Fujitsu ULTIMA90 User manual

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ULTIMA90/ULTIMA90 +/Impact4550 Pro
DOT MATRIX PRINTER
MAINTENANCE MANUAL

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CHAPTER 1
PRINTER SPECIFICATIONS, CONFIGURATION
PERFORMANCE, AND
1.1 Overview
This manual is for maintenance engineers, and covers overall DL7600 printer maintenance, together with
detailed information such as troubleshooting and component replacement.
The maintenance manual is described b the premise that understands the user's manual. Please
also refer to the following manual if needed.
DL7600 Printer USER’S MANUAL (C147-E052-01EN)
DL7600 Printer Product Description (A1KA02039-B001/E)
DL 7600 printer has a reliable, simple mechanism requires little maintenance.
1.2 Equipmen S ruc ure
1.2.1 Overview
This section outlines printer structure and features.
1.2.2 Model configura ion
The DL7600 printer is a 136-column printer.
Factor options are as follows
Power Suppl t pe; 100-120VAC input(M33325A)
220-240VAC input(M33325B)
Interface t pe; 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. (onl for the Centronics parallel + USB interfaces Models.)
Large paper table. Small paper table Large stacker.
The DL7600 has three emulations as follows.
Fujitsu DPL24C PLUS
IBM Proprinter XL24E
Epson ESC/P2

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1.2.3 S ruc ure
Major printer components are organized as shown below. Items in boldface are recommended spare parts
(see Chapter 6) that can be replaced in field b maintenance service engineers. Replacement and adjustment
are detailed in Chapter 4.
Fig re 1.1 Str ct re of DL7600
Block diagrams
The following figure shows printer functional components and connecting cables.
DL7600 printer
Stacker Unit
Mecha assembl
Ribbon cartridge
Tractor unit
Cut-sheet feeder
Front Cover assembl
Operating panel
Upper Cover assembl
Print Head
ROM board
Power suppl
Lower cover assembl
AC SWITCH assembl
AC INLET assembl
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 assembl
TR motor
Nip Roller assembl
Dv Roller assembl
Platen Roller assembl
LAN CARD
Reactor RF motor

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Fig re 1.2 Block Diagram of DL7600
(1)Ex erior componen s
This section gives information on exterior components of the printer: covers, removable mechanism units,etc.

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Fig re 1.3 Exterior components of DL7600
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.
Print head
Power switch
Soundproof cover Tractor unit
Front CSF connector
Interface
connector
Control panel
Front cover
Upper cover
Ribbon cassette
Rear stacker
Power connector
Rear CSF connector

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Fig re 1.4 Interface type of DL7600
b. Upper cover
The bottom cover and the upper cover are fixed with a back screw.
b. Front cover
The front cover is opened to replace the ribbon cartridge. There
is an Interlock SW for safet .
c. Soundproof cover
Soundproof cover is opened when the continuous form is set.
How to handle refer to the Quick Start Guide or User’s Manual.
d. Rear stacker
The rear stacker holds printed cut sheets.
The optional Large Stacker is necessar to use cut sheets exceeding 297 mm in length
e. Control panel
[LED t pe]
The control panel consists of an LSI, 10 push-button switches, 1 dial, 13 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.
[LCD t pe]
The control panel consists of an LSI, 11 push-button switches, 1 LCD, 8 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. LCD displa s the state of the printer. The buzzer sounds to indicate certain operating and printer
statuses.
[LED t pe]
RS232c Serial Connector
Centronics parallel Connector
Centronics parallel Connector
Clip USB Connector
LAN Connector Option
The ferrite core that
Comes with the LAN
Card must be attached.

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[LCD t pe]
Fig re 1.5 Control panel of DL7600
(2)Prin ing mechanism
HCPP motor
Stepping motor for
Carriage drive mechanism
Carriage
Sta shaft
Ribbon cartridge
Print head

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Fig re 1.6 Mechanism of DL7600
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 slides left and right on the sta shaft.
The ribbon feed gear s stem 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 sta shaft and the sta guide (upper angle) support the carriage; the stepping motor and timing belt move
the carriage horizontall .
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 b 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 automaticall
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 b a certain distance so that the gap (actuall between the print head and the paper) is
properl adjusted regardless of the paper thickness.
f. Paper sensors
HCPP mechanism
Paper feed mechanism
APTC mechanism

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There are six paper sensors for controlling paper feeding:
Name F nction 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 displa
remove paper indicator.
Photo reflectors
APTC
Detect the surface of the paper for control the print
head gap.
Panel Ke Board
(3) Lower cover

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Fig re 1.7 Electric components of DL7600
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. Memor 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 suppl power to motors, print head wires, and other components. LAN
rela board is connected to this board through the cable.
c. Power suppl unit
The power suppl unit supplies DC40V and DC5V b two transformers.
Two transformers realize that printer displa s fatal alarms though printer shuts down DC40V. (Even
if DC40V is shut down, DC5V still remains. )
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 suppl 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.
(4) Op ion and consumables
a. Cut-sheet feeders
Lower cover
ROM board
Power suppl unit
AC inlet
AC inlet CSF connector
Reactor
onl 200v) (

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A cut-sheet feeder allows both single-part cut sheets and multi-part cut sheets to be fed automaticall .
The SF94 single-bin feeder is available for DL7600.
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 onl on printer models with the Centronics parallel + USB interfaces.
d. Large paper table
The large paper table helps to increase operabilit when large cut sheets are used. Also,
sheets that are output from the front are easier to keep properl organized.
e. Small paper table
The Small paper table helps to increase operabilit when small cut sheets are used.
f. Large stacker.
The large stacker accommodates sheets output from the rear.
It is used in continuous printing with a cut sheet feeder.
g. Print head
The 24-wire print head is easil installed on and removed from the print head carriage.

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CHAPTER 2 UNPACKING, PERFORMANCE
CHECK, AND CONNECTION
2.1 Overview
The DL7600 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 No es on Ins alla ion
For best results, note the following points when installing the paper:
・ Place the printer on a level, vibration-free surface.
・ Keep the printer awa from sunlight and heaters.
・ Be sure printer ventilation ports are not blocked.
・ Do not operate the printer in a humid or dust environment.
・ Use an outlet that is separated from noise-generating equipment such as motors. ・ Use
the correct AC voltage to avoid unexpected problems.

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2.3 Unpacking
Unpacking the printer as follows(Figure 2.1)
1. Open the carton and remove 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).
Fig re 2.1 Unpacking the printer and accessories
4.Open the front cover and remove the cardboard shipping restraint holding the carriage in place

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Fig re 2.2 Removing the shipping materials
6.Store the original shipping carton and packing materials for future use in moving or shipping the printer.

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2.4 Inspec ion af er Unpacking
1. Carefull check assemblies and accessories for visible damage.
2. Install the ribbon cartridge. See the User’s Manual for details.
3. Check the rated voltage or the printer and AC power outlet, then connect the AC power cord between the
printer and AC power outlet.
5. Close the front cover.
6. Turn on the power switch.
7. Load continuous forms paper or cut sheet paper as explained in the User's Manual.
Check printing performance and qualit using self-test printing, detailed in User’s Manual.

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CHAPTER 3 TROUBLESHOOTING
This chapter helps pinpoint the causes of problems with the printer.
Section 3.1 is a troubleshooting table. The table shows how to determine what is wrong with the printer and what
to do to correct the problem.
Section 3.2 explains error displa s on the control panel that help clarif the cause of a problem.
Section 3.3 explains the self-correction functions of the DL7600 printer. For
replacement and adjustment after recover , see Chapter 4.
3.1 Trouble shoo ing Table
3.1.1 Problems a power-on ini ializa ion (par 001/4)
Symptom
Ca se Response
1 The POWER lamp does
not go on.
－ The power cord is not
connected to the outlet
or the printer.
Connect the power cord
properl
The power cord is connected
properl .
The power cord is
defective.
Replace the power cord.
The power suppl is
defective.
Replace the power
suppl .
The control board is
defective.
Replace and initialize the
control board.
The control panel board
is defective.
Replace the control
panel board.
The cable connected to
the control panel board
is defective.
Check the connection.
Check the cable.
2
The POWER lamp
comes on momentaril ,
but goes off. Then, turn
the power switch OFF,
and turn on the power
after 10 to 20 seconds.
However, the
POWER lamp does not
go on.
+40 V over voltage alarm The power suppl is
failing. (The power
suppl becomes a high
voltage.)
Replace the power suppl
unit.
3.1.1 Problems a power-on ini ializa ion (par 002/4)
Symptom Ca se Response
3 The POWER lamp is
on.
After the POWER lamp goes on,
simultaneous blinking of
all other lamps is not performed.
The control board Is
defective.
Replace and initialize
the control board.
After the POWER lamp goes
on, simultaneous blinking of all
other lamps is performed but
initialization is not performed
normall .
The cover is open. Close the front cover.
The cover open switch
assembl is defective.
Replace the cover open
switch assembl .
After the POWER lamp goes
on, simultaneous blinking of all
The interface cable is
defective.
Replace the interface
cable.

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other lamps is performed but
the PAPER OUT lamp
does not blink later. If the
interface cable is
disconnected, initialization is
performed normall .
The host is defective. Check the host.
The case of as stated above.
Initialization is not performed
normall even if the interface
cable is disconnected.
The control board is
defective.
Replace and initialize
the control board.
The control panel board
is defective.
Replace the control
panel board.
The cable connected
to the control panel
board is defective.
Check the connection.
Replace the cable.
The cover is open. Close the front cover.
3.1.1 Problems a power-on ini ializa ion (par 003/4)
Symptom Ca se Response
4 [LED t pe]
The PAPER OUT lamp
blinks.
[LCD t pe]
Error message blinks.
ROM/RAM alarm
[LED t pe]
Also HI IMPACT and
TRACTOR F lamps blink.
[LCD t pe]
LCD displa s as follows
FATAL!
ROM/RAM ALARM
Mismatch of ROM is
detected.
•
Download
correct program to the
flash
ROM.
• Replace the
ROM board .
Low-voltage alarm
[LED t pe]
Also QUIET and TRACTOR R
lamps blink.
[LCD t pe]
LCD displa s as follows
FATAL!
LOW VOLT ALARM
Low
-
voltage alarm is
detected.
•
Replace the power
suppl .
• Replace the control
board, then initialize the
EEPROM.
APTC home position sensor
alarm [LED t pe]
Also AUTO GAP and
TRACTOR R lamps blink.
[LCD t pe]
LCD displa s as follows
FATAL!
APTC HPS ALARM
•
APTCHPSW ASY
is defective.
• The APTC motor is
defective.
• APTCHPSW ASY
is not connected.
• The driver board is
defective.
• Replace the
APTCHPSW ASY.
• Replace the APTC
motor.
• Connect the
APTCHPSW ASY cable
properl .
• Replace the driver
board.
LRES alarm
[LED t pe]
Also REMOVE PAPER and
TRACTOR F lamps blink.
[LCD t pe]
LCD displa s as follows
FATAL!
LRES ALARM
A LRES alarm is
detected.
• LES detection is
poor.
• The carriage cable is
defective.
• The driver board is
defective.
• The carriage cable is
disconnected.
•
Clean or replace the
carriage PC board.
• Replace the carriage
cable.
• Replace the driver
board.
• Connect the carriage
cable properl .

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Fire check alarm of ribbon feed
motor [LED t pe]
Also REMOVE PAPER and
MENU2 lamps blink.
[LCD t pe]
LCD displa s as follows
FATAL!
RBFM ALARM
Ribbon motor alarm is
detected.
A. The RF motor
connector is
disconnected.
B. The RF motor is
defective.
C. The control board is
defective.
A. Connect the
Connector correctl .
B.
Replace the RF motor.
C. Replace the control
board, then initialize
the EEPROM.
3.1.1 Problems a power-on ini ializa ion (par 004/4)
Symptom Ca se Response
4 [LED t pe]
The PAPER OUT lamp
blinks.
[LCD t pe]
Error message blinks.
FAN alarm
[LED t pe]
Also REMOVE PAPER and CUT
SHEET lamps blink.
[LCD t pe]
LCD displa s as follows
FATAL!
FAN ALARM
FAN motor alarm is
detected.
A. The FAN motor
connector is
disconnected.
B. The FAN motor is
defective.
C. The control board is
defective.
A. Connect the
Connector correctl .
B. Replace the FAN
motor.
C. Replace the control
board, then initialize
the EEPROM.
SPACE alarm
[LED t pe]
Also REMOVE PAPER and
TRACTOR R lamps blink.
[LCD t pe]
LCD displa s as follows
FATAL!
SPACE ALARM
Space alarm is detected.
A. The SP motor
connector is
disconnected.
B. The SP motor is
defective.
C. The sta shaft is
rough.
D. The SP belt is loose.
E. The control board is
defective.
A. Connect the
Connector correctl .
B. Replace the space
motor.
C. Clean or lubricate the
sta shaft.
D. Check the tension
pulle .
E. Replace the control
board, then initialize
the EEPROM.
HCPP alarm
[LED t pe]
Also FRONT DIR and
TRACTOR R lamps blink.
[LCD t pe]
LCD displa s as follows
FATAL!
HCPP ALARM
•
HCPPSW ASY is
defective.
• The HCPP motor is
defective.
• HCPPSW ASY is
not connected.
• The control board is
defective.
• Replace the
HCPPSW ASY.
• Replace the HCPP
motor.
• Connect the
HCPPSW ASY cable
properl .
• Replace and initialize
the control board.
3.1.2 Problems rela ed o prin ing (par 001/2)
Symptom Ca se Response
1 The POWER lamp
goes off during printing.
Then, turn the power
switch OFF, and turn
on the power after 10 to
20 seconds.
However, the POWER
lamp does not go on.
+40 V over voltage alarm The power suppl is
fault .( The power
suppl is a high
voltage.)
Replace the power suppl
unit.

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2
[LED t pe]
The PAPER OUT lamp
starts blinking.
[LCD t pe]
Error message blinks.
APTC Gap Alarm is detected
[LED t pe]
Also AUTO GAP and
TRACTOR F lamps blink.
[LCD t pe]
LCD displa s as follows
FATAL!
APTC GAP ALARM
The paper to be
Printed on is too thick.
Replace the paper. (Use
paper of a thickness
specified in the paper
specification.)
Difference thickness of
the paper.
Replace the paper or use
manual mode properl .
Card guide adjustment
is incorrect
Adjust card guide
correctl .
APTC sensor is
defective
3 2pass printing is
performed.
•
Power overload is
detected (if more than
one character of the
solid pattern is
printed).
• Print head overheat is
detected (if print
patterns of rather
higher densit of
characters are printed
continuousl .
• The control board is
defective.
• The power suppl is
defective.
• The print head is
defective.
•
The print head
protection function
works normall .
Change the print
pattern.
• The print head
protection function
works normall .
Change the print
pattern or stop the
printer for a while.
• Replace the control
board.
• Replace the power
suppl .
• Replace the print head.
3.1.2 Problems rela ed o prin ing(par 002/2)
Symptom Ca se Response
4 Data sent from the host
is not printed at all.
Data cannot be
received from the
host.
Printing operation is not
performed at all.
The interface cable is
not connected properl .
Connect the interface
cable properl .
The front cover is open.
Close the front cover.
Self-test printing is performed
normall .
The host interface
setting of the printer
does not match the host
used.
Enter setup mode and
change the setting for the
host interface.
The interface is
defective.
•
Replace and initialize
the control board.
• Replace the interface
cable.
• Check the host.
Even self
-
test printing is not
performed.
The carriage cable is
improperl connected to
the print head or control
board.
Connect the carriage
cable properl .
The control board is
defective.
Replace and initialize the
control board.
Paper out condition is detected.
Paper pass select isn’t
correct.
Paper isn’t load.
CSF is empt .

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[LED t pe]
REMOVE PAPER indicator
blinks.
[LCD t pe]
Error message lighting.
Massage : REMOVE PAPER
Cut sheet leaved on the
paper table and printer
waiting removing it.
Remove the paper from
the paper table.
3.1.3 Problems rela ed o prin ing resul
Symptom Ca se Response
1 The data sent from the
host does not match the
print results.
Self-test printing is performed
normall .
The setup mode setting
is invalid.
Enter setup mode and
change the mode setting
properl .
The interface is
defective.
•
Replace and initialize
the control board.
• Replace the interface
cable.
• Check the host.
Even self-test printing is
abnormal.
The carriage cable is
improperl connected
to the print head or
control board.
Connect the carriage
cable properl .
The control board is
defective.
Replace and initialize
the
control board.
Printer ignores data that out of
print area.
Area over detection
works.
Area over detection cut the data
in the print area.
Printer misread the
black printing into the
paper edge.