Digital Equipment LA600 MultiPrinter Field Service Manual

LA600 MultiPrinter

Field Service Manual

Order No.: ER-LA600-SV

The information in this document is subject to change without notice and should not be construed as a
commitment by Digital Equipment Corporation. Digital Equipment Corporation assumes no
responsibility for any errors that may appear in this document.

Copyright © by Digital Equipment Corporation 1998.
All rights strictly reserved. Reproduction or issue to third parties in any form is not permitted without
written authorization from the publisher.

Pub. No. 5112 991 12933
November 1998

Table of Contents

I II

Table of Contents 5. Printer Subassemblies ....................................5-1

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

2. Safety Precautions ....................................... 2-1

3. Keeping the Printer Running ............................... 3-1

3.1 Basic Rules .......................................... 3-1

3.2 Cleaning ............................................. 3-2

3.2.1 Cleaning the Platen and Surrounding Areas ................ 3-2

PRINT TEST 3 .......................................... 3-3

3.2.2 Cleaning Procedures ................................. 3-4

3.3 Status and Error Messages .............................. 3-5

4. Specific Printer Functions ................................. 4-1

4.1 Print Gap Ajustment .................................... 4-1

4.1.1 Principle .......................................... 4-1

4.1.2 AGC Procedure ..................................... 4-2

4.1.3 AGC Adjust ........................................ 4-3

4.1.4 Automatic Gap Control (AGC) .......................... 4-4

4.1.5 Programmed Copy Control (PCC) ....................... 4-5

4.2 Print Head - Tilting Principle and related Print Speed ........... 4-6

4.2.1 Print Speed in DATA (DRAFT) Mode ..................... 4-7

4.4.2 Print Speed in NLQ Mode ............................. 4-7

4.4.3 Print Speed in LQ Mode 1 ............................. 4-8

4.4.4 Print Speed in LQ Mode 2 ............................. 4-8

4.3 Positioning System - Horizontal Positioner ................... 4-9

4.4 Paper Run / Paper In Control ............................ 4-10

4.5 Paper Path .......................................... 4-11

4.5.1 Paper Transportation Principle ......................... 4-11

5.1 Basic Elements of the Printer .............................5-1

5.2 Main Subassemblies ....................................5-2

5.3 Internal Wiring Scheme ..................................5-3

6. Built In Diagnostics and Trouble Shooting ....................6-1

How to use this Section .....................................6-1

6.1 Power related Problems .................................6-2

6.2 Error Messages ........................................6-2

6.3 No Printout ...........................................6-5

6.4 Operator related Problems ...............................6-6

6.5 Print related Problems ...................................6-7

6.6 Ribbon or Carriage-related Problems .......................6-9

6.7 Print Tests ...........................................6-9

Table of Contents Table of Contents

III IV

7. Procedures for Removal and Reassembly of Spare Parts ........ 7-1

Housing 405 ............................................. 7-2

Top Cover LA600 ......................................... 7-2

Top Cover 405 ........................................... 7-2

Front Cover 405 .......................................... 7-2

Front Insertion 405 ........................................ 7-2

Stacker Support 405 ....................................... 7-2

Print Engine LA600 ....................................... 7-4

PSU-40A ............................................... 7-6

DEV-40AE .............................................. 7-8

DEV-40A ............................................... 7-8

CU-40K ............................................... 7-10

Print CU-40L ........................................... 7-12

EEPROM CU-40X ....................................... 7-14

Operator Panel 40B ...................................... 7-16

Power Switch 40A ....................................... 7-18

Print Head Cable 405 ..................................... 7-20

Encoder Stripe 2 ........................................ 7-22

Kit Lubrication Felt ....................................... 7-24

Print H-Encoder ......................................... 7-26

H-Motor ............................................... 7-28

Carriage ............................................... 7-30

Protection Schield ....................................... 7-32

Ribbon Gear ........................................... 7-34

Stepper Motor 7.5 DEG (Palten Gap Control) ................... 7-36

Stepper Motor 1.8 DEG (Vertical Paper Transport) ............... 7-38

Tractor Gear ........................................... 7-40

Stacker Elements ........................................ 7-42

Paper Sensor ........................................... 7-44

Kit Pressure Rolls ........................................ 7-46

Kit V-Transport ..........................................7-48

Belt Stepper ............................................7-48

Belt Form Feed .......................................... 7-48

Kit Belt Pulley 2 ......................................... 7-50

Kit Cont. Form Exit .......................................7-52

Kit Tractor 2 ............................................7-54

Kit H-Drive Belt ..........................................7-56

Kit ASF Lever 2 ..........................................7-58

Kit Spring D-Axis ........................................7-60

Kit Screws and Springs .................................... 7-62

Noise Absorber ..........................................7-64

Rep Kit ASF-Cassette .....................................7-66

8 Wearing Parts ...........................................8-1

Print Head DH3024/2 ......................................8-2

Platen Assy .............................................8-4

ASF Pick-up Rollers .......................................8-6

9. List of Spare Parts, Wearing Parts, and Tools ..................9-1

9.1 List of Spare Parts ........................................9-1

9.2 List of Wearing Parts ......................................9-3

Introduction

1-1 1-2

1. Introduction proper handling of the wearing parts of the printer.

The manual is divided into the following chapters:

1 Introduction

This chapter gives an overview about the manual and some basic
informations.

2 Safety Precautions

This chapter contains all the important instructions a service technician
should obey during a service action.

3 Keeping the Printer Running

This chapter instructs the user about preventive meassures for troublefree
operation of the printer.

4 Specific Printer Functions

This chapter describes some basic functions of the printer, which should be
known by persons who are performing the technical support for this
product.

5 Printer Subassemblies

This chapter comprises diagrams, depicturing the printer´s subassemlies,
the internal wiring scheme and arrangement of the collective connectors.

6 Built In Diagnostics and Trouble Shouting

This chapter gives a description of some problem symptoms and how to
isolate the failures with regard to spare parts and field replaceable units
concerned.

7 Procedures for Removal and Reassembly of Subassemblies and

Spare Parts

This chapter contains all removal and reassembly procedures for an on­site- or workshop-repair of the printer.

8 Wearings Parts

This chapter describes the removal procedures which are necessary for

9 List of Spares and Repairs

This chapter lists all actually defined Spare Parts and Wearing Parts and
contains the relevant reference to the different chapters of this manual as
far as requested.

2-1 2-2

2. Safety Precautions

S Some of the maintenance procedures described in this section require that

the printers top housing is removed. This exposes the internal working parts
of the printer. During operating touching some of these parts may be
potentially dangerous.

S All replacement and cleaning procedures should be performed with the

printer switched OFF and the mains connector disconnected.

S Only recommended parts should be used to replace defective parts. Details

of field exchangeable parts, including part number and order number are
listed in Chapter 9.

S Switch the printer OFF while connecting or disconnecting a Personality

Module.

S Don´t touch the print head after long peroids of printing, because it can be

very hot.

Keeping the Printer Running

3-1 3-2

3. Keeping the Printer Running

3.1 Basic Rules

S Never print over the area of pin holes nor the edges of the fanfold paper.

Otherwise the print head can be damaged.

S Never print with no papaer loaded or no ribbon cartridge is installed in the

printer.

S Put the printer in stop mode immediately a paper jam occurs, using the

[START/STOP] key at the operator pannel.

The following points should be additionally checked on a service call.

Item Problem Remedial Action

Platen Paper feeding problems Remove platen and clean

surface thoroughly using
platen cleaner S/CP 09.

Paper input transport Paper feeding problems Disconnect mains cable,
rollers remove the ribbon, and

remove housing (see chapter
3, Part: Housing). Also
remove the paper guide
secured with two green
screws. Clean all transport
rollers using platen cleaner
S/CP 09.

Refer to Chapter 4 to check a necessary exchange of platen or

1)

pick-up rollers.

ASF Paper insertion Remove ASF cassette.

1)

problems Clean pick-up rollers

using platen cleaner
S/CP 09, and check the
paper handling of the
ASF cassette using a few
sheets of paper which
have to be transported
properly by manually
rotating the pick-up wheel
of the ASF-cassette.

3.2 Cleaning
Preferred Materials

The following materials and cleaning lubricants are recommended for use in
the maintenance procedure:

S Lint-free cloth
S Platen Cleaner C/CP09, commercial no: 8709 004 10931
S Vacuum cleaner
S Silicon Oil for resolving of glue.

3.2.1 Cleaning the Platen and Surrounding Areas

The user should clean the printer every six months or after 50,000 prints,
whichever occurs first. If you experience paper feed problems, or if the print
head carriage movement becomes restricted, cleaning should be carried out
more often.

Note: The Page Counter (PGCNT) in the PRINT-TEST 3 will inform you about

the actual number of printed pages.

Keeping the Printer Running Keeping the Printer Running

3-3 3-4

PRINT TEST3 3.2.2 Cleaning Procedure

CONFIGURATION

PM1 208xxxxx PM2 00000000 PM3 208079xx PBC 20807xxx
SPC 2080740x MC 00000000 CUR 4 PMR 0
MCR 0

NFQ 1800 DSF 100 GSF 70 NTF 240
TNA1 230 TNA2 260 TNA3 260 CAC 3.10
PTC1 2.75 PTC2 2.85 PTDT 5 PHCS1 2.20
PHCS2 1.00 PGC 30 PGCNT 25 SBP 38

C020 DEC NCR SETS C021 DEC SUPPLEMENT C022 DEC SPEC GRAP

C023 DEC TECHNICAL C024 DEC 7 HEBREW .... ... ....

Note: The number following PM1 identifies the micro program and the number

following PM3 identifies the character set.

1. Power the printer ON and remove the top cover.

2. Remove the ribbon cassette.

3. Thoroughly brush and vacuum all accessible areas to remove any paper
flock and dust.

4. Clean the platen's surface, the paper pressure rollers and the transport
rollers using the platen cleaner. In order to access the transport rollers
loosen the green screws and remove the metal bar with the metal rollers.

5. Clean the covers and the operator panel with a damp, lint-free cloth. Do not
use cleaning solvents or excessive amounts of water.

6. Insert the ribbon cassette.

7. Remount the top cover.

Keeping the Printer Running Keeping the Printer Running

3-5 3-6

3.3 Status and Error Messages TEAR OFF PAPER

The following messages are displayed if a condition exists which prevents paper source and the fanfold paper could not retreat into the parking position.
normal operation of the printer. The operator must "tear off" the paper along the tear off edge which is located

LOCAL right). Press to enable the fanfold paper to be fed backwards to a park
Entered when [START/STOP] was pressed. The STOP indicator is lit. position so that the newly selected paper source can be used.

COVER OPEN REMOVE PAPER

Displayed when the top cover is open and the printer is in the READY or BUSY This message will be displayed if the output for cut sheets (Bin or Manual) is
mode. selected to FRONT SIDE/KEY. After printing and moving out at the front side

LOAD BIN paper and press .
Displayed whenever a form feed command or print command is given by the
host to an empty ASF cassette. The printer enters the STOP mode. During normal operation the following error messages may occur also:

LOAD TRACTOR

Displayed when the host sends a form feed or print command to an empty
tractor cassette. The printer enters the STOP mode.

LOAD MANUAL

Same as LOAD TRACTOR except that the machine does not enter the STOP
mode! Paper should be fed manually; after a short delay the printer will accept
paper and starts printing.

PAPER JAM TRF
PAPER JAM ASF
PAPER JAM MANUAL

Displayed if a form jams in the ASF or if successive line feeds fail to move
fanfold paper correctly when tractor feed is used.

Displayed when a switch has been initiated from currently tractor to a different

directly above the fanfold paper output (paper should be torn off from left to

the printer enters the STOP mode and displays REMOVE PAPER. Remove

Display That means... Cause / Action

AGC ERROR AGC ADJUST - Distance print head and

procedure fault platen faulty

- Print head loose

- Platen incorrectly installed

- Ribbon not inserted

- Horizontal drive without
function

- Platen got dirty

Keeping the Printer Running

Display That means... Cause / Action

3-7 3-8

HOR. DRIVE ERROR Horizontal drive - Horizontal drive blocked

without function - Paper jam

- Distance of platen gap too
narrow

- AGC procedure on not
workable position

- Platen incorrectly installed

- No AGC ADJUST after
print head or platen
replacement

- Device electronic fault

- Encoder strip missing

- Horizontal drive fault

BUFFER Handshake - Check CTR - CTS or
OVERFLOW protocol error XON - XOFF protocol

- Repeat data transfer

FORMAT ERROR Protocol error - Check protocol setting of

printer and host

- Repeat data transfer

PARITY ERROR Protocol error - Check protocol setting of

printer and host

- Repeat data transfer

FRAMING ERROR Protocol error - Check protocol setting of

printer and host

- Repeat data transfer

For mesages during power up refer to Section 6.2 Error Messages during
Power Up.

Selected AGC Position

Lineal

Movement Area of the Print Head

1

1
2

3

22

4

Horizontal Encoder

1 / 120 “

Specific Printer Functions

4-1 4-2

4. Specific Printer Functions 4.1.2 AGC Procedure

4.1 Print Gap Adjustment

4.1.1 Principle

The print head carriage is mounted on two parallel guide rails which provide for
a precise movement over the whole print range in horizontal direction. The
lower rail is built up as an excentric shaft. The excentre arrangement is driven
by a stepper motor (AGC-Motor). Those both elements are responsible for the
precise adjustment of the print gap, that is the distance between the print head
top and the the paper respectively the platen assembly.
In conjunction with print gap adjustment the following three different procedures
have to be distinguished:

S Calibration of the print gap adjustment mechanics, called Automatic Gap

Control Adjustment (AGC Adjust)

S Automatic print gap adjustment, called Automatic Gap Control (AGC)
S Programmed print gap adjustment, called Programmed Copy Control (PCC)

AGC Adjust and AGC are performed by means of the AGC Procedure.

AGC Adjust can be called up via the operator panel and is performed after

installation of a Personality Module with a new firmware revision.

AGC is automatically performed after changing from online - offline – online, Position
and after changing of the paper path. S The carriage is permanently moved in horizontal direction by a distance of

PCC is performed if the command PCC is sent to the printer. For refernce see S The time period for horizontal movement is permanently recognized by the
“Quick Reference” of the printer control commands in the appendix of the user firmware and checked against a reference value.
manual. S Simultanously to the above shuttling the printhead / carriage is moved

S At the start the printhead/carriage is horizontally positioned at the AGC

1/120” to the left and right hand side of the AGC Position.

towards the platen assembly by means of the AGC drive until the print head
top gets in contact with the platen assembly or the surface of the paper.

S The contact of the printhead top with the surface of the paper or the platen

assembly is recognized by the firmware by checking the time interval for
positioning within the shuttling process.

Note: Horizontal Drive Error will not be checked by this procedure. If the

movement of the print head is to hard the printer use 0.5 A more.

Platen

Assy

Shuttle

Base

Position

Mechanical

Stop

Print
Head

Ribbon

Protection

Shield

Positioning

Shuttling Process

Positioning

No Form inserted !!

Platen

Assy

Shuttle

Base

Position

Mechanical

Stop

Print
Head

Ribbon

Protection

Shield

Shuttling Process

Print Gap

Platen Gap Adjust

(-3 ... +4)

Form

Specific Printer Functions Specific Printer Functions

4-3 4-4

4.1.3 AGC Adjust 4.1.4 Automatic Gap Control (AGC)

S The print head/carriage is positioned at the AGC Position
S The AGC procedure is started. It can be started from any value of the print

gap.

S The print head/carriage is positioned against the mechanical stop S AGC can be started from any value of the print gap.
S As soon as the mechanical stop has been reached the so called “AGC S The print head/carriage is positioned at the Shuttle Basis Position

procedure” is started S As soon as the the SBP has been reached, the so called “AGC Procedure”

S After finishing the AGC Procedure the carriage is positioned according to is started

the Shuttle Basis Posisition (see SBP in Print Test 3). S After finishing the shuttling process the carriage is positioned according to

Note: No form, but ribbon to be inserted.

Tolerance range for SBP: -12 ... +72.

the proper print gap value

Platen

Assy

Shuttle

Base

Position

Mechanical

Stop

Print
Head

Ribbon

Protection
Shield

Positioning Process

Print Gap

PCC:

Platen Gap Adjust (-3 ... +4)

1 23

4 6

5

Form

Specific Printer Functions Specific Printer Functions

4-5 4-6

4.1.5 Programmed Copy Control (PCC) 4.2 Print Head - Tilting Principle and related Print Speed

S The print gap is set according to the value commanded by the PCC

command.

Inclination Position for LQ mode

no print position

Inclination Position for DATA or NLQ mode

S The nose of the print head can be tilted according to the scheme above.

The different tilting positions are used for realizing of the different print
speeds and print resolutions.

S Switching between both print head tilting positions is accomplished by

positioning of the carriage to ist most right hand side position.

Print Speed '

Needle Strokes per Second

Number of Needles per Character

'

1800

3

' 600 cps

Print Speed '

Needle Strokes per Second

Number of Needles per Character

'

1800

6

' 300 cps

Print Speed '

Needle Strokes per Second

Number of Needles per Character

'

1800

12

' 150 cps

Print Speed '

Needle Strokes per Second

Number of Needles per Character

'

1800

18

' 100 cps

Specific Printer Functions Specific Printer Functions

4-7 4-8

4.2.1 Printing Speed in DATA mode 4.2.3 Printing Speed in LQ mode 1

Inclination Position Inclination Position
of the Print Head Lug of the Print Head Lug

Needle frequency 1.800 Hz Needle frequency 1.800 Hz

Number of columns per character: 12, 2x 12 needles in use Number of columns per character: 36
Number of needles per character: 3, each other needle activated Number of needles per character: 12, each 3rd needle activated

M = needle activated F = needle not activated M = needle activated F = needle not activated

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 .. .. .. 24 35 36

M F M F M F M F M F M F M F F M F F M F F M F F

4.2.2 Printing Speed in NLQ mode Inclination Position
Inclination Position

of the Print Head Lug

Needle frequency 1.800 Hz
Number of columns per character: 36, 2x 12 needles in use

Number of needles per character: 6, each 3rd needle activated
M = needle activated F = needle not activated

1 2 3 4 5 6 .. .. .. 34 35 36

M F F M F F M F F M F F

depending on the selected font

3

3)

4.2.4 Printing Speed in LQ mode 2

3)

of the Print Head Lug
Needle frequency 1.800 Hz
Number of columns per character: 36
Number of needles per character: 18, each other needle activated

M = needle activated F = needle not activated

1 2 3 4 5 6 .. .. .. 34 35 36

M F M F M F M F M F M F

Specific Printer Functions Specific Printer Functions

4-9 4-10

4.3 Positioning System - Horizontal Positioner 4.4 Paper Run / Paper In Control

The printer is equipped with a combined paper run/in feature realized by the
sensor as depicted below.

Following functions are realized:

S Cut Sheet Processing

S Paper In Detection

Detection of the upper edge of the form by means of the “Paper In”
feature

S Continuous Forms Processing

S Paper In Detection

Detection of the upper edge of the form by means of the “Paper In”
feature

S Paper Movement Detection

S Detection of paper movement by means of the “Paper Run” feature

S Check on missing paper run pulses by time out
S Tolerance range is in between 10,5 mm up to 19 mm

S Counting of paper run pulses and comparison with the equivalent value

according to the internal positioning command

S Evaluation of both criterions after each positiong process

Continuous Form Input

Continuous Form Output

Manual Input

Paper Sensor

Automatic Sheet
Feeding

Cut Sheet Ouput

Paper Run
Sensor

Paper In
Sensor

Print Head

Stacker Exit
Rollers

Stacker

Park Position

Manual

Form Feed
Rollers 1

Platen Assy

Form Feed
Rollers 2

Tractor Exit
Rollers

Tear Off

Specific Printer Functions

4-11 4-12

4.5 Paper Path

4.7.1 Paper Transportation Principle

1

2

3

4

5

6

7

6

A

B

Printer Subassemblies

5-1 5-2

5. Printer Subassemblies 5.2 Main Subassemblies

5.1 Basic Elements of the Printer

The printer contains of the following use accessable parts: S Electronic Subassembly (B)

- Top Cover (1) - Ribbon Cassette (2)

- Printer Engine including Electronic Subassembly (3) - Front Cover (4)

- Manual Front Insertion Guide (5) - Output Stacker (6)

- Personality Module (likewise named PM) (7)

You are able to disassembly each part without any tools.

The main subassemblies are:

S Mechanical Subassembly (A)

S Power Supply Unit (PSU-40A)
S Control Unit (Print CU-40L)
S Device Electronics (DEV-40AE)

Printer Subassemblies

5-3 5-4

5.3 Internal Wiring Scheme

Troubleshooting and Diagnostics

6-1 6-2

6 Troubleshooting and Diagnostics 6.1 Power-related Problems

How to Use This Section S Ask for the power connector connections (and fuse, if fitted) to be verified.

1. Find the category in which your problem occurs. The problem categories
are: 6.2 Error Messages

S Power-related Problems
S Error Messages After switching the power ON the printer runs a self test. During the test the
S No Printout following messages may be shown on the display:
S Operation-related Problems
S Print-related Problems
S Ribbon or Carriage-related Problems

For example, if the print appears very light on the paper, look at Section "Print­related Problems".

2. Find the symptom description that most closely matches the printer
symptom. In this example you would look at the symptom "Print faint

or of poor quality."

3. Try the first suggestion under that heading.

4. If the suggestion does not cure the problem, try the next suggestion.

5. If none of the suggestions enable you to continue printing, or if the fault
is not listed, contact your service office.

Each time the printer is switched ON the display indicates TEST while the
internal self-tests are run. If the test is completed successfully READY 4 ELQ
will be displayed. If an error message is displayed please refer to the following
section. All other messages on the display are described in section 2.4 Status

and Error Messages.

S Power indicator does not come On when power is switched On
S Check that the power cord and plug are securely fitted to the printer and to

an electrical outlet.

S Ask for the building electrical supply to be verified.

Display That means ... Cause / Action

No No power - Mains cable not connected
information, - Mains switch cable not
POWER ON connected
indicator not
lit.

green and hang up in reset after - Print PSU defective
yellow LED power on - Print CU-DEV defective
give light but
no reaction

######## Firmware does not - PM not inserted

work - PM not correctly inserted

- no firmware on PM

- PROMs not correctly installed

TEST.... Initializing of the - After first POWER ON

(flashing) EEPROM with new firmware (different

code number

- Contents of the EEPROM
faulty

I/O OK EEPROM located on EEPROM

the Control Unit not - not installed
addressable - not correctly installed

- defective

Troubleshooting and Diagnostics Troubleshooting and Diagnostics

Display That means ... Cause / Action

6-3 6-4

NV RAM OK Error on the RAM of - Control Unit defective

the Control Unit

RAM OK Checksum error - (P)ROM defective
ROM 1 OK No Fonts available - Character generator P(ROM)

on PM damaged or missing

ROM 2 OK IC damaged - IC on 3. socket defective
MC OK Fault on Control Unit - Control Unit defective

- false firmware release

- PBC (Printer Base
Controller) on Control Unit
damaged

- SPC (Speed Controller)
on Control Unit damaged

If all tests have been passed successfully the following message will be
displayed:

Display That means... Cause / Action
READY/BUSY The Printer is OK - Printer ready for

operation

During normal operation the following error messages may occur (for further
operator panel messages please refer to section 3.3 Status and Error

Messages):

Display That means... Cause / Action

AGC ERROR AGC ADJUST - Distance print head and

procedure fault platen faulty

- Print head loose

- Platen incorrectly installed

- Ribbon not inserted

- Horizontal drive without
function

- Platen got dirty

HOR. DRIVE ERROR Horizontal drive - Transport lock not removed

without - Horizontal drive blocked
function - Paper jam

- Distance of platen gap too
narrow

- AGC procedure on not
workable position

- Platen incorrectly installed

- No AGC ADJUST after
print head or platen
replacement

- Device electronic fault

- Encoder strip missing

- Horizontal drive fault

BUFFER Handshake - Check protocol setting of
OVERFLOW protocol error printer and host

- Repeat data transfer

PARITY ERROR Protocol error - Check protocol setting of

printer and host

- Repeat data transfer

Troubleshooting and Diagnostics Troubleshooting and Diagnostics

6-5 6-6

FRAMING ERROR Protocol error - Check protocol setting of

printer and host

- Repeat data transfer

6.3 No Printout

S Self-test printout does not start

S Make sure that you have closed the cover.
S Check if paper is loaded in the printer.

S Printing does not start

S Make sure that the READY or BUSY message is displayed. If there is a

different message displayed please refer to the above error message
table or to section 3.3 Status and Error Messages.

S Make sure that the printer is connected to the host computer. Make sure

that connectors are properly fixed at both ends.

S Make sure that the printer is receiving data from the host computer.
S Make sure that the correct protocol is enabled.
S Make sure that you have selected the correct port (if the automatic

feature has not been selected).

S Make sure that paper is loaded.
S Make sure that the ribbon is installed.
S Examine the ribbon path. Does the ribbon pass in front of the whole

printhead? Adjust the ribbon if necessary.

S Fanfold paper does not advance

S Make sure that the fanfold paper source tractor is selected.

S Single sheet paper does not advance

S Make sure that the paper source MANUAL or BIN x (x = 1 up to 3) is

selected.

6.4 Operation-related Problems

S Paper is not positioned at perforation for tear-off feature

S Select the correct form length using the Set-up feature.
S Reset top of form by performing a Parking function.
S Refer to User´s Manual section 3.4 Vertical Positioning Adjustment

S Paper tears or jams

S Examine the paper path; remove any obstructions
S Is the paper too loose or too taut between the tractors?

If the holes in the paper are deformed at their outer edges, the paper is
too taut.
If the paper rises between the tractors, it is too loose.
Readjust the tractor spacing so that the paper lies smoothly but without
any tension.
Ensure that the paper is horizontally aligned on the pins.

S Open the printer's top cover. If necessary, loosen the two green screws

and remove the paper guide plate to gain access to the paper.

S Parking paper and resetting top of form

S Tear off the paper at the perforation line.
S Press .
S Press until the paper is in the park position.
S Press . Printing will resume at the top of the next form.

S Print head carriage does not move smoothly/does not move at all

S Examine the paper pathway. Remove any obstructions.
S Examine the carriage area for obstructions. Remove, where necessary.

Press the key when the paper pathway is cleared.

S Make sure that the transport lock has been removed.

S Single sheets are skewed

S Adjust manual paer insertion guide.
S Adjust ASF cassette paper guides.

Troubleshooting and Diagnostics Troubleshooting and Diagnostics

6-7 6-8

6.5 Print-related Problems If the printout or the character set is not ok, the following procedure can help to

S Print faint or of poor quality.

S Have you used the correct paper? See User´s Manual Chapter 7

Technical Data which contains a full specification of the paper you
can use. Replace the paper if it does not match the specification.

S Make sure that the ribbon is stretched correctly.
S Does the ribbon need changing? Replace it with a new ribbon if

necessary.

S Is the ribbon cartridge properly installed? Adjust as necessary.

S Characters do not print evenly or are not uniform in pitch

S Examine the paper pathway for dirt or other obstruction that may cause

the gap between print head and platen to vary. Remove the obstruction.

S Print lines overlap

S Examine the paper pathway for dirt or other obstructions that may

prevent the platen from rotating freely. Remove the obstruction.

S On preprinted forms, the printing on the copies is not aligned with the

preprinted matter
S Refer to User´s Manual section 3.4. Vertical Positioning

(VERT.POS.ADJ.)

S Part of printed text is missing (loss of data)

S If you are using Serial communications check the buffer control setting

in Set-up.

S Check the data flow control setting on the host computer.

clear the situation.

Action Result Check
Select and start PRINT Print not OK? - PAPER SOURCE

TEST 1 selection

- Ribbon tension and
condition

- Print head condition

Stop SELF TEST and No printing starts - Printer ONLINE
start external printing READY

- Interface cable for
proper connection

- Interface selection

Some characters not - Emulation
correct - Character set

- National version

- Word length

- Baud rate

- Parity bit

- Protocol

Font and pitch quality - Font
fault - Pitch

- Line space

Troubleshooting and Diagnostics

6-9 6-10

6.6 Ribbon or Carriage-related Problems

S Ribbon Problems

S Make sure that the ribbon is:

S Stretched correctly
S Not worn thin or dry
S Not torn or damaged in any other way
S Not jammed

S Carriage does not move smoothly

S Examine the paper pathway. Remove any obstructions. Check that all

packing material is removed.

S Examine the carriage area for obstructions. Remove where necessary.

6.7 Print Tests

There are three different print tests as well as one interface test built into the
printer.

S I/F TEST is used to test the serial interface. It initiates data to be sent from

the printer and be returned by means of a closed loop connector plugged
into the serial interface connector. The test data used consists of PRINT
TEST 1 .

1 7-2

7. Procedures for Removal and Reassembly

This chapter describes the removal procedures which are necessary for proper
handling of the spare parts and subunits of the printer.

For detailed order information and description of the spare parts please refer to
the Spare Part Catalog (5112 991 1030x).

Note: All removal procedures consists of several steps indicated with a:

" to show preparation and

Y M to indicate the main removal steps.

3

1

2

4

5

6

DEC Field Service Instruction

7-2 7-3

Part: Housing 405 (1) Part No.: 5112 292 3840x

DEC P/N.: FD-W03RF-01

Part: Top Cover LA600 (2) Part No.: 5112 292 6826x

DEC P/N.: 29-31800-01

Part: Top Cover 40A (2) (PP 405) Part No.: 5112 292 6827x

DEC P/N.: FD-W03RH-01

Part: Front Cover 405 (3) Part No.: 5112 212 5490x

DEC P/N.: FD-W03RC-01

Part: Front Insertion 405 (4) Part No.: 5112 292 3842x

DEC P/N.: FD-W03RJ-01

Part: Stacker Support 405 (5) Part No.: 5112 212 5500x

DEC P/N.: FD-W03RD-01

REMOVAL

" Disconnect mains cable
" Remove the manual front insertion (4)

Y M Remove the front cover (3) resp. the ASF cassette(s) out of the

mounting slots

Y M Swing the top cover (2) to its nearly upright position and remove it
Y M a) Remove the housing (1) by releasing the cover snap locks (6)

with a flat bladed screwdriver

b) To remove the housing (1) grasp it by the sides, raise the front

slightly, push the housing back until the metal snaps are out of
the slots at the rear of the printer and then lift the housing

REASSEMBLY

Execute the REMOVAL procedure in reverse sequence

5112 991 10786

3

5

2

4

1

6

4

7

Figure 1

8

Step 2

Step 1

Figure 2

DEC Field Service Instruction

7-4 7-5

Part: Print Engine LA600 Part No.: 5112 292 6475x

DEC P/N.: 29-31790-01

REMOVAL

" Set the printer into "LOCAL MODE"
" Disconnect the system interface cable
" Remove the ribbon cartridge
" Switch the printer off and disconnect the mains cable

Y M Remove all encasing parts
Y M Remove the personality module (1)
Y M If present remove the plastic insert of the memory card interface (2)
Y M Loosen screw (3)
Y M Remove screws (4)
Y M Disconnect the Device Electronic (5)
Y M Disconnect the Control Unit (6)
Y M Loosen the fixation screws of the power on switch and remove it (7)
Y M Swivel the printer as shown in figure 2.
Y M Remove the safety angle by removing srew (8).

Note: For protection of the operator panel please use a part of the

packaging material of the new printer engine as support.

Y M Shift the entire Electronic Subassembly to the left. (Step 1)
Y M Swivel it in the direction towards you and remove it from the printer

engine. (Step 2)

REASSEMBLING

" Unpack the new printer engine
" Execute the REMOVAL procedure with the new printer engine in reverse

direction.
Y M Change the print head from the "old" printer engine into the "new"

one.

Y M Perform an AGC Adjust procedure
Y M Adjust the parameter "Paper In Adj." to the value indicated on the

field service instruction attached to the new printer engine.

Y M Perform "PRINT TEST 3" and check for proper operation of the

printer.

Note: Take a note of the value of the page counter (PGCNT) on the FRU-

label of the new printer engine.

5112 991 13242

2

4

3

5

1

DEC Field Service Instruction

7-6 7-7

Part: PSU-40A Part No.: 5112 292 3811x

DEC P/N.: FD-W028Y-01-A01

Part: PSU-40D Part No.: 5112 292 7627x

DEC P/N.: FD-W028Y-01-A02

Part: PSU-40DS Part No.: 5112 292 7628x

DEC P/N.: n. a.

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

" Loosen the two screws (1) securing the PSU-40A

Y M Lift the complete Power Supply Unit (PSU), using a screw driver

Y M Disconnect plug (3)

Y M Remove clamp (4) and disconnect plug (2)

REASSEMBLING

Execute the REMOVAL procedure in reverse sequence

Attention: Do not touch the PSU board within min. 2 minutes after

power OFF before exchanging the PSU, please check the
fuse (5)

5112 991 10415

1

Detail A

7

3

2

8

8

6

4

5

1

see Detail A

DEC Field Service Instruction

7-8 7-9

Part: DEV-40AE Part No.: 5112 292 7159x

DEC P/N.: 29-31791-01-A02

Part: DEV-40A (PP 405) *) Part No.: 5112 292 3810x

DEC P/N.: FD-W00CS-01

Part: DEV-40LA600 *) Part No.: 5112 292 6292x

DEC P/N.: 29-31791-01-A01

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

Y M Loosen the two screws (1) and remove screw (2)

Y M Remove the DEV-40

a) while removing, DEV-40 (3) is automatically disconnected from

CU-40 (4)

b) disconnect all plug connections from the DEV-board:

S plug (5)
S plug (6)
S plug (7)

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

Attention: Wire (8) has to be fastened by screw (2) as shown in Detail A

*) End of Life, repair only

5112 991 12902

1

IC pin marker

2

3

4

4

DEC Field Service Instruction

7-10 7-11

Part: CU-40K (repair only) Part No.: 5112 292 3885x

(With Memory Card interface) DEC P/N.:FD-W00CW-01

Part: CU-40LA600 (repair only) Part No.: 5112 292 6299x

(With Memory Card interface) DEC P/N.:29-31792-01-A1

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

" Remove DEV-40 (see Part: DEV-40)

Y M Remove memory card if plugged in (1)

Y M Remove the Personality Module after loosening the two

lockscrews (2)

Y M Disconnect plug (3) from CU-40-K and remove it

Y M Remove the EEPROM CU 40X (4) and plug it into the new CU-40.

Note: Pay attention, that EEPROM (4) is inserted correctly (see

IC pin marker)

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

Note: Start the function 'Print Out' and check 'Current Settings'

5112 991 16261

1

IC pin marker

2

3

3

DEC Field Service Instruction

7-12 7-13

Part: Print CU-40L Part No.: 5112 292 7383x

(Without Memory Card interface) DEC P/N.: 29-31792-01-A2

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

" Remove DEV-40 (see Part: DEV-40AE)

Y M Remove the Personality Module after loosening the two

lockscrews (1)

Y M Disconnect plug (2) from CU-40 and remove CU-40

Y M Remove the EEPROM CU 40X (3) and plug it into the new

CU-40 L.

Note: Pay attention, that EEPROM (3) is inserted correctly (see IC pin

marker)

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

Note: Start the function 'Print Out' and check 'Current Settings'

5112 991 16262

1

IC pin marker

2

3

3

DEC Field Service Instruction

7-14 7-15

Part: EEPROM CU-405 Part No.: 5112 000 4164x

DEC P/N.: 29-31802-01

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

" Remove DEV-40 (see Part: DEV-40)

" Remove CU-40 (see Part: CU-40)

Y M Exchange the EEPROM CU-40X (4)

Note: Pay attention, that EEPROM (4) is in correctly position (IC

pin marker)

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

Note: Start the function 'Print Out' and check 'Current Settings'

5112 991 11244

1

2

3

DEC Field Service Instruction

7-16 7-17

Part: Operator Panel 40B Part No.: 5112 292 6418x

DEC P/N.: FD-W00CU-01

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

Y M Disconnect the Operator Panel cable (1)

Y M Loosen the screw (2) located at the bottom of the Operating Panel

Y M Remove the Operator Panel

REASSEMBLING

" Execute the Removal procedure in reverse sequence

Note: Remove the protection foil (3) from the Operator Panel installed

before mounting the housing

5112 991 10494

1

DEC Field Service Instruction

7-18 7-19

Part: Power Switch 40A Part No.: 5112 292 3882x

DEC P/N.: FD-W02H3-01

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

Y M Loosen the two screws (1)

" Remove PSU-40x (see Part: PSU-40)

Y M Remove the power switch

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence.

5112 991 10713

6

1

3

4

2

5

DEC Field Service Instruction 5112 991 10655

7-20 7-21

Part: Print Head Cable 405 Part No.: 5112 292 3880x

DEC P/N.: FD-W02Y2-01

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

Y M Disconnect print head cable from the print head

Y M Remove the noise reduction foam (1) from the cable channel

Y M Clip the plastic support (2) from the print head carriage, by first

releasing clamps (3)

Y M Disconnect the wire-to-wire connection (4) of the H-Encoder

Y M Disconnect the colour option, if installed, incl. connector

Y M Disconnect cable (5) from the interface connection board

Y M Disconnect the print head cable from DEV-40

Y M Remove the two plastic clips (6)

Y M Remove the print head cable

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

2

1

Detail A

DEC Field Service Instruction 5112 991 10503

7-22 7-23

Part: Encoder Strip 2 Part No.: 5112 292 7454x

DEC P/N.: FD-W041701

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

Y M Remove the two screws (1)

Y M Remove the encoder strip (2)

Y M Move the carriage to the centre position

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

Caution: Pay attention, that the Encoder Strip is mounted in the correct

pistion by (Detail A) and observe that the strip is slipping under the
first two steel noses visible from the front side of the printer.

4

5

3

2

DEC Field Service Instruction 5112 991 12393

7-24 7-25

Part: Kit Lubrication Felt Part No.:5112 212 5589x

DEC P/N.: 29-31804-01

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

" Remove Encoder Strip (1) (see Part: Encoder Strip)

" Remove operator panel, but leave the interface cable connected (see Part:

Operator Panel)

Y M Remove srew (2) on both sides of the upper guide rail (3)

Y M Remove the upper guide rail (3)

Y M Exchange the lubrication felt (4). Insert the new felt with flatten

ear (5) towards the operator panel

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

1112

2

DEC Field Service Instruction 5112 991 10723

7-26 7-27

Part: Print H-Encoder Part No.: 5112 292 4310x

DEC P/N.: FD-W0290-01

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

" Remove encoder strip (1) (see Part: Encoder Strip)

Y M Remove the noise reduction foam (2)

Y M Remove at the left and right side the upper screws (5)

Y M Loosen at the left and right side the screws (6) and remove the

mounting plate (7)

Y M Move the carriage to the cutout (8)

Y M Remove the two screws (9) from the carriage

Y M Remove the screw (10) and the cable clamp from the carriage

Y M Disconnect the print head cable from the head

Y M Clip the plastic support (11) from the carriage and disconnect the

wire-to-wire connector (12) H-Encoder/print head cable

Y M Remove the print head H-encoder

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

Note: Pay attention that the logic cable is fixed correctly by clamp

(10)

2

3

A

Detail A

Dummy

4

3

Detail B

B

5

DEC Field Service Instruction 5112 991 10573

7-28 7-29

Part: H-Motor Part No.: 5112 292 3791x

DEC P/N.: FD-W0396-01

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

" Remove DEV-40 (see Part: DEV-40AE)

Y M Disengage the drive belt (1) from the drive wheel of the horizontal

motor by pressing the belt tension element (2), which is located at
the left side of the engine, upwards

Y M Pull off the belt from the wheel

Y M Disconnect the two pin motor cables (3) from the motors

connector (4) (see Detail A)

Y M Remove the two cables from the motor fixing plate (5)

Y M Remove the horizontal motor

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

Note: Pay attention that the cable installation is correct (Detail B)

Left hand side

7

1

1

2

Right hand
side

5

5

3

4

6

Left hand side

8

10

10

9

11

12

13

DEC Field Service Instruction 5112 991 10514

7-30 7-31

Part: Carriage Part No.: 5112 292 4094x

DEC P/N.: FD-W04JL-01

REMOVAL

" Disconnect mains cable
" Remove all encasing parts (see Part: Housing)
" Remove DEV-40 (see Part: DEV-40)
" Remove the encoder strip (see Part Encoder Strip)
" Remove operator panel, but leave the interface cable connected (see Part:

Operator Panel)

" Remove the cable print head from the print head carriage (see Part: Cable

Print Head)

" Remove the horizontal motor (see Part H-Motor)DEV-40)
" Remove the tractor gear (see Part Tractor Gear)

Y M Remove the two screws (1) and the upper rail (2)
Y M Pull the lever (3) from the lock pin and remove the lever
Y M Release springs (4), (5), and remove lever (6) including spring (4)
Y M Remove the screws (7) and (8). Push the shaft (9) including the

plastic segment (10) out towards the right hand side of the chassis

Note: The plastic segment (10) can not be removed

Y M Slide the carriage (11) out of the guide rail

REASSEMBLING

" Execute the REMOVAL procedure

in reverse sequence

Note: Engage the plastic segment in that way, that the guide rail (10) with

the marker (11) aligns with the marker (12) on the AGC gear (13)

2

1

3

3

4

DEC Field Service Instruction 5112 991 10526

7-32 7-33

Part: Protection Shield Part No.:5112 292 3839x

DEC P/N.:FD-W041W-01

REMOVAL

" Disconnect mains cable

" Open top cover

" Remove Ink Ribbon

" Remove Platen (4)

Y M Disconnect protection shield (1) by loosening the two screws (2).

This can easily be done by inserting of a torx screwdriver of at
minimum 110 mm length through the holes (3) in the bottom plate
and the platen channel

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

1

2

2

3

4

5

6

Detail A

Detail B

DEC Field Service Instruction 5112 991 10565

7-34 7-35

Part: Ribbon Gear Part No.: 5112 292 6384x

DEC P/N.: FD-W045M-01

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

" Remove DEV-40 (see Part: DEV-40)

Y M Locate the Ribbon Gear (1)

Y M Loosen the cable (2) from the cable guide (3)

Y M Loosen the spring (4) and remove lever (5)

Y M Disconnect the 2 pin motor cable (2) from the motor connector

Y M Push the lock tab (6) and remove the Ribbon Gear

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

Note: Pay attention that the cable installation is correct (Detail B)

1

2

Detail A

DEC Field Service Instruction

7-36 7-37

Part: Stepper Motor 7.5 DEG Part No.: 5112 292 4106x

(Platen gap control) DEC P/N.: FD-W0394-01

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

" Remove DEV-40A (see Part: DEV-40)

Y M Disconnect the four pin motor cables from the motors plug

Y M Remove the two screws (1) fixation of the stepper motor

Warning: Do not loosen the screw (2). This is a factory adjustment;

field adjustment is impossible

Y M Remove the stepper motor

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

Note: Make sure that the cable installation is correct (Detail A)

5112 991 10583

3

2

4

1

1

Detail A

DEC Field Service Instruction

7-38 7-39

Part: Stepper Motor 1.8 DEG Part No.: 5112 292 6241x

(Vertical Paper Transport) DEC P/N.: 29-31798-01

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

" Remove DEV-40 (see Part: DEV-40)

Y M Remove the motor cable guide from the DEV-40

Y M Remove the four pin motor cable (1) from the cable guide

Y M Remove the two screws (2), of the vertical drive motor

Y M Turn the motor anti-clockwise and remove it from the mounting

clamp

Y M Disengage the drive belt (3) from the drive pinion

Y M Remove the motor (4)

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

Note: Pay attention that the cable installation is correct (Detail A)

5112 991 13501

1

2

3

4

4

Spring

Detail B

5

1

Detail A

Horizontal Motor Cable

Stepping Motor 1.8 DEG Cable

Stepping Motor

7.5 DEG Cable

Ribbon Gear Cable

DEC Field Service Instruction

7-40 7-41

Part: Tractor Gear Part No.: 5112 292 3803x

DEC P/N.: FD-W045N-01

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

" Remove DEV-40 (see Part: DEV-40)

Y M The paper path for output must be set to tractor. By moving the

carriage to the uppermost right position the paper path will be
changed (an audible "click")

Y M The axle (1) must be turned to the position as shown in Detail B by

turning on the minipitch belt (2) in clockwise direction

Y M Remove all cables from the cable guide

Y M Remove the three screws (3) and remove the Tractor Gear

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

Note: - Before the new can be mounted, turn the gearwheel (4) in

such a way that the bold (5) reaches the uppermost position

- Observe that the cable installation is correct (Detail A)

5112 991 10603

DEC Field Service Instruction

7-42 7-43

Part: Stacker Elements Part No.: 5112 292 4099x

DEC P/N.: FD-W04KK-01

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

" Remove DEV-40 (see Part: DEV-40)

Y M Loosen the two screws (1) securing the Power ON/OFF switch

Y M Remove the two screws (2) which secure the stacker elements plate

Y M Remove the circlip (3) which secures the bearing (4)

Y M Slide the bearing (4) to the left and remove the Stacker Elements

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

5112 991 11952

1 2

3

5

4

DEC Field Service Instruction

7-44 7-45

Part: Paper Sensor Part No.: 5112 292 3805x

DEC P/N.: FD-W04JJ-01

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

Y M Remove circlip (1) and bearing (2). The axle (3) falls down

Y M Remove the Paper Sensor (4)

Y M Disconnect the cable (5)

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

5112 991 10628

1

2

2

1

3

DEC Field Service Instruction

7-46 7-47

Part: Kit Pressure Rolls Part No: 5112 292 6655x

DEC P/N.: 29-31801-01

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

" Remove the encoder strip (see Part: Encoder Strip)

Y M Remove the upper screws (1)

Y M Remove the foam under the neath of printhead cable

Y M Loosen the two screws (2) and remove the metal sheet coner

Y M Snap out the springs (3) using a knife

Y M Remove the pressure roller

Y M Grease the bearings of the pressure roller with Molykote DX or a

similar type of grease

Y M Grease the arms of the new springs at the positions which are in

contact with the FF1 roll with Molykote DX or a similar type of
grease

Y M Insert the new springs by snap in

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

5112 991 12402

Belt Stepper

Belt Form Feed

Kit V-Transport XXX

DEC Field Service Instruction

7-48 7-49

Part: Kit V-Transport Part No.: 5112 292 3845x

DEC P/N.. FD-W02M6-01

Part: Belt Stepper Part No.: 5112 200 0878x

DEC P/N.: FD-W032Y-01

Part: Belt Form Feed Part No.: 5112 200 0879x

DEC P/N.: FD-W0330-01

REMOVAL

" Disconnect mains cable
" Remove all encasing parts (see Part: Housing)
" Remove DEV-40 (see Part: DEV-40)

Y M Locate the right side of the form feed shaft for exchanging
Y M Remove both minipitch belts (1)
Y M Pull the belt pulley (2) from the wheel shaft for exchanging
Y M If the upper form feed shaft has to be exchanged remove the

bearing (3)

Y M Remove circlip (4) and bearing (5) on the left side from the wheel

shaft for exchanging

Y M Removing the bearings causes the wheel shaft to fall down into the

larger holes, for removal slide the wheel shaft to the left side

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

5112 991 10732

1

2

DEC Field Service Instruction

7-50 7-51

Part: Kit Belt Pulley 2 Part No.: 5112 292 7442x

DEC P/N.: FD-W05RM-01

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

" Remove DEV-40 (see Part: DEV-40)

Y M Locate the right side of the form feed shaft for exchanging

Y M Remove both minipitch belts (1)

Y M Pull the belt pulley (2) from the wheel shaft to be exchanged

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

5112 991 12003

6

5 4

2

3

1

4

DEC Field Service Instruction

7-52 7-53

Part: Kit Cont. Forms Exit Part No.: 5112 292 3846x

DEC P/N.: FD-W02M7-01

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

" Remove DEV-40 (see Part: DEV-40)

" Remove stacker elements (see Part:Stacker Elements)

Y M Locate the gearwheel (1), remove the circlip (2) and the washer (3),

remove gearwheel (1) and bearing (4) from the wheel shaft

Y M Remove circlip (5) from the wheel shaft and move it to the left.

Remove the shaft

Y M Prepare the left hand side bearing of the pressure roll (6) such that it

can be removed

Y M Remove the pressure roll

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

5112 991 10742

1

2

3

4

6

7

5

DEC Field Service Instruction

7-54 7-55

Part: Kit Tractor 2 Part No.: 5112 292 7441x

DEC P/N.: FD-W02M8-01

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

" Snap out the paper supports (1)

Y M Locate the bearing (2) and (3) on the left side of the printer

Y M Press the two locking tabs on the bearing (2) and remove it

Y M Press the three locking tabs on the bearing (3) and remove it

Y M For removal, slide the entire tractor kit first to the left and then

remove it by sliding out the right

Reassembly

" Execute the REMOVAL procedure in reverse sequence

Note: Fix the metal plate (4) with the srew (5) on both tractor

elements if not mounted.
When you insert the square shaft, the white dot (6) on the left
and right hand tractor must have the same position to ensure
synchronous running of the tractor elements.
Pay attention that the mounting position of the left tractor is
between the stoppers (7).

5112 991 10752

1

2

3

4

5

DEC Field Service Instruction

7-56 7-57

Part: Kit H-Drive Belt Part No.: 5112 292 3848x

DEC P/N.: FD-W02M5-01

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

" Remove the print head

Y M Disengage the drive belt (1) from the drive wheel horizontal motor

by pressing the belt tension elements on pos. (2)

Y M Slide the drive belt out of the drive wheel

Y M Remove the drive belt roller bearing (3) from its mounting bracket

Y M Remove the screw (4) and disengage the wedge (5) from the print

head carriage

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

5112 991 10761

Figure 4

Figure 5

right

left

Figure 2

Figure 3

1

2

3

4

1

2

3

4

Figure 1

1

2

3

DEC Field Service Instruction

7-58 7-59

Part: Kit ASF Lever 2 Part No.: 5112 292 6875x

DEC P/N.: FD-W0487-01

REMOVAL of the Force Adjustment Levers (Figure 2)
" Remove the ASF-Cassette from the printer and remove any paper loaded,

and the paper support (if mounted).
Y M Remove the lever-side cover of the ASF Cassette by releasing of the

four snaplocks (No. 1 - 4 in figure 1). Use a flat screw driver to do
so and keep the sequence of figure 1.

Y M Remove the circlip (No. 4 in figure 2) of the lever bar.
Y M Slide out the bar to the direction of the connector and snap the

lever out of the encasing.

REASSEMBLING of the Force Adjustment Levers (Figure 2)

Y M Assemble the three levers together (figure 3). Lever 2 (upper paper

release) onto lever 1 (paper pressure lever), and lever 3 (lower
paper release) onto lever 2. Observe that the little plug of lever 2 is
fitted in the hole provided in lever 3.

Y M Execute now the REMOVAL procedure in reverse sequence.

REMOVAL of the Locking Levers (Figure 5)

Y M Remove the ASF-Cassette from the printer and remove any paper

loaded, and the paper support (if mounted).

Y M Remove both side covers of the ASF Cassette by releasing of each

snaplocks (No. 1 - 4 in figure 1).

Y M Slide out the bar to the direction of the connector and release both

paper guides to exchange the locking levers.

REASSEMBLING of the Locking Lever (Figure 5)

Y M Insert the left and right locking lever into the paper guides.
Y M Push the bar through the locking levers, the paper guides, and the

support springs under neath the paper guides. Take care, that all
parts are properly adjusted.

Y M Execute now the REMOVAL procedure in reverse sequence.

5112 991 15071

1

2

DEC Field Service Instruction

7-60 7-61

Part: Kit Spring D-Axis Part No.: 5112 292 4107x

DEC P/N.: 29-31803-01

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

Y M Remove lever (1) from D-axis (the plastic snap-in will be destroyed)

Y M Remove the torsion spring (2)

REASSEMBLING

Y M Insert the new spring and grease the hole in the engine plate and the

surface of the spring gliding on the plate

Y M Insert the lever (1) delivered with the spring until the snap-in

5112 991 12351

Grased with Molycode DX
or a similar product

12

16

26

15

17

19

11

14

14

13

22

24

18

20

23 25

21

DEC Field Service Instruction

7-62 7-63

Part: Kit Screws and Springs Part No.: 5112 292 3849x

DEC P/N.: FD-W05RK-01

Location of Screws and Springs

11 Spring 0.6x4x23 ST F. Paper Run 16 Spring Print Head Shifter
12 Spring 0.3x4.5x20 ST Ribbon Gear 17 Spring Paper Stacker Elements
13 Spring Carriage Axis 19 Spring Paper Transport
14 Spring Carriage Bearing 26 Torsion Spring D Shaped Axis
15 Spring Encoder Cable

5112 991 13021

18 Spring Tractor Exit
20 Torsion Spring Tractor Gear
21 Spring Manual Front Insertion
22 Cable clip
23 Springs for Print Head Fixation
24 Holder right/left (green)
25 Bearing Platen (green)

1

DEC Field Service Instruction

7-64 7-65

Part: Noise Absorber Part No.: 5112 212 7043x

DEC P/N.: ____________

REMOVAL

" Disconnect mains cable

" Remove all encasing parts (see Part: Housing)

Y M Remove the noise reduction foam (1) from the cable channel

REASSEMBLING

" Execute the REMOVAL procedure in reverse sequence

5112 991 14621

6

7

9

5

1

2

3

4

15

8

10

11

13

12

14

16

see Note!

Field Service Instruction

7-66 7-67

Part: Rep Kit ASF-Cassette Part No.: 5112 292 7235X

DEC P/N.: ____________

REMOVAL

" Remove the ASF-Cassette from the printer. Remove any paper loaded and

the paper support (if mounted).

Y M Remove the cover (1) of the ASF-Cassette by releasing the snaplocks

(2). Use a flat screw driver to do so.

Y M Release the connector (3) out of the cover (1).
Y M Pull back the retaining parts (5) and remove the shaft (4).
Y M Remove the belt from the pulley (6) and remove the pulley.
Y M Cut the rest of the broken shaft (7) as well as the second (non broken)

shaft. Use a side nippers to do so. The remaining rest of both shafts
must not exceed 0.7 mm.

Y M Remove the female screw (13) and the washer (12) from the screw (11).
Y M Mount the metal part of the Rep. Kit ASF-Cassette (8) by inserting the

screw (11) into the hole (9).

Note: Mount the Rep. Kit ASF-Cassette (8) in the same orientation as

shown in the figure. Lift the metal part (8) up to the highest position,
nearly to the edge (16).

Y M Put a washer (12) on the screw and tighten the female screw (13).
Y M Mount the gears (10) and (15) as shwon in the figure and fix the

gear (15) with the snap-ring (14).

REASSEMBLING

Y M Assemble the pulley (6) and the belt.
Y M Execute now the REMOVAL procedure in reverse sequence.

5112 991 15321

8-1

8 Wearing Parts

This chapter describes the removal procedures which are necessary for proper
handling of the wearing parts of the printer.

Note: All removal procedures consists of several steps indicated with a:

" to show preparation and

Y M to indicate the main removal steps.

In terms of preventive actions for keeping the printer running, following
operation for the life time of wearing parts is given:

- Ribbon Cartridge: 16 Mio characters (draft quality)

- Print Head: > 350,000 pages

- Platen Assy: > 800,000 pages

- Pick up Rolls: > 200,000 pages

Recommendation for cleaning:

- Transport Rolls, Platen Assy, and Pick up Rolls every 50,000 Pages

Note: Number of pages printed can be obtained from print out of 'PRINT

TEST 3', parameter 'PGCNT' (see User's Manual, chapter 2)

1

6

7

2

3

5

4

9

6

DEC Field Service Instruction

8-2 8-3

Part: Print Head DH3024/2 Part No.: 5112 292 6652x

DEC P/N.: FD-52920-01 Y M Hold the print head (5) in its mounting position and press it against

Removal of the print head (5)

LL Caution: print head may be very hot immediately after printing! the adjustment guide (8)

" Lift and remove the output stacker (1) Y M Now tighten the two captive screws (6) (first left, then right).
" Switch the printer ON, lift and remove the top cover (2), switch the printer Y M Reconnect the print head cable (4) and fasten it with the enclosed

OFF spring on the top of the print head.

" Remove the ribbon cassette (3) Y M Switch the printer ON and insert the ink ribbon cassette (3).

Y M Disconnect the print head cable (4)
Y M Using the supplied tool (7), loosen the two captive screws (6),

retaining the print head (5) PM AGC: (s. User's Manual, Chapter 3)

Y M Remove the print head (5) Run the MENU-function AGC ADJUST with ribbon cassette installed but

Installing the new print head (5)

Ensure that the printer is switched OFF. For print head installation, the carriage
should be aligned with the cut-out on the paper guide plate (green insert).
(Same position as for Removal procedure).

its stop in direction of the platen. The two noses (9) of the
adjustment guide (8) support this procedure.

Note: Older versions of the print head are mounted with clamps instead of

Y M Refit the top cover (2) and the output stacker (1).

without paper loaded

1

2

1

2

DEC Field Service Instruction

8-4 8-5

Part: Platen Assembly Part No.: 5112 292 3801x Y M Move print head from its right hand position into the centre.

DEC P/N.: LA60X-PN Y M Fit the gear wheel end of the platen into the right hand side mounting.

To Remove the Platen (2) the platen into its mounting and lock in position by pushing the tag on

" Switch the printer OFF. " Install the ribbon cassette.
" Lift and remove the output stacker. " Fit and close the top cover.
" Lift and remove the top cover. " Fit the output stacker.
" Remove the Ribbon cassette.

Y M Position the print head to the very right.
Y M Release the plastic platen clamp (1) on the left platen mounting.
Y M Move platen (2) approximately 10 mm to the left, lift the left end of the

platen free of its mounting and withdraw the platen from the right
mounting.

Y M Lift the platen to the left underneath the print head and take it out.

5112 991 10352

PM AGC: (s. User's Manual, Chapter 2)
Run the MENU-function AGC ADJUST with ink ribbon cassette installed
but no paper inserted

To install the Platen Assy (2)

L Ensure that the printer is switched OFF.
Y M Place platen (2) in the vacant space between print head and metal bar.

Be careful not to damage the gear wheel.

Y M Ensure that the plastic platen clamp (1) is in the upright position, push

the clamp to the rear.

DEC Field Service Instruction

8-6 8-7

Part: ASF Pick-up Rollers Part No.: 5112 292 4100x Y M Insert the free end of the bar into its mounting, ensuring that each

DEC P/N.: LA60X-PR roller flange (67) is positioned so that they mate with the slots (68)

To Remove the ASF Pick-up Rollers (62) Y M Carefully snap the bar (65) into its mounting and fit the small

Y M Remove the ASF cassette (30) from the printer by drawing back the

release lever (63), releasing the mounting lugs.

Y M Remove the small access cover (64) by squeezing it together as shown.

Y M Pull back the retainers (66) as shown and lift up the bar (65).

Y M Pull the bar (65) out of the cassette and slide the pick-up rollers (62) off

the bar.

5112 991 10361

To install the Pick-up Rollers (62)

Y M Slide the new pick-up rollers (62) onto the bar (65).

in the paper sleeves.

access cover (64).

List of Spares and Repairs

9-1 9-2

9 List of Spares and Repairs

9.1 List of Spare Parts

Item Part No. DEC P/N. Page

Housing 405 5112 292 3840x FD-W03RF-01 7-2
Top Cover LA600 5112 292 6826x 29-31800-01 7-2
Top Cover 40A 5112 292 6827x FD-W03RH-01 7-2
Front Cover 405 5112 292 5490x FD-W03RC-01 7-2
Stacker Support 405 5112 212 5500x FD-W03RD-01 7-2
Front Insertion 405 5112 292 3842x FD-W03RJ-01 7-2
Print Engine LA600 5112 292 6475x 29-31790-01 7-4
PSU-40A 5112 292 3811x FD-W028Y-01-A01 7-6
PSU-40D 5112 292 7627x FD-W028Y-01-A02 7-6
PSU-40DS 5112 292 7628x n. a. 7-6
Fuse T 3A 250 5112 000 9302x n. a. 7-7
DEV-40 AE 5112 292 7159x 29-31791-01-A02 7-8
DEV-40LA600 5112 292 6292 29-31791-01-A01 7-8
DEV-40 A 5112 292 3810x FD-W00CS-01 7-8
CU-40K (Repair only; with MC) 5112 208 3885x FD-W00CW-01 7-10
CU-40LA600 5112 292 6299x 29-31792-01-A1 7-10

(Repair only; with MC)
Print CU-40L 5112 292 7384x 29-31792-01 7-12

(without MC interface)
EEPROM CU-40X 5112 000 4164x 29-31802-01 7-14
Operator Panel 40B 5112 292 6418x FD-W00CU-01 7-16
Power Switch 40A 5112 292 3882x FD-W02H3-01 7-18
Print Head Cable 405 5112 292 3880x FD-W02Y2-01 7-20
Encoder Strip 2 5112 292 7454x FD-W041701 7-22
Kit Lubrication Felt 5112 212 5589x 29-31804-01 7-24

Item Part No. DEC P/N. Page

Print H-Encoder 5112 292 4310x FD-W0290-01 7-26
H-Motor 5112 292 3791x FD-W0396-01 7-28
Carriage 5112 292 4094x FD-W04JL-01 7-30
Protection Shield 5112 292 3839x FD-W041W-01 7-32
Ribbon Gear 5112 292 6384x FD-W045M-01 7-34
Stepper Motor 7.5 DEG 5112 292 4106x FD-W0394-01 7-36
Stepper Motor 1.8 DEG 5112 292 6241x 29-31798-01 7-38
Tractor Gear 5112 292 3803x FD-W045N-01 7-40
Stacker Elements 5112 292 4099x FD-W04KK-01 7-42
Paper Sensor 5112 292 3805x FD-W04JJ-01 7-44
Kit Pressure Roll 5112 292 6655x 29-31801-01 7-46
Belt Stepper 5112 200 0878x FD-W032Y-01 7-48
Belt Form Feed 5112 200 0879x FD-W0330-01 7-48
Kit V-Transport 5112 292 3845x FD-W02M6-01 7-48
Kit Belt Pulley 2 405 5112 292 7442x FD-W05RM-01 7-50
Kit Cont. Forms Exit 5112 292 3846x FD-W02M7-01 7-52
Kit Tractor 2 5112 292 7441x FD-W02M8-01 7-54
Kit H-Drive Belt 5112 292 3848x FD-W02M5-01 7-56
Kit ASF-Lever 2 5112 292 6875x FD-W0487-01 7-58
Kit Spring D-Axis 5112 292 4107x 29-31803-01 7-60
Kit Screws and Springs 5112 292 3849x FD-W05RK-01 7-62
Noise Absorber 5112 212 7034x n. a. 7-64
Rep Kit ASF-Cassette 5112 292 7235x n. a. 7-66
Paper Guide 4 405 5112 292 6286x n. a. --­ASF Support 405 5112 212 5320x FD-W03RE-01 ---

List of Spares and Repairs

Item Part No. DEC P/N. Page

9-3 9-4

9.2 List of Wearing Parts

Item Part No. DEC P/N.

Print Head DH3024 / 2 5112 292 6652x FD-52920-01 8-2
Platen Assy 5112 292 3801x LA60X-PN 8-4
Pick-up Rolls ASF A and B 5112 292 4100x LA60X-PR 8-6