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REPAIR

SERVICE MANUAL

Mechanical

5-1

CHAPTER 5

MAINTENANCE

1. Lubrication

1.1. Lubricants

Table 5.1 Recommended Lubricants

Symbol

Lubricant

E

Epinoc grease #1

S1

Silicone grease G-501

S2

Silicone grease KS64F

SO

Silicone oil KF96

T

FBK Turbin#32

1.2. Precautions

1.

Lubricate carefully so that the oil or grease will not stick to places other than the
specified points; otherwise, the plastic parts and electronic boards will be adversely
affected.

2.

Do not apply an excessive amount of lubricant; otherwise, the lubricant may drip
onto places other than the specified lubrication points during use or storage.

3.

Make sure to apply a sufficient amount of lubricant to contact parts and sliding
surfaces consisting of more than one material.

1.3. Lubrication

Points

See the illustrations on the following pages for location and types of lubricant for the
following components:

NOTE:

•

Some assemblies must be disassembled for lubrication.

1. Carriage Assembly (see Fig. 5.1.)

2. Paper Feed Assembly (see Fig. 5.2.)

3. Eject Roller Assembly and PF Roller Assembly (see Fig. 5.3.)

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Summary of Contents for DP-550CJ

Page 1: ...R WORD PROCESSOR SERVICE MANUAL MODEL DP 525CJ DP 530CJ DP 540CJ DP 550CJ LW 800ic LW 810ic LW 810icBL LW 840ic REVISED EDITION ...

Page 2: ... Carriage Home Position Sensor 1 15 1 2 5 2 PE Sensor 1 16 1 3 INK CHG Ink Change Functions 1 17 1 3 1 Ink Cartridge Installation Replacement 1 17 1 3 2 Automatic Print head Cleaning Purging 1 17 2 Keyboard 1 18 CHAPTER 2 ELECTRICAL THEORY 2 1 1 System Configuration 2 1 1 1 Main PCB Printed Circuit Board 2 1 1 2 Switch PCB Printed Circuit Board 2 1 1 3 Keyboard FPC Flexible Printed Circuit 2 1 1 4...

Page 3: ...Circuit 2 10 6 Printer Control 2 11 6 1 Ink Jet Head Control 2 11 6 2 Carriage Motor Control 2 12 6 3 Line Feed Motor Control 2 13 6 4 Carriage Home Position Sensor 2 14 6 5 PE Sensor 2 14 7 Switch PCB 2 15 7 1 Configuration 2 15 8 Keyboard System 2 16 8 1 FPC Operation 2 16 8 2 Keyboard Scan 2 17 8 3 Keyboard Control Circuit 2 18 9 CRT Control 2 20 9 1 Configuration 2 20 9 2 SRAM and Display Scre...

Page 4: ... 3 14 7 3 Self Test Mode 3 17 7 3 1 Display CRT Test 3 19 7 3 1 1 Cross Hatch Pattern Test 3 20 7 3 1 2 Full Dot Screen Test 3 21 7 3 1 3 Blank Screen Test 3 22 7 3 1 4 H Pattern Test 3 23 7 3 1 5 mw Pattern Test 3 24 7 3 1 6 Dot Pattern Test 3 25 7 3 2 Print Checks 3 26 7 3 2 1 Print Test Pattern 1 3 26 7 3 2 2 Print Test Pattern 2 3 29 7 3 2 3 Dot Patterns 3 31 7 3 3 Keyboard Tests 3 33 7 3 4 FD...

Page 5: ... 4 16 3 3 3 3 Removing the ACF Shaft Assembly 4 17 3 3 3 4 Removing the Pressure Rollers and Roller Holders 4 18 3 3 3 5 Removing the Holder Plate 4 19 3 3 3 6 Removing the Hopper Assembly 4 20 3 3 3 7 Disassembling the Paper Feed Assembly 4 22 3 3 3 8 Removing the Eject Roller Assembly and the PF Roller Assembly 4 23 3 3 3 9 Removing the Motor Frame Assembly 4 24 3 3 3 10 Removing the PF Stopper ...

Page 6: ...g 5 6 3 1 Test Pattern 5 6 3 2 Measurement Conditions 5 7 3 2 1 Display Dimension Measurement 5 7 3 2 2 Raster Centering Tilt Adjustment see Fig 5 3 5 7 3 3 Adjustments 5 8 3 3 1 B Voltage Adjustments None required 5 8 3 3 2 Horizontal Adjustments 5 8 3 3 3 Vertical Adjustments see Fig 5 5 5 9 3 3 4 Brightness Contrast 5 9 3 3 5 Focus Adjustment 5 9 3 3 6 Raster Geometry Adjustments 5 10 3 3 6 1 P...

Page 7: ...Print Head Automatically 6 9 3 2 Cleaning the Ink Jet Nozzles and Contacts 6 9 3 3 Cleaning the Bracket Contacts Carriage 6 10 APPENDIX A SPECIFICATIONS APP 1 1 Electrical System APP 1 2 Printing APP 2 3 Keyboard APP 4 4 Monitor CT 1450 APP 4 5 Environmental Tolerance APP 5 6 Dimensions Weight APP 6 ...

Page 8: ...Print Maintenance Operation Capping 1 14 Fig 1 13 Carriage Home Position Sensor 1 15 Fig 1 14 PE Sensor Mechanism 1 16 Fig 1 15 Keyboard Assembly 1 18 Fig 1 16 Key Top Key Stem Assembly 1 19 Fig 1 17 LCD Unit Installation in the Upper Cover 1 21 Fig 1 18 LCD of DP 525CJ LW 800ic 1 22 Fig 1 19 LCD of DP 530CJ LW 810ic and LW 810icBL 1 23 Fig 1 20 LCD of DP 540CJ DP 550CJ LW 840ic 1 24 Fig 2 1 Major...

Page 9: ...1 Fig 2 23 LCD Drive Voltage Generation Circuit Minus Voltage VEE 2 22 Fig 2 24 LCD Drive Voltage Generation Circuit Plus Voltage VEE 2 22 Fig 2 25 CFL Backlight Circuit 2 23 Fig 2 26 FDD Block Diagram 2 25 Fig 3 1 Troubleshooting Flowchart 3 4 Fig 3 2 Troubleshooting Flowchart continued 3 5 Fig 3 3 Serial Number Entry Display 3 14 Fig 3 4 Self Print Pattern 3 15 Fig 3 5 Results of Self Print Test...

Page 10: ...8 FDD Read Error Rate Check Display 3 44 Fig 3 29 PE Sensor Test Start Display 1 3 46 Fig 3 30 PE Sensor Test Start Display 2 3 46 Fig 3 31 CR Test Start Display 1 3 47 Fig 3 32 Self Test Menu DISK TYPE Setting 3 48 Fig 3 33 RS232C Echo Back Test Start Display 3 49 Fig 4 1 Cover Assemblies 4 1 Fig 4 2 Removing the Sub Paper Support and Paper Support 4 3 Fig 4 3 Removing the Top Cover 4 4 Fig 4 4 R...

Page 11: ...rs and Roller Holders 4 36 Fig 4 29 Removing the Holder Plate 4 37 Fig 4 30 Removing the Hopper Assembly 4 39 Fig 4 31 Disassembling the Paper Feed Assembly 4 40 Fig 4 32 Removing the Eject Roller Assembly and the PF Roller Assembly 4 41 Fig 4 33 Removing the Motor Frame Assembly 4 42 Fig 4 34 Removing the PF Stopper 4 43 Fig 4 35 Removing the PE Sensor 4 44 Fig 4 36 Construction of the CA Unit 4 ...

Page 12: ...e LCD to the Uprige Position 5 6 Fig 5 5 Removing the Ink Jet Cartridge 5 7 Fig 5 6 Removing the Protection Tape 5 7 Fig 5 7 Placing the Cartridge in the Carriage 5 8 Fig 5 8 Fitting the Cartridge in the Carriage 5 8 Fig 5 9 Cleaning the Bracket Contacts 5 11 TABLES Table 1 1 Summary of Maintenance Operations 1 11 Table 2 1 Clock Circuit 2 8 Table 2 2 Table of LCD Modules 2 21 Table 2 3 FDC 5 and ...

Page 13: ...THEORY SERVICE MANUAL Mechanical 1 1 PART I THEORY OF OPERATION CHAPTER 1 MECHANICAL THEORY 1 Ink Jet Printer Fig 1 1 Ink Jet Printer Assembly ...

Page 14: ...arriage motion control system consists of the carriage motor motor pulley timing belt idle pulley and the idle pulley holder and holder spring 3 Paper Feed Mechanism The paper feed mechanism consists of the paper feed system paper eject system and the paper setting system 4 Maintenance Station The maintenance station consists of the MS holder the MS carriage assembly carriage rubber cap plunger co...

Page 15: ...THEORY SERVICE MANUAL Mechanical 1 3 Fig 1 2 General View of Printing Mechanism ...

Page 16: ...tor Paper feed system ACF Auto cut sheet feeder When the paper feed motor is driven in the opposite direction reverse rotation of the paper feeding the change lever 1 moves to engage the ACF shaft gear via the idle gear The separate roller rotates in the paper separation direction normal rotation and separates a sheet of paper The separate roller rotates with paper feeding operation and returns to...

Page 17: ...t roller gear pressure roller roller holder holder plate pressure roller spring star wheel holder and the star wheel After paper is registered the paper feed motor is driven in the paper feeding direction normal rotation and paper is fed by the PF roller and the pressure roller After printing paper is ejected by the eject roller and star wheel Fig 1 4 Paper Eject System ...

Page 18: ... the hopper hopper spring separate pad collar paper guide ACF change lever change spring and the ACF change shaft When inserting a thick paper the ACF change lever should place at the front position 24lb Thick Paper Envelope Label Transparency etc Fig 1 5 Paper Setting System ...

Page 19: ...ain PCB See Fig 1 6 The printer flat cable must be firmly in contact with the ink jet cartridge for printing to be enabled The flat cable is located in the carriage by four alignment pins proper alignment of the cartridge to the cable is established in three datums reference planes points X Y and Z When the cartridge is installed in the carriage the flat cable contacts are compressed against the c...

Page 20: ...THEORY Mechanical SERVICE MANUAL 1 8 Fig 1 7 Printer Flat Cable to Cartridge Alignment ...

Page 21: ...THEORY SERVICE MANUAL Mechanical 1 9 Fig 1 8 Ink Jet Cartridge to Flat Cable Alignment ...

Page 22: ...ssembly consists of a motor a timing belt an idle pulley and an idle pulley holder and pulley holder spring the motor and the idle pulley holder are mounted to the CA frame the belt runs between the motor and the pulley The pulley holder spring between the idle pulley holder and the CA frame sets belt tension See Fig 1 9 Fig 1 9 Carriage Motion Control ...

Page 23: ... Summary of Maintenance Operations Printer State Spitting Wiping Capping Power on 204 2 1 Beginning of print job 204 after wiping 1 0 Between pages of continuous printing 12 1 0 After 6 pages of continuous printing 204 after wiping 1 0 After 50 seconds of printing on the same page 12 after wiping 1 0 Purging 6 000 after wiping 1 1 Ink cartridge change 204 after wiping 1 1 If no cartridge motion fo...

Page 24: ...oing to the cap position otherwise wiping causes distorted printing if the wiper has experienced any wear The trough below he print line is intended to capture the ink during a spit cycle when no paper is present in the print area The cup around the wiper is used when spitting is required and paper is present in the print area Spitting with paper in print area occurs when a single page requires lo...

Page 25: ...her direction The printhead is wiped twice when power is turned on when beginning a print job after the print head has been capped for more than four minutes after six pages of continuous printing after 50 seconds of printing on the same page and after purging or changing the ink cartridge Fig 1 11 Print Maintenance Operation Wiping ...

Page 26: ...m is powered on when no data is received for 30 seconds and after purging or ink cartridge change Fig 1 12 Print Maintenance Operation Capping 1 2 4 4 Purging The purging function of the maintenance station is a combination of the wipe cap and spit operations This initiates a sequence of 6 000 spits of each nozzle in order to clear clogged ink from the nozzles The ink is captured in the trough loc...

Page 27: ...ght end of the CA frame and the paper end sensor attached to the bottom of the PF base at the right rear 1 2 5 1 Carriage Home Position Sensor Upon power up of the system or when the carriage is reset the carriage moves to the right end of the printer assembly and activates the home position sensor leaf switch assembly See Fig 1 13 Fig 1 13 Carriage Home Position Sensor ...

Page 28: ...echanical SERVICE MANUAL 1 16 1 2 5 2 PE Sensor PE sensor detects when the trailing edge of the paper passes the knob of PE sensor PE sensor is 1C 1P Switch normal open See Fig 1 14 Fig 1 14 PE Sensor Mechanism ...

Page 29: ...NK CHG moves the printhead from the maintenance station to the right end of the printer assembly Pressing RETURN after installing or replacing the ink cartridge initializes the system the cartridge activates the home position sensor switch and moves the printhead back to the maintenance station See Chapter 5 MAINTENANCE for ink cartridge replacement instructions 1 3 2 Automatic Print head Cleaning...

Page 30: ...HEORY Mechanical SERVICE MANUAL 1 18 2 Keyboard The keyboard assembly consists of the keyboard panel and keys the FPC flexible printed circuit board and the keyboard base plate Fig 1 15 Keyboard Assembly ...

Page 31: ...ts is fitted to the base plate See Fig 1 16 The FPC board is a single sheet of film FPC on which an electrode pattern is printed in layers When the key top is pressed the key actuator presses the rubber contact the conductive part of the contact connects both of the electrodes to output the predetermined signal for the key Fig 1 16 Key Top Key Stem Assembly ...

Page 32: ...The hinge assembly is the friction type holder that holds the LCD at whatever angle the user sets within a range approximately 31 from the upright position Contrast adjustment varies depending on the model as indicated below DP 525CJ LW 800ic DP 530CJ LW 810ic LW 810icBL The slide type LCD volume knob located on the right side of the LCD upper cover is used to adjust the contrast DP 540CJ DP 550CJ...

Page 33: ...THEORY SERVICE MANUAL Mechanical 1 21 Fig 1 17 LCD Unit Installation in the Upper Cover ...

Page 34: ...THEORY Mechanical SERVICE MANUAL 1 22 DP 525CJ LW 800ic Fig 1 18 LCD of DP 525CJ LW 800ic ...

Page 35: ...THEORY SERVICE MANUAL Mechanical 1 23 DP 530CJ LW 810ic LW 810icBL Fig 1 19 LCD of DP 530CJ LW 810ic and LW 810icBL ...

Page 36: ...THEORY Mechanical SERVICE MANUAL 1 24 DP 540CJ DP 550CJ LW 840ic Fig 1 20 LCD of DP 540CJ DP 550CJ LW 840ic ...

Page 37: ...iving power from the AC adaptor the switch PCB supplies voltage to the main PCB through the power switch and the fuse 1 3 Keyboard FPC Flexible Printed Circuit The keyboard FPC has electrodes arranged in a matrix circuit pattern The keyboard status is sent from the FPC to the main PCB 1 4 FDD Floppy Disk Drive Module The FDD can read and write information supplied to the main PCB The FDD is driven...

Page 38: ...THEORY Electrical SERVICE MANUAL 2 2 Fig 2 1 Major Electronic Component Parts ...

Page 39: ...iage step motor drives the carriage right and left with precision motion control 2 3 Line Feed Motor The line feed motor feeds the paper forward and in reverse 2 4 Carriage Home Position Sensor The carriage home position sensor is mounted on the right of the CA frame It detects the carriage home position to synchronize the carriage position and motor phase 2 5 PE Paper End Sensor The PE sensor det...

Page 40: ...hows the power supply circuit The power supply section converts the unstable input PWR supplied from the switch PCB into stable 24 VDC for motors and print head and 5 VDC for logic A 2 channel switching regulator IC 4 converts unstable input into stable output Fig 2 2 Power Supply Circuit ...

Page 41: ...oment Q6 is turned OFF Stabilization to 24V is achieved by changing the ON OFF duty ratio of Q6 Fig 2 3 Timing Chart of 24V Generation Circuit 3 3 5V Generator The timing chart of the 5V generation circuit during idling is shown in Fig 2 4 Switching Q12 by 4 at 100 kHz reduces the input voltage to a stable 5V While Q12 is ON energy is supplied to L3 C31 and load The energy accumulated in L3 is sup...

Page 42: ...The reset circuit is shown in Fig 2 5 The reset signal MRST used to initialize the system is generated using the leading and trailing edges of the 5V voltage The reset signal is input to the following devices Device Pin CBIC 8 17 Printer drivers 2 3 5 Fig 2 5 Reset Circuit ...

Page 43: ...ed 16 Mbit ROM 5 3 Main RAM 9 10 The following RAM can be installed at 9 and 10 9 16 Mbit DRAM 10 4 Mbit DRAM Note that simultaneous installation of RAM at 9 and 10 is not allowed 5 4 Video RAM 6 The capacity of the video RAM used to retain the data to be displayed on the LCD is 256 Kbit It secures the display area for different sizes of LCDs from 480 x 64 dots to 640 x 400 dots The RAM area not n...

Page 44: ...8 pin 167 20MHz XT3 is the standard clock for printer control and other several timing it inputs for 8 pints 14 15 14 74MHz XT4 is the standard clock for CPU core it inputs for 8 pints 94 95 5 8 Buzzer Drive Circuit The buzzer drive circuit is shown in Fig 2 6 A 4 kHz pulse of 50 duty is output from port BUZ pin 25 of CBIC 8 when buzzer operation is needed The piezoelectric element in BZ1 generate...

Page 45: ...ountry Specification Change over The country specification change over circuit is shown in Fig 2 7 The country specification is recognized by the CPU by sensing solder on the solder points Fig 2 7 Country Model Specification Change over Circuit ...

Page 46: ...AL 2 10 5 10 RS 232C I F Circuit The RS 232C I F circuit is shown in Fig 2 8 The driver IC 1 converts the signal level 5V 0V on the main PCB to the RS 232C signal level in the external line and vice versa Fig 2 8 RS 232C I F Circuit ...

Page 47: ...50 active nozzles monochrome Two addressable multiplexing printer drive circuits 2 3 activate the nozzles for printing Custom circuitry controls the timing and synchronization of ink deposited as the cartridge moves across the paper in printing The same system controls ink jet head maintenance spitting into the trough Fig 2 9 Ink Jet Head Drive Circuit ...

Page 48: ...hown in Fig 2 10 24 VDC is supplied to the motor through connector CN3 pin 5 Motor phases A B C and D are driven by the CBIC 8 through pins 150 153 respectively The outputs of the CBIC turn darlington transistors Q1 Q4 on and off which in turn affect the motor phases Fig 2 10 Carriage Motor Drive Circuit ...

Page 49: ...powered by 24 VDC Each of he four phases of the motor is excited when CBIC 8 via ports LF A B C and D outputs to turn on the darlington transistors Q23 Q26 This provides a path to ground through the transistor which allows current to flow When the printer gate array outputs a LOW the transistor remains off Fig 2 11 Line Feed Motor Drive Circuit ...

Page 50: ...ad by pin 164 of the CBIC 8 The signal goes LOW when the carriage reaches the home position Fig 2 12 Carriage Home Position Sensor Circuit 6 5 PE Sensor The PE sensor detection circuit is shown in Fig 2 13 The HIGH LOW status of the PE sensor is read by pin 165 of the CBIC 8 The signal is HIGH if there is no paper at the sensor position Fig 2 13 PE Sensor Detection Circuit ...

Page 51: ...installed between the AC adaptor and the main PCB to turn the power on and off and protect devices at the occurrence of an alarm etc Fig 2 14 shows the external view of the switch PCB and Fig 2 15 the switch PCB circuit Fig 2 14 External View of the Switch PCB Fig 2 15 Switch PCB Circuit ...

Page 52: ...uit pattern and electrodes are printed When a key is pressed the key stem is forced down until the carbon type conductive silicone rubber makes a contact with the FPC electrode and electricity is conducted See Fig 2 16 Key Actuator Contact Rubber Carbon Silicon Conductive Rubber FPC Board Base Plate Carbon Electrodes Fig 2 16 Key FPC Operation ...

Page 53: ...derstand the keyboard scanning operation described When a key is not pressed continuity does not exist in any combination of the matrix e g X1 and Y1 or X2 and Y2 For example if key A is pressed continuity will exist only in X2 and Y3 but not between any other pairs of points which are left in the OFF status In other words if continuity exists between X2 and Y3 it means that key A is being pressed...

Page 54: ...CBIC 8 according to data signals KO0 through KO8 The LOW level signals are output to output lines KO0 through KO8 The electrode wiring is scanned line by line The result of scanning is input to P70 through P77 of CBIC 8 CBIC 8 detects which key has been pressed The key matrix given in Fig 2 19 corresponds to the key arrangement shown in Fig 2 20 Fig 2 18 Keyboard Control Circuit ...

Page 55: ...THEORY SERVICE MANUAL Electrical 2 19 Fig 2 19 Keyboard Matrix Fig 2 20 Keyboard Symbols Corresponding to Keyboard Matrix in Fig 2 19 ...

Page 56: ...he main PCB outputs the LCD module control signals to the LCD module The LCD drive voltage VEE is generated by DC DC convertor by the pulses output from CBIC 8 Display data the data written to the SRAM 6 that functions as Video RAM is always sent to the LCD module as 4 bit parallel data Fig 2 21 LCD Display Operation Block Diagram ...

Page 57: ...te and by the setting in the program after the reset is canceled An example of the control signal timing chart is shown in Fig 2 22 Fig 2 22 Example of Control Signal Timing Chart 9 2 LCD Module The LCD modules used in the respective models are shown in Table 2 2 The control signal timing and drive voltage VEE differ according to the LCD module Table 2 2 Table of LCD Modules Model Name Specificati...

Page 58: ...erated by L5 is rectified by D6 and regulated by ZD5 The ZD5 determines the VEE voltage about 16 V The LCD module driven by the plus VEE voltage uses the circuit shown in Fig 2 24 The 24 VDC source voltage is switched continuously by the 90 kHz pulses from CBIC 8 to energize L2 The voltage generated by L2 is rectified by D5 and regulated by ZD4 and ZD6 The ZD4 and ZD6 determine the VEE voltage VEE...

Page 59: ...circuit that turns ON OFF the CFL and the inverter PCB The ON OFF status of the CFL is controlled by the CFLON terminal of the CBIC 8 The inverter PCB converts 5V to AC voltage to drive the CFL tube The type of inverter PCB differs according to the LCD Fig 2 25 shows the CFL backlight circuit Fig 2 25 CFL Backlight Circuit ...

Page 60: ... the WRITE GATE signal is LOW READ DATA 30 This signal indicates the polarity data read by the head SIDE1 SELECT 32 This signal is used to select the head LOW Head 1 HIGH Head 0 Motor Drive Circuit DC MOTOR MOTOR ON 16 This signal becomes LOW starting the DC motor when a disk is set in the drive Setting this signal to HIGH or removing the disk stops the DC Motor STEP MOTOR STEP 20 This signal sets...

Page 61: ... between CBIC 8 and FDC 5 If CBIC 8 accesses an internal register other than the data resister in FDC 5 the normal read write operation will be performed If CBIC 8 transmits data to or receives data from FDC 5 DMA communications will be performed using the DMA function of CBIC 8 CBIC 8 resets FDC 5 detects the density signal which indicates whether the floppy disk is a 2DD or 2HD and output to FDC...

Page 62: ...nd a stepping motor drive circuit The DC motor drive circuit controls the DC motor which rotates the spindle according to the MOTOR ON signal from the FDC The stepping motor drive circuit controls the stepping motor which operates the magnetic head unit according to the STEP and DIRECTION SELECT signals from the FDC 5 10 3 3 Sensor Circuits The following sensor circuits detect the status of the FD...

Page 63: ...level signal HIGH when no disk The output of the sensor is connected to the controller and sent as a DISK CHANGE signal that shows whether a disk is changed when a disk is changed the DISKCHANGE signal becomes LOW Once the DISK CHANGE signal becomes LOW it remains low until the STEP signal is received from the FDC 5 ...

Page 64: ...ty advice carefully In addition to any specific warnings as described above be sure to take the following precautions for your personal safety Unplug the AC adapter from the AC outlet before removing the covers and PCBs or before making any mechanical adjustments Unplug the AC adapter from the AC outlet before checking continuity When disconnecting a connector grasp it firmly Do not pull on the co...

Page 65: ...ibers and furniture Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a plugable module use the correct tool Be extra careful in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity Prevent ESD sensitive parts from being accidentally touched by other personnel Install machine cove...

Page 66: ...t Fuses Check for blown fuses F1 and the thermo fuse inside the AC adapter NOTE In the logic control circuit it is difficult to isolate faulty points in areas connected tot he CPU by the address bus or the data bus If a suspected problem involves the address bus or data bus first check the solder bridge and the cut circuit pattern If a faulty point cannot be isolated replace the peripheral devices...

Page 67: ...chart Line Feed operates correctly Power ON LCD operating correctly Carriage print head moves Printer home position detected Keys work properly Prints normally Paper feeds normally A YES YES YES YES YES YES NO NO NO NO NO NO Problem No 1 Problem No 2 Problem No 3 Problem No 4 Problem No 5 Problem No 6 ...

Page 68: ...oblem No 8 Problem No 9 Problem No 10 Problem No 11 Problem No 12 Problem No 13 YES NO Does the buzzer sound when an invalid key is pressed Does an error message appear on the display Does the fax modem optional operate properly Does the FDD operate correctly Does the unit print when paper is set or print when no paper is set Does the LCD display correctly Does the LCD operate ...

Page 69: ...e right but cannot detect its home position i e the home position indexing mechanism is faulty 4 Keys malfunction do not insert characters or insert wrong characters 5 Printing results abnormal various unsatisfactory printing results 6 The line feed LF motor does not rotate normally 7 The buzzer does not sound 8 Power in on but nothing appears on the LCD 9 LCD displays operates but data displayed ...

Page 70: ...n 5 on the Main PCB Defective Q6 Main PCB Replace the Main PCB Replace Q6 Is resistance value across each of the phases and COM terminal pin 5 of the carriage motor correct about 45Ω Phases 5 1 B 5 2 b 5 3 D 5 4 Broken wire in the carriage motor assembly broken wire in the carriage motor defective connector Replace carriage motor assembly Are carriage motor drive pulse output from pin 150 153 of 8...

Page 71: ...ange over solder point Incorrect or faulty solder point for specified country language Verify and correct solder point Problem Abnormal Printing Voids in characters Light print Prints off the page Prints satellites Carrier moves but does not print Print head dries out prematurely Vertical alignment off Ink smearing Vertical streaks on paper Print lines crowded Gaps or overlapped areas in print Wil...

Page 72: ... machine Wrong paper weight size Try correct paper Are star wheels binding Star wheels dirty worn or dislodged Replace star wheel assembly Is the main roller assembly rotating properly Worn or broken gears bearing defective line feed motor Replace main roller assembly Replace gears bearing and or motor Does not the line paper feed motor rotate normally See Problem 6 Line Feed Motor Does the sheet ...

Page 73: ...tor drive pulses output from the pin131 134 of 8 when printing Defective 8 Main PCB Replace the Main PCB Replace 8 Is output at the output pin of transistors Q23 Q26 on and off according the drive pulses indicated above Defective transistor Q23 Q26 or circuit on the Main PCB Replace the Main PCB Replace Q23 Q26 Problem The buzzer does not sound Points to Check Probable Cause Corrective Action Repa...

Page 74: ...ut wave form at each pin in the connector CN7 or CN8 Defective 8 or solder bridge Replace the Main PCB Replace 8 Is there faulty soldering the LCD module Replace the LCD module Do the CBIC 8 MA0 MA14 pulses change sequentially Defective 8 Replace 8 Do video RAM 6 MD0 M7 change in response to the MA0 MA14 pulses Defective 6 Replace 6 Problem Word processor prints when no paper is set or will not pr...

Page 75: ...k properly Points to Check Probable Cause Corrective Action Repair Is the fax modem cable connected properly Faulty improper connection Reconnect cable Replace cable Is each level of CN1 signal approx 10V Defective 1 Replace the Main PCB Replace 1 Do the TXD of the CBIC 8 signal change Defective 8 Replace the main PCB Replace 8 Do the RXD of the CBIC 8 signal change Defective 1 or circuit on the M...

Page 76: ...y Code Change Over circuit match the ROM Solder point setting is wrong or the ROM 11 12 is incorrectly mounted Replace the Main PCB Set the correct solder point or replace the ROM 3 RAM down RAM cannot be accessed at power on Is the RAM installed correctly RAM improperly installed e g solder bridge or defective RAM 10 Replace the Main PCB Reinstall replac e the RAM 10 ...

Page 77: ...before the test is started From the SELF PRINT screen From the SELF TEST menu after selecting a test of after pressing the S key Type SERIAL NO and press RETURN SERIAL NO Fig 3 3 Serial Number Entry Display NOTES The maximum number of characters that can be input is 9 alphanumeric keys are the only acceptable input The RETURN key can also be pressed without entering a serial number Pressing CANCEL...

Page 78: ...ng OK NG MAIN RAM Checking OK NG Fig 3 4 Self Print Pattern NOTES OK is displayed if the checked item is normal NG if there is an error If the result of all checks is OK the carriage is returned and the self print all character test is starts If there are any errors in the sum check self printing will not start The buzzer will not sound but the SELF PRINT screen will remain It will not be possible...

Page 79: ...the input character string will not be registered as a serial number and display will return to the Main Menu screen If the SPACE BAR or CANCEL key is pressed during printing self printing is suspended and the pop up screen shown below is displayed YES OK to cancel printing Use cursor to select and press RETURN NO If RETURN is entered while the cursor is located at YES self printing is canceled an...

Page 80: ...REPAIR SERVICE MANUAL Troubleshooting 3 17 Fig 3 5 Results of Self Print Test ...

Page 81: ...PACE keys and the menu shown below displays 2 Press the character key for the desired test 14 line model and 10 inch VGA model SELF TEST MENU Please select the number Press CANCEL to finish 2HD DISPLAY 1 PRINTER 2 3 KEYBOARD 4 5 6 FDD 7 8 9 D E PE A CR B RS 232C C SERIAL NO S XXXXXXXX DISK TYPE T 2DD 7 line model SELF TEST MENU Please select the number Press CANCEL to finish 2HD PE A CR B SERIAL N...

Page 82: ...e test CODE SHIFT INSERT paper insert CODE SHIFT CANCEL line feed CODE SHIFT HELP paper eject CANCEL returns to the Main Menu If a serial number has been input it will be displayed in the brackets to the right of the serial number menu item if no serial number has been entered only the brackets will be displayed If there is a problem with the printer an error message is displayed and testing will ...

Page 83: ...he LCD Test Menu 2 Press the number key for the desired display test The screen displays the selected test pattern 14 line model and 10 inch VGA model LCD TEST MENU 1 CHECK 2 CROSS 3 BLACK 4 DISP Q 5 SLANT LINE Please select the number Press CANCEL to finish 7 line model LCD TEST MENU 4 DISP Q 5 SLANT LINE 1 CHECK 2 CROSS 3 BLACK Please select the number Press CANCEL to finish Fig 3 7 LCD Test Men...

Page 84: ...e CHECK test displays every other bit as shown below magnified Select 1 from the MENU screen NOTE Press the space bar and the displayed bit pattern is reversed 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Fig 3 8 CHECK Test Display magnified ...

Page 85: ...he CROSS test displays the grid pattern shown below magnified Select 2 from the MENU screen NOTE Press the space bar and the displayed bit pattern is reversed 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Fig 3 9 CROSS Test Display magnified ...

Page 86: ...ng 3 23 7 3 1 3 Black Test The BLACK test checks for missing dots pixels Select 3 from the MENU screen NOTE Press the space bar and the displayed bit pattern is reversed Every pixel on the screen is displayed Fig 3 10 BLACK Test Display ...

Page 87: ... The DISP Q test displays the character Q on the entire screen Select 4 from the MENU screen NOTE Press the space bar and the displayed bit pattern is reversed 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Fig 3 11 DISP Q Test Display magnified ...

Page 88: ...n as shown below Select 5 from the MENU screen The following screen is displayed Upper left corner NOTE Press the space bar and the displayed bit pattern is reversed If any key other than the key indicated above is pressed the screen will return to the MENU screen Fig 3 12 Slant Line Test Display magnified ...

Page 89: ...go to MENU PRINTER CHECK Fig 3 13 Printer Check 1 in progress Display NOTES A paper check is performed before printing If paper is set the print test is executed if no paper is set the ERROR pop up window is displayed If you select to continue printing paper is automatically inserted by the ACF and to execute the print test Pressing the CANCEL key during printing will stop the test paper is advanc...

Page 90: ...ow of dots corresponding to a single raster scan is also highlighted in each character space the raster being one lower than in the previous character space total of 54 raster scans Printing of Color Bar If color ink is used The 20 H to 5F H characters are printed on this line 18 point GREEN BLUE The 20 H to EF H characters are printed on this line 7 point RED The 20 H to EF H characters are print...

Page 91: ...he print format settings are as follows Font Brougham Type Style Normal 12 point 7 point Bold 18 point Line space Auto Left right margins 1 0 7 4 inches Yellow Magenta Cyan Yellow Black Blue Red Green Yellow Yellow Fig 3 15 Sample Print Test Pattern 1 ...

Page 92: ...s executed if no paper is set the ERROR pop up window is displayed If you select to continue printing paper is automatically inserted by the ACF and to execute the print test Pressing the CANCEL key during printing will stop the test paper is advanced and return the display to the Self Test menu If a serial number has not been input before starting the test the pop up window will prompt for the se...

Page 93: ...REPAIR Troubleshooting SERVICE MANUAL 3 30 Pattern 1 Pattern 2 Pattern 3 Pattern 4 Pattern 5 32 36 XXXXXXXXX 9 digits Pattern 6 49 66 14 31 9 Fig 3 17 Sample Test Pattern 2 ...

Page 94: ...terns The following dot print patterns correspond to the print test 2 pattern result on the previous page See also Fig 3 17 for the location of each dot pattern type Pattern 2 Pattern 1 Pattern 4 Pattern 3 Fig 3 18 Dot Patterns for Print Test 2 Patterns 1 to 4 ...

Page 95: ...REPAIR Troubleshooting SERVICE MANUAL 3 32 Pattern 5 Pattern 6 Fig 3 19 Dot Patterns for Print Test 2 Patterns 5 and 6 ...

Page 96: ...put before starting the test the pop up window will prompt for the serial number either enter the serial number or press RETURN to start the test The display in Fig 3 20 below indicates that the keyboard test mode has been established Press RETURN twice to go to MENU KEYBOARD TEST Fig 3 20 Keyboard Test 1 Display NOTE The location of the keys tested in each test sequence test 4 5 or 6 are shown be...

Page 97: ...r is set the print test is executed if no paper is set the ERROR pop up window is displayed If you select to continue printing paper is automatically inserted by the ACF and to execute the print test If the keys are pressed in the wrong sequence a beep will sound The test will continue when the correct key is pressed At any time during the test you may cancel by pressing the RETURN key twice to re...

Page 98: ...riage return KB TEST OK is printed and the display returns to the SELF Test menu A paper check is performed before printing If paper is set the print test is executed if no paper is set the ERROR pop up window is displayed If you select to continue printing paper is automatically inserted by the ACF and to execute the print test If the keys are pressed in the wrong sequence a beep sounds The test ...

Page 99: ...ing errors 7 3 4 1 FDD Test 1 Insert a non write protected diskette in the disk drive and if necessary change the DISK TYPE 2HD or 2DD displayed on the Self Test menu to that of the test diskette 2 With paper set select 7 from the Self Test menu If a serial number has not been input before starting the menu the pop up window will prompt for the serial number either enter the serial number and pres...

Page 100: ...rmal DISK TEST OK DISK TYPE 0 2DD DISK TYPE 1 2HD If disk switch is defective DISK ERROR 01 If write protect switch is defective DISK ERROR 03 If other read write errors occur DISK ERROR 0F 7 3 4 2 Special FDD Test 1 With paper set and no diskette in the disk drive change the DISK TYPE 2HD or 2DD displayed on the Self Test menu to that of test diskette 2 Select 8 from the Self Test menu If a seria...

Page 101: ...ge to test disk SPECIAL FDD TEST Fig 3 24 Special FDD Test Display 2 4 When the direction Change to test disk is displayed insert a diskette that is not write protected if a write protected diskette is inserted an error will occur The display changes to the one below A reading and writing check is performed the test results are printed and the display returns to the Self Test menu Working SPECIAL ...

Page 102: ... of ABORT command Output of SPECIFY command Switching drive motor ON Checking write protect 1 Recalibration Reading SSB3 by means of CHECK DRIVE STATUS command and checking status of track 0 signal Seeking cylinder 1 Reading SSB3 by means of CHECK DEVICE STATUS command and checking status of track 0 signal 2 Seeking cylinder 0 Formatting cylinder 79 3 Formatting cylinder 0 4 Seeking cylinder 39 Fo...

Page 103: ...C error at the data area F SEEK command or RECALIBRATE command not completed normally IRQ not detected in IRQ waiting status No command or parameter output Data overrun detected End of DMA transfer not detected Number of sectors for which reading writing requested was 0 Attempt made to access sectors beyond the final sector on the disk Could not receive RESULT CODE NOTES If an error occurs at any ...

Page 104: ...ed The disk switch is checked the test results are printed and the display returns to the Self Test menu if a diskette that is not write protected is inserted an error will occur NOTES The test results are printed as shown below SERIAL NO if it was entered If normal DISK TEST OK DISK TYPE 0 2DD DISK TYPE 1 2HD If disk switch is defective DISK ERROR 01 If write protect switch is defective DISK ERRO...

Page 105: ...HECK ERROR TIMES PASS NO TRACK NO Fig 3 27 FDD Write Error Rate Check Display 2 With paper set insert a diskette that is not write protected in the drive and press RETURN The screen message changes to working during formatting and 0 is displayed at PASS NO then the Write Error Rate check is started a The diskette is formatted b Data DB6 is repeatedly written on both sides of a randomly designated ...

Page 106: ...out if disk switch is defective DISK ERROR 01 Printout if write protect switch is defective DISK ERROR 03 Printout if other read write errors DISK ERROR 0F After the check has run 500 times or the CANCEL key has been pressed the following items are printed PASS NO XX 1 500 TRACK NO XX 0 79 WRITE CHECK ERROR X type error TIMES XX SERIAL NO XXXXXXXXX if a serial no was input or blank if no errors de...

Page 107: ... Read Error Rate Check Display 2 With paper set insert a diskette that is not write protected in the drive and press RETURN The screen message changes to working during formatting and 0 is displayed at PASS NO then the Read Error Rate check is started a The diskette is formatted b Data DB6 is written to all daya areas in order setting with track 0 c The data on both sides of a randomly designated ...

Page 108: ...out if disk switch is defective DISK ERROR 01 Printout if write protect switch is defective DISK ERROR 03 Printout if other read write errors DISK ERROR 0F After the check has run 500 times or the CANCEL key has been pressed the following items are printed PASS NO XX 1 500 TRACK NO XX 0 79 READ CHECK ERROR X type error TIMES XX SERIAL NO XXXXXXXXX if a serial no was input or blank if no errors det...

Page 109: ... 1 From the Self Test menu press A The display changes to the following TEST START Press CANCEL to go to MENU PAPER EMPTY Fig 3 29 PE Sensor Test Start Display 1 2 Set paper in the carriage by pressing CODE SHIFT INSERT and verify that the screen message changes to the following Press CANCEL to go to MENU PAPER EXIST TEST START Fig 3 30 PE Sensor Test Start Display 2 ...

Page 110: ... Move CR by 1 step in forward direction Fig 3 31 CR Test Start Display 1 NOTES The following keys may be used to check the CR position as described 1 UP ARROW key turns CR motor with AB phase 2 DOWN ARROW key turn CR motor off 3 LEFT ARROW key moves CR by 1 step backward right to left CR phase change direction is AB A DA D CD C BC B 4 RIGHT ARROW key moves CR by 1 step forward left to right CR pha...

Page 111: ...s used in FDD tests Press T from the Self Test menu to change the DISK TYPE from 2DD to 2HD as appropriate SELF TEST MENU Please select the number Press CANCEL to finish 2HD DISPLAY 1 PRINTER 2 3 KEYBOARD 4 5 6 FDD 7 8 9 D E PE A CR B RS 232C C SERIAL NO S DISK TYPE T 2DD Fig 3 32 Self Test Menu DISK TYPE Setting RS232C item is not displayed for the LCD of 7 line type ...

Page 112: ...orking Fig 3 33 RS232C Echo Back Test Start Display 2 Check Procedures 1 Start the test with all RS232C serial port terminals open The status of the signal is checked in the following order 1 Checks that CTS HIGH and CD HIGH regardless of the HIGH LOW state of RTS 2 Checks that DSR HIGH regardless of the HIGH LOW state of DTR 3 Checks that data is not received at RXD by sending the data from TXD A...

Page 113: ...rinted RS 232C TEST OK 3 Functions 1 If an error is detected during execution of the test processing ends and the corresponding error code is printed RS 232C TEST ERROR XX X X Error code Lower digit State of the error in each step Upper digit The step where the error occurred 1 Upper digit A An error has occurred in the RTS CTS RTS CD test executed while the terminal is open The lower digit expres...

Page 114: ...ith the connector set The lower digit expresses the status by bits Bit 0 0 CTS LOW when RTS LOW Bit 0 1 CTS HIGH when RTS LOW error Bit 1 0 CTS HIGH when RTS HIGH Bit 0 1 CTS LOW when RTS HIGH error Bit 2 0 CD LOW when RTS LOW Bit 0 1 CD HIGH when RTS LOW error Bit 3 0 CD HIGH when RTS HIGH Bit 0 1 CD LOW when RTS HIGH error 5 Upper digit 2 An error has occurred in the DTR DSR test executed with t...

Page 115: ...SERVICE MANUAL 3 52 2 The test connector to be used in the echo back test is indicated below Output Input Input Output Output TXD RXD Input Input DSR CD CTS RTS 7 7 8 8 1 1 4 4 6 6 3 3 2 2 DTR Machine Terminal Test Connector ...

Page 116: ...REPAIR SERVICE MANUAL Mechanical 4 1 CHAPTER 4 COMPONENT DISASSEMBLY 1 Covers NOTE All model details may not be represented in all illustrations herein Fig 4 1 Cover Assemblies ...

Page 117: ...Upper Cover 1 Turn off the power switch 2 Unplug the AC adaptor from the wall outlet and unplug the adaptor from the machine 3 Remove the paper support a Push on the point indicated by the black arrow and disengage the hook from the rib on the paper support b Hold the middle of the support and carefully push on the point indicated by the black arrow and disengage the hook from the upper cover c Li...

Page 118: ...REPAIR SERVICE MANUAL Mechanical 4 3 Fig 4 2 Removing the Sub Paper Support and Paper Support ...

Page 119: ...er fits on tabs on the upper cover a Open the top cover to about 90 b Push on the point indicated by the black arrow and disengage the top cover from the upper cover Slide the top cover to the right and lift the upper cover clear of the top cover Fig 4 3 Removing the Top Cover ...

Page 120: ...tridge to the center position b Remove the two upper cover taptites at the rear of the machine Fig 4 4 Removing the Upper Cover c Unsnap the right and left retaining tabs inside the upper cover d Disengage the LCD latch from the upper cover and tilt the LCD to its upright position ...

Page 121: ...klit models also disconnect the backlight PCB harness from the main PCB g Release the four retaining locks at the rear and remove the upper cover from the bottom cover Remove the upper cover from the bottom cover 6 Remove the LCD module upper cover removed Electro Static Discharge Hazard Wear an anti static wrist strap with ground wire to prevent damage to sensitive electronic components NOTE For ...

Page 122: ...the LCD harness to the main PCB 3 Place the upper cover on the bottom cover and beginning in the middle of each side apply pressure on the upper cover to engage the left and right hooks 4 Apply pressure to the rear of the upper cover to engage the two rear locks then to the front of the upper cover to lock the four front locks keyboard side NOTE Make sure that the LCD harness is still locked into ...

Page 123: ...e the two screws that secure the hinge assy to the upper cover and remove the hinge assy from the upper cover b Remove the two taptites that secure the LCD bearing to the upper cover and remove the LCD bearing from the upper cover c Remove the LCD module harness from the LCD bearing by pulling the harness through the hole in the LCD bearing The LCD module can now be removed from the upper cover Fi...

Page 124: ...REPAIR SERVICE MANUAL Mechanical 4 9 Fig 4 6 Removing the LCD Unit ...

Page 125: ...Remove the LCD rubber LR 2 pcs b Remove the LCD spacers LCD spacer M 1 pc and LCD spacer LR 2 pcs c Remove the seven taptites and one screw that secure the LCD lower cover to the LCD upper cover The LCD lower cover can now be removed Fig 4 7 Removing the LCD Lower Cover ...

Page 126: ...to the model DP 525CJ LW 800ic DP 530CJ LW 810ic LW 810icBL Remove the taptites that secure the LCD PCB to the LCD upper cover and remove the LCD PCB by disengaging hook A on the LCD upper cover See Figs 4 8 4 9 and 4 10 DP 540CJ DP 550CJ LW 840ic Remove the taptites that secure the LCD PCB to the LCD upper cover and remove the LCD PCB See Figs 4 11 and 4 12 c Remove the inverter PCB by disengagin...

Page 127: ...REPAIR Mechanical SERVICE MANUAL 4 12 DP 525CJ LW 800ic Fig 4 8 Removing the LCD PCB 1 ...

Page 128: ...REPAIR SERVICE MANUAL Mechanical 4 13 DP 530CJ LW 810ic Fig 4 9 Removing the LCD PCB 2 ...

Page 129: ...REPAIR Mechanical SERVICE MANUAL 4 14 LW 810icBL Fig 4 10 Removing the LCD PCB 3 ...

Page 130: ...REPAIR SERVICE MANUAL Mechanical 4 15 DP 540CJ Fig 4 11 Removing the LCD PCB 4 ...

Page 131: ...REPAIR Mechanical SERVICE MANUAL 4 16 DP 550CJ LW 840ic Fig 4 12 Removing the LCD PCB 5 ...

Page 132: ...17 3 Remove the LCD latch and LCD plate a Slide the latch shafts outwards and remove the LCD latch from the LCD upper cover b Remove the taptites 2 pcs and the LCD plate from the LCD upper cover Fig 4 13 Removing LCD Latch and LCD Plate ...

Page 133: ... plate a Place the LCD plate on the LCD upper cover by aligning the holes in the LCD plate with the bosses on the LCD upper cover Then secure the LCD plate by tightening the taptites 2 pcs b Mount the LCD latch in the LCD upper cover Insert the right latch shaft first Then after inserting the left latch shaft slightly set the spring by inserting A into latch and B into slot Pass the shaft through ...

Page 134: ...REPAIR SERVICE MANUAL Mechanical 4 19 Fig 4 14 Installing LCD Latch ...

Page 135: ...ers according to the model DP 525CJ LW 800ic DP 530CJ LW 810ic LW 810icBL While holding the LCD PCB at an angle of 45 slide its edge into hooks B Then fit the LCD PCB in the LCD upper cover by prying hooks A outwards The LCD PCB is held in place by hooks A and hooks B When installing the LCD PCB determine the position by aligning the holes in the LCD PCB with the bosses on the LCD upper cover NOTE...

Page 136: ...REPAIR SERVICE MANUAL Mechanical 4 21 DP 525CJ LW 800ic DP 530CJ LW 810ic LW 810icBL Fig 4 15 Fitting LCD Volume Guide to LCD Volume Knob ...

Page 137: ...ginal position 3 Install the LCD lower cover a Place the LCD lower cover on the LCD upper cover b Place the assembly of the LCD lower cover and upper cover on the table with the LCD screen facing up c Tighten the screw 1 pc and taptites 7 pcs to clamp the LCD lower cover to the LCD upper cover d Fit the LCD spacer M 1 pc and LCD spacer LR 2 pcs to the LCD upper cover e Fit the LCD rubber LR 2 pcs ...

Page 138: ...e holes in the upper cover and the LCD module and secure it with the taptites 2 pcs d Insert the hinge assy into the holes in the upper cover and the LCD module LCD plate tighten the screws 2 pcs while holding the hinge assy NOTE When mounting the hinge assy push it fully into the LCD unit until the end of the hinge assy shaft touches the rib in the LCD upper cover See Fig 4 18 Fig 4 17 Fitting th...

Page 139: ...REPAIR Mechanical SERVICE MANUAL 4 24 Fig 4 18 Installing the Hinge Assy ...

Page 140: ...ord 2 Remove the sub paper support paper support top cover and the upper cover 3 Press outward on the two clips one on each side of the keyboard lift up on the keyboard panel to just clear the bottom cover keyboard supports and unplug the keyboard harness from the main PCB left side NOTE The keyboard PCB and the base plate are attached to the bottom of the keyboard and are not removable entire ass...

Page 141: ... 3 2 Installing the Keyboard Place the keyboard in the bottom cover on the keyboard supports plug the keyboard PCB harness into the main PCB and push down on each side of the keyboard to snap it into place Fig 4 20 Installing the Keyboard ...

Page 142: ...ll screwdriver to disengage the handle pivot shaft from the stoppers 4 Slide the handle fully to the left to clear the locks in the bottom cover and pull it toward you 4 2 Installing the Carrying Handle 1 Turn the handle perpendicular to the bottom cover and slide the left pivot shaft into the hole in the left side of the bottom cover 2 Align the right pivot shaft with its hole at the right side a...

Page 143: ... 4 28 5 Ink Jet Printer Assembly The ink jet printer assembly consists of the PF unit CA unit and the earth spring The ink jet printer assembly is secured to the rear of the bottom cover by two screws Fig 4 22 Ink Jet Printer Assembly ...

Page 144: ... from both sides of the PF base assembly and lift the printer assembly from the PF base assembly supports in the bottom cover 5 2 Installing the Printer Assembly 1 Slide the rear of the printer assembly into the catches in the bottom cover while holding harnesses 3 and 4 in the groove in the PF unit Then place the front of the printer assembly on the alignment posts in the bottom cover push down o...

Page 145: ...REPAIR Mechanical SERVICE MANUAL 4 30 5 3 Disassembling the Printer Assembly Fig 4 23 Disassembling the Printer Assembly ...

Page 146: ...A unit 3 Lift the CA unit to clear it from the catches in the PF unit 5 3 2 Installing the CA Unit 1 Hold both ends of the CA unit and slide it in so that the alignment ribs on both sides of the CA unit engage in the catch of the PF unit 2 Secure the CA unit to the PF unit by tightening the screws 2 pcs 3 Fit the earth spring ...

Page 147: ...REPAIR Mechanical SERVICE MANUAL 4 32 5 3 3 Disassembling the PF Unit This section describes the procedure for disassembling the PF unit Fig 4 24 Construction of the PF Unit ...

Page 148: ...REPAIR SERVICE MANUAL Mechanical 4 33 5 3 3 1 Removing the Form Remove the screw and the spacer then take out the form Fig 4 25 Removing the Form ...

Page 149: ...sembly by lightly pushing the leaf spring slide the release shaft in the thrust direction and align the recess in the release shaft with the cutout in the PF base assembly Remove the release shaft from the PF base assembly 3 Turn the release lever clockwise and remove it from the PF base assembly Fig 4 26 Removing the Release Lever and Release Shaft from the PF Base Assembly ...

Page 150: ... the PF base assembly 3 After disengaging the ACF shaft assembly from the PF base assembly by lightly pushing the leaf spring slide the ACF shaft assembly in the thrust direction and align the recess in the ACF shaft assembly with the cutout in the PF base assembly Remove the ACF shaft assembly from the PF base assembly Fig 4 27 Removing the ACF Shaft Assembly ...

Page 151: ...l procedure can be used for all of them 1 Remove the pressure roller springs spring A and springs B 2 Disengage a roller holder from a holder plate and take away the holder plate upward with a roller in it 3 Push the pressure roller to the cut out side in the roller holder to remove it from the roller holder Fig 4 28 Removing the Pressure Rollers and Roller Holders ...

Page 152: ...Unsnap the two hooks in the PF base assembly to disengage the holder plate from the PF base assembly Then lift the holder plate away from the PF base assembly upward by tilting it towards you 2 Remove the screw and then the ACF shaft stopper Fig 4 29 Removing the Holder Plate ...

Page 153: ...e assembly 2 Remove the hopper springs 3 Remove the change spring 4 Unsnap the hook in the hopper assembly to disengage the ACF change lever from the hopper assembly Then turn the ACF change lever up in the counterclockwise direction to remove it from the hopper assembly 5 Make sure that the pin on the ACF change shaft has cleared the hook in the hopper ass y Then turn the ACF change shaft to alig...

Page 154: ...REPAIR SERVICE MANUAL Mechanical 4 39 Fig 4 30 Removing the Hopper Assembly ...

Page 155: ... 4 3 Remove the eject roller gear 4 Remove E ring 3 5 Remove idle gears 1 5 and 6 6 Remove the change lever 1 assembly changer lever 1 idle gear 3 and spring washer 7 Remove idle gear 2 8 Remove the change lever 2 assembly change lever 2 idle gear 3 9 Remove the PF roller gear Fig 4 31 Disassembling the Paper Feed Assembly ...

Page 156: ...bly After releasing the hook in the ejector roller assembly slide it to the right to remove it from the PF base assembly Removing the PF Roller Assembly After releasing the E rings from the PF roller assembly slide it to the right to remove it from the PF base assembly Fig 4 32 Removing the Eject Roller Assembly and the PF Roller Assembly ...

Page 157: ...Motor Frame Assembly 1 Remove the spring R 2 Remove the two taptites 3x10 3x20 to remove the motor frame assembly from the PF base assembly 3 Remove the screw 3x5 to remove the PF motor from the PF motor frame assembly Fig 4 33 Removing the Motor Frame Assembly ...

Page 158: ... with a screwdriver from the rear of the PF base assembly and the PF stopper is forced upward by spring force Turn the PF stopper to align the cut out in the PF stopper bearing with the oval pin of the PF base assembly Remove the PF stopper from the PF base assembly 2 Remove the stopper spring Fig 4 34 Removing the PF Stopper ...

Page 159: ...1 Unsnap the hook on the PE sensor by pushing it from the top side of the F base assembly to disengage it from the PF base assembly Remove the PE sensor by sliding it towards you 2 Disconnect the sensor harness connector from the PE sensor Fig 4 35 Removing the PE Sensor ...

Page 160: ...REPAIR SERVICE MANUAL Mechanical 4 45 5 3 4 Disassembling the CA Unit This section describes the procedure for disassembling the CA unit Fig 4 36 Construction of the CA Unit ...

Page 161: ...the idle pulley holder spring to remove the timing belt from the idle pulley 3 Remove the screw from the main shaft stopper and remove the main shaft stopper 4 Remove the main shaft by sliding it to the right 5 Remove the FPC locker from the CA frame by unsnapping the hooks 2 pcs of the FPC locker 6 Disengage the carriage and the timing belt from the CA frame 7 The timing belt is held under the ca...

Page 162: ...REPAIR SERVICE MANUAL Mechanical 4 47 Fig 4 38 Removing the Carriage ...

Page 163: ...ull it up 2 Remove the CA motor screw then remove the CA motor by turning the CA motor in order to disengage the CA motor flange from the hook on the CA frame NOTE After reassembling the timing belt and the motor it is necessary to adjust the carriage home position and check the carriage belt tension See 5 4 1 Adjusting the Carriage Home Position and 5 4 2 Adjusting Belt Tension Fig 4 39 Removing ...

Page 164: ...lder forward to disengage the hook from the CA frame 2 Disengage the other hook in the same manner as described in step 1 above 3 Push the star wheel holder assembly forward to remove it from the CA frame NOTE When installing the star wheel holder assembly to the CA frame fit the rib under the star wheel holder into the slit in the CA frame Fig 4 40 Removing the Star Wheel Holder Assembly ...

Page 165: ...ical SERVICE MANUAL 4 50 5 3 4 4 Removing the MS Holder Assembly 1 Remove the MS holder assembly screw 2 Slide the MS holder to clear the hook and remove it from the CA frame Fig 4 41 Removing the MS Holder Assembly ...

Page 166: ...eaf switch assembly from the leaf switch cover NOTE When reassembling the leaf switch first fit the leaf switch cover on the leaf switch so that the alignment pin on the leaf switch assembly fits correctly into the alignment hole in the leaf switch cover Then determine the position by inserting the alignment pin into the alignment hole in the CA frame Fig 4 42 Removing the Leaf Switch Home Positio...

Page 167: ...ving and Mounting the KB Switch Assy The switch in the KB switch assy is used for the following specifications Belgium Switzerland Canada Remove the screw from the CA frame and remove the KB Switch Assy Fig 4 43 Removing and Mounting the KB Switch Assy ...

Page 168: ...ot available you may simply remove the two screws securing the printer assembly to the bottom cover and raise the mechanism to access the carriage motor screw however you MUST place a non conductive material such as paper between the printer and other electrical components especially the power supply PCB to avoid grounding damage to the equipment 3 Loosen the CA motor screw 4 Turn on all power and...

Page 169: ...f the carriage does not move freely or if the belt is removed or replaced the tension should be checked and adjusted as follows 1 With power disconnected from the machine move the carriage to the left end maintenance station side and verify that the belt is properly installed 2 Push the idle pulley holder to verify that it moves freely If the pulley holder cannot be moved smoothly there is too muc...

Page 170: ...rtridge friction belt tension is within the acceptable range NOTE If adjustment is not satisfactory and the carriage friction is still larger than the acceptable limit lubricate the idle pulley shaft and idle pulley rotation point See Lubrication in Chapter 5 MAINTENANCE for details Fig 4 44 Adjusting the Belt Tension ...

Page 171: ...REPAIR Mechanical SERVICE MANUAL 4 56 Fig 4 45 Measuring Friction during Carriage Movement ...

Page 172: ...from the Main PCB 2 Unplug the power cable from the FDD 3 Remove the two screws securing the FDD to the bottom cover The two ground plates secured on the FDD are also removed 4 Move the FDD to the left to clear the retainers in the bottom cover and lift it out Fig 4 46 Removing the FDD Assembly ...

Page 173: ...58 7 Switch PCB Electro Static Discharge hazard Wear an anti static wrist strap with ground wire to prevent damage to sensitive electronic components As shown in Fig 4 47 the switch PCB is mounted on the bottom cover Fig 4 47 Switch PCB ...

Page 174: ...h section slide it to the right and up to clear the switch housing and lift it out 7 2 Installing the Switch PCB 1 Place the switch PCB switch section into its location in the bottom cover slide it to the left and down to insert the switch in its housing and secure it in replace with the screw 2 Reconnect the power harness to the main PCB Fig 4 48 Switch PCB ...

Page 175: ...c components Be sure to hold the connector not the cable when connecting or disconnecting a harness The main PCB is fitted to the bottom cover and secured by screws Remove the screws and all harnesses and cables from the main PCB and lift it out of the bottom cover The ground plates secured on the main PCB are also removed when the screws are removed Fig 4 49 Removing the Main PCB ...

Page 176: ...Removing the Shield Plate ESD Lift up on the rear side of the shield plate to clear the alignment pin slide the shield plate forward to clear the three retaining clips in the bottom cover and lift it out Fig 4 50 Removing the Shield Plate ESD ...

Page 177: ... adversely affected 2 Do not apply an excessive amount of lubricant otherwise the lubricant may drip onto places other than the specified lubrication points during use or storage 3 Make sure to apply a sufficient amount of lubricant to contact parts and sliding surfaces consisting of more than one material 1 3 Lubrication Points See the illustrations on the following pages for location and types o...

Page 178: ...REPAIR Mechanical SERVICE MANUAL 5 2 Fig 5 1 Carriage Assembly Lubrication Points ...

Page 179: ...REPAIR SERVICE MANUAL Mechanical 5 3 Fig 5 2 Paper Feed Assembly Lubrication Points ...

Page 180: ...REPAIR Mechanical SERVICE MANUAL 5 4 Fig 5 3 Eject Roller Assembly and PF Roller Assembly Lubrication Points ...

Page 181: ...e print head and ink It should be replaced after about 1 000 000 characters estimated using normal text 12 point Brougham font 1 Open the paper support and the top cover 2 Tilt the LCD module into the upright position 3 At the keyboard press CODE INK CHG The carriage will move to the ink change home position Do not move the carriage manually from side to side The following screen message will appe...

Page 182: ...REPAIR Mechanical SERVICE MANUAL 5 6 Fig 5 4 Open the Paper Support and Top Cover and Tilting the LCD to the Uprige Position ...

Page 183: ...5 Grasp the ink jet cartridge as shown below and push it backward until a click of release is heard then pull the cartridge straight up and out of the carriage Fig 5 5 Removing the Ink Jet Cartridge 6 Remove the protection tape from the new ink jet cartridge Do not shake the cartridge after the tape has been removed Fig 5 6 Removing the Protection Tape ...

Page 184: ...REPAIR Mechanical SERVICE MANUAL 5 8 7 Slide the cartridge into the carriage bracket as shown below Fig 5 7 Placing the Cartridge in the Carriage ...

Page 185: ...ogether until the cartridge snaps under the latch on the bracket Fig 5 8 Fitting the Cartridge in the Carriage 9 Tile the LCD module into the upright position and at the keyboard press RETURN The ink jet cartridge is ready to use 10 Close the LCD module top cover and the paper support ...

Page 186: ...d Contacts If print quality does not improve after automatically cleaning the print head the problem may be dried ink on the nozzles contacts or on the print cartridge bracket contacts 1 Remove the ink jet cartridge 2 With a clean water dampened cloth gently wipe the entire copper colored area including the nozzles and contacts NOTE To dissolve any dried ink hold the damp cloth against the nozzles...

Page 187: ...hout turning off the machine unplug the DC jack from the DC plug connector on the rear of the machine This will keep the carriage assembly from returning to the maintenance station 3 Turn the machine off and remove the ink cartridge 4 With a clean dry cloth clean the gold colored contacts on the ink cartridge bracket as shown below Fig 5 9 Cleaning the Bracket Contacts ...

Page 188: ...Kbyte 5 FDC LG GM82C765B 6 KB Matrix 8 9 7 Switch PCB Size 58 49 mm 8 Display LCD 480 64 DP 525CJ 480 128 DP 530CJ 640 400 DP 540CJ 550CJ 9 Printer Mono Color 10 CA Step Motor Chopper Control 11 LF Step Motor Constant Voltage Control 12 HP Sensor Leaf Type Switch 13 PE Sensor Leaf Type Switch 14 Auxiliary Memory FDD 1 44 MB 720KB MFM form MS DOS format 3 5 2HD 3 5 2DD ...

Page 189: ...1 3 mm 9 5 Max Printing Width 205 74 mm 8 1 Possible Printing Area except 12 7 mm 1 2 from top and bottom and 25 4 mm 1 area from bottom 9 Paper Sizes length a 100 to 355 6 mm 3 94 to 14 0 width b 139 7 to 241 3 mm 5 5 to 9 5 10 Base Paper Handling Position right side 11 Paper Type letter 215 9 279 4 mm 8 5 11 0 legal 215 9 355 6 mm 8 5 14 0 B5 182 257 mm 7 17 10 2 A4 210 297 mm 8 27 11 69 executi...

Page 190: ...70 Paper 20 lb A4 US letter 13 Printing Direction text bidirectional graphics unidirectional 14 Cartridge Yield up to 1 000 pages of text at 5 1 170 characters 238k ink drops 15 Carriage Driving Resolution 1 968spmm 50 spi full step 16 Acoustics Printing noise 55 dB maximum 1m A Scale fast 17 Reliability Durable life time 5 year printing quality or 30 000 000 characters or 12 000 sheets printed Me...

Page 191: ...ator Koala style with 2 cranks 3 Keystroke 3 8 mm 0 3mm touch force 300g 4 Key Touch Load 60 g 20 g except SPACEBAR 70 g 30 g 5 Gap between Key Tops KB Panel 1 0 mm 2 0 mm 6 Gap between Key Tops 0 8 mm 1 0 mm 7 Keyboard Features Style fixed type Shape step key Key Roll over limited key Total keys 65 Key touch load 150 g Pressure resistance smooth return of keytop after 3 kg Key top take off force ...

Page 192: ...ay 1 500 times 2 Physical Environment Vibration cycles IMV vibration test machine 5 55 Hz each direction 0 1 G no operation error after 30 minute test Edge drop test 50 mm edge drop no damage Temperature Range 10 40 C Thermal shrinkage 2 hours 5 cycles between 40 C and 70 C no damage Cold start power on after 2 hours at 0 C no operation error print quality excluded Storage 48 hours at 20 C 60 C an...

Page 193: ...APPENDIX Specifications SERVICE MANUAL APP 6 5 Dimensions Weight 1 Dimensions 16 0 d 16 0 w 4 4 h in 2 Weight 11 1 lbs 5 0kg packaged ...

Page 194: ...Feb 98 53T010BE1 R ...

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