fur ~ Schreibmaschine Pr. 2000i (LW-710i) | aaa und ts

‘Quelle | | | | oe Ae.

Technische Unterlage 037.216.9

KUNDENDIENST 105.3 834

Servicemanual

_ fur

~ Schreibmaschine

Pr. 2000i (LW-710i) |

aaa und ts

Pr. 20011 (LW-7301)

ickedanz AG & Co.

entralleitung Duisburger Str. 57, 90451 Nurnberg

d die giiltigen Sicherheitsvorschriften zu

Q h Nachdruck nicht gestattet _

Kundendien Anderungen vorbehalten

Bei allen Reparaturen sind die gu

beachten!

SERVICE MANUAL a

CONTENTS |

PART 1 Theory of Operation

Chapter 1 Mechanical Theory .......2.2eceseeeee teen renee ence eee eene neces 1

4. INK JET PRINTER .....0 0. ccc cece eee eee e ee tent nnn nnes |

1.1. Ink Jet Printer System Configuration itidueeee Ado @ad hand aaa we pleltetanie diate oie ceanlaras sad 2

1.2 Ink Jet Printer Operation .... 0... cece eee teen e eens 3

41.2.1 Carriage Assembly 0.6... 66. cece ete eee e nent e nee 3

1.2.2 Carriage Motion Control 0.0.2... ccc cece eee eee eee eee nen n eee e ene eenes 5

1.2.3 Line Feed System ........ 0. ccc eee ent ee es 6

1.2.4 Paper Feed & Adjustment System .............-- Sepa Rag AAR AN ie mala acees 7

1.2.5 Maintenance Station Operation ..............06- fla aia Vola gtésbeh ead sucveriede aie ai 9

1:2:6> “SONSOIS i... ean eee does US Aa ee ae GM dee ieee BSS Hee tee hs 13

4.3. INK CHG (Ink Change) Functions ........... 6. ec ccc cece eee e tenn tents 15

4.3.1 Ink Cartridge Installation/Replacement ....... 6.6665 e cece serene teen eee eee 15

1.3.2 Automatic Printhead Cleaning (Purging) ..........-- 6s ee ee eee e eee eens 15

2. KEYBOARD.............+- id athens taste a alyssa oe See eI 16

Bo NLODies elk nets Vie h oid oa Gia Wattle Le eaten ete dea ee od de eels ea as 18

7. amy + \ >) Sane near ee Oe eae re eee eee rea 20

Chapter 2 Electrical Theory .......+ceceeeeeeeecseeees dubomnaxiouceuety 21

-4. SYSTEM CONFIGURATION ........ 0.00.6 cece ee eee eee ene aes Sohed MOORS 21

1.1. Power Supply PCB (printed circuit board) .........-. sce eee ee eee eee eens 21

1.2 Keyboard PCB (FPC: Flexible Printed Circuit) ......... 00... eee e eee eee ener ene 21

1.3. Main PCB (printed circuit board) ........ 2... cece tenet cnet ene 21

1.4 FDD (floppy disk drive) Module ............. eee e eee eee nent ene nees 21

41.5 LCD Module (Liquid Crystal Display) .......... 0. eee ee eee ence eee teenies 21

> INKJET PRINTER CONFIGURATION ....... 0.00. cece cee cece eee teen ees 23

2.4 Ink Cartridge ....... 0. renee ene e nent e nee e renee 23

2.2 Carriage Motor ................ gba ianto ia acala Soaaaadee tag aiiiaa i drectca de Meant ag Neca 23

2.3. Line Feed Motor ......... 0.20. cece cee ee cee eee enter ener cece tenn aneeees 23

2.4 Carriage Index (Home Position) Sensor ........ 56. c cece eee een ence eee 23

2.5 Paper—end Sensor ..... 6... e eet ete e nents ee 23

SERVICE MANUAL

MAIN PCB AND PERIPHERALS ..........- 6. eee c eee eee ence teen eee teen ees 24

3.1 CRU'PCB) ns S6cc02e%ecel eG te a nae easels deeds ead eet wees BR ee ae oe 25

3.2 ROM1 #1.......... s tayatrdeng hbaand e aecl UN adi aie moa eee b nie Maw Sasa tag ee 25

3.3 ROM2 #2 (if present)... eee eee ees 25

SA “Main RAM 2s cctecies valle toe De iste hd a ae eR age ee arimcblg A Ew Ee 25

35°. Video ‘Gale Altay so. ib oS aid oe tee GLa Ne ee ted eae eae Re ee 26

3:6° _ ‘Printer Driver Circuits: «sec. sou fos eo ee tas Baan e ta See aie Bee eh a te eA 26

3.7. Printer Gate Array ...........0..0.000 ee weil thas i ch ie sale th ated sachs tee Reaper Caine 26

3.8 FDC (Floppy Disk Controller) .................2.0065 ee ere eer ee 26

359°. “Clock Circuit si..c ooo ohn Sa acd ad Cae acca Ls ee Le i ee eee, 1S Ee eee ee 28

3.10 Reset Circuit 0.0.0... ccc ccc ec eee eee ee nett penne bene een eees 29

3.11. Buzzer Drive Circuit.......:.... kde tek a So Neca Se Cot ma Bet ec) aa tactas tS od rat 30

3.12 Memory Map........ 2.06. cece cece teen eee teen n nee e tee ennenes 31

SAB. WO:Map cess, otic OF we syew foctne ede dinate a Old, geen iene ade hag eine Cee eee evga ele ster sl

3.14 Country Specification Change-over ........ dg oa avi Peates Sia ge acevo tsbeat ee ed sat Seach Geren Mana gE 33

3.15 ROM Configuration Mode Change-Over ............. od Sieh dapeisnnalsloe SEE a aR es 35

PRINTER CONTROL .......... 0. cece cee reece tee ce eet eet e teen eee e renee 36

4:4 InkJet Head! Conttol cia icccc es ie ta ss Rae G a Ole phan oe eK Ree Rha he ee ee 36

4.2 Carriage Motor Control 2.0... eee ee een ee nn eee e enna 38

4.3. Line Feed Motor Control .......... 0.06 ccc cece eee eben ee eee 39

- 4.4. Carriage Index (Home Position) Sensor ..... 6... cece eet teeen ene 2... 40

4.5 Paper-End Sensor ........ 0.06 cece rnc c etree cen tent ee eneenenes ee 41

KEY BOARD PG Bina. es sees etek aie eb 4 ote was Vine Mead ol cote yds OGGinG, 4 teats 42

5.1 FPC Operation ...... ccc cece cece cece eee tegen eee rete en eee eters een ens 42

§.2 Keyboard Scan... ce cece ene e teen arene een enennns 42

5.3. Keyboard Control Circuit 2.0.0.2... cece eee eee eee Lava bidasvarh Maratea Sie whigie Meta 43

LOD:*MODULE (220.0284 Se Saree baw sed cists PEAR Bree are ARISE ee Ges Oe Pete ol ees SEs 45

6:4 - LOD Control) essen cae chee a Sse Siale ohtereevars eae ie eld ape old Qadana diac pS ele ade ales’ 46

6.1.1. Video Gate Array (#7) ........... 0. e eee repeated hire ass aad wees 46

6.1.2 Character Configuration ............ 0. ccc ee eee erent enes 46

6.2 LCD Module Operation 2.0.0.0... 6c ccc ccc cece ere eee een n eee enennene 47

-6.3. LCD Drive Voltage (VEE) Generation Circuit ...... 0... cece cece nee 50

SERVICE MANUAL

FDD (FLOPPY DISK DRIVE) CONTROL ........6. 6-0. eee tee eee eens Ree

7.1. FDD Configuration .......0. 0.00. ccc nee e eet ee teen t neta eens 51

7.2 FDD Operation .............. 00... cece ees ee ee eee er 52

72:1. Basic: Operation: 2.5.0 c cease haw else oa yale ta ek wl elie Weal Wad 52

7.2.2 Interface between CPU (#1) and FDC (#8) .... 0... cece eee 52

7:3: sFDD Module tecceec sc aban gee ees Peete Saye inteles tnas sruotite eoure TAR cas 53

7231. “Read/Write: Circuit. oe Ses icine sce SERS Ree eR Ral ae hg Soo 53

7.3.2 Motor Drive Circuit .............0. 000s sSisa than buat ahd acn ters cavefehicaarc tere uareareads 53

735° Sensor Citealite: oe cake bee Las oes tees Sa ee RS Lead 53

7.4 FDD Performance Specifications ........... 0. cee eect ete eee nena 54

POWER SUPPLY PCB ..... i ok ac inlac bach ONE aac tension Perea 2 ta See tle .. 55

8.1 Configuration ©... 2.6... cece cee erent teen tenet ees peated OS

8:2. Circuit. ii terete Sh te fe Saks ongle dass ied racanll ahoseahctcie ea hae Saat aoe wwe yee ore ea eases 56

PART 2 Component Repair

Chapter 3 Troubleshooting ........ Deena cg ekaia ie metas hans re eee 57

INFRODUGTION! secocotes. cae tees areas erase ae ee as Chae eave t Sea 57

2. PRECAUTIONS ......... ian ued Maree gs acd ea Ree eee Aa Riese eee aya Pune te eked 57

2.1 Personal Safety ............. remoaroue Ol aia gets satel, Saad asad eet agds IOV.

2.2 Handling ESD—Sensitive Parts ........ 66. e cece cece eee eet tenes 5B

3. CHECKS BEFORE REPAIR .......... 0c cece eect rete eee teen eet eseeeneses 89

4,. CHECKS AFTER REPAIR... 0... cece ccc ee eee tte e ee tenes Poe ere 59

5. TROUBLESHOOTING FLOW CHARTS ......... 00 0c eee c cece eee eee e eee eeeee 60

6. FAILURE ANALYSIS TABLES ............. 0.0 ee eee eee snags Ueto bcale a Wh cletes eltoy .+ 62

7. SELF-TESTS ............... salguee dia. wave: o Scab ie sre A ae a doa AR aTa Seta wth Slee aeaee dis 67

' 7.1. SERIAL NUMBER Input Display ............ 0.0 c cece eee eee eee eee eees seen tcat 67

7.2 Self Print Mode ..... 6.0... ccc cece cece ete erent reece een e te eeeens daleeatis 37a te 68

7.3.- Self-Test Mode: 0 vcscc.s. Sheed ie was deed Soins oe waned ee audt ak ete aes 71

7.3.1 DISPLAY (LCD) Tests 0.0.0.0... 6c cece ce cece ct n eee nett eeenees 72

7.3.2 Print Checks ...... gibalvage eters faerlsartie Bed ee am need bale rate bie a ae Lei LE

7.3.3. Keyboard Tests ........ eth tala bacayeiovtlars ia Sree etcastt Bookie die Seg Rdiake Math aaek Ge ha ena eae 84

/ 7.3.4 FDDTests......... cc 87

7.3.5 PE (Paper End Sensor) Test ........ 0... cee ce ccc ee eee teen nena 97

7:36. GR (Carmiage Reset) Test i. .6i0<k ay gheds estonia neat caeanec eae. 98

TBE. ISKAVE G ioriletinthonsestnad Gtene Sade e haa taaarees LubuMaateae 99 7.3.8 CUT SHEET FEEDER ..... sinter cthateaceh MP erdeale doa ben Ea hye a ee tee thw Sears Raden’ Gis 99

Chapter4 § ©Component Disassembly ......-.--eesceeceeeeeceeeeteetees 101

42 -<GOVERS Scie pec ehg ts Rene aa A eee ae sare ea te eee eee ee se 101

1.1. Upper Cover ......--...e eee eee e eens Bah Ste eiguitnast lati Malate ase tunnetalgttla dt Rea eae 102

4.1.1. Removal ......... 60. c cece eee eee ieee Bis lenses 102

1.1.2 Upper Cover Reassembly ........-0-- + secrete center ees e eet ens ens es . 107

1.2 Carrying Handle oH EA eal ate teces 00 led Meee AR AE Be eb eee aN Sadie Rao Rall ese was Oe 108

(OA - ASMOVAl ci cds kha Pe Re ete Sas erg ea aD Hi ee A 108 |

1.2.2 Installation ......0..00ceseeee eee cnet teeter ersten tees ees 108

& (LOD MODULE 2. se ccd ence aeakics hes Peewee te secen ae vg Mie ae Pe eee .. 109

2.1 LOD Disassembly ............ ccc eee erent eee terns entree a nee n sme tenn ees 109

22 LCD Module Reassembly ..........---0 eee eee rece eee eb ewes se ktiga whee wala ke hs 111

3. KEYBOARD ASSEMBLY ......... ee eee cree een eer e nee e tenant e nner eneeeas 112

3.1. Keyboard Removal ........0:ceees eres ee ncret rene res eee sen erseescscctee nes ees 112

3.2 Keyboard Installation .......... eer ve eee rere i 113 .

4. INK JET PRINTER ASSEMBLY ........-.------ Ss ge Bil pin @ E Reeatelscaral Soa ace aw Wie at 114

4.1. Ink Jet Printer Removal ........- 2... 0s eee eee terete eeee SoA Srey usa beetring atenereeerens 115

4.2 InkJet Printer Installation ......... 665s c eect nee teeter teens renee 115

4.3 Printer Disassembly ........ oi, Sattales A dos, open cgrnacet alist b g'dle age Maes aye ges Aeneas 116

4.3.1 Carriage Removal .......... 00. eee e eee enter eee ees Lon wi ged! Maviasinjat aves due 117

4.3.2 Carriage Transport Belt & Motor Removal .......0.0cccee ee eer eeeeeeeeees 119

4.3.3 Line Feed Assembly Removal .........:-.0 cece eee teen eens ghee Nineoe 120

4.3.4 Top Paper Guide Removal ........6-.. secre eee eter eee e ete t neces waa VAN?

4.3.5 Star-Wheel Assembly Removal ......-....--++ ‘gato uklstb ee, eGree s@akee ree 122

4.3.6 Star-Wheel Exit Roller Assembly Removal ........-- +--+ see er reer teers 123

4.3.7. Paper Separator Removal ........-..--- Saale innsiabun ated cao ne 124

4.3.8 Paper Adjustment Lever Removal .......... OS sacs Ooh A hasten ee 125

4.3.9 Main Paper Guide & Maintenance Station Removal ....-.6.. eee scene renee 126

4.3.10 Main Roller Assembly Removal .........-.. secs eee e eee teen eter ne eens 127

4.3.11 Main Paper Pan Removal ........-.. see e cece eee e eee r tenet nee er nesses 128

4.3.12 Paper Pressure Plate Removal .......--.. 0s eeee sees eect eee e teense eres 129

4.3 Printer Adjustments .......-6..00e0063 Bereta ataiinatedihd shemuse-2 Ser eee ee 130

5. FDD ASSEMBLY REMOVAL .......----. eee e eee eee e etter e etre ennes 2... 133

POWER SUPPLY ASSEMBLY .........-.-: eee e eect eee etn r eee e re enerenes 134

6.1. Power Supply PCB Removal ......... 5.05. e eect erent eee ene n snr n steer es 135

6.2 - Power Supply PCB Installation ..............+-- Wahabdes averenienie days vgeauahaatonaneiae ae oun 135

7. AC ADAPTOR DISASSEMBLY ........-- cantante aad ta seainawaceayewers 136 |

8. MAIN PCB REMOVAL ...........-0.008500 a euaeiideait iia tee Ae hae 137

9. ° SHIELD PLATE (ESD) REMOVAL ..........-- 22 eee eect reece NaS Steir Sia 138

10. AUTO CUT-SHEET FEEDER (ACF) DISASSEMBLY soca Scadaticrah te sen eae es 139

SERVICE MANUAL

SERVICE MANUAL

Chapter 5 MaintenanCe: <iieso see csecne eee desea gaswe Sue wew ease tees anes 143

4 “LUBRICATION? 2.4.65 oii oie nie eos Rat aes As Bhardiath 143

Po ° Rub ricanitSSiccshaeeeeaes Meets See dd hia SNE a aot 143

1.2 Precautions ........ 0.0 ccc cc ccc tee eee eee ent tena e eee ee eae Sie tiew sulci gal’s £0 143

1.3. Lubrication Points ........... 0. cee eee eee t ne eee e eens 143

2, REPLACING THE INK CARTRIDGE ......-. 2 eee eee eee eee 150

4. -CLEANING THE PRINTHEADS) .60heessdvbeumaadte goede nciteiteuateeus seers 153

3.1 Cleaning the Printhead Automatically ....... 6.6... eee e eee eee eee eee nee 153

3.2 Cleaning the Ink-Jet Nozzles and Contacts ............ 0. secrete nett nn eee renee 153

3.3 Cleaning the Bracket Contacts (Carriage) ioscc ines eee eddies’ be See esate 154

SERVICE MANUAL

APPENDIX A | Specifications

4. Electrical System ......-.- eee eee eres Hpudi rghit enklnn stays eee hea ee es A-1

Pe eee eb auc bat tet sineicrs Dates lt ina wate ine tie Oe eRe ee 72... A-2

' 3. Keyboard Pee ee ere Ma tie ahi apr ehe wotanitaen als A-4

As Menton (CED) tcc. sacerw ink a ede dip a eee hear ee Seen peek ee Monee A-4

5. Floppy Disk Drive (FDD) ...........e seer ereet teeter tte nme t nner tts ses ees A-5

6. Power Requirements (US) “cyaccenl cbiugs doting tassk ceeet ew iets treated . A-5

7. Environmental Tolerance ......... : : Sih wi Bae panies ha Sa augers wake eae mNate aa er eae A-5

8. Dimensions & Weight .............6++0e- oni aee ne rp auvanateledag te oeacrarste eee AG

9. Optional Equipment: ACF (Auto Cut-Sheet Feeder) ...... Gh mbpaasecap eee ka eres anges A-7

vi

SERVICE MANUAL Se II IE A A

FIGURES

Figure Title . Page

Fig. 1.1 — Ink Jet Printer Assembly ........ ndbaaatalbahat ec opiates Mocca teeta

Fig. 1.2 — Printer Flat Cable to Main PCB ....... 6-0. s eee eee ee eee Ba ahs cere.

Fig. 1.3 — Printer Flat Cable to Carriage Alignment ......... 2... eee eee e eee eres 4

Fig. 1.4 — Ink Jet Cartridge to Flat Cable Alignment .........-.--- eee eee eee eee 1. 4

Fig. 1.5 — Carriage Motion Control... 2.2... 0.0. e eee eee eee eee eens 5

Figs 116 Line Pedd Svstein in .hsucnsydounensaoeduheaseet sik aeaasaesns 6

Fig. 1.7 — Paper Feeding ........ 0. ccc cece cect een eee eaees Joan 7

Fig. 1.8 — Paper Adjustment Mechanism ......... eee ae oe ee gee er ae 8

Fig. 1.9 — Print Maintenance Operation — Spitting ............ 6. cece e eee ee eee 10

Fig. 1.10 — Print Maintenance Operation — Wiping ........ See Te ore eee ene er

Fig. 1.11 — Print Maintenance Operation — Capping ........-.... see eeeeeeeeeee 12

Fig. 1.12 — Carriage Home Position Sensor ..... 26... eee ee eee eee eee 13

Fig. 1.18 — Paper End Sensor Mechanism .........-.. 02sec cece e eee eee es 14

Fig. 1.14 — Keyboard Assembly ....... 2... cece eee e cece nents 16

Fig. 1.15 — Keyboard DayoUt fo teviaecnan tela: sid ha toto aslt apatiast. tease x anstiad oats ® 16

Fig. 1.16 — Key Top/Key Stem Assembly ......... 0s cee v ence eee enes xe eiunaes 17

Fig. 117 SLED: Mechanism x.csihis asuicanseed nie cnae ans obtadines ren: Fig. 1.18 —LCD Tilt Mechanism ....... 0... cece cece e teen t ee t eee nee tes 19

Fig. 1.19 -LCD with Backlit PCB ......... cee cece eee eee teen eens 19

Fig. 1.20 —~ ACK . 22... cece ccc cece tect e eee t eee ten nner es neetetesesaaenes 20

Fig. 2.1 — Major Electrical Components .......--..- 20sec eee ee ete nents 22

Fig. 2.2 — Main PCB (Block Diagram) ........-- 6. eee cree ence teen e eee enes 24

Fig. 2.3 — Printer Gate Array (#13B) .........00.0eces eee cnet een eees one 27

Fig. 2.4 — Reset Circuit ................ aeGagie se RAM ows s sia Sadan day be 29

Fig. 2.5 — Buzzer Drive Circuit ..... 0.60. c cece eee e ec te cence eens Sapigccaaeee 30

Fig. 2.6 — Country & Model Spec. Change-Over Circuit ........--- 6 sees ee eeee 33

Fig. 2.7 - ROM Configuration Change-Over Circuit .......... sete e tere eee eees 35

Fig. 2.8— Ink Jet Head Drive Circuit .......... 62. eee eee eee nee ee 37

Fig. 2.9- Carriage Motor Control Circuit ..........-...+-0+0e Ginn itea nen oawee 38

Fig. 2.10— Line Feed Motor Drive Circuit ........-..-. 6 cee ee cece ees peeneee ... 39

Fig. 2.11~ Carriage Index Sensor Circuit ..... 26.00... cece eee eee eee es 40

Fig. 2.12~ Paper-End Sensor Detection Circuit........ isha aeewors goats A Pidines saved 41

Fig. 2.13 — Key/FPC Operation ..............-..000- bee sede, denen eas, 42

Vii

SERVICE MANUAL

Figure Title a: Page

Fig. 2.14 — Electrode Wiring ..............-.. eens ree eee eee ne ee 42

Fig: 2-15:— Keyboard Circut 2.125 see si dew ee een ep hed a wap ewecsas aes ama Fo

Fig. 2.16 — Keyboard Matrix ........ open Seah a Mal pee a eR Ranma ek oe need ey 44.

Fige2.? = Keyboard Symbols... 2: ni wreteaieh lu hanes aie Siba Gam ey everest 44

Fig..2.18 = LED Control Configuration’ 220.300. 0s4ceeages cike so udeaie aes 45

. Fig. 2.19 — LCD Character Configuration ........... 0c ccc eee e eee eees 46

Fig. 2.20 — LCD Module Timing Chart.......... | ate aha aaote tated oc OG tate Oe erate 47

Fig. 2.21 — Block Diagram of LCD Module ............. 0. cece cece ee eee ee eee 48

Fig, 2.22: — LCD Display Pattetni.s sncces vsseepieee ced RGA erent ae ONS we 49

Fig. 2.23 — LCD Drive Voltage (VEE) Generation Circuit ...................020. 50

Fig: 2.24 —FDD Block Diagram said enaicid si awe lorena esa Wav cheeses 52

Fig. 2.25 — AC Adaptor & Power Supply ..... 0... ccc cee eee ee eee aes 55

Fig: 2.26 =-Power Supply Citcult 220 a bearded cag aw eeta ee oss ead 56

Fig. 3.1 — Troubleshooting Flowchart ............. ere oe oe 60

Fig. 3.2 — Troubleshooting Flowchart (cont’d.) .......... 0... 0. . eee ee eee 61

Fig. 3.3 — Serial Number Entry Display ................. tycal tian Olacece “dhe htens aia ped eats 67

Fig. 34 = SOH-Print MONG «ia sca oe rc tee ok ea es Sa eeted (Raa hone ede ees 68

Fig. 3.5 — Results of Self-Print Test ...................000. any ee ee 70

Fig) 3.6 — Self-Test Ment fexyasaasnules day cstaenedin ts si ate tasteless 71 Fig. 3.7 -LCD Test Menu .............-.-0es aie Cae amen techs Mae as 72

Fig. 3.8 - CHECK Test Display (magnified) ..........0...c0cceseeeseeeeees it Fig. 3.9 - CROSS Test Display (magnified) ........ 0... ccc cece ete ees 74°

Fig. 3.10 — BLACK Test Display .................. eee Tp duasdeiuees 75 Fig. 3.11 — DISP. Q Test Display (magnified) .......... 0.0... eee eee eee ... 16

Fig. 3.12 — Printer Check #1 Display ............0....00ceceeeaeee ore Serres 77 Fig. 3.13 — Diagram of Print Test Patten 1 ...... Semanes te ate aed nrcentaated 78

Fig. 3.14 — Sample Print Test Pattern 1°... 2... eee cece cece eee enees 79

Fig. 3.15 — Printer Check #2 Display ............ 000. cece eee eee be ee SO Fig. 3.16 — Sample Print Test Pattern 2 ..................0. tien elas e's, etree 81

Fig. 3.17 — Dot Patterns for Print Test 2 ........ PE oe eee Pee re eo ee. 82 Fig. 3.18 — Dot Patterns for Print Test 2 (cont’d.) ......... SiG oS Salinb-atee arden dass 83

Fig. 3.19 — Keyboard Test #1 Display .......... Wanted. De tape antacek ee 84

Fig. 3.20 — Keyboard Test Key Locations ......5...... 00.0. cece cee eee eee e ees B4

Fig. 3.21 — FDD Test (in progress) Display ............. 0. cece ee eens 87

Fig. 3.22 — Special FDD Test Display 1 ............ AGrh a Gale wee se betes .... 88

vill

SERVICE MANUAL

Figure Title Page

Fig. 3.23 — Special FDD Test Display 2 ............. dgeihatin Bani tea ato aes 89

Fig. 3.24 — Special FDD Test (in progress) Display ...............- ee eee eee 89

Fig. 3.25 — Special FDD Test Display 1 ........... sees eee eee eee eee 92

Fig. 3.26 — FDD Write Error Rate Check Display ............ ss cece eee eee, 93

_ Fig. 3.27 - FDD Read Error Rate Check Display .........--. 6. 0s eee e eee eee 95

Fig. 3.28 — PE Test Start Display 1 ........--. ee cee cece teen eee e ence ne ees 97

Fig. 3.29 = PE Test Start Display 2 ic ices doth iadiveseeguas Hen es toeeees eben 97

Fig. 3.30 — CR Test Start Display 1 ........-. eee eee eee eee eee Pdoauatwie weeded 98

Fig. 3.31 — Self-Test Menu ...... 0... cece cece ee ete erect eee e een ee eens 99

Fig. 4.1 — Cover Assemblies ......... 0... cece cece ee teen eee eet ne ee nees 101

Fig. 4.2 — Paper Support Removal .......... Hs SaanGin nih te aaa te esie Mgt ae Saag 102

Fig. 4.3 — Top Cover Removal ......... 0 cece cence erence ener e eet eneneee 103

Fig. 4.4 — Upper Cover Removal .......-....-..-5-+55 Pies Sea haunt eit aha 104

Fig. 4.5 — Access to Upper Cover Retaining TabS ............... eee eee ee eee 105

Fig. 4.6 — LCD Removal «265. cies. s0 eerie ed eee ee ewan beeen weee 106

Fig. 4.7 — Carrying Handle Removal .............+--++- Utes baiete Pied 108

Fig. 4.8 - LCD Lower Cover Removal ......... 0.0: eee eee eect eect eee eet eee 109

Fig: 4.9:= LED PCB Removal i005 a meaceaeean cose gee nexey the oni 110

Fig. 4.10 — Keyboard Assembly Removal .......... epee eer Sroreer ae

Fig. 4.11 — Keyboard Installation ..... 0.0... cece cece reece eee renner ee ees 113

Fig. 4.12 — Ink Jet Printer Assembly .........-- 2-00 c cece cee eee nee e een eens 114

Fig. 4.13 — Ink Jet Printer Mechanism (exploded view) ........-.--+eeeee cree 116

Fig. 4.14 — Printer Mechanism ........... 60. eee eee eee e eee ee e eee nee eee 117

_ Fig. 4.15 — Carriage Disassembly ...............--- Cale gutese ata my av ean 118

Fig. 4.16 — Carriage Transport Belt & Motor Removal .............--eeeeee eee 119

Fig. 4.17 — Line Feed Assembly Removal .........-..- 0+ eee ee eee e ee eee e tees 120

Fig. 4.18 — Top Paper Guide Removal ............. 0. sec eee e eee eee ener e eee 121

Fig. 4.19 — Star-Wheel Assembly Removal ........---- ccc cece eee cence ee ees 122

Fig. 4.20 — Star-Wheel Exit Roller Assembly Removal ........-.--...-.++-0e 123

Fig. 4.21 — Paper Separator Removal .........-.. 0.00 e cece eee e eee eee eens 124

Fig. 4.22 — Paper Adjustment Lever Removal .........-...- se see cece eens 125

Fig. 4.23 — Main Paper Guide Removal ...........--.. eee eee cece ence ees 126

Fig. 4.24 — Main Roller Assembly Removal ........-.--. 00: e eee e cece eee r ees 127

Fig. 4.25 — Main Paper Pan Removal .... 22.0.0... 6. cece cece cece eee e eee enee 128

Fig. 4.26 —- Paper Pressure Plate Removal ............... Aad saad keen may 129

SERVICE MANUAL

Figure Title | Page

Fig. 4.27 — FDD Assembly Removal ........cc cece eee e eee eee e ee teen eeees 132

Fig. 4.28 — FDD Assembly REMOVEl co Sec ducers She eee eS eee Se 133

Fig. 4.29 — Power Supply Assembly Removal ......--+++s seer errrterreeesces 134

Fig. 4.30 — Power Supply =) = 135

Fig. 431 AG Adaptor sscccoie pnbids Mocigats euanntenytaennaet ates 136

Fig. 4.32 — Main PCB Removal ...........00ssereeerrst er tsss estes eens n ss 137

Fig. 4.33 — Shield Plate (ESD) Fe rOVal occa nbledane didn mere See ages 138

Fig. 4.34 — ACF (Auto Cut-Sheet Feeder) Disassembly .....-----.+ee+ee seers 139

Fig. 4.35 — ACF (exploded View) ........-cc eee eee eect rere teeter nent eeees 141

Fig. 5.1 — Frame Assembly Lube =Zo) 9 cc 144

Fig. 5.2 — Carriage Movement Lube POINTS: inca ace de oes eC EGA R ae ERR 145

Fig. 5.3 — Idle Pulley Assembly Lube POINS: Hie veka cade a tenes sere ents 146

Fig. 5.4 — Star Wheel Roller Assembly Lube Points .....---- 6-2 e eee eee e reese 147

Fig. 5.5 — Main Paper Pan & Pinch Roller Assembly Lube Points .............. 148

Fig. 5.6 — Paper Pressure Plate Assembly Lube Points .....--.--+-+++eeeeees 149

TABLES

Table 1.1 — Summary of Maintenance Operations .....-. +--+ +seeeeeeee ree eees 9

Table 2.1 — Video Gate Array Address Map (ROM ANEA) wesw asst Sawn aaee ds 26

Table 2.2:— Clock Citcults ....02500%c2o< er teeedes este nees sn reas eet 28

Table 2.3 —LCD Address Map (RAM and V/O areas) ...-.- ++ +++ eee seer reer 31

Table 2.4—LCD Gate Array VO Map .... 20.0.0 c eee e eee teeter ee ener trees 32

Table 2.5 — Country Code Solder POINTS . 0... ccc ee teen eee ener eeee .. 34

Table 2.6 — ROM Mode Change-over Jumper Configuration .........---eee eee 36

Table 2.7 — LCD Interface Signal ......-.-... eee eee eect eee eee ee recess 49

Table 2.8 — FDC (#8) and FDD Module Links ........---- sees eee eee re terres 51

Table 2.9 — FDD Performance Specifications ......-.----- sere seer reer reese 54

Table 3.1 — Failure Analysis (Troubleshooting Tables) .....-.--+-++-+-++e+s055 62

Table 3.2 —-FDD Special Test Stage Codes ......-..-- see essere eee etree tcses 90

Table 3.3 — FDD Special Test Error Codes .......----+ e+e eeeeees ot arateades 91

Table 5.1 — Recommended Lubricants ........-.--- Lee Tine a aS 143

| | po 3 THEORY _ SERVICE MANUAL_ | ’ Mechanical

a Rae nn, nn EE ae

Part | THEORY OF OPERATION

CHAPTER1 = Mechanical Theory

“od ink Jet Printer

Fig. 1.1 — Ink Jet Printer Assembly

© Brother International Corp., 1995 oe I _ Printed in USA May, 1995

ORY : 5% 3 } | | tpt ne SERVICE MANUAL

1.1 Ink Jet Printer System Configuration

The ink jet printer contains the following components:

1. Carriage Assembly .

The carriage assembly consists of the carriage and ink cartridge (the cartridge

contains the ink jet nozzles). The carriage consists of the carriage bearings,

head-locker & spring, the rubber pad, and the flat cable...

2. Carriage Motion Control System

The carriage motion control system consists of the carriage motor, motor Pney

timing belt, and the idle pulley assembly.

3. Line Feed System

The line feed system consists of paper feed motor, idle gear, and a main roller gear.

4. Paper Feed & Adjustment System

The paper feed system consists of the paper separator, main paper pan and pinch

rollers, top paper guide and pinch rollers, main roller assembly, star-wheel roller

assembly, and star-wheel assemblies (attached to the carriage rail). Paper

adjustment is accomplished by the paper adjustment lever and the paper pan —

pressure plate & extension springs (mounted to the printer front frame). \

5. Maintenance Station

The maintenance station consists of the maintenance station carriage assembly

(carriage, rubber cap, plunger, compression spring, and extension spring); the

_ wiper; felt ink absorbers (in spitting trough and under carriage ass’y); and the cover.

6. Sensors

‘There are 2 sensors in the printer assembly: the carriage home position switch

(attached to the top left end of the front frame) and the paper end sensor (attached

to the bottom of the main paper pan at the left rear).

Printed in USA May, 1995 a" © Brother International Corp., 1995

THEORY

SERVICE MANUAL _ | | | Mechanical Deen eee ee

1.2

1.2.1

Ink Jet Printer Operation

Carriage Assembly

The carriage assembly consists of the carriage and ink cartridge (the cartridge contains

the ink jet nozzles). The carriage consists of the head-locker & spring, the rubber pad,

bearings, and the flat cable. The flat cable connects to the main PCB. See Fig. 1.2.

The printer flat cable must be firmly in contact with the ink jet cartridge for printing to be

enabled. The flat cable is located in the carriage by three alignment pins; proper

alignment of the cartridge to the cable is established in three datums (reference

planes/points): X, Y, and Z. When the cartridge is installed in the carriage, the flat cable

contacts are compressed against the cartridge contacts by the rubber pad. See Fig. 1.3

and Fig. 1.4.

Carriage Assembly (with Cartridge)

Flat Cable

™

<_———_._ MainPCB

Fig. 1.2 — Printer Flat Cable to Main PCB

© Brother International Corp., 1995 3 . Printed in USA May, 1995

SERVICE MANUAL THEORY Mechanical

Fig. 1.3 — Printer Flat Cable to Carriage Alignment

Alignment Pins

Alignment Holes

Fig. 1.4 — Ink Jet Cartridge to Fiat Cable Alignment

Y Datum

<—_——_— ZDatum

© Brother International Corp., 1995 Printed in USA May, 1995

| i oe THEORY

SERVICE MANUAL Mechanical

ON ——

4.2.2 Carriage Motion Control

All operations related to carriage movement are driven by the carriage motor. The

carriage motor assembly consists of a motor, a timing belt, and an idle pulley and

bracket: the motor and the idle pulley bracket are mounted to the printer frame; the belt

runs between the motor and the pulley. An extension spring between the idle pulley

bracket and printer frame sets belt tension. See Fig. 1.5.

<~—__—_————_ Drive Belt

Printer Frame (front) Pree

& Idle Pulley & Bracket -

Extension Spring Carriage Motor

es jee

Fig. 1.5 — Carriage Motion Control

© Brother International Corp., 1995 5 7 as Printed in USA May, 1995

HEORY | | ania SERVICE MANUAL

1.2.3 Line Feed System

The line feed system consists of line feed motor, idle gear, and a main roller gear. See

Fig. 1.6.

The main roller assembly is driven by a line feed motor (stepping motor). The line feed

motor is secured to the right end frame with two screws. Rotation of the line feed motor

is transmitted to the idle gear and then to the main roller gear.

Line feeding is possible by 1/6 inch (for line-spacing), 1/30 inch (for indexing and

reverse-indexing), and continuous feed (for indexing and reverse-indexing).

‘Idle Gear

Main Roller Gear

Line Feed Motor

Fig. 1.6 — Line Feed System

Printed in USA May, 1995 6. © Brother International Corp., 1995

: a ; THEORY

SERVICE MANUAL ; Mechanical

SEE ——————————_— SD

1.2.4 Paper Feed & Adjustment System

Operation

As the main roller assembly rotates, paper is caught and fed between the main rollers

and the pinch rollers. The necessary roller pressure is provided by the pressure plate

(mounted to the printer front frame), which pushes up the paper pan with the extension

springs. Paper adjustment is accomplished by the paper adjustment lever, releasing the

force of the pressure plate from the main paper pan.

Paper Feeding (Paper Path

With the paper adjustment lever in the set position (up), paper is fed into the machine

by inserting a sheet of paper into the paper insert slot to just contact the main rollers —

and bottom pinch rollers. Then pressing the PAPER INSERT key activates the line feed

motor to advance the paper to the printing position. See Fig. 1.7

Printer Frame (rail)

Print Area ISS .

; Star Wheel; Top Paper Guide \ & Roller

Pen Paper Catch

EX

Printer Frame Top Pinch Roller \ x X

trent \ ” \ eo ol \ OP:

\- 7 <t # SINGLE SHEET FEED

\ € ———— (MANUAL)

Wy

\ Main Paper Guide

yS Z

4, ©) YAS) <—____—_. Paper Separator

ALTERNATE PAPER FEED/ACF

pS ee ES

(xem % co i

Y

y, ay Ww

: w ol [KRY S77 Paper Pan

OF Main Roller 7)

Extension Spring . ;

Pressure Plate ;

Pinch Roller Pinch Roller

Fig. 1.7 — Paper Feeding

© Brother International Corp., 1995 - Printed in USA May, 1995

THEORY a _— . % Ae | | Mechanical , SERVICE MANUAL

Paper Adjustment

Paper position is adjusted by locking the paper adjustment lever down (toward the

front) to release the pressure between the main roller and the pinch rollers. The paper

_ can then be moved for proper alignment. See Fig. 1.8.

Release for Adjustment Paper Adjustment Lever

Main Roller

Paper Pan

Pivot Point Pinch Rollers

Fig. 1.8 — Paper Adjustment Mechanism

Printed in USA May, 1995 _ a 8 © Brother International Corp., 1995

THEORY


1.2.5. Maintenance Station Operation

The maintenance operations consist of spitting, wiping, capping, and purging.

Table 1.1 below shows a summary of maintenance operations for various printer

states.

Printer State

Beginning print job (after capping for more than 4 minutes)

Between pages of continuous printing

After 6 pages of continuous printing

After 50 seconds of printing on the same page

After ink cartridge change

If no carriage motion for more than 30 seconds

Table 1.1- Summary of Maintenance Operations

© Brother International Corp., 1995 9 Printed in USA May, 1995

ne | ;

Eby rieea SERVICE MANUAL

Spitting (see Fig. 1.9

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

station to clear dormant nozzles, and during the printing process to ensure that

infrequently used nozzles are available when required to print. There must also be

spitting after a wipe cycle, except when the head is going to the cap position; otherwise

wiping causes distorted printing if the wiper has experienced any wear.

The trough below the print line is intended to capture the ink during a spit cycle when

no paper is present in the print area. The cup around the wiper is used when spitting is

required and paper is present in the print area. Spitting with paper in the print area

occurs when a single page requires longer than 50 seconds to print. All spitting occurs

in the trough. At power on, any paper in the print area is ejected.

Fig. 1.9 Print Maintenance Operation

~ Spitting Ink Jet nozzles

= Ln

i

Ih | EERE 2 = REAR VIEW ee:

_ Printed in USA May, 1995 10 © Brother International Corp., 1995

— — aA ' THEORY SERVICE MANUAL ; ; Mechanical

Wiping (see Fig. 1.10

Wiping of the printhead occurs when the carriage moves across the wiper (in either

direction). The printhead is wiped (twice) when power is turned on, when beginning a |

print job (after the printhead has been capped for more than four minutes), after six

pages of continuous printing, after 50 seconds of printing on the same page, and after

purging or changing the ink cartridge. a

Wipes nozzle surfaces

towards the Maintenance Statio!

=

Cos

Carriage moves fi

Wiper

Fig. 1.10 Print Maintenance Operation

— Wiping

© Brother International Corp., 1995 _ a 1 Printed in USA May, 1995

. | a ;

See eal SERVICE MANUAL

Capping (see Fig. 1.11

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

which moves the MS carriage up the ramp to align the cap with the ink jet nozzles. The

cap prevents the ink from drying and causing the printhead to clog. The printer will

automatically cap the printhead when the system is powered on, when no data is

received for 30 seconds, and after purging or ink cartridge change.

<5 OD Fig. 111 Print Maintenance Operation

— Capping

Rubber Cap Carriage moves to the Maintenance Station

Rubber cap is moved right and up to seal the

ink jet nozzles

LITT REAR VIEW

Purging

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

spit operations. This initiates a sequence of 6,000 spits of each nozzle, in order to clear

clogged ink from the nozzles. The ink is captured in the trough located below the print

line. Purging is user-activated by pressing CODE + SHIFT + INK CHG from the

keyboard. See Cleaning the Printhead in Chapter 5, Maintenance, for instructions.

Printed in USA May, 1995 12 © Brother International Corp., 1995

| 7 | THEORY SERVICE MANUAL : ; Mechanical

ee

1.2.6 Sensors

There are 2 sensors in the printer assembly: the carriage home position sensor

(attached to the left end of the front frame) and the paper end sensor (attached to the

bottom of the main paper pan at the left rear).

Carriage Home Position Switch

Upon power-up of the system or when the carriage is reset, the carriage moves to the

left end of the printer assembly and activates the home position switch. See Fig. 1.12.

Home Position \, Sensor

Fig. 1.12 — Carriage Home Position Sensor

© Brother international Corp., 1995 13 . __ Printed in USA May, 1995

Aaah SERVICE MANUAL

Paper End Sensor

The paper end sensor detects when the trailing edge of the paper passes the paper

end lever. The paper end sensor is an optical sensor. The lever pivots within the main

paper pan, and acts as a “flag” to activate (open/close) the optical sensor circuit. See

_ Fig. 1.13.

Paper moving into the printer activates the sensor

Sensor Paper Trailing Edge

CLOSED OPEN

(on) (off)

Fig. 1.13 — Paper End Sensor Mechanism


' THEORY

gem a I SD

SERVICE MANUAL _ | a Se nanleal

1.3

1.3.1

1.3.2

INK CHG (Ink Change) Functions

There are two operator-initiated printer maintenance functions available from the

keyboard: ink cartridge replacement and automatic printhead cleaning (purging).

Ink Cartridge Installation/Replacement

There is an ink cartridge installation/replacement function available from the keyboard.

Pressing the key combination CODE + INK CHG moves the printhead from the

maintenance station to the left end of the printer assembly. After installing or replacing

the ink cartridge, pressing the RETURN key initializes the system: the carriage

activates the home position sensor switch and sends the printhead back to the

maintenance station. See Chapter 5, Maintenance, for ink cartridge replacement

instructions.

Automatic Printhead Cleaning (Purging)

With the ink cartridge installed, pressing the key combination CODE + SHIFT + INK —

_ CHG initiates printhead purging. See Chapter 5, Maintenance, for manual printhead

cleaning instructions.


SERVICE MANUAL THEORY Mechanical

Keyboard 2.

The keyboard assembly consists of the keyboard panel and keys

printed circuit) board

layout (key tops

flexible the FPC ( eT

and the keyboard base plate. Fig. 1.15 shows the keyboard

).

Fig. 1.14 — Keyboard Assembly

Fig. 1.15 — Keyboard Layout

Keyboard Assembly

© Brother International Corp., 1995 16 Printed in USA May, 1995"

as | aa + THEORY


Pe ne nnn aE

The key tops and key stems are assembled in the keyboard panel. The FPC (flexible

printed circuit) board with rubber contacts is fitted to the base plate. See Fig. 1.16.

The FPC board is a single sheet of film (FPC) on which an electrode pattern is printed

in layers. When the key top is pressed, the key actuator presses the rubber contact; the

conductive part of the contact connects both of the electrodes to output the

predetermined signal for the key.

Key Top

Key Actuator

Keyboard Panel

FPC

Base Plate

Rubber Contact

- Fig. 1.16 — Key Top/Key Stem Assembly

© Brother International Corp., 1995 17 Printed in USA May,. 1995

Lari 7 SERVICE MANUAL a BT RI A

3. LCD

The LCD (Liquid Crystal Display) is attached to the upper cover by a retaining pin at

each end and the hinge tab that fits into a slot in the upper cover. The LCD can be tilted

forward (from flat against the upper cover) to about 70° from the horizontal. The LCD

hinge is a friction type that holds the LCD at whatever (tilt) angle is applied by the user.

LCD contrast is controlled by a slider at the right side of the LCD upper cover. See

Fig. 1.17 and Fig. 1.18. Models for Europe also have a backlit PCB. See Fig. 1.19.

LCD Contrast Controller

Fig. 1.17 ~ LCD Mechanism


| 7 : THEORY SERVICE MANUAL Mechanical

Fig. 1.18 — LCD Tilt Mechanism

~<———_ Hinge assembly

LCD Lower Cover

Backlit PCB

Fig. 1.19 — LCD with Backlit PCB (Europe only)


EORY |

pilates SERVICE MANUAL

Mechanical

4. ACF (Auto Cut-Sheet Feeder)

The ACF uses a friction drive and friction retard (separator) pad system whose

operation is controlled by the friction materials for the drive roller and retard pad, and

the “nip” forces applied by the hopper plate and bottom separator springs. The balance

between the hopper plate and bottom separator spring forces is designed to optimize

feeding while minimizing the force needed by the printer to feed paper to the print area.

The feed rollers are situated to allow for feeding of letter, A4, and postal card size

sheets of paper. Paper is loaded against a fixed registration edge and secured by an

adjustable side guide, which minimizes skewing during feeding. The front tray provides

for stacking/storing of printed sheets, and holds the same number of sheets as the

paper tray. The wire supports can be removed to allow for loading accessibility or

storage of the machine. ;

Printed in USA May, 1995 20 © Brother international Corp., 1995

THEORY SERVICE MANUAL | | tos Electrical

CHAPTER 2 _ Electrical Theory

1.1

1.2

1.3

14

1.5

System Configuration

The major electronic components of the word processor are shown in Fig. a4,

Power Supply PCB (printed circuit board)

The power supply PCB receives 11.5 VDC power, converts it to +24 VDC, +5 VDC, +8

VDC (Europe), and supplies it to the Main PCB.

Keyboard PCB (FPC: Flexible Printed Circuit) |

The keyboard PCB has electrodes arranged in the matrix circuit pattern. The keyboard

status is sent from the PCB to the Main PCB.

Main PCB (printed circuit board) |

The Main PCB is controls the entire the word processor system including the LCD

display, the ink cartridge, and the motors in the printer.

The +24 VDC from the power supply PCB drives the ink cartridge and motors in the

printer. The CPU and other devices are driven by +5 VDC.

FDD (floppy disk drive) Module

The FDD can read and write information supplied to the Main PCB. The FDD is driven

by +5 VDC.

LCD Module (Liquid Crystal Display)

The LCD PCB contains the driver for the dot matrix of the LCD on which various

information is displayed. The optional “Backlight” (European models only) is driven by

+8 VDC from the Main PCB.


SERVICE MANUAL THEORY Electrical

| |

Power

Supply

Video Gate Array #7

Video Driver

Circuit

| |

| Video Display |!

| (Led)

|!

ae

ame |

Printer GA

(Ink

Jet

& Motor

Controller

Keyboard FPC

ie op wg trae

Ge

at

| a

5V

| PowerSupply

|———>

24V

| PCB

|»

8V |

(backlit) |

GND

Motor Drive

Circuit

Fig. 2.1 WP- 6400/6500J — Major Electrical Components

© Brother International Corp., 1995 i

22 Printed in USA May, 1995

' THEORY

SERVICE MANUAL | | Electrical Pt tl lane La

aL

2.1

2.2

2.3

2.4

2.5

Ink Jet Printer Configuration

The following describes the operation of the ink cartridge, motors, and other

components.

Ink Cartridge *

The ink cartridge contains the 56-nozzle ink jet head which has a resolution of 300 DPI.

Carriage Motor

The carriage step motor drives the carriage to the left and right with precision motion

— control.

Line Feed Motor

The line feed motor feeds the paper forward and reverse. It also drives the optional

“Auto Cut-Sheet Feeder mechanism.

Carriage Index (Home Position) Sensor

The carriage index sensor is mounted to the left end of the front printer frame. It detects _

the carriage home position to synchronizing position of the carriage and motor phasing.

Paper—end Sensor

The paper end sensor detects whether or not paper is in the printer. The paper-end

sensor is located on the bottom of the main paper pan at the left rear of the printer

assembly.


THEORY = | a Electrical ; SERVICE MANUAL

3. Main PCB and Peripherals

<

oF a2 ee re

oO =

Pp) >s

=F tt O

“24 Kew | 3125 OapiA

Main PCB

ork 2 oc 5s

283 ge 2 ae) "2 >

“Tl Oo ro) + oa

Fg She eae ae any Se ea ee Te en Te

= |-

9 ee me a ee te ee mn 4 2

| oO

The Main PCB {

consists of the CPU, |

ROM, ROM, main |

RAM, video gate {

array, printer driver

circuits, printer gate |

array, and FDC.

|

| |

Fig. 2.2

| | { |

- 1640948

L#Ndd

Block Diagram of Main PCB


THEORY

__-_————ETET———E——————lEll EEE ———————

SERVICE MANUAL __ , 7 > deyeeineal

3.1

3.2

3.3

3.4

CPU PCB

The CPU PCB controls the word processor system, and is directly connected to the

keyboard and the FDC.

It communicates with the video gate array and the printer gate array to contro! the video

output and printer functions, respectively.

ROM1 #1

The capacity of ROM1 is determined by the presence or absence of solder point SP12.

When SP12 is open, ROM1 has a capacity of 16 Mbits and stores the program,

dictionary, and font data. When SP12 is closed, ROM1 has a capacity of 8 Mbits and

stores the program only.

ROM2 #2 (if present)

The capacity of ROM2 is determined by the presence or absence of solder point SP11.

When SP11 is open, ROM2 has a capacity of 8 Mbits and stores the font data. When

SP11 is closed, ROM2 has a capacity of 16 Mbits and stores the font data and the

demonstration program.

Main RAM (Random Access Memory)

In the main RAM, 2 Mbits PSRAM (#4, #6) is used to provide the 256K bytes used as

the CPU's working area, and for storage of the LCD video display area.


THEORY

3.5

3.6

3.7

3.8

Bacar icel | : : SERVICE MANUAL

Video Gate Array

The video gate array is an IC (integrated circuit) incorporating the circuit which

generates bus control signals by receiving signals from the CPU and the LCD control

circuit (see Fig. 2.2). Solder point SP8 is not used with LCD modules. However, solder

point SP10 is used to change the LCD data reverse, and solder point SP13 (M107) is

used to change the LCD M signal frequency.

Debug 1, Debug 0

CE1

2 MB max | 2 MB max CE2

1 MB max

bd

CE2 - CE3 1 MB max

2 MB max CE3

1 MB max

1FFFFFH

Table 2.1 — Video Gate Array Address Map (ROM area)

ROM area

200000H os

3FFFFFH

Printer Driver Circuits ears & Motors — #100, #101, #17, #18, #16, ai-4)

The printer driver circuits convert the motor phase drive signals’ output from the printer

gate array (#13B) to +24V drive signals, which are output to the motors and the ink

cartridge. IC #15 provides feedback to the printer gate array to maintain constant

current to the carriage motor.

Printer Gate Array

The printer gate array controls all printer functions, including both carriage and line feed

motors, and the ink jet printhead (nozzle selection) signals. It also informs the CPU of

the carriage index switch and the paper-end sensor signals. See Fig. 2.3.

FDC (Floppy disk Controller)

The FDC controls floppy disk drive access through the FDD drive circuit.


SERVICE MANUAL

Fig. 2.3 — Printer Gate Array (#13B)

© Brother International Corp., 1995 27

cS RESET

RTCCE RTCAS RTCWR

PEQ PEI INT

PGO PG1 PG2 PG3 PG4 PGS PGE PG7

OPEN OPEN2 OPEN3 OPEN4 OPENS OPENG OPEN? OPENS OPENS OPEN1O OPEN11 OPENI2

Lies

PRINTER-GA

THEORY Electrical

AEN | 11 packour | 13 i

u DACKIN | °8

DREQIN |. 83 pra | 97

capi. {te cnD2 | &2

Printed in USA May, 1995

Ee. ra saat : SERVICE MANUAL AAI A EE So Te EE ED

3.9 Clock Circuit

Four different clock circuits shown in Table 2.2 are incorporated into the Main PCB.

Clock Circuit [Frequency | Function

XT1 is the standard clock for FDD

control; it inputs for #8 (pins 39, 40). 16 .OGHHz >

~ C195pF °

+3 C205pF

XT2 is the standard clock for CRT control; it inputs for #7 (pins 79. 80).

T4HCUO4 T74HCUC4

#13B Printer Gate Array

XT3 is the standard clock for printer control and printhead timing; it inputs for #13B (pin 23), #100 (pin 1), and #101 (pin 1).

XT4 is the CPU oscillation clock; it inputs for #1 (pins 7A, 75).

19.66 MHz

Table 2.2 — Clock Circuits


SERVICE MANUAL

3.10 Reset Circuit

THEORY Electrical

The reset circuit delays the system from starting while the voltage to the system

stabilizes. It also allows the system to restart from a known state. The reset circuit

causes a system delay of 80 - 150 ms upon initial power-up. See Fig. 2.4.

The following devices (and their pins) are attached to the reset line:

Device Pin

CPU (#1) 71

VGA (#7) 77

PGA #13B) 48

Printer Drivers

(#17, #18)

NCI

NCe

NC3 db wr -

VCC

2 R13 A A 2100 resel

GND

© Brother International Corp., 1995

Fig. 2.4 — Reset Circuit

29 Printed in USA May, 1995

THEORY i sasicdbe SERVICE MANUAL

3.11 Buzzer Drive Circuit

The buzzer drive circuit is shown in Fig. 2.5. A 4 kHz pulse of 50% duty is output from

port PA2 (Pin 107) of CPU (#1) when buzzer operation is needed.

The piezoelectric element in BZ! generates sound on reception of this pulse. The

output from port PA2 is HIGH when the buzzer is not in operation.

vec vec

VCC

RLS71 PAQ-TPO-TENDO' -TCLKO PA1-TP1-TEND1‘-TCLK1 PA2-TP2-TIOCAQ-ICLK2 PA3-TP3-TIOCBO-TCLK3 PA4-TP4-TIOCAI PAS-TP5-TI0CB1 PAG-TP6-TIOCAZ PAT-TP7-T1OCB2

871

BUZZER

DIO

Fig. 2.5 — Buzzer Drive Circuit



3.12

3.13


Memory Map

The CPU (H8/3003) has 24 address lines. The lower address lines are used to access

the system ROM and RAM, while the upper address lines access the video and printer

gate arrays, as well as the internal CPU registers and RAM.

DESCRIPTION

(not used)

ADDRESS

408000H

600000H RAM1 128 KB

620000H RAMS 128 KB (work area & Video RAM)

LCD Gate Array (internal register) EOORIOR See Table 2.4.

Table 2.3 -~- LCD Address Map (RAM and I/O areas)

/O Map

CPU #1 has a 64K byte I/O area in addition to a 512K byte memory area. Addresses

OOOOH to OO3FH are used as an internal CPU I/O area. The following external I/O

areas are controlled by the LCD gate array:

e FDC

Sas VRAM area

e LCD refresh

e LCD pulse & M frequencies

e Horizontal character

¢ LCD data & pulse output

These external I/O areas are enabled by outputting the address bus signals as shown

in Table 2.4.

THEORY 7 a | - 7 | piers SERVICE MANUAL

LCD Gate Array _ _ (internal register) Addresses

| EXXXOXH Decode out.

EXXX1XH Not used.

EXXX2XH Not used.

EXXX30H Set the LCD refresh cycle.

EXXX32H CSPLS _ Set the frequency of PULSE and M signal.

EXXX34H Set the starting address of VRAM.

EXXX36H Set the Horizontal Character.

EXXX38H Not used.

EXXX3AH Not used.

EXXX3CH Not applicable. | Not used.

EXXX3EH Not applicable.

EXXX4XH CSDAT © Control the Display DATA and PULSE output.

EXXX5XH CSRES sia CPU operates this one, GA counters are re-

EXXX6XH CSTST It is for GA simulation; CPU cannot operate this one. .

EXXX7XH Not applicable.

Table 2.4 —LCD Gate Array /O Map


| in . THEORY SERVICE MANUAL

Electrical

ee

3.14 Country Specification Change-over

The country specification change-over circuit is shown in Fig. 2.6. The country

specification is recognized by the CPU by sensing solder on the solder points.

Table 2.5 shows the solder points used for changing the country code.

| PRINTER GA | #13B 4

|

Fig. 2.6 — Country & Model Specification Change-Over Circuit


THEORY | a a . es . SERVICE MANUAL

Electrical

SOLDER POINTS COUNTRY

USA (Mass)

WP-6400J USA (Protected)

USA (Protected/A4*)

CANADA

MEXICO

CHILE

BRAZIL

NEW ZEALAND

SINGAPORE

UK (incl Ireland)

GERMANY

LW-700i w/o backlight AUSTRIA

WP-6500J

LW-710i w/backlight

20001 (Privileg) GERMAN

* Australia X = solder connection present at SP

Table 2.5 — Country Code Solder Points

Printed in USA May, 1995 34 ; © Brother International Corp., 1995

THEORY

SERVICE MANUAL . Electrical

ROM Configuration Mode Change-Over

The ROM configuration change-over circuit is shown in Fig. 2.7. The decoding area for

chip selection signal (CS) ROM1 is determined by the presence or absence of solder at

solder point SP12. The decoding area for ROM2 is determined by the presence or

absence of solder at solder point SP11.

#3 22 42] 419 he 12 Fig. 2.7 — ROM Configuration Change—Over Circuit

1 | A1g8 VS 2 A17 BYTE

33/416 Q 34/415 0 351414 013 36] 413-012 ST) a12 O11 38] 411 Q10 33} 410 40/49 08 41) ag QT 3 }a7 06 4 }ag 05 2145 04 . A403

AZ Q2 8 | a2 3 4A1 00 18}49 O€_N uPD65626GF

CE #7

=) 7

ROM1 CS (Chip Select”) is enabled from pin 95 of the video gate array (#7). ROM2 CS

is enabled from pin 96 of the video gate array, and SP14 must be soldered or resistor

R14 must be in place to activate. ROM3 CS is enabled from pin 97 of the video gate

array, and SP 15 must be soldered or resistor R15 must be in place to activate.

Table 2.6 shows the ROM mounting state for each of these cases.

PG-0 is used to adjust the alignment for bi-directional printing; this adjustment, if

necessary, may be accomplished with DIP switches or with solder points 17-20. The

pull down resistors in PG4 through PG7 ports of printer GA (GA2) are used for

changing the mode.


EORY sts 3 | atte paeetas | SERVICE MANUAL

[Pers [Function PG-0,PG-1, | Reserved (adjustment for tolerance of

PG-2, PG-3 bi-directional printing

[rez _[Resoned PG-5 Paper feed power up:

“HIGH” (without resistor) — normal “LOW?” (with resistor) — additional torque

Table 2.6 - ROM Mode Change-over Jumper Configuration

Carriage motion power up:

“HIGH” (without resistor) — normal

“LOW” (with resistor) — additional torque

ROM access speed: “HIGH” (without resistor) — 3 state with O wait

“LOW” (with resistor) — 3 state with 1 wait

4. Printer Control

41 Ink Jet Head Control!

The ink jet head drive circuit is shown in Fig. 2.8. The ink jet head has 50 active

nozzles (monochrome). Two multiplexing current drive circuits (#17, 18) address the

nozzles to perform printing. Custom circuitry controls the timing and synchronization to

fire the ink as the carriage moves across the paper in printing. The same system

controls maintenance spitting into the trough as needed.


| - & 2 | THEORY SERVICE MANUAL : Electrical :

CUSTOM CIRCUITRY Printh

ee) Control

rPDod

sri Fig. 2.8 — Ink Jet Head Drive Circuit


THEORY Flcciical: a aa | SERVICE MANUAL

4.2 Carriage Motor Control

The carriage motor control circuit is shown in Fig. 2.9. +24 VDC is applied to the motor

through connector CN17 (CNCA), pins 5 and 6. Motor phases A, B, C, and D are driven

by the printer gate array (#13B) through pins 81 — 84, respectively. The outputs of the

printer gate array turn transistors Q1 — Q4 on and off, which in turn affect the motor

_ phases.

During printing, the current through the motor phases is maintained at 400mA per

phase, by feeding the voltage through each phase into resistor R9 or R10 (1Q). The

result of this is to create a voltage-to-current transformation (i.e., 1V = 1A).

This transformed current is then fed into a comparator (#15 or #300) and compared to a

400mV (i.e. 400mA) reference signal generated by voltage dividers R11 and R35, or

Ri2 and R40. ff the current is greater than 400mA, the comparitor outputs a pulse to

the printer gate array (pin 86 or 87). The printer gate array then “chops” the phase until

the current drops below 400mA. This cycle continues until the motor phase changes,

and repeats for each phase until the motor is stopped.

5 § £3, rlk 3 4a pik

ATE plik

85 Pad 162 7 182 5 ver

PRINTER ame : ili ae “ GATE ARRAY [2-2 a A L il

a : ee a =e #13B Z a ue

181 {18S pig wialek

RMN AIK

Fig. 2.9 — Carriage Motor Control Circuit


SERVICE MANUAL

4.3 Line Feed Motor Control

THEORY Electrical

The line feed motor drive circuit is shown in Fig. 2.10. The line feed motor is powered

by +24 VDC. Each of the 4 phases of the motor are excited when CPU #1, via ports

BO-B3, of the printer gate array (#13B) outputs to turn on the transistors of transistor

array #16.

This provides a path to ground through the transistor, which allows current to flow.

When the printer gate array outputs a LOW, the transistor remains off (current does not

flow, and the motor remains off).

PA4

PAO PAI

PA2 PA3

fac won re ea ENi

Printer Gate Array #13B

MS286P

Fig. 2.10 — Line Feed Motor Drive Circuit

© Brother international Corp., 1995 39 Printed in USA May, 1995

Y ~ | flues SERVICE MANUAL

4.4 Carriage Index (Home Position) Sensor

The carriage home position sensor circuit is shown in Fig. 2.11. The sensor condition is

read by printer gate array (#13B) (pin 15) and a LOW is detected when the carrier

reaches the home position. ;

Printer Gate Array #13B

CN-CAIND

Fig. 2.11 — Carriage Index Sensor Circuit


4 Se 7 THEORY ~ SERVICE MANUAL . Electrical

4.5 Paper-End Sensor

The paper end sensor detection circuit is shown in Fig. 2.12. The HIGH/LOW status of

the paper-end sensor is read by printer gate array (#13B) (pin 16); a HIGH is output if

there is no paper at the sensor position.

Printer Gate Array

#13B

Fig. 2.12 — Paper—end Sensor Detection Circuit


HEORY gh ute” = - ee SERVICE MANUAL _

5. Keyboard PCB

5.1 FPC Operation

The keyboard is a flexible printed circuit (FPC) board on which the circuit pattern and electrodes are printed. When a key is pressed, the key stem is forced down until the carbon-type conductive silicon rubber makes contact with the FPC electrode and electricity is conducted. See Fig. 2.13. ,

Contact Rubber

Carbon silicon conductive rubber

FPC Board —EE tt et

“~~ _ Base Plate

Fig. 2.13 ~— Key/FPC Operation

Carbon Electrodes

5.2 . Keyboard Scan

Fig. 2.14 shows the pattern from wiring electrodes on the board (this figure shows only simplified wiring for ease of explanation and is Slightly different from the actual wiring). Refer to Fig. 2.14 to understand the keyboard scanning operation described. When a key is not pressed, continuity does not exist in any combination on the matrix (e.g. XI and Y1 or X1 and Y¥2). For example, if Key (A) is pressed, continuity will exist only in X2 and Y3, but not between any other pair of points which are left in the OFF status. In other words, if continuity exists between X2 and Y3, it means that Key (A) is being pressed.

xt

. ‘ a q S Pattern Circuit

(A) =

¥4 ¥3 Y2 Yt Pattern Circuit

Fig. 2.14 — Electrode Wiring

Printed in USA May, 1995 42 © Brother internationa! Corp., 1995

THEORY

_ SERVICE MANUAL _ — Electrical

5.3 Keyboard Control Circuit

The matrix pattern on the keyboard PCB controls port 7 (0:7) of CPU#1 according to

data signals PBO through PB3 of the CPU (#1) (see Fig. 2.15). The LOW level signals

are output to output lines KOO through KOS. The electrode wiring is scanned line by

line beginning with YO. The result of scanning is input to K10 through K17 of CPU (#1).

CPU (#1) detects which key has been pressed. The key matrix given shown in

Fig. 2.16 corresponds to the key arrangement shown in Fig. 2.17.

Fig. 2.15 — Keyboard Circuit

mscieell x = 2 - iS n «|S S6 S552 79

iit aa OK

EA 86 | p79-ANG ee Vy oH ge PrLaNe Sa

an es Re VV B3__| p73-AN3 paa-Resh'-IRao* | 180 : 2a} p74-4N4 pgi-cs3'-Ras‘-IRo1 | 18°

Lee! ES Fe rece ee | | =—— Ns cf Pras Paa-csa’ | 10

a 185 | pag-TPQ-TENDG‘-TCLKO pog-walt’ | §6 RAT 166 | PAT-TP1-TENOT'-TCLK! pgi-ereo’ | 8! 1K NG?) PA2-TP2-TIOCAB-TCLKZ pG2-Back’ | 88

188 | PA3-TP3-TTOCBG-TCLK3 9 | Pad-1P4-TIOCAI cikour | 69

vec u @} pas-TPS-TIOCBI 111 pag-TPG-TIOCAZ

V2 | pa7-1P7-TLOCB2 ash | 77

at $9 t vote ——21 ppg-1P8-TIOCA3 “-cas'-ve' | 78 82 : : 3 ahs PB1-1P9-TIOCB3 wwr'-uu'-Ucas’ | 73

3 : ret PB2-TP1G-TIOCA4 Lue'-tu'-Lcas' | 89

a mg “| Ra 87 i PBS-1P13-TOCXB4 P9a- 1x08 Be

e 8 | PBG-TP14-DREQO P91-1X01 3

% PB7-TP15-DREQ1'-ADTRG' pse-rxns | 22

2 a1 pa3-exo1 | 32

x ao HOG pg4-scxg-IRod' | & a H01 P35-SCK1-IRO5’ | 2

HOZ a resout | 19

42 Bia 423 | 8 PGA Pz 2 aig Wee BY

i #13B O 39 Di 428 95

p18 aig | 31 aig | 84 36 ai7 | 83

34 | 97-p47 aig | 62 z 06 -P46 ais | 8

05-P45 aia | 88 31 | p4-p44 aig | 23 - 03-P43 Ai2 | 38

D2 -P42 att | 37 a Di-P41 aig | 28

De-P48 a3 | 33 43 $4

8 PCT_IRQ7' ; Al 2 17 | pcs_ Ras" ag | 3 8 | P¢S_0ReD3" As | 8 15 | PC4_TEND3" aa | 8 ty | PC3-OREQ2 a} 2

. PC2_TEND2 A2 1 | pct a | &

1 PCG ag | 4



Fig. 2.16 — Keyboard Matrix

ft a © a uw 4 i <i Mm 4 as) Sal Os) Ad 9 in p

Fig. 2.17 Keyboard Symbols

(Corresponding to the Keyboard Matrix)


THEORY

SERVICE MANUAL Electrical

6. LCD Module

The LCD operation depends on two sections: the LCD controller and the LCD module.

The video gate array(#7) on the main PCB controls the contents to be displayed and

~ sends signals to the LCD module. The LCD module then displays characters according

to the 4-bit parallel display data by applying the LCD drive voltage. See Fig. 2.18 fora

block diagram of the LCD controller on the CPU PCB.

CPU PCB __

MAIN RAM

VIDEO RAM FOR LCD

CPU #1 GATE ARRAY #7

LCD

q

LCD DRIVE |

L Stas Merah! ean

LCD MODULE

Fig. 2.18 —- LCD Control Configuration (Block Diagram)

© Brother International Corp., 1995 45 ' Printed in USA May, 1995

e

6.1

6.1.1

Lait ——- | : SERVICE MANUAL

LCD Control!

The LCD control circuit includes the LCD video gate array, video memory, and the LCD

drive circuitry.

Video Gate Array (#7)

The video gate array (#7) is the core of the LCD control. It controls LCD and VRAM

access. It writes display data to the video RAM area of PSRAM (#6). After reading the

display data from the VRAM area of PSRAM (#6), it converts the data into 4-bit parallel

data to display the data on the LCD module. The video gate array then outputs the

converted data to the LCD module with the display timing control signal.

The video gate array (#7) also generates the control signals to be used for read and

write processing of the upper Main RAM data by the CPU.

Character Configuration

Characters are configured in 6 x 9 dot area as shown in Fig. 2.19.

NOTE: Only a5 x 7 dot area is used to display a single character; the remaining area

is used for the space between characters. ,

543210 543210 © of -1 OOOOOO -1 OOOOOO = o OOOOOO 0 SERRE

1 OOOOdO 1 BRS e . 2 OOOOOO 2 SEER ER et 3 OOOOOO 3 BREESE oO 4 0OOO0O000 4 SR SSE hs 5 D0DOOOOO 5 ERE RSES

cw) 6 OOOOO00 : 6 ER ESEH x 7 OOOOOOk— under 7 SRR

| Line Cursor

indication

Fig. 2.19 — Character Configuration :


THEORY - SERVICE MANUAL | Electrical

6.2 LCD Module Operation

An 80 column x 14 line LCD module is made up of 480 x 128 dots as shown in

Fig. 2.21 (Block Diagram). The interface signals are shown in Table 2.7. Signals are

sent to the LCD module in units of 4-bit dot data DO to D3). The display data for each

raster is configured by 120 unit data transmissions. See Fig. 2.22. After the data for

one raster is set, drive voltage is applied to that raster to give a display. Each display

screen is constructed by 128 rasters on an 80 column x 14 line LCD module.

The FRM signal controls one screen display cycle, the LOAD signal controls one laster

cycle, and the CP signal controls the 4-bit data transmission cycle. LCD operation

timing is listed in the chart in Fig. 2.20. Usually, the LCD will deteriorate if DC voltage is

applied. Therefore, AC voltage is applied to drive the LCD. The DF(M) signal controls

this drive.

Timing Chart

LOAD J a 123 gg eS

oe JU X36, X64, Xl 28 XI X2

Ds O08 reeence xX

po JORBOO O0KRE ao MIN mae

FRM _ —

LOAD 1 ae [| | “i {| 2 [|

a je. C4, 120K 1

a Z 1 i | 2nd FRAME

}st FRAME CF CM) +


THEORY SERVICE MANUAL Electrical

DO-D3 a -- +

CP [ * + 4 le

LOAD |

DPM ; | ae SRT ' ribyde y py yyy PoC) } Vice. aes (Ca. Fes | | es

80 80 86 (* " 80

\

Laer PN ek fee, 36

—LeF A80X128 DOTS

POWER ciikes.T

VDD —- VDD

| RI | . nas 6

VSS —— —=VO

VEE |

Fig. 2.21 — Block Diagram of LCD Module


THEORY

SERVICE MANUAL | Electrical

61. 39C1 4L INE) Fig. 2.22 — Display Pattern

be x

ao — — — —- —-—— neo ooo | . | Oo

WN

| 80X1 4LINE | o

| | 00 S

| | =

| Me af d Oo Z 7

SYMBOL LEVEL

vss

DF(M)

FRM H

a LOAD HL. Data Latch Pulse

H/L ee

Table 2.7— LCD interface Signal

V

GND


HEORY seta SERVICE MANUAL

6.3 LCD Drive Voltage (VEE) Generation Circuit

The LCD drive voltage (VEE) is supplied by the circuit shown in Fig. 2.23. It consists of

a DC-DC converter. The +24 VDC source voltage is switched continuously by the

20kHz pulses from gate array #7 to energize L1. The reverse voltage generated by L1

is rectified by D11 and regulated by ZD1. Zener diode ZD1 (RLZ20D) determines the

VEE voltage (-21.5).

Fig. 2.23 =

LCD Drive Voltage (VEE) ww) Generation Circuit oe am

as .

o> _ CO cae

1k reer R11 0 2 RS2 5

| | x SB FO Co ord Reo oOo f= > ras

oye ms = Lan

Abé+

022 18


2", =* i THEORY SERVICE MANUAL

Electrical

a

7. FDD (Floppy Disk Drive) Control

7.1 FDD Configuration

The FDD consists of two sections: the FDD controller and the FDD module. The FDD

controller circuit controls the contents to be received and stores the data in the FDD

module. The FDD module drives the motors, sensors, and magnetic head. The

interface signals between the FDD and the FDC are shown in Table 2.8 below:

DRIVE SELECT @ 1012 This signal is set to LOW when the FDD unit is opening (except for the DD Motor).

When this signal is set to LOW, data can be written by the WRITE DATA signal. When this signal is set to HIGH, the READ

and STEP operations are enabled.

WRITE GATE

Read/Write Circuits

Data is written at the falling edge of this

WRITE DATA signal while the WRITE GATE signal is LOW. This signal indicates the polarity data read

READ DATA by the head.

This signal is used to select the head:

SIDE 1 SELECT 32 LOW:Head 1

, HIGH:Head 0

This signal becomes LOW, starting the DD motor, when a disk is set in the drive.

DC MOTOR MOTOR ON Setting this signal to HIGH or removing the

disk stops the DD Motor.

16

This signal sets the head in the direction

STEP designated by the DIRECTION signal.

STEP MOTOR This signal designates the movement of

the read/write head:

DIRECTION 18 LOW: Inward to the disk’s center

22

Motor Drive

Circuit

SELECT HIGH: Outward from the disk’s center.

WRITE PROTECT

INDEX

Status Check

When this signal is LOW, either there is no disk in the drive or the disk in the drive is

write-protected.

This signal indicates the beginning of a track by outputting one pulse in each rotation of the disk.

When this signal is LOW, the head is located at track 00 (the outside track). Otherwise, the signal is HIGH.

When this signal is LOW, there is no disk in

the drive..

Table 2.8 — FDC (#8) and FDD Module Links

(Interface Signals)

TRACKOO

DISK CHANGE


THEORY Elecitcal | | SERVICE MANUAL

7.2 FDD Operation |

7.2.1

7.2.2

Basic operation

CPU (#1) writes commands to FDC (#8), and the FDC (#8) controls the FDD in

accordance with these commands and reads/writes data. See Fig. 2.24.

Interface between CPU (#1) and FDC (#8)

If CPU (#1) accesses an internal register other than the data register in FDC (#8), the

normal read/write operation will be performed. If CPU (#1) transmits data to or receives

data from FDC (#8), DMA communications will be performed using the DMA function of

CPU (#1).

CPU (#1) resets FDC (#8), detects the density signal which indicates whether the

floppy disk is a 2DD or 2HD, and outputs to FDC (#8).

READ/WRITE CIRCUIT

MOTOR DRIVE CIRCUIT

SENSOR CIRCUIT

Fig. 2.24 - FDD Block Diagram

Printed in USA May, 1995 52 © Brother tnternational Corp., 1995

THEORY

SERVICE MANUAL Electrical

al dn tla il TE

7.3 FDD Module

The FDD Module is composed of the motor, sensor, magnetic head, and the IC that

drives them. The FDD Module is controlled by the FDC #8 of the CPU PCB.

7.3.1. Read/Write Circuit

in read operation, the circuit amplifies the analog signals picked up by the magnetic

head and converts the analog signal to serial digital pulses. The serial pulses are then

transmitted to the FDC #8 and decoded to parallel digital data. In write operation, the

circuit controls the current at the magnetic head according to the serial digital pulses

from the FDC #8.

7.3.2 Motor Drive Circuit

The motor drive circuit consists of two parts: a DC motor drive circuit and a stepping

motor drive circuit. The DC motor drive circuit controls the DC motor, which rotates the

spindle according to the MOTOR ON signal from the FDC. The stepping motor drive

circuit controls the stepping motor, which operates the magnetic head unit according to

the “STEP” and “DIRECTION SELECT’ signals from the FDC #8.

7.3.3 Sensor Circuits

The following sensor circuits detect the status of the FDD:

1. Write Protect Sensor

When a write-protect notch on a disk is set to the write-protect position, the “WRITE

PROTECT’ signal becomes LOW. A micro-switch is used for detection.

2. Index Sensor

The “INDEX” signal shows the beginning of a track; when the beginning of a track is

detected, the “INDEX” signal becomes LOW. A magnetic sensor is used for

detection.

3. Track 00 Sensor

When the magnetic head is positioned in track 0 on a disk, the “TRACK 00” signal

becomes LOW. A photo sensor is used for detection.


Y : a: | LSet SERVICE MANUAL

4. Disk-in Sensor

When a disk is inserted in the FDD, this sensor outputs a LOW ievel signal (HIGH

when no disk). The output of the sensor is connected to the controller and sent as a

“DISK CHANGE” signal that shows whether a disk is changed; when a disk is

changed, the “DISK CHANGE” signal becomes LOW. Once the “DISK CHANGE”

signal becomes LOW, it remains low until the “STEP” signal is received from the FDC

#8. A micro-switch is used for detection.

7.4 FDD Performance Specifications

Specifications [we [28 Track (Kbyte) 6.25 12.50 Disk (Kbyte) 1,000 2,000

0.256 (16)| 0.256 (32) Sector [sector] [~ 9532 (9)| 0.512 (18)

(Kbyte)

Capacity Pe Formatted sesooaies (Kbyte) )

656.360 (16)

'319.200 (6) [1638.40 _(70)| Disk [sector] (Kbyte).4

Recording density of inside track (bpi) (side 1)

Date transmission speed (Kbit/sec)

Number of heads

Number of tracks

Track density (tpi) 135

Recording Method FM / MFM

Recording Density

Disk revolutions (RPM) 300

LSV (long-term speed variation) (%) + 1.0 (max.)

Motor ISV (instant speed variation) (%) + 1.5 (max.)

Properties Drive motor starting time (msec) 400 (max.)

Access time between tracks (msec) 3 (max.)

Settling time (msec) 15 (max.)

: ene : Insert (g) 400 (max.) inserting and Ejecting the Disk

Noise (scale A) (dB) (at a step rate of 3 ms) 40 (max.) (1 m away from FDD)

Table 2.9 - FDD Performance Specifications


THEORY SERVICE MANUAL | Electrical ER IEE PI ES EET II SESS)

8. Power Supply PCB

8.1 Configuration

CoS ae NOTE: R15 shown at right,

The AC input power is applied to the primary

side of adaptor. The adaptor secondary output

is converted to approx. +12 VDC by the internal

bridge rectifier and capacitor. The +12 VDC is

supplied to the power supply unit (PSU)

through switch SW1 and fuse F1. The voltage

is filtered through L1, and converted into +5V,

+8V (backlight models only), and +24V. This

voltage is then supplied to the main PCB

through CN1.

(silk-screen) but not used (replaced by jumper wire).

Fig. 2.25 — AC Adaptor & Power Supply


THEORY Electrical

. 8.2

SERVICE MANUAL

Circuit

The input voltage is converted to +5V by the regulation network Q1 and #3. The output

voltage of Q1 is selected by R5 and R6. The +24V is obtained using the network #1,

L1, D1, and Q2; the Q2 output voltage is determined by R8 and R9.See Fig. 2.26.

Fig. 2.26 — Power Supply Circuit

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REPAIR

SERVICE MANUAL A #eusigehostne

Part Il REPAIR

CHAPTER3 TROUBLESHOOTING

1. INTRODUCTION

This chapter explains troubleshooting procedures for the word processor. Since it is

impossible to troubleshoot all instances of a problem, only a limited number of cases

are presented. Thorough understanding of the procedures given in each section is

essential for efficient troubleshooting, and can provide a good insight to the problem.

2. PRECAUTIONS

2.1 Personal Safety

WARNING: _ If there is chance of electrical shock, this symbol will

precede any instructions in this manual. Follow the safety

advice carefully!

@

in addition to any specific warnings as described above, be sure to take the following

precautions for your personal safety:

¢ Unplug the AC adaptor from the AC outlet before removing the covers and PCBs, or

before making any mechanical adjustments.

¢ Unplug the AC adaptor from the AC outlet before checking continuity.

e When disconnecting a connector, grasp it firmly. Do not pull on the connector’s lead

wires. If the connector has a lock mechanism, unlock it before trying to disconnect it.

© Brother Internationa! Corp., 1995 57 Printed in USA May, 1995

REPAIR | . - Troubleshooting

SERVICE MANUAL

2.2 Handling ESD-Sensitive Parts

Many electronic products use parts that are known to be sensitive to electrostatic

discharge (ESD). To prevent damage to ESD-sensitive parts, observe the caution

symbols throughout these instructions, as well as the additional precautions below.

CAUTION: _ Electro-Static Discharge Hazard

Wear an anti-static wrist strap with ground wire to prevent

damage to sensitive electronic components.

In addition to the usual precautions, such as turning off power before removing circuit

boards:

* Keep the ESD-sensitive part in its original shipping container (a special “ESD bag”)

until you are ready to install it.

* Do not place the ESD-sensitive part on the machine cover or on a metal table; if you

need to put down the ESD-sensitive part for any reason, first put it into its special

bag.

e When holding ESD-sensitive parts, limit your body movement to prevent an increase

of static electricity from clothing fibers, carpets, and furniture.

e Hold the ESD-sensitive part by its edge connector shroud (cover); do not touch its

pins. If you are removing a plugable module, use the correct tool.

e Be extra careful in working with ESD-sensitive parts when cold-weather heating is

used, because low humidity increases static electricity.

* Prevent ESD-sensitive parts from being accidentally touched by other personnel.

Install machine covers when you are not working on the machine, and do not put un-

protected ESD-sensitive parts on a table.

« \f possible, keep all ESD-sensitive replacement parts stored in a grounded metal

cabinet (case) until ready for use.


ar

REPAIR SERVICE MANUAL Troubleshooting SS a AT Rr Oe I a NO I OI PE ON I I NE Re Ti ae NE LEED

3. CHECKS BEFORE REPAIR

CAUTION: — Electro-Static Discharge Hazard Wear an anti-static wrist strap with ground wire to prevent


Check the following possible causes before attempting more extensive repairs to the

machine:

¢ Run the appropriate Self Test operation (from the software) for the suspected problem before attempting any mechanical or electrical troubleshooting.

¢ Supply voltage: Check the AC input voltage and DC supply voltage for ail sections. Make sure they meet specified voltage values.

¢ Connectors: Check all connectors and make sure they are tight.

e Fuses: Check for blown fuses (Fl and the thermo-fuse inside the AC adaptor).

NOTE: In the logic control circuit, it is difficult to isolate faulty points in areas connected to the CPU by the address bus or the data bus or in the address bus or data bus connecting the VRAM to gate array #4. If a suspected problem involves the address bus or the data bus, first check the solder bridge and the cut circuit

pattern. If a faulty point cannot be isolated, replace the peripheral devices or the PCB.

4. CHECKS AFTER REPAIR

After completing a repair, check to confirm that the trouble has been eliminated. Also,

record the troubleshooting procedures used for reference.

© Brother International Corp., 1995 59 . Printed in USA May, 1995

REPAIR Troubleshooting

SERVICE MANUAL

5. TROUBLESHOOTING FLOW CHARTS

Printed in USA May, 1995 60

NO LCD Operating correctly? Problem No. 14

} Problem No. 2 Carriage (printhead) moves?

NO Printer home position detected? Problem No. 3

NO Keys work properly? Problem No. 4

NO Prints normally? Problem No. 5

Paper feeds normally? Problem No. 6

Fig. 3.1 — Troubleshooting Flowchart


SERVICE MANUAL

Does the buzzer sound when an invalid key is

pressed?

YES

Does the LCD operate?

YES

Does the LCD display correctly? Zo

YES

Does the unit prin when paper is set, or print when no paper is

set?

YES

Does the FDD operate correctly?

YES

Does the ACF operate correctly?

YES

Does an error message appear on the display?

END

NO

NO

NO

NO

NO

NO


Problem No. 7

Problem No. 8

Problem No. 9

Problem No. 10

Problem No. 11

Problem No. 12

Problem No. 13 LULYLELEL Fig. 3.2 - Troubleshooting Flowchart (cont’d.)


REPAIR | a 7 Troubleshooting SERVICE MANUAL

6. FAILURE ANALYSIS

The following table lists the failure problems for troubleshooting all basic systems. See

the Troubleshooting Tables on the following pages for a troubleshooting protocol.

Problem = fe)

Nothing happens when the power is switched on (Nothing appears on the LCD).

When the power is switched on, the LCD display operates but the carrier does not return to its home position.

When the power is switched on, the carrier moves to the left but cannot detect its home position (i.e., the home position indexing mechanism is faulty).

Keys malfunction (do not insert characters or insert wrong characters)

Printing results abnormal (various unsatisfactory printing results)

Line Feed motor does not work properly.

The buzzer does not sound.

Power in on, but nothing appears on the LCD.

LCD displays operates, but data displayed is incorrect (does not match input).

Word Processor prints when no paper is set, or will not print when paper is set (Paper End Sensor malfunction).

The FDD does not operate correctly.

The ACF (Auto Cut-Sheet Feeder) does not operate.

An error message appears on the display.

Table 3.1 — Failure Analysis

Printed in USA May, 1995 ; 62 © Brother International Corp., 1995

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‘Printed in USA May, 1995 66 © Brother International Corp., 1995

REPAIR SERVICE MANUAL Troubleshooting FN a a

7. Self-Tests

From the Main Menu, two self-test modes are available:

1. Self-Print

Press the CODE + SHIFT + RETURN keys.

2. Self-Test

Press the CODE + SHIFT + BACKSPACE keys.

7.1 SERIAL NUMBER Input Display

The machine prompts you for the unit serial number after the Self-Test mode is

accessed, but before the test is started:

¢ From the SELF PRINT screen

¢ From the SELF TEST menu, after selecting a test, or after pressing the “S” key.

SERIALNO.: &@

Type SERIAL NO. and press RETURN.

' Fig. 3.3 - Serial Number Eniry Display

NOTES: ¢ The maximum number of characters that can be input is 9; alphanumeric keys are the only acceptable input.

¢ The RETURN key can also be pressed without entering a serial number.

e Pressing CANCEL while the SERIAL NUMBER prompt is displayed cancels any number entered (before pressing RETURN), and returns to the SELF

TEST menu.



SERVICE MANUAL

7.2 Self Print Mode

(1) From the Main Menu, press CODE+SHIFT+RETURN. The SELF PRINT display

appears, with the SERIAL NO. input pop-up screen.

(2) Enter the unit serial number and press RETURN (or press return without entering

a number). The SERIAL NO. pop-up is replaced by another pop-up window

prompting you to verify whether the optional CUT SHEET FEEDER mechanism is

installed (the default setting is “OFF” — no CSF installed).

(3) Press RETURN (if no ACF installed), or press the SPACE bar to change the

setting to “ON” (if ACF installed), and press RETURN. The CSF pop-up window

disappears, and a sum check of the MAIN RAM, MAIN ROM and DICTIONARY

ROM are then performed.

kkkKK S ELF PRINT*****

VIDEO RAM Checking... OK.

MAIN ROM Checking... OK.

CG ROM Checking... OK.

DICTIONARY ROM — Checking...

D-RAM Checking...

Fig. 3.4 — Self-Print Screen

NOTES: ° “OK” is displayed if the checked item is normal (“NG° if there is an error). If

the result of all checks is “OK”, the carriage is returned and the self-print (“all

character’) test is started.

« If there are any errors in the sum check, self-printing will not start. The buzzer

will not sound, but the SELF PRINT screen will remain. It will not be possible

to proceed with any operation (cycle the power switch to reset the system).

* The following print format settings are in effect for the test:

Font type: Brougham

Font size: 12 point

Type style Normal

Line space: Auto

Left/right margins: | 0-9.1 inch (w/o CSF)

1 — 7.4 inch (with CSF)

Tab setting: None


REPAIR Troubleshooting SERVICE MANUAL

* The following printing pattern is printed:

LM Without Cut Sheet Feeder RM

9.1 inches

[Memory Codes 21(H) to 7E(H) printed]

LM With Cut Sheet Feeder RM

H

1 inch 6.4 inches

[Memory Codes 21(H) to 7E(H) printed]

Without the Cut Sheet Feeder, the serial number is printed on the first line (if

it was input), and then 65 lines of characters are printed at 91 characters per

line; with the Cut Sheet Feeder, the serial number is printed on the first line (if

it was input), and then 59 lines of characters are printed at 91 characters per

line; with each line beginning with one character from the right of the previous

line.

* If the CANCEL is pressed while the serial number input screen is displayed,

the input character string will not be registered as a serial number and display

will return to the Main Menu screen.

* If the SPACE BAR or CANCEL key is pressed during printing, self-printing is

suspended and the pop-up screen shown below is displayed:

OK to cancel printing?

Use cursor to: select and press: RETURN:

[YES]

@ If RETURN is entered while the cursor is located at “YES”, self-printing is

canceled and the display returns to the Main Menu.

¢ If RETURN is pressed while the cursor is located at “NO”, self-printing is

resumed.


REPAIR Troubleshooting SERVICE MANUAL SEA LL TL TE IONE LIT BI IL SEINE BETTE AN ES TREO TE 0S I SE EI ENE ST EET,

$%&'()*+, -./0123456789: ; <=>? @ABCDEFGHI JKLMNOPORSTUVWXYZ(\J *_"abcdefghijkimneoparstuy BY&* (5 *4+,-./0123456789: ; <=>? @ABCDEFGHI JKLMNOPQORSTUVWAYZ(\] *_ abcdefghijkimnopgqrstuv b&' () *+,-./0123456789: ; <=>? @ABCDEFGHIJKLMNOPORSTUVWXYZ {[\]*_” abcdefghijklmnopqrstuvw: '() #+,-./0123456789: ; <=>? @ABCDEFGHI JKLMNOPORSTUVWXYZ [\] “_" abcdefghijkimnopqrstuvwx:

() *+,-./0123456789: ; <=> ?@ABCDEFGHIJKLMNOPORSTUVWXYZI\] *_" abcdefghijkimnoparstuvwxy:

)%+,-./0123456789: ; <=>? @ABCDEFGHIJKLMNOFORSTUVWXYZ[\]*_" abcdefghijklmnopqrstuvwxyz

*+,-./0123456789: ; <=>? @ABCDEFGHIJKLMNOPORSTUVWXYZ[\] *_ abcdefghijklmnoparstuvwxyz{.- t+, ~./0123456789: ; <=>? @ABCDEFGHI JKLMNOPORSTUVWXYZi\j *_~abcdefghijklmnopqrstuvwxyz{|.

,-./0123456789: ; <=>? @ABCDEFGHI JKLMNOPQORSTUVWXYZ{\j*_" abcdefghijklmnopgqrstuvwxyz{j}° -./01234567 89: ; <=>? @ABCDEFGHIJKLMNOPOQRSTUVWXYZi\i*_° abcdefghijklmnopqrstuvwxyz{]}>~:

./0123456789: ; <=> ?@ABCDEFGHIJKLMNOPORSTUVWXYZ[\]*_"“abcdefghijklmnopqrstuvwxyz{j}7 1" /0123456789: ; <=>? @ABCDEFGHIJKLMNOPORSTUVWXYZ{\1*_ abcdefghijklmnopgrstuvwxyz{}}71"F

0123456789: ; <=>? @ABCDEFGH LUKLMNOPQRSTUVWXYZi\j *_"abcdefghijklmnopgrstuvwxyz{|}7!1"#§ D123456789: ; <=> ?@ABCDEFGHIJKLMNOPQRSTUVWAYZi\] 7_"abcdefghijkimnopqrstuvwxyz{j}7!"#ss 23456789: ; <=> ?@ABCDEFGHIJKLMNOPQRSTUVWXYZ{\]*_~abedefghijkilmnopaqrstuvwxyz{ |} ~!"#S%é 3456789: ; <=>? @ABCDEFGHI JKLMNOPORSTUVWXYZi\j *_" abcdefgnijklnnopgrstuvwxyz{[}71°#S%6'

8456789: ; <=> ?@ABCDEFGHI JKLMNOPORSTUVWXYZ{\] *_~abcdefghijkimnopgqrstuvwxyz{[}7!"#58&' ¢ H56789: ; <=>? @ABCDEFGHI JKLMNOPORSTUVWXYZ[\]*_~ abcdefghijklmnopqrstuvwxyz{{}7!"#$8&' { 6789: ; <=>? @ABCDEFGHIJKLMNOPORSTUVWXYZ[\j *_~ abcdefghijkimnopqrstuvwxyzi{}7!"#$e&' ()* 789 :;<=>?@ABCDEFGHIJKLMNOPORSTUVWXYZ{\]*_“abcdefghijkimnopqrstuvwxyz{j}7!"#$%&' () *4 789 : 5 <=>? @ABCDEFGH1IJKLMNOPQRSTUVWXYZ{\] *_~abcdefghijklmnopqrstuvwxyz{|}7~1"#$%&' () *+q B9: ; <=>?@ABCDEFGHIJKLMNOPQRSTUVWKYZ[\]*_"abcdefghijklmnopqrstuvwxyz{}}7!1"#$%a' () *+,

:j] <=> ?@ABCDEFGHI JKLMNOPORSTUVWXYZ[\] *_“abcdefghijklmnopgrstuvwxyz{|}71"#$8&' () F+,- | <=> P@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]}] *_"abcdefghijkimnopgqrstuvwxyz{|}~!"#S%&' () *+,-.

; <=> ?@ABCDEFGHIJKLMNOPQRSTUVWXYZ{\}*_" abcdefghi)klmnopgrstuvwxyz{|}7!"#$%&'() +,-. => ?@ABCDEFGH I JKLMNOPQRSTUVWXYZ[\] *_~ abcdefgni)jklmnopqrstuvwxyz{[}7!"#$%8' () t+,-. > P@ABCDEFGHI JKLMNOPQRSTUVWXYZ[\]*_ abcdefghijklmnopaqrstuvwxyz{|}7!"#$$&' ()*+,-./074 ? @ABCDEFGH I JKLMNOPQRSTUVWXYZ{\}*_~abcdefghijklmnopqr stuvwxyz{ {J} ~!"#$8e' () ¥+,-./012

? @ABCDEFGH1IJKLMNOPQRSTUVWXYZ[\] *_" abcdefghijkimnopqrstuvwxyz{ | }7!"#$%&' () *4+,-./0123 @ ABCDEFGHIJKLMNOPORSTUVWXYZ(\j*_"“abcdefgnijklmnopqrstuvwxyz{]}~1"#$%&' () *+,-./012344 ABCDEFGHLJKLMNOPQRSTUVWXYZ{\j*_" abcdefghijklmnopqrstuvwxyz{]}~!"#$%&' () *+,-./0123454 CDEFGHIJKLMNOPOQRSTUVWXYZ(\] *_~abcdefghijklmnopgrstuvwxyz{j}}7 !"#$B&' () *+,-./0123456

DEF GHIJKLMNOPORSTUVWXYZ[\}*_* abcdefghijklmnopqrstuvwxyz{ jj 7! "#$%&' () *+,-./012345678 IDEF GH IJKLMNOPQRSTUVWXYZ1\) *_"abcdefghijklmnopqrstuvwxyz{|}7!"#$%&' () #+,-./0123456784 EFGHLUKLMNOPQRSTUVWXYZ[\} *_~ abcdefghijklmnopgrstuvwxyz{]}~!"#$%&' () *+,-./6123456789 FGHI JKLMNOPORSTUVWXYZI\j*_"abcdefghijkimnopqrstuvwxyz{|{}7 1" #$%&' () *+,-./0123456789: GHI JKLMNOPQRSTUVWXYZ[\} *_" abcdefghijkimnopqrstuvwxyz{{}71"#$%&' () *4+,-./0123456789; ; + HIJKLMNOPORSTUVWXYZ{[\] *_~ abcdefghijklmnopaqrstuvwxyz{|J7 1" #$%&' () *+,-./0523456789:;< IJKLMNOPORSTUVWXYZ[\] *_~abcdefghijklmnopgrstuvwxyz{]}7!"#$8&' () *+,-./0123456789: 7 <=> JKLMNOPORSTUVWXYZI[\] *_"abcdefghijkilmnopqrstuvwxyz{}]}7!"#$sS' () *+,-./0123456789: ; <=>

KLMNOPQRSTUVWXYZ([\] *_~abcdefghijklimnopqrstuvwxyz{j}71"#$%&' () *+,-./0123456789: 5 <=>? LMNOPORSTUVWXYZ{[\] *_~abcdefghijklmnopgrstuvwxyz{ | }7!"#$%&' () ¥+,-./0123456789: ;<=>76h MNOFORSTUVWXYZ[\] *_" abcdefghijklmnopgqrstuvwxyz{|}7!"#$%&' () *+,-./0123456789: ; <=> 7@AE NOPQRSTUVWXYZ [\]*_~ abcdefghijklmnopgqrstuvwxyz{|}7!1"#$%&' () *+,-./0123456789: ;<=>?P@ABe OPQRSTUVWXYZ{\] *_" abcdefghijklmnopqrstuvwxyz{|}7!"#$%&' () *+,-./0123456789: ; <=>? @ABC PORSTUVWXYZ{\] *_ abcdefghijklmnopqrstuvwxyz{{}7!"#$8&' () *+,--/0123456789: ; <=>? @ABCD QIRSTUVWXYZ(\) *_” apcdefghijkimnoparstuvwxyz({s7!"#$%&' () *+,-./0123456789: ; <=>?@ABCDEF RSTUVWXYZ[\] °_" abcdefghijklmnopgqrstuvwxyz{|}71"#398&' (7 ¥+,-./0123456789: ; <=>?7@ABCDEF STUVWXYZi\)} 7 abcdefghijklmnoparstuvwxyzit]}7!"#$%&' () *4+,-./0123456789: ; <=>?@ABCDEFG TUVWXYZ{\] *_"abcdefghijkimnopgrstuvwxyz{|}~!"#$%&' () *+,-./0123456789: ; <=>?@ABCDEFGH

JVWXYZ(\]*_ abcdefghijklmnopqrstuvwxyz{}}~!"#$%ée' () #+,-./0123456789: ; <=>? @ABCDEFGHIL VWXYZ i\} *_abcdefghijklmnopqrstuvwxyz{|ji~!"#$%&' () #+,-./0123456789: ; <=>?@ABCDEFGHIT AXYZ[\] *_~ abcdefghijklmnopqrstuvwxyz{]}71"#$%&' () #+,--/0123456789: ; <=> ?@ABCDEFGHIJK XY¥Z[\]) *_ abcdefghijklmnoparstuvwxyzi|}7!"#$%4' (j *+,-./0123456789: ; <=> 7@ABCDEFGHIJKL} YZ|\)*_" abcdefghijkimnopqrstuvwxyz{[}7!1"#5%&' (j *+,-./0123456789: ; <=>7@ABCDEFGHIJKLM} 2(\}*_" abedefghijklmnopqrstuvwxyzi]j7!"#$8&' (j) #+,-./0123456789: ; <=>? @ABCDEFGHIJKLMN

1} i

Fig. 3.5 — Results of Self-Print Test

Printed in USA May, 1995 70 . © Brother International Corp., 1995

REPAIR

SERVICE MANUAL Troubleshooting

a nL a ED

7.3 Self-Test Mode

There are 6 tests types available in Self-Test Mode: (1) LCD Display tests, (2) Printer

Checks, (3) Keyboard Test, (4) FDD Tests , (5) PE (Paper Exist), and (6) CR (Carriage

Reset to Home Position).

(1) From the Main Menu, press the CODE + SHIFT + BACKSPACE keys, and the

menu shown below displays.

(2) Press the character key for the desired test.

“++ SELF TEST MENU ***** DISPLAY 1 PRINTER 2,3 KEYBOARD 4,5,6 FDD 7,8,9,D,E PE CR

SERIAL NO. DISK TYPE. « 2HD

CUT SHEET FEEDER. — ON

Please select the number. Press CANCEL to finish.

Fig. 3.6 — Self-Test Menu

NOTES: « Pressing the CANCEL key while the above menu is displayed will return the

display to the Main Menu.

¢ The keys that can be used while the Self Test menu is displayed are:

Alphanumeric keys start the test P INS, PUP/P DOWN , feed paper CANCEL retums to the Main Menu

¢ {f a serial number has been input, it will be displayed in the brackets to the right of the serial number menu item, if no serial number has been entered,

only the brackets will be displayed.

e If there is a problem with the printer, an error message is displayed, and

testing will continue without performing the printer test.

¢ During printing, HELP is enabled. If HELP is accessed, printing is suspended;

when HELP is closed, printing resumes.

© Brother Intemational Corp., 1995 71 Printed in USA May, 1995


7.3.1. DISPLAY (LCD) Tests

There are four display checks available: 1) CHECK, 2) CROSS, 3) BLACK, and 4)

DISP.Q.

(1) From the Self Test menu, select “1” to open the LCD Test Menu.

(2) Press the number key for the desired display test. The screen displays the selected test pattern.

***** LCD TEST MENU *****

1. CHECK

2. CROSS 3. BLACK

4. DISP. Q

-Please-select the number. Press CANCEL to finish:.’

Fig. 3.7 - LCD Test Menu


REPAIR

SERVICE MANUAL Troubleshooting SERA Sa re sa PE IEE BT OS 0 SEED

Check Test

The CHECK test displays every other bit as shown below (magnified).

Select “1” from the MENU screen. .

NOTE: Press the space bar and the displayed bit pattern is reversed.

1 2 3 4 5 6 7 8 9 10 11 12 138 14

Fig. 3.8 —- CHECK Test Display (magnified)


REPAIR SERVICE MANUAL Troubleshooting

Cross Test

The CROSS test displays the grid pattern shown below (magnified).

Select “2” from the MENU screen.

NOTE: Press the space bar and the displayed pattern is reversed.

1 2 3 4 5 6 7 8 9 10 41 #12 #13 «14

Fig. 3.9 - CROSS Test Display (magnified)


REPAIR SERVICE MANUAL Troubleshooting EE A ae I CI aE a a IN TI a ER ND ET TIE SITE

Black Test

The BLACK test checks for missing dots (pixels).


NOTE: Press the space bar and the displayed pattern is reversed.

Every pixel on the screen is displayed.

Fig. 3.10 — BLACK Test Display



Displa Test

The DISP Q test displays the character “Q” on the entire screen.


NOTE: Press the space bar and the displayed pattern is reversed. |

1 i: i ae <a: ne f 8 9 10 11 12 13 14

Fig. 3.11 — DISP. Q Test Display (magnified)


REPAIR ~ SERVICE MANUAL . Troubleshooting A LTS A TN i Nc NN BERS RTE aS OE AY

7.3.2 Print Checks

There are 2 self-test print checks.

Print Test Pattern 1

Purpose: to check that all characters are printed correctly.

From the Self Test menu, select “2” from the MENU screen. When printing is complete,

the display automatically returns to the Self Test menu. The diagram (see in Fig. 3.13)

shows which characters should be printed and their locations in reference to each

other. A sample of the printed test pattern is shown in Fig. 3.14.

"*** PRINTER CHECK ****

Press CANCEL to go to MENU.

Fig. 3.12 — Printer Check #1 (in progress) Display

NOTES: « A paper check is performed before printing. If paper is set, the print test is executed; if no paper is set, insert paper and press RETURN.

* Pressing the CANCEL key during printing will stop the test (paper is advanced), and return the display to the Self Test menu.

* If a serial number has been input before starting the test, the pop-up window will prompt for the serial number; either enter the serial number, or press RETURN to start the test. If a serial number is entered, it will be printed on the first line of the test.

¢ During printing, HELP is enabled. If HELP is accessed, printing is suspended; when HELP is closed, printing resumes.


REPAIR . | Troubleshooting SERVICE MANUAL

0.5 inch

SERIAL NO.: XXXXXXXXxX (9 digits)

1/6 inch

eee 1/6 inch

eee aerate t 4/6 inch

1/6 inch

| |

1/6 inch

A 12 point hyphen is printed 10 times on each of 26 lines here.

Fig. 3.13 — Diagram of Print Test Pattern 1

«<———— The 20(H) to EF(H) characters are printed on this line (12 point).

<————_ The 20(H) to EF(H) characters are printed on this line (7 point).

«<————_ The 20(H) to 5F(H) characters are printed on this line (24 point).

«<————_ This line is a printout of a screen line in which the column of single dots at the left margin of each character gen- erator character space is highlighted. A row of dois corresponding toa single raster scan is also highlighted in each character space, the raster being one lower than in the previous character space (total of 54 raster scans).


REPAIR

SERVICE MANUAL Troubleshooting Aa LE I I TEI eR ce OE LR SR EAD

SERIAL NO.:

1"#$%&' () ¥4,-./0123456789: }<=>?@ABCDEFGHIJKLMNOPORSTUVWXYZ[\]*

Adddae 6666111 LASO6SS6eEGOOOUYBYVS44$saijye j«mn* “CE¥ FAILG +++] -O@O/n8 Q°.

wits 205) 8. OSS ite eet pees Mass ey S.YAhUe NL eee gs res wevwayet fi ARARABM TS Py oo aye OV SAMA a dee eete Lit ls SARE LOLS STege Nyce ews MT | TPS 2

I"#$9&'" () *+,—-./0123456789: 7 <=>? @ABCDEFGHI JKLMNOPORSTUVWXYZ [\] *

: :

chad tahe toe bli t rd id cet wae See ee

26 7 ee NOTE: The print format settings are as follows:

_ Font: Brougham

Cems Type/Style: Normal (12 point/7 point); ret ds eaters Bold (24 point)

ced Pa a oh weed Line space: Auto

Bo ete Lefi/right margins: 1.0 — 7.4 inches

Fig. 3.14 — Sample Print Test Pattern 1



SERVICE MANUAL

Print Test Pattern 2

This print test checks that all characters are printed correctly.

Erom the Self Test menu, select “3” from the MENU screen. When printing is complete,

the display automatically retums to the Self Test menu. A sample of the printed test

pattern is shown in Fig. 3.14.

***** PRINTER CHECK *****


Fig. 3.15 — Printer Check #2

(in progress) Display

NOTES: « A paper check is performed before printing. If paper is set, the print test is

executed; if no paper is set, insert paper and press RETURN.

¢ Pressing the CANCEL key during printing will stop the test (paper is

advanced), and return the display to the Self Test menu.

* Ifa serial number has been input before starting the test, the pop-up window

will prompt for the serial number; either enter the serial number, or press

RETURN to start the test. If a serial number is entered, it will be printed on the

test.

¢ During printing, HELP is enabled. If HELP is accessed, printing is suspended;

when HELP is closed, printing resumes.

° The print format settings are as follows:

Font: Brougham

Type/Style: Normal

Line space: Auto

Left/right margins: 0.1 inch -8.1 inches


‘REPAIR


a ta a

Pattern 1 Mika ee

Pattern 4 Pattern 2 —__-_»

HHHHHUHHHHHH EHH HHH HHH HHH HHH HHH HHH

HHHHHHH HHHHH HHA HE HHHHBABH HHH HHH AHHH HHH HHH

TAINAN TET i

Pattern 5

36 et

igits)

Pl bale ik bol es ia etal SERIAL NO.: 9

XXXXXXXXX (9 Q.

Pattern 6

Fig. 3.16 —- Sample Print Test Pattern 2

© Brother International Corp., 1995 81 Printed in USA May, 1995 -


Dot Patterns

The following dot (print) patterns correspond to the print test #2 pattern result on the

previous page. See also Fig. 3.16 for the location of each dot pattern type.

<Pattern1 > : <Pattern2 > —

0 15 29 Q 18 29

0 2 2

25

51 §1 53 §3

<Pattern 3 > <Pattern4 >

0 23 0123 ; 29

ono one 633 OO

PREUGERERTERLEREE

PERRESEREREREEEE

PRUGERURRERREETE

BERGE RECET CRETE

SOR UREEREERRREEEE $1 a PURER EEEEREEEEES

_ Fig. 3.17 — Dot Patterns for Print Test #2


REPAIR

SERVICE MANUAL Troubleshooting Fe LR NN a a SS tS)

< Patterns > < Pattern 6 >

0123 29 0

{Eo i=)

Ei ry net tt th Sa ete et co lc rc

Fig. 3.18 — Dot Patterns for Print Test #2 (Patterns 5 & 6)



7.3.3 Keyboard Tests

Keyboard Inspection checks that the keys are making proper contact. There are three

keyboard self-tests.

(1) Select “4”, “5” or “6” from the Seif Test menu. If a serial number has not been input before starting the test, the pop-up window will prompt for the serial number; either enter the serial number, or press RETURN to start the test. The display in Fig. 3.19 below indicates that the keyboard test mode has been

established.

***** KEYBOARD TEST *****

Press: RETURN twice to go. to MENU.

Fig. 3.19 — Keyboard Test #1 Display

NOTE: The location of the keys tested in each test sequence (test 4, 5, or 6) are shown

below: ;

P

Fig. 3.20 — Keyboard Test Key Locations



(2) To run Test “4” (all keys in Fig. 3.20, “A”):

a) Starting from the top left of the keyboard, press each key in turn (see sequence in below).

b) Then press SHIFT. +Z, SHIFT+/, and CODE+SPACE. If there is no problem, the message “KB TEST OK” will be printed, and the display will return to the Self Test menu.

‘Sequence Test Keys

NOTES: « After automatic carrier return, “KB TEST OK.” is printed, and the display returns to the Self Test menu.

A paper check is performed before printing. If paper is set, the print test is executed; if no paper is set, insert paper and press RETURN.

* if the keys are pressed in the wrong sequence, a beep will sound. The test will continue when the correct key is pressed.

¢ At any time during the test, you may cancel by pressing the RETURN key twice to return to the Self Test menu.

| (3) To run Test “S” (all keys in Fig. 3.20, “B”):

a) Press the keys in the sequence indicated below.

b) Then press“ ”. If there is no problem, the message “KB TEST OK’ will be printed, and the display will return to the Self Test menu.

Lit]

co Test Keys

7 | Sequence



SERVICE MANUAL

(4) To run Test “6” (all keys in Fig. 3.20, “A” & “B”):

a) Starting from the top left of the keyboard, press all keys ("A” & “B”) in the

sequence indicated below.

b) Then press SHIFT+Z, SHIFT+/, and CODE+SPACE. If there is no problem,

the message “KB TEST OK’ will be printed, and the display will return to the

Self Test menu.

HED Test Keys

|

as

ele Sequenc

NOTES: After automatic carrier return, “KB TEST OK.” is printed, and the display

returns to the Self Test menu.

+ A paper check is performed before printing. If paper is set, the print test is

executed; if no paper is set, insert paper and press RETURN.

* if the keys are pressed in the wrong sequence, a beep will sound. The test

will continue when the correct key is pressed.

« At any time during the test, you may cancel by pressing the RETURN key

twice to return to the Self Test menu. R


m REPAIR SERVICE MANUAL Troubleshooting a aS Sa NR SN SA SS rE

7.3.4 FDD Tests

There are five tests of the FDD:

1. FOD Test (“7”) - - checks disk switch, write- -protect switch, and other read/write errors

2. Special FDD Test (“8”) — checks disk switch, write-protect switch, read/write

3. FDD Switch Test (“9”) — checks disk witch and write-protect switch

4. FDD Error Rate Check (“D”) — checks for disk writing errors

5. FDD Error Rate Check (“E”) — checks for disk reading errors

EDD Test

(1). Insert a non-write-protected diskette in the disk drive, and if necessary, change the “DISK TYPE” (2HD or 2DD) displayed on the Self Test menu to that of the test diskette.

(2) With paper set, select “7” from the Self Test menu. If a serial number has not been input before starting the test, the pop-up window will prompt for the serial number; either enter the serial number and press return, or press RETURN to start the test. The display as shown below APREale: the test results are printed, and the display returns to the Self Test menu.

Working ....

Fig. 3.21 — FDD Test (in progress) Display


REPAIR . Troubleshooting ; SERVICE MANUAL

NOTES: « If a key other than the RETURN key is pressed, an error will occur.

¢ A paper check is always performed before printing; printing will not start until paper is set.

« After completing the disk drive test, the carrier automatically returns and the test result is printed:

SERIAL NO.: (if it was entered)

If normal: DISK TEST OK DISK TYPE 0 (2DD)

DISK TYPE 1 (2HD)

if disk switch is defective: DISK ERROR 01

If write-protect switch is defective: DISK ERROR O3

lf other read/write errors occur: DISK ERROR OF

Special FDD Test

(1) With paper set and no diskette in the drive, change the “DISK TYPE” (2HD or 2DD) displayed on the Self Test menu to that of the test diskette.

(2) Select “8” from the Self Test menu. (If a serial number has not been input before starting the test, the pop-up window will prompt for the serial number; either enter the serial number and press return, or press RETURN to start the test.) The display as shown below appears.

“*™* SPECIAL FDD TEST *****

Insert write: protected disk.

Fig. 3.22 — Special FDD Test Display 1


_ REPAIR SERVICE MANUAL Troubleshooting

(3) When the direction “Insert write protected disk” is displayed, insert a write-protected diskette in the disk drive (if the disk is not write-protected, an error will occur). The display changes to the following:

a" SPECIAL PDD TEST *""*

‘Change totest disk.


(4) When the direction “Change to test disk” is displayed, insert a diskette that is not write-protected (if a write-protected diskette is inserted, an error will occur). The display changes to the one below. A reading and writing check is performed, the test results are printed, and the display returns to the Self Test menu.

***** SPECIAL FDD TEST *****

Working...

Fig. 3.24 - Special FDD Test (in progress) Display


REPAIR , Troubleshooting SERVICE MANUAL

NOTES: « After completing the disk drive test, the carrier automatically returns and the test result is printed:

SERIAL NO.: (if it was entered) If normal: DISK TEST OK DISK TYPE 0 (2DD)

DISK TYPE 1 (2HD) If disk switch is defective: DISK ERROR 01

If write-protect switch is defective: DISK ERROR O3 lf other read/write errors occur: DISK ERROR OF

e If an error is detected, a two-digit error code is printed: the first digit is the | stage number in the test at which the error was detected; the second digit is the type of error as described in the following tables.

STAGE NO. DESCRIPTION

Output of ABORT command Output of SPECIFY command Switching drive motor ON Checking write protect

Recalibration Reading SSB3 by means of CHECK DRIVE STATUS command and checking status of track 0 signal Seeking cylinder 1 Reading SSB3 by means of CHECK DEVICE STATUS command and checking status of track O signal

Seeking cylinder 0 Formatting cylinder 79

Formatting cylinder 0



Writing data for checking purposes (DB6DB6DB...)

Seeking cylinder 39 Writing data for checking purposes (B6DB6DBE...)

Seeking cylinder 0 (Command = RECALIBRATE) Writing data for checking purposes (GDB6DB6D...)

Reading and checking cylinder 0 data

Seeking cylinder 39 Reading and checking cylinder 39 data

Seeking cylinder 79 Reading and checking cylinder 79 data

Recalibration Switching drive motor OFF

Table 3.2 - FDD Special Test Error Stage Codes


’ REPAIR


ERROR NO. DESCRIPTION

1 READY signal has not been detected, although drive motor is ON

Disk change signal could not be cleared

eee all Disk change detected in the disk change check

Write protect error

Write protect status detected in the write protect check

No ID found

No address mark for ID area found

No address mark for data area found

CRC error at the ID area

CRC error at the data area

2

3

SEEK command or RECALIBRATE command not completed normally

IRQ not detected in IRQ waiting status

No command or parameter output

E Data overrun detected

End of DMA transfer not detected

Number of sectors for which reading/writing requested was 0

Attempt made to access sectors beyond the final sector on the disk

Could not receive RESULT CODE

Table 3.3 — FDD Special Test Error Codes

NOTES: « If an error occurs at any of the steps corresponding to the stage numbers in

Table 3.2, only stage C is executed and the check is terminated.

¢ Formatting, reading, and writing are performed on both sides of the disk.

e To check formatting, the reading verification check is performed.


REPAIR Troubleshooting | SERVICE MANUAL

FDD SW Test

(1) Without a diskette in the disk drive, select “9” from the Self Test menu. If a serial

number has not been input before starting the test, the pop-up window will prompt

for the serial number; either enter the serial number and press retum, or press

RETURN to start the test. The display as shown below appears.

““* SPECIAL FDD TEST *****

Insert write protected: disk.


(2) Insert a diskette with the write-protect tab enabled. The disk switch is checked,

the test results are printed, and the display retums to the Self Test menu (if a

diskette that is not write-protected is inserted, an error will occur).

NOTES: « The test results are printed as shown below:

SERIAL NO..: (if it was entered)

If normal: DISK TEST OK DISK TYPE 0 (2DD)

. _ DISK TYPE 14 (2HD)

If disk switch is defective: DISK ERROR 01

If write-protect switch is defective: DISK ERROR O3

lf other read/write errors occur: DISK ERROR OF

* A paper check is always performed before printing; printing will not start until

paper is set.


REPAIR SERVICE MANUAL Troubleshooting Dc ee a Sia TE Se DNR TO ET TE BN a TREE SAS NE 3 ST

FDD Write Error Rate Check

(1) Without a diskette in the disk drive, select “D” from the Self Test menu. (If a serial number has not been input before starting the test, the pop-up window will prompt for the serial number; either enter the serial number and press retum, or press

RETURN to start the test.) The display as shown below appears.

***** FDD ERROR RATE CHECK *****

WRITE CHECK ERROR TIMES PASS NO. TRACK NO.

Insert disk and press. RETURN. Press CANCEL to exit.

Fig. 3.26 — FDD Write Error Rate Check Display

(2) With paper set, insert a diskette that is not write-protected in the drive and press

RETURN. The screen message changes to “working” during formatting, and 0 is displayed at PASS NO; then the Write Error Rate check is started:

a) The diskette is formatted.

b) Data “DB6” is repeatedly written on both sides of a randomly designated track.

c) The data written above is read (PASS NO. and TRACK NO. are printed if an error occurs).

d) Steps (b) and (c) are repeated for all tracks (should not be repeated twice for the same track).

e) 1 is added to the PASS NO. counter.

f) Steps (b) through (e) are repeated 500 times.



NOTES: « if an error occurs during checking, PASS NO and TRACK NO are printed,

and 1 is added to the counter “WRITE CHECK ERROR XXX TIMES.

e When an error occurs during formatting, formatting ends after the following is

printed:

Printout if disk switch is defective: DISK ERROR 01

Printout if write protect switch is defective: DISK ERROR 03

Printout if other read/write errors: DISK ERROR OF

« After the check has run 500 times (or the CANCEL key has been pressed),

the following items are printed:

PASS NO. XX (1-500)

TRACK NO. XX (0-79)

WRITE CHECK ERROR X (type error) TIMES XX

SERIAL NO. : XXXXXXXXxX (if a serial no. was input, or blank)

(if no errors detected): DISK TEST OK DISK TYPE 0 (2DD)

or DISK TEST OK DISK TYPE 1 (2HD)


REPAIR


Pe nl

FDD Read Error Rate Check

(1) Without a diskette in the disk drive, select “E” from the Self Test menu. If a serial

number has not been input before starting the test, the pop-up window will prompt

for the serial number; either enter the serial number and press return, or press

RETURN to start the test. The display as shown below appears.

*“** EDD ERROR RATE CHECK *****

READ CHECK ERROR TIMES

PASS NO. TRACK NO.

Insert disk and press RETURN. Press CANCEL to exit.

Fig. 3.27 - FDD Read Error Rate Check Display

(2) With paper set, insert a diskette that is not write-protected in the drive and press —

RETURN. The screen message changes to “working” during formatting, and 0 is

displayed at PASS NO; then the Read Error Rate check is started:

a) The diskette is formatted.

b) Data “DB6" is written to all daya areas in order, starting with track 0.

c) The data on both sides of a randomly designated track is read (PASS NO.

and TRACK NO. are printed if an error occurs).

d) Step (c) is repeated for all tracks (should not be repeated twice for the same

track).

e) 1 is added to the PASS NO. counter.

f) Steps (b) through (e) are repeated 500 times.



SERVICE MANUAL

NOTES: « If an error occurs during checking, PASS NO and TRACK NO are printed,

and 1 is added to the counter “READ CHECK ERROR XXX TIMES.

- ¢ When an error occurs during formatting, formatting ends after the following is

printed: Printout if disk switch is defective: DISK ERROR 01

Printout if write protect switch is defective: DISK ERROR 03

Printout if other read/write errors: DISK ERROR OF

« After the check has run 500 times (or the CANCEL key has been pressed),

the following items are printed:

PASS NO. XX (1-500)

TRACK NO. XX (0-79)

READ CHECK ERROR X (type error) TIMES XX

SERIAL NO. : XXXXXXXXxX (if a serial no. was input, or blank)

(if no errors detected): DISK TEST OK DISK TYPE 0 (20D)

or DISK TEST OK DISK TYPE 1 (2HD)


REPAIR SERVICE MANUAL Troubleshooting ae

7.3.5 PE (Paper End Sensor) Test

The PE test checks that the paper end sensor is working properly by verifying if paper

is set or not.

(1) From the Self Test menu, press “A”. The display changes to the following:

kkk TEST START kkk

PAPER EMPTY


Fig. 3.28 — PE Test Start Display 1

(2) Set paper in the carriage and verify that the screen message changes to the following:

pape TEST START KKKKK

PAPER EXIST


Fig. 3.29 — PE Test Start Display 2


REPAIR a

Troubleshooting SERVICE MANUAL

7.3.6 CR (Carriage Reset) Test

The CR test checks the carriage home position.

(1) From the Self Test menu, press “B”. The following display appears:

***x* THE MODE TO ADJUST FOR THE HOME POSITION OF CR *****

CR PHASE OFF HP SENSOR: OFF

UP ARROW KEY — Turn CR motor on with 'AB’ phase. DOWN ARROW KEY -— Turn CR motor off. LEFT ARROW KEY — Move CR by 1 step in backward direction. RIGHT ARROW KEY — Move CR by 1 step in forward direction.

Press RETURN or CANCEL to reset this machine.

Fig. 3.30 — CR Test Start Display 1

NOTES: « The following keys may be used to check the CR position as described:

1. UP ARROW key — turns CR motor on with “AB” phase

2. DOWN ARROW key — turns CR motor off

3. LEFT ARROW key — moves CR by 1 step backwards (right to left)

(CR phase change directionisAB B BC C CD D DA A).

4. RIGHT ARROW key — moves CR by 1 step forward (left to right) (CR phase change directionisAB A DA D CD C BC B).

5. RETURN or CANCEL key — ends the test (resets the carriage to the

default home position and returns to the Main Menu).

« If no keys are pressed within 15 seconds of turning the motor on, the motor is

turned off. .


REPAIR


en

7.3.7 DISK TYPE

The DISK TYPE item on the Self Test menu toggles between 2DD and 2HD (used for

specifying which type disk used in FDD tests).

Press “T” from the Self Test menu to change the DISK TYPE from 2DD to 2HD, as

appropriate.

7.3.8 CUT SHEET FEEDER

The CUT SHEET FEEDER item on the Self Test menu toggles between OFF (the

default) and ON (when a cut sheet feeder is installed). This information is necessary to

properly perform the print tests.

Press “U” from the Self Test menu to change the CUT SHEET FEEDER from OFF to

ON, as appropriate.

weee* SELF TEST MENU *****

DISPLAY 1 PRINTER 2,3 KEYBOARD 4,5,6 FDD 7,8,9,D,E PE A CR B

SERIAL NO. Ss [ ] DISK TYPE. T 2DD « 2HD CUT SHEET FEEDER. U OFF <— ON

Please select the number. Press CANCEL to finish.

Fig. 3.31 — Self-Test Menu


REPAIR | SERVICE MANUAL Troubleshooting


REPAIR Mechanical

SERVICE MANUAL

Component Disassembly CHAPTER 4

Covers

Paper Support

ieee

Top Cover .

LCD Module

a ° Cc x 2 xe) c & is] =

eee Bottom Cover

baer Carrying Handle

Fig. 4.1 —- Cover Assemblies

© Brother International Corp., 1995 Printed in USA May, 1995 101

EPAIR Heinen SERVICE MANUAL nD

CAUTION: Many of the parts are held in place with plastic latches. The

latches may break if mishandled. To remove such parts,

press the hook end of the latch away from the part to which

it is latched. .

14 Upper Cover

1.1.1. Removal

(1) Turn off the power switch.

(2) Unpiug the AC adaptor from the wail outlet, and unplug the adaptor from the

machine.

(3) Remove the paper support:

a) Lower the paper support to its fully open position.

b) While holding the middle of the support, carefully apply pressure from the

inside of the support until the retaining pin at either side disengages, and

then remove the paper support.

Paper Support Removal Position

Fig. 4.2 — Paper Support Removal


REPAIR Mechanical

SERVICE MANUAL

Remove the main roller (platen) knob. (4)

Remove the top cover: (5)

NOTE: The top cover fits on tabs on the upper cover.

Tilt the LCD to the front to its fully upright position. a)

to the base of the machine. Open the top cover to about 90° b)

to remove the top cover. lift up c) With firm, but gentle pressure

Fig. 4.3 — Top Cover Removal


REPAIR Mechanical

SERVICE MANUAL

(6) Remove the upper cover:

a) Remove the two upper cover screws from the rear of the machine.

Fig. 4.4 — Upper Cover Removal

b) Unsnap the two retaining tabs at the rear of the upper cover to bottom cover.

c)_ Tilt the machine to rest on its rear side, with the bottom facing you.

d) On the underside of the bottom cover, locate the opening to the retaining tab

(at the rear) on the left and right sides.

e) Insert a flathead screwdriver into the opening between the outer edge of the

opening and retaining tab.

f) Apply slight pressure to the retaining tab toward the outer edge of the

opening, and separate the upper cover from the bottom cover until the tab is

about 1/4 inch clear.

Printed in USA May, 1995 — 104 © Brother International Corp., 1995

REPAIR Mechanical

wae | Mo ame WAL sient {a))

A | ot

Insert screwdriver

here

Fig. 4.5 — Access to Upper Cover Retaining Tabs (Underside)

g) Repeat steps (d) through (f) at the other side of the machine bottom.

h) Replace the machine flat (operating position).

i) Pry upon the front of the upper cover at the keyboard to release the four

retaining locks that connect the upper cover to the bottom cover.

j) Raise the upper cover to obtain access,

and disconnect the LCD harness

from the main PCB.

NOTE: For European backlit models, also disconnect the packlight PCB harness

from the main PCB.

k) Remove the upper cover from the bottom cover.

© Brother International Corp.. 1995 405 Printed in USA May, 41995

REPAIR Mechanical

SERVICE MANUAL

(7) Fremove the LCD module (upper cover removed):




a) Tilt the upper cover to rest on its rear side with the inside facing you.

b) Unhook the LCD harness core from the wire hook on the underside of the

upper cover.

c) Locate the opening on the right side (about 2/3 of the length up) where you

can see the underside of the LCD.

d) Locate the retaining tab over the metal retaining pin in the upper cover.

e) Carefully apply slight pressure to deflect the retaining tab down until it clears

the retaining pin, and push the pin until it clears the hole in the upper cover

(do not remove the pin).

f) Lay the upper cover flat (underside down), and lift up on the right side of the

LCD and slide it to the right and up to remove it from the upper cover.

acer a |

= / eS

Le come fas

1

LCD Retaining Tab Detail

Fig. 4.6 - LCD Removal


oo "REPAIR SERVICE MANUAL Mechanical

1.1.2 Upper Cover Reassembly

CAUTION: — Electro-Static Discharge Hazard Wear an anti-static wrist strap with ground wire to prevent damage to sensitive electronic components.

(1) Install the LCD module into the upper cover,

a) Put the LCD hamess through the opening in the upper cover. NOTE: For European backlit models, put the backlight PCB hamess through the upper Cover opening.

b) Place the LCD module into the recessed slot in the upper cover, and insert the hinge in its slot and the left (plastic) retaining pin in the hole in the upper cover.

-C) Turn the upper Cover upside-down, and push the metal retaining pin through the hole until it contacts the Stopper on the right side of the upper cover, and the retaining tab secures it. 7 d) Place the LCD harness with core into the hook on the underside of the upper cover.

NOTE: For European backlit models, also replace the backlight PCB harness into the hook.

(2) While holding the upper Cover assembly over the machine, connect the LCD _ harness to the main PC :

(3) Place the upper cover on the bottom cover, and beginning in the middle of each Side, apply pressure on the upper cover to engage the left and right hooks.

(4) Apply pressure to the rear of the upper cover to engage the two rear locks, then to the front of the upper Cover to lock the four front locks (keyboard side). NOTE: Make sure that the LCD hamess is still locked into the hook on the underside of the upper cover, that it is not pinched between the keyboard and any covers, and that all locks are Properly engaged.

(5) Replace the two Upper cover clamp screws.

(6) Reinstall the top cover, the Paper support, and the main roller knob,


REPAIR a _ | ; SERVICE MANUAL

Mechanical

1.2 Carrying Handle

1.2.1 Removal

(1) Place the machine on its rear side with the underside facing you.

(2) Turn the carrying handle perpendicular to the bottom cover.

(3) While pushing the carrying handle to the left, press in on each of the two stoppers

with a small screwdriver to disengage the handle pivot shaft from the stoppers.

(4) Slide the handle fully to the left to clear the locks in the bottom cover, and pull it

toward you.

1.2.2 Installation

(1) Turn the handie perpendicular to the bottom cover, and slide the left pivot shaft

into its hole in the left side of the bottom cover.

(2) Align the right pivot shaft with its hole at the right side, and slide the handle to the

right until the stoppers engage the locks.

Fig. 4.7 — Carrying Handle Removal

Stoppers


} ae REPAIR SERVICE MANUAL

Mechanical

Der renee ee ee enn nena

2. LCD Module

2.1 LCD Disassembly

The LCD module has three main parts: the LCD upper cover, the LCD PCB, and the

LCD lower cover.

(1) With the LCD module removed from the upper cover, place the LCD face down

(screen side down).

(2) Remove the LCD lower cover:

a) Remove the two Taptite screws securing the lower cover to the upper cover

and PCB section, and lift off the lower cover.

b) At each side of the LCD, carefully pry the lower cover up with a screwdriver

until the two retaining tabs at each side clear the edge of the upper cover.

c) Release the four retaining tabs that secure the top side (opposite hinge side)

of the lower cover (carefully pry open the tabs in the four slots if necessary).

d) With all six tabs released (2 each side and 4 top), rotate the lower cover up to

unsnap the three retainers at the bottom (hinge) side of the lower cover, and

remove the LCD lower cover.

Fig. 4.8 - LCD Lower Cover Removal


REPAIR Mechanical ~’ SERVICE MANUAL

(3) RRemove the LCD PCB:




a) Carefully pry up on the bottom of the LCD PCB (hinge side of upper cover) to

release the two retaining tabs in the LCD upper cover.

b) Rotate the bottom of the LCD PCB up (about 45°) to clear the two retaining

posts at the ends of the top of the PCB and LCD upper cover.

c) Gently pull the PCB toward you to clear the two retaining tabs at the top of

the PCB and upper cover.

Fig. 4.9 - LCD PCB Removai


REPAIR


2.2 LCD Module Reassembly

CAUTION: Electro-Static Discharge Hazard



(1) Install the LCD PCB into the LCD upper cover:

a) On the LCD upper cover, slide the contrast controller all the way up (toward

the top side of the cover), and slide the black contrast controller on the LCD

PCB aii ine way up.

Holding the LCD PCB at about a 45° angle, slide the top edge of the PCB

under the two retaining tabs in the top of the LCD upper cover, and align the ©

hole at each end with the posts in the upper cover.

Carefully lower the bottom edge of the PCB onto the LCD upper cover; then

apply slight pressure toward the center of the PCB at the retaining tabs to

snap the bottom edge of the PCB under the two tabs.

Check that the holes for the LCD lower cover screws are aligned, and that

the black LCD contrast slider is between the retainers in.the LCD upper cover

contrast controller.

(2) Plug the LCD harness into the LCD PCB.

(3) Install the LCD lower cover:

a)

b)

c)

Holding the LCD lower cover at about 45° to the LCD upper cover, engage

the three retaining tabs in the upper cover (hinge side) with the slots in the

LCD lower cover.

Applying slight pressure at the hinge side of the lower cover, rotate the top of :

‘the lower cover down to engage the retainers at the sides and top of the LCD

upper cover.

If necessary, apply pressure to each side and to the top of both covers to

snap them together.

(4) Replace the two Taptite screws in the bottom of the LCD lower cover.


* REPAIR Mechanical SERVICE MANUAL

3. Keyboard Assembly

CAUTION: Electro-Static Discharge Hazard



3.1 Keyboard Removal

(1) Turn off the power and unplug the power cord.

(2) Remove the paper support, top cover, and the upper cover.

(3) Press outward on the two clips (one on each side of the keyboard), lift up on the

keyboard panel to just clear the bottom cover keyboard supports, and unplug the

keyboard PCB harness from the main PCB (left side).

NOTE: The keyboard PCB and the base plate are attached to the bottom of the

keyboard, and are not removable (entire assembly must be replaced).

Fig. 4.10 - Keyboard Assembly Removal

Printed in USA May, 1995 2 ~— © Brother International Corp., 1995 _

. . REPAIR


or

3.2 Keyboard Installation

Place the keyboard in the bottom cover onto the keyboard supports, plug the keyboard

PCB harness into the main PCB, and push down on each side of the keyboard to snap

it into place.

SKIS a

[see ,

ie San Key Top

~ STZ

ca y Actuator

| VA ie

i> 17 _ 7 5 “ Q

Keyboard Panel

FPC

Base Plate Rubber

Contact

Fig. 4.11 — Keyboard Installation

© Brother International Corp., 1995 113 , Printed in USA May, 1995

SERVICE MANUAL |

REPAIR Mechanical

Ink Jet Printer Assembly 4.

The ink jet printer assembly is attached to the rear of the bottom cover by two screws.

Assembly Screws

Fig. 4.12 — ink Jet Printer Assembly

© Brother Internationa! Corp., 1995 114 Printed in USA May, 1995

REPAIR

SERVICE MANUAL . Mechanical

i I nec UNE

4.1

4.2

Ink Jet Printer Removal

(1)

(2)

(3)

(4)

(5)

Remove the upper cover (paper support, top cover, upper cover with LCD module,

and main roller knob).

Disconnect the six connectors from the main PCB:

e 2 flat cables (to carriage)

e home position sensor harness

* paper end sensor harness

* 2 motor harnesses (carriage motor & line feed motor)

NOTE: Remove the motor harnesses from the harness retainers in the bottom

cover.

_ Disconnect the ground wire from the printer.

Remove the two screws from the rear of the printer mechanism.

While lifting up on the printer frame to clear it from the rear alignment posts, slide

the ink jet printer assembly toward the rear of the machine, and lift it up and out of

the bottom cover.

Ink Jet Printer Installation

(1)

(2)

(3)

(4)

(5)

_Slide the front of the printer assembly into the catches in the bottom cover, and set

the rear of the assembly onto the alignment posts.

Connect the ground wire.

Connect the six connectors to the main PCB, and route the motor hamess into the

retainers in the bottom cover.

Install the two screws at the rear of the printer mechanism.

Install the upper cover assembly (upper cover with LCD, top cover, paper support,

and main roller knob).


REPAIR Mechanical , SERVICE MANUAL

4.3 Printer Disassembly

This section describes the procedures for removal and disassembly of all printer

mechanism components and assemblies: carriage, timing belt & motor, line feed

assembly, top paper guide, star-wheel assembly, star-wheel exit roller assembly, paper

separator, paper adjustment lever, main paper guide & maintenance station, main roller

assembly, main paper pan, and paper pressure plate.

‘asi; —- Cee aa a a=),

Uy

LET aK. St

=

= ww

Fig. 4.13 — Ink Jet Printer Mechanism

(exploded view)


REPAIR

SERVICE MANUAL _ | Siagehanieal Padilla a eee

Te

4.3.1. Carriage Removal

(1)

(2)

(3)

(4)

(5)

(6)

If necessary, remove the ink cartridge and store it in a safe place.

Loosen the idle pulley bracket screw and remove the spring to release the tension

on the timing belt.

Remove the screw from the main shaft stopper, and remove the stopper.

Remove the main shaft (from the left end).

Disengage the carriage from the carriage rail and from the drive (timing) belt.

Remove the cable holder and screw from the printer frame, and lift the carriage

assembly from the frame.

Carriage

Fig. 4.14 — Printer Mechanism


Mechanical REPAIR _ | |

SERVICE MANUAL

Fig. 4.15 — Carriage Disassembly

Head Locker ———-—_> & Spring

ne ; Ink Cartridge ——__—_»

Idle Pulley Bracket Screw Idle Pulley Bracket

Extension Spring

Carriage

Main Shaft

e ; . Cable Holder

ne : Flat Cable

Main Shaft Stopper & Screw


REPAIR


en

4.3.2 Carriage Transport Belt & Motor Removal

(1) Remove the idle pulley bracket screw, and remove the idle pulley bracket and

pulley. .

(2) Remove the timing belt.

(3) Remove the carriage motor.

NOTE: Upon reassembly of the belt and/or the motor, carriage home position

adjustment and carriage tension check are required. See section 4.4.

Timi

eo Carriage Motor >

Idle Pulley a Ee 2e

eee Idie Pulley Bracket

Fig. 4.16 — Carriage Transport Belt & Motor Removal


REPAIR Mechanical SERVICE MANUAL

4.3.3 Line Feed Assembly Removal

(1) Remove the C-clip from the main roller shaft.

(2) Remove the main roller gear from the main roller shaft.

(3) Remove the star-wheel roller gear from the star-wheel roller shaft.

(4) Remove the two (large & small) idle gears from their shafts.

(5) Remove the line feed motor.

Star-wheel Roiler Gear

Idle Gears A) |

ks 7 Line Feed Motor

Fig. 4.17 — Line Feed Assembly Removal


REPAIR

SERVICE MANUAL _ Mechanical

4.3.4 Top Paper Guide Removal

(1) Remove the four extension springs (connecting the top paper guide to the front

frame).

(2) Lift up on the rear of the top paper guide, and pull it out of the frame.

NOTE: Leave the top pinch rollers in the guide.

Top Pinch Rollers snap out from the bottom

Top Paper Guide

Fig. 4.18 - Top Paper Guide Removal


REPAIR | — | : Mechanical

SERVICE MANUAL

4.3.5 Star-Wheel Assembly Removal

(1) At any star-wheel assembly, disengage the assembly top hook from the carriage

rail.

(2) On the inside of the rear printer frame (carriage rail), push the two star-wheel

assembly retaining clips inward (toward each other) to clear the notches in the rail.

(3) While squeezing the retaining clips together, push the assembly down and then to

the rear of the frame, to clear the alignment pin from the hole in the rail, and

remove the assembly from the frame.

(4) Repeat steps (1) through (3) for the other assemblies.

Fig. 4.19 — Star-Wheel Assembly Removal

Star-Wheel Assembly a2 Detail : Retaining

Clips

Printed in USA May, 1995. 122 © Brother International Corp., 1995

. REPAIR


4.3.6 Star-Wheel Exit Roller Assembly Removal

‘Remove the two E-rings from the star-wheel roller shaft, push the shaft to the left (to

just clear the right end of the printer frame), and pull the assembly out from inside the

frame.

Star-Wheel Exit Roller Assembly

Fig. 4.20 — Star-Wheel Exit Roller Assembly Removal


REPAIR 7 , Mechanical

SERVICE MANUAL

4.3.7. Paper Separator Removal

From the rear of the printer mechanism, grasp the paper separator near the left end,

carefully deflect it downward until the retaining pin clears the hole in the frame, and pull

it out of the frame.

Apply slight pressure here

Fig. 4.21 — Paper Separator Removal ~


REPAIR


4.3.8 Paper Adjustment Lever Removal

(1) Apply and hold pressure to the pressure plate to release tension on the paper

adjustment lever.

(2) Rotate the lever clockwise (about 30°) until it is just past vertical to the base of the

printer assembly.

(3) Align the lever with the keyways in the printer right frame, and slide the lever off

the main roller shaft.

Apply pressure here

END VIEW FRONT VIEW

Fig. 4.22 — Paper Adjustment Lever Removal


REPAIR _ - SERVICE MANUAL

Mechanical

4.3.9 Main Paper Guide & Maintenance Station Removal

With the paper adjustment lever removed, rotate the rear of the main paper guide

down, lift it up to clear the ribs from the main roller shaft, and remove it from the printer

frame.

Main Paper Guide

Fig. 4.23 — Main Paper Guide Removal


: REPAIR


4.3.10 Main Roller Assembly Removal

(1) Remove the E-ring from the left end of the main roller shaft.

(2) Slide the main roller assembly to the right until it clears the main roller bearing in

the left end of the frame.

(3) Pull the left end of the main roller assembly out to clear the printer frame, and slide

the right end out of its hole, and remove the main roller assembly from the frame.

Main Roller Assembly

Main Roller Bearing

Fig. 4.24 — Main Roller Assembly Removal


REPAIR Be | SERVICE MANUAL Mechanical

4.3.11. Main Paper Pan Removal

With the main roller assembly removed, pull the main paper pan assembly out of the

printer frame.

Fig. 4.25 — Main Paper Pan Removal

Printed in USA May, 1995 428 © Brother International Corp., 1995 -

REPAIR Mechanical

SERVICE MANUAL |

4.3.12 Paper Pressure Plate Removal

(1) Remove the two extension springs.

(2) Lift up on the left end of the paper pressure plate to clear the spring hooks from

the printer front frame, and pull the right end of the pressure plate from its opening

in the printer right frame.

Paper Pressure Plate

Extension Springs

Fig. 4.26 — Paper Pressure Plate Removal


REPAIR

4.4.1

Mechanical | SERVICE MANUAL

4.4 Printer Adjustments

NOTE: Any time the motor or the belt is removed or replaced, the carriage friction and

home position should be checked and adjusted as required. Perform the

following adjustments with an ink cartridge installed.

CAUTION: _ Electro-Static Discharge Hazard Wear an anti-static wrist strap with ground wire to prevent


Carriage Home Position Adjustment

(1) Remove all covers and remove the printer mechanism.

(2) Install a wiring harness to connect the carriage motor and the home position

switch to the main PCB.

CAUTION: _ Ifanextra harness is not available, you may simply remove

the two screws securing the printer assembly to the bottom

cover and raise the mechanism to access. the carriage

motor screw; however, you MUST place a non-conductive

material (such as paper) between the printer and other

electrical components — especially the power supply PCB —

to avoid grounding damage to the equipment.

(3) Loosen the CA motor screw.

(4) Turn on all power and from the Main Menu press CODE + SHIFT + BACKSPACE,

then select “B” from the Self-Test menu to start the CR (Carriage Reset) Test.

(5) Move the carriage (manually) to the left end.

(6) While holding the carriage at the left end, press the UP arrow key to turn the motor

on, and verify that the motor is in phase AB (from display).


REPAIR Mechanical

SERVICE MANUAL

(7)

(8)

Slowly rotate the motor to the point of feast vibration (motor noise), hold the motor

at this position, and retighten the screw.

Check the carriage motor “jumping” phase:

a) With the CR test still active, press the UP arrow key to turn the motor on.

b) Step the motor left with the left arrow key until the carriage moves to the

leftmost position and then “jumps” (moves) back to the right one step.

c) Verify that the motor phase at the “jumping” point is “CD,” “D,” or “DA” only.

d) If the motor phase is not correct, repeat steps (3) through (7) above, and

repeat this step (8) to verify that the motor “jumping” phase is still correct.

e) Press RETURN oF CANCEL to end the Self Test, turn OFF the machine, and

reinstall the printer and all covers.

4.4.2 Belt Tension Adjustment

Belt tension is maintained by idle pulley bracket spring. The spring is preset to hold the

idle pulley in position to maintain the proper tension on the drive belt. If the carriage

does not moves freely, or if the belt is removed or replaced, the tension should be

checked and adjusted as follows:

(1)

(2)

(3)

(4)

(5)

With power disconnected from the machine, move the carriage to the right end |

(maintenance station side) and verify that the belt is properly installed.

Push the idle pulley bracket to verify that it moves freely (if binding, there is too

much friction between the bracket and the printer frame).

Line up the carriage with the first star-wheel holder from the right side of the

printer assembly (maintenance station side), and attach a friction meter attached

above the bearing portion of the carriage.

With the friction meter, pull the carriage to the left to the last star-wheel assembly

and verify that the carriage moves freely with a friction reading of 0.3 — 0.7kg

force.

lf the carriage friction is not correct, loosen the idle pulley bracket screw, move the

bracket as necessary to change tension on the spring, and retighten the screw.


REPAIR & Ce age oe | | | SERVICE MANUAL

Mechanical

(6) Repeat the test with the friction meter to verify that the carriage friction (belt

tension) is within the acceptable range.

NOTE: If friction is still not within acceptable limits, lubricate the idle pulley shaft and

idle pulley rotation point . See Lubrication in Chapter 5, Maintenance, for details.

Aa) = 4

= ¢

Loosen screw and move bracket as necessary.

Fig. 4.27 — Belt Tension Adjustment


REPAIR Mechanical SERVICE MANUAL

5. _ FDD Assembly Removal

(1) Remove the FDD flat cable from the main PCB.

(2) Unplug the power cable‘from the FDD.

(3) Remove the two screws securing the FDD to the bottom cover.

r, and lift it out. (4) Move the FDD to the left to clear the retainers in the bottom cove

Fig. 4.28 —- FDD Assembly Removal

Printed in USA May, 1995 © 133 © Brother International Corp., 1995

SERVICE MANUAL REPAIR Mechanica]

Power Supply Assembly 6.

Electro-Static Discharge Hazard CAUTION: Wear an anti-static wrist strap with ground wire to prevent


the power supply PCB is mounted on the bottom cover. As shown in Fig. 4.29,

Power Supply Assembly

Fig. 4.29 — Power Supply Assembly


SERVICE MANUAL

6.1 Power Supply PCB Removal

(1) Disconnect the ground harness (FG) from _ the printer assembly, and disconnect CN1

from the main PCB.

(2) Remove the two screws securing the PS PCB section (containing the heat sink) to the bottom cover, slide the section to the left to clear the retaining tab, and lift it out.

(3) Remove the screw securing the PS PCB switch section, slide it to the right and up to’

- clear the switch housing, and lift it out.

6.2 Power Supply PCB Installation

(1) Place the PS PCB section containing the - heat sink in the bottom cover, slide it to the

right to insert the edge under the retaining tab, and replace the two screws.

(2) Place the PS PCB switch section into its location in the bottom cover, slide it to the

left and down to insert the switch in its

housing, and replace the third screw.

(3) Reconnect the ground hamess (FG) to the printer assembly, and CN1 to the main PCB.

Fig. 4.30 —- Power Supply PCB

© Brother International Corp., 1995 135

REPAIR Mechanical


REPAIR Mechanical

SERVICE MANUAL

7. AC Adaptor Disassembly

WARNING: Low Voltage Shock Hazard exists. Before attempting to

disassemble the AC adaptor, ground the output connector

(through a 1K ohm resistor) to discharge any voltage

remaining in the unit.

@ The only serviceable item of the AC adaptor is the fuse. To replace the fuse:

a (= (1) Unplug the adaptor from

the power source.

(2) Remove the four screws

from the bottom cover.

(3) Remove the top cover.

(4) Remove the adaptor PCB

from the bottom cover. Fig. 4.31 — AC Adaptor

(5) Replace the fuse in the

adaptor with a same-rated

fuse.

(6) Reassemble the adaptor.


- - . REPAIR

SERVICE MANUAL > Mechanical

8. Main PCB Removal



damage to sensitive electronic components. Be sure to

hold the connector — not the cable — when connecting or

disconnecting a harness.

The main PCB is fitted to the bottom cover and secured by screws. Remove the screws

and all connectors and cables from the main PCB, and lift it out of the bottom cover.

Main PCB

Fig. 4.32 - Main PCB Removal


REPAIR a, 9 3 | Mechanical SERVICE MANUAL

9. Shield Plate (ESD) Removal

Lift up on the rear side of the shield plate to clear the alignment pin, slide the shield

plate forward to clear the three retaining clips in the bottom cover, and lift it out.

Shield Plate (ESD)

Fig. 4.33 - Shield Plate (ESD) Removal

Printed in USA May, 1995 138 _ © Brother International Corp., 1995

REPAIR SERVICE MANUAL Mechanical

10. Auto Cut-Sheet Feeder (ACF) Disassembly

Fig. 4.34 — ACF (Auto Cut-Sheet Feeder)

To disassemble the ACF:

(1) Remove the two paper support wires.

(2) Remove the front tray:

a) On the back of the ACF, remove the screw trom the bottom tray.

b) At the bottom comers of the bottom tray, pry open the two retaining tabs holding the front tray to the bottom tray.

C) Pull up on the front tray to release the other four retaining tabs, and lift the front tray off the ACF.


REPAIR Mechanical

(3)

SERVICE MANUAL

Remove the gear holder assembly:

a)

b)

¢)

Disengage the gear holder assembly extension spring from its hook on the

bottom tray.

Remove the two screws securing the gear holder assembly to the bottom

tray.

Lift up and out on ihe entire gear holder assembly to separate it from the

ACF.

(4) Remove the main shaft assembly:

(5)

(6)

(7)

(8)

(9)

a)

b)

oY ~“)

d)

Remove the main CF gear from the main shaft.

Remove the two E-rings from the left main shaft bearing (gear side).

Remove the main shaft bearing by prying the bearing leg out of the hole in

the bottom tray and rotating the bearing 90° up.

Slide the main shaft to the left until the right end clears the hole in the bottom

tray, and lift the main shaft out of the bottom tray.

Disassemble the main shaft:

a)

b)

Refnove the other six E-rings from the main shaft assembly.

Slide all rollers off the main shaft: .

idle roller, roller flanges (2 ea. main roller), two main rollers (rollers & cores).

Pull the hopper release lever (to release the retaining tab on the back of the

hopper from the slot in the bottom tray), and pull the hopper up and out of the

bottom tray.

Pull the hopper release lever cap up and out of its holder (some resistance will be

felt).

Unhook the lock lever spring from the bottom tray, and slide the lock lever off the

retaining post and out of the bottom tray.

Remove the two hopper springs from the bottom tray.

Printed in USA May, 1995 . 140 , © Brother International Corp., 1995

REPAIR


(10) Remove the two bottom separators from the left side of the bottom tray:

a) From the underside of the bottom tray, release the two bottom separator latches (press inward on each) for one separator.

b) If necessary, carefully release the retaining pins at the top of each side of the

bottom separator from the slots in the bottom tray.

c) Repeat steps (a) and (b) to remove the other separator.

Paper Support Wires

Front Tray

Hopper Plate ee

Lock Lever

Bottom Tray

i I Manotel Nesey Hopper Release Lever Cap

Pie Main Shaft Bearing

Main Shaft Bearing

Ss ‘ -”

Gear Holder Assembly :

Bottom Separators

Fig. 4.35 — ACF (Exploded View)


REPAIR _ 2 38 . SERVICE MANUAL

Mechanical


REPAIR SERVICE MANUAL | Sainlensnee

CHAPTER5 Maintenance

1.1

1.2

1.3

LUBRICATION

Lubricants

:

Table 5.1 —- Recommended Lubricants

Precautions

1. Lubricate carefully so that the oil or grease will not stick to places other than the Specified points; otherwise, the plastic parts and electronic boards will be adversely affected.

2. Do not apply an excessive amount of lubricant; otherwise, the lubricant may drip onto places other than the specified lubrication points during use or Storage.

3. Make sure to apply a sufficient amount of lubricant to contact parts and sliding surfaces consisting of more than one material.

Lubrication Points

See the illustrations on the following pages for location and types of lubricant for the following components:

NOTE: Some disassembly of components may be required.

1. Frame Assembly (see Fig. 5.1)

Carriage Movement Assembly (see Fig. 5.2)

Idle Pulley Assembly (see Fig. 5.3)

Star Wheel Roller Assembly (see Fig. 5.4)

Main Paper Pan & Pinch Roller Assembly (see Fig. 5.5) Paper Pressure Plate (see Fig. 5.6) Pak WO ND


REPAIR SERVICE MANUAL Maintenance

Fig. 5.1 — Frame Assembly Lubrication Points


REPAIR Maintenance

SERVICE MANUAL

4

Fig. 5.2 — Carriage Movement Lubrication Points


REPAIR . =- Oo SERVICE MANUAL

Maintenance

Fig. 5.3 — Idle Pulley Assembly Lubrication Points


REPAIR Maintenance

SERVICE MANUAL _ :

eo

Fig. 5.4 — Star Wheel Roller Assembly Lubrication Points


Maseaenee SERVICE MANUAL

sjulod 9} x

(azig paasg ewesas)

Ss

Fig. 5.5 ~ Main Paper Pan & Pinch Roller Assembly

Lubrication Points


REPAIR Maintenance

SERVICE MANUAL

Fig. 5.6 — Paper Pressure Plate Assembly Lubrication


REPAIR Maintenance

SERVICE MANUAL

2. REPLACING THE INK CARTRIDGE

WARNING: The bottom of the ink-jet cartridge is covered with wet ink.

Avoid contact of ink with skin and clothing. Ink may cause

irritation — especially to the eyes.

The Whispemriter uses a replaceable ink-jet cartridge that contains both the print head

and ink. It should be replaced after about 1,000,000 characters (estimated using

normal text, 12 point, Brougham font).

(1) Press CODE + INK CHG. The carriage will move to the ink change (home)

position. Do not move the carriage manually from side to side.

The following screen message will appear:

Change the ink cartridge?

After changing the ink cartridge, press RETURN toclean head.

(2) Open the paper support and tilt the LCD forward.


REPAIR SERVICE MANUAL Maintenance SAR AT RIP TT Ie I ETT

(3) Open the top cover.

L2> PEP? LEP ELLE LILIRES ORES > GRE =~

&

(4) Grasp the ink-jet cartridge as shown below and pull it towards you (until you hear the release “click”); then pull the cartridge straight up and out of the carriage.

(5) Remove the protection tape from the new ink-jet cartridge (do not shake the cartridge after the tape has been removed).


REPAIR SNe | SERVICE MANUAL

Maintenance

(6) Slide the cartridge into the carriage bracket as shown below.

(7) Squeeze the cartridge bracket and cartridge together until the cartridge snaps

under the latch on the bracket.

(8) Press RETURN. The ink-jet cartridge is ready to use.

(9) Close the LCD, paper support, and the top cover.


REPAIR

SERVICE MANUAL Maintenance

3.1

3.2

CLEANING THE PRINTHEAD

WARNING: _ The bottom of the ink-jet cartridge is covered with wet ink.

Avoid contact of ink with skin and clothing. Ink may cause

a) irritation — especially to the eyes.

tHE Cleaning the Printhead Automatically

If the ink on the page looks splotchy or smeared, or if blank spaces appear in

characters, the printhead may be cleaned. To automatically clean the printhead, press

CODE + SHIFT + INK CHG.

Cleaning the Ink-Jet Nozzles and Contacts

If print quality does not improve after automatically cleaning the printhead, the problem

may be dried ink on the nozzles, contacts, or on the print cartridge bracket contacts.

(1) Remove the ink-jet cartridge.

(2) With a clean, water-dampened cloth, gently wipe the entire copper-colored area,

including the nozzles and contacts.

NOTE: To dissolve any dried ink, hold the damp cloth against the nozzles for a few

seconds; then gently blot and wipe dry.

(3) Allow the copper-colored area to dry, and re-install the cartridge.

(4) Press RETURN, and then CODE + SHIFT + INK CHG, and close the cover.

NOTE: If the Whisperwriter is still not printing properly, clean the bracket contacts in the

carriage.


REPAIR - | a Maintenance SERVICE MANUAL

3.3 Cieaning the Bracket Contacts (Carriage)

(1) Press CODE + INK CHG to move the carriage assembly to the home (left side) position.

(2) Without turning off the machine, unplug the DC jack from the DC plug connector on the rear of the machine. (This will keep the carriage assembly from returning to the maintenance station).

(3) Turn the machine off and remove the ink cartridge.

(4) With a clean, dry cloth, clean the gold-colored contacts on the ink cartridge bracket as shown below:

Clean these contacts


SERVICE MANUAL

1. Electrical System

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(9)

(10)

(11)

(12)

(13)

(14)

(15)

Main PCB Size:

CPU:

ROM:

RAM:

FDC:

KB Matrix:

Power PCB Size:

Output Voltage:

Display (LCD):

Printer:

CA Step Motor:

LF Step Motor:

HP Sensor:

PE Sensor:

Auxiliary Memory:


APPENDIX Specifications

APPENDIX A

Specifications

156 x 190 mm

H8 3003

2 MB (3 fonts)

128KB x 2

HD63266F

8x9

156 x 62.5mm

24v, 5v (8v for Europe models)

480 x 128 (Backlit LCD for Europe models)

mono |

Constant Current Control

Constant Voltage Control

Leaf Type Switch

Optical Sensor

FDD (1.44 MB/720KB) MEM form (MS-DOS format)

3.5" 2HD, 3.5” 2DD

A-1 Printed in USA May, 1995

APPENDIX Specifications SERVICE MANUAL

2. Printing

(1) Printing Method: Lexmark Thermal Ink Jet

(2) Heads: Color/Mono

(3) Head Type:

(4) Nozzle (mono)

(5) Head weight:

(6) Ink Color:

Thermal Ink Jet

50 active + 6 nozzles (1/300” spots/inch)

74 g maximum (full)

36 g minimum (empty)

Black

(7) Head Cartridge Set Force: 4,000 g maximum

Release Force: 2,000 g maximum

(8) Printing Capacity:

(9) Paper Sizes:

Max. Paper Width: 304.70 mm (12.0) Max. Printing Width: 231.14 mm (9.1”) Possible Printing Area: except 12.7mm (1/2”) from top and

bottom, and 25.4mm (1") area from bottom

length (a): 100 to 364 mm (3.94 to 14.33”) . width (b): 100.to 304.8 mm (3.94 to 12.0”)

b:a=1:0.5 to 1:1.5

(10) Base Paper Handling Position: left side

(11) Paper Type:


ut letter: 215.9 x 279.4 mm (8.5 x 11.0

legal: 215.9 x 355.6 mm (8.5 x 14.0” B4: 257 x 364 mm (10.11 x 14.33”) B5: 182 x 257 mm (7.17 x 10.2”) A4: 210 x 297 mm (8.27 x 11.69”) executive: 184 x 267 mm (7.24 x 10.51”) A5: 148 x 210 mm (5.83 x 8.27") legal post card (Japanese): 100 x 148mm (3.94 x 5.83”)

paper weight: 180 g/sqm

thickness: 0.22 mm (0.0087) Ground or recycled paper can contain up to 40% de-inked or 50% post-mill fiber

Chemical wood pulp fiber

Transparencies: IBM 4079 printer original film

) )

A-2 © Brother International Corp., 1995

APPENDIX SERVICE MANUAL Specifications ea

(12)

(13)

(14)

(15)

(16)

(17)

(18)

(19)

(20)

Paper Cotton

Fiber Content: 0 to 100%

Paper Weight: 60 to 90 g/sqm (16 to 24 Ib)

Paper Thickness: 0.071 to 0.18 mm (0.0028 to 0.007”)

Print Speed: LQ: 160 cps; “Ink Saver Mode”: 160 cps

Printing Direction: text: bi-directional (accuracy +0.2 mm) graphics: unidirectional (accuracy 0.05 mm)

Cartridge Yield: _ up to 1,000 pages of text at 5% (1,170 characters, 238k ink drops)

Carriage Driving Resolution: 1.968spmm (50 spi) full step;

; 3.937spmm (100 spi) at 1/2 step

Acoustics:

Printing noise: 55 dB maximum (1m, A Scale fast)

Reliability

Durable life time: 5-year printing quality or 30,000,000

characters

Mean Time Between Failure: 2,000 hour minimum Ink cartridge

change duration: 500 times

Head travei duration: 700,000 times

Head initiation duration: 3,000 times

Paper feed duration: 2,500,000 lines (1/6” line) Paper release lever duration: 3,000 times

Allowable temperature range: +10 -—+40°C

(+15 — +35°C for best print quality) Allowable relative humidity: 20 —- 80% (20 — 70% for best print quality)

© Brother International Corp., 1995 . AB Printed in USA May, 1995

PENDIX i | | i Be emcaticne 7 SERVICE MANUAL

3. Keyboard

(1) Keying system: Conductive-rubber contact (plus Koala 1 actuator system)

(2) Construction: PCB: multi-layer printed FPC (single-sheet) Rubber: silicon rubber with conductive

Actuator: Koala style with 2 cranks

(3) Keystroke: 3.8 mm +0.3mm (touch force 300g)

(4) _ Key Touch Load: 60 g +20 g (except space bar: 70 g +30 g)

(5) Gap between key tops & KB panel: 1.0 mm — 2.0 mm

(6) Gap between key tops: 0.8 mm —1.0 mm

(7) Keyboard Features: Style: fixed-type Shape: step key

Key Roll-over: limited key Total keys: OS Key touch load: <150g Pressure resistance: smooth returm of keytop after 3 kg Key top take-off force: > 0.7 kg (except space bar: > 1 kg)

4. Monitor (LCD)

(1) LCD Screen Size: . 80 columns x 14 lines (480 x 128 dots)

(2) Character Dot Number: 9 x 6 dots (including underline)

(3) Tilt Function: Yes

(4) Display Control

e Resolution: 480 x 128 DPI

* VRAM size: 7.5 KB in main RAM

¢ Display: without the gray scale, just dot on/off

Printed in USA May, 1995 A-4 | © Brother International Corp., 1995

APPENDIX SERVICE MANUAL Specifications

5. Floppy Disk Drive (FDD)

(1) Size: 1.44Mb (3.5")

(2) Application Disk: MF-2DD or 2HD

(3) FDD Controller Hitachi HD63266F

6. Power Requirements (US)

(1) Source Voltage: 110-120V (60Hz)

(2) AC Adaptor: Power Input: 11.5V, 2.2A

Power Consumption: 35W

AC Line Noise: 1kV (min.) (pulse duration 50, 200, 1,000 ns) Rush Current: 30A (max.) ; Instantaneous Power

Outages: — will not malfunction with power outages of up to 1 cycle/50-60Hz

7. Environmental Tolerance

(1) Durability Keyboard cycles: 1,000,000 times/key

Top cover

operation cycles: 3,000 times

Paper support


LCD Cover


(2) Physical Environment Vibration cycles: IMV vibration test machine 5—55 Hz, each direction

0.1 G—no operation error after 30-minute test

Edge drop test: 50 mm edge drop — no damage Package drop test: 80 cm/6-side drop — no damage to product Temperature:

Range: +10 —+40°C

Thermal shrinkage: 2 hours &5 cycles between -40°C and +70°C

— no damage to product Cold-start: power on after 2 hours at 0°C

— no operation error (print quality excluded) Storage: 48 hours at -20°C, +60°C, and +45°C at 95%

relative humidity ~ no damage to product

© Brother International Corp., 1995 A-5 Printed in USA May, 1995

APPENDIX Specifications SERVICE MANUAL

8. Dimensions & Weight

(1) Dimensions: 16.1 (d) x 17.9 (w) x 5.8 (h) in.

(2) Weight: 11.5 Ibs. (5.2kg)

Printed in USA May, 1995 A-6 © Brother International Corp., 1995

; : APPENDIX

SERVICE MANUAL Specifications

9. Optional Equipment: Auto Cut-Sheet Feeder (ACF)

(1) Paper Specifications:

e Size: US letter, A4, & post card

« Weight: 16 — 24 Ib. (55-78kg)

¢ Thickness: 0.07 —-0.15 mm

0.22 mm (postal card size only)

(2) Paper Set Capacity:

e Feeder Tray: 3.0 mm max. (30 sheets of 20Ib paper)

15 sheets for post card

¢ Front Tray

(stacker): same as feeder tray

(3) Performance/Error Ratio:

e multi-feeds: 1/100 sheets (avg.)

* jam/misfeed: 1/200 (avg.)

_ © Misc.

(nick, wrinkle, dogear, etc.): 1/100 (avg.)

NOTE: The above results were achieved under the following conditions:

Temperature: 15-— 25°C

Relative Humidity: 45 — 70% Paper: 20lb, A4 & US letter

(4) Environmental Conditions: ~

e Operation: 10 — 35° C, 30 — 80% relative humidity

¢ Storage (re-packaged): -20 — 60° C; 5 - 95% relative humidity

(5) Reliability:

Service Life 5 years or 12,000 sheets printed

Mean Time Between Failure (MTBF): 2,000 hours (minimum)

© Brother International Corp., 1995 A-7 Printed in USA May, 1995

APPENDIX Specifications

Printed in USA May, 1995 A-8

SERVICE MANUAL


SERVICE MANUAL

A

ACF operation, 20

disassembly, 139-141

Cc Component Repair AC adaptor disassembly, 136 ACF disassembly, 139-141

cover removal, 101-108 FDD assembly removal, 133

Ink Jet Printer, disassembly, 116 carriage removal, 117-118 carriage transport belt & motor removal, 119

line feed assembly removal, 120

main paper guide removal, 126

main paper pan removal, 128

main roller assembly removal, 127 paper adjustment lever removal, 125

paper pressure plate removal, 129

paper separator removal, 124

star wheel assembly removal, 122 star wheel exit roller removal, 123 top paper guide removal, 121

keyboard assembly, 112

installation, 113 removal, 112

LCD module, 109-111

disassembly, 109—110

reassembly, 111

main PCB removal, 137

power supply assembly, 134-135

power supply PCB removal & installation, 135

printer adjustments, 130

carriage home position, 130

belt tension, 131-132

shield plate removal, 138

upper cover removal, 102-107

Covers, carrying handle removal, 108

E

Electrical System Configuration, 21—23

FDD module, 21

keyboard PCB, 21

LCD module, 21

main PCB, 21

Index-1

power supply PCB, 21

ESD-sensitive Parts, handling , 58

E

FDD Control

basic operation, 52

configuration, 51 interface, 52

FDD modules, 53

motor drive circuit, 53

performance specs, 54 read/write circuit, 53

sensor circuits, 53

disk—in, 54

index, 53

track 00, 53

write—protect, 5

Ink Cartridge Replacement, 146

Ink Jet Printer adjustments, 130-132 operation, 1-15 configuration, 2

carriage assembly, 2 carriage motion control system, 2

line feed system, 2 maintenance station, 2 paper feed & adjustment system, 2

carriage index sensor, home position, 23

carriage motor, 23 electrical control, printer, 36

carriage index (home position) sensor, 40 carriage motor control, 38 ink jet head control, 36

line feed motor control, 39 paper—end sensor, 41

printhead cleaning, 153-154

automatic, 153 bracket contacts (carriage), 154

ink-jet nozzles & contacts, 153 INK CHG functions

ink cartridge installation, 15, 150 printhead cleaning (purging), 15

line feed motor, 23 maintenance station operation

capping, 12 ; purging, 12

spitting, 10 wiping, 11

Ink Jet Printer, cont'd.

operation, 1-15

carriage assembly, 3-4

carriage motion control, 5

line feed system, 6

maintenance station, 9-13

paper feed & adjustment system, 7-8

paper-end sensor, 23

sensor operation, 13-14

carriage home position, 13

paper end sensor, 14

Keyboard, operation, 16

Keyboard PCB

control circuit, 43

FPC operation, 42

keyboard scan, 42

L LCD, operation, 18

LCD Module

. configuration, 45

control, 46-47

drive voltage (VEE), 50

operation, 47-48

Lubrication

jube points, 143-149

carriage movement, 145

frame assembly, 144

idle pulley assembly, 146

paper pressure plate assembly, 149

star wheel roller assembly, 147

recommended lubricants, 143

M Main PCB and Peripherals, 24

buzzer drive circuit, 30

clock circuit, 28

country specification change-over, 33

CPU PCB, 25 |

floppy disk controller (FDC), 26

/O map, 31

memory map, 31

printer driver circuits, 26

printer gate array, 26

SERVICE MANUAL

RAM, 25 reset circuit, 29

ROM configuration mode change-over, 35

ROM1, 25 ROM2, 25 video gate array, 26

p

Power Supply PCB

circuit, 56-57

configuration, 55

removal, 134-135

S Self—Tests

LCD tests display tests, 72-76

black test, 75

check test, 73

cross test, 74

display Q test, 76

self-print mode, 68-70

self-test mode, 71-100

display tests, 72-76

CR test, 98

FDD tests, 87-96

keyboard test, 84-86

PE test, 97

print checks, 77-83

test pattern 1, 77-719

test pattern 2, 80-83

serial number Input, 67

Specifications ACF, A-7

dimensions & weight, A-6

electrical system, A-1

environmental tolerance, A-5

FDD, A-5 keyboard, A-4 LCD, A-4 power requirements, A-5

printing, A-2

T

Troubleshooting

Index-2

checks after repair, 59

checks before repair, 59

failure analysis tables, 62-68

flowcharts, 60-65

Documents

fur ~ Schreibmaschine Pr. 2000i (LW-710i) | aaa und ts