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Chapter 3: Troubleshooting

3.1: Introduction

This chapter provides the technician with procedures for troubleshooting the printer. The
following table summarized some of the more common problems which may be
encountered with the printer. A brief description of the problem is provided with one or
more possible causes for each.

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Содержание XL 300 SERIES

Страница 1: ...XL300 MAINTENANCE MANUAL Part No 105880 Rev A ...

Страница 2: ...ocument The first part is an introduction to the printer systems and sub assemblies and theory of operation The second part provides troubleshooting and scheduled maintenance procedures including corrective maintenance removal and replacement procedures ...

Страница 3: ...ption 1 7 1 16 Current Loop Installation 1 8 1 17 TTL Parallel Interface 1 9 1 18 Physical Characteristics 1 11 2 THEORY OF OPERATION 2 1 2 1 Introduction 2 1 2 2 Microprocessor System 2 1 2 3 Character Printing 2 2 2 4 Printhead Theory of Operation 2 2 2 5 Paper Motor 2 3 2 6 Carriage Drive 2 4 2 7 System Clamp 2 5 3 TROUBLESHOOTING 3 1 3 1 Introduction 3 1 4 MAINTENANCE 4 1 4 1 Introduction 4 1 ...

Страница 4: ...t Figure 4 7 4 15 4 5 19 Spring loaded Idler Pulley Removal and Replacement Figure 4 8 4 19 4 5 20 Fixed Idler Pulley Assembly Removal and Replacement Figure 4 9 4 20 4 5 21 Left Margin Sensor Removal and Replacement Figure 4 10 4 22 4 5 22 Carriage Drive Motor Removal and Replacement Figure 4 11 4 23 4 5 23 Carriage Drive Spool Removal and Replacement Figure 4 11 4 24 4 5 24 Printhead Removal and...

Страница 5: ...re 4 6 Carriage Cables 4 16 Figure 4 7 Carriage Cable Replacement 4 17 Figure 4 8 Spring Loaded Idler 4 19 Figure 4 9 Fixed Idler 4 20 Figure 4 10 Left Margin Sensor 4 22 Figure 4 11 Carriage Drive Motor 4 24 Figure 4 12 Carriage Removal 4 27 Figure 4 13 Drive Belt Tension 4 30 Figure 4 14 Paper Drive Idler Shaft 4 33 Figure 4 15 Printhead To Platen Gap Alignment 4 36 Figure 4 16 Lower Paper Guide...

Страница 6: ...re All features including forms status are saved in a nonvolatile memory making setup quick and simple An LED display is provided to function as an enunciator in Setup mode and to show the line number in normal print mode 1 2 FUNCTIONAL DESCRIPTION The printer prints characters in a serial fashion by moving a 9 wire printhead in a bi directional manner along the print line The direction of print i...

Страница 7: ...rrectly positions the printhead as the solenoids drive the printwires in order to form characters A printwire is fired when 55 VDC is applied to a solenoid Power from a modulated pulse width power amplifier is supplied to the printhead solenoids via a ribbon cable 1 5 PAPER FEEDING The printer is designed to accommodate forms ranging in width from 3 to 15 inches Forms must be of the pin feed type ...

Страница 8: ...currence of a bell tone is not synchronized to any physical attribute of the printer such as printhead or paper position Bells may also be generated locally in setup mode to prompt the operator when certain errors have occurred It also alerts the operator when the paper supply is depleted 1 8 OPERATOR CONTROL PANEL A 16 key panel or pad is provided to enable the operator to define features which a...

Страница 9: ... serve to hold down the cartridge to the carriage The drive mechanism is a mechanical device which derives its power from motion of the carriage Power is coupled to it from two steel cables strung between the left and right endplates Each cable is wrapped 1 turn around a pulley which contains a unidirectional clutch bearing The cables are strung in a fashion that causes the pulleys to rotate in op...

Страница 10: ...PU would not be aware of the incorrect carriage position and the machine would not operate properly when required to print the next line This problem is avoided by returning the carriage to the left margin when the machine is idle Since the photosensor can monitor this position the MPU will detect any motion of the carriage away from the sensor A restore cycle will be automatically commanded if th...

Страница 11: ...standard 25 pin connector mounted on the PCB and is accessible through a slot in the rear of the printer cover To allow operation at high BAUD rates two handshaking or restraint protocols are supported XON XOFF and DTR Both are selectable by the operator as required XON XOFF functions by sending an XOFF control code to the host when the FIFO buffer fills to a high water mark and then an XON when i...

Страница 12: ...raint mode is available The XON XOFF mode of handshaking is not affected and may be used if desired The current loop receiver or transmitter may operate in either passive or active mode The standard factory setting is passive for both loops When operating in passive mode the host system must supply the excitation or drive current In active mode the printer provides the drive current and the host a...

Страница 13: ...n For a passive loop install the following jumpers W15 W17 W19 W27 For an active loop install the following jumpers W29 W18 W16 W28 W26 W20 The following jumpers should be removed when installing an active loop W15 W17 W19 W27 1 8 ...

Страница 14: ...lace of purchase The interface functions by accepting a 7 bit character code when a datastrobe transistions from high low to low high Upon acceptance of the character the acknowledge signal is pulsed low for a short period of time The host uses this as an indication that the character has been received and that another may be sent During certain nonprinting intervals such as when paper is in motio...

Страница 15: ...1 10 ...

Страница 16: ...TERISTICS The printer is packaged in a compact enclosure suitable for use on a desktop or for mounting to an optional free standing pedestal Dimensions for the printer and the pedestal Figure 1 1 Spacial Requirements 1 11 ...

Страница 17: ...This page intentionally left blank 1 12 ...

Страница 18: ...line buffers dot buffers and general purpose workspace The EPROM contains dot patterns for printable characters and software pro 7 rams firmware required to perform various printer functions The Intel 8155 s are used for general purpose 1 0 and the parallel interface They also provide timers for determining baud rate and processor interrupts The Intel 8251 USART converts the serial data arriving a...

Страница 19: ... places the dot pattern in a dot buffer The dot pattern is then loaded into a printwire latch When the printhead achieves the correct position the dot pattern is sent to the printhead power amplifier Seven sub columns are required to completely define each character Dots in each sub column are formed by energizing solenoids which cause the wires in the printhead to impact the ink ribbon and paper ...

Страница 20: ...in feed tractors are driven by the motor through a timing belt The motor is geared so that 8 steps of the motor advance the paper 1 6 of an inch The motor is controlled by the microprocessor which provides the step sequencing and timing functions see Figure 2 3 Figure2 3 Paper Motor Current Waveforms Power is delivered by a chopping current regulator operating off the 55V supply Power can be cut o...

Страница 21: ...gulator operating off the 55V supply Power can be cut off from the motor by disabling the system ready see section on system clamp When the printer is idle system ready is disabled by the processor and the motor is not energized When the carriage motor is idle and system ready is enabled the amplifier will maintain a holding current of 0 5 amps in each winding of the motor Any change in the inputs...

Страница 22: ...bit Any time a motor is moved the 1 0 bit system ready must be enabled This allows step data to be converted to motor current Therefore anytime system ready is enabled motors are either stepped by changing step data or clamped by unchanging step data present at the input of the amplifier System ready also enables the printwire driver circuit 2 5 ...

Страница 23: ...es the technician with procedures for troubleshooting the printer The following table summarized some of the more common problems which may be encountered with the printer A brief description of the problem is provided with one or more possible causes for each 3 1 ...

Страница 24: ...3 2 ...

Страница 25: ...3 3 ...

Страница 26: ...3 4 ...

Страница 27: ...3 5 ...

Страница 28: ...3 6 ...

Страница 29: ...Figure 3 1 Controller Schematic Part No 105947 Sheets 1 8 PC Board 105601 3 6 ...

Страница 30: ...3 7 ...

Страница 31: ...3 8 ...

Страница 32: ...3 9 ...

Страница 33: ...3 10 ...

Страница 34: ...3 11 ...

Страница 35: ...3 12 ...

Страница 36: ...3 13 ...

Страница 37: ...3 14 ...

Страница 38: ...Figure 3 2 Controller Finished Assembly Component Layout Part No 105535 Sheets 1 and 2 PC Board 105601 3 15 ...

Страница 39: ...3 16 ...

Страница 40: ...3 17 ...

Страница 41: ...Figure 3 3 Power Supply PCB Schematic Part No 105623 PC Board 105622 3 18 ...

Страница 42: ...3 19 ...

Страница 43: ...Figure 3 4 Power Supply PCB Assembly Part No 105621 PC Board 105622 3 20 ...

Страница 44: ...3 20 ...

Страница 45: ...Figure 3 5 Operator Panel PCB Schematics Part No 105815 PC Board 105800 3 21 ...

Страница 46: ...3 22 ...

Страница 47: ...Figure 3 6 Operator Panel PCB Assembly Part No 105801 PC Board 105800 3 23 ...

Страница 48: ...3 24 ...

Страница 49: ...4 inch shank 2 Phillips screwdriver 6 inch shank Assortment of Allen Hex wrenches Torque wrench capable of delivering a torque of 115 inch pounds with a 7 16 inch socket 0 010 inch flat feeler gage Common slip joint pliers Small bristle brush Soft clean cloths General purpose cleaner ie Formula 409 Fantastik etc Isopropyl alcohol Spring hook useful but not required 5 16 open end wrench Force gage ...

Страница 50: ...olvents or lubricants on any of the working parts of the printer The only scheduled maintenance which can be performed is periodic cleaning approximately every 3 months Use a vacuum cleaner with a plastic nozzle to remove dirt from the carriage and the platen A dry lint free cloth may be used to clean accumulated dirt from the carriage rods and the platen The top cover of the printer may be cleane...

Страница 51: ...tle brush and isopropyl alcohol Only the printhead should be cleaned including the wire tips and jewel bearing All ink and ribbon fabric residue should be removed in this process Do not attempt to clean inside the printhead case or around the cylinder the printhead coils 4 Replace in reverse order 4 5 CORRECTIVE MAINTENANCE This section contains procedures for removing and replacing components of ...

Страница 52: ... straight up 2 Using a long shank Phillips screwdriver remove the two front comer screws 7 in the bosses 3 Remove the screw 7 at each end of the keypad support 4 NOTE Failure to remove these two screws before removing the top cover may result in damage to the keypad or the keypad cable 4 Remove the two screws 8 on the back side of the top cover 1 and lift top cover 4 4 ...

Страница 53: ... 36 is clear of the bottom cover 5 Replace in reverse order 4 5 3 Operator Panel Removal and Replacement Figure 4 1 1 Remove top cover See Paragraph 4 5 1 2 Lift keypad support 4 off support tubes 5 3 Disconnect keypad from cable by pushing out on header locking tabs 4 Remove six screws holding PCB to keypad support 5 Replace in reverse order 4 5 4 Electronic Chassis Removal and Replacement Figure...

Страница 54: ...ller board with any object and attempt to pry it free from standoffs 4 Pull the controller board 21 free from each standoff 67 5 Pull the controller board 21 slightly away from the rear wall so the power connector 30 is accessible 6 Remove connector 30 7 Replace controller board in reverse order 4 5 6 Fan Removal and Replacement Figure 4 2 1 Remove top cover see Paragraph 4 5 1 2 Remove electronic...

Страница 55: ...ee Paragraph 4 5 1 2 Remove electronic chassis see Paragraph 4 5 4 3 Remove all connectors from power supply PCB 45 4 Remove two Phillips screws 46 securing power supply PCB 45 to electronic chassis 62 5 Pull power supply PCB 45 free from standoffs 6 Replace in reverse order 4 7 ...

Страница 56: ...Figure 4 2 Electronic Module 4 8 ...

Страница 57: ...ve top cover see Paragraph 4 5 1 2 Remove electronic chassis see Paragraph 4 5 4 3 Disconnect transformer connector 44 from power supply 4 Tag leads to ensure correct reconnection and remove leads 5 Remove four screws 42 securing transformer 44 to electronic chassis and remove transformer 6 Replace in reverse order 4 5 10 Power Switch Removal and Replacement Figure 4 2 1 Remove top cover see Parag...

Страница 58: ...tch 35 to ensure correct reconnection and remove leads 4 Remove two screws 34 to securing voltage switch 35 to electronic chassis and remove voltage switch 5 Replace in reverse order 4 5 12 Fuse holder Removal and Replacement Figure 4 2 1 Remove top cover see Paragraph 4 5 1 2 Remove electronic chassis see Paragraph 4 5 4 3 Tag leads of fuse holder 54 to ensure correct reconnection and remove lead...

Страница 59: ...4 5 2 4 Remove electronic chassis see Paragraph 4 5 4 5 Remove cable 23 from cable clamps on rear of lower power guide 6 Replace in reverse order 4 5 15 Ribbon Advance Drive Cable Removal and Replacement Figure 4 3 1 Remove top cover see Paragraph 4 5 1 2 Move carriage 160 to the left endplate 3 Stretch tensioning spring 75 and unhook cable eye from end of spring Do not remove spring 4 Thread cabl...

Страница 60: ...rator panel see Paragraph 4 5 3 3 Remove ribbon advance cables see Paragraph 4 5 15 4 Remove two screws 175 securing ribbon advance mechanism 161 to carriage 160 and remove mechanism 5 Replace in reverse order 6 After installation is complete move the carriage left right several times to make certain the drive blade is advancing counterclockwise 4 12 ...

Страница 61: ... 17 Ribbon Cartridge Spring Clips Removal and Replacement Figure 4 4 1 Lift access cover 3 2 Remove ribbon cartridge 3 Remove screw 163 securing spring clip 164 to carriage 4 Replace in reverse order 4 13 ...

Страница 62: ...Figure 4 4 Ribbon Advance Mechanism 4 14 ...

Страница 63: ... a small wrench to prevent rotation of the stud and drive cable 4 The inner nut 74 may now be removed The right hand cable 125 is now free of the carriage and may be threaded back through the right endplate 82 and back to the drive spool The cable may be removed from the spool by slipping the cable and bead out of the small slot on the end of the drive spool 5 The remaining left hand cable 117 may...

Страница 64: ...nsert the stud through the carriage bracket and install the inner nut 74 Tighten these nuts securely such that the threaded portion of the cable stud is approximately centered in the carriage bracket 8 Thread the beaded end of the left hand cable 117 through the left end 144 around the spring loaded idler pulley 156 and back through the endplate 144 The cable should run freely around the pulley wi...

Страница 65: ...Figure 4 7 Carriage Cable Replacement Figure 4 7 Carriage Cable Replacement 4 17 ...

Страница 66: ...ack through the endplate 82 14 Continue to hold tension on the cable 125 and install the outside nut 74 on the right hand cable stud Install the cable stud as previously done in step 6 15 Inspect the installation of the drive cable to the drive spool It should appear as in Figure 4 6 16 The screwdriver may now be removed from the idler arm 156 on the left endplate 144 The carriage drive system is ...

Страница 67: ...le 117 see Paragraph 4 5 18 3 Rotate spool pulley 119 on carriage motor clockwise until carriage rests against the right endplate 82 4 Remove brace from idler arm and allow spring to contract 5 Remove two screws 131 securing the front right angle bracket 139 to the left endplate 144 and remove bracket 139 Figure 4 8 Spring Loaded Idler 4 19 ...

Страница 68: ...dure to replace left carriage drive cable 117 11 The carriage cable should track perpendicular to the pulley axis 4 5 20 Fixed Idler Pulley Assembly Removal and Replacement Figure 4 9 To remove the fixed idler pulley assembly from the right endplate 1 Remove the carriage drive cables see Paragraph 4 5 18 2 Remove the two screws 106 which attach the fixed idler bracket 96 to the right endplate 82 S...

Страница 69: ...er board reads the status of the photo transistor to determine if the carriage is at the true left margin This is a reference point and carriage position is calculated relative to this position Being a semi conductor electronic device the sensor is subject to failure If this should happen it is easily replaced as described below 1 Move the carriage 160 away from the margin sensor 150 to allow ampl...

Страница 70: ...op cover see Paragraph 4 5 1 2 Remove the carriage drive cables 3 Remove screws 107 securing cable clamps 109 to right endplate 4 Remove four screws 63 securing the electronic chassis and pull the electronic chassis out far enough to access the motor connector 27 Disconnect the motor connector 27 from the controller board 21 5 Remove the two screws 105 which attach the carriage motor 123 to the en...

Страница 71: ...ables see Paragraph 4 5 18 2 Remove defective spool by loosening the set screw and slipping spool 1 from the motor shaft 3 Install new drive spool Refer to Paragraph 4 5 2 1 step 6 4 Replace carriage drive cables see Paragraph 4 5 18 to complete the installation 4 5 24 Printhead Removal and Replacement Figure 4 12 1 Remove top cover see Paragraph 4 5 1 2 Set the printhead adjustment lever 167 in t...

Страница 72: ...preparations and finish and in material characteristics The rails are hardened precision ground and hard chrome plated to provide a suitable bearing surface for the sleeve bearings which ride on them If the shaft surface becomes dented scratched or matted it will drastically reduce the life of the carriage bearings Additionally if the steel becomes exposed due to damage to the rail corrosion could...

Страница 73: ... the printhead adjustment lever 167 in the center detent position 11 Position the alignment notch on the eccentric clamp 101 in the straight up position 12 Secure eccentric clamp 101 with Phillips screw 97 and two set screws The printhead adjustment lever 167 should move easily with no binding Check the printhead to platen gap with the printhead adjustment lever 167 in the first detent position Th...

Страница 74: ...Figure 4 12 Carriage Removal 4 27 ...

Страница 75: ...O ring 165 onto the bearing Otherwise continue with the original bearing and O ring 9 Install the replacement shaft 121 by reversing steps 1 through 4 above 4 5 27 Carriage Removal and Replacement Figure 4 12 1 Remove top cover see Paragraph 4 5 1 2 Remove ribbon advance cables see Paragraph 4 5 15 3 Remove ribbon advance mechanism see Paragraph 4 5 23 4 Remove carriage drive cables see Paragraph ...

Страница 76: ...lt tension as shown in Figure 4 13 Tighten motor hardware securely 9 Check the belt for proper tracking It may be necessary to loosen one or both pulleys and align them so that the belt tracks parallel to the endplate Tighten the set screws in both pulleys securely 4 5 29 Drive Belt Removal and Replacement Figure 4 14 If the paper advance drive belt becomes cut or otherwise damaged or signs of fat...

Страница 77: ...t endplate 82 while restraining the endplate with the remaining hand The shaft 188 should push the bearing 91 out of the endplate 82 Carefully slide the drive shaft 188 to the right until it is free of both tractors and the right endplate 82 4 Remove the bearing 91 from the old drive shaft 188 Note that these bearings are sintered bronze and are relatively soft Hard tools may distort the bearings ...

Страница 78: ...crew 86 as this will deform the retainer 83 and possibly misalign the bearing 91 5 Reassemble the drive shaft 188 to the printer mechanism as detailed in Paragraph 4 5 29 4 5 32 Idler Shaft Removal and Replacement Figure 4 14 1 Remove top cover see Paragraph 4 5 1 2 Release the clutch handles on both the right and left tractors 191 181 The clutch is released when the handle is in the UP position a...

Страница 79: ...6 The idler shaft 187 may now be slipped from the tractors and set aside 7 To install the replacement shaft reverse steps 1 through 5 above Be sure to install new push on retainers 80 in step 2 4 32 ...

Страница 80: ...Figure 4 14 Paper Drive Idler Shaft 4 33 ...

Страница 81: ...base 8 Remove four hex screws 92 securing the platen 185 to the endplate 82 CAUTION After removing four platen screws support the platen at all times to prevent the platen from dropping 9 Hold rear of endplates 144 82 and flex them outwardly enough to platen 185 to be moved 10 Remove the platen 185 by moving it slightly down then out toward of the frame 11 Replace in reverse order NOTE Do not tigh...

Страница 82: ...on until a gap of 0 012 0 001 exists between the tips of the printwires and the platen surface This measurement should be made from above the printhead with a flat feeler gage Edges of the gage should be deburred to avoid scratching the platen 4 Move the carriage to the extreme right margin and again adjust the platen position for a 0 012 0 001 printhead to platen gap 5 Repeat steps 3 and 4 until ...

Страница 83: ...ssis see Paragraph 4 5 4 3 Remove three screws 184 securing lower paper guide 190 to platen 185 4 Remove four screws 15 16 17 securing printer mechanism to bottom cover 2 and lift rear of printer mechanism enough to remove lower paper guide 190 5 Replace in reverse order 6 Once installation is complete the lower paper guide must be aligned with the platen as shown in Figure 4 17 4 36 ...

Страница 84: ...Figure 4 16 Lower Paper Guide 4 37 ...

Страница 85: ...Figure 4 17 Lower Paper Guide Platen Alignment 4 38 ...

Страница 86: ...4 39 ...

Страница 87: ...4 40 ...

Страница 88: ...4 41 ...

Страница 89: ...4 42 ...

Страница 90: ...4 43 ...

Страница 91: ...4 44 ...

Страница 92: ...4 45 ...

Страница 93: ...4 45 ...

Страница 94: ...Figure 4 18 Illustrated Parts Breakdown 4 46 ...

Страница 95: ...4 47 ...

Страница 96: ...4 48 ...

Страница 97: ...4 49 ...

Страница 98: ...4 50 ...

Страница 99: ...4 51 ...

Страница 100: ...4 52 ...

Страница 101: ...4 53 ...

Страница 102: ...4 54 ...

Страница 103: ...4 55 ...

Страница 104: ...Figure 4 19 Illustrated Parts Breakdown DD 4 56 ...

Страница 105: ...APPENDIX A This section provides updated schematics for the Main Controller Board Figure A 1 Part No 105766 Sheets 1 8 PC Board 105767 ...

Страница 106: ......

Страница 107: ...A 1 ...

Страница 108: ...A 2 ...

Страница 109: ...A 3 ...

Страница 110: ...A 4 ...

Страница 111: ...A 5 ...

Страница 112: ...A 6 ...

Страница 113: ...A 7 ...

Страница 114: ...A 8 ...

Страница 115: ...Figure A 2 Controller Board Assembly Part No 105768 Sheet 1 and 2 PC Board 105767 ...

Страница 116: ...A 9 ...

Страница 117: ...A 10 ...

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