Page 1 DL7400 DOT MATRIX PRINTER MAINTENANCE MANUAL FUJITSU ISOTEC LIMITED...
Page 2 Revised contents March 2007 First issue Specification No.C147-F051-01EN The contents of this manual may be revised without prior notice. All Rights Reserved, Copyright © 2007 FUJITSU ISOTEC LIMITED. No part of this manual may be reproduced in any form without permission.
Page 3 Hayes Park Central, Phone: (886-2) 2311-2255 Hayes End Road, Fax: (886-2) 2311-2277 Hayes, Middlesex UB4 8FE, U.K. FUJITSU SYSTEMS BUSINESS (THAILAND) LTD. Phone:(44-20) 8573-4444 Exchange Tower, 22nd-23rd Fl, 388 Sukhumvit Road, Fax:(44-20) 8573-2643 Kwaeng Klongtoey, Khet Klongtoey, Bangkok 10110, Thailand...
Page 4 PREFACE This manual is for engineers who operate, install, or maintain the DL7400 printer, and covers: Chapter 1: Printer specifications, performance, and configuration Chapter 2: Unpacking, performance check, and connection Chapter 3: Troubleshooting Chapter 4: Maintenance Chapter 5: Principles of operation...
Page 5 CONTENTS CONTENTS..............................5 CHAPTER 1 PRINTER SPECIFICATIONS, PERFORMANCE, AND CONFIGURATION ......9 1.1 Overview............................9 1.2 Equipment Structure ........................9 1.2.1 Overview............................9 1.2.2 Model configuration........................9 1.2.3 Structure ..........................10 (1)Exterior components........................12 (2)Printing mechanism ........................14 (3) Lower cover ..........................16 (4) Option and consumables ......................17 CHAPTER 2 UNPACKING, PERFORMANCE CHECK, AND CONNECTION ........18 2.1 Overview............................18 2.2 Notes on Installation ........................18 2.3 Unpacking............................19...
Page 6 CHAPTER 4 MAINTENANCE ......................36 4.1 Overview............................36 4.2 Notes on USE..........................36 4.3 Maintenance Tools ........................36 4.4 Maintenance levels ........................37 4.5 Preventive Maintenance ........................37 4.6 Part Drawings ..........................37 4.7 Parts That must not be Disassembled ...................38 4.8 Level 1 Maintenance........................39 4.9 Level 2 maintenance........................40 4.9.1 Parts replacement........................40 (1) Tractor Unit removal and installation Front feed tractor.
Page 7 (31) HCPP Motor replacement .......................75 (32) SP FAN replacement ......................76 (33) INLK SW ASY replacement ....................77 (34) PS PCA replacement ......................78 (35) HCPP switch ASY replacement ....................79 (36) Sensor cover TR/TR PES ASY replacement ................80 (37) Ribbon Rope ASY replacement ....................81 (38) Card Guide ASY replacement....................82 (39) TOFL/R sensor ASY replacement...................84 (40) Carriage Unit and Stay Shaft replacement................85...
Page 8 5.2.1.2 Spacing operation ......................121 5.2.1.3 LRES (Carriage position) detection..................122 5.2.1.4 Ribbon feed mechanism ....................123 5.2.1.4 Automatic paper thickness control mechanism ..............124 5.2.1.5 Skew detection.........................125 5.2.2 Paper Feed Operation......................126 5.2.2.1 Paper path selection mechanism (HCPP) ................126 5.2.2.3 Paper feed operation......................128 5.2.2.4 Paper loading and ejection operation (auto loading) ............131 5.3 Electrical Operation ........................132 5.3.2 Printed Circuit Boards and Basic Configuration ..............132 5.3.2.1 Outline of Printed Circuit Boards ..................133...
Page 9 CHAPTER 1 PRINTER SPECIFICATIONS, PERFORMANCE, AND CONFIGURATION 1.1 Overview This manual is for maintenance engineers, and covers overall DL7400 printer maintenance, together with detailed information such as troubleshooting and component replacement. Recommended references are: DL7400 Printer Parts Catalogue (P3KA02038-B001/E) DL7400 Printer Schematic Diagrams (C1KA02038-B001/E) These three manuals contain all information needed for DL7400 maintenance.
Page 10 TR motor HCPP motor Power supply HCPPHP SW Connector Board Reactor PS Sensors AC SWITCH assembly Nip Roller assembly FTRPE Sensors AC INLET assembly Dv Roller assembly RTRPE Sensors Platen Roller assembly Lower cover assembly Figure 1.1 Structure of DL7400...
Page 11 APTCHP sensor Mecha Unit HCPP Connector board Motor motor INTER HCPPHP LOCK Motor FTRPE sensor sensors Motor 1 Motor driver Motor 2 Option board RS232C/LAN ROM Board Centro Power supply Control Panel FCSF inlet Figure 1.2 Block Diagram of DL7400...
Page 12 (1)Exterior components This section gives information on exterior components of the printer: covers, removable mechanism units,etc. Figure 1.3 Exterior components of DL7400...
Page 13 The interface cable connector is on the right side of the printer, as seen from the front of the upper cover, so the interface cable does not interfere with the paper feed path. Figure 1.4 Interface type of DL7400 b. Front cover The front cover is opened to replace the ribbon cartridge.
Page 14 (2)Printing mechanism Stay shaft Carriage Ribbon cartridge Stepping motor for Print head carriage drive mechanism HCPP motor APTC mechanism Paper feed mechanism HCPP mechanism Figure 1.6 Mechanism of DL7400...
Page 15 The printing mechanism fit into the bottom cover. And Upper Cover holds it in position. a. Carriage The carriage supports the removable 24-wire print head and the ribbon cartridge, and slides left and right on the stay shaft. The ribbon feed gear system moves the ribbon in one direction regardless of carriage movement.
Page 16 (only 100-120v) AC inlet CSF connector Lower cover Figure 1.7 Electric components of DL7400 a. Lower cover The Lower cover supports the printer mechanism and electric units as follows. b. ROM board (control board with flash ROM) The ROM board controls the host interface, control panel, and printing mechanism using an MPU and an LSI circuit.
Page 17 Cut-sheet feeders A cut-sheet feeder allows both single-part cut sheets and multi-part cut sheets to be fed automatically. The SF94 single-bin feeder is available for DL7400. b. Tractor unit An additional tractor unit can be installed in the printer. Because the standard tractor unit is installed at the front of the printer at shipment, the additional tractor is installed at the rear of the printer.
Page 18 CHAPTER 2 UNPACKING, PERFORMANCE CHECK, AND CONNECTION 2.1 Overview The DL7400 printer comes packed for transportation. After unpacking and before installation, the printer must undergo self-test printing. Installation requires minimum time and expense. 2.2 Notes on Installation For best results, note the following points when installing the paper: Place the printer on a level, vibration-free surface.
Page 19 2.3 Unpacking Unpacking the printer as follows(Figure 2.1) 1. Open the carton and remove Rear stacker, Ribbon cartridge and Cushion L/R. 2. Lift up the printer using the grip at right and left of the printer. 3. Take out accessories (Power cord, Manual). Figure 2.1 Unpacking the printer and accessories...
Page 20 4. Set the paper table as follows. Figure 2.2 Setting the paper table 5. Remove the Block FC. 6.Open the front cover and remove the cardboard shipping restraint holding the carriage in place Figure 2.3 Removing the shipping materials 7.Store the original shipping carton and packing materials for future use in moving or shipping the printer.
Page 21 2.4 Inspection after Unpacking 1. Carefully check assemblies and accessories for visible damage. 2. Install the ribbon cartridge. See the User’s Manual for details. 3. Check the rated voltage or the printer and AC power outlet, then connect the AC power cord between the printer and AC power outlet.
Page 22 CHAPTER 3 TROUBLESHOOTING This chapter helps pinpoint the causes of problems with the printer. Section 3.1 is a troubleshooting table. The table shows how to determine what is wrong with the printer and what to do to correct the problem. Section 3.2 explains error displays on the control panel that help clarify the cause of a problem.
Page 23 3.1.1 Problems at power-on initialization (part 002/3) Symptom Cause Response 3 The POWER lamp is After the POWER lamp goes The control board Replace and initialize on, simultaneous blinking of is defective. the control board. all other lamps is not performed.
Page 24 3.1.1 Problems at power-on initialization (part 003/3) Symptom Cause Response 4 The PAPER OUT lamp After the POWER lamp goes A ROM or RAM Replace and initialize blinks. on, simultaneous blinking of alarm is detected. the driver board. all other lamps is not Low-voltage alarm is •...
Page 25 3.1.2 Problems related to printing (part 001/2) Symptom Cause Response 1 The POWER lamp goes Turn off the power, then wait The accidental fire • It’s difficult to pinpoint off during printing. for about 10 minutes and turn check alarm is a cause.
Page 26 3.1.2 Problems related to printing(part 002/2) Symptom Cause Response 4 Data sent from the host Printing operation is not The interface cable is Connect the interface is not printed at all. performed at all. not connected cable properly. Data cannot be received properly.
Page 27 3.1.3 Problems related to printing result Symptom Cause Response 1 The data sent from the Self-test printing is The setup mode Enter setup mode and host does not match the performed normally. setting is invalid. change the mode setting print results. properly.
Page 28 3.1.4 Problems related to print quality (part 001/2) Symptom Cause Response 1 A dot is missing or an excess dot is printed. The print head is Replace the print head. (See other items about blurring of the top or bottom defective.
Page 29 3.1.4 Problems related to print quality (part 002/2) Symptom Cause Response 5 Printing is partly blank or the ribbon is out of place. • The manual paper • Adjust the manual paper thickness adjustment thickness adjustment dial The ribbon is loose. dial is set improperly.
Page 30 3.1.5 Problems related to paper feed (part 001/2) Symptom Cause Response 1 Paper selection cannot be performed properly. • The paper selection HCPP • Replace the HCPP motor does not work motor. • HCPPSW ASY is defective. • Replace the HCPPSW •...
Page 31 3.1.5 Problems related to paper feed (part 002/2) Symptom Cause Response 9 Paper skews or a paper jam occurs. • Paper is set improperly. • Set paper properly. • Paper is defective. • Replace paper • The manual paper thickness (with that conforming to adjustment dial is set the media specifications)
Page 32 3.1.6 Problems related to the control panel Symptom Cause Response 1 Switches on the control panel are disabled. • The printer is online. • Turn the printer offline. • The connection between • Connect the cable the control panel board properly, or replace the and control board is cable.
Page 33 3.2 Error Display This printer indicates errors on the control panel. There are three groups of errors as explained below. (1) Warning errors The buzzer sounds and the ONLINE indicator still lights. For a data transmission error in the interface, only the buzzer indicates the error. The printer continues printing unless placed offline or other groups of errors occur.
Page 34 (2) Operational errors The PAPER OUT indicator is lighted. The buzzer sounds, the PAPER OUT indicator lights up, and the printer is placed offline when operation is required. Refer to Table 3.2. Table 3.2 Operational errors Error name Cause of the error Recovery Paper end (PE) The printer has run out of continuous forms.
Page 35 The PAPER OUT lamp blinks with other lamps. For a circuit malfunction detected in the printer: • The printer stops printing immediately. • The ONLINE indicator turns off. • All buttons of the control panel are invalid. Table 3.4 Fatal alarms displayed on control panel Lamp Condition of occurrence Alarm name...
Page 36 This chapter explains the maintenance levels 1 and 2 for cleaning, lubrication, inspection, and adjustment of the DL7400 printer 4.1 Overview Designed using the latest technology, the DL7400 printer offers high reliability and easy maintenance. Parts requiring lubrication and adjustment have been reduced and the replacement of defective parts made easier than previous models.
Page 37 4.4 Maintenance levels Maintenance for the DL7400 printer is done at two levels. Level 1 maintenance includes cleaning and lubrication. Level 2 maintenance includes level 1 items, plus replacement of PC boards, units, and mechanical subassemblies, and adjustment after replacement.
Page 38 4.7 Parts That must not be Disassembled This section gives the locations of parts that must not be disassembled. Table 4.2 lists components not to be disassembled and whose mounting screws are not to be loosened or removed. Parts not to be Disassembled Components Parts Remark...
Page 39 Level 1 maintenance includes only cleaning and lubrication and lubrication. These can be performed without removing covers although Figure 4.3 shows the printer with the covers removed. Check the DL7400 printer inside for paper particles, dust, and dirt, and remove these as explained below. After cleaning, lubricate moving parts.
Page 40 4.9 Level 2 maintenance Level 2 maintenance includes lubrication, adjustment, and parts replacement. Level 1 maintenance should be done at the same time. 4.9.1 Parts replacement Remember the following notes when replacing any component. Keep working area clean. Turn off power to equipment and unplug it before disassembled. Follow procedures carefully.
Page 41 (1) Tractor Unit removal and installation Front feed tractor. Front feed tractor. Removal 1. Raise the paper table. 2. During pressing the Rock lever, Lift the left and right sides of the tractor unit, and then remove the tractor unit. Figure 4.4 Front feed tractor Removal Installation 1.
Page 42 Rear feed tractor. Removal 1. During pressing the Rock lever, Lift the left and right sides of the tractor unit, and then remove the tractor unit. Figure 4.6 Rear feed tractor removal Installation 1. Engage the U-grooves on the left and right sides of the tractor unit with the counterpart pins on the printer. (fit the ditch of left pin, there is any ditch of the right pin) 2.
Page 43 (2) Cut Sheet Feeder removal and installation Front cut sheet feeder Removal 1. Turn off the printer power. 2. Disconnect the cut sheet feeder cable. 3. Raise the paper table, then hold both ends of the cut sheet feeder and pull it off. Installation 1.
Page 44 Rear cut sheet feeder Removal 1. Turn off the printer power. 2. Disconnect the cut sheet feeder connector. 3. Raise the stacker table, then hold both ends of the cut sheet feeder and pull it off. Installation 1. Turn off the printer power. 2.
Page 45 (3) Stacker Plate removal and installation Removal 1. Raise the stacker plate in the direction indicated by an arrow. 2. Stretch the left and right sides of the stacker frame outward to disengage the stacker plate projections from the frame. Installation 1.
Page 46 (4) Stacker Unit removal and installation Removal 1. While pressing down the lock levers on the left and right sides of the stacker unit, pull out the stacker unit to the back of the printer. Installation 1. Install the stacker unit by reversing the removal procedure. Lock lever Stacker unit Lock lever...
Page 47 (5) Paper Table removal and installation Removal 1. After opening the paper table and adjusting it to a tilted position, remove the paper table by lifting it to separate the left and right protrusions on the paper table ends from the grooves on the cover. Figure 4.12 Paper Table removal Installation 1.
Page 48 (6) LAN card removal and installation Removal 1. Remove the two screws. 2. Remove the LAN card. Figure 4.14 LAN card removal Installation 1. Install the LAN card by reversing the removal procedure. Note; Take care to insert the card into the guide rail correctly. Setup of a LAN card is necessary.
Page 49 (7) Flap replacement Removal 1. Remove the paper table and stacker unit. 2. Remove the flap. Installation 1. Install the flap by reversing the removal procedure. Flap Paper table Stacker plate Stacker frame Flap Figure 4.16 Flap removal and Installation...
Page 50 (8) Ribbon Cassette replacement Removal 1. Close the front cover, and turn the power on. Then the Print Head move to ribbon replace position. 2. Turn the power off. And Open the front cover. 3. Press the ribbon release levers located on both side of the cartridge and carefully lift the cartridge out of the printer.
Page 51 3. Place the two mounting pins on the ribbon support brackets of the head cartridge. (The two mounting pins are located on the sides of the ribbon release levers.) Insert the ribbon so that the ribbon falls between the nose of the print head and the plastic print guide.
Page 52 (9) Print head replacement At printing or after printing, print head is high Caution Hot temperature. Don’t touch the print head still cool. Removal 1. Turn off the printer. 2. Open the front cover of the printer and remove the ribbon cartridge. 3.
Page 53 (10) Control Panel Unit removal and installation Removal 1. Open the front cover. 2. Unhook the control panel case at three positions, then pull out the control panel unit to the front. 3. Disconnect cable from the control panel board. Installation 1.
Page 54 (11) Front Cover removal and installation Removal 1. Open the front cover . 2. Pull The hinge of the Front Cover slantwise then remove the front cover. Installation 1. Install the front cover by reversing the removal procedure. Front cover Figure 4.23 Removing the Front cover...
Page 55 (12) Upper Cover removal and Installation Removal 1. Remove the control panel. 2. Remove the two screws securing the upper cover. 3. Raise the paper table. 4. Disengage the hooks on the front left and right of the upper cover, then lift off the upper cover. 5.
Page 56 (13) Print Mechanism Unit removal and installation Removal * Do this work on a no slippery level bench so that the mechanism can be tilted stably during replacement. On a slippery surface like paper, the printer may slide when the mechanism is tilted.
Page 57 8. Unplug cables from mechanism unit. (SP motor ,LF motor, TR motor, Carrier cable (3 flat cables),RCSF cable, Relay cable. Total 8 cables) 9. Lift the mechanism unit higher and remove it. Relay cable LF Motor cable TR Motor cable SP motor cables Carrier cable R-CSF...
Page 58 (14) Power Supply Unit removal and installation Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Remove the 3 screws securing the power supply unit. 4. Disconnect the AC switch assembly connector, reactor connector, and power supply unit connector, then remove the power supply unit.
Page 59 (15) ROM Board (Main Board) replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Remove the LAN cables. Remove the bracket (2 screws). 4. Remove the 6 screws securing the ROM board (4 on the top and 2 on the side), and remove the ROM board. 5.
Page 60 (16) LAN RELAY PCA / LAN cable 17P replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Remove the two LAN cables. Remove the bracket (2 screws). 4. Remove the screws securing the LAN RELAY PCA. 5.
Page 61 (17) RS232C BOARD replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Remove the two exclusive screws and RS232C BOARD. Installation 1. Install the RS232C BOARD and two exclusive screws by reversing the removal procedure. LAN RELAY PCA With two exclusive screws Figure 4.30 RS232C Board removal and installation...
Page 62 (18) AC Switch ASY removal and installation Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Remove the AC switch assembly from the lower cover. Installation 1. Install the AC switch assembly by reversing the removal procedure. AC switch assembly Red(upper side) White(lower side)
Page 63 (19) Inlet ASY replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Remove the two screws securing the inlet and one screw securing the frame ground wire, and 4. remove the inlet assembly. Installation 1. Install the inlet assembly by reversing the removal procedure. 2.
Page 64 (20) Reactor replacement Note Reactor used only 100-120V models. Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Remove the two screws securing the reactor. Disconnect the cable from the power supply and remove the reactor. Installation 1.
Page 65 (21) FAN UNIT 2 replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Remove the FAN UNIT 2 cable from ROM BOARD. 4. Remove the two screws securing the FAN UNIT 2. Installation 1. Install the FAN UNIT 2 by reversing the removal procedure. FAN UNIT 2 CABLE FAN UNIT 2 Screws...
Page 66 (22) Control Panel Cable replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Remove the FAN UNIT 2. 4. Remove the 4 operator cable covers and then disconnect the operator cable from the ROM board. Installation 1.
Page 67 (23) F-CSF Cable/CSF Connector PCA replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Remove the FAN UNIT 2. 4. Disconnect the cable from the front CSF PCA connector. 5. Remove the two screws securing the front CSF PCA to remove the PCA. Installation 1.
Page 68 (24) R-CSF Cable/CSF Connector replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Remove the screw securing the rear CSF PCA and remove the PCA. Installation 1. Install the rear CSF PCA by reversing the removal procedure.
Page 69 (25) Relay Cable replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Disconnect the relay cable from the sensor PCA connector. Installation 1. Install the relay cable by reversing the removal procedure. Sensor PCA Relay cable Figure 4.41 Relay cable replacement...
Page 70 (26) Sensor PCA replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Disconnect the mechanism cable and flat cable from the sensor PCA connectors. 4. Separate and remove the sensor PCA from the two saddles by using long-nosed pliers. Installation 1.
Page 71 (27) SP Motor ASY replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Loosen a screw securing the fan unit and turn the fan unit so that the screws securing SP motor may be removed 4.
Page 72 (28) LF Motor removal and installation Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. Note 3. Remove the idle gear LF bracket needs adjustment. Putting the mark 4. Remove the screws fixing lf motor before disassembly is gives aim to adjustment for 5.
Page 73 (29) TR Motor removal and installation Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Remove the shift gear and shift spring. 4. Remove the two screws securing the TR motor. 5. Remove the TR motor from the side frame. Installation 1.
Page 74 (30) APTC Unit replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Remove the two screws and APTC bracket. Installation 1. Install the APTC unit by reversing the removal procedure. APTC motor APTC bracket Screw (APTC motor) backside Screws (APTC bracket) Push against the bracket to the stud in...
Page 75 (31) HCPP Motor replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Remove the HCPP gear. 4. Remove the two screws securing the HCPP motor. 5. Disconnect cable from the sensor PCA connector, then remove the HCPP motor from the side frame. Installation 1.
Page 76 (32) SP FAN motor replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Remove the screw securing the bracket , then remove fan unit. Installation 1. Install the fan unit by reversing the removal procedure. FAN UNIT 1 Screws Figure 4.48 SP fan removal and installation...
Page 77 (33) INLK SW ASY replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Remove the SW holder and INLK SW ASY. Installation 1. Install the INLK SW ASY by reversing the removal procedure. INLK SW ASY SW holder SW holder INLK SW ASY...
Page 78 (34) PS PCA replacement Removal 1. Remove the upper cover. 2. Release the PS PCA from the three hooks on the PS holder. 3. Disconnect the cable from the connector and remove the PS PCA. Installation 1. Install the reactor by reversing the removal procedure. PS PCA PS holder Cable...
Page 79 (35) HCPP switch ASY replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Remove the rubber foot from side frame L, then unhook the holder at two locations. 4. Disconnect the cable from the sensor PCA connector, and remove the HCPP switch assemble. Installation 1.
Page 80 (36) Sensor cover TR/TR PES ASY replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Unhook the sensor cover TR and remove the sensor cover TR. 4. Unhook the TRPES ASY and remove the TRPES ASY. 5.
Page 81 (37) Ribbon Rope ASY replacement Removal 1. Remove the upper cover. 2. Remove the springs on the left and right side of ribbon rope. 3. Remove the ribbon rope. Installation 1. Install the ribbon rope. If necessary, remove the ribbon bracket to lead the ribbon rope under the ribbon pulley. (To remove the ribbon bracket release the craws of the ribbon bracket hooking the carriage.) 2.
Page 82 (38) Card Guide ASY replacement Removal 1. Remove the upper cover. 2. Remove the screws securing the upper guide F on its left and right, and release it to the front. 3. Remove the print head. 4. Disconnect the TOF1, TOF2, and panel keyboard cables from the carriage PC board. 5.
Page 83 Proper cable forming of card guide. 1. Lead the cables in front of the guide part of the carrier frame (aluminum die-cast parts). Don’t lead wires between the guide part and upper guide R or breaking wire may cause because of cables get into touch with upper guide F.
Page 84 (39) TOFL/R sensor ASY replacement Removal 1. Remove the upper cover. 2. Remove the screws securing the upper guide F on its left and right, and release it to the front. 3. Remove the print head. 4. Disconnect the TOFL/R cable from the carriage PC board. 5.
Page 85 (40) Carriage Unit and Stay Shaft replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. Note. 3. Release the upper guide F to the front. Don’t remove the screws for upper 4. Remove the SS gear, gear B. angle.
Page 86 (41) SP Timing Belt replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Remove the carriage unit. 4. Remove the belt clamp. 5. Remove the timing belt. Difference of teeth position shall be less than 1 teeth. Installation Belt Clamp 1.
Page 87 (42) SP Tension bracket replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Remove the SP motor. 4. Remove the stay bearing so that stay shaft falls downward. (Therefore the purpose of this work is for increasing space for the work which removes a spring, it is omissible.) 5.
Page 88 Installation As shown in the right figure, build a tension spring into a new tension bracket. Please attach a new tension bracket and a new spring in a frame. Attach the tension spring (1)Hold firmly the root of a spring hook by long nose prier.. Be careful not to give a crack to a shaft.
Page 89 (43) LF Timing Belt replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Put the mark to memory the LF tension bracket position. . 4. Remove the LF tension bracket and remove the LF belt. Installation 1.
Page 90 (44) Platen Roll replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Before remove the LF tension pulley ASY put the mark to memory its adjusted position. 4. Remove the LF tension pulley ASY and LF belt and Pulley gear. 5.
Page 91 7. Turn down the mechanism assembly. 8. Disconnect cables backside of printer mechanism unit, remove 6 screws of lower plate. 9. Remove the bearings and slide in the direction of allow then remove it. Platen roll Screws for lower plate Note: Take care of jamming cables together when install platen cover.
Page 92 (45) Nip Spring 1/2 replacement Removal 1. Remove the upper cover. 2. Unhook four nip springs 1 (two on each end) and four nip springs 2 (two on each end), and remove the springs. Installation 1. Install nip springs 1 and 2 by reversing the removal procedure. NIP spring1(silver NIP spring2(black) Figure 4.64 Nip Spring 1/2 replacement...
Page 93 (46) Nip Roller replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 2. Unhook one sides of 4 nip springs and remove 4 spring holders. 3. Remove the E ring of both side and Nip gear on the left side. 4.
Page 94 (47) DV Roller ASY replacement Removal 1. Remove the upper cover. 2. Remove the printer mechanism assembly. 3. Remove the LF bracket (one screw) and LF belt. 4. Remove the two flanges (two E-rings), two DV gears, two nip gears (two E-rings), and one platen gear (one E-ring) from the left of the mechanism assembly.
Page 95 10. Remove 8 screws fixing lower guide at base side and front and rear side. Screws Screws Figure 4.68 Removing Lower Guide 11. Shift the lower guide a little upward.
Page 96 12. Remove the lower plate. Disconnect cables backside of printer mechanism unit, remove 6 screws of lower plate. 13. Slide the DV rollerr assembly direction of arrow, then remove it. Screws for lower plate Figure 4.69 Removing DV Roller 14. Replace assembled parts on the DV roller. Installation 1.
Page 97 4.9.2 Adjustment (1) Print head gap adjustment Note: This adjustment needs the head gap adjustment jig (special dial gage), so this part is parts that must not be disassembled. If you don’t have head gap adjustment jig, don’t adjust this portion as much as possible. Procedure 1.
Page 98 5. Slightly loosen the three screws(a),(b) and (c) on the upper angle. Upper stay Upper angle Screw(b) Screw(c) Screw(a) Hole for adjustment Figure 4.72 Adjustment head gap A=0.00mm±0.01mm 6. Slide the carriage unit to the left end (1st column side) 7.
Page 99 (2) Card guide position adjustment Note: For improve the precision using the head gap adjustment jig is better. If you don’t have the head gap adjustment jig refer to the another procedure which comes out behind [Using the head gap adjustment jig] This adjustment should be done after print head gap adjustment is finished.
Page 100 6. Adjust the head gap to value A, by turning the SS gear. Stopper stud SS gear Stopper of SS gear Figure 4.75 Rotate SS gear A=0.25mm±0.01mm 7. Move the card guide up and down so that APTC SW should be switched into conducting state at the head gap is value A.
Page 101 9. Check the gap between the print head and paper after APTC function is operated. Turn the printer off immediately after printing is started. Check the value B by head gap adjustment jig. If the Value B is as follows adjustment is finished. B=0.29mm±0.03mm Paper Platen...
Page 102 (3) Card guide position adjustment (another way) [Without the head gap adjustment jig] This method uses the gear that is next to the motor pinion instead of head gap adjustment jig. This adjustment should be done after print head gap adjustment is finished. SS gear Stopper 1.
Page 103 7. Fasten the rightside screw temporly Fasten the right side screw during pushing right potion of curd guide by light force. 8. Remove the inserted paper. 9. Enter the adjustment mode. During pushing the “ ”,” ”SW, turn the power on. Fix temporary 10.
Page 104 (4) TOF sensor’s voltage adjustment Note This adjustment should be done after card guide adjustment is finished. Please make sure any dust has cleaned under the TOF sensors. 1. Turn the printer power on, then the carriage escape to the maximum gap and move and stop the ribbon replacing position.
Page 105 (5) LF belt’s tension adjustment 1. Adjust the tension using tension bracket position, so that reaction force is value A when LF belt is lowered 2mm. LF belt Screw Tension bracket Value A = 250gf±20gf (2.45N±0.2N) Figure 4.81 adjusting LF belt tension...
Page 106 (6) Vertical Alignment (V-ALMNT) adjustment 1. Load the continuous forms paper wider than 356mm (14 inches) from front tractor. 2. Enter adjustment mode. “ONLINE”SW + POW ON ,then printing start at “LQ”speed. 3. Check the direction of displacement and adjust the alignment using SW as follows.
Page 107 (7) Top-of-forms adjustment (factory use) Note . Other adjustment methods are in setup mode. Each adjustment value exists independently in each adjustment mode. Anyway vertical printing position effected by both adjustment value. If vertical printing position is adjusted by set up mode. Don’t adjust this value. Ideally set up mode should be done after this adjustment is satisfied.
Page 108 (8) Skew detection value adjustment Note. To correct the vertical span between TOFL and TOFR for correct skew detection. 1. Enter adjustment mode. Turn the power on while pressing the “LOAD” and ” ”SW . 2. Select the cut sheet position. Press the ”PAPER PASS”...
Page 109 4.9.3 Lubrication Lubrication is required only when the printer is overhauled or mechanical components are replaced. Lubrication codes are as follows: 2 – GD – D – O Cycle Amount (1 drop) Type (Mobil oil) 1. No. Sequential number for the location to be lubricated 2.
Page 110 (2) HCPP mechanism, Stud for gear Lubrication Oil Amount Location Remarks cycle Hole of slide cam Cam surface OC lever L sliding section Axis of OC lever L/R Studs for shift gears 2 points (stud) Studs for LF gears 6-SG-C-O 5-SG-C-O 3-SG-C-O 4-SG-C-O...
Page 111 (3) Detent for DV roller Lubrication Oil Amount Location Remarks cycle Spacer Collar NIP roller left side DV roller left side 1-SG-C-O Detent (Mechanism to keep the 2-SG-C-O accurate rotation) Figure 4.86 Detent lubrication (4) Bearings Lubrication Oil Amount Location Remarks cycle Bearings of stay shaft...
Page 112 (5) Guide to slide the paper table Lubrication Oil Amount Location Remarks cycle Guide rails of paper table. Studs for gears 1-KF-C-O 2-SG-C-O 1-KF-C-O Figure 4.88 paper table slide guide lubrication...
Page 113 (6) Carrier unit (Ribbon drive mechanism) Lubrication Oil Amount Location Remarks cycle Oil felt section 0.6 0.7CC Surface that RF shaft slides (Carrier) Teeth of RF shaft etc. Axis of pulley and gear Surface that RF shaft slides (Ribbon bracket) Surface that RF shaft slides (Ribbon bracket) 2-SG-C-O...
Page 114 4.10 Diagnostics This section describes how to use the following diagnostic functions: • SELF-TST • HEX-DUMP These functions are used for checking print quality and diagnosing printer problems. HEX-DUMP also provides useful information for programmers. 4.10.1 Printing the Self-Test The SELF-TST function prints test pages to check how the printer operates independently of your computer. The self-test does not check the interface between the computer and the printer.
Page 116 4.10.2 Hex dump The HEX-DUMP function prints data and commands in hexadecimal characters and abbreviated control codes. The IBM character set 2 is used for printing (see Appendix E). The HEX-DUMP function is useful for checking whether your computer is sending the correct commands to the printer and whether the printer is executing the commands correctly.
Page 117 Sample HEX-DUMP 4. Exit the HEX-DUMP function. Exit the HEX-DUMP function in either of the following ways: • To remain in setup mode, press the LF/FF button. The <<FUNCTION>> menu is then reprinted. For details on other functions, see other sections in this chapter. •...
Page 118 4.10.3 Power-on Features for DL7400 There are several special tests and setup modes built into the DL7400 printers. Holding down certain control panel buttons, while turning on the printer, activates these special printer modes. After the printer beeps, the buttons are released.
Page 119 CHAPTER 5 PRINCIPLES OF OPERATION 5.1 Overview This section explains the principles of DL7400 operation. A microprocessor controls the following basic functions: Carriage drive Print head drive Paper feed Figure 5.1 Function sequence...
Page 120 5.2 Mechanical Operation 5.2.1 Printing Operation 5.2.1.1 Print head The print head consists of 24 wires in six rows. The print head has 24 electromagnets that drive armatures with wires. The print head is fastened to the carriage by the lock wire. When not printing, the armature is parked against the stopper by the elasticity of the coil spring.
Page 121 5.2.1.2 Spacing operation Figure 5.3 shows spacing mechanism. Spacing operation is performed by the space motor (4-phase pulse motor) mounted on the right side of the side frame. The drive pulley used to move the carriage is mounted on the top of the space motor, and the timing belt is put on the drive pulley.
Page 122 5.2.1.3 LRES (Carriage position) detection The left and right carriage positions are detected using one LRES sensor provided on the back of the carriage and the left and right shield plates provided on the upper stay. The shield plates are different in length in the direction in which the carriage moves.
Page 123 5.2.1.4 Ribbon feed mechanism Figure 5.5 shows the ribbon feed mechanism. The ribbon is fed by the rotation of the ribbon feed shaft. The ribbon shaft always rotates in the same direction regardless of whether the carriage moves in direction A or B (left or right).
Page 124 5.2.1.4 Automatic paper thickness control mechanism The automatic paper thickness control mechanism consists of and the paper surface detection switch on the left side of the card guide. < The head approach mechanism> The mechanism consists of the pulse motor, stay shaft, and gear transmission mechanism. Because stay shaft is designed to work as eccentric cam, the print head is moved up and down by the angle of the stay shaft.
Page 125 5.2.1.5 Skew detection Skew is detected by two sensors provided on the card guide in the carriage unit when a cut sheet is loaded. The card guide has two sensors: TOFL and TOFR. If a detection difference between the two sensors when the top end of paper passes them is too large, paper is ejected to the front.
Page 126 5.2.2 Paper Feed Operation 5.2.2.1 Paper path selection mechanism (HCPP) Figure 5.10 Control panel The “PAPER PATH” button on the control panel is used to select cut sheet paper, front-fed continuous forms, and rear-fed continuous forms. The button lights a lamp indicating the type of paper to be used. When the PAPER PATH button is pressed to select the type of paper, the printer automatically operates the applicable components by using power of HCPP motor rotation.
Page 127 DV gear Nip roller gear front and rear front and rear Slide cam OC Lever OC cam PL idle gear Gear which drives Timing belt front tractor. Shift gear HCPHP SW Gear which drives rear Idle gear LF Motor Shift gear R TR Motor tractor.
Page 128 5.2.2.3 Paper feed operation Figure 5.12 shows the driving system of the paper feed mechanism. The LF and TR motors mounted on the frame via gears feed paper. The LF motor operates for both cut sheet paper and continuous forms to rotate the first and second transport rollers and platen roll. The TR motor operates only for continuous forms to rotate the front or rear tractor to feed paper.
Page 129 (2) Continuous forms paper feed operation Figure 5.13 shows the paper feed mechanism for continuous forms. Continuous forms paper is loaded with its sprocket holes fitted to the pins on the paper feed tractor belt and is fed by transmitting TR motor power to the transmission mechanism to rotate the tractor belt.
Page 130 (3) Cut sheet paper feed operation Figure 5.14 shows the paper feed mechanism for cut sheet paper. The cut sheet paper placed on the paper table, which is not shown in the figure below, against the first roller in the cut sheet feeding slot is fed between the first transport roller and first nip roller, which are driven by the LF motor, and pulled by the second transport roller and second nip roller.
Page 131 5.2.2.4 Paper loading and ejection operation (auto loading) Loading the paper is done automatically. < Continuous forms loading operation > After setting continuous forms on the front or rear tractor, press the LOAD button to start loading operation. When the top of paper reaches the paper sensor (mounted on the card guide) shown in Figure 5.15, the paper sensor changes from the “no-paper”...
Page 132 5.3 Electrical Operation The main control unit uses the MB90706 controller dedicated to the printer. The controller contains Centronics control and stepping motor control circuits while using 16-bit MPU FFMC-16 as its core element. It thus implements high-speed, compact, and low-cost control circuits.
Page 133 5.3.2.1 Outline of Printed Circuit Boards Main board (GMC06**) This printed circuit board consists of three basic blocks: the main control circuit, interface circuit, and drive circuit blocks. The main board has the following ten connectors: Name Abbreviation Connection destination Centronics connector IFCEN Host computer...
Page 134 RS232C Centronics Interface Interface Interface Interface RS232C IFCEN BOARD BOARD Main board GMC06** RELAY BOARD See the following page Control panel for the sensor board GAO99BA Space motor Front sheet Front sheet feeder feeder connector board FAN 1 Rear sheet Rear sheet driver feeder...
Page 135 Sensor board Main board Paper setting GMC06** sensor Rear-fed continuous forms sensor Skew correction motor Front-fed continuous forms sensor Front/rear tractor selection. Skew gear open/close motor correction roller phase position APTC reference APTC motor position sensor Transport roller position sensor Figure 5.3.3 Sensor board peripheral configuration Main board Carriage...
Page 136 Power supply unit +34V Interface unit Main control unit Driver unit USB 8bit EEPROM Controller Motor driver LAN Board (Option) Head driver Centronics MBCG4618 MBCG4618 MB90706 driver/receiver -525PFV 3-520PF Printer Motor Head control controller control LSI RS Board (Option) Control panel Sensor Carriage...
Page 137 5.3.3 Control Circuit Operation 5.3.3.1 Printer Special Controller (MB90706) Figure 5.3.6 is an MB90706 internal block diagram. FFMC-16 core External interrupt UART Control Noise INPRM,EXPRM resistant external Reception interrupt 16-bit timer I/O extension For control panel For head control serial control Stepping motor Chip select...
Page 138 5.3.3.2 Memory Circuit Control Figure 5.3.7 is a memory circuit control block diagram. MB90706 Defined space capacity DRAM Max. 1M Bytes External bus 256k×16 Bit RAS,CAS, PROGRAMROM CS0X DRAM control Max. 4M Bytes 1M×16 Bit Chip select address decoder I/O port EEPROM 16K Bits Figure 5.3.7 Memory control block diagram...
Page 139 [EEPROM] The MB90706 has a 16K-bit serial transmission EEPROM (equivalent to the M24C16) that contains setup information, mechanism information, and consumables information. If the board is replaced, remove the EEPROM from the board to be replaced and mount it on the replacing board. [ROM] The MB90706 uses a “512K x 16 bits”...
Page 140 5.3.3.3 Centronics Controller Figure 5.3.8 is an interface control block diagram. MB90706 Interface board Centronics CPU core DSTB, DATA1:8, Centronics controller Driver/ Centronics ACK,BUSY,PE receiver INPRM,EXPRM Interrup Anti-noise External interrupt control interrupt unit control unit Figure 5.3.8 Interface control block diagram [Centronics interface control] The Centronics interface controller uses the Centronics controller built in the MB90706 as shown in Figure 5.3.8 The INPRM and EXPRM signals, which are forcible reset signals from the host, are used as interrupt signals after noise is...
Page 141 (2) Circuit for generating a strobe signal (Ptr Clk) for data transmission from the printer MB90706 *Ptr CLK *ACK 10Pin LS08 * Ptr Clk *ACK [Centronics control circuit] Figure 5.3.9 shows a general timing chart for the Centronics control circuit. The Centronics control circuit latches received data DATA1 to DATA8 to the internal register at the falling edge of data strobe signal *DSTB, and simultaneously sends an interrupt signal to the external interrupt control circuit to inform the MPU of the receipt of data.
Page 142 5.3.3.4 The MPU(MB89P585) has the following main functions USB 8bit controller LSI3 (MB89P585) HOST D+,D- UNEGO URESET VBUS USBRQ UDATA1- UPRTRQ RQSTATUS Figure 5.3.10 MB89P585 block diagram (3) USB interface USB interface signal Signal name Function VBUS Power Data transfer Data transfer Shell Shield...
Page 143 5.3.3.5 LAN interface LAN interface signal Signal name Function TXO+ output Data transfer+ output Data transfer- RXI+ input Data transfer+ RXI+ input Data transfer- Specifications A transfer mode: 10/100BASE...
Page 144 2.3.6 Head Control LSI (MBCG46183-520PF) Figure 5.3.11 is a head control LSI block diagram. A1-A5 Address decoder PD1-PD24 HDTIM Print head controller D00-D15 FLYBK1-FLYBK6 General-purpose input port *RPS BKSION General-purpose output port PWSTOP HALM0-3 SPALMS Alarm detection SPALML circuit LFALMS *DVALM Figure 5.3.11 Head control LSI block diagram...
Page 145 2.3.7 Motor Control LSI (MBCG46183-525PFV) Figure 5.3.12 is a motor control LSI block diagram. A1-A5 Address decoder *RTRPESC *FTRPESC *RCSFC *FCSFC *HCPPMC *APTCMC *RPMC General-purpose input *TOFRSC port *RPJSC *FPJSC FANALM *GAP *APTCHPS APTCM0-3 HCPPM0-3 RPM0-3 General-purpose FCSFM0-3 output port D00-D15 RCSFM0-3 MLFM02...
Page 146 2.3.8 Control Panel Control Figure 5.3.13 is a control panel controller block diagram. Main board (GMC06**) MB90706 External Control panel board (GAO99BA) MBCG47492-502PF Switch Parallel input -> serial Serial input -> parallel Figure 5.3.13 Control panel control block diagram Switches and LEDs are provided on the control panel board. These switches and LEDs are controlled by serial-parallel conversion by the MPLSI (MBCG47492-502PF) mounted on the control panel.
Page 147 5.3.4 Motor Control and Drivers This printer has six motors (space motor, line feed motor, tractor motor, front and rear tractor selection gear open/close motor, APTC motor, and skew correction motor) in a standard configuration. It also enables two optional motors for the front and rear cut sheet feeders (the driving circuits are built in the sheet feeders) to be mounted.
Page 148 [Space, line feed, tractor, CSF, APTC, and skew correction motor drive circuits] Figure 5.3.15 shows a block diagram of the control and drive circuits for the standard motors in the printer. +34V Current detection resistor Space motor drive MB90706 circuit Space motor FFMC-16 Line feed motor drive...
Page 149 The space motor is rotated as follows: The MPU reads phase excitation data from ROM. The rotation direction and initial excitation phase are set in the control register of the stepping motor control circuit and simultaneously current specification data is written to the current specification register as needed.
Page 150 [Line feed motor and tractor motor drive circuits] The 4-phase line feed motor and tractor motor (bi-polar stepping motor) are controlled by the constant current drive circuit shown below. +34V HIC2,HIC3,HIC4,HIC5 HIC (A3953SLB) MB90706 MLFM0,1 (LSI1) TLFM0,1 Motor MLFM0-3 HDLSI TLFM0-3 MBCG46183-52 TLFM02,13...
Page 151 [Error detection circuit] Over current detection If the space motor, line feed motor, or tractor motor current exceeds the respective absolute rated value, an over current detection signal is sent to the HDLSI. After a given period of the receipt of the detection signal, the HDLSI controls the PWSTOP signal to turn off +34 V. It also notifies the MPU of the occurrence of a driver error.
Page 152 5.3.5 Print Head Driver Figure 5.3.19 is a print head drive circuit block diagram. Main board +34V Power Print head MB90706 DRAM +34V Voltage dividing +34V HDLSI (MBCG46183-520PF) FLYBK1-6 Flyback (Flyback control absorption output) Transistor array *BKSI SMA4032 (Print head driver) Flyback current PDV1 Pin data output...
Page 153 Print head drive circuit control] The controller (MB90706) reads print data from DRAM. The data is set on the HDLSI print control circuit. At this point, printing does not begin yet. The MPU sets the excitation time (T1) and flyback absorption time (T2) in the HDLSI. The MPU outputs print timing signal TIMER1.
Page 154 5.3.6 Alarms 5.3.6.1 Fire Check A fire check alarm occurs if: Abnormal current flows because of damage to the space, line feed, or tractor motor, or a motor driver. The space motor has been excited for a long time. Current flows to the head drive transistor for a period longer than specified. 5.3.6.2 ROM or RAM Error A ROM or RAM error occurs if an error is detected during the following checks when power is turned on.
Page 155 5.3.7. Power Supply The power supply circuit consists of the components shown in the block diagram in Figure 5.3.21 AC input filter Direct rectifying and smoothing circuit (including surge current preventive circuit) +5V/+34V switching regulator This section explains the +5V/+34V switching regulator and surge current preventive circuit according to the block diagram in Figure 5.3.21.
Page 156 detection PWSTOP Output filter Output filter PWSTOP +34V Figure 5.3.21 Power supply circuit block diagram...
Page 157 5.3.8 Surge Current Controller 2.8.1 Surge Current Controller Surge current caused at power-on is controlled by the power thermistor (NTC thermistor) on the power supply board. This section explains the surge current controller. At power-on The power thermistor is directly connected to the power supply input line and normally has several ohms of resistance when power is turned on.
Page 158 CHAPTER 6 RECOMMENDED SPARE PARTS The following table lists parts and product numbers to be used when replacing spare parts, and the sections that explain the replacement: area ASIA ASIA FSBT Item Description Parts number Section to be referred to Product number B119 B219...
Page 159 area ASIA ASIA FSBT Item Description Parts number Section to be referred to Product number B119 B219 B111 B211 B251 B203 B110 B210 B217 B228 Interface P+USB P+RS P+USB P+RS P+RS P+RS P+USB P+RS P+RS P+RS Revision 31 RELAY CABLE 35P KA02038-D231 4.9.1(24) ○...

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