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IBM Infoprint 6500-v05, Maintenance Manual

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IBM Infoprint 6500-v05 Maintenance Manual Download Page 315

List Of Procedures

315

Removal And Replacement Procedures

This section contains removal/installation procedures for components that are replaceable at the field service maintenance 
level. These procedures are listed below.

IMPORTANT

Do not try to repair electronic components or assemblies in the field. Replace a malfunctioning electronic assembly 
with an operational spare. Most electronic problems are corrected by replacing the circuit board, sensor, or cable that 
causes the fault indication. The same is true of failures traced to the hammer bank coils and electronics: you must 
replace the entire shuttle frame assembly. It is not field repairable. (Hammer spring assemblies are the only 
replaceable components of the shuttle frame assembly.)

List Of Procedures

Belt, Paper Feed Timing ..........................................................................................................................................  page 317

Belt, Platen Open .....................................................................................................................................................  page 318

Circuit Board: Controller...........................................................................................................................................  page 319

Circuit Board: Power Supply ....................................................................................................................................  page 321

Circuit Breaker .........................................................................................................................................................  page 322

Connector Shells .....................................................................................................................................................  page 323

Cover Assembly, Hammer Bank / Ribbon Mask ......................................................................................................  page 325

Cover Assembly, Shuttle ..........................................................................................................................................  page 326

Cover Assembly, Top, Pedestal Model ....................................................................................................................  page 327

Dashpot....................................................................................................................................................................  page 328

Ethernet Interface Assembly ..................................................................................................................................... page 329

Fan Assembly, Cabinet Exhaust ..............................................................................................................................  page 330

Fan Assembly, Card Cage .......................................................................................................................................  page 331

Fan Assembly, Hammer Bank .................................................................................................................................  page 332

Hammer Spring Assembly .......................................................................................................................................  page 333

IBM Coax/Twinax Expansion Board.........................................................................................................................  page 337

Magnetic Pick-up (MPU) Assembly..........................................................................................................................  page 338

Memory Modules and Security Key .......................................................................................................................... page 339

Motor Assembly, Paper Feed...................................................................................................................................  page 342

Summary of Contents for Infoprint 6500-v05

Page 1: ...Infoprint 6500 Line Matrix Printers Models 6500 v05 v5P v10 v1P v15 and v20 Maintenance Information Manual Form No G544 5978 00...

Page 2: ...ality Publications are not stocked at the address given below You may send your comments by facsimile to 1 800 524 1519 by E mail to printpub us ibm com or by mail to IBM Printing Systems Division Inf...

Page 3: ...ation 21 Prepare The Printer For Inspection 21 Inspect Mechanical Parts 22 Inspect Electrical Parts 23 Preface 26 About This Manual 26 Printing Conventions In This Manual 27 Related Documents 28 About...

Page 4: ...Contents 212 Operator Print Tests 213 Selecting And Running Tests 215 Customer Engineer CE Tests 216 Boot Diagnostics Menu 221 Hex Code Printout 224 Printer Information Menu 226 Soft vs Hard Reset 22...

Page 5: ...62 Locations Of Components And Assemblies 262 4 Circuit Diagrams Circuit Boards Cables and Switches 264 Contents 264 5 Removals and Adjustments 311 About This Chapter 311 Tools And Materials 311 Prepa...

Page 6: ...er Feed 342 Motor Assembly Platen Open 344 Motor Assembly Ribbon Drive 346 Operator Panel Assembly 347 Paper Guide Assembly 348 Paper Ironer 349 Platen 350 Platen Stop Assembly 354 Resistors Terminati...

Page 7: ...6 Parts Catalog 390 Organization Of This Chapter 390 Illustrated Parts Breakdown 390 7 Preventive Maintenance 431 Contents 431 Cleaning The Printer 432 Cleaning The Exterior 432 Cleaning The Interior...

Page 8: ...Constant Force Spring 485 Replacing The Timing Belts 487 Replacing The Roller Drive Shaft 491 Illustrated Parts Breakdown 494 List of Illustrations 494 F Printer Specifications 504 Contents 504 Ribbon...

Page 9: ...Table of Contents 9 Cables 511 Printing Rates 512 G Metric Conversion Tables 515 Length 515 Torque and Force 516 Mass and Density 516 Temperature 517 Power 517 H Torque Table 518 I Abbreviations 520...

Page 10: ...for products and services offered in the U S A IBM may not offer the products services or features discussed in this document in other countries Consult your IBM representative for information on the...

Page 11: ...Therefore the results obtained in other operating environments may vary significantly Some measurements may have been made on development level systems and there is no guarantee that these measuremen...

Page 12: ...e harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interfer...

Page 13: ...Such cables and connectors are available from IBM authorized dealers IBM cannot accept responsibility for any interference caused by using other than recommended cables and connectors Industry Canada...

Page 14: ...nvironment this product may cause radio interference in which case the user will be required to take adequate measures Australia New Zealand Attention This is a Class A Product In a domestic enviromen...

Page 15: ...Klasse A Text f r alle in Deutschland vertriebenen EN 55022 Klasse A Ger te Zulassungsbescheinigung laut dem Deutschen Gesetz ber die elektromagnetische Vertr glichket von Ger ten EMVG vom 18 Septembe...

Page 16: ...modification of the product including the fitting of non IBM option cards Dieses Ger t ist berechtigt in bereinstimmung mit dem deutschen EMVG vom 9 Nov 92 das EG Konformit tszeichen zu furhren Prope...

Page 17: ...erates under conditions of high electrical potentials and heat generation both of which are functionally necessary Lightning Safety To avoid personal risk do not install or reconfigure a communication...

Page 18: ...mportant indicates information vital to proper operation of the printer NOTE A note gives you helpful information and tips about printer operation and maintenance This symbol indicates a part or assem...

Page 19: ...companies and are designated by two asterisks in this manual Acrobat Adobe Systems Incorporated Adobe Adobe Systems Incorporated Auto Label Mapping Printronix Inc Centronics Genicom Corporation Code...

Page 20: ...ustrial Programming Inc PGL Printronix Inc PKZIP PKWARE Inc Printronix Printronix Inc PSA3 Printronix Inc QMS Quality Micro Systems Inc RibbonMinder Printronix Inc SureStak Printronix Inc Torx Camcar...

Page 21: ...Inspection Have the following items available Electrical Safety for IBM Customer Engineers Order No S229 8124 A Fluke meter P N 8496278 or similar device for measuring electrical resistance and voltag...

Page 22: ...e not loose or damaged Make sure they touch the contact strips on the frame when the cover is closed g Close the top cover Make sure the operator panel is centered in the opening of the cover 2 On cab...

Page 23: ...are summarized in and Figure 2 Figure 1 This figure is a detail drawing showing the ground lug for the circuit breaker of cabinet models 4 Set a Fluke meter P N 8496278 or similar device to the lowes...

Page 24: ...inter AC Power On Off Switch 5V Remote 5V 48V 5V 5V 48V 48V 24V 48V 8 5 48V 8 5V 5V 5V 48V 48V 5V Primary Earth Ground P101 1 2 3 4 5 6 7 8 9 10 11 12 N AC FAIL N STBY 5V 5V 5V RET LOGIC GND 5V RET LO...

Page 25: ...t operation of the printer This ground must be connected either to the electrical service ground or to a suitable building ground The printer power cable has a green or green yellow insulated groundin...

Page 26: ...s a field service maintenance manual for IBM Infoprint 6500 line matrix printers Refer to the Table of Contents or the Index to locate the maintenance information you need How To Replace Parts 1 Go to...

Page 27: ...llowing features in the illustrations Printing Conventions In This Manual Operator panel keys and LCD messages are set off from regular text in this manual Operator panel keys and indicators are print...

Page 28: ...eference G544 5979 IBM Infoprint 6500Line Matrix Printer CTA Programmer s Reference G544 5982 IBM Infoprint 6500Line Matrix Printer IPDS Programmer s Reference S544 5984 IBM Infoprint 6500Line Matrix...

Page 29: ...panel or by sending printer control codes in the data stream from the host computer The IBM Infoprint 6500 Printer Family The Infoprint 6500 line matrix printer family consists of pedestal mount and...

Page 30: ...er Print Speed of Draft Mode Text Enclosure Hammer Bank 6500 v05 500 LPM Floor Cabinet 28 Hammers 6500 v5P 500 LPM Pedestal 28 Hammers 6500 v10 1000 LPM Floor Cabinet 60 Hammers 6500 v1P 1000 LPM Pede...

Page 31: ...ion level and the MECA ASIC revision level The configuration is included in the configuration printout Figure 4 shows how to interpret the printer s configuration code Figure 4 This figure show how to...

Page 32: ...els The paper fence is a wireform divider that separates the source paper stack from the printed output stack For improved performance at higher throughputs the guide chains are used with a moveable f...

Page 33: ...ess the original shuttle frame assembly or platen has been replaced with a new or rebuilt unit or unless you are instructed to do so in a troubleshooting procedure Never bend or tweak hammer springs A...

Page 34: ...de moves to the previous menu Scroll function ENTER Selects the option displayed on the LCD This action either sets a value moves to the next lower level of configuration or starts a self test LINE FE...

Page 35: ...configuration into memory The printer must be in NOT READY mode to do a soft reset RETURN ENTER Toggles the lock on the configuration menus Status Lamp Lit when the printer is in READY mode and the pr...

Page 36: ...ical Controls Figure 5 36 Figure 5 This figure shows the locations of the electrical controls on floor cabinet and pedestal model printers B A A LCD Power Switch Off On Rotated 180 Degrees A B Status...

Page 37: ...rms and so on Forms Thickness Lever and Platen Stop The forms thickness lever closes the platen to the relative thickness of the paper The platen stop returns the platen to the lever adjustment set by...

Page 38: ...ows the locations of the mechanical controls on on floor cabinet and pedestal model printers Paper Supports Tractor Lock Left Tractor Right Tractor Vertical Position Knob Forms Thickness Lever and Sca...

Page 39: ...it This manual does not cover printer operation or configuration so always have the User s Manual handy when you troubleshoot Troubleshooting At A Glance Start Of Call page 40 How To Troubleshoot pag...

Page 40: ...inter does not complete IML page 185 Go to No power and operator panel is blank and card cage fan is not running page 184 YES NO Are there black squares on the operator panel NO Go to Printer does not...

Page 41: ...malfunctioning electronic assembly with an operational spare Most electronic problems are corrected by replacing the printed circuit board assembly sensor or cable that causes the fault indication Th...

Page 42: ...puter etc A Unit Check condition is a failure detected by self test and fault circuitry Unit check conditions are either recoverable or unrecoverable Recoverable unit check conditions are errors detec...

Page 43: ...r switch with the optional black back forms switch assembly 4 Power off and unplug the printer Remove the paper guide assembly or pedestal top cover Remove the barrier shield cabinet model or the barr...

Page 44: ...re replace the controller board page 319 After replacing the controller board DO NOT make the printer READY but proceed immediately to the next step 12 Download and install the latest code from IBM Fi...

Page 45: ...d platen does not open page 205 5 Check the paper tension between the tractors Adjust the right tractor so that it does not pull paper too tightly or leave it too loose The right tractor should hold t...

Page 46: ...he failure or message that brought you to this procedure replace the controller board page 319 After replacing the controller board DO NOT make the printer READY but proceed immediately to the next st...

Page 47: ...he READY state 2 Run the print job that generated the error message If the message appears check the host data for invalid characters 3 Ask the system operator to verify that the printer s Device ID i...

Page 48: ...e printer If the message appears replace the twinax cable 4 Send a print job to the printer If the message appears go to Communications Failures page 211 014 INVALID ACTIVATE The printer detects a twi...

Page 49: ...munication 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 the defective board 01...

Page 50: ...ed and not bent or stretched f drive rollers are not damaged Tighten setscrews and replace damaged components as necessary 4 Power off and unplug the printer Remove the paper guide assembly Disconnect...

Page 51: ...he drive rollers are not damaged g the constant force springs are tightly mounted and undamaged Tighten pulley setscrews and or replace damaged components as necessary 3 Adjust the stacker rails if th...

Page 52: ...Support 14 If the problem reappears replace the stacker motors 021 BUFFER OVERRUN VERIFY CONFIGURATION The print buffer has overflowed on a serial interface The printed output may contain random aster...

Page 53: ...e message appears replace the coax twinax multi platform interface Refer to the Coax Twinax Multi Platform Interface Feature Installation and Operation Guide Form Number S246 0149 025 FRAMING ERROR VE...

Page 54: ...t system 029 8344 DIAGNOSTIC FAILED Link level code test detects a hardware failure on the coax twinax expansion board This message can also occur if the software in flash memory is corrupted 1 Cycle...

Page 55: ...the paper guide assembly or pedestal top cover Remove the barrier shield cabinet model or the barrier shield and paper guide pedestal model Check that the paper detector switch assembly is securely m...

Page 56: ...ard DO NOT make the printer READY but proceed immediately to the next step 11 Download and install the latest code from IBM First page 231 12 Power on the printer in download mode and load flash memor...

Page 57: ...does not move down refer to Reverse paper feed platen does not open page 205 5 Check the paper tension between the tractors Adjust the right tractor so that it does not pull paper too tightly or leave...

Page 58: ...ading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedure replace the controller board page 319 After replacing the co...

Page 59: ...al Ready and Request to Send Set printer serial interface parameters to match those of the host 2 Send a print job to the printer If the message appears go to Communications Failures page 211 042 NO C...

Page 60: ...If the problem reappears the controller board or microcode is suspect Do the following 4 Save the printer configuration values Refer to the User s Manual 5 Clear NVRAM page 237 6 Download and install...

Page 61: ...nd load flash memory page 238 If the message appears replace the flash memory with blank flash containing boot code then load flash memory page 238 4 If the message reappears the controller board or m...

Page 62: ...Power on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that...

Page 63: ...re Harness Test Tables in Chapter 3 Replace the platen open motor if it fails the resistance test 6 Plug in the printer and power it on Run a print test If the problem reappears the controller board o...

Page 64: ...ppears power off the printer unplug the printer and go to the next step 5 Remove the shuttle cover Remove the paper guide assembly or the pedestal top cover Inspect the shuttle mechanism for obstructi...

Page 65: ...3 Download and install the latest code from IBM First page 231 14 Power on the printer in download mode and load flash memory page 238 15 If you encounter the failure after replacing the controller bo...

Page 66: ...ide assembly or pedestal top cover Check that all fan cables are connected 3 Inspect vents and fan airways for obstructions Look underneath cabinet models for items blocking the cabinet exhaust vents...

Page 67: ...e the paper guide assembly Disconnect connector P107 from the controller board Test connector P107 EHF for shorts or opens Refer to the Main Wire Harness Test Tables in Chapter 3 Replace components th...

Page 68: ...cedure replace the controller board page 319 After replacing the controller board DO NOT make the printer READY but proceed immediately to the next step 13 Download and install the latest code from IB...

Page 69: ...e problem reappears the controller board or microcode is suspect Do the following 8 Save the printer configuration values Refer to the User s Manual 9 Clear NVRAM page 237 10 Download and install the...

Page 70: ...Display Messages 70 069 DATA CLEARED This message appears when data are cleared out of printer after the CANCEL key has been pressed No action required Table 3 Message List Operator Panel Message Expl...

Page 71: ...check replace it If it passes the check go to the next step 3 Check the kinds of print jobs the user is running look for very dense graphics and layouts Advise the user to run jobs in smaller batches...

Page 72: ...ontroller board page 319 After replacing the controller board DO NOT make the printer READY but proceed immediately to the next step 13 Download and install the latest code from IBM First page 231 14...

Page 73: ...IBM First page 231 7 Power on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the fai...

Page 74: ...rinter in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to...

Page 75: ...at J106 on the controller board 5 Inspect for obstructions of airways and vents 6 Check the shuttle for electrical shorts page 252 7 Plug in the printer and power it on If the problem reappears the c...

Page 76: ...se errors as appropriate because they may be the cause of the 084 error 3 Power off and unplug the printer Remove the paper guide assembly or pedestal top cover Before handling circuit boards put on a...

Page 77: ...er on the printer If the operator panel lights up this indicates PS 5V is working If the CCF runs momentarily about 2 seconds the PS 48V is working and you can go to step 9 d The CCF did not come on i...

Page 78: ...oulder support Exit this procedure 9 In step 8 you determined that the PS 48V is working therefore an external cable or component connecting to the controller board or the PS is pulling down the PS 48...

Page 79: ...inter Do NOT put your hands or tools inside the printer when it is plugged in Table 3 Message List Operator Panel Message Explanation Corrective Action DANGER 3 Hazardous voltages are present in the p...

Page 80: ...V is OK Do P106 wire harness platen motor and other component checks P107 CCF comes on 090 SHUTTLE OPEN 48 V is OK Do P107 wire harness hammer bank fan and other component checks P108 CCF momentarily...

Page 81: ...propriate procedure in this manual 14 Go to OPERATOR PRINT TESTS in the configuration menu and print a full 136 character width test pattern of All H s If there is any print quality issue go to the ap...

Page 82: ...38 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedure replace the controller board page 31...

Page 83: ...shuttle motor by hand to check that the cables are clear of the shuttle as it moves 6 You can easily verify that when the shuttle cover is installed the hammer bank logic cable is clear of the shuttl...

Page 84: ...ables 8 Power on the printer If the problem persists check the shuttle for electrical shorts page 252 Replace the shuttle if it is defective 9 Power on the printer If the problem persists refer to the...

Page 85: ...interlock switch cable from P107 to the switch Replace the platen interlock switch assembly if it fails continuity test 3 Check that the platen interlock switch is not loose 4 Check and adjust the pla...

Page 86: ...ce the controller board page 319 After replacing the controller board DO NOT make the printer READY but proceed immediately to the next step 12 Download and install the latest code from IBM First page...

Page 87: ...m IBM First page 231 10 Power on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the...

Page 88: ...ing problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedure replace the controller board page 319 After replacing the cont...

Page 89: ...e appropriate error code for resolution b If you encounter the failure or message that brought you to this procedure replace the controller board page 319 After replacing the controller board DO NOT m...

Page 90: ...page 237 7 Download and install the latest code from IBM First page 231 8 Power on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate...

Page 91: ...er in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to thi...

Page 92: ...nd load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedure replace t...

Page 93: ...and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedure replace...

Page 94: ...load mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedur...

Page 95: ...wnload mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this proced...

Page 96: ...download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this pro...

Page 97: ...download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this pro...

Page 98: ...he printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought yo...

Page 99: ...and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedure replace...

Page 100: ...load mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedur...

Page 101: ...n download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this pr...

Page 102: ...load mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedur...

Page 103: ...install the latest code from IBM First page 231 7 Power on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resoluti...

Page 104: ...ter and power it on If the problem reappears the controller board or microcode is suspect Do the following 6 Save the printer configuration values Refer to the User s Manual 7 Clear NVRAM page 237 8 D...

Page 105: ...in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this...

Page 106: ...have good connections Replace as needed Refer to the Cable Shorts Test on page 254 5 Check the shuttle for shorts page 252 6 Plug in the printer and power it on Run the print job again If the message...

Page 107: ...ilure after replacing the controller board reinstall the original controller board and contact your DDS and Second Level Support 15 Power on the printer Run the print job again If the message appears...

Page 108: ...code is suspect Do the following 3 Save the printer configuration values Refer to the User s Manual 4 Clear NVRAM page 237 5 Download and install the latest code from IBM First page 231 6 Power on the...

Page 109: ...nload mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedu...

Page 110: ...nload mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedu...

Page 111: ...ownload mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this proce...

Page 112: ...load mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedur...

Page 113: ...in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this...

Page 114: ...nload mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedu...

Page 115: ...oad mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedure...

Page 116: ...ownload mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this proce...

Page 117: ...Power on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that...

Page 118: ...Power on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that...

Page 119: ...er on the printer If the problem reappears the controller board or microcode is suspect Do the following 5 Save the printer configuration values Refer to the User s Manual 6 Clear NVRAM page 237 7 Dow...

Page 120: ...r supply operational check page 258 If the power supply fails the check replace it If it passes the check the controller board or the code is suspect Do the following 4 Save the printer configuration...

Page 121: ...wing 3 Save the printer configuration values Refer to the Setup Guide 4 Clear NVRAM page 237 5 Download and install the latest code from IBM First page 231 6 Power on the printer in download mode and...

Page 122: ...and install the latest code from IBM First page 231 7 Power on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for reso...

Page 123: ...roblem reappears the controller board or microcode is suspect Do the following 8 Save the printer configuration values Refer to the User s Manual 9 Clear NVRAM page 237 10 Download and install the lat...

Page 124: ...ssages 124 146 RIBBON INK OUT CHANGE RIBBON RibbonMinder software has determined that the ribbon is out of ink Install a new IBM ribbon Table 3 Message List Operator Panel Message Explanation Correcti...

Page 125: ...83 2 Inspect the printer environment for severity Advise the user to move the printer to cooler cleaner location 3 Check the kinds of print jobs the user is running look for very dense graphics and la...

Page 126: ...replacing the controller board DO NOT make the printer READY but proceed immediately to the next step 14 Download and install the latest code from IBM First page 231 15 Power on the printer in downloa...

Page 127: ...the latest code from IBM First page 231 7 Power on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If...

Page 128: ...and power it on If the message appears again the controller board or microcode is suspect Do the following 8 Save the printer configuration values Refer to the User s Manual 9 Clear NVRAM page 237 10...

Page 129: ...to the User s Manual 9 Clear NVRAM page 237 10 Download and install the latest code from IBM First page 231 11 Power on the printer in download mode and load flash memory page 238 a If you encounter l...

Page 130: ...maller emulation program page 231 168 ERROR PROGRAM NEEDS MORE FLASH The printer requires more flash memory in order to run the downloaded program Add flash memory or use a smaller emulation program p...

Page 131: ...on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brough...

Page 132: ...Download and install the latest code from IBM First page 231 7 Power on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error cod...

Page 133: ...inter discards host data it cannot use because a fault condition exists While this message displays the asterisk rotates Wait When the asterisk stops rotating a different fault message will appear tro...

Page 134: ...de from IBM First page 231 7 Power on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter...

Page 135: ...PCI slot and make sure it has a good connection 4 Power on the printer If the message appears again replace the NIC 181 ETHERNET ADAPTER BEING INITIALIZED Status message that indicates that the Networ...

Page 136: ...on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brough...

Page 137: ...he following 4 Save the printer configuration values Refer to the User s Manual 5 Clear NVRAM page 237 6 Download and install the latest code from IBM First page 231 7 Power on the printer in download...

Page 138: ...nt job again If the message reappears replace the ribbon 3 Press START and run the print job again If the message appears replace the RibbonMinder sensor 304 BARCODE DAMAGED REVERSE RIBBON SPOOLS The...

Page 139: ...d is checking for the presence of SDRAM No action required B01 STATUS 8245 SDRAM TEST 32MB Status message printer boot up routines are testing SDRAM No action required B10 ERROR NO DRAM DETECTED Boot...

Page 140: ...message B20 STATUS 00 DOWNLOAD MODE Status message informing the operator that software is being downloaded Percentage figure indicates approximate amount loaded into the printer No action required B2...

Page 141: ...page 231 7 Power on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or m...

Page 142: ...ge 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedure replace the controller board pag...

Page 143: ...rst page 231 7 Power on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure o...

Page 144: ...u encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedure replace the controller board page 319 After re...

Page 145: ...r loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedure replace the controller board page 319 After replacing th...

Page 146: ...loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedure replace the controller board page 319 After replacing the...

Page 147: ...om IBM First page 231 7 Power on the printer in download mode and load flash memory page 238 8 If you encounter the failure after replacing the controller board reinstall the original controller board...

Page 148: ...sh memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedure replace the controll...

Page 149: ...the engine controller program into the engine controller No action required BOOT DIAGNOSTICS Non error status message No action required CLEARING PROGRAM FROM FLASH Status message emulation software s...

Page 150: ...load and install the latest code from IBM First page 231 9 Power on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for...

Page 151: ...t for E Net Ready to display then retry operation If it still fails power down unplug the printer and reseat the ethernet NIC in its PCI slot 2 Print the Ethernet Test Page from the Operator Print Tes...

Page 152: ...ading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedure replace the controller board page 319 After replacing the co...

Page 153: ...s go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedure replace the controller board page 319 After replacing the controller boar...

Page 154: ...rom IBM First page 231 7 Power on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the...

Page 155: ...User s Manual 9 Clear NVRAM page 237 10 Download and install the latest code from IBM First page 231 11 Power on the printer in download mode and load flash memory page 238 a If you encounter loading...

Page 156: ...configuration values Refer to the User s Manual 7 Clear NVRAM page 237 8 Download and install the latest code from IBM First page 231 9 Power on the printer in download mode and load flash memory pag...

Page 157: ...rs at power up clear NVRAM page 237 then replace the flash memory After replacing the memory DO NOT make the printer READY but go immediately to the next step 5 Download the latest code from IBM First...

Page 158: ...ad and install the latest code from IBM First page 231 9 Power on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for r...

Page 159: ...and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedure replace...

Page 160: ...d flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedure replace the con...

Page 161: ...de from IBM First page 231 7 Power on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter...

Page 162: ...he printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought yo...

Page 163: ...Plug in and power on the printer If the message appears at power up clear NVRAM page 237 then replace the flash memory After replacing the memory DO NOT make the printer READY but go immediately to th...

Page 164: ...ination procedures as recommended by the host system OPERATOR MENU menu item Non error status message No action required OPERATOR MENU LOCKED Non error status message No action required unless you wan...

Page 165: ...r resolution b If you encounter the failure or message that brought you to this procedure replace the controller board page 319 After replacing the controller board DO NOT make the printer READY but p...

Page 166: ...ng problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedure replace the controller board page 319 After replacing the contr...

Page 167: ...r it on in download mode and load flash memory page 238 4 Install the flash memory SIMM making sure is it fully and correctly seated Power on the printer Load the flash memory If the message appears r...

Page 168: ...uired SERVICE service test Non error status message No action required SHUTTLE TYPE NOT SUPPORTED The shuttle type was not detected at power up 1 Power off and unplug the printer Remove the paper guid...

Page 169: ...at appears when printer is first powered on if the internal Network Interface Card is installed An Ethernet adapter must be detected early in the power up sequence so the printer can tell the adapter...

Page 170: ...blies Replace a malfunctioning electronic assembly with an operational spare Most electronic problems are corrected by replacing the printed circuit board assembly sensor or cable that causes the faul...

Page 171: ...a copy of the Device Host Configuration if possible 4 Call your support group for assistance in problem analysis If you cannot obtain support or you have previous experience solving host printer comm...

Page 172: ...work configuration Printer logic Incorrect printer configuration Refer customer to the User s Manual Drops characters or coax Interface cable defective Controller Network configuration Printer logic I...

Page 173: ...ndicator is on press the STOP key The printer must be in the NOT READY state 3 Press MENU OPERATOR MENU QUICK SETUP appears on the display 4 Press RETURN ENTER to unlock the ENTER key 5 Press the SCRO...

Page 174: ...Software Handshaking XON and XOFF are software signals that control serial data flow between the printer and the host system When the printer input buffer is full the printer transmits the XOFF CTRL...

Page 175: ...rned on it resets itself to the following default serial communication parameters Use the Serial Port configuration menu to change serial interface parameters Refer to the User s Manual PARAMETER DEFA...

Page 176: ...e the paper detector switch assembly if either message appears 4 Check the shuttle for electrical shorts page 252 5 Plug in the printer and power it on If either message appears the controller board o...

Page 177: ...e Check for correct position and function of the paper motion detector assembly Reposition or replace if necessary f Inspect the paper path from above below the paper ironer and from below above the...

Page 178: ...r the failure or message that brought you to this procedure replace the controller board page 319 After replacing the controller board DO NOT make the printer READY but proceed immediately to the next...

Page 179: ...he message appears 6 Plug in the printer and power it on If the problem reappears the controller board or microcode is suspect Do the following 7 Save the printer configuration values Refer to the Use...

Page 180: ...n the printer and power it on If black squares appear on the LCD the flash memory could be blank Replace the flash SIMM in J11 with a new flash SIMM and reload code page 231 5 Make sure the controller...

Page 181: ...el cable assembly and or the operator panel as required 4 Check the shuttle for electrical shorts page 252 5 Plug in the printer and power it on If the operator panel is blank and the fans do not come...

Page 182: ...oller board or microcode is suspect Do the following 9 Save the printer configuration values Refer to the User s Manual 10 Clear NVRAM page 237 11 Download and install the latest code from IBM First p...

Page 183: ...tion of the operator panel keys If the keys do not work replace the controller board page 319 After replacing the controller board DO NOT make the printer READY but proceed immediately to the next ste...

Page 184: ...er supply operational check page 258 If the power supply fails the check replace it If it passes the check go to the next step 5 Check that AC in power cable connector P1 is connected to J1 on the pow...

Page 185: ...NVRAM page 237 6 Download and install the latest code from IBM First page 231 7 Power on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appro...

Page 186: ...NVRAM page 237 7 Download and install the latest code from IBM First page 231 8 Power on the printer in download mode and load flash memory page 238 a If you encounter loading problems go to the appro...

Page 187: ...replace the stacker operator panel If the voltages are not correct power off and unplug the printer remove the paper guide assembly and disconnect the stacker power cable from the controller board See...

Page 188: ...re that brought you to this procedure replace the controller board if it was not replaced earlier in this procedure page 319 After replacing the controller board DO NOT make the printer READY but proc...

Page 189: ...al and parallel 4 Make sure the elevator is parallel to the printer 5 Plug in the printer and power it on Operate the power stacker While the stacker is operating check that a all motors are operating...

Page 190: ...pulley setscrews and or replace damaged components as necessary 5 Check the stacker limit switches See page 191 If the limit switches are OK go to the next step 6 Check the stacker motors See page 192...

Page 191: ...tacker operator panel b If the elevator does NOT move the lower limit switch is OK Remove the magnet and go to step 4 c If the elevator moves release the ELEVATOR DOWN key power down and unplug the pr...

Page 192: ...ctor P107 from connector J3 on the back of the stacker operator panel See Figure 65 page 468 5 Disconnect stacker frame cable connector P102 from connector J4 on the rear of the stacker operator panel...

Page 193: ...re tight and the ribbon tracks straight across them Rewind or install an approved IBM ribbon If the ribbon does not track straight across the ribbon guides adjust the ribbon guides If the ribbon guide...

Page 194: ...shuttle frame assembly 13 Plug in the printer and power it on If the problem still occurs the controller board or microcode is suspect Do the following 14 Save the printer configuration values Refer...

Page 195: ...PU 7 Power on the printer Run a print test If the symptom is not gone replace the shuttle frame assembly 8 Power on the printer Run a print test If the problem reappears the controller board or microc...

Page 196: ...nt test If the problem occurs the controller board or microcode is suspect Do the following 9 Save the printer configuration values Refer to the User s Manual 10 Clear NVRAM page 237 11 Download and i...

Page 197: ...rint test If the problem occurs replace the shuttle frame assembly Incorrect output 1 Check the printer configuration for the proper values of CPI LPI print quality forms length and width 2 Refer to t...

Page 198: ...tractors and tractor door springs for damage excessive wear and equal door closing tension If either tractor is worn damaged or exhibits uneven door closing tension replace both tractor assemblies 8...

Page 199: ...Level Support 19 Run a print test If the problem occurs do the power supply operational check page 258 If the power supply fails the check replace it If it passes the check go to the next step 20 Run...

Page 200: ...replacing the controller board 3 Download the latest code from IBM First page 231 Plug in the printer and power it on in download mode and load flash memory page 238 4 Check that customer has the righ...

Page 201: ...type supported by the boot code on the original SIMM If SOURCE LARGER THAN DESTINATION appears the blank SIMM is not large enough to contain the code on the original SIMM If the SIMM does not copy or...

Page 202: ...damaged 6 Check and adjust the platen gap 7 Check the dynamic paper tension 8 If the platen gap is correct remove the shuttle frame assembly page 362 and check the following a Inspect the hammer bank...

Page 203: ...lowing 12 Save the printer configuration values Refer to the User s Manual 13 Clear NVRAM page 237 14 Download and install the latest code from IBM First page 231 15 Power on the printer in download m...

Page 204: ...values Refer to the User s Manual 6 Clear NVRAM page 237 7 Download and install the latest code from IBM First page 231 8 Power on the printer in download mode and load flash memory page 238 a If you...

Page 205: ...paper moves in both directions If the platen does not open during paper reverse the controller board or microcode is suspect Do the following 8 Save the printer configuration values Refer to the User...

Page 206: ...or hammer bank cover is damaged or deformed replace it b Inspect the paper ironer for distortion or misalignment Reposition or replace it if necessary c Make sure the paper guides are properly seated...

Page 207: ...ory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this procedure replace the controller boa...

Page 208: ...ownload mode and load flash memory page 238 a If you encounter loading problems go to the appropriate error code for resolution b If you encounter the failure or message that brought you to this proce...

Page 209: ...a print test and observe ribbon movement across the left and right ribbon guides Adjust the right and left ribbon guides if necessary 8 Observe ribbon movement at both left and right ribbon posts as t...

Page 210: ...th shuttle movement Make sure the hammer bank cover assembly is correctly installed on its mounting pegs Reinstall the hammer bank cover assembly Replace a damaged or deformed hammer bank cover assemb...

Page 211: ...ugh to permit movement of the mechanism base 2 Remove the ribbon 3 Remove the shuttle cover Check the shuttle frame assembly mounting clamp screws for looseness Torque the 5 32 inch socket head clamp...

Page 212: ...227 Soft vs Hard Reset page 228 Soft Reset page 228 Hard Reset Cycle Power page 228 Controller Board Status LEDs At Power Up page 229 Troubleshooting A New Installation page 230 Documentation page 230...

Page 213: ...ages are deleted so that the log never contains more than 50 messages Print Ribbon Log Prints the contents of the ribbon log The printer keeps a log of up to 100 previously depleted ribbons identifyin...

Page 214: ...s Hammer bank cover Power supply board Paper motion sensor or cable Paper feed belt or motor Splined shaft bearings Tractors or tractor belts Underlines An underline pattern useful for identifying ham...

Page 215: ...key allows you to test the printer 4 MENU OPERATOR MENU PRINTER CONTROL First of series of configuration menus 5 SCROLL until OPERATOR MENU OPERATOR PRINT TESTS Advances to the Operator Printer Tests...

Page 216: ...RVICE MEMORIZE IPDS DEMO SERVICE SELECT CT TYPE SERVICE SET COIL TEMPERATURE DISABLE ENABLE On printers using IPDS emulation NOTE Default Value 6500 v15 and v20 printers only Procedure on page 383 SER...

Page 217: ...Stop Bits 1 2 Serial Parity Parity None Odd Even Serial Modem Modem Disable Enable Serial Modem NVM Modem NVM Enable Disable Serial Modem Status Modem Status Enable Disable Serial Dial Method Dial Me...

Page 218: ...test to check ribbon tracking and reversing Hammer Phasing A hammer timing parameter that permits you to adjust the vertical alignment of dots in character printing End of Forms Adjust A vertical comb...

Page 219: ...ges are deleted so that the log never contains more than 50 messages Print Partial Line If the final line of a data stream has no line feed or carriage return character it is retained in the buffer DI...

Page 220: ...STS Burn In Test Press ENTER to view the different mechanism tests 5 SCROLL until PRINTER MECHANISM TESTS Plot Test Cycles through list of tests Stop when your test displays 6 RETURN ENTER OPERATOR ME...

Page 221: ...Boot Diagnostics Menu 1 Set the printer power switch to O off 2 Press and hold down the EJECT and STOP keys 3 While holding the EJECT and STOP keys set the printer power switch to 1 on 4 When BOOT DIA...

Page 222: ...12 Sep 03 ENTER DIAGNOSTICS MENU FILE SYSTEM FILE SYSTEM MENU VIEW FILES ENTER VIEW FILES 93779 sf Continued on next page VIEW FILES FILENAME FILE SYSTEM MENU FILE STATISTICS FILE SYSTEM MENU OPTIMIZ...

Page 223: ...DISABLE RAM TEST MMU OFF EC NO DC WR S2 B ENTER CACHE CONT MENU INSTRN CACHE OFF CACHE CONT MENU DATA CACHE ON CACHE CONT MENU INSTRN CACHE ON ENTER ENTER ENTER ENTER CACHE CONT MENU ALL CACHE ON ENT...

Page 224: ...indicates an active Paper Instruction PI line and a blank space 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...

Page 225: ...RATOR MENU UNLOCKED Relocks the ENTER key 12 START READY Puts printer in READY mode 13 Send a file from the host computer The printer outputs a hex dump Refer to the ASCII chart on page 447 14 When th...

Page 226: ...Information Menu Installed Memory Displays the amount of RAM in Megabytes installed in the printer Power on Time The cumulative time in hours that the printer has been powered on The range is 0 to 30...

Page 227: ...bon load paper and power on the printer 2 STOP NOT READY Puts printer in NOT READY mode 3 RETURN ENTER OPERATOR MENU UNLOCKED Unlocking the ENTER key gives you access to the configuration menus 4 MENU...

Page 228: ...ation 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 the...

Page 229: ...r up the amber LED will blink continuously At power up printer hardware also turns on the green LED See Figure 10 If a problem is detected with the software stored in the printer s flash memory both t...

Page 230: ...many system configurations and parameter options that configuring a printer can be challenging to those who do not do it often Check the customer s host interface to the printer and make sure the pri...

Page 231: ...use the same identification sequence number This permits the ribbon to be flipped over and re used one time while the system recognizes and tracks it as a new ribbon installation In this manual new ri...

Page 232: ...rement or decrement corresponds to a predetermined set value density Pressing SCROLL or RIGHT changes the value by one increment per key press The second line of the display changes to show the action...

Page 233: ...million characters Conversely decrementing the Lighter setting decreases the density which increases the yield Each Lighter decrement increases the yield by an additional percentage For example Light...

Page 234: ...led on either the left or right ribbon hub the software assumes that the full spool will be installed on the right hand hub The new ribbon detection routine runs after printer power is restored as par...

Page 235: ...ever installed on a particular printer is printed in the log for review The log also captures any attempts to run Unknown1 or Unknown2 ribbons This information is recorded in the log as Ribbon Not Rec...

Page 236: ...e type and click on the icon This will take you to the 6500 microcode page 8 Under the 6500 All Models tab find the code you need in the list move your mouse pointer so it points to the icon of the ne...

Page 237: ...ight or left to DIAGNOSTICS MENU MISC TOOLS and press the ENTER key 8 Scroll right or left to MISC TOOLS MENU ERASE ALL NVRAM and press the ENTER key 9 The operator panel will then display ERASE ALL N...

Page 238: ...has the ethernet Network Interface Card NIC installed NOTE To load software through the ethernet port page 248 you must know the IP Address of the printer and the flash memory must be operational and...

Page 239: ...ommand is different if you use this port so make sure you use the LPT2 commands in step 15 8 Connect the data cable to the appropriate I O port of the printer 9 Plug the AC power cord into the printer...

Page 240: ...file has successfully loaded into memory and the printer has reset itself set the printer power switch to O off 18 Unplug the AC power cord from the printer 19 Power off the personal computer 20 If yo...

Page 241: ...AM NOT VALID Printer cannot find the data controller program or the validation checksum is corrupted Download the program again Power off the printer and start over at step 11 If the message occurs ag...

Page 242: ...he appropriate error code for resolution b If you encounter the failure or message that brought you to this procedure replace the controller board page 319 Do NOT make the printer READY but proceed im...

Page 243: ...er at step 11 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 program...

Page 244: ...priate error code for resolution b If you encounter the failure or message that brought you to this procedure replace the controller board page 319 Do NOT make the printer READY but proceed immediatel...

Page 245: ...lash memory in order to run the downloaded program Add flash memory or use a smaller emulation program ERROR PROGRAM NOT COMPATIBLE The printer is not compatible with the downloaded program Use the co...

Page 246: ...tion values Refer to the User s Manual 3 Clear NVRAM page 237 4 Download and install the latest code from IBM First page 231 5 Power on the printer in download mode and load flash memory page 238 a If...

Page 247: ...but the checksum did not match The data were corrupted during download Download the program again Power off the printer and start over at step 11 ERROR OCCURRED FLUSHING QUEUES An interim message tha...

Page 248: ...hout releasing the keys power the printer on When you see B30 STATUS INITIALIZING on the on the LCD release the keys 5 Wait until you see WAITING FOR DOWNLOAD on the LCD before proceeding This can tak...

Page 249: ...administrator 11 At the password prompt press Enter 12 Once logged in type the following sequence at the command prompt to download the filename prg file to the printer cd dest Enter cd d1prn Enter b...

Page 250: ...remove covers and install a new security key on the controller board The SPX is used at power up only and is not left in the printer during normal operation Because it is a single use disposable item...

Page 251: ...at the rear of the printer 9 Press the ENTER key The printer will reboot itself and you may resume normal printing 10 You may need to download the emulation if the emulation supported by the SPX is no...

Page 252: ...r Ohmmeter to the 10K Ohm scale or the scale closest to 10K Ohms 7 Hold the two meter leads apart from each other not touching anything and note how your meter indicates an open circuit For example so...

Page 253: ...for shorts to ground If you find any shorts to ground replace the hammer bank power cable 6 Disconnect the common meter lead from the shuttle frame 7 Check the hammer bank power cable for shorts by c...

Page 254: ...Intermediate Cables Operator Panel Assembly Intermediate Cable Power Stacker Logic and Power Intermediate Cables The Procedure 1 Prepare the printer for maintenance page 313 2 Disconnect the cable to...

Page 255: ...o the next section which checks for pin to pin shorts Check for pin to pin shorts 10 Disconnect the common usually black meter lead from the ground point 11 Check for shorts within the cable by touchi...

Page 256: ...ors wait until the motor has cooled to room temperature then use the table to test for winding continuity and for no shorts between windings and the motor frame Rotate the motor by hand and test for s...

Page 257: ...n cabinet models Magnetic Pick up Unit MPU Shuttle Motor Intermediate Cable Hammer Bank Power and Logic Intermediate Cables Operator Panel Assembly Intermediate Cable Power Stacker Logic and Power Int...

Page 258: ...can be attached to the power supply just to how long you should hold down the push button 1 Prepare the printer for maintenance page 313 2 Cabinet Model Remove the paper guide assembly page 348 Pedest...

Page 259: ...Supply Tester Connector P101 Controller Board Connector J101 Power Supply Tester Load Block Can become warm when used continuously Power Supply Board Stacker Power Cable Only on cabinet models with t...

Page 260: ...t It should be 8 1 to 9 4 volts 18 Release the Push Button 19 If you must measure voltages again for each minute you held the Push Button down wait at least two minutes with the Push Button released T...

Page 261: ...acker power cable or connector J101 on the controller board Figure 12 25 Cabinet Model Remove the paper guide assembly page 348 Pedestal Model Remove the top cover assembly page 327 26 Return the prin...

Page 262: ...00 Figure 39 item 2 Cover Assembly Top Pedestal Model page 398 Figure 38 item 9 Dashpot page 396 Figure 37 item 5 Doors Cabinet page 392 Figure 35 item 5 Ethernet Interface Assembly page 423 Figure 49...

Page 263: ...re 45 item 7 Platen Stop Assembly and Forms Thickness Lever page 413 Figure 45 item 15 Resistors Terminating page 356 Figure 22 Ribbon Guide Assembly L R page 416 Figure 46 item 11 Ribbon Hub page 416...

Page 264: ...20 page 279 IBM Coax Twinax Expansion Board for PSA3 Controllers page 280 SureStak Power Stacker PCBA page 281 Cable Routing Cabinet Model page 282 Cable Routing Pedestal Model page 283 Cable Assembly...

Page 265: ...U page 298 Cable Assembly Ribbon Guide page 299 Cable Assembly Ribbon Motor Extension page 300 Cable Assembly Shuttle Motor Drive page 301 Frame Cable Power Stacker page 302 Logic Cable Power Stacker...

Page 266: ...266 Interconnection Diagram AC Power On Off Switch 5V Remote RibbonMinder Sensor Primary Earth Ground PSA3 Controller HBL...

Page 267: ...V 48V 5V 5V 48V 48V 24V 48V 8 5 48V 8 5V 5V 5V 48V 48V 5V Primary Earth Ground P101 1 2 3 4 5 6 7 8 9 10 11 12 N AC FAIL N STBY 5V 5V 5V RET LOGIC GND 5V RET LOGIC GND 5V RET LOGIC GND 5V RET LOGIC GN...

Page 268: ...r board An open circuit current sense resistor on the controller board will prevent the fan from running but will not allow software to detect the fault Device P106 Pins Normal LRIB M 2 4 and 6 8 7 2...

Page 269: ...RIB L4 CC FAN L RBN POST CC FAN L RBN POST POD A PMD A POD K PMD K POD C PMD C POD E PMD E 48V 01 10 100V F 1 J101 2 3 4 5 6 7 8 9 10 Power Supply 470 PF 10 50V 11 12 470 PF 10 50V 8 5V 48V VCC1 N TE...

Page 270: ...k Logic HMR DAT RET HMR CLK RET CMD DAT RET DMD CLK RET HMR CLK CMD DAT CMD CLK COIL 50 MHz 10V SW 01 10 50V F COIL 50 MHz 1 J120 2 3 4 5 6 7 8 9 10 C167 DB TXD EC Diagnostics PPR TRIG FT EVENT SHUT D...

Page 271: ...25 1 2 J28 J1 J28 J25 J20 J8 J23 J4 J16 1 J122 2 3 4 BC DATA LED CTRL VCC RibbonMinder Sensor 1 J102 2 External Power 1000 PF 10 50V 500 Ohm VCC1 10 10 16V 1000 PF 10 50V F 0 1 20 16V F 4 7 K 0 1 W U5...

Page 272: ...DTR DSR RTS CTS Host RS232 7 8 NC NC NC V TXC C V RXD C 1 2 3 J116 Shuttle Drive SHUT A SHUT B SHUT C 1 J110 2 3 4 5 6 N FP DATA AVAIL Operator Panel 470 PF 10 50V 7 8 FP CLK N FP LED WR FP DATA N FP...

Page 273: ...DIODE 4 N COILTEST CABLE DET HD SENSE LDFB Phase Driver Port 1 J6 2 3 4 5 6 7 8 9 10 NC NC SDA 1 J2 2 3 4 5 6 7 8 9 10 CPLD Program Port VCC RN7 1K RN7 1K RN7 1K NC NC NC RN7 1K LC TCK LC TDI LC TMS L...

Page 274: ...AD28 AD26 GND AD24 IDSEL 3 3V AD22 AD20 GND AD18 AD16 3 3V NFRAME GND NTRDY GND NSTOP 3 3V RSV RSV GND PAR AD15 3 3V AD13 AD11 GND AD9 GND GND NC BE0 3 3V AD6 AD4 GND AD2 AD0 3 3V I2CCLK 5V 5V RSV RS...

Page 275: ...AD28 AD26 GND AD24 IDSEL 3 3V AD22 AD20 GND AD18 AD16 3 3V NFRAME GND NTRDY GND NSTOP 3 3V RSV RSV GND PAR AD15 3 3V AD13 AD11 GND AD9 GND GND NC BE0 3 3V AD6 AD4 GND AD2 AD0 3 3V I2CCLK 5V 5V RSV RS...

Page 276: ...16 17 18 19 20 VCC1 Centronics Connector 21 22 23 24 25 26 27 28 29 30 10K 0 1W 31 32 33 34 35 36 37 38 39 40 1 4 7K 0 1W CHASSIS GND N STROBE P1 P2 P3 P4 P5 P6 P7 P8 N ACK BUSY PAPER EMPTY SELECT N I...

Page 277: ...G TERMINAL FAST ON TERMINAL 1 2 3 4 5 6 7 8 9 10 11 12 N TEMP N STDBY P101 White Orange Red Red Black Black Brown Brown Yellow Yellow Blue Blue 5V 5V 5V RTN 5V RTN 48V RTN 48V RTN 8 5V 8 5V 48V 48V AC...

Page 278: ...C AC COMMON CHASSIS GND Line Filter Area 1 2 3 4 5 6 7 8 9 10 11 12 NACFAIL Not AC Fail NSTBY Not Standby 5 Volts 5 Volts 5 Return Logic GND 5 Return Logic GND 48 8 5 Return 48 8 5 Return 8 5 Volts 8...

Page 279: ...5 Volts 5 Return Logic GND 5 Return Logic GND 48 8 5 Return 48 8 5 Return 8 5 Volts 8 5 Volts 48 Volts 48 Volts 1 2 3 4 5 6 7 8 9 10 PH1 PH2 PH3 PH4 LDFB Phase Driver Power Chassis GND 1 Phase Driver...

Page 280: ...ers 1 J2 2 3 4 5 6 7 8 9 10 Twinax Connection TWINAX PHASE A 11 12 13 14 15 16 17 TWINAX PHASE B NC NC NC NC NC NC NC NC NC NC NC NC 01 10 500V F 1 J3 2 Coax Connection COAX DATA COAX SHIELD 9400 pF 1...

Page 281: ...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 RESET 9 10 J1 Test N...

Page 282: ...282 Cable Routing Cabinet Model...

Page 283: ...283 Cable Routing Pedestal Model...

Page 284: ...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 assembly you must install the ferrite clamp See...

Page 285: ...285 Cable Assembly Centronics Dataproducts Adapter 14H5522...

Page 286: ...286 Cable Assembly 5V Remote Power 14H5589 To Controller Board...

Page 287: ...ield 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 0 0 0 38F8254 NOTE If the printer has a PSA3 controller and power stacker Smart T Ca...

Page 288: ...288 Cable Extension Smart T 75P2813 NOTE If the printer has a PSA3 controller and power stacker this cable extension is also required See also Figure 51 on page 427 Pin 1 Pin 1...

Page 289: ...289 Cable Assembly PS I O 2000 75P1614 To Power Supply To Controller Board NOTE This cable is used only on the 6500 v20...

Page 290: ...290 Cable Assembly AC In Power Supply To Power Supply J1 To Circuit Breaker Part of AC Kit 14H5289...

Page 291: ...291 Cable Assembly AC Power Input To Circuit Breaker Input Power Connector Part of AC Kit 14H5289...

Page 292: ...292 Cable Assembly Card Cage Fan PIN 1 PIN 1 14H5285...

Page 293: ...293 Cable Assembly Operator Panel PIN 1 PIN 1 PIN 8 PIN 8 Gray Brown Gray Brown 14H5300 To Controller Board To Operator Panel...

Page 294: ...294 Cable Assembly Exhaust Fan PIN 1 PIN 1 14H5286...

Page 295: ...tor is included on newer cable assemblies which protects the shuttle end of the cable from chafing and abrasion A bag of 10 protectors is available under part number 75P8157 which also includes instal...

Page 296: ...ower Wire Table P05 P105 2 1 1 2 4 3 3 4 6 5 5 6 8 7 7 8 10 9 9 10 39U2533 To Shuttle To Controller Board IMPORTANT Use this cable on all Infoprint 6500 printers except the 6500 v20 On the 6500 v20 us...

Page 297: ...ower 02N6214 To Shuttle IMPORTANT Use this cable on the 6500 v20 printer On all other Infoprint 6500 printers use 39U2533 shown on the previous page P06 P3 To Power Supply Wire Table P06 P3 2 1 1 2 4...

Page 298: ...298 Cable Assembly MPU PIN 1 PIN 3 PIN 2 PIN 1 14H5329...

Page 299: ...299 Cable Assembly Ribbon Guide Pin Connection P106 LRP P107 RRP Wire Color Pin 1 Black Pin 2 Black Left Guide P106 LRP Right Guide P107 RRP 39U2539 Left 39U2540 Right Pin 1 Pin 2...

Page 300: ...300 Cable Assembly Ribbon Motor Extension 63H7464...

Page 301: ...301 Cable Assembly Shuttle Motor Drive 14H5330 To Shuttle To Controller Board...

Page 302: ...302 Frame Cable Power Stacker 10R3912...

Page 303: ...303 Logic Cable Power Stacker 10R4590...

Page 304: ...304 Power Cable Power Stacker 57P1376 P1101 P1101...

Page 305: ...305 Vertical Rail Cable Power Stacker 10R3913...

Page 306: ...306 Elevator I O Cable Power Stacker 10R4053...

Page 307: ...307 Fan Assembly Hammer Bank P107 HBF P107 HBF 14H5159...

Page 308: ...308 Magnetic Pickup MPU Assembly 57G1476 P03...

Page 309: ...309 Switch Assembly Paper Detector Standard 14H5281 Black Back Forms Kit 02N7169...

Page 310: ...310 Switch Assembly Platen Interlock P107 PLO 14H5280...

Page 311: ...dures begin on page 368 Part numbers for replacement parts are listed in the Parts Catalog which begins on page 390 Tools And Materials You need the following tools and materials to service the printe...

Page 312: ...902 Screwdriver Phillips 1 73G5362 Screwdriver Phillips 2 73G5363 Spring Hook Heavy Duty Tie Wraps 75X5972 Torque Screwdriver Adapter 39F8449 Torque Screwdriver Hex Adapter 3 32 inch 39F8451 Torque Sc...

Page 313: ...ord from the AC power source 3 Disconnect the host data cable from the printer interface 4 Open the printer cover 5 Unload paper 6 Read the entire adjustment procedure before you begin working on the...

Page 314: ...the host data cable to the printer interface 2 Load paper 3 Plug the AC power cord into the power source 4 Close the cabinet doors 5 Power on the printer 6 Set the top of form Refer to the User s Man...

Page 315: ...e frame assembly It is not field repairable Hammer spring assemblies are the only replaceable components of the shuttle frame assembly List Of Procedures Belt Paper Feed Timing page 317 Belt Platen Op...

Page 316: ...Platen page 350 Platen Stop Assembly and Forms Thickness Lever page 354 Resistors Terminating page 355 Ribbon Guide Assembly L R page 357 RibbonMinder Sensor page 358 Security Key page 339 Shaft Splin...

Page 317: ...ey Installation 1 Work the paper feed timing belt onto the paper feed motor pulley and the splined shaft pulley 2 Using the straight end of a force gauge apply 15 pounds 66 7 N of pressure to the pape...

Page 318: ...pen 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 shaft and tighten the pulley setscrew ATTENTION...

Page 319: ...cable connector J201 6 Remove any attachment cards if equipped 7 Save any standoff connections if equipped 8 Loosen but do not remove the screw securing the controller shield to the bottom of the card...

Page 320: ...4 Tighten the screw securing the controller shield to the bottom of the card cage 5 Connect all cable connectors to the controller board See page 406 6 Cabinet Model Install the paper guide assembly p...

Page 321: ...the screws securing the power supply board to top rear wall of the card cage See page 406 item 15 5 Grasp the power supply by the handling loops tilt it forward and lift it out of the printer Installa...

Page 322: ...spring clips and 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 47 page 419 Pedest...

Page 323: ...om four wire connectors in a connector shell 5 Disengage the lock tab s on the cable connector from the slots in the side of the connector shell 6 Remove the cable connector from the connector shell R...

Page 324: ...spacer 8 6 4 2 7 5 3 1 12 10 20 18 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...

Page 325: ...st the hammer bank can break hammer tips 1 With the thick plate facing the hammer bank hold the hammer bank cover assembly at a slight angle and engage the bottom edge on the alignment pins First enga...

Page 326: ...ilt 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 the...

Page 327: ...f the top cover and the screw just to the right of the operator panel bracket See Figure 38 page 398 item 14 4 Loosen do not remove the two 2 Phillips hold down screws on the rear of the printer See F...

Page 328: ...rod uppermost 1 Position the dashpot against the ball studs on the upper and lower brackets with the narrow rod uppermost See page 396 Figure 37 2 Push the dashpot onto the ball joints and install th...

Page 329: ...plate to the rear of the card cage See page 423 item 4 5 Angle the NIC out of the card cage cutout as you lift the NIC off the expansion connector on the controller board See page 423 item 1 Installat...

Page 330: ...exhaust duct 6 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 Inst...

Page 331: ...el Remove the two fan mounting screws from the bottom of the fan See Figure 46 page 416 item 2 Pedestal Model Remove the four fan mounting screws and nuts See Figure 41 page 404 items 1 through 4 5 Re...

Page 332: ...ase casting and the base pan See Figure 46 page 416 Installation ATTENTION Install the fan so the label faces up Air flow is UP NOTE The hammer bank fan assembly is installed by angling it down and un...

Page 333: ...e damage or broken parts can be seen in the assembly 5 Remove the mounting screws from the old hammer spring assembly See Figure 16 page 334 6 Handling the hammer spring assembly by the mounting base...

Page 334: ...a hammer spring assembly from the hammer bank NOTE The 6500 v15 hammer bank is shown here Although the number of hammer springs and mounting screws varies among printer models removal and installation...

Page 335: ...the hammer bank mounting pins then gently press the mounting base down against the alignment pins See Figure 17 page 336 4 Continue pressing down on the mounting base of the the new hammer spring asse...

Page 336: ...e screws to 14 inch pounds 1 58 Newton meters New Hammer Spring Assembly NOTE The hammer spring assembly shown here is for a 6500 v15 printer Although the number of hammer springs and mounting screws...

Page 337: ...he coax twinax I O plate to the rear of the card cage See Figure 48 page 421 item 4 4 Carefully work the PCI CT board upward and out of the expansion slot on the controller board See Figure 48 page 42...

Page 338: ...6F1661 2 Using a feeler gauge adjust 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 18 2 inch pounds 2 03 0 23 N m 3 Check the gap bet...

Page 339: ...e with the hand wearing the wrist strap before you touch memory modules or the controller board 5 Remove the flash SIMM by gently opening the side locks angling the memory module upward and removing i...

Page 340: ...u must download the emulation again 3 Insert the flash SIMM into socket J11 on the controller board at about a 45 degree angle Position the flash SIMM with the notched end toward the right side of the...

Page 341: ...8 MB 8MB 8 MB 8 MB 8 MB 8 MB 8 MB 8 MB SDRAM Permanent Installation 32 MB 32 MB 32 MB 32 MB 32 MB 32 MB 32 MB 32 MB 32 MB 32 MB 32 MB CT Installed No No No No No Yes Yes Yes Yes Yes Yes Memory Requir...

Page 342: ...uring the heat sink to the paper feed motor Remove the heat sink and retain it for installation on the new paper feed motor 5 Loosen the paper feed motor mount screws page 416 Figure 46 item 10 6 Trac...

Page 343: ...ork the paper feed timing belt onto the paper feed motor pulley and the splined shaft pulley 5 Using the straight end of a force gauge apply 15 pounds 66 7 N of pressure to the paper feed drive motor...

Page 344: ...e 413 Figure 45 item 24 5 Using a 5 32 inch hex key loosen the upper motor mount screw page 416 Figure 46 item 24 6 Trace the platen open motor cables back to connector P106 on the controller board re...

Page 345: ...ate the motor all the way forward and install the platen open belt and motor pulley 5 Connect the platen motor cable connector to connector shell P106 6 Connect shell connector P106 to the controller...

Page 346: ...tor page 416 Figure 46 4 Lift and rotate the 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 Lift the motor...

Page 347: ...96 4 Remove the two screws securing the operator panel to the panel bracket 5 Remove the operator panel assembly from the panel bracket Installation 1 Engage the slot on the bottom of the operator pan...

Page 348: ...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 Figure 19 2 Slide the paper guide assembly to the rig...

Page 349: ...the front of the printer 1 Position the paper ironer so that the black tape is on the side that faces the paper detector switch assembly See page 413 Figure 45 item 3 2 Push the paper ironer down int...

Page 350: ...ling the assembly off the platen shaft See page 413 Figure 45 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 a...

Page 351: ...ism base platen seat See Figure 21 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 Inst...

Page 352: ...assembly attached onto the platen shaft and up against the right side plate b Install the Phillips 1 screw and washer securing the switch and bracket 11 Install the black metal washer onto the left si...

Page 353: ...he platen stop assembly onto the right side platen shaft pressing the interlock switch out of the way as the lever slides past it Tighten the 7 64 inch clamp screw See Figure 45 page 413 Open and clos...

Page 354: ...p assembly off the platen shaft See page 413 Figure 45 items 12 through15 Installation 1 Install the platen stop assembly on the right hand platen shaft pressing the interlock switch out of the way as...

Page 355: ...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 313 2 Cabinet Model Rem...

Page 356: ...ure 22 This figure shows the size and location of the terminating resistors on the controller board Resistor Kit 14H5525 Default 470 Ohm Alt 1 220 Ohm Alt 2 1K Ohm Default 1K Ohm Alt 1 330 Ohm Alt 2 N...

Page 357: ...de disconnect connector shell P106 from the controller board For the right ribbon cable disconnect connector shell P107 from the controller board 6 Trace the ribbon guide wires to the connector shell...

Page 358: ...base casting See page 413 Figure 45 items 28 and 29 4 Trace the sensor cable back to the controller board noting the cable routing and releasing the cable from restraints as necessary 5 Disconnect the...

Page 359: ...the left and right tractors Position the tractor belts so the alignment marks are at the top on both tractors See Figure 23 2 Grasping the vertical adjustment knob slide the splined shaft through the...

Page 360: ...Install the static brush assembly 10 Return the printer to normal operation page 314 Figure 23 This figure shows how to install the splined shaft into the paper feed tractors Splined Shaft NOTE Align...

Page 361: ...and 10 Installation 1 Slide the support shaft into the right side plate and through the lower holes in the tractors See page 411 items 9 10 and 11 2 Slide the support shaft through the left side plat...

Page 362: ...tor page 406 Figure 42 6 Disconnect the hammer drive and hammer logic cables connectors from the terminator board on the shuttle frame assembly 7 Loosen the side 5 32 inch socket head clamp screws and...

Page 363: ...he 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 30 2 inch pound...

Page 364: ...326 4 Unhook the extension spring from the spring lugs on the hammer bank and shuttle frame See Figure 43 page 409 Installation 1 Put a dab of IBM 20 bearing lubricant on both spring lugs ATTENTION Ma...

Page 365: ...emove 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 b...

Page 366: ...from the cutout in the right side plate Installation 1 Fully close the forms thickness lever position A 2 Position the platen interlock switch assembly on the switch bracket and install finger tight t...

Page 367: ...e page 313 2 Remove the splined shaft page 359 3 Remove the support shaft page 361 4 Remove the tractors Installation 1 Using the replacement tractors install the support shaft page 361 2 Install the...

Page 368: ...a removal installation procedure List Of Adjustments Belt Paper Feed Timing Adjustment page 369 Belt Platen Open Adjustment page 371 Paper Scale Alignment page 373 Platen Gap Adjustment page 374 Ribbo...

Page 369: ...e gauge apply 15 pounds 66 7 N of pressure to the paper feed drive motor 3 near the mounting base of the motor Use the splined shaft 4 to steady the gauge 6 Reduce tension to 12 pounds 53 4 N and torq...

Page 370: ...djustment Figure 24 370 Legend 1 Timing Belt Shield 2 Motor Mount Bolt 2 3 Paper Feed Drive Motor 4 Splined Shaft Figure 24 This figure shows how to adjust the paper feed timing belt 1 2 3 4 2 A Direc...

Page 371: ...s 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 Th...

Page 372: ...Belt Platen Open Adjustment Figure 25 372 Legend 1 Belt Cover 2 Motor Mount Screw 2 3 Platen Open Motor Shaft Figure 25 This figure shows how to adjust the platen open belt A 1 3 2 3 16 inch A...

Page 373: ...operator print tests page 213 7 Check alignment of the scale to the print at column positions 1 and 136 8 If adjustment is necessary loosen the three button head 5 64 inch hex screws 2 9 Position the...

Page 374: ...ution of the set screw Also insert the feeler gauge no more than two inches down from the top of the ribbon mask 8 Gently close the forms thickness lever 2 As the platen is closing gently slide the fe...

Page 375: ...Knob 2 Forms Thickness Lever 3 Feeler Gauge 0 012 inch or 0 30 mm 4 Hammer Bank Cover 5 Ribbon Mask 6 Set Screw 3 32 inch hex 2 Figure 27 This figure shows how to adjust the platen gap A 1 A NOTE Lef...

Page 376: ...SM TESTS Shuttle Slow page 216 6 On the ribbon guide to be adjusted momentarily short between the ribbon guide skid screws 1 to verify that the ribbon reverses 7 Observe how the ribbon 2 passes around...

Page 377: ...e Alignment Figure 28 377 Legend 1 Screw Skid 2 2 Ribbon 3 Steel Washer 4 Screw Retaining 2 Figure 28 This figure shows how to align Ribbon Guide Alignment A B Left Ribbon Guide Right Ribbon Guide 2 4...

Page 378: ...nting with multi part forms The procedure below describes how to run the END OF FORMS ADJUST printer test and modify the END OF FORMS ADJUSTMENT VALUE 1 Power on the printer 2 Load paper and set the t...

Page 379: ...ou 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 12 12 Me...

Page 380: ...s 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 OF...

Page 381: ...ith 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 I...

Page 382: ...correct and correct H patterns to illustrate vertical misalignment of text characters 15 When the print pattern is acceptable press STOP Printing stops and the printer automatically enters the current...

Page 383: ...er is in the READY state press the STOP key The printer must be in the NOT READY state to do this procedure 4 Press MENU CONFIG SCROLL SCROLL Press all four keys at the same time SERVICE PRINTER MECHA...

Page 384: ...y will go 4 Prepare a length of 14 inch wide paper consisting of three sheets that are still attached at the perforations The paper must be single part 18 lb maximum weight 0 0036 inch maximum thickne...

Page 385: ...note the maximum force exerted on the scale Do not pull any page perforations through the print station See Figure 33 Figure 33 This figure shows how to use the fish scale to measure paper tension 9...

Page 386: ...over is damaged or deformed replace it b Inspect the paper ironer for distortion or misalignment Reposition or replace it if necessary c Make sure the paper guides are properly seated on the splined a...

Page 387: ...etent at a time Over tightening a tractor belt can cause other paper feed problems and result in premature wear in the tractors 4 On the inner side of the left tractor use a Torx T 10 driver to rotate...

Page 388: ...ent 388 Figure 34 This figure shows how to adjust the tension of a tractor belt A A The arrow points to a LH left or a RH right tractor Left tractor is shown here Left Tractor One Click and Test Right...

Page 389: ...6 Press 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 diagn...

Page 390: ...nd Chains page 394 NOTE Parts for the power paper stacker are shown and listed in Appendix E Figure 37 Operator Panel and Cabinet Details page 396 Figure 38 Pedestal Details including Shipping Kit pag...

Page 391: ...own 391 Figure 48 IBM Coax Twinax Expansion Board page 421 Figure 49 Ethernet Interface Assembly page 423 Figure 50 RS 422 Interface page 425 Figure 51 Twinax Extension Cable page 427 Figure 52 Dipole...

Page 392: ...392 Figure 35 This illustrated parts breakdown shows the top cover doors casters and shipping kit on a cabinet model 1 2 3 4 5 6 7 13 8 12 9 14 15...

Page 393: ...Caster with Brake Two at front 7 57G1486 Caster without Brake Two at rear 8 39U2477 Logo IBM Infoprint 6500 9 30H4008 Wire Rope Front and Rear One on each door Rear not shown in Figure 35 10 30H3986 2...

Page 394: ...394 Figure 36 This illustrated parts breakdown shows the passive paper stacker and paper chains in a cabinet model 6 5 7 1 8 3 2 4 9 10 11 4...

Page 395: ...6 32 x 0 875 4 5 14H5296 Spares Kit Grommet 6 14H5272 Chain Assembly Kit Kit contains eight chains 7 57G7260 Power Cord U S 8 Ref Grommet Power Cord 2 Included in item 5 9 39U2545 Field Kit Tray Cab R...

Page 396: ...396 Figure 37 This illustrated parts breakdown shows the operator panel and cabinet details in a cabinet model A A 1 3 6 5 7 8 6 6 9 2 4 10 11 12...

Page 397: ...Panel Overlay Dutch Operator Panel Overlay Brazilian Portuguese Operator Panel Overlay Polish 3 Ref Screw Hex w Lock Washer 2 6 32x 375 4 14H5300 Cable Assy Operator Panel 5 57G1481 Dashpot Kit Inclu...

Page 398: ...398 Figure 38 This illustrated parts breakdown shows the main assemblies of a pedestal model and the shipping kit 5 6 10 7 1 9 3 8 4 11 2 12 13 14 15 17 19 18...

Page 399: ...Grey 7 39U2481 Field Kit Caster Kit Ped 8 39U2507 Window Top Cover 9 39U2482 Housing Pedestal V3 10 Ref Screw 4 10 32x 625 11 63H5118 Paper Tray 12 28P0595 Paper Fence Rear Ped 13 39U2541 Rear Acousti...

Page 400: ...400 Figure 39 This illustrated parts breakdown shows the inside covers and card cage of a cabinet model 1 2 3 4 5 6 7 8 9 10 11 3...

Page 401: ...4 6 32x 25 4 Ref Barrier Shield 5 57P1746 Paper Path V3 All cabinet models 6 Ref Screw w Lock Washer 3 6 32x 25 and 6 Flat Washer 7 54P1379 Platen Paper Feed Cover Kit Paper feed belt cover shown in F...

Page 402: ...402 Figure 40 This illustrated parts breakdown shows the inside covers and card cage of a pedestal model See Figure 41 page 404 A 3 4 3 5 1 2 8 6 7 5...

Page 403: ...Screw Captive 2 10 24x 62 with O ring 125x 250x 06 3 Ref Screw Thread Forming 4 6 32x 25 4 Ref Barrier Shield 5 Ref Power Supply Shield Taped to card cage along upper edge 6 57G1468 Belt Timing 050P...

Page 404: ...n assembly and circuit breaker on a pedestal model From Figure 40 page 402 Rotated 180 degrees 5 A To IEC 320 AC Power Input Connector J301 White Wire To Connector P1 Black Wire To IEC 320 AC Power In...

Page 405: ...t 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 Ref Card Cage P...

Page 406: ...and the circuit boards inside the card cage To J02 Shuttle Motor To J03 MPU To the Terminator Board on the Shuttle Frame Assembly Two places Exploded to show assembly Do not remove the holddown clamp...

Page 407: ...ring Assembly 10 Hammer Spring Assembly 15 Hammer Spring Assembly 20S Model v05 and v5P Model v05 and v5P Model v10 and v1P Model v10 and v1P Model v15 Model v15 Model v20 Model v20 Model v05 and v5P...

Page 408: ...See also page 293 14 14H5211 Clamp Shaft Receiving 15 Ref Screw Captive Power Supply 3 16 75P2810 10R4054 SIMM Flash Memory 8 MB SIMM Flash Memory 16 MB Must install in slot J11 J10 is not used See a...

Page 409: ...wn shows the magnetic pickup unit MPU and extension spring 21 Make sure the extension spring does not touch the MPU cable after installation Spring Lug Do not remove grease Spring Lug Do not remove gr...

Page 410: ...Description Notes 1 57G1476 Magnetic Pickup Assy MPU 2 Ref Screw Socket Cap 6 32x 38 3 30H3985 Spring Hammer Bank 4 14H5329 Cable Assembly MPU 5 Ref MPU Cable Connector P03 6 10R4587 Anti Rotation Spr...

Page 411: ...NT The barrier panel is removed in this illustration to more clearly illustrate the mounting hardware of the tractor shafts In order to preserve correct alignment of the side plates however the barrie...

Page 412: ...THK SS 6 39U2510 Splined Shaft Assembly Blue Handle 7 Ref Screw Socket Cap 6 32x 312 Trilob Self Tapping 8 Ref Plate Tractor Shaft Right 9 57P1181 Support Shaft 10a 10b 39U2543 39U2544 Tractor Set Wit...

Page 413: ...er assemblies 13 12 11 14 15 16 19 18 17 NOTE Black tape faces paper motion detector NOTE Item 25 Platen Hardware Kit 1 2 4 3 5 6 7 8 8 9 10 24 23 18 21 17 26 16 20 22 NOTE Models 6500 v15 and v20 onl...

Page 414: ...Ref Washer Flat 2 Part of item 25 9 Ref Screw 2 Part of item 11 10 Ref Washer Flat 4 2 Part of item 11 11 39U2509 Platen Switch Kit Platen Interlock Switch 12 Ref Screw Socket Cap 6 32x 75 Part of ite...

Page 415: ...r Kit Platen open belt cover shown in Figure 45 Paper feed belt cover page 400 item 7 25 10R3798 Platen Hardware Kit 26 Ref Platen Washer Part of item 25 27 75P8169 Paper Ironer Auxiliary Models v15 a...

Page 416: ...arts breakdown shows the motors cooling fans and the paper detector switch 1 2 13 15 16 14 12 6 9 5a 2 4 3 17 18 A See detail above 7 8 10 11 Install screws here Route cable under base casting Hammer...

Page 417: ...or Assy Model v20 Model v20 only Re use the original heat sink Install it on the motor base and torque the mounting screws to 18 inch pounds 2 03 N m 6 Ref Motor Pulley Platen Open Driver Part of item...

Page 418: ...14H5159 54P1454 Hammer Bank Fan Assembly All Except v20 Hammer Bank Fan Assembly Model v20 Air flow is up Air flow is up 19 Ref Screw Socket Cap 10 24x 75 20 Ref Post Platen Belt Spring 21 Ref Spring...

Page 419: ...abinet models To IEC 320 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 A A B See inside detail belo...

Page 420: ...tion 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 Assy AC In Power Sup...

Page 421: ...apter 6 Illustrated Parts Breakdown 421 Figure 48 This illustrated parts breakdown shows the IBM coax twinax expansion board 5 4 2 1 3 IMPORTANT Leave this slot empty if the printer has a power stacke...

Page 422: ...422 Figure 48 Item No Part No Description Notes 1 39U2757 39U2758 Spare PCBA PCI CT V3 Spare PCBA PCI CT V3 Advance Exchange 2 Ref Plate PCI Cover 3 Ref Card Cage 4 Ref Screw 5 Ref Controller Board...

Page 423: ...423 Figure 49 This illustrated parts breakdown shows the ethernet interface assembly 3 2 1 IMPORTANT Leave this slot empty if the printer has a power stacker 5 4...

Page 424: ...o Part No Description Notes 1 75P2812 17R7301 39U2514 Spare PCBA PCI NETWORK Spare PCBA PCI NTWRK Advance Exchange Spare PCBA PCI Wireless 2 Ref Plate PCI Cover 3 Ref Rear of Card Cage 4 Ref Screw 5 R...

Page 425: ...425 Figure 50 This illustrated parts breakdown shows the RS 422 interface 1 2 3 4 6 7 8 11 9 10 11 5 A A See detail at right Pin 10...

Page 426: ...3 75P1625 Cable Assembly RS 422 I O 4 Ref RS 422 Connector 9 Pin 5 Ref Connector J15 Note that there is no Pin 10 If Pin 10 is present remove it 6 Ref Controller Board 7 Ref Connector J201 RS 232 9 Pi...

Page 427: ...427 Figure 51 This illustrated parts breakdown shows the twinax extension cable required if the printer has a PSA3 controller board a twinax interface and the power stacker 1 2 3 4...

Page 428: ...winax Auto Termination Cable Smart T 2 75P2813 Cable Extension Smart T Required in printers with the power stacker so the twinax auto termination cable will clear the stacker elevator See also page 28...

Page 429: ...429 Figure 52 This illustrated parts breakdown shows the dipole antenna and cable used with the optional wireless NIC 1 Cabinet Model Pedestal Model 1 2 2...

Page 430: ...430 Figure 52 Item No Part No Description Notes 1 10R3183 Antenna Rubber Duck Dipole S24 2 75P2249 Cable MMCX BNC 10 inch S24...

Page 431: ...entive Maintenance Contents Cleaning The Printer page 432 Cleaning The Exterior page 432 Cleaning The Interior page 433 Cleaning The Shuttle Frame Assembly page 434 Cleaning The Card Cage Fan Assembly...

Page 432: ...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 the printer Do...

Page 433: ...n 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 cloth dampened with water and a mil...

Page 434: ...aning 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 strips Carefully wipe betwe...

Page 435: ...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 325 10 Install the shuttle frame assembly page 3...

Page 436: ...remove paper particles dust and lint See Figure 55 3 Cabinet Models Install the paper guide assembly page 348 Pedestal Model Install the top cover assembly page 327 4 Install the ribbon 5 Close the pr...

Page 437: ...o S246 0112 The Network Print Server Technical Reference Manual is included on a diskette that comes with the Network Print Server This softcopy document is in Adobe Acrobat Reader format Installation...

Page 438: ...438 B Communication Adapters Contents Ethernet Interface Assembly page 439 Ethernet Troubleshooting Tips page 439 IBM Coax Twinax Expansion Board page 444...

Page 439: ...ing Tips Tip 1 Infoprint 6500 IPDS Communication Failure Problem the customer can ping the printer but cannot print to it from an IPDS host or under certain conditions IPDS is disabled even though the...

Page 440: ...tioning properly See the User s Manual S544 5957 for configuration menu information 2 Wait for the READY ETHERNET IS READY message to display 3 If the READY indicator is on press the STOP key The prin...

Page 441: ...e Internet Protocol TCPIP option b Click on the Properties button c Select the use the folllowing IP address bullet 6 Enter the IP address of the printer plus or minus 1 in the last numeric octet Exam...

Page 442: ...and the NIC is working Tip 5 Printer Does Not Communicate Before doing the steps in this tip make sure the printer has the latest microcode installed and the NIC card is the correct one for this prin...

Page 443: ...file to print by doing the following a Type EDIT on the command line and press ENTER b An edit doc window pops up Type any amount of text in this window c Click on File then select Save As from the pu...

Page 444: ...ave already configured a TCP IP port you can select the old port and reconfigure it by selecting the Configure Port button 3 On the laptop while still on the PORTS tab make sure your new TCP IP port i...

Page 445: ...ras Peru Columbia Nicaragua Bermuda Bahamas Barbados Bolivia Guyana Ecuador Haiti Jamaica Venezuela Netherlands Antilles Trinidad Suriname Taiwan Tobago Saint Lucia Indonesia 8509386 Cable PC RS 232 I...

Page 446: ...lt 58F2861 Conn Cable RISC System 6000 IBM 63H7362 Cable RISC System 6000 63H7364 Cable AS 400 RS 232 63H7366 Cable PC Parallel 63H7368 Cable PC RS 232 63H7456 LAN Power Coupling 92F3176 Cable PC Para...

Page 447: ...T 3 03 DC3 19 13 35 23 3 51 33 EOT 4 04 DC4 20 14 36 24 4 52 34 ENQ 5 05 NAK 21 15 37 25 5 53 35 ACK 6 06 SYN 22 16 38 26 6 54 36 BEL 7 07 ETB 23 17 39 27 7 55 37 BS 8 08 CAN 24 18 40 28 8 56 38 HT 9...

Page 448: ...73 49 _ 95 5F u 117 75 139 8B J 74 4A 96 60 v 118 76 140 8C K 75 4B a 97 61 w 119 77 141 8D L 76 4C b 98 62 x 120 78 142 8E M 77 4D c 99 63 y 121 79 143 8F N 78 4E d 100 64 z 122 7A 144 90 O 79 4F e...

Page 449: ...61 A1 183 B7 205 CD 227 E3 162 A2 _ 184 B8 206 CE _ 228 E4 163 A3 1 185 B9 207 CF 229 E5 164 A4 186 BA _ 208 D0 230 E6 165 A5 187 BB 209 D1 231 E7 166 A6 188 BC 210 D2 _ 232 E8 _ 167 A7 189 BD 211 D3...

Page 450: ...FF commands XON Ctrl Q DC1 XOFF Ctrl S DC3 240 F0 244 F4 248 F8 252 FC _ 241 F1 245 F5 249 F9 253 FD 242 F2 _ 246 F6 I 250 FA 254 FE 3 4 243 F3 247 F7 251 FB 255 FF Character Decimal Hex Character Dec...

Page 451: ...cker page 457 Stacker Problems page 459 Stacker First Inspection page 459 Stacker Confidence Check page 460 Stacker Motor Check page 459 Removing The Power Stacker page 461 Installing The Power Stacke...

Page 452: ...paper tent in the pull out tray and from 3 to 15 5 inches 76 to 394 mm wide with the paper tent installed in the pull out tray IMPORTANT Access to the stacker assembly is restricted while it is in the...

Page 453: ...tacker Figure 56 This figure shows the locations of the main parts of the power stacker Pinch Rollers Paper Throat Stacker Operator Panel Elevator Assembly Wire Paper Tent In Pull Out Paper Tray Paddl...

Page 454: ...is in the NOT READY state ON LINE Key Toggles the printer between the READY and NOT READY states PAPER ADVANCE Key Moves paper one form length as defined by the currently active form length This key...

Page 455: ...elevator assembly to reach the top of its travel Figure 57 5 If the paper you will use is not wider than 15 5 inches 39 5 cm install the wireform paper tent in the pull out paper tray Figure 58 If th...

Page 456: ...he rear of the printer and set the paper length by aligning indicator notch on the bearing bracket with the paper length indicator Length range 5 to 12 inches Figure 59 Figure 59 This figure shows how...

Page 457: ...ce the paper until it reaches the wire tent and there are 3 to 5 extra sheets in the stacker Make sure the paper passes through the throat of the paper stacker Figure 60 2 Stack the three to five shee...

Page 458: ...printer in the online state The stacker elevator will descend to its lowest position Figure 61 Figure 61 This figure shows the power stacker in the print position 4 Check that the paper is still cent...

Page 459: ...ravel and loosen the drive belt pulley on the side s that does not seat properly b While holding the elevator in the fully down position tighten the pulley setscrews c Verify that the elevator seats a...

Page 460: ...sure it goes the READY state b The green LED should be on c Press the ON LINE key and observe the yellow LED The yellow LED should come on when the printer is online d The yellow LED should be off whe...

Page 461: ...STACKER when the elevator reaches the top of its travel 10 Lower the elebator by pressing ELEVATOR DOWN key The elevator should stop at its bottom position without motor noise If you hear motor noise...

Page 462: ...r motor assembly connector J4 pins 11 12 13 and 14 9 Replace any cable that is damaged or fails continuity shorts check 10 Replace any motor that fails the resistance check Table 7 Power Stacker Probl...

Page 463: ...by customer Various causes possible page 189 Stacker does not stack properly Reported by customer Various causes possible page 190 Stacker elevator does not move Reported by customer Various causes po...

Page 464: ...usually be referred to this procedure from other troubleshooting procedures When you have completed the procedure return to the procedure that sent you there page 192 Stacker not operating Reported b...

Page 465: ...printer power switch to O off 2 Unplug the power cord 3 Unload paper from the stacker area Refer to the User s Manual 4 Remove the paper tent if present Figure 62 Figure 62 This figure shows how to re...

Page 466: ...466 5 Cut the tie wrap if present and remove the paper fence Figure 63 Figure 63 This figure shows how to remove the paper fence Paper Fence...

Page 467: ...e screws washers and standoff from the stacker operator panel Figure 64 Figure 64 This figure shows how to remove an early stacker operator panel from the cabinet frame Standoff Washer Long Screw Shor...

Page 468: ...l and remove the stacker operator panel Figure 65 Figure 65 This figure shows how to remove the cables from the rear of the stacker operator panel A Remove the Tie Wrap Logic Cable P104 Power Cable El...

Page 469: ...e cabinet floor Figure 66 10 Remove the two Torx T 10 screws that secure the rail bracket to the cabinet floor Figure 66 Figure 66 This figure shows which screws to remove to prepare the stacker for r...

Page 470: ...e 67 12 Loosen one turn do not remove the M3x6 screws securing the vertical rails to the stacker base Each rail is secured by two screws Figure 67 Figure 67 This figure shows how to loosen the lower s...

Page 471: ...e elevator assembly and disconnect the stacker I O cable Figure 68 Figure 68 This figure shows where to disconnect the stacker I O cable from the stacker elevator Stacker I O Cable Vertical Rail Eleva...

Page 472: ...t duct Tilt the vertical rails toward the front of the printer until they clear the upper frame cross member Slide the stacker assembly to the rear and angle it out of the cabinet as shown in Figure 6...

Page 473: ...et the printer power switch to O off 2 Unplug the power cord 3 Remove paper 4 Loosen do not remove the three screws that secure the paper guide assembly Slide the paper guide assembly to the left and...

Page 474: ...r board Figure 71 8 Route the stacker power cable in front of the controller board and down through the cutout under the card cage fan Figure 71 9 Route the stacker logic cable in front of the control...

Page 475: ...e 72 11 Loosen one turn do not remove the M3x6 screws securing the vertical rails to the stacker base Each rail is secured by two screws Figure 72 Figure 72 This figure shows how to loosen the lower s...

Page 476: ...sembly and install the two 4 40 x 1 4 inch screws as shown in Figure 73 Figure 73 This figure shows where to connect the stacker I O cable to the stacker elevator Stacker I O Cable Vertical Rail Eleva...

Page 477: ...exhaust duct insert the vertical rails inside and under the upper frame cross member then slowly swing the base of the stacker assembly into the cabinet Refer to Figure 77a Leave the stacker loose in...

Page 478: ...17 Press rail cable connector P107 into the operator panel until the ejectors close then tie wrap the ejectors to the connector Figure 75 detail Figure 75 This figure shows how to install the operato...

Page 479: ...ner panel of the cabinet a If the operator panel lower bracket is flush with the cabinet inner panel proceed to step 20 b If there is a gap between the operator panel lower bracket and the cabinet inn...

Page 480: ...77b 22 Align the holes in the vertical rail brackets with the holes in the upper frame cross member Figure 77c and Figure 78 23 Align the holes in the stacker base with the holes in the cabinet floor...

Page 481: ...o the cabinet floor Figure 78 26 Install and tighten the two Torx T 10 screws that secure the rail bracket to the cabinet floor Figure 78 Figure 78 This figure shows which screws to install to secure...

Page 482: ...d by two screws Figure 72 31 Move the elevator assembly up and down and make sure it travels smoothly with no binding If the elevator binds or catches anywhere along its path of travel slightly loosen...

Page 483: ...483 33 Install the paper fence Figure 80 Figure 80 This figure shows how to install the paper fence in the cabinet Paper Fence Stacker Base...

Page 484: ...e paper is wider than 15 5 inches 39 5 cm leave the paper tent out of the printer Figure 81 This figure shows how to install the paper tent in the paper tray 35 Install the paper path that you removed...

Page 485: ...o hold the elevator up 2 Raise the elevator assembly to about 1 4 inch short of its highest position and secure it to the vertical rails using tie wraps or string Do not over tighten the tie wraps or...

Page 486: ...nd install the rail screw and washer Figure 83 6 Install the shoulder screw large washer spacer and small washer as shown in Figure 83 Figure 83 This figure shows how to remove the constant force spri...

Page 487: ...and washer from the pulley at the bottom of the left vertical rail and remove the pulley Figure 84 Go to step 6 4 If you are removing the right timing belt remove the two metric Allen screws that secu...

Page 488: ...to remove the pulley from the timing belt motor 6 Remove the shoulder screw washers and spacer that secures the constant force spring to the vertical rail Figure 86 Figure 86 This figure shows how to...

Page 489: ...ve two Allen screws from the belt clamp that secures the timing belt to the stacker frame Figure 87 Figure 87 This figure shows how to remove the timing belt clamps Allen Screw Belt Clamp Belt Clamp A...

Page 490: ...around the vertical rail and constant force spring Figure 88 Figure 88 This figure shows how to remove the timing belt 9 To install a timing belt reverse the steps of this procedure NOTE Left timing b...

Page 491: ...ight bearing pivot plate s extension spring from the tab on the elevator Figure 89 3 Using an M 2 Allen wrench remove the screw securing the right bearing pivot plate to the elevator Figure 89 Figure...

Page 492: ...wo screws securing the stepper motor to the elevator Figure 90 7 Using a 9 64 inch Allen wrench loosen do not remove the collar screw securing the collar to the roller drive shaft Figure 90 8 Support...

Page 493: ...aft Figure 91 12 Remove the new roller drive shaft new grounding clip and bearing lubricant from the packaging 13 Inspect the new roller drive shaft for oil and grease wipe off any oil or grease from...

Page 494: ...r assembly is damaged but does not have a part number replace the entire power stacker assembly The IPB starts on page 495 List of Illustrations Figure 92 Stacker Assembly page 495 Figure 93 Elevator...

Page 495: ...shows how the vertical rails attach the elevator to the stacker base and tray A 14 30 35 10 12 20 9 37 12 8 8 12 15 25 7 11 20 9 12 10 6 7 See page 498 NOTE The stacker operator panel and stacker cab...

Page 496: ...houlder 10 32 Part of item 36 10 24H8968 Timing Belt 11 39U2511 Shaft Lift 12 17R7812 Pulley Timing Fairloc 12T 14 10R2841 Clip Ground Dimpled Pwr Stkr Part of item 47 but can be ordered separately 15...

Page 497: ...perator Panel Assembly Rear Black 39U2530 Operator Panel Assembly Rear Black Advance Exchange 10R3913 Rail Cable Power Stacker See page 305 57P1376 Power Cable Power Stacker See page 304 10R4590 Logic...

Page 498: ...down is an exploded view of the stacker elevator showing the motors rollers and paddles 5snipb2 A 47 40 46 45 50 46 45 49 51 16 15 53 15 45 46 45 46 50 55 60 55 50 65 52 54 52 65 From page 495 See pag...

Page 499: ...rina Grease 1 Includes items 14 70 75 and 80 For Drive Shaft 49 Ref Bearing Flanged Part of item 36 50 Ref Bearing Part of item 36 51 24H9003 Collar Clamp 52 Ref Collar Setscrew Part of item 36 53 24H...

Page 500: ...arts breakdown is an exploded detail view of a motor bracket with its infrared LED and an elevator bracket with its rectifier and LED 95 95 96 96 100 Connector Flag Key From page 498 B E E 5snelvbk Fr...

Page 501: ...em 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 97 24H9000 Holder LED Flat 100 Ref LED IR T 1 3 4...

Page 502: ...trations 502 Figure 95 This illustrated parts breakdown is an exploded detail view of the paper motion detector 5sndtect Connector Key Nib 105 Rotated 180 Degrees 97 110 97 107 116 115 108 106 107 Fro...

Page 503: ...at 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 Switch Long...

Page 504: ...ifications page 505 Ordering Ribbons page 505 Paper Specifications page 507 Printer Dimensions and Weight page 508 Environmental Characteristics page 509 Electrical Characteristics page 510 Interfaces...

Page 505: ...and other parameters Label yield with high performance scanning equipment may exceed these yields Use only the ribbon listed below Ordering Ribbons 6500 v Models IBM Printing Supplies are distributed...

Page 506: ...establish the supply s life in the end user s application Many factors such as print coverage per page machine settings paper type and size and environmental conditions affect supply life Supply warr...

Page 507: ...Thickness 0 025 inches 0 064 cm maximum Multi part carbon 1 to 6 part forms maximum 12 pound 45 g m2 ply of upper plies Multi part carbonless maximum of 6 part forms Test readability of greater than 4...

Page 508: ...ing backing sheet On pedestal models when using the rear paper exit the maximum form width is 16 inches 40 64 cm On cabinet models forms longer than 12 inches can be used by opening the front and rear...

Page 509: ...ensing Noise Levels Cabinet Models Pedestal Models Acoustic Noise Levels per ISO 9296 v05 v10 v15 v20 v5P v1P Printing 50 dB 52 dB 55 dB 62 dB 66 dB 6 7 Bel 7 0 Bel 7 1 Bel 7 8 Bel 8 2 Bel Standby 46...

Page 510: ...1 6A 350W 1195 28W 96 6500 vP5 AC 100 200V 50 60 Hz 3A 275W 940 28W 96 AC 200 240V 50 60 Hz 1 5A 275W 940 28W 96 6500 v10 AC 100 200V 50 60 Hz 3 5A 350W 1195 28W 96 AC 200 240V 50 60 Hz 1 6A 350W 1195...

Page 511: ...pter Feature AS 400 The 6500 v is connected to the AS 400 ASCII Workstation Controller via the following IBM cables available through your IBM service representative Type Standard IEEE 1284 Parallel C...

Page 512: ...re Print rates for lines containing attributes such as bold or emphasized printing superscripts subscripts or elongated attributes will decrease to not less than half the rates of the font without suc...

Page 513: ...ESSING 60 120 x72 10 12 13 3 15 17 1 5 9 x 7 2 4 7 x 7 2 4 7 x 7 2 3 5 x 7 2 3 5 x 7 2 375 750 1125 1500 300 600 900 1200 HIGH SPEED 60 120 x 48 10 12 13 3 5 9 x 5 1 4 7 x 5 1 4 7 x 5 1 500 1000 1500...

Page 514: ...0 120 x 72 10 12 13 3 15 17 1 5 9 x 7 2 4 8 x 7 2 4 8 x 7 2 3 5 x 7 2 3 5 x 7 2 42 83 127 167 HIGH SPEED 60 120 x 48 10 12 13 3 5 9 x 5 1 4 7 x 5 1 4 7 x 5 1 62 124 186 250 Note 1 A B x C where A is m...

Page 515: ...eter foot 30 48 centimeter foot 304 8 millimeter inch 0 0254 meter inch 2 54 centimeter inch 25 4 millimeter meter 3 280840 foot centimeter 0 03280840 foot millimeter 0 003280840 foot meter 39 37008 i...

Page 516: ...und 0 11298 Newton meter foot pound 1 3558 Newton meter Newton meter 8 8511 inch pound Newton meter 0 7376 foot pound pound 4 4482 Newton Newton 0 22481 pound Multiply By To Obtain pound 0 4535924 kil...

Page 517: ...temperature Fahrenheit tf tf 1 8tc 32 temperature Fahrenheit tf temperature Celsius tc tc tf 32 1 8 Multiply By To Obtain Btu International Table hour 0 2930711 Watt Watt 3 412141 Btu International T...

Page 518: ...For example 2 56 means a No 2 screw with 56 threads per inch Carbon Steel Fasteners ANSI B18 6 3 1972 Fastener Size Into Alum or Brass 25 000 psi ultimate tensile strength Into Steel 60 000 psi ultim...

Page 519: ...lb 8 32 UNC 8 36 UNF 19 1 in lb 10 24 UNC 10 32 UNF 25 1 in lb Carbon Steel Fasteners ANSI B18 6 3 1972 Fastener Size Into Alum or Brass 25 000 psi ultimate tensile strength Into Steel 60 000 psi ulti...

Page 520: ...s Meg 1 000 000 Ohms F microfarad 10 6 farad s microsecond 10 6 second sec microsecond 10 6 second A0 A1 etc Address 0 Address 1 etc AC Alternating Current ACC Access ACK Acknowledge AMP Amplitude Amp...

Page 521: ...r BPS Bits Per Second BSY Busy BTU British Thermal Unit BUD Buffered Upper Driver CA Cathode CC Card Cage CCF Card Cage Fan CE Customer Engineer CHNG Change CIR Circuit CLK Clock CO Cover Open COLL Co...

Page 522: ...y Module DHIO Dual Hammerbank Input Output DMA Direct Memory Access DP Data Processing DataProducts DPI Dots Per Inch DPMC Dot Plucker Memory Controller DPU Data Processing Unit DRAM Dynamic Random Ac...

Page 523: ...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 FP Front Panel Operator Panel FTIC Fire Timer Integrated Cir...

Page 524: ...essor IML Initial Microcode Load INST Instruction INT Interrupt IPM Inches Per Minute I O Input Output IRQ Interrupt Request J Jack connector JEDEC Joint Electron Device Engineering Council An organiz...

Page 525: ...H Mounting Hole MOSFET Metal Oxide Semiconductor Field Effect Transistor MOT Motor MPU Magnetic Pickup Unit ms millisecond 10 3 second MSL Motor and Sensors Left MSR Motor and Sensors Right N Negative...

Page 526: ...Board Assembly PCB Printed Circuit Board PCI Peripheral Component Interconnect PD Paper Detector PE Printer Error Paper Empty PER Peripheral Device PF picofarad 10 12 farad PFC Paper Feed Controller P...

Page 527: ...3 Manufacturer s designation of the controller board used in Infoprint 6500 printers PS5 Power Supply 5 Volt PTR Pointer Printer PWM Pulse Width Modulation PWR Power R Right RBN Ribbon RD Read RET Ret...

Page 528: ...y SEC Security Key SEL Select SEN Sense Sensor SF Structured Field SG Signal Ground SHH Shuttle Hall Effect SHM Shuttle Motor SHUT Shuttle SHUTL Shuttle SIMM Single Inline Memory Module SLCT Select On...

Page 529: ...t Data UART Universal Asynchronous Receiver Transmitter UDPH Upper Drive Phase UNDEF Undefined USART Universal Synchronous Asynchronous Receiver Transmitter V Volts VAC Volts Alternating Current VDC V...

Page 530: ...530 WR Write w With w o Without XMT Transmit...

Page 531: ...531...

Page 532: ...028 COMMUNICATIONS CHECK CALL SYSTEM OPERATOR 54 029 8344 DIAGNOSTIC FAILED 54 031 END OF FORMS TMEOUT LOAD FORMS 55 032 FORMS JAMMED TIMEOUT CLEAR AND RELOAD FORMS 57 04 VIEW FORMS PRESS VIEW KEY 46...

Page 533: ...TL INVALID PARM SEE USERS MANUAL 118 139 OVERSPEED CHECK SEE USERS MANUAL 119 140 48 VOLTS FAILED SEE USERS MANUAL 120 142 PAP FEED DRIVE FAIL SEE USERS MANUAL 121 143 SHUTL DRIVER FAILED SEE USERS MA...

Page 534: ...MISSING 139 B13 ERROR NOT COMPATIBLE 139 B19 ERROR DC RETURNED 140 B20 STATUS 00 DOWNLOAD MODE 140 B21 STATUS PRINTER RESET 140 B22 ERROR DECOMPRESS SIZE 141 B23 ERROR DECOMPRESS CKSUM 142 B30 STATUS...

Page 535: ...7 Clearing LCD messages 42 CLEARING PROGRAM FROM FLASH 149 241 247 Coax twinax expansion board replacement 337 444 Code downloading from IBM First 236 Coil temperature adjustment 383 Communications fa...

Page 536: ...OT DETECTED 153 EC PROGRAM NOT VALID 154 241 EC STOPPED AT STATE XXXX 242 FLASH DID NOT PROGRAM 155 FLASH NOT DETECTED 156 243 NO DRAM DETECTED 157 243 NVRAM FAILURE 157 244 PROGRAM NEEDS MORE DRAM 24...

Page 537: ...248 SECURITY CODE VIOLATION 248 SENDING PROGRAM TO EC PROCESSOR 248 FLASH TYPE IS NOT SUPPORTED 160 FM HEADER ERROR 160 G Gap adjustment magnetic pick up MPU 338 platen 374 H Hammer phasing adjustment...

Page 538: ...s 37 Memory loading from hard disk 238 Memory modules PSA3 controller location and replacement 339 Memory installed 226 Menus boot diagnostics 221 Customer Engineer CE tests 216 Messages clearing 42 M...

Page 539: ...replaceable parts 390 Parts and assemblies locations of 262 Phasing adjustment 381 Platen gap adjustment 374 interlock switch assembly replacement 366 platen open belt adjustment 371 platen open motor...

Page 540: ...27 dashpot 328 Ethernet interface assembly 329 extension spring 364 hammer bank ribbon mask cover assembly 325 hammer bank fan assembly 330 332 hammer spring single hammer bank 333 IBM Coax twinax exp...

Page 541: ...reprogramming with the SPX 250 Security part transformer SPX 250 Self tests customer engineer CE 216 operator print 213 printer information menu 226 SENDING PROGRAM TO EC PROCESSOR 248 SERVICE 168 Se...

Page 542: ...spring 485 timing belts 487 Start of call 40 Start up sequence 229 Status LEDs on the controller board 229 Support shaft replacement 361 Switch paper detector switch assembly replacement 365 platen i...

Page 543: ...ble 518 values for fasteners 313 Tractor replacement 367 Troubleshooting communications failures 211 display messages 42 how to 41 message list 42 newly installed printer 230 other symptoms 170 power...

Page 544: ...G544 5978 00 07G544597800 Copyright IBM Corp 2005...

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