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Tektronix Phaser 600 Service Manual Download Page 103

 

Service Manual

 

5-9

 

Theory of Operation

 

5

 

To perform the maintenance cycles, the drum will rotate counterclockwise to 
three different positions: Air knife, wipe, and purge.

For example,  to perform a purge cycle:

 

■

 

The drum is rotated counterclockwise to move the cam to the purge 
position which forces the maintenance station against the faceplate 
and allows the cam pin to move towards the drum following a deeper 
channel in the maintenance track which closes the air valve.  

 

■

 

The vacuum pump is started and performs a  4- or 5-second purge.  

 

■

 

The drum is then rotated clockwise to move the cam pin up a ramp in 
the track to open the air valve and remove the vacuum. 

 

■

 

The drum continues to rotate clockwise to move the purge chamber 
away from the faceplate.  

 

■

 

Ink from the purge chamber runs out of the cutouts in the gasket onto 
the drip plate and into the waste bin. 

 

Figure 5-6  The maintenance station cam

9482-97

Waste bin track

Maintenance track

Purge

Air knife

Maintenance
station pin

Wipe

Summary of Contents for Phaser 600

Page 1: ...ollowing servicing instructions are for use by qualified service personnel only To avoid personal injury do not perform any servicing other than that contained in operating instructions unless you are qualified to do so This printing Dec 1996 070 9482 00 ...

Page 2: ...it provides information on installing and verifying the printer and training printer customers as a part of the Option S0 printer installation procedure The latter half of the manual includes troubleshooting guides adjustment procedures assembly disassembly procedures and an FRU list To ensure complete understanding of the product we recommend participation in Phaser 600 Color Printer service trai...

Page 3: ...the roll fed print from the roll when the print is complete Sheet media can also be manually fed into the printer Supported cut sheet media sizes are Metric A3 through A0 US B through E and Architectural 24 x 36 in 30 x 42 in and 36 x 48 in Roll fed media range in width from 420 to 914 mm 16 5 to 36 in with a maximum roll diameter of 127 mm 5 in Unique to the Phaser 600 Color Printer s solid ink t...

Page 4: ... a printhead cleaning and purge cycle upon power up The printer s purge cycle consumes some ink During normal use and servicing turn the printer off and allow it to cool only when necessary Memory considerations The capabilities of the printer increase with the addition of more RAM Table 1 1 Phaser 600 memory configuration and usage Memory configurations Color cache Virtual memory Band buffers Cap...

Page 5: ...formation Print engine assemblies Figure 1 2 Internal features of the print engine 9482 02 Top cover Back tension blade Drum Printhead Maintenance station Fuser Stripper fingers Roll holder Air pump Clamp bail rollers Ink loader motor assembly ...

Page 6: ...ds of the print engine Ink loader board Left junction board Top cover interconnect board Heater interconnect board Carriage board Right junction board Power supply in electronics bay Engine control board in electronics bay Image processor board in card cage 9482 03 ...

Page 7: ... sensor Exit sensor Left fuser closed sensor Input sensor Right cover closed sensor Cover open sensor Clamp ready sensor Clamp home sensor Waste bin sensor Left paper edge sensor on printhead Right paper edge sensor on printhead Ink low sensor Ink drop sensor Ink loader installed sensor Black origin sensor Magenta origin sensor Yellow origin sensor Cyan origin sensor Right fuser closed sensor ...

Page 8: ...re 1 5 Motors and solenoids on the print engine Printhead cover motor X axis motor Y axis motor Fuser motor Clamp close solenoids Clamp rotate solenoids Head to media motor Head maintenance cam gear motor Paper exit motor 9482 06 Ink load motors 4 ...

Page 9: ...lter air tubing and a cam gear for positioning the maintenance station Sensors in the printer provide information to the engine control board to determine the state of the printer The printer monitors the positions of some of the movable assemblies such as the printhead as well as the temperature of the printhead and fuser bar Figure 1 6 Printhead maintenance system of the print engine Maintenance...

Page 10: ...ter stores unique printer status and PostScript values in its NVRAM module The printer s IP address unique to each printer is stored in a socketed ROM IC RAM SIMM 1 must always be a 8 Mbyte RAM SIMM RAM SIMM 2 can be either a 16 Mbyte RAM SIMM or a 32 Mbyte RAM SIMM Figure 1 7 Features of the image processor board Extended Feature SIMM PhaserShare Card Printer ID ROM NVRAM PostScript ROM SIMM RAM ...

Page 11: ...rts and peripheral parameters Using the front panel to review and change parameters is discussed in Chapter 9 Checks and Adjustments Buttons Button 1 the left most button is an Exit key used to cancel or escape from an operation while in the interactive menu The functions of buttons 2 3 and 4 are defined by the particular menu or function being displayed on the LCD The bottom row of the LCD labels...

Page 12: ...eT Ethernet or Token Ring connectors Health LED Blinking The printer is operating normally The LED blink irregularly during diagnostics If a soft error occurs the image processor s 29K operates but in a reduced capacity Soft failures include failure of expansion memory SIMMs or any of the interface ports When a soft error occurs the printer automatically prints a startup page listing the error On ...

Page 13: ...tely 135 kgs 300 lbs Print engine weight only add additional weight for roll of paper Table 1 3 Printer clearances Clearances Value Top 61 cm 24 ins Left 31 cm 12 ins Right 31 cm 12 ins Front Unrestricted to replace rolls and clear paper jams Rear 31 cm 12 ins Mounting surface flatness Within 2o of horizontal with all four feet or adjustment legs in contact with the surface The printer should not ...

Page 14: ... due to image complexity Minimum printing margins for cut sheet media Right and left sides 5 mm 0 2 in Leading edge 22 mm 0 79 in Trailing 8 mm 0 33 in Maximum print area for sheet media ANSI B size 10 6 x 16 in ANSI C size 16 6 x 21 in ANSI D size 21 6 x 33 in ANSI E size 33 6 x 43 in Arch 18 x 24 in 17 6 x 23 in Arch 24 x 36 in 23 6 x 35 in Arch 30 x 42 in 29 6 x 41 in Arch 36 x 48 in 35 6 x 47 ...

Page 15: ...on 220 watts at idle 400 watts during printing Maximum power consumption 1000 watts during warm up Current rating 110 VAC configuration 4 5 amp max 220 VAC configuration 2 25 amp max Fusing 10 Amp 250 VAC rated Secondary voltages 5 VDC 0 25 12 VDC 0 6 12 VDC 0 6 40 VDC 0 4 78 VDC 2 adjustable from 68 to 102 VDC 78 VDC 2 adjustable from 68 to 102 VDC RF emissions Both 115 and 220 VAC configured ins...

Page 16: ...k Non Operating vibration Non operating shock Operating shock Will withstand 0 15G excitation 5 to 200 Hz 3 axes for up to 7 minutes with no impairment or subsequent damage 0 5 g 25 minute sweep 5 200 5 Hz 100 200 sec sweep cycles The printer may have any corner raised and dropped 1 5 cm 0 6 in while printing is in progress without impairment of operation that cannot be recovered by a printhead pu...

Page 17: ...5 VAC equipment EN55022 CISPR 22 Class B VCCI CISPR 22 Class B The packaged product meets National Safe Transit Committee Test Procedures Listed UL 1950 Information Technology Equipment Certified to CSA C22 2 No 950 Safety of Information Technology Equipment Including Electrical Business Equipment GS licensed IEC 950 1991 Second Edition EN60950 Information Technology Equipment ...

Page 18: ...nce such as network system administration will be available for the scheduled installation and that all necessary cables will be available Unpacking This is the procedure for taking the printer out of its shipping box Testing This checks that the printer works properly prior to connecting it to a host computer Cabling and configuring This discusses setting up the printer for communicating to the a...

Page 19: ...arallel What kind of network environment will the printer be installed into Hardware Protocols LocalTalk EtherTalk Token Ring TCP IP ThinNet 10Base2 Novell NetWare Twisted Pair 10BaseT other _______________ In the event that the printer is to be installed into a network environment will a network administrator be available to help in assigning network names and addresses for the printer Administra...

Page 20: ...andard 161 0230 01 _______ European Option A1 161 0104 06 _______ United Kingdom Option A2 161 0066 10 _______ Australian Option A3 161 0104 05 _______ Swiss Option A5 161 0154 00 Customers must provide the particular interface cable or network adapter they need to use with the printer Customers can purchase the following from the Tektronix Graphics Supplies Order Desk by calling 1 800 835 6100 Pa...

Page 21: ... extra height is open the top cover A space measuring about 6 meters 18 feet long by 2 meters 7 feet wide must be available to unpack the printer Weight support 135 kgs 300 lbs Driver software must be installed on the host computer to use the printer s fullest potential A host computer must meet the following conditions Mac Mac II Performa Centris Quadra or PowerMac Operating System 6 0 7 or later...

Page 22: ...ess the Tektronix Highly Automated Library HAL during business hours at 1 800 835 6100 ask to be transferred to HAL for articles that may help with installing the printer into a customer s network You can call HAL directly at 503 682 7450 24 hours a day 7 days a week The articles can be faxed to you in just minutes HAL has articles that may be of interest to your customer such as printing from a s...

Page 23: ...ith the printer Unpacking Instructions Quick Start Installation Instructions Phaser 600 Color Printer User Manual Phaser 600 CD ROM and diskettes TekColor Care information including the registration card Phaser 600 Quick Reference Card Supplies information sheet Power cord Optional PhaserShare manuals and diskettes Starter paper roll Paper roll holder Ink loader ColorStix ink sticks Output bin Med...

Page 24: ... Save all packing material in case moving or subsequent shipment is necessary 1 Follow the instruction on the exterior of the shipping box to remove the exterior packing material 2 Remove any adhesive tape that holds the printer s doors shut Figure 2 1 Removing the packing material 9482 119 ...

Page 25: ... Make sure that the leveling legs under the printer are screwed into the printer as far as possible This is necessary to allow the printer enough clearance to be rolled to the pallet ramps 2 Using a 13 mm socket wrench loosen and remove the two bolts holding each ramp to the pallet platform 3 Lift the ramps off the pallet and place them into the openings on the side of the pallet 4 Insert one bolt...

Page 26: ...g pallet Warning Because of its size and weight always use two people to move the printer off or onto the ramps also make sure that you guide the printer slowly down the ramps so that it doesn t roll into anyone or anything Failure to do so may injure a person or damage the printer 1 Gently move the printer so that the printer s wheels align with the ramps Unlock the wheels 2 Gently guide the prin...

Page 27: ...catch on the wood block if they are fully retracted they provide enough clearance 3 Remove the bolts from the ramp 4 Slide the ramps onto the pallet and secure with the bolts Store or discard the pallet 5 Roll the printer to the location that you have selected and prepared for its operation Figure 2 4 Guiding the printer down the ramps 3 2628 08 3 2628 06 ...

Page 28: ... Note Make sure that you have access to all sides of the printer while you are setting it up 1 Open the top cover 2 Remove the shipping block printhead restraint from inside the printer 3 Close the top cover making sure that it is locked Figure 2 5 Removing the shipping block 9482 121 ...

Page 29: ...move the thumbscrew from the back of the printer where the ink loader will install 3 Pull back the four sliders as shown 4 Insert the ink loader into the printer 5 At the rear of the ink loader insert the thumbscrew into the opening to secure the ink loader to the printer tighten the screw Figure 2 6 Installing the ink loader 2 1 3 2628 14 ...

Page 30: ... slots for that color Caution Load only one ink stick at a time in each slot otherwise the ink sticks might jam Note Each color ink stick is uniquely shaped to make ink loading easy 3 Pull back the black ink s slider to release the ink sticks into the printer 4 Repeat steps 2 and 3 for each color 5 Close the ink loader cover Figure 2 7 Loading ink 3 2628 15 3 2 1 ...

Page 31: ...its packing box 2 With the output bin folded at its joint hook the shorter end over the back rail of the printer 3 Align the screwholes of the longer end of the output bin with the screwholes in the front legs of the printer 4 Insert the screws into the holes and tighten with a 5 mm 7 32 in hex wrench Figure 2 8 Installing the output bin ...

Page 32: ... the paper cover 2 Lift the paper roll holder out of the printer Notice that each end of the holder is unique a The left side of the holder closest to the ink loader has a removable plastic nut and endcap b The right side of the holder closest to the front panel has a fixed endcap 3 Loosen the plastic nut from the left end of holder by unscrewing it 4 Slide the removable endcap from the shaft Figu...

Page 33: ... adapters which convert the roll holder to use 75 mm 3 inch diameter core rolls Removing the snap fit adapters allows the customer to use 50 mm 2 inch core rolls 6 Reinstall the removable endcap it fits inside the paper roll 7 Tighten the plastic nut Figure 2 11 Loading a media roll on the roll holder Figure 2 12 Securing the roll on the roll holder 4 5 9480 36 6 7 9480 37 ...

Page 34: ...e fixed end a closest to the front panel b 9 Feed the paper into the slot when the printer is ready the printer will pick up the paper If the paper is pushed in too far a jam may occur 10 Close the paper cover Figure 2 13 Loading the roll in the printer Figure 2 14 Feeding the roll into the printer a b 9480 38 4 9480 72 3 ...

Page 35: ... supports the EtherTalk Novell NetWare and TCP IP protocols The Token Ring Network Card supports Novell NetWare TokenTalk and TCP IP protocols To install a network card refer to the Chapter 8 topic Network card on page 8 68 3 Following RAM SIMM or network card installation turn on the printer as explained in the following topics to ensure that the card works properly The printer executes a power u...

Page 36: ...er Copystation refer to the CD ROM and World Wide Web topics The optional PhaserShare card provides the other printer ports The PhaserShare Ethernet card supports Novell NetWare EtherTalk and TCP IP protocols PhaserShare Token Ring card supports Novell NetWare TCP IP and TokenTalk protocols PhaserShare LocalTalk serial card provides a LocalTalk port and a 9 pin serial port Note Make all printer po...

Page 37: ...t can also be set for bi directional communications Refer to the CD ROM or World Wide Web for instructions on changing parallel communications and for information on cables and adapters 1 Connect a parallel interface cable to your computer and to the printer s parallel port Note The printer s parallel port uses a high density connector Type IEEE 1284 C To use a standard Centronics style parallel c...

Page 38: ...xible workgroup connectivity All data input ports and network protocols are simultaneously active Print jobs are processed on a first come first served basis To order the optional hardware contact your local Tektronix reseller or call Tektronix toll free in the United States at 1 800 835 6100 For detailed information on configuring and using the printer on networks refer to the PhaserShare Network...

Page 39: ...cables you are ready to connect the power cord and turn on the printer Caution To protect your printer from a power surge make sure that the power switch on the printer is in the off position before plugging in the cord Make sure that you use the power cord that is shipped with the printer 1 Plug the power cord into the printer and into a grounded outlet 2 Turn on the power to any peripherals you ...

Page 40: ...otors and systems The printer takes about 15 minutes to warm up and complete the self tests Note The printer s memory includes a startup page that is disabled by default You can turn on the startup page using either the front panel menu or a software utility file provided on the CD ROM or the Tektronix World Wide Web page When the printer is ready for operation When the power up sequence is comple...

Page 41: ...p page provides valuable information about the printer Fonts Ports Serial Parallel LocalTalk Ethernet Printer name Ethernet protocols TekColor corrections and print quality mode Pages printed RAM installed Tektronix version firmware Adobe PostScript version software Printer ID Authorization code SCSI disk attached If the printer detects a non fatal error at power up the startup page prints with an...

Page 42: ...mory Color settings such as Vivid Color Serial port settings if installed Parallel port settings LocalTalk port settings if installed EtherTalk settings if installed TCP IP settings if installed Novell NetWare settings if installed Table 2 1 Configuration page settings Parameter Description Saved in NVRAM Default Limits or alternate choices Printer name The current name of the printer as seen on a...

Page 43: ...s used to simulate different color uses yes None User defined Vivid Color Simulate Display SWOP Specification for Web Offset Publication Press Euroscale Press Commercial Press SNAP Specification for Non heat Advertising Print Newsprint Monochrome Raw RGB Colors Raw CMYK Colors Parallel port interpreter Indicates the type of interpreters in use at the port yes PostScript Level 2 Not installed Disab...

Page 44: ...coding for communication yes ASCII Binary Raw TBCP Serial port speed Baud rate yes 9600 38400 printer dependent 19200 9600 4800 2400 Serial port flagging Hardware or software flagging yes XonXoff DTR DTR low Etx Ack Robust Xon Xoff Xon Xoff2 Serial port check parity Determines if parity checking is done yes false true Serial port parity Parity check used between the printer and the host yes None S...

Page 45: ...dware dependent user defined Configuration file server Name of the configuring file server yes null string user defined Login Password Indicates whether a network password has been set yes Not set Set Queue Scan interval Interval between successive queue scans by the printer yes 15 seconds An integer 1 through 3600 in seconds Print server Status Print server status no null string Suppress Banners ...

Page 46: ...esolution Display and Control RARP requests and IP datagrams yes DIX Adaptive 802 2 SNAP may be followed by the word Dynamic LPR port interpreter Indicates the type of interpreter in use at the BSD system configured port yes Not Authorized Disabled null string LPR Host access list List of TCP IP network addresses for host access to printer yes Unrestricted only first 16 network addresses on list p...

Page 47: ...gnificant message 6 informational messages 7 debugging messages SNMP Allow the printer to respond to status queries from host resident Simple Network Management Protocol SNMP utilities yes Not Authorized null string System name Printer name yes Phaser 600 String of 0 to 255 characters System contact Name and phone number or address of person responsible for the printer yes String of 0 to 255 chara...

Page 48: ... address of printer when it is the initiator no 7 Copystation Indicates whether a Copystation is attached to the printer no Not connected Connected Copy control firmware Indicates the version number of the copy control firmware yes Firmware dependent Copy station firmware Indicates the version number of the Copystation firmware yes Firmware dependent HTTP Indicates whether or not HTTP is enabled y...

Page 49: ...arrow button scrolls forward through the selections pressing Menu enters the currently displayed menu 2 Using the left or right arrow buttons scroll through the selections until you see this message Language Menu 3 Press the Menu button to enter the language selection menu You see this message Language English Select where the asterisk indicates the currently selected language 4 Press the right ar...

Page 50: ...th one of the following applications install the appropriate file QuarkXPress The Quark XPress application uses a unique PDF file 1 Locate the TKPH6001 PDF On the printer s CD ROM in the QUARK directory On the Printer Software for Windows diskette in the QUARK directory 2 Copy the TKPH6001 PDF file to the PDF subdirectory of the Quark application on your hard disk For example COPY TKPH6001 PDF C X...

Page 51: ...driver for Windows 95 1 Use either the printer s CD ROM or diskette CD ROM Insert the printer s CD ROM into your CD ROM drive Diskette Insert the Printer Software for Windows diskette into your disk drive 2 Click the Start icon in the taskbar on your screen In the menu that appears click Settings 3 In the menu that appears click Printers the Printers window appears 4 In the Printers window double ...

Page 52: ...nfiguration of the printer you have the printer s startup page lists this information under Extended Features Yes No 10 Select the port your printer is connected to then click Next 11 It is recommended that you use the default printer name shown under Printer name Click Yes if you want this printer to be the default printer Then click Next 12 At the prompt Would you like to print a test page click...

Page 53: ...reen In the menu that appears click Run 3 In the Run window type in the drive the CD ROM is in followed by the ADOBEPS4 directory and the file name SETUP EXE and click OK For example C ADOBEPS4 SETUP 4 When the AdobePS4 PostScript Printer Driver Setup dialog box appears click the Read button if you wish to see a text file with driver instructions Click Next to continue or Exit to quit 5 In the Ins...

Page 54: ... No 8 In the Local Port Selection dialog box select the port you want to use then click Next You can configure the port in this dialog box at any time 9 In the Add Printer dialog box type in the printer s name select the printer as default and decide if you want to print a test page Click Next to continue 10 If you see the Different Versions Detected dialog box click Next to update the files from ...

Page 55: ...only 1 Insert the printer s CD ROM into your CD ROM drive or insert the Adobe PS 3 Driver diskette into your disk drive 2 In the Program Manager in Windows 3 1 select Run from the File menu 3 At the Command Line do one of the following CD ROM Type in the drive the CD ROM is in followed by the ADOBEPS3 directory and the file name SETUP EXE and click OK For example C ADOBEPS3 SETUP Diskette Type in ...

Page 56: ...ave the printer s startup page lists this information under Extended Features Yes No 8 At the installation successful message click OK 9 Click Close in the Install PostScript Printer from PPD dialog box 10 At the message click OK the Control Panel opens 11 From the Control Panel double click Printers 12 In the Printers dialog box select the Tektronix Phaser 600 printer you just installed then clic...

Page 57: ...e top level of the diskette to a new formatted floppy diskette Place all of these files at the top root level of the new diskette TEK1 PRINTER INF TK600171 PPD for the standard version of the printer TK600391 PPD for the printer s Extended Features option Note If you are installing a Tektronix printer other than a Phaser 600 printer copy the PRINTER INF and printer PPD files from the WIN95_NT dire...

Page 58: ...lick OK the Select Driver dialog box appears If you are using the Tektronix Printer Software for Windows diskette Type in the disk drive location of the diskette and the WIN95_NT directory Click OK the Select Driver dialog box appears If you are using an edited copy of the PRINTER INF file from Step 2 Type in the disk drive location of the diskette Click OK the Select Driver dialog box appears 7 U...

Page 59: ...the Printer menu select Remove Printer c At the prompt click OK to remove the selected printer Installing Adobe Acrobat Reader 1 Insert the printer s CD ROM into your CD ROM drive 2 Do one of the following depending on your system Windows 95 a Click the Start icon in the taskbar on your screen In the menu that appears click Run b In the Run window type in the drive the CD ROM is in followed by the...

Page 60: ... computer s CD ROM drive 2 Click the Start icon in the taskbar on your screen In the menu that appears click Run 3 In the Run window type in the drive the CD ROM is in followed by the ATM directory and the file name INSTALL1 EXE and click OK For example C ATM INSTALL 4 Follow the on screen instructions to install ATM For more information refer to the ATM quick reference cards that were shipped wit...

Page 61: ...ser 600 printer s diskette or CD ROM Floppy diskette Insert the Printer Software for Macintosh diskette into your computer s disk drive CD ROM Insert the Phaser 600 printer s CD ROM into your computer s CD ROM drive 2 Double click the Phaser 600 Installer icon Click Continue until the Easy Install window appears 3 To install the items listed in the Easy Install window click Install For details on ...

Page 62: ...inter is in See your network administrator if you have questions 5 Click on your Phaser 600 printer in the list of printers on the right side of the Chooser 6 Close the Chooser by clicking its close box Setting up the Adobe PSPrinter Driver The Adobe PSPrinter driver uses printer specific PPDs PostScript Printer Description files for information on a printer s page sizes printing options and media...

Page 63: ... information under Extended Features Yes No 8 In the dialog box that appears select the appropriate items under Installable Options then click OK 9 Click the Chooser s close box Setting up the Phaser 600 GX driver If you are using Apple Macintosh QuickDraw GX and System Software 7 5 or later use the Phaser 600 GX driver to print to your Phaser 600 printer The Phaser 600 GX driver works with QuickD...

Page 64: ...ears on the desktop with the same name as the printer selected in the Chooser 8 Close the Chooser by clicking its close box Setting up the Apple LaserWriter 8 x driver The LaserWriter 8 x driver uses printer specific PPDs PostScript Printer Description files to learn a printer s page sizes printing options and media type options To use the LaserWriter 8 x driver with a Phaser 600 printer do the fo...

Page 65: ...up button to see a list of options 8 The correct PPD file should be selected automatically If the PPD file is not automatically selected a dialog box opens showing the location of the PPD files you have installed in the Printer Descriptions folder in the Extensions folder inside your System Folder Click one of the following PPDs and click Select Use TKPH6001 PPD with the standard version of the pr...

Page 66: ...tation users can access utility files in the following ways Install the files from the Tektronix Phaser 600 CD ROM if your system includes a CD ROM drive Mount the PC diskette on the workstation most workstations with 3 5 inch disk drives provide a device driver that allows you to mount a PC floppy diskette Access the Tektronix anonymous ftp site on the Internet at ftp tek com Download utility fil...

Page 67: ... Check existing printer object port assignments before installing a new printer to be sure there is no conflict Once you are familiar with existing printer objects drivers and ports associated with these objects you can install a new printer In the procedure below the printer remains associated with LPT1 and you will set up a new printer object for LPT2 Following are the steps to create the LPT2 P...

Page 68: ... Settings Notebook by clicking the right mouse button on LPT2 PRINTER Click on the arrow to the right of OPEN click on SETTINGS b Select the Printer Driver Tab Confirm that the Tektronix Phaser 340 is selected highlighted Double click on the Phaser 340 driver to configure the Printer Properties this is where you can define printer paper sizes and orientation These settings can be adjusted from wit...

Page 69: ...queues The file is usually found in the workstation s etc directory Use a null modem cable since the printer is set up as a DTE device For this example the printer s serial port settings are as follows Speed 9600 Flagging Software XON XOFF Data Bits 8 Parity Ignore To set up a printcap entry perform the following steps 1 Make a backup copy of the etc printcap file 2 Add to the printcap file a new ...

Page 70: ...ort the printer on a Novell network The PhaserShare User Manual gives the step by step procedure you follow to perform this configuration There are two methods each using a different utility program that you can use to configure the file server and set up print queues In brief this is what you will do 1 Load the utility Advanced Configuration Tool ACT onto the file server through a workstation 2 L...

Page 71: ... and the printer for a TCP IP network The Phaser Share User Manual gives the step by step procedure you follow to perform this configuration You will first configure the host and then the printer Configuring the host 1 Add the printer name to the host table etc host and assign an Internet Protocol IP address to the printer s name 2 Assign a print queue to the printer by editing the etc printcap fi...

Page 72: ...r patent applications Information provided upon request from Tektronix Inc P O Box 1000 Wilsonville Oregon 97070 1000 Tektronix Phaser ColorStix and Made for Each Other are registered trademarks of Tektronix Inc TekColor Photofine PhaserShare PhaserMatch PhaserLink Finepoint and PhaserPrint are trademarks of Tektronix Inc RealSUPPORTSM and TekColor CareSM are service marks of Tektronix Inc Other m...

Page 73: ...the product into a power source Terms on product CAUTION A personal injury hazard exists that may not be apparent For example a panel may cover the hazardous area Also applies to a hazard to property including the product itself DANGER A personal injury hazard exists in the area where you see the sign Care of product Disconnect the power plug by pulling the plug not the cord Disconnect the power p...

Page 74: ...uch exposed connections and components while power is on Disconnect power before removing the power supply shield soldering or replacing components Do not wear jewelry Remove jewelry prior to servicing Rings necklaces and other metallic objects could come into contact with dangerous voltages and currents Power source This product is intended to operate from a power source that will not apply more ...

Page 75: ...the following echo showpage port Substitute port with LPT1 LPT2 or COM1 etc or whichever corresponds to the port the printer is attached to The printer should respond by picking processing and ejecting a blank sheet of paper if this does not happen check your cabling Ensure that you have the port properly configured as explained in the Chapter 2 topic Connecting the printer on page 2 19 Windows 95...

Page 76: ...essories icon 4 Double click on the Write icon If Write is not available you can use any other text editor type program 5 Type in a line of text such as THIS IS A TEST 6 Click the File menu item and select Printer Setup from the menu list Select Phaser 600 whichever applies from the displayed list of available printer drivers Click OK 7 Click File and select Print A print file will be transmitted ...

Page 77: ...rn finds all file servers with Phaser 600 queues and extracts its print files from them You must determine if a computer can communicate a print file to the file server Generally as outlined in the Chapter 2 topic Configuring a Novell NetWare server for the printer on page 2 53 the file server and printer are configured during the printer installation using software such as Advanced Configuration ...

Page 78: ...y If the PC does not print to the printer reset the printer and then load the error handling utility into the printer s memory using the menu item Printer Defaults PS Error Handler Alternatively reset the printer and then download one of the Tek Error Handler utility files to the printer or enable the error handler from the front panel 1 Locate the TEKEHAND PS file in the PHSR600 directory on the ...

Page 79: ...I O ports and peripheral parameters Using the front panel to review and change parameters is discussed in Chapter 9 Checks and Adjustments Buttons Button 1 the left most button is an Exit key used to cancel or escape from an operation while in the interactive menu The functions of buttons 2 3 and 4 are defined by the particular menu or function being displayed on the LCD The bottom row of the LCD ...

Page 80: ...side of the dialog box are icons representing the printer drivers installed on the Macintosh Select the driver icon Phaser 600 by clicking on it once If the host and the printer are a part of a zone you should first select the printer driver and then pick the zone that the printer resides in The configuration page lists the zone the printer is currently installed in 4 Displayed on the right side o...

Page 81: ...e printer This verifies that the Macintosh and the printer driver can send a file to the printer If the printer does not make a print then there may be a problem with the printer driver In this case if possible you should verify that the Macintosh can print to a different printer on the same network Choose a different PostScript printer driver such as an Apple LaserWriter in the Chooser and then r...

Page 82: ... into the printer s memory using the menu item Printer Defaults PS Error Handler Alternatively reset the printer and then download one of the Tek Error Handler utility files to the printer or enable the error handler from the front panel 1 Place the printer s Macintosh Printer Utilities diskette in the disk drive 2 Select the Phaser 600 printer in the Chooser 3 Locate the Tek Error Handler file in...

Page 83: ...e host you must first have the printer s queue established This is site dependent and requires the aid of the site s network administrator After the queue is in place you can proceed to the next step 3 Send a print file to the printer using the following syntax lpr P queue name file nam The queue name was established earlier in Step 3 The print file file nam can be any PostScript print file To kee...

Page 84: ...le nam where queue name is the printer s queue and file nam is any PostScript file Using the Error Handler utility If the workstation host does not print to the printer reset the printer and then load the error handling utility into the printer s memory using the menu item Printer Defaults PS Error Handler Alternatively reset the printer and then download the Tek Error Handler utility to the print...

Page 85: ...overs the last portion of the Tektronix Service Option S0 installation Training the printer s key operator The steps you follow here place an emphasis on encouraging the key operator to read and use the printer s user manual to operate clean and care for the printer ...

Page 86: ...el buttons and how they correspond to the display Error reporting Explain how error conditions are displayed on the front panel Show where error conditions are explained in the user manual Printer rear panel connections Network connections Explain the different types of PhaserShare cards that provide printer connectivity Show where these connections are explained in the user manual and where to fi...

Page 87: ...ot use ink sticks that have large pieces missing and not to load any small broken pieces Show where ink stick handling and loading instructions are explained in the user manual and on the ink stick card shipped with each ink stick box Emphasize that ink sticks must be kept clean contaminated ink sticks will eventually clog filters inside the printhead requiring it to be replaced Ink sticks should ...

Page 88: ...ffecting print quality Increasing RAM memory Explain the advantages of using more RAM in the printer to improving print times Using TekColor color corrections Explain that different color correction modes are available and where to find more information in the user manual Explain how fusing hot cold or none affects print quality and durability on different media Moving the printer Printhead restra...

Page 89: ... 5 00 pm PST Shipments are made within 24 hours Outside the United States Contact your nearest Tektronix dealer If you need help Customer Support Hotline If customers encounter problems while using their printer that cannot be resolved using the user manual they can call Tektronix Customer Support Hotline for help The Hotline can answer technical question regarding using the printer ranging from p...

Page 90: ...lable through on line services World Wide Web http www tek com Color_Printers Tektronix anonymous ftp server ftp tek com Color_Printers Automatic File Server color_printer_info tek com Technical support support ColorPrinters tek com America Online Keyword Tektronix Compuserve Go Tektronix Using the automated fax systems As an alternative to the Customer Support Hotline and to provide up to date in...

Page 91: ... some in English and some in other European languages If a localized version of the document is available EuroHAL will send it in that specific language Otherwise it will send English documents If customers have a tone dial telephone and a fax machine they can use EuroHAL If customers telephones have star and hash mark keys then they can probably use tones ask your local telephone supplier if unsu...

Page 92: ...their country code first as shown in the following table Country Country code Customers area code and fax number Press when finished Austria 00 43 area code fax number Belgium 00 32 area code fax number Denmark 00 45 area code fax number Finland 00 358 area code fax number France 00 33 area code fax number Germany 00 49 area code fax number Holland 00 31 area code fax number Italy 00 39 area code ...

Page 93: ... can request files from the Tektronix Color Printer Information Server an automatic file serving program on the Internet that responds to requests for files Send electronic mail requests for files to the following address color_printer_info tek com To receive the list of information available on the server type the following at the Subject prompt send index To examine the full index for any librar...

Page 94: ......

Page 95: ...Manual 5 1 Chapter 5 Theory of Operation Overview This chapter covers the theory of operation of each subsystem within the printer Functional block diagram Printhead maintenance cycle Print process in operation ...

Page 96: ... supply Engine control board Image processor board All printer functions are centered around the engine control board All DC voltages are routed through the engine control board to all other devices Figure 5 1 Overview of the printer Engine Control Board Drum Clamp Printhead Maintenance Station Ink loader Front panel Image processor Power supply Fuser Other motors solenoid 9482 10 ...

Page 97: ... of jets is 31 jets in height the printhead can print a swath 62 pixels in height by printing 31 pixel lines on a forward pass and then printing the interleaving 31 lines on the return pass of the printhead Variations on this interleaved printing scheme are used to actually print in the printer s two print modes Standard and Enhanced Cyan jet 0 shown in the illustration is a nonfunctional jet that...

Page 98: ...e alternate high altitude waveform The high altitude waveform is optimized for the atmospheric conditions placed upon the printhead during printing The printhead also features four ink melting chambers one for each color In each chamber the ink is heated into liquid form to 115o C 268o F and channeled to the jet stack where it can be printed onto paper A temperature of 135o F 300oF is maintained a...

Page 99: ...is the default printing mode It should be used for images with light colors text and lines and small areas of fully saturated colors saturated colors will exhibit a banding effect When printing solid fills the printhead ejects ink at a 8 5 kHz rate Standard mode can print an image on B size A3 media in about 2 15 minutes During Standard mode printing the paper is advanced vertically the equivalent...

Page 100: ...r the appropriate ink stick energizes to drive a belt featuring paddles that push one ink stick down into the printhead The ink drop sensor detects when an ink stick is pushed into the waiting printhead The four origin sensors detect the position of each of the ink load belts so the paddles of each belt will be in the proper position to push the next ink stick into the printhead Figure 5 4 The ink...

Page 101: ...t causes ink to be drawn through the printhead to clear air bubbles or remove clogged jets Cam pin It controls the air valve open or closed and movement of the maintenance station against or away from the printhead Air valve It allows or removes vacuum from the purge chamber Air knife Using a stream of air the bulk of the ink on the faceplate is moved to the drip plate Drip plate It directs hot li...

Page 102: ...the waste bin lock When the drum is rotated counterclockwise more than one revolution the waste bin lever is forced out of the center of the track which lifts the lever and unlocks the waste bin Rotating the drum clockwise locks the waste bin drawer The right side track is used by the maintenance station s cam pin to position the maintenance station against or away from the printhead as well as op...

Page 103: ... following a deeper channel in the maintenance track which closes the air valve The vacuum pump is started and performs a 4 or 5 second purge The drum is then rotated clockwise to move the cam pin up a ramp in the track to open the air valve and remove the vacuum The drum continues to rotate clockwise to move the purge chamber away from the faceplate Ink from the purge chamber runs out of the cuto...

Page 104: ...ng on how many prints were made after the last purge If it is less than three prints then a 4 second purge is performed Air knife while the printhead moves away from the maintenance station Air knife while the printhead moves toward the maintenance station Wipe while the printhead moves away from the maintenance station Air knife while the printhead moves toward the maintenance station 7 second je...

Page 105: ...side standby position off the print while the print is advanced for the next pass The fuser wheel is about 8 mm 0 33 ins wide Given that a pass of the printhead is not more than 2 5 0 1 in mm wide the fuser travels over each swath or band of printing at least twice once left to right and once right to left An exit sensor detects that the print properly exited the fuser If not a fuser jam is report...

Page 106: ...d s piezo crystals elements There are no field adjustments necessary on the power supply except for printhead drive voltages Engine control board The engine control board is responsible for data processing of information provided by the image processor board and of the inputs from the printer s sensors The engine control board features comparators to check for over temperature conditions and for s...

Page 107: ...the drum rotates forward to pull the media through the upper feed rollers and paper guides to insert the leading edge of the paper in the open clamp The three paper skew sensors mounted on the paper guides determine if the paper feeds into the paper path squarely After waiting long enough for this to occur the clamp close solenoid are energized to close the clamp against the drum clamping the lead...

Page 108: ...t 32 mils for printing This action assures the printhead will always be the same distance from the media surface regardless of the thickness of the media Next the X axis motor drives the printhead across the width of the drum Paper edge sensors on the printhead detect the left and right edge of the media informing the image processor of the width of media currently installed in the printer Followi...

Page 109: ... allow the shutting printhead to print the image in swaths upon the paper As the drum rotates far enough that the paper clamp reaches it home position and the leading edge of the paper is now under the clamp rollers the clamp close solenoids de energize to release the leading edge of the paper The Y axis motor continues to rotate the drum moving the friction fed media as the printhead prints Figur...

Page 110: ...fuser shuttle is driven to the extreme right of its travel this raises the fuser shuttle s cutting blade Then the fuser shuttle is driven to the left cutting the print from the roll As the fuser shuttle reaches the left end of its travel the cutting blade is lowered The exit motor energizes to pull the print out of the printer The Y motor reverse to draw the paper remaining in the paper path back ...

Page 111: ...st as one means of determining if the printer is operating correctly Power switch turned on Front panel LCD and LEDs turned on then off Power on self tests POSTS performed on electronic systems and the results displayed on the front panel Both front panel LEDs blink twice and the LCD blanks out The Error LED turns off and the front panel indicates Initializing Head maintenance motor runs until the...

Page 112: ...d to move the paper clamp to its raised position The paper clamp solenoids energized to close the paper clamp The drum rotates to lower the closed paper clamp The paper clamp solenoids de energized to open the paper clamp The Error LED turns off and the display indicates the printer is warming up and cleaning the printhead The printer continues to heat the printhead to its normal operating tempera...

Page 113: ... to the later topic PC based diagnostics on page 6 26 Turn on the printer 5 Select the menu test System Verify Test Print 6 After the print is made remove the PC If the printer prints a test pattern then the printer s image processor board and print engine are working correctly The printer s problem resides with the host computer to printer connection or the host computer Refer to the appropriate ...

Page 114: ...o sections the AC section used for heaters and the DC section for control logic printhead drivers and motors Verifying the power supply involves five steps Checking for proper AC voltage Testing DC output voltages Inspecting the power supply fuses Testing for a shorted DC output supply which shut down the power supply Testing for a shorted motor which shuts down the power supply Inspecting the pow...

Page 115: ... measure the expected DC voltages proceed to the next step Inspecting the power supply fuses If the 5 VDC 12 VDC 78 VDC voltages measure correctly proceed to the topic Testing for a shorted DC supply on page 6 6 Figure 6 1 Measuring the DC voltages test points Power supply board 7 8 9 10 11 12 1 2 3 4 5 6 12v 12v HVEN 5v 5v 5v 12v GND 12v GND PFAIL 5v GND 5v GND 5v GND CN3 6 7 8 9 10 1 2 3 4 5 78v...

Page 116: ...ses removed in the previous procedure 3 Disconnect the AC motors Y axis motor X axis motor and fuser motor by disconnecting J112 from the engine control board 4 Disconnect the stepper motors exit motor head maintenance cam gear motor head to media motor and the ink loader motor by disconnecting their individual wiring harnesses from the junction boards The wiring diagrams in Appendix C show this c...

Page 117: ...y low resistance from a motor winding to ground while the motor is installed and its wiring is not damaged replace that motor Table 6 1 Motor and solenoid resistances Motor or solenoid Resistance approximately X axis motor Pin1 to 2 10 to 30 ohms Y axis motor Pin1 to 2 3 ohms Fuser motor Pin1 to 2 5 5 ohms Exit motor Pin 1 2 to 3 4 5 or 6 10 to 15 ohms Head maintenance cam gear motor Pin 1 2 to 3 ...

Page 118: ...when the media is improperly clamped An entrance jam is declared if the media input sensor cannot detect the leading edge of the media A load error is also declared if the skew sensors detect the leading edge is skewed more than 5 mm 0 2 in from parallel with the X axis 1 Ensure that the media fits properly on the supply roller Ensure the leading edge is squarely cut and aligns with the edge guide...

Page 119: ...incorrectly operating the clamp During media loading 1 Check the paper eject path for obstructions 2 Ensure the leading edge of the media is straight and square Check the roll holder for a loose endcap 3 Ensure that roll media is correctly loaded on the roll holder with the adjustable end on the left end of the roll 4 Using diagnostics ensure the skew sensors operate correctly 5 Using diagnostics ...

Page 120: ...Check the rear and lower feed rollers Also make sure that the front door is properly closed 9 Clean all the printer rollers Fuser jam A fuser jam occurs when the printer cannot cut the media this is indicated by the fuser motor stalling 1 Check that the cutter blade is installed and in good working order 2 Is the loaded media appropriate for the cutting blade Thick hard media and some canvases sho...

Page 121: ...Printing and print quality problems Paper edges are rippled or wrinkled 1 If possible you should feed the paper into the printer with the paper s grain parallel to the paper path the direction the paper travels while it is fed through the printer Most papers are labeled either short grained or long grained In short grained paper the grain is parallel to the short axis of the paper and the paper sh...

Page 122: ... bottom If its not the print may be slipping in the clamp The image is printed skewed on the paper 1 The paper did not get clamped squarely on the paper clamp or it slipped out of the clamp Clean the paper clamp 2 Clean the paper feed rollers Use an alcohol dampened lint free cloth 3 Ensure that the paper is properly loaded During handfeeding ensure that the paper feeds squarely into the printer s...

Page 123: ... should be within 30 to 30 The drum is either stepping too much or not enough for each pass of the printhead Refer to the Chapter 9 topic Drum step adjustment on page 9 26 5 Ensure that no wiring harnesses are interfering with the horizontal movement of the printhead 6 Replace the engine control board 7 Replace the carriage board Scratches in transparencies parallel to the paper path travel 1 Usua...

Page 124: ...ard and reverse swaths of prints made in bidirectional mode do not align 1 Perform the bi directional alignment test described in the Chapter 9 topic Bi directional print convergence on page 9 21 2 Ensure that the paper tension blade paper clamp and drum are clean 3 Run the service mode s convergence adjustment to check and correct an alignment problem 4 Ensure that the printhead to media spacing ...

Page 125: ...not horizontally level with each other 1 The printhead is tilted Run the service mode s tilt adjustment see Chapter 9 Tilt adjustment on page 9 24 Severe banding in color fills 1 Ensure that the printhead tilt is correct 2 Increase the printhead temperature slightly See Chapter 9 Adjustments on page 9 4 The image is not centered on the print when it should be 1 Ensure that the paper edge sensors m...

Page 126: ...ey are properly positioned Refer to the Chapter 9 topic Ink loader sensor flag adjustment on page 9 13 4 Ensure the printhead is properly positioned to receive ink sticks Refer to the Chapter 9 topic Ink stick load position on page 9 14 Troubleshooting missing or deflected jets Customer performed steps to recover faulty jets 1 Run the Utilities menu item Clean Head to run a printhead cleaning cycl...

Page 127: ...ir hose leading to the top of the maintenance station should be routed so that it does not pinch or bind with the sheet metal bracket Refer to the Chapter 8 topic Maintenance station 5 Ensure the air pump runs during the cycle if it doesn t check its 40 VDC drive voltage Replace the air pump if the voltage is correct Under a running load the 40 VDC supply measures about 24 volts 6 As explained in ...

Page 128: ... as explained in Chapter 9 Adjusting for an aged printhead on page 9 31 and repeat Step 11 and then make a test print to see if the jet is cleared 13 If the problem persists replace the printhead SCSI hard drive failure 1 Check the wiring harnesses leading to the SCSI drive 2 Ensure the SCSI address jumper set on the SCSI drive is set is set to 4 The SCSI address of the internal hard drive is prin...

Page 129: ...0 4 8 8 5 16 16 6 32 0 Total 25 Error code 25 7 none Leds 7 and 8 are health LEDs that sequentially flash to indicated to proper operation of the engine board CPU 8 none Table 6 3 Engine error codes reported to the front panel Code Descriptions Possible causes 1 unused 2 Bus trap error Engine control board CPU Replace the engine control board 3 Address trap error Engine control board CPU Replace t...

Page 130: ... I O test failed Engine control board failure Replace the engine control board 23 to 24 unused 25 Printhead over temperature Check the carriage board wiring Replace the printhead Replace the carriage board Replace the engine control board 26 Over current X axis The motor is drawing more than 7 2 amps Check or replace the motor and its wiring harness Replace the engine control board 27 Over current...

Page 131: ... left junction board Replace the engine control board 36 Encoder failed fuser Readings are not being received from the motor Check or replace the motor and its wiring harnesses Replace the left junction board Replace the engine control board 37 Encoder failed Y axis Readings are not being received from the motor Check or replace the motor and its wiring harnesses Replace the left junction board Re...

Page 132: ...gine control board 51 Ink feeder failure The ink loader is not sensed installed in the printer Ensure the ink loader assembly is properly installed Check the ink loader installed sensor Check the ink loader motor assembly Replace the ink loader motor assembly Replace the left junction board Replace the engine control board 52 Overload failure X axis Check or replace the motor Replace the engine co...

Page 133: ... not successfully complete a scan of the dot clock encoder strip Ensure the strip is clean and properly in place and the sensor under the carriage board is in position to read the strip Check the X axis motor for proper operation Check or replace the carriage board Replace the engine control board 101 X Axis Origin Check Failure Check the X axis motor for proper operation Ensure the X axis belt is...

Page 134: ...ror is detected tests will repeat until switch 4 is pressed again For group tests the entire test suite is repeated If an error is detected the test failure is displayed on the LCD display and the failed test is continuously repeated To start the Service tests press switch 3 and hold it down during power up or reset until Initializing Service is displayed on the top line of the front panel The sec...

Page 135: ...nt panel wiring harness is correctly installed 2d SmartCard 2e 16550 Internal Loopback 2f 16550 External Loopback 34 DRAM Refresh 36 SIMM1 Data Paths Ensure an 8 Mbyte SIMM is installed in connector SIMM 1 37 SIMM1 Addrs Paths 38 Extended SIMM1 Data Paths 39 Extended SIMM1 Addrs Paths 3a SIMM2 Data Paths 3b SIMM2 Adrs Paths 3c Extended SIMM2 Data Paths Ensure a 16 Mbyte SIMM or 32 Mbyte RAM SIMM i...

Page 136: ...ble part number 012 1498 00 Apple PowerBook 540c or 5300c ce running SoftWindows in MS DOS mode An IBM PC or PC clone or compatible i86 operating environment preferably a 386 or 486 286 based PCs are intolerably slow At least 640 kbyte of RAM About 2 Mbytes of disk space to store the diagnostic program and its test suite A mouse is optional but is not supported by the user interface MS DOS environ...

Page 137: ...tor looking at the back of the printer Note the Pin 1 polarity mark on the cable adapter s connector The serial cable must be plugged into the diagnostic serial port before the printer is turned on in order to start the printer in service mode In the case of a Macintosh plug the serial cable from the printer into the Mac s serial port marked Modem 2 Turn on both the printer and your computer In th...

Page 138: ...aining the desired version of diagnostic software 7 Launch the diagnostics program by typing DIAGS Once launched the program repeatedly attempts to communicate with the printer The link status indicator in the bottom right corner of the screen reads NO until this link is established once communication is established it reads ok If the status does not change to ok then make sure the serial cable is...

Page 139: ...ystem it s divided into three fields The left most is the largest field and it is the message field it contains descriptive text summarizing the operation of tests in progress and of the diagnostics program itself Next is the completion indicator When downloading test files to the printer this field indicates the progress of the operation with a percentage complete display n where n is 0 to 100 Wh...

Page 140: ... PgDn move the display of tests one screen full at a time The highlight generally stays in place on the screen so this also changes the highlighted test In the Individual Test column Up Down arrows move the Individual Test selection highlight up or down on the screen At the top and bottom of the screen it causes the list to scroll if there are more tests in that direction on the list Space bar tog...

Page 141: ...at are available Escape or Enter removes the Help window F1 Brings up a more complete description about the currently highlighted test Esc and Enter Return either key causes the replaces the selection screen with the current tty window Any currently selected test remain selected Figure 6 5 The diagnostics global help screen ...

Page 142: ...ble test is selected it takes a few moments to download the test While the test is downloading the message bar indicates this fact and the completion indicator shows how much of the file has been loaded 1 Press the Return key to enter the test group selection window 2 Use the arrow keys to scroll through the list of tests suites Press the Tab key to select a test suite Figure 6 6 TheTest Suite lis...

Page 143: ...splayed 3 Press the space bar to select or deselect a test You can select as many tests as you like 4 Once selected press Ctrl R to start the test s Depending on the test a screen may be displayed to modify how the tests run Figure 6 7 The Individual test within a selected test suite Figure 6 8 Running a test ...

Page 144: ...est results is displayed If necessary you can press the F1 key while highlighting an individual test to display a help message that describes the test The Sensor Test shows you the real time state of the printer s sensors You can manually interrupt the sensors to determine if they operate correctly Figure 6 9 An IndividualTest help screen Figure 6 10 SensorTest summary ...

Page 145: ...or failed The Heater and Ink Levels Tests let you select start and observe the operation of the printers heaters and determine if they are operational The test displays the real time temperature of active heaters A graphic illustrates if the heater temperatures are within tolerance Figure 6 11 Test result of a Servo Motor Test Figure 6 12 The Heater and Ink LevelsTest ...

Page 146: ...tly the same as if the settings were re specified manually It provides a way to pre select tests for particular audiences Default file name extensions for saved test selections is TSV Saving and restoring other settings Any user configurable setting that the program knows about is saved in a configuration file called DIAGS INI and persists from session to session Presently there is a short list of...

Page 147: ...tches to the processor window to show results of test running on the processor Erase Screen erases all the characters from the currently selected window it has no affect on the test running Printer Info brings up a window summarizing information about the printer currently connected to the diagnostics Debug Check List Item enables or disables a trace of all I O between the user interface and the 2...

Page 148: ...rrent test selections in a particular file eXit Alt X exits the diagnostic program Options Menu Provides for customizing of program operation This menu contains some sub menus Communications provides for changing the baud rate of the link and for changing the communication port used The default baud rate is 19 2 k Help Menu The system includes limited On line help Most of the really useful help pe...

Page 149: ...r utility on page 3 8 If an error page is printed after printing the job again call the Customer Support Hotline for further assistance Please have the error page in hand If available try printing to a black and white PostScript printer such as an Apple LaserWriter If the file does not print on the black and white PostScript printer this may mean that the problem may be application or network rela...

Page 150: ... printer retry indefinitely Is the printer in PostScript mode Check this by sending the file TESTHPGL PLT located on the Tektronix Utilities diskette HP GL directory to the printer At the DOS prompt type the following DOS command COPY TESTHPGL PLT LPT1 If your port is not LPT1 substitute LPT2 or COM1 for the correct port The PC responds with 1 FILE COPIED If this file prints stating that the print...

Page 151: ...ss this option select Printer Setup Options Printer Features Media Selection You are now at theTekColor Options window select Vivid Color This TekColor Options window can also be accessed through the Windows Control Panel item Printers Printing from Windows produces the message Problem writing device LPT1 Cancel or Retry Option 1 1 Select Printers and click Configure 2 Change the port selection fr...

Page 152: ... serial LocalTalk parallel and Ethernet ports and their cabling or connections Table 6 9 Workstation printing problems Image never prints Printer acts as if it is receiving data but nothing comes out of the printer or the printer goes back to Ready mode without printing an image For serial or parallel printing Ensure that the print file ends with a CTRL D character CTRL D indicates the end of file...

Page 153: ...a pack of 10 pre soaked alcohol cloths 006 7824 00 Quick cleaning As a general rule you will get the best results from your printer if you perform these quick cleaning procedures once a week or as indicated in these instructions according to how much media you have used Feed rollers and paper guides Clean the drum feed rollers and paper guides after you have used approximately 80 large size prints...

Page 154: ...after you have used approximately 80 to 100 large size prints such as ANSI E Arch E ISO A0 or JIS B1 1 Using a large lint free cloth soaked with isopropyl alcohol or a pre soaked alcohol cloth wipe the entire length of the drum to remove any dust or wax residue 2 Using your hand rotate the drum toward the back of the printer to expose and clean more of the drum clean its entire surface in this man...

Page 155: ... Select button This places the printer in a neutral position Fuser shuttle is positioned to the right for easy access Back tension blade is loosened Paper clamp is raised The front panel displays Open Top Cover Cleaning the back tension blade Warning The back tension blade the steel belt behind it and the paper clamp are very sharp Make sure that you use the cleaning tool and keep your hands away ...

Page 156: ...ol 3 Pull forward on the back tension blade s blue handle and hold it in that position this lifts the blade away from the drum 4 Hook the tool under the blade it notches onto the rail to serve as a guide cleaning the front and back of the blade at the same time 5 Clean one section of the blade by wiping back and forth 3 4 times with pressure 6 Switch hands to clean the other end of the blade 9480 ...

Page 157: ...that need to be cleaned 1 Using a lint free cloth that has been moistened with 90 pure isopropyl alcohol and inserted into the cleaning tool place the V opening of the tool over the paper clamp 2 Clean the blade by wiping back and forth 3 4 times with gentle pressure Clean a small section at a time and repeat the process until the entire blade is clean Note The paper clamp is more flexible than th...

Page 158: ...SI E Arch E ISO A0 or JIS B1 1 Use a foam swab from the cleaning kit that has been moistened with 90 pure isopropyl alcohol 2 Rotate the drum to rotate the clamp rollers cleaning each roller with the swab Caution Do not pull the rollers away from the drum The metal that attaches it to the printer is very flexible and can be permanently bent 3 Repeat Step 2 for each of the 14 rollers 9480 21 2 3 ...

Page 159: ...rinting 500 600 large size prints such as ANSI E Arch E ISO A0 or JIS B1 3 2 cutters Replace if paper cuts appear jagged Setting the front panel 1 On the printer s front panel press the Menu button the printer displays this message Help Pages Menu 2 Press the arrow button until you see this message Utilities Menu 3 Press the Menu button the printer displays this message Test Print Menu 4 Press the...

Page 160: ...Open the exit cover a Push the blue lever on the lower right side of the printer the side closest to the front panel DOWN b Hold the exit cover and rotate it down c The fuser shuttle is visible on the far right inside the printer Removing the fuser s components 1 Remove the foam oiler wheel by lifting it out of the printer a c b 9480 25 ...

Page 161: ... The cutter blade is sharp To avoid injury always handle it by its shaft or yellow protective cover a Slide the lever on the cutter to unlock it b Lift the cutter out of the printer 4 If you are replacing the fuser s components dispose of the old components as normal office waste 9480 31 9480 30 a b ...

Page 162: ...r wheel with a lint free cloth 3 Wipe the fuser shuttle with a foam swab that has been moistened with 90 isopropyl alcohol Caution Be careful not to get any alcohol on the front and rear rails of the fuser shuttle It is oiled for smooth travel and the alcohol will remove the lubricant 4 If you are not replacing the fuser wheel wipe it with a dry lint free cloth 9480 26 9480 24 9480 45 ...

Page 163: ...cloth wipe the shuttle rail and the shelf under the rubber belt Remove all oil wax and dust 2 Using an alcohol moistened lint free cloth clean these parts a Wipe the metal exit roller thoroughly to remove any chaff build up turn the roller to clean its entire surface b Wipe the metal teeth to remove dust and ink c Wipe the rubber exit roller thoroughly turn the roller to clean its entire surface 9...

Page 164: ...nents Whether you are inserting new components or re inserting the existing ones follow these steps 1 Inserting the cutter blade into its slot on the fuser shuttle making sure that the exposed blade is facing up as shown 2 Secure the cutter by sliding the locking lever 9480 46 9480 61 ...

Page 165: ...Service Manual 7 13 Cleaning and Maintenance 7 3 Insert the foam oiler wheel into its slot on the fuser shuttle 4 Insert the fuser wheel into its slot on the fuser shuttle 9480 28 9480 31 ...

Page 166: ...veal the ink sticks Raise the slider of the affected ink stick Use a pen or pen like object to insert into opening and rotate the ink stick to the up position If an ink stick doesn t drop completely Use tweezers to pull the ink stick out of the printhead or use a pen or pen like object to push the ink stick into the printhead 9480 64 9480 33 1 2 ...

Page 167: ...he Menu button 4 Press an arrow button until the front panel displays this message Clean Head Select 5 Press the Select button 6 Press an arrow button until you see this message Test Print Print 7 Press the Print button the Test Print demonstrates the condition of the printhead jets If this does not clear the problem clean the head wiper manually using the following procedure 1 Make sure that the ...

Page 168: ...Never scrape the head wiper with a tool or your fingertip because you could damage it Clean the head wiper with an alcohol dampened swab only 3 Close the top cover 4 Make a test print from the front panel 5 If the problem does not clear replace the printhead 9480 47 ...

Page 169: ...er and remove any unused ink sticks 2 Use an alcohol swab to clean inside the ink loader 3 Detach the ink loader from the printer and repack it in its original shipping box Emptying the waste bin before moving the printer The printer locks the waste bin in place until it needs emptying However you can use the Utilities Unlock Waste Bin menu item to unlock the waste bin so that you can empty it bef...

Page 170: ...e original Tektronix shipping box es Repack the printer 4 Re insert the shipping block printhead restraint to secure the printhead Reverse the steps shown in the illustration Removing the shipping block on page 2 11 5 Detract the leveling legs under the printer this allows clearance for the printer to move freely on its wheels 6 Attach the pallet ramps to the pallet 7 Carefully guide the printer o...

Page 171: ...vice call Tektronix or your nearest Tektronix dealer for a return authorization number Inspection Rollers Replace the rollers when you see any of the following defects Flat spots Out of roundness Cracked rubber Loss of traction tackiness causing pick or feed failures Gears Replace gears that show any signs of wear or breakage Look for these problems Thinned gear teeth Bent or missing gear teeth ch...

Page 172: ...h lubrication can get into the paper path and attract dust so apply lubrication sparingly Lubricate the following only when needed Bushings Apply a drop of light oil to a bushing if it is noisy or running dry Maintenance station cam gear This gear requires only a small amount of white grease for noise reduction purposes Apply grease sparingly so that it does not fling off of the gears when they tu...

Page 173: ... Needle nose pliers Phaser 600 Tool Kit 650 3531 00 Tweezers 003 0236 00 Tension scale 003 0762 00 Head to media spring tool 003 1491 00 Test pattern generator 067 1433 99 Rheolube grease gears 006 2037 00 Velocite 10 Lubricating Oil rails 006 7056 00 Anti static mat 006 7056 00 Replacement cable ties 343 0549 00 Volt ohm meter such as a Tektronix DM252 4 Multimeter Magnifying lens such as Micront...

Page 174: ... screws and their standoff posts one at each end of the cover securing the cover to the printer frame Note that the right standoff features a shoulder to correctly align the roll cover to the printer frame Reverse these steps to reinstall the roll cover Support the weight of the cover while you thread the screws into the printer frame Tools required 4 mm hex wrench 1 POSIDRIV screwdriver Figure 8 ...

Page 175: ...nk loader remove the screw securing the ink loader to the printer cabinet Lift and remove the ink loader 4 Remove the three screws securing the left roll cover end cap Remove the end cap 5 Remove the four screws securing the left cover in place Spread the bottom of the cover and lift to remove it Reverse these steps to reinstall the left cover Figure 8 2 Removing the left cover 9482 25 Cover screw...

Page 176: ...g the right cover in place Spread the bottom of the cover and lift to remove it 5 With the cover raised disconnect the front panel ribbon cable from the front panel on the inside of the right cover Also free the ribbon cable from the inside of the right cover Note The ribbon cable features enough extra length to remain connected to the front panel while the right cover is removed to assist trouble...

Page 177: ...cover s interconnect board 5 Close the top cover 6 At the rear of the printer remove the rear plate held in place by 10 screws 7 Remove the four screws securing each top cover hinge to the printer frame Unlatch the top cover Lift and remove the top cover Reverse these steps to reinstall the top cover Make sure the cover open switch clicks before the top cover is about 1 cm 0 3 in from shutting Fig...

Page 178: ...the printer frame disconnect the fuser motor s wiring harness 4 With a hex wrench remove the two screws securing the fuser motor to its bracket Free the fuser motor s drive belt and remove the motor Reverse these steps to install the fuser motor Tension the fuser motor belt to 4 kgs 9 lbs as detailed in the Chapter 9 topic Fuser belt tension on page 9 6 Tools required 1 POSIDRIV screwdriver 3 mm h...

Page 179: ...c electricity 2 Remove the right cover as explained in the earlier procedure Right cover on page 8 4 3 Remove the left cover as explained in the earlier procedure Left cover on page 8 3 4 At the right end of the printer frame loosen the printhead belt tension screws Tools required 1 POSIDRIV screwdriver Flat blade screwdriver Figure 8 6 Loosening the printhead belt Loosen tension screws 9482 29 ...

Page 180: ... axis motor 5 Disconnect the X axis motor s wiring harness 6 At the left end of the printer frame remove the two screws securing the X axis motor to its bracket Remove the motor Figure 8 7 Removing the X axis printhead motor Disconnect wiring harness X axis motor Screws 9482 30 ...

Page 181: ...e carriage board 8 Carefully free the X axis belt from the X axis belt pulleys and remove the belt Reverse these steps to reinstall the motor and belt Refer to the Chapter 9 topic Printhead belt tension on page 9 5 for details on correctly setting the printhead belt s tension Figure 8 8 Removing the X axis printhead belt X axis belt ends Screws 9482 31 ...

Page 182: ...ined in the earlier procedure Left cover on page 8 3 3 Remove the fuser motor as described in the earlier procedure Fuser motor on page 8 6 4 Disconnect the wiring harness 5 At the left end of the printer remove the four screws securing the Y axis motor bracket to the printer frame Remove the motor and bracket Tools required 1 POSIDRIV screwdriver Figure 8 9 Removing theY axis drum motor Screws Di...

Page 183: ...ve the plate 9 Remove the E ring securing the Y axis motor pulley to its shaft Slide the Y axis motor belt off of the Y axis drive gear Slide the Y axis motor pulley and the Y axis drive belt off the pulley shaft Reverse these steps to install the Y axis motor Tension the Y motor belts to 5 kgs 11 lbs as detailed in the Chapter 9 topic Y axis motor belt and drum belt tension on page 9 7 Figure 8 1...

Page 184: ...top cover 3 Remove the right cover as explained in the earlier procedure Right cover on page 8 4 4 Disconnect the head to media motor s wiring harness from the right junction board 5 Remove the two screws securing the head to media motor Remove the motor and belt Reverse these steps to reinstall the motor Tools required 1 POSIDRIV screwdriver Figure 8 11 Removing the head to media motor 9482 34 He...

Page 185: ...2 Remove the right cover as explained in the earlier procedure Right cover on page 8 4 3 Disconnect the head maintenance cam gear motor s wiring harness from the right junction board 4 Remove the two screws securing the head maintenance cam gear motor Remove the motor Tools required 2 5 mm hex wrench Figure 8 12 Removing the head maintenance cam gear motor 9482 35 Head maintenance cam gear motor S...

Page 186: ...ling it 4 Move the printhead tailpiece s slide ramp to the printer s right to tilt the printhead backward slightly 5 Supporting the printhead carriage disconnect the printhead s sensor and heater wiring harnesses from the carriage board 6 Loosen the right side tilt adjusting hex screw securing the printhead in place Back out the screw and its tilt plate far enough to free the printhead In order to...

Page 187: ...it from the rear rail i Figure 8 13 Removing the printhead Disconnect the sensors and heater wiring harnesses Gently free the printhead from the rail as you remove it Back out the right side tilt adjusting screw Ensure slide ramp is over to the printer s right so the printhead moves back from the drum 9482 36 ...

Page 188: ... to the center of the rails 3 Cantilever the plastic printhead protector that the replacement printhead is shipped with between the center of the rear rail and the rear edge of the cabinet bottom 4 Gently place the printhead in the plastic protector and on the rear rail with the printhead s faceplate facing the drum Drape the printhead s hybrid cable over the lip of the plastic protector 5 Support...

Page 189: ...ositioned on the rail 7 Gently lower the printhead onto the carriage Center the printhead on the carriage and secure the printhead in place by tightening the right side tilt adjusting hex screw to 6 in lbs 68 Nm 8 Plug in the printhead s two media edge width sensors and its heaters into their connectors on the carriage board Note Dress all printhead wiring harnesses so they do not contact the prin...

Page 190: ...head to media spring loader refer to the illustration on page 9 17 Reset the tailpiece s slide ramp so it extends all the way the printhead s left viewed from the front of the printer Without pushing lightly tighten the three tailpiece screws to secure the tailpiece s position 14 Remove the spring loader and push the slide ramp to its extreme right viewed from printer front The printhead will tilt...

Page 191: ...ics to zero the ink stick usage count Refer to the Chapter 6 topic PC based diagnostics on page 6 26 Maintenance station 1 Turn off the printer Leave the power cord plugged in to provide a discharge path for static electricity Allow the maintenance station to cool this takes about 10 minutes 2 Remove the right cover as explained in the earlier procedure Right cover on page 8 4 Warning The printhea...

Page 192: ...Unit Disassembly Assembly 5 Disconnect the maintenance station wiring harness from the interconnect board on the side of the printer frame Figure 8 16 Disconnecting the maintenance station Disconnect wiring harness Air pump Disconnect air hoses 9842 39 ...

Page 193: ...emove the maintenance station pull out the air hoses and wiring harness with it Caution Do not nick or gouge the wiper or the vacuum chamber seal Reverse these steps to reinstall the maintenance station If necessary adjust the maintenance station bracket to align the maintenance station parallel to the face of the printhead Refer to the Chapter 9 topic Maintenance station alignment on page 9 8 Fig...

Page 194: ... wiper element 3 Insert a new wiper element squarely into the wiper retainer 4 Clip the wiper retainer with the wiper onto the ridge of the maintenance station Make sure that the element is firmly and squarely seated on the ridge Ensure there is no puckering where the wiper extends through the retainer Also ensure that the edge of the wiper element is parallel to the face of the maintenance statio...

Page 195: ...thead maintenance station and drip plate may still be hot To avoid injury allow them to cool before touching them 3 Move the printhead to the left away from the printhead s home position 4 To create more working room you can remove the maintenance station as described in the previous procedure 5 Disconnect the drip plate wiring harness from the interconnect board on the side of the printer frame 6...

Page 196: ...the drip plate slightly forward and then to the right to remove the drip plate and its rods and the spacer Reverse these steps to install the drip plate For reassembly note the spacer slides over the lower rod Figure 8 19 Removing the drip plate Drip plate C clips Brass spacer 9482 42 ...

Page 197: ...r on page 8 4 3 Disconnect the air hoses leading to the air pump 4 Disconnect the power connectors from the terminals on the right side of the air pump 5 With diagonal cutters snip the tops off the air pump mounting posts Remove the pump Tools required 1 POSIDRIV screwdriver Diagonal cutters Figure 8 20 Removing the air pump Disconnect power connectors Mounting bracket Air pump Disconnect air hose...

Page 198: ...the underside of the air pump mounting bracket Reverse these steps to reinstall the air pump Ink loader 1 Turn off the printer Leave the power cord plugged in to provide a discharge path for static electricity 2 At the rear of the ink loader remove the screw securing the ink loader to the printer cabinet Lift and remove the ink loader Tools required 1 POSIDRIV screwdriver Figure 8 21 Removing the ...

Page 199: ... procedure Left cover on page 8 3 3 Disconnect the wiring harness leading to the ink loader motor assembly 4 Disconnect the springs connecting the ink low sensor and ink drop sensors to the printer frame 5 Remove the four screws securing the ink loader motor assembly to the printer frame Remove the assembly Figure 8 22 Removing the ink loader motor assembly Screws 9842 45 Ink loader motor assembly...

Page 200: ...cover 1 Place the ink loader alignment jig on the left end printhead rails Laying against the alignment jig set the ink loader in its installed position 2 Tighten the screws that secure the ink loader motor assembly in place 3 Remove the alignment jigs 4 Manually slide the printhead under the ink loader to endure it passes under the ink loader with interference Figure 8 23 Installing the ink loade...

Page 201: ... Open the top cover 3 Using a hex wrench remove the two thumbscrews one at each end securing the clamp roller in place against the rear of the drum Lift and remove the clamp roller Reverse these steps to install the clamp roller assembly Tools required 1 POSIDRIV screwdriver 2 mm hex wrench Figure 8 24 Removing the clamp bail roller assembly Clamp bail roller assembly Remove two thumbscrews 9482 4...

Page 202: ...cover as explained in the earlier procedure Right cover on page 8 4 4 Open the top cover 5 Unclip the springs at each end of the back tension blade 6 Remove the retainer screw from the left end of the back tension blade 7 Remove the retainer from the right end of the back tension blade 8 Loosen the two set screws at the right end of the head to media set mechanism s sleeve Remove the head to media...

Page 203: ... 10 Slide the back tension blade assembly slightly to the right to free the left end Then slide it to the left to free the right end Remove the back tension blade Reverse these steps to install the back tension blade Figure 8 25 Removing the back tension blade 9482 47 Loosen two set screws Retainer screw Retainer Head to media drive shaft ...

Page 204: ...age 8 6 8 Remove the fuser assembly as explained in the earlier procedure Fuser and fuser belts on page 8 37 9 Remove the stripper finger assembly as explained in the procedure Stripper finger assembly on page 8 43 10 Remove the lower roller guide as explained in the procedure Lower rollers guide on page 8 44 11 Remove the clamp roller assembly as explained in the previous procedure Clamp bail rol...

Page 205: ...17 Loosen the Y motor drive belt tensioner 18 Remove the E ring securing the Y axis motor pulley to its shaft Slide the Y axis belt off the Y axis drive gear Slide the Y axis motor pulley and belts off the pulley shaft 19 Disconnect the wiring harness leading to the drum There are two wiring harnesses at each end Figure 8 26 Removing the drum s left outer plate outer bearing andY axis motor pulley...

Page 206: ... head maintenance station as detailed in the earlier procedure Maintenance station on page 8 19 23 Remove the head maintenance cam gear motor and cam as explained in the earlier procedure Head maintenance cam gear motor on page 8 13 24 Loosen the right drum bearing on the right end of the drum shaft The bearing is held in place by two screws 25 Disconnect the wiring harnesses leading to the paper ...

Page 207: ...bly 8 26 Remove the right roll holder It is held in place by four screws For reassembly note how the drip plate rod passes through the back of the roll holder Figure 8 27 Removing the right drum bearing 9482 48 Right drum bearing Right roll holder Wiring harness ...

Page 208: ...e steps to reinstall the drum When tightening the screws that secure the drum bearings at each end of the drum tighten them securely and then back the screw out 1 8 of a turn Perform the drum alignment check described in Chapter 9 Drum alignment on page 9 19 Then tighten the screws Following this complete the reassembly Figure 8 28 Removing the drum 9482 50 Brass spacer ...

Page 209: ...the right cover as explained in the earlier procedure Right cover on page 8 4 4 Disconnect the fuser s wiring harnesses and exit sensor wiring harness from the right junction board 5 Disconnect the wiring harness of the fuser motor Alternately you can remove the fuser motor as detailed in the earlier procedure Fuser motor on page 8 6 Also disconnect the exit roller motor wiring harness and the fus...

Page 210: ...Unit Disassembly Assembly 6 With a hex wrench remove the two screws securing each end of the fuser to the printer frame Tilt forward and remove the fuser The fuser motor belt is freed as you remove the fuser Figure 8 29 Removing the fuser 9482 51 Fuser ...

Page 211: ...right print engine frame to support the fuser as you install it Set the fuser on the pin and tilt it up into place Ensure the fuser is properly aligned to the lower roller guide as explained in the Chapter 9 topic Lower roller guide alignment on page 9 9 Also ensure the fuser belt is properly tensioned to 0 5 kgs 1 lb as explained in the Chapter 9 topic Fuser belt tension on page 9 6 Figure 8 30 U...

Page 212: ... in the earlier procedure Right cover on page 8 4 4 Manually rotate the drum and clamp to raise the clamp to its ready position 5 Remove the six screws three at each end securing the paper clamp to the drum Remove the clamp Reverse these steps to reinstall the paper clamp Ensure the clamp is correctly spaced and aligned to the drum by following the Chapter 9 procedure Paper clamp alignment on page...

Page 213: ...icity 2 Remove the left cover as explained in the earlier topic Left cover on page 8 3 3 Remove the right cover as explained in the earlier procedure Right cover on page 8 4 4 Unhook the spring from the left end of the timing fence Warning The printhead maintenance station and drip plate may still be hot To avoid injury allow them to cool before touching them Tools required 1 POSIDRIV screwdriver ...

Page 214: ...y Assembly 5 Remove the two screws securing the timing fence to the printer frame Carefully lift to the left and remove the timing fence Reverse these steps to reinstall the timing fence Figure 8 32 Removing the timing fence Remove screws at both ends of timing fence ...

Page 215: ... securing each end of the stripper finger assembly 6 Slide the assembly to the left to free the right end of the assembly and then side it to the right to free it from the printer frame Reverse these steps to reinstall the stripper finger assembly To ease re installation press the end fingers inward to the center of the assembly to compress the fingers and spacers together and keep them from rotat...

Page 216: ... Remove the right cover as explained in the earlier procedure Right cover on page 8 4 5 Open the fuser 6 Remove the stripper finger assembly as explained in the previous procedure 7 Remove the two screws from each end of the lower roller assembly Pull the assembly forward to remove it from the printer Reverse these steps to reinstall the lower roller guide Ensure the fingers of the guide fit squar...

Page 217: ...ft cover on page 8 3 3 Remove the right cover as explained in the earlier procedure Right cover on page 8 4 4 Open the card cage by removing the 10 screws securing it to the underside of the printer frame 5 Disconnect the umbilical cable from the print engine board s connector J104 Warning The printhead maintenance station and drip plate may still be hot To avoid injury allow them to cool before t...

Page 218: ...rd of the printhead Free the umbilical cable from the cable restrainer located on the underside of the carriage board 7 Free the umbilical cable from the printer frame Reverse these steps to reinstall the umbilical cable Figure 8 35 Removing the umbilical cable Disconnect umbilical cable Carriage board 9482 58 Cable retainer Umbilical cable ...

Page 219: ...n off the printer Leave the power cord plugged in to provide a discharge path for static electricity 2 Open the top cover 3 Remove the inner plate 9 screws from the inside of the top cover 4 Disconnect the ribbon cable leading to the sensor to be replaced 5 Locate and unclip the paper guide containing the skew sensor to be replaced Tools required 1 POSIDRIV screwdriver 0 POSIDRIV screwdriver ...

Page 220: ...Unit Disassembly Assembly 6 Remove the two screws securing the sensor to the paper guide Remove the sensor Reverse these steps to reinstall the skew sensors Figure 8 36 Removing the paper width sensors Skew sensors Paper guides Remove 9 screws 9482 59 ...

Page 221: ...left cover as detailed in the topic Left cover on page 8 3 3 Disconnect the left fuser closed sensor s wiring harness from the left junction board 4 Remove the two screws securing the left fuser closed sensor in place Remove the sensor Reverse these steps to install the left fuser closed sensor Figure 8 37 Removing the left fuser closed sensor Disconnect wiring harness Screws Left fuser closed sen...

Page 222: ...t cover on page 8 4 3 Disconnect the left and right printhead sensors wiring harnesses from the carriage board Clip the tie wraps securing the harnesses to the other printhead wiring harnesses 4 Free the sensors from their plastic mounting brackets on either side of the printhead Reverse these steps to install the left and right printhead sensors Figure 8 38 Removing the left and right printhead s...

Page 223: ...y 2 Open the top cover 3 Remove the inner plate 9 screws from the inside of the top cover 4 Disconnect the ribbon cable leading to the sensor to be replaced 5 In the case of the top cover unlocked sensors remove the two screws securing the sensor to the top cover Remove the sensor In the case of the top cover open sensor remove the screws securing the top cover open sensor bracket Remove the brack...

Page 224: ...th for static electricity 2 Remove the right cover as detailed in the topic Right cover on page 8 4 3 Disconnect the waste bin sensor s wiring harnesses from the right junction board 4 Remove the two screws securing the sensor to the waste bin frame Reverse these steps to install the waste bin sensor Figure 8 40 Removing the waste bin sensor 9482 63 Screws Waste bin sensor ...

Page 225: ... lower front cover It is held in place with four screws 3 Disconnect the exit sensor s wiring harnesses from the right junction board 4 Remove the two screws securing the exit sensor bracket to the printer frame Remove the two screws securing the sensor to the bracket Reverse these steps to install the exit sensor Figure 8 41 Removing the exit sensor Exit sensor Bracket Lower front cover 9482 64 ...

Page 226: ...e right roll cover end cap Remove the end cap 3 Remove the four screws securing the right cover in place Lift the cover 4 With the cover raised disconnect the front panel ribbon cable from the front panel on the inside of the right cover 5 Unclip the front panel from the inside of the front panel bezel Reverse these steps to reinstall the front panel Tools required 1 POSIDRIV screwdriver Figure 8 ...

Page 227: ...s securing it to the underside of the printer frame 4 Disconnect the AC wiring harness connecting to the power supply 5 Disconnect the two DC wiring harnesses connecting to the engine control board 6 Remove the six screws securing the power supply to the card cage Remove the power supply Reverse these steps to install the power supply Figure 8 43 Removing the power supply 9482 66 DC wiring harness...

Page 228: ... the printer frame 4 Disconnect the 11 wiring harnesses leading to the engine control board 5 Remove the seven screws securing the engine control board to the card cage Remove the engine control board Reverse these steps to install the engine control board Note To retain printer calibrations and preference values transfer the NVRAM chip U6 from the old board to the new board Figure 8 44 Removing t...

Page 229: ...ard receptacle J110 on the engine control board 5 Turn on the printer The LEDs on the engine board will all turn on and then turn off Next the LEDs will sequentially turn on as the new firmware is downloaded 6 When all the LEDs flash at the same time the firmware is downloaded Turn off the printer and wait 5 seconds 7 Remove the PCMCIA card 8 Close the electronics bay 9 Reinstall the output bin 10...

Page 230: ...ained in the earlier procedure Right cover on page 8 4 Warning The printhead is hot Allow it to cool before handling it 3 Move the printhead tailpiece s slide ramp to the right to tilt the printhead backward slightly 4 Supporting the printhead carriage disconnect the printhead s sensor and heater wiring harnesses from the carriage board 5 Remove the printhead as detailed in the earlier procedure P...

Page 231: ...ng the carriage board to the carriage Remove the carriage board Figure 8 45 Removing the carriage board 9482 68 Tilt adjusting hex screw Hybrid flex cable Carriage Carriage board Four screws Printhead assembly Five sensor and heater wiring harnesses Umbilical cable X axis belt Rear rail Front rail ...

Page 232: ...sembly Assembly Reverse these steps to install the carriage board Ensure the jumpers on the carriage board are correctly set for the Phaser 600 Color Printer Figure 8 46 Jumpers on the carriage board Phaser 300 Phaser 600 Phaser 300 Phaser 600 J362 J363 0052 01 ...

Page 233: ...ight cover as explained in the earlier procedure Right cover on page 8 4 3 Disconnect the 14 wiring harnesses leading to the right junction board 4 Remove the four screws securing the right junction board to the printer frame Reverse these steps to install the right junction board Figure 8 47 Removing the right junction board 9482 69 Remove 15 wire harnesses Remove four screws Junction board Right...

Page 234: ...eft cover as explained in the earlier procedure Left cover on page 8 3 3 Disconnect the 11 wiring harnesses leading to the left junction board 4 Remove the four screws securing the left junction board to the printer frame Reverse these steps to install the left junction board Figure 8 48 Removing the left junction board 9482 70 Remove 11 wire harnesses Remove four screws Junction board Left juncti...

Page 235: ...ectricity 2 Disconnect all host interface cables and SCSI cables from the rear of the image processor board 3 Remove the six screws securing the image processor board to the rear of the printer s card cage 4 Slide out the image processor board Reverse these steps to install the image processor board Figure 8 49 Removing the image processor board g p board Card cage Remove six screws ...

Page 236: ...e processor board with a new board you should transfer the items listed in the illustration below from the old board to the new board Figure 8 50 Transfer components from the image processor board Extended Feature SIMM PhaserShare Card Printer ID ROM NVRAM PostScript ROM SIMM RAM SIMM 2 RAM SIMM 1 9482 117 ...

Page 237: ...32 Mbyte RAM SIMM in connector SIMM 2 Insert the RAM SIMM in connector SIMM 2 a and tilt the module up until it locks in place b When properly inserted a tab on each end of the connector slips into a hole on each end of the RAM SIMM Also a pawl on each end of the connector latches around each end of the RAM SIMM to lock it in place 4 Reinstall the image processor board into the printer 5 Reconnect...

Page 238: ...the Extended Feature SIMM 4 Insert the an Extended Features SIMM in connector KANJI FEATURE a and tilt the module up until it locks in place b When properly inserted a tab on each end of the connector slips into a hole on each end of the SIMM A pawl on each end of the connector latches around each end of the SIMM to lock it in place 5 Reinstall the RAM SIMM s 6 Reinstall the image processor board ...

Page 239: ...d of the SIMMs in their connectors This makes room to remove the PostScript ROM SIMM 4 Remove the currently installed code ROM SIMM by spreading apart the pawls securing each end of the SIMM in its connector Remove the SIMM 5 Insert the a replacement code ROM SIMM in connector FIRMWARE a and tilt the module up until it locks in place b When properly inserted a tab on each end of the connector slip...

Page 240: ...page Network card 1 Turn off the printer Leave the power cord plugged in to provide a discharge path for static electricity 2 Unscrew the two thumbscrews securing the network card to the back of the image processor board 3 Slide out the network card Reverse these steps to install the network card Figure 8 54 Removing the network card 9482 73 Network card Thumbscrews Edge guide Image processor boar...

Page 241: ...drive bracket to the inside of the image processor board s rear panel Support the drive as you remove the screws 5 Remove the six screws securing the hard disk drive to the bracket Remove the drive Reverse these steps to install the hard drive Upon power up the image processor automatically checks and if necessary initializes the internal hard drive Install jumpers on Jumper Pins 1 and 4 to set th...

Page 242: ......

Page 243: ...1684 00 Lower roller guide alignment jig 003 1682 00 Serial cable adapter level shifter 174 3493 00 Mini DIN8 to DB25M serial cable 012 1498 00 PC based diagnostics diskette 063 2778 00 Hex wrench kit 003 1344 00 Grease 006 7997 00 Antistatic mat 006 7056 00 Flat blade screwdriver Magnifying lens such as Micronta Radio Shack Cat 63 851 Alternate cables to run diagnostics from a PC DB9F to DB25M se...

Page 244: ...n on the printer 2 Allow the printer to complete its power up self tests The front panel displays this menu Ready Pause Menu Figure 9 1 Main menu map Serial Settings Baud Rate Data Bits Stop Bits Parity Flow Control Printer Defaults Print Quality Image Smoothing TekColor Correction Startup Page SCSI Startup Mode PS Error Handler Media Defaults Media Size Media Fusing Media Cutting Help Pages Menu ...

Page 245: ...çais Language Deutsch Language Italiano Language Japanese Utilities Test Print Clean Head Clean Paper Clamp Unlock Waste Bin Change Fuser or Cutter Network Settings TCP IP EtherTalk NetWare HTTP Service Support Menu Press Menu Exit for extended Service Menu Engine Copy Count FW Version Fault History High Altitude ColorlStix Usage Reset Printer Reset NVRAM Test Print Clean Calibration Tilt Pattern ...

Page 246: ...rint Refer to Appendix B Test Patterns it discusses each test print and what printing defect it reveals Printing the configuration page While the printer is idle press the Menu button to enter the printer s menu Scroll to the Help pages menu item Press the Print button to print the configuration page The configuration page shows a great deal of information regarding the data and set up values stor...

Page 247: ...n screws on the right X axis pulley Rotate the screws ant the same time to keep the belt centered on the pulley 6 Once the belt tension is correct manually push the printhead to the left end of the printhead rails Observe the X axis belt as it rotates over its right and left pulleys check to see that it stays centered on the pulleys 7 Apply threadlock glue to the tension screws to secure them in p...

Page 248: ...screws on the right fuser pulley Rotate the screws ant the same time to keep the belt centered on the pulley 6 Once the belt tension is correct manually push the fuser shuttle to the left end of its travel Observe the fuser belt as it rotates over its right and left pulleys check to see that it stays centered on the pulleys Apply threadlock glue to the tension screws to secure them in place Figure...

Page 249: ...on the Y axis motor belt tension with a pressure of 5 kgs 11 lbs 5 Tighten the screws securing the Y axis motor 6 Loosen the screws securing the drum belt tensioner 7 With a tension gauge press down on the drum belt tension with a pressure of 5 kgs 11 lbs 8 Tighten the screws securing the drum belt tensioner Figure 9 5 SettingY motor belt tension Y axis motor Drum belt tensioner Tension gauge Pres...

Page 250: ...he bracket until the seal of the maintenance station is parallel with the faceplate of the printhead 5 Tighten the two bracket screws 6 Use the PC diagnostics to laterally adjust the position of the printhead when it is positioned in front of the maintenance station for a cleaning cycle Refer to the diagnostic menu item Calibration Engine NVRAM Menu Figure 9 6 Setting maintenance station alignment...

Page 251: ... front of the fuser 3 Open the fuser 4 Loosen the four alignment screws reached through the access holes through the fuser 5 Place the alignment shims in place between the fuser and the lower roller guide The shims should be under the lower roller guide and on top of the fuser 6 Gently bring the fuser to a near closed position until it stops 7 Tighten the four alignment screws ...

Page 252: ... Figure 9 7 Aligning the lower roller guide to the fuser 9482 113 Alignment screws through access holes under fuser Alignment screws through access holes under fuser Alignment screws Access hole Lower roller guide Fuser Alignment shims Lower front cover Lower roller guide Alignment shims Fuser ...

Page 253: ...f necessary loosen the three screws securing the clamp to the clamp side plate and adjust the clamp so has about a 3 mm 1 8 in gap from the surface of the drum 4 Tighten the three screws to secure the clamp in position 5 Repeat the adjustment for the left end of the clamp 6 Rotate the paper clamp so its top edge is even with the bottom edge of the back tension blade Figure 9 8 Setting the paper cl...

Page 254: ...ws on the clamp drive shaft and re position the shaft until the clamp is parallel with the back tension blade 8 Tighten the set screws once the adjustment is correct Figure 9 9 Aligning the paper clamp Loosen 2 hex set screws Paper clamp 9482 116 Back tension blade Parallel at each end Paper clamp Back tension blade ...

Page 255: ...the sensor emitter and receiver when there are no ink stick in the printer Use a 1 5 mm hex wrench to adjust the flag on its shaft The flag of the ink stick drop sensor is momentarily actuated when an ink stick drops into the printhead The flag of the ink low sensor should fully block the space between the sensor emitter and receiver only at that time Use a 1 5 mm hex wrench to adjust the flag on ...

Page 256: ...Ink Load Pos Adj Each increment is 1 300 of an inch 3 Retest for proper alignment Temperature offset adjustment for a new printhead On the back of each printhead a temperature offset value may be printed such as 3 SH or 2 SH This offset value must be set using the Extended Service Support menu If no offset value is listed on the printhead set the offset values to 0 1 Scroll to the Head Temp Adjust...

Page 257: ...e Pin 1 test point Measure HV on Pin 3 right pin with a small screwdriver adjust the voltage to the required value listed on the back of the printhead Use the right high voltage adjustment potentiometer located to the right of the Pin 3 test point Proceed to the next procedure Printhead to media spacing tailpiece adjustment Printhead to media adjustment tailpiece adjustment Note All printhead adju...

Page 258: ...on Then push the tailpiece s slide ramp to the right toward the home position to tilt the printhead away from the drum Then move the printhead so it is centered on the dimple at the right end of the back tension blade Note Perform Steps 5 and 6 as quickly as possible to prevent distorted settings due to thermal expansion 5 Position the tailpiece s slide ramp to its left most position toward the in...

Page 259: ... t touch it Move the printhead by pulling its X axis belt 7 Slide the tailpiece slide ramp full right and return the printhead to its home position Retract the shim by manually rotating the head to media motor 8 Slide the slide ramp full right and gently move the printhead so it is centered before the drum Slide the slide ramp to its full left position The printhead should move toward the drum Fig...

Page 260: ...p all the way to its right the printhead will move away from the drum Slide the printhead back to its home position 11 Make a test print on a sheet of the thin test media 2 7 mils thick included with a replacement printhead The tailpiece slide ramp should move about a 0 25 inch 6 mm to the left when the printhead passes in front of the media and sets the head to media spacing If the slide ramp doe...

Page 261: ...t marks at the far right and far left of the print If the drum is correctly aligned to the printhead rails the marks should be identical If they are not the drum is out of alignment and must be corrected The test print may also reveal other problems such as poor convergence or printhead tilt but these will be corrected in later procedures Figure 9 14 Checking drum alignment Left end of print Right...

Page 262: ...s tip contacts the drum surface Read the displayed value It will show the difference in alignment from the first reading The value read should be no more than 5 mils 005 in 7 At either the left end or the right end of the drum loosen the drum bearing securing the drum to the printer frame At the right end of the drum you must remove the maintenance station and the maintenance station drum cam At t...

Page 263: ...ts are required You can individually set the convergence used for standard mode printing and enhanced mode printing set standard mode printing convergence first The default convergence values for new printheads are Standard mode 40 Enhanced mode 40 1 Ensure that the printhead drive voltages are correct as explained in the earlier procedure Printhead drive voltage adjustment on page 9 15 2 Scroll t...

Page 264: ...ottom bar then the printhead is slow The final value should be between 50 to 30 If it is outside this range recheck the printhead to media spacing The printed alignment patterns shift in 1 4 pixel increments 5 If the Standard Convergence values must be changed scroll to the Standard Convergence menu Press the Menu button The currently set convergence value is displayed for example Convergence 40 U...

Page 265: ... 5 Enhanced 48 Standard 46 0 25 Enhanced 46 Standard 44 0 0 Enhanced 44 Standard 42 0 25 Enhanced 42 Standard 40 0 5 Enhanced 40 Standard 38 0 75 Enhanced 38 Standard 36 1 0 Enhanced 36 Standard 34 1 25 Enhanced 34 Standard 32 1 5 Enhanced 32 Standard 30 1 75 Enhanced 30 Each pattern represents a 1 4 pixel shift Pattern printed in enhanced mode Pattern printed in standard mode Set adjust value to ...

Page 266: ... to print a tilt adjustment pattern The printer then prints a tilt adjustment pattern 5 With a magnifying lens examine the test pattern Determine if the black printing is higher or lower than the cyan printing Warning The printhead is hot To avoid injury don t touch it 6 If black is higher than cyan Loosen the left side adjusting screw 1 2 turn as viewed from the rear of the printer Tighten the ri...

Page 267: ...nt 9482 101 Adjust the printhead s position in the carriage Lube the contact area between the printhead and the carriage Test prints Black higher than cyan Black lower than cyan First loosen this screw then tighten this screw First loosen this screw then tighten this screw Lube point ...

Page 268: ...he gradiated appearance of many of the patterns that is an artifact the test Only look for the thin horizontal black and white lines 4 Under ordinary circumstances the drum step pattern 0 should show the best convergence If thin horizontal black lines are visible the drum is stepping too far between printhead passes If thin horizontal white lines are visible the drum is not stepping far enough bet...

Page 269: ...nd Adjustments 9 Figure 9 17 Setting the drum step adjustment Step Adj 30 Step Adj 20 Step Adj 10 Step Adj 0 Step Adj 10 Step Adj 20 Step Adj 30 Step Adj 0 Present Overlap drum step is too long Skip drum step is too short 9482 79 ...

Page 270: ...rn If the solid fill appears to be well filled with even density and the 8 5 kHz manifold parallel line laydown is composed of even lines then the printhead temperature is correct Go to Step 7 4 If the solid fill is appears well filled and even but the 8 5 kHz pattern is composed of uneven lines that appear to jump in and out of neighboring lines this is called lane changing and feature lines that...

Page 271: ... by lane changing and hooked ends that indicate the printhead is too hot or the voltage is too high Good 8 5 kHz lines Lines show a broken appearance The printhead is too cold or the voltage is too low Hooked ends pattern in this box is for head test evaluation only 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Solid fills ...

Page 272: ... the PC diagnostics as explained in the Chapter 6 topic PC based diagnostics on page 6 26 2 Run the diagnostic test Calibrations Sensor Calibration Load Cal Media Load a hand fed sheet of Phaser 600 Tektronix brand translucent film use a pre cut B size sheet The printer will advance the media into the print position 3 Next run the diagnostic test Calibrations Sensor Calibration Adjust Thresholds T...

Page 273: ...and enter the Extended Service Support menu and then scroll to the Convergence Pattern menu item Press Print to print a test pattern to determine if a change is required 5 Examine the Standard mode alignment marks in the test print If the center of the alignment mark is shifted to the left minus direction this is called a slow printhead then the printhead voltage needs to be raised Refer to the ea...

Page 274: ...enoid valve In addition you can determine if the maintenance station is sealing properly against the printhead faceplate 1 Turn off the printer and remove the power cord 2 Remove the top and right side covers as explained in the Chapter 8 topic Printer cabinet on page 8 2 Tools required Magnetic screwdriver Vacuum gauge PC diagnostics ...

Page 275: ...C based diagnostics on page 6 26 5 Run the diagnostic test Servo Motors Vacuum Check 6 Measure the vacuum pulled by the pump it should measure a minimum of 8 5 psig 17 in Hg 430 mm Hg If the reading is lower you should suspect a leaky maintenance station seal to the printhead face Next the maintenance station itself may be defective Lastly the air pump may be faulty Figure 9 19 Connecting the vacu...

Page 276: ...procedure To reset the printer to its factory default values follow this procedure 1 With the printer in its Ready state press Menu 2 Scroll to the Service Support menu item 3 Press Menu and Exit to enter the special service menu 4 Scroll to the menu item Reset NVRAM 5 Press OK to reset NVRAM Alternately you can also use the PC diagnostics to selectively return either the print engine NVRAM conten...

Page 277: ...ering Particular fields in the serial number indicate the modification level of the printer the date of its manufacture and the sequence number of the printer produced on that day The serial number is coded as follows BYRxxxx B indicates the headquarter city of the manufacturing company Beaverton Y numerically indicates the last digit of the year of manufacture ranging from 0 to 9 R indicates the ...

Page 278: ...3 118 9396 00 1 Cabinet Roll End Cover Left or Right 4 118 9400 00 1 Cabinet Left Side Cover 5 118 9307 00 1 Ink Loader Ink Stick Cassette 6 118 9398 00 1 Cabinet Top Cover Assy including Hinge 7 118 9317 00 Cabinet Paper Guide Cover 8 650 3257 00 1 Front Panel LCD Board and Bezel 8a 671 3638 00 Front Panel LCD Board 9 118 9399 00 1 Cabinet Right Side Cover 10 118 9395 00 2 Casters Kit 11 118 9318...

Page 279: ...Service Manual A 3 A Figure A 1 The printer exterior FRUs 9482 83 10 4 5 3 2 1 3 13 9 8 6 11 12 7 ...

Page 280: ...rews Printhead Hold down Brackets 29 118 9304 00 1 Head Mounting Bracket Carriage Casting 30 650 3596 00 1 Head Carriage Bd 31 118 9287 00 1 Printhead Umbilical Cable 32 118 9310 00 1 Timing Fence Dot Clock Spring 33 118 9306 00 1 X Axis Steel Belt Assy 34 118 9288 00 1 Right Junction Board Assy 35 118 9305 00 1 X Axis Return Pulley 36 118 9308 00 1 Waste Bin Drawer 37 118 9309 00 1 Waste Bin Lock...

Page 281: ...gure A 2 Printer interior FRUs 37 42 48 43 44 47f 38 48 48 48 47e 25 48 32 33 34 36 30 31 11b 35 40 28 29 24 14 13 10 9 47b 9 9 48 2 4 17 47a 48 48 19 11a 20 48 15 21 9 9 7 5 3 6 48 47c 47d 8 16 48 26 48 27 48 41 39 23 48 22 1 12 45 48 46 9482 84 18 49 ...

Page 282: ...tended Features SIMM Kanji 12a 12b 12c 12d 671 3468 03 671 3469 00 671 3470 03 386 6815 00 213 1090 00 1 1 1 1 2 Ethernet Network Card Ver 3 0 LocalTalk Serial Network Card Ver 1 0 Token Ring Network Card Ver 3 0 Blank Cover Plate no card installed Blank Cover Plate Thumbscrews 13a 13b 13c 671 3318 00 671 3133 00 671 3138 00 1 8 Mbyte RAM SIMM 16 Mbyte RAM SIMM 32 Mbyte RAM SIMM 14 671 3750 00 1 I...

Page 283: ...Service Manual A 7 FRU Replaceable Parts List A Figure A 3 Printer electronics bay FRUs 9482 85 14 13 12 11 10 9 8 5 4 3 2 1 6 7 15 ...

Page 284: ......

Page 285: ...ow Origin Sensor Cyan Origin Sensor Ink Loader Installed Sensor Printhead Door Open Motor 20 10 12 Fan Fan Loader Door Open Sensor Ink Low Sensor Ink Stick Drop Sensor J408 J411 J412 J413 J414 J402 J404 J403 J405 J407 J409 J410 J401 J406 AC In CN1 CN3 CN4 J101 J113 J114 J110 J109 J102 J112 J103 J105 J301 J303 J310 J309 J308 J307 J304 J305 J306 J302 J107 J104 J203 J201 J211 J212 J209 J210 J215 J213...

Page 286: ...y cabinet panels or damaged by moving parts of the printer Power wiring for motors and solenoids is kept separate from signal wiring for sensors to minimize crosstalk Figure C 2 Wire routing at the right end of the printer 9482 87 Power motors solenoids Signal sensors Signal sensors Figure C 3 Wire dressing at the left end of the printer 9482 88 Power motors solenoids Signal sensors Ink loader ...

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