Brother TD-4000 Service Manual Download Page 3

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CONTENTS

1.1 MECHANICAL SPECIFICATIONS........................................................................................I-1

1.2 ELECTRONICS SPECIFICATIONS .......................................................................................I-2

1.2.1 Power Supply .....................................................................................................................I-2

CHAPTER II THEORY OF OPERATION

2.1 OUTLINE OF MECHANISMS .............................................................................................. II-1

2.2 OUTLINE OF CONTROL ELECTRONICS.......................................................................... II-7

2.3 MAIN PCB .............................................................................................................................. II-9

Summary of Contents for TD-4000

Page 1: ...SERVICE MANUAL MODEL TD 4000 TD 4100N ...

Page 2: ...e is always in best condition for the customer the service personnel must adequately understand and apply this manual This manual is made up of four chapters and appendices CHAPTER I SPECIFICATIONS CHAPTER II THEORY OF OPERATION CHAPTER III DISASSEMBLY AND REASSEMBLY CHAPTER IV TROUBLESHOOTING AND ERROR MESSAGE APPENDIX 1 SERVICEMAN SOFTWARE TOOL Copyright Brother 2009 All rights reserved No part ...

Page 3: ...LINE OF CONTROL ELECTRONICS II 7 2 2 1 Main PCB II 7 2 2 2 Media Position Detect Sensor PCB Tape Sensor II 7 2 2 3 Button LED PCB SB PCB II 8 2 2 4 Cutter Home Position Sensor II 8 2 2 5 Media Feed Motor Tape Feed Motor II 8 2 2 6 Full Cutter Motor II 8 2 2 7 Thermal Head II 8 2 3 MAIN PCB II 9 2 3 1 Logic Components II 11 2 3 2 Key LED Circuit II 12 2 3 3 Head and Motor Power Supply ON OFF Circui...

Page 4: ... ASSY and Cutter Unit ASSY III 46 4 Installing the Front Side Cover Panel Cover and Front Cover III 50 5 Installing the Main PCB ASSY and Power Supply ASSY III 54 6 Installing the Upper Cover III 64 7 Installing the Roll Roller and Roll Roller Shaft III 67 8 Installing the Ground Spring and Insert Guide III 68 9 Reassembling the Roll Guide III 69 10 Installing the Roll Guide III 71 11 Reassembling...

Page 5: ...nt Tool 1 3 1 2 2 Use Procedure of the VR Adjustment Tool 1 3 1 3 Setting and Use Procedure of the Serviceman Software Tool 1 4 1 3 1 Role of the Serviceman Software Tool 1 4 1 3 2 Setting Procedure of the Serviceman Software Tool 1 4 1 3 3 Use Procedure of the Serviceman Software Tool 1 6 1 3 4 Check Procedure of COM Port Number 1 21 1 4 Auto Power OFF Setting Tool 1 23 1 4 1 Role of the Auto Pow...

Page 6: ...1 8kg Machine proper only Figure 1 1 1 External Appearance 1 1 2 Keyboard 1 Number of function keys 3 2 Key arrangement See Fig 1 1 2 Figure 1 1 2 Key Arrangement 1 1 3 Display 1 Display type LED 1 ON OFF Green On Off Error Red blinking Cover open Yellow On Off Cooling Yellow blinking 158mm 173mm 229mm LED lamp POWER button CUT button FEED button ...

Page 7: ...n 300 dpi 1 1 5 Thermal Tape 1 Tape Roll type Die cut and free length 1 1 6 Cutter 1 Tape cutting Automatic cut Cutter unit is user unexchangeable component 1 1 7 PC Interface 1 Method Standard USB Standard Ver 2 0 Full speed 12Mbps RS232C Ethernet 10BASE T 100BASE TX TD 4100N only 2 Supported OS Microsoft Windows 2000 Professional Microsoft Windows XP Microsoft Windows Server 2003 Microsoft Windo...

Page 8: ...rce comes from a nip between the cylindrical rubber platen and the thermal head At this timing voltage is applied selectively to 1296 pieces of heating elements arrayed on the thermal head By this voltage application the heating elements generate heat and the thermal tape develops dots by itself at heat sensing points After application of voltage the thermal tape is fed to the next printing positi...

Page 9: ...ulled upwards they are unlocked so that the platen and top cover are released The tape can be loaded into the machine in this status If the head ASSY is pressed against the platen close the top cover Figure 2 1 2 Press Contact and Release Mechanism of Thermal Head Head ASSY Top cover ASSY Head spring Sub plate Platen Release lever R Platen Release lever L R Release lever L ...

Page 10: ...laten and the thermal head Here the tape feed motor step motor rotates of which drive power is transmitted via the gear train to the platen gear and the platen and consequently the platen can feed the tape Figure 2 1 3 Tape Feed Mechanism Thermal tape Platen Double gear C Double gear A Feed motor ASSY step motor Double gear B ...

Page 11: ...ys again at the position where the cutter home position sensor is ON This mechanism provides the mechanism to reverse the driving system which is used in case that the tape or the like is jammed between the blades For the details refer to CHAPTER IV TROUBLESHOOTING ERROR MESSEAGE When the driving system is reversed the cutter motor stops and stays again at the position where the cutter home positi...

Page 12: ...en cover lock sensors R and L push switch and the signal of top cover ASSY close status is output Figure 2 1 5 Cover Open Cover Lock Sensor Top cover ASSY Rib Cover sensor arm L Cover open cover lock sensor L push switch Cover open cover lock sensor L push switch Top cover ASSY Rib Cover sensor arm L Cutter unit ASSY SB PCB ASSY Top cover ASSY Rib Cover sensor arm R Cover open cover lock Sensor R ...

Page 13: ...urn to the roll guide shaft to the direction of the arrow D by releasing the roll guide actuator and releasing the cam of the roll guide actuator and the cam of the roll guide shaft Lock the claw of the roll guide to the gear part C of the upper cover by pressing the wall of the upper cover with the roll guide shaft At the same time lock the claw of the roll guide actuator to the gear part A of th...

Page 14: ... etc 2 2 2 Media Position Detect Sensor PCB Tape Sensor This sensor PCB detects the printing start position for the die cut label and checks existence of label for the free length label using reflection type photo sensor CN14 CN16 CN13 CN10 CN12 CN11 CN8 CN7 CN19 CN6 CN5 Cutter motor 220 230 240V model only Sub ASSY SW Cutter home position sensor Serial Fan motor unit Media feed motor Media positi...

Page 15: ...a Feed Motor Tape Feed Motor The media feed motor supplies the drive power to feed media This motor is step motor of which drive voltage is VH 25V 2 2 6 Full Cutter Motor The cutter motor supplied the drive power to cut media This motor is a DC motor of which drive voltage is VH 25V 2 2 7 Thermal Head Thermal head is thick film and drive built in type thermal head which consists of 1296 dots by on...

Page 16: ...50E MA3 ROM 256KB RAM 16KB FEED CUT button Green LED Red LED Oscillator circuit 7 6MHZ DC motor for full cut For tape feed driving EEPROM 4Kbits FROM 64Mbits Max 64Mbits TD 4100N SDRAM 128Mbits Max 128Mbits TD 4000 SDRAM 64Mbits Max 64Mbits RS232C IC RS232C IF Step motor Bipolar constant current drive circuit 100 120V Switch INT NEC 25V output LAN IF LAN IC LAN 9115 USB IF USB IC D12 Cutter home p...

Page 17: ...ontrol signal LAN IF LAN IC LAN 9115 USB IF USB IC D12 Cutter home position sensor Cover open sensor POWER button Cover left sensor Fan motor unit AC power supply Switching power supply Power supply shunt PCB 2 5V power supply circuit 3 3V power supply circuit Photo sensor for detecting top edge of media DC motor Normal reverse drive circuit Thermal head temperature detect circuit Thermal head 25V...

Page 18: ...It is used when the program is executed and when the received data is stored temporarily 4 EEPROM One 4Kbits EEPROM U3 is used This memory is used for write and storage of baud rate information Vendor ID code Product ID code and mechanical information If the main PCB is replaced it is needed to write the serial number printed on the EEPROM mounted on the main PCB and the mechanical configuration d...

Page 19: ... from PC Pressing this button in the condition that the status of power supply in ON and the status of ready for date acceptance from PC LED ON the CPU starts power OFF process turns the LED OFF and changes the status into power supply OFF LED OFF Pressing this button in the condition that the status of power supply is ON and now going on printing the CPU stops printing starts power OFF process af...

Page 20: ...High Q2 turns ON VH 25V power supply turns ON and consequently the head and motor is energized Turning the CPU status of 91pin VHON to Low Q2 turns OFF VH 25V power supply turns OFF and consequently the head and motor power supply is cut off Figure 2 3 4 Head and Motor Power Supply ON OFF Circuit ...

Page 21: ...r software it confirms that the top cover ASSY is closed and turns VHON 91 pin High Then the CPU controls C_DCF 114 pin and C_DCR 115 pin to drive the cutter motor 2 Media feed motor driver circuit When the CPU receives feed request from the key it confirms that the top cover ASSY is closed and turns VHON 91 pin High Then the CPU controls SIN1 27 pin through SIN6 20 pin to drive the media feed mot...

Page 22: ...rocesses this voltage through AD conversion and inspects between label that stays on the sensor position Figure 2 3 6 Media Position Detect Sensor Circuit 2 Cover open sensor circuit TD 4000 4100N has the cover open sensor It identifies open close of the top cover ASSY from the status of mechanical switch Opening the top cover ASSY the contact of cover open sensor on SB PCB opens The change of sta...

Page 23: ...rst confirms that the cutter stays on its home position prior to printing When the cutter returns to the home position the cutter home position sensor circuit recognizes it and stops the DC motor rotation Figure 2 3 9 Cutter Home Position Sensor Circuit 2 3 8 Reset Circuit TD 4000 4100N receives the electric power from the power supply PCB and output 5V and 3v to the CPU When the power is supplied...

Page 24: ...U12 establishes bus connection with 8 bits to send and receive the data Figure 2 3 11 USB Interface Circuit 2 3 10 RS232C Interface Circuit The CPU of TD 4000 4100N is connected with a PC using the RS232C cable via U11 and CN3 U11 and CPU U12 send and receive the data through the serial port Figure 2 3 12 RS232C Interface Circuit ...

Page 25: ...face Circuit TD 4100N only The CPU of TD 4100N is connected with a PC using the LAN cable via U1 and CN2 U1 and CPU U12 establishes bus connection with 8 bits to send and receive the data Figure 2 3 13 LAN Interface Circuit ...

Page 26: ...tite bind B M2 6 x 8 2 0 343 0 049 Lower plate ASSY Taptite bind B M2 6 x 8 4 0 343 0 049 Upper cover Taptite bind B M2 6 x 8 3 0 343 0 049 Screw bind M2 6 x 4 2 0 392 0 098 Insert guide Taptite bind B M2 6 x 8 1 0 343 0 049 Heat sink DC8V Taptite bind B M2 6 x 8 1 0 343 0 049 DC power PCB ASSY Power supply ASSY Taptite bind B M2 6 x 8 2 0 343 0 049 Ground spring plate Taptite bind B M2 6 x 8 4 0 ...

Page 27: ... to be used FLOIL BG 1507 one rice grain size Grease to be used FLOIL BG 1507 one rice grain size Cut moving pin Cut worm gear Section Grease B to be used Grease to be used Grease B quarter of a rice grain size Grease to be used Grease B one rice grain size Cut press spring Moving cutter blade Grease to be used Grease B one rice grain size ...

Page 28: ...III 3 Mecha ASSY Double gear B Double gear C Double gear A Grease to be used Silicon grease G501 one rice grain size ...

Page 29: ...the Thermal Tape and Top Cover ASSY 1 Press the power button 2 Turn OFF the main power switch 3 Unplug the AC cord from the outlet 4 Disconnect the AC cord from the machine Figure 3 4 1 Preparations AC cord AC cord Main power switch Power button ...

Page 30: ...om the machine Figure 3 4 2 Removing the Thermal Tape 7 Close the top cover ASSY loosely 8 Push the two hooks inwards to release them and remove the back cover from the machine Figure 3 4 3 Removing the Back Cover Top cover ASSY Thermal tape Release lever L Release lever R Back cover Hook Hook Top cover ASSY ...

Page 31: ...III 6 9 Slide the two top cover shafts inwards to remove them and remove the top cover ASSY Figure 3 4 4 Removing the Top Cover ASSY Top cover ASSY Top cover shaft ...

Page 32: ...ve the side panel R from the top cover Figure 3 4 5 Disassembling the Top Cover ASSY 1 3 Remove the two retaining rings 4 Remove platen shaft bearing A from the platen ASSY Figure 3 4 6 Disassembling the Top Cover ASSY 2 Hook Top cover Hook Side panel R Side panel L Screws Screws Retaining ring Platen ASSY Platen shaft bearing A Retaining ring ...

Page 33: ... platen ASSY from the top cover 6 Remove the platen ASSY from the top cover the platen gear and platen shaft bearing B Figure 3 4 7 Disassembling the Top Cover ASSY 3 Platen ASSY Top cover Platen gear Platen ASSY Platen shaft bearing B ...

Page 34: ...3 Removing the Roll Guide 1 Release the two hooks and remove the roll guide from the machine while pushing the roll guide actuator Figure 3 4 8 Removing the Roll Guide Hook Hook Roll guide Roll guide actuator ...

Page 35: ...e the roll guide shaft to the left and align the three grooves of the roll guide shaft with the three ribs of the roll guide to remove the roll guide shaft from the roll guide NOTE Take care not to lose the spring 4 Remove the roll guide spring B from the roll guide shaft Figure 3 4 9 Disassembling the Roll Guide Roll guide Ribs Roll guide shaft Roll guide spring A Roll guide spring B Roll guide a...

Page 36: ... Ground Spring 1 Remove the one screw and remove the insert guide from the upper cover 2 Remove the ground spring from the upper cover Figure 3 4 10 Removing the Insert Guide and Ground Spring Ground spring Screw Ground spring Insert guide ...

Page 37: ...aft and Roll Roller 1 Remove the four roll roller shafts from the machine 2 Remove each of the four roll rollers from the four roll roller shafts Figure 3 4 11 Removing the Roll Roller Shaft and Roll Roller Roll roller shaft Roll rollers ...

Page 38: ...e Lower Plate ASSY 3 Disconnect all connectors and FFC from the main PCB ASSY Figure 3 4 13 Removing the Connectors and FFC Screws Lower plate ASSY Screw Screw Fan motor Main PCB ASSY DC power PCB ASSY Sub ASSY SW 220 230 240V model only Cover open sensor Cutter motor ASSY Head ASSY Tape feed motor ASSY Tape sensor PCB ASSY Cutter home position sensor SB PCB ASSY ...

Page 39: ...ove the upper cover from the machine Figure 3 4 14 Removing the Upper Cover 6 Turn the upper cover upside down 7 Remove the filament tape which secures the harness of the tape sensor PCB ASSY Figure 3 4 15 Removing the Filament Tape Screws Upper cover Screws Upper cover Filament tape FFC ...

Page 40: ...III 15 8 Turn the upper cover upside down 9 Remove the tape sensor PCB ASSY from the upper cover Figure 3 4 16 Removing the Tape Sensor PCB ASSY Tape sensor PCB ASSY Upper cover ...

Page 41: ... the pin When disassembling the DC power PCB ASSY be careful not to bend the pin NOTE The power supply ASSY and DC power PCB ASSY cannot be removed from the machine in this status since the inlet of the power supply ASSY is still assembled onto the under cover For 100 120V model For 220 230 240V model Figure 3 4 17 Removing the Heat Sink DC8V Power Supply ASSY and DC Power PCB ASSY Screws Power su...

Page 42: ...ch other with the pins When disassembling the DC power PCB ASSY be careful not to bend the pins Figure 3 4 18 Removing the DC Power PCB ASSY 5 Disconnect the power supply harness from the power supply ASSY Figure 3 4 19 Removing the Power Supply Harness Pins DC power PCB ASSY Power supply PCB Power supply ASSY Power supply harness ...

Page 43: ...20 Removing the Main PCB ASSY 1 NOTE Pay attention to the USB connector serial connector and LAN connector when removing the main PCB ASSY Figure 3 4 21 Removing the Main PCB ASSY 2 Screw Main PCB ASSY Screw Ground spring plate Screw Screw FG harness ASSY Main PCB ASSY 1 USB connector Serial connector LAN connector Under cover 2 ...

Page 44: ...rom the machine 8 Remove the shield plate ASSY from the machine TD 4100N only Figure 3 4 22 Removing the Fan and Shield Plate ASSY NOTE From here procedures for 100 120V model and 220 230 240V model differs Shield plate ASSY TD 4100N only Fan Hook ...

Page 45: ...ector of the sub ASSY SW and remove it from the connector of the power supply ASSY 10 Release the two hooks to remove the sub ASSY SW from the machine NOTE The sub ASSY SW cannot be removed from the machine in this status Figure 3 4 23 Removing the Sub ASSY SW For 100 120V model 1 Connector power supply ASSY Ribs Rib Connector sub ASSY SW Sub ASSY SW Hook ...

Page 46: ...he power supply ASSY upside down 13 Unsolder the harness of sub ASSY SW from the power supply ASSY 14 Remove the sub ASSY SW Figure 3 4 24 Removing the Sub ASSY SW For 100 120V model 2 Power supply ASSY Sub ASSY SW Soldering iron Harness sub ASSY SW ...

Page 47: ...he under cover upside down and press the hook from the hole on the under cover Figure 3 4 25 Removing the Inlet For 100 120V model 16 Slide the harness of the inlet to the positioning hole of the fan and remove the inlet and the power supply ASSY from the machine Figure 3 4 26 Removing the Power Supply ASSY For 100 120V model Hook Hook Hook Inlet Hole Power supply ASSY Inlet Positioning hole of fa...

Page 48: ... For 220 230 240V model 11 Release the hook on both sides of the inlet and pull the inlet to the direction of the arrow as shown in the figure below to remove it NOTE For the hook on the lower side of the inlet turn the under cover upside down and press the hook from the hole on the under cover Figure 3 4 28 Removing the Inlet For 220 230 240V model Hole Filament tape Sub ASSY SW Hook Hook Hook In...

Page 49: ... of the inlet to the positioning hole of the fan and remove the inlet and the power supply ASSY from the machine Figure 3 4 29 Removing the Power Supply ASSY For 220 230 240V model Power supply ASSY Inlet Positioning hole of fan ...

Page 50: ...ver 2 Release the two hooks B of the front cover from the holes on the cutter unit ASSY to remove the front cover Figure 3 4 30 Removing the Front Cover 3 Remove the cover sensor arm L from the front cover Figure 3 4 31 Removing the Cover Sensor Arm L Screw Hooks B Front cover Cutter unit ASSY Screw Under cover Hook A Front cover Cover sensor arm L Front cover ...

Page 51: ...irection of the arrow Figure 3 4 32 Removing the Panel Cover 6 Remove the one screw and release the pin of the front side cover from the cutter unit ASSY Remove the front side cover from the machine while lifting up the upper side of the front side cover to the direction of the arrow Figure 3 4 33 Removing the Front Side Cover Cutter unit ASSY Harness SB PCB ASSY Hole Panel cover Pin Screw Hook Cu...

Page 52: ...ha ASSY 1 Take out the three harnesses from the hole of the under cover 2 Remove the two screws and remove the cutter unit ASSY from the mecha ASSY Figure 3 4 34 Removing the Cutter Unit ASSY Cutter unit ASSY Screws Mecha ASSY Harnesses Hole Harness ...

Page 53: ...wo head cables from the under cover 4 Remove the two screws and remove the mecha ASSY from the under cover while pulling both sides of the under cover outwards Figure 3 4 35 Removing the Mecha ASSY Screws Head cables Harness tape feed motor ASSY FG harness ASSY Mecha ASSY Under cover ...

Page 54: ... PCB ASSY from the guide 2 Remove the two screws and remove the SB PCB ASSY cover sensor arm R and SB PCB sheet from the panel cover Figure 3 4 36 Disassembling the Panel Cover 1 SB PCB sheet Screw Cover sensor arm R Screw SB PCB ASSY SB PCB ASSY Harness Panel cover Guide ...

Page 55: ...e power button and feed button from the panel cover 4 Remove the one screw and remove the LED guide from the panel cover Figure 3 4 37 Disassembling the Panel Cover 2 Feed button Power button Screw LED guide Panel cover ...

Page 56: ...f the double gear C to remove the double gear C from the mecha ASSY 3 Remove the retaining ring to remove the double gear B from the mecha ASSY 4 Remove the retaining ring to remove the double gear A from the mecha ASSY Figure 3 4 39 Disassembling the Mecha ASSY 2 Mecha ASSY Release lever R Release spring Retaining ring Release spring Release lever L Retaining ring Double gear C Double gear B Doub...

Page 57: ...emove the two screws to remove the chassis L sub ASSY from the sub plate Figure 3 4 40 Disassembling the Mecha ASSY 3 7 Remove the head plate from the sub plate Figure 3 4 41 Disassembling the Mecha ASSY 4 Screws Chassis R sub ASSY Sub plate Screws Chassis L sub ASSY Head plate Sub plate ...

Page 58: ...heating element of the head ASSY Figure 3 4 42 Disassembling the Mecha ASSY 5 8 Remove the two screws and remove the head ASSY from the head plate Figure 3 4 43 Disassembling the Mecha ASSY 6 Head ASSY Heating element Screw Screw Head plate Head ASSY ...

Page 59: ...white Figure 3 4 44 Disassembling the Mecha ASSY 7 11 Remove the two head springs from the sub plate 12 Remove the two tapes from the sub plate NOTE Keep the tape to use by the reassembly operation after removing it Figure 3 4 45 Disassembling the Mecha ASSY 8 Head ASSY Head cable white Ferrite core Head cable black Sub plate Head springs Tapes ...

Page 60: ...sub ASSY and the chassis L sub ASSY Figure 3 4 46 Disassembling the Mecha ASSY 9 14 Remove the two screws and remove the tape feed motor ASSY and FG harness ASSY from the chassis R sub ASSY Figure 3 4 47 Disassembling the Mecha ASSY 10 Chassis L sub ASSY Pin Pin Platen supports Chassis R sub ASSY Screw Tape feed motor ASSY Chassis R sub ASSY Screw FG harness ASSY ...

Page 61: ...e of the parts 1 Assemble the tape feed motor ASSY and FG harness ASSY onto the chassis R sub ASSY with the two screws NOTE Pay attention to the direction of the tape feed motor ASSY Figure 3 5 1 Reassembling the Mecha ASSY 1 Screw bind M3 x 4 Tape feed motor ASSY Chassis R sub ASSY Screw bind M3 x 4 FG harness ASSY ...

Page 62: ...is L sub ASSY and the chassis R sub ASSY and align the two pins of the platen supports with the chassis L sub ASSY and chassis R sub ASSY to secure them Figure 3 5 2 Reassembling the Mecha ASSY 2 Chassis L sub ASSY Pin Pin Platen supports Chassis R sub ASSY ...

Page 63: ...h them so that the sections A and B of the tape become the same position NOTE Reuse the two tapes that removed from the mecha ASSY 4 Push the two head springs into the sub plate Figure 3 5 3 Reassembling the Mecha ASSY 3 Sub plate Head springs Tapes Tape B A ...

Page 64: ...OTE1 Pay attention not to give strong impact on the heating element of a head ASSY when mounting the head ASSY NOTE2 Connect each head cable with the connector of the correct color Figure 3 5 5 Reassembling the Mecha ASSY 5 Head ASSY Head cable white Ferrite core Head cable black Head ASSY Heating element Head cable white Head cable black Connect both connectors so that the one inside wire of each...

Page 65: ...head ASSY to the two bosses of the head plate and align the end of the head ASSY with the end of the head plate to secure it as shown in the figure below Figure 3 5 6 Reassembling the Mecha ASSY 6 Head plate Head ASSY Boss Boss 0mm Screw bind M3 x 3 Screw bind M3 x 3 Head plate Head ASSY ...

Page 66: ...b plate with the two screws 10 Put the section B of the head ASSY into the hole B on the chassis L sub ASSY and assemble the chassis L sub ASSY onto the sub plate with the two screws NOTE Confirm that the head ASSY moves smoothly Figure 3 5 8 Reassembling the Mecha ASSY 8 Head ASSY Sub plate Head spring Head spring Screw bind M2 6 x 4 Hole B Section B Section A Hole A Head ASSY Chassis R sub ASSY ...

Page 67: ... sub ASSY and secure it with the retaining ring E2 5 12 Insert the double gear B into the shaft of the chassis R sub ASSY and secure it with the retaining ring E4 13 Insert the double gear C into the shaft of the chassis R sub ASSY and secure it by hanging on the hook Figure 3 5 10 Reassembling the Mecha ASSY 10 Gap Gap Double gear C Double gear B Double gear A Hook Retaining ring E4 Chassis R sub...

Page 68: ...he shaft of the chassis R sub ASSY and secure it with the retaining ring E2 5 17 Hang the release spring on the hook of the release lever R and the hook of the chassis R sub ASSY Figure 3 5 11 Reassembling the Mecha ASSY 11 Hook Hook Pay attention to the direction of the release spring Release lever R Hook Release lever Release spring Release spring Retaining ring E2 5 Release spring Release lever...

Page 69: ... Assemble the LED guide onto the panel cover with the one screw 2 Assemble the feed button and power button onto the panel cover Figure 3 5 12 Reassembling the Panel Cover 1 Feed button Power button Screw bind M2 6 x 8 LED guide Panel cover ...

Page 70: ...them with the two screws 4 Pass the harness of the SB PCB ASSY through the guide of the panel cover as shown in the figure below Figure 3 5 13 Reassembling the Panel Cover 2 SB PCB sheet Taptite bind B M2 6 x 8 Cover sensor arm R Taptite bind B M2 6 x 8 SB PCB ASSY SB PCB ASSY Harness Panel cover Guide ...

Page 71: ...ferrite core and wind up the harness once 2 Insert the two head cables and tape feed motor harness into the hole A 3 Insert the FG harness ASSY into the hole B Figure 3 5 14 Installing the Mecha ASSY 1 Head cables Ferrite core Tape feed motor harness FG harness ASSY Hole A Hole B Mecha ASSY Under cover ...

Page 72: ...e the mecha ASSY with the two screws while pulling both sides of the under cover outwards evenly Figure 3 5 15 Installing the Mecha ASSY 2 Taptite bind B M2 6 x 8 Be sure that the head cables are not attached onto the hatched portion Hook Hook A A A Mecha ASSY Hook Under cover Pins Head cables ...

Page 73: ...3 6 Bind the harnesses of the cutter unit ASSY with the fastening band NOTE Be sure to bind the harnesses securely so that there is no looseness Figure 3 5 17 Installing the Cutter Unit ASSY 1 Ferrite core Head cables Under cover Ferrite core Tape feed motor harness Cutter motor ASSY Cutter motor ASSY Cutter unit ASSY Fastening band Fastening band Cover left sensor ASSY Cover left sensor ASSY ...

Page 74: ...it harnesses and the cutter home position sensor harness pass through the under of the release lever L R Figure 3 5 18 Installing the Cutter Unit ASSY 2 Figure 3 5 19 Installing the Cutter Unit ASSY 3 Cutter unit ASSY Under cover Release lever R Release lever L Cutter home position sensor harness Hole Hole Cutter unit harnesses Screw bind M3 x 4 Mecha ASSY Rib Ribs Rib Hook Cutter unit ASSY Releas...

Page 75: ...ang the hook of the front side cover on the under cover and align the pin with the cutter unit ASSY then assemble the front side cover with the one screw Figure 3 5 20 Installing the Front Side Cover Cutter unit ASSY Under cover Front side cover Hook Pin Screw bind M2 6 x 4 ...

Page 76: ...h the under of the release lever R 3 Pass the harness of the SB PCB ASSY through the hole of the under cover as shown in the figure below Figure 3 5 21 Installing the Panel Cover 1 Figure 3 5 22 Installing the Panel Cover 2 Cutter unit ASSY Harness SB PCB ASSY Hole Release lever R Panel cover Pin Screw bind M2 6 x 4 Under cover Hook SB PCB ASSY Ribs Hole Harness SB PCB ASSY Release lever R Panel c...

Page 77: ...III 52 4 Assemble the cover sensor arm L into the front cover Figure 3 5 23 Installing the Cover Sensor Arm L Cover sensor arm L Front cover ...

Page 78: ...r cover with the two screws Figure 3 5 24 Installing the Front Cover 1 NOTE Put the cover sensor arm L into the gap between the cutter unit ASSY and front side cover before assembling the front cover Figure 3 5 25 Installing the Front Cover 2 Taptite bind B M3 x 8 Hooks A Front cover Cutter unit ASSY Under cover Hook B Front cover Cutter unit ASSY Front side cover Cover sensor arm L ...

Page 79: ...y ASSY NOTE 100 120V model and 220 230 240V model have different procedures For 100 120V model 1 Insert the connector of the inlet into the hole of the machine Figure 3 5 26 Installing the Inlet For 100 120V model 1 Power supply ASSY Connector Inlet Hole ...

Page 80: ...ne and slide the harness to the positioning hole of the inlet then set the inlet to the machine NOTE Make sure that the hooks of the inlet are locked on the under cover securely Figure 3 5 27 Installing the Inlet For 100 120V model 2 Inlet Hook Harness Under cover Hook Positioning hole of fan ...

Page 81: ...f the machine as shown in the figure below 4 Solder the harness of the sub ASSY SW to the power supply ASSY Figure 3 5 28 Installing the Sub ASSY SW For 100 120V model 1 Sub ASSY SW Soldering iron Harness sub ASSY SW Hole Hole Harness sub ASSY SW Power supply ASSY ...

Page 82: ...he figure below and put the connector in the positioning part of the machine NOTE Be sure not to catch the harness of the sub ASSY SW on the section A of the machine NOTE When there is the loose in the harness adjust it after assembling the power supply ASSY and the DC power PCB ASSY Figure 3 5 29 Installing the Sub ASSY SW For 100 120V model 2 Connector sub ASSY SW power supply ASSY Sub ASSY SW B...

Page 83: ...f the machine and slide the harness to the positioning hole of the inlet then set the inlet to the machine NOTE Make sure that the hooks of the inlet are locked on the under cover securely Figure 3 5 30 Installing the Inlet For 220 230 240V model Inlet Hook Harness Under cover Hook Positioning hole of fan ...

Page 84: ...two ribs and hole of the machine and secure it with the filament tape as shown in the figure below Figure 3 5 31 Attaching the Filament Tape For 220 230 240V model NOTE From here procedures for 100 120V model and 220 230 240V model are same Ribs Hole Filament tape 35mm Sub ASSY SW 25mm ...

Page 85: ...n of the following figure Figure 3 5 32 Installing the Shield Plate ASSY and Fan 7 Assemble the main PCB ASSY FG harness ASSY and ground spring plate with the four screws Figure 3 5 33 Installing the Main PCB ASSY and Ground Spring Plate Shield plate ASSY TD 4100N only Fan Hook Taptite bind B M2 6 x 8 Main PCB ASSY Taptite bind B M2 6 x 8 Ground spring plate Taptite bind B M2 6 x 8 Taptite bind B ...

Page 86: ...e Power Supply Harness 9 Connect the DC power PCB ASSY to the power supply ASSY NOTE Be careful not to break the pins between the DC power PCB ASSY and power supply ASSY Figure 3 5 35 Installing the DC Power PCB ASSY Power supply ASSY Power supply harness Pins DC power PCB ASSY Power supply ASSY ...

Page 87: ...f the power supply ASSY and the DC power PCB ASSY on the two ribs of the machine NOTE Confirm that the harness is not caught between each PCB and the machine 11 Assemble the heat sink DC8V onto the machine and secure it with the one screw For 100 120V model Figure 3 5 36 Installing the Power Supply ASSY DC Power PCB ASSY and Heat Sink DC8V For 100 120V model Figure 3 5 37 Installing the Power Supp...

Page 88: ...re 3 5 39 Installing the Power Supply ASSY and DC Power PCB ASSY For 220 230 240V model Taptite bind B M2 6 x 8 Power supply ASSY Taptite bind B M2 6 x 8 Heat sink DC8V DC power PCB ASSY Inlet Inlet Ribs Harnesses sub ASSY SW inlet Power supply ASSY Harness power supply ASSY Harness DC power PCB ASSY Slit Main PCB ASSY Slit DC power PCB ASSY ...

Page 89: ...III 64 6 Installing the Upper Cover 1 Assemble the tape sensor PCB ASSY onto the upper cover Figure 3 5 40 Installing the Tape Sensor PCB ASSY Tape sensor PCB ASSY Upper cover ...

Page 90: ...t the section A and B of the upper cover Figure 3 5 41 Attaching the Filament Tape 4 Pass the FFC of the tape sensor PCB ASSY through the hole of the machine Assemble the upper cover onto the machine and secure it with the five screws Figure 3 5 42 Installing the Upper Cover Upper cover A B Filament tape FFC Taptite bind B M2 6 x 8 Upper cover Hole Screw bind M2 6 x 4 FFC ...

Page 91: ...onto the machine with the four screws Figure 3 5 44 Installing the Lower Plate ASSY Fan motor DC power PCB ASSY Sub ASSY SW 220 230 240V model only Cutter motor ASSY Cover open sensor Inlet Head ASSY Slit Slit Slit Slit Slit Slit Slit Head ASSY Tape feed motor ASSY Power supply PCB Main PCB ASSY Tape sensor PCB ASSY Cutter home position sensor SB PCB ASSY Taptite bind B M2 6 x 8 Lower plate ASSY T...

Page 92: ...ollers to the four roll roller shafts 2 Assemble the four roll roller shafts onto the machine NOTE1 Install the roll roller shafts until them click NOTE2 Confirm that the roll rollers rotate smoothly Figure 3 5 45 Installing the Roll Roller and Roll Roller Shaft Roll roller shaft Roll rollers ...

Page 93: ... B contact the end face of the roll roller shaft NOTE Set the ground spring into the boss of the upper cover surely 2 Assemble the insert guide onto the upper cover and secure it with the one screw Figure 3 5 46 Installing the Ground Spring and Insert Guide Taptite bind B M2 6 x 8 Ground spring Insert guide A Hole Boss Rib Roll roller shaft Ground spring B Upper cover ...

Page 94: ...lign the two pins of the roll guide actuator with the positioning hole of the roll guide to assemble the roll guide actuator to the roll guide NOTE1 Confirm that the roll guide spring A align with the positioning groove of the roll guide spring A NOTE2 Confirm that the section A of the roll guide actuator is the inside of the rib of the roll guide Figure 3 5 47 Reassembling the Roll Guide 1 Positi...

Page 95: ...III 70 NOTE3 Push the roll guide actuator and confirm that the roll guide shaft moves smoothly Figure 3 5 48 Reassembling the Roll Guide 2 Roll guide Roll guide shaft Roll guide actuator ...

Page 96: ...oll guide actuator NOTE Press the roll guide actuator and confirm that the claws of the roll guide actuator and the roll guide slide smoothly without contacting the upper cover Figure 3 5 49 Installing the Roll Guide Roll guide Roll guide actuator Roll guide Roll guide actuator Claw Claw Upper cover ...

Page 97: ...e left hand side of the top cover Figure 3 5 50 Reassembling the Top Cover ASSY 1 3 Put the retaining ring onto the right end of the shaft of the platen ASSY 4 Put the platen shaft bearing A into the shaft on the left hand side and secure it with the retaining ring Figure 3 5 51 Reassembling the Top Cover ASSY 2 Platen ASSY Top cover Platen gear Platen ASSY Notch Platen shaft bearing B Cut surface...

Page 98: ...the hole of the side panel R 6 Hang the hook of the side panel L on the positioning hole of the top cover and secure the side panel L onto the top cover with the two screws NOTE Confirm that the pins of the inside of the top cover engage with the hole of the side panel L Figure 3 5 52 Reassembling the Top Cover ASSY 3 Hook Top cover Hook Side panel R Side panel L Taptite bind B M2 6 x 8 Taptite bi...

Page 99: ...f the hooks on the top cover until they hit the end of the hooks NOTE Confirm that the top cover ASSY is opened and closed smoothly Figure 3 5 53 Installing the Top Cover ASSY 3 Assemble the back cover onto the machine and hang the two hooks of the back cover on the machine Figure 3 5 54 Installing the Back Cover Top cover ASSY Top cover shafts Back cover Hook Hook ...

Page 100: ...III 75 4 Assemble the thermal tape onto the machine 5 Close the top cover ASSY Figure 3 5 55 Installing the Thermal Tape Top cover ASSY Thermal tape ...

Page 101: ...he energization Condition of energization 10 or less In the case of non energization Check the following points Is the ground spring correctly set Is the ground spring normally Refer to Installing the Ground Spring and Insert Guide Figure 3 5 56 Energization Check Probe Roll roller shaft Tester Probe Lower plate ASSY Probe ...

Page 102: ...y printing to 100mm length and repeat printing When turning the POWER button OFF printing stops Figure 3 5 57 Print sample in the case of 102mm 5 Confirm that the tape is fed properly printing is correct and the tape is cut accurately If any fault is found execute the troubleshooting referring to CHAPTER IV TROUBLESHOOTING AND ERROR MESSAGE 6 Pull the release levers upwards and confirm that the to...

Page 103: ...es and examines them well 4 1 PRECAUTIONS Be sure to observe the following precautions to prevent the secondary problems from happening during troubleshooting 1 Make sure to unplug an AC cord to ensure no power supply when doing conductivity test with a tester 2 When printing error occurs pull out the thermal head cable from the connecter until the peripheral circuit related to the thermal head wo...

Page 104: ...t transmit Check the power supply and the USB connector Check failure The Cut test failed Check if any obstacle is placed around the cutter and the delivery opening 6 Print test Die Cut Communication error Cannot transmit Check the power supply and the USB connector Print file not detected Don t find print file Check if the correct print file is set in the General Settings dialog box 7 Print test ...

Page 105: ...d and the platen dirty The thermal head and the platen are dirty Clean the thermal head and the platen Is the platen rubber deformed Is the head pressure 3 0kg 10 at the roller center The thermal head is defective Replace the thermal head ASSY Replace the platen ASSY Is the head spring attached correctly Attach the head spring in correct way Replace the head spring ...

Page 106: ...n the power supply PCB 7 to 5V Is the connector output of the DC8V power PCB 7 to 5V Are the key and LED signals of CN16 normal Is the cable of SB PCB connected correctly Correct the connection Y N Is the cable of power supply connected correctly Is the main power switch ON Correct the connection Turn ON the main power switch Re assemble the cover correctly Correct the connection Correct the conne...

Page 107: ...nd by status or printing 25V 1 5V Is the signal for thermal head normal The thermal head is defective Replace the thermal head ASSY Correct the connection Set the roll in the correct direction Any devices on the main PCB are defective or soldering is defective Replace the main PCB ASSY N Y Is the direction of the roll correctly The power supply PCB is defective Replace the power supply PCB ...

Page 108: ...e USB mode selected in printer property The interface malfunction Is the waveform of USB connector normal Is the USB cable connected correctly Correct the connection Re install the driver and editor correctly Set to the USB mode The USB driver or CPU is defective Replace the main PCB ASSY The USB cable is defective Replace the cable ...

Page 109: ... set correctly Y N Is the interlink cable cross used The interface malfunction Is the waveform of RS232C connector normal Is the RS232C cable connected correctly Correct the connection Use the interlink cable Re install the driver and editor correctly Set to the RS232C mode Set the baud rate correctly The RS232C driver or CPU is defective Replace the main PCB ASSY The RS232C cable is defective Rep...

Page 110: ... Y N Is the interlink cable cross used The interface malfunction Is the waveform of ethernet connector normal Is the ethernet cable connected correctly Correct the connection Use the interlink cable Re install the driver and editor correctly Set to the ethernet mode The ethernet driver or CPU is defective Replace the main PCB ASSY The ethernet cable is defective Replace the cable ...

Page 111: ... Press the POWER CUT or FEED button to reverse the cutter Then remove the jammed tape Replace the gears The tape is not cut Does the cutter unit work normally Replace the cutter unit Replace the cutter unit Replace the cutter unit Does the DC motor rotate Is the DC motor connected Correct the connection Do the gears rotate Replace the cutter unit Is the cable damaged Are the output waveforms of pi...

Page 112: ...e paper set between the transmission sensor Is the paper set at the prescribed position Cutter paper guide position Insert the paper correctly Is the head spring attached correctly Attach the head spring correctly Replace the head spring Does the motor rotate Is the motor connected correctly Correct the connection Replace the gears Do the gears rotate The platen is defective Replace the platen Is ...

Page 113: ...VICEMAN SOFTWARE TOOL again Y N Y N The tape is fed but the error message appears shortly Is the VR adjustment performed correctly Refer to APPENDIX 1 SERVICEMAN SOFTWARE TOOL Y N Is the flat cable of the tape sensor ASSY damaged Replace the tape sensor PCB ASSY Replace the tape sensor PCB ASSY Replace the main PCB ASSY Is the tape sensor ASSY assembled onto the upper cover correctly Y N Is the wa...

Page 114: ... reset the EEPROM before making an examination with a serviceman software tool after repair work is done 1 1 2 Use Procedure of the Reset Software Tool 1 Connect the machine TD 4000 or TD 4100N to your PC with the USB cable and turn the POWER button ON 2 When there is not a driver in your PC Found New Hardware Wizard screen is displayed In this case click the Cancel button Figure 1 Found New Hardw...

Page 115: ...tool a Reset EEPROM Reset the EEPROM of the machine to the factory settings Figure 3 Click the Reset EEPROM button b Check SerNo Check the serial number of the machine The serial number is indicated in the Results column If the serial number becomes B00000001 the EEPROM is initialized Figure 4 Click the Check SerNo button Double click a b The massage is displayed after reset The serial number is d...

Page 116: ... the Cancel button Refer to Figure 1 3 Start the VR adjustment tool TD4000tstVRAdjust exe and adjust the VR value Open the top cover and set the release coated paper Cord LP847301 Name 80GS OJI ROLL ASSY to the sensor part so that the sandpapery surface is the upper side and close the top cover 4 Click the VR adjustment button and adjust the sensor value by using the screwdriver so that the sensor...

Page 117: ...repair work is done 1 3 2 Setting Procedure of the Serviceman Software Tool Check the setting before making an examination with a serviceman software tool and change it The setting of the printing file pass of the adjustment print test can be changed and the COM port setting used in the RS test can be changed 1 Connect the machine to your PC with the USB cable and turn the POWER button ON 2 When t...

Page 118: ... inspection Select the file from the displayed screen with the Browse button Die cut margin adjustment print pattern TD4000_P51X26_LN_0901027 prn Free length margin adjustment print pattern TD4000_P102_LN_QAZ_090826 prn Normally it is not necessary to change the printing pattern 5 Click the OK button after completing all settings and return to the main screen When stop the setting click the Cancel...

Page 119: ...rform all inspections When perform the inspection of the TD 4100N the inspection log is output Store the inspection log 1 Type the Serial Number Read serial no Type the serial number The inputted serial number is written in the EEPROM of the machine with the Write serial number Type the lower nine digits of the serial number printed on the nameplate of the bottom side of the machine Figure 8 Type ...

Page 120: ...address is displayed in the MAC Address column Figure 9 Read the MAC address 2 When the Read serial no and Read MAC Address are completed the inspection button becomes effective Caution When the MAC address cannot be read the following error screen is displayed In this case have the causes of that the power supply is not ON and that the USB is not connected Read the MAC address again after display...

Page 121: ...n 2 The writing takes a few seconds 3 If the process is correctly completed the message that writing is successful and the EEPROM version appear in the Results column Figure 11 Write the default value Click and start the process This screen is TD 4100N In the case of TD 4000 operation is the same If default value writing is successful the EEPROM version is displayed ...

Page 122: ...Click the Sensor white level check button on the Photo sensor level setting screen to acquire the sensor value The acceptance range of the sensor value is 200 to 234 Figure 13 Check the photo sensor level 4 If the sensor value and the OK appear in the White level column click the OK button to finish the inspection If NG appears click the NG button In the case of NG make the setting with the VR adj...

Page 123: ...ates of off and on are detected Undo in the Results column is changed to Done Figure 15 Cover sensor of off and on states 3 If the Cover Sensor 0 and Cover Sensor 1 are changed to Done click the Quit sensors check button to finish the inspection If OK appears the inspection is completed correctly Figure 16 Check the cover sensor If the states of off and on are detected Undo is changed to Done If o...

Page 124: ...n to stop the fan Figure 18 Before the fan is turned 4 After the fan is turned the OK is displayed in the Results column If the fan works normally click the OK button If not click the NG button Then finish the inspection Figure 19 After the fan is turned Turn the fan It is disabled only during fan turning Stop the fan It is enabled only during fan turning The inspection result is displayed Fan Err...

Page 125: ... of the paper Then if the feed test OK message appears in the Results column press the CUT button on the machine 4 The cutting is finished Then if the feed and cut test OK message appears in the Results column click the Quit cut test button on the tool Figure 21 Cut Test flow Tool Click the Cut test button Tool The result of cut testing is displayed The judgement is OK Machine Press the FEED butto...

Page 126: ...ure 22 Check the printing head temperature 2 The temperature sensor value is displayed in the Results column 3 If the result is OK proceed to the next inspection If NG check the thermistor or the like Figure 23 Successful completion of checking the temperature The temperature sensor value is displayed If the value is in the range of 10 to 65 degrees C the judgement is OK The judgement is OK ...

Page 127: ...ment print test Print the print pattern for inspection and adjust the margin 1 Click the Adjustment print test button Figure 24 Adjustment print test 2 The Adjustment print test screen is displayed Figure 25 Adjustment print test screen ...

Page 128: ...lect the appropriate Adjusted value and click the Apply 0 button Then click the Print test continuous A button and print the print pattern for inspection again Check that the top margin of the print result is 3mm 0 25mm Figure 26 Adjustment print test free length roll of 102mm Figure 27 Print pattern free length roll of 102mm print pattern when initial setting Select the Adjusted value and click t...

Page 129: ...ect the appropriate Adjusted value and click the Apply 2 button Then click the Print test 50mm 1Label C button and print the print pattern for inspection again Check that the top margin of the print result is 3mm 0 25mm Figure 28 Adjustment print test die cut roll of 51mm x 26mm Figure 29 Print pattern die cut roll of 51mm x 26mm print pattern when initial setting Select the Adjusted value and cli...

Page 130: ...justment of the margin is completed click the OK button If not click the NG button Then proceed to the next inspection Figure 30 OK NG and Cancel button Figure 31 Successful completion of adjustment print test Print test continuous A Print test 50mm 1Label C When each is performed once the OK button is enabled The judgement is OK ...

Page 131: ...hen finishing writing the result is displayed in the Results column 3 If the judgement is OK the writing is correctly completed Figure 32 Write the serial number Write the serial number If the writing is correctly completed the message is displayed This screen is TD 4100N In the case of TD 4000 operation is the same The judgement is OK ...

Page 132: ...ine and conform whether the setting of the RS test port on the General settings screen is correct The procedure of investigating the COM port number that can be used with PC is indicated to the 1 3 4 Check Procedure of COM Port Number 3 Turn the POWER button ON 4 Click the RS test button Figure 33 RS 232C communication test Start the communication test The communication test result is displayed Th...

Page 133: ...e disconnecting error 2 The Error COM is the setting value of the RS test port on the General settings screen is displayed in the Results column As for the error cause have cause that the RS 232C cable is not connected to the specified COM port number of the RS test port Check the COM port number from the cable connecting and the device manager screen of the PC Refer to the following page for the ...

Page 134: ...etting the communication test fails Check the following procedure to find the COM port of the PC The following figures are Windows XP screen Caution When there is not COM port on the PC the communication test cannot be performed 1 Select the Control Panel from the Start menu Figure 36 Start menu 2 Select the Performance and Maintenance When the setting becomes the classic view jump this screen Fig...

Page 135: ... System Properties screen is displayed click the Device Manager on the Hardware tab Figure 39 System Properties screen 5 The devices on the PC are listed Click the of the Ports COM LPT There is the Communications Port COM Check the COM port number Figure 40 Device Manager screen ...

Page 136: ...102001 TD 4000 or LBC103001 TD 4100N 2 Model code of the product is listed in table below 1 4 1 Role of the Auto Power OFF Setting Tool This tool sets auto power OFF time on products with Erp Tier2 compliant PCB for particular destinations 1 4 2 How to Use Auto Power OFF Setting Tool 1 Connect the machine to your PC with the USB cable and turn ON the machine 2 When there is not a driver in your PC...

Page 137: ...d Check that the Auto power off time field shows None and click the Apply button Figure 41 Auto power OFF setting tool 4 Once the auto power OFF setting is written properly the window below appears Click the OK button to quit Auto Power OFF Setting Tool Figure 42 Window appears when the writing completed properly Double click Select the printer here ...

Page 138: ...r OFF Setting Tool error message below appears Check the Printer field on Auto Power OFF Setting Tool again Refer to Figure 41 Figure 43 Transmission error 2 When the Auto Power OFF Setting Tool is used for printers do not satisfy conditions 1 and 2 listed on 1 23 error message below appears Check printer s configuration Figure 44 Auto power OFF non compatible error ...

Page 139: ...Dec 2009 SM PT031 1 ...

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