Brother 525CJ, 530CJ, 540CJ, 550CJ, LW-800ic, 810ic(bl), 840ic Service Manual(1).pdf

WORD PROCESSOR

SERVICE MANUAL

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

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

REVISED EDITION

SERVICE MANUAL

CONTENTS

PART I

THEORY OF OPERATION

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

SERVICE MANUAL

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

SERVICE MANUAL

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

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

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

PART II

REPAIR

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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SERVICE MANUAL

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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