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IBM 6400 Series, Maintenance Manual

The Avaya 6400 Series Quick Reference Manual is a comprehensive guide designed to help users navigate through the features and functionalities of the Avaya 6400 Series products. This user-friendly manual is available for free download from our website, making it easily accessible to all users.

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192

Replacement Procedures and Illustrated Parts List

Section I: Replacement Procedures 

Preparing the Printer for Maintenance

194

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Belt, Paper Feed Timing

195

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Belt, Platen Open

197

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Cable Connectors and Connector Shells

198

. . . . . . . . . . . . . . . . . . . . . . . . 

Circuit Board: Controller

200

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Circuit Board: Power Supply

203

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Circuit Breaker

204

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Coax/Twinax Multi-Platform Interface

205

. . . . . . . . . . . . . . . . . . . . . . . . . . . 

Cover Assembly, Hammer Bank / Ribbon Mask

206

. . . . . . . . . . . . . . . . . . 

Cover Assembly, Shuttle

209

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Cover Assembly, Top, Pedestal Model

210

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Doors, Cabinet, Reversal

211

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Ethernet Interface Assemblies

212

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Fan Assembly, Cabinet Exhaust

215

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Fan Assembly, Card Cage

216

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Fan Assembly, Hammer Bank

217

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Hammer Spring Assembly

218

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

IBM Coax/Twinax Expansion Board

222

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Magnetic Pick-up (MPU) Assembly

223

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Memory Modules and Security PAL

224

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Motor Assembly, Paper Feed

227

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Motor Assembly, Platen Open

229

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Motor Assembly, Ribbon Drive

231

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Network Print Server

232

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Operator Panel Assembly, Cabinet Model

233

. . . . . . . . . . . . . . . . . . . . . . . 

Operator Panel Assembly, Pedestal Model

234

. . . . . . . . . . . . . . . . . . . . . . 

Paper Guide Assembly

235

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Paper Ironer

236

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Summary of Contents for 6400 Series

Page 1: ...6400 Line Matrix Printers Cabinet and Pedestal Models Form Number S246 0117 06 Copyright IBM Corp 1995 1998...

Page 2: ......

Page 3: ...S246 0117 06...

Page 4: ...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 p...

Page 5: ...Notes and Notices 16 Printing Conventions in This Manual 18 Related Documents 18 Controls and Indicators 20 Electrical Controls and Indicators 20 Mechanical Controls and Indicators 24 Tools Test Equi...

Page 6: ...roubleshooting Introduction 55 Troubleshooting Aids 55 Start of Call 56 Troubleshooting Display Messages 57 Message List 58 Troubleshooting Other Symptoms 66 General Symptom List 67 Troubleshooting Pr...

Page 7: ...er Phasing 179 Loading Flash Memory 181 Coil Temperature Adjustment 188 Set Shuttle Speed 189 7 Replacement Procedures and Illustrated Parts List Organization of This Chapter 191 Section I Replacement...

Page 8: ...per Ironer 236 Platen 237 Resistors Terminating 242 Ribbon Guide Assembly L R 244 Ribbon Hub 245 Security Module 224 Shaft Splined 246 Shaft Support 248 Shuttle Frame Assembly 249 Spring Assembly Gas...

Page 9: ...Figure 50 Motors Card Cage Fan and Paper Detector Switch 285 Figure 51 Circuit Breaker 287 Figure 52 IBM Coax Twinax Expansion Board 289 Figure 53 PrintNet Ethernet Interface Assemblies 291 Appendices...

Page 10: ...th other products except those expressly designated by IBM is the user s responsibility Any performance data contained in this document was obtained in a controlled environment based on the use of spe...

Page 11: ...g terms denoted by a double asterisk in this publication are trademarks of other companies Acrobat Adobe Systems Incorporated Adobe Adobe Systems Incorporated Code V Quality Micro Systems ECOS ECOS El...

Page 12: ...communication port teleport attachment connector or power cord during an electrical storm 5 Power off the printer and disconnect the power cord before connecting or disconnecting communication port te...

Page 13: ...ction at the control panel or by sending printer control codes in the data stream from the host computer This is also an excellent graphics printer with optional features that simplify the creation of...

Page 14: ...destal 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 Cabinet 49 Hammers 25 MHz 6400 09P 900 lpm Pedestal 49 Hammers 25 MHz 6...

Page 15: ...z clock speed on the Data Controller unit How to Identify the Printer The model number of the printer indicates printer family speed and type of enclosure See Figure 1 6400 04P IBM 6400 Printer Family...

Page 16: ...ly 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 th...

Page 17: ...e numbered to help you find the translated versions in the IBM 6400 Line Matrix Printer Safety Notices booklet CAUTION The word Caution indicates the presence of a hazard that has the potential of cau...

Page 18: ...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 Setup Guide IBM 6400 Line Matrix Prin...

Page 19: ...t is printed IBM 6400 IGP User s Manual Form No S544 5639 Provides information used with the optional IGP Printronix emulation enhancement feature The IGP Printronix emulation allows the user to creat...

Page 20: ...orm 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 current pr...

Page 21: ...el Processing Start Stop Form Feed Set Top Of Form Line Feed Enter Return Scroll Menu View Attention Scroll Micro Micro Printer Con figuration Eject Restore Power Switch Off On LCD Figure 2 Electrical...

Page 22: ...F 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 positio...

Page 23: ...On 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 figuration Eject Restore LCD Figure 3 Electrical...

Page 24: ...to set side margin and position paper horizontally Allows fine positioning of left print margin Moves paper and tractors left or right Used to set top of form or first line to be printed Rotate to mo...

Page 25: ...zontal Adjustment Knob Left Tractor Paper Scale Paper Supports Right Tractor Tractor Lock Vertical Position Knob Ribbon Loading Path Diagrams Forms Thickness Pointer Forms Thickness Lever and Scale Fi...

Page 26: ...ng 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 Extraction Tool 73G552...

Page 27: ...ion Installation and Operation Guide Form No S246 0149 Installation configuration and troubleshooting of the Network Print Server are covered in the following documents IBM Network Print Server Ethern...

Page 28: ...28 Installation...

Page 29: ...tee that the user will clean the printer regularly however so you should clean the printer whenever you are called to service it DANGER 2 Switch off printer power and unplug the printer power cord bef...

Page 30: ...the power source 3 Open the printer cover 4 Remove paper from the printer 5 Remove the ribbon 6 Using a soft bristled non metallic brush wipe paper dust and ribbon lint off the tractors shuttle cover...

Page 31: ...tle Frame Assembly 1 Remove the shuttle cover assembly page 209 2 Remove the shuttle frame assembly page 249 3 Remove the paper ironer page 236 CAUTION 2 Over time the upper edge of the paper ironer c...

Page 32: ...hip hammer tips 8 Using a stiff non metallic brush such as a toothbrush gently brush the hammer tips to remove lint and ink accumulations See Figure 6 Vacuum up any residue Hammer Tip NOTE 6400 004 04...

Page 33: ...fan assembly and surrounding areas to remove paper particles dust and lint 3 Cabinet Models Install the paper guide assembly page 235 Pedestal Model Install the top cover assembly page 210 4 Close the...

Page 34: ...34 Preventive Maintenance...

Page 35: ...matrix See Figure 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 do...

Page 36: ...ample 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 9 A...

Page 37: ...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 illustrated in this diagram Hammer Not Released No Do...

Page 38: ...ogic and the printing mechanism The printing mechanism consists of the shuttle frame assembly the ribbon transport system and the paper transport system Shuttle Frame Assembly The central element of t...

Page 39: ...rods on a crankshaft See Figure 11 The small end of one connecting rod attaches to the hammer bank the small end of the other connecting rod attaches to a counterweight frame surrounding the hammer b...

Page 40: ...nt pulse energizes the coils The polarity of the resulting magnetic field opposes the field of the permanent magnet canceling its effect and releasing the hammer The hammer springs forward strikes the...

Page 41: ...configuration is designed for continuous fan folded paper three to 17 inches wide and one to six sheets thick For reverse paper feeding the platen open motor opens and closes the platen via a toothed...

Page 42: ...and prolong ribbon life 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...

Page 43: ...t Paper Feed Motor Platen Open Switch Right Ribbon Guide Right Ribbon Motor Platen Motor Paper Motion Detector Paper Out Detector Left Ribbon Motor Card Cage Fan Left Ribbon Guide Hammer Bank Fan Shut...

Page 44: ...nformation 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 indicat...

Page 45: ...tional 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...

Page 46: ...ion Expansion Port RS 232 422 IEEE 1284 Parallel Fault Sensors Paper Feed Ribbon Shuttle Platen Hammer Drive TTL Diagnostic Port Control Panel RS 232 Diagnostic Port 25 or 40 MHz Figure 17 CMX Control...

Page 47: ...r is backward compatible with any 6400 Series printer but must be used in 6400 050 P50 010 P10 and 015 printers Although this chapter refers to the DC microprocessor as simply the 030 remember that tw...

Page 48: ...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 ad...

Page 49: ...serial host All the circuitry required for these host types is provided on the CMX board except for the drivers themselves ESD protection and terminations Host I O Drivers and Termination Beyond the...

Page 50: ...d for address decoding Power Reduction The 166 chip has two power reduction modes idle and Energy Star Idle mode is not used In Energy Star mode 48V and all motors are de energized but the 166 operate...

Page 51: ...the controller board and the hammer bank Common circuits are located on the controller board while hammer specific circuitry is contained on the hammer bank The EC uses the MECA ASIC on the controlle...

Page 52: ...d on the controller board and may be pulled down or disconnected by software or internal cable interlocks The 5 V output will remain stable for reporting and latching the fault condition The return fo...

Page 53: ...ics 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...

Page 54: ...54 Principles of Operation...

Page 55: ...oting 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 pr...

Page 56: ...me on after 10 seconds Did the fans come on after 10 seconds NO YES Press Stop Press Print Configuration Press Start Does machine configuration print YES The Operator Panel is not functioning see Tabl...

Page 57: ...ce 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 sto...

Page 58: ...s require that the printer be powered off and the condition corrected before powering the printer back on Clearing Error Messages Refer to the Message List below which lists the display messages numer...

Page 59: ...ALID COMMAND Page 75 017 STACKER JAM CHECK STACKER Page 76 018 STACKER FULL CHECK STACKER Page 76 019 STACKER FAULT CHECK STACKER Page 77 021 RECEIVE BUFFER OVERRUN VERIFY CONFIGURATION Page 78 022 UN...

Page 60: ...046 EC STOPPED AT STATE state Page 82 057 CLOSE PLATEN Page 83 058 SHUTTLE JAM SEE USER S GUIDE Page 84 059 CANCEL PRINT ACTIVE Page 85 060 PRINTER HOT Page 85 062 EXHAUST FAN FAULT Page 86 065 HAMMER...

Page 61: ...Page 96 111 STACK UNDERFLOW SEE USER S GUIDE Page 96 112 UNDEFINED OPCODE SEE USER S GUIDE Page 96 113 PROTECTED INSTRUCTION SEE USER S GUIDE Page 96 114 ILLEGAL OPERAND ACCESS SEE USER S GUIDE Page 9...

Page 62: ...GUIDE Page 101 128 PAPER FEED INVALID COMMAND SEE USER S GUIDE Page 101 129 PAPER FEED INVALID PARAMETER SEE USER S GUIDE Page 102 130 PAPER FEED PARTLY ENERGIZED SEE USER S GUIDE Page 102 131 PAPER...

Page 63: ...LASH Page 105 DRIVER CIRCUIT BAD Page 105 ENERGY SAVER MODE ACTIVE Page 105 ERROR DRAM NOT DETECTED Page 106 ERROR DRAM AT ADDRESS hex Page 106 ERROR FLASH DID NOT PROGRAM Page 106 ERROR PROGRAM NOT V...

Page 64: ...H NOT DETECTED Page 110 P62 ERROR DC PROGRAM NOT VALID Page 110 P63 ERROR PROGRAM NOT COMPATIBLE Page 110 P64 ERROR CHECKSUM WRONG hex Page 110 P65 ERROR PROGRAM NEEDS MORE FLASH Page 111 P66 ERROR PR...

Page 65: ...INK CHANGE RIBBON Page 112 SENDING PROGRAM TO EC PROCESSOR Page 113 SERVICE first service test Page 113 SOFTWARE ERROR Cycle power Page 113 TABLE MISMATCH DOWNLOAD AGAIN Page 113 TESTING HARDWARE PLE...

Page 66: ...to troubleshoot malfunctions that are not indicated by display messages These techniques are summarized below 1 Ask the operator to describe the problem 2 Verify the fault by running a diagnostic prin...

Page 67: ...aced earlier that did not solve the problem 8 Stop troubleshooting and return the printer to normal operation when the reported symptoms disappear Table 3 General Symptom List Symptom Troubleshooting...

Page 68: ...3 Print Quality Characters or dots are missing smeared too light or too dark Page 114 Horizontal misalignment of characters Dots or characters move left or right from dot row to dot row or line to lin...

Page 69: ...tom Troubleshooting Procedure Reverse paper feed platen does not open Page 124 TOF is lost repeatedly Page 131 Ribbon Ribbon folding or feed problems Page 125 Shuttle Shuttle does not move Page 126 Sh...

Page 70: ...the paper detector switch assembly is securely mounted in its bracket and the sensors are clean Make sure the sensors are securely snapped into the bracket the mounting screws hold the paper detector...

Page 71: ...n mask for bends or deformation that block the paper path or prevent paper from exiting the pedestal top cover Replace a damaged hammer bank cover assembly 7 Check the condition and tension of the pla...

Page 72: ...to print position 004 VIEW FORMS PRESS VIEW KEY 1 Non error status message Press View key to return paper to print position 006 HOST SYSTEM REQUEST ATTENTION 2 Host attention message the host computer...

Page 73: ...011 SCS COMMAND ERROR 1 The printer received an undefined control character hex 40 through the coax twinax interface The printer clears the error 2 Run the print job that generated the error message I...

Page 74: ...rint job to the printer If the message appears go to Communications Failures page 133 014 INVALID ACTIVATE 1 The printer detects a twinax protocol communications error and reports the error Power off...

Page 75: ...e is gone the host has reestablished communication with the printer If all other twinax devices work properly and the message still appears replace the coax twinax expansion board Record the message a...

Page 76: ...lleys are not slipping e the extension springs are attached and undamaged not bent or stretched f the drive rollers are not damaged Tighten pulley setscrews and or replace damaged components as necess...

Page 77: ...and without obstruction d the timing belts are undamaged and the belt pulleys are not slipping e the extension springs are attached and undamaged not bent or stretched f the drive rollers are not dam...

Page 78: ...R ADDRESS 1 Poll timeout on the twinax interface indicating the unit address is not recognized by the printer Have the system administrator make sure the printer address is correct 024 SERIAL LINE PAR...

Page 79: ...TOR 1 Poll timeout error The printer was not polled for one minute over a coax interface Power off the printer Disconnect the AC power cord from the printer Check data cable connection and host system...

Page 80: ...rd 032 FORMS JAMMED TIMEOUT CLEAR JAM AND RELOAD FORMS 1 On a coax interface a timeout message is sent to the host if paper motion has not occurred for 10 minutes after Stop was pressed to clear a pap...

Page 81: ...the paper feed belt Adjust the paper feed belt Replace the belt if it is damaged 11 Check the platen gap Adjust the platen gap 12 Clean the paper motion detector with a cotton swab and alcohol At the...

Page 82: ...s download the emulation software again 2 Cycle power Run the print job again If the message appears replace the flash memory 3 Cycle power Run the print job again If the message appears replace the C...

Page 83: ...tch cable from P107 PLO to the switch Replace the platen interlock switch assembly if it fails the continuity test Refer to Appendix A Switch Assembly Platen Interlock 3 Check that the platen interloc...

Page 84: ...ssembly Replace a damaged or deformed hammer bank cover assembly 4 Run a print test If the message appears power off the printer 5 Remove the shuttle cover Remove the paper guide assembly or the pedes...

Page 85: ...be stored under the printer Then check the operating environment A severe environment is one with an ambient temperature at or above above 40 Celsius 104 Fahrenheit or is dirty enough to create blocka...

Page 86: ...cable connector 4 Power off the printer Remove the paper guide assembly Disconnect connector P107 from the CMX controller board Test connector P107 EHF for shorts or opens Refer to the Main Wire Harn...

Page 87: ...been pressed No action required 080 POWER SUPPLY HOT NOTE The printer has sensor circuits that sample the operating temperature of key components of the power supply When higher than normal temperatur...

Page 88: ...irways for obstructions Look underneath cabinet models for items blocking the cabinet exhaust vents Remove any obstructions from vents and airways 6 Install paper guide assembly or pedestal top cover...

Page 89: ...ove obstructions 5 Power on the printer If the message appears replace the CMX controller board Record the message and return it with the defective board 084 POWER SUPPLY 48V FAILED 1 Power off the pr...

Page 90: ...board Record the message and return it with defective CMX board 4 Power on the printer Run the print job again If the message appears replace the power supply board 086 CONTROLLER 15V 1 Controller Vol...

Page 91: ...nterlock switch is not loose Tighten the screws securing the platen interlock switch 4 Check the condition and tension of the platen open belt Adjust the platen open belt Replace the belt if it is dam...

Page 92: ...to move while printing Check the forms thickness lever if it is set too tightly it can inhibit ribbon movement Set the forms thickness lever to match the thickness of the paper being used but not too...

Page 93: ...cover Disconnect P107 on the CMX controller board and check the CVO switch by testing for continuity across pins 18 and 20 Refer to the Main Wire Test Tables page 297 Replace the cover open switch as...

Page 94: ...ammer bank or in the hammer bank power cable are shorted to ground Cycle power If the message appears press Stop If the message does not clear replace the hammer bank logic cable and the hammer bank p...

Page 95: ...the printer is located in such an environment relocate it to a cooler cleaner area or reduce the size and duration of the print jobs 1 One or more hammer coils are overheating Inspect the printer env...

Page 96: ...again If the message appears download the emulation software again 2 Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it with...

Page 97: ...job again If the message appears download the emulation software again 2 Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it wi...

Page 98: ...b again If the message appears download the emulation software again 2 Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it with...

Page 99: ...huttle frame assembly 5 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 123 PAPER BUSY TO...

Page 100: ...DERFLOW SEE USER S GUIDE 1 Paper First In First Out Underflow 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...

Page 101: ...essage appears download the emulation software again 2 Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX b...

Page 102: ...int job again If the message appears download the emulation software again 2 Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return i...

Page 103: ...job again If the message appears download the emulation software again 2 Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it wi...

Page 104: ...ars download the emulation software again 2 Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board 139 SH...

Page 105: ...fully loaded into printer RAM and the checksum matched The old program is now being deleted from flash memory No action required DRIVER CIRCUIT BAD 1 The hammer coil count test failed Cycle power If t...

Page 106: ...install DRAM 2 Power on the printer If the message appears replace the DRAM 3 Power on the printer If the message appears replace the CMX controller board Record the message and return it with the def...

Page 107: ...rinter problem The system administrator should correct applications data or configuration HAMMER BANK NOT INSTALLED 1 Self test routines do not detect hammer coils at printer start up Power off the pr...

Page 108: ...OADING PROGRAM FROM PORT XX 1 The new emulation program is loading into printer RAM XX indicates how much of the program has loaded No action required LOADING PROGRAM INTO FLASH 1 The printer has dele...

Page 109: ...Remove the paper guide assembly or pedestal top cover Check that the security PAL is correctly installed See Figure 34 page 226 Install correct PAL for the customer s emulations with the notched end...

Page 110: ...le diskette in a CBO controlled printer or vice versa Use the correct emulation software option s for this model printer If the printer is an IBM 6404 B01 the controller is a CBO board If the printer...

Page 111: ...emory replace the CMX controller board Record the message and return it with the defective board P68 ERROR EC PROGRAM NOT VALID 1 The printer cannot find the engine controller program or the validatio...

Page 112: ...message and return it with defective CMX board PLEASE WAIT RESET IN PROGRESS 1 Status message the printer finished loading the program into flash memory and is automatically resetting itself No actio...

Page 113: ...r 2 Disconnect the input data line from the host computer Power on the printer If the message appears download the emulation software again 3 Cycle power Run the print job again If the message appears...

Page 114: ...MX controller board Make sure the 60 pin expansion adapter is correctly seated in the CMX controller board connector J111 and the coax twinax expansion board 3 Power off the printer Make sure the flas...

Page 115: ...gs Check the shuttle frame assembly for broken hammer springs hammer tips or contaminations Replace any damaged hammer spring assemblies Replace the hammer bank cover assembly if it is deformed or dam...

Page 116: ...collar snug against the motor pulley and torque the 7 64 inch setscrew to 25 2 inch pounds 2 82 0 23 N m 3 Check the condition and tension of the paper feed timing belt Adjust the paper feed timing b...

Page 117: ...he message and return it with the defective board Downloads consistently fail NOTE Most download problems are detected by software during the procedure and communicated by LCD messages If downloads fa...

Page 118: ...H SIMMS See page 142 If the DESTINATION NOT DETECTED message appears the blank SIMM is not a type supported by the boot code on the original SIMM If SOURCE LARGER THAN DESTINATION appears the blank SI...

Page 119: ...wer outlet and check for AC power at the printer end of the cord If there is no power through the AC power cord replace it Plug the AC power cord into the printer and power outlet 3 Remove the paper g...

Page 120: ...on board check the adapter connection to the CMX controller board Make sure the 60 pin expansion adapter is correctly seated in the CMX controller board and the coax twinax expansion board 3 Power on...

Page 121: ...r paper feed path of any obstructions 3 Inspect the tractors and tractor door springs for damage or excessive wear If either tractor is damaged or excessively worn replace both tractor assemblies 4 Ch...

Page 122: ...code is loaded in the machine If the printer does not have the coax twinax expansion board go to step 6 Download CT emulation software 3 Power off the printer Check that the user has enough flash memo...

Page 123: ...r P106 See the cable assembly drawing in Appendix A page 326 e Power on the printer f At connector P106 check for 48 volts DC between pins 1 and 2 and 5 volts DC between pins 3 and 4 If the voltages a...

Page 124: ...bly 3 Power on the printer Run a self test If the self test does not run replace the CMX controller board Reverse paper feed platen does not open 1 Raise the forms thickness lever and check that the p...

Page 125: ...and check the ground leads for continuity Replace the AC power cord if it fails continuity test 4 Make sure the printer is plugged in to a grounded power outlet Power up the printer Run a print test...

Page 126: ...troller board 6 While shorting across each ribbon post with the ribbon metal strip or a screwdriver check for continuity in connector P106 LRP pins 10 and 12 and connector P107 RRP pins 14 and 16 Refe...

Page 127: ...d 9 Power up the printer Run a Shuttle Slow or Shuttle Fast test If the shuttle does not move replace the CMX controller board Shuttle is noisy 1 Check the bolts securing the mechanism base to the bas...

Page 128: ...h 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 paddles...

Page 129: ...the stacker control panel see Figure 61 page 380 Check cables for cuts breaks or damaged pins Check continuity of cables See Appendix A Replace any cable that is damaged or fails continuity test Reco...

Page 130: ...7 d Check the stacker rail cable and limit switches for continuity and shorts Check continuity of the switch when open and closed See the power stacker control panel PCBA pinout drawing on page 304 ST...

Page 131: ...pulley is being used it should have 25 teeth Hold the collar snug against the motor pulley and torque the 7 64 inch setscrew to 25 2 inch pounds 2 82 0 23 N m Replace the paper feed pulley if it does...

Page 132: ...the 7 64 inch setscrew to 25 2 inch pounds 2 82 0 23 N m 3 Check the condition and tension of the paper feed timing belt Adjust the paper feed timing belt Replace the belt if it is damaged 4 Check th...

Page 133: ...communications background experience and the cause of the problem is not readily apparent do the following 1 Print out the printer configuration 2 Obtain a copy of the Device Host Configuration if po...

Page 134: ...le defective Host Network configuration Printer logic Terminating Resistors serial Host Printer interface cable pinouts incompatible Host Printer Network configuration Set DTR and RTS both True Interf...

Page 135: ...omatically records certain unit check conditions in a buffer in NVRAM that stores up to 50 messages The most recent message is stored at the top of the list the oldest message at the bottom of the lis...

Page 136: ...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 Tra...

Page 137: ...Menu OPERATOR MENU PRINTER CONTROL First of the series of configuration menus 5 Press Scroll UNTIL OPERATOR MENU OPERATOR PRINT TESTS Advances to the Operator Printer Tests menu 6 Press Enter OPERATOR...

Page 138: ...rn In Test Plot Test Shuttle Only Shuttle Slow Shuttle Fast Hammer Phasing End of Forms Adjust NOTE Default value CLEAR ERROR LOG Enter key activates SERVICE PRINT PARTIAL LINE ENABLE DISABLE TOP EXIT...

Page 139: ...nt of dots in character printing The numerical units are relative they do not represent a physical measurement or value There is no correct value or range The factory prints the initial phase value on...

Page 140: ...ee page 189 Set Coil Temperature An automatic sequence in printer software that recalibrates hammer coil temperature This procedure applies only to 6400 014 and 6400 15 printers See page 188 Selecting...

Page 141: ...ATOR MENU UNLOCKED Press both keys at the same time You must unlock the Enter key to run a test 7 Press Enter Plot Test Running The test starts See Chapter 6 for special instructions in the use of the...

Page 142: ...e Boot Diagnostic Menu 1 Set the printer power switch to O off 2 Press and hold down the Eject Restore and Stop keys 3 While holding the Eject Restore and Stop keys set the printer power switch to 1 o...

Page 143: ...HDISK STATUS OF FILES 000 FLASHDISK STATUS USED 0002048 FLASHDISK STATUS DELETED 0000000 BOOT DIAGNOSTICS FILE UTILITIES B NOTE To exit this menu cycle power B Scroll key ENTER ENTER B ENTER B ENTER B...

Page 144: ...RS232 9600 WAITING DOWNLOAD PORT RS232 9600 ENTER SELECT DOWNLOAD PORT RS232 19 2K WAITING DOWNLOAD PORT RS232 19 2K ENTER SELECT DOWNLOAD PORT RS232 38 4K WAITING DOWNLOAD PORT RS232 38 4K ENTER SELE...

Page 145: ...r is using a parallel interface 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 To convert an ASCII chara...

Page 146: ...NT MODE ENABLE Moves down to Enable the alternate option 8 Press Enter HEX PRINT MODE ENABLE Asterisk indicates this choice is now active 9 Press Stop NOT READY Returns the printer to Not Ready mode 1...

Page 147: ...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 3A 73 59 3B 74 60 3C 75 61 3D 76 62...

Page 148: ...te continuously they do not reset when you power off the printer All of the printer statistics are set to zero at the factory after burn in testing Installed Memory Displays the amount of RAM installe...

Page 149: ...st of the series of configuration menus 5 Press Scroll UNTIL OPERATOR MENU PRINTER INFORMATION Advances to the Printer Information menu 6 Press Enter PRINTER INFORMATION INSTALLED MEMORY Advances to I...

Page 150: ...ate 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 the printer loads the power up configuration...

Page 151: ...connected If a bad line is detected a 4 1 1 XX blink code is sent to the LED on the CMX controller where XX is the data line plus 1 For example a bad data line 8 would blink as 4 1 1 9 Initialize VX A...

Page 152: ...e contiguous block of DRAM The size and location of each bank is then displayed on the debug terminal through the debug serial port Test DRAM DRAM is tested by writing a pseudo random number sequence...

Page 153: ...can be disabled on a pedestal model FAN DISABLED is printed out at the debug serial port of a pedestal model Check for Download Mode Boot code checks whether the Cancel and Start keys were pressed at...

Page 154: ...d boot code checks for the presence of NVRAM If NVRAM is not found boot code displays ERROR NVRAM FAILURE Test for Powerup File Boot code checks for a DC executable file called powerup sbr If found it...

Page 155: ...d DRAM Boot code checks whether the amount of DRAM required to run the DC program is larger than the amount of DRAM in the printer If so it displays the message ERROR PROGRAM NEEDS MORE DRAM Tell EC P...

Page 156: ...heral Interfaces console driver etc Start Main Task supervisor Verify and Initialize NVRAM statistics are cleared if NVRAM is not valid Initialize Libraries fault system emulation Load Front Panel Men...

Page 157: ...s Introduction The printer is a durable low maintenance machine but some components and systems require occasional adjustment Usually you will be referred to this chapter by a troubleshooting procedur...

Page 158: ...ing To prepare the printer for maintenance do the following steps before making an adjustment 1 Power off the printer 2 Unplug the printer power cord from the AC power source 3 Disconnect the host dat...

Page 159: ...data 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 160: ...e 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 mounting base of the motor Use th...

Page 161: ...Adjustment Procedures 1 Timing Belt Shield 2 Motor Mount Bolt 2 3 Paper Feed Drive Motor 4 Splined Shaft 5 Paper Feed Timing Belt 2 1 3 2 4 Direction of Force 5 Figure 21 Paper Feed Timing Belt Adjust...

Page 162: ...TENTION 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 Using a force gauge appl...

Page 163: ...163 Adjustment Procedures 1 Belt Cover 2 Motor Mount Screw 2 3 Platen Open Motor Shaft 2 3 2 1 Direction of Force Figure 22 Platen Open Belt Adjustment...

Page 164: ...ey 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 collar 3 and the motor face plat...

Page 165: ...165 Adjustment Procedures 1 Belt Shield 2 Cap Screw 3 Motor Pulley Collar 4 Motor Pulley 5 Splined Shaft Pulley 4 1 2 3 5 Figure 23 Paper Drive Motor Pulley Alignment...

Page 166: ...Print a full 136 column line by selecting and running one of the diagnostic self tests See Chapter 4 7 Check alignment of the scale to the print at column positions 1 and 136 8 If adjustment is neces...

Page 167: ...167 Adjustment Procedures 1 Shuttle Cover 2 Screw Button Head 5 64 inch hex 3 3 Paper Scale 2 2 1 2 3 Figure 24 Paper Scale Alignment...

Page 168: ...check the other side Adjustment sensitivity is approximately 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...

Page 169: ...g adjustment page 179 12 Return the printer to normal operation page 159 1 Forms Thickness Lever 2 Feeler Gauge 0 011 inch or 0 28 mm 3 Hammer Bank Cover Plate 4 Ribbon Mask 5 Set Screw 3 32 inch hex...

Page 170: ...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 16 inch set screw 2 to 9 2...

Page 171: ...171 Adjustment Procedures 1 Belt Cover 2 Set Screw 3 Platen Open Motor Pulley 4 Platen Shaft Pulley 2 3 4 1 Figure 26 Platen Open Motor Pulley Alignment...

Page 172: ...he 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 the retaining screws...

Page 173: ...73 Adjustment Procedures 1 Screw Skid 2 2 Ribbon 3 White Nylon Washer 4 Screw Retaining 2 2 4 1 Left Ribbon Guide Right Ribbon Guide 3 1 Early Models Later Models 2 4 3 Figure 27 Ribbon Guide Alignmen...

Page 174: ...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 175: ...e 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...

Page 176: ...176 Adjustment Procedures 4 in 4 in Cut out here Page Perforation Page Perforation Page Perforation Figure 29 Paper Preparation for Paper Out Adjustment Test...

Page 177: ...bar from the comb pattern just meets the perforation the end of forms adjustment distance is correct A bar exactly on perforation is ideal 1 or 2 dot rows off is OK 5 to 7 dot rows off is too much Un...

Page 178: ...up or down by the number of dots you counted in step 12 If the comb pattern stopped short of the perforation increase the number of dots If the comb pattern printed beyond the perforation decrease the...

Page 179: ...he motor housing Adjust the phasing to this value and recheck the horizontal alignment When alignment is acceptable write the new phasing value on the shuttle Phasing should be adjusted with the print...

Page 180: ...ay 14 Press Scroll or Scroll to increase or decrease the phasing index then press Enter to activate the value as it prints Continue to increase or decrease the phasing index until the pattern of Hs ap...

Page 181: ...r and disconnect the power cord before connecting or disconnecting communication port teleport or attachment cable connector 1 Make a printout of all saved configurations Refer to the Setup Guide Inst...

Page 182: ...the printer 9 Power on the personal computer 10 Insert the emulation or upgrade diskette into diskette drive A or B of the personal computer 11 Make the diskette drive the active drive by typing the...

Page 183: ...election appears on the display 19 At the DOS prompt on the computer type FILENAME EXE pb return where FILENAME EXE is the file you noted in step 12 This command expands the file and copies it as a bi...

Page 184: ...If the printer is supposed to have this feature reseat the Coax Twinax board If the printer is not supposed to have this feature install new emulation code without the Coax Twinax feature Message Expl...

Page 185: ...over at step 13 If the message occurs again replace the flash memory ERROR FLASH NOT DETECTED The printer could not find any flash memory Install flash memory before attempting to download this progr...

Page 186: ...ity PAL at location U54 on the CMX controller If the PAL is absent install the correct PAL If security PAL is present replace the CMX controller board ERROR SHORT AT ADDRESS XXXX Hardware failure in D...

Page 187: ...ly resetting itself None RESTORING BOOT CODE Normal download initialization message None SECURITY CODE VIOLATION The software running or being downloaded does not match the security PAL code Install t...

Page 188: ...NOT READY 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...

Page 189: ...roll or Scroll key until SERVICE SHUTTLE SPEED appears on the display 6 Press Enter SHUTTLE SPEED 475 or SHUTTLE SPEED 500 appears on the display The asterisk indicates which shuttle speed is currentl...

Page 190: ...190 Adjustment Procedures...

Page 191: ...o two sections Section I Replacement Procedures This section contains written procedures for removing and installing components that are replaceable at the field service level of maintenance The proce...

Page 192: ...Assembly Shuttle 209 Cover Assembly Top Pedestal Model 210 Doors Cabinet Reversal 211 Ethernet Interface Assemblies 212 Fan Assembly Cabinet Exhaust 215 Fan Assembly Card Cage 216 Fan Assembly Hammer...

Page 193: ...Ribbon Guide Assembly L R 244 Ribbon Hub 245 Security Module 224 Shaft Splined 246 Shaft Support 248 Shuttle Frame Assembly 249 Spring Assembly Gas 251 Spring Extension 252 Switch Assembly Cover Open...

Page 194: ...ttle frame assembly It is not field repairable Hammer spring assemblies are the only replaceable components of the shuttle frame assembly DANGER 3 Hazardous voltages are present in the printer with th...

Page 195: ...osen the four screws securing the paper guide and barrier shield Remove the paper guide and barrier shield See page 271 Figure 44 items 3 4 and 5 4 Remove the timing belt cover by squeezing the front...

Page 196: ...e motor near the mounting base of the motor Use the splined shaft to steady the gauge 4 Reduce tension to 12 pounds 53 4 N and torque the paper feed motor mount bolts to 18 2 inch pounds 2 03 0 23 N m...

Page 197: ...e platen 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...

Page 198: ...onnectors in a connector shell Four wire connectors are grouped across from four wire connectors in a connector shell 5 Disengage the lock tab s on the cable connector from the slots in the side of th...

Page 199: ...t Switch CCF Card Cage Fan LRP Left Ribbon Guide PLAT M Platen Open Motor LRIB M Left Ribbon Motor Pull the side outward just enough to release the connector lock tab from the slot in the connector sh...

Page 200: ...ee page 275 Figure 45 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 201: ...right until the serial cable connector J201 on the board lines up with the cutout in the card cage See page 275 Figure 45 3 Tighten the screw securing the controller shield near serial cable connector...

Page 202: ...10 Adjust the hammer phasing page 179 11 Adjust the end of forms distance page 175 12 Return the printer to normal operation page 159 13 Using the configuration printout you made as step 1 of the remo...

Page 203: ...nector P1 from the power supply board 4 Loosen three captive screws securing the power supply board to the rear wall of the card cage See 275 Figure 45 item 4 5 Carefully disengage the power supply bo...

Page 204: ...the spring clips and remove the circuit breaker from the printer Installation 1 Press the circuit breaker into the cutout until the spring clips snap into place Cabinet Model See Figure 51 page 287 Pe...

Page 205: ...moval ATTENTION To 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 co...

Page 206: ...nk magnets See Figure 31 page 208 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...

Page 207: ...r models a Position the hammer bank cover on the allignment 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...

Page 208: ...er Bank Cover Assembly Early Models Later Models Hammer Bank Cover Screw 12 Screw 6 Ribbon Mask Clamp Plate 3 Hammer Bank Cover Thick Plate Ribbon Mask Thin Plate Hammer Bank Cover Torque Sequence 1 2...

Page 209: ...he edges of the shuttle cover assembly 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...

Page 210: ...bracket See Figure 42 page 267 items 3 and 4 4 Loosen the two captive 2 Phillips screws in the lower front corners of the top cover See Figure 42 page 267 item 14 5 Loosen but do not remove the two 2...

Page 211: ...rear 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...

Page 212: ...ls Remove the paper path page 235 Pedestal Models Remove the top cover assembly page 210 3 Disconnect Centronics cable connector P112 from connector J112 on the CMX controller board See Figure 53 page...

Page 213: ...Test OFF ON ON Network Interface Test OFF OFF ON PRN1 Test FLASH OFF FLASH Run Mode FLASH ON FLASH Auto Reset Mode FLASH FLASH OFF Firmware Panic ON FLASH ON Hardware Exception The Ethernet Interface...

Page 214: ...previously configured IP address Before reconfiguring the unit DIP switch 1 must be set back to the OFF up position otherwise it will lose its configuration through another power on off cycle DIP Swit...

Page 215: ...Remove 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...

Page 216: ...Model Remove the two fan mounting screws from the bottom of the fan See Figure 50 page 285 item 2 Pedestal Model Remove the four fan mounting screws and nut See See Figure 44a page 273 items 1 throug...

Page 217: ...etween the base casting and the base pan See Figure 50 page 285 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 218: ...ere is visible damage or broken parts can be seen in the assembly 5 Remove the mounting screws from the old hammer spring assembly See Figure 32 page 219 6 Handling the hammer spring assembly by the m...

Page 219: ...mmer Spring Assembly 1 Discard old screws NOTE The hammer spring assemblies shown below are for 6400 004 04P 005 05P printers The number of hammer springs and mounting screws varies among printer mode...

Page 220: ...rews from the 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 t...

Page 221: ...pounds 1 58 N m NOTE The hammer spring assemblies shown above are for 6400 004 04P 005 05P printers The number of hammer springs and mounting screws varies among printer models but installation proced...

Page 222: ...e 210 3 Loosen 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 t...

Page 223: ...st 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 flyw...

Page 224: ...onents wear a properly 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...

Page 225: ...odule 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 34 page 226 b Press the SIMM into the socket with the...

Page 226: ...ery that can explode if it is replaced incorrectly NVRAM is replaced only at the factory Security PAL Vendor P N 154143 002 154143 001 154143 002 154143 001 154143 002 154143 001 Installed Notch 80 pi...

Page 227: ...e plastic tabs from the slots in the side plate page 269 Figure 43 5 Loosen the paper feed motor mount screws page 285 Figure 50 6 Loosen the shaft collar setscrew and remove the paper feed motor pull...

Page 228: ...Hold 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...

Page 229: ...screws page 285 Figure 50 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...

Page 230: ...ble routing diagram on page 306 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 of...

Page 231: ...Lift and rotate the ribbon drive motor until the motor cable is aligned with the slot on the base casting 6 Disconnect the ribbon drive motor cable connector 7 Cabinet models remove the heat boot fro...

Page 232: ...procedures Removal ATTENTION To prevent electrostatic damage to electronic components wear a properly grounded static wrist strap when handling circuit boards the shuttle frame assembly and any other...

Page 233: ...cutouts 5 Lift the operator 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 41...

Page 234: ...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 Installation 1 Tilt the operator panel mounting plate toward the...

Page 235: ...e assembly to the left 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...

Page 236: ...h the ends of the paper ironer toward the rear of the printer disengage the tabs then lift it up and out page 283 Figure 49 Installation NOTE The black tape on the paper ironer faces the paper detecto...

Page 237: ...remove the spring link bushing and spring See Figure 49 page 283 items 16 17 and 18 8 Remove the forms thickness lever by loosening the 7 64 inch clamp screw and pulling the lever off the platen shaft...

Page 238: ...he mechanism base stay in place Installation IMPORTANT The dowel pins protruding from the ends of the platen are the platen shafts and are not equal in length The platen must be installed with the lon...

Page 239: ...acket onto the longer platen shaft with the screw at the top of the bracket 7 Place the other bracket onto the left side mechanism base platen seat so that the mechanism base platen seat is between th...

Page 240: ...and 18 13 Apply bearing lubricant to the two platen shafts on both sides between the ends of the platen and the platen adjustment brackets 14 Install the paper ironer bracket See Figure 35 a With the...

Page 241: ...w does not hit the left ribbon guide 18 Install but do not adjust the platen open belt and platen open motor pulley page 197 19 Install the paper ironer with the black tape towards the rear of the pri...

Page 242: ...P2 Pull Down Factory Default 470 Ohm 1K Ohm Alternate 1 220 Ohm 330 Ohm Alternate 2 1K Ohm None Removal ATTENTION To prevent electrostatic damage to electronic components wear a properly grounded stat...

Page 243: ...rts List 3 Return the printer to normal operation page 159 RP1 RP2 Default 470 ohm Alt 1 220 ohm Alt 2 1K ohm Default 1K ohm Alt 1 330 ohm Alt 2 none Resistor Kit 14H5525 CMX Controller Board Figure 3...

Page 244: ...ng it from the cable restraints See cable routing diagram on page 306 7 For the left ribbon guide disconnect connector shell P106 from the controller board For the right ribbon cable disconnect connec...

Page 245: ...n 3 Loosen the Torx T 10 screw in the ribbon spool hub page 285 Figure 50 4 Remove the hub from the shaft of the ribbon drive motor Installation 1 Install the ribbon spool hub over the motor shaft pag...

Page 246: ...ground clip page 281 Figure 48 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 sha...

Page 247: ...o the 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 spl...

Page 248: ...onsisting of the support 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 ass...

Page 249: ...e guide shaft Do not remove the clamps 7 Loosen the center 5 32 inch socket head screw enough to release the shuttle frame assembly from the base casting 8 Unlock and slide the tractors outward as far...

Page 250: ...center captive 5 32 inch socket head screw to 20 2 inch pounds 2 26 0 23 N m 7 Connect the hammer drive and hammer logic cable connectors to the terminator board on the shuttle frame assembly 8 Connec...

Page 251: ...retaining clips page 265 Figure 41 5 Remove the gas spring assembly from the ball studs Installation ATTENTION The gas spring assembly must be installed with gas cylinder in the up position 1 Position...

Page 252: ...ver assembly page 209 4 Unhook the extension spring from the spring lugs on the hammer bank and shuttle frame See Figure 47 page 279 Installation 1 Put a dab of IBM 20 bearing lubricant on both spring...

Page 253: ...motor wires to the connector shell and remove the cable connector from the connector shell page 198 Installation 1 Remove the protective covering from the adhesive backing on the cover open switch as...

Page 254: ...9 Pedestal Model Remove the paper guide barrier shield and four screws See page 271 Figure 44 items 3 4 and 5 4 Remove the two screws securing the paper detector switch assembly See Figure 50 page 28...

Page 255: ...the restraints under the base casting See cable routing diagram on page 306 4 Connect switch cables PMD and POD to the connector P106 page 198 then connect P106 to controller board connector J106 5 C...

Page 256: ...e platen interlock switch cable back to the controller board Remove tie wraps as necessary to free the cable See cable routing diagram on page 306 5 Disconnect connector shell P107 P7 from the control...

Page 257: ...49 page 283 3 Route the switch cable through the cutout in the right side plate and to the controller board See cable routing diagram on page 306 4 Connect the platen interlock switch cable to the con...

Page 258: ...nter for maintenance page 194 2 Remove the splined shaft page 246 3 Remove the support shaft page 248 4 Remove the tractors Installation 1 Using the replacement tractors install the support shaft page...

Page 259: ...69 Figure 44 Inside Covers and Card Cage Pedestal Model 271 Figure 44a Card Cage Detail Pedestal Model 273 Figure 45 Print Mechanism and Circuit Boards Early Models 275 Figure 46 Print Mechanism and C...

Page 260: ...ar Door Kit Includes mounting hardware Not visible in Figure 39 5 24H8959 Front Door Kit Includes mounting hardware 6 57G1485 Caster with Brake Two at front 7 57G1486 Caster without Brake Two at rear...

Page 261: ...Replacement Procedures and Illustrated Parts List 2 1 4 5 9 6 7 8 3 NOTE Item 10 Shipping Container Kit not shown Item 11 Hardware Kit not shown 12 13 Figure 39 Top Cover Doors and Casters Cabinet Mo...

Page 262: ...Order No 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...

Page 263: ...263 Replacement Procedures and Illustrated Parts List 7 5 6 8 1 4 3 2 Figure 40 Paper Stacker and Chains...

Page 264: ...Operator 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 L...

Page 265: ...265 Replacement Procedures and Illustrated Parts List 5 1 6 7 8 9 6 6 2 4 3 Figure 41 Control Panel and Cabinet Details...

Page 266: ...63H5125 Bracket Control Panel Models 04P 05P 08P 09P 5 63H5121 Hinge Lid Kit Models 04P 05P 08P 09P 6 14H5300 Cable Assy Control Panel 7 63H5119 Lid Pedestal Model Models 04P 05P 08P 09P 8 Ref Screw 2...

Page 267: ...7 Replacement Procedures and Illustrated Parts List 1 9 8 13 12 14 7 6 11 10 2 5 4 3 NOTE Item 16 Lid Accessory Kit not shown Item 17 Pedestal Shipping Container not shown 15 Figure 42 Pedestal Detail...

Page 268: ...6 32x 25 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...

Page 269: ...269 Replacement Procedures and Illustrated Parts List 1 7 8 2 3 5 6 4 9 10 3 11 Figure 43 Inside Covers Cabinet Model...

Page 270: ...06 3 Ref 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 up...

Page 271: ...271 Replacement Procedures and Illustrated Parts List See Figure 44a page 273 10 9 8 2 3 3 4 5 6 7 1 Figure 44 Inside Covers and Card Cage Pedestal Model...

Page 272: ...Item No 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...

Page 273: ...rom Figure 44 page 271 Rotated 180 degrees 3 2 4 5 6 1 To IEC 320 AC Power Input Connector J301 Black Wire To IEC 320 AC Power Input Connector J301 White Wire To Connector P1 Black Wire To Connector P...

Page 274: ...odels 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 V5 0 Controller Board CMX V5 5 25 MHz...

Page 275: ...2 Places Exploded to show assembly Do not remove holddown clamps and screws 18 1 2 3 5 6 4 7 8 9 10 11 12 13 14 15 15 15 16 17 To Terminator Board on Shuttle Frame To J02 Shuttle Motor To J03 MPU Figu...

Page 276: ...ld Kit 1500 Models 050 P50 Models 010 P10 Model 015 Models 050 P50 Models 010 P10 Model 015 6 90H3268 Power Supply PCBA 7 Ref P101 Cable Connector 8 Ref Cable Assy AC In Power Supply Part of Field Kit...

Page 277: ...8 9 7 10 11 12 13 14 15 16 17 18 18 18 19 20 2 Places Exploded to show assembly Do not remove holddown clamps and screws To J02 Shuttle Motor To J03 MPU To Terminator Board on Shuttle Frame 21 2 3 4...

Page 278: ...ement Procedures and Illustrated Parts List 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 Ass...

Page 279: ...rts List 0 010 001 inch 1 0 254 025mm 21 Make sure the extension spring does not touch the MPU cable after installation 2 3 Spring Lug Do not remove grease Spring Lug Do not remove grease 4 Figure 47...

Page 280: ...8 Ref Link Spring Part of item 18 9 Ref Spring Extension 1 00L Part of item 18 10 Ref Screw Hex w Lock Washer 4 20x 50 Part of item 11 11 57G1521 Ground Clip Spined Shaft 12 57G1460 Splined Shaft Asse...

Page 281: ...cement Procedures and Illustrated Parts List 20 11 12 15 16 1 2 5 6 7 8 9 10 13 14 17 3 16 21 NOTE Item 18 Tractor Shaft Hardware Kit not shown Item 19 Tractor Shaft Kit not shown 4 22 Figure 48 Tract...

Page 282: ...f 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 Part o...

Page 283: ...nt Procedures and Illustrated Parts List 1 2 4 5 7 8 11 12 14 15 24 23 22 21 20 3 13 19 16 17 18 6 9 10 1 2 26 16 18 17 NOTE Black tape faces paper motion detector NOTE Item 25 Platen Hardware Kit Fig...

Page 284: ...57G1509 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 Ribbo...

Page 285: ...ustrated Parts List 22 17 20 19 18 21 See detail above 6 12 3 5 7 11 2 4 8 9 10 13 14 15 11 2 16 1 Install screws here Hammer Bank Fan Route cable under base casting Top View 23 Figure 50 Motors Card...

Page 286: ...Part No 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 Ca...

Page 287: ...AC Power Input Connector J301 Black Wire To IEC 320 AC Power Input Connector J301 White Wire To Connector P1 Black Wire To Connector P1 White Wire Card cage fan and power supply board removed for clar...

Page 288: ...No Order 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 pi...

Page 289: ...289 Replacement Procedures and Illustrated Parts List 1 2 3 6 7 1 8 5 4 Figure 52 IBM Coax Twinax Expansion Board...

Page 290: ...on Notes 1 Ref Screw Connector 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 PC...

Page 291: ...291 Replacement Procedures and Illustrated Parts List 7 3 4 1 2 6 5 8 9 Figure 53 Ethernet Interface Assemblies...

Page 292: ...292 Replacement Procedures and Illustrated Parts List...

Page 293: ...d Pinouts Controller CMX 298 Power Supply 302 Expansion Coax Twinax 303 SureStak Power Stacker Control Panel PCBA 304 Cable Routing Cabinet Model 305 Cabinet Model Mechanism Base 306 Pedestal Model 30...

Page 294: ...V Remote Power 323 Power Stacker Cables Frame Cable Power Stacker 324 Logic Cable Power Stacker 325 Power Cable Power Stacker 326 Vertical Rail Cable Power Stacker 327 Fan Assembly Hammer Bank 328 Mag...

Page 295: ...2 4 4 4 4 2 2 4 J03 Hammer Bank Fan 2 P03 J02 P02 Shuttle Motor Hammer Bank Board Terminator Board J04 P04 J05 P05 10 10 Magnetic Pickup Unit 3 2 Shuttle J201 RS 232 I O Assy CMX Controller Board Leg...

Page 296: ...r Out Detector Left Ribbon Motor J106 MSL P106 MSL Card Cage Fan P306 Left Ribbon Guide Hammer Bank Fan J02 P02 Shuttle Motor Hammer Bank Board Terminator Board J04 P04 J05 P05 Shuttle Assy CMX Contro...

Page 297: ...ibbon Motor RRP Right Ribbon Post Only in cabinet models P106 2 4 and 6 8 Normal P106 Pins LRIB M Device Resistance 7 2 8 8 PLAT M 1 3 and 5 7 1 35 1 65 LRP CCF PMD POD 10 12 9 11 14 16 13 15 Open acr...

Page 298: ...ntains a lithium battery that can explode if it is replaced incorrectly NVRAM is replaced only at the factory 1 2 3 4 5 6 7 8 N STROBE 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 P1 P2 P3 P4 P5...

Page 299: ...0V 470 PF 10 50V 470 PF 10 50V 1 2 J102 External Power 10 mF 10 16V 1000 PF 10 50V 1000 PF 10 50V 5000HM L6 0 1 PF 20 50V 4 7K 0 1W OUT1 OUT2 OUT3 OUT4 GND IN1 IN2 EN 8 7 6 5 1 2 3 4 U56 VCC 4 7K 0 1W...

Page 300: ...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 4 7K 0 1W 4 7K 0 1W NC EXP N ID SEL 12 10 V NC N DMA REQ0 N DMA REQ1 NC E...

Page 301: ...TOROID 50 MHz TOROID 50 MHz 15V 0 01 mF 10 50V Controller CMX 4 7V 3 0W DRAM 72 pin SIMM J15 Bank 1 J16 Bank 0 See page 224 Flash 80 pin SIMM J10 Bank 1 J11 Bank 0 See page 224 1 2 3 4 5 6 7 8 EC DB...

Page 302: ...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 5...

Page 303: ...REQ1 NC EXP NINT 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 EXP D7 EXP D6 EXP D5 EXP D4 EXP D3 EXP D2 EXP D1 EXP D0 EXP A15 EXP A14 E...

Page 304: ...D PHA 1 PD PHB 1 PD PHA 2 PD PHB 2 PI PHA 1 PI PHA 2 PI PHB 1 PI PHB 2 IR LED A 1 2 3 4 5 6 7 8 9 10 J7 Stacker 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...

Page 305: ...305 Wire Data Cable Routing Cabinet Model...

Page 306: ...chanism Base Cabinet Model Looking up from below To J106 on Controller To J107 on Controller Left Side Right Side Front of Printer of Printer of Printer See page 199 for connector detail See page 199...

Page 307: ...307 Wire Data Cable Routing Pedestal Model...

Page 308: ...stal Model Looking up from Below To J106 on Controller To J107 on Controller Left Side Right Side Front of Printer of Printer of Printer See page 199 for connector detail See page 199 for connector de...

Page 309: ...309 Wire Data Cable Assembly AC In Power Supply Description Part No 14H5289 To Power Supply J1 To Circuit Breaker...

Page 310: ...Wire Data 310 Cable Assembly AC Power Input Description Part No 14H5289 To Circuit Breaker Input Power Connector...

Page 311: ...311 Wire Data Cable Assembly Card Cage Fan Description Part No 14H5285 PIN 1 PIN 1...

Page 312: ...Cable Assembly Operator Panel Description Part No 14H5300 IMPORTANT If you replace the control panel cable you must install two ferrite shielding beads See Appendix I PIN 1 PIN 1 PIN 8 PIN 8 Gray Bro...

Page 313: ...313 Wire Data Cable Assembly Exhaust Fan Description Part No 14H5286...

Page 314: ...Wire Data 314 Cable Assembly Hammer Bank Logic Description Part No 14H5279...

Page 315: ...315 Wire Data Cable Assembly Hammer Bank Power Description Part No 14H5283 PIN 1 PIN 1...

Page 316: ...Wire Data 316 Cable Assembly I O Centronics Description Part No 14H5287 PIN 1 PIN 1 NOTE If you replace the I O cable assembly you must install the ferrite clamp See Appendix I...

Page 317: ...317 Wire Data Cable Assembly MPU Description Part No 14H5329 PIN 1 PIN 3 PIN 2 PIN 1...

Page 318: ...Wire Data 318 Description Part No 24H8894 Ribbon Guide Kit Includes left and right guides PIN 1 PIN 2 LEFT GUIDE P106 LRP RIGHT GUIDE P107 RRP NOTE Left ribbon guide shown Right is mirror image...

Page 319: ...319 Wire Data Cable Assembly Ribbon Motor Extension Description Part No 63H7464...

Page 320: ...Wire Data 320 Cable Assembly Shuttle Motor Drive Description Part No 14H5330...

Page 321: ...uto Termination Description Part No 38F8254 White Gray Shield 14 7 5 Jack Jack 15 position D sub receptacle connector with EMI RFI shield 1 2 3 4 Resistance Chart Pin Pin Ohms 1 3 1 2 3 4 5 14 7 2 4 S...

Page 322: ...Wire Data 322 Cable Assembly Centronics DataProducts Adapter Description Part No 14H5522...

Page 323: ...323 Wire Data Cable Assembly 5V Remote Power Description Part No 14H5589...

Page 324: ...28 29 30 31 32 33 34 PMD A M1 A1 M1 A2 M1 B1 M1 B2 M2 A1 M2 A2 M2 B1 M2 B2 LD1 A LD1 K DT1 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...

Page 325: ...325 Wire Data Cable Logic Power Stacker Description Part No 24H8976...

Page 326: ...Wire Data 326 Cable Power Power Stacker Description Part No 24H8975...

Page 327: ...327 Wire Data Cable Vertical Rail Power Stacker Description Part No 24H8964...

Page 328: ...Wire Data 328 Fan Assembly Hammer Bank Description Part No 14H5159 P107 HBF P107 HBF...

Page 329: ...329 Wire Data Magnetic Pickup Assembly Description Part No 57G1476...

Page 330: ...Wire Data 330 Switch Assembly Cover Open Description Part No 14H5282...

Page 331: ...331 Wire Data Switch Assembly Paper Detector Standard Black Back Forms Kit 6400 Description Part No 14H5281 63H5133...

Page 332: ...Wire Data 332 Switch Assembly Platen Interlock Description Part No 14H5280 P107 PLO...

Page 333: ...uch 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 gener...

Page 334: ...24 inches 5 08 to 60 96 cm long 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 re...

Page 335: ...Printer Dimensions Cabinet Model Pedestal Model Height 42 5 inches 108 cm 35 5 inches 90 2 cm Width 27 inches 68 6 cm 24 6 inches 62 5 cm Depth 29 inches 73 7 cm 30 inches 76 2 cm Weight 225 lbs 102...

Page 336: ...8A 100 V 8A 88 V 178 270V RMS 47 63 Hz 3A 200 V 3A 200 V 3A 178 V 3A 200 V 3A 200 V 3A 178 V 4A 200 V 5A 200 V 5A 178 V Power Consumption 6400 004 6400 04P Operating DP Mode Standby 120 VAC 60 Hz All...

Page 337: ...Hz All H s Max Typical Not Energy Star Energy Star Watts 180 150 60 25 BTU Hour 615 510 205 85 VA 390 310 145 55 6400 050 6400 P50 Operating DP Mode Standby 120 VAC 60 Hz All H s Max Typical Not Ener...

Page 338: ...Hz All H s Max Typical Not Energy Star Energy Star Watts 210 180 60 25 BTU Hour 720 615 205 85 VA 435 360 145 55 6400 009 6400 09P Operating DP Mode Standby 120 VAC 60 Hz All H s Max Typical Not Ener...

Page 339: ...AC 50 Hz All H s Max Typical Not Energy Star Energy Star Watts 290 230 80 25 BTU Hour 990 790 275 85 VA 600 450 150 55 6400 012 Operating DP Mode Standby 120 VAC 60 Hz All H s Max Typical Not Energy S...

Page 340: ...All H s Max Typical Not Energy Star Energy Star Watts 380 255 75 25 BTU Hour 1300 870 255 85 VA 710 485 150 55 6400 015 Operating DP Mode Standby 120 VAC 60 Hz All H s Max Typical Not Energy Star Ene...

Page 341: ...Interfaces Type PC Parallel RS 232 serial RS 422 serial Logic Levels TTL EIA 232E EIA 422B Data Format ASCII Compatibility PC Parallel EIA 232E serial EIA 422B serial Transfer Rates Up to 200 Kilobyte...

Page 342: ...cters configured in a character set repertoire Print rates for lines containing attributes such as bold or emphasized printing superscripts subscripts or elongated attributes will decrease to not less...

Page 343: ...ED 60 120 X 48 10 12 13 3 5 9 X 5 1 4 7 X 5 1 1200 1026 150 320 200 600 375 800 500 012 08 05 154 247 480 300 428 684 33 21 42 67 100 63 014 560 1050 1400 432 840 1197 58 117 175 4 7 X 5 1 190 356 475...

Page 344: ...344 Printer Specifications...

Page 345: ...nch 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 is exact Torque and Force...

Page 346: ...ounce avoirdupois Temperature 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 Power Multiply By To Obtain...

Page 347: ...to Medium Carbon Steel Fasteners 105 000 psi ultimate tensile strength Into Steel 60 000 psi ultimate tensile strength Carbon Steel Fasteners ANSI B18 6 3 1972 2 56 4 40 6 32 8 32 10 24 10 32 1 4 20 2...

Page 348: ...348 Torque Table...

Page 349: ...fe conditions in a 6400 series printer Perform the inspection steps outlined in this guide before the normal inspection for Maintenance Agreement Qualification or any time you are instructed to make a...

Page 350: ...ty check on the following pages do the steps in the order presented Do not omit any steps Prepare the Printer for Inspection DANGER 3 Hazardous voltages are present in the printer with the power cord...

Page 351: ...sed 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 ar...

Page 352: ...he circuit breaker power leads is undamaged and firmly attached to the ground lug on the wall of the card cage as shown in Figure 54 NOTE Ground paths for the entire printer are summarized in Figure 5...

Page 353: ...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 Ba...

Page 354: ...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...

Page 355: ...e 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 a...

Page 356: ...356 Safety Inspection Guide...

Page 357: ...icrosecond 10 6 second 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 ATT...

Page 358: ...oard CNC Connector Connection 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 Da...

Page 359: ...mable 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 Filter...

Page 360: ...nch 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 Maintenance Jack RS 232 Optional MECA Mechanism Engi...

Page 361: ...meter PCBA Printed Circuit Board Assembly PCB Printed Circuit Board PE Printer Error Paper Empty PER Peripheral Device PF picofarad 10 12 farad PFC Paper Feed Controller PFM Paper Feed Motor PHA Phase...

Page 362: ...huttle Processor RST Reset RTPU Real Time Processing Unit RTS Request to Send RXD Receive Data SCS SNA Character Stream SEC Security Key SEL Select SEN Sense Sensor SF Structured Field SG Signal Groun...

Page 363: ...smit Data UART Universal Asynchronous Receiver Transmitter UDPH Upper Drive Phase UNDEF Undefined USART Universal Synchronous Asynchronous Receiver Transmitter V Volts VCC Voltage at Collector VDD Vol...

Page 364: ...364 Abbreviations and Signal Mnemonics...

Page 365: ...dor Haiti Jamaica Venezuela Netherlands Antilles Trinidad Suriname Taiwan Tobago Saint Lucia Indonesia 8509386 1 Cable PC RS 232 IBM 08H7968 1 Coax Adapter Cable for use with Multi Platform Interface...

Page 366: ...14H5323 1 Line Cord 6400 Australia 14H5325 1 Line Cord 6400 Japan 14H5335 1 Twinax Auto Termination Cable 47 Inches 14H5541 1 DP Adapter 6400 21F4342 1 Cable AS 400 RS 232 IBM 38F8254 1 Twinax Auto Te...

Page 367: ...5169 283 Platen Hardware Kit 14H5174 269 Platen Paper Feed Cover Kit 14H5179 269 Paper Scale 14H5211 275 Clamp Shaft Receiving 14H5214 281 Tractor Shaft Kit 14H5217 281 Tractor Shaft Hardware Kit 14H5...

Page 368: ...AC Field Kit 14H5289 310 Cable Assy AC Power Input Part of AC Field Kit 14H5296 263 Spares Kit Grommet 14H5299 265 Operator Panel Assembly Cabinet 14H5300 265 267 Cable Assembly Operator Panel 14H5329...

Page 369: ...ax Twinax Multi Platform Interface 14H5593 205 I O Bracket Assembly Coax Twinax Multi Platform Interface 14H5595 205 PROM Coax Twinax Multi Platform Interface 14H5603 261 Logo 6400 14H5643 275 CMX Con...

Page 370: ...e English 24H8775 18 6400 Line Matrix Printer Setup Guide Spanish 24H8776 18 6400 Operator s Guide French 24H8777 18 6400 Line Matrix Printer Setup Guide Italian 24H8778 18 6400 Line Matrix Printer Se...

Page 371: ...le Frame Assembly 1500 Model 015 24H8931 277 Hammer Spring Field Kit 500 Models 050 P50 24H8932 277 Hammer Spring Field Kit 1000 Models 010 10P 24H8933 277 Hammer Spring Field Kit 1500 Model 015 24H89...

Page 372: ...embly MPU 57G1479 285 Ribbon Hub Kit 57G1481 265 Gas Spring Kit 57G1485 261 Caster with Brake 57G1486 261 Caster without Brake 57G1492 261 Window Top Cover 57G1514 283 Platen Pulley Driven 57G1521 281...

Page 373: ...7 Bracket Control Panel 63H5133 285 331 Paper Detector Switch Assy Black Back 63H7379 26 6400 Line Matrix Printer Configuration Utility Disk 63H7398 261 Top Cover Seal Kit 63H7464 319 Cable Assembly R...

Page 374: ...Numbers Part Number Description Page 90H3271 275 CMX Controller Board V5 5 40 MHz Models 050 P50 010 P10 014 015 S246 0149 18 6400 Coax Twinax Multi Platform Interface Option Installation and Operati...

Page 375: ...2 Ferrite Clamp A noise suppression core housed in a hinged plastic case and attached with adhesive to the wall of the card cage The parallel I O cable assembly passes through this core Figure 56 sho...

Page 376: ...ssembly Parallel I O Cable Assembly Connector Shielding Bead P110 Connector P310 Connector J203 Connector P112 with Clamp and Adhesive Backing NOTE Two turns around each bead NOTE This core attaches t...

Page 377: ...y is inside the cabinet the stacker assembly must be removed from the printer in order to service the unit or replace most of its components This appendix consists of two parts Removal installation in...

Page 378: ...r maintenance page 194 2 Unload paper from the stacker area Refer to the User s Manual 3 Remove the paper tent See Figure 57 Paper Tent Figure 57 Removing the Paper Tent 4 Remove the paper fence See F...

Page 379: ...lector See Figure 59 Paper Deflector Figure 59 Removing the Paper Deflector 6 Remove three screws and washers from the stacker control panel See Figure 60 Washer Long Screw Short Screw 2 Washer 2 Figu...

Page 380: ...ble Frame Cable P102 Rail Cable P107 Figure 61 Removing Cables from the Stacker Control Panel 8 Remove the two 5 32 x 3 4 inch screws and washers securing the vertical rails to the upper frame cross m...

Page 381: ...se one turn do not remove the screws Each rail is secured by two screws See Figure 63 Vertical Rail Stacker Base Washer 2 Screw 2 Screw 2 Washer 2 Elevator Assembly NOTE Hardware exploded to show loca...

Page 382: ...elevator assembly to its lowest position 13 Tilt the vertical rails toward the front of the printer until they clear the upper frame cross member Slide the stacker assembly to rear and angle it out of...

Page 383: ...1 Prepare the printer for maintenance page 194 2 Remove paper 3 Loosen the three paper path hold down screws Slide the paper path to the left and lift it off the card cage See Figure 65 Paper Path Hol...

Page 384: ...ect the stacker power cable to connector J101 on the CMX controller board See Figure 66 7 Route the stacker power cable and the stacker logic cable in front of the CMX board and through the cutout ben...

Page 385: ...crews at the bottom of each vertical rail one turn do not remove the screws Each rail is secured by two screws See Figure 67 Frame Cable Rail Cable Screw 2 Screw 2 Vertical Rail Vertical Rail Figure 6...

Page 386: ...or assembly at the bottom of the vertical rails See Figure 68a 10 Insert the vertical rails inside and under the upper frame cross member then slowly swing the base of the stacker assembly into the ca...

Page 387: ...387 Power Stacker Upper Frame Cross Member a b c Stacker Base Vertical Rail Elevator Assembly Figure 68 Stacker Installation...

Page 388: ...screws and washers to secure the vertical rails to the upper frame cross member 15 Install four 7 64 x 1 2 inch screws and washers to secure the stacker base to the cabinet floor See Figure 69 Stacke...

Page 389: ...the four screws you loosened in step 8 When correctly installed the stacker vertical rails are parallel and vertical as shown in Figure 68c 17 Install the paper fence See Figure 70 Paper Fence Stacke...

Page 390: ...cable Make sure these cables are routed outboard of the elevator assembly 19 Connect the stacker cables to the rear of the stacker control panel assembly as shown in Figure 71 Power Cable Logic Frame...

Page 391: ...nd tie wrap the stacker control panel cables to the printer frame so they do not catch in the stacker mechanism as it moves up and down Route the stacker rail and frame cables so they move without sna...

Page 392: ...s with the angled portion toward the front of the printer as shown in Figure 73 23 Install the paper path that you removed in step 3 page 383 24 Install paper and test stacker operation Refer to the U...

Page 393: ...next step 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 ve...

Page 394: ...screw washers and spacer from the constant force spring and drum Let the spring coil itself up until it reaches the screw that secures it to the vertical rail See Figure 75 4 Firmly gripping the spri...

Page 395: ...remaining spring and drum See Figure 76 6 While holding the drum tightly continue to curl the spring until it is completely unwound from the drum See Figure 76 7 To install a new constant force sprin...

Page 396: ...move the shoulder screw from the pulley at the bottom of the left vertical rail and remove the pulley See Figure 77 Go to step 6 4 If you are removing the right timing belt remove the two metric Allen...

Page 397: ...Setscrew Pulley Setscrew Figure 78 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 79 Space...

Page 398: ...Clamp Belt Clamp Allen Screw 2 Figure 80 Removing the Belt Clamps 8 Remove the timing belt by working it around the vertical rail and constant force spring See Figure 81 9 To install a timing belt rev...

Page 399: ...embly c While holding downward pressure on the left side of the elevator assembly tighten the timing belt pulley screw Illustrated Parts Breakdown The Illustrated Parts Breakdown IPB consists of explo...

Page 400: ...400 Power Stacker Detail Figure 83 page 402 7 10 15 20 25 30 35 7 10 20 5 6 8 8 9A 9 9 11 12 12 12 13 14 Figure 82 Stacker Assembly...

Page 401: ...521 Clip Grounding 15 24H8969 Motor 20 24H8970 Constant Force Spring 25 24H8971 Chain Mount chains outboard of shafts 30 Ref Nylon Plug Part of item 36 35 24H8973 Cable 36 24H9004 Stacker Hardware Kit...

Page 402: ...5 50 45 60 40 Detail Figure 84 page 404 Detail Figure 86 page 408 Detail Figure 86 page 408 Detail Figure 85 page 406 Detail Figure 87 page 410 46 46 48 47 49 51 52 52 46 46 45 53 53 54 54 Figure 83 S...

Page 403: ...art 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 Clamp...

Page 404: ...404 Power Stacker 75 80 85 90 85 80 Figure 84 Stacker Detail Rollers...

Page 405: ...No Part No Order No Description Notes 36 24H9004 Stacker Hardware Kit Kit not illustrated 75 24H8985 Compression Spring 80 Ref Friction Washer Part of item 36 85 Ref Flanged Bushing Part of item 36 9...

Page 406: ...406 Power Stacker 95 95 100 Connector Flag Flat Side Key 96 96 Figure 85 Stacker Detail Motor Bracket...

Page 407: ...Power Stacker Item No Part No Order 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 IR T 1...

Page 408: ...408 Power Stacker 95 95 105 Connector Flag Nib Key 97 Figure 86 Stacker Detail Elevator Bracket...

Page 409: ...Stacker Item No Part No Order 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 Photodarlington NPN...

Page 410: ...410 Power Stacker ROTATED 180 105 110 115 Connector Flag Nib Key 106 97 97 107 107 108 116 109 111 Figure 87 Stacker Detail Paper Motion Detector...

Page 411: ...H8990 Photodarlington NPN Rectifier 106 Ref Screw Socket Cap 4x 25 Part of item 36 107 Ref Screw Panhead Type B 2x3 16 Part of item 36 108 Ref Retaining Ring 093 Part of item 36 109 Ref Nut Hex 4 40 P...

Page 412: ...412 Power Stacker...

Page 413: ...RIFY CONFIGURATION 78 025 SERIAL FRAMING ERROR VERIFY CONFIGURATION 78 026 HEX DUMP MODE 79 027 COMMUNICATIONS CHECK CALL SYSTEM OPERATOR 79 028 COMMUNICATIONS CHECK CALL SYSTEM OPERATOR 79 029 8344 D...

Page 414: ...DULED SEE USER S GUIDE 99 123 PAPER BUSY TOO LONG SEE USER S GUIDE 99 124 PAPER FIFO OVERFLOW SEE USER S GUIDE 100 125 PAPER FIFO UNDERFLOW SEE USER S GUIDE 100 126 PAPER FEED BAD TABLE SEE USER S GUI...

Page 415: ...rs reversing 211 Cable assembly interconnections 293 part numbers 293 shell and cable replacement 198 Cable connectors and shells replacement 198 Cable routing mechanism base 306 Call start of 56 Canc...

Page 416: ...pinouts 304 Customer Engineer CE tests 138 Cycle power 150 D Dark characters or dots 114 Data controller DC 47 DC Data Controller CMX board 47 Diagnostic menus boot 142 Diagnostic self tests customer...

Page 417: ...Ethernet interface assemblies replacement 212 LEDs and DIP switches 213 F Fan assembly card cage replacement 216 hammer bank replacement 215 217 Fault messages 57 Ferrite cores noise suppression 375 F...

Page 418: ...eplacement procedures 259 IML printer does not complete 122 Information menu printer 148 Inspection safety guide 349 Installation 27 Installed memory 148 Interface coax twinax multi platform replaceme...

Page 419: ...6 HOST SYSTEM REQUEST ATTENTION 72 007 FM HEADER ERROR 72 008 HOLD PRINT TIMEOUT PRESS START 72 009 INVALID KEY PRESS 72 010 PARAMETER ERROR 73 011 SCS COMMAND ERROR 73 012 STRUCTURE FIELD ERROR 73 01...

Page 420: ...AL INSTRUCTION ACCESS SEE USER S GUIDE 97 116 ILLEGAL EXTERNAL BUS ACCESS SEE USER S GUIDE 97 117 A TO D OVERRUN SEE USER S GUIDE 97 118 UNDEFINED INTERRUPT SEE USER S GUIDE 98 119 TCB CORRUPTED SEE U...

Page 421: ...FLASH NOT DETECTED 110 P62 ERROR DC PROGRAM NOT VALID 110 P63 ERROR PROGRAM NOT COMPATIBLE 110 P64 ERROR CHECKSUM WRONG hex 110 P65 ERROR PROGRAM NEEDS MORE FLASH 111 P66 ERROR PROGRAM NEEDS MORE DRAM...

Page 422: ...11 P66 ERROR PROGRAM NEEDS MORE DRAM 111 P67 ERROR WRITING TO FLASH 111 P68 ERROR EC PROGRAM NOT VALID 111 P69 ERROR EC STOPPED AT STATE XXXX 111 PA1 SELECTED 109 PA2 SELECTED 109 PAL security locatio...

Page 423: ...cker 123 does not print self tests 124 duty cycle 341 installation 27 limit switch check 129 logical control of 43 maintenance overview 13 models 13 evolution 15 how to identify 15 power paper stacker...

Page 424: ...n motor 229 power supply circuit board 203 print server network 232 resistors terminating 242 ribbon drive motor 231 ribbon guide assembly L R 244 ribbon hub 245 shuttle frame assembly 249 splined sha...

Page 425: ...6 environmental 335 interfaces 341 paper 334 printing rates 342 ribbon 333 Speed printing 342 shuttle set 189 Splined shaft replacement 246 skew adjustment 174 Spring extension replacement 252 gas ass...

Page 426: ...enu 148 Time power on 148 printing 148 TOF is lost repeatedly 131 Tools test equipment and supplies 26 TOP OF FORM SET 113 Torque conversion to or from metric 345 table 347 Tractor replacement 258 Tro...

Page 427: ......

Page 428: ...Copyright IBM Corp 1995 1998 S246 0117 06 07S246011706 b7 24H8887 0724H8887 b7 163983 001A...

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