DUPLO SEIKO CORPORATION Duprinter DP-460 User manual

N5-Y1071 2002.12
DUPRINTER
Ver.2
DP-460/DP-440
DP-430/DP-340
DP-330/DP-330L
SERVICE MANUAL
Be sure to read this manual carefully, so that you
repair and service this machine safely and
correctly. Do not begin work until you have
thoroughly understood the contents of this manual.
Repairing or servicing the machine with insufficient
knowledge about it could lead to unforeseen
accidents or falls in the machine's performance or
quality.
DUPLO SEIKO CORP.

1
Introduction
The cause of most accidents is failure to adhere to basic safety rules and observe
safety instructions. It is important to prevent potential causes of accidents from
occurring. In order to do so, read this manual carefully, and be sure to understand
all the safety instructions and correct inspection and servicing procedures that it
provides before beginning repair or servicing work.
Repairing or servicing the machine with insufficient knowledge about it could
lead to unforeseen accidents.
It is not possible to anticipate and describe in a manual such as this every possi-
ble hazard that could arise in the course of repair and servicing. Therefore, besides
observing the safety instructions marked in this manual and on the machine's
labels, service personnel should be safety-conscious and take other safety precau-
tions as necessary. When performing repair or service work not covered by this man-
ual, you should obtain safety guidance from an appropriately knowledgeable person.
Copyright 2002
DUPLO SEIKO CORPORATION
All Rights Reserved

2
'Safety-related instructions
If the instructions accompanying this symbol are ignored and the
machine is operated incorrectly, death or serious injury is likely to
result.
If the instructions accompanying this symbol are ignored and the
machine is operated incorrectly, death or serious injury, or else material
damage, is likely to result.
WARNING:
CAUTION:
Examples of pictorial symbols
A " " symbol tells you that a certain action is forbidden. Precisely what
is forbidden is indicated by a picture inside the symbol (in the example
here, the picture means that disassembly is forbidden), or in writing at the
side of the symbol.
A " " symbol means that a certain action is forbidden and/or that a
specific instruction must be followed. The specific instruction is indicated
by a picture inside the symbol (in the example here, the instruction is
"Remove the power plug from the socket").
IMPORTANT:
NOTE:
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.
Draws attention to information that is useful for operation or maintenance
of the machine, and to information about its performance, etc.
DUsing the service manual
• This manual contains the following information: structure and function of major parts,
disassembly and reassembly procedures, specifications, and procedures for adjustment,
maintenance, inspection and corrective action. This information is current as of December
2002, and applies basically to the model DP-460/440/430/340/330/330L DUPRINTER.
From time to time, parts are changed to improve quality, performance or safety. Note therefore
that in some cases, certain parts or machine structure aspects described in the text or
illustrations of this manual may not be precisely the same as the product being serviced.
• Safety instructions marked with a " " (WARNINGS and CAUTIONS) are very important for
safety and must be observed.

3
Safety instructions
Safety instructions
Safety instructions
1. Cautions regarding the installation location
Installation environment
s Avoid installing the machine in places exposed to direct sunlight.
• Sunlight will cause the temperature in the machine's interior to rise, possibly leading to
malfunction of the control system.
• Sunlight could cause misoperation of the sensors.
• The heat of direct sunlight could cause deformation of the machine's plastic parts.
* Also avoid installation near to a ground glass window; light and heat penetrate such windows
although they are opaque.
s Avoid installing the machine in places subject to high or low temperature or humidity.
• High or low temperature or humidity could cause the machine to operate abnormally.
Suitable temperature and humidity ranges are:
Ambient temperature: 10y430y
Ambient humidity: 40%470%
Optimum temperature and humidity: 20y, 65%
• If the machine is installed near to faucets, water heaters or humidifiers, or in cool (sunless)
parts of a building or in the vicinity of water sources, the paper could absorb moisture and curl,
leading to misfeeds or poor image quality.
sAvoid 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.
sAvoid installing the machine in poorly ventilated places.
sAvoid installing the machine in dusty places.
sThe machine should not be tilting when it is used.
• Install the machine so that it is level.
(The machine should be level to within 5mm in the front-rear direction, and 5mm in the lateral
direction.)
sDo 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.

4
Safety instructions
Warning
• The machine's power supply voltage and power consumption depend on the model. Details of this
are given in the tables below. The power supply voltage and power consumption for the machine
are given in the table below. The machine's power supply voltage is indicated on the identification
plate located on the machine's left side; the machine must be connected to a power supply of the
voltage indicated.
aOtherwise, 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.
Connect to outlet of 120V AC, 60Hz, at least 15A
With no load*
At full load
Power consumption
No more than 130V AC
At least 110V AC
During platemaking : 250W
During printing at speed 3 (printing speed) :230W
On standby : 60W
Power supply voltage
}
Use power supply meeting these requirements
Connect to outlet of 230V AC, 50Hz, at least 8A
With no load*
At full load
Power consumption
No more than 250V AC
At least 210V AC
During platemaking : 250W
During printing at speed 3 (printing speed) :230W
On standby : 60W
Power supply voltage
}
Use power supply meeting these requirements
* 120V AC model
* 230V AC model
* "With no load" - when the machine is on standby.
* "At full load" - when the machine is running at maximum power consumption.
• Use only the power cord that is provided among the accessories.
Insert the power cord plug firmly into the socket, so that proper electrical contact is effected.
• Install the machine close to its power supply. The outlet used should be exclusively for the
machine, and have no other equipment connected to it.
If an extension cord is necessary, it should have a ground terminal, and be of the following ratings:
* For a 120V AC model: 130V, at least 15A, length not exceeding 5m.
* For a 230V AC model: 250V, at least 8A, length not exceeding 5m.
• Never tread on the power cord or pinch it between other objects, or accidents could result.
2. Cautions for installation work
• Install the machine in accordance with the installation procedure appended to this manual.
• Lock the casters after the machine is installed.
aOtherwise, the machine could move or fall over, causing injury.
• To move the machine, push it by its mounting base.
aPushing the printing (upper) part of the machine could make it fall over.
CAUTION
Using the optional printer stand

5
Safety instructions
'Precautions for safe servicing
• Always remove the power cord plug from the outlet before starting work.
aOtherwise, 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.
aOtherwise, your hands/fingers could be injured.
• Do not touch the drum or rollers after turning on the jog switch.
• Do not put your hands or fingers inside the machine while the drum is rotating.
aOtherwise, your hands/fingers could get caught and crushed between the drum and rollers.
'Working clothes
• Wear clothing than enables you to work safely.
Warning
'Tools
• Use tools that are appropriate for the work.
CAUTION
3. Cautions for maintenance, inspection and servicing
• The tape clusters have hazardous blades. Exercise care when inspecting or replacing the
blades.
aOtherwise, your hands/fingers could be injured.
If optional tape clusters are used

tM7-T3060 1Caution Sticker 1
Caution Sticker 2
6
Safety instructions
DLocations of warning stickers
The locations of the machine's warning stickers are shown below. To ensure safe work, read the
stickers and heed their instructions. Keep the stickers clean at all times. If they become damaged
or peel off, replace them with new ones.
No. Parts No. Name Q'ty
qL1-T3060 Warning Sticker 1 1
wL5-T3020 Warning Sticker 2 2
e
r
M7-T3030
L8-T1090 Warning Sticker 3
Warning Sticker 4 1
1
View A
View A
M7-T3060
CAUTION
WARNING
Do NOT put hands inside machine
while it is operating.
Hands could get caught up
or crushed.
WARNING
● Do not remove this cover. The inside of the printer contains movable cutting instruments,
contact with which could result in injury.
L5-T3020
Do NOT touch the drum or rollers
when you operate the jog switch.
Do NOT put hands Inside
machine while it is operatung.
Hands could get caught up
or crushed.
WARNING
N5-T3010
Do not touch the roller below. Your clothes etc. may be stained with ink.
CAUTION
L8-T1090
WARNING
Use caution when working
near movable parts.
Disconnect power before
servicing.
q
t
y
e
wr
yN5-T3010 1

7
Chapter 8
Chapter 7
Chapter 6
Chapter 5
Chapter 4
Chapter 3
Chapter 2
Chapter 1
HELP Mode
Others
Troubleshooting
Maintenance / Check
Standard / Adjustment
Mechanism
Description of the Operation
Introduction

9
Table of Contents
Chapter 1
zFeatures................................................................................12
xSpecifications ......................................................................14
cDimensions ..........................................................................16
vSystem Setup.......................................................................18
bPart Names and Their Functions........................................19
nOperation Procedures.........................................................26
Chapter 2
z Scanner Section.........................................................30
x Platemaking/Master Feed/Ejection Section.............40
c Paper Feed Section ...................................................66
v Drum Driving Section................................................79
b Press Section.............................................................85
n Paper Ejection Section..............................................90
m Drum Section .............................................................97
, Option .......................................................................109
Chapter 3
z Exterior .....................................................................112
x Scanner Section.......................................................118
c Platemaking/Master Feed/Ejection Section...........125
v Paper Feed Section .................................................132
b Drum Driving Section..............................................137
n Paper Ejection Section............................................139
m Drum Section ...........................................................144
Chapter 4
z Scanner Section.......................................................154
x Platemaking/Master Feed/Ejection Section...........156
c Paper Feed Section .................................................164
v Drum Driving Section..............................................169
b Press Section...........................................................171
n Paper Ejection Section............................................173
m Drum Section ...........................................................175
, Electrical System.....................................................179
. Option .......................................................................188
Chapter 6
z Troubleshooting Guide ...........................................194
x Error Display ............................................................211
Chapter 7
Chapter 8
z Electrical Parts Layout and Their Functions.........314
x Overall Wiring Layout..............................................325
z HELP Mode List .......................................................214
x Overview...................................................................218
cHELP Mode Functions and Operation Procedures .......219
(1)Accessing HELP Modes......................................219
(2)Guide to the HELP Mode Descriptions..............219
• HELP Mode Descriptions .....................................220
Introduction.................................................................................1
Using the service manual ..........................................................2
Safety instructions ...............................................................3
1.Cautions regarding the installation location........................3
2.Cautions for installation work...............................................4
3.Cautions for maintenance, inspection and servicing .........5
• Locations of warning stickers................................................6
Troubleshooting
Chapter 5
z Guaranteed Periodical Maintenance......................190
x Cleaning and Oiling.................................................190
c Periodical Maintenance...........................................191
Maintenance / Check
Standards / Adjustment
HELP Mode
Others
Mechanism
Description of the Operation
Introduction