Fujitsu DL7400 User manual

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DL7400
DOT MATRIX PRINTER
MAINTENANCE MANUAL
FUJITSU ISOTEC LIMITED

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REVISION RECORD
Edition Date published Page Revised contents
01 March 2007 First issue
Specification No.C147-F051-01EN
The contents of this manual may be revised without prior notice.
All Rights Reserved, Copyright © 2007 FUJITSU ISOTEC LIMITED.
No part of this manual may be reproduced in any form without permission.

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Address your comments and inquiries on this manual to:
North American Contact:
FUJITSU CANADA INC.
6975 Credit view Road, Unit 1,
Mississauga,
Ontario L5N 8E9, CANADA
Phone: [phone]
Fax: [phone]
European Contact:
FUJITSU EUROPE LTD.
Hayes Park Central,
Hayes End Road,
Hayes,
Middlesex UB4 8FE, U.K.
Phone:[phone]
Fax:[phone]
FUJITSU DEUTSCHLAND GmbH
Frankfurter Ring 211,
80807 München, Germany
Phone:[phone]
Fax:[phone]
FUJITSU ITALIA S.p.A.
Via Nazario Sauro, 38
20099 Sesto S. Giovanni (MI), Italy
Phone: [phone],
Fax: [phone]
FUJITSU ESPAÑA, S.A.
Camino Cerro de los Gamos, 1-28224
Pozuelo de Alarcón, Madrid, Spain
Phone: [phone],
Fax: [phone]
Australian Contact:
FUJITSU AUSTRALIA LTD.
Fujitsu House 2 Julius Avenue
North Ryde N.S.W. 2113, Australia
Phone:[phone]
Fax:[phone]
Asian Contact:
FUJITSU HONG KONG LTD.
10F., Lincoln House, 979 King's Road, Taikoo
Place,
Island East, Hong Kong
Phone:[phone]
Fax:[phone]
FUJITSU TAIWAN LTD.
19th FL., No. 39, 1 Sec. Chung Hwa Rd.,
Taipei, Taiwan R.O.C.
Phone: [phone]
Fax: [phone]
FUJITSU SYSTEMS BUSINESS (THAILAND) LTD.
Exchange Tower, 22nd-23rd Fl, 388 Sukhumvit Road,
Kwaeng Klongtoey, Khet Klongtoey,
Bangkok 10110, Thailand
Phone:[phone]
Fax:[phone]
FUJITSU ASIA PTE. LTD.
20 Science Park Road #03-01, Tele Tech Park II
Singapore 117674
Phone: [phone]
Fax : [phone]
FUJITSU PHILIPPINES, INC.
2nd Fl., United Life Bldg., A.Arnaiz,
Legaspi Village, Makati, Metro Manila, Philippines
Phone: [phone]
Fax: [phone]
FUJITSU (MALAYSIA) SDN. BHD.
Level 1 & 2, 3505, Jatan Teknokrat 5,
63000 Cyberjaya, Selangor Darul Ehsan, MALAYSIA
Tel:[phone]
Fax:[phone]
PT FUJITSU INDONESIA
Kyoei Prince Building 10th Floor.
Jl. Jend. Sudirman Kav 3 - 4
Jakarta 10220, Indonesia
Phone: [phone]
Fax: [phone]
Manufacturer contact:
FUJITSU ISOTEC LIMITED
Printer Business Division
135, Higashinozaki, Hobara-machi, Date-shi, Fukushima
960-0695, JAPAN
Phone: [phone],
Fax: [phone]
URL http://jp.fujitsu.com/group/fit/en/
Contact Email [email protected].fujitsu.com

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PREFACE
This manual is for engineers who operate, install, or maintain the DL7400 printer, and covers:
Chapter 1: Printer specifications, performance, and configuration
Chapter 2: Unpacking, performance check, and connection
Chapter 3: Troubleshooting
Chapter 4: Maintenance
Chapter 5: Principles of operation
Chapter 6: Recommended spare parts

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CONTENTS
CONTENTS..............................................................................................................................................5
CHAPTER 1 PRINTER SPECIFICATIONS, PERFORMANCE, AND CONFIGURATION ......................9
1.1 Overview..........................................................................................................................................9
1.2 Equipment Structure........................................................................................................................9
1.2.1 Overview....................................................................................................................................9
1.2.2 Model configuration....................................................................................................................9
1.2.3 Structure ..................................................................................................................................10
(1)Exterior components..................................................................................................................12
(2)Printing mechanism ...................................................................................................................14
(3) Lower cover ..............................................................................................................................16
(4) Option and consumables ..........................................................................................................17
CHAPTER 2 UNPACKING, PERFORMANCE CHECK, AND CONNECTION ......................................18
2.1 Overview........................................................................................................................................18
2.2 Notes on Installation ......................................................................................................................18
2.3 Unpacking......................................................................................................................................19
2.4 Inspection after Unpacking ............................................................................................................21
CHAPTER 3 TROUBLESHOOTING ....................................................................................................22
3.1 Trouble shooting Table ..................................................................................................................22
3.1.1 Problems at power-on initialization (part 001/3).......................................................................22
3.1.1 Problems at power-on initialization (part 002/3).......................................................................23
3.1.1 Problems at power-on initialization (part 003/3).......................................................................24
3.1.2 Problems related to printing (part 001/3)..................................................................................25
3.1.2 Problems related to printing(part 002/3)...................................................................................26
3.1.3 Problems related to printing result ...........................................................................................27
3.1.4 Problems related to print quality (part 001/3) ...........................................................................28
3.1.4 Problems related to print quality (part 002/3) ...........................................................................29
3.1.5 Problems related to paper feed (part 001/3) ............................................................................30
3.1.5 Problems related to paper feed (part 002/3) ............................................................................31
3.1.6 Problems related to the control panel ......................................................................................32
3.2 Error Display..................................................................................................................................33
(1) Warning errors.............................................................................................................................33
The buzzer sounds and the ONLINE indicator still lights. ..............................................................33
(2) Operational errors........................................................................................................................34
The PAPER OUT indicator is lighted..............................................................................................34
The REMOVE PAPER indicator blinks...........................................................................................34
(3) Fatal alarms.................................................................................................................................34
The power shut down by itself........................................................................................................34
The PAPER OUT lamp blinks with other lamps. ............................................................................35

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CHAPTER 4 MAINTENANCE ..............................................................................................................36
4.1 Overview........................................................................................................................................36
4.2 Notes on USE................................................................................................................................36
4.3 Maintenance Tools ........................................................................................................................36
4.4 Maintenance levels........................................................................................................................37
4.5 Preventive Maintenance ................................................................................................................37
4.6 Part Drawings ................................................................................................................................37
4.7 Parts That must not be Disassembled...........................................................................................38
4.8 Level 1 Maintenance......................................................................................................................39
4.9 Level 2 maintenance......................................................................................................................40
4.9.1 Parts replacement....................................................................................................................40
(1) Tractor Unit removal and installation Front feed tractor. ...........................................................41
(2) Cut Sheet Feeder removal and installation...............................................................................43
(3) Stacker Plate removal and installation ......................................................................................45
(4) Stacker Unit removal and installation........................................................................................46
(5) Paper Table removal and installation ........................................................................................47
(6) LAN card removal and installation ............................................................................................48
(7) Flap replacement ......................................................................................................................49
(8) Ribbon Cassette replacement ..................................................................................................50
(9) Print head replacement.............................................................................................................52
(10) Control Panel Unit removal and installation ............................................................................53
(11) Front Cover removal and installation.......................................................................................54
(12) Upper Cover removal and Installation.....................................................................................55
(13) Print Mechanism Unit removal and installation .......................................................................56
(14) Power Supply Unit removal and installation............................................................................58
(15) ROM Board (Main Board) replacement ..................................................................................59
(16) LAN RELAY PCA / LAN cable 17P replacement.....................................................................60
(17) RS232C BOARD replacement................................................................................................61
(18) AC Switch ASY removal and installation .................................................................................62
(19) Inlet ASY replacement ............................................................................................................63
(20) Reactor replacement ..............................................................................................................64
(21) FAN UNIT 2 replacement........................................................................................................65
(22) Control Panel Cable replacement...........................................................................................66
(23) F-CSF Cable/CSF Connector PCA replacement ....................................................................67
(24) R-CSF Cable/CSF Connector replacement ............................................................................68
(25) Relay Cable replacement .......................................................................................................69
(26) Sensor PCA replacement .......................................................................................................70
(27) SP Motor ASY replacement ....................................................................................................71
(28) LF Motor removal and installation...........................................................................................72
(29) TR Motor removal and installation ..........................................................................................73
(30) APTC Unit replacement ..........................................................................................................74

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(31) HCPP Motor replacement.......................................................................................................75
(32) SP FAN replacement ..............................................................................................................76
(33) INLK SW ASY replacement ....................................................................................................77
(34) PS PCA replacement ..............................................................................................................78
(35) HCPP switch ASY replacement ..............................................................................................79
(36) Sensor cover TR/TR PES ASY replacement ..........................................................................80
(37) Ribbon Rope ASY replacement ..............................................................................................81
(38) Card Guide ASY replacement.................................................................................................82
(39) TOFL/R sensor ASY replacement...........................................................................................84
(40) Carriage Unit and Stay Shaft replacement..............................................................................85
(41) SP Timing Belt replacement....................................................................................................86
(42) SP Tension bracket replacement ............................................................................................87
(43) LF Timing Belt replacement ....................................................................................................89
(44) Platen Roll replacement..........................................................................................................90
(45) Nip Spring 1/2 replacement ....................................................................................................92
(46) Nip Roller replacement ...........................................................................................................93
(47) DV Roller ASY replacement....................................................................................................94
4.9.2 Adjustment ...............................................................................................................................97
(1) Print head gap adjustment........................................................................................................97
(2) Card guide position adjustment ................................................................................................99
(3) Card guide position adjustment (another way) .......................................................................102
(4) TOF sensor’s voltage adjustment ...........................................................................................104
(5) LF belt’s tension adjustment ...................................................................................................105
(6) Vertical Alignment (V-ALMNT) adjustment..............................................................................106
(7) Top-of-forms adjustment (factory use) ....................................................................................107
(8) Skew detection value adjustment ...........................................................................................108
4.9.3 Lubrication .............................................................................................................................109
(1) Upper angle ............................................................................................................................109
(2) HCPP mechanism, Stud for gear............................................................................................110
(3) Detent for DV roller ................................................................................................................. 111
(4) Bearings ................................................................................................................................. 111
(5) Guide to slide the paper table .................................................................................................112
(6) Carrier unit (Ribbon drive mechanism) ...................................................................................113
4.10 Diagnostics .............................................................................................................................114
4.10.1 Printing the Self-Test .........................................................................................................114
4.10.2 Hex dump..........................................................................................................................116
CHAPTER 5 PRINCIPLES OF OPERATION .....................................................................................119
5.1 Overview......................................................................................................................................119
5.2 Mechanical Operation..................................................................................................................120
5.2.1 Printing Operation..................................................................................................................120
5.2.1.1 Print head.........................................................................................................................120

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5.2.1.2 Spacing operation ............................................................................................................121
5.2.1.3 LRES (Carriage position) detection..................................................................................122
5.2.1.4 Ribbon feed mechanism ..................................................................................................123
5.2.1.4 Automatic paper thickness control mechanism ................................................................124
5.2.1.5 Skew detection.................................................................................................................125
5.2.2 Paper Feed Operation..........................................................................................................126
5.2.2.1 Paper path selection mechanism (HCPP)........................................................................126
5.2.2.3 Paper feed operation........................................................................................................128
5.2.2.4 Paper loading and ejection operation (auto loading) ........................................................131
5.3 Electrical Operation .....................................................................................................................132
5.3.2 Printed Circuit Boards and Basic Configuration ...................................................................132
5.3.2.1 Outline of Printed Circuit Boards ....................................................................................133
5.3.3 Control Circuit Operation .......................................................................................................137
5.3.3.1 Printer Special Controller (MB90706)...............................................................................137
5.3.3.2 Memory Circuit Control ....................................................................................................138
5.3.3.3 Centronics Controller .......................................................................................................140
5.3.3.4 The MPU(MB89P585) has the following main functions ..................................................142
5.3.3.5 LAN interface ...................................................................................................................143
5.3.4 Motor Control and Drivers ....................................................................................................147
5.3.5 Print Head Driver .................................................................................................................152
5.3.6 Alarms..................................................................................................................................154
5.3.6.1 Fire Check......................................................................................................................154
5.3.6.2 ROM or RAM Error.........................................................................................................154
5.3.6.3 Spacing Error..................................................................................................................154
5.3.6.4 APTC Gap Alarm............................................................................................................154
5.3.6.5 HCPP Alarm ...................................................................................................................154
5.3.6.6 Skew Unit Error ..............................................................................................................154
5.3.7. Power Supply......................................................................................................................155
5.3.8 Surge Current Controller ......................................................................................................157
CHAPTER 6 RECOMMENDED SPARE PARTS ................................................................................158

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CHAPTER 1 PRINTER SPECIFICATIONS,
PERFORMANCE, AND
CONFIGURATION
1.1 Overview
This manual is for maintenance engineers, and covers overall DL7400 printer maintenance, together with
detailed information such as troubleshooting and component replacement.
Recommended references are:
DL7400 Printer Parts Catalogue (P3KA02038-B001/E)
DL7400 Printer Schematic Diagrams (C1KA02038-B001/E)
These three manuals contain all information needed for DL7400 maintenance. This manual covers all
models.
The maintenance manual is described by the premise that understands the user's manual.
Please also refer to the following manual if needed.
DL7400 Printer USER’S MANUAL (C147-E051-01EN)
DL7400 Printer Product Description (A1KA02038-B001/E)
The DL7400 printer has a reliable, simple mechanism requires little maintenance.
1.2 Equipment Structure
1.2.1 Overview
This section outlines printer structure and features.
1.2.2 Model configuration
The DL7400 is a 136-column printer.
Factory options are as follows
Power Supply type; 100-120VAC input (M33324A)
220-240VAC input (M33324B)
Interface type; Centronics parallel + USB interfaces
Centronics parallel + RS232C serial interface
Add-on options are as follows.
Cut sheet feeder. (The SF940 single-bin feeder)
Tractor unit. (for a second tractor).
LAN card. (only for the Centronics parallel + USB interfaces Models.)
Large paper table.
Large stacker.
The DL7400 has three emulations as follows.
Fujitsu DPL24C PLUS
IBM Proprinter XL24E
Epson ESC/P2

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1.2.3 Structure
Major printer components are organized as shown below. Items in boldface are recommended spare parts
(see Chapter 6) that can be replaced in field by maintenance service engineers. Replacement and adjustment
are detailed in Chapter 4.
Figure 1.1 Structure of DL7400
DL7400 printer
Stacker Unit
Mecha assembly
Ribbon cartridge
Tractor unit
Cut-sheet feeder
Front Cover assembly
Operating panel
Upper Cover assembly
Print Head
ROM board
Power supply
Lower cover assembly
AC SWITCH assembly
AC INLET assembly
Components that operator can install and remove.
Frame
Carrier Unit Tof L/R sensor
Aptc sensor
Carrier Cable
L/RES sensor
SP motor
LF motor
APTC motor
Connector Board
Inter Lock SW
HCPP motor
PS Sensors
FTRPE Sensors
RTRPE Sensors
APTCHP SW
HCPPHP SW
Stacker plate
Paper Table assembly
TR motor
Nip Roller assembly
Dv Roller assembly
Platen Roller assembly
LAN CARD
Reactor

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Block diagrams
The following figure shows printer functional components and connecting cables.
Figure 1.2 Block Diagram of DL7400
Power supply
ROM Board
Control Panel
sw
inlet
Carrier board
LF
Motor
Print Head
TR
Motor
Connector board
SP
Motor
PS
sensors
HCPP
motor
HCPPHP
SW
APTCHP
SW
APTC
motor
FTRPE
sensor
RTRPE
sensor
FCSF
RCSF
connector
INTER
LOCK
SW
APTC
sensor
TOFR
sensor
TOFL
sensor
Option board
RS232C/LAN
Carrier
unit
Mecha
Unit
USB
Centro
FAN
Motor 2
LRES sensor
FAN
Motor 1
FAN
driver

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(1)Exterior components
This section gives information on exterior components of the printer: covers, removable mechanism units,etc.
Figure 1.3 Exterior components of DL7400

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a. Interface Connector
The interface cable connector is on the right side of the printer, as seen from the front of the upper cover, so
the interface cable does not interfere with the paper feed path.
Figure 1.4 Interface type of DL7400
b. Front cover
The front cover is opened to replace the ribbon cartridge.
There is an Interlock SW for safety.
c. Paper table
The paper table guides a cut sheet manually fed by the user. The optional Large Paper Table is necessary to use
cut sheets exceeding 297 mm in length
d. Rear stacker
The rear stacker holds printed cut sheets. The optional Large Stacker is necessary to use cut sheets exceeding
297 mm in length
e. Control panel
The control panel consists of an LSI, ten push-button switches, one dial, thirteen LEDs, and a buzzer.
The switches are used for operations such as loading and feeding paper and controlling printing pressure. Some
switches are also used in setup mode. The LEDs indicate printer basic statuses and paper feed path conditions.
The buzzer sounds to indicate certain operating and printer statuses.
Figure 1.5 Control panel of DL7400

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(2)Printing mechanism
Figure 1.6 Mechanism of DL7400
Print head
Ribbon cartridge
Stay shaft Carriage
Stepping motor for
carriage drive mechanism
Paper feed mechanism
HCPP motor
HCPP mechanism
APTC mechanism

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The printing mechanism fit into the bottom cover. And Upper Cover holds it in position.
a. Carriage
The carriage supports the removable 24-wire print head and the ribbon cartridge, and slides left and right
on the stay shaft. The ribbon feed gear system moves the ribbon in one direction regardless of carriage
movement. It has four sensors: LRES, TOFL, TOFR and APTC sensor. The LRES detects both left and
right ends of the carriage movement. The TOFL/R detects the edge (top, left, right, bottom) of paper.
The APTC sensor detects the surface of paper for control the gap between the print head and the paper.
b. Carriage drive mechanism
The stay shaft and the stay guide (upper angle) support the carriage; the stepping motor and timing belt move
the carriage horizontally.
c. Paper feed mechanism
There are two stepping motors. One of them drives the rollers and another one drives tractors.
d. Host-controlled paper path (HCPP) mechanism
The HCPP mechanism switches power transmission to the tractors. Three states are possible: front tractor is
selected, rear tractor is selected, and cut sheet is selected. Switching is possible through software or by the
control panel. The paper on the platen is unloaded to the park position or ejected, and then the paper feed path
is switched. When switching from a cut sheet to continuous forms, the continuous forms are automatically
loaded to the print position.
e. Automatic paper thickness control (APTC) mechanism
The APTC mechanism adjusts the gap between the print head and the paper surface. Before start printing,
the print head is approach to the platen until APTC sensor is pressed against the paper surface. And then the
print head is returned by a certain distance so that the gap (actually between the print head and the paper) is
properly adjusted regardless of the paper thickness.
f. Paper sensors
There are six paper sensors for controlling paper feeding:
Name Function Sensor type
TOFL
TOFR
Detect the top edge for paper loading
-TOFL is for front loading
-TOFR is for rear loading
Detect left and right edge for area over control
-TOFL is for left and right edge (small width paper)
-TOFR is for right edge (large width paper)
(Right and left are reversed for rear feed)
Detect the bottom edge for detecting paper end.
-TOFL is for front loading
-TOFR is for rear loading
Photo reflectors
FTRPE
RTRPE
Detect the continuous forms at the tractor for as
follows.
-Control the paper loading sequence.
-Detect the paper parking position.
-Detect the near paper end of continuous forms.
Photo interrupter
PSS Detect the cut sheet on the paper table for auto
loading.
Detect the bottom of the cut sheet for control carriage
position to detect the paper end .
Detect the leaved paper on the paper table for display
remove paper indicator.
Photo reflectors
APTC Detect the surface of the paper for control the print
head gap.
Panel Key Board

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(3) Lower cover
Figure 1.7 Electric components of DL7400
a. Lower cover
The Lower cover supports the printer mechanism and electric units as follows.
b. ROM board (control board with flash ROM)
The ROM board controls the host interface, control panel, and printing mechanism using an MPU and an
LSI circuit. Memory holds the resident character patterns and firmware, including resident emulation programs.
This board also has drivers and receivers for other components. The sensor receivers convert signals from the
sensors. The drivers supply power to motors, print head wires, and other components. The separate RS-232C
serial board or LAN relay board is connected to this board through the cable.
c. Power supply unit
The power supply unit supplies DC34V and DC5V by one transformer.
d. AC inlet and AC switch.
The AC inlet has protective earth cable. In order to prevent an electric shock, it must be fixed to frame ground.
The AC switch has cables to connect the Power supply unit and AC inlet.
e. CSF connector (front CSF)
The connector board for the front CSF is mounted at the front right of the lower over.
Lower cover
ROM board
Power supply unit
AC inlet
AC inlet CSF connector
Reactor
(only 100-120v)

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(4) Option and consumables
a. Cut-sheet feeders
A cut-sheet feeder allows both single-part cut sheets and multi-part cut sheets to be fed automatically.
The SF94 single-bin feeder is available for DL7400.
b. Tractor unit
An additional tractor unit can be installed in the printer. Because the standard tractor unit is installed at the
front of the printer at shipment, the additional tractor is installed at the rear of the printer. However, both
tractor units are the same, and installable at either position.
c. LAN card.
A LAN card is available as a printer add-on option. A user installable function, the LAN card can be installed
only on printer models with the Centronics parallel + USB interfaces.
c. Large paper table
The large paper table helps to increase operability when large cut sheets are used.
Also, sheets that are output from the front are easier to keep properly organized.
d. Large stacker.
The large stacker accommodates sheets output from the rear. It is used in continuous printing with a cut sheet
feeder.
e. Print head
The 24-wire print head is easily installed on and removed from the print head carriage.

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CHAPTER 2 UNPACKING, PERFORMANCE CHECK,
AND CONNECTION
2.1 Overview
The DL7400 printer comes packed for transportation.
After unpacking and before installation, the printer must undergo self-test printing. Installation requires minimum
time and expense.
2.2 Notes on Installation
For best results, note the following points when installing the paper:
Place the printer on a level, vibration-free surface.
Keep the printer away from sunlight and heaters.
Be sure printer ventilation ports are not blocked.
Do not operate the printer in a humid or dusty environment.
Use an outlet that is separated from noise-generating equipment such as motors.
Use the correct AC voltage unexpected problems.

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2.3 Unpacking
Unpacking the printer as follows(Figure 2.1)
1. Open the carton and remove Rear stacker, Ribbon cartridge and Cushion L/R.
2. Lift up the printer using the grip at right and left of the printer.
3. Take out accessories (Power cord, Manual).
Figure 2.1 Unpacking the printer and accessories

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4. Set the paper table as follows.
Figure 2.2 Setting the paper table
5. Remove the Block FC.
6.Open the front cover and remove the cardboard shipping restraint holding the carriage in place
Figure 2.3 Removing the shipping materials
7.Store the original shipping carton and packing materials for future use in moving or shipping the printer.