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TallyGenicom 6600 Series, Maintenance Manual

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 118

Chapter

3

Troubleshooting Other Symptoms

Power Stacker

Printer does not detect 
presence of power stacker

1.

Check that the power stacker is enabled under the Printer 
Control menu. (Refer to the 

User’s Manual.)

 If the power 

stacker enable/disable option does not appear in the 
menu, go to the next step.

2.

Open the rear cabinet door. Check that the ON/OFF 
indicator lamp is lit. If the ON/OFF indicator is not lit, go to 
step 3. If the ON/OFF indicator is lit, press the ON LINE 
key and check that the ON LINE indicator lights. If the ON 
LINE indicator comes on, the stacker is detected by the 
printer. If the ON LINE indicator does not come on, go to 
step 4.

3.

a) Power off the printer.

 

b) Unfasten the cable clamp holding the stacker control 
panel cables.

 

c) Disconnect the stacker power cable from the back of the 
stacker control panel. (See Figure 74, page 368.)

 

d) Locate pin 1 of connector P106. (See the cable 
assembly drawing in Appendix A.)

 

e) Power on the printer.

 

f) At connector P106 check for +48 volts DC between pins 
1 and 2 and +5 volts DC between pins 3 and 4. If the 
voltages are correct, replace the stacker control panel. If 
the voltages are not correct, power off the printer, remove 
the paper path, and disconnect the stacker power cable 
from the controller board. (See Figure 77, page 371.) 
Check the continuity of the stacker power cable between 
P105 and P106. If the cable fails the continuity test, 
replace it. If the cable is OK, replace the controller board.

4.

Power off the printer. Remove the paper path. Disconnect 
stacker cables from the controller board, stacker 
assembly, and the stacker control panel (see Figure 74, 
page 368). Check cables for cuts, breaks, or damaged 
pins. Check continuity of cables. (See Appendix A.) 
Replace any cable that is damaged or fails continuity test. 
Reconnect all stacker cables to the controller board, 
stacker, and stacker control panel.

5.

Power on the printer. Check that the ON LINE indicator 
lights on the stacker control panel. If the ON LINE indicator 
does not light, replace the stacker control panel.

6.

Power on the printer. Check that the ON LINE indicator 
lights on the stacker control panel. If the ON LINE indicator 
does not light, replace the controller board.

Table 4. General Symptom List

Symptom

Solution

Summary of Contents for 6600 Series

Page 1: ...6600 Series Printers Maintenance Manual Approved Final May 19 2011 ...

Page 2: ......

Page 3: ...6600 Series Printers Maintenance Manual ...

Page 4: ...gineers IGP is a registered trademark of Printronix Inc Intelligent Printer Data Stream and IPDS are trademarks of International Business Machines Corporation Java is a trademark of Sun Microsystems LinePrinter Plus is a registered trademark of Printronix Inc Linux is a registered trademark assigned to Linus Torvalds MS DOS and Microsoft Windows 3 1x 95 98 Me NT 2000 and XP are trademarks of Micro...

Page 5: ...incorporated in any other material in any form or by any means whether manual graphic electronic mechanical or otherwise without the prior written consent of Printronix Inc All rights reserved 2011 Printronix Inc ENERGY STAR The Environmental Protection Agency ENERGY STAR Computers program is a partnership effort with manufacturers of data processing equipment to promote the introduction of energy...

Page 6: ...ized changes or modifications to this equipment Unauthorized changes or modifications could void the user s authority to operate the equipment This device complies with Part 15 of the FCC Fules Operation is subject to the following two conditions 1 this device may not cause harmful interference and 2 this device must accept any interference received including interference that may cause undesired ...

Page 7: ...and connectors Industry Canada Compliance Statement This Class A digital apparatus complies with Canadian ICES 003 Cet appareil numérique de la classe A conform á la norme NMB 003 du Canada Statement of CISPR 22 Compliance Attention This is a Class A Product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures Japanese...

Page 8: ...nformationen in Hinsicht EMVG Paragraph 3 Abs 2 2 EN 55022 Klasse A Geräte bedürfen folgender Hinweise Nach dem EMVG Geräte dürfen an Orten für die sie nicht asreichend entstört sind nur mit besonderer Genehmigung des Bundesminesters für Post und Telekommunikation oder des Bundesamtes für Post und Telekommunikation betrieben werden Die Genehmigung wird erteilt wenn keine elektromagnetischen Störun...

Page 9: ...ation and to other electrical or electronic equipment Printronix cannot be responsible for any interference caused by using other than recommended cables and connectors This product has been tested and found to comply with limits for Class A Information Technology Equipment according to CISPR 22 European Standard EN 55022 The limits for Class A equipment were derived for commercial and industrial ...

Page 10: ......

Page 11: ...nual 22 Printing Conventions in this Manual 23 Safety Notices 23 Hinweise zur Sicherheit 24 Controls and Indicators 25 Electrical Controls 25 Mechanical Controls 28 Tools and Test Equipment 30 Plugging in the Printer 31 TallyGenicom Customer Support Center 32 TallyGenicom Supplies Department 32 Corporate Offices 33 Maintenance Training for TallyGenicom Products 33 2 Preventive Maintenance 35 Clean...

Page 12: ... 151 Hard Reset Cycle Power 152 4 Adjustments and Tests 153 Introduction 153 Adjustments and Tests 153 Preparing the Printer for Maintenance 154 Returning the Printer to Normal Operation 155 Belt Paper Feed Timing Adjustment 156 Belt Platen Open Adjustment 158 Paper Scale Alignment 160 Platen Gap Adjustment 162 Paper Out Adjustment 164 Hammer Phasing Adjustment 167 Loading Flash Memory 169 Loading...

Page 13: ...197 Control Panel Assembly 199 Controller Board 200 Cover Assembly Hammer Bank Ribbon Mask 202 Cover Assembly Shuttle 203 Cover Assembly Top Pedestal Models 204 Dashpot 205 Fan Assembly Cabinet Exhaust 206 Fan Assembly Card Cage 207 Fan Assembly Hammer Bank 208 Hammer Spring Assembly Version 1 209 Hammer Spring Assembly Version 2 211 Magnetic Pickup MPU Assembly 217 Memory Flash Expansion 218 Moto...

Page 14: ...ion 279 Line Matrix Printing 279 Printing Rates 282 Printing Mechanism 282 Shuttle Frame Assembly 283 Hammer Bank Assembly 283 Shuttle Drive Motor 284 Paper Transport System 285 Ribbon Transport System 286 Integrated Print Management System 287 Operation 287 Logical Control of the Printer 290 Control Panel 291 Controller Board 292 Data Controller 294 Engine Controller 296 Power Supply Board 298 AC...

Page 15: ...ns 390 E Zero Tear Pedestal ZTP Printer 403 Contents 403 Overview 404 Operation 405 Load Paper and Set Up the Tractors 405 Remove Paper 406 Adjust The Paper Guides 407 Position the Paper Out Sensor 409 Set the Tear Bar Distance 410 Set the Top Of Form 411 Control Panel Menus 412 Performance Limitations 413 Adjustments and Tests 415 List of Adjustments and Tests Procedures 415 Preparing the ZTP Pri...

Page 16: ...ort Gate 433 Illustrated Parts Lists 435 Illustrations of ZTP Components 435 F Paper Specifications And Forms Design 449 Introduction 449 General Paper Specifications 450 Paper Guidelines 451 Terms and Definitions 451 Environmental Considerations 453 Form Types 453 Form Weight 453 Form Thickness 453 Form Evenness 453 Tractor Pin Engagement 453 Methods of Forms Attachment 454 Chaff Content 455 Form...

Page 17: ...st longer and costs less to operate than other print technologies Integrated print management system provides precise control over print quality print costs and job planning Cabinet or Pedestal styles best user access and forms handling flexibility Unsurpassed ease of use simplifies operation and enhances productivity There are four printer configurations Enclosed Cabinet The enclosed cabinet mode...

Page 18: ...ve Pedestal configuration but with an enclosed input paper area with a front door side panels and bottom panel to seal the input paper path Provides a reduction in acoustic noise Zero Tear Pedestal Special push tractor configuration enables printing from the very first to the very last line of a form and then tear off with no forms lost The elimination of wasted forms between jobs can yield signif...

Page 19: ...affected by the interaction of many variables and varies from print job to print job For more information see Printing Rates on page 282 Zero Tear Pedestal ZTP Printers Zero Tear Pedestal ZTP printers are models equipped with special hardware and software that permits them to print small jobs or single sheets without losing a sheet between print jobs A ZTP printer automatically presents the curren...

Page 20: ...n be equipped with four kinds of paper stacking devices The fixed paper fence is a wireform divider that separates the source paper stack from the printed output stack and is used in combination with hanging chains that guide printed forms downward For improved performance at higher print speeds the chains are used with a moveable fence called the passive paper stacker which can be positioned to m...

Page 21: ... s warranty Never close the forms thickness lever platen lever too tightly Closing the forms thickness lever too tightly can lead to smeared print degraded print quality paper jams and damage to the platen and shuttle assembly Notices For your safety and to protect valuable equipment always read and comply with all information highlighted under notices The heading of a notice indicates the kind of...

Page 22: ...twork Interface Card User s Manual Information about network protocols configuration and network operation 6600 Series Printers Emulations Applications Manual Volume 1 Defines printer emulations 6600 Series Printers Fonts and Character Sets Applications Manual Volume 3 Defines printer fonts and character sets 6600 Series Printers Graphics Languages Applications Manual Volume 4 Defines Code V PGL a...

Page 23: ... the printer or power source before performing any maintenance procedure Failure to remove power could result in injury to persons or damage to equipment If you must apply power during maintenance you will be instructed to do so in the maintenance procedure WARNING Always disconnect the AC power cord before cleaning the printer WARNING To prevent injury from electric shock wait at least one minute...

Page 24: ...tzungen durch Elektroschocks zu vermeiden warten Sie mindestens eine Minute nach Stromausschaltung bevor Sie die elektrische Schaltkarte entfernen Bitte immer einen geerdeten statischen Handgelenkriemen tragen wenn Sie die elektrische Schaltkarte handhaben Halten Sie die Karte nur an den seitlichen Auswurfshebeln Während des Herausnehmens Installierens dürfen die Komponenten der Karte nicht berühr...

Page 25: ...ntry into the Clear menu 9 TOF Moves paper downward from TOF Top Of Form alignment mark to the print station and sets this as the first line of print on a page independent of forms length If there are data in the buffers the printer slews to the page position where printing left off and prints the data 9 VIEW When the printer is online or offline pressing this key executes the view or eject functi...

Page 26: ...ion printout 9 Moves up between levels in the configuration menus When in offline mode makes vertical forms adjust In VIEW mode moves paper up 1 72 inch See VIEW key 9 Moves down between levels in the configuration menus When in offline mode makes vertical forms adjust In VIEW mode moves paper down 1 72 inch See VIEW key 9 Moves between the options on the current level of configuration 9 Moves bet...

Page 27: ...l Controls 184071b 184071 REV B Off On A A Rotated 180 Degrees B C Power Switch C A 184136b FF LF ONLINE TOF VIEW CONFIG MENU ENTER CLEAR TOF VIEW CONFIG MENU ENTER ONLINE LF FF CLEAR Circular Pad ONLINE Message Display Status Indicator B C B ...

Page 28: ...h A for thin single part forms B for thicker forms and so on Forms Thickness Lever and Platen Stop Assembly The forms thickness lever closes the platen to the relative thickness of the paper The platen stop assembly returns the platen to the lever adjustment made by the user Tractors 2 Hold and feed paper Used to set side margins and position the paper horizontally Tractor Locks 2 Lock tractors in...

Page 29: ...F 183871 REV A 183871a Ribbon Ribbon Cartridge Ribbon Tension Knob Air Shroud Assembly Tab 2 Tab Slot 2 Blue Tractor Lock 2 Paper Support 2 Tractor 2 Vertical Position Knob Platen Lever Splined Shaft Platen Stop Hammer Bank Cover and Ribbon Mask Ribbon Cartridge Interface ...

Page 30: ...ld Kit Tester P5 Power Supplies Generic P N 178083 001 Force Gauge Chatillon NY Gauge r 0 20 lb CAT 719 20 Force Gauge Fish Scale type 0 16 oz Hardware Kit P5XXX Mech ZTP P N 178573 001 Hex bit 3 16 in torque screwdriver Hex bit 3 32 in torque screwdriver Hex bit 5 32 in torque screwdriver Hex bit 5 64 in torque screwdriver Lubricant Bearing P N 101805 001 Nut Driver 1 4 inch Nut Driver 5 16 inch ...

Page 31: ...h Electromagnetic Compatibility EMC regulatory requirements all interface cables must be of a minimal quality level be the correct length and be properly installed RS 232 port and parallel port cables must meet the following specifications The cable design must be double shielded with a copper braid over an aluminum mylar foil and not just a conductive foil spiral wrapped around a drain wire The s...

Page 32: ...ntout While offline press the MENU ENTER key on the control panel to enter the menu Press the Left Arrow key until the Help Menu displays Press the MENU ENTER key Is the problem with a new installation or an existing printer Description of the problem be specific Good and bad samples that clearly show the problem faxing or emailing these samples may be required Americas 714 368 2686 Europe Middle ...

Page 33: ...hanghai City 200120 P R China Phone 86 400 886 5598 Fax 86 21 5138 0564 Visit the web site at www tallygenicom com Maintenance Training for TallyGenicom Products Upon request TallyGenicom offers Product Maintenance Training Classes designed to enhance the knowledge of service personnel Taught by experienced professional instructors these classes include Theory of operation Hands on work with the p...

Page 34: ...34 Chapter 1 Maintenance Training for TallyGenicom Products ...

Page 35: ... printer regularly you should clean the printer every time you are called to service it NOTE A cabinet model printer is illustrated in this chapter but the cleaning procedures presented here pertain to all models WARNING Always disconnect the AC power cord before cleaning the printer CAUTION Do not use abrasive cleaners particularly on the window Do not drip water into the printer Damage to the eq...

Page 36: ...loth lightly moistened with anhydrous alcohol 1 The platen is the thick silver bar behind the hammer bank cover that rotates when the platen is rotated CAUTION When cleaning the platen be very careful not to get any alcohol in the hammer bank because alcohol will cause severe damage to the hammer bank Only a trained service technician should clean the shuttle assembly 11 For cabinet models a Brush...

Page 37: ...Ribbon Ribbon Cartridge Ribbon Tension Knob Tab 2 Tab Slot 2 Blue Tractor Lock 2 Paper Support 2 Tractor 2 Vertical Position Knob Platen Lever Splined Shaft Platen Stop Hammer Bank Cover and Ribbon Mask Ribbon Cartridge Interface Ribbon Turn Direction Arrow Base Casting Shuttle Cover Assembly Air Shroud ...

Page 38: ...aper ironer page 221 9 Wipe the paper ironer with a soft cloth to remove lint ink and paper residue 10 Install the paper ironer page 221 CAUTION The thin plate ribbon mask of the hammer bank cover assembly is fragile Do not over bend or kink the ribbon mask when handling and cleaning the hammer bank cover assembly WARNING Do not rub the edges of the mask and cover as they can be sharp 11 Remove th...

Page 39: ...er is required Do not use alcohol with high water content as the water could later cause corrosion The hammer bank contains a strong magnet To prevent damage to the hammer tips do not let the hammer bank cover assembly snap into place as the hammer bank magnet attracts it Any impact of the cover against the hammer bank can break hammer tips 16 Use tape or a nonabrasive marker or pencil to mark the...

Page 40: ...embly page 202 insuring that it is properly seated over the mounting pins 24 Reinstall the shuttle into the printer using a 25 inch pound driver and 5 32 hex bit 25 Install the shuttle cover assembly page 203 26 Return the printer to normal operation see page 155 27 Set the platen gap as appropriate 28 Run a test print to verify that the print quality is acceptable Table 2 Hammer Tip Alignment Too...

Page 41: ...y and surrounding areas to remove paper particles dust and lint Figure 7 3 Install the ribbon 4 Cabinet Models Install the paper path page 222 Pedestal Models Install the top cover assembly page 204 5 Return the printer to normal operation page 155 Figure 7 Cleaning the Card Cage Fan Assembly 183925a Card Cage Fan NOTE A cabinet model is shown here but the procedure is the same for pedestal models...

Page 42: ...42 Chapter 2 Cleaning the Card Cage Fan Assembly ...

Page 43: ...g Aids Troubleshooting is faster and more effective if you understand the equipment and make use of all available tools This manual has a number of troubleshooting aids to help you isolate printer malfunctions Start Here Logic Tree page 44 Troubleshooting Display Messages page 45 Message List page 46 Troubleshooting Other Symptoms page 111 General Symptom List page 112 Communications Failures page...

Page 44: ...id the fans come on YES YES NO Did the status indicator lamp come on and ONLINE appear on the display If default is OFFLINE status indicator will not come on NO YES Printer initialized successfully Other symptoms are listed in Table 4 page 112 Go to Printer does not initialize page 117 Did ANY of steps 1 thru 3 occur NO Press ONLINE Go to Help menu Press ENTER Does machine configuration print YES ...

Page 45: ... messages Configuration menus with associated options Fault messages Most fault messages are cleared from the LCD by correcting the fault condition then pressing the CLEAR key Some fault messages can only be cleared by shutting down and restarting the printer These fault messages are indicated by an asterisk after the message If printer logic circuits detect a fault condition three things happen T...

Page 46: ...e until the error is cleared Table 3 6600 Error Messages List Displayed Message Explanation Solution 8 5V POWER FAIL 8 5 Volt Power Failed Internal power failure 1 Cycle power If the message appears do the power supply operational check page 187 If the power supply fails the check replace it If it passes the check go to the next step 2 Power on the printer If the message appears replace the contro...

Page 47: ... 169 3 Cycle power Run the print job again If the message appears replace the flash memory 4 Power on the printer Run the print job again If the message appears replace the controller board Record the message and return it with the defective board 5 Power on the printer Run the print job again If the message appears do the power supply operational check page 187 If the power supply fails the check...

Page 48: ...power supply fails the check replace it If it passes the check go to the next step 5 Power on the printer If the message appears replace the shuttle frame assembly 48V CIRCUIT See User Manual Either the power supply is not generating a proper 48 Volts or the controller board is not detecting a 48 Volt output from the power supply board 1 Make sure the power supply board is correctly connected to t...

Page 49: ...embly P108 and the power cable assembly P105 Refer to Appendix A 3 Power on the printer If the message appears do the power supply operational check page 187 If the power supply fails the check replace it If it passes the check go to the next step 4 Power on the printer If the message appears replace the controller board Record the message and return it with the defective board 5 Power on the prin...

Page 50: ...ith the defective board 5 Power on the printer If the message appears replace shuttle frame assembly A TO D OVERRUN Analog to Digital Overrun The analog to digital converter overflowed Cycle power Run the print job again If the message appears replace the controller board Record the message and return it with the defective board ACCESS NULL PTR Access Null Pointer The processor tried to access a p...

Page 51: ...ith the defective board B11 ERROR RAM TEST FAILED SDRAM failed the boot initialization test 1 Cycle power If the message appears again reseat the SDRAM DIMM 2 Power up the printer If the message appears replace the SDRAM DIMM 3 Power up the printer If the message appears replace the controller board Record the message and return it with the defective board B12 ERROR PROGRAM MISSING The printer doe...

Page 52: ... flash SIMM 2 Power on the printer If the message appears replace the flash SIMM 3 Power on the printer If the message appears replace the controller board Record the message and return it with the defective board B23 ERROR DECOMPRESS CKSUM Flash memory has not passed boot initialization tests 1 Cycle power If the message appears again reseat the flash SIMM 2 Power on the printer If the message ap...

Page 53: ...and return it with the defective board B41 ERROR DIMM MEMORY NOT SDRAM The DRAM DIMM installed on the controller board is not Synchronous DRAM SDRAM 1 Cycle power If the message appears again reseat the SDRAM DIMM 2 Power on the printer If the message appears install a new SDRAM DIMM of the correct type and size 3 Power on the printer If the message appears replace the controller board Record the ...

Page 54: ...the message appears again reseat the SDRAM DIMM 2 Power on the printer If the message appears install a new SDRAM DIMM of the correct type and size 3 Power on the printer If the message appears replace the controller board Record the message and return it with the defective board B45 ERROR SDRAM IS WRONG VOLTAGE Printer boot initialization tests detect incorrect SDRAM 1 Cycle power If the message ...

Page 55: ... appears again reseat the SDRAM DIMM 2 Power on the printer If the message appears install a new SDRAM DIMM of the correct type and size 3 Power on the printer If the message appears replace the controller board Record the message and return it with the defective board B49 ERROR SDRAM LOGICAL BANKS Printer boot initialization tests detect incorrect SDRAM 1 Cycle power If the message appears again ...

Page 56: ...nd SDRAM No action required B52 ERROR I2C DID NOT COMPLETE There is a problem on the I2C bus which allows the SDRAM DIMM to communicate with the GPIO 1 Cycle power If the message appears again replace the GPIO in installed 2 Power on the printer If the message appears replace the controller board Record the message and return it with the defective board B53 ERROR I2C NO ARBITRATION There is a prob...

Page 57: ...ay if the security key is from a spool printer Replace the security key with a CRP security key BUFFER OVERRUN The print buffer has overflowed on a serial interface The printed output may contain random asterisk characters Make a configuration printout 1 Verify that the printer matches the host serial interface configuration settings for Data Protocol Baud Rate Data Bits Stop Bits Parity Data Term...

Page 58: ...he ribbon with an authorized cartridge that matches the printer s firmware level CRTG MISSING Install new RBN The ribbon cartridge is missing or installed improperly 1 Make sure a ribbon cartridge is installed in the printer 2 Make sure the ribbon cartridge is seated properly 3 Remove and replace the cartridge if necessary 4 Check the cable connection from the cartridge interface board to the cont...

Page 59: ...thickness lever rotates and the paper moves down If the forms thickness lever does not rotate and or the paper does not move down refer to Reverse paper feed platen does not open page 130 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 the paper under slight tension 6 Check the dy...

Page 60: ...ace the belt if it is damaged 11 Check and adjust the platen gap 12 Clean the paper motion detector with a cotton swab and alcohol At the control panel set the paper motion detector PMD fault setting to DISABLE Load paper Run a print test and observe how the paper feeds If the message appears replace the controller board Record the message and return it with the defective board If the message does...

Page 61: ...d position A hold a 0 011 inch 0 028 cm feeler gauge between the switch and the body of the forms thickness lever gently press down on the switch and tighten the two screws 4 Check and adjust the platen open belt Replace the belt if it is damaged 5 Disconnect connector P106 from the controller board Check the resistance of connector P106 PLAT M See the Main Wire Harness Test Tables in Appendix A R...

Page 62: ...he printer If the message appears replace the shuttle frame assembly D50 Status XX Clearing Flash Status message The printer is clearing its flash memory where XX represents the percentage completed No action required D51 Status XX Programming Status message The printer is loading firmware where XX represents the percentage completed No action required D55 Status Send Program to EC Status message ...

Page 63: ...D replace the shuttle frame assembly If HB NOT INSTALLD does not appear on the LCD replace the controller board E00 EXE ADDR0 See User Manual An illegal or unsupported instruction was attempted in the application program 1 Cycle Power Run the print job If the message appears again access the exception menu and record the displayed messages page 146 2 Power off the printer Provide this fault messag...

Page 64: ... the messages you recorded from the exception menu to your next higher support facility E03A DSI HASH L See User Manual An illegal or unsupported instruction was attempted in the application program 1 Cycle Power Run the print job If the message appears again access the exception menu and record the displayed messages page 146 2 Power off the printer Provide this fault message and the messages you...

Page 65: ...s you recorded from the exception menu to your next higher support facility E03E DSI CXIWX See User Manual An illegal or unsupported instruction was attempted in the application program 1 Cycle Power Run the print job If the message appears again access the exception menu and record the displayed messages page 146 2 Power off the printer Provide this fault message and the messages you recorded fro...

Page 66: ... the messages you recorded from the exception menu to your next higher support facility E04A ISI NO TRA See User Manual An illegal or unsupported instruction was attempted in the application program 1 Cycle Power Run the print job If the message appears again access the exception menu and record the displayed messages page 146 2 Power off the printer Provide this fault message and the messages you...

Page 67: ... you recorded from the exception menu to your next higher support facility E07 ILLEGAL INS See User Manual An illegal or unsupported instruction was attempted in the application program 1 Cycle Power Run the print job If the message appears again access the exception menu and record the displayed messages page 146 2 Power off the printer Provide this fault message and the messages you recorded fro...

Page 68: ... the messages you recorded from the exception menu to your next higher support facility E16 ITRANS MISS See User Manual An illegal or unsupported instruction was attempted in the application program 1 Cycle Power Run the print job If the message appears again access the exception menu and record the displayed messages page 146 2 Power off the printer Provide this fault message and the messages you...

Page 69: ...es you recorded from the exception menu to your next higher support facility E20 SYS MANAGE See User Manual An illegal or unsupported instruction was attempted in the application program 1 Cycle Power Run the print job If the message appears again access the exception menu and record the displayed messages page 146 2 Power off the printer Provide this fault message and the messages you recorded fr...

Page 70: ... the messages you recorded from the exception menu to your next higher support facility E31C EVENT 2 BP See User Manual An illegal or unsupported instruction was attempted in the application program 1 Cycle Power Run the print job If the message appears again access the exception menu and record the displayed messages page 146 2 Power off the printer Provide this fault message and the messages you...

Page 71: ... you recorded from the exception menu to your next higher support facility E31G EVENT 6 BP See User Manual An illegal or unsupported instruction was attempted in the application program 1 Cycle Power Run the print job If the message appears again access the exception menu and record the displayed messages page 146 2 Power off the printer Provide this fault message and the messages you recorded fro...

Page 72: ... the messages you recorded from the exception menu to your next higher support facility E32C CND 2 BP See User Manual An illegal or unsupported instruction was attempted in the application program 1 Cycle Power Run the print job If the message appears again access the exception menu and record the displayed messages page 146 2 Power off the printer Provide this fault message and the messages you r...

Page 73: ... you recorded from the exception menu to your next higher support facility E32G CND 6 BP See User Manual An illegal or unsupported instruction was attempted in the application program 1 Cycle Power Run the print job If the message appears again access the exception menu and record the displayed messages page 146 2 Power off the printer Provide this fault message and the messages you recorded from ...

Page 74: ...to your next higher support facility E99 UNKNOWN INT See User Manual An illegal or unsupported instruction was attempted in the application program 1 Cycle Power Run the print job If the message appears again access the exception menu and record the displayed messages page 146 2 Power off the printer Provide this fault message and the messages you recorded from the exception menu to your next high...

Page 75: ...the message appears replace the flash memory SIMM ERROR DRAM AT ADDRESS XXXXXXXX The printer found a defective memory location 1 Replace the DRAM DIMM 2 Power on the printer If the message appears replace the controller board Record the message and return it with the defective board ERROR EC PROGRAM NOT VALID The printer cannot find the engine controller program or the validation checksum is corru...

Page 76: ...lly and correctly seated Power on the printer Download the emulation page 169 If the message appears replace the flash SIMM 3 Power on the printer Download the emulation If the message appears replace the SDRAM DIMM 4 Power on the printer Download the emulation If the message appears replace the controller board Record the message and return it with the defective board ERROR FLASH DID NOT PROGRAM ...

Page 77: ...ears replace the controller board Record the message and return it with the defective board ERROR NVRAM FAILURE The non volatile SRAM on the controller board has failed Replace the controller board Do NOT attempt to replace NVRAM Record the message and return it with the controller board ERROR PROGRAM NEEDS MORE DRAM The printer requires more DRAM in order to run the downloaded program Add DRAM or...

Page 78: ...ller board Record the message and return it with the defective board ERROR WRONG CHECKSUM The printer received the complete program but the checksum did not match The data may have been corrupted during download 1 Power off the printer Download the program again from the beginning If the message appears replace the DRAM 2 Download the program using a new software diskette If the message appears re...

Page 79: ...hat the internal Network Interface Card is processing the boot procedure May occur with older versions of microcode No action required EXCESS RIBBON WEAR Install New RBN Status message that displays when ribbon reaches the end of its service life whether the Integrated Print Management System is enabled or not Install a new ribbon Table 3 6600 Error Messages List Displayed Message Explanation Solu...

Page 80: ...e Main Wire Harness Test Tables in Appendix A Replace components that fail test 4 Make sure connector P107 EHF has a good connection at J107 on the controller board 5 Inspect for obstructions of airways and vents Check for items beneath the printer blocking cabinet vents Remove obstructions Make sure cabinet exhaust fan vents are not blocked 6 Power on the printer Check for fan operation If the me...

Page 81: ...ance FRAMING ERROR The printed output may contain random exclamation point characters 1 Make a configuration printout Set printer serial interface parameters to match host configuration settings for Data Protocol Baud Rate Data Bits Stop Bits Parity Data Terminal Ready and Request to Send 2 Send a print job to the printer If the message appears go to Communications Failures page 134 H00 PCI SLOT S...

Page 82: ... replace the controller board Record the message and return it with the defective board H02 PCI J13 See User Manual The controller board is not communicating with the PCI card in PCI slot J13 This could indicate a bad PCI card poor connection or problem in the PCI bus 1 Cycle power If the message appears power down and reseat the PCI card 2 Power on the printer If the message appears move the PCI ...

Page 83: ... user is running look for very dense graphics and layouts Advise the user to run jobs in smaller batches 3 Power off the printer Remove the paper path or pedestal top cover Check all fan cable connections 4 Power on the printer Verify that all fans operate Replace any fan that does not operate 5 Inspect vents and fan airways for obstructions Look underneath cabinet models for items blocking the ca...

Page 84: ...ars replace the controller board Record the message and return it with the defective board HB NOT INSTALLD Hammer Bank Not Installed Self test routines do not detect hammer coils at printer start up Power off the printer Verify that the shuttle frame assembly is installed 1 Install the shuttle frame assembly 2 Remove the paper path or pedestal top cover Verify that the hammer bank logic cable is c...

Page 85: ...ears replace the controller board Record the message and return it with the defective board ILL EXT BUS ACC Illegal External Bus Access Firmware error on the controller board 1 Cycle power Run the print job again If the message appears download the emulation software again page 169 2 Cycle power Run the print job again If the message appears replace the controller board Record the message and retu...

Page 86: ...rinter Remove the installed NIC and replace it with the correct NIC for this printer INTAKE FAN FAULT Sensors cannot detect current in the card cage fan circuit 1 Cycle power If the message appears press CLEAR If the message does not clear go to step 2 2 Power off the printer Remove the paper path or pedestal top cover Disconnect connector P106 from the controller board Test connector P106 CCF for...

Page 87: ...er If the message appears suspect an application software error Request assistance from your local support group Install the original controller board LO DRV SHORT Lower Driver Short Circuit s on the hammer bank or in the hammer bank power cable are shorted to ground 1 Cycle power If the message appears press CLEAR If message does not clear replace the hammer bank logic cable and the hammer bank p...

Page 88: ...he paper path 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 mounted in its bracket 4 Check that connector P106 PMD is fully seated in connector J106 on the controller board 5 Load paper Power on the printer Replace the paper detector switch assembly if message appears 6 Lo...

Page 89: ...f this message appears when saving a configuration it means the printer is out of memory Previously saved configurations will still be available but the one that was saved when the message appeared is not in memory If this message appears at power up it means the flash memory is defective 1 If the message appears at power up replace the flash memory 2 If the message appears while saving a configur...

Page 90: ... bank logic cable and the hammer bank power cable are undamaged and have good connections Replace as necessary Refer to Appendix A 3 Power on the printer Run the print job again If the message appears replace the shuttle frame assembly 4 Power on the printer Run the print job again If the message appears replace the controller board Record the message and return it with the defective board PAP FD ...

Page 91: ...power Run the print job again If the message appears download the emulation software again 2 Power on the printer Run the print job again If the message appears replace the controller board Record the message and return it with the defective board Table 3 6600 Error Messages List Displayed Message Explanation Solution ...

Page 92: ...and have good connections Replace as necessary Refer to Appendix A 3 Check hammer phasing Try using a lower phasing value sometimes this message indicates too high a hammer phase value 4 Power on the printer Run the print job again If the message appears replace the shuttle frame assembly 5 Power on the printer Run the print job again If the message appears do the power supply operational check pa...

Page 93: ...e controller board Record the message and return it with the defective board PAP INVLD CMD Paper Invalid Command Firmware error on the controller board 1 Cycle power Run the print job again If the message appears download the emulation software again 2 Cycle power Run the print job again If the message appears replace the controller board Record the message and return it with the defective board P...

Page 94: ...bly 5 Power on the printer Run the print job again If the message appears replace the controller board Record the message and return it with the defective board PAP NT AT SPEED Paper Not At Speed Firmware error on the controller board 1 Cycle power Run the print job again If the message appears download the emulation software again 2 Cycle power Run the print job again If the message appears repla...

Page 95: ...oad the emulation software again 2 Cycle power Run the print job again If the message appears replace the controller board Record the message and return it with the defective board PLAT INV PARM Platen Invalid Parameter Firmware error on the controller board 1 Cycle power Run the print job again If the message appears download the emulation software again 2 Cycle power Run the print job again If t...

Page 96: ...The printer must never be run at ambient temperatures greater than 40 Celsius 104 Fahrenheit If the printer is located in such an environment relocate it to a cooler cleaner area 1 Inspect printer environment for severity Advise the user to move the printer to cooler cleaner location 2 Check the kinds of print jobs the user is running look for very dense graphics and layouts Advise the user to run...

Page 97: ...vise the user to move the printer to cooler cleaner location 2 Power off the printer Remove the paper path 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 Remove any obstructions from vents and airways 4 Install paper path or pedestal top cover Load paper Power...

Page 98: ...rinter X indicates the region of the printer Install Region X ribbon cartridge in the printer NOTE Specify the region of the printer when ordering ribbons REMOVE USED SPX THEN PRESS ENTER Status message An SPX is depleted because it has successfully reprogrammed the security key on the controller board 1 Remove the SPX from the Debug Port 2 Press the ENTER key The printer will reboot itself RESTOR...

Page 99: ...5 Remove the paper path or pedestal top cover Reseat the ribbon drive motor cable connection 6 Power on the printer Check that the ribbon drive motor winds the ribbon If the ribbon will not wind replace the defective ribbon drive motor 7 If the ribbon continues not to wind replace the controller board and download new function code Record the message and return it with defective board RIBBON UNDER...

Page 100: ...s present replace it 2 Power on the printer If the message appears replace the controller board Record the message and return it with the defective board SHTL MISMATCH Use Correct RBN This message displays when an Extended Life Ribbon is mounted on a 500 lpm printer Install Standard Life Ribbon SHUT DRVR CIR See User Manual The shuttle driver circuit on the controller board is drawing too much cur...

Page 101: ...UTL INV PARM Shuttle Invalid Parameter Firmware error on the controller board 1 Cycle power Run the print job again If the message appears download the emulation software again 2 Cycle power Run the print job again If the message appears replace the controller board Record the message and return it with the defective board SHUTL OVR SPEED The shuttle is oscillating too rapidly Adjust the gap betwe...

Page 102: ... Check that all cables are attached at the shuttle and the controller board Make sure the MPU cable is not pinched Refer to the Interconnection Diagrams in Appendix A Reseat all cables Check the resistance of the MPU at connector P107 Refer to the Main Wire Harness Test Tables in Appendix A Replace the MPU if it fails the test 6 Run a print test If the message appears do the power supply operation...

Page 103: ...ssage appears download the emulation software again page 169 3 Power on the printer If the message appears replace the controller board Record the message and return it with the defective board 4 Power on the printer If the message appears replace the shuttle frame assembly SOFTWARE ERROR CYCLE POWER Application software tried to perform an illegal printer function or damaged logic circuits were d...

Page 104: ...ycle printer power STACK OVERFLOW Firmware error on the controller board 1 Cycle power Run the print job again If the message appears download the emulation software again 2 Cycle power Run the print job again If the message appears replace the controller board Record the message and return it with the defective board STACK UNDERFLOW Firmware error on the controller board 1 Cycle power Run the pri...

Page 105: ...eys are not slipping e the extension springs are attached and undamaged not bent or stretched f the drive rollers are not damaged g the constant force springs are tightly mounted and undamaged Tighten pulley setscrews and or replace damaged components as necessary 3 Adjust the stacker rails if they are not vertical and parallel 4 Check the stacker limit switches See page 121 If the limit switches ...

Page 106: ... go to the next step 3 Power off the printer Remove the paper path Disconnect stacker cables from the controller board stacker assembly and the stacker control panel see Figure 75 page 369 Check cables for cuts breaks or damaged pins Check continuity of cables See Appendix A Replace any cable that is damaged or fails continuity test Table 3 6600 Error Messages List Displayed Message Explanation So...

Page 107: ...r 3 Power on the printer Operate the power stacker and check that a all motors are operating b the paddles are rotating c the elevator moves smoothly and without obstruction d the timing belts are undamaged and the belt pulleys are not slipping e extension springs are attached and not bent or stretched f drive rollers are not damaged Tighten setscrews and replace damaged components as necessary 4 ...

Page 108: ...ter 2 If the printer is online press the ONLINE key to place the printer offline 3 On the control panel press the U V keys to unlock the ENTER key 4 Press the U V Y Z keys simultaneously to enter the Factory Menu 5 Press Z until you reach the PRINTER MGMT menu then press V 6 Press Z until you reach the Diagnostics Port option then press V 7 Press Z until you reach Debug ethernet then press ENTER 8...

Page 109: ...with the defective board UNKNOWN RBN1 Install New RBN The sensor detects a ribbon cartridge but the ribbon model is not permitted on this printer Install a new ribbon UNKNOWN RBN2 Install New RBN The sensor detects a ribbon cartridge but the region code does not match the printer Install a new ribbon UP DRV SHORT Upper Driver Short Hammer driver circuits on the controller board are shorted to grou...

Page 110: ...d was not detected 1 Clear the fault message 2 If message persists replace the cartridge 3 If necessary replace the weld sensor WELD RESET ERROR See User Manual The cartridge weld circuitry lost power 1 Cycle power 2 If the message persists replace the weld sensor and cabling if necessary 3 Replace the cartridge interface board if necessary WELD SENSR ERR See User Manual The weld sensor fails the ...

Page 111: ...ow the numbered instructions 4 If you cannot find the symptom in the General Symptom List use the Half Split Method to find the malfunction a Start at a general level and work down to details b Isolate faults to half the remaining systems at a time until the final half is a field replaceable part or assembly Troubleshooting aids are listed on page 43 5 Replace the defective part or assembly Do not...

Page 112: ...Ribbon folding or feed problems 1 Make sure the ribbon cartridge is correctly installed and fully seated 2 Check that the ribbon runs between the ribbon mask and hammer bank cover Check that the hammer bank cover is installed correctly 3 Check that the ribbon cartridge is not rubbing against the shuttle cover assembly Install the shuttle cover assembly correctly so that the cartridge does not rub ...

Page 113: ...ard if either message appears Record the message and return it with the defective board CLEAR PAPER JAM message will not clear and paper does not move 1 Remove the paper path or pedestal top cover Make sure connector P107 PAPR M is fully seated in connector J107 on the controller board 2 Check the condition and tension of the paper feed timing belt Adjust the paper feed timing belt Replace the bel...

Page 114: ... Clean the paper detector switch if necessary 3 Check that the paper detector switch assembly is securely mounted to the mechanism base Tighten the two screws securing the paper detector switch assembly to the mechanism base 4 Check that the motion detector wheel rotates Replace the paper detector switch assembly if the wheel does not rotate 5 Load paper Power on the printer Replace the paper dete...

Page 115: ...nd return it with the defective board If the LCD displays characters correctly download the emulation software again page 169 Control panel blank 1 Power off the printer Remove the paper path or pedestal top cover Check all cable connections into the controller board make sure the control panel cable is seated in connector J110 on the controller board 2 Power on the printer Inspect the control pan...

Page 116: ...troller board Make sure the control panel cable is seated in connector J110 on the controller board 2 Make sure the SDRAM DIMM is seated properly in its slot on the controller board Reseat and re latch the SDRAM DIMM 3 Power on the printer Inspect the control panel display If the control panel shows broken characters replace the SDRAM Table 4 General Symptom List Symptom Solution ...

Page 117: ...heck all cable connections on the controller board 7 Disconnect AC in power supply cable connector P1 Set the circuit breaker to 1 on Measure AC voltage at pins 1 and 2 of connector P1 If no voltage replace the circuit breaker If there is voltage replace the power supply board Printer does not initialize NOTE Power on initialization is explained on page 152 1 Power off the printer Remove the paper...

Page 118: ... 2 and 5 volts DC between pins 3 and 4 If the voltages are correct replace the stacker control panel If the voltages are not correct power off the printer remove the paper path and disconnect the stacker power cable from the controller board See Figure 77 page 371 Check the continuity of the stacker power cable between P105 and P106 If the cable fails the continuity test replace it If the cable is...

Page 119: ...k that the limit switches are being tripped at the highest and lowest limits of elevator travel 4 Power on the printer Operate the power stacker Refer to the User s Manual While the stacker is operating check that a all motors are operating b the paddles are rotating c the elevator moves smoothly and without obstruction d the timing belts are undamaged and the belt pulleys are not slipping e the e...

Page 120: ...s See page 121 If the limit switches are OK go to the next step 5 Check the stacker motors See page 122 If the stacker motors are OK go to the next step 6 Remove the paper path Disconnect stacker cables from the controller board stacker assembly and the stacker control panel see Figure 74 page 368 Check cables for cuts breaks or damaged pins Check continuity of cables See Appendix A Replace any ca...

Page 121: ...n the stacker control 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 printer and replace the lower limit switch 4 Press the Elevator Disable Switch and manually move the elevator all the way down to the bottom of its travel 5 Position a small powerful magnet betwee...

Page 122: ...r control panel See Figure 74 page 368 5 Disconnect stacker frame cable connector P102 from connector J4 on the rear of the stacker control panel See Figure 74 page 368 6 Locate pin 1 of connector P102 and connector P107 See the cable assembly drawings in Appendix A page 333 and page 336 7 Check both cables for pin damage continuity and shorts 8 Check all motors for 15 2 1 5 Ohms on both phases Re...

Page 123: ...talled on its mounting pegs Check the shuttle frame assembly for broken hammer springs hammer tips or contaminations Replace any damaged hammer spring assemblies Replace the hammer bank cover assembly if it is deformed or damaged 6 Check the platen gap Adjust the platen gap if necessary 7 Remove the paper guide assembly or pedestal top cover Make sure Connectors P105 and P108 have good connections...

Page 124: ...y If the pattern of H s did not print OK go to the next step 2 Check the hammer phasing Adjust hammer phasing if necessary 3 Check the dynamic paper tension 4 Inspect the shuttle frame assembly area for ink residue paper chaff or debris Clean the shuttle frame assembly 5 Check the MPU gap Using a feeler gauge adjust the gap between the MPU assembly and the flywheel to 0 010 0 001 inch 0 254 0 025 ...

Page 125: ...he printer is plugged in to a grounded power outlet Power on the printer Run a print test If the problem occurs replace the hammer bank logic cable 5 Power on the printer Run a print test If the problem occurs replace the flash memory and SDRAM Download the emulation software again 6 Power on the printer Run a print test If the problem occurs replace the controller board 7 Power on the printer Run...

Page 126: ...eed timing belt Adjust the paper feed timing belt Replace the belt if it is damaged 3 Check the platen gap Adjust the platen gap 4 Inspect the 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 5 Check the dynamic paper tension 6 Remove the paper guide a...

Page 127: ...he download fails activate the Boot Diagnostics Menu page 141 and run MISC TOOLS MENU RUN MEMORY TESTS If memory fails test replace the SDRAM If memory tests OK replace the flash SIMM Boot code won t copy 1 Power off the printer Remove the flash SIMM Inspect the flash SIMM socket on the controller board If any SIMM socket pins are bent or damaged replace the controller board 2 Make sure the blank ...

Page 128: ...ssembly for ribbon debris paper debris or other foreign matter Make sure the four foam spacers on the ribbon mask are properly seated If the ribbon mask 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 on the splined and support shafts d Make sure t...

Page 129: ...printer interface 2 Make a configuration printout Verify that the printer matches host interface settings Set printer interface parameters to match those of the host 3 Power on the printer Send a print job from the host If printer does not print and the interface is RS 232 interchange the wires to pins 2 and 3 This is the most common cause of an inoperative RS 232 cable Verify that the host and pr...

Page 130: ...t run replace the controller board Reverse paper feed platen does not open 1 Raise the forms thickness lever and check that the platen opens If the platen opens with difficulty inspect for and remove jams or obstructions 2 Check the condition and tension of the platen open belt Adjust the platen open belt Replace the belt if it is damaged 3 Check the platen gap Adjust the platen gap 4 Power off th...

Page 131: ... timing belt Adjust the paper feed timing belt Replace the belt if it is damaged 4 Check the dynamic paper tension 5 Remove the paper path or pedestal top cover Make sure connector P107 PAPR M is fully seated in connector J107 on the controller board Connect P107 PAPR M to J107 on the controller board 6 Power on the printer Load paper and set TOF Press FF and VIEW several times and check that pape...

Page 132: ...just the platen gap 5 Inspect the ribbon mask for bends or deformation that snag and interfere with shuttle movement Make sure the hammer bank cover assembly is correctly installed on its mounting pegs Reinstall the hammer bank cover assembly Replace a damaged or deformed hammer bank cover assembly 6 Check continuity of the shuttle motor drive cable assembly Replace shuttle motor drive cable assem...

Page 133: ...t the shuttle area for loose hardware Tighten loose hardware 4 Check that the hammer bank cover assembly is correctly installed that it has not slipped off the mounting pegs Check that the ribbon mask has not partially separated from the hammer bank cover Check for debris trapped between the ribbon mask hammer bank cover and hammer bank Clean the shuttle frame assembly and hammer bank cover assemb...

Page 134: ... your support group for assistance in problem analysis If you cannot obtain support or you have experience solving host printer communications problems the following additional information is provided You can quickly check the ASCII portion of the printer logic by sending a plain text file from a PC to the printer via the parallel or serial port For a description of each of the ASCII interfaces re...

Page 135: ...d be able to access the ethernet card now through a browser by using the IP address as a URL as for example http xxx xxx xxx xxx NOTE If the ethernet card cannot be accessed by the Printer Manager do the steps listed under TCP Port Busy on page 108 Ethernet PCBA responds to ping telnet and ftp utilities but will not communicate from the host computer Ethernet 1 Open a telnet session using the IP a...

Page 136: ...ou can also use this test to check ribbon tracking and reversing Shuttle Fast Exercises the shuttle and ribbon mechanisms at high speed You can also use this test to check ribbon tracking and reversing Shuttle Only Runs the shuttle mechanism with no ribbon movement Phase Printer A hammer timing test that permits you to adjust the hammer phase value The hammer phase value is a timing parameter that...

Page 137: ...alled ribbon ribbon part number ribbon brand name ribbon life and ribbon end point Weld Patch Log Prints the ribbon weld log Checker This pattern helps identify marginal printhead elements quality of edge sharpness and uneven print quality Selecting And Running Diagnostic Printer Tests NOTE You must set TOF after running any diagnostic test Step Press LCD Result Notes 1 Make sure the printer is on...

Page 138: ...choices X Full Width or X 80 columns 13 Test Width X Test width is selected 14 PATTERN TEST WIDTH 15 PATTERN PRINTER TESTS 16 Printer Tests Shift Recycle 17 Printer Tests All E s Cycle through the choices 18 Printer Tests All E s Starts test 19 Printer Tests All E s Stops test Step Press LCD Result Notes UNTIL OR ENTER UNTIL OR ENTER ENTER ...

Page 139: ... SWITCH LOCKED Locks the ENTER key and control panel 21 ONLINE CONFIG 1 Places the printer in online mode 22 Examine print quality Characters should be fully formed and of uniform density 23 Set TOF Refer to the User s Manual Step Press LCD Result Notes ONLINE ...

Page 140: ... Load paper 3 Set TOF Refer to the User s Manual 4 OFFLINE QUICK SETUP The printer must be offline to run a print test 5 ENTER SWITCH UNLOCKED Unlocks ENTER key and control panel 6 OFFLINE QUICK SETUP 7 OFFLINE TEST MENU 8 TEST MENU PATTERN 9 PATTERN PRINTER TESTS 10 Printer Tests Shift Recycle 11 Printer Tests Ethernet Test 12 Printer Tests Ethernet Test Starts printing ONLINE MENU ENTER UNTIL OR...

Page 141: ...lding Y V set the printer power switch to 1 on 4 When BOOT DIAGNOSTICS PRESS ENTER appears on the LCD release the Y V keys and press the ENTER key Menu options are shown in Figure 8 Exiting The Boot Diagnostics Menu Method 1 Use the exit option in the Boot Diagnostics Menu 1 Using the arrow keys move to the DIAGNOSTICS MENU EXIT DIAGNOSTICS menu option Refer to the menu map on page 142 2 Press the...

Page 142: ...TER DIAGNOSTICS MENU FILE SYSTEM FILE SYSTEM MENU VIEW FILES ENTER VIEW FILES 93779 sf Continued on next page VIEW FILES FILENAME FILE STATS MENU BYTES AVAILABLE FILE SYSTEM MENU FILE STATISTICS FILE SYSTEM MENU OPTIMIZE FILES OPTIMIZING FLASH FILES ENTER FILE STATS MENU BYTES USED FILE STATS MENU UNOPTIMIZE BYTES FILE STATS MENU TOTAL ERASE CYCL FILE STATS MENU DELETED FILES FILE STATS MENU NUMBE...

Page 143: ...TER Down Arrow Key Next Arrow Key CACHE CONT MENU INSTRN CACHE OFF CACHE CONT MENU DATA CACHE ON CACHE CONT MENU INSTRN CACHE ON CACHE CONT MENU ALL CACHE ON SHOW STATUS MENU SHOW STATUS OFF SHOW STATUS MENU SHOW STATUS ON DIAGNOSTICS MENU EXCEPTION VIEWER A EXCEPTION MENU VIEW EXCEPTION EXCEPTION MENU WHERE IT OCCURED EXCEPTION MENU PPC INSTRUCTION NO EXCEPTION HAS OCCURRED OCCURRED AT ADDRESS 00...

Page 144: ...enu 1 Plug the AC power cord into the printer and the power source 2 Power on the printer 3 The printer must be offline to do this procedure If the printer is online press the ONLINE key Press the MENU ENTER key and OFFLINE QUICK SETUP will display 4 On the control panel press the U V keys to unlock the ENTER key ENTER SWITCH UNLOCKED briefly displays If LOCKED displays simply press U V again This...

Page 145: ...e on page 178 Factory PRINTER MGMT Factory Demo Count Demo Count 1 2 5 10 Continuous Use to view options Debug Port Cfg Baud Rate Baud Rate 9600 BAUD 19200 BAUD Use to view options 38400 BAUD 57600 BAUD 115200 BAUD 2400 BAUD 4800 BAUD Debug Port Cfg Word Length Word Length 8 7 Use to view options Debug Port Cfg Stop Bits Stop Bits 1 2 Use to view options Debug Port Cfg Parity Parity None Odd Use t...

Page 146: ...ENTER key The cause of the fault will display Write down the cause of the fault For example Machine Check Exception Error Machine Check 3 Press the Z RIGHT arrow key twice Where it Occurred will display 4 Press the ENTER key The address of the fault will display Write down the address of the fault For example 002BA160 5 Press the Z RIGHT arrow key twice PPC Instruction will display 6 Press the ENT...

Page 147: ...ild A special serial diagnostic port cable is required to connect the printer to a terminal emulator program on a PC The terminal emulator can then display and capture information directly from the printer Diagnostic Cable The printer debug port is a female RJ 12 connector The debug cable is a male RJ 12 to 9 pin PC RS232 connector A description of the pin outs is shown below Table 6 RJ 12 and DB ...

Page 148: ...r COM2 3 Turn on the file capture in the terminal emulator to log the information coming from the printer Transfer Capture File 4 Press the Return key on the PC If the connection is correct the following shall display on the terminal emulator Running The diagnosing engineer will tell you which command to type When a valid command is typed the printer will respond by printing the requested informat...

Page 149: ...quivalent If the printer is using a parallel interface the letter p before a hex code indicates an active Paper Instruction PI line and a blank space before a hex code indicates an inactive PI line To convert an ASCII character to its corresponding hex code or vice versa refer to the ASCII code chart on page 151 To make a hex code printout refer to the procedure on page 149 How To Print A Hex Dump...

Page 150: ...TER key and control panel 11 ONLINE DUMP ON Places the printer in online mode 12 Send a file from the host computer the printer outputs a hex dump Refer to the ASCII chart on page 151 13 When the hex dump is complete take the printer offline and change the Hex Dump Mode back to OFF Follow the steps outlined above and select OFF Step Press LCD Result Notes OR ENTER ONLINE ...

Page 151: ...29 52 42 2A 53 43 2B 54 44 2C 55 45 2D 56 46 2E 57 47 2F 0 1 2 3 4 5 6 7 8 9 60 48 30 61 49 31 62 50 32 63 51 33 64 52 34 65 53 35 66 54 36 67 55 37 70 56 38 71 57 39 72 58 3A 73 59 3B 74 60 3C 75 61 3D 76 62 3E 77 63 3F A B C D E F G H I J K L M N O 100 64 40 101 65 41 102 66 42 103 67 43 104 68 44 105 69 45 106 70 46 107 71 47 110 72 48 111 73 49 112 74 4A 113 75 4B 114 76 4C 115 77 4D 116 78 4E...

Page 152: ...lization and diagnostic routines This is also called cycling power 1 Set the printer power switch to O off 2 Wait 15 seconds 3 Set the printer power switch to 1 on NOTE A hard printer reset causes the 48V power supply fans motors etc to shut down in 1 to 5 seconds depending on the amount of memory installed on the controller board ...

Page 153: ...inter to Normal Operation page 155 Belt Paper Feed Timing Adjustment page 156 Belt Platen Open Adjustment page 158 Paper Scale Alignment page 160 Platen Gap Adjustment page 162 Paper Out Adjustment page 164 Hammer Phasing Adjustment page 167 Loading Flash Memory page 169 Reprogramming the Security Key page 176 Coil Temperature Adjustment page 178 Dynamic Paper Tension Adjustment page 179 Tractor B...

Page 154: ...rrected by replacing the printed circuit board assembly sensor or cable that causes the fault indication This is also true of failures traced to the hammer bank it is not field repairable and you must replace the entire shuttle frame assembly Hammer spring assemblies are the only replaceable components of the shuttle frame assembly To prepare the printer for maintenance do the following steps befo...

Page 155: ...he data signal cable s to the printer interface 3 Plug the AC power cord into the printer and the power source 4 Close the cabinet doors and the printer cover 5 Set the printer power switch to on 6 Test printer operation by selecting and running one of the operator print tests See page 136 7 Select the emulation Refer to the User s Manual 8 Set the top of form Refer to the User s Manual ...

Page 156: ...or mount bolts 2 5 Using the straight end of a force gauge apply 15 pounds 66 7 N of pressure to the paper feed drive motor 3 Use the splined shaft 4 to steady the gauge 6 Reduce tension to 12 pounds 53 4 N and torque the 5 16 inch paper feed motor mount bolts 2 to 18 inch pounds 2 03 N m NOTE Belt tension is correct if the belt deflects 1 8 inch 3 175 mm midway between the pulleys 7 Snap the timi...

Page 157: ... and Tests 157 Legend 1 Timing Belt Shield 2 Motor Mount Bolt 2 3 Paper Feed Drive Motor 4 Splined Shaft Figure 10 Paper Feed Timing Belt Adjustment 183985a 183930a 184074a Direction of Force 1 3 4 A A 1 8 inch 2 ...

Page 158: ...te 5 Close the forms thickness lever all the way CAUTION 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 The spring will automatically tension the belt 7 Slowly tighten the motor adjustment screw 2 NOTE Belt tension is correct if the belt deflects 3 16 inch 4 76 mm midway between...

Page 159: ...Adjustments and Tests 159 Legend 1 Belt Cover 2 Motor Mount Screw 2 3 Platen Open Motor Shaft Figure 11 Platen Open Belt Adjustment 183931a A 1 2 3 2 183891a A 183932a 3 16 inch ...

Page 160: ... a full 136 column line by selecting and running one of the diagnostic self tests See page 136 7 Check alignment of the scale to the print at column positions 1 and 136 8 If adjustment is necessary loosen the three 5 64 inch button head hex screws 2 9 Position the scale 3 so that column positions 1 and 136 line up with the first and last characters on the 136 character printout 10 Tighten the 5 64...

Page 161: ...Adjustments and Tests 161 Legend 1 Shuttle Cover 2 Screw Button Head 5 64 inch hex 3 3 Paper Scale Figure 12 Paper Scale Alignment 183891a 1 2 2 2 3 ...

Page 162: ...4 turn on one side then check the other side Adjustment sensitivity is approximately 0 03 inch per revolution of the setscrew Also insert the feeler gauge no more than 2 inches down from the top of the ribbon mask 8 Gently close the forms thickness lever 2 all the way As the platen is closing gently slide the feeler gauge up and down keeping it between the hammer tip and ribbon mask If the feel is...

Page 163: ...gend 1 Platen Stop Knob 2 Forms Thickness Lever 3 Feeler Gauge 4 Hammer Bank Cover 5 Ribbon Mask 6 Setscrew 3 32 inch hex 2 Figure 13 Platen Gap Adjustment 183935a NOTE Right side adjustment shown Left side is the same 3 4 5 6 2 1 ...

Page 164: ... although it is not required it is advisable to test the paper out triggering distance with 6 part paper in order to verify correct printing with multi part forms The procedure below describes how to run the Paperout Adj test and modify the paper out Dots value 1 Open the printer cover 2 On cabinet models open the cabinet front door 3 Load paper Make sure the forms thickness lever is closed 4 Powe...

Page 165: ...the vertical position knob and examine the area of the page perforation If the bottom of the comb just meets the perforation the paper out adjustment distance is correct skip to step 27 1 or 2 dot rows above the perforation is OK 5 to 7 dot rows above or any dots below the perforation mean adjustment of the Paper Out Dots value is required If the comb pattern stopped short of the perforation or pr...

Page 166: ... decrease the number of dots 24 Press ENTER to select the new number of dots as the active value The asterisk that appears tells you that it is now the active value 25 Press CLEAR to place the printer offline Press the MENU ENTER key and OFFLINE QUICK SETUP displays 26 Run the Paper Out Dots and the Paper Out Adjustment tests until the comb pattern prints at an acceptable distance from the page pe...

Page 167: ... s when the Phasing Value is changed or the New Phasing Value will not be written into memory If the value is changed when not printing the printer will return to its default phasing value when powered off then back on 1 Load full width 136 column paper and set the top of form 2 Power on the printer 3 If the printer is online press the ONLINE key to place the printer offline Press the MENU ENTER k...

Page 168: ...phasing index until the pattern of H s is acceptable 12 Press U twice Printer Tests Phase Printer displays 13 Press ENTER to stop the test 14 Press CLEAR OFFLINE displays 15 Press U V or the key combination set by the user ENTER SWITCH LOCKED briefly displays 16 Close the printer cover 17 Press the ONLINE key to place the printer online NOTE If you changed the phasing value power down the printer ...

Page 169: ... CD ROM to a computer s hard disk then download the file from the computer into printer memory IMPORTANT When downloading emulation and operating system software to the printer all other optional fonts customer supplied logos setup files feature files and TIFF files will be erased You will need to reload those files Before starting a download make sure you have all the necessary files on hand You ...

Page 170: ...r you will use to download the software 5 Connect the printer data cable to the appropriate I O port of the printer 6 On the printer control panel press and hold down the ONLINE and FF keys Without releasing the keys power the printer on When you see B01 STATUS 8245 SDRAM TEST 32MB on the LCD release the keys 7 Wait until you see PROGRAM DOWNLOAD on the LCD before doing the next step This can take...

Page 171: ...aved configurations Refer to the User s Manual 2 Set the printer power switch to O Off 3 Disconnect the data signal cable s from the printer interface connectors 4 Connect a parallel data printer cable to the LPT1 port or a serial data printer cable to the COM1 port of an IBM compatible computer running the PC DOS MS DOS or Windows 3 1x 95 98 Me NT 2000 or XP operating system NOTE Software loads a...

Page 172: ...mputer type the following at the command prompt on the computer filename exe pb Enter where filename exe is the file name you noted in step 11 This command decompresses the file on the hard drive and copies it as a binary file into the flash memory on the printer controller board IMPORTANT Do not interrupt the downloading process once it has started Interrupting a download will leave the flash mem...

Page 173: ... hold down the ONLINE FF VIEW keys Without releasing the keys power the printer on When you see B01 STATUS 8245 SDRAM TEST 32MB on the LCD release the keys 8 Wait until you see B20 STATUS 00 DOWNLOAD MODE or PROGRAM DOWNLOAD on the LCD before doing the next step 9 Using Windows Explorer create a directory named download at the root level of your C hard drive C download 10 Insert the printer emulat...

Page 174: ...the User s Manual 2 Set the printer power switch to O Off 3 Connect the ethernet cable to the printer interface 4 On the printer control panel press and hold down the ONLINE and FF keys Without releasing the keys power the printer on When you see B01 STATUS 8245 SDRAM TEST 32MB on the LCD release the keys 5 Wait until you see PROGRAM DOWNLOAD on the LCD before doing the next step This can take a f...

Page 175: ... memory on the controller board and NIC incompletely loaded and the printer may not boot up 14 When the new software has successfully loaded into flash memory and the printer has reset itself set the printer power switch to O off 15 Remove the CD ROM from the host computer and store it with the printer 16 If required reconnect the data input cable s to the printer 17 Set the printer power switch t...

Page 176: ...ntroller board The SPX is used only once It automatically overwrites itself after successfully reprogramming a security key 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 the user is not required to return it to the vendor or manufacturer How to Reprogram the Security Key 1 Power off the printer 2 On cabinet models...

Page 177: ...ramming sequence The display will read DO NOT POWER OFF Upgrading 7 When the security key is reprogrammed the display will read REMOVE USED SPX THEN PRESS ENTER 8 Remove the SPX from the debug port 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 not ...

Page 178: ...rinter must be offline to do this procedure If the printer is online press the ONLINE key Press the MENU ENTER key and OFFLINE QUICK SETUP will display 4 On the control panel press the U V keys to unlock the ENTER key ENTER SWITCH UNLOCKED briefly displays If LOCKED displays simply press and again This is the default key combination The lock unlock key combination can be programmed by the user If ...

Page 179: ...t the perforations The paper must be single part 18 lb maximum weight 0 0036 inch 0 09 mm maximum thickness Open the cabinet front door and feed the paper up through the print station until the first page clears the ribbon mask by about one inch Figure 16 5 Fold a two inch piece of plastic tape over the top sheet midway between the sides as shown in Figure 16 detail A Figure 16 Preparing Paper for...

Page 180: ... necessary and recheck the dynamic paper tension 12 If the platen gap is correct remove the shuttle frame assembly page 239 and check the following a Inspect the hammer bank cover assembly for ribbon debris paper debris or other foreign matter If the ribbon mask or hammer bank cover is damaged or deformed replace it b Inspect the paper ironer for distortion or misalignment Reposition or replace it...

Page 181: ...per 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 the adjustment screw one detent to increase tension On the inner side of the right tractor use a Torx T 10 driver to rotate the adjustment screw one detent to increase tension See Figure 18 5 Load paper run a print test and check for first line compression 6 If co...

Page 182: ...bank logic cable P04 and the hammer bank power cable P05 at the shuttle 7 Set your Ohmmeter to the 10K Ohm scale or the scale closest to 10K Ohms 8 Hold the two meter leads apart from each other not touching anything and note how your meter indicates an open circuit For example some meters read OL Over Load 1 flashing display infinite resistance etc 9 Attach the common meter lead usually black to ...

Page 183: ...ch of the 10 pins with the positive usually red meter lead and test 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 checking pin to pin touch pin 1 with one meter lead and pin 2 with the other meter lead If there is continuity it means there is a sho...

Page 184: ...e the cable routing as it was before you started this procedure 3 Set your Ohmmeter to the 10K Ohm scale or the scale closest to 10K Ohms 4 Hold the two meter leads apart from each other not touching anything and note how your meter indicates an open circuit For example some meters read OL Over Load 1 flashing display infinite resistance etc Record this indication for later reference Check for sho...

Page 185: ...d touching the positive usually red meter lead to pin 2 at the same end of the cable 12 Check for a pin to pin short which is indicated by a meter reading of continuity that is a low resistance of less than 1 Ohm For a properly functioning cable that has no pin to pin short you will see the open circuit meter reading you recorded in step 4 13 If you find a short replace the cable If no short is de...

Page 186: ... find any shorts in a motor replace the motor c Replace any defective devices 5 Shuttle Motor test a Remove the ribbon b Remove the shuttle cover assembly page 203 c Disconnect cable P02 d At P02 check for approximately 0 7 Ohms per phase Use this value to test for winding continuity and for no shorts between windings and the motor frame Rotate the motor by hand and test for shorts e Replace the s...

Page 187: ...me limit to how long the Load Block 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 154 2 Cabinet Models Remove the paper path page 222 Pedestal Models Remove the top cover assembly page 204 CAUTION To prevent electrostatic damage to electronic components wear a grounded static wrist strap when you work around the...

Page 188: ...4 85 to 5 15 volts Figure 20 11 Measure the voltage at the NTEMPHI test point it should be greater than 2 4 volts Figure 20 12 Measure the voltage at the 48 V test point it should be less than 0 2 volts Figure 20 13 Measure the voltage at the 8 5 V test point it should be less than 0 2 volts Figure 20 14 Press and HOLD IN the Push Button on the Monitor Block Figure 20 15 Measure the 5 V test point...

Page 189: ...ies a small electrical load to the power supply The tester load on the 5 volts is about 1 3 amps so that a printer boot up should be possible if the power supply tests OK However it is also possible that a power supply can test OK but still have an internal problem that prevents it from supporting a full print load If the printer still does not print jobs correctly after the power supply has teste...

Page 190: ...pply tester Load Block Figure 19 24 Connect power supply cable connector P101 to either the power stacker power cable or connector J101 on the controller board Figure 19 25 Cabinet Models Install the paper path page 222 Pedestal Models Install the top cover assembly page 204 26 Return the printer to normal operation page 155 ...

Page 191: ...repair these items in the field Also do not attempt field repairs of electronic components or assemblies Do not de solder any circuit board components 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 fault indication The same is true of failures traced to the...

Page 192: ... Motor Bracket Assembly page 219 Paper Feed Motor page 220 Paper Ironer page 221 Paper Guide Assembly page 222 Platen page 223 Platen Open Motor page 227 Platen Stop Assembly and Forms Thickness Lever page 229 Power Supply Board page 230 Resistors Terminating V6 Controller Board page 231 Ribbon Drive Motor page 233 Security Key page 234 Shaft Splined page 236 Shaft Support page 238 Shuttle Frame A...

Page 193: ...t pulley Installation 1 Roll the paper feed timing belt onto the splined shaft pulley and the motor pulley 2 Using the straight end of a force gauge apply 15 pounds 66 7 N of pressure to the paper feed drive motor Use the splined shaft to steady the gauge See page 157 item 2 NOTE Belt tension is correct if the belt deflects 1 8 inch 3 175 mm midway between the pulleys 3 Reduce tension to 12 pounds...

Page 194: ... item 3 6 Roll the platen open belt off the motor pulley and platen open pulley Installation 1 Push the platen motor toward the front of the printer and install the platen open belt over the platen open pulley and the motor pulley See page 159 item 3 2 Release the platen open motor the spring will automatically tension the belt 3 Slowly tighten the motor adjustment screw See page 159 item 2 NOTE B...

Page 195: ...et assembly 4 Remove the cartridge interface board Installation 1 Reverse step 2 through step 4 of the removal procedure 2 Mount the cartridge interface board onto the motor bracket assembly and secure by using three 6 32 x 1 4 inch button head fasteners 3 Torque the three fasteners to 18 inch lbs NOTE Make sure the cable from the motor is oriented to the right side of the bracket 4 Install the mo...

Page 196: ... the circuit breaker from the printer Installation 1 Press the circuit breaker into the cutout until the spring clips snap into place Cabinet models See page 274 Pedestal models See page 260 CAUTION To prevent severe damage to the printer the circuit breaker electrical leads must be connected correctly 2 Connect the four circuit breaker electrical leads Cabinet Models See page 274 Pedestal Models ...

Page 197: ... connectors 5 Disengage the key tab s on the cable connector from the slots in the side of the coupling shroud 6 Remove the cable connector from the coupling shroud Remove only the cable connector for the cable you are replacing leave the other cable connectors in the coupling shroud Installation 1 Position the cable connector in the connector coupling shroud Two wire connectors are always grouped...

Page 198: ...rom the controller board CCF Card Cage Fan PLAT M Platen Motor PMD Paper Motion Detector Switch POD Paper Out Detect Switch SP2 2 Position Spacer SP4 4 Position Spacer EHF Exhaust Fan HBF Hammer Bank Fan MPU Magnetic Pickup Unit PLO Platen Open Switch RIB M Ribbon Motor SP4 4 Position Spacer Spacer for 20 only PAPR M for 05 10 15 P106 Connector Configuration P107 Connector Configuration 8 6 4 2 7 ...

Page 199: ...two screws securing the control panel to the panel bracket See page 250 items 1 and 11 5 Remove the control panel assembly from the panel bracket Installation 1 Engage the slot on the bottom of the control panel on the bottom edge of the panel bracket cutout See page 250 items 1 and 11 2 Align the holes on the top rear of the control panel with the holes in the upper edge of the panel bracket and ...

Page 200: ...serial cable connector J201 6 Loosen but do not remove the screw securing the metal shield to the bottom of the card cage on the left side near the card cage fan CAUTION Do not separate the controller board from the metal shield The shield serves as a stiffener and ground plane and is an integral part of the controller board assembly 7 Slide the controller board assembly to the left until the keyw...

Page 201: ...page 262 3 Tighten the two screws securing the metal shield near serial cable connector J201 4 Tighten the screw securing the metal shield to the bottom of the card cage 5 Connect all cable connectors to the controller board using the Interconnection Diagram in Appendix A as your guide 6 Cabinet Models Install the paper path page 222 Pedestal Models Install the top cover assembly page 204 IMPORTAN...

Page 202: ...he cover against 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 engage the center round hole then the left oblong hole to ensure that the cover lies flat on the hammer bank See Figure 22 2 Gently lower the hammer bank cover assembly until it lies flush o...

Page 203: ... rear edge up 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 cover into position NOTE Make sure the two posts on the shuttle cover seat into the circular recesses in the base casting 2 Plug the weld sensor cable page 304 3 Tighten the shuttle cover screws page 256 it...

Page 204: ...hillips hold down screws on the rear of the printer See page 252 item 5 4 Remove the 2 Phillips screw in the lower left front corner of the top cover and the screw just to the right of the control panel bracket See page 252 item 3 5 Lift the top cover assembly off the printer base Installation 1 Reverse steps step 3 through step 5 of the removal procedure 2 Return the printer to normal operation p...

Page 205: ...stallation CAUTION Install the dashpot with the narrow rod uppermost Two persons may be required to do this procedure Prop or hold the printer cover securely while installing the dashpot 1 Position the dashpot against the ball studs on the upper and lower brackets with the narrow rod uppermost See Figure 40 page 250 2 Using external grip ring pliers to spread the retaining clips push the dashpot o...

Page 206: ...t duct See page 250 item 4 5 Remove the 1 4 inch screw directly below the forms thickness lever 6 Disconnect the fan cable connector from connector P307 and remove the air exhaust duct 7 Disconnect the fan cable connector from the side of the air exhaust duct 8 Remove the two 1 4 inch fan mounting screws and the cabinet exhaust fan assembly Installation CAUTION Air flow is DOWN Install the cabinet...

Page 207: ... fan mounting screws from the bottom of the fan See page 272 item 2 Pedestal Models Remove the four fan mounting screws and nut See page 260 items 1 through 4 5 Remove the card cage fan assembly from the card cage Installation CAUTION Air flow is INTO the card cage Install the card cage fan so the label faces toward the inside of the printer and the cable faces the front of the printer 1 Reverse s...

Page 208: ...nd cable connector out from between the base casting and the base pan See page 272 items 21 and 22 Installation CAUTION Air flow is UP Install the hammer bank fan so the label faces up 1 Feed the hammer bank fan cable connector and motor wires between the fan well of the base casting and the base pan Reach up under the base casting and route the fan cable to the right and angle the hammer bank fan...

Page 209: ...ns See Figure 23 7 Inspect the hammer bank and the old hammer spring assembly a If there is ink on the hammer bank mounting surface that was under the hammer spring or if there is ink on the hammer spring assembly mounting surface that was against the hammer bank or if there is ink on the hammer spring neck or tines ink migration has occured Reinstall the old hammer spring assembly and replace the...

Page 210: ...pter and starting with the inner screws torque each screw to 14 inch pounds 1 58 N m See Figure 24 5 Install the hammer bank cover assembly page 202 6 Install the shuttle frame assembly page 239 7 Install the ribbon and load paper CAUTION Do not attempt to adjust or tweak hammer springs 8 Run a Diagnostic Printer Test and check print quality page 136 a If print quality is acceptable return the pri...

Page 211: ...the screws that secured it 8 Inspect the hammer bank and the old hammer spring assembly a If there is ink on the hammer bank mounting surface that was under the hammer spring or if there is ink on the hammer spring assembly mounting surface that was against the hammer bank or if there is ink on the hammer spring neck or tines ink migration has occured Reinstall the old hammer spring assembly and r...

Page 212: ... screws from the box 3 Handling the hammer spring assembly by the mounting base position it on the hammer bank and center it over the mounting screw holes See Figure 26 4 Position the tip alignment tool over the end hammer tips of the new hammer spring and the end hammer tips of the adjacent hammer springs used for alignment Use the guide tool to maneuver the hammer tips into the alignment tool Se...

Page 213: ... both hammer springs Do not bend or re use the tip alignment tool 7 Install the hammer bank cover assembly page 202 8 Install the shuttle frame assembly page 239 9 Install the ribbon and load paper CAUTION Do not attempt to adjust or tweak hammer springs 10 Run a Diagnostic Printer Test and check print quality page 136 a If print quality is acceptable return the printer to normal operation page 15...

Page 214: ...y to the mounting base 2 Handling the hammer spring assemblies by the mounting bases only remove the new assemblies and mounting screws from the boxes 3 Handling the hammer spring assemblies by the mounting base position them on the hammer bank Center the hammer spring assemblies as closely as possible over the mounting screw holes in the hammer bank 4 Gently position the Long Tip Alignment Tool s...

Page 215: ... and gently swivel the guide tool in the hammer spring mounting holes to maneuver the hammer tips into the clearance and alignment holes in the alignment tool You will feel and or hear a small click when the hammer tips slip into the holes See Figure 29 Figure 29 Using the guide tool to maneuver the hammer tips into the alignment tool holes 184086a Long Tip Alignment Tool Apply gentle downward pre...

Page 216: ...ll hammer spring assemblies gently lift the long tip alignment tool off both hammer springs 8 Install the hammer bank cover assembly page 202 9 Install the shuttle frame assembly page 239 10 Install the ribbon and load paper CAUTION Do not attempt to adjust or tweak hammer springs 11 Run a Diagnostic Printer Test and check print quality page 136 a If print quality is acceptable return the printer ...

Page 217: ...U assembly and the flywheel to 0 010 001 inch 0 254 0 025 mm Torque the 7 16 inch MPU clamp screw to 18 inch pounds 2 03 N m 3 Check the gap between the MPU assembly and the flywheel with a feeler gauge a If the gap is 0 010 001 inch 0 254 0 025 mm go to step step 4 b If the gap is not 0 010 0 001 inch 0 254 0 025 mm loosen the MPU clamp screw and go back to step step 2 4 Route the MPU cable under...

Page 218: ...Installing flash memory from one controller board to another does not transfer all operating system software so you must download the emulation again 1 Put on a static wrist strap and ground the lead to an unpainted part of the printer frame Touch the printer frame with the hand wearing the wrist strap before you touch memory modules or the controller board 2 Insert the expansion flash SIMM in soc...

Page 219: ...cartridge Refer to the User s Manual 5 Remove the shuttle cover page 203 6 Disconnect the ribbon drive motor cable connector page 272 item 12 cable portion 7 Remove the three 6 32 x 1 2 captive screws securing the motor bracket assembly to the mech base 8 Unplug the weld sensor cable from the CIB PCBA 9 Remove the motor bracket assembly you may have to wiggle it off of the guide pins Installation ...

Page 220: ...s have threaded flanges eliminating the need for nuts 8 Remove the motor mount screws and nuts if present 9 Remove the paper feed motor assembly Installation 1 Position the paper feed motor assembly on the right side plate and install the motor mount bolts and nuts finger tight See page 272 items 6 and 18 2 Connect the paper feed motor cable connector to connector P107 then connect P107 to J107 on...

Page 221: ...rectly in front of the standard paper ironer Installation NOTE The black tape on the standard paper ironer faces toward the rear of the printer and toward the paper detector switch assembly 1 Position the paper ironer so the black tape is on the side that faces the rear of the printer towards the paper detector switch assembly See page 270 item 3 2 Push the paper ironer down into the slots until t...

Page 222: ...ft it off the card cage Installation 1 Position the paper path offset slightly to the left on the card cage with the keyway cutouts over the three loosened screws See Figure 31 2 Slide the paper path to the right engaging the three screws in the keyway slots Slide the paper path to the right as far as it will go 3 Tighten the screws securing the paper path to the card cage See Figure 31 4 Return t...

Page 223: ...270 items 16 17 and 18 8 Remove the platen stop assembly by loosening the 7 64 inch clamp screw and pulling the assembly off the platen shaft See page 270 item 15 9 Remove the right side platen support spring by repeating step 7 on the right side of the platen 10 Remove the Phillips 1 screw and washer securing the interlock switch bracket from the inside of the right side bracket See page 270 item...

Page 224: ...elow 5 Apply a layer of bearing lubricant 1 4 inch high to the seat of each wear saddle making the layer as wide as the saddle and touching the rear angled surface 6 Install one platen adjust bracket and bushing onto the longer platen shaft with the screw at the top of the bracket See Figure 32 7 Place the other bracket and bushing onto the left side mechanism base platen seat so that the mechanis...

Page 225: ...l the black metal washer onto the left side of the platen shaft See page 270 item 26 11 Apply bearing lubricant to the nylon bearings in the two spring links slide the spring links onto the platen shafts and connect the springs to the spring hooks in the side plates See page 270 items 16 17 and 18 12 Apply bearing lubricant to the platen shafts on both sides between the ends of the platen and the ...

Page 226: ...inch pounds 2 26 N m 14 Push the platen to the left 15 Install the platen stop assembly on the right hand platen shaft pressing the interlock switch out of the way as the lever slides past it Torque the 7 64 inch clamp screw to 18 inch pounds 2 03 N m See page 270 16 Install the platen shaft pulley with the 7 64 inch setscrew facing up and tighten the setscrew page 270 items 21 and 22 17 Install b...

Page 227: ... 24 5 Using a 5 32 inch Allen wrench loosen the platen motor adjustment screw page 272 item 10 6 Remove the platen open belt page 270 item 23 7 Trace the platen open motor cables back to connector P106 on the controller board releasing the cables from all tie wraps See cable routing diagrams in Appendix A 8 Remove the platen open cable connector from connector P106 See page 198 9 Remove the 5 32 i...

Page 228: ...ntroller board and install tie wraps to secure the motor cable See the wire routing diagrams in Appendix A 7 Close the forms thickness lever all the way CAUTION 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 8 The spring automatically tensions the belt 9 Slowly tighten the motor a...

Page 229: ...e the 7 64 inch clamp screw and pull the platen stop assembly off the platen shaft See page 270 items 12 through 15 Installation 1 Install the platen stop assembly on the right hand platen shaft pressing the interlock switch out of the way as the lever slides past it Torque the 7 64 inch clamp screw to 18 inch pounds 2 03 N m See page 270 2 Return the printer to normal operation page 155 ...

Page 230: ... Grasp the power supply by the handling loops tilt it forward and lift it out of the printer Installation 1 Holding the power supply by the handling loops tilt the bottom of the power supply toward the rear of the card cage and insert the tabs on the the power supply base in the channels on the lower rear card cage wall 2 Rotate the top of the power supply board toward the rear of the card cage un...

Page 231: ...To prevent electrostatic damage to electronic components always wear a properly grounded static wrist strap when you handle circuit boards 1 Prepare the printer for maintenance page 154 2 Cabinet Models Remove the paper path page 222 Pedestal Models Remove the top cover assembly page 204 3 Locate the terminating resistor packs See Figure 34 page 232 4 Using a chip puller remove the resistor packs ...

Page 232: ...232 Chapter 5 Replacement Procedures Figure 34 Terminating Resistors V6 Controller Board Removal Installation 183480b Default 470 1K Ohm Alt 220 330 Ohm RP1 and RP2 ...

Page 233: ...o the motor bracket page 272 items 12 22 and 23 9 Remove the ribbon drive motor Installation 1 Use four M3 screws to mount the ribbon drive motor to the motor bracket Orient the motor so that the motor cable exits to the right side of the bracket 2 Place a spacer plate onto the mech base aligning the plate onto the two dowel pins in the mech base 3 Place the motor bracket assembly onto the same tw...

Page 234: ...OM that enables the loading of microcode and emulation software The printer will not operate correctly without a security key If you need to replace the security key contact TallyGenicom for a replacement Installation 1 Put on a static wrist strap and ground the lead to an unpainted part of the printer frame Touch the printer frame with the hand wearing the wrist strap before you touch memory modu...

Page 235: ...ure 35 Memory Modules and Security Key J10 72 pin Flash Memory SIMM 4 MB P N 204480 901 8 MB P N 204480 902 16MB P N 204480 903 32MB P N 204480 904 Controller Board Notched End on this side Flash Memory J9 Security Key V5 ...

Page 236: ... alignment marks are at the top on both tractors See Figure 36 2 Slide the splined shaft through the right side plate and tractors Make sure the same spline passes the marked groove on each tractor See Figure 36 3 Install the tolerance ring on the left end of the splined shaft page 268 item 5 4 Insert the tolerance ring lead in portion into the sealed ball bearing in the left tractor shaft plate p...

Page 237: ...aft Splined 237 Figure 36 Splined Shaft and Tractor Installation 1840895a Splined Shaft NOTE Align the marks on both tractors before inserting the splined shaft Tractor Alignment Marks Tolerance Ring A A ...

Page 238: ...to the right out of the tractors and the right side plate See page 268 items 9 10 and 11 Installation 1 Slide the support shaft into the right side plate and through the lower holes in the tractors See page 268 items 9 10 and 11 2 Slide the support shaft through the left side plate until it bottoms in the left tractor shaft plate See page 268 items 9 and 12 3 Install the right tractor shaft plate ...

Page 239: ...uttle and pull the clamps back and off the guide shaft Do not remove the clamps Hand tighten the clamp screws to hold the clamps back 7 Loosen the center 5 32 inch socket head screw enough to release the shuttle frame assembly from the base casting 8 Unlock and slide the tractors outward as far as they will go on the tractor support shaft 9 Open the forms thickness lever all the way 10 Grasp the s...

Page 240: ...ile you do step step 6 CAUTION Do not over tighten the shuttle frame assembly clamp screws 6 Slide each side clamp over the guide shaft and torque the 5 32 inch socket head clamp screw to 20 inch pounds 2 26 N m 7 Torque the center captive 5 32 inch socket head screw to 20 inch pounds 2 26 N m 8 Connect the hammer drive and hammer logic cable connectors to the terminator board on the shuttle frame...

Page 241: ... from the spring lugs on the hammer bank and shuttle frame See page 266 item 4 Installation 1 Apply a dab of bearing lubricant to both spring lugs CAUTION Do not let the hammer bank rotate toward the platen during spring replacement Make sure the extension spring does not touch the MPU cable after installation 2 Hook the extension spring over the spring lugs See page 266 item 4 3 Model 6620 only I...

Page 242: ...he PMD and POD cable connector from the shroud page 197 7 Remove the paper detector switch assembly Installation 1 Holding the slotted wheel against the PMD sensor position the paper detector switch assembly and install the two 1 4 inch screws securing it to the printer base See page 272 items 3 and 4 2 Check PMD sensor arm range make sure it travels freely and completely back into the sensing cav...

Page 243: ... shroud page 198 7 Remove two Phillips 1 screws securing the platen interlock switch assembly See page 270 item 11 8 Remove the platen interlock switch assembly from the switch bracket 9 Remove the switch cable from the cutout in the right side plate Installation 1 Reverse steps step 2 through step 9 of the removal procedure and do the following when you have installed the switch on its bracket a ...

Page 244: ...e printer for maintenance page 154 2 Remove the shuttle cover see page 203 CAUTION Wear an ESD wrist strap for the next steps to avoid equipment damage 3 Remove the two plastite self tapping screws securing the weld sensor PCBA to the shuttle cover 4 Remove the weld sensor from the shuttle cover Installation 1 Place the weld sensor PCBA into the pocket on the shuttle cover 2 Use the two plastite s...

Page 245: ...ces in electrical and electronic equipment Illustrations of Printer Components Figure 38 Top Cover Doors and Casters page 246 Figure 39 Paper Fence Paper Chains and Front Access Stacker page 248 Figure 40 Control Panel and Cabinet Details page 250 Figure 41 Pedestal Details page 252 Figure 42 Quiet Pedestal Details page 254 Figure 43 Inside Covers Cabinet Models page 256 Figure 44 Inside Covers an...

Page 246: ...246 Chapter 6 Organization of this Chapter Figure 38 Top Cover Doors and Casters 183949a 1 2 3 4 5 6 7 9 10 11 12 13 ...

Page 247: ...t Gray Extended Door Assy Stealth Black Extended Door Assy Lt Gray For printers without power stacker includes items 9 10 11 12 and 13 For use with power stacker For use with power stacker 5 177502 901 179779 901 Front Door Assembly Stealth Black Front Door Assembly Lt Gray Includes items 9 10 11 12 and 13 6 141278 901 Caster with Brake Two at front 7 141278 902 Caster without Brake Two at rear 9 ...

Page 248: ...248 Chapter 6 Organization of this Chapter Figure 39 Paper Fence Paper Chains and Front Access Stacker 3 2 4 1 5 7 8 6 9 10 11 ...

Page 249: ... 001 Chain Assembly Kit 4 Ref AC Power Cord 5 Ref Grommet Power Cord 2 Included in item 2 6 151910 001 Guide Rail Stacker Part of item 1 7 151831 001 Clip Rail Stacker 8 Ref Screw 4 9 178913 001 179799 001 Field Kit Tray Cab Rear Black Tray Power Stacker Pull Out Gray Includes items 1 6 7 8 9 10 and paper tent 173864 001 10 174392 901 Slide Set Ball Bearing 11 250085 001 Field Kit Front Access Sta...

Page 250: ...250 Chapter 6 Organization of this Chapter Figure 40 Control Panel and Cabinet Details 183950a A A 1 2 4 3 5 6 4 7 4 8 9 10 11 12 ...

Page 251: ...w Lock Washer 3 6 32x 375 5 Ref Screw w Lock Washer 3 6 32x2 00 6 150261 901 Fan Assembly Includes mounting hardware 7 Ref Duct Air Exhaust 8 177296 001 Paper Entrance Guide V2 6620 and 6620Q only 9 173428 001 Spring Paper Entrance Guide 2 6620 and 6620Q only 10 173351 001 173352 001 Bracket Paper Entrance Guide Right Bracket Paper Entrance Guide Left 6620 and 6620Q only 6620 and 6620Q only 11 Ref...

Page 252: ...252 Chapter 6 Organization of this Chapter Figure 41 Pedestal Details 1 18 3 8 4 5 6 10 11 7 2 12 13 14 15 16 17 18 9 ...

Page 253: ...ield Kit Caster Kit Ped 8 178692 901 Window Top Cover 9 179193 901 Top Cover Ped Base Assy Stealth Black 6600 10 Ref Screw 4 10 32x 625 11 110718 001 Paper Tray 12 157070 901 Paper Fence Rear Ped 13 250083 001 Field Kit Acoustic Shroud Ped 6600 Optional on all pedestal models 14 178259 901 179765 901 Panel Lid Quick Access Black Panel Lid Quick Access Gray 15 178241 901 179766 901 Panel Quick Acce...

Page 254: ...254 Chapter 6 Organization of this Chapter Figure 42 Quiet Pedestal Details 184329a 1 17 3 8 4 5 6 10 11 7 2 12 13 14 15 18 16 18 9 19 21 20 ...

Page 255: ...ed Base Assy Stealth Black 6600 10 Ref Screw 4 10 32x 625 11 110718 001 Paper Tray 12 157070 901 Paper Fence Rear Ped 13 250083 001 Field Kit Acoustic Shroud Ped 6600 Optional on all pedestal models 14 178259 901 179765 901 Panel Lid Quick Access Black Panel Lid Quick Access Gray 15 178241 901 179766 901 Panel Quick Access Flip Up Black Panel Quick Access Flip Up Gray 16 179193 901 179770 901 Top ...

Page 256: ...ization of this Chapter Figure 43 Inside Covers Cabinet Models 184034a 1 2 11 3 4 10 9 8 7 6 5 12 184133a 13 14 Underside of the shuttle frame assembly B B Ribbon Weld Processor PCBA located on the underside see Detail B ...

Page 257: ...88 901 Paper Path V3 6 Ref Screw w Lock Washer 3 6 32 25 and 6 flat washer 7 153488 001 Field Kit Covers Paper Feed Belt Cover shown 8 108664 903 Belt Timing 080 Pitch 100 Teeth 500 Wide Paper Feed Belt 9 Ref Screw Thread forming 2 6 32x 25 10 179276 001 Power Supply Insulator Taped to the upper edge of the card cage 11 153528 901 Paper Scale 12 152284 901 Anti static Brush Kit Mounts to top of it...

Page 258: ... Chapter Figure 44 Inside Covers and Card Cage Pedestal Models 184035a See Figure 45 page 260 1 2 8 A 3 4 3 5 6 7 184133a 9 10 Underside of the shuttle frame assembly B B Ribbon Weld Processor PCBA located on the underside see Detail B ...

Page 259: ...Ref Screw Captive 2 10 24x 62 with O ring 125x 250x 06 3 Ref Screw Thread forming 2 6 32x 25 and 6 flat washer 4 Ref Barrier Shield 5 179276 001 Power Supply Insulator Taped to card cage along upper edge 6 108664 903 Belt Timing 080 Pitch 100 Teeth 500 Wide Paper Feed Belt 7 153488 001 Field Kit Covers Paper Feed Belt Cover shown 8 254478 901 Paper Scale 9 254476 001 PCBA Ribbon Weld Processor V1 ...

Page 260: ...rd Cage Detail Pedestal Models 184100a From Figure 44 page 258 Rotated 180 degrees 5 A To IEC 320 AC Power Input Connector J301 White Wire To IEC 320 AC Power Input Connector J301 Black Wire To Connector P1 White Wire 1 2 3 4 6 To Connector P1 Black Wire 7 ...

Page 261: ...t Description Notes 1 Ref Nut 6 32 1 Upper right fan corner only 2 150261 901 Card Cage Fan Assembly Air flow is into card cage 3 Ref Fan Guard 4 Ref Screw w Lock Washer 4 6 32x1 75 5 Ref Card Cage Pedestal 6 142013 901 Circuit Breaker 7 Ref Baffle Power Supply Ped 6600 ...

Page 262: ... 46 Print Mechanism and Circuit Boards 184036a To J02 Shuttle Motor To J03 MPU To the Terminator Board on the Shuttle Frame Two places Exploded to show assembly Do not remove the clamps and screws 14 2 7 8 9 4 6 11 16 17 12 13 15 5 3 1 10 18 19 20 10 ...

Page 263: ...y PFC 5 10 Power Supply PFC 5 10 Adv Exch Power Supply PFC 15 Power Supply PFC 15 Adv Exch Power Supply PFC 20 Power Supply PFC 20 Adv Exch 6605 6605Q 6610 6610Q 6605 6605Q 6610 6610Q 6615 6615Q 6615 6615Q 6620 6620Q 6620 6620Q 4 Ref P101 Cable Connector Part of item 3 5 Ref Cable Assembly AC In Power Supply Part of Field Kit AC Assy 153502 901 6 253081 901 253081 991 Controller PCBA V6 Controller...

Page 264: ...ly with Pulley 20 Paper Feed Motor Paper Feed Motor 6620 6620Q 6605 6605Q 6610 6610Q 6615 6615Q 6605 6605Q 6610 6610Q 19 179526 901 PCBA Cartridge Interface Board w harness 20 173164 901 Cable Assembly PS I O 2000 Used only in 6620 and 6620Q See page 323 Item No Part No RoHS Compliant Description Notes ...

Page 265: ...Illustrations of Printer Components 265 Parts lists continue on the next page ...

Page 266: ...47 Magnetic Pickup MPU and Extension Spring 184064a CAUTION Make sure the MPU cable does not touch the extension spring after cable connection 5 0 010 001 inch 0 254 025 mm Spring Lug Do not remove grease Spring Lug Do not remove grease 2 1 3 4 A A 6 7 ...

Page 267: ...otes 1 150281 901 Magnetic Pickup MPU Assembly 2 Ref Bracket MPU Part of item 1 3 Ref Screw Socket Cap 6 32x 38 4 153537 901 Spring Hammer Bank 5 Ref MPU Cable Connector P03 6 176507 001 Anti Rotation Spring Constraint 6620 and 6620Q only 7 152425 901 Magnetic Pickup MPU Cable Assembly ...

Page 268: ...84037a 1 2 3 4 5 8 7 9 10b 6 12 10a 11 IMPORTANT In order to preserve correct alignment of the side plates the barrier panel must remain installed and fastened if the splined or support shafts are removed or replaced The barrier panel is shown in Figure 43 and Figure 44 ...

Page 269: ... 204155 001 Tolerance Ring 37X 25 006 THK SS 6 178988 901 Splined Shaft Assembly Blue Handle 7 Ref Screw Socket Cap 6 32x 312 Trilob Self Tapping 8 173217 001 Plate Tractor Shaft Right 9 173137 001 Support Shaft 10a 10b 179061 901 179065 901 Tractor Set 20 Blue Tractor Set Non Roller 05 10 15 Blue 6620 and 6620Q Installed at the factory on models with power stacker comes standard on 6620 and 6620Q...

Page 270: ...tector NOTE Item 25 Platen Hardware Kit 1 2 4 3 5 6 7 8 8 1 2 9 10 13 12 11 14 15 18 16 17 19 24 23 22 18 21 17 26 16 20 NOTE On 6615 6615Q 6620 and 6620Q models install item 27 in front of item 3 that is on the shuttle side All others do not use item 27 Do NOT install Items 3 and 27 on ZTP printers 27 28 ...

Page 271: ...art of item 15 15 178705 901 Platen Stop Assembly Includes items 12 13 14 16 Ref Spring Extension 1 12L Part of item 25 17 Ref Link Spring Part of item 25 18 Ref Bearing Nylon 376 Part of item 25 19 Ref Bracket Switch Mount Part of item 11 20 Ref Wear Saddle Platen 2 Part of item 25 21 155071 902 Platen Pulley Drive 22 Ref Screw Socket Cap 6 32x 44 Part of item 21 23 141516 901 Belt Timing 080 Pit...

Page 272: ...272 Chapter 6 Organization of this Chapter Figure 50 Motors Fans and Paper Detector Switch 184039a 1 2 11 12 10 5 3 4 18a 2 6 16 17 19 20 21 18b Ribbon Drive Motor Cable Connector 22 23 24 25 ...

Page 273: ...ned 9 Undefined 10 Ref Screw w Lock Washer 10 32x 50 2 Part of item 5 11 Ref Shield Card Cage Fan 12 254507 901 Motor Stepper 6600 Ribbon Cartridge 16 Ref Screw w Lock Washer 2 6 32x1 25 17 152416 901 173427 901 Hammer Bank Fan Assembly Hammer Bank Fan Assembly All except 6620 and 6620Q air flow is up 6620 and 6620Q air flow is up 18a 18b 178046 001 177482 001 Field Kit Paper Feed Motor V3 Field K...

Page 274: ...EC 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 B A B See inside detail below Card cage fan and power supply board removed for clarity 4 5 3 2 White Wire Black Wire Black Wire 1 White Wire 6 ...

Page 275: ...C Power Connector Connector J301 Part of Field Kit AC Assy 153502 001 3 Ref Chassis Ground Stud Part of Field Kit AC Assy 153502 001 4 Ref Connector P1 To power supply board connector J1 AC Part of Field Kit AC Assy 153502 001 5 Ref Cable Assembly AC In Power Supply Part of Field Kit AC Assy 153502 001 6 153502 001 Field Kit AC Assy ...

Page 276: ...276 Chapter 6 Organization of this Chapter Figure 52 The NIC Network Interface Card on the V6 Controller Board 184105a 3 2 5 4 6 1 ...

Page 277: ...oller board the NIC is part of the board 2 176257 001 Cover Plate PCI 3 Ref Rear of Card Cage 4 Ref Screw 5 Ref V6 Controller Board Ethernet hard wired on V6 controller board 6 Ref Ethernet Port Ethernet hard wired on V6 Controller Board To replace port you must replace the entire V6 controller board Be sure to transfer the security key The new board has a new MAC address which is found on the con...

Page 278: ...278 Chapter 6 Organization of this Chapter ...

Page 279: ...re made by a row of hammer springs mounted on a shuttle that sweeps rapidly back and forth Logic circuits on the controller board divide every line of incoming print data into horizontal dot rows The hammers put dots at the required positions for the entire line by driving an inked ribbon onto the paper Figure 53 A Dot Matrix 1 12 Column No 0 01389 inch 0 02 inch First row and column of next chara...

Page 280: ...For example in the data processing DP font at a line spacing of six lines per inch lpi a dot matrix contains 12 dot rows from the top of one character line to the top of the next Figure 53 and Figure 54 At eight lpi there are nine dot rows per character line at nine lpi there are eight dot rows per character line and so on Each individual hammer spring can and usually does form more than one chara...

Page 281: ...1 3 5 7 1 3 5 7 9 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 1 2 3 4 1 2 1 7 6 5 3 4 2 1 1 2 3 NOTE Even column dot centers within the printed character area and character space hammer positions are not illustrated in this diagram Hammer Not Released No Dot Printed Succesive Hammer Strokes Per Scan Shuttle Scan Dot Row ...

Page 282: ...ically determining which dot rows contain adjacent dots and must be printed in two strokes The number of characters in a character set has no effect on printing speed The printing speed of graphics plot mode is expressed in inches per minute ipm The ability of the printer to feed paper both downward and upward allows the printing of multiple dot densities on a single line This makes it possible to...

Page 283: ...assembly and the number of hammer spring assemblies attached to the hammer bank vary by printer model Models 6605 6605Q and 6605Z have seven 4 hammer assemblies for a total of 28 individual hammer springs Models 6610 6610Q and 6610Z have six 10 hammer assemblies for a total of 60 individual hammer springs Models 6615 6615Q and 6615Z have six 17 hammer assemblies for a total of 102 individual hamme...

Page 284: ... with a cylindrical tungsten carbide tip attached to the free end Figure 57 A powerful permanent magnet is imbedded along the length of the hammer bank and acts on the hammer springs through individual pole pieces The pole pieces magnetically attract and hold the free end of the hammer spring under tension This is called the retracted state Figure 57 Hammer Springs and Hammer Bank Detail Two elect...

Page 285: ...ws occurring in 2 10 milliseconds Paper Transport System Figure 58 Paper Transport System A two phase DC stepper paper feed motor directed by the engine controller EC on the controller board drives two tractor sprockets by means of a toothed belt linked to a pulley on the splined shaft The stepper motor permits extremely accurate vertical paper movement in 1 72 inch increments This drive configura...

Page 286: ...y using the tractors Each tractor is locked in position with a friction lock and engages the paper perforations with six sprocket pins The vertical adjustment knob is used to position paper vertically by hand Ribbon Transport System Figure 59 Ribbon Cartridge System TO F TO F TO F TO F 183874a TO F TO F TO F TO F 183871 REV A 183871a Ribbon Ribbon Cartridge Ribbon Tension Knob Air Shroud Assembly ...

Page 287: ...printer is in the RBN END POINT Change Ribbon condition without losing data in the printer s buffer If a new ribbon is loaded and the fault is cleared the life restarts at 100 If a partially used ribbon is loaded the system continues the life at the percentage indicated for the used ribbon Ribbon usage information is calculated by maintaining a count of impressions dots that is stored on the ribbo...

Page 288: ...on life reaches 0 the message RIBBON INK OUT Install New RBN displays on the control panel The status lamp flashes the alarm sounds if enabled printing stops and the printer enters the fault state Printing cannot resume until this condition is cleared To complete a print job in progress you can return the printer to ONLINE state by pressing ONLINE This allows the printer to continue printing for a...

Page 289: ...ng message can be cleared by pressing the ONLINE Clear button however the message will persist again in two minutes This action will continue until a ribbon out ribbon life reaches 0 condition occurs Warn Pause This setting is similar to the Warn Continue selection with one exception When a ribbon low condition is reached the printer will still display the RIBBON UNDER XX Change RBN Soon warning m...

Page 290: ...inter The printer consists of four subsystems the control panel the controller board the power supply board and the print mechanism as illustrated in Figure 60 Figure 60 Functional Elements of the Printer 184041a Control Panel Controller Board Power Supply Print Mechanism ...

Page 291: ...d displays information from the controller on the LCD A status indicator next to the LCD also conveys printer status information to the user The LCD status indicator and keys are mounted on a printed circuit board assembly enclosed in a protective housing The functions of the keys and indicators are defined on page 25 Figure 61 Control Panel Functional Overview 184110a Control Panel Controller Boa...

Page 292: ...ta Controller and the EC Engine Controller The DC is responsible for Host Input Output I O Operator I O Security Interface Print Image Generation Overall High Level Logical Control The EC is responsible for Operating the print mechanism Monitoring the print mechanism for faults Power shutdown and power saving modes The EC and DC communicate through semaphore registers The DC receives input from th...

Page 293: ...ostic Port RS 232 Diagnostic Port MECA ASIC 20 MHz Siemens 80C167 Microcontroller EC Engine Controller EC Data Controller DC Control Panel Interface Control Panel Host I O Drivers RS 232 422 IEEE 1284 Parallel Analog Drive Circuitry Fault Monitoring Circuitry EC 64K x 16 FLASH TTL Diagnostic Port EC Diagnostic Port Memory Cajun Bus Fault Sensors Paper Feed Ink Shuttle Platen Hammer Drive Transport...

Page 294: ...V only flash memory which does not require higher programming and erasing voltages on the board it has an internal charge pump to make these voltages itself This memory supports at least 100 000 write erase cycles The flash memory is 8 bits wide A 72 pin SIMM socket designated J11 is provided for flash memory Socket J10 is not used Up to 32MB of flash may be installed on the PSA3 controller board ...

Page 295: ...mory DMA Channels The V8 provides two channels for direct memory access These channels move data from the host interface or expansion bus to the SDRAM and vice versa One address is an I O address the other is a memory address with auto increment Control Panel Interface The V8 control panel interface consists of five lines serial clock serial data and three select lines It is the V8 that handles al...

Page 296: ...interfaces These circuits include RS 232 drivers and receivers These circuits use internal charge pumps to eliminate the need for 12V power RS 422 differential drivers and receivers Parallel port pull up and pull down terminating resistors in DIP configuration for easy removal and installation All interface ICs and terminations have the following characteristics Provide ESD protection to 15KV for ...

Page 297: ...can be updated through the DC At run time the EC also stores tables in shared SDRAM which is accessed through the Cajun bus MECA ASIC The 80C167 uses many counters PWM generators and FIFOs in the MECA to control printer motor functions The MECA is a custom gate array specifically designed to drive this system Analog Drive Circuitry The analog drive circuits convert 48 volts and 8 5 volts into the ...

Page 298: ... power supply converts alternating current AC to direct current DC at three voltage levels and sends the DC voltages to the controller board The controller board distributes all DC power to the logic and electromechanical circuits AC Power The power supply operates on AC voltages ranging from 88 volts to 270 volts It can tolerate variations in frequency of 47 to 63 Hz The power supply is designed ...

Page 299: ... and from the host computer The printer supports a number of standard and optional interfaces to the host computer Centronics parallel standard IEEE 1284 parallel standard EIA 232 E serial standard EIA 422 B serial standard but requires 9 pin 25 pin interface adapter kit 10 100Base T Ethernet Network Interface Card NIC optional Selection of the interface is controlled by configuration menus access...

Page 300: ...300 Chapter 7 Printer Interface ...

Page 301: ...05Q 6610 and 6610Q page 314 Power Supply 6615 and 6615Q page 315 Power Supply 6620 and 6620Q page 316 SureStak Power Stacker PCBA page 317 Cable Assemblies Weld Sensor page 318 Centronics I O page 319 2 Pin Jumper 0 1 Ctr page 320 AC In Power Supply page 321 AC Power Input page 322 PS I O page 323 Card Cage Fan page 324 Control Panel page 325 Exhaust Fan page 326 Hammer Bank Logic page 327 Hammer ...

Page 302: ...ker page 334 Power Cable Power Stacker page 335 Rail Cable Power Stacker page 336 Elevator I O Cable Power Stacker page 337 Fan Assembly Hammer Bank page 338 Magnetic Pickup MPU Assembly page 339 Switch Assemblies Switch Assembly Paper Detector page 340 Switch Assembly Platen Interlock page 341 ...

Page 303: ...Y J11 FLASH P102 P110 P103 PSTR OPTIONAL J202 5V AT 1 AMP CONTROL PANEL ASSY POWER PAPER STACKER CONTROLLER P310 J310 P104 J7 J6 P106 PSA3 PCBA 36 2 8 10 4 12 12 10 20 4 2 2 4 2 3 10 10 2 4 4 4 AC TO DC POWER SUPPLY PCBA WIRE COLOR CODE RED BLACK WHITE ORANGE BROWN YELLOW BLUE VCC GROUND N_TEMP_HI N_STBY GROUND 8 5V 48V G G 2 ABBR LEGEND CHASSIS FRAME EARTH GROUND N NUMBER OF CONDUCTORS IN CABLE U...

Page 304: ...304 Appendix A Cable Routing Cabinet Model 184042a Exhaust Fan NOTE 6620 and 6620Q model uses a unique power supply See page 316 Weld Sensor Cable ...

Page 305: ...305 Cable Routing Pedestal Model 184043a Exhaust Fan Weld Sensor Cable ...

Page 306: ... into the controller board For connector assembly and disassembly see page 197 MOTOR NOTES All Motors Use the table values to test for winding continuity and for no shorts between winding and the motor frame Rotate the motor by hand and test for shorts replace the motor if you find any shorts Shuttle Motor approx 0 7 0 8 Ω per phase except for the P20Q printer which shows 0 42 Ω per phase Use this...

Page 307: ...OD K PMD K POD C PMD C POD E PMD E 48V μ 01 10 100V F 1 J107 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 PF 1 Motor Sensor Right RIB R1 PF 2 RIB R2 PF 3 RIB R3 PF 4 RIB R4 EXH FAN BANK FAN PLAT OPEN SW R RBN POST PLAT OPEN RET MPU MPU 48V μ 01 10 100V F EXH FAN R RBN POST COVER OPEN RET 100 PF 10 50V μ 01 10 100V F μ 10 10 16V TANT F CAUTION Do not try to remove or replace the NVRAM The NVRAM...

Page 308: ... Bank Logic HMR DAT RET HMR CLK RET CMD DAT RET DMD CLK RET HMR CLK CMD DAT CMD CLK COIL 50 MHz 10V SW μ 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 DIR C167 NCS1 C167 DB RXD PPR MOVING MPU OUT VCC 10K 1 0 1W 3300 PF 5 100V 3300 PF 5 100V 3300 PF 5 100V 3300 PF 5 100V EC BOOT STRAP 0 Ohm 0 125W ...

Page 309: ... Ohm VCC μ 10 10 16V 1000 PF 10 50V F μ 0 1 20 16V F 4 7 K 0 1 W U58 8 7 6 5 1 2 3 4 4 7 K 0 1 W PER CHASSIS GND LOGIC HIGH EXT 5V 2 Pin Jumpers J1 J4 J8 J16 J20 J23 J25 1 2 J1 J28 J25 J20 J8 J23 J4 J16 J28 1 J122 2 3 4 BC DATA COVER OPEN VCC Cartridge Interface Board NC Sensor ...

Page 310: ...ttle Drive SHUT A SHUT B SHUT C 1 J110 2 3 4 5 6 N FP DATA AVAIL Control Panel 470 PF 10 50V 7 8 FP CLK N FP LED WR FP DATA N FP LCD WR 1 J117 2 3 4 5 6 Paper Stacker 470 PF 10 50V 7 8 STK R NW VCC NC 9 10 NC NC NC 470 PF 10 50V 470 PF 10 50V 470 PF 10 50V 470 PF 10 50V STK DATA STK LOAD STK CLK 11 12 13 14 1 J6 2 3 4 5 6 TX RJ 45 LAN Ethernet 7 8 9 10 TX RX NC1 NC2 RX NC3 NC4 SHL1 SHL2 VCC ...

Page 311: ...H REF UD 3 UD 4 DIODE 1 DIODE 2 DIODE 3 DIODE 4 N COILTEST CABLE DET HD SENSE LDFB Phase Driver Port 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 LC TDO 1 2 3 J9 Software Security Key SOFT ID VDD 2 2K 0 062W 1 J15 2 3 4 5 6 Host RS422 7 8 9 10 NC NC NC NC NC DIFF TXD DIFF TXD DIFF RXD DIFF RXD ...

Page 312: ...D30 3 3V 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 RSV GND RSV 5V 5V NINTB NINTD NPRSNT1 RSV NPRSNT2 KEY KEY RSV GND CLK GND NREQ 3 3V AD31 AD29 GND AD27 AD25 3 3V NC BE3 AD23 GND AD21 AD19 3 3V AD17 NC BE2 GND NIRDY 3 3V NDEVSEL GND NLOCK NPERR...

Page 313: ...15 16 17 18 19 20 VCC 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 INIT N AUTOFEED N FAULT PI NDPSEL EXT 5V N SELECT IN HOST LOGIC H NDPEN 5 ...

Page 314: ... N TEMP HI N STDBY P101 White Orange Red Red Black Black Brown Brown Yellow Yellow Blue Blue 5V 5V 5V RTN 5V RTN 48V 8 5V RTN 48V 8 5V RTN 8 5V 8 5V 48V 48V 1 2 3 P1 LOAD GND LOAD RING TERMINAL FAST ON TERMINAL AC AC Common Chassis Ground J1 Cable Assembly AC In Power Supply 1 2 3 ...

Page 315: ...ut AC 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 5 Volts 48 Volts 48 Volts 1 2 3 P1 LOAD GND LOAD RING TERMINAL FAST ON TERMINAL ...

Page 316: ...trol 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 UD 1 UD 2 2 5V reference UD 3 UD 4 DIODE 1 DIODE 2 DIODE 3 DIODE 4 N COILTEST CABLE DET HD SENSE LDFB BUF J2 1 2 3 P1 LOAD GND LOAD RING TERMINAL FAST ON TERMINAL Controller GND OPTO RET 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 5 Volts 48 Volts 48 Volts Phase Driver Power Ch...

Page 317: ...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 42V FAIL PMD SIG PAP IN SIG SW1 SW2 SW3 SW4 1 2 3 4 5 6 7 8 STK FULL SWT 9 10 J3 Limit Switches and FULL SWT RET STK LIMIT SWT LIMIT SWT RET EL PHA 1 EL PHA 2 EL PHB 1 EL PHB 2 HW1 HW2 HW3 HW4 HW5 J3 J4 J6 J7 J5 Ele...

Page 318: ...318 Appendix A Cable Assembly Weld Sensor P N 254475 001 184095a Wiring Table CONN 1 CONN 2 PIN 1 PIN 1 PIN 2 PIN 2 PIN 3 PIN 3 PIN 4 PIN 4 ...

Page 319: ... shielded with a copper braid over an aluminum mylar foil and not just a conductive foil spiral wrapped around a drain wire 2 The shield must terminate coaxially 360 degrees to a metal connector housing and not be terminated by just a simple wire lead 3 Cable length including connectors must be three meters or less 4 The cable connector anchor screws must be securely seated in the printer receptor...

Page 320: ...320 Appendix A Cable Assembly 2 Pin Jumper 0 1 Ctr P N 154470 901 ...

Page 321: ...321 Cable Assembly AC In Power Supply AC Kit P N 153502 901 To Power Supply J1 To Circuit Breaker ...

Page 322: ...322 Appendix A Cable Assembly AC Power Input AC Kit P N 153502 901 To Circuit Breaker Input Power Connector ...

Page 323: ...323 Cable Assy PS I O P N 176601 901 NOTE This cable is used on 6620 and 6620Q printers ...

Page 324: ...324 Appendix A Cable Assembly Card Cage Fan P N 152422 901 PIN 1 PIN 1 ...

Page 325: ...325 Cable Assembly Control Panel P N 152440 901 PIN 1 PIN 1 PIN 8 PIN 8 Gray Brown Gray Brown ...

Page 326: ...326 Appendix A Cable Assembly Exhaust Fan P N 152424 901 PIN 1 PIN 1 ...

Page 327: ...327 Cable Assembly Hammer Bank Logic P N 152421 901 To Shuttle To Controller Board ...

Page 328: ...r P N 164805 901 Wire Table P05 P105 2 1 1 2 4 3 3 4 6 5 5 6 8 7 7 8 10 9 9 10 IMPORTANT Use this cable on any 6600 printer except the 6600 and 6620Q On the 6600 and 6620Q use P N 173215 901 shown on the next page To Shuttle To Controller Board ...

Page 329: ...r P N 173215 901 Wire Table P06 P3 2 1 1 2 4 3 3 4 6 5 5 6 8 7 7 8 10 9 9 10 P06 P3 IMPORTANT Use this cable on the 6620 and 6620Q printer On any other 6600 printer use P N 164805 901 shown on the previous page To Shuttle To Power Supply ...

Page 330: ...330 Appendix A Cable Assembly MPU P N 152425 901 PIN 1 PIN 3 PIN 2 PIN 1 ...

Page 331: ...331 Cable Assembly Ribbon Motor Extension P N 154067 001 ...

Page 332: ...332 Appendix A Cable Assembly Shuttle Motor Drive P N 152420 001 ...

Page 333: ...333 Frame Cable Power Stacker P N 173824 001 ...

Page 334: ...334 Appendix A Logic Cable Power Stacker P N 176029 001 ...

Page 335: ...335 Power Cable Power Stacker P N 174414 001 P1101 P1101 ...

Page 336: ...336 Appendix A Rail Cable Power Stacker P N 173823 001 ...

Page 337: ...337 Elevator I O Cable Power Stacker P N 174759 001 ...

Page 338: ...338 Appendix A Fan Assembly Hammer Bank P N 152416 901 P107 HBF P107 HBF ...

Page 339: ...339 Magnetic Pickup MPU Assembly P N 150281 901 ...

Page 340: ...340 Appendix A Switch Assembly Paper Detector P N 152415 901 ...

Page 341: ...341 Switch Assembly Platen Interlock P N 152417 901 P107 PLO ...

Page 342: ...342 Appendix A ...

Page 343: ...0 Address 1 etc AC Alternating Current ACC Access ACK Acknowledge AMP Amplitude Ampere AMPL Amplitude AN Anode ASIC Application Specific Integrated Circuit ATTN Attention B Buffered BANK FAN Hammer Bank Fan BCOM Buffered Communication BCP Bi phase Communications Processor BHSC Buffered Hammer Shift Clock BN Buffered Low True BNLD Buffered Low True Lower Driver BPS Bits Per Second BSY Busy BTU Brit...

Page 344: ...bbon System CTS Clear to Send CU Control Unit CUR Current D0 D1 etc Data Bit 0 Data Bit 1 etc DAT Data DBCS Double Byte Character Set DC Direct Current Data Controller a functional unit of the controller board DCD Data Carrier Detect DIAG Diagnostic DIFF Differential DIMM Dual Inline Memory Module DMA Direct Memory Access DP Data Processing Dataproducts DPEN Dataproducts Enable DPMC Dot Plucker Me...

Page 345: ...terference EMIT Emitter EPROM Electrically Programmable Read Only Memory ERR Error ESD Electrostatic Discharge EX Exhaust Extra EXH Exhaust EXF Exhaust Fan EXP Expansion EXPND Expand FD Feed FF Form Feed FIFO First In First Out FLT Fault FLTR Filter FP Front Panel Control Panel FRU Field Replaceable Unit FTIC Fire Timer Integrated Circuit GND Ground HB Hammer Bank HBA Hammer Bank ASIC HBF Hammer B...

Page 346: ...rrupt Request J Jack connector JEDEC Joint Electron Device Engineering Council An organization that sets standards for electronic devices and components L Left LAN Local Area Network LCD Liquid Crystal Display LED Light Emitting Diode LF Line Feed LO Low LPI Lines Per Inch LPM Lines Per Minute M Motor m meter metric unit of length MAIN Maintenance Jack RS 232 Optional MECA Mechanism Engine Control...

Page 347: ...AM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer OLV On Line Verify OP Operand P5 5 VDC P Pin connector P 1 P 2 etc Parallel data 1 data 2 etc PAL Programmable Array Logic PAP Paper PAPR Paper PARM Parameter PCBA Printed Circuit Board Assembly PCB Printed Circuit Board PCI Peripheral Component Interconnect PD Paper Detect or PE Printer Error Paper Empty PER Peripheral Device...

Page 348: ...ix System Architecture Third Generation PTR Pointer Printer PWM Pulse Width Modulation PWR Power R Right RBN Ribbon RD Read RDY Ready RET Return RIB Ribbon RM Ribbon Motor RoHS Restriction of Hazardous Substances In the illustrated parts sections part numbers listed in the column labeled Europe Mideast and Africa EMEA conform to requirements specified in DIRECTIVE 2002 95 EC OF THE EUROPEAN PARLIA...

Page 349: ...Field SG Signal Ground SHH Shuttle Hall Effect SHM Shuttle Motor SHUT Shuttle SHUTL Shuttle SIMM Single Inline Memory Module SLCT Select Online Slew Rapid vertical paper movement SMD Shuttle Motor Drive SNA Systems Network Architecture SOFT Software SPU Shuttle Processor Unit SPX Software Program Exchange module SRAM Static Random Access Memory STAT Status or State STBY Standby STK Stacker SW Swit...

Page 350: ... UNDEF Undefined USART Universal Synchronous Asynchronous Receiver Transmitter V Volts VAC Volts Alternating Current VDC Volts Direct Current VCC Voltage at Collector VDD Voltage at Drain VGL Code V Graphics Language VSS Voltage at Source V8 A special ASIC on the controller board containing circuits that help the data controller DC operate WR Write w With w o Without XMT Transmit ZTP Zero Tear Ped...

Page 351: ...nch 25 4 millimeter mm meter 3 280840 foot centimeter 0 03280840 foot millimeter 0 003280840 foot meter 39 37008 inch centimeter 0 3937008 inch millimeter 0 03937008 inch Figure is exact Multiply By To Obtain pound inch 0 11298 Newton meter N M pound foot 1 3558 Newton meter N M Newton meter N M 8 8511 pound inch Newton meter N M 0 7376 pound foot pound 4 4482 Newton N Newton N 0 22481 pound ...

Page 352: ...393 ounce avoirdupois To Convert To Use Formula temperature Celsius tc temperature Fahreheit tf tf 1 8 tc 32 temperature Fahreheit tf temperature Celsius tc tc tf 32 1 8 Multiply By To Obtain Btu International Table per hour 0 2930711 watt W watt W 3 412141 Btu International Table per hour watt W 0 001359621 horsepower metric horsepower metric 735 499 watt W ...

Page 353: ...acker page 358 Stacker Problems page 359 Stacker First Inspection page 359 Stacker Confidence Check page 360 Stacker Stacker Motor Check page 361 Removing The Power Stacker page 364 Installing The Power Stacker page 370 Replacement Procedures Constant Force Spring page 382 Timing Belts page 384 Roller Drive Shaft page 387 Illustrated Parts Breakdown page 390 ...

Page 354: ...verview of stacker operation Removal installation instructions for the entire power stacker assembly and for components that require the most frequent replacement An illustrated parts breakdown IPB showing how the power stacker is assembled and listing the part numbers for replaceable parts NOTE Only replaceable parts have part numbers in the IPB If you need to replace a part for which no part num...

Page 355: ...ontrol panel press the ON LINE key to take the printer offline Figure 64 3 Press the ELEVATOR UP key and wait for the elevator assembly to reach the top of its travel Figure 64 Figure 64 The Rear Control Panel 184108a ON OF F ON LIN E A A ELEVATOR UP ELEVATOR DOWN PAPER ADVANCE ON LINE ...

Page 356: ...inches 39 5 cm pull out the paper tray and install the wireform paper tent Figure 65 If the paper is wider than 15 5 inches 39 5 cm leave the paper tent out of the printer Figure 65 The Paper Tent 184120a Paper Tent Paper Tray A A Note the positions of alignment tab and the paper fence ...

Page 357: ...sired paper length Align the indicator notch on the bearing bracket with the paper length indicator The power stacker can handle paper or forms from 5 to 12 inches 12 7 to 30 5 cm long Figure 66 Figure 66 The Paper Length Indicator 184114a A A Paddle Shaft Bearing Bracket Paper Length Indicator ...

Page 358: ...at of the stacker Figure 67 2 Stack the extra pages on top of the wire paper tent if installed making sure the paper bends with the natural fold Figure 67 3 Press the ON LINE key to put the printer in the online state The stacker elevator will return to the correct position for printing 4 Check that the paper is still centered between the sides of the paper tent if installed 5 Close the cabinet re...

Page 359: ...elevator seats against both stops ATTENTION While doing the next step make sure the idler rollers do not interfere with the drive rollers as they move along the drive shaft 2 Verify that the friction washers do not bind on the driver shaft a Manually retract and hold the idler roller shaft so the paper throat is open While the throat is open slide the drive roller on one end toward the center of t...

Page 360: ...w LED The yellow LED should come on when the printer is online d The yellow LED should be off when the printer is offline e Press the PAPER ADVANCE down arrow key The printer should do a form feed every time you press this key f Press and release the ELEVATOR UP key The elevator should go up g Press and release the ELEVATOR DOWN key The elevator should go down 3 Disable the power stacker from the ...

Page 361: ...display STACKER FULL 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 do the Stacker chatters at upper or lower limit procedure on page 119 11 Set the elevator at the lowest position permitted by the amount of paper stacked in the tray Run an operator print...

Page 362: ...of Symptom Explanation Solution Printer does not detect presence of power stacker Reported by user Various causes possible page 118 STACKER FAULT Message on control panel LCD This message is triggered when the elevator cannot reach the top or bottom limit switch before timing out page 105 STACKER FULL Message on control panel LCD Status message the power paper stacker is full page 106 STACKER JAM ...

Page 363: ...ocedure that sent you there page 121 Stacker motor check Other troubleshooting procedures A procedure that tests the four stacker motors and their cables You will 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 122 Stacker not operating Reported by user Same symptom as Printer does no...

Page 364: ...ff 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 68 Figure 68 Removing the Paper Tent 5 Cut the tie wrap if present and remove the paper fence Figure 69 Figure 69 Removing the Paper Fence Paper Tent Stacker Base Paper Fence ...

Page 365: ...70 8 Remove the two Torx T 10 screws that secure the rail bracket to the cabinet floor Figure 70 Figure 70 Preparing the Stacker for Removal 9 Pull the paper tray out until the holes in the rails permit access to the M3 buttonhead screws Figure 71 183992a Washer Right Screw 10 32 x 5 32 inch Stacker Base Screw Torx T 10 Right Vertical Rail Upper Frame Cross Member Rail Bracket Screw Torx T 10 2 pl...

Page 366: ...osen one turn do not remove the M3x6 screws securing the vertical rails to the stacker base Each rail is secured by two screws Figure 71 Figure 71 The Lower Screws in the Vertical Rails M3x6 Buttonhead Screw Two on each rail Access Hole in Tray Rail ...

Page 367: ...ol panel 12 Remove the two 4 40 x 1 4 inch screws securing the elevator I O cable to the elevator assembly and disconnect the stacker I O cable Figure 72 Figure 72 Disconnecting the Stacker I O Cable Stacker I O Cable Vertical Rail Elevator Assembly Screw 4 40x1 4 Pan Head 2 Do not grasp the stacker in this area to lift it Lift the stacker by grasping the vertical rails ...

Page 368: ...cker Control Panel 14 Remove four cables from the stacker control panel and remove the stacker control panel Figure 74 Figure 74 Removing Cables from the Stacker Control Panel I O 184296a Standoff Long Screw Short Screw Washer Washer 184294a 184293a Logic Cable P104 Power Cable Elevator I O Cable P102 Rail Cable P107 A Ejection Lever A Remove the Tie Wrap ...

Page 369: ...aust duct Tilt the vertical rails toward the front of the printer until they clear the upper frame cross member Grasping the stacker assembly by the vertical rails lift and slide it to the rear and angle it out of the cabinet as shown in Figure 75 Figure 75 Removing the Stacker Assembly 184292a Vertical Rail Upper Frame Cross Member Elevator Assembly ...

Page 370: ...he stacker cable assemblies and the stacker control panel 1 Set the printer power switch to O off 2 Unplug the power cord 3 Remove paper 4 Loosen do not remove the three paper path hold down screws Slide the paper path to the left and lift it off the card cage Figure 76 Figure 76 Remove the Paper Path 183943a Paper Path Screw Screw Card Cage ...

Page 371: ...to connector J101 on the controller board Figure 77 8 Route the stacker power cable in front of the controller board and down through the cutout under the card cage fan Figure 77 9 Route the stacker logic cable in front of the controller board and down through the cutout under the card cage fan Figure 77 Figure 77 Power Stacker Connections on the PSA3 Controller Board 184295a Power Supply Connecto...

Page 372: ...ermit access to the M3 buttonhead screws Figure 78 11 Loosen one turn do not remove the M3 screws securing the vertical rails to the stacker base Each rail is secured by two screws Figure 78 Figure 78 The Lower Screws in the Vertical Rails M3x6 Buttonhead Screw Two on each rail Access Hole in Tray Rail ...

Page 373: ...inch screws as shown in Figure 79 Figure 79 The Elevator I O Cable CAUTION The paper stacker assembly mounts to the rear upper frame cross member and the cabinet floor It is a snug fit During installation grasp the stacker by the vertical rails and take care to avoid scratching painted surfaces or damaging the stacker Stacker I O Cable Screw 4 40x1 4 Pan Head 2 Vertical Rail Elevator Assembly ...

Page 374: ...ss member then slowly swing the base of the stacker assembly into the cabinet Figure 80a 15 Work the stacker base rearward and engage the upper brackets of the vertical rails under the upper frame cross member Figure 80b 16 Align the holes in the vertical rail brackets with the holes in the upper frame cross member Figure 80c and Figure 81 Figure 80 Stacker Installation 184291a a b c Upper Frame C...

Page 375: ...nd screw yet Figure 81 19 Install and tighten the two Torx T 10 screws securing the stacker base to the cabinet floor Figure 81 20 Install and tighten the two Torx T 10 screws that secure the rail bracket to the cabinet floor Figure 81 Figure 81 Stacker Fasteners 183992a Washer Right Screw 10 32 x 5 32 inch Stacker Base Screw Torx T 10 Right Vertical Rail Upper Frame Cross Member Rail Bracket Scre...

Page 376: ...rail cable elevator I O cable logic cable and power cable Route the cables outboard of the elevator assembly Figure 82 Figure 82 Stacker Cable Routing Elevator I O Cable Stacker Power Cable Stacker Logic Cable Rail Cable Elevator Assembly To Card Cage To Control Panel ...

Page 377: ...rs close over the connectors Figure 83 23 Press rail cable connector P107 into the control panel until the ejectors close then tie wrap the ejectors to the connector Figure 83 detail A Figure 83 Stacker Control Panel Cables 184293a Logic Cable P104 Power Cable Elevator I O Cable P102 Rail Cable P107 A Ejection Lever 184294a A Tie Wrap ...

Page 378: ...etween the control panel lower bracket and the inner panel of the cabinet a If the control panel lower bracket is flush with the cabinet inner panel proceed to step 26 b If there is a gap between the control panel lower bracket and the cabinet inner panel do the following 1 Peel the backing off the spacer adhesive Figure 84 2 Align the spacer with the holes in the lower bracket and inner panel Fig...

Page 379: ...ews Tighten the M3 screws securing the vertical rails to the stacker base Each rail is secured by two screws Figure 78 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 the upper rail screws and repeat steps 28 and 29 until the elevator moves smoothly 32 Bundle the stacker c...

Page 380: ...ndix D Installing the Power Stacker Figure 85 Securing Stacker Cables 33 Install the paper fence Figure 86 Figure 86 Paper Fence Cutout Beneath Card Cage Fan Stacker Cables Wire Saddle Paper Fence Stacker Base ...

Page 381: ...ent Figure 87 If the paper is wider than 15 5 inches 39 5 cm leave the paper tent out of the printer Figure 87 Paper Tent 35 Install the paper path that you removed in step 4 36 Install paper and test stacker operation Refer to the User s Manual 184120a Paper Tent Paper Tray A A Note the positions of the alignment tab and the paper fence ...

Page 382: ... See page 364 2 Raise the elevator assembly to within about 1 4 inch of its highest position and secure it to the vertical rails using tie wraps or string Do not over tighten the tie wraps or string tighten them just enough to hold the elevator up Figure 88 Figure 88 Securing the Elevator Assembly Tie Wrap Tie Wrap Elevator Assembly ...

Page 383: ...pring and drum Let the spring coil itself up until it reaches the top of its travel on the vertical rail Figure 89 4 Firmly gripping the spring and drum remove the rail screw and washer securing the spring to the vertical rail Figure 89 5 Position a new constant force spring on the vertical rail and install the rail screw and washer Figure 89 6 Install the shoulder screw large washer spacer and sm...

Page 384: ...pulley at the bottom of the left vertical rail and remove the pulley Figure 90 Go to step 6 4 If you are removing the right timing belt remove the two metric Allen screws that secure the timing belt motor to the right vertical rail Figure 90 Go to step 5 Figure 90 Removing the Timing Belt Pulley and Motor 5 Loosen the two setscrews on the motor pulley and remove the pulley Unplug the motor cable i...

Page 385: ...Figure 92 Figure 92 Releasing the Constant Force Spring 7 Remove two Allen screws from the belt clamp that secures the timing belt to the stacker frame Figure 93 Figure 93 Removing the Belt Clamps NOTE Left is shown Right is the same Large Washer Shoulder Screw Constant Force Spring Allen Screw Belt Clamp Belt Clamp Allen Screw ...

Page 386: ...e the timing belt by working it around the vertical rail and constant force spring Figure 94 9 To install a timing belt reverse the steps of this procedure Figure 94 Removing the Timing Belt NOTE Left timing belt is shown Right is the same Timing Belt ...

Page 387: ...right bearing pivot plate s extension spring from the tab on the elevator Figure 95 3 Using an M 2 Allen wrench remove the screw securing the right bearing pivot plate to the elevator Figure 95 Figure 95 Right Bearing Pivot Plate and Extension Spring 184091a 184091 REV A Screw Extension Spring Tab Right Bearing Pivot Plate A A ...

Page 388: ...remove the two screws securing the power stacker stepper motor to the elevator Figure 96 7 Using a 9 64 inch Allen wrench loosen do not remove the collar screw securing the collar to the roller drive shaft Figure 96 8 Support the roller drive shaft with one hand and pull the stepper motor shaft out of the roller drive shaft Let the stepper motor hang from its cables Figure 96 Power Stacker Stepper...

Page 389: ...ew roller driver shaft Figure 97 12 Remove the new roller drive shaft 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 the roller drive shaft and rollers The roller drive shaft must be dry and clean 14 Apply a small dab of bearing lubricant to the dimple in the new grounding clip Make sure this is the o...

Page 390: ...rts are assigned part numbers If a part or assembly is damaged but does not have a part number replace the entire power stacker assembly NOTE Part numbers listed in the column labeled Europe Mideast and Africa EMEA are RoHS compliant These parts conform to requirements specified in DIRECTIVE 2002 95 EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 27 January 2003 on the restriction of the use o...

Page 391: ...EA RoHS 250676 901 See Figure 84 page 378 Cont Pnl Assy Pwr Stkr Blk Adv Exch Americas and Asia Pacific 178911 991 EMEA RoHS 250676 991 Control Panel Assy Pwr Stkr Gray 179798 001 Stacker Hardware Kit 173830 001 Rail Cable Power Stacker 173823 001 See page 336 Power Cable Power Stacker 174414 001 See page 335 Logic Cable Power Stacker 176029 001 See page 334 Frame Cable Power Stacker 173824 001 Se...

Page 392: ...392 Appendix D Illustrated Parts Breakdown Figure 98 Stacker Assembly A 14 30 35 10 12 20 9 37 12 8 13 15 25 7 11 20 9 12 10 6 7 See page 394 8 2 3 4 5 2 23 21 22 1 ...

Page 393: ...item 36 9 Ref Screw Shoulder 10 32 Part of item 36 10 202716 001 Timing Belt 11 173726 001 Shaft Lift Phase III 12 178058 001 Pulley Timing Fairloc 12T 13 159398 001 Pulley Motor 14 175726 901 Clip Ground Dimpled Pwr Stkr Part of item 47 15 16 158446 001 173530 001 Motor Assembly Power Stacker Motor Stepper Power Stacker Elevator motor and paddle motor Paper puller motor 20 178918 001 Spring Confo...

Page 394: ...eakdown Figure 99 Elevator Detail 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 53 54 52 65 From page 392 See page 396 See page 398 See page 398 See page 400 66 B D C C 70 75 ...

Page 395: ... Part of item 36 51 202708 901 Collar Clamp 52 Ref Collar Setscrew Part of item 36 53 156390 001 Support Shaft 54 174570 001 Fence Wireform Phase III 55 203032 001 Extension Spring 60 157275 001 Idler Roller 65 157054 001 Paddle Power Stacker 66 204235 001 Switch Assy Rocker Elevator Disable Switch 70 157960 001 Drive Roller Part of item 47 75 176781 001 Compression Spring Part of item 47 76 20423...

Page 396: ...396 Appendix D Illustrated Parts Breakdown Figure 100 Stacker Detail Motor Bracket From page 394 95 95 96 96 100 Connector Flag Key B E E ...

Page 397: ...List of Illustrations 397 Item No Part No RoHS Compliant Description Notes 95 Ref Clip On Bearing Part of item 36 96 158288 001 Holder LED Round 100 Ref LED IR T 1 3 4 ...

Page 398: ...398 Appendix D Illustrated Parts Breakdown Figure 101 Stacker Detail Elevator Bracket 5snelvbk 95 97 Connector Flag Key 95 Nib 105 From page 394 C F F ...

Page 399: ...List of Illustrations 399 Item No Part No RoHS Compliant Description Notes 95 Ref Clip On Bearing Part of item 36 97 158290 001 Holder LED Flat 105 Ref Photodarlington NPN Rectifier ...

Page 400: ...400 Appendix D Illustrated Parts Breakdown Figure 102 Stacker Detail Paper Motion Detector 5sndtect Connector Key Nib 105 Rotated 180 Degrees 97 110 97 107 116 115 108 106 107 From page 394 D ...

Page 401: ...ington 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 Part of item 115 110 Ref LED IR Rectangular 115 170289 001 Field Kit Power Stacker PMD Paper Motion Detector 116 Ref Spring Torsion Part of item 115 ...

Page 402: ...402 Appendix D Illustrated Parts Breakdown ...

Page 403: ...rinter for Maintenance page 416 Returning the Printer to Normal Operation page 416 Barrier Panel page 417 Belt Paper Feed Timing Adjustment page 418 Paper Guide Leaf Front Center Outer page 420 Paper Out Sensor Adjustment page 420 Paper Tension Horizontal page 420 Replacement Procedures page 421 Belt Paper Feed Timing page 422 Control Panel Assembly page 423 Cover Assembly Top Pedestal Models page...

Page 404: ...egrated Print Mgmt Sensor Assy page 444 Figure 124 ZTP Hammer Bank Fan and Motors page 446 Overview The 6600 Zero Tear Pedestal ZTP printer can print a form and present it for tear off without losing a form between print jobs The printer automatically presents the current print line to the tear bar when it finishes printing and no data are being sent to the printer When it receives more data from ...

Page 405: ... Tractors Figure 103 Aligning and Loading Paper onto the Printer 1 Align the paper supply box with the label on the bottom left side of the modesty panel See Figure 103 2 Open the printer cover 183487b Paper Supply Box Paper Label A 183486b Top Cover A Paper Edge of Paper Box ...

Page 406: ...or sprockets and close the tractor door 6 Adjust the paper web tightness by sliding the right tractor to remove slack or to adjust for various paper widths See Figure 104 7 Lock the tractors in position by pressing down on the tractor locks Remove Paper 1 Open the left and right tractor doors 2 Pull the paper upward through the top of the printer NOTE DO NOT pull the paper downwards from the botto...

Page 407: ...aper guide leaves are not damaged 1 Remove the left paper guide knob and the left front paper guide leaf See Figure 105 2 Remove the center paper guide knob and the center front paper guide leaf 3 Remove the right paper guide knob and the right front paper guide leaf 184301a A Paper Guide Knob 3 Center Paper Guide Leaf Front Paper Guide Leaf 3 183483b A Outer Paper Guide Leaf 2 ...

Page 408: ...er paper guide leaf is 5 inches from the right tractor 6 Slide the center mount block so that the center paper guide leaf is centered between the left and right outer paper guide leaves 7 Install the paper guide knobs and front paper guide leaves See Figure 105 on page 407 8 Reload the paper without unlocking the tractors See page 405 183485b Paper Tractor 2 Outer Paper Guide Leaf 2 Center Paper G...

Page 409: ...tear bar page 411 2 Loosen the paper out sensor by turning the sensor knob counterclockwise 3 Position the paper out sensor so that there are at least 2 inches between the bottom of the aluminum extrusion bar and the top of the paper out sensor IMPORTANT For optimal performance 2 inches is recommended for 11 inch forms For shorter forms position the paper out sensor so that there are at least 2 in...

Page 410: ...e in increments of 1 144th of an inch 8 Press MENU ENTER to select the desired value An asterisk appears next the selected value and a scale prints to indicate the tear bar distance in relation to the tear bar For correct tear bar distance the zero should align with the tear bar See Figure 108 NOTE The Tear Distance value must be changed to print the scale Figure 108 Correct Tear Bar Distance NOTE...

Page 411: ...r 4 Position the perforation so it aligns with the tear off bar NOTE This is easily done by advancing one complete sheet above the tear off bar and folding it over at the perforation 5 Position the fold exactly at the tear bar 6 Tear the sheet off to ensure proper positioning NOTE If you do not want to lose a form position the top of the form at the tear bar Run a finger along the back of the form...

Page 412: ...ored and a scale is printed to indicate the current tear off position The default value is 1060 NOTE When a new value is selected the printer will lose the current print position You must reset the top of form to automatically save the new value ZTP DataTime This option sets the pause time in the data stream that the ZTP requires before moving the form to the tear bar once a print job is completed...

Page 413: ...an one form per page horizontally NOTE If you use forms outside these limits the print quality may not be optimum the printer may lose top of form or the frequency of paper jams will increase Table 8 Forms Type Description Length Width edge to edge One to three part continuous with carbon fan folded edge perforated paper forms 3 to 12 inches 7 to 16 5 inches One to four part continuous with carbon...

Page 414: ... tightness properly Position the form perforation against the tear bar Time the tear while the paper is not moving Direct the tear force toward the user and across the tear bar not upward To Clear Paper Jams 1 Raise the platen lever to open the platen 2 Open the left and right tractor doors 3 Pull the paper upward through the top of the printer NOTE DO NOT pull the paper downwards from the bottom ...

Page 415: ...ou usually will be referred to this chapter by a troubleshooting procedure or as part of a removal installation procedure List of Adjustments and Tests Procedures Preparing the ZTP Printer for Maintenance page 416 Returning the Printer to Normal Operation page 416 Barrier Panel page 417 Belt Paper Feed Timing Adjustment page 418 Paper Guide Leaf Front Center Outer page 420 Paper Out Sensor Adjustm...

Page 416: ...replaceable components of the shuttle frame assembly To prepare the printer for maintenance do the following steps before you make any adjustments or perform any maintenance procedure 1 Set the printer power switch to O off 2 Unplug the printer power cord from the printer or AC power source 3 Disconnect the data signal cable s from the printer interface 4 Unload paper 5 Read the entire adjustment ...

Page 417: ...ers of the barrier panel See Figure 110 Figure 110 The Barrier Panel 5 Adjust the top portion of the barrier panel so that it protrudes forward towards the front of the printer 1 10 inch Use a measurement scale as a guide See Figure 111 6 Tighten the screw Figure 111 Using a Scale to Adjust the Barrier Panel 7 Install the top cover assembly See page 423 8 Return the printer to normal operation pag...

Page 418: ...end of a force gauge apply 15 pounds 66 7 N of pressure to the paper feed drive motor item 4 Use the splined shaft to steady the gauge 6 Reduce tension to 12 pounds 53 4 N and torque the 5 16 inch paper feed motor mount bolts item 3 to 18 inch pounds 2 03 N m NOTE Belt tension is correct if the belt deflects 1 8 inch 3 175 mm midway between the pulleys 7 Install the hex screws and right cover plat...

Page 419: ... w Lockwasher 4 2 Cover Plate Right Extension 3 Motor Mount Bolt 2 4 Paper Feed Drive Motor 5 Splined Shaf Pulley 6 Paper Feed Timing Belt 7 Paper Feed Motor Pulley Figure 112 Paper Feed Timing Belt Adjustment 1 8 inch Direction of Force 3 4 3 A A 1 2 5 6 7 ...

Page 420: ... the printer for maintenance page 416 2 Adjust the paper out sensor See page 409 Paper Tension Horizontal 1 Prepare the printer for maintenance page 416 2 Unlock the right tractor 3 Slide the right tractor to properly adjust the paper web tightness NOTE The paper should be taut 4 Lock the right tractor Figure 113 Adjusting the Horizontal Paper Tension 183488b Tractor Lock 2 Tractor Door 2 Paper ...

Page 421: ... 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 The same is true of failures traced to the hammer bank it is not field repairable so you must replace the entire shuttle assembly Hammer spring assemblies the hammer bank cover and the ribbon mask are the only replace...

Page 422: ...oll the paper feed timing belt onto the splined shaft pulley and the motor pulley See page 419 items 5 6 and 7 2 Using the straight end of a force gauge apply 15 pounds 66 7 N of pressure to the paper feed drive motor Use the splined shaft to steady the gauge See page 419 item 3 NOTE Belt tension is correct if the belt deflects 1 8 inch 3 175 mm midway between the pulleys 3 Reduce tension to 12 po...

Page 423: ...h the holes in the upper edge of the panel bracket and install the two mounting screws 3 Connect RJ 11 connector P310 to connector J2 on the rear of the control panel See page 436 item 5 4 Return the printer to normal operation page 416 Cover Assembly Top Pedestal Models Removal 1 Prepare the printer for maintenance page 416 2 Remove the control panel assembly page 423 3 Loosen do not remove the t...

Page 424: ...OTE Some paper feed motors are mounted with nuts and bolts other motors have threaded flanges eliminating the need for nuts 6 Remove the motor mount screws and nuts if present 7 Remove the paper feed motor assembly See page 442 item 5 Installation 1 Position the paper feed motor assembly on the right side plate and install the motor mount bolts and nuts finger tight See page 442 items 5 and 6 2 Co...

Page 425: ...nob and the left front paper guide leaf See page 429 Figure 116 3 Repeat step 2 to remove the center and right front paper guide leaves Installation 1 Reverse step 2 and step 3 of the removal procedure above 2 Return the printer to normal operation page 416 Paper Guide Leaf Outer Removal 1 Prepare the printer for maintenance page 416 2 Remove the left paper guide knob and the left front paper guid...

Page 426: ...ie wrap holes to free the paper out sensor cable 4 Trace the paper out sensor cable back to the controller board releasing it from the cable restraints 5 Disconnect connector coupling shroud P106 from the controller board 6 Remove the sensor knob paper out sensor and paper out sensor cable Screw 4 Left Cover Plate 5 Paper Out Sensor Sensor Knob Paper Out Sensor Cable Tie Wrap Tie Wraps 5 See page ...

Page 427: ...the controller board and install tie wraps to secure the motor cable 4 Route the tie wraps through the tie wrap holes and around the paper out sensor cable NOTE Be sure that the tie wrap loops around the cable towards the back of the printer as shown in Figure 114 detail B on page 426 5 Install the screws and left cover plate 6 Position the paper out sensor See page 409 7 Return the printer to nor...

Page 428: ...ppendix E Replacement Procedures Shaft Splined Figure 115 Removing the Right Cover Plate and Back Cover Plate Screw 4 Right Cover Plate Screw 4 Back Cover Plate A A Paper Feed Timing Belt Motor Mount Screw 2 ...

Page 429: ...e screw securing the right tractor shaft plate and the tractor shaft plate See Figure 116 9 Slide the splined shaft out of the sealed ball bearing in the left tractor shaft plate and remove the tolerance ring from the left end of the splined shaft page 442 items 9 10 15 and 17 10 Grasp the splined shaft pulley and slide the splined shaft to the right out of the tractors and right side plate See Fi...

Page 430: ...mm from the ball bearing 5 Install the right tractor shaft plate and screw page 442 items 7 and 8 by first sliding the upper fingers up and against the flange on the ball bearing then sliding the rectangular cutout over the support shaft end then snapping the U shaped spring behind the tab on the right side plate 6 Install the tractor assembly support gates on the splined and support shafts See in...

Page 431: ...442 item 1 4 Remove the paper guide knob from the center leaf paper guide See page 442 item 14 5 Remove the tractor assembly supports from the splined shaft and support shaft See page 433 6 Remove the screw securing the right tractor shaft plate and remove the plate See page 442 items 7 and 8 7 Slide the support shaft to the right out of the tractors block mounts and the right side plate See page ...

Page 432: ...n sliding the rectangular cutout over the support shaft end then snapping the U shaped spring behind the tab on the right side plate 4 Install the tractor assembly supports to the splined shaft and support shaft See installation instructions on page 433 5 Install the hex screws and right cover plate See page 440 items 24 and 25 6 Return the printer to normal operation page 416 Tractor L R Removal ...

Page 433: ... and install the support gate to the left of the left tractor onto the support shaft and splined shaft See page 434 2 Slide the tractor assembly support gate until it is flushed against the left side plate 3 Slide the left tractor until it is flushed against the left tractor assembly support gate 4 Lock the left tractor 5 Squeeze the tab on the tractor assembly support gate and install the support...

Page 434: ... Procedures Figure 118 Removing and Installing the Tractor Assembly Support Gate 184298a A Tractor Assembly Support Gate 2 Support Shaft Splined Shaft Tractor Door 2 Tractor Lock 2 Left Side Plate Right Side Plate 184299a Tab A ...

Page 435: ... These parts conform to requirements specified in DIRECTIVE 2002 95 EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 27 January 2003 on the restriction of the use of certain hazardous substances in electrical and electronic equipment Illustrations of ZTP Components Figure 119 ZTP Details page 436 Figure 120 ZTP Inside Covers Barrier Shield and Shuttle Assy page 438 Figure 121 ZTP Circuit Boards...

Page 436: ...436 Appendix E Illustrated Parts Lists Figure 119 ZTP Details 184045a 1 9 3 8 4 5 6 7 2 11 12 13 14 15 16 17 10 18 19 20 ...

Page 437: ... Cover 9 Ref Housing Pedestal V3 10 Ref Screw 4 10 32x 625 11 250081 001 Field Kit Short Stack Ped 6600 Contains items 16 12 179395 001 Wireform Upper ZTP Ped 6600 13 178241 901 179766 901 Panel Quick Access Flip Up Black Panel Quick Access Flip Up Gray 14 157070 901 Paper Fence Rear Ped 15 179972 901 177119 901 Top Cover Full Assy 6600 ZTP Black Top Cover Full Assy 6600 ZTP Gray Does not include ...

Page 438: ...rts Lists Figure 120 ZTP Inside Covers Barrier Shield and Shuttle Assembly 184046a See Figure 45 page 260 1 2 9 A 4 3 5 Two places Exploded to show assembly Do not remove the clamps and screws 8 7 6 To J02 Shuttle Motor To J03 MPU ...

Page 439: ...4504 901 254504 991 254496 901 254496 991 254488 901 254488 991 254135 901 254135 991 252700 901 252715 901 252723 901 174514 901 Shuttle Assembly 05 Shuttle Assembly 05 Adv Exch Shuttle Assembly 10 Shuttle Assembly 10 Adv Exch Shuttle Assembly 15 Shuttle Assembly 15 Adv Exch Shuttle Assembly 20 Shuttle Assembly 20 Adv Exch Hammer Spring Assembly 05 Thin Hammer Spring Assembly 10 Thin Hammer Sprin...

Page 440: ...40 Appendix E Illustrated Parts Lists Figure 121 ZTP Circuit Boards and Paper Feed Assembly 184047a 7 8 9 4 6 11 16 17 12 13 15 5 3 10 18 19 10 To the Terminator Board on the Shuttle Frame 22 23 24 25 26 ...

Page 441: ...901 Hammer Bank Power Cable Assembly Used on all except 6620 and 6620Q 11 202362 001 Housing Connector Kit P107 Motor Sensor Right 12 152439 901 Centronics I O Cable Assembly 13 152440 901 Control Panel Cable Assembly 15 Ref Screw Captive Power Supply 2 16 250488 902 250488 903 SIMM Flash Memory 8 MB SIMM Flash Memory 16 MB Install in slot J11 J10 is not used 17 Ref Security Key 18 178046 001 1785...

Page 442: ...442 Appendix E Illustrated Parts Lists Figure 122 ZTP Tractor Shafts Paper Guides and Paper Feed Motor 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 25 27 26 28 ...

Page 443: ...front leaf guide assemblies 12 177812 001 Plate Clamping Paper Guide ZTP 3 Part of item 11 13 Ref Screw 6 32x 25 Hex Hd Washer 6 Part of item 11 14 Ref Screw M5X16X 8 SHCS Thumb SS ASTM F837M Part of item 24 15 Ref Bearing Ball Sealed 16 Ref Screw Socket Cap 6 32x 312 Trilob Self Tapping 2 17 173130 001 Plate Tractor Shaft Left 18 Ref Screw Flat HD Metric M3x6mm 3 19 179755 001 Leaf Guide Paper Ou...

Page 444: ... E Illustrated Parts Lists Figure 123 ZTP Platen and Integrated Print Management Sensor Assembly 184048a NOTE Item 24 Platen Hardware Kit 1 2 3 4 5 6 7 1 2 8 9 12 11 10 13 14 17 15 16 18 23 22 21 17 20 16 25 15 19 ...

Page 445: ... Screw Socket Cap 6 32x 75 Part of item 14 12 Ref Washer Part of item 14 13 Ref Nut Part of item 14 14 178705 901 Platen Stop Lever Kit Includes items 11 12 13 15 Ref Spring Extension 1 12L Part of item 24 16 Ref Link Spring Part of item 24 17 Ref Bearing Nylon 376 Part of item 24 18 Ref Bracket Switch Mount Part of item 10 19 Ref Wear Saddle Platen 2 Part of item 24 20 150703 902 Platen Pulley Dr...

Page 446: ...446 Appendix E Illustrated Parts Lists Figure 124 ZTP Hammer Bank Fan and Motors 184049a 9 8 7 3 1 2 11 12 13 14 15 ...

Page 447: ...Assembly Platen Includes pulley 4 Undefined 5 Undefined 6 Undefined 7 Ref Screw w Lock Washer 10 32x 50 2 Part of item 3 8 254507 001 Motor Stepper 6600 Ribbon Cartridge 9 203281 001 Screw M3 x6 x 5 4 10 Undefined 11 Ref Screw w Lock Washer 2 6 32x1 25 12 152416 901 173427 901 Hammer Bank Fan Assembly Hammer Bank Fan Assembly All except 6620 and 6620Q air flow is up 6620 and 6620Q air flow is up 1...

Page 448: ...448 Appendix E Illustrated Parts Lists ...

Page 449: ...ontinuous form paper used in this printer Specific brands of paper are not recommended The second section goes into more detail providing definitions guidelines and a checklist you can use to design forms that will run smoothly through the printer Adherence to these specifications will ensure the best print quality and reliable operation of the printer ...

Page 450: ...84 which cover common form widths and depths standards for sprocket feed holes and margins and other basic tolerances Table 9 Paper Sizes Maximum Form Width 17 0 inches 43 18 cm edge to edge Minimum Form Width 3 0 inches 7 62 cm edge to edge Maximum Printing Width 13 6 inches 34 54 cm Maximum Right Margin 1 to 13 6 inches 2 54 to 34 54 cm Maximum Left Margin 0 to 13 5 inches 0 to 34 29 cm Maximum ...

Page 451: ...area i e between the side perforations Form Thickness Thickness measured at the thickest point of the entire form This includes glue lines compressed staples perforations etc and is not limited to the printed region of the form Margin The region outside the print area of the form The margin is typically bounded by the outermost vertical perforations i e where the tractor holes are located and the ...

Page 452: ...lustrates the terms used in this appendix Figure 125 Forms Terminology Side Perforation Margin Area Form Span Print Area Tractor Pin Hole Side View of Form Printed Side of Form Outward Perforation Inward Perforation Cut Point Tie Point Page Perforation ...

Page 453: ...orms must be strong enough to assure that tractor holes and perforations do not tear or detach during form feed skipping and ejecting operations Form Thickness Forms must be no thicker than 0 025 inches 0 0635 cm at the thickest part of the form including glue lines staples perforations etc and is not restricted to just the print area Form Evenness The evenness of forms must not exceed 0 003 inche...

Page 454: ...s Staples must be used only in the margin area of the form and must not be in line with the path of the tractor holes Ideally staples are placed in the margins so that they coincide with areas of the form where printing does not occur Figure 126 below shows preferred and unacceptable ways of fabricating staples Specification Inches Millimeters Hole centerline CL to edge of form 0 236 0 028 6 0 0 1...

Page 455: ... a cut to tie ratio that causes a thickness buildup greater than 0 025 inch 0 635 mm or that creates an evenness variation greater than 0 003 inch 0 0762 mm will result in an unreliable and unpredictable form Perforation Intersections Whenever a horizontal line of perforations intersects with a vertical line of perforations the point of intersection must be a tie point Cut points at such intersect...

Page 456: ...Yes _______ No _______ If yes assure adequate form strength to prevent tractor holes and perforations from tearing or detaching during form feeds and page ejects Security Form Yes _______ No _______ If yes the last page of the form should have a minimum 50 reflectance and if possible the stippled page faces inward to the form Form Weight Form weight ________ Minimum 15 lb 6 8 kg Maximum 100 lb 45 ...

Page 457: ... coincide with major perforation or any horizontal perforation ________ Gluing lines must not result in a form that exceeds 0 025 in 0 0635 cm thickness ________ Staples must be used only in margin area of form ________ Staple cuts must not be in the direction of form movement through the tractors ________ Staples must not occur in line with the path of the tractor holes Specification Inches Milli...

Page 458: ...OTE A cut to tie ratio that causes a thickness buildup greater than 0 025 in 0 0635 cm or that creates an evenness variation greater than 0 003 in 0 00762 cm will result in an unreliable and unpredictable form Perforation Intersections ________ Horizontal vertical perforations are tie points Cut points at such intersections are unacceptable Chaff Content ________ Tractor holes are clear of chaff _...

Page 459: ...handling use top and bottom fillers in continuous form cartons to hold the paper stack firmly in place Proper packaging ensures that the paper remains flat and is not damaged along the edges Storage Do not store cartons directly on the floor and do not stack them more than six high Set each carton upright and squarely on the one underneath Do not place anything else on the stack of paper as this c...

Page 460: ...460 Appendix F Summary ...

Page 461: ...ial number located on the back of the printer Installed options i e interface and host type if applicable to the problem Help Menu printout While offline press the MENU ENTER key on the control panel to enter the menu Press the Left Arrow key until the Help Menu displays Press the MENU ENTER key Is the problem with a new installation or an existing printer Description of the problem be specific Go...

Page 462: ...es Printronix Inc 14600 Myford Road P O Box 19559 Irvine CA 92623 9559 Phone 714 368 2300 Fax 714 368 2600 Printronix Inc Nederland BV P O Box 163 Nieuweweg 283 NL 6600 Ad Wijchen The Netherlands Phone 31 24 6489489 Fax 31 24 6489499 Printronix Schweiz GmbH 42 Changi South Street 1 Changi South Industrial Estate Singapore 486763 Phone 65 6542 0110 Fax 65 6546 1588 Printronix Commercial Shanghai Co...

Page 463: ...TUS SDRAM DETECTION 166MHZ 50 B01 STATUS 8245 SDRAM TEST 32MB 51 B02 STATUS SDRAM PASSED 51 B10 ERROR NO DRAM DETECTED 51 B11 ERROR RAM TEST FAILED 51 B12 ERROR PROGRAM MISSING 51 B13 ERROR NOT COMPATIBLE 51 B19 ERROR DC RETURNED 51 B20 STATUS 00 DOWNLOAD MODE 52 B21 STATUS PRINTER RESET 52 B22 ERROR DECOMPRESS SIZE 52 B23 ERROR DECOMPRESS CKSUM 52 B30 STATUS INITIALIZING 52 B35 STATUS WAITING FOR...

Page 464: ...LATEN 61 Code configuration printer 20 Coil temperature adjustment 178 Communications failures 134 Configuration 22 Configuration code printer 20 Connector coupling shrouds replacement 197 Control panel block diagram 291 keys 25 replacement 199 Controller board principles of operation 292 replacement 200 Controls and indicators cabinet models 25 mechanical 28 printing conventions 23 Conventions pr...

Page 465: ... 70 E31B EVENT 1 BP See User Manual 70 E31C EVENT 2 BP See User Manual 70 E31D EVENT 3 BP See User Manual 70 E31E EVENT 4 BP See User Manual 71 E31F EVENT 5 BP See User Manual 71 E31G EVENT 6 BP See User Manual 71 E31H EVENT 7 BP See User Manual 71 E32A CND 0 BP See User Manual 72 E32B CND 1 BP See User Manual 72 E32C CND 2 BP See User Manual 72 E32D CND 3 BP See User Manual 72 E32E CND 4 BP See U...

Page 466: ...B NOT INSTALLED 84 HMR BANK FAN FLT 85 How to Identify the Printer 19 How to Use This Manual 22 I I O cable requirements 31 Identifying printer models 19 ILL EXT BUS ACC 85 ILL INST ACCSS 85 ILLGL OPR ACCSS 86 Illustrated Parts Lists ZTP 435 Important Maintenance Notes 21 Incompat E NET Remove NIC 86 Incompat WLAN Remove NIC 86 Installation 22 INTAKE FAN FAULT 86 Integrated Print Management System...

Page 467: ... N NEW SPX DETECTED PRESS ENTER 89 NON VOLATILE MEMORY FAILED 89 Notes and notices safety and information 23 NOVRAM ERROR n 89 O OLD RIBBON Install New RBN 90 Operation principles of 279 Overview printer models 17 P PAP BSY TOO LNG 90 PAP FD DRVR CIR See Manual 90 PAP FIFO OVERFL 91 PAP FIFO UNDRFL 92 PAP ILLGL ST 93 PAP INCMPL ENER 93 PAP INVLD CMD 93 PAP INVLD PARM 93 PAP NOT SCHED 94 PAP NT AT ...

Page 468: ...ns is this manual 23 line matrix printing explained 279 problems 43 Procedures adjustment 153 cleaning 35 PROTECTED INSTR 97 PWR SUPP VOLT 98 R RBN DRVR CIR 98 REGIONx MISMATCH 98 Removal paper guide assembly 222 paper path 222 REMOVE USED SPX THEN PRESS ENTER 98 Replacement card cage fan assembly 207 center paper guide ZTP 425 circuit breaker 196 connector coupling shrouds 197 control panel assem...

Page 469: ... PAL NOT DETECTED 100 SECURITY VIOLATION 100 Self tests diagnostic printer 136 printer 136 Setup SureStak Power Paper Stacker 355 Shaft splined replacement 236 splined skew adjustment 164 support replacement 238 Shorts cable checking for 184 hammer bank power cable checking for 183 Shorts electrical shuttle checking for 182 SHTL MISMATCH 100 SHUT DRVR CIR See User Manual 100 SHUTL INV CMD 101 SHUT...

Page 470: ...horts 183 main wire harness diagnostic 186 power supply operation 187 printer 136 printer diagnostic 136 TIP MISMATCH 108 Tool shuttle stabilizer 239 Tools test equipment and supplies 30 Torque conversion to or from metric 351 Tractor replacement 244 Training maintenance for TallyGenicom products 33 TRNSPT INVL CMD See User Manual 98 Troubleshooting 43 aids 43 communications failures 134 fault mes...

Page 471: ...aper out sensor adjustments 420 paper out sensor replacement 426 paper out sensor position 409 paper remove 406 replacement procedures 421 return to normal operation 416 splined shaft replacement 428 support shaft replacement 431 tear bar distance set 410 top cover assembly replacement 423 top of form set 411 tractor assembly support gate replacement 433 tractor replacement 432 tractor setup 405 Z...

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Page 474: ... 255559 001 255559 001A Approved Final May 19 2011 ...

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