IBM 6400 Line Matrix Printer Service Manual

6400 Line Matrix Printers
Maintenance Information Manual

Cabinet and Pedestal Models
Form Number S246011704 Copyright IBM Corp., 1995, 1997
6400 Line Matrix Printers Maintenance Information Manual Cabinet and Pedestal Models
S246011704
Preliminary 2
Note! Before using the information and the product it works with, make sure you read the general information under Notices on page vi.
Sixth Edition (August 1997) This edition applies to the 6400 Line Matrix Printer. The following paragraph does not apply to any other country where such provisions are inconsistent with local law: INTERNATIONAL BUSINESS MACHINES CORPORATION PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions; therefore, this statement may not apply to you. Requests for IBM 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 publication. You may send your comments by facsimile to 18005241519, by E-mail to print_pubs@vnet.ibm.com, or by mail to: IBM Printing Systems Company Information Development Department H7FE, Building 003G P.O. Box 1900 Boulder, CO 803019191, U.S.A. When you send information to IBM or IBM Printing Systems Company, you grant a nonexclusive right to use or distribute the information in any way IBM or IBM Printing Systems Company believes appropriate without incurring any obligation to you. E Copyright International Business Machines Corporation 1995, 1997. All rights reserved. Note to U.S. Government UsersDocumentation related to restricted rightsUse, duplication or disclosure is subject to restrictions set forth in GSA ADP Schedule Contract with IBM Corp.
Table of Contents
Maintenance Overview
About the Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Important Maintenance Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Notes and Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Printing Conventions in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Electrical Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Mechanical Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Tools, Test Equipment, and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Installation
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Preventive Maintenance
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Cleaning the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Cleaning the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Cleaning the Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Cleaning the Shuttle Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Cleaning the Card Cage Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Principles of Operation
Line Matrix Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Printing Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Shuttle Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Paper Transport System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Ribbon Transport System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Logical Control of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410 CMX Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411 Data Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 Engine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415 Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418 Printer Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
Troubleshooting
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Troubleshooting Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Symptoms Not Indicated by Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539 Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540 Printer Confidence Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544 Operator Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545 Selecting and Running Operator Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . 547 Customer Engineer (CE) Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548 Selecting and Running Customer Engineer Tests . . . . . . . . . . . . . . . . . . . . 550 Boot Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551 Hex Code Printout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554 Printer Information Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557 Displaying Printer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558 Soft vs. Hard Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559
Adjustment Procedures
Preparing the Printer for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Returning the Printer to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Belt, Paper Feed Timing, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Belt, Platen Open, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Paper Drive Motor Pulley Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Paper Scale Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610 Platen Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612 Platen Open Motor Pulley Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614 Ribbon Guide Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
ii
Splined Shaft Skew Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618 Adjusting the End of Forms Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620 Hammer Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624 Loading Flash Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626 Coil Temperature Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632 Set Shuttle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633
Replacement Procedures and Illustrated Parts List

Organization of This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Section I: Replacement Procedures Preparing the Printer for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Belt, Paper Feed Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Belt, Platen Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Cable Connectors and Connector Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Circuit Board: Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711 Circuit Board: Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713 Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714 Coax/Twinax Multi-Platform Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715 Cover Assembly, Hammer Bank / Ribbon Mask . . . . . . . . . . . . . . . . . . . . . . . . . 716 Cover Assembly, Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 717 Cover Assembly, Top, Pedestal Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718 Doors, Cabinet, Reversal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719 Fan Assembly, Cabinet Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720 Fan Assembly, Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721 Fan Assembly, Hammer Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722 Hammer Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723 IBM Coax/Twinax Expansion Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727 Magnetic Pick-up (MPU) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 728 Memory Modules and Security PAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729 Motor Assembly, Paper Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 732 Motor Assembly, Platen Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734 Motor Assembly, Ribbon Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 736 Network Print Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 737 Operator Panel Assembly, Cabinet Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 738 Operator Panel Assembly, Pedestal Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 739 Paper Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 740
iii
Paper Ironer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 741 Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 742 Resistors, Terminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 747 Ribbon Guide Assembly (L/R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 749 Ribbon Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 Security Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729 Shaft, Splined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 751 Shaft, Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 753 Shuttle Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754 Spring Assembly, Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 756 Spring, Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 757 Switch Assembly, Cover Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 758 Switch Assembly, Paper Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 759 Switch Assembly, Platen Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 761 Tractor (L/R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 762 Section II: Illustrated Parts List Figure 79. Top Cover, Doors, and Casters, Cabinet Model . . . . . . . . . . . . . . . 765 Figure 710. Paper Stacker and Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 767 Figure 711. Control Panel and Cabinet Details . . . . . . . . . . . . . . . . . . . . . . . . . 769 Figure 712. Pedestal Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 771 Figure 713. Inside Covers, Cabinet Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 773 Figure 714. Inside Covers and Card Cage, Pedestal Models . . . . . . . . . . . . . 775 Figure 714a. Card Cage Detail, Pedestal Models . . . . . . . . . . . . . . . . . . . . . . . 777 Figure 715. Print Mechanisms and Circuit Boards . . . . . . . . . . . . . . . . . . . . . . 779 Figure 716. Magnetic Pickup Unit (MPU) and Extension Spring . . . . . . . . . . 781 Figure 717. Tractor Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 783 Figure 718. Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 785 Figure 719. Motors, Card Cage Fan, and Paper Detector Switch . . . . . . . . . 787 Figure 720. Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 789 Figure 721. IBM Coax/Twinax Expansion Board . . . . . . . . . . . . . . . . . . . . . . . . 791
iv
Appendices A B C D E F G H I Wire Data Printer Specifications Metric Conversion Tables Torque Table Safety Inspection Guide Abbreviations and Signal Mnemonics Power Cords Part Numbers Noise Suppression Devices
Index
ENERGY STAR
The EPA ENERGY STAR** Computers program is a partnership effort with manufacturers of data processing equipment to promote the introduction of energy-efficient personal computers, monitors, and printers, and to reduce air pollution caused by power generation. IBM participates in this program by introducing printers that reduce power consumption when they are not being used. This feature can cut energy use by up to 50 percent. Note: The ENERGY STAR emblem does not represent EPA endorsement of any product or service.
Notices
References in this publication to IBM products, programs, or services do not imply that IBM intends to make these available in all countries in which IBM operates. Any reference to an IBM licensed product, program, or service is not intended to state or imply that only IBMs product, program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any of IBMs intellectual property rights may be used instead of the IBM product. Evaluation and verification of operation in conjunction with other products, except those expressly designated by IBM, is the users responsibility. Any performance data contained in this document was obtained in a controlled environment based on the use of specific data. The results that may be obtained in other operating environments may vary significantly. Users of this document should verify the applicable data in their specific environment. Therefore, such data does not constitute a performance guarantee or warranty. IBM may have patents or pending patent applications covering subject matter in this document. The furnishing of this document does not give you any license to these patents. You can send license inquiries, in writing, to the IBM Corporation, IBM Director of Licensing, 208 Harbor Drive, Stamford, Connecticut, United States, 06904.
Electrical Safety
This printer is inspected and listed by recognized national testing laboratories, such as Underwriters Laboratories, Inc. (UL) in the U.S.A. and Canadian Standards Association (CSA) in Canada. Listing of a product by a national testing laboratory indicates that the product is designed and manufactured in accordance with national requirements intended to minimize safety hazards. IBM equipment meets a very high standard of safety in design and manufacture. Remember, however, that this product operates under conditions of high electrical potentials and heat generation, both of which are functionally necessary.
vi
Trademarks and Service Marks

The following terms, denoted by an asterisk (*) in this publication, are trademarks of the IBM Corporation in the United States or other countries or both. IBM PC-DOS SCS Token-Ring The following terms, denoted by a double asterisk (**) in this publication, are trademarks of other companies: Acrobat Adobe Code V ECOS ENERGY STAR Epson Ethernet Fluke FX IGP MS-DOS Printronix Adobe Systems Incorporated Adobe Systems Incorporated Quality Micro Systems ECOS Electronics Corp., Inc., Oak Park, Ill. United States Environmental Protection Agency Epson Seiko Corporation Xerox Corporation John Fluke Manufacturing Co., Inc. Epson Seiko Corporation Printronix, Inc. Microsoft Corporation Printronix, Inc.
vii
Safety Notices
Danger, Caution, and Warning notices are numbered to help you find the translated versions in the IBM 6400 Line Matrix Printer Safety Notices booklet. DANGER <2> To prevent serious personal injury from electrical shock when connecting or disconnecting the signal cable, set the printer power switch to the off position and unplug the power cable.
DANGER <1> Always disconnect the AC power cord from the power source before performing any maintenance procedure. Failure to remove power could result in injury to persons or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure.
DANGER Always disconnect the AC power cord before cleaning the printer.
CAUTION To prevent injury from electric shock, wait at least one minute after shutting off power before removing the power supply circuit board. Wear a properly grounded static wrist strap when handling the power supply board. Handle the board by the sides. Do not touch components or flex the board during removal/installation.
CAUTION Over time, the upper edge of the paper ironer can become sharp. To avoid cutting yourself, handle the paper ironer on the sides.
CAUTION Hold the printer cover securely while disengaging the gas spring assembly.
viii
Chapter Contents
About the Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Important Maintenance Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Notes and Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Printing Conventions in This Manual . . . . . . . . . . . . . . . . . . . . . . . . 15 Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Electrical Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Mechanical Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . 112 Tools, Test Equipment, and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
11
Preliminary 2
About the Printers
The IBM* 6400 Line Matrix Printer family is summarized in Table 11. The 6400 Series consists of models that print 475, 500, 800, 900, 1200, and 1400 lines per minute (lpm). The 475, 500, 800, and 900 lpm models are available in either a floor cabinet or pedestal enclosure. The 1200 and 1400 lpm models are available only in a floor cabinet enclosure. The print speeds shown are maximum nominal speeds. Print speed is determined by the interaction of many variables. For more information, refer to the discussion of Printing Rates in Appendix B, page B9.
Table 11. The IBM 6400 Series Printer Family Model Number 6400004 640004P 6400005 640005P 6400008 640008P 6400009 640009P 6400012 6400014 Print Speed 475 lpm 475 lpm 500 lpm 500 lpm 800 lpm 800 lpm 900 lpm 900 lpm 1200 lpm 1400 lpm Enclosure Cabinet Pedestal Cabinet Pedestal Cabinet Pedestal Cabinet Pedestal Cabinet Cabinet
The model number indicates printer family, speed, and enclosure. (See Figure 11.)
Speed Rating: 004 = 475 lpm 005 = 500 lpm 008 = 800 lpm 009 = 900 lpm 012 = 1200 lpm 014 = 1400 lpm Enclosure Code*: P = Pedestal Model * No Code = Cabinet Model
6400 Printer Family
640004P
Figure 11. Interpreting the Printer Model Designation
12
The entire system architecture of the printer is contained on one circuit board, with memory requirements handled by DRAM and flash memory. This architecture permits rapid access to stored emulation software and enables the printer to print a wide variety of high-volume jobs with minimum maintenance and maximum reliability. The IBM 6400 is an excellent graphics printer, with optional features that simplify the creation of dot images. The IGP** and Code V** Printronix** emulations are simple but versatile graphics programming languages that load into flash memory. Although technologically advanced, the IBM 6400 printer is easy to use. The operator can select every printer function at the control panel or by sending printer control codes in the data stream from the host computer.
Important Maintenance Notes

To assure optimum performance, remember these important maintenance concepts when you service the printer: Do not adjust the platen gap unless the original shuttle frame assembly or platen has been replaced with a new or rebuilt unit. The hammer springs and hammer tips on the hammer bank are delicate and precisely aligned. Never bend or tweak hammer springs. Always handle hammer springs by the thick mounting base of the assembly. 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. Incorrect closure of the forms thickness lever can lead to smearing, degraded print quality, paper jams, and damage to the platen and shuttle assembly. Never close the forms thickness lever too tightly.
13
About This Manual

This is a field service maintenance manual for the IBM 6400 printer. This manual is designed so that you can quickly locate maintenance information.
How to Use This Manual

1. Locate the procedure or information you need: Use the Table of Contents at the front of the manual. Use the Chapter Contents listed at the front of each chapter. Use the Index at the back of the manual.
2. Read the entire procedure before you do it. 3. Gather the parts and tools you will need. 4. Make sure you understand all safety notices before you start a task. Notes and notices are defined below.
Notes and Notices

For your safety and to protect valuable equipment, it is very important that you read and comply with all information highlighted under notes and notices: DANGER A DANGER notice calls attention to a situation that is potentially lethal or extremely hazardous to people.
CAUTION A CAUTION notice calls attention to a situation that is extremely hazardous to people because of some existing condition.
WARNING A WARNING notice indicates the possibility of damage to a program, device, system, or data.
IMPORTANT An IMPORTANT notice draws your attention to information vital to proper operation of the printer.
14
NOTE: A note gives you helpful tips about printer operation and maintenance.
Printing Conventions in This Manual

Operator panel keys and indicators are printed bold. Example: Press the Cancel key, then press the Start key.
Liquid Crystal Display (LCD) messages are printed in capital letters inside quotation marks ( ). Example: Press the Stop key. NOT READY appears on the LCD.
Key combinations are denoted by the + (plus) symbol. Example: Press Scroll" + Scroll# means Press the Scroll" key and the Scroll# key at the same time.
15
Related Documents
This manual does not explain how to operate or configure the printer. For that information, refer to the Operators Guide and Setup Guide:
IBM 6400 Line Matrix Printer Safety Notices: Form No. G5445389 Provides a list of translated safety notices. IBM 6400 Line Matrix Printer Operators Guide Step-by-step, illustrated instructions on daily printer operation. This manual is available in a number of languages:
Brazilian Portuguese: Form No. S2170181 Dutch: Form No. S2460125 English: Form No. S2460115 French: Form No. SF110722 German: Form No. S2460137 Italian: Form No. S2460141 Japanese: Form No. S2460143 Spanish: Form No. S2460145
IBM 6400 Line Matrix Printer Setup Guide Explains how to install and configure the printer. This manual is available in a number of languages:
Brazilian Portuguese: Form No. S2170182 Dutch: Form No. S2460126 English: Form No. S2460116 French: Form No. SF110723 German: Form No. S2460138 Italian: Form No. S2460142 Japanese: Form No. S2460144 Spanish: Form No. S2460146
Coax/Twinax Multi-Platform Interface Option Installation and Operation Guide, Form Number S2460149
Information pertaining to printer control languages, emulations, and control codes is in the applicable Programmers Reference manual:
IBM 6400 ASCII Programmers Reference: Form No. S2460118 IBM 6400 CTA Programmers Reference: Form No. S2460147 IBM 6400 IPDS Programmers Reference: Form No. S2460148
Information pertaining to graphics programming is in the applicable Users Manual:
16
IBM 6400 Code V Users Manual: Form No. S2460150 Provides information used with the optional Code V Printronix emulation enhancement feature. The Code V Printronix emulation allows the user to create and store forms, generate logos, bar codes, and expanded characters, create other graphics, and merge graphics with alphanumeric data as a document is printed. IBM 6400 IGP Users Manual: Form No. S2460151 Provides information used with the optional IGP Printronix emulation enhancement feature. The IGP Printronix emulation allows the user to create and store forms, generate logos, bar codes, and expanded characters, create other graphics, and merge graphics with alphanumeric data as a document is printed.
Installation, configuration, and troubleshooting of the Network Print Server are covered in the following documents:
IBM Network Print Server Ethernet** Administrators Guide, Form No. S2460111 IBM Network Print Server Token-Ring* Administrators Guide, Form No. S2460112
The Network Print Server Technical Reference Manual is included on a diskette that comes with the Network Print Server. This softcopy document is in Adobe** Acrobat** Reader format.
17
Controls and Indicators

Electrical Controls and Indicators, Cabinet Models (Figure 12)
Key or Indicator
Power Indicator Ready Indicator Processing Indicator Attention Indicator Power Switch LCD Start Lit when the printer is on. Lit when the printer is in READY mode (on-line), no errors are pending, and the printer is ready to process data. Off when the printer is in NOT READY mode (off-line). Flashes when the printer is receiving data from the host. Flashes when an error occurs. After correcting the error, press Stop to turn off this LED. Applies power to the printer: (1 = on, 0 = off.) This switch is also a circuit breaker. The Liquid Crystal Display (LCD) displays printer status messages. Puts the printer in the READY (on-line) mode. This key also clears fault conditions, exits program mode menus, moves paper back to print position after View is pressed, and restores after an eject. Puts the printer in the NOT READY (off-line) mode. This key also silences the audible alarm, stops a Printer Test, and restores after an eject. Stop + Enter resets the printer. Advances paper to next Top-Of-Form, as defined by the current page length. Sets TOF and moves paper downward from the tractor alignment notches to the print position. Moves paper up one line, as determined by current line spacing. Press to move the current print position up to the tractor area for viewing. Press again to return paper to original print position. Cancels a print job. Moves paper for viewing or tear-off. This key is configurable: refer to the Operators Guide. If in the NOT READY mode, this key puts the printer in the PROGRAM mode. If the configuration menus are locked, the LCD indicates the operator panel is locked. Selects the option displayed on the LCD. This action either sets a value, moves to the next lower level of configuration, or starts a self-test. Stop + Enter resets the printer. Returns to the next higher level of a configuration menu. In the NOT READY mode, moves the paper upward 1/72 inch (micro-step function). In the NOT READY mode, moves the paper downward 1/72 inch (micro-step function). In the PROGRAM mode, this key moves to the next menu (Scroll function). In the PROGRAM mode, this key moves to the previous menu (Scroll function). Prints the current configuration. Soft reset: load power on configuration in memory. Printer must be in NOT READY mode. Toggles the lock on the configuration menus.
Function
Stop Form Feed Set Top Of Form Line Feed View Cancel Eject/Restore Menu Enter
Return Micro Micro Scroll Scroll Printer Configuration Stop + Enter Scroll + Scroll
18
(Off) (On)
Power Switch
Power
Liquid Crystal Display (LCD) Ready

Processing
Menu
Scroll
Enter
Micro
Line Feed
Form Feed
Start
Cancel
Attention
Printer Configuration
Scroll
Return
Micro
View
Set Top Of Form
Stop
Eject/ Restore
Figure 12. Electrical Controls and Indicators, Cabinet Models
19
Electrical Controls and Indicators, Pedestal Models (Figure 13)

Key or Indicator
Power Indicator Ready Indicator Lit when the printer is on. Lit when the printer is in READY mode (on-line), no errors are pending, and the printer is ready to process data. Off when the printer is in NOT READY mode (off-line). Flashes when the printer is receiving data from the host. Flashes when an error occurs. After correcting the error, press Stop to turn off this LED. Applies power to the printer: (1 = on, 0 = off.) This switch is also a circuit breaker. The Liquid Crystal Display (LCD) displays printer status messages. Puts the printer in the READY (on-line) mode. This key also clears fault conditions, exits program mode menus, moves paper back to print position after View is pressed, and restores after an eject. Puts the printer in the NOT READY (off-line) mode. This key also silences the audible alarm, stops a Printer Test, and restores after an eject. Stop + Enter resets the printer. Advances paper to next Top-Of-Form, as defined by the current page length. Sets TOF and moves paper downward from the tractor alignment notches to the print position. Moves paper up one line, as determined by current line spacing. Press to move the current print position up to the tractor area for viewing. Press again to return paper to original print position. Cancels a print job. Moves paper for viewing or tear-off. This key is configurable: refer to the Operators Guide. If in the NOT READY mode, this key puts the printer in the PROGRAM mode. If the configuration menus are locked, the LCD indicates the operator panel is locked. Selects the option displayed on the LCD. This action either sets a value, moves to the next lower level of configuration, or starts a self-test. Stop + Enter resets the printer. Returns to the next higher level of a configuration menu. In the NOT READY mode, moves the paper upward 1/72 inch (micro-step function). In the NOT READY mode, moves the paper downward 1/72 inch (micro-step function). In the PROGRAM mode, this key moves to the next menu (Scroll function). In the PROGRAM mode, this key moves to the previous menu (Scroll function). Prints the current configuration. Soft reset: load power on configuration in memory. Printer must be in NOT READY mode. Toggles the lock on the configuration menus.
Function
Processing Indicator Attention Indicator Power Switch LCD Start
Stop
Form Feed Set Top Of Form Line Feed View Cancel Eject/Restore Menu
Enter
Return Micro Micro Scroll Scroll Printer Configuration Stop + Enter Scroll + Scroll
110
(Off) (On)
Power Switch
Power
Liquid Crystal Display (LCD) Ready

Processing
Menu
Scroll
Enter
Micro
Line Feed
Form Feed
Start
Cancel
Attention
Printer Configuration
Scroll
Return
Micro
View
Set Top Of Form
Stop
Eject/ Restore
Figure 13. Electrical Controls and Indicators, Pedestal Model
111
Mechanical Controls and Indicators, All Models (Figure 14)
Control or Indicator
Function
Forms Thickness Lever
Sets the platen for paper and forms of different thicknesses. Lever must be fully opened (raised) to load or unload paper. Help prevent paper jams by supporting inner sections of paper. Positioned manually by sliding them along shafts. Indicates relative thickness of forms/paper. Set this lever at A for thin (single-part) forms, B for thicker forms, and so on. Hold and feed paper. Used to set side margin and position paper horizontally. Lock tractors in position. 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 move paper vertically. Works when Forms Thickness Lever is open. Instructions showing how to load the ribbon correctly. One diagram is cast in relief on the shuttle cover, and another is printed on the paper scale.
Paper Supports
Forms Thickness Pointer and Scale Tractors (2) Tractor locks (2) Horizontal Adjustment Knob Vertical Position Knob Ribbon Loading Path Diagrams
Paper Scale
A horizontal scale graduated in tenths of an inch, useful for setting paper margins and counting text columns. (See below.) 1 inch
1 0.1 inch
10 Column Number
20
112
Paper Scale Left Tractor Horizontal Adjustment Knob Paper Supports Right Tractor Tractor Lock Vertical Position Knob
Tractor Lock
Ribbon Loading Path Diagrams Forms Thickness Pointer
Forms Thickness Lever and Scale
Figure 14. Mechanical Controls and Indicators
113
Tools, Test Equipment, and Supplies

The tools and equipment required for field level maintenance of the IBM 6400 printer are listed below.
Item
Part No.
6400 Line Matrix Printer Configuration Utility Disk 130 Inch-pound Torque Screwdriver ESD Wrist Strap Feeler Gauge, .010 inch Feeler Gauge, .011 inch Feeler Gauge, .040 inch Force Gauge, 20 lb Grip Ring Pliers Lubricant, Bearing, IBM #20 DIP Module Extracting Tool Nut Driver, 1/4 inch Nut Driver, 5/16 inch Open End Wrench, 7/32 inch Open End Wrench, 5/16 inch PLCC Module Pick Extraction Tool PLCC Module Plier Extraction Tool Screwdriver, Philips, #1 Screwdriver, Philips, #2 Spring Hook, Heavy Duty Tie Wraps Torque Screwdriver Adapter Torque Screwdriver Hex Adapter 3/32 inch Torque Screwdriver Hex Adapter 5/32 inch Torque Screwdriver Hex Adapter 3/16 inch Torque Screwdriver Hex Adapter 5/64 inch
63H7379 16F1661 6405959
25F9687 9900317 117397 9900764
1650843 9900005 73G5523 10G3902 73G5362 73G5363 75X5972 39F8449 39F8451 39F8450 39F8455 16F1663
114
Installation
Installation and configuration of the printer are covered in the 6400 Line Matrix Printer SetUp Guide: Brazilian Portuguese: Form No. S2170182 Dutch: Form No. S2460126 English: Form No. S2460116 French: Form No. SF110722 German: Form No. S2460138 Italian: Form No. S2460142 Japanese: Form No. S2460144 Spanish: Form No. S2460146 Installation, operation, and replacement parts for the optional coax/twinax interface are covered in the Coax/Twinax MultiPlatform Interface Option Installation and Operation Guide, Form Number S2460149. Installation, configuration, and troubleshooting of the Network Print Server are covered in the following documents:
IBM Network Print Server Ethernet Administrators Guide, Form No. S2460111 IBM Network Print Server Token-Ring Administrators Guide, Form No. S2460112
The Network Print Server Technical Reference Manual is included on a diskette that comes with the Network Print Server. This softcopy document is in Adobe Acrobat Reader format.
Installation
21
22
Installation
Chapter Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Cleaning the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Cleaning the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Cleaning the Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Cleaning the Shuttle Frame Assembly . . . . . . . . . . . . . . . . . . . . . . 34 Cleaning the Card Cage Fan Assembly . . . . . . . . . . . . . . . . . . . . . 36
31
Overview
Aside from normal replenishment of paper and ribbons, the only preventive maintenance required for the printer is periodic cleaning. Because operating conditions vary widely, the user must determine how often to clean the printer. There is no guarantee that the user will clean the printer regularly, however, so you should clean the printer whenever you are called to service it. DANGER <1> Always disconnect the AC power cord from the power source before performing any maintenance procedure. Failure to remove power could result in injury to persons or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure.
Cleaning the Printer

WARNING <1> Do not use abrasive cleaners, particularly on the window. Do not drip water into the printer. Damage to the equipment will result. Do not spray directly onto the printer when using spray solutions (spray the cloth, then apply the dampened cloth to the printer). Do not vacuum circuit boards.
Cleaning the Exterior

1. Power off the printer. 2. Disconnect the AC power cord from the power source. 3. Wipe the outside of the enclosure with a clean, lint-free cloth dampened (not wet) with water and a mild detergent or window cleaning solution. 4. Dry the enclosure with a clean, lint-free cloth. 5. Clean the inside of the printer (page 33).
32
Cleaning the Interior (Figure 31)

1. Power off the printer. 2. Disconnect the AC power cord from 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 assembly, base casting, and ribbon guides. Vacuum up the residue. 7. Wipe the splined shaft and the ribbon guides with a soft cloth. 8. Vacuum up dust or residue that has accumulated inside the lower cabinet. 9. Wipe the interior of the lower cabinet with a clean, lint-free cloth dampened with water and a mild detergent or window cleaning solution. 10. Dry the cabinet interior with a clean, lint-free cloth. 11. Clean the shuttle frame assembly (page 34).
Splined Shaft Shuttle Cover Assembly Base Casting
Tractor
NOTE: Cabinet model shown. Procedure is the same for pedestal model.
Ribbon Guide (2)
Forms Thickness Lever
Figure 31. Cleaning Inside the Cabinet/Printer Case
33
Cleaning the Shuttle Frame Assembly (Figure 32)

1. Remove the shuttle cover assembly (page 717). 2. Remove the shuttle frame assembly (page 754). 3. Remove the paper ironer (page 741). CAUTION <1> Over time, the upper edge of the paper ironer can become sharp. To avoid cutting yourself, handle the paper ironer on the sides. 4. Wipe the paper ironer with a soft cloth to remove lint, ink, and paper residue. 5. Install the paper ironer (page 741). 6. Remove the hammer bank cover assembly (page 716). WARNING <3> The thin plate (ribbon mask) of the hammer bank cover assembly is fragile. Be careful not to over-bend or kink the ribbon mask when handling and cleaning the hammer bank cover assembly. 7. Using a soft cloth, wipe the hammer bank cover assembly to remove lint, ink, and paper residue. Clean the holes in the cover strips. Carefully open the cover assembly and wipe between the hammer bank cover and the ribbon mask. (See Figure 32.) WARNING <4> Do not use any solvents or liquids to clean the hammer tips. Clean the hammer tips gentlytoo much pressure can chip hammer tips. 8. Using a stiff, non-metallic brush (such as a toothbrush), gently brush the hammer tips to remove lint and ink accumulations. Vacuum up any residue. WARNING <5> The hammer bank contains a strong magnet. To prevent damage to the hammer tips, do not let the hammer bank cover assembly snap into place as the hammer bank magnet attracts it. Any impact of the cover against the hammer bank can break hammer tips. 9. Install the hammer bank cover assembly (page 716). 10. Install the shuttle frame assembly (page 754).
34
11. Install the shuttle cover assembly (page 717). 12. Clean the card cage fan assembly (page 36).
Hammer Bank Cover (Thick Plate)
Ribbon Mask (Thin Plate)
Hammer Bank Cover Assembly
Alignment Pin (2) (See Below)
Hammer Tip
NOTE: 6400004/04P hammer bank shown.
Hammer Bank Cover Alignment Pin
Figure 32. Cleaning the Shuttle Frame Assembly
35
Cleaning the Card Cage Fan Assembly (Figure 33)

1. Cabinet Models: Remove the paper guide assembly (page 740). Pedestal Model: Remove the top cover assembly (page 718). 2. Vacuum the card cage fan assembly and surrounding areas to remove paper particles, dust, and lint. 3. Cabinet Models: Install the paper guide assembly (page 740). Pedestal Model: Install the top cover assembly (page 718). 4. Close the printer cover. 5. Connect the AC power cord to the power source.
NOTE: Cabinet model shown. Procedure is the same for pedestal model.
Card Cage Fan Assembly
Figure 33. Cleaning the Card Cage Fan Assembly
36
4
Contents
Line Matrix Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Printing Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Shuttle Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Paper Transport System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Ribbon Transport System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Logical Control of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410 CMX Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411 Data Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 Engine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415 Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418 Printer Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
41
Line Matrix Printing

The printer creates characters and graphics by printing patterns of ink dots on paper, an entire line at a time. This technique is called line matrix printing. Every text character is stored in printer memory as a pattern of dots on a logical grid called the dot matrix. (See Figure 41.) 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 dot rows. The hammers put dots at the required positions for the entire line by striking an inked ribbon and the paper.
1
0.00835 0.01389 Column No. 0.10
12
First row and column of next character column (at 10 cpi)
First row and column of next character line (at 6 LPI)
Lowest descender dot line
0.02
Figure 41. A Dot Matrix
When the shuttle reaches the end of a sweep, it reverses direction, the paper is advanced one dot row, and the hammers print the next row of dots as the shuttle sweeps in the opposite direction. After a line of characters is printed, hammer action stops and the paper advances to the first dot row of the next print line. The number of dot rows allowed for line separation depends on the vertical line spacing the user selects. The dot matrix patterns of text characters vary according to the font the user selects. For example, in the data processing (DP) font at a line spacing of six lines per inch (lpi), a dot matrix contains 12 dot rows from the top of one character line to the top of the next. (See Figure 41 and Figure 42.) At eight lpi there are nine dot rows per character line, at nine lpi eight dot rows per character line, and so on.
42
Direction of Shuttle Movement Dot Row Start
One Text Line
1 2 3 4 5 6 7 8* 9* * 10 Number of rows determined by line spacing 11 n 1 2

* This row is used only for lowercase descenders ** This row is used for underlining and lowercase descenders
Paper Feed Direction
Figure 42. Standard Character Formation
Elongated characters are made by printing all but the first and last dot rows twice, as shown in Figure 43.
WITH UNDERLINE Dot Column 1 3 5 7 9 Dot Row 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 Dot Row 1 2 2 3 3 4 4 5 5 6 6 7 WITHOUT UNDERLINE Dot Column 1 3 5 7 9
Printed with underline
Figure 43. Elongated Character Formation
43
Succesive Hammer Strokes Per Scan
Shuttle Scan
1
Dot Row
1 1 2 1 2 3 1 2 3 4 1 2 3 4 5 1 2 3 4 5 6 1 2 3 4 5 6 7
*1
1 3 5
*1
3 5 7
1 3 5 7 9
Even column dot centers within the printed character area and character space hammer positions are not illustrated in this diagram. NOTE: = Hammer Released and Dot Printed = Hammer Not Released; No Dot Printed
Figure 44. Action of One Hammer Spring in Text Printing
Figure 44 shows how each individual hammer spring forms characters as the shuttle scans horizontally.
44
Preliminary 2
Printing Mechanism
While the principles of line matrix printing are easy to state, the act of printing dots accurately from a rapidly oscillating shuttle onto a vertically moving piece of paper requires complex timing and coordination between printer logic 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 the printing mechanism is the shuttle frame assembly, which houses the shuttle drive motor and the shuttle assembly. (Figure 45.) The hammer springs are grouped in seven comb-like assemblies mounted on the solid hammer bank: The 6400004/04P/005/05P hammer bank has seven 4-hammer assemblies. The 6400008/08P/009/09P hammer bank has seven 7-hammer assemblies. The 6400012/014 hammer bank has seven 13-hammer assemblies. The shuttle drive motor is built into the shuttle assembly casting and drives two connecting rods on an offset crankshaft. The end of one connecting rod attaches to the hammer bank, the other connecting rod attaches to a counterweight frame surrounding the hammer bank. (The hammer bank and the counterweight constitute the shuttle assembly.) The rotary motion of the shuttle drive motor converts to linear and opposing motion of the hammer bank assembly and the counterweight, in an arrangement similar to that of a horizontally-opposed gasoline engine. Mechanically, this design achieves the same benefits as such an engine: perfect primary balance, low vibration, and durability.
Hammer Bank Assembly Counterweight Assembly Connecting Rod
Guide Shaft Shuttle Motor
Figure 45. Shuttle Frame Assembly
45
Each hammer spring is a stiff leaf spring with a cylindrical tungsten carbide tip on the free end. (See Figure 46.) A permanent magnet runs the length of the hammer bank and acts on the hammer springs through individual pole pieces. The pole pieces magnetically attract and hold the free end of the hammer spring under tension. This is called the retracted state.
NOTE: 6400004/04P hammer bank shown. Hammer Bank Assembly: Coils, Magnet, Pole Pieces, Hammer Spring Assemblies
Tungsten Carbide Hammer Tip
Hammer Spring Assembly
Alignment Pin
Figure 46. Hammer Springs and Hammer Bank (Detail)
Two electromagnetic coils are mounted behind each hammer and wound around each pole piece. The coils are normally de-energized. When hammer driver logic determines that the hammer must print a dot, a current 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 ribbon and paper, and leaves a dot impression of the hammer tip on the paper. While the hammer is in flight the coil is de-energized and its field collapses. After striking the ribbon and paper, the hammer rebounds and the permanent magnet recaptures it. When the shuttle reaches the end of a sweep, it reverses direction, the paper is moved up one dot row, and the hammer springs print the next row of dots as the shuttle sweeps in the opposite direction.
46
Paper Transport System
Tractors Horizontal Adjustment Knob
Paper Path Splined Shaft
Vertical Adjustment Knob and Splined Shaft Pulley
Tractor Support Shaft
Shuttle Cover Assembly Paper Supports Paper Feed Timing Belt (Under the cover)
Figure 47. Paper Transport System
A two-phase DC stepper motor, directed by the EC on the controller board, drives two tractor sprockets by means of a toothed belt and splined shaft pulley arrangement. The stepper motor permits extremely accurate incremental vertical paper movement. This drive configuration is designed for continuous, fan-folded paper three to 16 inches wide and one to six sheets thick. For reverse paper feeding, the platen open motor opens and closes the platen via a toothed belt. Opening the platen prevents paper jams when paper direction is reversedthat is, moved downwardsin order to view the print area, set top of form, or allow applications to overprint forms. Paper is positioned horizontally using the tractors and the horizontal adjustment knob. Each tractor engages paper perforations with six sprocket pins and locks in place with a friction lock. The horizontal adjustment knob allows vernier positioning of the left print margin. Paper can be positioned vertically by hand with the vertical adjustment knob.
47
Ribbon Transport System
Ribbon Hub Left Ribbon Guide (Not Shown) Hub Locking Latch Ribbon Spool
Ribbon Motors Right Ribbon Guide Ribbon
Figure 48. Ribbon Transport System
An inked ribbon winds and unwinds continuously on a pair of spools latched to hubs that are driven by the ribbon motors. The hubs and spools are offset vertically to equalize ribbon wear 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, completing a circuit that causes both motors to reverse direction. Constant ribbon tension is maintained by controlling each motor with a drive or drag circuit. While the shuttle assembly is in motion, one motor acts as a drive motor, pulling the ribbon against the resistance exerted by the other motorthe drag motor. This system maintains a constant motor speed and ribbon tension.
48
Logical Control of the Printer

The printer is divided into four functional elements: the operator panel, the CMX controller board, the power supply, and the print mechanism. See Figure 49.
AC Input
AC POWER
Operator Panel
Circuit Breaker
ON/OFF SWITCH Line 1 Line 2 / Neutral
Power Supply Board
CHASSIS GND EIA232E Serial I/O
Card Cage Fan
CMX Controller Board

Parallel I/O Shield GND +5 V Remote Power
Common Ground
Cabinet Exhaust Fan (Cabinet models only)
Platen Motor Paper Motion Detector Paper Out Detector Left Ribbon Guide Left Ribbon Motor
Flex Circuits: Shuttle Assy Terminator Board Shuttle Motor MPU Hammer Bank Board Paper Feed Motor Platen Open Switch Right Ribbon Guide Right Ribbon Motor Hammer Bank Fan
Shuttle Assembly
Print Mechanism
Figure 49. Functional Elements of the Printer
49
Operator Panel
The user communicates with the printer by pressing keys on the operator panel. The keys are momentary contact switches. The operator panel processes and sends key closure information 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 indicator, and keys are mounted on a printed circuit board assembly enclosed in a protective housing.
Operator Panel
Data Control Key (Switch) Closures
J110
Figure 410. Operator Panel Functional Overview
410

The heart of the printer is the CMX controller board, which monitors and directs all printer functions. The controller board receives and processes all data from the host computer, builds the printable images, controls all motors, and drives the hammer springs. Except for the power supply and final hammer drive circuits, all logic and drive circuitry for the printer are contained on the controller board. The CMX controller board consists of two functional 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 responsible for: Print Mechanism Operation Print Mechanism Fault Monitoring Power Shutdown/Power Saving Modes
The EC and DC communicate through semaphore registers. The DC receives host and operator input and returns dot images and LCD messages to buffers in memory. Image data are passed to the EC upon request, are processed, then sent to the hammer bank. The EC synchronizes paper, ribbon, platen, and shuttle motion as it feeds dot data to the hammer drivers. Figure 411 summarizes this architecture.
411
Expansion Port
RS232 Diagnostic Port
RS232/422 IEEE1284 (Parallel)
Operator Panel
Fault Sensors
Paper Feed
Ribbon
Shuttle
TTL Diagnostic Port
Platen
Hammer Drive
Figure 411. CMX Controller Board Block Diagram
412
Data Controller
The data controller (DC) consists of the following elements: 68EC030 microprocessor Two flash SIMM sockets, used for up to 30MB of program memory (Base configuration: 1MB flash in bank 0) Two DRAM SIMM sockets, used for up to 32MB of data memory (Base configuration: 1MB DRAM in bank 0) 8K x 8 Non-Volatile Battery-Backed static RAM (NVRAM) for storage of configuration and system statistical data VX ASIC (Application-Specific Integrated Circuit) Host I/O Drivers/Termination
68EC030 Microprocessor A Motorola 68EC030 microprocessor serves as the processor of the DC unit. This processor runs at 25 MHz.
Flash Memory The DC stores program and emulation code in flash memory. Flash memory is erasable, non-volatile, and significantly faster than a disk drive. The DC uses AMD 5.0V-only flash memory, which does not require higher programming and erasing voltages on the board (it has an internal charge pump to make these voltages itself). This memory supports at least 100,000 write/erase cycles. The flash memory is 32 bits wide. It is byte, word, and double word readable, but is always written as double words. Two 80-pin SIMM sockets are provided for flash memory. Up to 30MB of flash (total), organized as up to four banks, may be installed in the two sockets on the controller board. The boot code for the 68EC030 processor must reside in bank 0. Programs stored in flash memory are changed through the parallel or serial port.
413
DRAM System DRAM is used for program variables, image buffers, and input buffers. All DRAM supports page mode operation and is addressable by individual byte. Two standard 72-pin DRAM SIMMs are used for expansion memory. The DC, through the VX ASIC, may address up to 32MB of DRAM in four banks. NVRAM A 8K x 8 bit Non-Volatile battery-backed static RAM (NVRAM) device provides for the storage of configuration and system statistical data. VX ASIC The VX is a multifunction custom gate array ASIC containing all the logic for the DC that is not contained in the 68EC030 processor. The VX provides the following services: Memory Access Controller DRAM Controller Flash Controller Two DMA Channels 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 address decoding, chip selects, DTACKs, and so on. DRAM Controller The VX supports up to four banks of page mode DRAM. FLASH Controller The VX supports up to four banks of flash memory. DMA Channels The VX provides two channels for direct memory access. These channels move data from the host interface or expansion bus to the DRAM and vice versa. One address is an I/O address, the other is a memory address with auto-increment. Operator Panel Interface The VX operator panel interface consists of five lines: serial clock, serial data, and three select lines. It is the VX that handles all parallel-to-serial (and vice versa) conversion to and from the panel, as well as any special timing needed when toggling select lines, etc. Dot Plucking and Adjacent Dot Checking Dot Plucking is a specialized DMA function that removes dot data from a dot image buffer in
414
DRAM in a programmable manner, serializes it, and sends it to the hammer bank. This function is actually controlled by the EC (see page 415), which has access to the VX through the Cajun Bus Interface. Cajun Bus Interface The Cajun bus interfaces the DC, the EC, and the expansion port. The EC uses this bus to access DC resources, including the semaphore registers. (The semaphore registers are the primary communications path between the EC and DC.) Ports The VX ASIC controls the following I/O functions: Interface to an IEEE 1284 Level 2 host Interface to RS232E serial host Interface to RS422 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 030 processor and VX ASIC, additional support circuitry completes the serial and parallel interfaces. These circuits include: RS232 drivers and receivers. These circuits use internal charge pumps to eliminate the need for 12V power. RS422 differential drivers and receivers Parallel port pull up and pull down terminating resistors are DIP-socketed for easy removal and installation.
All interface ICs and terminations have the following characteristics: Provide ESD protection to 15KV for all inputs. Less than 0.05V common mode ripple, measured at the power and ground of the interface ICs. Less than 0.02V common mode ripple, measured between chassis ground and the ground pins of the interface ICs. Greater than 200V/ms slew rate for all outputs.
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.
415
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 at zero wait states. An external PAL is used for address decoding. Power Reduction Modes The 166 chip has two power reduction modes: idle and power down. When the 166 is in idle mode the CPU shuts down, but all on-board peripherals continue to operate. (Idle power reduction of the 166 is not the same as printer idle.) Any previously enabled interrupt will wake up the processor, even if global interrupts are turned off or the interrupt does not have the priority to actually execute. All I/O pins remain active in idle power reduction mode. Power down reduction mode capability exists but is not used because it requires an external hardware reset to exit this mode. Watchdog Timer The 166 has an on-board watchdog timer. The Address Strobe of the 030 processor is fed into the watchdog input. If the 030 stops fetching addresses, something is seriously wrong and the 166 and its peripherals are automatically reset. The timer interval is set through software and has a range of 25.6 msec to 419 ms; default setting is 6.55 ms. EC Flash Memory The EC stores all boot code, program code, and tables in its own local flash memory. This flash is organized as 64Kx16 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. This memory is fixed, however, because it is soldered to the controller board. Its contents can be updated through the DC (through the serial or parallel ports). MECA ASIC The 166 uses numerous counters, timers, PWM generators, and FIFOs in the MECA to control nearly all of the motor functions in the printer. The MECA is a custom gate array, specifically designed to drive this system.
416
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. Five motors are used on the printer: paper feed, two ribbon drive, shuttle, and platen open. The shuttle motor is a brushless DC motor, driven by current control. The MPU encoder is used as feedback for motor commutations, hammer fire timing, and motor stall detection. The paper feed motor is a DC stepping motor driven by current control. The paper feed motor may be driven in full, half, or microsteps, depending on print requirements. The ribbon system uses two DC stepping motors that alternate drive and drag roles when the ribbon reaches turnabout. The drive ribbon motor is microstepped in voltage mode, while the drag motor is loaded and monitored to maintain correct linear speed and tension. The platen open motor is driven in current mode and can be full or half stepped. The overall current level may be reduced for standby modes. The paper feed, ribbon drive, and shuttle motors are driven in control loops containing power MOSFETs, voltage and current sensors, the MECA ASIC, and the EC processor. The platen open motor is driven by a stepping motor controller IC and the EC processor. Control of hammer drive is split between 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 controller board sets the timing and upper drive profile for driving a hammer fire event. The controller also contains diagnostic circuitry for the hammer system. The hammer bank contains HBA ASICs that interpret fire commands and data from the MECA and VX ASICs. The HBAs control lower drive MOSFETs on the hammer bank. These determine which hammers will participate in a fire event generated by the controllers upper drive.
417
Power Supply Board

The printer power supply is contained on a printed circuit board mounted in the card cage. The power supply automatically senses and adjusts to any commercial electrical system that provides AC mains potential in 50 or 60 Hertz systems. In other words, the printer is fully operational from available commercial power anywhere in the world. The power supply converts alternating current (AC) to direct current (DC) at three voltage levels and sends the DC voltages to the controller board. The controller board distributes all DC power to the logic and electromechanical circuits.
AC Power
The power supply operates on AC voltages ranging from 88 to 270 V. It can tolerate variations in frequency of 47 to 63 Hz. The power supply is designed to withstand an AC input overvoltage of 300 VAC for one second with no degradation of DC output voltage or damage to printer circuits.
DC Power
The power supply board contains two DC power supply systems for the printer. The first is a + 5 V bus for logic. The second consists of + 48 V and + 8.5 V buses for the hammer bank and all motors. The + 5 V supply has an isolated return line that connects to the + 48 V return at the printer load. Both returns are tied together in a single-point ground. The + 5 V power supply has its own inverter, separate from the + 48 V and + 8.5 V outputs. There is an opto-isolated input on the power supply that will shut down and latch off the + 48 V and + 8.5 V supplies unless it is pulled up to 5V with a 1K resistor. This resistor is mounted 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 for this signal is the + 5 V return. In addition, this shutdown circuit discharges and latches the + 48 V down to a level lower than 15 V in less than 200 milliseconds and requires recycling of the circuit breaker (On/Off switch) to reset the latch. Loss of + 48 V is seen by the EC and reported as a fault.
418
Printer Interface
The printer interface is the point where the data line from the host computer plugs into the printer. The printer interface processes all signals and data to and from the host computer. The printer supports PC Parallel, IEEE 1284 parallel, EIA232E serial, EIA422B serial, and optional coaxial/twinaxial (CT) interfaces to the host. Selection of the input/output interface is controlled by configuration menus accessed at the operator panel. It is possible to physically connect more than one interface, but only one interface at a time can be used electrically.
Graphics
The Code V programming language (a QMS graphics 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 forms, bar codes, logos, expanded characters, and other graphics. These languages enable the printer to print sideways, upside down, and to make forms combining graphics, alphanumeric data, and bar codesall in a single pass. Documents explaining configuration, operation, and programming are included with each option.
419
420
Troubleshooting
Chapter Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Troubleshooting Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Symptoms Not Indicated by Fault Messages . . . . . . . . . . . . . . . . . . . . 539 Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540 Printer Confidence Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544 Operator Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545 Selecting and Running Operator Print Tests . . . . . . . . . . . . . . . . . 547 Customer Engineer (CE) Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548 Selecting and Running Customer Engineer Tests . . . . . . . . . . . . . 550 Boot Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551 Hex Code Printout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554 Printer Information Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557 Displaying Printer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558 Soft vs. Hard Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559
Troubleshooting
51
Introduction
This chapter contains procedures for troubleshooting printer malfunctions. This manual does not cover operation or configuration of the printer, but you must operate the printer to check its performance, and sometimes you may have to reconfigure it. Therefore, have the Operators Guide and the Setup Guide handy whenever you troubleshoot the printer.
Troubleshooting 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 printer malfunctions: LCD Message Troubleshooting Table (Page 55) A troubleshooting symptom table for messages that appear on the Liquid Crystal Display (LCD). The LCD messages are defined and corrective actions provided. Symptoms Not Indicated by Fault Messages (Page 539) Basic procedures for troubleshooting problems that are not indicated by LCD messages. Also included is a logic table for troubleshooting common problems. Printer Confidence Check (Page 544) A systematic check of printer operation in the form of a logic table. Use this procedure to establish basic printer status or to troubleshoot imprecise or intermittent symptoms. Operator Print Tests (Page 545) A set of print tests included in the configuration menu structure for use as diagnostic tools. Customer Engineer (CE) Tests (Page 548) A set of print tests not available to the user. These tests are maintenance tools. Hex Code Printout (Page 554) The procedure for printing data streams in hexadecimal format. Use to troubleshoot printer data reception problems. ASCII Character Set (Page 556) A chart of standard ASCII characters and their equivalent codes. Printer Information Menu (Page 557) A set of menus that display accumulated statistics and information about the printer. Appendix A: Wire Data System interconnect and power distribution diagrams, circuit board pin-outs, and diagrams of the cable assemblies. Use as source material for tracing electrical problems.
52
Troubleshooting
Fault Messages
DANGER <1> Always disconnect the AC power cord from the power source before performing any maintenance procedure. Failure to remove power could result in injury to persons or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure. If a fault condition occurs in the printer, four things happen: The Attention indicator on the operator panel flashes on and off. If enabled, the audible alarm sounds. (Press Stop to silence 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 stores up to 50 messages as a list. The most recent message is stored at the top of the list, the oldest message at the bottom of the list. If more than 50 messages occur before the log is cleared, the oldest messages are deleted, so that the log never contains more than 50 messages. You can print the error log and clear it. (See page 548.)
The LCD displays two kinds of printer conditions: An Attention condition halts printing until the operator replenishes supplies, clears paper jams, corrects a problem of communication between the printer and host computer, etc. A Unit Check condition is a failure detected by self-test and fault circuitry. Unit check conditions are either recoverable or unrecoverable. a. Recoverable unit check conditions are errors detected in the electromechanical print mechanism that may be temporary and correctable by recycling power. The printer tries a number of times to correct the condition before posting the message to the operator panel. The first thing to do in such cases is to power the printer off, wait 15 seconds, then power the printer back on. If the message reappears, classify the check condition unrecoverable. b. Unrecoverable unit check conditions are hard failures such as overcurrent, component failure, or microcode failures that prevent printing until the conditions are corrected. Unrecoverable errors require that the printer be powered off and the condition corrected before powering the printer back on.
Troubleshooting
53
Clearing Errors Refer to Table 51 and follow the instructions. Table 51 explains each fault message and tells you how to correct the fault condition. After correcting an error, press the Stop key to clear the message and return the printer to the NOT READY state. Press Start to resume printing. (If an error is not cleared, the printer will try to print again but will display another error message until the error is cleared.)
NOTE: Abbreviations used in Table 51: DRAM NVRAM RAM SIMM Dynamic Random-Access Memory Non-Volatile Random-Access Memory Random-Access Memory Single In-line Memory Module
Acronyms and abbreviations are also defined in Appendix F.
54
Troubleshooting
Table 51. LCD Message Troubleshooting Table Required Action Load paper. If message recurs, see page 518. Clear jam and reload paper. If message recurs, see page 519. Press Eject/Restore key to return paper to print position. Press View key to return paper to print position. The host computer or printer controller requires attention. Not a printer problem. The system administrator should correct applications data or configuration. Press Start to put the printer in the READY state.
Message
001 END OF FORMS LOAD FORMS 002 FORMS JAMMED CLEAR JAM AND RELOAD FORMS
Explanation Attention message. The printer is out of paper. Attention message. Printer cannot detect paper motion. Non-error status message.
003 FORMS EJECTED PRESS EJECT/RESTORE 004 VIEW FORMS PRESS VIEW KEY 006 HOST SYSTEM REQUEST ATTENTION
Non-error status message.
Host attention message. Applications software has violated header format parameters. Printer was offline more than 10 minutes and the Intervention Required parameter is set to Send to Host. Attention message. Illegal parameter value received in command code. Printer received undefined control character (hex 40). Applications software has violated structured data field parameters. Printer detects twinax protocol communication errors. Printer detects twinax protocol communication errors.
007 FM HEADER ERROR
008 HOLD PRINT TIMEOUT PRESS START
009 INVALID KEY PRESS 010 PARAMETER ERROR
None Press Stop to clear fault. Press Start to go on-line. See also page 521. Printer clears the error. See also page 521. Not a printer problem. The system administrator should correct applications data or configuration. Page 522
011 SCS COMMAND ERROR
012 STRUCTURED FIELD ERROR
013 ACTIVATE LOST
014 INVALID ACTIVATE
Page 522
Troubleshooting
55
Message
015 COMMUNICATION CHECK CHECK CABLE 016 INVALID COMMAND
Explanation Line not active. (Twinax interface) Printer detects twinax protocol communication errors. Receive overrun. (Serial interface) Unit address not recognized by printer. (Poll timeout, twinax interface) Parity error. (Serial interface)
Required Action Page 523
Page 522
021 RECEIVE BUFFER OVERRUN VERIFY CONFIGURATION 022 UNIT ADDRESS NOT RECEIVED CHECK PRINTER ADDRESS
Page 524
System administrator: make sure the printer address is correct. Page 524
024 SERIAL LINE PARITY ERROR VERIFY CONFIGURATION 025 SERIAL FRAMING ERROR VERIFY CONFIGURATION 026 HEX DUMP MODE
Framing error. (Serial interface) Printer attach status message. Enable poll timeout. The printer was not enabled for one minute. (Coax interface) Poll timeout error. The printer was not polled for one minute. (Coax interface) Link-level code test detects hardware failure. A timeout message is sent to the host if paper is not loaded 10 minutes after Stop was pressed to clear the paper out fault. A timeout message is sent to the host if paper motion has not occurred for 10 minutes after Stop was pressed to clear the jam fault. Host sends data after the printer buffer is full. (Serial interface.)
Page 524
None Check cable connection and host system. Check cable connection and host system. Replace the controller board. Replace IBM coax/twinax expansion board Load paper. If the message recurs, see page 518.
027 COMMUNICATIONS CHECK CALL SYSTEM OPERATOR
028 COMMUNICATIONS CHECK CALL SYSTEM OPERATOR
029 8344 DIAGNOSTIC TEST FAILED
031 END OF FORMS TIMEOUT LOAD FORMS
032 FORMS JAMMED TIMEOUT CLEAR JAM AND RELOAD FORMS
Clear the jam and reload paper. If the message recurs, see page 519.
041 BUFFER OVERFLOW
Check printer serial port configuration setup. Ensure that it matches host setting.
56
Troubleshooting
Message
042 CUSTOM SET DOES NOT EXIST SAVE FIRST 043 CUSTOM SET ALREADY EXISTS DELETE EXISTING SET FIRST
Explanation The custom configuration set does not exist. Printer configuration: custom set is write-protected. Fatal firmware error on CMX controller board.
Required Action Save the custom configuration set. Delete the existing custom configuration set, then save the new set. Cycle power. Rerun print job. If message recurs, replace CMX controller board. Record the message and return it with the defective board. Cycle power. If message recurs, replace CMX controller board. Record the entire message and return it with the defective board. Page 525 Page 526
044 EC FIRMWARE/HARDWARE ERROR
046 EC STOPPED AT STATE <state>
The Engine Controller processor has stopped and is in the state identified by the number displayed. Forms thickness lever is raised to open position. No shuttle movement or shuttle moving at wrong speed. Non-error status message. Controller board sensors report high temperatures on the board. Sensors cannot detect current in fan circuit. Sensors cannot detect current in fan circuit. Sensors cannot detect current in fan circuit. Appears when data are cleared out of printer after Cancel key has been pressed. Circuits are overheating on the power supply board.
057 CLOSE PLATEN
058 SHUTTLE JAM SEE USERS GUIDE
059 CANCEL PRINT ACTIVE
None Page 527
060 PRINTER HOT
062 EXHAUST FAN FAULT
Page 528 Page 528 Page 528 None
063 INTAKE FAN FAULT
065 HAMMER BANK FAN FAULT
069 DATA CLEARED
080 POWER SUPPLY HOT
Page 529
Troubleshooting
57
Message
081 POWER SUPPLY VOLTAGE FAILURE
Explanation Internal power failure.
Required Action Cycle power. If message recurs, replace one at a time until message clears: a) power supply board b) controller board Cycle power. If message recurs, replace one at a time until message clears: a) power supply board b) controller board Cycle power. If message recurs, replace one at a time until message clears: a) power supply board b) controller board Cycle power. If message recurs, replace one at a time until message clears: a) controller board b) power supply board Cycle power. If message recurs, replace one at a time until message clears: a) controller board b) power supply board Page 525
082 POWER SUPPLY 8.5V FAILED
Internal power failure.
084 POWER SUPPLY 48V FAILED
Internal power failure.
085 CONTROLLER VOLTAGE
Controller voltage failure.
086 CONTROLLER 15V
Controller voltage failure.
087 PLATEN OPEN TIMEOUT CLOSE PLATEN
Forms thickness lever has been open for at least one minute. Controller voltage failure.
088 CONTROLLER 23.5V
Cycle power. If message recurs, replace one at a time until message clears: a) controller board b) power supply board Page 531 Page 532
089 RIBBON STALL 090 SHUTTLE COVER OPEN CLOSE SHUTTLE COVER
No ribbon movement. Shuttle cover is missing, damaged, or not correctly installed. CMX controller does not detect ribbon drive motor.
092 RIBBON DRIVER CIRCUIT
Check connections of both ribbon motors. If motors are connected OK, replace both ribbon drive motors and the controller board.
58
Troubleshooting
Message
101 UPPER DRIVER SHORT
Explanation Hammer driver circuits on the CMX boards shorted to ground. Circuit(s) on the hammer bank or in the hammer bank power cable shorted to ground. Electrical malfunction of one or more hammer coils.
Required Action Page 533
102 LOWER DRIVER SHORT
Page 534
105 HAMMER COIL <number> OPEN
Cycle power. If message recurs, replace one at a time until message clears: a) shuttle frame assembly b) controller board Page 535 Cycle power. Rerun print job. If message recurs, replace CMX controller board. Record the message and return it with the defective board. Cycle power. Rerun print job. If message recurs, replace CMX controller board. Record the message and return it with the defective board. Cycle power. Rerun print job. If message recurs, replace CMX controller board. Record the message and return it with the defective board. Cycle power. Rerun print job. If message recurs, replace CMX controller board. Record the message and return it with the defective board.
107 HAMMER COIL <number> HOT
One or more hammer coils are overheating. System stack has run out of room and overflowed into other memory.
110 STACK OVERFLOW SEE USERS GUIDE
111 STACK UNDERFLOW SEE USERS GUIDE
Fatal firmware error on CMX controller board.
112 UNDEFINED OPCODE SEE USERS GUIDE
113 PROTECTED INSTRUCTION SEE USERS GUIDE
Troubleshooting
59
Message
114 ILLEGAL OPERAND ACCESS SEE USERS GUIDE
Explanation Fatal firmware error on CMX controller board.
Required Action Cycle power. Rerun print job. If message recurs, replace CMX controller board. Record the message and return it with the defective board. Cycle power. Rerun print job. If message recurs, replace CMX controller board. Record the message and return it with the defective board. Cycle power. Rerun print job. If message recurs, replace CMX controller board. Record the message and return it with the defective board. Cycle power. Rerun print job. If message recurs, replace CMX controller board. Record the message and return it with the defective board. Cycle power. Rerun print job. If message recurs, replace CMX controller board. Record the message and return it with the defective board. Cycle power. Rerun print job. If message recurs, replace CMX controller board. Record the message and return it with the defective board. Cycle power. Rerun print job. If message recurs, replace CMX controller board. Record the message and return it with the defective board.
115 ILLEGAL INSTRUCTION ACCESS SEE USERS GUIDE
116 ILLEGAL EXTERNAL BUS ACCESS SEE USERS GUIDE
117 A TO D OVERRUN SEE USERS GUIDE
Analog to digital signal conversion problems.
118 UNDEFINED INTERRUPT SEE USERS GUIDE
119 TCB CORRUPTED SEE USERS GUIDE
The Task Control Block has been corrupted.
120 ACCESS NULL POINTER SEE USERS GUIDE
The processor tried to access a pointer that contains nothing (null).
510
Troubleshooting
Message
121 PAPER NOT AT SPEED SEE USERS GUIDE
122 PAPER NOT SCHEDULED SEE USERS GUIDE
The paper feed process is not working and the printer cannot advance paper.
123 PAPER BUSY TOO LONG SEE USERS GUIDE
124 PAPER FIFO OVERFLOW SEE USERS GUIDE
125 PAPER FIFO UNDERFLOW SEE USERS GUIDE
126 PAPER FEED BAD TABLE SEE USERS GUIDE
The paper feed process is using a bad table.
127 PAPER FEED ILLEGAL STATE SEE USERS GUIDE
Troubleshooting
511
Message
128 PAPER FEED INVALID COMMAND SEE USERS GUIDE
129 PAPER FEED INVALID PARAMETER SEE USERS GUIDE
130 PAPER FEED PARTLY ENERGIZED SEE USERS GUIDE
131 PAPER FEED INTERRUPT SEE USERS GUIDE
132 RIBBON INVALID COMMAND SEE USERS GUIDE
133 RIBBON INVALID STATE SEE USERS GUIDE
134 PLATEN INVALID COMMAND SEE USERS GUIDE
512
Troubleshooting
Message
135 PLATEN INVALID STATE SEE USERS GUIDE
Required Action Cycle power. Rerun print job. If message recurs, replace CMX controller board. Record the message and return it with the defective board. Cycle power. Rerun print job. If message recurs, replace CMX controller board. Record the message and return it with the defective board. Cycle power. Rerun print job. If message recurs, replace CMX controller board. Record the message and return it with the defective board. Cycle power. Rerun print job. If message recurs, replace CMX controller board. Record the message and return it with the defective board. Cycle power. Rerun print job. If message recurs, replace CMX controller board. Record the message and return it with the defective board. None Replace the controller board (page 711). Press Stop then Start.
136 PLATEN INVALID PARAMETER SEE USERS GUIDE
137 SHUTTLE INVALID COMMAND SEE USERS GUIDE
138 SHUTTLE INVALID PARAMETER SEE USERS GUIDE
139 SHUTTLE OVERSPEED SEE USERS GUIDE
990 MACHINE CHECK
Host status message. NVRAM defective. Printer has received a non-printable character. Non-error status message.
998 NON-VOLATILE MEMORY FAILED
A97 GRAPHIC CHECK ERROR PRESS STOP THEN START BOOT DIAGNOSTICS
None
Troubleshooting
513
Message
CLEARING PROGRAM FROM FLASH
Explanation Emulation program successfully loaded into printer RAM and the checksum matched. The old program is now being deleted from flash memory. Hammer coil count test failed. Status message: printer is in low-energy idle state, all fans and higher voltages are off, only +5Vdc logic circuits are active. DRAM defective or missing. None
Required Action
DRIVER CIRCUIT BAD
Page 537 None
ENERGY SAVER MODE ACTIVE
ERROR: DRAM NOT DETECTED
Reseat DRAM SIMM(s), install or replace DRAM (page 729). Check, reseat, install correct security PAL, as required (page 729). Page 538
ERROR: SECURITY PAL NOT DETECTED
Security PAL defective or missing. Self-test does not detect hammer coils at printer start-up. Hammer coil number # failed current test at power-up.
HAMMER BANK NOT INSTALLED
HAMMER COIL BAD #, #, #, #, ... etc.
Cycle power. If message recurs, make sure hammer bank cables are connected. If cables are OK, replace one at a time until message clears: a) shuttle frame assembly b) controller board c) Record the message and return it with the defective assembly None
LOADING PROGRAM FROM PORT XX%
Emulation program is loading into printer RAM. XX indicates how much of the program has loaded. The printer has deleted the previous emulation program from flash memory and is loading the new program into flash memory.
LOADING PROGRAM INTO FLASH
None
514
Troubleshooting
Message
NOT READY
Explanation Printer state message: printer is offline, not in communication with host. Non-error status message. None
Required Action
OPERATOR MENU <first menu item> OPERATOR MENU LOCKED
None
Non-error status message. Non-error status message. Attach status message. Attach status message. Non-error status message. Security code of PAL on controller board does not match code of firmware on the CMX controller board. Damaged DRAM at address <hex>.
None None None None None Verify correct firmware and security PAL installed (page 729). If OK, replace the CMX controller board. Remove one DRAM SIMM (page 729). Restart printer. If message is gone, replace the DRAM SIMM you just removed. If message reappears, replace the DRAM SIMM you left on the CMX board. Install or replace flash SIMM (page 729). Download the program again. If message recurs, diskette may be corrupted; try new diskette. Use correct emulation diskette. If the printer is an IBM 6404B01, the controller is a CBO board. If the printer is an IBM 6400, the controller is a CMX board.
OPERATOR MENU UNLOCKED
PA1 SELECTED
PA2 SELECTED
P05 DIAGNOSTIC TEST PASSED
P17 SECURITY VIOLATION
P60 ERROR: DRAM AT ADDRESS <hex>
P61 ERROR: FLASH NOT DETECTED P62 ERROR: DC PROGRAM NOT VALID
Flash memory is defective or missing. Data controller program is not working.
P63 ERROR: PROGRAM NOT COMPATIBLE
User tried to load CMX-compatible diskette in CBO-controlled printer, or vice versa.
Troubleshooting
515
Message
P64 ERROR: CHECKSUM WRONG <hex> P65 ERROR: PROGRAM NEEDS MORE FLASH
Explanation Corrupted data passed through the parallel port. Emulation program requires more flash memory than is present on the controller board. Emulation program requires more DRAM than is present on the controller board. Flash memory defective.
Required Action Run the download again, from the beginning. Add flash memory (page 729).
P66 ERROR: PROGRAM NEEDS MORE DRAM
Add DRAM (page 729).
P67 ERROR: WRITING TO FLASH P68 ERROR: EC PROGRAM NOT VALID
Replace flash SIMM (page 729). Download the EC program again. If message recurs, EC program may be corrupted. Obtain a new EC program. Replace the CMX controller board. Record the number indicated by XXXX and return it with the defective board. None
EC program on CMX controller board corrupted. (Power-up checksum incorrect.) Where XXXX is a number from 0000 to 0010. EC hung at process indicated by XXXX. Printer reset in progress.
P69 ERROR: EC STOPPED AT STATE XXXX
PLEASE WAIT... RESET IN PROGRESS READY
Printer state message: printer is online, in communication with host. Printer reset in progress.
None
RESETTING... PLEASE WAIT RESTORING BOOT CODE
None
Status message when downloading boot code. Code is checked then saved in flash memory. RibbonMinder software has determined that the ribbon is out of ink. Status message when downloading EC program. EC code is checked by the boot code, sent to the EC processor, then stored in flash memory.
None
RIBBON OUT OF INK CHANGE RIBBON
Change ribbon and set ribbon life to 100%. None
SENDING PROGRAM TO EC PROCESSOR
516
Troubleshooting
Message
SERVICE <first service test> TABLE MISMATCH DOWNLOAD AGAIN TESTING HARDWARE PLEASE WAIT
Explanation Non-error status message. None
Required Action
EC software update in process. Status message when printer runs self-tests and initialization routines. Non-error status message. Emulation download mode has been activated, but program download has not yet begun.
Run the download again, from the beginning. None
TOP OF FORM SET
None None
WAITING FOR PROGRAM DOWNLOAD
Troubleshooting
517
001 END OF FORMS LOAD FORMS 031 END OF FORMS TIMEOUT LOAD FORMS
Instruction 1. Load paper. Run an operator print test. Indication End of forms message. Yes Replace paper detector switch assembly. Go to step 2. Replace the controller board. No Return printer to normal operation.
2.
Run an operator print test.
End of forms message.
Return printer to normal operation.
518
Troubleshooting
002 FORMS JAMMED CLEAR JAM AND RELOAD FORMS 032 FORMS JAMMED TIMEOUT CLEAR JAM AND RELOAD FORMS
Instruction 1. Check for a failure to sense End of Forms. Indication End of Forms (last form) is past the hammer area. Yes Do one at a time until the problem is gone: a) Clean the paper detector sensor with a cotton swab and alcohol. b) Replace the paper detector switch assembly. c) Replace the controller board. Go to step 3. No Go to step 2.
2.
Inspect paper guide assembly for frayed, torn, folded paper or labels. Inspect the narrow passageway between the face of the platen and the ribbon mask for bits of torn paper or ribbon lint. Check the holes in the ribbon mask surrounding each hammer tip.
Paper guide assembly is clear.
Remove paper and go to step 3. Go to step 4.
3.
Debris found.
Gently remove paper or lint particles with a wooden stick or pair of tweezers. WARNING: Do not pry on or apply force to the hammer tips. Go to step 4. Go to step 5.
4.
Load paper. Press the Form Feed key several times.
Forms feed without erratic motion, noise, or pin-hole damage.
If pin holes are damaged, go to step 7. For erratic motion or noise, go to step 9. Go to step 6.
5.
Press the View key twice.
Forms move correctly in both directions, without jamming, tearing, or folding. Platen motor belt OK.
Suspect a false indication. Go to step 12. Replace one at a time until message goes away: a) platen motor b) controller board Replace the hammer bank cover assembly.
6.
Check the platen motor belt.
Replace platen motor belt.
7.
Check that the ribbon mask has not been deformed in such a way as to block the paper guide assembly.
Ribbon mask damaged or bent.
Go to step 8.
Troubleshooting
519
Instruction 8. 9. Check the platen gap adjustment. Check for damage to the paper feed belt.
Indication Platen gap incorrect. Paper feed or belt damaged.
Yes Adjust platen gap. Go to step 9. Replace the paper feed belt. Go to step 10. Go to step 11.
No Go to step 9. Go to step 10.
10. Check the tractors and tractor door springs for damage or excessive wear. 11. Run an operator print test.
Tractors are OK.
Replace defective tractor. Return printer to normal operation. Return printer to normal operation.
Paper Jam message.
Replace paper feed motor. Go to step 12. Clean the paper motion detector with cotton swab and alcohol. Go to step 13. Replace the controller board. Go to step 14
12. Load paper. Do some line feeds and run a diagnostic print test.
Paper Jam message.
13. Set the paper motion detector fault setting to DISABLE (Ref: Setup Guide). Run a print test and check paper feeding as the printer prints. 14. Run an operator print test.
Paper Jam message.
Paper Jam message.
Replace paper detector switch assembly.
520
Troubleshooting
010 PARAMETER ERROR 011 SCS COMMAND ERROR

Instruction 1. Run the print job that generated the error message. Ask the system operator to verify that the printers Device ID is set to the correct emulation with respect to the host configuration. Indication SCS COMMAND or PARAMETER ERROR message. SCS COMMAND or PARAMETER ERROR message. Yes Verify host data are correct and there are no invalid characters. Replace one at a time until message is gone: a) coax or twinax cable b) CMX controller board No Return printer to normal operation.
2.
Troubleshooting
521
013 ACTIVATE LOST 014 INVALID ACTIVATE 016 INVALID COMMAND

Instruction 1. Print the Error Log. (A few parity errors in the log are acceptable.) a) Power off the printer. b) Disconnect the power cord. c) Check coax/twinax cable terminations at the I/O plate. 3. Check coax and twinax I/O cable grounding and connections at controller board. Check that external coax/twinax cable is undamaged and is not longer than 4921.5 feet (1500 meters). a) Connect power cord to printer. b) Power on the printer. c) Send data from host.
Indication Host communication error message display logged. Coax and twinax cables are properly attached.
Yes Go to step 2.
No Return printer to normal operation. Attach cables correctly.
2.
Go to step 3.
Cables are grounded and attached to controller board correctly. Cable is OK.
Go to step 4.
Attach cables correctly.
4.
Go to step 5.
Replace cable.
5.
Error message displays.
Power off printer. Replace one at a time until message is gone: a) coax or twinax cable b) CMX controller board
522
Troubleshooting
015 COMMUNICATIONS CHECK CHECK CABLE

Instruction 1. a) Power off the printer. b) Disconnect the AC power cord from the printer. (See DANGER notice above.) c) Check the twinax host data cable connection. 2. a) Disconnect twinax auto-termination cable from printer and host. b) Check twinax auto-termination cable for the resistances shown on page A27. 3. a) Connect AC power cable to the printer. b) Power on the printer. c) Send a print job to the printer. 4. a) Verify that all other devices on the twinax line are working properly. (Refer to line problem determination procedures, as recommended by host system documentation.) b) Send a print job to the printer.
Indication Twinax host data cable connection is OK.
Yes Check and reseat the twinax I/O cable connection at the CT board. Go to step 2.
No Check and reseat the twinax host data cable connection. Go to step 2.
Twinax auto-termination cable checks out OK.
Connect twinax auto-termination cable to host and printer. Go to step 3.
Replace twinax auto-termination cable assembly.
Job prints OK and no communications check messages appear.
Go to step 4.
Twinax line devices work properly, but message still appears.
Replace the CMX controller board.
Problem is not in the printer. Correct twinax line device malfunction or replace twinax line.
Troubleshooting
523
021 RECEIVE BUFFER OVERRUN VERIFY CONFIGURATION 024 SERIAL LINE PARITY ERROR VERIFY CONFIGURATION 025 SERIAL FRAMING ERROR VERIFY CONFIGURATION
Instruction 1. a) Make a configuration printout. (Ref.: Setup Guide) b) Verify that host and printer serial interface configuration settings match for: Data Protocol Baud Rate Data Bits Stop Bits Parity Data Terminal Ready Request To Send Send a print job to the printer. Indication Host and printer serial interface parameters match. Yes Go to step 2. No Set printer serial interface parameters to match those of the host. (Ref.: Setup Guide)
2.
Job prints OK and no serial interface fault messages appear.
Replace controller board
524
Troubleshooting
057 CLOSE PLATEN 087 PLATEN OPEN TIMEOUT CLOSE PLATEN

Instruction 1. a) Load paper. b) Close the forms thickness lever. c) Run an operator print test. a) Power off the printer. b) Disconnect the platen interlock switch connector. c) Check the switch with a meter. Indication 057 CLOSE PLATEN message. Yes Go to step 2. No Return printer to normal operation.
2.
Switch is bad.
Replace platen interlock switch assembly.
Replace controller board.
Troubleshooting
525
058 SHUTTLE JAM SEE USERS GUIDE

Instruction 1. Check the forms thickness lever: if it is set too tightly, it can slow the shuttle enough to trigger the fault message. Run an operator print test and check for shuttle obstruction. Remove shuttle cover and inspect shuttle area and mechanism for obstruction. Run an operator print test and observe the shuttle. Check MPU adjustment. Run an operator print test. Run an operator print test. Indication Forms thickness lever set correctly. Yes Go to step 2. No Set forms thickness lever for thicker paper. Go to step 2. Return printer to normal operation. Install shuttle cover. Go to step 4. Go to step 7. Adjust MPU. Return printer to normal operation. Return printer to normal operation.
2.
058 SHUTTLE JAM message.
Go to step 3.
3.
Shuttle movement blocked.
Remove obstruction. Install shuttle cover. Go to step 4. Go to step 5. Go to step 6. Replace the MPU. Go to step 5. Replace controller board.
4. 5. 6. 7.
Shuttle moves. MPU adjustment OK. 058 SHUTTLE JAM message. 058 SHUTTLE JAM message.
526
Troubleshooting
060 PRINTER HOT

NOTE: This message indicates internal temperatures over 60 Celsius (140 Fahrenheit). Print jobs will not create such temperatures, so immediately determine that the fans are operating and that all air vents are unobstructed. It is crucial that the exhaust vents on the floor of the cabinet remain unblocked, since hot air from inside the printer is vented through the cabinet floor. Nothing should be stored under the printer. Then check the operating environment. A severe environment is one with an ambient temperature consistently above 40 Celsius (104 Fahrenheit) or is dirty enough to create blockage of the cabinet fan vents. If the printer is located in such an environment, consider relocating it to a cooler, cleaner area or reducing the size and duration of the print jobs.
Instruction 1. 2. Press the Stop key. Cycle power: Power off printer. Wait 15 seconds. Power on printer. Verify that all fans operate. a) Power off the printer. b) Check for obstruction of vents and fan airways.
Indication 060 PRINTER HOT message. 060 PRINTER HOT message.
Yes Go to step 2. Go to step 3.
No Return printer to normal operation. Return printer to normal operation. Replace defective fan(s). Remove obstructions. Make sure cabinet exhaust fan vents are not blocked. (Check for items beneath the printer blocking cabinet vents.) Move printer to cooler, cleaner location.
3. 4.
Fans are OK. Vents and airways are clear.
Go to step 4. Go to step 5.
5.
Examine printer environment for severity. (See NOTE above.)
Printer environment is OK.
Replace the CMX controller board.
Troubleshooting
527
062 EXHAUST FAN FAULT 063 INTAKE FAN FAULT 065 HAMMER BANK FAN FAULT
NOTE: Exhaust Fan Fault = cabinet exhaust fan. Intake Fan Fault = card cage fan.
Instruction 1. Cycle power: Power off printer. Wait 15 seconds. Power on printer. a) Power off the printer. b) Remove the paper guide assembly or pedestal top cover. c) Check that the fan cable connector is connected. (See Appendix A, Interconnect Diagram.) Check for obstruction of vents and fan airway.
Indication _____ FAN FLT message.
Yes Go to step 2.
No Return printer to normal operation. Connect the fan cable connector.
2.
Fan cable is properly connected.
Go to step 3.
3.
Vents and airway are unobstructed.
Go to step 4.
Remove obstructions. Make sure cabinet exhaust fan vents are not blocked. (Check for items beneath the printer blocking cabinet vents.) Replace defective fan(s).
4.
a) Power on the printer. b) Check for rotation of fans as printer powers up. c) Power off the printer. Power on the printer.
Fans are OK.
Go to step 5.
5.
_____ FAN FLT message.
Replace CMX controller board.
528
Troubleshooting
080 POWER SUPPLY HOT

NOTE: The printer has sensor circuits that sample the operating temperature of key print components. When higher than normal temperatures are sensed, print speed is automatically reduced. If the printer runs at reduced speed for an extended period of time, a (UNIT) HOT message is sent to the LCD and printing stops, allowing printer components to cool down. Pressing the Start key resumes the print task. Check the operating environment. A severe environment is one with an ambient temperature consistently above 40 Celsius (104 Fahrenheit) or is dirty enough to create blockage of the cabinet fan vents. If the printer is located in such an environment, consider relocating it to a cooler, cleaner area or reducing the size and duration of the print jobs.
Instruction 1. 2. Press the Start key. Cycle power: Power off printer. Wait 15 seconds. Power on printer. Run a diagnostic printer test. a) Power off the printer. b) Remove the paper guide assembly or pedestal top cover. c) Check that the power supply guard/air deflector is correctly positioned over the power supply board. d) WARNING: DO NOT TOUCH the power supply, but hold your hand close enough to check for heat radiating off the board. Verify that all fan cable connectors are connected. (See Appendix A, Interconnect Diagram.) a) Power on the printer. b) Verify that all fans operate. c) Power off printer.
Indication POWER SUPPLY HOT message. POWER SUPPLY HOT message. POWER SUPPLY HOT message. Power supply is noticeably hot.
No Return printer to normal operation. Return printer to normal operation. Return printer to normal operation. Replace power supply board.
3. 4.
5.
Fan cables are properly connected.
Go to step 6.
Connect fan cable connector(s).
6.
Fans are OK.
Go to step 7.
Replace defective fan(s).
Troubleshooting
529
Instruction 7. Check for obstruction of vents and fan airways.
Indication Vents and airways are clear.
Yes Go to step 8.
No Remove obstructions. Make sure cabinet exhaust fan vents are not blocked. (Check for items beneath the printer blocking cabinet vents.) Move printer to cooler, cleaner location. Replace the CMX controller board.
8.
Examine printer environment for severity. (See NOTE above.) Check the kinds of print jobs the user is running: look for very dense graphics and layouts.
Printer environment is OK.
Go to step 9.
9.
Print jobs are dense enough to slow the printer.
Advise the user to run jobs in smaller batches.
530
Troubleshooting
089 RIBBON STALL

Instruction 1. Using a screwdriver, short across the ribbon guide screws to reverse ribbon hub motion. Check for ribbon failing to reverse motion. Check for missing foil strip at end of ribbon. Check that forms thickness lever is not closed too tightly; this can jam the ribbon and shuttle. Run a ribbon and shuttle CE Test and check for shuttle obstruction. Check ribbon path for blockage or obstruction. Indication Ribbon fails to reverse. Yes Go to step 3. No Go to step 2.
2. 3.
Foil strip missing. Forms thickness lever is set correctly.
Replace the ribbon. Go to step 4.
Go to step 8. Readjust the setting of the forms thickness lever. Go to step 4. Return printer to normal operation. Remove obstructions from ribbon path and go to step 6. Replace ribbon, if damaged. Unfold and rewind ribbon if it was folded. Go to step 7. Align ribbon guides. Go to step 8. Go to step 9.
4.
Ribbon fault message.
Go to step 5.
5.
Ribbon path is clear
Go to step 6.
6.
Wind ribbon by hand and inspect for folds, tears, holes, fraying.
Ribbon is OK.
Rewind and reinstall ribbon. Go to step 7.
7.
Run the Shuttle Fast CE Test and check the alignment of the ribbon guides and hubs if the ribbon was folded. Using a screwdriver, short across the ribbon guide screws to reverse ribbon hub motion. Check for a ribbon drive motor that does not wind ribbon. On motor that does not wind the ribbon, check the motor cable and extension cable for pinches, damage, or shorts.
Ribbon tracks OK.
Go to step 8.
8.
Both motors wind the ribbon.
Replace the controller board.
9.
Motor cable and extension cable OK.
Replace the controller board.
Replace the defective ribbon drive motor, extension cable, and controller board.
Troubleshooting
531
090 SHUTTLE COVER OPEN CLOSE SHUTTLE COVER

Instruction 1. Inspect shuttle cover for warping, damage, or missing magnet. (The magnet covers the sensor housing when the cover is installed.) Check shuttle cover installation. Indication Shuttle cover damaged. Yes Replace the shuttle cover assembly. No Go to step 2.
2.
Shuttle cover installed correctly.
Go to step 3.
Install the cover correctly. Make sure the cover lies flat and the two captive screws are fully seated. Go to step 3. Replace the CMX controller board.
3.
Run an operator print test.
090 SHUTTLE COVER OPEN / CLOSE SHUTTLE COVER message.
Replace the cover open switch assembly.
532
Troubleshooting
101 UPPER DRIVER SHORT

Instruction 1. Cycle power: Power off printer. Wait 15 seconds. Power on printer. Press the Start key. Indication 101 UPPER DRIVER SHORT message. 101 UPPER DRIVER SHORT message. 101 UPPER DRIVER SHORT message. Yes Go to step 2. No Return printer to normal operation. Return printer to normal operation. Return printer to normal operation.
2.
Replace the CMX controller board. Go to step 3. Replace the shuttle frame assembly. Go to step 4. Replace hammer bank logic cable assembly and hammer bank power cable assembly.
3.
Power on the printer.
4.
101 UPPER DRIVER SHORT message.
Troubleshooting
533
102 LOWER DRIVER SHORT

Instruction 1. Cycle power: Power off printer. Wait 15 seconds. Power on printer. Press the Start key. Indication 102 LOWER DRIVER SHORT message. 102 LOWER DRIVER SHORT message. Yes Go to step 2. No Return printer to normal operation. Return printer to normal operation.
2.
Replace the shuttle frame assembly. Go to step 3. Replace the CMX controller board. Go to step 4. Replace hammer bank logic cable assembly and hammer bank power cable assembly.
3.
102 LOWER DRIVER SHORT message. 102 LOWER DRIVER SHORT message.
Return printer to normal operation. Return printer to normal operation.
4.
534
Troubleshooting
107 HAMMER COIL <number> HOT

NOTE: The printer has sensor circuits that sample the operating temperature of key print components. When higher than normal temperatures are sensed, print speed is automatically reduced. If the printer runs at reduced speed for an extended period of time, a (UNIT) HOT message is sent to the LCD and printing stops, allowing printer components to cool down. Pressing the Start key resumes the print task. If the printer often prints at half speed, it may be operating in a severe environment. A severe environment is one with an ambient temperature consistently above 40 Celsius (104 Fahrenheit) or that is dirty enough to create blockage of the cabinet fan vents. If the printer is located in such an environment, consider moving it to a cooler, cleaner area or reducing the size and duration of the print jobs.
Instruction 1. 2. Press the Start key. Cycle power: Power off printer. Wait 15 seconds. Power on printer. Run All Black print test for 1/4 page. a) Power off the printer. b) Remove the paper guide assembly or pedestal top cover. c) Verify that all fan cable connectors are connected. (See Appendix A, Interconnect Diagram.) a) Power on the printer. b) Verify that all fans operate. c) Power off printer. Check for obstruction of vents and fan airways.
Indication 107 HAMMER COIL <number> HOT message. 107 HAMMER COIL <number> HOT message. 107 HAMMER COIL <number> HOT message. Fan cables are properly connected.
No Return printer to normal operation. Return printer to normal operation. Return printer to normal operation. Connect fan cable connector(s).
3. 4.
5.
Fans are OK.
Go to step 6.
Replace defective fan(s). Remove obstructions. Make sure cabinet exhaust fan vents are not blocked. (Check for items beneath the printer blocking cabinet vents.)
6.
Vents and airways are clear.
Go to step 7.
Troubleshooting
535
Instruction 7. Examine printer environment for severity. (See NOTE above.) Check the kinds of print jobs the user is running: look for very dense graphics and layouts.
Indication Printer environment is OK.
Yes Go to step 8.
No Move printer to cooler, cleaner location. Replace one at a time until the problem goes away: a) shuttle frame assembly b) CMX controller board
8.
Print jobs are dense enough to slow the printer.
Advise the user to run jobs in smaller batches.
536
Troubleshooting
DRIVER CIRCUIT BAD

Instruction 1. Cycle power: Power off printer. Wait 15 seconds. Power on printer. Press the Start key. a) Power off the printer. b) Remove the shuttle cover. c) At the shuttle frame assembly, disconnect the hammer bank logic and power cables. d) Power on the printer. Indication DRVR CIR BAD* message. Yes Go to step 2. No Return printer to normal operation. Return printer to normal operation. Replace the CMX controller board.
2. 3.
DRVR CIR BAD* message. HAMMER BANK NOT INSTALLED* message.
Go to step 3. Replace the shuttle frame assembly.
Troubleshooting
537
HAMMER BANK NOT INSTALLED

Instruction 1. a) Power off the printer. b) Remove the shuttle cover. c) Verify that the shuttle frame assembly is installed. a) Remove the paper guide assembly or pedestal top cover. b) Verify that the hammer bank logic cable is connected to connector J108 on the CMX controller board and to its connector on the shuttle frame assembly. Verify that the hammer bank power cable is connected to connector J105 on the controller board and to its connector on the shuttle frame assembly. Power on the printer. Indication Shuttle frame assembly is installed in the printer. Yes Go to step 2. No Install the shuttle frame assembly.
2.
Hammer bank logic cable is connected to J108 on the controller board and to the shuttle frame assembly.
Go to step 3.
Connect hammer bank logic cable. Go to step 4.
3.
Hammer bank power cable is connected to J105 on the controller board and to the shuttle frame assembly.
Go to step 4.
Connect hammer bank power cable. Go to step 4.
4.
HAMMER BANK NOT INSTALLED message.
Replace the hammer bank logic cable. (See Appendix A.) Go to step 4. Replace the CMX controller board. Go to step 6. Replace the shuttle frame assembly.
5.
HAMMER BANK NOT INSTALLED message. HAMMER BANK NOT INSTALLED message.
Return printer to normal operation. Return printer to normal operation.
6.
538
Troubleshooting
Symptoms Not Indicated by Fault Messages

Use standard fault-isolation techniques to troubleshoot malfunctions not indicated by fault messages: 1. Ask the operator to describe the problem. 2. Verify the fault by running diagnostic tests or replicating the conditions reported by the user. 3. Look for a match in the Symptoms Not Indicated by Fault Messages Troubleshooting Table (page 540), and follow the instructions given. 4. Locate the malfunction using the half-split method: c. Start at a general level and work down to details.
d. Isolate faults to half the remaining system at a time, until the final half is a field-replaceable part or assembly. (Troubleshooting aids are listed on page 52.) 5. Replace the defective part or assembly. IMPORTANT DO NOT attempt field repairs of electronic components or assemblies. Replace a malfunctioning electronic assembly with an operational spare. Most electronic problems are corrected by replacing the circuit board, sensor, or cable that causes the fault indication. The same is true of failures traced to the hammer bank coils and electronics: you must replace the entire shuttle frame assembly. It is not field repairable. (Hammer spring assemblies are the only replaceable components of the shuttle frame assembly.) 6. Test printer operation after every corrective action. 7. Stop troubleshooting and return the printer to normal operation when the reported symptoms disappear.
Troubleshooting
539
Symptoms Not Indicated by Fault Messages Troubleshooting Table

Symptom
No power, operator panel LCD and LEDs blank, card cage fan not running. Power on hang condition. 1. 1.
Instruction
+5 volt distribution problem to the controller board. (Refer to the Power Distribution Diagram on page A4.) Replace one at a time until the problem is fixed: a) controller board b) power supply a) Power off printer. b) Remove the paper guide assembly or pedestal top cover. c) Reseat the IBM coax/twinax expansion board. d) Check all cable connections into the controller board, especially that the control panel cable is seated in connector J110 on the controller board. Make sure the flash memory SIMM(s) is/are seated properly in J10/J11. (Failed or corrupted flash memory can cause black squares. If you suspect flash memory is bad and you cannot load flash, contact your service support group.) e) Power on the printer. If the display is still blank or has a black line, go to step 2 Replace one at a time until the problem is fixed: a) IBM coax/twinax expansion board and adapter b) operator panel assembly c) operator panel cable assembly d) controller board Replace one at a time until the problem is fixed: a) operator panel assembly b) operator panel cable assembly c) controller board Clean the shuttle frame assembly (page 32). Check the left and right ribbon guide alignment (page 616). Perform a printer confidence check (page 544). Power off printer and disconnect the AC power cable. Check the host data cable connection at the rear of the printer. If the printer interface is RS232, interchange the wires to pins 2 and 3. This is the most common cause of a completely inoperative RS232 cable. Make sure the printer and host have the same baud rate, number of data bits, number of stop bits, and parity. In RS232, configure the host for XON/XOFF if possible; this requires the least complex cable. Replace the controller board
Blank or single line of black squares across top row of operator panel LCD.
1.
2.
Operator Panel key failure.
1.
Ribbon folding or feed problems.
1. 2.
Printer appears normal, but does not print data sent from the host.
1. 2. 3. 4.
5.
540
Troubleshooting
Symptom
Continuous IML cycle. 1.
Instruction
This symptom indicates coax/twinax code is being loaded into a printer with a missing, defective, or improperly installed Coax/Twinax board. If the printer is supposed to have this feature, reseat the IBM coax/twinax expansion board. If the printer is not supposed to have this feature, install new emulation code without the Coax/Twinax feature. If the printer prints from the host, but occasionally loses blocks of data, the most likely cause is the host not responding to send no more data signals from the printer. With a PC Parallel interface, this means the host is ignoring BUSY; in RS232, the host is ignoring the XOFF character or Data Terminal Ready signal (pin 20). Sometimes the cable is not conveying the necessary signals. Test this by using a serial line analyzer and software or test equipment that displays the data and handshake lines of the printer. A breakout box works, but will not debug XON/XOFF or other RS232 data protocols. If the printer is sending XOFF with one stop bit, the host may not be receiving it if the host requires 1.5 or 2 stop bits. a) If the printer prints from the host, but occasionally prints double characters, there is probably a noise problem at the interface or the host computer is sending an inverted strobe. This problem can occur on PC Parallel or Dataproducts interfaces, never on RS232. What happens is that the strobe signal registers logic 1 more than once for a certain character. To fix this, change the strobe to trailing edge or invert the strobe polarity. (Refer to the Setup Guide.) b) Also check that the terminating resistors are present on the controller board (page 731). You can correct some noise problems by using a shielded data cable or by changing the terminating resistors. The standard terminating resistors are optimized for high speed data transfer for cables between 1 and 5 meters long; you can change them for slower operation, which will provide slightly more noise immunity. c) Noise is caused by static, a floating logic ground, unshielded cable, changes in ground voltage from nearby equipment, or capacitively- or magnetically-induced noise. On very long cables, capacitively-induced noise from the other signals of the cable (especially PC Parallel ACK or Dataproducts DEMAND) can cause false strobes. Unshielded and flat ribbon cables are much more prone to problems due to increased length. The best solution is to shorten cable, shield it, and reduce local electromagnetic noise. Also, make sure that both the printer and the host computer are properly grounded.
Printer prints data sent from the host, but occasionally prints double characters or loses blocks of data.
1.
2.
Troubleshooting
541
Print Quality Problems

Missing, light, or smeared characters or dots: 1. 2. 3. 4. 5. 6. Check the forms thickness lever setting. Check adjustment of right tractor (too tight or loose can cause problems). Check platen belt tension (page 66). Check the ribbon for folds or tears. Clean the shuttle frame assembly (page 32). Replace one at a time until the problem is fixed: a) Replace appropriate hammer spring assembly ONLY if you see visible damage or broken parts (page 723); otherwise, proceed to step 6b. b) shuttle frame assembly (page 754) c) controller board (page 711) Check the forms thickness lever setting. Clean the shuttle frame assembly (page 32). Check the platen gap adjustment (page 612). Install a new ribbon. Replace one at a time until problem is fixed: a) controller board (page 711) b) shuttle frame assembly (page 754) If all dots between alternate rows are misaligned, check hammer phasing (page 624). Check adjustment of right tractor (too tight or loose can cause problems). Clean the shuttle frame assembly (page 32). Check the MPU gap adjustment (page 728). Replace one at a time until problem is fixed: a) MPU (page 728) b) controller board (page 711) c) shuttle frame assembly (page 754) Check paper feed motor belt (page 64). Check platen gap adjustment (page 612). Replace one at a time until problem is fixed: a) tractors (page 762) b) paper feed motor (page 732) c) controller board (page 711) d) power supply board (page 713)
All characters or dots are too light or too dark.
1. 2. 3. 4. 5.
Horizontal misalignment. (Dots or 1. characters move left or right from dot row to dot row or line to line.) 2. 3. 4. 5.
Vertical misalignment: 1. Dots or characters move up or down from dot row to dot row or line to line. 2. Incorrect spacing from dot row to dot row or line to line.
1. 2. 3.
542
Troubleshooting
Print Quality Problems

Randomly misplaced dots. 1. 2. 3. 4. Check platen gap adjustment (page 612). Check adjustment of right tractor (too tight or loose can cause problems). Check printer grounding (page E4). Replace one at a time until problem is fixed: a) controller board (page 711) b) power supply board (page 713) c) shuttle frame assembly (page 754) a) Put the printer into hex dump mode and analyze the binary data. One cause of garble is the host interface or cable not transmitting all 8 data bits. When this occurs, the PC Parallel or Dataproducts interface receives a 1 on every unconnected data line. Uncontrolled slewing is often caused by enabling PI (Paper Instruction) in the printer when the host lacks a PI signal. (PI shows as p on the hex dump.) Some RS232 and Dataproducts interfaces only send 7 data bits. In this case, the eighth bit will be received as a one. b) In RS232, a common cause of garble is the interface set to the wrong baud rate or parity. Sometimes the host sends 1.5 or 2 stop bits; in this case, the printers 1-stop-bit setting will accept both 1.5 and 2 stop bit data. Sometimes the data can fade or persist from one character to the next. This reveals a problem with PC Parallel or Dataproducts terminating resistors on the controller boardespecially if they are absent. Garble also can result from failed termination resistors or parallel logic, but this is rare. 2. Replace the controller board.
Garbled print or paper slews uncontrollably.
1.
Troubleshooting
543
Printer Confidence Check

Instruction 1. Check that printer is plugged into correct power source. Indication Power cable installed correctly to proper source. Yes Power off printer. Go to step 2. No Power off the printer. Connect printer to correct power source. Troubleshoot the fault message (page 53). Troubleshoot the fault message (page 53). Reconfigure the printer. (Ref.: Setup Guide)
2.
Printer goes to READY state.
Go to step 3.
3.
Run an operator print test (page 545). Make a configuration printout. (Ref.: Setup Guide)
Printer operates correctly
Go to step 4.
4.
a) Configuration is correct for the users application. b) Host computer and printer are using the same protocol (emulation). c) Configuration has not been inadvertently changed by user. Assemblies and components are adjusted in accordance with Chapter 6. Connections are clean and tight. Wires are not stripped, frayed, or out of connectors.
Go to step 5.
5.
a) Power off printer. b) Check alignments and adjustments. (Chapter 6.)
Go to step 6.
Adjust all assemblies that are out of spec. Replace stripped, frayed, or broken wires.
6.
a) Power off printer. b) Remove paper guide assembly or pedestal top cover (Chapter 7). c) Check all electrical connectors.
Go to step 7.
7.
Check that all printed circuit boards are correctly installed and cable connections are correct. (Ref.: Appendix A) Inspect for debris that could cause short circuits (loose fasteners, foil, etc.). a) Install paper guide assembly or pedestal top cover (Chapter 7). b) Power on the printer.
Printed circuit boards are firmly seated and all cables are correctly attached.
Go to step 8.
Install each board correctly. Check and correct the cable attachments. Go to step 9.
8.
Metallic debris found.
Remove debris. Clean the printer. (Chapter 3.) Printer checks out OK. Fault may not be in printer. Check host computer, applications software, cabling, etc.
9.
Printer powers up and initializes properly.
Troubleshoot the fault message (page 53).
544
Troubleshooting
Operator Print Tests

A set of print tests is included in the configuration menu structure for use as diagnostic tools. These are called the Operator Print Tests because they are available to the user. You can use these print tests to check the print quality and basic operation of the printer. The Operator Print Tests are summarized below.
NOTE: Under the description of some tests is a list of items that may need to be adjusted or replaced if the test produces a bad print pattern. The items are listed in the order you should check them: simplest items first, complex items last. Printer Demonstration Prints a sample page showing every print mode, font, and pitch available in the printer. Print Error Log Prints the contents of the error log. The error log automatically 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 list. If more than 50 messages occur before the log is cleared, the oldest messages are deleted, so that the log never contains more than 50 messages. Ripple Print A sliding alphanumeric pattern useful for identifying missing or malformed characters, improper vertical alignment, or vertical compression. Hammer bank cover Hammer spring Shuttle frame assembly All Es A pattern of all uppercase letter Es useful for identifying missing characters, misplaced dots, smeared characters, improper phasing, or light/dark character variations. Ribbon Splined shaft skew adjustment Hammer bank cover MPU sensor Hammer springs Hammer coils (shuttle frame assembly) All Hs A pattern of all uppercase letter Hs useful for detecting missing characters or dots, smeared characters, or improper phasing.
Troubleshooting
545
Ribbon Hammer bank cover MPU sensor Hammer springs Hammer coils (shuttle frame assembly) All Es + FF A pattern of all Es repeated for ten lines and followed by a form feed to the top of the 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 Tractors or tractor belts Underlines An underline pattern useful for identifying hammer bank misalignment. Hammer bank cover Hammer tips Paper feed belt or motor Splined shaft bearings Tractor bearings or belts
546
Troubleshooting
Selecting and Running Operator Print Tests

Step
1.
Key
Displayed Result
Notes
Make sure that the printer ribbon is installed in the printer and the printer is powered on and is loaded with paper. Press:
Stop
NOT READY
2.
Places the printer in Not Ready mode.
3.
Press:
Scroll
Scroll
Press both keys at the same time. Unlocking the Enter key allows you to test your printer. First of the series of configuration menus.
4.
Press:
Menu
OPERATOR MENU PRINTER CONTROL
5.
Press:
Scroll
UNTIL
OPERATOR MENU OPERATOR PRINT TESTS
Advances to the Operator Printer Tests menu. Advances to Printer Demonstration, the first option in Operator Printer Tests menu. Cycles through the list of Printer Tests. Stop when the name of the test you wish to run displays. The printer test you have selected starts printing.
6.
Press:
Enter
OPERATOR PRINT TESTS PRINTER DEMONSTRATION*
7.
Press:
Scroll UNTIL
OPERATOR PRINT TESTS [TEST NAME]
8.
Press:
Enter
OPERATOR PRINT TESTS [TEST NAME]
9.
Press:
Stop
NOT READY
The printer test stops printing.
Troubleshooting
547
Customer Engineer (CE) Tests

A set of printer tests is included in the configuration menu structure for use as maintenance tools. These are called Customer Engineer Tests (CE Tests) because they are for your usethey are not available to the user through his documentation. You will use these tests in various troubleshooting and adjustment procedures.
CE Tests
NOTE: * = Default value
SERVICE PRINTER MECHANISM TESTS
SERVICE HAMMER PHASE VALUE
SERVICE END OF FORMS ADJUSTMENT VALUE
SERVICE CLEAR ERROR LOG
Burn In Test Plot Test Shuttle Only Shuttle Slow Shuttle Fast Hammer Phasing End of Forms Adjust
1 1000 NOTE: Value is numeric unit only. Test defined on page 549. Procedure on page 624.
4 76, 40* Unit of measurement is dot rows. Procedure on page 620.
Enter key activates
SERVICE PRINT PARTIAL LINE
SERVICE TOP EXIT TEAR DISTANCE
SERVICE SHUTTLE SPEED
SERVICE SET COIL TEMPERATURE
ENABLE* DISABLE
5.25 to 5.75 inches in increments of 0.01 inch. 5.50*
475 500* Procedure on page 633.
Procedure on page 632.
Figure 51. CE Tests Menu
The CE Tests shown in Figure 51 are summarized below: Printer Mechanism Tests: Burn In Test Use of this test is not recommended. This test is used by the manufacturer to burn in the printer prior to shipment, and has no value as a maintenance tool. Plot Test Prints all dot positions, creating a solid black band. Exercises the shuttle and hammer bank at maximum capacity.
548
Troubleshooting
Power Supply board Hammer bank cover Hammer springs Hammer coils (the shuttle frame assembly) Shuttle Only This test runs only the shuttle. Shuttle Slow Verifies proper operation by exercising the shuttle and ribbon mechanisms at low speed. You can also use this test to check ribbon tracking and reversing. Shuttle Fast Verifies proper operation by exercising the shuttle and ribbon mechanisms at high speed. You can also use this test to check ribbon tracking and reversing. Hammer Phasing A hammer timing parameter that permits you to adjust the vertical alignment of dots in character printing. End of Forms Adjust A vertical comb pattern used to determine the number of dot rows from the completion of a paper out fault to the end of the paper.
Hammer Phase Value: The hammer phase value is a timing parameter that permits you to adjust the vertical alignment 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 the aluminum casting of the shuttle assembly, next to the motor housing. Use this value as your starting point when adjusting hammer phasing. End of Forms Adjustment Value: This parameter determines where on the paper the printer will stop printing when an out of paper fault is detected. The unit of measurement is dot rows. The number of dot rows may be adjusted up or down 1/2 from the factory default of 40 dots. Clear Error Log: This menu selection enables you to delete the stored contents of the error log. The error log automatically 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 list. If more than 50 messages occur before the log is cleared, the oldest messages are deleted, so that the log never contains more than 50 messages.
Troubleshooting
549
Print Partial Line: If the final line of a data stream has no line feed or carriage return character it is retained in the buffer. DISABLE holds the line in the buffer; ENABLE permits the line to be printed after a timeout. Top Exit Tear Distance: This parameter allows adjustment in 0.01 inch increments of the final location of page perforations when top paper exit is used. Shuttle Speed: Sets shuttle speed in 6400004, 04P, 005, and 05P printers. See page 633. Set Coil Temperature: An automatic sequence in printer software that recalibrates hammer coil temperature. This procedure applies only to 6400005, 05P, and 014 printers. See page 632.
Selecting and Running CE Tests

1. If the Ready indicator is on, press the Stop key. The printer must be in NOT READY state to access the CE Tests. 2. Press Scroll" + Scroll# + Return + Enter. (Press all four keys at the same time.) 3. The first menu item is PRINTER MECHANISM TESTS. To view the different mechanism tests, press Enter. 4. Scroll to the desired test by using the Scroll" or Scroll# key. 5. Press Scroll" + Scroll# to unlock the Enter key. 6. Press Enter. The selected test begins. To end the test, press the Enter key.
NOTE: See Chapter 6 for special instructions in the use of the Hammer Phasing and End of Forms Adjust tests. 7. Press Stop to halt any test, exit the menu, and put the printer in the NOT READY state. OR
550
Troubleshooting
8. Press Start to halt any test, exit the menu, and put the printer in the READY state.
Boot Diagnostics Menu

Printer boot-up software contains a menu structure that you can access by holding down the Eject/Restore and Stop keys while powering up the printer. These menus are not intended for the end user, but provide useful information for manufacturing and maintenance personnel. The boot diagnostic menu structure is depicted in Figure 52. To exit the hidden diagnostic menu, you must recycle power.
Activating the 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 (on). 4. When BOOT DIAGNOSTICS / PRESS ENTER appears on the LCD, release the Eject/Restore and Stop keys. 5. Press the Enter key. Menu options are shown in Figure 52.
Exiting the Boot Diagnostic Menu 1. Power off the printer. 2. Wait 15 seconds. 3. Power on the printer.
Troubleshooting
551
BOOT DIAGNOSTICS PRESS ENTER
B = Scroll
NOTE: To exit this menu, cycle power.
ENTER
BOOT DIAGNOSTICS VERSION CHECK
ENTER
VERSION CHECK BOOT VERSION
VERSION CHECK SOFTWARE VERSION
VERSION CHECK EC VERSION
VERSION CHECK ASIC VERSIONS
ENTER
BOOT/CMX V10B 12Sep95 #158945 09/08/95 11:41:08
ENTER
ENTER
EC V1.00H 07Sep95 #154643
ENTER
VX VERSION=F MECA VERSION=F
VERSION CHECK P.C. BOARD VERSION
VERSION CHECK SECURITY PART #
VERSION CHECK PROCESSOR SPEED
ENTER
P.C. BOARD VERSION 3.0
ENTER
SECURITY PART # 154143001
ENTER
PROCESSOR SPEED 68E030 AT 25 MHZ
BOOT DIAGNOSTICS FILE UTILITIES
"
ENTER
FILE UTILITIES VIEW FILES
Continued on Next Page

FILE UTILITIES FILE SYSTEM STATUS
FILE UTILITIES OPTIMIZE FILES
ENTER
VIEW FILES VERSION
ENTER
B
VIEW FILES FILENAME
ENTER
OPTIMIZING FLASH FILES
FLASHDISK STATUS FREE = 0012473
FLASHDISK STATUS #ERASES = 000073
FLASHDISK STATUS # OF FILES = 000
FLASHDISK STATUS USED = 0002048
FLASHDISK STATUS DELETED = 0000000
Figure 52. Boot Diagnostics Menu
552
Troubleshooting
BOOT DIAGNOSTICS MISC UTILITIES
B = Scroll
NOTE: To exit this menu, cycle power.
From Previous Page
ENTER
MISC UTILITIES DISPLAY MEMORY
MISC UTILITIES RESET PRINTER
MISC UTILITIES COPY FLASH SIMMS
MISC UTILITIES COPY BOOT SIMMS
ENTER
FLASH = 2 MBYTES DRAM = 2 MBYTES
ENTER
RESETTING... PLEASE WAIT
ENTER
ENTER
MISC UTILITIES ERASE ALL FLASH
MISC UTILITIES RUN MEMORY TESTS
MISC UTILITIES FILE DOWNLOAD
MISC UTILITIES CLEAR NVRAM
ENTER
ERASE ALL FLASH COMPLETED
ENTER
TESTING FOR ADDRESS SHORTS
ENTER
ENTER
CLEAR NVRAM COMPLETED
NOTE: You must cycle power to exit the file download menu.
SELECT DOWNLOAD PORT=CENTRONIC
SELECT DOWNLOAD PORT=RS2329600
SELECT DOWNLOAD PORT=RS23219.2K
SELECT DOWNLOAD PORT=RS232115K
ENTER
WAITING DOWNLOAD PORT=CENTRONIC
ENTER
WAITING DOWNLOAD PORT=RS2329600
ENTER
WAITING DOWNLOAD PORT=RS23219.2K
ENTER
ENTER
WAITING DOWNLOAD PORT=RS232115K
SELECT DOWNLOAD PORT=RS4229600
SELECT DOWNLOAD PORT=RS422115K
SELECT DOWNLOAD PORT=DATAPRODUCT
ENTER
WAITING DOWNLOAD PORT=RS4229600
ENTER
ENTER
ENTER
WAITING DOWNLOAD PORT=RS422115K
ENTER
WAITING DOWNLOAD PORT=DATAPRODUCT
Figure 52. Boot Diagnostics Menu (continued)
Troubleshooting
553
Hex Code Printout

A hex code printout (hex dump) prints every ASCII character received from the host computer with its corresponding two-digit hexadecimal code. Hex dumps can be used to troubleshoot printer data reception problems by comparing the printed hex data to the data sent from the host. In a hex dump, every character is printed as its assigned ASCII symbol and as the hexadecimal value of the character. A character that does not have a printed symbol (for example, a control character) is printed as a period (.) and the hex value of the control character. If the printer is using a parallel interface, the letter p before a hex code indicates an active Paper Instruction (PI) line and a blank space before a hex code indicates an inactive PI line. To convert an ASCII character to its corresponding hex code, or vice-versa, refer to the ASCII code chart on page 556.
Step
1. Press:
Key
Stop
Displayed Result
NOT READY
Notes
2.
Press:
Scroll
Scroll
Press both keys at the same time. Unlocking the Enter key allows you to test the printer. First of the series of configuration menus.
3.
Press:
Menu
4.
Press:
Enter
PRINTER CONTROL INTERFACE SELECTION
Moves down to the Interface Selection option. Moves down to the Hex Print Mode option.
5.
Press:
Scroll
UNTIL
PRINTER CONTROL HEX PRINT MODE
6.
Press:
Enter
HEX PRINT MODE DISABLE*
Moves down to Disable, the active option.
554
Troubleshooting
Step
7. Press:
Key
Scroll
Displayed Result
HEX PRINT MODE ENABLE
Notes
Moves down to Enable, the alternate option.
8.
Press:
Enter
HEX PRINT MODE ENABLE*
Asterisk (*) indicates this choice is now active. Returns the printer to Not Ready mode.
9.
Press:
Stop
NOT READY
10.
Press:
Scroll
+ Scroll
OPERATOR MENU LOCKED
Press both keys at the same time to relock the Enter key.
11.
Press:
Start
READY
Puts the printer in READY mode.
Troubleshooting
555
ASCII Character Set
B7
B6
0 B5
BITS
KEY
B4 B3 B2 B1 1 0 1 1
ESC
33 27 1B
OCTAL equivalent DECIMAL equivalent HEX equivalent ASCII Character

1 1 0 1 0 0 1 1 1 1 0 1 1
B7
B6
0 B5
0 0
0 1
0 0
BITS
B4 B3 B2 B1 ROW
COLUMN
0
NUL SOH STX ETX EOT ENQ ACK BEL BS HT LF VT FF CR SO SI
0 0 0 1 1 1 2 2 2 3 3 3 4 4 4 5 5 5 6 6 6 7 7 7 10 8 8 11 9 9 12 10 0A 13 11 0B 14 12 0C 15 13 0D 16 14 0E 17 15 0F
1
DLE DC1
(XON) 20 16 10 21 17 11 22 18 12 23 19 13 24 20 14 25 21 15 26 22 16 27 23 17 30 24 18 31 25 19 32 26 1A 33 27 1B 34 28 1C 35 29 1D 36 30 1E 37 31 1F
2
SP
40 32 20 41 33 21 42 34 22 43 35 23 44 36 24 45 37 25 46 38 26 47 39 27 50 40 28 51 41 29 52 42 2A 53 43 2B 54 44 2C 55 45 2D 56 46 2E 57 47 2F
3 0 1 2 3 4 5 6 7 8 9 : ; < = > ?
60 48 30 61 49 31 62 50 32 63 51 33 64 52 34 65 53 35 66 54 36 67 55 37 70 56 38 71 57 39 72 58 3A 73 59 3B 74 60 3C 75 61 3D 76 62 3E 77 63 3F
4 @ A B C D E F G H I J K L M N O
100 64 40 101 65 41 102 66 42 103 67 43 104 68 44 105 69 45 106 70 46 107 71 47 110 72 48 111 73 49 112 74 4A 113 75 4B 114 76 4C 115 77 4D 116 78 4E 117 79 4F
5 P Q R S T U V W X Y Z [ \ ] ^ _
120 80 50 121 81 51 122 82 52 123 83 53 124 84 54 125 85 55 126 86 56 127 87 57 130 88 58 131 89 59 132 90 5A 133 91 5B 134 92 5C 135 93 5D 136 94 5E 137 95 5F
6
140 96 60
7 p q r s t u v w x y z { | }
160 112 70 161 113 71 162 114 72 163 115 73 164 116 74 165 117 75 166 118 76 167 119 77 170 120 78 171 121 79 172 122 7A 173 123 7B 174 124 7C 175 125 7D 176 126 7E 177 127 7F
0 0 0 0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
0 0 0 1
! # $ % & ( )
a b c d e f g h i j k l m n o
141 97 61 142 98 62 143 99 63 144 100 64 145 101 65 146 102 66 147 103 67 150 104 68 151 105 69 152 106 6A 153 107 6B 154 108 6C 155 109 6D 156 110 6E 157 111 6F
0 0 1 0
DC2 DC3 DC4 NAK SYN ETB CAN EM SUB ESC FS GS RS US
0 0 1 1
(XOFF)
0 1 0 0
0 1 0 1
0 1 1 0
0 1 1 1
1 0 0 0
1 0 0 1
1 0 1 0
*
+
1 0 1 1
1 1 0 0
, . /
1 1 0 1
1 1 1 0
~
DEL
1 1 1 1
556
Troubleshooting
Printer Information Menu

PRINTER INFORMATION
Installed Memory
Power On Time
Printing Time
Print Strokes
11 Inch Pages
To view options, press:

Scroll Scroll Enter Return
Enter
To select an option, press:

Start Toexit exitthe theconfiguration configurationmenus menus To and return to READY, press:
* = Factory Default
Figure 53. Printer Information Menu
You can view various printer statistics, such as hours of usage, and refer to these figures for preventive maintenance purposes. Printer statistics accumulate 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 installed in the printer in megabytes. The cumulative time in hours the printer has been powered on. The range is 0 to 30,000 hours. The cumulative time in hours the printer has actually been printing. The range is 0 to 30,000 hours. The cumulative number of back-and-forth shuttle strokes the printer has printed during normal operation. The range is 0 to 4,000,000,000 shuttle strokes. The cumulative number of pages the printer has printed. The range is 0 to 363,000,000 pages.
Power-on Time:
Printing Time:
Print Strokes:
11 Inch Pages:
Troubleshooting
557
Displaying Printer Information

Step
1. 2.
Key
Power on the printer. Press:
Stop
Displayed Result
Notes
NOT READY
3.
Press:
Scroll
Scroll
Press both keys at the same time. Unlocking the Enter key gives you access to configuration menus. First of the series of configuration menus.
4.
Press:
Menu
5.
Press:
Scroll
UNTIL
OPERATOR MENU PRINTER INFORMATION
Advances to the Printer Information menu.
6.
Press:
Enter
PRINTER INFORMATION INSTALLED MEMORY
Advances to Installed Memory, the first of the Printer Information menus. Cycles through the Printer Information menus. Stop when you see the name of the menu you wish to display. The menu you selected displays the accumulated statistics or printer information. Puts the printer in NOT READY mode.
7.
Press:
Scroll
UNTIL
PRINTER INFORMATION [MENU NAME]
8.
Press:
Enter
[MENU NAME] [STATISTIC/INFORMATION]
9.
Press:
Stop
NOT READY
558
Troubleshooting
Soft vs. Hard Reset
Soft Reset
A soft(ware) reset clears printer memory then loads the power-up configuration into memory. (The procedure for saving configurations is described in the Setup Guide.) It is called a soft reset because no hardware is tested. All diagnostic and initialization tests are bypassed and memory is simply refreshed with the power-up printer configuration. Put the printer in the NOT READY state to do a soft reset: 1. Press the Stop key to put the printer in the NOT READY state. 2. Press the Stop + Enter keys. The LCD will display STANDBY..., SOFT RESET while the printer loads the power-up configuration.
Hard Reset
A hard(ware) reset runs all initialization and diagnostic routines. To do a hard reset: 1. Power off the printer. 2. Wait 15 seconds. 3. Power on the printer.
Troubleshooting
559
560
Troubleshooting
Chapter Contents
Preparing the Printer for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Returning the Printer to Normal Operation . . . . . . . . . . . . . . . . . . . . . . 63 Belt, Paper Feed Timing, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Belt, Platen Open, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Paper Drive Motor Pulley Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Paper Scale Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610 Platen Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612 Platen Open Motor Pulley Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . 614 Ribbon Guide Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616 Splined Shaft Skew Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618 Adjusting the End of Forms Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . 620 Hammer Phasing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624 Loading Flash Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626 Coil Temperature Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632 Set Shuttle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633
61
Preparing the Printer for Maintenance

DANGER <1> Always disconnect the AC power cord from the power source before performing any maintenance procedure. Failure to remove power could result in injury to persons or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure. 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 data cable from the printer interface. 4. Open the printer cover. 5. Unload paper. 6. Remove the ribbon. 7. Read the entire adjustment procedure before you begin working on the printer. 8. Gather the necessary parts before you begin working on the printer.
62
Returning the Printer to Normal Operation

When you are finished servicing the printer, restore it to operation by following the steps below: 1. Connect the host 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 Operators Guide.) 8. Select the emulation. (Refer to the Operators Guide.) 9. Test printer operation by selecting and running one of the operator print tests. 10. Close the printer cover.
63
Belt, Paper Feed Timing, Adjustment (Figure 61)

1. Prepare the printer for maintenance (page 62). 2. Cabinet Model: Remove the paper guide assembly (page 740). Pedestal Model: Remove the top cover assembly (page 718). 3. Cabinet Model: Loosen four screws and remove the barrier shield. (See page 773, Figure 713, items 3 and 4.) Pedestal Model: Remove the four screws securing the paper guide and barrier shield. Remove the paper guide and barrier shield. (See page 775, Figure 714, items 3, 4, and 5.) 4. Remove the timing belt cover (1) by squeezing the front and back to release the plastic tabs from the slots in the side plate. 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 the splined shaft (4) to steady the gauge. 7. Reduce tension to 12 pounds (53.4 N) and torque the paper feed motor mount bolts (2) to 18 2 inch-pounds (2.03 0.23 NSm). 8. Snap the timing belt cover (1) into the slots in the side plate. 9. Cabinet Model: Install the barrier shield and tighten the four screws. (See page 773, Figure 713, items 3 and 4.) Pedestal Model: Install the paper guide and barrier shield and tighten the four screws. (See page 775, Figure 714, items 3, 4, and 5.) 10. Cabinet Model: Install the paper guide assembly (page 740). Pedestal Model: Install the top cover assembly (page 718). 11. Return the printer to normal operation (page 63).
64
Direction of Force
5 3
1 2
1. 2. 3. 4. 5.
Timing Belt Shield Motor Mount Bolt (2) Paper Feed Drive Motor Splined Shaft Paper Feed Timing Belt
Figure 61. Paper Feed Timing Belt Adjustment
65
Belt, Platen Open, Adjustment (Figure 62)

1. Prepare the printer for maintenance (page 62). 2. Cabinet Model: Remove the paper guide assembly (page 740). Pedestal Model: Remove the top cover assembly (page 718). 3. Remove the platen open belt cover (1) by squeezing the top and bottom to release the plastic tabs from the slots in the side plate. 4. Loosen the motor mount screws (2). 5. Close the forms thickness lever all the way. WARNING <6> 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, apply 10 1 pounds (44.48 4.45 N) of tension to the shank of the platen drive pulley (3), pushing away from the large platen pulley. 7. Reduce tension to 5 1 pounds (22.24 4.45 N) and tighten the motor mount screws (2). 8. Snap the platen open belt cover (1) into the slots in the side plate. 9. Cabinet Model: Install the paper guide assembly (page 740). Pedestal Model: Install the top cover assembly (page 718). 10. Return the printer to normal operation (page 63).
66
1. Belt Cover 2. Motor Mount Screw 3. Platen Open Motor Shaft
Direction of Force
1 3
Figure 62. Platen Open Belt Adjustment
67
Paper Drive Motor Pulley Alignment (Figure 63)

1. Prepare the printer for maintenance (page 62). 2. Cabinet Model: Remove the paper guide assembly (page 740). Pedestal Model: Remove the top cover assembly (page 718). 3. Remove the timing belt cover (1) by squeezing the front and back to release the plastic tabs from the slots in the side plate. 4. Loosen the screw (2) in the motor pulley collar (3). 5. Align the paper drive motor pulley (4) with the splined shaft pulley (5). WARNING <7> Make sure there is at least 0.040 inches (1.016 mm) of clearance between the collar (3) and the motor face plate. 6. Hold the collar (3) flush against the motor pulley (4) and tighten the screw (2). 7. Check for correct tension on the paper feed timing belt (page 64). Adjust if necessary. 8. Snap the timing belt cover (1) into the slots in the side plate. 9. Cabinet Model: Install the paper guide assembly (page 740). Pedestal Model: Install the top cover assembly (page 718). 10. Return the printer to normal operation (page 63).
68
1. 2. 3. 4. 5.
Belt Shield Cap Screw Motor Pulley Collar Motor Pulley Splined Shaft Pulley
Figure 63. Paper Drive Motor Pulley Alignment
69
Paper Scale Alignment (Figure 64)

1. Load paper and ribbon. 2. Connect the power cord to the AC power source. 3. Set the printer power switch to 1 (on). 4. Open the printer cover. 5. Verify that the shuttle cover (1) is properly installed (page 717). 6. 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 necessary, loosen the three button-head 5/64 inch hex screws (2). 9. Position the scale (3) so that column positions 1 and 136 line up with the first and last characters on the 136 character printout. 10. Tighten the 5/64 inch button-head screws (2). 11. Close the printer cover.
610
2 3
2 2
1. Shuttle Cover 2. Screw, Button-Head, 5/64 inch hex 3. Paper Scale
Figure 64. Paper Scale Alignment
611
Platen Gap Adjustment (Figure 65)

IMPORTANT Only do this procedure if the original equipment shuttle frame assembly or platen has been replaced by a new or refurbished unit. 1. Prepare the printer for maintenance (page 62). 2. Remove the shuttle cover assembly (page 717). 3. Loosen the platen open belt (page 66, steps 3 and 4). 4. Raise the forms thickness lever (1) to the fully open position. WARNING <8> Do not force the platen against the feeler gauge. Damage to the hammer tips will result. 5. Insert a 0.011 inch (0.28 mm) flat feeler gauge (2) straight down between the hammer bank cover plate (3) and ribbon mask (4), within four hammer positions of the left end of the hammer bank. CAUTION <2> Adjust the platen set screws less than 1/4 turn on one side, then 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 close the forms thickness lever (1). As the platen is closing, gently slide the feeler gauge up and down, keeping it between the hammer tip and ribbon mask. If the feel is too tight when the platen is being closed, adjust the 3/32 inch set screw (5) at the end of the platen counterclockwise. If the feel is too loose, adjust the set screw clockwise. With the forms thickness lever closed all the way, the feeler gauge should contact both the tips and the ribbon mask and move with light friction. Shift the gauge slightly to verify. 7. Repeat steps 4 through 6 at the right end of the hammer bank. 8. After adjusting both sides, check the gap again at both ends. Readjust if necessary. 9. When the platen gap is correct at both ends of the platen, adjust the platen open belt (page 66). 10. Install the shuttle cover assembly (page 717).
612
11. Check the hammer phasing adjustment (page 624). 12. Return the printer to normal operation (page 63).
1. 2. 3. 4. 5.
Forms Thickness Lever Feeler Gauge (0.011 inch or 0.28 mm) Hammer Bank Cover Plate Ribbon Mask Set Screw, 3/32 inch hex (2)
NOTE: Left side adjustment shown. Right side is the same. 3 4
Figure 65. Platen Gap Adjustment
613
Platen Open Motor Pulley Alignment (Figure 66)

1. Prepare the printer for maintenance (page 62). 2. Cabinet Model: Go to step 3. Pedestal Model: Remove the top cover assembly (page 718). 3. Remove the platen open belt cover (1) by squeezing the top and bottom to release the plastic 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 inch-pounds (1.02 0.23 NSm). 6. Check the platen open belt tension (page 66). Adjust if necessary. 7. Snap the platen open belt cover (1) into the slots in the side plate. 8. Cabinet Model: Go to step 9. Pedestal Model: Install the top cover assembly (page 718). 9. Return the printer to normal operation (page 63).
614
1. 2. 3. 4.
Belt Cover Set Screw Platen Open Motor Pulley Platen Shaft Pulley
1 3 4
Figure 66. Platen Open Motor Pulley Alignment
615
Preliminary 2
Ribbon Guide Alignment (Figure 67)
1. Open the printer cover. 2. Load paper and install the ribbon. To adjust the left ribbon guide, the ribbon should have a full spool on the right hub (1). 3. Check ribbon tracking by running the PRINTER MECHANISM TESTS : Shuttle Slow (page 574). 4. To adjust the left ribbon guide, momentarily short between the left ribbon guide skid screws (2) to assure right to left motion of the ribbon. 5. Observe how the ribbon (3) is passing around the left ribbon guide (4). It should be centered and not folding against either of the two white nylon washers. 6. If the ribbon is not centered, loosen the retaining screws (5) just enough so that the ribbon guide (4) can be rotated to new positions, but remains in place once moved. 7. Rotate the ribbon guide (4) as necessary to center the ribbon (3). 8. Observe how the ribbon (3) is winding on the left spool (6). If the ribbon is interfering with the flange of the spool, make sure the ribbon hub and spool are mounted correctly. 9. Tighten the screws (5). 10. Allow most of the ribbon to accumulate on the left spool (6). Repeat steps 3 through 9 for the right ribbon guide (7).
616
1 2 4 3
7 5
1. 2. 3. 4. 5. 6. 7.
Right Hub Screw, Left Ribbon Guide Skid (2) Ribbon Ribbon Guide, Left Screw, Retaining (2) Left Ribbon Spool Ribbon Guide, Right
Figure 67. Ribbon Guide Alignment
617
Splined Shaft Skew Adjustment (Figure 68)

If lines of print are not parallel with the edge perforations on the paper, perform the following adjustment. 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 perforations. Tighten the screw (1). 4. Return the printer to normal operation (page 63).
618
1. Screw 2. Adjusting Link 3. Horizontal Adjustment Knob
Figure 68. Splined Shaft Skew Adjustment
619
Adjusting the End of Forms Distance

This procedure tests and sets the distance from the page perforation at which an END OF FORMS fault message is triggered. This adjustment prevents printing on the platen when the printer runs out of paper. The measurement units are dot rows. You will use the dot row patterns printed by the END OF FORMS ADJUST self-test to verify that this parameter is set correctly.
NOTE: Do this procedure only if a new paper detector switch assembly has been installed, or if you are sure that the end of forms adjustment is incorrect. An END OF FORMS triggering distance of 1 or 2 dot rows from the perforation is acceptable; 5 to 7 dot rows off indicates adjustment is required. Also, although it is not required, it is advisable to test the 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 FORMS ADJUSTMENT VALUE. 1. Power on the printer. 2. Load paper and set the top of form. Make sure the forms thickness lever is closed. Open the cabinet front door. 3. On the sheet of paper just below the paper entrance slot, tear a four-inch square on the left side, immediately below the perforation. (See Figure 69.) This creates a hole that will trigger an END OF FORMS condition, but allows printing to the right of the hole (which would normally be on the platen).
620
Page Perforation
Page Perforation
4 in. 4 in. Cut out here
Page Perforation
Figure 69. Paper Preparation for Paper Out Adjustment Test
621
4. Tear a four inch square in the manner described above, on every third sheet, until you have made 3 or 4 holes. 5. If the printer is in READY mode, press Stop to put it into NOT READY mode. 6. Press Scroll" + Scroll# to unlock the Enter key. 7. Press Scroll" + Scroll# + Return + Enter to enter the CE Tests menu. (Press all four keys at the same time.) 8. The display will show SERVICE / PRINTER MECHANISM TESTS, the first menu item. Press Enter to enter the mechanism tests menu. 9. Press Scroll" or Scroll# until PRINTER MECHANISM TESTS / END OF FORMS ADJUST is on the display. This test will print a vertical comb pattern at around column 70, each long bar separated by three shorter bars. An enlarged example of the comb pattern is shown below.
Short Bar
Long Bar
10. Press Enter until the END OF FORMS ADJUST test starts. The comb pattern will print until the display shows 001 END OF FORMS / LOAD FORMS and (if enabled) the audible alarm sounds. If the alarm sounds, press Stop to silence it. 11. Remove the paper from the tractors and examine the area of the page perforation. (If the alarm sounds when you open the platen, press Stop to silence it.) If a 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.) Unless you wish to restart the procedure with 6-part paper, you may stop the test here, and skip to step 22. (See the note at the beginning of this procedure.) If the comb pattern stopped short of the perforation or printed beyond the perforation, go to step 12. 12. Measure how short or long the comb pattern printed by counting the number of dot rows needed to reach the perforation, or the number of dot rows that printed beyond the perforation. NOTE: You can use the long bars to count the dot rows quickly. There are three dot rows between each long bar, so each long bar increases
622
the number of dot rows by four. You can also tear off a small piece of the comb pattern from the beginning of the pattern and use it as a ruler to help you measure the dot rows required either to reach the perforation or back up to it. 13. Reload the paper and set the top of form. 14. Press Scroll" + Scroll# + Return + Enter to enter the CE Tests menu. (Press all four keys at the same time.) 15. The display will show SERVICE / PRINTER MECHANISM TESTS, the first menu item. Press Scroll" or Scroll# until SERVICE / END OF FORMS ADJUSTMENT VALUE is on the display. 16. Press Enter. The top line of the display will show END OF FORMS ADJUSTMENT VALUE and the bottom line will show the current setting for the number of dots. 17. Press Enter. The number of dots will move up to the top line of the display. 18. Using the Scroll" or Scroll# key, adjust the XX DOTS value 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 number of dots.) 19. Press Enter to select the new number of dots as the active value. (The asterisk that appears tells you that it is now the active value.) 20. Press Stop to put the printer into NOT READY mode. 21. Run the END OF FORMS ADJUST and the END OF FORMS ADJUSTMENT VALUE tests until the comb pattern prints at an acceptable distance from the page perforation. (Return to step 7.) 22. When the End of Forms Adjustment is acceptable, reload the paper, feed it past any remaining unused holes that you tore in it, and set the top of form. 23. Press Scroll" + Scroll# to lock the Enter key. 24. Press Start to put the printer into READY mode.
623
Hammer Phasing Adjustment

You must check and adjust hammer phasing if the CMX controller board is replaced, the shuttle frame assembly is removed, or if the MPU is replaced. The hammer phase value is a timing parameter that permits you to adjust the horizontal alignment of dots in character printing. The phase value numerical units are relative; they do not represent a physical measurement or value. Thus there is no correct value or range. The factory prints the initial phase value on the aluminum casting of the shuttle assembly, next to the 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 printer printing at full paper width. IMPORTANT The printer must be printing the Phase pattern of Hs when the Phasing Value is changed, or the New Phasing Value will not be written into NVRAM. If the value is changed when not printing, the printer will return to its default phasing value when powered off then back on. 1. Power on the printer. 2. Install the ribbon. 3. Load full width (136 column) paper and set the top of form. 4. Press Stop to put the printer into NOT READY mode. 5. Press Scroll" + Scroll# to unlock the Enter key. 6. Press Scroll" + Scroll# + Return + Enter to enter the CE Tests menu. (Press all four keys at the same time.) 7. The display will show SERVICE / PRINTER MECHANISM TESTS, the first menu item. Press Enter to enter the mechanism tests menu. 8. Press Scroll" or Scroll# until PRINTER MECHANISM TESTS / HAMMER PHASING is on the display. 9. Press Enter. The printer begins printing all Hs, each line preceded by the phasing index number. 10. Press Return. The display will show SERVICE / PRINTER MECHANISM TESTS.
624
11. Press Scroll" or Scroll# until SERVICE / HAMMER PHASE VALUE is on the display. 12. Press Enter. The top line of the display will show HAMMER PHASE VALUE and the bottom line will show the current phasing index number. 13. Press Enter. The phasing index (followed by an asterisk) will move up to the top line of the display. 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 appears as shown below:
Needs Adjustment
Correct
Needs Adjustment
15. When the print pattern is acceptable, press Stop. Printing stops, and the printer automatically enters the current phase index value into NVRAM. The display shows NOT READY. 16. Press Scroll" + Scroll# to lock the Enter key. 17. Close the printer cover. Press Start to put the printer into READY mode.
NOTE: If you changed the phasing value, power down the printer, remove the shuttle cover, and write the new phase value on the aluminum shuttle casting.
625
Loading Flash Memory

Emulation and operating system software are loaded into flash memory at the factory, but you will install software in the following situations: The customer needs to upgrade printer software The customer needs different emulation software You have replaced the controller board You have added or replaced a flash memory SIMM
Emulation and operating system software are stored as a compressed file. The file is executable; you will expand it and copy it into printer flash memory with a single command. DANGER <2> To prevent serious personal injury from electrical shock when connecting or disconnecting the signal cable, power the printer off and unplug the power cable. 1. Make a printout of all saved configurations. (Refer to the Setup Guide.) (Installing new software erases all saved configurations. You will use the printouts to restore printer configuration.) 2. Set the printer power switch to O (off). 3. Unplug the AC power cord from the printer. 4. If the printers parallel data cable is connected to the parallel port of an IBM or IBM-compatible computer using the PC-DOS* or MS-DOS** operating system, skip to step 8. If not, go to step 5. 5. Disconnect all data input cables from the printer interface. 6. Connect the parallel data cable to the default parallel port (LPT1) of an IBM or IBM-compatible personal computer using the PC-DOS or MS-DOS operating system.
NOTE: You can connect the data cable to the LPT2 port if the LPT1 port is already in use. You can also download software through the printer serial port. The download commands are different if you use these ports, as described in the note after step 18. 7. Connect the parallel data cable to the parallel port of the printer. 8. Plug the AC power cord into the printer.
626
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 following at the DOS prompt: A:<return> (If the diskette is in drive B, type B:<return>) 12. Get the name of the compressed file on the diskette by listing the contents of the diskette; at the DOS prompt type: DIR<return> The compressed file on the diskette takes the form FILENAME.EXE Write down the complete name of the file with the .EXE extension. 13. On the printer control panel, press and hold down the Start + Cancel keys. Without releasing the keys, power the printer on. Continue holding the Start and Cancel keys down. 14. When you see WAITING FOR PROGRAM DOWNLOAD on the LCD, release the Start and Cancel keys.
NOTE: The port default is CENTRONICS; this is the standard download through the parallel port. If you want to use the default, continue at step 18. 15. Press the Scroll" key; SELECT DOWNLOAD PORT=DATAPRODUCT appears on the LCD. 16. Press Scroll" again to cycle through the download ports available in the printer: DATAPRODUCT (parallel) CENTRONICS* (parallel) (default port) RS2329600 (RS232 serial, 9600 baud) RS23219.2K (RS232 serial, 19200 baud) RS23238.4K (RS232 serial, 38400 baud) RS232115K (RS232 serial, 115000 baud) RS4229600 (RS422 serial, 9600 baud) RS42219.2K (RS422 serial, 19200 baud) RS42238.4K (RS422 serial, 38400 baud) RS422115K (RS422 serial, 115000 baud) 17. When the printer download port you want to use is displayed on the LCD, press ENTER. WAITING DOWNLOAD / PORT = <your selection> appears on the display.
627
18. 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 binary file into the flash memory on the CMX controller board.
NOTE: If you are downloading the file using the LPT2 port on the PC, enter the following DOS command: FILENAME.EXE pb 2 <Return> If you are downloading the file into the printer serial port, enter the following DOS commands: MODE COM1:9600,N,8,1,P<Return> FILENAME.EXE PBC1<Return> 19. While the file is copied into memory, the printer LCD informs you of the load process and status. (See Table 61.) 20. When the file has successfully loaded into memory and the printer has reset itself, set the printer power switch to O (off). 21. Unplug the AC power cord from the printer. 22. Remove the diskette from the personal computer and store it with the printer. 23. Power off the personal computer. 24. If you had to install a parallel data cable to the computer and printer in step 6, disconnect it from the computer and printer. 25. Reconnect the customers data input cable(s) to the printer, if required. 26. Return the printer to normal operation (page 63). 27. Using the configuration printout(s) you made in step 1, reconfigure the printer. (Refer to the Setup Guide.)
628
Table 61. Flash Memory Message Guide NOTE: A continuous IML cycle indicates coax/twinax code is being loaded into a printer with a missing, defective, or improperly installed Coax/Twinax board. If the printer is supposed to have this feature, reset the Coax/Twinax board. If the printer is not supposed to have this feature, install new emulation code without the Coax/Twinax feature.
Message
CLEARING PROGRAM FROM FLASH
Explanation The program successfully loaded into printer RAM and the checksum matched. The old program is now being deleted from flash memory. The printer passed its memory and hardware initialization tests. Printer cannot find the data controller program or the validation checksum is corrupt.
Required Action None
DIAGNOSTIC PASSED ERROR: DC PROGRAM NOT VALID
None
Download the program again: Power off the printer and start over at step 13. If the message occurs again, replace the flash memory. Replace the DRAM.
ERROR: DRAM AT ADDRESS XXXXXXXX ERROR: EC PROGRAM NOT VALID
The printer found a defective memory location. Printer cannot find the engine controller program or the validation checksum is corrupt.
Download the program again: Power off the printer and start over at step 13. If the message occurs again, replace the flash memory. Replace the CMX controller board. Download the program again: Power off the printer and start over at step 13. If the message occurs again, replace the flash memory.
ERROR: EC STOPPED AT STATE XXXX ERROR: FLASH DID NOT PROGRAM
Hardware fault in the engine controller. The printer encountered an error trying to program flash memory.
629
Message
ERROR: FLASH NOT DETECTED
Explanation The printer could not find any flash memory.
Required Action Install flash memory before attempting to download this program. Check DRAM on CMX. If present, reseat DRAM, If missing, install DRAM. Replace the CMX controller board. (Do NOT attempt to replace NVRAM.) Add DRAM or use a smaller emulation program. Add flash memory or use a smaller emulation program. Use the correct emulation software option(s) for this model. If the printer is an IBM 6404B01, the controller is a CBO board. If the printer is an IBM 6400, the controller is a CMX board. There is no program in printer memory. Go to step 2. Check the security 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: NO DRAM DETECTED
The printer could not find any DRAM.
ERROR: NVRAM FAILURE
The non-volatile memory has failed.
ERROR: PROGRAM NEEDS MORE DRAM ERROR: PROGRAM NEEDS MORE FLASH ERROR: PROGRAM NOT COMPATIBLE
The printer requires more DRAM memory in order to run the downloaded program. The printer requires more flash memory in order to run the downloaded program. The printer is not compatible with the downloaded program. User tried to load CMX-compatible diskette in CBO-controlled printer, or vice versa.
ERROR: PROGRAM NOT VALID
The printer does not see a program in flash memory. The security PAL is not present or has failed.
ERROR: SECURITY PAL NOT DETECTED
630
Message
ERROR: SHORT AT ADDRESS XXXX
Explanation Hardware failure in DRAM or CMX controller circuitry.
Required Action Replace DRAM. If message occurs with new DRAM, replace CMX controller board. Download the program again: Power off the printer and start over at step 13. If the message occurs again, replace the flash memory. Download the program again: Power off the printer and start over at step 13. None
ERROR: WRITING TO FLASH
Hardware or software fault in flash memory.
ERROR: WRONG CHECKSUM
The printer received the complete program but the checksum did not match. The data were corrupted during download. The new program is loading into printer RAM. XX indicates how much of the program has loaded. The printer has deleted the previous program from flash memory and is loading the new program into flash memory. The printer finished loading the program into flash memory and is automatically resetting itself. Normal download initialization message. The software running or being downloaded does not match the security PAL code. The printer is loading the engine controller program into the engine controller. EC software update in process.
LOADING PROGRAM FROM PORT XX%
None
RESETTING . . . PLEASE WAIT RESTORING BOOT CODE SECURITY CODE VIOLATION
None
None
Install the correct PAL or program. (PAL and program must match.) None
SENDING PROGRAM TO EC PROCESSOR TABLE MISMATCH DOWNLOAD AGAIN
Download the program again: Power off the printer and start over at step 13.
631
Preliminary 2
Coil Temperature Adjustment
IMPORTANT This procedure applies only to models 6400005, 05P, 009, 09P, and 014. Do this procedure only when the original CMX controller board or shuttle frame assembly have been replaced. Do not do this procedure if the original CMX board or shuttle frame assembly were removed and reinstalled as part of other maintenance tasks. The shuttle frame assembly must be at room temperature to do this procedure. 1. Raise the printer cover. 2. Power on the printer. 3. If the Ready indicator is on, press the Stop key. The printer must be in the 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 Enter key. 6. Press the Scroll" or Scroll# key until SERVICE / SET COIL TEMPERATURE appears on the display. 7. Press Enter. The display tells you to PLEASE WAIT while the coil temperature is set by an automatic calibration sequence in printer software. 8. When the display again reads SERVICE / SET COIL TEMPERATURE press Scroll" + Scroll# to lock the Enter key. 9. Press Stop to exit the menu and put the printer in the NOT READY state. OR 10. Press Start to exit the menu and put the printer in the READY state. 11. Coil temperature is now set. Power off the printer and close the printer cover.
632
Set Shuttle Speed

IMPORTANT This procedure applies only to models 6400004, 04P, 005, and 05P. Do this procedure only when the original CMX controller board or shuttle frame assembly have been replaced. Do not do this procedure if the original CMX board or shuttle frame assembly were removed and reinstalled as part of other maintenance tasks. 1. Raise the printer cover. 2. Power on the printer. 3. If the Ready indicator is on, press the Stop key. The printer must be in the 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 Enter key. 6. Press the Scroll" or Scroll# key until SERVICE / SHUTTLE SPEED appears on the display. 7. Press Enter. SHUTTLE SPEED / 475* or SHUTTLE SPEED / 500* appears on the display. The asterisk [*] indicates which shuttle speed is currently active. 8. Press Scroll" until the shuttle speed you want appears on the display. 9. Press the Enter. An asterisk [*] appears next to the selection, indicating it is now the active shuttle speed. 10. Press Scroll" + Scroll# to lock the Enter key. 11. Press Stop to exit the menu and put the printer in the NOT READY state. 12. Power off the printer, then power on the printer to activate the new shuttle speed value. 13. Install the ribbon and load full-width paper. 14. Select and run the Ripple Print printer test (page 545). 15. Examine the printout: if gaps or dark bars appear in the printout, go back to step 3 and set the shuttle speed to the other option. 16. When the printout is acceptable, power off the printer and close the printer cover.
633
634
Chapter Contents
Organization of This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Section I: Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . 75

Preparing the Printer for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Belt, Paper Feed Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Belt, Platen Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Cable Connectors and Connector Shells . . . . . . . . . . . . . . . . . . . . . . . . 79 Circuit Board: Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711 Circuit Board: Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713 Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714 Coax/Twinax Multi-Platform Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 715 Cover Assembly, Hammer Bank / Ribbon Mask . . . . . . . . . . . . . . . . . . 716 Cover Assembly, Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 717 Cover Assembly, Top, Pedestal Model . . . . . . . . . . . . . . . . . . . . . . . . . . 718 Doors, Cabinet, Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719 Fan Assembly, Cabinet Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720 Fan Assembly, Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721 Fan Assembly, Hammer Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722 Hammer Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723 IBM Coax/Twinax Expansion Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727 Magnetic Pick-up (MPU) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 728 Memory Modules and Security PAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729
71
Motor Assembly, Paper Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 732 Motor Assembly, Platen Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734 Motor Assembly, Ribbon Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 736 Network Print Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 737 Operator Panel Assembly, Cabinet Model . . . . . . . . . . . . . . . . . . . . . . . 738 Operator Panel Assembly, Pedestal Model . . . . . . . . . . . . . . . . . . . . . . 739 Paper Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 740 Paper Ironer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 741 Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 742 Resistors, Terminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 747 Ribbon Guide Assembly (L/R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 749 Ribbon Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 Security Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729 Shaft, Splined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 751 Shaft, Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 753 Shuttle Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754 Spring Assembly, Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 756 Spring, Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 757 Switch Assembly, Cover Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 758 Switch Assembly, Paper Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 759 Switch Assembly, Platen Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 761 Tractor (L/R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 762
72
Section II: Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 763

Figure 79. Top Cover, Doors, and Casters, Cabinet Model . . . . . . . 765 Figure 710. Paper Stacker and Chains . . . . . . . . . . . . . . . . . . . . . . . . 767 Figure 711. Control Panel and Cabinet Details . . . . . . . . . . . . . . . . . . 769 Figure 712. Pedestal Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 771 Figure 713. Inside Covers, Cabinet Model . . . . . . . . . . . . . . . . . . . . . 773 Figure 714. Inside Covers and Card Cage, Pedestal Model . . . . . . 775 Figure 714a. Card Cage Detail, Pedestal Model . . . . . . . . . . . . . . . . 777 Figure 715. Print Mechanisms and Circuit Boards . . . . . . . . . . . . . . . 779 Figure 716. Magnetic Pickup Unit (MPU) and Extension Spring . . . 781 Figure 717. Tractor Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 783 Figure 718. Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 785 Figure 719. Motors, Card Cage Fan, and Paper Detector Switch . . 787 Figure 720. Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 789 Figure 721. IBM Coax/Twinax Expansion Board . . . . . . . . . . . . . . . . 791
73
Organization of This Chapter

This chapter is divided into two sections. Section I: Replacement Procedures Written procedures for removing and installing components that are replaceable at the field service level of maintenance. Section I begins on page 75. The procedures refer you to the illustrations in Section II. Section II: Illustrated Parts List Drawings of all assemblies comprising the printer. On the page facing each illustration is a list of the illustrated parts and their part numbers. Section II begins on page 763.
74
Section I: Replacement Procedures

IMPORTANT The components specified in this chapter are field replaceable units (FRUs). FRUs must be repaired at the factory. Do not attempt field repair of these items.
Preparing the Printer for Maintenance

DANGER <1> Always disconnect the AC power cord from the power source before performing any maintenance procedure. Failure to remove power could result in injury to persons or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure. IMPORTANT DO NOT attempt field repairs of electronic components or assemblies. Replace a malfunctioning electronic assembly with an operational spare. Most electronic problems are corrected by replacing the circuit board, sensor, or cable that causes the fault indication. The same is true of failures traced to the hammer bank coils and electronics: you must replace the entire shuttle frame assembly. It is not field repairable. (Hammer spring assemblies are the only replaceable components of the shuttle frame assembly.) 1. Power off the printer. 2. Unplug the printer power cord from the AC power source. 3. Disconnect the host data cable from the printer interface. 4. Open the printer cover. 5. Unload paper. 6. Remove the ribbon. 7. Read the entire adjustment procedure before you begin working on the printer. 8. Gather the necessary parts before you begin working on the printer.
75
Belt, Paper Feed Timing

Removal 1. Prepare the printer for maintenance (page 75). 2. Cabinet Model: Remove the paper guide assembly (page 740). Pedestal Model: Remove the top cover assembly (page 718). 3. Cabinet Model: Loosen four screws and remove the barrier shield. (See page 773, Figure 713, items 3 and 4.) Pedestal Model: Loosen the four screws securing the paper guide and barrier shield. Remove the paper guide and barrier shield. (See page 775, Figure 714, items 3, 4, and 5.) 4. Remove the timing belt cover by squeezing the front and back to release the plastic tabs from the slots in the side plate (page 773, Figure 713). 5. Loosen (do not remove) the paper feed motor mount screws (page 787, Figure 719). 6. Loosen the setscrew in the paper feed motor pulley collar. 7. Remove the paper feed timing belt by sliding the paper feed motor pulley off the motor shaft and the belt off the splined shaft pulley.
76
Installation 1. Install the paper feed timing belt over the splined shaft pulley and the motor pulley. Slide the motor pulley onto the paper feed motor shaft (page 787, Figure 719). 2. Holding a 0.040 inch feeler gauge between the pulley collar and the (2.82 0.23 NSm). motor body, torque the 7/64 inch collar screw to 25 2 inch-pounds
3. Using the straight end of a force gauge, apply 15 pounds (66.7 N) of pressure to the paper feed drive 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 NSm). 5. Snap the timing belt cover into the slots in the side plate (page 773, Figure 713). 6. Cabinet Model: Install the barrier shield and tighten the four screws. (See page 773, Figure 713, items 3 and 4.) Pedestal Model: Install the barrier shield and paper guide and tighten the four screws. (See page 775, Figure 714, items 3, 4, and 5.) 7. Cabinet Model: Install the paper guide assembly (page 740). Pedestal Model: Install the top cover assembly (page 718). 8. Return the printer to normal operation (page 63).
77
Belt, Platen Open

Removal 1. Prepare the printer for maintenance (page 75). 2. Cabinet Model: Remove the paper guide assembly (page 740). Pedestal Model: Remove the top cover assembly (page 718). 3. Remove the platen open belt cover by squeezing the top and bottom to release the plastic tabs from the slots in the side plate (page 785, Figure 718). 4. Loosen (do not remove) the two motor mount screws (page 787, Figure 719). 5. Push the motor toward the front of the printer to loosen the platen open belt. 6. Loosen the setscrew in the platen open motor pulley. 7. Remove the platen open belt by sliding the platen motor pulley off the motor shaft and the belt off the 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 motor shaft and tighten the pulley setscrew. WARNING <6> 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. 3. Using a force gauge, apply 10 pounds (44.48 N) of tension to the motor shaft by pushing in the direction away from the large platen pulley. 4. Reduce tension to 5 pounds (22.24 N) and torque the motor mount screws to 11 2 inch-pounds (1.24 0.23 NSm). 5. Snap the platen open belt cover into the slots in the side plate. 6. Cabinet Model: Install the paper guide assembly (page 740). Pedestal Model: Install the top cover assembly (page 718). 7. Return the printer to normal operation (page 63).
78
Cable Connectors and Connector Shells

Some of the printer cable connectors are grouped inside connector shells. The procedure below explains how to remove and install cable assemblies from any connector shell in the printer.
NOTE: There is also a diagram of the P106 / P107 connector shells on the plastic cover over the power supply.
Removal 1. Prepare the printer for maintenance (page 75). 2. Cabinet Model: Remove the paper guide assembly (page 740). Pedestal Model: Remove the top cover assembly (page 718). 3. Disconnect the cable connector shell containing the cable assembly that will be replaced. 4. Pull the side of the connector shell outward and gently pull the cable connector upward. (See Figure 71.) Notice that two-wire connectors are grouped across from two-wire connectors 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 the connector shell. 6. Remove the cable connector from the connector shell. (Remove only the cable connector for the cable you are replacing; leave the rest in the shell.)
Installation 1. Position the cable connector in the connector shell. Two-wire connectors are always grouped across from two-wire connectors in a connector shell. Four-wire connectors are always grouped across from four-wire connectors in a connector shell. (See Figure 71.) 2. Pull the side of the connector shell outward and gently push the cable connector down into the connector shell. 3. Engage the tabs on the cable connector in the slots in the side of the connector shell. Press the sides of the connector shell inward to make sure all cable connector tabs are engaged in the shell slots. 4. Connect the cable connector shell to its printer connection.
79
5. Cabinet Model: Install the paper path (page 740). Pedestal Model: Install the top cover assembly (page 718). 6. Return the printer to normal operation (page 63).
Key Tab
POD = Paper Out Detect (Switch) PMD = Paper Motion Detect (Switch) CCF = Card Cage Fan LRP = Left Ribbon Guide PLAT M = Platen Open Motor LRIB M = Left Ribbon Motor P106 Connector Configuration
2 4 6 8 LRIB M PLAT M 1 3 5 7 10 12 LRP CCF 9 11 14 16 18 20 PMD POD 13 15 17 19
Typical 2-Wire Cable Connector
Typical 4-Wire Cable Connector
PIN NO.
(See also page A12.)
Pull the side outward just enough to release the connector lock tab from the slot in the connector shell.
PIN NO.
P107 Connector Configuration

2 4 6 8 RRIB M PAPR M 1 3 5 7 10 12 14 16 18 20 HBF EHF RRP PLO CVO MPU 17 19
Key Tab Slot Pin 1
Housing, Connector Kit P/N 14H5288
9 11 13 15
MPU = Magnetic Pickup CVO = Cover Open (Switch) PLO = Platen Open (Switch) RRP = Right Ribbon Guide EHF* = Exhaust Fan (Cabinet model) HBF = Hammer Bank Fan PAPR M = Paper Feed Motor RRIB M = Right Ribbon Motor * JMP on pedestal model (a spacer)
Push here to remove shell from controller board. Typical PCB Connector
Figure 71. Cable Shell Connector, Disassembly/Assembly
710
Circuit Board: Controller

WARNING <9> 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 component. Removal 1. Make a configuration printout of all configurations. (Refer to the Operators Guide.) 2. Prepare the printer for maintenance (page 75). 3. Cabinet Model: Remove the paper guide assembly (page 740). Pedestal Model: Remove the top cover assembly (page 718). 4. Disconnect all cable connectors from the controller board. (See page 779, Figure 715.) 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 bottom of the card cage, on the left side near the card cage fan. 7. Slide the controller board to left until the keyway clears the screw securing the controller board to the bottom of the card cage. 8. Remove the controller board. 9. Remove the DRAM SIMM, FLASH SIMM, and Security PAL from the controller board (page 729). These will be installed on the replacement controller board. The Security PAL must be installed on the replacement controller board to ensure the printer functions correctly. NOTE: When Flash SIMMs are removed from one controller board and placed on another controller board, the SIMMs must be placed on the new board in the same order and location as on the original board. Installation WARNING <9> 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 component.
711
Preliminary 2
NOTE: When flash SIMMs are removed from one controller board and placed on another controller board, the SIMMs must be placed on the new board in the same order and location as on the original board. 1. Install the DRAM SIMM, Flash Memory, and Security PAL on the controller board (page 729). 2. Position the controller board assembly in the card cage, shield side down, component side up. Engage the screw on the bottom of the card cage in the keyway in the controller shield. Slide the board to right until the serial cable connector J201 on the board lines up with the cutout in the card cage. (See page 779, Figure 715.) 3. Tighten the screw securing the controller shield near serial cable connector J201. 4. Tighten the screw securing the controller shield to the bottom of the card cage. 5. Connect all cable connectors to the controller board, using the Interconnection diagram on page A3 as your guide. 6. Cabinet Model: Install the paper guide assembly (page 740). Pedestal Model: Install the top cover assembly (page 718). IMPORTANT If the original CMX board was replaced, you must reload flash memory. (Installing flash memory from the old board onto the new board does not transfer all operating system software.) 7. Load flash memory (page 626). 8. Models 005, 05P, 009, 09P, and 014 only: adjust the coil temperature if the original CMX board was replaced (page 632). 9. Models 004, 04P, 005, and 05P only: set shuttle speed if the original CMX board was replaced (page 633). 10. Adjust the hammer phasing (page 624). 11. Adjust the end of forms distance (page 620). 12. Return the printer to normal operation (page 63). 13. Using the configuration printout you made as step 1 of the removal procedure, reset and save the printer configuration.
712
Circuit Board: Power Supply

CAUTION <3> To prevent injury from electric shock, wait at least one minute after shutting off power before removing the power supply board. Do not touch components or flex the board during removal/installation. Handle the board by the ejection levers and the sides. Wear a properly grounded static wrist strap when handling the power supply board.
Removal 1. Prepare the printer for maintenance (page 75). 2. Cabinet Model: Remove the paper guide assembly (page 740). Pedestal Model: Remove the top cover assembly (page 718). 3. Disconnect output connector P101 from the controller board and AC input connector 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 779, Figure 715, item 4.) 5. Carefully disengage the power supply board from the three standoffs on the rear wall of the card cage. 6. Remove the power supply board from the card cage.
Installation 1. Position the power supply board over the three standoffs on the rear wall of the card cage and gently push the board until it engages fully on the standoffs. 2. Install three screws securing the power supply board to the rear wall of the card cage. (See 779, Figure 715, item 4.) 3. Connect output connector P101 to the controller board and AC input connector P1 to the power supply board. 4. Cabinet Model: Install the paper guide assembly (page 740). Pedestal Model: Install the top cover assembly (page 718). 5. Return the printer to normal operation (page 63).
713
Circuit Breaker
Removal 1. Prepare the printer for maintenance (page 75). 2. Open the printer cover. 3. Remove the card cage fan (page 721). 4. Disconnect the four circuit breaker electrical leads. (Cabinet Model: See Figure 720, page 789. Pedestal Model: See Figure 714a, page 777.) 5. Press in on 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 720, page 789. Pedestal Model: See Figure 714a, page 777.) CAUTION <4> Make sure the four leads are connected as shown on page 789 (Figure 720). 2. Connect the four circuit breaker electrical leads. (Cabinet Model: See Figure 720, page 789. Pedestal Model: See Figure 714a, page 777.) 3. Install the card cage fan (page 721). 4. Return the printer to normal operation (page 63).
714
Coax/Twinax Multi-Platform Interface

NOTE: Installation, operation, and replacement parts for this optional feature are covered in detail in the Coax/Twinax Multi-Platform Interface Feature Installation and Operation Guide, Form Number S2460149.
Removal WARNING <9> 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 component. 1. Prepare the printer for maintenance (page 62). 2. Refer to the Coax/Twinax Multi-Platform Interface Feature Installation and Operation Guide, Form Number S2460149.
Installation 1. Refer to the Coax/Twinax Multi-Platform Interface Feature Installation and Operation Guide, Form Number S2460149.
715
Cover Assembly, Hammer Bank / Ribbon Mask

Removal 1. Prepare the printer for maintenance (page 75). 2. Remove the shuttle frame assembly (page 754). 3. Lift the thick plate of the hammer bank cover assembly at one end, and peel the cover away from hammer bank magnets (page 779, Figure 715).
Installation WARNING <5> The hammer bank contains a strong magnet. To prevent damage to the hammer tips, do not let the hammer bank cover assembly snap into place as the hammer bank magnet attracts it. Any impact of the cover against the hammer bank can break hammer tips. 1. With the thick plate facing the hammer bank, engage the bottom edge of the hammer bank cover assembly on the alignment pins. Engage the round hole first, then the oblong hole, to ensure that the cover lies flat on the hammer bank. (See Figure 715, page 779.) 2. Gently lower the hammer bank cover assembly until it lies flush on the hammer bank. Check that the hammer bank cover assembly is properly positioned over the alignment pins and hammer tips. 3. Install the shuttle frame assembly (page 754). 4. Return the printer to normal operation (page 63).
716
Cover Assembly, Shuttle

Removal 1. Prepare the printer for maintenance (page 75). 2. Open the printer cover. 3. Remove the ribbon spools. 4. Loosen the shuttle cover screws (page 773, Figure 713). 5. Grasping the 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 of the cover down slightly and work the cover into position (page 773, Figure 713).
NOTE: Make sure the holes in the cover are over the locating pins. 2. Tighten the shuttle cover screws (page 773, Figure 713). 3. Return the printer to normal operation (page 63).
717
Cover Assembly, Top, Pedestal Model

Removal 1. Prepare the printer for maintenance (page 75). 2. Remove the operator panel (page 739). 3. Remove five screws and the control panel bracket. (See Figure 712, page 771, items 3 and 4.) 4. Loosen the two captive #2 Phillips screws in the lower front corners of the top cover. (See Figure 712, page 771, item 14.) 5. Loosen, but do not remove, the two #2 Phillips hold-down screws on the rear of the printer. (See Figure 712, page 771, item 8.) 6. Lift the top cover assembly off the printer base.
Installation To install the top cover assembly, reverse the steps of the removal procedure.
718
Doors, Cabinet, Reversing

NOTE: Floor cabinet printers are assembled with the front door hinged on the left side so that it opens at the right side. The rear door is hinged on the right side so that it opens on the left side. This procedure enables you to reverse this door configuration. 1. Open the front and rear cabinet doors. 2. Mark the top of each door. 3. Remove the screws and wire ropes from the doors and cabinet frame. (See Figure 79, page 765, item 9.) 4. Lift each door up and off the hinge pins of the upper and lower cabinet hinge plates. Do not remove the hinge plates from the doors. 5. Remove two screws and the paper fence from the original rear door. 6. Remove the screws securing the hinge pin plates to the front and 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 of the printer frame. 8. Install pads and hinge pin plates to the left rear side of the frame, with the hinge pins up and toward the outside edge of the printer frame. 9. Move the original rear door to the front of the printer. With the marked top uppermost, slide the door hinges down onto the hinge pins. Adjust the position of the hinge pin plates as necessary so the door closes squarely against the frame. 10. Move the original front door to the rear of the printer. With the marked top uppermost, slide the door hinges down onto the hinge pins. Adjust the position of the hinge pin plates as necessary so the door closes squarely against the frame. 11. Install the paper fence to the new rear door with the two screws. 12. Install the wire ropes to the doors and the cabinet frame.
719
Fan Assembly, Cabinet Exhaust

Removal 1. Prepare the printer for maintenance (page 75). 2. Open the floor cabinet doors and the printer cover. 3. Remove the paper stacker. (See Figure 710, page 767.) 4. Remove the three screws securing the air exhaust duct. (The top screw is located near the right front of the card cage, in front of the square air holes in the printer base plate.) (See page 769, Figure 711). 5. Disconnect the fan cable connector from connector P307 and remove the air exhaust duct. 6. Remove the fan cable connector from the cutout in the side of the air exhaust duct. 7. Remove the two fan mounting screws and the cabinet exhaust fan assembly.
Installation WARNING <23> Make sure to install the fan so that air flow is down. 1. Position the cabinet exhaust fan assembly in the air exhaust duct so that air flow is down, and install the two screws securing the fan to the duct. (See page 769, Figure 711). 2. Snap the fan cable connector into the cutout in the side of the air exhaust duct. 3. Move the air exhaust duct back into position and install the three screws. 4. Connect the cabinet exhaust fan cable connector to connector P307. 5. Install the paper stacker. (See Figure 710, page 767.) 6. Return the printer to normal operation (page 63).
720
Fan Assembly, Card Cage

Removal 1. Prepare the printer for maintenance (page 75). 2. Cabinet Model: Remove the paper guide assembly (page 740). Pedestal Model: Remove the top cover assembly (page 718). 3. Disconnect the fan cable connector: Cabinet Model, Figure 719, page 787. Pedestal Model, Figure 714a, page 775. 4. Cabinet Model: Remove the two fan mounting screws from the bottom of the fan. (See Figure 719, page 787, item 2.) Pedestal Model: Remove the four fan mounting screws and nut. (See See Figure 714a, page 777, items 1 through 4.) 5. Remove the card cage fan assembly from the card cage. 6. Remove the screw securing the shield to the card cage fan.
Installation WARNING <10> Make sure to install the fan so the label faces toward the inside of the printer. Air flow is INTO the card cage. 1. Reverse steps 2 through 6 of the removal procedure. 2. Return the printer to normal operation (page 63).
721
Fan Assembly, Hammer Bank

Removal 1. Prepare the printer for maintenance (page 75). 2. Remove the shuttle cover assembly (page 717). 3. Pedestal Model: Remove the top cover assembly (page 718). 4. Trace the hammer bank fan cable assembly back to the controller board connector J107, releasing it from all cable constraints. (See the cable routing diagram on page A12.) 5. Disconnect connector P107 from the controller board and remove the fan connector (HBF) from on the controller board. (Refer to page 79.) 6. Remove the two screws securing the fan to the base casting. Angle the hammer bank fan assembly up and out of the base casting and feed the motor wires and cable connector out from between the base casting and the base pan. (See Figure 719, page 787.) Installation WARNING <11> Make sure to install the fan so the label faces up. Air flow is UP.
NOTE: The hammer bank fan assembly is installed by angling it down and under the shuttle motor. 1. Feed the hammer bank fan cable connector (HBF) and motor wires between the fan well of the base casting and the base pan. Reach up under the base casting and route the fan cable to the right and angle the hammer bank fan assembly under the shuttle motor and down into the fan well. (See Figure 719, page 787.) 2. Route the fan motor wires as shown on page A12, connect fan cable connector (HBF) to P107, then connect P107 to J107 on the controller board. (See page 79.) 3. Install two screws in the locations shown in Figure 715 (page 779). 4. Pedestal Model: Install the top cover assembly (page 718). 5. Install the shuttle cover assembly (page 717). 6. Return the printer to normal operation (page 63).
722
Hammer Spring Assembly

Removal 1. Prepare the printer for maintenance (page 75). 2. Remove the shuttle frame assembly (page 754). 3. Carefully vacuum the shuttle frame assembly. 4. Remove the hammer bank cover assembly (page 716). WARNING <12> Hammer springs and hammer tips are fragile. Do not touch the hammer springs or tips. Handle hammer springs by the thick mounting base only. Apply pressure only to the mounting base.
NOTE: Replace a hammer spring assembly only if there is visible damage or broken parts can be seen in the assembly. 5. Remove the three screws from the old hammer spring assembly. (See Figure 72, page 724.) 6. Handling the hammer spring assembly by the mounting base only, gently rotate the old hammer spring assembly off its mounting pins. (See Figure 72, page 724.) 7. Inspect the hammer bank and the old hammer hammer spring assembly: a. If there is ink on the hammer bank mounting surface, the hammer spring assembly mounting surface, or the hammer spring neck or tines, reinstall the old hammer spring assembly and replace the shuttle frame assembly (page 754). b. If the old hammer spring assembly and the hammer bank are free of ink, install the new hammer spring assembly (page 725).
723
Preliminary 2
NOTE: 6400004, 04P, 005, 05P shuttle frame assembly shown.
Hammer Spring Assembly 7
Hammer Spring Assemblies: 14H5275 6400004, 04P, 005, 05P 14H5512 6400008, 08P, 009, 09P 14H5513 6400012, 014
Hammer Spring Assembly 1
Discard old screws
Figure 72. Hammer Spring Assembly, Removal
724
Installation 1. Using a clean dry cloth, wipe the hammer spring mounting surface on the hammer bank. Make sure the cloth does not leave lint on the hammer bank.
WARNING <12> Hammer springs and hammer tips are fragile. Do not touch the hammer springs or tips. Handle hammer springs by the thick mounting base only. Apply pressure only to the mounting base.
NOTE: Replace a hammer spring assembly only if there is visible damage or broken parts can be seen in the assembly.
2. Handling it by the mounting base only, remove the new hammer spring assembly and mounting screws from the box. 3. Handling the hammer spring assembly by the mounting base only, carefully rotate the new hammer spring assembly onto the hammer bank mounting pins and press it into position with the flat end of the nylon stick supplied in the hammer spring replacement kit. (See Figure 73, page 726.) 4. Install the screws from the replacement kit. Using a TorxT T-10 bit adapter, torque each screw to 14 in-lbs (1.58 NSm). (See Figure 73, page 726.) 5. Install the hammer bank cover assembly (page 716). 6. Install the shuttle frame assembly (page 754). 7. Install the ribbon and load paper.
WARNING <13> Do not attempt to adjust or tweak hammer springs. 8. Run a Customer Engineer Test and check print quality (page 550): a. If print quality is acceptable, return the printer to normal operation (page 63). b. If print quality is still degraded, replace the shuttle frame assembly (page 754).
725
Preliminary 2
New Hammer Spring Assembly
Use new screws from the kit. Torque screws to 14 inch-pounds (1.58 NSm). Hammer Spring Assemblies: 14H5275 6400004, 04P, 005, 05P 14H5512 6400008, 08P, 009, 09P 14H5513 6400012, 014 NOTE: 6400004, 04P, 005, 05P hammer spring assemblies shown.
Figure 73. Hammer Spring Assembly, Installation
726
IBM Coax/Twinax Expansion Board

Removal WARNING <9> 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 component. 1. Prepare the printer for maintenance (page 75). 2. Cabinet Model: Remove the paper guide assembly (page 740). Pedestal Model: Remove the top cover assembly (page 718). 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 the controller board. (See Figure 721, page 791.) 4. Carefully lift the expansion-CT board out of the card cage cutout and off the expansion connector adapter that attaches the CT to the CMX board. 5. Remove the expansion connector adapter from the CMX controller board by carefully lifting it straight up and out of the controller connector.
Installation 1. Reverse steps 2 through 5 of the removal procedure. 2. Return the printer to normal operation (page 63).
727
Magnetic Pick-up (MPU) Assembly

Removal 1. Prepare the printer for maintenance (page 75). 2. Remove the shuttle cover (page 717). 3. Disconnect the shuttle cable assembly connector (page 779, Figure 715). 4. Disconnect the magnetic pick-up (MPU) cable connector (page 781, Figure 716). 5. Loosen the 7/64 inch hex MPU clamp screw (page 781, Figure 716). 6. Unscrew the MPU assembly from the MPU bracket. Installation 1. Install the MPU assembly by screwing it into the MPU bracket (page 781, Figure 716). 2. Using a feeler gauge, adjust the gap between the MPU assembly and the flywheel to 0.010 .001 inch (0.254 0.025 mm). Torque the MPU clamp screw to 19 1 inch-pounds (2.15 0.11 NSm).
3. Check the gap between the MPU assembly and the flywheel with a feeler gauge: a. If the gap is 0.010 .001 inch (0.254 0.025 mm), go to step 4. b. If the gap is not 0.010 0.001 inch (0.254 0.025 mm), loosen the MPU clamp screw and go back to step 2. WARNING <17> Make sure the MPU cable is below the extension spring and does not touch the spring after the cable is connected. 4. Connect the magnetic pick-up (MPU) cable connector. 5. Connect the shuttle cable assembly connector (page 781, Figure 716). 6. Install the shuttle cover (page 717). 7. Adjust the hammer phasing (page 624.) 8. Return the printer to normal operation (page 63).
728
Memory Modules and Security PAL

Removal 1. Make a configuration printout of all configurations. (Refer to the Setup Guide.) 2. Prepare the printer for maintenance (page 75). 3. Cabinet Model: Remove the paper guide assembly (page 740). Pedestal Model: Remove the top cover assembly (page 718). WARNING <9> 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 component.
NOTE: If flash SIMMs are removed from one controller board and placed on another controller board, the SIMMs must be placed on the new board in the same order and location as on the original board. 4. Gently pry the side locks open, angle the SIMM toward the front of the printer, and remove the SIMM from the socket. (See Figure 74, page 731 for the locations of memory modules.) 5. Using a module extraction tool, remove the security PAL. (See Figure 74, page 731.)
729
Installation WARNING <9> 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 component.
NOTE: Flash SIMMs from one CMX controller board must be placed in the same slot on a replacement CMX controller board. 1. Insert the memory module 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 74, page 731.) b. Press the SIMM into the socket with the top of the SIMM angled away from the center of the board. When the SIMM is seated in the socket, gently push on the ends until it locks in the upright position. 2. Install the security PAL. (See Figure 74, page 731.) 3. Cabinet Model: Install the paper guide assembly (page 740). Pedestal Model: Install the top cover assembly (page 718). 4. Download the emulation (page 626). 5. Return the printer to normal operation (page 63). 6. Using the configuration printouts you made as step 1 of the removal procedure, reset and save the printer configurations. (Refer to the Setup Guide.)
730
CAUTION: <5> Do not remove or replace the NVRAM. The NVRAM contains a lithium battery that can explode if it is replaced incorrectly. NVRAM is replaced only at the factory.
Bank 1 Bank 0 Bank 1 Bank 0
1
Notch
Flash Memory: 80-pin SIMM J11 = Bank 0 Must always be filled J10 = Bank 1 Reserved for upgrades If 1 Flash SIMM, use Bank 0 If 2 Flash SIMMs, use both banks, but be sure to place pre-programmed SIMMs in the marked location
DRAM: 72-pin SIMM
Security PAL*
J16 = Bank 0 (must always be filled) 1MB SIMM standard in LP+ option J15 = Bank 1 Reserved for upgrades If 1 DRAM SIMM, use Bank 0 If 2 DRAM SIMMs, use both banks (It does not matter which SIMM goes into which bank)
2
Latch
3
Latch
IMPORTANT: No matter what combination of SIMMs is used, J11 and J16 must always be filled. Flash SIMMs from one CMX controller must be placed in the same slots on another controller board. * Security PAL, Base: 14H5509 Security PAL, Graphics: 14H5490
Blank SIMMs: 1MB Flash 14H5539 2MB Flash 14H5540 1MB DRAM 14H5499 2MB DRAM 14H5481 4MB DRAM 14H5508
Minimum Memory Requirements

Datastream ASCII IGP ASCII Code V ASCII CTA CTA IGP CTA Code V IPDS CTA IPDS CTA IGP 2 MB IPDS CTA Code V 2 MB
Flash Memory
1 MB
2 MB
2 MB
1 MB
2MB
2 MB
2 MB
DRAM
1 MB
3 MB
3 MB
2MB
3 MB
3 MB
6 MB
8 MB
8 MB
CT Board Installed Security PAL Vendor P/N
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
154143002 154143001 154143001 154143002 154143001 154143001 154143002 154143001 154143001
Figure 74. Memory Modules and Security PAL
731
Motor Assembly, Paper Feed

Removal 1. Prepare the printer for maintenance (page 75). 2. Cabinet Model: Remove the paper guide assembly (page 740). Pedestal Model: Remove the top cover assembly (page 718). 3. Cabinet Model: Loosen four screws and remove the barrier shield. (See Figure 713, page 773, items 3, 4, and 9.) Pedestal Model: Remove the four screws, the barrier shield, and the paper guide. (See Figure 714, page 775, items 3, 4, and 5.) 4. Remove the timing belt cover by squeezing the top and bottom to release the plastic tabs from the slots in the side plate (page 773, Figure 713). 5. Loosen the paper feed motor mount screws (page 787, Figure 719). 6. Loosen the shaft collar setscrew and remove the paper feed motor pulley, shaft collar, and paper feed timing belt (page 787, Figure 719). 7. Trace the paper feed motor cables back to the controller board, releasing it from tie wraps. (See the cable routing diagram on page A12.) 8. Disconnect connector P107 from the controller board and remove the paper feed motor connector from connector P107. (See page 79.)
NOTE: Some paper feed motors are mounted with nuts and bolts; other motors have threaded flanges, eliminating the need for nuts. 9. Remove the motor mount bolts (and nuts, if present). 10. Remove the paper feed motor assembly.
732
Installation 1. Position the paper feed motor assembly on the right side plate and install the motor mount bolts and nuts finger tight (page 787, Figure 719). 2. Connect the paper feed motor cable connector to connector P107, then connect P107 to J107 on the controller board. (See page 79.) 3. Install the collar, paper feed motor pulley, and timing belt. 4. Align the paper feed motor pulley with the splined shaft pulley. WARNING <7> Make sure there is at least 0.040 inches (1.016 mm) of clearance between the collar/pulley and the motor face plate. 5. Hold the collar snug against the motor pulley and torque the setscrew to 25 2 inch-pounds (2.82 0.23 NSm). 6. Using the straight end of a force gauge, apply 12 pounds (53.4 N) of pressure to the paper feed motor. Use the splined shaft to steady the gauge. 7. Reduce pressure to 9 pounds (40.0 N) and torque the motor mount screws to 18 2 inch-pounds (1.36 0.23 NSm). 8. Snap the timing belt cover into the slots in the side plate. 9. Cabinet Model: Install the barrier shield and four screws. (See Figure 713, page 773, items 3, 4, and 9.) Pedestal Model: Install the barrier shield, paper guide, and four screws. (See Figure 714, page 775, items 3, 4, and 5.) 10. Cabinet Model: Install the paper guide assembly (page 740). Pedestal Model: Install the top cover assembly (page 718). 11. Return the printer to normal operation (page 63).
733
Motor Assembly, Platen Open

Removal 1. Prepare the printer for maintenance (page 75). 2. Cabinet Model: Remove the paper guide assembly (page 740). Pedestal Model: Remove the top cover assembly (page 718). 3. Cabinet Model: Remove the card cage fan (page 721). 4. Remove the platen open belt cover by squeezing the top and bottom to release the plastic tabs from the slots in the side plate (page 785, Figure 718). 5. Loosen the two 5/16 inch motor mount screws (page 787, Figure 719). 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 from the tie-wraps. (See cable routing diagram on page A12.) 8. Disconnect connector P106 from the controller board. 9. Trace the platen open motor cables to the connector shell and remove the platen open cable connector from the connector shell (page 79).
NOTE: Some platen open motors are mounted with nuts and bolts; other motors have threaded flanges, eliminating the need for nuts. 10. Remove the two 5/16 inch motor mount screws (and nuts, if present). 11. Remove the platen open motor assembly.
734
Installation 1. Position the platen open motor assembly with the wires toward the rear (page 787, Figure 719). 2. Install the two 5/16 inch motor mount screws (and nuts, if present) finger tight. 3. Install the platen open belt and motor pulley. Bottom out the motor pulley on the motor shaft and tighten the setscrew to 9 2 inch-pounds (1.24 0.23 NSm). 4. Connect the platen motor cable connector to connector shell P106. 5. Connect shell connector P106 to J106 on the controller board. Install tie-wraps to secure the motor cable. (See cable routing diagram on page A12.) 6. Close the forms thickness lever all the way. WARNING <6> 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. 7. Using a force gauge, apply 10 pounds (44.48 N) of tension to the platen open motor shaft by pushing away from the large platen pulley, reduce tension to 5 pounds (22.24 N) and torque the motor mount screws to 11 2 inch-pounds (1.24 0.23 NSm). 8. Snap the platen open belt cover into the slots in the side plate. 9. Cabinet Model: Install the card cage fan (page 721). 10. Cabinet Model: Install the paper guide assembly (page 740). Pedestal Model: Install the top cover assembly (page 718). 11. Return the printer to normal operation (page 63).
735
Motor Assembly, Ribbon Drive

Removal 1. Prepare the printer for maintenance (page 75). 2. Remove the ribbon. 3. Remove the ribbon hub (page 750). 4. Remove two screws and washers securing the ribbon drive motor to the base casting (page 787, Figure 719). 5. 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.
Installation 1. Reverse steps 2 through 6 of the removal procedure above.
NOTE: The ribbon drive motor should be secured at the front right and rear left corners. (See Figure 719, page 787.) 2. Return the printer to normal operation (page 63).
736
Network Print Server

NOTE: Installation and operation of this optional feature are described in the IBM Token-Ring Network Print Server Administrators Guide, S2460112, or the IBM Ethernet Network Print Server Administrators Guide, S2460111. Each guide describes error messages and troubleshooting information. Also provided is a section that describes IBM service procedures.
Removal WARNING <9> 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 component. 1. Prepare the printer for maintenance (page 62). 2. Refer to the IBM Token-Ring Network Print Server Administrators Guide (S2460112) or the IBM Ethernet Network Print Server Administrators Guide (S2460111) for information on determining if the print server is operating correctly.
Installation Refer to the IBM Token-Ring Network Print Server Administrators Guide (S2460112) or the IBM Ethernet Network Print Server Administrators Guide (S2460111) for information on installing and testing the feature.
737
Operator Panel Assembly, Cabinet Model

Removal 1. Prepare the printer for maintenance (page 75). 2. Open the printer cover. 3. Remove the four screws securing the operator panel plate to the panel bracket. (See Figure 711, page 769.) 4. Press down on the plastic tab at the upper rear 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. 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 711, page 769.) 2. Position the operator panel over the cutouts in the panel plate. Slide the panel upward on the plate until it will slide no further. 3. Position the operator panel and plate on the bracket and install the four screws finger tight. (See Figure 711, page 769.) 4. Slowly lower the printer cover and align the operator panel in the cover cutout. Open the printer cover and tighten the panel plate screws. 5. Return the printer to normal operation (page 63).
738
Operator Panel Assembly, Pedestal Model

Removal 1. Prepare the printer for maintenance (page 75). 2. Open the printer cover. 3. Tilt the operator panel toward the front of the printer. 4. Disconnect the phone-style cable connector at the rear of the operator panel. 5. Press down on the plastic tab at the upper rear 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 front of the printer. 2. Position the operator panel over the cutouts in the mounting plate and slide the panel upward until the plastic tab at the upper rear of the panel locks into the mounting plate. 3. Connect the phone-style operator panel cable to the bottom of the operator panel. 4. Close the printer cover. 5. Return the printer to normal operation (page 63).
739
Paper Guide Assembly

NOTE: This procedure applies only to cabinet models.
Removal 1. Prepare the printer for maintenance (page 75). 2. Open the printer cover. 3. Loosen the three paper guide assembly hold-down screws (page 773, Figure 713, item 6). 4. Slide the paper guide 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-down screws (page 773, Figure 713). 2. Slide the paper guide assembly to the right, engaging the three hold-down screws in the keyway slots. Slide the paper guide assembly to the right as far as it will go. 3. Tighten the three hold-down screws (page 773, Figure 713, item 6). 4. Return the printer to normal operation (page 63).
740
Paper Ironer
CAUTION <1> Over time, the upper edge of the paper ironer can become sharp. To avoid cutting yourself, handle the paper ironer on the sides.
Removal 1. Remove the shuttle frame assembly (page 754). 2. Move the forms thickness lever to the open position. 3. Push the ends of the paper ironer toward the rear of the printer, disengage the tabs, then lift it up and out (page 785, Figure 718).
Installation
NOTE: The black tape on the paper ironer faces the paper detector switch assembly. 1. Position the paper ironer so that the black tape is on the side that faces the paper detector switch assembly. (See page 785, Figure 718.) 2. Push the paper ironer down into the slots until the tabs engage. 3. Install the shuttle frame assembly (page 754). 4. Return the printer to normal operation (page 63).
741
Platen
Removal 1. Prepare the printer for maintenance (page 75). 2. Remove the shuttle frame assembly (page 754). 3. Remove the paper ironer (page 741). 4. Remove the three 1/4 inch screws securing the paper ironer bracket assembly and remove the assembly. (See Figure 718, page 785, items 4 through 6.) 5. Remove the platen open belt (page 78). 6. Remove the platen pulley (page 785, Figure 718, item 21): a. Loosen the 7/64 inch collar clamp screw. b. Pull the platen pulley off the platen shaft. 7. Pull the spring link and white plastic bushing off the platen shaft and remove the spring link, bushing, and spring. (See Figure 718, page 785, 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. (See Figure 718, page 785, item 15.) 9. Remove the right side platen support spring by repeating step 7 on the right side of the platen. 10. Remove the Phillips #1 screw and washer securing the forms thickness indicator plate from the inside of the right side bracket. (See Figure 718, page 785, items 9 and 10.) 11. Pull the indicator plate, with the interlock switch assembly attached, off the platen shaft. 12. Remove the two 7/32 inch screws and washers securing the right ribbon guide assembly to the side plate. (See Figure 719, page 787, item 12, 14, and 15.) 13. Slide the ribbon guide assembly out of the side plate. 14. Pull the right side of the platen toward the front of the printer and move the platen to the right and out of the left side plate. (Hold the black metal washer on the left side shaft as you remove the platen. Make sure the copper wear saddles in the platen seat of the mechanism base stay in place.)
742
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 longer shaft on the right side. 1. Wipe the platen shafts clean of grease and debris. 2. Install two washers on the longer (right) platen shaft. (See Figure 75.) 3. Apply bearing lubricant to both platen shafts.
Platen Shaft (Right Side)
Washer Ironer Bracket Washer Platen Adjust Bracket
Figure 75. Installing the Platen Adjust Brackets
743
Platen Installation (continued) 4. Make sure the two wear saddles are set flush into the corners of the mechanism base platen seat. (See Figure 76.) 5. Apply a layer of bearing lubricant 1/4 inch high to the seat of each wear saddle, making the layer as wide as the saddle and touching the rear angled surface. 6. Install one platen adjust bracket 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 the flanges of the bracket. 8. Insert the shorter platen shaft through the left adjust bracket and through the opening in the left side plate. Rotate the longer shaft into the opening in the right side plate and position the adjustment brackets as shown in Figure 76.
Washers
Platen Adjust Bracket
Platen
Mechanism Base Platen Seat Wear Saddle
Figure 76. Installing the Platen Adjust Brackets
744
Platen Installation (continued) 9. Slide the right ribbon guide assembly into the side plate and install the two 7/32 inch screws and washers. (See Figure 719, page 787, item 12, 14, and 15.) 10. Install the forms thickness indicator plate: a. Slide the indicator plate, with the interlock switch assembly attached, onto the platen shaft and up against the right side plate. b. Install the Phillips #1 screw and washer securing the indicator plate. 11. Install the black metal washer onto the left side of the platen shaft. (See Figure 718, page 785, item 26.) 12. Apply bearing lubricant to the nylon bearings in the two spring links, slide the spring links onto the two platen shafts, and connect the springs to the spring hooks in the side plates. (See Figure 718 page 785, items 16, 17, 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 75): a. With the flat part of the bracket facing the front of the printer, place the two hooks of the upper part of the paper ironer over the platen shafts.
The left hook of the paper ironer goes between the left platen adjustment bracket and the platen. For the right side of the platen, a washer goes on both sides of the paper ironer hook and the hook goes to the left of the right platen adjustment bracket. (See Figure 75.)
b. Install and torque three screws to 20 2 inch-pounds (2.26 0.23 NSm). 15. Push the platen to the left. 16. Install the forms thickness lever onto the right side platen shaft, pressing the interlock switch out of the way as the lever slides past it. Tighten the 7/64 inch setscrew. (See Figure 718, page 785.) Open and close the forms thickness lever to make sure the setscrew does not touch the right ribbon guide.
745
Platen Installation (continued) 17. Install the platen shaft pulley with the 7/64 inch setscrew facing up and tighten the setscrew. Open and close the forms thickness lever and check that the platen pulley setscrew does not hit the left ribbon guide. 18. Install, but do not adjust, the platen open belt and platen open motor pulley (page 78). 19. Install the paper ironer with the black tape towards the rear of the printer (page 741). 20. Install the shuttle frame assembly (page 754). 21. Adjust the platen gap (page 612). 22. Adjust the platen open belt (page 66). 23. Check ribbon guide alignment (page 616). 24. Check the hammer phasing (page 624). 25. Return the printer to normal operation (page 63).
746
Resistors, Terminating
For parallel interface configurations, the printer is equipped with 470 ohm pull-up terminating resistors and 1K ohm pull-down terminating resistors on the controller board. These are suitable for most applications. (See Figure 77, page 748.) If the standard terminating resistor pack is not compatible with the particular interface driver requirements of the host computer, other values of pull-up and pull-down resistors may be required. 220 ohm pull-up and 330 ohm pull-down alternate terminating resistors are provided with the printer. If you install the 220 ohm pull-up resistor, you must also install the 330 ohm pull-down resistor. Possible terminating resistor combinations are shown below. Configuration Factory Default Alternate 1 Alternate 2 Removal WARNING <9> 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 component. 1. Cabinet Model: Remove the paper path (page 740). Pedestal Model: Remove the top cover assembly (page 718). 2. Locate the terminating resistor packs. (See Figure 77.) 3. Using a chip puller, remove the packs. Installation WARNING <9> 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 component. 1. Using a chip installation tool, install the resistor packs in the correct socket. (See Figure 77, page 748.) 2. Cabinet Model: Install the paper path (page 740). Pedestal Model: Install the top cover assembly (page 718). 3. Return the printer to normal operation (page 63). RP1 (Pull-Up) 470 ohm 220 ohm 1K ohm RP2 (Pull-Down) 1K ohm 330 ohm none
747
RP1 Default: 470 ohm Alt 1: 220 ohm Alt 2: 1K ohm
Resistor Kit: 14H5525
RP2 Default: 1K ohm Alt 1: 330 ohm Alt 2: none
Figure 77. Resistors, Terminating, Removal/Installation
748
Ribbon Guide Assembly (L/R)

Removal 1. Prepare the printer for maintenance (page 75). 2. Open the printer cover. 3. Remove the printer ribbon.
NOTE: The right ribbon guide is shown in Figure 719. The removal procedure is the same for the left ribbon guide. 4. Cut and remove the tie-wrap from the tie wrap hole to free the ribbon guide cable (page 787, Figure 719). 5. Cabinet Model: Remove the paper guide assembly (page 740). Pedestal Model: Remove the top cover assembly (page 718). 6. Trace the ribbon guide cable back to the controller board, releasing it from the cable restraints. (See cable routing diagram on page A12.) 7. For the left ribbon guide, disconnect connector shell P106 from the controller board. For the right ribbon cable, disconnect connector shell P107 from the controller board. 8. Trace the ribbon guide wires to the connector shell, and remove the cable connector from the connector shell (page 79). 9. Remove the two screws and washers securing the ribbon guide assembly to the side plate. 10. Slide the ribbon guide assembly out of the side plate.
Installation
NOTE: The right ribbon guide is shown in Figure 719. The installation procedure is the same for the left ribbon guide. 1. Reverse steps 4 through 10 of the removal procedure above. 2. Align the ribbon guides (page 616). 3. Return the printer to normal operation (page 63).
749
Ribbon Hub
Removal 1. Prepare the printer for maintenance (page 75). 2. Remove the printer ribbon. 3. Loosen the screw in the ribbon spool hub (page 779, Figure 715). 4. Remove the hub from the shaft of the ribbon drive motor.
Installation 1. Install the ribbon spool hub over the motor shaft (page 779, Figure 715). 2. Tighten the hub screw so that it contacts the flat section of the motor shaft. 3. Return the printer to normal operation (page 63).
750
Shaft, Splined
Removal 1. Prepare the printer for maintenance (page 75). 2. Open the printer cover. 3. Remove the paper supports from the splined shaft and support shaft. (See Figure 717, page 783, item 21.) 4. Remove the paper feed timing belt (page 76). 5. Remove the ground clip (page 783, Figure 717). 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 shaft. 8. Unlock the left and right tractors and slide them to the center of the shaft. 9. Remove the bearing clamp on the right side of the splined shaft. 10. Hold the tractors so they do not fall, grasp the vertical adjustment knob, and slide the splined shaft to the right out of the side plates and the tractors.
751
Installation 1. Open the doors on the left and right tractors. Position the tractor belts so the alignment marks are at the top on both tractors. (See Figure 78.) 2. Grasp the vertical adjustment knob and slide the splined shaft through the right side plate, the tractors, and the left side plate (page 783, Figure 717). Make sure the same spline passes the marked groove on each tractor. 3. Install the bearing clamp and screw. 4. Apply a thin film of bearing lubricant to the bearing. 5. Slide the spring link and bearing onto 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 splined shaft with 0.010 inches of clearance between the grip ring and the nylon bearing. 8. Install the ground clip and screw. 9. Install the paper feed timing belt (page 76). 10. Set the paper feed timing belt tension (page 64). 11. Adjust splined shaft skew (page 618.) 12. Install the paper supports on the splined shaft and support shaft. (See Figure 717, page 783, item 21.) 13. Return the printer to normal operation (page 63).
Tractor
Alignment Mark Splined Shaft
NOTE: Align the marks on each tractor before inserting splined shaft.
Figure 78. Splined Shaft and Tractor Installation
752
Shaft, Support
Removal 1. Prepare the printer for maintenance (page 75). 2. Open the printer cover. 3. Unlock the tractors and slide them to the far right. 4. Remove the paper supports from the splined shaft and support shaft. (See Figure 717, page 783, item 21.) 5. Remove the E-ring (page 783, Figure 717). WARNING <15> Hold the tractors while removing the support shaft, and be careful not to lose the curved spring washers. (See Figure 717, page 783, item 5.) 6. Slide the support shaft assemblyconsisting of the support shaft, two curved washers, bushing, horizontal adjustment knob, washer and screwto the left, out of the tractors and the left side plate.
Installation 1. Slide the support shaft assemblyconsisting of the support shaft, two curved washers, bushing, horizontal adjustment knob, washer, and screwinto the left side plate. (See page 783, Figure 717.) 2. Slide the tractors onto the support shaft. 3. Slide the support shaft assembly through the right side plate. 4. While pushing on the knob to compress the curved washers, install the E-ring in the groove on the bushing. 5. Install the paper supports on the splined shaft and support shaft. (See Figure 717, page 783, item 21.) 6. Return the printer to normal operation (page 63).
753

Removal 1. Prepare the printer for maintenance (page 75). 2. Remove the shuttle cover assembly (page 717). 3. Disconnect the MPU cable connector (page 781, Figure 716). WARNING <9> 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 component. 4. Disconnect the shuttle motor cable connector (page 779, Figure 715). 5. Disconnect the hammer drive and hammer logic cables connectors from the terminator board on the shuttle frame assembly. 6. Loosen the side 5/32 inch socket head clamp screws and pull the clamps back and off the 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 as they will go on the tractor support shaft. 9. Grasping the support legs cast on both sides of the shuttle motor, lift the shuttle frame assembly out of the base casting. Lift it slowly and carefully: the shuttle frame assembly is heavy. Installation 1. Install the hammer bank / ribbon mask cover assembly (page 716), if it was removed. WARNING <9> 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 component. WARNING <16> Do not remove the grease from the shaft of the replacement shuttle frame assembly. The shuttle shaft is aluminum, and the clamped ends of the shaft must be greased to prevent galling.
754
2. Holding the shuttle frame assembly by the support legs cast on both sides of the shuttle motor, set it into the base casting. Use both hands: the shuttle frame assembly is heavy (page 779, Figure 715). 3. Align the center 5/32 inch socket head screw in the base casting and hand turn the screw until only two or three threads have started. 4. Pull the shuttle frame assembly toward the front of the printer and hold it in this position while you do step 5. IMPORTANT Do not over tighten the shuttle frame assembly hold-down screws. 5. Slide the side clamps over the guide shaft and torque the 5/32 inch socket head clamp screws to 20 2 inch-pounds (2.26 0.23 NSm). 6. Torque the center captive 5/32 inch socket head screw to 20 2 inch-pounds (2.26 0.23 NSm). 7. Connect the hammer drive and hammer logic cables connectors to the terminator board on the shuttle frame assembly. 8. Connect the shuttle motor cable connector. 9. Route the MPU cable under the extension spring and connect the MPU cable connector. (See Figure 716, page 781, item 4.) Make sure the MPU cable does not touch the extension spring after it is connected. 10. If the shuttle frame assembly is a new or refurbished unit, adjust the platen gap (page 612); otherwise, skip to step 11. 11. Install the shuttle cover assembly (page 717). 12. Models 005, 05P, and 014 only: adjust the coil temperature if the original shuttle frame assembly was replaced (page 632). 13. Models 004, 04P, 005, and 05P only: set shuttle speed if the original shuttle frame assembly was replaced (page 633). 14. Adjust the hammer phasing (page 624). 15. Return the printer to normal operation (page 63).
755
Spring Assembly, Gas

Removal WARNING <18> Two persons may be required to perform this procedure. Prop or hold the printer cover securely while disengaging the gas spring assembly. This procedure applies only to cabinet models. 1. Prepare the printer for maintenance (page 75). 2. Open the printer cover. 3. Open the floor cabinet rear door. 4. Pry back the spring retaining clips (page 769, Figure 711). 5. Remove the gas spring assembly from the ball studs.
Installation WARNING <19> The gas spring assembly must be installed with gas cylinder in the up position. 1. Position the gas spring assembly against the ball studs on the upper and lower brackets (page 769, Figure 711). The large cylinder must be uppermost. 2. Push the gas spring assembly onto the ball joints and install the spring clips. 3. Close the printer cover. If necessary, adjust the position of the ball joint stud in the lower bracket to achieve smooth and complete closure. 4. Return the printer to normal operation (page 63).
756
Spring, Extension
WARNING <20> Do not let the hammer bank rotate toward the platen during spring replacement.
Removal 1. Prepare the printer for maintenance (page 75). 2. Open the printer cover. 3. Remove the shuttle cover assembly (page 717). 4. Unhook the extension spring from the spring lugs on the hammer bank and shuttle frame. (See Figure 716, page 781.)
Installation 1. Put a dab of IBM #20 bearing lubricant on both spring lugs. WARNING <21> Make sure the extension spring does not touch the MPU cable after installation. 2. Hook the extension spring over the spring lugs. (See Figure 716, page 781.) 3. Install the shuttle cover assembly (page 717). 4. Return the printer to normal operation (page 63).
757
Switch Assembly, Cover Open

Removal 1. Remove the shuttle cover assembly (page 717). 2. Carefully lift and pry the cover open switch assembly out its well in the base casting to the right of the shuttle motor. (See Figure 715, page 779.) 3. Trace the cover open switch cable back to the controller board, releasing the cable from the restraints under the base casting. (See cable routing diagram on page A12.) 4. Disconnect connector shell P107 (P7) from the controller board. 5. Trace the ribbon motor wires to the connector shell, and remove the cable connector from the connector shell (page 79).
Installation 1. Remove the protective covering from the adhesive backing on the cover open switch assembly. 2. Feed the switch cable down into the cover open switch well to the right of the shuttle motor. Position the cover open switch assembly in the base casting and press it into place. 3. Route the cover open switch cable back to the controller board, installing the cable in the restraints under the base casting. (See cable routing diagram on page A12.) 4. Connect the cover open cable to the connector shell (page 79), then connect the connector shell P107 (P7) to the controller board. 5. Install the shuttle cover assembly (page 717). 6. Return the printer to normal operation (page 63).
758
Switch Assembly, Paper Detector

Removal 1. Prepare the printer for maintenance (page 75). 2. Cabinet Model: Remove the paper guide assembly (page 740). Pedestal Model: Remove the top cover assembly (page 718). 3. Cabinet Model: Loosen four screws and remove the barrier shield. (See page 773, Figure 713, items 3, 4, and 9.) Pedestal Model: Remove the paper guide, barrier shield, and four screws. (See page 775, Figure 714, items 3, 4, and 5.) 4. Remove the two screws securing the paper detector switch assembly. (See Figure 719, page 787.) 5. Trace the paper detector switch cables back to the controller board, releasing the cables from the restraints under the base casting. (See cable routing diagram on page A12.) 6. Disconnect connector shell P106 from the controller board. 7. Remove switch cable connectors PMD and POD from connector P106 (page 79). 8. Remove the paper detector switch assembly.
759
Installation 1. Holding the slotted wheel against the PMD sensor, position the paper detector switch assembly and install the screws securing it to the printer base. (See Figure 719, page 787.) 2. Check the PMD sensor arm range: make sure it travels freely and completely back into the sensing cavity. 3. Route switch cables PMD and POD back to the controller board, installing the cables in the restraints under the base casting. (See cable routing diagram on page A12.) 4. Connect switch cables PMD and POD to the connector P106 (page 79), then connect P106 to controller board connector J106. 5. Cabinet Model: Install the barrier shield and tighten the four screws. (See page 773, Figure 713, items 3, 4, and 9.) Pedestal Model: Install the paper guide, barrier shield, and four screws. (See page 775, Figure 714, items 3, 4, and 5.) 6. Cabinet Model: Install the paper guide assembly (page 740). Pedestal Model: Install the top cover assembly (page 718). 7. Check and adjust the End of Forms Distance (page 620). 8. Return the printer to normal operation (page 63).
760
Switch Assembly, Platen Interlock

Removal 1. Prepare the printer for maintenance (page 75). 2. Cabinet Model: Remove the paper guide assembly (page 740). Pedestal Model: Remove the top cover assembly (page 718). 3. Fully close the forms thickness lever (position A). 4. Trace the platen interlock switch cable back to the controller board. Remove tie-wraps as necessary to free the cable. (See cable routing diagram on page A12.) 5. Disconnect connector shell P107 (P7) from the controller board. 6. Remove the platen interlock cable connector from the connector shell (page 79). 7. Remove two screws securing the platen interlock switch assembly. (See Figure 718, page 785.) 8. Remove the platen interlock switch assembly from the switch bracket. 9. Remove the switch cable from the cutout in the right side plate.
Installation 1. Fully close the forms thickness lever (position A). 2. Position the platen interlock switch assembly on the switch bracket and install the two screws securing it to the bracket. (See Figure 718, page 785.) 3. Route the switch cable through the cutout in the right side plate and to the controller board. (See cable routing diagram on page A12.) 4. Connect the platen interlock switch cable to the connector shell P107 (P7) (see page 79), then connect the connector shell to the controller board. 5. Cabinet Model: Install the paper guide assembly (page 740). Pedestal Model: Install the top cover assembly (page 718). 6. Return the printer to normal operation (page 63).
761
Tractor (L/R)
Removal 1. Prepare the printer for maintenance (page 75). 2. Remove the splined shaft (page 751). 3. Remove the support shaft (page 753). 4. Remove the tractors.
Installation 1. Using the replacement tractors, install the support shaft (page 753). 2. Install the splined shaft (page 752). 3. Return the printer to normal operation (page 63).
762
Section II: Illustrated Parts List

List of Figures Figure 79. Top Cover, Doors, and Casters, Cabinet Model . . . . . . . 765 Figure 710. Paper Stacker and Chains . . . . . . . . . . . . . . . . . . . . . . . . 767 Figure 711. Control Panel and Cabinet Details . . . . . . . . . . . . . . . . . . 769 Figure 712. Pedestal Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 771 Figure 713. Inside Covers, Cabinet Model . . . . . . . . . . . . . . . . . . . . . 773 Figure 714. Inside Covers and Card Cage, Pedestal Model . . . . . . 775 Figure 714a. Card Cage Detail, Pedestal Model . . . . . . . . . . . . . . . . 777 Figure 715. Print Mechanisms and Circuit Boards . . . . . . . . . . . . . . . 779 Figure 716. Magnetic Pickup Unit (MPU) and Extension Spring . . . 781 Figure 717. Tractor Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 783 Figure 718. Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 785 Figure 719. Motors, Card Cage Fan, and Paper Detector Switch . . 787 Figure 720. Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 789 Figure 721. Expansion Coax/Twinax Board . . . . . . . . . . . . . . . . . . . . 791
763
Item No. 1 2 3 4
Part Number 14H5276 57G1492 14H5567 14H5278
Description Top Cover Kit Window, Top Cover Wireform paper guide assembly Rear Door Kit
Notes Includes mounting hardware Not visible in Figure 79 Includes mounting hardware Includes mounting hardware (Not visible in Figure 79) Includes mounting hardware Two at front Two at rear
5 6 7 8 9
14H5277 57G1485 57G1486 14H5603 30H4008
Front Door Kit Caster, with Brake Caster, without Brake Logo, 6400 Wire Rope, Front and Rear
One on each door (Rear not shown in Figure 79) Cabinet models only Not shown in Figure 79 Not shown in Figure 79
10 11 12 13
30H3986 14H5572 63H7510 63H7398
Shipping Container Kit Hardware Kit Door Seal Kit Top Cover Seal Kit
764
NOTE: Item 10: Shipping Container Kit not shown Item 11: Hardware Kit not shown 1
2 8 13
12
9 4
Figure 79. Top Cover, Doors, and Casters, Cabinet Model
765
Preliminary 2
Item No. 1 2 3 4 5 6 7 8 Part Number 57G7176 30H3981 04H4779 Ref 14H5296 14H5272 57G7260 Ref Stacker Runner, Stacker Riser, Stacker Runner Screw (4) Spares Kit, Grommet Chain Assembly Kit Power Cord, U.S. Grommet, Power Cord (2) Included in item 5 Kit contains eight chains Description Notes
766
7 1
Figure 710. Paper Stacker and Chains
767
Item No. 1 2
Part Number 14H5299 57G1598 57G1599 57G1600 57G1601 57G1602 57G1603 57G1604 Ref 14H5300 57G1481
Description
Notes
Operator Panel, Cabinet Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Screw, Hex w/Lock Washer (4) Cable Assy, Operator Panel Gas Spring Kit
Includes mounting hardware English Spanish French Italian German Dutch Brazilian Portuguese 632x.375
3 4 5
Includes ball studs, spring clips, and mounting hardware 632x.375 632x2.00 Includes mounting hardware
6 7 8 9
Ref Ref 57G1440 Ref
Screw w/Lock Washer (3) Screw w/Lock Washer (2) Fan Assembly Duct, Air Exhaust
768
6 5
9 8
Figure 711. Control Panel and Cabinet Details
769
Preliminary 2
Item No. Part Number Description Notes 1 2 63H5124 57G1598 57G1599 57G1600 57G1601 57G1602 57G1603 57G1604 Ref 63H5125 63H5121 14H5300 63H5119 Ref 63H5120 Ref 63H5118 24H8534 63H7509 Ref 24H8533 63H5122 64H5123 Operator Panel, Pedestal Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Operator Panel Overlay Screw (5) Bracket, Control Panel Hinge Lid Kit Cable Assy, Control Panel Lid, Pedestal Model Screw (2) Top Cover Screw (4) Paper Basket Caster, Pedestal (4) Pedestal Kit Screw, Captive (2) Input Tray Lid Accessory Kit Shipping Container, Pedestal Optional item: Models 04P, 05P, 08P, 09P Repl. acoustic seals (Not shown in Figure 712) Models 04P, 05P, 08P, 09P (Not shown in Figure 712) Models 04P, 05P, 08P, 09P 1032x.625 Models 04P, 05P, 08P, 09P Models 04P, 05P, 08P, 09P Models 04P, 05P, 08P, 09P Models 04P, 05P, 08P, 09P Models 04P, 05P, 08P, 09P English Spanish French Italian German Dutch Brazilian Portuguese 632x.50 Models 04P, 05P, 08P, 09P Models 04P, 05P, 08P, 09P
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
770
14
9 NOTE: Item 16: Lid Accessory Kit not shown Item 17: Pedestal Shipping Container not shown
11
15
13
10
12
Figure 712. Pedestal Details
771
Preliminary 2
Item No. 1 2 3 4 5 6 7 Part Number 14H5235 Ref Ref Ref 14H5271 Ref 14H5174 Description Notes Shroud Assembly, Air Screw, Captive (2) Screw (4), Thread forming Barrier Shield Paper Guide Assembly Screw, w/Lock Washer (3) Platen/Paper Feed Cover Kit Models 004, 005, 008, 009, 012, 014 632x.25, and #6 Flat Washer Paper feed belt cover shown in Figure 713. Platen open belt cover: item 24, page 785. Paper Feed Shuttle Cover Assembly 1024x.62 with O-ring, .125x.250x.06 632x.25
8 9 10 11
57G1468 08H7954 Ref 14H5179
Belt, Timing, 050P, 100 Teeth Anti-Static Brush Kit Power Supply Shield Paper Scale
Taped to card cage along upper edge
772
4 3
9 3
1 11 10
8 7
Figure 713. Inside Covers, Cabinet Model
773
Preliminary 2
Item No. 1 2 3 4 5 6 7 8 9 Part Number 14H5235 Ref Ref Ref Ref 63H5116 08H7954 Ref 57G1468 14H5174 Description Notes Shroud Assembly, Air Screw, Captive (2) Screw, Thread forming (4) Barrier Shield Paper Path Assembly Anti-Static Brush Kit Power Supply Shield Belt, Timing, 050P, 100 Teeth Platen/Paper Feed Cover Kit Taped to card cage along upper edge Paper Feed Paper feed belt cover shown in Figure 713. Platen open belt cover: item 24, page 785. Models 04P, 05P, 08P. 09P Shuttle Cover Assembly 1024x.62 with O-ring, .125x.250x.06 632x.25
774
3 5
4 3
See Figure 714a, page 777.
8 9
Figure 714. Inside Covers and Card Cage, Pedestal Model
775
Item No. 1 2 3 4 5 6
Part Number Ref 57G1440 Ref Ref Ref 14H5571
Description
Notes
Nut (1), 632 Card Cage Fan Assy Fan Guard Screw, w/Lock Washer (4) Card Cage, Pedestal Circuit Breaker
Upper right fan corner only Air flow into card cage
632x1.75
776
1 2
From Figure 714, page 775. (Rotated 180 degrees.)
To IEC 320 AC Power Input (Connector J301, White Wire) To Connector P1, (White Wire)
To Connector P1, (Black Wire) 6 To IEC 320 AC Power Input (Connector J301, Black Wire)
Figure 714a. Card Cage Detail, Pedestal Model
777
Preliminary 2
Item No.
1
Part Number
14H5273 14H5601 14H5602 14H5274 24H8648 14H5516 26H9625 14H5517 90H3269 14H5275 14H5512 14H5513
Description
Hammer Bank/Rbn Mask Cover Hammer Bank/Rbn Mask Cover Hammer Bank/Rbn Mask Cover Shuttle Frame Assembly Shuttle Frame Assembly Shuttle Frame Assembly Shuttle Frame Assembly Shuttle Frame Assembly Shuttle Frame Assembly Hammer Spring Assemblies: Hammer Spring Assembly Hammer Spring Assembly Hammer Spring Assembly Power Supply PCBA Power Supply PCBA P101 Cable Connector Cable Assy, AC In, Power Supply Controller Board, CMX, V5.0
Notes
Models 004, 04P, 005, 05P Models 008, 08P, 009, 09P Models 012, 014 Models 004, 04P Models 005, 05P Models 008, 08P Models 009, 09P Model 012 Model 014 Models 004, 04P, 005, 05P Models 008, 08P, 009, 09P Models 012, 014 Models 004, 04P, 005, 05P, 008, 08P, 012 Models 009, 09P, 014
14H5644 90H3268
4 5 6
Ref Ref 14H5643
Part of Field Kit, AC Assy 14H5289 All models 004 and 04P. Models 008 and 012 with Ser. Nos. 01AXXXX, 01BXXXX and 01CXXXX All models 005, 05P, and 08P. Models 008 and 012 with Ser. Nos.01DXXXX, 01EXXX, and higher. All models 009, 09P. Model 014 only Housing Connector Kit 14H5288
24H8647
Controller Board, CMX, V5.5, 25 MHz
90H3271 7 8 9 10 11 12 13 14 15 16 17 18 Ref Ref Ref Ref Ref 14H5287 14H5522 Ref 14H5211 Ref Ref Ref 14H5282
Controller Board, CMX, V5.5, 40 MHz Motor Sensor, Left, Cable Assy Hammer Bank Logic Cable Assy Shuttle Motor Cable Assy Hammer Bank Power Cable Assy Motor Sensor, Right, Cable Assy Centronics I/O Cable Assy Centronics/Dataproducts Adapter Control Panel Cable Assy Clamp, Shaft, Receiving Screw, Captive, Power Supply (3) SIMM, Flash Memory SIMM, DRAM Switch Assembly, Cover Open
Housing Connector Kit 14H5288 Optional cable assembly
See also page 729 See also page 729
778
2 Places: Exploded for clarity. Do not remove holdown clamps and screws.
14
3
To To J03 J02 (Shuttle (MPU) Motor)
15 2 8 9 5 4 15 11 16
10
6 12 13
15
17
To Terminator Board on 18 Shuttle Frame
Figure 715. Print Mechanisms and Circuit Boards
779
Item No. 1 2 3 4
Part Number 57G1476 Ref 30H3985 14H5329
Description
Notes
Magnetic Pickup Assy (MPU) Screw, socket cap Extension Spring Cable Assembly, MPU 632x.38
780
Spring Lug (Do not remove grease)
3 Spring Lug (Do not remove grease)
<21> Make sure the extension spring does not touch the MPU cable after installation.
0.010 .001 inch (0.254 .025mm)
Figure 716. Magnetic Pickup Unit (MPU) and Extension Spring
781
Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Part Number Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref 57G1521 57G1460 Ref Ref Ref 57G1466 Ref 14H5217 14H5214 Ref 24H8593
Description
Notes
Screw, Socket Cap, 440x.25 Washer, Flat #4 Knob, Tractor Adjust Bushing, Tractor Adjust Washer, Curved Spring (2) Ring, Grip Bearing, Nylon .626 Link Spring Spring, Extension 1.00L Screw, Hex w/Lock Washer, 420x.50 Ground Clip, Splined Shaft Splined Shaft Assembly Screw, Thread Forming, 632x.25 Clamp, Bearing Tractor Support Shaft Tractor Set E-Ring Tractor Shaft Hardware Kit Tractor Shaft Kit Bushing Paper Support (2)
Part of item 15 Part of item 15 Part of item 15 Part of item 15 Part of item 15 Part of item 18 Part of item 18 Part of item 18 Part of item 18 Part of item 11
Part of item 19 Part of item 18 Part of item 18 Part of item 19 Includes L and R tractors Part of item 15
Part of item 18
782
10 11 6 7 8 9 20 1 2 3 4 5
21
12
14 13
16 17 15 NOTE: Item 18: Tractor Shaft Hardware Kit not shown Item 19: Tractor Shaft Kit not shown
16
Figure 717. Tractor Shafts
783
Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Part Number Ref Ref 57G1469 Ref Ref Ref 08H7936 Ref Ref Ref 14H5280 Ref Ref Ref 14H5184 Ref Ref Ref Ref Ref 57G1514 Ref 57G1467 14H5174 Setscrew
Description
Notes Part of item 25 Part of item 25 Reverse Paper Feed 632x.25
Bracket, Platen (2) Ironer Assembly Screw, Thread Forming (3) Bracket, Ironer Plate, Ironer Platen Assembly Washer, Flat (2) Screw (2) Washer, Flat #4 (2) Platen Switch Kit Screw, Socket Cap, 632x.75 Washer Nut Part of item 15
Part of item 25 Part of item 11 Part of item 11
Part of item 15 Part of item 15
Platen Lever Kit Spring, Extension 1.12L Link, Spring Bearing, Nylon .376 Bracket, Switch Mount Wear Saddle, Platen (2) Platen Pulley, Driven Screw, Socket Cap, 632x.44 Belt, timing, 312W, 87 teeth Platen/Paper Feed Cover Kit Part of item 21 Platen Open Belt Platen open belt cover shown in Figure 718. Paper feed belt cover: page 773, item 7. Part of item 25 Part of item 25 Part of item 25 Part of item 11 Part of item 25
25 26
14H5169 Ref
Platen Hardware Kit Platen Washer Part of item 25
784
NOTE: Black tape faces paper motion detector.
NOTE: Item 25: Platen Hardware Kit 24
7 23 8 22 21 17 26 20 2 1
18 16
10
11
12 19 18 17 16
13
15
14
Figure 718. Platen
785
Item No. 1 2 3 4 5 6
Part Number 57G1440 Ref 14H5281 14H5570 Ref 14H5520 08H7934
Description
Notes
Fan Assembly, Card Cage Screw, w/Lock Washer (3) Paper Detector Switch Assy Paper Detector Switch Assy Screw, Thread Forming Paper Feed Motor Motor Pulley, Platen Open Two 632x1.75 on bottom One 632x0.50 on top left Standard Black back forms 632x.375 Paper Feed Motor Assy (includes items 7 through 9) Part of Platen Open Motor Assy (57G1509) and includes collar setscrew 632x.25
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Ref Ref 57G1421 Ref 14H5290 14H5154 Ref Ref Ref Ref 14H5521 Ref Ref 57G1479 Ref 14H5159
Collar Part of item 9 Screw, socket head Motor Pulley, Paper Feed Screw, Hex w/Lock Washer (2) Ribbon Guide Kit Platen Open Motor Assembly Washer (2) Screw, Hex w/Lock Washer (2) Screw, Hex w/Lock Washer (2) Shield, Card Cage Fan Motor Assy, Ribbon Screw, Hex w/Lock Washer (2) Washer, Flat #6 (2) Ribbon Hub Kit Screw, w/Lock Washer (2) Hammer Bank Fan Assy 632x1.25 Air flow up 632x.50 1032x.50 Includes left and right ribbon guides Includes item 6 Flat #4 440x.38 1032x.50 632x.51
786
Install screws here
16
1
Top View
Hammer Bank Fan
Route cable under base casting
4 3 6 20 12 18 19 17 15 2 5
11
8 7 22 21
10 14 13 11
See detail above
Figure 719. Motors, Card Cage Fan, and Paper Detector Switch
787
Item No. 1 2 3 4 5
Part Number 14H5571 Ref Ref Ref Ref
Description Circuit Breaker IEC 320 AC Power Connector Chassis Ground Stud Connector P1 Cable Assy, AC In, Power Supply
Notes
Connector J301
To power supply board connector J1 AC Part of Field Kit, AC Assy 14H5289
788
Inside detail
To IEC 320 AC Power Input (Connector J301) (Black Wire) To IEC 320 AC Power Input (Connector J301) (White Wire) 1
To Connector P1 (Black Wire) To Connector P1 (White Wire)
Card cage fan and power supply board removed for clarity Black Wire
Black Wire
2 WhiteWire 3 5 4
White Wire
Figure 720. Circuit Breaker
789
Item No.
Part Number
Description
Notes
1 2 3 4 5 6 7 8
Ref Ref 63H7382 Ref Ref 24H8535 Ref Ref
Screw (2) Card Cage IBM Coax/Twinax Expansion PCBA Screw, Captive Standoff, Hex, 3/16 inch Adapter, Expansion Connector CMX Controller Board Controller Board Connector J111 M/F, .813 Lg. 60-pin See item 6, page 778
790
4 3
7 2
1 8
Figure 721. IBM Coax/Twinax Expansion Board
791
792
Wire Data
NOTE: Acronyms and Signal mnemonics are defined in Appendix F.
IBM 6400 Interconnection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3 IBM 6400 Power Distribution Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . A4 Circuit Board Assemblies Controller, CMX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9 Expansion Coax/Twinax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10 Cable Routing Cabinet Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11 Cabinet Model, Mechanism Base . . . . . . . . . . . . . . . . . . . . . . . . . . . A12 Pedestal Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13 Pedestal Model, Mechanism Base . . . . . . . . . . . . . . . . . . . . . . . . . . A14 Cable Assemblies AC In, Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A15 AC Power Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A16 Card Cage Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A17 Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A18 Exhaust Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A19 Hammer Bank Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A20 Hammer Bank Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A21 I/O, Centronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A22 MPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A23 Ribbon Guide Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A24 Ribbon Motor, Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A25 Shuttle Motor Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A26
Wire Data
A1
Twinax AutoTermination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A27 Centronics / DataProducts Adapter . . . . . . . . . . . . . . . . . . . . . . . . . A28 +5V Remote Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A29 Fan Assembly, Hammer Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A30 Magnetic Pickup (MPU) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A31 Switch Assemblies Switch Assembly, Cover Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A32 Switch Assembly, Paper Detector . . . . . . . . . . . . . . . . . . . . . . . . . . A33 Switch Assembly, Platen Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . A34
A2
Wire Data
IBM 6400 INTERCONNECTION DIAGRAM

J301 AC INPUT IEC 320 AC POWER CONNECTOR
Operator Panel Legend:
J1 AC
P1
P112
J112
Card Cage Fan
J111 EXP PORT
J101 DC POWER
PLAT M P306 LRIB M 2 2 4 6 8
CCF LRP 10 12
POD PMD 14 16 18 20 J108 HLP P108 HLP 10
P101
2 4 6 8
10 12 14 16 * Spacer in pedestal model
18 20
J102
P110
J110
P03
J04
J05
Terminator Board
2
J03
P06
Cover Open Switch Assy Hammer Bank Fan

2
Print Mechanisms
P06
J06
J06
Wire Data A3
N CIRCUIT BREAKER ON/OFF SWITCH
Line 1 Line 2 / Neutral
AC to DC Power Supply Board

12
= Number of conductors in cable assembly
=Chassis/ frame/ earth ground
J310 P310
CHASSIS GND Diagnostic Port J6 J201 RS232 I/O 8
36 J203 Centronics I/O SHIELD GND
P107 Configuration
1 3 5 7 PAPR M RRIB M Point of Common Ground 9 11 13 15 EHF* HBF 17 19
P106 Configuration
1 3 5 7 9 11 13 15 17 19
PLO MPU RRP CVO
Exhaust Fan* +5V Remote Power
J106 MSL P106 MSL
J105 HBP P105 HBP 10
J116 SMD P116 SMD
J107 MSR P107 MSR
*Cabinet Models Only
P307
J02 P02
4 4 P04 Flex Circuits
Shuttle Assy
P05
Paper Feed Motor Platen Open Switch Right Ribbon Guide Right Ribbon Motor
Shuttle Motor
2
Hammer Bank Board

4
Magnetic Pickup Unit
AC POWER
J301 IEC 320 AC POWER CONNECTOR
IBM 6400 POWER DISTRIBUTION DIAGRAM

+48V +48V +5 V +5 V +8.5V +8.5V Operator Panel
J1 AC
P1
P306
J102
Ret +48V
J106 MSL P106 MSL
J108 HLP P108 HLP
J105 HBP P105 HBP
J116 SMD P116 SMD
J107 MSR P107 MSR
P110
J110
P06
P06
J06
+48V
J06
A4
Card Cage Fan
ON/OFF SWITCH CIRCUIT BREAKER Line 1 Line 2 / Neutral
J310 P310
CHASSIS GND
Exhaust Fan* Ret CMX Controller Board

P307 P101 J101 DC POWER 5 Point of Common Ground 6 7 8
*Cabinet Model Only +5V Remote Power +5 V
+8.5V Ret Platen Motor +48V

Flex Circuits P04 J04
+8.5/+48V Ret Shuttle Assy Terminator Board +48V Ret

P05 J05
+48V
J02 P02
Ret Paper Feed Motor
+48V
Paper Motion Detector Paper Out Detector Left Ribbon Guide
+5 V
Shuttle Motor +5 V Hammer Bank Board +5 V
+5 V
Platen Open Switch
+5 V Cover Open Switch Assy Ret Hammer Bank Fan +24V
Right Ribbon Guide
Wire Data
Left Ribbon Motor
+5 V +48V Right Ribbon Motor
Controller, CMX
Wire Data
J112 Centronics
I/O CNC PN 1 I/O CNC PN 19 I/O CNC PN 2 I/O CNC PN 20 I/O CNC PN 3 I/O CNC PN 21 I/O CNC PN 4 I/O CNC PN 22 I/O CNC PN 5 I/O CNC PN 23 I/O CNC PN 6 J107 I/O CNC PN 24 Sensor Right I/O CNC PN 7 I/O CNC PN 25 I/O CNC PN 8 PF 1 I/O CNC PN 26 RIB R1 I/O CNC PN 9 PF 2 I/O CNC PN 27 RIB R2 I/O CNC PN 10 PF 3 +48V I/O CNC PN 28 RIB R3 I/O CNC PN 11 PF 4 I/O CNC PN 29 RIB R4 I/O CNC PN 12 EXH FAN+ I/O CNC PN 30 BANK FAN+ I/O CNC PN 13 EXH FAN 0.01 mF I/O CNC PN 31 BANK FAN 10% I/O CNC PN 14 PLAT OPEN SW 100V I/O CNC PN 32 R RBN POST+ I/O CNC PN 15 PLAT OPEN RET R RBN POST I/O CNC PN 33 I/O CNC PN 16 MPU+ I/O CNC PN 34 COVER OPEN SW I/O CNC PN 17 MPU I/O CNC PN 35 COVER OPEN RET I/O CNC PN 18 I/O CNC PN 36
J201 RS232/RS422
J110 Front Panel

VCC
Motor
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 26 6 7 8 9 10 11 12 13 14 15 16 27 17 18 19 20 21 22 23 24 25
HOST TX HOST RX HOST RTS HOST CTS HOST DSR HOST DCD NC NC NC NC NC NC DIFF RXD NC DIFF RXD+ NC DIFF TXD HOST DTR NC NC NC NC DIFF TXD+
470 PF 10% 50V
1 2 3 4 5 6 7 8
N FP DAT AVAIL FP CLK N FP LED WR FP DATA N FP LCD WR 470 PF 10% 50V
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
N STROBE P1 P2 P3 P4 P5 P6 P7 P8 N ACK BUSY PAPER EMPTY SLCT N INIT N AUTOFEED N FAULT PI VCC 4.7K 0.1W N DP SEL EXT 5V N SELECT IN HOST LOGIC H NC 10K 0.1W
NC
470 PF 10% 50V
A5
CHASSIS GND
J6 Diagnostic Port CAUTION: <5> Do not remove or replace the NVRAM. The NVRAM contains a lithium battery that can explode if it is replaced incorrectly. NVRAM is replaced only at the factory.
7 8
Controller, CMX
1 2 3 4 5 6
NC VX DB TXD VX DB RXD NC 470 PF 10% 50V
A6
PER LOGIC 1 HIGH
J9 Online Verifier
1 2 3 4 5 6
EXT 5V DB TXD DB RXD OLV SYNC OLV IRQ
J17 Paper Stacker

PER LOGIC HIGH VCC
VCC
J102 External Power
4.7K 0.1W U56 3 1 2 3 4 GND IN1 IN2 EN OUT1 OUT2 OUT3 OUT4 8 7 6 5
4.7K 0.1W
L6
1 2
0.1 PF 20% 50V
10 mF 10% 16V
1000 PF 10% 50V
1 2 3 4 5 6 7 8 9 10
PPR STK STAT0 PPR STK STAT1 PPR STK CTL0 PPR STK CTL1 470 PF 10% 50V 470 PF 10% 50V 470 PF 10% 50V
NC NC NC NC
470 PF 10% 50V
470 PF 10% 50V
5000HM
1000 PF 10% 50V
Wire Data
Controller, CMX
Wire Data
VCC
J106 Motor Sensor Left

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
PLAT 1 RIB L1 PLAT 2 RIB L2 PLAT 3 +48V RIB L3 PLAT 4 RIB L4 CC FAN+ L RBN POST+ CC FAN L RBN POST POD A PMD A POD K POD C PMD C POD E PMD E 0.01 mF 10% 100V
J105 Hammer Bank Power

1 2 3 4 5 6 7 8 9 10
PH1 PH2 PH3 PH4 LDFB
J101 Power Supply

1 2 3 4 5 6 7 8 9 10 11 12
N TEMP HI N STBY VCC NC EXP N ID SEL 12/10 V NC 8.5V +48V NC EXP NINT EXP NWR N DMA REQ0 N DMA REQ1
J111 Expansion Connector

4.7K 0.1W 4.7K 0.1W
PMD K
EXP NRESET CAJ NACK EXP NMSEL
EXP NDS EXP D15 EXP D14 EXP D13 EXP D12 EXP D11 EXP D10 EXP D9 EXP D8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 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
EXP D7 EXP D6 EXP D5 EXP D4 EXP D3 EXP D2 EXP D1 EXP D0 EXP A15 EXP A14 EXP A13 EXP A12 EXP A11 EXP A10 EXP A9 EXP A8 EXP A7 EXP A6 EXP A5 EXP A4 EXP A3 EXP A2 EXP A1 EXP A0
A7
VCC
VCC
10K 1% 0.1W
Controller, CMX
EC DB TXD EC DB RXD
J2 EC Diagnostics
1 2 3 4 5 6 7 8 9 10
A8
15V
NC PPR TRIG PPR MOVING FT EVENT MPU OUT SHUT DIR
J1
2PIN JUMPER
J108 Hammer Bank Logic

TOROID 50 MHz HMR DAT HMR DAT RET HMR CLK HMR CLK RET CMD DAT CMD DAT RET CMD CLK CMD CLK RET
4.7V 3.0W
J116 Shuttle Motor

1 2 3
SHUT A SHUT B SHUT C
1 2 3 4 5 6 7 8 9 10
DRAM: 72pin SIMM J15 = Bank 1 J16 = Bank 0 (See page 729.)
Flash: 80pin SIMM J10 = Bank 1 J11 = Bank 0 (See page 729.)
J13
2PIN JUMPER
J12
2PIN JUMPER
J14
2PIN JUMPER 0.01 mF 10% 50V
J5
2PIN JUMPER
Wire Data
TOROID 50 MHz
Power Supply
Wire Data
LOAD GND LOAD
(Line Filter Area)
Cable Assy, AC In, Power Supply
1 1 2 P1 3
AC Input
AC AC COMMON CHASSIS GND
J1
= RING TERMINAL = FASTON TERMINAL PIN 1
P101 P101 Controller Board

N TEMP HI N STBY +5V +5V +5V RET / LOGIC GND +5V RET / LOGIC GND +5V RET / LOGIC GND +5V RET / LOGIC GND +8.5V +8.5B +48V +48V
1 2 3 4 5 6 7 8 9 10 11 12
N TEMP HI N STBY VCC
470 mF 10% 50V
470 mF 10% 50V
470 mF 10% 50V 8.5V
470 mF 10% 50V
A9
+48V
J2 Twinax Connector
IBM Coax/TwinaxExpansion Board

NC NC NC NC NC TWINAX PHASE B NC NC NC NC NC NC TWINAX PHASE A NC VCC
A10
16
SHIELD 1 SHIELD 2
17
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
J4 Expansion Connector
1K 0.1W
NC N CARD DETECT 12/10 V NC N DMA REQ0 N DMA REQ1 NC EXP NINT
J3 Coax Connector
1 2
COAX SHIELD COAX DATA
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
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 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
EXP D7 EXP D6 EXP D5 EXP D4 EXP D3 EXP D2 EXP D1 EXP D0 EXP A15 EXP A14 EXP A13 EXP A12 EXP A11 EXP A10 EXP A9 EXP A8 EXP A7 EXP A6 EXP A5 EXP A4 EXP A3 EXP A2 EXP A1 EXP A0
Wire Data
VCC
Cable Routing, Cabinet Model

Wire Data A11
Front of Printer
A12
Left Side of Printer Right Side of Printer To J106 on Controller
Cable Routing, Mechanism Base Cabinet Model

(Looking up from below)
Wire Data
P107 / CVO
(See page 710 for connector detail.)
To J107 on Controller
Cable Routing, Pedestal Model

Wire Data A13
Front of Printer
A14 Wire Data
Left Side of Printer
Right Side of Printer
Cable Routing, Mechanism Base, Pedestal Model (Looking up from Below)

To J106 on Controller (See page 710 for connector detail.)
P107/SPACER
P107/CVO
To J107 on Controller
Wire Data To Circuit Breaker To Power Supply J1
Part No. 14H5289

A15
Description Cable Assembly, AC In, Power Supply
A16 To Circuit Breaker Input Power Connector
Part No. 14H5289
Description Cable Assembly, AC Power Input
Wire Data
Wire Data
PIN 1 PIN 1
Part No. 14H5285
Description Cable Assembly, Card Cage Fan
A17
A18
IMPORTANT: If you replace the control panel cable, you must install two ferrite shielding beads. See Appendix I.
PIN 8 (Brown) PIN 1 (Gray) PIN 1 (Gray) PIN 8 (Brown)
Part No.
Wire Data
Description Cable Assembly, Operator Panel
14H5300
Wire Data
Part No. 14H5286
Description Cable Assembly, Exhaust Fan
A19
A20
Part No.
Wire Data
Description Cable Assembly, Hammer Bank Logic
14H5279
Wire Data
PIN 1 PIN 1
Part No. 14H5283
Description Cable Assembly, Hammer Bank Power
A21
A22
PIN 1 PIN 1
NOTE: If you replace the I/O cable assembly, you must install the ferrite clamp. See Appendix I.
Part No.
Wire Data
Description Cable Assembly, I/O, Centronics
14H5287
Wire Data
PIN 2 PIN 3 PIN 1 PIN 1
Part No. 14H5329
Description Cable Assembly, MPU
A23
A24
NOTE: Left ribbon guide shown. Right is mirror image.
PIN 1 LEFT GUIDE = P106 / LRP RIGHT GUIDE = P107 / RRP PIN 2
Part No.
Wire Data
Description
14H5290
Ribbon Guide Kit (Includes left and right guides)
Wire Data
Part No.
A25
Description Cable Assembly, Ribbon Motor, Extension
63H7464
A26
Part No.
Wire Data
Description Cable Assembly, Shuttle Motor Drive
14H5330
Wire Data
15 position Dsub receptacle connector with EMI/RFI shield. 1 Jack 2 White 14 Gray 7 Shield 5
Resistance Chart Pin 1 3 1, 2, 3, 4 5 14

3 Jack 4
Pin 2 4 Shield Shield 1, 4 2, 3
Ohms 110 110 55 0 0 0
Part No.
A27
Description Cable Assembly, Twinax AutoTermination
38F8254
A28
Part No.
Wire Data
Description Cable Assembly, Centronics/DataProducts Adapter
14H5522
Wire Data
Part No.
A29
Description Cable Assembly, +5V Remote Power
14H5589
P107/HBF
A30
P107 / HBF
Part No.
Wire Data
Description Fan Assembly, Hammer Bank
14H5159
Wire Data
Part No.
A31
Description Magnetic Pickup Assembly
57G1476
A32
Part No.
Wire Data
Description Switch Assembly, Cover Open
14H5282
Wire Data
Part No. 14H5281 (14H5570)

A33
Description Switch Assembly, Paper Detector (Standard) (Black Back Forms)
A34
Preliminary 2
Part No. 14H5281 (14H5570)

Wire Data
Description Switch Assembly, Paper Detector (Standard) (Black Back Forms)
P107/PLO
Wire Data
Preliminary 2
Part No.
A35
Description Switch Assembly, Platen Interlock
14H5280
Preliminary 2
B
Contents
Printer Specifications
Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2 Paper Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3 Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3 Printer Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4 Environmental Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4 Relative Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4 Energy Star . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5 Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5 Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8 Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B9 Printing Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B9
B1
Preliminary 2
Ribbon Specifications
NOTE: The ribbon life figures listed below are based on IBM tests conducted in accordance with ANSI Standard X3A.182. Actual ribbon life may vary depending upon the users quality criteria, printer condition, machine settings, paper quality, and bar code requirements. Label yield depends on label format, bar code symbology, and other parameters. Label yield with high-performance scanning equipment may exceed these yields. Use only the ribbons listed below. IBM General Purpose Ribbon P/N 1040990 Used for general text printing such 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 general text printing as well as OCR, graphics and bar code printing. Average yield: 20 million DP characters, 2500 AIAGB3 labels with visible light source scanning equipment, or 1300 AIAGB3 labels with infrared light source scanning equipment. IBM High Contrast Ribbon P/N 1040998 Average yield: 30 million DP characters, 3600 AIAGB3 labels with visible light source scanning equipment, or 1800 AIAGB3 labels with infrared light source scanning equipment. Ordering Ribbons (U.S. Only) Ribbons may be purchased from Lexmark Authorized IBM Supplies Dealers or directly from Lexmark by calling: 18004382468. Fax orders may be sent to: 18005223422 Mail orders may be sent to: Lexmark International, Inc., 1221 Alverser Drive, Midlothian, VA 23113. Ordering Ribbons (Outside of U.S.) Order supplies by contacting your local Lexmark International distributor or by writing to Lexmark International, Inc. Lexmark International, Inc. P.O. Box 11427 Lexington, KY, 405751427 USA
B2
Preliminary 2
Paper Specifications
NOTE: The following paper specifications are general guidelines. Paper stock should be tested with applications to determine print quality.
Paper
Type: Edge-perforated, fan-fold, 3 to 17 inches (7.62 to 43.18 cm) wide*, 2 to 24 inches (5.08 to 60.96 cm) long** S S S 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 readability of greater than 4-part.
Form Thickness: Drive: Slew Rate: 6400004, 04P 6400005, 05P 6400008, 08P 640009P 6400009 6400012 6400014
0.025 inches (0.064 cm) maximum Adjustable tractors (6-pin engagement) Fast 12 ips 12 ips 16 ips 16 ips 20 ips 20 ips 20 ips Slow 8 ips 8 ips 8 ips 8 ips 10 ips 10 ips 10 ips
Labels
On Backing: One-part continuous perforated fan-fold back form. Labels must be placed at least 1/6 inch (0.42 cm) from the fan-fold perforation. Backing adhesive must not be squeezed out during printing. 3 to 17 inches (7.62 to 43.18 cm) wide*, including the two standard perforated tractor feed strips. A maximum sheet length of 16 inches (40.64 cm) between top and bottom perforations.**
Sheet Size:
B3
Preliminary 2
Thickness Not to exceed 0.025 inch (0.064 cm), including backing sheet. * On pedestal models, when using the rear paper exit, the maximum width is 16 inches (40.64 cm). ** On cabinet models, forms longer than 12 inches (30.48 cm) can be used by opening the front and rear printer doors.
Printer Dimensions
Cabinet Model Height: Width: Depth: Weight: 42.5 inches (108 cm) 27 inches (68.6 cm) 29 inches (73.7 cm) 225 lbs. (102.1 kg) 285 lbs. (129.3 kg) packaged Pedestal Model 35.5 inches (90.2 cm) 24.6 inches (62.5 cm) 30 inches (76.2 cm) 120 lbs. (54.4 kg) 160 lbs. (72.6 kg) packaged
Environmental Characteristics
Temperature
Operating 41 to 90 F (5 to 32 C) up to 8000 feet (2438 meters) Storage 40 to 158 F (40 to 70 C) 41 to 104 F (5 to 40 C) up to 5000 feet (1524 meters)
Relative Humidity
Operating Storage 15% to 80% (noncondensing) 15% to 90% (noncondensing)
ENERGY STAR
IBM 6400 Series Printers comply with the requirements of the ENERGY
STAR Computers Program of the U.S. Environmental Protection Agency.
B4
Preliminary 2
Electrical Characteristics
Input Voltage
Line Voltage Design Range
88135V RMS 178270V RMS
Line Frequency 04, 04P

4763 Hz 4763 Hz 6A @ 100 V 3A @ 200 V
RMS Current 05, 05P

6A @ 100 V 3A @ 200 V
08, 08P
6A @ 100 V 3A @ 200 V
09, 09P
6A @ 100 V 3A @ 200 V
012
6.5A @ 100 V 4A @ 200 V
014
8A @ 100 V 5A @ 200 V
Power Consumption
6400004 640004P Operating DP Mode 120 VAC 60 Hz Watts BTU/Hour VA All Hs 200 680 350 Max Typical 165 560 290 Standby Not Energy Star 70 240 130 Energy Star 25 85 48
Operating DP Mode 220 VAC 50 Hz Watts BTU/Hour VA All Hs 180 615 390 Max Typical 150 510 310
Standby Not Energy Star 60 205 145 Energy Star 25 85 55
B5
Preliminary 2
B6
Preliminary 2
6400012 Operating DP Mode 120 VAC 60 Hz Watts BTU/Hour VA All Hs 290 990 490 Max Typical 215 735 370 Standby Not Energy Star 70 240 130 Energy Star 25 85 48
B7
Preliminary 2
6400014 Operating DP Mode 120 VAC 60 Hz Watts BTU/Hour VA All Hs 370 1260 635 Max Typical 260 885 445 Standby Not Energy Star 75 255 130 Energy Star 25 85 48
Interfaces
Type: Logic Levels: Data Format: Compatibility: PC Parallel, RS232 serial, RS422 serial TTL, EIA232E, EIA422B ASCII PC Parallel, EIA232E serial, EIA422B serial Up to 200 Kilobytes on parallel interface Up to 115.2K baud on RS232/422 serial interface
Transfer Rates:
B8
Preliminary 2
Duty Cycle
6400004, 04P prints 130, 000 pages per month 6400005, 05P prints 130, 000 pages per month 6400008, 08P prints 205, 000 pages per month 6400009, 09P prints 205, 000 pages per month 6400012, 014 prints 320, 000 pages per month under the following conditions: Uppercase text characters only (no graphics) 6 lines per inch 10 characters per inch 63% character density or 83 characters per line 63% line density or 42 lines per 11-inch page Single part (18 lb) paper Printer is installed in accordance with the Setup Guide Printer is maintained in accordance with this maintenance manual
Printing Rates
The printing speed of text is measured in lines per minute (lpm), and is a function of the selected font and the vertical dot density. Printing speed is independent of the number of characters configured in the 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 than half the rates of the font without such attributes. The exact print rate of lines containing these attributes depends on the specific print job, but software maximizes the throughput by dynamically determining which dot rows contain adjacent dots and must be printed in two strokes. The reverse paper feed capability allows the printing of multiple densities on a single line. This is useful in printing forms and text together or in mixing different fonts on a print line. Use of multiple densities and reverse paper feed also affects throughput. (Due to paper path restrictions, pedestal models have only limited reverse paper capability.) Printing rates are summarized in Table B1.
B9
Preliminary 2
Table B1. Printing Rates
PRINT QUALITY DOT DENSITY (DPI) NOTE CHARACTERS PER INCH DOT MATRIX NOTE
PERFORMANCE
UPPERCASE ONLY LPM
04 04P 05 05P 08 08P 09 09P 012 014 04 04P
DESCENDERS & UNDERLINE LPM

05 05P 08 08P 09 09P 012 014 04 04P
PLOT MODE IPM

05 05P 08 08P 09 09P 012 014

MODEL
CORRESPONDENCE
90 (180) X 96
10 12 15 10 12 13.3 15 17.1 10 12 13.3
7 (13) X 9 + 3 6 (11) X 9 + 3 5 (9) X 9 + 3 5 (9) X 7 + 2 4 (7) X 7 + 2 4 (7) X 7 + 2 3 (5) X 7 + 2 3 (5) X 7 + 2 5 (9) X 5 + 1 4 (7) X 5 + 1 4 (7) X 5 + 1
190 200 320 350 480 560 147 154 247 270 370 432 20 21 33 36.5 50 58
DATA PROCESSING
60 (120) X 72
356
375
600
658
900 1050 285
300
480
527
720
840
40
42
67
73
100
117
HIGH SPEED
60 (120) X 48
475
500
800
900 1200 1400 407
428
684
770 1026 1197
59
63
100
112
150
175
NOTE
A (B) X C, where:
A is maximum horizontal dot density B is horizontal dot placement density C is vertical dot density D is maximum number of dots that may be placed on E horizontal dot positions F is number of vertical dots for uppercase symbols G is number of dots available for descenders
NOTE
D (E) X F + G, where:
B10
Metric Conversion Tables
Length
Multiply foot foot foot inch inch inch meter centimeter millimeter meter centimeter millimeter
By 0.3048* 30.48* 304.8* 0.0254* 2.54* 25.4* 3.280840 0.03280840 0.003280840 39.37008 0.3937008 0.03937008 * Figure is exact.
To Obtain meter (m) centimeter (cm) millimeter (mm) meter (m) centimeter (cm) millimeter (mm) foot foot foot inch inch inch
Torque and Force
Multiply poundinch poundfoot Newtonmeter (NSm) Newtonmeter (NSm) pound Newton (N)
By 0.11298 1.3558 8.8511 0.7376 4.4482 0.22481
To Obtain Newtonmeter (NSm) Newtonmeter (NSm) poundinch poundfoot Newton (N) pound
C1
Mass and Density
Multiply pound* ounce* kilogram gram
By 0.4535924 28.34952 2.204622 0.03527397 * avoirdupois
To Obtain kilogram (kg) gram (g) pound* ounce*
Temperature
To Convert From
To
Use Formula
temperature Celsius (tC) temperature Fahrenheit (tF)
temperature Fahrenheit (tF) temperature Celsius (tC)
tF = 1.8tC + 32 tC = (tF 32)/1.8
Power
Multiply
By
To Obtain
Btu (International Table)/hour watt (W) watt (W) horsepower (metric)
0.2930711 3.412141 0.001359621 735.499
watt (W) Btu (International Table)/hour horsepower (metric) watt (W)
C2
Torque Table
The table below establishes the torque requirements for routine installation of threaded fasteners. These requirements apply to fasteners made of steel, at a minimum engagement of 3.5 threads, including chamfer and countersink. Fastener sizes are listed as Numbered Size Threads Per Inch.
Torque Table
Carbon Steel Fasteners (ANSI B18.6.3 1972) Into Alum. or Brass 25,000 psi ultimate tensile strength 25 + 2 in oz 62 + 4 in oz 122 + 7 in oz 11 + 1 in lb 20 + 1 in lb 15 + 1 in lb 40 + 3 in lb Into Steel 60,000 psi ultimate tensile strength Into Weld/Press Studs or Nuts Into Medium Carbon Steel Fasteners 105,000 psi ultimate tensile strength 105 + 5 in lb
Fastener Size 256 440 632 832 1024 1032 1/4 20
36 + 2 in oz 75 + 5 in oz 150 + 10 in oz 18 + 1 in lb 25 + 1.5 in lb 29 + 2 in lb 62 + 4 in lb
30 + 2 in oz 70 + 5 in oz 135 + 10 in oz 18 + 1 in lb 21 + 1 in lb 29 + 1 in lb 62 + 4 in lb
Fastener Size 440 UNC & 448 UNF 632 UNC & 640 UNF 832 UNC & 836 UNF 1024 UNC & 1032 UNF
Torque for Routine Tightening of Threaded Fasteners 4 + 1 in lb 11 + 1 in lb 19 + 1 in lb 25 + 1 in lb
Torque Table
D1
D2
Torque Table
Safety Inspection Guide
Safety Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2 Prepare the Printer for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3 Inspect Mechanical Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3 Top Cover and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3 Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E4 Inspect Electrical Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E4 Safety Ground Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E4 Customer Power Source Service Check . . . . . . . . . . . . . . . . . . . . . E7 Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E7 Power On/Off Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E8 Print Interlock Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E8
E1
Safety Inspections
IBM 6400 printers incorporate safety items installed to protect customers, operators, and service personnel from injury. Use this inspection guide as an aid in identifying possible unsafe 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 safety inspection. If you find any unsafe conditions, determine the severity of the hazard and whether or not you can continue the inspection without first correcting the problem.
NOTE: The correction of any unsafe condition is the customers responsibility.
Preparation
You must have completed the Electrical Safety Training Course for IBM Customer Engineers (self-study course 77170 or existing level) to do the Safety Inspection. Have the following items available: 1. Electrical Safety for IBM Customer Engineers, Order No. S2298124. 2. A Fluke** meter (P/N 8496278) or similar device for resistance and voltage measurements. 3. An ECOS** Electrical Safety Tester (P/N 6339695) in the United States or a similar safety tester in other countries. For each safety check on the following pages, do the steps in the order presented. Do not omit any steps.
E2
Prepare the Printer for Inspection

DANGER <1> Always disconnect the AC power cord from the power source before performing any maintenance procedure. Failure to remove power could result in injury to persons or damage to equipment. If you must apply power during maintenance, you will be instructed to so in the maintenance procedure. 1. Have the operator take the printer off-line. 2. Power off the printer. 3. Unplug the printer power cord from the customers power outlet.
Inspect Mechanical Parts
Top Cover and Cabinet Doors

1. Inspect the top cover: a. Open the top cover. On cabinet models, make sure the gas spring assembly holds the cover up in the open position. b. Make sure the window is not cracked or broken. c. Make sure the seal around the top cover is not cracked or broken.
d. Make sure there are no exposed or sharp edges. e. Make sure the wireform paper path is undamaged. f. Make sure the electrostatic discharge (ESD) fingers are not loose or damaged. Make sure they touch the contact strips on the frame when the cover is closed.
g. Close the top cover. Make sure the operator panel is centered in the opening of the cover. 2. On cabinet models, inspect the front and rear cabinet doors: a. Make sure the seals and magnetic strips are not loose or damaged. b. Make sure the restraining cable is attached and unbroken. c. Make sure there are no exposed or sharp edges.
E3
d. Open the rear cabinet door and inspect the lower rear paper path: a. Make sure the service panel permitting access to the I/O plate and circuit breaker (on/off switch) is installed. b. Make sure the paper stacker tray assembly is in place and undamaged.
Print Mechanism
1. Open the printer top cover. 2. Make sure the shuttle cover is correctly installed and undamaged. (See page 717.) 3. Make sure the paper path is correctly installed and undamaged. (See page 740.)
Inspect Electrical Parts
Safety Ground Path

1. Make sure the printer power cord is unplugged. 2. Remove the paper guide assembly (page 740). 3. Make sure the ground cable from the circuit breaker power leads is undamaged and firmly attached to the ground lug on the wall of the card cage, as shown in Figure E1.
NOTE: Ground paths for the entire printer are summarized in Figure E2.
E4
Card cage fan and power supply board removed for clarity.
Circuit Breaker
IEC 320 AC Power Connector (J301) Ground Lug Ground Cable (To Power Supply J1)
Figure E1. Circuit Breaker Ground, Cabinet Models
4. Set a Fluke meter (P/N 8496278) or similar device to the lowest resistance scale. Measure the resistance between the power cable ground pin and the printer frame: safety ground circuits should measure 0.1 Ohm or less. 5. Install the paper guide assembly (page 740).
E5
AC POWER J301 IEC 320 AC POWER CIRCUIT BREAKER

J1 AC P1 Line 1 Line 2 / Neutral +48V +48V +5 V +5 V +8.5V +8.5V
OPERATOR PANEL
J310 P310
CHASSIS GND
Return Ret EIA232E Serial I/O +5 V
P112
J112
CMX Controller Board Card Cage Fan
J101 DC POWER
Parallel I/O SHIELD GND
Point of Common Ground Ret +48V

J106 MSL P106 MSL J108 HBL P108 HBL +8.5V Ret J105 HBP P105 HBP +8.5/+48V Ret J116 SMD P116 SMD
+5 V Remote Power
P110 J110
J107 MSR P107 MSR
Exhaust Fan Cabinet models only +48V Ret Paper Feed Motor
+48V
Shuttle Assy +48V Terminator Board Ret Shuttle Motor

+48V
+5 V
+5 V
+5 V Hammer Bank Board +5 V +5 V
Platen Open Switch
Right Ribbon Guide
+48V Ret +24V Hammer Bank Fan
+48V
Right Ribbon Motor
Figure E2. Ground Path Diagram
E6
Customer Power Source Service Check

Use an ECOS Electrical Safety Tester (P/N 6339695) in the United States or a similar safety tester in other countries.
NOTE: The ECOS tester will trip ground fault detector protected outlets. This is a good test of the ground fault detector. Reset the outlet as needed. Plug the ECOS meter into the customers outlet. Follow the instructions supplied with the meter to test for the following: 1. Wiring errors 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 Representative (IPR) of any problems with the customers power source. Each branch circuit must be grounded for safety and correct operation of the printer. This ground must be connected either to the electrical service ground or to a suitable building ground. The printer power cable has a green or green/yellow insulated grounding conductor. This is not a neutral.
Power Cable
1. Make sure the power cable is not damaged. 2. Make sure the power plug is the correct type.
E7
Power On/Off Verification

1. Make sure all covers are installed. 2. Plug the power cable into the customers power outlet. 3. Power on the printer and watch the LCD. 4. Verify that the power-on diagnostic tests and initialization routines are successful. 5. After successful initialization, the printer should cycle 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 and all fans stop.
Print Interlock Service Check

1. Power on the printer. 2. Open the printer top cover. 3. Open the forms thickness lever. The LCD should display 057 CLOSE PLATEN and the audible alarm should sound if it is enabled. 4. Press Stop. The audible alarm should stop. 5. Close the forms thickness lever. The fault message should clear.
E8
Abbreviations and Signal Mnemonics
NOTE: Mnemonics with the first letter N are negative true.
Abbreviation/ Mnemonic
Definition
mF . . . . . . . . . . . . . . . . . . microfarad (106 farad) ms . . . . . . . . . . . . . . . . . . microsecond (106 second) msec . . . . . . . . . . . . . . . . microsecond (106 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 ATTN . . . . . . . . . . . . . . . Attention B . . . . . . . . . . . . . . . . . . . Buffered BANK FAN . . . . . . . . . . . Hammer Bank Fan BCOM . . . . . . . . . . . . . . . Buffered Communication BCP . . . . . . . . . . . . . . . . Bi-phase Communications Processor BHSC . . . . . . . . . . . . . . . Buffered Hammer Shift Clock BN . . . . . . . . . . . . . . . . . . Buffered, Low True BNLD . . . . . . . . . . . . . . . Buffered, Low True, Lower Driver BPS . . . . . . . . . . . . . . . . . Bits Per Second BSY . . . . . . . . . . . . . . . . . Busy BTU . . . . . . . . . . . . . . . . . British Thermal Unit BUD . . . . . . . . . . . . . . . . Buffered Upper Driver
F1
CA . . . . . . . . . . . . . . . . . . Cathode CC . . . . . . . . . . . . . . . . . . Card Cage CCF . . . . . . . . . . . . . . . . Card Cage Fan CE . . . . . . . . . . . . . . . . . . Customer Engineer CHNG . . . . . . . . . . . . . . . Change CIR . . . . . . . . . . . . . . . . . Circuit CLK . . . . . . . . . . . . . . . . . Clock CO . . . . . . . . . . . . . . . . . . Cover Open COLL . . . . . . . . . . . . . . . Collector COMM . . . . . . . . . . . . . . Communication CONTLR . . . . . . . . . . . . Controller CMD . . . . . . . . . . . . . . . . Command CMX . . . . . . . . . . . . . . . . Manufacturers designation of the controller board 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 . . . . . . . . . . . . . . . . . Data DC . . . . . . . . . . . . . . . . . . Direct Current, Data Controller (a functional unit of the CMX controller board) DCD . . . . . . . . . . . . . . . . Data Carrier Detect DIAG . . . . . . . . . . . . . . . . Diagnostic DIFF . . . . . . . . . . . . . . . . Differential DMA . . . . . . . . . . . . . . . . Direct Memory Access DP . . . . . . . . . . . . . . . . . . Data Processing, DataProducts DPMC . . . . . . . . . . . . . . . Dot Plucker Memory Controller DPU . . . . . . . . . . . . . . . . Data Processing Unit DRAM . . . . . . . . . . . . . . . Dynamic Random-Access Memory DRV . . . . . . . . . . . . . . . . Drive or Driver DRVR . . . . . . . . . . . . . . . Driver DSR . . . . . . . . . . . . . . . . Data Set Ready DTR . . . . . . . . . . . . . . . . Data Terminal Ready
F2
EC . . . . . . . . . . . . . . . . . . Engine Controller (a functional unit of the CMX board) EEPROM . . . . . . . . . . . . Electrically Erasable/Programmable Read-Only Memory EHF . . . . . . . . . . . . . . . . . Exhaust Fan EMI . . . . . . . . . . . . . . . . . ElectroMagnetic Interference EMIT . . . . . . . . . . . . . . . . Emitter EPROM . . . . . . . . . . . . . Electrically Programmable Read-Only Memory ERR . . . . . . . . . . . . . . . . Error ESD . . . . . . . . . . . . . . . . Electrostatic Discharge EX . . . . . . . . . . . . . . . . . . Exhaust, Extra EXH . . . . . . . . . . . . . . . . Exhaust EXF . . . . . . . . . . . . . . . . . Exhaust Fan EXP . . . . . . . . . . . . . . . . . Expansion EXPND . . . . . . . . . . . . . . Expand FD . . . . . . . . . . . . . . . . . . Feed FF . . . . . . . . . . . . . . . . . . Form Feed FIFO . . . . . . . . . . . . . . . . First In, First Out FLT . . . . . . . . . . . . . . . . . Fault FLTR . . . . . . . . . . . . . . . . Filter FP . . . . . . . . . . . . . . . . . . Front Panel (Operator Panel) FTIC . . . . . . . . . . . . . . . . Fire Timer Integrated Circuit GND . . . . . . . . . . . . . . . . Ground HB . . . . . . . . . . . . . . . . . . Hammer Bank HBA . . . . . . . . . . . . . . . . Hammer Bank ASIC HBF . . . . . . . . . . . . . . . . . Hammer Bank Fan HBL . . . . . . . . . . . . . . . . . Hammer Bank, Left HBP . . . . . . . . . . . . . . . . Hammer Bank Power HBR . . . . . . . . . . . . . . . . Hammer Bank, Right HD . . . . . . . . . . . . . . . . . . Hammer Driver HDIC . . . . . . . . . . . . . . . . Hammer Driver Integrated Circuit HDPH . . . . . . . . . . . . . . . Hammer Driver Phase HLP . . . . . . . . . . . . . . . . . Hammer Bank Logic, Signals and Power IC . . . . . . . . . . . . . . . . . . . Integrated Circuit ID . . . . . . . . . . . . . . . . . . . Identification IGP . . . . . . . . . . . . . . . . . Intelligent Graphics Processor INST . . . . . . . . . . . . . . . . Instruction INT . . . . . . . . . . . . . . . . . Interrupt
F3
I/O . . . . . . . . . . . . . . . . . . Input/Output IRQ . . . . . . . . . . . . . . . . . Interrupt Request (J) . . . . . . . . . . . . . . . . . . Jack connector L . . . . . . . . . . . . . . . . . . . Left LCD . . . . . . . . . . . . . . . . . Liquid Crystal Display LED . . . . . . . . . . . . . . . . . Light Emitting Diode LF . . . . . . . . . . . . . . . . . . Line Feed LO . . . . . . . . . . . . . . . . . . Low LPI . . . . . . . . . . . . . . . . . . Lines Per Inch LPM . . . . . . . . . . . . . . . . Lines Per Minute LRIB . . . . . . . . . . . . . . . . Left Ribbon LRP . . . . . . . . . . . . . . . . . Left Ribbon Guide M . . . . . . . . . . . . . . . . . . . Motor MAIN . . . . . . . . . . . . . . . . Maintenance Jack, RS232 (Optional) MECA . . . . . . . . . . . . . . . Mechanism Engine Control ASIC MECH . . . . . . . . . . . . . . . Mechanism MF . . . . . . . . . . . . . . . . . . microfarad (106 farad) MH . . . . . . . . . . . . . . . . . Mounting Hole MOSFET . . . . . . . . . . . . Metal Oxide Semiconductor Field Effect Transistor MOT . . . . . . . . . . . . . . . . Motor MPU . . . . . . . . . . . . . . . . Magnetic Pickup (Unit) ms . . . . . . . . . . . . . . . . . . millisecond (103 second) MSL . . . . . . . . . . . . . . . . Motor and Sensors, Left MSR . . . . . . . . . . . . . . . . Motor and Sensors, Right N . . . . . . . . . . . . . . . . . . . Negative True N/C . . . . . . . . . . . . . . . . . Not Connected NC . . . . . . . . . . . . . . . . . . Not Connected NLQ . . . . . . . . . . . . . . . . Near Letter Quality No. . . . . . . . . . . . . . . . . . Number NOVRAM . . . . . . . . . . . . Non-volatile Random-Access Memory ns . . . . . . . . . . . . . . . . . . nanosecond (109 second) NVRAM . . . . . . . . . . . . . Non-volatile Random-Access Memory NT . . . . . . . . . . . . . . . . . . Not OLV . . . . . . . . . . . . . . . . . On Line Verify OP . . . . . . . . . . . . . . . . . . Operand
F4
P5 . . . . . . . . . . . . . . . . . . + 5 V dc (P) . . . . . . . . . . . . . . . . . . Pin connector P(1), P(2), etc. . . . . . . . Parallel data 1, data 2, etc. PAL . . . . . . . . . . . . . . . . . Programmable Array Logic PAP . . . . . . . . . . . . . . . . . Paper PAPR . . . . . . . . . . . . . . . Paper PARM . . . . . . . . . . . . . . . Parameter PCBA . . . . . . . . . . . . . . . Printed Circuit Board Assembly PCB . . . . . . . . . . . . . . . . Printed Circuit Board PE . . . . . . . . . . . . . . . . . . Printer Error, Paper Empty PER . . . . . . . . . . . . . . . . Peripheral Device PF . . . . . . . . . . . . . . . . . . picofarad (1012 farad) PFC . . . . . . . . . . . . . . . . . Paper Feed Controller PFM . . . . . . . . . . . . . . . . Paper Feed Motor PHA . . . . . . . . . . . . . . . . Phase A PHB . . . . . . . . . . . . . . . . Phase B PI . . . . . . . . . . . . . . . . . . . Paper Instruction PLAT . . . . . . . . . . . . . . . . Platen PLM . . . . . . . . . . . . . . . . Platen Motor PLO . . . . . . . . . . . . . . . . . Platen Open (Switch) PMD . . . . . . . . . . . . . . . . Paper Motion Detect (Switch) PN . . . . . . . . . . . . . . . . . . Pin P/N . . . . . . . . . . . . . . . . . Part Number PO . . . . . . . . . . . . . . . . . . Paper Out POD . . . . . . . . . . . . . . . . Paper Out Detect (Switch) PPR . . . . . . . . . . . . . . . . Paper PROM . . . . . . . . . . . . . . . Programmable Read-Only Memory PS . . . . . . . . . . . . . . . . . . Power Supply PS5 . . . . . . . . . . . . . . . . . Power Supply + 5 Volt PTR . . . . . . . . . . . . . . . . . Pointer or Printer PWM . . . . . . . . . . . . . . . . Pulse Width Modulation PWR . . . . . . . . . . . . . . . . Power R . . . . . . . . . . . . . . . . . . . Right RBN . . . . . . . . . . . . . . . . Ribbon RD . . . . . . . . . . . . . . . . . . Read RET . . . . . . . . . . . . . . . . . Return RIB . . . . . . . . . . . . . . . . . Ribbon RG . . . . . . . . . . . . . . . . . . Ribbon Guide
F5
RGL . . . . . . . . . . . . . . . . Ribbon Guide, Left RGR . . . . . . . . . . . . . . . . Ribbon Guide, Right RM . . . . . . . . . . . . . . . . . Ribbon Motor RML . . . . . . . . . . . . . . . . Ribbon Motor, Left RMR . . . . . . . . . . . . . . . . Ribbon Motor, Right RQ . . . . . . . . . . . . . . . . . . Request RRIB . . . . . . . . . . . . . . . . Right Ribbon RRP . . . . . . . . . . . . . . . . Right Ribbon Guide RSP . . . . . . . . . . . . . . . . Ribbon and Shuttle 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 Ground SHH . . . . . . . . . . . . . . . . Shuttle Hall (Effect) SHM . . . . . . . . . . . . . . . . Shuttle Motor SHUT . . . . . . . . . . . . . . . Shuttle SHUTL . . . . . . . . . . . . . . Shuttle SIMM . . . . . . . . . . . . . . . Single Inline Memory Module SLCT . . . . . . . . . . . . . . . Select (On-line) Slew . . . . . . . . . . . . . . . . Rapid vertical paper movement SMD . . . . . . . . . . . . . . . . Shuttle Motor Drive SNA . . . . . . . . . . . . . . . . Systems Network Architecture SPU . . . . . . . . . . . . . . . . Shuttle Processor Unit SRAM . . . . . . . . . . . . . . . Static Random-Access Memory STAT . . . . . . . . . . . . . . . . Status STBY . . . . . . . . . . . . . . . Standby STK . . . . . . . . . . . . . . . . . Stacker SW . . . . . . . . . . . . . . . . . Switch SYNC . . . . . . . . . . . . . . . Synchronize TCB . . . . . . . . . . . . . . . . . Task Control Block TEMP . . . . . . . . . . . . . . . Temperature TOF . . . . . . . . . . . . . . . . . Top of Form (first print line)
F6
TP . . . . . . . . . . . . . . . . . . Test Point TTL . . . . . . . . . . . . . . . . . Transistor-Transistor Logic TXD . . . . . . . . . . . . . . . . . Transmit 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 . . . . . . . . . . . . . . . . . Voltage at Drain VSS . . . . . . . . . . . . . . . . . Voltage at Source VX . . . . . . . . . . . . . . . . . . A special ASIC containing circuits that help the DC controller operate. The letters VX do not stand for anything; they simply designate this ASIC. WR . . . . . . . . . . . . . . . . . Write w/ . . . . . . . . . . . . . . . . . . . With w/o . . . . . . . . . . . . . . . . . Without XMT . . . . . . . . . . . . . . . . Transmit
F7
F8
G
Part No. 57G7261 1838574 6952299 1838573
Power Cords
Units
Description
1 1 1
13F9941 13F9980
1 1
13F9998 14F0016 14F0034
1 1 1
14F0052 14F0070 14F0088 1332167 38F8254 14H5335 08H7968
1 1 1 1 1 1 1
Power Cord, 110V 6 Feet Non-Lock, U.S., Canada Power Cord, 220V 6 Feet Non-Lock, U.S., Canada Power Cord, 110V 12 Feet Non-Lock, U.S., Canada, Brazil, Cayman Islands, Costa Rica, Dominican Republic, El Salvador, Guatemala, Mexico, Liberia, Panama, Saudi Arabia, Phillipines, Honduras, Peru, Columbia, Nicaragua, Bermuda, Bahamas, Barbados, Bolivia, Guyana, Ecuador, Haiti, Jamaica, Venezuela, Netherlands, Antilles, Trinidad, Suriname, Taiwan, Tobago, Saint Lucia, Indonesia Power Cord, 220V 12 Feet Non-Lock, U.S., Canada, Honduras, Nicaragua, Peru, Phillipines, Saint Lucia, Taiwan, Thailand, Tobago, Panama Power Cord, 12 Feet, Argentina, Australia, Colombia, New Guinea, New Zealand, Paraguay, Samoa, Uraguay Power Cord, 9 Feet, Afghanistan, Algeria, Angola, Austria, Belgium, Benin Republic/Dahomey, Bulgaria, Burundi, Cameroon, Chad, Congo/Brazzaville, Central Africa Empire, Czechoslovakia, East Germany, Egypt, Finland, France, Greece, Guinea, Hungary, Iceland, Indonesia, Iran, Ivory Coast, Jordan, Korea, Lebanon, Luxembourg, Mali, Madagascar, Mauritania, Monaco, Morocco, Mozambique, Netherlands, Norway, Poland, Portugal, Rhodesia, Romania, Spain, Sudan, Sweden, Syria, Togo, Tunisia, Turkey, Upper Volta, USSR, West Germany, Yugoslavia, Zaire Power Cord, 9 Feet, Denmark Power Cord, 9 Feet, Bangladesh, Burma, Pakistan, South Africa, Sri Lanka Power Cord, 9 Feet, Bahrain, Brunei, Channel Islands, PRC, Cyprus, Hong Kong, India, Iraq, Ireland, Kenya, Kuwait, Malaysia, Malta, Nepal, Nigeria, Oman, Polynesia, Qatar, Sierra Leone, Singapore, Tanzania, Uganda, United Arab Emirates, U.K., Zambia Power Cord, 9 Feet, Switzerland, Liechtenstein Power Cord, 9 Feet, Chile, Ethiopia, Italy, Libya Power Cord, 9 Feet, Israel Power Cord, 12 Feet, Japan Twinax Auto-Termination Cable Twinax Auto-Termination Cable (47 in. Long) Coax Adapter Cable for use with Multi-Platform Interface
Power Cords
G1
G2
Power Cords
Preliminary 2
Part Numbers
Part Number 04H4779 08H7934 08H7936 08H7954 14H5154 14H5159 14H5169 14H5174 14H5179 14H5184 14H5211 14H5214 14H5217 14H5235 14H5271 14H5272 14H5273 14H5274 14H5275
Page 767 787 785 773 787 787, A31 785 773 773 785 779 783 783 773 773 767 779 779 779
Description Riser, Stacker Runner Platen Open Motor Pulley Platen Assembly AntiStatic Brush Kit Platen Open Motor Assembly Hammer Bank Fan Assembly Platen Hardware Kit Platen/Paper Feed Cover Kit Paper Scale Platen Lever Kit Clamp, Shaft, Receiving Tractor Shaft Kit Tractor Shaft Hardware Kit Shroud Assembly, Air (Shuttle Cover) Paper Guide Assembly (Models 004, 005, 008, 009, 012, 014) Chain Assembly Kit Hmr Bank/Rbn Mask Cov Assy (Models 004, 04P, 005, 05P) Shuttle Frame Assy (Models 004, 04P) Hammer Spring Kit (Models 004, 04P, 005, 05P)
Part Numbers
H1
Preliminary 2
Part Number 14H5276 14H5277 14H5278 14H5279 14H5280 Page 765 765 765 A21 785, A35 787, A34 779, A33 A22 A18 A20 779, A23 710 A16 A17 787, A25 767 769 769, 771 781, A24 A27 731 Top Cover Kit Front Door Kit Rear Door Kit Cable Assy, Hammer Bank Logic Platen Switch Kit Description
14H5281 14H5282
Paper Detector Switch Assembly (Standard) Switch Assembly, Cover Open
14H5283 14H5285 14H5286 14H5287 14H5288 14H5289 14H5289 14H5290
Cable Assy, Hammer Bank Power Cable Assy, Card Cage Fan Cable Assy, Exhaust Fan Centronics I/O Cable Assembly Housing, Connector Kit Cable Assy, AC In, Power Supply (Part of AC Field Kit) Cable Assy, AC Power Input (Part of AC Field Kit) Ribbon Guide Kit
14H5296 14H5299 14H5300 14H5329
Spares Kit, Grommet Operator Panel Assembly (Cabinet) Cable Assembly, Operator Panel Cable Assembly, MPU
14H5330 14H5481
Cable Assembly, Shuttle Motor Drive SIMM, DRAM, Blank, 2MB
H2
Part Numbers
Preliminary 2
Part Number 14H5490 14H5499 14H5508 14H5509 14H5512 14H5513 14H5516 14H5517 14H5520 14H5521 14H5522 14H5525 14H5589 14H5539 14H5540 14H5567 14H5570 14H5571 14H5572 14H5585 14H5592 14H5593 14H5595 14H5601 Page 731 731 731 731 779 779 779 779 787 787 779, A29 748 A30 731 731 765 787, A34 789 765 791 715 715 715 779 Description Security Module, Graphics SIMM, DRAM, Blank, 1MB SIMM, DRAM, Blank, 4MB Security Module, Base Hammer Spring Kit (Models 008, 08P, 009, 09P) Hammer Spring Kit (Models 012, 014) Shuttle Frame Assy (Models 008, 08P) Shuttle Frame Assy (Model 012) Paper Feed Motor Motor Assembly, Ribbon Cable Assy, Centronics/Dataproducts Adapter Resistor Kit Cable Assy, +5V Remote Power SIMM, Flash, Blank, 1MB SIMM, Flash, Blank, 2MB Wireform Paper Path Paper Detector Switch Assy (Black Back) Circuit Breaker Hardware Kit CT Plate Cable, Data, Coax/Twinax MultiPlatform Interface I/O Bracket Assembly, Coax/Twinax MultiPlatform Interface PROM, Coax/Twinax MultiPlatform Interface Hmr Bank/Rbn Mask Cov Assy (Models 008, 08P, 009, 09P)
Part Numbers
H3
Preliminary 2
Part Number 14H5602 14H5603 14H5643 Page 779 765 779 Description Hmr Bank/Rbn Mask Cov Assy (Models 012, 014) Logo, 6400 CMX Controller Board, V5.0 (All models 004 and 04P. Models 008 and 012 with Serial Nos. 01AXXXX, 01BXXXX, and 01CXXXX.) Power Supply PCBA, (Models 004, 04P, 005, 05P, 008, 08P, 012) Input Tray (Optional) Caster, Pedestal Adapter, Expansion Connector, 60pin Paper Support CMX Controller Board, V5.5, 25 MHz (All models 005, 05P, and 08P. Models 008 and 012 with Ser. Nos. 01DXXXX, 01EXXXX, and higher. All models 009 and 09P.) Shuttle Frame Assy (Models 005, 05P) Shuttle Frame Assy (Models 009, 09P) Runner, Stacker Extension Spring Shipping Container Kit Wire Rope Twinax AutoTermination (Smart T) Motor Pulley, Paper Feed Fan Assembly Paper Detector Switch Assy Splined Shaft Tractor Set Belt, Timing, 050P, 100 Teeth (Paper Feed) Belt, Timing, 312W, 87 Teeth (Platen Open)
14H5644 24H8533 24H8534 24H8535 24H8593 24H8647
779 771 771 791 783 779
24H8648 26H9625 30H3981 30H3985 30H3986 30H4008 38F8254 57G1421 57G1440 57G1453 57G1460 57G1466 57G1468 57G1467
779 779 767 781 765 765 A28 787 769 787 783 783 773 785
H4
Part Numbers
Preliminary 2
Part Number 57G1469 57G1476 57G1479 57G1481 57G1485 57G1486 57G1492 57G1514 57G1521 57G1598 57G1599 57G1600 57G1601 57G1602 57G1603 57G1604 57G7176 57G7260 63H5116 63H5118 63H5119 63H5120 63H5121 63H5122 63H5123 Page 785 781, A32 787 769 765 765 765 785 783 769 769 769 769 769 769 769 767 767 775 771 771 771 771 771 771 Description Ironer Assembly, Reverse Paper Feed Magnetic Pickup Assembly (MPU) Ribbon Hub Kit Gas Spring Kit Caster, with Brake Caster, without Brake Window, Top Cover Platen Pulley, Driven Ground Clip, Splined Shaft Operator Panel Overlay, English Operator Panel Overlay, Spanish Operator Panel Overlay, French Operator Panel Overlay, Italian Operator Panel Overlay, German Operator Panel Overlay, Dutch Operator Panel Overlay, Braz. Portuguese Stacker Power Cord, U.S. (See also Appendix G.) Paper Path Assembly (Models 04P, 05P, 08P, 09P) Paper Basket Lid, Pedestal Model Top Cover, Complete (Pedestal Model) Hinge Lid Kit (Pedestal Model) Lid Accessory Kit (Pedestal Model) Shipping Container, Pedestal
Part Numbers
H5
Preliminary 2
Part Number 63H5124 63H5125 63H7379 63H7382 63H7398 63H7464 63H7509 63H7510 90H3268 90H3269 90H3271 S2170181 S2170182 S2460111 S2460112 S2460115 S2460116 S2460118 S2460125 S2460126 S2460137 S2460138 S2460141 S2460142 Page 771 771 114 791 765 A26 771 765 779 779 779 16 16 17 17 16 16 16 16 16 16 16 16 16 Description Operator Panel (Pedestal) Bracket, Control Panel 6400 Line Matrix Printer Configuration Utility Disk Expansion-CT PCBA Top Cover Seal Kit Cable Assembly, Ribbon Motor, Extension Pedestal Kit Door Seal Kit Power Supply PCBA (Models 990, 09P, 014) Shuttle Frame Assy (Model 014) CMX Controller Board, V5.5, 40 MHz (Model 014 only) 6400 Operators Guide, Brazilian Portuguese 6400 Line Matrix Printer Setup Guide, Brazilian Portuguese IBM Network Print Server Ethernet Administrators Guide IBM Network Print Server Token-Ring Administrators Guide 6400 Operators Guide, English 6400 Line Matrix Printer Setup Guide, English 6400 ASCII Programmers Reference 6400 Operators Guide, Dutch 6400 Line Matrix Printer Setup Guide, Dutch 6400 Operators Guide, German 6400 Line Matrix Printer Setup Guide, German 6400 Operators Guide, Italian 6400 Line Matrix Printer Setup Guide, Italian
H6
Part Numbers
Preliminary 2
Part Number S2460143 S2460144 S2460145 S2460146 S2460147 S2460148 S2460149 S2460150 S2460151 SF110722 SF110723 Page 16 16 16 16 16 16 16 16 16 16 16 Description 6400 Line Matrix Printer Operators Guide, Japanese 6400 Line Matrix Printer Setup Guide, Japanese 6400 Operators Guide, Spanish 6400 Line Matrix Printer Setup Guide, Spanish 6400 CTA Programmers Reference 6400 IPDS Programmers Reference 6400 Coax/Twinax MultiPlatform Interface Option Installation and Operation Guide 6400 Code V Users Manual 6400 IGP Users Manual 6400 Line Matrix Printer Setup Guide, French 6400 Operators Guide, French
Part Numbers
H7
H8
Part Numbers
Noise Suppression Devices
Ferrite noise suppressors are installed in the printer to reduce radio frequency interference (RFI) to and from electronic equipment located near the printer. Two kinds of ferrite noise suppressors are used: 1. Shielding BeadCylindrical core through and around which the control panel cable assembly is wound. Two are required. 2. Ferrite ClampA 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 I1 shows how these devices are installed. If you replace either of these cable assemblies, note the number and location of noise suppressors before remove the defective cable. Make sure you install the noise suppressors on the replacement cable assembly. IMPORTANT Duplicate the number of turns around the shielding beads when installing or replacing the control panel cable. See Figure I1.
I1
Control Panel Cable Assembly

Connector P110 Connector P310 Shielding Bead
NOTE: Two turns around each bead.
Parallel I/O Cable Assembly
Connector P112
Ferrite Core with Clamp and Adhesive Backing
NOTE: This core attaches to right rear card cage wall. Connector J203
Figure I1. Ferrite Core Installation
I2
Index
Numbers
001 END OF FORMS / LOAD FORMS, 55 002 FORMS JAMMED / CLEAR JAM AND RELOAD FORMS, 55 003 FORMS EJECTED / PRESS EJECT/RESTORE, 55 004 VIEW FORMS / PRESS VIEW KEY, 55 006 HOST SYSTEM REQUEST ATTENTION, 55 007 FM HEADER ERROR, 55 008 HOLD PRINT TIMEOUT / PRESS START, 55 009 INVALID KEY PRESS, 55 010 PARAMETER ERROR, 55 011 SCS COMMAND ERROR, 55 012 STRUCTURED FIELD ERROR, 55 013 ACTIVATE LOST, 55 014 INVALID ACTIVATE, 55 015 COMMUNICATION CHECK / CHECK CABLE, 56 016 INVALID COMMAND, 56 021 RECEIVE BUFFER OVERRUN / VERIFY CONFIGURATION, 56 022 UNIT ADDRESS NOT RECEIVED / CHECK PRINTER ADDRESS, 56 024 SERIAL LINE PARITY ERROR / VERIFY CONFIGURATION, 56 025 SERIAL FRAMING ERROR / VERIFY CONFIGURATION, 56 026 HEX DUMP MODE, 56 027 COMMUNICATIONS CHECK / CALL SYSTEM OPERATOR, 56 028 COMMUNICATIONS CHECK / CALL SYSTEM OPERATOR, 56 029 8344 DIAGNOSTIC TEST FAILED, 56 031 END OF FORMS TIMEOUT / LOAD FORMS, 56 032 FORMS JAMMED TIMEOUT / CLEAR JAM AND RELOAD FORMS, 56 041 BUFFER OVERFLOW, 56 042 CUSTOM SET DOES NOT EXIST / SAVE FIRST, 57 043 CUSTOM SET ALREADY EXISTS / DELETE EXISTING SET FIRST, 57 044 EC FIRMWARE/HARDWARE ERROR, 57 046 EC STOPPED AT STATE (state), 57 057 CLOSE PLATEN, 57 058 SHUTTLE JAM / SEE USERS GUIDE, 57 059 CANCEL PRINT ACTIVE, 57 060 PRINTER HOT, 57 062 EXHAUST FAN FAULT, 57 063 INTAKE FAN FAULT, 57 065 HAMMER BANK FAN FAULT, 57 069 DATA CLEARED, 57 08 CONTROLLER 23.5V, 58 080 POWER SUPPLY HOT, 57 081 POWER SUPPLY VOLTAGE FAILURE, 58 082 POWER SUPPLY 8.5V FAILED, 58 084 POWER SUPPLY 48V FAILED, 58 085 CONTROLLER VOLTAGE, 58 087 PLATEN OPEN TIMEOUT / CLOSE PLATEN, 58 089 RIBBON STALL, 58 090 SHUTTLE COVER OPEN / CLOSE SHUTTLE COVER, 58 092 RIBBON DRIVER CIRCUIT, 58 101 UPPER DRIVER SHORT, 59
Index
102 LOWER DRIVER SHORT, 59 105 HAMMER COIL (number) OPEN, 59 107 HAMMER COIL (number) HOT, 59 11 inch pages, Printer Information Menu, 557 110 STACK OVERFLOW / SEE USERS GUIDE, 59 111 STACK UNDERFLOW / SEE USERS GUIDE, 59 112 UNDEFINED OPCODE / SEE USERS GUIDE, 59 113 PROTECTED INSTRUCTION / SEE USERS GUIDE, 59 114 ILLEGAL OPERAND ACCESS / SEE USERS GUIDE, 510 115 ILLEGAL INSTRUCTION ACCESS / SEE USERS GUIDE, 510 116 ILLEGAL EXTERNAL BUS ACCESS / SEE USERS GUIDE, 510 117 A TO D OVERRUN / SEE USERS GUIDE, 510 118 UNDEFINED INTERRUPT / SEE USERS GUIDE, 510 119 TCB CORRUPTED / SEE USERS GUIDE, 510 120 ACCESS NULL POINTER / SEE USERS GUIDE, 510 121 PAPER NOT AT SPEED / SEE USERS GUIDE, 511 122 PAPER NOT SCHEDULED / SEE USERS GUIDE, 511 123 PAPER BUSY TOO LONG / SEE USERS GUIDE, 511 124 PAPER FIFO OVERFLOW / SEE USERS GUIDE, 511 125 PAPER FIFO UNDERFLOW / SEE USERS GUIDE, 511 126 PAPER FEED BAD TABLE / SEE USERS GUIDE, 511
127 PAPER FEED ILLEGAL STATE / SEE USERS GUIDE, 511 128 PAPER FEED INVALID COMMAND / SEE USERS GUIDE, 512 129 PAPER FEED INVALID PARAMETER / SEE USERS GUIDE, 512 130 PAPER FEED PARTLY ENERGIZED / SEE USERS GUIDE, 512 131 PAPER FEED INTERRUPT / SEE USERS GUIDE, 512 132 RIBBON INVALID COMMAND / SEE USERS GUIDE, 512 133 RIBBON INVALID STATE / SEE USERS GUIDE, 512 134 PLATEN INVALID COMMAND / SEE USERS GUIDE, 512 135 PLATEN INVALID STATE / SEE USERS GUIDE, 513 136 PLATEN INVALID PARAMETER / SEE USERS GUIDE, 513 137 SHUTTLE INVALID COMMAND / SEE USERS GUIDE, 513 138 SHUTTLE INVALID PARAMETER / SEE USERS GUIDE, 513 139 SHUTTLE OVERSPEED / SEE USERS GUIDE, 513 990 MACHINE CHECK, 513 998 NONVOLATILE MEMORY FAILED, 513
A
A97 GRAPHIC CHECK ERROR / PRESS STOP THEN START, 513 Abbreviations, F1 About the printer, 12 Acronyms, F1 Adjustments, 61 coil temperature, 632 end of forms distance, 620
Index
hammer phasing, 624 loading flash memory, 626 paper drive motor pulley alignment, 68 paper feed timing belt tension, 64 paper scale, 610 platen gap, 612 platen open belt, 66 platen open motor pulley alignment, 614 ribbon guide, 616 software upgrades, 626 splined shaft skew adjustment, 618 Arrow keys cabinet model, 18 pedestal model, 110 ASCII Character Set chart, 556 Attention condition, 53
pedestal model, 110 Card cage, fan assembly, replacement, 721 CE tests, 548 Character Set, U.S. ASCII, 556 Characters, elongated, 43 Checks, service customers power source, E7 power on/off verification, E8 print interlock, E8 print mechanism, E4 printer power cable, E7 safety ground path, E4 top cover and doors, E3 Circuit board, replacement controller, 711 power supply, 713 Circuit breaker, replacement, 714
B
Belt paper feed timing, replacement, 76 paper feed timing, tension adjustment, 64 platen open, replacement, 78 platen open, tension adjustment, 66 Block diagram, operator panel, 410 Boards: layouts, connections, and pinouts, A1 BOOT DIAGNOSTICS, 513
Cleaning the printer, 32 CLEARING PROGRAM FROM FLASH, 514, 629, 631 CMX controller board. See Controller board Coax/twinax expansion board pinouts, A10 replacement, 727 Coax/twinax multiplatform interface, replacement, 715 Coil temperature adjustment, 632 Configuration, 21 Print key cabinet model, 18 pedestal model, 110 Control panel. See Operator panel Controller board pinouts, A5 principles of operation, 411 Controller circuit board, replacement, 711 Controls and indicators, 18 mechanical, all models, 112 printing conventions, 15
C
Cabinet, doors, reversing, 719 Cable assembly interconnections, A1 part numbers, A1 shell and cable replacement, 79 Cable connectors and shells, replacement, 79 Cable routing, mechanism base, A12 Cancel key cabinet model, 18
Index
Conversion, metric measurement, C1 Cords, power, G1 Cores, ferrite (noise suppression), I1 Cover assembly hammer bank / ribbon mask, replacement, 716 shuttle, 717 top, pedestal model, 718 Customer Engineer (CE) tests, 548
pedestal model, 110 Electrical characteristics, B6 Elongated characters, 43 End of Forms Adjust, procedure, 620 ENERGY SAVER MODE ACTIVE, 514 Energy Star compliance, B5 Engine controller (EC), 415 Enter key cabinet model, 18 pedestal model, 110 Environmental characteristics, B4 Error log clear, 549 print, 545 Error messages, 53 ERROR: DC PROGRAM NOT VALID, 629 ERROR: DRAM AT ADDRESS XXXXXXXX, 629 ERROR: DRAM NOT DETECTED, 514 ERROR: EC PROGRAM NOT VALID, 629 ERROR: EC STOPPED AT STATE XXXX, 629 ERROR: FLASH NOT DETECTED, 630 ERROR: NO DRAM DETECTED, 630 ERROR: NVRAM FAILURE, 630 ERROR: PROGRAM NEEDS MORE DRAM, 630 ERROR: PROGRAM NEEDS MORE FLASH, 630 ERROR: PROGRAM NOT COMPATIBLE, 630 ERROR: PROGRAM NOT VALID, 630
D
Data controller (DC), 413 DC (Data Controller, CMX board), 413 Diagnostic menus, boot, 551 Diagnostic selftests customer engineer (CE), 548 operator print, 545 printer information menu, 557 DIAGNOSTICS PASSED, 629 Diagrams ground path, E1 interconnection and cables, A1 Dimensions, printer, B4 Display (LCD) cabinet model, 18 pedestal model, 110 Display messages, printing conventions, 15 Documents related to this manual, 16 Doors, cabinet, reversing, 719 DRIVER CIRCUIT BAD, 514 Duty cycle, B7
E
EC (Engine Controller, CMX board), 415 Eject/Restore key cabinet model, 18
ERROR: SECURITY PAL NOT DETECTED, 514, 630 ERROR: SHORT AT ADDRESS XXXX, 631 ERROR: WRITING TO FLASH, 629, 631 ERROR: WRONG CHECKSUM, 631
Index
F
Fan assembly card cage, replacement, 721 hammer bank, replacement, 720, 722 Fault messages, 53 Ferrite cores (noise suppression), I1 Flash memory, loading, 626 Flash messages CLEARING PROGRAM FROM FLASH, 629, 631 DIAGNOSTICS PASSED, 629 ERROR: DC PROGRAM NOT VALID, 629 ERROR: DRAM AT ADDRESS XXXXXXXX, 629 ERROR: EC PROGRAM NOT VALID, 629 ERROR: EC STOPPED AT STATE XXXX, 629 ERROR: FLASH NOT DETECTED, 630 ERROR: NO DRAM DETECTED, 630 ERROR: NVRAM FAILURE, 630 ERROR: PROGRAM NEEDS MORE DRAM, 630 ERROR: PROGRAM NEEDS MORE FLASH, 630 ERROR: PROGRAM NOT COMPATIBLE, 630 ERROR: PROGRAM NOT VALID, 630 ERROR: SECURITY PAL NOT DETECTED, 630 ERROR: SHORT AT ADDRESS XXXX, 631 ERROR: WRITING TO FLASH, 629, 631 ERROR: WRONG CHECKSUM, 631 LOADING PROGRAM FROM PORT XX%, 631 RESETTING... PLEASE WAIT, 631 RESTORING BOOT CODE, 631 SECURITY CODE VIOLATION, 631
SENDING PROGRAM TO EC PROCESSOR, 631 TABLE MISMATCH / DOWNLOAD AGAIN, 631 Form Feed key cabinet model, 18 pedestal model, 110
G
Gap, adjustment magnetic pickup (MPU), 728 platen, 612 Ground path diagram, E1
H
Hammer phasing adjustment, 624 spring assembly, replacement, 723 Hammer bank cover assembly, replacement, 716 fan assembly, replacement, 720, 722 wiring diagram, A1 HAMMER BANK NOT INSTALLED, 514 HAMMER COIL BAD, 514 Hammer phasing adjustment, 624 Hard reset, 559 Hex code printout, 554 Hub, ribbon, replacement, 750
I
IBM Coax/twinax expansion board, replacement, 727 Illustrations, replacement procedures, 763 Information menu, printer, 557 Inspection, safety, guide, E1 Installation, 21 Installed memory, 557
Index
Interface coax/twinax multiplatform, replacement, 715 specifications, B7
notes and notices, 14 printing conventions, 15 related documents, 16 Mechanical controls and indicators, 112 Memory modules, location and replacement, 729 Memory, flash, loading software, 626 Memory, installed, 557 Menu key cabinet model, 18 pedestal model, 110 Menus boot diagnostics, 551 Customer Engineer (CE) tests, 548 Message display (LCD) cabinet model, 18 pedestal model, 110 Messages 001 END OF FORMS / LOAD FORMS, 55 002 FORMS JAMMED / CLEAR JAM AND RELOAD FORMS, 55 003 FORMS EJECTED / PRESS EJECT/RESTORE, 55 004 VIEW FORMS / PRESS VIEW KEY, 55 006 HOST SYSTEM REQUEST ATTENTION, 55 007 FM HEADER ERROR, 55 008 HOLD PRINT TIMEOUT / PRESS START, 55 009 INVALID KEY PRESS, 55 010 PARAMETER ERROR, 55 011 SCS COMMAND ERROR, 55 012 STRUCTURE FIELD ERROR, 55 013 ACTIVATE LOST, 55 014 INVALID ACTIVATE, 55 015 COMMUNICATION CHECK / CHECK CABLE, 56 016 INVALID COMMAND, 56
K
Keys, locations and operation cabinet model, 18 pedestal model, 110 Keys, operator panel, 18
L
Labels, specifications, B3 LCD cabinet model, 18 pedestal model, 110 Levers and knobs, 112 Line Feed key cabinet model, 18 pedestal model, 110 Line matrix printing explained, 42 LOADING PROGRAM FROM PORT 00%, 514 LOADING PROGRAM FROM PORT XX%, 631 LOADING PROGRAM INTO FLASH, 514
M
Magnetic pickup assembly, replacement, 728 Maintenance adjustments, 61 cleaning the printer, 32 overview, 11 preparing the printer for, 75 preventive, 31 Manual how to use, 14
Index
021 RECEIVE BUFFER OVERRUN / VERIFY CONFIGURATION, 56 022 UNIT ADDRESS NOT RECEIVED / CHECK PRINTER ADDRESS, 56 024 SERIAL LINE PARITY ERROR / VERIFY CONFIGURATION, 56 025 SERIAL FRAMING ERROR / VERIFY CONFIGURATION, 56 026 HEX DUMP MODE, 56 027 COMMUNICATIONS CHECK / CALL SYSTEM OPERATOR, 56 028 COMMUNICATIONS CHECK / CALL SYSTEM OPERATOR, 56 029 8344 DIAGNOSTIC TEST FAILED, 56 031 END OF FORMS TIMEOUT / LOAD FORMS, 56 032 FORMS JAMMED TIMEOUT / CLEAR JAM AND RELOAD FORMS, 56 041 BUFFER OVERFLOW, 56 042 CUSTOM SET DOES NOT EXIST / SAVE FIRST, 57 043 CUSTOM SET ALREADY EXISTS / DELETE EXISTING SET FIRST, 57 044 EC FIRMWARE/HARDWARE ERROR, 57 046 EC STOPPED AT STATE (state), 57 057 CLOSE PLATEN, 57 058 SHUTTLE JAM / SEE USERS GUIDE, 57 059 CANCEL PRINT ACTIVE, 57 060 PRINTER HOT, 57 062 EXHAUST FAN FAULT, 57 063 INTAKE FAN FAULT, 57 065 HAMMER BANK FAN FAULT, 57 069 DATA CLEARED, 57 080 POWER SUPPLY HOT, 57 081 POWER SUPPLY VOLTAGE FAILURE, 58 082 POWER SUPPLY 8.5V FAILED, 58 084 POWER SUPPLY 48V FAILED, 58 085 CONTROLLER VOLTAGE, 58
087 PLATEN OPEN TIMEOUT / CLOSE PLATEN, 58 088 CONTROLLER 23.5V, 58 089 RIBBON STALL, 58 090 SHUTTLE COVER OPEN / CLOSE SHUTTLE COVER, 58 092 RIBBON DRIVER CIRCUIT, 58 101 UPPER DRIVER SHORT, 59 102 LOWER DRIVER SHORT, 59 105 HAMMER COIL (number) OPEN, 59 107 HAMMER COIL (number) HOT, 59 110 STACK OVERFLOW / SEE USERS GUIDE, 59 111 STACK UNDERFLOW / SEE USERS GUIDE, 59 112 UNDEFINED OPCODE / SEE USERS GUIDE, 59 113 PROTECTED INSTRUCTION / SEE USERS GUIDE, 59 114 ILLEGAL OPERAND ACCESS / SEE USERS GUIDE, 510 115 ILLEGAL INSTRUCTION ACCESS / SEE USERS GUIDE, 510 116 ILLEGAL EXTERNAL BUS ACCESS / SEE USERS GUIDE, 510 117 A TO D OVERRUN / SEE USERS GUIDE, 510 118 UNDEFINED INTERRUPT / SEE USERS GUIDE, 510 119 TCB CORRUPTED / SEE USERS GUIDE, 510 120 ACCESS NULL POINTER / SEE USERS GUIDE, 510 121 PAPER NOT AT SPEED / SEE USERS GUIDE, 511 122 PAPER NOT SCHEDULED / SEE USERS GUIDE, 511 123 PAPER BUSY TOO LONG / SEE USERS GUIDE, 511 124 PAPER FIFO OVERFLOW / SEE USERS GUIDE, 511 125 PAPER FIFO UNDERFLOW / SEE USERS GUIDE, 511
Index
126 PAPER FEED BAD TABLE / SEE USERS GUIDE, 511 127 PAPER FEED ILLEGAL STATE / SEE USERS GUIDE, 511 128 PAPER FEED INVALID COMMAND / SEE USERS GUIDE, 512 129 PAPER FEED INVALID PARAMETER / SEE USERS GUIDE, 512 130 PAPER FEED PARTLY ENERGIZED / SEE USERS GUIDE, 512 131 PAPER FEED INTERRUPT / SEE USERS GUIDE, 512 132 RIBBON INVALID COMMAND / SEE USERS GUIDE, 512 133 RIBBON INVALID STATE / SEE USERS GUIDE, 512 134 PLATEN INVALID COMMAND / SEE USERS GUIDE, 512 135 PLATEN INVALID STATE / SEE USERS GUIDE, 513 136 PLATEN INVALID PARAMETER / SEE USERS GUIDE, 513 137 SHUTTLE INVALID COMMAND / SEE USERS GUIDE, 513 138 SHUTTLE INVALID PARAMETER / SEE USERS GUIDE, 513 139 SHUTTLE OVERSPEED / SEE USERS GUIDE, 513 990 MACHINE CHECK, 513 998 NONVOLATILE MEMORY FAILED, 513 A97 GRAPHIC CHECK ERROR / PRESS STOP THEN START, 513 BOOT DIAGNOSTICS, 513 CLEARING PROGRAM FROM FLASH, 514 DRIVER CIRCUIT BAD, 514 ENERGY SAVER MODE ACTIVE, 514 ERROR: DRAM NOT DETECTED, 514 ERROR: SECURITY PAL NOT DETECTED, 514 HAMMER BANK NOT INSTALLED, 514 HAMMER COIL BAD, 514
LOADING PROGRAM FROM PORT XX%, 514 LOADING PROGRAM INTO FLASH, 514 NOT READY, 515 OPERATOR MENU / (first menu item), 515 OPERATOR MENU LOCKED, 515 OPERATOR MENU UNLOCKED, 515 P05 DIAGNOSTIC TEST PASSED, 515 P17 SECURITY VIOLATION, 515 P60 ERROR: DRAM AT ADDRESS (hex), 515 P61 ERROR: FLASH NOT DETECTED, 515 P62 ERROR: DC PROGRAM NOT VALID, 515 P63 ERROR: PROGRAM NOT COMPATIBLE, 515 P64 ERROR: CHECKSUM WRONG (hex), 516 P65 ERROR: PROGRAM NEEDS MORE FLASH, 516 P66 ERROR: PROGRAM NEEDS MORE DRAM, 516 P67 ERROR: WRITING TO FLASH, 516 P68 ERROR: EC PROGRAM NOT VALID, 516 P69 ERROR: EC STOPPED AT STATE XXXX, 516 PA1 SELECTED, 515 PA2 SELECTED, 515 PLEASE WAIT... RESET IN PROGRESS, 516 READY, 516 RESETTING... PLEASE WAIT, 516 RESTORING BOOT CODE, 516 RIBBON OUT OF INK / CHANGE RIBBON, 516 SENDING PROGRAM TO EC PROCESSOR, 516 SERVICE / (first service test), 517 TABLE MISMATCH / DOWNLOAD AGAIN, 517
Index
TESTING HARDWARE / PLEASE WAIT, 517 TOP OF FORM SET, 517 WAITING FOR PROGRAM DOWNLOAD, 517 Metric measurement, conversion tables, C1 Micro keys cabinet model, 18 pedestal model, 110 Mnemonics, F1 Models, printer, 12 Motor paper feed drive, replacement, 732 platen open, replacement, 734 ribbon drive, replacement, 736 MPU. See Magnetic pickup assembly Multiplatform interface, replacement, 715
P
P05 DIAGNOSTIC TEST PASSED, 515 P17 SECURITY VIOLATION, 515 P60 ERROR: DRAM AT ADDRESS (hex), 515 P61 ERROR: FLASH NOT DETECTED, 515 P62 ERROR: DC PROGRAM NOT VALID, 515 P63 ERROR: PROGRAM NOT COMPATIBLE, 515 P64 ERROR: CHECKSUM WRONG (hex), 516 P65 ERROR: PROGRAM NEEDS MORE FLASH, 516 P66 ERROR: PROGRAM NEEDS MORE DRAM, 516 P67 ERROR: WRITING TO FLASH, 516
N
Network print server, replacement, 737 Noise Suppression, I1 NOT READY, 515 Notes and notices, 14 Numbers, replacement parts, H1
P68 ERROR: EC PROGRAM NOT VALID, 516 P69 ERROR: EC STOPPED AT STATE XXXX, 516 PA1 SELECTED, 515 PA2 SELECTED, 515 PAL, security, location, 731
O
Operation, principles of, 41 OPERATOR MENU / (first menu item), 515 OPERATOR MENU LOCKED, 515 OPERATOR MENU UNLOCKED, 515 Operator panel block diagram, 410 replacement cabinet model, 738 pedestal model, 739
Panel, control. See Operator panel Paper detector switch assembly, replacement, 759 drive motor pulley alignment, 68 feed drive motor, replacement, 732 feed timing belt replacement, 76 feed timing belt tension adjustment, 64 ironer, replacement, 741 scale adjustment, 610 specifications, B3 tractor (L/R), replacement, 762 Paper detector switch, replacement, 759 Paper guide assembly, removal, 740
Index
Paper jams, 55 Parts illustrations, 763 replacement part numbers, H1 replacement procedures, 75 Phasing adjustment, 624 Pinouts, A1 Platen gap adjustment, 612 interlock switch assembly, replacement, 761 platen open belt adjustment, 66 platen open motor, replacement, 734 Platen replacement, 742 PLEASE WAIT... RESET IN PROGRESS, 516 Plot, rates, B8 Power input voltage, B6 on/off verification, E8 Power consumption, B6 Power cords, G1 Power distribution diagram, A4 Power supply, circuit board replacement, 713 Power supply board, principles of operation, 418 Power-on time, 557 Principles of operation, 41 Print Configuration key cabinet model, 18 pedestal model, 110 Print server, network, 737 Print strokes, 557 Printer adjustments, 61 boot diagnostics menu, 551 cleaning, 32 configuration, 21
description, 12 dimensions, B4 duty cycle, B7 installation, 21 logical control of, 49 maintenance overview, 11 models, 12 preparing the printer for maintenance, 75 principles of operation, 41 reset, 559 selftests customer engineer (CE), 548 operator print, 545 specifications, B1 troubleshooting, 51 Printer information menu 11 inch pages, 557 installed memory, 557 power-on time, 557 print strokes, 557 printing time, 557 Printing conventions is this manual, 15 line matrix printing explained, 42 Printing time, 557 Printouts, hex code, 554 Procedures adjustment, 61 cleaning, 32 safety inspection, E1
R
READY, 516 Replacement cable connectors and connector shells, 79 card cage fan assembly, 721 circuit breaker, 714 Coax/twinax expansion board, 727 Coax/twinax multiplatform interface, 715 controller circuit board, 711
10
Index
cover assembly, shuttle, 717 cover assembly, top, pedestal model, 718 cover open switch assembly, 758 doors, cabinet, reversing, 719 extension spring, 757 gas spring assembly, 756 hammer bank /ribbon mask cover assembly, 716 hammer bank fan assembly, 720, 722 hammer spring, 723 IBM Coax/twinax expansion board, 727 magnetic pickup assembly, 728 memory modules, 729 multiplatform interface, 715 network print server, 737 operator panel assembly cabinet model, 738 pedestal model, 739 paper detector switch assembly, 759 paper feed drive motor, 732 paper feed timing belt, 76 paper guide assembly, 740 paper ironer, 741 platen, 742 platen interlock switch assembly, 761 platen open belt, 78 platen open motor, 734 power supply circuit board, 713 pprint server, network, 737 resistors, terminating, 747 ribbon drive motor, 736 ribbon guide assembly (L/R), 749 ribbon hub, 750 shuttle frame assembly, 754 splined shaft, 751 support shaft, 753 tractor (L/R), 762 Reset, soft vs. hard, 559 RESETTING... PLEASE WAIT, 516, 631 Resistors, terminating, location of, 748 RESTORING BOOT CODE (message), 516, 631
Return key cabinet model, 18 pedestal model, 110 Ribbon drive motor, replacement, 736 guide assembly (L/R), replacement, 749 guide assembly, alignment, 616 hub, replacement, 750 mask, replacement, 716 specifications, B2 RIBBON OUT OF INK / CHANGE RIBBON (message), 516
S
Safety inspection guide, E1 notices, viii notices, defined, 14 Scroll keys cabinet model, 18 pedestal model, 110 SECURITY CODE VIOLATION, 631 Security PAL, location, 731 Selftests customer engineer (CE), 548 operator print, 545 printer information menu, 557 SENDING PROGRAM TO EC PROCESSOR, 631 SENDING PROGRAM TO EC PROCESSOR (message), 516 SERVICE / (first service test), 517 Service checks customers power source, E7 power on/off verification, E8 print interlock, E8 print mechanism, E4 printer power cable, E7 safety ground path, E4 top cover and doors, E3
Index
11
Set shuttle speed, 633 Set Top Of Form key cabinet model, 18 pedestal model, 110 Shaft splined, replacement, 751 splined, skew adjustment, 618 support, replacement, 753 Shuttle cover assembly, replacement, 717 frame assembly, replacement, 754 speed setting, 633 Signal mnemonics, F1 SIMMs, location and replacement, 729 Soft reset, 559 Software, loading into flash memory, 626 Specifications dimensions, printer, B4 duty cycle, B7 electrical, B6 environmental, B4 interfaces, B7 paper, B3 printing rates, B8 ribbon, B2 Speed printing, B8 shuttle, set, 633 Splined shaft replacement, 751 skew adjustment, 618 Spring extension, replacement, 757 gas, assembly, replacement, 756 Start key cabinet model, 18 pedestal model, 110 Stop key cabinet model, 18 pedestal model, 110
Supplies, tools, and test equipment, 114 Support shaft, replacement, 753 Switch cover open switch assembly, replacement, 758 paper detector switch assembly, replacement, 759 platen interlock switch assembly, replacement, 761 power, replacement, 714
T
TABLE MISMATCH / DOWNLOAD AGAIN, 517, 631 Temperature, coil, adjustment, 632 Tension adjustment paper feed timing belt, 64 platen open belt, 66 Terminating resistors location of, 748 replacement, 747 Test, equipment, tools, and supplies, 114 TESTING HARDWARE / PLEASE WAIT, 517 Tests boot diagnostics menu, 551 customer engineer (CE), 548 print, operator, 545 printer information menu, 557 Time power-on, 557 printing, 557 Tools, test equipment, and supplies, 114 TOP OF FORM SET, 517 Torque conversion to or from metric, C1 table, D1 Tractor, replacement, 762
12
Index
Troubleshooting, 51 fault messages, 53 symptoms not indicated by fault messages, 539
U
Unit check condition, 53 Upgrading software, 626
V
View key cabinet model, 18 pedestal model, 110
W
WAITING FOR PROGRAM DOWNLOAD, 517 Wiring diagrams, A1
Index
13
14
Index
Copyright IBM Corp., 1995, 1997
S246011704

IBM 6400 Line Matrix Printer Service Manual

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

IBM 6400 Line Matrix Printer Service Manual

Hochgeladen von

Copyright:

Verfügbare Formate

6400 Line Matrix Printers

Maintenance Information Manual

Form Number S246011704 Copyright IBM Corp., 1995, 1997

Replacement Procedures and Illustrated Parts List

Trademarks and Service Marks

6400 Printer Family

Figure 11. Interpreting the Printer Model Designation

Important Maintenance Notes

About This Manual

How to Use This Manual

Notes and Notices

Printing Conventions in This Manual

Information pertaining to graphics programming is in the applicable Users Manual:

Controls and Indicators

Liquid Crystal Display (LCD) Ready

Set Top Of Form

Figure 12. Electrical Controls and Indicators, Cabinet Models

Electrical Controls and Indicators, Pedestal Models (Figure 13)

Processing Indicator Attention Indicator Power Switch LCD Start

Liquid Crystal Display (LCD) Ready

Set Top Of Form

Figure 13. Electrical Controls and Indicators, Pedestal Model

Mechanical Controls and Indicators, All Models (Figure 14)

Forms Thickness Lever

Ribbon Loading Path Diagrams Forms Thickness Pointer

Forms Thickness Lever and Scale

Figure 14. Mechanical Controls and Indicators

Tools, Test Equipment, and Supplies

63H7379 16F1661 6405959

25F9687 9900317 117397 9900764

Cleaning the Printer

Cleaning the Exterior

Cleaning the Interior (Figure 31)

Splined Shaft Shuttle Cover Assembly Base Casting

Ribbon Guide (2)

Forms Thickness Lever

Figure 31. Cleaning Inside the Cabinet/Printer Case

Cleaning the Shuttle Frame Assembly (Figure 32)

Hammer Bank Cover (Thick Plate)

Ribbon Mask (Thin Plate)

Hammer Bank Cover Assembly

Alignment Pin (2) (See Below)

NOTE: 6400004/04P hammer bank shown.

Hammer Bank Cover Alignment Pin

Figure 32. Cleaning the Shuttle Frame Assembly

Cleaning the Card Cage Fan Assembly (Figure 33)

Card Cage Fan Assembly

Figure 33. Cleaning the Card Cage Fan Assembly

Line Matrix Printing

First row and column of next character column (at 10 cpi)

First row and column of next character line (at 6 LPI)

Lowest descender dot line

Figure 41. A Dot Matrix

Direction of Shuttle Movement Dot Row Start

One Text Line

1 2 3 4 5 6 7 8* 9* * 10 Number of rows determined by line spacing 11 n 1 2

Paper Feed Direction

Figure 42. Standard Character Formation

Printed with underline

Figure 43. Elongated Character Formation

Succesive Hammer Strokes Per Scan

Figure 44. Action of One Hammer Spring in Text Printing

Shuttle Frame Assembly

Hammer Bank Assembly Counterweight Assembly Connecting Rod