Brother DP-550CJ, LW-840ic Service manual

WORD PROCESSOR

SERVICE MANUAL

MODEL:DP-525CJ/DP-530CJ/DP-540CJ/DP-550CJ

LW-800ic/LW-810ic/LW-810icBL/LW-840ic

REVISED EDITION

SERVICE MANUAL

CONTENTS

PART I THEORY OF OPERATION

CHAPTER 1 MECHANICAL THEORY....................................................................... 1-1

1. Ink Jet Printer........................................................................................................... 1-1

1.1. Ink Jet Printer System Configuration .......................................................................... 1-2

1.2. Ink Jet Operation........................................................................................................1-4

1.2.1. Paper Feed Mechanism ................................................................................ 1-4

1.2.2. Carriage Assembly ....................................................................................... 1-7

1.2.3. Carriage Motion Control.............................................................................. 1-10

1.2.4. Maintenance Station Operation................................................................... 1-11

1.2.4.1. Spitting ................................................................................................. 1-12

1.2.4.2. Wiping.................................................................................................. 1-13

1.2.4.3. Capping................................................................................................ 1-14

1.2.4.4. Purging................................................................................................. 1-14

1.2.5. Sensors...................................................................................................... 1-15

1.2.5.1. Carriage Home Position Sensor............................................................ 1-15

1.2.5.2. PE Sensor ............................................................................................ 1-16

1.3. INK CHG (Ink Change) Functions.............................................................................1-17

1.3.1. Ink Cartridge Installation/Replacement ....................................................... 1-17

1.3.2. Automatic Print head Cleaning (Purging).................................................... 1-17

2. Keyboard ................................................................................................................ 1-18

CHAPTER 2 ELECTRICAL THEORY........................................................................ 2-1

1. System Configuration...............................................................................................2-1

1.1. Main PCB (Printed Circuit Board)............................................................................... 2-1

1.2. Switch PCB (Printed Circuit Board)............................................................................. 2-1

1.3. Keyboard FPC (Flexible Printed Circuit)..................................................................... 2-1

1.4. FDD (Floppy Disk Drive) Module................................................................................ 2-1

1.5. CRT Display............................................................................................................... 2-1

2. Ink Jet Printer Configuration.....................................................................................2-3

2.1. Ink Cartridge............................................................................................................... 2-3

2.2. Carriage Motor ........................................................................................................... 2-3

2.3. Line Feed Motor......................................................................................................... 2-3

2.4. Carriage Home Position Sensor.................................................................................. 2-3

2.5. PE (Paper End) Sensor ..............................................................................................2-3

SERVICE MANUAL

3. Power Supply Circuit................................................................................................ 2-4

3.1. Configuration.............................................................................................................. 2-4

3.2. +24V Generator.......................................................................................................... 2-5

3.3. +5V Generator............................................................................................................ 2-5

4. Reset Circuit.............................................................................................................2-6

4.1. Configuration.............................................................................................................. 2-6

5. CBIC and Peripherals............................................................................................... 2-7

5.1. CBIC #9 ..................................................................................................................... 2-7

5.2. Main ROM (#12, #13)................................................................................................. 2-7

5.3. Main RAM (#10, #11) ................................................................................................. 2-7

5.4. Video RAM (#7) .......................................................................................................... 2-7

5.5. Printer Driver Circuits (#2, #3, Q1 to Q4, and Q14 to Q17)......................................... 2-7

5.6. FDC (Floppy Disk Controller)...................................................................................... 2-7

5.7. Clock Circuit............................................................................................................... 2-8

5.8. Buzzer Drive Circuit ................................................................................................... 2-8

5.9. Country Specification Change-over ............................................................................2-9

5.10. RS-232C I/F Circuit.................................................................................................. 2-10

6. Printer Control........................................................................................................ 2-11

6.1. Ink Jet Head Control ................................................................................................. 2-11

6.2. Carriage Motor Control............................................................................................. 2-12

6.3. Line Feed Motor Control........................................................................................... 2-13

6.4. Carriage Home Position Sensor................................................................................ 2-14

6.5. PE Sensor................................................................................................................ 2-14

7. Switch PCB ............................................................................................................2-15

7.1. Configuration............................................................................................................ 2-15

8. Keyboard System................................................................................................... 2-16

8.1. FPC Operation ......................................................................................................... 2-16

8.2. Keyboard Scan......................................................................................................... 2-17

8.3. Keyboard Control Circuit........................................................................................... 2-18

9. CRT Control ........................................................................................................... 2-20

9.1. Configuration............................................................................................................ 2-20

9.2. SRAM and Display Screen Relationship................................................................... 2-21

9.2.1. SRAM (#7) Access ..................................................................................... 2-22

9.2.2. CRT Display Timing Chart.......................................................................... 2-23

10. FDD (Floppy Disk Drive) Control ............................................................................2-24

10.1. FDD Configuration.................................................................................................... 2-24

10.2. FDD Operation......................................................................................................... 2-25

10.2.1. Basic Operation.......................................................................................... 2-25

10.2.2. Interface between CBIC (#8) and FDC (#5)................................................. 2-25

10.3. FDD Module............................................................................................................. 2-26

SERVICE MANUAL

10.3.1. Read/Write Circuit...................................................................................... 2-26

10.3.2. Motor Drive Circuit...................................................................................... 2-26

10.3.3. Sensor Circuits........................................................................................... 2-26

PART II REPAIR

CHAPTER 3 TROUBLESHOOTING..........................................................................3-1

1. Introduction .............................................................................................................. 3-1

2. Precautions..............................................................................................................3-1

2.1. Personal Safety.......................................................................................................... 3-1

2.2. Handling ESD-Sensitive Parts.................................................................................... 3-1

3. Checks Before Repair.............................................................................................. 3-2

4. Checks After Repair................................................................................................. 3-3

5. Troubleshooting Flow Charts....................................................................................3-4

6. Failure Analysis........................................................................................................3-6

7. SELF-TESTS..........................................................................................................3-13

7.1. SERIAL NUMBER Input Display............................................................................... 3-13

7.2. Self Print Mode......................................................................................................... 3-14

7.3. Self-Test Mode......................................................................................................... 3-17

7.3.1. Display (CRT) Test..................................................................................... 3-19

7.3.1.1. Cross Hatch Pattern Test...................................................................... 3-20

7.3.1.2. Full Dot Screen Test............................................................................. 3-21

7.3.1.3. Blank Screen Test ................................................................................ 3-22

7.3.1.4. H Pattern Test ...................................................................................... 3-23

7.3.1.5. mw Pattern Test.................................................................................... 3-24

7.3.1.6. Dot Pattern Test.................................................................................... 3-25

7.3.2. Print Checks............................................................................................... 3-26

7.3.2.1. Print Test Pattern 1............................................................................... 3-26

7.3.2.2. Print Test Pattern 2............................................................................... 3-29

7.3.2.3. Dot Patterns.......................................................................................... 3-31

7.3.3. Keyboard Tests........................................................................................... 3-33

7.3.4. FDD Tests.................................................................................................. 3-36

7.3.4.1. FDD Test.............................................................................................. 3-36

7.3.4.2. Special FDD Test.................................................................................. 3-37

7.3.4.3. FDD SW Test ....................................................................................... 3-41

7.3.4.4. FDD Write Error Rate Check ................................................................ 3-42

7.3.4.5. FDD Read Error Rate Check................................................................. 3-44

7.3.5. PE (Paper-End) Sensor Test....................................................................... 3-46

7.3.6. CR (Carriage Reset) Test ........................................................................... 3-47

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SERVICE MANUAL

7.3.7. DISK TYPE ................................................................................................ 3-48

7.3.8. RS-232C Test ("Echo Back") ...................................................................... 3-49

CHAPTER 4 COMPONENT DISASSEMBLY............................................................. 4-1

1. Covers...................................................................................................................... 4-1

1.1. Upper Cover ............................................................................................................... 4-2

1.1.1. Removing the Upper Cover.......................................................................... 4-2

1.1.2. Removing the Front Cover ........................................................................... 4-6

1.1.3. Installing the Upper Cover ............................................................................4-7

2. Keyboard Assembly ................................................................................................. 4-8

2.1. Removing the Keyboard............................................................................................. 4-8

2.2. Installing the Keyboard............................................................................................... 4-9

3. Ink Jet Printer Assembly.........................................................................................4-10

3.1. Removing the Printer Assembly ............................................................................... 4-11

3.2. Installing the Printer Assembly.................................................................................. 4-11

3.3. Disassembling the Printer Assembly ......................................................................... 4-12

3.3.1. Removing the CA Unit................................................................................ 4-13

3.3.2. Installing the CA Unit.................................................................................. 4-13

3.3.3. Disassembling the PF Unit.......................................................................... 4-14

3.3.3.1. Removing the Form.............................................................................. 4-15

3.3.3.2. Removing the Release Lever and Release Shaft.................................. 4-16

3.3.3.3. Removing the ACF Shaft Assembly...................................................... 4-17

3.3.3.4. Removing the Pressure Rollers and Roller Holders............................... 4-18

3.3.3.5. Removing the Holder Plate................................................................... 4-19

3.3.3.6. Removing the Hopper Assembly........................................................... 4-20

3.3.3.7. Disassembling the Paper Feed Assembly ............................................. 4-22

3.3.3.8. Removing the Eject Roller Assembly and the PF Roller Assembly........ 4-23

3.3.3.9. Removing the Motor Frame Assembly.................................................. 4-24

3.3.3.10. Removing the PF Stopper..................................................................... 4-25

3.3.3.11. Removing the PE Sensor...................................................................... 4-26

3.3.4. Disassembling the CA Unit ......................................................................... 4-27

3.3.4.1. Removing the Carriage......................................................................... 4-28

3.3.4.2. Removing the Carriage Drive................................................................ 4-30

3.3.4.3. Removing the Star Wheel Holder Assembly ......................................... 4-31

3.3.4.4. Removing the MS Holder Assembly...................................................... 4-32

3.3.4.5. Removing the Leaf Switch (Home Position Sensor).............................. 4-33

3.3.4.6. Removing and Mounting the KB Switch Assy........................................ 4-34

3.4. Adjusting the CA Unit ............................................................................................... 4-35

3.4.1. Adjusting the Carriage Home Position......................................................... 4-35

3.4.2. Adjusting Belt Tension................................................................................ 4-36

SERVICE MANUAL

4. Removing the FDD Assembly ................................................................................ 4-39

5. Switch PCB ............................................................................................................4-40

5.1. Removing the Switch PCB ....................................................................................... 4-41

5.2. Installing the Switch PCB.......................................................................................... 4-41

6. Removing the Main PCB........................................................................................ 4-42

7. Removing the Shield Plate (ESD) .......................................................................... 4-43

CHAPTER 5 MONITOR REPAIR AND ADJUSTMENT (MODEL CT-1450).............. 5-1

1. Safety Precautions...................................................................................................5-1

2. Theory of Operation.................................................................................................5-3

2.1. Video Process ............................................................................................................5-3

2.2. Video Amplifier ........................................................................................................... 5-3

2.3. Vertical Circuitry......................................................................................................... 5-4

2.4. Horizontal Sync and Drive.......................................................................................... 5-4

2.5. Horizontal Output Transistor....................................................................................... 5-5

2.6. High Voltage and Focus ............................................................................................. 5-5

3. Adjustment and Servicing......................................................................................... 5-6

3.1. Test Pattern................................................................................................................ 5-6

3.2. Measurement Conditions............................................................................................ 5-7

3.2.1. Display Dimension Measurement.................................................................. 5-7

3.2.2. Raster Centering & Tilt Adjustment (see Fig. 5.3) .........................................5-7

3.3. Adjustments ............................................................................................................... 5-8

3.3.1. B+ Voltage Adjustments: None required. ..................................................... 5-8

3.3.2. Horizontal Adjustments................................................................................. 5-8

3.3.3. Vertical Adjustments (see Fig. 5.5) ...............................................................5-9

3.3.4. Brightness & Contrast................................................................................... 5-9

3.3.5. Focus Adjustment......................................................................................... 5-9

3.3.6. Raster Geometry Adjustments.................................................................... 5-10

3.3.6.1. Pin Cushion/Barrel Correction (top, bottom and sides) Adjustment........ 5-10

3.3.6.2. Trapezoidal Correction (corners) Adjustment ........................................ 5-12

4. Troubleshooting ..................................................................................................... 5-13

5. Control Parts Location............................................................................................5-14

6. Monitor Block Diagram...........................................................................................5-15

CHAPTER 6 MAINTENANCE .................................................................................... 6-1

1. Lubrication................................................................................................................ 6-1

1.1. Lubricants................................................................................................................... 6-1

1.2. Precautions ................................................................................................................6-1

1.3. Lubrication Points....................................................................................................... 6-1

SERVICE MANUAL

2. Replacing the Ink Cartridge...................................................................................... 6-5

3. Cleaning the Print Head........................................................................................... 6-9

3.1. Cleaning the Print Head Automatically........................................................................ 6-9

3.2. Cleaning the Ink Jet Nozzles and Contacts................................................................. 6-9

3.3. Cleaning the Bracket Contacts (Carriage)................................................................. 6-10

APPENDIX A SPECIFICATIONS...........................................................................APP-1

1. Electrical System.................................................................................................APP-1

2. Printing................................................................................................................APP-2

3. Keyboard .............................................................................................................APP-4

4. Monitor (CT-1450)...............................................................................................APP-4

5. Environmental Tolerance ....................................................................................APP-5

6. Dimensions & Weight..........................................................................................APP-6

SERVICE MANUAL

FIGURES

Figure Title Page

Fig. 1.1 Ink Jet Printer Assembly....................................................................................... 1-1

Fig. 1.2 General View of Printing Mechanism .................................................................... 1-3

Fig. 1.3A Paper Feed Mechanism ................................................................ ........................ 1-4

Fig. 1.3B Paper Feed Mechanism ................................................................ ........................ 1-5

Fig. 1.4 Paper Eject System.............................................................................................. 1-5

Fig. 1.5 Paper Setting System........................................................................................... 1-6

Fig. 1.6 Printer Flat Cable to Main PCB............................................................................. 1-7

Fig. 1.7 Printer Flat Cable to Cartridge Alignment.............................................................. 1-8

Fig. 1.8 Ink Jet Cartridge to Flat Cable Alignment.............................................................. 1-9

Fig. 1.9 Carriage Motion Control ................................................................ ...................... 1-10

Fig. 1.10 Print Maintenance Operation - Spitting................................................................ 1-12

Fig. 1.11 Print Maintenance Operation - Wiping................................................................. 1-13

Fig. 1.12 Print Maintenance Operation - Capping .............................................................. 1-14

Fig. 1.13 Carriage Home Position Sensor ................................ .......................................... 1-15

Fig. 1.14 PE Sensor Mechanism....................................................................................... 1-16

Fig. 1.15 Keyboard Assembly............................................................................................ 1-18

Fig. 1.16 Key Top/Key Stem Assembly ............................................................................. 1-19

Fig. 1.17 LCD Unit Installation in the Upper Cover ................................ ............................. 1-21

Fig. 1.18 LCD of DP-525CJ/LW-800ic............................................................................... 1-22

Fig. 1.19 LCD of DP-530CJ/LW-810ic and LW-810icBL .................................................... 1-23

Fig. 1.20 LCD of DP-540CJ, DP-550CJ/LW-840ic............................................................. 1-24

Fig. 2.1 Major Electronic Component Parts........................................................................ 2-2

Fig. 2.2 Power Supply Circuit ............................................................................................ 2-4

Fig. 2.3 Timing Chart of +24V Generation Circuit............................................................... 2-5

Fig. 2.4 Timing Chart of +5V Generation Circuit ................................................................ 2-5

Fig. 2.5 Reset Circuit......................................................................................................... 2-6

Fig. 2.6 Buzzer Drive Circuit.............................................................................................. 2-8

Fig. 2.7 Country & Model Specification Change-over Circuit.............................................. 2-9

Fig. 2.8 RS-232C I/F Circuit ............................................................................................ 2-10

Fig. 2.9 Ink Jet Head Drive Circuit................................................................................... 2-11

SERVICE MANUAL

Figure Title Page

Fig. 2.10 Carriage Motor Drive Circuit................................................................................ 2-12

Fig. 2.11 Line Feed Motor Drive Circuit ............................................................................. 2-13

Fig. 2.12 Carriage Home Position Sensor Circuit............................................................... 2-14

Fig. 2.13 PE Sensor Detection Circuit ............................................................................... 2-14

Fig. 2.14 External View of the Switch PCB........................................................................ 2-15

Fig. 2.15 Switch PCB Circuit ............................................................................................. 2-15

Fig. 2.16 Key/FPC Operation ............................................................................................ 2-16

Fig. 2.17 Electrode Wiring................................................................................................. 2-17

Fig. 2.18 Keyboard Control Circuit ................................................................ ..................... 2-18

Fig. 2.19 Keyboard Matrix ................................................................................................. 2-19

Fig. 2.20 Keyboard Symbols (Corresponding to Keyboard Matrix in Fig. 2.19)................... 2-19

Fig. 2.21 LCD Display Operation Block Diagram................................................................ 2-20

Fig. 2.22 Example of Control Signal Timing Chart.............................................................. 2-21

Fig. 2.23 LCD Drive Voltage Generation Circuit (Minus Voltage VEE)................................ 2-22

Fig. 2.24 LCD Drive Voltage Generation Circuit (Plus Voltage VEE).................................. 2-22

Fig. 2.25 CFL Backlight Circuit.......................................................................................... 2-23

Fig. 2.26 FDD Block Diagram............................................................................................ 2-25

Fig. 3.1 Troubleshooting Flowchart.................................................................................... 3-4

Fig. 3.2 Troubleshooting Flowchart (continued) ................................................................. 3-5

Fig. 3.3 Serial Number Entry Display............................................................................... 3-14

Fig. 3.4 Self-Print Pattern................................................................................................ 3-15

Fig. 3.5 Results of Self-Print Test.................................................................................... 3-17

Fig. 3.6 Self-Test Menu................................................................................................... 3-18

Fig. 3.7 LCD Test Menu.................................................................................................. 3-20

Fig. 3.8 CHECK Test Display (magnified)........................................................................ 3-21

Fig. 3.9 CROSS Test Display (magnified)........................................................................ 3-22

Fig. 3.10 BLACK Test Display........................................................................................... 3-23

Fig. 3.11 DISP Q Test Display (magnified)........................................................................ 3-24

Fig. 3.12 Slant Line Test Display (magnified)..................................................................... 3-25

Fig. 3.13 Printer Check #1 (in progress) Display................................................................ 3-26

Fig. 3.14 Diagram of Print Test Pattern 1 .......................................................................... 3-27

Fig. 3.15 Sample Print Test Pattern 1................................................................................ 3-28

SERVICE MANUAL

Figure Title Page

Fig. 3.16 Printer Check #2 (in progress) Display................................................................ 3-29

Fig. 3.17 Sample Test Pattern 2........................................................................................ 3-30

Fig. 3.18 Dot Patterns for Print Test #2 (Patterns 1 to 4)................................................... 3-31

Fig. 3.19 Dot Patterns for Print Test #2 (Patterns 5 and 6) ................................................ 3-32

Fig. 3.20 Keyboard Test #1 Display ................................................................ ................... 3-33

Fig. 3.21 Keyboard Test Key Locations............................................................................. 3-33

Fig. 3.22 FDD Test (in progress) Display ................................ ........................................... 3-36

Fig. 3.23 Special FDD Test Display 1................................................................................ 3-37

Fig. 3.24 Special FDD Test Display 2................................................................................ 3-38

Fig. 3.25 Special FDD Test (in progress) Display .............................................................. 3-38

Fig. 3.26 Special FDD Test Display 1................................................................................ 3-41

Fig. 3.27 FDD Write Error Rate Check Display.................................................................. 3-42

Fig. 3.28 FDD Read Error Rate Check Display.................................................................. 3-44

Fig. 3.29 PE Sensor Test Start Display 1 .......................................................................... 3-46

Fig. 3.30 PE Sensor Test Start Display 2 .......................................................................... 3-46

Fig. 3.31 CR Test Start Display 1...................................................................................... 3-47

Fig. 3.32 Self-Test Menu (DISK TYPE Setting) ................................................................. 3-48

Fig. 3.33 RS232C Echo-Back Test Start Display............................................................... 3-49

Fig. 4.1 Cover Assemblies................................................................................................. 4-1

Fig. 4.2 Removing the Sub Paper Support and Paper Support .......................................... 4-3

Fig. 4.3 Removing the Top Cover...................................................................................... 4-4

Fig. 4.4 Removing the Upper Cover................................................................................... 4-5

Fig. 4.5 Removing the Core............................................................................................... 4-8

Fig. 4.6 Removing the LCD Unit........................................................................................ 4-9

Fig. 4.7 Removing the LCD Lower Cover......................................................................... 4-10

Fig. 4.8 Removing the LCD PCB (1)................................................................................ 4-12

Fig. 4.9 Removing the LCD PCB (2)................................................................................ 4-13

Fig. 4.10 Removing the LCD PCB (3)................................................................................ 4-14

Fig. 4.11 Removing the LCD PCB (4)................................................................................ 4-15

Fig. 4.12 Removing the LCD PCB (5)................................................................................ 4-16

Fig. 4.13 Removing LCD Latch and LCD Plate.................................................................. 4-17

Fig. 4.14 Installing LCD Latch............................................................................................ 4-19

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SERVICE MANUAL

Figure Title Page

Fig. 4.15 Fitting LCD Volume Guide to LCD Volume Knob................................................. 4-21

Fig. 4.16 Installing the LCD Lower Cover........................................................................... 4-22

Fig. 4.17 Fitting the Core ................................................................ .................................. 4-23

Fig. 4.18 Installing the Hinge Assy..................................................................................... 4-24

Fig. 4.19 Removing the Keyboard Assembly ..................................................................... 4-25

Fig. 4.20 Installing the Keyboard ....................................................................................... 4-26

Fig. 4.21 Removing the Carrying Handle........................................................................... 4-27

Fig. 4.22 Ink Jet Printer Assembly..................................................................................... 4-28

Fig. 4.23 Disassembling the Printer Assembly................................................................... 4-30

Fig. 4.24 Construction of the PF Unit................................................................................. 4-32

Fig. 4.25 Removing the Form............................................................................................ 4-33

Fig. 4.26 Removing the Release Lever and Release Shaft from the PF Base Assembly.... 4-34

Fig. 4.27 Removing the ACF Shaft Assembly.................................................................... 4-35

Fig. 4.28 Removing the Pressure Rollers and Roller Holders............................................. 4-36

Fig. 4.29 Removing the Holder Plate................................................................................. 4-37

Fig. 4.30 Removing the Hopper Assembly ................................ ......................................... 4-39

Fig. 4.31 Disassembling the Paper Feed Assembly........................................................... 4-40

Fig. 4.32 Removing the Eject Roller Assembly and the PF Roller Assembly...................... 4-41

Fig. 4.33 Removing the Motor Frame Assembly................................................................ 4-42

Fig. 4.34 Removing the PF Stopper................................................................................... 4-43

Fig. 4.35 Removing the PE Sensor.................................................................................... 4-44

Fig. 4.36 Construction of the CA Unit ................................................................................ 4-45

Fig. 4.37 Printer Mechanism.............................................................................................. 4-46

Fig. 4.38 Removing the Carriage....................................................................................... 4-47

Fig. 4.39 Removing the Carriage Drive.............................................................................. 4-48

Fig. 4.40 Removing the Star Wheel Holder Assembly........................................................ 4-49

Fig. 4.41 Removing the MS Holder Assembly.................................................................... 4-50

Fig. 4.42 Removing the Leaf Switch (Home Position Sensor) ............................................ 4-51

Fig. 4.43 Removing and Mounting the KB Switch Assy...................................................... 4-52

Fig. 4.44 Adjusting the Belt Tension.................................................................................. 4-55

Fig. 4.45 Measuring Friction during Carriage Movement.................................................... 4-56

Fig. 4.46 Removing the FDD Assembly............................................................................. 4-57

SERVICE MANUAL

Figure Title Page

Fig. 4.47 Switch PCB........................................................................................................ 4-58

Fig. 4.48 Switch PCB........................................................................................................ 4-59

Fig. 4.49 Removing the Main PCB..................................................................................... 4-60

Fig. 4.50 Removing the Shield Plate (ESD)....................................................................... 4-61

Fig. 5.1 Carriage Assembly Lubrication Points................................................................... 5-2

Fig. 5.2 Paper Feed Assembly Lubrication Points ................................ .............................. 5-3

Fig. 5.3 Eject Roller Assembly and PF Roller Assembly Lubrication Points........................ 5-4

Fig. 5.4 Open the Paper Support and Top Cover and

Tilting the LCD to the Uprige Position ................................................................... 5-6

Fig. 5.5 Removing the Ink Jet Cartridge............................................................................. 5-7

Fig. 5.6 Removing the Protection Tape.............................................................................. 5-7

Fig. 5.7 Placing the Cartridge in the Carriage .................................................................... 5-8

Fig. 5.8 Fitting the Cartridge in the Carriage ...................................................................... 5-8

Fig. 5.9 Cleaning the Bracket Contacts............................................................................ 5-11

TABLES

Table 1.1 Summary of Maintenance Operations................................................................. 1-11

Table 2.1 Clock Circuit ......................................................................................................... 2-8

Table 2.2 Table of LCD Modules........................................................................................ 2-21

Table 2.3 FDC(#5) and FDD Module Links (Interface Signals)............................................ 2-24

Table 3.1 Failure Analysis .................................................................................................... 3-6

Table 3.2 FDD Special Test Error Stage Codes ................................................................. 3-39

Table 3.3 FDD Special Test Error Codes............................................................................ 3-40

Table 5.1 Recommended Lubricants .................................................................................... 5-1

SERVICE MANUAL

PART I THEORY OF OPERATION

CHAPTER 1 MECHANICAL THEORY

1. Ink Jet Printer

THEORY

Mechanical

Fig. 1.1 Ink Jet Printer Assembly

1-1

THEORY

Mechanical

1.1. Ink Jet Printer System Configuration

The ink jet printer contains the following components:

Carriage assembly

•

Carriage motion control system

•

Paper feed mechanism

•

Maintenance station

•

Sensors

•

The outline of these components are described below.

1. Carriage Assembly The carriage assembly consists of the carriage and ink cartridge (the cartridge

contains the ink jet nozzles). The carriage consists of the head locker and locker spring, the rubber pad, and the flat cable.

SERVICE MANUAL

2. Carriage Motion Control System The carriage motion control system consists of the carriage motor, motor pulley,

timing belt, idle pulley, and the idle pulley holder and holder spring.

3. Paper Feed Mechanism The paper feed mechanism consists of the paper feed system, paper eject system,

and the paper setting system.

4. Maintenance Station The maintenance station consists of the MS holder, the MS carriage assembly

(carriage, rubber cap, plunger, compression spring, and extension spring), the wiper, and the felt form ink absorbers (in spitting trough and under carriage assembly ).

5. Sensors There are two sensors in the printer assembly: the carriage home position sensor

(attached to the top right end of the CA frame) and the paper end sensor (attached to the bottom of the PF base at the right rear).

1-2

SERVICE MANUAL

THEORY

Mechanical

Fig. 1.2 General View of Printing Mechanism

1-3

THEORY

Mechanical

1.2. Ink Jet Operation

1.2.1. Paper Feed Mechanism

The paper feed mechanism consist of the paper feed system, paper eject system, and the paper setting system.

(1) The paper feed system consists of the ACF shaft gear, separate roller, ACF shaft

locker, locker spring, idle gears 1, 2, 3, and 4, PF roller gear, changer lever 1 and 2, spring, and the line feed motor. Paper feed system ACF(Auto cut-sheet feeder) When the paper feed motor is driven in the opposite direction (reverse rotation) of the paper feeding, the change lever 1 moves to engage the ACF shaft gear via the idle gear. The separate roller rotates in the paper separation direction (normal rotation) and separates a sheet of paper. The separate roller rotates with paper feeding operation and returns to the initial position. Separated paper is fed to contact PF roller and the pressure roller by the separate roller where the top of the paper is registered.

SERVICE MANUAL

Fig. 1.3A Paper Feed Mechanism

1-4

SERVICE MANUAL

THEORY

Mechanical

Fig. 1.3B Paper Feed Mechanism

(2) The paper eject system consists of the line feed motor, collar, idle gears 1, 5, and 6,

PF roller gear, eject roller gear, pressure roller, roller holder, holder plate, pressure roller spring, star wheel holder, and the star wheel. After paper is registered, the paper feed motor is driven in the paper feeding direction (normal rotation) and paper is fed by the PF roller and the pressure roller. After printing paper is ejected by the eject roller and star wheel.

Fig. 1.4 Paper Eject System

1-5

THEORY

Mechanical

(3) The paper setting system consists of the hopper, hopper spring, separate pad, collar,

SERVICE MANUAL

paper guide, ACF change lever, change spring, and the ACF change shaft. When inserting a thick paper, the ACF change lever should place at the front position.

24lb Thick Paper

Envelope Label Transparency etc.

Fig. 1.5 Paper Setting System

1-6

SERVICE MANUAL

1.2.2. Carriage Assembly

The carriage assembly consists of the carriage and ink cartridge (the cartridge contains the ink jet nozzles). The carriage consists of the head locker and locker spring, the rubber pad, and the flat cable. The flat cable connects to the main PCB. See Fig. 1.6.

The printer flat cable must be firmly in contact with the ink jet cartridge for printing to be enabled. The flat cable is located in the carriage by four alignment pins; proper alignment of the cartridge to the cable is established in three datums (reference planes/points): X, Y, and Z. When the cartridge is installed in the carriage, the flat cable contacts are compressed against the cartridge contacts by the rubber pad. See Figs.

1.7 and 1.8.

THEORY

Mechanical

Fig. 1.6 Printer Flat Cable to Main PCB

1-7

THEORY

Mechanical

SERVICE MANUAL

Fig. 1.7 Printer Flat Cable to Cartridge Alignment

1-8

SERVICE MANUAL

THEORY

Mechanical

Fig. 1.8 Ink Jet Cartridge to Flat Cable Alignment

1-9

THEORY

Mechanical

1.2.3. Carriage Motion Control

All operations related to carriage movement are driven by the CA motor. The CA motor assembly consists of a motor, a timing belt, an idle pulley, and an idle pulley holder and pulley holder spring: the motor and the idle pulley holder are mounted to the CA frame; the belt runs between the motor and the pulley. The pulley holder spring between the idle pulley holder and the CA frame sets belt tension. See Fig. 1.9.

SERVICE MANUAL

Fig. 1.9 Carriage Motion Control

1-10

SERVICE MANUAL

1.2.4. Maintenance Station Operation

The maintenance station operation consists of spitting, wiping, capping, and purging. Table 1.1 shows a summary of maintenance operation for various printer states.

Printer State Spitting Wiping Capping

Power-on 204 2 1

Table 1.1 Summary of Maintenance Operations

THEORY

Mechanical

Beginning of print job 204

(after wiping)

Between pages of continuous printing

After 6 pages of continuous printing

After 50 seconds of printing on the same page

Purging 6,000

Ink cartridge change 204

If no cartridge motion for more than 30 seconds

Power-off 0 0 0

12 1 0

204

(after wiping)

011

1-11

THEORY

Mechanical

1.2.4.1. Spitting Spitting is performed at machine power-on, after uncapping from the maintenance

station to clear dormant nozzles, and during the printing process to ensure that infrequently used nozzles are available when required to print. There must also be spitting after a wipe cycle, except when the printhead is going to the cap position; otherwise wiping causes distorted printing if the wiper has experienced any wear.

The trough below he print line is intended to capture the ink during a spit cycle when no paper is present in the print area. The cup around the wiper is used when spitting is required and paper is present in the print area. Spitting with paper in print area occurs when a single page requires longer than 50 seconds to print. All spitting occurs in trough. At power on, any paper in the print area is ejected.

SERVICE MANUAL

Fig. 1.10 Print Maintenance Operation - Spitting

1-12

SERVICE MANUAL

1.2.4.2. Wiping Wiping of the print head occurs when the cartridge moves across the wiper (in either

direction). The printhead is wiped (twice) when power is turned on, when beginning a print job (after the print head has been capped for more than four minutes), after six pages of continuous printing, after 50 seconds of printing on the same page, and after purging or changing the ink cartridge.

THEORY

Mechanical

Fig. 1.11 Print Maintenance Operation - Wiping

1-13

THEORY

Mechanical

1.2.4.3. Capping Capping occurs by the movement of the carriage assembly to the maintenance station,

which moves the MS carriage up to the ramp to align the rubber cap with the ink jet nozzles. The rubber cap prevents the ink from drying and causing the printhead to clog. The printer will automatically cap the printhead when the system is powered on, when no data is received for 30 seconds, and after purging or ink cartridge change.

SERVICE MANUAL

1.2.4.4. Purging The purging function of the maintenance station is a combination of the wipe, cap, and

spit operations. This initiates a sequence of 6,000 spits of each nozzle, in order to clear clogged ink from the nozzles. The ink is captured in the trough located below the print line. Purging is user-activated by pressing keyboard. See 3. "Cleaning the Print head" in Chapter 5, MAINTENANCE, for instructions.

Fig. 1.12 Print Maintenance Operation - Capping

CODE + SHIFT + INK CHG

1-14

from the

SERVICE MANUAL

1.2.5. Sensors

There are two sensors in the printer assembly: the carriage home position sensor (leaf switch assembly, attached to the right end of the CA frame) and the paper end sensor (attached to the bottom of the PF base at the right rear).

1.2.5.1. Carriage Home Position Sensor Upon power-up of the system or when the carriage is reset, the carriage moves to the

right end of the printer assembly and activates the home position sensor (leaf switch assembly). See Fig. 1.13.

THEORY

Mechanical

Fig. 1.13 Carriage Home Position Sensor

1-15

THEORY

Mechanical

1.2.5.2. PE Sensor PE sensor detects when the trailing edge of the paper passes the knob of PE sensor.

PE sensor is 1C-1P Switch (normal open.) See Fig. 1.14.

SERVICE MANUAL

Fig. 1.14 PE Sensor Mechanism

1-16

SERVICE MANUAL

1.3. INK CHG (Ink Change) Functions

There are two operator-initiated printer maintenance functions available from the keyboard: ink cartridge replacement and automatic printhead cleaning (purging).

1.3.1. Ink Cartridge Installation/Replacement

There is an ink cartridge installation/replacement function available from the keyboard. Pressing the key combination maintenance station to the right end of the printer assembly. Pressing RETURN after installing or replacing the ink cartridge initializes the system: the cartridge activates the home position sensor switch and moves the printhead back to the maintenance station. See Chapter 5, MAINTENANCE, for ink cartridge replacement instructions.

1.3.2. Automatic Print head Cleaning (Purging)

CODE + INK CHG

THEORY

Mechanical

moves the printhead from the

With the ink cartridge installed, pressing the key combination

initiates print head purging. See Chapter 5, MAINTENANCE, for the instructions

CHG

to manually clean the print head.

CODE + SHIFT + INK

1-17

THEORY

Mechanical

2. Keyboard

The keyboard assembly consists of the keyboard panel and keys, the FPC (flexible printed circuit) board, and the keyboard base plate.

SERVICE MANUAL

Fig. 1.15 Keyboard Assembly

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