As you seem to have covered all the mechanical bases, you might try clearing
DC-Con and re-entering your data.
BUT ONLY DO SO AFTER OBTAINING A P-PRINT OR LABEL PRINT!!
Failure to have those printouts stored with the machine will be a grave mistake.
You can try the Clear operation and test the print registration without re-entering
the saved settings yet. You will know right away if that helped, but by all means,
do re-input those settings.
good luck
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