DP A120 Service

SERVICE MANUAL
DUPRINTER
DP-A120
Sep. 2009 Revision 0

DUPLO DP-A120
　U5-Y1130
Safety instructions
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 in-
structions and correct inspection and servicing procedures that it provides before
beginning repair or serving work. Reparing or servicing the machine with insufficient knowl-
edge about it could lead to unforeseen accidents.
It is not possible to anticipate and describe in a manual such as this every possible hazard that
could arise in the course of repair and servicing. Therefore, besides observing the safety in-
structions marked in this manual and on the machine’s labels, service personnel should be
safety-conscious and take other safety precautions as necessary. When performing repair or
service work not covered by this manual, you should obtain safety guidance from an appropri-
ately 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 © 2008
DUPLO SEIKO CORPORATION
All Right Reserved
U5-Y113 0-0 1
Safety instructions
■Using the service manual

●This manual contains the following information: structure and function of major parts, disassem-
bly and reassembly procedures, specifications and procedures for adjustment, maintenance, in-
spection and corrective action. This information is current as of August 2009, and applies basi-
cally to the model DP-A120 Duprinter.
From time to time, parts are changed to improve quality, performance of safety. Note therefore
that in some cases, certain parts or machine structure aspects described in the text or illustra-
tions 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 Indicates a high degree of potential danger. If the warning is ignored, death
or serious injury may result.
CAUTION Indicates a medium degree of potential danger. If the caution is ignored, me-
dium injury or damaged to property may result.
Examples of Pictorial Symbols
A “ ”circle with a line through it indicates a prohibited action.

The particular act prohibited is indicated by a picture inside the circle.
(In the example shown here, the prohibited act is disassembly.)
●
A “ ”black disc indicates an instruction, or sometimes a prohibited action.
The instruction itself is indicated by pictorial symbols drawn in white on the
disc. (In the example shown here, the instruction is ‘Remove the plug from
the outlet.’)
●For maintenance operation

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 U5-Y113 0-0
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 operation error 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: 10 - 30°C
Ambient humidity: 40% - 70%
Optimum temperature and humidity : 20°C, 65%
● If the machine is installed near to faucets, water heaters or humidifiers, or in cool (sunless)
parts of a building or in the vicinity of water sources, the paper could absorb moisture and curl,
leading to misfeeds or poor image quality.
► 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 5 mm in the front-rear direction, and 5 mm 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.
U5-Y113 0-0 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 table below. The machine’s power supply voltage is indicated on the iden-
tification plate located on the machine’s left side; the machine must be connected to a power
supply of the voltage indicated.
→ 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 230V AC model

Connect to outlet of 120V AC, 60Hz, Connect to outlet of 230V AC, 60Hz,
Power supply voltage
at least 15A at least 15A
] ]
No more than Use power No more than Use power
With no load*
130V AC supply meeting 250V AC supply meeting
At full load
At least 110V AC these requirements At least 210V AC these requirements
Master making: 43W
Power consumption Printing : 50W
Standby: 18W
* “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 ma-
chine, 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 rat-
ings:
• 125V, at least 15A, 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.
→ Otherwise, the machine could move or fall over, causing injury.
● To move the machine, push it by its mounting base.
→ Pushing the printing (upper) part of the machine could make it fall over.
4 U5-Y113 0-0
Safety instructions
3. Cautions for maintenance, inspection and servicing
WARNING
●Precautions for safe serving
● Always remove the power cord plug from the outlet before starting work.
→ 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.
→ Otherwise, your hands/fingers could be injured.
● Do not touch the rotating parts when operating the JOG switch or while the machine is run-
ning.
→ 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.
→ Otherwise, your hands/fingers could be injured.
●Working clothes
● Wear clothing that enables you to work safely.
Working clothes should be close-fitting.
CAUTION
●Tools
● Use tools that are appropriate for the work.
U5-Y113 0-0 5
Safety instructions
■Locations of Warning Labels

● Keep the WARNING and CAUTION labels clean at all times. If labels become damaged or
come off, please call our serviceperson.
1 CAUTION
M7-T3060
WARNING View A
2 Do not insert sharp objects into the master feed area,
or it will damage electrical 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
WARNING
3 Do NOT remove this cover.
There is moving cutting machinery
insibe that could injure you. J3-T3200
4
WARNING
Do NOT put hands inside machine
while it is operating.
Hands could get caught up
or crushed.
5
WARNING
Do NOT touch the drum or rollers
when you operate the jog switch.
Do NOT put hands inside

machine while if is operating.
Hands could get caught up
or crushed.
L5-T3020
View A
6 WARNING
Use caution when working

near movable parts.
Disconnect power before
servicing.
No. Parts No. Name Q'ty No. Parts No. Name Q'ty
1 M7-T3060 Caution Label 1 4 M7-T3030 Warning Label 1
2 U5-T3110 Warning Label 1 5 L5-T3020 Warning Label 1
3 J3-T3200 Warning Label 1 6 L8-T1090 Warning Label 1
6 U5-Y113 0-0
Introduction 1
Description of the Operation 2
Mechanism 3
Standards / Adjustment 4
Maintenance / Check 5
Troubleshooting 6
HELP Mode 7
Others 8
Table of Contents
Introduction .............................................................1
Using the service manual ........................................2
Chapter 4 Standards / Adjustment
Safety instructions .............................................3
1.Cautions regarding the installation location .............3 1 Master making/Master Feed/Ejection Section.........104
2.Cautions for installation work ...............................4 2 Paper Feed Section ........................................111
3.Cautions for maintenance, inspection and servicing ....5 3 Drum Driving Section ......................................112
• Locations of warning labels ..................................6 4 Paper Ejection Section....................................114
5 Drum Section ..................................................116
6 Electrical System ............................................119
Chapter 1 Introduction
1 Specifications ...................................................10
Chapter 5 Maintenance / Check
2 Dimensions .......................................................12
3 System Setup ...................................................13 1 Guaranteed Periodical Maintenance................128
4 Part Names and Their Functions ......................14 2 Cleaning and Oiling ........................................128
3 Periodical Maintenance...................................129
4 Recommend parts list .....................................130
Chapter 2 Description of the Oeration
1 Scanner Section................................................24
Chapter 6 Troubleshooting
2 Master making/Master Feed/Ejection Section..........33
3 Paper Feed Section ..........................................48 1 Troubleshooting Guide ...................................132
4 Drum Driving Section .......................................53
5 Press Section ...................................................58
6 Paper Ejection Section......................................60
Chapter 7 HELP Mode
7 Drum Section ....................................................63
1 HELP Mode List .............................................146
2 Overview ........................................................149
Chapter 3 Mechanism 3 HELP Mode Functions and Operation Procedures...150
Operation Procedures….....….......……………150
1 Exterior .............................................................72 (1) Accessing HELP Modes.............................150
2 Scanner Section................................................76 (2) Guide to the HELP Mode Descriptions.........150
3 Master making/Master Feed/Ejection Section...........81 Upgrading the Main PCB Software….......…151
4 Paper Feed Section..........................................89 ●HELP Mode Descriptions ..........................152
5 Drum Driving Section .......................................92
6 Paper Ejection Section......................................94
7 Drum Section ...................................................96
Chapter 8 Others
1 Electrical Parts Layout and Their Functions...........214

2 Overall Wiring Layout......................................220
8 U5-Y113 0-0
Chapter 1 Introduction 1
1 Specifications ...................................................10
2 Dimensions ......................................................12
3 System Setup ...................................................13
4 Part Names and Their Functions ......................14
1. Machine exteriors ...................................14
2. Control Panel (European paper sizes).....18
Control Panel (U.S. paper sizes).............20
U5-Y113 0-0
Chapter 1 1 Specifications
1 Specifications
● Specifications
Product name/
Duprinter DP-A120
model No.
Model Table top
Master making Thermal digital master making
method
Master making 45 seconds
interval
Resolution Scan (input) resolution: 300dpi×360dpi
Print (output) resolution: 300dpi×360dpi
*(Master punch density: 300dpi×360dpi)
Scanning method Automatic document feeder (ADF)
Document weight 64gsm - 128gsm
17lb - 34lb (bond)
Document 1 sheet
capacity
Printing method Stencil print
Document type Sheet
Document size MAX. 271mm×393mm , MIN. 100mm×148mm
MAX. 10.6"×15.5", MIN. 4"×6"
Scanning area MAX. 250mm×350mm (11.4"×16.6")
Image area MAX. 250mm×350mm (11.4"×16.6")
Feeding capacity 500 Sheet (80gsm)
Stacker capacity 500 Sheet (80gsm)
Paper size MAX. 271mm×393mm , MIN. 100mm×148mm
MAX. 10.6"×15.5", MIN. 4"×6"
Paper weight 53gsm - 128gsm
14lb - 34lb (bond)
Print speed 60ppm/90ppm (2 steps)
Zoom European paper sizes
100%
Preset reduction/enlargement : 70, 81, 86, 115, 122, 141%
Margin adjustment : 94%
U.S. paper sizes

100%
Preset reduction/enlargement : 60, 64, 78, 115, 129, 154%
Margin adjustment : 94%
Printing position Vertical +/-10mm
adjustment Horizontal +/-10mm (manual)
10 U5-Y113 0-0
Chapter 1 1 Specifications
Product name/
Duprinter DP-A120
model No.
Image mode Text mode / Photograph mode
Contrast control Master density : 3 steps
Ink supply method Automatic control (600ml)
Color print
Master Feeding
By replacing drum unit
Roll master automatic feed
1
method
Master ejection Automatic ejection
method
Used master 10 masters
capacity
Other function Feed pressure adjustment ( 3 steps)
2 IN 1 Function
Detection Master roll detection
Used master roll full detection
Ink detection
Online Optional USB interface kit (USB2.0 Full-Speed)*
Printer driver must be installed in computer.
● Windows 2000 Professional
● Windows XP Professional/Home Edition
● Windows Vista x86 (32-bit)
● MacOSX10.3/10.4/10.5
*USB cable must be 3m or shorter.
Optional network server FS-100U (USB LAN unit)

● Windows 2000 Professional
● Windows XP Professional/Home Edition
● Windows Vista x86 (32-bit)
● MacOSX10.3/10.4/10.5
Options Drum unit
Small paper stacker guides
Auto power OFF kit
USB interface
USB LAN unit ( FS-100U)
Power source 100-240V, 50/60Hz, 0.8-0.4A
Power 43W (Master making), 50W (Printing), 18W (Standing by)
consumption
Dimensions In use: 1050mm (W)×610mm (D)×475mm (H)
Folded: 760mm (W)× 610mm (D)×475mm (H)
Weight 41kg
Operating 10 - 30 degrees (C)
temperature (50-86 degrees (F) )
* Specifications are subject to change without prior notice.
U5-Y113 0-0 11
Chapter 1 2 Dimensions
2 Dimensions
610
930
475
195 565 290

1050
( mm )
12 U5-Y113 0-0
Chapter 1 3 System Setup
3 System Setup
The machine and its optional equipment are set up as follows:
Duplo Direct Print System
Personal computer
Drum unit :Option
U5-Y113 0-0 13
Chapter 1 4 Part Names and Their Functions
4 Part Names and Their Functions

1. Machine exteriors
3 2
4 1
11
6
10
7 8
No. Name Function

1 Document tray Place the document on this tray.
2 Document guide Slide to match the width of the document.
3 ADF Feeds one document of sheet type at a time for master
making.
4 Upper cover Open to replace the master roll, etc.
5 Feed pressure adjuster lever Use to adjust the paper feed pressure.
6 Feed tray Load paper on this tray.
7 Support tray
8 Side guides Slide to match the width of the paper.
9 Paper set lever Lower this lever down before loading paper on the feed
tray. Raise it up after loading paper correctly.
10 Front cover Open to replace ink pack and drum unit, etc.
11 Control panel Displays operations and status, and sets functions.
14 U5-Y113 0-0
MASTER SET LEVER

(THERMAL HEAD ESCAPE LEVER)
When the master set lever is pushed,
the master is pulled in and set.
1
MASTER
MASTER HOLDER
U5-Y113 0-0 15
FRONT COVER
DRUM UNIT
LEVER
This lever locks or
unlocks the drum.
INK PACK
DRUM HANDLE
16 U5-Y113 0-0
MASTER EJECTION BOX
17
16
12
13
14 15
PAPER STRIPPER FINGER
PAPER EJECTION ROLLER
JUMP PLATE
No. Name Function

12 JOG switch Press and hold to rotate the drum for a set time. Use to remove
paper jams, etc.
13 Power switch Press to turn the power on and off.
14 Print tray Printed paper is ejected to this tray.
15 Paper stacker guide Slide to match the size of printed paper.
16 Paper stopper Slide to match the size of printed paper.
17 Master ejection box Used master is stored in this box. Pull out it when it is full.
U5-Y113 0-0 17
2. Control panel (European paper sizes)
2 3 4 5 6 7
24 23 22 21 20
No. Name Function

1 Zoom indicator lamp Indicates the position of enlargement and reduction.
2 ENLARGEMENT and Press this key to change enlargement and reduction. Each press
REDUCTION key of this key moves the position of the lit lamp that indicates the se-
lected enlargement or reduction.
3 Document mode indicator lamp The lamp of the selected mode lights up.
4 2 IN 1 indicator lamp Lights up when "2 IN 1" is set.
5 2 IN 1 key Press this key to set "2 IN 1".
6 DOCUMENT MODE Press to switch between Text Mode and Photograph Mode. Each
SWITCH key press of this key moves the position of the lit lamp that indicates
the selected document mode.
7 Counter/Error display Displays the number of printed sheets.
panel Also displays an error message when an error occurs.
8 RESET key Returns the control panel settings to the “Standard Mode” set-
tings. Press and hold for at least 0.5 seconds.
9 PRINT POSITION keys Adjusts print position.
10 Print position indicator lamp The lamp of the specified print position lights up.
11 Print speed indicator lamp The lamp of the specified print speed lights up.
12 PRINT SPEED keys Adjusts print speed.
18 U5-Y113 0-0
8 9
10
11
12
13
19 18 17 16 15 14
Name Function
13 TEST PRINT key Prints 1 copy to check the image position and density.
14 STOP key Stops printing. When this key is pressed and held down while the
machine is not running, total number of printed sheets and the total
number of masters are displayed on the counter/error display panel.
15 PRINT key Starts printing. This key does not start making a master.
16 MASTER MAKING key Starts making a master.
17 ×
＝ key Enters the number of printed sheets and the number of sets in batch
printing.
18 NUMERIC keys Enters the number of printed sheets.
19 CLEAR key Returns the number of printed sheets to 0.
Other settings on the control panel are not changed.
20 OK monitor Flashes to display the content of the trouble and lights up to indicate
the part that caused the trouble in the machine.
21 MASTER DARKNESS key Adjusts the master darkness.
22 Master darkness indictor The lamp for the specified master darkness lights up.
lamp
23 94% key Reduces image to 94%.
24 94% indictor lamp Lights up when '94% reduction' is on.
U5-Y113 0-0 19
3. Control panel (U.S. paper sizes)
2 3 4 5 6 7
24 23 22 21 20
No. Name Function

1 Zoom indicator lamp Indicates the position of enlargement and reduction.
2 ENLARGEMENT and Press this key to change enlargement and reduction. Each press
REDUCTION key of this key moves the position of the lit lamp that indicates the
selected enlargement or reduction.
3 Document mode indicator lamp The lamp of the selected mode lights up.
4 2 IN 1 indicator lamp Lights up when "2 IN 1" is set.
5 2 IN 1 key Press this key to set "2 IN 1".
6 DOCUMENT MODE Press to switch between Text Mode and Photograph Mode. Each
SWITCH key press of this key moves the position of the lit lamp that indicates
the selected document mode.
7 Counter/Error display Displays the number of printed sheets.
panel Also displays an error message when an error occurs.
8 RESET key Returns the control panel settings to the “Standard Mode” set-
tings. Press and hold for at least 0.5 seconds.
9 PRINT POSITION keys Adjusts print position.
10 Printing position indicator lamp The lamp of the specified print position lights up.
11 Print speed indicator lamp The lamp of the specified printing speed lights up.
12 PRINT SPEED keys Adjusts print speed.
20 U5-Y113 0-0
8 9
10
11
12
13
19 18 17 16 15 14
Name Function
13 TEST PRINT key Prints 1 copy to check the image position and density.
14 STOP key Stops printing. When this key is pressed and held down while the
machine is not working, total number of printed sheets and the total
number of masters are displayed on the counter/error display panel.
15 PRINT key Starts printing.
This key does not start making a master.
16 MASTER MAKING key Starts making a master.
17 × key
＝ Enters the number of printed sheets and the number of sets in batch
printing.
18 NUMERIC keys Enters the print volume.
19 CLEAR key Returns the number of printed sheets to 0.
Other settings on the control panel are not changed.
20 OK monitor Flashes to display the content of the trouble and lights to indicate
the part that caused the trouble in the machine.
21 MASTER DARKNESS key The Master darkness is adjusted with this key.
22 Master darkness indictor The lamp for the specified master darkness lights up.
lamp
23 94% key Reduces image to 94%.
24 94% indictor lamp Lights up when 94% reduction is on.
U5-Y113 0-0 21
Chapter 2 Description of the Operation
1 Scanner Section.........................................24 3 Paper Feed Section ..................................48
1. Description ............................................24
2. Sequence of Operation .........................25
1. Description ............................................48
2. Operation...............................................49
2
(1) Document detection.............................25 (1) Paper Feed Roller Drive......................49
(2) Basic Operation for Feeding Paper to Scanner....26 (2) Paper Feed Length.............................50
3. Function of Parts and Circuit .................28 3. Function of Parts....................................51
(1) Document Sensors.............................28 (1) Printing Position Adjustment Mechanism.....51
(2) CIS (Contact Image Sensor)...............30 (2) Signal Lever........................................52
(3) Scanner Stepping Motor ..........................32 4 Drum Driving Section ................................53
2 Master making / Master Feed / Ejection Section ......33 1. Description ............................................53
<<Master making / Master Feed Section>> .................33 2. Function of Parts ...................................54
1. Description ............................................33 (1) Drum Removal Position Sensor..........54
2. Sequence of Operation .........................34 (2) Master Attachment / Detachment
(1) Operation when the master set switch is turned on....34 Position Sensor...................................55
(2) Master making / Master Feeding.............35 (3) Drum Rotator Switch..............................56
3. Function of Parts ...................................36 (4) Control of the Main Motor....................57
(1) Thermal Head.....................................36 1. Rotation Speed Control by Encoder Sensor....57
(2) End Mark Sensor................................38 5 Press Section..............................................58
1. Master Setting Error Detection ..........39 1. Description..............................................58
2. Master End Detection.........................39 6 Paper Ejection Section ..............................60
(3) Cutter Unit ..........................................40 1. Description ............................................60
<<Master Ejection Section>> .........................41 2. Function of Parts ...................................61
1. Description ............................................41 (1) Paper Stripper Finger .........................61
2. Circuit.....................................................41 (2) Ejected Paper JAM sensor..................62
<<Master Clump Opening / Closing Section>>..........42 7 Drum Section.....................................................63
1. Description ............................................42 1. Description ....................................................63
2. Operation of Master Clump Open / Close Lever.....43 2. Circuit.............................................................64
(1) Structure..............................................43 3. Function of Parts ...........................................65
(2) Master Attachment / Detachment Operation ......44 (1) Ink Detection ...............................................65
(3) Clump Opening / Closing Lever Position ( B / C Mode).....45 1. LED Display and Output Signal on
3. Function of Parts ...................................46 the Ink Detection PCB Unit.......................66
(1) B / C Mode Sensor..............................46 2. “NO INK” Display Timing..........................67
4. Returning Operation Flowchart (2) Ink Pump ...................................................68
When the Power is Cut Off Accidentally ........47 (3) Drum Switch ..............................................69
(4) Front Cover sensor ......................................70
U5-Y113 0-0
Chapter 2 1 Scanner Section
1 Scanner Section
1. Description
The machine contains a scanner of the document moving type which scans images while the docu-
ment is fed.
The document is illuminated with the contact image sensor (CIS) while being transferred, and the
reflection in proportion to the document image darkness is imaged on the contact image sensor
(CIS). Then the image is dissolved into picture elements and converted photoelectrically into the
level of electricity simultaneously.
The document is fed and carried by a single stepping motor.
CIS
Ejection roller Paper feed roller
Document sensor
24 U5-Y113 0-0
2. Sequence of Operation
(1) Document detection
1. Detection of the document

2. Detection of the front end of the document
3. Detection of the rear end of the document
4. Detection of the finish of the document
5. Detection of document jam

When the MASTER MAKING key is pressed and the document sensor is photointerrupted by
the document fed with the paper feed roller, the document sensor detects the presence of the
document. When the document is detected, master making is continued. If the document does
2
not reach the document sensor even it is fed for 35mm after the MASTER MAKING key is
pressed, 'No Paper' is displayed on the OK monitor and the machine stops.

When the document sensor is photointerrupted by the document fed with the ADF feed roller, it
detects the front end of the document.

When the document is fed for 17mm after the rear end is detected, the reading of the document
is finished and the scanner stepping motor runs at a slower speed than the document reading
speed to eject the document. When the document is fed for approx. 17mm after the reading is
finished, the scanner stepping motor stops.
IMPORTANT :
• The reading of document is terminated at the earlier time when the longitudinal length is
fed of the document size or the document is fed for approx. 17mm after the rear end is de-
tected. If master making for the document with an unspecified size is required, select a
document size on the control panel with a longer longitudinal length than the longitudinal
length of the document.

When the rear end of the document has passed by the document sensor, the sensor is
photopassed and detects the finish of the document.

• When the MASTER MAKING key is pressed, the document sensor already detected.
• While the scanner is operating, even the document of maximum size (382mm) is fed, the document
does not pass through the document sensor and the document sensor detects document jam.
U5-Y113 0-0 25
(2) Basic Operation for Feeding Paper to Scanner
1. Operation
(1) Paper feed 1

When the document is placed on the document
Document
tray and the MASTER MAKING key is pressed,
the scanner stepping motor is turned ON and
the document is fed. CIS
IMPORTANT :
When the MASTER MAKING key is pressed, the
print section detaches the master and then the Paper feed roller
drum moves to the master attachment position
to open the master clamp, while ADF remains
standby state.
(2) Positioning
When the front end of the document reaches
the document sensor, the document sensor is Document
photointerrupted and detects the front end of
the document. CIS
Document sensor
(3) Paper feed 2

The lamp of the CIS lights up to perform shad-
Document
ing before the document reaches the CIS.
Reading of the document for master making
is started when the document is fed for approx. CIS
19mm.
Ejection roller Paper feed roller
26 U5-Y113 0-0
(4) Ejection
When the rear end of the document has
passed by the document sensor, the document Document
sensor is photopassed and detects the rear
end of the document.
When the document is fed for approx. 17mm
after the end of the document is detected,
image reading for master making finishes,
and the scanner stepping motor stops when Ejection roller Paper feed roller
the document is fed for approx. 33mm after the
end of the document is detected.
Ejection roller
U5-Y113 0-0 27
3. Function of Parts and Circuit
(1) Document Sensor
Description
The document sensor detects the five types of document detection.

Circuit
Document sensor
5V Photopassed:0V
3.3V Photointerrupted:3.3V
1 Red 3 Red J7-12
2 Orange 4 Orange -14 3.3V
0
3 Blue 5 Blue -13
Main PCB Unit
Operation
Document sensor
28 U5-Y113 0-0
1. Detection of the document / finish of the document

The voltage V on the main PCB unit J7-14 varies depending on the received quantity of light of
the document sensor. The judgment is made on the voltage as shown below with the threshold of
1.5V. The result can be checked with HELP-08:A.
HELP-08:A
V > 1.5･･････Document present (Photointerrupted), HELP-08:A = 1
V<= 1.5･･････Document inexistent (Photopassed), HELP-08:A = 0
Main PCB Unit

J7-14 Voltage V HELP-08:A Indicated
＋3.3V
2
＋1.5V
0V
Document sensor
Photointerrupted Photopassed
2. Detection of the front / rear end of the document

The voltage V on the main PCB unit J7-14 varies depending on the received quantity of light of
the document sensor. The judgement is made on the voltage as shown below with the threshold
of 4.5V.
V > 4.5 • • • • • Document present (Photointerrupted)
V<= 4.5 • • • • • Document inexistent (Photopassed)
Main PCB Unit
J7-14 Voltage V HELP-08:A Indicated
＋3.3V
＋1.5V
0V
Document sensor
Photointerrupted Photopassed

Detection of document jam is performed on the conditions shown below.
• When the MASTER MAKING key is pressed, the document sensor already detected.
• While the scanner is operating, even the document of maximum size (382mm) is fed, the document
does not pass through the document sensor and the document sensor detects document jam.
Then, document jam is displayed on the OK monitor. The jam is cleared when the document sensor
is photopassed.
U5-Y113 0-0 29
(2) CIS (Contact Image Sensor)
The CIS illuminates the document and the reflected light is transmitted onto the CIS.
The CIS outputs the image signals in level of voltage.
Circuit
CIS (Contact Image Sensor)
White
6 J5-1 Main PCB Unit
Blue
2 -2
White
8 -3
Blue
11 -4
Red
3 -6
White
1 -12
Brown 1 Brown
10 J2-7
Yellow 2 Yellow
9 -8
CIS
The table below shows the specification for the CIS. The received quantity of light is A/D converted
to the value ( 0 to 255) which is shown in HELP-08:[master darkness:DARK].
Lower received quantity of light : 000 - 255 : Higher received quantity of light.
Specification
No. Item Specification
1 Readable Width 256mm
2 Number Of Sensor Elements 3024 (25 - 3048)
3 Resolution 300 dpi
4 Scanning Speed 3.1 msec/line
5 CLK Frequency 1.0 MHz
6 Light Source Wavelength 570nm
7 Data Output 1 Analogue
8.5 x 14 209mm x 349mm

8.5 x 11 209mm x 273mm
5.5 x 8.5 133mm x 209mm
8.5 x 5.5 209mm x 133mm
30 U5-Y113 0-0
Operation
● Shading
Shading plate Document
CIS
Document sensor
The CIS is lit to complete shading by the time the document reaches the glass from the holding posi-
tion. In shading, the quantity of light on the shading plate (white section) on the reverse side of the
2
ADF cover is detected to correct any local differences in the quantity of light of the CIS and/or any
changes in the quantity of light due to time.
IMPORTANT :
If the shading plate is dirty, no normal correction cannot be expected. On maintenance, take care
not to damage or dirt the plate. If the plate is dirty, clean with soft cloth not to damage it. At this
time, care should be taken not to bend the shading plate with an excessive force.
● Image reading
Document
Document
CIS
Image reading is performed when the document is fed on the glass from the holding position.
Image reading is started when the document is fed for approx. 15mm after the scanner stepping
motor is turned on.
Image reading is terminated either of the following conditions is met.
1. The document is fed for approx. 17mm after the document sensnor detects the end of the document.
2. Master making is completed.
The tables below show the range of master making for the document.
The range of master making for A/B size The range of master making for inch size
Set size Width Length Set size Width Length
(in the feeding direction) (in the feeding direction)
B4 250mm 350mm 8.5×14 209mm 349mm
A4 204mm 291mm 8.5×11 209mm 273mm
B5 176mm 251mm 5.5×8.5 133mm 209mm
A5 142mm 204mm 8.5×5.5 209mm 133mm
U5-Y113 0-0 31
(3) Scanner Stepping Motor
Circuit
Scanner Stepping Motor

1 Yellow J1-7
2 Orange -9
3 Brown
Main PCB Unit
-6
M 4 Black -10
5 Red -11
6 Blue -12
Operation
The rollers for ADF are driven by the scanner stepping motor .
(4) Upper Cover Opening / Closing Detection
Description
Opening and closing of the upper cover is detected by the upper
cover sensor. This machine does not work (except for the master set
switch and JOG switch) unless the upper cover is closed firmly for
safety. The machine stops immediately when the upper cover opens
during operation. (When the cover opens during master making, the
machine stops after master making process is completed.)
When opening of the upper cover is detected, the right display ap-
pears on the OK monitor.
Operation
When the upper cover is closed, the sensor is photointerrupted.
When the upper cover is opened, the sensor is photopassed.
● When upper cover sensor is closed ● When upper cover sensor is opened
Upper cover sensor Upper cover sensor
32 U5-Y113 0-0
Chapter 2 2 Master Making / Master Feed / Ejection Section
2 Mastermaking / Master Feed / Ejection Section

Master making / Master Feed Section Master Clamp Opening / Closing Section Master Ejection Section
<<Master Ejection Section>>
1. Description
Make the master clamp of the drum unit clamp the master top end, performing master making on
the master with the thermal head. (In this machine, the master on the drum is ejected at the same
time when master making is performed.)
The master is conveyed to the drum unit via the platen roller by driving of the stepping motor, while
it is being processed in the head section.
The end-mark sensor starts to detect when the end mark (black) section printed on the end of the
roll master is conveyed. An error message is displayed on the Counter/Error display panel and the
indicator lights are lit on the OK monitor.
The end mark sensor also detects whether the master is conveyed properly through the sensor.
Cutter unit
Drum unit
End mark sensor
Master
Platen roller
Thermal head
Master set sensor Master feed stepping motor
U5-Y113 0-0 33
2. Sequence of Operation
(1) Operation when the master set switch is turned on
When the master set lever is pressd down, the Master set lever
platen roller rotates and feeds out the document Master
for approx. 100mm.
Sensor ON
Platen roller (photointerrupting)
When the end mark sensor is interrupted, the

master is fed for 3mm and stopped.
End mark sensor
34 U5-Y113 0-0
(2) Master Making / Master Feeding
When master making operation starts, the drum unit

rotates to perform master removal process. The drum
which has finished master removal process stops at
the master set position.
Open the master clamp.
A certain amount of the master tip end is fed to the

master clamp section and the platen roller stops.
After the master clamp is closed and clamp the master

tip end, the drum rotates to roll up the master.
When the master bottom end reaches the top of the

drum, master set is completed. Start printing.
U5-Y113 0-0 35
3. Function of Parts
(1) Thermal Head
Description
The thermal elements are in alignment in the primary scanning (vertical direction), and are heated on
the image section to make holes on the master film.
Thermal Head
1 J2 -26
27
28
J4 -1
28 24
Main PCB unit
1 J3 -1
14 24
№ Item
1 Picture element (density) 300DPI(11.8dot/mm)
2 Effective memory width 260 ±0.2mm
36 U5-Y113 0-0
Exterior and Lot No.
276
Thermal resistor line
260±0.2
Label Thermistor
Model name
Lot No. Resistance 2

Power connector Signal connector
Pin (No.1) Pin (No.1)
Lot No.
Each digit has the following meanings.
Serial No.
Production month (X:Oct., Y:Nov., Z:Dec.)
Production year (Year of decade)
Resistance
Resistance value is described on the label. When the head is replaced and the HELP mode is
initialized, set the DIP-SW (HELP-044) of the HELP mode.
Resistance value(Ω) H-44

3663 - 3748 0000
3749 - 3834 0001
3835 - 3920 0010
3921 - 4006 0011
4007 - 4093 0100
4094 - 4179 0101
4180 - 4265 0110
4266 - 4351 0111
Resistance value 4352 - 4437 1000
4438 - 4524 1001
4525 - 4610 1010
4611 - 4696 1011
4697 - 4782 1100
4783 - 4868 1101
4869 - 4954 1110
4955 - 5041 1111
U5-Y113 0-0 37
(2) End Mark Sensor
Description
The end marks are located at a fixed distance End Mark Sensor
relative to the master; as the master is being
fed, the end mark sensor senses master
condition and the end marks by means of
intensity of reflected light.
End Mark
● Reflection light amount ●Value of the HELP mode H-13

The larger the reflection light amount is, the
smaller the output voltage is. The smaller the 5V 255
Output voltage
light amount is, the larger the output voltage
40
is. The value is checked with the HELP-13.
30
HELP-13 →See page 164
0V 00
Smaller Larger
Reflection light amount
Circuit
5V
VR1
5V
5V
CN1-1 Red 1 Red J7-29
2 Green 2 Green 27 5V
0
3 Blue 3 Blue 25
Main PCB unit
End mark sensor PCB unit
38 U5-Y113 0-0
1. Master Setting Error Detection

Operation
In master making, the end mark sensor uses amount of reflected light to detect presence or ab-
sence of a master on the transfer path. Then the following displays and operations are performed:
● When a master setting error (master is not attached to the drum) is detected, "C002" appears.
● Printing is not performed but master making is only performed when the display is cleared after
master setting error is detected. (Because the master is not attached to the drum.)
Timing
Master setting error is detected with the following condition.
● When the master rear end is not detected after master making process is finished and the master
is cut.
2
2. Master End Detection
Operation
The end mark is printed on the area about 10,000±50mm
from the end of the master.
● When the end mark is detected, the right display appears.
● When the right display appears, the next master cannot
be made.
C004
Timing
When it is considered that the end mark is read under the
following conditions, the display appears.
1. While the master is rolling up to the drum during
master making, the following is checked.
2. When the master passes under the end mark sensor,
the amount of reflected light is read.
3. When 120mm or more black is detected, it is considered
that the end mark is read.
● H-13
Display value
Smaller 255
MAX
Black
light amount
Reflection
40
30
MIN
White
Larger
00
U5-Y113 0-0 39
(3) Cutter Unit
Description
When master making is completed, the stepping motor for master making and the drum stop temporarily,
the cutter motor is turned on to drive the cutter and the master is cut.
Circuit
Cutter motor
Red 1 Red J1-19
M
Black 2 Black -20
Main PCB unit
Operation
Home position for the cutter motor is on the operation side.
When cutting the master, the cutter motor rotates normally (CW) and moves from the operation side
to the opposite side. After cutting is completed, the cutter motor stops and then rotates reversely
(CCW), and returns to its home position.
40 U5-Y113 0-0
1. Description
When the drum stops at the master detachment postiion and the master clamp which clamps the
master tip is opened (C mode), the pulling roller on the rolling section of the master ejection unit
pulls the master tip into inside of unit and keeps pulling until
the master rear end is pulled.
When the master ejection box never opens even after 10
maters are made, the right display appears on the counter/
C006
error display and the OK monitor. The display is cleared by
opening/closing the master ejection box and disposing of the
2
master.
Master detachment
Pulling roller
position
2.Circuit
Master detachment opening/ 3.3V

closing switch White 3 White
J7 - 5
White 2 White
-6
Interlock switch Main PCB unit

Master eject motor
1 Red 1 Red
J2 - 3
M 2 Black 2 Black
-4
U5-Y113 0-0 41
<<Master Clamp Opening / Closing Section>>
1.Description
The master clamp on the drum unit is opened or closed by the two opening / closing levers rota-
tion 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 master making. Opening / Closing operation is as fol-
lows:
1. When master making 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 master ejection unit.
(C mode)
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 the master clamp to have it grip the leading edge of the master made.
5. Rotate the drum to wind the master onto it.
Master clamp opening / closing lever

(Master attachment position)
Master clamp opening / Master clamp opening / closing lever
closing section (Master detachment position)
Drum
42 U5-Y113 0-0
2. Operation of Master Clamp Opening / Closing Lever
(1) Structure
Sensor plate
Clamp motor Master clamp opening /
closing lever
Master clamp opening /

closing lever
2
Master clamp
C mode sensor
B mode sensor
Master clamp opening / closing lever

(Master attachment position)
Master clamp opening / Master clamp opening / closing lever
closing section (Master detachment position)
Drum
B mode C mode
U5-Y113 0-0 43
(2) Master Attachment / Detachment Operation
1. B mode 2. B mode 3. B mode

The drum rotates to the master detach-
The drum rotates. ment position→Stops
4. B mode → C mode 5. C mode 6. C mode→ B mode

The clamp opens to pull the master. The pulling roller stops. The clamp is closed.
7. B mode
The drum rotates to the master attach- 8. B mode → C mode 9. The master is fed out.
ment position→Stops The clamp opens.
10. C mode→ B mode 11. B mode 12. B mode

The clamp grips the master. The drum rotates to attach the master.
44 U5-Y113 0-0
(3) Clamp Opening / Closing Lever Position

(B / C Modes)
2
B mode
C mode
U5-Y113 0-0 45
(1) B / C Mode Sensors
Circuit
Clamp motor
Black 2 Black
J1 - 21
M Main PCB unit
Red 1 Red
- 22
Clamp sensor 1
5V 3.3V
( B mode )
1 Red J6 - 31
2 White - 24 3.3V
3 Blue - 23
Photopassing : 0V
Photointerrupting : 3.3V
Clamp sensor 2
( C mode )
5V
5V
1 Red J6 - 30
2 Gray - 26 3.3V
3 Blue - 25 Photopassing : 0V
Operation / Sequence
Sequence C-mode B-mode C-mode B-mode C-mode B-mode C-mode
Clamp sensor 1
( B mode )
Clamp sensor 2
( C mode )
Clamp motor
: Motor normal rotation (CW),

Sensor photointerrupting(ON) Master tip end is pulled into the Master tip end is fed to Master clamp grips
: Motor stops,Sensor photopassing(OFF) master ejection box the master clamp section the master tip end
: Motor reverse rotation (CCW)
The mode is detected under the following conditions:

● B mode ➡ 46 ページ参照
When the clamp sensor 2 (C mode) is photointerrupted, the clamp sensor 1
(B mode) detects the edge of photointerrupting → photopassing.
● C mode
When the clamp sensor 1 (B mode) is photointerrupted, the clamp sensor 2
(C mode) detects the edge of photointerrupting → photopassing.
46 U5-Y113 0-0
4. Return Operation Flow Chart When the Power is Cut Off Accidentally
The machine returns to the initial status automatically when the power is turned off mistakenly dur-
ing processing master making, master detachment and master attachment simultaneously or when
the power returns after it is interrupted.
Power ON
Master attachment/ 2
detachment process Is the status the
same as the previous
status (before the
power is OFF)?
Return operation
(from power OFF)
Open the upper cover.
Remove the mis-set document.
Close the upper cover.
Initial screen
Standby
U5-Y113 0-0 47
Chapter 2 3 Paper Feed Section
3 Paper Feed Section

1. Description
The center separation method is taken to feed paper. There is no corner finger and paper feeding
is performed with the paper separator and paper feed roller. Paper is pressed to the roller by the
paper feed plate spring. The fed paper is conveyed with the timing roller (T roller) and guide roller
to the position where the paper tip is gripped between the drum surface and the press roller. The
paper is transferred by the rotation of the drum and press roller.
The ejected paper JAM sensor detects the transfer status of the fed paper. When any failure occurs
in the feeding paper, an error appears on the OK monitor.
Press roller Drum
T roller clutch
Guide roller
Paper feed clutch

Paper feed roller
Paper
Timing roller
Feed tray Paper separator
48 U5-Y113 0-0
2. Operation
(1) Driving of Paper Feed Roller / Timing Roller
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 status of the paper feed clutch and is controlled by the
program.
The timing roller driven by the main motor via the timing belt and the T roller clutch. The rotational
timing depends on the ON/OFF status of the T roller clutch and is controlled by the program.
2
Timing belt
T roller clutch
Paper feed clutch
Main motor
Paper feed roller
U5-Y113 0-0 49
(2) 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 firmly
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.
Paper feed length is controlled by program (HELP-67).
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
feed side).
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 wrin-
kling 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.
50 U5-Y113 0-0
3. Functions of parts
(1) Printing Position Adjusting Mechanism
The printing position is adjusted by changing the

timing of the paper toward the drum by pressing
the PRINT POSITION keys on the control panel.
2
Description
Drive timing of the timing roller is changed by the ON/OFF timing of the T roller clutch.
T roller clutch OFF-angle and paper feed clutch ON/OFF are automatically by adjusting T roller
clutch ON-angle. (HELP-73)
● Press ● Press
Print paper Print paper
Direction of Direction of
movement of movement of
Image Image
print paper print paper
U5-Y113 0-0 51
(2) Signal Lever
Description
The signal lever is positioned at the back of the guide roller / timing roller. Whether the paper is fed
or not 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 dirt as the press roller is in contact
with the drum when the paper is not fed.
Press lever
Pinch lever
Signal lever
Guide roller Press roller

T roller clutch
Paper Timing roller
View from A
Drum Signal lever
Pinch lever
Guide roller
Timing roller
Press roller
52 U5-Y113 0-0
Chapter 2 4 Drum Driving Section
4 Drum Driving Section

1. Description
2
Drum removal
position sensor
Master attachment /
detachment position sensor Drum gear
Main motor
Encoder
Encoder sensor
U5-Y113 0-0 53
2. Operation
(1) Drum Removal Position Sensor
Description
The drum removal position sensor detects the drum removal position and master detachment posi-
tion. Drum removal position is the position where the drum stops with a beep sounds after the drum
removal switch is held down.
Circuit
Drum removal position sensor

Main PCB unit
5V
3.3V
1 Red J6 - 28
2 Light blue - 20 3.3V
0
Operation
The drum removal position sensor is positioned while the drum is rotating as follows:-
● The stop position is detected with the edge of photointerrupting / photopassing.
Drum removal detection edge
Drum gear
54 U5-Y113 0-0
(2) Master Attachment / Detachment

Position Sensor
Description
Master attachment / detachment position sensor detects drum stop position where the master is
attached or detached.
Circuit
2
Master attachment / detachment
position sensor
5V Main PCB Unit
3.3V
1 Red J6 - 30
2 Gray - 26 3.3V
0
Operation
The diagram below shows the status of master attachment / detachment position sensor while the
drum is rotating.
● The master detachment position is detected with the edge of the detachment position.
● It is judged that the master can be detached when the master attachment / detachment position
sensor is in the status of photointerrupting and the drum removal position sensor is in the sta-
tus of photopassing, the master can be detached.
Master detachment position edge

Master attachment / detachment
Drum gear
position sensor
Master attachment position edge
U5-Y113 0-0 55
(3) JOG Switch
Description
The drum rotates as long as the JOG switch is pressed (within one rotation) and stops at the stop
position with a beep.
JOG switch
Circuit
JOG switch
Light blue GND Main PCB Unit

1 Light blue J7 - 9
3.3V
Light blue 2 Light blue - 10 3.3V
0
3.3V
0
56 U5-Y113 0-0
(4) Control of the Main Motor
Circuit
Main motor encoder sensor 5V 3.3V

1 Red J8 - 18
2 Gray - 11 3.3V
0
2
Main motor
Black 1 Black
J10 - 1
M Red Red
2 -2
Main PCB unit
1. Rotation speed control by encoder sensor
The encoder sensor detects the main motor rota-

tion. The main PCB unit controls the number of
main motor rotations with the encoder sensor sig- Encoder sensor
nal. The encoder sensor signal is transmitted to the
main PCB unit. The number of main motor rotations Encoder dividing
is checked with the HELP-01.
U5-Y113 0-0 57
Chapter 2 5 Press Section
5 Press Section
1. Description
In this machine, the master is rolled up to the drum, ink is transferred to the drum and the printing
paper is pressed to the drum by the press roller to print.
Printing is performed on only the sections that meet the following requirements.
(1) The sections of the master on which holes are made by processing master making.
(2) The hole sections of the drum.
(3) The section of the drum pressed with the press roller. (the area pressed ON)
When the pressed-on position is 0 under the normally adjusted conditions, relations among (1),
(2) and (3) are as follows*-
Cam curve
Press ON Press OFF Press ON

Drum hole section About 16mm Drum hole section
Printing area Press ON Printing area
Drum hole section 358
Center of the master clamp shaft
Bottom end of the hole section

Printing area 16
Press OFF Press ON
366 Press area
58 U5-Y113 0-0
Chapter 2 5 Press Section
● The press roller is ON (the press roller is pressed to the drum) or OFF by operating the press
lever up and down with the cam inside the drum gear.
●Press roller : OFF ●Press roller : ON
Cam Cam
Pinch lever
Pinch lever
Press lever Press roller Press lever Press roller
● Adjusting the printing area means that the Press OFF position Press ON position
cam curve goes up and down as shown in
the figure. The timing of drum ON / OFF
varies depending on the cam curve’s up
and down. The ON position is before the
drum hole section, so the printing area is
not influenced. (Do not shorten the printing Printing area Printing area
area length as it is influenced.) The OFF Drum hole section Drum hole section
end start
position is only changed and the printing
area is adjusted.
IMPORTANT:
Do not press off later than the hole section end position since ink seeps from the bottom end of the
master.
350mm
U5-Y113 0-0 59
Chapter 2 6 Paper Ejection Section
6 Paper Ejection Section

1. Description
In the paper ejection section, the printed paper is removed from the drum and is ejected to the print
tray.
Air pump
Paper stripper finger
Paper ejection roller
60 U5-Y113 0-0
(1) Paper Stripper Finger
Mechanical Structure and Operation

There is an air diffuser on the tip of the Paper Stripper Finger. Compressed air transmitted from the
air pump is blown out of this hole to detach the leading edge of the paper from the drum.
Air pump
To remove the paper from the drum surely, the gap between the tip of the finger and the drum sur-
face and between the tip of the finger and the corner of the master clamp are adjusted as follows:-
Drum
Paper ejection roller
0.5-1.0mm
U5-Y113 0-0 61
(2) Ejected Paper JAM Sensor
Description
The ejected paper JAM sensor is installed on the jump plate unit and de-
tects whether the paper is ejected normally.
When it is detected that the paper is not ejected normally, the right display
appears on the OK monitor.
Circuit
Ejected paper JAM sensor
Main PCB unit

5V
3.3V
1 Blue J7 - 17
2 Light blue - 18 3.3V
0
3 Red - 22 Photopassing : 0V
Operation
The ejected paper JAM sensor is installed on the jump plate unit.
LOW with the optical path interrupted. HIGH with the optical path passing.
62 U5-Y113 0-0
Chapter 2 7 Drum Section
7 Drum Section
1. Description
The ink control section is in the drum unit and is supplied with ink in the ink pack attached to the
drum attached to the drum unit by the ink pump 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 chang-
ing 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 JOG switch to move the drum unit to the drum stop position
and then replace the drum unit.)
In this machine, whether the drum unit is installed or not is detected. If the drum unit is not installed
properly, an error display appears on the OK monitor.
2
Ink pump motor
Squeegee roller
Ink roller
Ink detection PCB unit
Ink pump
U5-Y113 0-0 63
2. Circuit
Ink pump motor

Black 2 8 Black J2 - 5
Red 1 2 Red -6
Ink detection PCB unit +24V

CN1 - 3 1 9 Brown J2 - 1
-1 2 4 Black J6 - 10
-2 3 3 Blue -9
Main PCB unit
64 U5-Y113 0-0
(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 nit. The main PCB unit controls the ink pump motor ON / OFF by this signal.
When NO INK continues while the drum rotates 25 times (the number of
drum unit rotations; it varies depending on the printing speed.*) during
printing, it is judged that the ink pack is empty and the right display ap-
pears on the OK monitor, and then printing stops. 2
Ink roller
Detection needle
Ink
Squeegee roller
U5-Y113 0-0 65
1. LED Display and Output Signal on the Ink Detection PCB Unit
● When the electric capacity variation between the detection needle on the ink detection PCB unit
and GND is over the threshold value, the LED on the ink detection PCB unit lights up and the ink
signal (0V) is output.

LED CN-1
NO ink Light out +3.3V
Ink Light up 0V
● Timing of the LED and the ink pump motor operation is as follows. The ink pump motor works
only during printing (driving output signal).
Ink detection PCB unit Light up

LED
Light out
+3.3V
0V
CN-1-2
+24V
Main PCB unit
Between the J2-5 and GND
0V 0.5sec
Ink pump motor
rotates
66 U5-Y113 0-0
2. “NO INK” Display Timing

When HIGH (3.3V) is output by detecting ink while the drum continues to
rotate 25 times (the number of rotation varies depending on the printing
speed.*) during printing, it is judged that the ink pack is empty and the
right display appears on the OK monitor, and then printing stops. At the
same time, the power for the ink pump motor is turned off.
* The drum rotates until the right display appears on the OK monitor after
HIGH is output from the ink detection PCB unit during printing. The num-
ber of drum rotation varies depending on the printing speed as follows.
Print speed 1 2
Number of drum rotations 20 37 2
Drum removal position

Drum stops
3.3V
0V
1 2 3 19 20
No ink
+3.3V
Ink detection PCB unit CN-1-2 No ink
There is ink. 0 V
Ink pump +24V
Main PCB Output J2-5 0V
OFF
U5-Y113 0-0 67
(2) Ink Pump
Description
The ink control section in the drum is supplied with ink in the ink pack by driving the ink pump motor.
Mechanical Structure
Ink pump motor
Ink pump
Operation
The piston performs suction and release operation by moving up and down.
When the piston moves up, it draws ink from When the piston moves down, the pump
the ink pack into the pump. releases ink.
68 U5-Y113 0-0
(3) Drum Detection
Description
Connecting the floating connectors shown below detects whether the
drum is installed to the machine. When it is detected that no drum is
installed, the right display appears on the OK monitor and the machine
does not operate. When no drum is detected during operation, all the
operations stop immediately.
2
Operation
When the drum is installed in the machine, drum detection is performed by connecting the floating
connectors.
Floating connector
U5-Y113 0-0 69
(4) Front Cover Sensor
Description
The front cover sensor detects opening and closing of the front cover.
When the sensor detects opening of the front cover, it is displayed on the
OK monitor.
When the front cover is opened, master making and printing are not per-
formed.
When 'front cover open' is detected during printing, the machine stops
immediately. (When it is detected during master making, the machine
stops before processing printing.)
Circuit
Front Cover sensor

5V Main PCB unit
3.3V
1 Red J6 - 4
2 Pink -6 3.3V
0
3 Blue -5
Photopassing : 0V
Operation
When the front cover is closed, the lever blocking off the light to the sensor is closed.
When the front cover is opened, the lever separated from the sensor is opened.
Photointerrupting Photopassing
Front cover sensor CLOSE OPEN
70 U5-Y113 0-0
Chapter 3 Mechanism
1 Exterior………………………………..……..……72 4 Paper Feed Section………………..............……89
(1) Removing the Upper Cover……...…..………72 (1) Removing the Paper Feed Roller……...……89
(2) Removing the Document Tray.……....………72 (2) Removing the Paper Separator Unit….…...……90
(3) Removing the Main PCB Cover…...…...……73 (3) Removing the Auxiliary Separator………..…90
(4) Removing the Main PCB…………......………73 (4) Removing the Paper Feed Clutch…....…..…91
(5) Removing the Rear Cover…….………...……73 (5) Removing the T Roll Clutch………...……..…91
(6) Removing the Front Cover ……………...……74 5 Drum Driving Section………...…..............…..…92
(7) Removing the Drum Cover……………...……74
(8) Removing the Control Panel…...………...……75
(1) Removing the Drive Bracket………….…..…92
(2) Removing the Drum Gear…………......…..…93 3
(9) Removing the Control Panel PCB……......…75 6 Paper Ejection Section…….……..........……..…94
(10) Removing the Stabilized DC Power Supply………...…75 (1) Removing the Paper Stripper Finger….….…..…94
2 Scanner Section ……………..…….......…………76 (2) Removing the Ejected Paper JAM Sensor....……..…94
(1) Removing the Shading Plate……….......……76 (3) Removing the Jump Plate Unit……....……..…95
(2) Removing the Document Sensor…..…..……76 7 Drum Section…………...…......................…..…96
(3) Removing the CIS (Contact Image Sensor) …....……77 (1) Removing the Screen…………....….....…..…96
(4) Removing the ADF Unit………….....…...……79 (2) Removing the Master Clamp……….……..…97
(5) Removing the Scanner Stepping Motor……......…80 (3) Removing the Base Unit……….…....……..…97
3 Master Making / Master Feed and Ejection Section…...…81 (4) Removing the Outer Frame (right) Unit….......………98
<<Master Making/ Master Feed Section>>…….…..……81 (5) Removing the Outer Frame Shaft Assy……...………99
(1) Removing the Cutter Unit………............……81 (6) Removing the Inner Frame………….………100
(2) Removing the End Mark Sensor PCB…..........…81 (7) Removing the Ink Pump………….....………101
(3) Removing the Thermal Head…………..….…82 (8) Removing the Ink Pump Motor….....………101
(4) Removing the Master Feed Unit…….....……83 (9) Removing the Ink Detection PCB…….....…102
(5) Removing the Master Feed Stepping Motor.......…84
<<Master Ejection Section>>……………..……..…85
(1) Removing the Master Ejection Unit……….…..…85
(2) Removing the Master Ejection Motor………...……86
<<Master Clamp Opening/Closing Unit>>…….……..…87
(1) Removing the Master Clamp Opening/Closing Unit.…..87
(2) Removing the Clamp Motor…………......…..87
(3)Removing the Timing Belt…...................……88
Chapter 3 1 Exterior
1 Exterior
(1) Removing the Upper Cover
1. Open the upper cover and remove the 2

Upper cover
screws on the hinge.
Hinge
Screws
2. While bending the upper cover, remove the pin

at the fulcrum.
Pin
(2) Removing the Document Tray
1. Remove the 4 screws, then remove the Screws

document tray.
Screws
72
(3) Removing the Main PCB Cover
1. Remove the document tray previously

mentioned in (2).
2. Remove the 2 screws, then remove the main
PCB cover.
Screws
(4) Removing the Main PCB
WARNING
Screws
3
● Be sure to turn off the power before
replacing the PCB.
1. Remove the document tray and the main PCB

cover previously mentioned in (2) and (3).
2. Disconnect the connectors.
● Main PCB: 11 connectors
3. Remove the 5 screws, then remove the main Screws
PCB.
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.
(5) Removing the Rear Cover
1. Remove the 4 screws, then remove the rear Screws

cover.
Screws
73
(6) Removing the Front Cover
1. Push down the paper set lever and remove the

screw to remove the lever.
Paper
Screw set
lever
2. Open the drum cover and take out the drum

unit.
3. Open the upper cover.
4. Open the 3 screws, then remove the front cov-
er.
Screw
Screw
Screw
(7) Removing the Drum Cover
1. Remove the front cover previously mentioned in

(6).
2. Remove the 4 screws, then remove the drum
cover. Screws
Screws
74
(8) Removing the Control Panel
1. Remove the front cover and the drum cover

previously mentioned in (6) and (7).
2. Remove the 2 screws.
3. Remove the control panel upward.
Screws
4. Disconnect the connector, and remove the 2 Connector

screws fixing the ground wires.
Screw
Screw 3
Ground wire
(9) Removeing the Control Panel PCB
1. Remove the front cover, the drum cover and Panel PCB
the control panel previously mentioned in (6),
(7) and (8).
Screws Screws
(10) Removing the Stabilized DC Power Supply
1. Remove the front cover and the drum cover

previously mentioned in (6) and (7).
2. Disconnect the 3 connectors.
Stabilized DC power
supply
WARNING
● Be sure to turn off the power before Screws
replacing the PCB. Screws
75
2 Scanner Section
(1) Removing the Shading Plate
1. Open the scanner cover. Shading plate

2. Widen the installing part of the shading plate
and remove the shading plate.
(2) Removing the Document Sensor
1. Remove the document tray.

→ See page 72.
2. Open the scanner cover.
3. Remove the 4 screws, then remove the guide
plate.
Screws Screws
4. Disconnect the connector of the document

sensor.
5. Remove the screw, then remove the document
sensor with the bracket. Document sensor
Screw
6. Remove the screw, then remove the document

sensor. Document sensor
Screw
76
(3) Removing the CIS (Contact Image Sensor)

→ See page 72.
2. Open the scanner cover.
plate.
Screws Screws
4. Disconnect the connector of the CIS.

3
Connector
5. Remove the 2 screws, then remove the CIS

with the angle.
Screws
77
6. Remove the 4 screws, then remove the 2

angles from the CIS.
CIS
Operation side CIS
Screws
Angle
Opposite of operation side CIS
Angle
Screws
78
(4) Removing the ADF Unit
1. Remove the upper cover.

→ See page 72.
2. Remove the rear cover.
→ See page 73.
→ See page 72.
4. Remove the main PCB cover.
→ See page 73.
5. Remove the screw, then remove the sensor

with the bracket. Screw
Sensor
6. Disconnect the 3 connectors. Edge holder

7. Take out the cables from the edge holder.
Connectors
8. Remove the 4 screws, then remove the ADF

Screws
unit.
79
(5) Removing the Scanner Stepping Motor

1. Remove the ADF unit.
→ See page 79.
2. Remove the E ring, then remove the gear.
E ring
3. Remove the 2 screws, then remove the scan-

ner stepping motor.
Screw
Screw
80
Chapter 3 3 Master Making / Master Feed and Ejection Section
3 Master Making / Master Feed and Ejection Section

<<Master Making / Master Feed Section>>
(1) Removing the Cutter Unit

→ See page 72.
2. Take out the master roll.
3. Remove the 2 screws, then remove the platen
cover.
3
Screws
4. Pull out the connector.

5. Remove the 2 screws, then remove the cutter
unit.
WARNING
● Keep hands and fingers away from cutter
unit's blades. Do NOT touch the blades.
Connector Screws
(2) Removing the End Mark Sensor PCB

→ See page 72.
cover.
4. Disconnect the connector.
5. Remove the 2 screws, then remove the end
mark sensor PCB. Screw
End mark sensor PCB Screw
81
(3) Removing the Thermal Head

→ See page 72.
plate.
Screw
4. Remove the screw with the collar.

5. Disconnect the 2 connectors on the thermal
head with the brackets.
Connector
Connector Screw
6. Remove the 2 screws with the collars, then

remove the thermal head.
Collar
IMPORTANT: Screw
● Do NOT touch the head emission parts of
the thermal head.
● The thermal head is liable to corrode. Collar Thermal head

To avoid corrosion, keep the head free of Screw
moisture and salinity, and do not touch its
head emission parts. Touching these parts
could scratch them.
Reinstallation
IMPORTANT:
When the thermal head is replaced, set HELP
mode H-44.
82
(4) Removing the Master Feed Unit

→ See page 72.
3. Take out the drum unit.
4. Remove the front cover.
→ See page 74.
5. Remove the 2 screws, then remove the cover.
Cover
Screws
3
Connector

cover.
→ See page 81.(2)

plate.
9. Disconnect the 2 connectors on the thermal
head.
→ See page 82.(3)
10. Remove the 4 screws, then remove the

master feed unit.
Screws Screws
83
(5) Removing the Master Feed Stepping Motor
1. Remove the master feed unit.

→ See page 83.
3. Remove the timing belt.
4. Remove the 2 screws, then remove the master
feed stepping motor.
Timing belt
Connector
Screws
84
(1) Removing the Master Ejection Unit

→ See page 73.
Connectors
3
→ See page 72.
4. Remove the main PCB cover.
→ See page 73.
5. Loosen the 2 screws in the holes in the base.
Screws
6. Remove the 2 screws on the paper ejection Screws

side, then remove the master ejection unit.
85
(2) Removing the Master Ejection Motor
1. Remove the master ejection unit.

→ See page 85.
2. Remove the 3 screws, then remove the master Screw
ejection motor.
Reinstallation
IMPORTANT:
Do not forget to adjust the tension after the
motor is installed.
Screws
86
<<Master Clamp Opening/Closing Unit>>
(1) Removing the Master Clamp Opening/Closing Unit

→ See page 73.
2. Remove the drum.
3. Move the master clamp opening/closing lever Connector
to the B mode position. (Use HELP-20.)
Screws Screw
5. Remove the 3 screws, then remove the master Master clamp opening/
closing unit
clamp opening/closing unit.
Connector
3
(2) Removing the Clamp Motor
1. Remove the master clamp opening/closing

unit. (Refer to the above description.)
2. Loosen the set screw, then remove the gear.
3. Remove the 3 screws, then remove the motor.
Screws Clamp motor
Set screw
Screw
87
(3) Removing the Timing Belt
1. Remove the master clamp opening/closing Tension

unit. Screws
→ See page 87.
2. Loosen the 2 screws to loose the tension.
3. Remove the screws fixing the angle, then re- Screw fixing angle
move the angle. Screw fixing angle
4. Remove the timing belt.
Reinstallation
● Adjust tension by adjusting the master
Master clamp opening/closing lever on master ejection side
clamp opening/closing levers both on mas-
ter feed side and master ejection side. Then
fit the timing belt on.
→ See page 106
IMPORTANT:
Positioning hole
● Adjust the B and C modes after the master
Master clamp opening/
clamp opening/closing unit is installed to closing lever on master
the printer main body. feed side
→ See page 107 Positioning hole
Frame R
(printer main body)
Positioning hole
Positioning hole
88

(1) Removing the Paper Feed Roller
1. Remove the screw, then slide the paper feed

shaft in the direction of the arrow.
Screw Paper feed shaft
2. Loosen the set screw, then remove the paper

feed roller. Paper feed roller 3
Roller
Reinstallation
Set screw
● Reinstall the paper feed roller so that the
set screw is positioned at the paper feed
roller shaft's counterbore.
89
(2) Removing the Paper Separator Unit
1. Loosen the set screw to move the paper feed

roller.
2. Pull out the paper separator unit upward. Paper feed roller Set screw
Reinstallation
IMPORTANT:
● After reinstalling the paper separator unit, Paper separator unit
carry out adjustment of its gap.
→ See page 111
(3) Removing the Auxiliary Separator
1. Loosen the set screw to move the paper feed

roller.
2. Pull out the auxiliary separator. Paper feed roller
Set screw
Reinstallation
IMPORTANT:
● Care should be taken for the direction of the
auxiliary separator. Auxiliary separator
90
(4) Removing the Paper Feed Clutch

→ See page 73.
3. Open the cable clamp, and pull out the cables. Paper feed clutch
4. Remove the 2 screws, then remove the brack-
et. C ring
5. Remove the C ring, and remove the paper feed Connector
clutch.
Cable clamp
Screws
Reinstallation
IMPORTANT:
● Pay attention to the orientation of the D-
shaped cut.
3
● The clutch baffle should fit in the screw.
(5) Removing the T Roll Clutch
1. Remove the rear cover. → See page 91.

3. Open the cable clamp, and pull out the cables.
4. Remove the 2 screws, then remove the brack- T roll clutch
et.
C ring
5. Remove the C ring, and remove the T roll
clutch.
Cable clamp
Screw
Connector
Reinstallation
IMPORTANT:
● Pay attention to the orientation of the D-
shaped cut.
● The clutch baffle should fit in the screw.
91
(1) Removing the Drive Bracket

→ See page 73.
2. Remove the screw fixing the air pump link.
3. Remove the screw, then remove the crank.
Screws
Crank
Link
4. Open the 5 cable clamps.

Cable clamps
Connector
Cable
clamps
Connector
6. Remove the 4 screws, then remove the drive

bracket.
Screw
Drive
bracket
Screw Screws
92
(2) Removing the Drum Gear

→ See page 73.
2. Remove the drive bracket.
→ See page 92.
3. Remove the 2 screws, then remove the drum
gear.
Screws
93
(1) Removing the Paper Stripper Finger
1. Remove the drum.

2. Remove the rear cover. Paper stripper finger
→ See page 73. Screw Pipe
3. Move the pinch lever up.
4. Remove the screw fixing the paper stripper
finger.
5. Remove the paper stripper finger from the
shaft.
6. Pull out the paper stripper finger from the pipe.
Reinstallation
IMPORTANT:
● Adjust the paper stripper finger after it is
installed.
→ See page 114
(2) Removing the Ejected Paper JAM Sensor
1. Remove the screw.
Screw
2. Pull out the ejected paper JAM sensor assy.

4. Remove the screw fixing the sensor.
Screw
Connector
94
(3) Removing the Jump Plate Unit
1. Remove the screw, then remove the ejected

paper JAM sensor assy.
→ See page 94.
2. Remove the 3 screws, then remove the jump

plate unit.
Screws
3
95
7 Drum Section
(1) Removing the Screen
1. Remove the drum unit.

Screw
2. Remove the clamp on the bottom end of the
screen bar, and pull out the screen bar. Screen
3. Remove the 2 screws fixing the top end of the Top end of screen
bar
screen bar, and pull out the screen bar.
Screw
4. Remove the screen from the drum.
Bottom end
IMPORTANT: of screen bar
● Do not rotate the drum reversely.
Reinstallation
1. Pass the top end of the screen bar through the Top end of screen
bar Screen
screen (top end side).
Screw
2. Attach the top end of the screen bar to the
drum.
IMPORTANT: Screw 20mm

●Do not mistake the bottom end of the screen (bottom
end side)
for the top end. 58mm
(top end side)
3. Pass the bottom end of the screen bar through

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

the clamps.
IMPORTANT:
●The stainless screen does not return to the
original state once it is folded. Be careful to
Bottom end of screen bar
handle the screen.
Clamps
96
(2) Removing the Master Clamp
1. Remove the screen.

→ See page 96.
Spring Screw
2. Remove the 2 screws on the operation side. Master clamp
3. Remove the bearing plate and spring.
4. Remove the 2 screws on the opposite of op-
eration side, and take out the bearing plate. Screw
5. Remove the master clamp. The master clamp Bearing plate
is attached to the base with the magnet.
(3) Removing the Base Unit

3
1. Remove the master clamp. Screw Base unit
(Refer to the above.)
2. Remove the 2 screws, then remove the base Screw
unit.
97
(4) Removing the Outer Frame (right) Unit
1. Remove the drum unit. Stay

2. Remove the 2 screws fixing the rail and 1 Screw fixing stay
screw fixing the stay.
3. Remove the 3 screws fixing the outer frame
Screws
(right) unit.
Rail left Rail right
Reinstallation
Outer frame (right) unit Screws fixing rail
IMPORTANT:
● Be sure to adjust the rail space after the rail
is installed.
→ See page 118
4. Part the outer frame (right) unit a little, and Connector

disconnect the 2 connectors.
5. Remove the outer frame (right) unit.
Connector Outer frame (right) unit
98
(5) Removing the Outer Frame Shaft Assy
1. Remove the drum unit.

2. Remove the screw fixing the rail, and remove Stay
the rail.
3. Remove the screw fixing the stay, and remove
Rail left
the stay. Screw fixing stay
Rail right
Reinstallation
IMPORTANT:
● Be sure to adjust the rail space after the rail Screws fixing rail
is installed.
→ See page 118
4. Remove the 4 screws. Master clamp lever 3

Outer frame shaft assy
Screws
5. Pull out the outer frame shaft assy with the

master clamp open.
Outer frame shaft assy
99
(6) Removing the Inner Frame
1. Remove the outer frame (right) unit. Screws fixing supporting plate
→ See page 98.
2. Loosen the 2 screws fixing the supporting plate,
and move the supporting plate in the direction of
the arrow until it stops, then fix it with the screws.
Supporting
plate
3. Pull out the inner frame (section inside the

drum) in the direction of the arrow.
IMPORTANT:
● Be careful not to damage the drum inside.
Reinstallation
1. Slide the supporting plate in the direction of the
Screws fixing supporting plate
the arrow so that the supporting plate roller,
roller unit and roller are in contact with the inner Roller
surface of the flange right and tighten the roller Supporting
with the screw, pressing the roller to the inner plate
surface slightly.
Roller unit
Roller
100
(7) Removing the Ink Pump
1. Remove the inner frame. Hose band

→ See page 100. Screw
2. Loosen the screw on the hose band, and pull

out the hose.
Ink hose
3. Remove the screw, then remove the link. Screw

4. Remove the 2 screws, then pull out the ink Link
pump.
Ink pump
3
Screws
(8) Removing the Ink Pump Motor
1. Remove the inner frame. Rotating

→ See page 100. plate Set screw
2. Cut the banding band.
3. Loosen the set screw, then remove the rotating
Motor
plate.
4. Remove the 3 screws, then remove the ink
motor.
Screws
101
(9) Remove the Ink Detection PCB
1. Remove the inner frame. Screws

→ See page 100.
3. Remove the 2 screws, then remove the ink
detection PCB.
Connector
Reinstallation
IMPORTANT:
● When installing the ink detection PCB, Ink detection PCB
confirm that the detection needle is ver-
tical with the PCB unit and does not con-
Ink roller
tact anywhere. Detection
needle
Squeegee
roller
102
Chapter 4 Standards / Adjustment
1 Master Making / Master Feed / Ejection Section ....104 4 Paper Ejection Section ……...…………………114
<<Master Making / Master Feed Section>>…..…104 (1) Adjusting the Paper Stripper Finger Gap….114
(1) Adjusting the Timing Belt Tension…....……104 (2)Adjusting the gap between the Master
<<Master Ejection Section>>………………..……105 Clamp and the Paper Stripper Finger…...…115
(1) Adjusting the Timing Belt Tension……....…105 5 Drum Section ………....…………...……………116
<<Master Clamp Opening / Closing Section>>…...…106 (1) Adjusting the Ink Amount…….………...……116
(1) Adjusting the Timing Belt Tension…....……106 (2) Adjusting the Squeegee Gap……….………117
(2) Positioning the Master Clamp Opening/ (3) Adjusting the Master Infeed Amount………118
Closing Levers….....................................…106 (4) Adjusting the Drum Rail Gap…...............…118
1. Master clamp opening/closing lever on master 1. Rear side………...………………..………118
feed side...........................................……106 6 Electrical system …………….....………………119
2. Master clamp opening/closing lever on master (1)Adjusting the End Mark Sensor PCB Unit VR….119
ejection side…......................................…106 (2)Adjusting Reduction / Enlargement…...……120
(3) Adjusting the B / C Modes ………....………107
1. Adjustment for B mode……………………107
1. Adjusting Master Making Feed Volume
Magnification........................................…120
4
2. Adjustment for C mode.....................……109 2. Adjusting the Longitudinal R/E on the Master
2 Paper Feed Section..…………………...………111 Making Side……...............................……120
(1) Adjusting the Paper Separator Unit Gap…..........111 3. Adjusting the Longitudinal R/E on the
(2) Adjusting the Paper Separation Pressure ……111 Reading Side …....................................…121
3 Drum Driving Section ………………..…………112 (3) Reading Start Position………………………122
(1) Adjusting the Drum Removal Position.….…112 1. Adjusting the Top End Reading Start
(2) Adjusting the Master Attachment/Detachment Position...............................………………122
Position ………....................................……113 2. Adjusting the Lateral (Operation Side)
1. Master detachment position………...……113 Reading Start Position …....................…122
2. Master attachment position………………113 (4) Adjusting Master Making Start Position……123
1. Adjusting Master Making Start Position...…124
(5) Adjusting the Document Reading Darkness………124
1. Adjusting the white level of the Document
Darkness ………........................…………124
2. Adjusting the Reading Darkness ……..…124
(6) Adjusting Print Speed……………….....……125
1. Adjusting Pre-stop Speed ……..…………125
2. Adjusting Master Making Speed...........…125
3. Adjusting JOG Speed……..………………126
4. Adjusting Print Speed................…………126
U5-Y113 0-0
1 Master Making / Master Feed / Ejection Section

<<Master Making / Master Feed Section>>
(1) Adjusting the Timing Belt Tension
● For 'Removing the Master Feed Unit'

→ See page 83
<Adjustment Procedure>
1. Use the screws to adjust the belt tension so
Screws
that the amount of deflection is 1 - 2mm when a
force of 500g is applied to the belt in the middle
between pulleys.
104 U5-Y113 0-0


● For 'Removing the Master Ejection Unit'

→ See page 85
1. Use the screws to adjust the belt tension so Screw
that the amount of deflection is 1 - 2mm when
a force of 100g is applied to the belt in the
middle between pulleys.
<After Adjustment>
● Perform operation check of the master ejection
motor. Screws
1. Access HELP mode H-18.
2. Press and hold down the right or left PRINT
POSITION key.
While this key is held down, the master ejection
motor rotates and the ejection rollers rotate.
3. When the key is released, the master ejection
motor stops.
4. Press the STOP key. 4
The HELP mode menu will reappear.
→ To exit the HELP mode: Turn the power switch OFF.

→ To access another HELP mode:
Enter the desired mode number using the NUMERIC
keys.
U5-Y113 0-0 105

<<Master Clamp Opening / Closing Section>>

NOTE
Tension Screws
● For 'Removing the Master Clamp Opening/
Closing Unit'
→ See page 87
1. Loosen the screws fixing the tension.
2. Use the screws to adjust the belt tension so
that the amount of deflection is 1 - 2mm when a
force of 1kg is applied to the belt in the middle
between pulleys.
<After Adjustment>
IMPORTANT:
Be sure to adjust the B / C modes after installa-
tion to the Duprinter.
(2) Positioning the Master Clamp Opening/ Master clamp opening/closing lever on master ejection side
Closing Levers
● For 'Removing the Master Clamp Opening/

Closing Unit'
→ See page 87
Positioning hole
Master clamp opening/closing
lever on master feed side Positioning hole
1. Master clamp opening/closing lever on
master feed side
When tensioning the timing belt, install the timing ◦Master feed side
belt at the position where the upper surface of the
master clamp opening/closing lever is alighned Sub-frame
(0 - 0.5mm) with the positioning hole in the sub-
frame.
Master clamp
opening/closing lever
2. Master clamp opening/closing lever on on master feed side
Positioning hole
master ejection side Aligned (0-0.5mm)
When tensioning the timing belt, install the timing
belt at the position where the master clamp
opening/closing lever is co-centered with the ◦Master ejection side
subsframe's positioning hole. Frame R Positioning hole
(printer main body)
<After Adjustment>
● Be sure to adjust the B / C modes after Positioning
hole
installation to the Duprinter.
Master clamp
opening/closing unit
106 U5-Y113 0-0

(3) Adjusting the B / C Modes
NOTE
● For description of operation
● When drum is removed from machine body
→ See page 45
1. Adjustment for B mode
1. Remove the drum from the machine body.
3. Press and hold down the right PRINT

POSITION key until the master clamp open- ● More open than B mode (toward C mode) position
ing/closing lever moves into the "more open
C mode
than B mode (toward C mode) position".
B mode
4. Turn the power off, then on again.
The master clamp opening/closing lever will
move into the B mode position and stop there. 4
5. Turn off the power, and install the drum to the
machine body.
6. Remove the master ejection box. Then press

the JOG switch to move the master clamp to a 7.Shift
position in front of the opening/closing lever,
and stop it there. 6.Stop
in front
WARNING of lever
● Do not touch the drum or rollers when
operating the JOG switch.
● Do not put your hands or fingers inside
the machine during operation. They
could be caught up or crushed in the
machinery, resulting in injury.
7. Move the master clamp, paying attention to the

clearance at the same time.
U5-Y113 0-0 107

<Standard Value> 2.0-4.0mm

Check that the gap between the master clamp Master clamp lever
lever and master clamp opening/closing Master clamp opening/
lever is within the range given below. closing lever
Item Standard Value
Gap between master clamp lever 2.0 - 4.0mm
and master clamp opening/closing
lever
<If the gap is not the standard value>

1. Loosen the screw, then adjust the gap with the
mode sensor. Closed
B mode sensor
Opened
C mode sensor
108 U5-Y113 0-0

2. Adjustment for C mode
Before Adjustment
IMPORTANT:
C mode adjustment must be carried out
AFTER B mode adjustment is complete.
● When drum is removed from machine body

1. Remove the drum from the machine body.
3. Press and hold down the right PRINT

POSITION key until the master clamp open-
ing/closing lever moves into the "more open
than B mode (toward C mode) position".
4. Turn the power off, then on again. ● More open than B mode (toward C mode) position
The master clamp opening/closing lever will
C mode
move into the B mode position and stop there.
5. Turn off the power, and install the drum to the

B mode
4
machine body.
6) Access HELP mode H-09.
7. Press the [1] key to stop the drum at the mas-

ter detachment position.
8. Use HELP mode H-20 to move the master ● Stopping drum at master detachment position
clamp opening/closing lever to the C mode po-
sition.
9. Open the upper cover.
U5-Y113 0-0 109

<Standard Value> 0.5 - 1.0mm

Check that the gap between the master ejection
box's rubber roller and master clamp plate is
within the range given below.
Item Standard Value Rubber roller
Gap between master ejection box's 0.5 - 1.0mm
rubber roller and master clamp plate
Master clamp plate

1. Loosen the screw, then adjust the gap with the
C mode sensor.
Opened
B mode sensor
Closed
C mode sensor
110 U5-Y113 0-0

(1) Adjusting the Paper Separator Unit Clearance
NOTE
● For removal → See page 90
1
When the paper separator unit is installed, adjust
the gap with the adjusting screw so that the unit
moves in the direction of 1 (right fig.) without 2
backlash, and moves smoothly in the direction of Nut
2 (right fig.). Then tighten the nut to fix the unit.
(2) Adjusting the Paper Separation Pressure
NOTE Spring balance

4
150 - 160g
Paper separation
<Adjustment Procedure> pressure adjust
1. Turn the separation adjust screw so that the screw
spring balance reads 150 - 160g. At this time,
the top surface of the paper separator unit
should come out for 1mm more than that of the
feed inlet.
● Clockwise rotation (CW) → high
● Counterclockwise rotation (CCW) → low
U5-Y113 0-0 111


(1) Adjusting the Drum Removal Position
Before Adjustment
IMPORTANT:
Drum removal position adjustment must be

performed AFTER printing speed adjustment
is complete.
→ See page 125
1. Press and hold down the JOG switch. Release
the switch when a "beep" tone sounds and the
drum stops.
WARNING
●Do not touch the drum or rollers when
● 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.
NOTE
→ See page 54
<Standard Position>
The stop position is correctly adjusted when the
groove in the drum flange is aligned with the
stopper.
<If the drum is not adjusted to the standard stop position>

Adjust the position of the drum removal position/
JAM detection sensor so that the stopper fits Screws
smoothly into the groove when the drum is pulled
out.
← (left) Moving the sensor in this direction
Drum stop
decreases drum stop speed. position edge
→ (right) Moving the sensor in this direction
increases drum stop speed.
112 U5-Y113 0-0

(2) Adjusting the Master Attachment/Detachment Position
NOTE Master attachment position

Master
● For description of operation detachment
position
→ See page 55
Opening/
1. Master detachment position closing arm
The correct position for stopping the drum
(position for master detachment) is when the
center axis of the master clamp opening/closing
arm and the center axis of the master clamp
opening/closing lever are aligned in a straight Opening/closing lever
line. Adjust so that the offset of the alignment of
these two center axes is ±1mm (gauge this value
visually).
1. Access HELP mode H-09, and press the PRINT
key. Master
2. Press the [1] key to move the drum and stop it attachment/
detachment
at the master detachment position. (position
where the master attachment/detachment
position
edge
4
sensor senses the detachment position edge.)
3. Check the offset in the alignmen of the center
axis of master clamp opening/closing arm and
Opening/Closing arm
the center axis of the master clamp opening/
closing lever.
Item Standard Value
Offset in alignment of center ±1 mm
axes of master clamp opening/
closing arm and master clamp
opening/closing lever
4. Loosen the two screws, then turn the master Opening/closing lever
attachment/detachment sensor a little in the
direction of the arrows, and provisionally tighten
the two screws.
Screws
5. Repeat step 2), and check the center axis
alignment offset.
6. If necessary, repeate steps 2) through 5) until
the center axis alignment offset is within ±1mm.
7. Properly tighen the screws, and check 6)
again.
2. Master attachment position

Perform adjustment of master attachment
position at the same time as that of master
detachment position. Adjust both posiitons to
an accuracy of ±1mm.
U5-Y113 0-0 113


(1) Adjusting the Paper Stripper Finger Gap
NOTE
● For description of operation → See page 61
Load papers before adjustment.
key.
2. Press the PRINT key once again. The drum will
rotate and stop at press on state.
<Standard Value>
Check that the gap between the drum surface
and the paper stripper finger conforms to the
value shown below.
Paper
Item Standard Value ejection
Gap between drum surface and 0.5 - 1.0mm roller Drum
tip of paper stripper finger
0.5 - 1.0mm

1. Loosen the 2 screws and use the stopper to
Stopper angle
adjust the gap to the standard value. Then
Screws
retighten the screws.
<After Adjustment>
IMPORTANT:
After adjustment, press the JOG switch to return
the drum to its home position.
WARNING
114 U5-Y113 0-0

(2) Adjusting the gap between the Paper Ejection

Roller and the Paper Stripper Finger
NOTE
● For description of operation → See page 61
1. Pull out the drum.
2. Access HELP mode.
3. Press the JOG switch so that the drum gear
stops at the position where the bearing of the P
roll lever touches the cam part of the drum
gear.
<Standard Value>
Check the gap between the paper ejection roller
and the paper stripper finger.
Eccentric shaft
Item Standard Value
Gap between paper ejection 1.0 - 1.5 mm
roller and paper stripper finger
4
1. Loosen the screw and rotate the eccentric
shaft to adjust the gap. Then retighten the
screw.
1.0- 1.5mm
<After Adjustment>
After adjustment, press the JOG switch to return
the drum to its home position.
WARNING
U5-Y113 0-0 115

5 Drum Section
(1) Adjusting the Ink Amount
Adjusting the ink adjusting knob
NOTE
[Drum Section (1) - (6)]
Ink adjusting
knob on the rear side
Ink adjusting knob on the operation side
<Adjustment Procedure> * Ink adjusting knob on the operation side

1. When printed too dark or too light on the (standard position)
Too dark
operation side:
● Too dark: switch in the (-) direction (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:
Do not loosen set
● Adjust the above 1. and 2. at the same time. screw
IMPORTANT:
There are 7 settings, standard and ±3 settings
to adjust printing darkness. Print more than
ten sheets evey time the printing darkness
is switched by one setting until the most
preferred printing darkness is obtained.
Repeat the above procedures until the most
preferred printing darkness is obrained.
116 U5-Y113 0-0

(2) Adjusting the Squeegee Gap
NOTE Squeegee Ink roller
● For removal
[Drum Section (1) - (6)] Gap
→ See page 96
The gap between the squeegee and the ink roller Ink roller 0.02~ Squeegee 0.02~
0.02~
is adjusted as shwon in the figure when the ink 0.03mm
0.03mm 0.03mm
amount is based on the standards. If the ink

amount does not meet the standards, adjust it as
follows:
* Operation side
<Standard Value>
Item Standard Value
Gap between squeegee and ink 0.02 - 0.03mm
roller

1. 2 pcs. of set screw 1 are used in one place.
Remove 1 pce. of set screw 1 and loosen the
Set screw 2
Adjusting
screw 4
other one. Perform the same operation for both Ink adjusting knob Set screw 1
sides. Be careful not to lose the removed set
screws.
2. Loosen the set screws 2 on both sides.
3. Using a thickness gauge, adjust the gap with
the adjusting screws on both sides so that the
space on both sides meets the standards. * Rear side
<After Adjustment>
1. Tighten the set screw 2.
2. Tighten the set screw 1.
3. Check the gap again after the ink amount
adjusting knob is moved several times in the Adjusting
screw Set screw 2
direction of (+) or (-). Ink adjusting knob
Set screw 1
4. If the gap is proper, attach the set screw 1 and
tighten it to fix.
U5-Y113 0-0 117

(3) Adjusting the Master Infeed Amount
<Adjustment Procedure> Make sure that the

master edge is seen
from this hole for 1mm.
1mm or
key. less
2. Press the PRINT key once again. The drum
will move to the attachment position, the clamp
will open, the master will be fed to the
attachment position by master feeding, the
clamp will close, and then the master will be
cut.
3. Check the master infeed amount.
4. Use the [0] and [1] numeric keys to enter a
4-place binary value so that the master infeed
margin is within 1mm from the hole edge.
(4) Adjusting the Drum Rail Gap
1.Rear side
1. Remove the rear cover on the machine body.
2. Loosen the screws on the rail to adjust so that
the gap between the roller on the guide rail Drum rail unit
(right/left) and the drum rail unit (right/left) is Left Right
Screw Screw
about 0.3mm.
3. Tighten the screws to fix the rail.
Guide rail left 0.3mm 0.3mm Guide rail right
118 U5-Y113 0-0

Chapter 4 6 Electrical system
6 Electrical system
(1)Adjusting the End Mark Sensor PCB Unit VR
1. Feed the master to the top of the plastic film. VR 1

CN 1
2. Rotate the VR on the end mark sensor PCB unit
in the counterclockwise direction (CCW) as far
as it stops.
key.
4. Check the value indicated.
HELP mode H-13 display
<Standard Value>
Item Standard Value E ＊＊＊
Black area on master 220 or more
White area on master 14 - 16 Display of value
5. Rotate the VR1 on the end mark sensor PCB

unit for white area on the master to adjust so
4
that the value of HELP mode H-13 is 14 - 16.
U5-Y113 0-0 119

(2)Adjusting Reduction / Enlargement
1. Adjusting Master Making Feed Volume Magnification

<Adjustment Procedure> * Master making feed volume
key. H-34 → See page 186
2. Open the upper cover so that the master feed
area can be seen. Actual
measurement Cut master:
3. Press the MASTER MAKING key. The cutter 200mm
operates, the master is fed by 200mm, and then
the cutter operates again.
4. Measure the length of master cut into 200mm
length.
<Standard Value>
Item Standard Value
Length of the master cut into 200±0.5mm
200mm length
<If the length is not the standard value>

Adjust with H-34.
H-34 → See page 186
2. Adjusting the Longitudinal R/E on the Master Making Side
key. H-30 → See page182
2. Press the MASTER DARKNESS key to select
A = 200±0.5mm
[Master darkness: NORMAL]. Perform master
making and printing of test pattern 2 (paper:
B4).
No need to place the document.
3. Check that A section of the printed test pattern
2 is 200±0.5mm.
<Standard Value>
Item Standard Value
A section of the printed test 200±0.5mm
pattern
<If the dimension is not the standard value>

Adjust with H-22.
120 U5-Y113 0-0

3. Adjusting the Longitudinal R/E on the Reading Side * Basic document

Center of the paper
30mm
Before Adjustment
IMPORTANT:
Adjust the longitudinal R/E on the reading
side after the longitudinal R/E on the
A = 200mm
master making side.
1. Prepare a basic document as shown in the
figure. Draw a line at the position 30mm from
the top end of the paper (B4) and at the position
of 200mm from the above line.
2. Place the document on the document tray to
perform master making and printing.
Item Standard Value

Difference of the size of A ±2.0mm
section of the printed image with
that of the basic document
<If the difference is not the standard value>

Adjust with H-24 or H-25. 4
U5-Y113 0-0 121

(3) Reading Start Position
1. Adjusting the Top End Reading Start Position

<Adjustment Procedure> Document Image on drum
1. Mark with 1mm interval up to 5mm from the top
end of the paper to prepare a test document. 2 - 3mm
2. Perform master making and printing to the
Mark with
same size. 1mm
3. Adjust with H-35 so that the image on the drum interval
from the top
is printed with 3mm margin left. end of the
document
2. Adjusting the Lateral (Operation Side) Reading * Basic document

Start Position
<Adjustment Procedure> 100mm

30mm
1. Make a basic document as shown in the figure
from a sheet of paper (B4). Draw a 100mm line
at the position 30mm from the right end and
from the top end of the paper.
2. Compare the printed image with the basic doc-
ument. Check the difference between the
straight lines in the main scanning direction.
3. Adjust with H-36 so that L1 - L2 <= ±3mm. Print ejection
direction
H-36 → See page 188 Printing paper
Adjusting direction
● L1 < L2: Backward Document
● L1 > L2: Toward you
Mark this corner

with each other
Document basic
line
Basic line of the L2 L1

printed sample
122 U5-Y113 0-0

(4) Adjusting Master Making Start Position
1. Adjusting Master Making Start Position

* Basic document Draw a line at the
position 30mm from the
30mm
top end of the document
Before Adjustment
IMPORTANT:
● Adjust master making start position after the
following adjustments are completed.
● Adjusting the Master Attachment/Detachment
Position
→ See page 113
● Adjusting the Top End Reading Start Position
→ See page 122
1. Set the printing position (top and bottom di- Print ejection
direction
rection) to the basic document. Printing paper
2. Draw a line at the position 30mm from the top

end of the document and prepare a basic doc- Document
4
document as shown in the figure.
3. Compare the processed image with the basic
Mark this corner
document. Check the difference of the lines in with each other
the sub-scanning direction. Basic line of the Document
printed sample basic
4. Adjust with HELP mode, H-37 so that L1 - L2
line
< ±3mm.
=
Adjusting direction L1
● L1 < L2: Upward L2
● L1 > L2: Downward
U5-Y113 0-0 123

(5) Adjusting the Document Reading Darkness
NOTE
→ See page 24
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 White level
the white level is not proper, printed surface gets (white max.)
dirty or the light section of the document is not
Black level
processed for master making. (black max.)
* When white level is too high:
<Adjustment Procedure> ↑ section is printed dirty.
Take the following procedures for adjustment. White level
(white max.)
1. Text mode: H-33 H-33 → See page 185
2. Photograph mode: H-26
H-26 → See page 178 Black level
(black max.)
2. Enter the correction value on the keypad, [0] or * When white level is too low:
[1]. ↓ section is not processed for master making.
● When the processed document gets dirty:
[0 * * * ] The white level is corrected down.
● When the light section of the document is not White level
(white max.)
processed for master making:
Black level
[1 * * * ] The white level is corrected up. (black max.)
3. Press the the × ＝ key to memorize the cor-
rection value.
4. Perform master making and printing to check
the darkness.
2. Adjusting the Reading Darkness

Adjust the document reading darkness in master
making as follows:
Text mode: H-50 H-50 → See page 199
Photograph mode: H-23

2. Enter the correction value on the keypad, [0] or[1].

3. Press the × ＝ key to memorize the correction
value.
4. Perform master making and printing to check
the darkness.
* When adjusted with HELP mode H-23 by one
stage, the standard position changes.
124 U5-Y113 0-0

(6) Adjusting Print Speed
NOTE
● For HELP mode, H-01
1. Adjusting Pre-stop Speed
→ See page 125
1) Access HELP mode H-01, and press the PRINT
key.
2) Press the MASTER DARKNESS key repeat-
edly to select [master darkness: LIGHT]. ＊＊＊
3) Check the speed value displayed.
The pre-stop speed should be 5 - 9rpm. pre-stop speed
<If the value is not the standard value>

Press the right or left PRINT POSITION key to
adjust the displayed value to the standard value.
4) Press the STOP key. The adjusted value will be

memorized, and the HLEP mode menu will
reappear. 4
2. Adjusing Master Making Speed

key. ＊＊＊
2. Press the MASTER DARKNESS key repeat-
edly to select [master darkness: NORMAL]. master making speed
3. Check the speed value displayed.
The master making speed should be 8 - 12rpm.

4. Press the STOP key. The adjusted value will be

reappear.
U5-Y113 0-0 125

3. Adjusting JOG Speed
<Adjustment Procedure> HELP mode H-01 display

key.
2. Press the MASTER DARKNESS key repeat- ＊＊＊
edly to select [master darkness : DARK]. JOG speed
The JOG speed should be 20 - 23rpm.


reappear.
4. Adjusting Print Speed

key. ＊＊＊
2. Press the MASTER DARKNESS key repeat- Print speed
edly to light the 'Print Speed Indicator Lamp -
Speed 1'.
The print speed 1 should be 63 - 67rpm.

4. When continuously adjusting the print speed 2,

press the MASTER DARKNESS key repeatedly
to light the 'Print Speed Indicator Lamp - Speed
2'.
5. Check the speed value indicated.
The print speed 2 should be 93 - 97rpm.


reappear.
126 U5-Y113 0-0

Chapter 5 Maintenance/Check
1 Guaranteed Periodical Maintenance …………128

2 Cleaning and Oiling ........................................128
(1)Cleaning ....................................................128
(2)Oiling .........................................................128
3 Periodical Maintenance ..................................129
(1)6-month Periodical Checking ....................129
(2)Criteria for Replacing Primary Parts...............129
4 Recommend parts list .....................................130
U5-Y113 0-0
Chapter 5 1 Guaranteed Periodical Maintenance 2 Cleaning and Oiling
1 Guaranteed 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
2 Cleaning 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.
(2) Oiling
Oil or grease after ink or paper shreds are removed.
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.
128 U5-Y113 0-0

Chapter 5 3 Periodical Maintenance
3 Periodical Maintenance
(1) 6-month Periodical Checking
Section to be checked Description Inspection Standard

Shading plate Cleaning Clean with a soft and clean cloth.
Glass Cleaning Clean with a soft and clean cloth.
CIS (Contact image sensor) (CIS) 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.
Master 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
(2) Criteria for Replacing Primary Parts
№ Item Criterion Remarks

5
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 Up to 15 voids
4 Drum unit Printing 1,000,000 sheets Overhaul
5 Air pump Printing 1,000,000 sheets
6 Press roller 1,000,000 sheets
U5-Y113 0-0 129

4 Recommend parts list
№ PARTS No. PARTS NAME Criterion Remarks
1 26-2335* Paper feed roller unit 60S4.5M284 300,000 sheets or more
2 AJ031 Timing belt, 60S3M180
6 AJ208 Timing belt,
7 C9-2651* Signal lever EE-SX4235A-P2-S1
8 CA021 Photo microsensor GP2A25J0000F
9 CA022 Photointerrupter KR866-AA
10 CA032 Reflection sensor DL112-03UD
11 CA034 CIS (Contact Image Sensor)
12 U5-B505* Separator base unit 300,000 sheets or more
13 E1-3530* Spring T
14 F7-4680* Pawl A
15 J8-A149* Bar
16 J8-A150* Screen
17 J8-H207* Paper ejection roller
18 J8-H208* Paper stripper finger
19 J8-V334* End-mark PCB unit
20 J8-V346* Panel PCB unit
21 J8-X122* Motor
22 J8-X125* Motor VX-52-1A3
23 LA048 Micro switch VX-012-1A3 500,000 times
24 LA051 Micro switch AJ8R2024BBCF 500,000 times
25 LC033 Rocker Switch KCD4-201(JK1) 10,000 times
26 LC038 Seesaw switch 10,000 times
27 N5-X121* Ink detection ASSY
28 Q6-B610* Supplemental separator 300,000 sheets or more
29 U5-A604* Stopper
30 U5-C113* Timing roll
31 U5-C222* Guide roller
32 U5-D108* Press roller unit
33 U5-E112* Sheet
34 U5-E113* Rubber sheet
35 U5-F210* Durm gear
36 U5-V500* Main PCB unit
37 U5-X101* Main Motor
38 U5-X102* Clutch 1,500,000 sheets or more
39 U5-X103* Cutter unit 100,000 times or more
40 U5-X104* Stepping motor
41 U5-X105* Ink pump motor
42 U5-X106* Stepping motor
43 U5-X107* Thermal head ZWS150AF-24/J About 20,000 masters Up to 15 voids
44 UA043 Power supply board
130 U5-Y113 0-0

Chapter 6 Troubleshooting
1 Troubleshooting Guide ……….…….........……132
1. Countermeasures for the Defective Operation..…132
(1) CIS lamp does not light up……............…132
(2) "E001" is displayed………....................…132
(3) Cutter does not operate…...............……133
(4) "E012" is displayed………............….……133
(5) Error is shown as below.….....….….…..…134
(6) Error is shown as below.….......….….……134
(7) Error is shown as below........….….…....…135
(8) Error is shown as below.…….….…...……136
(9) Error is shown as below.…….….….…..…137
(10) Error is shown as below.…….….…........137
(11) Error is shown as below.…….….….....…138
(12) Error is shown as below.……....….….….138
(13) Error is shown as below.…….….….…....139
(14) Error is shown as below.….….….....……140
(15) Malfunction of master feed stepping motor.........140
(16) Master ejection error .………….....…..…141
(17) Malfunction of master ejection motor……141
(18) Paper jams on the paper feed side....…142
(19) Paper jams on the paper ejection side...…143
U5-Y113 0-0
Chapter 6 1 Troubleshooting Guide
1 Troubleshooting Guide
1. Countermeasures for the Defective Operation
(1) CIS lamp does not light up.
Cause/ Item to be checked Countermeasure

Defective section Procedure Result
Does the voltage between

1 J2-7(+) and J2-8(GND) of the NO Proceed to procedure 3.
main PCB unit show + 24V?
CIS Is trouble cleared by replacing Finish

2 YES
CIS?
Main PCB unit Is trouble cleared by replacing Finish

3 YES
main PCB unit?
(2) "E001" is displayed.

1 Does the drum rotate? NO Proceed to procedure 2.
Drum inter- Does the main motor rotate

feres with 2 without drum? YES Eliminate interfere.
body.
Drive gear Does the main motor rotate Check if the drive gear is
broken or without timing belt? broken or blocked with
3 YES
blocked with foreign matter. Remove
foreign matter cause.
24V power Does the voltage between Replace the 24V power
supply 4 CN51-1(+) and CN53-1(GND) of NO supply.
the power supply show +24V?
Main motor Does the main motor encoder Replace the main motor
encoder sensor work normally when encoder sensor. If it does
sensor 5 checked with HELP mode NO not work even after re-
(H-21)? placement, then replace
the main PCB unit.

6 YES
the main PCB unit?
Main motor Are there any problems in the Replace the main motor.
7 YES
above check items?
132 U5-Y113 0-0

(3) Cuttter does not operate.

Master JAM Is master jammed in the cutter Remove the jammed master.
1 YES
unit?
Broken belt 2 Is the cutter unit belt broken? NO Replace the cutter unit.
Cutter motor Does the voltage between J1-19 Replace the cutter unit.
and J1-20 of the main PCB unit
4 show +24V when the cutter motor YES
is moved (toward OPEN) with
HELP mode (H-17)?

5 YES
the main PCB unit?
(4) "E012" is displayed.

Does the clamp motor rotate when Proceed to procedure 2.

1 NO
checked with HELP mode (H-20)?
Clamp motor Does the voltage between J1-21 Check the bundled wire. If OK,
and J1-22 of the main PCB unit show
2 YES replace the clamp motor.
+24V or -24V when the clamp motor
is operated with HELP mode (H-20)? 6
24V power Does the voltage between CN51-1(+) Replace the 24V power supply.
supply 3 and CN53-1(GND) of the power NO
supply show +24V?
Clamp sensor 1 Turn the clamp sensor 1 on and off, Replace the clamp sensor 1.
and use a tester to measure the NO
4 voltage. Is the voltage normal?

YES
the main PCB unit?
Clamp sensor 2 Turn the clamp sensor 2 on and off, Replace the clamp sensor 2.
and use a tester to measure the NO
5
voltage. Is the voltage normal?

YES
the main PCB unit?
U5-Y113 0-0 133

(5) Error is shown as below.
Machine status: The front cover is open.

Or the drum is not installed.

Front cover When the front cover sensor is Replace the front cover sensor.
sensor checked with HELP mode (H-07), NO
1 does it indicate "0" when the front
Main PCB unit cover is open and "1" when it is Check the bundled wire and connector,
closed. YES and replace the main PCB unit.
Drum Is trouble cleared by reinstall- Finish

2 ing the drum? YES
installation
Main PCB unit Does the drum check work normally when Check the drum detection
3 YES
checked with HELP mode (H-08)? and replace the PCB unit.
Machine status: The upper cover is open.

Upper cover When the upper cover sensor Replace the upper cover
sensor is checked with HELP mode NO sensor.
1 (H-08), does it indicate "0" when
Main PCB unit the upper cover is open and "1" Check the bundled wire and connector,
when it is closed. YES and replace the main PCB unit.
134 U5-Y113 0-0

Machine status: Document JAM in the ADF

Do the document feed rollers

NO Proceed to procedure 3.
rotate?
Feed roller Do the feed rollers feed the Clean the feed rollers. If they
1 NO
document? do not work, replace them.
Document When the document position Replace the document posi-

position sensor is checked with HELP tion sensor.
sensor mode (H-08), does it indicate
2 NO
"10 or less" when paper is
present and "255" when paper
is absent?
Gear 3 Is the gear broken? YES Replace the gear.
Main PCB unit Is trouble cleared by replacing YES Finish

5 the main PCB unit?
6
Scanner Replace the scanner step-
NO
stepping motor ping motor.
U5-Y113 0-0 135

Machine status: No ink

Ink Is enough ink left in the ink

1 NO Replace the ink pack.
pack?
Setting Is the ink pack set properly? Set the ink pack properly
method of ink 2 NO and instruct user how to set
pack one.
Main PCB unit Does the LED of the ink detec- Check the bundled wire and
3 tion PCB unit light? YES connector, and replace the
main PCB unit.
Ink detection Is enough ink left in the drum? Replace the ink detection
PCB unit (Has ink reached the detection PCB unit.
3 NO
needle of the ink detection PCB
unit?)
4 Does the ink pumo operate? NO Proceed to procedure 6.
Foreign Is trouble cleared by cleaning Finish

material in ink inside of ink pump? YES
pump 5
Ink pump NO Replace the ink pump.
24V power Does the voltage between Replace the 24V DC power
Ink pump Does the voltage between J1-19 Replace the ink pump motor
motor and J1-20 of the main PCB unit
7 show +24V when the ink pump YES
motor is operated with HELP
mode (H-15)?

8 YES
the main PCB unit?
136 U5-Y113 0-0

Machine status: No master
C004

Adjustment Is trouble cleared by adjusting Finish

of end mark the end mark sensor PCB unit
1 YES
sensor PCB with HELP mode (H-13)?
unit
End mark Is trouble cleared by replacing Finish

sensor PCB the end mark sensor PCB unit? YES
unit
2
Main PCB unit Check the bundled wire and
NO connector, and replace the
main PCB unit.
Machine status: Master ejection box is full.
C006 6

Used master Is the master ejection box is full

1 YES Dispose of the used master.
of used master?
Main PCB unit Is trouble cleared by replacing

2 YES Finish
the main PCB unit?
U5-Y113 0-0 137

Machine status: Master ejection box is not installed or it is not

installed properly.

Master Is the ma ste r e je c t io n b o x Install the master ejection

ejection box installed properly? box properly and instruct
1 NO
user how to install the
master ejection box.
Master When the master ejection box

ejection box switch is checked with HELP
mode (H-05), does it indicate Replace the master ejection
switch 2 NO
"0" when the master ejection box switch.
box is installed and "1" when it
is not.

3 YES
the main PCB unit?
Machine status: No paper on the feed tray

Or the feed tray is not installed.
Or paper JAM on the feed tray side

Paper 1 Are papers loaded? NO Load papers.
Paper set lever 2 Is the paper set lever raised? NO Raise the paper set lever.
Is trouble cleared by checking Finish

3 items in the (18) Paper jams on YES
the paper feed side?

4 YES
the main PCB unit?
138 U5-Y113 0-0

Machine status: Paper JAM on the paper tray side

Paper Is the printing paper length Use paper conforming to

1 NO
within specified value? specification.
Ejected paper When the ejected paper JAM

JAM sensor sensor is checked with HELP
Replace the ejected paper
2 mode (H-06), does it indicate NO
JAM sensor.
"0" for photopassing and "1" for
photointerrupting?
Paper jammed Is paper JAM actually occurred See (19)Paper jams on the
3 YES
in the paper ejected area? paper ejection side.
Dirt or foreign Is there any dirt or foreign Clean the ejected paper
material on 4 material on the ejected paper YES JAM sensor.
sensor JAM sensor?

5 YES
the main PCB unit?
U5-Y113 0-0 139

Machine status: Trouble in master attachment process

End mark Does master set error actually If the VR of the end mark
sensor occur? sensor cannot be adjusted
with HELP mode (H-13),
replace the end mark sensor
PCB unit.
1 NO
IMPORTANT
Be sure to perform VR ad-
justment after the end mark
sensor is replaced.
Master feed Does the master feed stepping See (15) Malfunctino of mas-
2 NO
stepping motor motor operate normally? ter feed stepping motor.
Cutter unit 3 Is master cut normally? NO Replace the cutter unit.
Static Is the brush (eliminating static Replace the brush.

electricity 4 electricity) of the master feed YES
unit broken or deteriorated?
Master Is trouble clered by replacing YES Finish

the master?
Feed path 5 Remove and clean foreign
NO material on the feed path if
any.
(15) Malfunction of master feed stepping motor

Load on drive Is trouble cleared by adjusting Finish

area the tension of the master feed
1 YES
unit timing belt or lubricating the
bearing?
24V power Does the voltage between Replace the 24V power supply.
supply 2 CN51-1(+) and CN53-1(GND) of NO

3 YES
the main PCB unit?
140 U5-Y113 0-0

(16) Master ejection error

Master Does the master ejection motor See (17) Malfunctino of

1 YES
ejection motor rotate normally? master ejection motor.
Dirt on master Is the master clamp section dirty Clean the master clamp
2 YES
clamp with ink or oil? section.
Is the stripper finger or springs of Replace the stripper finger or

3 YES
the master ejection box damaged? springs.
Drum stop posi- Is the drum stop position for Adjust the drum stop position
tion for master master making within reference NO for master detachment.
detachment 4 value?
C mode YES Check and adjust C mode.
(17) Malfunction of master ejection motor

Master Does the voltage between J2-3

ejection motor (+) and J2-4 (GND) of the main
PCB unit show +24V when Replace the master ejection
1 YES
the master ejection morter is motor.
operated with HELP mode
(H-18) ?
supply 2 CN51-1(+) and CN53-1(GND) of
NO supply.
6
3 YES
the main PCB unit?
U5-Y113 0-0 141

(18) Paper jams on the paper feed side
Cause/ Symptoms Countermeasure

Defective section
Printing paper * If paper is too thick, it will not be likey fed. If it is Explain causes to user. Have
not suitable too thin, double sheets may be fed. user change to the paper con-
* Paper not clearly cut: 2 sheets still adhere to each forming to specifications.
other.
* Much paper scraps may deteriorate the paper
feed roller and separator performance.
Dirt/foreign * Paper gets stuck in the transfer path, causing Remove any dirt or foreign
material in creasing and tearing material.
transfer path
Incorrect paper * If pressure on paper is insufficient, paper will not Explain to user how to select
feed path be fed. correct paper pressure
pressure * If pressure on paper is excessive, double sheets depending on paper.
will be fed.
Worn paper feed * Paper may not be fed. Replace the paper feed roller.
roller
Paper separator * If gap is too large, the separator unit will rattle in Adjust paper separator unit
unit gap the direction of the paper transfer path, causing gap.
double sheets to be fed.
* If gap is too small, the paper separator unit
cannot follow angle change due to paper feed
shaft up-down movement, which may cause
double-sheet or slanted feed, and creasing. →See page 111
Paper separator * Wear, or adhesion of paper scraps causes dete- Clearn separating surfaces. If
unit rioration in separating performance, resulting in any trouble persists, replace.
double-sheet feed. the paper separator unit and
adjust its gap.
Separation * If pressure is very low, double sheets will be fed. Adjust separation pressure.
pressure Check separation pressure.
→See page 111
Paper feed * If amount is too small, paper slant cannot be cor- Set paper feed amount with
amount rected, printing position may not be uniform, or HELP mode H-67.
paper may not be fed.
* If amount is too large, loop becomes too large,
causing paper to buckle up between the paper
feed roller and timing roller, resulting in feed
error. HELP-67 →See page 208
Paper feed * Any slippage of the paper feed clutch will reduce Relace the paper feed clutch.
clutch feed amount.
* If the paper feed clutch does not disengage
properly, feed amount will be increased. (Refer to
"Paper feed amount" above.)
Timing roller * If the timing roller clutch slips, feed amount will Replace the timing roller
not be constant and printing position will not be clutch.
uniform. In the worst case, no paper will reach
the drum.
Signal lever * Paper may be damaged in the part of the leading Clean the bearing unit. Check
malfunction edge that touches the signal lever. In the worst that the signal lever moves
case, paper may stick to the signal lever. smoothly.
142 U5-Y113 0-0

(19) Paper jams on the paper ejection side
Cause/ Symptoms Countermeasure

Defective section
Printing paper * If paper is too thin, it will stick to the drum and Explain causes to user. Have
not suitable scrunch up. user change to the paper con-
* If grain of paper is sideways relative to transfer forming to specifications.
direction, paper will crunch up, or get jammed on
the paper receiving plate.
* If paper curls upward, it will likely scrunch up. If
curls downward, it will likely get jammed on the
paper receiving plate.
Document * If set-solid exists near the leading edge of paper, * Adjust leading edge margin to
image paper will likely scrunch up. about 10mm. (Too long margin
* If set-solid is blasted to one side of paper, paper will cause adverse result)
will not be ejected in a straight line. As a result, * Explain cause to user.If pos-
ejected paper will be disordinally piled and likely sible, have user change po-
jam on the paper receiving plate. sition for set-solid.
Static electricity * If ambient air is dry, static electricity may cause *Explain causes to user. Have
disordered piles or scrunch-up of paper. user desist from excessive use
of A/C or heating.
*If possible, have user take anti-
dryness measures in cluding
humidifiers.
Leading edge * If leading edge margin is not correct, scrunch-up Adjust with HELP mode H-46.
margin of paper will likely result.
IMPORTANT
Scrunch-up of paper may also result if the
margin is too long. HELP-46 →See page 196
Timing roller * Any slippage of the timing roller clutch will reduce Replace the timing roller
clutch feed amount and eliminate leading edge margin, clutch.
resulting in the paper scrunch-up.
Paper stripper * If timing is too slow, or the gap between the drum Adjust the paper stripper fin-
finger and the leading edge of paper is too large, the ger.
paper stripper finger will not enter into the gap,
causing the paper scrunch-up. →See page 114
Air * If sufficient air is not delivered from the tip of the * Check if the hole in the fin-
paper stripper finger, it will not lift the leading gers tip is blocked by for-
6
edge of paper off the drum. scrunch-up of paper eign material.
will result. * Check for the pipes for kinks
or disconnections.
* Check the valves and O-
rings on the air pump.
Ink * Too much ink transferred to paper will likely cause * Adjust ink amount on the
scrunch-up of paper. drum.
* Explain to user that ink
transfer amount increases
immediately after paper
scrunch-up, and advise
user to restart printing at
high speed.
→See page 116
U5-Y113 0-0 143

144 U5-Y113 0-0
Chapter 7 HELP Mode
1 HELP Mode List .......................................146

2 Overview .....….……………………………149
3 HELP Mode Functions and
Operation Procedures….....………………150
(1) Accessing HELP Modes…...…………150
(2) Guide to the HELP Mode Descriptions …150
Upgrading the Main PCB Software……151
●HELP Mode Descriptions…………..…152
U5-Y113 0-0
Chapter 7 1 Help mode List
1 HELP Mode List

HELP
Function Category Page
Mode No.
HELP-00 (1)Software version display Software version Display 152
(1)Display of print speeds Print speeds Display
HELP-01 153
(2)Adjustment of print speeds Adjustment / Specification setting
HELP-02 (1)Display of thermal head temperature Display of thermal head temperature 155
HELP-03 (Not used)
HELP-04 (1)Ink replenishment function test Function test 156
(1)Checking condition of master ejection box switch Sensor/switch condition
HELP-05 157
(2)Checking master ejection motor operation display, Function test
(1)Checking condition of the sensors listed below
●Clamp sensor 1, clamp sensor 2, main motor encoder Sensor/switch condition
HELP-06 158
sensor ●Drum stop position sensor, ejected paper jam display
sensor, master attachment/detachment sensor
(1)Checking condition of the sensors/switch listed below. Sensor/switch condition
HELP-07 159
● JOG switch, master set sensor, front cover sensor display
(1)Checking condition of sensors listed below and CIS
Sensor/switch condition
HELP-08 ● Upper cover sensor, drum detection, document sensor 160
display
● Display of amount of light received by CIS
(1)Checking drum position: master detachment, master attachment,
removal
● Function test of clamp motor, checking master infeed amount
HELP-09 (2)Cecking condition of the sensors listed below Function test 161
● Drum stop position sensor, master attachment/detachment posi-
tion sensor, main encoder sensor ● Clamp sensor 1, clamp sen-
sor 2
(1)Function test of scanner stepping motor and lamp CIS ON/OFF Function test/sensor/switch condi-
HELP-10 163
(2)Checking document sensor tion display
HELP-11
HELP-12 (Not used)
(1)Checking end mark sensor and condition of the sensors listed
below Sensor / switch condition display/
HELP-13 164
● Display of the amount of light received by end mark Function test
sensor ● Master set sensor
(1)Displaying the count of total master made in use mode
HELP-14 Total counter 165
(2)Resetting of count of total masters made in user mode
HELP-15 (1)Function test of ink pump motor Function test 166
(1)Setting of online (with PC interface) master making start
HELP-16 Adjustment / Specification setting 167
position
HELP-17 (1)Cutter motor function test Function test 168
(1)Function test of master ejection motor Function test / Sensor /
HELP-18 169
(2)Checking condition of master ejection box switch switch condition display
(1)Displaying total count of sheets printed in user mode
(2)Resetting total count of sheets printed in user mode
146 U5-Y113 0-0

HELP
Mode No.
(1)Function test of clamp motor and clamp position sensing
Function test/Sensor / switch condition
HELP-20 (B/C modes position) 171
display
(2)Checking clamp sensor 1 and clamp sensor 2
HELP-21 (1)Display of main motor encoder counter Encoder counter display 173
(1)Setting of lengthwise zoom factor correction amount for
master making side
HELP-23 (1)Setting of photograph mode document sensing darkness Adjustment / Specification setting 175
(1)Setting of reducing offset for reading longitudinal (sub-
scanning) R/E scanner
(1)Setting of enlarging offset for reading longitudinal (sub-
scanning) R/E scanner
(1)Compensation of document darkness white level in pho-
tograph mode
HELP-27 (1)Initialization of all HELP mode settings Adjustment / Specification setting 179
HELP-28 (1)Adjustment of paper stripper finger gap Adjustment / Specification setting 180
HELP-29 (1)Adjustment of master infeed amount Adjustment / Specification setting 181
(1)Test pattern (all shading, sub-scanning direction zoom
HELP-30 Function test 182
factor adjustment) master making and printing
HELP-31 (1)Setting of number of pre-print sheets Adjustment / Specification setting 183
(1)Setting of confidential safeguard function, setting of

TEST PRINT key function
HELP-33 (1)Compensation of document darkness white level in text mode Adjustment / Specification setting 185
(1)Setting of master making feed amount (sub-scanning:
lengthwise) adjustment
HELP-35 (1)Adjustment of scanner leading edge sensing position Adjustment / Specification setting 187
(1)Adjustment of Document widthwise (main-scanning) sensing
position
HELP-37 (1)Adjustment of master making start position Adjustment / Specification setting 189 7
HELP-38 (1)Adjustment of print speeds Adjustment / Specification setting 190
HELP-39 (1)Function test of paper feed clutch and T roll clutch Function test 191
HELP-40 (Not used)
HELP-41 (1)Setting of repeat count display, setting of auto power off Adjustment / Specification setting 192
(1)Setting of master making size selection specification,
setting of machine size selection specification
HELP-43 (1)Setting of thermal head offset value Adjustment / Specification setting 194
HELP-44 (1)Setting of thermal head resistance ranking Adjustment / Specification setting 195
HELP-45
U5-Y113 0-0 147

HELP
Mode No.
HELP-46 (1)Adjustment of T roll clutch On angle Adjustment / Specification setting 196
HELP-47
HELP-48 (1)Setting of reducing offset for main-scanning Adjustment / Specification setting 197
HELP-49 (1)Setting of enlarging offset for main-scanning Adjustment / Specification setting 198
HELP-50 (1)Setting of text mode document reading darkness Adjustment / Specification setting 199
HELP-51
HELP-52 (1)Setting of auto power off time Adjustment / Specification setting 200
(1)Setting of online (with PC interface) widthwise (main-
scanning) master making position
HELP-54
(1)Setting of ink replenishment before printing start, setting
of interlocks
HELP-56
HELP-57
HELP-58
HELP-59 (1)Setting of sort mode Adjustment / Specification setting 203
HELP-60 (1) Setting of special operation 204
HELP-61 (1)Checking LEDs on control panel Function test 206
HELP-62 (1)Auto power off function test Function test 207
HELP-63
HELP-64
HELP-65
HELP-66
HELP-67 (1)Setting of paper feed length Adjustment / Specification setting 208
HELP-68
HELP-69
HELP-70
HELP-71
HELP-72
HELP-73 (1)Setting of vertical registration Adjustment / Specification setting 209
HELP-74 (1)Setting of thermal head temperature correction Adjustment / Specification setting 210
HELP-75 (1)Printer ID setting of USB interface Adjustment / Specification setting 211
(1)Master making total counter display, Printing total counter
display
148 U5-Y113 0-0

Chapter 7 2 Overview
2 Overview
The DUPRINTER's HELP modes can be broadly classified into the following types:
■ Modes for ROM version display / version upgrade

These modes display the version numbers of the main PCB unit software, the panel PCB unit
software, and the I/F PCB unit software.
■ Modes for adjustment / specification setting

These modes set the functioning of variable resistors and switches by using the Main PCB unit
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 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 op-
erations, 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.
WARNING
● 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
7
printed by the DUPRINTER since it was manufactured. They also permit resetting of the total
count values displayed in the user mode.
U5-Y113 0-0 149

Chapter 7 3 HELP Mode Function and Operation Procedures
3 HELP Mode Function and Operation Procedures
(1) Accessing HELP Modes
1. During use of the DUPRINTER: first put the ma-

chine machine into the standby state, then turn the
Power switch OFF.
2. Simultaneously press and hold down the PRINT

SPEED keys, and turn the Power switch ON with
those keys held down. After about 2 seconds, a
beep-beep-beep tone will sound, and the HELP
mode display will appear.
3. Using the NUMERIC keys, enter the number of the

HELP mode you want to access.
Example: To access HELP mode H-00, enter [0], [0].
4. Press the PRINT key. The HELP mode specified in

"3." will be accessed, and either the initial value
(value set at factory) or the currently set value for the
mode will be displayed.
From this point on, follow the procedure given below
for the particular mode accessed.
(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-04 Function test

1. Functions
(1) Ink replenishment function test
Main functions While the ink level is detected, ink is replenished.
2. Operating Procedure
Display during ink replenishment
1. Access HELP mode H-04 and press the PRINT key.
Operation ● When the PRINT key is pressed, the drum will I N K Display
procedure for
rotate and the ink pump will rotate until the LED for function
lamp on the ink sensing PCB unit lights to signal that
individual ink supply is OK. When this lamp lights, a buzzer
functions sounds and the drum and ink pump stop.
150 U5-Y113 0-0

Upgrading the Main PCB Software

Upgrading Procedure
1.Turn the Power switch of the Duprinter OFF.
2. Loosen the 2 screws and displace the connector cover.
3. Connect the cable unit of the DDL to the connector as
shown in the right illustration.
4. Simultaneously press and hold down the MASTER A B C D

DARKNESS key and CLEAR key, and turn the Power
switch ON with those keys held down.
L . . .
5. The DUPRINTER enters upgrading mode and the right
display appears.
A B C D
6. Upgrade the version according to the Service Manual of
the DDL.
L . 0 .
7. After upgrading is completed correctly, the right display
appears.
8. Turn the Power switch OFF.

9. Disconnec the connector on the DDL.
10. Fix the connector cover with the 2 screws. A B C D
Reference:
L . E .
If an error has occurred during upgrading, the right display
will appear. You need to redo from step 4. 7
U5-Y113 0-0 151

●HELP Mode Descriptions

HELP mode H-00 (1)Software version display
1. Functions
(1) Software version display
●Displaying version of the main PCB unit.
●Displaying version of the panel PCB unit.
●Displaying version of the optional I/F PCB unit.
IMPORTANT
● Software version for the optional I/F PCB unit is
displayed only when connected with the I/F PCB unit.
(It takes some time to display the version due to com-
munication.)
(1) Software version display
1. Access HELP mode H-00, and press the PRINT key.
A B C D
Press the MASTER DARKNESS key to change the V ＊＊＊
display item.
Software version display
● Master darkness: LIGHT
Displays version of the main PCB unit.
● Master darkness: NORMAL
Displays version of the panel unit.
● Master darkness: DARK
Displays version of the I/F PCB unit.
2. Press the STOP key.

The HELP mode selection display will appear.

Enter the preferred mode number using the NUMERIC
keys.
152 U5-Y113 0-0

HELP mode H-01 (1) Display of print speeds
1. Functions
(1) Display of print speeds
(pre-stop, master making, JOG, speed 1, speed 2)
(2) Adjustment of print speeds

(1) Display of print speeds
Press the MASTER DARKNESS key to change the
display item.
●Master darkness: LIGHT

A B C D
Displays pre-stop speed. ＊＊＊
●Master darkness: NORMAL
Displays master making speed. Display of print speed
●Master darkness: DARK
Displays JOG speed.
●Master darkness: LEDs go out.
Displays Speed 1 or Speed 2 by pressing the PRINT
SPEED key.


keys.
U5-Y113 0-0 153

HELP mode H-01 (2)Adjustment/specification setting

A B C D
2. Press the MASTER DARKNESS key to select adjust-
ment item.
＊＊＊
• Press the PRINT SPEED key to switch print speed Display of print speed
from Speed 1 to Speed 2.
3. Press the right PRINT POSITION key or left PRINT
POSITION key to adjust the rotation value to the ref-
ference value.
The adjusted content will be stored and the HELP
mode selection display will appear.
Lighting-up LED Reference value Adjustment item

LIGHT 5 - 9rpm Pre-stop
NORMAL 8 - 12rpm Master making
DARK 20 - 23rpm JOG speed
Master darkness 63 - 67rpm Speed 1
LED/print speed
LED: Speed 1
Print speed LED: 93 - 97rpm Speed 2
Speed 2

keys.
154 U5-Y113 0-0

HELP mode H-02 (1)Display of thermal head temperture

1. Functions
(1) Display of thermal head temperature
DP-A120 serial # 09068014
(1) Display of thermal head temperature
Press the MASTER DARKNESS key to change the 136 to 137
display item.
A B C D
●Master darkness: LIGHT ＊＊＊
Displays thermistor analog value of the thermal head
Displayed range: 0 - 255 Display
●Master darkness: NORMAL A B C D

Displays Celsius temperature converted from thermal
head analog value (-) ＊＊＊ 21
Displayed range: -32 - 84ºC
Display

keys.
U5-Y113 0-0 155

HELP mode H-04 (1) Function test

1. Functions
While the ink level is detected, ink is replenished.
(1) Ink replenishment function test Display during ink replenishment
1. Access HELP mode H-04 and press the PRINT key.
● When the PRINT key is pressed, the drum will I N K
rotate and the ink pump will function until the LED
lamp on the ink detecting PCB lights up to signal
that ink supply is OK. When the LED lights up, a
buzzer will sound and the drum and ink pump will
stop.
2. After the test is completed, HELP mode selection

display will automatically appear.

keys.
156 U5-Y113 0-0

HELP mode H-05 (1)Sensor/switch condition display (2)Function test

1. Functions
(1) Checking condition of master ejection box switch
• Displays the condition of the master ejection siwtch as a value of [0], [1].
(2) Checking master ejection motor operation
1. Access HELP mode H-05, and press the PRINT key. A B C D
A display indicating the condition of the following
switch will appear. ＊＊＊＊
♦ Master ejection box switch: A
Not used
Not used
2.Press the STOP key.
The HELP mode selection display will appear. Not used
→ To exit the HELP mode: Turn the power switch OFF. Master ejection box switch
→ To access another HELP mode: 1 = No master ejection box
keys.
(2) Checking master ejection motor operation

2. Press and hold down the right or left PRINT POSI-
TION key.
While the key is held down, the master ejection motor
rotates and master ejection rollers rotate.
● The motor does not reverse.

● Due to interlocking mechanism, the motor does not
rotate if the master ejection box is open. 7
3. Release the right or left PRINT POSITION key.
The motor will stop.
4.Press the STOP key.


keys.
U5-Y113 0-0 157

HELP mode H-06 (1)Sensor/switch condition display

1. Functions
(1) Checking condition of the sensors listed below
• Clamp sensor 1 (B mode sensor), clamp sensor 2 (C mode sensor), main motor encoder
sensor
• Drum stop position sensor, ejected paper jam sensor, master attachment/detachment
position sensor
display item. ＊＊＊＊
● Master darkness: LIGHT Main motor encoder sensor
1 = Photointerrupting
Displays the condition of the sensors below.
Not used
♦ Clamp sansor 1 (B mode sensor): A
♦ Clamp sensor 2 (C mode sensor): B Clamp sensor 2
♦ Main motor encoder sensor: D
Clamp sensor 1

Displays the condition of the sensors below. A B C D
♦Drum stop position sensor: B ＊＊＊＊
♦Ejected paper jam sensor: C
♦Master attachment/detachment position sensor: D Master attachment/detachment
position sensor
Ejected paper jam sensor
Drum stop position sensor

Not used


keys.
158 U5-Y113 0-0


1. Functions
(1) Checking condition of the sensors and switch listed
below
• Displays condition of the JOG switch as a value of [0], [1].
• Master set sensor, front cover sensor
(1) Checking condition of the sensors and switch listed
below A B C D
Press the MASTER DARKNESS key to change the ＊＊＊＊
display item.
Not used
JOG switch
Displays the condition of the switch below. PUSH=0
♦ JOG switch: C Not used
Not used
●Master darkness: NORMAL A B C D

Displays the condition of the sensors belolw. ＊＊＊＊
♦ Master set sensor: A
♦ Front cover sensor: D
Font cover sensor
0 = cover OPEN
Not used
Not used
Master set sensor


7
keys.
U5-Y113 0-0 159

1. Functions
(1) Checking condition of the sensors listed below and CIS
• Upper cover sensor, drum detection, document sensor
• Display of amount of light received by CIS
(1) Checking condition of the sensors listed below and
CIS A B C D
＊＊＊＊
display item. Drum detection
1 = no drum
Not used
Displays the condition of the sensors below. Not used
♦ Upper cover sensor: A
♦ Drum detection: D Upper cover sensor
1 = Upper cover OPEN
A B C D
● Master darkness: NORMAL ＊＊＊＊
Displays the condition of the sensor below.
♦ Document sensor: A Not used
Not used
Not used
Documnet sensor
A B C D
● Master darkness: DARK 137
♦ Displays the amount of light received by CIS ＊＊＊
between [00] - [255].
Amount of light received
by CIS


keys.
160 U5-Y113 0-0

HELP mode H-09 (1)Function test
1. Functions
(1) Checking drum position : master detachment / master attachment / removal
• Function test of clamp motor, checking master infeed amount
• Drum stop position sensor, master attachment/detachment position sensor, main motor encoder
sensor
• Clamp sensor 1 (B mode sensor), clamp sensor 2 (C mode sensor)
(1) Checking drum position : master detachment / master Display during function test
attachment / removal
1. Access HELP mode H-09, and press the PRINT key. d P
• While the right PRINT POSITION key is held down,
the clamp motor rotates and the clamp opens. (C mode
direction)
(It stops when the key is released or C mode sensor is
photopassed.)
• While the left PRINT POSITION key is held down, the clamp motor rotates and the clamp
closes. (B mode direction)
(It stops when the key is released or B mode sensor is photopassed.)
• Every time the [1] key is pressed, the drum rotates and stops at the detachment position.
• Every time the [2] key is pressed, the drum rotates and stops at the attachment position.
• Every time the [3] key is pressed, the drum rotates and stops at the removal position.
• Every time the [4] key is pressed, the clamp moves to the B mode position.
• Every time the [5] key is pressed, the clamp moves to the C mode position.
• Every time the MASTER MAKING key is pressed, the drum rotates and stops at the
detachment position, attachment position, and removal position in order.
• When the PRINT key is pressed, the drum moves to the attachment position, the clamp
opens, the master is fed to the attachment position by master feeding, the clamp closes and
then the master is cut. 7

Enter the preferred mode number using the NUMERIC keys.
U5-Y113 0-0 161


A B C D
display item. ＊＊＊＊
Not used
Displays the condition of the sensors listed below. Main motor encoder sensor
♦ Drum stop position sensor: A 1= Photointerrupting
♦ Master attachment/detachment position sensor: B Master attachment/detachment position sensor

1= Photointerrupting
♦ Main motor encoder sensor: C Drum stop position sensor
● Master darkness: DARK A B C D

♦ Clamp sensor 1 (B mode sensor): A
♦ Clamp sensor 2 (C mode sensor): B ＊＊＊＊
Not used
Not used
Clamp sensor 2
Clamp sensor 1


Enter the preferred mode number using the numeric
keys.
162 U5-Y113 0-0

HELP mode H-10 (1)Function test (2)Sensor/switch condition display
1. Functions
(1) Function test of scanner stepping motor, and CIS lamp ON/OFF
(2) Checking document sensor
(1) Function test of scanner stepping motor, and CIS lamp Display during function test
ON/OFF
C I S
●When the right PRINT POSITION key is pressed, the

scanner stepping motor rotates in the positive direc-
tion.
●When the left PRINT POSITION key is pressed, the
scanner stepping motor rotates in the reverse direc-
tion.
●When the PRINT key is pressed, the lamp lights up
and when it is pressed once again, the lamp goes out.


Enter the preferred mode number using the numeric A B C D
keys.
＊＊＊＊
(2) Checking document sensor
Not used 7
Not used
display item.
Not used
Displays the condition of the sensor below. Document sensor
♦ Document senso: A

keys.
U5-Y113 0-0 163


1. Functions
(1) Checking end mark sensor and condition of the sensors listed below
• Display of the amount of light received by end mark sensor
• Master set sensor
(1) Checking end mark sensor and condition of the sensors
listed below
Press the MASTER DARKNESS key to change the A B C D

display item. ＊＊＊
● Master darkness: LIGHT Amount of light received by
end mark sensor
♦ Displays the amount of the light received by the
end mark sensor between [00] - [255].
A B C D
＊＊＊＊
Displays the condition of the sensor listed below. Not used
♦ Master set sensor: A Not used
• When the right PRINT POSITION key is pressed, the Not used
master feed stepping motor rotaes in the positive direc-
tion. Master set sensor
• When the left PRINT POSITION key is pressed, the
master feed stepping motor rotaes in the reverse direc-
tion.
• When the MASTER MAKING key is pressed, the mas-
ter is cut.
• When the TEST PRINT key is pressed, the master is
set.


keys.
164 U5-Y113 0-0

HELP mode H-14 (1), (2)Total counter

1. Functions
(1) Displaying the count of total masters made in user mode
(2) Resetting the count of total masters made in user mode
(1) Displaying the count of total masters made in user mode
A B C D
Press the MASTER DARKNESS key to change the F ＊＊＊
display item.
High-order 3 digits of masters made
[F]= Master making
Displays high-order 3 digits of masters made
● Master darkness: NORMAL A B C D

Displays low-order 4 digits of masters made
＊＊＊＊
The HELP mode selection display will appear. Low-order 4 digits of masters made

keys.
(2) Resetting the count of total masters made in user mode

2. Press the CLEAR key and the " × ＝" key simultane-
ously. The reset contents will be memorized. During
memorization, “SAVE” will be displayed.
7
IMPORTANT
Do not turn off the power before the “SAVE” display
has disappeared.


keys.
U5-Y113 0-0 165


1. Functions
(1) Function test of ink pump motor
(1) Function test of ink pump motor Display during function test
I N P U
2. Press and hold down the TEST PRINT key.
The ink pump motor will rotate for as long as the key
is held down.
IMPORTANT
Remember that ink will be delivered when the ink
motor rotates. Take any precautions necessary.
3. Release the TEST PRINT key.

The ink pump motor will stop.


keys.
166 U5-Y113 0-0


1. Functions
(1) Setting of online (with PC interface) master making start position
(1) Setting of online (with PC interface) master making start position
2. Use the [0] and [1] NUMERIC keys to enter a 4-place
binary value for the preferred correction amount.
(Values are adjusted by approx. 1.0mm.)
ABCD Correction
amount
0111 -7mm
0110 -6mm
0101 -5mm
Moves toward you from
0100 -4mm
default
0011 -3mm
0010 -2mm
0001 -1mm
0000
±0 No change
1000
1001 +1mm
1010 +2mm
1011 +3mm
Moves backward from
1100 +4mm
default
1101 +5mm
1110 +6mm
1111 +7mm
3. Press the " ×

＝" key. The setting will be memorized.
During memorization, “SAVE” will be displayed.
7
IMPORTANT
Do not turn off the power before the “SAVE” display has disappeared.


keys.
U5-Y113 0-0 167


1. Functions
(1) Function test of cutter motor
(1) Function test of cutter motor
1. Access HELP mode H-17, and press the PRINT key. Display during function test
2. Press the right PRINT POSITION key.
The cutter motor will rotate and the cutter will move to C U T
the operation side.
3. When the cutter reaches the opposite of the oper-
ation side, the cutter motor stops.
4. Press the left PRINT POSITION key.
The cutter motor will rotate and the cutter will move to
the opposite of the operation side.
5. When the cutter reaches the opposite of the operation
side, the cutter motor stops.
• When the MASTER MAKING key is pressed, the

master is cut.


keys.
168 U5-Y113 0-0

HELP mode H-18 (1)Function test (2)Sensor/switch condition display

1. Functions
(1) Function test of mster ejection motor
• Displaying the condition of the master ejection box switch as a value of [0], [1].
(1) Function test of master ejection motor Display during function test
2. Press and hold down the right PRINT POSITION key E J E
or left PRINT POSITION key.
While the key is held down, the master ejection motor
rotates and the ejection rollers rotate.
3. When the key is released, the master ejection motor
stops.
● The master ejection motor does not rotate in the

reverse direction.
● Due to interlocking mechanism, the motor does not
rotate if the master ejection box is open.


→ To access another HELP mode: A B C D
keys. ＊＊＊＊
(2) Checking condition of master ejection box switch Not used
display item.
Not used
Not used
7
Master ejection box switch
● Master darkness: NORMAL 1 = No master ejection box
Displays the condition of the switch below as a value
of [0], [1].
♦ Master ejection box switch: A

keys.
U5-Y113 0-0 169

HELP mode H-19 (1), (2) Total counter

1. Functions
(1) Displaying total count of sheets printed in user mode
(2) Resetting total count of sheets printed in user mode
(1) Displaying total count of sheets printed in user mode A B C D
P ＊＊＊
• Press the MASTER DARKNESS key to change the
display item. High-order 3 digits of sheets printed
[P] = Print
Displays high-order 3 digits of sheets printed.
A B C D
Displays low-order 4 digits of sheets printed. ＊＊＊＊
Low-order 4 digits of sheets printed

keys.
(2) Resetting total count of sheets printed in user mode

2. Press the CLEAR key and the " × ＝" key simultane-
ously. The reset content will be memorized. During
memorization, “SAVE” will be displayed.
IMPORTANT
has disappeared.


keys.
170 U5-Y113 0-0


1. Functions
(1) Function test of clamp motor and clamp position sensing (B/C modes position)
(2) Checking clamp sensor 1 (B mode sensor) and clamp sensor 2 (C mode sensor)
(1) Function test of clamp motor and clamp position sensing Display during function test
(B/C modes position)
C L A
2. Press and hold down the right PRINT POSITION key.

While this key is held down, the clamp motor rotates
and the clamp opens. (B→C mode direction)
3. The clamp motor stops when the right PRINT POSITION

key is released or the clamp sensor 2 (C mode sensor) is
photopassed.
4. Press and hold down the left PRINT POSITION key.

While this key is held down, the clamp motor rotates and the clamp closes.
(C→B mode direction)
5. The clamp motor stops when the left PRINT POSITION key is released or the clamp
sensor 1 (B mode sensor) is photopassed.
• Every time the [1] key is pressed, the drum rotates and stops at the detachment position.
• Every time the [2] key is pressed, the drum rotates and stops at the attachment position.
• Every time the [3] key is pressed, the drum rotates and stops at the removal position.
• Every time the [4] key is pressed, the clamp moves to the B mode position.
• Every time the [5] key is pressed, the clamp moves to the C mode position. 7
• Every time the MASTER MAKING key is pressed, the drum rotates and stops at the
detachment position, attachment position, and removal position in order.


U5-Y113 0-0 171

(2) Checking clamp sensor 1 (B mode sensor) and clamp A B C D

sensor 2 (C mode sensor) ＊＊＊＊
1. Access HELP mode H-20, and press the PRINT key. Not used
Press the MASTER DARKNESS key to change the Not used

display item.
Clamp sensor 2
● Master darkness: NORMAL Clamp sensor 1
Displays the condition of the sensors below. 1 = Photointerrupting
♦ Clamp sensor 1 (B mode sensor): A

♦ Clamp sensor 2 (C mode sensor): B


keys.
172 U5-Y113 0-0

HELP mode H-21 (1)Encoder counter display

1. Functions
(1) Display of main motor encoder counter
(1) Display of main motor encoder counter A B C D
1. Access HELP mode H-21, and press the PRINT key. ＊＊＊＊
* The main motor encoder count is displayed in hexa- Main motor encoder counter
decimal.


keys.
U5-Y113 0-0 173


1. Functions
(1) Setting of lengthwise zoom factor correction amount for master making side
(1) Setting of lengthwise zoom factor correction amount for master making side
(adjusted in increments of approx. 0.2%)
ABCD Correction
amount
0111 -1.4%
0110 -1.2%
0101 -1.0%
0100 -0.8% Shorter than default
0011 -0.6%
0010 -0.4%
0001 -0.2%
0000
±0 No change
1000
1001 +0.2%
1010 +0.4%
1011 +0.6%
1100 +0.8% Longer than default
1101 +1.0%
1110 +1.2%
1111 +1.4%
3. Press the " ×

IMPORTANT


174 U5-Y113 0-0


1. Functions
(1) Setting of photograph mode document sensing darkness
(1) Setting of photograph mode document sensing darkness
ABCD Correction
amount
0111 -42
0110 -36
0101 -30
0100 -24 Lighter than default
0011 -18
0010 -12
0001 -6
0000
±0 No change
1000
1001 +6
1010 +12
1011 +18
1100 +24 Darker than default
1101 +30
1110 +36
1111 +42
3. Press the " ×

7
IMPORTANT
Do not turn off the power before the “SAVE” display has disap-
peared.


U5-Y113 0-0 175


1. Functions
(1) Setting of reducing offset for reading longitudinal (sub-scanning) R/E scanner
(1) Setting of reducing offset for reading longitudinal (sub-scanning) R/E scanner

ABCD Correction
amount
0000 ±0 No change
0001 -0.2%
0010 -0.4%
0011 -0.6%
0100 -0.8%
0101 -1.0%
0110 -1.2%
0111 -1.4%
1001 -1.8%
1010 -2.0%
1011 -2.2%
1100 -2.4%
1101 -2.6%
1110 -2.8%
1111 -3.0%
3. Press the " ×

IMPORTANT


176 U5-Y113 0-0


1. Functions
(1) Setting of enlarging offset for reading longitudinal (sub-scanning) R/E scanner
(1) Setting of enlarging offset for reading longitudinal (sub-scanning) R/E scanner
ABCD Correction
amount
0000 ±0 No change
0001 +0.2%
0010 +0.4%
0011 +0.6%
0100 +0.8%
0101 +1.0%
0110 +1.2%
0111 +1.4%
1001 +1.8%
1010 +2.0%
1011 +2.2%
1100 +2.4%
1101 +2.6%
1110 +2.8%
1111 +3.0%
3. Press the " ×

7
IMPORTANT


U5-Y113 0-0 177


1. Functions
(1) Compensation of document darkness white level in photograph mode
(1) Compensation of document darkness white level in photograph mode
ABCD Correction
amount
0111 -70
0110 -60
0101 -50
0100 -40 Lowers from default
0011 -30
0010 -20
0001 -10
0000 ±0
1000 ±0 No change
1001 +10
1010 +20
1011 +30
1100 +40 Rises from default
1101 +50
1110 +60
1111 +70
3. Press the " ×

IMPORTANT


178 U5-Y113 0-0


1. Functions
(1) Initialization of all HELP mode settings
(1) Initialization of all HELP mode settings Display of H-27
2. Press the × ＝ and CLEAR keys simultaneously. I N I T
The adjustment and specification settings of the
HELP modes will be initialized.
However, for the total counts (H-14 and H-19), only the
user mode values will be initialized.
While initialization is in progress, “SAVE” will be dis-
played.
IMPORTANT
has disappeared.

keys.
U5-Y113 0-0 179


1. Functions
(1) Adjustment of paper stripper finger gap
(1) Adjustment of paper stripper finger gap Display of H-28
Set papers before adjustment.
1. Access HELP mode H-28, and press the PRINT key. P E
2. Press the PRINT key once again.
The drum will rotate and stop with the press roller
pressed against the drum.
3. Make adjustment of the paper stripper finger.
4. After adjustment is complete, press and hold down the
JOG switch until it stops with 'Pi' sound.
WARNING
● Do not touch the drum or rollers when you
operate the JOG switch.
machine while it is operating.
They could be caught up or crushed, result-
ing in injury .


keys.
180 U5-Y113 0-0


1. Functions
(1) Adjustment of master infeed amount
(1) Adjustment of master infeed amount
2. Press the PRINT key once again.
The drum will move to the attachment position, the clamp will open, the master will
be fed to the attachment position by master feeding, the clamp will close, and then
the master will be cut.
3. Check the master infeed amount.
(adjusted in increments of approx. 0.5mm)
ABCD Correction
amount
0111 -3.5mm
0110 -3.0mm
0101 -2.5mm
0100 -2.0mm Shorter than default
0011 -1.5mm
0010 -1.0mm
0001 -0.5mm
0000 ±0
No change
1000 ±0
1001 +0.5mm
1010 +1.0mm
1011 +1.5mm
1100
1101
+2.0mm
+2.5mm
Longer than default 7
1110 +3.0mm
1111 +3.5mm
5. Press the " ×
IMPORTANT

U5-Y113 0-0 181


1. Functions
(1) Test pattern (all shading, sub-scanning direction zoom factor adjustment) master making
and printing
(1) Test pattern (all shading, sub-scanning direction zoom factor adjustment) master making
and printing

2. Select one of the items below and follow the procedure given for it.
• Test pattern 1 (all shading)

→ Press the MASTER DARKNESS key to select [Master darkness: LIGHT].
Perform master making and printing of diagonal line pattern in maximum master mak-
ing size. At this time, note that master making size will be bigger than paper size.
• Test pattern 2 (sub-scanning direction zoom factor adjustment)

→Press the MASTER DARKNESS key to select [Master darkness: NORMAL].
Perform master making and printing of test pattern in selected master making length.
Sub-scanning direction zoom factor adjustment is adjusted in H-22 [Setting of length
wise (sub-scanning) zoom factor correction amount for master making side].
• Test pattern 3
→ Press the MASTER DARKNESS key to select [Master darkness: DARK].
Perform master making and printing of test pattern in selected master making
area. However, for the width, print test pattern in maximum width regardless of
selected master making size.
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.
3. Press the MASTER MAKING key to perform master making/printing.

4. Press the STOP key. The HELP mode selection display will appear.

REFERENCE:
Default of test pattern is test patter 2 (Master darkness: NORMAL).
182 U5-Y113 0-0

HELP mode H-31 (1) Adjustment/specification setting

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
ABCD Correction
amount
0000 0 sheet Default
0001 1 sheet
0010 2 sheets
0011 3 sheets
0100 4 sheets
0101 5 sheets
0110 6 sheets
0111 7 sheets
Number of
1000 8 sheets
pre-print sheets
1001 9 sheets
1010 10 sheets
1011 11 sheets
1100 12 sheets
1101 13 sheets
1110 14 sheets
1111 15 sheets
3. Press the " ×

7
IMPORTANT
has disappeared.


keys.
U5-Y113 0-0 183


1. Functions
(1) Setting of confidential safeguard function, setting of TEST PRINT key function
(1) Setting of confidential safeguard function, setting of TEST PRINT key function
binary value for the preferred setting.
ABCD Item Setting

0*** Confidential Disabled
1*** safeguard function Enabled (Default)
*0**
Not used
*1**
**0*
Not used
**1*
***0 Printing while TEST PRINT key is Disabled
***1 continuously held down Enabled (Default)
3. Press the " ×

IMPORTANT
has disappeared.


184 U5-Y113 0-0


1. Functions
(1) Compensation of document darkness white level in text mode
(1) Compensation of document darkness white level in text mode
ABCD Correction
amount
0111 -70
0110 -60
0101 -50
0100 -40 Lowers from default
0011 -30
0010 -20
0001 -10
0000 ±0
1000 ±0 No change
1001 +10
1010 +20
1011 +30
1100 +40 Rises from default
1101 +50
1110 +60
1111 +70
3. Press the " ×

7
IMPORTANT
has disappeared.


keys.
U5-Y113 0-0 185


1. Functions
(1) Setting of master making feed amount (sub-scanning: lengthwise) adjustment
(1) Setting of master making feed amount (sub-scanning: lengthwise) adjustment
ABCD Correction
amount
0111 -1.4%
0110 -1.2%
0101 -1.0%
0011 -0.6%
0010 -0.4%
0001 -0.2%
0000 ±0
No change
1000 ±0
1001 +0.2%
1010 +0.4%
1011 +0.6%
1101 +1.0%
1110 +1.2%
1111 +1.4%
3. Press the " ×

IMPORTANT


186 U5-Y113 0-0


1. Functions
(1) Adjustment of scanner leading edge sensing position
(1) Adjustment of scanner leading edge sensing position

ABCD Correction
amount
0111 -4.9mm
0110 -4.2mm
0101 -3.5mm
Moves toward you
0100 -2.8mm
from default
0011 -2.1mm
0010 -1.4mm
0001 -0.7mm
0000 ±0
No change
1000 ±0
1001 +0.7mm
1010 +1.4mm
1011 +2.1mm
Moves backward
1100 +2.8mm
from default
1101 +3.5mm
1110 +4.2mm
1111 +4.9mm
3. Press the " ×

7
IMPORTANT

U5-Y113 0-0 187


1. Functions
(1) Adjustment of document widthwise (main-scanning) sensing position
(1) Adjustment of document widthwise (main-scanning) sensing position
ABCD Correction
amount
0111 -4.2mm
0110 -3.6mm
0101 -3.0mm
Moves toward you
0100 -2.4mm
from default
0011 -1.8mm
0010 -1.2mm
0001 -0.6mm
0000 ±0
No change
1000 ±0
1001 +0.6mm
1010 +1.2mm
1011 +1.8mm
Moves backward
1100 +2.4mm
from default
1101 +3.0mm
1110 +3.6mm
1111 +4.2mm
3. Press the " ×

IMPORTANT

has disappeared.


188 U5-Y113 0-0


1. Functions
(1) Adjustment of master making start position
(1) Adjustment of master making start position
ABCD Correction
amount
0111 -7.0mm
0110 -6.0mm
0101 -5.0mm
0100 -4.0mm Shorter than default
0011 -3.0mm
0010 -2.0mm
0001 -1.0mm
0000 ±0
No change
1000 ±0
1001 +1.0mm
1010 +2.0mm
1011 +3.0mm
1100 +4.0mm Longer than default
1101 +5.0mm
1110 +6.0mm
1111 +7.0mm
3. Press the " ×

7
IMPORTANT
has disappeared.


keys.
U5-Y113 0-0 189


1. Functions
2. Press the MASTER DARKNESS key to select adjust-
ment item. ＊＊＊
• Press the PRINT SPEED key to switch print speed
from Speed 1 to Speed 2. Print speed
3. Press the right or left PRINT POSITION key to adjust
the rotation value to the reference value.
The adjusted content will be saved and the HELP
mode selection display will appear.
Lighting-up LED Reference value Adjustment item

Light 5-9rpm Pre-stop speed
Normal 8-12rpm Master making
Darkness 20-23rpm JOG speed
Print speed 63-67rpm Speed 1
LED: Speed 1
Print speed 93-97rpm Speed 2
LED: Speed 2

keys.
190 U5-Y113 0-0


1. Functions
(1) Function test of paper feed clutch and T roll clutch
(1) Function test of paper feed clutch and T roll clutch Display during function test
C L A
2. Press and hold down the right or left PRINT POSI-
TION key.
While the key is held down, the selected clutch will
operate.
● Press the MASTER DARKNESS key to select dis-

play item.
♦Master darkness: LIGHT → paper feed clutch
♦Master darkness: NORMAL→ T roll clutch
3. To stop the operation, release the right or left PRINT
POSITION key.


keys.
U5-Y113 0-0 191


1. Functions
(1) Setting of repeat count display, setting of auto power off
(1) Setting of repeat count display, setting of auto power off
ABCD Item Setting

0***
Not used
1***
*0**
Not used
*1**
**0* Enabled (default)
Repeat count display
**1* Disabled
***0 Disabled (default)
Auto power off
***1 Enabled
3. Press the " ×

IMPORTANT
has disappeared.


192 U5-Y113 0-0


1. Functions
(1) Setting of master making size selection specification, Setting of machine size selection
specification
(1) Setting of master making size (AB/INCH) and machine
size
ABCD Item Setting

0*** Master making size A/B
1*** selection specification inch
*0** Machine size selection B4, LG
*1** specification A4, LT
**0*
Not used
**1*
***0
Not used
***1
3. Press the " ×

IMPORTANT
has disappeared.

The HELP mode selection display will appear. 7
keys.
U5-Y113 0-0 193

Chapter7 3 HELP Mode Function and Operation Procedures

1. Functions
(1) Setting of thermal head offset value
(1) Setting of thermal head offset value
(adjusted in increments of approx. 1mm)
ABCD Correction amount
0111 -7
0110 -6
0101 -5
Lighter than
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 +6
1111 +7
3. Press the " ×

IMPORTANT
has disappeared.


keys.
194 U5-Y113 0-0


1. Functions
(1) Setting of thermal head resistance ranking
(1) Setting of thermal head resistance ranking
ABCD Head Rank Resistance (ohm)

0000 0 3663-3748
0001 1 3749-3834
0010 2 3835-3920
0011 3 3921-4006
0100 4 4007-4093
0101 5 4094-4179
0110 6 4180-4265
0111 7 4266-4351
1000 8 4352-4437
1001 9 4438-4524
1010 10 4525-4610
1011 11 4611-4696
1100 1 4697-4782
1101 13 4783-4868
1110 14 4869-4954
1111 15 4955-5041
3. Press the " ×

During memorization, “SAVE” will be displayed. 7
IMPORTANT
has disappeared.


keys.
U5-Y113 0-0 195


1. Functions
(1) Adjustment of T roll clutch ON angle
• For leading edge margin
(1) Adjustment of T roll clutch ON angle Display of H-46
• Press the MASTER DARKNESS key to select dis-
play item. ＊＊＊
from Speed 1 to Speed 2. Adjustment value
• Use the NUMERIC keys to enter an adjustment
value.
Lighting-up LED Adjustment range Adjustment item

LIGHT 15°-170° Pre-stop
NORMAL 15°-170° Master making
DARK 15°-170° JOG speed
Print speed 15°-170° Speed 1
LED: Speed 1
Print speed 15°-170° Speed 2
LED: Speed 2
2. Press the " ×

* T roll clutch OFF angle and paper feed clutch ON/

OFF angle are automatically calculated and saved
by adjusting T roll clutch ON angle.
IMPORTANT
has disappeared.


keys.
196 U5-Y113 0-0


1. Functions
(1) Setting of reducing offset for main-scanning
(1) Setting of reducing offset for main-scanning
ABCD Correction
amount
0000 ±0 Default
0001 -0.2%
0010 -0.4%
0011 -0.6%
0100 -0.8%
0101 -1.0%
0110 -1.2%
0111 -1.4%
1001 -1.8%
1010 -2.0%
1011 -2.2%
1100 -2.4%
1101 -2.6%
1110 -2.8%
1111 -3.0%
3. Press the " ×

7
IMPORTANT
has disappeared.


keys.
U5-Y113 0-0 197


1. Functions
(1) Setting of enlarging offset for main-scanning
(1) Setting of enlarging offset for main-scanning
ABCD Correction
amount
0000 ±0 Default
0001 +0.2%
0010 +0.4%
0011 +0.6%
0100 +0.8%
0101 +1.0%
0110 +1.2%
0111 +1.4%
1000 +1.6% Longer from default
1001 +1.8%
1010 +2.0%
1011 +2.2%
1100 +2.4%
1101 +2.6%
1110 +2.8%
1111 +3.0%
3. Press the " ×

IMPORTANT
has disappeared.


Enter the preferred mode number using the NUMER-
IC keys.
198 U5-Y113 0-0


1. Functions
(1) Setting of text mode document reading darkness
(1) Setting of text mode document reading darkness
ABCD Correction
amount
0111 -42
0110 -36
0101 -30
0100 -24 Lighter than default
0011 -18
0010 -12
0001 -6
0000 ±0 Default
1000 ±0 No change
1001 +6
1010 +12
1011 +18
1100 +24 Darker than default
1101 +30
1110 +36
1111 +42
3. Press the " ×

7
IMPORTANT
has disappeared.


keys.
U5-Y113 0-0 199


1. Functions
(1) Setting of auto power off time
(1) Setting of auto power off time A B C D
2. Use the [0] and [1] NUMERIC keys to enter a 4-place ＊＊
Auto power off time
● Auto power off time setting range: 1 - 10 min.
3. Press the " ×

IMPORTANT
has disappeared.


keys.
200 U5-Y113 0-0


1. Functions
(1) Setting of online (with PC interface) widthwise (main-scanning) master making position
(1) Setting of online (with PC interface) widthwise (main-scanning) master making position

ABCD Correction
amount
0111 -7.0mm
0110 -6.0mm
0101 -5.0mm
Moves toward you
0100 -4.0mm
from default
0011 -3.0mm
0010 -2.0mm
0001 -1.0mm
0000 ±0
No change
1000 ±0
1001 +1.0mm
1010 +2.0mm
1011 +3.0mm
Moves backward
1100 +4.0mm
from default
1101 +5.0mm
1110 +6.0mm
1111 +7.0mm
3. Press the " ×

7
IMPORTANT


U5-Y113 0-0 201


1. Functions
(1) Setting of ink replenishment before printing start, setting of interlocks
(1) Setting of ink replenishment before printing start, setting of interlocks

2. Use the [0] and [1] numeric keys to enter a 4-place
ABCD Item Setting

0 * * * Setting of ink check, that triggers Disabled
1 * * * ink replenishment if no ink is
Enabled
detected at printing start
*0**
Not used
*1**
* * 0 * Interlock: emergency stop if Disabled
upper cover, master ejection box,
**1* Enabled
or front cover is open
***0
Not used
***1
3. Press the " ×

IMPORTANT
has disappeared.


keys.
202 U5-Y113 0-0


1. Functions
(1) Setting of sort mode
• Operation of Duprinter during sorting
• Running time without paper during sorting
(1) Setting of sort mode
2. Press the MASTER DARKNESS key to select display item.
♦Master darkness: LIGHT
Operation of Duprinter during sorting
Use the [0] and [1] NUMERIC keys to enter a 4-place binary value for the preferred
setting.
ABCD Item Setting

0***
Not used
1***
*0**
Not used
*1**
**0*
Not used
**1*
***0 Stop
***1 Stops during sorting Running without
paper
♦Master darkness: NORMAL

Running time without paper during sorting
Use the NUMERIC keys to enter value for changing the preferred setting.
●Adjustment range of running time without paper during sorting: 0 - 99 sec.

3. Press the " ×
7
IMPORTANT


U5-Y113 0-0 203


1. Functions
(1) Setting of special operation
(1) Setting of special operation
2. Press the MASTER DARKNESS key to select displayed
item.

ABCD Item Setting
0*** Disabled
Drum detection
1*** Enabled (default))
*0** Disabled
Ejected paper jam sensor
*1** Enabled (default)
**0* Disabled
Front cover sensor
***0 Disabled
Upper cover sensor
***1 Enabled (default)

ABCD Item Setting
0*** Printing while TEST PRINT keyis Disabled
1*** continuously held down Enabled (default)
*0** Disabled
Interlock
**0* Disabled
Master ejection box switch
***0 Disabled
Ink detection
***1 Enabled (default)
204 U5-Y113
ABCD Item Setting
0*** Disabled
1*** Enabled (default)
*0** Disabled
Repeat count display
**0* Disabled
Auto power off
***0 Confidential Disabled
***1 safeguard function Enabled (default)
4. Press the " ×

IMPORTANT
has disappeared.


U5-Y113 205

1. Functions
(1) Checking LEDs on control panel
(1) Checking LEDs on control panel Display during function test
● All LEDs including 7SEG will light up. 8 8 8 8

IC keys.
206 U5-Y113 0-0


1. Functions
(1) Auto power off function test
(1) Auto power off function test Display during function test
2. Press the right and left PRINT POSITION keys. o F F
Auto power off will function.

keys.
U5-Y113 0-0 207


1. Functions
(1) Setting of paper feed length
(1) Setting of paper feed length Display of H-67
A B C D
• Press the MASTER DARKNESS key to change the
display item.
(-) ＊
Adjustment value
from Speed 1 to Speed 2.
• Use the NUMERIC keys to enter an adjustment (-) display
value.
Press the DOCUMENT MODE SWITCH key to switch
(+) / (-) display.
(+) direction→The arching dimension will be smaller.
(-) direction→The arching dimension will be larger.

LIGHT -8° - +8° Pre-stop speed
NORMAL -8° - +8° Master making
DARK -8° - +8° JOG speed
Print speed -8° - +8° Speed 1
LED: Speed 1
LED: Speed 2
2. Press the " ×

IMPORTANT
has disappeared.


keys.
208 U5-Y113 0-0


1. Functions
(1) Setting of vertical registration
(1) Setting of vertical registration Display of H-73
• Press the MASTER DARKNESS key to change the A B C D
display item.
(-) ＊
from Speed 1 to Speed 2. Adjustment value
• Use the NUMERIC keys to enter an adjustment
value. (-) display
Press the DOCUMENT MODE SWITCH key to switch
(+) / (-) display.

LIGHT -8° - +8° Pre-stop speed
NORMAL -8° - +8° Master making
DARK -8° - +8° JOG speed
LED: Speed 1
LED: Speed 2
2. Press the " ×

IMPORTANT 7
has disappeared.


keys.
U5-Y113 0-0 209


1. Functions
(1) Setting of thermal head temperature correction
(1) Setting of thermal head temperature correction
ABCD Item Setting

0***
Not used
1***
*0** Thermal head temperature Disabled
*1** correction Enabled
**0*
Not used
**1*
***0
Not used
***1
3. Press the " ×

IMPORTANT
has disappeared.


IC keys.
210 U5-Y113 0-0


1. Functions
(1) Printer ID setting of USB interface
* This setting is used when multiple units of Duprinter DP-A120 are connected using USB
interface.
(1) Printer ID setting of USB interface
When up to 15 units of Duprinter are connected to one computer, each

Duprinter is assigned with alphanumeric from 1 through 15 as below.
ABCD Setting
0001 1
0010 2
0011 3
0100 4
0101 5
0110 6
0111 7
1000 8
1001 9
1010 10
1011 11
1100 12
1101 13
1110 14
1111 15
3. Press the " ×

7
IMPORTANT
has disappeared.


U5-Y113 0-0 211

HELP mode H-76 (1) Total counter

1. Functions
(1) Master making total counter display, printing total counter display
(1) Master making total counter display, printing total A B C D
counter display
1. Access HELP mode H-76, and press the PRINT key. P ＊＊＊
2. Press the MASTER DARKNESS key to change the High-order 3 digits of sheets printed
display item. [P] = printing

Displays high-order 3 digits of sheets printed A B C D

＊＊＊＊
Displays low-order 4 digits of sheets printed
Low-order 4 digits of sheets printed

Displays high-order 3 digits of masters made
A B C D
Master Darkness
F ＊＊＊
● Master darkness: LED / print speed LEDs (all go off)
Displays low-order 4 digits of masters made
High-order 3 digits of masters made
3. Press the STOP key. [F] = master making

A B C D
→ To access another HELP mode: ＊＊＊＊
keys. Low-order 4 digits of masters made
212 U5-Y113 0-0

Chapter 8 Others
1Electrical Parts Layout and Their Functions.....214
(1) Switches / Clutches ............................214
(2) Sensors ..............................................215
(3) Motors ................................................216
(4) PCB units / Others .............................217
(5) Connector VR/LED Layout and Functions.......218
2 Overall Wiring Layout...............................220
Overall Wiring Layout .............................220
U5-Y113 0-0
Chapter 8 1 Electrical Parts Layout and Their Functions
1 Electrical Parts Layout and Their Functions

(1) Switches / Clutches
3
5
6
2
Item No. Function

Seesaw switch 1 Power ON/OFF
Push switch 2 Drum rotation
Micro switch 3 Master ejection box open/close detection
4 Interlock switch
Clutch 5 Timing roll clutch
6 Paper feed clutch
214 U5-Y113 0-0

(2) Sensors
11
1 12
2
3
4
5
7
6
8
10
Item No. Function

Micro sensor 1 Master clamp opening and closing lever (B mode position) is detected.
2 Master clamp opening and closing lever (C mode position) is detected.
3 Opening and closing of the upper cover is detected.
4 Master attachment/detachment position is detected.
5 Drum removal position is detected.
6 Main motor encoder is detected.
7 Master set is detected.
8 Opening and closing of the front cover is detected.
PCB sensor 9 Master end mark is detected.
Photointerrupter 10 Ejected paper jam is detected.
Contact image sensor (CIS)

11
12
Leading edge of document is detected.
Reading the image 8
U5-Y113 0-0 215

(3) Motors
5 6
Item No. Function

Motor 1 Scanner stepping motor
2 Master ejection motor
3 Master clamp motor
4 Main motor
5 Master feed stepping motor
6 Ink pump motor
216 U5-Y113 0-0

(4) PCB units / Others
2
1
Option
9
8
3
7
4
Item No. Function

Main PCB unit 1 Processing image, Controlling the entire Duprinter
Ink detection PCB unit 2 Detecting ink amount in the drum
Panel PCB 3 Keys and display on the control panel
Inlet 4 -
24V power supply 5 24V supply
Thermal head 6 Thermal head
Cutter unit 7 Cutter unit
USB PCB unit 8
I/F PCB unit 9
U5-Y113 0-0 217

(5) Connector VR / LED Layout and Functions
1. Control Panel PCB unit
CN 1
2. End Mark Sensor PCB unit
VR 1
CN 1
218 U5-Y113 0-0

3. Main PCB unit
J2 J3 J4
J1
J5
U13
J11
J10
J6
U23
J9 J8 J7
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.
4. 24V power supply
CN53
F1(FUSE)
CN1
CN51
AC250V T5AH
U5-Y113 0-0 219

Chapter8 2 Overall Wiring Layout
2 Overall Wiring Layout

BLACK
YELLOW/GREEN
AC(L) BLACK
CN1-1 CN51-2 BROWN +24V
-1 BROWN +24V
WHITE AC(N) WHITE
-3 CN53-2 BLUE GND
-1 BLUE GND
GND GREEN
-5
4 7 BLACK J1 -1 J9 -1
6 8 PINK -2 -2
MASTER FEED STEPPING
3 9 LIGHT GREEN
-3 -3
-4
1 10 LIGHT BLUE -4
5 11 +24V YELLOW -5
2 12 +24V WHITE -6 J2 -26 1 1
-27
THERMAL HEAD
1 +5V RED J7 -29 -28
1 2 GREEN -27
END-MARK PCB UNIT 2 3 GND BLUE -25 J4 -1 SIGNAL LINE POWER LINE
J8-V334* 3
MASTER SET SENSOR

1 4 +5V RED J7 -30
2 5 YELLOW -8 -24 28 14
3 6 GND BLUE -7 GND LINE(1-7)
J3 -1 +24V LINE(8-14)
1 1 YELLOW J1 -7
2 2 ORANGE -8
SCANNER STEPPING
3 3 BROWN -9
4 4 BLACK -10 -14
5 5 +24V RED -11
6 6 +24V RED -12 J5 -1 WHITE 6
-2 BLUE 2
-3 WHITE 8
U5-V****
-4 BLUE 11
CUTTER MOTOR
1 RED J1 -19 -6 RED 3
-12 WHITE 1
CIS
2 BLACK -20
A
BROWN +24V 10
CLAMP MOTOR
2 BLACK J1 -21 MAIN J2 YELLOW 9
1 RED -22
J6 -4 RED +5V 1
INK PUMP MOTOR

+24V 2 8 PINK J2 -5 -6 PINK 2 FRONT COVER SENSOR
-5 BLUE GND 3
1 2 ORANGE -6 J6 -32 RED +5V 1
-8 YELLOW 2 TOP COVER SENSOR
-7 BLUE GND 3
INK DETECTION ASSY +24V 1 9 BROWN J2 -1
2 4 BLACK J6 -10 J6 -27 RED +5V 1
N5-X125* GND 3 3 BLUE
-9 -18 GREEN 2 DRUM POSITION2 SENSOR
10
-11 -17 BLUE GND 3
11
-12 J6 -28 RED +5V 1
-20 LIGHT BLUE 2 DRUM POSITION1 SENSOR
-19 BLUE GND
A
3
BROWN 1 +24V BROWN
J2 -7 J6 -31
CIS LINE YELLOW 2 YELLOW
-8 RED +5V 1
-24 WHITE 2 CLAMP SENSOR 1
-23 BLUE GND 3
1 3 +5V RED J7 -12
DOCUMENT LEAD EDGE SENSOR 2 4 ORANGE
-14 J6 -30 RED +5V 1
3 5 GND BLUE
-13 -26 GRAY 2 CLAMP SENSOR 2
-25 BLUE GND 3
MASTER EJECTION 3 WHITE J7 -5 J7 -17 BLUE GND 1

OPEN/CLOSE SWICH
2 WHITE
-6 -18 LIGHT GREEN 2 PAPER EJECT JAM SENSOR
-22 RED +5V 3
INTERLOCK SWITCH
J8 -1 WHITE 2
1 1 +24V RED J2 -3 -2 PURPLE 6 CONTROL PANEL
MASTER EJECT MOTOR -3 YELLOW 10
PCB UNIT
-4 LIGHT BLUE 8
2 2 BLACK
-4 -6 ORANGE 4
-8 RED +5V 13 U5-V****
-9 BLUE GND 14
2 +24V BLACK J2 -9
PAPER FEED CLUTCH J8 -18 RED +5V 1
-21 GRAY 2 MAIN MOTOR ENCODER SENSOR
1 BLACK -10 -17 BLUE GND 3
2 +24V BLACK J2 -11 J10-1 BLACK 1

T ROLL CLUTCH MAIN MOTOR
1 BLACK -12 -2 RED 2
220
U5-Y1130
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DP A120 Service

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SERVICE MANUAL

Sep. 2009 Revision 0

Note: This symbol mark is for EU countries only.

■Using the service manual

Examples of Pictorial Symbols

A “ ”circle with a line through it indicates a prohibited action.

●For maintenance operation

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

2. Cautions for installation work

120V AC model 230V AC model

Using the optional printer stand

3. Cautions for maintenance, inspection and servicing

If optional tape clusters are used

■Locations of Warning Labels

Do NOT put hands inside

Use caution when working

Description of the Operation 2

1 Electrical Parts Layout and Their Functions...........214

U.S. paper sizes

Optional network server FS-100U (USB LAN unit)

* Specifications are subject to change without prior notice.

195 565 290

Duplo Direct Print System

Drum unit :Option

4 Part Names and Their Functions

No. Name Function

MASTER SET LEVER

MASTER EJECTION BOX

PAPER STRIPPER FINGER

PAPER EJECTION ROLLER

No. Name Function

2. Control panel (European paper sizes)

No. Name Function

3. Control panel (U.S. paper sizes)

No. Name Function

Ejection roller Paper feed roller

(1) Document detection

1. Detection of the document

1. Detection of the document

2. Detection of the front end of the document

3. Detection of the rear end of the document

4. Detection of the finish of the document

5. Detection of document jam

(2) Basic Operation for Feeding Paper to Scanner

(1) Paper feed 1

(3) Paper feed 2

Ejection roller Paper feed roller

3. Function of Parts and Circuit

(1) Document Sensor

The document sensor detects the five types of document detection.

Main PCB Unit

1. Detection of the document / finish of the document

Main PCB Unit

2. Detection of the front / rear end of the document

3. Detection of document jam

(2) CIS (Contact Image Sensor)

8.5 x 14 209mm x 349mm

(3) Scanner Stepping Motor

Scanner Stepping Motor

(4) Upper Cover Opening / Closing Detection

Upper cover sensor Upper cover sensor

2 Mastermaking / Master Feed / Ejection Section

<<Master Ejection Section>>

End mark sensor