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