Fujitsu Impact 3650 Maintenance Manual

1

Impact 3650

SERIAL PRINTER

MAINTENANCE MANUAL

FUJITSU ISOTEC LIMITED

FUJITSU ISOTEC LIMITED Proprietary Confidential

2

REVISION RECORD

Edition Date published Page Revised contents

01 October 2007 First issue

Specification No. P1KA02038-B112/E

The contents of this manual may be revised without prior notice.
All Rights Reserved, Copyright © 2007 FUJITSU ISOTEC LIMITED.

No part of this manual may be reproduced in any form without permission.

PREFACE

This manual is for engineers who operate, install, or maintain the impact 3650 printer, and covers:

Chapter 1: Printer specifications, performance, and configuration

Chapter 2: Unpacking, performance check, and connection

Chapter 3: Troubleshooting

Chapter 4: Maintenance

Chapter 5: Principles of operation

Chapter 6: Recommended spare parts

3

CONTENTS

CONTENTS..............................................................................................................................................3

CHAPTER 1 PRINTER SPECIFICATIONS, PERFORMANCE, AND CONFIGURATION......................7

1.1 Overview.........................................................................................................................................7

1.2 Equipment Structure.......................................................................................................................7

1.2.1 Overview..................................................................................................................................7

1.2.2 Model configuration..................................................................................................................7

1.2.3 Structure...................................................................................................................................8

(1) Exterior components ..............................................................................................................10

(2) Printing mechanism................................................................................................................12

(3) Lower cover............................................................................................................................14

(4) Option and consumables........................................................................................................15

CHAPTER 2 UNPACKING, PERFORMANCE CHECK, AND CONNECTION .....................................16

2.1 Overview.......................................................................................................................................16

2.2 Notes on Installation .....................................................................................................................16

2.3 Unpacking.....................................................................................................................................17

2.4 Inspection after Unpacking ...........................................................................................................19

CHAPTER 3 TROUBLESHOOTING....................................................................................................20

3.1 Trouble shooting Table.................................................................................................................20

3.1.1 Problems at power-on initialization (part 001/3) .....................................................................20

3.1.1 Problems at power-on initialization (part 002/3) .....................................................................21

3.1.1 Problems at power-on initialization (part 003/3) .....................................................................22

3.1.2 Problems related to printing (part 001/2)................................................................................23

3.1.2 Problems related to printing(part 002/2).................................................................................24

3.1.3 Problems related to printing result..........................................................................................25

3.1.4 Problems related to print quality (part 001/2)..........................................................................26

3.1.4 Problems related to print quality (part 002/2)..........................................................................2

7

3.1.5 Problems related to paper feed (part 001/2)...........................................................................28

3.1.5 Problems related to paper feed (part 002/2)...........................................................................29

3.1.6 Problems related to the control panel.....................................................................................30

3.2 Error Display.................................................................................................................................31

(1) Warning errors...........................................................................................................................31

(2) Operational errors......................................................................................................................32

(3) Fatal alarms...............................................................................................................................32

CHAPTER 4 MAINTENANCE..............................................................................................................34

4.1 Overview.......................................................................................................................................34

4.2 Notes on USE...............................................................................................................................34

4.3 Maintenance Tools........................................................................................................................34

4.4 Maintenance levels.......................................................................................................................35

4

4.5 Preventive Maintenance ...............................................................................................................35

4.6 Part Drawings ...............................................................................................................................35

4.7 Parts That must not be Disassembled..........................................................................................36

4.8 Level 1 Maintenance .....................................................................................................................37

4.9 Level 2 maintenance .....................................................................................................................38

4.9.1 Parts replacement..................................................................................................................38

(1) Tractor Unit removal and installation Front feed tractor..........................................................39

(2) Cut Sheet Feeder removal and installation.............................................................................41

(3) Stacker Plate removal and installation....................................................................................43

(4) Stacker Unit removal and installation .....................................................................................44

(5) Paper Table removal and installation......................................................................................45

(6) LAN card removal and installation..........................................................................................46

(7) Flap replacement....................................................................................................................47

(8) Ribbon Cassette replacement................................................................................................48

(9) Print head replacement..........................................................................................................50

(10) Control Panel Unit removal and installation..........................................................................51

(11) Front Cover removal and installation....................................................................................52

(12) Upper Cover removal and Installation..................................................................................53

(13) Print Mechanism Unit removal and installation.....................................................................54

(14) Power Supply Unit removal and installation .........................................................................56

(15) ROM Board (Main Board) replacement................................................................................57

(16) LAN RELAY PCA / LAN cable 17P replacement..................................................................58

(17) RS232C BOARD replacement .............................................................................................59

(18) AC Switch ASY removal and installation...............................................................................60

(19) Inlet ASY replacement..........................................................................................................61

(20) FAN UNIT 2 replacement .....................................................................................................62

(21) Control Panel Cable replacement.........................................................................................63

(22) F-CSF Cable/CSF Connector PCA replacement..................................................................64

(23) R-CSF Cable/CSF Connector replacement..........................................................................65

(24) Relay Cable replacement.....................................................................................................66

(25) Sensor PCA replacement.....................................................................................................67

(26) SP Motor ASY replacement..................................................................................................68

(27) LF Motor removal and installation ........................................................................................69

(28) TR Motor removal and installation........................................................................................70

(29) APTC Unit replacement........................................................................................................71

(30) HCPP Motor replacement.....................................................................................................72

(31) SP FAN motor replacement..................................................................................................73

(32) INLK SW ASY replacement..................................................................................................74

(33) PS PCA replacement............................................................................................................75

(34) HCPP switch ASY replacement............................................................................................76

(35) Sensor cover TR/TR PES ASY replacement........................................................................77

5

(36) Ribbon Rope ASY replacement............................................................................................78

(37) Card Guide ASY replacement ..............................................................................................79

(38) TOFL/R sensor ASY replacement ........................................................................................81

(39) Carriage Unit and Stay Shaft replacement ...........................................................................82

(40) SP Timing Belt replacement .................................................................................................83

(41) SP Tension bracket replacement..........................................................................................84

(42) LF Timing Belt replacement..................................................................................................86

(43) Platen Roll replacement .......................................................................................................87

(44) Nip Spring 1/2 replacement..................................................................................................89

(45) Nip Roller replacement.........................................................................................................90

(46) DV Roller ASY replacement .................................................................................................91

4.9.2 Adjustment .............................................................................................................................94

(1) Print head gap adjustment .....................................................................................................94

(2) Card guide position adjustment..............................................................................................96

(3) Card guide position adjustment (another way).......................................................................99

(4) TOF sensor’s voltage adjustment.........................................................................................101

(5) LF belt’s tension adjustment.................................................................................................102

(6) Vertical Alignment (V-ALMNT) adjustment...........................................................................103

(7) Top-of-forms adjustment (factory use)..................................................................................104

(8) Skew detection value adjustment.........................................................................................105

4.9.3 Lubrication............................................................................................................................106

(1) Upper angle..........................................................................................................................106

(2) HCPP mechanism, Stud for gear..........................................................................................107

(3) Detent for DV roller...............................................................................................................108

(4) Bearings...............................................................................................................................108

(5) Guide to slide the paper table.............................................................................................

..109

(6) Carrier unit (Ribbon drive mechanism).................................................................................110

4.10 Diagnostics...............................................................................................................................111

4.10.1 Printing the Self-Test..........................................................................................................111

4.10.2 Hex dump...........................................................................................................................113

CHAPTER 5 PRINCIPLES OF OPERATION.....................................................................................116

5.1 Overview.....................................................................................................................................116

5.2 Mechanical Operation.................................................................................................................117

5.2.1 Printing Operation ................................................................................................................117

5.2.1.1 Print head ......................................................................................................................117

5.2.1.2 Spacing operation..........................................................................................................118

5.2.1.3 LRES (Carriage position) detection ...............................................................................119

5.2.1.4 Ribbon feed mechanism................................................................................................120

5.2.1.5 Automatic paper thickness control mechanism..............................................................121

5.2.1.6 Skew detection ..............................................................................................................122

5.2.2 Paper Feed Operation..........................................................................................................123

6

5.2.2.1 Paper path selection mechanism (HCPP)......................................................................123

5.2.2.2 Paper feed operation .....................................................................................................125

5.2.2.3 Paper loading and ejection operation (auto loading)......................................................128

5.3 Electrical Operation.....................................................................................................................129

5.3.1 Printed Circuit Boards and Basic Configuration....................................................................129

5.3.1.1 Outline of Printed Circuit Boards....................................................................................130

5.3.2 Control Circuit Operation......................................................................................................134

5.3.2.1 Printer Special Controller (MB90706) ............................................................................ 134

5.3.2.2 Memory Circuit Control..................................................................................................135

5.3.2.3 Centronics Controller.....................................................................................................137

5.3.2.4 The MPU(MB89P585) has the following main functions................................................139

5.3.2.5 LAN interface.................................................................................................................140

5.3.3 Head Control LSI (MBCG46183-520PF)..............................................................................141

5.3.4 Motor Control LSI (MBCG46183-525PFV)...........................................................................142

5.3.5 Control Panel Control...........................................................................................................143

5.3.6 Motor Control and Drivers....................................................................................................144

5.3.7 Print Head Driver..................................................................................................................149

5.3.8 Alarms..................................................................................................................................151

5.3.8.1 Fire Check .....................................................................................................................151

5.3.8.2 ROM or RAM Error........................................................................................................151

5.3.8.3 Spacing Error.................................................................................................................151

5.3.8.4 APTC Gap Alarm ...........................................................................................................151

5.3.8.5 HCPP Alarm...................................................................................................................151

5.3.8.6 Skew Unit Error..............................................................................................................151

5.3.9. Power Supply......................................................................................................................152

5.3.9.1 +5 V Switching Regulator ..............................................................................................1

52

5.3.9.2 +34 Switching Regulator................................................................................................152

5.3.10 Surge Current Controller....................................................................................................154

CHAPTER 6 RECOMMENDED SPARE PARTS ...............................................................................155

7

CHAPTER 1 PRINTER SPECIFICATIONS,

PERFORMANCE, AND
CONFIGURATION

1.1 Overview

This manual is for maintenance engineers, and covers overall this impact 3650 printer maintenance, together
with detailed information such as troubleshooting and component replacement.

Recommended references are:

Impact 3650 Printer Parts Catalogue (P3KA02038-B112/E)
Impact 3650 Printer Schematic Diagrams (C1KA02038-B112/E)

These three manuals contain all information needed for this impact 3650 printer maintenance.
This manual covers all models.

Please also refer to the following manual if needed.

Impact 3650 Printer Product Description (A1KA02038-B112/E)

The impact 3650 printer has a reliable, simple mechanism requires little maintenance.

1.2 Equipment Structure

1.2.1 Overview

This section outlines printer structure and features.

1.2.2 Model configuration

The impact 3650 is a 136-column printer.

Factory options are as follows

Power Supply type; 220-240VAC input

Interface type; Centronics parallel + USB interfaces
Centronics parallel + RS232C serial interface

Add-on options are as follows.

Cut sheet feeder. (The SF940 single-bin feeder)
Tractor unit. (for a second tractor).
LAN card. (only for the Centronics parallel + USB interfaces Models.)
Large paper table.
Large stacker.

The impact 3650 has three emulations as follows.

Fujitsu DPL24C PLUS
IBM Proprinter XL24E
Epson ESC/P2

8

1.2.3 Structure

Major printer components are organized as shown below. Items in boldface are recommended spare parts
(see Chapter 6) that can be replaced in field by maintenance service engineers. Replacement and adjustment
are detailed in Chapter 4.

Figure 1.1 Structure of the impact 3650

Impact 3650 printer

Stacker Unit

Mecha assembly

Ribbon cartridge

Tractor unit

Cut-sheet feeder

Front Cover assembly

Operating panel

Upper Cover assembly

Print Head

ROM board

Power supply

Lower cover assembly

AC SWITCH assembly

AC INLET assembly

Components that operator can install and remove.

Frame

Carrier Unit Tof L / R s e n s or

Aptc sensor

Carrier Cable

L/RES sensor

SP motor

LF motor

APTC motor

Connector Board

Inter Lock SW

HCPP motor

PS Sensors

FTRPE Sensors

RTR PE Sensor s

APTCHP SW

HCPPHP SW

Stacker plate

Paper Table assembly

TR motor

Nip Roller assembly

Dv Roller assembly

Platen Roller assembly

LAN CARD

9

Block diagrams
The following figure shows printer functional components and connecting cables.

Figure 1.2 Block Diagram of the impact 3650

Power supply

ROM Board

Control Panel

sw

inlet

Carrier board

LF
Motor

Print Head

TR

Motor

Connector board

SP

Motor

PS
sensors

HCPP
motor

HCPP HP
SW

APTCHP
SW

APTC
motor

FTRPE
sensor

RTR PE

sensor

FCSF

RCSF
connector

INTER
LOCK
SW

APTC
sensor

TOFR
sensor

TOFL
sensor

Option board

LAN

Carrier

unit

Mecha
Unit

USB

Centro

FAN
Motor 2

LRES sensor

FAN

Motor 1

FAN

driver

RS232C

10

(1) Exterior components

This section gives information on exterior components of the printer: covers, removable mechanism units,etc.

Figure 1.3 Exterior components of the impact 3650

11

a. Interface Connector

The interface cable connector is on the right side of the printer, as seen from the front of the upper cover, so
the interface cable does not interfere with the paper feed path.

Figure 1.4 Interface type of the impact 3650

b. Front cover

The front cover is opened to replace the ribbon cartridge.
There is an Interlock SW for safety.

c. Paper table

The paper table guides a cut sheet manually fed by the user. The optional Large Paper Table is necessary to use
cut sheets exceeding 297 mm in length

d. Rear stacker

The rear stacker holds printed cut sheets. The optional Large Stacker is necessary to use cut sheets exceeding
297 mm in length

e. Control panel

The control panel consists of an LSI, ten push-button switches, one dial, thirteen LEDs, and a buzzer.
The switches are used for operations such as loading and feeding paper and controlling printing pressure. Some
switches are also used in setup mode. The LEDs indicate printer basic statuses and paper feed path conditions.
The buzzer sounds to indicate certain operating and printer statuses.

Figure 1.5 Control panel of the impact 3650

12

(2) Printing mechanism

Figure 1.6 Mechanism of the impact 3650

Print head

Ribbon cartridge

Stay shaft

Carriage

Stepping motor for
carriage drive mechanism

Paper feed mechanism

HCPP motor

HCPP mechanism

APTC mechanism

13

The printing mechanism fit into the bottom cover. And Upper Cover holds it in position.

a. Carriage

The carriage supports the removable 24-wire print head and the ribbon cartridge, and slides left and right
on the stay shaft. The ribbon feed gear system moves the ribbon in one direction regardless of carriage
movement. It has four sensors: LRES, TOFL, TOFR and APTC sensor. The LRES detects both left and
right ends of the carriage movement. The TOFL/R detects the edge (top, left, right, bottom) of paper.
The APTC sensor detects the surface of paper for control the gap between the print head and the paper.

b. Carriage drive mechanism

The stay shaft and the stay guide (upper angle) support the carriage; the stepping motor and timing belt move
the carriage horizontally.

c. Paper feed mechanism

There are two stepping motors. One of them drives the rollers and another one drives tractors.

d. Host-controlled paper path (HCPP) mechanism

The HCPP mechanism switches power transmission to the tractors. Three states are possible: front tractor is
selected, rear tractor is selected, and cut sheet is selected. Switching is possible through software or by the
control panel. The paper on the platen is unloaded to the park position or ejected, and then the paper feed path
is switched. When switching from a cut sheet to continuous forms, the continuous forms are automatically
loaded to the print position.

e. Automatic paper thickness control (APTC) mechanism

The APTC mechanism adjusts the gap between the print head and the paper surface. Before start printing,
the print head is approach to the platen until APTC sensor is pressed against the paper surface. And then the
print head is returned by a certain distance so that the gap (actually between the print head and the paper) is
properly adjusted regardless of the paper thickness.

f. Paper sensors

There are six paper sensors for controlling paper feeding:

Name Function Sensor type

TOFL
TOFR

Detect the top edge for paper loading

-TOFL is for front loading

-TOFR is for rear loading
Detect left and right edge for area over control

-TOFL is for left and right edge (small width paper)

-TOFR is for right edge (large width paper)
(Right and left are reversed for rear feed)
Detect the bottom edge for detecting paper end.

-TOFL is for front loading

-TOFR is for rear loading

Photo reflectors

FTRPE
RTRPE

Detect the continuous forms at the tractor for as
follows.

-Control the paper loading sequence.

-Detect the paper parking position.

-Detect the near paper end of continuous forms.

Photo interrupter

PSS Detect the cut sheet on the paper table for auto

loading.
Detect the bottom of the cut sheet for control carriage
position to detect the paper end .
Detect the leaved paper on the paper table for display
remove paper indicator.

Photo reflectors

APTC Detect the surface of the paper for control the print

head gap.

Panel Key Board

14

(3) Lower cover

Figure 1.7 Electric components of the impact 3650

a. Lower cover

The Lower cover supports the printer mechanism and electric units as follows.

b. ROM board (control board with flash ROM)

The ROM board controls the host interface, control panel, and printing mechanism using an MPU and an
LSI circuit. Memory holds the resident character patterns and firmware, including resident emulation programs.
This board also has drivers and receivers for other components. The sensor receivers convert signals from the
sensors. The drivers supply power to motors, print head wires, and other components. The separate RS-232C
serial board or LAN relay board is connected to this board through the cable.

c. Power supply unit

The power supply unit supplies DC34V and DC5V by one transformer.

d. AC inlet and AC switch.

The AC inlet has protective earth cable. In order to prevent an electric shock, it must be fixed to frame ground.
The AC switch has cables to connect the Power supply unit and AC inlet.

e. CSF connector (front CSF)

The connector board for the front CSF is mounted at the front right of the lower over.

Lower cover

ROM board

Power supply unit

AC inlet

AC inlet

CSF connector

15

(4) Option and consumables

a. Cut-sheet feeders

A cut-sheet feeder allows both single-part cut sheets and multi-part cut sheets to be fed automatically.
The SF940 single-bin feeder is available for the impact 3650.

b. Tractor unit

An additional tractor unit can be installed in the printer. Because the standard tractor unit is installed at the
front of the printer at shipment, the additional tractor is installed at the rear of the printer. However, both
tractor units are the same, and installable at either position.

c. LAN card.

A LAN card is available as a printer add-on option. A user installable function, the LAN card can be installed
only on printer models with the Centronics parallel + USB interfaces.

c. Large paper table

The large paper table helps to increase operability when large cut sheets are used.
Also, sheets that are output from the front are easier to keep properly organized.

d. Large stacker.

The large stacker accommodates sheets output from the rear. It is used in continuous printing with a cut sheet
feeder.

e. Print head

The 24-wire print head is easily installed on and removed from the print head carriage.

16

CHAPTER 2 UNPACKING, PERFORMANCE CHECK,

AND CONNECTION

2.1 Overview

The impact 3650 printer comes packed for transportation.

After unpacking and before installation, the printer must undergo self-test printing. Installation requires minimum
time and expense.

2.2 Notes on Installation

For best results, note the following points when installing the paper:

・Place the printer on a level, vibration-free surface.
・Keep the printer away from sunlight and heaters.
・Be sure printer ventilation ports are not blocked.
・Do not operate the printer in a humid or dusty environment.
・Use an outlet that is separated from noise-generating equipment such as motors.
・Use the correct AC voltage unexpected problems.

17

2.3 Unpacking

Unpacking the printer as follows(Figure 2.1)

1. Open the carton and remove Rear stacker, Ribbon cartridge and Cushion L/R.

2. Lift up the printer using the grip at right and left of the printer.

3. Take out accessories (Power cord, Manual).

Figure 2.1 Unpacking the printer and accessories

18

4. Set the paper table as follows.

Figure 2.2 Setting the paper table

5. Remove the Block FC.

6.Open the front cover and remove the cardboard shipping restraint holding the carriage in place

Figure 2.3 Removing the shipping materials

7.Store the original shipping carton and packing materials for future use in moving or shipping the printer.

19

2.4 Inspection after Unpacking

1. Carefully check assemblies and accessories for visible damage.

2. Install the ribbon cartridge. See the User’s Manual for details.

3. Check the rated voltage or the printer and AC power outlet, then connect the AC power cord between
the printer and AC power outlet.

5. Close the front cover.

6. Turn on the power switch.

7. Load cut sheet paper or continuous forms paper as explained in the User’s Manual.

Check printing performance and quality using self-test printing, detailed in User’s Manual.

20

CHAPTER 3 TROUBLESHOOTING

This chapter helps pinpoint the causes of problems with the printer.
Section 3.1 is a troubleshooting table. The table shows how to determine what is wrong with the printer and what
to do to correct the problem.
Section 3.2 explains error displays on the control panel that help clarify the cause of a problem.
Section 3.3 explains the self-correction functions of the impact 3650 printer.
For replacement and adjustment after recovery, see Chapter 4.

3.1 Trouble shooting Table

3.1.1 Problems at power-on initialization (part 001/3)

Symptom Cause Response

− The power cord is not

connected to the outlet
or the printer.

Connect the power cord
properly

The power cord is
defective.

Replace the power cord.

The power supply is
defective.

Replace the power

supply.
The control board is
defective.

Replace and initialize

the control board.
The control panel
board is defective.

Replace the control

panel board.

1 The POWER lamp does

not go on.

The power cord is connected
properly.

The cable connected
to the control panel
board is defective.

Check the connection.

Check the cable.

Turn off the power, then wait
for about 10 minutes.
Disconnect the space motor
connector and turn on the
power.
Initialization is not done but
The POWER lamp comes on.

An SP motor fire
check alarm is
detected.

• Replace the SP motor.

• Replace the control
board, then initialize
the EEPROM.

Turn off the power, then wait
for about 10 minutes.
Disconnect the main LF
motor connector and turn on
the power. Initialization is
done.

A main LF motor fire
check alarm is
detected.

• Replace the main
motor.

• Replace the control
board, then initialize
the EEPROM.

2 The POWER lamp

comes on momentarily,
but goes off. Then, turn
the power switch OFF,
and turn on the power
after 10 to 20 seconds.
However, the
POWER lamp does
not go on.

Turn off the power, then wait
for about 10 minutes.
Disconnect the tractor LF
motor connector and turn on
the power. Initialization is
done.

A tractor LF motor
fire check alarm is
detected.

• Replace the tractor LF
motor.

• Replace the control
board, then initialize
the EEPROM.

21

3.1.1 Problems at power-on initialization (part 002/3)

Symptom Cause Response

After the POWER lamp goes
on, simultaneous blinking of
all other lamps is not
performed.
The PAPER OUT lamp does
not blink, either.

The control board
is defective.

Replace and initialize
the control board.

The cover is open. Close the front cover.

After the POWER lamp goes
on, simultaneous blinking of
all other lamps is performed
but initialization is not
performed normally.

The cover open switch
assembly is defective.

Replace the cover
open switch assembly.

The interface cable is
defective.

Replace the interface
cable.

After the POWER lamp goes
on, simultaneous blinking of
all other lamps is performed
but the PAPER OUT lamp
does not blink later. If the
interface cable is
disconnected, initialization is
performed normally.

The host is defective. Check the host.

The control board is
defective.

Replace and initialize

the control board.
The control panel
board is defective.

Replace the control

panel board.
The cable
connected to the
control panel board is
defective.

Check the connection.

Replace the cable.

3 The POWER lamp is

on.

The case of as stated above.
Initialization is not
performed normally even if
the interface cable is
disconnected.

The cover is open.

Close the front cover.

22

3.1.1 Problems at power-on initialization (part 003/3)

Symptom Cause Response

A ROM or RAM
alarm is detected.

Replace and initialize

the driver board.

After the POWER lamp goes
on, simultaneous blinking of
all other lamps is not
performed but the PAPER
OUT lamp blinks.

Low-voltage alarm is
detected.

• Replace the power
supply.

• Replace the control
board, then initialize
the EEPROM.

After APTC initialization, the
PAPER OUT lamp blinks.

• APTCHPSW ASY
is defective.

• The APTC motor
is defective.

• APTCHPSW ASY
is not connected.

• The driver board
is defective.

• Replace the
APTCHPSW ASY.

• Replace the APTC
motor.

• Connect the
APTCHPSW ASY
cable properly.

• Replace the driver
board.

When the power is turned on
after the carriage is moved to
the center of the side frames,
the carriage moves smoothly
but hits the left or right side
frame.

A LRES alarm is
detected.

• LES detection is
poor.

• The carriage cable
is defective.

• The driver board
is defective.

• The carriage cable
is disconnected.

• Clean or replace the
carriage PC board.

• Replace the
carriage cable.

• Replace the driver
board.

• Connect the carriage
cable properly.

After APTC initialization,
the PAPER OUT
lamp flashes.

• The carriage does not
move.

• An abnormal sound is
made.

• Carriage movement is not
smooth.

Space alarm is
detected.
A. The SP motor

connector is
disconnected.

B. The SP motor is

defective.

C. The stay shaft is

rough.

D. The SP belt is

loose.

E. The control board is

defective.

A. Connect the

Connector correctly.

B. Replace the space

motor.

C. Clean or lubricate the

stay shaft.

D. Check the tension

pulley.

E. Replace the control

board, then initialize
the EEPROM.

4 The PAPER OUT lamp

blinks.

The PAPER OUT lamp
blinks immediately after the
HCPP starts operation.

• HCPPSW ASY is
defective.

• The HCPP motor
is defective.

• HCPPSW ASY is
not connected.

• The control board
is defective.

• Replace the
HCPPSW ASY.

• Replace the HCPP
motor.

• Connect the
HCPPSW ASY cable
properly.

• Replace and
initialize the control
board.

23

3.1.2 Problems related to printing (part 001/2)

Symptom Cause Response

1 The POWER lamp goes

off during printing.
Then, turn the power
switch OFF, and turn
on the power after 10
to 20 seconds.
However, the POWER
lamp does not go on.

Turn off the power, then wait
for about 10 minutes and turn
on the power. Initialization
is done normally.
(If problem occur again in
initialization refer to

3.1.1)

The accidental fire
check alarm is
detected.

• It’s difficult to pinpoint
a cause. Check the
SP/LF/TR motor and
HD and there drive
circuit on the ROM
board and replace them
if necessary.

Spacing isn’t smooth. Clean any obstacle.

Check the paper
thickness control.

SP Motor is defective Replace SP motor

Space problem alarm is
detected.

ROM board SK is
defective

Replace it

SP fan is locked by
anything.

Clean any obstacle.

Fan alarm is detected

SP fan is defective Replace it

Overload alarm detected
(+34V isn’t restore after
3pass printing.)

The power supply is
defective.

Replace it

The paper to be
Printed on is too thick.

Replace the paper.
(Use paper of a
thickness specified in
the paper specification.)

Difference thickness
of the paper.

Replace the paper or use

manual mode properly.

Card guide adjustment
is incorrect

Adjust card guide
correctly.

2 The PAPER OUT lamp

starts blinking.
(Refer to Alarm display
function)

APTC Gap Alarm is detected

APTC sensor is
defective

3 3 pass printing is

performed.

• Power overload is
detected (if more
than one character of
the solid pattern is
printed).

• Print head overheat
is detected (if print
patterns of rather
higher density of
characters are printed
continuously.

• The control board is
defective.

• The power supply is
defective.

• The print head is
defective.

• The print head
protection function
works normally.
Change the print
pattern.

• The print head
protection function
works normally.
Change the print
pattern or stop the
printer for a while.

• Replace the control
board.

• Replace the power
supply.

• Replace the print head.

24

3.1.2 Problems related to printing(part 002/2)

Symptom Cause Response

The interface cable is
not connected
properly.

Connect the interface
cable properly.

Printing operation is not
performed at all.

The front cover is
open.

Close the front cover.

The host interface
setting of the printer
does not match the
host used.

Enter setup mode and
change the setting for
the host interface.

Self-test printing is
performed normally.

The interface is
defective.

• Replace and initialize
the control board.

• Replace the interface
cable.

• Check the host.

The carriage cable is
improperly connected
to the print head or
control board.

Connect the carriage
cable properly.

Even self-test printing is not
performed.

The control board is
defective.

Replace and initialize
the control board.

Paper out condition is
detected.

Paper pass select isn’t
correct.

Paper isn’t load.

CSF is empty.

4 Data sent from the host

is not printed at all.
Data cannot be received
from the host.

REMOVE PAPER indicator
blinks.

Cut sheet leaved on
the paper table and
printer waiting
removing it.

Remove the paper from
the paper table.

25

3.1.3 Problems related to printing result

Symptom Cause Response

The setup mode
setting is invalid.

Enter setup mode and
change the mode setting
properly.

Self-test printing is
performed normally.

The interface is
defective.

• Replace and initialize
the control board.

• Replace the interface
cable.

• Check the host.

The carriage cable is
improperly connected
to the print head or
control board.

Connect the carriage
cable properly.

Even self-test printing is
abnormal.

The control board is
defective.

Replace and initialize
the control board.

Printer ignores data that out
of print area.

Area over detection
works.

1 The data sent from the

host does not match the
print results.

Area over detection cut the
data in the print area.

Printer misread the
black printing into the
paper edge.

26

3.1.4 Problems related to print quality (part 001/2)

Symptom Cause Response

The print head is
defective.

Replace the print head.

The carriage cable is
connected improperly.

Connect the carriage

cable properly.
The carriage cable is
defective.

Replace the carriage

cable.

1 A dot is missing or an excess dot is printed.

(See other items about blurring of the top or bottom
of a character.)

The control board is
defective.

Replace and initialize the

control board.
Bi-directional printing
position adjustment is
poor.

Properly adjust the

bi-directional printing

position.
Stay shaft movement is
not smooth.

Clean and grease the stay

shaft.
The space belt is
defective.

Replace the space belt.

The space belt tension is
inadequate.

Check the tension pulley

unit.
The space motor is
defective.

Replace the space motor.

2 The printing position in the horizontal direction

(character spacing direction ) is misaligned.
Check first that:

- Paper thickness is adjusted properly.

- The automatic paper thickness control
mechanism works normally.

The control board is
defective.

Replace and initialize the

control board.
The manual paper
thickness adjustment dial
is set improperly.

Adjust the manual paper

thickness adjustment dial.

Multipart paper or thick
paper is used.

Automatic paper
thickness control is
defective.

Replace and readjust the

card guide.

Paper is smeared by the
ribbon. (Haze)

The ribbon is fluffy. Replace the ribbon

cartridge.

3 Printing smears paper.

There is a blotch of ink. Ribbon residue or in

adheres the print head.

Remove ink or ribbon

residue from the print

head.

4 Printing is light or the top or bottom of characters is

blurred.

• The manual paper

thickness adjustment
dial is set improperly.

• The ink ribbon has

reached the end of its
life.

• The gap between the

print head and platen is
inadequate.

• The print head is

defective.

• The control board is

defective.

• Adjust the paper
thickness adjustment dial
according to paper
thickness.

• Replace the ink ribbon.

• Adjust the gap between
the print head and
platen.

• Replace the print head.

• Replace the control
board.

27

3.1.4 Problems related to print quality (part 002/2)

Symptom Cause Response

5 Printing is partly blank or the ribbon is out of place.

The ribbon is loose.
The ribbon is vertically misaligned.
The ribbon is twisted.

• The manual paper
thickness adjustment
dial is set improperly.
(Because the paper
thickness setting is too
narrow, the ribbon is
loosened.)

• The ribbon is loosened
on a locally thick
portion of paper.

• The ribbon is partly
twisted.

• Poor card guide
adjustment influenced
ribbon movement.

• The ribbon cartridge is
defective.

• The ribbon setting is
inadequate.

• Adjust the manual paper
thickness adjustment dial
properly according to
paper thickness.

• Check the paper
specifications.

• Check whether the
ribbon is twisted.

• Adjust the card guide.

• Replace the ribbon
cartridge.

• Set the ribbon properly.

28

3.1.5 Problems related to paper feed (part 001/2)

Symptom Cause Response

1 Paper selection cannot be performed properly. • The paper selection HCPP

motor does not work

• HCPPSW ASY is defective.

• The paper selection
mechanism is defective.

• The control board is
defective.

• Replace the HCPP
motor.

• Replace the HCPPSW
ASY.

• Replace the printer
mechanical unit.

• Replace the control
board.

2 The paper loading position is inadequate.

Or, the PAPER OUT lamp does not go off.

• The setup is inadequate.

• TOF adjustment in auto
load

mode is inadequate.

• Paper is defective.

• The sensor is defective.
For cut sheet paper
For front-fed continuous
forms
For rear-fed continuous
forms

• Correct the setup.

• Adjust the TOF
properly.

• Replace paper.
(with those conforming
to the media
specifications)

• Replace the sensor.
Replace the TOF 1
sensor.
Replace the FTRPE
sensor.
Replace the RTRPE
sensor.

3 Front-fed cut sheets are not loaded

automatically.

• The setup is inadequate.

• The TOF 1 or 2 sensor is
defective.

• The printer is detecting
paper.

• The paper detection

mechanism is defective.

• Correct the setup.

• Replace TOF 1 or 2
sensor.

• Eject the paper from the
printer.

• Replace the printing
mechanism unit.

4 Front-fed continuous forms do not move back. • The front tractor PE sensor

is defective.

• Replace the FTRPE
sensor.

• Replace the tractor unit.

5 Rear-fed continuous forms do not move back. • The rear tractor PE sensor is

defective.

• Replace the RTRPE
sensor.

• Replace the tractor unit.

6 Paper loading and ejection are abnormal. • Paper sensor output is

abnormal.

• Sensor cable connection is
defective.

• The control board is
defective.

• Replace the sensor.

• Connect the cable
sensor.

• Replace the control

board.

7 Line spacing is narrowed.. • Paper is defective.

• The LF motor is defective.

• The LF driver is defective.

• Power output is insufficient.

• Replace paper.

(with that conforming to
the media specifications)

• Replace the LF motor.

• Replace the control

board.

• Replace the power

supply.

8 The CSF does not load paper automatically. • The CSF cable is

disconnected.

• The CSF cable is defective.

• The CSF is set improperly.

• Connect the CSF cable

properly.

• Replace the CSF cable.

• Set the CSF properly.

29

3.1.5 Problems related to paper feed (part 002/2)

Symptom Cause Response

9 Paper skews or a paper jam occurs. • Paper is set improperly.

• Paper is defective.

• The manual paper thickness
adjustment dial is set
improperly.

• The card guide is mounted
out of place.

• The print head gap is
invalid.

• Paper skews in the CSF.

• Set paper properly.

• Replace paper
(with that conforming to
the media specifications)

• Adjust the manual paper
thickness adjustment
dial properly.

• Adjust the card guide
position.

• Adjust the print head
position.

• Replace the CSF.

30

3.1.6 Problems related to the control panel

Symptom Cause Response

• The printer is online.

• The connection between
the control panel board
and control board is
defective.

• The printer is in alarm
state.

• Turn the printer offline.

• Connect the cable
properly, or replace the
cable.

• Check the fault and then
turn on the power again.
If the fault is an unusual
order or smoke
emission, eliminate the
fault cause before
turning on the power
again.

1 Switches on the control panel are disabled.

• The control board is
defective.

• The control panel board
is defective.

• Replace the control
board.

• Replace the control
panel board.

2 Lamps on the control panel do not go on properly. • The connection between

the control panel board
and control board is
defective.

• The control board is
defective.

• The control panel board
is defective.

• Connect the cable
properly or replace the
cable.

• Replace the control
board.

• Replace the control
panel board.

31

3.2 Error Display

This printer indicates errors on the control panel. There are three groups of errors as explained below.

(1) Warning errors

The buzzer sounds and the ONLINE indicator still lights.

For a data transmission error in the interface, only the buzzer indicates the error. The printer continues printing
unless placed offline or other groups of errors occur. See Table 3.1.

Table 3.1 Warning errors

Error name Cause of the error Recovery

Parity error

An incorrect parity condition is detected in received
data in the RS-232C interface.

• Besides parity, this error may also occur due to
incorrect setting.

• The printer prints question marks (?).

• Check the baud rate and data
format.

• Check the interface cable.

Framing error An incorrect stop bit condition is detected in received

data in the RS-232C interface.

• The printer prints a question mark (?) for the first
error byte then ignores the succeeding data.

Overflow error

The host transmits data to the printer although the
input buffer is full of data (i.e., while the printer is
requesting the host to stop data transmission).

• The printer ignores the data (data is lost) and a
question mark (?) is stored in the input buffer when
the error is recovered.

Check all settings for the
RS-232C interface.

Download error

The download buffer overflows.

• The printer ignores the data (data is lost).

• Reduce downloaded data.

• Reduce the print buffer
capacity, i.e., increase the
download buffer capacity.

Overrun error

The printer cannot accept data at the rate it is
transmitted. That is, while the printer is reading out
the input buffer, the host transmits the next data.

• The printer ignores the data (data is lost).

Check all settings for the
RS-232C interface.

Transmission

timeout error

While the printer attempts to transmit data to the
host, ten seconds elapse with the output buffer full of
data.

• The printer ignores the data (data is lost).

Note:
Incorrect settings on the RS-232C do not always cause parity or framing errors. If the baud rates of the host
computer and the printer are multiples of 4800, such as 19200, framing errors are not detectable, and meaningless
data indicates a setting error. These errors do not affect the line from the host computer. An error remains if
the printer is online and no other warning is displayed until pushbutton operation or an operational error or fatal
error is detected.

32

(2) Operational errors

The PAPER OUT indicator is lighted.

The buzzer sounds, the PAPER OUT indicator lights up, and the printer is placed offline when operation is
required.
Refer to Table 3.2.

Table 3.2 Operational errors

Error name Cause of the error Recovery

Paper end (PE)

error

The printer has run out of continuous forms.

Supply forms and load them

into the printer.

Cut-sheet feeder
error

The cut-sheet feeder has run out of cut sheets or has
detected a paper jam.

• Remove the jammed sheet.
Clear any jam.

• Supply cut sheets and load a

cut sheet.

Notes:

1. The printer cannot be set online until these errors are cleared.

2. The paper end is ignored if setup item PPR-OUT: IGNORE is set.

3. A cut-sheet feeder error is detected during paper loading.

The REMOVE PAPER indicator blinks.

When removing the paper on the paper table is required The REMOVE PAPER indicator blinks.
In this case operator must remove paper for loading new paper.
The PS sensor detects this error by reflecting light form the paper or other obstruction.

It also detected by light that is shining into the photo sensor when the paper table is removed.
Therefore (anyway) paper table must be installed correctly.

(3) Fatal alarms

The power shut down by itself.

The printer cannot display the alarm if it detects one of the following alarms that turn off printer power.

Disconnect components or connectors for related alarms, then check the cause of the alarm.

Table 3.3 Alarms that turn power off

Error name Cause of the error

SP motor driver alarm The SP motor driver is faulty. (The motor is driven for an abnormally long

time.)

LF motor driver alarm The LF or CSF motor driver is faulty. (The motor is driven for an abnormally

long time.)

Print head alarm

+34 V over voltage alarm

33

The PAPER OUT lamp blinks with other lamps.

For a circuit malfunction detected in the printer:

• The printer stops printing immediately.

• The ONLINE indicator turns off.

• All buttons of the control panel are invalid.

Table 3.4 Fatal alarms displayed on control panel

Lamp

Alarm name

PAPER OUT

REMOVE PAPER

FRONT DIR

QUIET

AUTO GAP

HI IMPACT

TRACTOR F

TRACTOR R

CUT SHEET

MENU1

MENU2

ONLINE

Condition of occurrence

LES alarm    LES could not be detected

during the space initial

operation.
Space problem
alarm

   The shield board could not be

detected normally by the

LRES sensor.
Fan alarm    The cooling fan for the space

motor and the power supply

was stopped.
HCPP alarm    Switching between cut sheet

paper and continuous forms

paper was not possible.
Overload alarm    An overload occurred during

printing, and tripartite printing

was performed. However,

the power source voltage was

not restored.
Low voltage alarm    The power source voltage

dropped below the specified

level when no printing was in

progress.
APTC gap alarm    During the APTC operation,

paper was detected

immediately after the start of

approach motion, or no paper

was detected.
APTC hop position
sensor alarm

   During the APTC operation,

no reference position was

detected.
ROM/RAM alarm    A sum-check error or

read/write error occurred, or

no CG-ROM is mounted.
Sector protect alarm    A sector protect check of flash

ROM was performed, but no

sector protect information was

found.

 : Blinking
Blank : Off

34

CHAPTER 4 MAINTENANCE

This chapter explains the maintenance levels 1 and 2 for cleaning, lubrication, inspection, and adjustment of the
Impact 3650 printer

4.1 Overview

Designed using the latest technology, the impact 3650 printer offers high reliability and easy maintenance. Parts
requiring lubrication and adjustment have been reduced and the replacement of defective parts made easier than
previous models.

The printers has self-diagnostics and indicates the occurrence of errors on the control panel if the printer
malfunctions.

The printer also has the self-test print and hex dump functions to indicate whether an error is due to printer or the
host and to test operation after error recovery.

4.2 Notes on USE

Note the following:
Do not connect or disconnect connectors or printed circuit boards while power is on.
Use screwdrivers, wrenches, and other tools suited to the parts being replaced. Do not leave screws or parts inside
the printer.
Use only the specified type of oil, grease, and cleaning solutions.
Be sure power is turned off before starting to replace parts.

4.3 Maintenance Tools

Table 4.1lists the tools required for maintenance.

Table 4.1 Maintenance tools

No Tool Model(part number) Maintenance level

1
2
3
4
5
6
7
8

Screwdriver
Screwdriver
Screwdriver
Screwdriver
Tweezers
Spring hook
Long-nosed pliers
Thickness gage
Platen gap adjustment gage
Floil

M2-M2.5(Phillips)(*1)
M3-M5(Phillips) (*1)
M2-M2.5(standard)(*1)
M3-M5(standard) (*1)

0.03 to 1 mm

D98L-1020-0639

*1 A magnetized screwdriver is convenient.

2 For fitting E-ring.

35

4.4 Maintenance levels

Maintenance for the impact 3650 printer is done at two levels.
Level 1 maintenance includes cleaning and lubrication.
Level 2 maintenance includes level 1 items, plus replacement of PC boards, units, and mechanical subassemblies,
and adjustment after replacement.

4.5 Preventive Maintenance

No periodic maintenance is required. However keeping the printer clean lengthens its service life and MTBF

4.6 Part Drawings

This section gives basic components and their location.

Figure 4.1 Part Drawings

Print Head

Card Guide

Carriage

SP Timing Belt

SP Motor

Stay Shaft

Upper Angle

Print Mechanism Unit

Ribbon cartridge

Tractor Unit

HCPP motor

36

4.7 Parts That must not be Disassembled

This section gives the locations of parts that must not be disassembled. Table 4.2 lists components not to be
disassembled and whose mounting screws are not to be loosened or removed.
Parts not to be Disassembled

No. Components Parts Remark

1 Frames (L) and (R) All screws
2 Space motor All screws and pulleys
3 Print head
4 Upper Angle 3 screws
5 Card Guide 2 screws

Gage for Adjustment
is necessary

Figure 4.2 Parts That must not be disassembled

Print head

Space motor pulley

Upper stay screws

Rear stay screws

Front stay screws

Upper Angle

Card Guide

37

4.8 Level 1 Maintenance

Level 1 maintenance includes only cleaning and lubrication and lubrication. These can be performed without
removing covers although Figure 4.3 shows the printer with the covers removed.

Check the impact 3650 printer inside for paper particles, dust, and dirt, and remove these as explained below.
After
cleaning, lubricate moving parts.

Location Cleaning procedure Remarks

Paper path Remove paper particles and dirt
Top of print head Remove ribbon debris, paper scraps, and other contaminants.
Card guide Remove ribbon debris, paper scraps, and other contaminants.
Platen surface Clean the surface with soft cloth *1
Stay shaft Remove dust from the surface of the shaft and clean it with

soft cloth.

Refer to the lubrication
specifications.

*1 If paper becomes smeared or dirty, clean the platen. Use a very small amount of alcohol and wipe with clean

cloth.

Figure 4.3 Cleaning and lubrication

Print head

Stay shaft

Card guide

38

4.9 Level 2 maintenance

Level 2 maintenance includes lubrication, adjustment, and parts replacement.
Level 1 maintenance should be done at the same time.

4.9.1 Parts replacement

Remember the following notes when replacing any component.
Keep working area clean.
Turn off power to equipment and unplug it before disassembled.
Follow procedures carefully. Do not disassemble the parts that are not to be disassembled.
Store disassembled parts in a clean place where they will not get lost.
Check parts for number and shape after replacement, and adjust them if necessary.
Reassemble the printer, following the steps in reverse order of disassembly.
Confirm that all connectors are connected correctly.

39



(1) Tractor Unit removal and installation Front feed tractor.

Front feed tractor.

Removal

1. Raise the paper table.

2. During pressing the Rock lever, Lift the left and right sides of the tractor unit, and then remove the tractor unit.

Figure 4.4 Front feed tractor Removal

Installation

1. Engage the U-grooves on the left and right sides of the tractor unit with the counterpart pins on the printer.
(fit the ditch of left pin, there is any ditch of the right pin)

2. Press down the front shaft of the tractor unit to lock the unit.

3. Make sure that left and right mounting pins 2 have been hooked by lock levers.

Figure 4.5 Front feed tractor Installation

40

Rear feed tractor.

Removal

1. During pressing the Rock lever, Lift the left and right sides of the tractor unit, and then remove the tractor

unit.

Figure 4.6 Rear feed tractor removal

Installation

1. Engage the U-grooves on the left and right sides of the tractor unit with the counterpart pins on the printer.
(fit the ditch of left pin, there is any ditch of the right pin)

2. Press down the front shaft of the tractor unit to lock the unit.

Figure 4.7 Rear feed tractor Installation

41

(2) Cut Sheet Feeder removal and installation

Front cut sheet feeder

Removal

1. Turn off the printer power.

2. Disconnect the cut sheet feeder cable.

3. Raise the paper table, then hold both ends of the cut sheet feeder and pull it off.

Installation

1. Install the cut sheet feeder by reversing the removal procedure.

2. Turn off the printer power.

3. Raise the paper table, then engage the U-grooves on both ends of the cut sheet feeder with the mounting pins on
the printer and lower the cut sheet feeder carefully.
(Push in the cut sheet feeder while aligning label A on the feeder with label A on the right side of the printer.)

4. Connect the cut sheet feeder cable connector to the connector on the front right of the printer.

5. Insert the connector with the arrow side facing upward.

Figure 4.8 Front Cut Sheet Feeder Removal and Installation

Paper table

Mounting pin

Connector

42

Rear cut sheet feeder

Removal

1. Turn off the printer power.

2. Disconnect the cut sheet feeder connector.

3. Raise the stacker table, then hold both ends of the cut sheet feeder and pull it off.

Installation

1. Turn off the printer power.

2. Raise the stacker plate, then engage the U-grooves on both ends of the cut sheet feeder with the mounting pins
on the printer and lower the cut sheet feeder carefully.
(Push in the cut sheet feeder while aligning label A on the feeder with label A on the right side of the printer.)

3. Lower the cut sheet feeder like turning it using the mounting pins as fulcrums.

4. Connect the cut sheet feeder cable connector to the connector on the rear left of the printer.

5. Insert the connector with the arrow side facing upward.

Figure 4.9 Rear Cut Sheet Feeder Removal and Installation

Mounting pin

Stacker plate

Mounting pin 1

Mounting pin 2

Connector

43

(3) Stacker Plate removal and installation

Removal

1. Raise the stacker plate in the direction indicated by an arrow.

2. Stretch the left and right sides of the stacker frame outward to disengage the stacker plate projections from the
frame.

Installation

1. Install the stacker plate by reversing the removal procedure.

Figure 4.10 Stacker Plate removal and installation

Stacker frame

Stacker *1

*1
Actually, there are two kinds of stacker as
follows.

・Standard stacker; small size
・Large Stacker; large size(option)

(Stacker in Figure is Large Stacker.)

44

(4) Stacker Unit removal and installation

Removal

1. While pressing down the lock levers on the left and right sides of the stacker unit, pull out the stacker unit to the
back of the printer.

Installation

1. Install the stacker unit by reversing the removal procedure.

Figure 4.11 Stacker Frame removal and installation

Stacker unit

Lock lever

Lock lever

45

(5) Paper Table removal and installation

Removal

1. After opening the paper table and adjusting it to a tilted position, remove the paper table by lifting it to separate
the left and right protrusions on the paper table ends from the grooves on the cover.

Figure 4.12 Paper Table removal

Installation

1. Insert the left and right protrusions on the paper table ends into the grooves on the cover as
shown in the following figure.

2. Set the paper table in the normal position. (Paper table in the following figure is the Large paper table.) Both
standard paper table and large paper table can be opened or closed in the same way.

Figure 4.13 Paper Table Instillation

46

(6) LAN card removal and installation

Removal

1. Remove the two screws.

2. Remove the LAN card.

Figure 4.14 LAN card removal

Installation

1. Install the LAN card by reversing the removal procedure.

Note; Take care to insert the card into the guide rail correctly.
Setup of a LAN card is necessary. See the online manual in the CD of LAN card.

Figure 4.15 LAN card Installation

47

(7) Flap replacement

Removal

1. Remove the paper table and stacker unit.

2. Remove the flap.

Installation

1. Install the flap by reversing the removal procedure.

Figure 4.16 Flap removal and Installation

Flap

Flap

Paper table

Stacker frame

Stacker plate

48

(8) Ribbon Cassette replacement

Removal

1. Close the front cover, and turn the power on. Then the Print Head move to ribbon replace position.

2. Turn the power off. And Open the front cover.

3. Press the ribbon release levers located on both side of the cartridge and carefully lift the cartridge out of the
printer.

Figure 4.17 Replacing the Ribbon cartridge

Installation

1. Remove the new ribbon cartridge from its package. Push in the sides of the two ribbon release tabs. The tabs

will snap into the cartridge and the ribbon feed mechanism will engage.

2. Turn the ribbon feed knob clockwise to be sure that it feeds properly.

Figure 4.18 Preparing the Ribbon cartridge

49

3. Place the two mounting pins on the ribbon support brackets of the head cartridge. (The two mounting pins are
located on the sides of the ribbon release levers.) Insert the ribbon so that the ribbon falls between the nose of
the print head and the plastic print guide.

Figure 4.19 Installing the Ribbon cartridge

4. Turn the ribbon feed knob clockwise to tighten the ribbon.

5. Close the front cover of the printer.

Note:
The buzzer may sound if the print head is moved while the power supply is ON.

50

(9) Print head replacement

Caution Hot



At printing or after printing, print head is high
temperature. Donʼt touch the print head still cool.

Removal

1. Turn off the printer.

2. Open the front cover of the printer and remove the ribbon cartridge.

3. Pull the left end of the head lock wire forward to release it from the hook at the left of the print head carriage.

4. Then release the wire from the center hook.

5. Release the wire (under the head) on the left side.

Figure 4.20 Print head removal

6. Remove the print head from the connector on the carriage, as shown in the figure below.

Figure 4.21 Removing the Print head from connector

Installation

1. Install the print head by reversing the removal procedure.

51

(10) Control Panel Unit removal and installation

Removal

1. Open the front cover.

2. Unhook the control panel case at three positions, then pull out the control panel unit to the front.

3. Disconnect cable from the control panel board.

Installation

1. Install the control panel unit by reversing the removal procedure.

Figure 4.22 Removing the Control panel

Three hooks

52

(11) Front Cover removal and installation

Removal

1. Open the front cover .

2. Pull The hinge of the Front Cover slantwise then remove the front cover.

Installation

1. Install the front cover by reversing the removal procedure.

Figure 4.23 Removing the Front cover

Front cover

53

(12) Upper Cover removal and Installation

Removal

1. Remove the control panel.

2. Remove the two screws securing the upper cover.

3. Raise the paper table.

4. Disengage the hooks on the front left and right of the upper cover, then lift off the upper cover.

5. Remove the paper table.

Installation

1. Install the paper table.

2. When installing the upper cover, pass the control panel cable and cover open switch cable through the
openings on the upper cover and control panel holder.

3. Hereafter, follow the removal procedure in reverse order.

Unhooking on the left

Unhooking on the right

Figure 4.24 Removing the Upper cover

Screw

Upper cover

Hook

Hook

54

(13) Print Mechanism Unit removal and installation

Removal

* Do this work on a no slippery level bench so that the mechanism can be tilted stably during replacement.
On a slippery surface like paper, the printer may slide when
the mechanism is tilted. It deteriorates the work efficiency.

1. Remove the upper cover.

2. Access the mechanism assembly from the back of the
printer.

3. Hold the rubber foot and the side plate.

4. Slowly hold up the mechanism unit on the upper

side.(１)

Note; Too high position cause unplug the
connector. So be carefully.

5. Move the mechanism unit about 2cm to the right (when
looking form back of the printer) and then put the rubber
foots of the front of mechanism unit above the mounting
projection of lower cover(2).

6. Keep the left hand holding side plate. and then move the right
hand to the rear of the mechanism unit(3).

7. Lift up the rear of the mechanism unit(4).and then place the tilt
bar hole of the rubber foot(5)and hole of the lower cover to
support mechanism unit.

Figure 4.25 Print Mechanism Unit removal and installation

Rubber foot

Side plate

Mounting projection

Tilt bar storing
position

Tilt bar standing
position

Note
Be careful not to catch studs in a
lower cover.

Tilt bar

55

8. Unplug cables from mechanism unit.
(SP motor ,LF motor, TR motor, Carrier cable (3 flat cables),RCSF cable, Relay cable. Total 8 cables)

9. Lift the mechanism unit higher and remove it.

Figure 4.26 Print Mechanism Unit removal and installation

Installation

1. Install the mechanism assembly by reversing the removal procedure.

Note: The following adjustments are required after installation:

- Bi-directional printing positions

- Auto loading positions

- Skew detection

Relay cable

LF Motor cable

TR Motor cable

R-CSF

Carrier cable
(3 FFC Cables)

SP motor cables

Although not drawn a picture, there is also
the following cables in fact.

・SP FAN cable
・INLOK cable

56

(14) Power Supply Unit removal and installation

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Remove the 3 screws securing the power supply unit.

4. Disconnect the AC switch assembly connector, reactor connector, and power supply unit connector, then
remove the power supply unit.

Installation

1. Install the power supply unit by reversing the removal procedure.

2. Counter reset should be done after Power Supply Unit replacement.

Figure 4.27 Power Supply Unit removal and installation

Power supply unit connector

Power supply unit

Screws

AC switch assembly

57

(15) ROM Board (Main Board) replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Remove the LAN cables. Remove the bracket (2 screws).

4. Remove the 6 screws securing the ROM board (4 on the top and 2 on the side), and remove the ROM board.

5. The memory chip on the ROM board contains printer information (setup and counter data). Remove it from
the old ROM board and mount it on the ROM board to be installed.

Installation

1. Replace the NVRAM (memory chip) to put adjustment and set up information from old board into the new
board.

2. Install the ROM board by reversing the removal procedure.
Mount the memory chip on the IC socket with the dent facing the printer cable connector.

To reset the NVRAM see the procedure as follows.
(Note, Resetting NVRAM requires adjustment and setting up. If you don’t know set up value don’t reset
NVRAM)
To all clear NVRAM ;
To reset SET-UP ;











Figure 4.28 Rom board removal and installation

Screws

Memory chip
(dent side)

Screws

ROM Board

Screws

connector

NVRAM

LAN Card slot

Don’t mount the memory chip
in the wrong direction

58



(16) LAN RELAY PCA / LAN cable 17P replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Remove the two LAN cables. Remove the bracket (2 screws).

4. Remove the screws securing the LAN RELAY PCA.

5. Remove the LAN cable 17P.

Installation

1. Install the LAN RELAY PCA / LAN cable 17P by reversing the removal procedure.






Figure 4.29 LAN RELAY PCA / LAN CABLE 17P removal and installation



Two LAN cables 17P

Screw

LAN RELAY PCA

Screws

Bracket

59



(17) RS232C BOARD replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Remove the two exclusive screws and RS232C BOARD.

Installation

1. Install the RS232C BOARD and two exclusive screws by reversing the removal procedure.




















Figure 4.30 RS232C Board removal and installation



RS232C BOARD
With two exclusive screws

60



(18) AC Switch ASY removal and installation

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Remove the AC switch assembly from the lower cover.

Installation

1. Install the AC switch assembly by reversing the removal procedure.

Figure 4.31 AC Switch ASY removal and installation

AC switch assembl

y

Red(upper side)

White(lower side)

61

(19) Inlet ASY replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Remove the two screws securing the inlet and one screw securing the frame ground wire, and 4. remove the
inlet assembly.

Installation

1. Install the inlet assembly by reversing the removal procedure.

2. Regarding the connecting cables, refer to the front page.

Figure 4.32 Inlet ASY removal and installation

Inlet ASY

Screws

Screw

62



(20) FAN UNIT 2 replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Remove the FAN UNIT 2 cable from ROM BOARD.

4. Remove the two screws securing the FAN UNIT 2.

Installation

1. Install the FAN UNIT 2 by reversing the removal procedure.

Figure 4.33 FAN UNIT 2 replacement

FAN UNIT 2 CABLE FAN UNIT 2 Screws

63



(21) Control Panel Cable replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Remove the FAN UNIT 2.

4. Remove the 4 operator cable covers and then disconnect the operator cable from the ROM board.

Installation

1. Install the control panel cable by reversing the removal procedure.

Figure 4.34 Control Panel Cable replacement

Figure 4.35 bending size of control panel cable

ROM board

Control Panel cable

64



(22) F-CSF Cable/CSF Connector PCA replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Remove the FAN UNIT 2.

4. Disconnect the cable from the front CSF PCA connector.

5. Remove the two screws securing the front CSF PCA to remove the PCA.

Installation

1. Install the front CSF PCA by reversing the removal procedure.

Figure 4.36 bending size of control panel cable

Bending the front CSF cable (KA02027-Y192)











Figure 4.37 bending size of Front csf cable

Front CSF PCA

Screw

Cable

65



(23) R-CSF Cable/CSF Connector replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Remove the screw securing the rear CSF PCA and remove
the PCA.

Installation

1. Install the rear CSF PCA by reversing the

removal procedure.

Figure 4.38 R-CSF Cable/CSF Connector replacement

Bending the rear CSF cable (KA02022-Y191)

Figure 4.39 bending size of Rear csf cable

Screw

CSF CONNECTOR

R-CSF CABLE

66



(24) Relay Cable replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Disconnect the relay cable from the sensor PCA connector.

Installation

1. Install the relay cable by reversing the removal procedure.

Figure 4.40 Relay cable replacement

Relay cable

Sensor PCA

67



(25) Sensor PCA replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Disconnect the mechanism cable and flat cable from the sensor PCA connectors.

4. Separate and remove the sensor PCA from the two saddles by using long-nosed pliers.

Installation

1. Install the sensor PCA by reversing the removal procedure.

Figure 4.41 Sensor PCA replacement

Sensor PCA

Saddles

Flat cable

68



(26) SP Motor ASY replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Loosen a screw securing the fan unit and turn the fan unit so that the screws securing SP motor may be removed

4. Remove the screws securing SP motor.

5. Remove the SP motor while loosen the tension pulley by (-) driver.

Installation

1. Install the SP motor assembly by reversing the removal procedure.

Note:
After installation, the following adjustment is required:
Bi-directional printing position
























Figure 4.42 Sp motor removal and installation

Screw for
FAN unit 1

FAN unit 1

Screws for
SP MOTOR

Tension Pulley

69



(27) LF Motor removal and installation

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Remove the idle gear

4. Remove the screws fixing lf motor

5. Remove the LF motor from inside of side frame.

Installation

1. Install the LF motor by reversing the removal procedure.







Figure 4.43 LF motor removal and installation

Screws

Idle Gea

r

LF Moto

r

Note
LF bracket needs adjustment. Putting the mark
before disassembly is gives aim to adjustment for
assembly.

70



(28) TR Motor removal and installation

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Remove the shift gear and shift spring.

4. Remove the two screws securing the TR motor.

5. Remove the TR motor from the side frame.

Installation

1. Install the TR motor by reversing the removal procedure.



















Figure 4.44 TR motor removal and installation



Screws

Shift spring

TR motor

Shift gear

71



(29) APTC Unit replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Remove the two screws and APTC bracket.

Installation

1. Install the APTC unit by reversing the removal procedure.

Figure 4.45 APTC Unit removal and installation

Screws (APTC bracket)

APTC bracket

APTC motor

Screw (APTC motor)

（backside）

Push against the bracket to the stud in
the direction of right and lower side.

72



(30) HCPP Motor replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Remove the HCPP gear.

4. Remove the two screws securing the HCPP motor.

5. Disconnect cable from the sensor PCA connector, then remove the HCPP motor from the side frame.

Installation

1. Install the HCPP motor assembly by reversing the removal procedure.



















Figure 4.46 HCPP Motor removal and installation

HCPP M

otor

Screws

Ｅ-ring

H

C

PP

Gear

73



(31) SP FAN motor replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Remove the screw securing the bracket , then remove fan unit.

Installation

1. Install the fan unit by reversing the removal procedure.




Figure 4.47 SP fan removal and installation

Screws

FAN UNIT 1

74



(32) INLK SW ASY replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Remove the SW holder and INLK SW ASY.

Installation

1. Install the INLK SW ASY by reversing the removal procedure.



























Figure 4.48 INLK SW ASY removal and installation



INLK SW ASY

SW holder

INLK SW ASY

SW holder

75



(33) PS PCA replacement

Removal

1. Remove the upper cover.

2. Release the PS PCA from the three hooks on the PS holder.

3. Disconnect the cable from the connector and remove the PS PCA.

Installation

1. Install the reactor by reversing the removal procedure.



Figure 4.49 PS PCA removal and installation

PS PCA

PS holder

Cable

76



(34) HCPP switch ASY replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Remove the rubber foot from side frame L, then unhook the holder at two locations.

4. Disconnect the cable from the sensor PCA connector, and remove the HCPP switch assemble.

Installation

1. Install the HCPP switch assembly by reversing the removal procedure.




















Figure 4.50 HCPP switch ASY removal and installation

Side frame L

Holder

HCPP SW ASY

Rubber foot

77



(35) Sensor cover TR/TR PES ASY replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Unhook the sensor cover TR and remove the sensor cover TR.

4. Unhook the TRPES ASY and remove the TRPES ASY.

5. Disconnect the TRPES ASY connector.

Installation

1. Install the TRPES assembly and sensor cover TR by reversing the removal procedure.













Figure 4.51 Sensor cover TR/TR PES ASY replacement

sensor cover TR

TRPES ASY

78



(36) Ribbon Rope ASY replacement

Removal

1. Remove the upper cover.

2. Remove the springs on the left and right side of ribbon rope.

3. Remove the ribbon rope.

Installation

1. Install the ribbon rope. If necessary, remove the ribbon bracket to lead the ribbon rope under the ribbon pulley.
(To remove the ribbon bracket release the craws of the ribbon bracket hooking the carriage.)

2. Check the direction of turning.

3. Hook two springs left and right side of ribbon rope.

Figure 4.52 Ribbon Rope ASY replacement

Direction of turning

Ribbon pulley

Ribbon Ro

p

e ASY

79



(37) Card Guide ASY replacement

Removal

1. Remove the upper cover.

2. Remove the screws securing the upper guide F on its left and right, and release it to the front.

3. Remove the print head.

4. Disconnect the TOF1, TOF2, and panel keyboard cables from the carriage PC board.

5. Remove the two retaining screws, and remove the card guide assembly while turning it.

Installation

1. Install the card guide assembly by reversing the removal procedure.

2. Improper cable forming may cause the breaking of wire. See next page to form the wire appropriately.

3. After installation, the following adjustments are required:

- Card guide attaching position

- TOF sensor output

- Auto loading position

- Printing positions at paper end

- Left printing start position

- Skew detection

Figure 4.53 Card Guide ASY replacement

Screws securing the card guide assembly

Panel keyboard cable

TOFL cable

Upper guide F

TOFR cable

80

Proper cable forming of card guide.

1. Lead the cables in front of the guide part of the carrier frame (aluminum die-cast parts).

（Don’t lead wires between the guide part and upper guide R or breaking wire may cause because of cables get

into touch with upper guide F.）

2. Lead TOF L and APTC cables inside a rib behind the

mark.

3. Insert the extra length of TOFL cable into the place of “A”.

4. Insert the extra length of TOFR cable into place of “B”.

Figure 4.54 Card Guide cable forming

Guide part of the carrier frame

Upper guide Ｒ

mark

Place ”A” for extra length

Place ”B” for extra length

81



(38) TOFL/R sensor ASY replacement

Removal

1. Remove the upper cover.

2. Remove the screws securing the upper guide F on its left and right, and release it to the front.

3. Remove the print head.

4. Disconnect the TOFL/R cable from the carriage PC board.

5. Remove the small screws by precision driver, and remove the TOFL/R sensor.

Installation

1. Install the TOFL/R sensor assembly by reversing the removal procedure.

2. After installation, the following adjustments are required:

- TOF sensor’s voltage adjustment

- Top-of-forms adjustment (factory use)

- Skew detection value adjustment

Figure 4.55 TOFL/R sensor ASY replacement

TOFL sensor ASY

TOFL sensor ASY

82



(39) Carriage Unit and Stay Shaft replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Release the upper guide F to the front.

4. Remove the SS gear, gear B.

5. Remove the stay bearing and the stay shaft.

7. Remove the SP belt while pressing the tension bracket.

8. Remove the carrier cable holder.

9. Remove the card guide from the carrier.

(If you don’t have head gap jig don’t remove upper angle.)

10. Remove the carrier unit

Figure 4.56 Carriage Unit and Stay Shaft replacement

Installation

1. Install the Carriage Unit and Stay Shaft by reversing the removal procedure.

2. When insert the stay shaft, take care of the oil felt inside the carrier hole.
Refer to lubrication inspection.
The following adjustments are required:

- Print head gap adjustment (for upper angle).
(You may omit, when having not loosened the screw.)

- Card guide position adjustment

- TOF sensor’s voltage adjustment

- Vertical Alignment (V-ALMNT) adjustment

- Top-of-forms adjustment (factory use)

- Skew detection value adjustment

Removing print head and card guide is
necessary to remove carrier unit
without removing upper angle.

Note.
Don’t remove the screws for upper
angle. Head gap jig is necessary to
fasten them.

Screws for upper angle

Carrier cable holder
Slide it to remove it.

Carrier cable holder is behind the carriage.
Slide it to remove it.

83



(40) SP Timing Belt replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Remove the carriage unit.

4. Remove the belt clamp.

5. Remove the timing belt.

Installation

1. Install by reverse order

2. The following adjustments are required:

- Print head gap adjustment (for upper angle)

- Card guide position adjustment

- TOF sensor’s voltage adjustment

- Vertical Alignment (V-ALMNT) adjustment

- Top-of-forms adjustment (factory use)

- Skew detection value adjustment

Figure 4.57 SP Timing Belt replacement

Difference of teeth position shall be
less than 1 teeth.

Belt Clamp

Belt

Belt Clamp

84

(41) SP Tension bracket replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Remove the SP motor.

4. Remove the stay bearing so that stay shaft falls downward.
(Therefore the purpose of this work is for increasing space for the work which removes a spring, it is
omissible.)

5. Remove the tension pulley.

6. Remove the tension spring.

(1)Please hold firmly the hook part on the left side of a tension

spring (above) on long nose pliers.

(2) Attach thumb of left hand to a frame and attach index finger to a

pliers. And pull the pliers left by gripping force of left hand, so
that spring hook removed form tension bracket.

(3) Remove a tension bracket from a frame portion.

Figure 4.58 Removing SP Tension spring and SP tension bracket

Removing tension pulley

Tension bracket

Tension Pulley

Be careful not to give a crack to a
shaft.

85

Installation

As shown in the right figure, build a tension spring into a new tension bracket.

Please attach a new tension bracket and a new spring in a frame.

Attach the tension spring

(1)Hold firmly the root of a spring hook by long nose prier..

※Be careful not to give a crack to a shaft.
※It is desirable to work carrying a paper on a stay shaft and

protecting.

(2) Attach thumb of left hand to a frame and attach index finger to a pliers. And pull the pliers left by gripping
force of left hand, so that spring hook is installed hook part of upper stay..



Install subsequent process by reverse order
The following adjustments are required:

- Vertical Alignment (V-ALMNT) adjustment

Figure 4.59 Installing SP Tension spring and SP tension bracket



86



(42) LF Timing Belt replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Put the mark to memory the LF tension bracket position. .

4. Remove the LF tension bracket and remove the LF belt.

Installation

1. Install the LF timing belt by reversing the removal procedure.

2. Install the LF tension bracket while aligning it with the marking and secure it with a screw.

Note:
After installation is finished, the following adjustment is required:
LF belt tension















Figure 4.60 Replacing the LF timing belt

Lf tension bracket

screw

LF belt

Put the mark before
disassembly

87



(43) Platen Roll replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Before remove the LF tension pulley ASY put the mark to memory its adjusted position.

4. Remove the LF tension pulley ASY and LF belt and Pulley gear.

5. Remove the Platen gear, Flanges, DV gears.

6. Remove the slide cam.

Figure 4.61 Removing the Platen roll

Flange

DV roller gear

Platen gear

E ring

LF tension pulley ASY

Slide cam

Pulley gear

LF belt

88

7. Turn down the mechanism assembly.

8. Disconnect cables backside of printer mechanism unit, remove 6 screws of lower plate.

9. Remove the bearings and slide in the direction of allow then remove it.

Note:
Take care of jamming cables together when install platen cover.

Figure 4.62 Removing the Platen roll

Installation

1. Assembly by reverse order the removal.

Note Lubrication is necessary to right and left shaft of Platen roll.
(Refer to lubrication tables)



Platen roll

Screws for lower plate

89



(44) Nip Spring 1/2 replacement

Removal

1. Remove the upper cover.

2. Unhook four nip springs 1 (two on each end) and four nip springs 2 (two on each end), and remove the springs.

Installation

1. Install nip springs 1 and 2 by reversing the removal procedure.
















Figure 4.63 Nip Spring 1/2 replacement



NIP spring2(black)

NIP spring1(silve

r

）

90



(45) Nip Roller replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

2. Unhook one sides of 4 nip springs and remove 4 spring holders.

3. Remove the E ring of both side and Nip gear on the left side.

4. Remove the flanges, slide cam, OC cam and bearings..

5. Lift and slide the Nip roller to the right. And remove it from its left end.

Figure 4.64 Nip Roller replacement

Installation

1. Assembly by reveres order.

（Lubrication is necessary refer to lubrication table）

E-rings

Nip gears

OC Cams

Slide CAM Flanges

Bearings

91



(46) DV Roller ASY replacement

Removal

1. Remove the upper cover.

2. Remove the printer mechanism assembly.

3. Remove the LF bracket (one screw) and LF belt.

4. Remove the two flanges (two E-rings), two DV gears, two nip gears (two E-rings), and one platen gear (one
E-ring) from the left of the mechanism assembly.

5. Remove the slide cam and OC cam from the left side of the mechanism assembly.

6. Remove the bearings from the left side of the mechanism assembly.

Figure 4.66 Removing DV Roller

7. Remove 3 e-rings, 2 flanges and slide cam at right side of printer mechanism.

8. Remove the OC cam and bearing at right side of printer mechanism.

9. Remove 4 screws fixing lower guide at left and right side.

Figure 4.65 Removing DV Roller

92

10. Remove 8 screws fixing lower guide at base side and front and rear side.




Figure 4.66 Removing Lower Guide

11. Shift the lower guide a little upward.

Screws

Screws

93

12. Remove the lower plate.
Disconnect cables backside of printer mechanism unit, remove 6 screws of lower plate.

13. Slide the DV rollerr assembly direction of arrow, then remove it.

Figure 4.67 Removing DV Roller

14. Replace assembled parts on the DV roller.

Installation

1. Assembly by reverse order the removal.

Note Lubrication is necessary to right and left shaft of Platen roll.
(Refer to lubrication tables)

NOTE）after installation, the following adjustment are required.

(1)LF belt tension Note Lubrication is necessary to right and left shaft of Platen roll.
(Refer to lubrication tables)

Screws for lower plate

94



4.9.2 Adjustment

(1) Print head gap adjustment

Note:
This adjustment needs the head gap adjustment jig (special dial gage), so this part is parts that must not be
disassembled. If you don’t have head gap adjustment jig, don’t adjust this portion as much as possible.

Procedure

1. Attach the head gap adjustment jig on the carriage.

2. If necessary open the upper guide F open.

3. Move the card guide upper side.

Figure 4.68 Attach the print head gap jig

4. Rotate the SS gear (located at the left side of the stay shaft) clockwise (this direction makes the head gap
narrow) until its stopper touches the stopper (studs) of the side frame.

Figure 4.69 Rotate SS gear

SS gear

Stopper of SS gear

Stopper stud

Head gap adjustment jig

Upper guide F

Direction of moving card
guide.

95

5. Slightly loosen the three screws(a),(b) and (c) on the upper angle.

Figure 4.70 Adjustment head gap

6. Slide the carriage unit to the left end (1st column side)

7. Move the upper angle back and forth so that the head gap may have value A, then fasten the screw(a).

8. Slide the carriage to the right end (136 column side) and move the upper angle back and forth so that the head
gap may have value A, then fasten the screw(c).

9. Center the carriage unit and move the upper angle back and forth so that the head gap may have value A, then
fasten the screw(b).

10. Slide the carriage unit to the left, center and right, and the check the value A at each position.

11. If the head gap doesn’t have value A, loosen the screw at that position and move the upper angle back and

forth again so that the head gap may have value A, and then fasten the screw.

12. If the head gap has value A at the left, center, and right positions, that’s all for this adjustment.

Screw(a)

Screw(b) Screw(c)

Upper stay

Hole for adjustment

Upper angle

A=0.00mm±0.01mm

96

(2) Card guide position adjustment

Note:
For improve the precision using the head gap adjustment jig is better.
If you don’t have the head gap adjustment jig refer to the another procedure which comes out behind

[Using the head gap adjustment jig]
This adjustment should be done after print head gap adjustment is finished.

1. Attach the head gap adjustment jig on the carriage.

2. Open the upper guide F open.

3. Place the carriage to the ribbon replace position.

Figure 4.71 Attach the head gap adjustment jig

3. Enter adjustment mode
Turn the power on while pushing “

”SW and “ ”SW of operation panel. Then printer enters the adjustment

mode. Any motors don’t move in this mode.

4. Loosen the card guide mounting screws slightly (to an extent where the card guide doesn’t drop towards the
platen).

5. Place one sheet of 1p-55kg paper between the card guide and platen at the APTC switch side.

Figure 4.72 Insert paper for adjustment

Screw

Screw

1P 55Kg paper

t=0.08

APTC SW

Platen

Head gap adjustment jig

Upper guide F

Card Guide

97

6. Adjust the head gap to value A, by turning the SS gear.

Figure 4.73 Rotate SS gear

7. Move the card guide up and down so that APTC SW should be switched into conducting state at the head gap is
value A. (The value A should be checked during the SS gear is rotating in the direction of clockwise.)

8. Slope of card guide should be as follows.

Figure 4.74 Adjustment and check inclination of card guide

A=0.25mm±0.01mm

Stopper of SS gear

SS gear

Stopper stud

About 15 mm

Gap confirmation area

Platen

APTC SW

1P 55kg

t=0.08

98

9. Check the gap between the print head and paper after APTC function is operated.

Turn the printer off immediately after printing is started. Check the value B by head gap adjustment jig. If the

Value B is as follows adjustment is finished.

Figure 4.75 Check the gap after APTC operate

B=0.29mm±0.03mm

Paper

Platen

Dial gage

Head gap adjustment jig

Platen

Paper

99

(3) Card guide position adjustment (another way)

[Without the head gap adjustment jig]
This method uses the gear that is next to the motor pinion instead of head gap adjustment jig.
This adjustment should be done after print head gap adjustment is finished.

1. Remove the print head.

2. Open the upper guide F open.

3. Rotate the motor pinion counterclockwise until stopper of SS
gear touch against the stopper stud.

Note Please make sure to rotate gears by motor pinion.

4. Put the “MARK 1” as the base position.
Put the “MARK 1” on the tooth of the gear's, and put the mark
bracket at same position.

5. Put the “MARK 2” as the aim for adjustment.
Rotate the motor pinion clockwise to rotate drive gear by 10
teeth. Then put the “MARK 2” to the tooth, which becomes ten
pieces from the “MARK 1”.
And then rotate the motor pinion clockwise to rotate drive gear
by 2 teeth.

6. Insert the 8 parts of paper into the right of card guide and platen.
This spacer should be made as follows.
Fold the A4 size paper 3 times.
Total thickness of papers should

be 0.65±0.1mm

Figure 4.76 other way to adjust the card guide

Motor pinion

Stopper

SS gear

MARK 1

MARK on bracket

Drive gear

MARK 2

10

t

h

from

“MARK 1”

T

h

i

sprocedure finished at 12

th

tooth

Paper tip insertion point

100

7. Fasten the rightside screw temporly
Fasten the right side screw during pushing right potion of curd
guide by light force.

8. Remove the inserted paper.

9. Enter the adjustment mode.
During pushing the “

”,” ”SW, turn the power on.

10. Adjust the position of the card guide

Lower the left side of a card guide little by little until the

buzzer sounds, and then fasten the screw temporally.

The buzzer sounds during the APTC detect SW is pushed. To stop

the buzzer rotate motor pinion clockwise.

11. Check the drive gear position when the buzzer sound.

Once turn clockwise until buzzer is stop, and then turn the
motor pinion gear counterclockwise until buzzer sounds.
On an ideal target “MARK 2”agree the mark on the bracket.

±2 tooth is a permission level.

When the buzzer start souding, “MARK 2”is on the righte of
the mark on the bracket, upper the card guide.
When the buzzer start souding, “MARK 2”is on the left of the
mark on the bracket ,lower the card guide.

12. Fasten the screws.

Check result is ±2 teeth, and then fasten the screws.

After fasten the screws. Check again and check result is less
than two teeth it can finishe adjutment.

Figure 4.77 other way to adjust the card guide



Fix temporary

Fix temporary

Frame mark

Mark 2

Displacement should be less than 2