DP-M410 Service Manual PDF

SERVICE MANUAL
DUPRINTER
DP-M400/M410/M420
Dec. 2009 Revision 0

DUPLO DP-M400/M410/M420　U6-Y1100
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 possi-
ble 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 precau-
tions as necessary. When performing repair or service work not covered by this man-
ual, 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.
2
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: 10y430y
Ambient humidity: 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.
3
Safety instructions
2. Cautions for installation work
Warning
• The machine's power supply voltage and power consumption depend on the model. Details of this
are given in the tables below. The power supply voltage and power consumption for the machine
are given in the table below. The machine's power supply voltage is indicated on the identification
plate located on the machine's left side; the machine must be connected to a power supply of the
voltage indicated.
a Otherwise, fire or electric shock could result.
If the power supply voltage is unstable or if the power supply has insufficient capacity, the
machine may not operate normally.
Make sure that the power supply has sufficient capacity for the system as a whole, including
optional equipment.
* 120V AC model
Power supply voltage Connect to outlet of 120V AC, 60Hz, at least 15A
With no load*
At full load
No more than 130V AC
At least 110V AC } Use power supply meeting these requirements
During mastermaking : 95W
Power consumption During printing at speed 3 (printing speed) : 135W
On standby : 19W
* 230V AC model
Power supply voltage Connect to outlet of 230V AC, 50Hz, at least 8A
With no load*
At full load
No more than 250V AC
At least 210V AC } Use power supply meeting these requirements
During mastermaking : 95W
Power consumption 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.
5
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 CAUTION
2
WARNING M7-T3060
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. U5-T3110 2
3
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. Parts No. Name Q'ty

1 M7-T3060 Caution Label 1
2 U5-T3110 Warning Label 1
3 J3-T3200 Warning Label 1
4 M7-T3030 Warning Label 1
5 L5-T3020 Warning Label 1
6
Chapter 1
Introduction
Chapter 2
Description of the Operation
Chapter 3
Mechanism
Chapter 4
Standard / Adjustment
Chapter 5
Installation
Chapter 6
Maintenance / Check
Chapter 7
Troubleshooting
Chapter 8
HELP Mode
Chapter 9
Others
7
8
Table of Contents
Introduction.................................................................................1
Using the service manual ..........................................................2
Chapter 4 Standards / Adjustment
Safety instructions ...............................................................3 z Scanner Section.......................................................159
1.Cautions regarding the installation location........................3 x Mastermaking/Master Feed/Ejection Section........161
2.Cautions for installation work ...............................................4 c Paper Feed Section..................................................169
3.Cautions for maintenance, inspection and servicing .........5 v Drum Driving Section..............................................174
• Locations of warning stickers................................................6 b Press Section...........................................................176
n Paper Ejection Section............................................178
m Drum Section...........................................................179
Chapter 1 Introduction
, Electrical System.....................................................183
z Features................................................................................12
x Specifications ......................................................................14
c Dimensions ..........................................................................16
v Mechanism ...........................................................................17 Chapter 5 Installation
b Master ...................................................................................18 z DUPRINTER Installation Instructions....................192
n Ink..........................................................................................19
m System Setup .......................................................................20
, Part Names and Their Functions........................................21 Chapter 6 Maintenance / Check
. Operation Procedures .........................................................29
z Guaranteed Periodical Maintenance......................204
⁄0 Error Messages and Corrective Action .............................30
x Cleaning and Oiling.................................................204
c Periodical Maintenance...........................................205
Chapter 2 Description of the Operation

Chapter 7 Troubleshooting
z Scanner Section.........................................................55
z Troubleshooting Guide............................................208
x Mastermaking/Master Feed/Ejection Section......... 59
x Error Display............................................................223
c Paper Feed Section....................................................82
v Drum Driving Section................................................95
b Press Section............................................................101 Chapter 8 HELP Mode
n Paper Ejection Section............................................104
m Drum Section...........................................................109 z HELP Mode List.......................................................226
x Overview...................................................................230
c HELP Mode Functions and Operation Procedures .......231
(1)Basic Procedure for Accessing HELP Modes...231
Chapter 3 Mechanism (2)Guide to the HELP Mode Descriptions..............231
(3)Guide to version up.............................................232
z Exterior.....................................................................119
• HELP Mode Descriptions.....................................233
x Scanner Section.......................................................125
c Mastermaking/Master Feed/Ejection Section....... 131
v Paper Feed Section..................................................140 Chapter 9 Others
b Drum Driving Section..............................................145
n Paper Ejection Section............................................147 z Electrical Parts Layout and Their Functions.........308
m Drum Section...........................................................150 x Overall Wiring Layout..............................................314
9
10
1
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
11
chap.1 z Features
zFeatures
1. Size B4 printing (DP-M420)
The DP-M420 has size B4 (250 X 355mm) printing area. Size A/B models
The DP-M410 has size LG(210 X347mm) printing area. • Zoom settings (70, 81, 86, 115, 122, 141%)
The DP-M400 has size A4 (204X288mm) printing area. • Same-size (100%) printing
2. High-speed platemaking
DP-M420
With the DP-M400/410/420 , it takes 21 seconds *1 to Free zoom 50% -200% ( 1% )
print the first sheet of paper(A4,100%). 141% [B5/B4, A5/A4]
Enlargement 122% [A4/B4, A5/B5]
*1: Time required to print the first sheet of paper after
the mastermaking key is pressed. 115% [B5/A4]
86% [A3/B4, A4/B5]
Reduction 81% [B4/A4, B5/A5]
3. High print quality
A new, originally-developed superfine thermal head 70% [A3/A4, B4/B5]
gives beautifully accurate reproductions of fine print
and halftone photographs. DP-M400
Its resolution is 300dpi in the main scanning Free zoom 50% -200% ( 1% )
direction and 600dpi in the sub scanning direction. 141% [A5/A4]
Enlargement 122% [A5/B5]
4. Align paper 115% [B5/A4]
Adjusting the eject enables both thin and thick 86% [A4/B5]
sheets of paper to be aligned neatly. Reduction 81% [B4/A4]
70% [A3/A4, B4/B5]
5. High-performance lamp Inch size model

A long-life, high-brightness xenon arc lamp is used • Zoom settings (64, 74, 77, 121, 129, 141%)
to illuminate the documents. Since the lamp's • Same-size (100%) printing
intensity is not affected by temperature variation*2,
printing quality at low temperatures is greatly DP-M410
enhanced*3. Free zoom 50% -200% ( 1% )
141%
*2: The lamp is filled with xenon gas, which means that it
does not require heat to vaporize mercury, as a Enlargement 129% [ST/LTR]
fluorescent lamp does, and therefore its intensity does 121%
not vary with temperature. 77% [LGL/LTR]
*3: Increased viscosity of the ink at low temperatures Reduction 74% [LDG/LGL]
results in fainter printing than at normal
67% [LDG/LTR]
temperatures.
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.
12
chap.1 z Features
wSelf-diagnosis 7. Options
The machine has a self-diagnosis system, qADF
which notices user by flashing on and off Use of the ADF permits continuous
a message and lighting up the relevant mastermaking and printing of 100
lamp when a expendable part needs documents (64gsm ).
replacing. The ADF 's tray fits completely inside the
ADF,so as not to interfere with loading/
eError message display removal of printing paper.
An LCD panel displays error messages and
messages prompting replenishment of wTAPE CLUSTER
consumables. This permits sectionized printing, by
inserting tape automatically during
r2 in 1 Layout mode printing.
In conjunction with an ADF ( optional ),
this mode makes possible continuous e Drums
printing of 2 documents onto single sheets Replacing the drum with optional drums
of paper. permits printing with different colors.
tAdjusting the Printing Position (vertical) r On-line functions*4

In addition to vertical direction These enable data processed on a personal
adjustment. computer or word processor to be directly
input and used for platemaking/printing.
yUID control function
Raises the number of sections controlled t Auto Power Off Kit
to up to 100. This kit can turn off the machine
automatic when there is no operation within
5 minutes.
uMemory function
Allows 9 sets of memory settings. *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.
13
chap.1 x Specifications
xSpecifications
• Specifications
Product name/model No. DUPRINTERDP-M420 DUPRINTERDP-M410 DUPRINTERDP-M400
Model Table top model
Mastermaking method Thermal digital mastermaking
Mastermaking interval 21second (A4,same size)
Resolution 300dpi(Main scanning direction)x600dpi(Sub scanning direction)
Scanning method Flat bed scanner
ADF capacity 100 sheets ( 64gsm )
Document type Sheets, Book ( less than 10kg )
Document size Max.297mmx432mm Min.100mmx148mm
Document weight 64gsm to128gsm
Printing area Max. 250 x 355 mm Max.210x347mm Max. 204 x 288 mm
Feeding capacity 1300sheets(64gsm , duodecimo 55kg, high grade paper)
Stacking capacity 900 sheets (64gsm, duodecimo 55kg, high grade paper)
*Cabinet [Option] : 1300 sheets ( 64gsm, duodecimo 55kg, high grade paper)
Paper size Max. 297mm x 420mm Max. 297mm x 364mm
Min. 100mm x 148mm Min. 100mm x 148mm
Paper thickness 45 gsm to 210 gsm(40kg to 180kg)
Printing speed 130pagesparminute.(60 to 130 pages per minute, 3 step adjustment)
Print enlargement/reduction Same size 100%
AB size model 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%
Inch size model Print with border 94%
Free zoom 50-200% (1%)
Printing position adjustment Vertical: ±15mm
Horizontal: ±15mm(Paper Width: 297 ± 5mm)
Image mode Text mode / Photograph mode / Text and photograph mode
Darkness adjustment Master darkness: 3 steps
Ink supply method Complete automatic control
Color printing Drum unit exchange method
Master feeder Roll master automatic feed
Master ejection Complete automatic ejection master rolling method
Master ejection capacity 30sheets
Master ejection method Fan and paper ejection belt
LCD panel Light and compact type LCD
Other standard function OK monitor Master size select
Confidential Safeguard Master making density control
Entry of different number of prints or sets 2 in 1(when using ADF)
Special functions Minimum print restriction(50 sheets)
Memory Mode UID input function(manual operation)
2-up,4-up,8-up Energy Save Mode
Zoom (50-200%) Ink Save Mode
x94%
14
chap.1 x Specifications
• Specifications
Product name/model Duprinter DP-M420 Duprinter DP-M410 Duprinter DP-M400

Power source AC 100-240V±10% 1.6-0.8A 160W 50/60Hz
Size 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)
Weight Machine 79kg(when packed: 90kg) Optional ADF:8kg
Operating temperature 10°C to 30°C
Black(DC14),Red(DC13),Blue(DC12),Green(DC15)
Ink Brown(DC16),Gray(DC17) (600ml)
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
PC interface kit 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
FS-100U Network server (USB I/F is necessary)
OS：Windows 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.
15
chap.1 c Dimensions
cDimensions
105
478
472
380
615
915
130
666.5
517
229 563 470
1262
(mm)
16
chap.1 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
Drum
unit
Thermal head
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 stripper finger

Paper
Paper ejection belt

Press roller
Paper sepatator unit Fan unit
17
chap.1 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.
18
chap.1 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 (10°C 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 (30°C 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 (5°C or less, 35°C 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.
20
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
21
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
22
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
23
2. Sectional (structural) view of the machine
2A
1
2C
2B
4,8
3 6
24
Description of
No. Section Name the Operation
Mechanism Srandard/Adjustment
1 Scanner section 55page 125page 159page
2 Mastermaking/Master feed/ejection section 59page 131page 161page
2A Mastermaking/Master feed section 59page 131page 161page
2B Master ejection section 74page 136page 162page
2C Master clamp opening/closing section 76page 138page 164page
3 Paper feed section 82page 140page 169page
4 Drum driving section 95page 145page 174page
5 Press section 101page 4 176page
1 6 Paper ejection section 104page 147page 178page
7 Print tray 4 4 4
8 Drum section 109page 150page 179page
2B
4,8
24S067
25
3. Control Panel
(1).Key outside of the panel cover
w q
100%
0sht 1set
e
Reference
No. Name Function page
Displays the number of printed paper.
q LCD panel 24, 93
Also displays an error message when an error occurs.
“FUNCTION SWITCH” key Press to toggle between the normal mode and the function select mode. 52
w “LEFT SELECT” key Press to select left function. 52
“RIGHT SELECT” key Press to select right function. 52
“ENLARGEMENT 39
e Indiction for the ratio is selected.
/REDUCTION” lamp
“ENLARGEMENT
r Press to set the enlargement or 100% or reduction ratio. 39
/REDUCTION” key
t Document mode 47
The lamp of the selected mode lights.
indicator lamps
“DOCUMENT MODE Press to switch between the text mode, text/photograph mode and
y photograph mode. Each press of this key moves the position of the 47
SWITCH” key lit lamp that indicates the selected document mode.
Flashes to display the content of the trouble and lights to indicated

u “OK” monitor 93
the part that caused the trouble in the machine.
26
20 !9 !8 !7 !6
!5
!4
i o !0 !1 !2 !3
Reference
Press to reset the displayed number of prints to “0”.
i “CLEAR” key 33
Only the number of prints is cleared.
Key pad Use to enter the number of prints. 33
o
Press to enter the number of prints and number of sets 65
!0 =
X key for sectional prints.
!1 “MASTERMAKING” key Press to start mastermaking. 33
Starts printing. This will not start mastermaking.
!2 “PRINT” key Mastermaking will start automatically after the end of 33
printing if there is a document on the ADF.
Press to stop printing on the way.
!3 “STOP” key If this key is pressed while the machine is stopped,
the total number of prints and masters will be displayed 73
on the LCD panel.
“TEST PRINT” key Press to print only one piece of paper for checking the
!4 print darkness or printed position. 72
!5 Energy saving mode indicator lamp The lamp of the energy saving mode. 76
!6 “PRINTING SPEED ADJUSTMENT” keys Press to adjust the printing speed. 74
!7 Printing speed indicator lamp The lamp of the specified printing speed lights. 74
!8 Printing position indicator lamp The lamp of the specified printing speed lights. 75
!9 “PRINTING POSITION ADJUSTMENT” keys Press to adjust the printing position. 75
Returns the control panel settings to the “Standard
2 0 “ALL CLEAR” key Mode” settings. Press and hold for at least 0.5 32
seconds.
27
(2). LCD Panel
q w e
100%
0sht 1set
Reference
q Print count Displays the number of prints to be made. 33
w Sets Displays the number of sets to be printed. 65
e Zoom ratio Displays the selected (enlargement/reduction)ratio.
28
chap.1 . Operation Procedures
.Operation Procedures
1. Mastermaking & Printing
1 Set document
Function switch key

Reduction is selected.
Select key
Document size is selected.
Photograph mode is selected.
Master darkness is switched.
Document mode switch key Selects Texts, Text/Photograph &

Photograph mode.
2 Mastermaking key When the number of prints is input in

advance, printing starts automatically
after mastermaking.
Printing position adjustment / keys Printing position is adjusted.
Printing speed adjustment / keys Printing speed is adjusted.
Test print T
key Printing is tested (a sheet of paper.)
Input the number of prints

3 and the number of sets
Input the number of prints and
the number of sets on the key pad.
4 Print key
5 End
29
chap.1 ⁄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 Cause and corrective action See page

EXCHANGE INK Cause : There is no ink.
Action : Replace the old ink pack with a new one. 32
ROLL - MASTER END Cause : There is no master.

Action : Replace the master roll with a new one. 34
EXCHG. EJECT - CORE Cause : The master ejection core is full.

Action : Replace the core with a new one. 37
SET PRINT PAPER Cause : There is no paper in the feed tray.

Action : Load the feed tray with printing paper. 39
DRUM NOT SET Cause : There is no drum.

Action : Install a drum in the machine. 43
FRONT COVER OPEN Cause : The front cover is open.

Action : Close the front cover. 4
SCANNER OPEN Cause : The scanner is open.

Action : Close the scanner. 4
ADF OPEN Cause : The ADF cover is open.

Action : Close the ADF cover. 4
PAPER LEFT JAM Cause : A paper jam has occurred on the ejection side.
Action : Inspect the ejection side and remove the jammed paper. 45
PAPER RIGHT JAM Cause : A paper jam has occurred on the ejection side.
Action : Inspect the ejection side and remove the jammed paper. 46
ENTER ID AND PASSWORD Cause : UID function is opened.

Action : Please press PRINT key and input ID and password 4
given by manager.
RESET MAST. ROLL Cause : The master roll is not set correctly.
Action : Reset is correctly. 36
30
Message Cause and corrective action See page

MAST. EJECT MISS Cause : There is an old master on the drum.
Action : Remove all the masters from the drum. 49
MASTER SET MISS Cause : There is an error during master setting.

Action : Open the top cover and remove the master that is
51
left in the master feeder.
DOCUMENT JAM Cause : The document is jammed on the ADF.

Action : Open the ADF cover and remove the jammed document. 4
--- WAIT--- 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. 4
•If the message still remains after a few minutes, turn
the power OFF and contact your service person.
ID OR PASSWORD NOT CORRECT Action : ID or PASSWORD is not correct.

Please press key or PRINT key and input correct
4
ID and password again.
PLS MASTER MAKING Cause : Cannot print.

Action : This message is displayed if you press (PRINT)
or T
(TEST PRINT) keys without making a plate
immediately after a master setting error or when the 4
confidential safeguard function is ON.
PRINTING Cause : Printing is not complete.

Action : Either press (PRINT) key to resume printing or
press C (CLEAR) key to clear the counter. 4
SERVICE CALL Action : Follow the procedure below.

( "E***" flashes ) qRecord the error message "E***".
w Shut off the power and turn it back on.
eIf the message is displayed again, contact service 223
personnel.
•Report the error code and details of error occurrence
to service personnel.
* For displayed messages other than those listed above, refer to Chapter 7
"Troubleshooting". a See page 207
31
2. Corrective action
(1) Replacing the Ink Pack
IMPORTANT :
• Only use ink packs designed for this machine.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Open the front cover.

Front cover
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Lever
Grasp the lever and pull it toward you.
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
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
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 Set line
pack.
Set line
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Press the back of the holder in with the palm of

your hand.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Close the front cover.

Front cover
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
33
(2) Replacing the Master Roll
IMPORTANT :
• Only use a master roll designed for use in this machine.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Slide the scanner unit. Scanner unit
IMPORTANT
• 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 Master roll
pushing the thermal head escape lever.
Pull out the master.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Lift out the master roll,then remove the master

holder from the master roll.
master holder
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
34
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Take out a new master roll from the bag.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Set the master roll in the direction as shown in master holder

the illustration at right.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
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.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
35
MASTER SET SWITCH

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
THERMAL HEAD
Push the master set switch. ESCAPE LEVER
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.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
36
(3) Replacing the Master Ejection Core
IMPORTANT :
• Use only a master ejection core designed for use in this machine.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Master ejection box
Press the master ejection box release lever to release lever
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.
37
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
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.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
38
(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.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
39
Changing Paper Selection

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Press (STOP) key.

Printing stops.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Press the feed tray descend switch continuously. Feed tray descend switch
Release the switch when the feed tray is at the
proper height.
The feed tray will stop.
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.
40
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
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.
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Feed tray descend switch

Press the feed tray descend switch continuously.
Release the switch when the feed tray reaches
the proper height.
The feed tray will stop.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
41
IMPORTANT :
• If the sheet is still in the feed roller ring, pull it
out and align it with the stack.
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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 (STOP) key, printing
stops.
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42
(5) Replacing the Drum Unit
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JOG switch (Drum rotator switch)

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.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Open the front cover toward you.

Front cover
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Drum handle Drum securing lever
Lift the drum securing lever toward you and,
holding it there, then pull out the drum handle
straight toward you until it stops.
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Handle for end

Hold the handle on the far end of the drum, and of drum
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.
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43
Installing the Drum Unit

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Hold the drum level and place the drum guide

roller onto the rail in the machine. Roller
Rail
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Release the handle at the far end of the drum

and press the drum in about 10cm while lifting
up the front end slightly.
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Hold the drum level and press it in gently until it comes to a stop.
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Lever
Lift the drum securing lever toward you while
pressing the drum in.
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Lever
Lower the lever.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Close the front cover.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
44
(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 PAPER LEFT JAM
following the procedure below.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Switch to lower the feed tray slightly. Feed tray descend switch
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
WARNING
• Do not put your hands or fingers inside the
may be pulled in or nipped.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
45
(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 PAPER RIGHT JAM
following the procedure below.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Master ejection box
Press the master ejection box relase lever to release lever
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Remove the jammed paper.

Press the JOG switch to eject the partially printed paper.
WARNING
•Do not touch the drum or rollers when you
•Do not put your hands or fingers inside the
may be pulled in or nipped. JOG switch (Drum rotator switch)
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locks.
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46
Paper Adhering to Drum

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Master ejection box release lever
Press the master ejection box relase lever to
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Paper edge
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 put your hands inside the machine
while it is operating. Your hands may be
pulled in or nipped.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Peel off the edge of the paper from the drum.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
47
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
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

JOG switch
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

locks.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Make another master.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
48
(8) Master is Not Ejected
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Master ejection box
Press the master ejection box release lever to release lever
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
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
•Do not put your hands inside the machine
while it is operating. Your hands may be
pulled in or nipped.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Master clamp
Lift the lever toward you.
Lever
The master clamp opens and the edge of the master will be
released from the clamp. If the master is stuck, release it Master
manually.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
49
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
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.
JOG switch
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Hold the JOG switch down until the drum comes to a stop with a beep.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

locks.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Press (STOP) key.

The message is deleted.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Make another master.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
50
(9) Master Set Incorrectly("MASTER SET MISS" is displayed)
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Slide the scanner unit. Scanner unit
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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 origi- Scanner unit
nal position.
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Continue Page •••
51
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
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 (PRINT) key
is pressed without mastermaking being carried out.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
52
Chapter 2 Description of the Operation
z Scanner Section...........................................................55 Master Clamp opening/Closing Section....................76

1. Description...............................................................55 1. Description...............................................................76
2. Sequence of Operation...........................................56 2. Operation of Master Clamp Open / Close Lever ........77
(1) Sequence of the Scanner Operation..................56 (1) Structure.............................................................77
(2) Sequence of the Scanner Operation (ADF).......56 (2) Master Attachment / Detachment Operation...78
3. Function of Parts and Circuit.................................57 (3) Clamp Opening / Closing
(1) Home Position Sensors.......................................57 Lever Position (A / B / C Mode).........................79
(2) CCD / Lamps......................................................58 3. Function of Parts ....................................................80
(1) A / B / C Mode Sensor.........................................80
x Mastermaking / Master Feed / Ejection Section........59 4. Returning Operation Flowchart
Mastermaking / Master Feed Section .....................59 When the Power is Cut Off Accidentally.............. .81
1. Description...............................................................59
2. Sequence of Operation...........................................60 c Paper Feed Section......................................................82
Operation when the master set 1. Description...............................................................82
switch is turned on.............................................60 2. Operation................................................................. 83
Mastermaking and Master Feeding.......................62 (1) Rotation of the Paper Feed Roller and
3. Function of Parts ....................................................65 Timing Roller.....................................................83
Thermal Head...........................................................65 (2) Paper Feed Roller Drive.....................................84
End Mark Sensor1...................................................68 (3) Driving of the Timing Roller..............................85
1. Master Setting Error Detection......................69 (4) Escape the Guide Roller ................................... 86
2. Master End Detection......................................69 (5) Paper Feed Length.............................................87
End Mark Sensor2...................................................71
Cutter Unit...............................................................72
3. Function of Parts.....................................................88
Master Feed Clutch (Electromagnetic clutch)........73
(1) Printing Position Adjustment Mechanism........88
(2) Signal Lever........................................................90
Master Ejection Section..............................................74 (3) Feed Tray (Elevator) Upper Limit Sensor........ 91
1. Description...............................................................74 (4) Feed Tray (Elevator) Lower Limit Switch........ 92
2. Circuit.......................................................................74 (5) Paper Sensor.......................................................93
3. Function of Parts ....................................................75 (6) Paper Feed Length Sensor.................................94
(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 m Drum Section.............................................................109
1. Description...............................................................95 1. Description.............................................................109
2. Function of Parts ....................................................96 2. Circuit.....................................................................110
(1) Home Position / Jam Detection 3. Function of Part.....................................................111
Position Sensor..................................................96 (1) Ink Detection....................................................111
(2) Master Attachment / Detachment 1. LED Display and Output Signal on
2
Position Sensor..................................................97 the Ink Detection PCB Unit..........................112
(3) Jog Switch(Drum Rotator Switch).....................98 2. "EXCHANGE INK" Display Timing.............113
(4) Control of the Main Motor.................................99 (2) Ink Pump..........................................................114
1. Rotation Speed Control by Encoder Sensor...100 (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
54
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).
Fixed document
ADF
home position sensor(PS1)
home position sensor(PS2) Lamp
Mirror
CCD Mirror
Glass Lens
24S068
Optical System Operation (with ADF attached)

• When ADF is attached, set the ADF Home Position Sensor (PS2) as the optical system stop position, and
then read the document darkness.
ADF
Glass
Fixed document
Lamp
Mirror
Mirror Lens CCD

24S068A
55
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. Image reading
Following that, the optical system moves right
and returns to the home position.
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
Image reading
complete, it immediately moves to the right
and returns to the home position.
3) After it returns, the optical system is then on

standby for the printing process.
24S070
56
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
3.3V
1 Red J7-12
2 Yellow -14 3.3V Photopass : 0V
0 Photointerrupting : 3.3V
3 Blue -13
Main P C B U nit
Home position sensor (PS2)

5V
3.3V
1 Red J12-14
2 Orange J7-16 3.3V Photopass : 0V
3 Blue J7-15
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) • With ADF attached
Fixed document ADF

home position sensor(PS1) home position sensor(PS2)
Photointerrupting plate
Photointerrupting plate Photointerrupting Photointerrupting

plate plate
Slider A
Slider A
23S0214
57
(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. Item Specification
1 Optical signal storage time (SH cycle) 2.048 msec/line
2 Frequency 3.375MHz
3 The number of effective picture elements 3000 picture elements

Reading width
4 254mm
(This is not the image width which can be processed.)
5 Reading density 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) .
58
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
Stepping motor
Roll master
Thermal head
59
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.
60
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
Master set PS
3 seconds or more, the master feeding motor (PM2) is kept photointerrupting Remove cut pieces
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
Cutter limit SW
[Rear side] (MS2)
Cutter limit SW
61
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.
62
(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.
63
2Operation Sequence on Continuous Mastermaking
Cutter limit SW
[Rear side] (MS2)
Cutter limit SW
64
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
-14
Thermal head
Main PCB unit
J4-1
-24
Specifications
No. Item DP-24S/DP-22S/DP-22L
ＤＰ－Ｍ４００／ＤＰ－Ｍ４１０／ＤＰ－Ｍ４２０
1 Picture element density 300DPI (11.8 dot/mm)
2 Effective memory width 260.2 0.1mm
65
Exterior and Lot No.
276.0 0.2
Theramal resistor line
260.20 0.2
Label
１
5mm
２３４５６
70mm
Power connector Signal connector
Pin (No.1) Pin (No.1)
NOTE
Label
１
２３４５６
The following items are displayed with the label.

（１）Model name
（２）Production month (See the table)
Sign A B C D E F G H I J K L
Month Jan. Feb. Mar. Apr. May. Jun. Jul. Aug. Sep. Oct. Nov. Dec.
(３) Serial
製品番号（４桁シリアル
No. NO）
(４) Resistance
抵抗値ランク（弊社管理用）
value
（５）ヘッド平均抵抗値
Average of head resistance
（６）御社指定表示
Specification display
66
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 ( ) H-44
3825 3908 0000
3909 3993 0001
3994 4077 0010
4078 4162 0011
１ 4163 4246 0100

２３４５６
4247 4330 0101
4331 4415 0110

Resistance value
4416 4499 0111
23S0326
4500 4583 1000
4584 4668 1001
4669 4752 1010
4753 4837 1011
4838 4921 1100
4922 5005 1101
5006 5090 1110
5091 5175 1111
67
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
3.3V
Red 1 Red J7-29
Black 2 Black J7-27 3.3V
0
Blue 3 Blue J7-25
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
68
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
69
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.
70
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
3.3V
CN4-1 Red J7-30
-2 Light green -28 3.3V
0
-3 Blue -26
Main P C B U nit
End-mark sensor2 PCB unit
71
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 Red CN4J1-20

45 Main
Black Black 419
3.3V
J7-2
CN2 420
J7-1 3.3V
3.3V
3 J7-4
4 J7-3 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 Cutter
Reversely Normally
(CCW) (CW)
Cutter
Cutter limit switch(Rear side) Cutter limit switch

(Operation side) Cutter
Cutter motor Cutter motor Cutter limit

switch
(Operation side)
72
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 1 Brown
Brown 1 Black 24V J2-15 Main PCB unit
Black Purple
2 Purple 2 Black
-16
Operation
1. During mastermaking process the drum stops at C mode
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.
2. The master clamp opens and closes, to clamp C \ B mode

the master.
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
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 Master ejection

23S0311 Master detachment sensor photo-
position emitting PCB
Master
ejection box
Core
Master ejection sensor

photo-receiving PCB Core full switch
JAM sensor photo- Roll up motor

emitting PCB
23S0264
2. Circuit
Light Main PCB unit
Red 2 blue 2 Light blue
J2-8
Rollup motor 1 1
Green Green -7
Black
2 Pink
J7-18
Jam sensor
photo-receing PCB 1 Blue
-17
1 Blue
-19
photo-receing PCB 2 Gray
-20
3.3V 3.3V
1 Orange -5
Core full switch 2 Orange -6
1 3 Blue
Master ejection sensor -23
2 4 Gray
photo-emitting PCB -24
3.3V
1 5 Blue
Jam sensor -21
photo-emitting PCB 2 6 Pink
-22
3.3V
74
3. Function of Parts
(1) Master Ejection Sensor
Description 2HELP mode H-05 value

Photo-emission from the master ejection sensor is
255
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
HELP5. HELP mode H-05 \ see p.239
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 2HELP mode H-05 value

If the variation in the amount of light received by Threshold value :
the master ejection sensor during the making of 1 Value without master + 8
255
master is less than a certain level (8 in the HELP5
display value), a master ejection error is deemed to Threshold value
have occurred. HELP mode H-05 \ see p.239
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
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 lever
Master clamp opening / (Master detachment position)
closing section
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
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:-

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
(2) Master Attachment / Detachment Operation
78
(3) Clamp Opening / Closing Lever

Position (A / B / C Mode)
Mode Photointerrupter stop position / state of sensor Functions
A / C mode sensor (PS3) In the normal state or during printing, the

master clamp opening / closing lever turns
Photo- out from the master clamp opening /
B mode sensor
A passing closing lever.
(PS4)
m Photo-
o
d interrupting
e
B mode sensor A / C mode sensor (PS3) The master clamp opening / closing lever
(PS4)
pinch the master clamp opening / closing
Photo-
interruptinggPh arm.
B oto-passing or
Photopassing Photo-interrupting
m gPhoto-
o interrupting
d
e
A / C mode sensor (PS3) The master clamp is open. This state

occurs when the master is attached or
detached.
C B mode sensor
Photo-
passing
(PS4)
m
o Photo-
d passing
e
79
(1) A / B / C Mode Sensor
Circuit
Clamp 2 Yellow
J1-21
1 Orange
-22
3.3V
J6-30
-24 3.3V
-23 3.3V
3.3V
J6-31
-26 3.3V
-25 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
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
Is the state the same

Detachment/attachment process 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
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
(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
(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
(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
(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
controlled by program( HELP mode H-66,67 ). HELP mode H-66,67 \ see p.284-285
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
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 ¡Pressing makes cam follow-

Printing position motor
er move in the e direction
Paper feed cam
Top and bottom

limit sensor
Link cam
¡Pressing makes cam follow-

er move in the b direction
Timing roller
Cam follower
23S0258
88
Circuit
Yellow Main PCB Unit
J1-13
Orange
-14
3.3V
J7-2
J8-12 3.3V
J7-1
3.3V
3.3V
J7-4
J8-14 3.3V
J7-3
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 stan-
dard.
89
(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 Press lever P roll sensor
A 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
(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
3.3V
1 Red J8-20
2 Light green -13 3.3V Photopass : 0V
3 Light blue -24
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 sensor’s light
beam. Restoration of the sensor’s light beam signals that the paper tray has reached the upper limit, and
triggers stopping of the feed tray’s rise.
Sensing of paper decrease

2As printing progresses and the paper decreases, the paper feed roller gradually descends, until it obstructs
the sensor’s 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
(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
3.3V
Light blue J8-11
Light blue -23 3.3V

0
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 switch’s 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
(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
5V 3.3V
1 Red J6-32
2 Purple -16 3.3V Photopass : 0V
3 Blue -15
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
(6) Paper Feed length Sensor
Circuits
Paper feed length sensor

5V
5V
1 Red Red J12-6
2 Yellow Yellow J8-19 3.3V Photopass : 0V
3 Blue Blue J12-5
Main P C B U nit
94
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 (photo-
receiving) and P roll sensor.
Circuit
Drum home position /
jam detection position sensor (PS5) 5V
3.3V
1 Red J6-28
2 Yellow -20 3.3V Photopass : 0V
3 Blue -19
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
(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) 5V
3.3V
1 Red J6-27
2 Purple -18 3.3V Photopass : 0V
3 Blue -17
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 Master detachment

position edge
Master attachment
position edge
Master attachment /
detachment position sensor
23S0250
97
(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)
3.3V
Purple J7-9
Purple -10 3.3V

0
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
Jog switch
position. (Drum rotator switch)
When the P roll sensor is in the photopassing 23S0014
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) (SW3)
98
(4) Control of the Main Motor
Circuit
Main P C B U nit
Brown J9-3
Brown -4
DC24V Blue -1
Blue -2
5V
Encoder sensor (PS7) 3.3V
1 Red J8-18
2 Gray -21 3.3V
0 Photopass : 0V
3 Blue -17
Photointerrupting : 3.3V
Main motor (M1) J10-4

Red
Black -3
99
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.
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. (mm)
1) The sections of the master on which holes are DP-M420 DP-M410 DP-M400
made by processing mastermaking. (mastermaking area) Press ON length 369 314
2) The hole sections of the drum. Drum hole section length 365.3 315.3
355 300
3) The section of the drum pressed with the press Printing area length
roller. (the area pressed ON) DP-M410/420 : 365.3mm

DP-M400 : 315.3mm
Center of the
master clamp shaft
When the pressed-on position is 0 under the
DP-M410/420 : 250mm
normally adjusted conditions, relations among

DP-M400 : 210mm
1), 2) and 3) are as follows*- 9mm
Bottom end of the

hole section
101
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 Press roller : ON
Drum Cam
Drum gear Drum gear
Cam
Drum
Press roller Press roller
Press lever Press lever

23S0252
Adjusting the printing area means that the cam

curve goes up and down as shown in the figure. The Press OFF position Press ON position
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.
Printing area Printing
area
IMPORTANT : Do not press off later than the hole
section end position since ink Drum hole section Drum hole section
seeps from the bottom end of the end start
master.
DP-M410/420:355mm
DP-M400:315mm
102
(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
3.3V
1 Red J6-29
2 Light blue -22 3.3V Photopassing : 0V
3 Blue -21
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 Press roller : ON

Pinch lever
Pinch lever
Drum Drum
P roll sensor P roll sensor

Press roller :photointerru Press roller :photopassing
pting
Press lever Press lever
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
Main motor
Paper ejection fun
104
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
Sub paper Paper stripper finger
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
Paper stripper
finger
23S0247
105
(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
photo-emitting PCB
Blue 3 Blue J7-23

1
Gray 2 4 Gray -24

Jam sensor
photo-emitting PCB 3.3V
Blue 5 Blue -21
1
Pink 2 6 Pink -22
Jam sensor
photo-recieving PCB 3.3V
Gray Pink -20
Blue Blue -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
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
Jam sensor(Photo-emitting)
Signal lever
Jam sensor(Photo-receiving) P roll sensor
23S0256
107
(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
2. Circuit
Main PCB Unit

J2-10 Orange 2 Orange 1 Red
24V
-9 Pink 8 Pink 2 Black Ink motor (M7)
Ink detection PCB Unit

24V
J6-9 Blue 3 Blue 3 Blue
J2-1 Brown 9 Brown 1 Brown
J6-10 Black 4 Black 2 Black
110
(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
1. LED Display and Output Signal on the Ink

Detection PCB Unit
2When the electric capacity variation between the 1

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
2
signal (0V) is output.
Ink detection PCB unit
LED J6-10
CN1-2
No ink Light out +5V
Ink Light up 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
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:-
Printing speed 1 2 3
Number of rotations 17 20 24
113
(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 When the piston moves down, the pump releases
ink pack into the pump. ink.
114
(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
3.3V
J6-11
-12 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 2No drum

Lever Lever
Pin
Switch
Cam unit
23S0280
115
(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 : 2When the front cover is closed :
Lever Lever
Switch Switch
116
Chapter 3 Mechanism
z Exterior.......................................................................119 c Mastermaking / Master Feed and Ejection Section...131

(1) Removal of Document Cover................................119 Master Feed Section ...........................................131
(2) Removal of Front Cover.......................................119 (1) Removal of Cutter Unit .......................................131
(3) Removal of Scanner Outer Cover.......................120 (2) Removal of End Mark Sensor PCB Unit ............132
(4) Removal of Rear Cover........................................121 (3) Removal of Thermal Head...................................133
(5) Removal of Main PCB Unit.................................121 (4) Removal of Master Feed Unit .............................134
(6) Removal of Control Panel....................................123
(7)Removal of Control Panel PCB ............................123
(8) Removal of DC Regulated Power Supply............124
Master Ejection Section ......................................136
(1) Removal of Master Ejection Box .........................136
(2) Removal of Jam / Master Ejection Sensor
x Scanner Section ........................................................125 (Photo-emitting PCB Unit)..................................137
(1) Removal of Glass unit.........................................125 (3) Removal of Rollup Motor .....................................137
(2) Removal of Reading Cover..................................126
(3) Removal of Inverter PCB Unit............................126 Master Clamp opening/Closing Section...........138
(4) Removal of Lamp Unit.........................................127 (1) Removal of Master Clamp Opening /
(5) Removal of Lamp Cord........................................128 Closing Unit .........................................................138
(6) Removal of Slider A.............................................129 (2) Removal of Clamp Motor.....................................138
(7) Removal of Slider B.............................................130 (3) Removal of Timing Belt .......................................139
117
v Paper Feed Section....................................................140 m Drum Section.............................................................150
(1) Removal of Paper Sensor......................................140 (1) Removal of Screen ...............................................150
(2) Removal of Elevator Lower Limit Switch ...........140 (2) Removal of Master Clamp....................................151
(3) Removal of Paper Feed Roller ..............................141 (3) Removal of Base Unit...........................................151
(4) Removal of Paper Separator Unit........................141
(5) Removal of Paper Feed Clutch Unit ....................142
(4) Removal of Outer Frame (Right) Unit.................152
(5) Removal of Outer Frame (Left) Assy...................153 3
(6) Removal of Paper Feed Sensor.............................143 (6) Removal of Inner Frame......................................154
(7) Removal of Timing Roller.....................................144 (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. Screw
Screw
Side
¡ Remove the Side cover L cover
L
the side cover L.
Screw Front cover
Side Cover R
¡ Remove the Side cover R

the side cover R.
¡ Remove the Rear cover Screws

1) Remove the document cover.
\See page 119
Screw
the rear cover.
Screws
Rear cover
120
chap.3 z Exterior
(4) Removal of Rear Cover

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

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.

PCB
1) Remove the 2 screws. cover
2) Slide the PCB cover and remove it.
Screw
122
chap.3 z Exterior
9) Remove the connectors of.
¡ Main PCB unit (12 connectors) Screw
１０ ) Remove the mounting screws, and replace the Screw

Screw
PCB units.
¡ Main PCB unit: 5 screws
Screw 1 Control Panel Screw 2

(6) Removal of Control Panel
1) Remove the 4 screws.
Screw 3 Screw 4
2) Remove the connector and detach the control
panel upward.
(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.
1) Remove the front cover. \See page 119
2) Remove the connectors of.
¡ DC regulated power supply (3 connectors)
Regulated power
supply
3) Remove the mounting screws, and replace the
PCB units. Screws
Screws
¡ DC regulated power supply: 2 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
(2) Removal of Reading Cover
1) Carry out (1) and (2) above.

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

Spacers
\See page 125,126
2) Disconnect the 2 connectors.

3) Remove the 2 spacers indicated, and remove the
inverter PCB unit. Connector
Inverter PCB unit
Connector 24S020
126
(4) Removal of Lamp Unit Scanner R bracket Screws Screw Scanner F

Screws bracket
Screws
1) Carry out (1) through (3) above. Screws
\See page 125,126
2) Remove the scanner cover(L,R). \See page 120

scanner F bracket.
Screw
Screws Screw
scanner R bracket. 24S021
5) Turn the timing pulley, and move Slider A to the Timing pulley
position shown in the diagram.
Lamp unit
Screw
IMPORTANT : Do not move Slider A by hand. Screw

lamp unit. Screw
Slider A
24S022
Reinstallation
¡ Insert the slotted parts of the lamp unit into

the grooves on the brackets. Lamp unit
IMPORTANT : The lamp is fragile; handle it with care.

Bracket groove
Bracket groove
24S023
¡ When attaching the scanner's front and rear Notch

Notch
brackets:
1. Align the notches on the left and right sides. Notch
2. When attaching the scanner's rear bracket,
be careful to not pinch the wiring.
Notch
24S024
127
(5) Removal of Lamp Cord
1) Carry out (5) 1 through 4 above.

\See page 127 Cord clamp Inverter PCB unit
2) Remove the cord clamp.

3) Disconnect the inverter PCB unit CN2 connector.
Connector
24S025

Screws
lamp cord.
Lamp cord
24S026
128
(6) Removal of Slider A
1) Perform steps 1 through 4 of procedure (5).

2) Loosen the 2 screws shown, and remove Slider A Slider A
\See page 127
IMPORTANT : Do not move Slider A by hand. Screw
Screw
24S021
Reinstallation
¡ Required items
* Slider A attachation tool 1
Tool 1
* Slider A attachation tool 2
1) Attach 2 Slider A attachation tools 1.
Place in opening
24S028
2) Turn the timing pulley and move Slider A so

Slider A
that the Slider A positioning openings are
aligned with the Slider A attachation tool 1
positioning openings.
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
(7) Removal of Slider B

¡ Required items Fix the wire with the tool
* Wire fixing tools
1) Perform steps 1 through 3 of procedure (5).
2) To prevent loosening of the wire, attach 2 wire Fix the wire with the tool
fixing tools, one before and one after the wire pulley.
IMPORTANT : Do not remove the wire fixing tools
before Slider B is attached.
3) Remove the wire from the spring, in 2 locations
before and after the spring.
Attach the
4) Remove Slider B. spring 24S031
Reinstallation
¡ Required items Tool 1

* Slider B attachation tool 1
* Slider B attachation tool 2
1) Attach 2 Slider B attachation tools 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
Screw Cutter unit Screw

3) Remove the two screws and detach the cutter
unit.
131
(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 Connector

sensor 2.
4) Adjust the end-mark sensor 2.

Go to HELP-13 and set the document mode End-mark sensor 2
Screws
'Photo'. Rotate the sponge roller to adjust the
sensor (10 or less in white section, 40 or more in
black section) with VR.
132
Guide plate
(3) Removal of Thermal Head
1) Remove the two screws and detach the 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 Collar
the thermal head.
IMPORTANT: Do not touch the heat emission

Do not touch the heat emission parts
parts of the thermal head.
• The thermal head is sensitive to static electricity, so Thermal head
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 Collar
not touch its heat emission parts. Touching these Screw

parts could scratch them.
133
(4) Removal of Master Feed Unit
Guide plate
1) Remove the two screws and detach the 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
5) Remove the screw and take out the switch with Screws Master feeding unit Screw Screw
the switch bracket (with bundled wire connect-
ed).
6) Remove the four screws and detach the master

feeding unit.
Screw Switch bracket
135
(1) Removal of Master Ejection Box
1) Remove the rear cover. \See page 121

Connector
2) Disconnect the 3 connectors.
3) Remove the cord band.
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
(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.
Jam sensor
photo-emitting
Master ejection PCB unit
sensor photo-
emitting PCB
unit
Screw
(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. Timing belt
4) Remove the 3 motor mounting screws indicated,
and remove the roll - up motor.
Reinstallation
IMPORTANT : Do not forget to adjust the tension

after the motor is attached.
Pulley
\See page 163
Screws Motor
137
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)
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 Screws
unit. Connector
Screws
Master clamp
opening / closing unit
Connectors
23S0077
(2) Removal of Clamp Motor
1) Remove the master clamp opening / closing unit. Clamp motor

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

\See page 138 Tension Screws
2) Loosen 2 screws to loosen the tension as shown

in the figure.
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 mas- Master ejection master
Position hole clamp opening/closing lever
ter clamp opening/closing lever and master ejec-
tion master clamp opening/closing lever. Then fit
the timing belt on. \See page 164
IMPORTANT : Adjust the A, B and C modes after

the master clamp opening / closing
unit is attached to the printer main Master feed master clamp
opening/closing lever
body. \See page 165
Position hole
Main frame R
Master clamp
opening/closing unit
23S0082
139
chap.3 v Paper Feed Section
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. 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 Connector
bracket.
3) Disconnect the connector, and remove the eleva-
tor lower limit switch.
Reinstallation Screws
Elevator
lower
IMPORTANT : After reinstalling the elevator lower
limit switch
limit switch, carry out adjustment
of its clearance.
\For adjustment method see page 171
140
(3) Removal of Paper Feed Roller
1) Remove the screw indicated, and slide the paper

feed shaft in the direction of the arrow. Screw Paper feed shaft
23S0086
2) Loosen the set screw indicated, and remove the

paper feed roller. Paper feed roller Paper feed rollers
Reinstallation
¡ Reinstall the paper feed roller so that the set

screw is positioned at the paper feed roller
shaft's counter bore.
Set screw
IMPORTANT : Do not use an old paper feed roller
Set screws
together with a new one.
23S0087
(4) Removal of Paper Separator Unit
1) Loosen the set screws indicated, and move the 2 Set screws
paper feed rollers clear of the paper separator

unit.
2) Remove the paper separator unit.
Reinstallation
IMPORTANT : After reinstalling the paper separa-

Paper separator unit
tor unit, carry out adjustment of its
clearance. Paper feed rollers
\See page 169 23S0088
141
(5) Removal of Paper Feed Clutch Unit

Connector
2) Disconnect the connector. Paper feed shaft
3) Remove the screw indicated, and disconnect the Screw
paper feed shaft from the coupling.
4) Remove the 3 screws indicated, and remove the Screws

bracket.
5) Remove the 2 screws indicated, and remove the Bush
bush.
Screw Bracket
Screws
Paper Feed Clutch Unit
142
(6) Removal of Paper Feed Sensor
1) Remove the paper feed shaft.

\See page 141 (3) Bracket Paper feed shaft
2) Remove the paper separator unit.

\See page 140
bracket.
Screws Screws
23S0093
4) Disconnect the connector. Connector

5) Remove the screw indicated, and remove the Paper feed sensor
paper feed sensor.

Screw
23S0094
143
(7) Removal of Timing Roller

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. Screws Paper

7) Remove the 4 screws shown. Remove the chain feed shaft
stop angle.
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

Screws
feed inlet.
11) Unplug the paper feed sensor connector.
\See page 143
Screws
Paper feed inlet

24S037
12) Remove the 3 screws shown. Remove the bearing

bearing stops and the springs.
13) Remove the timing roller from the rear
(opposite side from the operation panel). Bearing
Screws
Timing roller
Screw
24S038
144
chap.3 b Drum Driving Section
b Drum Driving Section

(1) Removal of Sub-Frame
1) Remove the rear cover.

Screw
\See page 121 Screw

pump unit.
Screws
Pump unit
Screws 23S0095
3) Disconnect the 6 connectors. Screw Screw

sub-frame. Sub-frame
Screws
Screw
Screw Screws
23S0096
145
chap.3 b Drum Driving Section
(2) Removal of Drum Gear
1) Remove the rear cover. E-ring
\See page 121
2) Remove the Sub-frame.

\See page 145
3) Remove the 2 E-rings, and remove the links.

Links
E-ring
23S0097

Drum gear
drum gear.
Screws
23S0098
146
n Paper Ejection Section

(1) Removal of Paper Stripper Finger /
Sub Paper Stripper Finger

2) Remove the set screws. Paper stripper finger
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
(2) Removal of Paper Ejection Fan Unit
1) Remove the rear cover. Connector Connector
\See page 121

2) Disconnect the connector.
3) Open the front cover, and remove the drum.
5) Disconnect the connector.
7) Remove the 2 screws from the cover, and remove
the cover.
Screws
Cover
23S0099
8) Remove the 6 screws indicated, and remove the Jump plate R unit
Jump plate F unit Screws
jump plate F/R units.
Screws 23S0100
9) Remove the 4 screws, and pull out the paper Paper ejection fan unit
ejection fan unit sliding in the direction of an
arrow.
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
(3) Removal of Paper Ejection Belt
1) Remove the paper ejection fan unit.

Static removal brush
\See page 148
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,

Paper ejection belts
and remove the shaft.
4) Stretch the belts and install them oriented as
shown in the figure.
Screw Screw
Shaft 23S0103
(4) Removal of Jam Sensor (Photo-receiving

PCB UNIT)
1) Remove the paper ejection fan unit. Remove the 2 screws with a driver
\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.
Paper ejection belts 23S0104
4) Remove the 2 screws from the sensor PCB, and

Jam sensor
remove the PCB.
IMPORTANT : Do not lose the 2 spacers.

Screws
Spacers
149
m Drum Section
(1) Removal of Screen
Screw
Screen
1) Remove the drum.
2) Remove the clamp on the bottom end screen bar
Bottom end
to pull out the screen bar. screen bar Top end
3) Remove 2 set screws on the top screen bar to pull screen bar
Clamp
out the screen bar.
Screw
4) Remove the screen from the drum.
Screw
IMPORTANT : Do not rotate the drum reversely.
Reinstallation
1) Pass the top end screen bar through the screen Top end screen bar Screen
(top end side). Screw
2) Attach the top end screen bar to the drum.
IMPORTANT : Do not mistake the bottom end of Screw 20mm

the screen for the top end. (bottom end side)
58mm
(top end side)
3) Pass the bottom end screen bar through the

screen (bottom end side). Bottom end screen bar
4) Hold the bottom end screen bar in parallel with
the drum and roll it up to the drum rotating the
drum normally.
5) Tighten the screen bar with the clamp.

Bottom end screen bar
IMPORTANT : The stainless screen does not return

to the original state once it is folded.
Be careful to handle the screen.
Clamp
150
(2) Removal of Master Clamp
1) Remove the screen.

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

installation.
\See page 181
(3) Removal of Base Unit
1) Remove the master clamp. Screw Base unit

2) Remove 2 screws, and remove the base unit.
Screw
151
(4) Removal of Outer Frame (Right) Unit
1) Remove the drum.

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

remove 2 connectors.
5) Remove the outer frame (right) unit.
Connector
Outer frame (right) unit
152
(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. Stay
Reinstallation
Rail left
Screw
IMPORTANT : Do not forget to adjust the rail
space after the rail is installed. Rail right
\See page 182
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
(6) Removal of Inner Frame
1) Remove the outer frame (right) unit.

Screws
\See page 152
2) Loosen 2 set screws on the supporting plate,

move the supporting plate in the direction of
Supporting
arrow until it stops and fix it with the screw. 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 Screws

1 so that the supporting plate roller, roller unit and Roller
roller are in contact with the inner surface of the Supporting plate
flange right and tighten the roller with the screw,
pressing the roller to the inner surface lightly.
Roller unit
Roller
154
(7) Removal of Ink Pump
1) Remove the inner frame.

Hose band Screw
\See page 154
2) Loosen the screw on the hose band to remove the

hose.
Hose
3) Remove the screw to take out the link. Screw

4) Remove 2 screw to take out the ink pump. Link
Ink pump
Screws
(8) Removal of Ink Motor

\See page 154 Rotation plate Set screw
2) Cut the tie wrap.

Motor
3) Loosen the set screw to remove the rotation
plate.
4) Remove 3 screws to take out the motor.
Screws
155
(9) Removal of Ink Detection PCB Unit

\See page 154
2) Pull out the connector.

3) Remove 3 screws to take out the ink detection
PCB Unit.
Screws Connector
Reinstallation Ink detection PCB unit
IMPORTANT : Confirm that the detection needle is

vertical with the PCB Unit and does
not contact anywhere, when
installing the Ink detection PCB
Detection needle
Unit.
Squeegee roller Ink roller
156
Chapter 4 Standards / Adjustment
z Scanner Section.........................................................159 v Drum Driving Section................................................174

(1) Attaching the Rear Wire......................................159 (1) Adjusting the Stop Position.................................174
(2) Attaching the Front Wire.....................................160 (2) Adjusting the Master Attachment /
Detachment Position ..............................................175
x Mastermaking / Master Feed / Ejection Section......161

Mastermaking / Master Feed Section ......................161 b Press Section............................................................176
(1) Adjusting the Timing Belt Tension.....................161 (1) Adjusting the Press Roll (P Roll) Sensor.............176
(2) Adjusting the Printing Area
(Press OFF Timing) ...................................................177
Master Ejection Section.........................................162
(1) Attaching the Spring............................................162
(2) Adjusting the Timing Belt Tension.....................163
n Paper Ejection Section.............................................178
(1) Adjusting the Paper Stripper
Master Clamp opening/Closing Section..............164
Finger Clearance..................................................178
(1) Adjusting the Timing Belt Tension.....................164
(2) Positioning the Master Clamp
Opening / Closing Levers.....................................164
m Drum Section.............................................................179
(3) Adjusting the A / B / C Modes..............................165
(1) Adjusting the Ink Amount...................................179
(2) Adjusting the Squeegee Gap................................180
(3) Adjusting the Master Clamp...............................181
c Paper Feed Section....................................................169
(4) Adjusting the Master Clamp Section..................181
(1) Adjusting the Paper Separator
(5) Adjusting the Drum Rail Gap..............................182
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
DP-M400
Amount / Timing...................................................172
(6) Adjusting the Printing margin............................173
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 4
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
zScanner Section
(1) Attaching the Rear Wire
Fix at 13mm
w
Place on pulley
q
Ball end
Wrap 6 times
Wrap 4 times
r Fix with nut

Place on pulley e
y Place on pulley
u t Place on pulley
Place on corner guide
i 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
(2) Attaching the Front Wire
w Place on pulley
Wrap 4 times
Wrap 6 times
Ball end q
Place on pulley y r
Fix with nut
i
Place on spring
e
Place on pulley
u
Place on corner t Place on pulley
guide
Fix at 13mm
24S041
NOTE :
¡For removal of the front wire \See page 130
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
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 1
w Clutch 1
e Angle 1
r Timing belt 1
t Timing belt 1 r e
0.6kg
ｓｃｒｅｗ
w
q
0.5kg
161
(1) Attaching the Spring
rSpring T (B)(3) L220mm
E
A : Rubber roller
F B : Driving roller
C : Inverted roller
A B D : Driving roller
D E : Inverted roller
IMPORTANT : Set the hook on the spring F : Inverted roller
and crush it to prevent qSpring T (3) L90mm C
removing. wSpring T (3) L104.9mm eSpring T (B)(3) L220mm
1) Attaching the spring between A and B.

B
A
qSpring T (3) L90mm
2) Attaching the spring between B and C.

C
wSpring T (3) L104.9mm
3) Attaching the spring between C, D and E.

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

F
rSpring T (B)(3) L220mm
162
NOTE :
¡For removal of the master ejection box.

\See page 136
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.

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
Master Clamp Opening/Closing Section
NOTE :
¡For removal of master clamp opening / closing unit.

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

\See page 138
Master feed master clamp
opening/closing lever
Positioning hole
23S0081
1. Paper feed master clamp opening/closing lever ¡Paper feed side

When tensioning the timing belt, ensure that the
sub frame is positioned so that the upper surface of Sub-frame
the master clamp opening/closing lever is aligned

(to within 0.5mm) with the rim of the positioning Positioning hole
hole.
Aligned
(to within 0.5mm)
Master feed master clamp opening/closing lever
23S0081
2. Paper ejection master clamp opening/closing ¡Paper ejection side

lever Positioning hole
Main frame R
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

Master ejection master clamp
after installation to the printer. opening/closing lever
23S0082
164
(3) Adjusting the A / B / C Mode
NOTE :
¡For description of operation.

\See page 76
1. Adjustment for B mode ¡When drum is removed from main body (A mode)
1) Remove the drum from the machine body.
For basic HELP mode procedures.
\See page 231
3) Press and hold down the "up" PRINTING ¡More open than B mode (toward C mode) position
SPEED ADJUSTMENT key, until the master C mode
clamp open/close lever moves into the "more
B mode
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.
uShift
6) Open the master ejection box. Then press the JOG
switch (drum rotator switch) to move the master yStop in front
of lever
clamp to a position in front of the open/close
lever, and stop it there.
WARNING
¡Do not touch the drum or rolls when operat-
ing 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
Standard value 1.0~1.5mm

¡Check that the clearance between the master clamp Master clamp lever
lever and master clamp open/close lever is within the Master clamp
range given below. open/close lever
Item Standard value

Clearance between master
clamp lever and master clamp 1.0 - 1.5mm
open/close lever
If the clearance it outside the standard range: A / C mode sensor (PS3)

1) Turn the fixing screw indicated to move the B
mode shade plate and thereby adjust the B mode shade plate
clearance.
B mode sensor (PS4)
Fixing screw
Open
Close
After adjustment
Follow the procedure below to return to the
previous state.
1) Remove the drum.
\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).

machine body.
166
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 ¡When drum is removed from main body (A mode)

1) Remove the drum from the machine body.

\See page 231
3) Press and hold down the "up" PRINTING ¡More open than B mode (toward C mode) position
SPEED ADJUSTMENT key, until the master C mode
clamp open/close lever moves into the "more
B mode
open than B mode (toward C mode) position" (see
right).
The master clamp open/close lever will move into
the B mode position and stop there.
machine body.
¡Stopping drum in master detachment position
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.
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 0.5-1.0mm
master clamp.
9) Open the scanner unit.
167
Standard value
0.5~1.0mm
¡Check that the clearance between the master ejection
box's rubber roller and the master clamp plate is
within the range given below.
Rubber roller
Item Standard value
Clearance between master Master clamp plate
ejection box's rubber roller and 0.5 - 1.0mm
master clamp plate
If the clearance is outside the standard range A / C mode shade plate

1) Turn the fixing screw indicated to move the A/C
A mode sensor (PS3)
mode shade plate and thereby adjust the
clearance. This operation adjusts the clearance
for both the A and C modes.
IMPORTANT : Do not press the master clamp Fixing screw

B mode sensor (PS4)
against the rubber roller.
Open
Close
After adjustment
Follow the procedure below to return to the
previous state.
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. ¡A mode
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).

machine body.
168
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
¡When the paper separator unit is installed, use
Paper separator unit
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.
w
Nut 23S0106
169
(2) Adjusting the Paper Separation Pressure
NOTE :

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

\See page 91
1) Insert a 1mm thick strip of material between the Position bottom
paper feed roller and the paper feed inlet. surface at sensor's
center
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. Screw
3) After adjustment, tighten the screws.
Paper feed tray
upper limit sensor
Screw
1mm thick strip
23S0225
170
(4) Adjusting the Paper Feed Tray Lower Limit Switch
NOTE :

\See page 92
¡For removal. \See page 140
Adjustment method
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 Standard value
Paper feed tray clearance in

14mm
lower limit position
14mm
23S0109
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
Connector
clearance value.
cMoving the sensor in the direction shifts the
lowermost position downward.
dMoving the sensor in the direction shifts the
lowermost position upward.
Screws
2) After adjustment, tighten the screws.
Elevator
lower
limit switch
171
(5) Adjusting the G Roll Escape Amount /

Timing
Adjustment procedure Peek through the inspection hole. Bearing Escape lever
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±0.2mm
2) Loosen the eccentric shaft fixing screw. Then
turn the eccentric shaft to adjust the escape
Eccentric
amount. shaft
Screw
NOTE : Escape cam
23S0228

\See page 86
Standard value
Item Standard value

Clearance between escape
lever's bearing and escape 2±0.2mm
cam's bolt
172
(6) Adjusting the Printing margin
NOTE :
¡For description of operation. \See page 89
1) To adjust the Printing margin, position the screws Screw
of the sensor angle's rectangular holes in the
Center sensor
center of those holes, and fix the screws in that
position.

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
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 operat-
ing the JOG switch.
NOTE :
Stopper Groove
¡For description of operation . \See page 96
Standard position JOG switch

(DRUM ROTATOR
¡The stop position is correctly adjusted when the switch)
groove in the drum flange is aligned with the
stopper.
If the drum is not adjusted to the standard stop

position:
Screws Drum stop detection edge
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.
23S0232
174
chap.4 v Drum Drive Unit
(2) Adjusting the Master Attachment/Detachment Position
NOTE :
Master attachment position
¡For description of operation. \See page 97 Master detachment
position
1. Master detachment position

¡The correct position for stopping of the drum
(position for master detachment) is when the Open/close arm
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 +-1mm
center axes is ±1mm (gauge this value visually).
Open/close lever
23S0234
1) Access HELP mode H-09, the drum position
check mode. HELP mode H-09 \ see p.243
Master
attachment/det
achment
position edge
23S0235
Open/close arm
Item Standard value
Offset in alignment of center
axes of master clamp +-1mm
±1mm
open/close arm and master
clamp open/close lever
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. Open/close lever
23S0236
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 Screws
position at the same time as that of master
detachment position. Adjust both positions Advances the stop position
to an accuracy of ±1mm. Sets back the stop position 23S0233
175
bPress Section
(1) Adjusting the of Press Roll (P Roll) Sensor
NOTE :
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
Bracket
between the bottom of its sensor and the
end of the bracket is about 1mm. About
1mm P roll
sensor
Bracket
Screws
23S0238
176
(2) Adjusting the Printing Area (Press OFF Timing)
NOTE :

Rear end of opening
20mm
1) Make a mark on the end surface of the drum
flange, in a position 20mm forward (in the direc- Make
tion of the forward end) from the rear end of the mark here Drum unit
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).
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 Standard value Drum flange
Alignment of mark on flange
±2mm
end and center of press roll Press roll
23S0246
If the alignment is not correct:

1) Loosen the 2 hex bolts indicated.
2) Loosen the adjustment collar (eccentric) fixing Adjust collar
screw. Hex
bolts
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
Screw
of the press occur earlier \ thereby making the
printing range shorter 23S0239
177
nPaper Ejection Section

(1) Adjusting the Paper Stripper Finger Clearance
NOTE :
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.
Drum
surface
Standard value
¡Check that the clearance between the drum 0.5mm~1mm
surface and the paper stripper finger conforms
to the value shown below.
Item Standard value

Clearance between drum sur-
face and tip of paper stripper 0.5mm~1mm
finger
Paper stripper finger
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
Lever Screw
After adjustment:
IMPORTANT :
¡After adjustment, press the JOG switch (DRUM

ROTATOR switch) to return the drum to its
Roller
home position.
WARNING
¡ Do not touch the drum or rolls when
operating the JOG switch. Main motor shaft
23S0240
178
mDrum Section
(1) Adjusting the Ink Amount
Adjusting the ink adjusting knob

Ink adjusting knob on the
NOTE : operation side
Ink adjusting knob on the

rear side
¡Ink adjusting knob on the operation side
1) When printed too dark or too light on the (standard position)
operation side:
• Too dark: switch in the (-) direction Too dark
(3 settings)
• Too light: switch in the (+) direction
(3 settings) Too light
Do not loosen set screw
2) When printed too dark or too light on the rear

¡Ink adjusting knob on the rear side
side: (standard position)
• Too dark: switch in the (-) direction
(3 settings) Too dark
• Too light: switch in the (+) direction

(3 settings) Too light
3) When printed too dark or too light on the entire
surface:
• Adjust the above 1) and 2) at the same time. Do not loosen set screw
IMPORTANT : There are 7 settings, standard and

±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
(2) Adjusting the Squeegee Gap
NOTE : Squeegee
Ink roller
¡The gap between the squeegee and the ink roller Gap
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, 0.03±0.005mm Squeegee
adjust it as follows:-
Standard value
Ink roller
Item Standard value
Clearance between squeegee

0.03±0.005mm
and ink roller
If the clearance is not the standard value

¡Operation side
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. Adjusting
Set screw 2 screw
Ink adjusting knob 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 Adjusting screw Set screw 2
tighten it to fix.
Set screw 1 Ink adjusting knob
180
(3) Adjusting the Master Clamp
NOTE :
Set screws Set screws (for adjustment)
shaft
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. Operation side
Lever shaft Clamp plate
* Adjust the master clamp with the set screw on the
operation side.
1. Adjusting the clamp parallelism

Adjustment procedure Clamp plate
1) Loosen the set screws on the clamp plate and
shaft to adjust the parallelism.
IMPORTANT : Loosen the set screw on the Master Master Master

operation side to adjust. 20mm 20mm 20mm
But do not loosen the set screw on
the lever shaft. Clamp plate
2. Adjusting the clamp flatness

Rubber magnet Torsion
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.
(4) Adjusting the Master Clamp Section
1) Adjust with HELP mode 29 so that the clamp
amount of the master (A section in the figure) is Master clamp
0~3mm with the master attached.
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.
181
(5) Adjusting the Drum Rail Gap
1. Operation side
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 0.3mm
Guide rail left Guide rail right

23S0244
2. Rear side
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 0.3mm
Guide rail left 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
1) Set the HELP mode.
Turn the power on with the PRINTING SPEED ¡Test pattern 2
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
down. HELP mode H-30 \ see p.263
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.
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.
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* Center of the paper
and at the position 200mm from the above line.
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: 23S0312
1) If not, adjust with the H-24.

HELP mode H-24 ADF \ see p.257

183
(2) Reading Start Position
1. Adjusting the Top End Reading Start Position Document Print

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
2 printouts
size and to two printouts using 2-up function.
Mark with 1mm
3) Adjust with the HELP35 so that the image of the interval from the top 2 - 3mm
second printout is printed with 3mm margin left. end of the document

23S0313
2. Adjusting the Lateral (Operation Side)

¡Standard document
Reading Start Position
1) Make a standard document (as shown in the 100mm
figure) from a sheet of paper*. 30mm
Draw a 100mm line at the position 30mm
from the right end and from the top end of the
paper*.
23S0314
2) Compare the printed image with the basic

document. Print ejection
direction
Check the difference between the straight lines Printing paper
in the main-scanning direction.
Document
3) Adjust with the HELP H-36 so that
L1 - L2 ±3mm.
Mark this corner
HELP mode H-36 ADF \ see p.268 with each other
Document basic line
Adjusting direction
¡L1<L2 : Backward
¡L1<L2 : Toward you Basic line of the printed sample L2 L1
23S0315
184
(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 Draw a line at the position 30mm

¡Standard document
1) Set the printing position (top and bottom direction) from the top end of the document
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
23S0316
L1 - L2 ± 3mm.
HELP mode H-37 \ see p.269 Print ejection direction
Printing paper
Adjusting direction Document

¡L1<L2 : Upward
¡L1>L2 : Downward Mark this corner with each other
Basic line of the Document

printed sample basic line
L1
L2
23S0317
2. When in Online
Before adjustment
IMPORTANT :
¡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.
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
(4) Adjusting the Document Reading Darkness
NOTE :
1. Adjusting the White Level of the Document

Darkness
The basic darkness of the document (lightness of

¡In the normal state
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.
¡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:-
¡When the white level is too low:
1. Text mode: H-33 the section is not processed for Mastermaking

2. Photograph mode: H-26

2) Input the correction value on the keypad, "0" or "1".

¡HELP mode H-33/26 display
¡When the processed document gets dirty :
"0 1 1 1" The white level is corrected down. A: 0 B:1 C:1 D:1
Sign flag Correction amount display

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

value.
4) Perform Mastermaking and printing to check the

darkness.
186
2. Adjusting the Reading Darkness

Adjust the document reading darkness in
Mastermaking as follows:
1) Help mode
Text mode : H-50

Photograph mode : H-23

¡HELP mode H-50/23 display
A:1 B:1 C:1 D:1
2) Input the correction value on the keypad, "1" or
"0" (Sign flag / Collection amount display).

3) Press the = key to memorize the correction
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 dark H-50, H-23: [0001]
H-50, H-23: [0001]
dark
Normal
Normal light
light
light
23S0318
187
(5) Adjusting of Printer Unit's Printing Speed
1. Pre-stop Speed Adjustment

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 111 r pm

repeatedly, to select PHOTOGRAPH.
3) Check the speed value displayed. The value should be
Pre-stop speed
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.
2. JOG Speed Adjustment


¡HELP mode H-01 display
2) Press the DOCUMENT MODE SWITCH key
repeatedly, to select TEXT/PHOTOGRAPH.
111 r pm
16rpm. JOG speed

¡ 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.
188
3. Adjustment of Printing Speeds 3

2) Press the DOCUMENT MODE SWITCH key
repeatedly, to select TEXT.
3) Use the "down" PRINTING SPEED ADJUSTMENT
key to select SPEED 1. ¡HELP mode H-01 display
63-65rpm
. 111 r pm
Printing speed
¡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:

1) Access HELP mode H-01. HELP mode H-01 \ see p.234 ¡HELP mode H-01 display
For basic HELP mode procedures. \See page 231 HELP SELECT 01
2) Press the [=] and CLEAR C key. The settings Mode number flashes
will be initialized.
3) Press the STOP key. The HELP mode menu will
reappear.
NOTE :
¡After initialization, new speed values must be set.
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. VR 1
CN 1
(About 63 when master is not set)
3) Rotate the VR1 on the end mark sensor1 PCB End-Mark Sensor1 PCB Unit
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.)
(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.
VR 1
3) Rotate the VR1 on the end mark sensor2 PCB CN 1
Unit to adjust so that the value of HELP mode
End-Mark Sensor2 PCB Unit
H-13 is value from 0-10 when white mark is under ,
or the value from 50-63 when black mark is under.
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 2. Installation Instructions

Instructions
(1) Unpacking Checks
1. Before Installation :
q Packages for 1 complete DUPRINTER:
Safety precautions DP-M400

¡The precautions below are vital for safety and must • 1 printer unit package (product name: DP-M400)
be taken. DP-M410
• 1 printer unit package (product name: DP-M410)
WARNING DP-M420
• 1 printer unit package (product name: DP-M420 )
¡ Use only the power cord that is Check that the above 3 packages are present.
provided among the accessories.
w Unpack the package.
Insert the power cord plug firmly
into the socket, so that proper IMPORTANT : Carry out unpacking in a place
electrical contact is effected. that is safe for the work.
aUse of any other power cord could
result in imperfect grounding.
If grounding is imperfect and
e Contents checks for each package.
electrical leakage occurs, fire or
Check that the packages have the contents listed
electric shock could result.
below.
¡Do not use a source voltage other •Printer unit package

than that specified. Do not connect
multiple loads to a single outlet. Item Quantity
Fire or electrical shock can result. Printer unit proper 1
Installation manual 1
¡ Do not place the machine in an Operation Manual 1
unstable position, such as on an Warranty 1
unsteady support or sloping area. Master ejection core 1
If the machine drops or falls over, a Power cord 1
person could get injured. Print Tray 1

Master holder 2
¡Do not place the machine in a humid

or dusty area. Fire or electrical
shock can result. If the optional printer stand is used, install it now
by referring to the instructions on the following
If the optional printer stand is used: page. \See page 194
¡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.
192
r Attach the print tray, by fitting it into the slots

(2) Assembly
in the DUPRINTER's top section.
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.
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
Print tray
person alone. 23S0110
¡Place the printer unit on a flat, level surface.
Pull out
Handles
Pull out
Handles
w Push the 4 handles back in.
e Remove all the remaining fixing tape.
193
Using the optional printer stand

q Unpacking Check. !0 Remove all the remaining fixing tape.
2Check that the printer stand unit package is
!1 Attach the print tray, by fitting it into the slots
present.
in the DUPRINTER's bottom section.
w Unpack the printer stand unit package.
IMPORTANT : Carry out unpacking and assmbly

in a place that is safe for the work.
Slot in bottom section
e Check that the package has the contents listed
below.
Item Quantity
Printer stand unit 1
* Check the unit's casters for abnormality. Print tray

23S0111
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.
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
(3) Power Switch ON 230V AC model
q Make sure that the power switch is OFF. WARNING

w Insert the plug on one end of the power cord (one ¡Connect the DUPRINTER to an outlet providing
of the accessories) into the DUPRINTER's power a 50Hz, 8A power supply of at least 230V.
inlet. ¡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

r Turn the power switch ON.
cord into the power outlet.
t Check the liquid crystal display on the operation
panel.
120V AC model ¡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
(4) Setting the Master Roll
q Press the scanner switch and open the scanner. r Peel off the seal.
Scanner unit
SEAL
Scanner switch
w Take out a new master roll from the bag. t Pull out the master and insert the front
Insert the master holders deeply into both ends head of the master until it contacts the roller.
of the master roll. (Holders are interchangeable.)
Master holder
e Insert the master roll into the machine IMPORTANT

so that the ID mark line on the roll is facing •If the master is not pulled in ,then gently
the control panel. press in as far as possible to set again.
y 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
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.
u Remove the trimmed piece of the master.
IMPORTANT
¡ When the master stops, make sure that

you remove the trimmed piece of the
master.
i Gently close the document receiving tray.
Scanner unit
197
r Grip the upper drum shaft with your other hand,

(5) Preparation of Drum
and pull the drum out toward you while slightly
lifting the near end of the drum.
q Press the jog switch (drum rotator switch).
Hold down until the drum stops with a beep.
CAUTION
WARNING ¡Hold the drum level and place it on a flat,
solid surface.
¡Do not touch the drum or rollers when you
¡The stainless screen does not return to the
operate the jog switch.
original state once it is folded. Be careful to
¡Do not put hands inside machine while it is
handle the screen.
operating.
Hands could get caught up or crushed.
Upper drum shaft

q
Jog switch e 23S0017
t Move the lever with a hand to open and close the

23S0014
master clamp once or twice.

w Open the front cover toward you.
Master clamp
Front cover
23S0018
e Lift up the drum securing lever. y Hold the drum level and place the drum guide
While lifting the lever up, pull out the drum roller onto the rail in the machine.
handle toward you, pulling it straight out until it
stops. Drum
Drum handle Drum securing lever

Roller
Rail
23S0019
198
u Let go of the handle far end of drum, and push !1 Close the front cover.
the drum in about 10 cm while slightly lifting
the near end of the drum.
Front cover
!2 Press the jog switch (drum rotator switch).

Continue pushing until the drum stops with a
i Hold the drum level and push it in gently until it beep.
stops.
o Lift the drum securing lever toward you while
pushing the drum in. WARNING
¡Do NOT touch the drum or rollers when you
Drum securing lever
operate the jog switch.
¡Do NOT put hands inside machine while it is
operating.
Hands could get caught up or crushed.
!0 Push down the securing lever tightly with the

drum inside the machine.
Jog switch
Drum securing lever
23S0014
199
(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.
Set line
Holder release lever
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
e When the whole area of paper is darker or

(7) Supplying Ink and Adjusting Ink
lighter, turn stepwise the Ink Amount
Amount Adjustment Knob on both sides in the "4" or
"3" direction respectively (3 steps).
1. Supplying Ink
q Invoke the HELP mode.
While holding down the PRINTING SPEED
ADJUSTMENT keys and simultaneously,
Setscrew Never loosen!
turn the power on.
w Supply ink using HELP04.

Enter <0> <4> from the keypad and then press
the PRINT key.
Ink Amount Adjustment Knob on the near side
Drum will begin to rotate while the ink pump (Standard Position)
starts operation.After completion of supplying
ink, drum will stop rotating with continuous
beep sounds.
Setscrew Never loosen!
In general, it takes approx.30 seconds to supply
ink.
e Turn the power OFF and then ON again.

Ink Amount Adjustment Knob on the far side
r Perform Mastermaking and printing of the (Standard Position)
document.
IMPORTANT : For more information, refer to IMPORTANT : The Ink Amount Adjustment Knob has
"Mastermaking and printing procedure" a total of 7 positions : 3 positions
in the Instruction Manual. for each of "4" and "3" directions
The image will be light since ink is as well as a standard position.When
not fully spread over the drum adjusting the image density, you
surface. It is not a trouble. should print the image on dozens of
Continuously print approx.20 sheets. sheets to stabilize the density every
time you change it by every step.
Repeat the above steps until you
t Once ink is fully spread, check the printed
get desired print density.
image.If the density varies between the near and
far areas of paper, make adjustment according to
the "Adjusting Ink Amount".
2. Adjusting Ink Amount (8) If Options are Installed

q When the near area is darker or lighter, turn ¡Optional equipment should be installed AFTER
stepwise the Ink Amount Adjustment Knob on the machine itself has been installed and test-run
the near side in the "4" or "3" direction to check that it functions normally. For the
respectively (3 steps). procedure for installing optional equipment,
w When the far area is darker or lighter, turn see the Installation Procedures supplied with it.
stepwise the Ink Amount Adjustment Knob on
the far side in the "4" or "3" direction
respectively (3 steps).
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 Description Remarks

Shading plate Cleaning Clean with a soft and clean cloth
Glass Cleaning Clean with a soft and clean cloth
Lamp Cleaning Clean with a soft and clean cloth
Reflection mirror Cleaning Remove dust with blower brush
Thermal head Cleaning Clean with a soft and clean cloth (Do not damage the thermal head)
Platen roller Cleaning Remove paper shreds (Do not damage the platen roller)
Sensor Cleaning Remove dust with blower brush
Press roller Cleaning Remove paper shreds
Drum exterior Cleaning Remove ink and paper shreds
Paper feeding section Checking Paper is fed smoothly. Remove paper shreds
Plate making section Checking Paper is fed smoothly. Remove paper shreds
Roller shaft / bearing Oiling Except for the pinch lever bearing section
Gear Greasing
Air pump Greasing
Escape cam Greasing
(2) Criteria for Replacing Primary Parts
No. Item Criterion Remarks

1 Paper feed roller 300,000 sheets or more
2 Paper separator unit 300,000 sheets or more
3 Thermal head About 20,000 masters or one year Up to 10 voids
4 Drum unit Printing 1,000,000 sheets or one year Overhaul
5 Air pump Printing 1,000,000 sheets or one year
6 Tape cutter upper/lower blade Cutting 10,000 times or one year
7 Press roller 1,000,000 sheets or one year
8 Lamp 10,000 masters or one year
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
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. Page
SCANNER OPEN (12) 216

DOCUMENT JAM When power turnd on (15) 218
DRUM NOT SET (4) 212
E*** SERVICE CALL (3) 223
EXCHG. EJECT-CORE (18) 220
EXCHANGE INK (14) 217
FRONT COVER OPEN (11) 215
MAST. EJECT MISS (8) 214
MASTER SET MISS (5) 212
PAPER LEFT JAM (17) 220
PAPER RIGHT JAM (16) 219
ROLL-MASTER END (13) 216
SET PRINT PAPER (10) 215
Error item List
Item No. Page
Lamp does not light up (1) 209

Malfunction of master feeding clutch (6) 213
Malfunction of Mastermaking stepping motor (7) 213
Malfunction of roll-up motor (9) 214
Optical system dose not move forward/backward (2) 210
Paper JAM in the paper eject side (20) 222
Paper JAM in the paper feed side (19) 221
208
(1) LAMP does not light up
Cause/Defective section Procedures Item to be checked Result Countermeasure

1 Does voltage between main PCB unit NO Proceed to procedure 3.
J2-11(+) and J2-26(GND) show
+24V?
LAMP 2 Is trouble cleared by replacing LAMP? YES Finish.
Main PCB 3 Is trouble cleared by replacing YES Finish

main PCB?
209
(2) Optical system dose not move forward/backward
Cause/Detective section Procedures Items to be checked Result Countermeasure
Wire or timing belt is cut Are the optical system driving wire and
1 No Attach the wire and timing belt properly.
or removed. timing belt attached properly?
Is the rail clean?Does the optical sys-

There is a foreign object Check that there is no foreign object on
tem move smoothly when the optical
on the optical system 2 No the rail and that nothing contacts the
system driving timing pulley is rotated
moving way. optical system.
manually?
Measure the voltage between the regu-

lated power supply, CN2-1 (+) and
3 No Follow the procedure (5).
CN2-2(GND) with the tester.
Is it +24 V?
Main PCB Unit Yes Finish

Is the cause cleared by replacing the Check the bundled wire and connector.
Optical system stepping 4
main PCB Unit? No Replace the optical system stepping
motor
motor.
Remove the regulated power supply, Check the first side bundled wire con-
Regulated power supply 5 CN1, 2 and 3 and follow the procedure No nector. If OK, replace the regulated
(3). Is it +24V? power supply.
Follow the procedure (5) and insert the

6 regulated power supply, CN2. Is the Yes Follow the procedure (8).
voltage +24V?
Yes Finish
Thermal head Is the cause cleared by replacing the
7 The thermal head is defective.
thermal head?
No
Remove the main PCB Unit J1 and

At the J1 bundled wire or motors
Motors 8 follow the procedure (3). Is the voltage Yes
+24V produces a short-circuit to GND.
+24V? (CN1 is inserted)
210
(3) "E*** SERVICE CALL" is displayed

1 Is the same error message displayed NO Finish
again after power off and on?
2 According to P223 Error Display, Finish

shoot the trouble cause one by one.
* Error Display \ see p.223
211
(4) "DRUM NOT SET" is displayed

Drum setting 1 Is trouble cleared by setting drum YES Finish
again?
Main PCB unit 2 Does drum SW (MS4) checked by YES Check if drum SW (MS4) is
HELP mode (H-08)* prove to be nor- installed in place and replace
mal? main PCB unit.
Drum SW 3 NO Replace drum SW (MS4).
Does drum SW (MS4) checked by
Main PCB unit YES Check if drum SW (MS4) is
installed in place and replace
main PCB unit.
* HELP mode H-08 \ see p.242
(5) "MASTER SET MISS" is displayed

End mark sensor PCB 1 Has “MASTER SET ERROR” actually NO Adjust VR for end mark sensor
unit (PS3) occurred? by HELP mode (H-13)*. If unn-
able,replace end mark sensor
PCB unit.
NOTE:
VR must be adjusted after
replacement of end mark sensor
PCB unit.
Master feeding clutch 2 Does master feeding clutch (CL1) NO Refer to “(6) Malfunction of master
(CL1) operate normally? feeding clutch (CL1)”.
\ see page 213
Mastermaking stepping 3 NO Refer to “(7) Malfunction of

motor (PM2) (PM2) operate normally? mastermaking stepping motor
(PM2)”.
\ see page 213
Cutter unit 4 Is master cut normally? NO Replace cutter unit.

Static electricity 5 Is static-eliminating brush on master YES Remove static-eliminating brush.
feeding unit damaged or deteriorated?
Master 6 Is trouble cleared by replacing mas- YES Finish
ter?
Transfer path NO Remove any foreign matter in
transfer path
212
(6) Malfunction of master feeding clutch

Regulated power supply 1 Does voltage between regulated NO Replace regulated power supply.
power supply CN51-1(+) and CN53-1
(GND) show 24V?
Master feeding clutch 2 Does voltage between main PCB unit YES Check wiring and replace master
(CL1) J2-11 (+) and -12 (GND) show 24V feeding clutch.
when master feeding clutch is turned
on?
Main PCB unit 3 Is trouble cleared by replacing Main YES Finish
PCB unit?
(7) Malfunction of mastermaking stepping motor

Load on drive system 1 Is trouble cleared by adjusting tension YES Finish
of the master feeding unit timing belt
or supplying oil to bearing?
show 24V?
PCB unit?
213
(8) "MAST. EJECT MISS" is displayed

1 Has “MAST. EJECT ERROR” actually YES Proceed to procedure 5.
occurred?
Foreign material or dirt on 2 Are there any foreign matter or dirt YES Remove any foreign matter and
sensors between the master ejection sensor clean.
photo-receiving (PS13) and the mas-
ter ejection sensor photo-emitting
PCB?
Master ejection sensor 3 Is trouble cleared by replacing the YES Finish
photo-receiving (PS13) master ejection sensor photo-receiv-
ing (PS13)?
Master ejection sensor 4 Is trouble cleared by replacing the YES Finish
photo-emitting PCB master ejection sensor photo-emitting
PCB?
Main PCB unit NO Check bundled wire and
connectors and replace main
PCB unit.
Roll-up motor (M4) 5 Does roll-up motor (M4) rotate nor- NO Refer to “(9) Malfunction of roll-up
mally? motor (M4)”.
Master clamp dirty 6 Is the master clamp section dirty with YES Clean master clamp section.
ink or oil?
Master ejection box 7 Is stripper finger or springs damaged? YES Replace any damaged stripper
finger or springs.
Drum master ejection 8 Is the drum master ejection stop posi- NO Adjust the drum master ejection
stop position tion within reference value? stop position.
C mode YES Check and adjust C mode.
(9) Malfunction of roll-up motor

Roll-up motor (M4) 1 Does voltage between main PCB unit YES Replace roll-up motor (M4).
J2-3 (+) and -4 (GND) show 24V
when roll-up motor (M4) is operated
with HELP18?
show 24V?
PCB unit?
214
(10) "SET PRINT PAPER" is displayed

No paper is detected 1 Is trouble cleared by adding papers? YES Finish
Paper sensor (MS7) 2 Is actuator for paper sensor (MS7) is NO Adjust paper sensor (MS7) posi-
position pressed when paper tray is set? tion
Paper sensor (MS7) 3 When paper sensor (MS7) is checked NO Replace paper sensor (MS7).
with volt-ohm-milliammeter, does it
Main PCB unit CLOSE if actuator is pressed and YES Check bundled wire and
OPEN if released? connectors and replace main
PCB unit.
(11) "FRONT COVER OPEN" is displayed

Front cover open is 1 Is trouble cleared by closing the YES Finish
detected front cover?
Front cover SW (MS5) 2 Is front cover SW (MS5) pressed NO Adjust front cover SW (MS5)
position when front cover is set? position.
Front cover SW (MS5) 3 When front cover SW (MS5) is NO Replace front cover SW (MS5).
checked with volt-ohm-milliammeter,
Main PCB unit YES Check bundled wire and
does it OPEN if switch is pressed
(front cover open) and CLOSE if
PCB unit.
released (front cover close)?
215
(12) "SCANNER OPEN" is displayed

Scanner SW (MS3) 1 Is the scanner SW (MS3) pressed Adjust the scanner SW (MS3)
NO
position when the scanner is closed? position.
Scanner SW (MS3) 2 When the scanner SW (MS3) is NO Replace the scanner SW (MS3)
checked with volt-ohm-milliammeter,
does it CLOSE if switch is pressed
Main PCB unit and OPEN if released? YES Check bundled wire and
PCB unit.
(13) "ROLL MASTER END" is displayed

End mark is detected 1 Is trouble cleared by changing a YES Finish
new master?
Adjustment for the 2 Is trouble cleared by adjusting the YES Finish

end mark sensor PCB end mark sensor PCB unit (PS3) by
unit (PS3) HELP mode (H-13)*?
End mark sensor PCB 3 Is trouble cleared by replacing the end YES Finish
unit (PS3) mark sensor PCB unit (PS3)?
Main PCB unit NO Check bundled wire and
PCB unit.
216
(14) "EXCHANGE INK" is displayed

Ink 1 Is enough ink left in ink pack? NO Replace ink pack.
Setting method of ink 2 Is ink pack set properly? NO Set ink pack properly and teach
pack user how to set one.
Main PCB unit 3 Is LED on the ink detection PCB unit YES Check bundled wire and
lit? connectors and replace main
PCB unit.
Ink detection PCB unit 4 Is enough ink left in drum? (Has ink YES Replace Ink detection PCB unit
reached detection needle for the ink
detection PCB unit?)
5 Does ink pump operate? NO Proceed to procedure 7.
Foreign material in ink 6 Is trouble cleared by cleaning inside of YES Finish
pump ink pump?
Ink pump NO Replace ink pump.
show 24V?
Ink motor (M2) 8 Does voltage between main PCB unit YES Replace ink motor (M2).
J2-5 and -6 show 24V?
Main PCB unit 9 Is trouble cleared by replacing main YES Finish
PCB unit?
217
(15) "DOCUMENT JAM" is displayed(ADF)

1 Does the document feed roller rotate? NO Proceed to procedure 7.
Separator, paper feed 2 Is document fed by separator and the NO Clean separator and the paper
roller paper feed roller? feed roller. If necessary, replace.
Main PCB unit 3 When document sensor 1 (PS1) is YES Check bundled wire and
checked with HELP08, is 0 displayed connectors and replace main
if sensor is photo passing and is 1 dis- PCB unit.
played if photointerrupted?
Main PCB unit 4 Does voltage between main PCB unit YES Replace main PCB unit.
J7-16 and GND show HIGH value
(about 3.3V) if sensor is photointer-
rupted and LOW if photo passing?
Document sensor position 5 Is trouble cleared by adjusting the YES Finish

document sensor position?
Document sensor 6 When document sensor 1 (PS1) is YES Replace the document sensor
photo-emitting PCB checked with HELP08, is 0 displayed photo-emitting PCB
by directing another light to the photo-
Document sensor NO Replace the document sensor
receiving section of the document
photo-receiving PCB photo-receiving PCB
sensor photo-receiving PCB?
Gears 7 Are gears broken? YES Replace gears.

show 24V?
Main PCB unit 9 Is trouble cleared by replacing main YES Finish
PCB unit?
Scanner stepping motor 10 Is trouble cleared by replacing Scanner YES Finish
stepping motor? (PM1)
(PM1). Replace scanner stepping
NO
motor(PM1)
218
(16) "PAPER RIGHT JAM" is displayed

Paper 1 Is printing paper long within specified NO Use paper conforming to
value? specification.
2 When JAM sensor 1 (PS12) is YES Proceed to procedure 7.
checked with HELP08, is 0 displayed
if sensor is photopassing and is 1 dis-
played if photointerrupted?
Paper jammed 3 Is paper really jammed at master ejec- YES Refer to “Paper JAM in paper
tion section? eject side”.
Master ejection box is 4 Is trouble cleared by properly closing YES Finish
not closed. the master ejection box?
Dirt or foreign material 5 Is there any dirt or foreign material on YES Clean the photo-emitting and
on sensor the JAM sensor photo-emitting or photo-receiving sections of JAM
photo-receiving section? sensor.
Sensor position 6 Is trouble cleared by adjusting the YES Finish
JAM detection sensor position?
Document sensor 7 Is 0 displayed by directing another YES Replace JAM sensor photo-
photo-emitting PCB light to the photo-receiving section of emitting PCB.
the document sensor photo-receiving
Document sensor NO Replace JAM sensor photo-
PCB when JAM sensor 1 (PS12) is
photo-receiving PCB receiving PCB.
checked with HELP06?
Stop/JAM detection 8 When drum is checked with HELP06 NO Adjust position of the stop/JAM
position sensor (PS6) while rotating slowly, does the detection position sensor. If
stop/JAM detection position sensor necessary, replace.
(PS6) display 0 or 1 according to edge
Main PCB unit YES Replace main PCB unit.
of photointerrupter?
219
(17) "PAPER LEFT JAM" is displayed
LCD panel 1 Is trouble cleared by checking, refer- YES Finish

ring to “Paper jams in the paper feed
side”?
Main PCB unit 2 When P roller sensor (PS9) is YES Replace the main PCB unit.
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 print-
ing may differ depending on speed
or load. Recommended is to follow
procedure 3 and 4 below for further
check.
P roller sensor (PS9) 3 Is the trouble cleared by adjusting P YES Finish
position roller sensor (PS9) position?
P roller sensor (PS9) 4 Is the trouble cleared by replacing P YES Finish
roller sensor (PS9)?
Main PCB unit NO Check the bundled wire and
connectors and replace the main
PCB unit.
(18) "EXCHG. EJECT-CORE" is displayed

Core 1 Core is not included or core is full? YES Insert new core.
Core full SW (MS8) 2 Is core full SW (MS8) pressed when YES Adjust actuator of core full SW
actuator empty core is installed? (MS8).
Core full SW (MS8) 3 Does core full SW (MS8) tested volt- NO Replace core full SW (MS8).
ohm-milliammeter prove to be nor-
Main PCB unit YES Check bundled wire and
mal?
PCB unit.
220
(19) Paper Jams in the Paper Feed Side
Causes Symptoms Countermeasure
Printing paper not suit- • If paper is too thick, it won’t be likely fed. If too thin, dou- Explain causes to user. Have user
able ble sheets may be fed. change to the paper conforming to
• Paper not clearly cut: 2 sheets still adhere to each specifications.
other.
• Much paper scraps may deteriorate the paper feed
roller and separator performance.
Dirt*foreign matter in • Paper gets stuck in transfer path, causing creasing and Remove any dirt or foreign matter.
transfer path tearing.
Incorrect paper feed path • If pressure on paper is insufficient, paper will not be fed. Explain to users how to select cor-
pressure • If pressure on paper is excessive, double sheets will be rect pressure for paper.
fed.
Worn paper feed roller • Paper may not be fed. Replace paper feed roller.
Paper separator unit gap • If gap is too large, separator unit will rattle in direction of Perform paper separator unit gap
paper transfer path, causing double sheets to be fed. adjustment.
• If gap is too small, paper separator unit cannot follow
angle change due to paper feed shaft up-down move-
ment, which may cause double-sheet or slanted feed,
and creasing. \ see page 169
Paper separator unit • Wear, or adhesion of paper scraps causes deterioration Clean separating surfaces. If any
in separating performance, resulting in double-sheet trouble exists, replace. Perform sep-
feed. arator unit gap adjustment on new
unit. \ see page 169
Separation pressure • If pressure is very low, no paper will be fed. Perform separation pressure adjust-
ment.
\ see page 170
Paper tray upper position • Paper slant is large, causing creases. Perform paper feed tray upper limit
limit • During printing, paper feed errors often occur immedi- sensor adjustment.
ately before or after paper tray rises. \ see page 170
Paper feed amount • If amount is too short, paper slant cannot be corrected, Perform paper feed amount adjust-
printing position may not be uniform, or paper may not ment.
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.
HELP mode H-67 / 284 page
Paper feed clutch • Clutch slippage will reduce paper feed amount. Replace paper feed cluch.
• 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.)
Guide roller pressure & • If Guide roller pressure is insufficient, paper will not be Perform escape amount adjustment
timing gripped properly, and timing roller will not assure con- and escape timing adjustment.
stant 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.
\ see page 172
Timing roller • If the timing roller clutch slips, feed amount will not be Clean timing roller clutch . Replace
constant. As a result, printing position will not be uni- if necessary.
form. 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.
Incorrect signal lever • Paper may be damaged in the part of leading edge that Clean bearing unit. Check that sig-
operation touches the signal lever. In the worst case, paper may nal lever moves smoothly.
stick to the signal lever.
221
(20) Paper Jams in Paper Eject Side
Causes Symptoms Countermeasure
Printing paper not suit- • If paper is too thin, it will stick to drum and scrunch up. Explain causes to users. Have user
able • If grain of paper is sideways relative to transfer direction, paper will change to paper conforming to
crunch up, or get jammed on the paper receiving plate. specifications.
• If paper curl upward, it will likely scrunch up. If curl downward, it will
likely get jammed on the paper receiving plate.
Image of document • If set-solid exists near leading edge of paper, paper will likely scrunch • Adjust leading edge margin to
up. about 10 mm. (Too long margin
• If set-solid is blasted to one side of paper, paper will not be ejected in will cause adverse results.)
a straight line. As a result, ejected paper will be disorderly piled and • Explain causes to users. If possi-
likely jam on the paper receiving plate. ble, have user change position for
set-solid.
Static electricity • If ambient air is dry, static electricity may cause disordered piles or • Explain causes to users. Have user desist
scrunch-up of paper. from excessive use of A/C or heating.
• If possible, have user take anti-dryness
measures including humidifiers.
Leading edge margin • If leading edge margin is not correct, scrunch-up of paper will likely • Perform printing position sensors
result. adjustment.
IMPORTANT:
\ see page 173
Scrunch-up of paper may also result if the margin is too long.
Guide roller pressure & • If Guide roller pressure is insufficient, paper will not be gripped proper- Perform escape amount and escape
timing ly, causing less feed amount determined by timing roller, or disap- timing adjustments.
pearance of leading edge margin. This results in the paper scrunch-
up. \ see page 172
Timing roller clutch • Any slippage of the timing roller clutch will reduce feed amount and Clean timing roller clutch. Repair if
eliminate leading edge margin. This results in the paper scrunch-up. necessary.
• 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.
Paper stripper finger • If timing is too low, or the gap between drum and the leading edge of Perform paper stripper finger adjust-
paper is too large, paper stripper finger will not enter into the gap, ment.
causing the paper scrunch-up.
\ see page 178
Air • If sufficient air is not delivered from the tip of the paper stripper finger, • Check if the hole in the fingers tip
it will not lift the leading edge of paper off drum. Scrunch-up of paper is blocked by foreign matter.
will result. • Check pipes for kinks or discon-
nections.
• Check valves and O-rings on the
air pump.
Paper ejection belt • If the speed of the paper ejection belt, if cannot eject the paper onto If the belt is broken or stretched,
the paper receiving plate with sufficient force. replace it.
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 jam-
ming sensor and a paper jamming error is displayed.)
Paper ejection fan unit • If the suction force of the fan drops, it will not be able to blow the Clean the fan. If it still does not work
paper (which has risen clear of the ejection belt) onto the paper properly, replace it.
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.)
Ink • Too much ink transferred to paper will likely cause scrunch-up of • Perform ink volume adjustment of drum.
paper. • Explain user that ink transfer volume
increases immediately after paper scrunch-
up, and advise user to restart printing at
standard speed, then.
\ see page 179
222
xError Display
This machine has a self-diagnosis function. The
state of the machine is always checked with this LCD panel
function and is displayed with code on the control
panel. The following are the code display, cause and
detection timing.
E111
Code display
Code display Cause Detection timing
• The main motor (M1) is defective.

• The main PCB Unit is defective. • While the drum rotation signal is lit, the encoder sen-
E001
• The encoder sensor (PS7) is defective. sor (PS7) cannot detect the edge for 1 second.
• The elevator motor (M2) is defective.

• The elevator does not reach the top limit for 30 sec-
• The elevator top limit sensor (PS9) is defective.
onds after the elevator motor (M2) up signal is lit.
• The elevator bottom limit switch (MS6) is defective.
E002 - The main PCB Unit is defective. • The elevator does not reach the bottom limit for 30
• The elevator operation is defective. seconds after the elevator motor (M2) down signal
is lit.
• The cutter motor is defective. • The cutter does not reach the limit for 30 sec-
E003 • The cutter limit switch is defective. onds after the cutter motor move signal is lit.
- The main PCB Unit is defective.
• The lamp is defective. • In the lamp lighting check, amount of light received
E004 • The invertor unit is defective. by CCD does not reach regulation value. (Perform
• The CCD is defective. the lamp lighting check once only, with the power
• Main PCB unit is defective. turned on.)
• The main PCB Unit is defective.

• At start of mastermaking, thermal head drive voltage
E009 • The thermal head substrate is defective.
does not reach regulation value.
• The thermal head is defective.
• The master set sensor is defective. • The master set sensor signal is detected continually
E040 • The cord for master set sensor is unconnected. for 20 seconds after power is on.
- The main PCB Unit is defective.
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 : ADF
HELP Description Classification Page

Mode No.
H-00 Display of ROM versions ROM version displays 233
H-01 Display and adjustment of print speeds Adjustment / specification 234

setting
H-02 Elevator motor Function testing Function testing 236
H-03 Tape Cluster Function testing Function testing 237
H-04 Ink replenishment Function testing Function testing 238
Checking of condition of master ejection sensor and other sensors

listed below
H-05 Sensor/ switch condition
¡Paper feed sensor,Top/Bottom limit sensor, Top/Bottom center sensor display 239
¡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 Sensor/ switch condition
H-06 Light reception by the paper ejection jam sensor 240
display
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 Sensor/ switch condition
H-07 ¡ Master lever feed sensor,Paper sensor,Drum cover switch 241
display
¡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 Sensor/ switch condition
H-08 ¡Upper cover switch, Master roll Full switch, Drum switch 242
display ADF:242
¡ Value of ADF received
Checking of master attachment position, jam sensing position,
H-09 Function testing 243
master detachment position and drum stop position
(1) Function testing of LAMP (1)244

H-10 Function testing
(2) Testing of functioning of ADF scan motor operation function (2)244
(1) Document darkness values and scanner test (for use in factory checks) Sensor/ switch condition 245
H-11
(2) Testing of ADF. display ADF:245
H-12 (1) Checking of shading memory Function testing 246
H-13 (1) Check the condition of the end mark sensors Sensor/ switch condition 247
display
226
: ADF

Mode No.
(1) Mastermaking total counter display (1) 248
H-14 Total counts
(2) Resetting of count of total masters made in user mode (2) 248
H-15 Function testing of ink motor Function testing 249
Adjustment / specification
H-16 Setting of online (with PC interface) master making start position 250
setting
H-17 Function testing of Cutter motor Function testing 251
(1) Function testing of roll-up motor

(2) Function testing of fan motor
(1) Printing total counter display (1) 253
H-19 Total counts
(2) Resetting of count of total sheets printed in user mode (2) 253
Function testing of clamp motor and clamp position sensing
(A /B /C mode position)
H-21 (Not used) 4 4
Setting of lengthwise zoom factor correction amount for Adjustment /specification

H-22 255
mastermaking side setting
Adjustment /specification 256
H-23 Setting of photograph mode document sensing darkness ADF:256
setting
H-24 Setting of reducing offset for reading longitudinal R / E of scanner ADF:257
setting
H-25 Setting of enlarging offset for reading longitudinal R / E of scanner ADF:258
setting
Compensation of document darkness white level in photograph Adjustment /specification 259
H-26 ADF:259
mode setting
Adjustment /specification
H-27 Initialization of all HELP mode settings 260
setting
Setting of buzzer selection Adjustment /specification
H-28 261
setting
H-29 Adjustment of paper infeed amount 262
setting
Test pattern (all shading secondary scanning direction zoom
H-30 factor adjustment) mastermaking and printing Function testing 263
H-31 Setting of number of pre-print sheets 264
setting
Confidential safeguard function, selection of first print speed, Adjustment /specification
H-32 265
setting of master ejection error sensing setting
H-33 Compensation of document darkness white level in text mode
setting ADF:266
227
: ADF

Mode No.
H-34 (Not used) 4 4
Adjustment/specification 267
H-35 Adjustment of scanner leading edge sensing position ADF:267
setting
H-36 Adjustment of scanner widthwise (operation side) sensing position ADF:268
setting
H-37 Adjustment of mastermaking start position when scanner is used
setting ADF:269
H-38 Adjustment of drum speed automatically
setting
H-39 Function testing of clutches test and auto power off Function testing 271
H-40 (Not used) 4 4
Automatic initialization of the control panel setting, setting of repeat Adjustment/specification

H-41 272
count display,energy save mode and auto power off setting
Adjustment/specification
H-42 Setting of paper selection specification 273
setting
H-43 Setting of thermal head offset value 4 274
setting
H-44 Setting of thermal head resistance ranking 275
setting
H-45-49 (Not used) 4 4
H-50 Setting of text mode document sensing darkness
setting ADF:276
H-51/52 (Not used) 4 4
Adjustment of widthwise (operation side) mastermaking start position Adjustment/specification

H-53 277
for online mastermaking setting
H-54 (Not used) 4 4
Setting of ink check at printing start, cutting operation mode Adjustment/specification

H-55 278
for master cutting, and interlocks Setting
H-56 Seeting for selecting manipulation language 279
Setting
H-57/58 (Not used) 4 4
H-59 Setting of endmark sensor2 280
Setting
H-60 (Not used) 4 4
H-61 Function test for LCD screen and LED indicators 281
Function testing
(for use in factory checks)
H-62 (Not used) 4 4

Setting
H-63 Setting for A4 master cut 282
Setting
H-64 Buzzer (tone) setting Setting 283
228
: ADF

Mode No.
H-65 (Not used) 4 4
Setting: clamp opening/closing timing of when a master is attached; Adjustment/specification

H-66 284
H-67/68 ON/OFF Setting
H-67 Setting of paper feed length Adjustment/specification

Setting 285
H-68 Setting of paper feed angle 286
Setting
H-69 Setting of model 287
Setting
H-70/71 (Not used) 4 4

H-72 Adjustment of master making area length 288
Setting
Adjustment of master making area length on online printing Adjustment/specification

H-73 289
Setting
Setting of thermal head temperature supplementing and master Adjustment/specification
H-74 290
making darkness rank. Setting
H-75 (Not used) 4 4
Document darkness correction for photograph/text mode Adjustment/specification

H-76 291
Setting
H-77/79 (Not used) 4 4
H-80 Setting of speed rank, ADF and ink save mode 292
Setting
H-81/82 (Not used) 4 4

H-83 (1) Display of ROM version for ADF 293
Setting
H-84 (1) Checking of communication for ADF Setting 294
Adjustment for image sampling timing of scanning Adjustment/specification 295

H-85 (for use in factory checks). Setting
H-86 Setting of manual batch printing Setting
H-87-88 (Not used) 4 4
H-89 Setting of Tape cluster 297
Setting
H-90 Setting of several special functions. 300
Setting
H-91 Setting of tape lenghth for Tape cluster on online mode
Setting
H-92 Setting of tape lenghth for Tape cluster 302
Setting
Adjustment of widthwise (operation side) scaning start position Adjustment/specification
H-93 303
for 4-up and 8-up Setting
H-94 UID ADMINISTRATOR password reset Adjustment/specification 304
Setting
H-97 The display for machine model. 305
Setting
229
chap.8 x Overview
x Overview
The Duprinter's HELP modes can be broadly classified into the

following types:
◆ 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).
◆ 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).
◆ 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.
◆ Modes for sensor and switch displays

These modes provide displays of the conditions of sensors and
switches.
◆ 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.
230
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 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 Mode number
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 U6B 1 . 11 0 p : V 1 . 11
currently set value, for the mode will be displayed.
From this point on, follow the procedure given below for the
particular mode accessed.
(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
HELP mode H-03 (1)Function testing
1. Functions
For desccription of operation

(1) Tape cluster function test References
\See page 150
Main functions to related
(2) Stacker rise/descent motor function testing For removal
pages
\See page 195
2. Operation procedure
Operation (1) Testing the tape cluster's functioning

LC display
procedure for qAccess HELP mode H-03, and press the PRINT key.
For the basic procedure for accessing HELP modes. H - 0 3 for function
individual \See page 293
Mode number flashes
functions wPress and hold down the TEST PRINT T
key. The tape feed motor
will run, and feed out the tape, for as long as the key is held down.
231
(3)Guide to version up
screw1 cover version up socket
q Remove screw1 and loosen screw2,make cover to fall down,
and make version up socket out.
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
¡ HELP Mode Descriptions

HELP mode H-00 ROM version displays
1. Functions
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.
Displaying ROM versions

qAccess HELP mode H-00, and press the PRINT key.
For the basic procedure for accessing HELP modes.
\See page 231
¡Displaying ROM version

Displays version of the main PCB unit's ROM and I/F PCB unit
U6B 1 . 11 0 p : V 1 . 11
as right when TEXT mode is selected.
Main PCB unit I/F PCB unit
Displays version of the panel PCB unit's ROM and DSP as right
K E Y V 1 . 1 1D S P V 1 . 1 1
when TEXT/PHOTOGRAPH mode is selected.
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.
233
HELP mode H-01 (1) Adjustment / specification setting
1. Functions
Display and adjustment of print speeds Adjusting of Printing Speeds 1-3
\See page 188

¡Display and adjustment of print speeds (pre-stop speed, jog speed
and speeds 1-3)
IMPORTANT
¡You'd better adjust these speeds after auto-speed adjustment by using help 38.
Adjusting speeds and memorizing the adjusted values

\See page 231
wSelect the speed you want to adjust.

¡ Speeds 1-3 111 r pm
Press the DOCUMENT MODE SWITCH key as many times
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
as needed to select the TEXT/PHOTOGRAPH item. 1st 2nd 3rd speed
¡ Pre-stop speed
as needed to select the TEXT item.
eSelect the item speed you want to adjust

¡ To select the print speed:
as needed to select the PHOTOGRAPH item.
234
rUse the and PRINTING POSITION ADJUSTMENT keys to

adjust the speed value.
Adjustment standard (rpm)
Speed
Print speed
Pre-stop 5-7
JOG 16 - 18
1st. 63 - 65
2nd. 87 - 89
3rd. 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
235
HELP mode H-02 (1) Function testing
1. Functions
(1) Elevator motor function testing For electrical parts layout
\See page 304
(1) Testing the elevator motor's functioning

For the basic procedure for accessing HELP modesn.
\See page 231
wPress and hold down the PRINTING POSITION ADJUST-

MENT 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 key. The HELP mode selection display will
reappear.
236
HELP mode H-03 (1)Function testing
1. Functions
(1) Tape cluster function test
(1) Testing the tape cluster's functioning

For the basic procedure for accessing HELP modes. : TAPE TEST
\See page 231
wPress and hold down the TEST PRINT T

key. The tape feed motor
will run, and feed out the tape, for as long as the key is held down.
eRelease the TEST PRINT T
key. The tape cutting solenoid will
be activated, and the tape will be cut.
rPress the STOP key. The HELP mode selection display will
reappear.
237
1. Functions
(1) Ink replenishment function testing

Tests functioning of ink replenishment by sensing the ink
supplied.
(1) Testing the functioning of ink replenishment

: I NK CHECK
\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.
reappear.
238
HELP mode H-05 (1) Sensor / switch condition display
1. Functions
(1) Checking of condition of master ejection sensor and For electrical parts layout
other sensors listed below \See page 301
¡ Runs checks on the Paper feed sensor,Top/Bottom limit sensor,Top/
Bottom center sensor.Displays amount of light received by master ejection sensor. Master ejection sensor
¡ Displays the value of thermistor for Main PCB and Thermal head.
¡ Display the value of encoder count of drum rotated. \See page 75
(1) Checking the condition of master ejection sensor Top/bottom center sensor
1 = Photointerrupting
and other listed sensors
Top/bottom limit sensor
For the basic procedure for accessing HELP modes. Paper feed sensor
0=paper present
\See page 231
wWhen TEXT mode is selected, A display indicating the conditions
of the following sensors and the master ejection sensor's photo- A : 1 B : 1 C : 1 D : 111
receiving amount will appear, the amount is a value between 000 and
255.
◆ Paper feed sensor :A Amount of light received by
◆ Top/bottom limit sensor :B master ejection sensor
◆ Top/bottom center sensor :C
◆ 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 key. The HELP mode selection display will
reappear.
239
HELP mode H-06 (1) Sensor/switch condition display
1. Functions
(1) Checking of condition of sensors listed below For electrical parts layout
¡ Runs checks on the B mode sensor and A/C mode sensor.
¡ Runs checks on the press roller sensor, drum stop / paper ejection \See page 301
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.
(1) Checking the condition of the listed sensors

A/C mode sensor
qAccess HELP mode H-06, and press the PRINT key. 1 = Photointerrupting
w When TEXT mode is selected, A display indicating the conditions B mode sensor
of the following sensors will appear. 1 = Photointerrupting
◆ B mode sensor :A
Unused.
◆ A/C mode sensor :B
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. Drum master attachment / position sensor
◆ Press roller sensor :A
◆ Drum stop / paper ejection jam sensing position sensor : B Light reception by the paper
ejection jam sensor
◆ Light reception by the paper ejection jam sensor :C 1 = Photointerrupting
◆ Drum master attachment/detachment position sensor :D Drum stop / paper ejection jam
sensing position sensor
Press roller sensor

rPress the DOCUMENT MODE SWITCH key as many times 1 = Photointerrupting
as needed to select the PHOTOGRAPH item.
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
◆ Paper ejection jam sensor

A:1 B : 1 11
¡ [10] and under : Paper not present
¡ [255] : Paper present
unused Paper ejection jam sensor

tPress the STOP key. The HELP mode selection display will
reappear.
240
1. Functions
(1) Checking of condition of switches listed below: For electrical parts layout
¡ Displays condition of cutter switch operation/non-operation side, \See page 300
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.
(1) Checking the condition of the listed switches

Drum rotation switch 0 = PUSH
Cutter switch non-operation side 1=push
Cutter switch operation side
\See page 231 1=push
w When TEXT mode is selected, A display indicating the conditions unused

of the following sensors will appear.
S Cutter switch operation side :A
A:1 B:1 C:1 D:1
S Cutter switch non-operation side : B
S Drum rotation switch :C
Drum cover switch 1 = open
Paper sensor 0=paper present
e When TEXT/PHOTOGRAPH mode is selected,A display indicating
Unused
the conditions of the following sensors will appear.
Master feed sensor 1=PUSH.
S Master feed sensor :A
S Paper sensor :C
S Drum cover switch :D
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. Tape switch 0 = present
S Elevator upper limit sensor :A
Feed tray descend switch 0 = PUSH
S Elevator lower limit switch :B
Elevator lower limit switch 1=push
S Feed tray descend switch :C
Elevator upper limit sensor
S Tape switch :D 1 = Photointerrupting
reappear. A:1 B:1 C:1 D:1
241
1. Functions
(1) Checking of condition of switches listed below: For electrical parts layout
¡ Displays condition of upper cover sensor,master roll FULL
\See page 300, 301
switch, drum presence switch.
¡ Displays the value of ADF received .
(1) Checking the condition of the listed sensors

\See page 231
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 Fixed document home ADF home position sensor
position sensor 255=Photointerrupting
1=Photointerrupting
e When TEXT/PHOTOGRAPH mode is selected,the display
indicating the conditions of the following sensors will
appear. A:1 B:1 C:1 D:1
S Scanner opening/closing switch : A
S Paper roll FULL switch :B Scanner opening/closing switch
S Drum switch :D 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:1 B : 1 C : 1 D :1 11
S ADF document sensor :A
S ADF jam sensor :B ADF document sensor
1=Paper Present
S ADF cover switch :C
S ADF document position sensor :D ADF jam sensor
1=Paper Present
ADF cover switch
0=PUSH
ADF document position sensor
Paper present:190 or more ,
tPress the STOP key. The HELP mode selection display will Paper not present: less than 30
reappear.
242
1. Functions
(1) Checking of master attachment position, jam For Standards / Adjustment

sensing position, master detachment position and \See page 175
drum stop position
2. Operation procedures
(1) Checking the master attachment, jam sensing,

master position and drum stop positions

: D R UM P O S . T E S T
\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.
reappear.
243
HELP mode H-10 (1), (2) Function testing
1. Functions
(1) Testing of functioning of LAMP (on/off)

(2) Testing of functioning of scanner motor operation function
(1) Testing the functioning of lamp (on/off)

CCD TEST
\See page 231
¡ When the PRINT key is pressed, the leds in the CIS will light.
reappear.
(2) Testing of functioning of ADF scan motor operation function

\See page 231
wSelect SCAN motor rotated forward or backwards.
¡ Forward
Press the PRINTING POSITING RIGHT key.
¡ Backwards
Press the PRINTING POSITING LEFT key.
e Press the STOP key. The HELP mode selection display will
reappear.
244
1. Functions
(1) Document darkness values and scanner test (for use

in factory checks)
(1) Document darkness values and scanner test (for use

in factory checks)
\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". P1 1 1 1
The sensed size is displayed as a 4-digit number (****) and the
document is fed out.
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)
PHOTOGRAPH item. Feed a document to ADF.
A value between 000 ("darkest" value) and 255 ("lightest" value)
will be displayed.
ePress the STOP key. The HELP mode selection display will
reappear.
245
1. Functions
(1) Checking of shading memory.
(1) Checking of shading memory.

\See page 231
wSelect one of the items below, and follow the procedure given for it.
¡ Check of shading memory, and display of result
¡ Check result display
a Press the DOCUMENT MODE SWITCH key as many times
as needed to select the TEXT item. S-RAM TEST OK
An "S-RAM TEST OK" result display indicates the memory is
normal. Any other display indicates abnormality.
reappear.
246
1. Functions
(1) Checking of condition of switches listed below: End mark sensor

¡ Display of amount of light received by end mark sensors \See page 68,71
(1) Checking the condition of the listed switches

\See page 231
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. A: 11 B: 11
Make sure that the difference between black and white is "30" or
larger.
Press and hold down TEST PRINT key to feed master slowly. Amount of light received by end
mark sensor1
S End mark sensor2
¡Display of presence/absence of the master on its travel path, as A: 11 B: 11

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". Amount of light received by
end mark sensor2
Make sure that the difference between black and white is "30" or
larger.
Press and hold down TEST PRINT key to feed master slowly.
reappear.
247
HELP mode H-14 (1) Total counts
1. Functions
(1) Mastermaking total counter display

(2) Resetting of count of total masters made in user mode
(1) Mastermaking total counter display

\See page 231
F11111111
When the PRINT key is pressed, the total number of
mastermaking is displayed. Mastermaking total counter
[F] = mastermaking
reappear.
(2) Resetting the count of total masters made in user mode

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.
wPress the [=] key and CLEAR C keys simultaneously, to
execute resetting. The resetting will be memorized in the main
PCB unit's EEPROM.
reappear.
248
1. Functions
(1) Function testing of ink motor
1) Testing the functioning of the ink motor

For the basic procedure for accessing HELP modes INK MOTOR.TEST
\See page 231
wPress and hold the TEST PRINT T

key. The ink motor will run
for as long as the key is held down.
IMPORTANT
¡ Remember that ink will be delivered when the ink motor runs.
Take any precautions necessary.
eRelease the TEST PRINT T

key. The ink motor will stop.
reappear.
249
1. Functions
(1) Setting of online (with PC interface) mastermaking For Standards / Adjustment

start position. \See page 184
Related HELP mode
HELP mode H-37 \See page 269
(1) Setting of online (with PC interface) mastermaking

start position.
\See page 231
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
A:1 B:1 C:1 D:1
binary values and the corresponding correction amounts.
ABCD Item Setting Sign flag
Rises by the set amount for the Correction amount display
0***
lower 3 digits
Sign flag
Lowers by the set amount for the
1***
lower 3 digits
*000 Standard (initial value)
*001
*010
*011
Set amount
*100
*101
*110
*111 Maximum
ePress the [=] key. The correction amount will be memorized ¡During memorization:
in the main PCB unit's EEPROM. During memorization,
"SAVE" will be displayed. 111 SAVE 111
IMPORTANT
Do not turn off the power before the "SAVE" display has disappeared.
rPress the STOP key. The HELP mode selection display will reappear.
a To access another HELP mode : Enter the desired mode number using the numeric keys.
250
1. Functions
(1) Function testing of cutter motor For desccription of operation
\See page 72
(1) Testing the functioning of the cutter motor

CUTTER MTR TEST
\See page 231
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.
reappear.
a To access another HELP mod : Enter the desired mode number
251
1. Functions
(1) Function testing of roll-up motor For desccription of operation
(2) Function testing the of the fan motor \See page 77
(1) Testing the functioning of the roll-up motor

EJECT MOTOR TEST
\See page 231
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 FAN MOTOR TEST

\See page 231
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.
reappear.
a To access another HELP mod : Enter the desired mode number
252
HELP mode H-19 (1) Total counts
1. Functions
(1) Printing total counter display

(2) Resetting of count of total sheets printed in user
mode
(1) 8-digit display of count of total sheets printed

"P"=Print
\See page 231
¡When the PRINT key is pressed, the total number of print is

displayed. P11111111
Printing total counter
reappear.
(2) Resetting the count of total sheets printed in user mode

\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.
C
wPress the [=] key and CLEAR keys keys simultaneously,
to execute resetting. The resetting will be memorized in the
battery PCB unit's EEPROM.
reappear.
253
1. Functions
For Standards / Adjustment B mode

(1) Function testing of clamp motor and clamp position
\See page 165
sensing (A/B/C mode position)
For Standards / Adjustment A /C mode
\See page 167
For desccription of operation
\See page 76
(1) Testing the functioning of the clamp motor and

clamp position sensing (A/B/C mode position)

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 key. The HELP mode selection display will
reappear.
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
Mode H-21 is not used
1. Functions
For Standards / Adjustment

(1) Setting of lengthwise zoom factor correction amount
\See page 183
for mastermaking side
(1) Setting of lengthwise zoom factor correction amount

for mastermaking side

\See page 231
A:1 B:1 C:1 D:1

Shortens by the set amount for the Correction amount display
0***
lower 3 digits.
Sign flag
Lengthens by the set amount for
1***
the lower 3 digits.
*001
*010
*011 1 rank: 0.16%
Set amount
*100
*101
*110
*111 Maximum
"SAVE" will be displayed.
111 SAVE 111
IMPORTANT
reappear.
255
1. Functions
(1) Setting of photograph mode document sensing For Standards / Adjustment

darkness \See page 186
Related HELP mode
(1) Setting of photograph mode document sensing

darkness

\See page 231
A:1 B:1 C:1 D:1
binary values and the corresponding correction amounts. Sign flag
Correction amount display
ABCD Item Setting
Rises by the set amount for the
0***
lower 3 digits
Sign flag
E:1 F: 1 G:1 H:1
1***
lower 3 digits
*001 Sign flag
*010 Correction amount display
*011
Set amount
*100 Setting for ADF(When PHOTOGRAPH or
*101 TEXT/PHOTOGRAPH mode is set)
*110
*111 Maximum
IMPORTANT
reappear.
256
1. Functions
(1) Setting of reducing offset for reading longitudinal For Standards / Adjustment
R/E scanner \See page 183
Related HELP mode
(1) Setting of reducing offset for reading longitudinal

R/E scanner

\See page 231
A:1 B:1 C:1 D:1
ABCD Item Setting Correction amount display

0000 Standard (initial value)
0001 E:1 F: 1 G:1 H:1
0010 Set amount
•If help mode H-24 setting is
0011 required, HELP mode H-25 1 rank: 0.25%
must be set to "0000".
• Sign flag
•
• Correction amount display
•
•
1111 Maximum
Setting for ADF(When PHOTOGRAPH or
TEXT/PHOTOGRAPH mode is set)
ePress the [=] key. The correction amount will be memorized During memorization:
111 SAVE 111
IMPORTANT
257
1. Functions
(1) Setting of enlarging offset for reading longitudinal For Standards / Adjustment
R/E of scanner \See page 183
Related HELP mode
(1) Setting of enlarging offset for reading longitudinal

R/E of scanner

\See page 231
A:1 B:1 C:1 D:1

0000 Standard (initial value)
0001
Set amount
E:1 F: 1 G:1 H:1
0010
•If help mode H-25 setting is
0011 required, HELP mode H-24
1 rank: 0.25%
• must be set to "0000".
• Sign flag
• Correction amount display
•
•
1111 Maximum
TEXT/PHOTOGRAPH mode is set)
111 SAVE 111
IMPORTANT
258
1. Functions
(1) Compensation of document darkness white level in For Standards / Adjustment

photograph mode \See page 186
Related HELP mode
(1) Compensation of document darkness white level in

photograph mode

\See page 231
A:1 B:1 C:1 D:1

Rises by the set amount for the Correction amount display
0***
lower 3 digits
Sign flag
1***
lower 3 digits
*000
E:1 F: 1 G:1 H:1
Standard (initial value)
*001
*010
Sign flag
*011
Set amount Correction amount display
*100
*101
*110
Maximum TEXT/PHOTOGRAPH mode is set)
*111
111 SAVE 111
IMPORTANT
259
1. Functions
(1) Initialization of all HELP mode settings
(1) Initializing all the HELP mode settings

: I N I T I AL I ZE
\See page 231
wPress the [=] key. The adjustment and specification settings ¡During memorization:
of the HELP modes will be initialized. (But for the total counts (H-
14 and H-19), only the user mode values will be initialized.) While 111 SAVE 111
initialization is in progress, "SAVE" will be displayed.
IMPORTANT
¡ Do not turn off the power before the "SAVE" display has disappeared.
reappear.
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
1. Functions
(1) Setting of buzzer selection.
(1) Setting of buzzer selection.

\See page 231
A:1 B:1 C:1 D:1
0***
Not used.
1***
*00* Standard (Buzzer sounds)
Buzzer does not sound when trou-
*01*
Selecting buzzer. ble occurs.
*10* Does not sound
*11* Does not sound
***0
Not used.
***1
1001 Initial value
111 SAVE 111
IMPORTANT
reappear.
261
1. Functions
(1) Adjustment of master infeed amount For Standards / Adjustment

¡ Feed amount is adjusted after cutter operation.
\See page 181
(1) Adjustment of master infeed amount

\See page 231
the desired correction amount. See the table below for 4-place A:1 B:1 C:1 D:1

Shortens by the set amount for the Correction amount display
0***
lower 3 digits.
Sign flag
Lengthens by the set amount for
1***
the lower 3 digits.
*001
*010
*011
Set amount
*100
*101
*110
*111 Maximum
111 SAVE 111
IMPORTANT
reappear.
262
HELP mode H-30 (1) Function checking
1. Functions
(1) Test pattern (all shading, secondary scanning For adjusting reduction / enlargement
direction zoom factor adjustment) mastermaking and \See page 183
printing
(1) Test pattern (all shading, poor image area checking, ¡Test pattern 1
secondary scanning direction zoom factor adjustment)
mastermaking and printing

\See page 231
wSelect one of the items below, and follow the procedure given for it. ¡Test pattern 2
¡ Test pattern 1 (all shading)
aUse the DOCUMENT MODE SWITCH key to select the
PHOTOGRAPH item.
¡ Test pattern 2 (secondary scanning direction mastermaking area adjustment)

TEXT/PHOTOGRAPH item.
¡Test pattern 3 (secondary scanning direction zoom factor adjustment) ¡Test pattern 3
TEXT item.
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 key to implement mastermaking/printing

0sh t 1se t
reappear.
263
1. Functions
(1) Setting of number of pre-print sheets

Use this to set a value for the number of pre-print sheets. "Pre-
print sheets" are extra sheets that are printed at the start of
printing, without being added to the print count.
(1) Setting of number of pre-print sheets

\See page 231
ABCD Item ABCD Item Correction amount display
0000 0 sheet(initial value) 1000 8 sheets

0001 1 sheet 1001 9 sheets
0010 2 sheets 1010 10 sheets
into the main PCB unit's EEPROM. During memorization,
111 SAVE 111
IMPORTANT
reappear.
264
1. Functions
(1) Confidential safeguard function, selection of first

print speed, setting of master ejection error sensing
(1) Confidential safeguard function, selection of first

print speed, setting of master ejection error sensing

\See page 231
A:1 B:1 C:1 D:1

0*** Confidential safeguard Disabled
1*** function
Enabled
Selecting the first print
*0** speed. /Selecting the print 1st-speed (about 45 rpm)
speed for the first sheet
*1** after mastermaking is com- JOG speed (about 15 rpm)
pleted.
**0* Master mis-ejection detec- Enabled
**1* tion Disabled
***0
Not used.
***1
1000 Initial value
111 SAVE 111
IMPORTANT
reappear.
265
1. Functions
(1) Compensation of document darkness white level in For Standards / Adjustment

text mode \See page 186
Related HELP mode
(1) Compensation of document darkness white level in

text mode

\See page 231
A:1 B:1 C:1 D:1
ABCD Item Setting
Sign flag
0*** Correction amount display
lower 3 digits
Sign flag
1***
lower 3 digits
*000
E:1 F: 1 G:1 H:1
*001
*010
Sign flag
*011
*100
*101
*110
*111
111 SAVE 111
IMPORTANT
266
1. Functions
(1) Adjustment of scanner leading edge sensing position For Standards / Adjustment
\See page 184
Related HELP mode
(1) Scanner leading edge sensing position adjustment

\See page 231
ABCD Item Setting

Sign flag
Moves to the left by the set Correction amount display
0***
amount of the lower 3 digits.
Sign flag
Moves to the right by the set
1***
E:1 F: 1 G:1 H:1
*001
*010
Sign flag
*011
*100
*101
*110
*111 Maximum TEXT/PHOTOGRAPH mode is set)
111 SAVE 111
IMPORTANT
reappear.
267
1. Functions
(1) Adjustment of scanner widthwise (operation side) For Standards / Adjustment

sensing position
\See page 184
Related HELP mode
(1) Scanner widthwise (operation side) sensing position

adjustment

\See page 231

w Use the [0] and [1] numeric keys to enter a 4-place binary value for
A:1 B:1 C:1 D:1
ABCD Item Setting

Sign flag
Moves toward you by the set
0***
Sign flag
Moves backward by the set
1***
E:1 F: 1 G:1 H:1
*001
*010
Sign flag
*011
*100
*101
***1
*111
IMPORTANT
reappear.
268
1. Functions
(1) Adjustment of mastermaking start position when For Standards / Adjustment

scanner is used \See page 185
Related HELP mode
(1) Adjustment of mastermaking start position when

scanner is used

\See page 231
A:1 B:1 C:1 D:1
Sign flag
ABCD Item Setting
0***
lower 3 digits
Sign flag
1***
lower 3 digits
*000
E:1 F: 1 G:1 H:1
*001
*010
Sign flag
*011
*100
*101
*110
*111
111 SAVE 111
IMPORTANT
reappear.
269
1. Functions
(1)Adjustment of print speed automatically. For Standards / Adjustment
\See page 188
Related HELP mode
¡2.
TheOperation procedures
drum rotates \See page 233

\See page 231
w It will adjust speed of drum rotation automatically within 1 min.

SPEED 1-7
IMPORTANT
Before this operation, you must set drum accurately first.
¡During memorization:
reappear.
111 SAVE 111
270
HELP mode H-39 (1) Function checking
1. Functions
(1) Function testing of clutch test and Auto power off
(1) Correction of outline highlight when scanner is used

\See page 231
w Use these keys to test each function.
CLUTCH TEST
TEXT item.
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.
PHOTOGRAPH/TEXT item.
Mater feed clutch will be on, for as long as the key is held down.
PHOTOGRAPH item.
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.
reappear.
271
Modes H-40 is not used.
1. Functions
(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)
(1) Automatic initialization of the control panel setting,

setting of repeat count display

\See page 231
A:1 B:1 C:1 D:1

0*** Automatic initialization of
No automatic iniialization
the control panel setting
1*** Initialized in about 2 minutes
*0** No energy save mode

Energy save mode setting
*1** Energy save after no operation 3 min.
**0* Repeat display of count

Count repeat display
**1* No repeat display of count
***0 Automatic power off setting No automatic power off

(only available with optional
***1 Automatic power off kit) Auto off after no operation 5 min.
0000 Initial value
111 SAVE 111
IMPORTANT
reappear.
272
1. Functions
(1) Setting of paper selection specification
(1) Scanner leading edge sensing position adjustment

\See page 231

ABCD Item Setting
Paper selecting specifica-
00** B4/A4/B5/A5
tions (A/B size)
Paper selecting specifica-
10** 10914/LT•LG/ST/POST
tions (inch)
*0**
Not used
*1**
**00
**01 Not used
**10
**11
0000 Initial value
111 SAVE 111
IMPORTANT
reappear.
273
HELP mode H-43 (1)Adjustment/specification setting

1. Functions
(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. \See page 231
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 Correction amount A:1 B:1 C:1 D:1
0111 -5
0110 -5
0101 -5
Lighter than Correction amount display
0100 -4
default
0011 -3
0010 -2
0001 -1
0000 ±0
1000 ±0 No change
1001 +1
1010 +2
1011 +3
Darker than
1100 +4
default
1101 +5
1110 +5
1111 +5
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
1. Functions
(1) Setting of thermal head resistance ranking For desccription of operation

\See page 67
(1) Setting of thermal head resistance ranking

\See page 231
A:1 B:1 C:1 D:1
Sign flag
ABCD Resistance Correction amount display
0000 3825-3908
0001 3909-3993
0010 3994-4077
0011 4078-4162
0100 4163-4246
0101 4247-4330
0110 4331-4415
0111 4416-4499
1000 4500-4583
1001 4584-4668
1010 4669-4752
1011 4753-4837
1100 4838-4921
1101 4922-5005
1110 5006-5090
1111 5091-5175
IMPORTANT
275
Mode H-45, 46, 47, 48 and 49 are not used
1. Functions
(1) Setting of text mode document sensing darkness For Standards / Adjustment
\See page 187
Related HELP mode
(1) Setting of text mode document sensing darkness

\See page 231
A:1 B:1 C:1 D:1
Sign flag
Display Item Setting
Lighter by the set amount for the
0***
lower 3 digits
Sign flag
Darker by the set amount for the
1***
lower 3 digits
E:1 F: 1 G:1 H:1
*001
*010
Sign flag
*011
*100
*101
*110
*111
IMPORTANT
276
Mode H-51 and 52 are not used
1. Functions
(1) Adjustment of widthwise (operation side) Related HELP mode

mastermaking start position for online mastermaking HELP mode H-16 \See page 250
(1) Adjustment of widthwise (operation side)

mastermaking start position for online mastermaking

\See page 231
A:1 B:1 C:1 D:1
Sign flag
ABCD Item Setting
Moves toward you by the set
0***
Sign flag
1***
*001
*010
*011
Set amount
*100
*101
***1
*111 Maximum
111 SAVE 111
IMPORTANT
277
Mode H-54 is not used.
1. Functions
(1) Setting of ink check at printing start, cutting operation

mode for master cutting, and interlocks
(1) Setting of ink check at printing start, cutting operation

mode for master cutting, and interlocks
\See page 231
Setting of ink check, that

0*** Disabled
triggers ink replenishment if
no ink is detected at printing
1*** start Enabled
*0** Selection of cutter operation 1 stroke = one-way motion
*1** mode 1 stroke = reciprocating motion
**0* Interlock: emergency stop if Activated

top cover or ejection box
**1* open Deactivated
***0
Not used
***1
0110 Initial value
IMPORTANT
278
1. Functions
(1) Setting for selecting manipulation language
(1) Setting for selecting manipulation language

\See page 231
ABCD Manipulation language
0000 Japanese
0001 Korean
0010 Chinese Simplified1
0011 Chinese Simplified2
0100 English
0101 Spanish
0110 German
0111 French
1000 Italian
1001 Russian
1010 Traditional Chinese
1011
1100 Thai
1101 Polish

"FONT UPDATE"and "SAVE" will be displayed.
FONT UPDATE
IMPORTANT
111 SAVE 111
279
Mode H-57, H-58 are not used
1. Functions
(1) Setting for end mark sensor 2
(1) Setting for end mark sensor 2 .

qAccess HELP mode H-59, and press the PRINTkey.
\See page 231

* 0 ** Disabled
Setting for end mark sensor 2
* 1 ** Enabled
0 1 1 0 Factory setting
into the main PCB unit's EEPROM. During memorization, "SAVE"
will be displayed. 111 SAVE 111
IMPORTANT
reappear.
280
Mode H-60 are not used
1. Functions
(1) Function test for LCD screen and LED indicators
(1) Function test for LCD screen and LED indicators

\See page 231
wThe LCD screen will be displayed as right. All of the LED

will be twinkling. HELP SELECT 61
0000000000000000
reappear.
281
1. Functions
(1) Setting for A4 master cut
(1) Setting for A4 master cut .

\See page 231

* 0 ** A4 size master cut
Setting for A4 master cut
* 1 ** B4/LG size master cut
0 1 0 0 Factory setting
into the main PCB unit's EEPROM. During memorization, "SAVE"
will be displayed. 111 SAVE 111
IMPORTANT
reappear.
282
1. Functions
(1) Buzzer (tone) setting
(1) Buzzer (tone) setting

\See page 231
Sign flag
0*** Sign flag Tone setting
*000 Standard (initial value : 0000)

*001
Set amount Tone adjusting
*010
*011 Maximum
IMPORTANT
reappear.
283
1. Functions
(1) Setting: clamp opening/closing timing of when a

master is attached; Help 67/68 ON/OFF.
(1) Setting: clamp opening/closing timing of when a

master is attached; Help 67/68 ON/OFF.
\See page 231

ABCD Item Setting
0*** Setting for master clamp C mode master feed out B mode
opening/closing timing for
1*** master attachment master feed out C mode B mode
*0** Setting of HELP 67/68 OFF

ON/OFF
*1** ON
*10*
Not used
*11*
***0
Not used
***1
0000 At shipment
IMPORTANT
reappear.
284
1. Functions
(1) Setting of paper feed length.
(1) Setting of paper feed length.

\See page 231
A:1 B:1 C:1 D:1
ABCD Item Setting
0000 Min
Sign flag
0001 Correction amount display
0010
0***
Set amount
0111
1000
1***
1101
1110
1111 Max
0101 Initial value
IMPORTANT
reappear.
285
1. Functions
(1) Setting of paper feed angle
(1) Setting of paper feed angle

\See page 231
A:1 B:1 C:1 D:1
ABCD Item Setting
Smaller the paper feed angle

0*** Sign flag
(The set amount for the lower 3 digits)
Larger the paper feed angle
1***
(The set amount for the lower 3 digits)
*001
*010
*011
Set amount
*100
*101
*110
*111 Maximum
IMPORTANT
reappear.
286
1. Functions
(1) Setting of model
(1) Setting of model

\See page 231
ABCD Item Setting
0000 B4 SIZE
0001 Setting of model LEGAL SIZE
0011 A4 SIZE
IMPORTANT
reappear.
287
1. Functions
(1) Adjustment for mastermaking area lenghth.
(1) Adjustment for mastermaking area lenghth.

\See page 231

ABCD Item Setting
Mastermaking area lenghth
0***
shorter amount of the lower 3 digits.
Sign flag
1***
longer amount of the lower 3 digits.
*001
*010
*011
Set amount
*100
*101
***1
*111 Maximum
IMPORTANT
reappear.
288
1. Functions
(1) Adjustment for mastermaking area lenghth on online printing
(1)Adjustment for mastermaking area lenghth on online printing

\See page 231

0*** shorter amount of the lower 3 digits.
Sign flag
1*** longer amount of the lower 3 digits.

*001
*010
*011
Set amount
*100
*101
***1
*111 Maximum
IMPORTANT
reappear.
289
1. Functions
(1) Setting of thermal head temperature Supplementing

and master making darkness rank.
(1) Setting of thermal head temperature Supplementing

and master making darkness rank.
For the basic procedure for accessing HELP modes. \See page 231
*0** Setting of thermal head Disabled (initial value)
*1** temperature Supplementing Enabled
***0 Setting of master making 3 ranks.(initial value)
***1 darkness rank 5 ranks.
IMPORTANT :
reappear.
290
1. Functions
(1) Document darkness correction for text/photograph

mode
(1) Document darkness correction for text/photograph

mode
00** Normal (initial value)
01** Setting
Slightly lighter
10** Slightly darker
11** Much darker
IMPORTANT :
reappear.
291
Mode H-77-79 are not used
1. Functions
(1) Setting of print speed rank
Setting of ADF
Setting of INK save mode
(1) Setting of speed rank,ADF and Ink save mode.

\See page 231
ABCD Item Setting

0*** 3 print speed ranks
Setting of speed rank
1*** 5 print speed ranks
*0** With optional ADF

Setting of ADF
*1** Without optional ADF
**0*
Not used
**1*
***0 OFF
Setting of Ink save mode
***1 ON
0101 Initial value
IMPORTANT
Please adjust the drum speed by using H-38 when setting of print speed rank is changed.
IMPORTANT
reappear.
292
Mode H-81 and H-82 are not used
HELP mode H-83 (ADF) (1) ROM version displays
1. Functions
(1) Display of ROM version

¡ Displays version of the ADF PCB unit's ROM.
(1) Displaying ROM version

qAccess HELP mode H-83, and press the PRINT key. ¡Displaying ROM version
ADF OP V1 . 11
Displays version of the ROM.
ADF PCB unit
reappear.
293
HELP mode H-84 (ADF) (1) Checking of communication
1. Functions
(1) Checking of communication for ADF
(1) Checking of communication for ADF

For the basic procedure for accessing HELP modes. \See page 231 ¡Displaying ADF status.
ADF OK
¡ Perform a communication check between the ADF and the main board.
If an error is indicated, refer to the Troubleshooting Guide for a solution.
¡ When ADF error accoured.
ADF ERROR
reappear.
294
1. Functions
(1) Adjustment for image sampling timing of scanning(for use in factory checks).
(1) Adjustment for image sampling timing of scanning.

\See page 231
ABCD Item Setting
0000 1/8
*001 2/8
*010 Adjustment for image 3/8

*011 sampling timing of scanning 4/8
*100 5/8
*101 6/8
*110 7/8
*111 8/8
0000 Factrory seeting
IMPORTANT
Do not change this setting,otherwise the image will be changed.
IMPORTANT
reappear.
295
1. Functions
(1) Setting of manual batch printing
(1) Setting of manual batch printing

\See page 231
0***
Manual batch printing OFF
mode ON/OFF setting ON
1***
*00* 1.5 sec.

*01* Time between sets on 3 sec.
*10* manual batch printing mode 5 sec.
*11* 10 sec.
***0
Not used
***1
0000 Initial value
IMPORTANT
reappear.
296
Mode H-87/88 are not used
1. Functions
(1) Setting of several special functions.
(1) Setting of several special functions of A-D.

q Use the DOCUMENT MODE SWITCH key to select the
TEXT item.
wAccess HELP mode H-89, and press the PRINT key.

\See page 231
e Use the [0] and [1] numeric keys to enter a 4-place binary value for
ABCD Item Setting

0*** Disabled.
2IN1 with scanner.
(Only for China)
1*** Enabled.
*0**
Not used.
*1**
**0* Disabled.
Setting of User ID function
**1* Enabled.
***0 Setting of special zoom Disabled.
***1 60%,130%
Enabled.
0000 Initial value
r Press the [=] key. The correction amount will be memorized ¡During memorization:
IMPORTANT
reappear.
297
(2) Setting of several special functions of E-H.

TEXT/PHOTOGRAPH item.
w Access HELP mode H-89, and press the PRINT key.

\See page 231
EFGH Item Setting

E:1 F: 1 G:1 H:1
0*** Enabled
Setting of 94%
1*** Disabled
*0** Enabled
4-up,8-up
*1** Disabled
**0* Enabled
2IN1(Only available with ADF)
**1* Disabled
***0 Enabled
Book Shadow Eraser Mode
***1 Disabled
0000 Initial value
r Press the [=] key. The correction amount will be memorized

"SAVE" will be displayed. ¡During memorization:
IMPORTANT 111 SAVE 111

reappear.
298
(3) Setting of several special functions of I-L.

PHOTOGRAPH item.
w Access HELP mode H-89, and press the PRINT key.

\See page 231
IJKL Item Setting

I: 1 J: 1 K: 1 L: 1
0*** Disabled
Setting of special zoom
1*** 150% Enabled
*0**
Not used.
*1**
**0* Setting of min.printing paper Disabled

limit of 50
**1* Enabled
***0 Setting of master making Disabled
***1 without printing.

Enabled
0000 Initial value
¡During memorization:
r Press the [=] key. The correction amount will be memorized
IMPORTANT
reappear.
299
Mode H-87-89 are not used
1. Functions
(1) Setting of Tape cluster
(1) Setting of Tape cluster

\See page 231
ABCD Item Setting

0*** Disabled
Setting of tape cluster
1*** Enabled
*0** Setting of drum action Stop waiting for tape inserting.

*1** Do not stop.(only for TAP-14)
**0* Setting of timing of tape Insert and cut after printing.

inserting
**1* Insert before printing,cut after printing
***0 Divided by same tape lenghth

Setting of tape lenghth
***1 Divided by difference tape lenghth.
0000 Initial value
IMPORTANT
reappear.
300
1. Functions
(1) Setting of tape lenghth for Tape cluster on online mode
(1) Setting of tape lenghth for Tape cluster on online mode

\See page 231
ABCD Item Setting

0***
Not used
1***
*0**
Not used
*1**
**0*
Not used
**1*
***0 Setting of tape lenghth on = short lenghth

***1 online mode = long lenghth
0000 Initial value
IMPORTANT
reappear.
301
1. Functions
(1) Setting of tape length for Tape cluster
(1) Setting of tape length for Tape cluster

\See page 231
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): Correction amount display

TEXT item.
¡ TAPE LENGTH2(Setting for long tape length):

aUse the DOCUMENT MODE SWITCH key to select the TAPE LENGTH2:28
TEXT/PHOTOGRAPH or PHOTOGRAPH item.
Note: Unit is cm. Correction amount display
IMPORTANT
reappear.
302
1. Functions
(1) Adjustment of widthwise (operation side) scaning start position for 4-up and 8-up
(1) Adjustment of widthwise (operation side) scaning start position for 4-up and 8-up

\See page 231

Moves toward you by the Correction amount display
0*** set amount of the lower 3 digits.
Sign flag
1*** amount of the lower 3 digits.
*000
E:1 F: 1 G:1 H:1
*001
*010
Sign flag
*011
*100
*101
***1
*111
IMPORTANT
reappear.
303
1. Functions
(1) UID ADMINISTRATOR password reset
(1) UID ADMINISTRATOR password reset

\See page 231
C
wPress the [=] key and CLEAR keys keys simultaneously,
to execute resetting. The resetting will be memorized in the
CLEAR ADMIN PW
main PCB unit's EEPROM. After resetting ,the password of UID
ADMINISTRATOR will be reset to "000000".
reappear.
304
Mode H-95/96 are not used
1. Functions
(1) The display for machine model.
(1) The display for machine model.

\See page 231
w The machine model will be displayed as right.

The machine model is used on online mode.
DP-M4*0
Correction display
reappear.
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
307
chap.9 z Electrical Parts Layout and Their Functions
z Electrical Parts Layout and Their Functions

(1) Switches/Clutches
10
5
9 1
8
2
6
7
Item No. Functions

1 Whether the drum is set or not is detected.
2 Opening and closing of the front cover is detected.
Microswitch/switch 3 Whether the master ejection core is set or not and full or not is detected.
4 Power switch
5 Opening and closing of the Scanner is detected.
6 Elevator lower limit switch
7 Paper feed elevator descent switch
Push switch
8 JOG switch (drum rotator switch)
9 Master feeding clutch
Clutch
10 Paper feed clutch
308
(2) Sensors
5 6 1 11 10 8 3 4 2 15 16 18
13
7 14 12 9 17
Item No. Functions

1 Fixed document home position is detected.
2 ADF home position is detected.
3 Master clamp opening and closing lever A/C mode is detected.
4 Master clamp opening and closing lever B mode is detected.
5 Drum home position and JAM detection position are detected.
6 Master attachment/detachment position is detected.
Microsensor
7 Main motor encoder sensor.
8 Press roller ON and OFF is detected.
9 Paper feed elevator top limit detection.
10 Print position limit of the print position is detected.
11 Center position of the print position adjustment is detected.
12 Weather the paper is placed or not is detected.
13 Master feed is detected.
Photointerrupter 14 Paper feed Length is detected.
Master ejection sensor photo-emitting 15 Photo-emitting of the master ejection and JAM detection sensor.
Master ejection sensor photo-emitting 16 Master is detected at the inlet of the master ejection box.
Jam sensor photo-receiving 17 Paper on the paper delivery side is detected.
Jam sensor photo-emitting 18 Detection of paper on paper ejection side.
309
(3) Lamps/Motors
6
10
4
7
12
9
11
Item No. Functions

Lamp 1 Document lamp
Thermal head 2 Thermal head
3 Main motor
4 Paper feed tray elevator motor
5 Master clamp opening/closing lever motor
6 Roll-up motor
Motor 7 Cutter motor

8 Print position adjusting motor
9 Ink pump motor
10 Scanner stepping motor
11 Mastermaking stepping motor
Fan motor 12 Paper ejection fan
310
(4) PCB unit
7
1
Item No. Functions
Main PCB unit 1 Processing the image and controlling the machine on the whole.
Control panel PCB unit 2 Control panel key, display.
Ink detection PCB unit 3 Detecting Ink amount in the drum.
Regulated power supply 4 Supplying with DC power supply.
End mark sensor PCB unit 5 Detection of master presence on master feed travel path, and end mark.
Inverter PCB unit 6 Lamp lights up.
CCD PCB unit 7 Reading the picture image.
DP-24S
311
(5) Connector VR/LED Layout and Functions
1) Main PCB unit
J2(28P) J3(16P) J4(24P)

J1(24P)
J11(16P)
J5(12P)
U13
UNIT U6-V502*
U19
J6(32P)
J10(5P)
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 memo-
rized 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
4) Regulated power supply
CN53
F1(FUSE)
CN1
CN51
AC250V T5AH
UA043
5) End Mark Sensor PCB unit
VR Function
VR1 Sensor sensitivity adjustment
6) Inverter PCB unit
CN 2
CN 1
7) CCD PCB unit

CN 1
CCD
IMPORTANT:
● Do not to remove and replace the CCD PCB unit,otherwise,it is necessary to adjust in factory.
313
x Overall Wiring Layout
SCANNER
314
MASTER DETACHMENT/
ATTACHMENT POSITION SENSOR
CUTTER LIMIT SW(FRONT)
CUTTER LIMIT SW(REAR)
ENDMARK SENSOR PCB UNIT 1
315
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

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SERVICE MANUAL

Dec. 2009 Revision 0

Note: This symbol mark is for EU countries only.

Examples of pictorial symbols

'Service work-related instructions

IMPORTANT: Draws attention to important information. If this information is ignored

NOTE: Draws attention to information that is useful for operation or maintenance

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

2. Cautions for installation work

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

Using the optional printer stand

3. Cautions for maintenance, inspection and servicing

If optional tape clusters are used

' Working clothes

DLocations of warning stickers

Do not insert sharp objects into the master feed area

Do NOT put hands Inside

No. Parts No. Name Q'ty

Chapter 2 Description of the Operation

m System Setup ...............................................................20

, Part Names and Their Functions................................21

⁄0 Error Messages and Corrective Action......................30

5. High-performance lamp Inch size model

6. Full range of necessary functions

tAdjusting the Printing Position (vertical) r On-line functions*4

8 Ink save mode

9 Energy save mode

Same size 100%

Product name/model Duprinter DP-M420 Duprinter DP-M410 Duprinter DP-M400

Master roll DRC42/DRC42L/DRC425 DRC41/DRC415

* Specifications are subject to change without notice.

229 563 470

Master roll Master ejection box

Feeder roller Paper stripper finger

Paper ejection belt

1. Characteristics of the master

(2) Functions and materials of the layers

(3) Cross section of the master during mastermaking

(4) Printed image

Duplo Direct Print System

Cabinet (Printer stand)

Drum unit : Option

,Part Names and Their Functions

Master set switch/

Ink pack holder release lever Front cover

Ink pack Drum securing lever

Master ejection core

Master ejection box

Master ejection box

Master ejection box

Paper stacker guides

2. Sectional (structural) view of the machine

1 Scanner section 55page 125page 159page

2 Mastermaking/Master feed/ejection section 59page 131page 161page

2A Mastermaking/Master feed section 59page 131page 161page

2B Master ejection section 74page 136page 162page

2C Master clamp opening/closing section 76page 138page 164page

3 Paper feed section 82page 140page 169page

4 Drum driving section 95page 145page 174page

5 Press section 101page 4 176page

1 6 Paper ejection section 104page 147page 178page

8 Drum section 109page 150page 179page

Flashes to display the content of the trouble and lights to indicated