until the alarm tone
stops.
Note: The alarm tone may continue for several seconds.
4-69 Section 4—Replacement and Adjustment DBM-500

REP5.1
DBM-500
REP5.2 Sensors
WARNING
shock if touched.
DBM-500 has several sensors that consist of an LED (light emitter) and IC
(light receptor). When replacing these sensors, you must replace the LED
and IC at the same time.
1. Prepare two types of paper:
● Fine quality paper of 64 g/m²
● Tracing paper of 80 g/m²
Note: If the user always uses thin paper, you can use such paper instead of above-
mentioned fine quality paper.
2. Replace the sensor (LED and IC).
3. Adjust the light sensitivity (ADJ5.1).

REP5.2
DBM-500
REP5.3 Stitcher Head REP5.4 Removing Wire
1. Cut and remove the wire (REP5.4).

WARNING
2. Cut and remove the SK binders.
Note: When you attach the Stitcher Head, make sure that you use a new SK Turn off the Main Power Switch and disconnect the power cord before
binders. removing or mechanically adjusting the Stitchers. The stitching wire can
3. Loosen the fixing knob, and remove the wire detection unit. injure you severely. The Stitchers and drive mechanism can catch your
Note: The stitcher has a mechanism that holds the wire. To release the wire, push clothing, hands, hair, and any part of your body, injuring you severely.
down the release disk.
Wire detection unit
To remove the wire, follow these steps:
1. Turn the handle until the feed wheels are disengaged.
2. Press the disk down and pull the wire out.
Disk
Release disk
Fixing knob
SK binder
SK binder
4. Loosen the screws using the supplied wrench.

5. Remove the head by sliding the head to the out board side of the module.
The side jogger assembly should be positioned to it’s widest opening by
hand cranking the side jogger stopper motor. Handle
Head Holder
Feed Wheel
Wrench
Screw

REP5.3, REP5.4
DBM-500
REP5.5 Former REP5.6 Bender Stop
The bender stop prevents the bender from hitting booklets. The position of
Removing the Former the bender stop is adjusted before shipment. When you are going to remove
To remove the former, follow these steps: the bender stop, you must note the position of the bender stop.
1. Turn the spring leaf to the side. 1. Remove the former (REP5.5).
2. Remove the former. 2. See the gauge and note the position of the slide.
3. To remove the bender stop, remove the screw and slide.
Leaf spring
Former
Screw
Bender stop/Gauge Slide
Mounting the Former

To mount the former, follow these steps:
1. Mount the former. Replace the leaf spring.
2. Adjust the position of the former (ADJ5.26).

REP5.5, REP5.6
DBM-500
REP5.7 Bender Mounting the Bender
To mount the bender, follow these steps:
1. Remove the Bender Stop (REP5.6). 1. Mount the bender.
2. Move the main slide in the direction of the arrow until it stops, and 2. Adjust the protruded length (a) of the lack to the measurement you
measure and record the protruded length (a). recorded in step 2.
3. Turn the stitch length adjustment knob to the direction of “+” and
remove the lack.
Stitch length
adjustment knob
Lack
Main slide
4. Pull the bender (see arrow A). The main slide comes down with the
bender.
5. Remove the bender from main slide.
When you have reassembled them, check that the bender moves
correctly.
Main slide
Both
Bender

REP5.7
DBM-500
REP5.8 Knives 4. To use the other cutting edge, turn the flat knife. To replace the knife,
remove it from the slider.
5. To remove the disk knife, loosen the screw.
The flat knife has two cutting edges. You can use both edges before When you have reassembled them, adjust the position of the disc knife
replacing the knife. (ADJ5.29), and check that the slider and flat knife move correctly.
1. Remove the Bender (REP5.7).
2. Record the scale (a). Slider
3. Turn the dial upward and remove the knife box from the guide. Knife box
a
Dial
Screw
Disc knife Flat knife
Knife box
Guide
4. Push the slider and remove the knife assy from the knife box.
WARNING
Do not touch the edges of the knife. The knife can injure you severely. Be
careful while working on it.
Slider
Knife box
Knife assy
Flat knife

REP5.8
DBM-500
Mounting the Knives
1. Attach the knife assy to the knife box, pushing the spring of the knife
assy with a flat-head screw driver.
Knife assy
Spring
2. Insert the wire tube into the knife box and attach the knife box to the
guide.
Wire tube
Knife box
3. Adjust the scale of the knife box to the scale (a) you recorded in step 2 of
the previous page.

REP5.8
DBM-500
REP5.9 Clincher 7. Remove the pusher.
8. Turn the clincher upwards in the clincher box, and remove the clincher
from the retention pin.
2. Open the Front Top Cover.
Clincher
3. Move the Side Jog Guide outward (frame side).
4. Move the Clincher to make enough working space.
5. Loosen the two screws securing the Guide to the Clincher Assy on L Retention pin
side and R side, then remove the Guide.

Note: Use a spanner or flat-blade screwdriver to loosen the screws.
6. To remove the Clincher Assy on each side, move it to the right or left Clincher box
edge of the Clincher Holder.
Pusher
Put back the removed parts in the reverse procedures and adjust the
following parts.
• When attaching the Guide you removed in step 5, tighten the screws
while pressing the Guide downward to prevent it from tilting and
Guide Guide wobbling.
• Clincher position (ADJ5.20)
Clincher Clincher Clincher Clincher

assy Holder Holder assy

REP5.9
DBM-500
REP5.10 Fold Roller/Press Roller 6. Remove the E-ring.
7. Remove the four screws, then remove the bracket together with the
parts attached to them.
Screw E-ring Screw
Fold Roller
2. Remove the Fold Rollers Gap 1 Motor (M511) (REP5.39).
3. Remove one of the two FR screws and loosen the other.
4. Remove the gear.
Gear
Bearing Screw

FR Screws 9. Remove the bracket of R side (REP5.34, Step 1 to 6).
10. Remove the two chains of R side.
5. Loosen the FR screw to remove the two set collars of the Folding Roller.
Chain
Chain
Fold Roller
Set collar

REP5.10
DBM-500
11. Pull out the Fold Roller slowly toward the R side. Press Roller
1. Remove the Sub Frame (REP5.38, Step 1 to 3)
2. Open the Rear Top Cover.
3. Remove the Folding Side Guide (REP5.43).
4. Remove the Fold Rollers.
5. Remove the two sprockets attached to the Press Rollers on the R side.
Fold Roller
Sprocket
Sprocket
6. Loosen the FR screw to remove the set collar.
Set Collar

REP5.10
DBM-500
7. Loosen the nut of the tension pulley. 11. Remove the two E-rings and the two pulleys.
Note: When the pulley is removed, the key and pin are also removed.
8. Remove the nut and spring washer to remove the fixed pulley.
9. Loosen the two screws of pulley assy.
10. Take the belt off the two pulleys.
Nut,
Spring Washer
Pulley Pulley
Key
Pin
E-Ring E-Ring
Pulley Assy 12. Remove the E-ring.

13. Loosen the FR screw to remove the pulley.
Note: When the pulley is removed, the key is also removed.
FR screw
Screw
Fixed Pulley
Pulley
Key
Pulley
E-ring
Tension Pulley
Nut

REP5.10
DBM-500
14. Loosen the FR screw to remove the set collar. 16. Remove the screw on the L side and R side, then remove the
Conveyance Roller.
Conveyance Roller
Screw
Screw
Set Collar
17. Remove the two screws, then remove the Guide Plate.
Screw
Screw
15. Remove the pressure adjustment hook and spring on the L side and R Guide Plate
side.
Pressure adjustment hook 18. Remove the two springs and two E-rings.
Spring 19. Remove the two collars to remove the smaller Conveyance Roller.
E-Ring
Collar
Pillar
Conveyance Roller
Spring
Lever unit
Spring Collar
Collar
Spring
E-Ring

REP5.10
DBM-500
20. Remove each screw on the L side and R side to remove the bigger 22. Remove the two screws on the L side and R side, then remove the
Conveyance Roller. bearing holder on each side.
Screw
Bearing
Holder
Screw
Screw
Conveyance Roller
21. Remove the bearing on the L aide R side from the outside of the frame, 23. Loosen the two FR screws on the L side and R side.
then remove the press roller. 24. Push the bearing on the L side and R side inward to remove it from the
lever unit.
Lever Unit
Bearing PUSH
Bearing Press Roller Bearing Set Collar

REP5.10
DBM-500
25. Remove the nut, screw, and spacer on the R side, then remove the lever Attach the removed parts in the reverse procedures and adjust the following
unit. parts.
Note: Remove the lever by pulling it out toward the infeed direction. • Press Rollers (ADJ5.44)
Lever Unit
• Folding Rollers (ADJ5.43)
PULL • Main Drive System (ADJ5.47)
• When attaching the motor, press it lightly against the gear.
• Folding Side Guide (ADJ5.32)
Nut
Press Roller
26. Remove the bearing on the R side, then remove the press roller on the
paper infeed side.
Bearing
Press Roller

REP5.10
DBM-500
REP5.11 Exterior Covers Cover R
1. Remove the screws securing the Cover R to the machine.
WARNING
shock if touched.
Cover L
1. Remove the cap. Cover R
2. Remove the screw, knob and dial.
3. Remove the other screws securing the Cover L to the machine.
Dial
Knob
Screw
Cap
Cover L Front Top Cover

1. Remove the Cover L.
2. Remove the screw and pull out the Top Cover toward the L side.
Top Cover Top Cover
L side

REP5.11
DBM-500
Bracket with fan DBM-500BR
1. Remove the Cover L and Cover R (REP5.11). 1. Remove the screws securing the Exterior Cover L and Exterior Cover to
2. Remove the two screws, then the Main Power Switch Assy. the machine.
Main power switch assy
Screw Exterior cover L
Exterior cover R
Screw
3. Remove the six screws. Remove the bracket with fan, and disconnect the
connector of the fan.
Note: When you remove the bracket with fan, remove the joint attached to the air
pipe (outside of the machine) if necessary. Be careful not to damage the air pipe.
Screw
Bracket with fan
Connector
Screw

REP5.11
DBM-500

2. Disconnect all of the connectors on the Switching Power Supply 2. Disconnect all of the connectors on the Relay Board (PCB503).
(PCB504). 3. Remove the four screws of the Relay Board (PCB503) together with the
3. Remove the four screws securing the Switching Power Supply (PCB504). collars.
Note: The collars are attached to the both sides of the Relay Board (PCB503).
Screw Collar
Collar
Bush
Swithing Power Supply Screw
Screw
Relay board
Bush
Attach the removed parts in the reverse procedures. Screw
Attach the removed parts in the reverse procedures.

REP5.12, REP5.13
DBM-500
REP5.14 Control Panel REP5.15 Inverter

2. Disconnect the three connectors. 2. Remove the three cable clamps on the right hand side of the Inverter,
3. Remove the three screws to detach the earth wire. and disconnect the one connector from the isolation board.
3. Disconnect the two connectors on the left hand side of the Inverter, and
remove the two cable clamps.
4. Remove the screw securing the earth wire.
Screw
5. Disconnect the one connector, and remove the two screws and two cable
clamps.
Screw
6. Remove the four screws securing the Inverter to the machine.
Cable Clamp
Inverter Screw
Screw
Connector
Earth wire Connector
Connector
4. Remove the four screws securing the Control Panel to the machine.
Screw
Screw
Connector
Cover Screw
Earth Wire Cable Clamp Screw Connector

Screw
Screw Screw Cable Clamp

Control Panel

REP5.14, REP5.15
DBM-500
REP5.16 Main Drive Motor (M514) REP5.17 Jog Unit Moving Motor (M501)

2. Remove the one connector. 2. Remove the harness of the connector from the cable clamp, then
3. Remove the screw securing the earth wire to the chassis. disconnect the connector.
4. Remove the four screws, then remove the belt and the Main Drive Motor 3. Remove the four screws securing the Jog Unit Moving Motor (M501) to
(M514). the machine.
Main Drive Motor
Screw Screw
Screw
Cable Clamp
Screw
Belt
Motor Earth Wire
Screw
Connector Connector
Jog Unit Moving Motor
Attach the removed parts in the reverse procedures and adjust the following Attach the removed parts in the reverse procedures and make sure that you
part. press the motor lightly against the gear when attaching the motor.
• Main Drive System (ADJ5.47)

REP5.16, REP5.17
DBM-500
REP5.18 Back Jog Moving Motor (M502) 6. Turn the link, then loosen the set screw.
Link Set screw
1. Remove the Side Jog Guides (REP5.20, Step4).

2. Remove the bracket of upper infeed and the bracket of lower infeed
(REP5.42).
3. Remove the Jog Unit Moving Motor (M501) (REP5.17), then move the
Jogger Unit to make enough working space.
4. Remove the screw, then remove the cable clamp and connector.
Back Jog Unit
7. Remove the four screws, then remove the Back Jog Moving Motor
(M502).
Screw Screw
Screw Cord Clamp Connector
5. Remove the connector and two screws, then remove the Back Jogger
Home Sensor (PS504).
Bag Jogger Home Sensor

(PS504)
Bag Jog Moving Motor (M502)
Screw Connector Screw

REP5.18
DBM-500
Attach the removed parts in the reverse procedures and adjust the following
REP5.19 Jog Belt Drive Motor (M503) part.
• Drive Belt Tension (ADJ5.13)
(REP5.42).
3. Remove the Jog Unit Moving Motor (M501) (REP5.17), then move the
Jogger Unit to make enough working space.
4. Remove the screw, then remove the cable clamp and connector.
Back Jog Unit
Screw Cord Clamp Connector
5. Remove the four screws, remove the Jog Belt Drive Motor (M503).
Screw
Jog Belt Drive Motor (M503)

REP5.19
DBM-500
REP5.20 Side Jogger Unit 6. Remove the eight screws securing the four square bars.
Squaer bar Squaer bar (hole type)
1. Open the Front Top Cover, then open the Conveyance Roller Unit.
3. Remove the Side Jog Moving Motor (M504) (REP5.21).
4. Remove the four screws, two each on the L side and R side, to remove
the Side Jog Guides. Squaer bar
Note: The Side Jog Guides is removed together with the springs.
Side Jog Guide
(R side)
Screw
Collar Eccentric
Collar
Z Collar
Screw
Spring Eccentric
Collar Collar
Z Collar
Paper feed
Screw Screw
Side Jog Guide (There are two more screws on the opposite side.)
(L side) (There are two more screws on the opposite side.)
7. Remove the screws, bracket and then the square bar.
Spring
Side Jogger Unit
5. Loosen the two screws of conveyance belt tension roller.

L side R side
Sqaure bar Bracket
Screw Screw

REP5.20
DBM-500
8. Disconnect the connector and remove the three screws and three cable Attach the removed parts in the reverse procedures and adjust the following
clamps. parts.
• Conveyance Belt Tension (ADJ5.4)
R side • Side Jogger Drive (ADJ5.17)
• Side Jog Guide (ADJ5.15)
Connector
Cable clamp
Screw
9. Remove the two screws, then pull out the Side Jogger Unit to the L side.
Side Jogger Unit

REP5.20
DBM-500
REP5.21 Side Jog Moving Motor (M504) REP5.22 Side Jogger Brake (BRK501)

2. Disconnect the connector. 2. Disconnect the two connectors.
3. Remove the four screws, the belt and then the Side Jog Moving Motor 3. Remove the four screws securing the Side Jogger Brake (BRK501) to
(M504). the machine.
Connector
Side Jog Moving Motor
Connector
Screw
Screw
Screw Screw
Belt
Connector
Side Jogger Brake
part. Attach the removed parts in the reverse procedures. Adjust the following
• Side Jogger Drive (ADJ5.17) part.
• Side Jogger Brake (ADJ5.48)

REP5.21, REP5.22
DBM-500
REP5.23 Saddle Stop Moving Motor (M505) REP5.24 Saddle Stitch Stop Solenoid (SL501)

2. Disconnect the connector. 2. Remove the connector.
3. Remove the four screws and remove the Saddle Stop Moving Motor 3. Remove the screw and the Z collar securing the link.
(M505). 4. Remove the two screws securing the Saddle Stitch Stop Solenoid (SL501)
Saddle Stop Moving Motor
to the machine.
Connector
Screw
Z Collar
Screw
Connector
Screw
Attach the removed parts in the reverse procedures and make sure that you Saddle Stitch Stop Solenoid
press the motor lightly against the gear when attaching the motor.
par.
• Positions of Side Stitching Stopper (ADJ5.6)

REP5.25, REP5.26
DBM-500
REP5.25 Stitch Delivery 1 Solenoid (SL503) REP5.26 Stitch Delivery2 Solenoid (SL504)

2. Remove the two screws to open the bracket that has the MC Unit 2. Disconnect the connector, then remove the screw and Z collar securing
(PCB501) on it. the link.
3. Disconnect the connector, then remove the screw and Z collar securing 3. Remove the two screws securing the Stitch Delivery2 Solenoid (SL504)
the link. to the machine.
4. Remove the two screws securing the Stitch Delivery 1 Solenoid (SL503) Stitch Delivery2 Solenoid
to the machine.
Connector
Stitch Delivery1 Solenoid
Z Collar
Screw
Screw
Connector
Screw
part.
Z Collar
• Eject Roller 2 (ADJ5.10)
Screw
Screw
MC Unit
Bracket
part.
• Eject Roller 1 (ADJ5.30)

REP5.24, REP5.25
DBM-500
REP5.27 Stitcher Moving Motor (M506)

3. Remove the four screws securing the Stitcher Moving Motor (M506) to
the machine.
Screw Connector
Stitcher Moving Motor

(M506) Screw

REP5.27
DBM-500
REP5.28 Jogger Unit 5. Remove the two screws attached to the Jogger Unit to remove the pulley
unit.
Pulley Unit
(REP5.42).
3. Remove the two connectors and remove the screw of earth wire.
Connector
Screw

7. Remove the two screws and remove the Jogger Unit Home Sensor
4. Loosen the four screws, and remove the belt from the Jog Belt Drive (PS503).
Motor (M503).
Screw
Belt Jog Belt Drive Motor (M503)
Jogger Unit Home Sensor Connector

(PS503)

REP5.28
DBM-500
8. Remove each two screws of the L side and R side. 10. Pull the Jogger Unit from the rail toward the infeed section.
Note: When you remove the Jogger Unit, remove the joint attached to the air pipe
(outside of the machine) if necessary. Be careful not to damage the air pipe.
Rail
Screw Screw
Idler
9. Remove the idler attached to the L side and R side.

Nut
Washer
parts.
Idler • Drive Belt Tension (ADJ5.13)
• Aligning the Back Joggers (ADJ5.10)
• Timing Belt Tension (ADJ5.12)
• Aligning the Back Jog Unit (ADJ5.11)
Washer Idler
Nut

REP5.28
DBM-500
REP5.29 Back Stop Moving Motor (M507) REP5.30 Back Stopper Solenoid (SL505)

2. Remove the connector. 2. Remove the connector and clamp.
3. Remove the four screws securing the Back Stop Moving Motor (M507) 3. Remove the screw and Z collar securing the link.
to the machine. 4. Remove the two screws securing the Back Stopper Solenoid (SL505) to
Back Stop Moving Motor
the machine.
Screw
Clamp
Connector
Z Collar Screw
Connector
Back Stopper Solenoid

Screw Screw
Attach the removed parts in the reverse procedures and make sure that you Attach the removed parts in the reverse procedures and adjust the following
press the motor against the gear when attaching the motor. part.
• Solenoid Position of Saddle Stitching Stopper (ADJ5.7)

REP5.29, REP5.30
DBM-500
REP5.31 Folding Stop Moving Motor (M508) 5. Remove the four screws securing the Folding Stop Moving Motor (M508)
to the bracket.
1. Remove the DBM-500BR (See Section 8).
3. Remove the connector and screw on the R side to remove the cable
clamp.
4. Remove the six screws, three each on the R side and L side to remove
the bracket.
Bracket
Screw
Screw Folding Stop Moving Motor
Connector
Attach the removed parts in the reverse procedures and make sure that you
press the motor against the gear when attaching the motor.
Bracket
Connector
Screw
Cable Clamp Screw

REP5.31
DBM-500
REP5.32 Non-fold Delivery Motor Unit REP5.33 Folding Side Guide Motor (M510)

2. Remove the two connectors. 2. Remove the connector.
3. Remove the screw and cable clamp. 3. Remove the four screws and belt to remove the Folding Side Guide
4. Remove the snap band. Motor (M510).
5. Remove the four screws securing the Non-fold Delivery Motor Unit to
the machine.
Connector
Folding Side Guide Motor
Screw (M510)
Non-fold
Delivery Motor
(M510)
Cable Clamp
Connector
Screw
Screw
Screw Non-fold Delivery Motor

Unit
Snap Band Connector Screw
parts.
• Folding Guide Drive (ADJ5.33)
press the motor against the gear when attaching the motor.

REP5.32, REP5.33
DBM-500
REP5.34 Fold Delivery Clutch (CL501) 5. Remove the two E-rings and collar.
E-ring

2. Remove one of the two FR screws and loosen the other.
3. Remove the gear.
Gear
FR Screws
Collar
E-ring
6. Remove the four screws, then remove the bracket together with the
parts attached to them.
Screw
Bracket
4. Loosen the FR screw to remove the two set collars of the folding roller.
Screw
Screw
Bearing
Set collar

REP5.34
DBM-500
7. Remove the spring, then remove the belt. 8. Remove the screw and cable clamp, then remove the connector of the
Spring clutch.
Cable Clamp
Screw
Connector
9. Loosen the FR screw to remove the set collar and pulley.

Belt 10. Remove the Fold Delivery Clutch (CL501).
Set Collar Fold Delivery Clutch
Pulley

REP5.34
DBM-500
REP5.35 Side Stitch Delivery Solenoid (SL506)

2. Disconnect the connector and remove the screw and Z collar securing
the link.
3. Remove the two screws securing the Side Stitch Delivery Solenoid
(SL506) to the machine.
Side Stitch Delivery Solenoid
Z Collar
Connector
Screw
Screw
part.
• Side Stitch Ejection Roller (ADJ5.40)

REP5.35
DBM-500
REP5.36 Stitching Clutch (CL502) 7. Remove the six screws securing the bracket.
8. Remove the earth wire fixing screw.
2. Remove the Inverter (REP5.15).
3. Remove the Brake Plate (REP5.37, Step2 to 4). Cable Clamp
4. Loosen the nut and remove the chain from the sprocket.
Screw
5. Loosen the two screws, then remove the belt from the clutch.
6. Remove the connector. Screw
Nut
Screw
Screw
Connector Screw
Screw
Bracket
Screw
Ground Wire

REP5.36
DBM-500
9. Take out the Clutch Unit from the opening for the inverter you removed. 12. Remove the CFR screw, the collar along with the bearing, then the
bracket.
Bracket
Cluth Unit
CFR screw
Collar
10. Remove the five screws and five cable clamps. 13. Remove the snap-ring, then remove the collar and Stitching Clutch
11. Remove the cord bush. (CL502).
Cable Clamp Note: When the Stitching Clutch (CL502) is removed, the key is also removed.
Cable Clamp
Stitching Cluth (CL502)
Screw
Screw
Collar
Key
Snap-ring
Cord Bush

REP5.36
DBM-500
14. Remove the collar, adjusting washer and clutch plate.
Note: The thickness and number of adjusting washer varies depending on the
machine.
Clutch Plate
Adjusting
washer
Collar
part.
• Stitching Brake/Stitching Clutch (ADJ5.49)
• Chain and belt tension (ADJ5.47)

REP5.36
DBM-500
REP5.37 Stitching Brake (BRK502) 5. Disconnect the connector and remove the four CFR-screws to remove
the Stitching Brake (BRK502).
Note: When the Stitching Brake (BRK502) is removed, the key, washer, collar
1. Remove the Cover R (REP5.11). and bearing are also removed.
2. Loosen the two FR screws to remove the set collar.
3. Remove the brake plate. CFR-Screw
Note: When the brake plate is removed, the key is also removed.
Stiching Brake
Key CFR Screw CFR-Screw
CFR-Screw
Stiching Brake
Connector
Set Collar
Shaft
Set Collar
Cable Clip
4. Remove the adjusting washers and collar.
Note: The thickness and number of adjusting washer varies depending on the Attach the removed parts in the reverse procedures and adjust the following
machine. part.
• Stitching Brake/Stitching Clutch (ADJ5.49)
Key
Collar
Adjusting
washer

REP5.37
DBM-500
REP5.38 Folding Clutch (CL503)/ 5. Disconnect the two connectors, then remove the wire harness from the
two cable clips.
Folding Brake (BRK503)
6. Remove the two cable clamps and cord bush.
Cable clamp Cord bush Cable clamp
1. Remove the Paper Receiving Plate (See Section 8).
3. Remove the three screws from the both sides of the frame, then remove
the sub frame to which the Paper Receiving Plate was attached. Cable clip
Screw
Screw
Screw
Brake connector: Purple

Connect the brake connector to the For Brake
connector with purple and brown harness. BRN
Clutch connector: Sky-BLU

Connect the clutch connector to the connector For Clutch
Sub Frame with blue and brown harness. BRN
4. Loosen the nut, then remove the belt from the clutch and idler.
Idler
Cluth
Idler Nut
Belt
Nut
Belt

REP5.38
DBM-500
7. Remove each two E-rings of the L side and R side. 11. Pull out the spring pin from the lever (R side) using the tool.
8. Remove each connecting plate of the L side and R side. 12. Pull out the lever (R side).
9. Remove the snap band on the L side.
10. Remove the connector and two screws on the L side, then remove the
Folder Drive Home Sensor (PS518). Tool
E-Ring
Lever
Connecting Plate
E-Ring Spring Pin
13. Loosen the FR screw to remove the set collar.

R Side 14. Remove the two screws, then remove the bearing cover and bearing.
E-Ring
Connecting Plate
Connector Collar unit
Folder Drive Home

E-Ring Sensor (PS518)
Shaft
L Side Holder Set Collar

Screw

REP5.38
DBM-500
15. Remove the four screws. 17. Remove the snap-ring using a jig.
Screw
Tool
Snap-Ring
16. Remove the bracket together with the clutch and brake toward the L
side.
18. Pull out the jig and remove the one side of the clutch.
Note: When the clutch is removed, the adjusting washer is also removed.
Note: The thickness and number of adjusting washer varies depending on the
machine.
Brake
Clutch
Clutch
Collar
Adjusting
washer

REP5.38
DBM-500
19. Remove the other side of the Folding Clutch (CL503). 22. Remove the four CFR screws, then remove the bracket.
Note: When the clutch is removed, the key is also removed. Brake CFR-Screw
20. Remove the collar.
CFR-Screw
Key
Boss Collar
CFR-Screw
23. Remove the snap-ring, then remove the bearing.

Note: When the bearing is removed, the key is also removed.
24. Remove the adjusting washers, collar and Folding Brake (BRK503).
21. Loosen the FR screw to remove the set collar. Note: The thickness and number of adjusting washer varies depending on the
machine.
25. Loosen the FR screw, then remove the brake plate.
Set Collar
Brake Unit
Collar
Adjusting
washer
Collar
Snap-Ring

REP5.38
DBM-500
part.
• Folding Brake/Folding Clutch (ADJ5.50)
• Belt tension (ADJ5.47)

REP5.38
DBM-500
REP5.39 Fold Rollers Gap 1 Motor (M511) REP5.40 Fold Rollers Gap 2 Motor (M512)

2. Disconnect the connector. 2. Remove the connector.
3. Remove the four screws securing the Fold Rollers Gap 1 Motor (M511) 3. Remove the four screws securing the Fold Rollers Gap 2 Motor (M512)
to the machine. to the machine.
Folding Roller Gap1 Motor
Folding Roller Gap2 Motor
Connector
Connector
Screw
Screw Screw
Screw

REP5.39, REP5.40
DBM-500
REP5.41 Base Moving Motor (M513) 5. Disconnect the two connectors.
6. Remove the four screws securing the Base Moving Motor (M513) to the
machine.
1. Remove the Cover L, Cover R and bracket with fan (REP5.11).
Screw Base Moving Motor
2. Remove the Inverter (REP5.15). Connector
3. Remove the two screws securing the Wire Harness Cover to the Screw
machine.
4. Remove the six screws securing the Cover to the machine.
Cover Wire Harness Cover
Screw
Screw
Screw
Connector
parts.
• Home Positions of Main Body (ADJ5.2)
• Chain Tension (ADJ5.3)

REP5.41
DBM-500
REP5.42 Infeed Section 5. Remove the three screws and three cable clamps.
6. Open the MC Unit (REP5.25, Step2).
7. Remove the screw and the cable clamp.
Bracket of upper infeed 8. Remove the two connectors and put them through the two holes of the
1. Remove the Cover L, Cover R and Front Top Cover. frame toward the inside of the machine.
Cable clamp MC Unit MC Unit Cable clamp
2. Remove the two screws, then remove the bracket.
Screw
Cable clamp
Pass the removed connectors through these holes. Connector
Bracket Connector
9. Remove the two screws securing the Remote Switch to the machine.
10. Remove the four screws securing the bracket above the top infeed
section.
4. Remove the two screws securing the Conveyance Roller Unit to the
machine.
Conveyance Roller Unit

Remote switch
Bracket

REP5.42
DBM-500
Bracket of lower infeed 5. Remove the two screws securing the E port bracket to the machine.
1. Remove the bracket of upper infeed.
3. Remove the eight screws securing the four square bars.
Squaer bar Squaer bar (hole type)
Squaer bar
Bracket
6. Remove the two screws securing the roller unit to the bracket.
7. Remove the four screws, and detach the bracket of lower infeed.
Paper feed
Screw Screw Roller Unit
(There are two more screws on the opposite side.) (There are two more screws on the opposite side.)
Bracket

Note: When attaching the roller unit, loosen the tension of the conveyance belt if
Sqaure bar Bracket necessary. After attaching the conveyance belt, adjust its tension (ADJ5.4).

REP5.42
DBM-500
7. Loosen the nut securing the shaft of the Pulley-1.
REP5.43 Folding Side Guide Unit
Pulley-1
1. Open the Rear Top Cover, then open the Folding Back Guide Unit.
2. Remove the Cover L (REP5.11). Nut
the Folding Side Guides (REP5.44, Step 15).
4. Remove the eight screws (white circles shown in the figure), then detach
the five Guide Plates (REP5.44, Step 16).
brackets.
Screw
8. Remove the two screws, then remove belt .

Screw
Bracket
Belt
6. Remove the four screws, to remove the Roller Unit.

Screw
Roller Unit

REP5.43
DBM-500
9. Pull out the Folding Side Guide Unit to the L side.
Folding Side Guide Unit
parts.
• Folding Guide Drive (ADJ5.33)

REP5.43
DBM-500
REP5.44 Transport Belts 7. Loosen the both side screws, then remove the Main Belt Tension Shaft.
R side
Conveyance Belt
1. Remove the Static Eliminator from SCC (REP4.2, Step 3).
2. Open the Front Top Cover and Rear Top Cover, then open the
Conveyance Roller Unit and Folding Back Guide Unit. Screw
3. Remove the L side and R side covers (REP5.11). Main Belt Tension Shaft
4. Remove the Stitcher Head of L side (REP5.3).

5. Loosen the one screw, then remove the three screws securing from the
Jog Unit Moving Motor (M501).
Jog Unit Moving Motor
6. Move the Jogger Unit to the center.
Jogger Unit
Sqaure bar Bracket

REP5.44
DBM-500
9. Remove the two screws securing the roller unit to the bracket. 11. Remove Roller Bracket and Motor Belt.
Roller Unit 12. Remove the E-ring from the Roller Shaft, then remove the Belt from the
Roller Bracket.
E-ring
Screw
Bracket
Roller Bracket
10. Remove the two Back Jog Belts.

13. Remove the two screws, Z collar and spring. Then slide the Side Stitch
Shaft.
Side Stitch Shaft Screw, Z collar
Back Jog Belt
R side
Screw
Back Jog Belt
Spring

REP5.44
DBM-500
14. Move Belt Through the Clinchers toward the Side Frame. 16. Remove the eight screws (white circles shown in the figure), then
detach the five Guide Plates.
Guide Plate
Belt
Guide Plate
15. Remove the four screws securing the Folding Side Guide to the
machine. 17. Loosen the nut securing the shaft of the Pulley-1.
Screw
18. Remove the belt from the pulley-1 and Timing pulley.
Folding side guide
19. Remove the Timing pulley.
Nut
Folding side guide Screw
Pulley -1
Shaft
Screw
(MSK 4 x16)
Timing pulley
Belt

REP5.44
DBM-500
20. Remove the two screws securing the bearing holder to the machine. 22. Push the bearing and set collar outward.
Set Collar
Screw
Bearing
Bearing holder
21. Loosen the two FR screws securing the set collar. 23. Remove the two screws.
24. Disconnect the connector and place through side frame.
Screw Connector
FR screw
Set Collar

REP5.44
DBM-500
25. Remove the spring and loosen Belt. 28. Lift Plate and Move Belt Between Plate and Mounting Bracket.
26. Remove the four screws and detach the Bracket.
Screw
Plate
Spring
Belt
Belt
Screw
Bracket Mounting Bracket
29. Pull the Belt out through the opening for the shaft.
27. Remove three screws. 30. Remove the Belt from the shaft, and pull the Belt back inside.
Belt
Shaft
Screw Screw
The Conveyance Belt will be removed from the main body.

REP5.44
DBM-500
Move Belt 36. Pull the Belt out through the opening for the shaft.
31. Remove the Fold Delivery Cluth (CL501) (REP5.34). 37. Remove the Belt from the shaft, and pull the Belt back inside.
32. Remove the Bracket of Lside (REP5.10, Step 2 to 7).
33. Remove the Folding Side Guide Unit (REP5.43).
34. Remove the four screws. Belt
Screw
Screw
Shaft
38. Move the Belt to the opposite direction from what you did in step 35.
39. Slide Belts Through Braces as shown.
35. Move Belts over as shown. Belt
Belt
Belt
Brace

REP5.44
DBM-500
40. Move Belts Through Shaft and out of the machine as shown.
Belt
parts.
• Stitch Position (ADJ5.19)

REP5.44
DBM-500
ADJ5.1 Sensors ADJ5.2 Home Positions of Main Body
1. Remove the Cover L, Cover R and bracket with fan (REP5.11).

WARNING
2. Remove the Cover (REP5.41, Step4).
3. Align the main body and base. View from the rear side of the machine to
make sure that they are aligned.
shock if touched.
4. Loosen the screw on the actuator.
1. Prepare two types of paper: 5. Move the actuator to position its edge in the middle of the sensor.
● Fine quality paper of 64 g/m² Upstream side view
● Tracing paper of 80 g/m² Top view

Screw
Note: If the user always uses thin paper, you can use such paper instead of above- Moving Base
Home Sensor
mentioned fine quality paper. (PS527)
2. Turn on the machine and start the Maintenance Mode (GP 2.5).
Main Body Actuator
3. Navigate to SENSOR and select the sensor to be adjusted.
4. Put a piece of paper on the paper path. Turn the dial to adjust the light
sensitivity as listed below.
● The IC (light receptor) does not sense the light when the fine quality
paper is between the LED (light emitter) and IC. Base
● The IC senses the light when the tracing paper is between the LED and Aligned
IC.
Note: The indicator of the IC (light receptor) responds when the IC is sensing 6. Tighten the screw.
light. Even so, do not forget to check the display on the Control Panel.
7. Put back the removed parts in the reverse procedures.
Light receptor (3 pins)
Paper
Light emitter (2 pins)
Dial

ADJ5.1, ADJ5.2
DBM-500
ADJ5.3 Chain Tension ADJ5.4 Conveyance Belt Tension
1. Remove the Cover L, Cover R and bracket with fan (REP5.11). 1. Remove the Cover L and Cover R (REP5.11).
2. Remove the Cover (REP5.41, Step4). 2. Loosen the screw.
3. Loosen the screws on the motor bracket. 3. Adjust the tension of the belt evenly to prevent the belt from separating
4. To increase the chain tension, move the bracket away from the sprocket. from the roller.
To decrease the chain tension, move the bracket closer to the sprocket.
The slack must be 1 to 2 mm (0.04 to 0.08 inch) at the middle of the
chain.
Upstream side view
Screw Screw
L side view
Paper feed
1 to 2 mm/
0.04 to 0.08”
Paper feed Conveyance Belt
Bracket
Base Moving Motor (M513) Chain Sprocket

Screw


ADJ5.3, ADJ5.4
DBM-500
ADJ5.5 Aligning the Side Stitching Stopper ADJ5.6 Positions of Side Stitching Stopper
1. Open the Front Top Cover and Rear Top Cover. 1.Open the Front Top Cover and Rear Top Cover.
2. Remove the Cover L (REP5.11). 2.Remove the Cover R (REP5.11).
3. Move the stitcher while turning the timing belt by hand to the position 3.Loosen screw 1 and screw 2. When necessary, loosen screw 3’s.
where you can see the screw securing the Side Stitching Stopper. 4.Adjust the position of the angles. When necessary, adjust the position of
4. Loosen the screws. the solenoid base, too. Make sure the side-stitching stopper moves in an
5. Adjust the positions of the stoppers. appropriate range:
Stopper
● The side-stitching stopper moves down, not interfering with the paper
Paper feed
path.
● The side-stitching stopper moves up to stop the lead edges of the sheets.
Note: The manufacturer adjusts the topmost position of the side-stitching stopper
at 10 ± 0.5 mm (0.39 ± 0.02 inch) above the conveyance belt.
Stopper
R side view
( 0 . 3 9 ± 0.02 inch)
1 0 ± 0 .5 m m
Side-stitching stopper
Base
Conveyance belt
Paper feed
6. Tighten the screws. Gap 0 to 0.3 mm

(0 to 0.012 inch)
Angle
7. Put back the removed parts in the reverse procedures. Side Stitch Stop
Solenoid (SL502)
Screw 1
Screw 2
Angle
Screw 3 Solenoid base


ADJ5.5, ADJ5.6
DBM-500
ADJ5.7 Solenoid Position of Saddle Stitching ADJ5.8 Belt Tension of Saddle Stitching Stopper
Stopper
1. Remove the Cover L and Cover R (REP5.11). 2. Loosen nut.
2. Loosen two screws from R side. 3. Adjust the belt tension. The belt slack must be 12 to 13 mm (0.48 to 0.52
3. Adjust the position of the solenoid: inch) in 1020 gm using a tension gauge.
● When the solenoid is on, the stopper properly stops the sheets. R side view
● When the solenoid is off, the stopper does not interfere with the paper Paper feed
path.
L side view
Belt
Stopper
90˚ Paper feed
Conveyance Guide
Nut
Saddle Stitch Stop

Solenoid (SL501)
Screw
4. Tighten the screw 2.
Saddle Stitch Stop 5. Put back the removed parts in the reverse procedures.
Solenoid (SL501)


ADJ5.7, ADJ5.8
DBM-500
ADJ5.9 Stopper Angle ADJ5.10 Aligning the Back Joggers
The block moves in accordance with rotation of the adjuster, which changes The Back Joggers consists of four pieces. Of the four, you can move the L
the tilt of the Saddle Stitching Stopper. side piece and the R side piece. By moving these two, you can align these
1. Open the Rear Top Cover. four pieces:
2. Open the Folding Back Guide Unit. 1. Open the Front Top Cover.
3. Turn the adjuster to adjust the tilt of the Saddle Stitching Stopper. 2. Open the Conveyance Roller Unit.
Stopper 3. Move the Jogger Unit to make enough working space.
Paper feed 4. Loosen screw 1 and screw 2.
5. To move the L side or R side piece.
6. Make sure the four pieces are aligned.
Note: When the paper width is less than 200 mm (7.87 inch), the front- and rear-
side pieces are under the Side Joggers.
Top view Screw 1
Block
Adjuster
Back Jogger
Paper feed
Screw 2
7. Tighten the screw 1 and screw 2.


ADJ5.9, ADJ5.10
DBM-500
ADJ5.11 Aligning the Back Jog Unit ADJ5.12 Timing Belt Tension
1. Open the Front Top Cover. 1. Remove the Cover L and Cover R (REP5.11).
2. Loosen the screw 1 and screw 2. 2. Loosen screw 3 and screw 4.
3. Adjust the bracket position so that the Back Jog Unit is aligned with the 3. Adjust the belt tension. The belt slack must be 9 to 10 mm (0.35 to 0.39
shaft. inch) in 300 gm using a tension gauge.
Top view Top view
Bracket
Screw 4
Belt
Screw 2 Screw 1
Shaft
Paper feed
Paper feed
Back Jog Unit
Belt
Screw 3


ADJ5.11, ADJ5.12
DBM-500
ADJ5.13 Drive Belt Tension ADJ5.14 Conveyance Belt Tension
1. Remove the Cover L, Cover R and bracket with fan (REP5.11). 1. Open the Front Top Cover.
2. Loosen screw 1’s. 2. Loosen screw 2’s.
3. Adjust the drive belt tension. The belt slack must be 6 to 7 mm (0.24 to 3. Adjust the conveyance belt tension. The belt slack must be 6 to 7 mm
0.28 inch) in 510 gm using a tension gauge. (0.24 to 0.28 inch) in 408 gm using a tension gauge.
Rear view Rear view
Conveyance belt
Paper feed Paper feed
Angle
Screw 1
Drive belt Screw 2
Motor bracket
Jog Belt Drive Motor Jog Belt Drive Motor

(M503) (M503)
4. Tighten the screw 1’s. 4. Tighten the screw 2’s. Make sure that the belts do not touch the angle or
5. Put back the removed parts in the reverse procedures. joggers.

ADJ5.13, ADJ5.14
DBM-500
ADJ5.15 Aligning the Side Joggers ADJ5.16 Aligning Middle Guides
1. Open the Front Top Cover. 1. Open the Front Top Cover.
2. Loosen the screws. 2. Loosen the screws.
3. Turn the eccentric collars so that the edge of the Side Jog Guide is 3. Align the Middle Guide and Side Jog Guide. Make sure the Middle
aligned with that of the block. Guide is not lower to the paper path than the Side Jog Guide.
Note: If necessary, adjust the Side Jog Guide again depending on the paper
feeding condition. Top view
Top view
Middle Guide
Block
Side Jog Guide
Parallel
Screw
Side Jog
Guide
Paper feed Eccentric
collars
Screw
Paper feed
Parallel
Block

5. Close the Front Top Cover. 4. Tighten the screws.
5. Close the Front Top Cover.

ADJ5.15, ADJ5.16
DBM-500
ADJ5.17 Side Jogger Drive
Top view
Screw 2
Motor belt
Side Jog Moving

Motor (M504)
Common Procedure
Motor bracket
3. Adjust each part. Bracket

Block
Screw 4
Timing Belt Tension

1. Loosen the nut 1. Paper feed
Angle
2. Adjust the position of the pulley so that the slack of the timing belt is 14
Screw 3
to 15 mm (0.55 to 0.59 inch) when adding a load of 1 kgf to its center. Timing belt

Angle
Motor Belt Tension Block
1. Loosen the screw 2’s. Bracket

2. Adjust the position of the motor bracket so that the slack of the motor
belt is 4 to 5 mm (0.16 to 0.20 inch) when adding a load of 1 kgf to its
center.
3. Tighten the screws. Nut 1 Pulley
Block Positions
The two blocks must touch the brackets at the same time.
If the blocks are out of proper position, the side joggers will not move to the
correct position according to paper sizes entered.
1. Remove the Side Jog Guides (REP5.20).
2. Loosen screw 3’s and screw 4’s.
3. Move the block on the L side to the L side; move the block on the R
side to the R side. Make sure that both blocks are in contact with the
brackets.
5. Mount the Side Joggers.

ADJ5.17
DBM-500
ADJ5.18 Adjusting Stitchers Checking Stitching
WARNING
WARNING Keep your clothing, hands, hair, and any part of your body away from the
Stitchers and drive mechanism when operating the Stitchers. The stitching
Turn off the Main Power Switch and disconnect the power cord before
wire can injure you severely. The Stitchers and drive mechanism can catch
removing or mechanically adjusting the Stitchers. The stitching wire can
your clothing, hands, hair, and any part of your body, injuring you severely.
injure you severely. The Stitchers and drive mechanism can catch your
clothing, hands, hair, and any part of your body, injuring you severely.
Follow the procedures below for a stitch test of the stitcher.
1. Click the icon of the DUPLO Inline Controller. If you do not see the icon,
WARNING choose Start and DUPLO Inline Controller.
Keep your clothing, hands, hair, and any part of your body away from the The Setup screen will appear.
Stitchers and drive mechanism when operating the Stitchers. The stitching 2. Enter an Operator ID, Order ID, and Job name, then select a number of
wire can injure you severely. The Stitchers and drive mechanism can catch sheet.
3. Click the SCC tab.
WARNING
Do not operate the Stitcher when any part of the Stitchers and drive
mechanism is damaged. The Stitcher, stitching wi re, and/or dr ive 4. Set Process Mode to Through.
mechanism can make unexpected actions, injuring you severely.
CAUTION Through
Keep your tools away from the Stitchers and drive mechanism when
5. Click the DBM-500 tab.
operating the Stitchers. The Stitchers and/or drive mechanism may be
damaged if they catch or hit a tool.
6. Set Stitch Mode to Saddle.

ADJ5.18
DBM-500
7. Press the Send button. 12. Check each value shown to the right of “ L Guide “ and “ R Guide “ on
the screen.
8. Press the OPTION tab on the DBM-500 Touch Panel to display the
option menu.
9. Press the Next key to change the screen.
13. Move the L guide and R guide according to each value shown on the
Next key screen.
10. Press the Stitch Test key.

The stitch test action screen will appear.
Feed guide
Stitch Test key Stitch Action key

R Guide
11. Click the Hand Feed button on the DUPLO Inline Controller. L Guide

ADJ5.18
DBM-500
14. Push the Button A on the Control Panel of the SCC. 17. Take out the stitched sheet from the paper receive and check the
stitching condition.
When the condition is not satisfactory, adjust the stitcher head.
Button A
15. Put a sheet in the slot piece by piece.

The TR-DP will send the sheet to SCC.
Paper Receive
To finish the stitch test, press the MAINMENU tab on the DBM-500 Touch
Panel several times.
16. When all the sheets have been sent to the DBM-500, press the Stitch
Test Action key on the DBM-500 Touch Panel.
The DBM-500 will perform stitching actions several times and eject the
stitched sheet to the Paper Receive.
Stitch Action key

ADJ5.18
DBM-500
ADJ5.19 Aligning Stitcher Position ADJ5.20 Aligning Clincher Position
WARNING WARNING
Turn off the Main Power Switch and disconnect the power cord before Turn off the Main Power Switch and disconnect the power cord before
removing or mechanically adjusting the Stitchers. The stitching wire can removing or mechanically adjusting the Stitchers. The stitching wire can
injure you severely. The Stitchers and drive mechanism can catch your injure you severely. The Stitchers and drive mechanism can catch your
clothing, hands, hair, and any part of your body, injuring you severely. clothing, hands, hair, and any part of your body, injuring you severely.
To move the stitcher to the front side or rear side, follow these steps: To move the Clincher to the L side or R side, follow these steps:
1. Loosen the screws using the supplied wrench. 1. Loosen the nuts.
2. Adjust the position of the Stitcher. 2. Lower the driver of the stitcher head.
3. Tighten the screw 2. 3. Adjust the position of the Clincher. Check that the clincher meets the
middle line of the stitcher head, then secure the clincher.
To move the Stitcher to the upstream or downstream, follow these steps:
Note: When aligning the edge of the Clincher Holder with the edge of the Clincher
1. Remove the screws using the supplied wrench, then remove the stitcher Assy, the clincher will come to the center location of the stitcher head.
from the head holder. 4. Tighten the nuts.
2. Attach or remove the spacer or tape on the surface that faces the head
holder. Attach the similar spacer or tape over and below the opening. Or
remove the same number of strips from these two positions.
3. Mount the Stitcher back on the head holder.
Head holder
Opening
Stitcher Head Driver

Spacer
Clincher Nut
Wrench
Screw
Clincher
Clincher assy
holder

ADJ5.19, ADJ5.20
DBM-500
ADJ5.21 Stitcher and Clincher Positions ADJ5.22 Home Position of Stitcher
To adjust the home position of the stitchers, follow these steps:

WARNING
1. Start the Maintenance Mode (GP2.5).
removing or mechanically adjusting the Stitchers. The stitching wire can 2. Select MOTION & SIMULATE. The Motion Check panel is displayed.
injure you severely. The Stitchers and drive mechanism can catch your 3. Touch the right-arrow button ( ). The Simulation Check panel is
clothing, hands, hair, and any part of your body, injuring you severely. displayed.
4. Touch the down-arrow button ( ) several times until you see 14.
To adjust the positions of the Stitchers, Clinchers, and driving mechanism, Stitcher moving motor.
follow these steps:
5. Touch the start key ( ) on the display. The machine start to initialize its
1. Loosen the screws on the timing pulleys and collars. units and components. Wait until the machine stops.
2. Adjust the positions of the Stitchers and Clinchers. Make sure the 6. Measure the distance between the two front sides of the holders. The
Clinchers are right under the Stitchers. distance should be 70 mm (2.76 inch).
3. Tighten the screws. 7. To adjust the distance, loosen the two screws on the plate and move the
Upstream side view Stitcher Head Holder plate.
● If the distance is too long, move the plate to the R side.
● If the distance is too short, move the plate to the L side.
Shaft Paper feed
Collar
Timing pulley
Stitcher head
7.5±0.5 mm 7.5±0.5 mm
(0.3±0.02 inch) (0.3±0.02 inch)
70 mm (2.76 inches)
Shaft
Collar
Timing pulley Screw
Clincher Holder
Holder
Plate
Actuator

ADJ5.21, ADJ5.22
DBM-500
ADJ5.23 Wire Angle 5. Attach the former and reset the leaf spring.
WARNING
Handle
Leaf spring
If the wire does not go horizontal at its end, adjust the wire angle by
following these step: Leaf spring
1. Raise the bottom end of the leaf spring and turn it.
2. Remove the former by pulling it. Turn clockwise
Former
3. Attach the handle on the dial. OK
Turn counter-
Note: This handle comes with the machine. Wire straightener clockwise
Wire straightener
4. To feed the wire, turn the handle. See if the wire goes horizontal. When
the wire does not go horizontal at its end, turn the wire straightener to
adjust the wire path.
Note: Cut the end of wire by pressing down the top of the slider.
Slider

ADJ5.23
DBM-500
ADJ5.24 Wire Length
Wire length adjuster
WARNING
Gear rack
WARNING
Keep your clothing, hands, hair, and any part of your body away from the
Stitchers and drive mechanism when operating the Stitchers. The stitching
wire can injure you severely. The Stitchers and drive mechanism can catch
The recommended wire length for two-sheet stitching is about 23 mm (0.91

inch). To adjust the wire length, follow these steps:
1. For normal stitching, turn the Wire Length Adjuster until the top of the
Gear Rack is at “N.” For loop stitching, turn the adjuster until the top is
at “L.”
2. Conduct a Stitch test (ADJ5.18).
3. Replace the wire length, if necessary, as follows:
● To make the wire longer, turn the Wire Length Adjuster clockwise.
● To make the wire shorter, turn the Wire Length Adjuster
counterclockwise.
Note: If you turn the adjuster 360°, the wire length changes by 0.8 mm (0.03
inch).

ADJ5.24
DBM-500
ADJ5.25 Leg Length ● Turn the wheel up to correct the wire legs in example 1.
● Turn the wheel down to correct the wire legs in example 2.
Upstream side view
WARNING
Same length
Example 1 Example 2
clothing, hands, hair, and any part of your body, injuring you severely. 2. Conduct a Stitch test (ADJ5.18). See if the two wire legs are of the same
length. If necessary, repeat step 1.
When the length of the two wire legs are not the same, adjust it by following
these steps:
1. Turn the dial. See where the end of the Pin is. The unit of the gauge is
1 mm. For example, when you move the Pin from “3” to “7,” the wire
length becomes longer by 4 mm (0.16 inch). The upper gauge is for
normal stitching; the lower gauge is for loop stitching.
Pin
Gauge for normal stitching
Gauge for loop stitching
Dial

ADJ5.25
DBM-500
ADJ5.26 Wire Position ADJ5.27 Wire Clinch
WARNING WARNING
Turn off the Main Power Switch and disconnect the power cord before Turn off the Main Power Switch and disconnect the power cord before
removing or mechanically adjusting the Stitchers. The stitching wire can removing or mechanically adjusting the Stitchers. The stitching wire can
injure you severely. The Stitchers and drive mechanism can catch your injure you severely. The Stitchers and drive mechanism can catch your
clothing, hands, hair, and any part of your body, injuring you severely. clothing, hands, hair, and any part of your body, injuring you severely.
The wire must be right below the bender groove. When you change the size If stitch legs are clinched insufficiently, or clinched too much (and booklets
of the stitching wire, you must check the wire position. To adjust the wire are damaged), adjust the action of the Clincher by following these steps:
position, follow these steps: 1. When the stitcher head driver is at the lower limit position, check that
1. Loosen the screw 1. the cam follower (bearing) is at the cam top. If not at the above position,
2. Turn the screw 2 to adjust the position of the former. As the former adjust the cam position.
changes its position, the wire changes its position. 2. Setting a large protrusion of the clincher increases the bending of the
3. Tighten the screw 1. wire. However, if the protrusion amount is too large, take note that the
paper will break.
Former Screw 2
3. Adjust the attaching angle of the concentric center pin and adjust the
Groove Groove protrusion of the clincher.
4. Loosen the fixing screw of the center pin and secure after adjusting the
angle.
Screw 1
Clincher
Bender
Center pin
Cam follower
(Bearing)
Bottom view
Cam
Cam-adjusting hole

ADJ5.26, ADJ5.27
DBM-500
ADJ5.28 Bender Stop ADJ5.29 Disc Knife
1. Loosen the screw.

WARNING
2. Insert a screw driver behind the Disc Knife.
3. Push the disc knife on to the flat knife.
injure you severely. The Stitchers and drive mechanism can catch your 4. Tighten the screw.
clothing, hands, hair, and any part of your body, injuring you severely. When you have reassembled them, check that the bender and flat knife
moves correctly.
The Bender Stop prevents the bender from hitting booklets. The position of
the Bender Stop is adjusted before shipment.
1. See the gauge and note the position of the slide.
Disc knife
2. To adjust the position of the Bender Stop, loosen the screw and move the
slide.
Flat knife
Screw
Screw
Bender stop/Gauge Slide

ADJ5.28, ADJ5.29
DBM-500
ADJ5.30 Eject Roller 1 ADJ5.31 Eject Roller 2
1.Open the Front Top Cover. 1.Open the Rear Top Cover.
2.Remove the Cover R (REP5.11). 2.Remove the Cover R (REP5.11).
3.Open the MC Unit (REP5.25, Step2). 3.Loosen the screws.
4.Loosen the screws. 4.Adjust the position of the Solenoid Base. Make sure the Eject Roller 2
5.Adjust the position of the Solenoid Base. Make sure the Eject Roller 1 moves in an appropriate range:
moves in an appropriate range: ● When the roller moves down, it touches the conveyance belt.
● When the roller moves down, it touches the conveyance belt. ● When the roller moves up, it does not interfere with the paper path.
● When the roller moves up, it does not interfere with the paper path. Gap 0 to 0.3 mm
(0 to 0.012 inch)
Solenoid base
Screw
Solenoid base
Gap 0 to 0.3 mm
(0 to 0.012 inch)
Screw
Paper feed
Eject roller 2 Conveyance belt Stitch Delivery 2

Solenoid (SL504)
Stitch Delivery 1 Solenoid
(SL503)
Ejection roller 1
Conveyance belt
Paper feed


ADJ5.30, ADJ5.31
DBM-500
ADJ5.32 Aligning the Folding Side Guides
1. Open the Rear Top Cover.

2. Loosen the screws.
3. Position a sheet of 11”x17” card stack between folding side guides.
4. Turn the collars to adjust the position of the folding side guides. Make
sure the guides are parallel, just touching the card stack.
Top view
Screw Eccentric
collar
Folding Side Guide Paper feed
Eccentric
Screw collar

8. Close the Rear Top Cover.

ADJ5.32
DBM-500
ADJ5.33 Folding Guide Drive
Top view
Screw 2
Motor belt
Folding Side Guide

Motor (M510)
Common Procedure
Motor bracket
3. Adjust each part. Bracket

Block
Screw 4
Timing Belt Tension

1. Loosen the nut 1. Paper feed
Angle
2. Adjust the position of the pulley so that the slack of the timing belt is 14
Screw 3
to 15 mm (0.55 to 0.59 inch) when adding a load of 1 kgf to its center. Timing belt

Angle
Motor Belt Tension Block
1. Loosen screw 2’s. Bracket

2. Adjust the position of the motor bracket so that the slack of the motor
belt is 4 to 5 mm (0.16 to 0.20 inch) when adding a load of 1 kgf to its
center.
3. Tighten the screws. Nut 1 Pulley
Block Positions
The two blocks must touch the brackets at the same time.
If the blocks are out of proper position, the Folding Side Guides will not
move to the correct position according to paper sizes entered.
1. Remove the Folding Side Guides (REP5.20).
2. Loosen screw 3’s and screw 4’s.
3. Move the block on the L side to the L side; move the block on the R
side to the R side. Make sure that both blocks are in contact with the
Brackets.
5. Mount the Folding Side Guides.

ADJ5.33
DBM-500
ADJ5.34 Belt Tension of Folding Back Guide ADJ5.35 Aligning Blocks of Folding Back Guide
1. Open the Rear Top Cover. 1. Open the Rear Top Cover.
2. Loosen the screw. 2. Open the Folding Back Guide Unit.
3. To prevent the skipping of the belt, adjust the position of the shaft. 3. Loosen the screws.
Belt Screw/Shaft
4. To align the blocks, move the bracket.
Screw
Bracket
Block Block
Paper feed

Paper feed

6. Close the Folding Back Guide Unit.

ADJ5.34, ADJ5.35
DBM-500
ADJ5.36 Solenoid Position of Folding Back Guide ADJ5.37 Block Position of Folding Back Guide
1. Open the Rear Top Cover. 1. Open the Rear Top Cover.
2. Remove four screws, and remove the cover of the Folding Back Guide 2. Open the Folding Back Guide Unit.
Unit. 3. Loosen the screw.
3. Loosen the screws. 4. To adjust the position of the block, turn the angle. The block should be
4. Adjust the position of the solenoid. The solenoid should have 0.2 to 0.5 19 mm (0.75 inch) from the end of the bracket.
mm (0.008 to 0.02 inch) to go when the block has reached the stay.
0.2 to 0.5 mm(0.008 to 0.02 inch)
Angle
Solenoid Bracket Screw
Back Stopper
Solenoid
(SL505) Screw
Bracket
Paper feed
Block
19 mm
(0.75 inch)
Paper feed Block
Stay

5. Tighten the screws. 6. Close the Folding Back Guide Unit.
6. Put back the removed parts in the reverse procedures. 7. Close the Rear Top Cover.

ADJ5.36, ADJ5.37
DBM-500
ADJ5.38 Folding Stopper ADJ5.39 Lift Action

Common Procedure 2. Loosen the screw.
1. Open the Rear Top Cover. 3. Adjust the position of the actuator. The actuator must be in its lower
2. Adjust each part. position when the Folding Stopper is in its lower position.
3. Put back the removed parts in the reverse procedures. R side view
Timing Belt Non-fold Home

Screw
Paper feed
1. Loosen the screw 1. Sensor (PS513)
2. To prevent skipping of the timing belt, adjust the position of the gear.
Gear Timing belt
Screw 1
Paper feed
Actuator
Conveyance Belt 5. Put back the removed parts in the reverse procedures.
1. Loosen screw 2.
2. Adjust the position of the roller to prevent the slack of the conveyance
belt.
Conveyance belt
Paper feed
Screw 2 Roller

ADJ5.38, ADJ5.39
DBM-500
ADJ5.40 Side Stitch Ejection Roller ADJ5.41 Stacker Full Sensor
1. Remove the Cover R (REP5.11). 1. Remove the screws and the Stacker Full Sensor.
2. Loosen the screws. 2. Adjust sensor as needed.
3. To adjust the position of the Side Stitch Ejection Roller, move the
solenoid base. The solenoid should have 0.2 to 0.5 mm (0.008 to 0.02
inch) to go when the Ejection Roller has reached the drive roller.
R side view Stacker Full Sensor
(PS516)
Screw
(0.008 inch to 0.02 inch)
0 .2 m m to 0 .5 m m
Ejection roller

Solenoid base
Paper feed
Drive roller
Screw
Side Stitch Delivery

Solenoid (SL506)

5. Attach the Cover R.

ADJ5.40, ADJ5.41
DBM-500
ADJ5.42 Blade Position 4. Tighten the screws.
3. To adjust the blade position, move the brackets. The downstream side of
the base is 20±01 mm (0.78±0.004 inch) from the upstream edge of the
opening. Make sure the blade goes between the Folding Rollers.
L side view R side view
Folding Roller
Blade
Paper feed Paper feed
Screw Screw Screw Screw
Bracket Bracket Bracket Bracket
Screw Screw Screw Screw
Base
20 ± 0.1 mm
(0.78 ± 0.004 inch)
Opening on the frame
Opening on
the frame

ADJ5.42
DBM-500
ADJ5.43 Folding Rollers 4. Tighten the screws.
6. Turn on the machine or execute a Size Change. And wait until the
To adjust the distance between the Folding Rollers, adjust the position of
Folding Rollers come to their home positions.
the home position sensor. The Folding Rollers are in their home positions
when the actuator is in the sensor. 7. Make sure the gap is appropriate. If necessary, repeat these steps.
3. To adjust the gap between the Folding Rollers, move the position of the
sensor angle. You must adjust the positions of the sensor angles on both
sides of the machine. The distance between the centers of two Folding
Rollers must be 30.3 mm (1.19 inches).
Note: The gap does not change until you turn on the machine or execute a Size
Change (see step 4).
L side view R side view
Screw Screw
Actuator Sensor angle Sensor angle Actuator
Screw Screw
Folding Rollers Gap-1 Folding Rollers Gap-2

Home Sensor (PS520) Home Sensor (PS521)
Top view
Folding Roller
Paper feed
30.3 mm
(1.19 inch)

REP5.43
DBM-500
ADJ5.44 Press Rollers Gap
2. Loosen the nut.
Position 3. To adjust the gap between the Press Rollers, turn the screw. As screw
1. Remove the Cover L and Cover R (REP5.11). turns, the position of the cam changes. You must change the positions
of the cams on both sides of the machine. The gap between the rollers
2. Loosen the FR screws.
must be 0 to 0.5 mm (0 to 0.02 inch).
3. Adjust the position of the Press Rollers so that the distance between the Note: To measure the gap, insert several sheets of paper whose thickness you
inside of the R side frame and the edge of the Press Rollers is 36 ± 0.5 know.
mm (1.42 ± 0.02 inch). Top view
R side Washer 20N sprocket

Nut
(1.42 ± 0.02 inch)
Sprocket
36 ± 0.5 mm
Screw Cam
Gear
Spa gear
Press Roller Press Roller
Paper feed
0 to 0.5 mm
Lever unit R (0 to 0.02 inch)
Set collar (x2) 4. Put back the removed parts in the reverse procedures.
Press roller R
Press roller L
Lever unit L
Timing pulley Center pin (x2)
Collar (x2)
Set collar (x2) Center pin (x2)
20S5M pulley
4. Tighten the FR screws.

5. Close the Front Top Cover and Rear Top Cover.

ADJ5.44
DBM-500
ADJ5.45 Press Roller Adjusters ADJ5.46 Top Cover Switches
You can use adjusters: 1. Open the Front Top Cover and Rear Top Cover.
● Adjusting the pressure between the Press Rollers—The pressure 2. Loosen the screws on the bracket.
between the Press Rollers is automatically controlled. Keep Adjuster 3. To adjust the position of the switch, move the bracket:
1’s in the highest positions as long as no problem occurs. If the folded ● Make sure you can open and close the Top Covers with ease.
sheets are not fed by the Press Rollers, or if the sheets go oblique while
● Make sure the actuators engages with the switches.
passing between these rollers, change the positions of these adjusters.
Adjuster 1 Adjuster 2 Adjuster 2 Adjuster 1 ● Make sure the machine outputs an error message when you open the
Top Cover.
Lower Top view
Lower
Higher Higher
Lowest Lowest
Lower
Higher Lower
Paper feed
Highest Higher
Highest
● Adjusting the pressure on the paper path—After folded and pressed,

the sheets are transferred by the four belts that make the paper path Top Cover Switch (Front) Top Cover Switch (Back)
(SSW504) (SSW505)
to the paper exit. The pressure on this paper path can be adjusted by
Adjuster 2’s. Keep these adjusters in the higher positions as long as no Top Cover
problem occurs. If the sheets do not travel, change the positions of these
adjusters.
Actuator
Actuator
Bracket Bracket
Top Cover Switch (Front) Top Cover Switch (Back)

(SSW504) (SSW505)
Paper feed

5. Close the Front Top Cover and Rear Top Cover.

ADJ5.45, ADJ5.46
DBM-500
ADJ5.47 Main Drive System
B L side view
Screw
d
To adjust the tension of each belt, follow these steps:
2. Loosen the screw or screws. Screw
c
3. Adjust the position of the motor, gear, roller, or bracket. Push Screw
b
the belt or chain in the force of 1020 gm. For the recommended e
tension, see the table below. Screw
4. Tighten the screw or screws. Screw

The table lists the distance of slack
Slack
a 5 to 10 mm (0.20 to 0.39 inch)
b 5 to 8 mm (0.20 to 0.31 inch) Main Drive Motor (M514)
c 5 to 8 mm (0.20 to 0.31 inch) Screw a
d 5 to 8 mm (0.20 to 0.31 inch)

e 5 to 10 mm (0.20 to 0.39 inch)
f 5 to 10 mm (0.20 to 0.39 inch)
g 5 to 10 mm (0.20 to 0.39 inch) Linked to A
h 5 to 10 mm (0.20 to 0.39 inch)
R side view
i 10 to 15 mm (0.39 to 0.59 inch) Linked to B
j 5 to 10 mm (0.20 to 0.39 inch)
5. Attach the Cover L and Cover R.
j
Screw
i
Screw
Nut
h
f
g
Screw
Screw

ADJ5.47
DBM-500
ADJ5.48 Side Jogger Brake ADJ5.49 Stitching Brake/Stitching Clutch
1. Remove the Side Jogger Brake (BRK501) (REP5.22). R side
2. Pull the shaft in the direction of the arrow and attach the brake with the Armature Gap A 0.2 to 0.3 mm
(BRK502) (0.008 to 0.012 inch)
gap of 0.2 to 0.3 mm when there is no end-play of the shaft.
Bearing A
Sprocket
Position with shaft

Armature
pressed against
(CL502)
bearing
Gap B 0.2 to 0.3 mm

BRK501 Stator
(0.008 to 0.012 inch)
0.2 to 0.3 mm G ring

(0.008 to 0.012 inch)
Shaft
Shaft Stitching Brake (BRK502)

1. Remove the Stitching Brake (BRK502) (REP5.37).
2. Press the shaft against the bearing A.
3. Adjust the number of a shim so that the Gap A is 0.2 to 0.3 mm, then
3. Put back the removed parts in the reverse procedures. secure the armature.
Stitching Clutch (CL502)

1. Remove the Stitching Clutch (CL502) (REP5.36).
2. Make sure that the shaft does not move to the thrust direction.
3. While pressing the stator against the G ring, move the armature to the
stator.
4. Adjust the number of a shim so that the Gap B is 0.2 to 0.3 mm, then
secure the armature with the sprocket.

ADJ5.48, ADJ5.49
DBM-500
ADJ5.50 Folding Brake/Folding Clutch
R side
(1.02 ± 0.02 inch)

26 ± 0.5 mm
G ring
Armature unit
(CL503)
Gap A 0.2 to 0.3 mm

(0.008 to 0.012 inch)
Stator Bearing A
Collar
Gap B 0.2 to 0.3 mm
(0.008 to 0.012 inch)
Folding drive shaft unit Armature

(BRK503)
Folding Brake (BRK503)

1. Remove the Folding Brake (BRK503) (REP5.38).
3. Adjust the number of a shim so that the Gap A is 0.2 to 0.3 mm, then
secure the armature.
Folding Clutch (CL503)

1. Remove the Folding Clutch (CL503) (REP5.38).
3. While pressing the armature against the G ring, move the armature unit
to the stator.
4. Adjust the number of a shim so that the Gap B is 0.2 to 0.3 mm and
secure the stator with the collar.

ADJ5.50
DBM-500T
REP6.1 MC Unit (PCB601) Replacement Procedure
2. Remove all the connectors from the MC Unit.
Replacing the EEPROM 3. Remove the four screws to detach the MC Unit.
MC Unit
The EEPROM (U05), nonvolatile memory, on the MC Unit (PCB601) stores
the settings you and the user have made. When replacing the MC Unit
(PCB601), choose one of the following procedures:
• Remove the currently used EEPROM (U05) out of the old MC Unit
(PCB601), and install it on the new MC Unit (PCB601).
• Initialize the new EEPROM (U05) and manually restore all the
settings by typing necessary keys on the Control Panel (see Initializing
EEPROM ).
U02 U05 U04 4. Attach a new MC Unit.

Attach the MC Unit in the reverse procedure to removing it.
4-159 Section 4—Replacement and Adjustment DBM-500T

REP6.1
DBM-500T
Initializing EEPROM
You can initialize the EEPROM (U05). To do so, follow these steps:
1. Press the Ejection Button, and keep pressing it through the following
steps.
Ejection button
2. While pressing the Ejection Button, activate the DBM-500T alone

(GP1.2).
3. Keep pressing the Ejection Button until the machine makes an alarm
tone three times. These alarm tones indicate the EEPROM (U05) is
initialized.
4. Manually restore settings (GP2.6, Other Setting).

REP6.1
DBM-500T
REP6.2 Upper/Lower Blade 7. Remove the four screws securing the Protect Cover to the machine.
Protect Cover
CAUTION
Use extreme caution when handling the blade. You can be seriously
injured if you touch the edge.
1. Remove the Cover L, Cover R and Front Cover (REP6.3).

2. Remove the Guide Plate (REP6.4).
3. Release the brake (REP6.10).
5. Push the shaft in the direction of the arrow to remove it.
6. Remove the Conveyance Shaft Unit located on the paper infeed side.
Shaft
8. Remove the spring from the L side and R side.
L side R side
Shaft
Spring Spring
Conveyance
Shaft Unit

REP6.2
DBM-500T
9. Remove the screw and pull out the Sensor (PS603). 14. Remove the screw securing the shaft located on the each of the
10. Disconnect the connector and remove the Sensor (PS603). Conveyance Gap Unit.
11. Disconnect the connector. Note: Be careful not to lose the washer and spring when removing the shaft unit.
12. Remove the screw and cable clamp. Screw Shaft unit
Shaft unit
Connector
Cable Clamp
Spring
Washer
15. Remove the screw, Rail R and Conveyance Gap Unit.

Sensor (PS603) Connector Note: The bearings are inserted into the wheel unit (large). When you remove
the Rail R, the bearings may drop. Be careful not to lose the bearings.
13. Remove the four screws and pull out the Conveyance Gap Unit. Screw Bearing
Screw
Conveyance Gap Unit
Bearing Rail R
Conveyance gap unit
Screw
Bearing
Bearing
Wheel unit (Large)

REP6.2
DBM-500T
16. Take out the wheel unit (large). CAUTION
Note: The bearings are inserted into the wheel unit (large). When you remove Use extreme caution when handling the blade. You can be seriously
the Rail R, the bearings may drop. Be careful not to lose the bearings. injured if you touch the edge.
18. Remove the 16 screws, then remove the four Guide Plates from the
paper feed side.
Bearing
Bearing
Wheel unit (Large)
17. Remove the Top Cover and Back Cover (REP6.3) and loosen the two
screws to move the Stopper Unit.
Note: Turning the Pulley by hand will move the Stopper Unit.
Stopper unit Blade part Guide Plate
Pulley Screw

REP6.2
DBM-500T
19. Remove the Wheel Unit. 21. Remove the ten screws to pull out the five Pressure Units.
Note: When you remove it, make sure that the Wheel Unit does not touch the 22. Attach the adjustment screw with nut (HS6×25) to the central part of
Lower Conveyance Belt. the side of the lower blade by hand.
20. Remove the two screws to detach the Guide. Note: Use the adjustment screw with nut (HS6x25) supplied with the DBM-
500T. (See Introduction, Tool/Oil/Grease)
Guide
Pressure Unit Pressure Unit Screw with nut (HSK6x25)
Spacer
Z Collar
Wheel Unit

REP6.2
DBM-500T
23. Remove the eight screws securing the Air Blow Boxes on the L side CAUTION
and R side. Before removing the holding plate, fix it to the upper blade. If you do not fix
Note: To adjust interlocking between the upper blade and lower blade without the holding plate to the upper blade, the upper blade falls down into the
changing the blade, refer to ADJ6.17. machine when you remove the holding plate.
Air Blow Box
25. Attach the two drop prevention screws (HS6×100) to the upper blade.
Note: Use the drop prevention screw (HS6x100) supplied with the DBM-500T
(See Introduction, Tool/Oil/Grease).
Drop prevention screw
L side Air Blow Box R side
Note: After removing the Air Blow Boxes, the machine will look like the figure
below looking from the paper feed section side.
CAUTION
Do not hold the upper blade when removing it with the holding plate.
Grasp the two HS6x100 screws.
26. Remove the ten fixing screws for the upper blade and detach the upper
blade while gripping the two drop prevention screws (HS6x100).
Fixing screw for
the upperr blade
24. Remove the two screws securing the Angle to the machine.

Fixing screw for the upperr blade
Angle

REP6.2
DBM-500T
CAUTION CAUTION
To replace the lower blade safely, remove the upper blade first. Use extreme caution when handling the blade. You can be seriously
injured if you touch the edge.
27. Loosen the adjustment screws (a,b,c).
28. Remove the four fixing screws securing the lower blade to the machine. 31. Remove the two drop prevention screws (HS6×100) from the upper
blade that you removed in step 25 and attach those screws to the new
blade.
Adjustment screw (a)
32. Mount the new upper blade with the drop prevention screws (HS6×100)
attached.
33. Remove the two drop prevention screws (HS6×100) from the new upper
Fixing screw for blade.
the lower blade
34. Adjust interlocking between the upper and lower blades (ADJ6.9).
35. Attach the parts you removed in steps between 1 and 24 in the reverse
procedures.
CAUTION
Adjustment screw (b)
• You can attach the wheel unit for the lower conveyance only after
removing the adjustment screws with nut (HS6×25) you attached in step 22.
• After putting back the Z collar, Guide Plate and pressure units
removed in steps 20 and 21, make sure that these parts work properly.
• Make sure that you remove the brake release screw attached in step 3.
Turning on the power with the brake release screw attached may damage
the Upper Blade Clutch/Brake (CL/BRK).
Fixing screw for
the lower blade
Adjustment screw (c) 36. Check the followings after completing the above procedures.
• If the Conveyance Gap Motor (M603) works properly.
• If the Upper and Lower Conveyance Belts turn without winding.
• If the replaced blade trim paper neatly.
29. Loosen the adjustment screws (a,b,c) and attach a new lower blade.
Note: To loosen the adjustment screws (a,b,c), loosen their securing nuts first.
30. To prevent contact between the replaced lower blade and upper blade,
move the lower blade in the direction of the arrow and fasten them with
four screws temporarily.

REP6.2
DBM-500T
REP6.3 Exterior Covers REP6.4 Guide Plate of Waste Bin
1. Disconnect the DBM-500T from the downstream unit and upstream unit 1. Remove the Cover L, Cover R and Front Cover (REP6.3).
(See Section 8). 2. Remove the two screws securing the Waste Bin Switch (SSW603) to the
2. Take out the Waste Bin. Guide Plate.
3. Remove the screws securing the Cover L, Cover R, Front Cover and 3. Loosen the two fixing screws securing the Plate.
Back Cover to the machine. 4. Remove the six screws and Guide Plate while holding up the Plate.
Back Cover
Cover R
Waste Bin Switch
(SSW603)
Plate
Guide Plate
Front Cover
procedures.
Cover L
When you attach the parts removed in step 2, follow the reverse procedure
to removing them.

REP6.3, REP6.4
DBM-500T
1. Remove the Back Cover (REP6.3). 1. Remove the Back Cover (REP6.3).
2. Remove all the connectors from the Switching Power Supply (PCB603). 2. Remove all the connectors from the Relay Board (PCB604).
3. Remove the four screws securing the Switching Power Supply (PCB603) 3. Remove the four screws securing the Relay Board (PCB604) to the
to the machine. machine.
Switching Power Supply (PCB603) Note: The collars are attached to each screw as shown in the figure below.When
you remove the Relay Board (PCB604), be careful not to lose the collars.
RL PWB Unit (PCB604)
Connector
Collar
Collar
Connector
procedures. When you attach the parts removed in the above steps, follow the reverse
procedures.
CAUTION
After replacing the Relay Board, check the settings of the SW1 and SW2 on
the replaced Relay Board. (See Section8, Installing DBM-500T, Setting Relay
Board Switches)

REP6.5, REP6.6
DBM-500T
REP6.7 Control Panel

2. Remove the connector from the Control Panel.
Connector
3. Remove the four screws securing the Control Panel to the machine.
Control Panel
procedures.

REP6.7
DBM-500T
REP6.8 Main Motor (M601) 5. Remove the three screws to remove the Pulley together with the Belt.
6. Remove the four screws from the back of the chassis to remove the Main
Motor (M601) together with the screw plates.
1. Remove the Back Cover (REP6.3).
2. Remove the connector. Screw Plate Screw Plate
3. Remove the screw, then remove the cable clamp.

4. Remove the earth wire of the Main Motor (M601).
Earth wire
Belt
Connector
Pulley
Main Motor (M601)
Cable clamp
procedures. Make sure that you adjust the V Belt.
• V Belt (ADJ6.13)

REP6.8
DBM-500T
REP6.9 Conveyance Motor (M602)
1. Remove the Cover R and Back Cover (REP6.3).

2. Loosen the four nuts to remove the belt.
3. Remove the connector and screws, then remove the cable clamp.
4. Remove the following parts to remove the Conveyance Motor (M602).
-Four nuts
-Four spring washers
-Four washers
-Four screws
Cable clamp Connector Spring washer Nut Nut
Washer
Belt
Wsher Nut Nut
Spring washer
Conveyance Motor (M602)
procedures. Make sure that you adjust the belt tension.
• Belt Tension of Paper Feed (ADJ6.14)

REP6.9
DBM-500T
REP6.10 Upper Blade Clutch/Brake (CL/BRK) Screw
Releasing the Brake
WARNING
Do not release the brake without turning off the power. Do not turn on the
power when the brake has been released.

2. Take out the Waste Bin and remove the Guide Plate (REP6.4).
3. Attach the brake release screw (CFR5x20) to the screw hole of the
Upper Blade Clutch/Brake (CL/BRK).
Bolt
Note: Use the brake release screw (CFR5x20) supplied with the DBM-500T. (See L side
Introduction, Tool/Oil/Grease)
CAUTION CAUTION
When you attach the brake release screw, follow the procedures After completing the above procedures, make sure that you remove the
be l ow. T i g hte n i n g t h e sc rew too m uch m a y d a m a g e t h e b ra ke. brake release screw. Turning on the power with the brake release screw
1. T i g h t e n t h e b r a k e r e l e a s e s c r e w u n t i l i t s t i p t o u c h e s attached may damage the Upper Blade Clutch/Brake (CL/BRK).
the part located in the back of the screw hole.
L side view
2. Turn the brake release screw approximately 45 degrees to tighten using
a wrench.
Upper blade
4. Turn the bolt on the L Side and move up and down the upper blade to
check that the brake has been released.
Note: After checking that the brake has been released, return the upper blade to
its highest position.
Lowest position

REP6.10
DBM-500T
Replacement Procedure 4. Remove the two screws from the top side of the chassis, then remove the
1. Remove the Cover L, Cover R, Back Cover and Front Cover (REP6.3). Partition Plate from the back of the chassis.
2. Take out the Waste Bin and remove the Guide Plate (REP6.4). 5. Loosen the nuts securing the Upper Blade Clutch/Brake (CL/BRK) and
remove the four screws.
3. Remove the two connectors and four screws, then remove the four cable
clamps. Note: When the screws are removed, the angle on the belt side will also be
removed.
Paper ejecting side
Upper Blade Clutch/Brake
Connector
Belt
Washer
Angle
Washer Spring washer
Spring washer Nut
Nut
Partition Palte
Connector
Paper feeding side

REP6.10
DBM-500T
6. Loosen the nut securing the Gear on the L Side and move the Gear to
remove the Chain.
7. Remove the Upper Blade Clutch/Brake (CL/BRK).
Chain
Nut
L side Upper Blade Clutch/Brake
Gear
procedures. Make sure that you adjust the chain tension and V Belt.
• Chain the Tension (ADJ6.12)
• V Belt (ADJ6.13)

REP6.10
DBM-500T
REP6.11 Conveyance Clutch (CL601) When you attach the parts removed in the above steps, follow the reverse
procedures. Make sure that you adjust the position of the clutch.
• Clutches (ADJ6.15)
2. Remove the connector and screw to remove the cable clamp.
Cable clamp
Connector
3. Remove the two screws and bracket.

4. Remove the Bearing and E ring
5. Loosen the two screws to remove the Conveyance Clutch (CL601).
R side
Bearing E ring Screw
Bracket Conveyance Clutch (CL601)

REP6.11
DBM-500T
REP6.12 Delivery Clutch (CL602) When you attach the parts removed in the above steps, follow the reverse
procedures. Make sure that you adjust the position of the clutch.
• Clutches (ADJ6.15)
2. Remove the connector and screw to remove the cable clamp.
R side
Cable clamp
Connector
3. Remove the two screws to remove the bracket.

4. Remove the E ring and loosen the two screws to detach the set collar.
5. Remove the Delivery Clutch (CL602).
R side
Bracket Screw
Screw
Delivery Clutch (CL602)

Set collar E ring
Bearing

REP6.12
DBM-500T
REP6.13 Stopper Solenoid (SL601) 5. Insert a long screwdriver from the square hole of the L Side to remove
the screw securing the link.
Note: Move the Stopper Unit if necessary (REP6.2, Step 17).
6. Remove the four screws securing the Stopper Solenoid (SL601) to the
2. Remove the Cover L (REP6.3). machine.
3. Remove the four screws to remove the cover.
Note: Move the Stopper Unit if necessary (REP6.2, Step 17).
Stopper Solenoid (SL601)
Cover
Driver Z collar
Connector
procedures. Make sure that you adjust the position of the solenoid.
• Solenoid (ADJ6.6)

REP6.13
DBM-500T
REP6.14 Flap Solenoid (SL602) 4. Remove the shaft by pressing it in the direction of the arrow.
5. Push the Conveyance Shaft Unit in the direction of the arrow to remove
it.
1. Remove the Cover L (REP6.3)
2. Remove the connector coming out of the top hole of the Waste Bin, then
remove the screw and cable clamp. Shaft
Shaft
Cable clamp
Connector Conveyance Shaft Unit
Flap Solenoid (SL602)

6. Remove the five screws to remove the Plate and Feed Plate.
Feed plate
Plate

REP6.14
DBM-500T
7. Remove the screw and Z collar, then remove the link.
Note: When the link is removed, the Y collar will also be removed.
8. Remove the two screws securing the Flap Solenoid (SL602) to the
machine.
Y collar Z collar
Flap Solenoid (SL602)
procedures. Make sure that you adjust the Waste Gate.
• ADJ6.2 Waste Gate

REP6.14
DBM-500T
ADJ6.1 Conveyance Gap Unit ADJ6.2 Waste Gate
1. Open the Top Cover. 1. Gain access to the Flap Solenoid (SL602) (REP6.14, Step1 to 6).
2. Remove the four screws securing the Protect Cover to the machine 2. Loosen the screws.
(REP6.2, Step7). 3. Adjust the position of the solenoid. The waste gate must open (in its
3. Loosen the screws. vertical position) when the solenoid head still has 0 to 0.5 mm (0 to 0.02
4. Adjust the position of the actuator. The lower edge of the actuator must inch) to go.
be in the home sensor when bracket 2 is 40±0.2 mm (1.57±0.008 inch) L side view
from bracket 1. Blade

Downstream side view
Conveyance Gap Blade
Home sensor (PS603) Actuator
Screw Paper feed
Waste gate
Paper strips
Screw 40 + 0.2 mm
(1.57 + 0.008 inch)
OFF: Flap Solenoid ON: Flap Solenoid
(SL602) 0 to 0.5 mm (SL602)
(0 to 0.02 inch)



ADJ6.1, ADJ6.2
DBM-500T
ADJ6.3 Position of the Size Change Unit ADJ6.4 Move Motor (M604)
Adjust the position of the actuator when the actual finished size differs from 1. Remove the Cover L (REP6.3).
the size it is supposed to be. 2. Turn the worm wheel to see the backlash.
1. Open the Top Cover. 3. Loosen the screws.
2. Loosen the four screws and remove the cover. 4. To minimize the backlash, adjust the position of the motor.
3. Loosen the screws on the actuator. Top view
Paper feed Worm wheel
Top view
Stopper Actuator Stopper Unit
Motor (M604)
Screw Screw
Screw Stopper Unit

Stopper Unit Motor (M604)
Home Sensor (PS604)
Screw Screw
Paper feed
Motor bracket
Cover
4. Adjust the position of the actuator. The difference between the actual
finished sizes and specified finished sizes should be 1 mm (0.039 inch)
or less.
• When finished sizes are too short, move the actuator upstream.
• When finished sizes are too long, move the actuator downstream.
Actual size Specified size Actual size
(too short) (too long)


ADJ6.3, ADJ6.4
DBM-500T
ADJ6.5 Trimming Positions ADJ6.6 Stopper Solenoid (SL601)
1. Open the Top Cover. 1. Remove the Cover of the Stopper Unit (ADJ6.3, Step1 to 2)
2. Loosen the two dial “A’s”. 2. Loosen the screws.
3. To adjust trimming positions, turn the dial B. As you turn the dial, the 3. Adjust the position of the solenoid. The Stopper must come down to the
front edge or rear edge becomes longer or shorter. See the decal to paper path when the solenoid head still has 0 to 0.5 mm (0 to 0.02 inch)
know which way you should turn the dial. to go.
Screw R side view
Note: For easier adjustment, you should use a larger booklet.
Stopper Solenoid (SL601)
Decal
Paper feed
Dial B
0 to 0.5 mm
(0 to 0.02 inch)
Stopper
Dials “A”
Paper feed
Stopper
4. Tighten the two dial “A’s”. 5. Put back the removed parts in the reverse procedures.
5. Closet the Top Cover.

ADJ6.5, ADJ6.6
DBM-500T
ADJ6.7 Timing of Press Bar 4. Loosen the screws.
5. To adjust the timing of the Press Bar, adjust the position of the sprocket.
The cam top must push the bearing when the upper blade is in its
1. Open the Top Cover. topmost position.
3. Make sure the upper blade of the cutter is in its highest position
(REP6.10).
Upstream side view
Bearing Bearing
Upper Blade Cam Cam
Bearing Bearing
Screw
Cam Cam
Sprocket
Upstream side view


ADJ6.7
DBM-500T
ADJ6.8 Height of Press Bar

2. Remove the Guide Plate (REP6.4).
3. Release the Brake (REP6.10).
4. Move the upper blade to its lowest position (REP6.10).
5. Loosen the screw.
6. Adjust the position of the holder. The Press Bar must come down to the
paper path when the upper blade is in its lowermost position.
R side view
Press Bar
Paper feed
Holder Screw


ADJ6.8
DBM-500T
ADJ6.9 Lower Blade Position 4. Move the upper blade to its lowest position (REP6.10).
5. Loosen the four fixing screws.
6. Press the lower blade against the upper blade and secure the lower blade
CAUTION temporarily with the fixing screw.
•Be ca ref u l of th e ex t rem e l y s h a r p edg es o n the cut te r b l ades. Note: When pressing the lower blade against the upper blade, make sure that the
•When releasing the electromagnetic brake, make sure the screws are not lower blade touches the upper blade lightly and evenly.
excessively tightened. Otherwise the brake may be damaged.
CAUTION
1. Gain access to the lower blade (REP6.2, Step 1 to 18). Make sure the lower blade is not too close to the upper blade when the
2. Loosen the four fixing screws and adjustment screws (a, b, c). upper blade is cutting a booklet. If they are too close, these blades may
be damaged, the blade life may become short, or the load may increase.
Note: To loosen the adjustment screws (a, b, c), loosen their securing nuts first.
3. Move the lower blade in the direction of the arrow and secure it with 7. Turn the adjustment screws (a) and (c) by hand to bring them into
four fixing screws temporarily to prevent the contact between the lower contact with the lower blade lightly.
and upper blades. 8. Turn the adjustment screws (a) and (c) approximately 15 degrees to
tighten using a wrench.
Adjustment screw (a) 9. Bring the adjustment screw (b) into contact with the lower blade lightly.
10. Tighten the adjustment screws (a) and (c) to prevent them from
loosening using wrench.
Fixing screw for
the lower blade
CAUTION
When tightening the nut with a spanner, make sure that the adjustment
screw does not turn.
11. Secure the lower blade with four fixing screws.

Adjustment screw (b) 12. Move up and down the upper blade to check that it works properly
(REP6.10).
13. Put the upper blade closer to the lower blade (REP6.10).
14. Place paper between the lower and upper blades to check that they can
trim paper neatly. Check the trimming conditions using a piece of paper
and single-folded ten pieces of paper.
Fixing screw for
Note: Use Fine Quality Paper, A4 (8.5 x 11) and 81.4 g/m2 (22lb)
the lower blade
Adjustment screw (c)
Note: If the paper cannot be trimmed neatly, repeat the procedures from step 4 to
14.
15. Remove the adjustment screw (b).

ADJ6.9
DBM-500T
ADJ6.10 Home Position of Cutter Blade ADJ6.11 Uppermost Position
CAUTION CAUTION
Be careful of the extremely sharp edges on the cutter blades. Be careful of the extremely sharp edges on the cutter blades.
1. Remove the Cover L, Cover R and Front Cover (REP6.3). 1. Remove the Cover L, Cover R and Front Cover (REP6.3).
2. Remove the Guide Plate (REP6.4). 2. Remove the Guide Plate (REP6.4).
3. Loosen the two screws on the boss. 3. Release the Brake (REP6.10).
4. To adjust the home position of the upper blade, adjust the position of 4. Move the upper blade to its highest position (REP6.10).
the boss (with the actuator). The upper blade is in its home position 5. Loosen the nuts.
when the downstream-side edge of the actuator is parallel with the floor
or somewhat lower than this position. To check the position, use the 6. The Upper Blade Base must be 11 to 12 mm (0.43 to 0.47 inch) from the
Simulation Mode in the Maintenance Mode. frame joint.
Upstream side view
Note: The Sel. Dtc. Enc menu would be helpful (GP2.6). Frame joint
Upper Blade Base
Upstream side view Upper Blade

Home Sensor (PS601) 11 to 12 mm
Upper Blade (0.43 to 0.47 inch) Holding Plate
Index Sensor (PS602)
Actuator
Housing
Nut
Screw Upper Blade
Crank Downstream-side edge Rod
Actuator Boss (parallel with the floor
or somewhat lower)
Lower Blade Base Lower Blade

7. Tighten the nuts.

ADJ6.10, ADJ6.11
DBM-500T
ADJ6.12 Chain Tension ADJ6.13 V Belt
CAUTION CAUTION
After adjusting the V belt, check that the belt does not come out of After adjusting the V belt, check that the belt does not come out of
position. position.
1. Remove the Cover L, Front Cover and Back Cover (REP6.3). 1. Remove the Back Cover (REP6.3).
2. Loosen the four screws on the base of the Upper Blade Clutch/Brake 2. Loosen the screws.
(CL/BRK). 3. To adjust the belt tension, adjust the position of the Main Motor (M601).
3. To adjust the tension of the chain, adjust the position of the base of the The belt slack must be 8 to 10 mm (0.31 to 0.39 inch) in 1020 gm using a
Upper Blade Clutch/Brake (CL/BRK). The chain slack must be about 3 tension gauge.
mm (0.12 inch). Downstream side view V belt
L side view Press drive shaft
Main Motor (M601)
Chain
Upper Blade Plate
Clutch/Brake
(CL/BRK)
Screw Upper Blade Clutch/Brake

(CL/BRK)
Top view
26N sprocket
Upper blade Aligned

drive shaft
Chain 4. Tighten the screws.

Screw


ADJ6.12, ADJ6.13
DBM-500T
ADJ6.14 Belt Tension of Paper Feed Belt Tension
1. Remove the Cover R and Front Cover (REP6.3).
2. Loosen the screw 1.
Belt Tension on the Motor 3. To adjust the belt tension, adjust the position of the roller. The belt slack
1. Remove the Cover R and Back Cover (REP6.3). must be about 10 mm (0.39 inch) in 204 gm using a tension gauge.
R side view
2. Loosen screw 2’s.
3. To adjust the belt tension, adjust the position of the Conveyance Motor
(M602). The belt slack must be about 3 mm (0.12 inch) in 204 gm using
a tension gauge. For timing belt 3, move the pulley unit in the arrow
direction to adjust the tension, then tighten the belt.
R side view
Screw 1
Roller

Screw 2
Screw 2 5. Put back the removed parts in the reverse procedures.
Conveyance motor
(M602)


ADJ6.14
DBM-500T
ADJ6.15 Clutches ADJ6.16 Top Cover Switch
Measure the distance between the clutch and base. The appropriate 1. Remove the Cover R (REP6.3).
distance is 0.2 to 0.3 mm (0.008 to 0.012 inch). If the distance is out of this 2. Loosen the screws.
range, adjust the distance by following these steps: 3. Adjust the position of the switch. The switch works when the top of its
1. Remove the Cover R (REP6.3). lever is pushed by the actuator.
2. Remove the bearing. Refer the figure. It correct position of the switch and the actuator.
R side view
3. Remove the E ring. (Colsed Top Cover)
Set screw
4. Remove the two screw 1’s .

5. Remove the clutch.
6. Adjust the distance between the clutch and base:
• Remove the washer if the distance is too long. Top of lever
Actuator (linked to the Top Cover)
• Add a washer if the distance is too short.
Upstream side view 0.2 to 0.3 mm
Pulley Base (0.008 to 0.012 inch)
Clutch
Screw 2 Screw 1
Screw
Shaft
Top Cover Switch

(SSW602)
Screw 2 E ring Bearing
Collar Washer
Frame 4. Tighten the screws.


ADJ6.15, ADJ6.16
DBM-LS1/DBM-K
REP7.1 DBM-LS1—Bottom cover 5. Turn the Long Stacker upside down and remove its Back Cover.
Screw Back Cover

WARNING
Before following the procedures below, turn off the Main Power Switch and
disconnect the power cord.
1. Remove the DBM-K from the DBM-LS1 (REP7.4)

2. Remove the Plate.
3. Remove the DBM-LS1 from the DBM-500T.
DBM-LS1
DBM-500T
Plate
Power cord
4. Remove the screws to remove the Long Stacker.

Screw Long stacker
4-190 Section 4—Replacement and Adjustment DBM-LS1/DBM-K

REP7.1
DBM-LS1/DBM-K
REP7.2 DBM-LS1—Stacker motor
1. Remove the Bottom Cover from the Long Stacker (REP7.1).

2. Loosen the nut and remove the chain.
3. Remove the connector and nuts to remove the Stacker Motor Assy.
Stacker Motor Assy
Nut
Chain
4. Attach a new motor and adjust the chain tension (ADJ7.1).

5. Attach the Bottom Cover to the Long Stacker.

REP7.2
DBM-LS1/DBM-K
REP7.3 DBM-K—Exterior cover REP7.4 DBM-K—Kicker solenoid
1. Remove the Exterior Cover (REP7.3).

WARNING 2. Remove the connector and screws to remove the Kicker Solenoid
Before following the procedures below, turn off the Main Power Switch and (SL701).
disconnect the power cord. Screw Kicker Solenoid (SL701) Screw
1. Remove the DBM-K from the DBM-LS1.

DBM-500T
Screw
DBM-K DBM-LS1
Screw
Cable
3. Attach the new solenoid and adjust the position (ADJ7.2).
4. Attach the Exterior Cover.
2. Remove the screws to remove the Exterior Cover.
Exterior cover
Screw
Screw

REP7.3, REP7.4
DBM-LS1/DBM-K
ADJ7.1 DBM-LS1—Chain tension ADJ7.2 DBM-K—Solenoid position
1. Loosen the nuts.

2. To adjust the tension of the chain, adjust the position of the Motor When the solenoid is off
Bracket. The chain slack must be 10±2 mm (0.4±0.08 inch) in 500 gf 1. Loosen the screws.
using a tension gauge. 2. Adjust the position of the Stopper unit so that the distance between the
3. Tighten the nuts. kick face and the Chassis becomes 13±0.5 mm (0.52±0.02 inch).
Paper feed 3. Tighten the screws.
Chassis
10 ± 2 mm
(0.4±0.08 inch) 13 ± 0.5 mm
Stopper unit
(0.52±0.02 inch)
Screws
Kick face
Chain Motor bracket
When the solenoid is on

Nut
2. Adjust the position of the Stopper unit so that the distance between the
kick face and the Chassis becomes 57 to 58 mm (2.28 to 2.32 inches).
Solenoid Screws
Chassis
57 to 58 mm
(2.28 to
2.32 inches)
Kick face

ADJ7.1, ADJ7.2
SpineMaster
The LH and RH Side Covers are removed by undoing the two captive M5
8.0a Introduction (for REP8 & ADJ8) screws near the top of each panel.
8.0a-1 Test Booklets

Ensure that a supply of booklets is available for testing purposes. These
booklets should ideally be formed from A4 and A3 (or 81/2 x 11” and 11 x Top Delivery Assembly
17”), and should be available in a range of thicknesses of between two and
30 sheets of 80gsm (20# bond) paper.
8.0a-2 Metric and Imperial Measurements

In most cases metric measurements and specifications are used in this
manual. See the table below for conversion. Fig 4.8.2
PAPER SIZE MILLIMETRES EQUIVALENT IN INCHES

A5 148 x 210 51/2 x 81/2
A4 210 x 297 81/2 x 11
A3 297 x 420 11 x 17
B3 364 x 520 141/4 x 20 1/4
PAPER WEIGHT GSM (G/M2) EQUIVALENT IN # (USA)

35 8 # bond
40 11 # bond
80 20 # bond
200 74 # cover
250 93 # cover
300 110 # cover
8.0a-3 Machine Covers

Fig 4.8.1 and Fig 4.8.2 identify machine covers that are removed during
some service procedures.
Stacker
LH Side Cover
RH Side Cover
Infeed Assembly
Fig 4.8.1
4-194 Section 4—Replacement and Adjustment SpineMaster

8.0a Introduction (for REP8 & ADJ8)
SpineMaster
8.0b Clearing a Paper Jam
A paper jam will normally only occur for one of the following reasons:
● The unlikely event of the Drive Motor stalling
● There is a problem with the machine, e.g. a fuse has blown and the
Clamp is not operating
The SpineMaster should automatically clear a jam if it is switched off and
on. If this operation fails, then the following procedure should be adopted:
Procedure
1. Switch off the power and disconnect the mains input lead.
2. Undo the two screws to remove either Side Cover as necessary, and push
the Carriage clear of the jam with a wooden ruler, or similar.
3. Ease the booklet from the Clamp. Make sure that all of the booklet is
removed.
CAUTION
Do not try to lever the Clamp apart, this will damage the machine.
4. If the booklet is difficult to remove, cycle the machine by hand until the
Clamp is open (see GP2.7).
Find and rectify the cause of the jam (see Section2, RAP8.4) before
restarting the SpineMaster.

8.0b Clearing a Paper Jam
SpineMaster
8.0c Freeing a Carriage Roller Jam
8.0c-1 Auto Carriage Reset and SpineMaster Purge Procedure

This procedure can be done by the operator and is included in the Operator Limit Sensor
Manual.
Procedure
1. Make sure that all SpineMaster safety guards are closed. Fig 4.8.3
2. Switch off the mains power to the SpineMaster at the external power
switch, at the back of the machine. 5. If the Clamp is open, proceed to Step 6. If the Clamp is still holding the
3. After a few seconds pause, switch the power back on. booklet, reconnect the SpineMaster and switch on the mains power. The
machine will reset the Clamp. Switch off the power and disconnect the
4. On power-up, the SpineMaster will automatically check that the
mains input lead.
Carriage and Clamp are in the correct position. If they are not, the
Carriage Motor will drive the Roller Assembly towards the RH or the LH
WARNING
Limit Sensor. Once the Carriage has reached a Limit Sensor the Clamp
can be released and enable the jammed booklet to be withdrawn from Always ensure that the SpineMaster is switched off and disconnected from
the machine. the mains power supply before continuing to work inside.
If the booklet is jammed behind the Stop and it cannot be removed by this 6. Reach in through the aperture in the side frame and manually swivel
method, then the manual method must be employed. the Stop Assembly away from the booklet (see Fig 4.8.4). Remove the
booklet from the machine.
8.0c-2 Manual Carriage Reset and SpineMaster Purge Procedure
PARTS REQUIRED TOOLS REQUIRED
None 3mm Allen Key
Stop Assembly
Jammed Booklet
Procedure
2. Remove the Side Covers.
3. Locate the Carriage Roller Assembly and determine which direction it
will most easily travel in to reach a Limit Sensor.
Tip: When the Carriage jams it will be travelling ‘into’ the booklet. It will always
Fig 4.8.4
be easier to withdraw the Carriage in the opposite direction, i.e. ‘out’ of the
booklet. 7. Replace the Side Covers.
4. Reach in through the aperture in the side frame and take hold of the 8. Reconnect the mains power supply and test the machine is operating
Carriage Roller Assembly. Pull the Assembly towards you until it is correctly.
beneath the Limit Sensor (See Fig 4.8.3).

8.0c Freeing a Carriage Roller Jam
SpineMaster
8.0d Removing Components
4. Undo the two screws on top of the Infeed Assembly (see Fig 4.8.7).
8.0d-1 Removal of the SpineMaster Infeed Assembly

None 3mm Allen Key
Screw
4mm Allen Key
Screw
1. Open the Top Delivery Assembly.
2. Lift the Stacker Assembly to give internal access to the SpineMaster (see
Fig 4.8.5). Fig 4.8.7
Stacker Assembly
5. Lift and remove the Infeed Assembly (see Fig 4.8.8).
Top Delivery Assembly
Fig 4.8.8
Fig 4.8.5
3. Unplug the Cassette Bus Cable from the Machine Interface PCB
(900-198) and unplug the Earth Cable from the Side Panel (see Fig 4.8.6).
Divert Fingers
Bus
Earth
Fig 4.8.6

SpineMaster
8.0d-2 Removal of the Top Delivery Assembly 6. Ensure the Top Delivery Assembly is closed.
None 3mm Allen Key
4mm Allen Key
3. Tilt the Top Delivery Assembly Cover outward and remove the two
screws at the bottom.
Fig 4.8.11
7. Remove LH and RH Pivot Point Fixings.
Screw Fig 4.8.9
4. Remove another six screws on the Top Delivery Assembly Cover.

Pivot Point Fixing (RH)
Screw Fig 4.8.12

Screw
8. Remove the Top Delivery Assembly.
Fig 4.8.10
5. Lift and remove the Top Delivery Assembly Cover.

SpineMaster
REP8.1 Replacing the Holding Magnet

890-298 P.Assy, (ASM) Magnet Assembly 3mm Allen Key
165-205 M8 Crinkle Washer (2 off) 8mm Spanner
951-007 Loctite 242
2. Remove the Main Drive Motor Assembly (REP8.12).
3. Undo the screw that holds the Magnet in place (see Fig 4.8.13). Note the
position of the Crinkle Washers.
Magnet Assembly
Mounting screw
Fig 4.8.13
4. When fitting the new Magnet, use Loctite 242 on the mounting screw.
Do not overtighten this screw; the Crinkle Washers should allow the
Holding Magnet to move slightly from side to side.

REP8.1 Replacing the Holding Magnet
SpineMaster
REP8.2 Replacing the Power Interface PCB
The Power Interface PCB may be at fault if fuses blow regularly, or if there
are components in the SpineMaster that are not receiving power.
900-141 Power Interface PCB Assy 3mm Allen Key
Procedure
1. Switch off the power and disconnect the mains input lead. Position the
SpineMaster so that the RH side is easily accessible.
2. Remove the RH Side Cover.
3. Remove all the cables from the PCB assembly (see Fig 4.8.14). Note
their position for refitting. The cables will only fit into the correct
connector in the correct orientation.
PCB 900-141
Transformer
Fig 4.8.14
4. Remove the PCB.

5. When fitting the new PCB, check that all the fuses are the correct rating
as this PCB is used in other products (see Section7, WD1.8.2).

REP8.2 Replacing the Power Interface PCB
SpineMaster
REP8.3 Replacing the Transformer CAUTION
Before switching on the machine, check the voltage tappings on the
Transformer (see Section 7, WD1.8.5).
The Transformer may need replacing if there is no power supply to the
Power Interface PCB, or if the Mains Input fuses blow regularly.
908-882 Transformer Assy 3mm Allen Key
4mm Allen Key
8mm Spanner
Procedure
3. Remove the power and earth cables from the Power Interface PCB
Assembly.
Note their position for refitting. The cables will only fit into the correct connector
in the correct orientation (see Fig 4.8.14).
4. Remove the Infeed Assembly (see 8.0d-1) to give access to the
Transformer mounting screws.
5. Disconnect the power cable and the earth cable from the Transformer
Input PCB.
Earth Power
Cable Cable
Fig 4.8.15
6. Remove the two M5 screws that hold the Transformer in place, remove
Transformer.
7. When fitting the new Transformer Assembly, be sure to attach the earth
lead.

REP8.3 Replacing the Transformer
SpineMaster
REP8.4 Replacing the Carriage Motor Ballast 5. Remove PCB 900-197 and cut the four cable ties.
Resistor
The Ballast Resistor, fitted in to the Wiring Loom between PCB 900-197
and the Carriage Motor, is a current surge-limiting device. In the unlikely
event that this component should fail, it is a recommended precaution that
the complete assembly be replaced in case of wiring damage. PCB 900-197
905-377 Carriage Motor Ballast Resistor Assy 2.5mm Allen Key
3mm Allen Key Cable Tie Fig 4.8.18
6. Remove the two M3 x 10 mm fixing screws from the Ballast Resistor and
Procedure
remove the Assembly from the machine.
Screw
3. Remove all the cables from PCB 900-197.
PCB 900-197
Fig 4.8.19
7. Insert the new Ballast Resistor Assembly and re-assemble in the reverse
Fig 4.8.16
order.
4. Disconnect the Ballast Resistor Cable Assembly from the Carriage 8. Reconnect the power supply and test SpineMaster for correct operation.
Motor Connector.
Ballast Resistor
Carriage Motor
Connector
Fig 4.8.17

REP8.4 Replacing the Carriage Motor Ballast Resistor
SpineMaster
REP8.5 Replacing the Cam Links
It is very unlikely that a Cam Link will ever need replacing. However, it may
be necessary if the spines are not being formed evenly across the full width
of thin booklets: this may be due to a damaged spring inside either Cam
Link.
907-979 Cam Link 8mm Spanner
180-099 12.7mm Circlip (2 per Cam Link) Circlip Pliers (external)
150-315 M5 Nyloc Nut (2 off)
Procedure
SpineMaster so that the LH (or RH) side is easily accessible.
2. Remove the LH (or RH) Side Cover.
3. Remove the two circlips that hold the Cam Link in place (see Fig 4.8.20)
and withdraw the assembly from the machine.
Circlip
Circlip
Fig 4.8.20 Cam Link

4. When fitting a new Cam Link, make sure it is square to the Drive Shaft
ends. Always use new circlips.

REP8.5 Replacing the Cam Links
SpineMaster
REP8.6 Replacing the Transverse Drive Chain
The Transverse Drive Chain will need to be replaced if it has visibly worn.
The Chain is pre-stretched so it is unlikely that it will loosen to the extent Cut-out in
that the tension cannot be set correctly. The Chain should not be replaced Drive Mounting Plate
by an ordinary chain. Carriage

192-500 Transverse Drive Chain 3mm Allen Key
951-007 Loctite 242 5mm Allen Key (2 off)
Transverse Chain
Procedure
Fig 4.8.22
SpineMaster so that both sides are easily accessible.
2. Remove the Top Delivery Assembly. 7. Unbolt both Idler Sprockets. The Chain can now be removed from the
machine.
8. Remove the Chain Link Shaft from the old Chain, and replace it in the
4. Make sure the Carriage is parked on the LH side of the machine.
new Chain.
5. Position the carriage to give access to the Chain Link Shaft from the
9. When fitting the new Chain to the machine, do not forget to fit the
Rear Access Panel.
Sensor Flag between the Chain Link and the Carriage. Use Loctite
242 on the threads of the two screws that hold the Chain Link to the
Carriage.
10. Check the Chain tension (ADJ8.1).
Chain Link Shaft

Release Catch
Fig 4.8.21
6. Undo the two screws that hold the Chain Link Shaft (265-683) to
the Carriage. These screws can be accessed from the rear of the
SpineMaster. Be aware that the Sensor Flag is also attached to the
Carriage with these two screws.

REP8.6 Replacing the Transverse Drive Chain
SpineMaster
REP8.7 Replacing the Main Drive Chain and the Procedure
Drive Transfer Chain 1. Switch off the power and disconnect the mains input lead.
2. Remove the Infeed Assembly (see 8.0d-1)
3. Locate the Split Link on the Chain and rotate the Drive Train, so that the
The Drive Chains inside the SpineMaster have been pre-stretched and
link is located on top of the most easily accessible Sprocket. This can be
should not stretch any further during normal operation. Check the chain
done by turning the Hand Crank Shaft.
tension mid-way between sprockets.
4. Unclip the Locking Plate and the Link Plate. Withdraw the Split Link
DESCRIPTION DEFLECTION from the Chain.
Main Drive Chain 10mm +/- 2mm
Drive Transfer Chain 10mm +/- 2mm 5. Unhook the Chain from the Sprockets and remove.
6. Check the Sprockets for wear or damage. Replace if necessary.
(REP8.9, REP8.10)
7. Split the new Chain and place on to the Sprockets. Ensure that the join is
located over the most easily accessible Sprocket.
Drive Transfer Chain
8. Fit the Split Link, Link Plate and Locking Plate.
9. Rotate the Drive Train to check that the Chain runs smoothly and
Main Drive Chain lubricate with chain lubricant.
Fig 4.8.23
Regular maintenance and lubrication is essential to ensure a long, wear-free

life. The chains should be checked and lubricated at every service interval.
Inspect the condition of the Chain Sprockets, ensure that the Sprocket
teeth have not become worn or damaged as this will affect performance
and increase chain wear. If wear is observed on either the Chains or the
Sprockets it is advisable to replace both as a full set.
PARTS REQUIRED FOR MAIN DRIVE CHAIN TOOLS
192-502 8mm x 66 pitches chain (115V) 3mm Allen Key
192-455 8mm x 69 pitches chain (230V) 4mm Allen Key
PARTS REQUIRED FOR DRIVE TR ANSFER CHAIN Small Electrical Screwdriver
192-395 42T x 8mm Transfer Drive Chain 955-014 Hand Crank Tool

REP8.7 Replacing the Main Drive Chain and the Drive Transfer Chain
SpineMaster
REP8.8 Replacing the Final Drive Chain 4. Unclip the Locking Plate and the Link Plate. Withdraw the Split Link
from the Chain.
5. Unhook the Chain from the Sprockets and remove.
The Drive Chains inside the SpineMaster have been pre-stretched and
6. Check the Sprockets for wear or damage. Replace if necessary
should not stretch any further during normal operation. Check the chain
(REP8.11).
tension mid-way between sprockets.
7. Split the new Chain and place on to the Sprockets. Ensure that the join is
DESCRIPTION DEFLECTION located over the most easily accessible Sprocket.
Final Drive Chain 20mm +/- 2mm
8. Fit the Split Link, Link Plate and Locking Plate.
9. Ensure correct timing of Clamp mechanism (ADJ8.5).
10. Rotate the Drive Train to check that the Chain runs smoothly and
lubricate with chain lubricant.
Final Drive Chain
Fig 4.8.24
Regular maintenance and lubrication is essential to ensure a long, wear-free

life. The chains should be checked and lubricated at every service interval.
Inspect the condition of the Chain Sprockets, ensure that the Sprocket
teeth have not become worn or damaged as this will affect performance
and increase chain wear. If wear is observed on either the Chains or the
Sprockets it is advisable to replace both as a full set.
PARTS REQUIRED FOR FINAL DRIVE CHAIN TOOLS
192-459 8mm x 57 Pitch Final Drive Chain 3mm Allen Key
4mm Allen Key
Small Electrical Screwdriver
955-014 Hand Crank Tool
Procedure
2. Remove the Infeed Assembly (see 8.0d-1)
3. Locate the Split Link on the Chain and rotate the Drive Train, so that
the link is located on top of the most easily accessible Sprocket. This can
be done by turning the Hand Crank Shaft whilst activating the Clutch
Solenoid).

REP8.8 Replacing the Final Drive Chain
SpineMaster
3. Remove the worn Sprockets and re-assemble using new ones.
REP8.9 Replacing the Clutch Sprockets and/or
4. Replace the Clutch Assembly in the reverse order.
Intermediate Drive Sprocket
If the Clutch Sprockets and/or Intermediate Drive Sprocket are worn or

damaged they will require replacing to prevent further wear to the Drive
Chains.
PARTS REQUIRED TOOLS
192-439 29T 8mm Plate Wheel (2 off) 952-038 3/32” Allen Key
192-458 15T Intermediate Drive Sprocket 2mm Allen Key
180-099 12.7mm Circlip (2 off) 3mm Allen Key
400-392 4mm x 30mm Spirol Pin 4mm Allen Key
710-016 Cable Ties 5mm Allen Key
150-315 M5 Nyloc Nut (2 off) 8mm Spanner
160-203 M6 Spring Washer (3 off) Small Electrical Screwdriver
Circlip Pliers (external)
Hammer
4mm Pin Punch
Procedure
1. Remove the Clutch Assembly (REP8.14).
Clutch Sprockets
Clutch Assembly
Intermediate Drive
Sprocket
Fig 4.8.25
Note: If replacing a worn Intermediate Drive Sprocket, do not remove the Clutch
Shaft completely, slide the worn Sprocket off and replace with a new one. Re-
assemble the Clutch Shaft Assembly in the reverse order.
2. Place the Clutch Assembly onto a flat work surface and remove the
Sprocket fixing bolts, taking care to note the spacer and washer
positions.

REP8.9 Replacing the Clutch Sprockets and/or Intermediate Drive Sprocket
SpineMaster
REP8.10 Replacing the Main Drive Motor
Sprocket
If the Main Drive Motor Sprocket becomes worn or damaged it must be

replaced to prevent further wear to the Drive Chain.
192-466 24T Drive Sprocket (115V) 2mm Allen Key
192-464 29T Drive Sprocket (230V) 3mm Allen Key
4 mm Allen Key
Procedure
1. Remove the Main Drive Chain (REP8.7).
2. Remove the grub screw from the Main Drive Sprocket and slide the
Sprocket from the Motor Stub Shaft.
3. Replace the Sprocket and tighten the grub screw (do not fully tighten at
this point).
4. Replace the Drive Chain and check that the Main Drive Sprocket is
aligned with the Clutch Sprocket (see Fig 4.8.26). When aligned, fully
tighten the Main Drive Sprocket grub screw.
Clutch Sprocket
Main Drive Sprocket
Fig 4.8.26
5. Re-assemble the SpineMaster. Connect mains power and test.

REP8.10 Replacing the Main Drive Motor Sprocket
SpineMaster
REP8.11 Replacing the Final Drive Sprocket 8. Once the Final Drive Chain has been refitted, ensure that the Final
Drive Sprocket is aligned correctly with the Intermediate Drive
Sprocket. Tighten the grub screw.
If the Final Drive Sprocket becomes worn or damaged it must be replaced 9. Re-assemble the SpineMaster. Connect the mains power and test.
to prevent further wear to the Drive Chain, and to prevent the Chain from
jumping from the Sprocket under loading.
192-457 Final Drive Sprocket 2mm Allen Key
400-357 4mm x 40mm Spirol Pin (1 off) 3mm Allen Key
180-099 12.7mm Circlip (4 off) 4 mm Allen Key
Circlip Pliers (external)
Hammer
4mm Pin Punch
Procedure
1. Remove the Cam Links from the SpineMaster (REP8.5).
2. Remove the Final Drive Chain (REP8.8).
3. Knock the Roll Pin out from the LH Blade Return Cam at the end of the
Cam Link Drive Shaft (see Fig 4.8.27).
Roll Pin
Blade Return Cam - LH
Fig 4.8.27
4. Remove the Blade Return Cam.

5. Remove the Final Drive Sprocket grub screw.
6. Withdraw the Cam Link Drive Shaft from the RH side of the
SpineMaster, enough to allow the worn Final Drive Sprocket to be
removed.
7. Replace the Final Drive Sprocket with a new one and re-assemble the
Shaft using a new Spirol Pin.

REP8.11 Replacing the Final Drive Sprocket
SpineMaster
REP8.12 Replacing the 24V Motor 8. When refitting the Drive Sprocket, make sure the Transverse Chain is
parallel with the Drive Mounting Plate. Recheck this after tightening
the Trantorque Bush.
The 24V Motor powers the Carriage. It may be at fault if the Carriage does
not operate.
905-343 24V Motor Assy 3mm Allen Key
165-002 M6 Shake-proof washer (3 off) 5mm Allen Key
951-007 Loctite 242 19mm Spanner
Procedure
3. Undo the Connector Block that links the 24V Motor to the rest of the
wiring loom.
4. Undo the Trantorque Bush from the 24V Motor Drive (see Fig 4.8.28).
This will be easier if the Carriage is pulled against the stops at one end
of the Carriage Guide, because it will prevent the Drive Sprocket from
turning.
24V Motor
Transverse Chain
Trantorque Bush Fig 4.8.28
5. Withdraw the Drive Sprocket from the 24V Motor shaft.

6. Undo the three M6 screws that hold the 24V Motor to the Drive
Mounting Plate and withdraw the Motor from the machine.
7. When fitting the new Motor, use Loctite 242 on the threads of the three
M6 screws that hold it to the Drive Mounting Plate.

REP8.12 Replacing the 24V Motor
SpineMaster
REP8.13 Replacing the Cooling Fan 6. When fitting the new Fan, make sure it is fitted the correct way round.
There is an arrow on the body of the Fan that should face into the
SpineMaster.
The Cooling Fan cools the Drive Motor. The Cooling Fan should operate
whenever the Drive Motor operates: if it does not it may need replacing.
710-058 115V Fan 3mm Allen Key
710-057 230V Fan 4mm Allen Key
165-001 M4 Shake-proof Washer (5 off)
165-003 M5 Shake-proof Washer (10 off)
Procedure
Fig 4.8.31
2. Remove the Infeed Assembly (see 8.0d-1).
3. Undo the three screws to remove the Fan Mounting Bracket. 7. When fully assembled, check that air is being drawn into the
SpineMaster.
Fan Mounting
Bracket
Screw Fig 4.8.29
4. Disconnect the cable of the Fan Assembly.

5. Undo the four screws to remove the Fan Assembly.
Screw
Fig 4.8.30 Screw

REP8.13 Replacing the Cooling Fan
SpineMaster
REP8.14 Replacing the Clutch 7. Undo the grub screw that holds the Intermediate Drive Sprocket
(192-458) to the Drive shaft. Slide the Sprocket along the Shaft, and
remove the Steel Key.
If the Clutch wears, it may either slip or double-fire. If the Clutch slips it 8. Unplug the green and black wires from the Clutch Solenoid. Cut the
is likely that the Clamp will appear to be jammed in the closed position. cable ties that hold the wires to the Clutch Mounting Plate.
Doublefiring may cause booklets to jam.
9. Remove the M8 screw that holds the Clutch Mounting Plate to the
PARTS REQUIRED TOOLS REQUIRED Spacer (see Fig 4.8.32).
760-342 CB6 Clutch 952-038 3/32” Allen Key
10. Carefully withdraw the Drive Shaft from the LH side of the machine.
150-315 M5 Nyloc Nut (2 off) 2mm Allen Key
Hold the Clutch while doing this. When the Drive Shaft is clear of the
180-099 12.7mm Circlip (2 off) 3mm Allen Key
Clutch, remove the Clutch from the machine.
400-392 4x30mm Roll Pin 5mm Allen Key
254-502 SteeI Key 8mm Spanner 11. Replace any cable ties that were cut when removing the Clutch.
710-016 Cable Ties Circlip Pliers (external 12. After fitting, the new Clutch will need setting correctly (ADJ8.5).
165-003 M5 Shake-proof Washer (10 off) Hammer
4mm Pin Punch
Procedure
4. Using a pin punch and hammer, knock the Roll Pin out of the RH end of
the Drive Shaft that passes through the Clutch. Remove the large Nylon
Spacer.
5. Find the Connector Link in each of the three Drive Chains and remove
the Chains.
6. Using the 3/32” Allen Key, undo the grub screw that holds the Clutch to
the Drive Shaft. This grub screw is located in the RH side of the Clutch
Body (see Fig 4.8.32).
Clutch Body
Grub screw
M8 screw
Fig 4.8.32

REP8.14 Replacing the Clutch
SpineMaster
REP8.15 Replacing the Clutch Solenoid
If the solenoid fails, the Clutch will not fire. It is possible to replace the
Clutch Solenoid without removing the Clutch Assembly.
760-317 SOLENOID, 24V COIL FOR CB-6 CLUTCH 3mm Allen Key
165-003 M5 Shake-proof Washer (10 off) 4mm Allen Key
Note: Part No. 760-317 is not included in the parts catalog but can be ordered if
required.
Procedure
2. Unplug the green and black wires from the Clutch Solenoid.
3. Remove the two 1/4” UNC screws that hold the Solenoid to the Clutch
Mounting Plate (see Fig 4.8.33). A 4mm Allen Key will fit.
Solenoid Mounting screws
Fig 4.8.33
4. Lift the Solenoid Body from the Plunger.

5. After fitting, the new Clutch Solenoid will need setting correctly
(ADJ8.6).

REP8.15 Replacing the Clutch Solenoid
SpineMaster
REP8.16 Replacing the Drive Motor
Screw
If the Drive Motor fails, the Clamp will not operate.

905-351 Drive Motor, 115V 3mm Allen Key
905-345 Drive Motor, 230V 4mm Allen Key
5mm Allen Key
10mm Spanner
Pliers - Side Cutters, small
Fig 4.8.36
Procedure
1. Switch off the power and disconnect the mains input lead. 7. Unhook the Drive Chain and lower the main Drive Motor Assembly to
the floor.
3. Undo the three screws to remove the Fan Mounting Bracket.
Fan Mounting Main Drive Motor

Bracket
Fig 4.8.37
Screw Fig 4.8.34
4. Remove the Side Covers. 8. Replace the Motor.

5. Disconnect the power to the Motor (see Fig 4.8.70).
6. Remove the Base Pan Fixing screws.
Screw
Fig 4.8.35

REP8.16 Replacing the Drive Motor
SpineMaster
REP8.17 Replacing the Bolster and/or Anvil 5. Remove the Cam Link on the LH side. It is held in place by two circlips
(see Fig 4.8.38).
Clamp Bar
CAUTION Cam Link (LH)

Replacing either the Bolster or the Anvil Clamp Bar can take approximately
6 hours. It is essential that both are set accurately when rebuilding.
The Bolster and Anvil Clamp Bar could become damaged if the machine Circlip
is activated by anything other than a booklet. They are unlikely to fail in
normal operation.
Fig 4.8.38
251-437 Bolster 3mm Allen Key 6. Before removing the Cam Link on the RH side, remove the two plastic
251-438 Anvil Clamp Bar 4mm Allen Key gears, the Bearing Plate and the Pulley (REP8.20).
180-099 Circlip (4 off) 5mm Allen Key
Plastic Gear Pulley
165-001 M4 Shake-proof Washer (5 off) Circlip Pliers (external)
165-003 M5 Shake-proof Washer (15 off) 3mm Pin Punch
165-004 M10 Shake-proof Washer (4 off) 4mm Pin Punch
165-005 M8 Shake-proof Washer (10 off) 13mm Spanner
400-391 M3 x 20mm Spirol Pin Screwdriver - FLAT, 6.5mm
400-392 4 x 30mm Roll Pin Pliers - Side Cutters, small
951-007 Loctite 242 Pliers, Combination 6”
Bearing Plate
190-338 Grease Cap (6 off) 0.02mm Feeler gauge Fig 4.8.39
6” Steel Rule
Hammer 7. Undo the two circlips to remove the Cam Link on the RH side.
Procedure
3. Remove the Top Delivery Assembly (see 8.0d-2). Cam Link (RH)
Fig 4.8.40 Circlip

REP8.17 Replacing the Bolster and/or Anvil Clamp Bar
SpineMaster
8. Undo the eight screws to remove the two Paper Guides. 10. Remove the Bolster Sensor Mount (253-349) from the Bolster.
Screw
11. Find the Connector Link in the Main Drive Chain and remove this
Chain (REP8.7).
12. Remove the Adjuster Shaft (REP8.18).
Adjuster Shaft
Screw
Screw
Fig 4.8.43
13. Remove the Stop Assembly (907-404) from the machine by removing
the two M6 screws in the LH and RH Adjustment Supports (see Fig
Screw 4.8.44), and remove the screws securing the LH and RH Stop Springs.
Screw Screw
Paper Guides
Fig 4.8.41 Fig 4.8.44
9. Undo the LH and RH Limit Sensor Mounts (253-859/860) from the 14. Undo the two screws to remove the Clamp Sensor Mounting Bracket.
Anvil. Tie them out of the way.
Limit Sensor Mount Limit Sensor Mount

(LH) (RH)
Clamp Sensor
Mounting Bracket
Fig 4.8.45
Fig 4.8.42

SpineMaster
15. Unhook the two belts from the Idler Shaft, which makes it easy to move 18. Undo the M5 screw to remove the Anvil Clamp Bar (including the
the Infeed Drive Shaft afterward. Carriage Guide).
Idler Shaft
M5 Screw
Anvil Clamp Bar

Belt Belt
Fig 4.8.49
Fig 4.8.46
19. Remove the Carriage Guide (265-667) from the Anvil Clamp Bar (10 off
16. Remove the Spring Circlip and the Nylon Washer from the LH end of
M3 screws).
the Infeed Drive Shaft, and undo the M5 screw.
20. Remove the Grease Caps from the centre of the six Cam Eccentric
Spring Circlip Bearings. This can be done by tightening the tip of a coarse screw into
and each, gripping the screw with pliers and tapping the Cap out (see Fig
Nylon Washer
4.8.50). The Grease Caps need to be removed in order to be able to
adjust the Cam Eccentric Bearings.
M5 Screw
Pliers
screw head
Fig 4.8.47
17. Remove the Spring Circlip and the Nylon Washer from the RH end of
the Infeed Drive Shaft and push it back so that the M5 screw can be Fig 4.8.50
accessed.
Spring Circlip 21. Rotate the Cam Eccentric Bearings anti-clockwise using a flat blade
and screwdriver, to release the pressure on the Bolster.
Nylon Washer
M5 Screw
Cam Eccentric Bearing

Fig 4.8.48
Fig 4.8.51

SpineMaster
Cam Eccentric Bearing
Fig 4.8.52
22. To remove the Bolster, undo the Spigot Blade Return Shafts and lift the
Bolster out.
Spigot Blade Return Shaft
Fig 4.8.53
23. To remove the Anvil Clamp Bar, undo the four screws to remove the
two Mounting Blocks (265-672) from the Bolster Side Plates.
Screw
Mounting Block
Screw
Mounting Block
Fig 4.8.54

SpineMaster
When rebuilding the SpineMaster, it is important to make sure the Bolster 9. When attaching the Carriage Guide to the Anvil Clamp Bar, pull it fully
and Anvil Clamp Bar are set properly. The following steps should be towards the front of the channel before tightening the ten screws. These
followed when installing either item: screws should be tightened from the centre, outwards.
1. Use Loctite 242 on the screws that hold the Anvil Clamp Bar to the 10. Replace the Carriage on the Carriage Guide. Look along the length of
Mounting Blocks. the Anvil Clamp Bar as you move the Carriage along the Carriage Guide.
2. Hold the Anvil Clamp Bar firmly in place when tightening the screws Adjust the six Cam Eccentric Bearings to correct any unevenness in the
that hold the Mounting Blocks to the Bolster Side Plates. Use Loctite travel of the Carriage. Make sure that the Cam Eccentric Bearings still
242 on these screws. apply enough pressure to the Bolster.
3. Check that the gaps between the Anvil Clamp Bar and the faces of each 11. When you are happy with the settings of the Cam Eccentric Bearings,
Bolster Side Plate do not exceed 0.02mm (see Fig 4.8.55). lock them off and fit new Grease Caps to them.
12. When refitting the Stop Assembly, check that it is still parallel with the
Bolster Side Panel face of the Bolster and Anvil Clamp Bar. Refer to Procedure ADJ8.7 if
the Stop needs adjusting.
0.02mm max.
Anvil Clamp Bar

0.02mm max.
Fig 4.8.55
4. Ensure the Bolster and Anvil Clamp Bar are parallel to each other, by
clamping them together and checking that they are level using the flat
edge of a steel rule. The Cam Eccentric Bearings should be rotated
away from the Bolster before this is done.
5. With the Bolster and Anvil Clamp Bar fixed together, set the LH and RH
lower Cam Eccentric Bearings. They should be set so that they are tight
against the face of the Bolster.
6. Set the top Cam Eccentric Bearings. Tighten them in sided pairs, i.e. set
both LH Bearings and then set both RH Bearings.
7. Check that there is sufficient pressure from the six Bearings on the
Bolster: the Bolster should not be able to slip as it rolls between them.
When setting the Bearings, rotate them onto the Bolster in an anti-
clockwise direction. This prevents them from being overtightened when
they are set.
8. Apply a moderate pressure on the face of each Bearing in turn with your
finger, as you roll the Bolster back and forth: the Bearings should not be
able to slip. Tighten the Bearings if necessary.

SpineMaster
REP8.18 Replacing the Stop Assembly 7. Fit the new Stop Assembly.
8. Rebuild the SpineMaster, but do not refit the Side Covers.
9. Adjust the Stop (ADJ8.7).
907-404 Stop Assembly 3mm Allen Key 10. Refit the Side Covers.
165-001 M4 Shake-proof Washer (5 off) 5mm Allen Key
165-003 M5 Shake-proof Washer (15 off) 13mm Spanner
0.5mm Feeler Gauge
Procedure
3. Remove the Spirol Pin from the Adjuster Shaft (265-835).
4. Loosen the Trantorque Bush on the end of the Adjuster Shaft. Remove
the Trantorque Bush and the Flanged Pulley.
5. Lift the Adjuster Shaft out of the machine.
6. Remove the Stop Assembly (907-404) from the machine by removing the
two screws in the LH and RH Adjustment Supports and the LH and RH
Spring Mounting Brackets (see Fig 4.8.56). The Stop Assembly can be
withdrawn from either side of the SpineMaster. It may be necessary to
move the Stop and the Carriage when removing the assembly, in order
to gain enough clearance.
Screw
(for Spring Mounting Bracket)
Screw
(for Adjustment Support)
Fig 4.8.56

REP8.18 Replacing the Stop Assembly
SpineMaster
4. Disconnect the Infeed Sensor Cable from Socket on PCB 900-198
REP8.19 Replacing the Upper Infeed Sensor SpineMaster I/F.
Infeed Sensor Cable
If the SpineMaster starts when a booklet is not present, or fails to start
when a booklet is placed into the Upper Infeed, the Infeed Sensor may be
faulty. Place a booklet over the Sensor and watch the status of LED10 on
PCB 900-197. If the Sensor is functioning correctly the LED will illuminate.
If the Sensor is faulty the LED will remain off.
Socket
If the LED is lit when no book is present, ensure that the Sensor is not
reacting to reflections within the SpineMaster. A piece of black, light
absorbent tape is normally adhered to the underside of the Stacker Motor.
Tip: Connect a replacement Sensor to the PCB 900-198 and test before
dismantling the Infeed Assembly.
Fig 4.8.58
905-162 Fix Focus Sensor 4mm Allen Key
5. Loosen the upper plastic nut on the Sensor Housing. Pass the Sensor
710-016 Electrical Cable Tie (4 off) Pliers - Side Cutters, small
Assembly back through the hole in the Sensor Plate to remove it from
the Infeed.
Procedure 6. Take the replacement Sensor Assembly and remove the upper plastic nut
1. Switch off the power and disconnect the mains input lead. from the Sensor Housing. Ensure that the lower plastic nut is wound at
2. Remove the Infeed Assembly (see 8.0d-1). least halfway down the Sensor, allowing enough thread to be exposed for
the upper plastic nut to grip once the Sensor Housing has been inserted
3. Cut and remove the four cable ties securing the top Infeed Sensor Cable
into the Mounting Bracket.
to the Infeed Assembly.
7. Insert the Sensor Housing through the hole in the Sensor Plate. Turn
Sensor Assembly
the Sensor so that the Cable exits the back of the Housing to the left.
Infeed Sensor Cable 8. Attach the upper plastic nut and leave finger tight.
9. Place the Sensor Cable in position along the edge of the Sensor Plate.
Loosely cable tie to hold in place.
10. Pass the end of the Sensor Cable through the grommet in the Side Plate
and connect to PCB 900-198.
PCB 900-198
11. Loosely cable tie the Sensor Cable and Interface Cable to the Side Plate.
Check and adjust the Cable so as to allow enough slack in the loop at the
Fig 4.8.57 housing end before finally tightening the cable ties.
Cable Tie 12. Adjust the Sensor Housing plastic locking nuts so that the Sensor
protrudes above the upper nut by approximately 1mm. Tighten the nuts
to secure the Sensor.
13. Replace the Infeed Assembly (see 8.0d-1) and test.

REP8.19 Replacing the Upper Infeed Sensor
SpineMaster
5. Lift the Book Deflector Plate and push it back away from the clamp
REP8.20 Replacing the Clamp Optical Sensor Sensor Mounting Bracket. It is unnecessary to completely remove the
Deflector Plate from the machine (see Fig 4.8.60).
If the Clamp fails to operate it may be because the Clamp Sensor is Book Deflector Plate (pushed back)
damaged or faulty. When a book is placed in front of the Sensor, LED15 on
PCB 900-197 should illuminate. If not, check that the Clamp area is clear of
debris and then try adjusting the Sensor position (ADJ8.4). If adjusting the
Sensor makes no difference then it will need to be replaced.
Tip: Connect a replacement Sensor to the PCB 900-197 and text before
dismantling the Infeed Assembly.
905-287 Fixed Focus Sensor 3mm Allen Key
Clamp Sensor
710-016 Electrical Cable Tie (5 off) 4mm Allen Key Mounting Bracket
8mm Spanner
Pliers - Side Cutters, small Fig 4.8.60
Procedure 6. Remove the two Sensor Mounting Bracket fixing screws (see Fig 4.8.60).
1. Switch off the power and disconnect the mains input lead. 7. Unhook the two belts from the Idler Shaft, which makes it easy to move
the Infeed Drive Shaft afterward.
3. Open the Top Delivery Assembly.
4. Loosen the four locking nuts from the Book Deflector Plate fixing Idler Shaft
screws and withdraw the screws from the Side Plates.
Belt Belt
Locking
Nut
Fig 4.8.61
8. Remove the Spring Circlip from the Infeed Drive Shaft.
Spring Circlip
Locking
Nut
Fig 4.8.59 Fig 4.8.62

REP8.20 Replacing the Clamp Optical Sensor
SpineMaster
9. Undo the three screws from the Bearing Plate. 12. Cut and remove the five cable ties that secure the Sensor Cable to the
machine.
Screw
13. Disconnect the Cable from PL14 on the PCB 900-197. Remove the
Sensor Assembly.
PCB900-197
Screw
PL14
Fig 4.8.63
10. Undo the two Circlips to remove the two plastic gears. Note that the pin
is included in the Infeed Drive Shaft.
Circlip Fig 4.8.66
14. Loosen and remove the front plastic locking nut that is securing the
Sensor to the Bracket. (There is a second nut behind the Bracket that
determines the distance the Sensor protrudes from the Bracket - try not
to disturb the position of this nut as it will be a useful guide to initially
set the new Sensor position).
Back Nut Front Nut
Fig 4.8.64
11. Remove the Bearing Plate and pull the Infeed Drive Shaft to the front.
Do not withdraw it completely. It is only necessary to move the shaft so
that the Sensor Mounting Bracket can be taken out from the machine.
Bearing Plate Infeed Drive Shaft
Fig 4.8.67
Fig 4.8.65

SpineMaster
15. Withdraw the Sensor from the Mounting Bracket.
16. Remove the front locking nut from the new Sensor and set the back nut
to approximately the same position as the old Sensor.
17. Attach the new sensor to the Sensor Mounting Bracket.
18. Thread new cable ties but do not tighten.
Note: On the front of the Sensor Housing is a rectangular emitter/sensor
window. The Sensor will work best if this window is in a horizontal position. As
the window will not be visible after fitting, mark the Sensor Housing clearly to
show the correct position.
19. Thread the Sensor Cable into position and connect to the PCB. Ensure
that there is just enough slack at the PCB end to prevent stress on the
connection. Fasten cable ties.
20. Secure the Mounting Bracket to the Motor Mounting Plate and check
the Sensor Position (ADJ8.4).
21. Replace the Infeed Drive Shaft, the two plastic gears and the Bearing
Plate.
22. Engage the two belts.
23. Replace the Book Deflector Plate and secure.
24. Replace the Side Covers and close the Top Delivery Assembly.
25. Reconnect mains power and test.

SpineMaster
ADJ8.1 Adjusting the Transverse Chain Tension

No parts 3mm Allen Key
4mm Allen Key
Procedure
2. Make sure the Carriage is parked on the RH side of the machine.
4. Check the tension in the Transverse Chain. To do this, push the top
section of the Chain down mid-way between the Sprockets. If the
tension is correct, you should only be able to move the Chain down by
approximately 10mm (see Fig 4.8.68).
Look for 10mm

of movement here
Aluminium
Side Plate
M8 screw
Fig 4.8.68
5. When re-tensioning the Chain, the RH Tension Sprocket is positioned

fully up and the remainder of the required tension is set with the LH
Tension Sprocket.
6. To adjust the LH Tension Sprocket, loosen the M8 screw (see Fig 4.8.68),
move the Sprocket and retighten the screw. Re-check the tension in the
Transverse Chain.
CAUTION
DO NOT lubricate this Chain.

ADJ8.1 Adjusting the Transverse Chain Tension
SpineMaster
ADJ8.2 Adjusting LH & RH Limit Sensors 5. Unplug the main Drive Motor, unplug PL6 from PCB 900-197, and plug
in the Bypass Cable (see Fig 4.8.70).
The Limit Sensors (905-376) detect when the Carriage has reached either
end of the Carriage Guide. They must be adjusted so that the Carriage
clears the Book Infeed Slot, but does not to reach the End-stops on the
Carriage Guide. They may need adjusting periodically if the Transverse
Chain loses its tension.
Power to
PARTS REQUIRED TOOLS REQUIRED Main Drive Motor
No parts 3mm Allen Key
4mm Allen Key
740-294 Bypass Cable
Fig 4.8.70
Procedure 6. With the Stacker Assembly open, manually activate the Infeed Sensor to
1. Make sure the Carriage is parked on the RH side of the machine. start the SpineMaster.
2. Switch off the power and disconnect the mains input lead. 7. To cycle the carriage, manually activate the Clamp Optical Sensor.
3. Remove the LH Side Cover.
4. To adjust each Sensor, loosen the M5 screw that holds the Sensor Mount
to the Anvil. Move the Mount as required, and re-tighten the screw. The
Sensor Mount is accessed from the top of the unit (see Fig 4.8.69).
Clamp Optical Sensor
Fig 4.8.71
8. Check the stop position of the Carriage. When viewed from above, the
centre-line of the trailing Carriage Cam Roller should align with the
Sensor Mount Bracket vertical face of the Aluminium Side Plate (see Fig 4.8.72).
Fig 4.8.69 Aluminum Side Plate

(shown for position) Bolster
Carriage Cam Roller
WARNING Stop
When operating the SpineMaster with covers removed, be careful of Anvil
moving components and live circuits.
Fig 4.8.72

ADJ8.2 Adjusting LH & RH Limit Sensors
SpineMaster
9. If the Carriage does not stop in the right place, adjust the Sensor again.
Check the end position of the Carriage at both ends of the Carriage
Guide.

ADJ8.2 Adjusting LH & RH Limit Sensors
SpineMaster
ADJ8.3 Adjusting the Clamp Open Sensor 5. To check that the Sensor is positioned correctly, refit the Infeed
Assembly and switch the SpineMaster on. Check that the Clamp is in
the open position, and that the LED on the Sensor (or LED18 on PCB
The Clamp Open Sensor is mounted on the Bolster, and is only used when 900-197) is illuminated.
the SpineMaster is initially turned on. This Sensor checks that the Clamp is
open to ensure that the Bolster is not operating out of phase.
None 3mm Allen Key
4mm Allen Key
1mm Feeler Gauge
Procedure
3. Locate the Sensor (see Fig 4.8.73).
Sensor and Flag
Fig 4.8.73
4. To adjust the Sensor, loosen both the M5 screws that attach the Sensor
Mount to the Bolster. Set the gap between the Sensor and the Flag to
1mm, and re-tighten the screws.
WARNING
When operating the SpineMaster with covers removed, be careful of
moving components and live circuits.

ADJ8.3 Adjusting the Clamp Open Sensor
SpineMaster
ADJ8.4 Adjusting Clamp Optical Sensor 5. Lift the Book Deflector Plate and push it back, away from the Clamp
Sensor Mounting Bracket. It is unnecessary to completely remove the
Deflector Plate from the machine (see Fig 4.8.75).
If the Clamp fails to operate, it may be because the Clamp Sensor is
damaged or faulty. When a book is placed in front of the Sensor, LED15 on
PCB 900-197 should illuminate. If the LED is lit when no book is present,
the Sensor may be oversensitive.
Check that the Clamp area is free of debris and then try adjusting the Deflector Plate
Sensor position (moving the Sensor back can prevent false triggers or (pushed back)
reaction to background reflections). If adjusting the Sensor makes no
difference then it should be replaced (REP8.20). Clamp Sensor
Mounting Bracket
None 3mm Allen Key
Fig 4.8.75
4mm Allen Key
8mm Spanner
6. Check the Sensor position. It should extend out to a point just behind the
Transport Belts.
Procedure 7. Loosen the two locking nuts which secure the Clamp Sensor Mounting
1. Switch off the power and disconnect the mains input lead. Bracket to the Motor Mounting Plate. Adjust the position of the Clamp
2. Remove the Side Covers. Sensor Mounting Bracket.
To fine-adjust the sensor’s position as necessary, remove the bracket
3. Open the Top Delivery Assembly and the Stacker.
from the machine and set the position of the locking nuts on the sensor
4. Loosen the four locking nuts from the Book Deflector Plate fixing (see REP8.20).
screws. Withdraw the screws from the Side Plates.
Locking Clamp Sensor

Nut Mounting Bracket
Motor Mounting Plate
Locking Nut Fig 4.8.76
8. Tighten the two locking nuts to secure the Clamp Sensor Mounting
Locking Plate to the Motor Mounting Plate.
Nut
9. Replace the Book Deflector Plate and secure.
10. Replace the Side Covers and close the Top Delivery Assembly and the
Stacker.
Fig 4.8.74 11. Reconnect mains power and test.

ADJ8.4 Adjusting Clamp Optical Sensor
SpineMaster
ADJ8.5 Adjusting the Clutch Control Collar 5. Slide the Control Collar off the splines.
6. Using the Hand Crank Tool (955-014), rotate the SpineMaster until the
Cam Links are set to BDC (see Fig 4.8.78).
None 4mm Allen Key
Small Electrical Screwdriver BDC (Bottom Dead-Centre)
Crank Centre-line
Procedure
1. Switch off the power and disconnect the mains input lead. TDC (Top Dead-Centre)
3. Remove the Infeed Assembly (see 8.0d-1). Fig 4.8.78
4. Remove the Circlip, ease the Retaining Ring out of its groove and slide it
towards the Sprocket (see Fig 4.8.77).
7. Rotate the Control Collar until the tip of the Actuator Pawl is in line with
the Stop on the Control Collar (see Fig 4.8.79). Slide the Collar back
onto the Splines so that the Stop is agains the Actuator Pawl.
WARNING
When operating the SpineMaster with covers removed, be careful of
Splines moving components and live circuits.
Control Collar
Circlip 8. Release the Clutch Release Lever.
Retaining Ring 9. Replace the Infeed Assembly and connect, but do not replace fixing
screws.
10. Switch on the mains power supply. The Clamp will close and then open
again.
Fig 4.8.77
11. Switch off mains power supply and check that the Clamp has parked at
BDC.
12. If the Clamp does not park at BDC, reset the Control Collar as
necessary and re-test.
13. Once the Clutch is correctly set, replace the Retaining Ring in its
groove.

ADJ8.5 Adjusting the Clutch Control Collar
SpineMaster
ADJ8.6 Setting the Solenoid

None 4mm Allen Key
952-382 Feeler Gauges, Metric
Procedure
1. Loosen the Solenoid mounting screws slightly. You should be able to
move the Solenoid, but the screws should be just tight enough to allow
the Solenoid to stay in position.
2. Loosen the Eccentric Cam.
3. Fully depress the Plunger (see Fig 4.8.79) and adjust the position of the
Solenoid to give an air gap of 2.0 mm (0.08 inch) between the tip of the
Actuator Pawl and the tip of the Stop on the Control Collar.
Solenoid Mounting screws
Actuator Pawl
Stop
Plunger
2mm Airgap (once set, this

should be limited to 1.5mm Fig 4.8.79 Eccentric Cam
by the Eccentric Cam.
4. Rotate the Eccentric Cam until the airgap is limited to 1.5 mm (0.06
inch). Tighten the Eccentric Cam.
5. Tighten the Solenoid mounting screws, and recheck the airgap.

ADJ8.6 Setting the Solenoid
SpineMaster
ADJ8.7 Adjusting the Stop 5. The Stop is adjusted with an M5 screw at either end of the Stop
Assembly Remember to loosen the M5 screw locking nut and the two
locking screws (see Fig 4.8.81) before making any adjustments. Adjust
If booklet spines are being formed unevenly, it is possible that the Stop the Stop so that it is 0.5 mm (0.02 inch) below the Clamp/Bolster at both
needs adjusting. It is essential that the Stop is parallel with the Clamp, and ends. Double-check the gap is even for the entire length of the Stop.
that the minimum depth is correctly set.
Locktite 242 3mm Allen Key
4mm Allen Key Locking nut
8mm Spanner
13mm Spanner
0.5mm Feeler Gauge
Locking screw (2) M5 screw
Procedure
1. Switch off the power and disconnect the mains input.
3. Rotate the Adjuster Shaft (265-835) anti-clockwise, to bring the Stop to Fig 4.8.81
its minimum depth. Use a 13mm spanner to loosen the Trantorque Bush
on the end of the Adjuster Shaft. 6. Operate the Stop by hand, to make sure it does not stick when it is
4. There should be 0.5mm between the bottom face of the Bolster/Anvil moved. If the Stop does stick, tighten the Trantorque Bush on the
and the Stop. Use the 0.5mm Feeler Gauge to set this gap (see Fig Adjuster Shaft and slowly rotate the Adjuster Shaft until the Stop is
4.8.80). released.
7. Loosen the Trantorque Bush on the end of the Adjuster Shaft. Rotate the
Feeler Gauge Adjuster Shaft anti-clockwise and retighten the Trantorque Bush.
8. Retighten all the lockng sccrews and ensure that the M5 screw is
secured with the locking nut (use Locktite 242).
Anvil Bolster 9. Refit all the components.
Stop
Fig 4.8.80

ADJ8.7 Adjusting the Stop
SpineMaster
ADJ8.8 Adjusting the Stop Damping
To prevent the Stop from oscillating or bouncing when it is released,

there is a plastic thumb screw that can be adjusted to damp the motion.
It is important that the Stop does not oscillate too much, as this can allow
thinner booklets to become jammed. Two oscilations is the most desirable.
None 3mm Allen Key
8mm Spanner
Procedure
1. Switch off the power and disconnect the mains input.
3. Loosen the M5 lock nut on the plastic thumb screw (see Fig 4.8.82).
Plastic Thumb screw
Fig 4.8.82
4. Turn the thumb screw by hand, until it is finger-tight. DO NOT

overtighten.
5. Tighten the M5 lock nut.
6. Check that the Stop is adequately damped, and adjust again if necessary.

ADJ8.8 Adjusting the Stop Damping
SpineMaster
ADJ8.9 De-burring the Bolster
The Bolster can be damaged by poorly formed booklets. Booklets which

are too thin (below specification) or where the stitch is not on the spine,
may damage the bolster. This can produce visible marking on the finished
booklet.
None Fine File or Oil Stone
Procedure
The damaged area of the Clamp can be smoothed with a fine file or an oil
stone (used for sharpening cutting tools).
2. Examine the faulty booklet and determine where the Bolster or Anvil
are damaged.
3. Remove the Side Cover nearest to the damaged area.
4. Reach through the side access hole and smooth the damaged area with
either a fine file or an oil stone.
CAUTION
Take care to retain the existing profile of the Clamp. Do not file away the
Clamping Ridge. Do not file the corners of the Bolster or Anvil into a radius.
5. Replace the Covers and test.

6. Advise the operator that processing thin or badly formed booklets can
cause damage.

ADJ8.9 De-burring the Bolster
SpineMaster
ADJ8.10 Book Thickness Adjustment
This control alters the height of the Stop. The control is turned by hand,
which operates a worm drive via a toothed belt. If the control is set to a
thicker booklet size, the Stop will be lowered, leaving more of the spine
exposed to the Carriage. This is necessary to form the wider spine a thicker
booklet requires.
Max.
Min.
Fig 4.8.83

ADJ8.10 Book Thickness Adjustment
SpineMaster
Error Indicator / Reset Button
ADJ8.11 Operating Modes
This indicator/button performs several functions -
● A green light indicates an error. Correct the error and then press the
Single Pass: The SpineMaster will process the booklet a single time. This
button to reset the SpineMaster.
is the default setting, and is suitable for the vast majority of booklets. Each
subsequent booklet is formed by the Carriage travelling in the opposite ● The button can be used to start the machine if it is not automatically
direction, i.e if the first booklet is formed by the Carriage travelling from started by hand-feeding or by connected equipment.
left to right, the second booklet will be formed by the Carriage travelling ● When hand-feeding, the green light flashes as each booklet is processed.
from right to left. Another booklet can be inserted when the light goes out.
Double Pass: The SpineMaster will process the booklet twice. This can
be useful for thick, inflexible covers which are more resistant to re-forming.
In this mode, the Carriage passes along the booklet’s spine twice (once in
either direction)
SquareBack Mode: The booklets will be processed and receive a squared
spine (SquareBack).
Bypass Mode: The booklets will bypass the SquareBacking process and
will be delivered straight to the stacker. The Book Diverter, activated by a
solenoid, diverts the booklets directly to the stacker.
Error Indicator / Reset Button
Square Back
Mode
Bypass Mode Double Pass
Single Pass
Fig 4.8.84

ADJ8.11 Operating Modes
Section 5
Parts Lists
Contents
PL1 and INDEX1 Interface Box Section 5 Parts Lists ....................................................5-1 PL3.6 Rear Conveyance Section (2/2) .......... 5-35
Duplo Return Parts Process (For north America) .. 5-4 PL3.7 Slitter Unit (1/5).................................... 5-36
PL2 and INDEX2 TR-DP
Spare Parts............................................................. 5-6 PL3.7 Slitter Unit (2/5) ................................... 5-37
PL3 and INDEX3 SCC PL1.1 Hardware ............................................... 5-8 PL3.7 Slitter Unit (3/5) ................................... 5-38
INDEX1 Interface Box ......................................... 5-9 PL3.7 Slitter Unit (4/5) ................................... 5-39
PL4 and INDEX4 DCM Kit
PL2.1 Frame ...................................................5-10 PL3.7 Slitter Unit (5/5) ................................... 5-40
PL5a and INDEX5a DBM-500 PL2.2 Accessories (1/2) .................................. 5-11 PL3.8 Slitter Frame (1/2) ................................ 5-41
PL2.2 Accessories (2/2) .................................5-12 PL3.8 Slitter Frame (2/2) ............................... 5-42
PL5b and INDEX5b DBM-500BR
PL2.3 Paper Carrying .....................................5-13 PL3.9 Cutter (1/2)........................................... 5-43
PL6 and INDEX6 DBM-500T PL2.4 Bottom Conveyance .............................5-14 PL3.9 Cutter (2/2) .......................................... 5-44
PL2.5 Vertical Conveyance (1/2) ....................5-15 PL3.10 Creaser (1/4)........................................ 5-45
PL7 and INDEX7 DBM-LS1/DBM-K
PL2.5 Vertical Conveyance (2/2) ....................5-16 PL3.10 Creaser (2/4) ....................................... 5-46
PL8 and INDEX8 SpineMaster PL2.6 Electrical Parts .....................................5-17 PL3.10 Creaser (3/4) ....................................... 5-47
PL2.7 Harness ................................................5-18 PL3.10 Creaser (4/4) ....................................... 5-48
PL9 PC
PL2.8 Hand Feed ............................................5-19 PL3.11 Upper Conveyance (1/7) ..................... 5-49
PL2.9 Connecting Base ................................. 5-20 PL3.11 Upper Conveyance (2/7) ..................... 5-50
INDEX2 TR-DP...................................................5-21 PL3.11 Upper Conveyance (3/7) ......................5-51
PL3.1 Conveyance Entrance (1/2) ................. 5-22 PL3.11 Upper Conveyance (4/7) ..................... 5-52
PL3.1 Conveyance Entrance (2/2)................. 5-23 PL3.11 Upper Conveyance (5/7) ..................... 5-53
PL3.2 Front Conveyance Section (1/3) ...........5-24 PL3.11 Upper Conveyance (6/7) ..................... 5-54
PL3.2 Front Conveyance Section (2/3) ......... 5-25 PL3.11 Upper Conveyance (7/7) ..................... 5-55
PL3.2 Front Conveyance Section (3/3) ......... 5-26 PL3.12 Dust Box (1/2) ...................................... 5-56
PL3.3 Back Jogger......................................... 5-27 PL3.12 Dust Box (2/2)...................................... 5-57
PL3.4 Side Jogger (1/2) ................................. 5-28 PL3.13 Frame .................................................. 5-58
PL3.4 Side Jogger (2/2) ................................. 5-29 PL3.14 Exterior (1/2) ........................................ 5-59
PL3.5 Middle Conveyance Section (1/4)........ 5-30 PL3.14 Exterior (2/2) ....................................... 5-60
PL3.5 Middle Conveyance Section (2/4) ........5-31 PL3.15 Moving Unit (1/2) ................................. 5-61
PL3.5 Middle Conveyance Section (3/4) ....... 5-32 PL3.15 Moving Unit (2/2) ................................. 5-62
PL3.5 Middle Conveyance Section (4/4) ....... 5-33 PL3.16 Foot (1/2) ............................................. 5-63
PL3.6 Rear Conveyance Section (1/2) .......... 5-34 PL3.16 Foot (2/2) ............................................. 5-64
5-1
iGen3-M12D0-0612-0
PL3.17 Accessories (1/2) ................................. 5-65 PL5a.8 Saddle Stitching Stopper Section PL5a.25 Paper Receiving Section ....................5-145
PL3.17 Accessories (2/2) ................................ 5-66 (4/4) ....................................................5-104 PL5a.26 Cabinet Section (1/2) ..........................5-146
PL3.18 Driving Belt List ................................... 5-67 PL5a.9 Back Stopper Section (1/3) ................5-105 PL5a.26 Cabinet Section (2/2) ......................... 5-147
PL3.19 Labels .................................................. 5-68 PL5a.9 Back Stopper Section (2/3) ................5-106 PL5a.27 Accessory Section (1/2) .....................5-148
PL3.20 Wiring (1/2) .......................................... 5-69 PL5a.9 Back Stopper Section (3/3) ................5-107 PL5a.27 Accessory Section (2/2) .....................5-149
PL3.20 Wiring (2/2) ...........................................5-70 PL5a.10 Side Guide Section (1/3) ....................5-108 INDEX5a DBM-500 (1/6)....................................5-150
PL3.21 Electrical Parts (1/5) .............................5-71 PL5a.10 Side Guide Section (2/3) ....................5-109 INDEX5a DBM-500 (2/6) ................................... 5-151
PL3.21 Electrical Parts (2/5) .............................5-72 PL5a.10 Side Guide Section (3/3) .................... 5-110 INDEX5a DBM-500 (3/6) ...................................5-152
PL3.21 Electrical Parts (3/5).............................5-73 PL5a.11 Folding Blade Section ........................ 5-111 INDEX5a DBM-500 (4/6) ...................................5-153
PL3.21 Electrical Parts (4/5) .............................5-74 PL5a.12 Folding Stopper Section (1/3) ............. 5-112 INDEX5a DBM-500 (5/6) ...................................5-154
PL3.21 Electrical Parts (5/5).............................5-75 PL5a.12 Folding Stopper Section (2/3) ............ 5-113 INDEX5a DBM-500 (6/6) ...................................5-155
INDEX3 SCC (1/5) ..............................................5-76 PL5a.12 Folding Stopper Section (3/3) ............ 5-114 PL5b.1 Drive (1/2) ...........................................5-156
INDEX3 SCC (2/5) .............................................5-77 PL5a.13 Folding Roller Section (1/4) ................ 5-115 PL5b.1 Drive (2/2) ...........................................5-157
INDEX3 SCC (3/5) .............................................5-78 PL5a.13 Folding Roller Section (2/4) ................ 5-116 PL5b.2 Frame .................................................5-158
INDEX3 SCC (4/5)..............................................5-79 PL5a.13 Folding Roller Section (3/4) ................ 5-117 PL5b.3 Paper Receiving .................................5-159
INDEX3 SCC (5/5) ............................................ 5-80 PL5a.13 Folding Roller Section (4/4) ................ 5-118 PL5b.4 Accessories ........................................5-160
PL4.1 Cover ................................................... 5-81 PL5a.14 Conveyance Infeed Section (1/2) ....... 5-119 INDEX5b DBM-500BR .......................................5-161
PL4.2 Accessories ......................................... 5-82 PL5a.14 Conveyance Infeed Section (2/2) .......5-120 PL5c.1 Motor...................................................5-162
PL4.3 Hardware ............................................. 5-83 PL5a.15 Conveyance Roller Section (1/2) ........5-121 PL5c.2 Sensor ................................................5-163
PL4.4 Static-electricity Eliminator .................. 5-84 PL5a.15 Conveyance Roller Section (2/2) .......5-122 PL5c.3 Solenoid, Brake, Clutch ......................5-164
PL4.5 Harness ............................................... 5-85 PL5a.16 Stitching Outfeed Section (1/4) ..........5-123 PL5c.4 Miscellaneous (1/2) ............................5-165
INDEX4 DCM Kit ............................................... 5-86 PL5a.16 Stitching Outfeed Section (2/4) ..........5-124 PL5c.4 Miscellaneous (2/2) ............................5-166
PL5a.1 Stitcher Head Section (1/2) ................. 5-87 PL5a.16 Stitching Outfeed Section (3/4) ..........5-125 PL5c.5 Wiring (1/4) .........................................5-167
PL5a.1 Stitcher Head Section (2/2) ................. 5-88 PL5a.16 Stitching Outfeed Section (4/4) ..........5-126 PL5c.5 Wiring (2/4) .........................................5-168
PL5a.2 Clincher Section .................................. 5-89 PL5a.17 Folding Outfeed Section (1/2) ............5-127 PL5c.5 Wiring (3/4) .........................................5-169
PL5a.3 Driving Stitch Section (1/2) .................. 5-90 PL5a.17 Folding Outfeed Section (2/2) ............5-128 PL5c.5 Wiring (4/4) .........................................5-170
PL5a.3 Driving Stitch Section (2/2) ................. 5-91 PL5a.18 Side Stitching Outfeed Section (1/2) ..5-129 INDEX5c DBM-500/DBM-500BR ...................... 5-171
PL5a.4 Back Jog Section (1/4) ........................ 5-92 PL5a.18 Side Stitching Outfeed Section (2/2) ..5-130 PL6.1 Upper Section of
PL5a.4 Back Jog Section (2/4) ........................ 5-93 PL5a.19 Driving Main Section .......................... 5-131 Conveyance Entrance (1/2) ................5-172
PL5a.4 Back Jog Section (3/4) ........................ 5-94 PL5a.20 Driving Stitcher Section (1/2) .............5-132 PL6.1 Upper Section of
PL5a.4 Back Jog Section (4/4) ........................ 5-95 PL5a.20 Driving Stitcher Section (2/2) .............5-133 Conveyance Entrance (2/2)................5-173
PL5a.5 Side Jog Section (1/3) ......................... 5-96 PL5a.21 Driving Fold Section ...........................5-134 PL6.2 Lower Section of
PL5a.5 Side Jog Section (2/3) ......................... 5-97 PL5a.22 Driving Conveyance Section (1/3) ......5-135 Conveyance Entrance (1/2) ................ 5-174
PL5a.5 Side Jog Section (3/3) ......................... 5-98 PL5a.22 Driving Conveyance Section (2/3) .....5-136 PL6.2 Lower Section of
PL5a.6 Wire Feed Detection Section............... 5-99 PL5a.22 Driving Conveyance Section (3/3) .....5-137 Conveyance Entrance (2/2)................ 5-175
PL5a.7 Side Stitching Stopper Section ...........5-100 PL5a.23 Exterior Section (1/6) .........................5-138 PL6.3 Waste Gate Section............................5-176
PL5a.8 Saddle Stitching Stopper Section PL5a.23 Exterior Section (2/6) .........................5-139 PL6.4 Cutter Section (1/2) ............................5-177
(1/4).....................................................5-101 PL5a.23 Exterior Section (3/6) .........................5-140 PL6.4 Cutter Section (2/2) ............................5-178
PL5a.8 Saddle Stitching Stopper Section PL5a.23 Exterior Section (4/6) ......................... 5-141 PL6.5 Paper Scraps Holder Section .............5-179
(2/4) ....................................................5-102 PL5a.23 Exterior Section (5/6) .........................5-142 PL6.6 Fan Section ........................................5-180
PL5a.8 Saddle Stitching Stopper Section PL5a.23 Exterior Section (6/6) .........................5-143 PL6.7 Stopper Moving Section (1/2) .............5-181
(3/4) ....................................................5-103 PL5a.24 Control Panel Section.........................5-144 PL6.7 Stopper Moving Section (2/2).............5-182
5-2
PL6.8 Stopper Section ..................................5-183 INDEX7 DBM-LS1/DBM-K ...............................5-219 PL8.23 UPFEED CONVEYOR (2/2) ...............5-261
PL6.9 Press Section .....................................5-184 PL8.1 ASMD AUTO SPINEMASTER (1/2) .. 5-220 PL8.24 INFEED ASSEMBLY ......................... 5-262
PL6.10 Upper Section of PL8.1 ASMD AUTO SPINEMASTER (2/2).. 5-221 PL8.25 INFEED DRIVE (1/2) ......................... 5-263
Conveyance Exit (1/3) ........................5-185 PL8.2 MAIN FRAME STACKER .................. 5-222 PL8.25 INFEED DRIVE (2/2) ......................... 5-264
PL6.10 Upper Section of PL8.3 MAIN FRAME & FAN ........................ 5-223 PL8.26 ADJUSTABLE BASE ........................ 5-265
Conveyance Exit (2/3) ........................5-186 PL8.4 MAIN FRAME ELECTRICS (1/2) ...... 5-224 PL8.27 CONNECTING DRIVE (1/2) .............. 5-266
PL6.10 Upper Section of PL8.4 MAIN FRAME ELECTRICS (2/2) ...... 5-225 PL8.27 CONNECTING DRIVE (2/2) ............. 5-267
Conveyance Exit (3/3) ........................5-187 PL8.5 DIVERT & UPFEED (1/2) .................. 5-226 PL8.28 ACCESSORIES ................................. 5-268
PL6.11 Lower Section of PL8.5 DIVERT & UPFEED (2/2) .................. 5-227 INDEX8 SPINE MASTER (1/5) ....................... 5-269
Conveyance Exit (1/3) ........................5-188 PL8.6 SECONDARY DRIVE (1/2) ............... 5-228 INDEX8 SPINE MASTER (2/5) ........................5-270
PL6.11 Lower Section of PL8.6 SECONDARY DRIVE (2/2) ............... 5-229 INDEX8 SPINE MASTER (3/5) ........................5-271
Conveyance Exit (2/3) ........................5-189 PL8.7 PRIMARY DRIVE (1/2) ...................... 5-230 INDEX8 SPINE MASTER (4/5) ....................... 5-272
PL6.11 Lower Section of PL8.7 PRIMARY DRIVE (2/2) ......................5-231 INDEX8 SPINE MASTER (5/5) ....................... 5-273
Conveyance Exit (3/3) ........................5-190 PL8.8 MAIN DRIVE & STOP ....................... 5-232 PL9.1 PC (For north America) ......................5-274
PL6.12 Main Driving Section (1/2) ..................5-191 PL8.9 CRUSH & SIDE PLATES (1/2) .......... 5-233
PL6.12 Main Driving Section (2/2) ..................5-192 PL8.9 CRUSH & SIDE PLATES (2/2).......... 5-234
PL6.13 Conveyance Driving Section ..............5-193 PL8.10 CRUSH ASSEMBLY (1/2) ................. 5-235
PL6.14 Cutter Driving Section ........................5-194 PL8.10 CRUSH ASSEMBLY (2/2) ................. 5-236
PL6.15 Press Driving Section .........................5-195 PL8.11 BOLSTER DRIVE ASSEMBLY (1/2) . 5-237
PL6.16 Belt Stacker Section ...........................5-196 PL8.11 BOLSTER DRIVE ASSEMBLY (2/2) . 5-238
PL6.17 Frame Section (1/3) ............................5-197 PL8.12 BOLSTER SIDE PLATES (1/2) ......... 5-239
PL6.17 Frame Section (2/3)............................5-198 PL8.12 BOLSTER SIDE PLATES (2/2) ......... 5-240
PL6.17 Frame Section (3/3)............................5-199 PL8.13 SIDE PLATE R/H ELECTRICS (1/3)..5-241
PL6.18 Exterior Section ................................. 5-200 PL8.13 SIDE PLATE R/H ELECTRICS (2/3) .5-242
PL6.19 Control Panel Section.........................5-201 PL8.13 SIDE PLATE R/H ELECTRICS (3/3) 5-243
PL6.20 Accessories (1/2) ............................... 5-202 PL8.14 SIDE PLATE R/H (1/2) ...................... 5-244
PL6.20 Accessories (2/2) .............................. 5-203 PL8.14 SIDE PLATE R/H (2/2) ...................... 5-245
PL6.21 Motor, Relay, Clutch .......................... 5-204 PL8.15 SIDE PLATE L/H (1/2) ....................... 5-246
PL6.22 P.W.B, Sensor .................................... 5-205 PL8.15 SIDE PLATE L/H (2/2) .......................5-247
PL6.23 Switch, Solenoid, Noise Filter............ 5-206 PL8.16 MAIN DRIVE ASSEMBLY ................. 5-248
PL6.24 Wiring (1/2) ........................................ 5-207 PL8.17 STOP MECHANISM (1/2) ................. 5-249
PL6.24 Wiring (2/2) ........................................ 5-208 PL8.17 STOP MECHANISM (2/2) ................. 5-250
INDEX6 DBM-500T (1/4) ................................ 5-209 PL8.18 STACKER ASSEMBLY (1/2) ..............5-251
INDEX6 DBM-500T (2/4) .................................5-210 PL8.18 STACKER ASSEMBLY (2/2) ............. 5-252
INDEX6 DBM-500T (3/4) .................................5-211 PL8.19 STACKER DRIVE ASSEMBLY (1/2) . 5-253
INDEX6 DBM-500T (4/4) .................................5-212 PL8.19 STACKER DRIVE ASSEMBLY (2/2) . 5-254
PL7.1 Long Stacker (DBM-LS1) (1/2) ...........5-213 PL8.20 TOP ELECTRICAL PLATE ................ 5-255
PL7.1 Long Stacker (DBM-LS1) (2/2)...........5-214 PL8.21 INPUT CONVEYOR (1/2) .................. 5-256
PL7.2 Kicker (DBM-K) (1/2) ..........................5-215 PL8.21 INPUT CONVEYOR (2/2) ................. 5-257
PL7.2 Kicker (DBM-K) (2/2) .........................5-216 PL8.22 TOP DELIVERY ASSEMBLY (1/2) .... 5-258
PL7.3 Accessories (DBM-LS1) .....................5-217 PL8.22 TOP DELIVERY ASSEMBLY (2/2).... 5-259
PL7.4 Accessories (DBM-K) ........................5-218 PL8.23 UPFEED CONVEYOR (1/2) .............. 5-260
5-3
Duplo Return Parts Process (For north America) Duplo Return Parts Process
1. For parts that Duplo would like returned to them:
Duplo PARTS ORDERING PROCEDURE 2. Duplo Material Handler notifies the CSE at time of part ETA that this
part must be returned to Duplo within 5 business days of receipt.
Available 3X7 (24hrs/day 365days/year)
3. Duplo Material Handler places return instructions in the box of the new
1. Xerox CSE Faxes Parts Order form attention Parts Order Desk. part to be shipped. These instructions will be printed on a fluorescent
at 1-866-416-8237 8.5X11 sheet of paper.
2. If parts were ordered after normal business hours (8AM-5PM PST) 4. The return instructions will include a pre-paid self addressed label.
CSE then calls Duplo Technical Support Specialist at 1(949)419-7377 to
inform them that a Part Order has been sent.
5. The Xerox CSE will pack the return part in the original shipping box
and place the pre-paid return shipping label on the box and ship part
3. Duplo Material Handler picks the parts, fills order ships the part back to Duplo within 5 business days.
according to the priority noted on the form, (Next Flight Out for
Emergency orders).
4. The Duplo Material Handler returns phone call to relay shipping

information and Estimated Time of Arrival (ETA). Return phone call to
the ordering CSE within 1hr of received fax order form.
5. The Duplo Material Handler contacts the shipper and sends out the
parts that were ordered.
5-4 Section 5—Parts List Interface Box

Duplo Return Parts Process (For north America)
Interface Box
Duplo Parts Order Form

Fax To: 1-866-416-8237
Date: ___________________________
Dealer Number: XEROX Ordered by: _________________________________
Model Number: ___________________________ Serial Number: _________________________________
Contact Information SHIP TO:
Xerox CSE Name: Company:
Xerox CSE Phone #: Address:
Customer Contact name: City, State, ZIP:
Customer Phone Number: Attn:
Urgency, Please check one box below:
Emergency Part order Care pack replacement order
(Part will arrive within 36 hrs) (Part will arrive within 5 business days)
Special Instructions:
Part Number Qty Description
Duplo Return Parts Process (For north America)

Section 5—Parts List
5-5
Spare Parts SCC
Item PART # Name Qty. Remarks
1 12C-12050 FLAT BELT 1
The accessories for TR-DP includes the spare parts for five other products 2 11C-81061 ELECTROMAGNETIC CLUTCH 1
as well as ones for TR-DP itself. 3 8D3-31210 SLIT TER, LOWER 1
For details, refer to the following six tables. 4 8D3-31110 SLIT TER, UPPER 1
5 12C-28092 CUT TER GUIDE PLATE UNIT 1
Interface Box 6 12C-33640 FLAT BELT 4
7 12C-80039 MC UNIT 1
Item PART # Name Qty. Remarks 8 12C-81031 SERVO DRIVER 1
1 12S-80036 IF UNIT 1 9 96Y-80072 PR P.W.B. UNIT 1
2 057-10047 SWITCHING POWER SUPPLY 1 10 97J-80131 LED P.W.B. UNIT 1
3 11C-83902 D-PORT CABLE 1 11 99J-80159 OP UNIT 1
12 062-11006 INT.SENSOR 2
13 062-11095 INT.SENSOR 2
TR-DP 14 8N4-X1031 CCD SENSOR 1
Item PART # Name Qty. Remarks 15 12C-24531 NUT R 1
1 12C-80251 MC UNIT 1 16 12C-24541 NUT L 1
2 11C-80136 RM UNIT 1
3 11C-83902 D-PORT CABLE 1
4 11C-83232 D PORT CABLE 1
DCM Kit
5 057-10061 SWITCHING POWER SUPPLY 1 Item PART # Name Qty. Remarks
6 062-11006 INT.SENSOR 1 1 99T-80282 RM UNIT 1 For 120V
7 062-11095 INT.SENSOR 1 2 11C-80136 RM UNIT For 220-240V
8 93E-83150 MAGNET SENSOR 1 3 057-10037 SWITCHING POWER SUPPLY 1
4 99T-86100 I/F UNIT 1/2 1
5 99T-81050 POWER SUPPLY HIGH VOLTAGE 1
6 99T-81061 BAR SM, STATIC ACTIVE 1
7 99T-83191 WIRE UNIT 5 1
8 99T-83173 CONNECTING CABLE 1
9 053-90034 RELAY 1

Spare Parts
DBM-500 DBM-500T
Item PART # Name Qty. Remarks Item PART # Name Qty. Remarks
1 014-10503 BELT (BANDO 2-5MS615) 1 1 014-10279 V-BELT (BANDO A-26) 1
2 014-10526 BELT (BANDO 254XL050U) 1 2 014-00263 BELT (BANDO 150XL037G) 1
3 014-10506 STS BELT 1 3 014-00136 BELT (BANDO 120XL037G) 1
4 014-00235 BELT (BANDO 120XL037L) 2 4 014-10620 STS BELT(BANDO 100S3M192S) 1
5 11G-82602 FEED CLUTCH-C 1 5 014-10523 BELT (BANDO 564XL037G) 1
6 12J-19062 BOSS UNIT 2 6 014-10309 BELT (BANDO 390XL037G) 1
7 12J-40030 BELT 1 7 99W-20141 UPPER BLADE 1
8 057-10053 SWITCHING POWER SUPPLY 1 8 99W-20351 LOWER BLADE 1
9 11A-80253 RL P.W.B UNIT 2 9 12K-40330 FLAT BELT 3
10 11A-81390 ISOLATION BOARD 1 10 12K-41760 FLAT BELT 3
11 12J-82160 MOTOR DRIVER 1 For 120V 11 057-10054 SWITCHING POWER SUPPLY 1
12 12J-82140 MOTOR DRIVER 1 For 220-240V 12 12K-86103 MC UNIT 1
13 12J-86105 MC UNIT 1 13 99J-80159 OP UNIT 1
14 12J-85301 OPER ATION TERMINAL 1 14 95K-80063 PH P.W.B UNIT 1
15 12J-80112 KEY P.W.B.UNIT 1 15 95K-80083 LED P.W.B UNIT 1
16 12J-80211 DPIF P.W.B.UNIT 2 16 12K-82020 D PORT CABLE 1
17 98R-80230 INT.SENSOR 4 17 014-10429 STS BELT 1
18 12K-80370 INT.SENSOR 3 18 12K-80360 CLUTCH UNIT 1
19 062-11162 INT.SENSOR 1 19 11C-84100 INTERLOCK SWITCH 1
20 11C-83232 D PORT CABLE 1
21 11C-83390 E PORT CABLE 1
22 12J-83182 WIRE HARNESS-18 1
SpineMaster
23 12J-10211 SCREW 1 PART # Name QTY PK SIZE
24 99W-30111 SCREW 1 1 12C-91510 180-323 SPRING,(VFCN) TR AY PRESSURE 2 1
25 12J-11071 SCREW-R 1 SLIDE
26 12J-11081 SCREW-L 1 2 12C-91520 330-301 RUBBER MOULDING, FEED WHEEL 1 10
27 11J-53040 ROLLER G-32-40 4 (WHITE)
28 11S-83100 DC BRUSHLESS SERVO MOTOR 1 3 12C-91530 730-010 FUSE, 20mm, 3.15A,GLASS- ANTI 1 10
SURGE,T
29 12J-40161 SHAF T 1
4 12C-91540 730-020 FUSE, 1.25 10.0A HRC-QUICK ACTING 1 10
F”
5 12C-91550 730-031 FUSE, 20mm, 6.3A,GLASS- ANTI 1 10
SURGE,T
6 12C-91560 700-402 SWITCH, LEVER ARM - HAMLIN 1 1
7 12C-91570 742-480 CABLE ASSEMBLY, ASM I/FACE ATM 1 1
& TMP
8 12C-91580 900-141 PCB ASSEMBLY, ECO VARIO, 1 1
INTERFACE
9 12C-91590 914-493 BELT, (ASM) MAT-02H-25-382 LONG 2 1
10 12C-91600 914-494 BELT, (ASM) MAT 02H x 25 x 1925 LONG 2 1

Spare Parts
PL1.1 Hardware
ITEM PART # DESCRIPTION 1 2
1 x INSTRUCTION MANUAL (for 100[V]) 7

2 12S-90220 INSTRUCTION MANUAL (for
120,220-240[V])
3** 12J-90940 USA WARR ANTY (for 120[V])
4 12S-10120 ANGLE F
5 12S-10130 BR ACKET R
6 12S-10141 BR ACKET L
7 12S-10151 COVER
8 12S-10160 CONTROL BOARD BASE 3 (120V only) 10
9 12S-80036 IF UNIT
10 056-11137 SPACER
11 056-10357 INLET 5
12 056-10254 OUTLET 9
13 057-10047 SWITCHING POWER SUPPLY 4
14 12S-83010 BUNDLED WIRE UNIT 1
15 056-09002 CABLE CLAMP 19c (220-240V) 15 18
16
17
16 12S-83020 BUNDLED WIRE UNIT 2
17 056-09001 CABLE CLAMP 13
18 054-10190 LOCKER SWITCH

19b (120V)
19a x POWER CORD (for 100[V]) 6
19b** 055-10209 POWER CORD (for 120[V]) 8
19c* 055-10212 POWER CORD (for 220-240[V])

20 11C-83902 D-PORT CABLE 19a (100V)
14
NOTE: * Unique part for 220-240[V] 12
15
20 11
** Unique part for 120[V]

PL1.1 Hardware
INDEX1 Interface Box
PART # PL # ITEM PART # PL # ITEM PART # PL # ITEM PART # PL # ITEM PART # PL # ITEM
054-10190 PL1.1 18 - - - - - - - - - - - -
055-10209 PL1.1 19b - - - - - - - - - - - -
055-10212 PL1.1 19c - - - - - - - - - - - -
056-09001 PL1.1 17 - - - - - - - - - - - -
056-09002 PL1.1 15 - - - - - - - - - - - -
056-10254 PL1.1 12 - - - - - - - - - - - -
056-10357 PL1.1 11 - - - - - - - - - - - -
056-11137 PL1.1 10 - - - - - - - - - - - -
057-10047 PL1.1 13 - - - - - - - - - - - -
11C-83902 PL1.1 20 - - - - - - - - - - - -
12J-90940 PL1.1 3 - - - - - - - - - - - -
12S-10120 PL1.1 4 - - - - - - - - - - - -
12S-10130 PL1.1 5 - - - - - - - - - - - -
12S-10141 PL1.1 6 - - - - - - - - - - - -
12S-10151 PL1.1 7 - - - - - - - - - - - -
12S-10160 PL1.1 8 - - - - - - - - - - - -
12S-80036 PL1.1 9 - - - - - - - - - - - -
12S-83010 PL1.1 14 - - - - - - - - - - - -
12S-83020 PL1.1 16 - - - - - - - - - - - -
12S-90220 PL1.1 2 - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -

INDEX1 Interface Box
PL2.1 Frame
ITEM PART # DESCRIPTION

9
1 12C-53030 FR AME F 13
15
2 12C-53050 FR AME B
14
3 12C-53090 REINFORCING PLATE R
4 12C-53100 COVER 4
5 12C-53120 REINFORCING PLATE RD
3
6 12C-53130 GUARD PLATE
7 12C-53170 REINFORCING PLATE L
8 12C-53190 REINFORCING PLATE LD
9 12C-53230 REINFORCING PLATE T 1 10
10 12C-53270 COVER F
11 12C-53290 COVER B
12 12C-53330 COVER D 6 5
13 12C-53350 COVER R 7
14 12C-53240 GUIDE PLATE R
15 12C-53250 GUIDE PLATE L 11
2
12 8
5-10 Section 5—Parts List TR-DP

PL2.1 Frame
PL2.2 Accessories (1/2) 1 2 3 4 5 6 7 8

1 12C-58050 VERTICAL BR ACKET
2 12C-58030 UPPER HORIZONTAL BR ACKET
3 12C-58040 LOWER HORIZONTAL BR ACKET
4 12C-53390 POWER CORD COVER
9 10 11 12 13 14
5 12C-53410 PORT CABLE COVER 2
6 12C-53400 PORT CABLE COVER 1
7 x KNOB SCREW
8 12J-91000 CONNECTOR COVER
9 11C-83902 D-PORT CABLE 15 16 17 18 19
10 11C-83232 IF CABLE UNIT
11 x AIR-PIPE UNIT
12 99X-84310 EARTH WIRE
13 98Y-82570 EARTH WIRE
14 96F-83060 EARTH WIRE
15 x CONNECTING BASE
20 21 22 23 24 25 26
16 x MANUAL PAPER FEEDING TR AY
17 12S-90440 CD
18 12C-58610 GUIDE T
19 12C-58620 GUIDE D
20 12S-90460 INSTRUCTION MANUAL
21 12S-80140 ROM (when using the rotator)
27 28 29 30 31 32
22 12S-80150 ROM (when not using the rotator)
23 12C-58580 TIMING PULLEY
24 014-10643 TIMING BELT
25 056-09004 CABLE CLAMP 33 34 35
NOTE:
See next page for #26 to #32.

PL2.2 Accessories
PL2.2 Accessories (2/2) 1 2 3 4 5 6 7 8

26 056-09005 CABLE CLAMP
27 12C-90740 NAME PLATE
28 x SCREW (MSKW 3 x 8)
9 10 11 12 13 14
31 x SCREW (MSK 4 x 16)
32 x SCREW (HSKW 6 x 16)
33 12S-83072 PC CABLE
34 * 055-10212 POWER CORD 15 16 17 18 19
35 ** 055-10209 POWER CORD
NOTE:
* Unique part for 220-240[V]
See previous page for #1 to #25.
20 21 22 23 24 25 26
27 28 29 30 31 32
33 34 35

PL2.2 Accessories
PL2.3 Paper Carrying

1 12C-50030 SHAF T 23
2 99X-60090 ROLLER G-10-30
3 013-10024 COLLAR
4 12F-30122 TIMING PULLEY S3M-30-08
20
5 12C-50120 REINFORCING PLATE 12
10 11 14
6 12C-50130 GUIDE D
15 9 11 19
7 12C-50150 GUIDE BAR 6
11 13 19
8 12C-50160 ANGLE
10 20
9 99X-60380 SHAF T 11 13
12
10 96F-11252 PINCH ROLLER UNIT
11 011-10005 PC WASHER
24
12 991-13781 COLLAR
2 3
13 99X-60440 SPRING T
21 19
14 12C-50310 GUIDE T 1
4 19
15 12C-50320 COVER 2
16 12C-52090 SHAF T
17 11G-40620 ROLLER UNIT 18 17
18 12C-50440 ANGLE 8
19 12C-50480 PILLAR 11 3 16
17
20 12C-50490 COLLAR P 040-20-020 22 24 11
21 12C-50500 ANGLE UNIT
18 11
22 91H-51521 IDLER UNIT 5
23 12C-50330 GUIDE
24 12F-30270 BEARING HOLDER 7

PL2.3 Paper Carrying
PL2.4 Bottom Conveyance

21
1 12C-51030 SHAF T 14
2 99X-60090 ROLLER G-10-30 21 12
3 013-10024 COLLAR 11 15
5 014-10263 STS BELT 9 23
6 13 3
10
6 014-10621 STS BELT 17 16 22
12 2
7 12C-51150 GUIDE D 5 8
11 1
8 96F-41330 ANGLE 20 15 22
10
9 12C-52210 SHAF T 2 23
10 11G-40620 ROLLER UNIT 16 3
17
1 2
11 945-25310 COLLAR 23
12 92L-34100 SPRING C 1 3
2 2 8
13 12C-51310 ANGLE
3 2
14 12C-51330 STAY 8 7
15 12C-10130 ANGLE 4 23
19
16 12C-51480 CENTER PIN 4
17 94X-20050 MIDDLE PULLEY UNIT
18 99C-30222 TIMING PULLEY S3M-20-08 18
19 12C-51570 PLATE
23
20 014-10576 STS BELT 3 8
21 98V-41080 SHAF T 23
22 011-10005 PC WASHER
4
23 12F-30270 BEARING HOLDER

PL2.4 Bottom Conveyance
PL2.5 Vertical Conveyance (1/2)
ITEM PART # DESCRIPTION 15

1 12C-52030 SHAF T 13
2 95K-30081 ROLLER UNIT 125
3 947-12230 COLLAR 2 4
13 17
512 125
4 12C-51200 SHAF T
5 11G-40620 ROLLER UNIT 1
6 945-25310 COLLAR 4
2 14
7 92L-34100 SPRING C 35
12 125 16
8 11A-40260 SHAF T
4
9 12C-52330 LEVER
10 91H-11260 COLLAR
3 512
3
11 97J-30100 SHAF T
15
12 011-10005 PC WASHER
13 12C-52420 BELT 3
9 10
14 12C-52450 GUIDE T UNIT 6
7
15 12C-52480 GUIDE T
6 10
16 12C-52680 COVER 8 12
17 991-23261 MAGNET 9 10 2
10 2 11
7 12
12
11
12

PL2.5 Vertical Conveyance
PL2.5 Vertical Conveyance (2/2)

1 0Y4-08018 Y
11
2 99X-60380 SHAF T 9 1
4 011-10005 PC WASHER 10 12
5 991-13781 COLLAR 10
6 99X-60440 SPRING T 13
20
7 12C-52640 GUIDE T 5 5
3 4 19
8 12C-52690 LEVER 1 17
4
9 12C-52700 SHAF T 2
10 96G-12170 SPRING T
3 4 6
11 99X-36670 KNOB
18
4 6 8
12 12C-52730 LEVER R 5
13 12C-52740 LEVER L
4
14 93L-13130 PILLAR 7 17 14
15 12C-52790 SENSOR BR ACKET
18
16 12C-52800 PLATE
17 12C-52660 ANGLE
18 12H-10660 SPRING T
19 96G-12640 STUD
16
20 011-10061 WASHER 8
19
14 205 15
4

PL2.5 Vertical Conveyance
PL2.6 Electrical Parts

1 051-10169 DC BRUSHLESS MOTOR
2 92L-86152 SPACER
3 056-10215 SPACER
4 11C-80136 RM UNIT
6 062-11006 INT.SENSOR
7 062-11095 INT. SENSOR
8 93E-83150 MAGNET SENSOR
7
9 12C-80140 AC CABLE UNIT
10 12C-80251 MC UNIT
1
5
3
10
3 6
2
2

PL2.7 Harness

1 12C-80360 WIRE UNIT 1
2 12C-80210 WIRE UNIT 2
3 12C-80240 WIRE UNIT 3
4 12C-80140 AC WIRE UNIT
3 2

PL2.7 Harness
PL2.8 Hand Feed

2
1 12C-58570 SLIDE BLOCK
2 12C-58450 MANUAL FEED BASE
3 12C-58470 PAPER GUIDE UNIT 1
4 12C-58500 SUPPORT GUIDE
5 12C-58550 SUPPORT GUIDE 3
6 12C-58520 PAPER GUIDE
4
6

PL2.8 Hand Feed
PL2.9 Connecting Base

1 12C-58130 CONNECTION STAY
2 12C-58140 CENTER PIN
3 12C-58160 PILLAR
4 12C-58190 SHAF T
2
5 12C-58200 SHAF T
7 8
6 12C-58210 HOOK
7 12C-58220 HOOK
4 1
10 12C-58300 ANGLE
11 12C-58330 CONNECTION BR ACKET F 6 5 16
12 12C-58340 CONNECTION BR ACKET B 9
3
13 12C-58350 SCREW PLATE
0Z5-09031 Z COLLAR
15
14 14
15 011-10061 WASHER 2
16 016-00118 RUBBER LEG
8
9
11 13
13
10 12

PL2.9 Connecting Base
INDEX2 TR-DP
011-10005 PL2.3 11 12C-50320 PL2.3 15 12C-53240 PL2.1 14 12C-80251 PL2.6 10 99C-30222 PL2.4 18
011-10005 PL2.4 22 12C-50330 PL2.3 23 12C-53250 PL2.1 15 12C-80360 PL2.7 1 99X-36670 PL2.5(2/2) 11
011-10005 PL2.5(1/2) 12 12C-50440 PL2.3 18 12C-53270 PL2.1 10 12C-90740 PL2.2(2/2) 27 99X-60090 PL2.3 2
011-10005 PL2.5(2/2) 4 12C-50480 PL2.3 19 12C-53290 PL2.1 11 12F-30122 PL2.3 4 99X-60090 PL2.4 2
011-10061 PL2.5(2/2) 20 12C-50490 PL2.3 20 12C-53330 PL2.1 12 12F-30122 PL2.4 4 99X-60380 PL2.3 9
011-10061 PL2.9 15 12C-50500 PL2.3 21 12C-53350 PL2.1 13 12F-30270 PL2.3 24 99X-60380 PL2.5(2/2) 2
013-10024 PL2.3 3 12C-51030 PL2.4 1 12C-53390 PL2.2(1/2) 4 12F-30270 PL2.4 23 99X-60440 PL2.3 13
013-10024 PL2.4 3 12C-51150 PL2.4 7 12C-53400 PL2.2(1/2) 6 12H-10660 PL2.5(2/2) 18 99X-60440 PL2.5(2/2) 6
014-10263 PL2.4 5 12C-51200 PL2.5(1/2) 4 12C-53410 PL2.2(1/2) 5 12J-91000 PL2.2(1/2) 8 99X-84310 PL2.2(1/2) 12
014-10576 PL2.4 20 12C-51310 PL2.4 13 12C-58030 PL2.2(1/2) 2 12S-80140 PL2.2(1/2) 21 - - -
014-10621 PL2.4 6 12C-51330 PL2.4 14 12C-58040 PL2.2(1/2) 3 12S-80150 PL2.2(1/2) 22 - - -
014-10643 PL2.2(1/2) 24 12C-51480 PL2.4 16 12C-58050 PL2.2(1/2) 1 12S-83072 PL2.2(2/2) 33 - - -
016-00118 PL2.9 16 12C-51570 PL2.4 19 12C-58130 PL2.9 1 12S-90440 PL2.2(1/2) 17 - - -
051-10169 PL2.6 1 12C-52030 PL2.5(1/2) 1 12C-58140 PL2.9 2 12S-90460 PL2.2(1/2) 20 - - -
055-10209 PL2.2(2/2) 35 12C-52090 PL2.3 16 12C-58160 PL2.9 3 91H-11260 PL2.5(1/2) 10 - - -
055-10212 PL2.2(2/2) 34 12C-52210 PL2.4 9 12C-58190 PL2.9 4 91H-51521 PL2.3 22 - - -
056-09004 PL2.2(1/2) 25 12C-52330 PL2.5(1/2) 9 12C-58200 PL2.9 5 92L-34100 PL2.4 12 - - -
056-09005 PL2.2(2/2) 26 12C-52420 PL2.5(1/2) 13 12C-58210 PL2.9 6 92L-34100 PL2.5(1/2) 7 - - -
056-10215 PL2.6 3 12C-52450 PL2.5(1/2) 14 12C-58220 PL2.9 7 92L-86152 PL2.6 2 - - -
057-10061 PL2.6 5 12C-52480 PL2.5(1/2) 15 12C-58280 PL2.9 8 93E-83150 PL2.6 8 - - -
062-11006 PL2.6 6 12C-52640 PL2.5(2/2) 7 12C-58290 PL2.9 9 93L-13130 PL2.5(2/2) 14 - - -
062-11095 PL2.6 7 12C-52660 PL2.5(2/2) 17 12C-58300 PL2.9 10 945-25310 PL2.4 11 - - -
0Y4-08018 PL2.5(2/2) 1 12C-52680 PL2.5(1/2) 16 12C-58330 PL2.9 11 945-25310 PL2.5(1/2) 6 - - -
0Z5-09031 PL2.9 14 12C-52690 PL2.5(2/2) 8 12C-58340 PL2.9 12 947-12230 PL2.5(1/2) 3 - - -
11A-40260 PL2.5(1/2) 8 12C-52700 PL2.5(2/2) 9 12C-58350 PL2.9 13 94X-20050 PL2.4 17 - - -
11C-80136 PL2.6 4 12C-52730 PL2.5(2/2) 12 12C-58450 PL2.8 2 95K-30081 PL2.5(1/2) 2 - - -
11C-83232 PL2.2(1/2) 10 12C-52740 PL2.5(2/2) 13 12C-58470 PL2.8 3 96F-11252 PL2.3 10 - - -
11C-83902 PL2.2(1/2) 9 12C-52790 PL2.5(2/2) 15 12C-58500 PL2.8 4 96F-11252 PL2.5(2/2) 3 - - -
11G-40620 PL2.3 17 12C-52800 PL2.5(2/2) 16 12C-58520 PL2.8 6 96F-41330 PL2.4 8 - - -
11G-40620 PL2.4 10 12C-53030 PL2.1 1 12C-58550 PL2.8 5 96F-83060 PL2.2(1/2) 14 - - -
11G-40620 PL2.5(1/2) 5 12C-53050 PL2.1 2 12C-58570 PL2.8 1 96G-12170 PL2.5(2/2) 10 - - -
12C-10130 PL2.4 15 12C-53090 PL2.1 3 12C-58580 PL2.2(1/2) 23 96G-12640 PL2.5(2/2) 19 - - -
12C-50030 PL2.3 1 12C-53100 PL2.1 4 12C-58610 PL2.2(1/2) 18 97J-30100 PL2.5(1/2) 11 - - -
12C-50120 PL2.3 5 12C-53120 PL2.1 5 12C-58620 PL2.2(1/2) 19 98V-41080 PL2.4 21 - - -
12C-50130 PL2.3 6 12C-53130 PL2.1 6 12C-80140 PL2.6 9 98Y-82570 PL2.2(1/2) 13 - - -
12C-50150 PL2.3 7 12C-53170 PL2.1 7 12C-80140 PL2.7 4 991-13781 PL2.3 12 - - -
12C-50160 PL2.3 8 12C-53190 PL2.1 8 12C-80210 PL2.7 2 991-13781 PL2.5(2/2) 5 - - -
12C-50310 PL2.3 14 12C-53230 PL2.1 9 12C-80240 PL2.7 3 991-23261 PL2.5(1/2) 17 - - -

INDEX2 TR-DP
PL3.1 Conveyance Entrance (1/2)

1 12C-10030 CONVEYANCE SHAF T
2 99X-30101 ROLLER
3 12C-10120 CARRY GUIDE D
4 12C-10130 ANGLE 9
5 12C-10151 BR ACKET, SENSOR 6 10
6 12C-10190 IDLE SHAF T
8 22 11
4
7 96F-11252 PINCH ROLLER UNIT 9
8 966-14040 COLLAR
7 8 12
2
9 95K-30130 SPRING, C
10 12C-10281 BR ACKET 23
20
11 12C-10320 CARRY GUIDE T 13 1
4
12 12C-10352 BR ACKET, SENSOR 3
15 21 5 4
13 12C-10390 SHAF T 4
16
14 12C-10400 GUIDE PLATE 17
15 12C-10410 GUIDE PLATE 1 15
16 12C-10420 GUIDE PLATE 2 18 14
19
17 952-14380 ANGLE
18 12C-10601 GUIDE PLATE T
19 12C-10610 ANGLE L
20 12C-10620 ANGLE R
21 98R-80230 INT. SENSOR
22 062-11095 INT. SENSOR
23 062-11006 INT. SENSOR
5-22 Section 5—Parts List SCC

PL3.1 Conveyance Entrance
PL3.1 Conveyance Entrance (2/2)

1 013-10024 COLLAR 18
8
2 11T-61140 TIMING PULLEY 5
3 941-30131 COLLAR 6
4 12C-10461 LEVER UNIT 3 1
5 11A-10200 LINK
4
6 11G-12590 COLLAR 04-12-06 9
7 12C-10540 SOLENOID BASE
8 12C-10550 STOPPER
9 12C-10570 SPRING, T
10 12C-10660 CLUTCH BR ACKET
11 93E-40090 COLLAR
12 11K-30130 SPUR GEAR
13 12C-10730 BR ACKET, MOTOR
14 99C-30220 TIMING PULLEY S3M-20-08
15 014-10572 STS BELT
16 12C-81010 DC BRUSHLESS MOTOR 11
17 11C-810601 ELECTROMAGNETIC CLUTCH
12
17 10
11
18 94X-802101 DC SOLENOID
3 1
2
15
16
13
14

PL3.1 Conveyance Entrance
PL3.2 Front Conveyance Section (1/3)

1 12C-12030 SHAF T
2 12C-12040 ROLLER F08-32 12
3 12C-12050 FLAT BELT
14
4 013-10024 COLLAR
4 13
5 11K-30130 SPUR GEAR
6 12C-12130 BR ACKET
7 97J-30100 SHAF T
9 011-10005 PC WASHER 15
10 12C-12200 FRONT CONVEYOR UNIT 17
15
11 12C-12231 FRONT CONVEYOR GUIDE L 2
12 12C-12241 FRONT CONVEYOR GUIDE R 9 89 10 1
13 12C-12250 BR ACKET L 6 3
14 12C-12260 BR ACKET R
19
15 12C-12270 PILLAR 7
20
16 12C-12311 MIDDLE CONVEYOR GUIDE
18 21
17 96F-41330 ANGLE 16 4
18 12C-12360 REINFORCEMENT STAY 5
19
19 12C-10130 ANGLE
20 12C-12391 BR ACKET, SENSOR A
21 062-11006 INT. SENSOR A 17

PL3.2 Front Conveyance Section

1 12C-12441 REINFORCEMENT STAY
2 12C-10130 ANGLE
3 12C-12471 GUIDE PLATE
5
4 12C-12481 GUIDE PLATE L
18 6
5 12C-12491 GUIDE PLATE R 2
8 11G-41100 PILLAR
9 93K-50170 ROLLER 3
10 12C-12571 BR ACKET
7 4
11 0Z4-08022 COLLAR
11 1
12 11G-12590 COLLAR 04-12-06 17
2
13 12C-12600 STAY 13
10 13
14 12C-12611 PLATE
16
15 12C-12620 PLATE 13 12
13 18 14
16 12C-12631 COVER 16
17 12C-12651 BR ACKET UNIT 18 14
18 062-11095 INT. SENSOR 15


1 12C-13030 BLOCK STAY
10
20
2 12C-13060 STOPPER 22
A
3 11G-17210 COLLAR
23
4 941-30131 COLLAR 26 19 21 13
9
5 12C-10461 LEVER UNIT 7 24
6 18 24
6 11A-10200 LINK 5 11 15 14
8
7 11G-12590 COLLAR 04-12-06 17
A
8 952-14380 ANGLE 25 16
4 13
10 12C-10550 STOPPER
14 12
11 12C-10570 SPRING, T
12 12C-13240 FRONT CONVEYOR GUIDE T
13 12C-13251 BR ACKET
14 013-10053 NYLON BALL 7/8 " 1
15 12C-13271 BR ACKET
16 013-10154 STEEL BALL
2
17 12C-13311 BR ACKET
3
18 12C-13321 BR ACKET
19 98X-92281 SCREW
20 12C-13350 STAY
21 12C-13361 ANGLE L
22 12C-13371 ANGLE R 4
23 12C-13380 STAY
24 0Z3-06018 Z COLLAR

PL3.3 Back Jogger

1 12C-14031 JOG BASE 28
2 12C-14040 INTERRUPTER 7
3 12C-14050 STOPPER
22
4 12C-14070 STOPPER UNIT
4
5 12C-14100 SHAF T HOLDER
9 25 1 27
6 93L-11850 COLLAR
3
7 12C-14140 PLATE, MOTOR 10 6
11 24 5
8 12C-14180 JOG PLATE D
9 12C-14190 JOG PLATE T 12 2
14 6 26
10 12C-14200 STAY
13 8
5 24
11 11G-12590 COLLAR 04-12-06 16
12 98X-41520 SPACER 15 21
13 12C-14260 FULCRUM SHAF T
14 12C-14270 LEVER 23
15 12C-14280 SPRING, T 19
16 12C-14320 BR ACKET R
17 12C-14330 BR ACKET L
18 12C-14340 R ACK M100-126 20
19 12C-14350 GUIDE
18
20 12C-14360 STAY
21 12C-14400 SHAF T
22 99J-13650 WORM GEAR
17
23 11C-13640 WORM GEAR
24 93E-40090 COLLAR
25 96V-40450 PINION
26 93E-14171 ROLLER
28 99A-80131 STEPPING MOTOR

PL3.3 Back Jogger
PL3.4 Side Jogger (1/2)

1 12C-16040 CHASSIS 17
16
15
3 12C-16070 SHAF T 13
13
6 12C-16140 COVER 14
A
7
7 12C-16151 ANGLE 6 6
8 11C-16370 PLATE 12
10 7
9 93L-11850 COLLAR 8 6
5 6
10 93L-13130 PILLAR A 11 5
11 93E-14171 ROLLER 10 9
2 9
12 12C-16231 JOG SUPPORT 8
26 11
13 93E-21150 CAM SHAF T 21 B
4 3 10
14 12C-16253 JOG PLATE L UNIT 24
20 2
15 12C-16292 UPPER JOG PLATE L 25
23 4 24
16 12C-16313 JOG PLATE R UNIT 18 25
22 26
17 12C-16352 UPPER JOG PLATE R
19 21
18 11C-16450 BR ACKET, MOTOR 1 20 18
19 11C-16460 SPUR GEAR M1-15-05
20 11C-16490 CENTER PIN 20
B
21 94X-20420 GEAR PULLEY G2 UNIT
23 11C-16560 PULLEY UNIT
24 014-10089 STS BELT

PL3.4 Side Jogger
PL3.4 Side Jogger (2/2)

1 12C-16090 ANGLE 3
3 011-10047 KNOB STAR 4
4 12C-16590 STAY UNIT
17
5 96G-22190 WASHER 5
6 12C-16670 KNOB
2 A
7 12C-16682 GEAR UNIT
8 98Y-11500 WASHER
9 98X-42581 RUBBER PLATE
10 12C-16750 ANGLE A
3
11 12C-16770 STAY
12 12C-16780 CAM SHAF T
16
B 4
13 98X-41270 SPACER 10
14 96G-12640 STUD
15 96G-12651 SPRING, C 6 11
16 98F-26060 GEAR 12
9
17 12C-16850 COLLAR S 081-14-020 13
1
8
7 5 10 14
B
15
2

PL3.4 Side Jogger
PL3.5 Middle Conveyance Section (1/4)

1 12C-18031 BR ACKET, TENSION
4 014-10574 STS BELT
6 013-00003 COLLAR
8 94X-20050 MIDDLE PULLEY UNIT
9 014-10561 STS BELT
10 12C-18210 CENTER PIN 15 16
11 12C-18290 COLLAR S UNIT
12 12C-18331 TIMING PULLEY 11
1213
13 12C-18341 TIMING PULLEY 14
18
14 99Z-31270 32S3M PULLEY 17
25 8 19
15 12C-18381 BR ACKET 9
16 12C-18390 PILLAR 24
7
17 95T-60080 COLLAR 4
4
6
18 014-10575 STS BELT
10
19 014-10246 STS V BELT
3 21
20 12C-18450 ANGLE 23
22 23 1
23 11G-40620 ROLLER UNIT 6 5 20
24 12C-81020 DC BRUSHLESS MOTOR
25 941-30131 COLLAR

PL3.5 Middle Conveyance Section

1 12C-18260 SHAF T 12
16 11
2 99X-30100 ROLLER
13 17
3 013-00056 COLLAR 15 10
4 96G-11100 SET COLLAR
5 12C-18590 STAY
6 12C-18601 BR ACKET 14
4 3
7 12C-18610 SHAF T
8 12C-24351 ROLLER UNIT
6
9 011-10005 PC WASHER 2
8 5
10 941-30131 COLLAR 7
1
11 12C-10461 LEVER UNIT 9
12 11A-10200 LINK
13 11G-12590 COLLAR 04-12-06
14 952-14380 ANGLE
16 12C-10550 STOPPER
17 12C-10570 SPRING, T


2 99X-30100 ROLLER
3 013-00056 COLLAR
4 99Z-31270 32S3M PULLEY
7 12C-18390 PILLAR
8 95T-60080 COLLAR 13
9 12C-19131 SUB FR AME 19
10 014-10576 STS BELT 15
11 12C-19170 GUIDE PLATE D
12 12C-19180 ANGLE 1 1715
13 12C-19200 GUIDE PLATE 14 16
5 20 11
14 12C-19210 PLATE 3 18
20
15 96V-20631 SHAF T 9 1915
16 96Y-32220 BUSH 22 12 12
17 0X4-12050 X COLLAR 26
2
18 011-10061 WASHER 21
19 991-13781 COLLAR
20 12C-19320 ANGLE 7
4
22 12C-19600 BR ACKET
25 24
23 12C-19630 ANGLE 23 10 4 8
6
25 11G-40620 ROLLER UNIT
26 062-11006 INT. SENSOR


15 19
1 12C-19311 REINFORCEMENT PLATE
20
2 12C-19341 ANGLE
3 016-10004 MAGNET CATCH 14
4 12C-24311 BR ACKET UNIT 13
21
5 12C-24340 SHAF T 17 2
6 12C-24351 ROLLER UNIT 10 7 8 3
7 945-25310 COLLAR 16 6
12
8 12C-19470 SPRING, C 8 1
5 4 7 11
10 12C-19501 BR ACKET
11 12C-19511 ANGLE 9
12 12C-19530 STAY
13 12C-19541 GUIDE T
14 12C-19571 FAN COVER
15 016-10216 RUBBER CUSHION
16 98X-41520 SPACER
17 062-11095 INT. SENSOR
18 12Y-81200 FAN MOTOR UNIT
19 99T-67390 HOSE
20 12C-58650 AIR PIPE
21 12C-58640 ANGLE

PL3.6 Rear Conveyance Section (1/2)

6
B 13
2 12C-20040 ROLLER G UNIT
4
3 98X-41270 SPACER
13
4 013-00081 COLLAR B
11
5 99Z-31270 32S3M PULLEY
6 98X-41400 SET COLLAR 12
7 014-10577 STS BELT
8 12C-20160 BR ACKET 3
27 2
9 11C-16490 CENTER PIN 3 1
10 11G-40620 ROLLER UNIT 2
3
11 12C-20250 CONVEYANCE PLATE D 26 A
12 12C-20260 CONVEYANCE PLATE D 21

22
13 96F-41330 ANGLE 13
16 20
14 12C-20290 REAR CONVEYOR UNIT 24 23
15
15 12C-20330 SHAF T 19
16 28 10
16 12C-24351 ROLLER UNIT 25 25
18 A
84
17 945-25310 COLLAR 9
17 13
18 92L-34100 SPRING, C 14 5
19 12C-13321 BR ACKET 4
5
20 98X-92281 SCREW 7
21 12C-13350 STAY 18
22 12C-13360 ANGLE L 17
23 12C-13371 ANGLE R
24 12C-13380 STAY
25 0Z3-06018 Z COLLAR
27 12C-10610 ANGLE L
28 12C-10620 ANGLE R

PL3.6 Rear Conveyance Section
PL3.6 Rear Conveyance Section (2/2)

2 99X-30100 ROLLER
3 013-10024 COLLAR
14 12
4 11T-61140 TIMING PULLEY 8 11
12 17
5 12C-21120 REINFORCEMENT PLATE D
13
14
6 12C-10130 ANGLE 15
13
7 12C-21150 OUTFEED GUIDE D 3 6
8 96F-41330 ANGLE 23
9 12C-10352 BR ACKET, SENSOR
16 18 10
10 12C-10190 IDLE SHAF T 6
2
12 98X-41520 SPACER
22
13 966-14040 COLLAR 7
1 6
14 95K-30130 SPRING, C
21
15 12C-10281 BR ACKET
16 12C-21350 REINFORCEMENT PLATE T 24
9 8
17 12C-21381 OUTFEED GUIDE T
18 12C-21411 BR ACKET, SENSOR 6 19 20
3
20 99C-30220 TIMING PULLEY S3M-20-08 5 4
21 014-10572 STS BELT
22 12C-81010 DC BRUSHLESS MOTOR
23 062-11095 INT. SENSOR
24 062-11006 INT. SENSOR

PL3.6 Rear Conveyance Section
PL3.7 Slitter Unit (1/5)

1 8M5-C4110 HOUSING LEF T 13 14
2 12C-23053 COLLAR S UNIT 2 6
87
3 12C-23084 PLATE UNIT
4 013-00029 DU BUSH
78
16 10 6
5 8M5-C4030 HOUSING RIGHT 4 11
2
6 8M5-C1520 FELT 5 15
7 8M5-C1530 SUPPORT PLATE
8 8M5-C1540 SPRING, C 11
9 10 1
10 8M5-C1700 LID A 9
11 8C3-31120 CAM SHAF T 12 3
12 12C-23711 PLATE A
13 12C-23721 PLATE B
14 8M5-C1370 RIGHT, COVER
16
15 8M5-C1380 LEF T, COVER
16 12C-24031 PLATE

PL3.7 Slitter Unit

1 12C-23280 GUIDE DL
2 12C-23290 GUIDE DR
3 12C-23311 GUIDE L
4 12C-23320 GUIDE D
5 12C-23341 GUIDE R
6 12C-23450 SHAF T
15 17
7 12C-23460 SHAF T 18 14
12 16
8 8D3-31210 SLIT TER, LOWER
9 8C3-31081 SEPAR ATE PLATE 13
15
10 8F9-30120 GEAR 11 15
11 12C-23510 KEY 4-12 6 13
12 013-10137 COLLAR 10
9 14
12 17
13 8C7-31131 SHAF T 7
8
14 8F9-30020 BOSS A 12 16
15 872-45530 COLLAR 17
15
16 8D3-31110 SLIT TER, UPPER 8 18
7
17 8C3-31021 GEAR 5 9
2
18 8C3-31140 SPRING, C 6
11
4 12
1
3
4

PL3.7 Slitter Unit

1 12C-24011 BR ACKET L
2 12C-24040 GUIDE PLATE L
3 12C-24050 GUIDE PLATE R 21 20 17
4 12C-24061 PLATE
21
5 12C-24070 STAY 1 25
19
6 12C-24090 PILLAR 18 20
9
7 12C-24100 GUIDE PLATE F 12
10 14 12 23
8 12C-24110 GUIDE PLATE B 5 22
12
9 12C-24121 SHAF T 12 11 11
5 9 10
10 98F-15080 RUBBER ROLLER 26 5
8 7 12
11 12C-24141 TIMING PULLEY S3M-21-08 21 20 5 2 27
17
12 013-10024 COLLAR 10 16 24
21 13 12 8
13 12C-24190 SHAF T
19 3 11 15
18 20 14
14 014-10579 STS BELT 12 6
10
15 12C-24280 CENTER PIN 9 11
16 013-00003 COLLAR 11 16 12 5
12 21 20 17
17 12C-24311 BR ACKET UNIT 9
15 1 21
4 10 21 20 17
18 12C-24340 SHAF T 12 21
19 12C-24351 ROLLER UNIT 19 18
20
20 945-25310 COLLAR 19
18 20
21 11A-40220 SPRING, C
1211
22 12C-24531 NUT R 12
13
23 12C-24561 BR ACKET L
10
24 12C-24661 INTERRUPTER
25 12C-24440 STAY
26 12C-24580 SUPPORT PLATE

PL3.7 Slitter Unit

1 12C-24021 BR ACKET R
4
2 12C-24440 STAY 1
8
3 12C-24541 NUT L 3 9
4 12C-24571 BR ACKET R 7
5 12C-24580 SUPPORT PLATE
5
6
6 12C-24590 SCREW PLATE 2
7 12C-24631 BR ACKET, CCD
1
8 12C-24641 GUIDE PLATE
9 0X4-12040 X COLLAR
10 8N4-X1031 CCD SENSOR

PL3.7 Slitter Unit

1 12C-24080 STAY 2
2 12C-25040 COVER PLATE F
3 12C-25050 COVER PLATE B
4 12C-25091 LEVER F 13
5 12C-25101 LEVER B
12
6 0Z3-06014 COLLAR
7 0Y3-06018 Y COLLAR 13 10 12
17 11
8 11A-50350 SPRING T 10
9 98X-92281 SCREW 19
10 12C-25200 STAY 4 20 11 9
17 1
11 12C-25210 PLATE
14 18 1 19
12 12C-25220 ANGLE 19
13 12C-25260 BR ACKET 20 9 7
15 7
14 12C-25270 BR ACKET, ROLLER 20 18
19
15 12C-25280 PILLAR
3 15 14
16 12C-25530 ANGLE
20 2
17 12C-24351 ROLLER UNIT
18 12C-24340 SHAF T 8
16 8 16
19 945-25310 COLLAR
20 11A-40220 SPRING, C
22 5 21
21 12C-25441 SKEW GUIDE F UNIT
4 6
22 12C-25481 SKEW GUIDE B UNIT
6

PL3.7 Slitter Unit
PL3.8 Slitter Frame (1/2)

1 12C-26032 SLIT TER FR AME F
8 7
2 12C-26041 SLIT TER FR AME B 56
3 12C-26190 ANGLE 11
4 12C-26200 BR ACKET 10
19
5 013-00056 COLLAR 2
6 12C-26260 PLATE
7 96G-20080 HOLDER 18
8 96G-11100 SET COLLAR 16 3 A
9 12H-13030 TIMING PULLEY
10 013-10024 COLLAR
11 96G-42460 BOSS
21
12 96D-12030 PULLEY 15
1 13
13 12C-26500 ANGLE, SENSOR
14 0Z4-08031 COLLAR
17 22
15 12C-26610 PLATE 20
16 12C-26640 LEVER 6 5
17 12C-26670 BR ACKET, SWITCH 7
A
18 952-14380 ANGLE 9
19 99D-35600 SPRING T 10
14 11 12
21 99V-84051 LIMIT SWITCH UNIT
4
22 12C-26070 PLATE

PL3.8 Slitter Frame
PL3.8 Slitter Frame (2/2)

1 12C-26061 STAY
3 12C-26101 STAY
10
4 12C-26120 STAY 18 12
6 12C-26151 BR ACKET, SENSOR
7
2 13
8 12C-26231 DRIVE SHAF T A
9 12C-26321 LEAD SCREW UNIT
10 12C-26430 BR ACKET, MOTOR 1
11 99A-11160 BOSS 9 8
12 99A-11171 MOTOR PULLEY
13 014-10581 STS BELT 17 16
14 12C-26540 SHAF T
15 12C-26560 ANGLE F 14
16 12C-26590 ANGLE B
5
17 12C-26601 PLATE 15
4 A
18 99A-80131 STEPPING MOTOR 19
6 3
19 062-11006 INT. SENSOR

PL3.8 Slitter Frame
PL3.9 Cutter (1/2)

2 0Z4-08022 COLLAR
1
3 12C-28092 CUT TER GUIDE PLATE UNIT
16
2
5 12C-28141 ANGLE, MOTOR 9
6 12C-28160 SHAF T
21 B
8 12C-28180 COLLAR C 060-10-060 A 19
9 12C-28200 REINFORCEMENT STAY 5 6 8 7 17
B 14 15
10 12C-28210 BR ACKET
11 12C-28220 BR ACKET
12 12C-28230 REINFORCEMENT STAY 18 11
13 12C-28240 ANGLE 4
20
14 12C-28252 GUIDE PLATE F T
13 3 A
15 12C-28260 GUIDE PLATE T UNIT 12
16 12C-28290 PLATE
17 12C-28301 GUIDE PLATE BT
18 12C-28510 PLATE
19 12C-28650 GUIDE PLATE R
20 12C-81050 MOTOR
21 12C-28550 ANGLE

PL3.9 Cutter
PL3.9 Cutter (2/2)

2 12C-28350 SLIDE SHAF T
3 12C-28360 SPRING, C
4 12C-28370 PLATE
6 12C-28400 BR ACKET UNIT
7 12C-28430 LEVER, OPEN-CLOSE B
A
9 91H-31240 COLLAR
10 96V-20631 SHAF T
B
11 96Y-32220 BUSH
12 12C-28550 ANGLE
13 12C-28590 STOPPER UNIT
14 12C-28660 GUIDE PLATE L 10 8
A
9 11 3 1
6 12
14 5
7
2
9 13
4

PL3.9 Cutter
PL3.10 Creaser (1/4)

2 011-10047 KNOB STAR
3 12C-30060 PILLAR
4 96G-22190 WASHER
2
5 12C-30091 ANGLE
1
6 92G-91130 KNOB SCREW
8 3
7 011-10061 WASHER 4 5 23
6
8 0Z4-08022 COLLAR
22
9 12C-30190 STAY 21
7
10 12C-30200 BR ACKET 17
18 16
10
12 96G-60230 KEY 14 21
13 12C-30570 UPPER BLADE
20 9
17 12
14 12C-30580 STAY 19
18
15 12C-30591 ANGLE L 13 17
15
16 12C-30601 ANGLE R
17 98X-41520 SPACER 11
14
18 12C-30430 CR ANK
23
20 12C-30390 CAM SHAF T
21 12C-30460 COLLAR P 182-23-010
24* 12C-30382 CAM SHAF T UNIT
NOTE:
* Consists of five parts: 18, 19,
20, 21 on the list above and 12
on the list CREASER I-2

PL3.10 Creaser

1 12C-30171 CREASER FR AME
2 93X-10220 GUIDE
3 12C-30250 ANGLE
7 6
6 12C-30322 HOUSING UNIT 3
7 98X-20190 WASHER 2
12
9 96G-60220 STS PULLEY
10 12C-30530 INTERRUPTER UNIT 3
11 98R-80230 INT. SENSOR 2
2 4 1
3 4
2 2
7
3 8
10
6
4 2 9
5 1
2
11

PL3.10 Creaser

1 12C-30320 HOUSING UNIT
2 12C-31030 CAM SHAF T UNIT 20
17
3 12C-31080 COLLAR C 160-19-3880 19 21
4 12C-31100 COLLAR P 151-20-010
16
5 12C-31120 COLLAR C 130-16-890
9
6 12J-61400 KNOB
9 10 12 11 18
16
7 016-10198 KNOB 24 20
4 14
8 056-08011 CAP 17
1 22 19
9 12C-31170 COLLAR P 045-15-020
23 15
10 12C-31212 CR ANK UNIT 3 13
2
11 12C-31261 BLOCK 11
12
13 12C-31280 ANGLE L 4
9
14 12C-31290 ANGLE R
15 12C-31321 LOWER BLADE 1
16 12C-31341 BR ACKET 10
17 12C-31350 STAY
18 12C-31361 BLOCK UNIT
5
19 98X-41340 SPACER
20 12C-31400 SPRING, C
21 12C-31420 GUIDE PLATE FD UNIT 7
8
22 12C-31461 GUIDE PLATE BD
23 12C-31471 BR ACKET L 6
24 12C-31481 BR ACKET R

PL3.10 Creaser

3 12C-31531 SPUR GEAR M080-20-08
5 96D-45450 GEAR 56FE UNIT
6 12C-31600 SHAF T
7 96D-45130 GEAR 64
8 013-00056 COLLAR
9 013-00081 COLLAR
10 98X-40140 16S5M PULLEY
11 96G-60230 KEY
13 014-10391 STS BELT
7
14 12C-81040 DC MOTOR 6
11
14 5 4
9 8
2 12 13
10
1 3

PL3.10 Creaser
PL3.11 Upper Conveyance (1/7)

1 12C-33860 BRACKET
2 12C-33880 SPRING C
3 12C-33890 GUIDE
11 C
4 12C-33930 LEVER
1
5 12C-33950 ANGLE
6 12C-33940 COLLAR S
3 2 10 1
7 12C-33910 SPACER
11
8 12C-33870 BRACKET C
D
9 94X-20070 BUSH 9 8 3 2
97 10
10 12C-33900 BRACKET 5 D
4
11 12C-33850 CENTER PIN 6 8
4 9
9
65 7
A
11
1
3 2 10
B
1
A
11
9 8
97 3 2 10
5
4 B
6
4 9 8
9
65 7

PL3.11 Upper Conveyance

1 96V-10140 COLLAR
1 20
3 12C-33090 STAY 3 16
12 13
4 12C-33250 ANGLE
5 12C-33120 SHAF T
17 20
15
6 99A-11200 GEAR PULLEY
7 94X-20370 GEAR PULLEY G 11 11 19
18 14
8 013-10024 COLLAR
9 93E-40090 COLLAR
19 15
10 014-10580 STS BELT
1 12 15 21
11 12C-33231 ARM STAY 1
14 17 3
12 12C-33241 ARM STAY 2 19
8 4
13 12C-33251 BR ACKET 1, REINFORCEMENT 15
20 20
14 12C-33261 BR ACKET 2, REINFORCEMENT
16 10 6 5 9
15 12C-33271 BR ACKET, REINFORCEMENT 7
16 12C-33292 REINFORCEMENT STAY 1 13 3
17 12C-33301 REINFORCEMENT STAY 2 2
19 12C-33331 FULCRUM PLATE 3
8 4
20 12C-33340 BR ACKET
7
10 6 5 9


1 12C-33381 SHAF T UNIT
11
7 62 23
2 12C-12040 ROLLER F08-32
3
3 013-10024 COLLAR 17
21 5 4 24
9
5 12C-33470 PULLEY UNIT 10 14 3
13 15 14 11
16 2
7 12C-33540 PULLEY UNIT 7 14
6 8 12 4
8 12C-33590 SHAF T 10 5
9 6 7
9 947-12220 ROLLER 6 7 1
10 947-12230 COLLAR
21
6 22
11 12C-33640 FLAT BELT 7
12 12C-33671 BR ACKET 1 7 9
6 10
13 12C-33681 BR ACKET 2
14
14 12C-33690 STAY 4 15
5 8
15 12C-33701 BR ACKET 20 13 6
16 10 7
16 12C-33711 LEVEL 9
4 6
17 12C-33740 GUIDE PLATE FD1 7
2 12 14
18 12C-33750 GUIDE PLATE FD2 11 3 22
25 5
20 12C-33770 GUIDE PLATE FD4 28 26 3 19
21 12C-33800 GUIDE PLATE DL 27 1
11 2
22 12C-33810 GUIDE PLATE DR
23 12C-35481 BR ACKET
24 12C-35490 STAY
25 12C-35531 BR ACKET
26 96V-10280 COLLAR
27 12C-35551 ANGLE L
28 12C-35561 ANGLE R


10 13
2 12C-34040 GUIDE PLATE FD2
20 12 1211
3 12C-34070 GUIDE R AIL 19
4 12C-34100 GUIDE PLATE FD
18 10 13
5 12C-34151 ANGLE L
12
11
6 12C-34161 ANGLE R
7 11G-41100 PILLAR 21
8 93K-50170 ROLLER 17 9
13
9 12C-34441 CONVEYANCE PLATE FBT 8 2
12 7 7
10 12C-34240 SHAF T 11 8
16 15
13 6
11 947-12220 ROLLER 14
10 1
12 92T-10130 SLIDE R AIL 12
13 96Y-10290 SPRING, C
78
15 12C-34620 BR ACKET
16 12C-34681 GUIDE PLATE F T
3
18 12C-34750 COVER 5
19 016-10195 HANDLE
20 12C-34781 BR ACKET L
21 12C-34791 BR ACKET R 4


1 12C-34050 GUIDE PLATE BD1
13 11 13 1312
2 12C-34060 GUIDE PLATE BD2
3 12C-34070 GUIDE R AIL 11 14 20
22
13 19
4 12C-34110 GUIDE PLATE BD
12
6 12C-34151 ANGLE L 9
8 17
7 12C-34161 ANGLE R 23
8 11G-41100 PILLAR 21
9 93K-50170 ROLLER 14
18
10 12C-34521 CONVEYANCE PLATE BF T
2 1316 11
14 15
11 12C-34240 SHAF T 3 12
12 947-12220 ROLLER 9 13
8
13 92T-10130 SLIDE R AIL
6
14 96Y-10290 SPRING, C
16 12C-34620 BR ACKET
5
17 12C-34690 GUIDE PLATE BT
19 12C-34750 COVER 4
20 016-10195 HANDLE
8
21 12C-34781 BR ACKET L 9
22 12C-34791 BR ACKET R 7
23 062-11095 INT. SENSOR


1 12C-34221 CONVEYANCE PLATE FF T
24 8
2 12C-34240 SHAF T 16
22 23
3 947-12220 ROLLER 25 78
4 92T-10130 SLIDE R AIL
25 5 43
5 96Y-10290 SPRING, C 18 11 5
21 4
6 12C-34290 GUIDE D 15 2
7 12C-34300 PILLAR
3 5 23 22
19 2
8 995-13320 PILLAR 5 4 8
17 20 1 7
9 12C-34331 CONVEYANCE PLATE BBT 16 4
13
10 12C-35301 TOP COVER 2
10 14 6
11 12C-35310 HINGE 22 15
12 12J-62090 METAL PLATE 23 11 1921 12
8
13 12C-35330 GUIDE 9
13 20
14 95L-52170 PILLAR 7 5 54 3
15 12C-35360 SHAF T
8 42 14
12
16 12C-35371 LEVER UNIT 5 22
17 12C-35400 PLATE 3 4 5 2 4 23
18 12C-35440 BR ACKET
8 7
19 11G-41100 PILLAR
20 93K-50170 ROLLER
21 0X4-12050 X COLLAR
6
22 950-21320 PILLAR
24 054-10407 MICROSWITCH

ITEM PART # DESCRIPTION B

1 12C-35031 TOP COVER 1 14 15
2 12C-35040 HINGE B 2
3 12C-35070 GUIDE PLATE TL
4 12C-35080 GUIDE PLATE TR
A
5 12C-35090 GUIDE PLATE TL 1
16
6 12C-35100 GUIDE PLATE TR
7 12C-33590 SHAF T
8 947-12220 ROLLER 8 11
18 10
9 92T-10130 SLIDE R AIL 17 15 A
9 13
10 96Y-10290 SPRING, C 7 12
11 12C-35150 STAY 3
12 12C-35170 GUIDE R AIL 11 10
13 12C-35191 ANGLE L
2 4 9 8
14 12C-35201 ANGLE R
1
15 95L-52170 PILLAR
16 12C-35251 ANGLE, SENSOR 13 15 15
5
17 12C-35261 COVER, SENSOR 14 12
18 062-11006 INT. SENSOR
10 6
89 11
7
11 10 8
9

PL3.12 Dust Box (1/2)

1 12C-40040 DUST BOX ASSY
2 016-41952 STEEL HANDLE
3 0Y4-08031 COLLAR 8
4 12C-40220 ANGLE
5 12C-40311 ROLLER
6 12C-40320 SHAF T 8
8 12C-40450 ANGLE
7
4 5
6
3
1
6
5

PL3.12 Dust Box
PL3.12 Dust Box (2/2)

1 12C-40370 BR ACKET, R AIL
15
2 12C-40380 R AIL 14
4
4 12C-40430 FENCE R
13
5 12C-40490 FENCE L
6 12C-40510 BR ACKET, P.W.B. 2 15
7 92L-53190 ACTUATOR
2
9 12C-40580 ANGLE 3
11 97J-80131 LED P.W.B. UNIT
12 056-10443 LOCKING SPACER
11
13 96Y-80072 PR P.W.B. UNIT 9
12
14 12C-81031 SERVO DRIVER
1
15 056-11137 SPACER
16 947-13541 TENSION SPRING 10 6
1
17 12C-40620 SWITCH BR ACKET UNIT 17
7
16 8
9

PL3.12 Dust Box
PL3.13 Frame

1 12C-60011 FR AME F
2 12C-60031 FR AME B 4
4 12C-60071 REINFORCEMENT PLATE 8
7 12
5 12C-60091 REINFORCEMENT PLATE 2
6 12C-60500 COVER 5 3
7 12C-60611 COVER
8 054-10304 SWITCH
9 99W-83010 COUNTER UNIT 5 8
10 12C-80039 MC UNIT 4
11 056-11137 SPACER
6
12 056-11220 LABEL
11
9
3 7 11
1
10

PL3.13 Frame
PL3.14 Exterior (1/2)

1 12C-61030 COVER F 11
13 7
2 12C-61040 PLATE
3 12C-61050 BLIND PLATE 5 15
12
4 12C-61190 PANEL COVER UNIT 4
17
5 995-13320 PILLAR
8
6 12C-61251 BR ACKET 10
7 12C-61260 BR ACKET, PANEL 5 16
8 12C-61340 ANGLE
9 99J-62400 CONTROL PANEL
10 99J-62410 PANEL COVER 6
11 99J-62420 PLATE
12 99J-62451 DIAL 1
3 2
13 11F-67070 BUT TON A
14 11F-67080 BUT TON B
15 99J-62480 BUT TON C
17 99J-80159 OP UNIT

PL3.14 Exterior
PL3.14 Exterior (2/2)

1 12C-61061 COVER B
2 12C-61070 LID
3 12C-61080 COVER
4 12C-61090 PLATE
5 12C-61270 COVER
1
3

PL3.14 Exterior
PL3.15 Moving Unit (1/2)

1 12C-63051 BODY BASE
5
2 016-41951 CASTER 4 7
7
4 12C-63100 SHAF T 3
5 013-00015 COLLAR 8
6 98X-20190 WASHER 9
8 12C-63150 R ACK M200-30 6
9 12C-63170 INTERRUPTER 5
4 7
10 12C-63520 PLATE
3 10
7 2
8
1
10

PL3.15 Moving Unit
PL3.15 Moving Unit (2/2)

1 12C-63230 MOVE BASE
18 17
2 12C-63250 R AIL
3 12C-63260 R AIL GUIDE 1 2
15
4 12C-63270 R AIL GUIDE 2 4
5 12C-63290 ANGLE 13 25 25
6 12C-63310 PLATE 14
20 24
7 12C-63320 SHAF T 22 24 23
8 945-12061 COLLAR
12
22
9 12C-63341 SPUR GEAR M200-12-12
21
10 12C-63360 BR ACKET, MOTOR 2
11 12C-63370 COUPLING
12 12C-63391 MOVE BASE COVER 1
3
13 12C-63410 ANGLE
3
14 12C-63420 ANGLE, SENSOR 19
15 12C-63430 COVER
2 6
16 12C-63450 ANGLE 11 10
17 12C-63460 ANGLE
8 5
18 12C-63480 ANGLE 4
17 9
18 2
19 11C-81031 MOTOR UNIT 7
16
20 98R-80230 INT. SENSOR 9
5 8
21 057-10054 SWITCHING POWER SUPPLY
6
22 056-11137 SPACER
23 11C-80352 RELAY P.W.B. UNIT
24 056-11016 COLLAR
25 056-00778 BUSHING

PL3.15 Moving Unit
PL3.16 Foot (1/2)

1 12C-40450 ANGLE
2 12C-61150 SIDE COVER
3 12C-70050 FOOT FR
4 12C-70071 ANGLE
5 12C-70200 FOOT BR 2
6 12K-60180 CONNECTOR ANGLE
7 056-10357 INLET 1
8 054-10417 POWER SWITCH
9 12J-80211 DPIF P.W.B. UNIT
10 056-10958 DUST PROTECTION CAP
11 5
11 056-11343 CAP 6 1
12 12C-91730 FIXING PLATE
10
9
12
8
3
7

PL3.16 Foot
PL3.16 Foot (2/2)

1 12C-40450 ANGLE
2 12C-61151 SIDE COVER
3 12C-70150 FOOT FL
4 12C-70300 FOOT BL
5 12C-91730 FIXING PLATE
1
4
3
2

PL3.16 Foot
PL3.17 Accessories (1/2)
ITEM PART # DESCRIPTION 1 2 3 4 5 6 7

1 12C-91690 CONNECTING PLATE R
2 12C-91700 CONNECTING PLATE L
3 x PAPER EJECTION GUIDE
4 96F-60370 LEVEL ADJUSTER
5 96F-60380 PLATE
8 9 10 11 12 13 14
6 94L-90320 SPANNER
7 025-91391 OILER
8 98X-90270 CASE
9 12K-82020 D-PORT CABLE
10 11C-83390 E-PORT CABLE
11* 055-10212 POWER CORD (for 220 to 240 V)
15 16 17 18 19 20
12** 055-10209 POWER CORD (for 120 V)
13 x SCREW (MSKW 5 X 10)
14 x SCREW (HSKW 6 X 16)
15 x ANGLE F
16 x ANGLE B
17 x ANGLE (for DSF-2000) 21 23 25, 26 27 28 29
18 x ROM (for DSF-2000)
19 99T-86019 ROM (for DBM-500)
20 99T-86016 ROM (for DBM-500T)
21 99S-93530 LABEL (99S-93530) 22 24
22 99W-91930 LABEL (99W-91930)
23 12C-90230 LABEL (12C-90230)
24 99S-93490 LABEL (99S-93490)
25 ** 99T-91434 INSTRUCTION MANUAL
NOTE:
* Uniq part for 220-240V
** Uniq part for 120V

PL3.17 Accessories
ITEM PART # DESCRIPTION 1 2 3 4 5 6 7

26 * 12C-90145 INSTRUCTION MANUAL12C-90145
27 x INSTALLATION MANUAL
28 x CD ROM
29 x PC CABLE
8 9 10 11 12 13 14
NOTE:
* Uniq part for 220-240V
** Uniq part for 120V
15 16 17 18 19 20
21 23 25, 26 27 28 29
22 24

PL3.17 Accessories
PL3.18 Driving Belt List
014-10579
STS belt (60S3M372G)
014-10089
STS belt (60S3M537UK)
014-10580
014-10572
014-10561
014-10575
SC
C
014-10391 014-10574 014-10246
STS belt (100S5M350) STS belt (60S3M186G) STS V belt (60S3M699V)
014-10581
014-10576
014-10577 STS belt (60S3M396G)
014-10580
STS belt (60S2M290G) 014-10572

PL3.18 Driving Belt List
PL3.19 Labels
12C-9022X
Warning label
12C-9015X
Adjustment handle label
99S-9352X
Warning label
11F-9013X
Warning label
12C-9016X
12C-9017X SC
C
99S-9337X
Electric shock caution label
96G-9060X
PE CAUTION
Locking position label 1
Electric Shock Hazard Inside.
96D-9009X 99S-9338X
Ground label Caution label
99S-9336X
PE mark label

PL3.19 Labels
PL3.20 Wiring (1/2)

1 12C-83111 WIRE HARNESS 2
1
3 98H-80220 CORD UNIT 1
1
C
B
A
2

PL3.20 Wiring
PL3.20 Wiring (2/2)

6 3
1 12C-83210 WIRE HARNESS 12 4 9 1
2 12C-83160 WIRE HARNESS 7 13
C
2 B
10
A
12 12C-83302 WIRE HARNESS-1,AC 4 4
13 11C-83080 OP BUNDLE UNIT 1
6
11
3
1
12
10
6 4
10

PL3.20 Wiring
PL3.21 Electrical Parts (1/5)
ITEM PART # DESCRIPTION SYMBOL 5 12 8 8

1 12C-81010 DC BRUSHLESS MOTOR M301, M302 (SW301) (FM301) (SL303) (SL301)
2 11C-81061 ELECTROMAGNETIC CLUTCH CL301
3 12C-81020 DC BRUSHLESS MOTOR M303
4 9,10
4 12C-81050 MOTOR M304
(M304) (PS305)
5* 12C-28101 CUT TER UNIT SW301
6 12C-81040 DC MOTOR M305
7 98R-80230 INT. SENSOR PS301, PS310
8 94X-80211 DC SOLENOID SL301, SL303 9,10
9 062-11095 INT. SENSOR PS305, PS307 (PS305)
10 062-11006 INT. SENSOR PS305, PS307 2
11 99A-80131 STEPPING MOTOR M309 (CL301)
12 12Y-81200 FAN MOTOR UNIT FM301 9,10
(PS307)
1
NOTE: (M301)
* SW 301 is included in the Cutter Unit.
6
(M305) 11
(M309)
9,10
(PS307) 7
(PS310)
1 7 3
(M302) (PS301) (M303)

ITEM PART # DESCRIPTION SYMBOL 4,5 2 3

1 94X-80211 DC SOLENOID SL302, SL304 1 (PS308) (M307) (PS303) 2
(SL302)
2 99A-80131 STEPPING MOTOR M306, M307, M308 (M308)
3 98R-80230 INT. SENSOR PS303, PS304, PS314 4,5
4 062-11095 INT. SENSOR PS308, PS309, PS311, (PS309)
PS312 3
(PS304)
5 062-11006 INT. SENSOR PS308, PS309, PS311, 7
PS312 1
(SSW304) (SL304)
6 11C-81031 MOTOR UNIT M310 3
7 99V-84051 LIMIT SWITCH UNIT SSW304 (PS303)
4,5 2
(PS311) (M306)
6
4,5 (M310)
(PS312)
4,5
4,5 (PS308)
(PS312)
4,5
(PS309)
4,5 3
(PS311) (PS314)

ITEM PART # DESCRIPTION SYMBOL 6

1 062-11095 INT. SENSOR PS306 7 (SSW301)
(SSW302)
2 062-11006 INT. SENSOR PS306 5
3* 97J-80131 LED P.W.B. UNIT PS313 1,2 (SSW306)
(PS306)
4* 96Y-80072 PR P.W.B. UNIT PS313
5 054-10407 MICROSWITCH SSW305, SSW306
6 054-10304 SWITCH SSW301 1,2
7 99V-84051 LIMIT SWITCH UNIT SSW302, SSW303 (PS306)
8 054-10208 MICRO SWITCH SSW302
7
NOTE: (SSW303) 5
* PS 313s are included in the LED P.W.B Unit and (SSW305)
the PR P.W.B Unit..
3,4
(PS313)
3,4
(PS313)
8
(SSW302)

ITEM PART # DESCRIPTION SYMBOL

1 12C-80039 MC UNIT PCB301
2 99J-80159 OP UNIT PCB302
3 12C-81031 SERVO DRIVER PCB303 2
(PCB302)
4 057-10054 SWITCHING POWER SUPPLY PCB304
5 11C-80352 RELAY P.W.B. UNIT PCB305
1
6 99W-83010 COUNTER UNIT CNT301 (PCB301)
6
(CNT301)
3
(PCB303)
5
(PCB305)
4
(PCB304)


1* 12C-83301 WIRE HARNESS-1, AC PSW302
2 054-10417 POWER SWITCH PSW301 2
(PSW301)
NOTE:
* PSW 302 is included in the Wire Harness-1..
1
(PSW302)

INDEX3 SCC (1/5)
011-10005 PL3.2(1/3) 9 014-10581 PL3.8(2/2) 13 062-11006 PL3.11(7/7) 18 11C-16560 PL3.4(1/2) 23 12C-10281 PL3.1(1/2) 10
011-10005 PL3.5(2/4) 9 016-10004 PL3.5(4/4) 3 062-11006 PL3.21(1/5) 10 11C-80352 PL3.15(2/2) 23 12C-10281 PL3.6(2/2) 15
011-10047 PL3.4(2/2) 3 016-10195 PL3.11(4/7) 19 062-11006 PL3.21(2/5) 5 11C-80352 PL3.21(4/5) 5 12C-10320 PL3.1(1/2) 11
011-10047 PL3.10(1/4) 2 016-10195 PL3.11(5/7) 20 062-11006 PL3.21(3/5) 2 11C-81031 PL3.15(2/2) 19 12C-10352 PL3.1(1/2) 12
011-10061 PL3.5(3/4) 18 016-10198 PL3.10(3/4) 7 062-11095 PL3.1(1/2) 22 11C-81031 PL3.21(2/5) 6 12C-10352 PL3.6(2/2) 9
011-10061 PL3.10(1/4) 7 016-10216 PL3.5(4/4) 15 062-11095 PL3.2(2/3) 18 11C-810601 PL3.1(2/2) 17 12C-10390 PL3.1(1/2) 13
013-00003 PL3.5(1/4) 6 016-41951 PL3.15(1/2) 2 062-11095 PL3.5(4/4) 17 11C-81061 PL3.21(1/5) 2 12C-10400 PL3.1(1/2) 14
013-00003 PL3.7(3/5) 16 016-41952 PL3.12(1/2) 2 062-11095 PL3.6(2/2) 23 11C-83080 PL3.20(2/2) 13 12C-10410 PL3.1(1/2) 15
013-00015 PL3.15(1/2) 5 025-91391 PL3.17(1/2) 7 062-11095 PL3.11(5/7) 23 11C-83390 PL3.17(1/2) 10 12C-10420 PL3.1(1/2) 16
013-00029 PL3.7(1/5) 4 054-10208 PL3.12(2/2) 10 062-11095 PL3.21(1/5) 9 11F-67070 PL3.14(1/2) 13 12C-10461 PL3.1(2/2) 4
013-00056 PL3.5(2/4) 3 054-10208 PL3.21(3/5) 8 062-11095 PL3.21(2/5) 4 11F-67080 PL3.14(1/2) 14 12C-10461 PL3.2(3/3) 5
013-00056 PL3.5(3/4) 3 054-10304 PL3.13 8 062-11095 PL3.21(3/5) 1 11G-12590 PL3.1(2/2) 6 12C-10461 PL3.5(2/4) 11
013-00056 PL3.8(1/2) 5 054-10304 PL3.21(3/5) 6 0X4-12040 PL3.7(4/5) 9 11G-12590 PL3.2(2/3) 12 12C-10540 PL3.1(2/2) 7
013-00056 PL3.10(4/4) 8 054-10407 PL3.11(6/7) 24 0X4-12050 PL3.5(3/4) 17 11G-12590 PL3.2(3/3) 7 12C-10540 PL3.2(3/3) 9
013-00081 PL3.6(1/2) 4 054-10407 PL3.14(1/2) 16 0X4-12050 PL3.11(6/7) 21 11G-12590 PL3.3 11 12C-10540 PL3.5(2/4) 15
013-00081 PL3.10(4/4) 9 054-10407 PL3.21(3/5) 5 0Y3-06018 PL3.7(5/5) 7 11G-12590 PL3.5(2/4) 13 12C-10550 PL3.1(2/2) 8
013-10024 PL3.1(2/2) 1 054-10417 PL3.16(1/2) 8 0Y4-08031 PL3.12(1/2) 3 11G-17210 PL3.2(3/3) 3 12C-10550 PL3.2(3/3) 10
013-10024 PL3.2(1/3) 4 054-10417 PL3.21(5/5) 2 0Z3-06014 PL3.7(5/5) 6 11G-40620 PL3.5(1/4) 23 12C-10550 PL3.5(2/4) 16
013-10024 PL3.6(2/2) 3 055-10209 PL3.17(1/2) 12 0Z3-06018 PL3.2(3/3) 24 11G-40620 PL3.5(3/4) 25 12C-10570 PL3.1(2/2) 9
013-10024 PL3.7(3/5) 12 055-10212 PL3.17(1/2) 11 0Z3-06018 PL3.6(1/2) 25 11G-40620 PL3.6(1/2) 10 12C-10570 PL3.2(3/3) 11
013-10024 PL3.8(1/2) 10 056-00778 PL3.15(2/2) 25 0Z4-08022 PL3.2(2/3) 11 11G-41100 PL3.2(2/3) 8 12C-10570 PL3.5(2/4) 17
013-10024 PL3.11(2/7) 8 056-08011 PL3.10(3/4) 8 0Z4-08022 PL3.9(1/2) 2 11G-41100 PL3.11(4/7) 7 12C-10601 PL3.1(1/2) 18
013-10024 PL3.11(3/7) 3 056-10357 PL3.16(1/2) 7 0Z4-08022 PL3.10(1/4) 8 11G-41100 PL3.11(5/7) 8 12C-10610 PL3.1(1/2) 19
013-10053 PL3.2(3/3) 14 056-10443 PL3.12(2/2) 12 0Z4-08031 PL3.8(1/2) 14 11G-41100 PL3.11(6/7) 19 12C-10610 PL3.6(1/2) 27
013-10137 PL3.7(2/5) 12 056-10958 PL3.16(1/2) 10 11A-10200 PL3.1(2/2) 5 11K-30130 PL3.1(2/2) 12 12C-10620 PL3.1(1/2) 20
013-10154 PL3.2(3/3) 16 056-11016 PL3.15(2/2) 24 11A-10200 PL3.2(3/3) 6 11K-30130 PL3.2(1/3) 5 12C-10620 PL3.6(1/2) 28
014-10089 PL3.4(1/2) 24 056-11137 PL3.12(2/2) 15 11A-10200 PL3.5(2/4) 12 11T-61140 PL3.1(2/2) 2 12C-10660 PL3.1(2/2) 10
014-10246 PL3.5(1/4) 19 056-11137 PL3.13 11 11A-40220 PL3.7(3/5) 21 11T-61140 PL3.6(2/2) 4 12C-10730 PL3.1(2/2) 13
014-10391 PL3.10(4/4) 13 056-11137 PL3.15(2/2) 22 11A-40220 PL3.7(5/5) 20 12C-10030 PL3.1(1/2) 1 12C-10730 PL3.6(2/2) 19
014-10561 PL3.5(1/4) 9 056-11220 PL3.13 12 11A-50350 PL3.7(5/5) 8 12C-10030 PL3.6(2/2) 1 12C-12030 PL3.2(1/3) 1
014-10572 PL3.1(2/2) 15 056-11343 PL3.16(1/2) 11 11C-13640 PL3.3 23 12C-10120 PL3.1(1/2) 3 12C-12040 PL3.2(1/3) 2
014-10572 PL3.6(2/2) 21 057-10054 PL3.15(2/2) 21 11C-16370 PL3.4(1/2) 8 12C-10130 PL3.1(1/2) 4 12C-12040 PL3.11(3/7) 2
014-10574 PL3.5(1/4) 4 057-10054 PL3.21(4/5) 4 11C-16450 PL3.4(1/2) 18 12C-10130 PL3.2(1/3) 19 12C-12050 PL3.2(1/3) 3
014-10575 PL3.5(1/4) 18 062-11006 PL3.1(1/2) 23 11C-16460 PL3.4(1/2) 19 12C-10130 PL3.2(2/3) 2 12C-12130 PL3.2(1/3) 6
014-10576 PL3.5(3/4) 10 062-11006 PL3.2(1/3) 21 11C-16490 PL3.4(1/2) 20 12C-10130 PL3.6(2/2) 6 12C-12200 PL3.2(1/3) 10
014-10577 PL3.6(1/2) 7 062-11006 PL3.5(3/4) 26 11C-16490 PL3.5(3/4) 24 12C-10151 PL3.1(1/2) 5 12C-12231 PL3.2(1/3) 11
014-10579 PL3.7(3/5) 14 062-11006 PL3.6(2/2) 24 11C-16490 PL3.6(1/2) 9 12C-10190 PL3.1(1/2) 6 12C-12241 PL3.2(1/3) 12
014-10580 PL3.11(2/7) 10 062-11006 PL3.8(2/2) 19 11C-16560 PL3.4(1/2) 22 12C-10190 PL3.6(2/2) 10 12C-12250 PL3.2(1/3) 13

INDEX3 SCC
INDEX3 SCC (2/5)
12C-12260 PL3.2(1/3) 14 12C-14100 PL3.3 5 12C-18130 PL3.5(1/4) 7 12C-20250 PL3.6(1/2) 11 12C-24311 PL3.5(4/4) 4
12C-12620 PL3.2(2/3) 15 12C-16040 PL3.4(1/2) 1 12C-18601 PL3.5(2/4) 6 12C-23311 PL3.7(2/5) 3 12C-24561 PL3.7(3/5) 23
12C-14031 PL3.3 1 12C-16850 PL3.4(2/2) 17 12C-19630 PL3.5(3/4) 23 12C-24121 PL3.7(3/5) 9 12C-25481 PL3.7(5/5) 22

INDEX3 SCC
INDEX3 SCC (3/5)

INDEX3 SCC
INDEX3 SCC (4/5)
12C-35201 PL3.11(7/7) 14 12C-60091 PL3.13 5 12C-63480 PL3.15(2/2) 18 12C-91690 PL3.17(1/2) 1 92T-10130 PL3.11(7/7) 9
12C-35251 PL3.11(7/7) 16 12C-60500 PL3.13 6 12C-63520 PL3.15(1/2) 10 12C-91700 PL3.17(1/2) 2 93E-14171 PL3.3 26
12C-35261 PL3.11(7/7) 17 12C-60611 PL3.13 7 12C-70050 PL3.16(1/2) 3 12C-91730 PL3.16(1/2) 12 93E-14171 PL3.4(1/2) 11
12C-35301 PL3.11(6/7) 10 12C-61030 PL3.14(1/2) 1 12C-70071 PL3.16(1/2) 4 12C-91730 PL3.16(2/2) 5 93E-21150 PL3.4(1/2) 13
12C-35310 PL3.11(6/7) 11 12C-61040 PL3.14(1/2) 2 12C-70150 PL3.16(2/2) 3 12H-13030 PL3.8(1/2) 9 93E-40090 PL3.1(2/2) 11
12C-35330 PL3.11(6/7) 13 12C-61050 PL3.14(1/2) 3 12C-70200 PL3.16(1/2) 5 12J-61400 PL3.10(3/4) 6 93E-40090 PL3.3 24
12C-35360 PL3.11(6/7) 15 12C-61061 PL3.14(2/2) 1 12C-70300 PL3.16(2/2) 4 12J-62090 PL3.11(6/7) 12 93E-40090 PL3.11(2/7) 9
12C-35371 PL3.11(6/7) 16 12C-61070 PL3.14(2/2) 2 12C-80039 PL3.13 10 12J-80211 PL3.16(1/2) 9 93K-50170 PL3.2(2/3) 9
12C-35400 PL3.11(6/7) 17 12C-61080 PL3.14(2/2) 3 12C-80039 PL3.21(4/5) 1 12K-60180 PL3.16(1/2) 6 93K-50170 PL3.11(4/7) 8
12C-35440 PL3.11(6/7) 18 12C-61090 PL3.14(2/2) 4 12C-81010 PL3.1(2/2) 16 12K-82020 PL3.17(1/2) 9 93K-50170 PL3.11(5/7) 9
12C-35481 PL3.11(3/7) 23 12C-61150 PL3.16(1/2) 2 12C-81010 PL3.6(2/2) 22 12Y-81200 PL3.5(4/4) 18 93K-50170 PL3.11(6/7) 20
12C-35490 PL3.11(3/7) 24 12C-61151 PL3.16(2/2) 2 12C-81010 PL3.21(1/5) 1 12Y-81200 PL3.21(1/5) 12 93L-11850 PL3.3 6
12C-35531 PL3.11(3/7) 25 12C-61190 PL3.14(1/2) 4 12C-81020 PL3.5(1/4) 24 872-45530 PL3.7(2/5) 15 93L-11850 PL3.4(1/2) 9
12C-35551 PL3.11(3/7) 27 12C-61251 PL3.14(1/2) 6 12C-81020 PL3.21(1/5) 3 8C3-31021 PL3.7(2/5) 17 93L-13130 PL3.4(1/2) 10
12C-35561 PL3.11(3/7) 28 12C-61260 PL3.14(1/2) 7 12C-81031 PL3.12(2/2) 14 8C3-31081 PL3.7(2/5) 9 93X-10220 PL3.10(2/4) 2
12C-40040 PL3.12(1/2) 1 12C-61270 PL3.14(2/2) 5 12C-81031 PL3.21(4/5) 3 8C3-31120 PL3.7(1/5) 11 941-30131 PL3.1(2/2) 3
12C-40220 PL3.12(1/2) 4 12C-61340 PL3.14(1/2) 8 12C-81040 PL3.10(4/4) 14 8C3-31140 PL3.7(2/5) 18 941-30131 PL3.2(3/3) 4
12C-40311 PL3.12(1/2) 5 12C-63051 PL3.15(1/2) 1 12C-81040 PL3.21(1/5) 6 8C7-31131 PL3.7(2/5) 13 941-30131 PL3.5(1/4) 25
12C-40320 PL3.12(1/2) 6 12C-63090 PL3.15(1/2) 3 12C-81050 PL3.9(1/2) 20 8D3-31110 PL3.7(2/5) 16 941-30131 PL3.5(2/4) 10
12C-40330 PL3.12(1/2) 7 12C-63100 PL3.15(1/2) 4 12C-81050 PL3.21(1/5) 4 8D3-31210 PL3.7(2/5) 8 945-12061 PL3.15(2/2) 8
12C-40370 PL3.12(2/2) 1 12C-63150 PL3.15(1/2) 8 12C-83102 PL3.20(1/2) 4 8F9-30020 PL3.7(2/5) 14 945-25310 PL3.5(4/4) 7
12C-40380 PL3.12(2/2) 2 12C-63170 PL3.15(1/2) 9 12C-83102 PL3.20(2/2) 10 8F9-30120 PL3.7(2/5) 10 945-25310 PL3.6(1/2) 17
12C-40390 PL3.12(2/2) 3 12C-63230 PL3.15(2/2) 1 12C-83111 PL3.20(1/2) 1 8M5-C1370 PL3.7(1/5) 14 945-25310 PL3.7(3/5) 20
12C-40580 PL3.12(2/2) 9 12C-63360 PL3.15(2/2) 10 12C-83190 PL3.20(2/2) 3 8N4-X1031 PL3.7(4/5) 10 947-13541 PL3.12(2/2) 16
12C-40620 PL3.12(2/2) 17 12C-63370 PL3.15(2/2) 11 12C-83200 PL3.20(2/2) 5 91H-31240 PL3.9(2/2) 9 94L-90320 PL3.17(1/2) 6
12C-58640 PL3.5(4/4) 21 12C-63391 PL3.15(2/2) 12 12C-83210 PL3.20(2/2) 1 92G-91130 PL3.10(1/4) 6 94X-20050 PL3.5(1/4) 8
12C-58650 PL3.5(4/4) 20 12C-63410 PL3.15(2/2) 13 12C-83220 PL3.20(2/2) 4 92L-34100 PL3.6(1/2) 18 94X-20070 PL3.11(1/7) 9
12C-60011 PL3.13 1 12C-63420 PL3.15(2/2) 14 12C-83301 PL3.21(5/5) 1 92L-53190 PL3.12(2/2) 7 94X-20370 PL3.11(2/7) 7
12C-60031 PL3.13 2 12C-63430 PL3.15(2/2) 15 12C-83302 PL3.20(2/2) 12 92T-10130 PL3.11(4/7) 12 94X-20420 PL3.4(1/2) 21

INDEX3 SCC
INDEX3 SCC (5/5)
94X-80211 PL3.3 27 96G-22190 PL3.10(1/4) 4 98X-41400 PL3.6(1/2) 6 99T-86019 PL3.17(1/2) 19 - - -
94X-80211 PL3.5(2/4) 18 96G-42460 PL3.8(1/2) 11 98X-41520 PL3.3 12 99T-91434 PL3.17(1/2) 25 - - -
94X-80211 PL3.21(1/5) 8 96G-60220 PL3.10(2/4) 9 98X-41520 PL3.5(4/4) 16 99V-84051 PL3.8(1/2) 21 - - -
94X-80211 PL3.21(2/5) 1 96G-60230 PL3.10(1/4) 12 98X-41520 PL3.6(2/2) 12 99V-84051 PL3.11(6/7) 25 - - -
950-21320 PL3.11(6/7) 22 96G-60230 PL3.10(4/4) 11 98X-41520 PL3.10(1/4) 17 99V-84051 PL3.21(2/5) 7 - - -
952-14380 PL3.1(1/2) 17 96V-10140 PL3.11(2/7) 1 98X-42581 PL3.4(2/2) 9 99V-84051 PL3.21(3/5) 7 - - -
952-14380 PL3.2(3/3) 8 96V-10280 PL3.11(3/7) 26 98X-90270 PL3.17(1/2) 8 99W-83010 PL3.13 9 - - -
952-14380 PL3.5(2/4) 14 96V-20631 PL3.5(3/4) 15 98X-92281 PL3.2(3/3) 19 99W-83010 PL3.21(4/5) 6 - - -
952-14380 PL3.8(1/2) 18 96V-20631 PL3.9(2/2) 10 98X-92281 PL3.6(1/2) 20 99W-91930 PL3.17(1/2) 22 - - -
95K-30081 PL3.2(1/3) 8 96V-40450 PL3.3 25 98X-92281 PL3.7(5/5) 9 99X-30100 PL3.5(2/4) 2 - - -
95K-30130 PL3.1(1/2) 9 96Y-10290 PL3.11(4/7) 13 98Y-11500 PL3.4(2/2) 8 99X-30100 PL3.5(3/4) 2 - - -
95K-30130 PL3.6(2/2) 14 96Y-10290 PL3.11(5/7) 14 991-13781 PL3.5(3/4) 19 99X-30100 PL3.6(2/2) 2 - - -
95L-52170 PL3.11(6/7) 14 96Y-10290 PL3.11(6/7) 5 995-13320 PL3.11(6/7) 8 99X-30101 PL3.1(1/2) 2 - - -
95L-52170 PL3.11(7/7) 15 96Y-10290 PL3.11(7/7) 10 995-13320 PL3.14(1/2) 5 99Z-31270 PL3.5(1/4) 14 - - -
95T-60080 PL3.5(1/4) 17 96Y-32220 PL3.5(3/4) 16 99A-11160 PL3.8(2/2) 11 99Z-31270 PL3.5(3/4) 4 - - -
95T-60080 PL3.5(3/4) 8 96Y-32220 PL3.9(2/2) 11 99A-11171 PL3.8(2/2) 12 99Z-31270 PL3.6(1/2) 5 - - -
966-14040 PL3.1(1/2) 8 96Y-80072 PL3.12(2/2) 13 99A-11200 PL3.11(2/7) 6 - - - - - -
966-14040 PL3.6(2/2) 13 96Y-80072 PL3.21(3/5) 4 99A-80131 PL3.3 28 - - - - - -
96D-12030 PL3.8(1/2) 12 976-51220 PL3.11(6/7) 23 99A-80131 PL3.4(1/2) 26 - - - - - -
96D-45130 PL3.10(4/4) 7 97J-30100 PL3.2(1/3) 7 99A-80131 PL3.8(2/2) 18 - - - - - -
96D-45450 PL3.10(4/4) 5 97J-80131 PL3.12(2/2) 11 99A-80131 PL3.21(1/5) 11 - - - - - -
96F-11252 PL3.1(1/2) 7 97J-80131 PL3.21(3/5) 3 99A-80131 PL3.21(2/5) 2 - - - - - -
96F-11252 PL3.6(2/2) 11 98F-15080 PL3.7(3/5) 10 99C-30220 PL3.1(2/2) 14 - - - - - -
96F-41330 PL3.2(1/3) 17 98F-26060 PL3.4(2/2) 16 99C-30220 PL3.5(1/4) 3 - - - - - -
96F-41330 PL3.6(1/2) 13 98H-80220 PL3.20(1/2) 3 99C-30220 PL3.6(2/2) 20 - - - - - -
96F-41330 PL3.6(2/2) 8 98R-80230 PL3.1(1/2) 21 99D-35600 PL3.8(1/2) 19 - - - - - -
96F-60370 PL3.17(1/2) 4 98R-80230 PL3.4(1/2) 25 99J-13650 PL3.3 22 - - - - - -
96F-60380 PL3.17(1/2) 5 98R-80230 PL3.8(1/2) 20 99J-62400 PL3.14(1/2) 9 - - - - - -
96G-11100 PL3.5(2/4) 4 98R-80230 PL3.10(2/4) 11 99J-62410 PL3.14(1/2) 10 - - - - - -
96G-11100 PL3.5(3/4) 5 98R-80230 PL3.15(2/2) 20 99J-62420 PL3.14(1/2) 11 - - - - - -
96G-11100 PL3.8(1/2) 8 98R-80230 PL3.21(1/5) 7 99J-62451 PL3.14(1/2) 12 - - - - - -
96G-11100 PL3.10(2/4) 8 98R-80230 PL3.21(2/5) 3 99J-62480 PL3.14(1/2) 15 - - - - - -
96G-11100 PL3.10(4/4) 12 98X-20190 PL3.10(2/4) 7 99J-80159 PL3.14(1/2) 17 - - - - - -
96G-11100 PL3.15(1/2) 7 98X-20190 PL3.15(1/2) 6 99J-80159 PL3.21(4/5) 2 - - - - - -
96G-12640 PL3.4(2/2) 14 98X-40140 PL3.10(4/4) 10 99S-93490 PL3.17(1/2) 24 - - - - - -
96G-12651 PL3.4(2/2) 15 98X-41270 PL3.4(2/2) 13 99S-93530 PL3.17(1/2) 21 - - - - - -
96G-20080 PL3.8(1/2) 7 98X-41270 PL3.6(1/2) 3 99T-67390 PL3.5(4/4) 19 - - - - - -
96G-22190 PL3.4(2/2) 5 98X-41340 PL3.10(3/4) 19 99T-86016 PL3.17(1/2) 20 - - - - - -

INDEX3 SCC
PL4.1 Cover

1 99T-67362 COVER
2 99T-67520 BR ACKET 4
3 99T-67530 COVER
4 99T-91600 COVER
3
2
1
5-81 Section 5—Parts List DCM Kit

PL4.1 Cover
PL4.2 Accessories
ITEM PART # DESCRIPTION 1 2 3 4

1 x DCM KIT MAIN UNIT
2 x STATIC ELIMINATOR
3 x DSF-2000 GUIDE PLATE
4 x DBM-120 SHEET BY SHEET AIR-PIPE
5* 055-10212 POWER CORD (for 220 to 240 V)
6** 055-10209 POWER CORD (for 120 V)
7 99T-83173 CONNECTING CABLE
9 056-10322 BUSHING
5 6 7 8 9
10 052-10027 CABLE COVER UNIT
13 99T-90433 INSTRUCTION MANUAL
NOTE:
10 11 12 13 14

PL4.2 Accessories
PL4.3 Hardware

1 ** 99W-83211 COMPRESSOR UNIT (FOR 120[V])
25
2* 99T-81021 COMPRESSOR UNIT (FOR 220-240[V])
3* 11C-80136 RM UNIT (FOR 220-240[V]) 15
13
4 ** 99T-80282 RM UNIT (FOR 120[V])
5 99T-67200 REMOTE BR ACKET
6 015-10160 CONNECTOR
23
24
7 *** x COMPRESSOR UNIT (FOR 100[V]) 23 3,4
8 053-90034 RELAY 22
9 99T-67051 BASE 5
10 99T-91620 ANGLE 22 20 22
22 6
12 99T-67310 ANGLE R 1,2,7
21
13 056-10322 BUSHING
14 016-10175 RUBBER LEG 22 1,2,7
15 98Z-51160 AIR HOSE
17 8
8
16 015-10114 Y-FIT TING 6
17 97V-43210 HOSE 10
18 015-10168 VALVE
16 14
20 22 9
19 99T-67120 GUARD 19 12
20 99T-67230 ANGLE 6
21 99T-86100 I/F UNIT 1/2
18 13
22 056-11137 SPACER 22
23 056-10958 DUST PROTECTION CAP 22 14
24 99T-67160 BR ACKET
14
25 99T-91590 ANGLE L
11
26 99T-67390 HOSE
NOTE: 26
*** Unique part for 100[V]

PL4.3 Hardware
PL4.4 Static-electricity Eliminator

1 99T-91540 BR ACKET
2 99T-81061 BAR SM, STATIC ACTIVE
3 99T-91550 STAY 4 1
4 99T-91520 BR ACKET
3 9
5 99T-91530 STAY
2
6 99T-91660 GUIDE D
7 0X3-10050 COLLAR, X 7
8 99T-66111 ENTR ANCE GUIDE 5
9 99T-83232 GROUND WIRE 6
10 99T-83191 WIRE UNIT 5
11 99T-91560 BR ACKET
12 99T-81050 POWER SUPPLY HIGH VOLTAGE 8 7
13 99T-91580 PLATE 11 10
14 99T-91570 ANGLE 13 12
15 0X4-12050 X COLLAR
14
15
15

PL4.4 Static-electricity Eliminator
PL4.5 Harness

1 99T-83241 WIRE UNIT 1
2 99T-83300 WIRE UNIT 2
3 99T-83152 GROUND WIRE

PL4.5 Harness
INDEX4 DCM Kit
015-10114 PL4.3 16 99T-83241 PL4.5 1 - - - - - - - - -
015-10160 PL4.3 6 99T-83300 PL4.5 2 - - - - - - - - -
015-10168 PL4.3 18 99T-86100 PL4.3 21 - - - - - - - - -
016-10175 PL4.3 14 99T-90433 PL4.2 13 - - - - - - - - -
052-10027 PL4.2 10 99T-91520 PL4.4 4 - - - - - - - - -
053-90034 PL4.3 8 99T-91530 PL4.4 5 - - - - - - - - -
055-10209 PL4.2 6 99T-91540 PL4.4 1 - - - - - - - - -
055-10212 PL4.2 5 99T-91550 PL4.4 3 - - - - - - - - -
056-09004 PL4.2 8 99T-91560 PL4.4 11 - - - - - - - - -
056-10322 PL4.2 9 99T-91570 PL4.4 14 - - - - - - - - -
056-10322 PL4.3 13 99T-91580 PL4.4 13 - - - - - - - - -
056-10958 PL4.3 23 99T-91590 PL4.3 25 - - - - - - - - -
056-11137 PL4.3 22 99T-91600 PL4.1 4 - - - - - - - - -
057-10037 PL4.3 11 99T-91620 PL4.3 10 - - - - - - - - -
0X3-10050 PL4.4 7 99T-91660 PL4.4 6 - - - - - - - - -
0X4-12050 PL4.4 15 99W-83211 PL4.3 1 - - - - - - - - -
11C-80136 PL4.3 3 - - - - - - - - - - - -
97V-43210 PL4.3 17 - - - - - - - - - - - -
98Z-51160 PL4.3 15 - - - - - - - - - - - -
99T-66111 PL4.4 8 - - - - - - - - - - - -
99T-67051 PL4.3 9 - - - - - - - - - - - -
99T-67120 PL4.3 19 - - - - - - - - - - - -
99T-67160 PL4.3 24 - - - - - - - - - - - -
99T-67200 PL4.3 5 - - - - - - - - - - - -
99T-67230 PL4.3 20 - - - - - - - - - - - -
99T-67310 PL4.3 12 - - - - - - - - - - - -
99T-67362 PL4.1 1 - - - - - - - - - - - -
99T-67390 PL4.3 26 - - - - - - - - - - - -
99T-67520 PL4.1 2 - - - - - - - - - - - -
99T-67530 PL4.1 3 - - - - - - - - - - - -
99T-80282 PL4.3 4 - - - - - - - - - - - -
99T-81021 PL4.3 2 - - - - - - - - - - - -
99T-81050 PL4.4 12 - - - - - - - - - - - -
99T-81061 PL4.4 2 - - - - - - - - - - - -
99T-83152 PL4.5 3 - - - - - - - - - - - -
99T-83173 PL4.2 7 - - - - - - - - - - - -
99T-83191 PL4.4 10 - - - - - - - - - - - -
99T-83232 PL4.4 9 - - - - - - - - - - - -
5-86 Section 5—Parts List DCM-Kit

INDEX4 DCM Kit
PL5a.1 Stitcher Head Section (1/2)

1 12J-10020 STITCHER HEAD SET (HOHNER)
2
2 12J-10053 GUIDE
3 12J-10112 HEAD HOLDER UNIT 1 1 15
D
4 12J-10170 PLATE 2
5 99S-10200 CHANNEL BR ACKET 3 9,10 A
6 12J-10211 SCREW B
7 99W-30111 SCREW 3 C
14 7 4
8 99S-10220 SHAF T 9,10
9 12J-92120 SPACER
5 6 8
10 12J-92130 SPACER
12 13
11 12J-10330 SCREW SHAF T D
12 11A-41350 TENSION SPRING 5
11 A
13 0Z3-06012 Z COLLAR
B
14 12J-10510 ANGLE 8 C
15 12J-10601 FR AME
15
5-87 Section 5—DBM-500/DBM-500BR Parts List DBM-500

PL5a.1 Stitcher Head Section
PL5a.1 Stitcher Head Section (2/2)

2
1 99S-10230 BOLT
4
2 98R-80230 INT.SENSOR 1
3
3 12J-10340 SPAR GEAR M1-75-08 5 D
4 98H-10640 COLLAR 1
5 013-10024 COLLAR 10 A
6 96G-22450 COLLAR 18
B
9
C
8 014-10545 STS BELT
9 12J-10450 MOTOR-BR ACKET
10 12J-10460 SPAR GEAR
11 98H-16470 ANGLE
D
12 12J-10680 BR ACKET
A
13 12J-10690 SHAF T
B
14 96F-11252 PINCH ROLLER UNIT C
1
15 98X-41520 SPACER
5
16 12J-10740 PIN, CENTER 7
17 11C-16560 PULLEY UNIT 15 6
18 99D-85060 STEPPING MOTOR
14 1
17
13
8 16 12

PL5a.1 Stitcher Head Section
PL5a.2 Clincher Section

12
1 12J-11033 CLINCHER HOLDER-R UNIT 1
2 12J-11071 SCREW-R 11
CLINCHER
3 12J-11081 SCREW-L
4 12J-11103 CLINCHER HOLDER-L UNIT 12
5 12J-11130 SCREW SHAF T 6
6 013-10024 COLLAR 11
2 8 4
7 96G-22450 COLLAR CLINCHER
15
8 99C-30221 TIMING PULLEY S3M-20-08 13 9
9 12J-11220 SHAF T
10 12J-11230 SHAF T 5
11 99S-10230 BOLT
12 12J-11280 GUIDE 14
15
13 12J-11330 PLATE-R 3
14 12J-11340 PLATE-L
15 12J-11350 FELT
10
11
11
6
7

PL5a.2 Clincher Section
PL5a.3 Driving Stitch Section (1/2)

11 9 13
1 12J-12030 LEVER
2 93X-10220 GUIDE 5
3 12J-12070 GUIDE 6
3 12
4 013-00091 COLLAR
5 12J-12090 SPRING C 14
2
6 011-10034 SPACER
8 14
7 12J-12120 BAR UNIT
7 1
8 99S-10730 SPACER 8
9 12J-12210 BR ACKET UNIT 18
15 2
10 013-00003 COLLAR
11 12J-12540 PLATE 4
12 12J-12602 BLOCK 17
4 16
13 12J-12111 STOPPER
10 17 18
14 12J-12630 COLLAR
15 12J-12700 LEVER-UNIT R
10
16 12J-12740 LEVER-L UNIT
17 12J-12800 PIN CENTER

PL5a.3 Driving Stitch Section
PL5a.3 Driving Stitch Section (2/2)

1 98H-12370 COLLAR 4
2 12J-12170 CHANNEL 4 16
3 98H-12390 FLANGE UNIT 5
1
4 92W-10470 GUIDE
5 99S-10780 STOPPER PLATE
6 12J-12300 BAR
2
7 12J-12352 BLOCK
7 4
8 12J-12360 ANGLE
4
9 12J-12402 SHAF T UNIT
10 12J-12430 BOSS 18 13
3
11 98H-90881 CAM
1
12 94L-50200 PILLAR
12
13 12J-12470 FLANGE UNIT
14 96G-60141 COLLAR
5
15 12J-12560 SENSOR BR ACKET
8 2
14
16 98R-80230 PHOTO INTERRUPTER 10
11
17 12J-12411 SHAF T 5
7
18 98H-51170 CR ANK 3
9 17 13
6 11
17 18 10
14 18
12

PL5a.3 Driving Stitch Section
PL5a.4 Back Jog Section (1/4)

1 12J-13030 MOTOR-BR ACKET 5
2 12J-13050 TIMING PULLEY 6
3 96Y-21030 S2M PULLEY 30T
9
4 12J-13100 TIMING PULLEY XL-13-08 4 8
5 12J-13111 SHAF T 3
6 013-10032 COLLAR 9
7 12J-13141 BR ACKET
7 4
8 014-10527 STS BELT
9 014-00235 BELT(BANDO 120XL037L)
10 12J-13210 TIMING-PULLEY UNIT
11 12J-13240 PIN, CENTER 1
12 12J-13251 COLLAR-C080-12-020
13 12J-13262 ANGLE 14 16 2
14 12J-13321 ANGLE-R
8
1210
15 12J-13331 ANGLE-L
11
16 12J-13520 SENSOR ANGLE 11
10 15 18
17 12J-13570 BLOCK 13 12
18 11S-83100 DC BRUSHLESS SERVO MOTOR 17
9
9
17
13

PL5a.4 Back Jog Section

17
1 12J-13340 STAY
10
2 12J-13350 COLLAR-C 080-10-060 6 4
15 14 10
3 011-10067 SPACER 3
2
4 12J-13371 PLATE 3
7
5 12J-92490 SHAF T
5 13
11
6 12J-92500 PLATE UNIT R 8
9 19 14 12 2
7 12J-92520 PLATE UNIT L 1
8 12J-13451 ROLLER-UNIT 19 9 18
9 11J-53040 ROLLER G-32-40 8 11
15 16
10 12J-13490 SPRING, T
11 12J-92550 PILLAR 17
13
12 12J-13531 SENSOR ANGLE
13 12K-80370 INT.SENSOR
14 12J-92570 PLATE
17 12J-92600 PAPER GUIDE
18 99S-32681 KNOB SCREW
19 11G-17210 COLLAR
20 12J-13620 PAPER-GUIDE
21 12J-13631 ANGLE


1 12J-14032 SLIDE-BLOCK, UNIT 3
2 12J-14060 PLATE
3 12J-14070 SHAF T
4 12J-14100 BR ACKET 4 5
5 12J-14111 BACK-JOGGER M 1
6 12J-14122 BACK-JOGGER SR
2
7 12J-14132 BACK-JOGGER SL
9 11
7 19
9 12J-14350 SHAF T-UNIT
12 17 15
10 0Z4-08018 Z COLLAR
4 18
11 12J-14171 SPRING T 10 23
12 995-13320 PILLAR 8 10
16
13 12J-14200 SHAF T
13
14 12J-14220 MOTOR-BR ACKET 20 9 11 21
15 12J-14230 LINK
14
16 12J-14240 PLATE 12
17 12J-14250 LINK UNIT
10
18 12J-14280 COLLAR 040-060-065
8 10
19 12J-14290 COLLAR 040-06-165
22
20 12J-14310 COLLAR 030-10-075 20
21 12J-14330 SENSOR ANGLE 13
22 11K-83250 STEPPING MOTOR
23 98R-80230 PHOTO INTERRUPTER


8 19
1 12J-15023 BASE UNIT 1
9 5
2 12J-15033 BASE 4
22 18 2
3 12J-15040 SHEET 2 3
4 12J-15051 COLLER-S 040-08-065
19
5 013-00003 COLLAR 13 6 3
6 12J-15100 BR ACKET 17
7 11C-16370 PLATE 15 7
4 18
8 12J-15140 ANGLE
3 5
6
10 12J-15180 SHAF T UNIT 7
16 20
11 12J-15220 TIMING PULLEY S3M-20-12
20
12 945-12061 COLLAR 21 11
13 013-10039 COLLAR 10
14 96G-11100 SET COLLAR 11
19
17 12J-15310 PIN, CENTER 19
19 014-10434 BELT, STS
20 12J-15410 R AIL
21 99D-85060 STEPPING MOTOR 12

PL5a.5 Side Jog Section (1/3)
ITEM PART # DESCRIPTION 1 2 4

1 12J-16010 SIDE JOG GUIDE R UNIT
2 3 20 19 5
2 12J-16020 SIDE JOG GUIDE R 5 3
3 12J-16030 SHEET 21
4 12J-16040 SIDE JOG GUIDE L UNIT 19
5 12J-16050 SIDE JOG GUIDE L 20
3 3 21
6 12J-16072 BLOCK UNIT 13
7 12J-16100 SHAF T 15
33
8 12J-16111 CHANNEL 18
9 12J-16120 BR ACKET 17 11
18
10 013-10024 COLLAR 6 17
11 12J-16391 ANGLE
14 16
9
12 12J-16401 ANGLE
12
13 12J-16410 PLATE 7 6
14 12J-16560 SENSOR BASE 12
8 11
15 12J-16652 SIDE-JOG-BASE R UNIT
9
16 12J-16682 SIDE-JOG-BASE L UNIT
17 12J-16770 SHAF T
18 12J-16800 SPRING, C 10
19 12J-16910 COLLAR
20 11G-41340 COLLAR 08-15-02
21 0Z4-08031 Z COLLAR

PL5a.5 Side Jog Section

1 12J-15280 MOTOR-BR ACKET 9
2 12J-17031 SPAR GEAR UNIT 8
5
4 12J-16210 SHAF T 10
6 12J-16230 BR ACKET 21
7 013-10024 COLLAR
20
8 12J-10740 PIN, CENTER
9 11C-16560 PULLEY UNIT 15
10 98H-16470 ANGLE
11 014-10492 BELT, STS
12 014-10085 BELT, STS
17 19
13 12J-16600 ROLLER UNIT
14 12J-16750 GUIDE-BLOCK
3
15 12J-16760 BLOCK 14
16 12J-16780 GUIDE-L 13 12 4
23
17 12J-16790 GUIDE-R
15
18 12J-16950 GUIDE L 7
19 12J-16960 GUIDE R 18 6
14
20 11K-83250 STEPPING MOTOR 16
22
11
22 12J-16580 BR ACKET 2
23 12J-16591 SHAF T


1 12J-17031 SPAR GEAR UNIT
3 12J-17111 SPRING, T
4 12J-17150 SHAF T
5 12J-17160 BR ACKET 7
6 11C-16460 SPAR GEAR 12
7 013-10024 COLLAR
8 11A-30191 ANGLE, PH
5
9 98H-10540 PLATE
10* 12J-80370 ELECTRO MAGNETIC BR AKE (for 220-240[V]) 10, 13
11 96G-22270 KEY
13** 96F-81012 ELECTRO MAGNETIC BR AKE (for 120[V])
7
1
NOTE:
** Unique part for 120[V] 4
11
2 3
6

PL5a.6 Wire Feed Detection Section

1 12J-19032 PLATE
2 12J-19050 INDEX PLATE 11 10
3 12J-19062 BOSS UNIT 1
4 12J-19091 PILLAR 13
5
6 12J-19132 PILLAR
7 12J-19230 COVER UNIT
9
8 12J-19330 PILLAR
9 12J-19340 LEVER 5
10 12J-19181 SPRING T
4
11 12J-19211 BR ACKET 3
7
12 12J-19252 COVER
6 8
14 12J-19240 URETHANE PLATE 12 14 15
14
12

PL5a.6 Wire Feed Detection Section
PL5a.7 Side Stitching Stopper Section

1 12J-20030 BASE
3 13 12 15 16
2 93X-21380 GUIDE 11
8 12 11 13
6 1
4 98H-20300 PIN 10
5 12J-20180 PILLAR 5 2
6 12J-20190 LINK
7 98H-20130 SOLENOID BASE
8 0Z4-08031 Z COLLAR
2
9 0Z4-08022 Z COLLAR 17 14
10 12J-20250 SPRING T
11 99S-20310 STOPPER UNIT
12 99S-20320 STOPPER 3
13 98H-20330 RUBBER PLATE
14 952-61290 ANGLE 7 3
15 12J-20332 STOPPER R
16 12J-20342 STOPPER L
4
17 99S-83150 DC-SOLENOID

PL5a.7 Side Stitching Stopper Section
PL5a.8 Saddle Stitching Stopper Section (1/4)

15
1 12J-21040 LEVER 16
2 12J-21050 SHAF T 10 21 15 16 17
3* 12J-21073 BLOCK (for 220-240[V])
11 1
4 12J-21262 BLOCK UNIT
5 12J-21290 SHAF T 3, 18
12
6 013-10129 COLLAR 9 6
6 8
7 11C-16370 PLATE
4 5
8 12J-21350 PIN
7
9 12J-21360 BLOCK
10 12J-21372 BR ACKET 13
11 12J-21382 DIAL
12 12J-21390 SET COLLAR 040-10-060
14 12J-21450 STOPPER-UNIT
16 12J-21470 FILM
17 99A-35120 RUBBER PLATE
18** 12J-92052 BLOCK (for 120[V])
NOTE:

PL5a.8 Saddle Stitching Stopper Section

1 12J-20190 LINK,SOLENOID
3 12J-21510 LINK-UNIT
4 12J-21541 LEVER
5 12J-21580 PIN,CENTOR
6 12J-21590 PIN,CENTOR
7 013-00061 COLLAR
8 12J-21620 SHAF T
9 12J-21640 SPRING,T
10* 12J-21661 SOLENOID BASE (for 220-240[V])
11 99S-83150 DC-SOLENOID
12** 12J-21671 SOLENOID BASE (for 120[V]) 9
NOTE: 7
* Unique part for 220-240[V] 6
8
5 4
3
1
2
10, 12
11


10 12
1 12J-22031 BASE
2 12J-22170 ANGLE
7 7
16 15
5 12J-22360 ANGLE-L 9
13 9
6 12J-22370 ANGLE-R 8 6 5
18
7 98H-20051 R AIL 14 17
9
8 12J-22391 BR ACKET 9
9 12J-22431 PILLAR B B
A
10 12J-91981 GUIDE R 1
11 12J-91991 GUIDE L
12 12J-22480 GUIDE A
13 12J-22501 LEVER
14 12J-22512 SENSOR-BR ACKET 2
15 0Z3-06012 Z COLLAR
16 995-13320 PILLAR
3 4
18 12J-17111 SPRING, T


1 12J-22040 ANGLE-R
2 12J-22050 ANGLE-L
6 945-12061 COLLAR
8 014-10218 BELT 6
B 4 B
9 12J-15280 MOTOR-BR ACKET A
A
3
1 7
6
5
11 8
10 2
9

PL5a.9 Back Stopper Section (1/3)

2 12J-30062 BR ACKET-L 21
3 12J-30072 BR ACKET-R
4 12J-30080 ANGLE, SOL 20
5 12J-30092 PILLAR
18 19
6 12J-30100 R ACK
7 12J-30260 LINK
9* 12J-30351 BR ACKET (for 220-240[V])
10 12J-30361 SPRING, TO
22
11 12J-30371 SPRING, TO
12 12J-30380 SHAF T A
7
13 12J-30401 SHAF T A
14 99S-32681 KNOB
8 4 1
17
10
17 0Z4-08018 Z COLLAR
18 12J-15270 WORM GEAR 6
5 11
3
19 013-00056 COLLAR
23 2 16
9, 24
20 12J-30910 MOTOR BR ACKET 13
15 9, 24
22 99W-83110 DC-SOLENOID 15 12 5 14
23 12J-30020 PLATE UNIT
24** 12J-92060 BR ACKET (for 120[V])
NOTE:

PL5a.9 Back Stopper Section

15
2 12J-30160 BELT FIXING PIECE
21
5 12J-30230 STAY 14
12
17
7 12J-30252 PILLAR
8* 12J-30270 BLOCK (for 220-240[V])
9 12J-30280 SPRING, T 18
18
10 952-61290 ANGLE
4 19
11 013-00121 COLLAR 17
12 12J-30483 FR AME 22 20 16
11 A
10
13 12J-30491 STAY A
14 12J-30510 SENSOR, BR ACKET
9
15 12J-30521 COVER 11 17
3
16 12J-30540 DRIVE SHAF T UNIT 7
17 013-00056 COLLAR 8, 23
5
18 96G-11100 SET COLLAR 7 6
19 12J-30620 PULLEY UNIT 2 8, 23 10
20 014-10528 BELT, STS 13
1
22 12J-30242 BR ACKET-L
23** 12J-92000 BLOCK (for 120[V])
NOTE:


1 96Y-13420 COLLAR
9 19
2 952-61290 ANGLE
3 12J-30380 SHAF T
8
5 12J-30610 SHAF T
5 6
6 014-10528 BELT, STS 7 10 4
7 12J-30692 BR ACKET 2
8 12J-30700 STAY 18 13
9 12J-30710 KNOB
10 12J-30720 PLATE SPRING
17
11 12J-30740 BR ACKET 1
12 12J-30750 BR ACKET A
16
12 1 17
13 12J-30760 SHAF T A
16
14 12J-30780 SHAF T
15 99S-91182 ROLLER UNIT 3 14 15
16 966-14040 COLLAR 15
17 12J-30830 SPRING, C
11
18 12J-30840 SPRING, T
19 12J-30880 HOOK

PL5a.10 Side Guide Section (1/3)

2 12J-16100 SHAF T
15
3 12J-31150 CHANNEL
17
7 12J-31220 SHAF T
8 12J-16072 BLOCK UNIT 1
9 013-10024 COLLAR 8 13
4
8
11 12J-10740 PIN, CENTER 2
12 11C-16560 PULLEY UNIT 14
13 12J-16391 ANGLE
12 14
14 12J-16401 ANGLE
13
15 98H-16470 ANGLE 11
10 4
16 014-10492 BELT, STS
17 98R-80230 PHOTO INTERRUPTER 5 16
9
3
6
6
7

PL5a.10 Side Guide Section

1 12J-31051 SIDE-GUIDE-L
6
2 12J-31061 SIDE-GUIDE-R 7
3 12J-31070 BR ACKET-L 5 7
4 12J-31101 PAPER GUIDE L 4
5 12J-31091 PAPER GUIDE R
14
6 12J-31110 PILLAR 2
7 0Z3-06022 Z COLLAR 14 1
8 12J-16200 TIMING PULLEY S3M-60-08 12
9 12J-31330 SHAF T
10 013-10024 COLLAR
11 12J-16230 BR ACKET 3
12 12J-31480 PLATE
13 014-10085 BELT, STS
14 12J-16910 COLLAR
9
11 10
13


1 12J-31530 STAY
2 12J-31540 GUIDE-PLATE-1 3
3 12J-31550 GUIDE-PLATE-2
4 12J-31560 BELT-GUIDE PLATE
2
7 96D-22061 PULLEY,3M20
2
1
1 7
5

PL5a.11 Folding Blade Section

6
1 98H-30220 SQUARE METAL
3
2 12J-34060 CONNECTING PLATE 1
3 98H-30190 PIN, CENTER 4
4 93X-10220 GUIDE
12
5 12J-34100 BASE 2 11
6 12J-34111 FOLDING BLADE
10
7 98H-30120 BR ACKET 151211 3
1 5
8 93L-13131 PILLAR 14
9 013-00003 COLLAR 13 10
10 98H-90351 BR ACKET
15 4
12
11 98H-90360 SHAF T (INSERT ROLLER KIT) 14 11
7 13
12 98H-90370 ROLLER (INSERT ROLLER KIT) 9
8 10
13 99S-32681 KNOB SCREW 15
14 98H-90700 PILLAR (INSERT ROLLER KIT) 13 14
15 98H-90710 PILLAR (INSERT ROLLER KIT) 7 9 8 9
8 7
1
8
9
7
2
1

PL5a.11 Folding Blade Section
PL5a.12 Folding Stopper Section (1/3)

10
2 12J-35080 STAY
14
3 12J-35090 PILLAR 13
3
4 12J-35120 SHAF T
11
5 12J-30620 PULLEY UNIT 22 12 5
6 12J-35191 DRIVE SHAF T UNIT 9
4
8 013-10039 COLLAR 15 17
17
9 014-10495 BELT, STS 20
8 2
10 12J-30160 BELT FIXING PIECE
6 7
11 12J-35290 STAY
18
12 12J-35301 BR ACKET, SENSOR 9
1 20
14 12J-35372 PLATE 8
15 12J-35510 BR ACKET 19 16
16 12J-35520 SCREW-SHAF T 21
17 91H-11260 COLLAR
18 12J-35560 BR ACKET

PL5a.12Folding Stopper Section

1 12J-35060 COLLAR, SET 100-20-100 7 16
2 12J-35070 STAY
3 96V-11260 GEAR (42T)
6
4 12J-35390 STAY
5* 12J-35403 STOPPER, FOLDING (for 220-240[V]) 18
4 18 17
6 12J-35421 BR ACKET UNIT
7 12J-35450 LEVER 4 18
8 12J-35471 BR ACKET, SENSOR
9 12J-92021 CONVEYANCE GUIDE UPPER
10 12J-35623 BR ACKET-L 5, 19
11 12J-35633 BR ACKET-R
12 12J-35690 BR ACKET
13 12J-35700 SHAF T
10
14 92H-20032 COLLAR 11
14 1
15 99E-51570 COLLAR, SET 2
17 12J-35760 STAY UNIT 14 3
14
18 12J-35780 SHEET 15
19** 12J-92011 STOPPER, FOLDING (for 120[V])
12
NOTE: 14
13 3 9


1 12J-36051 BASE 24 14
2 12J-36070 PILLAR 25
18
3 013-00003 COLLAR
17 22
4 12J-36130 SHAF T
20 20
5 12J-36140 ROLLER UNIT 21 23
6 12J-36191 DRIVE SHAF T
19 4 11 13
11
7 12J-36200 ROLLER A10-40 23 5
8 12F-30122 TIMING PULLEY
10
9 12J-36220 COLLAR UNIT 9
10 96G-20080 HOLDER
11 12J-36260 BELT, FLAT 5
12
12 12J-36330 ANGLE
13 12J-92030 CONVEYANCE PLATE L 10
14 12J-92040 CONVEYANCE PLATE R 7
15 013-00056 COLLAR
15 7
16 12J-36422 ANGLE, SENSOR
1
17 96G-42440 SENSOR PLATE UNIT
18 12J-36460 BR ACKET, MOTOR 10
11 6
19 12J-36480 SHAF T UNIT 11
9
20 013-10024 COLLAR
15 23
21 12J-15270 WORM GEAR 10
8
22 12J-36540 CAM
23 12J-36570 PILLAR

PL5a.13 Folding Roller Section (1/4)

1 12J-37051 BR ACKET-F 9 7
6
2 12J-37061 BR ACKET-B 12
13
3 12J-37070 PILLAR
9 4 6 5
4 12J-37080 HOLDER, COLLAR 7 13 14
5 12J-92710 FOLDING ROLLER UNIT F30
6 12J-37130 SPROCKET 2 8 11
7 013-00056 COLLAR 5
10
9 96G-11110 SET COLLAR 3
10 12J-37220 LEVER A-UNIT
11 12J-37300 LEVER B-UNIT 12
11
12 98H-57270 PIN CENTER 1214 13 7
13 98H-57280 COLLAR
13 4
14 12J-93260 SPRING, T
7 9
9
10
3
1 8

PL5a.13 Folding Roller Section

1 12J-93270 PRESS-ROLLER-L
2 12J-38060 PLATE A
3 013-00056 COLLAR
7 10
4 96G-60230 KEY
11
5 12J-93290 PRESS-ROLE-R
6 12J-93300 LEVER UNIT-L
7 12J-93320 LEVER UNIT-R
2 9 5
8 12J-38500 ANGLE 11
9 98H-55340 PIN, CENTER 3 10 B
10 12J-38430 PIN, CENTER 14
11 98H-57280 COLLAR A 1 6
12 12J-38480 SPRING, T
4 9
13 12J-38490 PILLAR 12
8 2
13
12 B
8
3
13


1 98H-43060 SPROCKET RS25-20-16 8 3 7
12 4
2 98H-43060 20N SPROCKET
15 A
3 12J-38120 PIN, CENTER 16 6
11
4 12J-38130 LEVER UNIT 2
5 12J-38161 PILLAR 1
6 12J-38170 SPRING, T
7 952-14380 ANGLE
8 98Y-32760 SPROCKET UNIT
9 12J-93281 TIMING PULLEY B
10 12J-38230 PULLEY 20S5M
11 96G-11100 SET COLLAR A
12 014-10403 CHAIN (TS RS-25 40PCS.)
13 014-10273 CHAIN (TS RS-25 31PCS.)
14 96G-11240 WASHER
15 12J-93340 HOLDER 16 15
16 12J-93330 COLLAR UNIT B
17 96G-60220 STS PULLEY
17
9
1110


1 12J-39051 COLLAR FFDD12C
20 7
2 12J-39061 COLLAR FF12C 3 20
7
3 12J-39070 SHAF T
15 5 15
4 12J-39080 FOLDING GAP CAM 8 2
5 12J-39090 PRESSING GAP CAM 7
6 12J-39100 PLATE
18 2 7 18
17 21 5
7 96G-60230 KEY 17
19 3 13 19
14
9 12J-39170 WORM M100-R-1-06 8
10 12J-39180 WORM WHEEL M100-R-1-80-12
11 12J-39190 SHAF T
11 11
12 12J-39200 ANGLE
9 9
13 12J-39210 BR ACKET-F 21
12 12
14 12J-39220 BR ACKET-B 19 19
15 12J-39230 PLATE
16
16 12J-39240 COLLAR, SET 060-14-060
16
17 12J-10460 SPAR GEAR
18 96D-12210 GEAR PULLEY
19 93L-12220 COLLAR 10 1
4 4
1
10

PL5a.14 Conveyance Infeed Section (1/2)

19 2
1 12J-40030 BELT
18
4 12J-40130 PULLEY C8-30-30 13
17
5 013-10032 COLLAR
6 12J-40151 ROLLER F-8-32
7 12J-40161 SHAF T
11
8 12J-40201 SHAF T
20 20 13
9 99V-90221 ROLLER UNIT
11 12J-40400 GUIDE PLATE R 15
12 12J-40410 GUIDE PLATE L
16 17 12
13 12J-40420 GUIDE
14 12J-40470 ANGLE 3 15
15 12J-40480 ANGLE
6
16 12J-40510 GUIDE 5 1
17 12J-40520 GUIDE 10 8 4
9
14
7
19 12K-80370 INT.SENSOR 5 6
20 12J-92700 GUIDE

PL5a.14Conveyance Infeed Section
PL5a.14 Conveyance Infeed Section (2/2)

2 12J-40081 COVER 12
3 12J-40370 GUIDE
4
6 12J-40631 ANGLE
3
7 12J-40640 CENTER PIN
8 12J-13451 ROLLER-UNIT
9 11J-53040 ROLLER, G-32-40
10 12J-40690 CENTER PIN 5
3
11 12J-40700 SPRING T 11
13 12W-80200 FAN 7
14
14 051-10152 FAN GUARD
11
9
8
10
7 8
9
6
6
10
13
14 2

PL5a.14Conveyance Infeed Section
PL5a.15 Conveyance Roller Section (1/2)

1
16
2 12J-41511 COVER
3 12J-41040 SHAF T
2 8 6
4 12J-41062 STAY UNIT
5 12J-41081 PILLAR A
6 95T-60080 COLLAR 3
B
7 12J-41100 PILLAR 6
9 12J-41240 SPRING, T 14 A
4
10 12J-41250 SPRING, T
15
11 016-10195 HANDLE 7 5
12 12J-41330 BR ACKET
7
13 12J-41340 SHAF T
14 12J-41382 COVER
15 12J-41472 BR ACKET-R 12 B
16 12J-41501 BR ACKET 9
10
13
9 13

PL5a.15Conveyance Roller Section
PL5a.15 Conveyance Roller Section (2/2)

1 96F-82650 COPPER WIRE UNIT 1 1
2 12J-41051 CHANNEL
3 12J-41121 PLATE
2
4 12J-41131 BR ACKET 15
5 12J-41141 BR ACKET A
B
7 12J-41481 BR ACKET-L 4
8 12J-13451 ROLLER-UNIT
9 11J-53040 ROLLER G-32-40 A
3
10 12J-41210 SHAF T
13 12
11 12J-41220 SPRING, C
12
12 12J-41231 PILLAR 6
13 98X-20050 COLLAR 5 11
11
14 12J-41411 CHANNEL 9
8
15 12J-41420 SHAF T B 12 10
12 16
16 12J-41451 BR ACKET
13 11
11 7
9
8
10

PL5a.15Conveyance Roller Section
PL5a.16 Stitching Outfeed Section (1/4)

1 12J-42200 SPRING, T
2 12J-42231 SHAF T 14
3 12J-92460 LEVER
15
5 013-10024 COLLAR 16
13
6 013-00056 COLLAR
21 22
7 12J-42340 LEVER
10
8 96G-12640 STUD
12
11 20
9 12J-42380 COLLAR
5
10 12J-42410 LEVER UNIT 9
8
7
12 0Z4-08031 Z COLLAR 6
13 12J-20190 LINK
14 98H-20130 SOLENOID BASE
1 4
15 99S-83160 DC-SOL 6
16 12K-80370 INT.SENSOR 2
17 12J-92470 KNOB 18 3
17
19 12H-50451 GUIDE PILLAR
20* 12J-42500 STOPPER (for 120[V]) 19
21* 99S-32681 KNOB SCREW (for 120[V])
22* 0Z4-08018 Z COLLAR (for 120[V])
NOTE:
* Unique part for 120[V]

PL5a.16 Stitching Outfeed Section

2 8
1 12J-42034 STAY 3
2 12J-92400 SHAF T UNIT 15 4
3 99S-56051 ROLLER 9
4 013-10043 COLLAR
5 12J-42130 BR ACKET 2
6 12J-42140 SHAF T 5 4
7 12J-42150 PULLY-UNIT 8
8 12J-42192 BELT
18
11 1716
9 013-10024 COLLAR 7 6 19
10 12J-42060 SPRING, TO
13
10
11 12J-42052 BR ACKET 11
12
12 011-10020 SPACER 13
13 011-10024 SPACER 10 14
14 12J-92340 BR ACKET
15 12J-92390 SHAF T 12
16 96G-11111 HOUSING
17 013-10036 COLLAR 1
18 13D-11140 SPRING, C
19 011-10061 WASHER


1 12J-43031 BOSS
15
2 12J-43041 PLATE
12
4 16
4 12J-92370 ANGLE
5 12J-43080 PIN, CENTER 20 17
6 12J-43130 LEVER
7 98H-15590 PIN, CENTER
13 13
19
8 0Z4-08022 Z COLLAR 11
9 12J-43190 SHAF T 14 14
10 013-10024 COLLAR
11 12J-43390 ANGLE
3
3 3
12 12J-43403 STAY 5 3
13 12J-92350 PAPER GUIDE 10
14 11G-12591 COLLAR 04-12-06 9
1
15 12J-43530 BLOCK
16 12J-43540 BR ACKET 6
18 99S-91182 ROLLER UNIT 8
19 12J-92381 BLOCK
18
7
2


7 5 4
1 013-10024 COLLAR 2
1
2 96F-41162 LEVER UNIT
3 96G-12640 STUD 8 3
4 12J-42380 COLLAR 9
5 12J-42410 LEVER UNIT
6
12
8 11A-10200 LINK
9 12J-43341 SOLENOID BASE 10
10 12J-43350 SPRING T
11
11 952-14380 ANGLE
12 95D-80160 DC, SOLENOID

PL5a.17 Folding Outfeed Section (1/2)

1 12J-45051 DRIVEN SHAF T
13 6
2 966-14040 COLLAR
3 99S-45630 SPRING-C 11
4 12J-45080 PULLEY 17 14 8
5 12J-45130 ANGLE 13
15
6 12J-45141 FIXED GUIDE 3 2
11
7 12J-45250 SHAF T 4 8 7
8 11K-30361 PULLEY UNIT 10 4
9 12J-45290 ROLLER, P12-50
10 12J-45320 BELT
9 10
11 12J-45330 BELT 1
12
14
12 12J-45380 PULLEY C12-40-36 12 3 2 5
9 15
13 96G-20080 HOLDER 7 13
14 96G-11100 SET COLLAR 13
15 12J-36220 COLLAR UNIT
16 014-10464 BELT, STS
17 11K-30120 TIMING PULLEY

PL5a.17 Folding Outfeed Section
PL5a.17 Folding Outfeed Section (2/2)

1 11K-30361 PULLEY UNIT
2 12J-45320 BELT
3 12J-45330 BELT
4 12J-45360 DRIVE SHAF T-D
5 12J-45380 PULLEY C12-40-36
6 96G-20080 HOLDER
14
15 13 7
7 013-00056 COLLAR
6
7 6
8
10 12J-45490 DRIVE SHAF T-T 17
11 12J-45500 FULCRUM SHAF T
14
9 1 16 11
12 12J-45510 LEVER-F 18
3 8
13 12J-45520 LEVER-B
14 6
1 7
14 0Z4-08031 Z COLLAR 14
10
15 96G-11240 WASHER 5 12
14
15
16 12J-45560 PILLAR 3 17 7
17 12J-45570 ANGLE
6
18 12J-45580 SPRING, T 4
2 18
5
2 14
16
9

PL5a.17 Folding Outfeed Section
PL5a.18 Side Stitching Outfeed Section (1/2)

12
2 12J-47060 SHAF T 8
3 99S-91182 ROLLER UNIT
4 12J-47101 SHAF T
5 12J-47110 SHAF T
7 91H-11260 COLLAR
8 12J-47372 GUIDE-T 10
9 12J-47382 GUIDE D 12 10
10 12J-47391 ANGLE 4 9
11 12J-47451 DRIVE SHAF T
12 12K-80370 INT.SENSOR 5 16
6
13 12J-47520 PLATE 3
18
14 12J-47530 LEVER-UNIT
15 12J-47540 LEVER 13
16 12J-47550 SCREW-SHAF T 2 1 7
17 12J-47560 STOPPER 14
18 12J-47570 SET-COLLAR
3
15 16 17 18
17 15
11

PL5a.18 Side Stitching Outfeed Section
PL5a.18 Side Stitching Outfeed Section (2/2)

1 013-00136 COLLAR 12
2 12J-47241 LEVEER 13
3 0Z4-08031 Z COLLAR 6
4 12J-47251 BLOCK 5
5 12J-47320 SOLENOID BASE 7
6 98H-44160 SPRING T 7
7 952-14380 ANGLE
11 9
8 12F-30122 TIMING PULLEY
9 013-00056 COLLAR
11 96G-20080 HOLDER
12 99S-83140 DC-SOL UNIT
13 11A-10200 LINK
11
8

PL5a.18 Side Stitching Outfeed Section
PL5a.19 Driving Main Section

1 12J-50050 BR ACKET, MOTOR 15
2 98H-50100 MOTOR PULLEY 9
3 014-10503 BELT(BANDO 2-5MS615) 10
4 12J-50080 PULLEY E20-77-13 13
11
5 12J-50090 KEY-6-21
6 12J-50120 BOSS COLLAR UNIT 6 14 5
7 12J-50150 PLATE 16
8
8 12J-50161 MAIN SHAF T
10 12J-50180 KEY 6-34
7
11 12J-50210 INDEX PLATE UNIT 12
12 12J-50240 BR ACKET, SENSOR
13 12J-50280 KEY 6-80
15 12J-50301 TIMING PULLEY S5M-28-20 7
4
1
2 3

PL5a.19Driving Main Section
PL5a.20 Driving Stitcher Section (1/2)

2 98X-60651 CENTER PIN
3 91H-14090 ROLLER
16
4 013-00003 COLLAR
5 12J-51170 KEY 8-7-20 12
6 12J-51183 SHAF T
7 12J-51211 COLLAR HOLDER
8 12J-51231 COLLAR-C 150-20-223
9 96G-60141 COLLAR 14
10 99D-30260 KEY
8
11 12J-51260 SPROCKET RS25-25-25
11
12 013-10135 COLLAR
13 12J-51400 BOSS 7
14 014-10504 STS BELT
15 12J-82012 ELECTROMAGNETIC CLUTCH
1
16 12J-82033 ELECTROMAGNETIC BR AKE
2 15 10
4
3 5
13 5
4
6
9

PL5a.20 Driving Stitcher Section
PL5a.20 Driving Stitcher Section (2/2)

2 12J-50150 PLATE 8
7 9
3 12J-51220 COLLAR, SET 250-36-200
4 013-10138 COLLAR
5 12J-51340 CENTER PIN 5
6 98Y-41240 SPROCKET UNIT
10
7 12J-51410 KEY 6-24
8 98H-52220 45N SPROCKET
9 014-00191 CHAIN 6 4 3
10 12J-51110 COVER
2

PL5a.20 Driving Stitcher Section
PL5a.21 Driving Fold Section

1 99D-30260 KEY
2 12J-52130 ANGLE
10
3 96F-23250 COLLAR 3
4 12J-51231 COLLAR-C 150-20-223
6 013-10035 COLLAR 15
7 96G-20080 HOLDER 13
14
8 013-10138 COLLAR
9 12J-52291 FOLDING DRIVE SHAF T UNIT
7
6
10 99S-52260 CR ANK, PIN
11 12J-52331 INDEX
12 12J-52370 ANGLE, SENSOR 12
13 91H-51530 IDLER
11
14 013-00003 COLLAR
2 8 3
15 12J-52430 PIN, CENTER 17
16 014-10505 BELT, STS 4
18 12J-82022 ELECTROMAGNETIC CLUTCH 5
9 10
19 12J-82033 ELECTROMAGNETIC BR AKE 6
19 7
3
16 18 1
1

PL5a.21 Driving Fold Section
PL5a.22 Driving Conveyance Section (1/3)

1 20
1 12J-55050 BR ACKET 3 13 20
8 21
2 96G-20120 PULLEY
3 98X-25261 GEAR 38T
4 96G-11100 SET COLLAR 7 12 7
5 11
5 013-00094 COLLAR 4 10 7
2 12
6 12J-55100 SHAF T 11
3 6 13
7 12J-55110 KEY 5-16
5
8 014-10506 STS BELT 9
19
9 12J-55312 DRIVING SHAF T
10 12J-55320 PULLEY E15-40-30 19
11 12J-55430 COLLAR-C 015-18-052 18
13 96G-60141 COLLAR 15
14 12J-55462 CLUTCH SHAF T
15 12J-55481 ANGLE
16 12F-30122 TIMING PULLEY 17 19
18
17 12J-36200 ROLLER A10-40 18
17
19 96G-20080 HOLDER
20 14
20 12J-55640 BELT, FLAT
20 18 19
21 013-10032 COLLAR
16

PL5a.22 Driving Conveyance Section

1 96G-20120 PULLEY 19 18
3 014-10506 STS BELT 17
6
8 7 12 7 6
5 11A-31310 CENTER PIN 5
6 91H-51530 IDLER
21 9 2
7 013-00003 COLLAR 15 4
14 11
8 12J-55213 BR ACKET 10
16 3
9 013-00056 COLLAR 12
10 12J-55280 BOSS
1
13
11 945-12151 TIMING GEAR
12 014-10526 BELT (BANDO 254XL050U)
13 11G-82602 FEED CLUTCH-C
14 98R-23301 COLLAR
15 12J-55540 COLLAR-C 080-13-020
16 12J-55510 COLLAR 121-17-020
18 12J-55230 ANGLE
19 12J-55260 SPRING T
20 0Z4-08022 Z COLLAR
21 952-14380 ANGLE


1 12J-56071 PULLEY UNIT
2 96G-20101 TIMING PULLEY
2
3 014-00110 TIMING BELT
1
4
5 014-10636 BELT (BANDO 228XL037G)
6 014-10409 STS BELT 5
3
8 98X-60542 STS PULLEY UNIT 17
9 98X-40140 16S5M PULLEY
25
10 96G-60230 KEY
11 12J-56430 SPAR GEAR M150-39-12 22 24
23
21
13 12J-56470 BR ACKET
14 11A-31310 CENTER PIN 11
15 91H-51530 IDLER
7
16 013-00003 COLLAR
8
17 014-10494 BELT, STS
12
18 014-10544 BELT, STS 19 10 13 14
19 12J-56570 CENTER PIN 20 15
9 16
20 94X-20420 GEAR PULLEY G2 UNIT
6
21 12J-93361 TIMING PULLEY UNIT
18
23 12J-93391 TIMING PULLEY UNIT
24 014-10491 STS BELT

PL5a.23 Exterior Section (1/6)

1 12J-60053 FR AME-F 9 4
2 12J-60065 FR AME-B 11 15 10
3 12J-60120 SUB FR AME 7
4 12K-60180 CONNECTOR-ANGLE
5* 12J-60170 PLATE (for 220-240[V]) 5
6 12J-90060 BR ACKET, POWER SUPPLY 11
7 12J-60260 PLATE, SW
17
9 12J-90030 BOARD BR ACKET
10 12J-90040 BR ACKET
2
11 12J-90050 ANGLE
12 12J-90100 DIVIDING PLATE 18
6 16
13 12J-63100 PLATE
14 12J-63241 ANGLE
15 93E-83150 MAGNET SENSOR
16** 12J-60240 PLATE (for 120[V])
17** 12J-60190 PLATE (for 120[V])
18* 98H-60350 PLATE (for 220-240[V]) 8
14
NOTE:
15

PL5a.23 Exterior Section

16
1 12J-61052 SUB FR AME-F
2 12J-61062 SUB FR AME-B 14
3 12J-61131 SUB FR AME BOT TOM
4 12J-61141 BR ACKET, SENSOR 13 7
5 12J-61182 EJECT GUIDE
6 12J-61210 SUB FR AME-T
17
8
7 99S-91780 ANGLE 15 18
6
8 12J-61241 GUIDE, SENSOR
9 12J-61400 KNOB 17
10 12J-61410 COLLAR-C 110-15-1820 15
11 016-10198 KNOB
12 056-08011 CAP
1
13 12J-63110 PLATE
14 5
16
15 95L-52171 PILLAR 4
16 12J-62110 PILLAR
17 95K-30081 ROLLER UNIT
18 12J-45680 SHAF T
12
3
10
9 11


1 12J-62051 TOP COVER-1 3
67
2 12J-62071 HINGE
3 95L-52171 PILLAR 2
4 12J-62091 METAL PLATE 1
15 3
5 016-10195 HANDLE
16 5
6 950-21320 PILLAR
8
7 976-51220 RUBBER CUSHION 10
9 11
8 12J-62221 ANGLE
4
9 12J-62231 BR ACKET, SENSOR 16
76
10 12J-62240 THREADED PLATE 9
11 12J-62262 TOP COVER-2
12 5 7 6
12 12J-62273 TOP COVER-3
14
13 12J-62342 HINGE
14 12J-62470 R AIL-F 3 2
15 12J-62480 R AIL-B
16 054-10324 ACTUATOR
4
3
13


1 12J-63051 COVER-F
2 12J-63063 COVER-B
3 12J-63390 BR ACKET 7
4 950-21320 PILLAR 8 15
5 12J-63120 PLATE
6 12J-63140 SUB COVER-F
7 991-23261 MAGNET
2
8 12J-63181 SUB COVER-B 1
9 990-21322 GUIDE PLATE
10 12J-63301 SHUT TER BASE UNIT
11 12J-63311 BASE 7
12 99S-62870 RUBBER PLATE
13 12J-63340 PILLAR
14 99S-91870 SHUT TER 5 6
15 12J-63080 SUB COVER
3
12
13 9
10 9 14
11
11 12 12
4


1 12J-80211 DPIFP.W.B.UNIT
2* 97K-80284 POWER CORD UNIT (for 220-240[V])
11
3 11C-84100 INTERLOCK SWITCH
4 12J-60260 SW PLATE
1
5* 056-10254 OUTLET (for 220-240[V]) 2
3
6 054-10338 CIRCUIT PROTECTOR
10
7 054-10268 SWITCH
8 054-10270 SWITCH 6 12
9 053-10044 RELAY 5
10 054-10304 SWITCH 3 9
11** 97K-84012 POWER CORD UNIT (for 120[V]) 87
4
12** 056-05001 OUTLET (for 120[V])
12
13 99W-83010 COUNTER UNIT
NOTE: 5 13
13


1 12J-86105 MC UNIT 12 10
12 11
2 11A-80253 RL P.W.B UNIT 11 1
7
3* 12J-82140 MOTOR DRIVER (for 220-240[V]) 11 10 10
4 11A-81390 ISOLATION BOARD 10
8
5* 12J-82200 REACTOR UNIT (for 220-240[V]) 10
10
10
7 052-10013 NOISE FILTER
10
10 056-11137 SPACER
11 056-11016 COLLAR
12 056-00778 BUSH
13** 12J-82160 MOTOR DRIVER (for 120[V])
11
14** 12J-82220 REACTOR UNIT (for 120[V]) 4
12
11
NOTE:
* Unique part for 220-240[V] 11 12
** Unique part for 120[V] 5, 14
9
6
3, 13

PL5a.24 Control Panel Section

1 12J-65030 PANEL BASE
6 4
2 12J-65051 CONTROL PANEL
3 12J-65060 BOX
4 12J-65071 PANEL COVER
5 0Y4-08031 Y COLLAR
8 9
6 12J-65101 BASE
7 12J-85301 OPER ATION TERMINAL
2
8 92L-86130 KEY TOP 1
9 12J-80112 KEYP.W.B. UNIT
7
3
1
5

PL5a.24 Control Panel Section
PL5a.25 Paper Receiving Section

12
1 12J-66053 PAPER RECEIVING BASE 2
3 12J-66072 PAPER RECEIVING UNIT 15
4 12J-66082 PAPER RECEIVING PLATE 13
5 11G-51580 CUSHION
15
6 12J-66100 GUARD SHEET
7 12J-66110 COVER
8 013-00130 COLLAR
14
10 011-10047 KNOB STAR
11 12J-66170 KNOB
12 12J-66190 BR ACKET
13 12J-66200 GUIDE 1
9 6
14 12J-66220 DEFLECTOR STRIP 8
6
15 12J-66240 SHAF T 5
16 062-11162 INT.SENSOR 3
5
17 96F-83190 GROUND LINE 8
7
4 5 6
8
9
11 17
16 4 10
8

PL5a.25 Paper Receiving Section
PL5a.26 Cabinet Section (1/2)

24
1 12J-67082 CABINET LOWER 7
2 016-10068 CASTER 7 4
3 12J-67120 SHAF T 6 9
16 13
4 96F-25041 25T GEAR 3 15
17
5 013-10133 BLOCK 16 19 10
5 20
6 12J-67230 SPROCKET, RS35-24-20 2 11
7
7 98Y-11690 KEY 6x6 4 14 12
8 014-10500 CHAIN 18
22
9 12J-67271 SPROCKET RS35-12-08 16 19 20 16
15 15
10 98R-80230 PHOTO INTERRUPTER 17 21 17
16 23 16
11 12J-67301 MOTOR BR ACKET 10
12 98H-14500 ANGLE 18
13 12J-67340 SENSOR PLATE UNIT 14
14 12J-67400 BR ACKET 19 14 21 22
20
15 12J-67410 SHAF T 2
16 12J-67420 COLLAR, SET 200-26-100 18
17 013-00071 COLLAR 15 16
17
18 12J-67470 ANGLE
2 16
19 99A-14220 PIN, CENTER
20 013-00003 COLLAR
19 2
21 12J-67520 ANGLE 20
1 14
22 949-51180 RUBBER LEG 18
23 12J-67600 PH ANGLE
24 12D-82050 MOTOR, DC UNIT
25 12J-67960 GEAR HEAD

PL5a.26 Cabinet Section
PL5a.26 Cabinet Section (2/2)

1 98Y-85061 AC MOTOR 4
2 12J-67051 CABINET UPPER
3 12J-67060 R AIL 5
4 12J-67650 COVER 7
5 12J-67560 ANGLE
1 9
6 12J-67570 R ACK M-200-23
7 12J-67580 THREDED PLATE
8 12J-67610 SENSOR-PLATE
10
9 12J-90091 WIRE HARNESS COVER 6
7
10 12W-80300 MOTOR EARTH WIRE 5
3
8
3 2

PL5a.26 Cabinet Section
PL5a.27 Accessory Section (1/2)
1 2 3 4 5

6 7 8 9 10 11 12
2 11C-83232 D-PORT CABLE
3 x HARNESS
4 x WIRE REEL MOUNT
5 12J-67091 SAFETY COVER A 13 14 15 16 17 18 19 20
6 96F-60381 PLATE
7 94L-90320 SPANNER
8 99G-72500 HANDLE
10 025-91407 NEEDLE-NOSE PLIERS 21 22 23 24 25 26 27 28
11 025-91391 LUBRICATOR
12 12J-91430 STACKER PLATE
13 99S-71141 SQUARE ROD
29 30 31 32 33 34 35, 36 37 38
15 x PAPER GUIDE WHEEL
16 x PAPER GUIDE WHEEL (for small size)
17 12J-68050 CONNECTING PLATE A
18 12K-60570 CONNECTING PLATE B
39 40 41 42 43 44 45 46
19 x GUARD PLATE F
20 x GUARD PLATE B
21 x BR ACKET
22 x SCALE PLATE
23 98X-90270 CASE
47 48 49 50 51 52 53 54
24 x ADJUSTING HANDLE
25 x STAR-SHAPED WRENCH (Large)
26 x STAR-SHAPED WRENCH (Small)
27 x HEXAGONAL WRENCH T-SHAPE
NOTE:

PL5a.27 Accessory Section
PL5a.27 Accessory Section (2/2)
1 2 3 4 5

28 x STITCHER HEAD INSTRUCTION MANUAL (CD)
6 7 8 9 10 11 12
29 x SCREW (HSKW6 x 16)
30 x SCREW (MSKW4 x 8)
13 14 15 16 17 18 19 20
33 056-00876 SK BINDER
35 ** 12J-92802 INSTRUCTION MANUAL
36 * 12J-92811 INSTRUCTION MANUAL
37 x NAME PLATE
21 22 23 24 25 26 27 28
38 99S-19030 AIR PIPE UNIT
40 12J-90880 PAPER GUIDE WITH FILM
41 x SCREW (FR3 x 4)
42 x LABEL (applicable only to 220-240V) 29 30 31 32 33 34 35, 36 37 38
43 x LABEL (applicable only to 220-240V)
44 12J-90970 SAFETY COVER B
45 12J-90980 ANGLE
46 x UPPER WIRE TUBE
39 40 41 42 43 44 45 46
47 x WIRE FEED DETECTION UNIT
48 x EJECTION ROLLER UNIT
49 12J-92610 BELT GUIDE L
50 12J-92640 BELT GUIDE S
51 12J-92670 BELT GUIDE M 47 48 49 50 51 52 53 54
52 12J-92720 FILMED GUIDE R
53 12J-92760 FILMED GUIDE L
54 x SPONGE ROLLER UNIT
NOTE:

PL5a.27 Accessory Section
INDEX5a DBM-500 (1/6)
011-10020 PL5a.16(2/4) 12 013-10024 PL5a.12(3/3) 20 014-10506 PL5a.22(1/3) 8 0Z4-08018 PL5a.9(1/3) 17 11J-53040 PL5a.4(2/4) 9
011-10024 PL5a.16(2/4) 13 013-10024 PL5a.16(1/4) 5 014-10506 PL5a.22(2/3) 3 0Z4-08018 PL5a.16(1/4) 22 11J-53040 PL5a.14(2/2) 9
011-10034 PL5a.3(1/2) 6 013-10024 PL5a.16(2/4) 9 014-10526 PL5a.22(2/3) 12 0Z4-08022 PL5a.7 9 11J-53040 PL5a.15(2/2) 9
011-10047 PL5a.25 10 013-10024 PL5a.16(3/4) 10 014-10527 PL5a.4(1/4) 8 0Z4-08022 PL5a.9(1/3) 8 11K-30120 PL5a.17(1/2) 17
011-10061 PL5a.16(2/4) 19 013-10024 PL5a.16(4/4) 1 014-10528 PL5a.9(2/3) 20 0Z4-08022 PL5a.16(3/4) 8 11K-30361 PL5a.17(1/2) 8
013-00003 PL5a.4(4/4) 5 013-10032 PL5a.22(1/3) 21 014-10545 PL5a.1(2/2) 8 0Z4-08031 PL5a.7 8 11K-83250 PL5a.5(2/3) 20
013-00003 PL5a.11 9 013-10035 PL5a.21 6 014-10636 PL5a.22(3/3) 5 0Z4-08031 PL5a.8(2/4) 2 11S-83100 PL5a.4(1/4) 18
013-00003 PL5a.12(3/3) 3 013-10036 PL5a.16(2/4) 17 016-10068 PL5a.26(1/2) 2 0Z4-08031 PL5a.13(1/4) 8 12D-82050 PL5a.26(1/2) 24
013-00003 PL5a.20(1/2) 4 013-10039 PL5a.4(4/4) 13 016-10195 PL5a.15(1/2) 11 0Z4-08031 PL5a.16(1/4) 12 12F-30122 PL5a.12(3/3) 8
013-00003 PL5a.21 14 013-10039 PL5a.12(1/3) 8 016-10195 PL5a.23(3/6) 5 0Z4-08031 PL5a.16(4/4) 7 12F-30122 PL5a.18(2/2) 8
013-00003 PL5a.22(2/3) 7 013-10043 PL5a.16(2/4) 4 016-10198 PL5a.23(2/6) 11 0Z4-08031 PL5a.17(2/2) 14 12F-30122 PL5a.22(1/3) 16
013-00003 PL5a.22(3/3) 16 013-10129 PL5a.8(1/4) 6 025-91391 PL5a.27(1/2) 11 0Z4-08031 PL5a.18(2/2) 3 12H-50451 PL5a.16(1/4) 19
013-00003 PL5a.26(1/2) 20 013-10133 PL5a.26(1/2) 5 025-91407 PL5a.27(1/2) 10 11A-10200 PL5a.16(4/4) 8 12J-10020 PL5a.1(1/2) 1
013-00056 PL5a.12(3/3) 15 013-10138 PL5a.21 8 053-10044 PL5a.23(5/6) 9 11A-31310 PL5a.22(2/3) 5 12J-10170 PL5a.1(1/2) 4
013-00056 PL5a.18(2/2) 9 014-10085 PL5a.10(2/3) 13 054-10338 PL5a.23(5/6) 6 11C-16370 PL5a.4(4/4) 7 12J-10460 PL5a.1(2/2) 10
013-00130 PL5a.25 8 014-10491 PL5a.22(3/3) 24 056-11137 PL5a.23(6/6) 10 11C-16560 PL5a.10(1/3) 12 12J-10740 PL5a.5(2/3) 8
013-10024 PL5a.1(2/2) 5 014-10492 PL5a.10(1/3) 16 062-11162 PL5a.25 16 11C-83390 PL5a.27(1/2) 1 12J-11033 PL5a.2 1
013-10024 PL5a.2 6 014-10494 PL5a.22(3/3) 17 0X4-12050 PL5a.6 5 11C-84100 PL5a.23(5/6) 3 12J-11071 PL5a.2 2
013-10024 PL5a.5(1/3) 10 014-10495 PL5a.12(1/3) 9 0Y4-08031 PL5a.24 5 11G-12591 PL5a.16(3/4) 14 12J-11081 PL5a.2 3
013-10024 PL5a.5(2/3) 7 014-10500 PL5a.26(1/2) 8 0Z3-06012 PL5a.1(1/2) 13 11G-17210 PL5a.4(2/4) 19 12J-11103 PL5a.2 4
013-10024 PL5a.5(3/3) 7 014-10503 PL5a.19 3 0Z3-06012 PL5a.8(3/4) 15 11G-41340 PL5a.5(1/3) 20 12J-11130 PL5a.2 5
013-10024 PL5a.10(1/3) 9 014-10504 PL5a.20(1/2) 14 0Z3-06022 PL5a.10(2/3) 7 11G-51580 PL5a.25 5 12J-11220 PL5a.2 9
013-10024 PL5a.10(2/3) 10 014-10505 PL5a.21 16 0Z4-08018 PL5a.4(3/4) 10 11G-82602 PL5a.22(2/3) 13 12J-11230 PL5a.2 10

INDEX5a DBM-500
12J-11280 PL5a.2 12 12J-13350 PL5a.4(2/4) 2 12J-15220 PL5a.4(4/4) 11 12J-16560 PL5a.5(1/3) 14 12J-20180 PL5a.7 5
12J-11330 PL5a.2 13 12J-13371 PL5a.4(2/4) 4 12J-15220 PL5a.8(4/4) 5 12J-16580 PL5a.5(2/3) 22 12J-20190 PL5a.7 6
12J-11340 PL5a.2 14 12J-13451 PL5a.4(2/4) 8 12J-15220 PL5a.9(3/3) 4 12J-16591 PL5a.5(2/3) 23 12J-20190 PL5a.8(2/4) 1
12J-11350 PL5a.2 15 12J-13451 PL5a.14(2/2) 8 12J-15220 PL5a.12(1/3) 7 12J-16600 PL5a.5(2/3) 13 12J-20190 PL5a.16(1/4) 13
12J-12030 PL5a.3(1/2) 1 12J-13451 PL5a.15(2/2) 8 12J-15270 PL5a.4(4/4) 15 12J-16652 PL5a.5(1/3) 15 12J-20250 PL5a.7 10
12J-12111 PL5a.3(1/2) 13 12J-13531 PL5a.4(2/4) 12 12J-15270 PL5a.12(1/3) 19 12J-16760 PL5a.5(2/3) 15 12J-21040 PL5a.8(1/4) 1
12J-12740 PL5a.3(1/2) 16 12J-14240 PL5a.4(3/4) 16 12J-16100 PL5a.5(1/3) 7 12J-19032 PL5a.6 1 12J-21580 PL5a.8(2/4) 5

INDEX5a DBM-500
12J-30483 PL5a.9(2/3) 12 12J-34060 PL5a.11 2 12J-36220 PL5a.22(1/3) 18 12J-39230 PL5a.13(4/4) 15 12J-41210 PL5a.15(2/2) 10

INDEX5a DBM-500
12J-41411 PL5a.15(2/2) 14 12J-45080 PL5a.17(1/2) 4 12J-50050 PL5a.19 1 12J-55213 PL5a.22(2/3) 8 12J-62110 PL5a.23(2/6) 16
12J-43080 PL5a.16(3/4) 5 12J-47320 PL5a.18(2/2) 5 12J-52130 PL5a.21 2 12J-61062 PL5a.23(2/6) 2 12J-65101 PL5a.24 6

INDEX5a DBM-500
12J-66220 PL5a.25 14 12J-90030 PL5a.23(1/6) 9 12J-92590 PL5a.4(2/4) 16 91H-51530 PL5a.22(2/3) 6 96F-11252 PL5a.1(2/2) 14
12J-66240 PL5a.25 15 12J-90040 PL5a.23(1/6) 10 12J-92600 PL5a.4(2/4) 17 91H-51530 PL5a.22(3/3) 15 96F-23250 PL5a.21 3
12J-67051 PL5a.26(2/2) 2 12J-90050 PL5a.23(1/6) 11 12J-92610 PL5a.27(2/2) 49 92G-91130 PL5a.9(1/3) 16 96F-25041 PL5a.26(1/2) 4
12J-67060 PL5a.26(2/2) 3 12J-90060 PL5a.23(1/6) 6 12J-92640 PL5a.27(2/2) 50 92G-91130 PL5a.16(1/4) 18 96F-41162 PL5a.16(4/4) 2
12J-67082 PL5a.26(1/2) 1 12J-90091 PL5a.26(2/2) 9 12J-92670 PL5a.27(2/2) 51 92H-20032 PL5a.12(2/3) 14 96F-60370 PL5a.27(1/2) 9
12J-67091 PL5a.27(1/2) 5 12J-90100 PL5a.23(1/6) 12 12J-92700 PL5a.14(1/2) 20 92L-86130 PL5a.24 8 96F-60381 PL5a.27(1/2) 6
12J-67120 PL5a.26(1/2) 3 12J-90880 PL5a.27(1/2) 14 12J-92710 PL5a.13(1/4) 5 92W-10470 PL5a.3(2/2) 4 96F-81012 PL5a.5(3/3) 13
12J-67230 PL5a.26(1/2) 6 12J-90880 PL5a.27(2/2) 40 12J-92720 PL5a.27(2/2) 52 93E-83150 PL5a.23(1/6) 15 96F-82650 PL5a.15(2/2) 1
12J-67271 PL5a.26(1/2) 9 12J-90970 PL5a.27(2/2) 44 12J-92760 PL5a.27(2/2) 53 93L-12220 PL5a.13(4/4) 19 96F-83190 PL5a.25 17
12J-67301 PL5a.26(1/2) 11 12J-90980 PL5a.27(2/2) 45 12J-92802 PL5a.27(2/2) 35 93L-13131 PL5a.11 8 96G-11100 PL5a.4(4/4) 14
12J-67340 PL5a.26(1/2) 13 12J-91170 PL5a.27(2/2) 39 12J-92811 PL5a.27(2/2) 36 93X-10220 PL5a.3(1/2) 2 96G-11100 PL5a.8(4/4) 7
12J-67400 PL5a.26(1/2) 14 12J-91430 PL5a.27(1/2) 12 12J-93260 PL5a.13(1/4) 14 93X-10220 PL5a.11 4 96G-11100 PL5a.9(2/3) 18
12J-67410 PL5a.26(1/2) 15 12J-91981 PL5a.8(3/4) 10 12J-93270 PL5a.13(2/4) 1 93X-21380 PL5a.7 2 96G-11100 PL5a.13(3/4) 11
12J-67420 PL5a.26(1/2) 16 12J-91991 PL5a.8(3/4) 11 12J-93281 PL5a.13(3/4) 9 945-12061 PL5a.4(4/4) 12 96G-11100 PL5a.17(1/2) 14
12J-67570 PL5a.26(2/2) 6 12J-92030 PL5a.12(3/3) 13 12J-93330 PL5a.13(3/4) 16 94L-50200 PL5a.3(2/2) 12 96G-11100 PL5a.22(2/3) 2
12J-67580 PL5a.26(2/2) 7 12J-92040 PL5a.12(3/3) 14 12J-93340 PL5a.13(3/4) 15 94L-90320 PL5a.27(1/2) 7 96G-11100 PL5a.22(3/3) 12
12J-67600 PL5a.26(1/2) 23 12J-92052 PL5a.8(1/4) 18 12J-93350 PL5a.22(3/3) 22 94X-20420 PL5a.22(3/3) 20 96G-11110 PL5a.13(1/4) 9
12J-68050 PL5a.27(1/2) 17 12J-92340 PL5a.16(2/4) 14 12K-60180 PL5a.23(1/6) 4 952-14380 PL5a.16(4/4) 11 96G-12640 PL5a.16(1/4) 8
12J-80112 PL5a.24 9 12J-92350 PL5a.16(3/4) 13 12K-60570 PL5a.27(1/2) 18 952-14380 PL5a.18(2/2) 7 96G-12640 PL5a.16(4/4) 3
12J-80370 PL5a.5(3/3) 10 12J-92370 PL5a.16(3/4) 4 12K-80370 PL5a.14(1/2) 19 952-61290 PL5a.7 14 96G-20080 PL5a.17(1/2) 13
12J-82022 PL5a.21 18 12J-92390 PL5a.16(2/4) 15 12K-80370 PL5a.16(1/4) 16 952-61290 PL5a.9(3/3) 2 96G-20080 PL5a.18(2/2) 11
12J-82033 PL5a.20(1/2) 16 12J-92400 PL5a.16(2/4) 2 12K-80370 PL5a.18(1/2) 12 95D-80160 PL5a.16(4/4) 12 96G-20080 PL5a.21 7
12J-82033 PL5a.21 19 12J-92460 PL5a.16(1/4) 3 12K-80370 PL5a.23(2/6) 14 95K-30081 PL5a.23(2/6) 17 96G-20080 PL5a.22(1/3) 19
12J-82140 PL5a.23(6/6) 3 12J-92470 PL5a.16(1/4) 17 12W-80200 PL5a.14(2/2) 13 95L-52171 PL5a.23(2/6) 15 96G-20101 PL5a.22(3/3) 2
12J-82160 PL5a.23(6/6) 13 12J-92490 PL5a.4(2/4) 5 12W-80300 PL5a.26(2/2) 10 95L-52171 PL5a.23(3/6) 3 96G-20120 PL5a.22(1/3) 2
12J-82200 PL5a.23(6/6) 5 12J-92500 PL5a.4(2/4) 6 13D-11140 PL5a.16(2/4) 18 95T-60080 PL5a.15(1/2) 6 96G-20120 PL5a.22(2/3) 1
12J-82220 PL5a.23(6/6) 14 12J-92520 PL5a.4(2/4) 7 91H-11260 PL5a.12(1/3) 17 966-14040 PL5a.9(3/3) 16 96G-22270 PL5a.5(3/3) 11
12J-85301 PL5a.24 7 12J-92550 PL5a.4(2/4) 11 91H-11260 PL5a.18(1/2) 7 966-14040 PL5a.17(1/2) 2 96G-22450 PL5a.1(2/2) 6
12J-86105 PL5a.23(6/6) 1 12J-92570 PL5a.4(2/4) 14 91H-14090 PL5a.20(1/2) 3 96D-12210 PL5a.13(4/4) 18 96G-22450 PL5a.2 7
12J-90021 PL5a.23(1/6) 8 12J-92580 PL5a.4(2/4) 15 91H-51530 PL5a.21 13 96D-22061 PL5a.10(3/3) 7 96G-42440 PL5a.12(3/3) 17

INDEX5a DBM-500
96G-60141 PL5a.3(2/2) 14 98H-57280 PL5a.13(1/4) 13 990-21322 PL5a.23(4/6) 9 99S-52260 PL5a.21 10 - - -
96G-60141 PL5a.20(1/2) 9 98H-57280 PL5a.13(2/4) 11 991-23261 PL5a.23(4/6) 7 99S-56051 PL5a.16(2/4) 3 - - -
96G-60141 PL5a.22(1/3) 13 98H-60350 PL5a.23(1/6) 18 995-13320 PL5a.4(3/4) 12 99S-62870 PL5a.23(4/6) 12 - - -
96G-60220 PL5a.13(3/4) 17 98H-90351 PL5a.11 10 995-13320 PL5a.8(3/4) 16 99S-71141 PL5a.27(1/2) 13 - - -
96G-60230 PL5a.13(2/4) 4 98H-90360 PL5a.11 11 99A-14220 PL5a.26(1/2) 19 99S-83140 PL5a.18(2/2) 12 - - -
96G-60230 PL5a.13(4/4) 7 98H-90370 PL5a.11 12 99A-35120 PL5a.8(1/4) 17 99S-83150 PL5a.7 17 - - -
96G-60230 PL5a.22(3/3) 10 98H-90700 PL5a.11 14 99C-30221 PL5a.1(2/2) 7 99S-83150 PL5a.8(2/4) 11 - - -
96V-11260 PL5a.12(2/3) 3 98H-90710 PL5a.11 15 99C-30221 PL5a.2 8 99S-83160 PL5a.16(1/4) 15 - - -
96Y-13420 PL5a.9(3/3) 1 98H-90881 PL5a.3(2/2) 11 99C-30221 PL5a.5(2/3) 5 99S-91182 PL5a.9(3/3) 15 - - -
96Y-21030 PL5a.4(1/4) 3 98R-23301 PL5a.22(2/3) 14 99C-30221 PL5a.10(1/3) 10 99S-91182 PL5a.16(3/4) 18 - - -
976-51220 PL5a.23(3/6) 7 98R-80230 PL5a.1(2/2) 2 99D-30260 PL5a.20(1/2) 10 99S-91182 PL5a.18(1/2) 3 - - -
97K-80284 PL5a.23(5/6) 2 98R-80230 PL5a.3(2/2) 16 99D-30260 PL5a.21 1 99S-91780 PL5a.23(2/6) 7 - - -
97K-84012 PL5a.23(5/6) 11 98R-80230 PL5a.4(3/4) 23 99D-85060 PL5a.1(2/2) 18 99S-91870 PL5a.23(4/6) 14 - - -
98H-10540 PL5a.5(3/3) 9 98R-80230 PL5a.4(4/4) 22 99D-85060 PL5a.4(4/4) 21 99V-84051 PL5a.23(6/6) 6 - - -
98H-10640 PL5a.1(2/2) 4 98R-80230 PL5a.5(2/3) 21 99D-85060 PL5a.8(4/4) 11 99V-90221 PL5a.14(1/2) 9 - - -
98H-12370 PL5a.3(2/2) 1 98R-80230 PL5a.5(3/3) 12 99D-85060 PL5a.9(1/3) 21 99W-30111 PL5a.1(1/2) 7 - - -
98H-12390 PL5a.3(2/2) 3 98R-80230 PL5a.6 13 99D-85060 PL5a.10(3/3) 6 99W-83010 PL5a.23(5/6) 13 - - -
98H-14500 PL5a.26(1/2) 12 98R-80230 PL5a.8(3/4) 17 99D-85060 PL5a.12(1/3) 21 99W-83110 PL5a.9(1/3) 22 - - -
98H-15590 PL5a.16(3/4) 7 98R-80230 PL5a.9(2/3) 21 99D-85060 PL5a.12(3/3) 25 - - - - - -
98H-16470 PL5a.1(2/2) 11 98R-80230 PL5a.10(1/3) 17 99D-85060 PL5a.13(4/4) 20 - - - - - -
98H-16470 PL5a.5(2/3) 10 98R-80230 PL5a.12(1/3) 22 99E-51570 PL5a.12(2/3) 15 - - - - - -
98H-16470 PL5a.10(1/3) 15 98R-80230 PL5a.12(2/3) 16 99G-72500 PL5a.27(1/2) 8 - - - - - -
98H-20051 PL5a.8(3/4) 7 98R-80230 PL5a.12(3/3) 24 99S-10200 PL5a.1(1/2) 5 - - - - - -
98H-20130 PL5a.7 7 98R-80230 PL5a.13(4/4) 21 99S-10220 PL5a.1(1/2) 8 - - - - - -
98H-20130 PL5a.16(1/4) 14 98R-80230 PL5a.19 16 99S-10230 PL5a.1(2/2) 1 - - - - - -
98H-20300 PL5a.7 4 98R-80230 PL5a.21 17 99S-10230 PL5a.2 11 - - - - - -
98H-20330 PL5a.7 13 98R-80230 PL5a.26(1/2) 10 99S-10730 PL5a.3(1/2) 8 - - - - - -
98H-30120 PL5a.11 7 98X-20050 PL5a.15(2/2) 13 99S-10780 PL5a.3(2/2) 5 - - - - - -
98H-30190 PL5a.11 3 98X-25261 PL5a.22(1/3) 3 99S-19030 PL5a.27(2/2) 38 - - - - - -
98H-30220 PL5a.11 1 98X-40140 PL5a.22(3/3) 9 99S-20310 PL5a.7 11 - - - - - -
98H-43060 PL5a.13(3/4) 1 98X-41520 PL5a.1(2/2) 15 99S-20320 PL5a.7 12 - - - - - -
98H-43060 PL5a.13(3/4) 2 98X-60542 PL5a.22(3/3) 8 99S-32681 PL5a.4(2/4) 18 - - - - - -
98H-44160 PL5a.18(2/2) 6 98X-60651 PL5a.20(1/2) 2 99S-32681 PL5a.9(1/3) 14 - - - - - -
98H-50100 PL5a.19 2 98X-90270 PL5a.27(1/2) 23 99S-32681 PL5a.11 13 - - - - - -
98H-51170 PL5a.3(2/2) 18 98Y-11690 PL5a.26(1/2) 7 99S-32681 PL5a.12(1/3) 20 - - - - - -
98H-52220 PL5a.20(2/2) 8 98Y-32760 PL5a.13(3/4) 8 99S-32681 PL5a.16(1/4) 21 - - - - - -
98H-55340 PL5a.13(2/4) 9 98Y-41240 PL5a.20(2/2) 6 99S-32681 PL5a.16(3/4) 20 - - - - - -
98H-57270 PL5a.13(1/4) 12 98Y-85061 PL5a.26(2/2) 1 99S-45630 PL5a.17(1/2) 3 - - - - - -

INDEX5a DBM-500
PL5b.1 Drive (1/2)

1 12J-71150 BR ACKET 19
2 12J-71160 LEVER
16
20
3 0X4-12040 X COLLAR 10
20
4 0Z4-08018 Z COLLAR 21 10
11 18
6 91H-51521 IDLER UNIT 9
7 12J-71230 SPRING T 17
8 952-61290 ANGLE 18 19
18
9 12J-72240 DRIVE SHAF T T
10 12J-45380 PULLEY C12-40-36 11 18
11 013-00056 COLLAR 11
12 12F-30122 TIMING PULLEY S3M-30-08 1
22
13 013-10024 COLLAR 13
8
14 014-10610 STS BELT 4
3
15 12J-71520 BR ACKET 7
16 12J-72160 LEVER F 18 12
17 12J-72170 LEVER B
11
2 12
18 96G-20080 HOLDER 5
6
20 12J-72280 BELT 14
21 12J-72140 FULCRUM SHAF T
12
22 12F-30270 HOLDER 15
5-156 Section 5—DBM-500/DBM-500BR Parts List DBM-500BR

PL5b.1 Drive
PL5b.1 Drive (2/2)

10 8
2 014-10609 STS BELT
8
3 12J-72010 SHAF T 1 10
4 12J-72070 SHAF T 2 11
5 98X-32100 GEAR 26T 7 17 9
15
6 12J-71370 SHAF T D
14 18
13 19 7
8 12J-71340 BELT
20 1 14
9 12J-71270 DRIVE SHAF T D 12 15
10 12J-45380 PULLEY C12-40-36 13
11 14
11 013-00015 COLLAR 16 5 2
12 12J-72300 SHAF T T 8
13 12J-72280 BELT 10 14
8 15
14 12J-93330 COLLAR UNIT 16
10 6 51
15 96G-20080 HOLDER 14
15
16 98X-20190 WASHER 4 3
18 011-10002 PC WASHER
19 12J-72520 ANGLE
20 12J-72530 SCREW PLATE

PL5b.1 Drive
PL5b.2 Frame

1 12J-71010 FR AME F 20 17
1
2 12J-71030 FR AME B UNIT 21
3 12J-71040 FR AME B
4 12J-71050 EDGING 22
5 12J-71080 STAY 2 16
6 12J-71090 SHAF T 17
7 12J-71110 STAY 4
8 12J-71130 STAY 3 7
9 12J-71570 CONNECTING PLATE 21
10 12J-72400 STAY 1 11 22
11 12J-72370 BR ACKET
12 14 4 2
15 8 3
12 12J-72380 EDGING
13 12J-72360 BR ACKET UNIT 13
14 12J-72500 CONNECTING PLATE 12 11 12
19
15 12J-71440 STAY F 10
16 12J-72420 HINGE
6
17 95L-52170 SHAF T 9
18 12J-72440 TOP COVER 6
5
19 12J-71470 COVER B
20 12J-71450 COVER F
21 950-21320 SHAF T

PL5b.2 Frame
PL5b.3 Paper Receiving

1 12J-77050 PAPER TR AY
SENSOR COVER
9
2 12J-77070 3
20 5
3 016-41968 SLIDE R AIL
13
5 12J-77160 BASE BR ACKET
6 12J-77180 ANGLE 19
STUD 1 68
7 96G-12640
7
8 96G-12651 SPRING,C
9 12J-77220 FIXING ANGLE F 3
10 12J-77230 FIXING ANGLE B
4
11 12J-77260 STOPPER UNIT 22 12
12 12J-77450 KNOB
STOPPER
13 12J-77170
18 11
14 12J-77330 PLATE
10
15 12J-77340 SCREW PLATE
16 011-10042 SPACER
SENSOR COVER
14
17 12J-77370
18 12J-77380 ANGLE UNIT 17
19 12J-77420 BR ACKET 15
20 12J-77430 PILLAR 16
21 12J-77440 DEFLECTOR STRIP 2
22 013-00003 COLLAR

PL5b.3 Paper Receiving
PL5b.4 Accessories

1 x BRIDGE
2 x PAPER RECEIVER
3 12J-77440 FIXING ANGLE F
4 12J-77230 FIXING ANGLE B
6 014-10609 BELT
7 12J-71570 CONNECTING PLATE
5 6 7 8
8 12J-71500 ANGLE
9 12J-77440 DEFLECTOR STRIP
10 12J-78050 PROTECTION GUIDE
11 x BR ACKET
12 11K-30120 GEAR
13 x PIN 9 10 11 12 13
14 x E-RING (S)
15 x E-RING (L)
16 013-00056 COLLAR
17 x SCREW MSKW4x8
18 x SCREW SBT4x8 14 15 16 17 18 19 20
19 x SCREW HSK5x10
20 x SIDE STITCHING STOPPER
21 12J-93550 STICKER
22 12J-93600 STICKER
23 99S-92030 STICKER 21 22 23 24 25
24 12J-93580 INSTRUCTION MANUAL
INSTALLATION MANUAL
25 12J-93590 INSTALLATION MANUAL

PL5b.4 Accessories
INDEX5b DBM-500BR
011-10002 PL5b.1(2/2) 18 12J-71470 PL5b.2 19 12J-77420 PL5b.3 19 - - - - - -
011-10042 PL5b.3 16 12J-71500 PL5b.4 8 12J-77430 PL5b.3 20 - - - - - -
013-00003 PL5b.3 22 12J-71520 PL5b.1(1/2) 15 12J-77440 PL5b.3 21 - - - - - -
013-00015 PL5b.1(2/2) 11 12J-71520 PL5b.4 5 12J-77440 PL5b.4 3 - - - - - -
013-00056 PL5b.1(1/2) 11 12J-71570 PL5b.2 9 12J-77440 PL5b.4 9 - - - - - -
013-00056 PL5b.4 16 12J-71570 PL5b.4 7 12J-77450 PL5b.3 12 - - - - - -
013-10024 PL5b.1(1/2) 13 12J-72010 PL5b.1(2/2) 3 12J-78050 PL5b.4 10 - - - - - -
014-10609 PL5b.1(2/2) 2 12J-72070 PL5b.1(2/2) 4 12J-93330 PL5b.1(2/2) 14 - - - - - -
014-10609 PL5b.4 6 12J-72140 PL5b.1(1/2) 21 12J-93550 PL5b.4 21 - - - - - -
014-10610 PL5b.1(1/2) 14 12J-72160 PL5b.1(1/2) 16 12J-93580 PL5b.4 24 - - - - - -
016-41968 PL5b.3 3 12J-72170 PL5b.1(1/2) 17 12J-93590 PL5b.4 25 - - - - - -
0X4-12040 PL5b.1(1/2) 3 12J-72240 PL5b.1(1/2) 9 12J-93600 PL5b.4 22 - - - - - -
0Z4-08018 PL5b.1(1/2) 4 12J-72280 PL5b.1(1/2) 20 91H-51521 PL5b.1(1/2) 6 - - - - - -
11K-30120 PL5b.4 12 12J-72280 PL5b.1(2/2) 13 92G-91130 PL5b.1(2/2) 17 - - - - - -
11K-30361 PL5b.1(2/2) 7 12J-72300 PL5b.1(2/2) 12 950-21320 PL5b.2 21 - - - - - -
12F-30122 PL5b.1(1/2) 12 12J-72360 PL5b.2 13 952-61290 PL5b.1(1/2) 8 - - - - - -
12F-30122 PL5b.1(2/2) 1 12J-72370 PL5b.2 11 95L-52170 PL5b.2 17 - - - - - -
12F-30270 PL5b.1(1/2) 22 12J-72380 PL5b.2 12 96G-12640 PL5b.3 7 - - - - - -
12J-36220 PL5b.1(1/2) 19 12J-72400 PL5b.2 10 96G-12651 PL5b.3 8 - - - - - -
12J-45380 PL5b.1(1/2) 10 12J-72420 PL5b.2 16 96G-20080 PL5b.1(1/2) 18 - - - - - -
12J-45380 PL5b.1(2/2) 10 12J-72440 PL5b.2 18 96G-20080 PL5b.1(2/2) 15 - - - - - -
12J-71010 PL5b.2 1 12J-72500 PL5b.2 14 976-51220 PL5b.2 22 - - - - - -
12J-71030 PL5b.2 2 12J-72520 PL5b.1(2/2) 19 98X-20190 PL5b.1(2/2) 16 - - - - - -
12J-71040 PL5b.2 3 12J-72530 PL5b.1(2/2) 20 98X-32100 PL5b.1(2/2) 5 - - - - - -
12J-71050 PL5b.2 4 12J-77050 PL5b.3 1 99S-92030 PL5b.4 23 - - - - - -
12J-71080 PL5b.2 5 12J-77070 PL5b.3 2 - - - - - - - - -
12J-71090 PL5b.2 6 12J-77110 PL5b.3 4 - - - - - - - - -
12J-71110 PL5b.2 7 12J-77160 PL5b.3 5 - - - - - - - - -
12J-71130 PL5b.2 8 12J-77170 PL5b.3 13 - - - - - - - - -
12J-71150 PL5b.1(1/2) 1 12J-77180 PL5b.3 6 - - - - - - - - -
12J-71160 PL5b.1(1/2) 2 12J-77220 PL5b.3 9 - - - - - - - - -
12J-71190 PL5b.1(1/2) 5 12J-77230 PL5b.3 10 - - - - - - - - -
12J-71230 PL5b.1(1/2) 7 12J-77230 PL5b.4 4 - - - - - - - - -
12J-71270 PL5b.1(2/2) 9 12J-77260 PL5b.3 11 - - - - - - - - -
12J-71340 PL5b.1(2/2) 8 12J-77330 PL5b.3 14 - - - - - - - - -
12J-71370 PL5b.1(2/2) 6 12J-77340 PL5b.3 15 - - - - - - - - -
12J-71440 PL5b.2 15 12J-77370 PL5b.3 17 - - - - - - - - -
12J-71450 PL5b.2 20 12J-77380 PL5b.3 18 - - - - - - - - -

INDEX5b DBM-500BR
PL5c.1 Motor
ITEM PART # DESCRIPTION SYMBOL 1 1 1 1 2

M501, M505, M506, (M507) (M508) (M506) (M501) (M502)
1 99D-85060 STEPPING MOTOR M507, M508, M509,
M510, M511, M512
2 11S-83100 DC BRUSHLESS SERVO MOTOR M502

3 11K-83250 STEPPING MOTOR M503, M504
1
4 12D-82050 MOTOR,DC UNIT M513 (M512)
5 98Y-85061 AC MOTOR M514
1
(M509)
3
(M503)
3
(M504)
4
1
(M513)
(M505) 1 1
5
(M514) (M510) (M511)

PL5c.1 Motor
PL5c.2 Sensor

PS503, PS504, PS505, (PS523) 1
PS506, PS507, PS509, (PS525) (PS524)
PS510, PS511, PS512, (PS526) 1
1 98R-80230 INT.SENSOR PS513, PS514, PS517, 1 3 (PS503)
PS518, PS519, PS520, (PS517)
PS521, PS523, PS524, (PS508)
PS525, PS526, PS527, 2 3
PS528 (SSW501) (PS501)
2 93E-83150 MAGNET SENSOR SSW501, SSW502 1
(PS509)
PS501, PS502, PS508,
PS522, PS515
1 (PS505)
4 062-11162 INT.SENSOR PS516 3
(PS521)
(PS502)
1
(PS510) 2
1 (SSW502)
(PS514)
3 1
(PS515) (PS506)
1 1
(PS513) (PS504)
3
(PS522)
1
(PS507)
1
(PS528)
4 1
(PS516) (PS527)
1
1 (PS520)
1
(PS511) 1
(PS512) 1 1
(PS519) (PS518)
(PS507)

PL5c.2 Sensor
PL5c.3 Solenoid, Brake, Clutch
ITEM PART # DESCRIPTION SYMBOL 4 5

1 11G-82602 FEED CLUTCH-C CL501 (SL504) (SL503)
2 99S-83140 DC-SOL UNIT SL506
3 99W-83110 DC-SOLENOID SL505 3
4 95D-80160 DC,SOLENOID SL504 (SL505)
5 99S-83160 DC-SOL SL503
6* 12J-80370 ELECTRO MAGNETIC BR AKE (for 220-240[V]) BRK501 2
(SL506)
7** 96F-81012 ELECTRO MAGNETIC BR AKE (for 120[V]) BRK501
8 99S-83150 DC-SOLENOID SL501, SL502 1

9 12J-82012 ELECTROMAGNETIC CLUTCH CL502 (CL501)
10 12J-82033 ELECTROMAGNETIC BR AKE BRK502, BRK503
11 12J-82022 ELECTROMAGNETIC CLUTCH CL503
NOTE:
10
(BRK502)
11
(CL503)
6,7
(BRK501)
8
8 (SL502)
(SL501)
10
(BRK503)
9
(CL502)

PL5c.3 Solenoid,Brake,Clutch
PL5c.4 Miscellaneous (1/2)

1
1 11C-84100 INTERLOCK SWITCH SSW504, SSW505 2 (SSW504) 2 (PCB503)
2 054-10324 ACTUATER
3 11A-80253 RL P.W.B UNIT PCB503
4 12J-80211 DPIF P.W.B.UNIT
6* 056-10254 OUTLET (for 220-240[V]) 1
(SSW505) 4
7** 056-05001 OUTLET (for 120[V])
8 052-10013 NOISE FILTER 5
9 057-10053 SWITCHING POWER SUPPLY PCB504
6,7
NOTE: 8
** Unique part for 120[V] (PCB504)
6,7

PL5c.4 Miscellaneous
PL5c.4 Miscellaneous (2/2)

1 99W-83010 COUNTER UNIT CNT501, CNT502 (PCB501) 3 4,5
2 12J-86105 MC UNIT PCB501 (SSW503)
3 054-10304 SWITCH SSW503 7
4* 97K-80284 POWER CORD UNIT (for 220-240[V])
5** 97K-84013 POWER CORD UNIT (for 120[V])
1
(CNT501)
6 054-10268 SWITCH PSW501 6
1
7 12J-80112 KEYP.W.B.UNIT (CNT502) (PSW501)
8 12W-80201 FAN
9 11A-81390 ISOLATION BOARD PCB502
10* 12J-82200 REACTOR UNIT (for 220-240[V])
8
11** 12J-82220 REACTOR UNIT (for 120[V])
12* 12J-82140 MOTOR DRIVER (for 220-240[V])
13** 12J-82160 MOTOR DRIVER (for 120[V])
14 053-90030 RELAY RL501, RL502
15 99V-84051 LIMIT SWITCH UNIT SSW506
NOTE:
9
(PCB502)
10,11
12,13
14 14
15 (RL502)
(RL501)
(SSW506)

PL5c.4 Miscellaneous
PL5c.5 Wiring (1/4)

1 12J-83233 WIRE HARNESS-7
5 12J-83033 WIRE HARNESS-2,AC
6
11 12W-80300 MOTOR EARTH WIRE
7
1 3
8
11 10 9

PL5c.5 Wiring
PL5c.5 Wiring (2/4)

2 3 4 1
4 98H-80232 DC HARNESS UNIT 5

PL5c.5 Wiring
PL5c.5 Wiring (3/4)

6 96F-82650 COPPER WIRE UNIT 1 7

PL5c.5 Wiring
PL5c.5 Wiring (4/4)
ITEM PART # DESCRIPTION 3 4 5 6 7

8
9
7 98H-80220 CORD UNIT 1
8 11C-83363 SAFETY INTERFACE HARNESS
9 11C-83374 E-PORT HARNESS
10
1
14 96F-83190 GROUND LINE
13
15 14

PL5c.5 Wiring
INDEX5c DBM-500/DBM-500BR
052-10013 PL5c.4(1/2) 8 12J-83174 PL5c.5(3/4) 5 99S-83140 PL5c.3 2 - - - - - -
053-90030 PL5c.4(2/2) 14 12J-83174 PL5c.5(4/4) 6 99S-83150 PL5c.3 8 - - - - - -
054-10268 PL5c.4(2/2) 6 12J-83182 PL5c.5(3/4) 7 99S-83160 PL5c.3 5 - - - - - -
054-10304 PL5c.4(2/2) 3 12J-83193 PL5c.5(4/4) 4 99V-84051 PL5c.4(2/2) 15 - - - - - -
054-10324 PL5c.4(1/2) 2 12J-83210 PL5c.5(1/4) 2 99W-83010 PL5c.4(2/2) 1 - - - - - -
054-10338 PL5c.4(1/2) 5 12J-83210 PL5c.5(3/4) 2 99W-83110 PL5c.3 3 - - - - - -
056-05001 PL5c.4(1/2) 7 12J-83210 PL5c.5(4/4) 2 - - - - - - - - -
056-10254 PL5c.4(1/2) 6 12J-83233 PL5c.5(1/4) 1 - - - - - - - - -
057-10053 PL5c.4(1/2) 9 12J-83233 PL5c.5(3/4) 1 - - - - - - - - -
062-11162 PL5c.2 4 12J-83233 PL5c.5(4/4) 1 - - - - - - - - -
11A-80253 PL5c.4(1/2) 3 12J-83251 PL5c.5(4/4) 3 - - - - - - - - -
11A-81390 PL5c.4(2/2) 9 12J-83270 PL5c.5(4/4) 15 - - - - - - - - -
11C-83363 PL5c.5(4/4) 8 12J-83294 PL5c.5(2/4) 3 - - - - - - - - -
11C-83374 PL5c.5(4/4) 9 12J-83313 PL5c.5(4/4) 13 - - - - - - - - -
11C-84100 PL5c.4(1/2) 1 12J-83333 PL5c.5(4/4) 12 - - - - - - - - -
11G-82602 PL5c.3 1 12J-83374 PL5c.5(2/4) 2 - - - - - - - - -
11K-83250 PL5c.1 3 12J-83393 PL5c.5(2/4) 5 - - - - - - - - -
11S-83100 PL5c.1 2 12J-83410 PL5c.5(4/4) 11 - - - - - - - - -
12D-82050 PL5c.1 4 12J-83430 PL5c.5(3/4) 4 - - - - - - - - -
12J-80112 PL5c.4(2/2) 7 12J-83430 PL5c.5(4/4) 5 - - - - - - - - -
12J-80211 PL5c.4(1/2) 4 12J-83453 PL5c.5(1/4) 4 - - - - - - - - -
12J-80370 PL5c.3 6 12J-83532 PL5c.5(1/4) 8 - - - - - - - - -
12J-82012 PL5c.3 9 12J-86105 PL5c.4(2/2) 2 - - - - - - - - -
12J-82022 PL5c.3 11 12K-80370 PL5c.2 3 - - - - - - - - -
12J-82033 PL5c.3 10 12W-80201 PL5c.4(2/2) 8 - - - - - - - - -
12J-82140 PL5c.4(2/2) 12 12W-80300 PL5c.5(1/4) 11 - - - - - - - - -
12J-82160 PL5c.4(2/2) 13 93E-83150 PL5c.2 2 - - - - - - - - -
12J-82200 PL5c.4(2/2) 10 95D-80160 PL5c.3 4 - - - - - - - - -
12J-82220 PL5c.4(2/2) 11 96F-81012 PL5c.3 7 - - - - - - - - -
12J-83013 PL5c.5(1/4) 6 96F-82650 PL5c.5(3/4) 6 - - - - - - - - -
12J-83033 PL5c.5(1/4) 5 96F-83190 PL5c.5(4/4) 14 - - - - - - - - -
12J-83054 PL5c.5(1/4) 7 97K-80284 PL5c.4(2/2) 4 - - - - - - - - -
12J-83112 PL5c.5(1/4) 9 97K-84013 PL5c.4(2/2) 5 - - - - - - - - -
12J-83131 PL5c.5(1/4) 10 98H-80220 PL5c.5(4/4) 7 - - - - - - - - -
12J-83156 PL5c.5(1/4) 3 98H-80232 PL5c.5(2/4) 4 - - - - - - - - -
12J-83156 PL5c.5(2/4) 1 98R-80230 PL5c.2 1 - - - - - - - - -
12J-83156 PL5c.5(3/4) 3 98Y-85061 PL5c.1 5 - - - - - - - - -
12J-83156 PL5c.5(4/4) 10 99D-85060 PL5c.1 1 - - - - - - - - -
5-171 Section 5—DBM-500/DBM-500BR Parts List DBM-500/DBM-500BR

INDEX5c DBM-500/DBM-500BR
PL6.1 Upper Section of Conveyance Entrance
(1/2)

1 011-10061 WASHER
2 96G-11111 HOUSING 16
3 96G-11140 SPRING,C 20
4 12K-10320 BR ACKET 18 16
5 17
5 99W-10332 COLLAR UNIT 19 6 8
6 94T-10430 SHAF T
5 7
7 99W-10371 BR ACKET 17
6 8
8 0Y4-08022 Y COLLAR 4
7
9 12K-10412 SHAF T
8 8 15
10 99W-10420 PLATE 4
11 99W-10430 SHAF T
13 9
15 PN4
12 99W-10442 COLLAR UNIT
9 14
13 99W-10500 LEVER 10
13 PN4
14 99W-10510 PLATE, SCREW 14 11
12
15 99S-32681 KNOB SCREW 10
16 99W-10570 SHAF T UNIT 3
21 11
17 99W-10590 SPRING-C
2 12
18 99W-10610 JOINT UNIT
19 99W-10620 JOINT
20 99W-10630 SPRING C 1
21 013-10036 COLLAR
5-172 Section 5—Parts List DBM-500T

(2/2)

16
1 12K-10051 BR ACKET
12
2 12K-10060 SHAF T
3 93L-11850 COLLAR
4 11A-42321 ROLLER
5 12K-10090 PULLEY
6 12K-10241 SHAF T
14
7 12K-10120 FLAT BELT 17
15
8 12K-10100 PULLEY
9 96G-11060 COLLAR
10 93X-20050 PULLEY, RUBBER
11 12K-10470 FLAT BELT
12 12K-10730 BR ACKET
13 96G-25181 JOINT 13
4
14 12K-10691 SHAF T 1 3
15 94T-10111 GEAR
16 013-00081 COLLAR 9 43
17 013-10024 COLLAR 10
9
9
8 11
99 5
10
6 2 7
9
11

PL6.2 Lower Section of Conveyance Entrance
(1/2)

1 12K-11031 GUIDE BASE
9 C
2 952-61290 ANGLE
3 12K-11120 SHAF T UNIT 10
4 96D-12080 PULLEY C
5 013-10024 COLLAR 8
6 014-10429 STS BELT 6
7 12K-11230 SHAF T B 12
7 3
8 12K-90980 BR ACKET 2 4
14
9 99W-11314 GUIDE PLATE 11
13
10 98H-45521 ANGLE
11 99W-11330 PILLAR 14 A
12 14 15 5
12 94T-91671 ROLLER UNIT
13 99W-11570 BR ACKET
14 93E-40090 COLLAR
1
15 12K-11600 ANGLE
10

(2/2)

1 12K-11050 SHAF T UNIT
2 93X-20050 PULLEY, RUBBER
3 12K-80360 CLUTCH UNIT
4 91H-11260 COLLAR
5 99W-11100 BR ACKET
6 96D-12080 PULLEY
7 94T-10111 GEAR
16
8 013-00056 COLLAR 3
14 11
9 96G-20080 HOLDER
12
13
10 99W-11361 FLAT BELT(SIEGLING U10W) 15
11 99W-11400 BR ACKET 7 17
12 94T-90944 CLUTCH BOSS UNIT 9
13 945-12151 TIMING GEAR
8
14 94T-90931 COLLAR
6
15 93A-40181 PLATE
2 1
16 013-10024 COLLAR 2
17 056-00464 BUSHING
10
10 4
4 A

PL6.3 Waste Gate Section

1 12K-12031 FLAP
2 12K-12041 BLOCK
3 98X-41390 LINK 2
1
4 12K-12060 SPRING T
5 98H-32160 LINK
7 99W-12110 BASE, DC-SOL
4
2
9 99W-83110 DC-SOLENOID
2
5
6
3
8 7
9

PL6.3 Waste Gate Section
PL6.4 Cutter Section (1/2)

1 99W-20050 FR AME L
12
13
2 94T-20160 SHAF T
11
3 99W-20103 UPPER BLADE BASE UNIT 13 8
10
4 99W-20141 UPPER BLADE
5 12K-20150 HOLDING PLATE 7
6 99W-20190 PUSHER 12 8
10 6
7 99W-20200 SPRING-C
8 94T-20220 PLATE 7
9
9 99W-20221 PLATE
6 4
10 99W-20231 ANGLE
5
11 99W-20260 GUIDE 3
17
12 96G-71120 SPACER 16
13 0Y4-08022 Y COLLAR
17
14 99W-20310 HOUSING L
15 013-10018 SLIDE BUSH
15 1
16 99W-20420 ANGLE
17 99W-20440 ANGLE
14
15
2

PL6.4 Cutter Section
PL6.4 Cutter Section (2/2)

1 99W-20040 FR AME R
2 99W-20060 STAY
3 94T-20160 SHAF T
4 99W-20160 BR ACKET UNIT
6 99W-20180 GUIDE
7 99W-20300 HOUSING R
2
8 013-10018 SLIDE BUSH
3
9 12K-20340 LOWER BLADE BASE 8
10 99W-20351 LOWER BLADE
11 99W-20360 PLATE,SPRING
7
1 8
56
11 4
10
2 9

PL6.4 Cutter Section
PL6.5 Paper Scraps Holder Section

1 12K-21040 PAPER SCR APS HOLDER 21 12
2 12K-21051 PLATE
3 12K-21061 ACRYLIC PLATE
4 12K-21070 SLIDE BASE
19
11
9
6 93E-50670 GUIDE PLATE
7 990-21330 SLIDE PLATE
18
8 12K-21150 GUIDE PLATE
10
9 93A-20500 ANGLE
10 12K-21170 SCERW PLATE 13
9
11 12K-21200 BR ACKET 13
12 99W-21220 PLATE 17
13 99W-21260 BR ACKET
14 12K-21290 BR ACKET UNIT 5
20
15 12K-21300 BR ACKET
3
16 12K-21310 RUBBER MAGNET
17 95K-80063 PH P.W.B UNIT 9
9
18 95K-80083 LED P.W.B UNIT 6
19 11C-84100 INTERLOCK SWITCH 7 4 22 1 9 16 15
20 054-10324 ACTUATER
21 12F-83210 EDGING
2 3 4 14
22 12K-21110 ACRYLIC PLATE ASSY

PL6.5 Paper Scraps Holder Section
PL6.6 Fan Section

18
2 12K-28041 GUIDE 1 UNIT
19 1
3 99D-83511 EDGING H
14
4 12K-28060 GUIDE 1
5 12K-28070 GUIDE 2 16
6 12K-28080 GUIDE 3
7 12K-28090 GUIDE 4 17
15
8 12K-28151 BR ACKET 10
9 12K-28140 GUIDE 1 UNIT 4
10 12F-42040 CUSHION
11 12K-28160 GUIDE 1 7
12 12K-28170 GUIDE 2
13 12K-28180 GUIDE 3
6 5 2
14 11A-80400 DC FAN UNIT
8
15 12K-28220 ANGLE 15 7
14 4 10
16 96G-85510 EDGING
10
17 12K-28100 BR ACKET
18 12K-28111 BR ACKET 11
19 12K-28121 BR ACKET
9
3 13
10 11 12

PL6.6 Fan Section
PL6.7 Stopper Moving Section (1/2)

19
1 013-00003 COLLAR 18 3
2 95D-10180 PULLEY
17
22
3 12K-30190 MOVING BR ACKET
4 12K-30200 ANGLE 23 23
A 21
5 98H-14500 ANGLE
6 013-10024 COLLAR
2 16 4
7 12K-30360 BLACKET 9 5
8 12K-30400 SHAF T UNIT 6
11
9 98H-10640 COLLAR 1
15
10 94K-23151 TIMING PULLEY 10 12
13
11 014-10489 BELT 7 14
12 99W-30670 BR ACKET A
13 99W-30690 PIN, CENTER
8
14 91H-51530 IDLER
6
15 013-00003 COLLAR
16 12K-30581 PH BR ACKET
17 12K-30610 SET SCREW
18 12K-30620 PILLAR
19 12K-30630 PLATE
20 011-10047 KNOB STAR
21 12K-30670 PILLAR
22 12K-30680 KNOB SCREW
23 98R-80230 INT.SENSOR

PL6.7 Stopper Moving Section
PL6.7 Stopper Moving Section (2/2)

1 12K-30030 STAY
2 99W-30040 SHAF T
3 12K-30051 PLATE
4 12K-30060 BLOCK UNIT
A
5 12K-30111 SCREW
6 99W-30120 SCREW SHAF T
7 013-00003 COLLAR
8 96G-22450 COLLAR 17
9 12K-30182 MOVING BASE
4
10 99W-30210 PLATE
11 0Z4-08062 Z COLLAR 3
12 12K-30230 PLATE A 6 2
1
13 12K-30250 SENSOR BR ACKET
15 5
14 12K-30290 PLATE 9
4
15 12K-30340 MOTOR BR ACKET 16 3
16 12J-15270 WORM GEAR 18 2
17 12K-30700 COVER 10
19 12K-80370 INT.SENSOR 19 13 78
14 1
10
12
11

PL6.7 Stopper Moving Section
PL6.8 Stopper Section

14 15
1 12K-31032 STOPPER
2 99W-31053 BLOCK
5
3 99W-31091 COVER
4 99W-31101 SHAF T UNIT 7
5 015-10013 O RING 10 6 4
6 12K-31120 SHAF T UNIT 12 9
7 95T-60080 COLLAR
8 99W-31212 ANGLE
13
9 952-61290 ANGLE 3 2
10 98H-22250 SPRING T
7 8
11 952-14380 ANGLE
11
12 98H-20140 LINK
13 0Z4-08022 Z COLLAR 5
14 99S-83150 DC-SOLENOID 3
15 12K-31191 ANGLE 4 16
16 013-10050 SLIDE-BEARING 1
17
17 99W-31070 PLATE
16
17 2

PL6.8 Stopper Section
PL6.9 Press Section

19 3 2122 A
1 99W-32052 SLIDE BLOCK UNIT 20 7
11
2 013-00015 COLLAR 19 1 16
3 99W-32101 SHAF T
18 2 5 10 15 9 14
17 4 8 13
4 12K-32123 PRESS BAR 18
3
5 99W-32160 R AIL 15
6 16
6 99W-32171 SHAF T HOLDER A
1
7 99W-32180 ANGLE 11
8 99W-32190 PLATE 2 8
12
9 013-00003 COLLAR
7
10 99W-32240 SLIDE SHAF T 11
11 99W-32301 BUSH HOLDER UNIT 16 21 7
22 2221
12 12K-32352 SPRING T
10 2221
13 12K-32370 PILLAR 7 5
14 12K-32380 COLLAR-C 012-14-160
15 12K-32390 PLATE
8
16 99W-92040 ANGLE
15 12
17 12K-32510 PLATE 9
18 12K-32520 PIN
6
19 12K-32531 BLOCK 14 13
20 12K-32540 ANGLE 15 8
21 013-00137 COLLAR 16 11
22 12K-32211 COLLAR-C 080-12-060

PL6.9 Press Section
PL6.10 Upper Section of Conveyance Exit (1/3)

9 11
1 12K-40211 COVER
2 12K-40260 SHAF T 16 3 8
3 93X-20050 PULLEY, RUBBER 9
16 17 15
4 94T-10111 GEAR 14
5 013-00056 COLLAR 9 3 15 5
6
8 13
14 15
6 96G-20080 HOLDER
7
7 12K-40560 SHAF T 15
2
8 99W-40570 SPRING-T 3 13
9 95K-30081 ROLLER UNIT
10 12K-40620 ANGLE 12
13
11 952-14380 ANGLE
12 12K-40660 SHAF T
13 11G-40620 ROLLER UNIT
10
1
14 12K-40721 BR ACKET 5
15 96G-11060 COLLAR
16 12K-40750 SPRING-T
17 952-61290 ANGLE 6
4

PL6.10 Upper Section of Conveyance Exit

1 12K-40041 ANGLE L
2 12K-40140 SHAF T
6 12K-40380 MOTOR BR ACKET
7 99V-30781 WORM M1-R-2-05
10 96F-10280 SPRING,C
4
12 12K-90870 R AIL L
7
13 4 6
13 9 11 8
13
3 10
2 5
B
A 3
5
12
3 1
2 5


2 12K-40051 ANGLE R
3 12K-90880 R AIL R
4 12K-90890 ANGLE
5 12K-90900 PILLAR
6 013-00091 COLLAR
8 013-10024 COLLAR
8
9 12K-40400 SCREW SHAF T UNIT
10 12K-90950 BR ACKET 7 13 17
11 12K-40461 SCREW 9 14
12 12K-40470 SENSOR PLATE
13 12K-40480 PH ANGLE B
14 12K-90960 PLATE
14
15 12K-40510 SHAF T 1 16 2
8
16 12K-40520 SPRING C 16 15 56 3
17 98R-80230 INT.SENSOR 20
15 18 18 6
18 12K-90910 BR ACKET 20 5
5 A 19 4
19 12K-90920 PILLAR 6 19
5 6
20 011-10006 PC WASHER 6
4 12
6
10 11

PL6.11 Lower Section of Conveyance Exit (1/3)

2 12K-41070 SHAF T
4 12K-41142 GUIDE-1
5 12K-41152 GUIDE-2
6 12K-41162 GUIDE-3
7 99W-41171 BELT GUIDE
4
8 12K-41181 STAY 7
9 94T-10111 GEAR 5
7
10 12K-41450 HOLDER UNIT 8
5
11 12K-41480 BR ACKET 7
14 12K-40560 SHAF T
1 13
15 12K-41870 SHAF T 3 13
16 99W-40570 SPRING-T 8 1 13
14
17 12K-40620 ANGLE 3 12
9 16 1 12
10 2 12
11 12 12
17 13
12 13
15 13

PL6.11 Lower Section of Conveyance Exit

1 12K-41221 SHAF T
8
2 93X-20050 PULLEY, RUBBER 3
5
9 3
4 12K-41591 BR ACKET 5 4
10
5 12K-41600 SHAF T 7 11
3 10
6 12K-41611 SHAF T 5 10
7 12K-41670 SPRING T 7 11
4 2
8 12K-41653 GUIDE 1010
11 2
9 12K-41680 SHAF T 4 1
10 2
10 93E-23130 COLLAR 6
11 12K-41630 HOSE


1 12K-30051 PLATE
1
2 013-00056 COLLAR
14 10
6 75
4 96G-20080 HOLDER 8
3
5 94T-90944 CLUTCH BOSS UNIT 2 4
6 945-12151 TIMING GEAR 9 15 11
7 94T-90931 COLLAR 12 15
8 93A-40181 PLATE
9 99W-41350 BR ACKET 13
10 013-10024 COLLAR
1
11 12K-41791 BR ACKET
12 99W-40570 SPRING-T
13 952-14380 ANGLE
14 12K-80360 CLUTCH UNIT

PL6.12 Main Driving Section (1/2)

19 1,16 7
1+ 12K-50023 PULLEY (for 50[Hz]) 7
2 014-10279 V-BELT(BANDO A-26) 2
18
3 12K-50060 ANGLE
4 12K-50072 BASE
3 13,20
5 12K-50080 COVER
6 12K-50093 COVER 14
7 945-30030 PLATE
10 10
8 12K-50130 PLATE
9
9 12K-50200 21N SPROCKET 9
10 014-10525 ROLLER CHAIN 11
11 99W-50280 19N SPROCKET UNIT 12
6
13 * 99S-81472 MOTOR UNIT (for 220-240[V])
14 12K-82014 CLUTCH BR AKE
15 12W-80201 FAN 4 8
15
16 ++ 12K-50033 PULLEY (for 60[Hz])
17 12K-50150 COVER
18 014-00263 BELT(BANDO 150XL037G) 17
19 96G-60040 TIMING PULLEY
20 ** 99S-81512 MOTOR UNIT (for 120[V])
5
NOTE:
+ Unique part for 50[Hz]
++ Unique part for 60[Hz]

PL6.12 Main Driving Section
PL6.12 Main Driving Section (2/2)

1 12F-30122 TIMING PULLEY 1
2+ 93E-30040 TIMING GEAR (for 50[Hz]) 4 13
3 12K-50591 SHAF T 78
12
4 12K-50600 GEAR 6
5 013-00081 COLLAR 5 11 13
6 98X-41400 SET-COLLAR 2,9
10
7 12K-50540 GEAR
8 12K-50451 BOSS
9 ++ 94K-23151 TIMING PULLEY (for 60[Hz])
10 12K-50532 SHAF T
11 12K-50522 BR ACKT
12 98Y-32260 KEY 4X4
13 12K-50550 COLLAR UNIT
NOTE:
+ Unique part for 50[Hz]
++ Unique part for 60[Hz]

PL6.12 Main Driving Section
PL6.13 Conveyance Driving Section

1 95K-20012 TIMING PULLEY XL-15-10
14
2 014-00136 BELT(BANDO 120XL037G)
3 98X-50240 24 XL PULLEY
4 12K-51500 BR ACKET 13
5 12K-51121 SHAF T 3
6 013-00056 COLLAR 7
8
7 013-10024 COLLAR
19
9 94T-51120 PULLEY UNIT 17
18
10 99W-51230 PIN, CENTER 19
4
11 91H-51521 IDLER UNIT 6 11
12
13 014-10523 BELT(BANDO 564XL037G)
14 014-10309 BELT(BANDO 390XL037G) 5 11
12
15 12H-81010 DC MOTOR 3
16 12K-51070 PLATE 2
17 014-10620 STS BELT(BANDO 100S3M192S) 9 15
10
18 12K-51430 TIMING PULLEY UNIT
1
16

PL6.13 Conveyance Driving Section
PL6.14 Cutter Driving Section

1 99W-52040 26N SPROCKET 19 10
16
2 99W-52060 KEY
3 99W-52110 SHAF T 22 13
4 99W-52120 CR ANK 10 21 17
5
5 99W-52130 KEY 14 2
13 16
6 93A-50250 HOUSING
8 9
7 013-00071 COLLAR
8 94T-50480 COLLAR 3
9 94T-20470 SHAF T 5
20
10 013-10019 ROD END BEARING
9 1 11
11 99W-52230 COLLAR 6 4
7
12 99W-52240 SCREW 4 7 12
13 99W-52250 COVER 18 6
10
14 94T-50490 SCREW
15 12K-52290 SENSOR PLATE
8 23 8
16 12K-52300 INDEX DISC 11 23
17 12K-52310 BOSS 10
12
18 12K-52350 PH BR ACKET
19 99W-52380 STAY
20 94T-50440 ANGLE
21 94T-50450 FIXED PLATE
22 013-00163 COLLAR

PL6.14 Cutter Driving Section
PL6.15 Press Driving Section

1 99W-53030 BOSS 7
8
2 99W-53040 26N SPROCKET 5
3 99W-52060 KEY
6
4 99W-53100 SHAF T
5 99W-53110 FLANGE UNIT 14
13
6 94T-50480 COLLAR
7 94T-50700 CAM 11
8 99W-53181 BOSS
9 99W-52130 KEY
10 12K-32420 SCCENTRIC BOSS
11 12K-32450 LINK
12 12K-32360 PILLAR 6
13 013-00056 COLLAR 5
8
14 96G-20080 HOLDER 7 9
10
3
4
12 9
11 1
13 2
14

PL6.15 Press Driving Section
PL6.16 Belt Stacker Section

1 12K-54011 BR ACKET 14
2 99W-54020 BLOCK
21
3 013-00003 COLLAR 5
16 4
4 95D-10180 PULLEY 3
8 2
7
5 99W-54051 SHAF T
6 99W-54061 SCREW SHAF T 6 8 16 15
7 99W-54113 DIAL 13 17
8 99W-54131 BUSH
9 99W-54140 BR ACKET 15 18 1
18 19
10 12K-54150 BR ACKET 19
9
11 12K-54160 BR ACKET
12
12 12K-54170 SCREW
13 99S-32681 KNOB SCREW 12
14 12K-54200 COVER
15 0Z4-08031 Z COLLAR 20
16 98X-41520 SPACER
11
17 12K-54250 BR ACKET UNIT
18 12K-54260 RUBBER PLATE
10
19 12K-54270 BR ACKET
21 99W-54070 SHAF T COUPLING

PL6.16 Belt Stacker Section
PL6.17 Frame Section (1/3)

1 12K-60053 FR AME-L 4
2 12
2 12K-60065 FR AME-R
3 12K-60141 BR ACKET 10
16 9
6 950-21320 PILLAR 14
7 12K-60340 C BASE 6
8
8 12K-60390 SW BR ACKET UNIT 6
15 5
9 11A-32420 SPRING TO 17
10 92L-53190 ACTUATER
5
11 12K-60450 SW ANGLE UNIT
12 99W-60511 BR ACKET 3
5 7
13 ** 96F-60160 CONNECTOR PLATE (for 120[V]) 6 10
14 054-10400 MINIATURE SWITCH 14
18
15 * 056-10254 OUTLET (for 220-240[V]) 8 5 13
9 11
16 99J-81030 COUNTER UNIT
17 ** 056-05001 OUTLET (for 120[V]) 1
14 6
18 * 96F-60150 CONNECTOR PLATE (for 220-240[V])
NOTE: 9 10

PL6.17 Frame Section

1 995-13320 PILLAR (for 120[V])
2 12K-60094 STAND 9
3 016-10068 CASTER
17 10 11
17 17 17
4 12K-60330 RELAY BASE
5 12K-60360 SW PLATE 12
6 x CONNECTING PLATE B
7 x CONNECTING PLATE C 1
16 16
8 11A-80251 RL P.W.B UNIT 14 16 16
19 4
9 053-10069 RELAY 2
10 053-10017 RELAY 5
11 062-10784 RELAY 1
1
15
13 052-10013 NOISE FILTER 18
14 054-10361 SWITCH
16 056-11137 SPACER
17 056-11016 COLLAR
13 1
18 99S-61010 COVER
19 99V-60160 PLATE
3 6


1 12K-60180 CONNECTOR ANGLE
8
4 1
3 12K-60301 MC BASE
4 12K-80248 MC UNIT 2
5 12J-80210 DPIF P.W.B.UNIT
7
6* 97K-80284 POWER CORD UNIT (for 220-240[V]) 3 2
7 056-11137 SPACER
8 ** 97K-84012 POWER CORD UNIT (for 120[V])
NOTE: 5

PL6.18 Exterior Section

1 054-10304 SWITCH 4
2 12K-61051 COVER-L 8 10 6
3 12K-90830 COVER-R 13
4 99V-84051 LIMIT SWITCH UNIT 12 5
5 12K-61090 ANGLE 16
3
6 12K-61100 ANGLE 9
7 12K-61121 TOP COVER
1 7
8 12K-61130 SHAF T
9 12K-61140 BR ACKET 11
10 12K-61150 LEVER
11 12K-61161 ANGLE
12 016-10195 HANDLE 15
13 12K-61201 COVER
14 12K-61210 COVER 2
15 12K-61250 BR ACKET
16 12K-61220 PLATE 14

PL6.18 Exterior Section
PL6.19 Control Panel Section

1 12K-62050 COVER
14 1
3 12K-62070 SCREW PLATE
4 99J-62451 DIAL 8
5 011-10055 SPACER
12
6 12K-62120 ANGLE
13 5
7 99J-80159 OP UNIT
2
8 12K-62920 CONTROL PANEL
9 99J-62410 PANEL COVER
4 11
5
10 11F-67070 BUT TON A
10 3
7
11 11F-67080 BUT TON B
12 99J-62480 BUT TON C
13 99J-62420 PLATE
9
14 12K-62040 RUBBER MAGNET
15 12K-62030 PANEL COVER UNIT

PL6.19 Control Panel Section

1 x CONNECTING PLATE B
2 x CONNECTING PLATE C
3 96F-60381 PLATE
4 x JOINT
5 x SCREW SHAF T UNIT
6 x COVER UNIT
7 x ANGLE 1 6 7 8 9 10 11
8 x ANGLE 2
9 x BR ACKET UNIT
10 12K-60630 OUTFEED GUIDE
12 12K-82020 D-PORT CABLE
13 x NAME PLATE
14 x KNOB SCREW 12 13 14 15 16 17 18 19 20 21
15 x SCREW (HS6 x 100)
16 x SCREW (HS6 x 25) + NUT (N6)
17 x SCREW (MSK5 x 8)
19 x SCREW (MS3 x 18)
20 x SCREW (CFR5 x 20) 22 23 24 25 26 27 28 29
21 x SCREW (HSKW6 x 16)
23 12K-90025 INSTRUCTION MANUAL
NOTE:

PL6.20 Accessories

28 x SPINE SPLIT PREVENTER
29 x SCREW (CFR5 x 10)
NOTE: 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29

PL6.20 Accessories
PL6.21 Motor, Relay, Clutch

1 99J-81030 COUNTER UNIT CNT 1
4 (CNT)
2 99A-80131 STEPPING MOTOR M603 (CL602) 2
3 11A-80400 DC FAN UNIT FM601, FM602 (M603)
4 12K-80360 CLUTCH UNIT CL601, CL602
5 12H-81010 DC MOTOR M602
6 12W-80201 FAN M603 3
13 (FM602)
7 062-10784 SOLID-STATE RELAY SSR
(M604)
8 053-10017 RELAY RL601
9 053-90032 RELAY RL602 3
10 12K-82014 CLUTCH BR AKE CL/BRK (FM601)
11* 99S-81472 MOTOR UNIT (for 220-240[V]) M601 4
11,12 (CL601)
12** 99S-81512 MOTOR UNIT (for 120[V]) M601 (M601)
13 99D-85060 STEPPING MOTOR M604
NOTE: 10
(CL/BRK)
(M602)
9
(RL602)
6
(FM603)
8
(RL601) 8
(RL601)
(for 120[V])
7
(SSR)

PL6.21 Motor, Relay, Clutch
PL6.22 P.W.B, Sensor

1 9
1 12K-80370 INT.SENSOR PS606, PS606 (PCB602)
2 (PS606)
2 98R-80230 INT.SENSOR PS601, PS602, PS603, (PS701) 1
PS604, PS701
(PS605)
3 95K-80083 LED P.W.B PS607
2
4 95K-80063 PH P.W.B PS607 (PS603)
5 12K-86103 MC UNIT PCB601
6 12J-80211 DPIF P.W.B. PCB605
7 057-10054 SWITCHING POWER SUPPLY PCB603 3
(PS607)
8 11A-80252 RL P.W.B PCB604 2
9 99J-80159 OP UNIT PCB602 (PS604)
4
(PS607)
2
(PS601)
2
(PS602)
8 5
(PCB604) (PCB601)
6
(PCB605)
7
(PCB603)

PL6.22 P.W.B, Sensor
PL6.23 Switch, Solenoid, Noise Filter

1 99V-84051 LIMIT SWITCH UNIT SSW602 (SSW601) 1
2 054-10400 MINIATURE SWITCH SSW604, SSW605, (SSW602)
2
SSW606
(SSW605)
3* 056-10254 OUTLET (for 220-240[V])
4** 056-05001 OUTLET (for 120[V])
5 99W-83110 DC-SOLENOID SL602
6 11C-84100 INTERLOCK SWITCH SSW603
7 054-10324 ACTUATER
8 052-10013 NOISE FILTER
11 3,4
9 054-10338 CIRCUIT PROTECTOR PSW601 (SL601)
10 054-10361 SWITCH PSW602
11 99S-83150 DC-SOLENOID SL601
2
12 054-10304 SWITCH SSW601
(SSW604)
2
NOTE: (SSW606)
** Unique part for 120[V] (SL602)
10
(PSW602)
9
(PSW601)
8 6
(SSW603)
7

PL6.23 Switch, Solenoid, Noise Filter
PL6.24 Wiring (1/2)
ITEM PART # DESCRIPTION 1 9 2,3

1 12K-83613 WIRE HARNESS 15 17
2* 99W-83074 MOTOR HARNESS UNIT 1 (for 220-240[V])
3** 99W-83105 MOTOR WIRE HARNESS 2 (for 120[V])
4 99W-84041 BUNDLED WIRE UNIT 4
5 11C-83363 SAFETY INTERFACE HARNESS
6 11C-83374 E-PORT HARNESS
7 12K-83071 WIRE HARNESS 13
9 12K-83013 WIRE HARNESS

12 12K-83640 WIRE HARNESS 18 B
15,16
15* 97K-80284 POWER CORD (for 220-240[V])
14 5
16** 97K-84012 POWER CORD (for 120[V])
13
17 98H-80232 DC HARNESS UNIT 5 A
12
6
NOTE:
7
1
11 9
10
8
9

PL6.24 Wiring
PL6.24 Wiring (2/2)

2 12K-83013 WIRE HARNESS
9
1
6* 99W-83074 MOTOR HARNESS UNIT 1 (for 220-240[V])
7** 99W-83105 MOTOR WIRE HARNESS 2 (for 120[V])
2
NOTE:
B 3
6,7
4
5
A
B
2

PL6.24 Wiring
INDEX6 DBM-500T (1/4)
011-10006 PL6.10(3/3) 20 014-10489 PL6.7(1/2) 11 0Z3-06018 PL6.5 5 12K-10730 PL6.1(2/2) 12 12K-30051 PL6.7(2/2) 3
011-10047 PL6.7(1/2) 20 014-10523 PL6.13 13 0Z4-08018 PL6.3 6 12K-11031 PL6.2(1/2) 1 12K-30051 PL6.11(3/3) 1
011-10055 PL6.19 5 014-10525 PL6.12(1/2) 10 0Z4-08022 PL6.8 13 12K-11050 PL6.2(2/2) 1 12K-30060 PL6.7(2/2) 4
011-10061 PL6.1(1/2) 1 014-10620 PL6.13 17 0Z4-08031 PL6.16 15 12K-11120 PL6.2(1/2) 3 12K-30111 PL6.7(2/2) 5
013-00003 PL6.7(1/2) 1 015-10013 PL6.8 5 0Z4-08062 PL6.7(2/2) 11 12K-11230 PL6.2(1/2) 7 12K-30182 PL6.7(2/2) 9
013-00003 PL6.7(1/2) 15 016-10068 PL6.17(2/3) 3 11A-32420 PL6.17(1/3) 9 12K-11600 PL6.2(1/2) 15 12K-30190 PL6.7(1/2) 3
013-00003 PL6.7(2/2) 7 016-10195 PL6.18 12 11A-42321 PL6.1(2/2) 4 12K-12031 PL6.3 1 12K-30200 PL6.7(1/2) 4
013-00003 PL6.9 9 052-10013 PL6.17(2/3) 13 11A-80251 PL6.17(2/3) 8 12K-12041 PL6.3 2 12K-30230 PL6.7(2/2) 12
013-00003 PL6.16 3 052-10013 PL6.23 8 11A-80252 PL6.22 8 12K-12060 PL6.3 4 12K-30250 PL6.7(2/2) 13
013-00015 PL6.9 2 053-10017 PL6.17(2/3) 10 11A-80400 PL6.6 14 12K-20150 PL6.4(1/2) 5 12K-30290 PL6.7(2/2) 14
013-00056 PL6.2(2/2) 8 053-10017 PL6.21 8 11A-80400 PL6.21 3 12K-20340 PL6.4(2/2) 9 12K-30340 PL6.7(2/2) 15
013-00056 PL6.10(1/3) 5 053-10069 PL6.17(2/3) 9 11C-83363 PL6.24(1/2) 5 12K-21040 PL6.5 1 12K-30360 PL6.7(1/2) 7
013-00056 PL6.11(3/3) 2 053-90032 PL6.21 9 11C-83374 PL6.24(1/2) 6 12K-21051 PL6.5 2 12K-30400 PL6.7(1/2) 8
013-00056 PL6.13 6 054-10304 PL6.18 1 11C-83390 PL6.20(1/2) 11 12K-21061 PL6.5 3 12K-30581 PL6.7(1/2) 16
013-00056 PL6.15 13 054-10304 PL6.23 12 11C-84100 PL6.5 19 12K-21070 PL6.5 4 12K-30610 PL6.7(1/2) 17
013-00071 PL6.14 7 054-10324 PL6.5 20 11C-84100 PL6.23 6 12K-21110 PL6.5 22 12K-30620 PL6.7(1/2) 18
013-00081 PL6.1(2/2) 16 054-10324 PL6.23 7 11F-67070 PL6.19 10 12K-21150 PL6.5 8 12K-30630 PL6.7(1/2) 19
013-00081 PL6.12(2/2) 5 054-10338 PL6.17(2/3) 15 11F-67080 PL6.19 11 12K-21170 PL6.5 10 12K-30670 PL6.7(1/2) 21
013-00091 PL6.10(3/3) 6 054-10338 PL6.23 9 11G-40620 PL6.10(1/3) 13 12K-21200 PL6.5 11 12K-30680 PL6.7(1/2) 22
013-00137 PL6.9 21 054-10361 PL6.17(2/3) 14 12F-30122 PL6.12(2/2) 1 12K-21290 PL6.5 14 12K-30700 PL6.7(2/2) 17
013-00163 PL6.14 22 054-10361 PL6.23 10 12F-42040 PL6.6 10 12K-21300 PL6.5 15 12K-31032 PL6.8 1
013-10018 PL6.4(1/2) 15 054-10400 PL6.17(1/3) 14 12F-83210 PL6.5 21 12K-21310 PL6.5 16 12K-31120 PL6.8 6
013-10018 PL6.4(2/2) 8 054-10400 PL6.23 2 12H-81010 PL6.13 15 12K-28041 PL6.6 2 12K-31191 PL6.8 15
013-10019 PL6.14 10 056-00464 PL6.2(2/2) 17 12H-81010 PL6.21 5 12K-28051 PL6.6 1 12K-32123 PL6.9 4
013-10024 PL6.1(2/2) 17 056-05001 PL6.17(1/3) 17 12J-15270 PL6.7(2/2) 16 12K-28060 PL6.6 4 12K-32211 PL6.9 22
013-10024 PL6.2(1/2) 5 056-05001 PL6.23 4 12J-80210 PL6.17(3/3) 5 12K-28070 PL6.6 5 12K-32352 PL6.9 12
013-10024 PL6.2(2/2) 16 056-10254 PL6.17(1/3) 15 12J-80211 PL6.22 6 12K-28080 PL6.6 6 12K-32360 PL6.15 12
013-10024 PL6.7(1/2) 6 056-10254 PL6.23 3 12K-10051 PL6.1(2/2) 1 12K-28090 PL6.6 7 12K-32370 PL6.9 13
013-10024 PL6.10(3/3) 8 056-11016 PL6.17(2/3) 17 12K-10060 PL6.1(2/2) 2 12K-28100 PL6.6 17 12K-32380 PL6.9 14
013-10024 PL6.11(3/3) 10 056-11137 PL6.17(2/3) 16 12K-10090 PL6.1(2/2) 5 12K-28111 PL6.6 18 12K-32390 PL6.9 15
013-10024 PL6.13 7 056-11137 PL6.17(3/3) 7 12K-10100 PL6.1(2/2) 8 12K-28121 PL6.6 19 12K-32420 PL6.15 10
013-10036 PL6.1(1/2) 21 057-10054 PL6.17(2/3) 12 12K-10120 PL6.1(2/2) 7 12K-28140 PL6.6 9 12K-32450 PL6.15 11
013-10050 PL6.8 16 057-10054 PL6.22 7 12K-10241 PL6.1(2/2) 6 12K-28151 PL6.6 8 12K-32510 PL6.9 17
014-00136 PL6.13 2 062-10784 PL6.17(2/3) 11 12K-10320 PL6.1(1/2) 4 12K-28160 PL6.6 11 12K-32520 PL6.9 18
014-00263 PL6.12(1/2) 18 062-10784 PL6.21 7 12K-10412 PL6.1(1/2) 9 12K-28170 PL6.6 12 12K-32531 PL6.9 19
014-10279 PL6.12(1/2) 2 0X4-12050 PL6.3 8 12K-10470 PL6.1(2/2) 11 12K-28180 PL6.6 13 12K-32540 PL6.9 20
014-10309 PL6.13 14 0Y4-08022 PL6.1(1/2) 8 12K-10651 PL6.10(2/3) 9 12K-28220 PL6.6 15 12K-40041 PL6.10(2/3) 1
014-10429 PL6.2(1/2) 6 0Y4-08022 PL6.4(1/2) 13 12K-10691 PL6.1(2/2) 14 12K-30030 PL6.7(2/2) 1 12K-40051 PL6.10(3/3) 2

INDEX6 DBM-500T
12K-40140 PL6.10(2/3) 2 12K-41870 PL6.11(1/3) 15 12K-60151 PL6.17(1/3) 4 12K-82020 PL6.20(1/2) 12 92L-53190 PL6.17(1/3) 10
12K-40211 PL6.10(1/3) 1 12K-50023 PL6.12(1/2) 1 12K-60180 PL6.17(3/3) 1 12K-83013 PL6.24(1/2) 9 93A-20500 PL6.5 9
12K-40220 PL6.10(2/3) 4 12K-50033 PL6.12(1/2) 16 12K-60191 PL6.17(3/3) 2 12K-83013 PL6.24(2/2) 2 93A-40181 PL6.2(2/2) 15
12K-40260 PL6.10(1/3) 2 12K-50060 PL6.12(1/2) 3 12K-60301 PL6.17(3/3) 3 12K-83021 PL6.24(2/2) 1 93A-40181 PL6.11(3/3) 8
12K-40330 PL6.10(2/3) 5 12K-50072 PL6.12(1/2) 4 12K-60330 PL6.17(2/3) 4 12K-83031 PL6.24(2/2) 10 93A-50250 PL6.14 6
12K-40360 PL6.10(3/3) 7 12K-50080 PL6.12(1/2) 5 12K-60340 PL6.17(1/3) 7 12K-83041 PL6.24(2/2) 3 93E-23130 PL6.11(2/3) 10
12K-40461 PL6.10(3/3) 11 12K-50150 PL6.12(1/2) 17 12K-60450 PL6.17(1/3) 11 12K-83071 PL6.24(1/2) 7 93E-50670 PL6.5 6
12K-40470 PL6.10(3/3) 12 12K-50200 PL6.12(1/2) 9 12K-60630 PL6.20(1/2) 10 12K-83081 PL6.24(1/2) 8 93L-11850 PL6.1(2/2) 3
12K-40480 PL6.10(3/3) 13 12K-50451 PL6.12(2/2) 8 12K-61051 PL6.18 2 12K-83081 PL6.24(2/2) 4 93X-20050 PL6.1(2/2) 10
12K-40560 PL6.11(1/3) 14 12K-50550 PL6.12(2/2) 13 12K-61130 PL6.18 8 12K-83613 PL6.24(1/2) 1 945-12151 PL6.2(2/2) 13
12K-40620 PL6.10(1/3) 10 12K-50591 PL6.12(2/2) 3 12K-61140 PL6.18 9 12K-83620 PL6.24(1/2) 11 945-12151 PL6.11(3/3) 6
12K-40620 PL6.11(1/3) 17 12K-50600 PL6.12(2/2) 4 12K-61150 PL6.18 10 12K-83631 PL6.24(1/2) 13 945-30030 PL6.12(1/2) 7
12K-40660 PL6.10(1/3) 12 12K-51070 PL6.13 16 12K-61161 PL6.18 11 12K-83640 PL6.24(1/2) 12 94K-23151 PL6.7(1/2) 10
12K-40721 PL6.10(1/3) 14 12K-51121 PL6.13 5 12K-61201 PL6.18 13 12K-86103 PL6.22 5 94K-23151 PL6.12(2/2) 9
12K-40750 PL6.10(1/3) 16 12K-51150 PL6.13 8 12K-61210 PL6.18 14 12K-90025 PL6.20(1/2) 23 94T-10111 PL6.1(2/2) 15
12K-41070 PL6.11(1/3) 2 12K-51430 PL6.13 18 12K-61220 PL6.18 16 12K-90830 PL6.18 3 94T-10111 PL6.2(2/2) 7
12K-41450 PL6.11(1/3) 10 12K-54150 PL6.16 10 12K-62120 PL6.19 6 12K-90920 PL6.10(3/3) 19 94T-20470 PL6.14 9
12K-41480 PL6.11(1/3) 11 12K-54160 PL6.16 11 12K-62920 PL6.19 8 12K-90930 PL6.10(2/3) 13 94T-50440 PL6.14 20
12K-41591 PL6.11(2/3) 4 12K-54170 PL6.16 12 12K-80248 PL6.17(3/3) 4 12K-90950 PL6.10(3/3) 10 94T-50450 PL6.14 21
12K-41630 PL6.11(2/3) 11 12K-54260 PL6.16 18 12K-80360 PL6.21 4 12W-80201 PL6.12(1/2) 15 94T-50490 PL6.14 14
12K-41653 PL6.11(2/3) 8 12K-54270 PL6.16 19 12K-80370 PL6.7(2/2) 19 12W-80201 PL6.21 6 94T-50700 PL6.15 7
12K-41670 PL6.11(2/3) 7 12K-60053 PL6.17(1/3) 1 12K-80370 PL6.11(3/3) 15 91H-11260 PL6.2(2/2) 4 94T-51120 PL6.13 9
12K-41680 PL6.11(2/3) 9 12K-60065 PL6.17(1/3) 2 12K-80370 PL6.22 1 91H-51521 PL6.13 11 94T-90931 PL6.2(2/2) 14
12K-41760 PL6.11(1/3) 13 12K-60094 PL6.17(2/3) 2 12K-82014 PL6.12(1/2) 14 91H-51530 PL6.7(1/2) 14 94T-90931 PL6.11(3/3) 7
12K-41791 PL6.11(3/3) 11 12K-60141 PL6.17(1/3) 3 12K-82014 PL6.21 10 92G-91130 PL6.10(2/3) 11 94T-90944 PL6.2(2/2) 12

INDEX6 DBM-500T
94T-90944 PL6.11(3/3) 5 96G-25181 PL6.1(2/2) 13 99J-80159 PL6.22 9 99W-20050 PL6.4(1/2) 1 99W-40570 PL6.10(1/3) 8
94T-91671 PL6.2(1/2) 12 96G-60040 PL6.12(1/2) 19 99J-81030 PL6.17(1/3) 16 99W-20060 PL6.4(2/2) 2 99W-40570 PL6.11(1/3) 16
950-21320 PL6.17(1/3) 6 96G-71120 PL6.4(1/2) 12 99J-81030 PL6.21 1 99W-20103 PL6.4(1/2) 3 99W-40570 PL6.11(3/3) 12
952-14380 PL6.8 11 96G-85510 PL6.6 16 99S-32681 PL6.1(1/2) 15 99W-20141 PL6.4(1/2) 4 99W-41171 PL6.11(1/3) 7
952-14380 PL6.10(1/3) 11 976-51220 PL6.17(1/3) 5 99S-32681 PL6.16 13 99W-20160 PL6.4(2/2) 4 99W-41350 PL6.11(3/3) 9
952-14380 PL6.11(3/3) 13 97K-80284 PL6.17(3/3) 6 99S-61010 PL6.17(2/3) 18 99W-20170 PL6.4(2/2) 5 99W-50280 PL6.12(1/2) 11
952-61290 PL6.2(1/2) 2 97K-80284 PL6.24(1/2) 15 99S-81472 PL6.12(1/2) 13 99W-20180 PL6.4(2/2) 6 99W-50310 PL6.12(1/2) 12
952-61290 PL6.8 9 97K-84012 PL6.17(3/3) 8 99S-81472 PL6.21 11 99W-20190 PL6.4(1/2) 6 99W-51220 PL6.13 12
952-61290 PL6.10(1/3) 17 97K-84012 PL6.24(1/2) 16 99S-81512 PL6.12(1/2) 20 99W-20200 PL6.4(1/2) 7 99W-51230 PL6.13 10
95D-10180 PL6.7(1/2) 2 98H-10640 PL6.7(1/2) 9 99S-81512 PL6.21 12 99W-20221 PL6.4(1/2) 9 99W-52040 PL6.14 1
95D-10180 PL6.16 4 98H-14500 PL6.7(1/2) 5 99S-83150 PL6.8 14 99W-20231 PL6.4(1/2) 10 99W-52060 PL6.14 2
95K-20012 PL6.13 1 98H-20140 PL6.8 12 99S-83150 PL6.23 11 99W-20260 PL6.4(1/2) 11 99W-52060 PL6.15 3
95K-30081 PL6.10(1/3) 9 98H-22250 PL6.8 10 99V-30781 PL6.10(2/3) 7 99W-20300 PL6.4(2/2) 7 99W-52110 PL6.14 3
95K-30081 PL6.11(1/3) 12 98H-32160 PL6.3 5 99V-60160 PL6.17(2/3) 19 99W-20310 PL6.4(1/2) 14 99W-52120 PL6.14 4
95K-30081 PL6.11(2/3) 3 98H-45521 PL6.2(1/2) 10 99V-84051 PL6.18 4 99W-20351 PL6.4(2/2) 10 99W-52130 PL6.14 5
95K-80063 PL6.5 17 98H-80232 PL6.24(1/2) 17 99V-84051 PL6.23 1 99W-20360 PL6.4(2/2) 11 99W-52130 PL6.15 9
95K-80063 PL6.22 4 98R-80230 PL6.7(1/2) 23 99W-10332 PL6.1(1/2) 5 99W-20420 PL6.4(1/2) 16 99W-52230 PL6.14 11
95K-80083 PL6.5 18 98R-80230 PL6.10(3/3) 17 99W-10332 PL6.10(2/3) 3 99W-20440 PL6.4(1/2) 17 99W-52240 PL6.14 12
95K-80083 PL6.22 3 98R-80230 PL6.14 23 99W-10371 PL6.1(1/2) 7 99W-21220 PL6.5 12 99W-52250 PL6.14 13
95T-60080 PL6.8 7 98R-80230 PL6.16 20 99W-10420 PL6.1(1/2) 10 99W-21260 PL6.5 13 99W-52380 PL6.14 19
96D-12080 PL6.2(1/2) 4 98R-80230 PL6.22 2 99W-10430 PL6.1(1/2) 11 99W-30040 PL6.7(2/2) 2 99W-53030 PL6.15 1
96D-12080 PL6.2(2/2) 6 98X-41390 PL6.3 3 99W-10442 PL6.1(1/2) 12 99W-30120 PL6.7(2/2) 6 99W-53040 PL6.15 2
96F-10280 PL6.10(2/3) 10 98X-41400 PL6.12(2/2) 6 99W-10442 PL6.11(1/3) 1 99W-30210 PL6.7(2/2) 10 99W-53100 PL6.15 4
96F-60150 PL6.17(1/3) 18 98X-41520 PL6.16 16 99W-10500 PL6.1(1/2) 13 99W-30670 PL6.7(1/2) 12 99W-53110 PL6.15 5
96F-60160 PL6.17(1/3) 13 98X-50240 PL6.13 3 99W-10510 PL6.1(1/2) 14 99W-30690 PL6.7(1/2) 13 99W-53181 PL6.15 8
96F-60370 PL6.20(2/2) 27 98Y-32260 PL6.12(2/2) 12 99W-10570 PL6.1(1/2) 16 99W-31053 PL6.8 2 99W-54020 PL6.16 2
96F-60381 PL6.20(1/2) 3 990-21330 PL6.5 7 99W-10590 PL6.1(1/2) 17 99W-31070 PL6.8 17 99W-54051 PL6.16 5
96G-11060 PL6.1(2/2) 9 995-13320 PL6.17(2/3) 1 99W-10610 PL6.1(1/2) 18 99W-31091 PL6.8 3 99W-54061 PL6.16 6
96G-11060 PL6.10(1/3) 15 99A-80131 PL6.10(2/3) 8 99W-10620 PL6.1(1/2) 19 99W-31101 PL6.8 4 99W-54070 PL6.16 21
96G-11100 PL6.11(3/3) 3 99A-80131 PL6.21 2 99W-10630 PL6.1(1/2) 20 99W-31212 PL6.8 8 99W-54113 PL6.16 7
96G-11100 PL6.13 19 99D-83511 PL6.6 3 99W-11100 PL6.2(2/2) 5 99W-32052 PL6.9 1 99W-54131 PL6.16 8
96G-11111 PL6.1(1/2) 2 99D-85060 PL6.7(2/2) 18 99W-11314 PL6.2(1/2) 9 99W-32101 PL6.9 3 99W-54140 PL6.16 9
96G-11140 PL6.1(1/2) 3 99D-85060 PL6.21 13 99W-11330 PL6.2(1/2) 11 99W-32160 PL6.9 5 99W-60511 PL6.17(1/3) 12
96G-20080 PL6.2(2/2) 9 99J-62410 PL6.19 9 99W-11361 PL6.2(2/2) 10 99W-32171 PL6.9 6 99W-83074 PL6.24(1/2) 2
96G-20080 PL6.15 14 99J-62480 PL6.19 12 99W-12110 PL6.3 7 99W-32240 PL6.9 10 99W-83105 PL6.24(2/2) 7
96G-22450 PL6.7(2/2) 8 99J-80159 PL6.19 7 99W-20040 PL6.4(2/2) 1 99W-32301 PL6.9 11 99W-83110 PL6.3 9

INDEX6 DBM-500T
99W-83110 PL6.23 5 - - - - - - - - - - - -
99W-84041 PL6.24(1/2) 4 - - - - - - - - - - - -
99W-92040 PL6.9 16 - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -
- - - - - - - - - - - - - - -

INDEX6 DBM-500T
PL7.1 Long Stacker (DBM-LS1) (1/2)
ITEM PART # DESCRIPTION 19 17,22

1 99W-90901 STUCKER BASE 16 (M701)
2 99W-70081 PILLAR
15
3
3 92Z-60180 PILLAR
4 93Y-70121 BR ACKET 4 7 18
5 99W-70130 SHAF T 11 7 9,23 8
5
6 93Y-40050 PULLEY 13
6 14
7 945-12061 COLLAR 6
10 1
8 12K-70330 BR ACKET, MOTOR
9* 12K-70360 SPROCKET RS15-24-10 (for 220-240[V]) 12 2
10 99W-70370 14N SPROCKET
11 014-10547 ROLLER CHAIN
12 12K-70450 PLATE
20,21
13 99W-90930 FOOT A
14
14 99W-90940 FOOT B
15 056-00255 BUSHING
16 * 94R-80238 POWER CORD (for 220-240[V]) 13
17 * 94R-80342 MOTOR UNIT (for 220-240[V])
18 051-10160 GEAR HEAD
19 ** 94R-80213 POWER CORD (for 120[V])
20 ** 067-10420 C (for 120[V])
21 * 067-10298 C (for 220-240[V])
22 ** 12K-82300 MOTOR UNIT (for 120[V])
23 ** 12K-70390 SPROCKET RS15-20-10 (for 120[V])
NOTE:
5-213 Section 5—Parts List DBM-LS1/DBM-K

PL7.1 Long Stacker (DBM-LS1)
PL7.1 Long Stacker (DBM-LS1) (2/2)

1 93Y-70170 SPRING,C
2 93Y-70181 BR ACKET
3 93A-10200 PULLEY
4 93Y-70200 SHAF T
5 966-14040 COLLAR
6 99W-70262 FLAT BELT
7 99W-90910 COVER UNIT
8 99W-90920 COVER
9 99W-70300 TAPE
10 99W-70470 COVER 7
11 99W-90951 PLATE,BOT TOM
8 9
12 016-41959 CASTER
13 016-10157 ADJUSTER
9
7
8
10
11
2
1
13
2 5
12 3
4
12 12
12 5 3 6
1 6

PL7.1 Long Stacker (DBM-LS1)
PL7.2 Kicker (DBM-K) (1/2)

13
1 99W-75071 SHAF T
2 93X-21380 GUIDE 14 15 16
14
3 98H-20140 LINK
4 99W-75201 LEVER
5 99W-75210 SHAF T
6 99W-75220 LINK
7 0Z4-08022 Z COLLAR 21
3
8 99W-75270 SPRING-T 7
9 952-14380 ANGLE
10 99W-75312 STOPPER UNIT 9 5
7 22 2
11 99W-75320 STOPPER
8 4
12 99W-75332 CUSHION 6
7
13 99W-75391 CHASSIS UNIT 15 16
14 99W-75401 CHASSIS
19
15 99W-75410 SLIDE TAPE 1
16 99W-75420 SLIDE TAPE
17 99W-90960 COVER
18 99W-75460 KICKER BASE 11
10 18
19 011-09040 KNOB BOLT 17 12 20
20 0Z4-08022 Z COLLAR
22 056-10322 BUSHING

PL7.2 Kicker (DBM-K)
PL7.2 Kicker (DBM-K) (2/2)
ITEM PART # DESCRIPTION 5 (SL701)

1 99W-75050 ANGLE
2 99W-75100 BLOCK 15
3 013-10050 SIDE-BEARING
17
4 99W-75140 SHAF T
12
5 99S-83160 DC-SOL
9 10
6 947-12220 ROLLER 11 13 14
7 99W-75510 SHAF T 16
9 99W-75600 STOPPER UNIT 6
10 99W-75610 STOPPER
11 99W-75620 RUBBER MAGNET
12 99W-75661 GUIDE UNIT
13 99W-75671 GUIDE 7
2
14 99W-75680 RUBBER MAGNET 4 8
15 99W-90970 SPARE TABLE
16 99W-75530 ANGLE 3

PL7.2 Kicker (DBM-K)
PL7.3 Accessories (DBM-LS1)
1 2 3

1 x LONG STACKER
2 99W-90930 FOOT A
3 99W-90940 FOOT B
4 x BASE PLATE
5 x SCREW (SBK 5 x 10)
6 12K-90320 INSTALLATION MANUAL
4 5 6

PL7.3 Accessories (DBM-LS1)
PL7.4 Accessories (DBM-K)

1 x KICKER
2 99W-90970 AUXILIARY PLATE
3 99W-75661 GUIDE FOR SMALL PAPER
4 99W-75600 STOPPER
7 12K-90190 INSTALLATION MANUAL
4 5 6 7

PL7.4 Accessories (DBM-K)
INDEX7 DBM-LS1/DBM-K
011-09040 PL7.2(1/2) 19 99W-70081 PL7.1(1/2) 2 99W-90940 PL7.1(1/2) 14 - - - - - -
013-10050 PL7.2(2/2) 3 99W-70130 PL7.1(1/2) 5 99W-90940 PL7.3 3 - - - - - -
014-10547 PL7.1(1/2) 11 99W-70262 PL7.1(2/2) 6 99W-90951 PL7.1(2/2) 11 - - - - - -
016-10157 PL7.1(2/2) 13 99W-70300 PL7.1(2/2) 9 99W-90960 PL7.2(1/2) 17 - - - - - -
016-41959 PL7.1(2/2) 12 99W-70370 PL7.1(1/2) 10 99W-90970 PL7.2(2/2) 15 - - - - - -
051-10160 PL7.1(1/2) 18 99W-70470 PL7.1(2/2) 10 99W-90970 PL7.4 2 - - - - - -
056-00255 PL7.1(1/2) 15 99W-75050 PL7.2(2/2) 1 - - - - - - - - -
056-09001 PL7.2(2/2) 17 99W-75071 PL7.2(1/2) 1 - - - - - - - - -
056-09002 PL7.2(1/2) 21 99W-75100 PL7.2(2/2) 2 - - - - - - - - -
056-10322 PL7.2(1/2) 22 99W-75140 PL7.2(2/2) 4 - - - - - - - - -
067-10298 PL7.1(1/2) 21 99W-75201 PL7.2(1/2) 4 - - - - - - - - -
067-10420 PL7.1(1/2) 20 99W-75210 PL7.2(1/2) 5 - - - - - - - - -
0Z4-08022 PL7.2(1/2) 7 99W-75220 PL7.2(1/2) 6 - - - - - - - - -
0Z4-08022 PL7.2(1/2) 20 99W-75270 PL7.2(1/2) 8 - - - - - - - - -
12K-70330 PL7.1(1/2) 8 99W-75312 PL7.2(1/2) 10 - - - - - - - - -
12K-70360 PL7.1(1/2) 9 99W-75320 PL7.2(1/2) 11 - - - - - - - - -
12K-70390 PL7.1(1/2) 23 99W-75332 PL7.2(1/2) 12 - - - - - - - - -
12K-70450 PL7.1(1/2) 12 99W-75391 PL7.2(1/2) 13 - - - - - - - - -
12K-82300 PL7.1(1/2) 22 99W-75401 PL7.2(1/2) 14 - - - - - - - - -
12K-90190 PL7.4 7 99W-75410 PL7.2(1/2) 15 - - - - - - - - -
12K-90320 PL7.3 6 99W-75420 PL7.2(1/2) 16 - - - - - - - - -
92Z-60180 PL7.1(1/2) 3 99W-75460 PL7.2(1/2) 18 - - - - - - - - -
93A-10200 PL7.1(2/2) 3 99W-75510 PL7.2(2/2) 7 - - - - - - - - -
93X-21380 PL7.2(1/2) 2 99W-75521 PL7.2(2/2) 8 - - - - - - - - -
93Y-40050 PL7.1(1/2) 6 99W-75530 PL7.2(2/2) 16 - - - - - - - - -
93Y-70121 PL7.1(1/2) 4 99W-75600 PL7.2(2/2) 9 - - - - - - - - -
93Y-70170 PL7.1(2/2) 1 99W-75600 PL7.4 4 - - - - - - - - -
93Y-70181 PL7.1(2/2) 2 99W-75610 PL7.2(2/2) 10 - - - - - - - - -
93Y-70200 PL7.1(2/2) 4 99W-75620 PL7.2(2/2) 11 - - - - - - - - -
945-12061 PL7.1(1/2) 7 99W-75661 PL7.2(2/2) 12 - - - - - - - - -
947-12220 PL7.2(2/2) 6 99W-75661 PL7.4 3 - - - - - - - - -
94R-80213 PL7.1(1/2) 19 99W-75671 PL7.2(2/2) 13 - - - - - - - - -
94R-80238 PL7.1(1/2) 16 99W-75680 PL7.2(2/2) 14 - - - - - - - - -
94R-80342 PL7.1(1/2) 17 99W-90901 PL7.1(1/2) 1 - - - - - - - - -
952-14380 PL7.2(1/2) 9 99W-90910 PL7.1(2/2) 7 - - - - - - - - -
966-14040 PL7.1(2/2) 5 99W-90920 PL7.1(2/2) 8 - - - - - - - - -
98H-20140 PL7.2(1/2) 3 99W-90930 PL7.1(1/2) 13 - - - - - - - - -
99S-83160 PL7.2(2/2) 5 99W-90930 PL7.3 2 - - - - - - - - -

INDEX7 DBM-LS1/DBM-K
PL8.1 ASMD AUTO SPINEMASTER (1/2)

Fig1* 62-041 AUTO SPINEMASTER, DUPLO INTERFACE 115V
8e
Fig1** 62-042 AUTO SPINEMASTER, DUPLO INTERFACE 230V
8d
1 62-094 ● ASM INFEED -> DUPLO INFEED
8c
1a 890-342 ●● P.ASSY, (ASMD) INFEED ASSEMBLY
1b 914-863 ●● FIXING KIT, ASM TO DUPLO
1ba 150-036 ●●● NUT, M6 NYLOC-TYPE P BZP 1a
1bb 160-004 ●●● WASHER, M6 FORM A BZP 1ba
1bc 100-331 ●●● SCREW, SKT HD CAP, M6 x 20mm STAINLESS 1bb
1bd 160-040 ●●● WASHER, M6 T4HPTC BZP 1bc
1be 742-485 ●●● CABLE ASSY, ATM/TMP ASM SHORTING PLUG
1bf 150-033 ●●● NUT, M3 NYLOC-TYPE T BZP 1bd
1bg 165-000 ●●● SHAKEPROOF WASHER, M3 INTERNAL BZP
1bh 101-314 ●●● SCREW, SKT HD BUT TON,M3x10mm STAINLESS 1be
1bi 252-071 ●●● STEEL, (ASM) DUPLO DRILL FIXTURE 1bf
1bj 742-514 ●●● CABLE ASSEMBLY, ASM DUPLO 4000 I/FACE
1bg
2 165-003 ● SHAKEPROOF WASHER, M5 INTERNAL BZP 8b
1bh
3 100-094 ● SCREW,SKT HD CAP,M5x10 HIGH TENSILE ZP
4* 740-003 ● WIRE, MAINS,UK PLUG/2M5/IEC R/A SOCKET 1bi
4** 740-006 ● WIRE, MAINS,USA PLUG/2M5/IEC R/A SOCK.
2
3
4
4
FIG 1
5-220 Section 5—Parts List Spine Master

PL8.1 ASMD AUTO SPINEMASTER
PL8.1 ASMD AUTO SPINEMASTER (2/2)

8 907-957 ● P.ASSY, (ASM) SIDE PANEL & FIXINGS
8e
8b 253-858 ●● STEEL, (ASM) SIDE COVER
8d
8c 101-307 ●● SCREW, SKT HD BUT TON,M5x16mm STAINLESS
8c
8d 160-003 ●● WASHER, M5 FORM A BZP
8e 150-035 ●● NUT, M5 NYLOC-TYPE P BZP
9* 890-007 ● P.ASSY, (ASM) MAIN FR AME STACKER 115V 1a
9** 907-997 ● P.ASSY, (ASM) MAIN FR AME STACKER 230V 1ba
1bb
1bc
1bd
1be
1bf
1bg
8b
1bh
1bi
2
3
4
4
FIG 1

PL8.1 ASMD AUTO SPINEMASTER
PL8.2 MAIN FRAME STACKER

Fig2* 890-007 P.ASSY, (ASM) MAIN FR AME STACKER 115V 1
Fig2** 907-997 P.ASSY, (ASM) MAIN FR AME STACKER 230V 2
1 101-301 ● SCREW, SKT HD BUT TON,M5x10mm STAINLESS
3
2 165-003 ● SHAKEPROOF WASHER, M5 INTERNAL BZP
4
3 907-819 ● P.ASSY, (ASM) STACKER
4 907-818 ● P.ASSY, (ASM) SAMPLE CONVEYOR 5
5 105-320 ● SCREW,SKT HD C/S,M3x10 HIGH TENSILE ZP 6
6 257-357 ● ST. STEEL,SPACER OD8mm xID5.1mm x2.7mm 7
7 160-005 ● WASHER, M5 FORM C (12.5mmOD) BZP 8
8 100-347 ● SCREW,SKT HD CAP,M5x12 HIGH TENSILE ZP 9
9 160-002 ● WASHER, M3 FORM A BZP
10
10 150-033 ● NUT, M3 NYLOC-TYPE T BZP
11* 890-006 ● P.ASSY, MAIN FR AME & FAN 115V
11** 907-998 ● P.ASSY, MAIN FR AME & FAN 230V
12 907-796 ● P.ASSY, (ASM) TOP DELIVERY ASSY
12
11
8
2
FIG 2

PL8.2 MAIN FRAME STACKER
PL8.3 MAIN FRAME & FAN

Fig3* 890-006 P.ASSY, MAIN FR AME & FAN 115V
Fig3** 907-998 P.ASSY, MAIN FR AME & FAN 230V
1* 890-061 ● P.ASSY, (ASM) FAN 115V
1** 907-817 ● P.ASSY, (ASM) FAN 230V
1a 150-034 ●● NUT, M4 NYLOC-TYPE T HALF HEIGHT BZP
1b 160-001 ●● WASHER, M4 FORM A BZP
1c* 710-058 ●● ELEC HARDWARE, 120mm 115V FAN
1c** 710-057 ●● ELEC HARDWARE, 120mm 240V FAN
1d 165-001 ●● SHAKEPROOF WASHER, M4 INTERNAL BZP
1e 101-323 ●● SCREW, SKT HD BUT TON,M4x16mm STAINLESS 4
1f 253-840 ●● STEEL, (ASM) FAN MOUNTING BR ACKET
1i
1g* 500-252 ●● LABEL, 115V
1b
1g** 500-009 ●● LABEL, 230V
1d
1h 742-406 ●● CABLE ASSY, (VSPM) FAN SUPPLY LEAD
1h
1i 100-306 ●● SCREW, SKT HD CAP, M4 x 8mm STAINLESS
1g
4* 907-996 ● P.ASSY, ASM MAIN FR AME ELECTRICS 115V
4** 907-948 ● P.ASSY, ASM MAIN FR AME ELECTRICS 230V
1f
1e
1d
1c
3
2 1b
1a FIG 3

PL8.3 MAIN FRAME & FAN
PL8.4 MAIN FRAME ELECTRICS (1/2)

4 5 6 7
6 8
Fig4* 907-996 P.ASSY, ASM MAIN FR AME ELECTRICS 115V
1c 1d 1e 9
Fig4** 907-948 P.ASSY, ASM MAIN FR AME ELECTRICS 230V 1a 1b
38
1 907-822 ● P.ASSY, (ASM) SWITCH BR ACKET 37
36
1a 150-033 ●● NUT, M3 NYLOC-TYPE T BZP
37
1b 700-088 ●● SWITCH, (VTRM) BIN GUARD 36
35b
1c 253-855 ●● STEEL, (ASM) SWITCH BR ACKET (SAFETY) 35a 10
1d 160-002
22 11
●● WASHER, M3 FORM A BZP
29 12
3334
1e 100-311 ●● SCREW, SKT HD CAP, M3 x 25mm STAINLESS 31 32 12
2 742-492 ● CABLE ASSEMBLY,(ASM) GUARD TOP COVER 30
29 13
28 25
4 100-305 ● SCREW, SKT HD CAP, M4 x 6mm STAINLESS 27 24
25 26
5* 907-993 ● P.ASSY, (ASM) DIVERT & UPFEED 115V 23
22
5** 907-816 ● P.ASSY, (ASM) DIVERT & UPFEED 230V
21
6 700-104 ● SWITCH, CONTACT BLOCK N/C 20
7 742-518 ● CABLE ASSY, (ASM) FUNCTION SWITCH LINK 19
18
8 700-422 ● SWITCH, 3 MOD CLIP/NC CONTACT/L.HOLDER
17
9 315-603 ● PLASTIC, (VSPM) ANTI ROTATION RING 16
10 700-421 ● SWITCH, ILLUM. PUSH BUT TON GREEN 15
14
11 700-420 ● SWITCH, 30V 2W BULB
12 907-426 ● P.ASSY, (VSPM) 2-POSN NON-ILLUM SWITCH
13 500-275 ● LABEL, (ASM) SWITCH FIG 4
14 900-197 ● PCB ASSEMBLY, SPINEMASTER CONTROL PCB
15 742-495 ● CABLE ASSEMBLY,(ASM) FUNCTION SWITCHES
16 742-489 ● CABLE ASSEMBLY,(ASM) MAGNET ASSY
17 742-487 ● CABLE ASSEMBLY,(ASM) DRIVE CLUTCH
18 742-494 ● CABLE ASSEMBLY,(ASM) CASSET TE BUS 12W
19 742-490 ● CABLE ASSEMBLY,(ASM) BYPASS SOLENOID

PL8.4 MAIN FRAME ELECTRICS
PL8.4 MAIN FRAME ELECTRICS (2/2)

4 5 6 7
6 8
20 742-501 ● CABLE ASSY,(ASM) PAYOUT BUS ASSY
1c 1d 1e 9
21 742-521 ● CABLE ASSY,(ASM)GUARD REAR DOOR & DRIVE 1a 1b
38
22 150-035 ● NUT, M5 NYLOC-TYPE P BZP 37
36
23 320-304 ● NYLON, M5 WASHER
37
24 150-034 ● NUT, M4 NYLOC-TYPE T HALF HEIGHT BZP 36
35b
25 160-001 ● WASHER, M4 FORM A BZP 35a 10
26 180-302
22 11
● CIRCLIP 8mm SHAF T 0.66mm WIDE
29 12
3334
27 100-342 ● SCREW, SKT HD CAP, M4 X 20 STAINLESS 31 32 12
29 13
29 160-005 ● WASHER, M5 FORM C (12.5mmOD) BZP
28 25
30 257-357 ● ST. STEEL,SPACER OD8mm xID5.1mm x2.7mm 27 24
25 26
31 253-848 ● STEEL, (ASM) SOLENOID LINK 23
22
32 253-829 ● STEEL, (ASM) LINK
21
33 400-384 ● PIN, NEEDLE ROLLER 2.388dia x12.55mmLG 20
34 253-828 ● STEEL, (ASM) ACTUATOR LINK 19
18
35 907-200 ● P.ASSY,(VBM)E/STITCH SOLENOID & SPRING
17
35a 180-355 ●● SPRING,(VSF) COMP 2N-15N E/STITCH 16
35b 760-339 ●● SOLENOID, GE-40.08 80% 24 FLANGED 15
14
38 710-016 ● ELEC-HARDWARE, CABLE TIE-small FIG 4

PL8.4 MAIN FRAME ELECTRICS
PL8.5 DIVERT & UPFEED (1/2) 1 2a
2b 2c 2d
2e 2f 2g
22d
22c
ITEM PART # DESCRIPTION 22b
Fig5* 907-993 P.ASSY, (ASM) DIVERT & UPFEED 115V 22a
Fig5** 907-816 P.ASSY, (ASM) DIVERT & UPFEED 230V 21e
1 914-495 ● BELT, MAT-02H x 25 x 965 LONG 21d
21c
2 907-803 ● P.ASSY, (ASM) INTERMEDIATE DRIVE ASSY
21b
2a 265-825 ●● SHAF T, (ASM) INTERMEDIATE DRIVE
21a
2b 310-690 ●● PLASTIC MOULDING, ROLLER 25.4mm 3a
20d
2c 400-405 ●● PIN, DIA 4mm x 20mm DOWEL 20c 3b
2d 310-691 3c
●● PLASTIC MLDG, ROLLER RETAINER 25.4mm 20b
3d
2e 400-355 ●● PIN, DIA 4mm x 24mm DOWEL 20a
4a
2f 192-497 ●● GEAR, R/H HELICAL 14T 10DP ACETAL 16
13 4b
2g 180-099 ●● SPRING, CIRCLIP 12.7mm SHAF T 1mm WIDE 4c 5 6 7 8
14 9
3 907-953 ● P.ASSY, (ASM) STUB SHAF T ASSY
15 10
3a 400-355 ●● PIN, DIA 4mm x 24mm DOWEL
3b 192-497
13
●● GEAR, R/H HELICAL 14T 10DP ACETAL
14
3c 180-099 ●● SPRING, CIRCLIP 12.7mm SHAF T 1mm WIDE
19 9
3d 265-823 ●● SHAF T, (ASM) STUB SHAF T 7
4 907-994 ● P.ASSY, (ASM) ADJUSTER SHAF T 6
4a 315-598 ●● PLASTIC, (VSPM) TOP COVER HANDLE
11
12
4b 400-391 ●● PIN, M3 x 20 SPIROL 13
4c 265-835 ●● SHAF T, (ASM) ADJUSTABLE SHAF T 14
5 500-258 ● LABEL, SPINEMASTER MIN./MA X. 15
12
6 180-099 ● SPRING, CIRCLIP 12.7mm SHAF T 1mm WIDE
11
7 320-323 ● NYLON, WASHER OD19mmxID13mmx1.5mmTHICK
9
8 320-342 ● NYLON, WASHER OD19mmxID13mmx0.80mm 7
9 190-341 ● BEARING, (DIG) FLANGED ROLLER BEARING 13
10 253-814 ● STEEL, (ASM) BR ACKET BELT SUPPORT
16 14
9
14 7 4b
11 165-003 ● SHAKEPROOF WASHER, M5 INTERNAL BZP 17
18
FIG 5

PL8.5 DIVERT & UPFEED
PL8.5 DIVERT & UPFEED (2/2)
1 2a
2b 2c 2d
2e 2f 2g
22d
22c
ITEM PART # DESCRIPTION 22b
12 100-347 ● SCREW,SKT HD CAP,M5x12 HIGH TENSILE ZP 22a
13 180-302 ● CIRCLIP 8mm SHAF T 0.66mm WIDE 21e
14 320-302 ● NYLON, WASHER 16mmODx8.2IDx.83mm thick 21d
21c
15 310-610 ● PL MOULDING, ANTI-STATIC BEARING BUSH
21b
16 190-321 ● BEARING,ROLLER FLANGE 22mmODx8mmIDx7mm
21a
17 192-456 ● PULLEY, FLANGED T5 - 16T 3a
20d
18 190-332 ● BEARING, TR ANTORQUE BUSH - 6mm 20c 3b
19* 907-992 ● P.ASSY, (ASM) SECONDARY DRIVE 115V 3c
20b
3d
19** 907-985 ● P.ASSY, (ASM) SECONDARY DRIVE 230V 20a
4a
20 907-804 ● P.ASSY, (ASM) IDLER SHAF T ASSY 16
13 4b
20a 265-826 ●● SHAF T, (ASM) IDLER SHAF T 4c 5 6 7 8
14 9
20b 310-690 ●● PLASTIC MOULDING, ROLLER 25.4mm
15 10
20c 310-691 ●● PLASTIC MLDG, ROLLER RETAINER 25.4mm
20d 400-405 ●● PIN, DIA 4mm x 20mm DOWEL
13
14
21 907-805 ● P.ASSY, (ASM) TIE BAR ASSY
19 9
21a 265-827 ●● SHAF T, (ASM) TIE BAR 12.7 x 423 LONG 7
21b 310-690 ●● PLASTIC MOULDING, ROLLER 25.4mm 6
21c 310-691 ●● PLASTIC MLDG, ROLLER RETAINER 25.4mm 11
12
21d 320-342 ●● NYLON, WASHER OD19mmxID13mmx0.80mm
13
21e 180-099 ●● SPRING, CIRCLIP 12.7mm SHAF T 1mm WIDE 14
22 907-951 ● P.ASSY, (ASM) DIVERT SHAF T 15
12
22a 265-830 ●● SHAF T, (ASM) DIVERT SHAF T
11
22b 180-099 ●● SPRING, CIRCLIP 12.7mm SHAF T 1mm WIDE
9
22c 310-708 ●● PLASTIC MOULDING, (ASM) DIVERTER 7
22d 400-355 ●● PIN, DIA 4mm x 24mm DOWEL 13
16 14
9
14 7 4b
17
18
FIG 5

PL8.5 DIVERT & UPFEED
PL8.6 SECONDARY DRIVE (1/2)
ITEM PART # DESCRIPTION 1a 1b

1c 2 3a
Fig6* 907-992 P.ASSY, (ASM) SECONDARY DRIVE 115V 3b 3c
Fig6** 907-985 P.ASSY, (ASM) SECONDARY DRIVE 230V 3d 4
5 6
1 907-952 ● P.ASSY, (ASM) IDLER SHAF T 75mm WHEELS
1a 400-392 ●● PIN, DIA 4mm x 30mm LONG ROLL PIN 6
1b 320-409 ●● NYLON, (ASM) WHEEL MODIFIED 320-311 5
4
1c 265-826 ●● SHAF T, (ASM) IDLER SHAF T
15
2 914-498 ● BELT, MAM-04H x 25 x 686 LONG
26
3 907-804 ● P.ASSY, (ASM) IDLER SHAF T ASSY 25 7 8
9 5
3a 265-826 ●● SHAF T, (ASM) IDLER SHAF T 24 10 11
23 12 13
9
3c 400-405 ●● PIN, DIA 4mm x 20mm DOWEL 8 14
3d 310-691 ●● PLASTIC MLDG, ROLLER RETAINER 25.4mm 7 5
4 150-035 ● NUT, M5 NYLOC-TYPE P BZP 10 10
5 165-003 ● SHAKEPROOF WASHER, M5 INTERNAL BZP 5 15
20 16
6 257-501 ● STAINLESS STEEL, (ASPM) BOOK DEFLECTOR
12 5
22 10
8 320-302 ● NYLON, WASHER 16mmODx8.2IDx.83mm thick 7
9 180-302 ● CIRCLIP 8mm SHAF T 0.66mm WIDE 8
17
17
11 914-511 ● BELT, (ASM) HTD-535-5M-9mm WIDE
9
12 320-323 ● NYLON, WASHER OD19mmxID13mmx1.5mmTHICK 9
13 190-341 ● BEARING, (DIG) FLANGED ROLLER BEARING
21 20 21 20 19 7 8 18 18
14 253-826 ● STEEL, (ASM) BEARING PLATE
15 400-405 ● PIN, DIA 4mm x 20mm DOWEL FIG 6
16 192-494 ● PULLEY, FLANGED 28T HTD 5M 12.7 BORE
17 400-030 ● PIN, NEEDLE ROLLER 3mm x 12.8mm
18 192-489 ● GEAR, 56T ACETAL WITH BOSS

PL8.6 SECONDARY DRIVE
PL8.6 SECONDARY DRIVE (2/2)
ITEM PART # DESCRIPTION 1a 1b

1c 2 3a
19 253-876 ● STEEL, (ASM) BEARING PLATE 3b 3c
20 180-099 ● SPRING, CIRCLIP 12.7mm SHAF T 1mm WIDE 3d 4
5 6
21 320-342 ● NYLON, WASHER OD19mmxID13mmx0.80mm
22* 907-991 ● P.ASSY, (ASM) PRIMARY DRIVE 115V 6
22** 907-984 ● P.ASSY, (ASM) PRIMARY DRIVE 230V 5
4
23 265-844 ● SHAF T, (ASM) INFEED DRIVE SHAF T CRUSH
15
24 310-690 ● PLASTIC MOULDING, ROLLER 25.4mm
26
25 310-691 ● PLASTIC MLDG, ROLLER RETAINER 25.4mm 25 7 8
9 5
26 914-504 ● BELT, STACKER MAM-04H x 25 x 536 LONG 24 10 11
23 12 13
9
8 14
7 5
10 10
5 15
20 16
12 5
22 10
7
8
17
17
9
9
21 20 21 20 19 7 8 18 18
FIG 6

PL8.6 SECONDARY DRIVE
PL8.7 PRIMARY DRIVE (1/2)
ITEM PART # DESCRIPTION 4g

4d 4e 4f
Fig7* 907-991 P.ASSY, (ASM) PRIMARY DRIVE 115V 2d 3 4a 4b 4c
2b 2c
Fig7** 907-984 P.ASSY, (ASM) PRIMARY DRIVE 230V 1 2a
1 914-496 ● BELT, MAT-02H x 25 x 350 LONG
2 907-804 ● P.ASSY, (ASM) IDLER SHAF T ASSY
5
2a 310-691 ●● PLASTIC MLDG, ROLLER RETAINER 25.4mm 6
2b 400-405 ●● PIN, DIA 4mm x 20mm DOWEL 24d 7
24c 8
2c 310-690 ●● PLASTIC MOULDING, ROLLER 25.4mm 9
24b 10
2d 265-826 ●● SHAF T, (ASM) IDLER SHAF T
24a 11
3 265-843 ● SHAF T, (ASM) TIE BAR 12.7 x 423 LONG
23 12
4 907-802 ● P.ASSY, (ASM) DRIVE SHAF T ASSY 13
4a 265-841 ●● SHAF T, (ASM) 12.7mm x 501 LONG 14
15
16
4c 400-405 ●● PIN, DIA 4mm x 20mm DOWEL 8
4e 400-355
13 17
●● PIN, DIA 4mm x 24mm DOWEL
12 5
4f 192-498 ●● GEAR, L/H HELICAL 14T 10DP ACETAL 11 9
4g 180-099 ●● SPRING, CIRCLIP 12.7mm SHAF T 1mm WIDE 10
14 18
5 190-341 ● BEARING, (DIG) FLANGED ROLLER BEARING 13 7
5 6 19
6 320-342 ● NYLON, WASHER OD19mmxID13mmx0.80mm 12 20a
7 400-355 ● PIN, DIA 4mm x 24mm DOWEL
7 20b
9
8 192-494 ● PULLEY, FLANGED 28T HTD 5M 12.7 BORE 22 20c
6 20d
5 21
13 320-302 ● NYLON, WASHER 16mmODx8.2IDx.83mm thick FIG 7
14 180-302 ● CIRCLIP 8mm SHAF T 0.66mm WIDE

PL8.7 PRIMARY DRIVE
PL8.7 PRIMARY DRIVE (2/2)
ITEM PART # DESCRIPTION 4g

4d 4e 4f
15 914-508 ● BELT, (ASM) HTD-900-5M-9mm WIDE 2d 3 4a 4b 4c
2b 2c
16 400-405 ● PIN, DIA 4mm x 20mm DOWEL 1 2a
18 914-507 ● BELT, (ASM) HTD-375-5M-9mm WIDE
5
19 192-495 ● PULLEY, (ASM) HTD 44-5M-25 6
20 907-953 ● P.ASSY, (ASM) STUB SHAF T ASSY 24d 7
24c 8
20a 265-823 ●● SHAF T, (ASM) STUB SHAF T 9
24b 10
20b 180-099 ●● SPRING, CIRCLIP 12.7mm SHAF T 1mm WIDE
24a 11
20c 192-497 ●● GEAR, R/H HELICAL 14T 10DP ACETAL
23 12
20d 400-355 ●● PIN, DIA 4mm x 24mm DOWEL 13
21* 907-987 ● P.ASSY, (ASM) MAIN DRIVE & STOP 115V 14
15
21** 907-983 ● P.ASSY, (ASM) MAIN DRIVE & STOP 230V
16
22 192-491 ● PULLEY, (ASM) HTD 44-5M-09 8
23 192-395 ● CHAIN,(VECO)8mmx42 PITCH INC. CON LINK 14 9
24 907-795
13 17
● P.ASSY, (ASM) DRIVE SHAF T
12 5
24a 149-201 ●● GRUB SCREW, M4 x 6mm CUP POINT 11 9
24b 192-458 ●● SPROCKET,(VSPM) INTERMEDIATE DRIVE 15T 10
14 18
24c 265-816 ●● SHAF T, (ASM) DRIVE SHAF T 19.5mm Dia 13 7
5 6 19
24d 254-502 ●● STEEL,KEY 3/16” SQx24/25mm LG FLAT END 12 20a
7 20b
9
22 20c
6 20d
5 21
FIG 7

PL8.7 PRIMARY DRIVE
PL8.8 MAIN DRIVE & STOP

Fig8* 907-987 P.ASSY, (ASM) MAIN DRIVE & STOP 115V
Fig8** 907-983 P.ASSY, (ASM) MAIN DRIVE & STOP 230V
1 100-351 ● SCREW,SKT HD CAP,M6x20 H.TENSILE BZP
4 150-036 ● NUT, M6 NYLOC-TYPE P BZP
5* 907-988 ● P.ASSY, (ASM) MAIN DRIVE 115V
5** 907-814 ● P.ASSY, (ASM) MAIN DRIVE 230V
6* 192-502 ● CHAIN, (ASM) 115V 66 PITCHES 8mm
6** 192-455 ● CHAIN,DRIVE 8mm x 69PITCH INC.CON LINK
7 907-404 ● P.ASSY, (VSPM) STOP MECHANISM
8 100-369 ● SCREW,SKT HD CAP, M6xM16 H/T BZP
9 100-326 ● SCREW, SKT HD CAP, M3 x 10mm STAINLESS 1
11 253-352 ● STEEL, (VSPM) MOUNTING BR ACKET-SPRING 3
16
12 265-673 ● SHAF T, (VSPM) SPACER x 25mm LONG
15
13 180-383 ● SPRING, (VSPM) STOP RETURN SPRING 14
14 160-001 ● WASHER, M4 FORM A BZP 13
15 105-301 ● SCREW, SKT HD C/S, M3 x 10mm STAINLESS 12
16* 907-990 ● P.ASSY, (ASM) CRUSH & SIDE PLATES 115V 8
16** 907-982 ● P.ASSY, (ASM) CRUSH & SIDE PLATES 230
2
11
10
9
8
2
7
6 3
2
5 4
FIG 8

PL8.8 MAIN DRIVE & STOP
PL8.9 CRUSH & SIDE PLATES (1/2)

Fig9* 907-990 P.ASSY, (ASM) CRUSH & SIDE PLATES 115V
Fig9** 907-982 P.ASSY, (ASM) CRUSH & SIDE PLATES 230
34
2 100-359 ● SCREW, SKT HD CAP, M8 x 16mm BZP 5 6
3 265-683
7a
● SHAF T, (VSPM) CHAIN LINK 7b
8
5 192-500 ● CHAIN, (ASM) 8mm x 157 PITCHES 2 CON. 9
6 100-351 ● SCREW,SKT HD CAP,M6x20 H.TENSILE BZP 10
7 907-840 ● P.ASSY, (ASM) MOTOR ASSY 11
12
7a 190-333 ●● BEARING, TR ANTORQUE BUSH - 10mm
7b 905-343 ●● EL ASSY, (VSPM) CARRIAGE MOTOR 24V DC 10
9
7c 253-883 ●● STEEL, (ASM) MOTOR MOUNTING BR ACKET
8 7c
7d 192-461 ●● SPROCKET, (VSPM) DRIVE 20T 7f 7e7d
21h 13
7e 160-004 ●● WASHER, M6 FORM A BZP 21g 15 14
16
7f 100-355 ●● SCREW, SKT HD CAP, M6 x 12mm BZP 21f
17 17 14
21e 11
8 100-369 ● SCREW,SKT HD CAP, M6xM16 H/T BZP 21d 18
17
9 160-203 ● WASHER, M6 SQ.SECT.SPRING BZP 21c 14
21b 1 19
10 160-004 ● WASHER, M6 FORM A BZP 21a 20 2 FIG 9
11
11 165-003 ● SHAKEPROOF WASHER, M5 INTERNAL BZP 12 15 14
13* 907-989 ● P.ASSY, SIDE PLATE R/H ELECTRICS 115V
13** 890-048 ● P.ASSY, SIDE PLATE RH ELECTRICS 230V
16 253-347 ● STEEL, (VSPM) SENSOR FLAG
18 257-503 ● ST STEEL, (ASM) BOOK GUIDE UPFEED

PL8.9 CRUSH & SIDE PLATES
PL8.9 CRUSH & SIDE PLATES (2/2)

19 907-958 ● P.ASSY, (ASM) CRUSH
20 907-981 ● P.ASSY, (ASM) SIDE PLATE L/H
21 907-839 ● P.ASSY, (ASM) SPIGOT SUPPORT 1 2
34
21a 907-838 ●● P.ASSY, (ASM) SPIGOT BR ACKET 5 6
21b 100-373
7a
●● SCREW, SKT HD CAP, M8 x 20 BZP 7b
21c 160-212 ●● WASHER, M8 FORM C BZP
8
21d 265-682 ●● SHAF T, (VSPM) IDLER 9
21e 890-046 ●● P.ASSY, IDLER SPROCKET 20T & OILITE 10
21f 255-395 ●● STEEL, WASHER 25mm OD x 6.5mm ID 11
12
21g 100-369 ●● SCREW,SKT HD CAP, M6xM16 H/T BZP
21h 160-014 ●● WASHER, REPAIR (M6 x 25mm OD) BZP 10
9
8 7c
7f 7e7d
21h 13
21g 15 14
16
21f
17 17 14
21e 11
21d 18
17
21c 14
21b 1 19
21a 20 2 FIG 9
11
12 15 14

PL8.9 CRUSH & SIDE PLATES
PL8.10 CRUSH ASSEMBLY (1/2)
ITEM PART # DESCRIPTION 9 8 7 6 3 4 5 6 7

6 7 8 6 8
Fig10 907-958 P.ASSY, (ASM) CRUSH
1 2 3 4 5 10
1 907-959 ● P.ASSY, (ASM) BOLSTER DRIVE 3
4
2 253-859 ● STEEL, (ASM) SENSOR MOUNT L/H 5
3 905-376 ● ELECT ASSY,(ASM) PROX SENSOR 800mm 11
5 100-360 ● SCREW, SKT HD CAP, M3 x 14mm BLACK 12
7 160-204 ● WASHER, M5 SQ.SECT.SPRING BZP 11
9 253-349 ● STEEL, (VSPM) SENSOR MOUNT
10 253-860 ● STEEL, (ASM) SENSOR MOUNT R/H
11 265-572 ● SHAF T, SIDE COVER SPACER x 70mm LONG
15
12 16
13
14 265-659 ● SPACER,(VSPM) M6 x 111.5mm 10AF 14 17
24
15 160-212 ● WASHER, M8 FORM C BZP 23
8
17 100-359 ● SCREW, SKT HD CAP, M8 x 16mm BZP 23
22
18 907-986 ● P.ASSY, (ASM) IDLER SHAF T
18a 265-682 ●● SHAF T, (VSPM) IDLER
FIG 10 21b
18b 160-004 ●● WASHER, M6 FORM A BZP 21a
18c 100-355 ●● SCREW, SKT HD CAP, M6 x 12mm BZP 20 18b 18a
19 18c
19 907-432 ● P.ASSY, (VSPM) TENSION SPROCKET
20 710-016 ● ELEC-HARDWARE, CABLE TIE-small
21 907-955 ● P.ASSY, (ASM) SENSOR BR ACKET
21a 905-287 ●● EL ASSY, VARIO FIXED FOCUS SENSOR-STR
21b 253-908 ●● STEEL, (ASM) SENSOR BR ACKET

PL8.10 CRUSH ASSEMBLY
PL8.10 CRUSH ASSEMBLY (2/2)
ITEM PART # DESCRIPTION 9 8 7 6 3 4 5 6 7

6 7 8 6 8
22 253-906 ● STEEL, DRIVE MOUNTING PLATE
1 2 3 4 5 10
4
24 253-348 ● STEEL, (VSPM) MOUNTING BAR 5
11
11
12
13
11
14
15
12 16
13
14 17
24
23
8
8
23
22
FIG 10 21b
21a
20 18b 18a
19 18c

PL8.10 CRUSH ASSEMBLY
PL8.11 BOLSTER DRIVE ASSEMBLY (1/2)
9
8
7 10
6 11
Fig11 907-959 P.ASSY, (ASM) BOLSTER DRIVE 11
12
1 907-977 ● P.ASSY, CB-6 CLUTCH ANTI CLOCKWISE
1a 100-320 ●● SCREW, SKT HD CAP,1/4”20UNCx1 1/4” S/S 6
5
1b 160-203 ●● WASHER, M6 SQ.SECT.SPRING BZP 4
1c 160-004 ●● WASHER, M6 FORM A BZP 3
2
1d 192-439 ●● SPROCKET, 29T x 8mm PLATE WHEEL 1f
1e
1e 257-408 ●● ST STEEL, (VTM) SPACER 12.7x6.4x16 LG 1d
1f 760-342
1c
●● CLUTCH, CB6 ANTI-CLOCKWISE 3/4” BORE 1b
1a 13
2 265-661 ● SPACER,(VSPM) HEX M8 x 120mm 13AF
14
3 150-007 ● NUT, M8 HEX FULL BZP 13 15
4 360-408 ● TUBE, (VTM) 11mmO/D x 8mmI/D x 14mm LG 16 16
5 100-327 ● SCREW, SKT HD CAP, M8 x 35mm BZP 14
24 17
6 254-502 ● STEEL,KEY 3/16” SQx24/25mm LG FLAT END
18a 18
7 265-660 ● SHAF T, DRIVE 19mm dia x 455mm LONG
23 19
8 265-851 ● SHAF T, (ASM) HAND CR ANK 20
18k
9 192-458 ● SPROCKET,(VSPM) INTERMEDIATE DRIVE 15T
10 192-459 ● CHAIN,DRIVE 8mm x 57PITCH (+CON LINK) 14
11 149-201 ● GRUB SCREW, M4 x 6mm CUP POINT 15
12 192-457 ● SPROCKET, (VSPM) FINAL DRIVE - 30T 18j
13 400-392 ● PIN, DIA 4mm x 30mm LONG ROLL PIN 18i
14 180-099 ● SPRING, CIRCLIP 12.7mm SHAF T 1mm WIDE 18h
15 500-248 ● LABEL, (VTM) SAFETY BLADE GUARD 18g
21a
16 315-599 ● NYLON, (VSPM) SPACER x 5mm THICK 21k 22 18f 18e
21j 21b 18d
18c
21i 18b
21c 14
21h 17
21d 18a
21g 21e
21f FIG 11

PL8.11 BOLSTER DRIVE ASSEMBLY
PL8.11 BOLSTER DRIVE ASSEMBLY (2/2)
9
8
7 10
6 11
18 907-979 ● P.ASSY, (ASM) CAM LINK 11
12
18a 190-311 ●● BEAR,OILITE FLANGED ID1/2”xOD3/4”x1/2”
18b 907-978 ●● P.ASSY, (ASM) LINK ARM PILLAR 6
5
18c 265-664 ●● SHAF T, (VSPM) BALL BUSH 4
18d 180-381 ●● SPRING, (VSPM) DIE 3
2
18e 180-384 ●● SPRING, DISC 15 x 8.2 x 0.8thick 1f
1e
18f 253-911 ●● STEEL, (ASM) RETURN PLATE 1d
18g 100-094
1c
●● SCREW,SKT HD CAP,M5x10 HIGH TENSILE ZP 1b
1a 13
18h 160-005 ●● WASHER, M5 FORM C (12.5mmOD) BZP
14
18i 265-666 ●● SPACER, (VSPM) STAND-OFF POST 4mmLG 13 15
18j 320-302 ●● NYLON, WASHER 16mmODx8.2IDx.83mm thick 16 16
18k 265-662 ●● SHAF T, (VSPM) LINK ARM - UPPER 14
24 17
19 400-357 ● PIN, DIA 4mm x 40mm SPIROL PIN
18a 18
20 909-684 ● PART ASSY,(VTRM) CAM BLADE RETURN
23 19
21 907-388 ● P.ASSY, (VSPM) CARRIAGE GUIDE 20
18k
21a 265-667 ●● SHAF T, (VSPM) CARRIAGE GUIDE
21b 265-670 ●● SHAF T, (VSPM) ECCENTRIC COLLAR 14
21c 110-207 ●● SCREW, SKT HD SHLDER, M8 x 16mm (MOD) 15
21d 265-671 ●● SHAF T, (VSPM) CAM ROLLER - DELRIN 18j
21e 150-007 ●● NUT, M8 HEX FULL BZP 18i
21f 100-349 ●● SCREW,SKT HD CAP,M4x25 HIGH TENSILE 18h
21g 160-205 ●● WASHER, M4 SQ.SECT.SPRING BZP 18g
21a
21h 253-351 ●● STEEL, (VSPM) WHEEL PLATE 21k 22 18f 18e
21i 190-334 ●● BEARING, (VSPM) ROLLER FOLLOWER
21j 21b 18d
18c
21j 265-669 ●● SHAF T, (VSPM) CARRIAGE MOUNT 21i 18b
21c 14
21k 265-668 ●● SHAF T, (VSPM) CARRIAGE 21h 17
21d 18a
22 100-361 ● SCREW, SKT HD CAP, M3x16mm STAINLESS
21g 21e
23 100-318 ● SCREW, SKT HD CAP, M5 x 12mm STAINLESS FIG 11
21f
24 907-961 ● P.ASSY, (ASM) BOLSTER SIDE PLATES

PL8.11 BOLSTER DRIVE ASSEMBLY
PL8.12 BOLSTER SIDE PLATES (1/2)
ITEM PART # DESCRIPTION 7a

8
Fig12 907-961 P.ASSY, (ASM) BOLSTER SIDE PLATES 9
10
1 907-962 ● P.ASSY, (ASM) SIDE PLATE R/H 11
6 12
1a 251-435 ●● ALUMINIUM, (VSPM) SIDE PLATE 3 4 5 13
2c 7b
1b 190-346 ●● BEARING, FLANGED OILITE 1/2”x5/8”x1/2” 2a 2b
1d 1e 7c
1c 160-006 ●● WASHER, M10 FORM A BZP
1b 1c 14
1d 190-310 ●● BEAR, OILITE FLANGED ID3/4”xOD1”x3/4” 1a
1e 190-317 ●● BEARING, CAM ECCENTRIC 26mm 9 11
2 907-389 ● P.ASSY, (VSPM) BOLSTER 15
10
2a 265-674 ●● SHAF T, (VSPM) SPIGOT BLADE RETURN
8
2b 400-315 ●● PIN, NEEDLE ROLLER 5mm x 11.8mm
11
2c 251-437 ●● ALUMINIUM, (VSPM) BOLSTER
3 257-443 ● ST STEEL, (VSPM) BOLSTER SENSOR FLAG
7d
4 890-298 ● P.ASSY, (ASM) MAGNET ASSEMBLY 16 7e
17
5 180-403 ● SPRING, (ASM) CONICAL 18
13 19
6 251-438 ● ALUMINIUM, (VSPM) ANVIL CLAMP BAR 12
14
7 907-963 ● P.ASSY, (ASM) SIDE PLATE L/H 11
15
7a 190-346 ●● BEARING, FLANGED OILITE 1/2”x5/8”x1/2” 16 FIG 12
7b 160-006 ●● WASHER, M10 FORM A BZP
7c 190-310 ●● BEAR, OILITE FLANGED ID3/4”xOD1”x3/4”
7d 251-435 ●● ALUMINIUM, (VSPM) SIDE PLATE
7e 190-317 ●● BEARING, CAM ECCENTRIC 26mm
8 265-672 ● SHAF T, (VSPM) MOUNTING BLOCK
9 100-351 ● SCREW,SKT HD CAP,M6x20 H.TENSILE BZP
10 160-203 ● WASHER, M6 SQ.SECT.SPRING BZP
11 100-356 ● SCREW, SKT HD CAP, M6 x 25mm BZP
12 150-005 ● NUT, M5 HEX FULL BZP
13 315-447 ● PLASTIC, THUMB SCREW M5 x 20mm

PL8.12 BOLSTER SIDE PLATES
PL8.12 BOLSTER SIDE PLATES (2/2)
ITEM PART # DESCRIPTION 7a

8
10
6 12
16 190-317 ● BEARING, CAM ECCENTRIC 26mm 3 4 5 13
2c 7b
17 251-436 ● ALUMINIUM,(VSPM) TIE PLATE x 397mm LG 2a 2b
1d 1e 7c
18 150-315 ● NUT, M5 NYLOC-TYPE T HALF HEIGHT BZP
1b 1c 14
19 160-003 ● WASHER, M5 FORM A BZP 1a
9 11
10 15
8
11
7d
16 7e
17
18
13 19
12
14
11
15
16 FIG 12

PL8.12 BOLSTER SIDE PLATES
PL8.13 SIDE PLATE R/H ELECTRICS (1/3)
ITEM PART # DESCRIPTION 4* 6* 7 8 9a* 9b* 9c*9d* 9e*

5
Fig13* 907-989 P.ASSY, SIDE PLATE R/H ELECTRICS 115V 4 2c 2d 2e
1 2a 2b 3
Fig13** 890-048 P.ASSY, SIDE PLATE RH ELECTRICS 230V 2f
2g
1* 700-013 ● SWITCH, ILLUM 115V RED HIGH INRUSH 10a
1** 700-012 ● SWITCH, ILLUM 230V GREEN, 16A/150Apk 10b
10c
2 742-486 ● CABLE ASSEMBLY,(ASM) HIGH VOLTS 10d
2a 740-292 ●● WIRE ASSY, PUSH-ON/BLUE/PUSH-ON 2q 11
2p 4
2b 740-274 ●● WIRE, P-BKPUSH-ON/1.0mm2BLUE/720-070 4
2c 740-293 ●● WIRE ASSY, PUSH-ON/BROWN/PUSH-ON 2o 12
2e
2d 740-273 ●● WIRE, P-BKPUSH-ON/1.0mm2BROWN/720-070 32 13
2e 722-074 ●● SOCKET, MLX 4 WAY BODY 31 3
14
2f 740-279 ●● WIRE, 720-070/1.0mm2VIOLET/720-070 30 16
15
17
2g 740-278 ●● WIRE, 720-070/1.0mm2VIOLET/720-070 29
18
2h 710-016 ●● ELEC-HARDWARE, CABLE TIE-small 28 19
2i 740-276 ●● WIRE, 2BAEYELET/1.0mm2GN-Y/PUSH-ON 20
2n 2h
2j 740-283 ●● WIRE, 2BA-EYELET/1.0mm2GN-Y/720-070 21
2i 22
2k 740-282 ●● WIRE, 2BA-EYELET/1.0mm2GN-Y/720-070 12 23
11
2l 740-284 ●● WIRE, 2BA-EYELET/1.0mm2GN-Y/2BA-EYELET
2j
2m 740-275 ●● WIRE, 2BAEYELET/1.0mm2GN-Y/720-070 24 2m 2l 2k
26 25 11 4 2n
2n 722-073 ●● SOCKET, MLX 3 WAY BODY 27 4
2o 740-277 ●● WIRE, PUSH-ON/1.0mm2BROWN/720-070
FIG 13
2p 740-281 ●● WIRE, PUSH-ON/1.0mm2BLUE/720-070
2q 740-280 ●● WIRE, P-BKPUSH-ON/1.0mm2BLUE/720-070
4* 165-003 ● SHAKEPROOF WASHER, M5 INTERNAL BZP
4** 165-003 ● SHAKEPROOF WASHER, M5 INTERNAL BZP
5* 257-302 ● STAINLESS STEEL, MAIN SWITCH PLATE
6* 100-094 ● SCREW,SKT HD CAP,M5x10 HIGH TENSILE ZP

PL8.13 SIDE PLATE R/H ELECTRICS

5
7 900-141 ● PCB ASSEMBLY, POWER INTERFACE (ECO) 4 2c 2d 2e
1 2a 2b 3
8 742-493 ● CABLE ASSEMBLY,(ASM) LOW VOLTS POWER
2f
2g
9* 890-302 ● P.ASSY, (ASM) FAN & BR ACKET 10a
9a 150-002 ●● NUT, M3 HEX FULL BZP 10b
10c
9b 165-000 ●● SHAKEPROOF WASHER, M3 INTERNAL BZP 10d
9c 252-199 ●● STEEL, FAN BR ACKET 2q 11
2p 4
9d 905-389 ●● ELECTRICAL ASSEMBLY,(ASM) 12VDC FAN 4
9e 100-361 ●● SCREW, SKT HD CAP, M3x16mm STAINLESS 2o 12
2e
10 908-882 ● P.ASSY, (VBM) TR ANSFORMER & BR ACKET 32 13
10a 253-089 ●● STEEL, (VBM) TR ANSFORMER BR ACKET 31 3
14
10b 165-003 ●● SHAKEPROOF WASHER, M5 INTERNAL BZP 30 16
15
17
10c 101-300 ●● SCREW, SKT HD BUT TON,M5x 8mm STAINLESS 29
18
10d 905-154 ●● ELECT.ASSY, VARIO INPUT TR ANS.100-240V 28 19
11 150-005 ● NUT, M5 HEX FULL BZP 20
2n 2h
2i 22
13 101-301 ● SCREW, SKT HD BUT TON,M5x10mm STAINLESS 12 23
11
2j
15 165-000 ● SHAKEPROOF WASHER, M3 INTERNAL BZP 24 2m 2l 2k
26 25 11 4 2n
16* 500-252 ● LABEL, 115V 27 4
16** 500-009 ● LABEL, 230V
FIG 13
17 145-006 ● SCREW, POZI Mach C/S, M3 x 16mm BZP
18 730-008 ● FUSE,1.25” HOLDER (FOR 720-016/019)
19* 730-020 ● FUSE, 1.25”,10.0A, HRC-QUICK ACTING,F
19** 730-016 ● FUSE, 1.25”, 5.0A, HRC-QUICK ACTING,F
20 740-291 ● WIRE,PUSHON0.187/1.0mm2BROWN/PUSHON
21 740-272 ● WIRE,PUSH-ON0.187/1.0mm2GN/Y/2BAEYELET
22 720-019 ● PLUG, MAINS ENTRY - 10A


5
23 740-290 ● WIRE,PUSHON0.187/1.0mm2BLUE/PUSHON 4 2c 2d 2e
1 2a 2b 3
24 740-289 ● WIRE,PUSHON 1.0mm 2GN/Y/2BA-EYELET
2f
2g
25 500-254 ● LABEL, (VDRV) PRIMARY EARTH 10a
26 640-076 ● FILTER, MAINS - 100-250V 10A 50/60Hz 10b
10c
27 113-309 ● HEX HEAD SCREW, M5 x 30 HIGH TENSILE 10d
28 907-980 ● P.ASSY, (ASM) SIDE PLATE R/H 2q 11
2p 4
29 100-326 ● SCREW, SKT HD CAP, M3 x 10mm STAINLESS 4
30 905-377 ● ELECT ASSY,(ASM) CARRIAGE MTR 0R68 25W 2o 12
2e
31 160-002 ● WASHER, M3 FORM A BZP 32 13
32 150-033 ● NUT, M3 NYLOC-TYPE T BZP 31 3
14
30 16
15
17
29
18
28 19
20
2n 2h 21
2i 22
12 23
11
2j
24 2m 2l 2k
26 25 11 4 2n
27 4
FIG 13

PL8.14 SIDE PLATE R/H (1/2)
14 15
12 13 12
3 11
8 9 10
5 6 7
1 2 3
Fig14 907-980 P.ASSY, (ASM) SIDE PLATE R/H
1 100-350 ● SCREW,SKT HD CAP,M5x45 HIGH TENSILE ZP 29 11
2 265-814 ● SHAF T, (ASM) LOCATION POST 6 12
13
4 265-829 ● SHAF T, (ASM) LOCATION SPIGOT
28
5 710-341 ● ELEC-HARDWARE, PCB PILLAR 15.9mm
9
30
12
29
16
8 253-874 ● STEEL, (ASM) BEARING PLATE 22mm OD 29
9 252-089 ● STEEL, (ASM) COVER BR ACKET 17
3
10 265-839 ● SHAF T, (ASM) SPACER M5 x 19OD x 26.5L 6
28
7
12 160-052 ● WASHER, M5 x 20mm OD 3 18
15 330-013 ● RUBBER,GROMMET 25.5mmOD 22mmID 16SWG
7
16 265-822 ● SHAF T, (ASM) HEX SPACER 8AF x M5 x 60
17 253-815 ● STEEL, (ASM) BEARING PLATE
18 315-580 ● PLASTIC, MAINS TIE WR AP SPACER
22 315-561 ● PLASTIC, (VTM) BUMP STOP 27
23 150-034 ● NUT, M4 NYLOC-TYPE T HALF HEIGHT BZP 23
21
21 20
26 253-886 ● STEEL, (ASM) MOTOR SUPPORT BR ACKET
21 25
24 22 23 21 22
21 20 FIG 14

PL8.14 SIDE PLATE R/H
PL8.14 SIDE PLATE R/H (2/2)
14 15
12 13 12
3 11
8 9 10
5 6 7
3 4
1 3
27 907-950 ● P.ASSY, (ASM) SIDE FR AME R/H WELDED
28 500-006 ● LABEL, EARTH SYMBOL 29 11
30 711-091 ● CRIMP CONNECTOR, M5-0.25” SPADE 45 DEG 29
13
28
9
30
12
29
16
29
17
3
6
28
7
3 18
6 19
27
23
21
26 23
21 20
21 25
24 22 23 21 22
21 20 FIG 14

PL8.14 SIDE PLATE R/H
PL8.15 SIDE PLATE L/H (1/2)
1 2 3 4 5 6 7 8 9 1 2 10 5 3 11
Fig15 907-981 P.ASSY, (ASM) SIDE PLATE L/H 28
2
1 101-301 ● SCREW, SKT HD BUT TON,M5x10mm STAINLESS 5
3 252-089 ● STEEL, (ASM) COVER BR ACKET 14

26 2
5 160-052 ● WASHER, M5 x 20mm OD 27 14
6 253-816 ● STEEL, (ASM) DOUBLE BEARING PLATE 8 5
7 150-315 ● NUT, M5 NYLOC-TYPE T HALF HEIGHT BZP 7 7
26
9 265-839 ● SHAF T, (ASM) SPACER M5 x 19OD x 26.5L
8
11 265-829 ● SHAF T, (ASM) LOCATION SPIGOT 14
13 265-814 ● SHAF T, (ASM) LOCATION POST
19 315-561 ● PLASTIC, (VTM) BUMP STOP
20 253-886 ● STEEL, (ASM) MOTOR SUPPORT BR ACKET
22 955-014 ● SERVICE AID, (ASM) CR ANK BAR
23 710-327 ● ELEC-HARDWARE,S/A CABLE TIE PAD(SMALL)
24 710-016 ● ELEC-HARDWARE, CABLE TIE-small 21 18
19 18 17
25 500-236 ● LABEL, (VBM) HAND CR ANK DIRECTION 24 23
22 21
26 253-815 ● STEEL, (ASM) BEARING PLATE 18 21 FIG 15
20 18 19
18 17 16 15

PL8.15 SIDE PLATE L/H
PL8.15 SIDE PLATE L/H (2/2)
1 2 3 4 5 6 7 8 9 1 2 10 5 3 11
27 265-822 ● SHAF T, (ASM) HEX SPACER 8AF x M5 x 60 28
2
28 907-949 ● P.ASSY, (ASM) SIDE FR AME L/H WELDED 5
10 14
14
26 2
27 14
8 5
7 7
26 2
8
14
25
21 18
19 18 17
24 23
22 21
18 21 FIG 15
20 18 19
18 17 16 15

PL8.15 SIDE PLATE L/H
PL8.16 MAIN DRIVE ASSEMBLY
3e
ITEM2 IS FREQUENCY DEPENDENT
3d
3c
3b
3a
2
Fig16* 907-988 P.ASSY, (ASM) MAIN DRIVE 115V 1
Fig16** 907-814 P.ASSY, (ASM) MAIN DRIVE 230V
1 149-201 ● GRUB SCREW, M4 x 6mm CUP POINT
2* 192-466 ● SPROCKET, (VSPM) MOTOR 24T 115V
2** 192-464 ● SPROCKET, (VSPM) MOTOR 29T 230V
3* 905-379 ● EL ASSY, (ASM) BASE PAN & MOTOR 115V
3** 905-380 ● EL ASSY, (ASM) BASE PAN & MOTOR 230V
3a 165-204 ●● SHAKEPROOF WASHER, M8 EXTERNAL
3b 150-038 ●● NUT, M8 NYLOC-TYPE P BZP
3c* 905-351 ●● EL ASSY, (VSPM) MOTOR 115V
3c** 905-345 ●● EL ASSY, (VSPM) MOTOR 230V
3d* 500-252 ●● LABEL, 115V
3d** 500-009 ●● LABEL, 230V
3e 710-308 ●● ELEC-HARDWARE, CABLE CLAMP 7.9 dia
3f 160-011 ●● WASHER, M8 FORM B BZP
3g 150-007 ●● NUT, M8 HEX FULL BZP
3h* 253-389 ●● STEEL, (VSPM) SPACER PLATE
3i 907-815 ●● P.ASSY, (ASM) BASE PAN
3j 165-005 ●● SHAKEPROOF WASHER, M8 INTERNAL BZP
3k 100-327 ●● SCREW, SKT HD CAP, M8 x 35mm BZP
4 315-556 ● PLASTIC, (VBM) BUMP STOP 3c
3a
5 160-005 ● WASHER, M5 FORM C (12.5mmOD) BZP 3f
6 100-348 ● SCREW,SKT HD CAP,M5x20 HIGH TENSILE ZP 4 3g
5
6
FIG 16 3h*
3i
3j
3k

PL8.16 MAIN DRIVE ASSEMBLY
PL8.17 STOP MECHANISM (1/2)

3 4a
Fig17 907-404 P.ASSY, (VSPM) STOP MECHANISM 4b 4c
4d 5
1 907-395 ● P.ASSY, (VSPM) STOP 6 7
8 9
2 320-302 ● NYLON, WASHER 16mmODx8.2IDx.83mm thick 4e 4b
10 11
12 4f
3 907-396 ● P.ASSY, (VSPM) STOP MOUNT 13a14
15 16 17
4 907-397 ● P.ASSY, (VSPM) STOP ARM 1819
4a 105-317 ●● SCREW, SKT HD C/S, M5 x 10 (+ NYLON)
4b 190-335 ●● BEARING, FLANGED OILITE BUSH 8x12x12
4c 265-677 ●● WASHER, (VSPM) M5 SKT C’SK
4d 265-678 ●● SHAF T, (VSPM) STOP ARM
14
4e 149-201 ●● GRUB SCREW, M4 x 6mm CUP POINT
18 20
4f 265-679 ●● SHAF T, (VSPM) STOP ARM STUB x 90mm LG 26
18
5 257-365 ● ST STEEL, WASHER OD16mmxID8.2mmx0.5mm 16
6 257-366 ● ST STEEL, WASHER OD16mmxID8.2mmx0.25mm 18 16 13a
14 17
7 165-205 ● S/PROOF WASHER, M8 STAINLESS CRINKLE 18 25
19 13h
8 160-011 ● WASHER, M8 FORM B BZP 13g13f
18 20
13b
10 265-680 ● SHAF T, ADJUSTER BAR x 180mm LG 13d 13c
FIG 17 21
11 180-382 ● SPRING, (VSPM) COMPRESSION 22
24 23
12 265-681
23
● SHAF T, ADJUSTER STUB x 62mm LONG 13e
13 907-398 ● P.ASSY, (VSPM) ADJUSTER SUPPORT
13a 190-311 ●● BEAR,OILITE FLANGED ID1/2”xOD3/4”x1/2”
13b 315-447 ●● PLASTIC, THUMB SCREW M5 x 20mm
13c 150-005 ●● NUT, M5 HEX FULL BZP
13d 265-684 ●● SHAF T, (VSPM) SUPPORT SLEEVE (TAPPED)
13e 914-427 ●● BELT, TIMING T5 - 127t x 10mm WIDE
13f 100-357 ●● SCREW,SKT HD CAP,M5x25 HIGH TENSILE ZP
13g 907-399 ●● P.ASSY, (VSPM) ADJUSTER STOP SUPPORT
13h 190-335 ●● BEARING, FLANGED OILITE BUSH 8x12x12

PL8.17 STOP MECHANISM
PL8.17 STOP MECHANISM (2/2)

3 4a
14 150-005 ● NUT, M5 HEX FULL BZP 4b 4c
4d 5
15 907-425 ● P.ASSY, (VSPM) ADJ. SUPPORT R/H 6 7
8 9
16 100-347 ● SCREW,SKT HD CAP,M5x12 HIGH TENSILE ZP 4e 4b
10 11
12 4f
17 160-204 ● WASHER, M5 SQ.SECT.SPRING BZP 13a14
15 16 17
19 180-012 ● SPRING, COMPRESSION, 25.4mm x 11.5mm
21 192-460 ● PULLEY, FLANGED T5 - 16T
22 400-393 ● PIN, M3 x 18mm LG SPIROL
14
18 20
24 180-001 ● SPRING, 15mm x 20mm, 33 lb/in 26
18
25 907-424 ● P.ASSY, (VSPM) ADJ. SUPPORT L/H 16
26 150-315 ● NUT, M5 NYLOC-TYPE T HALF HEIGHT BZP 18 16 13a
14 17
18 25
19 13h
13g13f
18 20
13b
13d 13c
FIG 17 21
22
24 23
23
13e

PL8.17 STOP MECHANISM
PL8.18 STACKER ASSEMBLY (1/2) 9a 9b
9c 9d
9e
6 7 8
4 5
1 2 3
9c
9f
9g
Fig18 907-819 P.ASSY, (ASM) STACKER
9g
9g
2 9g
3 320-321 ● NYLON, SPACER OD12mmxID8.2mmx5mm LONG
26
4 265-445 ● SHAF T,(VOSC) SPACER 8mmODx5mmIDx22mm
5 310-377 ● PLASTIC MOULD, (V) PINCH WHEEL 25
10a
6 320-302 ● NYLON, WASHER 16mmODx8.2IDx.83mm thick
10b
10c
20 10e
9 907-821 ● P.ASSY, (ASM) STACKER SUPPORT
24 10d
9a 150-035 ●● NUT, M5 NYLOC-TYPE P BZP
11 11
9b 150-005 ●● NUT, M5 HEX FULL BZP
1 1
9c 165-003 ●● SHAKEPROOF WASHER, M5 INTERNAL BZP
23 12
9d 253-853 ●● STEEL, (ASM) STACKER TOP
13
9e 101-305 ●● SCREW, SKT HD BUT TON,M5x20mm STAINLESS 22
6
9f 101-301 ●● SCREW, SKT HD BUT TON,M5x10mm STAINLESS 21 5
9g 907-935 ●● P.ASSY, (ASM) FRONT SHAF T 22 14
10 907-946 ● P.ASSY, (ASM) STACKER LOCK ASSY 15
21
10a 253-854 ●● STEEL, (ASM) STACKER RELEASE LEVER 2
10b 265-833 ●● SHAF T, (ASM) TIE BAR 8 x 213.5
20
10c 310-377 ●● PLASTIC MOULD, (V) PINCH WHEEL
10d 180-302 ●● CIRCLIP 8mm SHAF T 0.66mm WIDE
10e 320-302 ●● NYLON, WASHER 16mmODx8.2IDx.83mm thick
11 105-320 ● SCREW,SKT HD C/S,M3x10 HIGH TENSILE ZP
12 253-887 ● STEEL, (ASM) BR ACKET STACKER GUIDE RH
19
18
14 265-850 ● SHAF T, (ASM) TIE BAR 8 x 149.4mm 1
7 16 2
17 2
17
FIG 18

PL8.18 STACKER ASSEMBLY
PL8.18 STACKER ASSEMBLY (2/2) 9a 9b
9c 9d
9e
6 7 8
4 5
1 2 3
9c
9f
15 907-975
9g
● P.ASSY, (ASM) STACKER DRIVE
16 253-856 ● STEEL, (ASM) BACK STOP STACKER
9g
17 100-347
9g
● SCREW,SKT HD CAP,M5x12 HIGH TENSILE ZP
2 9g
18 253-879 ● STEEL, (ASM) DEFLECTOR BR ACKET
26
19 907-976 ● P.ASSY, (ASM) TOP ELECTRICAL PLATE
20 150-005 ● NUT, M5 HEX FULL BZP 25
21 150-033
10a
● NUT, M3 NYLOC-TYPE T BZP
10b
10c
23 253-888 ● STEEL, (ASM) BR ACKET STACKER GUIDE LH
20 10e
24 10d
25 180-322 ● SPRING,(VFCN) BALANCE
11 11
1 1
23 12
13
22
6
21 5
22 14
21 15
2
20
19
18
7 2 1
2 16
17
17
FIG 18

PL8.18 STACKER ASSEMBLY
PL8.19 STACKER DRIVE ASSEMBLY (1/2)

3 6 7
Fig19 907-975 P.ASSY, (ASM) STACKER DRIVE
2 1b 1c 8 4
1a 9
1 907-944 ● P.ASSY, (ASM) STACKER PINCH DRIVE
1a 265-840 ●● SHAF T, SPACER M5 x 8OD x 166 & GROOVES
1b 180-302 ●● CIRCLIP 8mm SHAF T 0.66mm WIDE 10
1c 315-660 ●● PLASTIC, (ASM) NIP ROLLER 8x15x27 Lg 7
2 907-820
8
● P.ASSY, (ASM) STACKER TOP
2a 253-846 ●● STEEL, (ASM) STACKER TOP
2b 253-844 ●● STEEL, (ASM) SIDE PLATE R/H
9
2c 253-845 ●● STEEL, (ASM) SIDE PLATE L/H
4
3 253-852 ● STEEL, (ASM) STACKER SUPPORT L/H
14
6 310-610 ● PL MOULDING, ANTI-STATIC BEARING BUSH
10 190-321 ● BEARING,ROLLER FLANGE 22mmODx8mmIDx7mm 13a
13c 13b
11 907-940 ● P.ASSY, (ASM) STACKER DRIVE SHAF T 13f 13e 13d 11a
11a 310-691 ●● PLASTIC MLDG, ROLLER RETAINER 25.4mm 11d11c 11b
11f 11e
11b 400-405 ●● PIN, DIA 4mm x 20mm DOWEL FIG 19 11g 12
11c 310-690 ●● PLASTIC MOULDING, ROLLER 25.4mm
11d 400-355 ●● PIN, DIA 4mm x 24mm DOWEL
11e 192-496 ●● GEAR, (ASM) 37T WITH BOSS 1/2” BORE
11f 180-099 ●● SPRING, CIRCLIP 12.7mm SHAF T 1mm WIDE
11g 265-832 ●● SHAF T, (ASM) DRIVE SHAF T
12 914-503 ● BELT, (ASM) STACKER MAM-04Hx25x1012

PL8.19 STACKER DRIVE ASSEMBLY
PL8.19 STACKER DRIVE ASSEMBLY (2/2)

3 6 7
13 907-945 ● P.ASSY, (ASM) STACKER IDLER SHAF T
2 1b 1c 8 4
1a 9
13a 265-834 ●● SHAF T, (ASM) IDLER SHAF T
13b 907-596 ●● P.ASSY, (VOGB) PULLEY ASSY
13c 330-301 ●● RUBBER MOULDING, FEED WHEEL (WHITE) 10
13d 310-600 ●● PL MLDING, PINCH WHEEL BUSHx16.5mm LG 7
13e 320-302
8
●● NYLON, WASHER 16mmODx8.2IDx.83mm thick
13f 180-302 ●● CIRCLIP 8mm SHAF T 0.66mm WIDE
14 253-851 ● STEEL, (ASM) STACKER SUPPORT R/H
9
4
14
13a
13c 13b
13f 13e 13d 11a
11d11c 11b
11f 11e
FIG 19 11g 12

PL8.19 STACKER DRIVE ASSEMBLY
PL8.20 TOP ELECTRICAL PLATE 1 2
3 4 5 6 7

Fig20 907-976 P.ASSY, (ASM) TOP ELECTRICAL PLATE
3 253-865 ● STEEL, HAMLIN SENSOR BR ACKET
4 742-499 ● CABLE ASSEMBLY,(ASM) PAYOUT FEED SW
5 700-402 ● SWITCH, LEVER ARM - HAMLIN
6 330-049 ● RUBBER, GROMMET 3/8” BORE 16SWG PANEL
7 907-825 ● P.ASSY, (ASM) TOP PLATE
9 907-943 ● P.ASSY, STACKER DRIVE MOTOR SWITCH
9a 742-500 ●● CABLE ASSY,(ASM) PAYOUT FEED FULL SW
9b 907-954 ●● P.ASSY, (ASM) TR AY LIF T MOTOR & GEAR
9c 150-033 ●● NUT, M3 NYLOC-TYPE T BZP
9d 160-002 ●● WASHER, M3 FORM A BZP
9e 700-088 ●● SWITCH, (VTRM) BIN GUARD
9f 165-000 ●● SHAKEPROOF WASHER, M3 INTERNAL BZP
9g 101-002 ●● SCREW, SKT HD BUT TON, M3 x 10mm BLACK
9h 253-849 ●● STEEL, (ASM) MOTOR BR ACKET
9i 100-311
8
●● SCREW, SKT HD CAP, M3 x 25mm STAINLESS
10 900-201 ● PCB ASSEMBLY, ASM PAYOUT CONNECT
9a
11 710-329 ● ELEC-HARDWARE, PCB PILLAR 6.4mm
9i
14
13
12
9h 9g 9f 9e 9d 9c 9b FIG 20
PL8.20 TOP ELECTRICAL PLATE
PL8.21 INPUT CONVEYOR (1/2)

6 8
Fig21 907-818 P.ASSY, (ASM) SAMPLE CONVEYOR 5
2
7
4 5
3 330-013 ● RUBBER,GROMMET 25.5mmOD 22mmID 16SWG 3
2
4 265-271 ● SHAF T,(VSF) Dia8mmx365mm CONV TIE ROD
1 9
4
10a
5 180-302 ● CIRCLIP 8mm SHAF T 0.66mm WIDE 10b
6 320-302 ● NYLON, WASHER 16mmODx8.2IDx.83mm thick 10c
10d
7 190-321 ● BEARING,ROLLER FLANGE 22mmODx8mmIDx7mm 11
12
8 253-841 ● STEEL, (ASM) SAMPLE CONVEYOR BRKT R/H
9 914-502 ● BELT, SAMPLE CONVEYOR MAT-02Hx25x855
10 907-810 ● P.ASSY, (ASM) PICK UP DRIVE
10a 265-819 ●● SHAF T, (ASM) INFEED SHAF T 12.7 x 398
23
10c 400-405 ●● PIN, DIA 4mm x 20mm DOWEL FIG 21 23d 23c 1413
23b 16 15
10d 310-691 ●● PLASTIC MLDG, ROLLER RETAINER 25.4mm 17
2
11 253-842 ● STEEL, (ASM) SAMPLE CONVEYOR BRKT L/H 23a 7 6 18
22 19
21 20
12 400-355 ● PIN, DIA 4mm x 24mm DOWEL 5
14 192-497 ● GEAR, R/H HELICAL 14T 10DP ACETAL
18 180-374 ● SPRING STRUT, (VBM) LID STAY
21 257-366 ● ST STEEL, WASHER OD16mmxID8.2mmx0.25mm
22 257-365 ● ST STEEL, WASHER OD16mmxID8.2mmx0.5mm

PL8.21 INPUT CONVEYOR
PL8.21 INPUT CONVEYOR (2/2)

6 8
23 907-797 ● P.ASSY, (ASM) IDLER SHAF T 5
2
7
23b 400-405 ●● PIN, DIA 4mm x 20mm DOWEL 6
4 5
23c 310-690 ●● PLASTIC MOULDING, ROLLER 25.4mm 3
2
23d 265-818 ●● SHAF T, (ASM) INFEED IDLER SHAF T
1 9
4
10a
10b
10c
10d
11
12
23
FIG 21 23d 23c 1413
23b 16 15
17
2
23a 7 6 18
22 19
21 20
5

PL8.21 INPUT CONVEYOR
PL8.22 TOP DELIVERY ASSEMBLY (1/2) 3 4 5a 1b 1c
6a 7a 1d 1e 1f 7b
7c 7d
1a 2
8
5b

6b
Fig22 907-796 P.ASSY, (ASM) TOP DELIVERY ASSY
6c
1 907-974 ● P.ASSY, (ASM) COVER
1a 253-823 ●● STEEL, (ASM) COVER
6d
1b 160-003 ●● WASHER, M5 FORM A BZP 9

1c 101-301 ●● SCREW, SKT HD BUT TON,M5x10mm STAINLESS 10
1d 907-947 ●● P.ASSY, (ASM) TOP COVER
11
29 12
1e 165-003 ●● SHAKEPROOF WASHER, M5 INTERNAL BZP
10 13
1f 100-347 ●● SCREW,SKT HD CAP,M5x12 HIGH TENSILE ZP 9
14
15
28 16
4 257-511 ● STAINLESS STEEL, (ASM) LEAF SPRING
19 17
5 907-937 ● P.ASSY, (ASM) FEED WHEEL
10 18
5a 265-817 ●● SHAF T, (ASM) IDLER FEED SHAF T 3
3
5b 330-301 ●● RUBBER MOULDING, FEED WHEEL (WHITE)
18 10
6 907-938 ● P.ASSY, (ASM) OUTFEED 5 WHEEL SHAF T 19
2
6a 265-837 ●● SHAF T, (ASM) UPFEED SHAF T 12.7 x 398 2
20
6b 400-405 ●● PIN, DIA 4mm x 20mm DOWEL
20
23
6c 310-690
21
●● PLASTIC MOULDING, ROLLER 25.4mm
20
6d 310-691
3
●● PLASTIC MLDG, ROLLER RETAINER 25.4mm
22
7 907-936 ● P.ASSY, (ASM) TOP SHAF T OUTFEED
7a 265-838 ●● SHAF T, (ASM) TOP DEFLECTOR SHAF T
7c 310-691 ●● PLASTIC MLDG, ROLLER RETAINER 25.4mm
7d 310-690 ●● PLASTIC MOULDING, ROLLER 25.4mm
8 914-493 ● BELT, (ASM) MAT-02H-25-382 LONG
27
26
25 24
20 FIG 22
23
PL8.22 TOP DELIVERY ASSEMBLY
PL8.22 TOP DELIVERY ASSEMBLY (2/2) 3 4 5a 1b 1c
6a 7a 1d 1e 1f 7b
7c 7d
1a 2
8
5b

6b
6c
6d
14 192-498 ● GEAR, L/H HELICAL 14T 10DP ACETAL 9

15 320-342 ● NYLON, WASHER OD19mmxID13mmx0.80mm 10
11
29 12
17 257-546 ● ST STEEL, (ASM) CHANNEL BELT GUIDE
10 13
14
19 265-522 ● SHAF T, (VATR) SPACER DIA 8mmx5.1x8mmLG 1
15
28 16
21 907-798 ● P.ASSY, (ASM) LATCH ASSY L/H
19 17
10 18
3
24 890-091 ● P.ASSY, (ASM) UNDER COVER
18 10
25 907-995 ● P.ASSY, (ASM) UPFEED CONVEYOR 19
2
26 265-843 ● SHAF T, (ASM) TIE BAR 12.7 x 423 LONG 2
20
27 360-661 ● TUBE, (ASM) 17.2 OD x 1.5 WALL x 26.5
20
23
28 907-799
21
● P.ASSY, (ASM) LATCH ASSY R/H
20
29 310-610
3
● PL MOULDING, ANTI-STATIC BEARING BUSH
22
27
26
25 24
20 FIG 22
23
PL8.22 TOP DELIVERY ASSEMBLY
PL8.23 UPFEED CONVEYOR (1/2)
14
Fig23 907-995 P.ASSY, (ASM) UPFEED CONVEYOR 3
1 253-819 ● STEEL, (ASM) TOP DELIVERY FR AME L/H 4
2 907-826 ● P.ASSY, (ASM) NYLON WHEEL 12d
2a 265-820 ●● SHAF T, (ASM) TIE BAR 12.7 x 365 12c
2b 320-407 ●● NYLON, (ASM) WHEEL 150mm OD x 20mm ID 12b
2c 149-011 ●● GRUB SCREW, M5 x 8mm CONE POINT 12a
2d 265-821 ●● SHAF T, (ASM) WHEEL COLLAR 3 1
4
3 165-003 ● SHAKEPROOF WASHER, M5 INTERNAL BZP 2a
11e
11d 2b
11c 2c
11b
7 190-321 ● BEARING,ROLLER FLANGE 22mmODx8mmIDx7mm 2d
4
8 907-797 ● P.ASSY, (ASM) IDLER SHAF T 3
3
11a
8c 310-690 ●● PLASTIC MOULDING, ROLLER 25.4mm
8d 265-818 ●● SHAF T, (ASM) INFEED IDLER SHAF T
9 914-494 ● BELT, (ASM) MAT 02H x 25 x 1925 LONG
10 265-271 ● SHAF T,(VSF) Dia8mmx365mm CONV TIE ROD
11 907-939 ● P.ASSY, (ASM) TIE BAR 25.4mm ROLLERS
11a 180-099 ●● SPRING, CIRCLIP 12.7mm SHAF T 1mm WIDE
5
7 6
11b 320-342 ●● NYLON, WASHER OD19mmxID13mmx0.80mm
8c 8b 8a
11c 310-691 8d
●● PLASTIC MLDG, ROLLER RETAINER 25.4mm
10 9
11d 310-690 ●● PLASTIC MOULDING, ROLLER 25.4mm
11e 265-842 ●● SHAF T, (ASM) TIE BAR 12.7 x 365 3 FIG 23
4

PL8.23 UPFEED CONVEYOR
PL8.23 UPFEED CONVEYOR (2/2)
14
12 907-622 ● P.ASSY, (ASM) TIE BAR 25.4 ROLLERS 3
12a 180-099 ●● SPRING, CIRCLIP 12.7mm SHAF T 1mm WIDE 4
12b 310-691 ●● PLASTIC MLDG, ROLLER RETAINER 25.4mm 12d
12c 310-690 ●● PLASTIC MOULDING, ROLLER 25.4mm 12c
12d 265-842 ●● SHAF T, (ASM) TIE BAR 12.7 x 365 12b
13 253-818 ● STEEL, (ASM) TOP DELIVERY FR AME R/H 12a
14 253-872 ● STEEL, (ASM) BR ACKET LEAF SPRING 3 1
4
2a
11e
11d 2b
11c 2c
11b
2d
4
3
3
4
11a
5
7 6
8c 8b 8a
8d
10 9
3 FIG 23
4

PL8.23 UPFEED CONVEYOR
PL8.24 INFEED ASSEMBLY

2
Fig24 890-342 P.ASSY, (ASMD) INFEED ASSEMBLY 3
4a
1 890-317 ● P.ASSY, (ASMB) CONNECTING DRIVE 4b
4c
2 165-003
4d
● SHAKEPROOF WASHER, M5 INTERNAL BZP
4a 265-819 ●● SHAF T, (ASM) INFEED SHAF T 12.7 x 398 5
6
7
4c 400-405 ●● PIN, DIA 4mm x 20mm DOWEL
4d 310-691 ●● PLASTIC MLDG, ROLLER RETAINER 25.4mm
9 742-480 ● CABLE ASSEMBLY, ASM I/FACE ATM & TMP
10 890-319 ● P.ASSY, (ASMB) INFEED DRIVE
13 400-355 ● PIN, DIA 4mm x 24mm DOWEL 21
3
14 192-497 ● GEAR, R/H HELICAL 14T 10DP ACETAL 2
20
15 180-099 ● SPRING, CIRCLIP 12.7mm SHAF T 1mm WIDE 19
18 3 2 17 16 15 14 13 12 11 10 9 8
16 330-339 ● RUBBER,(VDPS) GROMMET FOR CYLINDER
17 907-828 ● P.ASSY, (BDF) INFEED COVER ASSY FIG 24
18 148-311 ● HAND SCREW, CROSS KNOB M5x 15mm
20 252-017 ● STEEL, (ASM) DUPLO ADJST DOCKING BRKT
21 252-018 ● STEEL, (ASM) DUPLO FIXED DOCKING BRKT

PL8.24 INFEED ASSEMBLY
PL8.25 INFEED DRIVE (1/2)

Fig25 890-319 P.ASSY, (ASMB) INFEED DRIVE 3 4
5
8 9
2 1
26 1
3 253-862 ● STEEL, (BDF) INFEED SIDEPLATE
4 265-271 ● SHAF T,(VSF) Dia8mmx365mm CONV TIE ROD 25
5 253-836 ● STEEL, (ASM) SENSOR PLATE
24
23
9 253-861 ● STEEL, (BDF) INFEED SIDEPLATE 22

10 330-013 ● RUBBER,GROMMET 25.5mmOD 22mmID 16SWG 1
11 180-302 ● CIRCLIP 8mm SHAF T 0.66mm WIDE 2
21d
14 900-198 ● PCB ASSEMBLY, SPINEMASTER AUTO I/F 21c 21b
21a
15 253-847 ● STEEL, (ASM) PCB MOUNTING PLATE
16 150-035 ● NUT, M5 NYLOC-TYPE P BZP 5 2 20
FIG 25 19 18
17 710-329 ● ELEC-HARDWARE, PCB PILLAR 6.4mm 17 16
15 7 14
18 160-003 ● WASHER, M5 FORM A BZP 13 12
11 10
19 740-266 ● WIRE, (ASPM) CASSET TE EARTH
21a 265-819 ●● SHAF T, (ASM) INFEED SHAF T 12.7 x 398
21c 400-405 ●● PIN, DIA 4mm x 20mm DOWEL
21d 310-691 ●● PLASTIC MLDG, ROLLER RETAINER 25.4mm

PL8.25 INFEED DRIVE
PL8.25 INFEED DRIVE (2/2)

23 320-342 ● NYLON, WASHER OD19mmxID13mmx0.80mm 3 4
5
24 192-498 ● GEAR, L/H HELICAL 14T 10DP ACETAL
8 9
25 180-099 ● SPRING, CIRCLIP 12.7mm SHAF T 1mm WIDE 2
2 1
26 1
25
24
23
22
1
2
21d
21c 21b
21a
5 2 20
FIG 25 19 18
17 16
15 7 14
13 12
11 10

PL8.25 INFEED DRIVE
PL8.26 ADJUSTABLE BASE
ITEM PART # DESCRIPTION B

11
Fig26_1 x ASSEMBLY, ASM ADJUSTABLE BASE 9
1 12J-79050 ● BASE-D
2 016-10179 ● CASTER 10 B
3 12J-67520 ● ANGLE
10 A
4 949-51180 ● RUBBER LEG
10
5 12J-67400 ● BR ACKET 7 8
11 6 10
6 12J-79120 ● SHAF T 8 7 4
6 7 5
7 12J-67420 ● SET-COLLAR 7 3 5
8
8 013-00071 ● COLLAR 7 6 7
5
9 12J-79160 ● BASE-T
3
10 12J-67060 ● R AIL 2
4 12
11 12J-79190 ● STAY A
2
12 12J-79210 ● FIXING PLATE 2
7 1
5
6 7 2
8
FIG 26_1

PL8.26 ADJUSTABLE BASE 355MM
PL8.27 CONNECTING DRIVE (1/2)
2
1
6c
6d
ITEM PART # DESCRIPTION 6b 7a
6a 7b
Fig27 890-317 P.ASSY, (ASMB) CONNECTING DRIVE 7c
5
1 7d
3 8
3 252-201 ● STEEL, (ASMB) BLANKING BR ACKET 2 7a
1
4 252-185 ● STEEL, (ASMB) INFEED COVER
7b
5 265-945 ● SHAF T, (ASMB) TIE BAR DIA8mm x 364mm
7c
6 890-320 ● P.ASSY, (ASMB) TOP IDLER
9
6a 265-924 ●● SHAF T, (ASMB) IDLER SHAF T
7d
6c 400-405
10
●● PIN, DIA 4mm x 20mm DOWEL
7 890-321 ● P.ASSY, (ASMB) TOP DRIVE 12 12
2
7a 265-925 ●● SHAF T, (ASMB) DRIVE SHAF T INFEED 21
1
7b 400-405 ●● PIN, DIA 4mm x 20mm DOWEL 12
10
7c 310-690 ●● PLASTIC MOULDING, ROLLER 25.4mm 11 11
7d 310-691 ●● PLASTIC MLDG, ROLLER RETAINER 25.4mm 10
12
8 914-867 ● BELT, (ASMB) MAT-O2H x 25 x 221 LG 16
10
9 914-868 ● BELT, (ASMB) MAT-O2H x 25 x 540LG 17
10 11
12
13
12 190-352 ● BEARING, FLANGED ROLLER 8mm ID x 16mm
14
13 890-279 ● P.ASSY, (ASMB) INFEED BKT LH WELDED
14 252-186 ● STEEL, (ASMB) INFEED BASE
15 265-984 ● SPACER, 8mmOD x 5.1mmID x 10.5mm
16 400-030 ● PIN, NEEDLE ROLLER 3mm x 12.8mm FIG 27
20
17 192-525 ● GEAR, (ASMB) 26T 8mm WIDE & SLOT 19
18
18 890-340 ● P.ASSY, (BDF) 26T ACETAL CW OILITE 10
17 12
16 11
15
11

PL8.27 CONNECTING DRIVE
PL8.27 CONNECTING DRIVE (2/2)
2
1
6c
6d
ITEM PART # DESCRIPTION 6b 7a
6a 7b
19 160-005 ● WASHER, M5 FORM C (12.5mmOD) BZP 7c
5
20 150-035 ● NUT, M5 NYLOC-TYPE P BZP 2
1 7d
21 330-352 ● RUBBER, (VSLM)’O’RING 7.6 X 1.78 THICK 4
3 8
22 890-278 ● P.ASSY, (ASMB) INFEED BKT RH WELDED 2 7a
1
7b
7c
9
7d
10
22 11
12 12
2
21
1
12
10
11 11
10
12
16
10
17
10 11
12
13
14
FIG 27
20
19
18
10
17 12
16 11
15
11

PL8.27 CONNECTING DRIVE
PL8.28 ACCESSORIES

1 x BR ACKET
2 12J-79310 COVER
3 12J-79230 CONNECTING BR ACKET
4 x CONNECTING BR ACKET 1
5 12J-79340 SHAF T
6 12J-79350 SET-COLLAR
7 12J-79360 SPARGEAR 5 6 7 8 9
8 98Y-11690 KEY 6x6
9 12J-79390 R ACK 1
10 12J-79400 R ACK 2
11 12J-79410 SPACER
12 x LEVEL ADJUSTER
13 96F-60381 PLATE
14 x PROTECT COVER 10 11 12 13 14
15 99V-90071 LABEL(for 120V, for 220-240V)
16 99V-90390 LABEL(for 100V)
17 99V-90940 LABEL(for 220-240V)
18 12K-82400 CONNECTING CABLE-20
19 12K-83500 FUSE UNIT
20 x SCREW (HSKW 6 x 12) 15 16 17 18
19 20 21 22 23

PL8.28 ACCESSORIES
INDEX8 SPINE MASTER (1/5)
013-00071 PL8.26 8 100-348 PL8.16 6 101-301 PL8.18(1/2) 9f 12K-82400 PL8.28 18 150-035 PL8.25(1/2) 16
016-10179 PL8.26 2 100-348 PL8.18(2/2) 24 101-301 PL8.19(1/2) 5 12K-83500 PL8.28 19 150-035 PL8.27(2/2) 20
100-094 PL8.1(1/2) 3 100-348 PL8.22(2/2) 18 101-301 PL8.22(1/2) 1c 145-006 PL8.13(2/3) 17 150-036 PL8.1(1/2) 1ba
100-094 PL8.10(2/2) 23 100-348 PL8.25(1/2) 8 101-301 PL8.22(2/2) 23 148-311 PL8.24 18 150-036 PL8.8 4
100-094 PL8.11(2/2) 18g 100-349 PL8.11(2/2) 21f 101-301 PL8.24 3 149-011 PL8.23(1/2) 2c 150-038 PL8.16 3b
100-094 PL8.13(1/3) 6 100-350 PL8.14(1/2) 1 101-301 PL8.27(1/2) 2 149-201 PL8.7(2/2) 24a 150-315 PL8.12(2/2) 18
100-094 PL8.20 13 100-350 PL8.15(1/2) 12 101-302 PL8.18(1/2) 1 149-201 PL8.11(1/2) 11 150-315 PL8.14(1/2) 7
100-094 PL8.25(1/2) 1 100-351 PL8.8 1 101-302 PL8.21(1/2) 17 149-201 PL8.16 1 150-315 PL8.15(1/2) 7
100-305 PL8.4(1/2) 4 100-351 PL8.9(1/2) 6 101-305 PL8.18(1/2) 9e 149-201 PL8.17(1/2) 4e 150-315 PL8.17(2/2) 26
100-306 PL8.3 1i 100-351 PL8.12(1/2) 9 101-307 PL8.1(2/2) 8c 150-002 PL8.13(2/3) 9a 150-315 PL8.18(1/2) 8
100-311 PL8.4(1/2) 1e 100-355 PL8.9(1/2) 7f 101-309 PL8.18(2/2) 26 150-002 PL8.13(2/3) 14 150-315 PL8.21(1/2) 20
100-311 PL8.20 9i 100-355 PL8.10(1/2) 18c 101-314 PL8.1(1/2) 1bh 150-005 PL8.12(1/2) 12 150-315 PL8.22(2/2) 22
100-318 PL8.11(2/2) 23 100-356 PL8.12(1/2) 11 101-323 PL8.3 1e 150-005 PL8.13(2/3) 11 160-001 PL8.3 1b
100-320 PL8.11(1/2) 1a 100-357 PL8.17(1/2) 13f 101-331 PL8.14(1/2) 24 150-005 PL8.17(1/2) 13c 160-001 PL8.4(2/2) 25
100-326 PL8.8 9 100-357 PL8.17(2/2) 20 101-331 PL8.15(1/2) 15 150-005 PL8.17(2/2) 14 160-001 PL8.8 14
100-326 PL8.13(3/3) 29 100-359 PL8.9(1/2) 2 105-301 PL8.8 15 150-005 PL8.18(1/2) 9b 160-001 PL8.14(1/2) 21
100-327 PL8.11(1/2) 5 100-359 PL8.10(1/2) 17 105-317 PL8.17(1/2) 4a 150-005 PL8.18(2/2) 20 160-001 PL8.15(1/2) 18
100-327 PL8.16 3k 100-360 PL8.10(1/2) 5 105-320 PL8.2 5 150-005 PL8.25(1/2) 20 160-002 PL8.2 9
100-331 PL8.1(1/2) 1bc 100-361 PL8.11(2/2) 22 105-320 PL8.18(1/2) 11 150-007 PL8.11(1/2) 3 160-002 PL8.4(1/2) 1d
100-342 PL8.4(2/2) 27 100-361 PL8.13(2/3) 9e 110-207 PL8.11(2/2) 21c 150-007 PL8.11(2/2) 21e 160-002 PL8.13(3/3) 31
100-347 PL8.2 8 100-367 PL8.4(2/2) 28 113-309 PL8.13(3/3) 27 150-007 PL8.16 3g 160-002 PL8.18(2/2) 22
100-347 PL8.4(2/2) 36 100-367 PL8.9(1/2) 12 12J-67060 PL8.26 10 150-033 PL8.1(1/2) 1bf 160-002 PL8.20 9d
100-347 PL8.5(2/2) 12 100-367 PL8.10(1/2) 6 12J-67400 PL8.26 5 150-033 PL8.2 10 160-003 PL8.1(2/2) 8d
100-347 PL8.6(1/2) 10 100-367 PL8.14(1/2) 13 12J-67420 PL8.26 7 150-033 PL8.4(1/2) 1a 160-003 PL8.10(1/2) 13
100-347 PL8.7(1/2) 11 100-367 PL8.15(1/2) 10 12J-67520 PL8.26 3 150-033 PL8.13(3/3) 32 160-003 PL8.12(2/2) 19
100-347 PL8.9(1/2) 17 100-369 PL8.8 8 12J-79050 PL8.26 1 150-033 PL8.18(2/2) 21 160-003 PL8.13(2/3) 12
100-347 PL8.13(1/3) 3 100-369 PL8.9(1/2) 8 12J-79120 PL8.26 6 150-033 PL8.20 9c 160-003 PL8.14(1/2) 6
100-347 PL8.14(2/2) 29 100-369 PL8.9(2/2) 21g 12J-79160 PL8.26 9 150-034 PL8.3 1a 160-003 PL8.15(1/2) 8
100-347 PL8.15(1/2) 14 100-373 PL8.9(2/2) 21b 12J-79190 PL8.26 11 150-034 PL8.4(2/2) 24 160-003 PL8.21(1/2) 19
100-347 PL8.17(2/2) 16 101-002 PL8.20 9g 12J-79210 PL8.26 12 150-034 PL8.14(1/2) 23 160-003 PL8.22(1/2) 1b
100-347 PL8.18(2/2) 17 101-047 PL8.14(1/2) 20 12J-79230 PL8.28 3 150-034 PL8.15(1/2) 21 160-003 PL8.25(1/2) 18
100-347 PL8.19(1/2) 9 101-047 PL8.15(1/2) 17 12J-79310 PL8.28 2 150-035 PL8.1(2/2) 8e 160-004 PL8.1(1/2) 1bb
100-347 PL8.20 1 101-300 PL8.13(2/3) 10c 12J-79340 PL8.28 5 150-035 PL8.4(2/2) 22 160-004 PL8.8 2
100-347 PL8.21(1/2) 1 101-301 PL8.2 1 12J-79350 PL8.28 6 150-035 PL8.6(1/2) 4 160-004 PL8.9(1/2) 7e
100-347 PL8.22(1/2) 1f 101-301 PL8.3 3 12J-79360 PL8.28 7 150-035 PL8.9(1/2) 15 160-004 PL8.9(1/2) 10
100-347 PL8.22(1/2) 2 101-301 PL8.13(2/3) 13 12J-79390 PL8.28 9 150-035 PL8.14(1/2) 14 160-004 PL8.10(1/2) 18b
100-347 PL8.23(1/2) 4 101-301 PL8.14(1/2) 11 12J-79400 PL8.28 10 150-035 PL8.15(1/2) 4 160-004 PL8.11(1/2) 1c
100-348 PL8.10(1/2) 12 101-301 PL8.15(1/2) 1 12J-79410 PL8.28 11 150-035 PL8.18(1/2) 9a 160-004 PL8.12(2/2) 15
5-269 Section 5—Parts List SPINE MASTER

INDEX8 SPINE MASTER
160-005 PL8.2 7 165-001 PL8.3 1d 180-099 PL8.5(1/2) 6 180-403 PL8.12(1/2) 5 192-458 PL8.11(1/2) 9
160-005 PL8.4(2/2) 29 165-001 PL8.4(1/2) 3 180-099 PL8.5(2/2) 21e 190-310 PL8.12(1/2) 1d 192-459 PL8.11(1/2) 10
160-005 PL8.9(1/2) 14 165-001 PL8.14(1/2) 25 180-099 PL8.5(2/2) 22b 190-310 PL8.12(1/2) 7c 192-460 PL8.17(2/2) 21
160-005 PL8.10(1/2) 8 165-001 PL8.15(1/2) 16 180-099 PL8.6(2/2) 20 190-311 PL8.11(2/2) 18a 192-461 PL8.9(1/2) 7d
160-005 PL8.11(2/2) 18h 165-002 PL8.8 3 180-099 PL8.7(1/2) 4g 190-311 PL8.17(1/2) 13a 192-464 PL8.16 2
160-005 PL8.16 5 165-002 PL8.9(1/2) 4 180-099 PL8.7(1/2) 9 190-317 PL8.12(1/2) 1e 192-466 PL8.16 2
160-005 PL8.17(2/2) 18 165-003 PL8.1(1/2) 2 180-099 PL8.7(2/2) 20b 190-317 PL8.12(1/2) 7e 192-489 PL8.6(1/2) 18
160-005 PL8.18(1/2) 7 165-003 PL8.2 2 180-099 PL8.11(1/2) 14 190-317 PL8.12(2/2) 16 192-491 PL8.7(2/2) 22
160-005 PL8.20 12 165-003 PL8.3 2 180-099 PL8.19(1/2) 11f 190-321 PL8.5(2/2) 16 192-494 PL8.6(1/2) 16
160-005 PL8.22(1/2) 3 165-003 PL8.4(2/2) 37 180-099 PL8.21(1/2) 13 190-321 PL8.6(1/2) 7 192-494 PL8.7(1/2) 8
160-005 PL8.24 19 165-003 PL8.5(1/2) 11 180-099 PL8.22(2/2) 13 190-321 PL8.7(1/2) 12 192-495 PL8.7(2/2) 19
160-005 PL8.27(2/2) 19 165-003 PL8.6(1/2) 5 180-099 PL8.23(1/2) 11a 190-321 PL8.19(1/2) 10 192-496 PL8.19(1/2) 11e
160-006 PL8.12(1/2) 1c 165-003 PL8.7(1/2) 10 180-099 PL8.23(2/2) 12a 190-321 PL8.21(1/2) 7 192-497 PL8.5(1/2) 2f
160-006 PL8.12(1/2) 7b 165-003 PL8.9(1/2) 11 180-099 PL8.24 15 190-321 PL8.22(2/2) 11 192-497 PL8.5(1/2) 3b
160-006 PL8.12(2/2) 14 165-003 PL8.13(1/3) 4 180-099 PL8.25(2/2) 25 190-321 PL8.23(1/2) 7 192-497 PL8.7(2/2) 20c
160-006 PL8.17(2/2) 23 165-003 PL8.13(1/3) 4 180-302 PL8.4(2/2) 26 190-321 PL8.24 5 192-497 PL8.21(1/2) 14
160-011 PL8.16 3f 165-003 PL8.13(2/3) 10b 180-302 PL8.5(2/2) 13 190-321 PL8.25(1/2) 13 192-497 PL8.24 14
160-011 PL8.17(1/2) 8 165-003 PL8.14(1/2) 3 180-302 PL8.6(1/2) 9 190-332 PL8.5(2/2) 18 192-498 PL8.7(1/2) 4f
160-014 PL8.9(2/2) 21h 165-003 PL8.15(1/2) 2 180-302 PL8.7(1/2) 14 190-333 PL8.9(1/2) 7a 192-498 PL8.22(2/2) 14
160-040 PL8.1(1/2) 1bd 165-003 PL8.18(1/2) 2 180-302 PL8.17(1/2) 9 190-334 PL8.11(2/2) 21i 192-498 PL8.25(2/2) 24
160-052 PL8.14(1/2) 12 165-003 PL8.18(1/2) 9c 180-302 PL8.18(1/2) 10d 190-335 PL8.17(1/2) 4b 192-500 PL8.9(1/2) 5
160-052 PL8.15(1/2) 5 165-003 PL8.19(1/2) 4 180-302 PL8.18(1/2) 13 190-335 PL8.17(1/2) 13h 192-502 PL8.8 6
160-203 PL8.9(1/2) 9 165-003 PL8.20 2 180-302 PL8.19(1/2) 1b 190-341 PL8.5(1/2) 9 192-525 PL8.27(1/2) 17
160-203 PL8.11(1/2) 1b 165-003 PL8.21(1/2) 2 180-302 PL8.19(1/2) 8 190-341 PL8.6(1/2) 13 251-435 PL8.12(1/2) 1a
160-203 PL8.12(1/2) 10 165-003 PL8.22(1/2) 1e 180-302 PL8.19(2/2) 13f 190-341 PL8.7(1/2) 5 251-435 PL8.12(1/2) 7d
160-204 PL8.10(1/2) 7 165-003 PL8.22(2/2) 20 180-302 PL8.21(1/2) 5 190-341 PL8.21(1/2) 16 251-436 PL8.12(2/2) 17
160-204 PL8.17(2/2) 17 165-003 PL8.23(1/2) 3 180-302 PL8.22(1/2) 9 190-341 PL8.22(2/2) 16 251-437 PL8.12(1/2) 2c
160-204 PL8.20 14 165-003 PL8.24 2 180-302 PL8.23(1/2) 5 190-341 PL8.24 11 251-438 PL8.12(1/2) 6
160-205 PL8.11(2/2) 21g 165-003 PL8.25(1/2) 2 180-302 PL8.24 7 190-341 PL8.25(1/2) 22 252-017 PL8.24 20
160-206 PL8.10(1/2) 16 165-003 PL8.27(1/2) 1 180-302 PL8.25(1/2) 11 190-346 PL8.12(1/2) 1b 252-018 PL8.24 21
160-212 PL8.9(2/2) 21c 165-005 PL8.9(1/2) 1 180-302 PL8.27(1/2) 10 190-346 PL8.12(1/2) 7a 252-071 PL8.1(1/2) 1bi
160-212 PL8.10(1/2) 15 165-005 PL8.16 3j 180-322 PL8.18(2/2) 25 190-352 PL8.27(1/2) 12 252-089 PL8.14(1/2) 9
165-000 PL8.1(1/2) 1bg 165-204 PL8.16 3a 180-355 PL8.4(2/2) 35a 192-395 PL8.7(2/2) 23 252-089 PL8.15(1/2) 3
165-000 PL8.8 10 165-205 PL8.17(1/2) 7 180-374 PL8.21(1/2) 18 192-439 PL8.11(1/2) 1d 252-185 PL8.27(1/2) 4
165-000 PL8.10(1/2) 4 180-001 PL8.17(2/2) 24 180-381 PL8.11(2/2) 18d 192-455 PL8.8 6 252-186 PL8.27(1/2) 14
165-000 PL8.13(2/3) 9b 180-012 PL8.17(2/2) 19 180-382 PL8.17(1/2) 11 192-456 PL8.5(2/2) 17 252-199 PL8.13(2/3) 9c
165-000 PL8.13(2/3) 15 180-099 PL8.5(1/2) 2g 180-383 PL8.8 13 192-457 PL8.11(1/2) 12 252-201 PL8.27(1/2) 3
165-000 PL8.20 9f 180-099 PL8.5(1/2) 3c 180-384 PL8.11(2/2) 18e 192-458 PL8.7(2/2) 24b 253-089 PL8.13(2/3) 10a

INDEX8 SPINE MASTER
253-347 PL8.9(1/2) 16 253-872 PL8.23(2/2) 14 265-664 PL8.11(2/2) 18c 265-826 PL8.7(1/2) 2d 310-690 PL8.7(1/2) 4b
253-348 PL8.10(2/2) 24 253-874 PL8.14(1/2) 8 265-666 PL8.11(2/2) 18i 265-827 PL8.5(2/2) 21a 310-690 PL8.19(1/2) 11c
253-349 PL8.10(1/2) 9 253-876 PL8.6(2/2) 19 265-667 PL8.11(2/2) 21a 265-829 PL8.14(1/2) 4 310-690 PL8.21(1/2) 10b
253-351 PL8.11(2/2) 21h 253-879 PL8.18(2/2) 18 265-668 PL8.11(2/2) 21k 265-829 PL8.15(1/2) 11 310-690 PL8.21(2/2) 23c
253-352 PL8.8 11 253-883 PL8.9(1/2) 7c 265-669 PL8.11(2/2) 21j 265-830 PL8.5(2/2) 22a 310-690 PL8.22(1/2) 6c
253-389 PL8.16 3h 253-886 PL8.14(1/2) 26 265-670 PL8.11(2/2) 21b 265-832 PL8.19(1/2) 11g 310-690 PL8.22(1/2) 7d
253-814 PL8.5(1/2) 10 253-886 PL8.15(1/2) 20 265-671 PL8.11(2/2) 21d 265-833 PL8.18(1/2) 10b 310-690 PL8.23(1/2) 8c
253-815 PL8.14(1/2) 17 253-887 PL8.18(1/2) 12 265-672 PL8.12(1/2) 8 265-834 PL8.19(2/2) 13a 310-690 PL8.23(1/2) 11d
253-815 PL8.15(1/2) 26 253-888 PL8.18(2/2) 23 265-673 PL8.8 12 265-835 PL8.5(1/2) 4c 310-690 PL8.23(2/2) 12c
253-816 PL8.15(1/2) 6 253-906 PL8.10(2/2) 22 265-674 PL8.12(1/2) 2a 265-837 PL8.22(1/2) 6a 310-690 PL8.24 4b
253-818 PL8.23(2/2) 13 253-908 PL8.10(1/2) 21b 265-677 PL8.17(1/2) 4c 265-838 PL8.22(1/2) 7a 310-690 PL8.25(1/2) 21b
253-819 PL8.23(1/2) 1 253-911 PL8.11(2/2) 18f 265-678 PL8.17(1/2) 4d 265-839 PL8.14(1/2) 10 310-690 PL8.27(1/2) 6b
253-823 PL8.22(1/2) 1a 254-502 PL8.7(2/2) 24d 265-679 PL8.17(1/2) 4f 265-839 PL8.15(1/2) 9 310-690 PL8.27(1/2) 7c
253-826 PL8.6(1/2) 14 254-502 PL8.11(1/2) 6 265-680 PL8.17(1/2) 10 265-840 PL8.19(1/2) 1a 310-691 PL8.5(1/2) 2d
253-828 PL8.4(2/2) 34 255-395 PL8.9(2/2) 21f 265-681 PL8.17(1/2) 12 265-841 PL8.7(1/2) 4a 310-691 PL8.5(2/2) 20c
253-829 PL8.4(2/2) 32 257-302 PL8.13(1/3) 5 265-682 PL8.9(2/2) 21d 265-842 PL8.23(1/2) 11e 310-691 PL8.5(2/2) 21c
253-836 PL8.25(1/2) 5 257-357 PL8.2 6 265-682 PL8.10(1/2) 18a 265-842 PL8.23(2/2) 12d 310-691 PL8.6(1/2) 3d
253-840 PL8.3 1f 257-357 PL8.4(2/2) 30 265-683 PL8.9(1/2) 3 265-843 PL8.7(1/2) 3 310-691 PL8.6(2/2) 25
253-841 PL8.21(1/2) 8 257-365 PL8.17(1/2) 5 265-684 PL8.17(1/2) 13d 265-843 PL8.22(2/2) 26 310-691 PL8.7(1/2) 2a
253-842 PL8.21(1/2) 11 257-365 PL8.21(1/2) 22 265-814 PL8.14(1/2) 2 265-844 PL8.6(2/2) 23 310-691 PL8.7(1/2) 4d
253-844 PL8.19(1/2) 2b 257-366 PL8.17(1/2) 6 265-814 PL8.15(1/2) 13 265-850 PL8.18(1/2) 14 310-691 PL8.19(1/2) 11a
253-845 PL8.19(1/2) 2c 257-366 PL8.21(1/2) 21 265-816 PL8.7(2/2) 24c 265-851 PL8.11(1/2) 8 310-691 PL8.21(1/2) 10d
253-846 PL8.19(1/2) 2a 257-408 PL8.11(1/2) 1e 265-817 PL8.22(1/2) 5a 265-924 PL8.27(1/2) 6a 310-691 PL8.21(2/2) 23a
253-847 PL8.25(1/2) 15 257-443 PL8.12(1/2) 3 265-818 PL8.21(2/2) 23d 265-925 PL8.27(1/2) 7a 310-691 PL8.22(1/2) 6d
253-848 PL8.4(2/2) 31 257-501 PL8.6(1/2) 6 265-818 PL8.23(1/2) 8d 265-945 PL8.27(1/2) 5 310-691 PL8.22(1/2) 7c
253-849 PL8.20 9h 257-503 PL8.9(1/2) 18 265-819 PL8.21(1/2) 10a 265-984 PL8.27(1/2) 15 310-691 PL8.23(1/2) 8a
253-851 PL8.19(2/2) 14 257-511 PL8.22(1/2) 4 265-819 PL8.24 4a 310-377 PL8.18(1/2) 5 310-691 PL8.23(1/2) 11c
253-852 PL8.19(1/2) 3 257-546 PL8.22(2/2) 17 265-819 PL8.25(1/2) 21a 310-377 PL8.18(1/2) 10c 310-691 PL8.23(2/2) 12b
253-853 PL8.18(1/2) 9d 265-271 PL8.21(1/2) 4 265-820 PL8.23(1/2) 2a 310-600 PL8.19(2/2) 13d 310-691 PL8.24 4d
253-854 PL8.18(1/2) 10a 265-271 PL8.23(1/2) 10 265-821 PL8.23(1/2) 2d 310-610 PL8.5(2/2) 15 310-691 PL8.25(1/2) 21d
253-855 PL8.4(1/2) 1c 265-271 PL8.25(1/2) 4 265-822 PL8.14(1/2) 16 310-610 PL8.19(1/2) 6 310-691 PL8.27(1/2) 6d
253-856 PL8.18(2/2) 16 265-445 PL8.18(1/2) 4 265-822 PL8.15(2/2) 27 310-610 PL8.22(2/2) 29 310-691 PL8.27(1/2) 7d
253-858 PL8.1(2/2) 8b 265-522 PL8.22(2/2) 19 265-823 PL8.5(1/2) 3d 310-690 PL8.5(1/2) 2b 310-708 PL8.5(2/2) 22c
253-859 PL8.10(1/2) 2 265-572 PL8.10(1/2) 11 265-823 PL8.7(2/2) 20a 310-690 PL8.5(2/2) 20b 315-447 PL8.12(1/2) 13
253-860 PL8.10(1/2) 10 265-659 PL8.10(1/2) 14 265-825 PL8.5(1/2) 2a 310-690 PL8.5(2/2) 21b 315-447 PL8.17(1/2) 13b
253-861 PL8.25(1/2) 9 265-660 PL8.11(1/2) 7 265-826 PL8.5(2/2) 20a 310-690 PL8.6(1/2) 3b 315-556 PL8.16 4
253-862 PL8.25(1/2) 3 265-661 PL8.11(1/2) 2 265-826 PL8.6(1/2) 1c 310-690 PL8.6(2/2) 24 315-561 PL8.14(1/2) 22
253-865 PL8.20 3 265-662 PL8.11(2/2) 18k 265-826 PL8.6(1/2) 3a 310-690 PL8.7(1/2) 2c 315-561 PL8.15(1/2) 19

INDEX8 SPINE MASTER
315-580 PL8.14(1/2) 18 330-013 PL8.21(1/2) 3 400-405 PL8.21(2/2) 23b 710-016 PL8.20 8 742-406 PL8.3 1h
315-598 PL8.5(1/2) 4a 330-013 PL8.25(1/2) 10 400-405 PL8.22(1/2) 6b 710-016 PL8.24 8 742-480 PL8.24 9
315-599 PL8.11(1/2) 16 330-049 PL8.20 6 400-405 PL8.22(1/2) 7b 710-016 PL8.25(1/2) 7 742-485 PL8.1(1/2) 1be
315-603 PL8.4(1/2) 9 330-301 PL8.19(2/2) 13c 400-405 PL8.23(1/2) 8b 710-057 PL8.3 1c 742-486 PL8.13(1/3) 2
315-660 PL8.19(1/2) 1c 330-301 PL8.22(1/2) 5b 400-405 PL8.24 4c 710-058 PL8.3 1c 742-487 PL8.4(1/2) 17
320-302 PL8.5(2/2) 14 330-339 PL8.24 16 400-405 PL8.25(1/2) 21c 710-308 PL8.16 3e 742-489 PL8.4(1/2) 16
320-302 PL8.6(1/2) 8 330-352 PL8.27(2/2) 21 400-405 PL8.27(1/2) 6c 710-327 PL8.15(1/2) 23 742-490 PL8.4(1/2) 19
320-302 PL8.7(1/2) 13 360-408 PL8.11(1/2) 4 400-405 PL8.27(1/2) 7b 710-329 PL8.20 11 742-492 PL8.4(1/2) 2
320-302 PL8.11(2/2) 18j 360-661 PL8.22(2/2) 27 500-006 PL8.14(2/2) 28 710-329 PL8.25(1/2) 17 742-493 PL8.13(2/3) 8
320-302 PL8.17(1/2) 2 400-030 PL8.6(1/2) 17 500-009 PL8.3 1g 710-341 PL8.14(1/2) 5 742-494 PL8.4(1/2) 18
320-302 PL8.18(1/2) 6 400-030 PL8.27(1/2) 16 500-009 PL8.13(2/3) 16 711-091 PL8.14(2/2) 30 742-495 PL8.4(1/2) 15
320-302 PL8.18(1/2) 10e 400-315 PL8.12(1/2) 2b 500-009 PL8.16 3d 720-019 PL8.13(2/3) 22 742-499 PL8.20 4
320-302 PL8.19(1/2) 7 400-355 PL8.5(1/2) 2e 500-236 PL8.15(1/2) 25 722-073 PL8.13(1/3) 2n 742-500 PL8.20 9a
320-302 PL8.19(2/2) 13e 400-355 PL8.5(1/2) 3a 500-248 PL8.11(1/2) 15 722-074 PL8.13(1/3) 2e 742-501 PL8.4(2/2) 20
320-302 PL8.21(1/2) 6 400-355 PL8.5(2/2) 22d 500-252 PL8.3 1g 730-008 PL8.13(2/3) 18 742-514 PL8.1(1/2) 1bj
320-302 PL8.22(1/2) 10 400-355 PL8.7(1/2) 4e 500-252 PL8.13(2/3) 16 730-016 PL8.13(2/3) 19 742-518 PL8.4(1/2) 7
320-302 PL8.23(1/2) 6 400-355 PL8.7(1/2) 7 500-252 PL8.16 3d 730-020 PL8.13(2/3) 19 742-521 PL8.4(2/2) 21
320-302 PL8.24 6 400-355 PL8.7(2/2) 20d 500-254 PL8.13(3/3) 25 740-003 PL8.1(1/2) 4 760-339 PL8.4(2/2) 35b
320-302 PL8.25(1/2) 12 400-355 PL8.19(1/2) 11d 500-258 PL8.5(1/2) 5 740-006 PL8.1(1/2) 4 760-342 PL8.11(1/2) 1f
320-302 PL8.27(1/2) 11 400-355 PL8.21(1/2) 12 500-275 PL8.4(1/2) 13 740-266 PL8.25(1/2) 19 890-006 PL8.2 11
320-304 PL8.4(2/2) 23 400-355 PL8.22(2/2) 12 62-041 PL8.1(1/2) Fig1 740-272 PL8.13(2/3) 21 890-006 PL8.3 Fig3
320-321 PL8.18(1/2) 3 400-355 PL8.24 13 62-042 PL8.1(1/2) Fig1 740-273 PL8.13(1/3) 2d 890-007 PL8.1(2/2) 9
320-323 PL8.5(1/2) 7 400-355 PL8.25(2/2) 26 62-094 PL8.1(1/2) 1 740-274 PL8.13(1/3) 2b 890-007 PL8.2 Fig2
320-323 PL8.6(1/2) 12 400-357 PL8.11(2/2) 19 640-076 PL8.13(3/3) 26 740-275 PL8.13(1/3) 2m 890-046 PL8.9(2/2) 21e
320-323 PL8.7(2/2) 17 400-384 PL8.4(2/2) 33 700-012 PL8.13(1/3) 1 740-276 PL8.13(1/3) 2i 890-048 PL8.9(1/2) 13
320-323 PL8.11(1/2) 17 400-391 PL8.5(1/2) 4b 700-013 PL8.13(1/3) 1 740-277 PL8.13(1/3) 2o 890-048 PL8.13(1/3) Fig13
320-342 PL8.5(1/2) 8 400-392 PL8.6(1/2) 1a 700-088 PL8.4(1/2) 1b 740-278 PL8.13(1/3) 2g 890-061 PL8.3 1
320-342 PL8.5(2/2) 21d 400-392 PL8.11(1/2) 13 700-088 PL8.20 9e 740-279 PL8.13(1/3) 2f 890-091 PL8.22(2/2) 24
320-342 PL8.6(2/2) 21 400-393 PL8.17(2/2) 22 700-104 PL8.4(1/2) 6 740-280 PL8.13(1/3) 2q 890-278 PL8.27(2/2) 22
320-342 PL8.7(1/2) 6 400-405 PL8.5(1/2) 2c 700-402 PL8.20 5 740-281 PL8.13(1/3) 2p 890-279 PL8.27(1/2) 13
320-342 PL8.21(1/2) 15 400-405 PL8.5(2/2) 20d 700-420 PL8.4(1/2) 11 740-282 PL8.13(1/3) 2k 890-298 PL8.12(1/2) 4
320-342 PL8.22(2/2) 15 400-405 PL8.6(1/2) 3c 700-421 PL8.4(1/2) 10 740-283 PL8.13(1/3) 2j 890-302 PL8.13(2/3) 9
320-342 PL8.23(1/2) 11b 400-405 PL8.6(1/2) 15 700-422 PL8.4(1/2) 8 740-284 PL8.13(1/3) 2l 890-317 PL8.24 1
320-342 PL8.24 12 400-405 PL8.7(1/2) 2b 710-016 PL8.4(2/2) 38 740-289 PL8.13(3/3) 24 890-317 PL8.27(1/2) Fig27
320-342 PL8.25(2/2) 23 400-405 PL8.7(1/2) 4c 710-016 PL8.10(1/2) 20 740-290 PL8.13(3/3) 23 890-319 PL8.24 10
320-407 PL8.23(1/2) 2b 400-405 PL8.7(2/2) 16 710-016 PL8.13(1/3) 2h 740-291 PL8.13(2/3) 20 890-319 PL8.25(1/2) Fig25
320-409 PL8.6(1/2) 1b 400-405 PL8.19(1/2) 11b 710-016 PL8.14(1/2) 19 740-292 PL8.13(1/3) 2a 890-320 PL8.27(1/2) 6
330-013 PL8.14(1/2) 15 400-405 PL8.21(1/2) 10c 710-016 PL8.15(1/2) 24 740-293 PL8.13(1/3) 2c 890-321 PL8.27(1/2) 7

INDEX8 SPINE MASTER
890-340 PL8.27(1/2) 18 907-798 PL8.22(2/2) 21 907-945 PL8.19(2/2) 13 907-984 PL8.6(2/2) 22 914-504 PL8.6(2/2) 26
890-342 PL8.1(1/2) 1a 907-799 PL8.22(2/2) 28 907-946 PL8.18(1/2) 10 907-984 PL8.7(1/2) Fig7 914-507 PL8.7(2/2) 18
890-342 PL8.24 Fig24 907-802 PL8.7(1/2) 4 907-947 PL8.22(1/2) 1d 907-985 PL8.5(2/2) 19 914-508 PL8.7(2/2) 15
900-141 PL8.13(2/3) 7 907-803 PL8.5(1/2) 2 907-948 PL8.3 4 907-985 PL8.6(1/2) Fig6 914-511 PL8.6(1/2) 11
900-197 PL8.4(1/2) 14 907-804 PL8.5(2/2) 20 907-948 PL8.4(1/2) Fig4 907-986 PL8.10(1/2) 18 914-863 PL8.1(1/2) 1b
900-198 PL8.25(1/2) 14 907-804 PL8.6(1/2) 3 907-949 PL8.15(2/2) 28 907-987 PL8.7(2/2) 21 914-867 PL8.27(1/2) 8
900-201 PL8.20 10 907-804 PL8.7(1/2) 2 907-950 PL8.14(2/2) 27 907-987 PL8.8 Fig8 914-868 PL8.27(1/2) 9
905-154 PL8.13(2/3) 10d 907-805 PL8.5(2/2) 21 907-951 PL8.5(2/2) 22 907-988 PL8.8 5 949-51180 PL8.26 4
905-287 PL8.10(1/2) 21a 907-810 PL8.21(1/2) 10 907-952 PL8.6(1/2) 1 907-988 PL8.16 Fig16 955-014 PL8.15(1/2) 22
905-343 PL8.9(1/2) 7b 907-810 PL8.24 4 907-953 PL8.5(1/2) 3 907-989 PL8.9(1/2) 13 96F-60381 PL8.28 13
905-345 PL8.16 3c 907-810 PL8.25(1/2) 21 907-953 PL8.7(2/2) 20 907-989 PL8.13(1/3) Fig13 98Y-11690 PL8.28 8
905-351 PL8.16 3c 907-814 PL8.8 5 907-954 PL8.20 9b 907-990 PL8.8 16 99V-90071 PL8.28 15
905-376 PL8.10(1/2) 3 907-814 PL8.16 Fig16 907-955 PL8.10(1/2) 21 907-990 PL8.9(1/2) Fig9 99V-90390 PL8.28 16
905-377 PL8.13(3/3) 30 907-815 PL8.16 3i 907-957 PL8.1(2/2) 8 907-991 PL8.6(2/2) 22 99V-90940 PL8.28 17
905-379 PL8.16 3 907-816 PL8.4(1/2) 5 907-958 PL8.9(2/2) 19 907-991 PL8.7(1/2) Fig7 - - -
905-380 PL8.16 3 907-816 PL8.5(1/2) Fig5 907-958 PL8.10(1/2) Fig10 907-992 PL8.5(2/2) 19 - - -
905-389 PL8.13(2/3) 9d 907-817 PL8.3 1 907-959 PL8.10(1/2) 1 907-992 PL8.6(1/2) Fig6 - - -
907-200 PL8.4(2/2) 35 907-818 PL8.2 4 907-959 PL8.11(1/2) Fig11 907-993 PL8.4(1/2) 5 - - -
907-388 PL8.11(2/2) 21 907-818 PL8.21(1/2) Fig21 907-961 PL8.11(2/2) 24 907-993 PL8.5(1/2) Fig5 - - -
907-389 PL8.12(1/2) 2 907-819 PL8.2 3 907-961 PL8.12(1/2) Fig12 907-994 PL8.5(1/2) 4 - - -
907-395 PL8.17(1/2) 1 907-819 PL8.18(1/2) Fig18 907-962 PL8.12(1/2) 1 907-995 PL8.22(2/2) 25 - - -
907-396 PL8.17(1/2) 3 907-820 PL8.19(1/2) 2 907-963 PL8.12(1/2) 7 907-995 PL8.23(1/2) Fig23 - - -
907-397 PL8.17(1/2) 4 907-821 PL8.18(1/2) 9 907-974 PL8.22(1/2) 1 907-996 PL8.3 4 - - -
907-398 PL8.17(1/2) 13 907-822 PL8.4(1/2) 1 907-975 PL8.18(2/2) 15 907-996 PL8.4(1/2) Fig4 - - -
907-399 PL8.17(1/2) 13g 907-825 PL8.20 7 907-975 PL8.19(1/2) Fig19 907-997 PL8.1(2/2) 9 - - -
907-404 PL8.8 7 907-826 PL8.23(1/2) 2 907-976 PL8.18(2/2) 19 907-997 PL8.2 Fig2 - - -
907-404 PL8.17(1/2) Fig17 907-828 PL8.24 17 907-976 PL8.20 Fig20 907-998 PL8.2 11 - - -
907-424 PL8.17(2/2) 25 907-838 PL8.9(2/2) 21a 907-977 PL8.11(1/2) 1 907-998 PL8.3 Fig3 - - -
907-425 PL8.17(2/2) 15 907-839 PL8.9(2/2) 21 907-978 PL8.11(2/2) 18b 908-882 PL8.13(2/3) 10 - - -
907-426 PL8.4(1/2) 12 907-840 PL8.9(1/2) 7 907-979 PL8.11(2/2) 18 909-684 PL8.11(2/2) 20 - - -
907-432 PL8.10(1/2) 19 907-935 PL8.18(1/2) 9g 907-980 PL8.13(3/3) 28 914-427 PL8.17(1/2) 13e - - -
907-596 PL8.19(2/2) 13b 907-936 PL8.22(1/2) 7 907-980 PL8.14(1/2) Fig14 914-493 PL8.22(1/2) 8 - - -
907-622 PL8.23(2/2) 12 907-937 PL8.22(1/2) 5 907-981 PL8.9(2/2) 20 914-494 PL8.23(1/2) 9 - - -
907-795 PL8.7(2/2) 24 907-938 PL8.22(1/2) 6 907-981 PL8.15(1/2) Fig15 914-495 PL8.5(1/2) 1 - - -
907-796 PL8.2 12 907-939 PL8.23(1/2) 11 907-982 PL8.8 16 914-496 PL8.7(1/2) 1 - - -
907-796 PL8.22(1/2) Fig22 907-940 PL8.19(1/2) 11 907-982 PL8.9(1/2) Fig9 914-498 PL8.6(1/2) 2 - - -
907-797 PL8.21(2/2) 23 907-943 PL8.20 9 907-983 PL8.7(2/2) 21 914-502 PL8.21(1/2) 9 - - -
907-797 PL8.23(1/2) 8 907-944 PL8.19(1/2) 1 907-983 PL8.8 Fig8 914-503 PL8.19(1/2) 12 - - -

INDEX8 SPINE MASTER
PL9.1 PC (For north America)

1 A A0SCCPC PT-5500
5-274 Section 5—Parts List PC

PL9.1 PC (For north America)
Section 6
General Procedures
Contents
Section 6 General Procedures .....................................6-1
GP1.1 Proper shutdown of Inline Controller ..... 6-2
GP1.2 Activating Machines Independently ....... 6-3
GP1.3 TAG Sheet ............................................. 6-5
GP1.4 Releasing Safety Switch........................ 6-6
GP1.5 iGen3 Finisher Profile Settings ...............6-7
GP2.1 Maintenance Mode of Interface Box .... 6-11
GP2.2 Maintenance Mode of TR-DP ...............6-12
GP2.3 Maintenance Mode of SCC ..................6-17
GP2.5 Maintenance Mode of DBM-500 ......... 6-25
GP2.5a Wire Replacement ............................... 6-35
GP2.6 Maintenance Mode of DBM-500T ....... 6-36
GP2.7 Cycling the SpineMaster by Hand ....... 6-40
GP3.0 Updating Programs of
Inline Controller ................................... 6-41
GP3.1 Updating Programs of Interface Box ... 6-43
GP3.2 Updating Programs of TR-DP ............. 6-44
GP3.3 Updating Programs of SCC ................. 6-45
GP3.5 Updating Programs of DBM-500 ......... 6-47
GP3.6 Updating Programs of DBM-500T........6-51
GP4.1 Specifications of Interface Box ............ 6-52
GP4.2 Specifications of TR-DP ...................... 6-53
GP4.3 Specifications of SCC.......................... 6-54
GP4.4 Specifications of DCM Kit .................... 6-55
GP4.5 Specifications of
DBM-500/DBM-500BR ....................... 6-56
GP4.6 Specifications of DBM-500T ............... 6-57
GP4.7 Specifications of DBM-LS1/DBM-K .... 6-58
GP4.8 Specifications of SpineMaster ............. 6-59
6-1
iGen3-M12D0-0612-0
GP1.1 Proper shutdown of Inline Controller
Quitting the Inline Controller

1. Check that the binding process is complete for all the sheets delivered
from the iGen3.
2. Click the “Exit” on the Inline Controller to close the application.
3. Turn off the Interface Box.
4. Shut down the computer.
When the Duplo Inline Controller does not work properly

Example
1. The Inline Controller has frozen.
2. The Inline Controller is out of control.
3. The computer does not work properly.
How to solve the problem

2. Click the “Exit” on the Inline Controller to close the application.
If you cannot close the application, press the Ctrl+Alt+Del keys to start
Windows Task Manager and exit the Inline Controller.
3. Restart the computer.
6-2 Section 6—General Procedures

GP1.1 Proper shutdown of PC platform
GP1.2 Activating Machines Independently <BG/non BG Setting>
DBM-500T
Some of the machines comprising the Duplo DBM-5000 can be activated non BG SW1 SW2 ON ON
ON ON
independently to check operations.
BG SW1 SW2
Machine BG/non BG Activate ON
BG SW1 SW2
independently ON
OFF
Interface Box ×
OFF DBM-500
TR-DP o
SCC non BG o
non BG SW1 SW2
DCM Kit × ON ON
DBM-500/DBM-500BR non BG o
DBM-500T non BG o
BG SW1 SW2
DBM-LS1 ×
DBM-K × OFF OFF
SpineMaster o

switch DBM-500T
SpineMaster
DCM Kit DBM-500
Main power
switch

switch
DBM-500
Interface Box TR-DP

Main power
switch
Remote switch


GP1.2
1. To activate the SCC, DBM-500 and DBM-500T independently, set the
machine to non BG. (Refer to the REP of each machine for details on
how to access to the Relay Board.)
Note: If your Duplo DBM-5000 is destined for North America, you do not have
to change the settings as it has already been set to non BG.
CAUTION
If you try to activate each machine independently when it is set to BG,“ RV
VP error” will be displayed. When the machine has been set to BG, set it to
non BG before activating the machine. After finishing checking operations
for each machine, make sure that you return the setting to BG.
2. Turn the System Power Switch of the Duplo DBM-5000 to OFF.

3. Turn the Remote Switch of the machine you want to activate to ON.
Note: Turn the Main Power Switch to ON for the SpineMaster.
To activate the DBM-500 alone, follow the following step 4.

4. When the DBM-500 is free of defects, the MAIN MENU screen appears
and Please wait. will be displayed on the screen. When you keep
pressing the Stop key for several seconds, the message on the screen
will change to Perform paper size change. Then you can check
the settings for the DBM-500.
Stop Key
When an error such as paper jam and others has occured on the DBM-500,
a message about the error is displayed. In this case, you can enter only the
Maintenance Mode (GP2.5).

GP1.2
GP1.3 TAG Sheet
The TAG sheet for the Duplo DBM-5000 is stored inside the Exterior Cover
(L side) of the SCC.
SCC
Exterior cover
(L side)
TAG sheet

GP1.3 TAG Sheet
GP1.4 Releasing Safety Switch Releasing Safety Switch by Hand
How to release the safety switch by hand varies depending on the type of
the switch.
CAUTION
Module Safety Switch Type of Switch
Use extreme caution to operate the machine with an exterior cover SCC SSW305 Side Cover Switch 1 Micro switch
detached. You can be seriously injured if you touch a moving part. SSW306 Side Cover Switch 2
DBM-500 SSW501 Side Cover Switch (Right) Magnetic detection switch
CAUTION SSW502 Side Cover Switch (Left)
SSW504 Top Cover Switch (Front) Lever switch
The safety switches are installed on this system for the safety of customers
SSW505 Top Cover Switch (Back)
and service personnels. Make sure that you return the safety switches
DBM-500T SSW603 Waste Bin Switch Lever switch
to their original positions and check that if they work properly after SSW604 Cover L Switch Micro switch
maintenancing the system. SSW605 Cover R Switch
SSW606 Cover B Switch
Before you adjust and check operation of each part, you can deactivate
the detection switch (safety switch) for the exterior covers and others • Micro switch
temporarily.
Secure the detection lever with an adhesive tape.
For the switches except the ones mentioned below, you can adjust and
check operation without deactivating the switch.
• Magnetic detection switch
Using the Maintenance Mode Remove the magnet attached to the cover side and secure the magnet to
Note: Top Cover Switches are not effected by this Maintenace Mode. the detection part of the switch with an adhesive tape.
• See Detect Cover of “GP2.3 Maintenance Mode of SCC, BG Menu”.
• See Exterior cover detection of “GP2.5 Maintenance Mode of DBM-500, • Lever switch
Various Settings”. Remove the lever attached to the cover side and insert it to the detection
• See Detect Enclosure of “GP2.6 Maintenance Mode of DBM-500T, BG part of the switch.
Menu”.

GP1.4
GP1.5 iGen3 Finisher Profile Settings 2. Then, the name of the most suitable profile will show up in the window.
Create the DFA timing profile and device profile on iGen3 system using
this profile. You can see the concrete values in the following pages.
There are five different variations among DFA timing profile and device The profile name
profile depending on the SCC’s setting.
Profile Name Process of SCC
Duplo-01 Bypass
Duplo-02 •Slit Ready !
Profile Duplo-04
•Crease
•Slit and Crease
Duplo-03 •Cut oki
SCxSS
•Slit and Cut job100
Duplo-04 •Cut and Crease 25
•Slit, Cut and Crease

Duplo-05 •Cut and Crease * The speed is lower
than Duplo-04.
When using the Inline Controller on the PC, you can easily make sure
which profile to apply by following the procedures below.
1. Once you finish setting parameters, click ‘Send’ button.

Note: For detailed information on how to set the parameters in the Inline
Click here
Controller window, refer to Inline Controller Instruction Manual.
CAUTION
When using Bourg Sheet Rotator (BSR), it is necessary to change certain
parameters. For details, refer to the following pages. Unless otherwise
noted, use the default values.
oki
SCxSS
job100
25

GP1.5 iGen3 Finisher Profi le Settings
1-1. Press Interface DFA Profile Settings: Duplo-01 2-1. Press Interface DFA Profile Settings: Duplo-02
TAB ITEM VALUE When using BSR TAB ITEM VALUE When using BSR
General Timing Profile Name Duplo-01 General Timing Profile Name Duplo-02
Time to Cycle Up 60 [sec] Time to Cycle Up 60 [sec]
Time to Cycle Down 60 [sec] Time to Cycle Down 60 [sec]
Finisher Capacity 0 [set] Finisher Capacity 0 [set]
Recovery Behavior Set Recovery Recovery Behavior Set Recovery
Jam Timings Time Between Sheets 0 [ms] Jam Timings Time Between Sheets 730 [ms]
Sheet Jam Time 1000 [ms] 1615 [ms] Sheet Jam Time 1000 [ms] 1615 [ms]
Time Between Sets 0 [ms] Time Between Sets 0 [ms]
Set Jam Time 10000 [ms] 10615 [ms] Set Jam Time 12000 [ms] 12615 [ms]
Set Processing time 500 [ms] Set Processing time 1300 [ms]
Status Signals Offline (S0) Enable Status Signals Offline (S0) Enable
Faulted (S1) Enable Faulted (S1) Enable
Full (S2) Enable Full (S2) Enable
Sheet Delivered (S3) Enable Sheet Delivered (S3) Enable
Set delivered (S4) Enable Set delivered (S4) Enable
Empty (S5) Disable Empty (S5) Disable
Not Ready (S6) Disable Not Ready (S6) Disable
Sheet Fed (S7) Disable Sheet Fed (S7) Disable
Delivery Delivery Signal Type Lead Edge Trail Edge Delivery Delivery Signal Type Lead Edge Trail Edge
Delivery Start Adjust 0 [ms] Delivery Start Adjust 0 [ms]
Delivery End Adjust 30 [ms] 50 [ms] Delivery End Adjust 30 [ms] 50 [ms]
End of Set Offset 0 [ms] 20 [ms] End of Set Offset 0 [ms] 20 [ms]
1-2. DocuSP Device Profile Settings: Duplo-01 2-2. DocuSP Device Profile Settings: Duplo-02
TAB ITEM VALUE TAB ITEM VALUE
Properties and Name Duplo-01 Properties and Name Duplo-02
Default Limits Type External Default Limits Type External
Function 1 Line Off Function 1 Line Off
Sheet Sequence N-1 Sheet Sequence N-1
Side 1 Direction Face Up Side 1 Direction Face Up
Minimum Sheet Length 140 [mm] / 5.50 [inch] Minimum Sheet Length 140 [mm] / 5.50 [inch]
Maximum Sheet Length 320 [mm] / 12.60 [inch] Maximum Sheet Length 320 [mm] / 12.60 [inch]
Minimum Sheet Width 178 [mm] / 7.00 [inch] Minimum Sheet Width 178 [mm] / 7.00 [inch]
Maximum Sheet Width 457 [mm] / 18.00 [inch] Maximum Sheet Width 457 [mm] / 18.00 [inch]
Minimum Sheet Weight 82 [g/m 2 ] Minimum Sheet Weight 82 [g/m 2 ]
Maximum Sheet Weight 128 [g/m 2 ] Maximum Sheet Weight 128 [g/m 2 ]
Minimum Set Size 1 [sheet] Minimum Set Size 1 [sheet]
Maximum Set Size 25 [sheet] Maximum Set Size 25 [sheet]

Sheet Jam Time 1000[ms] 1615 [ms] Sheet Jam Time 1000 [ms] 1615 [ms]
Time Between Sets 0[ms] Time Between Sets 0 [ms]
Set Jam Time 14000[ms] 14615 [ms] Set Jam Time 15000 [ms] 15615 [ms]
Set Processing time 2400[ms] Set Processing time 2400 [ms]
Delivery Start Adjust 0[ms] Delivery Start Adjust 0 [ms]
Delivery End Adjust 30[ms] 50 [ms] Delivery End Adjust 30 [ms] 50 [ms]
End of Set Offset 0[ms] 20 [ms] End of Set Offset 0 [ms] 20 [ms]

5-1. Press Interface DFA Profile Settings: Duplo-05
TAB ITEM VALUE When using BSR
General Timing Profile Name Duplo-05
Time to Cycle Up 60 [sec]
Time to Cycle Down 60 [sec]
Finisher Capacity 0 [set]
Recovery Behavior Set Recovery
Jam Timings Time Between Sheets 3500 [ms]
Sheet Jam Time 1000 [ms] 1615 [ms]
Time Between Sets 0 [ms]
Set Jam Time 16000 [ms] 16615 [ms]
Set Processing time 5000 [ms]
Status Signals Offline (S0) Enable
Faulted (S1) Enable
Full (S2) Enable
Sheet Delivered (S3) Enable
Set delivered (S4) Enable
Empty (S5) Disable
Not Ready (S6) Disable
Sheet Fed (S7) Disable
Delivery Delivery Signal Type Lead Edge Trail Edge
Delivery Start Adjust 0 [ms]
Delivery End Adjust 30 [ms] 50 [ms]
End of Set Offset 0 [ms] 20 [ms]
5-2. DocuSP Device Profile Settings: Duplo-05

TAB ITEM VALUE
Properties and Name Duplo-05
Default Limits Type External
Function 1 Line Off
Function 2 Line Off
Sheet Sequence N-1
Side 1 Direction Face Up
Minimum Sheet Length 140 [mm] / 5.50 [inch]
Maximum Sheet Length 320 [mm] / 12.60 [inch]
Minimum Sheet Width 178 [mm] / 7.00 [inch]
Maximum Sheet Width 457 [mm] / 18.00 [inch]
Minimum Sheet Weight 82 [g/m 2 ]
Maximum Sheet Weight 128 [g/m 2 ]
Minimum Set Size 1 [sheet]
Maximum Set Size 25 [sheet]

GP2.1 Maintenance Mode of Interface Box
LED03-09, 12-17 (Red)

LED for communication monitor of OEM port-1.
Details are described below.
LED positions
RA32
LED
LD17
17 16 09 08
LD08
LD16
LD09
RA31 RA07
LED
J09
15 14 13 12
LD15
LD12
LD14
LD13
RA27 LD05 LD06 LED
03 04 05 06 07
LD03
LD04
LD07
RA28
Description of signals
Location Command State Paper can be passed
LDE03 Status0 (Off-line) OFF Lit
LDE04 Status1 (Faulted) OFF Lit
LDE05 Status2 (Full) OFF Lit
LDE06 Status3 (Sheet Delivered) Lit OFF
LDE07 Status4 (Set Delivered) Lit OFF
LDE08 Command4 (Reserved) Lit OFF
LDE12 Command0 (Sheet Exit) Lit OFF
LDE13 Command1 (End of Set) Lit OFF
LDE14 Command2 (Cycle Up) Lit OFF
Note) Signal names conform to the DFA interface.

GP2.1 Maintenance Mode of Interface Box
GP2.2 Maintenance Mode of TR-DP 3. Make sure the switches on the MC Unit are set to off (lower positions).
While in the Maintenance Mode

While in the Maintenance Mode, TR-DP does not communicate with other
machines.
Activating the Maintenance Mode MC unit
To access Maintenance Menus, you must activate the Maintenance Mode.

1. Turn off the Main Power Switch on the Interface Box.
DBM-500T
1 2 3 4 5 6
Switch
DCM Kit DBM-500 4. Make sure the Main Power Switch of TR-DP is set to on.
5. Turn on the Remote Switch of TR-DP.
SCC
Interface Box TR-DP
DBM-500
Main power
switch
2. Remove the Cover F (REP2.1). Remote switch
Main power switch

GP2.2 Maintenance Mode of TR-DP
6. Make sure the orange LED is off and that the green LED is on. Quitting the Maintenance Mode
To quit the Maintenance Mode, follow these steps:
1. Turn off ( ) the Main Power Switch.
2. Turn off (lower positions) the switches on the MC Unit.
LED (orange)
MC unit
LED (green)
1 2 3 4 5 6
7. Turn on any one of the switches on the MC Unit. The Maintenance
Switch
Mode starts.
3. Replace the covers and reconnect the connectors.
MC unit
1 2 3 4 5 6
Switch

Checking the Cover Switch Checking the Paper Sensor
To check the Cover Switch, follow these steps: To check the Paper Sensor, follow these steps:
1. Activate the Maintenance Mode. 1. Activate the Maintenance Mode.
2. Set the switch on the MC Unit as shown in the table. 2. Set the switch on the MC Unit as shown in the table.
1 2 3 4 5 6 1 2 3 4 5 6
Lower Lower Lower Lower Lower Lower Lower Lower Lower Lower Lower Upper
position position position position position position position position position position position position
MC Unit MC Unit
1 2 3 4 5 6 1 2 3 4 5 6
Switch Switch
3. Open the Paper Path Cover and close it. TR-DP sounds a tone when you 3. Insert a sheet of paper into the paper path. TR-DP sounds a tone when
close the Paper Path Cover. the paper interrupt the light between the sensors.
Handle
Paper Path Cover

Checking the Alarm Checking the Motor—Forward
To check the alarm, follow these steps: To make the motor operate forward, follow these steps:
1. Activate the Maintenance Mode. 1. Activate the Maintenance Mode.
2. Set the switch on the MC Unit as shown in the table. TR-DP starts 2. Set the switch on the MC Unit as shown in the table. The motor starts
making alarm tones. operating forward. The normal speed is 1337 rpm—the paper travel
speed is 1400 mm/s. If any problem occurs, TR-DP sounds an alarm
1 2 3 4 5 6 tone and the motor stops.
Upper Lower Lower Lower Lower Upper
1 2 3 4 5 6
Upper Upper Lower Lower Lower Upper
MC Unit
MC Unit
1 2 3 4 5 6
Switch
1 2 3 4 5 6
Switch

Checking the Motor—Backward
To make the motor operate forward, follow these steps:
1. Activate the Maintenance Mode.
2. Set the switch on the MC Unit as shown in the table. The motor starts
operating forward. The normal speed is 1337 rpm—the paper travel
speed is 1400 mm/s. If any problem occurs, TR-DP sounds an alarm
tone and the motor stops.
1 2 3 4 5 6
Upper Upper Lower Lower Upper Lower
MC Unit
1 2 3 4 5 6
Switch

GP2.3 Maintenance Mode of SCC Menus and Functions
Menu What to do
Jog Dial Button B ROM Version To Viewing the ROM Version.
Simulation Mode To Starting the Simulation Mode.
Sensor Check To Checking Sensors.
Motor, Sol Test To Conducting Motor and Solenoid Tests.
Fine Adjustment To Conducting Fine-adjustments.
BG Menu To Viewing BG Import Data.
Counter To Viewing Counters and Clearing Counters.
Escape Button Clear Button Button A
Others To Activating or Deactivating Tone, Setting LCD, Selecting Unit of
Measure, Selecting Language, Saving or Not Saving Adjustments,
Changing Feed Speed, Creaser Front Sensor, Activating or
Deactivating D-Box Full Sensor, and Program Version Up.
Starting the Maintenance Mode
To access Maintenance Menus, you must activate the Maintenance Mode. ROM Version
Note: You can enter the Maintenance Mode even when a failure such as paper
jam has occurred. This menu shows you the information on software.
1. Push the Escape Button until the Initial screen is displayed. 1. Turn the Jog Dial to select ROM Version.
Note: When a failure such as paper jam has occurred, check that an error 2. Push the Jog Dial.
message is displayed.
3. To select a menu, turn the Jog Dial. The following menus are available.
• MC ROM Version: MC Unit software
• OP ROM Version: OP Unit (Control Panel) software
2. Press the Escape Button once.
• SPM ROM Version: Stepping motor driver
3. Turn the Jog Dial three steps clockwise.
• SRV ROM Version: Servo Motor Control Unit software
Note: As you turn the Jog Dial, different menus are displayed one by one.
4. Push the Clear Button. You hear a tone.
Simulation Mode
Note: If you do not hear a tone, go back to step 1.
5. Turn the Jog Dial five steps counterclockwise. Release the safety switch when you operate the machine without the cover
(GP1.4).
6. Push the Clear Button. You hear a tone two times and Maintenance
Menu is displayed. In this mode, SCC operates without paper.
Note: If you do not hear a tone or if Maintenance Menu is not displayed, go back 1. Turn the Jog Dial to select Simulation Mode.
to step 1.
2. Push the Jog Dial. The Simulation Mode is activated.
7. Push the Jog Dial. The Maintenance Mode is activated.
3. Push Button A. SCC starts operation.
Deactivating Maintenance Mode 4. Push Button B to stop operation.
Push the Escape Button several times until you go back to the Initial
Screen.

GP2.3 Maintenance Mode of SCC
Sensor Check Motor, Sol Test
Release the safety switch when you operate the machine without the cover Release the safety switch when you operate the machine without the cover
(GP1.4). (GP1.4).
This menu enables you to check the status of sensors. This menu enables you to test motors and solenoids.
1. Turn the Jog Dial to select Sensor Check. 1. Turn the Jog Dial to select Motor•Sol Test.
2. Push the Jog Dial. 2. Push the Jog Dial.
3. Turn the Jog Dial to select a sensor. 3. To select a motor or a solenoid, turn the Jog Dial. The following menus
4. Actuate or de-actuate the sensor manually. You see a message on the are available.
display and hear a tone. The following menus are available. Symbol Menu Symbol Menu
Symbol Menu Symbol Menu M301 Conv Motor 1 SL301 Flap Solenoid
PS305 Entrance SSW302 Top cover-F M302 Conv Motor 2 SL304 Back Jogger
PS308 Stopper SSW303 Top cover-R M303 Servo Motor SL302 Stopper
PS309 Stopper Rear SSW305 Side Cover M306 Side Jogger 1 SL303 Idler Roller
PS311 Cutter Frt SSW306 M307 Side Jogger 2 CL301 Clutch
PS312 Creaser Frt PS313 D-Box Full M308 Back Jogger M304 Cutter
PS307 Delivery SSW304 Slitter Cov M309 Slitter M305 Creaser
PS306 Bypass SW302 D-Box Pstn M310 Main Body FM301 Fan
PS314 Main Body CCD (Not used.)
4. To operate the motor or solenoid, push Button A. (When you have
PS304 Back Jogger P-4
PS302 S•J1 Home P-9
selected Side Jogger 1 Motor, Side Jogger 2 Motor, Back Jogger Motor,
PS303 S•J2 Home P-3
or Slitter Motor, you must keep pushing Button A to operate the motor.)
PS310 Slitter FP5 5. To stop the motor or solenoid, push Button B. (When you have selected
PS301 Creaser P-J Side Jogger 1 Motor, Side Jogger 2 Motor, Back Jogger Motor, or Slitter
SW301 Cutter Motor, you must push Button B to make the component go back to its
home position.)
Note: You may have difficulty to see actions of some motors and solenoids. In
a case like this, listen for a sound. For example, you hear a short, sharp sound
when the Clutch turns on.
Jog Dial Button B

Fine Adjustment Menu Adjusts… Min. Default Max. Step Check
Here
This menu enables you to change the values of initial adjustments. The Side This menu adjusts the -35 0 +35 0.15 mm Side Joggers
default values are specific to each machine. Before changing any value, take Jogger 1 distance from Side Jogger 1 and their
to paper. Greater numbers Home
notes and keep a record of initial settings. You might need to change values move Side Jogger 1 farther Sensors
back to their default. from the center.
Note: See also Using User Menus and Maintenance Menus for Adjustment. Side This menu adjusts the -35 0 +35 0.15 mm Side Joggers
Jogger 2 distance from Side Jogger 2 and their
1. Turn the Jog Dial to select Fine Adjustment. to paper. Greater numbers Home
move Side Jogger 2 farther Sensors
2. Push the Jog Dial. from the center.
3. Turn the Jog Dial to select a menu. For available menus, see the table Back This menu adjusts the -99 0 +99 0.1 mm Back Jogger;
Jogger distance from the Back Back Jogger
below. Jogger to paper. Greater Sensor
4. Push the Jog Dial. numbers move the Back
Jogger upstream.
5. Turn the Jog Dial to change the value. Slitter This menu adjusts the -50 0 +50 0.05x2 Slitters;
6. Push the Jog Dial to enter the value. Position distance from the Slitters to mm Slitter
paper. The both Slitters are Sensor
adjusted at the same time.
The table lists available menus. If your adjustment does not work, check the
CCD-X Not used.
components in Check Here. Should you specify a value out of these ranges, Position
make sure no trouble occurs in any component. Note that Default is the CCD-Y Not used.
value before the manufacturer adjusts the machine. Position
Note: The information on the default value is shown on the inside of the cover as Crease This menu adjusts the -1 0 +1 10 milli- Creaser;
shown in the figure below. Timing timing of paper transport seconds Creaser
after creasing. When you Sensor and
change the Crease Timing, its Actuator
process speed may change.
Greater numbers delay the
start of the next process
after creasing.
Reference This menu offsets the -30 0 +30 0.1 mm Cutter;
X difference in the position Cutter Front
of the Cutter Front Sensor. Sensor
Greater numbers make
paper-travel distance longer
between the Stopper and
the Cutter.
Reference This menu offsets the -35 0 +35 0.15 mm Slitters; Side
Y difference in the positions Jogger 2 and
of the Side Joggers and its Home
Slitters. Greater numbers Sensor
move Side Jogger 1 nearer
to the center and Side
Jogger 2 farther from the
center.
Crease This menu offsets the -30 0 +30 0.1 mm Creaser;
Position difference in the actual Cutter Front
position and specified Sensor
position of crease lines.
Greater numbers make
paper-travel distance longer
between the Cutter and the
Creaser.

Menu Adjusts… Min. Default Max. Step Check Using User Menus and Maintenance Menus for Adjustment
Here
Main Body This menu offsets the -99 0 +99 0.1 mm Machine The user menu has its own adjustment menus—Adjustment 1 and
Position difference in the actual base; Main Adjustment 2. You can adjust each component and immediately see the
position and specified Body
position of the main body. Sensor; result when using Adjustment 1 or Adjustment 2. On the other hand,
Greater number make the Linkage the Fine Adjustment in the Maintenance Mode does not allow you to
main body farther from the between immediately see the result. You need to finish the Maintenance Mode to
home position. machines
Side This menu adjusts the -99 +50 +99 0.1 mm Side Jogger check the result when having used the Fine Adjustment menu. To get a
Jogger 1 home position of the Side 1 and this quick result while you making some adjustments, follow these steps:
Home Jogger. If you increase the Home
value, the home position of Sensors 1. Adjust components by using Adjustment 1 and/or Adjustment 2 in the
Side the Side Jogger will move -99 +50 +99 0.1 mm Side Jogger User mode.
Jogger 2 outward. 2 and this
Home Home 2. Write your specifications and settings on a piece of paper.
Sensors 3. Enter your specifications and settings by using the Fine Adjustment
menu in the Maintenance Mode.
4. Nullify the specifications and settings in Adjustment 1 and Adjustment 2
in the User Mode.
The table lists counterparts in these menus. Note that the Length menu in
the Finished Size menu of the User Mode has nothing equivalent. This is
because the Length menu makes an adjustment for the very sheets in use.
Maintenance User Remarks
Side Jogger 1 Adjustment 1—Side Jog
Position
Side Jogger 2 —
Back Jogger Adjustment 1—Back Jog
Position.
Slitter Position Adjustment 2—Finished
Size, Width
CCD-X Position —
CCD-Y Position —
Crease Timing —
Reference X Adjustment 2—Ref.
Position, Reference X
Reference Y Adjustment 2—Ref.
Position, Reference Y
Crease Position Adjustment 2—Crease
Position
Main Body Position Adjustment 1—M. BODY One step in Maintenance is
Position 0.1 mm; one step in User is 0.5
mm.
— Adjustment 2—Finished
Size, Length

Listed below are some examples of adjustment procedures. When you BG Menu
change the values in the Maintenance Mode as described below, clear the
values in the User Mode to zero. Deactivating the Detect Cover Option
• Example 1: Back Jogger in the Maintenance Mode is +3, and Back
Jog Position in the User Mode is +10. +3+10=+13. Set +13 for Back CAUTION
Jogger in the Maintenance Mode. Clear the value in the User Mode to Use extreme caution to operate the machine with an exterior cover
zero. detached. You can be seriously injured if you touch a moving part.
• Example 2: Back Jogger in the Maintenance Mode is +12, and Back
Jog Position in the User Mode is -5. +12-5=+7. Set +7 for Back CAUTION
Jogger in the Maintenance Mode. Clear the value in the User Mode to The cover switches are installed on the machine for your safety. Make sure
zero. that you activate the cover switches and check that if they work properly
• Example 3: Back Jogger in the Maintenance Mode is +3, and Back after maintenancing the machine.
Jog Position in the User Mode is -12. +3-12=-9. Set -9 for Back
Jogger in the Maintenance Mode. Clear the value in the User Mode to You can deactivate the Side Cover Sensors by using this menu. You can
zero. let SCC operate with external covers removed. Note that the Side Cover
• Example 4: Back Jogger in the Maintenance Mode is -5, and Back Sensors are automatically activated when you turn off and on the Remote
Jog Position in the User Mode is -10. -5-10=-15. Sit -15 for Back Switch.
Jogger in the Maintenance Mode. Clear the value in the User Mode to 1. Turn the Jog Dial to select BG Menu.
zero. 2. Push the Jog Dial.
• Example 5: Back Jogger in the Maintenance Mode is -8, and Back 3. Turn the Jog Dial to select Detect Cover.
Jog Position in the User Mode is +6. -8+6=-2. Set -2 for Back Jogger
4. Push the Jog Dial.
in the Maintenance Mode. Clear the value in the User Mode to zero.
5. Turn the Jog Dial to select on or off.
• Example 6: Back Jogger in the Maintenance Mode is -8, and Back
Note: When the cover switch is deactivated, “Motor, Sol Test” does not
Jog Position in the User Mode is +15. -8+15=+7. Set +7 for Back Jog function.
Position in the Maintenance Mode. Clear the value in the User Mode Note: The setting automatically returns to on when you turn off and on the
to zero. Remote Switch.
• Example 7: Main Body Position in the Maintenance Mode is +4, and Switch that can be deactivated
M. BODY Position in the User Mode is +3. +4+3×5=+19 Set +19 for SSW305 Side Cover Switch 1
Main Body Position in the Maintenance Mode. Clear the value in SSW306 Side Cover Switch 2
the User Mode to zero.
Viewing BG Import Data

This menu is for the manufacturer. You will not use it when servicing the
machine.

Counter Others
Viewing Counters Activating or Deactivating Tone
This menu enables you to view counters. This menu enables you to activate or deactivate the tone SCC makes when
1. Turn the Jog Dial to select Counter. you work on the Control Panel.
2. Push the Jog Dial. 1. Turn the Jog Dial to select Others.
3. Turn the Jog Dial to select a counter. 2. Push the Jog Dial.
• Bypassing Sheets This counter shows the number of sheets that go 3. Turn the Jog Dial to select Tone.
down the Bypass. 4. Push the Jog Dial.
• Processing Sheet This counter shows the number of sheets that go 5. Turn the Jog Dial to select on or off.
down the Process Path. 6. Push the Jog Dial.
• Cutter This counter shows how many times the Cutter operates.
• Creaser This counter shows how many times the Creaser operates.
Setting LCD
• Clutch This counter shows how many times the Clutch turns on.
This menu enables you to select the way of displaying messages.
1. Turn the Jog Dial to select Others.
Clearing Counters
This menu enables you to clear counters. 3. Turn the Jog Dial to select LCD Setting.
1. Turn the Jog Dial to select Counter. 4. Push the Jog Dial.
2. Push the Jog Dial. 5. Turn the Jog Dial to select Running Speed or Blink Speed.
3. Turn the Jog Dial to select a counter. Running Speed decides the speed of scrolling. Blink Speed decides
4. Push the Jog Dial. the speed of blinking.
5. Turn the Jog Dial to select Yes. 6. Push the Jog Dial.
6. Push the Jog Dial. 7. Turn the Jog Dial to select a speed.
Selecting Unit of Measure

This menu enables you to change the unit of measure.
3. Turn the Jog Dial to select mm/inch Setting.
5. Turn the Jog Dial to select mm or inch.

Selecting Language Changing Feed Speed
This menu enables you to change the language displayed. This menu enables you to change the speed of paper transport.
1. Turn the Jog Dial to select Others. 1. Turn the Jog Dial to select Others.
3. Turn the Jog Dial to select Language. 3. Turn the Jog Dial to select Feed Speed.
5. Turn the Jog Dial to select a language. 5. Turn the Jog Dial to specify a speed.
7. Turn off the Remote Switch. The table lists the default feed speeds of machines.
Machine Default Duplo DBM-5000 setting
SCC 1400 mm/sec 1400 mm/sec
Saving or Not Saving Adjustments DBM-500 1440 mm/sec 1440 mm/sec
DBM-500T 1000 mm/sec 600 mm/sec
This menu enables you to select how the settings are used after the user
has changed values in Adjustment 1 and/or Adjustment 2.
• Save—The settings are saved in memory. The settings are referenced
when a jog is executed. These settings are not cleared when you turn off
and on the Remote Switch. If the user updates settings, old settings are
discarded and new settings are saved.
• Not Save—The settings are saved in memory. The settings are
referenced as long as the paper size (including its original size and
finished size) is not changed. If the paper size is changed, these settings
are discarded. They are discarded also when you turn on and off the
Remote Switch.
3. Turn the Jog Dial to select FineAdjust Value.
5. Turn the Jog Dial to select Save or Not Save.

Creaser Front Sensor Activating or Deactivating D-Box Full Sensor
This menu enables you to deactivate the Creaser Front Sensor. This menu This menu enables you to deactivate the D-Box Full Sensor. When you
is helpful when some other sensor becomes defective. When you have complete your maintenance work, activate the D-Box Full Sensor. You must
deactivated the Creaser Front Sensor, SCC ignores the signals from this not let the user operate SCC with the D-Box Full Sensor deactivated.
sensor. In other words, SCC works even if the MC Unit does not receive 1. Turn the Jog Dial to select Others.
any signal from the Creaser Front Sensor. Therefore, you can remove the
Creaser Front Sensor. You can use the removed sensor to substitute for a
defective sensor. 3. Turn the Jog Dial to select Detect Scrap Full.
After you have deactivated and removed the Creaser Front Sensor, SCC
may take a longer time to detect a paper jam. This is the case when a paper 5. Turn the Jog Dial to select on or off.
jam has occurred around the place where the Creaser Front Sensor should 6. Push the Jog Dial.
be. In a case like this, SCC keeps on working until some other sensor, such
as the Cutter Front Sensor, detects the paper jam after more sheets have
jammed. Program Version Up
Deactivating the Creaser Front Sensor is only a temporary fix, and you For Program Ver. UP, see Updating Program.
need to install it as soon as possible.
3. Turn the Jog Dial to select Creaser Front Sensor.
5. Turn the Jog Dial to select on or off.

GP2.5 Maintenance Mode of DBM-500 Menus and Functions
Activating the Maintenance Mode

1. Touch the upper left corner and lower right corner on the display.
jam has occurred.
Menu What to do
MOTION & SIMULATE To see overall actions. To check particular motors and solenoids.
SENSOR To check sensors.
KEYS To check keys.
OFFSET To view and change Offset Data.
LANGUAGE To change languages.
VARIOUS SETTINGS To view and change machine settings.
RESET To reset data in memory.
2. An input box is displayed. Touch the input box. A numeric key pad is
COUNTER To view counters.
displayed.
VERSIONS To view the version and to update the program.
3. Touch 630304 on the numeric keypad. And touch the ENT key. RESERVE SETTINGS To make each setting of the machine.
4. Touch the Door Key. The Maintenance Mode starts.
Note: Same error screen appears again was selected “MOTION & SIMULATE”
function when after error screen appeared.
Press Emergency Stop Switch, and release possible to use “MOTION &
SIMULATE” function. Make to use each “Menu function”.
Input box
Cancel
Door Key

GP2.5 Maintenance Mode of DBM-500
Motion & Simulate The table lists menus.
Release the safety switch when you operate the machine without the cover Symbol Menu Remarks
(GP1.4). M514 1.Main drive motor
Note: Same error screen appears again was selected “MOTION & SIMULATE” M503 2.Jog belt drive motor
function when after error screen appeared. M513 3.Base moving motor
Press Emergency Stop Switch, and release possible to use “MOTION & M501 4.Jog unit moving motor
SIMULATE” function. Make to use each “Menu function”.
M502 5.Back jog moving motor
M504 6.Side jog moving motor
M505 7.Saddle stop moving motor
The duty ratio of Stitch Delivery 1 Solenoid (#18) and Stitch Delivery 2 M507 8.Back stop moving motor
Solenoid (#19) is 50%. Do not keep either of them activated. To test a motor M510 9.Folding side guide motor
or solenoid, follow these steps: M508 10.Folding stop moving motor
1. To Select a menu, use the Up or Down Arrow Key. M509 11.Non-fold delivery motor
M511 12.Fold rollers gap 1 motor When Folding rollers gap-1 home
2. To conduct a test, use the Start Key or Trigger Key. sensor (PS520) detects sensor plate,
• Start Key—The component keeps operating until you touch the Stop motor can not be moved.
Key. M512 13.Fold rollers gap 2 motor When Folding rollers gap-2 home
sensor (PS521) detects sensor plate,
• Trigger Key—The component stops operating when it reaches the home motor can not be moved.
position or the position defined by the current settings. M506 14.Stitcher moving motor
SL501 15.Saddle stitch stop solenoid
3. To operate the machine after adjusting the operation of a guide, make
SL502 16.Side stitch stop solenoid
the machine execute the Size Change. 17.Side stitch delivery solenoid
SL506
SL503 18.Stitch delivery 1 solenoid
SL504 19.Stitch delivery 2 solenoid
Up arrow key SL505 20.Back Stopper solenoid
CL502 21.Stitching clutch
Down arrow key CL503 22.Folding clutch
CL501 23.Folding delivery clutch
Start key Trigger key BRK5 24.Stitching brake
BRK5 25.Folding brake
Stop key BRK5 26.Side jogger brake
CNT5 27.Stitching counter
CNT5 28.Folding counter
M701 29.Belt stacker(Outlet1)
30.Pump(Outlet2) Not used.

To make the machine simulate regular operation, follow these steps:
1. To select a menu, use the Up or Down Arrow Key.
2. Take necessary actions:
• Simulated motion—(i) Make the machine execute the Size Change.
(ii) Touch the Start Key. The machine operates as if it were handling
sheets. (iii) To stop the machine, touch the Stop Key.
• Stitching motion—(i) Touch the Start Key. The Conveyance Motor
starts. (ii) Touch the Trigger Key. The machine operates as if it were
stitching booklets. iii) To stop the machine, touch the Stop Key.
• Folding motion—(i) Touch the Start Key. The Conveyance Motor
Starts. (ii) Touch the Trigger Key. The machine operates as if it were
folding booklets. (iii) To stop the machine, touch the Stop Key.
• Back jogger motion—Touch the Trigger Key. The Back Jogger
operates.
• Side jogger motion—Touch the Trigger Key. The Side Joggers
operate.
• Motion to initial position—Touch the Start Key. The machine
sets the guides to their home positions.
Up arrow key
Down arrow key
Start key Trigger key
Stop key
The table lists menus.

Menu Remarks
1.Simulated motion
2.Stitching motion
3.Folding motion
4.Back jogger motion
5.Side jogger motion
6.Motion to initial position

Sensor The following menus shows whether each sensor is working:
• Stepping error detection sensor
Release the safety switch when you operate the machine without the cover
(GP1.4). • Wire feed detection sensor
• Main index sensor
PS501 PS523
• Main unit moving index sensor
PS502 PS524
PS508 PS525
Other menus show whether each sensor is on or off.
PS515 PS526
PS512 PS519
PS522 PS528
PS516 PS527
PS506 PS517
Keys
Touch numeric keys to see if they are working.
PS518 PS513
PS503 PS520
PS504 PS521
PS505 PS509
PS507 ―
PS510 ―
PS514
PS511
SSW503
SSW506
SSW504
SSW505
SSW501
SSW502
PCB503
PCB503
Cancel key Return key Next key Cancel

key Cancel key Next key
Note: The menus (page 6/6) that start with “RL” are for the manufacturer.
You will not use it when servicing the machine.

Offset 3. Touch the right-arrow key or the left-arrow key to select the paper size
you have used.
OFFSET is a series of values that indicate the difference between the actual
home positions and the optimum home positions of components. When
DBM-500 is initializing components, it references their home positions
and set them on specific locations. If a home position is not in the optimum
position, the component will be in a wrong place.
OFFSET shows the distance between an actual home position and its
optimum position. You can also adjust OFFSET values from this menu.
Plus/minus key
Note: The information on the default value is shown on the inside of the cover as
shown in the figure below. Left-arrow key
Right-arrow key
Calculator key Memory key
4. Touch the calculator key to see the values.

5. See if the values are all in the ranges shown in this table.
Range Step Relevant Sensor
MOVE –53 to 1870 1 = 0.13 mm Base Home Sensor
HEAD 0 to 1500 500 = 1 mm Stitching Head Home Sensor
B _ JOG –200 to 133 1 = 0.03 mm Jogger Unit Home Sensor
B _ STOP –33 to 134 1 = 0.03 mm Back Stop Home Sensor
C _ STOP –33 to 100 1 = 0.03 mm Saddle Stopper Home Sensor
F _ STOP –66 to 234 1 = 0.03 mm Folding Unit Home Sensor
S _ JOG –10 to 90 1 = 0.1 mm Side Jogger Home Sensor
GUIDE –40 to 50 1 = 0.1 mm Folding Guide Home Sensor
To view OFFSET values, follow these steps: • If a value is out of range, adjust the position of the relevant sensor or its
actuator. And resume the procedure from step 1.
CAUTION • When all values are in the ranges, go on to the next step.
Take note of current OFFSET values if you need them. They are overwritten 6. Touch the memory key to store the values. When necessary, you can
when you touch the memory key to store new values (see step 6). change values before storing them as follows:
1. Make booklets with the paper of one of the following sizes: A3, A4, LGR, • Touch the value you want to change. And type a new value by using the
LTR. When making booklets, adjust each process by using the Step numeric keypad.
Mode and the ADJUST menus. • To toggle between plus and minus, touch the plus/minus key. Positive
2. Activate the Maintenance Mode and navigate to OFFSET. values make the component more distant from its home position;
negative values make it closer to the home position.
Note: For example, if you enter +10, the component goes away from the home
position by 10 steps. See the table above for the distance of one step.

Languages Various Settings
To select a language, follow these steps: a. Unit of measure—Select mm or inch.
1. Touch one of the flag keys. b. Main conveyance speed—To change the speed of paper travel, (i) touch
the Up or Down Arrow Key, and (ii) touch the Start Key. The machine
operates the main drive motor for a while and stops it.
Flag keys
a
Return key Start key
c. Online/Offline—Select Online. To validate a change, turn off and of

the Remote Switch.
Note: If you do not connect this machine to any other machine, choose Offline.
When you chose Offline, you can select SET/SET or SHEET/SHEET. SET/
SET—All sheets are fed at the same time. SHEET/SHEET—sheets are fed one
by one.
d. Duplo DBM-5000 is not used.
e. Duplo DBM-5000 is not used.

f. Number of sheets: Auto—An upstream machine informs DBM-500 of i. Exterior cover detection:
the number of sheets to be processed.
Note: If you manually specify the number of sheets to be processed, select Manual. CAUTION
g. Number of jogs: Auto—An upstream machine decides the number of Use extreme caution to operate the machine with an exterior cover
jogs. detached. You can be seriously injured if you touch a moving part.
Note: If you manually specify the number of jogs, select Manual.
h. Saddle Stitching Stopper timing—This decides when the Saddle CAUTION
Stitching Stopper goes up. The up arrow key delays the action while the
The cover switches are installed on the machine for your safety. Make sure
down arrow key hastens it.
that you activate the cover switches and check that if they work properly
Note: In other words, this setting specifies how long the Stopper takes to start.
after maintenancing the machine.
• ON—DBM-500 does not operate while an exterior cover is detached.

f • OFF—DBM-500 operates even when an exterior cover is detached.
Note: When the cover switch is deactivated, “Motor, Sol Test” does not
g function.
Note: The setting automatically returns to on when you turn off and on the
Remote Switch.
h
Switch that can be deactivated
SSW501 Side Cover Switch (Right)
SSW502 Side Cover Switch (Left)

j. Folding Roller Gap: l. Four-head Stitcher
Note: The Folding Roller Gap is the distance between the two Folding Rollers. • ON—Select ON when the stitcher has four heads.
You can also mechanically adjust the pressure between them (see Adjusting
Folding Mechanism). Make sure to set the Duplo DBM-5000 to ON. • OFF—Select OFF when the stitcher has two heads.
• ON—Your adjustment is valid even after you turn off and on the Remote m. Stitching Width setting of Four-head Stitcher
Switch or even after DBM-500 has executed a Size Change. • ON—Select ON to set the stitching width between the existing stitcher
• OFF—You adjustment is nullified when you turn off the Remote Switch and the added stitcher to 80 mm (3.15 inch).
or when DBM-500 has executed a Size Change. • OFF—Select ON to set the stitching width between the existing stitcher
k. D-PORT ID setting and the added stitcher to 70 mm (2.76 inch).
Set to “Auto” when connecting the Interface Box. n. Wire detection for add-on stitchers (These settings affect add-on
Set to “Fixation” when not connecting to the Interface Box. stitchers only.)
• ON—This enables the Wire Detection for the add-on stitcher.
• OFF—This disables the Wire Detection for the add-on stitcher.
o. Calendar Kit
j • ON—Select ON when the optional Calendar Kit is installed.
• OFF—Select OFF when the optional Calendar Kit is not installed.
k m

p. Duplo DBM-5000 is not used. Reset
q. Switching the display on the Control Panel between leftward and To restore default settings, touch the RESET Key:
rightward paper transportation
• Ordinary menus—This resets the following settings: Memory
• LEFT—Select LEFT for leftward transportation of paper. Number, Option, Accessory.
• RIGHT—Select RIGHT for rightward transportation of paper. • Maintenance menus—This resets most of the Various Settings, but
Note: When you have changed the location of the Control Panel for rightward does not reset the Offset Data, Language and Counter.
transportation, select RIGHT. RIGHT has been selected as default on the Duplo
DBM-5000 (see Section 8, Installing DBM-500). • All resetting—This resets all settings except Counter.
Counter
This displays counters.

Versions Reserve Settings
This displays program versions.
CAUTION
Note: You can upgrade the programs by touching the Ver. UP icon (see GP3.5
Updating Programs of DBM-500). The No. that does not appear in the table below may be used when
the program is changed in the future. Do not change settings that have
nothing to do with the Duplo DBM-5000.
CAUTION
Do not press [System Call]. If you mistakenly press it, press [X] on the right
top of the screen to end the operation.
No. Menu Details

1 Duplo DBM-5000 is not used.
2 D-PORT ID setting This menu is same as “k. D-PORT ID
setting” of the Various Settings menu.
3 factory setting OFF— except north America
ON— for north America
4 Duplo DBM-5000 is not used.
5-1 Duplo DBM-5000 is not used.
5-2 Duplo DBM-5000 is not used.
5-3 Fine adjustment level of the Base Plate ON (indicated in white)— fine adjusted by 3
(see Section 8, Setting Control panels) mm
OFF (indicated in black)— fine adjusted by
1 mm
5-6 Setting of jam detect time for the ON (indicated in white)— for Duplo
folding conveyance section (J11, J12) DBM-5000
(see Section 8, Setting Control panels)

GP2.5a Wire Replacement
Change a wire in the following way.

1. Remove the wire remaining in the stitcher head.
(see DBM-500 Instruction Manual,“12-5. Removing Wire”
2. Remove the empty wire reel and attach a new one.
3. Feed a wire to the stitcher head.
(see DBM-500 Instruction Manual,“12-3. Feeding the Wire”)
4. Perform stitching tests (ADJ5.18).

GP2.5a Wire Replacement
GP2.6 Maintenance Mode of DBM-500T Menus and Functions
Menu What to do
Button B ROM Version To view the version and to update the program.
Simulation Mode To see overall machine actions.
Sensor Check To check the sensors.
Motor, Sol Test To check the motors, sensors, and counter.
BG Menu To view or make safety-related settings.
Other Setting To view or make other settings including languages and feed
speeds.
Escape button Clear button Jog dial Button A
Using the Control Panel

Starting the Maintenance Mode • To scroll through menus and options, turn the Jog Dial clockwise or
counterclockwise. As you turn the Jog Dial, available menus or options
To access Maintenance Menus, you must activate the Maintenance Mode. are displayed.
jam has occurred. • To select a menu or option, push the Jog Dial. Note that you can push the
Jog Dial.
1. Push the Escape Button until the Initial screen is displayed.
Note: When a failure such as paper jam has occurred, check that an error • To increase or decrease a number displayed, turn the Jog Dial just like
message is displayed. you scroll through menus or options.
• To enter a number, push the Jog Dial just like you select a menu or
option.
2. Press the Escape Button once. • To go back to a previous menu, push the Stopper Button.
Note: As you turn the Jog Dial, different menus are displayed one by one. ROM Version
4. Push the Clear Button. You hear a tone. This displays the ROM version.
Note: If you do not hear a tone, go back to step 1. Note: You can upgrade the program in the ROM (see Updating the Program).
5. Turn the Jog Dial five steps counterclockwise.
Menu is displayed.
Note: If you do not hear a tone or if Maintenance Menu is not displayed, go back
to step 1.
7. Push the Jog Dial. The Maintenance Mode is activated.
Deactivating Maintenance Mode

Push the Escape Button several times until you go back to the Initial
Screen.

GP2.6 Maintenance Mode of DBM-500T
Simulation Mode Sensor Check
Release the safety switch when you operate the machine without the cover Release the safety switch when you operate the machine without the cover
(GP1.4). (GP1.4).
The machine acts as if it were making booklets. But the machine does not 1. Start the Maintenance Mode and navigate to Sensor Check.
handle any paper. When you make this machine operate alone, follow these 2. To choose a sensor or switch, turn the Jog Dial. As you turn the Jog Dial,
steps: sensor names and switch names are displayed.
1. Turn off the System Power Switch of the Duplo DBM-5000. 3. To see if a sensor or switch is working, actuate or de-actuate the sensor
2. Make sure the Main Power Switch of DBM-500T is set to on. or switch. As you actuate or de-actuate one, the status on the display
changes.
3. Turn on the Remote Switch of DBM-500T.
4. Start the Maintenance Mode and navigate to Simulation. Symbol Menu Symbol Menu
PS601 Knife Home SSW604 Cover-L
PS602 Knife index SSW605 Cover-R
6. Push Button A. To stop the machine, push Button B. PS605 Paper-IN SSW606 Cover-B
PS606 Paper-OUT PCB604 Dip-SW1
PS701 Roller Limit Dip-SW2
Remote Switch PS607 D-box full Auxiliary
Kicker SW (Not used.) PS604 MV Mot Home
SSW602 Top cover SW PS603 GAP Mot Home
SSW603 Dust box SW M602 Feed index
SSW601 Emergency SW
Main Power Switch

Motor, Sol Test
Release the safety switch when you operate the machine without the cover
(GP1.4).
1. Start the Maintenance Mode and navigate to Sensor Check. Push the
Jog Dial.
2. To choose a motor or solenoid, turn the Jog Dial. As you turn the Jog
Dial, motor names and solenoid names are displayed.
3. Push a necessary button or buttons:
• Move motor, gap motor—Push button A or button B. The motor operates
forward or backward. To stop the motor, stop pushing the button.
• Conveyance Motor, DC Fan L, DC Fan R, Stacker Relay, Infeed
Electromagnetic Brake, Conveyance Electromagnetic Clutch, Stopper
Solenoid, Flap Solenoid, Kicker Solenoid, Cutter Clutch, Cutter Brake,
Main Motor Drive Relay, Main Motor Rotation Selection Relay—To
operate these, push Button A. To stop them, push Button B.
• Counter—Push Button A. The counter counts up.
Symbol Menu Symbol Menu
M604 Move motor CL/BRK Knife (Clutch)
M603 Gap motor Knife (Brake)
M602 Feed motor FM602 Fan R
SL601 Stopper FM601 Fan L
SL602 Flap RL601 Main drive-Relay
SL701 Kicker RL602 Main CCW Relay
CL601 Carrying in SSR StackerMot Relay
CL602 Conveyance CNT Knife Counter
Note: When you execute “Main drive-Relay” with the SpineMaster attached
to the machine, the conveyance section of the SpineMaster will be working for a
certain time.

BG Menu Other Setting
1. Start the Maintenance Mode and navigate to BG Menu. Push the Jog 1. Start the Maintenance Mode and navigate to Other Settings. Push
Dial. the Jog Dial.
2. To choose a submenu, turn the Jog Dial. Available are Sel. Dtc. Enc 2. To choose a submenu, turn the Jog Dial. Available are Language and
(Select Detect Enclosure), Relay Error, and BG Import Data: Feed Speed.
• Sel. Dtc. Enc (Select Detect Enclosure)—This disables exterior cover • Language—This allows you to select a language. To select a language,
detection. To disable the detection, (i) navigate to Sel. Dtc. Enc, (ii) push (i) navigate to Language (ii) push the Jog Dial and turn it to select a
the Jog Dial, (iii) Turn the Jog Dial to choose off, and (iv) push the Jog language, and (iii) push the Jog Dial.
Dial. This setting returns to on when you turn off and on the machine. • Feed Speed—This changes the speed of paper travel. To change the
speed, (i) navigate to Feed Speed, (ii) push the Jog Dial and turn it to
CAUTION select a seed, and (iii) push the Jog Dial. You can select a speed from
Use extreme caution to operate the machine with an exterior cover 600 to 1200 mm (23.6 to 47.2 inches) per second.
detached. You can be seriously injured if you touch a moving part. • Program Ver.UP—See GP3.6 Updating Programs of DBM-500T.
• D-Port ID—Duplo DBM-5000 is set to “Variable”.
CAUTION • EntranceJam Time—Duplo DBM-5000 is set to “6.”
The cover switches are installed on the machine for your safety. Make sure • mm/inch Setting—Select a unit to be displayed on the Control Panel:
that you activate the cover switches and check that if they work properly mm or inch.
after maintenancing the machine.
• Spine Master—Set to “on” when not connecting to the SpineMaster.
Note: When the cover switch is deactivated, the following maintenance menus do
not function.
•Simulation Mode
•“Move motor”, “Gap motor”, “Feed motor” of Motor, Sol Test
Note: The setting automatically returns to on when you turn off and on the
Remote Switch.
Switch that can be deactivated
SSW604 Cover L Switch
SSW605 Cover R Switch
SSW606 Cover B Switch
• Relay Error—Once an RL relay problem has occurred, you cannot clear

it by turning off and on the machine. To clear the problem, (i) remove
the cause of the problem, (ii) navigate to Relay Error, (iii) push the
Jog Dial and turn it to select Release, (iv) push the Jog Dial, and (vi)
turn off and on the machine.
• BG Import Data—This menu is for the manufacturer. You will not use it
when servicing the machine.

GP2.7 Cycling the SpineMaster by Hand 5. Place the Hand Crank Tool in the end of the Drive Shaft (see the figure
below).
The mechanism within the SpineMaster can be cycled by hand to aid End of Drive Shaft
the service engineer. This may be necessary when replacing certain
components (such as the Clutch) or in the unlikely event of the Drive Motor
stalling.
None 3mm Allen Key
4mm Allen Key
17mm Spanner
WARNING
It is necessary to remove the machine covers when cycling the machine
by hand: be careful of all moving parts, in particular the Clamp. Make sure
the power supply is disconnected. 6. Manually crank the SpineMaster by turning the Hand Crank Tool in a
clockwise direction. Note that the Clutch will not allow the shaft to be
cranked in an anti-clockwise direction.
Procedure
7. The Drive Shaft rotates 720° to perform one cycle. After the first
complete rotation, the Clutch will lock and will need to be released again
2. Remove the Side Covers. to manually crank the machine through the rest of the cycle.
3. Remove the Infeed Assembly (see Section 4, 8.0d-1).
4. Before hand-cranking the SpineMaster, it is first necessary to release
the Drive Motor Clutch. To release the Clutch, lift the lever shown in the
fugure below.
Clutch Solenoid
Clutch Release Lever

GP2.7 Cycling the SpineMaster by Hand
GP3.0 Updating Programs of Inline Controller Updating the Program
1. Turn on the computer to start Windows.
2. Exit all the programs on the taskbar.
When updating the program of the Inline Controller, the following data in
the “DUPLO Inline Controller”will not be deleted. The data will be retained 3. Place the supplied CD-ROM on the CD-ROM drive.
in the upgraded version. Note: The installer will automatically start. If the installer screen is not
displayed.
Note: The following data will not be deleted even when you remove the Inline
Controller application. 1) Double-click the My Computer icon.
2) Right-click the DUPLO icon and click [Open].
• “Duplo Settings” data
3) Double-click [Setup.exe].
• “History Logs” data
4. Choose a language.
• “Log” data
• “My Data_inch” data
• “My Data_mm” data
5. Click [Yes].
6. Click [Next].

GP3.0 Updating Programs of Inline Controller
7. Click [Finish]. Checking the Program Version (Inline Controller)
1. Start the Inline Controller.
2. Turn on the System Power Switch of the Duplo DBM-5000.
3. Select the ”Maintenance” tab on the Inline Controller.
Note: The Maintenance Settings Screen appears.
4. Select the ”xxxxx” tab on the Maintenance Settings Screen.
5. Check the version of the program.
The program upgrade is completed.
CAUTION
After upgrading the program, start the DUPLO Inline Controller to make
sure that the program has been updated. If you failed to upgrade the Checking the Program Version (Duplo DBM-5000)
program, first uninstall the old version and install the upgraded version. 1. Start the Inline Controller.
After uninstalling the program, you can continue to use the data created 2. Turn on the System Power Switch of the Duplo DBM-5000.
using the old version.
3. Select the ”Maintenance” tab on the Inline Controller.
Note: The Maintenance Settings Screen appears.
4. Select the “Monitor” tab on the Maintenance Settings Screen.
5. Check the version of the program.

GP3.0 Updating Programs of Inline Controller
GP3.1 Updating Programs of Interface Box 3. The system switch is turned ON, and it supplies power to the interface
box.
4. Rewriting starts, and a confirmation buzzer sounds during rewriting.
Check that the data in the tool is appropriate at the beginning of
Creating the Writing Tool (ROM)
rewriting. If no appropriate data, the buzzer will sound three times
Create the tool for writing the program data for this machine “12S-8xxxx. repeatedly (long buzzer three times), and the rewriting process will
mot” in the EPROM. be interrupted. Note that rewriting is performed by transferring data
in the tool. If an error occurs, the buzzer will also sound three times
EPROM used: ST microelectronics M27C4001 or equivalent
repeatedly (long buzzer three times), and the rewriting process will be
stopped.
Rewriting Procedure
5. Rewriting completes when the confirmation buzzer stops sounding.
1. With the power OFF, disconnect all interface related cables (connect
6. The system switch is turn OFF, remove the tool, and turn OFF dip
only the power cord). Then insert the above tool into U07 of the interface
switch 1 again.
unit (take note of the direction to insert).
7. Check the program version on the Inline Controller (GP3.0).
2. Turn ON dip switch 1 (DSW1).
Interface unit
U18 U19
DSW1
U08
U05
U07

GP3.1 Updating Programs of Interface Box
GP3.2 Updating Programs of TR-DP 5. Turn on the Main Power Switch and the Remote Switch and activate the
Maintenance Mode.
6. Set the switch on the MC Unit as shown in the table. TR-DP starts
CAUTION updating the program.
Before you mount the EPROM on the MC Unit, make sure TR-DP is NOT • TR-DP has successfully updated the program, TR-DP sounds a short
energized. If TR-DP is energized, the program may be corrupted. alarm tone.
• When the program in the EPROM is corrupted or incorrect, the alarm
1. Turn off the Main Power Switch on the Interface Box. tone goes “beep, beep, beep, ….”
DBM-500T
• When TR-DP fails to delete the old program on the MC Unit, TR-DP
sounds a continuous alarm tone.
1 2 3 4 5 6
DCM Kit DBM-500
Upper Lower Upper Lower Upper Lower
SCC
Interface Box TR-DP
MC Unit
DBM-500
Main power
switch
2. Make sure the Make sure TR-DP is not energized. 1 2 3 4 5 6

3. Remove the Cover F (REP2.1). Switch
4. Mount the EPROM on the IC socket U03. Make sure the half-disc marks
on the EPROM and on the socket are in the same direction. 7. Turn off the Remote Switch and remove the EPROM.
8. Replace the covers.
Socket
Half-disc mark
EPROM

GP3.2 Updating Programs of TR-DP
You can access the EPROM by removing the MC Unit Cover.
GP3.3 Updating Programs of SCC
1. Remove the MC Unit Cover.
MC unit cover
Overview
You can update the programs of the MC Unit. You copy new programs in
an EPROM, and make the MC Unit read them. Before updating programs,
you should check the condition of SCC. When any maintenance work
is necessary, do it before updating. Do not turn off the Remote Switch
and Main Power Switch during updating. If you do so, programs may be
corrupted.
How to Update Program

Paper feed
Before updating the program, check the condition of SCC.
1. Copy new programs in an EPROM. New programs have the file name
“12C8xxxx.mot”, where “xxxx” are alphanumeric characters. The
EPROM must be ST Micro Electronix M27C4001 or equivalent. 2. Install the EPROM to U02 on the MC Unit. When you install the
2. Check the condition of SCC. When any maintenance work is necessary, EPROM, align the half disc on the EPROM with the half disc on U02.
do it before updating.
U02

4. Activate the Maintenance Mode (GP2.3, Activating Maintenance Mode).
Select Others and push the Jog Dial. Select Program Ver. UP.
5. Check that the correct part number is displayed on the second line in
the screen. If the correct part number is not displayed, go back to step 1.
Push the A button and keep pressing it until you hear tones:
Jog Dial Button B
• When SCC is correctly executing the update, the tone goes “beep, p, p, p,
….” Wait until the tone ends.
• When an error has occurred, the tone goes “beep–beep–beep, beep–
beep–beep,….” Turn off the Remote Switch and go back to step 5. If an
error occurs again, go back to step 1.
6. When SCC has finished updating, SCC quits making tones. SCC may
automatically restart. In this case, wait until SCC finishes initializing.
7. Turn off the Remote Switch. Remove the EPROM and store in a safe
location. Attach the MC Unit Cover.
8. Turn on the Remote Switch and check the operation of SCC.

GP3.5 Updating Programs of DBM-500 2. Attach the EPROM to U02 on the MC Unit. Make sure the half-disc
marks on the EPROM and socket are in the same direction.
Updating the Main Program

You must copy 12J-8xxxx.mot in an EPROM. You must use
STMicroelectronics M27C4001 or its equivalent.
CAUTION U02
Turn off the Main Power Switch and Remote Switch before you attach the
EPROM to the MC Unit. The EPROM data may be corrupted if you do not
MC unit
turn off the Main Power Switch and Remote Switch.
1. Turn off the Main Power Switch and Remote Switch, and remove the 3. Turn on the Main Power Switch and Remote Switch, and start the
cover. Maintenance Mode (GP2.5). Navigate to VERSIONS.
Downstream
Cover
4. Touch the Ver. UP icon.

GP3.5 Updating Programs of DBM-500
5. Make sure the versions are displayed. The number in the left pane is 7. Wait until DBM-500 stops making alarm tones. When it does, check that
the current version; the number in the right pane is the version you you see the message that prompts you to restart the machine.
are installing. If DBM-500 is unable to read the EPROM data, question
marks (????????) are displayed in the right pane. If question marks are
displayed, (i) touch the Cancel key, and (ii) quit the Maintenance Mode.
8. When you see the message, turn off the Main Power Switch and Remote
Switch. Remove the EPROM.
Cancel key 9. Attach the exterior cover.
6. Touch the without Boot Data key. (You use the All Data key only
when you are given a special instruction.) DBM-500 starts updating.
• While updating the program, DBM-500 periodically sounds alarm
tones.
• If having detected an error in the EPROM data, DBM-500 makes alarm
tones three times, and stops updating.
Note: The tones that indicate an error are longer than the tones that indicate
normal updating. Sometimes, however, you might not be so sure whether they
are longer tones or shorter tones, especially if you have never tried this updating
procedure before. In a case like this, just see if the message in the next step is
displayed.

Updating the Control-Panel Program 3. Open the Card Cover on the back of the Control Panel and insert the CF
Card to the socket.
Preparing Writing Medium
4. Close the Card Cover and turn on the CF Card Switch on the Control
1. Prepare a Compact Flash Card (hereinafter called CF Card) with
Panel.
capacity of 16MB or more and format it on a PC.
2. Copy the updater for this machine (see the figure below) to the CF Card.
CF card switch
CF card
Upgrading Procedures
CAUTION Card cover
Do not turn off the machine or the CF Card Switch during upgrade. This
may damage the Control Panel. If the power is turned off with a power
failure, turn off the Remote Switch and the Main Power Switch of the 5. Turn on the Main Power Switch of the machine.
machine. Then copy the updater to the CF Card again and start from Step 6. While touching the top and bottom left of the Control Panel screen, turn
3. on the Remote Switch of the machine.
1. Remove the Control Panel (REP5.14).
2. Connect the removed Control Panel to the connector of the machine.

7. Check that the message “Checking CF Card” is displayed on the screen
and lift your fingers off the screen.
8. Check that the message “Basic OS has been already installed.” is
displayed on the screen and then press [OK].
Note: Press [OK] regardless of the version of the Basic OS.
9. Check that the message “Install now...” is displayed.
Note: It will take 2 or 3 minutes to complete the installation of the Basic OS.
10. Check that the message “Download now?” is displayed on the screen
and then press [OK].
Note: When pressing [OK], the message “Download now...”is displayed.
Downloading the data will take between 20 to 30 seconds.
11. Check that the message “Install is completed. Restart now.” is displayed
on the screen and then press [OK].
Note: The Control Panel will restart.
12. Check that the panel version displayed on the bottom right of the start-
up screen is same as the updater.
Note: If the panel version is different from the updater, the upgrade might have
not been successfully completed. In this case, turn off the Remote Switch and
Main Power Switch of the machine. Then copy the updater to the CF Card again
and repeat the procedures from Step 3. If you still cannot upgrade the program, it
is possible that the Control Panel has been damaged. Replace the Control Panel.
13. Turn off the Remote Switch and Main Power Switch of the machine.
14. Turn off the CF Card Switch on the Control Panel and take out the card.
15. Attach the Control Panel.

GP3.6 Updating Programs of DBM-500T 3. Turn on the Remote Switch and Main Power Switch, and go into the
Maintenance Mode. Navigate to Other Setting, and Program Ver.
UP.
4. Make sure the version number is displayed. This is the version number
Preparing ROM
of the program you are going to install. When no version number is
You must copy 12K8xxxx.mot in an EPROM. You must use displayed, (i) turn off the Remote Switch, (ii) remove and attach the
STMicroelectronics M27C1001 or its equivalent. EPROM, and (iii) turn on the Remote Switch. If you still do not see any
version number, the EPROM data may be corrupted.
CAUTION
Turn off the Remote Switch and Main Power Switch before you attach the
EPROM to the MC Unit. The EPROM data may be corrupted if you do not
turn off the Remote Switch and MAin Power Switch.
5. Keep pressing the Button A until the machine starts updating. The
1. Turn off the Remote Switch and Main Power Switch, and remove the machine makes alarm tones while updating.
exterior cover (PL6.18). Button B
2. Attach the EPROM to U02 on the MC Unit. Make sure the half-disc
Escape button Clear button Jog dial Button A
6. After finishing updating, the machine automatically turns off and on.
Leave the EPROM attached.
U02
U05
U04 7. Turn off the Remote Switch and Main Power Switch, and remove the
EPROM.
8. Attach the exterior cover (PL6.18).

GP3.6 Updating Programs of DBM-500T
GP4.1 Specifications of Interface Box
Model Interface Box

Power Supply • AC 120 V, 60 Hz
• AC 220 to 240 V, 50/60 Hz
Dimensions (W × D × H) 229 × 192 × 96 mm (9.02 × 7.56 × 3.78 in.)
Weight 3.5 kg (7.7 lb)

GP4.1 Specifications of Interface Box
GP4.2 Specifications of TR-DP
Model TR-DP
Type Add-on transport bridge
Paper Size (W × L) Max: 356 × 500 mm (14.0 × 19.7 in.)
Min: 120 × 170 mm (4.72 × 6.69 in.)
Paper Type • Fine: 60 to 300 g/m²
• Coated: 84.9 to 300 g/m²
Paper Curl 6 mm (0.24 in.) or less, R20 or larger
Paper Path Alignment Center of the paper
Height of paper entrance 845 to 1086 mm(33.3 to 42.8 in.)
Process Speed 1000 to 1500 mm/sec (39.4 to 59.1 in./sec)
Sensors • Paper jam
• Paper path cover
Operating Environment • Temperature: 15°C to 35°C (59°F to 95°F)
• Humidity: 20% to 85%RH
• Luminosity: 1500 lux or less
(Dew condensation must be avoided.)
Noise Emission 67 dB or less
Power Supply • AC 100 V +10% to -10%, 50/60 Hz
• AC 120 V + 6% to -10%, 60 Hz
• AC 220 to 240 V +6% to -10%, 50 Hz
Weight • Main body: 27 kg (59.5 lb) excluding accessories
• Accessories: 2 kg (4.4 lb)

GP4.2 Specifications of TR-DP
GP4.3 Specifications of SCC Cutter • Lead edge: 4 to 25 mm (0.16 to 0.98 in.)*6
• Trail edge: 5 to 25 mm (0.20 to 0.98 in.)*6
Creaser One crease per sheet (The following conditions must be met.)
Main Body • 80 to 360 mm (3.1 to 14.2 in. ) from lead edge, and
• 80 mm (3.1 in.) or more from tail edge
Model SCC
Adjustable Range of • Side Joggers: ±0.5°
Type Slitter cutter creaser; Floor model Paper Skew
• Cutter: ±1.0°
Paper Size (W × L) • Process Path
• Creaser: ±1.0°
Max: 356 × 500 mm (14.0 × 19.7 in.)
Finished Size (W × L) Max: 356 × 500 mm (14.0 × 19.7 in.)
Min: 120 × 170 mm (4.72 × 6.69 in.)
Min: 120 × 170 mm (4.72 × 6.69 in.)
• Bypass
Operating Environment • Temperature: 5˚C to 35˚C (41°F to 95°F)
Max: 356 × 500 mm (14.0 × 19.7 in.)
Min: 120 × 170 mm (4.72 × 6.69 in.)
Paper Type • Process Path
Noise Emission • SCC: 67dB*7
Fine 80 to 300 g/m 2
Power Supply • Europe: 220 to 240 V (+6% to –10%), 50 Hz, 0.6 A
Art/Coated: 84.9 m 2 to 300 g/m 2
• North America: 120 V (+6% to –10%), 60 Hz, 1.1 A
• Bypass
Dimensions (W × D × H) Max: 1320 × 735 × 810 mm
Fine 60 to 127.9 g/m 2
Min: 1320 × 610 × 810 mm
Art/Coated*1 84.9 to 157 g/m 2
Weight 187 kg (412 lb)
Paper Curl • 60 to 127.9 g/m 2 : 10 mm (0.39 in.) or less
• 127.9 to 300 g/m 2 : 5 mm (0.20 in.) or less * The maximum size is A3 or 11 × 17 in. when paper weight is 105 g/m 2 or less.
1
Process Speed • All Mode (Process Path) *2 25 sheets when crease positions are more than 300 mm from tail edges
Slitter: 60 sheets/minute *3 Can be restricted by downstream units
Cutter: 25 sheets/minute *4 1400 mm/sec as default
Creaser: 60 sheets/minute* 2 *5 Edges for both sides are slit.
Slitter + Creaser: 60 sheets/minute*2 *6 Both edges are cut.
Cutter + Creaser: 25 sheets/minute *7 Measured under the following conditions:
Slitter + Cutter: 25 sheets/minute Horizontal distance: 1 meter from the Control Panel
Slitter + Cutter + Creaser: 25 sheets/minute Vertical distance: 1 meter from the floor
• Through Mode (Bypass)
A3: 150 sheets/minute
A4: 200 sheets/minute*3
Paper Travel Speed • Paper feed/Paper exit: 1000 to 1500 mm/sec*4
• Bypass: 1000 to 1500 mm/sec
Slitter 4 to 25 mm (0.16 to 0.98 in.)*5

GP4.3 Specifications of SCC
GP4.4 Specifications of DCM Kit
Model DCM Kit

Type Floor-type static eliminator/air supply unit
• AC 220 to 240 V, 50/60 Hz
(Main unit only)
Weight 19 kg (41.85 lb)
(Main unit only)

GP4.2 Specifications of DCM Kit
GP4.5 Specifications of DBM-500/DBM-500BR
SEF: Short Edge Feeding
LEF: Long Edge Feeding
*1 Thick paper: 1.5 mm (0.06 in.) or less, 127.9 g/m² (23lb)
*2 5.0 mm (0.20 in.) or less, 81.4 g/m² (22lb), A4/LTR
Model DBM-500 *3 Up to 4 (optional)
Type Stitcher folder
*4 1 cover (300 g/m² (79 lb)) + 24 sheets (81.4 g/m² (22 lb))
Paper Size (W × L) • Saddle stitching
Max: 356 × 508 mm (14.02 × 20.00 in.)
Min: 120 × 178 mm (7.01 to 4.72 in.)
• Side stitching/corner stitching
B5 LEF, A4 (LTR) SEF/LEF, B4 SEF, LGL LEF
Paper Type • Saddle stitching and folding
Fine quality paper—64 to 127.9 g/m² (17 to 33 lb)
Art and coated paper—84.9 to 157 g/m² (24 to 41 lb)
Thickness of one set—2.5 mm (0.10 in.) or less (normal
paper)*1
Cover sheet—Below 300 g/m² (79 lb)
• Side and corner stitching
Fine quality 64 to 127.9 g/m² (17 to 33 lb)
paper)*2
Process Speed • 5000 sets/hour
Fine quality paper, 178 × 120 mm (7.01 × 4.72 in.), 5 sheets or
less
• 4500 sets/hour
Fine quality paper, 81.4 g/m² (22 lb), 10 sheets or less,
A4 saddle stitching, Folded (to A5)
• 3900 sets/hour
Stitching • Number of stitches—0 to 2*3
• Stitch thickness—5 mm or less (Fine quality paper,
81.4 g/m² (22 lb), 50 sheets)
• Wire size— #25 to #27
Folding 25 sheets or less*4
Operating Environment • Temperature: 5˚C to 35˚C(41°F to 95°F)

Noise Emission 78 dB (A scale; Peak included)
Power Supply 120 V 60 Hz 6.5 A
Dimensions (W × D × H) • In storage
1610 × 770 × 1020 mm (63.39 × 30.31 × 40.16 in.)
excluding stitcher heads
• In use
2230 × 865 × 1300 mm (87.80 × 34.06 × 51.18 in.)
including the belt stacker

GP4.5 Specifications of DBM-500/DBM-500BR
GP4.6 Specifications of DBM-500T
Model DBM-500T
Type Fore-edge trimmer
Paper size (W × L) Max: 356 × 250 mm (14.02 × 9.84 in.)
Min: 120 × 85 mm (4.72 to 3.35 in.)
The length above is before trimming.
Paper Type • Fine quality paper—64 to 127.9 g/m² (17 to 33 lb)
• Art, coated paper—84.9 to 157 g/m² (24 to 41 lb)
less
• 4500 sets/hour
Fine quality paper, 81.4 g/m² (22 lb), 10 sheets, A4/Letter,
Saddle-stitched
• 3900 sets/hour
Fine quality paper 81.4 g/m² (22 lb), 10 sheets, A3/Ledger,
Saddle-stitched
Trimming 2 blades (top/bottom)
Trimming Capacity 50 sheets, 81.4 g/m² (22 lb)
Finished Size 75 to 250mm (2.95 to 9.84 in.)
Trimmed Size 1 to 25 mm (0.04 to 0.98 in.)
Power Supply 220 to 240 V, 50 Hz, 3.3A/120 V, 60 Hz, 5.4A
Weight 241 kg (531.3 lb) including accessories

GP4.6 Specifications of DBM-500T
GP4.7 Specifications of DBM-LS1/DBM-K
DBM-LS1
Model DBM-LS1
Type Long stacker
* When DBM-K is mounted
1369 × 670 × 970 mm (53.90 × 26.38 × 38.19 in.)
DBM-K
Model DBM-K
Type Kicker

GP4.7 Specifications of DBM-LS1/DBM-K
GP4.8 Specifications of SpineMaster Safety Data Sheet
Date: July 2003, Rev 1
SAFETY DATA SHEET
Product Specifications JULY 2003, REVISION 1
Intended Use This product is intended for the re-forming of booklet spines, to Model Watkiss Automatic SpineMaster
flatten the booklet and give a square appearance to the spine, Description Spine-former for post-processing saddle stitched
within the specifications below. booklets to produce a SquareBack spine
Operating Conditions 10-35°C at 35-85% relative humidity
Production up to 1400 per hour single pass Dimensions
Width 707mm
Booklet Size from 80 x 120mm to 250 x 350mm Depth 745mm
(dependant on specification of connected equipment) Height 1242mm
Weight 132kg
Booklet Thickness minimum of 1mm, 0.04” Voltage 230V (210-254V) 115V (105-127V)
maximum of 6.5mm, 0.25”. This is approximately 30 sheets of Frequency 50Hz 60Hz
80gsm (20# bond) folded into a 120 page booklet.
Current 3.0A 4.8A
Protection Fuse 5.0A 10A
Dimensions
Power consumption, operation 600VA 415VA
Width 707, 28”
Power consumption, standby 37VA 19VA
Depth 690-762mm, 27-30” (dependant on version)
Mains connection removable cable & plug removable cable & plug
Height 1138-1178mm, 45-461/2 ” (dependant on version)
Safety class I I
Weight 132kg, 291lb
Protection class IP 20 IP 20
Sound pressure level
Electrical 230V, 50Hz, 3A or 115V, 60Hz, 5A
(at operator/bystander position) Standby: 0 dB (A); In use: 72 dB (A) typical
Single Phase, Earthed supply required
Radio interference Complies with Directive 89/336/EEC
Radiation Not applicable
Noise 72 dB(A)
Ozone emission Not applicable
Room volume No special requirements
Room ventilation No special requirements
Consumables None
Production and specifications are subject to operating conditions. The specified paper CE Compliance
thickness figures are given for guidance only. The actual performance of the machine
will depend on the nature of the paper and covers used. In line with a policy of continual Safety: 73/23/EEC and 98/37/EC
improvement, the manufacturer reserves the right to alter the materials or specifications of EMC: 89/336/EEC
this product at any time without notice.
Radio Frequency Emissions This safety data sheet has been compiled to the best of our knowledge as a compact guide
to safe handling of this product. We reserve the right to revise safety data sheets as new
This equipment has been tested and found to comply with the limits for a Class A digital information becomes available. It is the user’s responsibility to determine the suitability
device, pursuant to part 15 of the FCC Rules. These limits are designed to provide of this information for the adoption of safety precautions as may be necessary and to
reasonable protection against harmful interference when the equipment is operated in a contact the company to make sure that this sheet is the latest one issued. If and in so far as
commercial environment. This equipment generates, uses and can radiate radio frequency limitation of liability is permitted under the applicable laws, we do not accept liability for
energy and, if not installed and used in accordance with the instruction manual, may cause any inaccuracy that may occur in this information.
harmful interference to radio communications.Operation of this equipment in a residential
area is likely to cause harmful interference in which case the user will be required to correct
the interference at his own expense.

GP4.8 Specifications of SpineMaster
Space Requirements Recommended Tools & Consumables
B It is recommended that engineers carry the following tools and materials
with them. Watkiss part numbers are included where relevant, although
many of the recommendations are standard tools which are readily
Top view (ASM version shown) available.
USA readers: Please note that the terms ‘spanner’ and ‘wrench’ are inter-
changeable.
Recommended Tools & Consumables
A
DESCRIPTION REMARKS
Screwdriver - FLAT, 6.5mm
Spanner - Combination, 5.5mm
Spanner - Combination, 8mm (M5)
Spanner - Combination, 13mm (M8)
Spanner - Combination 17mm (M10)
Spanner - 19mm A/F
Spanner - 10mm A/F
Pliers - Side cutters, small
Side view (ASM version shown) Circlip Pliers (external)
Allen Key ‘L’ - 2.5mm
Allen Key ‘L’ - 3/32”
Feeler Gauges Metric (0.05 - 1.0mm)
C 0.02mm Feeler Gauge
0.5mm Cranked Feeler Gauge
6” Rule (steel)
3, 4, 5mm Pin Punches
3/4LB Ball Pein Hammer
Fine File or Oil Stone
Bypass Cable
Special Tool: ASM Hand Crank Tool Part No. 955-014
Loctite 242 (Thread Locking Compound)

Chain Lubricant
VERSION ‘A’ WIDTH ‘B’ DEPTH ‘C’ HEIGHT
ASMD 745mm; 29 1/2 ” 690mm; 271/4 ” 1092mm; 43”

GP4.8 Specifications of SpineMaster
Section 7
Wiring Data
Contents
Section 7 Wiring Data .................................................. 7-1 WD3.7 Schematic Diagrams of DBM-LS1 ....... 7-71
WD1.1 Plug/Jack Locations of Interface Box .....7-2 WD3.8 Schematic Diagrams of SpineMaster ... 7-72
WD1.2 Plug/Jack Locations of TR-DP ...............7-3
WD1.3 Plug/Jack Locations of SCC ...................7-4
WD1.4 Plug/Jack Locations of DCM Kit ........... 7-12
WD1.5 Plug/Jack Locations of
DBM-500/DBM-500BR ........................ 7-13
WD1.6 Plug/Jack Locations of
DBM-500T/DBM-K ...............................7-20
WD1.7 Plug/Jack Locations of DBM-LS1 ........7-25
WD1.8 Wiring Diagrams & Electrics of
SpineMaster .........................................7-26
WD2.1 Block Schematic Diagrams of
Interface Box ........................................7-30
WD2.2 Block Schematic Diagrams of TR-DP .. 7-31
WD2.3 Block Schematic Diagrams of SCC ......7-32
DCM Kit ................................................7-33
DBM-500/DBM-500BR ........................7-34
DBM-500T/DBM-LS1/DBM-K..............7-36
WD3.1 Schematic Diagrams of Interface Box ..7-37
WD3.2 Schematic Diagrams of TR-DP ............7-42
WD3.3 Schematic Diagrams of SCC ................7-45
WD3.4 Schematic Diagrams of DCM Kit ..........7-52
WD3.5 Schematic Diagrams of
DBM-500/DBM-500BR ........................7-55
WD3.6 Schematic Diagrams of
DBM-500T/DBM-K ...............................7-65
7-1
iGen3-M12D0-0612-0
WD1.1 Plug/Jack Locations of Interface Box
V IE W A V IE W C
D E T A IL O F L O C K E R S W IT C H
DUST PROTECTION
CAP
B L A C K :IN L E T W H IT E :IN L E T
13
B L A C K :S W IT C H IN G W H IT E :S W IT C H IN G
LOCKER SWITCH ANGLE F
24
POW ER POW ER
SUPPLY SU PPLY
3N N o te ) C o n n e c t in s u la tio n s le e v e ( B L U E ) to 1 ,3
a n d in s u la tio n s le e v e ( G R E E N ) to 2 ,4 .
SPACERx2
A
CN1 BUNDLED WIRE
UNIT 1
SPACERx2
V IE W B
SWITCHING
I F UNIT POWER 3N
SUPPLY D E T A IL O F IN L E T V IE W D
BRASS
SCREW GREEN/YELLOW
C WHITE:LOCKER BLACK:LOCKER
B SWITCH SWITCH
CN2
WHITE:OUTLET BLACK:OUTLET
2N
D E T A IL O F O U T L E T
GREEN/YELLOW
BUNDLED WIRE
UNIT 2
D INLET
SCREW SCREW
BLACK:INLET WHITE:INLET DUST PROTECTION DUST PROTECTION
CAP CAP
OUTLET CONTROL BOARD BASE

CABLE CLAM P
2N: 3302
3N : 3303 12S-85034
7-2 Section 7—Wiring Data

WD1.1 Plug/Jack Locations of Interface Box
WD1.2 Plug/Jack Locations of TR-DP
A B C D E F G H I J K L M
Cable clamp
1 3302
3303
3304
Frame F
Photo interrupter
Earth wire unit 2

Sensor bracket
3
Wire Harness 3
Magnet sensor
A
Sensor angle Cover

4
Frame B
3302 Bracket R Photo interrupter
Bushing
Bushing OCB-625
OCB-625
3303 3303 3303 3303
6 Earth wire unit 4 Wire
Harness 3
A
3304
3304 3304 3304
7 Wire Harness 2 DC brushless motor 3303
3302
J01 J02 Cable clip

Spacer ×4 1197 3303
Wire Harness 1 Bushing
8 Cable clip OCB-875
1197 Bushing AC wire Harness
MC unit OCB-875
J06 J08
J3 J2 J4
J5
9 Spacer ×4
RM unit Bracket RD
12C-80340

WD1.2 Plug/Jack Locations of TR-DP
WD1.3 Plug/Jack Locations of SCC (1 of 8)
M
2
BLU
Universal bush Foot FR
3 Reinforcement plate
(PCB 304) BLK WHT (PCB 304)
Switching power supply Switching power supply Screw (Brass)
BLK WHT
Wire harness 11
Inlet Inlet
2N
GRN
2N
4 3N CCD Details of
Main Power Switch (PSW301) AC Wire harness 1
Main Power
3N
Switch
ON OFF
2N
7 (PSW 301)
Remote switch
3N Wire harness 9 WHT (PSW 302)
5 3N GRN/YEL Main Power Switch
N
Bracket Int. sensor (Lr) (PSW301) Ferrite core Inlet
Screw (Brass)1 BLK
E
(PS 308)
L
Int. sensor (LED side)
3 (FM 301) 2N
(PS 308) Details of inlet
3N
AC Wire harness 1
DC fan motor
5N (PS 309)
Int. sensor (Lr) Bracket 4 M
6
(PS 312) Int. sensor (LED side) Sensor bracket
Purple
2N
3N
5 05-0
Wire harness 13
Switching power supply
6
5N (PCB 304) GRY
AC Wire harness 1
Wire harness 13 05-0
7 AC Wire harness 1 N
Wire harness 7
Sensor bracket 7 View (Remote switch)
2N 05-0
5N
5N Wire harness 9
8 E Cable clamp Cable clip

G H
2N: 3302 1/8 M: 1197
3N: 3303 3/16 L: 5076
Jog conveyance section
4N: 3304 1/4 XL: 4253
5N: 3305 5/16
6N: 3306 3/8 Miniclamp
7N: 3307 7/16 05-0: UAMS-05-0
9 8N: 3308 1/2
12C-85103

WD1.3 Plug/Jack Locations of SCC
(2 of 8)
Switch
OP unit 1/2 (PCB 302) Bracket Label
(SSW 301)
1
4N
Motor bracket
5N
Wire harness 1
3N 3N
2N
Stepping motor
2 4N 4N
(M 309)
DC harness unit 5
OPWire harness 1 K
Sensor angle (CL 301)
Wire harness 13 MC unit
3 (PCB 301) Electromagnetic clutch
(M 306)
(PS 310) Stepping motor Angle
G M
Photo interrupter
(SSW 305)
Microswitch
Tension Bracket 2 L
XL
4
H J Counter unit
(CNT 301)
a 4N
M
M
5
XL
M L
7N 7N
XL M
(M 301)
6 DC motor Wire harness 9 Wire harness 1 Spacer x4 DC brushless motor
(M 303) I
Wire harness 1
Sky-BLU YEL
7 Photo interrupter Photo interrupter
(PS 303) (PS 303)
Sensor bracket M Sensor bracket M
Wire harness 1 Wire harness 2
J Q
Microswitch
8 Side jog section Chassis
(SSW 305)
a Details of microswitch
12C-85103

(3 of 8)
Frame F
1 Wire harness 7 Wire harness 13
Binder
3N
2
5N
6N
Photo interrupter
(PS 301) E OPWire harness 1
2N
3 Sensor bracket Wire harness 11
A (M 305)
DC motor 2N
M
1
Motor bracket Motor bracket
B 6N
4
2N Angle
C
Wire harness 9
F
D
5
M
M L M M L
7N
(M 302)
6 DC brushless motor Wire harness 1
Reinforcement plateT Wire harness 10 Int. sensor (Lr) Int. sensor (Lr) Carry guide T Wire harness 10
(PS 307) (PS 305)
05-0 05-0 05-0 05-0 05-0 05-0
A K
7
Sensor bracket Sensor bracket
Sensor bracket Wire harness 12 Sensor bracket

8
B L
05-0 05-0 05-0 05-0 05-0 05-0
Reinforcement plateD Wire harness 12 Int. sensor (LED side) Int. sensor (LED side) Photo interrupter Wire harness 8 Carry guide D
9 (PS 307) (PS 305) (PS 304)
Paper exit section Paper entrance section

12C-85103

(4 of 8)
Universal bush Reinforcement Wire harness 13

DC motor 3N
DC motor (M 303) plate E
2
Motor bracket T Int. sensor (Lr)
(PS 312)

3 (PS 312)
C
Reinforcement plate Sensor bracket

1 View 2 View Motor bracket Wire harness 9
05-0 M
4 Bracket Wire harness 7 Bracket

3N 2N 3 View
E
Sensor bracket
2N Wire harness 13 2N
5
G
Int. sensor (Lr) Binder Int. sensor (Lr)
(PS 311) Plate (PS 309)
Int. sensor (LED side) Plate Int. sensor (LED side)
(PS 311) (PS 309)
6 Sensor bracket
Sensor bracket 5 View Int. sensor (Lr) (PS 308) Reinforcement stay
05-0 W
8
F
2N
Wire harness 9 (PS 308) Int. sensor (LED side)
Wire harness 9
7
H
4 View 05-0 05-0 05-0 W
8 Sensor bracket (PS 311)

6 View Sensor bracket Wire harness 9 Reinforcement stay
05-0 2N
Wire harness 9 2N
9
8 View
12C-85103

(5 of 8)
1 Limit switch unit Sensor bracket

(SSW 303)
Cutter unit
2 Reinforcement stay
2N
2N
2N
3 S
Wire harness 4
4 M
M
M
Motor
(M 304)
Sky-BLU
5 R
M M M M
6 SWBracket Limit switch unit Wire harness 2

(SSW 304)
12C-85103

(6 of 8)
1 Sensor bracket Microswitch Limit switch unit Frame B

b (SSW 306) (SSW 302)
(SSW 306)
BRN
Microswitch
Wire harness 2 3N
SOL (SL 303)
Sky-BLU GRY BRN
2 3N
b Details of microswitch YEL BRN

4N 2N
2N 2N
3
Stepping motor
Cord unit 1 (M 307)
SOL
Wire harness 2
Sky-BLU
(SL 302)
5 BRN
M SOL
M M
O
6
P
12C-85103

(7 of 8)
M M M
O
2
M O
Wire harness 3
Wire harness 3
Foot BR
3 Screw (Brass) Universal bush
Cap
M
Safety interface
harness 1
M V
4 Safety interface Fence R
9 View
harness 2
M
5 T
I
U
XL XL
Dust protection
cap 10
P
XL
Wire harness 1
DC motor
6
DPIF P.W.B. unit
(PCB 306) (PS 313)
PRP.W.B. unit
7 Fence R
Fence section Servo driver Spacer x4
10 View
9 XL Wire harness 1
12C-85103

(8 of 8)
M M
Fence section Microswitch Body base section
M
1 R (SSW 302)
Motor unit
Photo interrupter
(M 310)
(PS 314)
COM NC Sensor angle M
Locking spacer ×2
2N
(PS 313)
P.W.B.Bracket
2 LED P.W.B. unit BLU Sky-BLU M M
M
Wire harness 2
2N CN2
Wire harness 2 c Details of microswitch
c (PCB 305) Collar x4
M RL P.W.B. unit Bush x4
M
3
J03
J03
(PCB 304) M Wire harness 3
J03
BLU Sky-BLU Switching power supply J03
V
SW bracket unit
Microswitch Purple
M
(SSW 302) M
4 Wire harness 6 M
CN1
BRN M
M
N
M
SOL M
Fence L 11 View
AC wire harness 1 Move base
Spacer ×4
5
Bypass section Int. sensor (Lr) Reinforcement stay
2N 2N (PS 306) (PS 306) Sensor angle Back jog section
05-0 05-0
Frame B
4N
U
Wire harness 6
(M 308)
4N
Stepping motor
11
(SL 304)
9
S S SOL
12C-85103

WD1.4 Plug/Jack Locations of DCM Kit
Remote Bracket RM Unit

1 Angle
Spacer
Wire unit 5
Hose
To Power supply Wire unit 1
2
Angle Compressor unit
B
3N 3N Earth wire unit
5N
2N
Air Hose
3
Bushing (OCB-562)
5N 5N
5N
Screw(Brass)
BLK BLK
Bracket Compressor unit D BLK BLK D
Bushing
Spacer x 4 Sky-BLU BRN YEL BRN (OCB-562)
3N
4 Dust protection 4N 3N 3N 3N 2N 2N
cap x 2 3N C
I/F unit Hose

A
Switiching
Base Wire unit 2
Screw
Earth wire unit Angle
Relay Guard Spacer x 4 Power supply
(Brass)
Bar SM, Static Active Angle Angle R
5
Earth wire unit
Bracket
I/F unit
A View 6N B View Remote Bracket
Bracket
6 RM Unit
S Power supply high voltage S

Bracket
Wire unit 5
3N
To Static-electricity
Eliminator S
7 Wire unit 2
M Wire unit 2 Wire unit 1
Cable clamp
2N: 3302
3N: 3303
M 4N: 3304 S
8 5N: 3305 Z
6N: 3306
Stand lock clip
S SLCS2-250-3-01 Note 3: Each model code corresponds to destinaion as below.
M SLCS2-370-3-01 120V,60Hz (for USA)
220-240V,50Hz (for UK)
Note 2: On each relay marked D , each black cable can be connected to either of two terminals indicated in above illustration.
9 Note 1: The cable marked C must be tightened to avoid contact with the Switching Power Supply.
99T-85215

WD1.4 Plug/Jack Locations of DCM Kit
WD1.5 Plug/Jack Locations of DBM-500/DBM-500BR (1 of 7)
Wire harness 1 7N 6N 4N Spacer x6 Wire harness 1 Wire harness 1
5N 8N 9N
J17 J16 J15 J14 J13 J12 8N
8N 9N
2
Wire harness 1 Wire harness 16 (SL503)
To MC unit DC solenoid Push mount tie
J11
Cord unit 1 Screw (Brass) 4N
2N
Sensor bracket
J04
Photo interrupter
MC unit 5N (PS517)
J09
Edging (PCB501) Core D
6N
J10
4N 3N
3 4N
6N
(SSW501)
C Magnet
J08
6N
J22
Wire harness 2 sensor

Clamp filter 4N Angle
Screw (Brass) Screw (Brass) 4N Wire harness 1
J03
J06
J21 J05 J02 J01 J07 J20 J19 J18
A 14N
3N
4
7N To MC unit 14N Angle 3N
B
7N Screw (Brass) Photo interrupter Wire harness 1 Wire harness 1 Photo interrupter
13N 12N
(PS503) (PS505)
Wire harness 16 Wire harness 1 Screw (Brass)
SI wire harness 1 Ferrite core
5
4N 5N
SI wire harness 2 CN52 CN51 G
Collar x4
J02
4L J02
Wire harness 1 J01 Bush x4
14N
CN2
Dust protection M Stepping motor
J03
J04
cap (M501)
6
J01
AC wire harness 1 RL P.W.B. unit Switching power Bush
Cable clamp (PCB503) supply M
2N: 3302 DPIF P.W.B. unit
J05
WHT BLK (PCB504)
3N: 3303 AC wire harness 1
BLK
BRN YEL
4N: 3304 Wire WHT
5N: 3305 Sky-BLU
BRN harness 1 Circuit protector 5N
6N: 3306 BLK Spark killer
(PSW502) AC wire harness 2
7 Power cord unit BLK Wire harness 1
7N: 3307
Details of AC wire harness 3 Noise filter
8N: 3308 Outlet
9N: 3329 Circuit protector Details of relay Screw 5N
CN1
10N: 3330 220-240V 120V AC wire harness 3 (Brass) 7N BLK 14N Partition plate
11N: 3331 L
WHT
BLK WHT
12N: 3332 WHT Ferrite core Spacer x4
GRN/YEL
Edging H
14N: 3334
BLK
8 GRN/YEL Power cord unit
Stand lock clip Details of Outlet Details of Outlet
S: SLCS2-250-3-01 L
M: SLCS2-370-3-01 Bush
L: SLCS2-500-3-01 5N 2N
2L: SLCS2-750-3-01
Universal bush Relay Universal bush Wire harness 1
3L: SLCS2-250-16-01 AC wire harness 3
9 4L: SLCS2-370-16-01 (RL502)
12J-85119 (120V) / 12J-85129 (220-240V)

WD1.5 Plug/Jack Locations of DBM-500/DBM-500BR
(2 of 7)
Wire harness 1 Wire harness 1 Wire harness 1 Wire harness 1 Frame B Sub frame B
6N 5N 3N 3N
S
2
8N 7N Wire harness 16 7N (M507)
Angle 3N
Stepping motor 3N
Wire harness 15
Photo 3N
interrupter (M512) 5N
2N
(PS509) 3N
Stepping motor
4N 3N
L
5N
Screw (Brass)
3 Wire harness 6
(M506)
Stepping Wire harness 4 Wire harness 1
2N Wire harness 5
motor 1 pin:YEL
Sensor angle (PS521) BracketB P 2 pin:BLU
K 4N 3N
Angle Photo interrupter 3 pin:Pink
Wire harness 1 Screw (Brass) Wire harness 6
5N
Photo interrupter DC solenoid
4 (PS514) (SL506) Stepping motor
Wire harness 7
DC solenoid 3N (M509)
7N
(SL504)
5N M
2N
I Photo interrupter
Wire harness 15 (PS513) Q
5
Sensor angle
DC solenoid (SL502) 2N 2N N Edging
2N
Electromagnetic Push mount tie
2N
clutchC
(CL501)
J Paper receiving table unit

6
Brake 1 pin:Purple
(short) 2 pin:BRN
5N
Clutch 1 pin:Sky-BLU
(long) 2 pin:BRN Photo sensor
3N 3N
Paper receiving base (PS516)
Electromagnetic brake Photo interrupter
(BRK502) (PS519) Wire harness 1
7 3N 3N
Sensor bracket
3N
M
(RL501)
Edging Relay O
H Screw (Brass) Screw (Brass)
8 L
Ground line
L L M Screw (Brass) 3N
Wire harness 1 5N 5N M
5N
Universal bush Outlet

AC wire harness 3
9
12J-85119 (120V) / 12J-85129 (220-240V)

(3 of 7)
Wire Wire harness 18

Sensor bracket
harness 2 E (SSW504) (SSW505)
Sensor bracket
Inter lock switch
Photo interrupter DC solenoid (SL505)
2 Bracket (PS523) (PS524) Photo interrupter Bracket Frame
Sensor
(PS525) (PS526) (PS510)
Screw (Brass) Screw bracket
Photo interrupter (Brass)
(Lr) (PS508)
2N 4N
K
Wire harness 18 Wire harness 18 MSKW3x6 3N

3 2N 2N
Wire harness 4
Back stopper unit
L C
Bracket
(SL501) Wire harness 15 Photo interrupter
3N
Wire DC solenoid I (PS507)
Wire harness 18
4 harness 2 3N
3N
X
F
Screw (Brass) Sensor bracket
Bracket 4N
E F
Wire feed detection unit Base
5
C D
J
Stitching ejection unit 1 View Solenoid base
Stepping motor
Photo interrupter (M505)
1
6 Channel (Le) (PS508) Wire harness 12
Screw (Brass)
3N
DC solenoid
Ground line 3N (SL501) X
Sensor base
7 Saddle stitch stopper unit

Base
3N
Channel
Photo interrupter (Lr)
(PS501)
A
3N
(PS501)
8 Bracket Photo interrupter (Le)
Bracket
B
Channel
Conveyance unit Sensor bracket
G
9
12J-85119 (120V) / 12J-85129 (220-240V)

(4 of 7)
220-240V 120V BRN Purple
Photo interrupter Photo interrupter WHT BLK

BLK WHT Wire
(Lr) (Le) Sensor bracket Spark killer harness 1
BLK BLK
(PS515) (PS515)
2 GRN/YEL
GRN/YEL AC wire harness 3
Outlet Details of Outlet Details of Details of relay
Photo interrupter
(PS511)
3N 3N Reinfrocement plate T
Photo interrupter (PS512)

3N
3 3N 3N 3N 3N
S
Sensor bracket Screw
3N
(Brass)
N Sensor guide
Stepping motor (PS522)
Guide T Photo interrupter Fold stopper 2 (M508)
6N
4 Guide D (Le) (PS522)
6N
Wire harness 6 Wire harness 7 Photo interrupter (Le) Reinfrocement plate D
Side stitching R
ejection unit Photo interrupter (Lr)
Fold stopper unit P Q 2 View

Sensor bracket
5
Paper receiving table unit

3N R
Wire harness 8
3N
6 3N Photo sensor
(PS516)
7
Reinfrocement
plate
3N
Wire harness 1
8
3N
Paper receiving base

O Paper receiving unit
12J-85119 (120V) / 12J-85129 (220-240V)

(5 of 7)
1
V
Frame F Switch (SSW503)
Wire harness 1 Wire harness 10 Wire harness 1
3N 3N 3N 4N
Stepping motor
8N 8N 8N 8N
2 (M511) Counter unit 8N
2N
(CNT501) 3N
3N
4N
(SSW502) DC harness unit 5
Magnet
Screw (Brass) Switch
sensor (PSW501)
Sensor angle Counter unit
(CNT502) Angle
PH angle 8N
3 Photo interrupter
3N
(PS506) 3N
Photo interrupter Wire harness 1

(PS520) Electromagnetic brake AC wire harness 3
(BRK501)
3N
4 4N
Stepping motor 3N
(M504)
Wire harness 1
Screw (Brass) 9N
5 3N 3N
M
Stepping motor Wire harness 12
Photo interrupter (M510)
(PS518) X 3N
Collar x4
Push mount tie Bush x4 2L
AC wire harness 3
3N 3N 3N
6 Sensor angle
Edging 3L
M
S S S S
Wire harness 14 3L
4N
3N
Inverter Wire harness 1
AC wire harness 3
Limit switch unit Transformer
7 (SSW506)
AC motor
(M514) Isolation board
AC wire harness 7 2L
4N 4N (PCB502)
Ferrite core
M
Screw (Brass)
Screw (Brass)
8 Wire harness 13
U T
Ferrite core Ferrite core Universal bush Universal bush
12J-85119 (120V) / 12J-85129 (220-240V)

(6 of 7)
Frame B
AC wire harness 3
3N 3N 3N 3N 3N 3N 3N 3N
2
5N 5N
M Wire harness 3 2N
Electromagnetic brake H
Screw (Brass)
(BRK502) AC wire harness 3 Edging
3 Electromagnetic
Wire harness 9 Cable clip
clutch
Wire harness 1
(CL502) W
3N
Screw (Brass)
Cabinet T
3N
Photo interrupter
(PS527) 10N
4 Harness
PH angle Cabinet lower Edging cover
2N 2N Photo interrupter
3N
(PS528) Angle
2N 2N
DC motor unit
5 (M513) 10N
Fan unit
5N
Screw (Brass) 5N
3N
6 Screw Gear head

Motor (Brass)
earth wire Wire harness 3 2N Cover
10N
AC motor
Screw
(Brass) (M514)
Screw 2N 2N
3N
7
4N Screw (Brass)
U
Ferrite core Edging

4N 4N Ferrite core
T
8 4N 10N Wire harness 1
4N 4N
AC wire harness 6 4N
AC wire harness 5 3N 3N
Wire harness 14
4N
Wire harness 13
Frame F
9
12J-85119 (120V) / 12J-85129 (220-240V)

(7 of 7)
Control panel unit
1 Control panel MSK2.6x4 Operation terminal
MSKW3x6F
KEYP.W.B. unit
2
MSKW3x6F
Wire harness 10
V
3
Details of switch
2b: 1b:
Back jog unit
2: 1 :Purple
2a: 1a:GRY
Bracket unit
4 Bush Fold drive unit

Bracket
Binder Electromagnetic clutch
(SKB-1M) (CL503) Electromagnetic brake
Cover (BRK503)
Details of inverter
Bracket
AC wire harness 7
:YEL
R/L1:WHT Sensor angle Photo interrupter (Lr) (PS502)
5 S/L2:BLK
Photo interrupter (Le) (PS502)

Sensor angle
P5:Pink(2 pin)
Electromagnetic
FM/OUT:Purple(12 pin) Bush
VI/S3:GRY
(3 pin)
brake
CC:BLU (BRK503)
2N 3N 2N
(14 pin)
6 F:YEL(4 pin) CC:BLU(10 pin)
R:Purple(5 pin) S1:Sky-BLU(8 pin) M
Wire harness 13 Photo interrupter
(PS504) W S
Sensor angle S
W/T3:BLK
U/T1:RED Wire harness 9
V/T2:WHT
Stepping motor
7 AC wire harness 5 (M502) Stitch driver unit
DC brushless motor
3 (M503)
2N Electromagnetic clutch
2N
3 View
2N
2N
Bracket
8
7N
8N
Bush
Wire harness 1
Wire 2N
M4 Screw harness 9
9 (Brass) H
2N 2N
3N
12J-85119 (120V) / 12J-85129 (220-240V) W

WD1.6 Plug/Jack Locations of DBM-500T/DBM-K (1 of 5)
Control panel Microswitch
Switch OP wire harness 1
(SSW601)
(PCB602) (SSW604) 6 View
Cable clamp
Purple
1 2N: 3302 Frame L
Sky-BLU
3N: 3303 Edging
6
4N: 3304
DC fan unit
5N: 3305 3N
(FM601)
6N: 3306 DC harness unit 5 4N
7N: 3307 Edging
Photo interrupter Stepping motor
8N: 3308
(M604)
2 9N: 3329 (PS604) Wire harness
Wire harness 19
Stand lock clip Edging
3L: SLCS2-250-16-01
DC solenoid
4N
3N (SL602)
3N
3N
4N Universal bush
4 4N
Microswitch 3N
(SSW606)
7 Edging
7 View
5 5N 3N
5N 5N
BLU
Sky-BLU
6
Details of Circuit protector 5N 3N
120V
Wire harness 18
Wire harness
WHT BLK
Switch Wire harness 19
7 (PSW602)
WHT BLK GRY
3N 3N
Wire harness 18 5N
Power cord unit Purple
Grouding cable unit 4 Actuater

220-240V Wire harness 17
Circuit protector Inter lock switch
Wire harness 18 WHT WHT
(PSW601) (SSW603)
8 WHT BLK
Noize filter
BLK BLK U
Sky-BLU BRN Screw (Brass) 5N
Power cord unit 3N

4N
Wire harness 16
Power cord unit 6N T
Q
9 R
P S Guide plate
5N
Universal bush 12K-85116 (120V) / 12K-85126 (220-240V)

WD1.6 Plug/Jack Locations of DBM-500T
(2 of 5)
2 View Microswitch Limit switch unit
(SSW605) Cord unit 1 (SSW602)
YEL
1 BLU DC fan unit

(FM602) Counter unit
2 (CNT)
3N 3N 9 View
Wire Wire harness 5 K

harness 1 J 2N
5N
2 Wire harness 2
Frame R I 2N Bush
5N 9 Bracket
Edging
Screw (Brass) 2N Bush
4N
Wire harness 1
Photo interrupter (Lr) Electromagnetic clutch
5N (PS606) (CL602)
3 2N
3N
Electromagnetic clutch 4N
(CL601) 5N
H Wire harness 8
2N Photo interrupter (Le) 4 View 5 View 120V
(PS606) 5N 4N
5N GRY
3N DIN socket BLK WHT
Bush 3N
4N
4
5N L
2N
Wire harness 4 4 BRN Purple GRN/YEL
F 220-240V
E 4N
Screw
5N 4N
(Brass) BLK
GRN/YEL
2N D Wire harness 3 5
WHT
G Outlet (120V)
5 Outlet (220-240V)
4N
Wire harness
3N
6N
Wire harness 15
3N
4N
Core
7N 4N
6N
8N
6 Universal bush
Wire harness 19 A
Wire harness
3N Edging
To SI wire harness 1 Push mount tie
3 View To SI wire harness 28N
7 8 Ferrite core Spacerx4
Screw (Brass)
To Screw Wire harness 9
SI wire harness 1 8 View
(Brass) 1
3L
SI wire harness 2 N 2
3N 3N DC brushless
To Screw motor
8 (Brass) (M602)
3 8N
Power cord unit
DPIF P.W.B. unit
M MC unit
(PCB605) M (PCB601) 4N
Dust protection cap 3L
9 N
O
3N Bush
Universal bush 8N 7N
12K-85116 (120V) / 12K-85126 (220-240V)

(3 of 5)
1
Frame R
3 To Photo interrupter
(Le)
120V
H
3N
250WVAC
40μF
4 Mounting tie
250WVAC
125WVAC
40μF
400μF
Motor harness 2 Motor harness 2 1 View
D Photo interrupter PH bracket

5 125WVAC 125WVAC
200μF (PS601)
400μF
A A Photo interrupter
(PS602)
Tube
6N Tube 6N 1
6 Wire harness 3
Binder
B C B C
12K-85116 (120V) / 12K-85126 (220-240V)

(4 of 5)
1 PH bracket
Stay
3N 3N
Photo interrupter
3N 3N
2 3N 2N
Wire harness 2 (PS701)
Bracket
Photo interrupter Stepping motor
(PS603) (M603)
Wire harness
3 G Fan unit Wire harness 1
(FM603)
3N
4N
I
Screw Screw
4 (Brass) Grouding cable unit (Brass) Earth wire
2N
H Tooth washer
Base
(PS605) Moving base
Universal C Photo interrupter (Le)
bush Clutch brake (PS605)
5 (CL/BRK) Wire harness 5
B 8N Motor unit (120V) Moving base
3N
Motor unit (220-240V)
(M601) 4N
3N 2N
5N
V J
2N
6 3N 3N
Motor harness 2 (120V)

Motor harness 2 (220-240V) DC solenoid
Screw (Brass) (SL601)
12K-85116 (120V) / 12K-85126 (220-240V)

(5 of 5)
Details of relay
120V
1
B V
3+
2
-4
1
GRY,BLK Sky-BLU,BLK
BLK
(RL602a) E PH P.W.B. unit Wire harness 19 Stand
2 Ferrite core
3N
(PS607) 3N 3N
Orange
N
(RL602b) N T
U S
Sky-BLU,BLK GRY,BLK
5N
(RL601) 9N 7N 5N
F
3 BLK
LED P.W.B. unit Wire harness
(PS607)
SSR
(SSR)
Relay base
Wire harness 12
220-240V
4
B V
BRN
3+
3+
ZNR unit
2
2
3N 2N Wire harness 6 5N
7N 6N
-4
-4
1
1
Relay GRY Wire harness 16
RED (RL602) GRY
5 (RL602) 3N 4N RR
Wire harness 14 Switching power
BRN
Sky-BLU,BLK GRY,BLK
3N supply
6N 3N (PCB603)
Screw (Brass)
Spacer x4
YEL
(RL601) 8N
BRN
2N RL P.W.B. unit
(PCB604)
6 Relay
BLK
(RL601) 3N Wire harness 15
Q
Q
8N 7N 7N
O
Wire harness 11
6N Bush x4 6N Wire harness 10 6N
Collar x4 PP
7
Kicker (option)
DC solenoid
8
2N
3N
Screw (Brass)
3N (SL701)
L
9
Bush Wire harness 7
12K-85116 (120V) / 12K-85126 (220-240V)

WD1.7 Plug/Jack Locations of DBM-LS1
Stacker base
(Bottom View) Crown washer
Gear head
3 Motor unit (120V)

Motor unit (220-240V) Cord with plug (220-240V)
(M701)
Brass screw M4 +
4
phosphor bronze SW
Cord with plug (120V)
5
Motor unit
BLK BLU
Grouding cable unit

Crown washer
Screw
Stand lock clip
Stand lock clip
6
Bush
C (120V)
C (220-240V)
Gear head Grouding cable unit
Details
12J-85151 / 12K-85151

WD1.7 Plug/Jack Locations of DBM-LS1/DBM-K
WD1.8 Wiring Diagrams & Electrics of SpineMaster
SENSORS AND 1 Infeed Optical Sensor 905-162
WD1.8.1 Location of Components SWITCHES 2 Clamp Optical Sensor 905-287
3 LH Limit Sensor 905-376
4 RH Limit Sensor 905-376
5 Clamp Open Proximity Sensor 905-376
6 Guard Switch for Top Delivery Assembly 700-088
9 7 Guard Switch for Stacker Open 700-088
8 Stacker Advance Switch 700-402
8 19 9 Stacker Full Switch 700-088
1 10 PCBS 10 SpineMaster Payout Interface PCB 900-201
11 Power Interface PCB 900-141
18 11 12 SpineMaster Machine Interface PCB 900-198
13 SpineMaster Control PCB 900-197
14 Transformer 908-882
7 12 ELECTRO 15 SpineMaster Drive Moter 115V 905-351
MECHANICAL
6 14 SpineMaster Drive Motor 203V 905-345
16 Hold Magnet 905-251
13 17 Clutch 907-977
3
18 Diverter Solenoid 760-339
2 17 19 Stacker Drive Motor 907-954
5 Others 20 Noise Filter 640-076
16 21 Inlet 720-019
4
20
15
21

WD1.8 Plug/Jack Locations of SpineMaster
WD1.8.2 Fuses WD1.8.4 Electronic Sensors
WARNING Sensor activation is indicated on the 900-197 Control PCB.

There is also a LED on the back of each sensor.
The SpineMaster uses double-pole/neutral fusing (i.e. two fuses), so
when removing any covers or changing fuses always first disconnect the
machine from the mains electricity supply by switching off and unplugging WD1.8.4a Infeed Optical Sensor
the machine.In addition to the two main fuses, there are three located on The Infeed Optical Sensor detects the booklet as it enters the SpineMaster.
the Power Interface PCB and one on the Transformer PCB. Both of these
PCB’s are located behind the RH Side Cover. The table below lists the fuses
fitted in the SpineMaster.Ensure that the fuse holder grips the fuse firmly. A WD1.8.4b Clamp Optical Sensor (booklet presence)
loose fuse holder may cause connection problems. If needed, bend the This sensor detects the presence of a booklet when it reaches the Clamp.
tabs on the holder to tighten the fit.
WD1.8.4c Clamp Open Proximity Sensor

LOCATION FUSE FUNCTION RATING This sensor is positioned on the Bolster. It is only used when the machine
Mains Input - Main line fuse 240V - 5.0A, HRC Quick acting, F is initially switched on, to check that the Clamp is open. This prevents the
Socket x2 (1 per line) 115V - 10A, HRC Quick acting, F Clamp from operating out of phase with the Carriage.
900-141 PCB F1 9V Rail 3.15A Glass, Anti-surge, T
F2 28V Rail 6.3A Glass, Anti-surge, T
WD1.8.4d RH Limit/LH Limit Proximity Sensors
F3 Drive Motor 230V - 4.0A Glass, Anti-surge, T
115V - 6.3A Glass, Anti-surge, T These detect the Carriage when it has reached either end of the Carriage
Transformer PCB F6 Transformer 3.15A HRC Anti-surge, T Guide. This acts a signal to stop the Carriage, and then to open the Clamp.
Note:
● If F1 fails, the processor will not work, so the SpineMaster will not function. WD1.8.4e Stacker Advance Sensor
● If F2 fails, the input sensors will not work, but the drive will run. This is a Hamlin magnetic reed switch which advances the stacker each
● If F3 fails, there will be no drive, but the clamp will still operate. time a booklet is delivered.
● If F6 fails, the SpineMaster will not function at all.
WD1.8.4f Stacker Full Microswitch
The SpineMaster may work out of phase once fuses have been replaced. To
correct this, simply switch the machine off and then on again. This microswitch is activated when the stacker is full.
WD1.8.3 Limits for Machine Interface

MIN MAX
Start Signal (Relay Coil) 17V DC 30V DC
Stop Signal (Relay Contacts) - 40V IA
Note: Polarity is important. See individual installation instructions.

WD1.8.4g Guard Switches WD1.8.5 Transformer
Guard Switches disconnect power if the Stacker or Top Delivery Assembly The transformer is fitted with push-fit Taps (blue) which must be set to the
are open. correct position for the input voltage. Tap setting positions are shown on the
Table 7-1 : Sensor Reporting on 900-197 Control PCB transformer PCB itself (see the figure below). All the Taps must be set in
SENSOR REPORTING ON 900-197 CONTROL PCB
the same position. Details of the Tap settings are shown in the table below.
Infeed Optical Sensor, Upper (SpineMasterB & SpineMasterD) LED10 TAP SETTING INPUT
Infeed Optical Sensor, Lower (SpineMaster & SpineMasterN) LED11 100 93-110V
Clamp Optical Sensor (booklet presence) LED15 115 105-127V
Clamp Open Proximity Sensor LED18 200 187-220V
R/H Limit Proximity Sensor LED20 230 210-254V
L/H Limit Proximity Sensor LED19
Stacker Advance Sensor LED4
Stacker Full Microswitch LED2
10
Taps (Blue)
0
115
0
20
230
F6
SK3
Transformer Tap Settings (115V Selected)

WD1.8.6 SpineMaster Control PCB (900-197)
0
Ullll ...
:D
12~ ~
~~ i§
~UI
0 c:l
:D
PUS
PL1 PUB
looooool 1···1
PL21!1
~ ••
lD[j] 0 000 LED21Q ••• 91!11!1-19B BOARD
•••
GUARD ...I • BYPASS UPPER INFEEO INFEED SENSORS
a.. LED9 !;; !;; !!! ....m LEDii!IQ REMOTE STOP/START
o o ~ LE011j.Q
1\J:;;.,.. ~ LEDUQ
,. ,. I....A.I
REHDTE OUT LO~R INFEEO
•
•••
> ,. > LED17Q
~ > ~ Ul REMOTE IN
c:: ~ c:: ~
-i ~ -i Ulc!
~ 0 ...,
....... I!!
.... :D
~
~ Ul
SPARE z:
OPTD ~
:1:
PO~R
::J:
COUNTER
PU7
lil 0 COUNTER 1-
w
~
Ul
z
w PUB
a..
~ LED23 z w Ul ....
c
i - ~!
LEFT HAND
PROXIMITY
SENSOR
PU~
0
LED19
LEFT
SENSOR
CLAtf'
OPTD
cjED15 LED21{)
1•••••11•••11•••1
Plilt- PL21 PU3
QLED21!1
N
N
0
w
~~~
...I
0 000
0
1••11······1
PL19
ID
PLS
Ul t
~oo
~
...I
0 1•••1
PLU
. PL22
CARRIAGE
HOTDR
DRIVE
Iii- :I:
t~
....10
~d~
....I::::J
u U....l
u

WD2.1 Block Schematic Diagrams of Interface Box
[1] IF unit
[19] Interface cable

(for parallel communication)
Upstream unit [6] OEM port 1
Upstream unit / [7] OEM port 2

Computer [22] PC cable
(for serial communication) [14] LED01 (Orange)
[15] LED02 (Green)

[16] LED18 (Green)
[17] LED19 (Red)
[18] LED03-09 (Red),

LED12-17 (Red)
[2] Switching power supply
[20] D-port cable

[8] D-port 1 Downstream unit
[3] System switch
[9] D-port 2
[10] D-port 3
[4] Inlet [11] D-port 4
[12] D-port 5
[21] Power cord (with plug)

[5] Outlet
(Attached to downstream unit)
[13] Power cord

WD2.1 Block Schematic Diagrams of Interface Box
WD2.2 Block Schematic Diagrams of TR-DP
Cover Magnet Switch Power Supply Unit
Paper Jam Sensor Switch Unit

RM Unit
Conveyance Motor MC Unit Power Cord
D-port 1 D-port Cable
D-port 2 D-port Cable

WD2.2 Block Schematic Diagrams of TR-DP
D-02 OP Unit (Control Panel) (PCB302) B-19 Back Jogger Solenoid (SL304)
A-03 Conveyer Motor 1 (M301) B-20 Back Jogger Motor (M308)
A-04 Clutch (CL301) B-21 Back Jogger Sensor (PS304)
A-05 Conveyer Motor 2 (M302) C-22 CCD Scanner
A-06 Servo Motor (M303) D-07 Servo Motor Control Unit A-23 Entrance Sensor (PS305)
(PCB303)
A-08 Cutter Motor (M304) C-24 Bypass Sensor (PS306)
A-09 Cutter Sensor (SW301) A-25 Delivery Sensor (PS307)
A-10 Creaser Motor (M305) B-26 Stopper Sensor (PS308)
A-11 Creaser Sensor (PS301) B-27 Stopper Rear Sensor (PS309)
A-12 Flap Solenoid (SL301) A-28 Slitter Motor (M309)
D-01 MC Unit
(PCB301)
B-13 Stopper Solenoid (SL302) A-29 Slitter Sensor (PS310)
A-14 Idler Roller Solenoid (SL303) B-30 Cutter Front Sensor (PS311)
B-15 Side Jogger 1 Motor (M306) B-31 Creaser Front Sensor (PS312)
B-16 S-J1 Home Sensor (PS302) C-32 D-Box Full Sensor (PS313)
B-17 Side Jogger 2 Motor (M307) A-33 Fan (FM301)
Block Schematic Diagrams of SCC
B-18 S-J2 Home Sensor (PS303) B-34 Main Body Motor (M310)
E-41 Main Power
Switch (PSW301) D-42 Switching Power Supply (PCB304) B-35 Main Body Sensor (PS314)
E-40 Power Supply C-36 Side Cover Switch 1
E-39 Remote Switch (PSW302) (SSW305)
Inlet
WD2.3 Block Schematic Diagrams of SCC

C-37 Side Cover Switch 2
D-56 Relay Board (PCB305) (SSW306)
Z-43 Power Cord
C-38 D-Box Position Sensor

(SW302)
C-49 Emergency Stop Switch

B-52 Slitter Cover Sensor
E-55 E-port Connector 2
E-54 E-port Connector 1
C-51 Top Cover-R Sensor
C-50 Top Cover-F Sensor

(SSW304)
(SSW301)
Section 7—Wiring Data

(SSW302)
(SSW303)
D-57 Mechanical Counter
(CNT301)
Z-53 E-port Cable
Z-48 D-Port Cable

E-44 D-port Connector 1 Upstream Unit
E-45 D-port Connector 2 Downstream Unit
E-47 LED 2 E-46 LED 1
(PCB306)
WD2.3
7-32
WD2.4 Block Schematic Diagrams of DCM Kit
[8] D-port 1 [2]

[9] D-port 2 [3] [1]
I/F Unit RM Unit Power Cord
[10] Power Supply

[4] Relay 2
High Voltage
[5] Compressor (DBM)

[11] Static Bar
[6] Relay 3
[7] Compressor (DSF)

WD2.4 Block Schematic Diagrams of DCM Kit
2. Control panel
• Touch panel
• Numerical pad
3. Infeed sensor (PS501) 32. Folding guide home sensor (PS514)
1. MC unit
(PCB501)
4. Jogger sensor (PS502) 33. Folding side guide motor (M510)
5. Jogger unit home sensor (PS503) 34. Fold delivery clutch (CL501)
6. Back jogger home sensor (PS504) 35. Side stitch outfeed sensor (PS515)
7. Jog unit moving motor (M501) 36. Stacker full sensor (PS516)
8. Back jog moving motor (M502) 37. Side stitch delivery solenoid (SL506)
9. Jog belt drive motor (M503) 38. Stitcher driver home sensor (PS517)
10. Side jogger home sensor (PS505) 39. Stitching clutch (CL502)
11. Step motor over sensor (PS506) 40. Stitching brake (BRK502)
12. Side jog moving motor (M504) 41. Folder drive home sensor (PS518)
13. Side jogger brake (BRK501) 42. Folding clutch (CL503)
14. Saddle stopper home sensor (PS507) 43. Folding brake (BRK503)
15. Saddle stop moving motor (M505) 44. Folding counter (CNT502)
Block Schematic Diagrams of DBM-500/DBM-500BR
16. Saddle stitch stop solenoid (SL501) 45. Feed motor index sensor (PS519)
17. Stitch sensor (PS508) 46. Folding rollers gap-1 home sensor (PS520)
18. Side stitch stop solenoid (SL502) 47. Folding rollers gap-2 home sensor (PS521)
19. Stitch delivery 1 solenoid (SL503) 48. Fold rollers gap 1 motor (M511)
20. Stitch delivery 2 solenoid (SL504) 49. Fold rollers gap 2 motor (M512)
21. Stitching head home sensor (PS509) 50. Fold outfeed sensor (PS522)
WD2.5 Block Schematic Diagrams of DBM-500/DBM-500BR

22. Stitcher moving motor (M506) 51. Wire feed sensor (L1) (PS523)
23. Stitching counter (CNT501) 52. Wire feed sensor (R1) (PS524)
24. Back stopper home sensor (PS510) 53. Wire feed sensor (L2) (Optional) (PS525)
25. Back stop moving motor (M507) 54. Wire feed sensor (R2) (Optional) (PS526)
26. Back stopper solenoid (SL505) 55. Moving base home sensor (PS527)
27. Folding unit home sensor (PS511) 56. Moving base index sensor (PS528)
28. Fold sensor (PS512) 57. Base moving motor (M513)

29. Non-fold home sensor (PS513) 58. Side cover switch (Right) (SSW501)
30. Folding stop moving motor (M508) 59. Side cover switch (Left) (SSW502)
31. Non-fold delivery motor (M509)
To next page
WD2.5
7-34
From previous page
60. D-port 1 Upstream unit
D-port cable
61. D-port 2 Downstream unit
62. LED 1 (Green)
1. MC unit 63. LED 2 (Orange)
(PCB501)
WD2.5 Block Schematic Diagrams of DBM-500/DBM-500BR

64. Emergency stop switch (SSW503)
65. Top cover switch (Front) (SSW504)
66. Top cover switch (Back) (SSW505)
67. Shutter switch (SSW506)
82. Isolation board (PCB502)
Upstream unit
68. Relay board (PCB503) 69. E-port 1
E-port cable

70. E-port 2
Downstream unit
72. Remote 71. Switching power supply
switch (PSW502) (PCB504) 73. Relay 1 (RL501) 75. Outlet 1
74. Relay 2 (RL502) 76. Outlet 2
80. Noise filter
Power cord 77. Reactor unit 78. Inverter
81. Main Power Switch (PSW501)
7-35
79. Main drive motor (M514)
WD2.6 Block Schematic Diagrams of DBM-500T/DBM-LS1/DBM-K
Control panel
(PCB602)
Upper blade home sensor (PS601) MC unit Upper blade clutch/brake (CL/BRK)
(PCB601)
Upper blade index sensor (PS602) Conveyance motor (M602)
Conveyance gap home sensor (PS603) Conveyance gap motor (M603)
Stopper unit home sensor (PS604) Stopper unit motor (M604)
Stopper unit sensor (PS605) Infeed clutch (CL601)
Delivery unit sensor (PS606) Conveyance clutch (CL602)
Waste bin full sensor (PS607) Stopper solenoid (SL601)
Cover L switch (SSW604) Flap solenoid (SL602)
Cover R switch (SSW605) Fan 1 (FM601)

Cover B switch (SSW606) Fan 2 (FM602)
Paper guide wheel limit sensor (PS701) Cutter counter (CNT)
*DBM-K
Upstream unit Kicker solenoid (SL701)

D-port connector 1
D-port cable
D-port connector 2 Emergency stop switch (SSW601)
Downstream
unit
LED1 Top cover switch (SSW602)
LED2 DPIF PWB unit
(PCB605) Dust box switch (SSW603)
Upstream
unit
Relay Board E-port connector 1
E-port cable
Main motor cooling fan (FM603)
E-port connector 2
(PCB604) Downstream
unit
*DBM-LS1
Remote switch Switching power supply Stacker motor Outlet Stacker motor (M701)
(PSW602) (PCB603) relay (SSR)
Noise filter Main motor drive Main motor (M601)

relay (RL601)
Power cord Main power switch Main motor CW/CCW
(PSW601) relay (RL602)

WD2.6 Block Schematic Diagrams of DBM-500T/DBM-LS1/DBM-K
WD3.1 Schematic Diagrams of Interface Box (1 of 5)
1
OUTLET
250V 10A
2
BLACK AC(L)
3 WHITE AC(N)
4 GREEN/YELLOW FG
INLET
6 250V 10A
SWITCHING POWER SUPPLY
to I-8 POWER SW
(4 of 5)
CN1 BLACK BLACK AC(L)
7 IF UNIT 1 AC(L)
J01 CN2 2 WHITE AC(N)
BROWN 4 3 AC(N) WHITE
+24V 1 +24V
4 POWER CORD
GND 2
FG 3 BLUE 32 +24V
GND 5 FG
8 VH03T 1 GND AC120V 60Hz
GREEN/YELLOW FG AC220-240V 50/60Hz
FG
9 to M-1
(5 of 5)

WD3.1 Schematic Diagrams of Interface Box
(2 of 5)
to E-1
1 IF UNIT (4 of 3)
IF UNIT
J06 A
1 DOUT+
2 2 DOUT-
3 CLK+
4 CLK-
5 DIN+
6 DIN- A
3 7 +6.5V
8 GND
TM11R-5L-3232 J06 D
J06 B 1 DOUT+
4 1 DOUT+ 2 DOUT-
2 DOUT- 3 CLK+
3 CLK+ 4 CLK-
4 CLK- 5 DIN+
5 DIN+ 6 DIN-
5 6 DIN- 7 +6.5V
7 +6.5V 8 GND
8 GND TM11R-5L-3232
TM11R-5L-3232 J07
6 J06 C 1 DOUT+
1 DOUT+ 2 DOUT-
2 DOUT- 3 CLK+
3 CLK+ 4 CLK-
7 4 CLK- 5 DIN+
5 DIN+ 6 DIN-
6 DIN- 7 +6.5V
7 +6.5V 8 GND
8 GND TM11R-5C-88
8 TM11R-5L-3232
9 to D-2
(3 of 5)
A
9
8
7
6
5
4
3
2
1
7-39
(3 of 5)
A
B
IF UNIT

C
D
to I-9
(2 of 5)

J99
9 TDI
1 TCK
5 TMS
4 VCC
3 TDO
12 GND
10 GND
8 GND
2 GND
6 TxD1
J09
7 RxD1
11 BOOT
PHD12T
1 FG
2 N/C
E
3 N/C
4 STATUS0
5 STATUS1
6 STATUS2
7 STATUS3
F
8 STATUS4
9 N/C
10 N/C
11 N/C
12 COMMAND0
G
IF UNIT
13 COMMAND1
14 COMMAND2
15 COMMAND3
16 COMMAND4
H
17 COMMAND5
18 COMMAND6
19 COMMAND7
20 N/C
21 N/C
I
FOR PRINTER
22 STATUS0x
23 STATUS1x
24 STATUS2x
25 STATUS3x
26 STATUS4x
J
27 N/C
28 N/C
29 N/C
30 COMMAND0x
31 COMMAND1x
K
32 COMMAND2x
33 COMMAND3x
34 COMMAND4x
35 COMMAND5x
36 COMMAND6x
L
37 COMMAND7x
DSB37S
M
to D-9
(5 of 5)
(4 of 5)
to H-1
1 IF UNIT (2 of 5)
IF UNIT J04
IN0 1
IN1 2
+5V 3
2 +5V 4
GND 5
GND 6
IN2 7
IN3 8
3 +5V 9
+5V 10
GND 11
GND 12
4 IN4 13
IN5 14
+5V 15
+5V 16
GND 17
5 GND 18
IN6 19
IN7 20
+5V 21
+5V 22
6 GND 23
GND 24
+5VL 25
+5VL 26
GND 27
7 GND 28
+5VL 29
+5VL 30
GND 31
8 GND 32
PHD32T
to B-7
9 (1 of 5)

(5 of 5)
to B-9
J03 (1 of 5)
1 IF UNIT IF UNIT N/C 1
TXD 2
RXD 3
N/C 4
2 GND 5
N/C 6
CTS 7
RTS 8
3 N/C 9
DSB9S
J05
+24V 1
4 OUT0 2
+24V 3
OUT1 4
+24V 5
OUT2 6
5 +24V 7
OUT3 8
+24V 9
OUT4 10
6 +24V 11
OUT5 12
PHD12T
J02
7 SCL 1
GND 2
SDA 3
GND 4
N/C 5
8 GND 6
+6.5V 7
GND 8
XH08T
9 FG
to M-9
(3 of 5)

WD3.2 Schematic Diagrams of TR-DP (1 of 3)
1 to L-1
(2 of 3)
RM UNIT
MC UNIT Power supply
2 ZWS75AF-24/J REMOTE SWITCH UNIT
J01 J2 J4
0101 BROWN 1
+24V 1 1 FG REM SW-B 1 BLACK
CN2 CN1 REM SW-C 2 2
+24V 2 0103 BLUE BLACK 2 GRAY
REM SW-A 3 3
0V 3 1 -V AC_L 1 3 AC200VL
3 0V 4 2 -V 4
WHITE
FG 5 3 -V AC_N 3 5 AC200VN
4 +V
5 +V FG 5
4 6 +V
FG
5 FG
J5 J3
J06 1 REMOTE24V AC200VN 1
+6V 0601 ORANGE 2 REMOTE6V AC200VN
1 2
GND 2 0602 BLUE 3 GND 3
6
4 POWER+ AC200VL 4
5 POWER- AC200VL 5
6
7 to L-1 FG 7
(3 of 3) FG 8
J1 POWER CORD
L
AC200VN 1
8 FG
FG 2
N
AC200VL 3
AC120V 60Hz (USA)

9 FG AC220~240V 50/60Hz (UK)

WD3.2 Schematic Diagrams of TR-DP
(2 of 3)
1
to A-1
(1 of 3)
2 MC UNIT
MAGNET
J08
1 0801 YELLOW 0801 YELLOW
3 COVER SW 1 1 0802 PURPLE 1 TOPCOVA
2 2 2 0802 PURPLE
0803 GRAY 2 TOPCOVB
MAGNET SENSOR 3 JAM
0804 BLUE
0805 ORANGE 4 GND
0810 BLUE 5 +6.5V
4 6 GND
0811 YELLOW
7 RPAD
8 GND
9
5 ORANGE 0805 ORANGE 10 +5V
C.V.C. Vcc 1 1 1
OUT 2 11
GRAY 2 2 0803 GRAY
GND 3 12 GND
BLUE 3 3 0804 BLUE 13 +6.5V
6 14 GND
KB1240-AA22LF 15
PAPER JAM SENSOR 16 GND
17
7 18 +5V
Anode1 1 YELLOW 0811 YELLOW 19
Anode2 2 1 1 20 GND
BLUE 2 2 0810 BLUE
Cathode 3 to J-1
8 (3 of 3)
KB1242-AA12LF

(3 of 3)
to B-7
1 to K-7 (1 of 3)
(2 of 3)
21 +6.5V
22 GND MC UNIT
2 23
0824 BLUE 24 GND
0825 PINK 25 +5V
CONVEYANCE MOTOR 0826 PURPLE 26 HU
FGOUT 1 0827 GRAY 27 HV
3 0825 PINK 0828 SKYBLUE
DC5V 2 0826 PURPLE 28 HW
HU 3 0827 GRAY
HV 4 0828 SKYBLUE
DC Motor HW 5
4 0824 BLUE J02 J04
GND 6
PURPLE 0201 PURPLE 1 U DOUT+ 1
UCOIL 7 1 1
YELLOW 0202 YELLOW DOUT- 2
VCOIL 8 2 2 2 V
SKYBLUE 0203 SKYBLUE
WCOIL 9 3 3 3 W CLK+ 3
5 CLK- 4
24V 37.4W DIN+ 5
DIN- 6
J99 +6.5V 7
6 1 TCK GND 8
2 GND
3 TDO D-PORT
4 +5V J05
5 TMS DIN+ 1
7 6 TXD1 DIN- 2
7 RXD1 CLK+ 3
8 GND CLK- 4
9 TDI DOUT+ 5
8 10 GND DOUT- 6
11 MD1 +6.5V 7
12 GND GND 8
9 FG

WD3.3 Schematic Diagrams of SCC (1 of 7)
to M-1
1 (4 of 7) MC UNIT RL P.W.B.UNIT
(PCB301) (PCB305)
J01 BROWN 0101 1 BROWN J01 J03
1 +24V BROWN 1 +24V 1 rl F GRAY 1 GRAY 1
2 +24V 2 BROWN 2 +24V 2 YELLOW 2 EMMERGENCY
BROWN 0103 3 BLUE BROWN 2 YELLOW 3 PURPLE 3
2 3 +24VA BROWN 0104 to E -5 4 BLUE 3 +24VA 3 rl F
4 SKYBLUE 4 INTERFACE
4 +24VA BLUE 0105 BLUE 2010 4 +24VA 4 PURPLE (UPSTREAM)
5 GND (4 of 7 ) 5 GND 5 rl 2 5 BLACK E
6 GND BLUE 0106 6
BLUE 0107 VH05T SKYBLUE
7 GND 7 rl 2
8 FG YELOW 2001 J041 VEMG 8
VH08T GRAY 1 GRAY 1
3
J12 PURPLE 2002 23 V1 9 rl 1
10 2 YELLOW 2 EMMERGENCY
1 VEMG YELOW 1201 1 YELLOW 3 PURPLE 3 INTERFACE
2 2 SKYBLUE 2003 45 VR 11 rl 1
12 GND 4 SKYBLUE 4
3 V1 PURPLE 1203 3 6 13 rl R PURPLE 5 BLACK E (UPSTREAM)
4 4 GRAY 2004 7 V2 14 GND
5 VR SKYBLUE 1205 5 SKYBLUE
4
6 6 SKYBLUE 2005 89 VF 15 rl R
EH15T
7 V2 GRAY 1207 7
8 GND BLUE 1208 8 YELLOW 2006 10
11 VDR
9 VF SKYBLUE 1209 9
10 10 PURPLE 2009 12 VP2C
13 VP1
5 11 VDR YELLOW 1211 14 VP2E
12 PURPLE 1213 EH14T
13 VP J05
EH13T to A-7
1 ACL
2 LOAD
to A-3 (2 of 7) 3 LOAD
6 (7 of 7) 4 ACN
to A-6 to C-6 to C-9 VL04T
(6 of 7) (6 of 7) (2 of 7)
DPIF P.W.B.UNIT SWITCHING POWER SUPPLY Power Card

7 (PCB306) (PCB304) SWITCH AC120V 60Hz(USA)
J02 ORANGE 3001 CN52 CN2 PURPLE 2 3
1 +6V 1 +R 1 +R GRAY (PSW302)
AC220-240V 50/60Hz(UK)
2 GND BLUE 3002 2 -R 2 -R INLET
EH02S XH02 XH02
CN51 CN1 3T
8 BLUE 1 GND 1 AC(L) BLACK 3 4 BLACK L
BLUE 2 GND 2 WHITE 1 2 WHITE N
3 GND 3 AC(N)
4 +24V 4 POWER SWITCH GREEN/YELLOW E
BROWN 5 +24V 5 FG (PSW301)
BROWN 6 +24V VH05T
9 FERITE CORE
VH06T FG ZCAT3035-1330

WD3.3 Schematic Diagrams of SCC
(2 of 7)
to A-7
MC UNIT (PCB301) (7 of 7) YELLOW 1316 NO C
1 J13
15 +24V BROWN 1315 14 COVER SW1
16 COVER SW 15 SKYBLUE 2435
17 (FRONT)T-COVER SW GRAY 1317 1 (SSW305)
18 GND BLUE 1318 2
2 19 (REAR)T-COVER SW PURPLE 1319 3 SKYBLUE 2415 NO C
20 GND BLUE 1320 4
PURPLE 1321 5 COVER SW2
21 SLIT COVER SW BROWN 2414
22 GND BLUE 1322 6
(SSW306)
3 23 GARBAGE SW
24 GND TOP COVER FRONT SW
PHD24T GRAY 2201 1 BLACK
J99 BLUE 2202 2 WHITE
1 TCK PURPLE 2131 3 RED (SSW302)
4 2 GND SKYBLUE 4 GREEN
3 TDO
4 VCC TOP COVER REAR SW
5 TMS PURPLE 2203 1 BLACK
6 TXD1 Update Connector BLUE 2204 2 WHITE
FOR WRITING ON SKYBLUE 3 RED (SSW303)
5 7 RXD1
8 GND H8S/2638 FLASH MEMORY YELLOW 4 GREEN
9 TDI SLITER COVER SW
10 GND PURPLE 2205 1 BLACK
11 BOOT BLUE 2206 2 WHITE
6 12 GND PURPLE 2111 11 3 RED (SSW304)
PHD12T YELLOW
GRAY 2112 12 GRAY 2132 4 GREEN
to G-5 to C-1
(1 of 7) (5 of 7) NC C
RL P.W.B.UNIT SKYBLUE2317
7 (PCB305) SKYBLUE 1323 17 GARBAGE CAN SW
J02
1 EMG SW BLUE 1324 18 BLUE 2318
2 (SW302)
3 EMG SW EMERGENCY SW
8 4 (FRONT) BROWN
5 DOOR SW GRAY 2007 7 GRAY 2521 1
6 YELLOW 2008 8 YELLOW 2028 2 BROWN
7 DOOR SW (SSW301)
EH07T to H-6 (REAR)
9 (1 of 7) GRAY 2521 1 GRAY 2501 1 BROWN
GRAY 2522 2 SKYBLUE 2502 2 CORD UNIT1

(3 of 7)
SIDE JOG1 UNIT HOME (PS302)
1 GRAY 0520
1 COLLECTOR BLUE 0524
2 GND PINK 0522
3 +5V
SIDE JOG2 UNIT HOME (PS303)
2 YELLOW 2304 4 YELLOW 0525
1 COLLECTOR BLUE 2306 5 PINK 0527 to L-8
2 GND PINK 2305 6 BLUE 0529 (7 of 7)
3 +5V
SLITER HOME (PS310) MC UNIT
3 PURPLE 0526 (PCB301)
1 COLLECTOR J05
BLUE 0530 SKYBLUE 0514 14 MACHINE MOVE HOME
2 GND PINK 0528
3 +5V PINK 0516 15 +5V
16 +5V
BACK JOG UNIT HOME (PS304) 17 GND
4 SKYBLUE 1 SKYBLUE 0519 BLUE 0518
1 COLLECTOR BLUE 2 BLUE 0523 SKYBLUE 0519 18 GND
2 GND
3 +5V
PINK 3 PINK 0521 GRAY 0520 20 BACK
19
SIDE
JOG UNIT HOME
JOG1 UNIT HOME
PINK 0521 21 +5V
CREASER HOME (PS301) PINK 0522 22 +5V
5 YELLOW 0624 BLUE 0523
1 COLLECTOR BLUE 0628 BLUE 0524 23 GND
2 GND PINK 0626 to I -7 YELLOW 0525 24 GND
3 +5V (4 of 7 ) PURPLE 0526 26 SIDE
25 JOG2 UNIT HOME
SLITER HOME
6 MACHINE MOVE HOME (PS314) PINK 0527 27 +5V
SKYBLUE 2113 13 SKYBLUE 2416 16 SKYBLUE 0514 PINK 0528 28 +5V
1 COLLECTOR BLUE 2114 14 BLUE 2417 17 BLUE 0518 BLUE 0529
2 GND PINK 2115 15 PINK 2418 18 PINK 0516 BLUE 0530 29 GND
3 +5V 30 GND
GARBAGE CAN FULL(LED) (PS313) PHD30T
7
BLUE 2504 3 PURPLE 2523
2 GND PURPLE 2503 4 BLUE 2524
to J-1
1 LED A (6 of 7)
8 GARBAGE CAN FULL(PHOTO) (PS313)

PINK 0632
PHOTO 5 +5V BLUE 0634
4 GND YELLOW 0630 to I -8
IC 3 SIG (4 of 7 )
9 PURPLE 2523
2 LED A BLUE 2524
1 GND

(4 of 7)
to A -1
J03 MC UNIT
1 SCL PURPLE 1501 (PCB301) (1of 7 )
1 SARVO 2 GND BLUE 1502 PURPLE 1501 1 SCL
MOTOR 3 SDA GRAY 1503 BLUE 1502 2 GND
DRIVER 4 GND BLUE 1504 GRAY 1503 3 SDA
SARVO MOTOR (PCB303) 5 N.C. BLUE 1504 4 GND
RED 6 GND 5 N.C.
2 (M303) BLACK 1 +5V 7 +6.5V ORANGE 1507 6 GND
2 GND BLUE 1508 ORANGE 1507 7 +6.5V
BLUE 8 GND BLUE 1508
YELLOW 3 A XH08T 8 GND
WHITE 4 B XH08T
5 THERMISTOR 1 LIMIT-A YELLOW 3000
2 LIMIT-B to I-6 J06
3 6 N.C. SKYBLUE 3003 1 GND
PH06T 3 LIMIT-O GRAY 0602 (7 of 7) GRAY 0602 2 ENCODER-A
MOT BROWN 1 +5V 4 ENCODER-A YELLOW 0603 YELLOW 0603 3 ENCODER-B
BLUE 5 ENCODER-B BLUE 0604 4 GND
YELLOW 23 GND 6 ALARM GRAY 0605 5 HU-3
GREEN 4 C3 7 SRV-ON BLUE 0604
YELLOW 0606 6 HV-3
4 ORANGE 5 C2
C1 8 GND INFEED MOTOR DC24V1.8A (M301) PURPLE 0607 7 HW-3
EH08T BLUE 0608 8 GND
PH05T BROWN 0104 1 FGOUT PINK 0613 GRAY 0609
RED 1 W3 1 +24VA 2 +5V YELLOW 0610 9 HU-4
WHITE 2 W2 2 +24VA BLUE 0105 3 H_U GRAY 0605
YELLOW 0606 PURPLE 0611 10 HV-4
11 HW-4
BLACK 3 W1 3 GND 4 H_V BLUE 0612
5 4 GND H_W PURPLE 0607 12 GND
VH03T to D-2 MOT 5 to H-2 PINK 0613 13 +5V
VH04T
(1 of 7) 6 GND BLUE
GRAY
0608
0901
(6 of 7) PINK 0614 14 +5V
7 UCOIL SKYBLUE 0902 15 +5V
8 VCOIL YELLOW 0903 16 OPTION1
6 LCD 9 WCOIL to L-1
(7 of 7)
OP UNIT CN3
1 0V 1 0V
DELIVERY MOTOR DC24V 1.8A (M302)
(PCB302) 2 +5V 1 FGOUT PINK 0614 to L-3
2 +5V 2 +5V (7 of 7)
3 VO 3 VO 3 H_U GRAY 0609 J06
MC UNIT (PCB301)
7 4 RS 4 RS 4 H_V YELLOW 0610 SKYBLUE 0623
23 MOVE MOTOR INDEX
5 R/W 5 R/W PURPLE
MOT 5 H_W BLUE 0612 0611 to F-6 YELLOW 0624
24 CREASE HOME
6 E E 6 GND GRAY 0904
(3 of 7) PINK 0625
25 +5V
7 LD0 7 LD0 to F-9 PINK 0626
26 +5V
8 LD1 8 LD1 7 UCOIL SKYBLUE 0905 BLUE 0627
PURPLE 1501 1 PURPLE CN1 8 VCOIL YELLOW 0906
(3 of 7) 27 GND
BLUE 0628
1 SCL 9 LD2 9 LD2 28 GND
8 BLUE 1502 2 BLUE 2 GND 10 LD3 10 LD3 9 WCOIL to H-1 PURPLE 0629
29 CUT HOME
GRAY 1503 3 GRAY 3 SDA 11 LD4 11 LD4 MOTOR UNIT DC24V 0.15A (M310) (6 of 7) YELLOW 0630
30 GARBAGE CAN FULL
BLUE 1504 4 BLUE 4 GND 12 LD5 12 LD5 RED 1 BROWN 2014 14 GRAY 0909
5 5 N.C. 13 LD6 13 LD6 PINK 0632 31 +5V
6 BLACK 2 YELLOW 2015 15 YELLOW 0910 32 +5V
BLUE 0633 33 GND
6 GND 14 LD7 14 LD7
9 ORANGE 1507
BLUE 1508
ORANGE
BLUE 7 +6.5V 15 BL+ 15 BL+ M ORANGE 3 PINK 2016
YELLOW 4 SKYBLUE 2017 17
16 PINK 0625
SKYBLUE 0623 BLUE 0634 34 GND
8 GND 16 16 BLUE 5 BLUE 2018 18 BLUE 0627 to H-3 to L-4 PHD34T
(FRONT) (6 of 7) (7 of 7)

(5 of 7)
to C-6
1 J16 (2 of 7)
1 +24V
2 OPTION
EH02T BROWN 0701 9 BROWN 2309 YELLOW CHANGE SOL SLITER UNIT MOTOR
J07 YELLOW 0702 10 YELLOW 2310 YELLOW SOL DC24V 72Ω 1/1 (M309)
2 (SL301) 333.3mA A PURPLE 1015
1 +24V 6 A-
2 CHANGE SOL BROWN 0705 11 BROWN 2311 YELLOW STOPPER SOL BROWN 1014 5 +24V
1 SKYBLUE 0706 12 SKYBLUE 2312 YELLOW SOL DC24V 72Ω 1/1 GRAY 1013
3 +24V 2 SKYBLUE 1011
4 A
SPM
4 BACK JOG SOL (SL302) 333.3mA J10 3 B
5 +24V 11 9 A-SLITER UNIT MOTOR YELLOW 1009 BROWN 1010 2 +24V
3 12 BROWN 0707 13 BROWN 2313 YELLOW ROLLER SOL BROWN 1010 YELLOW 1009
6 STOPPER SOL GRAY 0708 14 GRAY 2314 YELLOW SOL
DC24V 72Ω 1/1 10 +24V 1 B-
7 +24V 13 333.3mA 11 A+ SKYBLUE 1011 DC7.3V 0.5A
14 (SL303)
8 ROLLER SOL 12 +24V
1 BROWN 0709 1 BLUE JOG CL B+ GRAY 1013
9 +24V 2 YELLOW 0710 2 BLUE CL DC24V 156Ω 13 14 +24V BROWN 1014 SIDE JOG UNIT1 MOTOR
4 10 CLUTCH (CL301) 153.8mA (M306)
11 +24V 1 15 B- PURPLE 1015 PURPLE 1023
12 FAN 2 BROWN 0711 1 BROWN 1 RED FAN MOTOR 16 +24V BROWN 1022 6 A-
13 +24V 1 SKYBLUE 0712 2 PURPLE DC24V0.1A
2 BLACK FAN 17 A-SIDE JOG1 UNIT MOTOR YELLOW 1017 GRAY 1021 5 +24V
14 COUNTER 2 (FM301) 18 +24V BROWN 1018 SKYBLUE 1019 4 A
SKYBLUE 1019 3 B SPM
5 EH14T 19 A+ BROWN 1018
BROWN 0713 1 BROWN COUNTER 2 +24V
PURPLE 0714 DC24V 590Ω 20
2 WHITE COU +24V YELLOW 1017
21 B+ GRAY 1021 1 B-
MC UNIT (CNT301) 41mA BROWN 1022 DC7.3V 0.5A
(PCB301) 22 +24V PURPLE 1023
BROWN YELLOW BACK JOG SOL 23 B-
6 PURPLE YELLOW SOL
DC24V 72Ω 1/1 24 +24V SIDE JOG UNIT2 MOTOR
(SL304) 333.3mA 25 A-SIDE JOG2 UNIT MOTOR PURPLE 1031 (M307)
26 +24V BROWN 1030 12 PURPLE 2212 6 A-
BROWN 0703 1 BACK JOG UNIT MOTOR 11 BROWN 2211
PURPLE 0704 2 (M308) 27 A+ 5 +24V
J10 28 +24V GRAY 1029 10 GRAY 2210 4 A
7 1 A-BACK JOG UINT MOTOR YELLOW 1001 3 6 A- SKYBLUE 1027 9 SKYBLUE 2209 SPM
BROWN 1002 4 29 B+ 3 B
2 +24V 5 +24V 30 +24V BROWN 1026 8 BROWN 2208 2 +24V
3 A+ SKYBLUE 1003 5 4 A YELLOW 1025 7 YELLOW 2207
GRAY 1005 6 SPM 31 B- 1 B-
4 +24V 3 B 32 +24V DC7.3V 0.5A
B+ BROWN 1006 7 2 +24V
8 5 PURPLE 1007 8 PHD32T
6 +24V 1 B-
7 B- DC7.3V 0.5A FG
8 +24V
to M-9
9 (6 of 7)
A
(6 of 7)
YELLOW to K-7
CUTTER HOME (3 of 7)
1 1 PURPLE 2315 15 PURPLE 0629 to I-8 J09
NO C 2 BLUE 2316 16 BLUE 0633 (4 of 7) GRAY 0901 MC UNIT
SKYBLUE 0902 1 M3U (PCB301)
NC 2 M3V
YELLOW 0903
CUTTER UNIT (SW301) YELLOW GRAY 0904 3 M3W
2 SKYBLUE 0905 4 M4U
CUTTER MOTOR to I-5 5 M4V
DC24V1.44A YELLOW 0906 6 M4W
RED 1 BROWN 2307 7 (4 of 7) BROWN 0907
M WHITE 2 PURPLE 2308 8 PURPLE 0908 7 CUT(+M)
GRAY 0909 8 CUT(-M)
3 (M304) to I-9 YELLOW 0910 9 MOVE MOTOR(+A)
(4 of 7) 10 MOVE MOTOR(-A)
EH10T
J01 J14
DPIF 1 DOUT+ SKYBLUE
YELLOW
2101
2102
1 SKYBLUE 2404
2 YELLOW 2405
4
5
SKYBLUE 1401
YELLOW 1402 1 DOUT+
4 P.W.B.UNIT 2 DOUT- PURPLE 2103 3 PURPLE 2406 6 PURPLE 1403 2 DOUT-
(PCB306) 3 CLK+ YELLOW 2104 4 YELLOW 2407 7 YELLOW 1404 3 CLK+
4 CLK- GRAY 2105 5 GRAY 2408 8 GRAY 1405 4 CLK-
5 DIN+ SKYBLUE 2106 6 SKYBLUE 2409 9 SKYBLUE 1406 5 DIN+
6 DIN- ORANGE 2107 7 ORANGE 2410 10 ORANGE 1407 6 DIN-
5 7 +6V 7 6.3V
8 GND BLUE 2108 8 BLUE 2411 11 BLUE 1408 8 GND
9 GND BLUE 2109 9 BLUE 2412 12 BLUE 1409 9 GND
10 LD+ PURPLE 2110 10 PURPLE 2413 13 PURPLE 1410 10 LD+
EH10S EH10T
6 J08
CREASER MOTOR BLACK 1 SKYBLUE 0801 1 CREASER(+M)
to C-6 to E-6 DC24V1.6A M WHITE 2 YELLOW 0802 2 CREASER(-M)
(1 of 7) (1 of 7) (M305) VH02T
7 BLACK(shield) J04
RED 1 GND
CCD SCANNER BLUE 2 +5V
GREEN 3 CS(N.C.)
GRAY 4 SD(N.C.)
8 WHITE 5 RS(N.C.)
BROWN 6 RD(N.C.)
ORANGE 7 TRIGGER
PURPLE 8 ROG
YELLOW 9 TTL
9 10 CLK
DF11-10DP-2DSA to H-8
(5 of 7)

(7 of 7)
INFEED SENSOR (PS305)
1 3 CATHODE BLUE 2 BLUE 1302
2 ANODE YELLOW 1 YELLOW 1301 to K-5
1 ANODE POSITION SENSOR (PS311) C (4 of 7)
3 CATHODE BLUE 2 BLUE 1314 MC UNIT
2 3 GND BLUE 3 BLUE 0505 2 ANODE YELLOW 1 YELLOW 1313 (PCB301)
2 Vout PINK 21
YELLOW YELLOW 0501
PINK 0503 1 ANODE SKYBLUE 0617 17J06
1 Vcc PURPLE 0618 18 POSITION SENSOR
to B-6 Constant voltage circuit PINK 0619 19 CUT-CRE
(1 of 7) 3 GND BLUE 6 BLUE 0621 PINK 0620 20 +5V
SKYBLUE
2 Vout PINK 5 SKYBLUE SKYBLUE 0617 BLUE 0621 21 +5V
3 MC UNIT STOPPER FRONT PAPER SENSOR (PS308) 1 Vcc 4 PINK 0619 BLUE 0622 22 GND GND
3 CATHODE BLUE 2 BLUE 1304 Constant voltage circuit
(PCB301) YELLOW 1 YELLOW 1303 PHD34T
2 ANODE
J13 1 ANODE to K-6
YELLOW 1301 STOPPER FRONT PAPER SENSOR (PS309) A
1 LD1 (4 of 7)
4 2 GND BLUE 1302 BLUE 3 BLUE 0506 BLUE 2 BLUE 1306
YELLOW 1303 3 GND PURPLE 3 CATHODE
3 LD2 Vout 2 PURPLE 0502 2 ANODE YELLOW 1 YELLOW 1305 to K-9
BLUE 1304 2 PINK 1 PINK 0504
4 GND 1 Vcc 1 ANODE (4 of 7)
5 LD3 YELLOW 1305 A
BLUE 1306 Constant voltage circuit
6 GND 3 BLUE 0511 MC UNIT
5 7 LD4 YELLOW 1307 3 GND BLUE
YELLOW 2 YELLOW YELLOW 0507 (PCB301)
8 GND BLUE 1308
YELLOW 1309 PAPER JAM SENSOR (PS312)
2 Vout PINK 1 PINK 0509 YELLOW 0501 1J05
9 LD5 BLUE 2 BLUE 1308
1 Vcc PURPLE 0502 2 INFEED SENSOR
STOPPER SENSOR(F)
10 GND BLUE 1310 3 CATHODE Constant voltage circuit PINK 0503 3 +5V
SKYBLUE 1311 2 ANODE YELLOW 1 YELLOW 1307 PINK 0504
11 LD6 BLUE 1312 1 ANODE BLUE 0505 45 +5V
6 12 GND
13 LD7 YELLOW 1313 B YELLOW 3000 BLUE 0506 GND GND
BLUE 1314 to F-3
SKYBLUE 3003 YELLOW 0507 67 STOPPER
14 GND C 3 GND BLUE 3 BLUE 0622 (4 of 7) YELLOW 0508 8 DELIVERY SENSOR(R)
PHD24T 2 Vout PURPLE 2 PURPLE 0618
PINK 0620 PINK 0509 9 +5V SENSOR
1 Vcc PINK 1 B PINK 0510 +5V
7 to C-1 Constant voltage circuit BLUE 0511 10
(2 of 7) BYPASS PAPER SENSOR (PS306) 5 SKYBLUE 1311 BLUE 0512 1112
GND
GND
3 CATHODE BLUE 2 BLUE 2506 6 BLUE 1312 13 BYPASS SENSOR
DELIVERY PAPER SENSOR (PS307) 2 ANODE SKYBLUE 1 SKYBLUE 2505 14 MACHIN MOVE HOME
BLUE 2 BLUE 1310 1 ANODE 3 PINK 2401 1 PINK 0515 15 +5V
3 CATHODE YELLOW 1 4 YELLOW 2402 2 YELLOW 0513
2 ANODE YELLOW 1309 16 +5V
8 5 BLUE 2403 3 BLUE 0517 17 GND
1 ANODE
3 GND BLUE PHD30T
2 Vout YELLOW
3 GND BLUE 3 BLUE 0512 1 Vcc PINK
2 Vout PINK 21
YELLOW YELLOW 0508
PINK 0510 Constant voltage circuit to K-2
9 1 Vcc (3 of 7)
Constant voltage circuit

WD3.4 Schematic Diagrams of DCM Kit (1 of 3)
J2
1 DOUT+ I/F UNIT RM UNIT
2 Power supply
2 DOUT-
D-PORT1 3 CLK+
(Upstream Unit) 4 CLK- AC_L 1 BLACK J2 J4
5 DIN+ J1 4 V+ 1 FG REM SW-B 1
6 DIN- +24V 1 BROWN 3 V+ AC_N 3 WHITE 2 REM SW-C 2
3 7 +6.5V GND 2 BLUE 2 V- 3 AC200VL REM SW-A 3
8 GND FG 3 1 V- FG 5 4
J3
1 DIN+ 5 AC200VN
2 DIN-
FG
J4 FG
3 CLK+
4 D-PORT2 4 CLK- REMOTE6V 1 ORANGE
(Downstream Unit) 5 DOUT+ GND 2 BLUE
6 DOUT-
7 +6.5V AC220~240V 50/60Hz
8 GND AC120V 60Hz
5
J5
1 REMOTE24V POWER CORD
2 REMOTE6V J1
to E-3 3 GND AC200VN 1 N
6 FG
(2 of 3) 4 POWER+ FG 2
5 POWER- AC200VL 3 L
AC120V 60Hz
7 AC220~240V 50/60Hz
to L-4
(3 of 3)
8

WD3.4 Schematic Diagrams of DCM Kit
(2 of 3)
2
to E-6
(1 of 3)
0202 BROWN 1
3 I/F UNIT 0203 BROWN
0217 SKYBLUE 2 To A-5
0201 BROWN J5 3 (3 of 3)
1 +24V 0218 YELLOW 4
0202 BROWN 2 +24V
0203 BROWN 3 +24V
0204 BROWN 4 +24V
4
5 +5V
6 +5V Power Supply High Voltage
7 +5V
8 OPERROR
9 OPSEL1 Static Bar
5 10 OPSEL2 0216 PURPLE WHITE
11 OPSEL3 0224 BLUE 1
2
1
2 SHIELD 1
2
REMOTE
GND
RED 1 1 WHITE
12 CSTSW 0201 BROWN 3 3 BRACK 3 +24V
13 OPSW1 4 REMOTE
14 OPSW2
6 15 OPSPEED
BLACK 1 1 YELLOW
0216 PURPLE 16 CLSPEED
0217 SKYBLUE 17 CLERROR
0218 YELLOW 18 CLSTRAT 0219 GRAY 1 1 WHITE 1 FG
0219 GRAY 19 RSVOUT1 0225 BLUE 2 2 SHIELD
BRACK 2
20 RSVOUT2 0204 BROWN 3 3 3
7 21 RSVOUT3
22 RSVOUT4
0224 BLUE 23 RSVOUT5
0225 BLUE 24 GND
25 GND
8 26 GND
FG FG

(3 of 3)
2002 BROWN
1
RELAY
2017 SKYBLUE POS NEG
(Downstream Unit)
2 AC120V 60Hz N.C.
BLACK 1 BLACK
COM
COM WHITE 12
Compressor
2 N.O.
GREEN/YELLOW
3 FG
120 0.1uF
AC220-240V 50/60Hz spark_killer to L-7
SKYBLUE (1 of 3)
4 COM BROWN 12
RM UNIT
GREEN/YELLOW
FG J3
WHITE 1 AC200VN
5 WHITE 2 AC200VN
1 2003 BROWN 3
To H-3 2 BLACK 4 AC200VL
(2 of 3) 3 RELAY BLACK
4 5 AC200VL
6 2018 YELLOW POS NEG 6
7 FG
AC120V 60Hz 8 FG
(Upstream Unit)
N.C.
BLACK COM
COM WHITE 12 1 BLACK
Compressor
7 2 N.O.
GREEN/YELLOW
FG
120 0.1uF
8 AC220-240V 50/60Hz
SKYBLUE spark_killer
COM BROWN 12 FG FG
9 GREEN/YELLOW
FG

WD3.5 Schematic Diagrams of DBM-500/DBM-500BR (1 of 10)
Fan
2 DC 24V 0.2A
5108 BRN 1 RED Noise Filter
5104 BLU 2 BLK Ferrite core
AC/DC 250V 10A (PSW502) 1T Power cord
WHT WHT WHT
3 BLK BLK BLK
Switching Power Supply YEL
Ferrite core CN51 CN1
GRY GND YEL GRN/YEL
0608 BLU 1 5 FG Circuit protector
4 0B03 BLU 2 GND WHT
5104 BLU 3 GND 3 N
0601 BRN 4 GND BLK
BRN 5 +24V 1 L
0B07 BRN 6 +24V
5 (5toofK-2 7 +24V CN2 Purple Switch (PSW501)
10) 5108 BRN 8 +24V 1 Purple
1 +R 2 GRY
1T 2 -R GRY
0A01 ORN 1 CN52
to E-5 0A02 BLU 2 +R
-R
6 (4 of 10) (PCB504)
to A-3 to D-8
(2 of 10) (2 of 10)
7
to D-9
(2 of 10)

WD3.4 Schematic Diagrams of DBM-500/DBM-500BR
(2 of 10)
to K-9
(4 of 10)
1
J07
0701 YEL 1 DOOR1
0702 BLU 2 GND
0703 GRY 3 DOOR2
2 0704 BLU 4 GND
Emergency stop sw(SSW503) 0705 Purple 5 DOOR3
1 0706 BLU 6 GND
2 BRN
MC UNIT
to D-7 BRN 1 BRN J08
3 Relay Board 2 0801 YEL 1 VEMG
(1 of 10) Top Cover (Front) (SSW504)
(PCB503) 0803 GRY 2
Shutter SW (SSW506) Top Cover (Rear) (SSW505) 3 V1
J01 J02 0805 Sky-BLU 45 VR
BRN 1 +24V 1 EMG BRN 1 2 BRN 1 2 BRN 1 2
4 2 +24V 2 4 3 4 3 4 3 0703 GRY 0807 Purple 6
0604 BRN 3 +24VA 3 EMG 0704 BLU 7 V2
0606 BLU 4 +24VA 4 BRN 0701 YEL 0809 YEL 8
5 GND 5 DOOR 0702 BLU 9 VF
J04 6 BRN 0705 Purple 0811 GRY 10
5 0801 YEL 1 VEMG 7 DOOR 0706 BLU 0812 Sky-BLU 11 VDR
0803 GRY 2 J03
YEL 1 GRY 0813 Purple 12
13
VP2C
VP1
3 V1 1 RL F 2 YEL 1 0814 BLU 14 VP2F
0805 Sky-BLU 45 VR
2
3 RL F GRY 3 Purple 2
3 to Up stream unit
4 WHT
6 0807 Purple 67 V2
4
5 RL 2 Sky BLU 5 BLK 4
FG to K-4
to A-5
(3 of 10)
0809 YEL 8 6 Purple (5 of 10)
9 VF 7 RL 2
0811 GRY 10 8 YEL 1 GRY
7 0812 Sky-BLU 11 VDR 9 RL 1 2 YEL 1
0813 Purple 12
13
VP2C 10
VP1 11 RL 1 GRY 3 Purple 2
3 to Down stream unit
0814 BLU 14 VP2F 12 GND 4 WHT 4
Sky-BLU BLK 2T
13 RL R FG
14 GND Purple BLK
S/L2 WHT BLK 1 BLK WHT 1 BLK
8 15 RL R WHT 2 WHT 2 BLK
R/L1
J05 to I-7
E YEL
1 AC L BLK (1 of 10)
2 LOAD BLK 1 BLK Ferrite core Reactor unit
3 LOAD WHT 2 WHT 9.5mH,6.2A
9 4 AC N WHT to J-7 Motor driver
(1 of 10)
(Inverter)

(3 of 10)
to C-9 2010 BRN
1 (5 of 10) J05 2013 YEL Magnetic relay (RL501)
MC UNIT 1 AC L BLK 1 BLK 1 8
J20 2 LOAD WHT 2 WHT
1 CTL0 2001 ORN(BLK) 3 LOAD
2002 ORN(RED) 4 AC N BLK 4 6 BLK L
2 CTL1 2003 YEL(BLK) WHT WHT Pump Outlet
2 3 CTL2 N
2004 YEL(RED) 0.1μF+120Ω GRN/YEL
4 GND 2005 GRN(BLK) Relay Board E
5 INVERR 2006 RED (PCB503)
6 GND 2007 WHT Spark Quencher
7 INVSP 2011 BRN
3 8 +24V 2008 YEL 2014 Purple Magnetic relay (RL502)
9 2T 1 8
10 +24VA 2010 BRN
11 +24VA 2011 BRN
BLK 4 6 BLK L
12 WHT WHT Stacker Outlet
4 13 OUTRL 2013
2014
YEL
Purple 0.1μF+120Ω GRN/YEL
N
14 BLTPRL E
Shield
to M-6 Shield Spark Quencher
5 (2 of 10)
Ferrite core 2T
CN1 CN2 2T
2008 YEL 8 BRN RED BLK BLK 1 BLK WHT 1 BLK
2007 WHT 7 GRY 1 24V 1 P15 Pink P15 S/L2 WHT WHT 2 WHT 2 BLK
6 2001 ORN(BLK) 1 YEL 2 Fin 2 P5 GRY P5 R/L1
3 I1 3 Vout(V1) E YEL
2002 ORN(RED) 2 Purple 4 I2 4 I1(F) YEL
Purple F Ferrite core Reactor unit
5 I3 5 I2(R) R 9.5mH,6.2A
7 2003 YEL(BLK) 3 Sky-BLU 67 I4
I5
6
7
I3(S1)
I4(S2)
8 I6 8 I5 Sky-BLU 2T
2004 YEL(RED) 4 BLU S1
9 G1 9 I6 BLU S2 U/T1 RED 1 RED 1 RED 1 RED
2005 GRN(BLK) 5 Purple 10 NC 10 G1(CC) CC V/T2 WHT 2 WHT 2 WHT 2 WHT
11 O1 11 NC Purple W/T3 BLK 3 BLK 3 BLK 3 BLK
8 12 O2 12 O1(OUT) FM/OUT
2006 RED 6 BLU 13 G2 13 O2 BLU Ferrite core
Shield 14 G2 CC GRN/YEL
Shield (M514)
9 ISOLATION BOARD Motor driver (Inverter)
Main motor
(PCB502) 50/60Hz 200-220V 0.4kW
(4 of 10)
to L-8
1
(8 of 10) MC UNIT
J03 J01 J22
1 DOUT+ 1 DOUT+ 2201 YEL 2201 YEL 1 DOUT+
2 DOUT- 2 DOUT- 2202 GRY 2202 GRY 2 DOUT-
To Up stream 3 CLK+ 3 CLK+ 2203 Sky-BLU 2203 Sky-BLU 3 CLK+
4 CLK- 4 CLK- 2204 Purple 2204 Purple 4 CLK-
2 unit 5 DIN+ 5 DIN+ 2205 GRY 2205 GRY 5 DIN+
6 DIN- 6 DIN- 2206 YEL 2206 YEL 6 DIN-
7 +6V 7 +6V 2207 ORN 2207 ORN 7 +6V
8 GND 8 GND 2208 BLU 2208 BLU 8 GND
9 GND 2209 BLU 2209 BLU 9 GND
3 J04 10 LD+ 2210 YEL 2210 YEL 10 LD+
1 DOUT+ AX J10
J02 Body motor 1 GRY 7 GRY
2 DOUT- 0A01 ORN DC24V 2.0A 1 MT1o+
To Down stream 3 CLK+ 1 +6V 0A02 BLU
2 YEL 8 YEL 2 MTo1-
unit 4 CLK- 2 GND (M513) BI J04
4 5 DIN+ BLK 1 BLU 7 BLU
6 DIN- RED 2 YEL 8 YEL 1 GND
7 +6V WHT 3 GRY 9 GRY 2 HU
8 GND BLU 4 Sky-BLU 10 Sky-BLU 3 HV
BRN 5 Purple 11 Purple 4 HW
5 to B-6 YEL 6 RED 12 RED 5 RE
DPIF P.W.B.UNIT (1 of 10) 6 +12V
J09
ORN 7 YEL 13 YEL 1 U
to M-2 GRY 8 GRY 14 GRY
(6 of 10) Sky-BLU 9 Sky-BLU 15 Sky-BLU 23 V
W
6 MC UNIT J07
J03 1 DOOR1
Feed motor 2 GND
1 SCL
2 GND DC 24V DC 0.6A 3 DOOR2
7 3 SDA (M503) 4 GND
4 GND 5 DOOR3
5 Magnet Sensor 6 GND
6 GND 1 0709 Sky-BLU 7 DOOR4
(PCB side) 2 0710 BLU
7
8
+6.3V
GND 0709 Sky-BLU 89 GND
DOOR5
8 (SSW501) 0710 BLU
0711 GRY 10 GND
0712 BLU 11 DOOR6
Magnet Sensor 1 0711 GRY 12 GND
2 0712 BLU 13 DOOR7
9 (SSW502) 14 GND
to C-1
(9 of 10) to K-1
(2 of 10)

(5 of 10)
to H-9
(10 of 10)
1 0608 BLU
J16 1 +24VA BRN 1 BLK
BRN 2 WHT 0B03 BLU
2 +24VA GRY 4 ORN
3 PM9A- 3 BRN Fold roll gap motor1 (M511) 0601 BRN
4 PM9A+ Purple DC 3.0V 2.0A
Sky-BLU 5 RED
2 5 PM9B+ YEL 6 YEL to A-5
6 PM9B- 0B07 BRN (1 of 10)
MC UNIT 7 +24VA BRN 1 BLK
8 +24VA BRN 2 WHT
9 PM10A- GRY 4 ORN
Purple 3 BRN Fold roll gap motor2 (M512)
3 10 PM10A+ Sky-BLU DC 3.0V 2.0A
11 PM10B+ 5 RED
12 PM10B- YEL 6 YEL
13 0604 BRN
J17 1 +24VA BRN 1 BLK to I-6
4 BRN 2 WHT 0606 BLU
2 +24VA (2 of 10)
GRY 4 ORN Stitcher head motor (M506)
3 PM11A- Purple 3 BRN
4 PM11A+ Sky-BLU 5 RED DC 3.0V 2.0A
5 PM11B+ YEL 6 YEL
6 PM11B- 0B03 BRN 1 BRN 1 +24V
5 0B07 BLU 2 BLU
J06 1 +24V 0601 BRN GRY 2 GND
2 +24V 3 FG
3 +24V 0604 BRN OPERATION TERMINAL
4 +24VA 1
6 5 +24VA 0606 BLU 2101 RED 1 RED 2
6 GND 2102 WHT 2 WHT RxD
7 GND 2103 YEL 3 BLK 3 TxD
8 GND 0608 BLU Shield YEL 4 DTR
9 FG BLK 5 SG
7 Shield BLK 6 DSR
J21 1 TxD0 2101 RED BLK 7 RTS
2 RxD0 2102 WHT 8 CTS
3 GND 2103 YEL 9
4 KEYDAT1 2104 ORN(BLK)
5 KEYSTB 2105 ORN(Rad) 2104 ORN(BLK) 1 ORN(BLK)
8 2106 YEL(BLK) 2105 ORN(RED) 2 ORN(RED) 1 KEYDAT J01
6 SFTCLK 2 KEYSTB
7 +5V 2107 YEL(RED) 2106 YEL(BLK) 3 YEL(BLK)
2107 YEL(RED) 4 YEL(RED) 3 SFTCLK KEYP.W.B.UNIT
8 +5V 4 +5V
9 GND 2109 GRN(BLK) 2109 GRN(BLK) 5 GRN(BLK)
Shield Shield Shield 5 GND
9 10 GND
Shield
to B-1 OPERATION PANEL
(3 of 10)

(6 of 10)
1
Side jog index 1 INDEX1 0501 GRY to A-6
2 GND 0517 BLU (4 of 10)
(PS506) 3 +5V 0509 Pink
2 MC UNIT
Ferrite core J05
INDEX3 3 YEL 1 1 0503 YEL 0501 GRY 1
1 INDEX1
Stitch wire index1 2 GND 19 WHT 2 2 0519 BLU 2 INDEX2
3 +5V 11 RED 3 3 0511 Pink 0503 YEL 3
(PS523) 3 0504 Sky-BLU INDEX3
4 4 INDEX4
0505 Purple 5
Shield Shield 0506 GRY INDEX5
6 INDEX6
4 7 INDEX7
1 INDEX4 YEL 1 1 0504 Sky-BLU 8 INDEX8
GND WHT 2 2 0520 BLU 0509 Pink 9
Stitch wire index2 2 +5V
3 +5V RED 3 3 0512 Pink 10 +5V
(PS524) 4 0511 Pink
0512 Pink 11 +5V
5 Shield Shield 12 +5V
0513 Pink 13
Option 0514 Pink +5V
14 +5V
INDEX5 Purple 1 1 0505 Purple 15 +5V
6 1 GND BLU 2 2 0521 BLU 16 +5V
2 0517 BLU 17
+5V Pink 3 3 0513 Pink GND
Stitch wire index3 3 18 GND
(PS525) 4 0519 BLU
0520 BLU 19 GND
Shield Shield 20 GND
7 0521 BLU 21
0522 BLU GND
22 GND
INDEX6 GRY 1 1 0506 GRY 23 GND
1 GND 2 2 24 GND
2 BLU 0522 BLU
8 Stitch wire index4 3 +5V Pink 3 3 0514 Pink
(PS526) 4
Shield Shield to E-1
(7 of 10)
9

(7 of 10)
AX
1 INDEX7 Sky BLU 1 0507 Sky-BLU to L-8 A
1
2 GND BLU 2 0523 BLU (6 of 10) f
3 +5V Pink 3 0515 Pink 1 +5V Pink 7 0115 Pink
Index (PS528) MC UNIT 2 GND BLU 8 0127 BLU MC UNIT
3 PH11 GRY 9 0105 GRY
1 INDEX8 0508 YEL
J05 1 +5V Pink 10 0116 Pink 0105 GRY
J01
2 2 GND 0524 BLU 0507 Sky-BLU 7 INDEX7 2 GND BLU 11 0128 BLU 0106 YEL 5 PH11
3 +5V 0516 Pink 0508 YEL 6 PH5
Main motor index 8 INDEX8 Fold eject
...
...
0115 Pink
...
...
(PS519) 0515 Pink jam sensor 15 +5V
15 +5V 0116 Pink
3 1 +5V 0107 Pink 0516 Pink 16 +5V (PS522) 0117 Pink 16 +5V
2 GND 0119 BLU
1 +5V Pink 1 0117 Pink 17 +5V
3 PH1 0101 YEL
...
...
0523 BLU 2 PH5 YEL 2 0106 YEL
...
...
23 GND 0127 BLU
1 +5V 0108 Pink 0524 BLU 24 GND 3 GND BLU 3 0129 BLU 0128 BLU 27 GND
2 GND 0120 BLU
Side stitch eject 0129 BLU 28 GND
Input Jam sensor J01 29 GND
4 0101 YEL full sensor 30 GND
(PS501) 0102 GRY 1 PH1
(PS516) J02
1 +5V 0109 Pink 0103 Sky-BLU 23 PH2 0201 YEL
2 GND 0121 BLU PH3
0104 Purple 4 PH6 1 PH4 YEL 1 YEL 4 0201 YEL 0202 GRY 1 PH4
3 PH2 0102 GRY
2 GND BLU 2 BLU 5 0213 BLU 0203 Sky-BLU 23 PH7
5 AY 3 +5V Pink 3 Pink 6 0207 Pink PH8
...
...
1 +5V Pink 1 0110 Pink 0107 Pink 7 +5V 4 PH9
2 GND BLU 2 0122 BLU 0108 Pink 8 +5V Fold stopper f 0206 Purple 5 PH10
Jog timing sensor 0109 Pink 9 +5V timing sensor 0207 Pink 6 PH12
0110 Pink 10 +5V (PS512) 0208 Pink 7 +5V
(PS502) 0111 Pink 8 +5V
6 0111 Pink 11 +5V 0209 Pink
1 +5V 0112 Pink 12 +5V 1 PH7 0202 GRY 9 +5V
2 GND 0123 BLU 0113 Pink 13 +5V 2 GND 0214 BLU 10 +5V
3 PH3 0103 Sky-BLU 0114 Pink 14 +5V 3 +5V 0208 Pink 0212 Pink 11 +5V
1 +5V 0112 Pink 0213 BLU 12 +5V
Stitch initial sensor
...
...
2 GND 0124 BLU 0119 BLU 0214 BLU 13 GND

7 0120 BLU 19 GND (PS517) 14 GND
Side stitch stopper 20 GND 0215 BLU 15 GND
timing sensor 0121 BLU 21 GND 1 PH8 0203 Sky-BLU
16 GND
0122 BLU 22 GND 2 GND 0215 BLU
17 GND
(PS508) 0123 BLU 3 +5V 0209 Pink 0218 BLU
1 +5V 0113 Pink 0124 BLU 23 GND 18 GND
24 GND Fold initial sensor
8 2 GND 0125 BLU 0125 BLU 25 GND
3 PH6 0104 Purple 0126 BLU (PS518) AX
26 GND
1 +5V 0114 Pink 1 PH12 Purple 4 0206 Purple
2 GND 0126 BLU 2 GND BLU 5 0218 BLU
Side stitch eject 3 +5V Pink 6 0212 Pink
9 initial (PS527) to F-1
jam sensor A (8 of 10)
(PS515)
(8 of 10)
to L-9
BRN 1 +24V BRN 1 1801 BRN (7 of 10) ORN 1 +24V 1815 BRN
1 WHT 2 SOL1 YEL 2 1802 YEL ORN 2 BR3 1816 Purple
Saddle stitch stopper MC UNIT Side jog
Solenoid (SL501) Break (BRK501)
24V,41Ω,1/1,0.585A J18 24V,122Ω,0.199A,4.7W
2 1801 BRN 1 +24V
BRN 1 +24V 1803 BRN 1802 YEL BRN 1 +24V 1817 BRN
WHT 2 SOL2 1804 GRY 2 SOL1 WHT 2 CO1 1818 Sky-BLU
1803 BRN 3 +24V
Side stitch stopper 1804 GRY 4 SOL2 Stitch conter
Solenoid (SL502) 1805 BRN 5 +24V (CNT501)
3 24V,41Ω,1/1,0.585A 1806 Sky-BLU 6 SOL3
1807 BRN 24V,590Ω,41mA, 1.0W
BRN 1 +24V 1811 BRN 7 +24V BRN 1 +24V 1819 BRN
1808 Purple 8 SOL4
WHT 2 SOL3 1812 Sky-BLU 1809 BRN WHT 2 CO2 1820 Purple
9 +24V
Stitch eject roll 1810 GRY 10 SOL5 Fold carry counter
4 Solenoid (SL503) 1811 BRN +24V
A
1812 Sky-BLU 11 (CNT502)
24V,20.5Ω,1/2,1.17A 12 SOL6 24V,590Ω,41mA, 1.0W
1813 BRN 13 +24V
BRN 1 +24V 1807 BRN 1814 YEL 14 CL3 BLK 1 +24V 1901 BRN
WHT 2 SOL4 1808 Purple BLK 2 CL1 1902 YEL 1815 BRN 15
5 1816 Purple +24V
Stitch eject roll Stitch clutch 1817 BRN 16 BR3
Solenoid2 (SL504) (CL502) 1818 Sky-BLU 17 +24V
24V,36Ω,1/2,0.667A Y
A 24V,23Ω,1.09A,25W 1819 BRN 18 CO1
1820 Purple 19 +24V
6 ORN 1 +24V BRN 4 1809 BRN BLK 1 +24V 1903 BRN 20 CO2
WHT 2 SOL5 GRY 5 1810 GRY BLK 2 BR1 1904 GRY
J19
Back stopper Stitch break 1901 BRN 1 +24V
Solenoid (SL505) (BRK502) 1902 YEL 2 CL1
24V,72Ω,1/1,0.333A 24V,38Ω,0.63A,15W 1903 BRN 3 +24V
7 1904 GRY
ORN 1 +24V 1805 BRN BLK 1 +24V 1905 BRN 1905 BRN 4 BR1
WHT 2 SOL6 1806 Sky-BLU BLK 2 CL2 1906 Sky-BLU 1906 Sky-BLU 5 +24V
1907 BRN 6 CL2
Side stitch roll Fold clutch 7 +24V
1908 Purple
8 Solenoid (SL506) (CL503) 8 BR2
24V,72Ω,1/1,0.333A 24V,38Ω,0.63A,15W
WHT 1 +24V 1813 BRN BLK 1 +24V 1907 BRN
WHT 2 CL3 1814 YEL BLK 2 BR2 1908 Purple to K-1
(4 of 10)
9 Fold carry Fold break
Clutch (CL501) (BRK503)
24V,0.27A,88Ω,6.5W 24V,38Ω,0.63A,15W
(9 of 10)
to C-9 1101 YEL PM-HOME1 1
1 (4 of 10) 1123 BLU GND Jog unit initial sensor
MC UNIT 1112 Pink +5V 2 (PS503)
AY 3
J11
1 PM-HOME1 1101 YEL 1102 Purple 3 Purple PM-HOME2
2 PM-HOME2 1102 Purple 1124 BLU 4 BLU GND 1 Back jog initial sensor
2 3 PM-HOME3 1103 Sky-BLU 1113 Pink 5 Pink +5V 2 (PS504)
1104 Purple 3
4 PM-HOME4 1105 GRY 1103 Sky-BLU PM-HOME3
5 PM-HOME5 1106 YEL 1125 BLU GND 1 Side jog initial sensor
6 PM-HOME6 1107 GRY 1114 Pink +5V 2 (PS505)
3 7 PM-HOME7 3
8 PM-HOME8 1108 Sky-BLU 1104 Purple 1 Purple PM-HOME4
9 PM-HOME9 1109 Purple 1126 BLU 2 BLU GND 1 Stitch stopper initial
10 PM-HOME10 1110 YEL 1115 Pink 3 Pink +5V 2 sensor (PS507)
1111 GRY 3
4 11 PM-HOME11 1112 Pink 1105 GRY 1 GRY PM-HOME5
12 +5V 1113 Pink 1127 BLU 2 BLU GND 1 Back stopper initial
13 +5V 1114 Pink 1116 Pink 3 Pink +5V 2 sensor (PS510)
14 +5V 3
15 +5V 1115 Pink 1106 YEL Y PM-HOME6
5 16 +5V 1116 Pink 1128 BLU GND 1 Fold side guide
17 +5V 1117 Pink 1117 Pink +5V 2 initial sensor (PS514)
1118 Pink f GRY 3
18 +5v 1119 Pink 1107 GRY 1 7 GRY PM-HOME7 1
19 +5V 1120 Pink 1129 BLU 2 BLU 8 BLU GND Fold stopper initial
6 20 +5V 1121 Pink 1118 Pink 3 Pink 9 Pink +5V 2 sensor (PS511)
21 +5V 3
22 +5V 1122 Pink 1108 Sky-BLU 12 Sky-BLU PM-HOME8
23 GND 1123 BLU 1130 BLU 13 BLU GND 1 Fold unit release
24 GND 1124 BLU 1119 Pink 14 Pink +5V 2 initial sensor (PS513)
7 1125 BLU 3
25 GND 1126 BLU
26 GND 1109 Purple PM-HOME9
27 GND 1127 BLU 1131 BLU GND 1 Fold roll gap initial
28 GND 1128 BLU 1120 Pink +5V 2 sensor1 (PS520)
1129 BLU 3
8 29 GND 1130 BLU 1110 YEL PM-HOME10
30 GND 1131 BLU 1132 BLU GND 1 Fold roll gap initial
31 GND 1132 BLU 1121 Pink +5V 2 sensor2 (PS521)
32 GND 3
33 GND 1133 BLU 1111 GRY PM-HOME11 1
9 34 GND 1133 BLU GND 2 Stitcher initial sensor
to B-1 1122 Pink +5V 3
(10 of 10) (PS509)
(10 of 10)
to C-9
(9 of 10) Jog unit motor A
1 MC UNIT
J12 DC 3.0V 2.0A (M501) Back stopper motor
BRN 1 BLK MC UNIT
1 +24VA 2 WHT J14 DC 3.0V 2.0A (M507)
BRN BRN
2 +24VA 4 ORN 1 BLK
2 GRY 3 BRN 1 +24VA 2 WHT
3 PM1A- 5 RED BRN 4 ORN
Purple 2 +24VA
4 PM1A+ 6 YEL GRY 3 BRN
Sky-BLU 3 PM5A- 5 RED
5 PM1B+ Purple
YEL 4 PM5A+ 6 YEL
6 PM1B- Back jog motor Sky-BLU
3 BRN 5 PM5B+
7 +24VA DC 3.6V 2.0A (M502) YEL
BRN BI 6 PM5B- Fold side guide motor
8 +24VA 1 BRN 1 BLK BRN
GRY 7 +24VA DC 3.0V 2.0A (M510)
9 PM2A- 2 BRN 2 WHT BRN
Purple 4 GRY 4 ORN 8 +24VA 1 BLK
4 10 PM2A+ 3 Purple 3 BRN GRY 2 WHT
Sky-BLU 9 PM6A-
11 PM2B+ 5 Sky-BLU 5 RED Purple 4 ORN
YEL 6 YEL 6 YEL 10 PM6A+ 3 BRN
12 PM2B- Sky-BLU
11 PM6B+ 5 RED
13 YEL 6 YEL
5 12 PM6B-
Side jog motor 13
J13 DC 3.6V 2.0A (M504) Fold stopper motor
BRN 1 BLK
1 +24VA 2 WHT J15 DC 3.0V 2.0A (M508)
BRN BRN
6 2 +24VA 4 ORN 1 BRN 1 BRN 1 BLK
GRY 3 BRN 1 +24VA 2 BRN 2 BRN 2 WHT
3 PM3A- 5 RED BRN 4 GRY 4 GRY 4 ORN
Purple 2 +24VA
4 PM3A+ 6 YEL GRY 3 Purple 3 Purple 3 BRN
Sky-BLU 3 PM7A- 5 Sky-BLU 5 Sky-BLU 5 RED
5 PM3B+ Purple 6 YEL 6 YEL 6 YEL
YEL 4 PM7A+
7 6 PM3B- Stitch stopper motor Sky-BLU
BRN 5 PM7B+
7 +24VA DC 3.0V 2.0A (M505) YEL
BRN 6 PM7B- Fold unit release motor
8 +24VA 1 BLK BRN
GRY 7 +24VA DC 3.0V 2.0A (M509)
9 PM4A- 2 WHT BRN
8 Purple 4 ORN 8 +24VA 7 BRN 1 BLK
10 PM4A+ 3 BRN GRY 8 BRN 2 WHT
Sky-BLU 9 PM8A-
11 PM4B+ 5 RED Purple 10 GRY 4 ORN
YEL 6 YEL 10 PM8A+ 9 Purple 3 BRN
12 PM4B- Sky-BLU 11 Sky-BLU 5 RED
11 PM8B+
YEL 12 YEL 6 YEL
9 12 PM8B-
to C-1
A (5 of 10)

WD3.6 Schematic Diagrams of DBM-500T/DBM-K (1 of 6)
to M-1
1 (4 of 6) 152 BRN 1 452 BRN 1 RED Fan3 (forKnifemotorcooling)
151 BLU 2 451 BLU 2 BLK 24V,0.16A
MC Unit (FM603)
(PCB601)
Noise Filter
J03 88 Sky-BLU 1 BLU AC/DC250V10A Circuit protector Power cord
2 1 U 89 Purple 2 Purple DC24V3.8A 455 BLK 184 BLK BLK
2 V 90 GRY 3 GRY Carrymotor
3 W 456 WHT 185 WHT WHT
(M602) 2 1 902 GRN/YEL (PSW601)
J02 91 BLU 4 YEL
1 GND 92 YEL 5 GRN GRN/YEL
3 2 HU 93 Sky-BLU 6 BRN
3 HV 94 Purple 7 RED
4 HW Switching Power Supply
5 8 ORN
96 RED 9 CN51 CN1
6 +12V 414 BLU 1 GND 1 L 155 BLK
150 BLU 2 to C-8
4 J07 97 BRN 1 BLK GND 156 WHT (2 of 6)
1 +24VA 2 WHT 151 BLU 3 GND 3 N
98 BRN 409 BRN
2 +24VA 99 YEL 4 ORN Moveunitmotor 4 +24V
3 PM1A- 100 GRY 3 BRN DC3.0V2.0A 153 BRN 5 +24V 5 FG 154 GRY
4 PM1A+ 5 RED 152 BRN (PSW602)
5 PM1B+ 101 Sky-BLU 6 YEL (M604) 6 +24V CN2
5 102 Purple 157 Purple
1 +R 158 2 457 Purple
6 PM1B- 103 BRN 438 ORN 1 CN52 2 -R GRY 1 458 GRY Switch
7
8
+24VA
+24VA 104 BRN 439 BLU 2 +R
-R (PCB603)
9 PM2A- 105 YEL
10 PM2A+ 106 GRY to B-1
6 11 PM2B+ 107 Sky-BLU (2 of 6)
PM2B- 108 Purple 103 BRN 5 403 BRN 5
12
Ferrite core
104 BRN 2 404 BRN 2 RL P.W.B.Unit
J04 105 YEL 6 405 YEL 6 J01
1 +24V 109 BRN 1 409 BRN 106 GRY 4 406 GRY 1 +24V
107 Sky-BLU 3 407 Sky-BLU 4
7 2 +24V 3 2 +24V
3 +24V 108 Purple 1 408 Purple 1 412 BRN 3 +24VA
4 +24VA 112 BRN 2 412 BRN 7 (M603) 4 +24VA
5 +24VA 114 BLU 8 5 GND
6 GND 3 414 BLU 9
to L-2 438 ORN
8 7 GND 439 BLU
8 GND (6 of 6)
to L-4
9 FG (6 of 6)
9 to B-1
(6 of 6)

WD3.6 Schematic Diagrams of DBM-500T/DBM-K
(2 of 6)
1 to M-6 1 474 BRN Emergency stop sw Top Cover SW

(1 of 6)
RLP.W.B.Unit 2 174 BRN (SSW601) Limit SW Unit (SSW602)
J02 (SSW603)
159 BRN 1 459 BRN 163 BRN1 165 BRN
1 EMG 2 460 BRN 2
2 2 160 BRN 3 461 GRY 1 BLU
3 EMG 4 462 GRY 2 BLU/WHT
4 161 GRY 62 Sky-BLU 3 ORN
5 DOOR 63 BLU 4 ORN/WHT 64 YEL RED
6 162 GRY RED
7 DOOR 60 YEL RED
3 J03 61 BLU RED
1 RLF 166 YEL
2 1 466 YEL 1 566 GRY 1
3 RLF 167 GRY 2 467 GRY 2 567 YEL 2
4 3 468 SkyBLU 3 568 Purple 3
4 5 RL2 168 SkyBLU 4 469 YEL 4 569 WHT 4
6 5 470 Purple 5 186 BLK FG
169 YEL 6 471 YEL 60 YEL
7 RL2 7 472 GRY to Up stream unit 61 BLU
8 170 Purple 8 473 SkyBLU 1 570 GRY 62 Sky-BLU
9 RL1 2 571 YEL 1 63 BLU
5 10 3 572 Purple 2
11 RL1 171 YEL 3 to I-7
4 573 WHT 4
12 GND 172 GRY 187 BLK (5 of 6)
13 RLR FG
14 GND 173 SkyBLU to Down stream unit
6 15 RLR
J05 255 BRN Solid state relay
1 ACL 155 BLK 256 GRY
475 BLK 4 3
2 LOAD Ferrite Core
3 LOAD 476 WHT INPUT (SSR)
4 ACN 156 WHT 475 BLK 2 LOAD 1 177 BLK 1 477 BLK L stacker
7 476 WHT 2 576 WHT N
to M-8
188 GRN/YEL Outlet
FG
(6 of 6) 155 BLK 253 BRN ZNR Unit
to L-4 254 YEL
(1 of 6) 156 WHT Magnetic relay
8 (RL601) DC24V
475 BLK COM NO
253 BRN 178 BLK 1 to G-1,G-6
254 YEL Spark 0.1μF+120Ω 476 WHT 2 (3 of 6)
to H-5,H-6 Quencher
9 (5 of 6) 255 BRN
256 GRY

(3 of 6)
220-240V
1 178 BLK 1 478 WHT 1 WHT
to J-9
Magnetic relay (2 of 6) 476 WHT 2 576 GRY 576 GRY 2 GRY
GRY 480 BLU 4 BLU
to H-5 241 BRN 1 341 BRN DC24V 681 RED 6 RED
(5 of 6) 242 Purple 2 342 GRY 5 YEL
2 3
(RL602) GRN/YEL
NC 179 GRY 179 GRY 3 (M601)
181 RED COM 180 Sky-BLU 2
NO 180 Sky-BLU 181 RED 1 481 ORN ORN 581 WHT Knife motor
3 φ1 240V 50Hz 2.6A 0.4kW
125WVAC 400μF
0.1μF+120Ω X2
ORN 781 YEL
0.1μF+120Ω
4 Spark Quencher 250WVAC 40μF
5
120V
to J-9 178 BLK 1 478 WHT 1 WHT
Magnetic relay Magnetic relay (2 of 6) 476 WHT 2 576 GRY 576 GRY 2 GRY
6 480 BLU 4 BLU
to H-5 241 BRN 1 341 BRN DC24V DC24V
179 GRY 3 576 GRY 481 BLK 3 BLK
(5 of 6) 242 Purple 2 342 GRY 180 Sky-BLU 4 682 RED 6 RED
(RL602a) 181 BLK 2 882 YEL 5 YEL
(RL602b) 182 ORN 1 482 ORN 582 WHT GRN/YEL
7 NC 180 Sky-BLU NC 179 GRY (M601)
COM COM 125WVAC 200μF
NO 179 GRY NO 180 Sky-BLU Knife motor
φ1 120V 60Hz 5.0A 0.4kW
782 GRY
8 0.1μF+120Ω 0.1μF+120Ω 250WVAC 40μF
0.1μF+120Ω 0.1μF+120Ω
Spark Quencher
9

(4 of 6)
1 RED 1 13 Pink to A-1
1 2 BLK 2 23 BLU (1 of 6)
Input Jam Sensor 3 YEL 3 2 Sky-BLU
1 YEL J08
(PS605) 1 RED 1 14 Pink 1 PH2
2 2 Sky-BLU
2 BLK 24 BLU
3 YEL 2 PH3
2 4 GRY 3 PH5
1 206 Purple 1 6 Purple 4 PH1
103 BRN 5 403 BRN 228 BLU 2 28 BLU 5 Sky-BLU 5 RSW1
104 BRN 2 404 BRN 5 Stacker limit sensor 2 217 Pink 3 17 Pink 6 Purple
2 3 6 PH4
105 YEL 6 405 YEL 6 Roller gap motor (PS701) 7 INP1
1 8 YEL
3 106 GRY 4 406 GRY 4 DC7.3V 0.5A 1 204 GRY
2
4 GRY
9 Purple 8 INDEX1
107 Sky-BLU 3 407 Sky-BLU 3 Knife initial sensor 2 216 BLU
226
Pink 3
26 BLU
16 Pink 10 YEL 9 PM-HOME1
108 Purple 1 408 Purple 1 3 10 PM-HOME2
10 YEL 7 (PS601) 11 Pink 11 +5V
31 BLU 8 (M603) 1 208 YEL 4 8 YEL 12 Pink 12 +5V
19 Pink 9 Knife Index sensor 230 BLU
2 218 5 30 BLU 13 Pink 13 +5V
4 210 YEL 1 Pink 6 18 Pink 14 Pink
231 BLU 2 Roller gap initial (PS602) 3 15 Pink 14 +5V
219 Pink 3 sensor 1 15 +5V
1 215 Pink
2
15 Pink 16 Pink 16 +5V
a (PS603) 2 203 BLU
225
3
25 BLU 17 Pink 17 +5V
5 3 136 YEL
ORN
3 YEL 18 Pink 18 +5V
4 137 BLU 19 Pink 19 +5V
Dust full sensor 5 20 Pink
21 BLU 20 +5V
(PS607) 21 GND
1 22 BLU 22 GND
2 23 BLU 23 GND
6 10 YEL 24 BLU 24 GND
31 BLU 25 BLU 25 GND
19 Pink 26 BLU 26 GND
27 BLU
a Move unit initial sensor 1 329 BLU
Purple
28 BLU 27 GND
2 20 Pink 28 GND
7 29 GND
(PS604) 3 30 BLU
31 BLU 30 GND
1 RED 1 12 Pink 31 GND
2 22 BLU 32 BLU
2 BLK 32 GND
Jog timing sensor
8 (PS606)
1 RED 1 211 Pink 1 11 Pink MC Unit
2 BLK 2 221 BLU 3 21 BLU (PCB601)
3 YEL 3 201 YEL 2 1 YEL
9 205 Sky-BLU 4 5 Sky-BLU to K-1

227 BLU 5 27 BLU (5 of 6)

(5 of 6)
to L-9
Stopper solenoid (4 of 6) J05
1 (SL601) 33 BRN 1 +24V
BRN 1 237 BRN 6 37 BRN 34 Sky-BLU 2 CL2
WHT 2 238 GRY 7 38 GRY 35 BRN 3 +24V
36 YEL 4 CL3
Carry clutch (CL601) 37 BRN 5 +24V
2 BLU 1 33 BRN 38 GRY
BLU 2 34 Sky-BLU 39 BRN 6 SOL1
24V,41Ω,1/1,0.585A 7 +24V
40 Sky-BLU 8 SOL2
Drive clutch (CL602) 41 BRN 9 +24V
BLU 1 35 BRN 42 Purple
BLU 2 36 YEL 10 CW-CCW-RL
3 24V,41Ω,1/1,0.585A 43 BRN 11 +24V
44 GRY 12 CO1
Hold solenoid (SL602) 45 BRN 13 +24V
BLK 1 39 BRN 46 YEL
24V,72Ω,1/1,0.333A BLK 2 40 Sky-BLU 47 BRN 14 FAN1
48 GRY 15 +24V
4
Total counter (CNT) 16 FAN2 MC Unit
BRN 1 43 BRN J06 (PCB601)
WHT 2 44 WHT 49 BRN 1 +24VA
24V,590Ω,41mA, 1.0W 50 Purple
51 BRN 2 CL1
Fan1 (FM601) 41 BRN 1 241 BRN to B-2,A-6 52 Sky-BLU 3 +24VA
5 RED 1 45 BRN 42 Purple 2 242 Purple (3 of 6) 4 BR1
24V,0.7A,16.8W BLK 2 46 YEL 53 BRN 3 253 BRN 53 BRN 5 +24VA
54 YEL 4 254 YEL 54 YEL 6 MOTPRL
(FM602) 55 BRN 5 255 BRN to C-9 55 BRN 7 +24VA
Fan2 RED 1 47 BRN (2 of 6) 56 GRY
56 GRY 6 256 GRY 8 BLTPRL
6 24V,0.7A,16.8W BLK 2 48 GRY 9
58 BRN 10 SOL3V
(CL/BRK) 59 Purple
BLK 1 49 BRN 11 SOL3
BLK 2 50 Purple 60 YEL J10
Knife clutch to L-5 1 DOOR1
24V,38Ω,0.63A,15W (2 of 6) 61 BLU
7 Cover SW R 62 Sky-BLU 3 GND
2
DOOR2
(Board side) 69 BLU 63 BLU 4 GND
BLK 1 51 BRN (SSW605)
BLK 2 52 Sky-BLU 5 DOOR3
Knife brake 6 GND
70 Sky-BLU
8 24V,25.6Ω,0.94A,22.5W Cover SW B 7 DOOR4
(Outfeed side) 71 BLU 8 GND
DBM-K (Option) (SSW606) 68 YEL 9 DOOR5
69 BLU
900 BLK 1 158 BRN 1 58 BRN 72 Purple
10
70 Sky-BLU 11 GND
DOOR6
Kicker 901 WHT 2 159 Purple 2 59 Purple Cover SW L 71 BLU
9 3 183 GRN (Non board side) 73 BLU 72 Purple 12 GND
Solenoid 3 (SSW604) 13 DOOR7 to A-9
(SL701) 4 73 BLU 14 GND (6 of 6)

(6 of 6)
to B-9 DPIF P.W.B Unit
(1 of 6)
1 J09 118 YEL J01 J03
1 DOUT+ 119 Purple DOUT+
1 1 DOUT+
2 DOUT- 120 Sky-BLU DOUT-
2 2 DOUT-
3 CLK+ 121 Purple CLK+
3 3 CLK+
4 CLK- CLK-
4 4 CLK- 138 ORN 1 438 ORN to H-8
5 DIN+ 22 GRY DIN+
5 5 DIN+ 139 BLU 2 439 BLU (1 of 6)
2 6 DIN- 123 Sky-BLU DIN-
6 6 DIN- to Up 74 YEL 3 274 YEL
7 +6V 124 ORN +6V7 7 +6V stream unit 76 GRY 4 276 GRY
8 GND 125 BLU GND8 8 GND 78 Sky-BLU 5 278 Sky-BLU
9 GND 126 BLU GND9 80 Purple 6 280 Purple
10 LD+ 127 YEL LD+
10 J04 82 GRY 7 282 GRY
3 1 DOUT+ 84 Purple 8 284 Purple
138 ORN J02 2 DOUT- 85 YEL 9 285 YEL
MC Unit 139 BLU 12 +6V 3 CLK+ to Down 86 Sky-BLU 10 286 Sky-BLU
(PCB601) GND 4 CLK- 87 BLU 11 287 BLU
5 DIN+ stream unit
4 J01 6 DIN-
1 SCL 128 Purple 7 +6V RL P.W.B.Unit
129 BLU 8 GND to K-8
2 GND 130 GRY (PCB605) (1 of 6)
3 SDA 131 BLU 274 YEL J04
4 GND 1 VEMG
5 5 OP UNIT (PCB602) 2
6 GND 276 GRY 3 V1
134 ORN J01 J03 LCD
7
8
+6.3V
GND 135 BLU 128 Purple 1 428 Purple 1 SCL 1 GND 278 Sky-BLU 45 VR
129 BLU 2 429 BLU 2 GND 2 +5V
6 J11 130 GRY 3 430 GRY 3 SDA 3 VO 280 Purple 67 V2
1 VEMG 74 YEL 131 BLU 4 431 BLU 4 GND 4 RS 8
134 ORN 5 434 ORN 128 Purple 1 282 GRY
2 76 GRY 135 BLU 6 435 BLU 5 +6.3V 5 R/W 129 BLU 2 9 VF
3 V1 6 GND 6 E 130 GRY 3 10
284 Purple 11
4 78 Sky-BLU 7 LD0 131 BLU 4 285 YEL VDR
7 5 VR 8 LD1 134 ORN 5 286 Sky-BLU 12 VP2C
6 80 Purple 9 LD2 135 BLU 6 287 BLU 13 VP1
7 V2 10 LD3 14 VP2F
8 82 GRY 11 LD4
9 VF 12 LD5 (PCB604)
8 10 84 Purple Ferrite core 13 LD6
11 VDR 85 YEL 14 LD7 to B-7
12 VP2C 86 Sky-BLU
x2 15 BL+ (2 of 6)
13 VP1 87 BLU 16
14 VP2F
9
to M-9
(5 of 6)

WD3.7 Schematic Diagrams of DBM-LS1
3 2.5 F 300V (120V)

1 F 430V (220-240V)
BLU BLK
4 TO DBM-500 (M701)
BLK (BLK) [BRN] 1 BLU BLU
WHT (WHT) [Sky-BLU] 2 BRN M 15W
5 Power Cord
GRN/YEL
RED YEL
6

WD3.7 Schematic Diagrams of DBM-LS1
WD3.8 Schematic Diagrams of SpineMaster (1 of 5)
1 PAYOUT FEED
742-499
760-339
HAMLIN SWITCH
BLU
WAL 09/02 Pre-1
PL3 PL1
BLK
2 PAYOUT FULL BYPASS
742-500 BLK SOLENOID
BLU
MICROSWITCH Purple
900-201
3
PL2
PL4
ORN
740-490
742-501
FEED MOTOR
WHT
RED
YEL
Purple
BLU
GLY
WHT
ORN
4
to A-2
GUARD REAR GUARD TOP (3 of 5)
5 MICROSWITCH MICROSWITCH PL6 PL1 PL18

GRN
GRN
742-491 + 742-492
PL9
To PL4
7 900-197 ASM CONTROL
PL2
PL17
8
BRN
PL12
BLK
LH LIMIT SNSR BLU
9 905-376
to C-2
(4 of 5)

WD3.8 Schematic Diagrams of SpineMaster
(2 of 5)
1 LOWER FLOW OPTO
2 905-162
BRN
WHT
BLU
BRN
LOWER
3 PL2
PL2
PL4
4
INFEED
PL3
900-198B YEL
PL1 UPPER WHT
CABLE TO SUIT MACHINE INTERFACE
5 BRN
BLK ATM OR TMP
BRN
RED BDF
Light GRN
740-494
6 GND
EARTH POINT
ON CASSETTE
to M-4 740-265
7 (1 of 5) PINK
Light GRN
RED
WHT
740-266
PL15
Purple
GRY
YEL
8 ORN EARTH POINT
Purple ON SIDE PANEL
GRN
900-197 ASM CONTROL BLU
Purple
9 to C-4
(3 of 5)

(3 of 5)
FROM
1 TRANSFORMER
ASSEMBLY
WHT
GRN
BLK
905-154
DRIVE MOTOR
PL2 PL3
DRIVE MOTOR
2 to M-4 Purple LED1
BIN POWER BUS

PL4 CONTROL PANEL
742-493
(1 of 5) ORN
ORN
ORN
WHT
WHT
PL20
ZEROX PCB
BLK
3
RED
WAL 900-141 REL.B 4/95

ECO VARIO INTERFACE PCB
PL1
PL5
4
900-197 ASM CONTROL
9V T3.15A
28V T6.3A
RED
900-141
BLK SK1
5
PL10
ORN SP1
Purple
F1 F2 F3
6
BRN
PL22
GRN
7 905-377
to J-2
(4 of 5)
8
9
CARRIAGE MOTOR

(4 of 5)
1
to G-9 900-197 ASM CONTROL to C-7
(1 of 5) (3 of 5)
2 PL14 PL21 PL13 PL19 PL5 PL11
BLU
BLK
BRN
GRN
WHT
BRN
BLK
BLU
RED
WHT
Light GRN
Purple
YEL
Sky BLU
RED
BLK
BRN
BLK
BLU
3
905-376
742-487
905-376
742-489
4
RH LIMIT SNSR
742-495
5
CLAMP OPTO
905-287 CLUTCH YEL START/RESET
BLK
6 760-342
BLU
BYPASS
MAGNET BLK
RED DOUBLE CYCLE

905-251 BLK
7
CLAMP OPEN SNSR
8
FRONT PANEL SWITCHES

(5 of 5)
to M-2
PL1 (3 of 5)
1 PCB 900-141 SK1
Purple
2
ORN
ORN
WHT
WHT
Purple
BRN
SP1
to I-5
(3 of 5)
3 GRN/YEL
4
Purple
Transformer GRN/YEL
Transformer Input PCB 905-351
GRN/YEL Motor
Assembly 905-354
5 Sky BLU Sky BLU
905-154 SK3 BRN
Purple
6
710-058
GRN/YEL GRN/YEL
Fan 710-057
Sky BLU
7
Plug
with Fuse (250V/10A)
8 BRN BRN
BLU BLU
NF GRN/YEL GRN/YEL
9 720-019
640-076

Section 8
Installation
Contents
Section 8 Installation ....................................................8-1
Taking an Overview .................................................8-2
Unpacking of the Machines .................................... 8-3
Checking Accessories ...........................................8-13
Installing SCC ........................................................8-27
Installing TR-DP ................................................... 8-37
Connecting to Printing System ............................. 8-38
Installing the PC Unit ............................................ 8-42
Installing the Interface Box ................................... 8-44
Installing DBM-500 ............................................... 8-46
Installing DBM-500BR ......................................... 8-61
Installing DBM-500T ............................................ 8-65
Installing DBM-LS1................................................8-75
Installing DBM-K ...................................................8-76
Installing DCM Kit ..................................................8-77
Installing SpineMaster ...........................................8-79
Connecting Cables ............................................... 8-86
Checking Software ............................................... 8-88
Setting Control panels .......................................... 8-96
Installing and Upgrading the Inline Controller .....8-101
Setting Power-related Switches ..........................8-106
Profile Installation on iGen3 System ...................8-107
iGen3 Finisher Profile Settings ............................8-108
8-1
iGen3-M12D0-0612-0
Taking an Overview ● Installing SpineMaster
Note: When using SpineMaster, you cannot use DBM-LS1 and DBM-K in the
system.
Section 8, Installation, describes how to make available the booklet making SpineMaster
system. You must follow all these procedures: DBM-500T
● Unpacking of the machines DBM-500BR

DBM-500
● Checking accessories
SCC
● Installing SCC DCM Kit
● Mounting TR-DP TR-DP
● Installing the Interface Box

● Installing DBM-500
● Installing DBM-500T Interface Box
● Installing DBM-LS1
● Installing DBM-K Iline Controller*
● Installing the DCM Kit

● Installing the Inline Controller
*The computer is not included
Note: No computer is included in the accessories. To use the Inline Controller, in the accessories.
you must prepare a computer. For requirements, see the Inline Controller
Instruction Manual. ● PC stand (Arm type)
DBM-LS1 Note: No PC stand is included in the accessories.
DBM-K
DBM-500T
DBM-500BR
DBM-500
SCC
DCM Kit
TR-DP
● PC stand (Stand-alone type)

Note: No PC stand is included in the accessories.
Interface Box
Inline Controller*
*The computer is not included

in the accessories.
8-2 Section 8—Installation

Taking an Overview
Unpacking of the Machines 4. Remove the sixteen screws and remove the four brackets.
Unpacking of SCC
1. Remove the ten screws and the ten washers, which fix the carton box to
the wood base.
Carton Box
Wood
Screw
Screw
Bracket
Screw
5. Unload SCC from the wood base by using a forklift truck.

Screw
Wood Base Note: Make sure to insert the forks from the opposite side of the cabinet, or the
Washer
cabinet may bump against the forklift if it opens in the middle of unloading..
Forklift Truck
2. Remove the carton box. SCC
(Cabinet Side)
Wood Base
Carton Box
3. Remove the cover.

6. Confirm that the cabinet contains the package of accessories.
Cover
Accessories
Cabinet

Unpacking of the Machines
Unpacking of TR-DP 4. Remove the cardboard box.
1. Remove the packing bands. Cardboard box
Packing band
Duplo
TR-DP
Dup
lo
TR-D
P
5. Open the plastic bag and take out the TR-DP.

2. Remove the lid and brace. TR-DP
Brace
Lid
Dup
Plastic bag
lo
TR-D
P
3. Remove the brace and protections.

Brace Protection
Protection
Dup
lo
TR-D
P

Unpacking of Interface Box
1. Open the cardboard box.
2. Take out the cushion.
3. Open the plastic bag and take out the Interface Box.
Plastic bag
Cushion
I/
F-
B
O
X
Interface Box
Cardboard box

Unpacking of DBM-500 4. Remove the sixteen screws and remove the four brackets.
1. Remove the twelve wood screws and the twelve washers, which fix the
carton box to the wood base.
Carton Box
Wood Screw
Screw
Wood Screw
Washer
5. Unload DBM-500 from the wood base by using a forklift truck.
DBM-500
2. Remove the carton box.

Forklift Truck
Wood Base
Carton Box
3. Remove the cover.

Cover

Unpacking of DBM-500BR 4. Remove the protections.
1. Remove the packing bands.
Packing band
protection
protection
Du
DB plo
M-5
00B
R
2. Remove the lid and braces. 5. Open the plastic bag and take out the DBM-500BR.
Lid DBM-500BR
Brace
Brace
Du
DB plo
M-5
00B
R
Plastic bag
3. Remove the cardboard box.
Cardboard box
Dup
lo
DBM
-500
BR

Unpacking of DBM-500T 4. Remove the ten screws and the two brackets..
1. Remove the ten wood screws and the ten washers, which fix the carton Front Side Rear Side
box to the wood base. Bracket Bracket
Wood Screw
Carton Box
Screw Screw
5. Slide DBM-500T to the rear until the surfaces of the Rear Panel and the
Screw wood block approximately align.
Washer
2. Remove the carton box.
Carton Box
3. Remove the tapes and the cover.

Tape Cover
DBM-500T
Wood Block

6. Remove the six screws and remove the wood block on the handle side.
Handle
Screw
Screw
Screw
Wood Block
7. Unload DBM-500T from the wood base by using a forklift truck.

Note: Support DBM-500T by your hands while unloading.
Handle
DBM-500T
Wood Base

Unpacking of DBM-LS1 3. Remove the protection.
1. Open the cardboard box and remove the braces. 4. Open the plastic bag and take out the DBM-LS1.
Protection
Brace
Plastic bag
Brace
Cardboard box
DBM-LS1
2. Take out the Accessories Box and Base.
Accessories box
Base

Unpacking of DBM-K
2. Take out the manuals.
Manuals
-K
M
B
D
Du
pl
o
D
B
M
-K
Cardboard box
3. Open the inner lid.

4. Open the plastic bag and take out the DBM-K.
Plastic bag
DBM-K
Inner lid
Inner lid

Unpacking of the PC Unit(Touch Screen Computer)
2. Take out the cable accessories and the PC Unit.
Note:The PC Unit is packed according to below.
Do not discard any of the packaging. It may be used again in the event
the PC Unit needs to be replaced.

Checking Accessories Item Name Qty. Remarks
1 Connecting plate R 1
2 Connecting plate L 1
3 Paper ejection guide 1
Checking the Accessories for SCC 4 Level adjuster 4
5 Plate 4
Some accessories may not be necessary for your system. 6 Spanner 1
1 2 3 4 5
7 Oiler 1
8 Case 1
9 D-port cable 1
10 E-port cable 1 Except north America
11 Power cord (for 220 to 240 V) 1 Not enclosed for 120V
12 Power cord (for 120 V) 1
6 7 8 9 10
13 Screw (MSKW 5 x 10) 4
14 Screw (HSKW 6 x 16) 4
15 Angle F 1 Not used.
16 Angle B 1 Not used.
17 Angle (for DSF-2000) 1 Not used.
18 ROM (for DSF-2000) 1 Not used. (99T-86***)
11 12 13 14 15 19 ROM (for DBM-500) 1 (12J-86***)
20 ROM (for DBM-500T) 1 (12K-86***)
21 Label (99S-93530) 1 Not enclosed for 120V.
22 Label (99W-91930) 1 Not enclosed for 120V.
23 Label (12C-90230) 2 Not enclosed for 120V.
24 Label (99S-93490) 1 Not enclosed for 120V.
16 17 18 19 20 25 Instruction manual 1
26 Instruction manual 1 Not enclosed for 120V.
27 Installation manual 1 Not used. (Refer to this manual.)
28 CD ROM 1 Not used.
21 23 25 26
29 Serial cable 1 Not used
27
30 Supplementary Information 1 Not used
31 Warranty card 1 Not enclosed for 220 to 240 V
22 24
28 29 30 31
Supplementary Information for Near-Line
PC Controller Version 1.0.0 (99T-80441)
Near-Line PC Controller version 2.0.0 (99T-80442) or later does not support
the file format used by Near-Line PC Controller version 1.0.0 (99T-80441).
If you want to use the file created by Near-Line PC Controller version 1.0.0
(99T-80441) after upgrading the software to the version 2.0.0 (99T-80442) or
later, ask your dealer to convert the old file format into a new format.
You can check the version you are using in the following way.
1 Start the Near-Line PC Controller on Windows.
2 On the Maintenance menu,
click About.
The version will appear on the

screen. Version
99T-91611-06050010D-0

Checking Accessories
Checking the Accessories for TR-DP Item Name Qty. Remarks
1 Vertical Bracket 2
Some accessories may not be necessary for your system. 2 Upper Horizontal Bracket 1
1 2 3 4 5 6 3 Lower Horizontal Bracket 1
4 Power Cord Cover 1
5 Port Cable Cover 2 1
6 Port Cable Cover 1 1
7 Knob Screw 2
8 Connector cover 1 used for DBM-500T
9 D-port Cable (gray) 1 (L = 2000 mm)
10 IF Cable unit (light blue) 1 (L = 1000 mm)
7 8 9 10 11
11 Air-pipe unit 1 used for SCC
12 Earth wire (long) 2 (L = 700 mm)
13 Earth wire (middle) 1 (L = 280 mm)
14 Earth wire (short) 1 (L = 150 mm)
15 Connecting base 1
12 13 14 15 16 16 Manual paper feeding tray 1
17 CD 1 DUPLO Inline Controller (Software)
18 Guide T 1 used for SCC
19 Guide D 1 used for SCC
20 Instruction manual 1 DUPLO Inline Controller (Software)
17 18
21 ROM (when using the Rotator) 1 Used for Interface Box
19 20
22 ROM (when not using the Rotator) 1 Used for Interface Box
23 Timing pulley 1 Used for DBM-500
24 Timing belt 1 Used for DBM-500
25 Cable clamp (small) 2 (056-09004)
26 Cable clamp (large) 2 (056-09005)
21 22 23 24 25 26
27 Name plate 1
31 Screw (MSK 4 x 16) 1
27 28 29 30 31 32 33 PC cable unit 1
34 Power Cord 1 Not enclosed for 120V
35 Power Cord 1
33 34 35

The accessories for TR-DP includes the spare parts for five other products The Spare Parts for DBM-500T
as well as ones for TR-DP itself. Item PART # Name Qty. Remarks
For details, refer to the following six tables. 1 014-10279 V-BELT (BANDO A-26) 1
2 014-00263 BELT (BANDO 150XL037G) 1
The Spare Parts for DBM-500 3 014-00136 BELT (BANDO 120XL037G) 1
Item PART # Name Qty. Remarks 4 014-10620 STS BELT(BANDO 100S3M192S) 1
1 014-10503 BELT (BANDO 2-5MS615) 1 5 014-10523 BELT (BANDO 564XL037G) 1
2 014-10526 BELT (BANDO 254XL050U) 1 6 014-10309 BELT (BANDO 390XL037G) 1
3 014-10506 STS BELT 1 7 99W-20141 UPPER BLADE 1
4 014-00235 BELT (BANDO 120XL037L) 2 8 99W-20351 LOWER BLADE 1
5 11G-82602 FEED CLUTCH-C 1 9 12K-40330 FLAT BELT 3
6 12J-19062 BOSS UNIT 2 10 12K-41760 FLAT BELT 3
7 12J-40030 BELT 1 11 057-10054 SWITCHING POWER SUPPLY 1
8 057-10053 SWITCHING POWER SUPPLY 1 12 12K-86103 MC UNIT 1
9 11A-80253 RL P.W.B UNIT 2 13 99J-80159 OP UNIT 1
10 11A-81390 ISOLATION BOARD 1 14 95K-80063 PH P.W.B UNIT 1
11 12J-82160 MOTOR DRIVER 1 For 120V 15 95K-80083 LED P.W.B UNIT 1
12 12J-82140 MOTOR DRIVER 1 For 220-240V 16 12K-82020 D PORT CABLE 1
13 12J-86105 MC UNIT 1 17 014-10429 STS BELT 1
14 12J-85301 OPER ATION TERMINAL 1 18 12K-80360 CLUTCH UNIT 1
15 12J-80112 KEY P.W.B.UNIT 1 19 11C-84100 INTERLOCK SWITCH 1
16 12J-80211 DPIF P.W.B.UNIT 2
17 98R-80230 INT.SENSOR 4
The Spare Parts for SCC
19 062-11162 INT.SENSOR 1 Item PART # Name Qty. Remarks
20 11C-83232 D PORT CABLE 1 1 12C-12050 FLAT BELT 1
21 11C-83390 E PORT CABLE 1 2 11C-81061 ELECTROMAGNETIC CLUTCH 1
22 12J-83182 WIRE HARNESS-18 1 3 8D3-31210 SLIT TER, LOWER 1
23 12J-10211 SCREW 1 4 8D3-31110 SLIT TER, UPPER 1
24 99W-30111 SCREW 1 5 12C-28092 CUT TER GUIDE PLATE UNIT 1
25 12J-11071 SCREW-R 1 6 12C-33640 FLAT BELT 4
26 12J-11081 SCREW-L 1 7 12C-80039 MC UNIT 1
27 11J-53040 ROLLER G-32-40 4 8 12C-81031 SERVO DRIVER 1
28 11S-83100 DC BRUSHLESS SERVO MOTOR 1 9 96Y-80072 PR P.W.B. UNIT 1
29 12J-40161 SHAF T 1 10 97J-80131 LED P.W.B. UNIT 1
11 99J-80159 OP UNIT 1
12 062-11006 INT.SENSOR 2
13 062-11095 INT.SENSOR 2
14 8N4-X1031 CCD SENSOR 1
15 12C-24531 NUT R 1
16 12C-24541 NUT L 1

The Spare Parts for TR-DP The Spare Parts for SpineMaster
Item PART # Name Qty. Remarks Item PART # Name QTY PK SIZE
1 12C-80251 MC UNIT 1 1 12C-91510 180-323 SPRING,(VFCN) TR AY PRESSURE 2 1
SLIDE
2 11C-80136 RM UNIT 1
2 12C-91520 330-301 RUBBER MOULDING, FEED WHEEL 1 10
3 11C-83902 D-PORT CABLE 1 (WHITE)
4 11C-83232 D PORT CABLE 1 3 12C-91530 730-010 FUSE, 20mm, 3.15A,GLASS- ANTI 1 10
5 057-10061 SWITCHING POWER SUPPLY 1 SURGE,T
6 062-11006 INT.SENSOR 1 4 12C-91540 730-020 FUSE, 1.25 10.0A HRC-QUICK ACTING 1 10
7 062-11095 INT.SENSOR 1 F”
8 93E-83150 MAGNET SENSOR 1 5 12C-91550 730-031 FUSE, 20mm, 6.3A,GLASS- ANTI 1 10
SURGE,T
6 12C-91560 700-402 SWITCH, LEVER ARM - HAMLIN 1 1
The Spare Parts for Interface Box 7 12C-91570 742-480 CABLE ASSEMBLY, ASM I/FACE ATM 1 1
& TMP
Item PART # Name Qty. Remarks 8 12C-91580 900-141 PCB ASSEMBLY, ECO VARIO, 1 1
1 12S-80036 IF UNIT 1 INTERFACE
2 057-10047 SWITCHING POWER SUPPLY 1 9 12C-91590 914-493 BELT, (ASM) MAT-02H-25-382 LONG 2 1
3 11C-83902 D-PORT CABLE 1 10 12C-91600 914-494 BELT, (ASM) MAT 02H x 25 x 1925 LONG 2 1
The Spare Parts for DCM Kit

Item PART # Name Qty. Remarks
1 99T-80282 RM UNIT 1 For 120V
2 11C-80136 RM UNIT For 220-240V
4 99T-86100 I/F UNIT 1/2 1
5 99T-81050 POWER SUPPLY HIGH VOLTAGE 1
6 99T-81061 BAR SM, STATIC ACTIVE 1
7 99T-83191 WIRE UNIT 5 1
8 99T-83173 CONNECTING CABLE 1
9 053-90034 RELAY 1

Checking the Accessories for Interface Box Item Name Qty. Remarks
1 Interface box 1
Some accessories may not be necessary for your system. 2 Power cord 1
3
1 2 3 Power cord 1 Not enclosed for 120V
4 Instruction manual 1
4 5

Checking the Accessories for DBM-500 (1/2) Item Name Qty. Remarks
1 E-port cable 1 Except north America
Some accessories may not be necessary for your system. 2 D-port cable 1
1 2 3 4
3 Harness 1 Not used.
4 Wire reel mount 2
5 Safety cover A 1
6 Plate 4
7 Spanner 1
5 6 7 8 9 8 Handle 1
9 Level adjuster 4
10 Needle-nose pliers 1
11 Lubricator 1
14
12 Stacker plate 1
10 11 12 13
13 Square rod 1
14 Paper guide 1 Not used
15 Paper guide wheel 1
16 Paper guide wheel (For small size) 1
17 Connecting plate A 1
15 16 17 18 19 20
18 Connecting plate B 1
19 Guard plate F 1 Not used.
20 Guard plate B 1 Not used.
21 Bracket 1 Not used.
22 Scale plate 1
21 22 23 24 25 26 27
23 Case 1
24 Adjusting handle 1
25 Star-shaped wrench (Large) 1
26 Star-shaped wrench (Small) 1
27 Hexagonal wrench—T-shaped 1
Note: Wire reels (see Installing Stitchers) are not included in the accessories.
You must prepare appropriate wire reels.

Checking the Accessories for DBM-500 (2/2) Item Name Qty. Remarks
28 Stitcher head instruction manual 1
Some accessories may not be necessary for your system. 29 Screw (HSKW 6 x 16) 2
28 29 30 31 32 33 34 35
(CD)
33 SK binder 6
41
36 37 38 39 40
36 Name plate 1 Not used.
37 Air pipe unit 1
38 Paper guide 1
42 43 44 46 47
39 Paper guide with film 1
45
40 Screw (FR 3 x 4) 1
41 Label (for 220-240 V) 1 Not enclosed for 120V
43 Safety cover B 1
44 Angle 2
45 Upper wire tube 2
48 49 50 51 52 53
46 Wire feed detection 2
47 Ejection roller unit 1
48 Belt guide L 2
49 Belt guide S 2
50 Belt guide M 2
54 55
51 Filmed guide R 1
52 Filmed guide L 1
53 Sponge roller unit 1 Not enclosed for 220 to 240 V
55 Instruction manual 1 Not enclosed for 120V

Checking the Accessories for DBM-500BR Name Qty. Remarks
1 2 3 4 1 Bridge 1
2 Paper Receive 1
3 Fixing Angle F 1
4 Fixing Angle B 1
5 Bracket 1
6 Belt 1
7 Connecting Plate 1
8 Angle 1
9 Deflector Strip 1
10 Protection Guide 1
5 6 7 8
11 Bracket 1
12 Gear 1
13 Pin 1
14 E-Ring (S) 1
15 E-Ring (L) 1
16 Collar 1
17 Screw MSKW4x8 8
9 10 11 12 13 18 Screw SBT4x8 2
19 Screw HSK5x10 6
20 Side stitching stopper 1
21 Sticker 1
22 Sticker 1
23 Sticker 1
24 Instruction Manual 1
14 15 16 17 18 19
20 25 Installation Manual 1
21 22 23 24 25
INSTALLATION MANUAL

Checking the Accessories for DBM-500T Name Qty. Remarks
1 Connecting plate B 1 Used when not connecting the
Some accessories may not be necessary for your system. machine to the SpineMaster.
1 2 3 4 5 2 Connecting plate C 1 Used when not connecting the
machine to the SpineMaster.
3 Plate 4
4 Joint 1
5 Screw shaft unit 1
6 7 8 9 10 11 6 Cover unit 1
7 Angle 1 1
8 Angle 2 1
9 Bracket unit 1
10 Out-feed guide 2
12 13 14 15 16 17 18 19 20 21 11 E-port cable 1 Except north America
12 D-port cable 1
13 Name plate 1 Not used.
22 23
14 Knob screw 4
15 Screw (HS 6 x 100) 2
16 Screw (HS 6 x 25) + nut (N6) 1
17 Screw (MSK 5 x 8) 2
19 Screw (MS 3 x 18) 1
24 25 26 27 28 29 30
20 Screw (CFR 5 x 20) 2
27 Level adjuster 4
28 Spine split prevent 1
29 Screw (CFR 5 x 10) 2

Checking the Accessories for DBM-LS1 Name Qty. Remarks
1 Long stacker 1
Some accessories may not be necessary for your system. 2 Foot A 2
1 2 3
3 Foot B 2
4 Base plate 1
5 Screw (SBK 5 x 10) 12
4 5 6

Checking the Accessories for DBM-K Name Qty. Remarks
1 Kicker 1
Some accessories may not be necessary for your system. 2 Auxiliary plate 1
1 2 3
3 Guide for small paper 1
4 Stopper 1
7 Installation Manual 1 Not used. (Refer to this manual.)
4 5 6 7

Checking the Accessories for DCM Kit Name Qty. Remarks
1 DCM kit main unit 1
Some accessories may not be necessary for your system. 2 Static eliminator 1
1 2 3 3 DSF-2000 guide plate 1 Not used.
4 DBM-120 Sheet by Sheet air-pipe unit 1 Not used.
5 Power cord (for 220 to 240 V) 1 Not enclosed for 120V
6 Power cord (for 120 V) 1
7 Connecting cable 1
8 Cable clamp 2
9 Bushing 1
10 Cable cover unit 1
11 Screw (MSKW 4 ×8) 4
4 5 6 7 12 Screw (MSK 3 ×6) 2
8 9 10 11 12
13 14

Checking the Accessories for SpineMaster Name Qty. Remarks
1 2 3 4
1 Bracket unit 2
2 Cover 2
3 Connecting bracket 2
4 Connecting bracket 1 unit 2
5 Shaft 1
6 Set-collar 2
7 Spargear 2
8 Key 6×6 2
5 6 7 8 9 Rack 1 1 Wide
10 Rack 2 1 Narrow
11 Spacer 1
12 Level adjuster 4
13 Plate 4
14 Protect cover 1
15 Label (for 120V, for 220-240V) 1
9 10 11 12 13 16 Label (for 100V) 1 Not used.
17 Label (for 220-240V) 1 Not used.
18 Connecting cable-20 1
19 Fuse unit 1
20 Screw (HSKW 6 ×12) 2
21 Screw (HSKW 6 ×16) 10
22 Screw (HSKW 6 ×20) 2
14 15 16 17
23 Screw (MSKW 4 ×8) 6
18 19 20 21 22
23

Checking the PC Unit package contents Name Qty. Remarks
1 2 3 1 PT-5500 1 Pre-Loaded with Windows XP
2 Power cable 1
3 Adapter 1
4 CD ROM 3 Windows XP Pro POS Terminal
Touch Kit, drivers, and user manual
PDF
5 MSR(Optional) 1 Not enclosed
6 Customer Display (Optional) 1 Not enclosed
7 User Manual 1
8 Warranty Card 1
9 Keyboard 1
4 5 6
7 8 9
��
��

Installing SCC Repositioning the Control Panel
To remove the Control Panel and mount it to the opposite side, follow these
steps:
Setting the Relay Board Switches 1. Remove the exterior cover on the rear side.
Exterior cover
If you use the machine in the North America, set the relay board switches
to non BG.
1. Remove the exterior cover on the front side.
Exterior cover
2. To remove the Control Panel, disconnect the connector and remove the
cable clamp.
3. Remove the four screws on the Bracket. Remove the Control Panel with
2. Set the switches on the Relay Board as follows: the Bracket.
Cable clamp Connector Control panel Bracket
SW No. BG non BG (For north America)
SW1 ON ON
SW2 OFF ON
Paper feed
<Relay board setting>

ON ON
SW1:ON
SW2:OFF
OFF OFF
SW1 SW2
Relay board

Installing SCC
4. Go to the opposite side of the machine. Remove the Cover. Repositioning the Emergency-stop Switch
5. Mount the Control Panel with the Bracket. 1. Disconnect the connector. Remove the lock by pulling it in the direction
6. Connect the connector. of A.
7. Fasten the cable with the cable clamp. 2. Turn the lever in the direction of B.
Cover Connector Cable clamp Control panel 3. Remove the lower half by pulling it in the direction of C.
4. Turn the ring until you can remove the upper half.
Emergency stop switch
Connector
Upper half
B
Ring
Lower half
8. Go to the opposite side of the machine. Attach the Cover. Lock

C
Cover Lever
5. Go to the opposite side of the machine. Remove the cover. Disconnect

the jumper connector.
Jumper connector Cover

Installing SCC
6. See the bottom of the upper half. Make sure that the TOP signs are in Repositioning the Scrap Box
the same direction. Attach the upper half to the machine, and fasten it
with the ring. You can reposition the Scrap Box of SCC to the opposite side. The user can
dispose of paper scraps by drawing the scrap box from the front side of
Upper half SCC.
Note: You cannot reposition the scrap box of DBM-500T. The user has to dispose
of paper scraps from the rear of DBM-500T.
First, reposition rollers and stoppers by following these steps:

1. Draw the Scrap Box out of the machine.
2. Remove the two Stoppers and four Rollers.
Roller
7. Connect the lower half to the upper half. The lever on the lower half
must be in the same direction as the TOP signs (see step 6). Fasten the
lock.
8. Connect the connector.
Stopper
Scrap box Roller

Connector
3. Go to the opposite side of the machine. Remove the two Rail Stoppers.
9. Go to the opposite side of the machine. Attach the cover and the jumper
connector.
Cover
Jumper connector
Rail stopper

Installing SCC
4. Attach the two Stoppers and four Rollers. Secondly, reposition the D box sensor and its actuator by following these
5. Go to the opposite side of the machine. Attach the Rail Stoppers. steps:
Roller 1. Remove the Fixing Plates on the upstream side and the downstream
side. Retain the screws. You are going to use the screws (see Mounting
Accessories).
Note: Actually, you do not have to remove the fixing plate on the upstream side
for now. But, sooner or later, you have to remove this plate.
Stopper
Roller
Rail stopper
Roller
Fixing plate
Fixing plate
2. Remove the Side Cover on the downstream side.

3. Remove the D Box position sensor with the bracket.
4. Turn the sensor and bracket upside down (180 degrees), and attach
them.
Note: Do not attach the exterior cover yet. You are going to adjust the position of
the sensor.
D box position sensor
Side Cover

Installing SCC
5. Remove the actuator from the Scrap Box and attach it to the opposite Thirdly, replace the exterior covers and check the actuator and sensor by
side of the box. following these steps:
1. Remove the center part of the exterior cover and attach it to the other
Actuator exterior cover.
Exterior cover
Scrap box
Center part
2. To check the actuator and the sensor, set the scrap box in the machine.
● If they do not engage correctly, adjust the positions of the actuator and/
or sensor.
Top view
Actuator Scrap box
Lever
Scrap box
D box position sensor

Installing SCC
Mounting the Air-pipe unit on SCC 4. Pass the Air-pipe Unit inward through the round hole of the Frame.
1. Raise the upstream and downstream Bypass. 5. Pass the Air-pipe Unit through the round hole of the Side Cover.
2. Screw the Air-pipe Unit supplied with the TR-DP to the machine using Air-pipe unit
cable clamps as shown in the figure below.

3. Pass the Air-pipe Unit through the square hole in the direction of the
arrow as shown in the figure below.
Screw Screw
(MSKW 4 x 8 ) Screw (MSKW 4 x 8 )
Screw (MSKW 4 x 8 )
Side Cover
Air-pipe unit (to the DCM Kit)
6. Remove the cable clamps securing the harness.

7. Attach the Air-pipe Unit to the frame together with the harness using
the cable clamps supplied with the TR-DP.
Cable clamp(small) Air-pipe unit
Downstream Bypass Upstream Bypass

Exterior cover
Screw
Screw
Cable clamp (large)
8. Attach the Side Cover.

Note: You are going to connect this pipe to the DCM Kit (see Installing the DCM
Kit).

Installing SCC
Attaching the Case for TAG Sheets
1. Take out the manuals from the case supplied with your booklet-making
system and attach the case to the back of the exterior cover front side.
Exterior cover
Approx. 10cm
(4 inch)
Case
2. Attach the exterior cover on the front side.

3. Attach the exterior cover on the rear side.

Installing SCC
Mounting Accessories 3. Remove the two screws on the downstream side, below the paper exit.
1. Mount the four Level Adjusters. Use the screw you have removed (see Each of these screws is the closest to the front cover and the rear cover
Repositioning the Scrap Box). respectively. By using these screws, mount the Brackets.
Viewed from downstream
Note: If you have left one of the fixing plates attached (see Repositioning the
Screw Screw Bracket
Scrap Box), remove it.
Level adjuster Level adjuster
2. Remove the Brackets from the Guide. Retain the screws and collars to
use them afterward (see Mounting the DCM Kit Accessory on SCC). In
this section, you are going to use the Brackets only.
Bracket
Bracket

Installing SCC
Mounting the DCM Kit Accessory on SCC
Mount the Static-electricity Eliminator on the Brackets. Use the screws and
collars you have removed (see Mounting Accessories).
Static Eliminator

Installing SCC
Mounting the TR-DP Accessory on SCC 2. Remove the two screws securing the Roller Unit to the machine, and
1. Remove the two screws from the machine and attach the Guide D attach the Guide T to the machine together with the Roller Unit using
supplied with the TR-DP to the machine using the screws. the screws.
Guide D
Guide T Roller unit
Screw
Screw

Installing SCC
Installing TR-DP 3. Attach the Manual Paper Feeding Tray to the TR-DP.
Screw
Screw
Mounting TR-DP
CAUTION
When mounting TR-DP, make sure the upper side and lower side engage TR-DP
with the Upper Horizontal Bracket and Lower Horizontal Brackets (see step
4). If they do not engage, TR-DP falls off. Manual paper feeding tray
1. Remove the screws on the downstream machine. Using them, mount the
Vertical Brackets. Do not tighten the screws too much. You are going to 4. Mount TR-DP between the Upper Horizontal Bracket and the Lower
adjust the positions of the brackets (see step 3). Horizontal Brackets. Make sure the upper side and lower side engage
with these two brackets.
2. Mount the Upper Horizontal Bracket and Lower Horizontal Bracket
on the Vertical Brackets. The Upper Horizontal Bracket has two screw 5. Tighten the knob screws on the top of the Upper Horizontal Bracket.
holes on top. Knob screw
3. Check that the four brackets are all in place. Tighten the screws on the
Vertical Brackets (see step 1).
Vertical bracket
Upper
horizontal bracket
Screw (MSKW 4 x 8) TR-DP
Horizontal bracket
Screw (MSKW 4 x 8)
Screw (MSKW 4 x 8)
Lower
horizontal bracket
Screw (MSKW 4 x 8)
Horizontal bracket

Installing TR-DP
Connecting to Printing System 4. Make the hook catch the mechanical interface of the printing system.
Hook
1. Mount the Connecting base to SCC.

Sign Shaft
Shaft
Bracket(iGen 3)
5. Tighten the nut of the hook.
Screw(HSKW 6 x 16) Nut
Hook Shaft
Screw(HSKW 6 x 16)
Bracket(iGen 3)
Connecting base
2. Move SCC closer to the Printing System. 6. Match the cutout of the printing system with the position mark of the
TR-DP.
3. Loosen the six screws of the Connecting Base. Cutout
Sign
TR-DP
Connecting base
Screw
Printer(iGen 3)

Installing TR-DP
7. Attach the Level Adjuster to the SCC and adjust the height of the SCC.
TR-DP
Plate
Level Adjuster
Printer(iGen 3)
8. Tighten the six screws of the Connecting Base.
Connecting base
Screw
Note: When the printing system and SCC 20mm

are connected correctly, there is a clearance
Printing System TR-DP
gap of 20 mm between the printing system
and TR-DP.

Installing TR-DP
Height Adjustment of Paper Path 3. Loosen the four screws on the Feed Roller Unit. Adjust the position of
1. Check that the paper feed inlet of the TR-DP and the delivery outlet of the Feed Roller Unit.
the Printing System are vertically aligned on the same level.
● If they are aligned, skip this section, Height Adjustment of Paper Path,
and go to the next section, Connecting Cables.
● If they are not aligned, go on to step 2.
Printing System TR-DP
Feed Roller Unit
Paper
2. Remove the exterior covers.

Exterior cover
Note: The paper exit of the upstream machine is designed to be approximately

860 mm high above the ground. However, this value should be used as a rough
guide and you can determine the right position of the paper entrance only by fine
adjusting it to the upstream machine installed actually.
Exterior cover

Installing TR-DP
4. If you cannot move the Feed Roller Unit because of the Idle Roller Unit, Connecting Cables
remove the Idle Roller Unit. And mount the Idle Roller Unit below the 1. Mount the Power Cord Cover.
Feed Roller Unit.
2. Mount Cable Cover 1. Cable Cover 1 has two openings. Do not mount
Cable Cover 2 yet.
Note: You are going to mount cable cover 1 after connecting D-port Cables (see
Connecting Cables).
Feed roller unit
Idle roller unit
Power cord cover

Screw(MSKW 4 x 8)
Cable cover 1
Feed roller unit
Screw(MSKW 4 x 8)
3. Remove the screw securing the cover to the TR-DP, and attach the one
end of the Earth Wire (L = 150 mm) to the TR-DP together with the
cover using the screw.
4. Remove the screw securing the cover to the SCC and attach the other
end of the Earth Wire (L = 150 mm) to the SCC together with the cover
using the screw.
Earth wire (L=150)
Idle roller unit

SCC
Screw
TR-DP
MC unit
5. Make sure both sides of the Feed Roller Unit are at the same height. Screw
Tighten the four screws on the Feed Roller Unit.

6. Replace the Exterior Covers.

Installing TR-DP
Installing the PC Unit 3. Open the rear cover latches.
4. Remove the rear cover.
1. Place the PC unit and the Key Board on the PC Stand/Arm.
5. Connect the Keyboard to the USB connector on the PC unit.

6. Connect the PC cable unit to the COM1 connector on the PC unit.
7. Connect the power cable and AC adapter to the power connector on the
PC unit.
2. Rotate the display until it’s perpendicular.
Rear connectors
PC CABLE UNIT POWER CABLE

KEYBOARD
(Com 1 connector) AC ADAPTER
(USB connector)
(Power connector)

Installing the Interface Box
8. Connect the other end of PC cable unit to the Interface Box.
Interface Box
9. Put the rear cover back.

10. Close the rear cover latches.
11. Connect the AC adapter to an electrical outlet.

Installing the Interface Box Connecting the Interface Box
1. Connect the interface box, personal computer and iGen3 system as
shown below.
iGen 3 / Interface Box
Updating the Program of the Interface Box
1. Turn off the Main Power Switch, and remove the cover. to iGen 3
PC cable unit
2. Attach the EPROM to U07 on the Interface Unit. Make sure the half- to iGen 3
��
disc marks on the EPROM and socket are in the same direction. ��
Types of EPROM
When using the Rotator, use 12S-80150X. Note: X= 0 to 9
When not using the Rotator, use 12S-80140X. RS-232C
PC
3. Turn ON dip switch 1 (DSW1). Interface Box
4. Turn on the Main Power Switch, and start updating. The machine
makes alarm tones while updating.
● When the Interface Box is correctly executing the update, the tone goes
“beep, p, p, p,….” Wait until the tone ends. PC cable unit Power cord
● When an error has occurred, the tone goes “beep–beep–beep, beep– PC stand (Arm Type)
beep–beep,….” Turn off the Main Power Switch and go back to step 2. ��
��
5. When the Interface Box has finished updating, the Interface Box quits
making tones.
6. Turn off the Main Power Switch.
7. Turn OFF dip switch 1 (DSW1).
8. Remove the EPROM. Replace the cover.
Cover
iGen 3 cable
Power cord
ROM
Main power switch

DSW1
1
2
3
4
O
F
F
DIP Switch

2. Remove the screw securing the cover to the Interface Box and attach the
one end of the Earth Wire (L = 280 mm) to the Interface Box together
with the cover using the screw.
3. Remove the screw securing the cover to the TR-DP and attach the other
end of the Earth Wire (L = 280 mm) to the TR-DP together with the
cover using the screw.
TR-DP
Earth wire (L=280)
Screw
Cover
Screw
Interface Box
4. Remove the two screws from the Interface Box and secure the Interface
Box to the Connecting Base with the screws (MSKW 3 x 8) supplied
with the TR-DP.
Screw(MSKW 3 x 8)
Connecting Base
Interface Box

Installing DBM-500 6. Install the panel bracket to the location where the base belonged.
7. Connect the three connectors and the three grounding cables.
Panel bracket
HSK5 x 10 Control panel HSK5 x 10
Repositioning the Control Panel of DBM-500 Grounding cable x 3
1. Remove the dial.

Note: This dial should be installed at the same location after the exterior covers
are installed again.
2. Remove the base.
3. Remove the exterior covers.
Exterior Cover
Base Connector x 3
8. Remove connector L from J21 on the MC Unit. Connect connector R to

Control Panel J21.
Dial MC Unit
Harness of Connector R
Harness of Connector L Connector L
Connector R
4. To remove the control panel, disconnect the three connectors and the
three grounding cables.
5. Remove the panel bracket (4 screws).
MSK4 x 8
Control panel
Panel bracket 9. Install the base to the location where the control panel bracket belonged.
MSK4 x 8 Connector x 3
Grounding cable x 3

Installing DBM-500
Repositioning the Emergency-stop Switch 6. Remove the screws and open the MC board. Disconnect the jumper
1. Disconnect the connector. Remove the lock by pulling it in the direction connector. Connect this jumper connector to the connector in step 1.
of A. Screw MC board
2. Turn the lever in the direction of B.

3. Remove the lower half by pulling it in the direction of C.
4. Turn the ring until you can remove the upper half. MC board
Jumper connector
Screw
Upper half
7. See the bottom of the upper half of the emergency-stop switch. Make
B sure that the TOP signs are in the same direction. Attach the upper half
Ring
to the machine, and fasten it with the ring.
A
Upper half
Lower half
Lock
C
Lever
Connector
5. Remove the plate and attach it on the opposite side.

8. Disengage the top corner of the bracket. Connect the lower half to the
upper half. The lever on the lower half must be in the same direction as
the TOP signs. Fasten the lock.
Plate 9. Connect the connector.
Bracket
Connector

Installing DBM-500
Replacing the Pulley 5. Insert the Timing Pulley supplied with the TR-DP to the shaft.
6. Hang the belt supplied with the TR-DP onto the Pulley-1 and Timing
1. Loosen the nut securing the shaft of the Pulley-1. Pulley.
2. Remove the E ring of the Pulley-2. 7. Secure the Timing Pulley with the screw (MSK 4 x 16).
3. Remove the belt from the Pulley-1 and Pulley-2. 8. Tighten the nut of the Pulley-1.
4. Remove the Pulley-2.
Nut
Nut
Pulley -1
Pulley -1
Belt
Shaft
Pulley -2
Screw
(MSK 4 x16)
Timing pulley
Belt
E ring

Installing DBM-500
Installing PC stand (for arm type) 3. Put the PC cables under the PC stand’s arms and install each cover with
the four screws as shown in the figure below.
Install the PC stand to the location where the emergency-stop button was
Screw Cover
installed. PC Screw
Note: The PC stand is not included in the accessories. PC Cable
1. Place the two washers and the set screw as shown in the figure below.
Frame
Washer Arm
Frame
PC Cable
Washer
Set Screw
PC Stand
2. Insert the set screw into the threaded hole on the PC stand’s arm and
tighten the set screw to fix.
PC Stand
Set Screw
Nut

Installing DBM-500
Assembling PC stand (for stand-alone type) 3. Install the four adjustable feet to the tube As.
This type of PC stand is not mechanically attached to the system. Put Adjustable Foot
assembled PC stand in the suitable position according to your working
environment.
1. Attach the two tube cover S’s to each tube A, and the tube cover L to the
tube B.
Tube Cover S
Tube A
Tube Cover L
Adjustable Foot
Tube A
Tube A
Tube B
4. Attach the tube C to the tube A’s and temporarily fix by the two screws.
Note: When attaching the Tube C, the screw inserted to the opening should be
parallel to the Tube A. Refer to the figure of the next step.
Tube C
Tube Cover S
Opening
2. Attach the tube As to the base and fix by the four screws. Screw
Screw Tube A
Washer
Screw Nut
Washer Base
Washer
Tube A
Tube A
Nut
Washer
Tube A Screw

Installing DBM-500
5. Attach the tube B to the tube C and the base, and fix by the three 7. Attach the keyboard tray to the arm and fix by the two screws.
screws. Tighten completely the two screws installed at the previous step.
Tube B Arm
Washer Pipe B
Tube C
Nut
Screw Keyboard Tray
Keyboard Tray
Washer
Pipe B
Arm
Screw Screw
6. Install the arm to the tube B and fix by the two screws. As shown in the 8. Attach the PC monitor to the monitor bracket and fix by the four screws.
figure below, loosen the lever, turn the shaft upward and fix the monitor
bracket by the two screws.
Screw Screw Screw
Monitor bracket
Monitor
Shaft
Screw Screw
Lever
Tube B Arm
Tube B
Arm

Installing DBM-500
9. Put the PC cables under the arms and install each cover with the four
screws as shown in the figure below.
Screw Cable Cover Screw
Cable
Monitor
Arm
Keyboard
Cable

Installing DBM-500
Installing Stitchers 5. Attach the wire feed detection on the tube.
Wire reels are not included in the accessories. You must prepare wire reels
(wire size #25 to #27).
1. Mount the Wire reel mounts.
Wire feed detection
Wire Reel Mount
Wire Reel Mount
Screw Screw
MSKW 5 x10 MSKW 5 x10 Tube
Base
2. Mount the wire reels. Make sure the wire goes from the lower side of 6. Tighten the screw and fasten cable with the SK binder. Fasten the end of
the reel. the ground wire with the screw. Fasten the ground wire and cable with
3. Attach the leaf springs and the collars. the SK binder.
Wire Reel Mount Wire Reel
Wire feed detection
Leaf spring
Collar
4. Attach the tubes on the stitchers. Use the wrench that comes with the Screw
machine.
SK binder Tube
Tube
Screw

Installing DBM-500
7. Connect the connector to the other connector.
Connector
Connector

Installing DBM-500
Feeding Wires 5. Check that the triangular handle is at the stitching position where there
1. Pass the wire through the wire guides. is no clearance.
Wire guide Triangular handle
Wire guide
Wire
Wire guide
Wire
No clearance Clearance
Stitching position Non stitching position
2. Pass the wire to the wire feed detection unit. 6. Insert the wire into the tip of the wire tube upper, and feed with pliers
until the wire reaches the feed wheels.
Wire
Bearing Wire
Roller
Sandwich the wire
between the bearing and roller.
Pliers
Wire feed detection unit Wire tube upper
3. Pass the wire between the two felt disks and through the wire return
lock. Feed wheels
4. Insert the wire into the tip of the wire tube upper.
Be careful not to bend the wire.
Wire
Felt disks
Wire return lock Be careful not to bend the wire.

Installing DBM-500
7. Mount the adjusting handle onto the feed wheel, rotate to the right, so
that the wheels grip the wire.
8. Rotate the handle clockwise about two times to feed the wire
Note: If the wire is bent, it will not enter the wire tube, and jam instead. Pull the
wire, cut off the bent part, and feed it again.
Feed Wheel
Adjusting Handle
Wire tube lower

Installing DBM-500
Mounting the DCM Kit Accessory on DBM-500 Setting the Relay Board Switches of DBM-500
1. Open the top cover on the upstream side of DBM-500. The relay board switches are set to non BG by default. You need to change
2. Remove the conveyance roller unit. the switch settings depending on the area where you use the bookletmaker.
3. Remove the two guides. SW No. BG non BG (For north America)
Downstream Downstream SW1 OFF ON
Conveyance roller unit
SW2 OFF ON
R side view
Guide
DBM-500 DBM-500
4. Mount the air pipe unit. The air mouth must face the downstream side.
The metal end must be 17 mm (0.67”) from the top of the block. Tighten Relay board
the screw (FR 3 × 4).
Note: The air pipe and screw come with DBM-500.
5. Pass the other end of the air pipe through an opening near the power
cord.
Note: You are going to connect this pipe to the DCM Kit (see Installing the DCM
Kit).
DBM-500 DBM-500
Air mouth
Block
17 mm
(0.67")
Screw (FR3 x 4)
Air pipe (to the DCM Kit)
Power cord
Air pipe
6. Replace the conveyance roller unit and the guides.

Installing DBM-500
Remove the Fixing Plate Connecting to SCC
1. Remove the fixing plates on the upstream side and the downstream side. 1. Mount connecting plate L to SCC.
Retain the screws. You are going use them (see Connecting to SCC).
Retain the fixing plate. You are going to use it when moving DBM-500.
SCC
Upstream side view Downstream side view
Connecting plate L
Screw (HSKW 6 x 16)
Fixing plate Fixing plate 2. Connect the connecting plate B to the upstream side of DBM-500. Use
two screws out of the ten you have removed (see Installing the Stacker).
HSKW 6 x16
DBM-500
Connecting Plate B
HSKW 6 x16
3. Move DBM-500 close to the paper exit of SCC.

Installing DBM-500
4. Connect the connecting plates. Do not tighten the screws yet. You are Aligning Paper Path
going to align the paper paths (see Aligning Paper Path). 1. Align the triangle sign (on DBM-500) with the arrow sign (on the static
eliminator).
SCC 2. Adjust the distance between the DBM-500 and the static eliminator. The
distance must be 7 to 10 mm (0.28 to 0.39 inch).
DBM-500
Hole used
3. Adjust the height of DBM-500 to align the paper paths. Use the level
Screw (MSKW 5 x 10) adjusters of DBM-500. To adjust the direction of the DCM kit, loosen the
screw on the bracket.
Top view L side view
DCM kit
7 to 10 mm (0.28 to 0.39 inch)
DBM-500
Hole used Triangle sign
Connecting plate A
Connecting plate B
Arrow sign
SCC
5. Mount the level adjusters. Use eight screws out of the ten you have Screw
removed (see Installing the Stacker). DBM-500 Bracket SCC
6. Place the plates under the level adjusters.

4. Tighten the screws on the connecting plates.
Plate Level adjuster

Installing DBM-500
Installing the Safety Cover
1. Install safety cover A at the bottom of the front side.
2. Install safety cover B to safety cover A.
3. Attach the angles to the upstream and downstream ends of safety cover
B. Make sure the angles touch the floor to support safety covers.
MSKW4x10
Angle
MSKW5x10 MSKW4x10
MSKW4x10 Safety cover B
MSKW4x10
MSKW5x10 Safety cover A
Safety cover A
Angle

Installing DBM-500
Installing DBM-500BR Installing DBM-500BR Paper Receive
1. Undo the four screws on the stopper unit to remove the angle unit and
the sensor cover.
Removing DBM-500 Paper Receive Sensor Cover
1. Rotate the knob on the paper receive counter-clockwise and slide up the
Stopper Unit
paper receiving plate (Refer to [A].)
Screw
2. Disconnect the connectors inside the paper receive (Refer to [B].)
3. Remove the lower screw on the paper receive (Refer to [A]).
Follow the same procedure with the opposite side.
Note: These screws will be used to install the fixing plate F and B afterward.
4. Loosen the upper screw (Refer to [A]). It is not necessary to remove it
completely. Follow the same procedure with the opposite side. Angle Unit
Screw
5. Lift up the paper receive slightly and pull it to the front to remove (Refer
to [C]). 2. Pass the cable of the paper receive through the rectangle hole on the
[A]
stopper unit, and connect the cable to the sensor.
Paper Receive
Paper Receiving Plate Sensor
Knob
Cable
Upper Screw
[C]
Lower Screw
[B]
3. Reinstall the angle unit and the sensor cover removed at step 1 above.
4. Insert the stopper unit into the slit of the DBM-500BR paper receive, and
fix by turning the knob clockwise.
DBM-500BR Stopper Unit

Paper Receive
Knob

Installing DBM-500BR
5. Install the fixing angle F and the fixing angle B to where DBM-500 8. Place DBM-500BR paper receive on the fixing angle F, B and fix by the
paper receive was located. four included screws (MSKW4x8).
Note: Use the screws which have been removed at step 3 of the previous section
(Removing DBM-500 Paper Receive) to fix these angles.
Fixing Angle B Fixing Angle F
Screw
(MSKW4x8)
9. Insert the V-shaped side of the deflector strip into the bracket which
have been installed at step 7 above. Insert the other side into the slit on
the stopper unit.
6. Undo the two screws to remove the guide on DBM-500. Deflector Strip
Stopper
Bracket
Unit
DBM-500
Guide Screw
Deflector
Strip
Fixing Angle B Fixing Angle F
10. Connect the connector behind the paper receive.
7. Install the bracket to where the guide was located and fix it by the two
included screws (SBT4x8).
Screw Paper Receive

(SBT4x8)
Bracket

Installing the Bridge 4. Fix the bridge by the two included screws (MSKW4x8).
1. Undo the four screws to remove the plate and the angle from DBM-500. Screw
(MSKW4x8)
DBM-500 Angle
Plate 5. Tighten the three included screws (HSK5x10) on the bottom of the
angle to join the bridge and the angle completely.
2. Install the angle and fix by the three included screws (HSK5x10).
DBM-500
Screw
(HSK5x10)
Angle
6. Remove the two cable clamps from DBM-500. It is not necessary to

remove the cables from the cable clamps.
Screw To know which cable clamps to remove, hold the bracket in place (see step 6).
(HSK5x10) The two cable clamps behind the bracket can be seen through the screw holes.
Either of the two screws removed at this step will be used to reinstall the cable
3. Insert two hooks on the back of the bridge into the holes on DBM-500. clamp afterward.
Hole
Cable Clamp

7. Install the bracket and fix it by the two included screws (MSKW4x8). Attaching the Stickers
8. Install the upper cable clamp which have been removed at step 5 onto 1. Attach the name plate and the three included stickers as the figure
the side of the bracket. below indicates.
9. Install the collar, the E-ring (L), the pin, the gear and the E-ring (S) in Note: The name plate is included in the accessories for TR-DP.
this order to the shaft.
Pin
Cable Clamp
Collar
E-Ring
(L)
Screw
E-Ring (MSKW4x8)
Bracket
(S)
Gear
10. Remove the exterior cover B of the bridge and engage the belt with the
gears.
Belt
CAUTION
The protection guide and the connecting plate, which are included in the
accessories for DBM-500BR, should be installed to DBM-500T afterward.
DBM-500 Bridge
Exterior Cover B
11. Replace the exterior cover B of the bridge.

12. Replace the exterior covers of DBM-500.

Installing DBM-500T 5. To remove the Control Panel, disconnect the connector. Remove the four
screws on the Bracket. Remove the Control Panel with the Bracket.
Connector
Repositioning the Control Panel and Emergency-stop Switch Cover
1. Draw the Scrap Box out of the machine.

Control panel
Scrap Box
MSK4 x 8
MSK4 x 8 MSK4 x 8
6. To remove the emergency stop switch, disconnect the connector and

remove the cable clamp. Remove the Bracket with the emergency-stop
switch.
2. Remove the Control-panel Cover from the Cover L. Emergency stop switch Cable clamp
3. Remove the Cover L and R.

4. Mount the Control-panel Cover to the Cover R.
Cover R
Control-panel Cover
Bracket
Connector
Cover L

Installing DBM-500T
7. Go to the opposite side. Disconnect the jumper connector. Remove the
cable clamp. Remove the covers.
8. Mount the Control Panel with the Bracket. Connect the connector.
9. Mount the emergency-stop switch with the bracket. Fasten the cable
with the cable clamp.
Cover MSK4 x 8 Control panel Emergency stop switch
Jumper connector Connector
10. Go to the opposite side. Mount the covers.

11. Connect the jumper connector. Fasten the cable with the cable clamp.

Installing DBM-500T
Removing the Belt 4. Raise the Bracket and remove the Belt in the direction of the arrow.
1. Remove the back cover. 5. Put back the Bracket to the original position and screw it.
Belt
Back Cover
Bracket
2. Remove the screws securing the Bracket.

3. Loosen the Belt and remove it from the Pulley.
Belt
Bracket

Installing DBM-500T
Removing the plug of the Clutch Brake Unit
1. Remove the screw cap
2. Remove the two plugs.
3. Tighten the screw cap to extent that the air duct is not completely
sealed.
Air duct Plug
Screw cap
Air duct
Plug
Clutch brake unit
CAUTION
Please keep the removed plug at hand. When you move the DBM-500T,
attach the plug to its original position. Moving the DBM-500T without the
plug may cause oil leaks from the clutch brake unit.

Installing DBM-500T
Setting the Relay Board Switches Connecting to DBM-500 (without Watkiss SpineMaster)
1. Change the switch settings on the relay board depending on the area 1. Attach the Connecting Plate supplied with the DBM-500BR to the
where you use the bookletmaker as follows: DBM-500.
SW No. BG non BG (For north America) DBM-500
SW1 OFF ON
SW2 ON ON
SW 1
OFF OFF
ON ON
SW 2
Screw(HSKW 6X16)
Connecting Plate
Screw(HSKW 6X16)
Relay board
2. Attach the Level Adjusters to the DBM-500T.

If you use the SpineMaster, skip the steps 2 and 3 and go to Connecting the DBM-500T
SpineMaster.
2. Attach the back cover (see Removing the belt).

3. Attach the Cover L and R (see Repositioning the Control-panel and
Emergency-stop Switch).
Level adjuster
Screw(HSKW 6X16)
Level adjuster
Screw(HSKW 6X16)

Installing DBM-500T
3. Attach the Connecting Plate B to the DBM-500T. 5. Attach the cover unit to DBM-500T.
Screw(MSKW4x8) DBM-500T
DBM-500T
Cover Unit
Screw(MSKW4x8)
Screw(HSKW 6X16)
6. Remove the knobscrew of paper guide wheel used for DBM-500.
Screw(HSKW 6X16)
Connecting plate B Note: The paper guide wheel is included in the accessories for DBM-500.
● If the finished size of the booklet is less than 121 mm/4.76 inch, replace
4. Screw the Connecting Plate B to the Connecting Plate. Apply each the paper guide wheel with the one for small size. To replace it, loosen
screw to the middle hole of the Connecting Plate B. knobscrew B, and remove the paper guide wheel. When mounting the
DBM-500T guide, tighten knobscrew B at the cut-away.
MSK5 x 8 MSK5 x 8
Angle 1
Angle 2 knobscrew
Screw(HSKW 6X16)
knobscrew
Connecting Plate B
Screw(HSKW 6X16)
Screw(HSKW
Connecting Plate 6X16) PPaper guide wheel Paper guide wheel (For small size)
Middle hole
Connecting Plate

Installing DBM-500T
7. Attach the angle with the screw (MSK 5 x 8).
8. Secure the screw shaft unit with knobscrew 2 at the cut-away of the
angle.
Knobscrew 2
Screw shaft unit
Paper guide wheel
Screw shaft unit
cut-away
Knobscrew 2
9. Loosen the nut of the bolt using the spanner supplied with the DBM-500.
10. Place the bolt under the plate and press the bolt against the plate.
Tighten the nut to prevent the plate from moving.
Bolt
Spanner
Nut
Plate
11. Mount the Scrap Box in the machine (see Repositioning the Control
Panel and Emergency-stop Switch).

Installing DBM-500T
Connecting the SpineMaster 4. Disconnect the harness from the relay of the machine.
When you connect the Watkiss SpineMaster to the machine, you need 5. Connect the cable of the Interface Socket to the relay.
parts for the connection. 6. Connect the fuse unit between the cable of the Interface Socket and the
1. Remove the front cover. harness of the machine.
7. Place the Connecting Cable-20 as shown in the figure below.
8. Attach the connector of the Connecting Cable-20 to the connector of the
Interface Socket.
Fuse unit
Cable of interface socket Brown

Front Cover Green
Yellow Yellow
Black
Brown Green
Black
Relay
2. Remove the plate from the back cover.
Plate
Interface socket
Connecting cable-20
Back Cover
Cable of
interface socket Connecting cable-20
3. Attach the Interface socket to the back cover.

Nut
Blue
Nut Interface socket
Red Purple
Purple
Screw
Screw

Installing DBM-500T
9. Insert the edge of the Connecting Cable-20 to the connector of the J-10
as shown in the figure below.
Connecting cable-20
MC unit
J10 Connector
No.5
J10 Connector
Purple No.5 - Purple
Blue No.6 - Blue
No.6
Connecting cable-20
10. Mount the back cover (see Removing the Belt).

11. Mount the front cover.
12. Mount the cover L and R (see Repositioning the Control Panel and
Emergency-stop Switch).
13. Mount the Scrap Box in the machine (see Repositioning the Control
Panel and Emergency-stop Switch).

Installing DBM-500T
Mounting the DBM-500BR Accessory on DBM-500T
Remove the screw on DBM-500T as shown in the figure. Install the
protection guide and fix it by this screw.
Note: The protection guide is included in the accessories for DBM-500BR.
DBM-500T
Screw
Protection Guide

Installing DBM-500T
Installing DBM-LS1 5. Connect the wheels with the mechanical link on DBM-500T. (see
Installing DBM-500T )
Note: The wheel is included in the accessories for DBM-500.
1. Mount the Foot A and Foot B on the Base Plate.
6. Mount the Stacker plate.
2. Mount the Long Stacker. Make sure the power cord and the Level
Adjusters are on the same side. Note: The Stacker plate is included in the accessories for DBM-500.
Power cord
DBM-500T Stacker plate
Foot A Screw (SBK 5 x 10) Long stacker Screw(MS 3x18) Wheel

Foot B
Foot B
Foot A Mechanical link
Screw shaft unit
7. Attach one of the outfeed guides to the center holes located on the
Screw (SBK5 x 10)
outfeed side of the DBM-500T. Attach the other outfeed guide to the
right or left holes depending the size of paper to be used.
Base plate Note: The outfeed guide is included in the accessories for DBM-500T.
Outfeed guide
Level adjuster
3. Connect the DBM-LS1 to the DBM-500T. Make sure the top of each Outfeed guide attaching hole
screw on the upstream side is in the opening of DBM-500T.
4. Adjust the height of the Level Adjuster. Make sure the Long Stacker is
parallel with the floor.
DBM-500T DBM-500T
DBM-LS1 Knobscrew
DBM-LS1
8. Connect the power cord to DBM-500T.
DBM-LS1
Level adjuster
Power cord
DBM-500T

Installing DBM-LS1
Installing DBM-K
1. Mount the DBM-K on the DBM-LS1.

2. Connect the cable to the DBM-500T.
DBM-500T
DBM-LS1
Screw (MSK5x10)
Cable
3. Mount the Plate on the opposite side of the DBM-LS1.

DBM-500T
DBM-LS1
Plate
Screw (MSK4x8)

Installing DBM-K
Installing DCM Kit 6. Remove the screw shown in the figure of the cable cover unit, and
separate the Cover L and Cover R.
Cover L
1. Place the DCM Kit near the SCC and DBM-500.
2. Remove the cable cover of the DCM kit. Cover R
3. Connect the cable that comes from the static-electricity eliminator.

4. Connect the Air-pipe that comes from DBM-500 (see Mounting the DCM
Kit Accessory on DBM-500).
5. Connect the Air-pipe that comes from SCC (see Mounting the Air-pipe
unit on SCC).
SCC 7. Pass the connecting cable through the notch on the cover L and attach
Screw the Cover L to the DCM kit.
Static eliminator
Cover L
Screws
Cable cover Air pipe (to SCC)
Cable (from the

static eliminator)
8. Attach back the Cover R to the Cover L.
DCM Kit Cover R
Control valve
Air pipe (to DBM-500)

Installing the DCM Kit
9. Remove the screw securing the cover to the SCC and attach the one
end of the Earth wire (L=700 mm) supplied with the TR-DP to the SCC
together with the cover using the screw.
10. Remove the screw securing the cover to the DBM-500 and attach the
one end of the Earth wire (L=700 mm) supplied with the TR-DP to the
DBM-500 together with the cover using the screw.
11. Remove the screw securing the cover to the DCM Kit and attach the
other ends of the Earth Wire attached in steps 9 and 10 to the DCM Kit
together with the cover.
Earth wire (L=700mm)
SCC
DBM-500
DCM kit
Screw
Screw
Screw
Earth wire (L=700mm)

Installing the DCM Kit
Installing SpineMaster 4. Insert the Shaft to the bearing of the Bracket.
1. Remove the fixing plate on the SpineMaster. Retain the fixing plate and
screws. You are going to use them when moving SpineMaster.
SpineMaster
Set-Collar
Shaft
Bearing
Bracket
Fixing plate
2. Mount the Bracket to the Cabinet lower. 5. Remove the screws from the Connecting Bracket 1 to stretch the
bracket, and then attach the screws to the bracket again.
Note: Do not tighten the screws.
Screw
Screw
DBM-500
Cabinet lower
Screw
Bracket HSKW 6 X12
Connecting bracket 1
3. Place the key 6 x 6 on the hollow of the Shaft shown in the figure below
and pass the shaft through the Spargear and Set-collar. Make sure that
you pass the shaft in the right direction. 6. Remove the screws from the Level adjuster, and then connect the
Note: Do not tighten the glove screws. Connecting Bracket 1 to the paper exit of DBM-500.
Set-collar
Spargear
key 6×6
Level adjuster
Hollow
Screw
Shaft Connecting bracket 1
Screw
Level adjuster

Installing SpineMaster
Screw
7. Move DBM-500T close to the paper exit of DBM-500. 9. Tighten the screws of the Connecting Bracket 1 so that the gap between
the DBM-500BR and DBM-500T is 7 to 10 mm.
7 to 10mm
DBM-500 DBM-500T
DBM-500
DBM-500BR
DBM-500T
Connecting Bracket 1
Screw
8. Remove the screws from the Level adjuster, and then connect the 10. Remove the screws from the Level adjuster, and then mount the
Connecting Bracket 1 to DBM-500T. Connecting Bracket to the exit side of DBM-500T.
Level adjuster
Level adjuster
Screw
Screw
Level adjuster
Level adjuster
Connecting bracket

11. Attach the Protect Cover to the DBM-500T. 13. Mount the Bracket to SpineMaster.
Holes to be used
Protect cover SpineMaster
Screw(MSKW 4 x 8)
Screw
HSKW 6 X16 Bracket
12. Place the key 6×6 on the hollow of the Shaft and insert the Spargear
and Set-collar to the Shaft. 14. Move SpineMaster close to the paper exit of DBM-500T.
Note: Do not tighten the glove screws. DBM-500T
Set-collar
Spargear
key 6×6 SpineMaster
Hollow

15. Insert the Shaft to the Bearing of the Bracket. 17. Align the cabinet of the DBM-500, DBM-500T, and SpineMaster with
the base line.
18. Place the Plate under the Level Adjuster and secure the adjuster to the
Plate.
DBM-500
DBM-500T
SpineMaster
SpineMaster
Level adjuster
Shaft
Base line
Bearing Plate
Bracket
16. Connect the Connecting Bracket to SpineMaster.
19. Adjust the position of the Set-collar on the SpineMaster side so that it
comes to the end of the hollow to prevent rattle as shown in the figure
below. Press the Shaft against the DBM-500.
20. Adjust the position of the Set-collar on the DBM-500 side so that it
comes to the end of the hollow as shown in the figure below.
SpineMaster
Note: Position the glove screw as shown in the figure.
DBM-500
Glove screw
SpineMaster
Screw
Set-collar
Glove screw
Screw
Connecting bracket
Glove screw Shaft
Glove screw
Set-collar

21. Turn on the Main Power Switch and the Remote Switch. 23. Mount the Rack 1 to the DBM-500. Use the right two screw holes out of
the three screw holes on the DBM-500.
DBM-500
Remote switch
Rack 2
Rack 1
Main power switch
Narrow
Wide
Rack 1
Screw
22. Keep pressing the Stop key until the message on the Control Panel HSKW 6 x 16
changes. While pressing the “0” key, press the Size Change key to move 24. Move the SpineMaster to the non-operating side until the surfaces of
the DBM-500 to the standard position. the SpineMaster and the Base align as shown in the figure below.
Numerical “ 0 ” key
DBM-500
SpineMaster
[Stop key]
[Size Change key]
Base

25. Mount the Rack 2 to the Spacer. 27. Adjust the position of the Rack 1 and Spargear so that they interlock
Spacer with each other.
Rack 2 28. Adjust the Spargear using the glove screw.
Rack 1
Screw
HSKW 6 x 12
Spargear
short Long
29. Attach the cover.
26. Mount the Spacer to the SpineMaster. Screw
MSKW 4 x 8
Cover
Screw
MSKW 4 x 8
SpineMaster
Spacer
Screw
HSKW 6 x 20

30. Adjust the position of the Rack 2 and Spargear so that they interlock 35. Connect the cable of the SpineMaster to the DBM-500T.
with each other.
31. Adjust the Spargear using the glove screw.
32. Adjust the position of the Spacer.
DBM-500T
SpineMaster
Spacer
Rack 2
36. Attach the warning label to the DBM-500T as shown in the figure
Spargear below.
33. Attach the Cover. DBM-500T
Screw
MSKW 4 x 8
Cover
Screw
MSKW 4 x 8
34. Turn off the DBM-500.

Connecting Cables 2. Remove the screws from DBM-500T and then attach the connector
cover to DBM-500T.
1. Connect the E-port cables and D-port cables as illustrated in the

diagram.
Note: For the connection between the Interface Box and PC, see Installing the
Inline Controller.
Connector cover
RS-232C
PC
Interface box
CAUTION
Interface box SCC DBM-500 DBM-500T When mounting Port Cable Cover 2, make sure D-port Cables are not
OEM PORT E-PORT E-PORT E-PORT caught between Port Cable Cover 1 and Port Cable Cover 2. If the cables
iGen3 1 1 1 1 are caught, they may be damaged.
PC 2 2 2 2
3. Mount Port Cable Cover 2 on Port Cable Cover 1 of TR-DP.
TR-DP DCM Kit
D-PORT D-PORT D-PORT D-PORT D-PORT D-PORT
1 1 1 1 1 1
2
2 2 2 2 2
3 Cable cover 1
: E-port cable
4
: D-port cable
: Other cable
5 : LED (green)
�� : LED (orange)
Note: If your booklet-making system is not a BG System, you do not have to Cable cover 2
connect E-port Cables. Refer to Section 3, GP2.3, Other Systems for details.
CAUTION
When mounting Port Cable Cover 2, make sure D-port Cables are not
caught between Port Cable Cover 1 and Port Cable Cover 2. If the cables
are caught, they may be damaged.

Connecting Cables
4. Make sure the main power switches are set to off ( or ). Some DBM-500T
machines have two power-related switches. See the following figures to

know which switches are main power switches.
SpineMaster
DBM-500T
DCM Kit DBM-500
Main power
DCM Kit DBM-500 switch
0: OFF
1: ON
SCC
Main power
switch
Main power
switch
SCC
Main power
switch Interface Box TR-DP Main power
switch
Interface Box TR-DP

DBM-500
DBM-500 When using SpineMaster

When using DBM-LS1 and DBM-K 5. Connect the power cords to the machines.

Connecting Cables
Checking Software 2. Connect the removed Control Panel to the connector of the machine.
Modifying the Control-Panel Program of DBM-500

This procedure, Modifying the Control-Panel Program, is necessary when
you reposition the control panel of DBM-500 (see Repositioning the Control
Panel of DBM-500). If you do not reposition the control panel, skip this
procedure.
Note: Make sure that you set the relay board switches to non BG (see Setting
the Relay Board Switches of DBM-500) when you use the machine in the North
America.
3. Open the Card Cover on the back of the Control Panel and insert the CF
Preparing Writing Medium Card to the socket.
1. Prepare a Compact Flash Card (hereinafter called CF Card) with 4. Close the Card Cover and turn on the CF Card Switch on the Control
capacity of 16MB or more and format it on a PC. Panel.
2. Copy the updater for this machine (see the figure below) to the CF Card.
CF card switch
CF card
Upgrading Procedures
CAUTION
Card cover
Do not turn off the machine or the CF Card Switch during upgrade. This
may damage the Control Panel. If the power is turned off with a power
failure, turn off the Remote Switch and the Main Power Switch of the
machine. Then copy the updater to the CF Card again and start from Step
3.
1. Remove the Control Panel (REP 5.14 ).

Checking Software
5. Turn on the Main Power Switch of the machine. 11. Check that the message “Install is completed. Restart now.” is displayed
6. While touching the top and bottom left of the Control Panel screen, turn on the screen and then press [OK].
on the Remote Switch of the machine. Note: The Control Panel will restart.
DBM-500
12. Check that the panel version displayed on the bottom right of the start-
Remote switch
up screen is same as the updater.
Note: If the panel version is different from the updater, the upgrade might have
not been successfully completed. In this case, turn off the Remote Switch and
Main Power Switch of the machine. Then copy the updater to the CF Card again
Main power switch
and repeat the procedures from Step 3. If you still cannot upgrade the program, it
is possible that the Control Panel has been damaged. Replace the Control Panel.
13. Turn off the Remote Switch and Main Power Switch of the machine.
14. Turn off the CF Card Switch on the Control Panel and take out the card.
15. Attach the Control Panel.
7. Check that the message “Checking CF Card” is displayed on the screen

and lift your fingers off the screen.
8. Check that the message “Basic OS has been already installed.” is
displayed on the screen and then press [OK].
Note: Press [OK] regardless of the version of the Basic OS.
9. Check that the message “Install now...” is displayed.
Note: It will take 2 or 3 minutes to complete the installation of the Basic OS.
10. Check that the message “Download now?” is displayed on the screen
and then press [OK].
Note: When pressing [OK], the message “Download now...”is displayed.
Downloading the data will take between 20 to 30 seconds.

Checking Software
Checking the Program of DBM-500 3. An input box is displayed. Touch inside the input box. A numeric keypad
is displayed.
CAUTION
Set the dip switches to the correct positions before starting productive
operations. The machine does not work if the switches are incorrectly set.
Input box
The main-program version of DBM-500 has to be 12J-8602X or later, where

X is a number. To check the program version, follow these steps:
1. Turn on the Main Power Switch and the Remote Switch. If the message, Numeric keypad
Please wait, is displayed, keep touching the Stop Key until the
message is cleared. This takes a few seconds.
2. Make sure the MAINTENANCE MENU or an error message is displayed.
Touch the upper-left corner and the lower-right corner on the display at
the same time.
Note: The screen has multiple rectangular areas on its surface. You see them if 4. Touch 630304 on the numeric keypad. And touch the ENT key.
you look at the screen closely.
5. Touch the Door Key. The Maintenance Mode starts.
Input box
Upper-left
corner
Lower-right Cancel
corner
Door Key
Control panel

Checking Software
6. Navigate to the Versions menu. See the version of the main program: Updating the Main Program of DBM-500
● If the version is 12J-8602X or later, you do not have to update the You must copy 12J-8xxxx.mot in an EPROM. You must use
program. STMicroelectronics M27C4001 or its equivalent.
● If the version is earlier than 12J-86020, see Updating the Main Program
of DBM-500 to update the program. CAUTION
Turn off the Main Power Switch and Remote Switch before you attach the
The version of EPROM to the MC Unit. The EPROM data may be corrupted if you do not
the main program
turn off the Main Power Switch and Remote Switch.
1. Turn off the Main Power Switch and Remote Switch, and remove the
cover.
Downstream
Cover

Checking Software
2. Attach the EPROM to U02 on the MC Unit. Make sure the half-disc 4. Touch the Ver. UP icon.
5. Make sure the versions are displayed. The number in the left pane is
the current version; the number in the right pane is the version you
are installing. If DBM-500 is unable to read the EPROM data, question
marks (????????) are displayed in the right pane. If question marks are
displayed, (i) touch the Cancel key, and (ii) quit the Maintenance Mode.
3. Turn on the Remote Switch, and start the Maintenance Mode (see
Checking the Program of DBM-500). Navigate to VERSIONS.
Cancel key

Checking Software
6. Touch the without Boot Data key. (You use the All Data key only 7. Wait until DBM-500 stops making alarm tones. When it does, check that
when you are given a special instruction.) DBM-500 starts updating. you see the message that prompts you to restart the machine.
● When DBM-500 is correctly executing the update, DBM-500 makes
alarm tones. The tone goes “beep, p, p, p,….” Wait until the tone ends.
● When an error has occurred, the tone goes “beep–beep–beep, beep–
beep–beep,….” Turn off the Remote Switch and go back to step 2.
8. When you see the message, turn off the Remote Switch. Remove the
EPROM. Set the switches on the relay board as follows:
SW No. BG non BG (For north America)
SW1 OFF ON
Note: The tones that indicate an error are longer than the tones that indicate SW2 OFF ON
normal updating. Sometimes, however, you might not be so sure whether they R side view
are longer tones or shorter tones, especially if you have never tried this updating
procedure before. In a case like this, just see if the message in the next step is
displayed.
Relay board
9. Attach the cover.
CAUTION
Set the dip switches to the correct positions before starting productive
operations. The machine does not work if the switches are incorrectly set.

Checking Software
Checking the Program of DBM-500T 7. Make sure you see the message, Maintenance Menu. Push the Jog
Dial.
The program version of DBM-500T has to be 12K-8602X or later, where X is
a number. To check the program version, follow these steps: 8. Turn the Jog Dial until you see the menu ROM Version. Push the Jog
Dial.
1. Turn on the Main power switch and the Remote Switch.
9. See the version of the program:
Remote Switch
● If the version is 12K-8602X or later, you do not have to update the
program.
● If the version is earlier than 12K-86020, see Updating the Program of
DBM-500T to update the program.
Main Power Switch
2. To make sure you see the initial screen, push the Escape Button on the
Control Panel of DBM-500T several times.
Button B
Escape button Eject button Clear button Jog dial Button A


Checking Software
Updating the Program of DBM-500T 4. Turn on the Remote Switch, and start the Maintenance Mode (see
Checking the Program of DBM-500). Navigate to Other Setting, and
You must copy 12K8xxxx.mot in an EPROM. You must use Program Ver. UP.
STMicroelectronics M27C1001 or its equivalent.
5. Make sure the version number is displayed. This is the version number
of the program you are going to install. When no version number is
CAUTION displayed, (i) turn off the Remote Switch, (ii) remove and attach the
Turn off the Remote Switch and Main Power Switch before you attach the EPROM, and (iii) turn on the Power Switch. If you still do not see any
EPROM to the MC Unit. The EPROM data may be corrupted if you do not version number, the EPROM data may be corrupted.
turn off the Remote Switch and MAin Power Switch.
1. Make sure the Main Power Switch and the Remote Switch are off.
2. Remove the exterior cover.
6. Keep pressing button A until the machine starts updating. The machine
makes alarm tones while updating.
● When DBM-500T is correctly executing the update, the tone goes “beep,
p, p, p,….” Wait until the tone ends.
● When an error has occurred, the tone goes “beep–beep–beep, beep–
beep–beep,….” Turn off the Remote Switch and go back to step 5. If an
error occurs again, go back to step 3.
Exterior cover
Button A
3. Attach the EPROM to U02 on the MC Unit. Make sure the half-disc
marks on the EPROM and socket are in the same direction. 7. When DBM-500T has finished updating, DBM-500T quits making
tones. DBM-500T may automatically restart. In this case, wait until
DBM-500T finishes initializing.
8. Turn off the Remote Switch and Main Power Switch.
9. Remove the EPROM. Replace the exterior cover.
U02
MC unit

Checking Software
Setting Control panels 6. Push the Jog Dial. The Maintenance Mode is activated.
Initial Setting for the Control Panel of SCC 9. Turn the Jog Dial to select D-Port ID.
1. Turn on the Main Power Switch and Remote Switch. 10. Push the Jog Dial.
11. Turn the Jog Dial to select Variable.
Main Power Switch
13. Push the Escape Button.
14. Turn the Jog Dial to select Fine Adjustment.
16. Turn the Jog Dial to select Side jogger 1 Home.
18. Turn the Jog Dial to adjust the value “50.”
Remote Switch
20. Turn the Jog Dial to select Side jogger 2 Home.
Jog Dial Button B
22. Turn the Jog Dial to adjust the value “50.”
Screen.
25. Turn off the Main power switch and the Remote Switch.

Note: As you turn the Jog Dial, different menus are displayed one by one.
Menu is displayed.
Note: If you do not hear a tone or if Maintenance Menu is not displayed, go back
to step 1.

Setting Control panels
Initial setting the Control panel of DBM-500 3. Set the Memory of folding roller gap fine adjustment setting to “ON”.
1. Turn on the Remote Switch, and start the Maintenance Mode (see
Checking the Program of DBM-500). Navigate to VARIOUS SETTINGS.
Return key Next key
4. Press the next key a few times to display the screen to select leftward or
2. Press the next key a few times to display the Folding Roller Gap. rightward paper transportation.
5. Set it to RIGHT.
Folding Roller Gap
leftward or rightward
paper transportation
Return key Next key

6. Press the Return key a few times to go back to the Maintenance menu. 9. Press No.5-3 (unit for fine-tuning base). When it is selected, the number
changes to white on a black background.
Return key
7. Press the RESERVE SET TINGS key.
Return key
10.Press No.5-6 (change jam detect time for the folding conveyance
section). When it is selected, the number changes to white on a black
background.
6
8. Set N0.2 (D-PORT ID setting) to ON.
6
Return key

11. Press the Return key a few times to go back to the MAIN MENU.
12. Turn off the Main Power Switch and Remote Switch.

Initial setting the Control panel of DBM-500T 21. Push the Escape Button several times until you go back to the Initial
Note: If you do not use the SpineMater, ignore the procedures between step 17 Screen.
and step 20. 22. Turn off the Main Power Switch and the Remote Switch.
1. Turn on the Main Power Switch and the Remote Switch.
Button B
Escape button Eject button Clear button Jog dial Button A
2. Start the Maintenance Mode(see Checking the Program of DBM-500T ).

3. Turn the Jog Dial to select Other Setting.
5. Turn the Jog Dial to select D-Port ID.
7. Turn the Jog Dial to select Variable.
9. Turn the Jog Dial to select Feed Speed.
11. Turn the Jog Dial to change the value “600.”
13. Turn the Jog Dial to select EntranceJam time.
15. Turn the Jog Dial to change the value “6.”
17. Turn the Jog Dial to select SpineMaster.
19. Turn the Jog Dial to select on.

Installing and Upgrading the Inline Controller 5. On the taskbar, click [Start].
Requirements 6. Click [My computer].

● PC with 800 MHz processor clock speed
● 15-inch monitor with 1024 x 768 resolution
● Windows 2000 Professional/Windows XP
Note: Windows is a trade mark of Microsoft Corporation.
● 128MB RAM
● 300MB of free disk space
● USB Flash Drive (for installation)
● Serial port
Copying the Inline Controller program from the CD-ROM to a

removable disk (USB device)
7. Right-click [Duplo(D:)] in My Computer.
1. Turn on the PC.
8. Click [Copy].
2. Insert a removable disk to the USB connector.
3. Put the CD-ROM in the CD-ROM drive.
4. When “Choose Setup Language” screen appears on the PC screen, click
[Cancel].

Installing the Inline Controller
9. Right-click [Removable DISK(E:)] in My Computer. 11. Double-click [Removable DISK(E:)] in My Computer.
10. Click [Paste].
12. Double-click [Duplo(D:)] in Removable DISK (E:).
The following message is displayed when the data on the CD-ROM is being
copied to the removable disk.
When the message has disappeared, the copying process is complete.

Check if the data is copied completely, according to the following
procedure.

If the following files exist in the Duplo (D) folder, the copy is complete. 15. Click [Stop].
16. Select the device you are using and click [OK].
CAUTION
If the copy is not complete, format the removable disk and follow the copy
procedure again.
13. Remove the CD-ROM from the CD-ROM drive.

14. Locate your cursor on the icon for the removable disk in the notification
area and double-click the icon.

17. Click [Close]. Installing and Upgrading
Requirements
● 15-inch monitor with 1024 x 768 resolution
Note: Windows is a trade mark of Microsoft Corporation.
● 128MB RAM
● USB Flash Drive (for installation)
● Serial port
1. Turn on the PC.

2. Insert the CD. Insert the USB Flash drive into USB port C. The Chose
18. Remove the removable disk from the USB connector. Setup Language panel appears on the screen. If it does not, (i) navigate
19. Shut down the computer. to the CD drive, USB Drive, and (ii) double-click the setup file or the
setup.exe file.
Note: You may find the setup file or the setup.exe file according to your PC
setting.
3. Choose a language. The language of your choice is used during
installation.
4. Click the OK button.

5. Follow the messages to continue installation. 8. Click [Install].
6. Type a user-name and organization. If only the current login user uses
the program, select [Only for me]. Click [Next].
9. Click [Finish].
User-name
Organization
10. Remove USB Flash Drive.
● Installation is completed. Check that the icon below is displayed on the
desktop.
DUPLO Inline
Controller
7. Check the install destination of the program and click [Next]. 11. Shut down the computer.
Install destination

Setting Power-related Switches 3. Make sure the Main Power Switches or Remote Switches are all set to
off.
Interface Box TR-DP SCC DCM Kit DBM-500 DBM-500T SpineMaster
Starting the System Main Power
off( )
Switch
For productive operation, the user uses the Main power switch on the Remote
Switch — off( ) off( ) — off( ) off( ) —
Interface Box to turn on or off the Duplo DBM-5000. Having installed the
system, set the power-related switches as following these steps: 4. Turn on the Main power switches on( ) TR-DP, SCC, DCM Kit,
1. Make sure the Inline Controller has not started. DBM-500, DBM-500T and SpineMaster (if used).
2. Make sure the Main power switch on the Interface Box is set to off. Now Interface Box TR-DP SCC DCM Kit DBM-500 DBM-500T SpineMaster
the power-related switches are set as shown in the table. You need not Main Power
care about black-colored cells. A dash indicates there is no such switch Switch off( ) on on on on on on
on the machine or module. Remote
Note: You can pass over SpineMaster’s information if you do not use it in your
system. 5. Turn on the Main power switch on the Interface Box.
Interface Box TR-DP SCC DCM Kit DBM-500 DBM-500T SpineMaster Interface Box TR-DP SCC DCM Kit DBM-500 DBM-500T SpineMaster
Main Power Main Power
Switch off( ) Switch on on on on on on on
Remote Remote
Switch — — — —
Switch off( ) off( ) off( ) off( )
Remote switch Main power Main Power switch Remote switch
switch DBM-500T 6. Start the Inline Controller on the PC.
SpineMaster Ending the System

1. Quit the Inline Controller on the PC.
DCM Kit DBM-500
2. Turn off the Main power switch on the Interface Box. Leave other Main
switches set to on.
Main power
switch
0: OFF
Interface Box TR-DP SCC DCM Kit DBM-500 DBM-500T SpineMaster
1: ON Main Power
Switch off( ) on on on on on on
switch
DBM-500
Remote
Interface Box TR-DP

Main power
Remote switch switch


Setting Power-related Switches
Profile Installation on iGen3 System Creating the Device Profile
1. On the DocuSP, click Printer. The Printer Manager window will appear.
2. Select the Finishing tab.
To perform communication with iGen3 system properly, it is necessary to
create the DFA profiles for Duplo DBM-5000 by the following procedures. 3. Click the Device Setup. The Device Setup window will appear.
All these works should be done on the PSIP or the DocuSP, which are the 4. Right click the mouse and click New. The Device Profile window will
computer systems connected to iGen3. appear.
5. Set parameters to the suitable values.
Creating the DFA Timing Profile Note: To know the values to be entered here, refer to the next section ‘iGen3
1. On the PSIP, click Administration. The Administration window will Finisher Profile Settings’.
appear. 6. Click OK. The Name and Type of the device will show up in the Device
2. Select the DFA Timing Profiles tab. Setup window.
3. Click Options and click New. The DFA Timing Profiles Settings 7. Click Close in the Device Setup window.
Window will appear. There are four sub-tabs within the window.
4. Select each tab and set parameters to the suitable values. Creating the Finisher Profile
Note: To know the values to be entered here, refer to the next section ‘iGen3 1. Right click the mouse in the External Finishers section of the Printer
Finisher Profile Settings’. Manager window and then click New. The Finisher Profile window will
5. Click Save to save the DFA Timing Profile. appear.
2. Type the DFA Timing Profile’s name in the Name box.
Activating the new DFA Timing Profile 3. Select the Device Profile under the Type list.
1. From the PSIP Administration window, select the DFA Timing Profiles 4. Click OK. The new profile will show up under the External Finishers
tab. Created profiles are under this tab. section in the Printer Manager window.
2. Highlight the profile created by the procedures above (Creating the
DFA Timing Profile). Activating the Finisher Profile
3. Click Options and click Assign. The Assigned box will be checked. 1. In the External Finishers section of the Printer Manager window,
highlight the desired profile name.
2. Right click the mouse, click Online and then click Enable to activate
the profile.

Profi le Installation on iGen3 System
iGen3 Finisher Profile Settings 2. Then, the name of the most suitable profile will show up in the window.
Create the DFA timing profile and device profile on iGen3 system using
this profile. You can see the concrete values in the following pages.
There are five different variations among DFA timing profile and device The profile name
profile depending on the SCC’s setting.
Profile Name Process of SCC
Duplo-01 Bypass
Duplo-02 •Slit Ready !
Profile Duplo-04
•Crease
•Slit and Crease
oki
Duplo-03 •Cut
SCxSS
•Slit and Cut job100
Duplo-04 •Cut and Crease 25

Duplo-05 •Cut and Crease * The speed is lower
than Duplo-04.
When using the Inline Controller on the PC, you can easily make sure
which profile to apply by following the procedures below.
1. Once you finish setting parameters, click ‘Send’ button. Note: For detailed information on how to set the parameters in the Inline
Click here Controller window, refer to Inline Controller Instruction Manual.
CAUTION
When using Bourg Sheet Rotator (BSR), it is necessary to change certain
parameters. For details, refer to the following pages. Unless otherwise
noted, use the default values.
oki
SCxSS
job100
25

iGen3 Finisher Profi le Settings
Sheet Jam Time 1000 [ms] 1615 [ms] Sheet Jam Time 1000 [ms] 1615 [ms]
Time Between Sets 0 [ms] Time Between Sets 0 [ms]
Set Jam Time 10000 [ms] 10615 [ms] Set Jam Time 12000 [ms] 12615 [ms]
Set Processing time 500 [ms] Set Processing time 1300 [ms]
Delivery Start Adjust 0 [ms] Delivery Start Adjust 0 [ms]
Delivery End Adjust 30 [ms] 50 [ms] Delivery End Adjust 30 [ms] 50 [ms]
End of Set Offset 0 [ms] 20 [ms] End of Set Offset 0 [ms] 20 [ms]

Sheet Jam Time 1000[ms] 1615 [ms] Sheet Jam Time 1000 [ms] 1615 [ms]
Time Between Sets 0[ms] Time Between Sets 0 [ms]
Set Jam Time 14000[ms] 14615 [ms] Set Jam Time 15000 [ms] 15615 [ms]
Set Processing time 2400[ms] Set Processing time 2400 [ms]
Delivery Start Adjust 0[ms] Delivery Start Adjust 0 [ms]
Delivery End Adjust 30[ms] 50 [ms] Delivery End Adjust 30 [ms] 50 [ms]
End of Set Offset 0[ms] 20 [ms] End of Set Offset 0 [ms] 20 [ms]

5-1. Press Interface DFA Profile Settings: Duplo-05
TAB ITEM VALUE When using BSR
General Timing Profile Name Duplo-05
Time to Cycle Up 60 [sec]
Time to Cycle Down 60 [sec]
Finisher Capacity 0 [set]
Recovery Behavior Set Recovery
Jam Timings Time Between Sheets 3500 [ms]
Sheet Jam Time 1000 [ms] 1615 [ms]
Time Between Sets 0 [ms]
Set Jam Time 16000 [ms] 16615 [ms]
Set Processing time 5000 [ms]
Status Signals Offline (S0) Enable
Faulted (S1) Enable
Full (S2) Enable
Sheet Delivered (S3) Enable
Set delivered (S4) Enable
Empty (S5) Disable
Not Ready (S6) Disable
Sheet Fed (S7) Disable
Delivery Delivery Signal Type Lead Edge Trail Edge
Delivery Start Adjust 0 [ms]
Delivery End Adjust 30 [ms] 50 [ms]
End of Set Offset 0 [ms] 20 [ms]
5-2. DocuSP Device Profile Settings: Duplo-05

TAB ITEM VALUE
Properties and Name Duplo-05
Default Limits Type External
Function 1 Line Off
Function 2 Line Off
Sheet Sequence N-1
Side 1 Direction Face Up
Minimum Sheet Length 140 [mm] / 5.50 [inch]
Maximum Sheet Length 320 [mm] / 12.60 [inch]
Minimum Sheet Width 178 [mm] / 7.00 [inch]
Maximum Sheet Width 457 [mm] / 18.00 [inch]
Minimum Sheet Weight 82 [g/m 2 ]
Maximum Sheet Weight 128 [g/m 2 ]
Minimum Set Size 1 [sheet]
Maximum Set Size 25 [sheet]

Section 9
Information
Contents
Section 9 Information ...................................................9-1
PC (except north America) ..................................... 9-2
Instruction Manual .................................................. 9-3
9-1
iGen3-M12D0-0612-0
PC (except north America) Switzerland 0848 833 933
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Dell™ Business Support Contact Information
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9-2 Section 9—Information

PC (except north America)
Instruction Manual
DUPLO Inline Controller Instruction Manual

See next page.
9-3 Section 9—Information

Instruction Manual
DUPLO Inline Controller
Instruction Manual
Requirements
● 15-inch monitor with 1024x768 resolution
● 128MB RAM
● CD-ROM drive (for installation)
● Serial port
Upgrade and inheritance
When having upgraded the In-Line PC Controller, you cannot use the files that have been created
by using the former version. The files shown in My Data are no exception. The DUPLO Inline
Controller does not work if you use any of them.
Supported Units and Components
The DUPLO Inline Controller is capable of controlling the following units and components:
● DOCUCOLOR iGen3 system
● TR-DP
● SCC
● DBM-500
● DCM Kit
● DBM-LS1(Long stacker)
● DBM-500T
● DBM-K(Kicker)
● Watkiss Automatic SpineMaster TM*
Restrictions of DBM-500
The following keys are displayed, but you cannot use them:
● Main Menu—Memory Number Selection Key, Setting Key, Size Change Key
● Adjust—Trim On/Off Key
● Accessory—Trimmer Key, Stacker Key, Kicker Key
The following key is not displayed:
● Main Menu—Trim Setting Display
*SpineMaster TM is the registered trademark of Watkiss Automation Ltd.
i
Duplo DBM-5000 In-line Bookletmaker Overview
TR-DP SCC DBM-500 DBM-500T

DBM-K
DBM-LS1
Paper travel SpineMaster
TR-DP:
TR-DP is a machine that receives a sheet of paper from the DOCUCOLOR iGen3 system and
transfers it to SCC, the downstream machine of TR-DP. You can also feed a sheet of
paper manually from its manual feed station when you want to fine-tune the operation
of downstream units.
SCC:
SCC is a machine that cuts paper edges and creases
a sheet of paper. SCC can cut four paper edges. From
this moment on, we use the words “cut” and “slit” in
the following manner:
To “slit” paper To “cut” paper
● Cut—to remove the lead edge or the tail edge of paper
● Slit—to remove either of the side edges of paper
Paper travel Paper travel
● Crease—When SCC creases a sheet of paper,

a crease line is made on the paper. Creased
Paper
Crease line
DBM-500:
DBM-500 is a machine that makes booklets out of
multiple sheets. To make booklets, DBM-500 can
stitch sheets and/or fold them.
DBM-500T:
DBM-500T is a machine that trims an edge of the booklet.
II
DBM-LS1:
DBM-LS1 stacks booklets. This machine has two belts that transfer DBM-500T
booklets from the exit of DBM-500T to the downstream end of the
booklet-making system. DBM-K
DBM-K:
DBM-K is the component that connects to DBM-LS1.
DBM-K, at regular intervals, pushes one of the booklets
DBM-LS1
that travel on DBM-LS1. Doing so, this component lets
the user easily know how many booklets are on the stacker.
SpineMaster TM:
SpineMasterTM post-processes stitched booklets to give them
the professional flat apperance of a perfect bound book.
From DBM-500T
iii
DISPLAY Overview
A B C
D E
A: Message Box—Messages appear to show information about the bookletmaking system and
DUPLO Inline Controller.
B: Action Buttons—Use the Send button to send the setting data to the bookletmaking system.
Use the Save button to store the data.
Use the Hand Feed button to fine-tune the bookletmaking system.
These buttons may not be available depending on the state of the
bookletmaking system or DUPLO Inline Controller.
C: Counter—The Counter shows how many sheets are already processed.
D: Menu Buttons—These buttons switch the display on the Main Screen.
E: Main Panel—You can select and specify options and settings from this Screen.
Job Process Items

Process Mode Cut Slit Crease
Through Active Active Active
All Inactive Inactive Inactive
Stitch Fold Trim
Saddle Active Active
Side Inactive Inactive
No Stitch Not available
iv
Table of Contents
1. GETTING READY ......................................1 2-7-2. Finished Size ...............................18

2-7-3. Crease Position ...........................19
1-1. Starting and Stopping the System ........1
2-7-4. Side Jog Positions .......................20
Starting the System..................................1
2-7-5. Back Jog Position ........................21
When a Communication Error Occurs .....1
2-7-6. SCC Main Body Position .............22
Stopping the System ................................1
DBM-500 ................................................23
1-2. Initial Settings (Maintenance Menu) .....1 2-7-7. Stitch Position ..............................23
When to Change ......................................1 2-7-8. Fold Position ................................24
Overview of Initial Settings.......................2 2-7-9. Stitch and Fold Positions .............25
System Configuration ............................2 2-7-10. Stitch, Fold and Crease Positions .
Unit of Measure .....................................2 ............................................................26
Communication Port ..............................2 2-7-11. Stitch Width ...............................27
How to Set ...............................................2 2-7-12. Side Jogger Positions ................28
Monitor ..................................................3 2-7-13. Stitch Back Jogger.....................29
2-7-14. Fold Side Guide .........................30
2-7-15. Fold Back Guide ........................31
2. SETTING JOBS..........................................4
2-7-16. Fold Roller Gap .........................32
2-1. Overview...............................................4 2-7-17. DBM-500 Main Body Position....33
Counter ....................................................4 DBM-500T..............................................34
Job Manager Screen................................4 2-7-18. Trim Position..............................34
Job Process Items .................................4 2-7-19. Roller Gap .................................35
Control Screen Display .........................4 Fine-tuning the Finished Length on the
Machine Properties ...............................4 DBM-500T ....................................................36
How to Set the Job Manager.................4
2-2. Setting SCC ..........................................5 3.MANAGING DATA AND LOGS .................37
SCC Panel ...............................................5
3-1. My Data ..............................................37
Setting Details ..........................................5
Making My Data .....................................37
SCC Detail Settings ..............................5
Making a New File .................................37
SCC Process Preview ...........................6
Saving My Data......................................37
2-3. Setting DBM-500 ..................................7 Using or Deleting My Data .....................37
DBM-500 Panel........................................7 Loading My Data .................................37
Timer Function of DCM Kit ....................7 Finding My Data from the File Menu ...38
DBM-500 Detail Settings..........................7 Deleting My Data .................................38
DBM-500 Process Preview ......................8 Deleting My Data Files ........................38
DCM Kit .................................................8
3-2. Job History..........................................38
2-4. Setting DBM-500T ................................9 Viewing Job History ...............................38
DBM-500T Panel .....................................9 Loading Job History ...............................38
DBM-500T Detail Settings .......................9
DBM-500T Process Preview ..................10
4. TECHNICAL INFORMATION ...................39
2-5. Saving Data and Sending Data ..........11
4-1. Troubleshooting ..................................39
Saving My Data......................................11
4-1-1. Communication-related Errors.....39
Sending Data .........................................11
Failed to communicate with TR-DP .....39
System Status ........................................11
Failed to communicate with SCC ........39
2-6. Starting or Stopping the Bookletmaker12 Failed to communicate with DBM-500 39
Using Hand Feed ...................................12 Failed to communicate with DBM-500T39
Stitching Test .........................................13 Failed to communicate with DCM Kit ..39
Follow the procedures below for a stitch test Failed to communicate with Kicker ......39
of the stitcher. ...............................................13 Symptom .............................................39
Adjust the stitcher head .........................14 Corrective Action 1 ..............................39
Counter Clear.........................................15 Corrective Action 2 ..............................39
Start .......................................................15 Corrective Action 3 ..............................39
Stop........................................................15 Turn off and on the system. ................39
Cause ..................................................39
2-7. Fine Adjust..........................................16
Corrective Action----------------------------39
SCC .......................................................17
System Communicate Error ! ..............39
2-7-1. Reference Position ......................17
v
Symptom .............................................39
Corrective Action .................................39
Invalid Data Transfer..............................40
Symptom .............................................40
Malfunction.............................................40
Check SCC ! .......................................40
Check DBM-500 ! ................................40
Check DBM-500T ! ..............................40
Symptom .............................................40
4-1-2. Emergency stop...........................41
Emergency Stop - SCC ! .....................41
Emergency Stop - DBM-500 ! .............41
Emergency Stop - DBM-500T ! ...........41
4-1-3. Paper Jam ...................................42
Paper Jam- TR-DP ! ............................42
Paper Jam- SCC ! ...............................42
Paper Jam- DBM-500 ! .......................45
Paper Jam- DBM-500T ! .....................46
4-1-4. Cover Open .................................47
4-1-5. Scrap Box Full .............................48
4-1-6. Stacker Full..................................49
4-1-7. Staple Empty ...............................50
4-1-8. Incorrect Display ..........................52
Symptom ............................................52
4-1-9. Setting-related Errors ..................52
DCM Kit Timer Function ......................52
4-2. Default Folders ...................................52
My Data ..................................................52
Job History .............................................52
5. SPECIFICATIONS....................................53
5-1. Interface Box ......................................53
5-2. TR-DP.................................................53
5-3. SCC ....................................................54
5-4. DCM kit ...............................................55
5-5. DBM-500/DBM-500BR .......................56
5-6. DBM-500T ..........................................57
5-7. DBM-LS1/DBM-K ...............................57
DBM-LS1 ...............................................57
DBM-K ...................................................57
5-8. SpineMaster .......................................58
Product Specifications ...........................58
Safety Data Sheet ..................................59
VI
1. GETTING READY
1-1. STARTING AND STOPPING THE SYSTEM
Starting the System
To turn on the system, follow the procedures below. If you tun on the
system in a wrong order, a communication error occurs.
1. Make sure the connection between the PC and Interface Box is
good.
2. Turn on the PC.
3. Turn on the Interface Box. See the Instruction Manual of each unit Power switch
for turning on the bookletmaking system.

4. Make sure that the date and time displayed on the PC is correct.
5. Click the icon of the DUPLO Inline Controller.If you do not see the
icon, choose Start and DUPLO Inline Controller.
CAUTION ● Do not start the DUPLO Inline Controller while it

is already running. If you do, an error occurs.
● The graphical interface of the DUPLO Inline
Controller looks disorganised if your PC setting is
not compatible (see Incorrect Display, page 52).
When a Communication Error Occurs

A communication error occurs if you turn off the Interface Box while the DUPLO
Inline Controller is running. Clear the error by following these steps:
1. Click the Exit button or select the File menu and Exit. If the data has not been
saved, you will be prompted to save it. Click “Yes” or “No.”
2. Turn on the Interface Box.
3. Start the DUPLO Inline Controller.
Stopping the System

1. Make sure the bookletmaking system is not executing a job.
2. Click the Exit button or select File and Exit. If the data has not been saved, you will be
prompted to save it. Click “Yes” or “No.”
3. Turn off the bookletmaking system. See the Instruction Manual of each unit for turning off the
bookletmaking system.
1-2. INITIAL SETTINGS (MAINTENANCE MENU)

When to Change
You have to adjust the initial settings from the Maintenance Settings Screen in any of the following
cases:
● You want to change the unit of measure from millimetre to inch or from inch to millimetre.
● You want to change the language displayed.
● You have replaced the PC. You have re-installed the DUPLO Inline Controller.
● You need to change the communication port of the PC.
NOTE: Our service staff may change initial settings when necessary.
CAUTION You cannot use saved My Data if you change Maintenance Settings (see Making
My Data, page 37). To use saved My Data, recover the Maintenance Settings of the
time when you have saved My Data.
1
Overview of Initial Settings
System Configuration
The units and components in the bookletmaking system are specified. You may have to change this
setting when you have re-installed the DUPLO Inline Controller. In any other case, do not change
this.
Unit of Measure
You can choose a unit of measure. Your selection is valid for the DUPLO Inline Controller, but not
for the machines in the bookletmaking system.
CAUTION Select mm when using My Data that defines distance in millimetre (see Making My
Data, page 37). Select inch when using My Data that defines distance in inch.
Communication Port
You can define the communication port of the PC.
How to Set
1. Choose the Maintenance menu and Maintenance.
The Maintenance Settings Screen appears.
2. Select the System Configuration tab.
3. Choose “ mm or inch “.
NOTE: This does not change the unit of measure that
is displayed on the Control Panel of each machine in the
bookletmaking system.
4. Choose a speed ” 1400 ”.
5. Make sure Direction is Right.
6. Select the Multi Languages tab.

7. Choose a language.
8. Choose a font type.
NOTE:If the character is not displayed properly, choose a font
type.
9. Select the Comm tab.

10. Select a communication port.
2
11. Choose the Maintenance menu and Version
Information.
12. Make sure DUPLO Inline Controller Version.
13. Click OK.
14. Click the Exit button or choose the File menu

and Exit. You have to restart the DUPLO Inline
Controller to enable these settings.
Monitor
The Monitor displays the sent and received data Program version
between the PC and the Interface Box. You can find
the program version of the machines connected to the
Inline Controller on the top right of the Monitor. I / F Box :12S80150
TR-DP :12C80260
SCC :12C80106
DBM-500 :12J86029
Save: Saves the sent and received data being DBM-500T:12K86027

DCM Kit :99T-86200
displayed on the Monitor to the PC.
Enable: Starts displaying the sent and received data

after Disable or Clear is pressed.
Disable: Stops displaying the sent and received data.
Clear: Erases the sent and received data being
displayed on the Monitor.
Note: The Monitor menu is only for a service engineer.
1-3. Re-installing DUPLO Inline Controller

After re-installing the DUPLO Inline Controller, you have to recover the System Configuration
settings. Before removing or re-installing the DUPLO Inline Controller, check the System
Configuration settings as follows:
2. Make sure the System Configuration Screen is
displayed. Select the System Configuration tab if
any other Screen is displayed.
3. See which units and components are selected, and
take notes.
4. See which measure is selected, and take notes.
5. See which speed is selected, and take notes.
6. See which direction is selected, and take notes.
7. Re-install the DUPLO Inline Controller.
10. Refer to the notes in step 3 to 6, and choose the
same units and components on the System Configuration Screen.
11. Click Close.
12. Click the Exit button or choose the File menu and Exit. You have to restart the DUPLO Inline
Controller to enable these settings.
3
2. SETTING JOBS
2-1. OVERVIEW
Counter
The counter shows how many sheets are already processed.
Job Manager Screen

The Job Manager gives you the overall information about your booklet making.
Job Process Items
The Job Manager has the Job Process Items Screen. The Job Process Items shows which
processes are executed by the bookletmaking system. For the signs displayed, see DISPLAY
Overview, page iv.
Control Screen Display
The DUPLO Inline Controller transfers data to the bookletmaking system after you click the Send
button. Before you do this, the displays on machine Control Panels may contradict the settings on
the DUPLO Inline Controller.
Machine Properties
You are going to set each unit and component after setting the Job Manager. Some unit- or
component-specific properties are displayed on the Screen with the machine name on the tab.
Other properties are displayed on separate Screens that you can access by clicking a couple of
buttons.
How to Set the Job Manager
1. Type an Operator ID, Order ID, and Job name. These
are displayed in the Job History (see Job History, page
38).
● Operator ID—The name of the operator, or you can
type some other information.
● Order ID—The reference number of the business,
work, project, or booklet; or you can type some other
information.
● Job Name—The name of the settings you are making
with the DUPLO Inline Controller.
2. Click the Paper Size button.
3. Select a paper size. In order to specify the custom
paper size, type the length and the width directly in each field. After typing the length and
width, click the OK button and Close button.
CAUTION ● The Fold setting of DBM-500 is set to Yes if you change the paper size in
the Job Manager Screen or in the SCC panel.
● When you choose Yes in the Fold field on the DBM-500 panel, the number
of Sheets on the Job Manager Screen is set to 25 if it has been 26 or a
larger number.
4. Type the number of Sheets. When you are to specify a number from 26 to 50, you must
disable the Fold on the DBM-500 panel beforehand (see
DBM-500 Panel, page 7). If you do not disable it, you see an
error message when specifying 26 or a larger number.
5. Make sure the Send button and Save button are both
coloured. If they are not, you may not be able to select some
options afterwards.
4
2-2. SETTING SCC
SCC Panel
CAUTION The settings of DBM-500 returns to its default if you have changed the paper size
in the Job Manager Screen or in the SCC panel. Use caution when changing the
paper size.
1. Select the SCC tab.

2. Choose a process.
● SCC has two Process Modes. The Through and All.
Through: All the sheets go down the Bypass. No sheet is
slitted, cut, or creased.
All: All sheets go down the Process Path and slitted, cut,
and/or creased.
3. Check Crease to enable the creaser, or uncheck it to disable
the creaser.
● To select an option in the All field on the SCC Detail Settings
… Screen, choose All in the Process Mode field and check
Crease.
● You cannot check Crease if you have selected Through in the
Process Mode field.
4. Click the Setting Detail… as necessary.
NOTE: For the Fine Adjust button, see Fine Adjust, page 16.
Setting Details
SCC Detail Settings
1. Click the Setting Detail... button.
2. Select an ALL Mode option. To select an option, select All and
check Crease beforehand.
● Mode-1: SCC creases all sheets.
● Mode-2: SCC creases cover sheets, but

does not crease other sheets.
● Mode-3: SCC creases cover sheets and

innermost sheets of booklets, but
does not crease other sheets.
3. Adjust the Back Jog Delay as necessary.
● As default, the Back Jogger starts aligning a

sheet at the moment when the sheet reaches
the Stopper. You can enter a number from
0 to 99, where one step equals 10 milliseconds. The Back Jogger waits for the specified
time before starting operation. For example, if you enter 10, the Back Jogger waits for 100
milliseconds, or 0.1 second, before starting.
5
CAUTION The specification on the Select Process Pages panel is nullified if you change
the number of Sheets on the Job Manager panel. After changing the number of
Sheets, specify the sheets on the Select Process Pages Screen once again.
SCC Process Preview

Processed Length
You can change several settings in the Crease Position
Process Preview. If you are going to change
two or more settings, change them in the
following order: (i) sheet size (width and
Processed Width
length), (ii) reference position, (iii) crease
position.
1. Click a number in the Process Preview.

2. Specify a number. You can use the
buttons on the Screen.
● Cancel—This button closes the Screen
without changing the specified number.
● Back—This button erases one digit at a
time or erases all highlighted digits.
● Clear—This button erases all digits at the Reference Y
same time. Reference X
3. Click the OK button after specifying a
number. The OK button is disabled if
you try to specify slit or cut positions that
SCC cannot handle. Slit positions must
be between 4 mm/0.16” and 25 mm/0.98”
from the side edge of the paper. Cut
positions must be between 4 mm/0.16” and
25 mm/0.98” from the front edge, and 5
mm/0.20” from the rear edge of the paper.
25mm/0.98” 25mm/0.98” 25mm/0.98”

4mm/0.16” 5mm/0.20” 4mm/0.16”
Paper travel
4mm/0.16”
25mm/0.98”
Cut position Slit position
6
2-3. SETTING DBM-500
CAUTION The settings of DBM-500 returns to its default if you have changed the paper size
in the Job Manager Screen or in the SCC panel. Use caution when changing the
paper size.
DBM-500 Panel
● In order to enable the Trim on the DBM-500T panel, check the Fold check box.
● When 26 Sheets and above are specified, you can not check the Fold check box.
● In order to specify more than 25 sheets on the Job Manager Screen, uncheck the Fold check
box on DBM-500 panel.
1. Select the DBM-500 tab.
2. Choose an option in the Stitch field.
3. Check the Fold check box when you need to fold the
booklet. When this check box is checked, you can not
specify more than 25 sheets on Job manager Screen.
4. Click the Setting Detail button for detailed setting.
5. Click the Fine Adjust button for fine-tuning of the system.
NOTE: For the Fine Adjust button, see Fine Adjust, page 16.
Timer Function of DCM Kit

You cannot operate the bookletmaking system for about one minute
while the Timer Function of the DCM Kit is working. The Timer
Function starts about three minutes after booklet making ends. You
do not have to do anything to clear this function. The Timer Function
automatically ends in about one minute.
DBM-500 Detail Settings

1. Specify the Start Timing and the Conveyance Time in the
Stacker section. The Stacker section is not available if DBM-
500T is connected. In such a configuration, you use the DBM-
500T Detail Settings Screen to specify the Start Timing and
the Conveyance Time (see DBM-500T Detail Settings, page 9).
2. Check Left 1 in the Wire feed sensor section to enable the Wire
feed detection, or uncheck it to disable
the detection. Check or uncheck Right
1 likewise.
3. Select the Jog Width of the Side
Jogger among from 5 mm (0.12 inch)
or 2 mm (0.08 inch). Normally use 5
mm (0.20 inch). Select 2mm (0.08
inch) only when paper jams at the
stitching section.
4. Select the Opening Timing of the Side
Jogger from the range between 0 and
10. “0” is the standard setting. 0 is
the fastest opening timing, and +10
the slowest. If stitched paper jams
without being ejected from the stitching
section, select a smaller number. If
stitched paper is ejected skewed and
jams at the folding section, select a
larger number.
5. Select the Number of jogs at the
stitching section from between 1 and 9
times. The default setting is 1. If paper alignment is poor, increase the number.
6. Check the Folding Conveyance Belt box to keep the Fold Conveyance Belt operating, or
uncheck it not to keep the belt operating. Normally leave it unchecked because continuous
belt running keeps pressing booklets against the folding stopper. Check the box only when
you have selected “Inactive” for Stitch and “Active” for Fold (see page iv), check the box.
7
DBM-500 Process Preview Fold Position
Stitch Position
You can change several settings in the
DBM-500 Process Preview.
1. Click a number in the Process Preview.
2. Specify a number. You can use the
buttons on the Screen.
● Cancel—This button closes the Screen
without changing the specified number.
● Back—This button erases one digit at a
time or erases all highlighted digits.
● Clear—This button erases all digits at the
same time.
3. Click the OK button after specifying a
number.
Stitch width
DCM Kit
If you cannot use the DCM Kit Screen, see if the DCM Kit
is selected in the Maintenance Settings panel (see Initial Settings (Maintenance Menu), page 1).
1. Select the DCM Kit tab.
2. Check or uncheck Compressor 1 to use or not to use it. Check or uncheck Compressor 2 to
use or not to use it.
3. Select an option to use or not to use the Static Bar.
8
2-4. SETTING DBM-500T
The DBM-500T panel is not available if you select None in the Fold field on the DBM-500 panel.
DBM-500T Panel
1. Select the DBM-500T tab.
2. Check Trim ON to enable the trimmer, or uncheck it to
disable the trimmer. Unlike other settings, the trimmer
is enabled even if you do not click the Send button (see
Sending Data, page 11). This is helpful when you want to
enable or disable the trimmer to examine the results of booklet-
making.
3. Click the Setting Detail… button as necessary.
DBM-500T Detail Settings

1. Specify the operating time of the DBM-
500T Conveyance Belt.
2. Specify the Start Timing of the stacker
Conveyance Belt.
3. Specify the Conveyance Time of the
stacker.
4. Check On in the Kicker section to enable
the kicker or uncheck it to disable the
kicker.
5. Specify how often the kicker operates.
9
DBM-500T Process Preview
1. Click a number in the Process Preview. Trim Position
2. Specify a number. You can use the buttons on the Screen.
● Cancel—This button closes the Screen without changing
the specified number.
● Back—This button erases one digit at a time or erases all
highlighted digits.
● Clear—This button erases all digits at the same time.
3. Click the OK button after specifying a number.
10
2-5. SAVING DATA AND SENDING DATA
It is recommended that you save the settings when you finish specifying them. After this, let the
DUPLO Inline Controller communicate with the bookletmaking system.
Saving My Data
You can save the settings as My Data on your PC or some removable storage. You can use My
Data when you need them. For more information about My Data, see My Data, page 37.
1. Make sure the Operator ID, Order ID, and Job Name on the Job Manager Screen are correct.
2. When you want to save the settings in the default folder by overwriting the previous data of
the same Job Name, click the Save button. When you want to select another folder and/or
when you want to give the settings a new file name (not the ‘Job Name’), select the File menu
and Save. For the difference between these procedures, see My Data, page 37.
Sending Data
You must let the DUPLO Inline Controller communicate with the bookletmaking system to send the
settings to the system. Do not attempt to start the bookletmaking system before the DUPLO Inline
Controller and bookletmaking system communicate. The bookletmaking system may make some
unexpected actions.
NOTE: The DUPLO Inline Controller transfers data to the bookletmaking system after you click the Send button.
Before you do this, the displays on machine Control Panels may contradict the settings on the DUPLO Inline
Controller.
1. Click the Send button on the Job Manager Screen. The bookletmaking system
tries to get ready.
2. Make sure the Send button, Save button, and Hand Feed button are coloured.
These buttons are not coloured while you are making settings.
● These buttons are not coloured when any kind of error has occurred. Solve the
error by referring to the error messages.
● These buttons are not coloured when the DUPLO Inline
Controller has sent the settings that are not supported
by the bookletmaking system. Double-check the settings
and correct them.
System Status
You can view the status of the bookletmaking system from the DUPLO Inline Controller.
1. Click the Status button. The System Status is displayed on the Main Screen.
NOTE: To go back to the Job Manager, push the Job button.
2. If the System Status indicates an error, solve the problem.
● When a paper jam has occurred, the sign is shown on the machine in the
System Status.
● When a cover or door is open, its location is shown
in the System Status.
● When a communication error has occurred,
an exclamation-point sign is shown on the line
between the PC and Interface Box in the System
Status.
● For the details, see the display on the Control
Panel of the machine in question.
11
2-6. STARTING OR STOPPING THE BOOKLETMAKER
Using Hand Feed
Adjust the bookletmaking system before starting booklet-making. The bookletmaking system stores
the information about the sheet in its memory (not in the memory on the PC). By referencing this
information, the bookletmaker manages booklet-making processes. (see 2-7 Fine Adjust, page 16)
1. Click the Hand Feed button on the DUPLO Inline Controller.
2. Check each value shown to the right of “ L

Guide “ and “ R Guide “ on the screen.
3. Move the L guide and R guide according to each

value shown on the screen above.
Feed guide
R Guide
L Guide
4. Push Button A on the Control Panel of SCC (not a button on the DUPLO Inline Controller but
the actual button on SCC). Then TR-DP and SCC started.
Button A
12
5. Put a Sheet in the slot. Then TR-DP sends the sheet to
SCC.
● When [All] has been selected in the Process Mode menu of the
SCC, the sheet will stop inside the SCC.
● When [Through] has been selected in the Process Mode menu of
the SCC, the sheet will be transported to the DBM-500. Go on to
the step 7.
6. Push Button A on the Control Panel of SCC
7. Prepare the number of sheets you have specified and insert the
sheets one by one into the slot. Button B
NOTE: Before you insert a sheet, make sure that the

sheet you inserted right before has been ejected from
the SCC.
● When all of the sheets ejected from the SCC reached the
DBM-500, the DBM-500 will start booklet making and output
booklets.
8. Check for the finish. When necessary, change settings on the
In-Line Controller or adjust the bookletmaking system. You may
have to mechanically adjust the bookletmaking system.
Stitching Test
NOTE: Before you start a stitching test, follow the procedures below.
● SELect [Through] in the Process Mode
menu of the SCC (see 2-2 Setting SCC, page Option Tab
5) and [Saddle] in the Stitch Mode menu of the
DBM-500 (see 2-3 Setting DBM-500, page 7).
Then transfer the data (see 2-5 Saving data and
Sending data, page 11).
Follow the procedures below for a stitch test of the
stitcher.
420. 0 � 297. 0 00
1. Press the OPTION tab on the DBM-500
Touch Panel to display the option menu.
207. 0 � 297. 0
00000
2. Press the Next key to change the screen.
Next key
13
3. Press the Stitch Test key.
The stitch test action screen will appear.
Stitch Test key Stitch Test Action key

4. Follow the steps 1 through 4 in Using <Stitch Test Action> Screen
Hand Feed (see using Hand Feed , page
12).
5. Put a sheet in the slot piece by piece. The TR-DP will send the sheet to SCC.
6. When all the sheets have been sent to the DBM-500, press the Stitch Test Action key on
the DBM-500 Touch Panel. After the sheet is stitched several times, it will be ejected to the
stacker of the DBM-500.
7. Check the stitching condition. When the condition is not satisfactory, adjust the stitcher head.
To finish the stitch test, press the MAIN MENU tab on the DBM-500 Touch Panel several
times.
Stitch length adjusting

knob
Adjust the stitcher head
1. Adjusting the stitch length
● Rotate the stitch length adjusting knob

clockwise to cut the wire short.
● Rotate counterclockwise to cut it long.
● The length changes by about 0.8 mm/0.03
inch with each rotation.
2. Adjusting the left and right

legs length
Adjust the left and right legs to the
same length using the balance L R L R
adjustment wheel.
● When this wheel is rotated upward, Upward Downward

the L side leg becomes longer. U p ward
● When this wheel is rotated
downward, the L side leg becomes Downward
shorter. Balance Viewed from the paper feed inlet
adjustment wheel
14
3. Straightening the wire
Straight wire enables more stable stitching operations.
1. Remove the leaf spring and remove the former.

2. Feed the wire with the adjusting handle. Feed Wheel
Adjusting Handle
Leaf spring
Former
Wire tube lower
3. Rotate the wire straightener.

● Clockwise wraps the wire downward and
rotating it counterclockwise warps it upward.
Adjust until the wire runs out straight.
Clockwise
4. Pull the wire back inside with the handle.
5. Return the former to its original position.
6. Return the leaf spring to its original position. Counter-
clockwise
Rotate clockwise
Wire is straight
Rotate
counterclockwise
Wire straightener
Counter Clear
The number in the counter may not be immediately
reset by changing the number of Sheets on the Job
Manager Screen. To reset the Counter, click the Clear
button.
Start
You must check booklet-making processes or make
some necessary adjustments. When the finish is Clear button
satisfactory, start productive operation.
1. Make sure the Counter on the DUPLO Inline
Controller displays the correct number. Click the Clear button when necessary.
2. Start the DOCUCOLOR iGen 3 system. The bookletmaking system starts making booklets.
Stop
In order to stop the bookletmaking system, stop the DOCUCOLOR iGen 3 system. The
bookletmaking system automatically stops when it finishes making the specified number of
booklets.
15
2-7. FINE ADJUST
You can fine-tune SCC, DBM-500, and DBM-500T by clicking the Fine Adjust button. You can find
a Fine Adjust button on the SCC panel and DBM-500 panel.
CAUTION ● After specifying settings, you must make the DUPLO Inline Controller send
those data to the bookletmaking system (see Sending Data, page 11).
● The DUPLO Inline Controller adjusts the Fold Back Guide and Fold Side
Guides in the range of ±5 mm. DBM-500, on the other hand, can adjust
these guides out of this range. If you, from the Control Panel of DBM-500,
move one of these guides out of the range that the DUPLO Inline Controller
can manage, the DUPLO Inline Controller cannot control the positions any
more.
1. Click the Send button (see Sending Data, page 11).

2. Execute Hand Feed and, if necessary, conduct a test to see the finish (see Starting or Stopping
the Bookletmaker, page 12).
3. Select the SCC tab or the DBM-500, 500T tab.
4. Click the Fine Adjust button.
5. To adjust settings, click one of the following buttons.
SCC DBM-500/DBM-500T
● Reference Position(see 2-7-1, page 17) ● Stitch Position (see 2-7-7, page 23)
● Finished Size (see 2-7-2, page 18) ● Fold Position (see 2-7-8, page 24)
● Crease Position (see 2-7-3, page 19) ● Stitch and Fold Positions (see 2-7-9, page 25)
● Side Jog Positions(see 2-7-4, page 20) ● Stitch, Fold and Crease Positions*(see 2-7-10,
● Back Jog Position (see 2-7-5, page 21) page 26)
● Main Body Position(see 2-7-6, page 22) ● Stitch Width (see 2-7-11, page 27)
● Side Jogger Positions(see 2-7-12, page 28)
● Stitch Back Jogger(see 2-7-13, page 29)
● Fold Side Guides (see 2-7-14, page 30)
● Fold Back Guide (see 2-7-15, page 31)
● Fold Roller Gap (see 2-7-16, page 32)
● DBM-500 Main Body Position(see 2-7-17, page
33)
● Trim Position(see 2-7-18, page 34)
● Roller Gap (see 2-7-19, page 35)
*SCC and DBM-500 can be adjusted at the same time.
6. Use each panel to adjust settings. You can see a drawing on

each panel. Click one of the Adjustment Buttons ( ). The
adjusted position is shown on the panel.
7. Click the Close button.
8. Execute Hand Feed or conduct a test to see the finish.
9. If necessary, repeat these steps.
16
SCC
2-7-1. Reference Position
You can specify a number from –4.50mm (-0.177 inch) to +4.50mm (+0.177 inch), in Y direction.
A number from –3.00mm (-0.118 inch) to +3.00mm (+0.118 inch), in X direction. If you enter a
positive number, the Reference Position goes farther from the actual corner of a sheet. If you enter
a negative number, the Reference Position comes closer to the actual corner of a sheet.
Positive Negative
numbers numbers
X
Positive Reference
numbers Position
Negative Y
numbers
Edge of Corner of
a sheet a sheet
1. Click the Ref. Position button.
2. Click One of the Adjust button( ). The adjusted position is shown on the Screen.
NOTE: For more information, see the Instruction Manual of SCC.
17
2-7-2. Finished Size
By entering a number from –3.00mm (-0.118 inch) to +3.00mm (+0.118 inch), you can adjust the
length of finished size and width of finished size.
Length of
Finished Size
Finished Size
Finished Size Finished Size

Width of
Sheet before Sheet after

processing processing
1. Click the Finished Size button.
18
2-7-3. Crease Position
By entering a number from –3.00mm (-0.118 inch) to +3.00 (+0.118 inch), you can adjust the
crease position.
Length of
Finished Size
80 mm (3.15”) 80 mm (3.15”)
Not Crease Not

possible possible possible
Crease Crease Sheet after

Sheet before
Position processing processing
1. Click the Crease button.
19
2-7-4. Side Jog Positions
SCC has two Side Joggers. The Side Joggers push the side edges of a sheet to correct the
position of the sheet. By entering a number from –4.5mm (-0.177 inch) to +4.5mm (+0.177 inch),
you can adjust the side jog position.
Side Jogger
Paper
Opening
1. Click the Side Jogger button.
20
2-7-5. Back Jog Position
SCC has one Back Jogger. The Back Jogger pushes the tail edge of a sheet in the direction of its
lead edge. Doing so, the Back Jogger aligns the lead edge of a sheet with the Stopper of SCC. By
entering a number from –3.00mm (-0.118 inch) to +3.00mm (+0.118 inch), you can adjust the back
jog position.
Paper travel
Back Jogger
Paper
Stopper Stopper
1. Click the Back Jogger button.
21
2-7-6. SCC Main Body Position
If paper does not pass on the center of the paper pass, paper may not be trimmed at the intended
position or paper jam may occur. In this case, adjust the position of the SCC main unit. You can
specify a number from –30 to +30, where one step equals 0.5 mm (0.02 inch). For example, if you
enter +10, the main body of SCC moves 5.0mm in the direction of A in the drawing.
1. Click the SCC Main Body button.
22
DBM-500
2-7-7. Stitch Position
The saddle stitching stopper and back jogger are moved to finely adjust the stitching position.
By entering a number from -5mm (-0.195 inch) to +5mm (+0.195 inch), you can adjust the stitch
position.
Saddle-stitching stopper
Paper travel
Back jogger
1. Click the Stitch Position button.
NOTE: For more information, see the Instruction Manual of DBM-500.
23
2-7-8. Fold Position
The folding stopper and folding back guide are moved to finely adjust the folding position.
By entering a number from -5mm (-0.195 inch) to +5mm (+0.195 inch), you can adjust the fold
position.
Paper travel
Folding stopper
Back guide
1. Click the Fold Position button.
24
2-7-9. Stitch and Fold Positions
The saddle stitching stopper, back jogger, folding stopper, and folding back guide are moved all
together at the same time to finely adjust the stitching/folding position. By entering a number from
-5mm (-0.195 inch) to +5mm (+0.195 inch), you can adjust the stitch and fold position.
Paper travel
Folding stopper
Saddle-stitching stopper
Paper travel
Back guide
Back jogger
1. Click the Stitch, Fold button.

25
2-7-10. Stitch, Fold and Crease Positions
DBM-500:The saddle stitching stopper, back jogger, folding stopper, and folding back guide are
moved all together at the same time to finely adjust the stitching/folding position. (see 2-7-9 Stitch and
fold Positions, page 25)
SCC: You can adjust the Crease positionen at the same time. (see 2-7-3 Crease Position, page 19)
1. Click the Stitch, Fold, Crease button.
NOTE: For more information, see the Instruction Manual of DBM-500 and SCC.
26
2-7-11. Stitch Width
Move the position of the stitcher to finely adjust the stitching width. Stitching width is the length
between the centers of two stitches. The two stitches are positioned on the centerline of the paper
width. By entering a number from -5mm (-0.197 inch) to +5mm (+0.197 inch), you can adjust the
stitch width.
Stitcher
1. Click the Stitch Width button.
27
2-7-12. Side Jogger Positions
DBM-500 has two Side Joggers. The Side Joggers push the side edges of a sheet to correct the
position of the sheet. By entering a number from -5mm (-0.197 inch) to +5mm (+0.197 inch), you
can adjust the side jogger positions.
Side jogger
1. Click the Side Jogger button.
28
2-7-13. Stitch Back Jogger
DBM-500 has a Stitch Back Jogger. The Stitch Back Jogger aligns the tail edges of the sheets.
By entering a number from -5mm (-0.209 inch) to +5mm (+0.209 inch), you can adjust the Stitch
Back Jogger.
Stitich Back jogger
1. Click the Stitch Back Jogger button.
29
2-7-14. Fold Side Guide
DBM-500 has two Fold Side Guides. By entering a number from -5mm (-0.197 inch) to +5mm (+0.197
inch), you can adjust the Fold Side Guide.
Folding back guide Folding back guide
Folding side guide
Folding side guide
“Opened state of folding back guide”
1. Click the Fold Side Guide button.
30
2-7-15. Fold Back Guide
DBM-500 has a Fold Back Guide. By entering a number from -5mm (-0.209 inch) to +5mm (+0.209
inch), you can adjust the Fold Back Guide.
Paper travel
Back guide
1. Click the Fold Back Guide button.
31
2-7-16. Fold Roller Gap
You can fine-tune the Fold Roller Gap. You can specify a number from –5 to 5, where one step
equals 0.2 mm (0.0078 inch).
Press roller
Folding roller
Viewed from upstream
1. Click the Fold Roller Gap button.
32
2-7-17. DBM-500 Main Body Position
You can fine-tune the position of the DBM-500 main body. You can specify a number from –5 to 5,
where one step equals 3.0 mm (0.12 inch). For example, if you enter +2, the main body of DBM-500
moves 6.0mm in the direction of B in the drawing.
1. Click the DBM-500 Main Body button.
33
DBM-500T
2-7-18. Trim Position
You can fine-tune the finished length. By entering a number from -5mm (-0.195 inch) to +5mm
(+0.195 inch), you can adjust the trim positions.
Trimmer stopper
Spine Booklet Blade
Fore-edge
Short Long
Finished length
1. Click the Trim Position button.
34
2-7-19. Roller Gap
DBM-500T has a pair of conveyance rollers. Adjust the distance between the conveyance rollers.
The standard setting is 0. The distance can be selected between –30 (minimum) to 30 (maximum).
Conveyance roller
1. Click the Roller Gap button.
NOTE: For more information, see the Instruction Manual of DBM-500 and
DBM-500T.
35
Fine-tuning the Finished Length on the DBM-500T
You can fine-tune the finished length on the control panel of the DBM-500T as well.
Jog dial
1 Turn the jog dial until “Adjustment “ is

displayed and press the center of the dial. ��
“ Trim Position“ will be displayed.

��
��
2 Press the center of the jog dial. The value

to be adjusted will be displayed. ��
��
3 Turn the jog dial to display the desired
value.
● Turn the dial to the right--- + (plus) value
will be displayed.
��
● Turn the dial to the left --- – (minus) value
will be displayed.
��
● You can specify a number from –5 to
5mm (-0.197 to 0.197inch), where one step equals 0.1 mm (0.004 inch).
* The maximum finished length is 251.9 mm.
4 Press the center of the jog dial to confirm

the value. ��
● The stopper unit will move according to the
●
value you selected in the step 3.
While the stopper unit is moving, “Please
��
wait“ will be displayed.
5 Press the center of the jog dial.
The finished length will be displayed.

��
��
36
3.MANAGING DATA AND
LOGS
3-1. MY DATA
Making My Data
You can save your settings as My Data and use them when you need them. My Data can be files
on your computer or in some removable storage. Before creating My Data, you must know the
following:
● If you change System Configuration (see Initial Settings (Maintenance Menu), page 1) after saving
files as My Data, the DUPLO Inline Controller does not read these files. To let the DUPLO
Inline Controller read these files, you must change the System Configuration back to the
setting of the time when you have saved these files.
● If you change the unit of measure (see Initial Settings (Maintenance Menu), page 1) after saving files
as My Data, the DUPLO Inline Controller does not read these files. To let the DUPLO Inline
Controller read these files, you must change the unit of measure back to the setting of the time
when you have saved these files.
● You can save 2000 files or less in the default folder.
● The first time you start the DUPLO Inline Controller after turning on the PC, it may take seven
to eight seconds to get started if the file number reaches 2000. The time varies depending on
PC specifications.
● You cannot save a file with incorrect settings. Correct your settings if an error message
appears.
Making a New File

You can make a new file as follows.
1. Select the File menu and New File.
2. Type an Operator ID, Order ID, and Job Name.
3. Specify necessary settings (see Setting Jobs, page 4).
Saving My Data
You can use the Save button or Save as… menu.
1. Specify necessary settings (see Setting Jobs, page 4).
2. Click the Save button or select the File menu and Save as…. These two make the following
difference.
Clicking the Save button Selecting the Save as… menu
Storage Default folder (see Default Folders, page 52) Any folder of your choice
Accessibility Listed in the My Data list Not listed in the My Data list
Job Name/File Unique Job Name for each file You can give each file a name. You can save
Name multiple files that contain the settings of the
same Job Name.
How to Loaded from the My Data list Accessible from the File menu
retrieve
How to delete Deleted from the My Data list Deleted like any other file on the PC
Using or Deleting My Data

As mentioned above, you can save your files in the default folder as My Data. You
can view these files from the My Data list. You can load, or reuse, these files from
this list.
Loading My Data
1. Click the My Data button. The My Data list is displayed.
2. Find necessary data. You can sort the entries by clicking the Job Name bar, Operator ID, and
so on.
37
3. Right-click on a job name.
4. Select Load.
5. Click Save changes? and select “Yes” .
Finding My Data from the File Menu
1. Select the File menu.
2. If you see the file name in the list, you
can select and open it. If you do not see
the file name in the list, choose Open in
the File menu.
Deleting My Data
1. Right-click on the job name.
2. Select Delete.
Deleting My Data Files
When you do not see files in the Main Screen of My Data, you can delete them in the same way as
you delete other files from the PC.
3-2. JOB HISTORY

When the DUPLO Inline Controller sends
a job setting to the bookletmaking system,
the history of the job—Job History— is
automatically saved. The Job History is saved
in the default folder (see Default Folders, page
52). You cannot disable the Job History or
change the storage folder. You can load an
entry from the Job History list, and make the
bookletmaking system execute the same job
as is logged.
● You can save 1000 files or less on the Job History.

● The first time you start the DUPLO Inline Controller after turning on the PC,
it may take seven to eight seconds to get started if the file number reaches
1000. The time varies depending on PC specifications.
Viewing Job History

The Job History shows the following information:
● No.—This shows the order of execution.
● Job Name—This shows the Job Name specified on the Job Manager Screen.
● Sets—This shows how many sets are processed.
● Sheets—This shows how many sheets one booklet has.
● Last Time—This shows the date and time when the Job ends.
Loading Job History

1. Click the Job History button.
2. Find the necessary history.
3. Right-click on the number.
4. Select Load.
5. Click Save changes? and select “Yes” .
38
4. TECHNICAL INFORMATION
4-1. TROUBLESHOOTING
4-1-1. Communication-related Errors
The following error messages appear when the PC and bookletmaking system are not
communicating correctly. Also, these errors may occur when you specify illegal settings on the
Failed to communicate with TR-DP
Failed to communicate with SCC
Failed to communicate with DBM-500
Failed to communicate with DBM-500T
Failed to communicate with DCM Kit
Failed to communicate with Kicker
Symptom
When one of these errors occurs, you see an error message. ‘Failed to communicate with SCC’ is
one of the examples. You cannot use the Send button or some of the Action Buttons on the DUPLO
Inline Controller.
Corrective Action 1
You can, more often than not, solve communication-related errors by quitting the DUPLO Inline
Controller.
1. Quit the DUPLO Inline Controller. If you have not saved current data, you may have to save it.
3. See if any error message appears.
Corrective Action 2
If the above-mentioned action does not clear the error, you have to quit the DUPLO Inline Controller
and have to stop the bookletmaking system.
1. Quit the DUPLO Inline Controller.
3. Check that the connection between the PC and Interface Box is right.
Corrective Action 3
If the above-mentioned actions do not clear the error, you have to see if you have selected a correct
communication port (see Initial Settings (Maintenance Menu), page 1).
---------------------------------------------------------------------------------------------------------------------
Turn off and on the system.
Cause
The Interface Box is turned off.
Corrective Action
Turn on the Interface Box.
---------------------------------------------------------------------------------------------------------------------
System Communicate Error !
Symptom
After communication has started, there is no reply from the Interface Box.
Corrective Action
Turn on the Interface Box.
39
Invalid Data Transfer
Symptom
Under either of the following conditions, you cannot send data to the bookletmaking system:
● The bookletmaking system is executing a size change.
● The Control Panel of a unit or component in the bookletmaking system is used.
● The job setting requires more sheets than is specified.
● The job setting needs DBM-500 to fold the booklets. But the number of sheets in one booklet
is 26 or more.
Corrective Action
● Wait for the bookletmaking system to finish the size change.
● Do not use any Control Panel in the bookletmaking system. Return each Control Panel display
to its initial display.
● Correct the setting.
Malfunction
The following error messages are indicated when the PC and bookletmaking system cannot
operate.
Check TR-DP !
Check SCC !
Check DBM-500 !
Check DBM-500T !
Symptom
When one of these errors occurs, You cannot use
the Send button or some of the Action Buttons on the

3. Quit the DUPLO Inline Controller.
4. Restart the PC.
6. Turn on the Interface Box.
9. If you see the same message, call the service bureau.
40
4-1-2. Emergency stop
The machine stops immediately when you push the Emergency Stop Switch.
The System Status indicates a signal on the bookletmaking system.
Emergency Stop - SCC !
Solve the problem as follows:
1. Turn the Emergency Stop Switch of SCC clockwise.
2. Remove the jammed paper.
Emergency
Stop Switch
Emergency Stop - DBM-500 !

1. Turn the Emergency Stop Switch of DBM-500 clockwise.
Emergency
Stop Switch
Emergency Stop - DBM-500T !

1. Turn the Emergency Stop Switch of DBM-500T clockwise.
Emergency
Stop Switch
41
4-1-3. Paper Jam
When a paper jam occurs, the System Status indicates a signal on the bookletmaking system.
Paper Jam- TR-DP !

1. Grasp the Handle on the Paper Path Cover, and open the cover. Hold the cover so that the
cover is not accidentally closed.
3. Set the Paper Path Cover back to the original position slowly.
Handle
Paper Path Cover
Paper Jam- SCC !

On the Control Panel of SCC, you see the message Paper Jam followed by another message that
shows where the paper jam has occurred.
Paper Jam Entrance 01

1. Grasp the Handle on the Paper Path Cover, and
open the cover. Hold the cover so that the cover is
not accidentally closed.
3. Set the Paper Path Cover back to the original
position slowly.
Paper Jam Entrance 02

1. Grasp the Handle on the Paper Path Cover, and open the cover. Hold the cover so that the
cover is not accidentally closed.
3. Set the Paper Path Cover back to the original position slowly.
4. Open the upstream Top Cover.
5. Raise the Guide.
7. Set the Guide back to the original position.
8. Close the Top Cover.
9. Raise the upstream Bypass.
11. Set the Bypass back in the original position.
upstream Bypass
upstream Top Cover Bypass
Guide
Jammed Paper
Jammed Paper
42
Paper Jam Stopper 01 upstream Bypass
1. Raise the upstream Bypass.
3. Set the Bypass back in the original position.
Bypass
Jammed Paper
Paper Jam Lower conveyance Downstream Bypass

1. Raise the upstream Bypass. upstream Bypass
2. Raise the downstream Bypass.
3. Raise the Sensor Bracket. Sensor Bracket
5. Set the Sensor Bracket in the original
position
6. Set the upstream Bypass and the
downstream Bypass in the original
position.
7. Check that the Scrap Box is not full.
Downstream
Jammed Paper Bypass
Guide
Paper Jam Delivery 01

1. Raise the Downstream Bypass.
2. Make sure that Guide is raised.
Jammed Paper
3. Raise the Cover. Downstream Bypass

5. Set the Cover back to the original position
6. Set the Bypass and Guide back to the original Cover Jammed
positions. Paper
43
Paper Jam Delivery 02
1. Raise the downstream Bypass. Downstream Bypass
2. Make sure that Guide is raised.
4. Set the Guide back to the original position. Guide
5. Set the Bypass and Guide back to the
original positions.
Jammed Paper
Paper Jam Bypass Front

1. Open the upstream Top Cover. upstream Top Cover
2. Raise the Guide.
3. Remove the jammed paper. Guide
5. Close the upstream Top Cover.
Jammed Paper
upstream Top Cover

Paper Jam Bypass Center
1. Open the upstream Top Cover.
2. Open another Top Cover next to the Jammed
upstream Top Cover. Paper
3. Open the downstream Top Cover. Downstream Top Cover

4. Open another Top Cover next to the
downstream Top Cover.
5. Remove the jammed paper. Jammed
6. Close the downstream Top Cover. Paper
7. Close the upstream Top Cover.
44
Paper Jam Bypass Rear
1. Open the downstream Top Cover. Downstream Top Cover
2. Raise the Guide.
3. Remove the jammed paper. Jammed Paper
5. Close the downstream Top Cover.
Guide
Paper Jam- DBM-500 !

You see the Jam locations on the touch panel of DBM-500 where the paper jam has occurred.
If paper jam has occurred at the stitching section

1. Open the Front top cover.
2. Raise the conveyance roller lifting handle.
3. Remove the jammed paper. Conveyance roller
lifting handle
4. Set the conveyance roller lifting handle back
to the original position.
5. Close the Front top Cover.
Jammed Paper
If paper jam has occurred at the folding section

1. Open the Rear top cover.
2. Raise the Back guide handle. Back guide handle
4. Set the Back guide handle back to the
original position.
5. Close the Rear top Cover.
Jammed Paper
If booklet remain at the folding rollers.
45
1. Slide the Shutter open.
2. Set the handle.
3. Turn the Folding roller.
4. Remove the booklets.
5. Remove the handle.
6. Close the Shutter.
Handle
Paper Press roller
Paper Jam- DBM-500T !

On the Control Panel of DBM-500T, you see the message Paper Jam followed by another message
that shows where the paper jam has occurred.
1. Open the Top cover.

Top cover
If cannot remove the jammed paper, detach the Infeed roller unit
infeed roller unit as shown right.
1. Press the shaft top to release it from the bracket.

2. Moving the infeed roller unit in the arrow direction Shaft
and detach the unit. Shaft
4. Set the infeed roller unit back to the original
position.
Shaft
Infeed roller unit
46
4-1-4. Cover Open
When a cover is out of position, the System Status indicates a signal on the bookletmaking system.
Cover Open - TR-DP !

Close the Paper Path Cover.
Paper Path Cover
Cover Open - SCC !
Close the Top Covers.

Top Cover
Top Cover
Set the Scrap Box back in the original position.

Close the Bottom Cover of Slitter.
Bottom Cover
Scrap Box
47
Cover Open - DBM-500 !
Close the Top Covers.

Top Cover
Top Cover
Cover Open - 500T !
Close the Top Cover.

Set the Scrap Box back in the original position.
Top cover Scrap Box
4-1-5. Scrap Box Full

When the Scrap Box is Full, the System Status indicates
a signal on the bookletmaking system.
Scrap Box Full - SCC

CAUTION: Do not remove the Scrap Box out of SCC
until the system stops. Also, do not remove the sheets
left inside DBM-500. Once you set the Scrap Box in
its original position after emptying it, the system will
automatically start and resume binding for the sheets left
inside DBM-500.
1. Remove the Scrap Box out of SCC.

2. Empty the Scrap Box.
Scrap Box Scrap Box
48
Scrap Box Full - DBM-500T
CAUTION: Do not remove the Scrap Box out of DBM-

500T until the system stops. Also, do not remove the
sheets left inside DBM-500. Once you set the Scrap Box
in its original position after emptying it, the system will
automatically start and resume binding for the sheets left
inside DBM-500.
1. Remove the Scrap Box out of DBM-500T.

2. Empty the Scrap Box.
Scrap Box
4-1-6. Stacker Full

When the Stacker is Full, the System Status indicates a signal on the bookletmaking system.
Stacker Full - DBM-500
Remove the booklets on the stacker.

The error message is cleared when the Top cover opened/closed.
Booklets
System Error - Spine Master !
Remove the booklets on the SpineMaster TM.
Booklets
49
4-1-7. Staple Empty
When Stitcher’s wire is empty, the System Status
indicates a signal on the bookletmaking system.
Staple Empty - DBM-500
1. Remove the leaf spring and collar from the wire reel.
2. Exchange the wire reel for new one.
3. Attach the leaf spring and collar to the wire Wire Reel Mount Wire Reel
reel.
Leaf spring
Collar
4. Pass the wire through the wire guides.
Wire guide
Wire guide
Wire
Wire guide
Wire
5. Pass the wire to the wire feed detection unit.

Sandwich the wire between the bearing and Wire
roller. Bearing
6. Pass the wire between the two felt disks and
Roller
through the wire return lock.
Wire feed detection unit
7. Insert the wire into the tip of the wire tube

upper. Wire
Be careful not to bend the wire
Felt disks
Wire return lock
50
8. Check that the triangular handle is at the stitching Triangular handle
position where there is no clearance.
No clearance Clearance
Stitching position Non stitching position
9. Insert the wire into the tip of the wire tube upper,
and feed with pliers until the wire reaches the Wire
feed wheels.
Be careful not to bend the wire
Pliers
Wire tube upper
Feed wheels
10. Mount the adjusting handle onto the feed

wheel, rotate to the right, so that the wheels
grip the wire. Feed Wheel
11. Rotate the handle clockwise about two times
to feed the wire
Adjusting Handle
Wire tube lower
NOTE: If the wire is bent, it will not enter the wire tube, and jam instead. Pull the wire,
cut off the bent part, and feed it again.
51
4-1-8. Incorrect Display
Symptom
The graphical user interface seems to be disorganised. Some characters, buttons, and/or images
are in wrong places. If such symptom occurs, you should change the DPI setting of your PC display.
Corrective Action
1. Right-click on the desktop.
2. Select Properties.
3. Select the Settings tab.

4. Click the Advanced button.
5. Select the General tab.

6. In the Display section, choose Normal size (96 DPI).
7. Click the OK button. If you are prompted to restart Windows, click the OK button and restart
your PC.
4-1-9. Setting-related Errors

These errors occur when you have made some setting that the bookletmaking cannot manage.
DCM Kit Timer Function
When you use the Timer Function of the DCM Kit, some of the Actions Buttons and the Send
button may become temporarily unavailable. This may continue for about one minute (see Timer
Function of DCM Kit, page 7).
4-2. DEFAULT FOLDERS

My Data
The following folders save My Data:
● My Data_inch—For the data specified in inch.
● My Data_mm—For the data specified in millimetre
Job History
The following folder saves Job History:
● History Logs
52
5. SPECIFICATIONS
5-1. INTERFACE BOX
Model Interface Box
• AC 220 to 240 V, 50/60 Hz
5-2. TR-DP
Model TR-DP
Type Add-on transport bridge
Paper Size (W × L) Max: 356 × 500 mm (14.0 × 19.7 in.)
Min: 120 × 170 mm (4.72 × 6.69 in.)
Paper Type • Fine: 60 to 300 g/m²
• Coated: 84.9 to 300 g/m²
Paper Curl 6 mm (0.24 in.) or less, R20 or larger
Paper Path Alignment Center of the paper
Height of paper entrance 845 to 1086 mm(33.3 to 42.8 in.)
Process Speed 1000 to 1500 mm/sec (39.4 to 59.1 in./sec)
Sensors • Paper jam
• Paper path cover
Operating Environment • Temperature: 15°C to 35°C (59°F to 95°F)
• Luminosity: 1500 lux or less
Noise Emission 67 dB or less
Power Supply • AC 120 V + 6% to -10%, 60 Hz
• AC 220 to 240 V +6% to -10%, 50 Hz
Weight • Main body: 27 kg (59.5 lb) excluding accessories
• Accessories: 2 kg (4.4 lb)
53
5-3. SCC
Model SCC
Type Slitter cutter creaser; Floor model
Paper Size (W × L) • Process Path
Max: 356 × 500 mm (14.0 × 19.7 in.)
Min: 120 × 170 mm (4.72 × 6.69 in.)
• Bypass
Max: 356 × 500 mm (14.0 × 19.7 in.)
Min: 120 × 170 mm (4.72 × 6.69 in.)
Paper Type • Process Path
Fine 80 to 300 g/m 2
Art/Coated: 84.9 m 2 to 300 g/m 2
• Bypass
Fine 60 to 127.9 g/m 2
Art/Coated*1 84.9 to 157 g/m 2
Paper Curl • 60 to 127.9 g/m 2 : 10 mm (0.39 in.) or less
• 127.9 to 300 g/m 2 : 5 mm (0.20 in.) or less
Process Speed • All Mode (Process Path)
Slitter: 60 sheets/minute
Cutter: 25 sheets/minute
Creaser: 60 sheets/minute*2
Slitter + Creaser: 60 sheets/minute*2
Cutter + Creaser: 25 sheets/minute
Slitter + Cutter: 25 sheets/minute
Slitter + Cutter + Creaser: 25 sheets/minute
• Through Mode (Bypass)
A3: 150 sheets/minute
A4: 200 sheets/minute*3
Paper Travel Speed • Paper feed/Paper exit: 1000 to 1500 mm/sec*4
• Bypass: 1000 to 1500 mm/sec
Slitter 4 to 25 mm (0.16 to 0.98 in.)*5
54
Cutter • Lead edge: 4 to 25 mm (0.16 to 0.98 in.)*6
• Trail edge: 5 to 25 mm (0.20 to 0.98 in.)*6
Creaser One crease per sheet (The following conditions must be met.)
• 80 to 360 mm (3.1 to 14.2 in. ) from lead edge, and
• 80 mm (3.1 in.) or more from tail edge
Adjustable Range of • Side Joggers: ±0.5°
Paper Skew
• Cutter: ±1.0°
• Creaser: ±1.0°
Finished Size (W × L) Max: 356 × 500 mm (14.0 × 19.7 in.)
Min: 120 × 170 mm (4.72 × 6.69 in.)
Noise Emission • SCC: 67dB*7
Power Supply • Europe: AC 220 to 240 V (+6% to –10%), 50 Hz, 0.6 A
• North America: AC120 V (+6% to –10%), 60 Hz, 1.1 A
Dimensions (W × D × H) Max: 1320 × 735 × 810 mm
Min: 1320 × 610 × 810 mm
*1 The maximum size is A3 or 11 × 17 in. when paper weight is 105 g/m 2 or less.
*2 25 sheets when crease positions are more than 300 mm from tail edges
*3 Can be restricted by downstream units
*4 1400 mm/sec as default
*5 Edges for both sides are slit.
*6 Both edges are cut.
*7 Measured under the following conditions:
Horizontal distance: 1 meter from the Control Panel
Vertical distance: 1 meter from the floor
5-4. DCM KIT
Model DCM Kit

Type Floor-type static eliminator/air supply unit
• AC 220 to 240 V, 50/60 Hz
(Main unit only)
(Main unit only)
55
5-5. DBM-500/DBM-500BR
Model DBM-500
Type Stitcher folder
Paper Size (W × L) • Saddle stitching
Max: 356 × 508 mm (14.02 × 20.00 in.)
Min: 120 × 178 mm (7.01 to 4.72 in.)
• Side stitching/corner stitching
B5 LEF, A4 (LTR) SEF/LEF, B4 SEF, LGL LEF
Paper Type • Saddle stitching and folding
Fine quality paper—64 to 127.9 g/m² (17 to 33 lb)
Art and coated paper—84.9 to 157 g/m² (24 to 41 lb)
paper)*1
Cover sheet—Below 300 g/m² (79 lb)
• Side and corner stitching
Fine quality 64 to 127.9 g/m² (17 to 33 lb)
paper)*2
Fine quality paper, 178 × 120 mm (7.01 × 4.72 in.), 5 sheets or less
• 4500 sets/hour
• 3900 sets/hour
Stitching • Number of stitches—0 to 2*3
• Stitch thickness—5 mm or less (Fine quality paper,
81.4 g/m² (22 lb), 50 sheets)
• Wire size— #25 to #27
Folding 25 sheets or less*4
Operating Environment • Temperature: 5˚C to 35˚C(41°F to 95°F)

Power Supply AC 220 to 240 V, 50 Hz, 3.8A/ AC 120 V, 60 Hz, 6.5 A
Dimensions (W × D × H) • In storage
1610 × 770 × 1020 mm (63.39 × 30.31 × 40.16 in.)
excluding stitcher heads
• In use
2230 × 865 × 1300 mm (87.80 × 34.06 × 51.18 in.)
including the belt stacker
EF: Short Edge Feeding

LEF: Long Edge Feeding
*1 Thick paper: 1.5 mm (0.06 in.) or less, 127.9 g/m² (23lb)
*2 5.0 mm (0.20 in.) or less, 81.4 g/m² (22lb), A4/LTR
*3 Up to 4 (optional)
*4 1 cover (300 g/m² (79 lb)) + 24 sheets (81.4 g/m² (22 lb))
56
5-6. DBM-500T
Model DBM-500T
Type Fore-edge trimmer
Paper size (W × L) Max: 356 × 250 mm (14.02 × 9.84 in.)
Min: 120 × 85 mm (4.72 to 3.35 in.)
The length above is before trimming.
Paper Type • Fine quality paper—64 to 127.9 g/m² (17 to 33 lb)
• Art, coated paper—84.9 to 157 g/m² (24 to 41 lb)
less
• 4500 sets/hour
Fine quality paper, 81.4 g/m² (22 lb), 10 sheets, A4/Letter,
Saddle-stitched
• 3900 sets/hour
Fine quality paper 81.4 g/m² (22 lb), 10 sheets, A3/Ledger,
Saddle-stitched
Trimming 2 blades (top/bottom)
Trimming Capacity 50 sheets, 81.4 g/m² (22 lb)
Finished Size 75 to 250mm (2.95 to 9.84 in.)
Trimmed Size 1 to 25 mm (0.04 to 0.98 in.)
Power Supply 220 to 240 V, 50 Hz, 3.3A/120 V, 60 Hz, 5.4A
Weight 241 kg (531.3 lb) including accessories
5-7. DBM-LS1/DBM-K
DBM-LS1
Model DBM-LS1
Type Long stacker
* When DBM-K is mounted
1369 × 670 × 970 mm (53.90 × 26.38 × 38.19 in.)
DBM-K
Model DBM-K
Type Kicker
57
5-8. SPINEMASTER
Product Specifications
Intended Use This product is intended for the re-forming of booklet spines, to flatten the booklet and give a square
appearance to the spine, within the specifications below.
Production up to 1400 per hour single pass
Booklet Size from 80 x 120mm to 250 x 350mm

(dependant on specification of connected equipment)
Booklet Thickness minimum of 1mm, 0.04”

maximum of 6.5mm, 0.25”. This is approximately 30 sheets of 80gsm (20# bond) folded into a 120 page
booklet.
Dimensions
Width 707, 28”
Depth 690-762mm, 27-30” (dependant on version)
Height 1138-1178mm, 45-461/2 ” (dependant on version)
Weight 132kg, 291lb
Electrical 230V, 50Hz, 3A or 115V, 60Hz, 5A

Single Phase, Earthed supply required
Noise 72 dB(A)
Production and specifications are subject to operating conditions. The specified paper thickness figures are given for guidance only.
The actual performance of the machine will depend on the nature of the paper and covers used. In line with a policy of continual
improvement, the manufacturer reserves the right to alter the materials or specifications of this product at any time without notice.
Radio Frequency Emissions

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC
Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in
a commercial environment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful interference to radio communications.Operation of this equipment in a
residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own
expense.
58
Safety Data Sheet
Date: July 2003, Rev 1
SAFETY DATA SHEET

JULY 2003, REVISION 1
Model Watkiss Automatic SpineMaster
Description Spine-former for post-processing saddle stitched booklets to produce a SquareBack spine
Dimensions
Width 707mm
Depth 745mm
Height 1242mm
Weight 132kg
Voltage 230V (210-254V) 115V (105-127V)
Frequency 50Hz 60Hz
Current 3.0A 4.8A
Protection Fuse 5.0A 10A
Power consumption, operation 600VA 415VA
Power consumption, standby 37VA 19VA
Mains connection removable cable & plug removable cable & plug
Safety class I I
Protection class IP 20 IP 20
Sound pressure level
(at operator/bystander position) Standby: 0 dB (A); In use: 72 dB (A) typical
Radio interference Complies with Directive 89/336/EEC
Radiation Not applicable
Ozone emission Not applicable
Room volume No special requirements
Room ventilation No special requirements
Consumables None
CE Compliance
Safety: 73/23/EEC and 98/37/EC
EMC: 89/336/EEC
This safety data sheet has been compiled to the best of our knowledge as a compact guide to safe handling of this product. We reserve
the right to revise safety data sheets as new information becomes available. It is the user’s responsibility to determine the suitability
of this information for the adoption of safety precautions as may be necessary and to contact the company to make sure that this sheet
is the latest one issued. If and in so far as limitation of liability is permitted under the applicable laws, we do not accept liability for any
inaccuracy that may occur in this information.
59
Duplo Corporation
Duplo Building, 4–1–6, Oyama, Sagamiharashi, Kanagawa, 229–1180, Japan
Tel.: +81–42–775–3602
Fax: +81–42–775–3606
E-mail: info@duplo.com
12C-90521-0612-0010D-0

DUPLO DBM-5000 In-Line Bookletmaker Service Manual

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DUPLO DBM-5000 In-Line Bookletmaker Service Manual

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Duplo DBM-5000 In-line Bookletmaker

Page iii Introduction

Duplo DBM-5000 is a bookletmaking system that is managed by the Inline

If the only error message is displayed on Inline Controller, see Section 2,

1-2 Section 1—Service Call Procedures

Perform a maintenance check approximately every six months or every

Cleaning and Inspection

1-3 Section 1—Service Call Procedures

1-4 Section 1—Service Call Procedures

1-5 Section 1—Service Call Procedures

• The shoe tongues

• All gears and racks

Bracket Bracket Press roller

Viewed from upstream

1-6 Section 1—Service Call Procedures

1-7 Section 1—Service Call Procedures

Perform a maintenance check approximately every six months or every

Cleaning and Inspection

Clean and inspect components as often as reasonably possible.

1-8 Section 1—Service Call Procedures

Perform a maintenance check approximately every six months or every

Cleaning and Inspection

1-9 Section 1—Service Call Procedures

Cleaning the Carriage Roller and Stop

Operating Modes Book Thickness Adjustment

1-10 Section 1—Service Call Procedures

Stopping the System

Starting the System

1-11 Section 1—Service Call Procedures

Do you see an error message on the Inline Controller?

2-2 Section 2—Repair Analysis Procedures Inline Controller

2-3 Section 2—Repair Analysis Procedures Inline Controller

2-4 Section 2—Repair Analysis Procedures Inline Controller

2-5 Section 2—Repair Analysis Procedures Inline Controller

Go to the section in See….

2-6 Section 2—Repair Analysis Procedures Inline Controller

2-7 Section 2—Repair Analysis Procedures Inline Controller

2-8 Section 2—Repair Analysis Procedures Interface Box

2-9 Section 2—Repair Analysis Procedures Interface Box

Continue with RAP on next page.

2-10 Section 2—Repair Analysis Procedures Interface Box

WARNING 250V 10A

| Switching Power Supply and the Interface unit.

2-11 Section 2—Repair Analysis Procedures Interface Box

2-12 Section 2—Repair Analysis Procedures Interface Box

Do you hear an alarm sound?

2-13 Section 2—Repair Analysis Procedures TR-DP

2-14 Section 2—Repair Analysis Procedures TR-DP

Remote switch Main power Main power switch Remote switch

DCM Kit DBM-500

SCC Remote switch Main power

Interface Box TR-DP

Main power switch Main power switch

2-15 Section 2—Repair Analysis Procedures TR-DP

Check that the fuse on the RM Unit is not damaged.

2-16 Section 2—Repair Analysis Procedures TR-DP

2-17 Section 2—Repair Analysis Procedures TR-DP

2-18 Section 2—Repair Analysis Procedures TR-DP

Remote Switch Main Power Switch

2. Remove the Cover F (REP2.1).

4. Replace the covers.

2-19 Section 2—Repair Analysis Procedures TR-DP

2-20 Section 2—Repair Analysis Procedures TR-DP