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Principles of Operation

Engine Controller

The engine controller (EC) consists of four main elements:

♦

80C166 Microcontroller

♦

128KB 5.0V-only FLASH program memory, organized as 64K x 16 bits.
This memory is not expandable.

♦

MECA (Mechanism Engine Control ASIC)

♦

Analog drive circuitry

80C166 Microprocessor

The Siemens SAB 80C166 is a high-integration microcontroller. It has many
features that suit it extremely well to real-time control applications. This
controller and the MECA ASIC provide the functionality of three separate
processors used in earlier controller board architectures. In this manual, the
80C166 is referred to as either the EC or the 166.

The 166 used on the CMX board runs at 20MHz and is housed in a 100-pin
metric rectangular flat pack.

Bus Configuration The 166 bus is configured for 18-bit address, 16-bit data,
non-multiplexed and segmented operation. The flash memory runs with zero
wait states. An external PAL is used for address decoding.

Power Reduction The 166 chip has two power reduction modes: idle and
Energy Star. Idle mode is not used. In Energy Star mode, +48V and all
motors are de-energized, but the 166 operates as normal.

EC Flash Memory The EC stores all boot code, program code, and tables in
its own local flash memory. This flash is organized as 64K x16 bits and uses
the same technology as the DC flash: it is + 5.0V-only and is rated for a
minimum of 100,000 write/erase cycles. EC memory is fixed; it is soldered to
the controller board. Its contents can be updated through the DC (through the
serial or parallel ports). At run time, the EC also stores tables in shared
DRAM, which is accessed through the Cajun bus.

MECA ASIC The 166 uses numerous counters, PWM generators, and FIFOs
in the MECA to control many printer motor functions. The MECA is a custom
gate array, specifically designed to drive this system.

Analog Drive Circuitry

The analog drive functions convert 48 and 8.5 volts into the power used to
drive the motors and hammers in the printer. Sensors are used to monitor the
operation and status of critical components within the printer.

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Содержание 6400 Series

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

Страница 2: ......

Страница 3: ...S246 0117 06...

Страница 4: ...publications should be made to your IBM representative or to the IBM branch office serving your locality Publications are not stocked at the address given below IBM welcomes your comments about this p...

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

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

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

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

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

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

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

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

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

Страница 14: ...destal 28 Hammers 40 MHz 6400 008 800 lpm Cabinet 49 Hammers 25 MHz 6400 08P 800 lpm Pedestal 49 Hammers 25 MHz 6400 009 900 lpm Cabinet 49 Hammers 25 MHz 6400 09P 900 lpm Pedestal 49 Hammers 25 MHz 6...

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

Страница 16: ...ly aligned Use only the ribbons specified in Appendix B Use of incorrect ribbons can lead to ink migration problems degraded print quality and expensive damage to the printer Do not close the forms th...

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

Страница 18: ...Notices Form No G544 5389 This maintenance manual does not explain how to operate or configure the printer For that information refer to the Operator s Guide and Setup Guide IBM 6400 Line Matrix Prin...

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

Страница 20: ...orm Sets TOF and moves paper downward from the tractor alignment notches to the print position Line Feed Moves paper up one line as determined by current line spacing View Press to move the current pr...

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

Страница 22: ...F and moves paper downward from the tractor alignment notches to the print position Line Feed Moves paper up one line as determined by current line spacing View Press to move the current print positio...

Страница 23: ...On Ready Power Cancel Processing Start Stop Form Feed Set Top Of Form Line Feed Enter Return Scroll Menu View Attention Scroll Micro Micro Printer Con figuration Eject Restore LCD Figure 3 Electrical...

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

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

Страница 26: ...ng IBM 20 117397 DIP Module Extracting Tool 9900764 Nut Driver 1 4 inch Nut Driver 5 16 inch Open End Wrench 7 32 inch 1650843 Open End Wrench 5 16 inch 9900005 PLCC Module Pick Extraction Tool 73G552...

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

Страница 28: ...28 Installation...

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

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

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

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

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

Страница 34: ...34 Preventive Maintenance...

Страница 35: ...matrix See Figure 8 The ink dots are made by a row of small hammers mounted on a shuttle that sweeps rapidly back and forth Printer logic circuits divide every line of incoming data into horizontal do...

Страница 36: ...ample in the data processing DP font at a line spacing of six lines per inch lpi a dot matrix contains 12 dot rows from the top of one character line to the top of the next See Figure 8 and Figure 9 A...

Страница 37: ...4 5 1 2 3 4 1 2 1 7 6 5 3 4 2 1 1 2 3 NOTE Even column dot centers within the printed character area and character space hammer positions are not illustrated in this diagram Hammer Not Released No Do...

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

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

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

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

Страница 42: ...and prolong ribbon life The ribbon motors operate only when the shuttle assembly is moving Ribbon motion reverses when a metal strip at either end of the ribbon crosses the left or right ribbon guide...

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

Страница 44: ...nformation to the controller board and displays information from the controller on the LCD A status indicator next to the LCD also conveys printer status information to the user The LCD status indicat...

Страница 45: ...tional units the Data Controller DC and the Engine Controller EC The DC is responsible for Host I O Operator I O Security Interface Print Image Generation Overall High Level Logical Control The EC is...

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

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

Страница 48: ...Operator Panel Interface Dot Plucking and Adjacent Dot Checking Cajun Bus Interface Host I O and Diagnostic Port Memory Access Controller All 030 addresses go through the VX ASIC The VX handles all ad...

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

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

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

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

Страница 53: ...ics emulation and the IGP programming language a Printronix IGP emulation are options that install in flash memory on the CMX controller board These programming languages simplify the job of creating...

Страница 54: ...54 Principles of Operation...

Страница 55: ...oting Aids Troubleshooting is faster and more effective if you understand the equipment and make use of all available tools This manual provides a number of troubleshooting aids to help you isolate pr...

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

Страница 57: ...ce the alarm A message describing the fault condition appears on the LCD Certain Unit Check conditions see below are automatically recorded in the error log The error log is a buffer in NVRAM that sto...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 99: ...huttle frame assembly 5 Power on the printer Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board 123 PAPER BUSY TO...

Страница 100: ...DERFLOW SEE USER S GUIDE 1 Paper First In First Out Underflow Cycle power Run the print job again If the message appears download the emulation software again 2 Run the print job again If the message...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 128: ...h that requires adjustment replace it 4 Power on the printer Operate the power stacker Refer to the Operator s Guide While the stacker is operating check that a all motors are operating b the paddles...

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

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

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

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

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

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

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

Страница 136: ...next page This test is useful for identifying paper motion or paper feed problems Hammer bank cover Power supply board Paper motion sensor or cable Paper feed belt or motor Splined shaft bearings Tra...

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

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

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

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

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

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

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

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

Страница 145: ...r is using a parallel interface the letter p before a hex code indicates an active Paper Instruction PI line and a blank space before a hex code indicates an inactive PI line To convert an ASCII chara...

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

Страница 147: ...2A 53 43 2B 54 44 2C 55 45 2D 56 46 2E 57 47 2F 0 1 2 3 4 5 6 7 8 9 60 48 30 61 49 31 62 50 32 63 51 33 64 52 34 65 53 35 66 54 36 67 55 37 70 56 38 71 57 39 72 58 3A 73 59 3B 74 60 3C 75 61 3D 76 62...

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

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

Страница 150: ...ate to do a soft reset 1 Press the Stop key to put the printer in the NOT READY state 2 Press the Stop Enter keys The LCD displays STANDBY SOFT RESET while the printer loads the power up configuration...

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

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

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

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

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

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

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

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

Страница 159: ...data cable to the printer interface 2 Install the ribbon 3 Load paper 4 Plug the AC power cord into the power source 5 Close the cabinet doors 6 Power on the printer 7 Set the top of form Refer to the...

Страница 160: ...e 5 Loosen do not remove the motor mount bolts 2 6 Using the straight end of a force gauge apply 15 pounds 66 7 N of pressure to the paper feed drive motor 3 near the mounting base of the motor Use th...

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

Страница 162: ...TENTION Too much tension on the platen open belt can cause the platen gap to change which can lead to premature wear of the platen damaged hammer tips and poor print quality 6 Using a force gauge appl...

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

Страница 164: ...ey collar 3 5 Align the paper drive motor pulley 4 with the splined shaft pulley 5 ATTENTION Make sure there is at least 0 040 inches 1 016 mm of clearance between the collar 3 and the motor face plat...

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

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

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

Страница 168: ...check the other side Adjustment sensitivity is approximately 0 03 inch per revolution of the set screw Also insert the feeler gauge no more than 2 inches down from the top of the ribbon mask 6 Gently...

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

Страница 170: ...tabs from the slots in the side plate 4 Loosen the 1 16 inch set screw 2 in the motor pulley 5 Bottom out the platen open motor pulley 3 on the motor shaft and torque the 1 16 inch set screw 2 to 9 2...

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

Страница 172: ...he ribbon 2 passes around and across the ribbon guide It should be centered and not folding against either of the two white nylon washers 3 6 If the ribbon is not centered loosen the retaining screws...

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

Страница 174: ...t 1 Open the printer cover 2 Loosen the screw 1 securing the adjusting link 2 3 Adjust the link 2 by raising or lowering the horizontal adjustment knob 3 to obtain print parallel with paper perforatio...

Страница 175: ...e End of Forms distance with 6 part paper in order to verify correct printing with multi part forms The procedure below describes how to run the END OF FORMS ADJUST printer test and modify the END OF...

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

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

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

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

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

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

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

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

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

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

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

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

Страница 188: ...NOT READY state to do this procedure 4 Press Scroll Scroll Return Enter Press all four keys at the same time SERVICE PRINTER MECHANISM TESTS appears on the display 5 Press Scroll Scroll to unlock the...

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

Страница 190: ...190 Adjustment Procedures...

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

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

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

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

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

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

Страница 197: ...e platen open pulley Installation 1 Slide the platen open timing belt over the platen open pulley and the motor pulley and tighten the 1 16 inch setscrew 2 Slide the motor pulley onto the platen open...

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

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

Страница 200: ...ee page 275 Figure 45 5 Loosen but do not remove the screws securing the controller shield near serial cable connector J201 6 Loosen but do not remove the screw securing the controller shield to the b...

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

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

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

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

Страница 205: ...moval ATTENTION To prevent electrostatic damage to electronic components wear a properly grounded static wrist strap when handling circuit boards the shuttle frame assembly and any other electronic co...

Страница 206: ...nk magnets See Figure 31 page 208 4 Later models a Using a Torx T 10 driver remove the six screws and three ribbon mask clamp plates securing the ribbon mask to the hammer bank cover Remove the ribbon...

Страница 207: ...r models a Position the hammer bank cover on the allignment pins on the hammer bank Make sure the hammer bank cover is properly positioned over the alignment pins and hammer tips and lies flat on the...

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

Страница 209: ...he edges of the shuttle cover assembly tilt up the rear edge and lift the shuttle cover assembly out of the printer Installation 1 Place the shuttle cover assembly in the printer Tilt the forward edge...

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

Страница 211: ...rear of the cabinet Remove the hinge plates and the pads beneath the plates 7 Install pads and hinge pin plates to the right front side of the frame with the hinge pins up and toward the outside edge...

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

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

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

Страница 215: ...Remove the fan cable connector from the cutout in the side of the air exhaust duct 7 Remove the two fan mounting screws and the cabinet exhaust fan assembly Installation ATTENTION Make sure to install...

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

Страница 217: ...etween the base casting and the base pan See Figure 50 page 285 Installation ATTENTION Make sure to install the fan so the label faces up Air flow is UP NOTE The hammer bank fan assembly is installed...

Страница 218: ...ere is visible damage or broken parts can be seen in the assembly 5 Remove the mounting screws from the old hammer spring assembly See Figure 32 page 219 6 Handling the hammer spring assembly by the m...

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

Страница 220: ...rews from the box 3 Handling the hammer spring assembly by the mounting base only carefully position the new hammer spring assembly onto the hammer bank mounting pins and press it into position with t...

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

Страница 222: ...e 210 3 Loosen but do not remove the two screws securing the coax twinax I O plate to the rear of the card cage Loosen the thumbscrew on the CT board until the screw is released from the standoff on t...

Страница 223: ...st the gap between the MPU assembly and the flywheel to 0 010 001 inch 0 254 0 025 mm Torque the MPU clamp screw to 19 1 inch pounds 2 15 0 11 N m 3 Check the gap between the MPU assembly and the flyw...

Страница 224: ...onents wear a properly grounded static wrist strap when handling circuit boards the shuttle frame assembly and any other electronic component NOTE If flash SIMMs are removed from one controller board...

Страница 225: ...odule into the correct socket on the CMX controller board a Position the SIMM so the notched end is toward the right hand side of board See Figure 34 page 226 b Press the SIMM into the socket with the...

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

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

Страница 228: ...Hold the collar snug against the motor pulley and torque the setscrew to 25 2 inch pounds 2 82 0 23 N m 6 Using the straight end of a force gauge apply 12 pounds 53 4 N of pressure to the paper feed...

Страница 229: ...screws page 285 Figure 50 6 Loosen the 1 16 hex pulley setscrew and remove the motor pulley and platen open belt 7 Trace the platen open motor cables back to the controller board releasing the cables...

Страница 230: ...ble routing diagram on page 306 6 Close the forms thickness lever all the way ATTENTION Too much tension on the platen open belt can cause the platen gap to change which can lead to premature wear of...

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

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

Страница 233: ...cutouts 5 Lift the operator panel assembly and disconnect the phone style cable connector Installation 1 Connect the phone style operator panel cable to the bottom of the operator panel See Figure 41...

Страница 234: ...of the panel and slide the operator panel downward on the mounting plate until the tabs on the panel housing slide out of the cutouts Installation 1 Tilt the operator panel mounting plate toward the...

Страница 235: ...e assembly to the left and lift it off the card cage Installation 1 Position the paper guide assembly offset slightly to the left on the card cage with the keyway cutouts over the three loosened hold...

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

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

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

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

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

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

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

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

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

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

Страница 246: ...ground clip page 281 Figure 48 6 With grip ring pliers remove the grip ring from left side of the splined shaft 7 Pull the bearing and spring link with the spring off the left side of the splined sha...

Страница 247: ...o the left side of the splined shaft with the white nylon bushing flange to the outside of the printer 6 Attach the spring to the left side plate and the spring link 7 Install the grip ring on the spl...

Страница 248: ...onsisting of the support shaft two curved washers bushing horizontal adjustment knob washer and screw to the left out of the tractors and the left side plate Installation 1 Slide the support shaft ass...

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 262: ...Order No Description Notes 1 57G7176 Stacker 2 30H3981 Runner Stacker 3 04H4779 Riser Stacker Runner 4 Ref Screw 4 5 14H5296 Spares Kit Grommet 6 14H5272 Chain Assembly Kit Kit contains eight chains 7...

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

Страница 264: ...Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay English Spanish French Italian German Dutch Brazilian Portuguese 3 Ref Screw Hex w L...

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

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

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

Страница 268: ...6 32x 25 4 Ref Barrier Shield 5 14H5271 Paper Guide Assembly Models 004 005 008 009 012 014 6 Ref Screw w Lock Washer 3 6 32x 25 and 6 Flat Washer 7 14H5174 Platen Paper Feed Cover Kit Paper feed belt...

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

Страница 270: ...06 3 Ref Screw Thread Forming 4 6 32x 25 4 Ref Barrier Shield 5 63H5116 Paper Path Assembly Models 04P 05P 08P 09P 6 08H7954 Anti Static Brush Kit 7 Ref Power Supply Shield Taped to card cage along up...

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

Страница 272: ...Item No Part No Order No Description Notes 1 Ref Nut 6 32 1 Upper right fan corner only 2 57G1440 Card Cage Fan Assembly Air flow is into card cage 3 Ref Fan Guard 4 Ref Screw w Lock Washer 4 6 32x 1...

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

Страница 274: ...odels 009 09P 014 4 Ref P101 Cable Connector 5 Ref Cable Assy AC In Power Supply Part of Field Kit AC Assy 14H5289 6 14H5643 24H8647 90H3271 Controller Board CMX V5 0 Controller Board CMX V5 5 25 MHz...

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

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

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

Страница 278: ...ement Procedures and Illustrated Parts List Item No Part No Order No Description Notes 1 57G1476 Magnetic Pickup Assy MPU 2 Ref Screw Socket Cap 6 32x 38 3 30H3985 Extension Spring 4 14H5329 Cable Ass...

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

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

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

Страница 282: ...f Screw Socket Cap 6 32x 75 Part of item 15 13 Ref Washer Part of item 15 14 Ref Nut Part of item 15 15 63H7478 Platen Lever Kit 16 Ref Spring Extension 1 12L Part of item 25 17 Ref Link Spring Part o...

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

Страница 284: ...57G1509 and includes collar setscrew 6 32x 25 7 Ref Collar Part of item 9 8 Ref Screw Socket Head 6 32x 51 9 57G1421 Motor Pulley Paper Feed 10 Ref Screw Hex w Lock Washer 2 10 32x 50 11 24H8894 Ribbo...

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

Страница 286: ...Part No Order No Description Notes 1 14H5571 Circuit Breaker 2 Ref IEC 320 AC Power Connector Connector J301 3 Ref Chassis Ground Stud 4 Ref Connector P1 To power supply board connector J1 AC 5 Ref Ca...

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

Страница 288: ...No Order No Description Notes 1 Ref Screw 2 2 Ref Card Cage 3 24H9011 IBM Coax Twinax Expansion 4 Ref Screw Captive 5 Ref Standoff Hex 3 16 inch M F 813 Lg 6 24H8535 Adapter Expansion Connector 60 pi...

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

Страница 290: ...on Notes 1 Ref Screw Connector Cover 2 2 Ref Cover Plate Centronics 3 Ref Ferrite Clamp See also Appendix I 4 Ref CMX Controller Board 5 14H5287 Centronics I O Cable Assembly 6 24H8995 Ethernet LAN PC...

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

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

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

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

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

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

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

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

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

Страница 300: ...19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 4 7K 0 1W 4 7K 0 1W NC EXP N ID SEL 12 10 V NC N DMA REQ0 N DMA REQ1 NC E...

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

Страница 302: ...FAST ON TERMINAL Line Filter Area PIN 1 1 2 3 4 5 6 7 8 N TEMP HI 9 10 11 12 P101 Controller Board N STBY 470 mF 10 50V VCC 470 mF 10 50V 470 mF 10 50V 470 mF 10 50V 8 5V 48V N TEMP HI N STBY 5V 5V 5...

Страница 303: ...REQ1 NC EXP NINT EXP NWR EXP NRESET EXP NACK EXP NMSEL EXPNDSEL EXP D15 EXP D14 EXP D13 EXP D12 EXP D11 EXP D10 EXP D9 EXP D8 EXP D7 EXP D6 EXP D5 EXP D4 EXP D3 EXP D2 EXP D1 EXP D0 EXP A15 EXP A14 E...

Страница 304: ...D PHA 1 PD PHB 1 PD PHA 2 PD PHB 2 PI PHA 1 PI PHA 2 PI PHB 1 PI PHB 2 IR LED A 1 2 3 4 5 6 7 8 9 10 J7 Stacker VCC 100 PF 10 50V 1K 0 1W 100 PF 10 50V 100 PF 10 50V 100 PF 10 50V 100 PF 10 50V Logic...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 324: ...28 29 30 31 32 33 34 PMD A M1 A1 M1 A2 M1 B1 M1 B2 M2 A1 M2 A2 M2 B1 M2 B2 LD1 A LD1 K DT1 C DT1 E LD2 A LD2 K DT2 C DT2 E PMD K PMD C PMD E PID C PID E PID K PID A PI PHA 1 PI PHA 2 PI PHB 1 PI PHB 2...

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

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

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

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

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

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

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

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

Страница 333: ...uch as data and word processing Average yield 20 million DP characters IBM General Purpose Ribbon P N 1040995 Average yield 30 million DP characters IBM High Contrast Ribbon P N 1040993 Used for gener...

Страница 334: ...24 inches 5 08 to 60 96 cm long Single part 15 pound 57 g m2 to 100 pound 377 g m2 stock Multi part carbon 1 to 6 part forms maximum 12 pound 45 g m2 ply of upper plies Multi part carbonless Verify re...

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

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

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

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

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

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

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

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

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

Страница 344: ...344 Printer Specifications...

Страница 345: ...nch 25 4 millimeter meter 3 280840 foot centimeter 0 03280840 foot millimeter 0 003280840 foot meter 39 37008 inch centimeter 0 3937008 inch millimeter 0 03937008 inch Figure is exact Torque and Force...

Страница 346: ...ounce avoirdupois Temperature From To Use Formula temperature Celsius tc temperature Fahrenheit tf tf 1 8tc 32 temperature Fahrenheit tf temperature Celsius tc tc tf 32 1 8 Power Multiply By To Obtain...

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

Страница 348: ...348 Torque Table...

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

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

Страница 351: ...sed g Close the top cover Make sure the operator panel is centered in the opening of the cover 2 On cabinet models inspect the front and rear cabinet doors a Make sure the seals and magnetic strips ar...

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

Страница 353: ...Feed Motor Platen Open Switch Right Ribbon Guide Right Ribbon Motor Platen Motor Paper Motion Detector Paper Out Detector Left Ribbon Motor J106 MSL P106 MSL Card Cage Fan Left Ribbon Guide Hammer Ba...

Страница 354: ...2 Low voltage 3 Neutral to ground short 4 Ground path impedance 5 Neutral impedance NOTE The customer is responsible for correcting problems with the power source Inform the IBM Installation Planning...

Страница 355: ...e automatically to either the READY or NOT READY mode depending on which power on state was selected when the printer was configured 6 Power off the printer Verify that the LCD goes completely blank a...

Страница 356: ...356 Safety Inspection Guide...

Страница 357: ...icrosecond 10 6 second A0 A1 etc Address 0 Address 1 etc AC Alternating Current ACC Access ACK Acknowledge AMP Amplitude Ampere AMPL Amplitude AN Anode ASIC Application Specific Integrated Circuit ATT...

Страница 358: ...oard CNC Connector Connection CPI Characters Per Inch CR Carriage Return CT Coaxial Twinaxial CTL Control CTS Clear to Send CUR Current CVO Cover Open Switch D0 D1 etc Data Bit 0 Data Bit 1 etc DAT Da...

Страница 359: ...mable Read Only Memory ERR Error ESD Electrostatic Discharge EX Exhaust Extra EXH Exhaust EXF Exhaust Fan EXP Expansion EXPND Expand FD Feed FF Form Feed FIFO First In First Out FLT Fault FLTR Filter...

Страница 360: ...nch LPM Lines Per Minute LRIB Left Ribbon LRP Left Ribbon Guide M1 Rear Paddle Motor Power Stacker M2 Front Paddle Motor Power Stacker M Motor MAIN Maintenance Jack RS 232 Optional MECA Mechanism Engi...

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

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

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

Страница 364: ...364 Abbreviations and Signal Mnemonics...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 393: ...next step do not over tighten the tie wraps or string Tighten the tie wraps or string just enough to hold the elevator up 2 Raise the elevator assembly to its highest position and secure it to the ve...

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

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

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

Страница 397: ...Setscrew Pulley Setscrew Figure 78 Removing the Timing Belt Motor Pulley 6 Remove the shoulder screw washers and spacer that secures the constant force spring to the vertical rail See Figure 79 Space...

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

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

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

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

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

Страница 403: ...art of item 36 46 Ref Cap Nut Part of item 36 47 24H9005 Shaft Drive Roller 48 24H9006 Spacer Drive Roller 49 Ref Bearing Flanged Part of item 36 50 Ref Bearing Part of item 36 51 24H9003 Collar Clamp...

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

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

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

Страница 407: ...Power Stacker Item No Part No Order No Description Notes 36 24H9004 Stacker Hardware Kit Kit not illustrated 95 Ref Clip On Bearing Part of item 36 96 24H8999 Holder LED Round 100 24H8989 LED IR T 1...

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

Страница 409: ...Stacker Item No Part No Order No Description Notes 36 24H9004 Stacker Hardware Kit Kit not illustrated 95 Ref Clip On Bearing Part of item 36 97 24H9000 Holder LED Flat 105 24H8990 Photodarlington NPN...

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

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

Страница 412: ...412 Power Stacker...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 427: ......

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

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