Manual Servicio Dp-m410

SERVICE MANUAL
DUPRINTER
DP-M400/M410/M420
Dec. 2009
DUPLO DP-M400/M410/M420U6-Y1100
Revision 0
Introduction
The cause of most accidents is failure to adhere to basic safety rules and observe safety instructions. It is important to prevent potential causes of accidents from occurring. In order to do so, read this manual carefully, and be sure to understand all the safety instructions and correct inspection and servicing procedures that it provides before beginning repair or servicing work. Repairing or servicing the machine with insufficient knowledge about it could lead to unforeseen accidents. It is not possible to anticipate and describe in a manual such as this every possible hazard that could arise in the course of repair and servicing. Therefore, besides observing the safety instructions marked in this manual and on the machine's labels, service personnel should be safety-conscious and take other safety precautions as necessary. When performing repair or service work not covered by this manual, you should obtain safety guidance from an appropriately knowledgeable person.
Note: This symbol mark is for EU countries only. This symbol mark is according to the directive 2006/66/EC Article 20 Information for end-users and Annex II. This symbol means that batteries and accumulators, at their end-of-life, should be disposed of separately from your household waste. If a chemical symbol is printed beneath the symbol shown above, this chemical symbol means that the battery or accumulator contains a heavy metal at a certain concentration. This will be indicated as follows: Hg: mercury (0.0005%), Cd: cadmium (0.002%), Pb: lead (0.004%) In the European Union there are separate collection systems for used batteries and accumulators. Please, dispose of batteries and accumulators correctly at your local community waste collection/recycling centre.
Copyright 2009 DUPLO SEIKO CORPORATION All Rights Reserved

1
D Using the service manual

This manual contains the following information: structure and function of major parts, disassembly and reassembly procedures, specifications, and procedures for adjustment, maintenance, inspection and corrective action. This information is current as of December 2009, and applies basically to the model DP-M400/410/420 DUPRINTER. From time to time, parts are changed to improve quality, performance or safety. Note therefore that in some cases, certain parts or machine structure aspects described in the text or illustrations of this manual may not be precisely the same as the product being serviced. Safety instructions marked with a " " (WARNINGS and CAUTIONS) are very important for safety and must be observed.
'Safety-related instructions WARNING: If the instructions accompanying this symbol are ignored and the
machine is operated incorrectly, death or serious injury is likely to result.
CAUTION: If the instructions accompanying this symbol are ignored and the
machine is operated incorrectly, death or serious injury, or else material damage, is likely to result.
Examples of pictorial symbols

A " " symbol tells you that a certain action is forbidden. Precisely what is forbidden is indicated by a picture inside the symbol (in the example here, the picture means that disassembly is forbidden), or in writing at the side of the symbol. A " " symbol means that a certain action is forbidden and/or that a specific instruction must be followed. The specific instruction is indicated by a picture inside the symbol (in the example here, the instruction is "Remove the power plug from the socket").
'Service work-related instructions IMPORTANT: Draws attention to important information. If this information is ignored
and the machine is operated or serviced incorrectly, the machine`s performance could drop, or it could break down.
NOTE:
Draws attention to information that is useful for operation or maintenance of the machine, and to information about its performance, etc.
Safety instructions
Safety instructions
1. Cautions regarding the installation location
Safety instructions
Installation environment Avoid installing the machine in places exposed to direct sunlight. Sunlight will cause the temperature in the machine's interior to rise, possibly leading to malfunction of the control system. Sunlight could cause misoperation of the sensors. The heat of direct sunlight could cause deformation of the machine's plastic parts. * Also avoid installation near to a ground glass window; light and heat penetrate such windows although they are opaque. Avoid installing the machine in places subject to high or low temperature or humidity. High or low temperature or humidity could cause the machine to operate abnormally. Suitable temperature and humidity ranges are: Ambient temperature: Ambient humidity: 10y430y 40%470%
Optimum temperature and humidity: 20y, 65% If the machine is installed near to faucets, water heaters or humidifiers, or in cool (sunless) parts of a building or in the vicinity of water sources, the paper could absorb moisture and curl, leading to misfeeds or poor image quality. Avoid installing the machine in places with open flames, or where reflected heat or other hot air currents (from stoves, etc), or cold air currents from coolers, etc will strike it directly. Avoid installing the machine in poorly ventilated places. Avoid installing the machine in dusty places. The machine should not be tilting when it is used. Install the machine so that it is level. (The machine should be level to within 5mm in the front-rear direction, and 5mm in the lateral direction.) Do not install the machine on shaky, sloping or otherwise unstable surfaces. The machine could fall over on such surfaces, or fall off them, causing injury.
Safety instructions
2. Cautions for installation work
Warning
The machine's power supply voltage and power consumption depend on the model. Details of this are given in the tables below. The power supply voltage and power consumption for the machine are given in the table below. The machine's power supply voltage is indicated on the identification plate located on the machine's left side; the machine must be connected to a power supply of the voltage indicated. a Otherwise, fire or electric shock could result. If the power supply voltage is unstable or if the power supply has insufficient capacity, the machine may not operate normally. Make sure that the power supply has sufficient capacity for the system as a whole, including optional equipment.
* 120V AC model
Power supply voltage With no load* At full load Power consumption Connect to outlet of 120V AC, 60Hz, at least 15A No more than 130V AC At least 110V AC
} Use power supply meeting these requirements
During mastermaking : 95W During printing at speed 3 (printing speed) : 135W On standby : 19W
* 230V AC model
Power supply voltage With no load* At full load Power consumption Connect to outlet of 230V AC, 50Hz, at least 8A No more than 250V AC At least 210V AC
} Use power supply meeting these requirements
During mastermaking : 95W During printing at speed 3 (printing speed) : 135W On standby : 19W
* "With no load" - when the machine is on standby. * "At full load" - when the machine is running at maximum power consumption.
Use only the power cord that is provided among the accessories. Insert the power cord plug firmly into the socket, so that proper electrical contact is effected. Install the machine close to its power supply. The outlet used should be exclusively for the machine, and have no other equipment connected to it. If an extension cord is necessary, it should have a ground terminal, and be of the following ratings: * For a 120V AC model: 130V, at least 15A, length not exceeding 5m. * For a 230V AC model: 250V, at least 8A, length not exceeding 5m. Never tread on the power cord or pinch it between other objects, or accidents could result.
CAUTION
Install the machine in accordance with the installation procedure appended to this manual. Using the optional printer stand Lock the casters after the machine is installed. a Otherwise, the machine could move or fall over, causing injury. To move the machine, push it by its mounting base. a Pushing the printing (upper) part of the machine could make it fall over. 4
Safety instructions
3. Cautions for maintenance, inspection and servicing
Warning
' Precautions for safe servicing Always remove the power cord plug from the outlet before starting work. a Otherwise, you could get a shock or your hands/fingers could be injured. However, the plug must be left connected to the outlet when performing function checks (of individual motors, a given series of operations, or electrical circuits). When motors are operated alone in function checks, interlocks are deactivated, so be aware of the conditions and positions of related equipment, and take great care not to put your hands or fingers into moving parts. The cutter unit contains hazardous sharp blades. Exercise great care when inspecting the cutter unit or replacing it or its parts. a Otherwise, your hands/fingers could be injured. Do not touch the drum or rollers after turning on the jog switch. Do not put your hands or fingers inside the machine while the drum is rotating. a Otherwise, your hands/fingers could get caught and crushed between the drum and rollers. If optional tape clusters are used The tape clusters have hazardous blades. Exercise care when inspecting or replacing the blades. a Otherwise, your hands/fingers could be injured.
' Working clothes Wear clothing than enables you to work safely.
CAUTION
' Tools Use tools that are appropriate for the work.
Safety instructions
DLocations of warning stickers

The locations of the machine's warning stickers are shown below. To ensure safe work, read the stickers and heed their instructions. Keep the stickers clean at all times. If they become damaged or peel off, replace them with new ones.
1 2
CAUTION
WARNING
Do not insert sharp objects into the master feed area or it will damage electric parts inside. When a master sheet is caught in the master feed area, remove carefully. Please refer to manual for the correct procedure.
M7-T3060
U5-T3110
WARNING
Do NOT remove this cover. There is moving cutting machinery insibe that could injure you. J3-T3200
WARNING
Do NOT put hands inside machine while it is operating. Hands could get caught up or crushed.
WARNING
Do NOT touch the drum or rollers when you operate the jog switch. Do NOT put hands Inside machine while it is operatung. Hands could get caught up or crushed.
L5-T3020
No. 1 2 3 4 5
Parts No. M7-T3060 U5-T3110 J3-T3200 M7-T3030 L5-T3020
Name Caution Label Warning Label Warning Label Warning Label Warning Label
Q'ty 1 1 1 1 1
Introduction
Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 Chapter 9

7
Description of the Operation
Mechanism
Standard / Adjustment
Installation
Maintenance / Check
Troubleshooting
HELP Mode
Others
Table of Contents
Introduction.................................................................................1 Using the service manual ..........................................................2 Safety instructions ...............................................................3 1.Cautions regarding the installation location........................3 2.Cautions for installation work ...............................................4 3.Cautions for maintenance, inspection and servicing .........5 Locations of warning stickers................................................6
Chapter 4
Standards / Adjustment
z Scanner Section.......................................................159 x Mastermaking/Master Feed/Ejection Section........161 c Paper Feed Section..................................................169 v Drum Driving Section..............................................174 b Press Section...........................................................176 n Paper Ejection Section............................................178 m Drum Section...........................................................179 , Electrical System.....................................................183
Chapter 1
Introduction
z Features................................................................................12 x Specifications ......................................................................14 c Dimensions ..........................................................................16 v Mechanism ...........................................................................17 b Master ...................................................................................18 n Ink..........................................................................................19 m System Setup .......................................................................20 , Part Names and Their Functions........................................21 . Operation Procedures .........................................................29 0 Error Messages and Corrective Action .............................30
Chapter 5
Installation
z DUPRINTER Installation Instructions....................192
Chapter 6
Maintenance / Check
z Guaranteed Periodical Maintenance......................204 x Cleaning and Oiling.................................................204 c Periodical Maintenance...........................................205
Chapter 2
Chapter 7
Troubleshooting
z Scanner Section.........................................................55 x Mastermaking/Master Feed/Ejection Section......... 59 c Paper Feed Section....................................................82 v Drum Driving Section................................................95 b Press Section............................................................101 n Paper Ejection Section............................................104 m Drum Section...........................................................109
z Troubleshooting Guide............................................208 x Error Display............................................................223
Chapter 8
HELP Mode
z HELP Mode List.......................................................226 x Overview...................................................................230 c HELP Mode Functions and Operation Procedures .......231 (1)Basic Procedure for Accessing HELP Modes...231 (2)Guide to the HELP Mode Descriptions..............231 (3)Guide to version up.............................................232 HELP Mode Descriptions.....................................233
Chapter 3
Mechanism
z Exterior.....................................................................119 x Scanner Section.......................................................125 c Mastermaking/Master Feed/Ejection Section....... 131 v Paper Feed Section..................................................140 b Drum Driving Section..............................................145 n Paper Ejection Section............................................147 m Drum Section...........................................................150
Chapter 9
Others
z Electrical Parts Layout and Their Functions.........308 x Overall Wiring Layout..............................................314
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Chapter 1
Introduction
z Features ........................................................................12 x Specifications...............................................................14 c Dimensions...................................................................16 v Mechanism ...................................................................17 b Master ...........................................................................18 n Ink..................................................................................19 m System Setup ...............................................................20 , Part Names and Their Functions................................21 1. Machine exteriors ....................................................21 2. Sectional (structural) view of the machine ...........24 3. Control Panel ..........................................................26 (1) Key outside of the panel cover...........................26 (2) LCD Panel...........................................................28 . Operation Procedures .................................................29 1. Mastermaking & Printing........................................ 29 0 Error Messages and Corrective Action......................30 1. Error messages .......................................................30 2. Corrective action .....................................................32 (1) Replacing the Ink Pack ......................................32 (2) Replacing the Master Roll .................................34 (3) Replacing the Master Ejection Core..................37 (4) Supplying Paper ................................................39 (5) Replacing the Drum Unit ..................................43 (6) Paper Jam (Feeder side).....................................45 (7) Paper Jam (Ejection side) ..................................46 (8) Master is Not Ejected.........................................49 (9) Master Set Incorrectly ("MASTER SET MISS"is displayed)..................51
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z Features
zFeatures
1. Size B4 printing (DP-M420) The DP-M420 has size B4 (250 X 355mm) printing area. The DP-M410 has size LG(210 X347mm) printing area. The DP-M400 has size A4 (204 X288mm) printing area. 2. High-speed platemaking With the DP-M400/410/420 , it takes 21 seconds *1 to print the first sheet of paper(A4,100%).
*1: Time required to print the first sheet of paper after the mastermaking key is pressed.
Size A/B models Zoom settings (70, 81, 86, 115, 122, 141%) Same-size (100%) printing
DP-M420
Free zoom 50% -200% ( 1% ) 141% [B5/B4, A5/A4] 122% [A4/B4, A5/B5] 115% [B5/A4] 86% [A3/B4, A4/B5] 81% [B4/A4, B5/A5] 70% [A3/A4, B4/B5]
Enlargement
3. High print quality A new, originally-developed superfine thermal head gives beautifully accurate reproductions of fine print and halftone photographs. Its resolution is 300dpi in the main scanning direction and 600dpi in the sub scanning direction. 4. Align paper Adjusting the eject enables both thin and thick sheets of paper to be aligned neatly.
Reduction
DP-M400
Free zoom 50% -200% ( 1% ) 141% [A5/A4] 122% [A5/B5] 115% [B5/A4] 86% [A4/B5] 81% [B4/A4] 70% [A3/A4, B4/B5]
Enlargement
Reduction
5. High-performance lamp A long-life, high-brightness xenon arc lamp is used to illuminate the documents. Since the lamp's intensity is not affected by temperature variation*2, printing quality at low temperatures is greatly enhanced*3.
*2: The lamp is filled with xenon gas, which means that it does not require heat to vaporize mercury, as a fluorescent lamp does, and therefore its intensity does not vary with temperature. *3: Increased viscosity of the ink at low temperatures results in fainter printing than at normal temperatures.
Inch size model Zoom settings (64, 74, 77, 121, 129, 141%) Same-size (100%) printing
DP-M410
Free zoom 50% -200% ( 1% ) 141% 129% [ST/LTR] 121% 77% [LGL/LTR] 74% [LDG/LGL] 67% [LDG/LTR]
Enlargement
Reduction
6. Full range of necessary functions qDocuments are easily enlarged or reduced. In addition to same-size printing, there are three automatic settings for both enlargement and reduction. The margin function (94% reduction) can be used with any setting.
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z Features
wSelf-diagnosis The machine has a self-diagnosis system, which notices user by flashing on and off a message and lighting up the relevant lamp when a expendable part needs replacing. eError message display An LCD panel displays error messages and messages prompting replenishment of consumables. r2 in 1 Layout mode In conjunction with an ADF ( optional ), this mode makes possible continuous printing of 2 documents onto single sheets of paper. tAdjusting the Printing Position (vertical) In addition to vertical direction adjustment. yUID control function Raises the number of sections controlled to up to 100. uMemory function Allows 9 sets of memory settings.
7. Options qADF Use of the ADF permits continuous mastermaking and printing of 100 documents (64gsm ). The ADF 's tray fits completely inside the ADF,so as not to interfere with loading/ removal of printing paper. wTAPE CLUSTER This permits sectionized printing, by inserting tape automatically during printing. e Drums Replacing the drum with optional drums permits printing with different colors. r On-line functions*4 These enable data processed on a personal computer or word processor to be directly input and used for platemaking/printing. t Auto Power Off Kit This kit can turn off the machine automatic when there is no operation within 5 minutes.
*4: This function require PC interface.
8 Ink save mode
This mode can save ink.

9 Energy save mode
This mode can turn off the backlight of LCD and the LED light on panel, when there is no operation within 3 minutes in order to save energy.
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x Specifications
xSpecifications
Specifications
Product name/model No. Model Mastermaking method Mastermaking interval Resolution Scanning method ADF capacity Document type Document size Document weight Printing area Feeding capacity Stacking capacity Paper size DUPRINTERDP-M420 Table top model Thermal digital mastermaking 21second (A4,same size) 300dpi(Main scanning direction)x600dpi(Sub scanning direction) Flat bed scanner 100 sheets ( 64gsm ) Sheets, Book ( less than 10kg ) Max.297mmx432mm 64gsm to128gsm Max. 250 x 355 mm Max.210x347mm Max. 204 x 288 mm 1300sheets(64gsm , duodecimo 55kg, high grade paper) 900 sheets (64gsm, duodecimo 55kg, high grade paper) *Cabinet [Option] : 1300 sheets ( 64gsm, duodecimo 55kg, high grade paper) Min.100mmx148mm DUPRINTERDP-M410 DUPRINTERDP-M400
Max. 297mm x 420mm Min. 100mm x 148mm

45 gsm to 210 gsm(40kg to 180kg)
Max. 297mm x 364mm Min. 100mm x 148mm
Paper thickness Printing speed Print enlargement/reduction
130pagesparminute.(60 to 130 pages per minute, 3 step adjustment) Same size 100% Fixed zoom ratios 70, 81, 86, 115, 122, 141% Print with border 94% Free zoom 50-200% (1%) Same size 100% Fixedzoomratios64,74,77, 121,129, 141% Print with border 94% Free zoom 50-200% (1%)
AB size model
Inch size model
Printing position adjustment Vertical: 15mm
Horizontal: 15mm(Paper Width: 297 5mm)

Image mode Text mode / Photograph mode / Text and photograph mode
Darkness adjustment
Ink supply method Color printing Master feeder Master ejection Master ejection capacity Master ejection method LCD panel Other standard function
Master darkness: 3 steps

Complete automatic control Drum unit exchange method Roll master automatic feed Complete automatic ejection master rolling method 30sheets Fan and paper ejection belt Light and compact type LCD
OK monitor Confidential Safeguard Entry of different number of prints or sets Special functions Memory Mode 2-up,4-up,8-up Zoom (50-200%) x94%
Master size select Master making density control 2 in 1(when using ADF) Minimum print restriction(50 sheets) UID input function(manual operation) Energy Save Mode Ink Save Mode
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x Specifications
Specifications Product name/model Power source Size
Duprinter DP-M420
AC 100-240V10%
Duprinter DP-M410
1.6-0.8A 160W 50/60Hz
Duprinter DP-M400
In use: 1270mm (W) x 615mm (D) x 666mm (H) In storage: 695mm (W) x 615mm (D) x 666mm (H) <When ADF is installed> In use: 1270mm (W) x 615mm (D) x 805mm (H) In storage: 695mm (W) x 615mm (D) x 805mm (H) Machine 79kg(when packed: 90kg) 10C to 30C
Brown(DC16),Gray(DC17) (600ml)
Weight Operating temperature Ink
Optional ADF:8kg
Black(DC14),Red(DC13),Blue(DC12),Green(DC15)
600ml package only
Master roll
DRC42/DRC42L/DRC425
DRC41/DRC415
Options
DRM- 78 Drum unit (M420) DRM- 81 Drum unit (M420 China) DRM- 79 Drum unit (M410) DRM- 82 Drum unit (M400 China) DRM- 80 Drum unit (M400) TAP-13 Tape cluster (English) I/F-43 USB interface kit FS-100U (Optional USB I/F kit is necessary) UPC-01 UID PC I/F kit CAB-13 Cabinet U6-S0001 Automatic power off kit (power is turned off by time specified) S5-ADF I/F-43 USB interface kit (I/F board in main unit) USB interface (USB2.0 Full-Speed) * OS Windows 2000 Professional Windows XP professional/Home Edition Windows Vista x86 (32bit) Mac OSX10.3/10.4/10.5
* USB cable must be 3m or shorter
PC interface kit
FS-100U Network server (USB I/F is necessary) OSWindows 2000 Professional Windows XP professional/Home Edition Windows Vista x86 (32bit) Mac OSX10.3/10.4/10.5
* Specifications are subject to change without notice.
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c Dimensions
cDimensions
105
472
615
380
478 470
666.5
517
229
563 1262
130
(mm)
16
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v Mechanism
vMechanism
The machine carries out the processes of mastermaking and printing. Mastermaking In the mastermaking process, the old master on the drum is removed while the thermal head creates the scanned image on the new master and transfers it onto the drum.
Master roll
Master ejection box
Thermal head
Drum unit
Printing In the printing process, paper separated from the stack by the paper feed roller and the paper separator unit is pressed against the drum unit by the press roller. There are small holes over only the image area of the master that is attached to the drum, and ink that seeps from these holes is transferred to the paper. The paper is then peeled from the master by the paper stripper finger. The paper is directed onto the paper ejection belt by a fan unit and discharged from the machine.
Drum unit Feeder roller Paper Paper stripper finger
Press roller Paper sepatator unit
Paper ejection belt Fan unit
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b Master
bMaster
1. Characteristics of the master
(1) Structure of the thermal master
(2) Functions and materials of the layers Coated surface Prevents the film from fusing, being damaged due to friction,being peeled, and being conveyed defectively due to electric static charge. Material: silicon fluorine mold lubricant Thermal film Holes are made by the heat of the thermal head. Material: Polyethylene terephthalate (polyester) Adhesive 1] Adheres the film to the base. 2] Does not prevent ink from seeping. 3] Increases impression endurance. Base 1] Base material for the master. Fibrous layer 2] Ink seeps the base. (3) Cross section of the master during mastermaking Holes are made on the coated surface, thermal film and adhesive, while base fiber, base material for the master, is left. A part of the film fused by the thermal head is stuck to the head or banks up.
(4) Printed image As the image consists of innumerable dots, it is taken as a continuous line through our eye. IMPORTANT : Precautions to be taken in dealing in the master. (1) Do not put a heavy thing on the box in which masters are packed. This may damage the master and may cause defective mastermaking. (2) Do not leave the master as it is after it is taken out. Foreign objects are stuck to the master and this may cause defective mastermaking. (3) Keep the master from direct sunlight, too high or low temperature and too high or low humidity. (Desirable storage temperature and humidity: 5-35 C, 20-80%) If the master curls, defective plate attachment may occur.
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n Ink
nInk
1. Characteristics of ink
(1)Ink type Ink for the digital printer is an emulsion type. It has a water-in-oil type structure. Emulsion type
(2) 2 characteristics The surface active agent has 2 characteristics: hydrophilic group and lipophilic group in 1 molecule. Oil and water bond together by these 2 characteristics as shown in the figure.
(3) Temperature Ink viscosity is high at a low temperature and it is low at a high temperature. So when ink is used at a low temperature (10C or less), the amount of ink transferred to the paper is smaller and the print darkness is slightly lighter. When ink is used at a high temperature (30C or more), the amount of ink transferred to the paper is larger and the print darkness is slightly darker. IMPORTANT : Precautions to be taken in handling ink (1) Storage environment When an emulsion type ink is stored at too high or low temperature for a long time, oil and water in the ink pack may be isolated. Keep the ink from too high or low temperature (5C or less, 35C or more). Also keep the ink from direct sunlight since the temperature rises sharply in the direct sunlight. When the water content is frozen, the water content is solidified and the bond characteristics decreases. When ink is stored at a high temperature, the bond characteristics decreases due to the change of the surface conditions (surface tension, solubility). The bond characteristics also decreases due to evaporatin of the water content. (2) Precautions to be taken in handling the ink pack When the ink pack is removed from the drum unit to store, put the ink pack with its mouth up, screw the cap firmly after expelling air from the ink tube. (If air is in the ink pack, water content is generated.) 19
chap.1
m System Setup
mSystem Setup
The machine and its optional equipment are set up as follows:
S5-ADF Duplo Direct Print System TAPE CLUSTER 13
Personal computer
Cabinet (Printer stand)
Drum unit
: Option
NOTE :
DDP system Documents prepared on a personal computer can be printed on this machine. The PC interface kit is required to connect this machine to a personal computer.
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chap.1
, Part Names and Their Functions
,Part Names and Their Functions

1. Machine exteriors
Document cover Scanner switch Scanner Control panel Feed tray descend switch Feed pressure adjuster lever Slide guides Front cover Feed tray Supplemental paper tray Power switch Cabinet Optional (Printer stand) Caster locks
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chap.1
Master set switch/ Thermal head escape lever

When the master set switch is pushed, the master is pulled in and set.
Master roll
Master holder
Ink pack holder release lever
Front cover
Drum handle
Drum unit
Ink pack
Drum securing lever
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Master ejection core
Master ejection box release lever
Master ejection box lid release lever Master ejection box
Paper stacker guides
Paper stopper
Print tray JOG switch (Drum rotator switch) Jamp plate
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2. Sectional (structural) view of the machine
2A
1 2C
2B 4,8 3
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No. 1 2
Section Name Scanner section

Mastermaking/Master feed/ejection section
Mechanism 125page 131page 131page 136page 138page 140page 145page 4 147page 4 150page
Srandard/Adjustment 159page 161page 161page 162page 164page 169page 174page 176page 178page 4 179page
55page 59page 59page 74page 76page 82page 95page 101page 104page 4 109page
2A Mastermaking/Master feed section 2B 2C 3 4 5 Master ejection section Master clamp opening/closing section Paper feed section Drum driving section Press section Paper ejection section Print tray Drum section
6 7 8
2B 4,8
6 7
24S067
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3. Control Panel
(1).Key outside of the panel cover
0sht
e
r
1 0 0%
1set
t y
No. q w LCD panel
Name
Function
Reference page
Displays the number of printed paper. Also displays an error message when an error occurs. FUNCTION SWITCH key Press to toggle between the normal mode and the function select mode. LEFT SELECT key Press to select left function. Press to select right function. RIGHT SELECT key ENLARGEMENT /REDUCTION lamp ENLARGEMENT /REDUCTION key Indiction for the ratio is selected. Press to set the enlargement or 100% or reduction ratio. The lamp of the selected mode lights. Press to switch between the text mode, text/photograph mode and photograph mode. Each press of this key moves the position of the lit lamp that indicates the selected document mode. Flashes to display the content of the trouble and lights to indicated the part that caused the trouble in the machine.
24, 93 52 52 52 39
e r t
39 47
Document mode indicator lamps

DOCUMENT MODE SWITCH key
47
OK monitor
93
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20
!9
!8
!7
!6
!5
!4
i
No. i o !0 !1 !2 !3
o
Name CLEAR key Key pad
=
X
!0
!1
!2
Function
!3
Reference page
Press to reset the displayed number of prints to 0. Only the number of prints is cleared. Use to enter the number of prints. Press to enter the number of prints and number of sets for sectional prints. Press to start mastermaking. Starts printing. This will not start mastermaking. Mastermaking will start automatically after the end of printing if there is a document on the ADF. Press to stop printing on the way. If this key is pressed while the machine is stopped, the total number of prints and masters will be displayed on the LCD panel. Press to print only one piece of paper for checking the print darkness or printed position. The lamp of the energy saving mode. Press to adjust the printing speed. The lamp of the specified printing speed lights. The lamp of the specified printing speed lights. Press to adjust the printing position. Returns the control panel settings to the Standard Mode settings. Press and hold for at least 0.5 seconds.
33 33 65 33 33
key
MASTERMAKING key PRINT key STOP key
73
!4 !5 !6 !7 !8 !9 2 0
TEST PRINT key Energy saving mode indicator lamp PRINTING SPEED ADJUSTMENT keys Printing speed indicator lamp Printing position indicator lamp PRINTING POSITION ADJUSTMENT keys ALL CLEAR key
72 76 74 74 75 75 32
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(2). LCD Panel
0sht
No. q w e Print count Sets Zoom ratio Name
1 0 0%
1set
Function
Reference page
Displays the number of prints to be made. Displays the number of sets to be printed. Displays the selected (enlargement/reduction)ratio.
33 65
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chap.1
. Operation Procedures
.Operation Procedures
1. Mastermaking & Printing
Set document
Function switch Select key key Reduction is selected. Document size is selected. Photograph mode is selected. Master darkness is switched. Document mode switch key Selects Texts, Text/Photograph & Photograph mode. When the number of prints is input in advance, printing starts automatically after mastermaking. / / keys keys Printing position is adjusted. Printing speed is adjusted. Printing is tested (a sheet of paper.)
Mastermaking
key
Printing position adjustment Printing speed adjustment Test print key
Input the number of prints and the number of sets
Input the number of prints and the number of sets on the key pad.
Print
key
End
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0 Error Messages and Corrective Action
0Error Messages and Corrective Action

1. Error messages
The LCD displays a message when the replenishment of consumables or the assistance of service personnel is required.
Message
EXCHANGE INK
Cause and corrective action

Cause : There is no ink. Action : Replace the old ink pack with a new one. Cause : There is no master. Action : Replace the master roll with a new one. Cause : The master ejection core is full. Action : Replace the core with a new one. Cause : There is no paper in the feed tray. Action : Load the feed tray with printing paper. Cause : There is no drum. Action : Install a drum in the machine. Cause : The front cover is open. Action : Close the front cover. Cause : The scanner is open. Action : Close the scanner. Cause : The ADF cover is open. Action : Close the ADF cover. Cause : A paper jam has occurred on the ejection side. Action : Inspect the ejection side and remove the jammed paper. Cause : A paper jam has occurred on the ejection side. Action : Inspect the ejection side and remove the jammed paper.
See page
32
ROLL - MASTER END
34
EXCHG. EJECT - CORE
37
SET PRINT PAPER
39
DRUM NOT SET
43
FRONT COVER OPEN
SCANNER OPEN
ADF OPEN
PAPER LEFT JAM
45
PAPER RIGHT JAM
46
ENTER ID AND PASSWORD
Cause : UID function is opened. Action : Please press PRINT key and input ID and password given by manager. Cause : The master roll is not set correctly. Action : Reset is correctly.
RESET MAST. ROLL
36
30
chap.1
Message
MAST. EJECT MISS
Cause and corrective action

Cause : There is an old master on the drum. Action : Remove all the masters from the drum. Cause : There is an error during master setting. Action : Open the top cover and remove the master that is left in the master feeder. Cause : The document is jammed on the ADF. Action : Open the ADF cover and remove the jammed document. Cause : The printer is not ready. Action : Please wait with the power ON. If the message remains after a few minutes, turn the power OFF and ON again. If the message still remains after a few minutes, turn the power OFF and contact your service person.
See page
49
MASTER SET MISS
51
DOCUMENT JAM
--- WAIT---
ID OR PASSWORD NOT CORRECT
Action : ID or PASSWORD is not correct.
Please press key or PRINT key and input correct ID and password again.
PLS MASTER MAKING Cause : Cannot print. Action : This message is displayed if you press (PRINT) or (TEST PRINT) keys without making a plate immediately after a master setting error or when the confidential safeguard function is ON.
T
PRINTING
Cause : Printing is not complete. Action : Either press (PRINT) key to resume printing or press C (CLEAR) key to clear the counter.
SERVICE CALL ( "E***" flashes )
Action : Follow the procedure below. qRecord the error message "E***". w Shut off the power and turn it back on. eIf the message is displayed again, contact service personnel. Report the error code and details of error occurrence to service personnel.
223
* For displayed messages other than those listed above, refer to Chapter 7 "Troubleshooting". a See page 207
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chap.1
2. Corrective action
(1) Replacing the Ink Pack
IMPORTANT : Only use ink packs designed for this machine.

Open the front cover.

Front cover
Grasp the lever and pull it toward you.
Lever
Ink pack

Lift out the empty ink pack.
Ink pack
Remove the cap from a new ink pack.

IMPORTANT : Do not leave an ink pack uncapped for longer than necessary.
32
chap.1

Insert the ink pack so that the groove on the lip fits onto the U groove of the holder.
"U" groove of holder

Push the ink pack in to the set line on the ink pack.
Set line
Set line
Press the back of the holder in with the palm of your hand.
Close the front cover.
Front cover
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chap.1
(2) Replacing the Master Roll
IMPORTANT : Only use a master roll designed for use in this machine.
Slide the scanner unit.

IMPORTANT
Scanner unit
Do not touch the heat generator of thermal head. Doing so may cause damages, leading to a malfunction of mastermaking.
Pull out the master. Turn the master holder toward you while pushing the thermal head escape lever. Pull out the master.
Master roll
Lift out the master roll,then remove the master holder from the master roll.
master holder
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chap.1
Take out a new master roll from the bag.

Set the master roll in the direction as shown in the illustration at right.
master holder
Insert the master roll into the machine the control panel.
Peel off the seal.
SEAL
Pull out the master and insert the front head of the master until it contacts the roller.
IMPORTANT
If the master is not pulled in open the master cover, and gently press in as far as possible to set again.
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chap.1
MASTER SET SWITCH THERMAL HEAD ESCAPE LEVER
Push the master set switch. The master will be pulled in, and cut automatically. If the master does not go in, pull the master back.
IMPORTANT
If the master is wrinkled:push and hold the master set switch again, and push down the thermal head escape lever 2 or 3 times. The cutter operates and stops after the master is cut. Remove the cut piece left inside the machine.

Remove the trimmed piece of the master.

IMPORTANT
When the master stops, make sure that you remove the trimmed piece of the master.
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chap.1
(3) Replacing the Master Ejection Core
IMPORTANT : Use only a master ejection core designed for use in this machine.

Press the master ejection box release lever to open the master ejection box.
Open the master ejection box until it stops.
Open the cover while pressing and holding the lid release lever.
Master ejection box lid release lever
Holding the edges of the master ejection core, pull out the core and discard it.
IMPORTANT : Ink adheres to the master ejection core. Take care to prevent ink from getting onto your clothing.
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chap.1

Insert a new master ejection core.

Gently close the master ejection box cover, pressing it until it locks.
Close the master ejection box, pressing it until it locks.
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chap.1
(4) Supplying Paper Supplying Paper

Open the supplemental paper tray if it is closed.
Hold the lever and adjust the side guides to the paper size.
Load a stack of aligned sheets between the paper guides and press the stack lightly toward the machine.
IMPORTANT : You can load the feed tray with approximately 1,300 sheets of 55gsm high-grade paper.
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chap.1
Changing Paper Selection

Press
(STOP) key.
Printing stops.
Press the feed tray descend switch continuously. Release the switch when the feed tray is at the proper height.
The feed tray will stop.
Feed tray descend switch
IMPORTANT : If the sheet is still in the paper feed roller, pull it out and align it with the stack.
Remove paper from the feed tray.

The feed tray will automatically descend.
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chap.1
When the feed tray comes to a syop, reset the paper size.
Press
(PRINT) key.
The feed tray will rise automatically and printing will resume.
If Paper Runs Out During Printing

If paper runs out during printing, printing stops and the feed tray is lowered automatically. a See page 39

Adding Paper While Printing

Press
(STOP) key.
Printing stops.
Press the feed tray descend switch continuously. Release the switch when the feed tray reaches the proper height.
The feed tray will stop.
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chap.1
IMPORTANT : If the sheet is still in the feed roller ring, pull it out and align it with the stack.
Align the stack to be added and place it on top of the existing stack. Press the stack lightly toward the machine.
Press
(PRINT) key.
The feed tray will rise automatically and printing will resume. NOTE : When you press stops.
(STOP) key, printing
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chap.1
(5) Replacing the Drum Unit

Press and hold the JOG switch until the drum comes to a stop with a beep.
WARNING Do not touch the drum or rollers when you operate the JOG switch. Do not put your hands or fingers inside the machine while it is operating. Your hands may be pulled in or nipped.
JOG switch (Drum rotator switch)
Open the front cover toward you.
Front cover
Lift the drum securing lever toward you and, holding it there, then pull out the drum handle straight toward you until it stops.
Drum handle
Drum securing lever
Hold the handle on the far end of the drum, and lift the front end of the drum slightly to pull the drum toward you.
IMPORTANT : Do not touch the drum surface. Ink may transfer to your clothes. Hold the drum level and place it on a flat, solid surface.
Handle for end of drum
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chap.1
Installing the Drum Unit

Hold the drum level and place the drum guide roller onto the rail in the machine.
Roller
Rail

Release the handle at the far end of the drum and press the drum in about 10cm while lifting up the front end slightly.
Hold the drum level and press it in gently until it comes to a stop.

Lift the drum securing lever toward you while pressing the drum in.
Lever
Lower the lever.
Lever
Close the front cover.

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chap.1
(6) Paper Jam (Feeder Side)
If the message "PAPER LEFT JAM" is indicated in the LCD, check the feeder side and remove the jammed paper by following the procedure below.
PAPER LEFT JAM
Switch to lower the feed tray slightly. The feed tray is lowered for the time that the switch is pressed.
Pull out the jammed paper as shown in the diagram.
Press and hold the JOG switch until the drum comes to a stop with a beep.
WARNING Do not touch the drum or rollers when you operate the JOG switch. Do not put your hands or fingers inside the machine while it is operating. Your hands may be pulled in or nipped.
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chap.1
(7) Paper Jam (Ejection Side)
If the message "PAPER RIGHT JAM" is indicated in the LCD, check the ejection side and remove the jammed paper by following the procedure below.
PAPER RIGHT JAM
Press the master ejection box relase lever to open the master ejection box.
Remove the jammed paper.

Press the JOG switch to eject the partially printed paper. WARNING Do not touch the drum or rollers when you operate the JOG switch. Do not put your hands or fingers inside the machine while it is operating. Your hands may be pulled in or nipped.

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chap.1
Paper Adhering to Drum

Press the master ejection box relase lever to open the master ejection box.
Press the JOG switch to find the edge of the paper, then stop the drum at the position shown in the diagram.
WARNING Do not touch the drum or rollers when you operate the JOG switch. Do not put your hands inside the machine while it is operating. Your hands may be pulled in or nipped.
Paper edge
Peel off the edge of the paper from the drum.
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chap.1

Pull the paper toward the ejection side while pressing the JOG switch to peel the paper off.
IMPORTANT : Make sure that the peeled paper does not stick to your clothing.
Hold the JOG switch down until the drum comes to a stop with a beep.

Make another master.

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chap.1
(8) Master is Not Ejected

Press the master ejection box release lever to open the master ejection box.
Press the JOG switch to find the edge of the paper, then stop the drum at the position shown in the diagram.
WARNING Do not touch the drum or rollers when you operate the JOG switch. Do not put your hands inside the machine while it is operating. Your hands may be pulled in or nipped.
Lift the lever toward you.

The master clamp opens and the edge of the master will be released from the clamp. If the master is stuck, release it manually.
Master clamp Lever Master
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chap.1

Return the lever.

Pull the front end of the master toward you and press the JOG switch intermittently.
Hold the switch down until the master peels off. IMPORTANT : Discard the old master, making sure that it does not touch your clothing.
Hold the JOG switch down until the drum comes to a stop with a beep.

Press
(STOP) key.
The message is deleted.
Make another master.

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chap.1
(9) Master Set Incorrectly("MASTER SET MISS" is displayed)
Slide the scanner unit.
Scanner unit
Remove the master left in the master feeder. Reset the master and take away the cutted master.
Slide the scanner unit and return it to the original position.
Scanner unit
Continue Page
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chap.1
Check that the error message is deleted.
Make a new master and start printing.

IMPORTANT
The message PLS MASTER MAKING is displayed on the LCD panel when is pressed without mastermaking being carried out.
(PRINT) key
52
Chapter 2

Master Clamp opening/Closing Section....................76 1. Description...............................................................76 2. Operation of Master Clamp Open / Close Lever ........77 (1) Structure.............................................................77 (2) Master Attachment / Detachment Operation...78 (3) Clamp Opening / Closing Lever Position (A / B / C Mode).........................79 3. Function of Parts ....................................................80 (1) A / B / C Mode Sensor.........................................80 4. Returning Operation Flowchart When the Power is Cut Off Accidentally.............. .81 c Paper Feed Section......................................................82 1. Description...............................................................82 2. Operation................................................................. 83 (1) Rotation of the Paper Feed Roller and Timing Roller.....................................................83 (2) Paper Feed Roller Drive.....................................84 (3) Driving of the Timing Roller..............................85 (4) Escape the Guide Roller ................................... 86 (5) Paper Feed Length.............................................87 3. Function of Parts.....................................................88 (1) Printing Position Adjustment Mechanism........88 (2) Signal Lever........................................................90 (3) Feed Tray (Elevator) Upper Limit Sensor........ 91 (4) Feed Tray (Elevator) Lower Limit Switch........ 92 (5) Paper Sensor.......................................................93 (6) Paper Feed Length Sensor.................................94
z Scanner Section...........................................................55 1. Description...............................................................55 2. Sequence of Operation...........................................56 (1) Sequence of the Scanner Operation..................56 (2) Sequence of the Scanner Operation (ADF).......56 3. Function of Parts and Circuit.................................57 (1) Home Position Sensors.......................................57 (2) CCD / Lamps......................................................58 x Mastermaking / Master Feed / Ejection Section........59 Mastermaking / Master Feed Section .....................59 1. Description...............................................................59 2. Sequence of Operation...........................................60 Operation when the master set switch is turned on.............................................60 Mastermaking and Master Feeding.......................62 3. Function of Parts ....................................................65 Thermal Head...........................................................65 End Mark Sensor1...................................................68 1. Master Setting Error Detection......................69 2. Master End Detection......................................69 End Mark Sensor2...................................................71 Cutter Unit...............................................................72 Master Feed Clutch (Electromagnetic clutch)........73 Master Ejection Section..............................................74 1. Description...............................................................74 2. Circuit.......................................................................74 3. Function of Parts ....................................................75 (1) Master Ejection Sensor......................................75 1. Plate Ejection Error Detection........................75 2. Rotation Control of the Roll-up Motor............75
53
v Drum Driving Section..................................................95 1. Description...............................................................95 2. Function of Parts ....................................................96 (1) Home Position / Jam Detection Position Sensor..................................................96 (2) Master Attachment / Detachment Position Sensor..................................................97 (3) Jog Switch(Drum Rotator Switch).....................98 (4) Control of the Main Motor.................................99 1. Rotation Speed Control by Encoder Sensor...100
m Drum Section.............................................................109 1. Description.............................................................109 2. Circuit.....................................................................110 3. Function of Part.....................................................111 (1) Ink Detection....................................................111 1. LED Display and Output Signal on the Ink Detection PCB Unit..........................112 2. "EXCHANGE INK" Display Timing.............113 (2) Ink Pump..........................................................114 (3) Drum Switch.....................................................115 (4) Front Cover Open / Close Detection Switch....116
b Press Section...............................................................101 1. Description...............................................................101 (1) Press Roller Timing & Printing Area................101 2. Function of Parts .................................................. 103 (1) Press Roller (P Roll) Sensor............................. 103 n Paper Ejection Section..............................................104 1. Description.............................................................104 2. Function of Parts ..................................................105 (1) Paper Stripper Finger......................................105 (2) Jam Sensor ......................................................106 1. Paper Jam Detection Timing........................107 (3) Paper aligning mechanism..............................108
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chap.2
z Scanner Section
zScanner Section
1. Description
The document is illuminated with the lamps, and the document reflection in proportion to the document image darkness is imaged on the CCDs through the mirror and lens. Then it is resoluted into picture elements and converted photoelectrically.
Optical System Operation
The optical system gose forward (to the left) or back ward with a stop position of Fixed document home position sensor(PS1).
ADF home position sensor(PS2) Fixed document home position sensor(PS1)
Lamp
Mirror
Glass
Lens
CCD
Mirror
24S068
When ADF is attached, set the ADF Home Position Sensor (PS2) as the optical system stop position, and then read the document darkness.
ADF home position sensor(PS2) Glass Fixed document home position sensor(PS1)
Optical System Operation (with ADF attached)
Lamp Mirror
Mirror
Lens
CCD
24S068A
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chap.2
z Scanner Section
2. Sequence of Operation
(1) Sequence of the Scanner Operation(with ADF unconnected)
1) When the MASTERMAKING key is pressed, the optical system moves to the left and reads the image.
Image reading begins
24S069
2) When image reading is complate, the lamp gose out, but the optical system decelerates, then stops. Following that, the optical system moves right and returns to the home position.
Image reading
3) The system is then on standby for the printing process.

24S070
(2) Sequence of the Scanner Operation(with ADF connected)

1) When the MASTERMAKING key is pressed, the optical system will perform shading at home position (PS1), and then move to the left.
Image reading begins
24S069
2) The optical system reads the image stopped at home position (PS2). When image reading is complete, it immediately moves to the right and returns to the home position.
Image reading
3) After it returns, the optical system is then on standby for the printing process.
24S070
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chap.2
z Scanner Section
3. Function of Parts and Circuit

(1) Home Position Sensors Description
PS1 detects the optical system home position when ADF is not used. PS2 detects the optical system home position when ADF is used.
Circuit
Home position sensor (PS1) 5V 1 2 3 Red Yellow Blue J7-12 -14 -13 0 3.3V 3.3V Photopass : 0V Photointerrupting : 3.3V
Main P C B U nit
Home position sensor (PS2) 5V 1 2 3 Red Orange Blue J12-14 J7-16 J7-15 0 3.3V 3.3V Photopass : 0V Photointerrupting : 3.3V
Main P C B U nit
Operation
A shading plate is attached on slider A of the optical system. The position where PS1 is shaded becomes the optical system home position when ADF is not attached. The position where PS2 is shaded becomes the optical system home position when ADF is attached.
Standard (ADF not attached)

Fixed document home position sensor(PS1)
With ADF attached

ADF home position sensor(PS2)
Photointerrupting plate
Photointerrupting plate Slider A
Slider A
23S0214
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chap.2
z Scanner Section
(2) CCD / Lamp Description

The lamp illuminates the document and the reflected light is transmitted onto the CCDs.The CCDs output the image signals in level of voltage.
Circuit
Brown
J2-12 J2-26
Yellow
J2-11
J5-1 J5-12
Specification
CCD The table below shows the specification for the CCD.
No. 1 2 3 4 5
Item Optical signal storage time (SH cycle) Frequency The number of effective picture elements Reading width (This is not the image width which can be processed.) Reading density
Specification 2.048 msec/line 3.375MHz 3000 picture elements 254mm 11.8 dot/mm(300DPI)
Lamp This machine adopts a xenon lamp which is lit quickly when turned on, and the quantity of light is stable.The lamp is lit when the the control signal CN1-1 for the lamp inverter unit is LOW (0V) .
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chap.2
x Mastermaking / Master Feed / Ejection Section
xMastermaking / Master Feed / Ejection Section

Mastermaking / Master Feed Section
1. Description
Make the master clamp of the drum unit clamp the master top end, performing mastermaking on the master with the thermal head. (In this machine, the master on the drum is ejected at the same time when platemaking is performed.) The master is conveyed to the drum unit via the platen roller and sponge roller by driving of the stepping motor, while it is being processed in the head section. Sponge roller is driven through the master feeding clutch (electromagnetic clutch), and controls the amount of master conveyed to the master clamp section of the drum unit with the master feeding clutch ON / OFF. The end-mark sensor1 starts to detect when the end mark (black) section printed on the end of the roll master is conveyed. The indicator lights for "roll-master end" are lit on the control panel. The endmark sensor also detects whether the master is conveyed properly through the sensor.
End-mark sensor 2
Sponge roller
Platen roller
End-mark sensor 1
Master feeding clutch
Roll master Thermal head
Stepping motor
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chap.2
2. Sequence of Operation Operation when the master set switch is turned on

(1) Pressing the master set switch turns on the master feeding motor (PM2) and the master feeding clutch (CL1) to rotate the platen roller and the sponge roller.
(2) When the master is fed and the end mark sensor (PS3) detects the front end of the master, the master feeding clutch (CL1) is turned off.
(3)The master feeding motor (PM2) stops approx. 3 seconds after the master set switch (SW1) is pressed.
(4) The cutter motor (M5) is turned on to move the cutter from the operation side to rear side while cutting the master.
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chap.2
NOTE :
If the end mark sensor (PS3) does not detect the master for approx.3 seconds after the master set sensor (PS0) is photointerrupted, the machine stops with a warning beep.The cutter does not operate.
(5) When the cutter limit switch (rear side) is turned on, the cutter motor (M5) stops and then rotates reversely, and when the cutter limit switch (operation side) (MS2) is turned on, the motor stops. (6) The master feeding motor (PM2) is turned on to feed the master 10mm and then stops.
Basic operation sequence

Master set PS photointerrupting
Remove cut pieces
HELP 29 setting changes this length
Cutter limit SW [Rear side] (MS2) Cutter limit SW [Operation side] (MS1)
End-mark sensor 1(PS3)
Sequence when the master set switch is kept pressed

If the master set sensor (PS0) is photointerrupted for 3 seconds or more, the master feeding motor (PM2) is kept on during the time to feed the master. If the switch released, the cutter operates to cut the master. The other operations are the same as the basic operations described above.
HELP 29 setting changes this length
Master set PS photointerrupting
Remove cut pieces
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chap.2
Mastermaking and Master feeding operations

(1) Pressing "MASTERMAKING" key turns on the master feeding motor (PM2) and master feeding clutch (CL1) to feed out the master.
(2) When the master is fed approx. 50mm, the master feeding motor (PM2) and master feeding clutch (CL1) stops.
(3) After the print section performs master detachment, the drum moves to the master attachment position to open the master clamp, and then the master feeding motor (PM2) and the master feeding clutch (CL1) are turned on and the thermal head (TH1) starts mastermaking. The master is fed toward the master clamp.
(4) When the master is fed approx. 20mm, the master feeding clutch (CL1) is turned off to stop the sponge roller.
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chap.2
(5) After the master clamp clamps the top end of the master, the drum rotates to wind the finished master around it. The sponge roller is not driven by the motor because the master feeding clutch (CL1) is turned off. The roller follows the movement of the master pulled out by the drum.
(6) When mastermaking is completed, the thermal head (TH1) is turned off and the master feeding motor (PM2) feeds the master for the specified value (the total length: 490mm) and then stops.
(7) The cutter cuts the master.
(8) The master feeding motor (PM2) is turned on to feed the master approx. 10mm and then stops.
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chap.2
2Operation Sequence on Continuous Mastermaking
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chap.2
3. Functions of Parts
Thermal Head Description
The thermal elements are in alignment in the scanning direction, and are heated on the image section to make holes on the master film.
Circuit
Main PCB unit J3-1
Thermal head
-14
Main PCB unit J4-1
-24
Specifications
No. 1 2 Item Picture element density Effective memory width DP-24S/DP-22S/DP-22L 300DPI (11.8 dot/mm) 260.2 0.1mm
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chap.2
Exterior and Lot No.
276.0 260.20 0.2
0.2 Theramal resistor line
Label
70mm 5mm
Power connector
Signal connector
Pin (No.1)
Pin (No.1)
NOTE
Label

The following items are displayed with the label.
Model name Production month (See the table)
Sign
Month Jan. Feb. Mar. Apr. May. Jun. Jul. Aug. Sep. Oct. Nov. Dec.
No. () Serial NO () Resistance value Average of head resistance Specification display
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chap.2
NOTE :
Resistance
Resistance value is described on the label. When the head is replaced and the HELP mode is initialized, set the DIP-SW (H-44) of the HELP mode. HELP mode H-44 \ see p.274
Resistance value ( 3825 3909 3994 4078

H-44 0000 0001 0010 0011 0100 0101 0110 0111 1000 1001 1010 1011 1100 1101 1110 1111
3908 3993 4077 4162 4246 4330 4415 4499 4583 4668 4752 4837 4921 5005 5090 5175
4163 4247 4331 4416

23S0326
Resistance value
4500 4584 4669 4753 4838 4922 5006 5091
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chap.2
End-mark sensor 1
The end marks are located at a fixed distance relative to the master; as the master is being fed, the end-mark sensor1 senses master condition and the end marks by means of intensity of reflected light.
End-mark sensor 1
End mark
Circuit
5V
VR1
5V Red Black Blue 1 2 3 Red Blue J7-29 J7-25
3.3V 3.3V
Black J7-27
Main P C B U nit End-mark sensor1 PCB unit
Operation The larger the reflection light amount is, the smaller the output voltage is. The smaller the light amount is, the larger the output voltage is. The value is checked with the HELP 13.
White level<=10, Black level>50
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chap.2
qMaster Setting Error Detection

Operation In mastermaking, the end-mark sensor1 uses amount of reflected light to detect presence or absence of a master on the transfer path. Then the following displays and operations are performed: When a master setting error is detected, "MASTER SET MISS" is displayed and printing is not processed. "MASTER SET MISS" is only cleared by resetting master rightly again. (It is not cleared by turning the power off.) Printing is not performed but mastermaking is only performed when the display is cleared after "MASTER SET MISS" is displayed. (Because the master is not attached to the drum.) Timing (1) While mastermaking is being processed, the reflection light amount does not turn to be in a white level. (2) When mastermaking process is finished (before printing process), the reflection light amount is in a white level.
wMaster End Detection

Operation The end mark is printed on the area about 1 m from the end of the master. The end-mark sensor1 detects the changed value of the reflection light amount of the end mark during mastermaking,if the changed value is more than 4 and the reflection values are more than white level both,the end mark is detected. When the end mark is detected, "ROLL-MASTER END" is displayed. When "ROLL-MASTER END" is displayed, mastermaking is not performed next,please change new master.
End mark
"Master end" is stuck Core
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chap.2
Timing When it is considered that the end mark is read under the following conditions, the indicator lights for "roll-master end" are lit on the control panel. (1) While the master is rolling up to the drum during mastermaking, the following is checked. (2) The reflection light amount is read while the master passes. (3) When the data meet the following requirements, the end mark is detected.. Maximum-Minimum > 4 and Minimum White level top limit.
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chap.2
End-mark sensor 2
Operation Master set miss : master is not fed rightly(the roll shaft sticked with End mark label is not rotated ) during mastermaking. Master roll reverses. "MASTER SET MISS" is indicated. The message could be cleared by master is set rightly again. Master set miss : When drum fail to clamp master correctly. When the clamp failed, master is cut. The master fed into cutter section is pulled back. "MASTER SET MISS" is indicated. The message could be cleared by master is set rightly again. * The cut master is left on the path. Make sure to remove it before setting a master.
End-mark sensor 2 End mark label
Circuit
5V
VR1
5V CN4-1 -2 -3 Red Light green Blue J7-30 -28 -26
3.3V 0 3.3V
Main P C B U nit End-mark sensor2 PCB unit
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chap.2
Cutter Unit
Completed, the stepping motor for mastermaking and the drum stops temporarily, the cutter motor (MS) is turned on to drive the cutter and the master is cut. The home position for the cutter motor is at the cutter limit SW on the operation side (MS1). When the cutter moves to turn on the cutter limit SW on the rear side (MS2), the cutter motor stops and then reversely rotates to return to the home position.(The cutter motor can rotate normally and/or reversely.) Circuit
White Black
Red Black
CN4 45 J1-20 419
Main
J7-2 CN2 420 J7-1 3 4 J7-4 J7-3
3.3V
3.3V 3.3V 3.3V
Operation The cutter motor is at the home position when the cutter limit SW (MS1) is closed and the cutter limit SW (MS2) is opened. When cutting the master, the cutter motor rotates normally (CW) and moves from the operation side to the rear side. When the cutter limit SW (MS1) is opened and the cutter limit SW (MS2) is closed after cutting is completed, the cutter motor stops and then rotates reversely (CCW) , and moves from the rear side to the operation side.
Cutter limit switch(Rear side) Cutter Reversely (CCW) Cutter Cutter limit switch(Rear side) Cutter limit switch (Operation side) Cutter motor Normally (CW) Cutter
Cutter Cutter limit switch (Operation side)
Cutter motor
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chap.2
Master Feeding Clutch(Electromagnetic clutch)

Description Sponge roller is attached to the bottom section of the master conveyance way of the master feeding unit, and is driven via the master feeding clutch (CL1) by the mastermaking motor. The rotation of sponge roller is controlled with the master feeding clutch ON / OFF. Circuit
Master feeding clutch (CL1) Black Black 1 Brown Brown Purple 2 Purple 1 Black 2 Black 24V J2-15 -16 Main PCB unit
Operation 1. During mastermaking process the drum stops at the master attachment position and the master clamp is open (C mode) to turn the clutch on. Sponge roller is driven. The clutch is turned off when a certain amount of the master is fed.
C mode
2. The master clamp opens and closes, to clamp the master.
C \ B mode
3. When the master is wound onto the drum, the master feed clutch turns off, leaving sponge roller free to be turned by the master as it is wound off the drum.
73
chap.2
Master Ejection Section
1. Description
When the drum stops at the master detachment position and the master clamp which clamps the master tip end is opened (C mode), the pulling roller on the rolling section of the master ejection box pulls the master tip end into the box inside, and the master is rolled up to the core. If no core is installed, or when the master is fully wound onto the core, the core full switch (MS8) is mechanically actuated, and the message "EXCHG. EJECT-CORE" appears on the operation panel LCD panel.
Pulling roller
23S0311
Master detachment position
Master ejection sensor photoemitting PCB
Master ejection box Core Master ejection sensor photo-receiving PCB JAM sensor photoemitting PCB
Core full switch Roll up motor

23S0264
2. Circuit
Red Rollup motor Black
Light 2 blue 1 Green
2 Light blue 1 Green
Main PCB unit J2-8 -7
2 Jam sensor photo-receing PCB 1
Pink Blue Blue Gray Orange Orange Blue Gray 3.3V
J7-18 -17 -19 -20 3.3V -5 -6 -23 -24 3.3V -21 -22 3.3V
1 Master ejection sensor photo-receing PCB 2 1 Core full switch Master ejection sensor photo-emitting PCB Jam sensor photo-emitting PCB 1 2 1 2 2 3 4 5 6
Blue Pink
74
chap.2
3. Function of Parts
(1) Master Ejection Sensor
Description Photo-emission from the master ejection sensor is received on the master ejection sensor, and the sensor detects with the photo strength whether the master is pulled to the master ejection box. Photo-receiving amount is checked with the HELP mode H-05 \ see p.239 HELP5. 2HELP mode H-05 value
255
00 Smaller Larger Photo-receiving amount
1. Master Ejection Error Detection

Operation While one mastermaking is being processed, the difference of photo-receiving amount is less than 8 by checking with the HELP5, which is determined as an master ejection error. The following display and operation are shown. 2"MAST. EJECT ERROR" is displayed on the error display panel and printing is not processed. 2 "MAST. EJECT ERROR" is cleared with the ALL CLEAR key , STOP key or by performing mastermaking / printing. 2A master ejection error is not detected for one mastermaking soon after a master ejection error or master setting error is detected.
IMPORTANT : If incorrect sensing occurs due to sensor malfunction, etc., HELP32can be used to
prohibit master ejection error sensing.
HELP mode H-32 \ see p.265
Timing If the variation in the amount of light received by the master ejection sensor during the making of 1 master is less than a certain level (8 in the HELP5 display value), a master ejection error is deemed to have occurred. HELP mode H-05 \ see p.239
2HELP mode H-05 value

Threshold value : Value without master + 8 255
Threshold value
00
Time Value without master : the photo receiving amount of the master ejection sensor at the position where the first paper jam is detected after starting mastermaking.
2. Rotation Control of the Roll-up Motor

If the roll-up motor is kept rotating when the master tip end is pulled to the ejection box in the master detachment process, the drum is actuated by the master and the stop position slips. To prevent this, the roll-up motor is stopped when the master is detected by the master ejection sensor. (If the master is not detected by the master ejection sensor, the Roll-up motor is stopped by the timer.) 75
chap.2
Master Clamp Opening / Closing Section
1. Description
The master clamp on the drum unit is opened or closed by the two opening / closing levers' rotation operation. The opening / closing levers (one for the master attachment position, and the other for the master detachment position) are on the master clamp opening / closing section on the main body rear side. The master clamp is opened or closed during mastermaking. Opening / closing operation is as follows:Master clamp opening / closing lever (Master attachment position) Master clamp opening / closing section Master clamp opening / closing lever (Master detachment position)
Drum unit
23S0265
1) When mastermaking starts, the drum unit rotates from the stop position to the opening / closing lever section (master detachment position) and it stops temporarily. (B mode)
2) Open the master clamp to have the used master tip end gripped by the plate ejection unit.
3) Close the master clamp, rotate the drum again and stop the drum at the next opening / closing lever section (master attachment position).
4) Open and close the master clamp to have it grip the leading edge of the used master.
5) Rotate the drum, to wind the master onto it.
76
chap.2
2. Operation of Master Clamp Open / Close Lever

(1) Structure
The following is the structure of the master clamp opening / closing section viewed with the rear cover opened. The rotation stop position of the master clamp opening / closing lever is determined by the clamp motor and two cams. There are 3 rotation stop positions: A mode, B mode and C mode. Their functions are as follows:-
Master clamp opening / closing lever
Master clamp opening / closing lever Clamp motor
Master clamp B mode adjusting cam A / C mode adjusting cam B mode sensor A / C mode sensor
The drawing below is a section through the machine's interior, viewed from the control side.
Master attachment position Master detachment position
Master clamp opening / closing section
Drum
2A mode
2B mode
2C mode
23S0266
77
chap.2
(2) Master Attachment / Detachment Operation
78
chap.2
(3) Clamp Opening / Closing Lever Position (A / B / C Mode)

Mode Photointerrupter stop position / state of sensor
A / C mode sensor (PS3)
Functions In the normal state or during printing, the master clamp opening / closing lever turns out from the master clamp opening / closing lever.
A m o d e
B mode sensor (PS4) Photointerrupting
Photopassing
B m o d e
B mode sensor (PS4) PhotointerruptinggPh oto-passing or Photopassing gPhotointerrupting
The master clamp opening / closing lever pinch the master clamp opening / closing arm.
Photo-interrupting
The master clamp is open. This state occurs when the master is attached or detached.
C m o d e
B mode sensor (PS4) Photopassing
Photopassing
79
chap.2
(1) A / B / C Mode Sensor
Circuit
Clamp
2 1
Yellow Orange
J1-21 -22
3.3V
J6-30 -24 -23

3.3V 3.3V
3.3V
J6-31 -26 -25

3.3V 3.3V
Operation / Sequence
The mode is detected under the following conditions 2A mode When the B mode sensor (PS4) is photointerrupted, the A / C mode sensor (PS3) detects the edge of photointerrupting f photopasing. *With the power ON, the A mode is determined when the B mode sensor is in the photointerrupting state and the A/C mode sensor is in the photopassing state. If not in the A mode with the power ON, the master clamp opening / closing lever rotates to the B mode and stops. When the lever stops at the B mode, the drum rotates with the drum rotation switch and returns to the A mode at the stop position. 2B mode When the A/C mode sensor is photointerrupted, the B mode sensor detects the edge of photointerrupting / /photopassing or photopassing - photointerrupting. 2C mode When the B mode sensor is photopassing, the A/C mode sensor detects the edge of photointerrupting f photopassing. 80
chap.2
4. Returning Operation Flowchart When the Power Is Cut Off Accidentally

The machine returns to the initial state automatically when the power is turned off mistakenly during processing mastermaking, plate-detaching and master-attaching simultaneously or when the power returns after it is interrupted.
Power ON Power ON
Detachment/attachment process
Is the state the same as the previous state (before the power is turned OFF)?
"---WAIT---" display
Process other than detachment/attachment
Attachment/detachment operation continues
"---WAIT---" lights out
no "MASTER SET MISS" displayed? yes Open the document receiving tray
Remove the mis-set master
Close the document receiving tray
OK monitor lights out Initial desplay
Standby
81
chap.2
c Paper Feed Section
cPaper Feed Section

1. Description
Feeding of the paper is performed by the paper separator (employing the center separation method) and paper feed roller (there is no corner finger). Elevation of the feed tray is powered by the elevator motor. Paper fed by the paper separator and paper feed roller is fed further by the timing roller and guide roller to the point where its leading edge is sandwiched between the drum and the press roller. Then the pression of the timing roller and guide roller is released (by moving the guide roller upward several mm), so that the paper is fed through at a speed equal to the circumferential speed of the drum and press roller. The press roller sensor senses the paper feed condition; if a feed error occurs, the message PAPER LEFT JAM is displayed. For details, see 1.Paper Jam Detection Timing in chapter 2 (n Paper ejection section). \See page 107
Drum Press roller Elevator motor P roll sensor Guide roller
Paper feed roller
Paper separator
Paper
Timing roller
Supplemental paper tray
Feed tray
23S0274
82
chap.2
2. Operation
(1) Rotation of the Paper Feed Roller and Timing Roller
When the main motor turns, the paper feed cam rotates, causing the paper feed segment and timing segment to execute the reciprocating motion shown below, which turns the pinion gear.
Paper feed roller Paper feed segment
Paper feed roller
Timing roller
Pinion gear
Timing segment
23S0223
83
chap.2
(2) Paper Feed Roller Drive

The paper feed roller is driven by the main motor via the timing belt and the paper feed clutch. The rotational timing depends on the ON/OFF state of the paper feed clutch and is controlled by the program.
Timing roller Paper feed clutch Main motor
Paper feed roller
23S0279
84
chap.2
(3) Driving of the Timing Roller

Timing roller is actuated to rotate by the pinion gear and spring clutch. When the paper feed cam rotates, the reciprocating motion of the timing roller segment is transmitted to the pinion gear, and the spring clutch works to rotate the Timing roller in the direction of conveyance.
Paper feed cam
Pinion gear
Spring clutch Spring clutch
Paper feed segment
Timing roller
23S0275
85
chap.2
(4) Escape the Guide Roller

After the Press roller is pressed to the drum, the printing paper is gripped firmly with the drum and Press roller, the Guide roller is released from the Timing roller. This is called "escaped". Escape timing is within a period when the printing paper is conveyed about 10 mm after it is gripped with the drum and Press roller.
IMPORTANT : When the timing is too late, the printing paper is gripped at two places too long. Thus
master elongation and slippage occur. On the contrary, when the timing is too early, the printing paper is not gripped at all, and it is not well settled. Thus creasing of paper and dispersion of the printing position occurs.
Escape lever Drum
about 10mm
Escape cam
Guide roller Press roller Timing roller

23S0286
Escape cam Press roller Guide roller Drum
Timing roller
about 10mm
Paper
23S0287
86
chap.2
(5) Paper Feed Length

The paper feed length is the length by which the paper feed roller feeds out the print paper. When the paper feed roller feeds out the print paper, the guide roller is pressed against the timing roller and does not rotate; as a result, the paper arches up between the paper separator and the timing roller, since the distance between these two items is only 80mm, while the length by which the paper is fed out from the paper feed roller is 95mm. This arching has the effect of correcting any skewing of the paper (as the leading edge is held firm between the guide and timing rollers). It also has the effect of lessening the load on the timing roller when it feeds the paper through, thus minimizing slippage. For feed amount, the leading edge of the paper is detected by the paper feed length sensor and paper feed is HELP mode H-66,67 \ see p.284-285 controlled by program( HELP mode H-66,67 ).
Guide roller
Paper feed roller
Paper
Paper feed cam
Cam follower Paper separator
Timing roller
Paper feed length sensor
23S0260
IMPORTANT : If paper feed length is too large: the arching dimension will be too large, and if the paper is
of a very stiff type, it will buckle up between the paper feed roller and the paper feed inlet (upper), causing a PAPER JAM error ("PAPER LEFT JAM"). If paper feed length is too small: the arching dimension will be too small, so that arching will be unable to correct skewing of the paper, and skewing and wrinkling will be liable to occur. Furthermore, the slippage that occurs when the timing roller feeds the paper through will be very large, resulting in printing position errors.
87
chap.2
3. Functions of parts
PRINTING POSITION ADJUSTMENT key
(1) Printing Position Adjusting Mechanism

The printing position is adjusted by changing the timing of the paper toward the drum with the PRINTING POSITION ADJUSTMENT , key on the control panel. Description When the PRINTING POSITION ADJUSTMENT , key on the control panel is pressed, the link cam is driven by the motor. As the link cam moves, the cam follower position (bearing) from the paper feed cam changes. Accordingly drive timing for the timing roller can be changed. 2Press the key ; Cam follower moves in the direction of : e Drive timing of the timing roller becomes earlier. Paper timing becomes earlier, and the picture image moves backward. 2Press the key ; Cam follower moves in the direction of : b Drive timing of the timing roller becomes later. Paper timing becomes later, and the picture image moves forward.
Standard position sensor Printing position motor Paper feed cam
makes cam followPressing er move in the e direction
Top and bottom limit sensor Link cam
makes cam followPressing er move in the b direction

Timing roller
Cam follower
23S0258
88
chap.2
Circuit
Yellow Orange J1-13 -14 Main PCB Unit
3.3V
J7-2 J8-12 J7-1
3.3V 3.3V 3.3V
J7-4 J8-14 J7-3
3.3V 3.3V
Operation Top and bottom limit of print position is detected by the top and bottom limit sensor and the standard position sensor. The center position is detected by the standard position sensor.
2 Standard sensor: photopassing, Limit sensor: photointerrupting

The printing position is between the standard position and bottom limit.
2 Standard position sensor: photopassing, Limit sensor: the edge of photointerrupting - photopassing
is detected The printing position is at the bottom limit.
2 Standard position sensor: photointerrupting, Limit sensor: photointerrupting

The printing position is between the standard position and the top limit.
2 Standard position sensor: photointerrupting, Limit sensor: the edge of photointerrupting - photopassing
is detected The printing position is at the top limit. Operation with the Power ON The printing position returns to the standard position by operating with the power ON, depending on the sensor state as follows. 2When positioned between the standard position and the bottom limit: Rotate the printing position motor normally (CW) to return the printing position to the standard.
2When positioned between the standard position

and the top limit: Rotate the printing position motor reversely (CCW) to return the printing position to the standard. 89
chap.2
(2) Signal Lever

Description The signal lever is positioned at the back of the Guide roller / Timing roller. Whether the paper is fed by the Timing roller is detected mechanically. Operation The pinch lever is attached to the other end of the shaft to which the signal lever is attached. As the signal lever is jumped by the paper, the pinch lever also jumps. Accordingly the Press roller is out of control and rises. The above operation keeps the drum from dirts as the Press roller is in contact with the drum when the paper is not fed. As the Press roller sensor detects rising of the Press roller, Whether the paper is fed from the paper feed section to the printing section normally is detected indirectly.
Pinch lever
A
Press lever
P roll sensor Signal lever

Press roller
Guide roller
Timing roller
Paper
23S0277
View from Signal lever
Drum
Pinch lever
Press roller
Guide roller P roll sensor Timing roller

23S0257
90
chap.2
(3) Feed Tray (Elevator) Upper Limit Sensor

Description The feed tray (elevator) upper limit sensor senses decrease of the paper pile, and the upper limit position of the feed tray. It does so by detecting the up/down motion of the paper feed shaft. Circuits
Feed tray (elevator) upper limit sensor 5V 1 2 3 Red Light green Light blue J8-20 -13 -24 0 3.3V 3.3V Photopass : 0V Photointerrupting : 3.3V
Main P C B U nit
23S0301
Operation Sensing of feed tray upper limit 2When the feed tray rises, the paper in it presses the paper feed roller upward, making the paper feed shaft lever (photointerrupter) rotate upwards about its fulcrum, until it no longer obstructs the sensors light beam. Restoration of the sensors light beam signals that the paper tray has reached the upper limit, and triggers stopping of the feed trays rise. Sensing of paper decrease 2As printing progresses and the paper decreases, the paper feed roller gradually descends, until it obstructs the sensors light beam. When this happens, the feed tray is raised until the light beam is restored. If the light beam is not restored within about 30 seconds of the sending of the RAISE FEED TRAY command, error E002 (elevator lock) is displayed.
Paper feed shaft lever Paper feed roller Paper tray upper limit sensor Fulcrum Paper
23S0224
91
chap.2
(4) Feed Tray (Elevator) Lower Limit Switch

Description This is a micro switch (SM6) that senses the lower limit position of the feed tray.
Circuits
Feed tray (elevator) lower limit switch Lower limit (PUSH) : OPEN Light blue Light blue J8-11 -23 3.3V
3.3V
Main P C B U nit
Operation When the feed tray rises, the bracket disengages from the switch and the switch closes. When the feed tray descends to its lower limit position, the bracket engages the switchs actuator, opening the switch. If the switch does not open within about 30 seconds of the sending of the LOWER FEED TRAY command, error E002 (elevator lock) is displayed. 2Lower limit position
Connector
Screws Elevator lower limit switch
92
chap.2
(5) Paper Sensor

Description Senses presence/absence of paper in the feed tray. When the paper in the tray runs out, the message "SET PRINT PAPER" is displayed and printing stops. Circuits
Paper sensor Closed when paper present Open when paper absent 1 2 3 Red Purple Blue J6-32 -16 -15 0
5V
3.3V 3.3V Photopass : 0V Photointerrupting : 3.3V
Main P C B U nit
Operation When there is no paper, the lever moves away and the sensor opens. When paper is placed inside, the lever presses the actuator and the sensor closes. When an absence of paper is detected, the message "SET PRINT PAPER" is displayed on the operation panel. 2When absence of paper is sensed, mastermaking, printing and test printing are not possible. 2If the paper runs out during printing, "SET PRINT PAPER" is displayed on the operation panel, printing is stopped, and the feed tray descends to its lower limit position. 2If the paper runs out during platemaking, operation continues until the end of the mastermaking process, then operation stops (without proceeding to the printing process), and the feed tray descends to its lower limit position.
When there is paper placed :
When there is no paper :
Photointerrupting
Photopassing
Actuator Paper sensor

23S0226
93
chap.2
(6) Paper Feed length Sensor

Circuits
Paper feed length sensor 5V 1 2 3 Red Yellow Blue Red Yellow Blue J12-6 J8-19 J12-5 0 5V 3.3V Photopass : 0V Photointerrupting : 3.3V
Main P C B U nit
94
chap.2
vDrum Driving Section

1. Description
Drum home / jam detection position sensor
Drum gear
Master attachment / detachment position sensor
(P roll sensor)
Main motor
Encoder
Encoder sensor
23S0248
95
chap.2
v Drum Driving Section
(1) Home Position / Jam Detection Position Sensor
The home position / jam detection position sensor detects the drum home position and jam detection position. 2The drum home position is the position where the drum stops at the same time when a beep sounds after the jog switch (drum rotator switch) is kept pressing. 2The jam detection position is the timing to check paper jamming in the paper ejection section. 2Paper jamming in the paper ejection section is checked in the above timing with the jam sensor (photoreceiving) and P roll sensor. Circuit
Drum home position / jam detection position sensor (PS5) 1 2 3 Red Yellow Blue J6-28 -20 -19 0
5V
3.3V 3.3V Photopass : 0V Photointerrupting : 3.3V
Main P C B U nit
Operation The home position / jam detection position sensor is positioned while the drum is rotating as follows:2The home position is detected with the edge of photointerrupting / photopassing. 2The jam detection position is detected with the edge of photopassing / photointerrupting.
Drum home/jam detection position edge
Drum home/jam detection position sensor
Jam detection position edge

23S0249
96
chap.2
(2) Master Attachment / Detachment Position Sensor

The master attachment / detachment position sensor detects the drum stop position when the master is attached or detached. It also detects the speed reducing timing for stopping at the printing speed and for pressing the JOG switch (drum rotator switch) . Circuit
Master attachment / detachment position sensor (PS6) 1 2 3 Red Purple Blue J6-27 -18 -17 0 5V 3.3V 3.3V Photopass : 0V Photointerrupting : 3.3V
Main P C B U nit
Operation The following is the state of the master attachment / detachment position sensor while the drum is rotating. 2The master detachment position is detected with the edge of photopassing f photointerrupting. 2The master attachment position is detected with the edge of photointerrupting f potopassing. 2The drum speed is reduced to the slow (before-stop) speed at the master detachment position before the drum stops.
Master attachment position
Master detachment position edge
Master attachment position edge Master attachment / detachment position sensor

23S0250
97
chap.2
(3) JOG Switch (Drum Rotator Switch)

Description The drum rotates as long as the JOG switch (drum rotator switch) is pressed (within one rotation) and stops at the stop position with a beep. Circuit
Jog switch (drum rotator switch) (SW3) Purple Purple J7-9 -10 3.3V
3.3V
Main P C B U nit
Sequence of Operation 2When the JOG Switch (Drum Rotator Switch) Is Pressed Down In the normal state, the drum rotates (within one rotation) when the JOG switch (drum rotator switch) is kept pressed and the drum stops at the stop position, reducing the speed to the slow (before-stop) speed at the first master detachment position. When the P roll sensor is in the photopassing state (P roll ON) at the first master detachment position, the drum passes the stop position without reducing the speed.
Jog switch (Drum rotator switch)

23S0014
JOG switch (drum rotator switch) (SW3)
98
chap.2
(4) Control of the Main Motor

Circuit
Main P C B U nit Brown Brown Blue Blue J9-3 -4 -1 -2 5V Red Gray Blue J8-18 -21 -17 0 3.3V 3.3V Photopass : 0V Photointerrupting : 3.3V
DC24V
Encoder sensor (PS7) 1 2 3
Main motor (M1)
Red Black
J10-4 -3
99
chap.2
1. Rotation Speed Control by Encoder Sensor The encoder sensor detects the main motor rotation. The main PCB Unit controls the number of main motor rotations with the encoder sensor signal. The encoder sensor signal is transmitted to the main PCB Unit as encoder dividing signal . The number of main motor rotations is checked with the HELP05. HELP mode H-05 \ see p.234
100
chap.2
b Press Section
bPress Section
1. Description
Drum gear
Press lever Press roller P roll sensor

23S0251
(1) Press Roller Timing & Printing Area

Description In this machine, the master is rolled up to the drum, ink is transferred to the drum and the printing paper is pressed to the drum by the press roller to print. Printing is performed on only the sections that meet the following requirements. 1) The sections of the master on which holes are made by processing mastermaking. (mastermaking area) 2) The hole sections of the drum. 3) The section of the drum pressed with the press roller. (the area pressed ON) When the pressed-on position is 0 under the normally adjusted conditions, relations among 1), 2) and 3) are as follows*DP-M420 DP-M410 DP-M400
(mm)
Press ON length Drum hole section length Printing area length
369 365.3 355
314 315.3 300
DP-M410/420 : 365.3mm DP-M400 : 315.3mm

Center of the master clamp shaft
DP-M410/420 : 250mm DP-M400 : 210mm
9mm
Bottom end of the hole section
101
chap.2
b Press Section
The press roller is ON (the press roller is pressed to the drum) or OFF by operating the press lever up and down with the cam inside the drum gear. Press roller : OFF
Drum Drum gear Cam
Press roller : ON
Cam Drum gear Drum
Press roller Press lever

23S0252
Adjusting the printing area means that the cam curve goes up and down as shown in the figure. The timing of drum ON / OFF varies depending on the cam curve`s up and down. The ON position is before the drum hole section, so the printing area is not influenced. (Do not shorten the printing area length as it is influenced.) The OFF position is only changed and the printing area is adjusted.
IMPORTANT : Do not press off later than the hole
Press OFF position
Press ON position
Printing area
Printing area
section end position since ink seeps from the bottom end of the master.
Drum hole section end
Drum hole section start
DP-M410/420:355mm
DP-M400:315mm
102
chap.2
b Press Section
(1) Press Roller (P Roll) Sensor
The P roll sensor detects up and down of the press roller. The press roller only ascends when the paper is fed from the paper feed section by the pinch lever. The P roll sensor also is used to know whether the paper is fed. Circuit
Press roll limit sensor(PS8) 5V 1 2 3 Red Light blue Blue J6-29 -22 -21 0 3.3V 3.3V Photopassing : 0V Photointerrupting : 3.3V
Main P C B U nit
Operation The P roll sensor position varies depending on the press roller position as follows: When the press roller is OFF (DOWN) : photointerrupting When the press roller is ON (UP) : photopassing Press roller : OFF
Pinch lever Drum Drum
Press roller : ON
Pinch lever
P roll sensor :photointerru pting
P roll sensor :photopassing
23S0253
103
chap.2
n Paper Ejection Section
nPaper Ejection Section

1. Description
In the paper ejection section the printed paper is removed from the drum and is ejected to the print tray.
Drum
Paper stripper finger
Paper ejection belt
Paper ejection fun
Main motor
104
chap.2
2. Functions of Parts
(1) Paper Stripper Finger
Mechanical Structure and Operation In addition to the paper stripper finger installed in the center, there are two sub paper remover fingers on both sides. There is an air diffuser on the tip of the finger. Compressed air transmitted from the air pump is blowed out of this hole to detach the tip end of the paper from the drum.
Air pump
Sub paper stripper finger
Sub paper Paper stripper finger stripper finger

23S0278
To remove the paper from the drum firmly, the gap between the tip of finger and the drum surface and between the tip of finger and the corner of the master clamp are adjusted as follows:Drum surface Approx 0.5mm

23S0247
105
chap.2
(2) Jam Sensor

Description The jam sensor photo-receiving element is installed on the paper ejection fan unit and detects whether the paper is ejected normally. When it is detected that the paper is not ejected normally, "PAPER RIGHT JAM" (ejection side) is displayed on the error display panel on the control panel. Circuit
Master ejection sensor photo-emitting PCB Blue Gray Jam sensor photo-emitting PCB Blue Pink Jam sensor photo-recieving PCB 1 2 5 Blue 6 Pink -21 -22 3.3V 1 2 3 Blue 4 Gray J7-23 -24 3.3V
Gray Blue
Pink Blue
-20 -19
3.3V
Main PCB Unit
Operation The Jam photo-emitting PCB is installed in the master ejection box, and the photo-receiving PCB in the paper ejection fan unit. HIGH with the optical path interrupted. LOW with the optical path passing. There are two cases of interruption; interrupted by the paper and the master ejection box is open.
Master ejection box
Jam sensor(Photo-emitting)
Jam sensor(Photo-receiving)
Paper ejection fun unit
23S0255
106
chap.2
1. Paper Jam Detection Timing Description Paper jamming is divided into two types: "PAPER RIGHT JAM" (ejection side) and "PAPER LEFT JAM"(feeder side). Paper jamming is detected under the following conditions. When paper jamming is detected, "PAPER JAM" is displayed on the error display panel on the control panel, and the machine stops printing operation. The display is cleared by removing the cause of paper jam and pressing the STOP key or by restarting printing.
2Paper jamming on the ejection side
JAM1: The bottom end of the paper is not ejected. When the jam sensor (light-emitting and light-receiving) is interrupted at the timing of jam detection position edge (photopassing \ photointerrupting) of the drum home / jam detection position sensor PS5. JAM2: The tip end of the paper is not ejected. When the JAM sensor is not interrupted at all while the P roll sensor is in the state of photopassing (pressed ON). JAM (stop): When the JAM sensor is interrupted as the master ejection box is open when the machine stops. The display is cleared when the sensor is in the state of photopassing. 2Paper jamming on the feeder side JAM3: The paper does not pass the signal lever though the paper is fed. The P roll sensor is not in the state of photopassing when the drum rotates twice after the paper feed solenoid is ordered ON. Sequence of Operation
A4 LG B4
A4 LG B4
A4 LG B4
Drum home/jam detection position sensor Master attachment/detachment position sensor Signal lever
Jam sensor(Photo-emitting)
Jam sensor(Photo-receiving)
P roll sensor
23S0256
107
chap.2
(3) Paper aligning mechanism

Description Paper can be aligned neatly by considering the ejection angle. Adjustments should be made in accordance with paper thickness. For thinner paper: Set the lever in the upper position. For thicker paper: Set the lever in the lower position. * Although the lever is usually set at the intermediate position for paper of normal thickness (65g/m2), the lever position should be adjusted depending on the condition of the paper.
Lever Thinner paper Normal(65g/ ) Ticker paper
23S0285
108
chap.2
m Drum Section
mDrum Section
1. Description
The ink control section is in the drum unit. The ink control section is supplied with ink in the ink pack attached to the drum unit by the motor. The ink control section has an ink detection function, and is always supplied with a fixed amount of ink. Printing darkness is adjusted by changing the gap between the squeegee roller and the ink roller. Five color inks are available: black, red, blue, green and brown. Perform color printing to replace the drum unit for each color. (Press the drum rotation switch to the drum home position to replace the drum unit.) In this machine, whether there is a drum or not is detected. If the drum is not attached properly, it is taken as "DRUM NOT SET", and "DRUM NOT SET" is displayed on the control panel.
Ink detection PCB unit
Ink motor
Squeegee roller
Ink roller
Ink pack
109
chap.2
m Drum Section
2. Circuit
Main PCB Unit 24V J2-10 -9 Orange Pink 2 8 Orange Pink 1 Red 2 Black Ink motor (M7)
24V
Ink detection PCB Unit J6-9 J2-1 J6-10 Blue Brown Black 3 9 4 Blue Brown Black 3 Blue 1 Brown 2 Black
110
chap.2
m Drum Section
(1) Ink Detection
Description The ink amount variation in the ink control section is read by the electric capacity variation between the detection needles on the ink detection PCB Unit and the GND and the ink signal is output to the main PCB Unit. The main PCB Unit controls the motor ON and OFF by this signal. When NO INK continues while the drum rotates 20 times (the number of drum unit rotations; it varies depending on the printing speed.*) during printing, it is determined that the ink pack is empty, "EXCHANGE INK" is displayed and the machine stops printing. \See page 113
111
chap.2
m Drum Section
1. LED Display and Output Signal on the Ink Detection PCB Unit 2When the electric capacity variation between the detection needles on the ink detection PCB Unit and GND is over the threshold value, the LED on the ink detection PCB Unit lights up and the ink signal (0V) is output.
1
Ink detection PCB unit LED No ink Ink Light out Light up CN1-2 J6-10 +5V 0V
3
1 Cord
2 LED(red)
3 Detection needles
2Timing of the LED and the ink motor operation is as follows. The ink motor works during printing (driving output signal).
J6-10
Main PCB Unit

J2-9
112
chap.2
m Drum Section
2. "EXCHANGE INK" Display Timing When HIGH (5V) is output by detecting ink while the drum continues to rotate 20 times (the number of rotations varies depending on the printing speed.*) during printing, it is detected that the ink pack is empty, "EXCHANGE INK" is displayed on the error display, and printing stops. At the same time the power for the ink motor is turned off.
J6-10 24V
Main PCB Unit
J2-9
*The drum rotates until "EXCHANGE INK" is displayed after HIGH is output from the ink detection PCB unit during printing. The number of drum rotations varies depending on the printing speed as follows:1 17 2 20 3 24
Printing speed
Number of rotations
113
chap.2
m Drum Section
(2) Ink Pump

Description The ink control section in the drum is supplied with ink in the ink pack by driving the ink motor. Mechanical Structure
Operation The piston performs suction and release operation by moving up and down.
When the piston moves up, it draws ink from the ink pack into the pump.
When the piston moves down, the pump releases ink.
114
chap.2
m Drum Section
(3)Drum Switch
Description The drum switch detects whether the drum is installed to the machine. When it is detected that there is no drum installed, "DRUM NOT SET" is displayed on the error display panel on the control panel the machine stops operation. When no drum is detected during operation, all the operations stops emergently. Circuit
J6-11 -12
3.3V
3.3V
Operation When the drum is attached to the main body, the cam unit covers the pin and is locked firmly. The difference of the cam unit prevents the cam unit from being loosened due to the machine vibration. When the pin is at the bottom of the cam unit difference, the drum SW is open as shown in the figure. When the pin is over the cam unit difference, the drum SW is closed. 2Drum installed
Lever
2No drum
Lever
Pin Switch Cam unit

23S0280
115
chap.2
m Drum Section
(4) Front Cover Open / Close Detection Switch

Description The front cover switch detects opening and closing of the front cover. "FRONT COVER OPEN" is displayed on the error display panel on the control panel, when it is detected that the front cover is open. When the front cover is open, mastermaking and printing is not performed. When the front cover open is detected during printing, the machine stops immediately. (When the front cover open is detected during mastermaking, the machine stops before processing printing.) Circuit
3.3V
J6-5 -6
3.3V
Operation When the front cover is closed, the lever presses the switch and is closed. When the front cover is open, the lever is apart from the switch and is open.
Switch
Front cover
2When the front cover is open :

Lever
2When the front cover is closed :

Lever
Switch
Switch
116
Chapter 3
z Exterior.......................................................................119 (1) Removal of Document Cover................................119 (2) Removal of Front Cover.......................................119 (3) Removal of Scanner Outer Cover.......................120 (4) Removal of Rear Cover........................................121 (5) Removal of Main PCB Unit.................................121 (6) Removal of Control Panel....................................123 (7)Removal of Control Panel PCB ............................123 (8) Removal of DC Regulated Power Supply............124
Mechanism
c Mastermaking / Master Feed and Ejection Section...131 Master Feed Section ...........................................131 (1) Removal of Cutter Unit .......................................131 (2) Removal of End Mark Sensor PCB Unit ............132 (3) Removal of Thermal Head...................................133 (4) Removal of Master Feed Unit .............................134
x Scanner Section ........................................................125 (1) Removal of Glass unit.........................................125 (2) Removal of Reading Cover..................................126 (3) Removal of Inverter PCB Unit............................126 (4) Removal of Lamp Unit.........................................127 (5) Removal of Lamp Cord........................................128 (6) Removal of Slider A.............................................129 (7) Removal of Slider B.............................................130
Master Ejection Section ......................................136 (1) Removal of Master Ejection Box .........................136 (2) Removal of Jam / Master Ejection Sensor (Photo-emitting PCB Unit)..................................137 (3) Removal of Rollup Motor .....................................137 Master Clamp opening/Closing Section...........138 (1) Removal of Master Clamp Opening / Closing Unit .........................................................138 (2) Removal of Clamp Motor.....................................138 (3) Removal of Timing Belt .......................................139
117
v Paper Feed Section....................................................140 (1) Removal of Paper Sensor......................................140 (2) Removal of Elevator Lower Limit Switch ...........140 (3) Removal of Paper Feed Roller ..............................141 (4) Removal of Paper Separator Unit........................141 (5) Removal of Paper Feed Clutch Unit ....................142 (6) Removal of Paper Feed Sensor.............................143 (7) Removal of Timing Roller.....................................144
m Drum Section.............................................................150 (1) Removal of Screen ...............................................150 (2) Removal of Master Clamp....................................151 (3) Removal of Base Unit...........................................151 (4) Removal of Outer Frame (Right) Unit.................152 (5) Removal of Outer Frame (Left) Assy...................153 (6) Removal of Inner Frame......................................154 (7) Removal of Ink Pump...........................................155 (8) Removal of Ink Motor...........................................155 (9) Removal of Ink Detection PCB Unit....................156
b Drum Driving Section................................................145 (1) Removal of Sub-Frame.........................................145 (2) Removal of Drum Gear.........................................146 n Paper Ejection Section..............................................147 (1) Removal of Paper Stripper Finger / Sub Paper Stripper Finger...................................147 (2) Removal of Paper Ejection Fan Unit...................148 (3) Removal of Paper Ejection Belt...........................149 (4) Removal of Jam Sensor (Photo-receiving PCB Unit)..................................149
CAUTION
Always remove the power cord plug from the outlet before
starting work.
Cautions Regarding Disassembly and Assembly

In principle, do not operate this machine with parts removed. When assembling:
Unless specified otherwise, perform the disassembly procedure in
reverse. Make sure that screw types (radius, length) and locations are correct. Be sure to use rosette washers when they are specified. (Rosette washers are used with installation screws to prevent static electricity.) To ensure electrical current, a rosette washer is used with the installation screw on the ground wire. Be sure to use the rosette washer during assembly.
118
chap.3
z Exterior
z Exterior
(1) Removal of Document Cover
1) Open the document cover.
Document cover
S2002
2) Remove the 2 screws shown. Slide the document cover back 1cm, and then pull it up to remove it.
Screws
S2004
(2) Removal of Front Cover

1) Open the front cover, and take out the drum unit. 2) Open the master ejection box.
Screws Screws
3) Remove the 6 screws indicated, then remove the front cover.
Screws
119
chap.3
z Exterior
(3) Removal of Scanner Outer Cover

Remove the Front cover 1) Remove the 2 screws indicated, then remove the front cover. Remove the Side cover L 1) Remove the 2 screws indicated, then remove the side cover L.
Screw Side cover L
Screw
Screw
Front cover
Side Cover R
Remove the Side cover R 1) Remove the 2 screws indicated, then remove the side cover R.
Remove the Rear cover 1) Remove the document cover. \See page 119 2) Remove the 4 screws indicated, then remove the rear cover.
Screws
Screw
Screws
Rear cover
120
chap.3
z Exterior
(4) Removal of Rear Cover

1) Remove the 4 screws indicated, then remove the rear cover.
Rear cover
Screws
Screws
24S005
(5) Removal of Main PCB Unit
WARNING
Always remove the power cord plug from the outlet before replacing a PCB Unit. 1) Remove the scanner cover(L,R). \See page 120 2) Press the Scanner switch to slide the scanner to its far position.
Scanner switch
3) Loosen the 2 screws shown. 4) Slide connector bracket A down.
Screw
Connector cover A
Screw
121
chap.3
z Exterior
5) Remove the 4 screws indicated, then remove the bracket(F,R).
Screws
Bracket (F)
Bracket (R)
Screws
24S009
6) Remove the screw indicated, then remove the PIN UNIT.
Screw
PIN UNIT
7) Press and hold the Scanner switch while sliding the scanner all the way in the paper feed direction.
8) Remove the PCB cover. 1) Remove the 2 screws. 2) Slide the PCB cover and remove it.
PCB cover
Screw
122
chap.3
z Exterior
9) Remove the connectors of. Main PCB unit (12 connectors)

Screw
) Remove the mounting screws, and replace the PCB units. Main PCB unit: 5 screws
Screw
Screw
(6) Removal of Control Panel

1) Remove the 4 screws.
Screw 1
Control Panel
Screw 2
2) Remove the connector and detach the control panel upward.
Screw 3
Screw 4
(7) Removal of Control Panel PCB Unit

Control Panel PCB Unit Screw
Remove the 14 screws and detach the control panel.
123
chap.3
z Exterior
(8) Removal of DC Regulated Power Supply
WARNING
Always remove the power cord plug from the outlet before replacing a PCB Unit. \See page 119
1) Remove the front cover. 2) Remove the connectors of.
DC regulated power supply (3 connectors)

Regulated power supply
3) Remove the mounting screws, and replace the PCB units. DC regulated power supply: 2 screws
Screws Screws
124
chap.3
x Scanner Section
x Scanner Section
(1) Removal of Glass unit
1) Remove the document cover. \See page 119
2) Remove the Side Cover R.
\See page 120
Screws
3) Remove the 2 screws indicated, then pull out and remove the Glass unit at the direction as right carefully.
IMPORTANT : Do not dirt the shaiding plate.
Clean it if it is dirty.
1 2
125
chap.3
x Scanner Section
(2) Removal of Reading Cover

1) Carry out (1) and (2) above. \See page 125 2) Remove the 4 screws indicated, and remove the reading cover.
Screw Reading cover Screw
Screw Screw
24S019
(3) Removal of Inverter PCB Unit

1) Carry out (1) through (3) above. \See page 125,126 2) Disconnect the 2 connectors. 3) Remove the 2 spacers indicated, and remove the inverter PCB unit.
Spacers
Connector
Inverter PCB unit Connector

24S020
126
chap.3
x Scanner Section
(4) Removal of Lamp Unit

1) Carry out (1) through (3) above. \See page 125,126 2) Remove the scanner cover(L,R). \See page 120 3) Remove the 7 spacers indicated, and remove the scanner F bracket. 4) Remove the 8 spacers indicated, and remove the scanner R bracket.
Scanner R bracket Screws Screws
Screws
Screw Scanner F bracket Screws
Screw Screws Screw

24S021
5) Turn the timing pulley, and move Slider A to the position shown in the diagram.
IMPORTANT : Do not move Slider A by hand. Screw
Timing pulley Lamp unit Screw
6) Remove the 3 screws indicated, and remove the lamp unit.

Slider A
Screw
24S022
Reinstallation
Insert the slotted parts of the lamp unit into the grooves on the brackets.
IMPORTANT : The lamp is fragile; handle it with care. Bracket groove
Lamp unit
Bracket groove
24S023
When attaching the scanner's front and rear brackets: 1. Align the notches on the left and right sides. 2. When attaching the scanner's rear bracket, be careful to not pinch the wiring.
Notch
Notch
Notch
Notch
24S024
127
chap.3
x Scanner Section
(5) Removal of Lamp Cord

1) Carry out (5) 1 through 4 above. \See page 127 2) Remove the cord clamp. 3) Disconnect the inverter PCB unit CN2 connector.
Cord clamp Inverter PCB unit
Connector
24S025
4) Remove the 4 screws indicated, and remove the lamp cord.
Screws Lamp cord
24S026
128
chap.3
x Scanner Section
(6) Removal of Slider A

1) Perform steps 1 through 4 of procedure (5). 2) Loosen the 2 screws shown, and remove Slider A \See page 127
IMPORTANT :
Slider A
Do not move Slider A by hand.
Screw
Screw
24S021
Reinstallation
Required items * Slider A attachation tool 1 * Slider A attachation tool 2 1) Attach 2 Slider A attachation tools 1.
Tool 1
Place in opening
24S028
2) Turn the timing pulley and move Slider A so that the Slider A positioning openings are aligned with the Slider A attachation tool 1 positioning openings.
Slider A
IMPORTANT : Do not move Slider A by hand.
Align opening positions

24S029
3) Attach 2 Slider A attachation tools 2. 4) Fix the wire with 2 screws. 5) Remove the Slider A attachation tools 2. 6) Remove the Slider A attachation tools 1.
Tool 2
24S030
129
chap.3
x Scanner Section
(7) Removal of Slider B

Required items * Wire fixing tools 1) Perform steps 1 through 3 of procedure (5). 2) To prevent loosening of the wire, attach 2 wire fixing tools, one before and one after the wire pulley.
IMPORTANT : Do not remove the wire fixing tools Fix the wire with the tool
Fix the wire with the tool
before Slider B is attached. 3) Remove the wire from the spring, in 2 locations before and after the spring. 4) Remove Slider B.
Reinstallation
Attach the spring
24S031
Required items * Slider B attachation tool 1 * Slider B attachation tool 2 1) Attach 2 Slider B attachation tools 1.
Tool 1
Place in opening
24S032
2) Place the wire on the pulley, both before and after. \See page 159
Slider B
3) Move Slider B so that the Slider B positioning openings are aligned with the Slider B attachation tool 1 positioning openings.
Align opening positions

24S033
4) Attach 2 Slider B attachation tools 2. 5) Place the spring on the hook(wire). 6) Remove the Wire fixing tools. 7) Remove the Slider B attachation tools 2. 8) Remove the Slider B attachation tools 1.
Tool 2
24S034
130
chap.3
c Mastermaking/Master Feed and Ejection Section
c Mastermaking / Master Feed and Ejection Section

Master Feed Section
(1) Removal of Cutter Unit
Connectors
1) Pull out the two connectors (with 2, 4 pins).
Cover
2) Remove the two screws and detach the cover.
Screws
3) Remove the two screws and detach the cutter unit.
Screw
Cutter unit
Screw
131
chap.3
(2) Removal of End Mark Sensor PCB Unit.

Screw
Sensor cover
1) Remove the screw and detach the sensor cover.
2) Pull out the connector (end-mark sensor 2). 3) Remove the two screws and detach the end-mark sensor 2.
Connector
4) Adjust the end-mark sensor 2. Go to HELP-13 and set the document mode 'Photo'. Rotate the sponge roller to adjust the sensor (10 or less in white section, 40 or more in black section) with VR.
Screws
End-mark sensor 2
132
chap.3
(3) Removal of Thermal Head

1) Remove the two screws and detach the guide plate.
Guide plate
Screws
2) Pull out the two connectors.
Connectors
3) Remove both screw and collar.

Bracket
4) Remove the bracket from the bottom.
Screw
5) Remove the two screws with the collars to detach the thermal head.
Collar
IMPORTANT:
Do not touch the heat emission parts of the thermal head.
Do not touch the heat emission parts
The thermal head is sensitive to static electricity, so before touching it, be sure to touch ground to get rid of your body static. The head is also liable to corrode. To avoid corrosion, keep the head free of moisture and salinity, and do not touch its heat emission parts. Touching these parts could scratch them.
Collar Screw
Thermal head
133
chap.3
(4) Removal of Master Feed Unit

1) Remove the two screws and detach the guide plate.
Guide plate
Screws
2) Cut the two banding bands.

Thermal head connectors
3) Pull out the two thermal head connectors.
Banding band
Connectors
4) Remove the two cord bands and pull out the four connectors.
Cord bands
134
chap.3
5) Remove the screw and take out the switch with the switch bracket (with bundled wire connected). 6) Remove the four screws and detach the master feeding unit.
Screws
Master feeding unit
Screw
Screw
Screw
Switch bracket
135
chap.3

(1) Removal of Master Ejection Box
1) Remove the rear cover. 2) Disconnect the 3 connectors. 3) Remove the cord band. \See page 121
Connector
Connector
Cord band
Connector
4) Remove the nuts.

Nuts
5) Remove the 2 screws indicated, and remove the master ejection box.
Master ejection box
Screws
136
chap.3
(2) Removal of Jam / Master Ejection Sensor (Photo-emitting PCB Unit)

1 ) Remove the master ejection box. \See page 136 2) Remove the respective photo-emitting PCB units by removing the 2 screws.
Master ejection sensor photoemitting PCB unit Screw
Jam sensor photo-emitting PCB unit
(3) Removal of Roll - up Motor

1) Remove the master ejection box. \See page 136 2) Remove the 1 screw indicated, and remove the cover.
Cover Screw
3) Remove the timing belt from the pulley at the part shown by the arrow. 4) Remove the 3 motor mounting screws indicated, and remove the roll - up motor.
Timing belt
Reinstallation IMPORTANT : Do not forget to adjust the tension
after the motor is attached. \See page 163

Screws Motor Pulley
137
chap.3
Master Clamp opening/Closing Section

(1) Removal of Master Clamp Opening / Closing Unit
1) Remove the rear cover. \See page 121 2) Remove the drum. 3) Move the position of the master clamp opening / closing lever to the mode other than A mode. (Use the HELP 20) HELP mode H-20 \ see p.254 4) Turn the power off and turn it on again. The opening / closing lever moves to the B mode and stops.
5) Pull out 3 connectors. 6) Remove 3 screws to take out the opening / closing unit.
Screws Connector
Screws Master clamp opening / closing unit Connectors

23S0077
(2) Removal of Clamp Motor

1) Remove the master clamp opening / closing unit. 2) Loosen the set screw to remove the gear. 3) Remove 3 screws to take out the motor.
Clamp motor Screws Set screw
Screw
23S0078
138
chap.3
(3) Removal of Timing Belt

1) Remove the master clamp opening / closing unit. \See page 138 2) Loosen 2 screws to loosen the tension as shown in the figure.
Tension Screws
23S0079
3) Remove the screw to remove the angle. 4) Remove the timing belt.
Screw
Screw
Timing belt
23S0080
Reinstallation
Adjust tension by adjusting the master feed master clamp opening/closing lever and master ejection master clamp opening/closing lever. Then fit the timing belt on. \See page 164
Position hole
Master ejection master clamp opening/closing lever
IMPORTANT : Adjust the A, B and C modes after
the master clamp opening / closing unit is attached to the printer main \See page 165 body.
Master feed master clamp opening/closing lever Main frame R Position hole
Master clamp opening/closing unit

23S0082
139
chap.3
v Paper Feed Section

(1) Removal of Paper Sensor
1) Access HELP mode H-02, and use it to raise the elevator to its uppermost position. HELP mode H-02 \ see p.236
Feed tray
23S0083
2) Disconnect the connector, and remove the paper sensor.
Paper sensor
Connector
23S0084
(2) Removal of Elevator Lower Limit Switch

1) Remove the front cover. \See page 119 2) Remove the 2 screws indicated, then remove the bracket. 3) Disconnect the connector, and remove the elevator lower limit switch.
Reinstallation IMPORTANT : After reinstalling the elevator lower Screws Elevator lower limit switch Connector
limit switch, carry out adjustment of its clearance. \For adjustment method see page 171
140
chap.3
(3) Removal of Paper Feed Roller

1) Remove the screw indicated, and slide the paper feed shaft in the direction of the arrow.
Paper feed shaft
Screw
23S0086
2) Loosen the set screw indicated, and remove the paper feed roller.
Reinstallation
Paper feed roller
Paper feed rollers
Reinstall the paper feed roller so that the set screw is positioned at the paper feed roller shaft's counter bore.
IMPORTANT : Do not use an old paper feed roller Set screw Set screws
23S0087
together with a new one.
(4) Removal of Paper Separator Unit

1) Loosen the set screws indicated, and move the 2 paper feed rollers clear of the paper separator unit. 2) Remove the paper separator unit.
Reinstallation IMPORTANT : After reinstalling the paper separaSet screws
tor unit, carry out adjustment of its clearance. \See page 169
Paper separator unit Paper feed rollers

23S0088
141
chap.3
(5) Removal of Paper Feed Clutch Unit

\See page 121 1) Remove the rear cover. 2) Disconnect the connector. 3) Remove the screw indicated, and disconnect the paper feed shaft from the coupling.
Connector Screw Paper feed shaft
4) Remove the 3 screws indicated, and remove the bracket. 5) Remove the 2 screws indicated, and remove the bush.
Screws
Bush
Screw
Bracket Screws
Paper Feed Clutch Unit
142
chap.3
(6) Removal of Paper Feed Sensor

1) Remove the paper feed shaft. \See page 141 (3) 2) Remove the paper separator unit. \See page 140 3) Remove the 4 screws indicated, and remove the bracket.
Screws Screws Bracket Paper feed shaft
23S0093
4) Disconnect the connector. 5) Remove the screw indicated, and remove the paper feed sensor.
Paper feed sensor Screw
Connector
23S0094
143
chap.3
(7) Removal of Timing Roller

1) Remove the front cover. 2) Remove the rear cover. \See page 119 \See page 121
Screws Bracket
3) Remove the drum. 4) Disconnect the connector.(Paper sensor) \See page 140 5) Remove the 3 screws shown. Remove the rear rail (opposite side from the operation panel).
24S035
6) Remove the springs. 7) Remove the 4 screws shown. Remove the chain stop angle.
Screws
Paper feed shaft
8) Remove the paper feed tray. 9) Remove the paper feed shaft. \See page 141
Screws Paper feed tray

24S036
10) Remove the 4 screws shown. Remove the paper feed inlet. 11) Unplug the paper feed sensor connector. \See page 143
Screws
Screws
Paper feed inlet

24S037
12) Remove the 3 screws shown. Remove the bearing stops and the springs. 13) Remove the timing roller from the rear (opposite side from the operation panel).
Screws
bearing
Bearing
Timing roller Screw

24S038
144
chap.3
b Drum Driving Section

(1) Removal of Sub-Frame
1) Remove the rear cover. \See page 121 2) Remove the 7 screws indicated, and remove the pump unit.
Screws Pump unit Screw Screw
Screws
23S0095
3) Disconnect the 6 connectors. 4) Remove the 11 screws indicated, and remove the sub-frame.
Screw Sub-frame
Screw
Screws Screw
Screw
Screws
23S0096
145
chap.3
(2) Removal of Drum Gear

1) Remove the rear cover. \See page 121 2) Remove the Sub-frame. \See page 145 3) Remove the 2 E-rings, and remove the links.
Links E-ring
E-ring
23S0097
4) Remove the 2 screws indicated, and remove the drum gear.

Screws
Drum gear
23S0098
146
chap.3

(1) Removal of Paper Stripper Finger / Sub Paper Stripper Finger
1) Open the master ejection box. 2) Remove the set screws. 3) Remove the paper stripper finger and sub paper stripper fingers from the shaft.
Sub paper stripper fingers
4) Take out the paper stripper finger and sub paper stripper fingers from the pipe.
Pipe Pipe
Reinstallation IMPORTANT : Adjust the paper stripper finger
after it is installed. \See page 178

Paper stripper finger Sub paper stripper finger
147
chap.3
(2) Removal of Paper Ejection Fan Unit

1) Remove the rear cover. \See page 121 2) Disconnect the connector. 3) Open the front cover, and remove the drum. \See page 119 4) Remove the front cover. 5) Disconnect the connector. 6) Open the master ejection box. 7) Remove the 2 screws from the cover, and remove the cover.
Cover Screws
23S0099
Connector
Connector
8) Remove the 6 screws indicated, and remove the jump plate F/R units.
Jump plate F unit
Jump plate R unit
Screws
Screws
23S0100
9) Remove the 4 screws, and pull out the paper ejection fan unit sliding in the direction of an arrow.
Paper ejection fan unit
Screws
Screws
23S0101
Reinstallation
Insert the driving shaft coupler to install the paper ejection fan unit.
Drive shaft coupler (Paper ejection fan unit)
23S0105
148
chap.3
(3) Removal of Paper Ejection Belt

1) Remove the paper ejection fan unit. \See page 148
Static removal brush
2) Remove the 2 screws from the static removal brush, and remove the static removal brush.
Screws
23S0102
3) Remove the 2 screws from the ends of the shaft, and remove the shaft. 4) Stretch the belts and install them oriented as shown in the figure.
Paper ejection belts
Screw Shaft
Screw
23S0103
(4) Removal of Jam Sensor (Photo-receiving PCB UNIT)

1) Remove the paper ejection fan unit. \See page 148 2) Pull the paper ejection belts wider apart to expose the screws, and secure the belts in that position. 3) Remove the 2 screws securing the sensor mounting angle, and remove the angle.
Remove the 2 screws with a driver
Paper ejection belts
23S0104
4) Remove the 2 screws from the sensor PCB, and remove the PCB.
IMPORTANT : Do not lose the 2 spacers.
Jam sensor
Screws
Spacers
149
chap.3
m Drum Section
m Drum Section
(1) Removal of Screen
1) Remove the drum. 2) Remove the clamp on the bottom end screen bar to pull out the screen bar. 3) Remove 2 set screws on the top screen bar to pull out the screen bar. 4) Remove the screen from the drum.
IMPORTANT : Do not rotate the drum reversely. Reinstallation Screw Screen
Bottom end screen bar Clamp
Top end screen bar Screw
Screw
1) Pass the top end screen bar through the screen (top end side). 2) Attach the top end screen bar to the drum.
IMPORTANT : Do not mistake the bottom end of
Top end screen bar Screw
Screen
Screw
the screen for the top end.
20mm (bottom end side)
58mm (top end side)
3) Pass the bottom end screen bar through the screen (bottom end side). 4) Hold the bottom end screen bar in parallel with the drum and roll it up to the drum rotating the drum normally.
Bottom end screen bar
5) Tighten the screen bar with the clamp.

IMPORTANT : The stainless screen does not return
Bottom end screen bar
to the original state once it is folded. Be careful to handle the screen.
Clamp
150
chap.3
m Drum Section
(2) Removal of Master Clamp

1) Remove the screen. \See page 150 2) Remove 2 screws on the operation side. 3) Remove the bearing plate and spring. 4) Remove 2 screws on the anti-operation side to take out the bearing plate. 5) Remove the master clamp. The master clamp is attached to the base with the magnet.
Reinstallation IMPORTANT : Master clamp Spring Screw
Screw Bearing plate
Adjust the master clamp after installation. \See page 181
(3) Removal of Base Unit

1) Remove the master clamp. 2) Remove 2 screws, and remove the base unit.
Screw Base unit Screw
151
chap.3
m Drum Section
(4) Removal of Outer Frame (Right) Unit

1) Remove the drum. 2) Remove 2 screws on the rail and 1 screw on the stay. 3) Remove 3 screws on the outer frame (right) unit and knob screw.
Reinstallation IMPORTANT : Do not forget to adjust the rail Rail left Rail right Screw Screws Stay
space after the rail is installed. \See page 182

Screw Outer frame (right) unit
Screws
4) Part the outer frame (right) unit a little and remove 2 connectors. 5) Remove the outer frame (right) unit.
Connector
Connector Outer frame (right) unit
152
chap.3
m Drum Section
(5) Removal of Outer Frame (Left) Assy

1) Remove the dram. 2) Remove the screw on the rail to take out the rail. 3) Remove the screw on the stay to remove the stay.
Reinstallation Screw IMPORTANT : Do not forget to adjust the rail
Stay
Rail left
space after the rail is installed. \See page 182
Rail right
Screws
4) Remove 4 screws.
Master clamp lever Outer frame shaft Assy
Screws
5) Pull out the outer frame (left) assy with the master clamp open.
Outer frame shaft assy
153
chap.3
m Drum Section
(6) Removal of Inner Frame

1) Remove the outer frame (right) unit. \See page 152 2) Loosen 2 set screws on the supporting plate, move the supporting plate in the direction of arrow until it stops and fix it with the screw.
Screws
Supporting plate
3) Pull out the inner frame (section inside the drum) in the direction of an arrow.
IMPORTANT : Be careful not to damage the drum
inside.
Reinstallation
Slide the supporting plate in the direction of arrow 1 so that the supporting plate roller, roller unit and roller are in contact with the inner surface of the flange right and tighten the roller with the screw, pressing the roller to the inner surface lightly.
Screws Roller Supporting plate
Roller unit
Roller
154
chap.3
m Drum Section
(7) Removal of Ink Pump

1) Remove the inner frame. \See page 154
Hose band Screw
2) Loosen the screw on the hose band to remove the hose.
Hose
3) Remove the screw to take out the link. 4) Remove 2 screw to take out the ink pump.
Screw Link Ink pump
Screws
(8) Removal of Ink Motor

Rotation plate Set screw
2) Cut the tie wrap. 3) Loosen the set screw to remove the rotation plate. 4) Remove 3 screws to take out the motor.
Screws
Motor
155
chap.3
m Drum Section
(9) Removal of Ink Detection PCB Unit

2) Pull out the connector. 3) Remove 3 screws to take out the ink detection PCB Unit.
Screws
Connector
Reinstallation IMPORTANT : Confirm that the detection needle is
vertical with the PCB Unit and does not contact anywhere, when installing the Ink detection PCB Unit.
Detection needle
Squeegee roller
Ink roller
156
Chapter 4
Standards / Adjustment
v Drum Driving Section................................................174 (1) Adjusting the Stop Position.................................174 (2) Adjusting the Master Attachment / Detachment Position ..............................................175
z Scanner Section.........................................................159 (1) Attaching the Rear Wire......................................159 (2) Attaching the Front Wire.....................................160
x Mastermaking / Master Feed / Ejection Section......161 Mastermaking / Master Feed Section ......................161 (1) Adjusting the Timing Belt Tension.....................161 Master Ejection Section.........................................162 (1) Attaching the Spring............................................162 (2) Adjusting the Timing Belt Tension.....................163 Master Clamp opening/Closing Section..............164 (1) Adjusting the Timing Belt Tension.....................164 (2) Positioning the Master Clamp Opening / Closing Levers.....................................164 (3) Adjusting the A / B / C Modes..............................165 b Press Section............................................................176 (1) Adjusting the Press Roll (P Roll) Sensor.............176 (2) Adjusting the Printing Area (Press OFF Timing) ...................................................177
n Paper Ejection Section.............................................178 (1) Adjusting the Paper Stripper Finger Clearance..................................................178
c Paper Feed Section....................................................169 (1) Adjusting the Paper Separator Unit Clearance.....................................................169 (2) Adjusting the Paper Separation Pressure...........170 (3) Adjusting the Paper Feed Tray Upper Limit Sensor.............................................170 (4) Adjusting the Paper Feed Tray Lower Limit Switch.............................................171 (5) Adjusting the G Roll Escape Amount / Timing...................................................172 DP-M400 (6) Adjusting the Printing margin............................173
m Drum Section.............................................................179 (1) Adjusting the Ink Amount...................................179 (2) Adjusting the Squeegee Gap................................180 (3) Adjusting the Master Clamp...............................181 (4) Adjusting the Master Clamp Section..................181 (5) Adjusting the Drum Rail Gap..............................182
157
, Electrical System.......................................................183 (1) Adjusting Reduction / Enlargement....................183 1. Adjusting the Longitudinal R/E on the Mastermaking Side................................183 2. Adjusting the Longitudinal R/E on the Reading Side...........................................183 (2) Reading Start Position.........................................184 1. Adjusting the Top End Reading Start Position.....................................................184 2. Adjusting the Lateral (Operation Side) Reading Start Position......................................184 (3) Adjusting the Mastermaking Start Position.......185 1. When the Scanner Is in Use..............................185 2. When in Online..................................................185 (4) Adjusting the Document Reading Darkness.......186 1. Adjusting the White Level of the Document Darkness..........................................186 2. Adjusting the Reading Darkness......................187 (5) Adjusting of Printer Unit's Printing Speed.........188 1. Pre-stop Speed Adjustment...............................188 2. JOG Speed Adjustment.....................................188 3. Adjustment of Printing Speeds 1-3...................189 4. To Initialize Speed Settings..............................189 (6) Adjusting the End-Mark Sensor1 PCB Unit VR..190 (7) Adjusting the End-Mark Sensor2 PCB Unit VR..190
158
chap.4
z Scanner Section
zScanner Section
(1) Attaching the Rear Wire
Fix at 13mm
w
Place on pulley
q
Ball end Wrap 6 times Wrap 4 times
Place on pulley e
r Fix with nut y

Place on pulley
u
Place on corner guide
t i
Place on pulley Place on spring

24S040
NOTE : For removal of the rear wire
\See page 130
Adjustment procedure 1) Insert the ball end of the wire into the groove opening on the pulley. Wrap the wire 6 times in the rear, and 4 times on the operation side. 2) Place the wire on the screw side onto the pulley. 3) Place the wire on the rear pulley of Slider B. 4) Pass the screw through the bracket opening, and fix it in place with 2 nuts. (There should be a 13mm gap between the screw tip and the bracket.) 5) Place the wire on the hook side on the pulley. 6) Place the wire on the pulley in front of Slider B. 7) Place the wire on the corner guide. 8) Place the spring on the hook. 159
chap.4
z Scanner Section
(2) Attaching the Front Wire
Place on pulley Wrap 4 times Wrap 6 times
Ball end
Place on pulley
y e
r
Fix with nut
i
Place on spring Place on pulley
u
Place on corner guide
Place on pulley
Fix at 13mm
24S041
NOTE : For removal of the front wire
\See page 130
Adjustment procedure 1) Insert the ball end of the wire into the groove opening on the pulley. Wrap the wire 4 times in the rear, and 6 times on the operation side. 2) Place the wire on the screw side onto the pulley. 3) Place the wire on the front pulley of Slider B. 4) Pass the screw through the bracket opening, and fix it in place with 2 nuts. (There should be a 13mm gap between the screw tip and the bracket.) 5) Place the wire on the hook side on the pulley. 6) Place the wire on the pulley in rear of Slider B. 7) Place the wire on the corner guide. 8) Place the spring on the hook.
160
chap.4
xMastermaking / Master Feed / Ejection Section

Mastermaking / Master Feed Section
(1) Adjusting the Timing Belt Tension
Adjust the tension as shown in the figure. 1) Apply a force of about 0.6kg in the direction of the arrow to tension the belt, then tighten the set screw to secure the tension. 2) Apply a force of about 0.5kg in the direction of the arrow to tension the belt, then tighten the set screw to secure the tension.
q Tension assy w Clutch e Angle r Timing belt t Timing belt
1 1 1 1 1
0.6kg
w q
0.5kg
161
chap.4

(1) Attaching the Spring
rSpring T (B)(3) L220mm E F A IMPORTANT : Set the hook on the spring B C eSpring T (B)(3) L220mm D A B C D E F : Rubber roller : Driving roller : Inverted roller : Driving roller : Inverted roller : Inverted roller
and crush it to prevent removing.
qSpring T (3) L90mm wSpring T (3) L104.9mm
1) Attaching the spring between A and B.

B A qSpring T (3) L90mm
2) Attaching the spring between B and C.
B wSpring T (3) L104.9mm
3) Attaching the spring between C, D and E.

E
C eSpring T (B)(3) L220mm
4) Attaching the spring between D, E and F.

F
D rSpring T (B)(3) L220mm
162
chap.4

NOTE : For removal of the master ejection box.
\See page 136 Adjustment procedure 1) Loosen the motor's screws. 2) Use the motor's screws to adjust the belt's tension with a force of 0.75kg applied to the tension shaft, as shown in the figure at right.
0.75kg
After adjustment
Function testing of roll-up motor
1) Access HELP mode H-18. HELP mode H-18 \ see p.252
For basic HELP mode procedures \See page 231 2) Press and hold down the "down" PRINTING SPEED ADJUSTMENT key. For as long as this key is held down, the roll-up motor will rotate in the reverse direction (counterclockwise), causing the rollers inside the master ejection box to rotate. 3) The motor will stop when the "down" PRINTING SPEED ADJUSTMENT key is released. 4) Press the STOP key. The HELP mode menu will reappear.
\ To exit the HELP mode: Turn the power switch to OFF. \ To select another HELP mode: Enter the desired HELP mode number using the numeric keys.
163
chap.4 x Mastermaking / Master Feed / Ejection Section
Master Clamp Opening/Closing Section

NOTE : For removal of master clamp opening / closing unit. Tension Screws
\See page 138 Adjustment procedure 1) Loosen the tension set screw. 2) Use the set screw to adjust the belt's tension to about 1kg.
1kg
After Adjustment
IMPORTANT : Be sure to adjust the A/B/C mode
23S0079
after installation to the printer.
(2) Positioning the Master Clamp Opening / Closing Levers

NOTE : For removal of master clamp opening / closing unit.
Position hole
\See page 138

Master feed master clamp opening/closing lever Positioning hole
23S0081
1. Paper feed master clamp opening/closing lever When tensioning the timing belt, ensure that the sub frame is positioned so that the upper surface of the master clamp opening/closing lever is aligned (to within 0.5mm) with the rim of the positioning hole.
Paper feed side Sub-frame
Positioning hole Aligned (to within 0.5mm) Master feed master clamp opening/closing lever
23S0081
2. Paper ejection master clamp opening/closing lever When tensioning the timing belt, ensure that the master clamp opening/closing lever is co-centered with the sub-frame's positioning holes. After Adjustment
IMPORTANT : Be sure to adjust the A/B/C mode
Paper ejection side Positioning hole Main frame R
after installation to the printer. 164

23S0082
chap.4
(3) Adjusting the A / B / C Mode

NOTE : For description of operation.
\See page 76 Adjustment procedure 1) Remove the drum from the machine body. 2) Access HELP mode H-20. HELP mode H-20 \ see p.254 For basic HELP mode procedures. \See page 231
1. Adjustment for B mode
When drum is removed from main body (A mode)
3) Press and hold down the "up" PRINTING SPEED ADJUSTMENT key, until the master clamp open/close lever moves into the "more open than B mode (toward C mode) position" (see right). 4) Turn the power off, then on again. The master clamp switch lever will move into the B mode position and stop there. 5) Turn off the power, and install the drum to the machine body.
More open than B mode (toward C mode) position C mode B mode
uShift
6) Open the master ejection box. Then press the JOG switch (drum rotator switch) to move the master clamp to a position in front of the open/close lever, and stop it there.
yStop in front of lever
WARNING
Do not touch the drum or rolls when operating the JOG switch. Do not put your hands or fingers inside the machine during operation. They could be caught up or crushed in the machinery, resulting in injury.
7) Move the master clamp, paying attention to the clearance at the same time.
165
chap.4
Standard value
Check that the clearance between the master clamp lever and master clamp open/close lever is within the range given below.
Item Clearance between master clamp lever and master clamp open/close lever Standard value 1.0 - 1.5mm
1.0~1.5mm Master clamp lever Master clamp open/close lever
If the clearance it outside the standard range: 1) Turn the fixing screw indicated to move the B mode shade plate and thereby adjust the clearance.
A / C mode sensor (PS3) B mode shade plate
B mode sensor (PS4) Fixing screw
Open
Close
After adjustment Follow the procedure below to return to the previous state. 1) Remove the drum. 2) Access HELP mode H-20. HELP mode H-20 \ see p.254 For basic HELP mode procedures. \See page 231 A mode
3) Press and hold down the "up" PRINTING SPEED ADJUSTMENT key, until the master clamp open/close lever moves into the A mode position (see right). 4) Turn off the power, and install the drum to the machine body.
166
chap.4
2. Adjustment for A and C modes

Before adjustment
IMPORTANT : A and C mode adjustment must be
carried out AFTER B mode adjustment has been completed. Adjustment procedure 1) Remove the drum from the machine body. 2) Access HELP mode H-20. HELP mode H-20 \ see p.254 For basic HELP mode procedures. \See page 231
When drum is removed from main body (A mode)
3) Press and hold down the "up" PRINTING SPEED ADJUSTMENT key, until the master clamp open/close lever moves into the "more open than B mode (toward C mode) position" (see right). 4) Turn the power off, then on again. The master clamp open/close lever will move into the B mode position and stop there. 5) Turn off the power, and install the drum to the machine body. 6) Access HELP mode H-09. HELP mode H-09 \ see p.243 7) Press the PRINT key to move the drum to the master detachment position, and stop it there. 8) Use HELP20 to move the master clamp open/ close lever to the C mode position.
More open than B mode (toward C mode) position C mode B mode
Stopping drum in master detachment position
IMPORTANT : Do not move the master clamp
open/close lever towards the A mode position from the B mode position. Doing so will break the master clamp. 9) Open the scanner unit.
0.5-1.0mm
167
chap.4
Standard value
Check that the clearance between the master ejection box's rubber roller and the master clamp plate is within the range given below.
Item Clearance between master ejection box's rubber roller and master clamp plate Standard value 0.5 - 1.0mm
0.5~1.0mm
Rubber roller Master clamp plate
If the clearance is outside the standard range 1) Turn the fixing screw indicated to move the A/C mode shade plate and thereby adjust the clearance. This operation adjusts the clearance for both the A and C modes.
IMPORTANT :
A / C mode shade plate A mode sensor (PS3)
Do not press the master clamp against the rubber roller.
Fixing screw B mode sensor (PS4)
Open Close
After adjustment Follow the procedure below to return to the previous state. 1) Turn the power off, then on again. The master clamp open/close lever will move into the B mode position and stop there. 2) Remove the drum. 3) Access HELP mode H-20. HELP mode H-20 \ see p.254 4) Press and hold down the "up" PRINTING SPEED ADJUSTMENT key, until the master clamp open/close lever moves into the A mode position (see right). 5) Turn off the power, and install the drum to the machine body.
A mode
168
chap.4
cPaper Feed Section

(1) Adjusting the Paper Separator Unit Clearance
NOTE : For description of operation .
\See page 82
For removal of paper separator unit .
\See page 141 Adjustment procedure When the paper separator unit is installed, use the adjustment bolt to adjust the unit so that it moves in direction q without sticking, and moves smoothly in direction w. Tighten the bolt's nut to fix the unit in the adjusted position.
q
Paper separator unit
w Nut
23S0106
169
chap.4
(2) Adjusting the Paper Separation Pressure

\See page 82
For removal .
\See page 141 Adjustment procedure 1) Apply a spring balance as shown at right, then turn the separation pressure adjust screw so that the balance reads 140-150g. Turning the screw clockwise increases the pressure. Turning the screw counterclockwise decreases the pressure.
Spring balance 140-150g
Paper separation pressure adjust screw
43SH0403
(3) Adjusting the Paper Feed Tray Upper Limit Sensor

\See page 91 Adjustment procedure 1) Insert a 1mm thick strip of material between the paper feed roller and the paper feed inlet. 2) Loosen the 2 screws indicated, then adjust the sensor's position so that the bottom surface of the paper feed shaft lever is at the center of the sensor. 3) After adjustment, tighten the screws.
Position bottom surface at sensor's center
Screw Paper feed tray upper limit sensor Screw 1mm thick strip
23S0225
170
chap.4
(4) Adjusting the Paper Feed Tray Lower Limit Switch

\See page 92
For removal.
\See page 140
Adjustment method 1) Access HELP mode H-02. HELP mode H-02 \ see p.236 For the basic procedure for accessing HELP modes: \See page 231 2) Press and hold down the "down" PRINTING SPEED ADJUSTMENT key until the paper feed tray is at its lowermost position. The elevator motor will run (i.e. the paper feed tray will descend) for as long as the key is held down. 3) Check that the dimension indicated in the figure at right conforms to the value shown below.
Standard value
Item Paper feed tray clearance in lower limit position Standard value 14mm
14mm
If the feed length is not the standard value 1) Loosen the screws, then adjust the lower limit switch to a position that yields the standard clearance value. cMoving the sensor in the direction shifts the lowermost position downward. dMoving the sensor in the direction shifts the lowermost position upward. 2) After adjustment, tighten the screws.
23S0109
Connector
Screws Elevator lower limit switch
171
chap.4
(5) Adjusting the G Roll Escape Amount / Timing

Adjustment procedure 1) Turn the main motor shaft by hand, to move the escape cam. Stop turning when the bottom of the escape cam reaches the bearing side of the escape lever, so that the cam stops in that position. 2) Loosen the eccentric shaft fixing screw. Then turn the eccentric shaft to adjust the escape amount.
NOTE : For description of operation. Peek through the inspection hole. Bearing Escape lever
20.2mm Eccentric shaft Screw Escape cam

23S0228
\See page 86 Standard value
Item Clearance between escape lever's bearing and escape cam's bolt
Standard value 20.2mm
172
chap.4
(6) Adjusting the Printing margin

\See page 89
Adjustment procedure 1) To adjust the Printing margin, position the screws of the sensor angle's rectangular holes in the center of those holes, and fix the screws in that position.
Screw Center sensor
2) Access HELP mode H-30. HELP mode H-30 \ see p.261

Screw
3) Choose test pattern 1 then make master and print.

23S0229
4) Adjust the center sensor position to make the Printing margin to 7 1mm.
7 1mm.
173
chap.4
v Drum Drive Unit
vDrum Driving Section

(1) Adjusting the Stop Position
Before adjustment
IMPORTANT :
Adjusting the the drum position must be performed AFTER printing speed adjustment is complete. \See page 188
Adjustment procedure 1) Press and hold down the JOG switch (DRUM ROTATOR switch). Release the switch when a "beep" tone sounds and the drum stops.
WARNING
Do not touch the drum or rolls when operating the JOG switch. Do not put your hands or fingers inside the machine during operation. They could be caught up or crushed in the machinery, resulting in injury.
Stopper
Groove
\See page 96
Standard position The stop position is correctly adjusted when the groove in the drum flange is aligned with the stopper. If the drum is not adjusted to the standard stop position: Adjust the position of the drum home position / JAM detection sensor so that the stopper fits smoothly into the groove when the drum is pulled out. [ Moving the sensor in this direction makes stopping occur later. \ Moving the sensor in this direction makes stopping occur earlier.
JOG switch (DRUM ROTATOR switch)
Screws
Drum stop detection edge
23S0232
174
chap.4
v Drum Drive Unit
(2) Adjusting the Master Attachment/Detachment Position

NOTE : For description of operation. Master attachment position
\See page 97
1. Master detachment position The correct position for stopping of the drum (position for master detachment) is when the center axis of the master clamp open/close arm and the center axis of the master clamp open/ close lever are aligned in a straight line. Adjust so that the offset of the alignment of these two center axes is 1mm (gauge this value visually).
Open/close lever
Open/close arm
+ -1mm
Adjustment procedure 1) Access HELP mode H-09, the drum position check mode. HELP mode H-09 \ see p.243
23S0234
Master attachment/det achment position edge

23S0235
Item Offset in alignment of center axes of master clamp open/close arm and master clamp open/close lever
Standard value 1mm
Open/close arm
+ -1mm
4) Loosen the screws indicated, turn the master attachment/detachment sensor shade plate a little in the direction of the arrows, and provisionally tighten the screws. 5) Repeat step 2), and check the center axis alignment offset. 6) If necessary, repeat steps 2) through 5) until the center axis alignment offset is within 1mm. 7) Properly tighten the screws, and check 6) again. 2. Master attachment position Perform adjustment of master attachment position at the same time as that of master detachment position. Adjust both positions to an accuracy of 1mm . 175
Open/close lever
23S0236
Screws
Advances the stop position Sets back the stop position

23S0233
chap.4
b Press Section
bPress Section
(1) Adjusting the of Press Roll (P Roll) Sensor
\See page 103
Adjustment procedure 1) Loosen the screw indicated. Then move the sensor bracket up/down to adjust the press roll so that when it is pushed down to the lowest position by the cam, the distance between the bottom of its sensor and the end of the bracket is about 1mm.
Bracket About 1mm P roll sensor Bracket Screws

23S0238
176
chap.4
b Press Section
(2) Adjusting the Printing Area (Press OFF Timing)

\See page 101

Rear end of opening
20mm
Adjustment procedure 1) Make a mark on the end surface of the drum flange, in a position 20mm forward (in the direction of the forward end) from the rear end of the drum's opening(hole section). 2) With the press roll activated, turn the main motor shaft by hand, and stop turning when the press roll starts to descend (move in the direction of the arrow).
Make mark here
Drum unit
Press roll
Main motor shaft
23S0237
Standard value Open the front cover, and check whether the center of the press roll is aligned with the mark made in step 1).
Mark
Item Alignment of mark on flange end and center of press roll Standard value 2mm
Drum flange Press roll

23S0246
If the alignment is not correct: 1) Loosen the 2 hex bolts indicated. 2) Loosen the adjustment collar (eccentric) fixing screw. 3) Turn the adjustment collar (eccentric) to move the flange and adjust the alignment. Moving the flange upward makes turning off of the press occur later \ thereby making the printing range longer Moving the flange downward makes turning off of the press occur earlier \ thereby making the printing range shorter
Adjust collar
Hex bolts
Screw
23S0239
177
chap.4
nPaper Ejection Section

(1) Adjusting the Paper Stripper Finger Clearance
\See page 105
Adjustment procedure 1) With the pinch lever raised up, turn the main motor shaft. Stop turning when the lever's roller is positioned at the bottom of the paper stripper finger cam.
Standard value Check that the clearance between the drum surface and the paper stripper finger conforms to the value shown below.
Item Clearance between drum surface and tip of paper stripper finger Standard value 0.5mm~1mm
Drum surface
0.5mm~1mm

23S0247
If the clearance is not the standard value: 1) Loosen the screw indicated and use the stopper to adjust the clearance to the standard value. Then retighten the screws.
Pinch lever
After adjustment:
IMPORTANT :
Lever Screw
After adjustment, press the JOG switch (DRUM ROTATOR switch) to return the drum to its home position.
Roller
WARNING
Do not touch the drum or rolls when operating the JOG switch. Do not put your hands or fingers inside the machine during operation. They could be caught up or crushed in the machinery, resulting in injury. 178
Main motor shaft
23S0240
chap.4
m Drum Section
mDrum Section
(1) Adjusting the Ink Amount
Adjusting the ink adjusting knob
NOTE : For removal. Ink adjusting knob on the operation side
\See page 150
Ink adjusting knob on the rear side
Adjustment procedure 1) When printed too dark or too light on the operation side: Too dark: switch in the (-) direction (3 settings) Too light: switch in the (+) direction (3 settings)
Ink adjusting knob on the operation side (standard position) Too dark
Too light
Do not loosen set screw
2) When printed too dark or too light on the rear side: Too dark: switch in the (-) direction (3 settings) Too light: switch in the (+) direction (3 settings) 3) When printed too dark or too light on the entire surface: Adjust the above 1) and 2) at the same time.
IMPORTANT : There are 7 settings, standard and
Ink adjusting knob on the rear side (standard position) Too dark
Too light
Do not loosen set screw
3 settings to adjust the printing darkness. Print more than ten sheets every time the printing darkness is switched by one setting until the most desirable printing darkness is obtained. Repeat the above procedures until the most desirable printing darkness is obtained. 179
chap.4
m Drum Section
(2) Adjusting the Squeegee Gap

NOTE : For removal. Squeegee
Ink roller
\See page 150
Adjustment procedure The gap between the squeegee and the ink roller is adjusted as shown in the figure when the ink amount is based on the standards. If the ink amount does not meet the standards, adjust it as follows:Standard value
Item Clearance between squeegee and ink roller Standard value 0.030.005mm
Gap
0.030.005mm
Squeegee
Ink roller
If the clearance is not the standard value 1) 2 set screws 1 are used in one place. Remove one set screw 1 and loosen the other one. Perform the same operation for both sides. Be careful not to lose the removed set screws. 2) Loosen set screws 2 on both sides. 3) Adjust the gap with the adjusting screws on both sides so that the space on both sides meets the standards.
Operation side
Set screw 2 Ink adjusting knob
Adjusting screw Set screw 1
Rear side After adjustment 1) Tighten set screw 2. 2) Tighten set screw 1. 3) Check the gap again after the ink amount adjusting knob is moved several times in the direction + or -. 4) If the gap is proper, attach set screw 1 and tighten it to fix.
Adjusting screw Set screw 1
Set screw 2 Ink adjusting knob
180
chap.4
m Drum Section
(3) Adjusting the Master Clamp

NOTE : For removal. Set screws Set screws (for adjustment) shaft
\See page 150
When the master clamp parallelism is not proper, the master creases. When the master clamp is not flat, the master is easily removed and creases. * Adjust the master clamp with the set screw on the operation side.
Operation side Lever shaft Clamp plate
1. Adjusting the clamp parallelism

Adjustment procedure 1) Loosen the set screws on the clamp plate and shaft to adjust the parallelism.
IMPORTANT : Loosen the set screw on the Clamp plate
Master 20mm 20mm
Master 20mm
Master
operation side to adjust. But do not loosen the set screw on the lever shaft.
Clamp plate
2. Adjusting the clamp flatness

Adjustment procedure 1) Cut the master, leaving 20mm wide piece at three places, both sides and center. Have the clamp plate grip the three sections. 2) When the resistance for pulling the master out is not stable, rotate the clamp screw to adjust.
Rubber magnet
Torsion
(4) Adjusting the Master Clamp Section

Adjustment procedure 1) Adjust with HELP mode 29 so that the clamp amount of the master (A section in the figure) is 0~3mm with the master attached. HELP mode H-29 \ see p.262 2) After HELP 29 adjustment, press the master set switch and perform master set movement once. (Be sure to remove all paper scraps.) Then perform Mastermaking, and check the gripper margin.
Master clamp
181
chap.4
m Drum Section
(5) Adjusting the Drum Rail Gap

1. Operation side
Adjustment procedure 1) Attach the drum to the main body. 2) Loosen the set screw on the rail to adjust so that the gap between the rail (both sides) and the roller on the operation side is about 0.3mm. 3) Tighten the set screw to fix the rail.
Screw
Rail unit left
Rail unit right
Screw
0.3mm Guide rail left
0.3mm Guide rail right

23S0244
2. Rear side
Adjustment procedure 1) Open the rear cover on the main body. 2) Loosen the screws on the rail to adjust so that the gap between the roller on the rear side and the rail right / left unit is about 0.3mm. 3) Tighten the screw to fix the rail.
Screw
Rail unit left
Rail unit right
Screw
0.3mm Guide rail left
0.3mm Guide rail right

23S0245
182
chap.4
, Electrical system
,Electrical system
(1) Adjusting Reduction / Enlargement
1. Adjusting the Longitudinal R / E on the Mastermaking Side
Adjustment procedure 1) Set the HELP mode. Turn the power on with the PRINTING SPEED ADJUSTMENT keys and held down. 2) Set to H-30 (Test pattern printing mode). Press the PRINT key with the 3 and 0 keys held HELP mode H-30 \ see p.263 down. 3) Set the master darkness to NORMAL , perform Mastermaking and print paper*. No need to place the document. *DP-M420 : print B4 paper *DP-M400/410 : print A4 paper Standard values: Check that A section of the printed test pattern is 200 0.5mm. If the clearance is not the standard value: 1) If not, adjust with the H-22. HELP mode H-22 \ see p.255
Test pattern 2
2. Adjusting the Longitudinal R / E on the Reading Side

Before adjustment
IMPORTANT : Adjust the longitudinal R / E on the
reading side after the longitudinal R / E on the Mastermaking side. Adjustment procedure 1) Prepare a basic document as shown in the figure. Draw a line (main-scanning direction) at the position 30mm from the top end of the paper* and at the position 200mm from the above line. *DP-M420 : print B4 paper *DP-M400/410 : print A4 paper 2) Place the document on the document table to perform mastermaking and printing. Standard values: Compare the size of A section of the printed image with that of the basic document. Check that the difference of the size is 2.0 mm . If the clearance is not the standard value: 1) If not, adjust with the H-24. HELP mode H-24 \ see p.257 HELP mode H-24 ADF \ see p.257 183
23S0312
Center of the paper
chap.4
, Electrical system
(2) Reading Start Position

1. Adjusting the Top End Reading Start Position
Adjustment procedure 1) Mark with 1mm interval up to 5mm from the top end of the paper to prepare a test document. 2) Perform Mastermaking and printing to the same size and to two printouts using 2-up function. 3) Adjust with the HELP35 so that the image of the second printout is printed with 3mm margin left. HELP mode H-35 \ see p.267 HELP mode H-35 ADF \ see p.267
23S0313
Document
Print
2 printouts Mark with 1mm interval from the top end of the document 2 - 3mm
2. Adjusting the Lateral (Operation Side) Reading Start Position

Adjustment procedure 1) Make a standard document (as shown in the figure) from a sheet of paper*. Draw a 100mm line at the position 30mm from the right end and from the top end of the paper*. *DP-M420 : print B4 paper *DP-M400/410 : print A4 paper
Standard document
100mm 30mm
23S0314
2) Compare the printed image with the basic document. Check the difference between the straight lines in the main-scanning direction.
Printing paper
Print ejection direction
Document
3) Adjust with the HELP H-36 so that L1 - L2 3mm . HELP mode H-36 \ see p.268 HELP mode H-36 ADF \ see p.268
Document basic line Mark this corner with each other
Adjusting direction L1<L2 : Backward L1<L2 : Toward you
Basic line of the printed sample
L2
L1
23S0315
184
chap.4
, Electrical system
(3) Adjusting the Mastermaking Start Position

1. When the Scanner Is in Use Before adjustment
IMPORTANT :
Adjust the Mastermaking start position with the scanner in use after the printing position sensor \See page 173 , master attachment / detachment position \See page 175 and top end reading start position \See page 184 are adjusted. Adjustment procedure 1) Set the printing position (top and bottom direction) to the standard. 2) Draw a line at the position 30mm from the top end of the document and prepare a basic document as shown in the figure. 3) Compare the processed image with the basic document. Check the difference of the lines inthe sub-scanning direction. 4) Adjust with the HELP mode, H-37 so that L1 - L2 3mm. HELP mode H-37 \ see p.269
Printing paper
Standard document
Draw a line at the position 30mm from the top end of the document
23S0316
Print ejection direction
HELP mode H-37 ADF \ see p.269
Adjusting direction L1<L2 : Upward L1>L2 : Downward
Document
Mark this corner with each other
Basic line of the printed sample
Document basic line
L1 L2
2. When in Online Before adjustment

IMPORTANT :
23S0317
Adjust the Mastermaking start position when in online after the printing position sensor \See page 173 and master attachment / detachment position \See page 175 are adjusted. Adjustment procedure 1) Perform mastermaking and printing of the online test pattern. Adjust with the HELP mode, H-16 so that the basic line is positioned 3mm from the top end of the paper. HELP mode H-16 \ see p.250 185
chap.4
, Electrical system
(4) Adjusting the Document Reading Darkness

\See page 55
1. Adjusting the White Level of the Document Darkness The basic darkness of the document (lightness of the white section of the document = white level) is detected by reading the document darkness. If the white level is not proper, printed surface gets dirty or the light section of the document is not processed for Mastermaking.
In the normal state
When the white level is too high:

the section is printed dirty
Adjusting the White Level 1) Call the HELP mode. Take the following procedures for adjustment:1. Text mode: H-33 HELP mode H-33 \ see p.266 HELP mode H-33 ADF \ see p.266 2. Photograph mode: H-26 HELP mode H-26 \ see p.259 HELP mode H-26 ADF \ see p.259 2) Input the correction value on the keypad, "0" or "1". When the processed document gets dirty : "0 1 1 1" The white level is corrected down. HELP mode H-33/26 display
When the white level is too low:
the section is not processed for Mastermaking
A: 0
Sign flag
B:1 C:1 D:1

Correction amount display
When the thin section of the document is not processed for Mastermaking : "1 1 1 1" The white level is corrected up. 3) Press the = value. key to memorize the correction
A: 1
Sign flag
B:1 C:1 D:1

4) Perform Mastermaking and printing to check the darkness.
186
chap.4
, Electrical system
2. Adjusting the Reading Darkness Adjustment procedure Adjust the document reading darkness in Mastermaking as follows: 1) Help mode Text mode : H-50 HELP mode H-50 \ see p.275 HELP mode H-50 ADF \ see p.275 Photograph mode : H-23 HELP mode H-23 \ see p.256 HELP mode H-23 ADF \ see p.256 2) Input the correction value on the keypad, "1" or "0" (Sign flag / Collection amount display). 3) Press the = key to memorize the correction HELP mode H-50/23 display
A:1 B:1 C:1 D:1

Sign flag Correction amount display
value 4) Perform Mastermaking and printing to check the darkness. When adjusted with the H-23 by one stage, the standard position on the control panel changes to 3/8 stage as follows : -
Adjusting the Mastermaking darkness on the control panel dark H-50, H-23: [0001] dark Normal light light light
23S0318
dark
H-50, H-23: [0001]
Normal
187
chap.4
, Electrical system
(5) Adjusting of Printer Unit's Printing Speed

1. Pre-stop Speed Adjustment Adjustment procedure 1) Access HELP mode H-01. HELP mode H-01 \ see p.234 For basic HELP mode procedures. \See page 231 HELP mode H-01 display
2) Press the DOCUMENT MODE SWITCH key repeatedly, to select PHOTOGRAPH. 3) Check the speed value displayed. The value should be 4-6rpm. If the value is not correct: Press the "PRINTING POSITION ADJUSTMENT "keys to adjustment the speed. 4) Press the STOP key. The new (adjusted) value will be memorized, and the HELP mode menu will reappear.
111
r pm
Pre-stop speed
2. JOG Speed Adjustment Adjustment procedure 1) Access HELP mode H-01.
HELP mode H-01 \ see p.234 \See page 231 HELP mode H-01 display
For basic HELP mode procedures.
2) Press the DOCUMENT MODE SWITCH key repeatedly, to select TEXT/PHOTOGRAPH. 3) Check the speed value displayed. The value should be 16rpm. If the value is not correct: Press the "PRINTING POSITION ADJUSTMENT "keys to adjustment the speed. 4) Press the STOP key. The new (adjusted) value will be memorized, and the HELP mode menu will reappear.
111
r pm
JOG speed
188
chap.4
, Electrical system
3. Adjustment of Printing Speeds 3 Adjustment procedure 1) Access HELP mode H-01. HELP mode H-01 \ see p.234 For basic HELP mode procedures. \See page 231
2) Press the DOCUMENT MODE SWITCH key repeatedly, to select TEXT. 3) Use the "down" PRINTING SPEED ADJUSTMENT key to select SPEED 1. 4) Check the speed value displayed. The value should be 63-65rpm .
HELP mode H-01 display
111
r pm
Printing speed
If the value is not correct: Use the FUNCTION SWITCH and SELECT keys to adjust the displayed value to the correct value. 5) If desired, set the other printing speeds (2,3) by repeating steps 2) through 4) , and selecting the desired speed in step 2). 6) (If setting the other speeds:) Check the speed values displayed. The values should be:
Speed 2 ... 87-89rpm Speed 3 ... 140-142rpm
If the values are not correct: Use the FUNCTION SWITCH and SELECT keys to adjust the displayed values to the correct values. 7) Press the STOP key. The new (adjusted) value will be memorized, and the HELP mode menu will reappear. 4. To Initialize Speed Settings: HELP mode H-01 \ see p.234 1) Access HELP mode H-01. For basic HELP mode procedures. \See page 231
HELP mode H-01 display
HELP
SELECT
01
2) Press the [=] and CLEAR C key. The settings will be initialized. 3) Press the STOP key. The HELP mode menu will reappear.
NOTE : After initialization, new speed values must be set.
Mode number flashes
189
(6) Adjusting the End-Mark Sensor1 PCB Unit VR

1) Rotate the VR1 on the end mark sensor1 PCB Unit in the counterclockwise direction (CCW) as far as it stops. 2) Call HELP mode, H-13 to read the value. (About 63 when master is not set) 3) Rotate the VR1 on the end mark sensor1 PCB Unit to adjust so that the value of HELP mode H-13 is value from 60-63 when master is not set, and the value is from 40-55 when end mark(black master) is set,and the value is from 0-10 when white master is set.(Reference to page.68.)
CN 1
VR 1
End-Mark Sensor1 PCB Unit
(7) Adjusting the End-Mark Sensor2 PCB Unit VR

1) Rotate the VR1 on the end mark sensor2 PCB Unit in the counterclockwise direction (CCW) as far as it stops. 2) Call HELP mode, H-13 to read the value. 3) Rotate the VR1 on the end mark sensor2 PCB Unit to adjust so that the value of HELP mode H-13 is value from 0-10 when white mark is under , or the value from 50-63 when black mark is under.
CN 1 VR 1
End-Mark Sensor2 PCB Unit
190
Chapter 5
Installation
z DUPRINTER Installation Instructions.....................192 1. Before Installation..................................................192 2. Installation Instructions.........................................192 (1) Unpacking Checks............................................192 (2) Assembly ...........................................................193 (3) Power Switch ON ..............................................195 (4) Setting the Master Roll ....................................196 (5) Preparation of Drum .........................................198 (6) Setting the Ink Pack .........................................200 (7) Supplying Ink and Adjusting Ink Amount ......201 (8) If Option are Installed ......................................201
191
chap.5
z DUPRINTER Installation Instructions
zDUPRINTER Installation Instructions

1. Before Installation :
Safety precautions
The precautions below are vital for safety and must be taken.
2. Installation Instructions
(1) Unpacking Checks
q Packages for 1 complete DUPRINTER: DP-M400 1 printer unit package (product name: DP-M400 ) DP-M410 1 printer unit package (product name: DP-M410 )
WARNING
Use only the power cord that is provided among the accessories. Insert the power cord plug firmly into the socket, so that proper electrical contact is effected. aUse of any other power cord could result in imperfect grounding. If grounding is imperfect and electrical leakage occurs, fire or electric shock could result. Do not use a source voltage other than that specified. Do not connect multiple loads to a single outlet. Fire or electrical shock can result. Do not place the machine in an unstable position, such as on an unsteady support or sloping area. If the machine drops or falls over, a person could get injured. Do not place the machine in a humid or dusty area. Fire or electrical shock can result. If the optional printer stand is used: When the DUPRINTER is installed to the printer stand, lock the casters. Otherwise the equipment could move or fall over, causing injury. To move the equipment, push on the printer stand. Pushing on the DUPRINTER is dangerous and could make the equipment fall over.
DP-M420 1 printer unit package (product name: DP-M420 ) Check that the above 3 packages are present. w Unpack the package.
IMPORTANT : Carry out unpacking in a place
that is safe for the work.
e Contents checks for each package. Check that the packages have the contents listed below. Printer unit package
Item Printer unit proper Installation manual Operation Manual Warranty Master ejection core Power cord Print Tray Master holder Quantity 1 1 1 1 1 1 1 2
If the optional printer stand is used, install it now by referring to the instructions on the following page.
\See page 194
192
chap.5
(2) Assembly
q Pull out the printer unit's 4 handles. Then lift the printer unit up by its handles and place it in the installation location.
r Attach the print tray, by fitting it into the slots in the DUPRINTER's top section.
Slot in top section
CAUTION
To lift the printer unit, hold it by its handles ONLY. Lifting of the printer unit should be performed by 2 or more persons, not by 1 person alone. Place the printer unit on a flat, level surface.
Print tray
23S0110
Pull out
Handles Pull out Handles
w Push the 4 handles back in. e Remove all the remaining fixing tape.
193
chap.5
Using the optional printer stand q Unpacking Check. 2Check that the printer stand unit package is present. w Unpack the printer stand unit package.
IMPORTANT : Carry out unpacking and assmbly
!0 Remove all the remaining fixing tape. !1 Attach the print tray, by fitting it into the slots in the DUPRINTER's bottom section.
in a place that is safe for the work. e Check that the package has the contents listed below.
Item Quantity 1
Slot in bottom section
Printer stand unit
* Check the unit's casters for abnormality. r Assemble the printer stand unit. t Place the printer stand unit on a flat, level surface. y Lock the printer stand unit's casters. u Pull out the printer unit's 4 handles.
Print tray
23S0111
CAUTION
To lift the printer unit, hold it by its handles ONLY. Lifting of the printer unit should be performed by 2 or more persons, not by 1 person alone.
i Lift up the printer unit by its handles, and mount it onto the printer stand unit so that its rubber feet mate into the recesses in the printer stand.
Handle
Handle
Pull out
Runner feet
Recesses Recesses
23S0027
o Push the 4 handles back in.
194
chap.5
(3) Power Switch ON

q Make sure that the power switch is OFF. w Insert the plug on one end of the power cord (one of the accessories) into the DUPRINTER's power inlet.
230V AC model
WARNING
Connect the DUPRINTER to an outlet providing a 50Hz, 8A power supply of at least 230V. Insert the power cord's plug correctly into the outlet, so that electrical connection is effected completely. Position the DUPRINTER close to the power outlet. Do not connect multiple loads to a single outlet. If use of an extension cord is necessary: Extension cord should be of at least 250V, 8A specification, conform to standard, and not exceed 5m in length. The power cord should never be stepped on, or crushed between objects. If it is, accidents
Power inlet
Power cord
23S0010
could result.
e Insert the plug on the other end of the power cord into the power outlet.
120V AC model
r Turn the power switch ON. t Check the liquid crystal display on the operation panel. The display should function normally.
WARNING
Connect the DUPRINTER to an outlet providing a 60Hz, 15A power supply of at least 120V. Insert the power cord's plug correctly into the outlet, so that electrical connection is effected completely. Position the DUPRINTER close to the power outlet. Do not connect multiple loads to a single outlet. If use of an extension cord is necessary: Extension cord should be of at least 130V, 15A specification, conform to standard, and not exceed 5m in length. The power cord should never be stepped on, or crushed between objects. If it is, accidents could result.
195
chap.5
(4) Setting the Master Roll
q Press the scanner switch and open the scanner.

Scanner unit
Peel off the seal.
Scanner switch
SEAL
Take out a new master roll from the bag. Insert the master holders deeply into both ends of the master roll. (Holders are interchangeable.)
Pull out the master and insert the front head of the master until it contacts the roller.
Master holder
Insert the master roll into the machine so that the ID mark line on the roll is facing the control panel.
IMPORTANT
If the master is not pulled in ,then gently press in as far as possible to set again.
Push the THERMAL HEAD ESCAPE LEVER. The master will be pulled in, and cut auto -matically.If the master does not enter, pull the master back.
THERMAL HEAD ESCAPE LEVER
196
chap.5
IMPORTANT
If the master is wrinkled:push down the thermal head escape lever 2 or 3 times. The cutter operates and stops after the master is cut. Remove the cut piece left inside the machine.
Remove the trimmed piece of the master.
IMPORTANT
When the master stops, make sure that you remove the trimmed piece of the master.
Gently close the document receiving tray.
Scanner unit
197
chap.5
(5) Preparation of Drum

q Press the jog switch (drum rotator switch). Hold down until the drum stops with a beep.
r Grip the upper drum shaft with your other hand, and pull the drum out toward you while slightly lifting the near end of the drum.
CAUTION WARNING
Do not touch the drum or rollers when you operate the jog switch. Do not put hands inside machine while it is operating. Hands could get caught up or crushed.
Upper drum shaft
Hold the drum level and place it on a flat, solid surface. The stainless screen does not return to the original state once it is folded. Be careful to handle the screen.
Jog switch
23S0014
23S0017
w Open the front cover toward you.
t Move the lever with a hand to open and close the master clamp once or twice.
Master clamp
Front cover
23S0018
e Lift up the drum securing lever. While lifting the lever up, pull out the drum handle toward you, pulling it straight out until it stops.
Drum handle Drum securing lever
y Hold the drum level and place the drum guide roller onto the rail in the machine.
Drum Roller
Rail
23S0019
198
chap.5
u Let go of the handle far end of drum, and push the drum in about 10 cm while slightly lifting the near end of the drum.
!1 Close the front cover.
Front cover
i Hold the drum level and push it in gently until it stops. o Lift the drum securing lever toward you while pushing the drum in.
!2 Press the jog switch (drum rotator switch). Continue pushing until the drum stops with a beep.
WARNING
Do NOT touch the drum or rollers when you operate the jog switch. Do NOT put hands inside machine while it is operating. Hands could get caught up or crushed.
Drum securing lever
!0 Push down the securing lever tightly with the drum inside the machine.
Jog switch
Drum securing lever
23S0014
199
chap.5
(6) Setting the Ink Pack

q Open the front cover. Front cover
"U" groove of holder
t Push the ink pack to the set line on the ink pack.
Set line
w Hold the ink pack holder release lever and pull it toward you.
Holder release lever
Set line
y Push the side of the holder in with the palm of your hand.
e Twist open the cap of the new ink pack.
CAUTION
Do not leave an uncapped INK PACK for
a period longer than necessary.

Ink pack
u Close the front cover.
Front cover
r Insert the ink pack so that the groove on the LIP fits into the "U" groove of the holder.
Holder Holder
Ink pack
Ink pack
200
chap.5
(7) Supplying Ink and Adjusting Ink Amount

1. Supplying Ink
q Invoke the HELP mode. While holding down the PRINTING SPEED ADJUSTMENT keys and simultaneously, turn the power on. w Supply ink using HELP04. Enter <0> <4> from the keypad and then press the PRINT key. Drum will begin to rotate while the ink pump starts operation.After completion of supplying ink, drum will stop rotating with continuous beep sounds. In general, it takes approx.30 seconds to supply ink. e Turn the power OFF and then ON again. r Perform Mastermaking and printing of the document.
IMPORTANT : For more information, refer to
e When the whole area of paper is darker or lighter, turn stepwise the Ink Amount Adjustment Knob on both sides in the " 4" or "3" direction respectively (3 steps).
Setscrew Never loosen!
Ink Amount Adjustment Knob on the near side (Standard Position)
Setscrew Never loosen!
Ink Amount Adjustment Knob on the far side (Standard Position)
IMPORTANT : The Ink Amount Adjustment Knob has
"Mastermaking and printing procedure" in the Instruction Manual. The image will be light since ink is not fully spread over the drum surface. It is not a trouble. Continuously print approx.20 sheets. t Once ink is fully spread, check the printed image.If the density varies between the near and far areas of paper, make adjustment according to the "Adjusting Ink Amount".
a total of 7 positions : 3 positions for each of "4" and "3" directions as well as a standard position.When adjusting the image density, you should print the image on dozens of sheets to stabilize the density every time you change it by every step. Repeat the above steps until you get desired print density.
2. Adjusting Ink Amount

q When the near area is darker or lighter, turn stepwise the Ink Amount Adjustment Knob on the near side in the " 4 " or " 3 " direction respectively (3 steps). w When the far area is darker or lighter, turn stepwise the Ink Amount Adjustment Knob on the far side in the " 4 " or " 3 " direction respectively (3 steps).
(8) If Options are Installed

Optional equipment should be installed AFTER the machine itself has been installed and test-run to check that it functions normally. For the procedure for installing optional equipment, see the Installation Procedures supplied with it.
201
MEMO
202
Chapter 6
Maintenance/Check
z Guaranteed Periodical Maintenance.......................204 x Cleaning and Oiling..................................................204 (1) Cleaning ...............................................................204 (2) Oiling ....................................................................204 c Periodical Maintenance............................................205 (1) 6-month Periodical Checking ..............................205 (2) Criteria for Replacing the Primary Parts ........... 205
203
chap.6
z Guaranteed Periodical Maintenance x Cleaning and Oiling
zGuaranteed Periodical Maintenance

The serviceman will visit the user periodically after delivery. The maintenance operation described in the periodical maintenance list is performed and instructs how to follow the operation. When the serviceman is called by telephone, the following maintenance must be performed after clearing the trouble.
1. Cleaning the document. 2. Cleaning the document table glass. 3. Cleaning the thermal head.
xCleaning and Oiling

(1) Cleaning
1.Paper shreds: Clean with a brush or dry cloth. Clean the mirror and reflection plate in the scanner section with a blower brush. 2.Ink: Clean with soap.
Oil or grease after ink or paper shreds are removed.
(2) Oiling
1.Bearing section:
Oil the edge surface and bearing sections with oiler, rotating the lever and roller.
2.Gear section:
Grease the gear section after removing paper shreds on the bottom of gear.
204
chap.6
c Periodical Maintenance
cPeriodical Maintenance
(1) 6-month Periodical Checking
Section to be checked Shading plate Glass Lamp Reflection mirror Thermal head Platen roller Sensor Press roller Drum exterior Paper feeding section Plate making section Roller shaft / bearing Gear Air pump Escape cam Description Cleaning Cleaning Cleaning Cleaning Cleaning Cleaning Cleaning Cleaning Cleaning Checking Checking Oiling Greasing Greasing Greasing Remarks Clean with a soft and clean cloth Clean with a soft and clean cloth Clean with a soft and clean cloth Remove dust with blower brush Clean with a soft and clean cloth (Do not damage the thermal head) Remove paper shreds (Do not damage the platen roller) Remove dust with blower brush Remove paper shreds Remove ink and paper shreds Paper is fed smoothly. Remove paper shreds Paper is fed smoothly. Remove paper shreds Except for the pinch lever bearing section
(2) Criteria for Replacing Primary Parts

No. 1 2 3 4 5 6 7 8 Paper feed roller Paper separator unit Thermal head Drum unit Air pump Tape cutter upper/lower blade Press roller Lamp Item Criterion 300,000 sheets or more 300,000 sheets or more About 20,000 masters or one year Printing 1,000,000 sheets or one year Printing 1,000,000 sheets or one year Cutting 10,000 times or one year 1,000,000 sheets or one year 10,000 masters or one year Up to 10 voids Overhaul Remarks
205
MEMO
206
Chapter 7
Troubleshooting
z Troubleshooting Guide ............................................208 1.Countermeasures for the Defective Operation ...208 (1) LAMP does not light Up....................................209 (2) Optical System Dose Not Move Forward/Backward ....................................210 (3) "E** SERVICE CALL" is displayed .................211 (4) "DRUM NOT SET" is displayed ........................212 (5) "MASTER SET MISS" is displayed ...................212 (6) Malfunction of Master Feeding Clutch .............213 (7) Malfunction of Mastermaking Stepping Motor.213 (8) "MAST. EJECT MISS" is displayed .................214 (9) Malfunction of Roll-up Motor ............................214 (10) "SET PRINT PAPER" is displayed ..................215 (11) "FRONT COVER OPEN" is displayed ............215 (12) "SCANNER OPEN" is displayed .......................216 (13) "ROLL MASTER END" is displayed ...............216 (14) "EXCHANGE INK" is displayed .....................217 (15) "DOCUMENT JAM" is displayed, when power turned on .........218 (16) "PAPER RIGHT JAM" is displayed ................219 (17) "PAPER LEFT JAM" is displayed ...................220 (18) "EXCHG. EJECT-CORE" is displayed ............220 (19) Paper Jams in the Paper Feed Side ................221 (20) Paper Jams in the Paper Eject Side ................222 x Error Display .............................................................223
207
chap.7
zTroubleshooting Guide
1. Countermeasures for the Defective Operation

When the messages listed below are displayed on the LCD or when trouble such as malfunctioning or a paper jam occurs, proceed with an inspection following the procedure for the item and take measures accordingly.
Message List
Massage Remarks No. (12) When power turnd on (15) (4) (3) (18) (14) (11) (8) (5) (17) (16) (13) (10) Page 216 218 212 223 220 217 215 214 212 220 219 216 215
SCANNER OPEN DOCUMENT JAM DRUM NOT SET E*** SERVICE CALL EXCHG. EJECT-CORE EXCHANGE INK FRONT COVER OPEN MAST. EJECT MISS MASTER SET MISS PAPER LEFT JAM PAPER RIGHT JAM ROLL-MASTER END SET PRINT PAPER
Error item List

Item No. (1) (6) (7) (9) (2) (20) (19) 208 Page 209 213 213 214 210 222 221
Lamp does not light up Malfunction of master feeding clutch Malfunction of Mastermaking stepping motor Malfunction of roll-up motor Optical system dose not move forward/backward Paper JAM in the paper eject side Paper JAM in the paper feed side
chap.7
(1) LAMP does not light up
Cause/Defective section Procedures 1
Item to be checked Does voltage between main PCB unit J2-11(+) and J2-26(GND) show +24V? Is trouble cleared by replacing LAMP?
Result NO
Countermeasure Proceed to procedure 3.
LAMP
YES
Finish.
Main PCB
Is trouble cleared by replacing

main PCB?
YES
Finish
209
chap.7
(2) Optical system dose not move forward/backward

Cause/Detective section Procedures Wire or timing belt is cut or removed. There is a foreign object on the optical system moving way. 1 Items to be checked Are the optical system driving wire and timing belt attached properly? Is the rail clean?Does the optical system move smoothly when the optical system driving timing pulley is rotated manually? Measure the voltage between the regulated power supply, CN2-1 (+) and CN2-2(GND) with the tester. Is it +24 V? Result No Countermeasure Attach the wire and timing belt properly.
No
Check that there is no foreign object on the rail and that nothing contacts the optical system.
No
Follow the procedure (5).
Main PCB Unit Optical system stepping motor 4 Is the cause cleared by replacing the main PCB Unit?
Yes
Finish Check the bundled wire and connector. Replace the optical system stepping motor. Check the first side bundled wire connector. If OK, replace the regulated power supply.
No
Remove the regulated power supply, CN1, 2 and 3 and follow the procedure (3). Is it +24V? Follow the procedure (5) and insert the regulated power supply, CN2. Is the voltage +24V?
No
Yes
Follow the procedure (8).
Yes Thermal head 7 Is the cause cleared by replacing the thermal head? No
Finish The thermal head is defective.
Motors
Remove the main PCB Unit J1 and follow the procedure (3). Is the voltage +24V? (CN1 is inserted)
Yes
At the J1 bundled wire or motors +24V produces a short-circuit to GND.
210
chap.7
(3) "E*** SERVICE CALL" is displayed

Cause/Defective section Procedures 1 Item to be checked Is the same error message displayed again after power off and on? Result NO Countermeasure Finish
According to P223 Error Display, shoot the trouble cause one by one.
Finish
Error Display
\ see p.223
211
chap.7
(4) "DRUM NOT SET" is displayed

Cause/Defective section Procedures Drum setting Main PCB unit 1 2 Item to be checked Is trouble cleared by setting drum again? Does drum SW (MS4) checked by HELP mode (H-08)* prove to be normal? Does drum SW (MS4) checked by Result YES YES Finish Check if drum SW (MS4) is installed in place and replace main PCB unit. Replace drum SW (MS4). Check if drum SW (MS4) is installed in place and replace main PCB unit. Countermeasure
Drum SW Main PCB unit
NO YES
*
(5) "MASTER SET MISS" is displayed
Cause/Defective section Procedures End mark sensor PCB unit (PS3) 1 Item to be checked Has MASTER SET ERROR actually occurred? Result NO
Countermeasure Adjust VR for end mark sensor by HELP mode (H-13)*. If unnable,replace end mark sensor PCB unit. NOTE: VR must be adjusted after replacement of end mark sensor PCB unit. Refer to (6) Malfunction of master feeding clutch (CL1).
Master feeding clutch (CL1)
Does master feeding clutch (CL1) operate normally?
NO
\ see page 213

Mastermaking stepping motor (PM2) 3 (PM2) operate normally? NO Refer to (7) Malfunction of mastermaking stepping motor (PM2). Replace cutter unit. Remove static-eliminating brush. Finish Remove any foreign matter in transfer path
\ see page 213
Cutter unit Static electricity Master Transfer path
4 5 6
Is master cut normally? Is static-eliminating brush on master feeding unit damaged or deteriorated? Is trouble cleared by replacing master?
NO YES YES NO
212
chap.7
(6) Malfunction of master feeding clutch

Cause/Defective section Procedures Regulated power supply 1 Item to be checked Does voltage between regulated power supply CN51-1(+) and CN53-1 (GND) show 24V? Does voltage between main PCB unit J2-11 (+) and -12 (GND) show 24V when master feeding clutch is turned on? Is trouble cleared by replacing Main PCB unit? Result NO Countermeasure Replace regulated power supply.
Master feeding clutch (CL1)
YES
Check wiring and replace master feeding clutch.
Main PCB unit
YES
Finish
(7) Malfunction of mastermaking stepping motor

Cause/Defective section Procedures Load on drive system 1 Item to be checked Is trouble cleared by adjusting tension of the master feeding unit timing belt or supplying oil to bearing? Does voltage between regulated power supply CN51-1(+) and CN53-1 show 24V? Is trouble cleared by replacing Main PCB unit? Result YES Finish Countermeasure
NO
Replace regulated power supply.
Main PCB unit
YES
Finish
213
chap.7
(8) "MAST. EJECT MISS" is displayed

Cause/Defective section Procedures 1 Foreign material or dirt on sensors 2 Item to be checked Has MAST. EJECT ERROR actually occurred? Are there any foreign matter or dirt between the master ejection sensor photo-receiving (PS13) and the master ejection sensor photo-emitting PCB? Is trouble cleared by replacing the master ejection sensor photo-receiving (PS13)? Is trouble cleared by replacing the master ejection sensor photo-emitting PCB? Result YES YES Countermeasure Proceed to procedure 5. Remove any foreign matter and clean.
Master ejection sensor photo-receiving (PS13) Master ejection sensor photo-emitting PCB Main PCB unit
YES
Finish
YES NO
Finish Check bundled wire and connectors and replace main PCB unit. Refer to (9) Malfunction of roll-up motor (M4). Clean master clamp section. Replace any damaged stripper finger or springs. Adjust the drum master ejection stop position. Check and adjust C mode.
Roll-up motor (M4) Master clamp dirty Master ejection box Drum master ejection stop position C mode
5 6 7 8
Does roll-up motor (M4) rotate normally? Is the master clamp section dirty with ink or oil? Is stripper finger or springs damaged? Is the drum master ejection stop position within reference value?
NO YES YES NO YES
(9) Malfunction of roll-up motor

Cause/Defective section Procedures Roll-up motor (M4) 1 Item to be checked Does voltage between main PCB unit J2-3 (+) and -4 (GND) show 24V when roll-up motor (M4) is operated with HELP18? Does voltage between regulated power supply CN51-1(+) and CN53-1 show 24V? Is trouble cleared by replacing Main PCB unit? Result YES Countermeasure Replace roll-up motor (M4).
NO
Replace regulated power supply.
Main PCB unit
YES
Finish
214
chap.7
(10) "SET PRINT PAPER" is displayed

Cause/Defective section Procedures No paper is detected 1 Item to be checked Is trouble cleared by adding papers? Result YES Finish Countermeasure
Paper sensor (MS7) position Paper sensor (MS7) Main PCB unit
Is actuator for paper sensor (MS7) is pressed when paper tray is set? When paper sensor (MS7) is checked with volt-ohm-milliammeter, does it CLOSE if actuator is pressed and OPEN if released?
NO
Adjust paper sensor (MS7) position Replace paper sensor (MS7). Check bundled wire and connectors and replace main PCB unit.
NO YES
(11) "FRONT COVER OPEN" is displayed
Cause/Defective section Procedures Front cover open is detected Front cover SW (MS5) position Front cover SW (MS5) Main PCB unit 1
Item to be checked Is trouble cleared by closing the front cover?
Result YES Finish
Countermeasure
Is front cover SW (MS5) pressed when front cover is set? When front cover SW (MS5) is checked with volt-ohm-milliammeter, does it OPEN if switch is pressed (front cover open) and CLOSE if released (front cover close)?
NO
Adjust front cover SW (MS5) position. Replace front cover SW (MS5). Check bundled wire and connectors and replace main PCB unit.
NO YES
215
chap.7
(12) "SCANNER OPEN" is displayed

Cause/Defective section Procedures Scanner SW (MS3) position Scanner SW (MS3) Main PCB unit 1 Item to be checked Is the scanner SW (MS3) pressed when the scanner is closed? When the scanner SW (MS3) is checked with volt-ohm-milliammeter, does it CLOSE if switch is pressed and OPEN if released? Result NO Countermeasure Adjust the scanner SW (MS3) position. Replace the scanner SW (MS3) Check bundled wire and connectors and replace main PCB unit.
NO YES
(13) "ROLL MASTER END" is displayed

Cause/Defective section Procedures End mark is detected 1 Item to be checked Is trouble cleared by changing a new master? Adjustment for the end mark sensor PCB unit (PS3) End mark sensor PCB unit (PS3) Main PCB unit 2 Is trouble cleared by adjusting the end mark sensor PCB unit (PS3) by HELP mode (H-13)*? Is trouble cleared by replacing the end mark sensor PCB unit (PS3)? YES Finish Result YES Finish Countermeasure
YES NO
Finish Check bundled wire and connectors and replace main PCB unit.
216
chap.7
(14) "EXCHANGE INK" is displayed

Cause/Defective section Procedures Ink Setting method of ink pack Main PCB unit 1 2 3 Item to be checked Is enough ink left in ink pack? Is ink pack set properly? Is LED on the ink detection PCB unit lit? Is enough ink left in drum? (Has ink reached detection needle for the ink detection PCB unit?) Does ink pump operate? Is trouble cleared by cleaning inside of ink pump? Result NO NO YES Countermeasure Replace ink pack. Set ink pack properly and teach user how to set one. Check bundled wire and connectors and replace main PCB unit. Replace Ink detection PCB unit
YES
5 Foreign material in ink pump Ink pump Regulated power supply 7 6
NO YES NO
Proceed to procedure 7. Finish Replace ink pump. Replace regulated power supply.
Does voltage between regulated power supply CN51-1(+) and CN53-1 show 24V? Does voltage between main PCB unit J2-5 and -6 show 24V? Is trouble cleared by replacing main PCB unit?
NO
Ink motor (M2) Main PCB unit
8 9
YES YES
Replace ink motor (M2). Finish
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chap.7
(15) "DOCUMENT JAM" is displayed(ADF)

Cause/Defective section Procedures 1 Separator, paper feed roller Main PCB unit 2 3 Item to be checked Does the document feed roller rotate? Is document fed by separator and the paper feed roller? When document sensor 1 (PS1) is checked with HELP08, is 0 displayed if sensor is photo passing and is 1 displayed if photointerrupted? Does voltage between main PCB unit J7-16 and GND show HIGH value (about 3.3V) if sensor is photointerrupted and LOW if photo passing? Is trouble cleared by adjusting the document sensor position? When document sensor 1 (PS1) is checked with HELP08, is 0 displayed by directing another light to the photoreceiving section of the document sensor photo-receiving PCB? Are gears broken? Does voltage between regulated power supply CN51-1(+) and CN53-1 show 24V? Is trouble cleared by replacing main PCB unit? Is trouble cleared by replacing Scanner stepping motor? (PM1) Result NO NO YES Countermeasure Proceed to procedure 7. Clean separator and the paper feed roller. If necessary, replace. Check bundled wire and connectors and replace main PCB unit. Replace main PCB unit.
Main PCB unit
YES
Document sensor position Document sensor photo-emitting PCB Document sensor photo-receiving PCB Gears Regulated power supply
5 6
YES YES NO
Finish Replace the document sensor photo-emitting PCB Replace the document sensor photo-receiving PCB Replace gears. Replace regulated power supply.
7 8
YES NO
Main PCB unit Scanner stepping motor (PM1).
9 10
YES YES NO
Finish Finish Replace scanner stepping motor(PM1)
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chap.7
(16) "PAPER RIGHT JAM" is displayed

Cause/Defective section Procedures Paper 1 2 Item to be checked Is printing paper long within specified value? When JAM sensor 1 (PS12) is checked with HELP08, is 0 displayed if sensor is photopassing and is 1 displayed if photointerrupted? Is paper really jammed at master ejection section? Is trouble cleared by properly closing the master ejection box? Is there any dirt or foreign material on the JAM sensor photo-emitting or photo-receiving section? Is trouble cleared by adjusting the JAM detection sensor position? Is 0 displayed by directing another light to the photo-receiving section of the document sensor photo-receiving PCB when JAM sensor 1 (PS12) is checked with HELP06? When drum is checked with HELP06 while rotating slowly, does the stop/JAM detection position sensor (PS6) display 0 or 1 according to edge of photointerrupter? Result NO YES Countermeasure Use paper conforming to specification. Proceed to procedure 7.
Paper jammed Master ejection box is not closed. Dirt or foreign material on sensor Sensor position Document sensor photo-emitting PCB Document sensor photo-receiving PCB Stop/JAM detection position sensor (PS6) Main PCB unit
3 4 5
YES YES YES
Refer to Paper JAM in paper eject side. Finish Clean the photo-emitting and photo-receiving sections of JAM sensor. Finish Replace JAM sensor photoemitting PCB. Replace JAM sensor photoreceiving PCB. Adjust position of the stop/JAM detection position sensor. If necessary, replace. Replace main PCB unit.
6 7
YES YES NO
NO
YES
* *
HELP mode H-06 \ see p.240 HELP mode H-08 \ see p.242
219
chap.7
(17) "PAPER LEFT JAM" is displayed

Cause/Defective section Procedures Item to be checked Is trouble cleared by checking, referring to Paper jams in the paper feed side? When P roller sensor (PS9) is checked with HELP06, is 0 displayed if press is turned ON and 1 displayed if OFF? NOTE: If no problem is detected by the check with HELP06, result on printing may differ depending on speed or load. Recommended is to follow procedure 3 and 4 below for further check. Is the trouble cleared by adjusting P roller sensor (PS9) position? Is the trouble cleared by replacing P roller sensor (PS9)? Result YES Finish Countermeasure
LCD panel
Main PCB unit
YES
Replace the main PCB unit.
P roller sensor (PS9) position P roller sensor (PS9) Main PCB unit
3 4
YES YES NO
Finish Finish Check the bundled wire and connectors and replace the main PCB unit.
(18) "EXCHG. EJECT-CORE" is displayed

Cause/Defective section Procedures Core Core full SW (MS8) actuator Core full SW (MS8) Main PCB unit 1 2 3 Item to be checked Core is not included or core is full? Is core full SW (MS8) pressed when empty core is installed? Does core full SW (MS8) tested voltohm-milliammeter prove to be normal? Result YES YES NO YES Countermeasure Insert new core. Adjust actuator of core full SW (MS8). Replace core full SW (MS8). Check bundled wire and connectors and replace main PCB unit.
220
chap.7
(19) Paper Jams in the Paper Feed Side

Causes Printing paper not suitable Symptoms If paper is too thick, it wont be likely fed. If too thin, double sheets may be fed. Paper not clearly cut: 2 sheets still adhere to each other. Much paper scraps may deteriorate the paper feed roller and separator performance. Paper gets stuck in transfer path, causing creasing and tearing. If pressure on paper is insufficient, paper will not be fed. If pressure on paper is excessive, double sheets will be fed. Paper may not be fed. If gap is too large, separator unit will rattle in direction of paper transfer path, causing double sheets to be fed. If gap is too small, paper separator unit cannot follow angle change due to paper feed shaft up-down movement, which may cause double-sheet or slanted feed, and creasing. Wear, or adhesion of paper scraps causes deterioration in separating performance, resulting in double-sheet feed. Countermeasure Explain causes to user. Have user change to the paper conforming to specifications.
Dirt*foreign matter in transfer path Incorrect paper feed path pressure Worn paper feed roller Paper separator unit gap
Remove any dirt or foreign matter. Explain to users how to select correct pressure for paper. Replace paper feed roller. Perform paper separator unit gap adjustment.
\ see page 169

Clean separating surfaces. If any trouble exists, replace. Perform separator unit gap adjustment on new unit. \ see page 169 Perform separation pressure adjustment. Perform paper feed tray upper limit sensor adjustment.
Paper separator unit
Separation pressure
If pressure is very low, no paper will be fed.
\ see page 170
Paper tray upper position limit
Paper slant is large, causing creases. During printing, paper feed errors often occur immediately before or after paper tray rises. If amount is too short, paper slant cannot be corrected, printing position may not be uniform, or paper may not be fed. If amount is too long, loop becomes too large, causing paper to buckle up between paper feed roller and timing roller, resulting in feed error. Clutch slippage will reduce paper feed amount. If clutch does not disengage properly, the paper feed segment gear will not return correctly, leading to reduced feed amount. (See Paper feed amount above.) If Guide roller pressure is insufficient, paper will not be gripped properly, and timing roller will not assure constant feed amount. As a result, printing position will not be uniform. In the worst case, no paper will reach drum. If there is a gap between Guide roller and the timing roller, paper slant cannot be corrected. If the timing roller clutch slips, feed amount will not be constant. As a result, printing position will not be uniform. In the worst case, no paper will reach drum. If the timing roller clutch does not disengage properly, the paper feed segment gear will not return correctly, leading to reduced and unstable feed amount. As a result, printing position will not be uniform. In the worst case, no paper will reach drum. Paper may be damaged in the part of leading edge that touches the signal lever. In the worst case, paper may stick to the signal lever.
\ see page 170

Perform paper feed amount adjustment.
Paper feed amount
HELP mode H-67 / 284 page

Replace paper feed cluch.
Paper feed clutch
Guide roller pressure & timing
Perform escape amount adjustment and escape timing adjustment.
\ see page 172

Clean timing roller clutch . Replace if necessary.
Timing roller
Incorrect signal lever operation
Clean bearing unit. Check that signal lever moves smoothly.
221
chap.7
(20) Paper Jams in Paper Eject Side

Causes Printing paper not suitable Symptoms If paper is too thin, it will stick to drum and scrunch up. If grain of paper is sideways relative to transfer direction, paper will crunch up, or get jammed on the paper receiving plate. If paper curl upward, it will likely scrunch up. If curl downward, it will likely get jammed on the paper receiving plate. If set-solid exists near leading edge of paper, paper will likely scrunch up. If set-solid is blasted to one side of paper, paper will not be ejected in a straight line. As a result, ejected paper will be disorderly piled and likely jam on the paper receiving plate. If ambient air is dry, static electricity may cause disordered piles or scrunch-up of paper. Countermeasure Explain causes to users. Have user change to paper conforming to specifications.
Image of document
Adjust leading edge margin to about 10 mm. (Too long margin will cause adverse results.) Explain causes to users. If possible, have user change position for set-solid. Explain causes to users. Have user desist from excessive use of A/C or heating. If possible, have user take anti-dryness measures including humidifiers. Perform printing position sensors adjustment.
Static electricity
Leading edge margin
If leading edge margin is not correct, scrunch-up of paper will likely result. IMPORTANT: Scrunch-up of paper may also result if the margin is too long. If Guide roller pressure is insufficient, paper will not be gripped properly, causing less feed amount determined by timing roller, or disappearance of leading edge margin. This results in the paper scrunchup. Any slippage of the timing roller clutch will reduce feed amount and eliminate leading edge margin. This results in the paper scrunch-up. If the timing roller clutch does not disengage properly, the timing roller segment gear will not return correctly, causing reduction of feed amount or disappearance of leading edge margin. As a result, paper will scrunch up. If timing is too low, or the gap between drum and the leading edge of paper is too large, paper stripper finger will not enter into the gap, causing the paper scrunch-up. If sufficient air is not delivered from the tip of the paper stripper finger, it will not lift the leading edge of paper off drum. Scrunch-up of paper will result.
\ see page 173

Perform escape amount and escape timing adjustments.
Guide roller pressure & timing
\ see page 172

Clean timing roller clutch. Repair if necessary.
Timing roller clutch
Perform paper stripper finger adjustment.
\ see page 178
Air
Check if the hole in the fingers tip is blocked by foreign matter. Check pipes for kinks or disconnections. Check valves and O-rings on the air pump. If the belt is broken or stretched, replace it.
Paper ejection belt
If the speed of the paper ejection belt, if cannot eject the paper onto the paper receiving plate with sufficient force. As a result, there will be paper jams in the vicinity of the discharge port. (Sometimes the trailing edge of the paper gets caught in the jamming sensor and a paper jamming error is displayed.) If the suction force of the fan drops, it will not be able to blow the paper (which has risen clear of the ejection belt) onto the paper receiving plate with be paper jams in the vicinity of the discharge port. (Sometimes the trailing edge of the paper gets caught in the jamming sensor and a paper jamming error is displayed.) Too much ink transferred to paper will likely cause scrunch-up of paper.
Paper ejection fan unit
Clean the fan. If it still does not work properly, replace it.
Ink
Perform ink volume adjustment of drum. Explain user that ink transfer volume increases immediately after paper scrunchup, and advise user to restart printing at standard speed, then.
\ see page 179
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chap.7
xError Display
This machine has a self-diagnosis function. The state of the machine is always checked with this function and is displayed with code on the control panel. The following are the code display, cause and detection timing.
LCD panel
E111
Code display
Code display
Cause The main motor (M1) is defective. The main PCB Unit is defective. The encoder sensor (PS7) is defective. The elevator motor (M2) is defective. The elevator top limit sensor (PS9) is defective. The elevator bottom limit switch (MS6) is defective. - The main PCB Unit is defective. The elevator operation is defective.
Detection timing
E001
While the drum rotation signal is lit, the encoder sensor (PS7) cannot detect the edge for 1 second.
E002
The elevator does not reach the top limit for 30 seconds after the elevator motor (M2) up signal is lit. The elevator does not reach the bottom limit for 30 seconds after the elevator motor (M2) down signal is lit. The cutter does not reach the limit for 30 seconds after the cutter motor move signal is lit. In the lamp lighting check, amount of light received by CCD does not reach regulation value. (Perform the lamp lighting check once only, with the power turned on.)
E003
The cutter motor is defective. The cutter limit switch is defective. - The main PCB Unit is defective. The lamp is defective. The invertor unit is defective. The CCD is defective. Main PCB unit is defective. The main PCB Unit is defective. The thermal head substrate is defective. The thermal head is defective. The master set sensor is defective. The cord for master set sensor is unconnected. - The main PCB Unit is defective.
E004
E009
At start of mastermaking, thermal head drive voltage does not reach regulation value.
E040
The master set sensor signal is detected continually for 20 seconds after power is on.
223
MEMO
224
Chapter 8
HELP Mode
z HELP Mode List ........................................................226 x Overview .................................................................... 230 c HELP Mode Functions and Operation Procedures ..............................231 (1) Basic Procedure for Accessing HELP Modes .....231 (2) Guide to the HELP Mode Descriptions ..............231 (3) Guide to version up ..............................................232 HELP Mode Descriptions ....................................233
225
chap.8
z Help mode List
z HELP Mode List

HELP Mode No. H-00 Display of ROM versions Description Classification ROM version displays
: ADF
Page 233
H-01
Display and adjustment of print speeds
Adjustment / specification setting Function testing Function testing Function testing
234
H-02 H-03 H-04
Elevator motor Function testing Tape Cluster Function testing Ink replenishment Function testing
236 237 238
H-05
Checking of condition of master ejection sensor and other sensors listed below Sensor/ switch condition Paper feed sensor,Top/Bottom limit sensor, Top/Bottom center sensor display Value of thermistor for Main PCB and Thermal head Value of encoder count of drum rotated Checking of condition of sensors listed below B mode sensor, A/C mode sensor Press roll sensor, Drum stop/paper ejection jam Light reception by the paper ejection jam sensor Drum master attachment /detachment position sensor , Paper ejection jam sensor Checking of condition of switches listed below: Cutter switch of operation /non-operation side,Drum rotation switch Master lever feed sensor,Paper sensor,Drum cover switch Elevator upper limit sensor, Elevator lower limit sensor,Feed tray descend switch,Tape switch Checking of condition of sensors/swtches listed below: Document sensor1, Document sensor2 Upper cover switch, Master roll Full switch, Drum switch Value of ADF received Checking of master attachment position, jam sensing position, master detachment position and drum stop position (1) Function testing of LAMP (2) Testing of functioning of ADF scan motor operation function
239
H-06
Sensor/ switch condition display
240
H-07
241
H-08
Sensor/ switch condition display Function testing Function testing
242 ADF:242 243 (1)244 (2)244 245 ADF:245 246
H-09 H-10 H-11 H-12
(1) Document darkness values and scanner test (for use in factory checks) Sensor/ switch condition display (2) Testing of ADF. (1) Checking of shading memory Function testing
H-13
(1) Check the condition of the end mark sensors
247
226
chap.8
z Help mode List
: ADF
HELP Mode No. H-14 H-15 H-16 H-17 H-18 H-19 H-20 H-21 H-22 H-23 H-24 H-25 H-26 H-27 H-28 H-29 H-30 H-31 H-32 H-33
Description (1) Mastermaking total counter display (2) Resetting of count of total masters made in user mode Function testing of ink motor Setting of online (with PC interface) master making start position Function testing of Cutter motor (1) Function testing of roll-up motor (2) Function testing of fan motor (1) Printing total counter display (2) Resetting of count of total sheets printed in user mode Function testing of clamp motor and clamp position sensing (A /B /C mode position) (Not used) Setting of lengthwise zoom factor correction amount for mastermaking side Setting of photograph mode document sensing darkness Setting of reducing offset for reading longitudinal R / E of scanner Setting of enlarging offset for reading longitudinal R / E of scanner Compensation of document darkness white level in photograph mode Initialization of all HELP mode settings Setting of buzzer selection
Classification Total counts Function testing Adjustment / specification setting Function testing Function testing Total counts Function testing 4 Adjustment /specification setting Adjustment /specification setting Adjustment /specification setting Adjustment /specification setting Adjustment /specification setting Adjustment /specification setting Adjustment /specification setting Adjustment /specification setting Function testing Adjustment /specification setting Adjustment /specification setting Adjustment /specification setting
Page (1) 248 (2) 248 249 250 251 252 (1) 253 (2) 253 254 4 255 256 ADF:256 257 ADF:257 258 ADF:258 259 ADF:259 260 261 262 263 264 265 266
ADF:266
Adjustment of paper infeed amount Test pattern (all shading secondary scanning direction zoom factor adjustment) mastermaking and printing Setting of number of pre-print sheets Confidential safeguard function, selection of first print speed, setting of master ejection error sensing Compensation of document darkness white level in text mode
227
chap.8
z Help mode List

: ADF
HELP Mode No. H-34 H-35 H-36 H-37 H-38 H-39 H-40 H-41 H-42 H-43 H-44 H-45-49 H-50 H-51/52 H-53 H-54 H-55 H-56 H-57/58 H-59 H-60 H-61 (Not used)
Description
Classification 4 Adjustment/specification setting Adjustment/specification setting Adjustment/specification setting Adjustment/specification setting Function testing 4 Adjustment/specification setting Adjustment/specification setting Adjustment/specification 4 setting Adjustment/specification setting 4 Adjustment/specification setting 4 Adjustment/specification setting 4 Adjustment/specification Setting Adjustment/specification Setting 4 Adjustment/specification Setting 4 Function testing 4 Setting Adjustment/specification Setting Adjustment/specification Setting
Page 4 267
ADF:267
Adjustment of scanner leading edge sensing position Adjustment of scanner widthwise (operation side) sensing position Adjustment of mastermaking start position when scanner is used Adjustment of drum speed automatically Function testing of clutches test and auto power off (Not used) Automatic initialization of the control panel setting, setting of repeat count display,energy save mode and auto power off Setting of paper selection specification Setting of thermal head offset value Setting of thermal head resistance ranking (Not used) Setting of text mode document sensing darkness (Not used) Adjustment of widthwise (operation side) mastermaking start position for online mastermaking (Not used) Setting of ink check at printing start, cutting operation mode for master cutting, and interlocks Seeting for selecting manipulation language (Not used) Setting of endmark sensor2 (Not used) Function test for LCD screen and LED indicators (for use in factory checks) (Not used) Setting for A4 master cut Buzzer (tone) setting
268
ADF:268
269
ADF:269
270 271 4 272 273 274 275 4 276

ADF:276
4 277 4 278 279 4 280 4 281 4 282 283
H-62 H-63 H-64
228
chap.8
z Help mode List

: ADF
HELP Mode No. H-65 H-66 H-67 H-68 H-69 (Not used)
Description
Classification 4 Adjustment/specification Setting Adjustment/specification Setting Adjustment/specification Setting Adjustment/specification Setting 4 Adjustment/specification Setting Adjustment/specification Setting Adjustment/specification Setting 4 Adjustment/specification Setting 4 Adjustment/specification Setting 4 Adjustment/specification Setting Adjustment/specification Setting Adjustment/specification Setting Adjustment/specification Setting 4 Adjustment/specification Setting Adjustment/specification Setting Adjustment/specification Setting Adjustment/specification Setting Adjustment/specification Setting Adjustment/specification Setting Adjustment/specification Setting
Page 4 284 285 286 287
Setting: clamp opening/closing timing of when a master is attached; H-67/68 ON/OFF Setting of paper feed length Setting of paper feed angle Setting of model
H-70/71 (Not used) H-72 H-73 H-74 Adjustment of master making area length Adjustment of master making area length on online printing Setting of thermal head temperature supplementing and master making darkness rank. (Not used)
4 288 289 290
H-75 H-76
4 291
Document darkness correction for photograph/text mode
H-77/79 (Not used) H-80
4 292
Setting of speed rank, ADF and ink save mode

(Not used) (1) Display of ROM version for ADF (1) Checking of communication for ADF
H-81/82 H-83 H-84 H-85 H-86 H-87-88 H-89 H-90 H-91 H-92 H-93 H-94 H-97
4 293 294 295 296 4 297 300 301 302 303 304 305
Adjustment for image sampling timing of scanning (for use in factory checks). Setting of manual batch printing
(Not used)
Setting of Tape cluster Setting of several special functions. Setting of tape lenghth for Tape cluster on online mode Setting of tape lenghth for Tape cluster
Adjustment of widthwise (operation side) scaning start position for 4-up and 8-up UID ADMINISTRATOR password reset The display for machine model.
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chap.8
x Overview
x Overview
The Duprinter's HELP modes can be broadly classified into the following types:
x Modes for ROM version display

These modes display the version numbers of the main PCB unit's ROM (U19), the I/F PCB unit's ROM,the Panel PCB unit's ROM, and the DSP(U13).
x Modes for adjustment / specification setting

These modes set the functioning of variable resistors and switches by using the main PCB unit's EEPROM(U23) to memorize settings made on the operation panel. All of these adjustments and settings are made at the factory prior to shipment of each Duprinter.
IMPORTANT New adjustments and appropriate settings must be made after the
main PCB unit is replaced and after initialization setting has been implemented (using HELP mode H-27).
x Modes for function checks
These modes permit the running of function checks on: individual motors, given series of operations, and electrical circuits. When these modes are used to check motor functioning, the motor being checked is run by itself, but interlocks are suspended. When such checks are run, take care not to put hands or fingers in motor-related moving parts that could start up unexpectedly.
Failure to heed the above could result in crushed or otherwise injured hands or fingers.
x Modes for sensor and switch displays

These modes provide displays of the conditions of sensors and switches.
x Modes for total count displays

These modes provide displays of the counts of the total number of masters made and sheets printed by the Duprinter since it was manufactured. They also permit resetting of the total count values displayed in the user mode.
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chap.8
c HELP Mode Function and Operation Procedures
c HELP Mode Functions and Operation Procedures

(1) Basic Procedure for Accessing HELP Modes q During use of the Duprinter: first put the machine into the
standby state, then turn the power switch OFF.
wSimultaneously press and hold down the
and
printing
HELP
SELECT
Mode number
00
speed keys, and turn the power switch ON with those keys held down. After about 2 seconds, a beep-beep-beep tone will sound, and the HELP mode display will appear.
eUsing the numeric keys, enter the number of the HELP mode you
want to access. Example: To access HELP mode H-00, enter [0], [0].
rPress the PRINT
key. The HELP mode specified in e will be
accessed, and either the initial value (value set at factory), or the currently set value, for the mode will be displayed. From this point on, follow the procedure given below for the particular mode accessed.
U6B 1 . 11
0 p : V 1 . 11
(2) Guide to the HELP Mode Descriptions
The descriptions of each HELP mode given on the following pages are laid out as follows: HELP mode number Function category
chap.7
HELP mode
1. Functions
H-03
(1)Function testing
(1) Tape cluster function test
For desccription of operation \See page 150
Main functions
(2) Stacker rise/descent motor function testing
For removal \See page 195
References to related pages
2. Operation procedure
Operation procedure for individual functions
(1) Testing the tape cluster's functioning qAccess HELP mode H-03, and press the PRINT
key. For the basic procedure for accessing HELP modes. \See page 293
H - 0 3
Mode number flashes
LC display for function
wPress and hold down the TEST PRINT
key. The tape feed motor
will run, and feed out the tape, for as long as the key is held down.
231
chap.8
(3)Guide to version up
q Remove screw1 and loosen screw2,make cover to fall down,
and make version up socket out. screw1 cover version up socket
screw2
w Make sure the power is turned off,connect the connector of

downloader( DDL-01 OR DDL-02 ) to version up socket. connector
eSimultaneously press and hold down the DOCUMENT MODE key

and CLEAR key , and turn the power switch ON with those keys held down. After about 2 seconds, a beep-beep-beep tone will sound, and the version up mode display will appear.
IMPORTANT
rOperate according to DDL-01 service manual or DDL-02 service

manual to version up,when finished normally,the LCD panel will be shown as right.
t Turn power off,remove the connector of downloader from the socket,

then fix the cover back with the screws.
232
chap.8
HELP Mode Descriptions
HELP mode
1. Functions
H-00
ROM version displays
Display of ROM versions

Displays version of the main PCB unit's ROM. Displays version of the I/F PCB unit. Displays version of the Panel PCB unit. Displays version of the DSP.
IMPORTANT
ROM version for I/F PCB unit is displayed only when connected with the
computer.
2. Operation procedure Displaying ROM versions qAccess HELP mode H-00, and press the PRINT
For the basic procedure for accessing HELP modes. \See page 231
Displaying ROM version
key.
Displays version of the main PCB unit's ROM and I/F PCB unit as right when TEXT mode is selected.
U6B 1 . 11
0 p : V 1 . 11
Main PCB unit
I/F PCB unit
Displays version of the panel PCB unit's ROM and DSP as right when TEXT/PHOTOGRAPH mode is selected.
K E Y V 1 . 1 1D S P V 1 . 1 1
PANEL PCB unit
DSP
wPress the STOP
key. The HELP mode selection display will
reappear. a To exit the HELP mode : Turn the power switch OFF. a To access another HELP mode : Enter the desired mode number using the numeric keys.
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chap.8
HELP mode
1. Functions
H-01
(1) Adjustment / specification setting
Display and adjustment of print speeds

Display and adjustment of print speeds (pre-stop speed, jog speed and speeds 1-3)
Adjusting of Printing Speeds 1-3 \See page 188
IMPORTANT
You'd better adjust these speeds after auto-speed adjustment by using help 38.
2. Operation procedure Adjusting speeds and memorizing the adjusted values qAccess HELP mode H-01, and press the PRINT
For the basic procedure for accessing HELP modes. \See page 231 key.
wSelect the speed you want to adjust.

Speeds 1-3
111
key as many times
r pm
Press the DOCUMENT MODE SWITCH
as needed to select the PHOTOGRAPH item. Then use the and PRINTING SPEED ADJUSTMENT keys to select one of speeds 1 through 3.
Jog speed
Press the DOCUMENT MODE SWITCH key as many times as needed to select the TEXT/PHOTOGRAPH item.
Pre-stop speed
1st 2nd 3rd
speed
Press the DOCUMENT MODE SWITCH as needed to select the TEXT item.
key as many times
eSelect the item speed you want to adjust

To select the print speed:
Press the DOCUMENT MODE SWITCH as needed to select the PHOTOGRAPH item.
key as many times
234
chap.8
HELP mode
rUse the
and
H-01
PRINTING POSITION ADJUSTMENT keys to
adjust the speed value.

Speed Pre-stop JOG 1st. 2nd. 3rd. Adjustment standard (rpm) Print speed 5-7 16 - 18 63 - 65 87 - 89 140-142
tTo display or adjust other another speed(s), repeat steps wthrough r. yPress the STOP
key. The newly adjusted value(s) will be
memorized, and the HELP mode selection display will reappear. a To exit the HELP mode: Turn the power switch OFF. a To access another HELP mode: Enter the desired mode number using the numeric keys.
235
chap.8
HELP mode
1. Functions
H-02
(1) Function testing
(1) Elevator motor function testing
For electrical parts layout \See page 304
2. Operation procedure (1) Testing the elevator motor's functioning qAccess HELP mode H-02, and press the PRINT
For the basic procedure for accessing HELP modesn. \See page 231 key.
wPress and hold down the PRINTING POSITION ADJUSTMENT RIGHT key. The elevator motor will run, making the paper tray rise, for as long as the key is held down.
eTo stop the elevator motor, either release the PRINTING

POSITION key, or de-obstruct the elevator upper limit sensor's light beam.
rPress and hold down the PRINTING POSITION ADJUSTMENT

LEFT key. The elevator motorwill run, making the paper tray descend, for as long as the key is held down.
tTo stop the elevator motor, either release the PRINTING POSITION
key, or alter the elevator lower limit switch's condition from closed to open.
yPress the STOP
reappear. a To exit the HELP mode: Turn the power switch OFF. a To access another HELP mode: Enter the desired mode number using the numeric keys.
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chap.8
HELP mode
1. Functions
H-03
(1)Function testing
(1) Tape cluster function test
2. Operation procedure (1) Testing the tape cluster's functioning qAccess HELP mode H-03, and press the PRINT
TAPE
TEST
wPress and hold down the TEST PRINT eRelease the TEST PRINT rPress the STOP
T
key. The tape feed motor
will run, and feed out the tape, for as long as the key is held down. key. The tape cutting solenoid will be activated, and the tape will be cut. key. The HELP mode selection display will reappear. a To exit the HELP mode: Turn the power switch OFF. a To access another HELP mode: Enter the desired mode number using the numeric keys.
237
chap.8
HELP mode
1. Functions
H-04
(1) Ink replenishment function testing

Tests functioning of ink replenishment by sensing the ink supplied.
2. Operation procedure (1) Testing the functioning of ink replenishment qAccess HELP mode H-04, and press the PRINT
key. For the basic procedure for accessing HELP modes. \See page 231 When the PRINT key is pressed, the drum will rotate, and the ink pump run, until the ink sensing PCB unit's LED lamp lights to signal that ink supply is OK. When this lamp lights, a buzzer sounds and the drum and ink pump stop. key. The HELP mode selection display will wPress the STOP reappear. a To exit the HELP mode: Turn the power switch OFF. a To access another HELP mode: Enter the desired mode number using the numeric keys.
I NK
CHECK
238
chap.8
HELP mode
1. Functions
H-05
(1) Sensor / switch condition display
(1) Checking of condition of master ejection sensor and other sensors listed below
Runs checks on the Paper feed sensor,Top/Bottom limit sensor,Top/
Bottom center sensor.Displays amount of light received by master ejection sensor. Displays the value of thermistor for Main PCB and Thermal head. Display the value of encoder count of drum rotated.
For electrical parts layout \See page 301 Master ejection sensor \See page 75
2. Operation procedure (1) Checking the condition of master ejection sensor and other listed sensors key. qAccess HELP mode H-05, and press the PRINT
Top/bottom center sensor 1 = Photointerrupting Top/bottom limit sensor 1 = Photointerrupting Paper feed sensor 0=paper present
wWhen TEXT mode is selected, A display indicating the conditions

of the following sensors and the master ejection sensor's photoreceiving amount will appear, the amount is a value between 000 and 255.
x Paper feed sensor x Top/bottom limit sensor x Top/bottom center sensor :A :B :C
A : 1 B : 1 C : 1 D : 111
Amount of light received by master ejection sensor
x Reading the displayed value of D [000] : Maximum amount of light received [255] : No light received [000 displayed value 180]: No master between sensor components * Displayed value when master present > Displayed value when master absent
eWhen TEXT/PHOTOGRAPH mode is selected,the value of thermistor

of main PCB and thermal head.
A : 111
B : 1 11
main PCB
thermal head
r When PHOTOGRAPH mode is selected, the value of encoder count

of drum rotated will displayed in hex.
11111111
encorder
t Press the STOP
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chap.8
HELP mode
1. Functions
H-06
(1) Sensor/switch condition display
(1) Checking of condition of sensors listed below

Runs checks on the B mode sensor and A/C mode sensor. Runs checks on the press roller sensor, drum stop / paper ejection jam sensing position sensor,light reception by the paper ejection jam sensor,and drum master attachment/detachment position sensor. Runs checks on Paper ejection jam sensor.
2. Operation procedure (1) Checking the condition of the listed sensors qAccess HELP mode H-06, and press the PRINT
of the following sensors will appear.
x B mode sensor x A/C mode sensor :A :B
key.
A/C mode sensor 1 = Photointerrupting B mode sensor 1 = Photointerrupting Unused.
w When TEXT mode is selected, A display indicating the conditions
A:1 B:1 C:1 D:1

e When TEXT/PHOTOGRAPH mode is selected,A display indicating
the conditions of the following sensors will appear.
x Press roller sensor x Light reception by the paper ejection jam sensor x Drum master attachment/detachment position sensor :A :C :D x Drum stop / paper ejection jam sensing position sensor : B Drum master attachment / position sensor 1 = Photointerrupting Light reception by the paper ejection jam sensor 1 = Photointerrupting Drum stop / paper ejection jam sensing position sensor 1 = Photointerrupting Press roller sensor 1 = Photointerrupting
rPress the DOCUMENT MODE SWITCH

as needed to select the PHOTOGRAPH item.
key as many times
The paper ejection jam sensor's photo-receiving amount will be displayed, as a value between 000 and 255.
A:1 B:1 C:1 D:1 A:1 B : 1 11
x Paper ejection jam sensor [10] and under : Paper not present [255] : Paper present
tPress the STOP
unused
Paper ejection jam sensor
240
chap.8
HELP mode
1. Functions
H-07
(1) Checking of condition of switches listed below:

Displays condition of cutter switch operation/non-operation side, drum rotation switch. Displays condition of master feed sensor,paper sensor,drum cover switch. Displays condition of elevator upper/lower limit switch,feed tray descend switch,tape switch.
2. Operation procedure (1) Checking the condition of the listed switches qAccess HELP mode H-07, and press the PRINT
Drum rotation switch 0 = PUSH Cutter switch non-operation side 1=push Cutter switch operation side 1=push unused
w When TEXT mode is selected, A display indicating the conditions

of the following sensors will appear.
:A S Cutter switch operation side S Cutter switch non-operation side : B :C S Drum rotation switch
A:1 B:1 C:1 D:1

Drum cover switch 1 = open
e When TEXT/PHOTOGRAPH mode is selected,A display indicating

the conditions of the following sensors will appear. S Master feed sensor S Paper sensor S Drum cover switch
:A :C :D
Paper sensor 0=paper present Unused Master feed sensor 1=PUSH.
A:1 B:1 C:1 D:1

r When PHOTOGRAPH mode is selected,A display indicating
the conditions of the following sensors will appear. S Elevator upper limit sensor S Elevator lower limit switch S Feed tray descend switch S Tape switch
:A :B :C :D Tape switch 0 = present Feed tray descend switch 0 = PUSH Elevator lower limit switch 1=push Elevator upper limit sensor 1 = Photointerrupting
t Press the STOP
A:1 B:1 C:1 D:1
241
chap.8
HELP mode
1. Functions
H-08

Displays condition of upper cover sensor,master roll FULL switch, drum presence switch. Displays the value of ADF received .
For electrical parts layout \See page 300, 301
2. Operation procedure (1) Checking the condition of the listed sensors qAccess HELP mode H-08, and press the PRINT
A : 1 B :1 11
w When TEXT mode is selected, the display indicating

the conditions of the following sensors will appear. S ADF home position sensor : A S Fixed document home position sensor : B
e When TEXT/PHOTOGRAPH mode is selected,the display

indicating the conditions of the following sensors will appear. S Scanner opening/closing switch : A S Paper roll FULL switch S Drum switch
:B :D
Fixed document home ADF home position sensor position sensor 255=Photointerrupting 1=Photointerrupting
A:1 B:1 C:1 D:1

Scanner opening/closing switch 1=Push Master roll FULL switch 0=Push Not used Drum switch 0=Drum present
r When PHOTOGRAPH mode is selected,A display indicating

the conditions of the following sensors will appear.
:A S ADF document sensor :B S ADF jam sensor :C S ADF cover switch S ADF document position sensor :D
A:1
B : 1 C : 1 D :1 11
ADF document sensor 1=Paper Present ADF jam sensor 1=Paper Present ADF cover switch 0=PUSH ADF document position sensor Paper present:190 or more , Paper not present: less than 30
tPress the STOP
242
chap.8
HELP mode
1. Functions
H-09
(1) Checking of master attachment position, jam sensing position, master detachment position and drum stop position
For Standards / Adjustment \See page 175
2. Operation procedures (1) Checking the master attachment, jam sensing, master position and drum stop positions qAccess HELP mode H-09, and press the PRINT
For the basic procedure for accessing HELP modes. \See page 231 Each time the PRINT key is pressed, the drum stop and jam sensing position sensors, and the master attachment/detachment positions sensors, will alternately sense the edge of the shade plate, then stop. key.
: D R UM P O S . T E S T
wPress the STOP
key. The HELP mode selection display will : Turn the power switch OFF. : Enter the desired mode number using the numeric keys.
reappear. a To exit the HELP mode a To access another HELP mode
243
chap.8
HELP mode
1. Functions
H-10
(1), (2) Function testing
(1) Testing of functioning of LAMP (on/off) (2) Testing of functioning of scanner motor operation function 2. Operation procedures (1) Testing the functioning of lamp (on/off) qAccess HELP mode H-10, and press the PRINT
For the basic procedure for accessing HELP modes. \See page 231 When the PRINT key is pressed, the leds in the CIS will light. key.
CCD TEST
wPress the STOP
(2) Testing of functioning of ADF scan motor operation function qAccess HELP mode H-10, and press the PRINT
wSelect SCAN motor rotated forward or backwards.

Forward Press the PRINTING POSITING RIGHT Backwards Press the PRINTING POSITING LEFT key. key.
e Press the STOP
244
chap.8
HELP mode
1. Functions
H-11
(1) Document darkness values and scanner test (for use in factory checks) 2. Operation procedures (1) Document darkness values and scanner test (for use in factory checks) qAccess HELP mode H-11, and press the PRINT
For the basic procedure for accessing HELP modes. \See page 231 When the PRINT key is pressed, the CIS lights up and the document is conveyed to the "position for sensing document size". The sensed size is displayed as a 4-digit number (****) and the document is fed out. key.
P1 1 1 1
Sensed size display
w Select one of the items below, and follow the procedure given for it.
Display of darkness value for lightest part of document a Use the DOCUMENT MODE SWITCH key to select the TEXT item. Feed a document to ADF. A value between 000 ("darkest" value) and 255 ("lightest" value) will be displayed.
Display of darkness value for darkest part of document (relative to lightest part, above) a Use the DOCUMENT MODE SWITCH key to select the PHOTOGRAPH item. Feed a document to ADF. A value between 000 ("darkest" value) and 255 ("lightest" value) will be displayed.
ePress the STOP
245
chap.8
HELP mode
1. Functions
H-12
(1) Checking of shading memory.
2. Operation procedures (1) Checking of shading memory. qAccess HELP mode H-12, and press the PRINT
key.
wSelect one of the items below, and follow the procedure given for it.
Check of shading memory, and display of result a Press the DOCUMENT MODE SWITCH key as many times as needed to select the TEXT item. An "S-RAM TEST OK" result display indicates the memory is normal. Any other display indicates abnormality. Check result display
S-RAM TEST OK
ePress the STOP
246
chap.8
HELP mode
1. Functions
H-13

Display of amount of light received by end mark sensors
End mark sensor \See page 68,71
2. Operation procedures (1) Checking the condition of the listed switches qAccess HELP mode H-13, and press the PRINT
wSelect the sensor below and follow the procedure accordingly.

S End mark sensor1
Display of presence/absence of the master on its travel path, as a numerical value. <Sensitivity adjustment of the end mark sensor> Adjust the sensitivity using the driver to adjust end mark pcb.
Set the white level <10 and black level >50.

Make sure that the difference between black and white is "30" or larger. Press and hold down TEST PRINT key to feed master slowly.
S End mark sensor2
A: 11
B: 11
Amount of light received by end mark sensor1
Display of presence/absence of the master on its travel path, as a numerical value. Adjust the sensitivity using the driver to adjust end mark pcb. Set the white level to "0-10" and black level to "45-63". Make sure that the difference between black and white is "30" or larger. Press and hold down TEST PRINT key to feed master slowly.
A: 11
B: 11
Amount of light received by end mark sensor2
ePress the STOP
key. The HELP mode selection display will reappear. a To exit the HELP mode : Turn the power switch OFF. a To access another HELP mode : Enter the desired mode number using the numeric keys.
247
chap.8
HELP mode
1. Functions
H-14
(1) Total counts
(1) Mastermaking total counter display (2) Resetting of count of total masters made in user mode
2. Operation procedures (1) Mastermaking total counter display qAccess HELP mode H-14, and press the PRINT
For the basic procedure for accessing HELP modes. \See page 231 When the PRINT key is pressed, the total number of mastermaking is displayed. key.
F11111111
Mastermaking total counter [F] = mastermaking
wPress the STOP
(2) Resetting the count of total masters made in user mode qAccess HELP mode H-14, and press the PRINT
For the basic procedure for accessing HELP mode. \See page 231 When the PRINT key is pressed, the current value for the count of total masters made in user mode will be displayed. Press the [=] key and CLEAR C keys simultaneously, to w execute resetting. The resetting will be memorized in the main PCB unit's EEPROM. key.
ePress the STOP
248
chap.8
HELP mode
1. Functions
H-15
(1) Function testing of ink motor
2. Operation procedures 1) Testing the functioning of the ink motor qAccess HELP mode H-15, and press the PRINT
For the basic procedure for accessing HELP modes \See page 231 key.
INK MOTOR.TEST
wPress and hold the TEST PRINT

for as long as the key is held down.
IMPORTANT
key. The ink motor will run
Remember that ink will be delivered when the ink motor runs. Take any precautions necessary.
eRelease the TEST PRINT
key. The ink motor will stop.
rPress the STOP
249
chap.8
HELP mode
1. Functions
H-16
(1) Setting of online (with PC interface) mastermaking start position.
For Standards / Adjustment \See page 184 Related HELP mode HELP mode H-37 \See page 269
HELP mode H-53 \See page 276
2. Operation procedures (1) Setting of online (with PC interface) mastermaking start position. qAccess HELP mode H-16, and press the PRINT
wUse the [0] and [1] numeric keys to enter a 4-place binary value for
the desired correction amount. See the table below for 4-place binary values and the corresponding correction amounts.
ABCD 0*** Sign flag 1*** *000 *001 *010 *011 *100 *101 *110 *111 Maximum Set amount Item Setting Rises by the set amount for the lower 3 digits Lowers by the set amount for the lower 3 digits Standard (initial value)
A:1 B:1 C:1 D:1

ePress the [=]
key. The correction amount will be memorized
During memorization:
in the main PCB unit's EEPROM. During memorization, "SAVE" will be displayed.
IMPORTANT
111 SAVE 111
Do not turn off the power before the "SAVE" display has disappeared.
rPress the STOP
250
chap.8
HELP mode
1. Functions
H-17
(1) Function testing of cutter motor
2. Operation procedures (1) Testing the functioning of the cutter motor qAccess HELP mode H-17, and press the PRINT
CUTTER MTR TEST
wPress and hold down the PRINT POSITION ADJUST key. The
cutter will go to the no-operation side when right key is held on, and will come back to the operation side when left key is held on.
eTo stop the motor (and the roller), release the PRINT POSITION
ADJUST key.
rPress the STOP
reappear. a To exit the HELP mode a To access another HELP mod
251
chap.8
HELP mode
1. Functions
H-18
(1) Function testing of roll-up motor (2) Function testing the of the fan motor
2. Operation procedures (1) Testing the functioning of the roll-up motor qAccess HELP mode H-18, and press the PRINT
EJECT MOTOR TEST
w Select TEXT mode by pressing the DOCUMENT MODE SELECT key.

Press and hold down the PRINT POSITION ADJUSTENT RIGHT key. The take-up motor will rotate in the reverse direction (counterclockwise), so that the roller inside the master ejection box turns, for as long as the key is held down.
ADJUSTMENT key.
(2) Testing the functioning of the fan motor qAccess HELP mode H-18, and press the PRINT
FAN MOTOR TEST
w Select PHOTOGRAPH or TEXT/PHOTOGRAPH mode by pressing

the DOCUMENT MODE SELECT key. Press and hold down the PRINT POSITION ADJUSTMENT RIGHT key. The fan motor will rotate, so that it will inhale.for as long as the key is held down.
ADJUSTMENT key.
rPress the STOP
reappear. a To exit the HELP mode a To access another HELP mod
252
chap.8
HELP mode
1. Functions
H-19
(1) Total counts
(1) Printing total counter display (2) Resetting of count of total sheets printed in user mode
2. Operation procedures (1) 8-digit display of count of total sheets printed qAccess HELP mode H-19, and press the PRINT
For the basic procedure for accessing HELP modes. \See page 231 When the PRINT displayed. key is pressed, the total number of print is key.
"P"=Print
P11111111
wPress the STOP
Printing total counter
(2) Resetting the count of total sheets printed in user mode qAccess HELP mode H-19, and press the PRINT
For the basic procedure for accessing HELP modes. \See page 231 When the PRINT key is pressed, the current value for the count of total sheets printed in user mode will be displayed. key.
wPress the [=]
key and CLEAR
keys keys simultaneously,
to execute resetting. The resetting will be memorized in the battery PCB unit's EEPROM.
ePress the STOP
key. The HELP mode selection display will : Turn the power switch OFF.
reappear. a To exit the HELP mode
a To access another HELP mode : Enter the desired mode number using the numeric keys.
253
chap.8
HELP mode
1. Functions
H-20
(1) Function testing of clamp motor and clamp position sensing (A/B/C mode position)
For Standards / Adjustment B mode \See page 165 For Standards / Adjustment A /C mode \See page 167 For desccription of operation \See page 76
2. Operation procedures (1) Testing the functioning of the clamp motor and clamp position sensing (A/B/C mode position) qAccess HELP mode H-20, and press the PRINT
For the basic procedure for accessing HELP modes. key.
CLAMP MOTOR TEST
wPress and hold down the PRINT POSITION RIGHT key. The clamp
motor will rotate in the reverse direction (counterclockwise), opening out the clamp, for as long as the key is held down.
eTo stop opening of the clamp, release the PRINT POSITION RIGHT
key. (Alternatively, opening will stop automatically when the light beam of the A/C mode sensor (PS3) is restored).
rPress and hold down the PRINT POSITION LEFT key. The clamp motor will
rotate in the regular direction (clockwise), closing the clamp, for as long as the key is held down.
tTo stop closing of the clamp, release the PRINT POSITION LEFT key.
(Alternatively, closing will stop automatically when the light beam of the A/C mode sensor (PS3) is restored).
yPress the STOP
NOTE Whether the clamp is in the A, B or C mode position is determined by the B mode sensor and the A/C mode sensor in combination:
A mode position : When the light beam of both the B mode and A/C mode sensor is unobstructed. C mode position : When the light beam of both the B mode sensor is obstructed and that of the A/C mode sensor unobstructed. B mode position : When the B mode sensor senses edge, and the light beam of the A/C mode sensor is obstructed.
If the clamp is not in the A mode position when the power is turned on, it will rotate to the B position and stop there.
254
chap.8
c HELP Mode Function and Operation Procedures Mode H-21 is not used
HELP mode
1. Functions
H-22
(1) Setting of lengthwise zoom factor correction amount for mastermaking side
2. Operation procedures (1) Setting of lengthwise zoom factor correction amount for mastermaking side qAccess HELP mode H-22, and press the PRINT
ABCD 0*** Sign flag 1*** *000 *001 *010 *011 *100 *101 *110 *111 Maximum Set amount Item Setting Shortens by the set amount for the lower 3 digits. Lengthens by the set amount for the lower 3 digits. Standard (initial value)
A:1 B:1 C:1 D:1

1 rank: 0.16%
ePress the [=]
IMPORTANT
111 SAVE 111
rPress the STOP
255
chap.8
HELP mode
1. Functions
H-23
(1) Setting of photograph mode document sensing darkness
2. Operation procedures (1) Setting of photograph mode document sensing darkness qAccess HELP mode H-23, and press the PRINT
A:1 B:1 C:1 D:1

E:1 F: 1 G:1 H:1

Setting for ADF(When PHOTOGRAPH or TEXT/PHOTOGRAPH mode is set)
ePress the [=]
IMPORTANT
111 SAVE 111
rPress the STOP
256
chap.8
HELP mode
1. Functions
H-24
(1) Setting of reducing offset for reading longitudinal R/E scanner
2. Operation procedures (1) Setting of reducing offset for reading longitudinal R/E scanner qAccess HELP mode H-24, and press the PRINT
ABCD 0000 0001 0010 0011 1111 Set amount If help mode H-24 setting is required, HELP mode H-25 must be set to "0000". Item Setting Standard (initial value)
A:1 B:1 C:1 D:1
E:1 F: 1 G:1 H:1

1 rank: 0.25% Sign flag Correction amount display
Maximum
ePress the [=]
IMPORTANT
111 SAVE 111
rPress the STOP
257
chap.8
HELP mode
1. Functions
H-25
(1) Setting of enlarging offset for reading longitudinal R/E of scanner
2. Operation procedures (1) Setting of enlarging offset for reading longitudinal R/E of scanner qAccess HELP mode H-25, and press the PRINT
ABCD 0000 0001 0010 0011 1111 Set amount If help mode H-25 setting is required, HELP mode H-24 must be set to "0000". Item Setting Standard (initial value)
A:1 B:1 C:1 D:1
E:1 F: 1 G:1 H:1

1 rank: 0.25% Sign flag Correction amount display
Maximum
ePress the [=]
IMPORTANT
111 SAVE 111
rPress the STOP
258
chap.8
HELP mode
1. Functions
H-26
(1) Compensation of document darkness white level in photograph mode
2. Operation procedures (1) Compensation of document darkness white level in photograph mode qAccess HELP mode H-26, and press the PRINT
A:1 B:1 C:1 D:1

E:1 F: 1 G:1 H:1


ePress the [=]
IMPORTANT
111 SAVE 111
rPress the STOP
259
chap.8
HELP mode
1. Functions
H-27
(1) Initialization of all HELP mode settings
2. Operation procedures (1) Initializing all the HELP mode settings qAccess HELP mode H-27, and press the PRINT
I N I T I AL I ZE
wPress the [=]
key. The adjustment and specification settings
of the HELP modes will be initialized. (But for the total counts (H14 and H-19), only the user mode values will be initialized.) While initialization is in progress, "SAVE" will be displayed.
IMPORTANT
111 SAVE 111
ePress the STOP
IMPORTANT
For the values after initialization, see the initialization values for each mode, and the HELP decals (on the inside of the rear cover). After initialization, carry out the adjustment and specification setting operations for the various modes. Inappropriate settings will results in operational problems.
260
chap.8
HELP mode
1. Functions
H-28
(1) Setting of buzzer selection.
2. Operation procedures (1) Setting of buzzer selection. qAccess HELP mode H-28, and press the PRINT
key.
ABCD 0*** 1*** *00* *01* *10* *11* ***0 ***1 1001 Initial value Not used. Selecting buzzer. Not used. Standard (Buzzer sounds) Buzzer does not sound when trouble occurs. Does not sound Does not sound Item Setting
A:1 B:1 C:1 D:1
ePress the [=]
IMPORTANT
111 SAVE 111
rPress the STOP
261
chap.8
HELP mode
1. Functions
H-29
(1) Adjustment of master infeed amount

Feed amount is adjusted after cutter operation.
2. Operation procedures (1) Adjustment of master infeed amount qAccess HELP mode H-29, and press the PRINT
ABCD 0*** Sign flag 1*** *000 *001 *010 *011 *100 *101 *110 *111 Maximum Set amount Item Setting Shortens by the set amount for the lower 3 digits. Lengthens by the set amount for the lower 3 digits. Standard (initial value)
A:1 B:1 C:1 D:1

ePress the [=]
IMPORTANT
111 SAVE 111
rPress the STOP
262
chap.8
HELP mode
1. Functions
H-30
(1) Function checking
(1) Test pattern (all shading, secondary scanning For adjusting reduction / enlargement direction zoom factor adjustment) mastermaking and \See page 183 printing
2. Operation procedures (1) Test pattern (all shading, poor image area checking, secondary scanning direction zoom factor adjustment) mastermaking and printing qAccess HELP mode H-30, and press the PRINT
Test pattern 1
wSelect one of the items below, and follow the procedure given for it.
Test pattern 1 (all shading)
Test pattern 2
a Use the DOCUMENT MODE SWITCH PHOTOGRAPH item.
key to select the
Test pattern 2 (secondary scanning direction mastermaking area adjustment)
a Use the DOCUMENT MODE SWITCH TEXT/PHOTOGRAPH item.
key to select the
Test pattern 3 (secondary scanning direction zoom factor adjustment)
Test pattern 3
a Use the DOCUMENT MODE SWITCH TEXT item.
key to select the
IMPORTANT
Once this mode has been entered, it is not possible to switch to any other mode. To exit this mode, turn off the power.
ePress the MASTERMAKING rPress the STOP
key to implement mastermaking/printing
0sh t
1se t
263
chap.8
HELP mode
1. Functions
H-31
(1) Setting of number of pre-print sheets

Use this to set a value for the number of pre-print sheets. "Preprint sheets" are extra sheets that are printed at the start of printing, without being added to the print count.
2. Operation procedures (1) Setting of number of pre-print sheets qAccess HELP mode H-31, and press the PRINT
ABCD 0000 0001 0010 0011 0100 0101 0110 0111 Item 0 sheet(initial value) 1 sheet 2 sheets 3 sheets 4 sheets 5 sheets 6 sheets 7 sheets ABCD 1000 1001 1010 1011 1100 1101 1110 1111 8 sheets 9 sheets 10 sheets 11 sheets 12 sheets 13 sheets 14 sheets 15 sheets Item
A:1 B:1 C:1 D:1
ePress the [=]
key. The correction amount will be memorized into the main PCB unit's EEPROM. During memorization, "SAVE" will be displayed.
111 SAVE 111
IMPORTANT
rPress the STOP
264
chap.8
HELP mode
1. Functions
H-32
(1) Confidential safeguard function, selection of first print speed, setting of master ejection error sensing
2. Operation procedures (1) Confidential safeguard function, selection of first print speed, setting of master ejection error sensing qAccess HELP mode H-32, and press the PRINT
ABCD 0*** 1*** *0** *1** **0* **1* ***0 ***1 1000 Initial value Item Confidential safeguard function Disabled Setting
A:1 B:1 C:1 D:1
Enabled Selecting the first print 1st-speed (about 45 rpm) speed. /Selecting the print speed for the first sheet after mastermaking is com- JOG speed (about 15 rpm) pleted. Master mis-ejection detection Not used. Enabled Disabled
ePress the [=]
key. The correction amount will be memorized into the main PCB unit's EEPROM. During memorization,
"SAVE" will be displayed.

IMPORTANT
111 SAVE 111
rPress the STOP
265
chap.8
HELP mode
1. Functions
H-33
(1) Compensation of document darkness white level in text mode
2. Operation procedures (1) Compensation of document darkness white level in text mode qAccess HELP mode H-33, and press the PRINT
A:1 B:1 C:1 D:1

E:1 F: 1 G:1 H:1

ePress the [=]

IMPORTANT
111 SAVE 111
rPress the STOP
266
chap.8
HELP mode
1. Functions
H-35
(1) Adjustment of scanner leading edge sensing position
2. Operation procedures (1) Scanner leading edge sensing position adjustment qAccess HELP mode H-35, and press the PRINT
ABCD 0*** Sign flag 1*** *000 *001 *010 *011 *100 *101 *110 *111 Maximum Set amount Item Setting Moves to the left by the set amount of the lower 3 digits. Moves to the right by the set amount of the lower 3 digits. Standard (initial value)
A:1 B:1 C:1 D:1

E:1 F: 1 G:1 H:1

ePress the [=]

IMPORTANT
111 SAVE 111
rPress the STOP
267
chap.8
HELP mode
1. Functions
H-36
(1) Adjustment of scanner widthwise (operation side) sensing position
2. Operation procedures (1) Scanner widthwise (operation side) sensing position adjustment qAccess HELP mode H-36, and press the PRINT
For the basic procedure for accessing HELP modes. \See page 231 Use the [0] and [1] numeric keys to enter a 4-place binary value for w the desired correction amount. See the table below for 4-place binary values and the corresponding correction amounts.
ABCD 0*** Sign flag 1*** *000 *001 *010 *011 *100 *101 ***1 *111 Maximum Set amount Item Setting Moves toward you by the set amount of the lower 3 digits. Moves backward by the set amount of the lower 3 digits. Standard (initial value)
key.
A:1 B:1 C:1 D:1

E:1 F: 1 G:1 H:1

ePress the [=]

IMPORTANT
111 SAVE 111
rPress the STOP
268
chap.8
HELP mode
1. Functions
H-37
(1) Adjustment of mastermaking start position when For Standards / Adjustment scanner is used \See page 185
Related HELP mode HELP mode H-16 \See page 250
2. Operation procedures (1) Adjustment of mastermaking start position when scanner is used qAccess HELP mode H-37, and press the PRINT
A:1 B:1 C:1 D:1

E:1 F: 1 G:1 H:1


ePress the [=]
into the main PCB unit's EEPROM. During memorization, "SAVE" will be displayed.
IMPORTANT
111 SAVE 111
rPress the STOP
269
chap.8
HELP mode
1. Functions
H-38
(1)Adjustment of print speed automatically.
The drum rotates 2. Operation procedures
\See page 233
qAccess HELP mode H-38, and press the PRINT

For the basic procedure for accessing HELP modes.
key. \See page 231
w It will adjust speed of drum rotation automatically within 1 min.

IMPORTANT
SPEED 1-7
Do not turn off the power before the "SAVE" display has disappeared. Before this operation, you must set drum accurately first.
ePress the STOP
111 SAVE 111
270
chap.8
HELP mode
1. Functions
H-39
(1) Function checking
(1) Function testing of clutch test and Auto power off
2. Operation procedures (1) Correction of outline highlight when scanner is used qAccess HELP mode H-39, and press the PRINT
w Use these keys to test each function.

a Use the DOCUMENT MODE SWITCH TEXT item. key to select the
CLUTCH TEST
Press and hold down the PRINT POSITION ADJUST RIGHT key. The ADF clutch will be on, for as long as the key is held down. a Use the DOCUMENT MODE SWITCH key to select the PHOTOGRAPH/TEXT item. Press and hold down the PRINT POSITION ADJUST RIGHT key. The Mater feed clutch will be on, for as long as the key is held down. a Use the DOCUMENT MODE SWITCH key to select the PHOTOGRAPH item. Press and hold down the PRINT POSITION ADJUST RIGHT key. The Paper feed clutch will be on, for as long as the key is held down. a Use the TEST PRINT key to test the function of Auto power off.
IMPORTANT
Please do not press the key for long time,It would be injured.
e Press the STOP
271
chap.8
c HELP Mode Function and Operation Procedures Modes H-40 is not used.
HELP mode
1. Functions
H-41
(1) Automatic initialization of the control panel setting, Energy save mode setting setting of repeat count display Automatic POWER off setting (only available with optional Automatic power off kit) 2. Operation procedures (1) Automatic initialization of the control panel setting, setting of repeat count display qAccess HELP mode H-41, and press the PRINT
ABCD 0*** 1*** *0** *1** **0* **1* ***0 ***1 0000 Item Automatic initialization of the control panel setting Setting No automatic iniialization Initialized in about 2 minutes No energy save mode Energy save after no operation 3 min. Repeat display of count Count repeat display No repeat display of count Automatic power off setting No automatic power off (only available with optional Auto off after no operation 5 min. Automatic power off kit) Initial value
A:1 B:1 C:1 D:1
Energy save mode setting
ePress the [=]

IMPORTANT
111 SAVE 111
rPress the STOP
272
chap.8
HELP mode
1. Functions
H-42
(1) Setting of paper selection specification
2. Operation procedures (1) Scanner leading edge sensing position adjustment qAccess HELP mode H-42, and press the PRINT
A:1 B:1 C:1 D:1

ABCD 00** 10** *0** *1** **00 **01 **10 **11 0000 Initial value Not used Item Paper selecting specifications (A/B size) Paper selecting specifications (inch) Not used B4/A4/B5/A5 10914/LTLG/ST/POST Setting
ePress the [=]

IMPORTANT
111 SAVE 111
rPress the STOP
273
chap.7
HELP mode 1. Functions
H-43
(1)Adjustment/specication setting
(1) Setting of thermal head offset value
2. Operating Procedure
(1) Setting of thermal head offset value 1. Access HELP mode H-43, and press the PRINT key. 2. Use the [0] and [1] NUMERIC keys to enter a 4-place binary value for the preferred correction amount. (adjusted in increments of approx. 1mm)
ABCD 0111 0110 0101 0100 0011 0010 0001 0000 1000 1001 1010 1011 1100 1101 1110 1111 Correction amount -5 -5 -5 -4 -3 -2 -1 0 0 +1 +2 +3 +4 +5 +5 +5 \See page 231
A:1 B:1 C:1 D:1

Lighter than default
No change
Darker than default
3. Press the " " key. The setting will be memorized. During memorization, SAVE will be displayed.
IMPORTANT
Do not turn off the power before the SAVE display has disappeared. 4. Press the STOP key. The HELP mode selection display will appear. To exit the HELP mode: Turn the power switch OFF. To access another HELP mode: Enter the preferred mode number using the NUMERIC keys.
274
chap.8
HELP mode
1. Functions
H-44
(1) Setting of thermal head resistance ranking
2. Operation procedures (1) Setting of thermal head resistance ranking qAccess HELP mode H-44, and press the PRINT
A:1 B:1 C:1 D:1

Sign flag
ABCD 0000 0001 0010 0011 0100 0101 0110 0111 1000 1001 1010 1011 1100 1101 1110 1111
Resistance 3825-3908 3909-3993 3994-4077 4078-4162 4163-4246 4247-4330 4331-4415 4416-4499 4500-4583 4584-4668 4669-4752 4753-4837 4838-4921 4922-5005 5006-5090 5091-5175
ePress the [=]
IMPORTANT
111 SAVE 111
rPress the STOP
275
chap.8
c HELP Mode Function and Operation Procedures Mode H-45, 46, 47, 48 and 49 are not used
HELP mode
1. Functions
H-50
(1) Setting of text mode document sensing darkness
2. Operation procedures (1) Setting of text mode document sensing darkness qAccess HELP mode H-50, and press the PRINT
Display 0*** Sign flag 1*** *000 *001 *010 *011 *100 *101 *110 *111 Maximum Set amount Item Setting Lighter by the set amount for the lower 3 digits Darker by the set amount for the lower 3 digits Standard (initial value)
A:1 B:1 C:1 D:1

E:1 F: 1 G:1 H:1

ePress the [=]
IMPORTANT
111 SAVE 111
rPress the STOP
276
chap.8
c HELP Mode Function and Operation Procedures Mode H-51 and 52 are not used
HELP mode
1. Functions
H-53
(1) Adjustment of widthwise (operation side) mastermaking start position for online mastermaking
Related HELP mode HELP mode H-16 \See page 250
2. Operation procedures (1) Adjustment of widthwise (operation side) mastermaking start position for online mastermaking qAccess HELP mode H-53, and press the PRINT
ABCD 0*** Sign flag 1*** *000 *001 *010 *011 *100 *101 ***1 *111 Maximum Set amount Item Setting Moves toward you by the set amount of the lower 3 digits. Moves backward by the set amount of the lower 3 digits. Standard (initial value)
A:1 B:1 C:1 D:1

ePress the [=]
IMPORTANT
111 SAVE 111
rPress the STOP
277
chap.8
c HELP Mode Function and Operation Procedures Mode H-54 is not used.
HELP mode
1. Functions
H-55
(1) Setting of ink check at printing start, cutting operation mode for master cutting, and interlocks 2. Operation procedures (1) Setting of ink check at printing start, cutting operation mode for master cutting, and interlocks qAccess HELP mode H-55, and press the PRINT
ABCD 0*** 1*** *0** *1** **0* **1* ***0 ***1 0110 Item Setting of ink check, that triggers ink replenishment if no ink is detected at printing start Selection of cutter operation mode Interlock: emergency stop if top cover or ejection box open Not used Initial value Disabled Enabled 1 stroke = one-way motion 1 stroke = reciprocating motion Activated Deactivated Setting
A:1 B:1 C:1 D:1
ePress the [=]
111 SAVE 111
IMPORTANT
rPress the STOP
278
chap.8
HELP mode
1. Functions
H-56
(1) Setting for selecting manipulation language 2. Operation procedures (1) Setting for selecting manipulation language qAccess HELP mode H-56, and press the PRINT
ABCD 0000 0001 0010 0011 0100 0101 0110 0111 1000 1001 1010 1011 1100 1101 Thai Polish Manipulation language Japanese Korean Chinese Simplified1 Chinese Simplified2 English Spanish German French Italian Russian Traditional Chinese
A:1 B:1 C:1 D:1
ePress the [=]
key. The correction amount will be memorized into the main PCB unit's EEPROM. During memorization, "FONT UPDATE"and "SAVE" will be displayed.
FONT UPDATE
IMPORTANT
111 SAVE 111
rPress the STOP
279
chap.8
c HELP Mode Function and Operation Procedures Mode H-57, H-58 are not used
HELP mode
1. Functions
H-59
(1) Setting for end mark sensor 2
2. Operation procedures (1) Setting for end mark sensor 2 . qAccess HELP mode H-59, and press the PRINTkey.
Display * 0 ** * 1 ** 0 1 1 0 Item Setting for end mark sensor 2 Factory setting
Disabled Enabled
A:1 B:1 C:1 D:1
Setting Correction amount display
ePress the [=]
111 SAVE 111
IMPORTANT
rPress the STOP
280
chap.8
c HELP Mode Function and Operation Procedures Mode H-60 are not used
HELP mode
1. Functions
H-61
(1) Function test for LCD screen and LED indicators
2. Operation procedures (1) Function test for LCD screen and LED indicators qAccess HELP mode H-61, and press the PRINT
wThe LCD screen will be displayed as right. All of the LED

will be twinkling.
HELP SELECT 61 0000000000000000
e Press the STOP
281
chap.8
HELP mode
1. Functions
H-63
(1) Setting for A4 master cut
2. Operation procedures (1) Setting for A4 master cut . qAccess HELP mode H-63, and press the PRINT
Display * 0 ** * 1 ** 0 1 0 0 Item Setting for A4 master cut B4/LG size master cut Factory setting Setting A4 size master cut
A:1 B:1 C:1 D:1
ePress the [=]
111 SAVE 111
IMPORTANT
rPress the STOP
282
chap.8
HELP mode
1. Functions
H-64
(1) Buzzer (tone) setting
2. Operation procedures (1) Buzzer (tone) setting qAccess HELP mode H-64, and press the PRINT
A:1 B:1 C:1 D:1

Sign flag
ABCD 0*** *000 *001 *010 *011 Set amount Sign flag
Item Tone setting
Setting
Standard (initial value : 0000) Tone adjusting Maximum
ePress the [=]
111 SAVE 111
IMPORTANT
rPress the STOP
283
chap.8
HELP mode
1. Functions
H-66
(1) Setting: clamp opening/closing timing of when a master is attached; Help 67/68 ON/OFF.
2. Operation procedures (1) Setting: clamp opening/closing timing of when a master is attached; Help 67/68 ON/OFF.
\See page 231
qAccess HELP mode H-66, and press the PRINT

key.
A:1 B:1 C:1 D:1
ABCD 0*** 1*** *0** *1** *10* *11* ***0 ***1 0000 Not used
Item Setting for master clamp opening/closing timing for master attachment Setting of HELP 67/68 ON/OFF Not used C mode
Setting master feed out C mode B mode B mode
master feed out OFF ON
At shipment
ePress the [=]
111 SAVE 111
IMPORTANT
rPress the STOP
284
chap.8
HELP mode
1. Functions
H-67
(1) Setting of paper feed length.
2. Operation procedures (1) Setting of paper feed length. qAccess HELP mode H-67, and press the PRINT
A:1 B:1 C:1 D:1

ABCD 0000 0001 0010 0*** 0111 1000 1*** 1101 1110 1111
0101 Initial value
Item Min
Setting
Set amount
Max
ePress the [=]
IMPORTANT
111 SAVE 111
rPress the STOP
285
chap.8
HELP mode
1. Functions
H-68
(1) Setting of paper feed angle
2. Operation procedures (1) Setting of paper feed angle qAccess HELP mode H-68, and press the PRINT
A:1 B:1 C:1 D:1

ABCD 0*** Sign flag 1*** *000 *001 *010 *011 *100 *101 *110 *111 Maximum Set amount Item Setting Smaller the paper feed angle (The set amount for the lower 3 digits) Larger the paper feed angle (The set amount for the lower 3 digits) Standard (initial value)
ePress the [=]
IMPORTANT
111 SAVE 111
rPress the STOP
286
chap.8
HELP mode
1. Functions
H-69
(1) Setting of model
2. Operation procedures (1) Setting of model qAccess HELP mode H-69, and press the PRINT
A:1 B:1 C:1 D:1
ABCD 0000 0001 0011
Item B4 SIZE Setting of model LEGAL SIZE A4 SIZE
Setting
ePress the [=]

IMPORTANT
111 SAVE 111
rPress the STOP
287
chap.8
HELP mode
1. Functions
H-72
(1) Adjustment for mastermaking area lenghth.
2. Operation procedures (1) Adjustment for mastermaking area lenghth. qAccess HELP mode H-72, and press the PRINT
A:1 B:1 C:1 D:1

ABCD 0*** Sign flag 1*** *000 *001 *010 *011 *100 *101 ***1 *111 Maximum Set amount Item Setting Mastermaking area lenghth shorter amount of the lower 3 digits. Mastermaking area lenghth longer amount of the lower 3 digits. Standard (initial value)
ePress the [=]

IMPORTANT
111 SAVE 111
rPress the STOP
288
chap.8
HELP mode
1. Functions
H-73
(1) Adjustment for mastermaking area lenghth on online printing
2. Operation procedures (1)Adjustment for mastermaking area lenghth on online printing qAccess HELP mode H-73, and press the PRINT
ABCD 0*** Sign flag 1*** *000 *001 *010 *011 *100 *101 ***1 *111 Maximum Set amount Item Setting Mastermaking area lenghth shorter amount of the lower 3 digits. Mastermaking area lenghth longer amount of the lower 3 digits. Standard (initial value)
A:1 B:1 C:1 D:1
ePress the [=]
IMPORTANT
111 SAVE 111
rPress the STOP
289
chap.8
HELP mode
1. Functions
H-74
(1) Setting of thermal head temperature Supplementing and master making darkness rank.
2. Operation procedures (1) Setting of thermal head temperature Supplementing and master making darkness rank. qAccess HELP mode H-74, and press the PRINT
key. \See page 231
ABCD *0** *1** ***0 ***1 Item Setting of thermal head temperature Supplementing Setting of master making darkness rank Setting Disabled (initial value) Enabled 3 ranks.(initial value) 5 ranks.
A:1 B:1 C:1 D:1
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
key. The HELP mode selection display will : Turn the power switch OFF.
reappear. a To exit the HELP mode
a To access another HELP mode : Enter the desired mode number using the numeric keys.
290
chap.8
HELP mode
1. Functions
H-76
(1) Document darkness correction for text/photograph mode
2. Operation procedures (1) Document darkness correction for text/photograph mode qAccess HELP mode H-76, and press the PRINT
key. \See page 231
ABCD 00** 01** 10** 11** Setting Item Setting Normal (initial value) Slightly lighter Slightly darker Much darker
A:1 B:1 C:1 D:1
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
291
chap.8
Mode H-77-79 are not used
HELP mode
1. Functions
H-80
(1) Setting of print speed rank Setting of ADF Setting of INK save mode
2. Operation procedures (1) Setting of speed rank,ADF and Ink save mode. qAccess HELP mode H-80, and press the PRINT
ABCD 0*** Setting of speed rank 1*** *0** *1** **0* Not used **1* ***0 ***1 0101 Setting of Ink save mode Initial value OFF ON Setting of ADF 5 print speed ranks With optional ADF Item Setting
A:1 B:1 C:1 D:1

3 print speed ranks
Without optional ADF
IMPORTANT
Please adjust the drum speed by using H-38 when setting of print speed rank is changed.
ePress the [=]
IMPORTANT
111 SAVE 111
rPress the STOP
292
chap.8
c HELP Mode Function and Operation Procedures Mode H-81 and H-82 are not used
HELP mode
1. Functions
H-83 (ADF)
(1) ROM version displays
(1) Display of ROM version

Displays version of the ADF PCB unit's ROM.
2. Operation procedure (1) Displaying ROM version qAccess HELP mode H-83, and press the PRINT
key. \See page 231
Displaying ROM version
ADF OP
V1 . 11
Displays version of the ROM.

ADF PCB unit
wPress the STOP
293
chap.8
HELP mode
1. Functions
H-84 (ADF)
(1) Checking of communication
(1) Checking of communication for ADF
2. Operation procedure (1) Checking of communication for ADF qAccess HELP mode H-84, and press the PRINT
key. \See page 231

Displaying ADF status.
Perform a communication check between the ADF and the main board. If an error is indicated, refer to the Troubleshooting Guide for a solution.
ADF OK
When ADF error accoured.
ADF ERROR
wPress the STOP
294
chap.8
HELP mode
1. Functions
H-85
(1) Adjustment for image sampling timing of scanning(for use in factory checks).
2. Operation procedures (1) Adjustment for image sampling timing of scanning. qAccess HELP mode H-85, and press the PRINT
ABCD 0000 *001 *010 *011 *100 *101 *110 *111 0000 Factrory seeting Adjustment for image Item 1/8 2/8 3/8 Setting
A:1 B:1 C:1 D:1
sampling timing of scanning 4/8 5/8 6/8 7/8 8/8
IMPORTANT
Do not change this setting,otherwise the image will be changed.
ePress the [=]
IMPORTANT
111 SAVE 111
rPress the STOP
295
chap.8
HELP mode
1. Functions
H-86
(1) Setting of manual batch printing
2. Operation procedures (1) Setting of manual batch printing qAccess HELP mode H-86, and press the PRINT
ABCD 0*** 1*** *00* *01* *10* *11* ***0 ***1 0000 Initial value Not used Time between sets on Item Manual batch printing mode ON/OFF setting OFF ON 1.5 sec. 3 sec. Setting
A:1 B:1 C:1 D:1
manual batch printing mode 5 sec. 10 sec.
ePress the [=]

IMPORTANT
111 SAVE 111
rPress the STOP
296
chap.8
Mode H-87/88 are not used
HELP mode
1. Functions
H-89
(1) Setting of several special functions.
2. Operation procedures (1) Setting of several special functions of A-D. q Use the DOCUMENT MODE SWITCH
TEXT item. key to select the key.
wAccess HELP mode H-89, and press the PRINT
e Use the [0] and [1] numeric keys to enter a 4-place binary value for
ABCD 0*** 1*** *0** *1** **0* Setting of User ID function **1* ***0 ***1 0000 Setting of special zoom 60%,130% Initial value Item Setting
A:1 B:1 C:1 D:1
2IN1 with scanner. (Only for China)
Disabled. Enabled.
Not used.
Disabled. Enabled. Disabled. Enabled.
r Press the [=]
IMPORTANT
111 SAVE 111
t Press the STOP
297
chap.8
HELP mode
H-89
(2) Setting of several special functions of E-H. q Use the DOCUMENT MODE SWITCH
TEXT/PHOTOGRAPH item. key to select the
w Access HELP mode H-89, and press the PRINT
EFGH 0*** Setting of 94% 1*** *0** *1** **0* 2IN1(Only available with ADF) **1* ***0 ***1 0000 Book Shadow Eraser Mode Initial value Disabled Enabled Disabled 4-up,8-up Disabled Item Enabled Setting
E:1 F: 1 G:1 H:1

Enabled Disabled Enabled
r Press the [=]

IMPORTANT
111 SAVE 111
t Press the STOP
298
chap.8
HELP mode
H-89
(3) Setting of several special functions of I-L. q Use the DOCUMENT MODE SWITCH
PHOTOGRAPH item. key to select the
w Access HELP mode H-89, and press the PRINT
key.
IJKL 0***
Item Disabled Setting of special zoom 150% Enabled
Setting
I: 1 J: 1 K: 1 L: 1
1*** *0** *1** **0* **1* ***0 ***1 0000

Not used. Setting of min.printing paper limit of 50 Setting of master making without printing. Initial value Disabled Enabled Disabled Enabled
r Press the [=]
IMPORTANT
111 SAVE 111
t Press the STOP

reappear.
a To exit the HELP mode : Turn the power switch OFF. a To access another HELP mode : Enter the desired mode number using the numeric keys.
299
chap.8
Mode H-87-89 are not used
HELP mode
1. Functions
H-90
(1) Setting of Tape cluster
2. Operation procedures (1) Setting of Tape cluster qAccess HELP mode H-90, and press the PRINT
A:1 B:1 C:1 D:1
ABCD 0***
Item Disabled Setting of tape cluster Enabled Setting of drum action
Setting
1*** *0** *1** **0* **1* ***0 ***1 0000 Setting of timing of tape inserting
Stop waiting for tape inserting. Do not stop.(only for TAP-14) Insert and cut after printing.
Insert before printing,cut after printing Divided by same tape lenghth Divided by difference tape lenghth.
Setting of tape lenghth Initial value
ePress the [=]
IMPORTANT
111 SAVE 111
rPress the STOP
300
chap.8
HELP mode
1. Functions
H-91
(1) Setting of tape lenghth for Tape cluster on online mode
2. Operation procedures (1) Setting of tape lenghth for Tape cluster on online mode qAccess HELP mode H-91, and press the PRINT
A:1 B:1 C:1 D:1
ABCD 0*** Not used 1*** *0** *1** **0* Not used **1* ***0 ***1 0000 Not used
Item
Setting
Setting of tape lenghth on = short lenghth online mode Initial value = long lenghth
ePress the [=]
IMPORTANT
111 SAVE 111
Do not turn off the power before the "SAVE" display has disappeared. key. The HELP mode selection display will reappear. a To exit the HELP mode : Turn the power switch OFF. a To access another HELP mode : Enter the desired mode number using the numeric keys.
rPress the STOP
301
chap.8
HELP mode
1. Functions
H-92
(1) Setting of tape length for Tape cluster
2. Operation procedures (1) Setting of tape length for Tape cluster qAccess HELP mode H-92, and press the PRINT
wUse the numeric keys to enter a 2-bit value from 23-50 for
the desired correction amount.
TAPE LENGTH1:28
TAPE LENGTH1(Setting for short tape length):
a Use the DOCUMENT MODE SWITCH TEXT item.
key to select the
TAPE LENGTH2(Setting for long tape length):
a Use the DOCUMENT MODE SWITCH TEXT/PHOTOGRAPH or PHOTOGRAPH item. Note: Unit is cm.
key to select the
TAPE LENGTH2:28
ePress the [=]
IMPORTANT
111 SAVE 111
rPress the STOP
302
chap.8
HELP mode
1. Functions
H-93
(1) Adjustment of widthwise (operation side) scaning start position for 4-up and 8-up
2. Operation procedures (1) Adjustment of widthwise (operation side) scaning start position for 4-up and 8-up qAccess HELP mode H-93, and press the PRINT
ABCD 0*** Sign flag 1*** *000 *001 *010 *011 *100 *101 ***1 *111 Maximum Set amount Moves backward by the set amount of the lower 3 digits. Standard (initial value) Item Setting Moves toward you by the set amount of the lower 3 digits.
A:1 B:1 C:1 D:1

E:1 F: 1 G:1 H:1

ePress the [=]
IMPORTANT
111 SAVE 111
rPress the STOP
303
chap.8
HELP mode
1. Functions
H-94
(1) UID ADMINISTRATOR password reset
2. Operation procedures (1) UID ADMINISTRATOR password reset qAccess HELP mode H-94, and press the PRINT
wPress the [=]
key and CLEAR
keys keys simultaneously,
to execute resetting. The resetting will be memorized in the main PCB unit's EEPROM. After resetting ,the password of UID ADMINISTRATOR will be reset to "000000".
CLEAR ADMIN PW
ePress the STOP
304
chap.8
Mode H-95/96 are not used
HELP mode
1. Functions
H-97
(1) The display for machine model.
2. Operation procedures (1) The display for machine model. qAccess HELP mode H-97, and press the PRINT
w The machine model will be displayed as right.

The machine model is used on online mode.
DP-M4*0
Correction display
ePress the STOP
305
MEMO
306
Chapter 9 8
Others
z Electrical Parts Layout and Their Functions...........308 (1) Switch / Clutches ................................................. 308 (2) Sensors..................................................................309 (3) Lamps / Motors.....................................................310 (4) PCB unit................................................................311 (5) Connector VR/LED Layout and Functions..........312 x Overall Wiring Layout................................................314
9
307
chap.9
z Electrical Parts Layout and Their Functions
Electrical Parts Layout and Their Functions
(1) Switches/Clutches
10 5
3 1 8
2 6 7
4
Item No. 1 2 Microswitch/switch 3 4 5 6 Push switch Clutch 7 8 9 10 Functions Whether the drum is set or not is detected. Opening and closing of the front cover is detected. Whether the master ejection core is set or not and full or not is detected. Power switch Opening and closing of the Scanner is detected. Elevator lower limit switch Paper feed elevator descent switch JOG switch (drum rotator switch) Master feeding clutch Paper feed clutch
308
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(2) Sensors
5 6 1 11 10 8 3 4 2 15 16 18
13
14
12
17
Item
No. 1 2 3 4 5 6
Functions Fixed document home position is detected. ADF home position is detected. Master clamp opening and closing lever A/C mode is detected. Master clamp opening and closing lever B mode is detected. Drum home position and JAM detection position are detected. Master attachment/detachment position is detected. Main motor encoder sensor. Press roller ON and OFF is detected. Paper feed elevator top limit detection. Print position limit of the print position is detected. Center position of the print position adjustment is detected. Weather the paper is placed or not is detected. Master feed is detected. Paper feed Length is detected. Photo-emitting of the master ejection and JAM detection sensor. Master is detected at the inlet of the master ejection box. Paper on the paper delivery side is detected. Detection of paper on paper ejection side.
Microsensor
7 8 9 10 11 12 13
Photointerrupter Master ejection sensor photo-emitting Master ejection sensor photo-emitting Jam sensor photo-receiving Jam sensor photo-emitting
14 15 16 17 18
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(3) Lamps/Motors
1 10 5 8 6
4 7
12 9
2 11 3
Item Lamp Thermal head
No. 1 2 3 4 5 6 Document lamp Thermal head Main motor Paper feed tray elevator motor
Functions
Master clamp opening/closing lever motor Roll-up motor Cutter motor Print position adjusting motor Ink pump motor Scanner stepping motor Mastermaking stepping motor Paper ejection fan
Motor
7 8 9 10 11
Fan motor
12
310
chap.9
(4) PCB unit

7 1 6
Item Main PCB unit Control panel PCB unit Ink detection PCB unit Regulated power supply End mark sensor PCB unit Inverter PCB unit CCD PCB unit
No. 1 2 3 4 5 6 7
Functions Processing the image and controlling the machine on the whole. Control panel key, display. Detecting Ink amount in the drum. Supplying with DC power supply. Detection of master presence on master feed travel path, and end mark. Lamp lights up. Reading the picture image.
DP-24S
311
chap.9
(5) Connector VR/LED Layout and Functions

1) Main PCB unit
J2(28P) J1(24P) J3(16P) J4(24P)
J11(16P)
U13
UNIT U6-V502* U19 J10(5P) J6(32P)
U23
J9(4P)
J12(16P)
J8(24P)
J7(30P)
IMPORTANT: CAUTION when replacing the main PCB

Never fail to replace a new EP ROM on a new main PCB with the old one on the old main PCB. The EP ROM on the old main PCB has the data already memorized and the data in the EP ROM are not reflected if they are not exchanged.
2) Control Panel PCB unit
J2
UNIT U6-V500*
3) Ink Detection PCB unit
LED
CN 1
312
J5(12P)
chap.9
4) Regulated power supply
F1(FUSE)
CN1
AC250V T5AH
UA043
5) End Mark Sensor PCB unit
VR VR1
Function Sensor sensitivity adjustment
6) Inverter PCB unit
7) CCD PCB unit
CN 1
CN 1
CN 2
CCD
IMPORTANT:
Do not to remove and replace the CCD PCB unit,otherwise,it is necessary to adjust in factory.
313
CN51
CN53
x Overall Wiring Layout
SCANNER
314
MASTER DETACHMENT/ ATTACHMENT POSITION SENSOR CUTTER LIMIT SW(FRONT) CUTTER LIMIT SW(REAR)
315
ENDMARK SENSOR PCB UNIT 1
ENDMARK SENSOR PCB UNIT 2
ELEVATOR DESCEND SW
chap.9
z Electorical Parts Layout and Their Functions
Reproduction prohibited
Issued by : DUPLO CORPORATION
U6-Y1100
DUPLO DP-M400/M410/M420 U6-Y1100

Manual Servicio Dp-m410

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Manual Servicio Dp-m410

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SERVICE MANUAL

Copyright 2009 DUPLO SEIKO CORPORATION All Rights Reserved

D Using the service manual

Examples of pictorial symbols

2. Cautions for installation work

} Use power supply meeting these requirements

} Use power supply meeting these requirements

3. Cautions for maintenance, inspection and servicing

DLocations of warning stickers

Parts No. M7-T3060 U5-T3110 J3-T3200 M7-T3030 L5-T3020

Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 Chapter 9

Description of the Operation

z DUPRINTER Installation Instructions....................192

z Guaranteed Periodical Maintenance......................204 x Cleaning and Oiling.................................................204 c Periodical Maintenance...........................................205

Description of the Operation

z Troubleshooting Guide............................................208 x Error Display............................................................223

z Electrical Parts Layout and Their Functions.........308 x Overall Wiring Layout..............................................314

8 Ink save mode

This mode can save ink.

Max. 297mm x 420mm Min. 100mm x 148mm

Max. 297mm x 364mm Min. 100mm x 148mm

Paper thickness Printing speed Print enlargement/reduction

Inch size model

Printing position adjustment Vertical: 15mm

Horizontal: 15mm(Paper Width: 297 5mm)

Master darkness: 3 steps

Specifications Product name/model Power source Size

Weight Operating temperature Ink

600ml package only

* Specifications are subject to change without notice.

Master ejection box

Drum unit Feeder roller Paper Paper stripper finger

Press roller Paper sepatator unit

Paper ejection belt Fan unit

S5-ADF Duplo Direct Print System TAPE CLUSTER 13

Cabinet (Printer stand)

, Part Names and Their Functions

,Part Names and Their Functions

, Part Names and Their Functions

Master set switch/ Thermal head escape lever

Ink pack holder release lever

Drum securing lever

, Part Names and Their Functions

Master ejection core

Master ejection box release lever

Master ejection box lid release lever Master ejection box

Paper stacker guides

Print tray JOG switch (Drum rotator switch) Jamp plate

, Part Names and Their Functions

2. Sectional (structural) view of the machine

, Part Names and Their Functions

Section Name Scanner section

Description of the Operation

, Part Names and Their Functions

No. q w LCD panel

Document mode indicator lamps

, Part Names and Their Functions

MASTERMAKING key PRINT key STOP key

, Part Names and Their Functions

(2). LCD Panel

Printing position adjustment Printing speed adjustment Test print key

Input the number of prints and the number of sets

0 Error Messages and Corrective Action