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Service Guide ML395/395C
Chapter 0 About This Manual
ML395 // ML395C Dot Matrix Printers
Adobe Acrobat printable reference copy of the OKIDATA Service Training Manual. 09/17/97
Note: This Adobe Acrobat version of the Okidata Service Training Manual was built with the pictures rendered at 300 dpi, which is ideal for printing, but does not view on most displays well.
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Table of Contents
Page
Service Guide ML395/395C
0 About This Manual Front Cover ....Manual Copyright 1 Product Specifications 1.1 Overview - General Information 1.2 Product Specifications 1.3 Paper Specifications 1.4 Physical Specifications 1.5 Power Requirements 1.6 Environmental Conditions 1.7 Agency Approvals 1.8 Options 1.9 Consumables 1.10 Memory Specifications 1.11 Printer Reliability 2 Principles of Operation 2.1Electrical Operation - General Information ....2.1.02 Microprocessors (MPUs) and Peripheral Circuits ....2.1.03 Initialization ....2.1.04 Interface Control ....2.1.05 Printhead Drive Circuit ....2.1.06 Spacing Drive Circuit ....2.1.07 Line Feed Circuit ....2.1.08 Alarm Circuits ....2.1.09 Paper End Detection Circuit ....2.1.10 Power Supply 2.2 Mechanical Operation ....2.2.02 Spacing ....2.2.03 Ribbon Drive ....2.2.04 Paper Feed ....2.2.05 Paper-End Detection ....2.2.06 Automatic Paper Loading ....2.2.07 Paper Park 3 Maintenance & Disassembly 3.1Maintenance - General Information ....3.1.02 Maintenance Items ....3.1.03 Maintenance Precautions 3.2 Disassembly/Assembly Procedures - General Information ....3.2.01 Preliminary Items Printhead ....3.2.02 Ribbon Guide ....3.2.03 Ribbon Protector ....3.2.04 Upper Cover Assembly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
Table of Contents ....3.2.05 Operator Panel Assembly ....3.2.06 Control Board (TFCB) ....3.2.07 Interface Connector Board (TFIF or LQPN) ....3.2.08 Printer Mechanism ....3.2.09 Platen Assembly ....3.2.10 Line Feed Motor ....3.2.11 Head Cable Assembly ....3.2.12 Sensor Board ....3.2.13 Ribbon Feed Assembly ....3.2.14 Space Motor Assembly ....3.2.15 Space Belt ....3.2.16 Cooling Fan ....3.2.17 Bail/Ribbon Motor Assembly ....3.2.18 Paper Bail Assembly ....3.2.19 Carriage and Carriage Shaft ....3.2.20 Paper Pressure Guide ....3.2.21 Printhead Gap / Release Lever Microswitches ....3.2.22 Push Tractor Assembly ....3.2.23 Power Supply Unit ....3.2.24 Ribbon Shift Arm Spring / Ribbon Shift Arm ....3.2.25 Roller Lever ....3.2.26 Ribbon Guide ....3.2.27 Bail Open Cam and Bail Open Gear ....3.2.28 Ribbon Shift Cam and Ribbon Shift Gear ....3.2.29 Ribbon Shift Cam Lever Assembly ....3.2.30 Printer Unit ....3.2.31 BTFD Printed Circuit Board ....3.2.32 Tension Spring ....3.2.33 Sheet Guide ....3.2.34 BTF Front Door Assembly ....3.2.35 Drive Pulley and Mini-pitch Belt ....3.2.36 Line Feed Motor ....3.2.37 Tractor Assembly 3.3 Printer Adjustments - Printhead Gap ....3.3.02 Line Feed Belt Tension ....3.3.03 Color Adjustment (Microline 395C Printer) ....3.3.04 Key Combinations ....3.3.05 Menu Operation - Menu Mode ........Menu Print ........Sample Menu ........Menu Settings ........Menu Reset ........Limited Operation ....3.3.06 Top of Form
Page 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82
Table of Contents ....3.3.07 Paper Park ....3.3.08 Forms Tear Off 3.4 Cleaning 3.5 Lubrication ........Lubrication Points (Monochrome and Color) ............Lubrication Points (Monochrome and Color) Continued ............Lubrication Points (Monochrome and Color) Continued ........Lubrication Points (Color) ........Lubrication Points (Options) 3.6 Shipping Instructions - Return For Service ....3.6.02 All Other Returns 4 Failure & Repair Analysis 4.1 Overview ....4.1.02 Printer Serial Number Identification 4.2 Reporting Problems - General Information ....4.2.02 Problem Lists ....4.2.03 Reporting Methods 4.3 Troubleshooting Updates - General Information ....4.3.02 Okilink II ....4.3.03 Faxable Facts ....4.3.04 Technical Service Bulletins 4.4 Troubleshooting Tips - Preliminary Checks ....4.4.02 Problem Categories ....4.4.03 START HERE Flowchart ....4.4.04 Tips for Preventing Image Problems ....4.4.05 Common Problems 4.5 Abnormal Output 4.6 Fault Alarms - General Information 4.7 Repair Analysis Procedures (RAPS) - Using The RAPS ....4.7.02 RAP Index ........RAP 01: Power Lamp Does Not Light ........RAP 02: Space Error (ALARM 5B) ........RAP 03: Head Homing Error (ALARM 53) ........RAP 04: Ribbon Homing Error (ALARM 57) ........RAP 05: Bail Home Error (ALARM 5C) ........RAP 06: Wrong Character, Character Omission, or Dot Omission ........RAP 07: Ribbon Feed Trouble ........RAP 08: Line Feed Trouble ........RAP 09: Malfunction of Operator Panel Switch ........RAP 10A: Data Receive Failure ........RAP 10B: Parallel Interface Problem
Page 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122
Table of Contents ........RAP 10C: Serial Interface Problem ........RAP 10D: Data Receive Failure (Alarm Light Lit) ........RAP 11: Color Ribbon Shift Problem 4.8 Printer Tests ....4.8.02 Font Test ....4.8.03 Serial Interface - Loopback Test ....4.8.04 Hexadecimal Dump 4.9 Resistance Checks - General Information ....4.9.02 Printhead Resistance Check ....4.9.03 Line Feed Motor Resistance Check ....4.9.04 Space Motor Resistance Check ....4.9.05 Ribbon Motor Resistance Check A Board Diagrams A.1 Overview - General Information A.2 Index To Charts ....A.2.01 Main Controller Board (TFCB) ............ML395/395C Jumper Plugs SP2 : Jim Fitzpatrick/Project Leader/Okidata; 11/18/96 ....A.2.02 Power Supply Board (POW) ....A.2.03 Interface Board (TFIF) ............Change sp102 jumper : Eric Tomenga/OKI_ELECTRIC/US ............Shorting Plug SP102 : Jim Fitzpatrick/Project Leader/Okidata; 11/18/96 ....A.2.04 Sensor Board (LQEW) ....A.2.05 Operator Panel (TFOP) B Illustrated Parts Listing B1.1 Overview - General Information ....B.1.02 Definition of Terms ....B.1.03 Parts Ordering Information B.2 Charts ....B.2.01 Upper Cover Assembly ....B.2.02 Printer Unit General Assembly ....B.2.03 Operator Panel ....B.2.04 Carriage Assembly (Black and White) ....B.2.05 Carriage Assembly (Color) ....B.2.06 Printer Unit - Black and White (1 of 3) ....B.2.07 Printer Unit - Black and White (2 of 3) ....B.2.08 Printer Unit - Black and White (3 of 3) ....B.2.09 Printer Unit - Color (1 of 3) ....B.2.10 Printer Unit - Color (2 of 3) ....B.2.11 Printer Unit - Color (3 of 3) ....B.2.12 Cables and Connectors ....B.2.13 Options
Page 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161
Table of Contents ....B.2.14 Pull Tractor Assembly (Option) ....B.2.15 Bottom Tractor Feed Unit (Push) [BTF] (Option) ....B.2.16 BTF Pull-Up Roller Assembly (Option) ....B.2.17 Consumables ....B.2.18 Packing Materials ....B.2.19 Documentation
Page 162 163 164 165 166 167
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Service Guide ML395/395C
Chapter 0 About This Manual
This document may not be reproduced without the written permission of the Okidata ® Technical Training Group. Every effort has been made to ensure the accuracy of the information contained in this training course. Okidata is not responsible for errors beyond its control. © 1994 by Okidata All rights reserved. First Edition May, 1993 P/N 59260501 Second Edition October, 1994 P/N 59260502 Written and produced by the Okidata Technical Training Group Please send any comments on this publication to the address listed below. Technical Training Group Okidata 532 Fellowship Road Mount Laurel, NJ 08054-3499 Okilink Login Name: Technical Training OKI is a registered trademark of Oki Electric Industry Company, Ltd.; marques deposee de Oki Electric Industry Company, Ltd.; marca registrada, Oki Electric Industry Company, Ltd. OKIDATA is a registered trademark of Oki Electric Industry Company, Ltd.; marques deposee de Oki Electric Industry Company, Ltd.; marca registrada, Oki Electric Industry Company, Ltd. MICROLINE is a registered trademark of Oki Electric Industry Company, Ltd.; marque depose de Oki Electric Industry Company, Ltd. Centronics is a registered trademark of the Centronics Data Computer Corp. Epson is a registered trademark of Seiko Epson Corporation. IBM is a registered trademark of International Business Machine Corporation. Microsoft is a registered trademark of Microsoft Corporation. MS-DOS is a registered trademark of Microsoft Corporation. PC is a registered trademark of International Business Machine Corporation. Proprinter is a registered trademark of International Business Machine Corporation. Windows is a trademark of Microsoft Corporation Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Service Guide ML395/395C
Chapter 1 Product Specifications
1.1 OVERVIEW 1.1.01 General Information The Microline 395 is a high speed, dot matrix printer, which utilizes a 24 wire printhead. The Microline 395 comes standard with both an RS232-C Serial Interface and a Centronics Parallel Interface. The printer is available in either a standard version (Microline 395; single color output) or a color capable version (Microline 395C; multiple color output). The Microline 395 is capable of emulating the Epson LQ 850/1050 or the IBM Proprinter XL24 printers. The Microline 395C emulates the Epson LQ 2550, Epson LQ850/1050 or the IBM Proprinter XL24. Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Chapter 1 Product Specifications
1.2 PRODUCT SPECIFICATIONS 1.2.01 Paper Feed Method Built-in push tractor Friction feed 1.2.02 Paper Path Bottom Feed Rear Feed Top Feed 1.2.03 Printhead Type Staggered, 24 pin, stored energy printhead 1.2.04 Interface Methods
Both are Standard
Centronics Parallel Interface RS232-C Serial Interface 1.2.05 Print Speed
Pitch 10 cpi 12 cpi 15 cpi 17.1 cpi 20 cpi 10 cpi 12 cpi 15 cpi 17.1 cpi 20 cpi
Head Gap Setting 1,2 1,2 1,2 1,2 1,2 3+ 3+ 3+ 3+ 3+
High Speed Draft 607 cps 607 cps
Utility 405 cps 486 cps 303 cps 347 cps 405 cps 352 cps 422 cps 263 cps 300 cps 352 cps
Near Letter Quality 202 cps 242 cps
Letter Quality 135 cps 162 cps 202 cps 231 cps 270 cps 117 cps 140 cps 175 cps 200 cps 234 cps
175 cps 211 cps
528 cps 528 cps
cpi - Characters Per Inch cps - Characters Per Second
1.2.06 Symbol Sets Standard ASCII Epson Character Set IBM Character Set I and Set II IBM Proprinter All Character Set International Characters Line Graphics Code Page 850, 863,437 1.2.07 Standard Fonts Utility (Used in Utility and High Speed Draft Modes) Courier Swiss Roman Orator 1.2.08 Line Feed Increments 1/6" n/180" 1/8" n/216" n/60" n/360" n/72" 1.2.09 Line Feed Time 55 ms @ 6 LPI 8.0 IPS (inches per second) slew rate @ gap 1,2 6.0 IPS (inches per second) slew rate @ gap 3+ 1.2.10 Paper Out Detection
Printhead distance from edge of paper when End of Paper is detected
Rear Feed: 5.8" Bottom Feed: 2.4" Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Chapter 1 Product Specifications
1.3 PAPER SPECIFICATIONS 1.3.01 Types Letter Legal Labels - Bottom feed only Continuous Forms Envelopes Card Stock Transparency 1.3.02 Weight 12 - 24 lb. (Continuous Form Paper) 16 - 24 lbs (Cut Sheet Paper) 1.3.03 Number of Copies 1 - 4 (4 Part Form Maximum) 1.3.04 Maximum Thickness .014 inches (Rear Feed) .020 inches (Bottom Feed) Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Service Guide ML395/395C
Chapter 1 Product Specifications
1.4 PHYSICAL SPECIFICATIONS 1.4.01 Printer Dimensions Width: 16.42" Height: 7.09" Length: 22.44" 1.4.02 Printer Weight 37 lbs. Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Service Guide ML395/395C
Chapter 1 Product Specifications
1.5 POWER REQUIREMENTS 1.5.01 Input Power Input Voltage 120 VAC +10%, -15% 220/240 +10%, -15% Frequency 50/60 hz. +/-2% 1.5.02 Power Consumption During Self Test : 180 VA During Standby : 60 VA Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Service Guide ML395/395C
Chapter 1 Product Specifications
1.6 ENVIRONMENTAL CONDITIONS 1.6.01 Ambient Temperature and Relative Humidity While in operation: 41°F to 104°F @ 20% - 80% Relative Humidity While in storage: 14°F to 122°F @ 5% - 95% Relative Humidity 1.6.02 Printer Noise Level (10 cpi - LQ Mode) Standard noise level: 58 dba Quite mode noise level: 56 dba Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Service Guide ML395/395C
Chapter 1 Product Specifications
1.7 AGENCY APPROVALS North America FCC Class B UL 1950 - D3 CSA 950 - D3 Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Service Guide ML395/395C
Chapter 1 Product Specifications
1.8 OPTIONS 1.8.01 Cut Sheet Feeders CSF 3001 - Single bin Cut Sheet Feeder CSF 3002 - Dual bin Cut Sheet Feeder 1.8.02 Pull Tractor Assembly The Pull Tractor Assembly is required for bottom feeding if the optional Bottom Push Tractor Unit is not installed. 1.8.03 Bottom Push Tractor Unit Card Stock and Labels
NOTE: A Pull Tractor Assembly or Bottom Push Tractor must be used to feed labels.
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Service Guide ML395/395C
Chapter 1 Product Specifications
1.9 CONSUMABLES 1.9.01 Black Ribbon Cartridge Microline 395 and Microline 395C Type: Nylon Fabric Ribbon Ribbon Life: 5 million characters 1.9.02 Color Ribbon Cartridge Microline 395C Type: Four band color ribbon (Yellow, Magenta, Cyan, Black) Ribbon Life: Black: 2.1 million characters Cyan: 1.9 million characters Magenta: 1.9 million characters Yellow: 1.3 million characters 1.9.03 Film Ribbon Can be used in both the Microline 395 and Microline 395C. Ribbon Life 400K Characters at 10 cpi in LQ mode Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Chapter 1 Product Specifications
1.10 MEMORY SPECIFICATIONS 1.10.01 ROM Resident Program ROM = 128 Kbytes Resident Fonts = 384 Kbytes 1.10.02 RAM Total RAM = 64 Kbytes Print Buffer = 23 Kbytes I/F Buffer = 8 K bytes DLL Buffer = 22 Kbytes Command Buffer = 11 Kbytes 1.10.03 EEPROM Internal Control, Menu = 256 bits Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Service Guide ML395/395C
Chapter 1 Product Specifications
1 . 1 1 P R I N T E R R E L I A B I L I T Y
1 . 1 1 . 0 1 M e a n T i m e B e t w e e n F
a i l u r e ( M T B F )
8 , 0 0 0 h o u r s @ 2 5 % D u t y C y c l e , 3 5 % P a g e D e n s i t y
1 .
1 1 . 0 2 M e a n T i m e T o R e p a i r ( M T T R )
1 5 m i n u t e s @ m a j o r s u b a s s e m b l
y l e v e l
1 . 1 1 . 0 3 P r i n t e r L i f e
1 2 , 0 0 0 h o u r s @ 2 5 % D u t y , 3 5 % P a g e D
e n s i t y
1 . 1 1 . 0 4 P r i n t h e a d L i f e
2 0 0 M i l l i o n C h a r a c t e r s ( a v e r
a g e ) @ 1 0 c p i D r a f t M o d e @ 2 5 % D u t y C y c l e , 3 5 % P a g e D e n s i t y
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Chapter 2 Principles of Operation
2.1 ELECTRICAL OPERATION 2.1.01 General Information The Control Board consists of the microprocessor and its peripheral circuits, the drive circuits. The power to the Control Board is supplied by the power supply unit. The power to the other electrical parts is distributed via the connectors on the Control Board. Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Chapter 2 Principles of Operation
2.1.02 Microprocessors (MPUs) and Peripheral Circuits Microprocessors (Q16: 80C154HGS and Q11: 80C154VGS) The Microprocessors are the nucleus of the control circuit. The peripheral circuits operate under program control by these microprocessors. The Master MPU (Q16) controls the interface, code processing and the Slave MPU. The Slave MPU (Q11) controls the spacing and printing functions. Program ROM for Master MPU (Q6: 27C101) This Program ROM contains the control program for the printer. The master microprocessor operates by execution of this program. Program ROM for Slave MPU (Q17: 2764) This Program ROM contains the control program for the printer. The slave microprocessor operates by execution of this program. DRAM (Q18 and Q19) The Dynamic RAM chips, each consisting of 64x4 Kbits, are used as the Receive Buffer and Print Buffer. The total buffer size is 64x8 Kbits. CGROM (Q7) This is a 1 Mbit ROM which stores the resident character fonts. EEPROM (Q20) This 256-bit serial Electrically Erasable and Programmable ROM stores the menu data. Motor Control LSI (Q9: MSM6990) This LSI controls the following functions: Space Motor Speed Control To obtain the carriage speed instructed by the Microprocessor, the LSI generates the pulse switch timing and overdrive time Dot ON Timing generation I/O Port (Input port used to read Operator Panel switches) Address Latch (for lower 8 bits of the slave MPU) LSI (Q8: MSM74H002) This LSI drives the 24 pin printhead. The following describes the function of the LSI.
Printhead Drive Control Printhead Drive Correction Modifies the drive time under the following circumstances Correction for edge pin driving Correction for drive voltage fluctuations Correction for head gap setting Interface LSI (Q12: MSM60306) The MSM60306 is an external interface LSI and controls the following functions. Interface Control Controls both the parallel and serial interface functions Pin 4 of this LSI enables selection of the serial or parallel interface Address Latch (for lower 8 bits of the master MPU) MMU (Memory Management Unit) LSI (Q13: LC92018B-728) This LSI is connected between the Master and Slave MPUs and performs these functions. Master/Slave MPU Interface Transfers commands and data between the Master and Slave MPUs Memory Control Extends the addressable memory by switching banks in/out Dynamic RAM Refresh Block Diagram of Microline 395
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Service Guide ML395/395C
Chapter 2 Principles of Operation
2.1.03 Initialization The Printer is initialized whenever the power is turned ON or when the I-PRIME signal is received at the parallel interface. Initialization is started when the RST-P signal is sent from the reset circuit to the MPUs and LSIs. When RST-P is generated, ROM program execution starts with the mode setting of Q8, Q9, Q12 and Q13. Next, ROM and RAM are checked for errors, RAM is initialized and the carriage, bail and ribbon (color model only) are homed. The program finally establishes the interface signals (output level of ACK, BUSY, etc.), then turns the SELECT lamp ON to inform the host computer that the printer is ready to receive data. Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Chapter 2 Principles of Operation
2.1.04 Interface Control The Microline 395 is capable of serial or parallel operation. The desired interface method is selected by sliding the interface cover to expose the desired connector. When this is done, the interface select switch is turned ON or OFF to inform the Interface Control LSI (Q12) of the selected interface. Parallel Interface When the interface select switch is turned OFF, the parallel interface is selected and the Interface Control LSI is in the parallel mode. The data from the interface is received through connector (CN-1) and the Interface LSI (Q12) latches this data to the internal register in the LSI at the rising edge of the STB-N signal. The BUSY signal is turned ON as the data is processed. When processing is completed, the BUSY signal is turned OFF and an ACK signal is sent to the host to request more data. The BUSY signal is also turned ON when the printer is not able to receive data (buffer is full, printer is deselected or an error condition exists).
RS232-C Serial Interface When the interface select switch is turned ON, the serial interface is selected and the Interface Control LSI is in the serial mode. Then the RS232-C interface signals (DSR, CTS, CD and RD) are converted to TTL levels by the line receiver (Q4) and input to the Master MPU, Slave MPU and MMU. The Master MPU converts the serial data to parallel data. The interface signals (DTR, RTS, SSD and TD) output from the Master MPU and Interface LSI are
converted from TTL levels to RS232-C levels by the line driver (Q2) and sent to the serial interface connector.
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Service Guide ML395/395C
Chapter 2 Principles of Operation
2.1.05 Printhead Drive Circuit This circuit is used to drive the 24 print wires. The signals HD1 through HD24 control the individual print wires. The HD ON signal (even/odd trigger) enables the drive circuit when printing is desired. The head drive duration is determined by an RC integrating circuit, which modifies the HD ON pulse width. The pulse width of the HD ON signal varies with the number of pins being driven. Printhead Drive Time The drive time increases as more pins are driven. The drive time decreases as less pins are driven. The drive time also increases if the head gap lever is placed in positions 4 through 9. An RC circuit also is used to compensate for the fluctuation of drive voltage (+38 vdc).2-1-04B.pcx Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Chapter 2 Principles of Operation
2.1.06 Spacing Drive Circuit The Motor Control LSI (Q9) outputs the SPMO DA signal upon receiving the spacing command from the Slave MPU (Q11). This is a fixed cycle pulse signal. To control the motor speed, the Motor Control LSI varies the pulse duty cycle according to the speed data from the Slave MPU. The SPMO FOW or SPMO REV signal from the Head Control LSI (Q8) changes the current direction in the DC motor to run the motor in either the forward or reverse direction. As the space motor rotates, it generates feedback pulse signals SPfA and SPfB. The Motor Control LSI detects the edge pulses from these signals and divides the frequency to output the MO LSI IPT signal for use in Dot Timing.
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Service Guide ML395/395C
Chapter 2 Principles of Operation
2.1.07 Line Feed Circuit The Line Feed Motor Shaft is held stationary by +8 vdc supplied according to the pulse duty cycle of the LFCHOP signal (the holding current is approximately 30 ma) whenever in a stopped position. During line feed operation, the Line Feed Motor is driven by +38 vdc in accordance with the LFOVDV-N signal. The signals LFf1 through LFf4 establish the proper phase relationship for driving the motor.
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Chapter 2 Principles of Operation
2.1.08 Alarm Circuits Fault Alarm Circuit (in Power Supply Unit) This protective circuit turns off the Power Supply when a fault occurs in the printhead, line feed, or bail/ribbon motor drive circuits, thus preventing secondary component failure. To accomplish this, the circuit monitors the overdrive signal of each drive circuit. If the duration of any drive circuit exceeds a predetermined length of time, the appropriate signal (HDE ALM, HDO ALM, LF COM or RBN COM) will be sent to the fault alarm circuit. The fault alarm circuit generates the ALM signal (high) which causes the power supply to turn all DC power OFF. Printhead Overheat Alarm Circuit In order to protect the printhead coils, this circuit monitors the printhead temperature by using a thermistor contained in the printhead. The CPU senses this circuit every time a line is printed. When printing, the printhead temperature rises. If the head temperature reaches approximately 115 degrees Celsius, a head overheat condition (ALARM 1) is generated. When ALARM 1 is detected, bi-directional printing stops. Uni-directional printing continues. If the printhead temperature continues to rise, ALARM 2 is generated. All printing stops. Printing resumes when the head temperature falls below the ALARM 1 level. Cover Open Alarm Circuit When the front access cover is opened, the COVOPEN-N signal is sent to the Slave MPU from the cover interlock microswitch. The Slave MPU relays the switch status to the Master MPU. The Master MPU will halt printing at the completion of the current line and light the ALARM Lamp. Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Chapter 2 Principles of Operation
2.1.09 Paper End Detection Circuit Whenever the Release Lever is in the Continuous Feed position, Paper End is detected by the microswitch on the Push Tractor (rear feed) or the Paper End sensor on the sensor board (bottom feed). Whenever the Release Lever is in the Sheet Feed position, Paper End is detected by a photosensor located in the paper pressure guide. When the printer detects an out of paper condition, the PE-N signal goes low, the printing is stopped and the ALARM LAMP is turned ON. Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Chapter 2 Principles of Operation
2.1.10 Power Supply This switching power supply converts the AC input voltage to +5 vdc, +/-8 vdc and +38 vdc for use throughout the printer.
Voltage/Signal +5 vdc +8 vdc -8 vdc +38 vdc POW ALM
Purpose IC Logic Levels - LED Drive Voltage Serial I/F Logic Levels - LF Motor Locking Voltage Serial I/F Logic Levels Printhead Space Motor LF Motor Bail/Ribbon Motor Drive Voltage Output from the Power Supply in the event of an abnormal temperature rise in the power supply unit or an overcurrent condition of the +38 vdc. The Main Control Board suppresses this condition by temporarily suspending printing. If the condition does not change the Main Control Board will enable the FAN ALARM (Alarm 60) See Section 4 Output from the Main Control Board upon detection of an overdrive condition in the printhead LF motor or bail/ribbon motor drive circuits.
ALM
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Service Guide ML395/395C
Chapter 2 Principles of Operation
2.2 MECHANICAL OPERATION 2.2.01 The Printhead Mechanism The Microline 395 uses a highly efficient stored energy type printhead. Power is not consumed until the printwires are activated, thereby extending the printhead life to approximately 200 million characters. The printhead uses 24 printwires (two columns of 12 wires each). Each wire is welded to an armature. Behind this armature is a spacer ring. Each of the 24 printwire armatures have a permanent magnet behind them. The magnets attract the armatures, drawing the printwires into the wire guide, thus keeping the wires inside the printhead. A coil is wrapped around each of the permanent magnets. When a dot is to be printed, current is passed through the appropriate coil. This creates an electromagnetic field which opposes the magnetic field of the permanent magnet. The armature can then spring forward and the print wire (which is attached to the armature) strikes the ribbon and imprints a dot on the paper. When current is removed from the coil, the magnetic field of the permanent magnet attracts the armature, causing the printwire to retract into the wire guide once again. The printhead contains a built-in thermistor used to monitor the printhead temperature. The parts listed below make up the printhead. Wire Guide Print Wires Armature Assembly Spacer Permanent Magnet Assembly Thermistor Printed Circuit Board with Coils Head Gap Adjusting The head gap adjusting mechanism adjusts the gap between the platen and printhead. This is accomplished by moving the adjusting lever on the left side of the printer mechanism. When the lever is moved the carriage shaft rotates. Since the carriage shaft is attached to the printer mechanism with eccentric collars, as the carriage shaft rotates, the distance between the platen and carriage shaft changes.
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Service Guide ML395/395C
Chapter 2 Principles of Operation
2.2.02 Spacing Spacing is performed when the servo motor drives the carriage along the carriage shaft, parallel to the platen. The spacing mechanism consists of the: Servo Motor Drive Pulley Idle Pulley Carriage Shaft Carriage Frame Space Belt Spacing Operation The carriage containing the printhead moves parallel to the platen along the main carriage shaft. Power from the space motor is transferred via the space belt, which is attached to the bottom of the carriage frame. The carriage is designed to move 1.6 inches when the servo motor performs one rotation.
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Service Guide ML395/395C
Chapter 2 Principles of Operation
2.2.03 Ribbon Drive The ribbon drive mechanism moves the ribbon in synchronization with the space motor operation. The ribbon drive mechanism consists of the following items. Ribbon Drive Assembly Ribbon Cartridge Ribbon Cartridge An endless ribbon with a single direction feed is used. Ink is supplied from an ink tank, which is built-in to the ribbon cartridge. Ribbon Feed Operation The rotation of the space motor is transmitted to the drive gear in the ribbon cartridge through the ribbon feed gear assembly, thereby feeding the ink ribbon. The feed direction of the ribbon is maintained by switching the rotational direction of the gears in the ribbon drive assembly. This ensures unidirectional ribbon movement when bidirectional printing is used.
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Service Guide ML395/395C
Chapter 2 Principles of Operation
2.2.04 Paper Feed Paper feeding is performed by turning the platen and the pin tractor, which is driven by the line feed pulse motor. The paper feed mechanism consists of the following items. Pulse Motor (with gears) Idler Gear Change Spring Change Gear Platen Tractor Feed Unit Paper Pressure Guide Friction Feed When the release lever is set to the SHEET FEED position, the change gear is disengaged from the tractor gear. At the same time, the release lever applies pressure to push the pressure rollers against the platen, allowing paper to be fed.
Tractor Feed
When the release lever is set to the TRACTOR FEED position, the release lever allows the reset spring to push the change gear toward the tractor gear. At the same time, the release lever pushes the pressure rollers away from the platen, allowing paper to be fed by the tractors.
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Service Guide ML395/395C
Chapter 2 Principles of Operation
2.2.05 Paper-End Detection Cut-Sheet Paper-End When the release lever is in the SHEET FEED position, the photosensor located in the paper pressure guide is active. If sheet paper is installed, the paper is detected by the sensor and the sensor is turned on. When the printer is out of sheet paper, the sensor is turned off indicating a paper-end condition.
Bottom Feed Paper-End (Used with optional Pull Tractor) When the release lever is in the TRACTOR FEED position, the switch on the left push tractor and the paper-end sensor on the sensor board are active. If paper is detected by either of these sensors, paper-end is inhibited. When bottom feed paper is installed, it moves the bottom paper-end lever to turn the sensor ON. When a paper out condition exists, the lever blocks the sensor indicating a paper-end condition.
Rear Feed Paper-End When the release lever is in the TRACTOR FEED position, the switch on the left push tractor and the paper-end sensor on the sensor board are active. If paper is detected by either of these sensors, paper-end is inhibited. When rear feed paper is installed, pressure is placed on the microswitch, located in the left push tractor. Since the switch is turned ON, paper is detected.
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Service Guide ML395/395C
Chapter 2 Principles of Operation
2.2.06 Automatic Paper Loading Automatic Paper Loading is used to consistently set the print start position when using cut-sheet or continuous sheet paper. The procedure is listed below. Cut-Sheet Paper 1. Push the Paper Release Lever to the Cut-Sheet position. 2. Insert the paper from behind the platen. 3. Press the FORM FEED switch. 4. The Paper Bail will automatically open. 5. The Line Feed operation will load the paper. 6. The Paper Bail will automatically close.
NOTE: If the paper does not move, the Auto-Load motion becomes invalid and is treated like an ordinary paper-end.
Continuous Sheet (Rear Feed) SASF 1. Push the Paper Release Lever to the Continuous Sheet side (front of printer). 2. Insert the paper into the push tractor. The white guide line on the tractor MUST be visible. 3. Press the FORM FEED switch. 4. The Paper Bail will automatically open. 5. The Line Feed operation will load the paper. 6. The Paper Bail will automatically close.
NOTE: If the paper does not advance after the line feed motor has fed the equivalent of 2.4 inches of paper, the Auto-Load process stops. This situation is treated like an ordinary paper-end condition.
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Chapter 2 Principles of Operation
2.2.07 Paper Park The Paper Park feature operates as follows. The PARK/TOF switch is pressed. Reverse line feed retracts the paper until a paper-end condition exists or until 14 inches of paper has been retracted. The paper will remain on the push tractor, but out of the printing path. Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Service Guide ML395/395C
Chapter 3 Maintenance & Disassembly
3.1 MAINTENANCE 3.1.01 General Information This section lists the parts replacement, adjustment, cleaning, lubrication, and shipping procedures. Disassembly should not be performed unless absolutely necessary. NEVER perform disassembly on a malfunctioning unit until you have followed the failure analysis procedures in Section Four of this Service Handbook. Follow the procedures listed in Adjustments and Service Settings. Adjustments may be required when either consumables or parts are replaced. Failure to perform these procedures could result in unnecessary service calls. Cleaning procedures must be performed correctly if high print quality is to be achieved. Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Chapter 3 Maintenance & Disassembly
3.1.02 Maintenance Items The following items are required to service the unit. #1 Phillips Screwdriver (with magnetic tip) #2 Phillips Screwdriver (with magnetic tip) #3 Phillips Screwdriver (with magnetic tip) Straight-slot Screwdriver Needle Nose Pliers (4 inch) Diagonal Cutters Tension Gauge (capable of measuring 1 pound of pressure) 7 mm open-ended wrench Ruler (capable of measuring 1/16 inch increments) 3/32 inch socket with driver Feeler Gauge Digital Multimeter Shop Vacuum Cloth (soft and lint-free) All-Purpose Cleaner Dow Corning Molycoat BR-2 or Molycoat ME-300L or equivalent Contact Kleen (Okidata P/N 51802301) Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Service Guide ML395/395C
Chapter 3 Maintenance & Disassembly
3.1.03 Maintenance Precautions 1. Do not disassemble the unit if it is operating normally. 2. Before starting disassembly and assembly, always power OFF the unit and detach the AC power cord. 3. Detach the interface cable, if installed. 4. Do not remove parts unnecessarily. Try to keep disassembly to a minimum. 5. Use the recommended maintenance tools. 6. When disassembling, follow the listed sequence. Failure to follow the correct sequence may result in damaged parts. 7. Since screws, collars and other small parts are easily lost, they should be temporarily attached to the original positions. 8. When handling circuit boards use extreme care. Integrated circuits (microprocessors, ROM, and RAM) can be destroyed by static electricity. 9. Do not place printed circuit boards directly on conductive surfaces. 10. Follow the recommended procedures when replacing assemblies and units. Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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Service Guide ML395/395C
Chapter 3 Maintenance & Disassembly
3.2 DISASSEMBLY/ASSEMBLY PROCEDURES General Information This section contains the printer disassembly procedures. Only the removal procedures are explained here. Reverse the procedure for the installation. At the bottom of each procedure is a listing of the parts covered in that procedure. The Okidata part number, item description, comment (RSPL, Option, Consumable) and cross-reference to Appendix B is provided for each part. Items included in the Recommended Spare Parts List are indicated by the acronym RSPL. N/A will appear where a part number is not available. Part Item Comment Appendix B Number Description Reference This Service Handbook lists the disassembly procedures for major components of the unit. Okidata DOES NOT recommend disassembling a unit which is operating normally. If you decide to perform disassembly during this training, Okidata recommends that you perform only the disassembly procedures for RSPL items. All other procedures are provided to assist you in identifying parts. It is not likely that you will perform these procedures while servicing the unit. Be sure to read all notes, cautions, and warnings, as they contain important information regarding disassembly / assembly. Microline 395C-Plus Only (Color Version) 3.2.24 Ribbon Shift Arm and Shift Arm Spring 3.2.25 Roller Lever 3.2.26 Ribbon Guide 3.2.27 Bail Open Cam and Bail Open Gear 3.2.28 Ribbon Shift Cam and Ribbon Shift Gear 3.2.29 Ribbon Shift Cam Lever Assembly Optional Bottom Push Tractor Unit (BPTU) 3.2.30 Printer Unit 3.2.31 BTFD PCB 3.2.32 Tension Spring 3.2.33 Sheet Guide 3.2.34 Bottom Cover
3.2.35 Drive Pulley and Mini-Pitch Belt 3.2.36 Line Feed Motor 3.2.37 Tractor Assembly
NOTE: Refer to Appendix B (Illustrated Parts Listing) for the location of the printers major assemblies.
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Chapter 3 Maintenance & Disassembly
3.2.01 Preliminary Items Printhead WARNING: The printhead will be HOT immediately after printing. 1. Open the printer access cover. 2. Remove the ribbon cartridge (1). 3. Place the head gap adjusting lever (2) to the range 9 position. 4. Remove the two mounting screws (3). 5. Lift the printhead (4) from the connector to remove it.
NOTE: When installing the printhead, pull the printhead towards the stopper (in the direction of Arrow A)
P/N 50099905 Printhead: Assembly RSPL B.2.02 P/N 52103601 Ribbon Cartridge (Black) Nylon Consumable B.2.02 P/N 52103701 Ribbon Cartridge (Color) Consumable B.2.02 , 17 , 17 , 17
P/N 52103801 Ribbon Cartridge (Black) Film Consumable B.2.02 P/N 56609701 Cord: AC 120V RSPL B.2.02 , 12
P/N 56624101 Cord: AC (220V) ML Series Option RSPL B.2.02 P/N 70000803 IBM PC Cable Kit (Interface Cable) B.2.02 , 12
, 12
, 13
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Chapter 3 Maintenance & Disassembly
3.2.02 Ribbon Guide 1. Remove the printhead (3.2.01). 2. Remove the two mounting screws (1). 3. Lift the ribbon guide (2) and remove it. P/N 53055901 Guide: Ribbon (Black) RSPL B.2.04
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Service Guide ML395/395C
Chapter 3 Maintenance & Disassembly
3.2.03 Ribbon Protector 1. Remove the printhead (3.2.01). 2. Remove the ribbon guide (3.2.02). 3. Remove the two mounting screws (1). 4. Lift the ribbon protector (2) and remove it. P/N 53527001 Protector: Ribbon RSPL B.2.04 , 05
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Service Guide ML395/395C
Chapter 3 Maintenance & Disassembly
3.2.04 Upper Cover Assembly 1. Disconnect the interface cable (1). 2. Detach the platen knob (2). 3. Remove the two cover mounting screws (3) at the rear of the printer. 4. Lift the rear access cover (4) to the open position. 5. Lift the upper cover at the back and tilt it towards the front to remove it.
NOTE: When installing the upper cover assembly: Move the release lever (5) towards the front of the printer. Move the bail arm lever (6) towards the back of the printer. Check that the paper bail moves properly.
P/N 50212441 Cover: Middle Assembly RSPL B.2.01 P/N 50212442 Cover: Middle Assembly RSPL B.2.01 (Color) P/N 50215701 Cover: Access (ML395) RSPL B.2.01 P/N 50215703 Cover: Access (ML395C) RSPL B.2.01 P/N 50215801 Cover: Rear Assembly RSPL B.2.01 P/N 53478601 Platen Knob RSPL B.2.02
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Service Guide ML395/395C
Chapter 3 Maintenance & Disassembly
3.2.05 Operator Panel Assembly 1. Remove the upper cover assembly (3.2.04). 2. Disconnect the operator panel cable (1) from CN10 (2) on the control board. 3. Remove the two mounting screws (3). 4. Detach the operator panel holder (4) by moving it upward, and then pulling toward the front of the printer. 5. Open the eleven claws and detach the operator panel (5) from the operator panel holder. P/N 50100001 Panel: Operator ML395 RSPL B.2.03 P/N 50910505 Spring: Cover Open RSPL B.2.03 P/N 55071701 PCB: TFOP Op Panel RSPL B.2.03 P/N 56212601 Switch: Interlock (Assembly) RSPL B.2.03 P/N 56614301 Cable: Microswitch RSPL B.2.03 P/N 56628403 Cable: Op (ML395) RSPL B.2.03 , 12 , 12
(Cover Open)
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Service Guide ML395/395C
Chapter 3 Maintenance & Disassembly
3.2.06 Control Board (TFCB) 1. Remove the upper cover assembly (3.2.04). 2. Remove the ribbon cartridge. 3. Release the lock of connector CN10 (1) and detach the operator panel cable (2). 4. Remove the five shield cover mounting screws (3). 5. While slightly lifting the shield cover (4), detach connector CN13 (5) and CN11 (6) from the control board (7), then remove the shield cover. 6. Detach the remaining connectors from the control board. 7. Loosen the mounting screw and remove the control board.
NOTES: When assembling the printer: Do not allow cables to get caught under the control board. Insert the control board into the groove in the base tray (8). Place the control board into the groove (9) in the shield cover, then attach the shield cover.
P/N 55071811 PCB: TFCB-1 (w/o ROM) RSPL B.2.02 P/N 55071812 PCB: TFCB-2 (w/o ROM) RSPL B.2.02 (Color) P/N 56301703 Fuse: 2A, 125V RSPL B.2.02 P/N 56619201 IF - Main Board Connection (50P) RSPL B.2.02 , 12
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Chapter 3 Maintenance & Disassembly
3.2.07 Interface Connector Board (TFIF or LQPN)
NOTE: To allow easier access to the mounting screw and cables, configure the interface connector board to use the serial interface connector.
1. Remove the upper cover assembly (3.2.04). 2. Disconnect connectors CN102 (1) and CN103 (2). 3. Remove the two mounting screws (3). 4. Lift the interface connector board (4). 5. Detach connector CN101 (5). 6. Remove the interface connector board.
NOTE: After assembly, configure the interface connector board (if necessary).
P/N 55034501 PCB: Assembly I/F Connector TFIF or LQPN RSPL B.2.02
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Service Guide ML395/395C
Chapter 3 Maintenance & Disassembly
3.2.08 Printer Mechanism 1. Remove the control board (3.2.06). 2. Detach connectors CN102 (1) and CN103 (2) from the interface connector board. 3. Remove the three mounting screws (3) at the rear of the printer mechanism (4). 4. Remove the three mounting screws and brackets (5). There are two on the left side of the printer mechanism and one on the right side. CAUTION: Do not grasp the ribbon cartridge bracket, paper chute, or the guide shaft of the sheet feeder assembly when lifting the printer during the next step. These parts are easily bent. 5. While holding the base tray, lift the printer mechanism and remove it.
NOTE: When assembling the printer, do not allow cables to get caught under the control board.
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Service Guide ML395/395C
Chapter 3 Maintenance & Disassembly
3.2.09 Platen Assembly 1. Remove the upper cover assembly (3.2.04). 2. Loosen the three 7 mm line feed motor mounting bolts (1). 3. Move the line feed motor (2) closer to the platen (3) and detach the line feed drive belt (4). 4. Remove the E-ring, washer, spring and idle gear (5). 5. Remove the screw and detach the gear pulley, washer and bushing (6). 6. Remove the screw and detach the gear and bushing (7). 7. Push in the platen lever (8), lift the bail, and remove the platen assembly.
NOTE: Perform the line feed belt tension adjustment (3.3.02) belt.
P/N 50215902 Separator: Sheet RSPL B.2.02 P/N 50054101 Platen Assembly RSPL B.2.06 P/N 51214501 Gear: Platen "A" RSPL B.2.06 P/N 51215001 Pulley: Platen RSPL B.2.06 , 09 , 09
after replacing the line feed drive
, 09 , 09
P/N 51302790 Belt: Mini Pitch (Line Feed) RSPL B.2.06
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Service Guide ML395/395C
Chapter 3 Maintenance & Disassembly
3.2.10 Line Feed Motor 1. Remove the printer mechanism (3.2.09). 2. Remove the three mounting bolts and washers (1). 3. Remove the line feed motor (2).
NOTE: When installing the line feed motor, the cable should be positioned toward the top.
Adjust the line feed belt tension (3.3.02) after installing the line feed motor. , 09
P/N 56510601 Motor: Line Feed (ML395) RSPL B.2.06
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Chapter 3 Maintenance & Disassembly
3.2.11 Head Cable Assembly 1. Detach the printhead (3.2.01). 2. Remove the printer mechanism (3.2.09). 3. Work from the bottom of the printer mechanism and loosen the two mounting screws (1). 4. Detach tabs (A) and (B) from the frame and remove the cable holder (2). 5. Remove the two ribbon cartridge bracket mounting screws (3). 6. Detach the cartridge bracket (4). 7. Remove the mounting screw (5) 8. Detach the connector clamp (6). 9. Detach the head cable connector (7) from the carriage frame (8). 10. Lift the front of the printer mechanism and remove the head cable assembly by pulling downward. P/N N/A Clamp B.2.04 , 05 , 05 , 12
P/N 56614201 Cable: Printhead (Assembly) RSPL B.2.04
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Service Guide ML395/395C
Chapter 3 Maintenance & Disassembly
3.2.12 Sensor Board 1. Remove the printer mechanism (3.2.09). 2. Raise the front of the printer mechanism. 3. Disconnect cables CN2 (1) and CN3 (2) from the sensor board (3). 4. Remove the three sensor board mounting screws (4). 5. Disconnect connector CN1 (5) and detach the sensor board. P/N 55050501 PCB: Sensor Board RSPL B.2.06 , 09 (LQEW or LPRW) , 09 , 12
P/N 56619104 Cord: Sensor PCB Connection RSPL B.2.06
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Service Guide ML395/395C
Chapter 3 Maintenance & Disassembly
3.2.13 Ribbon Feed Assembly 1. Remove the printer mechanism (3.2.08). 2. Remove the two ribbon cartridge bracket mounting screws (1). 3. Detach the cartridge bracket (2). 4. Remove the two mounting screws (3). 5. Detach the ribbon feed assembly (4).
NOTE: When assembling, install the ribbon drive assembly so that the gear teeth contact properly (5). The gears must not bind together.
P/N 50054301 Feed: Ribbon Assembly RSPL B.2.06 , 09
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Chapter 3 Maintenance & Disassembly
3.2.14 Space Motor Assembly 1. Remove the printhead (3.2.01). 2. Remove the ribbon feed assembly (3.2.13). 3. Loosen the two belt pulley bracket mounting screws (1). 4. While pushing the belt pulley bracket (2) to the left, temporarily tighten the two screws. This will ease the tension on the space belt. 5. Remove the three space motor mounting screws (3). 6. Using needle-nosed pliers, detach the nylon cable clamp (4) from the cooling fan. 7. Remove the space motor (5) by pulling it toward the front of the printer. P/N 56506205 Motor: Space (ML395) RSPL B.2.06 , 09
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Chapter 3 Maintenance & Disassembly
3.2.15 Space Belt 1. Remove the printhead (3.2.01). 2. Remove the head cable assembly (3.2.11). 3. Remove the space motor assembly (3.2.14). 4. Remove the mounting screw (1). 5. Detach the belt clamp (2). 6. Remove the belt pulley (3) from the bracket (4) and detach the space belt (5).
NOTE: When installing the belt clamp: Place the ribbed side of the belt clamp facing up as shown.
P/N 50702301 Belt Clamp B.2.04, 05 P/N 51303101 Belt: Mini Pitch (Space) RSPL B.2.04, 05
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Chapter 3 Maintenance & Disassembly
3.2.16 Cooling Fan 1. Remove the printer mechanism (3.2.08). 2. Remove the two ribbon cartridge bracket mounting screws (1). 3. Detach the cartridge bracket (2). 4. Using needle-nosed pliers, detach the nylon cable clamp (3) from the fan cover (4). 5. Remove the two fan cover mounting screws (5). 6. Remove the cooling fan / fan cover assembly. 7. Remove the two cooling fan mounting screws (6). 8. Detach the cooling fan (7). P/N 56509501 Fan: Cooling RSPL B.2.06 , 09
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Chapter 3 Maintenance & Disassembly
3.2.17 Bail/Ribbon Motor Assembly 1. Remove the printer mechanism (3.2.09). 2. Disconnect connector CN2 (1). 3. Remove the two mounting screws (2). 4. Detach the bail/ribbon motor assembly (3).
NOTE: When assembling, install the bail/ribbon motor assembly so that the gear teeth contact properly. he gears must not bind together.
P/N 56506301 Motor: Step (Bail Arm) Assembly RSPL B.2.06 , 09
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Chapter 3 Maintenance & Disassembly
3.2.18 Paper Bail Assembly 1. Remove the printer mechanism (3.2.08). 2. Remove the bail/ribbon motor assembly (3.2.17). 3. Detach the bail arm springs (1).
NOTE: The left bail arm spring is longer than the right bail arm spring. Be sure to install each spring on the proper side.
4. Remove the bail arm idle gear (2). 5. Detach the E snap ring and remove the bail open cam (3). 6. Detach the E snap ring (4) and remove the left bail arm (5) from the indicator shaft assembly (6) by pulling to the left. 7. Remove the right bail arm (7) by pulling to the right while expanding the clamps (8). 8. Detach the right bail arm from the indicator shaft assembly. P/N 50054401 Indicator Bar Assembly RSPL B.2.06 P/N 50910701 Spring: Bail Arm (Left) RSPL B.2.06 P/N 50910801 Spring: Bail Arm (Right) RSPL B.2.06 P/N 51210201 Gear: Idler (Bail Arm) RSPL B.2.06 P/N 53478501 Bail Arm (Left) RSPL B.2.06 P/N 53478502 Bail Arm (Right) RSPL B.2.06 , 10 , 10 , 10 , 10 , 10
, 10
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Chapter 3 Maintenance & Disassembly
3.2.19 Carriage and Carriage Shaft 1. Loosen the screw (1) and slide it towards the back of the printer. 2. Loosen the mounting screw (2) and detach the left eccentric collar (3).
NOTE: The protrusions on the eccentric collars face the outside of the printer.
3. Remove the screw and detach the blue printhead gap adjusting lever. (Not shown) 4. Loosen the screw (4) and detach the right eccentric collar (5). 5. Remove the two rubber carriage bumpers (6). 6. Slide the carriage shaft (7) to the right and remove the carriage (8). 7. Continue sliding the carriage shaft to the right then remove the carriage shaft.
NOTE: When installing, be sure that the larger extension at the end of the carriage shaft is positioned at the right side of the printer.
P/N Spacer B.2.04 , 05 , 05 , 07 , 10 , 10
P/N Spacer: Round B.2.04
P/N 50057601 Carriage Assembly (Black) B.2.04 P/N 50069401 Carriage Assembly (Color) B.2.05
P/N 50703701 Collar: Eccentric Carriage Rail RSPL B.2.07 P/N 51110301 Shaft: Carriage RSPL B.2.07 , 10
P/N 53478401 Lever: Adjust (Printhead Gap) RSPL B.2.07
, 10
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Service Guide ML395/395C
Chapter 3 Maintenance & Disassembly
3.2.20 Paper Pressure Guide 1. Remove the two springs (1) located on each side of the paper pressure guide (2). 2. Remove the detent spring (3) located on the release lever at the right side of the printer. 3. Separate the claws and remove the release lever (4). 4. Remove the release link. 5. Remove the paper pressure bar (5) by sliding it to the right.
NOTE: The flat side of the paper pressure bar faces up.
6. Using needle-nose pliers, squeeze the nylon latch (6) to release the switch harness (7) which is located at the left side of the printer mechanism. 7. Lift and remove the paper pressure guide. P/N 50907502 Spring: Paper Chute RSPL B.2.07 , 10 , 10
P/N 50910201 Spring: Detent (Release Lever) RSPL B.2.07 P/N 50910305 Spring: Idle Gear RSPL B.2.07 , 10 , 10
P/N 51214401 Gear: Idle (Release Lever) RSPL B.2.07 P/N 53478706 Lever: Release RSPL B.2.07 , 10
P/N 53478801 Block: Release Lever Guide RSPL B.2.07 P/N 55034801 Sensor: Cut-Sheet Paper-End RSPL B.2.07
, 10 , 10
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Service Guide ML395/395C
Chapter 3 Maintenance & Disassembly
3.2.21 Printhead Gap / Release Lever Microswitches 1. Remove the mounting screw to remove the release lever microswitch (1). 2. Push down on the mounting tab and remove the printhead gap microswitch (2). 3. Using a needle nose pliers, detach the nylon cable clamp (3) and remove the harness and switches from the printer mechanism. P/N 53068602 Indicator: PH Gap (Adj Bracket) RSPL B.2.07 P/N 56209901 Switch: Micro RSPL B.2.07 , 11 , 11
(Adj & Release Lever)
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Service Guide ML395/395C
Chapter 3 Maintenance & Disassembly
3.2.22 Push Tractor Assembly 1. Remove the lower center guide (1). 2. Separate the claws (2) and remove the two drive gears (3) from the right side of the printer mechanism. 3. Using a needle nose pliers, remove the nylon cable clamp (4). 4. Slide the upper drive shaft (5) to the left and remove it. 5. Slide the lower drive shaft (6) to the left. 6. Remove the upper center guide (7), being careful not to lose the friction ring (8). 7. Remove the lower drive shaft. 8. Loosen the two screws (9) [one is located on each side of the printer mechanism]. 9. Lift and remove the push tractor assemblies (10) and locking shaft (11).
NOTE: To remove the tractors from the locking shaft, raise the lock lever and slide the tractor off.
When installing the push tractor assembly, take the following precautions: 1. First, install the friction ring in the upper center guide. If the upper center guide moves easily along the locking shaft, you must rotate the friction ring 45 degrees, using a standard screwdriver (12). 2. Check the installation; if the guide moves with difficulty, it is properly installed. 3. Synchronize the tractors by aligning the synchronization marks in the same direction. 4. Position the guide holes (13) in the tractor drive gears in the same direction. 5. Position the groove of the upper center guide behind the paper pressure guide (14). 6. The left tractor assembly must be positioned between the two locking tabs (15). P/N 50054501 Tractor: Push (Left) Assembly RSPL B.2.08 P/N 50054601 Tractor: Push (Right) Assembly RSPL B.2.08 P/N 51002301 Friction: Piece RSPL B.2.08 , 11 , 11 , 11 , 11 , 11
P/N 51002401 Guide: Center, Upper RSPL B.2.08 P/N 51002501 Guide: Center Lower A RSPL B.2.08
P/N 51002601 Guide: Center Lower B RSPL B.2.08 P/N 51214201 Gear: Drive A RSPL B.2.08 P/N 51214301 Gear: Drive B RSPL B.2.08 , 11 , 11
, 11
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Service Guide ML395/395C
Chapter 3 Maintenance & Disassembly
3.2.23 Power Supply Unit 1. Remove the printer mechanism (3.2.08). 2. Disconnect the two cables (1) from the left side of the power supply unit (2). 3. Remove the four power supply mounting screws (3). 4. Remove the power supply unit by pulling toward the left-front side of the printer. You must raise the power supply unit slightly so it will become detached from the two guides (A) in the lower cover.
NOTE: Be careful not to damage the cables with the power supply unit mounting bracket (located at the left/rear of the power supply unit).
P/N 56411201 Power Supply Assembly (120V) RSPL B.2.02 P/N 56506302 Power Supply Assembly Option RSPL B.2.02 P/N 56614101 Cord: Power Connection (9 pin) RSPL B.2.02 P/N 56614801 Cord: Power Connection (13 pin) RSPL B.2.02 , 13 , 12 , 12 (220/240V)
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Service Guide ML395/395C
Chapter 3 Maintenance & Disassembly
3.2.24 Ribbon Shift Arm Spring / Ribbon Shift Arm Microline 395C - Color Model Only 1. Detach the printer access cover. 2. Remove the ribbon cartridge (1). 3. Remove the shift arm spring (2). 4. Remove the 7 mm mounting bolt (3) and detach the ribbon shift arm (4). P/N 50315401 Screw (Color) RSPL B.2.05 P/N 50924001 Spring: Shift Arm (Color) RSPL B.2.05 P/N 53478901 Arm: Ribbon Shift (Color) RSPL B.2.05
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Service Guide ML395/395C
Chapter 3 Maintenance & Disassembly
3.2.25 Roller Lever 1. Open the printer access cover. 2. Remove the ribbon cartridge. 3. Remove the shift arm spring (3.2.23). 4. Remove the two 7 mm bolts (1) and detach the roller lever (2). P/N 53479001 Lever: Roller (Color) RSPL B.2.05
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Service Guide ML395/395