PP-100 Chapter1 PDF

Confidential
Service manual
Issued Date , ,
Issued by
English
411384703
Rev. D
Confidential PP-100 Service Manual
CONFIDENTIALITY AGREEMENT
BY USING THIS DOCUMENT, YOU AGREE TO ABIDE BY THE TERMS OF THIS AGREEMENT. PLEASE RETURN
THIS DOCUMENT IMMEDIATELY IF YOU DO NOT AGREE TO THESE TERMS.
❏ This document contains confidential, proprietary information of Seiko Epson Corporation or its affiliates. You
must keep such information confidential. If the user is a business entity or organization, you must limit disclosure
to those of your employees, agents, and contractors who have a need to know and who are also bound by
obligations of confidentiality.
❏ On the earlier of (a) termination of your relationship with Seiko Epson, or (b) Seiko Epson’s request, you must
stop using the confidential information. You must then return or destroy the information, as directed by Seiko
Epson.
❏ If a court, arbitrator, government agency, or the like orders you to disclose any confidential information, you must
immediately notify Seiko Epson. You agree to give Seiko Epson reasonable cooperation and assistance in the
negotiation.
❏ You may use confidential information only for the purpose of operating or servicing the products to which the
document relates, unless you obtain the prior written consent of Seiko Epson for some other use.
❏ Seiko Epson warrants that it has the right to disclose the confidential information. SEIKO EPSON MAKES NO
OTHER WARRANTIES CONCERNING THE CONFIDENTIAL INFORMATION OR ANY OTHER
INFORMATION IN THE DOCUMENT, INCLUDING (WITHOUT LIMITATION) ANY WARRANTY OF TITLE
OR NON-INFRINGEMENT. Seiko Epson has no liability for loss or damage arising from or relating to your use of
or reliance on the information in the document.
❏ You may not reproduce, store, or transmit the confidential information in any form or by any means (electronic,
mechanical, photocopying, recording, or otherwise) without the prior written permission of Seiko Epson.
❏ Your obligations under this Agreement are in addition to any other legal obligations. Seiko Epson does not waive
any right under this Agreement by failing to exercise it. The laws of Japan apply to this Agreement.
Cautions
❏ No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any
means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of
Seiko Epson Corporation.
❏ The contents of this document are subject to change without notice. Please contact us for the latest information.
❏ While every precaution has been taken in the preparation of this document, Seiko Epson Corporation assumes no
responsibility for errors or omissions.
❏ Neither is any liability assumed for damages resulting from the use of the information contained herein.
❏ Neither Seiko Epson Corporation nor its affiliates shall be liable to the purchaser of this product or third parties
for damages, losses, costs, or expenses incurred by the purchaser or third parties as a result of: accident, misuse, or
abuse of this product or unauthorized modifications, repairs, or alterations to this product, or (excluding the U.S.)
failure to strictly comply with Seiko Epson Corporation’s operating and maintenance instructions.
❏ Seiko Epson Corporation shall not be liable against any damages or problems arising from the use of any options
or any consumable products other than those designated as Original EPSON Products or EPSON Approved
Products by Seiko Epson Corporation.
EPSON® is a registered trademark of Seiko Epson Corporation.
Rev. D i
Confidential
For Safe Repair and Maintenance Work
Key to Symbols
The symbols in this manual are identified by their level of importance, as defined below. Read
the following carefully before handling the product.
WARNING:
You must follow warnings carefully to avoid serious bodily injury.
CAUTION:
Observe cautions to avoid minor injury to yourself, damage to your equipment, or loss of
data.
Note:
Notes have important information and useful tips on the operation of your equipment.
Safety Precautions on Handling

This section presents important information intended to ensure safe and effective use of this
product. Please read this section carefully and store it in an accessible location.
WARNING:
Shut down your equipment immediately if it produces smoke, a strange odor, or unusual
noise. Continued use may lead to fire or electric shock. Immediately unplug the
equipment.
Only disassemble this product as described in this manual. Do not make modifications to
the unit. Tampering with this product may result in injury, fire, or electric shock.
Never insert or disconnect the power plug with wet hands. Doing so may result in severe
shock.
Do not allow foreign matter to fall into the equipment. Penetration by foreign objects
may lead to fire or shock.
If water or other liquid spills into this equipment, unplug the power cord immediately.
Continued use may lead to fire or shock.
Do not place multiple loads on the power outlet (wall outlet). Overloading the outlet
may lead to fire.
ii Rev. D
Handle the power cord with care. Improper handling may lead to fire or shock.
Do not modify or attempt to repair the cord.
Do not place any object on top of the cord.
Avoid excessive bending, twisting, and pulling.
Do not place cord near heating equipment.
Check that the plug is clean before plugging it in.
Be sure to push the prongs all the way in.
CAUTION:
Do not connect cables in ways other than those mentioned in this manual.
Different connections may cause equipment damage and burning.
Be sure to set this equipment on a firm, stable, horizontal surface. Product may break or
cause injury if it falls.
Do not use in locations subject to high humidity or dust levels. Excessive humidity and
dust may cause equipment damage, fire, or shock.
Do not place heavy objects on top of this product. Never stand or lean on this product.
Equipment may fall or collapse, causing breakage and possible injury.
To ensure safety, please unplug this product prior to leaving it unused for an extended
period.
Do not touch the thermal head or paper feed motor. Wait for the head and the motor
to cool. The head and the motor can be very hot after printing for a long time. Touching
them may cause burns.
Safety Precautions on Maintenance/Repair/Inspection
WARNING:
Remove the power cord and all other cables from this product before disassembly or
reassembly to prevent electrical shock.
To prevent the possibility of electrical shock, do not perform maintenance, repair, or

inspection during a thunderstorm.
Rev. D iii
Confidential
CAUTION:
Wear a grounded wrist band when handling the internal circuit board to prevent
damage from static electricity.
When removing the internal circuit board, place it on an anti-static rubber sheet or
similar surface to prevent damage from static electricity.
Parts on the circuit board may become hot during operation. Therefore, wait
approximately 10 minutes after turning the power off before touching them.
Be careful not to subject the circuit board to shock or vibration, because this may
damage it.
Do not touch the circuit board or cable terminals with your hands to prevent
contamination that may result in a malfunction.
Do not use an alcohol, benzine, thinner, trichloroethylene, or ketone-based solvent to

clean the parts. This type of solvent may damage the plastic and rubber parts.
Wipe off any dirt with a dry or slightly moist cloth. Be sure to remove the power cord from
the outlet at this time.
If you want to use a compressed air product, such as an air duster, for cleaning during
repair and maintenance, never use products containing flammable gas.
Note on Disposal
Note:
Follow current laws or regulations when disposing of the product.
iv Rev. D
About this Manual
Aim of the Manual

This manual was created to provide the information on maintenance and repair required by
technicians who handle this work.
Manual Content
The manual is made up of the following sections:
Chapter 1 Product Overview Describes features and general specifications of

the product.
Chapter 2 Handling Gives information on how to install, handle, and

operate the product.
Chapter 3 Troubleshooting Explains how to troubleshoot problems.
Chapter 4 Disassembly/Assembly Provides step-by-step procedures for

disassembling the product.
Chapter 5 Adjustment Provides methods for adjustment.
Chapter 6 Maintenance Describes routine maintenance procedures, such

as lubrication, cleaning and etc.
Appendix A Parts List and Tool List Provides a parts list, including information on
screw types.
Appendix B Tools for Repair and Provides a list of tools required for servicing the
Adjustment product.
Appendix C Exploded Diagrams Provides exploded diagrams and lubrication

Lubrication Diagrams diagrams of the product.
Rev. D v
Confidential
Contents
For Safe Repair and Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐ii
Key to Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐ii
Safety Precautions on Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐ii
Safety Precautions on Maintenance/Repair/Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐iii
Note on Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐iv
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐v
Aim of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐v
Manual Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐v
Contents
Revision Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐xii
Chapter 1 Product Overview

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐1
Function Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐2
Duplication Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐2
Basic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐3
Duplicating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐3
Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐3
Moving Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐4
Supported Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐4
Softwares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐5
Ink Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐6
Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐6
Auto‐loading Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐6
Stackers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐6
Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐7
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐7
Reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐8
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐9
Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐9
Operation Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐10
LED Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐11
Warning Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐12
LED as Internal Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐12
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐13
Disc Edition Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐13
Label Image Edition Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐14
Duplication Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐14
Manual Cleaning Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐14
System Incorporation Function (TD Bridge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐15
Diagnosing Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐18
Adjustment Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐18
Other Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐18
Dimensions & Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐19
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐19
Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐19
vi Contents Rev. D
Chapter 2 Handling
Names and Functions of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐1
Operation Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐2
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐3
Installing the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐4
Installing the Stacker Sub Assembly (Stacker 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐4
Installing the Stacker Sub Assembly (Stacker 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐4
Installing Stacker 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐5
Handling Stacker 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐6
Connecting the Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐7
Installing/Changing the Ink Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐8
Changing the ink cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐8
Installing/Changing the Ink Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐9
Ink cartridge life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐10
What to do with used ink cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐10
Handling discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐11
Removing Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐11
Transporting the PP‐100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐15
Preparing the Packing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐15
Securing the Auto Loader Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐16
Securing the Stackers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐17
Securing the Front Cover and Ink Cartridge Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐19
Packing with Laminate Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐20
Packing with External Packing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐21
Storing the PP‐100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐21
Chapter 3 Troubleshooting
Repair Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐1
Repair Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐1
Preliminary Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐1
Repair Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐2
Maintenance check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐4
Identifying Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐5
Identifying problems by fault symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐5
Identifying problems by the LED indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐5
Identifying Problems by Fault Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐6
Problems during initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐6
Malfunctions of the auto‐loader mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐10
Malfunctions of the DVD drive mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐12
Malfunctions of the printer mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐14
Identifying Problems by the LED Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐19
Some or all LED indicator(s) is(are) lit or flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐19
Troubleshooting the indicated errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐21
Motor & Sensor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐33
Printer Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐33
Auto Loader mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐33
Rev. D Contents vii

Confidential
Chapter 4 Disassembly/Assembly
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐1
Disassembly/Assembly Part List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐2
Parts shown in Flowchart 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐2
Reference Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐5
Quickest Disassembly Route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐6
Flowchart 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐6
Flowchart 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐7
Flowchart 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐8
Flowchart 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐9
Flowchart 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐10
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐11
Check after disassembly/reassembly/replacement of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐11
Unlocking and Moving the Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐12
Unlocking the Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐12
Moving the Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐13
Disassembly/Reassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐14
Stacker Sub Assembly (Stacker 1, Stacker 2) / Stacker 3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐14
Lower Left Case / Lower Right Case / Foot Rubber;A / Foot Rubber;B Removal . . . . . . . . . . . . . . . . 4‐15
Disc Cover Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐17
Upper Case / Right Case / Left Case Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐18
Operation Panel Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐20
Stacker Frame Cover Sub Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐21
Auto Loader Cover Sub Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐22
Front Case Sub Assembly / Main Power Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐24
Cartridge Cover Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐26
Drive Tray Lever Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐28
Lower Left Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐29
Printer Relay Board Sub Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐30
Stacker Guide Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐31
Right Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐34
Lower A/L Relay Board Sub Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐35
Dust Control Filter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐36
Dust Filter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐37
Upper Rear Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐38
Rear Frame Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐39
DC Fan Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐41
USB Hub Board Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐43
LPS Board Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐45
Upper Left Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐46
Printer Control Board Sub Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐47
DVD Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐50
Upper Drive Frame / DVD Drive Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐55
Power Supply Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐58
Waste Ink Case Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐60
IS Pump Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐61
Loader Board Sub Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐64
Print Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐66
Upper Front Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐69
Auto Loader Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐70
Pick FFC / Upper A/L Board FFC Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐72
Lift HP Detector Sub Assembly / Rotation Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐74
viii Contents Rev. D

Stacker Frame Sub Assembly / Rear Stacker Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐75

IS Cover / Inner Case Sub Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐76
Rotation HP Detector Sub Assembly / Rotation Transmission Gear Removal . . . . . . . . . . . . . . . . . . 4‐78
Ink Cartridge Board Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐82
Left Frame Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐83
Pressure Pump Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐85
Front Frame Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐88
Cartridge Sub Unit Holder / Duct Joint Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐91
Disc Tray Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐94
DF Detection Encoder Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐98
DF Motor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐100
Right Frame Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐103
Inner Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐105
Valve Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐107
CR Scale Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐110
CR Motor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐112
Cartridge Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐115
Mechanism Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐118
Routing the Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐122
USB Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐122
Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐123
Operation Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐123
Auto Loader Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐124
Ink Supply system (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐124
Ink Supply system (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐125
DVD Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐125
Disc Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐126
Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐126
Connector Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐127
Printer Relay Board Sub Assembly (503) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐127
Ink Cartridge Board Assembly (523) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐128
Printer Control Board Sub Unit (537) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐129
Lower A/L Relay Board Sub Assembly (544) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐130
Loader Board Sub Unit (101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐131
LPS Board Assembly (117) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐132
USB Hub Board Assembly (125) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐133
Chapter 5 Adjustment
Adjustment Workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐1
Parts and Units that Require Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐2
Required Adjustments by Part or Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐4
Description of Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐15
Tools for Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐17
Disabling the Cover Detection Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐18
ʺAdjustment Tool for PP‐100/PP‐100Nʺ Basic Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐19
System requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Installation and Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐19
Sequential mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐20
Individual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐20
Error messages of Adjustment Program (Adjustment tool for PP‐100/PP‐100N) . . . . . . . . . . . . . . . . . . . . 5‐21
Mechanical Adjustment (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐23
Platen Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐23
DF Timing Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐27
PF Timing Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐28
Mechanical Adjustment (Auto Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐29
Auto Loader Drive Height Position Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐29
Tray Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐29
Arm Position Initialize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐29
Arm Rotation HP Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐30
Rev. D Contents ix
Confidential
Arm Stacker Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐31
Drive Position Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐33
Lever/Drive Tray Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐37
Disc Pick Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐38
Stacker Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐39
Mechanical Inspection (Auto Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐40
Auto Loader Operation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐40
Double Pick Up Detection On Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐40
Mechanical Inspection (Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐41
DVD‐R Write & Compare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐41
CD‐R Write & Compare & Print Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐41
Mechanical Inspection (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐42
Print Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐42
Mechanical Inspection (Others) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐43
Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐43
Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐43
DVD‐R Write & Compare & Print Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐44
Basic Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐45
Angular Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐45
Bi‐D Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐46
Disc Feed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐47
Print Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐49
Carriage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐50
DF Measurement Initialize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐50
Writing USB‐ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐50
Writing Market ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐50
Head ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐51
INK Charge Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐51
Carriage Measurement worst value setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐51
PRN EEPROM data backup/restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐52
ALD EEPROM data backup/restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐52
Reset a maintenance counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐53
Drive1 unit counters reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐53
Drive2 unit counters reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐53
Accumulate Print Page Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐53
Picker Open Close Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐53
Accumulate Print Pass Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐54
Tube Maintenance Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐54
Waste Ink Protection Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐54
Holder Waste Ink Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐54
Pressure Pump Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐54
Additional Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐55
Cap Free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐55
Get printer information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐55
Pressure Pump Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐55
Manual Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐56
Update Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐56
x Contents Rev. D
Chapter 6 Maintenance
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐1
Cleaning Exterior Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐2
Cleaning Interior Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐2
Cleaning Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐3
Cleaning Printer Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐4
Cleaning Head Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐6
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐7
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐8
Disc Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐8
Cartridge Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐9
Upper Front Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐10
Printer Tray Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐11
DF Driven Pulley Holder (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐12
DF Driven Pulley Holder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐13
CR Driven Pulley Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐14
Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐15
Rotation Transmission Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐16
Auto Loader Unit (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐17
Auto Loader Unit (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐18
Appendix A Parts List and Tool List

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix A‐1
Alphanumeric Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix A‐1
Reference Number Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix A‐7
Screw Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix A‐13
Appendix B Tools
Tools for Repair and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix B‐1
Appendix C Exploded Diagrams and Lubrication Diagrams

Exploded Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix C‐1
No.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix C‐1
No.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix C‐2
No.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix C‐3
No.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix C‐4
No.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix C‐5
No.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix C‐6
No.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix C‐7
No.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix C‐8
Lubrication Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix C‐9
No.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix C‐9
No.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix C‐10
No.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix C‐11
No.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix C‐12
No.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix C‐13
No.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix C‐14
Rev. D Contents xi
Confidential
Revision Sheet
Revision Page Altered Items and Contents
Rev. A All First release
Rev. B All All pages are reviewed and revised.

page 1-3 "Duplicating" on page 1-3 was changed.
page 5-21 Error message for Adjustment Program (Adjustment tool for PP-
page 5-28 100) was added.
page 5-45 "PF Timing Belt Tension Adjustment" on page 5-28 was added.
Made changes in illustration for printout pattern
Rev. C All The specification is changed due to the change of the product
specification.
page 2-15 The packing material is changed due to the change of the ASP.
page 3-2 The repair flow is revised with the addition of the maintenance
check.
page 3-3 "Maintenance check" on page 3-3 was added.
Chapter 4 Assembly procedure is reviewed.
page 5-39 "Stacker Height Adjustment" on page 5-39 was added.
Chapter 6 Lubrication procedure is reviewed.
page Appendix A-1 "Parts List" on page Appendix A-1 was changed.
Rev. D page 4-18 Change of the screw type.

page 4-50 Since the TEAC drive is installed in the shipment for China and
Thaiwan,
page 4-58 the distinction of the drive, between Pioneer and TEAC, is
added.
Change of the screw type.
page 4-70 Illustration change.
page 5-33 Since the TEAC drive is installed in the shipment for China and
Taiwan, the table of adjustment tool for the manufacturers
each is added.
Adjustment procedure to be complied with the drive/jigs is
added.
page 5-39 "Stacker Height Adjustment" on page 5-39: The specification of
page 5-50 the threshold value is modified.
Change of the indication of "Market ID setting"
page Appendix A-1 ("002: Asia" => "002 Australia/china/Taiwan")
page Appendix B-1 "Parts List" on page Appendix A-1 was changed.
page Appendix C-1 Drive Tray Adjust, TEAC was added.
"Exploded Diagrams" on page Appendix C-1 was changed.
xii Rev. D
Confidential PP-100 Series Service Manual
Rev. D xiii
Confidential
xiv Rev. D
Chapter 1
Product Overview
The PP-100 is a professional-use CD/DVD duplicator that automatically burns and prints CDs
or DVDs.
Figure 1-1 External View
Features
Feature includes;
❏ Fully-automated CD/DVD duplication system
• Disc auto-loading with a robotic arm
• Duplicates up to 100 CDs or DVDs at a time
❏ High-quality printing, Easy-to-use, High-reliability
• Print : Six-color dye ink and special image process for CD/DVD media offer
high-quality printing with excellent color brilliance and high
waterproofness.
• Operability: All operations; editing data to be copied, editing label images, burning
and printing, can be made using a single application.
• Reliability : Auto-loading mechanism picks discs up one by one reliably even if the
discs are sticky.
Disc stacking mechanism prevents both sides of discs from being
scratched.
Reliable status indications
•Busy, Error, Ink LEDs
•Status indication by the application
•Ink status indication by the printer driver
Rev. D Product Overview 1-1

Confidential
❏ Compact, small-footprint
❏ Large-capacity ink cartridge per color
❏ Accepts a wide variety of disc types and formats
❏ Offers multiple publishing modes (standard, external output, batch)
❏ Can be controlled by other systems for automatic disc publication using a special software
Function Overview
Function Explanation
Disc edition Specifies data to be copied to a CD or DVD. Selection of disc type and source data, and
editing volume label, attributes of album and title can be made.
Label image edition Creates a label image to be printed on a CD or DVD. Template and background selection,
and locating/editing desire items can be made.
Disc publishing Publishes discs (burns and/or prints CDs/DVDs). Requires only three steps; opening a job, specifying
(duplication) attributes, and publishing. Each process (burning, printing) is handled as a separate job.
Monitor Status of an ongoing job or status of the PP-100 can be checked.
Configuration Selection of duplication mode, stacker setting, or other initial settings can be made.
Duplication Modes
Mode Operation overview
Standard Stacker 1 is used for blank discs, and stacker 2 or 4 is used for Stacker 3 Stacker 1
duplicated (ejected) discs. When stacker 2 is specified,
making up to 50 copies (discs) can be made at a time. By
adding blank discs and removing ejected discs, up to 1,000
copies can be made per job.
Stacker 3 is not used for this mode.
Stacker 2
Stacker 4
External Stacker 1 and 2 are used for blank discs, and stacker 4 is used
output for duplicated (ejected) discs. When automatic blank disc
Stacker 3 Stacker 1
stacker selection is enabled, up to 100 copies can be made
at a time. When the automatic stacker selection is disabled,
the number of copies specified at a time is limited up to 50.
However, a job is interrupted each time stacker 4 becomes
full (the capacity is up to five discs). The specified number of
copies can be made by removing duplicated discs from Stacker 2
stacker 4 each time the stacker becomes full. Stacker 4
Stacker 3 is not used for this mode.
Batch Stacker 1 and 2 are used for blank discs, and stacker 2 and 3
are used for duplicated (ejected) discs. This enables making
up to 100 copies at a time without user intervention. (Stacker Stacker 3 Stacker 1
2 is first used for blank discs, and once all the blank discs are
gone, it used for stacking ejected discs.)
Stacker 3 must have been installed to enable this mode.
Stacker 4 cannot be used for this mode.
Caution: The output stacker is switched to stacker 2
when stacker 3 becomes full. The number of Stacker 2
discs set in the input stacker may differ from
that created in the output stacker.
1-2 Product Overview Rev. D

Basic Specifications
Duplicating
Item No. of copies Conditions
Copying & CD 30 / hour Media : EPSON-approved CD-R

Printing Writing speed : 40x drive speed
Writing data : The PP-100 evaluation data (600 MB)
Print mode/direction :Speed/Bi-directional printing
DVD 15 / hour Media : EPSON-approved DVD-R

Writing speed : 12x drive speed
Writing data : The PP-100 evaluation data (3.8 GB)
Print mode/direction :Speed/Bi-directional printing
Printing only Speed mode 60 / hour Print direction : Bi-directional printing
Quality mode 40 / hour Print direction : Bi-directional printing
Note: Depending on the operating environment or disc quality, the PP-100 may not achieve the above
performance.
Printing
Item Specifications
Print method Inkjet
Print head Nozzles Black : 180 nozzles

Cyan : 180 nozzles
Magenta : 180 nozzles
Yellow : 180 nozzles
Light cyan : 180 nozzles
Light magenta : 180 nozzles
Print resolution Speed : 1,440 × 720 dpi

Quality : 1,440 × 1,440 dpi
Print direction Bi-directional, Uni-directional
[dpi: number of dots per inch (25.4 mm)]
[cps: number of characters per second)]
[cpi: number of characters per inch (25.4 mm)]

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Moving Discs
Item Specifications
Disc conveyance method Belt drive
Disc feed/ejection method Automatic loading/ejection mechanism
Supported Discs
Item Specifications
Dimension Outer diameter: 120 mm {4.72"} ± 0.3 mm {0.02"}

Inner diameter: 15 mm {0.59"} + 0.1 mm {0.004"} /-0 mm
Thickness: 1.2 mm {0.04"} + 0.3 mm {0.01"} /-0.1 mm {0.004"}
Shape • Supports most-commonly used 12cm {4.7"} discs

• The following discs cannot be used:
- Specially-shaped discs
- The height of stacking ring (the small ridge around the inner plastic center
ring on the data side) is less than 0.12 mm.
- The print side is not completely flat.
CD Type CD-R
Label surface Inkjet printable

Note: As for printable glossy discs, only EPSON-approved products are supported.
DVD Type DVD-R, DVD+R, DVD-R DL, DVD+R DL
Label surface Inkjet Printable

Note: As for printable glossy discs, only EPSON-approved products are supported.
CD-R CDR80WPPSB-WS (Taiyo Yuden)

Approved discs
DVD-R DVD-R47WPPSB16-WS (Taiyo Yuden)

Softwares
Item Specifications / Explanation
Applications Total Disc Maker All-in-one application for burning and printing discs.
Total Disc Monitor Indicates statuses of ongoing jobs and devices.
Total Disc Setup For configuring initial settings of the Total DiscMaker
TD Bridge System incorporation tool to use the PP-100 with other companies’
applications.
(Provided separately from the bundled CD)
Printer driver • Total Disc Control Service

(Performs integrates control over auto loading, drive, and printer)
• Printer class driver (Performs print data rendering)
• Storage class driver (Uses Windows standard driver)
• HID class driver (Uses Windows standard driver)
Supported TD Bridge and Japanese and English

languages maintenance tool
Others Japanese, English, French, German, Italian, Spanish, Dutch, and

Portuguese
Minimum system OS Windows Vista SP1 or later 32-bit Home Basic, Home Premium, Business,
requirements Enterprise, Ultimate*1
Windows XP SP2 or later 32-bit Home Edition, Professional
Windows 2000 Professional SP4 or later
CPU Pentium 4 1.4 GHz or higher, or its compatible processor
Memory ❏ 512 MB or larger (Windows 2000, Windows XP)

❏ 1 GB or larger (Windows Vista)
HDD capacity ❏ 10 GB or larger (Windows 2000, Windows XP)

❏ 25 GB or larger (Windows Vista)
HDD speed 7200 rpm or more
Graphic XGA or better
USB interface USB2.0 only (Both A and B requirements shown below must be satisfied)
A: USB2.0 compliant
B: USB2.0 performance is ensured
Note: Hi-Speed USB 2.0 interfaces of ATI chip set South Bridge (IXP460 or earlier) are not
supported.
Number of 65536 colors or more

display colors
Audio Sound devices and corresponding driver must have been installed to
create sound
discs.
*1: When using Vista, use Total Disc Maker Version 1.5 or later.
Note: The PP-100 may not deliver its full performance in environments in which commercially available software
applications for CD/DVD writing and/or virus checking, etc. are installed.
Note: The PP-100 performance may drop if the host computer is also connected to other printers, scanners, hard
disk drives or any other external drives via USB.
Note: The drive to be used for reading source data must support MMC4 or later and be able to read sub channel
data.
Note: Remote Desktop is not available, and use of the product from PCs not connected to the product is therefore
not supported.

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Ink Cartridges
Item Specifications
Cartridge type Individual color cartridges (Off carriage type)
Ink type Dye-based
Color Yellow, Magenta, Cyan, Light cyan, Light magenta, Black
Capacity 1,000 or more prints are available by continuous printing under the following
conditions:
Ambient temp.: Normal room temperature
Print range: 116 - 45 mm {4.57" - 1.77"}
Coverage per color: 16.7 %
Disc type: CD/DVD
Print mode: Quality
Color mode: Natural
Lifetime Two years. Six months after unpacked (included in the two years).
Ambient Packed and -20 ~ 60 °C {-4 ~ 140 °F} Within five days at 60 °C
temperature transported {140 °F}
Packed and -20 ~ 40 °C {-4 ~ 104 °F} Within one month at 40 °C

stored {104 °F}
Installed -20 ~ 50 °C {-4 ~ 122 °F} Within one month at 50 °C

{122 °F}
Dimension 42.0 mm {1.65"} (W) x 83.0 mm {3.28"} (D) x 26.4 mm {1.04"} (H)
Drives
Item Specification
Number of drives (driving Two drives (tray loading method)

method)
Note:Drives specified by PP-100 must be used.
Auto-loading Mechanism
Item Specifications
Pickup arm Disc conveyance Conveys discs during a duplication job.
Disc pickup Picks a disc up and releases it.
Multi-feed Activates a disc kick-function to prevent multiple discs from being fed at a
prevention time.
function
Stackers
Name For loading/taking out discs; Capacity Available duplication mode
Stacker 1 Take the stacker out from the main unit 50 discs All modes
Stacker 2 Take the stacker out from the main unit 50 discs All modes
Stacker 3 Take the stacker out from the main unit 50 discs Batch mode
Stacker 4 Draw the stacker out from the main unit 5 discs Standard, External output mode

Covers
Item Explanation
Disc cover Open/close this cover for loading/taking out discs.
Ink cartridge cover Open/close this cover when replacing the ink cartridges.
Electrical
Item Specification
Rated voltage 100 ~ 240 VAC
Rated frequency 50 ~ 60 Hz
Rated current 1.0 A
Power Operating Approx. 41 W (average)

consumption
Standby Approx. 24 W (average)
Safety approvals Europe CE marking

EMC Directive: 2004/108/EC
EN55022 Class B
EN61000-3-2
EN61000-3-3
EN55024
Safety Standard: Low Voltage Directive: 2006/95/EC
EN60950-1
TUV marking EN60950-1 (TUV)
Russia GOST-R EMC CISPR Pub.22
Safety Standard IEC60950-1
North America EMI:
FCC Part 15 Subpart B Class B
CAN/CAS-CEI/IEC CISPR22 Class B
Safety standard:
UL60950-1
CAN/CSA-C22.2 No.60950-1

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Reliability
Item Specifications
Life Until any one of the following conditions is met.

Number of copies: 30,000 discs
(when printing at 1,440 x 720 dpi Uni-di / Bi-di or at 1,440 x
1,440 dpi Bi-di)
15,000 discs
(when printing at 1,440 x 1,440 dpi Uni-di )
Years: Five years at normal room temperature
Drive life Until any one of the following conditions is met.

Number of opening/closing operations: 30,000 cycles
Writing: 1,000 hours (at room temperature, time ratio: CD = 50%,
DVD = 50%)
Ink absorber life Number of prints: 30,000 discs

Calculation criterion: 2,000 discs per month
Note: The above values may not be reached if manual cleaning is run more than
necessary.
Load capacity The two PP-100 units are vertically stackable. (The four sides of the two PP-100s
Double stack
must be aligned with each other)
294.2 N {30 kgf} (When the load is applied to an area larger than a 60-mm-
Other load
dia circle.)
[Uni-di : Uni-directional printing]

[Bi-di : Bi-directional printing]

Environmental
Item Specifications
1 10 ~ 35 °C {50 ~ 95°F}
Temperature* Operating Within one month at 40°C
{104°F}
Storage -20 ~ 40 °C {-4 ~ 104°F}
Within 120 hours at 60°C
Transporting -20 ~ 60 °C {-4 ~ 140°F} {140°F}
Humidity Operating 20 ~ 80 %RH

Should cause no
Storage 5 ~ 85 %RH
condensation
Transporting 5 ~ 85 %RH
The temperature and humidity combination

should be within the blue-shaded range.
Humidity
(%)
Temperature (°C)
Vibration Operating 0.1 G, 10 ~ 55 Hz

resistance*2
Storage*3 2 G, 5 ~ 55 Hz
X, Y, Z directions
Shock Operating 0.5 G, 11 ms, half sine G: acceleration of gravity
resistance (1G=9.8m/s2)
Storage*3 2 G, 11 ms, half sine
Note: When the packed product is held by its one side
and dropped from 50 cm {19.7"} height.
Noise 45 dB (A) at the operator position
Installation*4*5*6 Must be installed horizontally.
*1: Dot missing may occur after storing the PP-100 for a long time or transporting the PP-100.
*2: The resonance point is excluded from the above frequency range.
*3: The test was conducted with the product packed with the dedicated package.
*4: When storing and transporting the product, turn the power off with the Power switch (the Power LED turns off).
And make sure the print head is covered with the cap.
*5: Transport the product with the ink cartridges installed in the printer.
*6: Avoid excessive dust, dirt, or smoke from cigarettes.
Interface
Item Specifications
Communication Standard Hi-Speed USB

speed
Transfer rate 480 Mbps (High Speed Device)
Connector USB Series B
Cable The one supplied with the product must be used

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Operation Panel
INK LED (Cyan, Light cyan, Light magenta, Magenta, Yellow, Black)
Stacker 1 LED
Stacker 2 LED
Stacker 3 LED
Stacker 4 LED
Power LED
BUSY LED
ERROR LED
Cleaning button
Power switch
Figure 1-2 Operation Panel & Buttons
Item Explanation
Buttons Power switch*

Cleaning button
Indicators (LEDs) Power : Green

BUSY : Green
ERROR : Orange
INK (Cyan) : Orange
INK (Light cyan) : Orange
INK (Light magenta) : Orange
INK (Magenta) : Orange
INK (Yellow) : Orange
INK (Black) : Orange
STACKER (1) : Green
STACKER (2) : Green
STACKER (3) : Green
STACKER (4) : Green
*: When the printer is to be stored or not used for an extended period (around 6 months), set the power switch to
OFF, and disconnect the power cord.

LED Indications
Note:
The following table shows the LEDs statuses using the symbols described below.
ON: LED stays ON, : LED flashes, H: LED flashes at high speed,
OFF: LED stays OFF, --: LED keeps the current status
*: The corresponding INK LED(s) lights ON or flashes.
LED
Error Name Stacker Ink

Power
Busy
Error
1 2 3 4 C LC LM M Y K
Powering OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
Powering ON ON -- -- -- -- -- -- -- -- -- -- -- --
Initializing -- -- -- -- -- -- -- -- -- -- -- --
Standby ON -- -- -- -- -- -- -- -- -- -- -- --
Executing shut-down sequence H -- -- -- -- -- -- -- -- -- -- -- --
Executing a job -- -- -- -- -- -- -- -- -- -- -- --
Cleaning -- -- -- -- -- -- -- -- -- -- -- --
Performing ink sequence -- -- -- -- -- -- -- -- -- -- -- --
Replacing ink cartridge(s) -- -- -- -- -- -- -- -- -- -- -- --
Other errors -- -- ON -- -- -- -- -- -- -- -- -- --
Maintenance request ON ON ON ON ON ON ON ON ON ON ON ON ON
Fatal error OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
Stacker 1 Full -- -- ON ON -- -- -- -- -- -- -- -- --
Not installed, or
installed improperly
-- -- ON -- -- -- -- -- -- -- -- --
No blank discs -- -- -- -- -- -- -- -- -- -- -- --
Height of discs
stacked in the stacker -- -- -- OFF -- -- -- -- -- -- -- -- --
not determined
Stacker 2 Full -- -- -- -- ON -- -- -- -- -- -- -- --
Exceeding the
-- -- ON -- ON -- -- -- -- -- -- -- --
capacity
Not installed, or
-- -- ON -- -- -- -- -- -- -- -- --
No blank discs -- -- -- -- -- -- -- -- -- -- -- --
Height of discs
stacked in the stacker -- -- -- -- OFF -- -- -- -- -- -- -- --
not determined

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LED
Error Name Stacker Ink
Power
Busy
Error
1 2 3 4 C LC LM M Y K
Stacker 3 Full -- -- -- -- -- ON -- -- -- -- -- -- --
Exceeding the
-- -- ON -- -- ON -- -- -- -- -- -- --
capacity
Installed wrongly -- -- ON -- -- ON -- -- -- -- -- -- --
Not installed, or
-- -- ON -- -- -- -- -- -- -- -- --
Height of discs
stacked in the stacker -- -- -- -- -- OFF -- -- -- -- -- -- --
not determined
Stacker 4 Full -- -- -- -- -- -- ON -- -- -- -- -- --
Opening -- -- -- -- -- -- -- -- -- -- -- --
Warning for not

opening
-- H -- -- -- -- H -- -- -- -- -- --
Ink cartridges Ink Low -- -- -- -- -- -- -- * * * * * *

Replace Ink Cartridge -- -- -- -- -- -- -- ON* ON* ON* ON* ON* ON*
Warning Buzzer
Item Description
Purpose Notifies the user that the cover is opened during duplication process, which may
cause a quality problem, or warns the user not to insert hands into the product or
move the stackers while the auto loader is operating.
Buzzer pattern The buzzer sounds for 0.5 seconds five times at interval of 0.2 seconds. The cycle is
repeated four times at interval of 1.5 seconds.
Note: The buzzer is stopped as soon as an operation for pausing the job is performed even if the buzzer pattern
described above has not finished.
LED as Internal Light
Item Description
Purpose Opening/closing the cover in the middle of a duplication job may adversely affect the
duplicated discs quality due to the vibration or impact caused by the opening/closing
operations. This LED allows the user to see the discs inside the machine without
opening the cover.
Location Provided at the top end of the arm.

Functions
Disc Edition Function
Item Explanation
Function Data edition • Creates and edits data to be written to a disc.

• Writes data to a disc.
• Stores data to be written to the hard disk as a disc image file.
Copy • Specifies a drive or a disc image file to be copied.

• Writes specified copy source data.
The table below shows the availability of functions by disc type and format.
O: both creation and compare are supported. @: Only creation is supported.
Data
Copy Function*2
Edition
(For discs with data written using Disc-at-once mode)
Function
Media Type Disc Disc Image*3
Creation*1 Direct copy of

Disc image Disc image
created using edited with the
the master disc
the master disc Total Disc Maker
CD-R Data ISO9660 Level2 O O @ O
Jolit O O @ O
UDF 1.02 O O @ O
UDF Bridge O O @ O
Hybrid CD O O @ O
Music CD-DA @ @ @ @
CD-Text @ @ @ @
Data & music CD-Extra @ @ @ @
Video Video-CD O O @ O
DVD +/-R Data ISO9660 Level2 O O O O

(DL)
UDF 1.02 O O O O
UDF Bridge O O O O
*4
Video DVD-Video O O O O
*1: Once data is written to a disc, you cannot add more data to the disc.
*2: Copying discs created with Disc-at-once is supported. Copying discs of multiple sessions and discs on which
contents are recorded with packet write is not supported.
*3: Disc image files saved by the Total Disc Maker data edition function.
*4: When duplicating a DVD-Video, use an original whose duplication is confirmed. However, some players cannot
play the duplicated DVDs due to their compatibility.

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Label Image Edition Function
Item Explanation
Function • Creates a label data to be printed on discs.

• The created label data is printed by the duplication function.
• Stores the created label data as a template, or exports the data as an image file.
Template The user can use preset templates or templates pre-stored by the user for label
creation.
Background None / Solid color / Gradation / Image (bitmap)
Item Text / Image (bitmap) / Thumbnail / Tree / Graphic (line, rectangle, ellipse)/Bar codes
(JAN/EAN(8,13), ITF, CODE128, PDF417, QR (Model 2))
Duplication Function
Item Explanation
Function • Controls the built-in auto loader, drive, and printer to print labels on discs.
• Depending on the specified number of copies, the built-in two drives and
one printer are used efficiently.
• While the job is in progress, Total Disc Monitor allows the user to check the
job status, the PP-100 status, and error occurrence.
Job selection Write data / Print label / Write data + Print label
Output device selection Output device / Stacker for blank discs, Stacker for ejected (duplicated)
discs
Writing CD 40X at maximum

speed *1*2
DVD-R, DVD+R 12X at maximum
DVD-R DL, DVD+R DL 8X at maximum
Print Label type CD/DVD label / High quality CD/DVD label / EPSON approved CD/DVD label
setting*3
Print mode Quality/Speed
Number of Standard mode 1 ~ 1,000

copies
Batch mode 1 ~ 100
External output 1 ~ 100 (when enabling auto detection of stacker for blank discs)
mode 1 ~ 50 (when Not enabling auto detection of stacker for blank discs)
*1: Even if discs that support the write speed higher than the above are used, the above speed is always applied in
order to ensure the write quality.
*2: Depending on the disc quality, the write speed may become slower than that specified by the user.
*3: The "Quality" mode is available only when EPSON-specified CD/DVD labels are used.
Manual Cleaning Function
Item Explanation
Basic Press and hold the cleaning button on the PP-100 for three seconds or longer. (The PP-100 must
operation*1 have been connected to a computer)
Basic function • Clears print head nozzle clogging.

• Ensures the print quality.
• The user can check if nozzle clogging is cleared by printing a nozzle check pattern.
*1: The cleaning button is disabled while a job is being processed. Run cleaning while the JOB is suspended or after
canceling the job.

System Incorporation Function (TD Bridge)

A hot folder (monitoring folder) type system incorporation tool is downloadable from Web.
Functions
Publishes CDs and DVDs from user’s system using an incorporating application developed to
control TD Bridge.
❏ Publishes discs by copying a JOB description file (JDF file) that specifies write data and print
data to a hot folder (a monitoring folder).
❏ Monitors the status of JOB and devices with a status file (STF file).
❏ Controls (cancels) JOBs with a JOB cancel file (JCF file).
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䎳䎳䎐䎔䎓䎓

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Specifications
❏ Monitoring folder
A local drive in the user PC to which the PP-100 is connected must have a monitoring folder.
❏ Specifying the write data with a JDF file
• Direct file specification
• Direct folder specification
• Indirect file specification
• No specification (Version 1.50 or later): Specify the JOB to print only.
❏ Supported media formats
S: both creation and compare are supported. C: Only creation is supported. N: Creation not supported.
Data
Copy Function*2
Edition
(For discs with data written using Disc-at-once mode)
Function
Media Type Disc Disc Image*3
Creation*1 Direct copy of

Disc image Disc image
created using edited with the
the master disc
the master disc Total Disc Maker
CD-R Data ISO9660 Level2 S N C S
Jolit S N C S
UDF 1.02 S N C S
UDF Bridge S N C S
Hybrid CD N N C S
Music CD-DA C N C C
CD-Text C N C C
Data & music CD-Extra N N C C
Video Video-CD S N C S
DVD +/-R Data ISO9660 Level2 N N S S

(DL)
UDF 1.02 S N S S
UDF Bridge S N S S
Video DVD-Video*4 S N S S
*1: Once data is written to a disc, you cannot add more data to the disc.
*2: Copying discs created with Disc-at-once is supported. Copying discs of multiple sessions and discs on which
contents are recorded with packet write is not supported.
*3: Disc image files saved by the Total Disc Maker data edition function.
*4: When duplicating a DVD-Video, use an original whose duplication is confirmed. However, some players cannot
play the duplicated DVDs due to their compatibility.

❏ Specifying the print data with a JDF file
• Direct file specification
• No specification: Specify the JOB to write only.
❏ Supported file formats
• tdd files
• PRN files
• General image files (*1): JPEG, PNG, TIFF, BMP
*1: Margins, register marks, and other parts unnecessary for printing must not be included. The label
design must be arranged in the center of the image.
❏ Merge print
Can replace arbitrary text data and bar codes in a tdd file with specified data.
❏ Status that STF file can monitor
• JOB status
• PP-100 status
• Ink cartridge status
• Type of error that has occurred
❏ JOB control with a JCF file
• JOB cancellation
Specify the ID of the JOB to cancel.

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Diagnosing Function
The following items are provided for checking printing conditions.
Check item Required tool Explanation
Nozzle clogging Printer driver A nozzle check pattern can be printed for checking nozzles for
clogging.
Gap adjustment Printer driver A gap adjustment pattern can be printed for checking the gap.
Print position adjustment Printer driver A print position adjustment pattern can be printed for checking
the print position.
Firmware version Total Disc Setup The currently installed firmware version can be checked.
Adjustment Function
The following adjustment items for printing are provided.
Item Required tool Explanation
Gap adjustment Printer driver Adjusts the head gap.§
Print position correction Printer driver Print starting position can be corrected.
Other Functions
Function Explanation
Monitor Indicates job status, the PP-100 status, ink status, and error occurrence. Pausing,
resuming, or canceling jobs can be made.
Environmental setting Registers the PP-100 and makes settings for using the PP-100 in a system.
The setting items are as follows:
• Duplication method and type of blank discs
• Drive usage method, and number of write retries
• Printer driver to be used and its property
• Error mark addition
Non-Epson application Label data created using other application can be printed by the PP-100 through the
support printer driver.
Intersystem coordination A hot folder (monitoring folder) type system incorporation tool is downloadable from
Web.

Dimensions & Weight

Item Specification
Outer dimensions 377 mm {14.8"} (W) x 465 mm {18.3"} (D) x 348 mm {13.7"} (H)
Approx. 24 kg (including the stackers and ink cartridges. excluding the AC cable and
Weight
discs)
377 mm
465 mm
348 mm
Figure 1-3 Dimensions
Consumables
❏ Ink cartridge Cyan: PJIC1 (C)
❏ Ink cartridge Light cyan: PJIC2 (LC)
❏ Ink cartridge Light magenta: PJIC3 (LM)
❏ Ink cartridge Magenta: PJIC4 (M)
❏ Ink cartridge Yellow: PJIC5 (Y)
❏ Ink cartridge Black: PJIC6 (K)
Option
Intersystem coordination tool "TD Bridge"

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Chapter 2
Handling
This chapter explains the installation, handling, and operation of the unit.
Names and Functions of Parts
Front Rear
Operation Panel Assembly USB interface connector Interface cable
Fixing saddle
Disc Cover Assembly AC Inlet
Cartridge Cover Assembly Main Power Switch Disc Access Cover Air vent
Interior
Picker Arm Assembly

DVD Drive 1
Stacker Sub
DVD Drive 2 Assembly
(Stacker 1)
Printer
Stacker Sub
Stacker 3 Assembly
(Stacker 2)
Stacker 4 Lock Lever
Rev. D Handling 2-1

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EPSON® is a registered trademark of Seiko Epson Corporation.

Safety Precautions on Handling

Safety Precautions on Maintenance/Repair/Inspection

To prevent the possibility of electrical shock, do not perform maintenance, repair, or

Do not use an alcohol, benzine, thinner, trichloroethylene, or ketone-based solvent to

About this Manual

Aim of the Manual

Chapter 1 Product Overview Describes features and general specifications of

Chapter 2 Handling Gives information on how to install, handle, and

Chapter 3 Troubleshooting Explains how to troubleshoot problems.

Chapter 4 Disassembly/Assembly Provides step-by-step procedures for

Chapter 5 Adjustment Provides methods for adjustment.

Chapter 6 Maintenance Describes routine maintenance procedures, such

Appendix C Exploded Diagrams Provides exploded diagrams and lubrication

Chapter 1 Product Overview

Rev. D Contents vii

viii Contents Rev. D

Stacker Frame Sub Assembly / Rear Stacker Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐75

Appendix A Parts List and Tool List

Appendix C Exploded Diagrams and Lubrication Diagrams

Revision Page Altered Items and Contents

Rev. A All First release

Rev. B All All pages are reviewed and revised.

Rev. D page 4-18 Change of the screw type.

Figure 1-1 External View

• Disc auto-loading with a robotic arm

• Duplicates up to 100 CDs or DVDs at a time

❏ High-quality printing, Easy-to-use, High-reliability

Rev. D Product Overview 1-1

❏ Large-capacity ink cartridge per color

❏ Accepts a wide variety of disc types and formats

❏ Offers multiple publishing modes (standard, external output, batch)

Monitor Status of an ongoing job or status of the PP-100 can be checked.

1-2 Product Overview Rev. D

Item No. of copies Conditions

Copying & CD 30 / hour Media : EPSON-approved CD-R

DVD 15 / hour Media : EPSON-approved DVD-R

Printing only Speed mode 60 / hour Print direction : Bi-directional printing

Quality mode 40 / hour Print direction : Bi-directional printing

Print method Inkjet

Print head Nozzles Black : 180 nozzles

Print resolution Speed : 1,440 × 720 dpi

Print direction Bi-directional, Uni-directional

[dpi: number of dots per inch (25.4 mm)]

[cps: number of characters per second)]

[cpi: number of characters per inch (25.4 mm)]

Rev. D Product Overview 1-3

Disc conveyance method Belt drive

Disc feed/ejection method Automatic loading/ejection mechanism

Dimension Outer diameter: 120 mm {4.72"} ± 0.3 mm {0.02"}

Shape • Supports most-commonly used 12cm {4.7"} discs

Label surface Inkjet printable

DVD Type DVD-R, DVD+R, DVD-R DL, DVD+R DL

Label surface Inkjet Printable

CD-R CDR80WPPSB-WS (Taiyo Yuden)

1-4 Product Overview Rev. D

Item Specifications / Explanation

Total Disc Monitor Indicates statuses of ongoing jobs and devices.

Printer driver • Total Disc Control Service

Supported TD Bridge and Japanese and English

Others Japanese, English, French, German, Italian, Spanish, Dutch, and

CPU Pentium 4 1.4 GHz or higher, or its compatible processor

Installation45*6 Must be installed horizontally.

Executing shut-down sequence H -- -- -- -- -- -- -- -- -- -- -- --

Performing ink sequence -- -- -- -- -- -- -- -- -- -- -- --

Replacing ink cartridge(s) -- -- -- -- -- -- -- -- -- -- -- --

Ink cartridges Ink Low -- -- -- -- -- -- -- * * * * * *