IBM 6400 Line Matrix Printer Service Manual

6400 Line Matrix PrintersMaintenance Information Manual Cabinet and Pedestal Models Form Number S246–0117–04 ©Copyright IBM Corp., 1995, 1997 6400 Line Matrix Printers Maintenance Information Manual Cabinet and Pedestal Models S246–0117–04 Preliminary 2 Note! Before using the information and the product it works with, make sure you read the general information under “Notices” on page vi. Sixth Edition (August 1997) This edition applies to the 6400 Line Matrix Printer. The following paragraph does not apply to any other country where such provisions are inconsistent with local law: INTERNATIONAL BUSINESS MACHINES CORPORATION PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions; therefore, this statement may not apply to you. Requests for IBM publications should be made to your IBM representative or to the IBM branch office serving your locality. Publications are not stocked at the address given below. IBM welcomes your comments about this publication. You may send your comments by facsimile to 1–800–524–1519, by E-mail to [email protected], or by mail to: IBM Printing Systems Company Information Development Department H7FE, Building 003G P.O. Box 1900 Boulder, CO 80301–9191, U.S.A. When you send information to IBM or IBM Printing Systems Company, you grant a nonexclusive right to use or distribute the information in any way IBM or IBM Printing Systems Company believes appropriate without incurring any obligation to you. E Copyright International Business Machines Corporation 1995, 1997. All rights reserved. Note to U.S. Government Users—Documentation related to restricted rights—Use, duplication or disclosure is subject to restrictions set forth in GSA ADP Schedule Contract with IBM Corp. Table of Contents 1 Maintenance Overview About the Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 Important Maintenance Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 Notes and Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 Printing Conventions in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 Electrical Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 Mechanical Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 Tools, Test Equipment, and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14 2 Installation Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 3 Preventive Maintenance Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 Cleaning the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 Cleaning the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 Cleaning the Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3 Cleaning the Shuttle Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4 Cleaning the Card Cage Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6 4 Principles of Operation Line Matrix Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2 Printing Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5 Shuttle Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5 Paper Transport System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7 Ribbon Transport System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8 i Logical Control of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–9 Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10 CMX Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–11 Data Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–13 Engine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–15 Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–18 Printer Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–19 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–19 5 Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 Troubleshooting Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3 Symptoms Not Indicated by Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–39 Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–40 Printer Confidence Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–44 Operator Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–45 Selecting and Running Operator Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . 5–47 Customer Engineer (CE) Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–48 Selecting and Running Customer Engineer Tests . . . . . . . . . . . . . . . . . . . . 5–50 Boot Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–51 Hex Code Printout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–54 Printer Information Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–57 Displaying Printer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–58 Soft vs. Hard Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–59 6 Adjustment Procedures Preparing the Printer for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2 Returning the Printer to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3 Belt, Paper Feed Timing, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4 Belt, Platen Open, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6 Paper Drive Motor Pulley Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8 Paper Scale Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10 Platen Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12 Platen Open Motor Pulley Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14 Ribbon Guide Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–16 ii . . . . . 7–22 Hammer Spring Assembly . . . . .Splined Shaft Skew Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–20 Fan Assembly. . . . . . . . . . . . . . . 7–39 Paper Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reversal . . 7–15 Cover Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–40 iii . . Paper Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hammer Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13 Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pedestal Model . . . . . . . . . . . . . . . . . . Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–19 Fan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper Feed Timing . 7–16 Cover Assembly. . . . . . . . . . . . . . . . . . . . 7–23 IBM Coax/Twinax Expansion Board . . . . . . . . . . . . . 7–29 Motor Assembly. . . . . . . . . . . . . 6–33 7 Replacement Procedures and Illustrated Parts List Organization of This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Top. Platen Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Card Cage . Platen Open . . . . . . . . . . . . . . . . . . . . . . . 7–37 Operator Panel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–18 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pedestal Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4 Section I: Replacement Procedures Preparing the Printer for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–27 Magnetic Pick-up (MPU) Assembly . . . 7–14 Coax/Twinax Multi-Platform Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–32 Set Shuttle Speed . . . 7–34 Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–38 Operator Panel Assembly. . . . . . . . . . . . . . . . . . . 6–20 Hammer Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–26 Coil Temperature Adjustment . . . . . . . . . . . . . Cabinet Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–36 Network Print Server . 7–5 Belt. . . . . . . . . . . . . . . . Ribbon Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–32 Motor Assembly. . . . . . . . . . . . . . . . . . . . . 6–24 Loading Flash Memory . . . . . . . . . . . . . 7–28 Memory Modules and Security PAL . . . . . . . . . . . 7–8 Cable Connectors and Connector Shells . . . . . . . . . . . . . . 7–17 Cover Assembly. . . . . . . . . . . . . . . 7–21 Fan Assembly. . . . . . . . 7–11 Circuit Board: Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–18 Adjusting the End of Forms Distance . . . . . . . . . 7–6 Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9 Circuit Board: Controller . . . . . . . . . . Hammer Bank / Ribbon Mask . . . . . . . . . . Cabinet Exhaust . . . . . . . . . . . . . . . . Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Breaker . . . 7–83 Figure 7–18. . . . . . . . . . . . . . . . . . . . . . . . . . Inside Covers. . . . . . . . . . . . . . . . . . . . . . . . . . and Casters. . . . . 7–75 Figure 7–14a. . . . . . Top Cover. . . . . . . . . . . . Motors. . . . . . . . 7–50 Security Module . . . . . . . . . . . . . . . . . . . . . . Pedestal Models . 7–57 Switch Assembly. . . . . . . . . . . . . . . . . . . . . . . . 7–79 Figure 7–16. . 7–85 Figure 7–19. . . . . . . . . . . . . . . . . . . 7–49 Ribbon Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–56 Spring. 7–69 Figure 7–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–77 Figure 7–15. . . . . Inside Covers and Card Cage. . . . . . . . . . 7–59 Switch Assembly. . . 7–67 Figure 7–11. . . . . . 7–65 Figure 7–10. . . . . Tractor Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–42 Resistors. . . . . . . . . . . . . . . . . . . . . . 7–81 Figure 7–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Card Cage Fan. 7–29 Shaft. . . . . . . . . Cabinet Model . . . . . . . . . . . Platen Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–53 Shuttle Frame Assembly . . . . 7–87 Figure 7–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminating . . . . . . . . . . . . . . . . . . . . . Paper Detector . . . . . . . . . . . . . . . . 7–58 Switch Assembly. . . . . . 7–89 Figure 7–21. . . . Splined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–51 Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . IBM Coax/Twinax Expansion Board . . . . . . . . . . . . . 7–61 Tractor (L/R) . . . . . . . . . . . . . . . 7–47 Ribbon Guide Assembly (L/R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Platen . . . . . . Control Panel and Cabinet Details . . . . . . . . . . . . Doors. . . . 7–91 iv . . . . . . . . . . 7–41 Platen . . . . . . . . . . . . . . . . Extension . . . . . 7–62 Section II: Illustrated Parts List Figure 7–9. . . . . . . . Card Cage Detail. . . . Paper Stacker and Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cabinet Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . Support . Pedestal Details . . . . . . . . . . . . . . . . . . . 7–71 Figure 7–13. . . . . . . . . . 7–54 Spring Assembly. . . . Magnetic Pickup Unit (MPU) and Extension Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover Open . . . . . . . . . . . . . . . . . . . . . . . . . .Paper Ironer . 7–73 Figure 7–14. . . . . . . . . . . . . . . . . . . . Pedestal Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Mechanisms and Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . and Paper Detector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendices A B C D E F G H I Wire Data Printer Specifications Metric Conversion Tables Torque Table Safety Inspection Guide Abbreviations and Signal Mnemonics Power Cords Part Numbers Noise Suppression Devices Index v . This feature can cut energy use by up to 50 percent.ENERGY STAR The EPA ENERGY STAR** Computers program is a partnership effort with manufacturers of data processing equipment to promote the introduction of energy-efficient personal computers. Evaluation and verification of operation in conjunction with other products. Electrical Safety This printer is inspected and listed by recognized national testing laboratories. and printers. Inc. Users of this document should verify the applicable data in their specific environment. is the user’s responsibility. monitors. Stamford. 06904. and Canadian Standards Association (CSA) in Canada. 208 Harbor Drive. program. Connecticut. and to reduce air pollution caused by power generation. Any reference to an IBM licensed product. such as Underwriters Laboratories. (UL) in the U. The results that may be obtained in other operating environments may vary significantly. program. or service may be used. vi . IBM may have patents or pending patent applications covering subject matter in this document.S. programs. except those expressly designated by IBM. or service that does not infringe any of IBM’s intellectual property rights may be used instead of the IBM product. or services do not imply that IBM intends to make these available in all countries in which IBM operates. Therefore. or service is not intended to state or imply that only IBM’s product. The furnishing of this document does not give you any license to these patents. Listing of a product by a national testing laboratory indicates that the product is designed and manufactured in accordance with national requirements intended to minimize safety hazards. that this product operates under conditions of high electrical potentials and heat generation. in writing. IBM participates in this program by introducing printers that reduce power consumption when they are not being used. You can send license inquiries. Notices References in this publication to IBM products. Any performance data contained in this document was obtained in a controlled environment based on the use of specific data. both of which are functionally necessary. to the IBM Corporation. however. IBM Director of Licensing. United States. Note: The ENERGY STAR emblem does not represent EPA endorsement of any product or service. IBM equipment meets a very high standard of safety in design and manufacture.A. Any functionally equivalent product. such data does not constitute a performance guarantee or warranty. program. Remember. .. Ill. IBM PC-DOS SCS Token-Ring The following terms. are trademarks of the IBM Corporation in the United States or other countries or both. Inc. denoted by an asterisk (*) in this publication. Inc.Trademarks and Service Marks The following terms. Epson Seiko Corporation Printronix. United States Environmental Protection Agency Epson Seiko Corporation Xerox Corporation John Fluke Manufacturing Co. are trademarks of other companies: Acrobat Adobe Code V ECOS ENERGY STAR Epson Ethernet Fluke FX IGP MS-DOS Printronix Adobe Systems Incorporated Adobe Systems Incorporated Quality Micro Systems ECOS Electronics Corp. Microsoft Corporation Printronix. Inc.. Oak Park. vii . denoted by a double asterisk (**) in this publication. Inc. handle the paper ironer on the sides. CAUTION Hold the printer cover securely while disengaging the gas spring assembly. Do not touch components or flex the board during removal/installation. If you must apply power during maintenance. CAUTION To prevent injury from electric shock. DANGER <1> Always disconnect the AC power cord from the power source before performing any maintenance procedure. and Warning notices are numbered to help you find the translated versions in the IBM 6400 Line Matrix Printer Safety Notices booklet. viii .Safety Notices Danger. the upper edge of the paper ironer can become sharp. DANGER Always disconnect the AC power cord before cleaning the printer. Caution. set the printer power switch to the off position and unplug the power cable. Handle the board by the sides. you will be instructed to do so in the maintenance procedure. To avoid cutting yourself. DANGER <2> To prevent serious personal injury from electrical shock when connecting or disconnecting the signal cable. Failure to remove power could result in injury to persons or damage to equipment. Wear a properly grounded static wrist strap when handling the power supply board. wait at least one minute after shutting off power before removing the power supply circuit board. CAUTION Over time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 Printing Conventions in This Manual . . . . . . . . . . . . . . . 1–6 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 About This Manual . . . . . . . . 1–14 Maintenance Overview 1–1 . . . . . . . . . . . . . . . . . 1–8 Electrical Controls and Indicators . . 1–5 Related Documents . . . . . . . . . . . 1–12 Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 Important Maintenance Notes . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 Notes and Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 How to Use This Manual . . . . . . 1–8 Mechanical Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment. . . . . . . . . . . . . . . . .1 Maintenance Overview Chapter Contents About the Printers . . refer to the discussion of Printing Rates in Appendix B. For more information. and 1400 lines per minute (lpm). speed. page B–9. The 1200 and 1400 lpm models are available only in a floor cabinet enclosure. 500. 500. (See Figure 1–1. 900. Interpreting the Printer Model Designation 1–2 Maintenance Overview . The print speeds shown are maximum nominal speeds. Print speed is determined by the interaction of many variables. 800. and 900 lpm models are available in either a floor cabinet or pedestal enclosure. The 6400 Series consists of models that print 475. Table 1–1. 1200. 800. and enclosure. The IBM 6400 Series Printer Family Model Number 6400–004 6400–04P 6400–005 6400–05P 6400–008 6400–08P 6400–009 6400–09P 6400–012 6400–014 Print Speed 475 lpm 475 lpm 500 lpm 500 lpm 800 lpm 800 lpm 900 lpm 900 lpm 1200 lpm 1400 lpm Enclosure Cabinet Pedestal Cabinet Pedestal Cabinet Pedestal Cabinet Pedestal Cabinet Cabinet The model number indicates printer family.Preliminary 2 About the Printers The IBM* 6400 Line Matrix Printer family is summarized in Table 1–1. The 475.) Speed Rating: 004 = 475 lpm 005 = 500 lpm 008 = 800 lpm 009 = 900 lpm 012 = 1200 lpm 014 = 1400 lpm Enclosure Code*: P = Pedestal Model * No Code = Cabinet Model 6400 Printer Family 6400–04P Figure 1–1. Use of incorrect ribbons can lead to ink migration problems. The hammer springs and hammer tips on the hammer bank are delicate and precisely aligned. Never close the forms thickness lever too tightly. paper jams.The entire system architecture of the printer is contained on one circuit board. This architecture permits rapid access to stored emulation software and enables the printer to print a wide variety of high-volume jobs with minimum maintenance and maximum reliability. The IBM 6400 is an excellent graphics printer. Use only the ribbons specified in Appendix B. Incorrect closure of the forms thickness lever can lead to smearing. and damage to the platen and shuttle assembly. Never bend or tweak hammer springs. with memory requirements handled by DRAM and flash memory. The IGP** and Code V** Printronix** emulations are simple but versatile graphics programming languages that load into flash memory. Important Maintenance Notes To assure optimum performance. Although technologically advanced. The operator can select every printer function at the control panel or by sending printer control codes in the data stream from the host computer. with optional features that simplify the creation of dot images. the IBM 6400 printer is easy to use. and expensive damage to the printer. remember these important maintenance concepts when you service the printer: ♦ ♦ Do not adjust the platen gap unless the original shuttle frame assembly or platen has been replaced with a new or rebuilt unit. ♦ ♦ Maintenance Overview 1–3 . degraded print quality. Always handle hammer springs by the thick mounting base of the assembly. degraded print quality. This manual is designed so that you can quickly locate maintenance information. device. Locate the procedure or information you need: ♦ ♦ ♦ Use the Table of Contents at the front of the manual. WARNING A WARNING notice indicates the possibility of damage to a program. CAUTION A CAUTION notice calls attention to a situation that is extremely hazardous to people because of some existing condition. Use the Chapter Contents listed at the front of each chapter.About This Manual This is a field service maintenance manual for the IBM 6400 printer. or data. Read the entire procedure before you do it. IMPORTANT An IMPORTANT notice draws your attention to information vital to proper operation of the printer. 3. system. 1–4 Maintenance Overview . Notes and notices are defined below. Notes and Notices For your safety and to protect valuable equipment. it is very important that you read and comply with all information highlighted under notes and notices: DANGER A DANGER notice calls attention to a situation that is potentially lethal or extremely hazardous to people. Make sure you understand all safety notices before you start a task. Use the Index at the back of the manual. 4. 2. How to Use This Manual 1. Gather the parts and tools you will need. “NOT READY” appears on the LCD. ♦ Key combinations are denoted by the + (plus) symbol. Example: Press the Stop key. ♦ Liquid Crystal Display (LCD) messages are printed in capital letters inside quotation marks ( “ ” ).NOTE: A note gives you helpful tips about printer operation and maintenance.” Maintenance Overview 1–5 . Printing Conventions in This Manual ♦ Operator panel keys and indicators are printed bold. then press the Start key. Example: “Press Scroll" + Scroll# ” means “Press the Scroll" key and the Scroll# key at the same time. Example: Press the Cancel key. S246–0146 ♦ Coax/Twinax Multi-Platform Interface Option Installation and Operation Guide. illustrated instructions on daily printer operation. This manual is available in a number of languages: Brazilian Portuguese: Form No. S246–0147 IBM 6400 IPDS Programmer’s Reference: Form No. S246–0126 English: Form No. S217–0181 Dutch: Form No. G544–5389 Provides a list of translated safety notices.Related Documents This manual does not explain how to operate or configure the printer. SF11–0723 German: Form No. This manual is available in a number of languages: Brazilian Portuguese: Form No. S246–0143 Spanish: Form No. S246–0138 Italian: Form No. S246–0141 Japanese: Form No. SF11–0722 German: Form No. For that information. S246–0116 French: Form No. S246–0137 Italian: Form No. S246–0142 Japanese: Form No. IBM 6400 Line Matrix Printer Operator’s Guide Step-by-step. S246–0115 French: Form No. S217–0182 Dutch: Form No. refer to the Operator’s Guide and Setup Guide: ♦ ♦ IBM 6400 Line Matrix Printer Safety Notices: Form No. emulations. S246–0118 IBM 6400 CTA Programmer’s Reference: Form No. and control codes is in the applicable Programmer’s Reference manual: ♦ ♦ ♦ IBM 6400 ASCII Programmer’s Reference: Form No. S246–0145 ♦ IBM 6400 Line Matrix Printer Setup Guide Explains how to install and configure the printer. S246–0148 Information pertaining to graphics programming is in the applicable User’s Manual: 1–6 Maintenance Overview . S246–0144 Spanish: Form No. S246–0125 English: Form No. Form Number S246–0149 Information pertaining to printer control languages. Form No.♦ IBM 6400 Code V User’s Manual: Form No. Form No. and expanded characters. S246–0112 The Network Print Server Technical Reference Manual is included on a diskette that comes with the Network Print Server. and merge graphics with alphanumeric data as a document is printed. S246–0111 IBM Network Print Server Token-Ring* Administrator’s Guide. bar codes. The IGP Printronix emulation allows the user to create and store forms. This “softcopy” document is in Adobe** Acrobat** Reader format. S246–0150 Provides information used with the optional Code V Printronix emulation enhancement feature. generate logos. and merge graphics with alphanumeric data as a document is printed. S246–0151 Provides information used with the optional IGP Printronix emulation enhancement feature. IBM 6400 IGP User’s Manual: Form No. and expanded characters. create other graphics. and troubleshooting of the Network Print Server are covered in the following documents: ♦ ♦ ♦ IBM Network Print Server Ethernet** Administrator’s Guide. bar codes. ♦ Installation. The Code V Printronix emulation allows the user to create and store forms. create other graphics. Maintenance Overview 1–7 . generate logos. configuration. Applies power to the printer: (1 = on. This key is configurable: refer to the Operator’s Guide. In the PROGRAM mode. stops a Printer Test. Lit when the printer is in READY mode (on-line). the LCD indicates the operator panel is locked. Cabinet Models (Figure 1–2) Key or Indicator Power Indicator Ready Indicator Processing Indicator Attention Indicator Power Switch LCD Start Lit when the printer is on. After correcting the error. exits program mode menus. This key also silences the audible alarm. Puts the printer in the READY (on-line) mode. Prints the current configuration. and restores after an eject. Sets TOF and moves paper downward from the tractor alignment notches to the print position. Stop + Enter resets the printer. press Stop to turn off this LED. moves to the next lower level of configuration. 0 = off. Selects the option displayed on the LCD. Off when the printer is in NOT READY mode (off-line). Printer must be in NOT READY mode. no errors are pending. or starts a self-test. In the NOT READY mode. Puts the printer in the NOT READY (off-line) mode. moves the paper downward 1/72 inch (“micro-step” function). The Liquid Crystal Display (LCD) displays printer status messages. Advances paper to next Top-Of-Form. this key puts the printer in the PROGRAM mode. Flashes when the printer is receiving data from the host. Press again to return paper to original print position. If the configuration menus are locked. Toggles the lock on the configuration menus. as defined by the current page length. This key also clears fault conditions. moves paper back to print position after View is pressed. as determined by current line spacing. and the printer is ready to process data. this key moves to the next menu (“Scroll” function). Returns to the next higher level of a configuration menu. In the PROGRAM mode. Cancels a print job. Press to move the current print position up to the tractor area for viewing. Soft reset: load power on configuration in memory. If in the NOT READY mode. This action either sets a value. In the NOT READY mode. Flashes when an error occurs.Controls and Indicators Electrical Controls and Indicators. and restores after an eject. moves the paper upward 1/72 inch (“micro-step” function). Moves paper for viewing or tear-off. Moves paper up one line.) This switch is also a circuit breaker. Stop + Enter resets the printer. this key moves to the previous menu (“Scroll” function). Function Stop Form Feed Set Top Of Form Line Feed View Cancel Eject/Restore Menu Enter Return Micro Micro Scroll Scroll Printer Configuration Stop + Enter Scroll + Scroll 1–8 Maintenance Overview . Cabinet Models Maintenance Overview 1–9 .(Off) (On) Power Switch Power Liquid Crystal Display (LCD) Ready Processing Menu Scroll Enter Micro Line Feed Form Feed Start Cancel Attention Printer Configuration Scroll Return Micro View Set Top Of Form Stop Eject/ Restore Figure 1–2. Electrical Controls and Indicators. press Stop to turn off this LED. moves the paper downward 1/72 inch (“micro-step” function). Selects the option displayed on the LCD. Puts the printer in the READY (on-line) mode. This action either sets a value. Function Processing Indicator Attention Indicator Power Switch LCD Start Stop Form Feed Set Top Of Form Line Feed View Cancel Eject/Restore Menu Enter Return Micro Micro Scroll Scroll Printer Configuration Stop + Enter Scroll + Scroll 1–10 Maintenance Overview . this key puts the printer in the PROGRAM mode. Sets TOF and moves paper downward from the tractor alignment notches to the print position. Flashes when an error occurs. Returns to the next higher level of a configuration menu. Lit when the printer is in READY mode (on-line). no errors are pending. If the configuration menus are locked. or starts a self-test.Electrical Controls and Indicators. In the PROGRAM mode. this key moves to the previous menu (“Scroll” function). In the PROGRAM mode. the LCD indicates the operator panel is locked. Applies power to the printer: (1 = on. This key also clears fault conditions. as determined by current line spacing. The Liquid Crystal Display (LCD) displays printer status messages. Cancels a print job. Stop + Enter resets the printer. Printer must be in NOT READY mode. Pedestal Models (Figure 1–3) Key or Indicator Power Indicator Ready Indicator Lit when the printer is on. This key also silences the audible alarm. this key moves to the next menu (“Scroll” function). Advances paper to next Top-Of-Form. Soft reset: load power on configuration in memory. Prints the current configuration. exits program mode menus. In the NOT READY mode. and restores after an eject. Press again to return paper to original print position. as defined by the current page length. Press to move the current print position up to the tractor area for viewing. 0 = off. moves paper back to print position after View is pressed. After correcting the error. This key is configurable: refer to the Operator’s Guide. Moves paper up one line. and the printer is ready to process data. moves to the next lower level of configuration. In the NOT READY mode. Puts the printer in the NOT READY (off-line) mode. stops a Printer Test. Toggles the lock on the configuration menus. Stop + Enter resets the printer. and restores after an eject. moves the paper upward 1/72 inch (“micro-step” function). Off when the printer is in NOT READY mode (off-line). Flashes when the printer is receiving data from the host.) This switch is also a circuit breaker. If in the NOT READY mode. Moves paper for viewing or tear-off. Pedestal Model Maintenance Overview 1–11 .(Off) (On) Power Switch Power Liquid Crystal Display (LCD) Ready Processing Menu Scroll Enter Micro Line Feed Form Feed Start Cancel Attention Printer Configuration Scroll Return Micro View Set Top Of Form Stop Eject/ Restore Figure 1–3. Electrical Controls and Indicators. Used to set side margin and position paper horizontally. B for thicker forms. One diagram is cast in relief on the shuttle cover. useful for setting paper margins and counting text columns. Set this lever at A for thin (single-part) forms.Mechanical Controls and Indicators. Indicates relative thickness of forms/paper.1 inch 10 Column Number 20 1–12 Maintenance Overview . Lever must be fully opened (raised) to load or unload paper. Instructions showing how to load the ribbon correctly. Works when Forms Thickness Lever is open. and so on. Positioned manually by sliding them along shafts. Rotate to move paper vertically. Help prevent paper jams by supporting inner sections of paper. Lock tractors in position. All Models (Figure 1–4) Control or Indicator Function Forms Thickness Lever Sets the platen for paper and forms of different thicknesses. Used to set top of form or first line to be printed. and another is printed on the paper scale. Allows fine positioning of left print margin.) 1 inch 1 0. Hold and feed paper. (See below. Paper Supports Forms Thickness Pointer and Scale Tractors (2) Tractor locks (2) Horizontal Adjustment Knob Vertical Position Knob Ribbon Loading Path Diagrams Paper Scale A horizontal scale graduated in tenths of an inch. Moves paper and tractors left or right. Paper Scale Left Tractor Horizontal Adjustment Knob Paper Supports Right Tractor Tractor Lock Vertical Position Knob Tractor Lock Ribbon Loading Path Diagrams Forms Thickness Pointer Forms Thickness Lever and Scale Figure 1–4. Mechanical Controls and Indicators Maintenance Overview 1–13 . #1 Screwdriver. 7/32 inch Open End Wrench. 5/16 inch PLCC Module Pick Extraction Tool PLCC Module Plier Extraction Tool Screwdriver. Philips. #2 Spring Hook. . Item Part No. 6400 Line Matrix Printer Configuration Utility Disk 1–30 Inch-pound Torque Screwdriver ESD Wrist Strap Feeler Gauge.010 inch Feeler Gauge. Bearing.Tools. Test Equipment.040 inch Force Gauge. 5/16 inch Open End Wrench. . IBM #20 DIP Module Extracting Tool Nut Driver. Philips. 20 lb Grip Ring Pliers Lubricant. Heavy Duty Tie Wraps Torque Screwdriver Adapter Torque Screwdriver Hex Adapter 3/32 inch Torque Screwdriver Hex Adapter 5/32 inch Torque Screwdriver Hex Adapter 3/16 inch Torque Screwdriver Hex Adapter 5/64 inch 63H7379 16F1661 6405959 25F9687 9900317 117397 9900764 1650843 9900005 73G5523 10G3902 73G5362 73G5363 75X5972 39F8449 39F8451 39F8450 39F8455 16F1663 1–14 Maintenance Overview .011 inch Feeler Gauge. . 1/4 inch Nut Driver. and Supplies The tools and equipment required for field level maintenance of the IBM 6400 printer are listed below. S246–0142 Japanese: Form No. This “softcopy” document is in Adobe Acrobat Reader format. Form No. SF11–0722 German: Form No. S246–0126 English: Form No. S246–0138 Italian: Form No. Installation. S217–0182 Dutch: Form No. Installation 2–1 . S246–0112 The Network Print Server Technical Reference Manual is included on a diskette that comes with the Network Print Server. configuration. S246–0116 French: Form No. and troubleshooting of the Network Print Server are covered in the following documents: ♦ ♦ ♦ IBM Network Print Server Ethernet Administrator’s Guide.2 Installation Installation and configuration of the printer are covered in the 6400 Line Matrix Printer Set–Up Guide: Brazilian Portuguese: Form No. S246–0146 Installation. Form No. S246–0111 IBM Network Print Server Token-Ring Administrator’s Guide. and replacement parts for the optional coax/twinax interface are covered in the Coax/Twinax Multi–Platform Interface Option Installation and Operation Guide. operation. Form Number S246–0149. S246–0144 Spanish: Form No. 2–2 Installation . . . . . . . . . . . . . . . . . . . . . 3–6 Preventive Maintenance 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4 Cleaning the Card Cage Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 Cleaning the Exterior . . . . . . . . . . . . . . . . . . . . 3–2 Cleaning the Interior . . . . . . . . . . . . . 3–3 Cleaning the Shuttle Frame Assembly . . . . . . . . . . 3–2 Cleaning the Printer .3 Preventive Maintenance Chapter Contents Overview . . . . . . . . . . . . . . . . . . . . . Power off the printer. There is no guarantee that the user will clean the printer regularly. you will be instructed to do so in the maintenance procedure. Damage to the equipment will result. however. the user must determine how often to clean the printer. Disconnect the AC power cord from the power source. Do not spray directly onto the printer when using spray solutions (spray the cloth. so you should clean the printer whenever you are called to service it. DANGER <1> Always disconnect the AC power cord from the power source before performing any maintenance procedure. 2. 5. 3–2 Preventive Maintenance . Clean the inside of the printer (page 3–3). Cleaning the Printer WARNING <1> Do not use abrasive cleaners. If you must apply power during maintenance. Do not drip water into the printer. particularly on the window. Failure to remove power could result in injury to persons or damage to equipment. Because operating conditions vary widely. Cleaning the Exterior 1. the only preventive maintenance required for the printer is periodic cleaning. Dry the enclosure with a clean. lint-free cloth.Overview Aside from normal replenishment of paper and ribbons. Wipe the outside of the enclosure with a clean. Do not vacuum circuit boards. 4. 3. lint-free cloth dampened (not wet) with water and a mild detergent or window cleaning solution. then apply the dampened cloth to the printer). 4. Vacuum up dust or residue that has accumulated inside the lower cabinet. 6. Open the printer cover. shuttle cover assembly. Wipe the splined shaft and the ribbon guides with a soft cloth. Splined Shaft Shuttle Cover Assembly Base Casting Tractor NOTE: Cabinet model shown. Remove paper from the printer. Ribbon Guide (2) Forms Thickness Lever Figure 3–1. 9. Remove the ribbon. lint-free cloth. 8. non-metallic brush. 3. 2. base casting. 11. Wipe the interior of the lower cabinet with a clean. lint-free cloth dampened with water and a mild detergent or window cleaning solution. 10.Cleaning the Interior (Figure 3–1) 1. 7. Dry the cabinet interior with a clean. and ribbon guides. Clean the shuttle frame assembly (page 3–4). Using a soft-bristled. Vacuum up the residue. 5. wipe paper dust and ribbon lint off the tractors. Power off the printer. Procedure is the same for pedestal model. Disconnect the AC power cord from the power source. Cleaning Inside the Cabinet/Printer Case Preventive Maintenance 3–3 . and paper residue. 8. 2. WARNING <5> The hammer bank contains a strong magnet. Remove the paper ironer (page 7–41). 7. Remove the shuttle frame assembly (page 7–54). Be careful not to over-bend or kink the ribbon mask when handling and cleaning the hammer bank cover assembly. ink. handle the paper ironer on the sides. Install the paper ironer (page 7–41). 4. Carefully open the cover assembly and wipe between the hammer bank cover and the ribbon mask. 9. gently brush the hammer tips to remove lint and ink accumulations. (See Figure 3–2. Remove the hammer bank cover assembly (page 7–16). Remove the shuttle cover assembly (page 7–17). 5. Install the shuttle frame assembly (page 7–54). 3–4 Preventive Maintenance . Wipe the paper ironer with a soft cloth to remove lint. do not let the hammer bank cover assembly snap into place as the hammer bank magnet attracts it. WARNING <3> The thin plate (ribbon mask) of the hammer bank cover assembly is fragile. Install the hammer bank cover assembly (page 7–16). wipe the hammer bank cover assembly to remove lint. ink. To prevent damage to the hammer tips.) WARNING <4> Do not use any solvents or liquids to clean the hammer tips. 6. To avoid cutting yourself. 10. Any impact of the cover against the hammer bank can break hammer tips.Cleaning the Shuttle Frame Assembly (Figure 3–2) 1. CAUTION <1> Over time. and paper residue. Using a stiff. Using a soft cloth. Vacuum up any residue. the upper edge of the paper ironer can become sharp. Clean the holes in the cover strips. 3. non-metallic brush (such as a toothbrush). Clean the hammer tips gently—too much pressure can chip hammer tips. Hammer Bank Cover (Thick Plate) Ribbon Mask (Thin Plate) Hammer Bank Cover Assembly Alignment Pin (2) (See Below) Hammer Tip NOTE: 6400–004/04P hammer bank shown. Hammer Bank Cover Alignment Pin Figure 3–2. Cleaning the Shuttle Frame Assembly Preventive Maintenance 3–5 . Install the shuttle cover assembly (page 7–17).11. 12. Clean the card cage fan assembly (page 3–6). Cleaning the Card Cage Fan Assembly 3–6 Preventive Maintenance . 2. and lint. Close the printer cover.Cleaning the Card Cage Fan Assembly (Figure 3–3) 1. Pedestal Model: Install the top cover assembly (page 7–18). 3. 5. Vacuum the card cage fan assembly and surrounding areas to remove paper particles. Cabinet Models: Remove the paper guide assembly (page 7–40). Connect the AC power cord to the power source. Cabinet Models: Install the paper guide assembly (page 7–40). dust. Pedestal Model: Remove the top cover assembly (page 7–18). NOTE: Cabinet model shown. Procedure is the same for pedestal model. 4. Card Cage Fan Assembly Figure 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8 Logical Control of the Printer . . . . . . . . . . . . . . . . . . 4–2 Printing Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10 CMX Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5 Shuttle Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Contents Principles of Operation Line Matrix Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7 Ribbon Transport System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–13 Engine Controller . . . . . . . . . . . . . . . . . . . . . . 4–5 Paper Transport System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–19 Graphics . . . . . . . . . . . . . . . . . . . . . . . . 4–18 Printer Interface . . . . . . . . . . . . . 4–9 Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . 4–15 Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–11 Data Controller . . 4–19 Principles of Operation 4–1 . . at nine lpi eight dot rows per character line. (See Figure 4–1 and Figure 4–2. For example. 0. (See Figure 4–1. 1 0. an entire line at a time.01389 ” Column No. it reverses direction.) At eight lpi there are nine dot rows per character line.00835 ” 0. 4–2 Principles of Operation .10 ” 12 First row and column of next character column (at 10 cpi) First row and column of next character line (at 6 LPI) Lowest descender dot line 0. The number of dot rows allowed for line separation depends on the vertical line spacing the user selects.02 ” Figure 4–1. and the hammers print the next row of dots as the shuttle sweeps in the opposite direction.Line Matrix Printing The printer creates characters and graphics by printing patterns of ink dots on paper. A Dot Matrix When the shuttle reaches the end of a sweep. the paper is advanced one dot row. After a line of characters is printed. Every text character is stored in printer memory as a pattern of dots on a logical grid called the dot matrix. Printer logic circuits divide every line of incoming data into horizontal dot rows. in the data processing (DP) font at a line spacing of six lines per inch (lpi).) The ink dots are made by a row of small hammers mounted on a shuttle that sweeps rapidly back and forth. This technique is called line matrix printing. and so on. The hammers put dots at the required positions for the entire line by striking an inked ribbon and the paper. The dot matrix patterns of text characters vary according to the font the user selects. a dot matrix contains 12 dot rows from the top of one character line to the top of the next. hammer action stops and the paper advances to the first dot row of the next print line. WITH UNDERLINE Dot Column 1 3 5 7 9 Dot Row 1 2 2’ 3 3’ 4 4’ 5 5’ 6 6’ 7 7’ 8 8’ 9 Dot Row 1 2 2’ 3 3’ 4 4’ 5 5’ 6 6’ 7 WITHOUT UNDERLINE Dot Column 1 3 5 7 9 Printed with underline Figure 4–3. Elongated Character Formation Principles of Operation 4–3 .Direction of Shuttle Movement Dot Row Start One Text Line 1 2 3 4 5 6 7 8* 9* * 10 Number of rows determined by line spacing 11 n 1 2 * This row is used only for lowercase descenders ** This row is used for underlining and lowercase descenders Paper Feed Direction Figure 4–2. Standard Character Formation Elongated characters are made by printing all but the first and last dot rows twice. as shown in Figure 4–3. No Dot Printed Figure 4–4.Succesive Hammer Strokes Per Scan Shuttle Scan 1 Dot Row 1 1 2 1 2 3 1 2 3 4 1 2 3 4 5 1 2 3 4 5 6 1 2 3 4 5 6 7 * 1 *1 3 * 1 3 5 *1 3 5 7 * 1 3 5 7 9 * 2 3 4 5 6 7 * Even column dot centers within the printed character area and character space hammer positions are not illustrated in this diagram. Action of One Hammer Spring in Text Printing Figure 4–4 shows how each individual hammer spring forms characters as the shuttle scans horizontally. 4–4 Principles of Operation . NOTE: = Hammer Released and Dot Printed = Hammer Not Released. Preliminary 2 Printing Mechanism While the principles of line matrix printing are easy to state. low vibration. this design achieves the same benefits as such an engine: perfect primary balance. The 6400–012/–014 hammer bank has seven 13-hammer assemblies. and durability. The printing mechanism consists of the shuttle frame assembly. The end of one connecting rod attaches to the hammer bank. which houses the shuttle drive motor and the shuttle assembly.) The hammer springs are grouped in seven comb-like assemblies mounted on the solid hammer bank: The 6400–004/–04P/–005/–05P hammer bank has seven 4-hammer assemblies. the ribbon transport system. Mechanically. the act of printing dots accurately from a rapidly oscillating shuttle onto a vertically moving piece of paper requires complex timing and coordination between printer logic and the printing mechanism. and the paper transport system. Hammer Bank Assembly Counterweight Assembly Connecting Rod Shuttle Frame Assembly Guide Shaft Shuttle Motor Figure 4–5. (The hammer bank and the counterweight constitute the shuttle assembly.) The rotary motion of the shuttle drive motor converts to linear and opposing motion of the hammer bank assembly and the counterweight. Shuttle Frame Assembly Principles of Operation 4–5 . (Figure 4–5. in an arrangement similar to that of a horizontally-opposed gasoline engine. The 6400–008/–08P/009/–09P hammer bank has seven 7-hammer assemblies. Shuttle Frame Assembly The central element of the printing mechanism is the shuttle frame assembly. The shuttle drive motor is built into the shuttle assembly casting and drives two connecting rods on an offset crankshaft. the other connecting rod attaches to a counterweight frame surrounding the hammer bank. The polarity of the resulting magnetic field opposes the field of the permanent magnet. The pole pieces magnetically attract and hold the free end of the hammer spring under tension. The hammer springs forward. Hammer Bank Assembly: Coils. 4–6 Principles of Operation . a current pulse energizes the coils.Each hammer spring is a stiff leaf spring with a cylindrical tungsten carbide tip on the free end. canceling its effect and releasing the hammer. When hammer driver logic determines that the hammer must print a dot. Hammer Spring Assemblies Tungsten Carbide Hammer Tip Hammer Spring Assembly Alignment Pin Figure 4–6. NOTE: 6400–004/04P hammer bank shown.) A permanent magnet runs the length of the hammer bank and acts on the hammer springs through individual pole pieces. This is called the retracted state. (See Figure 4–6. and the hammer springs print the next row of dots as the shuttle sweeps in the opposite direction. Magnet. While the hammer is in flight the coil is de-energized and its field collapses. the hammer rebounds and the permanent magnet recaptures it. the paper is moved up one dot row. Pole Pieces. The coils are normally de-energized. and leaves a dot impression of the hammer tip on the paper. it reverses direction. strikes the ribbon and paper. When the shuttle reaches the end of a sweep. Hammer Springs and Hammer Bank (Detail) Two electromagnetic coils are mounted behind each hammer and wound around each pole piece. After striking the ribbon and paper. drives two tractor sprockets by means of a toothed belt and splined shaft pulley arrangement. The horizontal adjustment knob allows vernier positioning of the left print margin. or allow applications to overprint forms. the platen open motor opens and closes the platen via a toothed belt. Each tractor engages paper perforations with six sprocket pins and locks in place with a friction lock.Paper Transport System Tractors Horizontal Adjustment Knob Paper Path Splined Shaft Vertical Adjustment Knob and Splined Shaft Pulley Tractor Support Shaft Shuttle Cover Assembly Paper Supports Paper Feed Timing Belt (Under the cover) Figure 4–7. The stepper motor permits extremely accurate incremental vertical paper movement. set top of form. moved downwards—in order to view the print area. Principles of Operation 4–7 . directed by the EC on the controller board. Paper is positioned horizontally using the tractors and the horizontal adjustment knob. For reverse paper feeding. Paper Transport System A two-phase DC stepper motor. This drive configuration is designed for continuous. Paper can be positioned vertically by hand with the vertical adjustment knob. Opening the platen prevents paper jams when paper direction is reversed—that is. fan-folded paper three to 16 inches wide and one to six sheets thick. The hubs and spools are offset vertically to equalize ribbon wear and prolong ribbon life.Ribbon Transport System Ribbon Hub Left Ribbon Guide (Not Shown) Hub Locking Latch Ribbon Spool Ribbon Motors Right Ribbon Guide Ribbon Figure 4–8. 4–8 Principles of Operation . pulling the ribbon against the resistance exerted by the other motor—the drag motor. This system maintains a constant motor speed and ribbon tension. The ribbon motors operate only when the shuttle assembly is moving. Ribbon motion reverses when a metal strip at either end of the ribbon crosses the left or right ribbon guide. completing a circuit that causes both motors to reverse direction. Ribbon Transport System An inked ribbon winds and unwinds continuously on a pair of spools latched to hubs that are driven by the ribbon motors. Constant ribbon tension is maintained by controlling each motor with a drive or drag circuit. While the shuttle assembly is in motion. one motor acts as a drive motor. Functional Elements of the Printer Principles of Operation 4–9 . and the print mechanism. AC Input AC POWER Operator Panel Circuit Breaker ON/OFF SWITCH Line 1 Line 2 / Neutral Power Supply Board CHASSIS GND EIA–232–E Serial I/O Card Cage Fan CMX Controller Board Parallel I/O Shield GND +5 V Remote Power Common Ground Cabinet Exhaust Fan (Cabinet models only) Platen Motor Paper Motion Detector Paper Out Detector Left Ribbon Guide Left Ribbon Motor Flex Circuits: Shuttle Assy Terminator Board Shuttle Motor MPU Hammer Bank Board Paper Feed Motor Platen Open Switch Right Ribbon Guide Right Ribbon Motor Hammer Bank Fan Shuttle Assembly Print Mechanism Figure 4–9.Logical Control of the Printer The printer is divided into four functional elements: the operator panel. See Figure 4–9. the CMX controller board. the power supply. The keys are momentary contact switches. Operator Panel Functional Overview 4–10 Principles of Operation . The LCD.Operator Panel The user communicates with the printer by pressing keys on the operator panel. Operator Panel ♦ Data ♦ Control ♦ Key (Switch) Closures CMX Controller Board J110 Figure 4–10. The operator panel processes and sends key closure information to the controller board and displays information from the controller on the LCD. A status indicator next to the LCD also conveys printer status information to the user. status indicator. and keys are mounted on a printed circuit board assembly enclosed in a protective housing. The EC synchronizes paper. controls all motors. Image data are passed to the EC upon request. The CMX controller board consists of two functional units: the Data Controller (DC) and the Engine Controller (EC). Figure 4–11 summarizes this architecture. ribbon. platen. The DC receives host and operator input and returns dot images and LCD messages to buffers in memory. then sent to the hammer bank. which monitors and directs all printer functions. builds the printable images. and drives the hammer springs.CMX Controller Board The heart of the printer is the CMX controller board. The DC is responsible for: ♦ ♦ ♦ ♦ ♦ Host I/O Operator I/O Security Interface Print Image Generation Overall High Level (Logical) Control The EC is responsible for: ♦ ♦ ♦ Print Mechanism Operation Print Mechanism Fault Monitoring Power Shutdown/Power Saving Modes The EC and DC communicate through semaphore registers. are processed. and shuttle motion as it feeds dot data to the hammer drivers. The controller board receives and processes all data from the host computer. Except for the power supply and final hammer drive circuits. all logic and drive circuitry for the printer are contained on the controller board. Principles of Operation 4–11 . CMX Controller Board Block Diagram 4–12 Principles of Operation .Expansion Port RS–232 Diagnostic Port RS–232/422 IEEE–1284 (Parallel) Operator Panel Fault Sensors Paper Feed Ribbon Shuttle TTL Diagnostic Port Platen Hammer Drive Figure 4–11. It is byte. Flash memory is erasable. Programs stored in flash memory are changed through the parallel or serial port. Up to 30MB of flash (total). used for up to 32MB of data memory (Base configuration: 1MB DRAM in bank 0) 8K x 8 Non-Volatile Battery-Backed static RAM (NVRAM) for storage of configuration and system statistical data VX ASIC (Application-Specific Integrated Circuit) Host I/O Drivers/Termination 68EC030 Microprocessor A Motorola 68EC030 microprocessor serves as the processor of the DC unit. and significantly faster than a disk drive. Flash Memory The DC stores program and emulation code in flash memory. organized as up to four banks. This processor runs at 25 MHz. which does not require higher programming and erasing voltages on the board (it has an internal charge pump to make these voltages itself).000 write/erase cycles. and double word readable. The DC uses AMD 5. The flash memory is 32 bits wide. This memory supports at least 100.Data Controller The data controller (DC) consists of the following elements: ♦ ♦ ♦ ♦ ♦ ♦ 68EC030 microprocessor Two flash SIMM sockets. Principles of Operation 4–13 . The boot code for the 68EC030 processor must reside in bank 0. used for up to 30MB of program memory (Base configuration: 1MB flash in bank 0) Two DRAM SIMM sockets. may be installed in the two sockets on the controller board. non-volatile. but is always written as double words. word.0V-only flash memory. Two 80-pin SIMM sockets are provided for flash memory. NVRAM A 8K x 8 bit Non-Volatile battery-backed static RAM (NVRAM) device provides for the storage of configuration and system statistical data. and so on. DRAM Controller The VX supports up to four banks of page mode DRAM. Two standard 72-pin DRAM SIMM’s are used for expansion memory. the other is a memory address with auto-increment. through the VX ASIC. All DRAM supports page mode operation and is addressable by individual byte. The VX provides the following services: ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ Memory Access Controller DRAM Controller Flash Controller Two DMA Channels Operator Panel Interface “Dot Plucking” and Adjacent Dot Checking “Cajun” Bus Interface Host I/O and Diagnostic Port Memory Access Controller All 030 addresses go through the VX ASIC. The VX handles all address decoding. and three select lines. FLASH Controller The VX supports up to four banks of flash memory. may address up to 32MB of DRAM in four banks. VX ASIC The VX is a multifunction custom gate array ASIC containing all the logic for the DC that is not contained in the 68EC030 processor. etc. chip selects. The DC. DTACK’s.DRAM System DRAM is used for program variables. Operator Panel Interface The VX operator panel interface consists of five lines: serial clock. “Dot Plucking” and Adjacent Dot Checking “Dot Plucking” is a specialized DMA function that removes dot data from a dot image buffer in 4–14 Principles of Operation . image buffers. These channels move data from the host interface or expansion bus to the DRAM and vice versa. and input buffers. It is the VX that handles all parallel-to-serial (and vice versa) conversion to and from the panel. DMA Channels The VX provides two channels for direct memory access. serial data. One address is an I/O address. as well as any special timing needed when toggling select lines. and terminations. These circuits include: ♦ ♦ ♦ RS–232 drivers and receivers. RS–422 differential drivers and receivers Parallel port pull up and pull down terminating resistors are DIP-socketed for easy removal and installation.) Ports The VX ASIC controls the following I/O functions: ♦ ♦ ♦ Interface to an IEEE 1284 Level 2 host Interface to RS–232E serial host Interface to RS–422 serial host All the circuitry required for these host types is provided on the CMX board. The EC uses this bus to access DC resources. This function is actually controlled by the EC (see page 4–15). Principles of Operation 4–15 . measured between chassis ground and the ground pins of the interface IC’s. and sends it to the hammer bank.05V common mode ripple. “Cajun” Bus Interface The “Cajun” bus interfaces the DC. (The semaphore registers are the primary communications path between the EC and DC. This memory is not expandable. These circuits use internal charge pumps to eliminate the need for 12V power. All interface IC’s and terminations have the following characteristics: ♦ ♦ ♦ ♦ Provide ESD protection to 15KV for all inputs. serializes it. Engine Controller The engine controller (EC) consists of four main elements: ♦ ♦ 80C166 Microcontroller 128KB 5.DRAM in a programmable manner. Host I/O Drivers and Termination Beyond the 030 processor and VX ASIC. Less than 0. additional support circuitry completes the serial and parallel interfaces. including the semaphore registers. except for the drivers themselves. organized as 64K x 16 bits.02V common mode ripple. ESD protection. the EC. measured at the power and ground of the interface IC’s. which has access to the VX through the “Cajun” Bus Interface. Less than 0. and the expansion port. Greater than 200V/ms slew rate for all outputs.0V-only FLASH program memory. however. and FIFO’s in the MECA to control nearly all of the motor functions in the printer.) Any previously enabled interrupt will “wake up” the processor.6 msec to 419 ms. In this manual. PWM generators. MECA ASIC The 166 uses numerous counters. This memory is fixed. This flash is organized as 64Kx16 bits and uses the same technology as the DC flash: it is 5. timers. default setting is 6. (Idle power reduction of the 166 is not the same as printer idle. Watchdog Timer The 166 has an on-board watchdog timer. Its contents can be updated through the DC (through the serial or parallel ports). If the 030 stops fetching addresses. 4–16 Principles of Operation . An external PAL is used for address decoding. something is seriously wrong and the 166 and its peripherals are automatically reset. All I/O pins remain active in idle power reduction mode. Power Reduction Modes The 166 chip has two power reduction modes: idle and power down. specifically designed to drive this system. non-multiplexed and segmented operation. The timer interval is set through software and has a range of 25. The Address Strobe of the 030 processor is fed into the watchdog input. The 166 used on the CMX board runs at 20MHz and is housed in a 100-pin metric rectangular flat pack. This controller and the MECA ASIC provide the functionality of three separate processors used in earlier controller board architectures. and tables in its own local flash memory.000 write/erase cycles. but all on-board peripherals continue to operate. The flash memory runs at zero wait states. It has many features that suit it extremely well to real-time control applications. program code.0V-only and is rated for a minimum of 100. EC Flash Memory The EC stores all boot code. even if global interrupts are turned off or the interrupt does not have the priority to actually execute. 16-bit data.55 ms.♦ ♦ MECA (Mechanism Engine Control ASIC) Analog drive circuitry 80C166 Microprocessor The Siemens SAB 80C166 is a high-integration microcontroller. The MECA is a custom gate array. Power down reduction mode capability exists but is not used because it requires an external hardware reset to exit this mode. When the 166 is in idle mode the CPU shuts down. because it is soldered to the controller board. the 80C166 is referred to as either the EC or the 166. Bus Configuration The 166 bus is configured for 18-bit address. hammer fire timing. and shuttle motors are driven in control loops containing power MOSFET’s.Analog Drive Circuitry The analog drive functions convert 48 and 8. half. two ribbon drive. These determine which hammers will participate in a fire event generated by the controller’s upper drive. The paper feed motor is a DC stepping motor driven by current control. voltage and current sensors. Five motors are used on the printer: paper feed. or microsteps. The controller board sets the timing and upper drive profile for driving a hammer fire event. Sensors are used to monitor the operation and status of critical components within the printer. while the drag motor is loaded and monitored to maintain correct linear speed and tension. The overall current level may be reduced for standby modes. The ribbon system uses two DC stepping motors that alternate drive and drag roles when the ribbon reaches turnabout. Control of hammer drive is split between the controller board and the hammer bank. The controller also contains diagnostic circuitry for the hammer system. ribbon drive. The paper feed. while hammer specific circuitry is contained on the hammer bank. The platen open motor is driven by a stepping motor controller IC and the EC processor. The MPU encoder is used as feedback for motor commutations. shuttle. driven by current control. Common circuits are located on the controller board. and platen open. The platen open motor is driven in current mode and can be full or half stepped. The drive ribbon motor is microstepped in voltage mode.5 volts into the power used to drive the motors and hammers in the printer. and motor stall detection. and the EC processor. depending on print requirements. The paper feed motor may be driven in full. The HBA’s control lower drive MOSFET’s on the hammer bank. The shuttle motor is a brushless DC motor. The hammer bank contains HBA ASIC’s that interpret fire commands and data from the MECA and VX ASIC’s. Principles of Operation 4–17 . the MECA ASIC. The + 5 V output will remain stable for reporting and latching the fault condition. The power supply automatically senses and adjusts to any commercial electrical system that provides AC mains potential in 50 or 60 Hertz systems. 4–18 Principles of Operation . The second consists of + 48 V and + 8. The first is a + 5 V bus for logic. separate from the + 48 V and + 8. DC Power The power supply board contains two DC power supply systems for the printer. In addition. The return for this signal is the + 5 V return. There is an opto-isolated input on the power supply that will shut down and latch off the + 48 V and + 8. The power supply converts alternating current (AC) to direct current (DC) at three voltage levels and sends the DC voltages to the controller board. The controller board distributes all DC power to the logic and electromechanical circuits. In other words. Both returns are tied together in a single-point ground.5 V buses for the hammer bank and all motors. It can tolerate variations in frequency of 47 to 63 Hz. This resistor is mounted on the controller board and may be pulled down or disconnected by software or internal cable interlocks. The power supply is designed to withstand an AC input overvoltage of 300 VAC for one second with no degradation of DC output voltage or damage to printer circuits. The + 5 V power supply has its own inverter. Loss of + 48 V is seen by the EC and reported as a fault. this shutdown circuit discharges and latches the + 48 V down to a level lower than 15 V in less than 200 milliseconds and requires recycling of the circuit breaker (On/Off switch) to reset the latch.5 V outputs. The + 5 V supply has an isolated return line that connects to the + 48 V return at the printer load.Power Supply Board The printer power supply is contained on a printed circuit board mounted in the card cage. the printer is fully operational from available commercial power anywhere in the world.5 V supplies unless it is pulled up to 5V with a 1K Ω resistor. AC Power The power supply operates on AC voltages ranging from 88 to 270 V. Printer Interface The printer interface is the point where the data line from the host computer plugs into the printer. The printer interface processes all signals and data to and from the host computer. The printer supports PC Parallel, IEEE 1284 parallel, EIA–232–E serial, EIA–422–B serial, and optional coaxial/twinaxial (CT) interfaces to the host. Selection of the input/output interface is controlled by configuration menus accessed at the operator panel. It is possible to physically connect more than one interface, but only one interface at a time can be used electrically. Graphics The Code V programming language (a QMS graphics emulation) and the IGP programming language (a Printronix IGP emulation) are options that install in flash memory on the CMX controller board. These programming languages simplify the job of creating forms, bar codes, logos, expanded characters, and other graphics. These languages enable the printer to print sideways, upside down, and to make forms combining graphics, alphanumeric data, and bar codes—all in a single pass. Documents explaining configuration, operation, and programming are included with each option. Principles of Operation 4–19 4–20 Principles of Operation 5 Troubleshooting Chapter Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 Troubleshooting Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3 Symptoms Not Indicated by Fault Messages . . . . . . . . . . . . . . . . . . . . 5–39 Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–40 Printer Confidence Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–44 Operator Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–45 Selecting and Running Operator Print Tests . . . . . . . . . . . . . . . . . 5–47 Customer Engineer (CE) Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–48 Selecting and Running Customer Engineer Tests . . . . . . . . . . . . . 5–50 Boot Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–51 Hex Code Printout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–54 Printer Information Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–57 Displaying Printer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–58 Soft vs. Hard Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–59 Troubleshooting 5–1 Introduction This chapter contains procedures for troubleshooting printer malfunctions. This manual does not cover operation or configuration of the printer, but you must operate the printer to check its performance, and sometimes you may have to reconfigure it. Therefore, have the Operator’s Guide and the Setup Guide handy whenever you troubleshoot the printer. Troubleshooting Aids Troubleshooting is faster and more effective if you understand the equipment and make use of all available tools. This manual provides a number of troubleshooting aids to help you isolate printer malfunctions: ♦ LCD Message Troubleshooting Table (Page 5–5) A troubleshooting symptom table for messages that appear on the Liquid Crystal Display (LCD). The LCD messages are defined and corrective actions provided. Symptoms Not Indicated by Fault Messages (Page 5–39) Basic procedures for troubleshooting problems that are not indicated by LCD messages. Also included is a logic table for troubleshooting common problems. Printer Confidence Check (Page 5–44) A systematic check of printer operation in the form of a logic table. Use this procedure to establish basic printer status or to troubleshoot imprecise or intermittent symptoms. Operator Print Tests (Page 5–45) A set of print tests included in the configuration menu structure for use as diagnostic tools. Customer Engineer (CE) Tests (Page 5–48) A set of print tests not available to the user. These tests are maintenance tools. Hex Code Printout (Page 5–54) The procedure for printing data streams in hexadecimal format. Use to troubleshoot printer data reception problems. ASCII Character Set (Page 5–56) A chart of standard ASCII characters and their equivalent codes. Printer Information Menu (Page 5–57) A set of menus that display accumulated statistics and information about the printer. Appendix A: Wire Data System interconnect and power distribution diagrams, circuit board pin-outs, and diagrams of the cable assemblies. Use as source material for tracing electrical problems. ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ 5–2 Troubleshooting Fault Messages DANGER <1> Always disconnect the AC power cord from the power source before performing any maintenance procedure. Failure to remove power could result in injury to persons or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure. If a fault condition occurs in the printer, four things happen: ♦ ♦ ♦ ♦ The Attention indicator on the operator panel flashes on and off. If enabled, the audible alarm sounds. (Press Stop to silence the alarm.) A message describing the fault condition appears on the LCD. Certain Unit Check conditions (see below) are automatically recorded in the error log. The error log is a buffer in NVRAM that stores up to 50 messages as a list. The most recent message is stored at the top of the list, the oldest message at the bottom of the list. If more than 50 messages occur before the log is cleared, the oldest messages are deleted, so that the log never contains more than 50 messages. You can print the error log and clear it. (See page 5–48.) The LCD displays two kinds of printer conditions: ♦ An Attention condition halts printing until the operator replenishes supplies, clears paper jams, corrects a problem of communication between the printer and host computer, etc. A Unit Check condition is a failure detected by self-test and fault circuitry. Unit check conditions are either recoverable or unrecoverable. a. Recoverable unit check conditions are errors detected in the electromechanical print mechanism that may be temporary and correctable by recycling power. The printer tries a number of times to correct the condition before posting the message to the operator panel. The first thing to do in such cases is to power the printer off, wait 15 seconds, then power the printer back on. If the message reappears, classify the check condition unrecoverable. b. Unrecoverable unit check conditions are “hard” failures such as overcurrent, component failure, or microcode failures that prevent printing until the conditions are corrected. Unrecoverable errors require that the printer be powered off and the condition corrected before powering the printer back on. ♦ Troubleshooting 5–3 Clearing Errors Refer to Table 5–1 and follow the instructions. Table 5–1 explains each fault message and tells you how to correct the fault condition. After correcting an error, press the Stop key to clear the message and return the printer to the NOT READY state. Press Start to resume printing. (If an error is not cleared, the printer will try to print again but will display another error message until the error is cleared.) NOTE: Abbreviations used in Table 5–1: DRAM NVRAM RAM SIMM Dynamic Random-Access Memory Non-Volatile Random-Access Memory Random-Access Memory Single In-line Memory Module Acronyms and abbreviations are also defined in Appendix F. 5–4 Troubleshooting The system administrator should correct applications data or configuration. Message 001 END OF FORMS LOAD FORMS 002 FORMS JAMMED CLEAR JAM AND RELOAD FORMS Explanation Attention message. See also page 5–21. Applications software has violated header format parameters.Table 5–1.” Attention message. LCD Message Troubleshooting Table Required Action Load paper. Illegal parameter value received in command code. Not a printer problem. Attention message. Page 5–22 011 SCS COMMAND ERROR 012 STRUCTURED FIELD ERROR 013 ACTIVATE LOST 014 INVALID ACTIVATE Page 5–22 Troubleshooting 5–5 . Applications software has violated structured data field parameters. see page 5–19. 003 FORMS EJECTED PRESS EJECT/RESTORE 004 VIEW FORMS PRESS VIEW KEY 006 HOST SYSTEM REQUEST ATTENTION Non-error status message. The host computer or printer controller requires attention. Non-error status message. Printer detects twinax protocol communication errors. 007 FM HEADER ERROR 008 HOLD PRINT TIMEOUT PRESS START 009 INVALID KEY PRESS 010 PARAMETER ERROR None Press Stop to clear fault. The system administrator should correct applications data or configuration. Clear jam and reload paper. Printer cannot detect paper motion. Printer was offline more than 10 minutes and the “Intervention Required” parameter is set to “Send to Host. Printer clears the error. Press View key to return paper to print position. see page 5–18. Printer received undefined control character (hex 40). The printer is out of paper. Host attention message. See also page 5–21. Not a printer problem. Press Start to go on-line. If message recurs. If message recurs. Printer detects twinax protocol communication errors. Press Start to put the printer in the READY state. Press Eject/Restore key to return paper to print position. A timeout message is sent to the host if paper motion has not occurred for 10 minutes after Stop was pressed to clear the jam fault. 5–6 Troubleshooting .) Page 5–24 None Check cable connection and host system. 027 COMMUNICATIONS CHECK CALL SYSTEM OPERATOR 028 COMMUNICATIONS CHECK CALL SYSTEM OPERATOR 029 8344 DIAGNOSTIC TEST FAILED 031 END OF FORMS TIMEOUT LOAD FORMS 032 FORMS JAMMED TIMEOUT CLEAR JAM AND RELOAD FORMS Clear the jam and reload paper. Page 5–24 024 SERIAL LINE PARITY ERROR VERIFY CONFIGURATION 025 SERIAL FRAMING ERROR VERIFY CONFIGURATION 026 HEX DUMP MODE Framing error. Receive overrun. 041 BUFFER OVERFLOW Check printer serial port configuration setup. Replace the controller board. (Poll timeout. (Serial interface) Printer attach status message. If the message recurs. Check cable connection and host system. (Twinax interface) Printer detects twinax protocol communication errors. Enable poll timeout. A timeout message is sent to the host if paper is not loaded 10 minutes after Stop was pressed to clear the paper out fault. The printer was not enabled for one minute. (Serial interface) Unit address not recognized by printer. If the message recurs. Replace IBM coax/twinax expansion board Load paper. see page 5–18. (Serial interface. see page 5–19. The printer was not polled for one minute. twinax interface) Parity error. (Coax interface) Poll timeout error.Message 015 COMMUNICATION CHECK CHECK CABLE 016 INVALID COMMAND Explanation Line not active. (Serial interface) Required Action Page 5–23 Page 5–22 021 RECEIVE BUFFER OVERRUN VERIFY CONFIGURATION 022 UNIT ADDRESS NOT RECEIVED CHECK PRINTER ADDRESS Page 5–24 System administrator: make sure the printer address is correct. Ensure that it matches host setting. (Coax interface) Link-level code test detects hardware failure. Host sends data after the printer buffer is full. If message recurs. Cycle power. If message recurs. Delete the existing custom configuration set. replace CMX controller board. Record the entire message and return it with the defective board.Message 042 CUSTOM SET DOES NOT EXIST SAVE FIRST 043 CUSTOM SET ALREADY EXISTS DELETE EXISTING SET FIRST Explanation The custom configuration set does not exist. replace CMX controller board. Printer configuration: custom set is write-protected. Forms thickness lever is raised to open position. Page 5–25 Page 5–26 044 EC FIRMWARE/HARDWARE ERROR 046 EC STOPPED AT STATE <state> The Engine Controller processor has stopped and is in the state identified by the number displayed. Rerun print job. Sensors cannot detect current in fan circuit. Appears when data are cleared out of printer after Cancel key has been pressed. Required Action Save the custom configuration set. Record the message and return it with the defective board. then save the new set. Controller board sensors report high temperatures on the board. Circuits are overheating on the power supply board. Cycle power. No shuttle movement or shuttle moving at wrong speed. 057 CLOSE PLATEN 058 SHUTTLE JAM SEE USER’S GUIDE 059 CANCEL PRINT ACTIVE None Page 5–27 060 PRINTER HOT 062 EXHAUST FAN FAULT Page 5–28 Page 5–28 Page 5–28 None 063 INTAKE FAN FAULT 065 HAMMER BANK FAN FAULT 069 DATA CLEARED 080 POWER SUPPLY HOT Page 5–29 Troubleshooting 5–7 . Sensors cannot detect current in fan circuit. Non-error status message. Fatal firmware error on CMX controller board. Sensors cannot detect current in fan circuit. CMX controller does not detect ribbon drive motor. replace one at a time until message clears: a) power supply board b) controller board Cycle power. replace one at a time until message clears: a) power supply board b) controller board Cycle power. 084 POWER SUPPLY 48V FAILED Internal power failure. If message recurs.5V Cycle power. If message recurs. 5–8 Troubleshooting . or not correctly installed. If motors are connected OK. If message recurs. 087 PLATEN OPEN TIMEOUT CLOSE PLATEN Forms thickness lever has been open for at least one minute. replace one at a time until message clears: a) controller board b) power supply board Page 5–31 Page 5–32 089 RIBBON STALL 090 SHUTTLE COVER OPEN CLOSE SHUTTLE COVER No ribbon movement.5V FAILED Internal power failure. If message recurs. If message recurs. damaged. replace one at a time until message clears: a) controller board b) power supply board Page 5–25 082 POWER SUPPLY 8. 086 CONTROLLER 15V Controller voltage failure. replace both ribbon drive motors and the controller board.Message 081 POWER SUPPLY VOLTAGE FAILURE Explanation Internal power failure. 088 CONTROLLER 23. Required Action Cycle power. replace one at a time until message clears: a) power supply board b) controller board Cycle power. If message recurs. Shuttle cover is missing. 092 RIBBON DRIVER CIRCUIT Check connections of both ribbon motors. Controller voltage failure. 085 CONTROLLER VOLTAGE Controller voltage failure. replace one at a time until message clears: a) controller board b) power supply board Cycle power. replace CMX controller board. Electrical malfunction of one or more hammer coils. Cycle power. If message recurs. Record the message and return it with the defective board. 107 HAMMER COIL <number> HOT One or more hammer coils are overheating. replace CMX controller board. replace CMX controller board. 110 STACK OVERFLOW SEE USER’S GUIDE 111 STACK UNDERFLOW SEE USER’S GUIDE Fatal firmware error on CMX controller board. replace one at a time until message clears: a) shuttle frame assembly b) controller board Page 5–35 Cycle power. Troubleshooting 5–9 . Required Action Page 5–33 102 LOWER DRIVER SHORT Page 5–34 105 HAMMER COIL <number> OPEN Cycle power.Message 101 UPPER DRIVER SHORT Explanation Hammer driver circuits on the CMX boards shorted to ground. Rerun print job. If message recurs. If message recurs. Cycle power. System stack has run out of room and overflowed into other memory. Circuit(s) on the hammer bank or in the hammer bank power cable shorted to ground. Rerun print job. Cycle power. replace CMX controller board. Record the message and return it with the defective board. Rerun print job. 113 PROTECTED INSTRUCTION SEE USER’S GUIDE Fatal firmware error on CMX controller board. Record the message and return it with the defective board. If message recurs. Rerun print job. 112 UNDEFINED OPCODE SEE USER’S GUIDE Fatal firmware error on CMX controller board. If message recurs. Record the message and return it with the defective board. Rerun print job.Message 114 ILLEGAL OPERAND ACCESS SEE USER’S GUIDE Explanation Fatal firmware error on CMX controller board. Rerun print job. Rerun print job. If message recurs. replace CMX controller board. Record the message and return it with the defective board. Cycle power. Record the message and return it with the defective board. Cycle power. If message recurs. 5–10 Troubleshooting . Cycle power. Cycle power. Cycle power. replace CMX controller board. If message recurs. replace CMX controller board. Record the message and return it with the defective board. 120 ACCESS NULL POINTER SEE USER’S GUIDE The processor tried to access a pointer that contains nothing (null). If message recurs. replace CMX controller board. Record the message and return it with the defective board. replace CMX controller board. 119 TCB CORRUPTED SEE USER’S GUIDE The Task Control Block has been corrupted. If message recurs. 115 ILLEGAL INSTRUCTION ACCESS SEE USER’S GUIDE Fatal firmware error on CMX controller board. Record the message and return it with the defective board. If message recurs. replace CMX controller board. 118 UNDEFINED INTERRUPT SEE USER’S GUIDE Fatal firmware error on CMX controller board. Cycle power. If message recurs. Rerun print job. Rerun print job. Record the message and return it with the defective board. replace CMX controller board. Record the message and return it with the defective board. Rerun print job. Rerun print job. 116 ILLEGAL EXTERNAL BUS ACCESS SEE USER’S GUIDE Fatal firmware error on CMX controller board. Required Action Cycle power. 117 A TO D OVERRUN SEE USER’S GUIDE Analog to digital signal conversion problems. Record the message and return it with the defective board. Cycle power. replace CMX controller board. Cycle power. 124 PAPER FIFO OVERFLOW SEE USER’S GUIDE Fatal firmware error on CMX controller board. Record the message and return it with the defective board. Rerun print job. 127 PAPER FEED ILLEGAL STATE SEE USER’S GUIDE Fatal firmware error on CMX controller board. Record the message and return it with the defective board. replace CMX controller board. 126 PAPER FEED BAD TABLE SEE USER’S GUIDE The paper feed process is using a bad table. replace CMX controller board. Rerun print job. If message recurs. Record the message and return it with the defective board. replace CMX controller board. replace CMX controller board. 123 PAPER BUSY TOO LONG SEE USER’S GUIDE Fatal firmware error on CMX controller board. Record the message and return it with the defective board. Cycle power. replace CMX controller board. Rerun print job. If message recurs. Rerun print job. Record the message and return it with the defective board. Rerun print job. If message recurs. If message recurs. Troubleshooting 5–11 . If message recurs. 125 PAPER FIFO UNDERFLOW SEE USER’S GUIDE Fatal firmware error on CMX controller board. If message recurs. Cycle power.Message 121 PAPER NOT AT SPEED SEE USER’S GUIDE Explanation Fatal firmware error on CMX controller board. 122 PAPER NOT SCHEDULED SEE USER’S GUIDE The paper feed process is not working and the printer cannot advance paper. replace CMX controller board. If message recurs. Cycle power. Rerun print job. Rerun print job. Record the message and return it with the defective board. Cycle power. Required Action Cycle power. If message recurs. Rerun print job. If message recurs. replace CMX controller board. Cycle power. replace CMX controller board. replace CMX controller board. Cycle power. Record the message and return it with the defective board. Record the message and return it with the defective board. replace CMX controller board. 130 PAPER FEED PARTLY ENERGIZED SEE USER’S GUIDE Fatal firmware error on CMX controller board. If message recurs. If message recurs. If message recurs. If message recurs. Record the message and return it with the defective board.Message 128 PAPER FEED INVALID COMMAND SEE USER’S GUIDE Explanation Fatal firmware error on CMX controller board. Required Action Cycle power. Rerun print job. replace CMX controller board. Cycle power. Rerun print job. Record the message and return it with the defective board. replace CMX controller board. Cycle power. Record the message and return it with the defective board. Record the message and return it with the defective board. Cycle power. Cycle power. 129 PAPER FEED INVALID PARAMETER SEE USER’S GUIDE Fatal firmware error on CMX controller board. 132 RIBBON INVALID COMMAND SEE USER’S GUIDE Fatal firmware error on CMX controller board. Rerun print job. Rerun print job. Rerun print job. 134 PLATEN INVALID COMMAND SEE USER’S GUIDE Fatal firmware error on CMX controller board. 131 PAPER FEED INTERRUPT SEE USER’S GUIDE Fatal firmware error on CMX controller board. If message recurs. Record the message and return it with the defective board. replace CMX controller board. 5–12 Troubleshooting . Rerun print job. 133 RIBBON INVALID STATE SEE USER’S GUIDE Fatal firmware error on CMX controller board. Rerun print job. Printer has received a non-printable character. Record the message and return it with the defective board. Rerun print job. Required Action Cycle power. Rerun print job. Non-error status message. Record the message and return it with the defective board. Cycle power. If message recurs. If message recurs. Press Stop then Start. If message recurs. 139 SHUTTLE OVERSPEED SEE USER’S GUIDE Fatal firmware error on CMX controller board. Record the message and return it with the defective board. If message recurs. 990 MACHINE CHECK Host status message. replace CMX controller board. 137 SHUTTLE INVALID COMMAND SEE USER’S GUIDE Fatal firmware error on CMX controller board. None Replace the controller board (page 7–11). Record the message and return it with the defective board. Rerun print job. 136 PLATEN INVALID PARAMETER SEE USER’S GUIDE Fatal firmware error on CMX controller board. Cycle power. replace CMX controller board.Message 135 PLATEN INVALID STATE SEE USER’S GUIDE Explanation Fatal firmware error on CMX controller board. 138 SHUTTLE INVALID PARAMETER SEE USER’S GUIDE Fatal firmware error on CMX controller board. Record the message and return it with the defective board. replace CMX controller board. replace CMX controller board. replace CMX controller board. Cycle power. Cycle power. Rerun print job. 998 NON-VOLATILE MEMORY FAILED A97 GRAPHIC CHECK ERROR PRESS STOP THEN START BOOT DIAGNOSTICS None Troubleshooting 5–13 . NVRAM defective. If message recurs. The old program is now being deleted from flash memory.Message CLEARING PROGRAM FROM FLASH Explanation Emulation program successfully loaded into printer RAM and the checksum matched. install correct security PAL. DRAM defective or missing. If message recurs. #. Status message: printer is in low-energy idle state. install or replace DRAM (page 7–29). #. If cables are OK. Hammer coil count test failed. replace one at a time until message clears: a) shuttle frame assembly b) controller board c) Record the message and return it with the defective assembly None LOADING PROGRAM FROM PORT XX% Emulation program is loading into printer RAM. Hammer coil number # failed current test at power-up. LOADING PROGRAM INTO FLASH None 5–14 Troubleshooting . XX indicates how much of the program has loaded. Cycle power. Page 5–38 ERROR: SECURITY PAL NOT DETECTED Security PAL defective or missing. only +5Vdc logic circuits are active. HAMMER BANK NOT INSTALLED HAMMER COIL BAD #.. Self-test does not detect hammer coils at printer start-up. The printer has deleted the previous emulation program from flash memory and is loading the new program into flash memory. #. Check. make sure hammer bank cables are connected. reseat. . as required (page 7–29). None Required Action DRIVER CIRCUIT BAD Page 5–37 None ENERGY SAVER MODE ACTIVE ERROR: DRAM NOT DETECTED Reseat DRAM SIMM(s). all fans and higher voltages are off.. etc. If message reappears. Attach status message. Remove one DRAM SIMM (page 7–29). try new diskette. If message is gone. None Required Action OPERATOR MENU <first menu item> OPERATOR MENU LOCKED None Non-error status message. If message recurs. Security code of PAL on controller board does not match code of firmware on the CMX controller board. Attach status message. If the printer is an IBM 6404–B01. If the printer is an IBM 6400. Install or replace flash SIMM (page 7–29). Non-error status message. replace the DRAM SIMM you just removed. diskette may be corrupted. replace the DRAM SIMM you left on the CMX board. P63 ERROR: PROGRAM NOT COMPATIBLE User tried to load CMX-compatible diskette in CBO-controlled printer. Restart printer. Non-error status message. Data controller program is not working. Troubleshooting 5–15 . If OK. Damaged DRAM at address <hex>. Download the program again. the controller is a CBO board. Use correct emulation diskette. replace the CMX controller board. OPERATOR MENU UNLOCKED PA1 SELECTED PA2 SELECTED P05 DIAGNOSTIC TEST PASSED P17 SECURITY VIOLATION P60 ERROR: DRAM AT ADDRESS <hex> P61 ERROR: FLASH NOT DETECTED P62 ERROR: DC PROGRAM NOT VALID Flash memory is defective or missing. or vice versa.Message NOT READY Explanation Printer state message: printer is offline. Non-error status message. not in communication with host. None None None None None Verify correct firmware and security PAL installed (page 7–29). the controller is a CMX board. ) Where XXXX is a number from 0000 to 0010. Record the number indicated by XXXX and return it with the defective board. EC program may be corrupted. Obtain a new EC program. Code is checked then saved in flash memory.. PLEASE WAIT RESTORING BOOT CODE None Status message when downloading boot code. Printer reset in progress. Replace the CMX controller board. None SENDING PROGRAM TO EC PROCESSOR 5–16 Troubleshooting . then stored in flash memory. None RESETTING.. Download the EC program again. P66 ERROR: PROGRAM NEEDS MORE DRAM Add DRAM (page 7–29).. RibbonMinder software has determined that the ribbon is out of ink. None EC program on CMX controller board corrupted. P69 ERROR: EC STOPPED AT STATE XXXX PLEASE WAIT. EC hung at process indicated by XXXX. Emulation program requires more flash memory than is present on the controller board. If message recurs. P67 ERROR: WRITING TO FLASH P68 ERROR: EC PROGRAM NOT VALID Replace flash SIMM (page 7–29). None RIBBON OUT OF INK CHANGE RIBBON Change ribbon and set ribbon life to 100%. from the beginning.Message P64 ERROR: CHECKSUM WRONG <hex> P65 ERROR: PROGRAM NEEDS MORE FLASH Explanation Corrupted data passed through the parallel port.. RESET IN PROGRESS READY Printer state message: printer is online. Required Action Run the download again. Status message when downloading EC program. sent to the EC processor. Printer reset in progress. Emulation program requires more DRAM than is present on the controller board. Add flash memory (page 7–29). (Power-up checksum incorrect. in communication with host. Flash memory defective. EC code is checked by the boot code. Emulation download mode has been activated. but program download has not yet begun. None TOP OF FORM SET None None WAITING FOR PROGRAM DOWNLOAD Troubleshooting 5–17 . from the beginning.Message SERVICE <first service test> TABLE MISMATCH DOWNLOAD AGAIN TESTING HARDWARE PLEASE WAIT Explanation Non-error status message. Non-error status message. Run the download again. None Required Action EC software update in process. Status message when printer runs self-tests and initialization routines. Run an operator print test. Yes Replace paper detector switch assembly. Load paper.001 END OF FORMS LOAD FORMS 031 END OF FORMS TIMEOUT LOAD FORMS Instruction 1. End of forms message. 5–18 Troubleshooting . No Return printer to normal operation. Run an operator print test. Return printer to normal operation. 2. Indication End of forms message. Replace the controller board. Go to step 2. or folding. without jamming. Load paper. Check the holes in the ribbon mask surrounding each hammer tip. 2. Check the platen motor belt. If pin holes are damaged. 6.002 FORMS JAMMED CLEAR JAM AND RELOAD FORMS 032 FORMS JAMMED TIMEOUT CLEAR JAM AND RELOAD FORMS Instruction 1. Remove paper and go to step 3. Press the Form Feed key several times. 4. Go to step 6. torn. Go to step 12. WARNING: Do not pry on or apply force to the hammer tips. Replace platen motor belt. Go to step 5. Platen motor belt OK. For erratic motion or noise. Forms feed without erratic motion. Forms move correctly in both directions. tearing. Go to step 4. 5. c) Replace the controller board. or pin-hole damage. Replace one at a time until message goes away: a) platen motor b) controller board Replace the hammer bank cover assembly. Yes Do one at a time until the problem is gone: a) Clean the paper detector sensor with a cotton swab and alcohol. Gently remove paper or lint particles with a wooden stick or pair of tweezers. Inspect paper guide assembly for frayed. Go to step 3. go to step 9. Suspect a false indication. Go to step 4. go to step 7. b) Replace the paper detector switch assembly. Debris found. folded paper or labels. Check that the ribbon mask has not been deformed in such a way as to block the paper guide assembly. noise. 7. Go to step 8. Ribbon mask damaged or bent. Press the View key twice. Inspect the narrow passageway between the face of the platen and the ribbon mask for bits of torn paper or ribbon lint. Paper guide assembly is clear. Troubleshooting 5–19 . 3. Indication End of Forms (last form) is past the hammer area. Check for a failure to sense End of Forms. No Go to step 2. Replace paper detector switch assembly. Check the platen gap adjustment. Return printer to normal operation. Yes Adjust platen gap. Check the tractors and tractor door springs for damage or excessive wear. Load paper. Replace the controller board. 13. 9. No Go to step 9. Paper Jam message. Paper Jam message. Go to step 9. Run a print test and check paper feeding as the printer prints. Paper Jam message. Return printer to normal operation. Paper feed or belt damaged. Tractors are OK. Replace the paper feed belt. Set the paper motion detector fault setting to DISABLE (Ref: Setup Guide). Go to step 12. 5–20 Troubleshooting . 11. Indication Platen gap incorrect. Go to step 13. Paper Jam message. Return printer to normal operation. 14. Run an operator print test. 10. Go to step 14 12. Go to step 10. Replace paper feed motor.Instruction 8. Go to step 10. Run an operator print test. Check for damage to the paper feed belt. Do some line feeds and run a diagnostic print test. Clean the paper motion detector with cotton swab and alcohol. Replace defective tractor. Return printer to normal operation. Go to step 11. Yes Verify host data are correct and there are no invalid characters. 2. Return printer to normal operation. Ask the system operator to verify that the printer’s Device ID is set to the correct emulation with respect to the host configuration. Troubleshooting 5–21 . Replace one at a time until message is gone: a) coax or twinax cable b) CMX controller board No Return printer to normal operation. SCS COMMAND or PARAMETER ERROR message. Indication SCS COMMAND or PARAMETER ERROR message.010 PARAMETER ERROR 011 SCS COMMAND ERROR Instruction 1. Run the print job that generated the error message. b) Disconnect the power cord. 5–22 Troubleshooting . you will be instructed to do so in the maintenance procedure. Replace one at a time until message is gone: a) coax or twinax cable b) CMX controller board Return printer to normal operation. c) Check coax/twinax cable terminations at the I/O plate. Cable is OK. Check coax and twinax I/O cable grounding and connections at controller board. b) Power on the printer.5 feet (1500 meters).) a) Power off the printer. Yes Go to step 2. Error message displays. Go to step 4. (A few parity errors in the log are acceptable. Coax and twinax cables are properly attached. 3.013 ACTIVATE LOST 014 INVALID ACTIVATE 016 INVALID COMMAND DANGER <1> Always disconnect the AC power cord from the power source before performing any maintenance procedure. Cables are grounded and attached to controller board correctly. Replace cable. Indication Host communication error message display logged. No Return printer to normal operation. a) Connect power cord to printer. Failure to remove power could result in injury to persons or damage to equipment. Go to step 3. Go to step 5. If you must apply power during maintenance. 4. Power off printer. 5. Check that external coax/twinax cable is undamaged and is not longer than 4921. Print the Error Log. Attach cables correctly. Instruction 1. 2. c) Send data from host. Attach cables correctly. b) Power on the printer. but message still appears. Failure to remove power could result in injury to persons or damage to equipment. Troubleshooting 5–23 . (Refer to line problem determination procedures. Go to step 2. Twinax auto-termination cable checks out OK. Instruction 1. (See DANGER notice above. Return printer to normal operation. Replace the CMX controller board. a) Disconnect twinax auto-termination cable from printer and host.) b) Send a print job to the printer. a) Connect AC power cable to the printer. Go to step 3. Correct twinax line device malfunction or replace twinax line. Connect twinax auto-termination cable to host and printer.015 COMMUNICATIONS CHECK CHECK CABLE DANGER <1> Always disconnect the AC power cord from the power source before performing any maintenance procedure. If you must apply power during maintenance. you will be instructed to do so in the maintenance procedure.) c) Check the twinax host data cable connection. Indication Twinax host data cable connection is OK. Yes Check and reseat the twinax I/O cable connection at the CT board. 2. Problem is not in the printer. Job prints OK and no communications check messages appear. No Check and reseat the twinax host data cable connection. 4. a) Power off the printer. b) Disconnect the AC power cord from the printer. 3. as recommended by host system documentation. Go to step 2. c) Send a print job to the printer. b) Check twinax auto-termination cable for the resistances shown on page A–27. Replace twinax auto-termination cable assembly. Go to step 4. Twinax line devices work properly. a) Verify that all other devices on the twinax line are working properly. 021 RECEIVE BUFFER OVERRUN VERIFY CONFIGURATION 024 SERIAL LINE PARITY ERROR VERIFY CONFIGURATION 025 SERIAL FRAMING ERROR VERIFY CONFIGURATION Instruction 1. a) Make a configuration printout. (Ref.: Setup Guide) b) Verify that host and printer serial interface configuration settings match for: — Data Protocol — Baud Rate — Data Bits — Stop Bits — Parity — Data Terminal Ready — Request To Send Send a print job to the printer. Indication Host and printer serial interface parameters match. Yes Go to step 2. No Set printer serial interface parameters to match those of the host. (Ref.: Setup Guide) 2. Job prints OK and no serial interface fault messages appear. Return printer to normal operation. Replace controller board 5–24 Troubleshooting 057 CLOSE PLATEN 087 PLATEN OPEN TIMEOUT CLOSE PLATEN Instruction 1. a) Load paper. b) Close the forms thickness lever. c) Run an operator print test. a) Power off the printer. b) Disconnect the platen interlock switch connector. c) Check the switch with a meter. Indication “057 CLOSE PLATEN” message. Yes Go to step 2. No Return printer to normal operation. 2. Switch is bad. Replace platen interlock switch assembly. Replace controller board. Troubleshooting 5–25 058 SHUTTLE JAM SEE USER‘S GUIDE Instruction 1. Check the forms thickness lever: if it is set too tightly, it can slow the shuttle enough to trigger the fault message. Run an operator print test and check for shuttle obstruction. Remove shuttle cover and inspect shuttle area and mechanism for obstruction. Run an operator print test and observe the shuttle. Check MPU adjustment. Run an operator print test. Run an operator print test. Indication Forms thickness lever set correctly. Yes Go to step 2. No Set forms thickness lever for thicker paper. Go to step 2. Return printer to normal operation. Install shuttle cover. Go to step 4. Go to step 7. Adjust MPU. Return printer to normal operation. Return printer to normal operation. 2. “058 SHUTTLE JAM” message. Go to step 3. 3. Shuttle movement blocked. Remove obstruction. Install shuttle cover. Go to step 4. Go to step 5. Go to step 6. Replace the MPU. Go to step 5. Replace controller board. 4. 5. 6. 7. Shuttle moves. MPU adjustment OK. “058 SHUTTLE JAM” message. “058 SHUTTLE JAM” message. 5–26 Troubleshooting 060 PRINTER HOT NOTE: This message indicates internal temperatures over 60° Celsius (140° Fahrenheit). Print jobs will not create such temperatures, so immediately determine that the fans are operating and that all air vents are unobstructed. It is crucial that the exhaust vents on the floor of the cabinet remain unblocked, since hot air from inside the printer is vented through the cabinet floor. Nothing should be stored under the printer. Then check the operating environment. A severe environment is one with an ambient temperature consistently above 40° Celsius (104° Fahrenheit) or is dirty enough to create blockage of the cabinet fan vents. If the printer is located in such an environment, consider relocating it to a cooler, cleaner area or reducing the size and duration of the print jobs. Instruction 1. 2. Press the Stop key. Cycle power: Power off printer. Wait 15 seconds. Power on printer. Verify that all fans operate. a) Power off the printer. b) Check for obstruction of vents and fan airways. Indication “060 PRINTER HOT” message. “060 PRINTER HOT ” message. Yes Go to step 2. Go to step 3. No Return printer to normal operation. Return printer to normal operation. Replace defective fan(s). Remove obstructions. Make sure cabinet exhaust fan vents are not blocked. (Check for items beneath the printer blocking cabinet vents.) Move printer to cooler, cleaner location. 3. 4. Fans are OK. Vents and airways are clear. Go to step 4. Go to step 5. 5. Examine printer environment for severity. (See NOTE above.) Printer environment is OK. Replace the CMX controller board. Troubleshooting 5–27 062 EXHAUST FAN FAULT 063 INTAKE FAN FAULT 065 HAMMER BANK FAN FAULT NOTE: Exhaust Fan Fault = cabinet exhaust fan. Intake Fan Fault = card cage fan. Instruction 1. Cycle power: Power off printer. Wait 15 seconds. Power on printer. a) Power off the printer. b) Remove the paper guide assembly or pedestal top cover. c) Check that the fan cable connector is connected. (See Appendix A, Interconnect Diagram.) Check for obstruction of vents and fan airway. Indication “_____ FAN FLT” message. Yes Go to step 2. No Return printer to normal operation. Connect the fan cable connector. 2. Fan cable is properly connected. Go to step 3. 3. Vents and airway are unobstructed. Go to step 4. Remove obstructions. Make sure cabinet exhaust fan vents are not blocked. (Check for items beneath the printer blocking cabinet vents.) Replace defective fan(s). 4. a) Power on the printer. b) Check for rotation of fans as printer powers up. c) Power off the printer. Power on the printer. Fans are OK. Go to step 5. 5. “_____ FAN FLT” message. Replace CMX controller board. Return printer to normal operation. 5–28 Troubleshooting 080 POWER SUPPLY HOT NOTE: The printer has sensor circuits that sample the operating temperature of key print components. When higher than normal temperatures are sensed, print speed is automatically reduced. If the printer runs at reduced speed for an extended period of time, a (UNIT) HOT message is sent to the LCD and printing stops, allowing printer components to cool down. Pressing the Start key resumes the print task. Check the operating environment. A severe environment is one with an ambient temperature consistently above 40° Celsius (104° Fahrenheit) or is dirty enough to create blockage of the cabinet fan vents. If the printer is located in such an environment, consider relocating it to a cooler, cleaner area or reducing the size and duration of the print jobs. Instruction 1. 2. Press the Start key. Cycle power: Power off printer. Wait 15 seconds. Power on printer. Run a diagnostic printer test. a) Power off the printer. b) Remove the paper guide assembly or pedestal top cover. c) Check that the power supply guard/air deflector is correctly positioned over the power supply board. d) WARNING: DO NOT TOUCH the power supply, but hold your hand close enough to check for heat radiating off the board. Verify that all fan cable connectors are connected. (See Appendix A, Interconnect Diagram.) a) Power on the printer. b) Verify that all fans operate. c) Power off printer. Indication “POWER SUPPLY HOT” message. “POWER SUPPLY HOT ” message. “POWER SUPPLY HOT” message. Power supply is noticeably hot. Yes Go to step 2. Go to step 3. No Return printer to normal operation. Return printer to normal operation. Return printer to normal operation. Replace power supply board. 3. 4. Go to step 4. Go to step 5. 5. Fan cables are properly connected. Go to step 6. Connect fan cable connector(s). 6. Fans are OK. Go to step 7. Replace defective fan(s). Troubleshooting 5–29 Check for obstruction of vents and fan airways. Examine printer environment for severity. (See NOTE above. Advise the user to run jobs in smaller batches. Yes Go to step 8.) Check the kinds of print jobs the user is running: look for very dense graphics and layouts. 5–30 Troubleshooting . 8. Print jobs are dense enough to slow the printer. No Remove obstructions. Make sure cabinet exhaust fan vents are not blocked. Printer environment is OK. (Check for items beneath the printer blocking cabinet vents.Instruction 7. cleaner location. 9. Go to step 9. Indication Vents and airways are clear. Replace the CMX controller board.) Move printer to cooler. 2. Check for ribbon failing to reverse motion. Indication Ribbon fails to reverse. Go to step 7. Check that forms thickness lever is not closed too tightly. Go to step 9. Troubleshooting 5–31 . Go to step 7. Go to step 4. extension cable. Ribbon path is clear Go to step 6. Replace ribbon. Ribbon tracks OK. Check ribbon path for blockage or obstruction. Go to step 4. fraying. Go to step 8. Rewind and reinstall ribbon. Run a ribbon and shuttle CE Test and check for shuttle obstruction. Go to step 8. Run the “Shuttle Fast” CE Test and check the alignment of the ribbon guides and hubs if the ribbon was folded. Motor cable and extension cable OK. Replace the defective ribbon drive motor. this can jam the ribbon and shuttle. Unfold and rewind ribbon if it was folded. Forms thickness lever is set correctly. Yes Go to step 3. Go to step 5. Ribbon is OK. short across the ribbon guide screws to reverse ribbon hub motion. Return printer to normal operation. 7. 3. Align ribbon guides. Check for a ribbon drive motor that does not wind ribbon. 5. Replace the controller board. and controller board. Replace the controller board. Check for missing foil strip at end of ribbon. 4. or shorts. Replace the ribbon. No Go to step 2. Ribbon fault message. 8. On motor that does not wind the ribbon.089 RIBBON STALL Instruction 1. 9. Readjust the setting of the forms thickness lever. short across the ribbon guide screws to reverse ribbon hub motion. Go to step 8. 6. if damaged. Remove obstructions from ribbon path and go to step 6. Using a screwdriver. Wind ribbon by hand and inspect for folds. damage. Foil strip missing. tears. holes. Using a screwdriver. Both motors wind the ribbon. check the motor cable and extension cable for pinches. damage. (The magnet covers the sensor housing when the cover is installed. 3. 2. “090 SHUTTLE COVER OPEN / CLOSE SHUTTLE COVER” message. Shuttle cover installed correctly. Yes Replace the shuttle cover assembly. Run an operator print test.090 SHUTTLE COVER OPEN CLOSE SHUTTLE COVER Instruction 1. Go to step 3. 5–32 Troubleshooting . Replace the CMX controller board. Inspect shuttle cover for warping. Indication Shuttle cover damaged. Install the cover correctly. or missing magnet.) Check shuttle cover installation. Replace the cover open switch assembly. Make sure the cover lies flat and the two captive screws are fully seated. No Go to step 2. Go to step 3. Troubleshooting 5–33 . Replace the CMX controller board. “101 UPPER DRIVER SHORT” message. 2.101 UPPER DRIVER SHORT Instruction 1. Power on the printer. “101 UPPER DRIVER SHORT” message. Go to step 4. 3. Return printer to normal operation. Cycle power: Power off printer. Power on the printer. 4. Wait 15 seconds. Indication “101 UPPER DRIVER SHORT” message. Return printer to normal operation. No Return printer to normal operation. Replace the shuttle frame assembly. Power on printer. “101 UPPER DRIVER SHORT” message. Press the Start key. Go to step 3. Return printer to normal operation. Yes Go to step 2. Replace hammer bank logic cable assembly and hammer bank power cable assembly. “102 LOWER DRIVER SHORT” message. Go to step 3. Go to step 4. 3. Power on the printer. 4. Cycle power: Power off printer. “102 LOWER DRIVER SHORT” message. Return printer to normal operation. Indication “102 LOWER DRIVER SHORT” message. Power on the printer. “102 LOWER DRIVER SHORT” message. Power on printer. Replace hammer bank logic cable assembly and hammer bank power cable assembly. Replace the CMX controller board. Return printer to normal operation. Yes Go to step 2. No Return printer to normal operation. Replace the shuttle frame assembly. 2. 5–34 Troubleshooting . Return printer to normal operation.102 LOWER DRIVER SHORT Instruction 1. Wait 15 seconds. Press the Start key. 4. allowing printer components to cool down. 2. Troubleshooting 5–35 . print speed is automatically reduced.) 6. Cycle power: Power off printer. No Return printer to normal operation. Replace defective fan(s). c) Power off printer. Press the Start key. it may be operating in a severe environment. Instruction 1. Pressing the Start key resumes the print task. A severe environment is one with an ambient temperature consistently above 40° Celsius (104° Fahrenheit) or that is dirty enough to create blockage of the cabinet fan vents. Return printer to normal operation. Go to step 5. Go to step 3. Check for obstruction of vents and fan airways. b) Remove the paper guide assembly or pedestal top cover. When higher than normal temperatures are sensed. a (UNIT) HOT message is sent to the LCD and printing stops. cleaner area or reducing the size and duration of the print jobs. 5. Vents and airways are clear.) a) Power on the printer. Wait 15 seconds. “107 HAMMER COIL <number> HOT” message. 3. If the printer often prints at half speed. b) Verify that all fans operate. Go to step 4. Yes Go to step 2. “107 HAMMER COIL <number> HOT” message. consider moving it to a cooler. Make sure cabinet exhaust fan vents are not blocked. (Check for items beneath the printer blocking cabinet vents. a) Power off the printer. If the printer is located in such an environment. Connect fan cable connector(s). Go to step 7. (See Appendix A. Go to step 6. Fan cables are properly connected. Remove obstructions. Return printer to normal operation. Indication “107 HAMMER COIL <number> HOT” message. Interconnect Diagram. If the printer runs at reduced speed for an extended period of time.107 HAMMER COIL <number> HOT NOTE: The printer has sensor circuits that sample the operating temperature of key print components. Run “All Black” print test for 1/4 page. Fans are OK. c) Verify that all fan cable connectors are connected. Power on printer. ) Check the kinds of print jobs the user is running: look for very dense graphics and layouts. cleaner location. (See NOTE above. Yes Go to step 8. Advise the user to run jobs in smaller batches.Instruction 7. Replace one at a time until the problem goes away: a) shuttle frame assembly b) CMX controller board 8. Examine printer environment for severity. 5–36 Troubleshooting . Indication Printer environment is OK. No Move printer to cooler. Print jobs are dense enough to slow the printer. “DRVR CIR BAD*” message. disconnect the hammer bank logic and power cables. 2. Go to step 3.DRIVER CIRCUIT BAD Instruction 1. “HAMMER BANK NOT INSTALLED*” message. Cycle power: Power off printer. Yes Go to step 2. Indication “DRVR CIR BAD*” message. No Return printer to normal operation. c) At the shuttle frame assembly. b) Remove the shuttle cover. Troubleshooting 5–37 . Replace the shuttle frame assembly. 3. Return printer to normal operation. Press the Start key. Power on printer. Replace the CMX controller board. d) Power on the printer. a) Power off the printer. Wait 15 seconds. 5. (See Appendix A. Return printer to normal operation. Power on the printer. “HAMMER BANK NOT INSTALLED” message. “HAMMER BANK NOT INSTALLED” message. 6. Hammer bank power cable is connected to J105 on the controller board and to the shuttle frame assembly. Go to step 6. Connect hammer bank power cable. 3. Indication Shuttle frame assembly is installed in the printer. Power on the printer. Yes Go to step 2. Go to step 3. Return printer to normal operation. a) Remove the paper guide assembly or pedestal top cover. 2. c) Verify that the shuttle frame assembly is installed.) Go to step 4. Go to step 4. Replace the CMX controller board. b) Verify that the hammer bank logic cable is connected to connector J108 on the CMX controller board and to its connector on the shuttle frame assembly. “HAMMER BANK NOT INSTALLED” message. a) Power off the printer. 4. Power on the printer. Connect hammer bank logic cable. Verify that the hammer bank power cable is connected to connector J105 on the controller board and to its connector on the shuttle frame assembly. Go to step 4. 5–38 Troubleshooting . b) Remove the shuttle cover. Replace the hammer bank logic cable. No Install the shuttle frame assembly. Go to step 4.HAMMER BANK NOT INSTALLED Instruction 1. Return printer to normal operation. Replace the shuttle frame assembly. Hammer bank logic cable is connected to J108 on the controller board and to the shuttle frame assembly. Replace a malfunctioning electronic assembly with an operational spare. until the final half is a field-replaceable part or assembly. 7. Verify the fault by running diagnostic tests or replicating the conditions reported by the user. Troubleshooting 5–39 . or cable that causes the fault indication. d. 3. 2. (Troubleshooting aids are listed on page 5–2. and follow the instructions given. Stop troubleshooting and return the printer to normal operation when the reported symptoms disappear. Locate the malfunction using the half-split method: c. Ask the operator to describe the problem. It is not field repairable. Start at a general level and work down to details. Test printer operation after every corrective action. Look for a match in the “Symptoms Not Indicated by Fault Messages Troubleshooting Table” (page 5–40). IMPORTANT DO NOT attempt field repairs of electronic components or assemblies. The same is true of failures traced to the hammer bank coils and electronics: you must replace the entire shuttle frame assembly. Isolate faults to half the remaining system at a time.) 5. (Hammer spring assemblies are the only replaceable components of the shuttle frame assembly. Replace the defective part or assembly. sensor.Symptoms Not Indicated by Fault Messages Use standard fault-isolation techniques to troubleshoot malfunctions not indicated by fault messages: 1.) 6. 4. Most electronic problems are corrected by replacing the circuit board. 1. Make sure the printer and host have the same baud rate. Power off printer and disconnect the AC power cable. 1. 3. and parity. Check the left and right ribbon guide alignment (page 6–16). 1. 4. (Failed or corrupted flash memory can cause black squares. operator panel LCD and LEDs blank. 1. 2. Replace the controller board Blank or single line of black squares across top row of operator panel LCD. configure the host for XON/XOFF if possible. contact your service support group. If you suspect flash memory is bad and you cannot load flash. number of stop bits. (Refer to the Power Distribution Diagram on page A–4.) e) Power on the printer. This is the most common cause of a completely inoperative RS–232 cable. 5. go to step 2 Replace one at a time until the problem is fixed: a) IBM coax/twinax expansion board and adapter b) operator panel assembly c) operator panel cable assembly d) controller board Replace one at a time until the problem is fixed: a) operator panel assembly b) operator panel cable assembly c) controller board Clean the shuttle frame assembly (page 3–2). 1. number of data bits. card cage fan not running. this requires the least complex cable. Printer appears normal. Ribbon folding or feed problems. Perform a printer confidence check (page 5–44). 2. interchange the wires to pins 2 and 3. If the display is still blank or has a black line. Power on hang condition. Make sure the flash memory SIMM(s) is/are seated properly in J10/J11. If the printer interface is RS–232. especially that the control panel cable is seated in connector J110 on the controller board. but does not print data sent from the host.) Replace one at a time until the problem is fixed: a) controller board b) power supply a) Power off printer.Symptoms Not Indicated by Fault Messages Troubleshooting Table Symptom No power. c) Reseat the IBM coax/twinax expansion board. Instruction +5 volt distribution problem to the controller board. In RS–232. 5–40 Troubleshooting . d) Check all cable connections into the controller board. Check the host data cable connection at the rear of the printer. 2. 1. b) Remove the paper guide assembly or pedestal top cover. Operator Panel key failure. the host is ignoring the XOFF character or “Data Terminal Ready” signal (pin 20). If the printer is not supposed to have this feature. With a PC Parallel interface.5 or 2 stop bits.) b) Also check that the terminating resistors are present on the controller board (page 7–31). a) If the printer prints from the host. shield it. never on RS–232. A breakout box works. but will not debug XON/XOFF or other RS–232 data protocols. capacitively-induced noise from the other signals of the cable (especially PC Parallel “ACK” or Dataproducts “DEMAND”) can cause false strobes. the most likely cause is the host not responding to “send no more data” signals from the printer. What happens is that the strobe signal registers logic 1 more than once for a certain character. but occasionally prints double characters or loses blocks of data. Troubleshooting 5–41 . or capacitively. 1. You can correct some noise problems by using a shielded data cable or by changing the terminating resistors. unshielded cable. which will provide slightly more noise immunity. 2. If the printer is sending XOFF with one stop bit. this means the host is ignoring BUSY. To fix this. you can change them for slower operation. Test this by using a serial line analyzer and software or test equipment that displays the data and handshake lines of the printer. the host may not be receiving it if the host requires 1. This problem can occur on PC Parallel or Dataproducts interfaces.or magnetically-induced noise. Unshielded and flat ribbon cables are much more prone to problems due to increased length. reseat the IBM coax/twinax expansion board. but occasionally prints double characters. changes in ground voltage from nearby equipment. defective.Symptom Continuous IML cycle. in RS–232. Sometimes the cable is not conveying the necessary signals. c) Noise is caused by static. On very long cables. (Refer to the Setup Guide. make sure that both the printer and the host computer are properly grounded. Printer prints data sent from the host. 1. change the strobe to trailing edge or invert the strobe polarity. The standard terminating resistors are optimized for high speed data transfer for cables between 1 and 5 meters long. Instruction This symptom indicates coax/twinax code is being loaded into a printer with a missing. The best solution is to shorten cable. Also. and reduce local electromagnetic noise. or improperly installed Coax/Twinax board. If the printer prints from the host. there is probably a noise problem at the interface or the host computer is sending an inverted strobe. If the printer is supposed to have this feature. install new emulation code without the Coax/Twinax feature. a floating logic ground. but occasionally loses blocks of data. ) 2. proceed to step 6b. b) shuttle frame assembly (page 7–54) c) controller board (page 7–11) Check the forms thickness lever setting. otherwise. 1. Incorrect spacing from dot row to dot row or line to line. Check the ribbon for folds or tears. Replace one at a time until the problem is fixed: a) Replace appropriate hammer spring assembly ONLY if you see visible damage or broken parts (page 7–23). Horizontal misalignment. Check platen gap adjustment (page 6–12). 2. (Dots or 1. 3. characters move left or right from dot row to dot row or line to line. light. Replace one at a time until problem is fixed: a) controller board (page 7–11) b) shuttle frame assembly (page 7–54) If all dots between alternate rows are misaligned. 5–42 Troubleshooting . Clean the shuttle frame assembly (page 3–2). 4. Replace one at a time until problem is fixed: a) MPU (page 7–28) b) controller board (page 7–11) c) shuttle frame assembly (page 7–54) Check paper feed motor belt (page 6–4). Clean the shuttle frame assembly (page 3–2). 4. 5. 5. 3. 3. Check platen belt tension (page 6–6). Check the forms thickness lever setting. 2. 6. 2. Check the platen gap adjustment (page 6–12). 3. 4. 1. Dots or characters move up or down from dot row to dot row or line to line. or smeared characters or dots: 1. Install a new ribbon. Check adjustment of right tractor (too tight or loose can cause problems). Clean the shuttle frame assembly (page 3–2). Check adjustment of right tractor (too tight or loose can cause problems). Replace one at a time until problem is fixed: a) tractors (page 7–62) b) paper feed motor (page 7–32) c) controller board (page 7–11) d) power supply board (page 7–13) All characters or dots are too light or too dark. Vertical misalignment: 1. check hammer phasing (page 6–24). Check the MPU gap adjustment (page 7–28). 2.Print Quality Problems Missing. 5. the eighth bit will be received as a one. In this case.5 and 2 stop bit data. the printer’s “1-stop-bit” setting will accept both 1. 1. 1. Replace the controller board. One cause of garble is the host interface or cable not transmitting all 8 data bits. the PC Parallel or Dataproducts interface receives a 1 on every unconnected data line. Uncontrolled slewing is often caused by enabling PI (Paper Instruction) in the printer when the host lacks a PI signal. Check platen gap adjustment (page 6–12). Garble also can result from failed termination resistors or parallel logic. (PI shows as “p” on the hex dump. Garbled print or paper slews uncontrollably. in this case. Sometimes the data can “fade” or “persist” from one character to the next. but this is rare. This reveals a problem with PC Parallel or Dataproducts terminating resistors on the controller board—especially if they are absent. 2. a common cause of garble is the interface set to the wrong baud rate or parity. Sometimes the host sends 1. 2. 4. Check printer grounding (page E–4).5 or 2 stop bits. Troubleshooting 5–43 . When this occurs. b) In RS–232. Check adjustment of right tractor (too tight or loose can cause problems).Print Quality Problems Randomly misplaced dots. Replace one at a time until problem is fixed: a) controller board (page 7–11) b) power supply board (page 7–13) c) shuttle frame assembly (page 7–54) a) Put the printer into hex dump mode and analyze the binary data.) Some RS–232 and Dataproducts interfaces only send 7 data bits. 3. Printed circuit boards are firmly seated and all cables are correctly attached. (Chapter 3. or out of connectors.) Go to step 6. cabling. Go to step 3. Make a configuration printout. or broken wires. Troubleshoot the fault message (page 5–3). Check host computer. a) Power off printer. a) Install paper guide assembly or pedestal top cover (Chapter 7). (Ref.).) Printer checks out OK. Fault may not be in printer. a) Configuration is correct for the user’s application. Printer powers up and initializes properly. 3. c) Configuration has not been inadvertently changed by user. etc. 4. Replace stripped. Indication Power cable installed correctly to proper source. b) Power on the printer. (Chapter 6. a) Power off printer. Metallic debris found.: Appendix A) Inspect for debris that could cause short circuits (loose fasteners. Wires are not stripped. 9. 8. (Ref. frayed. 5. etc. Go to step 2. Yes Power off printer. Printer goes to READY state. 6. Go to step 9. Check that all printed circuit boards are correctly installed and cable connections are correct. Connections are clean and tight. b) Host computer and printer are using the same protocol (emulation). Troubleshoot the fault message (page 5–3). Check and correct the cable attachments. foil.Printer Confidence Check Instruction 1. applications software. Troubleshoot the fault message (page 5–3). b) Remove paper guide assembly or pedestal top cover (Chapter 7). Reconfigure the printer. Connect printer to correct power source. Power on the printer. No Power off the printer. Adjust all assemblies that are out of spec. frayed. Remove debris. Check that printer is plugged into correct power source. Go to step 7. Go to step 8. Install each board correctly.: Setup Guide) 2. 5–44 Troubleshooting . Clean the printer. Run an operator print test (page 5–45). 7. Go to step 5. b) Check alignments and adjustments. (Ref. Assemblies and components are adjusted in accordance with Chapter 6.: Setup Guide) Printer operates correctly Go to step 4. c) Check all electrical connectors. the oldest messages are deleted. improper phasing. and pitch available in the printer. Hammer bank cover Hammer spring Shuttle frame assembly ♦ All E’s A pattern of all uppercase letter E’s useful for identifying missing characters. Print Error Log Prints the contents of the error log. or light/dark character variations. ♦ Troubleshooting 5–45 . These are called the “Operator Print Tests” because they are available to the user. ♦ ♦ Printer Demonstration Prints a sample page showing every print mode. smeared characters. The most recent message is stored at the top of the list. improper vertical alignment. smeared characters. font. misplaced dots. If more than 50 messages occur before the log is cleared. The items are listed in the order you should check them: simplest items first. or vertical compression. so that the log never contains more than 50 messages. or improper phasing. The error log automatically records certain unit check conditions in a buffer in NVRAM that stores up to 50 messages. You can use these print tests to check the print quality and basic operation of the printer. Ripple Print A “sliding” alphanumeric pattern useful for identifying missing or malformed characters. NOTE: Under the description of some tests is a list of items that may need to be adjusted or replaced if the test produces a bad print pattern. the oldest message at the bottom of the list. The Operator Print Tests are summarized below. complex items last.Operator Print Tests A set of print tests is included in the configuration menu structure for use as diagnostic tools. Ribbon Splined shaft skew adjustment Hammer bank cover MPU sensor Hammer springs Hammer coils (shuttle frame assembly) ♦ All H’s A pattern of all uppercase letter H’s useful for detecting missing characters or dots. Ribbon Hammer bank cover MPU sensor Hammer springs Hammer coils (shuttle frame assembly) ♦ All E’s + FF A pattern of all E’s repeated for ten lines and followed by a form feed to the top of the next page. This test is useful for identifying paper motion or paper feed problems. Hammer bank cover Power supply board Paper motion sensor or cable Paper feed belt or motor Splined shaft bearings Tractors or tractor belts ♦ Underlines An underline pattern useful for identifying hammer bank misalignment. Hammer bank cover Hammer tips Paper feed belt or motor Splined shaft bearings Tractor bearings or belts 5–46 Troubleshooting . Press: Stop NOT READY The printer test stops printing. Press: Menu OPERATOR MENU PRINTER CONTROL 5. 6. Press: Scroll + Scroll OPERATOR MENU UNLOCKED Press both keys at the same time. First of the series of configuration menus. The printer test you have selected starts printing. the first option in Operator Printer Tests menu. Press: Scroll UNTIL OPERATOR MENU OPERATOR PRINT TESTS Advances to the Operator Printer Tests menu.Selecting and Running Operator Print Tests Step 1. Cycles through the list of Printer Tests. 3. Stop when the name of the test you wish to run displays. 4. Key Displayed Result Notes Make sure that the printer ribbon is installed in the printer and the printer is powered on and is loaded with paper. Press: Scroll UNTIL OPERATOR PRINT TESTS [TEST NAME] 8. Press: Stop NOT READY 2. Troubleshooting 5–47 . Press: Enter OPERATOR PRINT TESTS PRINTER DEMONSTRATION* 7. Advances to Printer Demonstration. Places the printer in Not Ready mode. Unlocking the Enter key allows you to test your printer. Press: Enter OPERATOR PRINT TESTS [TEST NAME] 9. 40* Unit of measurement is dot rows.50* 475 500* Procedure on page 6–33.25 to 5. You will use these tests in various troubleshooting and adjustment procedures. Procedure on page 6–24. Figure 5–1. CE Tests NOTE: * = Default value SERVICE PRINTER MECHANISM TESTS SERVICE HAMMER PHASE VALUE SERVICE END OF FORMS ADJUSTMENT VALUE SERVICE CLEAR ERROR LOG Burn In Test Plot Test Shuttle Only Shuttle Slow Shuttle Fast Hammer Phasing End of Forms Adjust 1 – 1000 NOTE: Value is numeric unit only. Plot Test Prints all dot positions. Enter key activates SERVICE PRINT PARTIAL LINE SERVICE TOP EXIT TEAR DISTANCE SERVICE SHUTTLE SPEED SERVICE SET COIL TEMPERATURE ENABLE* DISABLE 5. 5. These are called “Customer Engineer Tests” (CE Tests) because they are for your use—they are not available to the user through his documentation. CE Tests Menu The CE Tests shown in Figure 5–1 are summarized below: Printer Mechanism Tests: ♦ Burn In Test Use of this test is not recommended. and has no value as a maintenance tool. Test defined on page 5–49. Exercises the shuttle and hammer bank at maximum capacity. 4 – 76. Procedure on page 6–20.01 inch. creating a solid black band.75 inches in increments of 0.Customer Engineer (CE) Tests A set of printer tests is included in the configuration menu structure for use as maintenance tools. Procedure on page 6–32. ♦ 5–48 Troubleshooting . This test is used by the manufacturer to burn in the printer prior to shipment. Use this value as your starting point when adjusting hammer phasing. The error log automatically records certain unit check conditions in a buffer in NVRAM that stores up to 50 messages. End of Forms Adjust A vertical comb pattern used to determine the number of dot rows from the completion of a paper out fault to the end of the paper. the oldest messages are deleted. If more than 50 messages occur before the log is cleared. Hammer Phasing A hammer timing parameter that permits you to adjust the vertical alignment of dots in character printing.Power Supply board Hammer bank cover Hammer springs Hammer coils (the shuttle frame assembly) ♦ ♦ Shuttle Only This test runs only the shuttle. The numerical units are relative. next to the motor housing. the oldest message at the bottom of the list. The unit of measurement is dot rows. Shuttle Fast Verifies proper operation by exercising the shuttle and ribbon mechanisms at high speed. Shuttle Slow Verifies proper operation by exercising the shuttle and ribbon mechanisms at low speed. You can also use this test to check ribbon tracking and reversing. Troubleshooting 5–49 . The most recent message is stored at the top of the list. The number of dot rows may be adjusted up or down 1/2” from the factory default of 40 dots. they do not represent a physical measurement or value. You can also use this test to check ribbon tracking and reversing. ♦ ♦ ♦ Hammer Phase Value: The hammer phase value is a timing parameter that permits you to adjust the vertical alignment of dots in character printing. There is no “correct” value or range. The factory prints the initial phase value on the aluminum casting of the shuttle assembly. Clear Error Log: This menu selection enables you to delete the stored contents of the error log. End of Forms Adjustment Value: This parameter determines where on the paper the printer will stop printing when an out of paper fault is detected. so that the log never contains more than 50 messages. 4. press the Enter key. NOTE: See Chapter 6 for special instructions in the use of the Hammer Phasing and End of Forms Adjust tests. See page 6–32. This procedure applies only to 6400–005. –05P.” To view the different mechanism tests. The printer must be in NOT READY state to access the CE Tests. The selected test begins. exit the menu. See page 6–33. and –014 printers. Top Exit Tear Distance: This parameter allows adjustment in 0. and –05P printers. The first menu item is “PRINTER MECHANISM TESTS.01 inch increments of the final location of page perforations when top paper exit is used. and put the printer in the NOT READY state. Selecting and Running CE Tests 1. 7. DISABLE holds the line in the buffer. (Press all four keys at the same time. Set Coil Temperature: An automatic sequence in printer software that recalibrates hammer coil temperature. –005. Press Scroll" + Scroll# + Return + Enter. 6. ENABLE permits the line to be printed after a timeout. Shuttle Speed: Sets shuttle speed in 6400–004. 5. Press Enter. 2. —OR— 5–50 Troubleshooting . –04P. If the Ready indicator is on. Scroll to the desired test by using the Scroll" or Scroll# key. To end the test. press Enter. Press Scroll" + Scroll# to unlock the Enter key.) 3.Print Partial Line: If the final line of a data stream has no line feed or carriage return character it is retained in the buffer. press the Stop key. Press Stop to halt any test. The boot diagnostic menu structure is depicted in Figure 5–2. Exiting the Boot Diagnostic Menu 1.8. These menus are not intended for the end user. release the Eject/Restore and Stop keys. but provide useful information for manufacturing and maintenance personnel. Boot Diagnostics Menu Printer boot-up software contains a menu structure that you can access by holding down the Eject/Restore and Stop keys while powering up the printer. Wait 15 seconds. 5. Press and hold down the Eject/Restore and Stop keys. Power on the printer. exit the menu. Power off the printer. Press Start to halt any test. Set the printer power switch to O (off). 2. While holding the Eject/Restore and Stop keys. 4. When “BOOT DIAGNOSTICS / PRESS ENTER” appears on the LCD. and put the printer in the READY state. Activating the Boot Diagnostic Menu 1. To exit the hidden diagnostic menu. 3. Troubleshooting 5–51 . 2. set the printer power switch to 1 (on). 3. Press the Enter key. Menu options are shown in Figure 5–2. you must recycle power. cycle power.00H 07Sep95 #154643 ENTER VX VERSION=F MECA VERSION=F VERSION CHECK P. BOARD VERSION 3. Boot Diagnostics Menu 5–52 Troubleshooting .C.BOOT DIAGNOSTICS PRESS ENTER B = Scroll ↓ NOTE: To exit this menu.0 ENTER SECURITY PART # 154143–001 ENTER PROCESSOR SPEED 68E030 AT 25 MHZ BOOT DIAGNOSTICS FILE UTILITIES B " ENTER FILE UTILITIES VIEW FILES B Continued on Next Page FILE UTILITIES FILE SYSTEM STATUS B FILE UTILITIES OPTIMIZE FILES ENTER VIEW FILES VERSION ENTER B VIEW FILES FILENAME ENTER OPTIMIZING FLASH FILES FLASHDISK STATUS FREE = 0012473 B FLASHDISK STATUS #ERASES = 000073 B FLASHDISK STATUS # OF FILES = 000 B FLASHDISK STATUS USED = 0002048 B FLASHDISK STATUS DELETED = 0000000 Figure 5–2.C. ENTER BOOT DIAGNOSTICS VERSION CHECK B ENTER VERSION CHECK BOOT VERSION B VERSION CHECK SOFTWARE VERSION B VERSION CHECK EC VERSION B VERSION CHECK ASIC VERSIONS B ENTER BOOT/CMX V10B 12Sep95 #158945 09/08/95 11:41:08 ENTER ENTER EC V1. BOARD VERSION B VERSION CHECK SECURITY PART # B VERSION CHECK PROCESSOR SPEED ENTER P. .4K ENTER WAITING DOWNLOAD PORT=RS422–115K ENTER WAITING DOWNLOAD PORT=DATAPRODUCT Figure 5–2.2K ENTER WAITING DOWNLOAD PORT=RS422–38.2K ENTER WAITING DOWNLOAD PORT=RS232–38.4K B SELECT DOWNLOAD PORT=RS232–115K B ENTER WAITING DOWNLOAD PORT=CENTRONIC ENTER WAITING DOWNLOAD PORT=RS232–9600 ENTER WAITING DOWNLOAD PORT=RS232–19. cycle power. SELECT DOWNLOAD PORT=CENTRONIC B SELECT DOWNLOAD PORT=RS232–9600 B SELECT DOWNLOAD PORT=RS232–19.2K B SELECT DOWNLOAD PORT=RS232–38..4K B SELECT DOWNLOAD PORT=RS422–115K B SELECT DOWNLOAD PORT=DATAPRODUCT ENTER WAITING DOWNLOAD PORT=RS422–9600 ENTER WAITING DOWNLOAD PORT=RS422–19. Boot Diagnostics Menu (continued) Troubleshooting 5–53 . PLEASE WAIT ENTER LOADING PROGRAM INTO FLASH ENTER LOADING PROGRAM INTO FLASH MISC UTILITIES ERASE ALL FLASH B MISC UTILITIES RUN MEMORY TESTS B MISC UTILITIES FILE DOWNLOAD B MISC UTILITIES CLEAR NVRAM ENTER ERASE ALL FLASH COMPLETED ENTER TESTING FOR ADDRESS SHORTS ENTER ENTER CLEAR NVRAM COMPLETED NOTE: You must cycle power to exit the file download menu. From Previous Page ENTER MISC UTILITIES DISPLAY MEMORY B MISC UTILITIES RESET PRINTER B MISC UTILITIES COPY FLASH SIMMS B MISC UTILITIES COPY BOOT SIMMS B ENTER FLASH = 2 MBYTES DRAM = 2 MBYTES ENTER RESETTING.BOOT DIAGNOSTICS MISC UTILITIES B = Scroll ↓ NOTE: To exit this menu.4K ENTER WAITING DOWNLOAD PORT=RS232–115K SELECT DOWNLOAD PORT=RS422–9600 B SELECT DOWNLOAD PORT=RS422–19.2K B SELECT DOWNLOAD PORT=RS422–38. Hex Code Printout A hex code printout (“hex dump”) prints every ASCII character received from the host computer with its corresponding two-digit hexadecimal code. In a hex dump. 3. Press: Enter HEX PRINT MODE DISABLE* Moves down to Disable. A character that does not have a printed symbol (for example. the active option. Press: Scroll UNTIL PRINTER CONTROL HEX PRINT MODE 6. 2.) and the hex value of the control character. every character is printed as its assigned ASCII symbol and as the hexadecimal value of the character. Unlocking the Enter key allows you to test the printer. Press: Enter PRINTER CONTROL INTERFACE SELECTION Moves down to the Interface Selection option. the letter p before a hex code indicates an active Paper Instruction (PI) line and a blank space before a hex code indicates an inactive PI line. First of the series of configuration menus. Step 1. 5–54 Troubleshooting . Hex dumps can be used to troubleshoot printer data reception problems by comparing the printed hex data to the data sent from the host. or vice-versa. If the printer is using a parallel interface. Press: Scroll + Scroll OPERATOR MENU UNLOCKED Press both keys at the same time. To convert an ASCII character to its corresponding hex code. 5. a control character) is printed as a period (. Press: Menu OPERATOR MENU PRINTER CONTROL 4. Moves down to the Hex Print Mode option. refer to the ASCII code chart on page 5–56. Press: Key Stop Displayed Result NOT READY Notes Places the printer in Not Ready mode. Press: Stop NOT READY 10. the alternate option. 11.Step 7. Returns the printer to Not Ready mode. Press: Scroll + Scroll OPERATOR MENU LOCKED Press both keys at the same time to relock the Enter key. 8. 9. Press: Enter HEX PRINT MODE ENABLE* Asterisk (*) indicates this choice is now active. Troubleshooting 5–55 . Press: Key Scroll Displayed Result HEX PRINT MODE ENABLE Notes Moves down to Enable. Press: Start READY Puts the printer in READY mode. – . < = > ? 60 48 30 61 49 31 62 50 32 63 51 33 64 52 34 65 53 35 66 54 36 67 55 37 70 56 38 71 57 39 72 58 3A 73 59 3B 74 60 3C 75 61 3D 76 62 3E 77 63 3F 4 @ A B C D E F G H I J K L M N O 100 64 40 101 65 41 102 66 42 103 67 43 104 68 44 105 69 45 106 70 46 107 71 47 110 72 48 111 73 49 112 74 4A 113 75 4B 114 76 4C 115 77 4D 116 78 4E 117 79 4F 5 P Q R S T U V W X Y Z [ \ ] ^ _ 120 80 50 121 81 51 122 82 52 123 83 53 124 84 54 125 85 55 126 86 56 127 87 57 130 88 58 131 89 59 132 90 5A 133 91 5B 134 92 5C 135 93 5D 136 94 5E 137 95 5F 6 140 96 60 7 p q r s t u v w x y z { | } 160 112 70 161 113 71 162 114 72 163 115 73 164 116 74 165 117 75 166 118 76 167 119 77 170 120 78 171 121 79 172 122 7A 173 123 7B 174 124 7C 175 125 7D 176 126 7E 177 127 7F 0 0 0 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 0 0 0 1 ! ” # $ % & ’ ( ) a b c d e f g h i j k l m n o 141 97 61 142 98 62 143 99 63 144 100 64 145 101 65 146 102 66 147 103 67 150 104 68 151 105 69 152 106 6A 153 107 6B 154 108 6C 155 109 6D 156 110 6E 157 111 6F 0 0 1 0 DC2 DC3 DC4 NAK SYN ETB CAN EM SUB ESC FS GS RS US 0 0 1 1 (XOFF) 0 1 0 0 0 1 0 1 0 1 1 0 0 1 1 1 1 0 0 0 1 0 0 1 1 0 1 0 * + 1 0 1 1 1 1 0 0 .ASCII Character Set B7 B6 0 B5 0 BITS 1 KEY B4 B3 B2 B1 1 0 1 1 ESC 33 27 1B OCTAL equivalent DECIMAL equivalent HEX equivalent ASCII Character 1 1 0 1 0 0 1 1 1 1 0 1 1 B7 B6 0 B5 0 0 0 0 0 1 1 0 0 1 BITS B4 B3 B2 B1 ROW COLUMN 0 NUL SOH STX ETX EOT ENQ ACK BEL BS HT LF VT FF CR SO SI 0 0 0 1 1 1 2 2 2 3 3 3 4 4 4 5 5 5 6 6 6 7 7 7 10 8 8 11 9 9 12 10 0A 13 11 0B 14 12 0C 15 13 0D 16 14 0E 17 15 0F 1 DLE DC1 (XON) 20 16 10 21 17 11 22 18 12 23 19 13 24 20 14 25 21 15 26 22 16 27 23 17 30 24 18 31 25 19 32 26 1A 33 27 1B 34 28 1C 35 29 1D 36 30 1E 37 31 1F 2 SP 40 32 20 41 33 21 42 34 22 43 35 23 44 36 24 45 37 25 46 38 26 47 39 27 50 40 28 51 41 29 52 42 2A 53 43 2B 54 44 2C 55 45 2D 56 46 2E 57 47 2F 3 0 1 2 3 4 5 6 7 8 9 : . / 1 1 0 1 1 1 1 0 ~ DEL 1 1 1 1 5–56 Troubleshooting . press: * = Factory Default Figure 5–3. and refer to these figures for preventive maintenance purposes. The cumulative time in hours the printer has been powered on. Printer statistics accumulate continuously. The cumulative time in hours the printer has actually been printing. The range is 0 to 30. The cumulative number of back-and-forth shuttle strokes the printer has printed during normal operation. Printer Information Menu You can view various printer statistics. Power-on Time: Printing Time: Print Strokes: 11 Inch Pages: Troubleshooting 5–57 . The range is 0 to 363.000.000 shuttle strokes.000 hours.000 pages.000.000. The range is 0 to 4. Installed Memory: Displays the amount of RAM installed in the printer in megabytes. All of the printer statistics are set to zero at the factory after burn-in testing. press: Scroll Scroll Enter Return Enter To select an option.Printer Information Menu PRINTER INFORMATION Installed Memory Power On Time Printing Time Print Strokes 11 Inch Pages To view options.000 hours. press: Start Toexit exitthe theconfiguration configurationmenus menus To and return to READY. they do not reset when you power off the printer. The cumulative number of pages the printer has printed. The range is 0 to 30. such as hours of usage. Key Power on the printer. Press: Scroll + Scroll OPERATOR MENU UNLOCKED Press both keys at the same time. Press: Enter PRINTER INFORMATION INSTALLED MEMORY Advances to Installed Memory. 2. First of the series of configuration menus. 3. Cycles through the Printer Information menus. the first of the Printer Information menus.Displaying Printer Information Step 1. 4. Puts the printer in NOT READY mode. Press: Menu OPERATOR MENU PRINTER CONTROL 5. The menu you selected displays the accumulated statistics or printer information. Unlocking the Enter key gives you access to configuration menus. Press: Stop NOT READY 5–58 Troubleshooting . 6. Press: Enter [MENU NAME] [STATISTIC/INFORMATION] 9. 7. Press: Scroll UNTIL OPERATOR MENU PRINTER INFORMATION Advances to the Printer Information menu. Press: Stop Displayed Result Notes NOT READY Places the printer in Not Ready mode. Stop when you see the name of the menu you wish to display. Press: Scroll UNTIL PRINTER INFORMATION [MENU NAME] 8. To do a hard reset: 1. “SOFT RESET” while the printer loads the power-up configuration. All diagnostic and initialization tests are bypassed and memory is simply refreshed with the power-up printer configuration.. Troubleshooting 5–59 . Hard Reset Soft Reset A soft(ware) reset clears printer memory then loads the power-up configuration into memory. 2.) It is called a soft reset because no hardware is tested. Power on the printer. Hard Reset A hard(ware) reset runs all initialization and diagnostic routines. 3. Press the Stop key to put the printer in the NOT READY state.. Put the printer in the NOT READY state to do a soft reset: 1. The LCD will display “STANDBY.Soft vs. 2.”. (The procedure for saving configurations is described in the Setup Guide. Wait 15 seconds. Press the Stop + Enter keys. Power off the printer. 5–60 Troubleshooting . . . . . . . . . . . . . . 6–18 Adjusting the End of Forms Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12 Platen Open Motor Pulley Alignment . . . . . . . . . . . . . . . . . . . 6–10 Platen Gap Adjustment . . . . . . . . . 6–6 Paper Drive Motor Pulley Alignment . . . . . . . . . . Paper Feed Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–32 Set Shuttle Speed . . . . 6–16 Splined Shaft Skew Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . 6–33 Adjustment Procedures 6–1 . . . . . . 6–4 Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–26 Coil Temperature Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Adjustment Procedures Chapter Contents Preparing the Printer for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 6–3 Belt. . . . . . . . . . . . . . . . . 6–8 Paper Scale Alignment . 6–2 Returning the Printer to Normal Operation . . . . . . . . . Platen Open. 6–24 Loading Flash Memory . . . . . 6–20 Hammer Phasing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14 Ribbon Guide Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. Read the entire adjustment procedure before you begin working on the printer. 8. Unplug the printer power cord from the AC power source. To prepare the printer for maintenance. 3. you will be instructed to do so in the maintenance procedure. 6–2 Adjustment Procedures .Preparing the Printer for Maintenance DANGER <1> Always disconnect the AC power cord from the power source before performing any maintenance procedure. If you must apply power during maintenance. Disconnect the host data cable from the printer interface. Gather the necessary parts before you begin working on the printer. Power off the printer. do the following steps before making an adjustment: 1. Unload paper. Remove the ribbon. Open the printer cover. 6. 2. Failure to remove power could result in injury to persons or damage to equipment. 4. 5. Close the cabinet doors. Plug the AC power cord into the power source. 10. Set the top-of-form. Close the printer cover. Load paper. Select the emulation. 4. (Refer to the Operator’s Guide. (Refer to the Operator’s Guide. 5. Connect the host data cable to the printer interface. restore it to operation by following the steps below: 1. 6. 2. 3.) 9. Adjustment Procedures 6–3 . Test printer operation by selecting and running one of the operator print tests. Power on the printer. 7. Install the ribbon.) 8.Returning the Printer to Normal Operation When you are finished servicing the printer. 23 NSm). 4. Return the printer to normal operation (page 6–3). items 3.7 N) of pressure to the paper feed drive motor (3) near the mounting base of the motor. Pedestal Model: Remove the top cover assembly (page 7–18). Snap the timing belt cover (1) into the slots in the side plate. apply 15 pounds (66. (See page 7–73. Paper Feed Timing. 7. Figure 7–14. Cabinet Model: Install the paper guide assembly (page 7–40). Figure 7–14. Adjustment (Figure 6–1) 1. (See page 7–75. Loosen (do not remove) the motor mount bolts (2).Belt. and 5. (See page 7–75. Cabinet Model: Install the barrier shield and tighten the four screws.) 4. 5. Pedestal Model: Install the top cover assembly (page 7–18). (See page 7–73. 3. Prepare the printer for maintenance (page 6–2).03 ± 0. 4. 6–4 Adjustment Procedures .) Pedestal Model: Remove the four screws securing the paper guide and barrier shield. and 5. Using the straight end of a force gauge. items 3 and 4. Cabinet Model: Loosen four screws and remove the barrier shield. Figure 7–13. 6. 11.4 N) and torque the paper feed motor mount bolts (2) to 18 ± 2 inch-pounds (2. 2. Use the splined shaft (4) to steady the gauge. items 3 and 4.) 10. 8. Remove the paper guide and barrier shield. Remove the timing belt cover (1) by squeezing the front and back to release the plastic tabs from the slots in the side plate. 9. Cabinet Model: Remove the paper guide assembly (page 7–40). Reduce tension to 12 pounds (53.) Pedestal Model: Install the paper guide and barrier shield and tighten the four screws. Figure 7–13. items 3. Paper Feed Timing Belt Adjustment Adjustment Procedures 6–5 .4 Direction of Force 5 3 1 2 2 1. 2. 3. 4. 5. Timing Belt Shield Motor Mount Bolt (2) Paper Feed Drive Motor Splined Shaft Paper Feed Timing Belt Figure 6–1. Return the printer to normal operation (page 6–3). and poor print quality. Platen Open. pushing away from the large platen pulley. WARNING <6> Too much tension on the platen open belt can cause the platen gap to change. Prepare the printer for maintenance (page 6–2). Cabinet Model: Remove the paper guide assembly (page 7–40). Remove the platen open belt cover (1) by squeezing the top and bottom to release the plastic tabs from the slots in the side plate. Close the forms thickness lever all the way. 3. Reduce tension to 5 ± 1 pounds (22.24 ± 4. which can lead to premature wear of the platen. 9. 6–6 Adjustment Procedures .48 ± 4.45 N) and tighten the motor mount screws (2). Pedestal Model: Install the top cover assembly (page 7–18). Using a force gauge.45 N) of tension to the shank of the platen drive pulley (3). damaged hammer tips. Loosen the motor mount screws (2). 10. apply 10 ± 1 pounds (44. Cabinet Model: Install the paper guide assembly (page 7–40). 5. 7.Belt. Pedestal Model: Remove the top cover assembly (page 7–18). Adjustment (Figure 6–2) 1. 2. 8. 4. Snap the platen open belt cover (1) into the slots in the side plate. 6. Motor Mount Screw 3. Platen Open Motor Shaft 2 Direction of Force 1 3 2 Figure 6–2.1. Belt Cover 2. Platen Open Belt Adjustment Adjustment Procedures 6–7 . 5. 8. 6.Paper Drive Motor Pulley Alignment (Figure 6–3) 1. Hold the collar (3) flush against the motor pulley (4) and tighten the screw (2). 7. 3. Align the paper drive motor pulley (4) with the splined shaft pulley (5). Adjust if necessary. Check for correct tension on the paper feed timing belt (page 6–4). 6–8 Adjustment Procedures . Cabinet Model: Install the paper guide assembly (page 7–40).016 mm) of clearance between the collar (3) and the motor face plate. Pedestal Model: Remove the top cover assembly (page 7–18). WARNING <7> Make sure there is at least 0.040 inches (1. Pedestal Model: Install the top cover assembly (page 7–18). Cabinet Model: Remove the paper guide assembly (page 7–40). 2. Prepare the printer for maintenance (page 6–2). Snap the timing belt cover (1) into the slots in the side plate. 10. Loosen the screw (2) in the motor pulley collar (3). Return the printer to normal operation (page 6–3). 9. Remove the timing belt cover (1) by squeezing the front and back to release the plastic tabs from the slots in the side plate. 4. 3. Belt Shield Cap Screw Motor Pulley Collar Motor Pulley Splined Shaft Pulley Figure 6–3.5 2 4 1 3 1. 4. Paper Drive Motor Pulley Alignment Adjustment Procedures 6–9 . 5. 2. loosen the three button-head 5/64 inch hex screws (2). 9. 2. 6. 10. Set the printer power switch to 1 (on). Check alignment of the scale to the print at column positions 1 and 136. If adjustment is necessary. Connect the power cord to the AC power source. 8. Print a full 136 column line by selecting and running one of the diagnostic self-tests. 11. 4. Tighten the 5/64 inch button-head screws (2). (See Chapter 4. 5. Open the printer cover. Close the printer cover. Load paper and ribbon.) 7. Position the scale (3) so that column positions 1 and 136 line up with the first and last characters on the 136 character printout. Verify that the shuttle cover (1) is properly installed (page 7–17). 3.Paper Scale Alignment (Figure 6–4) 1. 6–10 Adjustment Procedures . Paper Scale Figure 6–4. Shuttle Cover 2. Screw. Button-Head.2 3 2 2 1 1. 5/64 inch hex 3. Paper Scale Alignment Adjustment Procedures 6–11 . Readjust if necessary. If the feel is too tight when the platen is being closed. Damage to the hammer tips will result. Raise the forms thickness lever (1) to the fully open position.28 mm) flat feeler gauge (2) straight down between the hammer bank cover plate (3) and ribbon mask (4). 6. check the gap again at both ends. Prepare the printer for maintenance (page 6–2). 2. Install the shuttle cover assembly (page 7–17). Gently close the forms thickness lever (1). Adjustment sensitivity is approximately 0. the feeler gauge should contact both the tips and the ribbon mask and move with light friction. 5. If the feel is too loose. Loosen the platen open belt (page 6–6. With the forms thickness lever closed all the way. 3. Repeat steps 4 through 6 at the right end of the hammer bank. When the platen gap is correct at both ends of the platen. insert the feeler gauge no more than 2 inches down from the top of the ribbon mask. 8. 10. within four hammer positions of the left end of the hammer bank. Also. adjust the platen open belt (page 6–6). Shift the gauge slightly to verify. keeping it between the hammer tip and ribbon mask. Remove the shuttle cover assembly (page 7–17). After adjusting both sides. 1. 7. then check the other side. gently slide the feeler gauge up and down. WARNING <8> Do not force the platen against the feeler gauge. 4. As the platen is closing. CAUTION <2> Adjust the platen set screws less than 1/4 turn on one side. 9.011 inch (0. steps 3 and 4).03 inch per revolution of the set screw. Insert a 0.Platen Gap Adjustment (Figure 6–5) IMPORTANT Only do this procedure if the original equipment shuttle frame assembly or platen has been replaced by a new or refurbished unit. 6–12 Adjustment Procedures . adjust the set screw clockwise. adjust the 3/32 inch set screw (5) at the end of the platen counterclockwise. Forms Thickness Lever Feeler Gauge (0.28 mm) Hammer Bank Cover Plate Ribbon Mask Set Screw.11. 12. 2. 4. 3. Return the printer to normal operation (page 6–3). 1. 3 4 2 Figure 6–5. 5. Right side is the same. Check the hammer phasing adjustment (page 6–24). Platen Gap Adjustment Adjustment Procedures 6–13 . 3/32 inch hex (2) 1 5 NOTE: Left side adjustment shown.011 inch or 0. Check the platen open belt tension (page 6–6).23 NSm). Pedestal Model: Remove the top cover assembly (page 7–18). 2. 7.Platen Open Motor Pulley Alignment (Figure 6–6) 1. Pedestal Model: Install the top cover assembly (page 7–18). Prepare the printer for maintenance (page 6–2). Remove the platen open belt cover (1) by squeezing the top and bottom to release the plastic tabs from the slots in the side plate. Cabinet Model: Go to step 9. 5. 8. 9. Cabinet Model: Go to step 3. 6–14 Adjustment Procedures .02 ± 0. Return the printer to normal operation (page 6–3). Adjust if necessary. Bottom out the platen open motor pulley (3) on the motor shaft and torque the 1/16 inch set screw (2) to 9 ± 2 inch-pounds (1. Loosen the 1/16 inch set screw (2) in the motor pulley. Snap the platen open belt cover (1) into the slots in the side plate. 4. 6. 3. Platen Open Motor Pulley Alignment Adjustment Procedures 6–15 . 2. 3. Belt Cover Set Screw Platen Open Motor Pulley Platen Shaft Pulley 2 1 3 4 Figure 6–6.1. 4. 8. but remains in place once moved. 6–16 Adjustment Procedures . To adjust the left ribbon guide. Tighten the screws (5). If the ribbon is not centered. momentarily short between the left ribbon guide skid screws (2) to assure right to left motion of the ribbon. 2. 9. the ribbon should have a full spool on the right hub (1). 3. 4. Repeat steps 3 through 9 for the right ribbon guide (7). Rotate the ribbon guide (4) as necessary to center the ribbon (3).Preliminary 2 Ribbon Guide Alignment (Figure 6–7) 1. To adjust the left ribbon guide. Open the printer cover. 10. loosen the retaining screws (5) just enough so that the ribbon guide (4) can be rotated to new positions. Observe how the ribbon (3) is winding on the left spool (6). Observe how the ribbon (3) is passing around the left ribbon guide (4). 6. Allow most of the ribbon to accumulate on the left spool (6). make sure the ribbon hub and spool are mounted correctly. 5. Load paper and install the ribbon. If the ribbon is interfering with the flange of the spool. Check ribbon tracking by running the PRINTER MECHANISM TESTS : Shuttle Slow (page 5–74). It should be centered and not folding against either of the two white nylon washers. 7. Left Ribbon Guide Skid (2) Ribbon Ribbon Guide. Right Hub Screw. 7. Retaining (2) Left Ribbon Spool Ribbon Guide. 2. Left Screw. 5. 3. 4.6 1 2 4 3 7 5 3 1. 6. Ribbon Guide Alignment Adjustment Procedures 6–17 . Right Figure 6–7. Loosen the screw (1) securing the adjusting link (2). 2. Adjust the link (2) by raising or lowering the horizontal adjustment knob (3) to obtain print parallel with paper perforations. 6–18 Adjustment Procedures . Tighten the screw (1). Return the printer to normal operation (page 6–3). 1. perform the following adjustment.Splined Shaft Skew Adjustment (Figure 6–8) If lines of print are not parallel with the edge perforations on the paper. 4. 3. Open the printer cover. Horizontal Adjustment Knob Figure 6–8. Screw 2.1 3 2 1. Adjusting Link 3. Splined Shaft Skew Adjustment Adjustment Procedures 6–19 . 6–20 Adjustment Procedures . 3. 1. Make sure the forms thickness lever is closed. but allows printing to the right of the hole (which would normally be on the platen). it is advisable to test the End of Forms distance with 6-part paper. (See Figure 6–9. NOTE: Do this procedure only if a new paper detector switch assembly has been installed. 2. The procedure below describes how to run the END OF FORMS ADJUST printer test and modify the END OF FORMS ADJUSTMENT VALUE. This adjustment prevents printing on the platen when the printer runs out of paper. Power on the printer. The measurement units are dot rows. in order to verify correct printing with multi-part forms. tear a four-inch square on the left side. Also. or if you are sure that the end of forms adjustment is incorrect. An END OF FORMS triggering distance of 1 or 2 dot rows from the perforation is acceptable.) This creates a hole that will trigger an END OF FORMS condition. On the sheet of paper just below the paper entrance slot. although it is not required. Open the cabinet front door. You will use the dot row patterns printed by the END OF FORMS ADJUST self-test to verify that this parameter is set correctly. immediately below the perforation.Adjusting the End of Forms Distance This procedure tests and sets the distance from the page perforation at which an END OF FORMS fault message is triggered. Load paper and set the top of form. 5 to 7 dot rows off indicates adjustment is required. Cut out here Page Perforation Figure 6–9.Page Perforation Page Perforation 4 in. Paper Preparation for Paper Out Adjustment Test Adjustment Procedures 6–21 . 4 in. If the alarm sounds. until you have made 3 or 4 holes. An enlarged example of the comb pattern is shown below. and skip to step 22. or the number of dot rows that printed beyond the perforation. press Stop to silence it. Press Scroll" + Scroll# to unlock the Enter key. 1 or 2 dot rows off is OK. Press Scroll" + Scroll# + Return + Enter to enter the CE Tests menu. 12. Short Bar Long Bar 10.) Unless you wish to restart the procedure with 6-part paper. Remove the paper from the tractors and examine the area of the page perforation. so each long bar increases 6–22 Adjustment Procedures . The display will show “SERVICE / PRINTER MECHANISM TESTS”. Press Enter to enter the mechanism tests menu. NOTE: You can use the long bars to count the dot rows quickly. The comb pattern will print until the display shows “001 END OF FORMS / LOAD FORMS” and (if enabled) the audible alarm sounds. you may stop the test here. each long bar separated by three shorter bars.) If the comb pattern stopped short of the perforation or printed beyond the perforation.) If a bar from the comb pattern just meets the perforation. 5 to 7 dot rows off is too much. Measure how short or long the comb pattern printed by counting the number of dot rows needed to reach the perforation. the end of forms adjustment distance is correct. press Stop to put it into NOT READY mode. (Press all four keys at the same time. the first menu item. go to step 12. 9. (If the alarm sounds when you open the platen. There are three dot rows between each long bar. This test will print a vertical “comb” pattern at around column 70. 11. 5. (See the note at the beginning of this procedure. Tear a four inch square in the manner described above. 7.) 8. press Stop to silence it. on every third sheet.4. (A bar exactly on perforation is ideal. If the printer is in READY mode. Press Enter until the END OF FORMS ADJUST test starts. 6. Press Scroll" or Scroll# until “PRINTER MECHANISM TESTS / END OF FORMS ADJUST” is on the display. adjust the XX DOTS value up or down by the number of dots you counted in step 12. 13. and set the top of form. You can also tear off a small piece of the comb pattern from the beginning of the pattern and use it as a ruler to help you measure the dot rows required either to reach the perforation or back up to it. If the comb pattern printed beyond the perforation. The display will show “SERVICE / PRINTER MECHANISM TESTS.) 20. Press Scroll" + Scroll# + Return + Enter to enter the CE Tests menu. (If the comb pattern stopped short of the perforation. (Return to step 7.) 22. The number of dots will move up to the top line of the display. reload the paper. Reload the paper and set the top of form. decrease the number of dots. Press Enter. feed it past any remaining unused holes that you tore in it. 21.” the first menu item. 24.the number of dot rows by four. 23. Press Enter to select the new number of dots as the active value. Press Scroll" or Scroll# until “SERVICE / END OF FORMS ADJUSTMENT VALUE” is on the display. Adjustment Procedures 6–23 . Run the END OF FORMS ADJUST and the END OF FORMS ADJUSTMENT VALUE tests until the comb pattern prints at an acceptable distance from the page perforation. Press Start to put the printer into READY mode. Press Stop to put the printer into NOT READY mode. 18. When the End of Forms Adjustment is acceptable.) 15. Press Scroll" + Scroll# to lock the Enter key. (Press all four keys at the same time. 14. increase the number of dots.) 19. The top line of the display will show “END OF FORMS ADJUSTMENT VALUE” and the bottom line will show the current setting for the number of dots. Press Enter. 16. 17. Using the Scroll" or Scroll# key. (The asterisk that appears tells you that it is now the active value. If the value is changed when not printing. the printer will return to its default phasing value when powered off then back on. The display will show “SERVICE / PRINTER MECHANISM TESTS”. Press Scroll" + Scroll# + Return + Enter to enter the CE Tests menu. The printer begins printing all Hs.Hammer Phasing Adjustment You must check and adjust hammer phasing if the CMX controller board is replaced. 6. Phasing should be adjusted with the printer printing at full paper width. IMPORTANT The printer must be printing the Phase pattern of “H’s” when the Phasing Value is changed. 9. Power on the printer.) 7. the first menu item. 8. The phase value numerical units are relative. 1. Load full width (136 column) paper and set the top of form. The display will show “SERVICE / PRINTER MECHANISM TESTS”. 6–24 Adjustment Procedures . 3. 10. Adjust the phasing to this value and recheck the horizontal alignment. 2. 4. Press Enter to enter the mechanism tests menu. or if the MPU is replaced. or the New Phasing Value will not be written into NVRAM. The factory prints the initial phase value on the aluminum casting of the shuttle assembly. (Press all four keys at the same time. The hammer phase value is a timing parameter that permits you to adjust the horizontal alignment of dots in character printing. each line preceded by the phasing index number. Press Enter. Install the ribbon. they do not represent a physical measurement or value. next to the motor housing. Press Stop to put the printer into NOT READY mode. the shuttle frame assembly is removed. 5. Press Return. write the new phasing value on the shuttle. When alignment is acceptable. Press Scroll" + Scroll# to unlock the Enter key. Press Scroll" or Scroll# until “PRINTER MECHANISM TESTS / HAMMER PHASING” is on the display. Thus there is no “correct” value or range. Press Scroll" or Scroll# until “SERVICE / HAMMER PHASE VALUE” is on the display. 17. press Stop. When the print pattern is acceptable. Press Enter. Adjustment Procedures 6–25 .11. 12. The display shows “NOT READY”. The top line of the display will show “HAMMER PHASE VALUE” and the bottom line will show the current phasing index number. Close the printer cover. remove the shuttle cover. 16. Printing stops. Press Scroll" or Scroll# to increase or decrease the phasing index. 14. Continue to increase or decrease the phasing index until the pattern of Hs appears as shown below: Needs Adjustment Correct Needs Adjustment 15. NOTE: If you changed the phasing value. Press Scroll" + Scroll# to lock the Enter key. and write the new phase value on the aluminum shuttle casting. Press Start to put the printer into READY mode. then press Enter to activate the value as it prints. power down the printer. 13. and the printer automatically enters the current phase index value into NVRAM. The phasing index (followed by an asterisk) will move up to the top line of the display. Press Enter. power the printer off and unplug the power cable. Set the printer power switch to O (off). The download commands are different if you use these ports. Unplug the AC power cord from the printer. NOTE: You can connect the data cable to the LPT2 port if the LPT1 port is already in use.) (Installing new software erases all saved configurations. skip to step 8. Connect the parallel data cable to the default parallel port (LPT1) of an IBM or IBM-compatible personal computer using the PC-DOS or MS-DOS operating system. You can also download software through the printer serial port. 6–26 Adjustment Procedures . Plug the AC power cord into the printer. but you will install software in the following situations: ♦ ♦ ♦ ♦ The customer needs to upgrade printer software The customer needs different emulation software You have replaced the controller board You have added or replaced a flash memory SIMM Emulation and operating system software are stored as a compressed file. Make a printout of all saved configurations. 1. 6. (Refer to the Setup Guide. The file is “executable. Connect the parallel data cable to the parallel port of the printer. 4.Loading Flash Memory Emulation and operating system software are loaded into flash memory at the factory. as described in the note after step 18. If the printer’s parallel data cable is connected to the parallel port of an IBM or IBM-compatible computer using the PC-DOS* or MS-DOS** operating system.) 2. 3. You will use the printouts to restore printer configuration. If not. 7. 8. Disconnect all data input cables from the printer interface. 5. DANGER <2> To prevent serious personal injury from electrical shock when connecting or disconnecting the signal cable. go to step 5.” you will expand it and copy it into printer flash memory with a single command. When the printer download port you want to use is displayed on the LCD.2K (RS–422 serial. 13.EXE extension. If you want to use the default. “WAITING DOWNLOAD / PORT = <your selection>” appears on the display. Get the name of the compressed file on the diskette by listing the contents of the diskette. 14. 38400 baud) RS232–115K (RS–232 serial. 19200 baud) RS232–38.4K (RS–422 serial. Press Scroll" again to cycle through the download ports available in the printer: DATAPRODUCT (parallel) CENTRONICS* (parallel) (default port) RS232–9600 (RS–232 serial. Adjustment Procedures 6–27 . 9600 baud) RS422–19. Power on the personal computer. this is the standard download through the parallel port. 15. NOTE: The port default is CENTRONICS. 19200 baud) RS422–38. 115000 baud) 17. 16.9. Make the diskette drive the active drive by typing the following at the DOS prompt: A:<return> (If the diskette is in drive B. power the printer on. On the printer control panel. continue at step 18. 11.2K (RS–232 serial. 9600 baud) RS232–19. Press the Scroll" key. 10. Continue holding the Start and Cancel keys down. release the Start and Cancel keys. at the DOS prompt type: DIR<return> The compressed file on the diskette takes the form FILENAME. Without releasing the keys. press ENTER. press and hold down the Start + Cancel keys. type B:<return>) 12. Insert the emulation or upgrade diskette into diskette drive A (or B) of the personal computer. “SELECT DOWNLOAD PORT=DATAPRODUCT” appears on the LCD.EXE Write down the complete name of the file with the . When you see “WAITING FOR PROGRAM DOWNLOAD” on the LCD. 38400 baud) RS422–115K (RS–422 serial. 115000 baud) RS422–9600 (RS–422 serial.4K (RS–232 serial. Remove the diskette from the personal computer and store it with the printer. While the file is copied into memory. reconfigure the printer. 23.) 20. 21. Return the printer to normal operation (page 6–3). This command expands the file and copies it as a binary file into the flash memory on the CMX controller board. enter the following DOS command: FILENAME.) 6–28 Adjustment Procedures . When the file has successfully loaded into memory and the printer has reset itself. if required. Using the configuration printout(s) you made in step 1. enter the following DOS commands: MODE COM1:9600. 22. 27.EXE –pb 2 <Return> If you are downloading the file into the printer serial port. 26. NOTE: If you are downloading the file using the LPT2 port on the PC. At the DOS prompt on the computer type: FILENAME.P<Return> FILENAME. (See Table 6–1.18. Power off the personal computer. 25.8.EXE –pb<return> where FILENAME. If you had to install a parallel data cable to the computer and printer in step 6. 24. Unplug the AC power cord from the printer. the printer LCD informs you of the load process and status. set the printer power switch to O (off). Reconnect the customer’s data input cable(s) to the printer. (Refer to the Setup Guide.EXE is the file you noted in step 12.1.N. disconnect it from the computer and printer.EXE –PBC1<Return> 19. replace the flash memory. The printer encountered an error trying to program flash memory. Replace the DRAM. Replace the CMX controller board. If the printer is supposed to have this feature. If the message occurs again. reset the Coax/Twinax board. The old program is now being deleted from flash memory. If the message occurs again. or improperly installed Coax/Twinax board. If the message occurs again. Download the program again: Power off the printer and start over at step 13. Message CLEARING PROGRAM FROM FLASH Explanation The program successfully loaded into printer RAM and the checksum matched. If the printer is not supposed to have this feature. defective. install new emulation code without the Coax/Twinax feature. The printer passed its memory and hardware initialization tests. replace the flash memory. ERROR: EC STOPPED AT STATE XXXX ERROR: FLASH DID NOT PROGRAM Hardware fault in the engine controller. Download the program again: Power off the printer and start over at step 13. Required Action None DIAGNOSTIC PASSED ERROR: DC PROGRAM NOT VALID None Download the program again: Power off the printer and start over at step 13. Flash Memory Message Guide NOTE: A continuous IML cycle indicates coax/twinax code is being loaded into a printer with a missing. Printer cannot find the data controller program or the validation checksum is corrupt.Table 6–1. Printer cannot find the engine controller program or the validation checksum is corrupt. Adjustment Procedures 6–29 . replace the flash memory. ERROR: DRAM AT ADDRESS XXXXXXXX ERROR: EC PROGRAM NOT VALID The printer found a defective memory location. If the printer is an IBM 6400. If the printer is an IBM 6404–B01. If security PAL is present. the controller is a CBO board. ERROR: NVRAM FAILURE The non-volatile memory has failed. ERROR: SECURITY PAL NOT DETECTED 6–30 Adjustment Procedures . the controller is a CMX board. Go to step 2. ERROR: PROGRAM NOT VALID The printer does not see a program in flash memory. If the PAL is absent. If missing. Add flash memory or use a smaller emulation program. install DRAM. The security PAL is not present or has failed. ERROR: PROGRAM NEEDS MORE DRAM ERROR: PROGRAM NEEDS MORE FLASH ERROR: PROGRAM NOT COMPATIBLE The printer requires more DRAM memory in order to run the downloaded program. There is no program in printer memory. User tried to load CMX-compatible diskette in CBO-controlled printer. replace the CMX controller board. Use the correct emulation software option(s) for this model. ERROR: NO DRAM DETECTED The printer could not find any DRAM. The printer is not compatible with the downloaded program. The printer requires more flash memory in order to run the downloaded program. Check the security PAL at location U54 on the CMX controller. (Do NOT attempt to replace NVRAM. Check DRAM on CMX.Message ERROR: FLASH NOT DETECTED Explanation The printer could not find any flash memory. install the correct PAL. reseat DRAM. Replace the CMX controller board. or vice versa. Required Action Install flash memory before attempting to download this program. If present.) Add DRAM or use a smaller emulation program. If message occurs with new DRAM. replace CMX controller board.Message ERROR: SHORT AT ADDRESS XXXX Explanation Hardware failure in DRAM or CMX controller circuitry. The data were corrupted during download. . replace the flash memory. Adjustment Procedures 6–31 .) None SENDING PROGRAM TO EC PROCESSOR TABLE MISMATCH DOWNLOAD AGAIN Download the program again: Power off the printer and start over at step 13. The new program is loading into printer RAM. ERROR: WRONG CHECKSUM The printer received the complete program but the checksum did not match. The printer is loading the engine controller program into the engine controller. The printer has deleted the previous program from flash memory and is loading the new program into flash memory. Normal download initialization message. LOADING PROGRAM FROM PORT XX% LOADING PROGRAM INTO FLASH None RESETTING . EC software update in process. . None ERROR: WRITING TO FLASH Hardware or software fault in flash memory. The software running or being downloaded does not match the security PAL code. Download the program again: Power off the printer and start over at step 13. If the message occurs again. Download the program again: Power off the printer and start over at step 13. PLEASE WAIT RESTORING BOOT CODE SECURITY CODE VIOLATION None None Install the correct PAL or program. The printer finished loading the program into flash memory and is automatically resetting itself. (PAL and program must match. Required Action Replace DRAM. XX indicates how much of the program has loaded. The shuttle frame assembly must be at room temperature to do this procedure. Raise the printer cover. 5. Coil temperature is now set. 4. Press Enter. Do not do this procedure if the original CMX board or shuttle frame assembly were removed and reinstalled as part of other maintenance tasks. Do this procedure only when the original CMX controller board or shuttle frame assembly have been replaced.Preliminary 2 Coil Temperature Adjustment IMPORTANT This procedure applies only to models 6400–005. (Press all four keys at the same time. 6. 11. Press Scroll" + Scroll# to unlock the Enter key. press the Stop key.) “SERVICE / PRINTER MECHANISM TESTS” appears on the display. –05P. 3. 2. —OR— 10. Press the Scroll" or Scroll# key until “SERVICE / SET COIL TEMPERATURE” appears on the display. 8. The display tells you to “PLEASE WAIT” while the coil temperature is set by an automatic calibration sequence in printer software. 6–32 Adjustment Procedures . If the Ready indicator is on. 9. –09P. 1. When the display again reads “SERVICE / SET COIL TEMPERATURE” press Scroll" + Scroll# to lock the Enter key. Press Start to exit the menu and put the printer in the READY state. Press Scroll" + Scroll# + Return + Enter. Power off the printer and close the printer cover. and –014. The printer must be in the NOT READY state to do this procedure. Power on the printer. –009. Press Stop to exit the menu and put the printer in the NOT READY state. 7. 7. –04P. 1. Press Enter.) “SERVICE / PRINTER MECHANISM TESTS” appears on the display. 3. 5. 4. –005. When the printout is acceptable. Press Scroll" + Scroll# + Return + Enter. press the Stop key. 16. power off the printer and close the printer cover. Power off the printer. Do this procedure only when the original CMX controller board or shuttle frame assembly have been replaced. Select and run the Ripple Print printer test (page 5–45). 13. 6. 8. Raise the printer cover. “SHUTTLE SPEED / 475* ” or “SHUTTLE SPEED / 500* ” appears on the display.Set Shuttle Speed IMPORTANT This procedure applies only to models 6400–004. The asterisk [*] indicates which shuttle speed is currently active. 10. and –05P. 14. The printer must be in the NOT READY state to do this procedure. Power on the printer. go back to step 3 and set the shuttle speed to the other option. Press the Scroll" or Scroll# key until “SERVICE / SHUTTLE SPEED” appears on the display. An asterisk [*] appears next to the selection. indicating it is now the active shuttle speed. 2. 12. Press Scroll" + Scroll# to lock the Enter key. 9. Press the Enter. 11. then power on the printer to activate the new shuttle speed value. Examine the printout: if gaps or dark bars appear in the printout. Press Scroll" + Scroll# to unlock the Enter key. 15. Adjustment Procedures 6–33 . Install the ribbon and load full-width paper. Press Stop to exit the menu and put the printer in the NOT READY state. Press Scroll" until the shuttle speed you want appears on the display. (Press all four keys at the same time. Do not do this procedure if the original CMX board or shuttle frame assembly were removed and reinstalled as part of other maintenance tasks. If the Ready indicator is on. 6–34 Adjustment Procedures . . . . . . . 7–11 Circuit Board: Power Supply . . . . . . . . . . . . . . . . 7–18 Doors. . . . . . . . . . . . . . . . . . . Top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13 Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–21 Fan Assembly. . . . . . . . . . . . . . . . . . . . . . . Shuttle . . . . . . . . . 7–14 Coax/Twinax Multi-Platform Interface . Platen Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–19 Fan Assembly. 7–4 Section I: Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hammer Bank . . . . Reversing . . 7–16 Cover Assembly. . 7–28 Memory Modules and Security PAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–27 Magnetic Pick-up (MPU) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cabinet Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5 Preparing the Printer for Maintenance . . . . . . . . . . . . . . 7–17 Cover Assembly. . . . . . . . . . . . . . 7–8 Cable Connectors and Connector Shells . . . . . . . . . . . . . . . . . . . Paper Feed Timing . . . . . . . . . . . . . . . . .7 Replacement Procedures and Illustrated Parts List Chapter Contents Organization of This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cabinet. . . . . . . . . . . . . . 7–22 Hammer Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5 Belt. . . . . . 7–9 Circuit Board: Controller . . . . . . . . . . . . . 7–23 IBM Coax/Twinax Expansion Board . . . . . . . . . . . . . . . 7–15 Cover Assembly. . . . . . . . . . . . Hammer Bank / Ribbon Mask . . . . . . . . . . . . . . . . . . . 7–20 Fan Assembly. . . . . . . . . . . . . . . . Pedestal Model . . . . . . . . . . . 7–6 Belt. . . . . . . . . . . . . . . . . 7–29 Replacement Procedures and Illustrated Parts List 7–1 . . . . . . . . . . . . . . . . . . . . . . . . 7–61 Tractor (L/R) . . . . . . . . . . . . . . . . 7–32 Motor Assembly. . Platen Interlock . . . . . . . . . . . . . 7–49 Ribbon Hub . . . 7–53 Shuttle Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–36 Network Print Server . . . . . . . . . . . . . . . . . . . 7–59 Switch Assembly. . . . . . . . 7–34 Motor Assembly. . . 7–54 Spring Assembly. . . . 7–40 Paper Ironer . . . . . . . . . . . . .Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–62 7–2 Replacement Procedures and Illustrated Parts List . . . . . . Gas . . . . . . . . . . . . . . . . . . . 7–38 Operator Panel Assembly. . . . . Platen Open . . . . . . . . Terminating . . . 7–37 Operator Panel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–47 Ribbon Guide Assembly (L/R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–51 Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cabinet Model . 7–29 Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–39 Paper Guide Assembly . . . . . . . . . . . . . . . 7–58 Switch Assembly. . . Splined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41 Platen . . . 7–56 Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Support . . . . . . . . . . . 7–50 Security Module . . . . . . . . . . . . . . . . . . 7–57 Switch Assembly. . Cover Open . . . . . . . . . . . . . . . Paper Feed . . . . . . . . . . . . . . 7–42 Resistors. . . Ribbon Drive . . . . . . . . . . . . . . . . . . . . . . . . . . Pedestal Model . . . . . . . . . . . . . . . . . . . . . . . . 7–81 Figure 7–17. Inside Covers. . . . . . . . . . . . . IBM Coax/Twinax Expansion Board . . . . . . . . . . . Platen . . . . . . Pedestal Model . . . . . . . . . . 7–91 Replacement Procedures and Illustrated Parts List 7–3 . Pedestal Model . Cabinet Model . . Top Cover. Print Mechanisms and Circuit Boards . . . . . . . . . . . . . . . . . . . . Cabinet Model . . . . . . . . . . . . . . and Paper Detector Switch . . . . . 7–83 Figure 7–18. . . . . 7–73 Figure 7–14. . 7–65 Figure 7–10. . . . . . . . . . . . . . . . . . . . . . . . 7–77 Figure 7–15. . . . . . . . . . . . . . . . . . . 7–79 Figure 7–16. . 7–67 Figure 7–11. . . Card Cage Fan. Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motors. . . . . . . Pedestal Details . 7–87 Figure 7–20. . . . . . . . . . . . . 7–89 Figure 7–21. . . . . . . . . . Control Panel and Cabinet Details . . . . . . . . . . . . . Doors. . . . . . .Section II: Illustrated Parts List . . . . . 7–75 Figure 7–14a. . Card Cage Detail. . and Casters. 7–69 Figure 7–12. . . . . . . . . . . . . . . . . . . . . . . Magnetic Pickup Unit (MPU) and Extension Spring . . . . . . 7–63 Figure 7–9. . . . . . 7–85 Figure 7–19. . . . Tractor Shafts . 7–71 Figure 7–13. . . . . . . Paper Stacker and Chains . . . . . Inside Covers and Card Cage. . . . . . . . . . . . ♦ Section I: Replacement Procedures Written procedures for removing and installing components that are replaceable at the field service level of maintenance. ♦ Section II: Illustrated Parts List Drawings of all assemblies comprising the printer. 7–4 Replacement Procedures and Illustrated Parts List . Section II begins on page 7–63.Organization of This Chapter This chapter is divided into two sections. The procedures refer you to the illustrations in Section II. Section I begins on page 7–5. On the page facing each illustration is a list of the illustrated parts and their part numbers. Unplug the printer power cord from the AC power source. Power off the printer. (Hammer spring assemblies are the only replaceable components of the shuttle frame assembly. 3. Disconnect the host data cable from the printer interface. The same is true of failures traced to the hammer bank coils and electronics: you must replace the entire shuttle frame assembly. Gather the necessary parts before you begin working on the printer. Do not attempt field repair of these items. sensor. 5. Most electronic problems are corrected by replacing the circuit board. Failure to remove power could result in injury to persons or damage to equipment.Section I: Replacement Procedures IMPORTANT The components specified in this chapter are field replaceable units (FRUs). Remove the ribbon. Replace a malfunctioning electronic assembly with an operational spare. IMPORTANT DO NOT attempt field repairs of electronic components or assemblies. 8. 6. 7. or cable that causes the fault indication.) 1. 2. Read the entire adjustment procedure before you begin working on the printer. you will be instructed to do so in the maintenance procedure. FRUs must be repaired at the factory. Open the printer cover. Preparing the Printer for Maintenance DANGER <1> Always disconnect the AC power cord from the power source before performing any maintenance procedure. Unload paper. 4. Replacement Procedures and Illustrated Parts List 7–5 . It is not field repairable. If you must apply power during maintenance. Paper Feed Timing Removal 1. Remove the paper feed timing belt by sliding the paper feed motor pulley off the motor shaft and the belt off the splined shaft pulley. items 3. items 3 and 4. 3. Cabinet Model: Remove the paper guide assembly (page 7–40). Remove the paper guide and barrier shield. Remove the timing belt cover by squeezing the front and back to release the plastic tabs from the slots in the side plate (page 7–73. Loosen (do not remove) the paper feed motor mount screws (page 7–87. 2. Prepare the printer for maintenance (page 7–5). 7. Figure 7–19). (See page 7–73.Belt. 4. and 5. Pedestal Model: Remove the top cover assembly (page 7–18). 5. Figure 7–13.) Pedestal Model: Loosen the four screws securing the paper guide and barrier shield. Figure 7–14. Figure 7–13).) 4. Loosen the setscrew in the paper feed motor pulley collar. Cabinet Model: Loosen four screws and remove the barrier shield. 6. (See page 7–75. 7–6 Replacement Procedures and Illustrated Parts List . Figure 7–13. Snap the timing belt cover into the slots in the side plate (page 7–73.23 NSm).03 ± 0. Figure 7–14. 2.040 inch feeler gauge between the pulley collar and the (2. 6.7 N) of pressure to the paper feed drive motor near the mounting base of the motor. Reduce tension to 12 pounds (53. Using the straight end of a force gauge. motor body. 4. items 3. Figure 7–13). Replacement Procedures and Illustrated Parts List 7–7 . torque the 7/64 inch collar screw to 25 ± 2 inch-pounds 3. Cabinet Model: Install the paper guide assembly (page 7–40). (See page 7–75. Return the printer to normal operation (page 6–3).23 NSm). and 5. Cabinet Model: Install the barrier shield and tighten the four screws. Install the paper feed timing belt over the splined shaft pulley and the motor pulley. 5. Slide the motor pulley onto the paper feed motor shaft (page 7–87. items 3 and 4. 4.) Pedestal Model: Install the barrier shield and paper guide and tighten the four screws. Holding a 0.82 ± 0. (See page 7–73. Figure 7–19). Use the splined shaft to steady the gauge.Installation 1.4 N) and torque the paper feed motor mount bolts to 18 ± 2 inch-pounds (2.) 7. Pedestal Model: Install the top cover assembly (page 7–18). 8. apply 15 pounds (66. Using a force gauge. Reduce tension to 5 pounds (22. 6.24 N) and torque the motor mount screws to 11 ± 2 inch-pounds (1. Push the motor toward the front of the printer to loosen the platen open belt. Cabinet Model: Install the paper guide assembly (page 7–40). Slide the platen open timing belt over the platen open pulley and the motor pulley and tighten the 1/16 inch setscrew. 7. 3. Figure 7–19). Remove the platen open belt cover by squeezing the top and bottom to release the plastic tabs from the slots in the side plate (page 7–85. WARNING <6> Too much tension on the platen open belt can cause the platen gap to change. 4.48 N) of tension to the motor shaft by pushing in the direction away from the large platen pulley. Pedestal Model: Remove the top cover assembly (page 7–18). 4. Figure 7–18). Loosen (do not remove) the two motor mount screws (page 7–87. Snap the platen open belt cover into the slots in the side plate. 5. 2. 5. Cabinet Model: Remove the paper guide assembly (page 7–40). Platen Open Removal 1. Prepare the printer for maintenance (page 7–5). Slide the motor pulley onto the platen open motor shaft and tighten the pulley setscrew. apply 10 pounds (44. Remove the platen open belt by sliding the platen motor pulley off the motor shaft and the belt off the platen open pulley. Return the printer to normal operation (page 6–3). and poor print quality. Installation 1. which can lead to premature wear of the platen. Loosen the setscrew in the platen open motor pulley. 2. 7. damaged hammer tips. 3.24 ± 0.23 NSm). 7–8 Replacement Procedures and Illustrated Parts List .Belt. Pedestal Model: Install the top cover assembly (page 7–18). 6. Pull the side of the connector shell outward and gently pull the cable connector upward. Pull the side of the connector shell outward and gently push the cable connector down into the connector shell. Engage the tabs on the cable connector in the slots in the side of the connector shell. 4. (See Figure 7–1. Connect the cable connector shell to its printer connection. 3.) Installation 1. Remove the cable connector from the connector shell. Disconnect the cable connector shell containing the cable assembly that will be replaced. leave the rest in the shell.Cable Connectors and Connector Shells Some of the printer cable connectors are grouped inside connector shells. Prepare the printer for maintenance (page 7–5). Cabinet Model: Remove the paper guide assembly (page 7–40). Four-wire connectors are always grouped across from four-wire connectors in a connector shell. 3. Two-wire connectors are always grouped across from two-wire connectors in a connector shell. Disengage the lock tab(s) on the cable connector from the slots in the side of the connector shell. Removal 1. 5. Pedestal Model: Remove the top cover assembly (page 7–18). (See Figure 7–1. Replacement Procedures and Illustrated Parts List 7–9 .) 2. Press the sides of the connector shell inward to make sure all cable connector tabs are engaged in the shell slots. (Remove only the cable connector for the cable you are replacing. 4. Position the cable connector in the connector shell. Four-wire connectors are grouped across from four-wire connectors in a connector shell. NOTE: There is also a diagram of the P106 / P107 connector shells on the plastic cover over the power supply. 2. 6.) Notice that two-wire connectors are grouped across from two-wire connectors in a connector shell. The procedure below explains how to remove and install cable assemblies from any connector shell in the printer. Disassembly/Assembly 7–10 Replacement Procedures and Illustrated Parts List . P107 Connector Configuration 2 4 6 8 RRIB M PAPR M 1 3 5 7 10 12 14 16 18 20 HBF EHF RRP PLO CVO MPU 17 19 Key Tab Slot Pin 1 Housing. PIN NO. Connector Kit P/N 14H5288 9 11 13 15 MPU = Magnetic Pickup CVO = Cover Open (Switch) PLO = Platen Open (Switch) RRP = Right Ribbon Guide EHF* = Exhaust Fan (Cabinet model) HBF = Hammer Bank Fan PAPR M = Paper Feed Motor RRIB M = Right Ribbon Motor * JMP on pedestal model (a spacer) Push here to remove shell from controller board. Cabinet Model: Install the paper path (page 7–40). Key Tab POD = Paper Out Detect (Switch) PMD = Paper Motion Detect (Switch) CCF = Card Cage Fan LRP = Left Ribbon Guide PLAT M = Platen Open Motor LRIB M = Left Ribbon Motor P106 Connector Configuration 2 4 6 8 LRIB M PLAT M 1 3 5 7 10 12 LRP CCF 9 11 14 16 18 20 PMD POD 13 15 17 19 Typical 2-Wire Cable Connector Typical 4-Wire Cable Connector PIN NO. Typical PCB Connector Figure 7–1. (See also page A–12.5. Pedestal Model: Install the top cover assembly (page 7–18).) Pull the side outward just enough to release the connector lock tab from the slot in the connector shell. Cable Shell Connector. 6. Return the printer to normal operation (page 6–3). Disconnect all cable connectors from the controller board. Pedestal Model: Remove the top cover assembly (page 7–18). FLASH SIMM. but do not remove. the shuttle frame assembly. 7. the SIMM’s must be placed on the new board in the same order and location as on the original board. but do not remove. wear a properly grounded static wrist strap when handling circuit boards. Installation WARNING <9> To prevent electrostatic damage to electronic components. These will be installed on the replacement controller board. Removal 1. Make a configuration printout of all configurations.Circuit Board: Controller WARNING <9> To prevent electrostatic damage to electronic components. the shuttle frame assembly. wear a properly grounded static wrist strap when handling circuit boards. NOTE: When Flash SIMM’s are removed from one controller board and placed on another controller board. on the left side near the card cage fan. Prepare the printer for maintenance (page 7–5). 9. Slide the controller board to left until the keyway clears the screw securing the controller board to the bottom of the card cage. Loosen. Replacement Procedures and Illustrated Parts List 7–11 . The Security PAL must be installed on the replacement controller board to ensure the printer functions correctly.) 2. Figure 7–15. and any other electronic component. 3. 8.) 5. 4. (Refer to the Operator’s Guide. Remove the DRAM SIMM. the screws securing the controller shield near serial cable connector J201. and any other electronic component. Cabinet Model: Remove the paper guide assembly (page 7–40). the screw securing the controller shield to the bottom of the card cage. Remove the controller board. Loosen. and Security PAL from the controller board (page 7–29). (See page 7–79. 6. Install the DRAM SIMM. and –05P only: set shuttle speed if the original CMX board was replaced (page 6–33). Engage the screw on the bottom of the card cage in the keyway in the controller shield. Return the printer to normal operation (page 6–3). and –014 only: adjust the coil temperature if the original CMX board was replaced (page 6–32).) 7. 4. reset and save the printer configuration. Connect all cable connectors to the controller board. 12. the SIMM’s must be placed on the new board in the same order and location as on the original board. 8. –04P. –09P. (Installing flash memory from the old board onto the new board does not transfer all operating system software. –009. Cabinet Model: Install the paper guide assembly (page 7–40). Figure 7–15. Pedestal Model: Install the top cover assembly (page 7–18). 9. Position the controller board assembly in the card cage. Tighten the screw securing the controller shield to the bottom of the card cage. 6. 2. Adjust the hammer phasing (page 6–24). Adjust the end of forms distance (page 6–20). 13. Models –005. using the Interconnection diagram on page A–3 as your guide. component side up. 5. 10.Preliminary 2 NOTE: When flash SIMM’s are removed from one controller board and placed on another controller board. and Security PAL on the controller board (page 7–29). Flash Memory. –05P. 1. Slide the board to right until the serial cable connector J201 on the board lines up with the cutout in the card cage.) 3. Load flash memory (page 6–26). Using the configuration printout you made as step 1 of the removal procedure. you must reload flash memory. 7–12 Replacement Procedures and Illustrated Parts List . (See page 7–79. 11. Models –004. IMPORTANT If the original CMX board was replaced. –005. Tighten the screw securing the controller shield near serial cable connector J201. shield side down. Cabinet Model: Install the paper guide assembly (page 7–40). Remove the power supply board from the card cage. (See 7–79. 4. Do not touch components or flex the board during removal/installation. Position the power supply board over the three standoffs on the rear wall of the card cage and gently push the board until it engages fully on the standoffs. Carefully disengage the power supply board from the three standoffs on the rear wall of the card cage. Figure 7–15. 4. (See 7–79. Cabinet Model: Remove the paper guide assembly (page 7–40).) 3. Pedestal Model: Install the top cover assembly (page 7–18). wait at least one minute after shutting off power before removing the power supply board. Connect output connector P101 to the controller board and AC input connector P1 to the power supply board. Wear a properly grounded static wrist strap when handling the power supply board. 2. Prepare the printer for maintenance (page 7–5).Circuit Board: Power Supply CAUTION <3> To prevent injury from electric shock. 3.) 5. Install three screws securing the power supply board to the rear wall of the card cage. Installation 1. Figure 7–15. item 4. Handle the board by the ejection levers and the sides. Disconnect output connector P101 from the controller board and AC input connector P1 from the power supply board. 6. Loosen three captive screws securing the power supply board to the rear wall of the card cage. 5. Replacement Procedures and Illustrated Parts List 7–13 . item 4. 2. Pedestal Model: Remove the top cover assembly (page 7–18). Return the printer to normal operation (page 6–3). Removal 1. 3. page 7–89. page 7–77. (Cabinet Model: See Figure 7–20. Connect the four circuit breaker electrical leads. Press in on the spring clips and remove the circuit breaker from the printer.) 5. (Cabinet Model: See Figure 7–20. page 7–77. Press the circuit breaker into the cutout until the spring clips snap into place. 7–14 Replacement Procedures and Illustrated Parts List . Pedestal Model: See Figure 7–14a. Remove the card cage fan (page 7–21). Disconnect the four circuit breaker electrical leads. (Cabinet Model: See Figure 7–20. 4.) 3. 2. Open the printer cover.) CAUTION <4> Make sure the four leads are connected as shown on page 7–89 (Figure 7–20).Circuit Breaker Removal 1. page 7–89. 4. 2. Pedestal Model: See Figure 7–14a. Install the card cage fan (page 7–21). Prepare the printer for maintenance (page 7–5). Pedestal Model: See Figure 7–14a. Installation 1. page 7–77. page 7–89. Return the printer to normal operation (page 6–3). operation. and any other electronic component. Form Number S246–0149. Replacement Procedures and Illustrated Parts List 7–15 . 2. wear a properly grounded static wrist strap when handling circuit boards. 1. Installation 1. Refer to the Coax/Twinax Multi-Platform Interface Feature Installation and Operation Guide. Removal WARNING <9> To prevent electrostatic damage to electronic components. Form Number S246–0149. and replacement parts for this optional feature are covered in detail in the Coax/Twinax Multi-Platform Interface Feature Installation and Operation Guide. Prepare the printer for maintenance (page 6–2). the shuttle frame assembly. Refer to the Coax/Twinax Multi-Platform Interface Feature Installation and Operation Guide. Form Number S246–0149.Coax/Twinax Multi-Platform Interface NOTE: Installation. Engage the round hole first. Figure 7–15). Check that the hammer bank cover assembly is properly positioned over the alignment pins and hammer tips. Lift the thick plate of the hammer bank cover assembly at one end. Installation WARNING <5> The hammer bank contains a strong magnet. then the oblong hole. Prepare the printer for maintenance (page 7–5). to ensure that the cover lies flat on the hammer bank. page 7–79. 7–16 Replacement Procedures and Illustrated Parts List . Remove the shuttle frame assembly (page 7–54).Cover Assembly. 4. 1. do not let the hammer bank cover assembly snap into place as the hammer bank magnet attracts it. 3. Gently lower the hammer bank cover assembly until it lies flush on the hammer bank. 3. (See Figure 7–15. engage the bottom edge of the hammer bank cover assembly on the alignment pins. With the thick plate facing the hammer bank. Any impact of the cover against the hammer bank can break hammer tips. Install the shuttle frame assembly (page 7–54). 2.) 2. To prevent damage to the hammer tips. and peel the cover away from hammer bank magnets (page 7–79. Return the printer to normal operation (page 6–3). Hammer Bank / Ribbon Mask Removal 1. Figure 7–13). Tilt the forward edge of the cover down slightly and work the cover into position (page 7–73. 5. Figure 7–13). 2. Grasping the edges of the shuttle cover assembly. Place the shuttle cover assembly in the printer. Return the printer to normal operation (page 6–3). Open the printer cover. 4. tilt up the rear edge and lift the shuttle cover assembly out of the printer. Prepare the printer for maintenance (page 7–5). Remove the ribbon spools. 2. Installation 1. 3. Shuttle Removal 1. Loosen the shuttle cover screws (page 7–73. 3. Tighten the shuttle cover screws (page 7–73. NOTE: Make sure the holes in the cover are over the locating pins.Cover Assembly. Replacement Procedures and Illustrated Parts List 7–17 . Figure 7–13). page 7–71. Remove five screws and the control panel bracket. 2. (See Figure 7–12. but do not remove. 7–18 Replacement Procedures and Illustrated Parts List . Lift the top cover assembly off the printer base. Top. 3. Loosen. (See Figure 7–12. Installation To install the top cover assembly. items 3 and 4. Pedestal Model Removal 1. reverse the steps of the removal procedure. the two #2 Phillips hold-down screws on the rear of the printer. item 14. (See Figure 7–12.Cover Assembly.) 6. Prepare the printer for maintenance (page 7–5). page 7–71.) 5.) 4. Loosen the two captive #2 Phillips screws in the lower front corners of the top cover. item 8. page 7–71. Remove the operator panel (page 7–39). 8. Replacement Procedures and Illustrated Parts List 7–19 . The rear door is hinged on the right side so that it opens on the left side. 6. Remove the hinge plates and the pads beneath the plates. Open the front and rear cabinet doors. Remove the screws and wire ropes from the doors and cabinet frame. Install pads and hinge pin plates to the left rear side of the frame. page 7–65. This procedure enables you to reverse this door configuration. 11. Move the original front door to the rear of the printer. With the marked top uppermost. 5. (See Figure 7–9. Adjust the position of the hinge pin plates as necessary so the door closes squarely against the frame. Install the wire ropes to the doors and the cabinet frame. 1. Reversing NOTE: Floor cabinet printers are assembled with the front door hinged on the left side so that it opens at the right side. with the hinge pins up and toward the outside edge of the printer frame.Doors. 7. Remove the screws securing the hinge pin plates to the front and rear of the cabinet. with the hinge pins up and toward the outside edge of the printer frame. 3. 10. 12. slide the door hinges down onto the hinge pins. slide the door hinges down onto the hinge pins. Move the original rear door to the front of the printer. Cabinet. Remove two screws and the paper fence from the original rear door.) 4. Install the paper fence to the “new” rear door with the two screws. item 9. 9. Lift each door up and off the hinge pins of the upper and lower cabinet hinge plates. Install pads and hinge pin plates to the right front side of the frame. Adjust the position of the hinge pin plates as necessary so the door closes squarely against the frame. Mark the top of each door. With the marked top uppermost. 2. Do not remove the hinge plates from the doors. ) (See page 7–69. Remove the three screws securing the air exhaust duct. (See Figure 7–10. Prepare the printer for maintenance (page 7–5). Installation WARNING <23> Make sure to install the fan so that air flow is down. Disconnect the fan cable connector from connector P307 and remove the air exhaust duct. page 7–67. Position the cabinet exhaust fan assembly in the air exhaust duct so that air flow is down. Figure 7–11). 7–20 Replacement Procedures and Illustrated Parts List . Connect the cabinet exhaust fan cable connector to connector P307. (See page 7–69. 3.) 4. Remove the fan cable connector from the cutout in the side of the air exhaust duct. Figure 7–11). Return the printer to normal operation (page 6–3). 2.Fan Assembly. 6. (See Figure 7–10. Open the floor cabinet doors and the printer cover. Cabinet Exhaust Removal 1. 1. page 7–67. Remove the paper stacker. Snap the fan cable connector into the cutout in the side of the air exhaust duct. and install the two screws securing the fan to the duct. Install the paper stacker. 2. (The top screw is located near the right front of the card cage. 7. Move the air exhaust duct back into position and install the three screws. 3. in front of the square air holes in the printer base plate. 5. Remove the two fan mounting screws and the cabinet exhaust fan assembly. 5. 4.) 6. 3. Remove the card cage fan assembly from the card cage.) Pedestal Model: Remove the four fan mounting screws and nut. Cabinet Model: Remove the paper guide assembly (page 7–40). 1. page 7–77. item 2. Pedestal Model: Remove the top cover assembly (page 7–18). Replacement Procedures and Illustrated Parts List 7–21 . Pedestal Model. (See Figure 7–19. Figure 7–14a. Reverse steps 2 through 6 of the removal procedure. Installation WARNING <10> Make sure to install the fan so the label faces toward the inside of the printer. Air flow is INTO the card cage. page 7–75. Prepare the printer for maintenance (page 7–5). 2. page 7–87.) 5. 4. (See See Figure 7–14a. 2. items 1 through 4. page 7–87. Card Cage Removal 1. Remove the screw securing the shield to the card cage fan. 6.Fan Assembly. Return the printer to normal operation (page 6–3). Figure 7–19. Cabinet Model: Remove the two fan mounting screws from the bottom of the fan. Disconnect the fan cable connector: Cabinet Model. 2. 4. (See Figure 7–19. Pedestal Model: Remove the top cover assembly (page 7–18).) 6.) 3.) 5. Install two screws in the locations shown in Figure 7–15 (page 7–79). 4. (See Figure 7–19. Remove the shuttle cover assembly (page 7–17). Return the printer to normal operation (page 6–3). Hammer Bank Removal 1. (See page 7–9. connect fan cable connector (HBF) to P107. Trace the hammer bank fan cable assembly back to the controller board connector J107. (Refer to page 7–9. Prepare the printer for maintenance (page 7–5).) 2. 1.) Installation WARNING <11> Make sure to install the fan so the label faces up. 6. page 7–87. NOTE: The hammer bank fan assembly is installed by angling it down and under the shuttle motor. Feed the hammer bank fan cable connector (HBF) and motor wires between the fan well of the base casting and the base pan. releasing it from all cable constraints. Remove the two screws securing the fan to the base casting. 7–22 Replacement Procedures and Illustrated Parts List . Reach up under the base casting and route the fan cable to the right and angle the hammer bank fan assembly under the shuttle motor and down into the fan well.Fan Assembly. Angle the hammer bank fan assembly up and out of the base casting and feed the motor wires and cable connector out from between the base casting and the base pan. 3. Air flow is UP. Pedestal Model: Install the top cover assembly (page 7–18). Disconnect connector P107 from the controller board and remove the fan connector (HBF) from on the controller board. 5. Install the shuttle cover assembly (page 7–17). page 7–87. then connect P107 to J107 on the controller board. (See the cable routing diagram on page A–12. Route the fan motor wires as shown on page A–12. NOTE: Replace a hammer spring assembly only if there is visible damage or broken parts can be seen in the assembly. Replacement Procedures and Illustrated Parts List 7–23 . reinstall the old hammer spring assembly and replace the shuttle frame assembly (page 7–54). the hammer spring assembly mounting surface. Inspect the hammer bank and the old hammer hammer spring assembly: a. Carefully vacuum the shuttle frame assembly. Handle hammer springs by the thick mounting base only. Apply pressure only to the mounting base. Remove the hammer bank cover assembly (page 7–16). 5. 3. gently rotate the old hammer spring assembly off its mounting pins. Do not touch the hammer springs or tips. Remove the shuttle frame assembly (page 7–54).) 6. WARNING <12> Hammer springs and hammer tips are fragile. (See Figure 7–2. 4. (See Figure 7–2. Handling the hammer spring assembly by the mounting base only. b. If the old hammer spring assembly and the hammer bank are free of ink.) 7. If there is ink on the hammer bank mounting surface.Hammer Spring Assembly Removal 1. page 7–24. Remove the three screws from the old hammer spring assembly. Prepare the printer for maintenance (page 7–5). install the new hammer spring assembly (page 7–25). or the hammer spring neck or tines. 2. page 7–24. 04P.Preliminary 2 NOTE: 6400–004. 05P shuttle frame assembly shown. 005. Hammer Spring Assembly. 014 Hammer Spring Assembly 1 Discard old screws Figure 7–2. Removal 7–24 Replacement Procedures and Illustrated Parts List . Hammer Spring Assembly 7 Hammer Spring Assemblies: 14H5275 6400–004. 005. 08P. 04P. 09P 14H5513 6400–012. 05P 14H5512 6400–008. 009. Handling the hammer spring assembly by the mounting base only. Handle hammer springs by the thick mounting base only.) 4. WARNING <12> Hammer springs and hammer tips are fragile. page 7–26. Replacement Procedures and Illustrated Parts List 7–25 . 8. 6. remove the new hammer spring assembly and mounting screws from the box. Install the hammer bank cover assembly (page 7–16).Installation 1. If print quality is acceptable.) 5. torque each screw to 14 in-lbs (1. WARNING <13> Do not attempt to adjust or “tweak” hammer springs. Using a TorxT T-10 bit adapter. Install the shuttle frame assembly (page 7–54). Run a Customer Engineer Test and check print quality (page 5–50): a. wipe the hammer spring mounting surface on the hammer bank. (See Figure 7–3. return the printer to normal operation (page 6–3). replace the shuttle frame assembly (page 7–54). NOTE: Replace a hammer spring assembly only if there is visible damage or broken parts can be seen in the assembly. page 7–26.58 NSm). Using a clean dry cloth. b. Install the screws from the replacement kit. Do not touch the hammer springs or tips. Apply pressure only to the mounting base. 2. Make sure the cloth does not leave lint on the hammer bank. Install the ribbon and load paper. If print quality is still degraded. 3. Handling it by the mounting base only. (See Figure 7–3. 7. carefully rotate the new hammer spring assembly onto the hammer bank mounting pins and press it into position with the flat end of the nylon stick supplied in the hammer spring replacement kit. Hammer Spring Assemblies: 14H5275 6400–004.58 NSm). 009. Figure 7–3. 04P. 04P. 005. 05P hammer spring assemblies shown. 05P 14H5512 6400–008. Torque screws to 14 inch-pounds (1.Preliminary 2 New Hammer Spring Assembly Use new screws from the kit. 09P 14H5513 6400–012. 08P. Installation 7–26 Replacement Procedures and Illustrated Parts List . 005. Hammer Spring Assembly. 014 NOTE: 6400–004. Replacement Procedures and Illustrated Parts List 7–27 . Installation 1. Remove the expansion connector adapter from the CMX controller board by carefully lifting it straight up and out of the controller connector. Cabinet Model: Remove the paper guide assembly (page 7–40). and any other electronic component. 2. Carefully lift the expansion-CT board out of the card cage cutout and off the expansion connector adapter that attaches the CT to the CMX board. Loosen the thumbscrew on the CT board until the screw is released from the standoff on the controller board. Prepare the printer for maintenance (page 7–5). Reverse steps 2 through 5 of the removal procedure. 5. (See Figure 7–21. 2. Return the printer to normal operation (page 6–3). page 7–91. 1. 3. the shuttle frame assembly.IBM Coax/Twinax Expansion Board Removal WARNING <9> To prevent electrostatic damage to electronic components.) 4. wear a properly grounded static wrist strap when handling circuit boards. Loosen. the two screws securing the coax/twinax I/O plate to the rear of the card cage. but do not remove. Pedestal Model: Remove the top cover assembly (page 7–18). 3. 3. If the gap is 0. Adjust the hammer phasing (page 6–24. 5.025 mm). 2. Remove the shuttle cover (page 7–17). Check the gap between the MPU assembly and the flywheel with a feeler gauge: a.254 ± 0.010 ± 0. Prepare the printer for maintenance (page 7–5).001 inch (0. Figure 7–16).001 inch (0. 6. 7–28 Replacement Procedures and Illustrated Parts List .010 ± . 2.025 mm). Install the shuttle cover (page 7–17). Disconnect the magnetic pick-up (MPU) cable connector (page 7–81. If the gap is not 0.010 ± . Return the printer to normal operation (page 6–3). Installation 1. Disconnect the shuttle cable assembly connector (page 7–79. 4. loosen the MPU clamp screw and go back to step 2. Loosen the 7/64 inch hex MPU clamp screw (page 7–81. Figure 7–16).11 NSm). b. Figure 7–15). 4. Figure 7–16).025 mm). WARNING <17> Make sure the MPU cable is below the extension spring and does not touch the spring after the cable is connected. go to step 4. Torque the MPU clamp screw to 19 ± 1 inch-pounds (2. 6. Install the MPU assembly by screwing it into the MPU bracket (page 7–81. Using a feeler gauge.15 ± 0. adjust the gap between the MPU assembly and the flywheel to 0.001 inch (0. 7. 5. Unscrew the MPU assembly from the MPU bracket. Connect the magnetic pick-up (MPU) cable connector.254 ± 0. Connect the shuttle cable assembly connector (page 7–81.) 8.Magnetic Pick-up (MPU) Assembly Removal 1. Figure 7–16).254 ± 0. wear a properly grounded static wrist strap when handling circuit boards.Memory Modules and Security PAL Removal 1. the shuttle frame assembly. and remove the SIMM from the socket. page 7–31 for the locations of memory modules. (See Figure 7–4. (See Figure 7–4. NOTE: If flash SIMMs are removed from one controller board and placed on another controller board. Pedestal Model: Remove the top cover assembly (page 7–18). angle the SIMM toward the front of the printer. Make a configuration printout of all configurations. 3.) Replacement Procedures and Illustrated Parts List 7–29 . Cabinet Model: Remove the paper guide assembly (page 7–40). Using a module extraction tool. the SIMMs must be placed on the new board in the same order and location as on the original board.) 5.) 2. Prepare the printer for maintenance (page 7–5). remove the security PAL. WARNING <9> To prevent electrostatic damage to electronic components. and any other electronic component. page 7–31. Gently pry the side locks open. (Refer to the Setup Guide. 4. ) 3. and any other electronic component. Insert the memory module into the correct socket on the CMX controller board: a. gently push on the ends until it locks in the upright position. Install the security PAL.Installation WARNING <9> To prevent electrostatic damage to electronic components. Press the SIMM into the socket with the top of the SIMM angled away from the center of the board.) b. (Refer to the Setup Guide. Cabinet Model: Install the paper guide assembly (page 7–40). Return the printer to normal operation (page 6–3). page 7–31. 4.) 7–30 Replacement Procedures and Illustrated Parts List . 5. wear a properly grounded static wrist strap when handling circuit boards. 6. reset and save the printer configurations. 1. Download the emulation (page 6–26). NOTE: Flash SIMMs from one CMX controller board must be placed in the same slot on a replacement CMX controller board. the shuttle frame assembly. When the SIMM is seated in the socket. 2. (See Figure 7–4. page 7–31. Position the SIMM so the notched end is toward the right-hand side of board. Using the configuration printouts you made as step 1 of the removal procedure. Pedestal Model: Install the top cover assembly (page 7–18). (See Figure 7–4. * Security PAL. NVRAM is replaced only at the factory. Base: 14H5509 Security PAL. Bank 1 Bank 0 Bank 1 Bank 0 1 Notch Flash Memory: 80-pin SIMM J11 = Bank 0 Must always be filled J10 = Bank 1 Reserved for upgrades If 1 Flash SIMM. Graphics: 14H5490 Blank SIMM’s: 1MB Flash – 14H5539 2MB Flash – 14H5540 1MB DRAM – 14H5499 2MB DRAM – 14H5481 4MB DRAM – 14H5508 Minimum Memory Requirements Datastream ASCII IGP ASCII Code V ASCII CTA CTA IGP CTA Code V IPDS CTA IPDS CTA IGP 2 MB IPDS CTA Code V 2 MB Flash Memory 1 MB 2 MB 2 MB 1 MB 2MB 2 MB 2 MB DRAM 1 MB 3 MB 3 MB 2MB 3 MB 3 MB 6 MB 8 MB 8 MB CT Board Installed Security PAL Vendor P/N No No No Yes Yes Yes Yes Yes Yes 154143–002 154143–001 154143–001 154143–002 154143–001 154143–001 154143–002 154143–001 154143–001 Figure 7–4. Flash SIMM’s from one CMX controller must be placed in the same slots on another controller board.CMX Controller Board CAUTION: <5> Do not remove or replace the NVRAM. use Bank 0 If 2 DRAM SIMM’s. use Bank 0 If 2 Flash SIMM’s. use both banks. J11 and J16 must always be filled. The NVRAM contains a lithium battery that can explode if it is replaced incorrectly. use both banks (It does not matter which SIMM goes into which bank) 2 Latch 3 Latch IMPORTANT: No matter what combination of SIMM’s is used. Memory Modules and Security PAL Replacement Procedures and Illustrated Parts List 7–31 . but be sure to place pre-programmed SIMM’s in the marked location DRAM: 72-pin SIMM Security PAL* J16 = Bank 0 (must always be filled) 1MB SIMM standard in LP+ option J15 = Bank 1 Reserved for upgrades If 1 DRAM SIMM. page 7–75. Loosen the paper feed motor mount screws (page 7–87. Cabinet Model: Loosen four screws and remove the barrier shield. Pedestal Model: Remove the top cover assembly (page 7–18). items 3.) 8. if present).Motor Assembly. 7. (See Figure 7–13. 4. releasing it from tie wraps. Remove the paper feed motor assembly. Paper Feed Removal 1. Disconnect connector P107 from the controller board and remove the paper feed motor connector from connector P107. 2. 7–32 Replacement Procedures and Illustrated Parts List . and 5. Trace the paper feed motor cables back to the controller board. items 3. and paper feed timing belt (page 7–87. (See the cable routing diagram on page A–12. 5. page 7–73. (See page 7–9. eliminating the need for nuts. 10. Figure 7–19). Loosen the shaft collar setscrew and remove the paper feed motor pulley. Remove the motor mount bolts (and nuts. 3. Prepare the printer for maintenance (page 7–5). Cabinet Model: Remove the paper guide assembly (page 7–40). Remove the timing belt cover by squeezing the top and bottom to release the plastic tabs from the slots in the side plate (page 7–73.) Pedestal Model: Remove the four screws. the barrier shield.) 4. and the paper guide. Figure 7–19). Figure 7–13). other motors have threaded flanges. 4. and 9. 9. (See Figure 7–14.) NOTE: Some paper feed motors are mounted with nuts and bolts. shaft collar. 6. Connect the paper feed motor cable connector to connector P107. 4.016 mm) of clearance between the collar/pulley and the motor face plate. apply 12 pounds (53.0 N) and torque the motor mount screws to 18 ± 2 inch-pounds (1. 7. page 7–73. and 5. 2. 4. Using the straight end of a force gauge. (See Figure 7–14. Align the paper feed motor pulley with the splined shaft pulley. paper guide.) 3. items 3. (See page 7–9. Position the paper feed motor assembly on the right side plate and install the motor mount bolts and nuts finger tight (page 7–87. (See Figure 7–13. and 9. 4. WARNING <7> Make sure there is at least 0. Cabinet Model: Install the barrier shield and four screws.4 N) of pressure to the paper feed motor. Replacement Procedures and Illustrated Parts List 7–33 . 9. Install the collar.Installation 1.) 10.040 inches (1. page 7–75. Use the splined shaft to steady the gauge. items 3. paper feed motor pulley. Hold the collar snug against the motor pulley and torque the setscrew to 25 ± 2 inch-pounds (2. Figure 7–19).) Pedestal Model: Install the barrier shield. and timing belt. Cabinet Model: Install the paper guide assembly (page 7–40).23 NSm). then connect P107 to J107 on the controller board.23 NSm). 5. Snap the timing belt cover into the slots in the side plate. Return the printer to normal operation (page 6–3).82 ± 0. 11. 6. and four screws.36 ± 0. Reduce pressure to 9 pounds (40. 8. Pedestal Model: Install the top cover assembly (page 7–18). 7. Figure 7–18). (See cable routing diagram on page A–12. Remove the two 5/16 inch motor mount screws (and nuts.Motor Assembly. Remove the platen open belt cover by squeezing the top and bottom to release the plastic tabs from the slots in the side plate (page 7–85. 7–34 Replacement Procedures and Illustrated Parts List . 5. Cabinet Model: Remove the paper guide assembly (page 7–40). other motors have threaded flanges. Prepare the printer for maintenance (page 7–5). 2. 3. if present). 4. Pedestal Model: Remove the top cover assembly (page 7–18). releasing the cables from the tie-wraps. 10. eliminating the need for nuts. Disconnect connector P106 from the controller board. Trace the platen open motor cables back to the controller board.) 8. Loosen the 1/16 hex pulley setscrew and remove the motor pulley and platen open belt. Trace the platen open motor cables to the connector shell and remove the platen open cable connector from the connector shell (page 7–9). Loosen the two 5/16 inch motor mount screws (page 7–87. 6. Platen Open Removal 1. Cabinet Model: Remove the card cage fan (page 7–21). 9. 11. Remove the platen open motor assembly. NOTE: Some platen open motors are mounted with nuts and bolts. Figure 7–19). 11. 7. Pedestal Model: Install the top cover assembly (page 7–18). Connect the platen motor cable connector to connector shell P106. (See cable routing diagram on page A–12. 9. and poor print quality. damaged hammer tips. 4. Cabinet Model: Install the card cage fan (page 7–21). 8. apply 10 pounds (44. 5. Snap the platen open belt cover into the slots in the side plate. Bottom out the motor pulley on the motor shaft and tighten the setscrew to 9 ± 2 inch-pounds (1. reduce tension to 5 pounds (22.48 N) of tension to the platen open motor shaft by pushing away from the large platen pulley. 3. if present) finger tight. WARNING <6> Too much tension on the platen open belt can cause the platen gap to change.24 N) and torque the motor mount screws to 11 ± 2 inch-pounds (1. Figure 7–19). Install the two 5/16 inch motor mount screws (and nuts. Return the printer to normal operation (page 6–3). Close the forms thickness lever all the way. Using a force gauge.23 NSm). Replacement Procedures and Illustrated Parts List 7–35 . Install tie-wraps to secure the motor cable.24 ± 0.23 NSm). 10. Install the platen open belt and motor pulley. Position the platen open motor assembly with the wires toward the rear (page 7–87. which can lead to premature wear of the platen. 2. Cabinet Model: Install the paper guide assembly (page 7–40).Installation 1.) 6.24 ± 0. Connect shell connector P106 to J106 on the controller board. page 7–87. Remove the ribbon hub (page 7–50).) 2. 2. (See Figure 7–19. Remove two screws and washers securing the ribbon drive motor to the base casting (page 7–87. 6. Prepare the printer for maintenance (page 7–5). Return the printer to normal operation (page 6–3). 7–36 Replacement Procedures and Illustrated Parts List . Reverse steps 2 through 6 of the removal procedure above. 3. Installation 1. NOTE: The ribbon drive motor should be secured at the front right and rear left corners. Lift and rotate the ribbon drive motor until the motor cable is aligned with the slot on the base casting.Motor Assembly. Figure 7–19). Remove the ribbon. Ribbon Drive Removal 1. Disconnect the ribbon drive motor cable connector. 5. 4. 1. or the IBM Ethernet Network Print Server Administrator’s Guide. S246–0111. Prepare the printer for maintenance (page 6–2). Replacement Procedures and Illustrated Parts List 7–37 . and any other electronic component. Each guide describes error messages and troubleshooting information. wear a properly grounded static wrist strap when handling circuit boards. Also provided is a section that describes IBM service procedures. S246–0112. Installation Refer to the IBM Token-Ring Network Print Server Administrator’s Guide (S246–0112) or the IBM Ethernet Network Print Server Administrator’s Guide (S246–0111) for information on installing and testing the feature. 2. Refer to the IBM Token-Ring Network Print Server Administrator’s Guide (S246–0112) or the IBM Ethernet Network Print Server Administrator’s Guide (S246–0111) for information on determining if the print server is operating correctly. Removal WARNING <9> To prevent electrostatic damage to electronic components. the shuttle frame assembly.Network Print Server NOTE: Installation and operation of this optional feature are described in the IBM Token-Ring Network Print Server Administrator’s Guide. 3. Press down on the plastic tab at the upper rear of the panel and slide the operator panel downward on the mounting plate until the tabs on the panel housing slide out of the cutouts. Open the printer cover and tighten the panel plate screws. Position the operator panel and plate on the bracket and install the four screws finger tight. page 7–69. Position the operator panel over the cutouts in the panel plate.Operator Panel Assembly. page 7–69. 2. Slide the panel upward on the plate until it will slide no further. Cabinet Model Removal 1. Open the printer cover.) 4. (See Figure 7–11. Remove the four screws securing the operator panel plate to the panel bracket.) 2. (See Figure 7–11. Installation 1. Slowly lower the printer cover and align the operator panel in the cover cutout.) 4. Prepare the printer for maintenance (page 7–5). Return the printer to normal operation (page 6–3). 3. Lift the operator panel assembly and disconnect the phone-style cable connector. 7–38 Replacement Procedures and Illustrated Parts List . 5. (See Figure 7–11. 5. page 7–69. Connect the phone-style operator panel cable to the bottom of the operator panel. Installation 1. Tilt the operator panel toward the front of the printer. 4. 3. 3. Press down on the plastic tab at the upper rear of the panel and slide the operator panel downward on the mounting plate until the tabs on the panel housing slide out of the cutouts. Close the printer cover. Open the printer cover. Tilt the operator panel mounting plate toward the front of the printer. 5. 2.Operator Panel Assembly. Return the printer to normal operation (page 6–3). Prepare the printer for maintenance (page 7–5). 4. Pedestal Model Removal 1. Replacement Procedures and Illustrated Parts List 7–39 . Disconnect the phone-style cable connector at the rear of the operator panel. Position the operator panel over the cutouts in the mounting plate and slide the panel upward until the plastic tab at the upper rear of the panel locks into the mounting plate. Connect the phone-style operator panel cable to the bottom of the operator panel. 5. 2. item 6). Slide the paper guide assembly to the right. 2. NOTE: This procedure applies only to cabinet models. 4. you will be instructed to do so in the maintenance procedure. 7–40 Replacement Procedures and Illustrated Parts List . Figure 7–13. item 6). Figure 7–13. Installation 1. Loosen the three paper guide assembly hold-down screws (page 7–73. Position the paper guide assembly offset slightly to the left on the card cage with the keyway cutouts over the three loosened hold-down screws (page 7–73. Failure to remove power could result in injury to persons or damage to equipment. Slide the paper guide assembly to the left and lift it off the card cage. Return the printer to normal operation (page 6–3). 2. 3. Figure 7–13). 3. Prepare the printer for maintenance (page 7–5). 4. Slide the paper guide assembly to the right as far as it will go. Tighten the three hold-down screws (page 7–73. If you must apply power during maintenance. Open the printer cover.Paper Guide Assembly DANGER <1> Always disconnect the AC power cord from the power source before performing any maintenance procedure. Removal 1. engaging the three hold-down screws in the keyway slots. Replacement Procedures and Illustrated Parts List 7–41 . Push the ends of the paper ironer toward the rear of the printer. 3. Return the printer to normal operation (page 6–3). Push the paper ironer down into the slots until the tabs engage. Figure 7–18. 4.Paper Ironer CAUTION <1> Over time. Install the shuttle frame assembly (page 7–54). (See page 7–85. Removal 1. Figure 7–18). 1. the upper edge of the paper ironer can become sharp. 3. disengage the tabs.) 2. Move the forms thickness lever to the open position. Position the paper ironer so that the black tape is on the side that faces the paper detector switch assembly. Installation NOTE: The black tape on the paper ironer faces the paper detector switch assembly. Remove the shuttle frame assembly (page 7–54). 2. then lift it up and out (page 7–85. To avoid cutting yourself. handle the paper ironer on the sides. Remove the paper ironer (page 7–41). 7. Make sure the copper wear saddles in the platen seat of the mechanism base stay in place. Remove the Phillips #1 screw and washer securing the forms thickness indicator plate from the inside of the right side bracket. items 9 and 10.) 5.) 7–42 Replacement Procedures and Illustrated Parts List . (See Figure 7–18. Remove the two 7/32 inch screws and washers securing the right ribbon guide assembly to the side plate. 10. (See Figure 7–18. Pull the indicator plate. 14. (See Figure 7–18. item 21): a. page 7–85.Platen Removal 1. 3. off the platen shaft. (See Figure 7–18. and 15. Figure 7–18. item 15. Pull the spring link and white plastic bushing off the platen shaft and remove the spring link. bushing. Loosen the 7/64 inch collar clamp screw. 4. page 7–85. with the interlock switch assembly attached. page 7–87.) 13. Remove the right side platen support spring by repeating step 7 on the right side of the platen.) 9. items 16.) 11. Remove the forms thickness lever by loosening the 7/64 inch clamp screw and pulling the lever off the platen shaft. page 7–85. Pull the right side of the platen toward the front of the printer and move the platen to the right and out of the left side plate. Remove the three 1/4 inch screws securing the paper ironer bracket assembly and remove the assembly. 6. page 7–85. b. 12.) 8. items 4 through 6. Remove the platen open belt (page 7–8). and 18. Prepare the printer for maintenance (page 7–5). Pull the platen pulley off the platen shaft. 14. (Hold the black metal washer on the left side shaft as you remove the platen. Slide the ribbon guide assembly out of the side plate. Remove the shuttle frame assembly (page 7–54). and spring. 2. Remove the platen pulley (page 7–85. (See Figure 7–19. 17. item 12. Installation IMPORTANT The dowel pins protruding from the ends of the platen are the platen shafts. 1. Wipe the platen shafts clean of grease and debris. Installing the Platen Adjust Brackets Replacement Procedures and Illustrated Parts List 7–43 . (See Figure 7–5.) 3. 2. Apply bearing lubricant to both platen shafts. Install two washers on the longer (right) platen shaft. The platen must be installed with the longer shaft on the right side. Platen Shaft (Right Side) Washer Ironer Bracket Washer Platen Adjust Bracket Figure 7–5. and are not equal in length. Installing the Platen Adjust Brackets 7–44 Replacement Procedures and Illustrated Parts List . Washers Platen Adjust Bracket Platen Mechanism Base Platen Seat Wear Saddle Figure 7–6. 7. Insert the shorter platen shaft through the left adjust bracket and through the opening in the left side plate. (See Figure 7–6. Apply a layer of bearing lubricant 1/4 inch high to the seat of each wear saddle. 8. Install one platen adjust bracket onto the longer platen shaft. Place the other bracket onto the left side mechanism base platen seat so that the mechanism base platen seat is between the flanges of the bracket. with the screw at the top of the bracket. Rotate the longer shaft into the opening in the right side plate and position the adjustment brackets as shown in Figure 7–6.Platen Installation (continued) 4. 6.) 5. Make sure the two wear saddles are set flush into the corners of the mechanism base platen seat. making the layer as wide as the saddle and touching the rear angled surface. Apply bearing lubricant to the nylon bearings in the two spring links. 16.26 ± 0. 17. 14. (See Figure 7–5. For the right side of the platen.23 NSm). page 7–85. 15.Platen Installation (continued) 9. Apply bearing lubricant to the two platen shafts on both sides. Install and torque three screws to 20 ± 2 inch-pounds (2. Tighten the 7/64 inch setscrew. Slide the indicator plate. with the interlock switch assembly attached. Install the forms thickness lever onto the right side platen shaft. 11.) 12. b. With the flat part of the bracket facing the front of the printer. Replacement Procedures and Illustrated Parts List 7–45 . Slide the right ribbon guide assembly into the side plate and install the two 7/32 inch screws and washers. (See Figure 7–18 page 7–85. pressing the interlock switch out of the way as the lever slides past it. (See Figure 7–19. item 12. Push the platen to the left.) 10. Install the Phillips #1 screw and washer securing the indicator plate. Install the black metal washer onto the left side of the platen shaft. The left hook of the paper ironer goes between the left platen adjustment bracket and the platen. and 15. item 26. and 18. onto the platen shaft and up against the right side plate. Install the paper ironer bracket. page 7–87. 14. Install the forms thickness indicator plate: a. place the two hooks of the upper part of the paper ironer over the platen shafts. a washer goes on both sides of the paper ironer hook and the hook goes to the left of the right platen adjustment bracket. and connect the springs to the spring hooks in the side plates. between the ends of the platen and the platen adjustment brackets. (See Figure 7–18. page 7–85.) b. (See Figure 7–18.) 13. items 16.) Open and close the forms thickness lever to make sure the setscrew does not touch the right ribbon guide. (See Figure 7–5): a. slide the spring links onto the two platen shafts. 19. Install. Check the hammer phasing (page 6–24). 24. 7–46 Replacement Procedures and Illustrated Parts List . Install the paper ironer with the black tape towards the rear of the printer (page 7–41). Check ribbon guide alignment (page 6–16). 18. 22. Open and close the forms thickness lever and check that the platen pulley setscrew does not hit the left ribbon guide. Return the printer to normal operation (page 6–3). Adjust the platen open belt (page 6–6). 20.Platen Installation (continued) 17. Adjust the platen gap (page 6–12). the platen open belt and platen open motor pulley (page 7–8). 21. 25. but do not adjust. 23. Install the shuttle frame assembly (page 7–54). Install the platen shaft pulley with the 7/64 inch setscrew facing up and tighten the setscrew. Configuration Factory Default Alternate 1 Alternate 2 Removal WARNING <9> To prevent electrostatic damage to electronic components. wear a properly grounded static wrist strap when handling circuit boards.) If the standard terminating resistor pack is not compatible with the particular interface driver requirements of the host computer. the shuttle frame assembly. Locate the terminating resistor packs. 1. other values of pull-up and pull-down resistors may be required.Resistors. you must also install the 330 ohm pull-down resistor. These are suitable for most applications.) 3. Cabinet Model: Remove the paper path (page 7–40). 1. and any other electronic component. the shuttle frame assembly. 2.) 2. install the resistor packs in the correct socket. Cabinet Model: Install the paper path (page 7–40). Pedestal Model: Install the top cover assembly (page 7–18). (See Figure 7–7. 3. (See Figure 7–7. Possible terminating resistor combinations are shown below. wear a properly grounded static wrist strap when handling circuit boards. Terminating For parallel interface configurations. 220 ohm pull-up and 330 ohm pull-down alternate terminating resistors are provided with the printer. page 7–48. If you install the 220 ohm pull-up resistor. RP1 (Pull-Up) 470 ohm 220 ohm 1K ohm RP2 (Pull-Down) 1K ohm 330 ohm none Replacement Procedures and Illustrated Parts List 7–47 . Pedestal Model: Remove the top cover assembly (page 7–18). (See Figure 7–7. the printer is equipped with 470 ohm pull-up terminating resistors and 1K ohm pull-down terminating resistors on the controller board. Using a chip puller. and any other electronic component. Installation WARNING <9> To prevent electrostatic damage to electronic components. page 7–48. Using a chip installation tool. remove the packs. Return the printer to normal operation (page 6–3). Resistors.CMX Controller Board RP1 Default: 470 ohm Alt 1: 220 ohm Alt 2: 1K ohm Resistor Kit: 14H5525 RP2 Default: 1K ohm Alt 1: 330 ohm Alt 2: none Figure 7–7. Terminating. Removal/Installation 7–48 Replacement Procedures and Illustrated Parts List . (See cable routing diagram on page A–12. Remove the two screws and washers securing the ribbon guide assembly to the side plate. releasing it from the cable restraints. NOTE: The right ribbon guide is shown in Figure 7–19. 3. 10. For the left ribbon guide. Slide the ribbon guide assembly out of the side plate.Ribbon Guide Assembly (L/R) Removal 1. The removal procedure is the same for the left ribbon guide. Align the ribbon guides (page 6–16). 8. 6. disconnect connector shell P106 from the controller board. 4. 2. Open the printer cover. Return the printer to normal operation (page 6–3). Installation NOTE: The right ribbon guide is shown in Figure 7–19. Cut and remove the tie-wrap from the tie wrap hole to free the ribbon guide cable (page 7–87. 3. The installation procedure is the same for the left ribbon guide. For the right ribbon cable. Figure 7–19). Replacement Procedures and Illustrated Parts List 7–49 . 9. Prepare the printer for maintenance (page 7–5). 2.) 7. 1. Trace the ribbon guide wires to the connector shell. Reverse steps 4 through 10 of the removal procedure above. Pedestal Model: Remove the top cover assembly (page 7–18). 5. Remove the printer ribbon. and remove the cable connector from the connector shell (page 7–9). Cabinet Model: Remove the paper guide assembly (page 7–40). Trace the ribbon guide cable back to the controller board. disconnect connector shell P107 from the controller board. 7–50 Replacement Procedures and Illustrated Parts List . Install the ribbon spool hub over the motor shaft (page 7–79. 2. Prepare the printer for maintenance (page 7–5). Remove the hub from the shaft of the ribbon drive motor.Ribbon Hub Removal 1. Loosen the screw in the ribbon spool hub (page 7–79. 3. 4. 2. Installation 1. Figure 7–15). Remove the printer ribbon. Return the printer to normal operation (page 6–3). Tighten the hub screw so that it contacts the flat section of the motor shaft. 3. Figure 7–15). Shaft. Pull the bearing and spring link with the spring off the left side of the splined shaft. page 7–83. Splined Removal 1. Figure 7–17). Prepare the printer for maintenance (page 7–5). Hold the tractors so they do not fall. With grip ring pliers. Remove the paper supports from the splined shaft and support shaft. 9. 3. (See Figure 7–17. Remove the bearing clamp on the right side of the splined shaft. remove the grip ring from left side of the splined shaft. 5. 2. and slide the splined shaft to the right out of the side plates and the tractors. 8.) 4. 6. Replacement Procedures and Illustrated Parts List 7–51 . Remove the ground clip (page 7–83. 10. grasp the vertical adjustment knob. Open the printer cover. Unlock the left and right tractors and slide them to the center of the shaft. item 21. 7. Remove the paper feed timing belt (page 7–6). Install the grip ring on the splined shaft with 0. the tractors.) 12. and the left side plate (page 7–83. Slide the spring link and bearing onto the left side of the splined shaft with the white nylon bushing flange to the outside of the printer.010 inches of clearance between the grip ring and the nylon bearing. Attach the spring to the left side plate and the spring link. 4. 8. Position the tractor belts so the alignment marks are at the top on both tractors. Tractor Alignment Mark Splined Shaft NOTE: Align the marks on each tractor before inserting splined shaft. Set the paper feed timing belt tension (page 6–4).) 2. item 21. (See Figure 7–17. (See Figure 7–8. 6. Splined Shaft and Tractor Installation 7–52 Replacement Procedures and Illustrated Parts List . Figure 7–8. Install the ground clip and screw. Make sure the same spline passes the marked groove on each tractor. Adjust splined shaft skew (page 6–18. Install the paper feed timing belt (page 7–6). page 7–83. 11. Open the doors on the left and right tractors. Return the printer to normal operation (page 6–3). 9. 3.Installation 1. Figure 7–17).) 13. 10. Install the paper supports on the splined shaft and support shaft. Apply a thin film of bearing lubricant to the bearing. Grasp the vertical adjustment knob and slide the splined shaft through the right side plate. 7. 5. Install the bearing clamp and screw. 4. horizontal adjustment knob. (See Figure 7–17. Slide the support shaft assembly—consisting of the support shaft. 4. Replacement Procedures and Illustrated Parts List 7–53 . Install the paper supports on the splined shaft and support shaft. Remove the paper supports from the splined shaft and support shaft. 3. horizontal adjustment knob. 2. Slide the support shaft assembly through the right side plate. Installation 1. item 21.Shaft. Slide the tractors onto the support shaft. washer and screw—to the left.) 6. page 7–83. While pushing on the knob to compress the curved washers. install the E-ring in the groove on the bushing. Remove the E-ring (page 7–83. bushing. Figure 7–17). Prepare the printer for maintenance (page 7–5). item 5. bushing. (See page 7–83. and be careful not to lose the curved spring washers. (See Figure 7–17.) 5. Slide the support shaft assembly—consisting of the support shaft. (See Figure 7–17. washer. Unlock the tractors and slide them to the far right. Return the printer to normal operation (page 6–3). page 7–83.) 6. WARNING <15> Hold the tractors while removing the support shaft. Figure 7–17. and screw—into the left side plate. 3. page 7–83. out of the tractors and the left side plate. Support Removal 1. 5.) 2. two curved washers. item 21. two curved washers. Open the printer cover. if it was removed. Figure 7–15). Unlock and slide the tractors outward as far as they will go on the tractor support shaft. Do not remove the clamps. Loosen the center 5/32 inch socket head screw enough to release the shuttle frame assembly from the base casting. 9. and any other electronic component. 4. and any other electronic component. Install the hammer bank / ribbon mask cover assembly (page 7–16). Loosen the side 5/32 inch socket head clamp screws and pull the clamps back and off the guide shaft. 6. 5. WARNING <9> To prevent electrostatic damage to electronic components. wear a properly grounded static wrist strap when handling circuit boards. Lift it slowly and carefully: the shuttle frame assembly is heavy. 2.Shuttle Frame Assembly Removal 1. Remove the shuttle cover assembly (page 7–17). Disconnect the hammer drive and hammer logic cables connectors from the terminator board on the shuttle frame assembly. 3. 7. 8. 7–54 Replacement Procedures and Illustrated Parts List . lift the shuttle frame assembly out of the base casting. the shuttle frame assembly. Disconnect the shuttle motor cable connector (page 7–79. Figure 7–16). the shuttle frame assembly. Disconnect the MPU cable connector (page 7–81. wear a properly grounded static wrist strap when handling circuit boards. and the clamped ends of the shaft must be greased to prevent galling. The shuttle shaft is aluminum. Grasping the support legs cast on both sides of the shuttle motor. Prepare the printer for maintenance (page 7–5). Installation 1. WARNING <16> Do not remove the grease from the shaft of the replacement shuttle frame assembly. WARNING <9> To prevent electrostatic damage to electronic components. Models –005. Return the printer to normal operation (page 6–3). Route the MPU cable under the extension spring and connect the MPU cable connector. Figure 7–15). (See Figure 7–16.26 ± 0. and –05P only: set shuttle speed if the original shuttle frame assembly was replaced (page 6–33). –04P. 11. Replacement Procedures and Illustrated Parts List 7–55 .) Make sure the MPU cable does not touch the extension spring after it is connected. 12. Adjust the hammer phasing (page 6–24). Holding the shuttle frame assembly by the support legs cast on both sides of the shuttle motor.23 NSm). Connect the hammer drive and hammer logic cables connectors to the terminator board on the shuttle frame assembly. 6. IMPORTANT Do not over tighten the shuttle frame assembly hold-down screws. otherwise. 14. page 7–81. Use both hands: the shuttle frame assembly is heavy (page 7–79. 13. 5. –05P. adjust the platen gap (page 6–12). Slide the side clamps over the guide shaft and torque the 5/32 inch socket head clamp screws to 20 ± 2 inch-pounds (2. –005.26 ± 0. Connect the shuttle motor cable connector. Pull the shuttle frame assembly toward the front of the printer and hold it in this position while you do step 5. Torque the center captive 5/32 inch socket head screw to 20 ± 2 inch-pounds (2.2. 15. item 4. If the shuttle frame assembly is a new or refurbished unit. Align the center 5/32 inch socket head screw in the base casting and hand turn the screw until only two or three threads have started. set it into the base casting. Install the shuttle cover assembly (page 7–17). skip to step 11.23 NSm). 4. 9. 10. and –014 only: adjust the coil temperature if the original shuttle frame assembly was replaced (page 6–32). 7. Models –004. 8. 3. If necessary. Pry back the spring retaining clips (page 7–69. Return the printer to normal operation (page 6–3). Prop or hold the printer cover securely while disengaging the gas spring assembly. 7–56 Replacement Procedures and Illustrated Parts List . Installation WARNING <19> The gas spring assembly must be installed with gas cylinder in the up position. 2. 5. 3. This procedure applies only to cabinet models. 2. Close the printer cover. Open the floor cabinet rear door. Push the gas spring assembly onto the ball joints and install the spring clips. Figure 7–11). Gas Removal WARNING <18> Two persons may be required to perform this procedure. Prepare the printer for maintenance (page 7–5). 3. Remove the gas spring assembly from the ball studs.Spring Assembly. The large cylinder must be uppermost. adjust the position of the ball joint stud in the lower bracket to achieve smooth and complete closure. Position the gas spring assembly against the ball studs on the upper and lower brackets (page 7–69. 4. 1. Open the printer cover. Figure 7–11). 4. 1. Put a dab of IBM #20 bearing lubricant on both spring lugs.) 3. page 7–81. 2. Replacement Procedures and Illustrated Parts List 7–57 . page 7–81. 4. 2. (See Figure 7–16. Return the printer to normal operation (page 6–3). Prepare the printer for maintenance (page 7–5). Unhook the extension spring from the spring lugs on the hammer bank and shuttle frame. (See Figure 7–16. Open the printer cover. 4.) Installation 1. Removal 1. Remove the shuttle cover assembly (page 7–17). Extension WARNING <20> Do not let the hammer bank rotate toward the platen during spring replacement. Install the shuttle cover assembly (page 7–17).Spring. 3. WARNING <21> Make sure the extension spring does not touch the MPU cable after installation. Hook the extension spring over the spring lugs. installing the cable in the restraints under the base casting. and remove the cable connector from the connector shell (page 7–9). Installation 1.) 4. Feed the switch cable down into the cover open switch well to the right of the shuttle motor. then connect the connector shell P107 (P7) to the controller board.Switch Assembly. 5. Carefully lift and pry the cover open switch assembly out its well in the base casting to the right of the shuttle motor. (See Figure 7–15. Disconnect connector shell P107 (P7) from the controller board. Trace the ribbon motor wires to the connector shell. Remove the shuttle cover assembly (page 7–17).) 3. Return the printer to normal operation (page 6–3). 2. 7–58 Replacement Procedures and Illustrated Parts List . (See cable routing diagram on page A–12. Install the shuttle cover assembly (page 7–17). releasing the cable from the restraints under the base casting. Position the cover open switch assembly in the base casting and press it into place. Cover Open Removal 1. (See cable routing diagram on page A–12. 2. page 7–79.) 4. Route the cover open switch cable back to the controller board. Trace the cover open switch cable back to the controller board. 5. Remove the protective covering from the adhesive backing on the cover open switch assembly. Connect the cover open cable to the connector shell (page 7–9). 3. 6. ) 5. 8. page 7–87. releasing the cables from the restraints under the base casting.) 6. (See Figure 7–19. (See page 7–75. (See cable routing diagram on page A–12. items 3.Switch Assembly. Remove switch cable connectors PMD and POD from connector P106 (page 7–9). and 9. Figure 7–13. Pedestal Model: Remove the top cover assembly (page 7–18). (See page 7–73. items 3. barrier shield.) 4. Paper Detector Removal 1. Replacement Procedures and Illustrated Parts List 7–59 . 4. Disconnect connector shell P106 from the controller board. Cabinet Model: Remove the paper guide assembly (page 7–40). Figure 7–14. Prepare the printer for maintenance (page 7–5). Remove the two screws securing the paper detector switch assembly. and four screws. 7. and 5.) Pedestal Model: Remove the paper guide. Cabinet Model: Loosen four screws and remove the barrier shield. Remove the paper detector switch assembly. 4. 3. 2. Trace the paper detector switch cables back to the controller board. then connect P106 to controller board connector J106. Figure 7–14. Figure 7–13. Check the PMD sensor arm range: make sure it travels freely and completely back into the sensing cavity.) 6. and four screws. position the paper detector switch assembly and install the screws securing it to the printer base. Cabinet Model: Install the paper guide assembly (page 7–40). Check and adjust the End of Forms Distance (page 6–20). 4. 4. Pedestal Model: Install the top cover assembly (page 7–18).Installation 1. items 3. (See page 7–75. and 5. items 3. Holding the slotted wheel against the PMD sensor. page 7–87. (See page 7–73. Cabinet Model: Install the barrier shield and tighten the four screws.) Pedestal Model: Install the paper guide. 8. 7. 5. barrier shield. Return the printer to normal operation (page 6–3). (See Figure 7–19. and 9. installing the cables in the restraints under the base casting. (See cable routing diagram on page A–12. Connect switch cables PMD and POD to the connector P106 (page 7–9).) 4.) 2. 3. Route switch cables PMD and POD back to the controller board. 7–60 Replacement Procedures and Illustrated Parts List . 6. Route the switch cable through the cutout in the right side plate and to the controller board. Connect the platen interlock switch cable to the connector shell P107 (P7) (see page 7–9). Pedestal Model: Remove the top cover assembly (page 7–18). 3. page 7–85. Platen Interlock Removal 1. Return the printer to normal operation (page 6–3). Remove two screws securing the platen interlock switch assembly. Prepare the printer for maintenance (page 7–5). (See cable routing diagram on page A–12.) 4. Position the platen interlock switch assembly on the switch bracket and install the two screws securing it to the bracket. Pedestal Model: Install the top cover assembly (page 7–18). Cabinet Model: Remove the paper guide assembly (page 7–40). 2. 9. then connect the connector shell to the controller board. 7. 4. Disconnect connector shell P107 (P7) from the controller board. Remove the platen interlock cable connector from the connector shell (page 7–9). Fully close the forms thickness lever (position ‘A’). Remove the platen interlock switch assembly from the switch bracket. Installation 1. Remove tie-wraps as necessary to free the cable.) 5. Replacement Procedures and Illustrated Parts List 7–61 . Remove the switch cable from the cutout in the right side plate. 5. page 7–85. Cabinet Model: Install the paper guide assembly (page 7–40). (See Figure 7–18. 6. Trace the platen interlock switch cable back to the controller board.Switch Assembly.) 3.) 8. (See cable routing diagram on page A–12. Fully close the forms thickness lever (position ‘A’). 2. (See Figure 7–18. install the support shaft (page 7–53). Installation 1. 2. Remove the support shaft (page 7–53). Using the replacement tractors. Remove the tractors. 4. Remove the splined shaft (page 7–51). Install the splined shaft (page 7–52). Return the printer to normal operation (page 6–3).Tractor (L/R) Removal 1. 3. 7–62 Replacement Procedures and Illustrated Parts List . 3. Prepare the printer for maintenance (page 7–5). 2. . . . Pedestal Details . . . . . . Expansion Coax/Twinax Board . . . . . . . . . . . 7–69 Figure 7–12. . . . Control Panel and Cabinet Details . . . . . . . . . . . . . . . Magnetic Pickup Unit (MPU) and Extension Spring . . . . 7–87 Figure 7–20. . . . . . . . . . .Section II: Illustrated Parts List List of Figures Figure 7–9. . . . . . . . . . Print Mechanisms and Circuit Boards . . . . . . . . . . . . Doors. . . . . . . . . . . Circuit Breaker . . . . . Cabinet Model . . . Pedestal Model . . . . Card Cage Fan. . . 7–77 Figure 7–15. . . . . . . . . . . . . . . . . . . . . . Card Cage Detail. . 7–65 Figure 7–10. and Casters. . . . . . 7–85 Figure 7–19. . . . 7–73 Figure 7–14. 7–83 Figure 7–18. . 7–79 Figure 7–16. . . Cabinet Model . . . . . . . . . . . . . . . . Motors. . Top Cover. . . . . . . . . 7–91 Replacement Procedures and Illustrated Parts List 7–63 . . . . Paper Stacker and Chains . . Pedestal Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–89 Figure 7–21. . . . . . . . . . . . . . . . . . 7–71 Figure 7–13. . . . . . 7–75 Figure 7–14a. . . . . . . . . . . . . 7–67 Figure 7–11. . 7–81 Figure 7–17. . . Inside Covers and Card Cage. . . and Paper Detector Switch . . . . . . . . . Tractor Shafts . . . . . . . . . . . . . . . . . . . Inside Covers. . Platen . . . . . . . . . . . . . with Brake Caster. without Brake Logo. 1 2 3 4 Part Number 14H5276 57G1492 14H5567 14H5278 Description Top Cover Kit Window. Front and Rear One on each door (Rear not shown in Figure 7–9) Cabinet models only Not shown in Figure 7–9 Not shown in Figure 7–9 10 11 12 13 30H3986 14H5572 63H7510 63H7398 Shipping Container Kit Hardware Kit Door Seal Kit Top Cover Seal Kit 7–64 Replacement Procedures and Illustrated Parts List . Top Cover Wireform paper guide assembly Rear Door Kit Notes Includes mounting hardware Not visible in Figure 7–9 Includes mounting hardware Includes mounting hardware (Not visible in Figure 7–9) Includes mounting hardware Two at front Two at rear 5 6 7 8 9 14H5277 57G1485 57G1486 14H5603 30H4008 Front Door Kit Caster. 6400 Wire Rope.Item No. Doors.NOTE: Item 10: Shipping Container Kit not shown Item 11: Hardware Kit not shown 1 2 8 13 3 12 5 9 4 7 6 Figure 7–9. Cabinet Model Replacement Procedures and Illustrated Parts List 7–65 . Top Cover. and Casters. 1 2 3 4 5 6 7 8 Part Number 57G7176 30H3981 04H4779 Ref 14H5296 14H5272 57G7260 Ref Stacker Runner.S. Grommet. Grommet Chain Assembly Kit Power Cord. Stacker Riser. U.Preliminary 2 Item No. Power Cord (2) Included in item 5 Kit contains eight chains Description Notes 7–66 Replacement Procedures and Illustrated Parts List . Stacker Runner Screw (4) Spares Kit. Paper Stacker and Chains Replacement Procedures and Illustrated Parts List 7–67 .6 4 3 5 7 1 8 2 Figure 7–10. Air Exhaust 7–68 Replacement Procedures and Illustrated Parts List .375 3 4 5 Includes ball studs. spring clips.00 Includes mounting hardware 6 7 8 9 Ref Ref 57G1440 Ref Screw w/Lock Washer (3) Screw w/Lock Washer (2) Fan Assembly Duct. 1 2 Part Number 14H5299 57G1598 57G1599 57G1600 57G1601 57G1602 57G1603 57G1604 Ref 14H5300 57G1481 Description Notes Operator Panel. Cabinet Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Screw. Operator Panel Gas Spring Kit Includes mounting hardware English Spanish French Italian German Dutch Brazilian Portuguese 6–32x. Hex w/Lock Washer (4) Cable Assy.Item No. and mounting hardware 6–32x.375 6–32x2. 2 1 6 5 4 3 7 9 8 6 6 Figure 7–11. Control Panel and Cabinet Details Replacement Procedures and Illustrated Parts List 7–69 . 09P Models 04P. 09P English Spanish French Italian German Dutch Brazilian Portuguese 6–32x. 05P. 05P. 09P 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 7–70 Replacement Procedures and Illustrated Parts List . Part Number Description Notes 1 2 63H5124 57G1598 57G1599 57G1600 57G1601 57G1602 57G1603 57G1604 Ref 63H5125 63H5121 14H5300 63H5119 Ref 63H5120 Ref 63H5118 24H8534 63H7509 Ref 24H8533 63H5122 64H5123 Operator Panel. 09P Models 04P. 05P. 08P. 05P. 08P. 05P. 08P. 05P. 05P. Control Panel Hinge Lid Kit Cable Assy. 09P Repl. 08P. 05P. 08P. 08P. 09P Models 04P. 08P. acoustic seals (Not shown in Figure 7–12) Models 04P.50 Models 04P. 09P 10–32x. 09P Models 04P. Control Panel Lid. Pedestal Optional item: Models 04P. Captive (2) Input Tray Lid Accessory Kit Shipping Container. Pedestal Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Screw (5) Bracket. 08P. Pedestal (4) Pedestal Kit Screw. 05P. 09P (Not shown in Figure 7–12) Models 04P. 08P. 05P.625 Models 04P.Preliminary 2 Item No. 08P. 09P Models 04P. Pedestal Model Screw (2) Top Cover Screw (4) Paper Basket Caster. Pedestal Details Replacement Procedures and Illustrated Parts List 7–71 .1 2 7 4 5 3 6 8 14 9 NOTE: Item 16: Lid Accessory Kit not shown Item 17: Pedestal Shipping Container not shown 11 15 13 10 12 Figure 7–12. 014 6–32x. and #6 Flat Washer Paper feed belt cover shown in Figure 7–13. Platen open belt cover: item 24. Timing.62 with O-ring. 1 2 3 4 5 6 7 Part Number 14H5235 Ref Ref Ref 14H5271 Ref 14H5174 Description Notes Shroud Assembly. 009.06 6–32x.25 8 9 10 11 57G1468 08H7954 Ref 14H5179 Belt. 012.250x. . 050P. 005. w/Lock Washer (3) Platen/Paper Feed Cover Kit Models 004. Thread forming Barrier Shield Paper Guide Assembly Screw.25.125x. 100 Teeth Anti-Static Brush Kit Power Supply Shield Paper Scale Taped to card cage along upper edge 7–72 Replacement Procedures and Illustrated Parts List . 008. page 7–85. Paper Feed Shuttle Cover Assembly 10–24x. Captive (2) Screw (4). Air Screw.Preliminary 2 Item No. 5 6 4 3 9 3 1 11 10 2 8 7 Figure 7–13. Cabinet Model Replacement Procedures and Illustrated Parts List 7–73 . Inside Covers. 250x. 100 Teeth Platen/Paper Feed Cover Kit Taped to card cage along upper edge Paper Feed Paper feed belt cover shown in Figure 7–13.Preliminary 2 Item No. Timing.25 7–74 Replacement Procedures and Illustrated Parts List .62 with O-ring. page 7–85. . Captive (2) Screw.06 6–32x. Air Screw. 1 2 3 4 5 6 7 8 9 Part Number 14H5235 Ref Ref Ref Ref 63H5116 08H7954 Ref 57G1468 14H5174 Description Notes Shroud Assembly. 08P. 050P. Models 04P. 09P Shuttle Cover Assembly 10–24x. Platen open belt cover: item 24.125x. 05P. Thread forming (4) Barrier Shield Paper Path Assembly Anti-Static Brush Kit Power Supply Shield Belt. 2 8 9 Figure 7–14. Pedestal Model Replacement Procedures and Illustrated Parts List 7–75 .3 5 4 3 6 7 1 See Figure 7–14a. page 7–77. Inside Covers and Card Cage. 1 2 3 4 5 6 Part Number Ref 57G1440 Ref Ref Ref 14H5571 Description Notes Nut (1).75 7–76 Replacement Procedures and Illustrated Parts List . 6–32 Card Cage Fan Assy Fan Guard Screw. Pedestal Circuit Breaker Upper right fan corner only Air flow into card cage 6–32x1. w/Lock Washer (4) Card Cage.Item No. 1 2 From Figure 7–14. page 7–75. (Black Wire) 6 To IEC 320 AC Power Input (Connector J301. (White Wire) To Connector P1. Black Wire) Figure 7–14a. Card Cage Detail.) 3 4 5 To IEC 320 AC Power Input (Connector J301. (Rotated 180 degrees. Pedestal Model Replacement Procedures and Illustrated Parts List 7–77 . White Wire) To Connector P1. Shaft. 09P Models 012. Flash Memory SIMM. 01AXXXX. 09P. 09P Model 012 Model 014 Models 004. 08P. and 08P. CMX. CMX. Nos. 05P Models 008. 09P Models 012. 009. V5. All models 009. Model 014 only Housing Connector Kit 14H5288 24H8647 Controller Board. 1 Part Number 14H5273 14H5601 14H5602 14H5274 24H8648 14H5516 26H9625 14H5517 90H3269 14H5275 14H5512 14H5513 Description Hammer Bank/Rbn Mask Cover Hammer Bank/Rbn Mask Cover Hammer Bank/Rbn Mask Cover Shuttle Frame Assembly Shuttle Frame Assembly Shuttle Frame Assembly Shuttle Frame Assembly Shuttle Frame Assembly Shuttle Frame Assembly Hammer Spring Assemblies: Hammer Spring Assembly Hammer Spring Assembly Hammer Spring Assembly Power Supply PCBA Power Supply PCBA P101 Cable Connector Cable Assy. Power Supply Controller Board. 05P. 04P Models 005. Left. DRAM Switch Assembly. Receiving Screw. 005. Nos. 05P Models 008. 05P.0 Notes Models 004. Power Supply (3) SIMM. V5. 08P. 014 Models 004. 014 2 3 14H5644 90H3268 4 5 6 Ref Ref 14H5643 Part of Field Kit. AC In. 40 MHz Motor Sensor. 01EXXX. Right. 05P Models 008. Cover Open Housing Connector Kit 14H5288 Optional cable assembly See also page 7–29 See also page 7–29 7–78 Replacement Procedures and Illustrated Parts List . 25 MHz 90H3271 7 8 9 10 11 12 13 14 15 16 17 18 Ref Ref Ref Ref Ref 14H5287 14H5522 Ref 14H5211 Ref Ref Ref 14H5282 Controller Board. 09P. Cable Assy Centronics I/O Cable Assy Centronics/Dataproducts Adapter Control Panel Cable Assy Clamp. CMX. V5. 04P. Captive. AC Assy 14H5289 All models 004 and 04P.5. 08P Models 009. 014 Models 004.5. 08P. 01BXXXX and 01CXXXX All models 005. 005. 012 Models 009. 005. 04P. 04P.Preliminary 2 Item No.01DXXXX. and higher. Cable Assy Hammer Bank Logic Cable Assy Shuttle Motor Cable Assy Hammer Bank Power Cable Assy Motor Sensor. Models 008 and 012 with Ser. 009. 008. Models 008 and 012 with Ser. 2 Places: Exploded for clarity. Do not remove holdown clamps and screws. 14 1 3 To To J03 J02 (Shuttle (MPU) Motor) 15 2 8 9 5 4 15 11 16 7 10 6 12 13 15 17 To Terminator Board on 18 Shuttle Frame Figure 7–15. Print Mechanisms and Circuit Boards Replacement Procedures and Illustrated Parts List 7–79 . MPU 6–32x.Item No. socket cap Extension Spring Cable Assembly. 1 2 3 4 Part Number 57G1476 Ref 30H3985 14H5329 Description Notes Magnetic Pickup Assy (MPU) Screw.38 7–80 Replacement Procedures and Illustrated Parts List . Magnetic Pickup Unit (MPU) and Extension Spring Replacement Procedures and Illustrated Parts List 7–81 .Spring Lug (Do not remove grease) 2 3 Spring Lug (Do not remove grease) <21> Make sure the extension spring does not touch the MPU cable after installation.254 ± .010 ± .001 inch (0. 1 4 0.025mm) Figure 7–16. Item No. Tractor Adjust Bushing.25 Clamp. Tractor Adjust Washer.50 Ground Clip. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Part Number Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref 57G1521 57G1460 Ref Ref Ref 57G1466 Ref 14H5217 14H5214 Ref 24H8593 Description Notes Screw. Thread Forming.626 Link Spring Spring. 4–40x. Bearing Tractor Support Shaft Tractor Set E-Ring Tractor Shaft Hardware Kit Tractor Shaft Kit Bushing Paper Support (2) Part of item 15 Part of item 15 Part of item 15 Part of item 15 Part of item 15 Part of item 18 Part of item 18 Part of item 18 Part of item 18 Part of item 11 Part of item 19 Part of item 18 Part of item 18 Part of item 19 Includes L and R tractors Part of item 15 Part of item 18 7–82 Replacement Procedures and Illustrated Parts List . 6–32x.25 Washer. 4–20x. Nylon . Hex w/Lock Washer. Extension 1. Curved Spring (2) Ring.00L Screw. Grip Bearing. Socket Cap. Flat #4 Knob. Splined Shaft Splined Shaft Assembly Screw. Tractor Shafts Replacement Procedures and Illustrated Parts List 7–83 .10 11 6 7 8 9 20 1 2 3 4 5 21 12 14 13 16 17 15 NOTE: Item 18: Tractor Shaft Hardware Kit not shown Item 19: Tractor Shaft Kit not shown 16 Figure 7–17. 87 teeth Platen/Paper Feed Cover Kit Part of item 21 Platen Open Belt Platen open belt cover shown in Figure 7–18. Flat (2) Screw (2) Washer. Nylon . item 7.376 Bracket. Switch Mount Wear Saddle.25 Bracket.44 Belt. 6–32x.12L Link. Platen (2) Ironer Assembly Screw.Item No. Paper feed belt cover: page 7–73. Flat #4 (2) Platen Switch Kit Screw.75 Washer Nut Part of item 15 Part of item 25 Part of item 11 Part of item 11 Part of item 15 Part of item 15 Platen Lever Kit Spring. Driven Screw. Ironer Platen Assembly Washer. Part of item 25 Part of item 25 Part of item 25 Part of item 11 Part of item 25 25 26 14H5169 Ref Platen Hardware Kit Platen Washer Part of item 25 7–84 Replacement Procedures and Illustrated Parts List . Thread Forming (3) Bracket. Platen (2) Platen Pulley. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Part Number Ref Ref 57G1469 Ref Ref Ref 08H7936 Ref Ref Ref 14H5280 Ref Ref Ref 14H5184 Ref Ref Ref Ref Ref 57G1514 Ref 57G1467 14H5174 Setscrew Description Notes Part of item 25 Part of item 25 Reverse Paper Feed 6–32x. timing. 312W. Socket Cap. Socket Cap. 6–32x. Extension 1. Spring Bearing. Ironer Plate. Platen Replacement Procedures and Illustrated Parts List 7–85 . 3 1 2 4 NOTE: Item 25: Platen Hardware Kit 24 6 5 7 23 8 22 21 17 26 20 2 1 18 16 9 10 11 12 19 18 17 16 13 15 14 Figure 7–18.NOTE: Black tape faces paper motion detector. 50 10–32x. Hex w/Lock Washer (2) Washer. socket head Motor Pulley. 1 2 3 4 5 6 Part Number 57G1440 Ref 14H5281 14H5570 Ref 14H5520 08H7934 Description Notes Fan Assembly. Hex w/Lock Washer (2) Shield.51 7–86 Replacement Procedures and Illustrated Parts List .375 Paper Feed Motor Assy (includes items 7 through 9) Part of Platen Open Motor Assy (57G1509) and includes collar setscrew 6–32x.25 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Ref Ref 57G1421 Ref 14H5290 14H5154 Ref Ref Ref Ref 14H5521 Ref Ref 57G1479 Ref 14H5159 Collar Part of item 9 Screw. Ribbon Screw. w/Lock Washer (3) Paper Detector Switch Assy Paper Detector Switch Assy Screw. Paper Feed Screw. Hex w/Lock Washer (2) Screw.Item No.50 Includes left and right ribbon guides Includes item 6 Flat #4 4–40x. Platen Open Two 6–32x1. Flat #6 (2) Ribbon Hub Kit Screw.25 Air flow up 6–32x.50 on top left Standard Black back forms 6–32x. w/Lock Washer (2) Hammer Bank Fan Assy 6–32x1. Hex w/Lock Washer (2) Ribbon Guide Kit Platen Open Motor Assembly Washer (2) Screw. Thread Forming Paper Feed Motor Motor Pulley. Card Cage Screw.75 on bottom One 6–32x0. Card Cage Fan Motor Assy.38 10–32x.50 6–32x. and Paper Detector Switch Replacement Procedures and Illustrated Parts List 7–87 . Motors.2 Install screws here 16 1 Top View Hammer Bank Fan Route cable under base casting 4 3 6 20 12 18 19 17 15 2 5 11 8 7 22 21 10 14 13 11 9 See detail above Figure 7–19. Card Cage Fan. AC Assy 14H5289 7–88 Replacement Procedures and Illustrated Parts List .Item No. AC In. Power Supply Notes Connector J301 To power supply board connector J1 AC Part of Field Kit. 1 2 3 4 5 Part Number 14H5571 Ref Ref Ref Ref Description Circuit Breaker IEC 320 AC Power Connector Chassis Ground Stud Connector P1 Cable Assy. Inside detail To IEC 320 AC Power Input (Connector J301) (Black Wire) To IEC 320 AC Power Input (Connector J301) (White Wire) 1 To Connector P1 (Black Wire) To Connector P1 (White Wire) Card cage fan and power supply board removed for clarity Black Wire Black Wire 2 WhiteWire 3 5 4 White Wire Figure 7–20. Circuit Breaker Replacement Procedures and Illustrated Parts List 7–89 . Captive Standoff. page 7–78 7–90 Replacement Procedures and Illustrated Parts List .Item No. 60-pin See item 6. Part Number Description Notes 1 2 3 4 5 6 7 8 Ref Ref 63H7382 Ref Ref 24H8535 Ref Ref Screw (2) Card Cage IBM Coax/Twinax Expansion PCBA Screw. Hex. Expansion Connector CMX Controller Board Controller Board Connector J111 M/F.813 Lg. 3/16 inch Adapter. . IBM Coax/Twinax Expansion Board Replacement Procedures and Illustrated Parts List 7–91 .4 3 5 6 7 2 1 8 1 Figure 7–21. 7–92 Replacement Procedures and Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CMX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centronics . . . . . . . . . . . . . . . . . . . . . . . . . IBM 6400 Interconnection Diagram . . . . . . . A–22 MPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–13 Pedestal Model. . . . . . . . . . . . . . . . . A–5 Power Supply . . . . . . . . A–23 Ribbon Guide Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–11 Cabinet Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–4 Circuit Board Assemblies Controller. . . . . . . . . . . . . . .A Wire Data NOTE: Acronyms and Signal mnemonics are defined in Appendix F. . . . . . . . . . . . . . . . . . . . . . . A–18 Exhaust Fan . . . . A–12 Pedestal Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–14 Cable Assemblies AC In. . . . . . . . . . . . . . . . . . A–26 Wire Data A–1 . . . . . . . . . . . . . . . Extension . Mechanism Base . . . . . . . . . . . . . . . . . . . . . . . . A–17 Operator Panel . . . . A–3 IBM 6400 Power Distribution Diagram . . . . . . . . . . . . . . . . . A–21 I/O. . . . . . . . . . . . A–9 Expansion Coax/Twinax . . . . . . . . . . . . . . . . . . . . . A–20 Hammer Bank Power . . . . . . . . . . . . . . . . . . . . . . . . . . . A–24 Ribbon Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanism Base . . . . Power Supply . . . . . . . . . . . . . . A–25 Shuttle Motor Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–15 AC Power Input . . . . . A–16 Card Cage Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–19 Hammer Bank Logic . . . . . . . . . . . . . . . . . A–10 Cable Routing Cabinet Model . . . . . . . . . . . . . . . . . . . . . . . . . . A–32 Switch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–27 Centronics / DataProducts Adapter . . . . . . . . . . . . . . Platen Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover Open . . . . A–30 Magnetic Pickup (MPU) Assembly . . . . . A–33 Switch Assembly. . . . . . . . . . . . . . . A–31 Switch Assemblies Switch Assembly. . . . . . . . . . . . . . . . . . A–34 A–2 Wire Data . . . A–28 +5V Remote Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–29 Fan Assembly. . . . Hammer Bank . . . . . . . .Twinax Auto–Termination . . . . . . . . Paper Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IBM 6400 INTERCONNECTION DIAGRAM J301 AC INPUT IEC 320 AC POWER CONNECTOR Operator Panel Legend: J1 AC P1 P112 J112 Card Cage Fan J111 EXP PORT J101 DC POWER 8 PLAT M P306 LRIB M 2 2 4 6 8 CCF LRP 10 12 POD PMD 14 16 18 20 J108 HLP P108 HLP 10 P101 7 2 4 6 8 10 12 14 16 * Spacer in pedestal model 18 20 J102 5 P110 J110 6 P03 J04 J05 Terminator Board 2 J03 P06 Cover Open Switch Assy Hammer Bank Fan 2 2 Print Mechanisms P06 J06 J06 Wire Data A–3 N CIRCUIT BREAKER ON/OFF SWITCH Line 1 Line 2 / Neutral AC to DC Power Supply Board 12 = Number of conductors in cable assembly =Chassis/ frame/ earth ground J310 P310 CHASSIS GND Diagnostic Port J6 J201 RS–232 I/O 8 CMX Controller Board 36 J203 Centronics I/O SHIELD GND P107 Configuration 1 3 5 7 PAPR M RRIB M Point of Common Ground 9 11 13 15 EHF* HBF 17 19 P106 Configuration 1 3 5 7 9 11 13 15 17 19 PLO MPU RRP CVO Exhaust Fan* +5V Remote Power J106 MSL P106 MSL J105 HBP P105 HBP 10 J116 SMD P116 SMD J107 MSR P107 MSR *Cabinet Models Only P307 Platen Motor Paper Motion Detector Paper Out Detector Left Ribbon Guide Left Ribbon Motor J02 P02 2 4 4 P04 Flex Circuits Shuttle Assy P05 3 4 Paper Feed Motor Platen Open Switch Right Ribbon Guide Right Ribbon Motor 4 2 Shuttle Motor 2 Hammer Bank Board 4 Magnetic Pickup Unit 2 4 . 5V Ret Platen Motor +48V Flex Circuits P04 J04 +8.5V +8.5/+48V Ret Shuttle Assy Terminator Board +48V Ret P05 J05 +48V J02 P02 Ret Paper Feed Motor +48V Paper Motion Detector Paper Out Detector Left Ribbon Guide +5 V Shuttle Motor +5 V Hammer Bank Board +5 V +5 V Platen Open Switch +5 V Cover Open Switch Assy Ret Hammer Bank Fan +24V Right Ribbon Guide Wire Data Left Ribbon Motor +5 V +48V Right Ribbon Motor .AC POWER J301 IEC 320 AC POWER CONNECTOR IBM 6400 POWER DISTRIBUTION DIAGRAM +48V +48V +5 V +5 V +8.5V Operator Panel J1 AC P1 P306 J102 Ret +48V J106 MSL P106 MSL J108 HLP P108 HLP J105 HBP P105 HBP J116 SMD P116 SMD J107 MSR P107 MSR P110 J110 P06 P06 J06 +48V J06 A–4 Card Cage Fan ON/OFF SWITCH CIRCUIT BREAKER Line 1 Line 2 / Neutral AC to DC Power Supply Board J310 P310 CHASSIS GND Exhaust Fan* Ret CMX Controller Board P307 P101 J101 DC POWER 5 Point of Common Ground 6 7 8 *Cabinet Model Only +5V Remote Power +5 V +8. 7K 0. NVRAM is replaced only at the factory.01 mF I/O CNC PN 31 BANK FAN– 10% I/O CNC PN 14 PLAT OPEN SW 100V I/O CNC PN 32 R RBN POST+ I/O CNC PN 15 PLAT OPEN RET R RBN POST– I/O CNC PN 33 I/O CNC PN 16 MPU+ I/O CNC PN 34 COVER OPEN SW I/O CNC PN 17 MPU– I/O CNC PN 35 COVER OPEN RET I/O CNC PN 18 I/O CNC PN 36 J201 RS232/RS422 J110 Front Panel VCC Motor 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 26 6 7 8 9 10 11 12 13 14 15 16 27 17 18 19 20 21 22 23 24 25 HOST TX HOST RX HOST RTS HOST CTS HOST DSR HOST DCD NC NC NC NC NC NC DIFF RXD– NC DIFF RXD+ NC DIFF TXD– HOST DTR NC NC NC NC DIFF TXD+ 470 PF 10% 50V 1 2 3 4 5 6 7 8 N FP DAT AVAIL FP CLK N FP LED WR FP DATA N FP LCD WR 470 PF 10% 50V CAUTION: <5> Do not remove or replace the NVRAM.Controller. 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 39 40 N STROBE P1 P2 P3 P4 P5 P6 P7 P8 N ACK BUSY PAPER EMPTY SLCT N INIT N AUTOFEED N FAULT PI VCC 4. CMX Wire Data J112 Centronics I/O CNC PN 1 I/O CNC PN 19 I/O CNC PN 2 I/O CNC PN 20 I/O CNC PN 3 I/O CNC PN 21 I/O CNC PN 4 I/O CNC PN 22 I/O CNC PN 5 I/O CNC PN 23 I/O CNC PN 6 J107 I/O CNC PN 24 Sensor Right I/O CNC PN 7 I/O CNC PN 25 I/O CNC PN 8 PF 1 I/O CNC PN 26 RIB R1 I/O CNC PN 9 PF 2 I/O CNC PN 27 RIB R2 I/O CNC PN 10 PF 3 +48V I/O CNC PN 28 RIB R3 I/O CNC PN 11 PF 4 I/O CNC PN 29 RIB R4 I/O CNC PN 12 EXH FAN+ I/O CNC PN 30 BANK FAN+ I/O CNC PN 13 EXH FAN– 0. The NVRAM contains a lithium battery that can explode if it is replaced incorrectly.1W N DP SEL EXT 5V N SELECT IN HOST LOGIC H NC 10K 0.1W NC 470 PF 10% 50V A–5 CHASSIS GND . 7K 0.7K 0. CMX 1 2 3 4 5 6 NC VX DB TXD VX DB RXD NC 470 PF 10% 50V A–6 PER LOGIC 1 HIGH J9 Online Verifier 1 2 3 4 5 6 EXT 5V DB TXD DB RXD OLV SYNC OLV IRQ J17 Paper Stacker PER LOGIC HIGH VCC VCC J102 External Power 4. The NVRAM contains a lithium battery that can explode if it is replaced incorrectly.1 PF 20% 50V + 10 mF 10% 16V 1000 PF 10% 50V 1 2 3 4 5 6 7 8 9 10 PPR STK STAT0 PPR STK STAT1 PPR STK CTL0 PPR STK CTL1 470 PF 10% 50V 470 PF 10% 50V 470 PF 10% 50V NC NC NC NC 470 PF 10% 50V 470 PF 10% 50V 5000HM 2 1000 PF 10% 50V Wire Data .1W U56 3 1 2 3 4 GND IN1 IN2 EN OUT1 OUT2 OUT3 OUT4 8 7 6 5 4. NVRAM is replaced only at the factory.J6 Diagnostic Port CAUTION: <5> Do not remove or replace the NVRAM.1W L6 1 2 0. 7 8 Controller. 1W 4. NVRAM is replaced only at the factory.7K 0.7K 0. EXP NDS EXP D15 EXP D14 EXP D13 EXP D12 EXP D11 EXP D10 EXP D9 EXP D8 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 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 EXP D7 EXP D6 EXP D5 EXP D4 EXP D3 EXP D2 EXP D1 EXP D0 EXP A15 EXP A14 EXP A13 EXP A12 EXP A11 EXP A10 EXP A9 EXP A8 EXP A7 EXP A6 EXP A5 EXP A4 EXP A3 EXP A2 EXP A1 EXP A0 A–7 VCC .01 mF 10% 100V J105 Hammer Bank Power 1 2 3 4 5 6 7 8 9 10 PH1 PH2 PH3 PH4 LDFB J101 Power Supply 1 2 3 4 5 6 7 8 9 10 11 12 N TEMP HI N STBY VCC NC EXP N ID SEL 12/10 V NC 8. The NVRAM contains a lithium battery that can explode if it is replaced incorrectly.5V +48V NC EXP NINT EXP NWR N DMA REQ0 N DMA REQ1 J111 Expansion Connector 4. CMX Wire Data VCC J106 Motor Sensor Left 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 PLAT 1 RIB L1 PLAT 2 RIB L2 PLAT 3 +48V RIB L3 PLAT 4 RIB L4 CC FAN+ L RBN POST+ CC FAN– L RBN POST– POD A PMD A POD K POD C PMD C POD E PMD E 0.1W PMD K EXP NRESET CAJ NACK EXP NMSEL CAUTION: <5> Do not remove or replace the NVRAM.Controller. NVRAM is replaced only at the factory.) J13 2–PIN JUMPER J12 2–PIN JUMPER J14 2–PIN JUMPER 0. CMX EC DB TXD EC DB RXD J2 EC Diagnostics 1 2 3 4 5 6 7 8 9 10 A–8 15V NC PPR TRIG PPR MOVING FT EVENT MPU OUT SHUT DIR J1 2–PIN JUMPER J108 Hammer Bank Logic TOROID 50 MHz HMR DAT HMR DAT RET HMR CLK HMR CLK RET CMD DAT CMD DAT RET CMD CLK CMD CLK RET 4.01 mF 10% 50V CAUTION: <5> Do not remove or replace the NVRAM.0W J116 Shuttle Motor 1 2 3 SHUT A SHUT B SHUT C 1 2 3 4 5 6 7 8 9 10 DRAM: 72–pin SIMM J15 = Bank 1 J16 = Bank 0 (See page 7–29. The NVRAM contains a lithium battery that can explode if it is replaced incorrectly.1W Controller.VCC 10K 1% 0. J5 2–PIN JUMPER Wire Data TOROID 50 MHz .7V 3.) Flash: 80–pin SIMM J10 = Bank 1 J11 = Bank 0 (See page 7–29. Power Supply 1 1 2 P1 3 AC Input AC AC COMMON CHASSIS GND J1 = RING TERMINAL = FAST–ON TERMINAL PIN 1 P101 P101 Controller Board N TEMP HI N STBY +5V +5V +5V RET / LOGIC GND +5V RET / LOGIC GND +5V RET / LOGIC GND +5V RET / LOGIC GND +8.5V 470 mF 10% 50V A–9 +48V . AC In.Power Supply Wire Data LOAD GND LOAD (Line Filter Area) Cable Assy.5B +48V +48V 1 2 3 4 5 6 7 8 9 10 11 12 N TEMP HI N STBY VCC 470 mF 10% 50V 470 mF 10% 50V 470 mF 10% 50V 8.5V +8. J2 Twinax Connector IBM Coax/TwinaxExpansion Board NC NC NC NC NC TWINAX PHASE B NC NC NC NC NC NC TWINAX PHASE A NC VCC A–10 16 SHIELD 1 SHIELD 2 17 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 J4 Expansion Connector 1K 0.1W NC N CARD DETECT 12/10 V NC N DMA REQ0 N DMA REQ1 NC EXP NINT J3 Coax Connector 1 2 COAX SHIELD COAX DATA EXP NWR EXP NRESET EXP NACK EXP NMSEL EXPNDSEL EXP D15 EXP D14 EXP D13 EXP D12 EXP D11 EXP D10 EXP D9 EXP D8 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 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 EXP D7 EXP D6 EXP D5 EXP D4 EXP D3 EXP D2 EXP D1 EXP D0 EXP A15 EXP A14 EXP A13 EXP A12 EXP A11 EXP A10 EXP A9 EXP A8 EXP A7 EXP A6 EXP A5 EXP A4 EXP A3 EXP A2 EXP A1 EXP A0 Wire Data VCC . Cable Routing. Cabinet Model Wire Data A–11 . ) To J107 on Controller (See page 7–10 for connector detail.Front of Printer A–12 Left Side of Printer Right Side of Printer To J106 on Controller Cable Routing. Mechanism Base Cabinet Model (Looking up from below) Wire Data P107 / CVO (See page 7–10 for connector detail.) . Cable Routing. Pedestal Model Wire Data A–13 . Front of Printer A–14 Wire Data Left Side of Printer Right Side of Printer Cable Routing.) P107/SPACER P107/CVO To J107 on Controller (See page 7–10 for connector detail. Mechanism Base. Pedestal Model (Looking up from Below) To J106 on Controller (See page 7–10 for connector detail.) . AC In. Power Supply .Wire Data To Circuit Breaker To Power Supply J1 Part No. 14H5289 A–15 Description Cable Assembly. A–16 To Circuit Breaker Input Power Connector Part No. 14H5289 Description Cable Assembly. AC Power Input Wire Data . Wire Data PIN 1 PIN 1 Part No. Card Cage Fan A–17 . 14H5285 Description Cable Assembly. PIN 8 (Brown) PIN 1 (Gray) PIN 1 (Gray) PIN 8 (Brown) Part No. See Appendix I.A–18 IMPORTANT: If you replace the control panel cable. you must install two ferrite shielding beads. Wire Data Description Cable Assembly. Operator Panel 14H5300 . Exhaust Fan A–19 . 14H5286 Description Cable Assembly.Wire Data Part No. A–20 Part No. Wire Data Description Cable Assembly. Hammer Bank Logic 14H5279 . 14H5283 Description Cable Assembly.Wire Data PIN 1 PIN 1 Part No. Hammer Bank Power A–21 . Centronics 14H5287 . See Appendix I.A–22 PIN 1 PIN 1 NOTE: If you replace the I/O cable assembly. Wire Data Description Cable Assembly. you must install the ferrite clamp. Part No. I/O. 14H5329 Description Cable Assembly.Wire Data PIN 2 PIN 3 PIN 1 PIN 1 Part No. MPU A–23 . Wire Data Description 14H5290 Ribbon Guide Kit (Includes left and right guides) . PIN 1 LEFT GUIDE = P106 / LRP RIGHT GUIDE = P107 / RRP PIN 2 Part No. Right is mirror image.A–24 NOTE: Left ribbon guide shown. A–25 Description Cable Assembly. Ribbon Motor. Extension 63H7464 .Wire Data Part No. Shuttle Motor Drive 14H5330 .A–26 Part No. Wire Data Description Cable Assembly. Wire Data 15 position D–sub receptacle connector with EMI/RFI shield. Twinax Auto–Termination 38F8254 . 4 2. 3. A–27 Description Cable Assembly. 3 Ohms 110 110 55 0 0 0 7 Part No. 2. 4 5 14 3 Jack 4 Pin 2 4 Shield Shield 1. 1 Jack 2 White 14 Gray 7 Shield 5 Resistance Chart Pin 1 3 1. Centronics/DataProducts Adapter 14H5522 .A–28 Part No. Wire Data Description Cable Assembly. +5V Remote Power 14H5589 .Wire Data Part No. A–29 Description Cable Assembly. Hammer Bank 14H5159 .P107/HBF A–30 P107 / HBF Part No. Wire Data Description Fan Assembly. A–31 Description Magnetic Pickup Assembly 57G1476 .Wire Data Part No. Cover Open 14H5282 . Wire Data Description Switch Assembly.A–32 Part No. Wire Data Part No. Paper Detector (Standard) (Black Back Forms) . 14H5281 (14H5570) A–33 Description Switch Assembly. Paper Detector (Standard) (Black Back Forms) .A–34 Preliminary 2 Part No. 14H5281 (14H5570) Wire Data Description Switch Assembly. P107/PLO Wire Data Preliminary 2 Part No. A–35 Description Switch Assembly, Platen Interlock 14H5280 Preliminary 2 B Contents Printer Specifications Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–2 Paper Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–3 Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–3 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–3 Printer Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–4 Environmental Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–4 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–4 Relative Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–4 Energy Star . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–4 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–5 Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–5 Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–5 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–8 Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–9 Printing Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–9 Printer Specifications B–1 Preliminary 2 Ribbon Specifications NOTE: The ribbon life figures listed below are based on IBM tests conducted in accordance with ANSI Standard X3A.182. Actual ribbon life may vary depending upon the user’s quality criteria, printer condition, machine settings, paper quality, and bar code requirements. Label yield depends on label format, bar code symbology, and other parameters. Label yield with high-performance scanning equipment may exceed these yields. Use only the ribbons listed below. IBM General Purpose Ribbon P/N 1040990 Used for general text printing such as data and word processing. Average yield: 20 million DP characters IBM General Purpose Ribbon P/N 1040995 Average yield: 30 million DP characters IBM High Contrast Ribbon P/N 1040993 Used for general text printing as well as OCR, graphics and bar code printing. Average yield: 20 million DP characters, 2500 AIAG–B3 labels with visible light source scanning equipment, or 1300 AIAG–B3 labels with infrared light source scanning equipment. IBM High Contrast Ribbon P/N 1040998 Average yield: 30 million DP characters, 3600 AIAG–B3 labels with visible light source scanning equipment, or 1800 AIAG–B3 labels with infrared light source scanning equipment. Ordering Ribbons (U.S. Only) Ribbons may be purchased from Lexmark Authorized IBM Supplies Dealers or directly from Lexmark by calling: 1–800–438–2468. Fax orders may be sent to: 1–800–522–3422 Mail orders may be sent to: Lexmark International, Inc., 1221 Alverser Drive, Midlothian, VA 23113. Ordering Ribbons (Outside of U.S.) Order supplies by contacting your local Lexmark International distributor or by writing to Lexmark International, Inc. Lexmark International, Inc. P.O. Box 11427 Lexington, KY, 40575–1427 USA B–2 Printer Specifications Preliminary 2 Paper Specifications NOTE: The following paper specifications are general guidelines. Paper stock should be tested with applications to determine print quality. Paper Type: Edge-perforated, fan-fold, 3 to 17 inches (7.62 to 43.18 cm) wide*, 2 to 24 inches (5.08 to 60.96 cm) long** S S S Single-part: 15 pound (57 g/m2) to 100 pound (377 g/m2) stock. Multi-part carbon: 1- to 6-part forms, maximum 12 pound (45 g/m2) ply of upper plies Multi-part carbonless. Verify readability of greater than 4-part. Form Thickness: Drive: Slew Rate: 6400–004, –04P 6400–005, –05P 6400–008, –08P 6400–09P 6400–009 6400–012 6400–014 0.025 inches (0.064 cm) maximum Adjustable tractors (6-pin engagement) Fast 12 ips 12 ips 16 ips 16 ips 20 ips 20 ips 20 ips Slow 8 ips 8 ips 8 ips 8 ips 10 ips 10 ips 10 ips Labels On Backing: One-part continuous perforated fan-fold back form. Labels must be placed at least 1/6 inch (0.42 cm) from the fan-fold perforation. Backing adhesive must not be squeezed out during printing. 3 to 17 inches (7.62 to 43.18 cm) wide*, including the two standard perforated tractor feed strips. A maximum sheet length of 16 inches (40.64 cm) between top and bottom perforations.** Sheet Size: Printer Specifications B–3 Preliminary 2 Thickness Not to exceed 0.025 inch (0.064 cm), including backing sheet. * On pedestal models, when using the rear paper exit, the maximum width is 16 inches (40.64 cm). ** On cabinet models, forms longer than 12 inches (30.48 cm) can be used by opening the front and rear printer doors. Printer Dimensions Cabinet Model Height: Width: Depth: Weight: 42.5 inches (108 cm) 27 inches (68.6 cm) 29 inches (73.7 cm) 225 lbs. (102.1 kg) 285 lbs. (129.3 kg) packaged Pedestal Model 35.5 inches (90.2 cm) 24.6 inches (62.5 cm) 30 inches (76.2 cm) 120 lbs. (54.4 kg) 160 lbs. (72.6 kg) packaged Environmental Characteristics Temperature Operating 41° to 90° F (5° to 32° C) up to 8000 feet (2438 meters) Storage –40° to 158° F (–40° to 70° C) 41° to 104° F (5° to 40° C) up to 5000 feet (1524 meters) Relative Humidity Operating Storage 15% to 80% (noncondensing) 15% to 90% (noncondensing) ENERGY STAR IBM 6400 Series Printers comply with the requirements of the ENERGY STAR Computers Program of the U.S. Environmental Protection Agency. B–4 Printer Specifications Preliminary 2 Electrical Characteristics Input Voltage Line Voltage Design Range 88–135V RMS 178–270V RMS Line Frequency –04, –04P 47–63 Hz 47–63 Hz 6A @ 100 V 3A @ 200 V RMS Current –05, –05P 6A @ 100 V 3A @ 200 V –08, –08P 6A @ 100 V 3A @ 200 V –09, –09P 6A @ 100 V 3A @ 200 V –012 6.5A @ 100 V 4A @ 200 V –014 8A @ 100 V 5A @ 200 V Power Consumption 6400–004 6400–04P Operating DP Mode 120 VAC 60 Hz Watts BTU/Hour VA All H’s 200 680 350 Max Typical 165 560 290 Standby Not Energy Star 70 240 130 Energy Star 25 85 48 Operating DP Mode 220 VAC 50 Hz Watts BTU/Hour VA All H’s 180 615 390 Max Typical 150 510 310 Standby Not Energy Star 60 205 145 Energy Star 25 85 55 Printer Specifications B–5 Preliminary 2 6400–005 6400–05P Operating DP Mode 120 VAC 60 Hz Watts BTU/Hour VA All H’s 200 680 350 Max Typical 165 560 290 Standby Not Energy Star 70 240 130 Energy Star 25 85 48 Operating DP Mode 220 VAC 50 Hz Watts BTU/Hour VA All H’s 180 615 390 Max Typical 150 510 310 Standby Not Energy Star 60 205 145 Energy Star 25 85 55 6400–008 6400–08P Operating DP Mode 120 VAC 60 Hz Watts BTU/Hour VA All H’s 240 820 415 Max Typical 190 650 330 Standby Not Energy Star 70 240 130 Energy Star 25 85 48 Operating DP Mode 220 VAC 50 Hz Watts BTU/Hour VA All H’s 210 720 435 Max Typical 180 615 360 Standby Not Energy Star 60 205 145 Energy Star 25 85 55 B–6 Printer Specifications . Preliminary 2 6400–009 6400–09P Operating DP Mode 120 VAC 60 Hz Watts BTU/Hour VA All H’s 290 990 500 Max Typical 225 770 380 Standby Not Energy Star 80 275 140 Energy Star 25 85 48 Operating DP Mode 220 VAC 50 Hz Watts BTU/Hour VA All H’s 280 960 550 Max Typical 220 750 440 Standby Not Energy Star 75 255 150 Energy Star 25 85 55 6400–012 Operating DP Mode 120 VAC 60 Hz Watts BTU/Hour VA All H’s 290 990 490 Max Typical 215 735 370 Standby Not Energy Star 70 240 130 Energy Star 25 85 48 Operating DP Mode 220 VAC 50 Hz Watts BTU/Hour VA All H’s 280 960 550 Max Typical 200 615 410 Standby Not Energy Star 60 205 145 Energy Star 25 85 55 Printer Specifications B–7 . RS–232 serial. RS–422 serial TTL. EIA–422B ASCII PC Parallel. EIA–232E serial. EIA–422B serial Up to 200 Kilobytes on parallel interface Up to 115.Preliminary 2 6400–014 Operating DP Mode 120 VAC 60 Hz Watts BTU/Hour VA All H’s 370 1260 635 Max Typical 260 885 445 Standby Not Energy Star 75 255 130 Energy Star 25 85 48 Operating DP Mode 220 VAC 50 Hz Watts BTU/Hour VA All H’s 380 1300 710 Max Typical 255 870 485 Standby Not Energy Star 75 255 150 Energy Star 25 85 55 Interfaces Type: Logic Levels: Data Format: Compatibility: PC Parallel. EIA–232E.2K baud on RS–232/422 serial interface Transfer Rates: B–8 Printer Specifications . or elongated attributes will decrease to not less than half the rates of the font without such attributes. Use of multiple densities and reverse paper feed also affects throughput.) Printing rates are summarized in Table B–1. 000 pages per month 6400–008. The reverse paper feed capability allows the printing of multiple densities on a single line. 014 prints 320.Preliminary 2 Duty Cycle 6400–004. but software maximizes the throughput by dynamically determining which dot rows contain adjacent dots and must be printed in two strokes. This is useful in printing forms and text together or in mixing different fonts on a print line. 08P prints 205. subscripts. 000 pages per month 6400–009. Printer Specifications B–9 . and is a function of the selected font and the vertical dot density. 04P prints 130. The exact print rate of lines containing these attributes depends on the specific print job. Print rates for lines containing attributes such as bold or emphasized printing. Printing speed is independent of the number of characters configured in the character set repertoire. (Due to paper path restrictions. 000 pages per month 6400–012. 09P prints 205. 05P prints 130. 000 pages per month 6400–005. 000 pages per month —under the following conditions: ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ Uppercase text characters only (no graphics) 6 lines per inch 10 characters per inch 63% character density or 83 characters per line 63% line density or 42 lines per 11-inch page Single part (18 lb) paper Printer is installed in accordance with the Setup Guide Printer is maintained in accordance with this maintenance manual Printing Rates The printing speed of text is measured in lines per minute (lpm). pedestal models have only limited reverse paper capability. superscripts. Preliminary 2 Table B–1.5 50 58 DATA PROCESSING 60 (120) X 72 356 375 600 658 900 1050 285 300 480 527 720 840 40 42 67 73 100 117 HIGH SPEED 60 (120) X 48 475 500 800 900 1200 1400 407 428 684 770 1026 1197 59 63 100 112 150 175 NOTE
A (B) X C. where: A is maximum horizontal dot density B is horizontal dot placement density C is vertical dot density D is maximum number of dots that may be placed on E horizontal dot positions F is number of vertical dots for uppercase symbols G is number of dots available for descenders NOTE  D (E) X F + G.1 10 12 13.3 15 17.3 7 (13) X 9 + 3 6 (11) X 9 + 3 5 (9) X 9 + 3 5 (9) X 7 + 2 4 (7) X 7 + 2 4 (7) X 7 + 2 3 (5) X 7 + 2 3 (5) X 7 + 2 5 (9) X 5 + 1 4 (7) X 5 + 1 4 (7) X 5 + 1 190 200 320 350 480 560 147 154 247 270 370 432 20 21 33 36. Printing Rates PRINT QUALITY DOT DENSITY (DPI) NOTE Ă
CHARACTERS PER INCH DOT MATRIX NOTE PERFORMANCE UPPERCASE ONLY LPM 04 04P 05 05P 08 08P 09 09P 012 014 04 04P DESCENDERS & UNDERLINE LPM 05 05P 08 08P 09 09P 012 014 04 04P PLOT MODE IPM 05 05P 08 08P 09 09P 012 014  MODEL CORRESPONDENCE 90 (180) X 96 10 12 15 10 12 13. where: B–10 Printer Specifications . 003280840 39.280840 0. To Obtain meter (m) centimeter (cm) millimeter (mm) meter (m) centimeter (cm) millimeter (mm) foot foot foot inch inch inch Torque and Force Multiply pound–inch pound–foot Newton–meter (NSm) Newton–meter (NSm) pound Newton (N) By 0.54* 25.0254* 2.3937008 0.11298 1.22481 To Obtain Newton–meter (NSm) Newton–meter (NSm) pound–inch pound–foot Newton (N) pound Metric Conversion Tables C–1 .C Metric Conversion Tables Length Multiply foot foot foot inch inch inch meter centimeter millimeter meter centimeter millimeter By 0.37008 0.8511 0.03280840 0.4* 3.8* 0.3048* 30.7376 4.4482 0.3558 8.48* 304.03937008 * Figure is exact. 001359621 735.2930711 3.412141 0.34952 2.8 Power Multiply By To Obtain Btu (International Table)/hour watt (W) watt (W) horsepower (metric) 0.Mass and Density Multiply pound* ounce* kilogram gram By 0.204622 0.499 watt (W) Btu (International Table)/hour horsepower (metric) watt (W) C–2 Metric Conversion Tables .8tC + 32 tC = (tF – 32)/1.03527397 * avoirdupois To Obtain kilogram (kg) gram (g) pound* ounce* Temperature To Convert From To Use Formula temperature Celsius (tC) temperature Fahrenheit (tF) temperature Fahrenheit (tF) temperature Celsius (tC) tF = 1.4535924 28. at a minimum engagement of 3.000 psi ultimate tensile strength 25 + 2 in oz 62 + 4 in oz 122 + 7 in oz 11 + 1 in lb 20 + 1 in lb 15 + 1 in lb 40 + 3 in lb Into Steel 60.D Torque Table The table below establishes the torque requirements for routine installation of threaded fasteners. Torque Table Carbon Steel Fasteners (ANSI B18.3 – 1972) Into Alum.000 psi ultimate tensile strength — — — — — — 105 + 5 in lb Fastener Size 2–56 4–40 6–32 8–32 10–24 10–32 1/4 – 20 36 + 2 in oz 75 + 5 in oz 150 + 10 in oz 18 + 1 in lb 25 + 1.5 in lb 29 + 2 in lb 62 + 4 in lb 30 + 2 in oz 70 + 5 in oz 135 + 10 in oz 18 + 1 in lb 21 + 1 in lb 29 + 1 in lb 62 + 4 in lb Fastener Size 4–40 UNC & 4–48 UNF 6–32 UNC & 6–40 UNF 8–32 UNC & 8–36 UNF 10–24 UNC & 10–32 UNF Torque for Routine Tightening of Threaded Fasteners 4 + 1 in lb 11 + 1 in lb 19 + 1 in lb 25 + 1 in lb Torque Table D–1 . Fastener sizes are listed as Numbered Size – Threads Per Inch.6. or Brass 25. These requirements apply to fasteners made of steel.5 threads. including chamfer and countersink.000 psi ultimate tensile strength Into Weld/Press Studs or Nuts Into Medium Carbon Steel Fasteners 105. D–2 Torque Table . . . . . . . . . . . . . . . . . . . . . . . . . . E–7 Power Cable . . . E–3 Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . E–2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–4 Safety Ground Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–8 Print Interlock Service Check . . . E–8 Safety Inspection Guide E–1 . . . . . . . . . . . . . . . . E–4 Inspect Electrical Parts . . . . . . . . . . . . . . . . . . . . E–4 Customer Power Source Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–7 Power On/Off Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E Safety Inspection Guide Safety Inspections . . . . . E–2 Prepare the Printer for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–3 Top Cover and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–3 Inspect Mechanical Parts . . . . . . . . . . . . . . . . . . . . A Fluke** meter (P/N 8496278) or similar device for resistance and voltage measurements. If you find any unsafe conditions. and service personnel from injury. For each safety check on the following pages. Have the following items available: 1. 3. Use this inspection guide as an aid in identifying possible unsafe conditions in a 6400 series printer. do the steps in the order presented. 2.Safety Inspections IBM 6400 printers incorporate safety items installed to protect customers. determine the severity of the hazard and whether or not you can continue the inspection without first correcting the problem. Perform the inspection steps outlined in this guide before the normal inspection for Maintenance Agreement Qualification. Preparation You must have completed the “Electrical Safety Training Course for IBM Customer Engineers” (self-study course 77170 or existing level) to do the Safety Inspection. S229–8124. Order No. Do not omit any steps. An ECOS** Electrical Safety Tester (P/N 6339695) in the United States or a similar safety tester in other countries. E–2 Safety Inspection Guide . operators. NOTE: The correction of any unsafe condition is the customer’s responsibility. or any time you are instructed to make a safety inspection. Electrical Safety for IBM Customer Engineers. Prepare the Printer for Inspection DANGER <1> Always disconnect the AC power cord from the power source before performing any maintenance procedure. Failure to remove power could result in injury to persons or damage to equipment. If you must apply power during maintenance, you will be instructed to so in the maintenance procedure. 1. Have the operator take the printer off-line. 2. Power off the printer. 3. Unplug the printer power cord from the customer’s power outlet. Inspect Mechanical Parts Top Cover and Cabinet Doors 1. Inspect the top cover: a. Open the top cover. On cabinet models, make sure the gas spring assembly holds the cover up in the open position. b. Make sure the window is not cracked or broken. c. Make sure the seal around the top cover is not cracked or broken. d. Make sure there are no exposed or sharp edges. e. Make sure the wireform paper path is undamaged. f. Make sure the electrostatic discharge (ESD) fingers are not loose or damaged. Make sure they touch the contact strips on the frame when the cover is closed. g. Close the top cover. Make sure the operator panel is centered in the opening of the cover. 2. On cabinet models, inspect the front and rear cabinet doors: a. Make sure the seals and magnetic strips are not loose or damaged. b. Make sure the restraining cable is attached and unbroken. c. Make sure there are no exposed or sharp edges. Safety Inspection Guide E–3 d. Open the rear cabinet door and inspect the lower rear paper path: a. Make sure the service panel permitting access to the I/O plate and circuit breaker (on/off switch) is installed. b. Make sure the paper stacker tray assembly is in place and undamaged. Print Mechanism 1. Open the printer top cover. 2. Make sure the shuttle cover is correctly installed and undamaged. (See page 7–17.) 3. Make sure the paper path is correctly installed and undamaged. (See page 7–40.) Inspect Electrical Parts Safety Ground Path 1. Make sure the printer power cord is unplugged. 2. Remove the paper guide assembly (page 7–40). 3. Make sure the ground cable from the circuit breaker power leads is undamaged and firmly attached to the ground lug on the wall of the card cage, as shown in Figure E–1. NOTE: Ground paths for the entire printer are summarized in Figure E–2. E–4 Safety Inspection Guide Card cage fan and power supply board removed for clarity. Circuit Breaker IEC 320 AC Power Connector (J301) Ground Lug Ground Cable (To Power Supply J1) Figure E–1. Circuit Breaker Ground, Cabinet Models 4. Set a Fluke meter (P/N 8496278) or similar device to the lowest resistance scale. Measure the resistance between the power cable ground pin and the printer frame: safety ground circuits should measure 0.1 Ohm or less. 5. Install the paper guide assembly (page 7–40). Safety Inspection Guide E–5 AC POWER J301 IEC 320 AC POWER CIRCUIT BREAKER J1 AC P1 Line 1 Line 2 / Neutral +48V +48V +5 V +5 V +8.5V +8.5V OPERATOR PANEL AC to DC Power Supply Board J310 P310 CHASSIS GND Return Ret EIA–232–E Serial I/O +5 V P112 J112 CMX Controller Board Card Cage Fan J101 DC POWER Parallel I/O SHIELD GND Point of Common Ground Ret +48V J106 MSL P106 MSL J108 HBL P108 HBL +8.5V Ret J105 HBP P105 HBP +8.5/+48V Ret J116 SMD P116 SMD +5 V Remote Power P110 J110 J107 MSR P107 MSR Exhaust Fan Cabinet models only +48V Ret Paper Feed Motor Platen Motor Paper Motion Detector Paper Out Detector Left Ribbon Guide Left Ribbon Motor +48V Shuttle Assy +48V Terminator Board Ret Shuttle Motor +48V +5 V +5 V +5 V Hammer Bank Board +5 V +5 V Platen Open Switch Right Ribbon Guide +48V Ret +24V Hammer Bank Fan +48V Right Ribbon Motor Figure E–2. Ground Path Diagram E–6 Safety Inspection Guide Customer Power Source Service Check Use an ECOS Electrical Safety Tester (P/N 6339695) in the United States or a similar safety tester in other countries. NOTE: The ECOS tester will trip ground fault detector protected outlets. This is a good test of the ground fault detector. Reset the outlet as needed. Plug the ECOS meter into the customer’s outlet. Follow the instructions supplied with the meter to test for the following: 1. Wiring errors 2. Low voltage 3. Neutral to ground short 4. Ground path impedance 5. Neutral impedance NOTE: The customer is responsible for correcting problems with the power source. Inform the IBM Installation Planning Representative (IPR) of any problems with the customer’s power source. Each branch circuit must be grounded for safety and correct operation of the printer. This ground must be connected either to the electrical service ground or to a suitable building ground. The printer power cable has a green or green/yellow insulated grounding conductor. This is not a neutral. Power Cable 1. Make sure the power cable is not damaged. 2. Make sure the power plug is the correct type. Safety Inspection Guide E–7 Power On/Off Verification 1. Make sure all covers are installed. 2. Plug the power cable into the customer’s power outlet. 3. Power on the printer and watch the LCD. 4. Verify that the power-on diagnostic tests and initialization routines are successful. 5. After successful initialization, the printer should cycle automatically to either the READY or NOT READY mode, depending on which power-on state was selected when the printer was configured. 6. Power off the printer. Verify that the LCD goes completely blank and all fans stop. Print Interlock Service Check 1. Power on the printer. 2. Open the printer top cover. 3. Open the forms thickness lever. The LCD should display “057 CLOSE PLATEN” and the audible alarm should sound if it is enabled. 4. Press Stop. The audible alarm should stop. 5. Close the forms thickness lever. The fault message should clear. E–8 Safety Inspection Guide . .F Abbreviations and Signal Mnemonics NOTE: Mnemonics with the first letter “N” are negative true. . . . . . . . . . . . . . . . . . . Ampere AMPL . . . . Abbreviation/ Mnemonic Definition mF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . microfarad (10–6 farad) ms . . . . Access ACK . . Bi-phase Communications Processor BHSC . . . . . . . . . . . . . Buffered. . . . . . . . . Buffered. . Address 1. . etc. . . . . . . . . A1. . . . . . . . . . . . Application-Specific Integrated Circuit ATTN . . . . . . . . . . . . . . etc. . . . AC . Address 0. . . . Busy BTU . . Amplitude AN . . . . . . . . Amplitude. . . . . . Alternating Current ACC . . . . . Attention B . . . Lower Driver BPS . Hammer Bank Fan BCOM . . . . . . . . Buffered BANK FAN . . . . . . . microsecond (10–6 second) msec . . . . . . . . . . Buffered Upper Driver Abbreviations and Signal Mnemonics F–1 . . . . . . . . . . . . . . . . . . . Low True BNLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anode ASIC . . . . . Bits Per Second BSY . . . . . . . British Thermal Unit BUD . . . . . . . . Acknowledge AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low True. . . . . microsecond (10–6 second) A0. Buffered Communication BCP . . . . . . . . . . . . . . . . . . . Buffered Hammer Shift Clock BN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driver DSR . . Cover Open (Switch) D0. . . . . . . . . . Manufacturer’s designation of the controller board CNC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection CPI . . . . . Data Controller (a functional unit of the CMX controller board) DCD . . . . . . . . . . . . . . . . . . . . Data Bit 1. . . . . . . . . . . . . . . . . . DAT . . . . . . . . . . . . . . . . . . . Command CMX . . . . . . . . Dot Plucker Memory Controller DPU . . . . . . . . . . . . . . . . . Data Processing. . . . . . . . . . . . . . . . . . Customer Engineer CHNG . . . . . . Card Cage CCF . . . . . Control CTS . . . . . . . . . . . . . . . Data Terminal Ready F–2 Abbreviations and Signal Mnemonics . . . . . Controller CMD . . . . . . . . . . . . . . . . . . . . Characters Per Inch CR . . . . . . . . . . . . . . . . . . . Data Bit 0. . . Collector COMM . . . . . . Change CIR . . . . etc. . . . . etc. . Clear to Send CUR . . . . . . . . . . . . Cover Open COLL . . . . . . . . . Data Processing Unit DRAM . . . . . . . . . . . . . . . . . . . . . . . . . Direct Current. . . . . . . . . Differential DMA . . . . . . . . . . DataProducts DPMC . . . . Cathode CC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive or Driver DRVR . . . . . . . . . Dynamic Random-Access Memory DRV . . . . . . . . . . . . . . . . . . . . . . . Communication CONTLR . . . . . . . .CA . . . Connector. . . . . Data DC . . . . . . . . . . . . D1. Data Carrier Detect DIAG . . . . . . . . . Diagnostic DIFF . . . . . . Data Set Ready DTR . . . Carriage Return CT . . . . . . . . . . . . . . Clock CO . . . . . . . . . . Card Cage Fan CE . . . . . . . . . . . . . . . . . . . . . Circuit CLK . . . . . . . . . Current CVO . Coaxial/Twinaxial CTL . . . . . . . Direct Memory Access DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ElectroMagnetic Interference EMIT . . . . . . . Hammer Driver Integrated Circuit HDPH . . . . . . . . . . . . . . . . . Integrated Circuit ID . Hammer Bank Power HBR . . . . . . . . . . . Expand FD . . . . . . . . . . . Right HD . . . . . . Ground HB . . . . . Electrostatic Discharge EX . . . . . . . . . . . . . . . . . . . . . . Hammer Bank. . . . . . . . . . . . . Form Feed FIFO . . . . . . . . . . . . . . . . . . . . Exhaust Fan EXP . . . Instruction INT . Electrically Programmable Read-Only Memory ERR . . Hammer Bank Fan HBL . . . . . . . . . . . . . . . . Exhaust EXF . . . . . . . . . Feed FF . . . . . . . . . . . . . . . Fault FLTR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interrupt Abbreviations and Signal Mnemonics F–3 . . . . . . . . . Exhaust Fan EMI . . . . . . . . . . . . . . . . . . . . . . . . . Hammer Bank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust. . . Intelligent Graphics Processor INST . Filter FP . . Hammer Driver Phase HLP . . . . . . . . . . . . . . . . . . . Electrically Erasable/Programmable Read-Only Memory EHF . . . . . . . . . . . . . . . . . . . . . . . . . Hammer Bank Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . Error ESD . . . Expansion EXPND . . . . . . . . . . . . . Hammer Bank HBA . . . . . . . . . . . . . . . . . . . . . . . . . . First In. . . . . . . . . . . . . . . . . . . . . . . Hammer Bank ASIC HBF . . . . Emitter EPROM . . . . . Identification IGP . . . . .EC . . . . . . . . . Engine Controller (a functional unit of the CMX board) EEPROM . . . . Front Panel (Operator Panel) FTIC . . . . . . . . . . . . . . . . First Out FLT . . . . . . . . . Left HBP . . Extra EXH . . . . . . . Fire Timer Integrated Circuit GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signals and Power IC . . . . . . . . . . . . . Hammer Driver HDIC . . . . . . . . . . . . . Input/Output IRQ . Non-volatile Random-Access Memory NT . . . . . . Light Emitting Diode LF . . . . . . . . Left MSR . . . . . . . . . . . . . . . . . . . Motor and Sensors. . . . . Right N . . . . . . . . . . Not OLV . . Magnetic Pickup (Unit) ms . . . . . . . . . . . . . . . . Jack connector L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Connected NLQ . . . . . . . . . . . . . . . . nanosecond (10–9 second) NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative True N/C . . . . . . Line Feed LO . . . . . . . . . . . . . . . . . . Mechanism MF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operand F–4 Abbreviations and Signal Mnemonics . . . . . . . . . . . . . . . . . Number NOVRAM . . . . . RS–232 (Optional) MECA . . . . . . . . .I/O . . . . . . . . . . . . Low LPI . microfarad (10–6 farad) MH . . . . . . . . . . . . . . . . Mounting Hole MOSFET . . . . . . . . . . . . . . . Interrupt Request (J) . . . . . . . . . . . . . . . . . . . . . Mechanism Engine Control ASIC MECH . . . . . . . . . . . . . . . . . . . Metal Oxide Semiconductor Field Effect Transistor MOT . . . . . . Lines Per Inch LPM . millisecond (10–3 second) MSL . . . . . . . . . . . . . . Not Connected NC . . . . Motor and Sensors. . . . . . . . . . . . . . . . Motor MPU . . . . . . . . . . . . . . . . . . Motor MAIN . . . Lines Per Minute LRIB . . . . . . . . Near Letter Quality No. . . . . . . . . . Maintenance Jack. . . . . . . . . . . . . . . . Left Ribbon LRP . . . . . . . . . . Left LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid Crystal Display LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Ribbon Guide M . . . . On Line Verify OP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-volatile Random-Access Memory ns . . . . . . . . . . . . . . . . . . . . Paper Motion Detect (Switch) PN . . . . . . . . . . . Pointer or Printer PWM . . . . . . . . . . . . . . . . . . etc. . . . . Power R . . . . . . . . . . . Platen Open (Switch) PMD . . . . . . . Return RIB . . . . . . . . . . . . . . . . . . . . . . . . . Phase B PI . . . . . . . . . . . . . . Peripheral Device PF . . . . . Parameter PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . + 5 V dc (P) . . . . . . . . . . . . . . . . Power Supply + 5 Volt PTR . . . . . . . Paper Instruction PLAT . . . . Phase A PHB . . . Paper PROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Guide Abbreviations and Signal Mnemonics F–5 . . . . . . . . Paper PARM . . . . . . . . . . . . . . . . . . . . Paper Out POD . . . .P5 . Pin P/N . . . . . . . . . . . . . Power Supply PS5 . . . . . Paper Feed Controller PFM . . . . . . . . . . . . . . . . Pin connector P(1). . . . . . . . . . P(2). . . . . . . . . . . Ribbon RG . . . . . . . . Read RET . . . . . Platen Motor PLO . Paper Out Detect (Switch) PPR . . . . . . . . . . . . . . . . . . . Paper Feed Motor PHA . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulse Width Modulation PWR . . . . . . . . . . . . . . . Paper Empty PER . . . Programmable Read-Only Memory PS . . . . . . . . . . . . . . Printed Circuit Board PE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . data 2. . . . . Part Number PO . . . . . . . . picofarad (10–12 farad) PFC . . . Platen PLM . . . . . . . . . . . . . . . . . . . . . . . Paper PAPR . . . . . . . . . . . . . . . . . . Parallel data 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Error. . . . etc. . . . . . . . PAL . Programmable Array Logic PAP . . . . . . . . . . . . . . . . . . . Printed Circuit Board Assembly PCB . . . Ribbon RD . . . . . . . . . . . . . . . . . . . . Right RBN . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reset RTPU . . . . . . . . . . . . . Synchronize TCB . . . . Sense. . . . Select (On-line) Slew . . . . . . . Request to Send RXD . . . . Right RQ . . . . . . Systems Network Architecture SPU . Status STBY . . . . Static Random-Access Memory STAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Task Control Block TEMP . . Right Ribbon RRP . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Motor RML . . . . Top of Form (first print line) F–6 Abbreviations and Signal Mnemonics . . . . . . . . . . . . . Ribbon Motor. . . . . . . . . . . . . . . . . . . . . . Structured Field SG . . . . . . . . . . . . . . . . . . . . . . . Right RM . . . . . . . . . . . . . . . . . . . . . . . . . . . Shuttle Processor Unit SRAM . . . . . . . . . . . . . Security (Key) SEL . . . . . . . Shuttle SIMM . . . . . . . Shuttle SHUTL . . . . . . . . . . . . Select SEN . . . . Ribbon Motor. . . SNA Character Stream SEC . . . .RGL . . . . . . Sensor SF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature TOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Inline Memory Module SLCT . . . . . . . . Request RRIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shuttle Motor Drive SNA . . . . . . . . . . . . . . . . . . . . Shuttle Motor SHUT . . . . . Right Ribbon Guide RSP . . . . . . . . . . Rapid vertical paper movement SMD . . . Receive Data SCS . . . . . . . . . . . . . . . . . . . . . . Shuttle Hall (Effect) SHM . . . . . . . Ribbon Guide. . . . . . . . . . . . . . Signal Ground SHH . . . . Stacker SW . . . . . . . . . . . Standby STK . . . . . . . . . . . . . . . . . . . . . . . . . Real-Time Processing Unit RTS . . . . . . . . . . . . . . . . . . . . . . . . Left RGR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Guide. . . . . . . . . . . . . . . . . . . . Ribbon and Shuttle Processor RST . . . . . . . . . . Left RMR . . . . . . . . . . . Switch SYNC . . . . . . . . . . . Without XMT . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage at Drain VSS . . . . . . . . . . .TP . . . . . . . . Voltage at Source VX . . . Transistor-Transistor Logic TXD . . Upper Drive Phase UNDEF . . . . . . . . . . . . . Volts VCC . . . . . . . . . Undefined USART . . . . Test Point TTL . . . . . . Transmit Data UART . . . . . . The letters VX do not stand for anything. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmit Abbreviations and Signal Mnemonics F–7 . . . . . . WR . . . . . . . . . . . . . . . . . . A special ASIC containing circuits that help the DC controller operate. . . . . . . . . . . . . they simply designate this ASIC. . . . . . . . . . . . . . Universal Asynchronous Receiver/Transmitter UDPH . . . . . . . . . . . . . . . . . . . Voltage at Collector VDD . . . . . . . . . . . . . . . With w/o . . . . . . . . . . . Write w/ . . . . . . . Universal Synchronous/Asynchronous Receiver/Transmitter V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–8 Abbreviations and Signal Mnemonics . Barbados. Panama.S. Venezuela. Romania. Italy. El Salvador. Saint Lucia. Malaysia. Zaire Power Cord. Cameroon. Hong Kong. Phillipines. Canada Power Cord. Bulgaria. Dominican Republic. Qatar. Algeria. 220V 12 Feet Non-Lock. Singapore. Central Africa Empire. France. Portugal. Bermuda. 9 Feet. Chile. Sudan. Long) Coax Adapter Cable for use with Multi-Platform Interface Power Cords G–1 . USSR. Ireland..G Part No. 9 Feet. Taiwan. Afghanistan. Spain.S. Upper Volta. Channel Islands. Luxembourg. Korea.. Greece. Japan Twinax Auto-Termination Cable Twinax Auto-Termination Cable (47 in. 110V 12 Feet Non-Lock. Yugoslavia. Guatemala. Nigeria. Monaco. Finland. Bahamas. Argentina. Colombia. Chad. Haiti. Peru. Bolivia. Austria. 220V 6 Feet Non-Lock. Libya Power Cord. Malta. East Germany. Morocco. PRC. Brunei. Iraq. Nepal. Czechoslovakia. Saudi Arabia.. Honduras. Rhodesia. Samoa. Cayman Islands. Netherlands. 12 Feet. Netherlands. Sweden. 9 Feet. Indonesia. U. Trinidad. 9 Feet. Norway. Cyprus. Syria. Jamaica. Polynesia. Phillipines. Peru. Ecuador. New Zealand.S. Hungary. South Africa. Madagascar. Paraguay. Ivory Coast. Sri Lanka Power Cord. Brazil. Pakistan.S. Indonesia Power Cord. Iran. Uraguay Power Cord. 57G7261 1838574 6952299 1838573 Power Cords Units Description 1 1 1 1 13F9941 13F9980 1 1 13F9998 14F0016 14F0034 1 1 1 14F0052 14F0070 14F0088 1332167 38F8254 14H5335 08H7968 1 1 1 1 1 1 1 Power Cord. Kenya. Costa Rica. Jordan. Congo/Brazzaville. Thailand. Nicaragua. U. Uganda. Angola. New Guinea. Denmark Power Cord. India. Canada. Mexico. Iceland. 110V 6 Feet Non-Lock. Mauritania. Lebanon.K. Guinea. West Germany. Benin Republic/Dahomey. Tanzania. Antilles. Liberia. Nicaragua. Mali. Liechtenstein Power Cord. Tunisia. Israel Power Cord. Sierra Leone. 12 Feet.. Turkey. United Arab Emirates. Kuwait. Taiwan. Guyana. Bangladesh. Saint Lucia. 9 Feet. Togo. Columbia. Tobago. Oman. Canada Power Cord. U. 9 Feet. Burundi. U. Egypt. U. Poland. Belgium.. Mozambique. Canada. Bahrain. Switzerland. Zambia Power Cord. Ethiopia. Burma. Tobago. Australia. Honduras. Suriname. 9 Feet. Panama Power Cord. G–2 Power Cords . 009. A–31 7–85 7–73 7–73 7–85 7–79 7–83 7–83 7–73 7–73 7–67 7–79 7–79 7–79 Description Riser. 005.Preliminary 2 H Part Numbers Part Number 04H4779 08H7934 08H7936 08H7954 14H5154 14H5159 14H5169 14H5174 14H5179 14H5184 14H5211 14H5214 14H5217 14H5235 14H5271 14H5272 14H5273 14H5274 14H5275 Page 7–67 7–87 7–85 7–73 7–87 7–87. 05P) Part Numbers H–1 . 04P. 04P. 014) Chain Assembly Kit Hmr Bank/Rbn Mask Cov Assy (Models 004. 008. Shaft. 005. Stacker Runner Platen Open Motor Pulley Platen Assembly Anti–Static Brush Kit Platen Open Motor Assembly Hammer Bank Fan Assembly Platen Hardware Kit Platen/Paper Feed Cover Kit Paper Scale Platen Lever Kit Clamp. 04P) Hammer Spring Kit (Models 004. 012. 05P) Shuttle Frame Assy (Models 004. 005. Receiving Tractor Shaft Kit Tractor Shaft Hardware Kit Shroud Assembly. Air (Shuttle Cover) Paper Guide Assembly (Models 004. Shuttle Motor Drive SIMM.Preliminary 2 Part Number 14H5276 14H5277 14H5278 14H5279 14H5280 Page 7–65 7–65 7–65 A–21 7–85. MPU 14H5330 14H5481 Cable Assembly. A–34 7–79. Operator Panel Cable Assembly. AC In. A–24 A–27 7–31 Top Cover Kit Front Door Kit Rear Door Kit Cable Assy. DRAM. Cover Open 14H5283 14H5285 14H5286 14H5287 14H5288 14H5289 14H5289 14H5290 Cable Assy. Hammer Bank Power Cable Assy. 2MB H–2 Part Numbers . Card Cage Fan Cable Assy. Power Supply (Part of AC Field Kit) Cable Assy. A–23 7–10 A–16 A–17 7–87. A–25 7–67 7–69 7–69. Connector Kit Cable Assy. Exhaust Fan Centronics I/O Cable Assembly Housing. Hammer Bank Logic Platen Switch Kit Description 14H5281 14H5282 Paper Detector Switch Assembly (Standard) Switch Assembly. Blank. A–35 7–87. Grommet Operator Panel Assembly (Cabinet) Cable Assembly. A–33 A–22 A–18 A–20 7–79. AC Power Input (Part of AC Field Kit) Ribbon Guide Kit 14H5296 14H5299 14H5300 14H5329 Spares Kit. 7–71 7–81. Flash. 1MB SIMM. 009. Ribbon Cable Assy. 08P. Graphics SIMM. DRAM. 009. Data. 014) Shuttle Frame Assy (Models 008. DRAM. 2MB Wireform Paper Path Paper Detector Switch Assy (Black Back) Circuit Breaker Hardware Kit CT Plate Cable. Blank. Coax/Twinax Multi–Platform Interface Hmr Bank/Rbn Mask Cov Assy (Models 008. Blank. A–34 7–89 7–65 7–91 7–15 7–15 7–15 7–79 Description Security Module. 1MB SIMM. 4MB Security Module.Preliminary 2 Part Number 14H5490 14H5499 14H5508 14H5509 14H5512 14H5513 14H5516 14H5517 14H5520 14H5521 14H5522 14H5525 14H5589 14H5539 14H5540 14H5567 14H5570 14H5571 14H5572 14H5585 14H5592 14H5593 14H5595 14H5601 Page 7–31 7–31 7–31 7–31 7–79 7–79 7–79 7–79 7–87 7–87 7–79. 08P. Coax/Twinax Multi–Platform Interface I/O Bracket Assembly. Base Hammer Spring Kit (Models 008. 09P) Hammer Spring Kit (Models 012. 08P) Shuttle Frame Assy (Model 012) Paper Feed Motor Motor Assembly. Flash. +5V Remote Power SIMM. Centronics/Dataproducts Adapter Resistor Kit Cable Assy. 09P) Part Numbers H–3 . Coax/Twinax Multi–Platform Interface PROM. A–29 7–48 A–30 7–31 7–31 7–65 7–87. Blank. Blank. 05P. 87 Teeth (Platen Open) 14H5644 24H8533 24H8534 24H8535 24H8593 24H8647 7–79 7–71 7–71 7–91 7–83 7–79 24H8648 26H9625 30H3981 30H3985 30H3986 30H4008 38F8254 57G1421 57G1440 57G1453 57G1460 57G1466 57G1468 57G1467 7–79 7–79 7–67 7–81 7–65 7–65 A–28 7–87 7–69 7–87 7–83 7–83 7–73 7–85 H–4 Part Numbers .) Shuttle Frame Assy (Models 005. Nos. 008. 01BXXXX. 6400 CMX Controller Board. 100 Teeth (Paper Feed) Belt. 09P) Runner. V5.5. All models 009 and 09P. Models 008 and 012 with Ser. 05P.0 (All models 004 and 04P. Timing.) Power Supply PCBA. 01EXXXX. Expansion Connector. (Models 004. 25 MHz (All models 005. 05P) Shuttle Frame Assy (Models 009. Models 008 and 012 with Serial Nos. 014) Logo. 050P. 312W. and 08P. 60–pin Paper Support CMX Controller Board. 012) Input Tray (Optional) Caster. and higher. Stacker Extension Spring Shipping Container Kit Wire Rope Twinax Auto–Termination (“Smart T”) Motor Pulley. 01AXXXX. Pedestal Adapter. Paper Feed Fan Assembly Paper Detector Switch Assy Splined Shaft Tractor Set Belt. Timing. V5. 005. 04P. 08P.Preliminary 2 Part Number 14H5602 14H5603 14H5643 Page 7–79 7–65 7–79 Description Hmr Bank/Rbn Mask Cov Assy (Models 012. and 01CXXXX. 01DXXXX. Dutch Operator Panel Overlay. Driven Ground Clip. English Operator Panel Overlay. Splined Shaft Operator Panel Overlay. German Operator Panel Overlay. 05P. Italian Operator Panel Overlay. without Brake Window. U. Pedestal Part Numbers H–5 . Portuguese Stacker Power Cord. 09P) Paper Basket Lid. with Brake Caster. French Operator Panel Overlay.) Paper Path Assembly (Models 04P. 08P. Spanish Operator Panel Overlay. Top Cover Platen Pulley.S. A–32 7–87 7–69 7–65 7–65 7–65 7–85 7–83 7–69 7–69 7–69 7–69 7–69 7–69 7–69 7–67 7–67 7–75 7–71 7–71 7–71 7–71 7–71 7–71 Description Ironer Assembly. Pedestal Model Top Cover. Reverse Paper Feed Magnetic Pickup Assembly (MPU) Ribbon Hub Kit Gas Spring Kit Caster. Complete (Pedestal Model) Hinge Lid Kit (Pedestal Model) Lid Accessory Kit (Pedestal Model) Shipping Container. (See also Appendix G. Braz.Preliminary 2 Part Number 57G1469 57G1476 57G1479 57G1481 57G1485 57G1486 57G1492 57G1514 57G1521 57G1598 57G1599 57G1600 57G1601 57G1602 57G1603 57G1604 57G7176 57G7260 63H5116 63H5118 63H5119 63H5120 63H5121 63H5122 63H5123 Page 7–85 7–81. Ribbon Motor.Preliminary 2 Part Number 63H5124 63H5125 63H7379 63H7382 63H7398 63H7464 63H7509 63H7510 90H3268 90H3269 90H3271 S217–0181 S217–0182 S246–0111 S246–0112 S246–0115 S246–0116 S246–0118 S246–0125 S246–0126 S246–0137 S246–0138 S246–0141 S246–0142 Page 7–71 7–71 1–14 7–91 7–65 A–26 7–71 7–65 7–79 7–79 7–79 1–6 1–6 1–7 1–7 1–6 1–6 1–6 1–6 1–6 1–6 1–6 1–6 1–6 Description Operator Panel (Pedestal) Bracket. English 6400 Line Matrix Printer Setup Guide. Italian H–6 Part Numbers . Brazilian Portuguese 6400 Line Matrix Printer Setup Guide. Extension Pedestal Kit Door Seal Kit Power Supply PCBA (Models 990. German 6400 Operator’s Guide. 014) Shuttle Frame Assy (Model 014) CMX Controller Board.5. V5. English 6400 ASCII Programmer’s Reference 6400 Operator’s Guide. Italian 6400 Line Matrix Printer Setup Guide. Brazilian Portuguese IBM Network Print Server Ethernet Administrator’s Guide IBM Network Print Server Token-Ring Administrator’s Guide 6400 Operator’s Guide. Control Panel 6400 Line Matrix Printer Configuration Utility Disk Expansion-CT PCBA Top Cover Seal Kit Cable Assembly. German 6400 Line Matrix Printer Setup Guide. Dutch 6400 Line Matrix Printer Setup Guide. 40 MHz (Model 014 only) 6400 Operator’s Guide. Dutch 6400 Operator’s Guide. 09P. Preliminary 2 Part Number S246–0143 S246–0144 S246–0145 S246–0146 S246–0147 S246–0148 S246–0149 S246–0150 S246–0151 SF11–0722 SF11–0723 Page 1–6 1–6 1–6 1–6 1–6 1–6 1–6 1–6 1–6 1–6 1–6 Description 6400 Line Matrix Printer Operator’s Guide. Spanish 6400 CTA Programmer’s Reference 6400 IPDS Programmer’s Reference 6400 Coax/Twinax Multi–Platform Interface Option Installation and Operation Guide 6400 Code V User’s Manual 6400 IGP User’s Manual 6400 Line Matrix Printer Setup Guide. Japanese 6400 Operator’s Guide. Spanish 6400 Line Matrix Printer Setup Guide. French 6400 Operator’s Guide. French Part Numbers H–7 . Japanese 6400 Line Matrix Printer Setup Guide. H–8 Part Numbers . Noise Suppression Devices I–1 . Make sure you install the noise suppressors on the replacement cable assembly. The parallel I/O cable assembly passes through this core. Two kinds of ferrite noise suppressors are used: 1. note the number and location of noise suppressors before remove the defective cable.I Noise Suppression Devices Ferrite noise suppressors are installed in the printer to reduce radio frequency interference (RFI) to and from electronic equipment located near the printer. See Figure I–1. If you replace either of these cable assemblies. Figure I–1 shows how these devices are installed. 2. Shielding Bead—Cylindrical core through and around which the control panel cable assembly is wound. Two are required. IMPORTANT Duplicate the number of turns around the shielding beads when installing or replacing the control panel cable. Ferrite Clamp—A noise suppression core housed in a hinged plastic case and attached with adhesive to the wall of the card cage. Connector J203 Figure I–1. Ferrite Core Installation I–2 Noise Suppression Devices .Control Panel Cable Assembly Connector P110 Connector P310 Shielding Bead NOTE: Two turns around each bead. Parallel I/O Cable Assembly Connector P112 Ferrite Core with Clamp and Adhesive Backing NOTE: This core attaches to right rear card cage wall. 5–7 060 PRINTER HOT. 5–5 015 COMMUNICATION CHECK / CHECK CABLE. 5–8 101 UPPER DRIVER SHORT. 5–8 080 POWER SUPPLY HOT. 5–8 085 CONTROLLER VOLTAGE. 5–7 081 POWER SUPPLY VOLTAGE FAILURE. 5–7 08 CONTROLLER 23. 5–5 013 ACTIVATE LOST. 5–8 087 PLATEN OPEN TIMEOUT / CLOSE PLATEN.5V FAILED. 5–6 042 CUSTOM SET DOES NOT EXIST / SAVE FIRST. 5–8 090 SHUTTLE COVER OPEN / CLOSE SHUTTLE COVER. 5–6 028 COMMUNICATIONS CHECK / CALL SYSTEM OPERATOR. 5–9 Index 1 . 5–5 006 HOST SYSTEM REQUEST ATTENTION. 5–6 022 UNIT ADDRESS NOT RECEIVED / CHECK PRINTER ADDRESS. 5–5 003 FORMS EJECTED / PRESS EJECT/RESTORE.5V. 5–8 082 POWER SUPPLY 8. 5–8 092 RIBBON DRIVER CIRCUIT. 5–6 032 FORMS JAMMED TIMEOUT / CLEAR JAM AND RELOAD FORMS. 5–6 031 END OF FORMS TIMEOUT / LOAD FORMS. 5–7 059 CANCEL PRINT ACTIVE. 5–7 062 EXHAUST FAN FAULT. 5–6 025 SERIAL FRAMING ERROR / VERIFY CONFIGURATION. 5–6 041 BUFFER OVERFLOW. 5–5 010 PARAMETER ERROR. 5–6 024 SERIAL LINE PARITY ERROR / VERIFY CONFIGURATION. 5–5 007 FM HEADER ERROR. 5–5 009 INVALID KEY PRESS. 5–5 002 FORMS JAMMED / CLEAR JAM AND RELOAD FORMS. 5–5 004 VIEW FORMS / PRESS VIEW KEY. 5–6 021 RECEIVE BUFFER OVERRUN / VERIFY CONFIGURATION. 5–6 016 INVALID COMMAND.Index Numbers 001 END OF FORMS / LOAD FORMS. 5–8 084 POWER SUPPLY 48V FAILED. 5–7 057 CLOSE PLATEN. 5–8 089 RIBBON STALL. 5–7 063 INTAKE FAN FAULT. 5–5 014 INVALID ACTIVATE. 5–7 058 SHUTTLE JAM / SEE USER’S GUIDE. 5–6 029 8344 DIAGNOSTIC TEST FAILED. 5–7 069 DATA CLEARED. 5–7 043 CUSTOM SET ALREADY EXISTS / DELETE EXISTING SET FIRST. 5–7 046 EC STOPPED AT STATE (state). 5–5 011 SCS COMMAND ERROR. 5–6 026 HEX DUMP MODE. 5–7 065 HAMMER BANK FAN FAULT. 5–5 012 STRUCTURED FIELD ERROR. 5–7 044 EC FIRMWARE/HARDWARE ERROR. 5–6 027 COMMUNICATIONS CHECK / CALL SYSTEM OPERATOR. 5–5 008 HOLD PRINT TIMEOUT / PRESS START. 5–12 134 PLATEN INVALID COMMAND / SEE USER’S GUIDE.102 LOWER DRIVER SHORT. 5–13 Abbreviations. 5–9 112 UNDEFINED OPCODE / SEE USER’S GUIDE. 5–9 113 PROTECTED INSTRUCTION / SEE USER’S GUIDE. Printer Information Menu. 5–11 128 PAPER FEED INVALID COMMAND / SEE USER’S GUIDE. 6–20 2 Index . 5–9 111 STACK UNDERFLOW / SEE USER’S GUIDE. 5–9 105 HAMMER COIL (number) OPEN. 5–10 117 A TO D OVERRUN / SEE USER’S GUIDE. 5–10 119 TCB CORRUPTED / SEE USER’S GUIDE. 5–12 129 PAPER FEED INVALID PARAMETER / SEE USER’S GUIDE. 5–12 131 PAPER FEED INTERRUPT / SEE USER’S GUIDE. 6–32 end of forms distance. 5–10 118 UNDEFINED INTERRUPT / SEE USER’S GUIDE. 5–12 135 PLATEN INVALID STATE / SEE USER’S GUIDE. 5–13 A A97 GRAPHIC CHECK ERROR / PRESS STOP THEN START. 5–13 137 SHUTTLE INVALID COMMAND / SEE USER’S GUIDE. 5–11 126 PAPER FEED BAD TABLE / SEE USER’S GUIDE. 5–12 132 RIBBON INVALID COMMAND / SEE USER’S GUIDE. 6–1 coil temperature. 5–13 136 PLATEN INVALID PARAMETER / SEE USER’S GUIDE. F–1 About the printer. 5–10 116 ILLEGAL EXTERNAL BUS ACCESS / SEE USER’S GUIDE. 5–13 990 MACHINE CHECK. 5–13 998 NON–VOLATILE MEMORY FAILED. 5–57 110 STACK OVERFLOW / SEE USER’S GUIDE. 5–11 127 PAPER FEED ILLEGAL STATE / SEE USER’S GUIDE. F–1 Adjustments. 5–13 138 SHUTTLE INVALID PARAMETER / SEE USER’S GUIDE. 5–11 124 PAPER FIFO OVERFLOW / SEE USER’S GUIDE. 5–11 125 PAPER FIFO UNDERFLOW / SEE USER’S GUIDE. 5–10 115 ILLEGAL INSTRUCTION ACCESS / SEE USER’S GUIDE. 1–2 Acronyms. 5–10 121 PAPER NOT AT SPEED / SEE USER’S GUIDE. 5–12 130 PAPER FEED PARTLY ENERGIZED / SEE USER’S GUIDE. 5–12 133 RIBBON INVALID STATE / SEE USER’S GUIDE. 5–9 107 HAMMER COIL (number) HOT. 5–9 11 inch pages. 5–11 122 PAPER NOT SCHEDULED / SEE USER’S GUIDE. 5–9 114 ILLEGAL OPERAND ACCESS / SEE USER’S GUIDE. 5–10 120 ACCESS NULL POINTER / SEE USER’S GUIDE. 5–11 123 PAPER BUSY TOO LONG / SEE USER’S GUIDE. 5–13 139 SHUTTLE OVERSPEED / SEE USER’S GUIDE. 6–8 paper feed timing belt tension. replacement.S. A–10 replacement. 5–56 Attention condition. 6–24 loading flash memory.hammer phasing. 1–8 pedestal model. A–1 shell and cable replacement. and pin–outs. 7–11 power supply. all models. 7–11 Controls and indicators. See Operator panel Controller board pinouts. 5–48 Character Set. 6–16 software upgrades. doors. 7–14 B Belt paper feed timing. 6–32 Configuration. 6–26 splined shaft skew adjustment. replacement controller. 7–8 platen open. E–8 print mechanism. 6–12 platen open belt. 1–8 pedestal model. 7–15 Coil temperature adjustment. operator panel. replacement. E–3 Circuit board. 6–4 paper scale. 7–27 Coax/twinax multi–platform interface. 6–10 platen gap. 1–10 Card cage. E–4 printer power cable. 6–14 ribbon guide. 1–5 C Cabinet. 7–13 Circuit breaker. tension adjustment. replacement. E–8 print interlock. 7–9 Cable routing. See Controller board Coax/twinax expansion board pinouts. ASCII. 4–3 Checks. 6–31 CMX controller board. 7–21 CE tests. A–1 BOOT DIAGNOSTICS. 6–6 platen open motor pulley alignment. A–12 Cancel key cabinet model. 1–10 ASCII Character Set chart. E–7 power on/off verification. 1–10 Control panel. A–5 principles of operation. elongated. 3–2 CLEARING PROGRAM FROM FLASH. 6–29. 6–18 Arrow keys cabinet model. 6–4 platen open. mechanism base. 1–12 printing conventions. 5–13 Cleaning the printer. 6–6 Block diagram. fan assembly. 7–9 Cable connectors and shells. 2–1 Print key cabinet model. 5–3 pedestal model. 4–10 Boards: layouts. replacement. 6–26 paper drive motor pulley alignment. 1–8 Index 3 . 7–19 Cable assembly interconnections. connections. 1–8 mechanical. 5–56 Characters. replacement. 5–14. service customer’s power source. replacement. reversing. tension adjustment. 4–11 Controller circuit board. E–7 safety ground path. 7–6 paper feed timing. E–4 top cover and doors. A–1 part numbers. U. replacement. CMX board). replacement. 6–30 ERROR: PROGRAM NOT COMPATIBLE. 6–29 ERROR: FLASH NOT DETECTED. 1–6 Doors. 6–29 ERROR: EC STOPPED AT STATE XXXX. CMX board). B–4 Error log clear. power. 6–29 Diagrams ground path. 5–48 pedestal model. 6–29. 5–48 operator print. 6–20 ENERGY SAVER MODE ACTIVE. 1–10 Electrical characteristics. 6–30 ERROR: NO DRAM DETECTED. printer. 5–14 ERROR: EC PROGRAM NOT VALID. B–5 Engine controller (EC). 7–18 Customer Engineer (CE) tests. pedestal model. I–1 Cover assembly hammer bank / ribbon mask. 1–10 Display messages. 5–14 Duty cycle. cabinet. C–1 Cords. 6–29 ERROR: DRAM NOT DETECTED. B–6 Elongated characters. ferrite (noise suppression). 7–19 DRIVER CIRCUIT BAD. A–1 Dimensions. 4–13 Diagnostic menus. 5–45 printer information menu. reversing. 6–29 ERROR: DRAM AT ADDRESS XXXXXXXX. 4–3 End of Forms Adjust. procedure. metric measurement. 5–14 Energy Star compliance. 4–15 Enter key cabinet model. printing conventions. 6–31 ERROR: WRITING TO FLASH. 7–16 shuttle. 1–5 Documents related to this manual. 5–49 print. 1–8 pedestal model. 6–31 4 Index . 6–30 ERROR: NVRAM FAILURE. 6–30 D Data controller (DC). 5–14. boot. B–4 Display (LCD) cabinet model. G–1 Cores. 6–31 ERROR: WRONG CHECKSUM.Conversion. 5–45 Error messages. 1–10 Environmental characteristics. 5–3 ERROR: DC PROGRAM NOT VALID. 6–30 ERROR: PROGRAM NEEDS MORE DRAM. 4–15 Eject/Restore key cabinet model. B–7 E EC (Engine Controller. 5–51 Diagnostic self–tests customer engineer (CE). 6–30 ERROR: PROGRAM NEEDS MORE FLASH. 1–8 ERROR: SECURITY PAL NOT DETECTED. 1–8 pedestal model. 6–30 ERROR: PROGRAM NOT VALID. E–1 interconnection and cables. 7–17 top. 5–57 DIAGNOSTICS PASSED. 4–13 DC (Data Controller. 6–30 ERROR: SHORT AT ADDRESS XXXX. replacement. E–1 H Hammer phasing adjustment. 6–31 SENDING PROGRAM TO EC PROCESSOR. E–1 Installation. 6–29. 6–31 SECURITY CODE VIOLATION. replacement. 6–30 ERROR: SHORT AT ADDRESS XXXX. 5–14 Hammer phasing adjustment. 5–57 Index 5 . 6–24 Hard reset. adjustment magnetic pick–up (MPU). 5–59 Hex code printout. 5–14 HAMMER COIL BAD. 7–27 Illustrations. loading. 6–29 ERROR: EC PROGRAM NOT VALID. replacement procedures.F Fan assembly card cage. 2–1 Installed memory. 6–29 ERROR: EC STOPPED AT STATE XXXX. 1–10 G Gap. 6–12 Ground path diagram. 6–30 ERROR: PROGRAM NOT VALID. 6–31 RESTORING BOOT CODE. guide. 7–16 fan assembly. 7–20. replacement. 5–3 Ferrite cores (noise suppression). I–1 Flash memory. 6–31 RESETTING. replacement. 6–30 ERROR: PROGRAM NEEDS MORE DRAM. 6–30 ERROR: SECURITY PAL NOT DETECTED. 7–28 platen. 6–30 ERROR: PROGRAM NOT COMPATIBLE. 6–31 ERROR: WRITING TO FLASH. replacement. 7–50 I IBM Coax/twinax expansion board. A–1 HAMMER BANK NOT INSTALLED. 7–20. 7–21 hammer bank. 6–30 ERROR: NVRAM FAILURE. 6–29 ERROR: FLASH NOT DETECTED. 7–22 wiring diagram. ribbon. replacement. 5–57 Inspection. 6–29 ERROR: DRAM AT ADDRESS XXXXXXXX. 6–24 spring assembly. 6–26 Flash messages CLEARING PROGRAM FROM FLASH. 6–31 DIAGNOSTICS PASSED. 5–54 Hub.. 7–23 Hammer bank cover assembly. 7–22 Fault messages. 6–31 ERROR: WRONG CHECKSUM.. replacement. 6–31 Form Feed key cabinet model. PLEASE WAIT. 7–63 Information menu. 6–29. 6–29 ERROR: DC PROGRAM NOT VALID. safety. 1–8 pedestal model. 6–30 ERROR: NO DRAM DETECTED. 6–31 TABLE MISMATCH / DOWNLOAD AGAIN. 6–30 ERROR: PROGRAM NEEDS MORE FLASH. 6–31 LOADING PROGRAM FROM PORT XX%. printer. 1–8 pedestal model. installed. 5–48 Message display (LCD) cabinet model. 1–12 Memory modules. 5–57 Menu key cabinet model. 7–5 preventive. 5–6 016 INVALID COMMAND. 1–8 L Labels. 1–8 pedestal model. 5–6 K Keys. loading software. 5–5 003 FORMS EJECTED / PRESS EJECT/RESTORE. 5–5 002 FORMS JAMMED / CLEAR JAM AND RELOAD FORMS. 1–8 pedestal model. replacement. 1–10 Messages 001 END OF FORMS / LOAD FORMS. 5–5 015 COMMUNICATION CHECK / CHECK CABLE. operator panel. 6–26 Memory. 5–5 010 PARAMETER ERROR. 5–5 012 STRUCTURE FIELD ERROR. 5–5 013 ACTIVATE LOST. 1–4 6 Index . locations and operation cabinet model. 1–10 Line matrix printing explained. 1–6 Mechanical controls and indicators. 5–5 014 INVALID ACTIVATE. 5–14 LOADING PROGRAM FROM PORT XX%. replacement. B–7 notes and notices. 5–5 007 FM HEADER ERROR. 7–29 Memory. 1–8 pedestal model. 1–10 Menus boot diagnostics. 3–1 Manual how to use. location and replacement. 5–5 006 HOST SYSTEM REQUEST ATTENTION. 5–5 004 VIEW FORMS / PRESS VIEW KEY. 6–1 cleaning the printer. 5–5 009 INVALID KEY PRESS. 5–14 M Magnetic pick–up assembly. 6–31 LOADING PROGRAM INTO FLASH. 1–4 printing conventions. B–3 LCD cabinet model. 1–10 Keys. 1–1 preparing the printer for. 7–15 specifications. 1–10 Levers and knobs.Interface coax/twinax multi–platform. 1–5 related documents. 5–51 Customer Engineer (CE) tests. 5–5 011 SCS COMMAND ERROR. 4–2 LOADING PROGRAM FROM PORT 00%. specifications. 5–5 008 HOLD PRINT TIMEOUT / PRESS START. 1–12 Line Feed key cabinet model. flash. 3–2 overview. 1–8 pedestal model. 7–28 Maintenance adjustments. 5–6 025 SERIAL FRAMING ERROR / VERIFY CONFIGURATION. 5–10 118 UNDEFINED INTERRUPT / SEE USER’S GUIDE. 5–10 121 PAPER NOT AT SPEED / SEE USER’S GUIDE. 5–8 101 UPPER DRIVER SHORT.021 RECEIVE BUFFER OVERRUN / VERIFY CONFIGURATION. 5–6 022 UNIT ADDRESS NOT RECEIVED / CHECK PRINTER ADDRESS. 5–7 046 EC STOPPED AT STATE (state). 5–7 044 EC FIRMWARE/HARDWARE ERROR. 5–6 026 HEX DUMP MODE. 5–9 105 HAMMER COIL (number) OPEN. 5–9 111 STACK UNDERFLOW / SEE USER’S GUIDE. 5–8 087 PLATEN OPEN TIMEOUT / CLOSE PLATEN. 5–8 092 RIBBON DRIVER CIRCUIT. 5–6 032 FORMS JAMMED TIMEOUT / CLEAR JAM AND RELOAD FORMS. 5–9 112 UNDEFINED OPCODE / SEE USER’S GUIDE. 5–6 031 END OF FORMS TIMEOUT / LOAD FORMS. 5–6 027 COMMUNICATIONS CHECK / CALL SYSTEM OPERATOR. 5–9 102 LOWER DRIVER SHORT. 5–11 123 PAPER BUSY TOO LONG / SEE USER’S GUIDE. 5–6 041 BUFFER OVERFLOW. 5–6 042 CUSTOM SET DOES NOT EXIST / SAVE FIRST. 5–7 060 PRINTER HOT.5V. 5–7 058 SHUTTLE JAM / SEE USER’S GUIDE. 5–10 115 ILLEGAL INSTRUCTION ACCESS / SEE USER’S GUIDE. 5–11 125 PAPER FIFO UNDERFLOW / SEE USER’S GUIDE.5V FAILED. 5–11 Index 7 . 5–7 043 CUSTOM SET ALREADY EXISTS / DELETE EXISTING SET FIRST. 5–7 080 POWER SUPPLY HOT. 5–9 107 HAMMER COIL (number) HOT. 5–7 065 HAMMER BANK FAN FAULT. 5–8 090 SHUTTLE COVER OPEN / CLOSE SHUTTLE COVER. 5–11 122 PAPER NOT SCHEDULED / SEE USER’S GUIDE. 5–6 028 COMMUNICATIONS CHECK / CALL SYSTEM OPERATOR. 5–6 029 8344 DIAGNOSTIC TEST FAILED. 5–9 113 PROTECTED INSTRUCTION / SEE USER’S GUIDE. 5–11 124 PAPER FIFO OVERFLOW / SEE USER’S GUIDE. 5–10 117 A TO D OVERRUN / SEE USER’S GUIDE. 5–6 024 SERIAL LINE PARITY ERROR / VERIFY CONFIGURATION. 5–8 084 POWER SUPPLY 48V FAILED. 5–7 069 DATA CLEARED. 5–7 063 INTAKE FAN FAULT. 5–9 110 STACK OVERFLOW / SEE USER’S GUIDE. 5–7 062 EXHAUST FAN FAULT. 5–10 119 TCB CORRUPTED / SEE USER’S GUIDE. 5–8 082 POWER SUPPLY 8. 5–10 120 ACCESS NULL POINTER / SEE USER’S GUIDE. 5–7 059 CANCEL PRINT ACTIVE. 5–8 085 CONTROLLER VOLTAGE. 5–7 081 POWER SUPPLY VOLTAGE FAILURE. 5–8 089 RIBBON STALL. 5–10 116 ILLEGAL EXTERNAL BUS ACCESS / SEE USER’S GUIDE. 5–7 057 CLOSE PLATEN. 5–8 088 CONTROLLER 23. 5–9 114 ILLEGAL OPERAND ACCESS / SEE USER’S GUIDE. 5–14 LOADING PROGRAM FROM PORT XX%. 5–14 HAMMER BANK NOT INSTALLED. 5–12 129 PAPER FEED INVALID PARAMETER / SEE USER’S GUIDE. 5–15 P05 DIAGNOSTIC TEST PASSED. 5–14 ENERGY SAVER MODE ACTIVE. RESET IN PROGRESS. 5–15 OPERATOR MENU UNLOCKED. 5–15 P62 ERROR: DC PROGRAM NOT VALID.. 5–15 P63 ERROR: PROGRAM NOT COMPATIBLE. PLEASE WAIT..126 PAPER FEED BAD TABLE / SEE USER’S GUIDE. 5–12 135 PLATEN INVALID STATE / SEE USER’S GUIDE. 5–16 READY. 5–15 OPERATOR MENU / (first menu item). 5–12 132 RIBBON INVALID COMMAND / SEE USER’S GUIDE. 5–15 P60 ERROR: DRAM AT ADDRESS (hex). 5–16 SERVICE / (first service test). 5–14 ERROR: SECURITY PAL NOT DETECTED. 5–13 CLEARING PROGRAM FROM FLASH. 5–16 P67 ERROR: WRITING TO FLASH. 5–12 134 PLATEN INVALID COMMAND / SEE USER’S GUIDE. 5–11 128 PAPER FEED INVALID COMMAND / SEE USER’S GUIDE. 5–15 OPERATOR MENU LOCKED. 5–14 ERROR: DRAM NOT DETECTED. 5–13 A97 GRAPHIC CHECK ERROR / PRESS STOP THEN START.. 5–12 130 PAPER FEED PARTLY ENERGIZED / SEE USER’S GUIDE. 5–13 136 PLATEN INVALID PARAMETER / SEE USER’S GUIDE. 5–12 131 PAPER FEED INTERRUPT / SEE USER’S GUIDE. 5–14 HAMMER COIL BAD. 5–12 133 RIBBON INVALID STATE / SEE USER’S GUIDE. 5–16 P69 ERROR: EC STOPPED AT STATE XXXX. 5–13 137 SHUTTLE INVALID COMMAND / SEE USER’S GUIDE. 5–14 LOADING PROGRAM INTO FLASH. 5–15 P64 ERROR: CHECKSUM WRONG (hex). 5–15 PLEASE WAIT. 5–16 PA1 SELECTED. 5–13 138 SHUTTLE INVALID PARAMETER / SEE USER’S GUIDE. 5–16 P66 ERROR: PROGRAM NEEDS MORE DRAM. 5–16 RESTORING BOOT CODE. 5–15 PA2 SELECTED. 5–15 P17 SECURITY VIOLATION.. 5–15 P61 ERROR: FLASH NOT DETECTED. 5–16 P68 ERROR: EC PROGRAM NOT VALID. 5–16 SENDING PROGRAM TO EC PROCESSOR. 5–16 RIBBON OUT OF INK / CHANGE RIBBON. 5–14 NOT READY. 5–13 139 SHUTTLE OVERSPEED / SEE USER’S GUIDE. 5–13 998 NON–VOLATILE MEMORY FAILED. 5–11 127 PAPER FEED ILLEGAL STATE / SEE USER’S GUIDE. 5–14 DRIVER CIRCUIT BAD. 5–13 BOOT DIAGNOSTICS. 5–17 8 Index . 5–16 P65 ERROR: PROGRAM NEEDS MORE FLASH. 5–13 990 MACHINE CHECK. 5–17 TABLE MISMATCH / DOWNLOAD AGAIN. 5–16 RESETTING. 5–15 OPERATOR MENU UNLOCKED. 7–36 MPU. location. replacement parts. 5–17 WAITING FOR PROGRAM DOWNLOAD. conversion tables. 6–4 ironer. principles of. 4–10 replacement cabinet model. printer. replacement. 5–15 P60 ERROR: DRAM AT ADDRESS (hex). replacement. 1–4 Numbers. F–1 Models. 7–32 feed timing belt replacement. 7–62 Paper detector switch. 5–16 PA1 SELECTED. 7–40 Index 9 . replacement. 1–2 Motor paper feed drive. security. replacement. 7–41 scale adjustment. 7–38 pedestal model. 7–59 Paper guide assembly. 7–34 ribbon drive. 5–15 P62 ERROR: DC PROGRAM NOT VALID. removal. replacement. 7–32 platen open. 5–15 OPERATOR MENU LOCKED. H–1 P68 ERROR: EC PROGRAM NOT VALID. 5–16 P65 ERROR: PROGRAM NEEDS MORE FLASH. 7–15 P P05 DIAGNOSTIC TEST PASSED. B–3 tractor (L/R). 5–15 P61 ERROR: FLASH NOT DETECTED. C–1 Micro keys cabinet model. control. 5–15 Notes and notices. 5–15 PAL. 1–10 Mnemonics. 5–15 Operator panel block diagram. 6–10 specifications. I–1 NOT READY. replacement. 5–17 TOP OF FORM SET. 1–8 pedestal model. 5–16 P69 ERROR: EC STOPPED AT STATE XXXX. 5–16 P67 ERROR: WRITING TO FLASH. 5–15 PA2 SELECTED. See Magnetic pick–up assembly Multi–platform interface. replacement. 7–59 drive motor pulley alignment. 7–31 O Operation. 5–15 P63 ERROR: PROGRAM NOT COMPATIBLE. 4–1 OPERATOR MENU / (first menu item). replacement. 5–16 N Network print server. replacement. 7–6 feed timing belt tension adjustment. 7–37 Noise Suppression. 5–15 P64 ERROR: CHECKSUM WRONG (hex). See Operator panel Paper detector switch assembly. 5–15 P17 SECURITY VIOLATION. 5–16 P66 ERROR: PROGRAM NEEDS MORE DRAM.TESTING HARDWARE / PLEASE WAIT. replacement. 7–39 Panel. 6–8 feed drive motor. 5–17 Metric measurement. 5–59 self–tests customer engineer (CE). 7–63 replacement part numbers. rates. 5–5 Parts illustrations. G–1 Power distribution diagram. 5–57 Printer adjustments. 4–1 reset. 1–2 dimensions. 2–1 description. A–1 Platen gap adjustment. 5–16 Plot. B–4 duty cycle. 7–15 controller circuit board. 7–27 Coax/twinax multi–platform interface. 2–1 logical control of. 7–5 principles of operation. 5–57 Printouts.. 5–57 installed memory. B–8 Power input voltage. 6–1 cleaning. A–4 Power supply. B–7 installation.. B–1 troubleshooting.Paper jams. 3–2 safety inspection. circuit board replacement. 7–34 Platen replacement. H–1 replacement procedures. B–6 on/off verification. E–8 Power consumption. 4–9 maintenance overview. B–6 Power cords. 7–14 Coax/twinax expansion board. 1–8 pedestal model. 5–45 specifications. 1–2 preparing the printer for maintenance. 1–5 line matrix printing explained. 1–10 Print server. 5–48 operator print. 4–1 Print Configuration key cabinet model. 5–51 cleaning. 5–16 Replacement cable connectors and connector shells. 7–9 card cage fan assembly. 7–11 10 Index . 5–57 Printing conventions is this manual. 1–1 models. 7–61 platen open belt adjustment. replacement. 5–57 power-on time. 5–57 print strokes. hex code. 6–12 interlock switch assembly. 7–21 circuit breaker. 7–5 Phasing adjustment. 7–42 PLEASE WAIT. 3–2 configuration. 4–2 Printing time. 5–54 Procedures adjustment. 5–1 Printer information menu 11 inch pages. network. 5–57 Principles of operation. 7–37 Print strokes. RESET IN PROGRESS. 6–1 boot diagnostics menu. replacement. 6–6 platen open motor. 4–18 Power-on time. principles of operation. 5–57 printing time. 6–24 Pin–outs. 7–13 Power supply board. E–1 R READY. 7–58 doors. location. 7–16 hammer bank fan assembly. top. 6–31 SENDING PROGRAM TO EC PROCESSOR (message). E–8 print mechanism. 5–45 printer information menu. shuttle. E–7 power on/off verification. 1–8 pedestal model. 6–31 Resistors. 7–32 paper feed timing belt. 1–10 SECURITY CODE VIOLATION. 7–53 tractor (L/R). 7–62 Reset. pedestal model. cabinet. 5–16. 7–57 gas spring assembly. 7–19 extension spring.. 5–16 SERVICE / (first service test). 7–40 paper ironer. PLEASE WAIT. E–1 notices. 7–49 ribbon hub. replacement. 7–17 cover assembly. 7–51 support shaft. 7–37 resistors. terminating. 7–8 platen open motor. 7–6 paper guide assembly. 7–50 shuttle frame assembly. 7–15 network print server. E–7 safety ground path. replacement. 7–20. replacement. 1–10 Ribbon drive motor. 5–48 operator print. 7–54 splined shaft. 7–16 specifications. viii notices. soft vs. 7–42 platen interlock switch assembly. 7–37 operator panel assembly cabinet model. 5–57 SENDING PROGRAM TO EC PROCESSOR. 6–16 hub. 7–39 paper detector switch assembly. alignment. 7–41 platen. 7–13 pprint server. 5–17 Service checks customer’s power source. replacement. 7–48 RESTORING BOOT CODE (message). terminating. 7–50 mask. 7–34 power supply circuit board. location of. 7–61 platen open belt. 7–36 guide assembly (L/R). E–3 Index 11 . 7–18 cover open switch assembly. 7–22 hammer spring. 7–56 hammer bank /ribbon mask cover assembly. 5–16. 7–28 memory modules. 7–49 guide assembly. 7–23 IBM Coax/twinax expansion board. 7–36 ribbon guide assembly (L/R). E–4 printer power cable. network.. defined. 1–8 pedestal model. 7–27 magnetic pick–up assembly. 7–29 multi–platform interface. 5–59 RESETTING. 7–47 ribbon drive motor. 6–31 Return key cabinet model. 7–38 pedestal model. 1–4 Scroll keys cabinet model. 7–31 Self–tests customer engineer (CE). E–4 top cover and doors. 7–59 paper feed drive motor. B–2 RIBBON OUT OF INK / CHANGE RIBBON (message). 6–31 Security PAL.cover assembly. hard. 5–16 S Safety inspection guide. reversing. E–8 print interlock. 1–10 Supplies. 7–14 T TABLE MISMATCH / DOWNLOAD AGAIN. replacement. replacement. loading into flash memory. 1–14 TESTING HARDWARE / PLEASE WAIT. B–2 Speed printing. 5–57 Tools. 1–14 TOP OF FORM SET. 6–4 platen open belt. 6–18 Spring extension. 6–31 Temperature. 7–47 Test. 7–59 platen interlock switch assembly. B–6 environmental. printer. replacement. 6–6 Terminating resistors location of. F–1 SIMMs. replacement. 7–29 Soft reset. 7–53 Switch cover open switch assembly. 6–32 Tension adjustment paper feed timing belt. 5–17 Tests boot diagnostics menu. replacement. coil. 1–10 Stop key cabinet model. replacement. and supplies. replacement. 5–45 printer information menu. skew adjustment. C–1 table. 5–51 customer engineer (CE). location and replacement. replacement. 6–33 Splined shaft replacement. assembly. B–7 paper. 1–8 pedestal model. 1–8 pedestal model. 6–33 Set Top Of Form key cabinet model. equipment. 7–62 12 Index . 1–10 Shaft splined. 7–17 frame assembly. B–8 ribbon. 7–53 Shuttle cover assembly. replacement. D–1 Tractor. 5–17. set. operator. 5–48 print. and supplies. 5–57 Time power-on. 6–26 Specifications dimensions. 7–51 skew adjustment. 5–57 printing. test equipment. 7–58 paper detector switch assembly. 7–54 speed setting. B–4 interfaces. 7–61 power. replacement. 5–17 Torque conversion to or from metric. tools. 7–56 Start key cabinet model. B–3 printing rates. 7–57 gas. 5–59 Software. tools. 7–48 replacement. B–4 duty cycle. B–7 electrical. replacement. B–8 shuttle. replacement. 1–8 pedestal model. 1–14 Support shaft. 7–51 splined. and test equipment.Set shuttle speed. adjustment. 6–33 Signal mnemonics. 6–18 support. 6–26 V View key cabinet model. 5–1 fault messages.Troubleshooting. A–1 Index 13 . 1–10 W WAITING FOR PROGRAM DOWNLOAD. 1–8 pedestal model. 5–3 symptoms not indicated by fault messages. 5–17 Wiring diagrams. 5–39 U Unit check condition. 5–3 Upgrading software. 14 Index . . © Copyright IBM Corp. 1997 S246–0117–04 . 1995..