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344

Appendix E

Inspect Electrical Parts

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 229).

Figure 57. Ground Path Diagram

OPERATOR PANEL

+5 V

AC

POWER

Parallel

I/O

P

112

J1

12

SHIELD

GND

J3

10

P310

J301

CIRCUIT

BREAKER

IEC 320

AC POWER

P

1

J1

AC

AC to DC

Power Supply

Board

Line 1

Line 2 / Neutral

CHASSIS

GND

J108 HBL

P108 HBL

J105 HBP

P105 HBP

J116 SMD

P116 SMD

J107 MSR

P107 MSR

Exhaust

Fan

Paper Feed

Motor

Platen Open

Switch

Right Ribbon

Guide

Right Ribbon

Motor

Platen

Motor

Paper Motion

Detector

Paper Out

Detector

Left Ribbon

Motor

J106 MSL

P106 MSL

Card Cage

Fan

Left Ribbon

Guide

Hammer Bank

Fan

Shuttle Motor

Hammer Bank Board

Terminator Board

Shuttle

P

110

J1

10

J101 DC POWER

Point

of

Common

Ground

Assy

CMX

Controller Board

+5 V

Ret

Ret

+48V

+48V

+48V

+5 V

+24V

Ret

+48V

Ret

+8.5V

Ret

+48V

Ret

+48V

+48V

+5 V

+5 V

+5 V

+8.5/+48V

Ret

Cabinet

models

only

+5 V Remote

Power

EIA-232-E

Serial I/O

1
2
3
4
5
6
7
8
9

10
11
12

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
+8.5V
+48V
+48V

* V3.5 BOARD PIN 1 = N TEMP HI
V4 BOARD PIN 1 = N AC FAIL

P101

Ret

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Summary of Contents for 6400 Series

Page 1: ...6400 Line Matrix Printers Maintenance Information Manual Cabinet and Pedestal Models Form Number S246 0117 08 Copyright IBM Corp 1995 2000...

Page 2: ......

Page 3: ...Maintenance Information Manual Cabinet and Pedestal Models 6400 Line Matrix Printers S246 0117 08...

Page 4: ...e to 1 800 524 1519 by E mail to print_pubs vnet ibm com or by mail to IBM Printing Systems Company Information Development Department H7FE Building 003G P O Box 1900 Boulder CO 80301 9191 USA When yo...

Page 5: ...significantly Users of this document should verify the applicable data in their specific environment Therefore such data does not constitute a performance guarantee or warranty IBM may have patents o...

Page 6: ...Canadian Standards Association Dataproducts Dataproducts Corporation ECOS ECOS Electronics Corp Inc Oak Park Ill EIA Electronic Industries Association Energy Star United States Environmental Protecti...

Page 7: ...ting Conventions In This Manual 18 Related Documents 18 Controls And Indicators 20 Electrical Controls Cabinet Models 20 Electrical Controls Pedestal Models 22 Mechanical Controls All Models 24 Tools...

Page 8: ...r 57 Graphics 58 5 Troubleshooting 59 Introduction 59 Troubleshooting Aids 59 Start Of Call 60 Troubleshooting Display Messages 61 Message List 62 Troubleshooting Other Symptoms 109 General Symptom Li...

Page 9: ...e World Wide Web 175 Loading Flash Memory 176 Coil Temperature Adjustment 181 Set Shuttle Speed 182 Ethernet Initialization 183 7 Replacement Procedures And Illustrated Parts Lists 185 Organization Of...

Page 10: ...ting 235 Ribbon Guide Assembly L R 237 Ribbon Hub 238 Shaft Splined 239 Shaft Support 241 Shuttle Frame Assembly 242 Spring Extension 244 Switch Assembly Cover Open 245 Switch Assembly Paper Detector...

Page 11: ...cal Parts 342 Inspect Electrical Parts 343 F Abbreviations And Signal Mnemonics 347 G Cords And Adapters 355 H Part Numbers 357 I Noise Suppression Devices 365 J SureStak Power Stacker 367 Contents 36...

Page 12: ...Table of Contents...

Page 13: ...data stream from the host computer This is also an excellent graphics printer with optional features that simplify the creation of dot images The IGP and Code V Printronix emulations are simple but ve...

Page 14: ...Hz 6400 050 500 lpm Cabinet 28 Hammers 40 MHz 6400 P50 500 lpm Pedestal 28 Hammers 40 MHz 6400 008 800 lpm Cabinet 49 Hammers 25 MHz 6400 08P 800 lpm Pedestal 49 Hammers 25 MHz 6400 009 900 lpm Cabine...

Page 15: ...lock speed on the Data Controller unit Except for the CMX 040 controller board and ribbon guides which are backwards compatible with all 6400 printers the redesigned components of these newer models a...

Page 16: ...isely aligned Use only the ribbons specified in Appendix B Use of incorrect ribbons can lead to ink migration problems degraded print quality and expensive damage to the printer Do not close the forms...

Page 17: ...of a hazard that could cause death or serious personal injury Danger and Caution notices are numbered to help you find the translated versions in the IBM 4400 Safety Notices booklet The word Caution...

Page 18: ...IBM 6400 Line Matrix Printer Safety Notices Form No G544 5389 This maintenance manual does not explain how to operate or configure the printer For that information refer to the Operator s Guide and S...

Page 19: ...formation used with the optional IGP Printronix emulation enhancement feature The IGP Printronix emulation allows the user to create and store forms generate logos bar codes and expanded characters cr...

Page 20: ...Of Form Sets TOF and moves paper downward from the tractor alignment notches to the print position Line Feed Moves paper up one line as determined by current line spacing View Press to move the curren...

Page 21: ...igure 2 Electrical Controls Cabinet Models Ready Power Cancel Processing Start Stop Form Feed Set Top Of Form Line Feed Enter Return Scroll Menu View Attention Scroll Micro Micro Printer Con figuratio...

Page 22: ...TOF and moves paper downward from the tractor alignment notches to the print position Line Feed Moves paper up one line as determined by current line spacing View Press to move the current print posi...

Page 23: ...igure 3 Electrical Controls Pedestal Models Ready Power Cancel Processing Start Stop Form Feed Set Top Of Form Line Feed Enter Return Scroll Menu View Attention Scroll Micro Micro Printer Con figurati...

Page 24: ...on Tractors 2 Hold and feed paper Used to set side margin and position paper horizontally Tractor Locks 2 Lock tractors in position Horizontal Adjustment Knob Allows fine positioning of left print mar...

Page 25: ...re 4 Mechanical Controls All Models Horizontal Adjustment Knob Tractor Lock Left Tractor Right Tractor Vertical Position Knob Forms Thickness Lever and Scale Forms Thickness Pointer Tractor Lock Paper...

Page 26: ...9900317 Lubricant Bearing IBM 20 117397 DIP Module Extracting Tool 9900764 Nut Driver 1 4 inch Nut Driver 5 16 inch Open End Wrench 7 32 inch 1650843 Open End Wrench 5 16 inch 9900005 PLCC Module Pick...

Page 27: ...work Print Server are covered in the following documents IBM Network Print Server Ethernet Administrator s Guide Form No S246 0111 IBM Network Print Server Token Ring Administrator s Guide Form No S24...

Page 28: ...28 Chapter 2 Installing And Configuring The IBM 6400 Printer...

Page 29: ...the window Do not drip water into the printer Damage to the equipment will result Do not spray directly onto the printer when using spray solutions spray the cloth then apply the dampened cloth to th...

Page 30: ...e the splined shaft and the ribbon guides with a soft cloth 8 Vacuum up dust or residue that has accumulated inside the lower cabinet 9 Wipe the interior of the lower cabinet with a clean lint free cl...

Page 31: ...sk when handling and cleaning the hammer bank cover assembly 7 Using a clean soft cloth wipe the hammer bank cover and ribbon mask to remove lint ink and paper residue Clean the holes in the cover str...

Page 32: ...the hammer bank magnet attracts it Any impact of the cover against the hammer bank can break hammer tips 9 Install the hammer bank ribbon mask cover assembly page 200 10 Install the shuttle frame ass...

Page 33: ...card cage fan assembly and surrounding areas to remove paper particles dust and lint See Figure 7 3 Cabinet Models Install the paper guide assembly page 229 Pedestal Model Install the top cover assem...

Page 34: ...34 Chapter 3 Cleaning The Printer...

Page 35: ...igure 8 The ink dots are made by a row of small hammers mounted on a shuttle that sweeps rapidly back and forth Printer logic circuits divide every line of incoming data into horizontal dot rows The h...

Page 36: ...example in the data processing DP font at a line spacing of six lines per inch lpi a dot matrix contains 12 dot rows from the top of one character line to the top of the next See Figure 8 and Figure...

Page 37: ...7 1 3 5 7 9 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 1 2 3 4 1 2 1 7 6 5 3 4 2 1 1 2 3 NOTE Even column dot centers within the printed character area and character space hammer positions are not illustrate...

Page 38: ...mining which dot rows contain adjacent dots and must be printed in two strokes Printing speed is not affected by the number of characters in a character set The printing speed of graphics plot mode is...

Page 39: ...05P 050 P50 seven 4 hammer assemblies for a total of 28 hammer springs 6400 008 08P 009 09P seven 7 hammer assemblies for a total of 49 hammer springs 6400 010 and 10P six 10 hammer assemblies for a...

Page 40: ...ted state Figure 12 Hammer Springs and Hammer Bank Detail Two electromagnetic coils are mounted behind each hammer and wound around each pole piece The coils are normally de energized When hammer driv...

Page 41: ...ing the platen prevents paper jams when paper direction is reversed that is paper is moved downwards in order to view the print area set top of form or allow applications to overprint forms Paper is p...

Page 42: ...everses 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 Constant ribbon tension is maintained by...

Page 43: ...ral Flex Circuits AC ON OFF SWITCH Power Supply Board Line 1 CHASSIS GND Cabinet Paper Feed Motor Platen Open Switch Right Ribbon Guide Right Ribbon Motor Platen Motor Paper Motion Detector Paper Out...

Page 44: ...e 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 The LCD status indi...

Page 45: ...onal units the Data Controller DC and the Engine Controller EC The DC is responsible for Host I O Operator I O Security Interface Print Image Generation Overall High Level Logical Control The EC is re...

Page 46: ...Board Figure 17 CMX Controller Board Block Diagram Expansion Port RS 232 422 IEEE 1284 Parallel Fault Sensors Paper Feed Ribbon Shuttle Platen Hammer Drive TTL Diagnostic Port Control Panel RS 232 Di...

Page 47: ...y the 030 remember that two different clock speeds are available Flash Memory The DC stores program and emulation code in flash memory Flash memory is erasable non volatile and significantly faster th...

Page 48: ...ode DRAM FLASH Controller The VX supports up to four banks of flash memory DMA Channels The VX provides two channels for direct memory access These channels move data from the host interface or expans...

Page 49: ...rnal charge pumps to eliminate the need for 12V power RS 422 differential drivers and receivers Parallel port pull up and pull down terminating resistors are DIP socketed for easy removal and installa...

Page 50: ...EC also stores tables in shared DRAM which is accessed through the Cajun bus MECA ASIC The 166 uses numerous counters PWM generators and FIFOs in the MECA to control many printer motor functions The M...

Page 51: ...and data from the MECA and VX ASICs The HBAs control lower drive MOSFETs on the hammer bank These determine which hammers will participate in a fire event generated by the controller s upper drive Pri...

Page 52: ...est A seven stage power on self test performs diagnostics on the Ethernet Interface processor RAM ROM EEPROM parallel port and network interface The STAT ERR and NET LEDs indicate which test is curren...

Page 53: ...e printer off then on resets a previously configured IP address to the factory default setting no IP address However this does not cause the unit to lose its other stored configuration settings as hap...

Page 54: ...these two conditions are met you should be able to ping the printer from a network host You can test by starting a telnet session telnet IP address and sending start fox prn Return stop prn Return Thi...

Page 55: ...etwork link DIP Switches On the back of the 10 100Base T interface inside the printer there are two DIP switches labeled 1 and 2 The functions of the DIP switches are explained in Table 3 STAT Rate In...

Page 56: ...this configuration the interface boots up and all settings stored in flash memory are erased except the Ethernet address and key value OFF ON Default IP With the DIP switches in this configuration the...

Page 57: ...The power supply board contains two DC power supply systems for the printer The first is a 5 V bus for logic The second consists of 48 V and 8 5 V buses for the hammer bank and all motors The 5 V sup...

Page 58: ...n 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 up...

Page 59: ...roubleshooting 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 i...

Page 60: ...YES NO Did Power and Ready LEDs come after 10 seconds NO YES IML was successful Other symptoms are listed in Table 5 page 110 Go to Printer does not complete IML page 115 Did ANY of steps 1 thru 3 oc...

Page 61: ...cted by self test and fault circuitry Unit check conditions are either recoverable or unrecoverable Recoverable unit check conditions are errors detected in the electromechanical print mechanism that...

Page 62: ...r dark backs or holes perforations large enough to cause false End Of Forms messages Consider ordering the black back paper detector switch assembly 3 Power off the printer Remove the paper guide asse...

Page 63: ...o tightly or leave it too loose The right tractor should hold the paper under slight tension 6 Inspect the ribbon mask for bends or deformation that block the paper path or prevent paper from exiting...

Page 64: ...tore key to return paper to print position 004 VIEW FORMS PRESS VIEW KEY0 Non error status message Press View key to return paper to print position 006 HOST SYSTEM REQUEST ATTENTION Host attention mes...

Page 65: ...ceived an undefined control character hex 40 through the coax twinax interface 1 The printer clears the error 2 Run the print job that generated the error message If the message appears verify that th...

Page 66: ...If the message appears go to Communications Failures page 131 014 INVALID ACTIVATE The printer detects a twinax protocol communications error and reports the error 1 Power off the printer Disconnect t...

Page 67: ...ommunication with the printer If all other twinax devices work properly and the message still appears replace the coax twinax expansion board Record the message and return it with defective board 016...

Page 68: ...per motion detector 3 Power on the printer Operate the power stacker and check that a all motors are operating b the paddles are rotating c the elevator moves smoothly and without obstruction d the ti...

Page 69: ...guide assembly Disconnect stacker cables from the CMX controller board stacker assembly and the stacker control panel see Figure 68 page 376 Check cables for cuts breaks or damaged pins Check continu...

Page 70: ...he belt pulleys are not slipping e the extension springs are attached and undamaged not bent or stretched f the drive rollers are not damaged g the constant force springs are tightly mounted and undam...

Page 71: ...in random question mark characters 1 Make a configuration printout Verify that the printer matches host serial configuration settings for Data Protocol Baud Rate Data Bits Stop Bits Parity Data Termin...

Page 72: ...inter Check data cable connection and host system Refer to line problem determination procedures as recommended by the host system 028 COMMUNICATIONS CHECK CALL SYSTEM OPERATOR Poll timeout error The...

Page 73: ...shield cabinet model or the barrier shield and paper guide pedestal model Check that the paper detector switch assembly is securely mounted in its bracket 3 Check that connector P106 PMD is fully sea...

Page 74: ...Adjust the right tractor so that it does not pull paper too tightly or leave it too loose The right tractor should hold the paper under slight tension 6 Inspect the ribbon mask for bends or deformati...

Page 75: ...rface The printed output may contain random asterisk characters 1 Make a configuration printout Verify that the printer matches the host serial interface configuration settings for Data Protocol Baud...

Page 76: ...o request assistance 046 EC STOPPED AT STATE state Where state is a number from 0000 to 0010 The Engine Controller processor has stopped and is in the state identified by the number displayed If the E...

Page 77: ...it is damaged 5 Check the platen open pulley and the platen pulley for looseness Bottom out the platen open motor pulley on the motor shaft and torque the 1 16 inch set screw to 9 2 inch pounds 1 02...

Page 78: ...m for obstructions Check that all cables are attached at the shuttle and the CMX controller board Make sure the MPU cable is not pinched Refer to Appendix A Interconnection Diagram page 289 Remove obs...

Page 79: ...R S GUIDE continued 10 Run a print test If the message appears replace the shuttle frame assembly 059 CANCEL PRINT ACTIVE Non error status message No action required Table 4 Message List Operator Pane...

Page 80: ...ge of the cabinet fan vents The printer must never be run at ambienttemperatures greater than 40 Celsius 104 Fahrenheit If the printer is located in such an environment relocate it to a cooler cleaner...

Page 81: ...ler board Test connector P107 EHF for shorts or opens Refer to the Main Wire Harness Test Tables on page 291 Replace components that fail test 5 Make sure connector P107 EHF has a good connection at J...

Page 82: ...or opens Refer to the Main Wire Harness Test Tables on page 291 Replace components that fail test 3 Make sure P107 HBF has a good connection at J107 on the CMX controller board 4 Inspect airways and v...

Page 83: ...for severity Advise the user to move the printer to cooler cleaner location 2 Check the kinds of print jobs the user is running look for very dense graphics and layouts Advise the user to run jobs in...

Page 84: ...shuttle frame assembly 083 INTAKE FAN FAULT Sensors cannot detect current in the card cage fan circuit 1 Cycle power If the message appears press Stop 2 Power off the printer Remove the paper guide as...

Page 85: ...replace the power supply board 5 Power on the printer If the message appears replace the CMX controller board Record the message and return it with the defective board 6 Power on the printer If the me...

Page 86: ...page 219 and Figure 35 on page 220 3 Power on the printer Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board Also...

Page 87: ...ten open belt Replace the belt if it is damaged 5 Check the platen open pulley and the platen pulley for looseness Bottom out the platen open motor pulley on the motor shaft and torque the 1 16 inch s...

Page 88: ...itten flash See Table 8 and Table 9 on page 219 and Figure 35 on page 220 3 Power on the printer Run the print job again If the message appears replace the CMX controller board Record the message and...

Page 89: ...cover assembly if it is bent or damaged 4 Check the platen gap If the gap is too small it can inhibit ribbon movement Adjust the platen gap 5 Power off the printer Remove the paper guide assembly or...

Page 90: ...e Harness Test Tables page 291 Replace the cover open switch assembly as required 4 Power on the printer If the message appears replace the CMX controller board Record the message and return it with t...

Page 91: ...ble are shorted to ground 1 Cycle power If the message appears press Stop If the message does not clear replace the hammer bank logic cable and the hammer bank power cable 2 Power on the printer If th...

Page 92: ...uch an environment relocate it to a cooler cleaner area or reduce the size and duration of the print jobs 1 Inspect the printer environment for severity Advise the user to move the printer to cooler c...

Page 93: ...turn it with defective CMX board 113 PROTECTED INSTRUCTION SEE USER S GUIDE Protected Instruction Firmware error on the CMX controller board 1 Cycle power Run the print job again If the message appear...

Page 94: ...appears replace the CMX controller board Record the message and return it with defective CMX board 119 TCB CORRUPTED SEE USER S GUIDE Task Control Block on the CMX controller board has been corrupted...

Page 95: ...S GUIDE Firmware error on the CMX controller board 1 Cycle power Run the print job again If the message appears download the emulation software again 2 Run the print job again If the message appears...

Page 96: ...top cover Make sure connectors P106 and P107 are fully seated on the CMX controller board 3 Check hammer phasing Try using a lower phasing value sometimes this message indicates too high a hammer phas...

Page 97: ...S GUIDE Paper Invalid Command Firmware error on the CMX controller board 1 Cycle power Run the print job again If the message appears download the emulation software again 2 Cycle power Run the print...

Page 98: ...appears replace the CMX controller board Record the message and return it with defective CMX board 134 PLATEN INVALID COMMAND SEE USER S GUIDE Firmware error on the CMX controller board 1 Cycle power...

Page 99: ...oad the emulation software again 2 Remove the shuttle cover Remove the paper guide assembly or the pedestal top cover Make sure the MPU cable P N 14H5329 is not pinched Check both the section of MPU c...

Page 100: ...ar on the LCD replace the CMX controller board ENERGY SAVER MODE ACTIVE Status message the printer is in low energy idle state all fans and higher voltages are off only 5Vdc logic circuits are active...

Page 101: ...rity PAL is missing or has failed Power off the printer Remove the paper guide assembly or pedestal top cover 1 Check the security PAL at location U54 on the CMX controller board If the PAL is absent...

Page 102: ...aintenance personnel 1 Power off the printer Hold any control panel key down and power on the printer Hold the key down until the printer powers up and the message FREEFORM OFF appears on the LCD 2 If...

Page 103: ...check the grounding of the printer If the machine is correctly grounded replace the CMX controller board 2 Power on the printer Cycle power If the message appears suspect an application software erro...

Page 104: ...RAM SIMM sockets 2 Run a print test If the message appears replace the CMX controller board Record the message and return it with the defective board P60 ERROR DRAM AT ADDRESS hex The printer found a...

Page 105: ...written flash See Table 8 and Table 9 on page 219 and Figure 35 on page 220 3 Download the program If the message appears replace the CMX controller board Record the message and return it with the def...

Page 106: ...re 35 page 220 If any socket pins are bent or damaged replace the CMX controller board 2 Install the flash and DRAM SIMMs making sure they are fully and correctly seated Power on the printer Download...

Page 107: ...on the CMX controller board 1 Cycle power If the message appears power off the printer 2 Disconnect the input data line from the host computer Power on the printer If the message appears download the...

Page 108: ...en detected and continue with its own power up sequence Compared to the printer the Ethernet adapter takes a long time to complete its internal diagnostic tests so the boot code allows the adapter to...

Page 109: ...MPORTANT Do not attempt field repairs of electronic components or assemblies Replace a malfunctioning electronic assembly with an operational spare Most electronic problems are corrected by replacing...

Page 110: ...ications Failures page 131 Jams CLEAR JAM message instead of LOAD FORMS when printer is out of paper 1 Power off the printer Remove the paper guide assembly or pedestal top cover Remove the barrier sh...

Page 111: ...r moves erratically Record the message and return it with the defective board CLEAR JAM message will not clear but paper moves 1 Power off the printer Remove the paper guide assembly or pedestal top c...

Page 112: ...ear on the LCD replace the CMX controller board Operator panel blank 1 Power off the printer Remove the paper guide assembly or pedestal top cover Check all cable connections into the CMX controller b...

Page 113: ...tor panel if keys do not work 2 Power on the printer Check the operation of the operator panel keys Replace the operator panel cable assembly if keys do not work 3 Power on the printer Check the opera...

Page 114: ...page 280 Connect the AC in power supply cable and AC power input cables to the on off switch circuit breaker Make sure all ground connections are clean and tight 4 Check that AC in power cable connect...

Page 115: ...nter Check that the user has enough flash memory installed to handle his emulation software See Figure 35 on page 220 and the Boot Diagnostics Menu on page 137 Install flash memory and download emulat...

Page 116: ...lts DC between pins 3 and 4 If the voltages are correct replace the stacker control panel If the voltages are not correct power off the printer remove the paper guide assembly and disconnect the stack...

Page 117: ...a switch that requires adjustment replace it 4 Power on the printer Operate the power stacker Refer to the Operator s Guide While the stacker is operating check that a all motors are operating b the p...

Page 118: ...ssary 4 Check the stacker limit switches See page 119 If the limit switches are OK go to the next step 5 Check the stacker motors See page 120 If the stacker motors are OK go to the next step 6 Remove...

Page 119: ...and down by hand Check that the limit switches are physically tripped when elevator reaches top and bottom of travel If necessary gently bend the contact arms to adjust limit switches If you cannot a...

Page 120: ...connector J3 on the back of the stacker control panel See Figure 68 page 376 e Disconnect stacker frame cable connector P102 from connector J4 on the rear of the stacker control panel See Figure 68 p...

Page 121: ...Make sure the hammer bank cover assembly is correctly installed on its mounting pegs Check the shuttle frame assembly for broken hammer springs hammer tips or contaminations Replace any damaged hamme...

Page 122: ...se a configuration change may be necessary If the pattern of H s did not print OK go to the next step 2 Check and adjust hammer phasing 3 If the printer is a model 6400 004 04P 005 or 05P check the sh...

Page 123: ...cters 1 Dots or characters move up or down from dot row to dot row or line to line 2 Incorrect spacing from dot row to dot row or line to line 3 Characters randomly compressed and or enlarged 1 Load p...

Page 124: ...RUN MEMORY TESTS If memory fails test replace the DRAM If memory tests OK replace the flash memory with pre written flash See Table 8 and Table 9 on page 219 and Figure 35 on page 220 5 Power up the p...

Page 125: ...ler board 8 Power on the printer Load paper Press Form Feed and View several times and check that paper moves in both directions Replace the paper feed motor if paper does not move in both directions...

Page 126: ...kness lever and check that the platen pulley setscrew does not hit the left ribbon guide 3 Check and adjust the platen open belt Replace the belt if it is damaged 4 Check and adjust the platen gap 5 P...

Page 127: ...e 7 64 inch setscrew to 25 2 inch pounds 2 82 0 23 N m Replace the paper feed pulley if it does not have 25 teeth 4 Check and adjust the paper feed timing belt Replace the belt if it is damaged 5 Remo...

Page 128: ...ss the left and right ribbon guides Adjust the right and left ribbon guides 5 Observe ribbon movement at both left and right ribbon posts as the metal end strip crosses each ribbon post If the metal s...

Page 129: ...for bends or deformation that snag and interfere with shuttle movement Make sure the hammer bank cover assembly is correctly installed on its mounting pegs Reinstall the hammer bank cover assembly Re...

Page 130: ...m 3 Inspect the shuttle area for loose hardware Tighten loose hardware 4 Check that the hammer bank cover assembly is correctly installed that it has not slipped off the mounting pegs Check that the...

Page 131: ...ter communications problems the following additional information is provided You can quickly check the ASCII portion of the printer logic by sending a plain text file from a PC to the printer via the...

Page 132: ...ge 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 Ripple Print A sliding alphan...

Page 133: ...2 NOT READY Printer must be in NOT READY mode to access the tests 3 OPERATOR MENU UNLOCKED Unlocking ENTER key allows you to test the printer 4 OPERATOR MENU PRINTER CONTROL First of series of configu...

Page 134: ...dot positions creating a solid black band Exercises the shuttle and hammer bank at maximum capacity Power Supply board Hammer bank cover CE Tests SERVICE PRINTER MECHANISM TESTS SERVICE HAMMER PHASE V...

Page 135: ...ere is no correct value or range The factory prints the initial phase value on the aluminum casting of the shuttle assembly next to the motor housing Use this value as your starting point when adjusti...

Page 136: ...n menus as shown below Step Press Displayed Result Notes 1 Install the ribbon load paper and power on the printer 2 NOT READY Printer must be in NOT READY mode to access the tests 3 SERVICE PRINTER ME...

Page 137: ...he Eject Restore and Stop keys set the printer power switch to 1 on 4 When BOOT DIAGNOSTICS PRESS ENTER appears on the LCD release the Eject Restore and Stop keys 5 Press the Enter key Menu options ar...

Page 138: ...F ENTER VERSION CHECK P C BOARD VERSION VERSION CHECK SECURITY PART VERSION CHECK PROCESSOR SPEED P C BOARD VERSION 3 0 ENTER SECURITY PART 154143 001 ENTER PROCESSOR SPEED 68E030 AT 25 MHZ ENTER BOOT...

Page 139: ...WNLOAD PORT CENTRONIC SELECT DOWNLOAD PORT RS232 9600 SELECT DOWNLOAD PORT RS232 19 2K SELECT DOWNLOAD PORT RS232 38 4K SELECT DOWNLOAD PORT RS232 115K ENTER WAITING DOWNLOAD PORT CENTRONIC ENTER WAIT...

Page 140: ...ace before a hex code indicates an inactive PI line To convert an ASCII character to its corresponding hex code or vice versa refer to the ASCII code chart on page 142 Step Press Displayed Result Note...

Page 141: ...Send a file from the host computer The printer outputs a hex dump Refer to the ASCII chart on page 142 14 When the hex dump is complete take the printer offline and change the Hex Dump Mode back to D...

Page 142: ...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 0 1 2 3 4 5 6 7 8 9 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...

Page 143: ...in hours that the printer has been powered on The range is 0 to 30 000 hours Printing Time The cumulative time in hours that the printer has actually been printing The range is 0 to 30 000 hours Print...

Page 144: ...you access to the configuration menus 4 OPERATOR MENU PRINTER CONTROL First of series of configuration menus 5 OPERATOR MENU PRINTER INFORMATION Advances to the Printer Information menu 6 PRINTER INFO...

Page 145: ...uration Put the printer in the NOT READY state to do a soft reset 1 Press the Stop key to put the printer in the NOT READY state 2 Press the Stop Enter keys The LCD displays STANDBY SOFT RESET while t...

Page 146: ...ntroller where XX is the data line plus 1 For example a bad data line 8 would blink as 4 1 1 9 Initialize VX ASIC The boot code detects the processor type and sets up the internal registers of the VX...

Page 147: ...be used This is done by putting the message DCS1 in the ECDC communications register in the VX ASIC Detect Ethernet Adapter An Ethernet adapter must be detected early in the power up sequence so the p...

Page 148: ...enter download mode If so the printer enters download mode If not the printer continues boot routines Check for Flash Optimize Boot code checks if the user requested the flash file system to be optimi...

Page 149: ...MM and if found copies the contents of flash memory into the SIMM then remaps the address of the SIMM to the location of flash This allows breakpoints and single stepping from the MTOS debugger When t...

Page 150: ...asking Operating System Initialize the Processor cache vector table etc Partition RAM for Tasks Allocate Peripheral Interfaces console driver etc Start Main Task supervisor Verify and Initialize NVRAM...

Page 151: ...l Operation page 153 Belt Paper Feed Timing Adjustment page 154 Belt Platen Open Adjustment page 156 Paper Drive Motor Pulley Alignment page 158 Paper Scale Alignment page 160 Platen Gap Adjustment pa...

Page 152: ...C power source 3 Disconnect the host data cable from the printer interface 4 Open the printer cover 5 Unload paper 6 Remove the ribbon 7 Read the entire adjustment procedure before you begin working o...

Page 153: ...ata cable to the printer interface 2 Install the ribbon 3 Load paper 4 Plug the AC power cord into the power source 5 Close the cabinet doors 6 Power on the printer 7 Set the top of form Refer to the...

Page 154: ...m the slots in the side plate 5 Loosen do not remove the motor mount bolts 2 6 Using the straight end of a force gauge apply 15 pounds 66 7 N of pressure to the paper feed drive motor 3 near the mount...

Page 155: ...List Of Adjustments 155 Legend 1 Timing Belt Shield 2 Motor Mount Bolt 2 3 Paper Feed Drive Motor 4 Splined Shaft Figure 21 Paper Feed Timing Belt Adjustment Direction of Force 1 2 3 4 2...

Page 156: ...ess lever all the way ATTENTION Too much tension on the platen open belt can cause the platen gap to change which can lead to premature wear of the platen damaged hammer tips and poor print quality 6...

Page 157: ...List Of Adjustments 157 Legend 1 Belt Cover 2 Motor Mount Screw 2 3 Platen Open Motor Shaft Figure 22 Platen Open Belt Adjustment Direction of Force 1 2 3 2...

Page 158: ...he screw 2 in the motor pulley collar 3 5 Align the paper drive motor pulley 4 with the splined shaft pulley 5 ATTENTION Make sure there is at least 0 040 inches 1 016 mm of clearance between the coll...

Page 159: ...List Of Adjustments 159 Legend 1 Belt Shield 2 Cap Screw 3 Motor Pulley Collar 4 Motor Pulley 5 Splined Shaft Pulley Figure 23 Paper Drive Motor Pulley Alignment 1 2 3 5 4...

Page 160: ...installed page 203 6 Print a full 136 column line by selecting and running one of the diagnostic self tests See Chapter 5 7 Check alignment of the scale to the print at column positions 1 and 136 8 I...

Page 161: ...List Of Adjustments 161 Legend 1 Shuttle Cover 2 Screw Button Head 5 64 inch hex 3 3 Paper Scale Figure 24 Paper Scale Alignment 1 2 2 2 3...

Page 162: ...oximately 0 03 inch per revolution of the set screw Also insert the feeler gauge no more than 2 inches down from the top of the ribbon mask 6 Gently close the forms thickness lever 1 As the platen is...

Page 163: ...d 1 Forms Thickness Lever 2 Feeler Gauge 0 011 inch or 0 28 mm 3 Hammer Bank Cover 4 Ribbon Mask 5 Set Screw 3 32 inch hex 2 Figure 25 Platen Gap Adjustment ORF 0D NOTE Left side adjustment shown Righ...

Page 164: ...ttom to release the plastic tabs from the slots in the side plate 4 Loosen the 1 16 inch set screw 2 in the motor pulley 5 Bottom out the platen open motor pulley 3 on the motor shaft and torque the 1...

Page 165: ...List Of Adjustments 165 Legend 1 Belt Cover 2 Set Screw 3 Platen Open Motor Pulley 4 Platen Shaft Pulley Figure 26 Platen Open Motor Pulley Alignment 1 4 3 2...

Page 166: ...verses 5 Observe how the ribbon 2 passes around and across the ribbon guide It should be centered and not folding against either of the two white nylon washers 3 6 If the ribbon is not centered loosen...

Page 167: ...Of Adjustments 167 Legend 1 Screw Skid 2 2 Ribbon 3 White Nylon Washer 4 Screw Retaining 2 Figure 27 Ribbon Guide Alignment Left Ribbon Guide Right Ribbon Guide 2 3 2 4 4 Early Models Later Models 1...

Page 168: ...t 1 Open the printer cover 2 Loosen the screw 1 securing the adjusting link 2 3 Adjust the link 2 by raising or lowering the horizontal adjustment knob 3 to obtain print parallel with paper perforatio...

Page 169: ...End of Forms distance with 6 part paper in order to verify correct printing with multi part forms The procedure below describes how to run the END OF FORMS ADJUST printer test and modify the END OF F...

Page 170: ...170 Chapter 6 Adjusting The End Of Forms Distance Figure 29 Paper Preparation for Paper Out Adjustment Test Page Perforation Page Perforation Page Perforation Cut out here 4 in 4 in...

Page 171: ...paper you may stop the test here and skip to step 22 See the note at the beginning of this procedure If the comb pattern stopped short of the perforation or printed beyond the perforation go to step 1...

Page 172: ...Press Enter to select the new number of dots as the active value The asterisk that appears tells you that it is now the active value 20 Press Stop to put the printer into NOT READY mode 21 Run the END...

Page 173: ...th 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 or the New Phasing Value will not be written into NVRAM If...

Page 174: ...e pattern of Hs appears as shown below 15 When the print pattern is acceptable press Stop Printing stops and the printer automatically enters the current phase index value into NVRAM The display shows...

Page 175: ...ne Records via the WEB Primary Site click on the OK button 6 When the next screen reads PSC Machine Microcode scroll down to the 6400 machine type and click on ICON 7 Netscape will open the Code downl...

Page 176: ...talling new software erases all saved configurations You will use the printouts to restore printer configuration 4 Set the printer power switch to O off 5 Unplug the AC power cord from the printer 6 I...

Page 177: ...aud RS422 19 2K RS 422 serial 19200 baud RS422 38 4K RS 422 serial 38400 baud RS422 115K RS 422 serial 115000 baud 15 Press Scroll Scroll to unlock the Enter key 16 When the printer download port you...

Page 178: ...RAM and the checksum matched The old program is now being deleted from flash memory None DIAGNOSTIC PASSED The printer passed its memory and hardware initialization tests None ERROR DC PROGRAM NOT VAL...

Page 179: ...COMPATIBLE The printer is not compatible with the downloaded program User tried to load CMX compatible diskette in CBO controlled printer or vice versa Use the correct emulation software option s for...

Page 180: ...OADING PROGRAM FROM PORT XX The new program is loading into printer RAM XX indicates how much of the program has loaded None LOADING PROGRAM INTO FLASH The printer has deleted the previous program fro...

Page 181: ...EADY state to do this procedure 4 Press Scroll Scroll Return Enter Press all four keys at the same time SERVICE PRINTER MECHANISM TESTS appears on the display 5 Press Scroll Scroll to unlock the Enter...

Page 182: ...ter key 6 Press the Scroll or Scroll key until SERVICE SHUTTLE SPEED appears on the display 7 Press Enter SHUTTLE SPEED 475 or SHUTTLE SPEED 500 appears on the display The asterisk indicates which shu...

Page 183: ...s the Scroll or Scroll key until SERVICE PRINTER MGMT appears on the display 7 Press Enter PRINTER MGMT DIAGNOSTIC PORT appears on the display 8 Press Enter DIAGNOSTIC PORT and the current diagnostic...

Page 184: ...184 Chapter 6 Ethernet Initialization...

Page 185: ...e The procedures in this section refer you to the illustrations in Section II Section I begins on page 186 Section II Illustrated Parts Lists This section contains drawings of all assemblies comprisin...

Page 186: ...lies are the only replaceable components of the shuttle frame assembly List Of Procedures Belt Paper Feed Timing page 188 Belt Platen Open page 189 Circuit Board Controller page 190 Circuit Board Powe...

Page 187: ...ly page 229 Paper Ironer page 230 Platen page 231 Resistors Terminating page 235 Ribbon Guide Assembly L R page 237 Ribbon Hub page 238 Security Module page 217 Shaft Splined page 239 Shaft Support pa...

Page 188: ...haft pulley Installation 1 Install the paper feed timing belt over the splined shaft pulley and the motor pulley Slide the motor pulley onto the paper feed motor shaft page 278 Figure 52 2 Holding a 0...

Page 189: ...n open pulley Installation 1 Slide the platen open timing belt over the platen open pulley and the motor pulley and tighten the 1 16 inch setscrew 2 Slide the motor pulley onto the platen open motor s...

Page 190: ...ee page 264 Figure 47 5 Loosen but do not remove the screws securing the controller shield near serial cable connector J201 6 Loosen but do not remove the screw securing the controller shield to the b...

Page 191: ...controller shield to the bottom of the card cage 5 Connect all cable connectors to the controller board using the Interconnection diagram on page 289 as your guide 6 Cabinet Model Install the paper gu...

Page 192: ...e 264 Figure 47 item 15 5 Carefully disengage the power supply board from the three standoffs on the rear wall of the card cage 6 Remove the power supply board from the card cage Installation 1 Positi...

Page 193: ...nd remove the circuit breaker from the printer Installation 6 Press the circuit breaker into the cutout until the spring clips snap into place Cabinet Model See Figure 53 page 280 Pedestal Model See F...

Page 194: ...lectrostatic damage to electronic components wear a properly grounded static wrist strap when handling circuit boards the shuttle frame assembly and any other electronic component 1 Prepare the printe...

Page 195: ...over assembly page 204 NOTE Later models have stiffening clips on connectors P106 and P107 3 On later model printers remove the stiffening clip page 198 4 Disconnect the cable connector shell containi...

Page 196: ...tor down into the connector shell 3 Engage the tabs on the cable connector in the slots in the side of the connector shell Press the sides of the connector shell inward to make sure all cable connecto...

Page 197: ...16 14 11 9 19 17 15 13 LRIB M PLAT M LRP CCF PMD POD P106 Connector Configuration RRIB M PAPR M HBF EHF CVO MPU RRP PLO P107 Connector Configuration Pin No 8 6 4 2 7 5 3 1 12 10 20 18 16 14 11 9 19 1...

Page 198: ...ctor shell P107 and work the stiffening clip off the cable bundle See Figure 31 4 Repeat step 3 for the P106 connector 5 Cabinet Model Install the paper guide assembly page 229 Pedestal Model Install...

Page 199: ...Connector Stiffening Clips 199 Figure 31 Connector Stiffening Clips P107 P106 Stiffening Clip Connector Shell...

Page 200: ...agnets See Figure 32 page 202 4 Later models a Using a Torx T 10 driver remove the six screws and three ribbon mask clamp plates securing the ribbon mask to the hammer bank cover Remove the ribbon mas...

Page 201: ...dels a Position the hammer bank cover on the alignment pins on the hammer bank Make sure the hammer bank cover is properly positioned over the alignment pins and hammer tips and lies flat on the hamme...

Page 202: ...y Ribbon Mask 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 5 4 6 Early Models Later Models Hammer Bank Cover Thick Plate Ribbon Mask Torque Sequence Hammer Bank Cover Torque Sequence Ribbon Mask Thin Plate Hammer...

Page 203: ...tilt up the rear edge and lift the shuttle cover assembly out of the printer Installation 1 Place the shuttle cover assembly in the printer Tilt the forward edge of the cover down slightly and work th...

Page 204: ...ms 3 and 4 4 Loosen the two captive 2 Phillips screws in the lower front corners of the top cover See Figure 43 page 256 item 14 5 Loosen but do not remove the two 2 Phillips hold down screws on the r...

Page 205: ...e cylinder uppermost 1 Position the dashpot against the ball studs on the upper and lower brackets page 254 Figure 42 The large cylinder must be uppermost 2 Push the dashpot onto the ball joints and i...

Page 206: ...r of the cabinet Remove the hinge plates and the pads beneath the plates 7 Install pads and hinge pin plates to the right front side of the frame with the hinge pins up and toward the outside edge of...

Page 207: ...ards the shuttle frame assembly and any other electronic component 1 Prepare the printer for maintenance page 152 2 Cabinet Model Remove the paper guide assembly page 229 Pedestal Model Remove the top...

Page 208: ...ve the fan cable connector from the cutout in the side of the air exhaust duct 7 Remove the two fan mounting screws and the cabinet exhaust fan assembly Installation ATTENTION Make sure to install the...

Page 209: ...ve the two fan mounting screws from the bottom of the fan See Figure 52 page 278 item 2 Pedestal Model Remove the four fan mounting screws and nut See Figure 46 page 262 items 1 through 4 5 Remove the...

Page 210: ...between the base casting and the base pan See Figure 52 page 278 Installation ATTENTION Make sure to install the fan so the label faces up Air flow is UP NOTE The hammer bank fan assembly is installed...

Page 211: ...e damage or broken parts can be seen in the assembly 5 Remove the mounting screws from the old hammer spring assembly See Figure 33 page 212 6 Handling the hammer spring assembly by the mounting base...

Page 212: ...Removal Hammer Spring Assembly 7 Hammer Spring Assembly 1 NOTE The hammer spring assemblies shown here are for 6400 004 04P 005 05P printers The number of hammer springs and mounting screws varies am...

Page 213: ...box 3 Handling the hammer spring assembly by the mounting base only carefully position the new hammer spring assembly onto the hammer bank mounting pins and press it into position with the flat end of...

Page 214: ...crews from the kit Torque the screws to 14 inch pounds 1 58 Newton meters New Hammer Spring Assembly NOTE The hammer spring assemblies shown here are for 6400 004 04P 005 05P printers The number of ha...

Page 215: ...oosen but do not remove the two screws securing the coax twinax I O plate to the rear of the card cage Loosen the thumbscrew on the CT board until the screw is released from the standoff on the contro...

Page 216: ...the gap between the MPU assembly and the flywheel to 0 010 001 inch 0 254 0 025 mm Torque the MPU clamp screw to 19 1 inch pounds 2 15 0 11 N m 3 Check the gap between the MPU assembly and the flywhee...

Page 217: ...roperly grounded static wrist strap when handling circuit boards the shuttle frame assembly and any other electronic component NOTE If flash SIMMs are removed from one controller board and placed on a...

Page 218: ...ted in Table 8 and Table 9 1 Insert the memory module into the correct socket on the CMX controller board a Position the SIMM so the notched end is toward the right hand side of board See Figure 35 pa...

Page 219: ...winax with Code V 24H9335 14H5490 154143 001 IPDS Coax 24H9336 14H5509 154143 002 IPDS Coax with IGP 24H9337 14H5490 154143 001 IPDS Coax with Code V 24H9338 14H5490 154143 001 LQ 1600K Hanzi 24L5211...

Page 220: ...d does not support EDO RAM CMX Controller Board Security PAL Notched End DRAM Flash Datastream ASCII ASCII IGP Code V CTA CTA IGP Code V IPDS CTA IPDS CTA IGP Code V LQ 1600K Hanzi Flash Memory 8 MB 8...

Page 221: ...slots in the side plate page 258 Figure 44 5 Loosen the paper feed motor mount screws page 278 Figure 52 item 10 6 Loosen the shaft collar setscrew and remove the paper feed motor pulley shaft collar...

Page 222: ...old the collar snug against the motor pulley and torque the setscrew to 25 2 inch pounds 2 82 0 23 N m 6 Using the straight end of a force gauge apply 12 pounds 53 4 N of pressure to the paper feed mo...

Page 223: ...igure 52 6 Loosen the 1 16 hex pulley setscrew and remove the motor pulley and platen open belt 7 Trace the platen open motor cables back to the controller board releasing the cables from the tie wrap...

Page 224: ...diagrams on page 300 and page 302 6 Close the forms thickness lever all the way ATTENTION Too much tension on the platen open belt can cause the platen gap to change which can lead to premature wear...

Page 225: ...ribbon drive motor until the motor cable is aligned with the slot on the base casting 5 Disconnect the ribbon drive motor cable connector 6 Cabinet models remove the heat boot from the motor You will...

Page 226: ...prevent electrostatic damage to electronic components wear a properly grounded static wrist strap when handling circuit boards the shuttle frame assembly and any other electronic component 1 Prepare t...

Page 227: ...or panel assembly and disconnect the phone style cable connector Installation 1 Connect the phone style operator panel cable to the bottom of the operator panel See Figure 42 page 254 2 Position the o...

Page 228: ...the panel and slide the operator panel downward on the mounting plate until the tabs on the panel housing slide out of the cutouts Installation 1 Tilt the operator panel mounting plate toward the fro...

Page 229: ...ft and lift it off the card cage Installation 1 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 258...

Page 230: ...TE The black tape on the paper ironer faces the paper detector switch assembly 1 Position the paper ironer so that the black tape is on the side that faces the paper detector switch assembly See page...

Page 231: ...the lever off the platen shaft See Figure 51 page 276 item 15 9 Remove the right side platen support spring by repeating step 7 on the right side of the platen 10 Remove the Phillips 1 screw and washe...

Page 232: ...ten seat See Figure 37 5 Apply a layer of bearing lubricant 1 4 inch high to the seat of each wear saddle making the layer as wide as the saddle and touching the rear angled surface 6 Install one plat...

Page 233: ...76 item 26 12 Apply bearing lubricant to the nylon bearings in the two spring links slide the spring links onto the two platen shafts and connect the springs to the spring hooks in the side plates See...

Page 234: ...e the forms thickness lever to make sure the setscrew does not touch the right ribbon guide 17 Install the platen shaft pulley with the 7 64 inch setscrew facing up and tighten the setscrew Open and c...

Page 235: ...ear a properly grounded static wrist strap when handling circuit boards the shuttle frame assembly and any other electronic component 1 Prepare the printer for maintenance page 152 2 Cabinet Model Rem...

Page 236: ...ction I Replacement Procedures Figure 38 Terminating Resistors Removal Installation Default 470 Ohm Alt 1 220 Ohm Alt 2 1K Ohm Default 1K Ohm Alt 1 330 Ohm Alt 2 None RP1 RP2 CMX Controller Board Resi...

Page 237: ...uting diagrams on page 300 and page 302 5 For the left ribbon guide disconnect connector shell P106 from the controller board For the right ribbon cable disconnect connector shell P107 from the contro...

Page 238: ...n 1 Install the ribbon spool hub over the motor shaft page 278 Figure 52 ATTENTION Tightening the hub screw too much can crack the ribbon hub Be careful not to over tighten the hub screw 2 Tighten the...

Page 239: ...274 Figure 50 6 With grip ring pliers remove the grip ring from left side of the splined shaft 7 Pull the bearing and spring link with the spring off the left side of the splined shaft 8 Unlock the le...

Page 240: ...left side of the splined shaft with the white nylon bushing flange to the outside of the printer 6 Attach the spring to the left side plate and the spring link 7 Install the grip ring on the splined s...

Page 241: ...upport shaft two curved washers bushing horizontal adjustment knob washer and screw to the left out of the tractors and the left side plate Installation 1 Slide the support shaft assembly consisting o...

Page 242: ...ector page 272 Figure 49 5 Disconnect the hammer drive and hammer logic cables connectors from the terminator board on the shuttle frame assembly 6 Loosen the side 5 32 inch socket head clamp screws a...

Page 243: ...the next step IMPORTANT Do not over tighten the shuttle frame assembly hold down screws 5 Slide the side clamps over the guide shaft and torque the 5 32 inch socket head clamp screws to 20 2 inch poun...

Page 244: ...assembly page 203 4 Unhook the extension spring from the spring lugs on the hammer bank and shuttle frame See Figure 49 page 272 Installation 1 Put a dab of IBM 20 bearing lubricant on both spring lug...

Page 245: ...nnector shell and remove the cable connector from the connector shell page 195 Installation 1 Remove the protective covering from the adhesive backing on the cover open switch assembly 2 Feed the swit...

Page 246: ...Remove the paper detector switch assembly Installation 1 Holding the slotted wheel against the PMD sensor position the paper detector switch assembly and install the screws securing it to the printer...

Page 247: ...lock switch assembly See Figure 51 page 276 8 Remove the platen interlock switch assembly from the switch bracket 9 Remove the switch cable from the cutout in the right side plate Installation 1 Fully...

Page 248: ...for maintenance page 152 2 Remove the splined shaft page 239 3 Remove the support shaft page 241 4 Remove the tractors Installation 1 Using the replacement tractors install the support shaft page 241...

Page 249: ...trol Panel and Cabinet Details page 254 Figure 43 Pedestal Details page 256 Figure 44 Inside Covers Cabinet Model page 258 Figure 45 Inside Covers and Card Cage Pedestal Model page 260 Figure 46 Card...

Page 250: ...250 Chapter 7 Section II Illustrated Parts Lists Figure 40 Top Cover Doors and Casters Cabinet Model 1 2 3 4 5 6 7 13 8 12 9 14 15...

Page 251: ...14 5 24H8959 Front Door Kit Includes item 14 6 57G1485 Caster with Brake Two at front 7 57G1486 Caster without Brake Two at rear 8 14H5603 Logo 6400 9 30H4008 Wire Rope Front and Rear One on each door...

Page 252: ...252 Chapter 7 Section II Illustrated Parts Lists Figure 41 Paper Stacker and Chains 6 5 7 1 8 3 2 4...

Page 253: ...o Description Notes 1 57G7176 Stacker 2 30H3981 Runner Stacker 3 04H4779 Riser Stacker Runner 4 Ref Screw 4 5 14H5296 Spares Kit Grommet 6 14H5272 Chain Assembly Kit Kit contains eight chains 7 57G726...

Page 254: ...254 Chapter 7 Section II Illustrated Parts Lists Figure 42 Operator Panel and Cabinet Details 1 3 6 5 7 8 6 6 9 2...

Page 255: ...tor Panel Overlay Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay English Spanish French Italian German Dutch Brazilian Portuguese 3 Ref Screw Hex w Lock Wa...

Page 256: ...256 Chapter 7 Section II Illustrated Parts Lists Figure 43 Pedestal Details 1 2 7 3 4 5 13 10 11 15 8 9 14 12 6 NOTE Item 16 Lid Accessory Kit not shown Item 17 Pedestal Shipping Container not shown...

Page 257: ...Bracket Operator Panel Models 04P 05P 08P 09P 5 63H5121 Hinge Lid Kit Models 04P 05P 08P 09P 6 14H5300 Cable Assy Operator Panel 7 63H5119 Lid Pedestal Model Models 04P 05P 08P 09P 8 Ref Screw 2 9 63H...

Page 258: ...258 Chapter 7 Section II Illustrated Parts Lists Figure 44 Inside Covers Cabinet Model 1 2 11 3 4 9 10 3 8 7 6 5...

Page 259: ...5 4 Ref Barrier Shield 5 14H5271 Paper Guide Assembly Models 004 005 008 009 012 014 6 Ref Screw w Lock Washer 3 6 32x 25 and 6 Flat Washer 7 14H5174 Platen Paper Feed Cover Kit Paper feed belt cover...

Page 260: ...260 Chapter 7 Section II Illustrated Parts Lists Figure 45 Inside Covers and Card Cage Pedestal Model See Figure 46 page 262 1 2 10 5 3 4 3 6 7 8 9...

Page 261: ...f Screw Thread Forming 4 6 32x 25 4 Ref Barrier Shield 5 63H5116 Paper Path Assembly Models 04P 05P 08P 09P 6 08H7954 Anti Static Brush Kit 7 Ref Power Supply Shield Taped to card cage along upper edg...

Page 262: ...ure 46 Card Cage Detail Pedestal Model From Figure 45 page 260 Rotated 180 degrees 5 To IEC 320 AC Power Input Connector J301 White Wire To Connector P1 Black Wire To IEC 320 AC Power Input Connector...

Page 263: ...Part No Order No Description Notes 1 Ref Nut 6 32 1 Upper right fan corner only 2 57G1440 Card Cage Fan Assembly Air flow is into card cage 3 Ref Fan Guard 4 Ref Screw w Lock Washer 4 6 32x 1 75 5 Re...

Page 264: ...ure 47 Print Mechanism and Circuit Boards Early Models 1 Two places Exploded to show assembly Do not remove holddown clamps and screws 14 To J02 Shuttle Motor To J03 MPU 2 7 8 9 10 4 6 To Terminator B...

Page 265: ...BA Models 004 04P 005 05P 008 08P 012 Models 009 09P 014 4 Ref P101 Cable Connector 5 Ref Cable Assy AC In Power Supply Part of Field Kit AC Assy 14H5289 6 14H5643 24H8647 90H3271 Controller Board CMX...

Page 266: ...Chapter 7 Section II Illustrated Parts Lists 16 Ref SIMM Flash Memory See also page 217 17 Ref SIMM DRAM See also page 217 18 14H5282 Switch Assembly Cover Open Item No Part No Order No Description No...

Page 267: ...Illustrations Of Printer Components 267 Illustrated parts lists continue on next page...

Page 268: ...int Mechanism and Circuit Boards Later Models To J02 Shuttle Motor To J03 MPU To Terminator Board on Shuttle Frame Two places Exploded to show assembly Do not remove holddown clamps and screws 17 5 10...

Page 269: ...ring Field Kit 500 Hammer Spring Field Kit 1000 Hammer Spring Field Kit 1500 Hammer Spring Field Kit Hanzi Models 050 P50 Models 010 P10 Model 015 Models C05 C5P Models 050 P50 Models 010 P10 Model 01...

Page 270: ...tion II Illustrated Parts Lists 19 Ref SIMM Flash Memory See also page 217 20 Ref SIMM DRAM See also page 217 21 14H5282 Switch Assembly Cover Open 22 02N8261 Connector Clip Item No Part No Order No D...

Page 271: ...Illustrations Of Printer Components 271 Illustrated parts lists continue on next page...

Page 272: ...Lists Figure 49 Magnetic Pickup Unit MPU and Extension Spring 0 010 001 inch 0 254 025mm 21 Make sure the extension spring does not touch the MPU cable after installation Spring Lug Do not remove grea...

Page 273: ...ustrations Of Printer Components 273 Item No Part No Order No Description Notes 1 57G1476 Magnetic Pickup Assy MPU 2 Ref Screw Socket Cap 6 32x 38 3 30H3985 Extension Spring 4 14H5329 Cable Assembly M...

Page 274: ...ter 7 Section II Illustrated Parts Lists Figure 50 Tractor Shafts NOTE Item 18 Tractor Shaft Hardware Kit not shown Item 19 Tractor Shaft Kit not shown 2 3 17 4 5 7 9 10 11 20 21 12 14 13 16 15 16 6 8...

Page 275: ...on 1 00L Part of item 18 10 Ref Screw Hex w Lock Washer 4 20x 50 Part of item 11 11 57G1521 Ground Clip Splined Shaft 12 57G1460 Splined Shaft Assembly 13 Ref Screw Thread Forming 6 32x 25 Part of ite...

Page 276: ...7 Section II Illustrated Parts Lists Figure 51 Platen NOTE Black tape faces paper motion detector NOTE Item 25 Platen Hardware Kit 1 2 4 3 5 6 7 8 8 2 9 10 13 12 11 14 15 16 19 24 23 18 21 17 26 16 2...

Page 277: ...12 Ref Screw Socket Cap 6 32x 75 Part of item 15 13 Ref Washer Part of item 15 14 Ref Nut Part of item 15 15 63H7478 Platen Lever Kit 16 Ref Spring Extension 1 12L Part of item 25 17 Ref Link Spring P...

Page 278: ...ted Parts Lists Figure 52 Motors Card Cage Fan and Paper Detector Switch Install screws here Hammer Bank Fan Route cable under base casting Top View 1 2 16 20 18 19 17 15 6 12 4 5 2 7 9 10 11 13 14 21...

Page 279: ...and includes collar setscrew 6 32x 25 7 Ref Collar Part of item 9 8 Ref Screw Socket Head 6 32x 51 9 57G1421 Motor Pulley Paper Feed 10 Ref Screw Hex w Lock Washer 2 10 32x 50 11 24H8894 Ribbon Guide...

Page 280: ...0 AC Power Input Connector J301 White Wire To Connector P1 Black Wire To IEC 320 AC Power Input Connector J301 Black Wire To Connector P1 White Wire See inside detail below Card cage fan and power sup...

Page 281: ...Order No Description Notes 1 14H5571 Circuit Breaker 2 Ref IEC 320 AC Power Connector Connector J301 3 Ref Chassis Ground Stud 4 Ref Connector P1 To power supply board connector J1 AC 5 Ref Cable Ass...

Page 282: ...282 Chapter 7 Section II Illustrated Parts Lists Figure 54 IBM Coax Twinax Expansion Board 1 2 3 4 5 6 8 7...

Page 283: ...er No Description Notes 1 Ref Screw 2 2 Ref Card Cage 3 24H9011 IBM Coax Twinax Expansion 4 Ref Screw Captive 5 Ref Standoff Hex 3 16 inch M F 813 Lg 6 24H8535 Adapter Expansion Connector 60 pin 7 Ref...

Page 284: ...284 Chapter 7 Section II Illustrated Parts Lists Figure 55 Ethernet Interface Assemblies 1 2 3 4 5 6 7 9 10 8...

Page 285: ...tor Cover 2 2 Ref Cover Plate Centronics 3 Ref Ferrite Clamp See also Appendix I 4 Ref CMX Controller Board 5 14H5287 Centronics I O Cable Assembly 6 24H8995 Ethernet LAN PCBA 10Base T 7 24H8994 Ether...

Page 286: ...286 Chapter 7 Section II Illustrated Parts Lists...

Page 287: ...tacker PCBA page 298 Cable Routing Cabinet Model page 299 Cabinet Model Mechanism Base page 300 Pedestal Model page 301 Pedestal Model Mechanism Base page 302 Cable Assemblies Centronics I O page 303...

Page 288: ...e 318 Logic Cable Power Stacker page 319 Power Cable Power Stacker page 320 Vertical Rail Cable Power Stacker page 321 Fan Assembly Hammer Bank page 322 Magnetic Pickup MPU Assembly page 323 Switch As...

Page 289: ...106 MSL J108 HLP P108 HLP J105 HBP P105 HBP J116 SMD P116 SMD J107 MSR P107 MSR J102 5V Remote Power J110 P110 J112 P112 J201 J6 Serial I O Diagnostic Port N Number of conductors in cable assembly Cha...

Page 290: ...t Ribbon Motor Left Ribbon Giude Paper Out Detector Paper Motion Detector Motor Platen J06 J02 Shuttle Motor Hammer Bank Board Terminator Board P05 P04 Hammer Bank Fan P06 P02 J04 J05 Control Panel As...

Page 291: ...O MPU RRP PLO CVO Cover Open Switch EHF Exhaust Fan HBF Hammer Bank Fan MPU Magnetic Pickup PAPR M Paper Feed Motor PLO Platen Open Switch RRIB M Right Ribbon Motor RRP Right Ribbon Guide Only in cabi...

Page 292: ...CNC PN 33 I O CNC PN 16 I O CNC PN 34 I O CNC PN 17 I O CNC PN 35 I O CNC PN 18 I O CNC PN 36 470 PF 10 50V 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 HOST RXD HOST CTS NC NC NC...

Page 293: ...6 DB TXD DB RXD Diagnostic Port J6 470 PF 10 50V NC NC 7 8 1 2 3 4 5 6 Online Verifier J9 EXT 5V DB TXD DB RXD OLV SYNC OLV IRQ 0 1 mF 20 50V 4 7K 0 1W OUT1 OUT2 OUT3 OUT4 GND IN1 IN2 EN 8 7 6 5 1 2...

Page 294: ...0 1W NC EXP N ID SEL 12 10 V NC N DMA REQ0 N DMA REQ1 NC EXP NINT EXP NWR EXP NRESET CAJ NACK EXP NMSEL EXP NDS EXP D15 EXP D14 EXP D13 EXP D12 EXP D11 EXP D10 EXP D9 EXP D8 EXP D7 EXP D6 EXP D5 EXP...

Page 295: ...AT HMR DAT RET HMR CLK HMR CLK RET CMD DAT CMD DAT RET CMD CLK CMD CLK RET TOROID 50 MHz TOROID 50 MHz 15V 0 01 mF 10 50V 4 7V 3 0W DRAM 72 pin SIMM J15 Bank 1 J16 Bank 0 See page 187 Flash 80 pin SIM...

Page 296: ...FAST ON TERMINAL Line Filter Area PIN 1 1 2 3 4 5 6 7 8 N TEMP HI 9 10 11 12 P101 Controller Board N STBY 470 mF 10 50V VCC 470 mF 10 50V 470 mF 10 50V 470 mF 10 50V 8 5V 48V N TEMP HI N STBY 5V 5V 5V...

Page 297: ...NC EXP NINT EXP NWR EXP NRESET EXP NACK EXP NMSEL EXP NDSEL EXP D15 EXP D14 EXP D13 EXP D12 EXP D11 EXP D10 EXP D9 EXP D8 EXP D7 EXP D6 EXP D5 EXP D4 EXP D3 EXP D2 EXP D1 EXP D0 EXP A15 EXP A14 EXP A...

Page 298: ...acker VCC 100 PF 10 50V 1K 0 1W 100 PF 10 50V 100 PF 10 50V 100 PF 10 50V 100 PF 10 50V Logic 0 1W 33 0 1W 33 0 1W 33 0 1W 33 10K 0 1W 10K 0 1W 10K 0 1W R NW DATA LOAD CLK LOGIC CON 1 2 3 4 5 6 7 8 N...

Page 299: ...299 Cable Routing Cabinet Model...

Page 300: ...able Pinouts Cable Routing Mechanism Base Cabinet Model To J107 on CMX board To J106 on CMX board Front of Printer Left Side of Printer Right Side of Printer NOTE This view shows the underside of the...

Page 301: ...301 Cable Routing Pedestal Model...

Page 302: ...oller Left Side Right Side Front of Printer of Printer of Printer See page 166 for connector detail See page 166 for connector detail Not connected on pedestal models To J107 on CMX board To J106 on C...

Page 303: ...bly Centronics I O PIN 1 PIN 1 NOTE If you replace the I O cable assembly you must install the ferrite clamp See Appendix E NOTE If you replace this cable you must also install a ferrite clamp See App...

Page 304: ...304 Appendix A Circuit Board And Cable Pinouts Cable Assembly Centronics Dataproducts Adapter 14H5522...

Page 305: ...305 Cable Assembly 5V Remote Power 14H5589...

Page 306: ...Circuit Board And Cable Pinouts Cable Assembly Twinax Auto Termination White Gray Shield 14 7 5 Jack Jack 1 2 3 4 Resistance Chart Pin Pin Ohms 1 3 1 2 3 4 5 14 7 2 4 Shield Shield 1 4 2 3 110 110 55...

Page 307: ...307 Cable Assembly AC In Power Supply To Power Supply J1 To Circuit Breaker AC Kit 14H5289...

Page 308: ...308 Appendix A Circuit Board And Cable Pinouts Cable Assembly AC Power Input To Circuit Breaker Input Power Connector AC Kit 14H5289...

Page 309: ...309 Cable Assembly Card Cage Fan PIN 1 PIN 1 14H5285...

Page 310: ...rcuit Board And Cable Pinouts Cable Assembly Operator Panel PIN 1 PIN 1 PIN 8 PIN 8 Gray Brown Gray Brown NOTE If you replace the control panel cable you must install two ferrite shielding beads See A...

Page 311: ...311 Cable Assembly Exhaust Fan PIN 1 PIN 1 14H5286...

Page 312: ...312 Appendix A Circuit Board And Cable Pinouts Cable Assembly Hammer Bank Logic 14H5279...

Page 313: ...313 Cable Assembly Hammer Bank Power PIN 1 PIN 1 02N6214...

Page 314: ...314 Appendix A Circuit Board And Cable Pinouts Cable Assembly MPU PIN 1 PIN 3 PIN 2 PIN 1 14H5329...

Page 315: ...e Assembly Ribbon Guide Kit 24H8894 NOTE Left ribbon guide shown Right is mirror image Pin Connection P106 LRP P107 RRP Wire Color Pin 1 Black Pin 2 Black Left Guide P106 LRP Right Guide P107 RRP Pin...

Page 316: ...316 Appendix A Circuit Board And Cable Pinouts Cable Assembly Ribbon Motor Extension 63H7464...

Page 317: ...317 Cable Assembly Shuttle Motor Drive 14H5330...

Page 318: ...C DT1 E LD2 A LD2 K DT2 C DT2 E PMD K PMD C PMD E PID C PID E PID K PID A PI PHA 1 PI PHA 2 PI PHB 1 PI PHB 2 M1 REAR PADDLE MOTOR RESISTANCE 15 2 1 5 W PHASE M2 FRONT PADDLE MOTOR RESISTANCE 15 2 1...

Page 319: ...319 Logic Cable Power Stacker 24H8976...

Page 320: ...320 Appendix A Circuit Board And Cable Pinouts Power Cable Power Stacker 24H8975...

Page 321: ...321 Vertical Rail Cable Power Stacker Reference only not spared...

Page 322: ...322 Appendix A Circuit Board And Cable Pinouts Fan Assembly Hammer Bank P107 HBF P107 HBF 14H5159...

Page 323: ...323 Magnetic Pickup MPU Assembly 57G1476...

Page 324: ...324 Appendix A Circuit Board And Cable Pinouts Switch Assembly Paper Detector Standard 14H5281 Black Back Forms Kit 14H5570...

Page 325: ...325 Switch Assembly Platen Interlock P107 PLO 14H5280...

Page 326: ...326 Appendix A Circuit Board And Cable Pinouts Switch Assembly Cover Open 14H5282...

Page 327: ...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 w...

Page 328: ...r plies Multi part carbonless Verify readability of greater than 4 part Thickness 0 025 inches 0 064 cm maximum Drive Adjustable tractors 6 pin engagement Labels On Backing One part continuous perfora...

Page 329: ...e 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 Cabinet Model Pedestal Model...

Page 330: ...V 6A 100 V 6A 100 V 6A 100 V 6A 100 V 8A 100 V 8A 100 V 6A 100 V 178 270V RMS 47 63 Hz 3A 200 V 3A 200 V 3A 200 V 3A 200 V 3A 200 V 3A 200 V 3A 200 V 5A 200 V 5A 200 V 3A 200 V 120 VAC 60 Hz Operatin...

Page 331: ...ng HS Mode Standby All H s Max Typical Not Energy Star Energy Star Watts 223 239 86 22 BTU Hour 761 816 294 75 VA 410 449 173 41 120 VAC 60 Hz Operating HS Mode Standby All H s Max Typical Not Energy...

Page 332: ...3 287 85 VA 450 492 140 48 240 VAC 50 Hz Operating HS Mode Standby All H s Max Typical Not Energy Star Energy Star Watts 320 360 86 25 BTU Hour 1092 1228 294 85 VA 528 600 173 55 120 VAC 60 Hz Operati...

Page 333: ...by All H s Max Typical Not Energy Star Energy Star Watts 332 360 86 25 BTU Hour 1133 1229 294 85 VA 457 527 143 48 240 VAC 50 Hz Operating HS Mode Standby All H s Max Typical Not Energy Star Energy St...

Page 334: ...HS Mode Standby All H s Max Typical Not Energy Star Energy Star Watts 410 430 84 25 BTU Hour 1399 1468 287 85 VA 540 564 139 48 240 VAC 50 Hz Operating HS Mode Standby All H s Max Typical Not Energy...

Page 335: ...nergy Star Watts 424 490 79 27 BTU Hour 1447 1672 270 92 VA 722 857 163 58 120 VAC 60 Hz Max Typical Standby Not Energy Star Energy Star Watts 341 49 25 BTU Hour 1163 167 85 VA 475 79 48 240 VAC 50 Hz...

Page 336: ...422 serial interface 6400 004 04P 130 000 pages per month 6400 005 05P 130 000 pages per month 6400 050 P50 130 000 pages per month 6400 008 08P 205 000 pages per month 6400 009 09P 205 000 pages per...

Page 337: ...r inch 2 54 centimeter inch 25 4 millimeter meter 3 280840 foot centimeter 0 03280840 foot millimeter 0 003280840 foot meter 39 37008 inch centimeter 0 3937008 inch millimeter 0 03937008 inch Figure i...

Page 338: ...nd gram 0 03527397 ounce avoirdupois From To Use Formula temperature Celsius tc temperature Fahrenheit tf tf 1 8tc 32 temperature Fahrenheit tf temperature Celsius tc tc tf 32 1 8 Multiply By To Obtai...

Page 339: ...6 3 1972 Fastener Size Into Alum or Brass 25 000 psi ultimate tensile strength Into Steel 60 000 psi ultimate tensile strength Into Weld Press Studs or Nuts Into Medium Carbon Steel Fasteners 100 000...

Page 340: ...340 Appendix D...

Page 341: ...ether or not you can continue the inspection without first correcting the problem NOTE The correction of any unsafe condition is the customer s responsibility Preparation You must have completed the E...

Page 342: ...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 clo...

Page 343: ...maged See page 203 3 Make sure the paper guide assembly is correctly installed and undamaged See page 229 Inspect Electrical Parts Safety Ground Path 1 Make sure the printer power cord is unplugged 2...

Page 344: ...HBP J116 SMD P116 SMD J107 MSR P107 MSR Exhaust Fan Paper Feed Motor Platen Open Switch Right Ribbon Guide Right Ribbon Motor Platen Motor Paper Motion Detector Paper Out Detector Left Ribbon Motor J...

Page 345: ...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 line Power Cable 1 Mak...

Page 346: ...346 Appendix E Inspect Electrical Parts 4 Press Stop The audible alarm should stop 5 Close the forms thickness lever The fault message should clear...

Page 347: ...cond A0 A1 etc Address 0 Address 1 etc AC Alternating Current ACC Access ACK Acknowledge AMP Amplitude Ampere AMPL Amplitude AN Anode ASIC Application Specific Integrated Circuit ATTN Attention B Buff...

Page 348: ...CPI Characters Per Inch CR Carriage Return CT Coaxial Twinaxial CTL Control CTS Clear to Send CUR Current CVO Cover Open Switch D0 D1 etc Data Bit 0 Data Bit 1 etc DAT Data DC Direct Current Data Con...

Page 349: ...rammable Read Only Memory ERR Error ESD Electrostatic Discharge EX Exhaust Extra EXH Exhaust EXF Exhaust Fan EXP Expansion EXPND Expand FD Feed FF Form Feed FIFO First In First Out FLT Fault FLTR Filt...

Page 350: ...ting Diode LF Line Feed LO Low LPI Lines Per Inch LPM Lines Per Minute LRIB Left Ribbon LRP Left Ribbon Guide M1 Rear Paddle Motor Power Stacker M2 Front Paddle Motor Power Stacker M Motor MAIN Mainte...

Page 351: ...ne Verify OP Operand P5 5 V dc P Pin connector P 1 P 2 etc Parallel data 1 data 2 etc PAL Programmable Array Logic PAP Paper PAPR Paper PARM Parameter PCBA Printed Circuit Board Assembly PCB Printed C...

Page 352: ...Ribbon RD Read RET Return RIB Ribbon RG Ribbon Guide RGL Ribbon Guide Left RGR Ribbon Guide Right RM Ribbon Motor RML Ribbon Motor Left RMR Ribbon Motor Right RQ Request RRIB Right Ribbon RRP Right Ri...

Page 353: ...h SYNC Synchronize TCB Task Control Block TEMP Temperature TOF Top of Form first print line TP Test Point TTL Transistor Transistor Logic TXD Transmit Data UART Universal Asynchronous Receiver Transmi...

Page 354: ...354 Appendix F WR Write w With w o Without XMT Transmit...

Page 355: ...ands Antilles Trinidad Suriname Taiwan Tobago Saint Lucia Indonesia 8509386 Cable PC RS 232 IBM 08H7968 Coax Adapter Cable for use with Multi Platform Interface 13F9941 Line Cord IBM Australia 13F9980...

Page 356: ...14H5335 Twinax Auto Termination Cable 47 Inches 14H5541 DP Adapter 6400 21F4342 Cable AS 400 RS 232 IBM 38F8254 Twinax Auto Termination Cable 57G7261 Power Cord 6 Feet Non Lock United States Canada 11...

Page 357: ...Stacker PMD 02N8329 page 399 Pivot Arm Block 04H4779 page 252 Riser Stacker Runner 08H7934 page 278 Platen Open Motor Pulley 08H7936 page 276 Platen Assembly 08H7954 page 258 Anti Static Brush Kit 14H...

Page 358: ...entronics I O Cable Assembly 14H5288 page 197 Housing Connector Kit 14H5289 page 307 Cable Assy AC In Power Supply Part of AC Field Kit 14H5289 page 308 Cable Assy AC Power Input Part of AC Field Kit...

Page 359: ...0 Logo 6400 14H5643 page 264 CMX Controller Board V5 0 All models 004 and 04P Models 008 and 012 with Serial Nos 01AXXXX 01BXXXX and 01CXXXX 14H5644 page 264 Power Supply PCBA Models 004 04P 005 05P 0...

Page 360: ...k 1000 Models 010 10P 24H8858 page 268 Ribbon Mask 1500 Model 015 24H8872 page 268 Hammer Bank Cover Assy 500 Models 050 P50 24H8886 page 268 Hammer Bank Cover Assy 1000 Models 010 10P 24H8888 page 18...

Page 361: ...wer Stacker 24H8976 page 319 Logic Cable Power Stacker 24H8978 page 401 Anti Static Brush Power Stacker 24H8981 page 401 Extension Spring Power Stacker 24H8982 page 401 Idler Roller Power Stacker 24H8...

Page 362: ...9P 24L5203 page 18 6400 Line Matrix Printers Operator s Guide Hanzi 24L5204 page 18 6400 C05 C5P Line Matrix Printers Setup Guide 24L5205 page 18 6400 C05 C5P Line Matrix Printers Programmer s Referen...

Page 363: ...Ironer 57G1598 page 254 Operator Panel Overlay English 57G1599 page 254 Operator Panel Overlay Spanish 57G1600 page 254 Operator Panel Overlay French 57G1601 page 254 Operator Panel Overlay Italian 5...

Page 364: ...Hmr Bank Rbn Mask Cov Assy Models 004 04P 005 05P 63H7519 page 264 Hmr Bank Rbn Mask Cov Assy Models 008 08P 009 09P 63H7520 page 264 Hmr Bank Rbn Mask Cov Assy Models 012 014 C05 C5P 83F2834 page 26...

Page 365: ...indrical core through and around which the control panel cable assembly is wound Two are required 2 Ferrite Clamp a noise suppression core in a hinged plastic case and attached to the wall of the card...

Page 366: ...s to the right rear card cage wall Ferrite Core with Clamp and Adhesive Backing P N 202049 001 Connector P112 Connector P110 Connector P310 Connector J203 NOTE Two turns around each bead Shielding Bea...

Page 367: ...Control Panel page 370 Using The Power Stacker page 371 Loading And Starting The Power Stacker page 372 Stacker Troubleshooting page 374 Removing The Power Stacker page 375 Installing The Power Stacke...

Page 368: ...stallation instructions for the power stacker assembly and components that require the most frequent replacement An illustrated parts breakdown IPB showing how the entire power stacker unit is assembl...

Page 369: ...per Throat 3 Stacker Control Panel 4 Elevator Assembly 5 Motor Bracket 6 Wire Paper Tent 7 Paddle Shaft 8 Alignment Rod 2 9 Bearing Bracket 10 Paper Length Indicator Figure 59 Power Stacker Component...

Page 370: ...en printer power is off ON LINE Indicator Lamp Lit when printer is online to host computer READY Unlit when printer is offline NOT READY ON LINE Key Toggles the printer between the READY and NOT READY...

Page 371: ...f its travel See Figure 60 5 Make sure the wire paper tent is in the base of the stacker with the alignment rods against the vertical rails See Figure 61 Legend 1 Vertical Rail 2 Paper Tent 3 Alignmen...

Page 372: ...ntrol panel and hand feed the paper down into the paper throat Continue to advance the paper until it reaches the wire tent and there are 3 to 5 extra sheets in the stacker Make sure the paper passes...

Page 373: ...rol panel to put the printer in the READY state The stacker elevator will descend to its lowest position See Figure 64 Figure 64 Power Stacker in Print Position 4 Check that the paper is still centere...

Page 374: ...rious causes possible page 116 017 STACKER JAM CHECK STACKER Message on control panel LCD Paper is bunching above the elevator or the paper motion detector is not working properly page 68 018 STACKER...

Page 375: ...d 3 Unload paper from the stacker area Refer to the Setup Guide 4 Remove the paper tent See Figure 65 Legend 1 Paper Tent Figure 65 Removing the Paper Tent 5 Cut the tie wrap and remove the paper fenc...

Page 376: ...ng Screw 2 Washer 3 Short Screw Figure 67 Removing the Stacker Control Panel 7 Remove four cables from the stacker control panel and remove the stacker control panel See Figure 68 Legend 1 Logic Cable...

Page 377: ...cross member at the rear of the cabinet See Figure 69 9 Raise the elevator assembly Legend 1 Vertical Rail 2 Washer 2 3 Screw 5 32 x 3 4 inch 2 4 Screw 7 64 x 1 2 inch or Torx T 10 2 5 Washer 2 but no...

Page 378: ...ng the Lower Screws in the Vertical Rails 11 Remove the 7 64 x 1 2 inch screws and washers or Torx T 10 screws securing the base plate to the cabinet floor See Figure 69 12 Lower the elevator assembly...

Page 379: ...379 Legend 1 Upper Frame Cross Member 2 Elevator Assembly 3 Stacker Base 4 Vertical Rail Figure 71 Removing the Stacker Assembly 1 2 3 4...

Page 380: ...r including cable assemblies and the stacker control panel 1 Set the printer power switch to O off 2 Unplug the power cord 3 Remove paper 4 Loosen the three paper guide hold down screws Slide the pape...

Page 381: ...r power cable to connector J101 on the CMX controller board See Figure 73 8 Route the stacker power cable and the stacker logic cable in front of the CMX board and through the cutout beneath the card...

Page 382: ...on take care to avoid scratching painted surfaces or damaging the stacker 9 Loosen one turn DO NOT REMOVE the Torx T 10 screws securing the vertical rails to the stacker base Each rail is secured by t...

Page 383: ...cal rails inside and under the upper frame cross member then slowly swing the base of the stacker assembly into the cabinet See Figure 75a 12 Work the stacker base rearward and engage the upper bracke...

Page 384: ...384 Appendix J Installing The Power Stacker Legend 1 Upper Frame Cross Member 2 Elevator Assembly 3 Stacker Base 4 Vertical Rail Figure 75 Stacker Installation 1 2 3 4 a b c...

Page 385: ...s until it travels smoothly with no binding 18 Tighten the two 5 32 x 3 4 inch screws and washers securing the vertical rails to the upper frame cross member 19 Move the elevator assembly up and down...

Page 386: ...x 3 4 inch 2 3 Stacker Base 4 Screw 7 64 x 1 2 inch or Torx T 10 2 5 Washer 2 but no washers with Torx T 10 screws 6 Vertical Rail 7 Upper Frame Cross Member Figure 76 Stacker Fasteners 1 2 3 6 NOTE T...

Page 387: ...387 22 Install the paper fence See Figure 77 Legend 1 Paper Fence 2 Stacker Base Figure 77 Paper Fence 1 2...

Page 388: ...and power cable Route the cables outboard of the elevator assembly 24 Connect the stacker cables to the rear of the stacker control panel assembly as shown in Figure 78 Legend 1 Logic Cable P104 2 Pow...

Page 389: ...25 Position the stacker control panel as shown in Figure 79 and install the mounting screws Legend 1 Stacker Control Panel 2 Long Screw 3 Short Screw 2 Figure 79 Installing the Stacker Control Panel 3...

Page 390: ...the stacker mechanism as it moves up and down Route the stacker rail and frame cables so they move without snagging as the elevator assembly moves up and down Legend 1 Wire Saddle 2 places 2 Cutout B...

Page 391: ...do not over tighten the tie wraps or string Tighten the tie wraps or string just enough to hold the elevator up 2 Raise the elevator assembly to its highest position and secure it to the vertical rail...

Page 392: ...e 82 4 Firmly gripping the spring and drum remove the screw securing the spring to the vertical rail See Figure 82 Legend 1 Rail Screw 2 Washer 3 Constant Force Spring 4 Large Washer 5 Spacer 6 Drum 7...

Page 393: ...ng and drum See Figure 83 6 While holding the drum tightly continue to curl the spring until it is completely unwound from the drum See Figure 83 7 To install a new constant force spring reverse the s...

Page 394: ...ve the shoulder screw from the pulley at the bottom of the left vertical rail and remove the pulley See Figure 84 Go to step 6 4 If you are removing the right timing belt remove the two metric Allen s...

Page 395: ...2 Setscrew 3 Pulley Figure 85 Removing the Timing Belt Motor Pulley 6 Remove the shoulder screw washers and spacer that secures the constant force spring to the vertical rail See Figure 86 Legend 1 L...

Page 396: ...Replacing The Timing Belts 7 Remove two Allen screws from the belt clamp that secures the timing belt to the stacker frame See Figure 87 Legend 1 Allen Screw 2 Belt Clamp Figure 87 Removing the Belt...

Page 397: ...it around the vertical rail and constant force spring See Figure 88 Legend 1 Timing Belt Figure 88 Removing the Timing Belt 9 To install a timing belt reverse the steps of this procedure NOTE Left ti...

Page 398: ...B consists of exploded drawings of the power stacker assembly and subassemblies Parts are listed next to each drawing Only replaceable parts are assigned part numbers If a part or assembly is damaged...

Page 399: ...399 Figure 89 Stacker Assembly 14 30 35 10 12 20 9 37 12 5 8 8 13 15 25 7 11 20 9 12 10 6 7 38 38 38 See page 401 40...

Page 400: ...unt chains outboard of shafts 30 Ref Nylon Plug 35 24H8973 Cable 36 24H9004 Stacker Hardware Kit Kit not illustrated 37 Ref Screw Shoulder 8 32 Part of item 36 38 01P4699 Power Stacker Limit Switch Ki...

Page 401: ...0 Stacker Detail Motors Rollers and Paddles 47 48 40 46 45 50 46 45 49 51 15 15 53 15 45 46 45 46 50 55 60 55 50 65 52 53 54 54 52 65 From page 399 See page 405 See page 403 See page 407 See page 407...

Page 402: ...Part of item 36 46 Ref Cap Nut Part of item 36 47 24H9005 Shaft Drive Roller 48 24H9006 Spacer Drive Roller 49 Ref Bearing Flanged Part of item 36 50 Ref Bearing Part of item 36 51 24H9003 Collar Clam...

Page 403: ...403 Figure 91 Stacker Detail Rollers 75 80 85 90 85 80 From page 401...

Page 404: ...Description Notes 36 24H9004 Stacker Hardware Kit Kit not illustrated 75 24H8985 Compression Spring On left end of shaft on early models 80 Ref Friction Washer Part of item 36 85 Ref Flanged Bushing P...

Page 405: ...405 Figure 92 Stacker Detail Motor Bracket 95 95 96 96 100 Connector Flat Side Flag Key From page 401...

Page 406: ...x J Illustrated Parts Breakdown Item No Part No Description Notes 36 24H9004 Stacker Hardware Kit Kit not illustrated 95 Ref Clip On Bearing Part of item 36 96 24H8999 Holder LED Round 100 24H8989 LED...

Page 407: ...407 Figure 93 Stacker Detail Elevator Bracket 95 97 Connector Flag Key 95 Nib 105 From page 401...

Page 408: ...ustrated Parts Breakdown Item No Part No Description Notes 36 24H9004 Stacker Hardware Kit Kit not illustrated 95 Ref Clip On Bearing Part of item 36 97 24H9000 Holder LED Flat 105 24H8990 Photodarlin...

Page 409: ...409 Figure 94 Stacker Detail Paper Motion Detector P5STK01Z T5stk01x 105 Connector Flag Key Nib 105 Rotated 180 Degrees 97 110 97 107 107 116 115 107 108 106 107 From page 401...

Page 410: ...Holder LED Flat 105 24H8990 Photodarlington NPN Rectifier 106 Ref Retaining Ring External 0 093 inch Part of item 115 107 Ref Screw Panhead Type B 2 x 3 16 Part of item 36 108 Ref Shaft Paper Detector...

Page 411: ...T 81 026 HEX DUMP MODE 72 027 COMMUNICATIONS CHECK CALL SYSTEM OPERATOR 72 028 COMMUNICATIONS CHECK CALL SYSTEM OPERATOR 72 029 8344 DIAGNOSTIC TEST FAILED 72 031 END OF FORMS TIMEOUT LOAD FORMS 73 03...

Page 412: ...7 128 PAPER FEED INVALID COMMAND SEE USER S GUIDE 97 129 PAPER FEED INVALID PARAMETER SEE USER S GUIDE 97 130 PAPER FEED PARTLY ENERGIZED SEE USER S GUIDE 97 131 PAPER FEED INTERRUPT SEE USER S GUIDE...

Page 413: ...0 power supply 192 Circuit breaker replacement 193 Cleaning the printer 29 CLEARING PROGRAM FROM FLASH 100 178 180 CMX controller board See Controller board 45 Coax twinax expansion board replacement...

Page 414: ...OGRAM NOT VALID 101 179 SECURITY PAL NOT DETECTED 101 179 SHORT AT ADDRESS XXXX 101 179 WRITING TO FLASH 178 180 Error log clear 135 print 132 Error messages 61 Error messages list of 62 ERROR OCCURRE...

Page 415: ...ement 238 I IBM Coax twinax expansion board replacement 215 Illustrations replacement procedures 249 Indicators 10 100Base T 54 Information menu printer 143 Inspection safety guide 341 Installation 27...

Page 416: ...104 P61 ERROR FLASH NOT DETECTED 104 P62 ERROR DC PROGRAM NOT VALID 104 P63 ERROR PROGRAM NOT COMPATIBLE 105 P64 ERROR CHECKSUM WRONG 105 P65 ERROR PROGRAM NEEDS MORE FLASH 105 P66 ERROR PROGRAM NEED...

Page 417: ...er engineer CE 134 operator print 132 specifications 327 troubleshooting 59 Printer information menu 11 inch pages 143 installed memory 143 poweron time 143 print strokes 143 printing time 143 Printin...

Page 418: ...ide assembly L R replacement 237 guide assembly alignment 166 hub replacement 238 mask replacement 200 specifications 327 RIBBON OUT OF INK CHANGE RIBBON 107 Run Mode 55 S Safety inspection guide 341...

Page 419: ...sages 62 not from messages 110 T TABLE MISMATCH DOWNLOAD AGAIN 107 180 Temperature coil adjustment 181 Tension adjustment paper feed timing belt 154 platen open belt 156 Terminating resistors location...

Page 420: ...420...

Page 421: ...Preliminary 1...

Page 422: ...Copyright IBM Corp 1995 2000 S246 0117 08 164636 001B 07S246011708 01P4612 0401P4612...

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