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LineJet™ series

1. J111 Expansion Connector 5 E O 2a 0 00 O 0 4 A 1 PRINTRONIX ky E CONFIGURATION g gt e V D MEN Kd U aq ui o oq 24 B me am J105 J101 Hammer Bank Power Power Supply J106 1 1 1 N TEMP Motor Sensor Left 2 2 N STBY ROMS 3 PH2 3 55 1 PLATI E EXP N ID SEL 2 L 5 PH3 5 3 PLAT2 6 5 12 40 V 4 L 2 8 Ke 8 NC 5 L PLAT3 48V RBS 9 LDFB 9 8 5V REQO 6 I 4 10 10 N DMA REQ1 8 RIB L4 11 48V E CC FAN 12 NC 10 LRBNPOST 0 01 m 77 EXP NINT 10 ae 12 L POST AN 479
2. PERLOGIC M j HIGH eg d J102 External Power 0 1 mF 2096 50V E EXT 5V 500 OHM ai J17 Paper Stacker EXT 5V DB TXD DB RXD OLV SYNC OLV IRQ penunuoo PPR STK STATO PPR STK STAT1 PPR STK CTLO PPR STK CTL1 470 PF 10 50V Ove
3. a O 0 re mi fo a 1 __ g O B 4 D a E LJ of LJ StF ja N a Les d AES 5 0000 17 T me p 0 2A Oa 2 156208 001 aey ag oi UJ a ae 2 TA 15V J108 Hammer Bank Logic J116 DRAM 72 Pin Flash 80 Pin 3 0W SIMM SIMM Shuttle Motor TOROID 1 SOMME 1 SHUTA 2 HMRDAT 5 3 HMRDAT RET 4 L HMRCLK 5 L HMRCLK RET xU 0 01 mF 6 L _ CMD DAT 10 7 507 CAUTION Do not remove or replace the an NVRAM The NVRAM contains a lithium 8 battery that can explode if it is replaced 9 CMDCLKRET incorrectly NVRAM is replaced only at the 10 factory BO MHZ 7 J1 2 PIN JUMPER J13 2 PIN JUMPER J12 0 2 PIN JUMPER J14 6 0 O
4. Connector p112 Ferrite Core with Clamp and Adhesive Backing P N 202049 001PX NOTE This core attaches to the right rear card cage wall Connector J203 al gt Figure 55 Ferrite Core Installation 310 Power Stacker Contents eU Ed ides 311 Removing the Power page 312 Installing the Power 2 page 317 Replacement Procedures Constant Force page 328 Timing Belts 5 uet edt emeret end page 331 Illustrated Parts Breakdown page 335 Introduction The Power Stacker is a factory installed option for cabinet model printers Most of the stacker assembly is inside the cabinet so you must remove the stacker assembly from the printer in order to service it or replace most of its components The power paper stacker is designed to work with forms from 5 to 12 inches 12 7 to 30 5 cm long Using longer or shorter paper can cause error messages and unpredictable behavior of the stacker This appendix has two par
5. 100 zls ue yueg JOlOIN i o9 437 peog yueg 1 lt 391 3 Nd 1 U9IIMS 5 i uedo z 7 jno sede gy l e pieog Jojeuiuue JOON e x Jojeieq poeJ v 818 5 A 90 vor K quiessy uono aded i 90 70 emnus 0 JOlO A oL oL ueteld HSW 0ld ONS asusoia d E EE YSN 0 QNS 9 dH 8017 ISN 9017 499815 lt sepow N E 2798 0121 191 8102 JOUIeD vie o aja T 2998 0121 191 8102 jsneux3 awe IN 1V1d 399 dOd T LEGZ 611 8191 216 IN HdVd 9017 2 lt v uey peg ozr ole 1657 611 191 Zier 8 pueog 1ajonuoo 017 XINO Koen 9r 8 INO ns F SISSYH onsoubeiq d reues y gt Gu peog Ajddng semog 9 gt 0 9Y C quiessy jeueg 10u09 ewes SISSeYyO quiesse ejqeo SJOJONPUOD JequunN pue6e1 T
6. Ribbon Transport System Non Volatile 40 MHz Memory DC FLASH Motorola 8k x8 Up to 30Mb in 68EC030 2 SIMM Sockets Microprocessor DC Expansion N Port Expansion Port DC DRAM Interface Up to 32Mb in uum 2 SIMM Sockets RS 232 DC VX ASIC Diagnostic Diagnostic PEERS RS 232 422 ig IEEE 1284 Parallel Control Control Panel Panel TE Interface Data Controller DC 4 a x 2 Engine Controller 9 n Fault Monitoring Fault Circuitry Sensors ASIC se I Ribbon EC 64k x 16 Analog Drive Shuttle FLASH gt Zo Circuitry Memory Siemens 80C166 Microcontroller TTL 8 Diagnostic Diagnostic 7 Port Port Hammer Drive Figure 51 CMX Controller Board Block Diagram 225 Chapter 7 226 CMX Controller Board Data Controller The data controller DC consists of the following elements e 68 030 microprocessor e Two flash SIMM sockets used for up to 30MB of program memory e Two DRAM SIMM sockets used for up to 32MB of data memory e 8Kx8 Non Volatile Battery Backed static RAM NVRAM for storage of configuration and system statistical data e VX ASIC Application Specific Integrated Circuit e Host I O Dri
7. AT P306 TO CARD CAGE ae PLAT M P106 CCF P106 P106 LRP P106 PMD P106 POD L RBN M To J106 on CMX board P4108 P105 P116 NOTE This view shows the underside of the mechanism base P307 TO EXHAUST FAN Fe GUIDE PLATEN LEVER Ee TE 1 SIDE PLATE VIEW A A TIE WRAP P107 EHF BN P107 MPU P107 JMP WIRE P107 PPR M P107 RRP R RBN M P107 HBF To J107 on CMX board Japoyy 1euiqe wsiueYydeyy ejqe3 Appendix Cable Routing Pedestal Model 246 Lve Front of Printer H nm Left Side 2 of Printer Right Side H Printer IK ld X97 Pos E e 6 RBN CABLE ASSY L RBNM 4 case assy A Jos 4 N N 4 206
8. 148 Fan Assembly Hammer 149 Hammer Spring 4 150 Magnetic Pickup MPU 154 Memory Modules and Security PAL 155 Paper Feed 158 dece e Sid 160 Paper Pallium iti Mae UO i 161 Platon zin eet e RE anc t eet ere RR DER RA 162 Platen Open MOIOL ioca ueteri 166 Power Supply Board 168 Resistors 169 Ribbon Drive Motor tette te te de e ees 171 Ribbon Guide Assembly L R seen 172 Ribbon Hub erectae drain eaae 173 Shaft Spline t iter peregri e 174 SMALL SUP PON catechins st ches cans diae eee 176 Shuttle Frame 177 Spring Extension Hammer 179 Switch Assembly Paper 180 Switch Assembly Platen 181 Tractor E B uote dd o eret ete Pe eerie bna co 182 Section 11 Illustrated Parts 5 0 00011 183 Illustrations of Printer Components 183 7 Principles of Operation
9. oO Notched End Security PAL Flash Memory DRAM 80 SIMM J11 Bank 0 must always be filled J10 Bank 1 Reserved for upgrades Latch NOTES SIMM slots J11 and J16 must always be filled CMX board does not support EDO RAM Standard Memory All Models One 4MB flash SIMM One 4MB DRAM SIMM Figure 23 Memory Modules and Security PAL 157 Chapter 6 Section I Replacement Procedures Paper Feed Motor Removal 1 Prepare the printer for maintenance page 100 2 Cabinet Models Remove the paper path page 161 Pedestal Models Remove the top cover assembly page 142 3 Cabinet Models Loosen four screws and remove the barrier shield See page 192 items 3 4 and 9 Pedestal Models Loosen the four screws and remove the barrier shield and paper guide See page 194 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 192 item 7 5 Loosen but do not remove the two 5 16 inch paper feed motor mounting screws See page 208 item 10 6 Loosen the 7 64 inch shaft collar setscrew and remove the paper feed motor pulley shaft collar and paper feed timing belt See page 208 items 7 8 and 9 7 Trace the paper feed motor cables back to the controller board releasing it from tie wraps See the cable
10. 215 Line Matrix Printing 215 Printing Mechanism esses 218 Shuttle Frame 840 218 Paper Transport System 1 sss 220 Ribbon Transport 221 Logical Control of the 222 GontrolPariel r xe at Ex 223 Controller 4 042440 0 0 224 Data Controller 1 0 226 Engine Controller 229 Power Supply Boadas iid ro tiet 230 VNO AOE A t mU 230 BOX mp 231 Printer Interface eese nnne 231 ciel EE 232 A EERRRPME 233 Table of Contents B Printer Specifications and Regulatory Information 269 Ribbon 042 269 Printer DIMENSIONS 101 270 Environmental Characteristics 7 271 Electrical Characteristics 271 Material Safety Data 2 00 272 Communication 4 4 274 Abbreviations amp Signa
11. To Circuit Breaker Input Power Connector PIN WIRE COLOR LINE BLACK NEUTRAL WHITE GROUND GREEN YELLOW 251 Appendix PIN 1 252 Cable Assembly Card Cage Fan 152422 901PX 1 Hep d Er WIRE TABLE CCI P306 WIRE COLOR PIN 1 BLACK PIN 2 PIN 2 GRAY PIN 4 i Cable Assembly Control Panel 152440 901 PX 253 Appendix Cable Assembly Exhaust Fan 152424 901PX WIRE TABLE 507 WIRE COLOR PIN 4 PIN 3 BLACK PIN 2 PIN 2 GRAY PIN 1 N E 1 254 Cable Assembly Hammer Bank Logic 152421 901PX 255 Appendix Cable Assembly Hammer Bank Power 164805 901 PX 256 Cable Assembly MPU 152425 901 PX 257 Appendix Ribbon Guide Kit 163597 901PX Pin Connection P106 LRP P107 RRP Wire Color Pin 1 2 258 Ping Pin 1 NOTE Left ribbon guide shown Right is mirror image Cable Assembly Ribbon Motor Extension 154067 001PX 259 Appendix Cable Assembly Shuttle Motor Drive 152420 001PX 1
12. Maintenance Manual TRADEMARKS AND SERVICE MARKS Hewlett Packard Company makes no representations or warranties of any kind regarding this material including but not limited to implied warranties of merchantability and fitness for a particular purpose Hewlett Packard Company shall not be held responsible for errors contained herein or any omissions from this material or for any damages whether direct indirect incidental or consequential in connection with the furnishing distribution performance or use of this material The information in this manual is subject to change without notice This document contains proprietary information protected by copyright No part of this document may be reproduced copied translated or incorporated in any other material in any form or by any means whether manual graphic electronic mechanical or otherwise without the prior written consent of Hewlett Packard Company All rights reserved TRADEMARKS AND SERVICE MARKS AMD is registered trademark of Advanced Micro Devices Inc ANSI is a registered trademark of American National Standards Institute Inc Bi Tronics HP HP UX HP in a circle HP a rounded rectangle and Hewlett Packard are registered trademarks of Hewlett Packard Company LineJet is a trademark of Hewlett Packard Company Code V is a trademark of Quality Micro Systems Inc EIA is a registered service mark of the Electronic Industries Assoc
13. Power Switch Next Down Clear Shift Adj ENTER SER A FEL L Adj On Line LED onis FF LF View d E Figure 2 Electrical Controls Pedestal Models Chapter 1 Controls and Indicators Mechanical Controls and Indicators All Models Figure 3 Control or Indicator Function Forms Thickness Lever Paper Supports Forms Thickness Pointer and Scale Tractors 2 Tractor Locks 2 Horizontal Adjustment Knob Vertical Position Knob Ribbon Loading Path Diagrams Paper Scale 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 They are positioned manually by sliding them along the shafts Indicates relative thickness of forms and 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 this knob 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
14. page 33 Message Uist onesie Ret reste de ea page 34 e Troubleshooting Other page 64 General Symptom List 65 e Communications 83 Diagnostic Printer page 84 Code 2 0 2224 0 nenne page 90 ASGIl nete oo Tee page 92 e Power On Sequence sss page 94 e Appendix A Wire Data page 233 31 Chapter 4 Start Here Start Here Are you here because of an error message NO wv Power on the printer and observe the control panel for the following sequence of events retry as required 1 All black squares appear on the display 2 Display goes blank 3 TESTING HARDWARE PLEASE WAIT appears on display Power on the printer Did steps 1 2 and 3 occur NO Did the fans come on after 10 seconds NO Did ANY of steps 1 thru 3 occur NO Go to No power control panel is blank and card cage fan is not running page 67 32 After about 10 on and ONLINE YES b seconds did the YES appear on the printout Ref YES b User s Guide Are there black YES b gt squares on the Display Messages Go to Troubleshooting gt page 33 Did the status indicator lam
15. LAdNI OV Loer HOLO3NNOO H3MOd OV 026 235 Appendix Power Distribution Diagram Ue 4 yueg lt 19 epnib uoqqn 1 Ass uoqqu uei xueg m 1 2 lod 5 1 youms E emn sede uedo uejeld AS 2 mr peog Jojeuiuue uono sede JOON 5 A8v sor vor pao jade A quessy JOlOJA emnus hera leu zor E jo A8Y Y Y Asp ris ot a b gt A Y HSIN 014 ANS 9 SOld 80144 SW 9014 YSN 2017 CWS 9 Solr 8017 TSW 9017 2930815 jamog lt AGt T B 206 g 70 AGH ue4 0 A8v A8p bE OF 1 2 AS 9 6 n jog 21902 13H AG ee 4 ane isneux3 OND 21501 13H ASt 2 nu SISSVHO GND goo 134 Ast 9 0 Ler INO 0IDOT1 LJH AS S ast gt 5 X
16. eene page 255 Hammer Bank Power 256 ue page 257 Ribbon Guide Kit 2 1 dnt dec nite page 258 Ribbon Motor page 259 Shuttle Motor 2 400 0 page 260 Power Stacker Cables Frame Cable Power page 261 Logic Cable Power page 262 Power Cable Power Stacker page 263 233 Appendix 234 Vertical Rail Cable Power Stacker page 264 Fan Assembly Hammer Bank page 265 Magnetic Pickup MPU Assembly page 266 Switch Assemblies Switch Assembly Paper Detector page 267 Switch Assembly Platen page 268 Interconnection Diagram JUL
17. Only field replaceable spares are given part numbers in the illustrated parts lists Part numbers are not listed for common fasteners and attachment hardware Items marked Ref in the illustrations refer to parts that are not spared or are part of another assembly Illustrations of Printer Components Figure 28 Top Cover Doors and Casters Figure 29 Paper Fence and Chains Figure 30 Control Panel and Cabinet Details Figure 31 Pedestal Details eese Figure 32 Inside Covers Cabinet Models Figure 33 Inside Covers and Card Cage Pedestal Models Figure 34 Card Cage Detail Pedestal Models Figure 35 Print Mechanism and Circuit Boards Figure 36 Magnetic Pickup MPU and Extension Spring Figure 37 Tractor aii ini 38 Platoni ide Figure 39 Motors Fans and Paper Detector Switch Figure 40 Circuit Breaker Cabinet Models Figure 41 Ethernet Interface page 184 page 186 page 188 page 190 page 192 page 194 page 196 page 198 page 202 page 204 page 206 page
18. Figure 19 Connector Stiffening Clips 134 Control Panel Assembly Cabinet Models Control Panel Assembly Cabinet Models Removal 1 Prepare the printer for maintenance page 100 2 Disconnect RJ11 connector P310 from connector J310 on the control panel 3 Loosen four screws securing the control panel to the control panel bracket See page 188 item 1 4 Remove the control panel assembly from the keyways in the control panel bracket Installation 1 Position the control panel assembly on the bracket engage the mounting screws in the keyways and hand tighten the screws See page 188 item 1 Connect RJ11 connector P310 to connector J310 on the control panel Lower the printer cover and center the control panel assembly in the cutout of the printer cover 4 Open the printer cover and tighten the four control panel mounting Screws 5 Return the printer to normal operation page 101 135 Chapter 6 Section Replacement Procedures Control Panel Assembly Pedestal Models Removal 1 Prepare the printer for maintenance page 100 Open the printer cover Loosen the four captive screws until the control panel is released from the printer top cover See page 190 item 2 4 Remove the two 5 16 inch screws securing the control panel ground straps See page 190 item 11 5 Lift the control panel and disconnect the RJ11 cable connector from the control panel assembly 6 Remove the con
19. x B B N D gt d 0000 g PRINTRONIX J1 12 Uo n a Centronics ni ETT 0 BC 156298 001 REV __ LJ 9 M CNC PN 1 1 ar VOCNCPN19 2 U p VOCNCPN2 3 VOCNCPN20 4 VOCNCPN3 5 og VOCNCPN21 6 d VOCNCPN4 7 o lO 22 8 J110 VOCNCPN5 9 201 VO PN23 10 RS J an Front Panel J107 6 11 232 RS422 vec Motor Sensor Right VOCNC PN 24 12 VOCNCPN7 13 E N FP DAT AVAIL nan VO CNC PN25 14 L 470 PF CNC PN8 15 1 10 3 FPCLK 2 PN26 16 2 HOST TXD 50V 4 3 q Pre lO CNC PN9 17 3 5 N FP LED WR HOTE 4 RIB R2 VO CNC PN27 18 4 HOSTRTS 6 FP DATA 50V 5 448V CNC PN 10 19 5 7 6 RIBR3 Q PN28 20 og 6 8 N FP LCD WR p CNC PN 11 21 2 sence 5 RBR4 REIR CNC PN29 22 CNC PN 12 23 d F NC 1 Sa VO CNC PN30 24 EENG 11 wc 12 PN 81 26 ES WE j VO PN 32 14 15 PLAT OPEN RET CNC PN 15 29 15 DIFF 16 x FEREN POST CNC PN33 30 F VOCNC PN 16 31 27 17 DIFF RXD 18 COVER OPEN SW VOCNCPN34 32 NC Sub 25 CNC PN 17 33 COVER OPEN RET CNC PN35 34 20 HOST DTR
20. 12 Related 13 Safety NOlC6S onsite pote 14 Hinweise zur 15 Controls and 16 Tools Test Equipment and 22 Installation d 23 InStallatiQW GUAE 23 Preventive Maintenance 25 Cleaning the eene 25 Cleaning the Outside 26 Cleaning the Shuttle Frame Assembly 28 Cleaning the Card Cage Fan Assembly 30 TEOHDIGSHOOLHG t 31 et 31 Troubleshooting 31 Siga NP 32 Troubleshooting Display 33 Listo Messages e in eae B d rius 33 Troubleshooting Other Symptoms sse 64 General Symptom List 65 Communications 83 Diagnostic Printer Tests cette tenter tete 84 Selecting and Running Diagnostic Printer 85 Boot Diagnostics enne 87 Hex Gode PrintoUt eet 90 How to Print a Hex
21. 91 ASGII Gharacter Ee eere ee eet bone eden 92 Table of Contents Soft vs Hard 93 The Power On Sequence 94 Controller Board Handshake Sequences 94 DC Software Initialization and Power Up 98 5 Adjustment Procedures 99 99 List of enne 99 Preparing the Printer for 100 Returning the Printer to Normal Operation 101 Belt Paper Feed Timing 102 Belt Platen Open 104 Paper Drive Motor Pulley 106 Paper Scale 108 Platen 00444 000000 110 Platen Open Motor Pulley 112 Ribbon Guide 114 Splined Shaft Skew 116 Paper Out Adjustment sss 117 Hammer Phasing Adjustment
22. Legend Washer 2 Screw 5 32 x 3 4 inch 2 Stacker Base Screw 7 64 x 1 2 inch or Torx T 10 2 Washer 2 but no washers with Torx T 10 screws Vertical Rail Upper Frame Cross Member Figure 67 Stacker Fasteners On oor ce 323 Appendix Installing the Power Stacker 22 Install the paper fence See Figure 68 Legend 1 Paper Fence 2 Stacker Base Figure 68 Paper Fence 324 23 Gather the rail cable frame cable logic cable and power cable Route the cables outboard of the elevator assembly 24 Connect the stacker cables to the rear of the stacker control panel assembly as shown in Figure 69 Legend 1 Logic Cable P104 Power Cable 2 3 Frame Cable P102 4 Rail Cable P107 Figure 69 Stacker Control Panel Cables 325 Appendix H Installing the Power Stacker 326 25 Position the stacker control panel as shown in Figure 70 and install the mounting screws S Ry 1 Stacker Control Panel 2 Long Screw 3 Short Screw 2 Figure 70 Installing the Stacker Control Panel 26 Bundle the stacker control panel cables in the wire harness clips located under the card cage See Figure 71 Tie wrap the cables so they do not catch in the stacker mechanism as it moves up and down Route the stacker rail and frame cables so they move without snagging as the elevator assembl
23. Section I Replacement Procedures P106 Connector Configuration P107 Connector Configuration 19171513 119 7531 Connectors are viewed 19171513 119 7531 from the top as seen POD CCF PLATM when plugged into CMX MPU PLO EHF PAPRM controller board PMD LRP LRIB M CVO RRP HBF Lo Pin No 20181614 1210 8642 20181614 1210 8642 CCF Card Cage Fan EHF Exhaust Fan LRIB M Left Ribbon Motor HBF Hammer Bank Fan LRP Left Ribbon Guide JMP Jumper Wire PLAT M Platen Open Motor MPU Magnetic Pickup PMD Paper Motion Detector Switch PAPR M Paper Feed Motor POD Paper Out Detect Switch PLO Platen Open Switch Connectors P106 and P107 have stiffening clips page 133 RRIB M Right Ribbon Motor RRP Right Ribbon Guide JMP jumper on pedestal models which is used as a spacer Key Tab 0 0 Typical 4 Wire Typical 2 Wire oy n Cable Connector Cable Connector s I ff B Pull the sides outward just X enough to release the 1 connector lock tab from the nJ r slot in the connector shell 2 Connector shell P106 P107 72 202362 901 Key Tab Slot Push here to JD remove the shell from the controller J106 or J107 on CMX board Controller Board Figure 18 Cable Connector Shell Disassembly Assembly Connector Stiffening Clips Connector Stiffening Cl
24. Send a print job to the printer If the message appears go to Communications Failures page 83 Firmware error on the CMX controller board PLAT INV CMD Platen Invalid Command 1 Cycle power Run the print job again If the message appears download the emulation software again Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board 52 Table 2 Message List List of Messages Message Explanation Solution PLAT INV PARM Platen Invalid Parameter 1 Firmware error on the controller board Cycle power Run the print job again If the message appears download the emulation software again Cycle power Run the print job again If the message appears replace the controller board Record the message and return it with defective board PLAT INV STATE Platen Invalid State Firmware 1 error on the CMX controller board Cycle power Run the print job again If the message appears download the emulation software again Cycle power Run the print job again If the message appears replace the controller board Record the message and return it with defective board PLEASE WAIT RESET IN PROGRESS Status message the printer finished loading the program into flash memory and is automatically resetting itself No action re
25. a Legend 1 Upper Frame Cross Member 2 Elevator Assembly 3 Stacker Base 4 Vertical Rail Figure 66 Stacker Installation 321 Appendix Installing the Power Stacker 322 14 15 16 17 18 19 20 21 Align the holes in the stacker base with the holes in the cabinet floor See Figure 66c and Figure 67 Install finger tight the two 5 32 x 3 4 inch screws and washers securing the vertical rails to the upper frame cross member Install and tighten the 7 64 x 1 2 inch screws and washers or Torx T 10 screws securing the stacker base to the cabinet floor See Figure 67 Move the elevator assembly up and down on the vertical rails until it travels smoothly with no binding Tighten the two 5 32 x 3 4 inch screws and washers securing the vertical rails to the upper frame cross member Move the elevator assembly up and down again to make sure it travels smoothly with no binding Tighten the screws securing the vertical rails to the stacker base Each rail is secured by two screws See Figure 65 Move the elevator assembly up and down to make sure it travels smoothly with no binding If the elevator binds or catches anywhere along its path of travel slightly loosen the upper and lower rail screws and repeat steps 17 through 20 until the elevator moves smoothly NOTE The stacker assembly is exploded to show mounting screws and locations
26. esee 121 Set Sh ttl Sp66d i enituit 123 6 Replacement Procedures and Illustrated Parts Lists 125 Organization of This 125 Section Replacement Procedures 126 List of Removal Installation 126 Belt Paper Feed 128 Belt Platen OPET etit ee E ce tei e ewan ee 129 Circuit Breaker 130 Connector Shell 131 Connector Stiffening 040 8 133 Control Panel Assembly Cabinet 135 Control Panel Assembly Pedestal Models 136 Controller Board enn 137 Cover Assembly Hammer Bank Ribbon Mask 139 Cover Assembly 141 Cover Assembly Top Pedestal Models 142 Dashpot EE 143 Ethernet Interface 144 10 100Base T LEDs and DIP Switches 145 Fan Assembly Cabinet 147 Table of Contents Fan Assembly Card
27. eur eur mu peog jddng 1 i od u v3d8 O OVN peog YN rora HOLO3NNOO 4 31 N 1 peog 2v Loer 022041 J9MOg OV g 236 Main Wire Harness Test Tables P106 Connector 19171513 119 Connectors are viewed P107 Connector from the top as seen 7531 when plugged 1917 1513 119 7531 POD CCF PLATM contro er Goat MPU PLO PAPR M PMD LRP LRIB M PinN RRP HBF in No 20181614 1210 8542 2018 1614 1210 8642 Resistance Resistance Device P106 Pins Normal Device P107 Pins Normal LRIBM 2 4and6 8 72 880 RRIBM 2 4 6 8 7 2 8 8 1 5 7 1 35 1 65 Q PAPRM 1 5 7 0 417 0 681 Q LRP 10 12 Open across pins HBF 10 12 2 7 Short across post EHF 9 11 4 6 KQ CCF 9 11 4 6 KQ RRP 14 16 Open across pins PMD 14 16 8 Meg Q Short across post 18 20 Open PLO 13 15 Continuity switch closed POD 13 15 8 Meg Q Open switch open 17 19 Open CCF Card Cage Fan LRIB M Left Ribbon Motor LRP Left Ribbon Guide CVO 18 20 Continuity switch closed Open switch open MPU 17 19 6700 PLAT Platen Open Motor PMD Paper
28. 1 Logic Cable P104 2 Power Cable 3 Frame Cable P102 4 Rail Cable P107 Figure 59 Removing Cables from the Stacker Control Panel 313 Appendix _ Removing the Power Stacker 8 Remove the two 5 32 x 3 4 inch screws and washers securing the vertical rails to the upper frame cross member at the rear of the cabinet See Figure 60 9 Raise the elevator assembly Legend Vertical Rail Washer 2 Screw 5 32 x 3 4 inch 2 Screw 7 64 x 1 2 inch or Torx T 10 2 Washer 2 but no washers with Torx T 10 screws Stacker Base Figure 60 Preparing the Stacker for Removal 314 10 Loosen one turn DO NOT REMOVE the Torx 10 screws securing the vertical rails to the stacker base Each rail is secured by two screws See Figure 61 Legend 1 Screw 6 32x1 4 Torx T 10 two at bottom of each rail 2 Vertical Rail 3 Stacker Base Figure 61 Loosening the Lower Screws in the Vertical Rails 11 Remove the 7 64 x 1 2 inch screws and washers or Torx T 10 screws securing the base plate to the cabinet floor See Figure 60 12 Lower the elevator assembly to its lowest position 13 Slide the stacker assembly slightly to the right to clear the air exhaust duct Tilt the vertical rails toward the front of the printer until they clear the upper frame cross member Slide the stacker assembly to rear and angle it out of the cabinet as sh
29. 10 Remove the platen open motor assembly 166 Platen Open Motor Installation 1 Position the platen open motor assembly with the wires toward the rear page 208 item 5 Install the two 5 16 inch motor mount screws and nuts if present finger tight Install the platen open belt and motor pulley Bottom out the motor pulley on the motor shaft and tighten the 1 16 inch setscrew Connect the platen motor cable connector to connector shell P106 Connect shell connector P106 to the controller board and install tie wraps to secure the motor cable See the wire routing diagrams in Appendix A Close the forms thickness lever all the way Finger tighten the two 5 16 inch screws securing the platen open motor Too much tension on the platen open belt can change the platen gap which can lead to premature wear of the platen damaged hammer tips and poor print quality 10 11 While pulling the platen open motor toward the rear of the printer adjust the belt tension to 1 8 inch deflection midway between the pulleys Tighten the upper motor mount screw with a 5 16 inch nutdriver Tighten the lower 5 16 inch screw with an open end wrench Check the deflection of the platen open belt again after the mount screws are tight Snap the platen open belt cover into the slots in the side plate Cabinet Models Install the card cage fan page 148 Cabinet Models Install the paper path page 161 Pedestal Models Insta
30. Cycle power If the message appears power off the printer Disconnect the input data line from the host computer Power on the printer If the message appears download the emulation software again page 129 Cycle power Run the print job again If the message appears replace the CMX controller board If the message is gone there is an application software error Request assistance from your local support group STACK OVERFLOW Firmware error on the CMX 1 controller board Cycle power Run the print job again If the message appears download the emulation software again Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board STACK UNDERFLOW Firmware error on the CMX 1 controller board Cycle power Run the print job again If the message appears download the emulation software again Cycle power Run the print job again If the message appears replace the controller board Record the message and return it with defective board 59 Chapter 4 Troubleshooting Display Messages Table 2 Message List Message Solution STACKER FAULT Explanation This message is triggered when 1 the elevator cannot reach either the top or bottom position switch before timing out 2 3 4 5 6 Power on the printer Operate the power stacker
31. Die obere Kante der Papierschiene wird mit der Zeit scharf Halten Sie die Schiene deshalb an den Seiten damit Sie sich nicht schneiden Behalten Sie die Druckerabdeckung sicher im Griff wenn Sie das Gasfederpaket entfernen Chapter 1 Controls and Indicators Controls and Indicators Electrical Controls and Indicators Cabinet Models Figure 1 Switch or Active Active Indicator Funcion Online Offline Power Switch Turns printer on and off 1 on 0 off This switch is also a circuit breaker Status Indicator On when the printer is online off when the printer is offline v Flashes to indicate a fault or warning LCD Liquid Crystal Display Displays printer status messages Y Y fault messages and menus which permit user to set various configurations ONLINE Toggles the printer online and offline Clears the printer after Y v a fault is corrected and returns the printer to offline state FF Prints any data in the buffer then moves paper to top of form Y Y as defined by the currently active form length LF Prints any data in the buffer then moves one line feed as v v defined by the currently active line spacing Repeats if held down VIEW Moves the current print position to the tractor area for Y Y viewing Press again to move paper back to the print position A UP Displays next higher level of a configuration menu After VIEW is pressed moves paper up 1 72 inch Y DOWN Displays next l
32. Pin or Plug Part Number Paper Out Paper Out Detect Switch Paper Programmable Read Only Memory Power Supply Power Supply 5 Volt Pointer Printer Printronix Pulse Width Modulation Power Right Ribbon Read Return Ribbon 281 Appendix 282 RG RGL RGR RM RML RMR RQ RRIB RRP RSP RST RTS RXD SEC SEL SEN SF SG SHH SHM SHUT SHUTL SIMM SLCT Slew SMD SPU SRAM STAT STBY STK SW SYNC TCB TEMP TOF TP Ribbon Guide Ribbon Guide Left Ribbon Guide Right Ribbon Motor Ribbon Motor Left Ribbon Motor Right Request Right Ribbon Right Ribbon Guide Ribbon and Shuttle Processor Reset Request to Send Receive Data Security Key Select Sense Sensor Structured Field Signal Ground Shuttle Hall Effect Shuttle Motor Shuttle Shuttle Single Inline Memory Module Select On line Rapid vertical paper movement Shuttle Motor Drive Shuttle Processor Unit Static Random Access Memory Status or State Standby Stacker Switch Synchronize Task Control Block Temperature Top of Form first print line 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 Vec Voltage at Collector Vss Voltage at Source VX A special ASIC on the CMX controller board co
33. SECT WIRE TABLE 302 WIRE COLOR 1 1 BLACK 2 BLACK 5 5 BLACK PIN 1 5 260 Frame Cable Power Stacker eseud WYO GL F c SI eouejsiseH YOLOW 831104 HONId eseud WYO CSI eouejsiseH YHOLOWN LNOtH ZW WYO F Z S 994 5 59 4 YOLOW uvad LN aNd 3 9 Gld V Gld Medi 4101 vid 8Hd Id Id VHd Id VHd Id 8 cw ev ZN LV za IW LW ev IW LW 000 OQ T N ON OD RTD AAA o 0909 L NId po 00 8 261 Appendix Logic Cable Power Stacker 158444 001PX a a e EN oH ER a I pe pem CONNECTION TABLE _ 103 LINE P104 LINE DAT PIN 1 1 BRN PIN B PIN 2 3 RED PIN gt SIN 3 5 0RN N 3 5 PIN 4 FINE N 4 PIN 5 S GRN PIN 5 IRN PIN 6 2 4 6 10 PIN 2 PIN 7
34. Weight Height Width Depth Cabinet Model 42 5 inches 108 cm 27 inches 68 6 cm 29 inches 73 7 cm 225 Ibs 102 1 kg unpackaged 285 Ibs 129 3 kg packaged Cabinet Model with Power Stacker Option 42 5 inches 108 cm 27 inches 68 6 cm 32 5 inches 82 5 cm 246 Ibs 112 kg unpackaged 306 Ibs 139 kg packaged Pedestal Model 35 inches 88 9 cm 24 6 inches 62 5 cm 20 7 inches 52 6 cm Weight 105 16 47 6 kg unpackaged 115 16 52 2 kg packaged Environmental Characteristics Temperature Operating 41 to 104 F 5 to 40 C up to 5000 feet 1524 meters 41 to 90 F 5 to 32 C up to 8000 feet 2438 meters Storage 40 to 158 F 40 to 70 C Relative Humidity Operating 15 to 80 noncondensing Storage 15 to 90 noncondensing ENERGY STAR LineJet printers comply with the requirements of the ENERGY STAR Office Equipment Program of the U S Environmental Protection Agency When in the reduced power state the printer displays Power Saver Mode and is activated at the control panel Refer to the User s Guide Electrical Characteristics Current LineJet 500P LineJet 500Q LineJet 1000Q LineJet 1500Q Printing Typical 2 15A 2 43A 3 28A 4 37 Printing Maximum 3 60 3 05 4 39 6 06 Non Printing 0 90A 1 17A 1 19A 1 16A Power Printing Typical 190W 191W 271W 364W Printing Maximum 32
35. at upper or lower limit Power off the printer Unload paper Open the rear cabinet door and check that stacker motion is not obstructed by the control panel cable or other obstruction Remove obstruction or reroute the stacker control panel cable as necessary Verify that the stacker rails are vertical and parallel Adjust the stacker rails if necessary they must be vertical and parallel Move the elevator up and down by hand and check that the limit switches are being tripped at the highest and lowest limits of elevator travel Adjust the limit switches if necessary by gently bending the contact arms Replace switches that cannot be adjusted Power on the printer Operate the power stacker Refer to the User s Guide While the stacker is operating check that a all motors are operating b the paddles are rotating c the elevator moves smoothly and without obstruction d the timing belts are undamaged and the belt pulleys are not slipping e the extension springs are attached and undamaged not bent or stretched f the drive rollers are not damaged g the constant force springs are tightly mounted and undamaged Tighten pulley setscrews and or replace damaged components as necessary 69 Chapter 4 Troubleshooting Other Symptoms Table 3 General Symptom List Symptom Solution Stacker does not stack properly Check for and removeobstructions preventing elevator movement Check for misa
36. within four hammer positions of the left end of the hammer bank 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 Repeat steps 4 through 6 at the right end of the hammer bank 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 104 10 Install the shuttle cover assembly page 141 11 Check the hammer phasing adjustment page 121 12 Return the printer to normal operation page 101 110 List of Adjustments NOTE Left side adjustment shown Right side is the same b A gt lt ee NL Legend 1 Forms Thickness Lever
37. 1 164295 001PX Shuttle Cover Shroud Assembly Air 2 Ref Screw Captive 2 10 24x 62 with O ring 125x 250x 06 3 Ref Screw Thread forming 4 6 32x 25 and 6 flat washer 4 Ref Barrier Shield 5 154286 001PX Paper Path 6 152284 901PX Anti Static Brush Kit 7 Ref Power Supply Shield Taped to upper edge of card cage 8 108664 903PX Belt Timing 080 Pitch 100 Teeth 500 Paper Feed Belt Wide 9 153488 001PX Feed Cover Kit Paper Feed Belt Cover 10 153528 901PX Paper Scale 195 Chapter 6 Section II Illustrated Parts Lists 1 From Figure 33 page 194 Rotated 180 degrees To IEC 320 AC Power Input To Connector P1 White Wire To Connector P1 Black Wire To IEC 320 AC Power Input Connector J301 Black Wire Figure 34 Card Cage Detail Pedestal Models 196 Illustrations of Printer Components ltem No Part No Description Notes 1 Ref Nut 6 32 1 Upper right fan corner only 2 150261 901PX Card Cage Fan Assembly Air flow is into card cage 3 Ref Fan Guard 4 Ref Screw w Lock Washer 4 6 32x1 75 5 Ref Card Cage Pedestal 6 142013 901PX Circuit Breaker 197 Chapter 6 Section II Illustrated Parts Lists Two places Exploded to show assembly Do not remove holddown clamps and Screws Shuttle Motor To Terminator Board on Shuttle Frame Figure 35 Print Mechanism and Circuit Boards 198 Illustrations of Printer
38. 23 154068 901PX Motor Assembly Paper Feed 209 Chapter 6 Section II Illustrated Parts Lists See inside detail below To IEC 320 AC Power Input Connector J301 Black Wire To IEC 320 AC Power N Input Connector J301 AS White Wire A 25 1 Black Wire To Connector P1 White Wire 1 Card cage fan and power supply board removed for clarity Black Wire Black Wire mie Figure 40 Circuit Breaker Cabinet Models 210 Illustrations of Printer Components ltem No Part No Description Notes 1 142013 901PX Circuit Breaker 2 Ref IEC 320 AC Power Connector Connector J301 3 Ref Chassis Ground Stud 4 Ref Connector P1 To power supply board connector J1 AC 5 Ref Cable Assembly AC In Power Supply Part of Field Kit AC Assy 153502 001PX 211 Chapter 6 Section II Illustrated Parts Lists Figure 41 Ethernet Interface Assembly 212 Illustrations of Printer Components ltem No Part No Description Notes 1 Ref Screw Connector Cover 2 2 Ref Cover Plate Centronics 3 202049 001 Ferrite Clamp See Appendix E 4 Ref CMX Controller Board 5 152439 901 Centronics I O Cable Assembly 6 170622 001 LineJet Print Server 7 Ref Rear of Card Cage 8 Ref Screw 2 213 Chapter 6 Section II Illustrated Parts Lists 214 7 Principles of Operation Line Matrix Printing The printer creates characters and graphics by pr
39. Adjust the link 2 by raising or lowering the horizontal adjustment knob 3 to obtain print parallel with paper perforations Tighten the screw 1 Return the printer to normal operation page 101 Legend 1 Screw 2 Adjusting Link 3 Horizontal Adjustment Knob Figure 16 Splined Shaft Skew Adjustment List of Adjustments Paper Out Adjustment This procedure tests and sets the distance from the page perforation at which a LOAD PAPER 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 Paper Out Adjustment test to verify that this parameter is set correctly Do this procedure only if a new paper detector switch assembly has been installed the CMX controller board has been replaced or if you are sure the paper out adjustment is incorrect A paper out triggering distance of 1 or 2 dot rows above the perforation is acceptable 5 to 7 dot rows above or any dot rows below indicates adjustment is required Also although it is not required it is advisable to test the paper out triggering distance with 6 part paper in order to verify correct printing with multi part forms The procedure below describes how to run the Paper Out Adjustment test and modify the paper out Dots value 1 Open the printer cover On cabinet models open the cabinet front door Load p
40. BUFFER OVERRUN The print buffer has overflowed 1 Verify that the printer matches the on a serial interface The host serial interface configuration printed output may contain settings for Data Protocol Baud random asterisk characters Rate Data Bits Stop Bits Parity Make a configuration printout Data Terminal Ready and Request to Send Set printer serial interface parameters to match those of the host 2 Senda print job to the printer If the message appears go to Communications Failures page 83 CLEAR PAPER JAM Paper jam 1 Inspect the paper path for jams Clear jams Load paper 2 Press PAPER ADVANCE several times and check that forms feed without erratic motion noise or pin hole damage If forms do not feed go to Paper feeds poorly page 77 If forms feed go to step 3 3 Press VIEW once and check that forms move up Make sure the forms thickness lever is not set too tightly 4 Press VIEW again and check that the forms thickness lever rotates and the paper moves down If the forms thickness lever does not rotate and or the paper does not move down refer to Reverse paper feed platen does not open page 79 5 Check the paper tension between the tractors Adjust the right tractor so that it does not pull paper too tightly or leave it too loose The right tractor should hold the paper under slight tension 6 Inspect the ribbon mask for bends or deformation Replace if damaged 7 Check and
41. C Y RIBBON GUIDE PLATEN LEVER SIDE PLATE Ir 2 Q C ki 2 view P307 TO EXHAUST FAN TIE WRAP odoood Pa BOTH SIDE S Not connected ATE CAGE iod e146 on pedestal models BEADED E TIE WRAP P107 EHF P407 PLO P106 POD P106 CCF L RBN M P106 LRP P407 MPU RIQZARRR R RBN M P107 JMP WIRE To J106 on CMX board NN P107 HBF NOTE This view shows the underside of the To J107 on CMX board mechanism base JOPOW je1sopag eseg uisiueuoojy Cable Assembly Centronics 152439 901PX 248 Cable Assembly 2 Jumper 0 1 Ctr 154470 001 JM 249 Appendix Cable Assembly AC In Power Supply Kit No 153502 001 250 Cable Assembly AC Power Input Kit No 153502 001
42. Power Stacker E 311 311 311 Table of Contents Removing the Power 312 Installing the Power 317 Replacing the Constant Force 328 Replacing the Timing 331 Illustrated Parts Breakdown eese 335 Table of Contents Maintenance Overview About the Printer The Hewlett Packard LineJet series consists of five fast reliable line matrix printers The name of the printer indicates its speed rating and the type of printer housing as shown below Table 1 LineJet Printers Print Model Name Noas Speed Housing Hammer Bank Number LPM LineJet 500P C3201D 500 Pedestal 28 Hammers LineJet 500Q C3202D 500 Cabinet 28 Hammers LineJet 1000Q C3204D 1000 Cabinet 60 Hammers LineJet 1500Q C3205D 1500 Cabinet 102 Hammers LineJet 1500Q C5640D 1500 Cabinet amp 102 Hammers Power Stacker 1 Printing speed is determined by the interaction of many variables The speeds listed in this table are the highest speeds attainable under controlled conditions LineJet printers use a flash memory architecture that permits rapid access to stored printer emulations A variable speed shuttle half step paper control and system architecture contained on a single cir
43. Switch Assembly Platen Interlock Switch Assembly Platen Interlock Removal 1 Prepare the printer for maintenance page 100 2 Cabinet Models Remove the paper path page 161 Pedestal Models Remove the top cover assembly page 142 Fully close the forms thickness lever position A Trace the platen interlock switch cable back to the controller board Remove tie wraps as necessary to free the cable See cable routing diagrams in Appendix A Disconnect connector shell P107 from the controller board Remove the platen interlock cable connector from the connector shell page 132 7 Remove two Phillips 1 screws securing the platen interlock switch assembly See page 206 item 11 Remove the platen interlock switch assembly from the switch bracket Remove the switch cable from the cutout in the right side plate Installation 1 Reverse steps 2 through 9 of the removal procedure 2 Return the printer to normal operation page 101 181 Chapter 6 Section Replacement Procedures Tractor L R Removal 1 Prepare the printer for maintenance page 100 2 Remove the support shaft page 176 3 Remove the splined shaft page 174 Installation 1 Using the replacement tractors install the support shaft page 176 2 Install the splined shaft page 174 3 Return the printer to normal operation page 101 182 Illustrations of Printer Components Section Il Illustrated Parts Lists
44. binary file into the flash memory on the printer controller board 290 If you are loading the file using the LPT2 port on the computer enter the following DOS command FILENAME EXE pb 2 lt Return gt The 9600 baud rate is the only selection older versions of DOS can use The baud rate information entered in the following DOS commands must match the selection you made in step 25 If you are loading the file through the printer serial port enter the following DOS commands MODE COM1 9600 N 8 1 P lt Return gt FILENAME EXE pbc1 lt Return gt 27 While the file is copied into memory the printer LCD informs you of the load process and status See Table 2 page 34 28 When the new program has successfully loaded into memory and the printer has reset itself set the printer power switch to O off 29 Unplug the AC power cord from the printer 30 Remove the diskette from the computer and store it with the printer 31 Power off the computer 32 If you had to install a data cable to the computer and printer in step 6 disconnect it from the computer and printer 33 Reconnect the customer s data input cable s to the printer if required 34 Return the printer to normal operation page 101 35 Using the configuration printout s you made in step 1 reconfigure the printer Refer to the User s Guide 291 Appendix _Loading Flash Memory from Multiple Diskettes 292 Host Configurations and Dri
45. following at the DOS prompt DIR A lt Return gt If the diskette is in drive B type DIR B lt Return gt The compressed file on the diskette takes the form FILENAME ZIP where the filename is a six digit number e g 123456 zip 14 At the DOS prompt type A PKUNZIP A FILENAME Replace A with B if you are using the B dirve where FILENAME is the six digit number you noted in the previous step 15 The PKUNZIP program will execute and the following message will appear on the computer screen Insert disk 1 Press a key when ready 16 Remove the diskette in the disk drive and insert the diskette labeled Disk 1 of 2 or 1 of 3 etc 17 Press the lt Return gt key After the file is decompressed to the hard drive the following message will appear on the computer screen Insert disk 2 Press a key when ready 18 Remove the diskette in the disk drive and insert the diskette labeled Disk 2 of 2 or 2 of 3 etc 19 Press the lt Return gt key If there are only two diskettes for the emulation you will be Returned to the DOS prompt when the decompression is 289 Appendix _Loading Flash Memory from Multiple Diskettes complete If there are three diskettes you will be asked to insert disk 3 and press a key 20 When all diskettes have been decompressed type the following at the DOS prompt DIR lt Return gt You will see a directory listing containing the file FILENAME EXE where the filename is the six
46. page 141 6 Print a full 136 column line by selecting and running one of the diagnostic 108 10 11 self tests See page 85 Check alignment of the scale to the print at column positions 1 and 136 If adjustment is necessary loosen the three 5 64 inch button head hex screws 2 Position the scale 3 so that column positions 1 and 136 line up with the first and last characters on the 136 character printout Tighten the 5 64 inch button head hex screws 2 Close the printer cover List of Adjustments Legend 1 Shuttle Cover 2 Screw Button Head 5 64 inch hex 3 3 Paper Scale Figure 12 Paper Scale Alignment 109 Chapter 5 Platen Gap Adjustment Platen Gap Adjustment Only do this procedure if the original equipment shuttle frame assembly or platen has been replaced by a new or refurbished unit or if you have been instructed to do so in a troubleshooting procedure Prepare the printer for maintenance page 100 Remove the shuttle cover assembly page 141 Loosen the platen open belt page 104 steps 2 3 and 4 Pa Raise the forms thickness lever 1 to the fully open position Do not force the platen against the feeler gauge and do not move the feeler gauge laterally across the hammer bank 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
47. pedestal models 18 LAN interface assemblies replacement 144 LED ON LINE pedestal models 18 LF key pedestal models 18 Line matrix printing explained 215 LO DRV SHORT 47 LOAD PAPER 48 LOADING PROGRAM FROM PORT 48 LOADING PROGRAM INTO FLASH 48 Magnetic pick up assembly gap adjustment 154 replacement 154 Maintenance adjustments 99 cleaning the printer 25 overview 9 preventive 25 Manual how to use 11 notes and notices 11 printing conventions 12 related documents 13 Memory loading from multiple diskettes 288 loading from one diskette 285 351 Memory modules location and replacement 155 Menus printer test 84 Message display pedestal models 18 Message Display LCD pedestal models 18 Message List troubleshooting 33 Messages asterisk what it means 33 Mnemonics 277 285 Mode auto reset 145 run 145 Models printer 9 Motor paper feed drive replacement 158 platen open replacement 166 ribbon drive replacement 171 MPU See Magnetic pick up assembly 154 N NEXT arrow key pedestal models 18 Noise Suppression 309 Notes and notices 11 ON LINE key pedestal models 18 ON LINE LED pedestal models 18 Operation principles of 215 PAGE L ADJ key pedestal models 18 PAL security location 157 PAP BAD TABLE 48 BSY 49 PAP FIFO OVERFL 49 PAP FIFO UNDRFL 50 PAP ILLGL ST 50 PAP INCMPL 50 352 PAP
48. up to 2438 meters 8000 feet with a non condensing relative humidity of 1096 to 9096 For best results however store the printer paper at 18 to 24 C 65 to 75 F with a relative humidity of 4096 to 50 If the printer is in an environment subject to extremes of temperature or humidity store the printer paper in a better environment and move it to the printer as needed 307 Appendix Summary 308 G 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 Bead P N 141445 001PX is a cylindrical core through and around which the control panel cable assembly is wound Two are required 2 Ferrite Clamp P N 202049 001PX is a noise suppression core in hinged plastic case and attached to the wall of the card cage with adhesive The parallel I O cable assembly passes through this core Figure 55 shows how these devices are installed Duplicate the number of turns around the shielding beads when installing or replacing the control panel cable See Figure 55 309 Appendix Control Panel Cable Assembly Connector Connector O P310 Ee Shielding Bead weis P N 141445 001PX NOTE Two A around each bead Parallel I O Cable Assembly
49. with defective CMX board ERROR EC STOPPED AT STATE XXXX Where XXXX is a number from 0000 to 0010 The Engine Controller has stopped and is in the state identified by the number displayed If the EC stops at state 0000 at power up replace the CMX controller board Record the message and return it with the defective board 1 Power off the printer Remove all flash memory and DRAM SIMMs Inspect the SIMM sockets on the controller board If any socket pins are bent or damaged replace the CMX controller board 2 Install the flash and DRAM SIMMs making sure they are fully and correctly seated Power on the printer Download the emulation page 129 If the message appears replace the flash SIMM s 3 Power on the printer Download the emulation If the message appears replace the DRAM SIMM s 4 Power on the printer Download the emulation If the message appears replace the CMX controller board Record the message and return it with defective CMX board ERROR FLASH DID NOT PROGRAM The printer encountered an error trying to program flash memory Download the program again page 129 If the message occurs again replace the flash memory ERROR FLASH NOT DETECTED The printer could not find flash memory Check flash memory on the CMX controller board If present reseat the flash SIMMs if missing install flash SIMMs ERROR NO DRAM DETECTED The printer could not find an
50. 0762 mm will result in an unreliable and unpredictable form Perforation Intersections Whenever a horizontal perforation intersects with a vertical perforation the point of intersection must be a tie point Cut points at such intersections make the form unacceptable Chaff Content Tractors holes should be clear of chaff As much as possible there should not be loose chaff in the box in which the paper is packed 303 Appendix F _ Form Design Checklist Form Design Checklist 304 Use this checklist to help you remember key areas of consideration when designing and ordering forms and paper stocks Environment Before they are used forms are given at least 24 hours of condensing time in the environment in which they will be used Forms are not stored in environments that result in such damage as delamination of glue lines creasing folding etc Type of Form Form Type Check One 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part lt Carbonless Range gt lt Carbon Range gt Recycled Paper Yes No If yes assure adequate form strength to prevent tractor holes and perforations from tearing or detaching during form feeds and page ejects Security Form Yes No If yes the last page of the form should have a minimum 50 reflectance and if possible the stipled page faces inward to the form Form We
51. 14 Adjust the hammer phasing page 121 15 Return the printer to normal operation page 101 178 Spring Extension Hammer Bank Spring Extension Hammer Bank Do not let the hammer bank rotate toward the platen during spring replacement Removal 1 Prepare the printer for maintenance page 100 Remove the shuttle cover assembly page 141 Unhook the extension spring from the spring lugs on the hammer bank and shuttle frame See page 202 item 4 Installation 1 Apply a dab of bearing lubricant to both spring lugs Do not let the hammer bank rotate toward the platen during spring replacement Make sure the extension spring does not touch the MPU cable after installation 2 Hook the extension spring over the spring lugs See page 202 item 4 3 Install the shuttle cover assembly page 141 4 Return the printer to normal operation page 101 179 Chapter 6 Section Replacement Procedures Switch Assembly Paper Detector Removal 1 Prepare the printer for maintenance page 100 2 Cabinet Models Remove the paper path page 161 Pedestal Models Remove the top cover assembly page 142 3 Cabinet Models Loosen four screws and remove the barrier shield See page 192 items 3 4 and 9 Pedestal Models Loosen the four screws and remove the paper guide and barrier shield See page 194 items 3 4 and 5 4 Remove the two 1 4 inch screws securing the paper detector switch a
52. 2 Included in item 3 7 151910 001PX Rail Stacker 8 163559 001PX Kit Clip 2 9 Ref Screw 4 Part of item 8 187 Section II Illustrated Parts Lists 6 Chapter Figure 30 Control Panel and Cabinet Details 188 Illustrations of Printer Components ltem No Part No Description Notes 1 153700 901PX Control Panel Assembly Includes mounting hardware Does not include language overlay 1 154249 901PX Overlay Kit Cabinet Contains overlays in English French German Italian and Spanish 2 152440 901PX Cable Assembly Control Panel Installed with shielding beads See Appendix G 3 107961 905PX Dashpot Kit Includes ball studs spring clips and mounting hardware 4 Ref Screw w Lock Washer 2 6 32x 375 5 Ref Screw w Lock Washer 3 6 32x2 00 6 150261 901PX Fan Assembly Includes mounting hardware 7 Ref Duct Air Exhaust 189 Section II Illustrated Parts Lists 6 Chapter Figure 31 Pedestal Details 190 Illustrations of Printer Components Item No Part No Description Notes 1 153366 901PX Control Panel Assembly Does not include language overlay 1 154249 902PX Overlay Kit Pedestal Contains overlays in English French German Italian and Spanish 2 Ref Screw Captive 4 3 Ref Screw Captive 2 Part of item 10 4 Ref Lid Pedestal Model Part of item 10 5 Ref Screw 2 6 152440 901PX C
53. 20 21 22 23 24 25 amp 012345 26 27 28 29 BA 2B 2E 2F JO 31 32 33 34 35 6789 gt 7 ABCDE 36 37 38 39 3B 3C 3D 40 41 42 43 44 45 FGHIJK 4 amp 0 4 46 47 48 49 4A OD OA 24 25 26 27 28 29 BA BB 0123456789 2E 30 31 32 33 34 35 37 38 39 B lt gt 35 3D 40 41 42 43 44 45 46 47 48 49 4B LMNOPGRSTUVWXYZUL 4C 4D 4E 50 51 59 53 54 55 55 57 58 59 SA 5B N1 abcdefghijk 5C 50 5 SF 60 61 462 63 64 65 66 67 69 GA 4B imnopqrstuvuxgzt C 6D 6F 70 71 72 73 74 75 76 77 78 79 7 7B 0D BEAR 0s 7C 7D 7E 20 2i 22 23 24 25 26 27 28 29 2A 2B Figure 8 Sample Hex Dump How to Print a Hex Dump How to Print a Hex Dump Step Press LCD Result Notes 1 Make sure the printer is on Raise the printer cover 2 ON LINE OFFLINE CONFIG CONTROL 3 ENTER SWITCH Unlocks ENTER key a x UNLOCKED and control panel OFFLINE CONFIG CONTROL 4 OFFLINE gt T MAINT MISC 5 MAINT MISC S Hex Dump Mode 6 Hex Dump Mode Default S Disable 7 Hex Dump Mode Cycle through choices 4 OF Enable 8 ENTER Hex Dump Mode Asterisk indicates Enable choice is active 9 ENTER SWITCH Locks the ENTER key Y m LOCKED and control panel 10 ON LINE ONLINE Places the printer in LinePrinter online
54. 73 Removing the Constant Force Spring Rail Screw Washer Constant Force Spring Large Washer Spacer Drum Shoulder Screw 329 Appendix _ Replacing the Constant Force Spring 330 5 Lift the loose end of the constant force spring and let it curl up on the outside of the remaining spring and drum See Figure 74 6 While holding the drum tightly continue to curl the spring until it is completely unwound from the drum See Figure 74 7 install a new constant force spring reverse the steps of this procedure Legend 1 Spring 2 Drum Figure 74 Removing the Constant Force Spring from the Drum Replacing the Timing Belts 1 Remove the stacker assembly from the printer See page 312 2 Raise the elevator assembly to its highest position and secure it to the vertical rails using tie wraps or string See Figure 72 page 328 3 If you are removing the left timing belt remove the shoulder screw from the pulley at the bottom of the left vertical rail and remove the pulley See Figure 75 Go to step 6 4 lf you are removing the right timing belt remove the two metric Allen screws that secure the timing belt motor to the right vertical rail See Figure 75 Go to step 5 Legend 1 2 3 4 5 6 7 8 Metric Allen Screw and Washer Right Vertical Rail Timing Belt Motor Stacker Base Bushing Pulley Shoulder Screw Left Vertical Rail Figure 75 Removing the Timin
55. Check for obstructions preventing elevator movement Operate the power stacker and check that a all motors are operating b the paddles are rotating c the elevator moves smoothly and without obstruction the timing belts are undamaged and the belt pulleys are not slipping e the extension springs are attached and undamaged not bent or stretched f the drive rollers are not damaged g the constant force springs are tightly mounted and undamaged Tighten pulley setscrews and or replace damaged components as necessary Adjust the stacker rails if they are not vertical and parallel Check the stacker limit switches See page 71 If the limit switches are OK go to the next step Disable the power stacker unit under the Printer Control menu Refer to the Setup Guide If the message occurs replace the CMX controller board Power off the printer Remove the paper path Disconnect stacker cables from the CMX controller board stacker assembly and the stacker control panel see Figure 59 page 307 Check cables for cuts breaks or damaged pins Check continuity of cables See Appendix A Replace any cable that is damaged or fails continuity test 60 Table 2 Message List List of Messages Message Explanation Solution STACKER FULL Status message the power 1 paper stacker is full 2 Unload the stacker Check the stacker limit switches See page 71 If the limit
56. Components Item No Part No Description Notes 1 163802 901PX 163795 901PX 164216 901PX 2 163789 901PX 163797 901PX 164204 901PX 3 163812 001PX 4 Ref 5 163984 901PX 163984 991 C3201 69203 163985 901PX 163985 991 C3204 69003 157735 901PX 157735 991 C3205 69003 164266 001PX 164267 001PX 164269 001PX 6 157102 901PX 157102 991 C3201 69103 7 Ref 8 Ref 9 157450 901PX 157450 991 C3201 69102 10 202362 001PX 11 152421 901PX 12 152420 901PX 13 164805 901PX 14 202362 001PX 15 152439 901PX 16 Ref 17 150399 901PX continued on next page Hammer Bank Cover Hammer Bank Cover Hammer Bank Cover Ribbon Mask 500 Ribbon Mask 1000 Ribbon Mask 1500 Ribbon Mask Clamp Plate Screw Torx T 10 500 Shuttle Assembly Spare 500 Shuttle Assembly Advance Exchange 500 Shuttle Assembly Europe only 1000 Shuttle Assembly Spare 1000 Shuttle Assembly Advance Exchange 1000 Shuttle Assembly Europe only 1500 Shuttle Assembly Spare 1500 Shuttle Assembly Advance Exchange 1500 Shuttle Assembly Europe only Hammer Spring Assembly Field Kit Hammer Spring Assembly Field Kit Hammer Spring Assembly Field Kit Power Supply Spare Power Supply Advance Exchange Power Supply Europe only P101 Cable Connector Cable Assembly AC In Power Supply CMX Controller Spare CMX Controller Advance Exchange CMX Controller Europe only Connector Kit P106 P107 Hammer Bank Logic Cable Assembl
57. DC program is larger than the amount of DRAM in the printer If so it displays the message ERROR PROGRAM NEEDS MORE DRAM Tell EC Processor to Finish Booting Boot code informs the EC processor that everything is okay and can finish booting up Diagnostics Passed If all tests pass boot code displays DIAGNOSTICS PASSED At this point the ribbon motors engage Boot code then jumps to the start address of the DC software Display DC Program Information Boot code sends the following information out the debug port the compile time date and the address it will jump to to start the DC program Waiting Ethernet If boot code earlier detected an Ethernet adapter it places the message WAITING FOR THE ETHERNET ADAPTER on the LCD so the user will not think the printer has crashed Jump Back into Flash and Clear DRAM Boot code jumps back into flash memory then clears the DRAM that held the boot code 97 Chapter 4 Power On Sequence e Jump to MTOS Jump to start initialization of the MTOS Multi Tasking Operating System DC Software Initialization and Power Up The final part of the power up sequence is initialization and startup of the DC software which occurs in the following order e Clear Uninitialized RAM Variables e Setlnitialized RAM Variables e Configure RAM allocated based upon amount in the printer e Jump to MTOS Multi Tasking Operating System e initialize the Process
58. Feeler Gauge Hammer Bank Cover Ribbon Mask Set Screw 3 32 inch hex 2 SHE Figure 13 Platen Gap Adjustment 111 Chapter 5 Platen Open Motor Pulley Alignment Platen Open Motor Pulley Alignment 1 Prepare the printer for maintenance page 100 2 Cabinet Models Go to step 3 Pedestal Models Remove the top cover assembly page 142 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 Loosen the 1 16 inch set screw 2 in the motor pulley Bottom out the platen open motor pulley 3 on the motor shaft and tighten the 1 16 inch set screw 2 Check the platen open belt tension page 104 Adjust if necessary Snap the platen open belt cover 1 into the slots in the side plate Cabinet Models Go to step 9 Pedestal Models Install the top cover assembly page 142 9 Return the printer to normal operation page 101 112 List of Adjustments Legend 1 Belt Cover 2 Set Screw 3 Platen Open Motor Pulley 4 Platen Shaft Pulley Figure 14 Platen Open Motor Pulley Alignment 113 Chapter 5 Ribbon Guide Alignment Ribbon Guide Alignment 114 Open the printer cover Load paper and install the ribbon To align a ribbon guide wind the ribbon fully onto the ribbon spool on the opposite side For example to align the left ribbon guide wind the ribbon until the right ribbon spool is full Chec
59. Motion Detector Switch POD Paper Out Detect Switch NOTE For cable shell connector assembly and disassembly see page 131 CVO Cover Open Switch EHF Exhaust Fan HBF Hammer Bank Fan MPU Magnetic Pickup PAPR M Paper Feed Motor PLO Platen Open Switch RRIB M Right Ribbon Motor RRP Right Ribbon Guide Only in cabinet models 237 862 2 P m pe 1 BE 2 SS 0 4 p Bo Bu 3 1
60. P02 page 202 items 5 and 6 To prevent electrostatic damage to electronic components always wear a properly grounded static wrist strap when you handle the shuttle frame assembly 4 Disconnect the hammer drive and hammer logic cable connectors from the terminator board on the shuttle frame assembly See page 198 5 Loosen the side 5 32 inch socket head clamp screws on each end of the shuttle and pull the clamps back and off the guide shaft Do not remove the clamps Hand tighten the clamp screws to hold the clamps back 6 Loosen the center 5 32 inch socket head screw enough to release the shuttle frame assembly from the base casting 7 Unlock and slide the tractors outward as far as they will go on the tractor support shaft Open the forms thickness lever all the way Grasping the support legs cast on both sides of the shuttle motor lift the shuttle frame assembly out of the base casting Lift the shuttle frame assembly slowly and carefully it is heavy 177 Chapter 6 Section Replacement Procedures Installation 1 Install the hammer bank ribbon mask cover assembly if it was removed page 139 To prevent electrostatic damage to electronic components wear a properly grounded static wrist strap when you handle the shuttle frame assembly 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
61. PIN 7 YEL SIN 8 N C SIN PIN 9 PIN 9 GRN PIN 10 N C PIN 10 TAN 262 Power Cable Power Stacker 158443 001 263 Appendix Vertical Rail Cable Power Stacker 158442 001 mmm 1 264 Fan Assembly Hammer Bank NId yvig 2 AlIHV lOd dH 24 MOTA 106 91 291 a 2 38H 7014 265 Magnetic Pickup MPU Assembly 150281 901 266 Switch Assembly Paper Detector 152415 901 267 Appendix Switch Assembly Platen Interlock 152417 901PX COM PIN 2 By e A D 2 b NE 2 ee E m 1 P WIRE TABLE PIN NO INTERLOCK SWITCH i e COLOR PIN 1 COM BLACK NO PIN 2 NO GRAY 268 Printer Specifications Regulatory Information Ribbon Specifications Use only these Hewlett Packard ribbon kits Kit No Ribbon Type Qty Kit Part No C3207A 60 yard text ribbon 6 C3207 60001 C3208A 100 yard text ribbon 6 C3208 60001 C3209A 60 yard bar code OCR ribbon 6 C3209 60001 C3210A 100 yard bar code OCR ribbon 6 C3210 60001 C3212A 60 yard security ribbon 1 C3212 6000
62. Power Stacker Frame Cable Power Stacker Figure 69 page 325 See page 288 See page 287 See page 286 See page 285 337 Appendix H Illustrated Parts Breakdown From page 336 15 15 See page 340 51 M See page 342 See page 344 2 4 0 See 344 AI e Figure 81 Elevator Detail Motor Roller and Paddle Assemblies 338 Item No Part No Description Notes 40 158313 001PX Anti Static Brush 45 Ref Shear Grommet Part of item 36 46 Ref Cap Nut Part of item 36 47 156391 001PX Shaft Drive Roller 48 156393 001PX Spacer Drive Roller 49 202789 901PX Bearing Flanged Part of item 36 50 202824 901PX Bearing Part of item 36 51 202708 001PX Collar Clamp 52 Ref Collar Setscrew Part of item 36 53 156390 001PX Support Shaft 54 171209 001PX Fence Wireform 55 203032 001PX Extension Spring 60 157275 001PX Idler Roller Five on early models 65 157054 001PX Paddle Power Stacker 70 170306 001PX Power Stacker Pivot Arm Field Kit Early models only not illustrated 339 Appendix H Illustrated Parts Breakdown Figure 82 Stacker Detail Rollers Item No Part No Description Notes 75 80 85 90 159425 001PX 156392 901PX Ref 157960 001PX Compression Spring Friction Washer Flanged Bushing Drive Roller On left end of shaft on early models Part of item 36 Part of item 36 Five on early models 34
63. Shaft Kit Includes items 1 2 3 4 5 15 and 17 20 155182 901PX Paper Support 21 Ref Bushing Part of item 18 205 Chapter 6 Section II Illustrated Parts Lists NOTE Black tape faces paper motion 3 detector NOTE Item 25 Platen Hardware Kit Figure 38 Platen 206 Illustrations of Printer Components ben Part No Description Notes 1 Ref Setscrew 2 Part of item 25 2 Ref Bracket Platen 2 Part of item 25 3 150957 901PX lroner Paper 4 Ref Screw Thread forming 3 6 32x 25 5 Ref Bracket 6 Ref Plate Ironer 7 112657 901PX Platen Assembly 8 Ref Washer Flat 2 Part of item 25 9 Ref Screw 2 Part of item 11 10 Ref Washer Flat 4 2 Part of item 11 11 152417 901PX Platen Switch Kit Includes items 9 10 19 12 Ref Screw Socket Cap 6 32x 75 Part of item 15 13 Ref Washer Part of item 15 14 Ref Nut Part of item 15 15 154650 901PX Platen Lever Kit Includes items 12 13 14 16 Ref Spring Extension 1 12L Part of item 25 17 Ref Link Spring Part of item 25 18 Ref Bearing Nylon 376 Part of item 25 19 Ref Bracket Switch Mount Part of item 11 20 Ref Wear Saddle Platen 2 Part of item 25 21 150703 902PX Platen Pulley Drive 22 Ref Screw Socket Cap 6 32x 44 Part of item 21 23 141516 901PX Belt Timing 080 Pitch 312 Wide Platen Open Belt 24 153488 001PX Platen Paper Feed Cover Kit Cover belt platen open shown 25 153430 001PX Platen Hardware Kit Includes items 1 2 8 1
64. The power supply has failed Replace the power supply board RESTORING BOOT CODE Normal download initialization message No action required RIB INVLD CMD Ribbon Invalid Command Firmware error on the CMX controller board 1 Oycle power Run the print job again If the message appears download the emulation software again 2 Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board 55 Chapter 4 Troubleshooting Display Messages Table 2 Message List Message Explanation Solution RIB INVLD STATE Ribbon Invalid State Firmware error on the CMX controller board 1 Oycle power Run the print job again If the message appears download the emulation software again 2 Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board RIBBON DRIVE The CMX controller board does not detect a ribbon drive motor 1 Oycle power If the message appears power off the printer Remove the paper path or pedestal top cover Reseat the cable connections of both ribbon drive motors 2 Power on the printer Using a screwdriver short across the ribbon guide screws to reverse ribbon hub motion Check for a ribbon drive motor that will not wind the ribbon If the ribbon will not win
65. always wear a properly grounded static wrist strap when you handle circuit boards 1 Position the controller board 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 the right until the serial cable connector J201 on the controller board lines up with the cutout in the card cage See page 198 2 Tighten the two screws securing the controller shield near serial cable connector J201 3 Tighten the screw securing the controller shield to the bottom of the card cage 4 Connect all cable connectors to the controller board using the Interconnection Diagram in Appendix A as your guide 5 Cabinet Models Install the paper path page 161 Pedestal Models Install the top cover assembly page 142 If the original CMX board was replaced you must download the emulation software again Installing flash memory from the old board onto the new board does not transfer all operating system software Load flash memory See Appendix D 500 lpm models only set shuttle speed if the original CMX board was replaced page 123 Adjust the hammer phasing page 121 Adjust the paper out distance page 117 10 Using the configuration printout s you made as step 1 of the removal procedure reset and save the printer configuration s Refer to the User s Guide 138 Cover Assembly Hammer Bank Ribbon Mask C
66. 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 NO LineJet 5000 hammer ban Coils Magnet Pole Pieces Hammer Spring Assemblies ungsten Carbide Hammer Tip 227 ammer spring Assembly Alignment Fin 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 a hammer must print a dot a current pulse energizes the coils behind it 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 an impression of its tip a dot on the paper While the hammer is in flight the coils are de energized and their magnetic 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 219 Chapter 7 Printing Mechanism Paper Transport System Paper Path m cl Tractors Vertical Horizontal 2 a 24 Splined Kb nn oe M
67. assembly page 142 3 Cabinet Models Loosen four screws and remove the barrier shield See page 192 items 3 4 and 9 Pedestal Models Loosen the four screws securing the paper guide and barrier shield and remove both See page 194 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 Loosen do not remove the two 5 16 inch motor mount bolts 2 Push the motor 3 toward the rear of the printer until there is 1 8 inch deflection of the belt midway between the pulleys then tighten the two 5 16 inch mount bolts Snap the timing belt cover 1 into the slots in the side plate Cabinet Models Install the barrier shield and tighten the four screws See page 192 items 3 4 and 9 Pedestal Models Install the barrier shield and paper guide and tighten the four screws See page 194 items 3 4 and 5 9 Cabinet Models Install the paper path page 161 Pedestal Models Install the top cover assembly page 142 10 Return the printer to normal operation page 101 102 List of Adjustments Legend 1 Timing Belt Shield 2 Motor Mount Bolt 2 3 Paper Feed Drive Motor 4 Splined Shaft Figure 9 Paper Feed Timing Belt Adjustment 103 Chapter 5 Platen Open Adjustment Belt Platen Open Adjustment 1 Prepare the printer for maintenance page 100 2 Cabinet Models Remove the paper path pa
68. between copies of a form Hard or wire brads and staples must not be used Any attachment must not coincide with the major perforation or any horizontal perforation Gluing Gluing must be controlled and uniform since it is a major contributor to the maximum form thickness A form that meets the maximum forms thickness requirement in the print area but which exceeds the maximum thickness at a glue line is considered an unreliable and unpredictable form Staples Staples must be used only in the margin area of the form and must not be in line with the path of the tractor holes Ideally staples are placed in the margins so that they coincide with areas of the form where printing does not occur The figure below shows acceptable and unacceptable ways of fabricating staples Chaff Content Preferred Unacceptable Tie Point Cut Point Direction of Forms Movement Cut S Tie Point Cut to Tie Ratio A common cut to tie ratio for bond forms is 4 1 that is 80 cut to 20 ties This value is dictated chiefly by the application program that the form runs under Lower cut to tie ratios will yield better form handling but stacking may suffer due to increased stiffness of the perforations Some level of experimentation is required to determine the best cut to tie ratio But remember that a cut to tie ratio that causes a thickness buildup greater than 0 025 inch 0 635 mm or that creates an evenness variation greater than 0 003 inch 0
69. does not initialize NOTE Power on initialization is explained on page 94 1 Power off the printer Remove the paper guide or pedestal top cover Reseat all cable connectors on the CMX controller board especially connectors P106 and P107 Power up the printer If the fans run but the printer does not initialize replace the power supply board Power up the printer If the fans run but the printer does not initialize replace the CMX controller board 67 Chapter 4 Troubleshooting Other Symptoms Table 3 General Symptom List Symptom Solution Power Stacker Printer does not detect presence of power stacker Check that the power stacker is enabled under the Printer Control menu Refer to the Setup Guide If the power stacker enable disable option does not appear in the menu go to the next step Open the rear cabinet door Check that the ON OFF indicator lamp is lit If the ON OFF indicator is not lit go to step 3 If the ON OFF indicator is lit press the ON LINE key and check that the ON LINE indicator lights If the ON LINE indicator comes on the stacker is detected by the printer If the ON LINE indicator does not come on go to step 4 a Power off the printer b Unfasten the cable clamp holding the stacker control panel cables Disconnect the stacker power cable from the back of the stacker control panel See Figure 59 page 307 d Locate pin 1 of connector P106 See the ca
70. installed when the angled ends of the ribbon mask match the angled ends of the hammer bank cover Install the three clamp plates and six screws finger tight Using a Torx T 10 driver tighten the six screws in the sequence shown in Figure 20 Install the shuttle frame assembly page 177 Return the printer to normal operation page 101 139 Chapter 6 Section Replacement Procedures Ribbon Mask Tightening Sequence Bank Ribbon Mask Hammer Bank Cover Clamp Plate 3 Figure 20 Hammer Bank Cover Assembly Ribbon Mask 140 Cover Assembly Shuitle Cover Assembly Shuttle Removal 1 Prepare the printer for maintenance page 100 Loosen the shuttle cover screws page 192 item 2 Grasping the edges of the shuttle cover assembly tilt the rear edge up and lift the shuttle cover assembly out of the printer Installation 1 Place the shuttle cover assembly in the printer Tilt the forward edge of the cover down slightly and work the cover into position Make sure the holes in the cover are over the locating pins on the base casting 2 Tighten the shuttle cover screws page 192 item 2 3 Return the printer to normal operation page 101 141 Chapter 6 Section Replacement Procedures Cover Assembly Top Pedestal Models Removal 1 Prepare the printer for maintenance page 100 2 Loosen but do not remove the two 2 Phillips hold down screws on the rear of the
71. is now being deleted from flash memory No action required 37 Chapter 4 Troubleshooting Display Messages Table 2 Message List Message Explanation Solution CLOSE PLATEN open The forms thickness lever is 1 Load paper Close the forms thickness lever Power off the printer Remove the paper path or pedestal top cover Disconnect connector P107 from the controller board Check continuity of the platen interlock switch from P107 PLO to the switch Replace the switch assembly if it fails the continuity test Refer to Appendix A Switch Assembly Platen Interlock Tighten the screws securing the platen interlock switch Check and adjust the platen open belt Replace the belt if it is damaged Bottom out the platen open motor pulley on the motor shaft and torque the 1 16 inch set screw to 9 2 inch pounds 1 02 0 23 Nem Tighten the 7 64 inch setscrew in the platen shaft pulley then open and close the forms thickness lever and check that the platen pulley setscrew does not hit the left ribbon guide Disconnect connector P106 from the controller board Check the resistance of connector P106 PLAT M See the Main Wire Harness Test Tables in Appendix A Replace the platen open motor if it fails the resistance test Run a print test If the message appears replace the CMX controller board Record the message and return it with the defective board
72. not remove the two 5 16 inch mounting screws of the platen open motor page 208 item 15 5 Push the motor toward the front of the printer to loosen the platen open belt 6 Loosen the 1 16 inch setscrew in the platen open motor pulley and remove the pulley See page 208 item 6 7 Remove the platen open belt by sliding the belt off the platen open pulley Installation 1 Slide the platen open timing belt over the platen open pulley and the motor pulley 2 Slide the motor pulley onto the platen open motor shaft and tighten the 1 16 inch pulley setscrew 3 Finger tighten the two 5 16 inch screws securing the platen open motor 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 4 While pulling the platen open motor toward the rear adjust the belt tension to 1 8 inch deflection midway between the pulleys tighten the upper motor mount screw with a 5 16 inch nutdriver Tighten the lower 5 16 inch with an open end wrench Check the deflection of the platen open belt again after the mount screws are tight Snap the platen open belt cover into the slots in the side plate Cabinet Models Install the paper path page 161 Pedestal Models Install the top cover assembly page 142 7 Return the printer to normal operation page 101 129 Chapter 6 Section Replacement Procedures Circuit Bre
73. of the form Must not use hard brads or staples Must not coincide with major perforation or any horizontal perforation Gluing lines must not result in a form that exceeds 0 025 in 0 0635 cm thickness Staples must be used only in margin area of form Staple cuts must not be in the direction of form movement through the tractors Staples must not occur in line with the path of the tractor holes Staples should be placed in the margins so that they coincide with areas of the form where printing will not occur Cut to Tie Ratio Typical ratio is 4 1 or 80 cut to 20 tie 305 Appendix F _ Form Design Checklist 306 Thickness Buildup in cm NOTE A cut to tie ratio that causes a thickness buildup greater than 0 025 0 0635 cm or that creates an evenness variation greater than 0 003 in 0 00762 cm will result in an unreliable and unpredictable form Perforation Intersections Horizontal vertical perforations are tie points Cut points at such intersections are unacceptable Chaff Content Tractor holes are clear of chaff There is no loose chaff in the box the paper is packed in Storage and Handling Summary Because it is impossible to test all possible forms available for use in the printer Hewlett Packard recommends that paper conform to the specifications outlined in this appendix for the best printer performance But the guidelines in this appendix are not a substitute for act
74. on the LCD Key combinations are denoted by the plus symbol Example Press means Press the A UP key and the Y DOWN key at the same time 12 Related Documents Related Documents This manual does not explain how to set up operate or configure the printer That information is covered in the following manuals LineJet Printers User s Guide Part Number 171252 001PX Explains how to configure the printer and provides simple troubleshooting guidelines LineJet Printers Cabinet and Pedestal Model Installation Instructions Part Number 171253 001PX Explains how to set up the printer for operation LineJet Printers Quick Reference Guide Part Number 171248 001PX Describes the keys on the control panel and provides quick reference information on daily printer operations such as loading paper and replacing ribbons LineJet Printers PCL Il LinePrinter Plus Technical Reference Manual Part Number 171249 001PX Describes the host control codes and character sets for the LinePrinter Plus and PCL II emulations LineJet Printers QMS Code V Technical Reference Manual Part Number 171251 001PX Explains how to write graphics programs using the optional QMS Code V Printronix emulation This graphics programming language allows the user to create and store forms generate logos bar codes and expanded characters create graphic images and merge graphics with alphanumeric data as a document is printe
75. pedestal models 136 Controller board principles of operation 224 replacement 137 Controls and indicators pedestal models 18 printing conventions 12 Cores Noise Suppression 309 Cover assembly hammer bank ribbon mask replacement 139 shuttle replacement 141 top pedestal models 142 CT board replacement 147 CTL VOLT FAIL 40 Cycle power 93 D Dashpot replacement 143 Data controller DC 226 DC Data Controller CMX board 226 Diagnostic menus operator print 84 DIAGNOSTIC PASSED 40 Diagnostics 10 100Base T 145 Diagrams cable routing 233 interconnection and cables 233 Dipswitches 350 10 100Base T 146 Display LCD pedestal models 18 Display messages printing conventions 12 Documents related to this manual 13 DOWN arrow key pedestal models 18 Downloading software from multiple diskettes 288 from one diskette 285 DRVR CIR 40 E EC Engine Controller CMX board 229 Electrical characteristics 271 Emulation software loading from multiple diskettes 288 loading from one diskette 285 Engine controller EC 229 ENTER key pedestal models 18 Environmental characteristics 271 ERROR DC PROGRAM NOT VALID 40 DRAM AT ADDRESS 40 EC PROGRAM NOT VALID 41 EC STOPPED AT STATE 41 FLASH DID NOT PROGRAM 41 FLASH NOT DETECTED 41 NO DRAM DETECTED 41 NVRAM FAILURE 41 PROGRAM NEEDS MORE DRAM 41 PROGRAM NEEDS MORE FLASH 42 PROGRAM NOT COMPATI
76. points measured across the print area i e between the side perforations Form Thickness Thickness measured at the thickest point of the entire form Margin Print Area Print Station Staple Tenting Tie Point This includes glue lines compressed staples perforations etc and is not limited to the printed region of the form The region outside the print area of the form The margin is typically bounded by the outermost vertical perforations i e where the tractor holes are located and the edge of the form The region where printing occurs and which is always between the side perforations The area in the printer where the actual impacts that constitute printing occur A punch cut fastening stitch located along the vertical edge and within the side perforation region of a multipart form Note that this is not a metal staple The measured thickness between the print area of the form and the peak thickness of a major perforation Tenting is typically caused by overly stiff perforations or incorrect registration of the inner parts of multipart forms The area along a perforation between the cut points see above 299 Appendix F _ Paper Guidelines 300 The figures below illustrate the terms used in this appendix Side Perforation Margin Area PA od Tractor Pin Hole Major Perforation 5 Print Area Q PN Form Span Figu
77. prevent galling 2 Open the forms thickness lever and move the tractors as far left and right as possible 3 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 198 4 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 5 Pull the shuttle frame assembly toward the front of the printer and hold it in this position while you do step 6 Do not over tighten the shuttle frame assembly clamp screws d 6 Slide the side clamps over the guide shaft and tighten the 5 32 inch socket head clamp screws Tighten the center captive 5 32 inch socket head screw Connect the hammer drive and hammer logic cable connectors to the terminator board on the shuttle frame assembly 9 Connect the shuttle motor cable connector See page 202 item 6 10 Route the MPU cable under the extension spring and connect the MPU cable connector See page 202 item 5 Make sure the MPU cable does not touch the extension spring after it is connected 11 If the shuttle assembly is a new or refurbished unit adjust the platen gap page 110 otherwise skip to step 12 12 Install the shuttle cover assembly page 141 13 500 models only set shuttle speed if original shuttle frame assembly was replaced page 123
78. print area Form Evenness The evenness of forms must not exceed 0 003 inches 0 00762 cm across the print area between the side perforations Tenting caused by buildup of perforation thickness must be minimized A perforation thickness measured at the major perforation that exceeds 1 25 times the forms thickness measured in the print area will result in an unpredictable and unreliable form The perforation thickness must never exceed the maximum forms thickness of 0 025 inches 0 0635 cm Tractor Pin Engagement The printer uses tractors with 6 pin engagement Detailed engagement specifications are given in ISO 2784 but are summarized in the table below 301 Appendix F _ Paper Guidelines 302 Specification Inches Millimeters Hole centerline CL to edge of form 0 236 0 028 6 0 0 1 Hole Diameter Serrations or any 0 156 0 004 4 0 0 1 occlusion due to incorrect registration of multipart forms cannot exceed this dimension Distance between centers of two 0 500 0 002 12 7 0 05 consecutive holes Maximum deviation of holes from their 0 004 0 1 centerline Maximum deviation of lefthand hole to 0 006 0 15 adjacent righthand hole CL to CL Maximum parallel deviation of lefthand 0 006 0 15 hole CL to righthand hole CL Methods of Forms Attachment Any method of attachment staples crimps gluing etc must be designed in a way that does not permit air to be trapped
79. printer See page 190 item 5 Open the printer cover Loosen the four captive 1 Phillips screws until the control panel is released from the printer top cover See page 190 items 1 and 2 Set the control panel assembly on the shuttle cover assembly 5 Loosen the two captive 2 Phillips screws in the lower front corners of the top cover See page 190 item 3 6 Liftthe top cover assembly off the printer base Installation 1 Reverse steps 2 through 6 of the removal procedure 2 Return the printer to normal operation page 101 142 Dashpot Dashpot Two persons may be required to do this procedure Prop or hold the printer cover securely while disengaging the dashpot This procedure applies only to cabinet models Removal 1 Prepare the printer for maintenance page 100 2 Open the cabinet rear door 3 Pry back the spring retaining clips See Figure 30 page 188 4 Remove the dashpot from the ball studs Installation The dashpot must be installed with the large cylinder in the uppermost position Two persons may be required to do this procedure Prop or hold the printer cover securely while installing the dashpot 1 Position the dashpot against the ball studs on the upper and lower brackets See Figure 30 page 188 The large cylinder must be uppermost 2 Using external grip ring pliers to spread the retaining clips push the dashpot onto the ball joints and slide the spr
80. pulley page 206 items 21 and 23 Install the paper ironer with the black tape towards the rear of the printer page 206 item 3 Install the shuttle frame assembly page 177 Adjust the platen gap page 110 Adjust the platen open belt page 104 Check ribbon guide alignment page 114 Check the hammer phasing page 121 Return the printer to normal operation page 101 165 Chapter 6 Section Replacement Procedures Platen Open Motor Removal 1 Prepare the printer for maintenance page 100 2 Cabinet Models Remove the paper path page 161 Pedestal Models Remove the top cover assembly page 142 Cabinet Models Remove the card cage fan page 148 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 206 item 24 Loosen the two 5 16 inch motor mount screws page 208 item 15 Loosen the 1 16 inch hex pulley setscrew and remove the motor pulley and platen open belt 7 Trace the platen open motor cables back to connector P106 on the controller board releasing the cables from all tie wraps See cable routing diagrams in Appendix A 8 Remove the platen open cable connector from connector P106 See page 132 Some platen open motors are mounted with nuts and bolts other motors have threaded flanges eliminating the need for nuts 9 Remove the two 5 16 inch motor mount screws and nuts if present
81. shuttle cover and another is printed on the paper scale A horizontal scale graduated in tenths of an inch useful for setting paper margins and counting text columns See below 20 Related Documents Legend 1 Tractor Lock Horizontal Adjustment Knob Left Tractor Paper Supports Right Tractor Vertical Position Knob Forms Thickness Lever Forms Thickness Pointer Ribbon Loading Diagrams Figure 3 Mechanical Controls and Indicators All Models 21 Chapter 1 Tools Test Equipment and Supplies Tools Test Equipment and Supplies The tools and equipment required for field level maintenance of the printer are listed below Alcohol Anhydrous Allen Wrench 1 16 inch Allen Wrench 3 32 inch Allen Wrench 5 64 inch Allen Wrench 7 64 inch ESD Wrist Strap Feeler Gauge 010 inch Feeler Gauge 011 inch Feeler Gauge 040 inch Grip Ring Pliers External Lubricant Bearing Lubriko M 3 Master Lubricants Co P N101805 001 PX Nut Driver 1 4 inch Nut Driver 5 16 inch Nut Driver or Open End Wrench 7 32 inch Open End Wrench 5 16 inch Screwdriver Philips 1 Screwdriver Philips 2 Spring Hook Heavy Duty Tie Wraps 4 inch Torx T 10 Driver 22 2 Installation Installation To install and configure the printer refer to the following documents e LineJet Printers Cabinet and Pedestal Model Installation Instructions Part Number 171253 001P
82. switches are OK go to the next step Power off the printer Remove the paper path Disconnect stacker cables from the CMX controller board stacker assembly and the stacker control panel see Figure 59 page 307 Check cables for cuts breaks or damaged pins Check continuity of cables See Appendix A Replace any cable that is damaged or fails continuity test STACKER JAM Paper is bunching above the 1 elevator or the paper motion 2 detector is not working properly Remove the paper jam Power off the printer Check that the wheel of the stacker paper motion detector rests against the rear brace of the paper throat Also make sure the wheel rotates freely If necessary gently bend the brace toward the paper motion detector wheel until the wheel contacts the brace Clean the stacker paper motion detector Power on the printer Operate the power stacker and check that a all motors are operating b the paddles are rotating c the elevator moves smoothly and without obstruction d the timing belts are undamaged and the belt pulleys are not slipping e extension springs are attached and not bent or stretched f drive rollers are not damaged Tighten setscrews and replace damaged components as necessary Power off the printer Remove the paper path Disconnect stacker cables from the CMX controller board stacker assembly and stacker control panel Check cables for cuts breaks or damaged pins
83. the message and return it with defective board PAP INVLD PARM Paper Invalid Parameter 1 Firmware error on the CMX controller board Cycle power Run the print job again If the message appears download the emulation software again Cycle power Run the print job again If the message appears replace the controller board Record the message and return it with defective board PAP NOT SCHED Paper Not Scheduled The 1 paper feed process is not scheduling on the CMX controller board and the printer 5 cannot feed paper Cycle power Run the print job again If the message appears download the emulation software again Cycle power Run the print job again If the message appears replace the MPU cable assembly Power on the printer Run the print job again If the message appears replace the power supply board Power on the printer Run the print job again If the message appears replace the shuttle frame assembly Power on the printer Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board PAP NT AT SPEED Paper Not At Speed Firmware 1 error on the CMX controller board Cycle power Run the print job again If the message appears download the emulation software again Cycle power Run the print job again If the message appears replace the contro
84. the boot sequence Automatic EC Update Boot code checks whether the automatic EC update feature is enabled by the DC program If so it looks for a copy of the EC program in the Flash File System If it has a copy it compares the program in EC flash to the program in the Flash File System and updates the EC program if they are different If the automatic EC update was not enabled or if any key was held down during power up automatic EC update is skipped and the boot sequence continues normally Debug SIMM The debug SIMM contains fast static RAM that automatically replaces the flash memory Boot code checks for the debug SIMM and if found copies the contents of flash memory into the SIMM then remaps the address of the SIMM to the location of flash This allows breakpoints single stepping from the MTOS debugger When the debug SIMM is found boot code displays DEBUG SIMM ACTIVATED on the panel and out the debug port Verify DC Program Boot code calculates a checksum at every power up to verify that the program has not been corrupted If the checksum does not match boot code displays ERROR DC PROGRAM NOT VALID Check Security The security check verifies that security PAL supports the software that is loaded in flash memory If the PAL does not support the software boot code displays SECURITY CODE VIOLATION Check Required DRAM Boot code checks whether the amount of DRAM required to run the
85. the drag motor is loaded and monitored to maintain correct linear speed and tension The platen 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 motor is driven by a stepping motor controller IC and the EC processor Control of the 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 EC uses the MECA ASIC on the controller board to set timing and upper drive profiles for hammer fire events 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 controller s upper drive Power Supply Board 230 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 can operate anywhere in the world on local comm
86. the host to the printer Check the parallel cable connection at J112 on the CMX controller board Inspect all cables for damaged bent broken or burnt pins Replace any damaged cables Reconnect all I O cables make sure all connections are clean and tight 2 Remove the flash SIMMs Inspect the flash SIMM sockets on the CMxX controller board If any socket pins are bent or damaged replace the CMX controller board 3 Check that customer has the right size SIMMs for the emulation See page 166 Install SIMMs that support the emulation software 4 Power up the printer Download the emulation page 129 If the download fails activate the Boot Diagnostics Menu page 87 and run MISC UTILITIES RUN MEMORY TESTS If memory fails test replace the DRAM If memory tests OK replace the flash SIMM s 5 Power up the printer Download the emulation page 129 If the download fails replace the CMX controller board Flash SIMM won t copy 1 Power off the printer Remove the flash SIMMs Inspect the flash SIMM sockets on the CMX controller board If any SIMM socket pins are bent or damaged replace the CMX controller board 2 Make sure the blank SIMM is the same size as the SIMM to be copied Install the SIMMs making sure they are fully and correctly seated Power on the printer From the Boot Diagnostics menu select and run MISC UTILITIES COPY FLASH SIMMS See page 87 If the DESTINATION NOT DETECTED message appears th
87. the message appears replace the shuttle frame assembly Power on the printer Run the print job again If the message appears replace the power supply board Power on the printer Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board PAP ILLGL ST Paper Illegal State Firmware 1 error on the CMX controller board Cycle power Run the print job again If the message appears download the emulation software again Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board PAP INCMPL ENER Paper Incompletely Energized 1 Firmware error on the CMX controller board Cycle power Run the print job again If the message appears download the emulation software again Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board 50 Table 2 Message List List of Messages Message Explanation Solution PAP INVLD CMD Paper Invalid Command 1 Firmware error on the controller board Cycle power Run the print job again If the message appears download the emulation software again Cycle power Run the print job again If the message appears replace the controller board Record
88. 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 Printer Interface The printer interface is the point where the data cable from the host computer plugs into the printer The printer interface processes all signals and data to and from the host computer The printer is equipped with Centronics parallel 232 serial and EIA 422B serial interfaces The interfaces are mounted on the CMX controller board and the interface cable connectors are accessible through a cutout at the rear of the card cage These interfaces accept data in the U S ASCII protocol Selection of the interface is controlled by configuration menus accessed at the control panel It is possible to physically connect more than one interface but only one interface at a time can be used electrically 231 Chapter 7 Graphics Graphics The Code V Il programming language a QMS graphics emulation and the PGL Advanced Graphics 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 The languages enable the printer to print sideways upside down and to make forms comb
89. to dot row or line to line Take the printer offline and print a test pattern of All H s If characters shift left or right from line to line there might be a proportional spacing problem If the pattern of H s prints correctly that is all the columns line up contact your support group or configuration help desk because a configuration change may be necessary If the pattern of H s did not print OK go to the next step Check the hammer phasing Adjust hammer phasing if necessary If the printer is a a 500 lpm model check the shuttle speed setting Set the shuttle speed page 132 Inspect the shuttle frame assembly area for ink residue paper chaff or debris Clean the shuttle frame assembly Check the MPU gap 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 7 16 inch MPU clamp screw to 18 1 inch pounds 2 03 0 11 Nem Power up the printer Run a print test If the symptom is not gone replace the MPU Power up the printer Run a print test If the symptom is not gone replace the CMX controller board Power up the printer Run a print test If the symptom is not gone replace the shuttle frame assembly Randomly misplaced dots Power off the printer Check the platen gap Adjust the platen gap if necessary Remove the paper guide assembly or pedestal top cover On the left rear wall of the card cage make sure the nut wh
90. to cause harmful interference in which case the user will be required to correct the interference at his own expense Properly shielded and grounded cables and connectors must be used in order to meet FCC emission limits Hewlett Packard Company is not responsible for any radio or television interference caused by using other than recommended cables and connectors or by unauthorized changes or modifications to this equipment Unauthorized changes or modifications could void the user s authority to operate the equipment This device complies with Part 15 of the FCC Rules Operation is subject to the following two conditions 1 this device may not cause harmful interference and 2 this device must accept any interference received including interference that may cause undesired operation Canadian Department of Communications Compliance Statement This Class A digital apparatus meets all requirements of the Canadian Interference Causing Equipment Regulations Avis de conformit aux normes du minist re des Communications du Canada Cet appareil num rique de la classe A respecte toutes les exigences du R glement sur le mat riel brouilleur du Canada European Union EC Electromagnetic Compatibility Directives This product is in conformity with the protection requirements of EC Council Directive 89 336 EEC on the approximation of the laws of the Member States relating to electromagnetic compatibility Hewlett Packard Company cannot
91. 0W 244W 380W 514W Non Printing 90W 84W 86W 84W 271 Appendix _ Material Safety Data Sheets Current LineJet 500P LineJet 500Q LineJet 1000Q LineJet 1500Q Heat Printing Typical 648 BTU hr 652 BTU hr 925 BTU hr 1342 BTU hr Printing maximum 1092 BTU hr 833 BTU hr 1297 BTU hr 1754 BTU hr Non Printing 307 BTU hr 287 BTU hr 294 BTU hr 287 BTU hr 1 Printing Typical 120 VAC 50 60 Hz Shift Recycle ASCII Swirl High Speed Mode 2 3 Printing Maximum 120 VAC 50 60 Hz Black High Speed Mode Non Printing 120 VAC 50 60 Hz Standby Mode Material Safety Data Sheets 272 If the customer site needs a Material Safety Data Sheet provide the following information HP part or product number Chemical substance description Customer name Customer address Customer telephone number Customer FAX number DECLARATION OF CONFORMITY according to ISO IEC Guide 22 and EN 45014 Manufacturer s Name Hewlett Packard Company Internet amp Applications Systems Division Manufacturer s Address 19420 Homestead Road Cupertino CA 95014 USA declares that the product Product Name Line Impact Dot Matrix Printer Model Number s C3201C C3202C C3204C C3205C C5640C Product Options N A conforms to the following Product Specifications Safety IEC 950 1991 A1 2 A4 EN 60950 1992 A1 2 4 GB 4943 1995 CISPR 22 1993 EN 55022 1
92. 1 Printers are shipped with one box of six 60 yard bar code OCR ribbons 100 yard ribbons can only be used with cabinet models For more information please contact any of our worldwide sales offices of HP Channel Partners or check out http Awww hp com go linejet For the location of the nearest office in the United States call 1 800 637 7740 Ribbon Life Product Number Description For Use on Model Product Lifetime C3206A Box of six 60 yard All LineJet Models 30 Million Characters non inked security All HP LP Series ribbons Models C3207A Box of six 60 yard All LineJet Models 30 Million Characters black text ribbons All HP LP Series Models 269 Printer Dimensions OCR Bar Code ribbons LineJet 1000Q LineJet 1500Q LPQ475 LPQ500 LPQ800 LPQ1000 LPQ1200 LPQ1400 LPQ1500 Product Number Description For Use on Model Product Lifetime C3208A Box of six 100 yard LineJet 500Q 50 Million Characters black text ribbons LineJet 1000Q LineJet 1500Q LPQ475 LPQ500 LPQ800 LPQ1000 LPQ1200 LPQ1400 LPQ1500 C3209A Box of six 60 yard All LineJet Models 27 Million Characters OCR Bar Code All HP LP Series or ribbons Models 2 800 shipping labels C3210A Box of six 100 yard LineJet 500Q 45 Million Characters or 4 667 shipping labels Printer Dimensions 270 Height Width Depth Weight Height Width Depth
93. 1 Appendix Illustrated Parts Breakdown Figure 83 Stacker Detail Motor Bracket Item No Part No Description Notes 95 Ref Clip On Bearing 96 158288 001PX Holder LED Round 100 202727 001PX LED IR T 1 3 4 Part of item 36 343 Appendix H Illustrated Parts Breakdown Figure 84 Stacker Detail Elevator Bracket Item No Part No Description Notes 95 Ref Clip On Bearing Part of item 36 97 158290 001PX Holder LED Flat 105 202728 001PX Photodarlington NPN Rectifier 345 Appendix H Illustrated Parts Breakdown From page 338 Rotated 180 Degrees Connector 8g Figure 85 Stacker Detail Paper Motion Detector 346 Item No Part No Description Notes 97 158290 001PX Holder LED Flat 105 202728 001PX Photodarlington NPN Rectifier 106 Ref Retaining Ring External 0 093 inch Part of item 115 107 Ref Screw Panhead Type B 2 x 3 16 Part of item 36 108 Ref Shaft Paper Detector Switch Long Part of item 115 110 202729 001PX LED IR Rectangular 115 170289 001 Field Kit Power Stacker PMD 116 Spring Torsion Part of item 115 347 Appendix _ Illustrated Parts Breakdown 348 Index Numerics 15V CTL FAIL 34 23 5V CTL FAIL 35 48V PWR FAIL 35 8 5V POWER 34 A A D OVERRUN 36 Abbreviations 277 285 About the printer 9 ACCESS NULL 35 Acronyms 277 285 Adjustme
94. 1 of the removal procedure reset and save the printer configuration s Refer to the User s Guide 156 Memory Modules and Security PAL CMX Controller Board Oo a ilg Bg E E Bbo 9 20 56 Ds oO O A 2 1 m ABs s i 24 E 2 T 1 no Ee M E 0000 Cn v 1 e 2 D D em d d Q ce 158258 001 REV _ gt Ex Bank 0 O E ji u i 1 go E Bank 0 hs o A O
95. 2 Ref Bracket MPU Part of item 1 3 Ref Screw Socket Cap 6 32x 38 4 153537 901PX Extension Spring 5 Ref MPU Cable Connector P03 6 Ref Shuttle Motor Cable Connector P02 203 Chapter 6 Section II Illustrated Parts Lists NOTE Item 18 not shown Tractor Shaft Hardware Kit includes items 6 7 8 9 13 14 and 21 Item 19 not shown Tractor Shaft Kit includes items 1 2 3 4 5 15 and 17 Figure 37 Tractor Shafts 204 Illustrations of Printer Components ben Part No Description Notes 1 Ref Screw Socket Cap Part of item 19 2 Ref Washer Flat 4 Part of item 19 3 Ref Knob Tractor Adjust Part of item 19 4 Ref Bushing Tractor Adjust Part of item 19 5 Ref Washer Curved Spring 2 Part of item 19 6 Ref Ring Grip Part of item 18 7 Ref Bearing Nylon 626 Part of item 18 8 Ref Link Spring Part of item 18 9 Ref Spring Extension 1 00L Part of item 18 10 Ref Screw Hex w Lock Washer 4 20x 50 Part of item 11 11 150784 901PX Grounding 12 150491 901PX Shaft Assembly 13 Ref Screw Thread forming Part of item 18 14 Ref Clamp Bearing Part of item 18 15 Ref Tractor Shaft Part of item 19 16 140716 903PX Tractor Set RH amp LH 158741 001PX Tractor Assembly Power Stacker Installed at factory on models with power stacker 17 Ref E Ring Part of item 19 18 153540 001PX Tractor Shaft Hardware Kit Includes items 6 7 8 9 18 14 and 21 19 153431 001PX Tractor
96. 208 page 210 183 Section II Illustrated Parts Lists 6 Chapter Figure 28 Top Cover Doors and Casters 184 Illustrations of Printer Components Pen Part No Description Notes 1 164212 905PX Cover Kit Cabinet Includes mounting hardware 2 131803 901PX Window Top Cover Not visible in Figure 28 3 153997 001PX Field Kit Paper Path Includes mounting hardware and static brush 4 153084 902PX Rear Door Kit Includes mounting hardware 5 153084 903PX Front Door Kit Includes mounting hardware 6 141278 901PX Caster with Brake Two at front 7 141278 902PX Caster without Brake Two at rear 8 Ref Logo 9 131829 001PX Hinge Plate Door Top 112367 001PX Hinge Plate Door Bottom 185 Section II Illustrated Parts Lists 6 Chapter Figure 29 Paper Fence and Chains 186 Illustrations of Printer Components Item No Part No Description Notes 1 Ref Paper Fence 500 models 2 134844 001PX Stacker Option Kit 1000 and 1500 Ipm cabinet models Power Stacker Option available for cabinet models see Appendix H 3 153503 001PX Grommet Kit Cabinet 4 153778 001PX Chain Assembly Kit 5 Ref AC Power Cord 6 Ref Grommet Power Cord
97. 38 Table 2 Message List List of Messages Message Explanation Solution COIL HOT One or more hammer coils are 1 overheating Inspect printer environment for severity The 2 printer has sensor circuits that sample the operating temperature of key components of the print mechanism When higher than normal 3 temperatures are sensed print speed is automatically reduced by 50 and a COIL HOT 4 message is sent to the LCD to inform the operator When the coil s cool down print speed 5 automatically returns to 100 and the message clears from the LCD This message is normal for extremely dense print jobs such as All Black plot If the printer often prints at 6 half speed it may be operating in a severe environment A severe environment is one with an ambient temperature at or above 40 Celsius 104 7 Fahrenheit or that is dirty enough to create blockage of the cabinet fan vents The printer must never be run at ambient temperatures greater than 40 Celsius 104 Fahrenheit If the printer is located in such an environment relocate it to a cooler cleaner area Advise the user to move the printer to cooler cleaner location Check the kinds of print jobs the user is running look for very dense graphics and layouts Advise the user to run jobs in smaller batches Power off the printer Remove the paper path or pedestal top cover Check all fan cable conne
98. 5 RIB INVLD STATE 56 Ribbon drive motor replacement 171 guide assembly L R replacement 172 guide assembly alignment 114 hub replacement 173 mask replacement 139 specifications 269 RIBBON DRIVE 56 RIBBON INK OUT CHANGE RIBBON 56 Run Mode 145 5 Safety notices defined 11 SECURITY CODE VIOLATION 56 SECURITY PAL NOT DETECTED 56 Security PAL location 157 Self Test 10 100Base T 145 Self tests diagnostic printer 84 operator print 84 SENDING PROGRAM TO EC PROCESSOR 57 SET TOF key pedestal models 18 Shaft splined replacement 174 splined skew adjustment 116 support replacement 176 SHIFT key pedestal models 18 SHUTL INV 57 SHUTL INV PARM 57 Shuttle cover assembly replacement 141 frame assembly replacement 177 SHUTTLE JAM 58 Signal mnemonics 277 285 SIMMs location and replacement 155 Soft reset 93 Software 354 loading from multiple diskettes 288 loading from one diskette 285 SOFTWARE ERROR CYCLE POWER 59 Specifications electrical 271 environmental 271 interfaces 272 paper 297 printing rates 275 ribbon 269 Speed printing 275 Splined shaft replacement 174 skew adjustment 116 Spring extension hammer bank replacement 179 STACK OVERFLOW 59 STACK UNDERFLOW 59 STACKER FAULT 60 STACKER FULL 61 STACKER JAM 61 Stacker power installation 317 removal 312 replacing constant force spring 328 timing belts 331 Start up sequence 94 Supp
99. 5 46 GHIJALMNOUPGRSTUV 47 48 49 4A 4B 4C 4D 4E 4F 50 51 52 53 54 55 56 WXYZLN21 abcdef 57 58 59 SA 5B 5C 50 SE SF 60 61 462 43 64 65 ghijkimnopqrstuv 67 68 69 6A B 6C 6D 6E 70 71 72 73 74 75 76 uxuzii 27 78 79 7 7B 7C 7D 7E 20 21 22 23 24 25 26 927 ee 701234567 28 29 2A 2B 2C 20 BE 30 31 32 33 34 35 36 37 89 gt 7 ABCDEFG 38 39 3B 3C 30 40 41 42 43 44 45 46 47 HI A 4 amp 0O034 48 49 OD 22 23 24 25 26 27 28 29 2A 2B 2C 10123456789 lt 30 31 32 33 34 35 36 37 38 39 3B 3C 40 41 42 43 44 45 46 47 48 49 44 4B 4 40 NOP RSTUVWXYZE 4E 50 51 52 53 54 55 54 57 SB 59 SA SB SC 5 abcdefghijklm SE 5F 60 61 62 63 64 65 65 67 68 69 6B C nopqrstuvuxyzi 2 6E F 70 71 72 73 74 75 76 77 78 79 7A 7B 7C 7D Cet 20 21 22 23 24 25 265 28 29 2A SB 2C BE 0123456789 lt gt PF 30 31 32 33 34 35 36 37 38 39 3B 7GABCDEFGHIJ 8 SF 40 41 42 43 44 45 46 47 48 49 OD OA 23 24 701234 25 26 27 28 29 2 2B 2C 20 2E 2F 30 32 33 34 56789 lt gt 7 ABCD 35 36 37 38 39 3B 3C 3D 40 41 42 43 44 EFGHIJKLMNGPGRST 45 46 47 48 49 4A 4B 4 4D 4E 50 51 52 53 54 UVWXYZENIC_ abed 55 5 57 58 59 SA 5B 5 SD SE SF 60 61 62 63 44 efghijkimnopqrst 65 66 67 68 69 6A GB 6C 60 6E amp 70 71 72 73 74 uvuxyzti 15 75 76 77 78 79 7A 7B 7C 7D 7E
100. 5 mm Torque the 7 16 inch MPU clamp screw to 18 1 inch pounds 2 03 0 11 Nem 2 Check that the MPU cable is connected to J03 on the mechanism base Check that the shuttle motor cable is connected to J02 on the mechanism base Connect the MPU and the shuttle motor cables 3 Remove the paper path or pedestal top cover Check that the shuttle motor drive cable is connected to J116 on the CMX controller board 4 Check the platen gap Adjust the platen gap 5 Inspect the ribbon mask for bends or deformation that snag and interfere with shuttle movement Make sure the hammer bank cover assembly is correctly installed on its mounting pegs Reinstall the hammer bank cover assembly Replace a damaged or deformed hammer bank cover assembly 6 Check continuity of the shuttle motor drive cable assembly Replace shuttle motor drive cable assembly if it fails continuity test 7 Power up the printer Run a Shuttle Slow or Shuttle Fast test If the shuttle does not move replace the shuttle frame assembly 8 Power up the printer Run a Shuttle Slow or Shuttle Fast test If the shuttle does not move replace the power supply board 9 Power up the printer Run a Shuttle Slow or Shuttle Fast test If the shuttle does not move replace the CMX controller board 81 Chapter 4 Troubleshooting Other Symptoms Table 3 General Symptom List Symptom Solution Shuttle is noisy Check the bolts securing the mech
101. 6 17 18 20 26 26 Ref Platen Washer Part of item 25 207 Section II Illustrated Parts Lists 6 Chapter Install screws here 2 D lt 2 M c A G a I base casting See detail above Figure 39 Motors Fans and Paper Detector Switch 208 Illustrations of Printer Components hen Part No Description Notes 1 150261 901PX Cage Fan Assembly Air flow is into card cage 2 Ref Screw w Lock Washer 3 Two 6 32x1 75 on bottom One 6 32x0 50 on top left 3 152415 901PX Switch Assembly Paper Detector 4 Ref Screw Thread forming 6 32x 375 2 Part of item 3 5 152299 901PX Motor Assembly Platen 6 155071 902PX Platen Pulley Drive Motor With setscrew 6 32x 25 7 Ref Collar Shaft Part of item 9 8 Ref Setscrew 6 32x 51 Part of item 7 9 108627 901PX Pulley Paper Feed 10 Ref Screw Hex w Lock Washer 10 24x 50 2 Part of item 23 11 163597 901PX Ribbon Guide Kit 12 Ref Ribbon Guide Kit Same as item 11 13 Ref Washer Flat 4 Part of item 12 14 Ref Screw w Lock Washer 4 40x 38 Part of item 12 15 Ref Screw w Lock Washer 10 32x 50 2 Part of item 5 16 Ref Shield Card Cage Fan 17 154071 901PX Motor Assembly Ribbon 18 Ref Screw Hex w Lock Washer 2 6 32x 50 19 Ref Washer Flat 6 2 20 150868 001PX Ribbon Hub Kit 21 Ref Screw w Lock Washer 2 6 32x1 25 22 152416 901PX Hammer Bank Fan Assembly Air flow is up
102. 80 LPI LPM LRIB LRP MAIN MECA MECH MF MH MOSFET MOT MPU ms MSL MSR N NLQ No NOVRAM ns NT NVRAM OLV OP Interrupt Input Output Interrupt Request Jack connector Left Local Area Network Liquid Crystal Display Light Emitting Diode Line Feed Low Lines Per Inch Lines Per Minute Left Ribbon Left Ribbon Guide Motor Maintenance Jack RS 232 Optional Mechanism Engine Control ASIC Mechanism microfarad 106 farad Mounting Hole Main Harness Metal Oxide Semiconductor Field Effect Transistor Motor Magnetic Pick Up Unit millisecond 10 second Motor and Sensors Left Motor and Sensors Right Negative True Not Connected Not Connected Near Letter Quality Number Nonvolatile Random Access Memory nanosecond 1 09 second Not Nonvolatile Random Access Memory On Line Verify Operand 5 1 2 PAL PAP PAPR PARM PCBA PCB PD PE PER PF PFM PHA PHB PLM PLO PMD PN P N PO POD PPR PROM PS PS5 PTR PWM PWR RBN RD RET RIB 5Vdc Pin connector Parallel data 1 data 2 etc Programmable Array Logic Paper Paper Parameter Printed Circuit Board Assembly Printed Circuit Board Paper Detect or Printer Error Paper Empty Peripheral Device Paper Feed picofarad 10 farad Paper Feed Motor Phase A Phase B Paper Instruction Platen Platen Motor Platen Open Switch Paper Motion Detect
103. 92 item 6 3 Slide the paper path to the left and lift it off the card cage Installation 1 Position the paper path offset slightly to the left on the card cage with the keyway cutouts over the three loosened hold down screws page 192 Figure 32 2 Slide the paper path to the right engaging the three hold down screws in the keyway slots Slide the paper path to the right as far as it will go Tighten the three hold down screws page 192 item 6 Return the printer to normal operation page 101 161 Chapter 6 162 Section I Replacement Procedures Platen Removal 1 Prepare the printer for maintenance page 100 2 Remove the shuttle frame assembly page 177 3 Remove the paper ironer page 160 4 Remove the three 1 4 inch screws securing the paper ironer bracket 10 11 12 13 14 assembly and remove the assembly See page 206 items 4 5 and 6 Remove the platen open belt page 129 Remove the platen pulley page 206 item 21 as follows a Loosen the 7 64 inch collar clamp screw b Pull the platen pulley off the platen shaft Pull the spring link and white plastic bushing off the platen shaft and remove the spring link bushing and spring See page 206 items 16 17 and 18 Remove the forms thickness lever by loosening the 7 64 inch clamp screw and pulling the lever off the platen shaft See page 206 item 15 Remove the right side platen support spring by repeating ste
104. 994 Class GB 9254 1988 EN 50082 1 1992 IEC 801 2 1991 prEN 55024 2 1992 4 kV CD 8 kV AD IEC 801 3 1984 prEN 55024 3 1991 3 V m IEC 801 4 1988 prEN 55024 4 1993 0 5 kV Signal Lines 1 kV Power Lines IEC 1000 3 2 1995 EN 61000 3 2 1995 Class B Harmonics IEC 1000 3 3 1994 EN 61000 3 3 1995 Flicker Supplementary Information The product herewith complies with the requirements of the Low Voltage Directive 73 23 EEC and the EMC Directive 89 336 EEC and carries the CE marking accordingly 1 The Product was tested in representative computer systems Cupertino March 22 1999 European Contact Your local Hewlett Packard Sales and Service Office or Hewlett Packard GmbH Department HQ TRE Herrenberger Stra e 130 D 71034 B blingen FAX 49 7031 14 3143 273 Appendix _ Communication Notices Communication Notices 274 Federal Communications Commission FCC Statement This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely
105. AM FROM PORT XX Status message the new emulation program is loading into printer RAM XX indicates how much of the program has loaded No action required LOADING PROGRAM INTO FLASH The printer has deleted the previous program from flash memory and is loading the new program into flash memory No action required PAP BAD TABLE Paper Bad Table The paper 1 feed process on the CMX controller board has a corrupted table 2 Cycle power Run the print job again If the message appears download the emulation software again Cycle power Run the print job again If the message appears replace the controller board Record the message and return it with defective board 48 Table 2 Message List List of Messages Message Explanation Solution PAP BSY TOO LNG Paper Busy Too Long Firmware 1 error on the CMX controller board Cycle power Run the print job again If the message appears download the emulation software again page 129 Run the print job again If the message appears power off the printer Remove the paper path or pedestal top cover Make sure connectors P106 and P107 are fully seated on the CMX controller board Make sure the MPU cable the hammer bank logic cable and the hammer bank power cable are undamaged and have good connections Replace as necessary Refer to Appendix A Power on the printer Run the print job
106. AR NVRAM ENTER ENTER ERASE ALL FLASH TESTING FOR CLEAR NVRAM COMPLETED ADDRESS SHORTS COMPLETED SELECT DOWNLOAD PORT SELECT DOWNLOAD PORT RS232 9600 SELECT DOWNLOAD SELECT DOWNLOAD SELECT DOWNLOAD PORT RS232 19 2K PORT RS232 38 4K PORT RS232 115K ENTER ENTER ENTER ENTER ENTER WAITING DOWNLOAD PORT CENTRONIC WAITING DOWNLOAD PORT RS232 9600 WAITING DOWNLOAD PORT RS232 19 2K WAITING DOWNLOAD PORT RS232 38 4K WAITING DOWNLOAD PORT RS232 115K SELECT DOWNLOAD PORT RS422 9600 SELECT DOWNLOAD PORT RS422 19 2K SELECT DOWNLOAD PORT RS422 38 4K SELECT DOWNLOAD p PORT RS422 115K SELECT DOWNLOAD gt PORT DATAPRODUCT ENTER ENTER ENTER ENTER ENTER WAITING DOWNLOAD PORT RS422 9600 WAITING DOWNLOAD PORT RS422 19 2K WAITING DOWNLOAD PORT RS422 38 4K WAITING DOWNLOAD PORT RS422 115K WAITING DOWNLOAD PORT DATAPRODUCT Figure 7 Boot Diagnostics Menu continued 89 Chapter 4 Hex Code Printout Hex Code Printout A hex code printout or hex dump prints every ASCII data character received from the host computer and lists its corresponding two digit hexadecimal code See F
107. BLE 42 PROGRAM NOT VALID 42 SECURITY PAL NOT DETECTED 42 SHORT AT ADDRESS 42 WRITING TO FLASH 42 WRONG CHECKSUM 42 Error messages 33 ERROR OCCURRED FLUSHING QUEUES 42 ETHERNET ADAPTER BEING INITIALIZED 43 ETHERNET DETECTED 43 Ethernet interface assemblies replacement 144 Ethernet interface assembly replacement 144 EXHAUST FAN FAULT 43 Expansion CT board replacement 147 F Fan assembly card cage replacement 148 hammer bank replacement 147 149 Fault messages 33 FF key pedestal models 18 FIRMWARE ERROR 44 FRAMING ERROR 44 FREEFORM OFF 44 FREEFORM ON OFF HOLD KEY PWRUP 44 G Gap adjustment magnetic pick up MPU 154 platen 110 H HAM COIL 45 Hammer phasing adjustment 121 spring assembly replacement 150 Hammer bank cover assembly replacement 139 fan assembly replacement 147 149 wiring diagram 233 HAMMER COIL BAD etc 45 Hammer phasing adjustment 121 Hard reset 93 HB NOT INSTALLD 45 Hex code printout 90 HMR BANK FAN FLT 46 Hub ribbon replacement 173 Humidity operating specifications 271 ILL EXT BUS 46 ILL INST 5 46 ILLGL 5 46 Illustrations replacement procedures 183 Indicators 10 100Base T 145 Installation 23 INTAKE FAN FAULT 47 Interface specifications 272 INTERRUPT UNUSED VECTOR 00 47 K Keys locations and operation pedestal models 18 L L P I ADJ key
108. Card Cage Fan Change Circuit Clock Cover Open Collector Communication Controller Command The controller board Connector Connection Characters Per Inch Carriage Return Control Clear to Send Control Unit Current Data Bit 0 Data Bit 1 etc Data Direct Current Data Controller a functional unit of the CMX controller board Data Carrier Detect Diagnostic Differential Direct Memory Access Data Processing Dataproducts Enable Dot Plucker Memory Controller Data Processing Unit Dynamic Random Access Memory Drive or Driver Driver Data Set Ready Data Terminal Ready EEPROM EHF EL EMI EMIT EPROM ERR ESD EX EXH EXF EXP EXPND FD Engine Controller a functional unit of the CMX controller board Electrically Erasable Programmable Read Only Memory Exhaust Fan Elevator stacker ElectroMagnetic Interference Emitter Electrically Programmable Read Only Memory Error Electrostatic Discharge Exhaust Extra Exhaust Exhaust Fan Expansion Expand Feed Form Feed First In First Out Fault Filter Front Panel Control Panel Fire Timer Integrated Circuit Ground Hammer Bank Hammer Bank ASIC Hammer Bank Fan Hammer Bank Left Hammer Bank Power Hammer Bank Right Hammer Driver Hammer Driver Integrated Circuit Hammer Driver Phase Hammer Bank Logic Signals and Power Integrated Circuit Identification Intelligent Graphics Printing Instruction 279 Appendix 2
109. Check continuity of cables See Appendix A Replace any cable that is damaged or fails continuity test TABLE MISMATCH DOWNLOAD AGAIN This message indicates that an EC software update is in process Power off the printer Download the program again from the beginning 61 Chapter 4 Troubleshooting Display Messages Table 2 Message List Message Explanation Solution Firmware error on the CMX controller board TCB CORRUPTED Task Control Block Corrupted 1 Cycle power Run the print job again If the message appears download the emulation software again Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board error on the CMX controller board UNDEF INTERRUPT Undefined Interrupt Firmware 1 Cycle power Run the print job again If the message appears download the emulation software again Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board error on the CMX controller board UNDFNED OPCODE Undefined Opcode Firmware 1 Cycle power Run the print job again If the message appears download the emulation software again page 129 Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it wit
110. EAR PAPER JAM message will not clear and paper does not move 1 Remove the paper path or pedestal top cover Make sure connector P107 PAPR M is fully seated in connector J107 on the CMX controller board 2 Check the paper feed motor pulley for looseness Hold the collar snug against the motor pulley and torque the 7 64 inch setscrew to 25 2 inch pounds 2 82 0 23 Nem 3 Check the condition and tension of the paper feed timing belt Adjust the paper feed timing belt Replace the belt if it is damaged 4 Load paper Power on the printer Press PAPER ADVANCE and VIEW several times and check that paper moves correctly in both directions Replace the paper feed motor if the message appears or the paper moves erratically 5 Power on the printer Press PAPER ADVANCE and VIEW several times and check that paper moves correctly in both directions Replace the CMX controller board if the message appears or the paper moves erratically Record the message and return it with defective CMX board 65 Chapter 4 Troubleshooting Other Symptoms Table 3 General Symptom List Symptom Solution CLEAR PAPER JAM message will not clear but paper moves Power off the printer Remove the paper path or pedestal top cover Check that connector P106 PMD is fully seated in connector J106 on the CMX controller board Remove the barrier shield cabinet model or the barrier shield and paper guide pedestal model Check that the p
111. ECK SECURITY PART VERSION CHECK gt PROCESSOR SPEED ENTER ENTER ENTER P C BOARD VERSION 3 5 SECURITY PART PROCESSOR SPEED 154140 017 68E030 AT 25 MHZ BOOT DIAGNOSTICS gt FILE UTILITIES p Continued on v next page FILE UTILITIES gt FILE UTILITIES FILE UTILITIES VIEW FILES FILE SYSTEM STATUS OPTIMIZE FILES ENTER ENTER OPTIMIZING FLASH FILES VIEW FILES VIEW FILES VERSION gt FILENAME FLASHDISK STATUS FREE 0012473 gt FLASHDISK STATUS ERASES 000073 FLASHDISK STATUS OF FILES 000 gt FLASHDISK STATUS USED 0002048 FLASHDISK STATUS DELETED 0000000 88 Figure 7 Boot Diagnostics Menu Selecting and Running Diagnostic Printer Tests NOTE v BOOT DIAGNOSTICS DOWN Kay MISC UTILITIES gt NEXT key From previous page MISC UTILITIES MISC UTILITIES MISC UTILITIES MISC UTILITIES DISPLAY MEMORY gt RESET PRINTER COPY FLASH SIMMS COPY BOOT SIMMS ENTER ENTER ENTER ENTER FLASH 2 MBYTES RESETTING LOADING PROGRAM LOADING PROGRAM DRAM 2 MBYTES PLEASE WAIT INTO FLASH INTO FLASH MISC UTILITIES MISC UTILITIES MISC UTILITIES MISC UTILITIES ERASE ALL FLASH gt RUN MEMORY TESTS FILE DOWNLOAD gt CLE
112. EXP NWR 13 FODA 50 50V 50V 50V 15 PODK EXP NMSEL 16 17 18 PMDC EXP NDS 19 PODE EXP D15 20 PMD E EXP D14 EXP D13 z EXP D12 CAUTION Do not remove or replace the EXB Dii NVRAM The NVRAM contains a lithium EXP D10 battery that can explode if it is replaced EXP D9 incorrectly NVRAM is replaced only at the factory 07 06 05 04 EXP D3 EXP D2 I EXP D1 EXP EXP A15 EXP A14 EXP A13 EXP A12 EXP A11 EXP A10 EXP 9 EXP A8 EXP A7 EXP A6 5 4 I EXP EXP A2 EXP A1 EXP VCC penunuoo 2 v Xipueddy 42 EC Diagnostics PPR TRIG PPR MOVING FT EVENT MPU OUT SHUT DIR 71 EC DB TXD EC DB RXD
113. INVLD 51 PAP INVLD PARM 51 PAP NOT SCHED 51 PAP NT AT SPEED 51 PAP UNEXP INT 52 Paper detector switch assembly replacement 180 drive motor pulley alignment 106 feed drive motor replacement 158 feed timing belt replacement 128 feed timing belt tension adjustment 102 ironer replacement 160 path removal 161 scale adjustment 108 specifications 297 tractor L R replacement 182 Paper out adjustment procedure 117 PARAMETER ERROR 52 PARITY ERROR 52 Parts illustrations 183 Phasing adjustment 121 Pinouts 233 PLAT INV 52 PLAT INV PARM 53 PLAT INV STATE 53 Platen gap adjustment 110 interlock switch assembly replacement 181 platen open belt adjustment 104 platen open motor replacement 166 replacement 162 PLEASE RESET IN PROGRESS 53 Plot rates 275 Power consumption printer 271 cycle how to 93 start up sequence 94 Power on sequence 94 POWER SAVER MODE 53 Power supply board principles of operation 230 replacement 168 POWER SUPPLY HOT 54 Power switch location pedestal models 18 PREV arrow key pedestal models 18 Principles of operation 215 Printer adjustments 99 cleaning 25 configuration 23 host configurations and drivers 293 installation 23 logical control of 222 maintenance overview 9 models 9 principles of operation 215 reset 93 self tests diagnostic print 84 operator print 84 specifications and regulatory 269 troubleshoo
114. Pedestal Models Remove the four fan mounting screws and nut See page 196 items 1 through 4 5 Remove the card cage fan assembly from the card cage Installation Air flow is INTO the card cage Install the card cage fan so the label faces toward the inside of the printer and the cable faces the front of the printer 1 Reverse steps 2 through 5 of the removal procedure 2 Return the printer to normal operation page 101 148 Fan Assembly Hammer Bank Fan Assembly Hammer Bank Removal 1 Prepare the printer for maintenance page 100 Remove the shuttle cover assembly page 141 Cabinet Models Remove the paper path page 161 Pedestal Models Remove the top cover assembly page 142 4 Trace the hammer bank fan cable assembly back to the controller board connector P107 releasing it from all cable constraints See the cable routing diagrams in Appendix A 5 Disconnect the fan connector from connector shell P107 on the controller board See page 131 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 page 208 items 21 and 22 Installation Air flow is UP Install the hammer bank fan so the label faces up 1 Feed the hammer bank fan cable connector and motor wires between the fan well of the base casting
115. Pull the side of the connector shell outward and gently pull the cable connector upward See Figure 18 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 6 Disengage the key tab s on the cable connector from the slots in the side of the connector shell 7 Remove the cable connector from the connector shell Remove only the cable connector for the cable you are replacing leave the other cable connectors 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 18 2 Pull the side of the connector shell outward and gently push the cable connector down into the connector shell 3 Engage the key tab s 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 Install the stiffening clip page 133 Connect the cable connector shell to its printer connection Cabinet Models Install the paper path page 161 Pedestal Models Install the top cover assembly page 142 7 Return the printer to normal operation page 101 131 Chapter 6 132
116. Reverse steps 2 through 6 of the removal procedure above The ribbon drive motor should be secured at the front right and rear left corners See page 208 item 17 2 Return the printer to normal operation page 101 171 Chapter 6 Section Replacement Procedures Ribbon Guide Assembly L R The right ribbon guide is shown exploded in Figure 39 on page 208 The removal procedure is the same for both ribbon guides Removal 1 Prepare the printer for maintenance page 100 2 Cutand remove the tie wrap from the tie wrap hole to free the ribbon guide cable See page 208 item 11 3 Cabinet Models Remove the paper path page 161 Pedestal Models Remove the top cover assembly page 142 4 Trace the ribbon guide cable back to the controller board releasing it from the cable restraints See the cable routing diagrams in Appendix A 5 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 6 Trace the ribbon guide wires to the connector shell and remove the cable connector from the connector shell page 132 7 Remove the two 7 32 inch screws and washers securing the ribbon guide assembly to the side plate See page 208 items 13 and 14 8 Slide the ribbon guide assembly out of the side plate Installation 1 Reverse steps 2 through 8 of the removal procedure above 2 Al
117. VOCNC PN 18 35 2 NC 777 CNC PN36 36 77 NC 37 23 NC 38 24 NC 39 25 DIFF TXD 40 CAUTION 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 N STROBE P1 P2 P3 P4 XIN 2 P5 P6 P7 P8 N ACK BUSY PAPER EMPTY SLCT N INIT N AUTOFEED N FAULT PI 4 7K 0 1W N DP SEL EXT 5V N SELECT IN HOST LOGIC H N DP EN 470 PF 10 50V CHASSIS GND v Xipueddy 6 c Diagnostic Port CAUTION Do not remove or replace the J9 Online Verifier nie 1 NVRAM The NVRAM contains a lithium 7 2 battery that can explode if it is replaced DB TXD incorrectly NVRAM is replaced only at the 5 factory 6 Ps 470 PF 10 50V B fX a B E gi M 49 5 l a N F f paturaonty 1 Bn ml g 2A 2 2 e B x LL M
118. Volt Power Failed an le internal power failure Power off the printer Remove the paper path or pedestal top cover Check that power supply connector P101 is fully seated in connector J101 on the CMX controller board Power on the printer If the message appears replace the hammer bank logic cable assembly P108 and the power cable assembly P105 Refer to Appendix A Power on the printer If the message appears replace the power supply board Power on the printer If the message appears replace the CMX controller board Record the message and return it with defective CMX board Power on the printer If the message appears replace shuttle frame assembly ACCESS NULL Access Null Pointer The 1 processor tried to access a pointer that contains nothing null Cycle power Run the print job again If the message appears download the emulation software again page 129 Cycle power Run the print job again If the message appears replace the controller board Record the message and return it with defective board 35 Chapter 4 Troubleshooting Display Messages Table 2 Message List Message Explanation Solution A TO D OVERRUN Analog to Digital Overrun The Cycle power Run the print job again If analog to digital converter the message appears replace the CMX overflowed controller board Record the message and return it with defective CMX board
119. X e LineJet Printers User s Guide Part Number 171252 001PX 23 Chapter 2 Installation 24 3 Preventive Maintenance Cleaning the Printer The LineJet printer is designed to require very little maintenance Aside from normal replenishment of paper and ribbons the only preventive maintenance required is periodic cleaning Because operating conditions vary widely the user must determine how often to clean the printer Since there is no guarantee that the user will clean the printer regularly you should clean the printer whenever you are called to service it Always disconnect the AC power cord before cleaning the printer Do not use abrasive cleaners particularly on the window Do not drip water into the printer Damage to the equipment will result YT 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 the circuit boards The cleaning procedures in this chapter are the same for all models 25 Chapter 3 Cleaning the Outside Surfaces Cleaning the Outside Surfaces 1 Power off the printer 2 Disconnect the AC power cord from the printer or the power source 3 Remove paper and the ribbon 4 Dampen aclean lint free cloth with water and a mild detergent or with window cleaning solution The cloth must be damp not wet Wipe down the outside surfaces of the printer 5 Dry the outside surf
120. able Assembly Control Panel 7 154288 002PX Pedestal Kit w Tray 8 158635 001PX Caster w Brake Pedestal 4 9 Ref Window Top Cover Part of item 10 10 157337 901PX Top Cover Complete 11 Ref Screw 2 Control panel ground strap 12 110718 001PX Paper Tray 13 Ref Screw 4 10 32x 625 191 Section II Illustrated Parts Lists 6 Chapter Figure 32 Inside Covers Cabinet Models 192 Illustrations of Printer Components Item No Part No Description Notes 1 164295 001PX Shuttle Cover Shroud Assembly Air 2 Ref Screw Captive 2 10 24x 62 with O ring 125 250 06 3 Ref Screw Thread forming 2 6 32x 25 and 6 flat washer 4 Ref Barrier Shield 5 152290 901PX Paper Path 6 Ref Screw w Lock Washer 3 6 32 25 and 6 flat washer 7 153488 001PX Feed Cover Kit 8 108664 903PX Belt Timing 080 Pitch 100 Teeth 500 Paper Feed Belt Wide 9 Ref Screw Thread forming 2 6 32x 25 10 152284 901PX Anti Static Brush Kit 11 Ref Power Supply Shield Taped to upper edge of card cage 12 153528 901PX Paper Scale 193 S amp 795 90 2 vs d 4 PI in lt SEXES 4 2 3 yy d See Figure 34 Section II Illustrated Parts Lists 6 Chapter 10 Figure 33 Inside Covers and Card Cage Pedestal Models 194 Illustrations of Printer Components Item No Part No Description Notes
121. accept responsibility for any failure to satisfy the protection requirements resulting from a non recommended modification of the product including the fitting of non Hewlett Packard Company option cards Dieses Ger t ist berechtigt in bereinstimmung mit dem deutschen EMVG vom 9 Nov 92 das EG Konformitatszeichen zu furhren Properly shielded and grounded cables and connectors must be used in order to reduce the potential for causing interference to radio and TV communication and to other electrical or electronic equipment This product has been tested and found to comply with limits for Class A Information Technology Equipment according to CISPR 22 European Standard EN 55022 The limits for Class A equipment were derived for commercial and industrial environments to provide reasonable protection against interference with licensed communication equipment Warning This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures Dieses Ger t erf llt die Bedingungen der EN 55022 Klasse A F r diese Klasse von Ger ten gilt folgende Bestimmung nach dem EMVG Ger te d rfen an Orten f r die sie nicht ausreichend entst rt sind nur mit besonderer Genehmigung des Bundesminesters f r Post und Telekommunikation oder des Bundesamtes f r Post und Telekommunikation betrieben werden Die Genehmigung wird erteilt wenn keine elektromagnetischen St
122. ace the entire shuttle frame assembly It is not field repairable Hammer spring assemblies are the only replaceable components of the shuttle frame assembly Set the printer power switch to O off Unplug the printer power cord from the printer or AC power source Disconnect the data signal cable from the printer interface Open the printer cover Unload paper Remove the ribbon qe rs Read the entire maintenance procedure before you begin working on the printer 8 Gather the necessary parts before you begin working on the printer 100 List of Adjustments Returning the Printer to Normal Operation When you are finished servicing the printer do the following steps 9 OI v Install the ribbon Load paper Connect the data signal cable to the printer interface Plug the AC power cord into the printer and the power source Close the cabinet doors Set the printer power switch to on Test printer operation by selecting and running one of the operator print tests See page 85 Select the emulation Refer to the User s Guide Set the top of form Refer to the User s Guide 10 Close the printer cover 101 Chapter 5 Belt Paper Feed Timing Adjustment Belt Paper Feed Timing Adjustment 1 Prepare the printer for maintenance page 100 2 Cabinet Models Remove the paper path page 161 Pedestal Models Remove the top cover
123. aces with a clean lint free cloth Open the printer cover Using a soft bristled non metallic brush Such as a toothbrush brush paper dust and ribbon lint off the tractors shuttle cover assembly base casting and ribbon guides Vacuum up the residue See Figure 4 8 Wipe the splined shaft with a soft cloth To avoid corrosion damage use only alcohol when cleaning printer mechanical elements and make sure the cleaning solution contains no water 9 Using acloth dampened not wet with alcohol clean the ribbon guides 10 Vacuum up dust and residue from the lower cabinet 11 Wipe the interior of the lower cabinet with a clean lint free cloth dampened with water and a mild detergent or window cleaning solution 12 Dry the cabinet interior with a clean lint free cloth 13 Clean the shuttle frame assembly as described in the next section 26 Legend 1 Base Casting Shuttle Cover Assembly Splined Shaft Tractors Forms Thickness Lever Ribbon Guide 2 Garon Figure 4 Cleaning Inside the Cabinet or Top Cover 27 Chapter 3 Cleaning the Shuttle Frame Assembly Cleaning the Shuttle Frame Assembly 1 Remove the shuttle cover assembly page 141 2 Remove the shuttle frame assembly page 177 3 Remove the paper ironer page 160 Over time the upper edge of the paper ironer can become sharp To avoid cutting yourself handle the paper ironer on the sides 4 Moisten a clean
124. again If the message appears replace the shuttle frame assembly Power on the printer Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board PAP FIFO OVERFL Paper First In First Out 1 Overflow Firmware error on the CMX controller board Cycle power Run the print job again If the message appears download the emulation software again Power on the printer Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board 49 Chapter 4 Troubleshooting Display Messages Table 2 Message List Message Explanation Solution PAP FIFO UNDRFL Paper First In First Out 1 Underflow Cycle power Run the print job again If the message appears download the emulation software again Run the print job again If the message appears power off the printer Remove the paper path or pedestal top cover Make sure connectors P106 and P107 are fully seated on the CMX controller board Make sure the MPU cable the hammer bank logic cable and the hammer bank power cable are undamaged and have good connections Replace as necessary Refer to Appendix A Check hammer phasing Try using a lower phasing value sometimes this message indicates too high a hammer phase value Power on the printer Run the print job again If
125. age appears power off the printer 5 Remove the shuttle cover and paper path or the pedestal top cover Inspect the shuttle mechanism for obstructions Check that all cables are attached at the shuttle and the CMX controller board Make sure the MPU cable is not pinched Refer to the Interconnection Diagrams in Appendix A Reseat all cables Check the resistance of the MPU at connector P107 Refer to the Main Wire Harness Test Tables in Appendix A Replace the MPU if it fails the test 6 Runa print test If the message appears replace the power supply board 7 shuttle test and observe shuttle movement If the shuttle oscillates too slowly adjust the gap between the MPU assembly and the flywheel to 0 010 001 inch 0 254 0 025 mm Torque the 7 16 inch MPU clamp screw to 18 1 inch pounds 2 03 0 11 Nem 8 Run a print test If the message appears replace the MPU and the MPU cable assembly 9 Run a print test If the message appears replace the CMX controller board Record the message and return it with defective CMX board 10 Run a print test If the message appears replace the shuttle frame assembly 58 Table 2 Message List List of Messages Message Explanation Solution SOFTWARE ERROR CYCLE POWER Application software tried to 1 perform an illegal printer function or damaged logic 2 circuits were detected on the controller board
126. aker Removal 1 Prepare the printer for maintenance page 100 Remove the card cage fan page 148 Disconnect the four circuit breaker electrical leads Cabinet Models See page 210 Pedestal Models See page 196 4 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 models See page 210 Pedestal models See page 196 To prevent severe damage to the printer the circuit breaker electrical leads must be connected correctly 2 Connect the four circuit breaker electrical leads Cabinet Models See page 210 Pedestal Models See page 196 Install the card cage fan page 148 Return the printer to normal operation page 101 130 Connector Shells Connector Shells Some of the cable connectors in the printer are grouped inside connector shells The procedure below explains how to remove and install cable connectors from connector shells There is also a diagram of the P106 and P107 connector shells on the plastic heat shield over the power supply Removal 1 Prepare the printer for maintenance page 100 2 Cabinet Models Remove the paper path page 161 Pedestal Models Remove the top cover assembly page 142 Remove the stiffening clip page 133 Disconnect the cable connector shell containing the cable assembly that you will replace 5
127. alling new software erases all saved configurations You will use the printouts to restore printer configuration Set the printer power switch to O off If the printer is already connected to the serial or parallel port of a computer capable of running an MS DOS based PKZIP self extracting file go to step 10 If not go to step 4 Unplug the AC power cord from the printer Disconnect all data input cables from the printer interface 288 6 Connect a parallel data cable to the LPT1 port or a serial data cable to the COM port of an IBM compatible computer that is using the PC DOS or MS DOS operating system You can connect the cable to the LPT2 port if the LPT1 port is already in use The load commands are different if you use this port as described in the note after step 26 Connect the data cable to the appropriate I O port of the printer Plug the AC power cord into the printer Power on the computer 10 Create a directory on your computer hard drive where you will store the recombined files from the emulation diskettes by typing the following at the DOS prompt MD DOWNLOAD lt Return gt 11 Make the newly created directory the active directory by typing the following at the DOS prompt CD DOWNLOAD lt Return gt 12 Insert the last diskette in the series e g 2 of 2 3 of 3 etc into diskette drive A or B of the computer 13 Get the name of the compressed file on the diskette by typing the
128. 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 page 208 2 Route the fan motor wires see cable routing diagrams Appendix A and connect the fan cable connector to J107 on the controller board See page 131 Install two screws in the locations shown in Figure 39 page 208 item 21 Cabinet Models Install the paper path page 161 Pedestal Models Install the top cover assembly page 142 Install the shuttle cover assembly page 141 Return the printer to normal operation page 101 149 Chapter 6 Section Replacement Procedures Hammer Spring Assembly Removal 1 Prepare the printer for maintenance page 100 2 Remove the shuttle frame assembly page 177 3 Carefully vacuum the shuttle frame assembly 4 Remove the hammer bank cover assembly page 139 Hammer springs and hammer tips are fragile Do not touch the hammer springs or tips Handle hammer spring assemblies by the thick mounting base only Apply pressure only to the mounting base 5 Remove the mounting screws from the old hammer spring assembly See Figure 21 page 151 6 Handling the hammer spring assembly by the mounting base only gently push up the mounting base and pry the old spring assembly off its mounting pins See Figure 21 page 151 7 Inspect the hammer bank and the old hammer spring
129. anism base to the base pan Tighten the mechanism base mounting bolts if they are loose enough to permit movement of the mechanism base Remove the shuttle cover Check the shuttle frame assembly mounting clamp screws for looseness Torque the 5 32 inch socket head clamp screws to 20 2 inch pounds 2 26 0 23 Nem Torque the center captive 5 32 inch socket head screw to 20 2 inch pounds 2 26 0 23 Nem Inspect the shuttle area for loose hardware Tighten loose hardware Check that the hammer bank cover assembly is correctly installed that it has not slipped off the mounting pegs Check that the ribbon mask has not partially separated from the hammer bank cover Check for debris trapped between the ribbon mask hammer bank cover and hammer bank Clean the shuttle frame assembly and hammer bank cover assembly if you find debris Replace the hammer bank cover assembly if you find any damage to the ribbon mask or hammer bank cover Power up the printer Run a shuttle test Replace the shuttle frame assembly if it is noisy or rattles 82 General Symptom List Communications Failures Many host printer communications problems are complex With the exception of a defective interface cable most communications problems are not a result of a hardware failure They usually result from an incompatible configuration of the host computer system network LAN print server controller multiplexer etc or the printer Sometime
130. aper Make sure the forms thickness lever is closed Power on the printer On the sheet of paper just below the paper entrance slot tear four inch square on the left side immediately below the perforation See Figure 17 This creates a hole that will trigger LOAD PAPER fault message but allows printing to the right of the hole which would normally be on the platen 6 Ifthe printer is online press the ON LINE key to place the printer offline 117 Chapter 5 _ Paper Out Adjustment Figure 17 Paper Preparation for Paper Out Adjustment Test List of Adjustments 7 the control panel press the keys to unlock the ENTER key ENTER SWITCH UNLOCKED briefly displays If LOCKED displays simply press and Y again 8 Press the 4 key DIAGNOSTICS displays 9 Press DIAGNOSTICS Printer Tests displays 10 Press v SHIFT RECYCLE displays 11 Press until Paper Out Adjustment displays 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 12 Press ENTER until the Paper Out Adjustment test starts The comb pattern will print until the display shows LOAD PAPER and the audible alarm sounds 13 Open the platen and move the paper up with the vertical position knob and examine the area of the page perforation If a long bar just meets th
131. aper detector switch assembly is securely mounted in its bracket Check that the paper detector switch assembly is securely mounted to the mechanism base Tighten the two screws securing the paper detector switch assembly to the mechanism base Check that the motion detector wheel rotates Replace the paper detector switch assembly if the wheel does not rotate Load paper Power on the printer Replace the paper detector switch assembly if the message appears Load paper Power on the printer Replace the CMX controller board if the message appears Record the message and return it with defective CMX board Control Panel Black squares on control panel Power off the printer Remove the paper path or pedestal top cover Disconnect the control panel cable from the panel and from J110 on the CMX controller board Check continuity of the cable See Appendix A Replace the control panel cable if it fails continuity test Connect the cable Power on the printer If the symptom appears replace the control panel Power off the printer Make sure the flash memory is seated properly in J10 and J11 on the CMX controller board Regardless of memory configuration J11 must be used Power on the printer If black squares appear on the LCD the flash memory could be blank Replace the flash SIMM in J11 with a new flash SIMM with the boot program installed Power on the printer If black squares appear on the LCD replace the CMX contro
132. aring degraded print quality paper jams and damage to the platen and shuttle assembly Notes and Notices About This Manual This is a field service maintenance manual It is designed so that you can quickly locate maintenance information Taking a systematic approach to maintenance tasks will help you restore the printer to operation as quickly as possible 1 Locate the procedure or information you need Refer to the Table of Contents or the Index Read the entire procedure before you do it Gather the parts and tools you will need Make sure you understand all notes and notices before you start a task Notes and notices are defined below Notes and Notices For your safety and to protect valuable equipment read and comply with all information highlighted in notes and notices The hand symbol of a notice indicates the kind of information it contains Warning messages call attention to situations that could hurt you Caution messages call attention to situations that could result in damage to equipment f Notes contain important information set off from the text Chapter 1 _ About This Manual Printing Conventions in This Manual Control panel keys and indicators are highlighted in bold print Example Press the CLEAR key then press the ON LINE key LCD Liquid Crystal Display messages are set off by quotation marks Example Press the ON LINE key OFF LINE appears
133. ash Memory from Multiple Diskettes Flash memory is contained in SIMMs single in line memory modules located on the controller board Printer emulation and operating system software are loaded into flash memory at the factory but you will install software in some situations e The customer buys the PGL or Code V graphics option after the printer is installed e customer needs to upgrade printer software e customer needs different emulation software e You have replaced the controller board e You have added or replaced the flash memory SIMM Emulation and operating system software are stored as compressed files on more than one 3 5 inch floppy diskette You will recombine the multiple files from the diskettes into one file on your computer s hard disk in order to download the file to the printer To assist in this process the MS DOS based program PKUNZIP is included on the last diskette with the program file You can load software through the serial parallel or Ethernet ports of the printer The following procedure is for loading software through the serial or parallel port To download software through the Ethernet interface refer to the LineJet Print Server User s Guide 170989 001PX The load commands are different depending on the printer port you use These differences are explained in the note following step 26 1 Make a printout of a saved configurations Refer to the User s Manual Inst
134. 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 177 b Ifthe old hammer spring assembly and the hammer bank are free of ink install the new hammer spring assembly as shown in the next section 150 Hammer Sp Assembly 7 Hammer Spring Assembly NOTE LineJet 500Q hammer bank and hammer spring assemblies are shown here Although hammer spring assemblies vary removal and installation are the same for all models Hammer Spring Assembly 1 Discard old screws Figure 21 Hammer Spring Assembly Removal 151 Chapter 6 Section Replacement Procedures 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 Hammer springs and hammer tips are fragile Do not touch the hammer springs or tips Handle hammer spring assemblies by the thick mounting YT base only Apply pressure only to the mounting base d 2 Handling the hammer spring assembly by the mounting base only remove the new assembly and mounting screws from the box 3 Handling the hammer spring assembly by the mounting base only carefully position the new assembly onto the hammer bank mounting pins and press it into position with the stick supplied in the
135. assembly by screwing it into the MPU bracket See Figure 36 page 202 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 Tighten the 7 16 inch MPU clamp screw 3 Check the gap between the MPU assembly and the flywheel with feeler gauge a Ifthe gap is 0 010 001 inch 0 254 0 025 mm to step 4 b Ifthe gap is not 0 010 0 001 inch 0 254 0 025 mm loosen the MPU clamp screw and go back to step 2 4 Route the MPU cable under the extension spring and connect the MPU cable connector page 202 item 5 Make sure the MPU cable does not touch the extension spring after cable connection Install the shuttle cover page 141 Adjust the hammer phasing page 121 Return the printer to normal operation page 101 154 Memory Modules and Security PAL Memory Modules and Security PAL Removal 1 Make configuration printout of all saved configurations Refer to the User s Guide Prepare the printer for maintenance page 100 Cabinet Models Remove the paper path page 161 Pedestal Models Remove the top cover assembly page 142 To prevent electrostatic damage to electronic components always wear a properly grounded static wrist strap when you handle memory modules circuit boards a 4 Gently pry the side locks open angle the SIMM toward the front of the printer and remove the SIMM from the socke
136. asured at the power and ground of the interface ICs e Less than 0 02V common mode ripple measured between chassis ground and the ground pins of the interface ICs e Greater than 200V us slew rate for all outputs 228 Engine Controller Engine Controller The engine controller EC consists of four main elements e 80 166 Microcontroller e 128KB 5 0V only FLASH program memory organized as 64K x 16 bits This memory is not expandable e Mechanism Engine Control ASIC e 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 Bus Configuration The 166 bus is configured for 18 bit address 16 bit data non multiplexed and segmented operation The flash memory runs with zero wait states An external PAL is used for address decoding Power Reduction The 166 chip has two power reduction modes idle and Energy Star Idle mode is not used In Energy Star mode 48V and all motors are de energized but the 166 operates as normal EC Flash Memory The EC stores all boot code program code and tables in its own local flash memory This flash is organized as 64Kx16 bits and us
137. ble assembly drawing in Appendix A Power on the printer f At connector P106 check for 48 volts DC between pins 1 and 2 and 5 volts DC between pins 3 and 4 If the voltages are correct replace the stacker control panel If the voltages are not correct power off the printer remove the paper path and disconnect the stacker power cable from the CMX controller board See Figure 64 page 312 Check the continuity of the stacker power cable between P105 and P106 If the cable fails the continuity test replace it If the cable is OK replace the CMX controller board Power off the printer Remove the paper path Disconnect stacker cables from the CMX controller board stacker assembly and the stacker control panel see Figure 59 page 307 Check cables for cuts breaks or damaged pins Check continuity of cables See Appendix A Replace any cable that is damaged or fails continuity test Reconnect all stacker cables to the CMX controller board stacker and stacker control panel Power on the printer Check that the ON LINE indicator lights on the stacker control panel If the ON LINE indicator does not light replace the stacker control panel Power on the printer Check that the ON LINE indicator lights on the stacker control panel If the ON LINE indicator does not light replace the CMX controller board 68 General Symptom List Table 3 General Symptom List Symptom Solution Stacker chatters
138. bles in Appendix A Replace components that fail test Make sure P107 HBF has a good connection at J107 on the CMX controller board Inspect for obstructions of airways and vents Remove obstructions Power on the printer If the message appears replace the CMX controller board Record the message and return it with defective CMX board ILL EXT BUS ACC External Bus Access 1 Firmware error on the CMX controller board Cycle power Run the print job again If the message appears download the emulation software again page 129 Cycle power Run the print job again If the message appears replace the controller board Record the message and return it with defective board ILL INST ACCSS Illegal Instruction Accessed 1 Firmware error on the CMX controller board Cycle power Run the print job again If the message appears download the emulation software again page 129 Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board ILLGL OPR ACCSS 1 Illegal Operand Accessed 1 Firmware error on the CMX controller board Cycle power Run the print job again If the message appears download the emulation software again page 129 Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and retur
139. cover Make sure connector P107 PAPR M is fully seated in connector J107 on the controller board 8 Load paper Power on the printer Press PAPER ADVANCE and VIEW several times and check that paper moves in both directions Replace the paper feed motor if paper does not move in both directions 9 Power on the printer Press PAPER ADVANCE and VIEW several times and check that paper moves in both directions Replace the CMX controller board if paper does not move in both directions Power on condition 1 Remove the paper path or pedestal top cover Reseat all cable connections to the CMX controller board and the power supply board 2 Power up the printer If the printer hangs replace the CMX controller board 3 Power up the printer If the printer hangs replace the power supply board 77 Chapter 4 Troubleshooting Other Symptoms Table 3 General Symptom List Symptom Solution Printer does not print from the host Check the host data cable connection at the rear of the printer Attach the data cable to the printer interface Make a configuration printout Verify that the printer matches host interface settings Set printer interface parameters to match those of the host Power up the printer Send a print job from the host If printer does not print and the interface is RS 232 interchange the wires to pins 2 and 3 This is the most common cause of an inoperati
140. ctions Power on the printer Verify that all fans operate Replace any fan that does not operate Inspect vents and fan airways for obstructions Look underneath cabinet models for items blocking the cabinet exhaust vents Remove any obstructions from vents and airways Install the paper path or pedestal top cover Load paper Run the All E s print test for 5 to 10 minutes If the message appears replace the shuttle frame assembly Run the All E s print test for 5 to 10 minutes If the message appears replace the CMX controller board Record the message and return it with defective CMX board 39 Chapter 4 Troubleshooting Display Messages Table 2 Message List Message Explanation Solution failure on the CMX controller board CTL VOLT FAIL Controller Voltage Failure 15 V 1 Cycle Power Run the print job again If the message appears download the emulation software again page 129 Cycle power Run the print job again If the message appears replace the flash memory Power on the printer Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board Power on the printer Run the print job again If the message appears replace the power supply board Power on the printer If the message appears replace the shuttle frame assembly PASSED passed its memory and hardware initializati
141. cuit board enable these printers to print a wide variety of high volume jobs with minimum maintenance and maximum reliability LineJet printers are excellent graphics printers Code V and PGL are simple but versatile programming languages available as options for LineJet printers The Code V II graphics language is a QMS emulation PGL is a Printronix IGP emulation Although technologically advanced the LineJet 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 Chapter 1 10 About the Printer Important Maintenance Notes To ensure the best performance of the LineJet printer remember the following principles whenever you service it e Do not adjust the platen gap unless 1 the original shuttle frame assembly or platen has been replaced with a new or rebuilt unit or 2 you are instructed to do so in a troubleshooting procedure The hammer springs and hammer tips on the hammer bank are delicate and precisely aligned Never bend or tweak hammer springs and always handle hammer springs by the thick mounting base e Use only the ribbons specified in Appendix Use of incorrect ribbons can lead to ink migration problems degraded print quality and expensive damage to the printer e Never close the forms thickness lever too tightly Incorrect closure of the forms thickness lever can lead to sme
142. d LineJet Printers PGL Programmer s Reference Manual Part Number 171250 001 Explains how to write graphics programs using the optional PGL Printronix IGP emulation This graphics programming language allows the user to create and store forms generate logos bar codes and expanded characters create graphic images and merge graphics with alphanumeric data as a document is printed LineJet Printers LineJet Print Server User s Guide Part Number 170989 001 Explains how to use the 10 100Base T Ethernet network interface LineJet Printer Manager User s Guide Part Number 170988 001 PX Explains how to use the printer management software with the 10 100Base T Ethernet network interface Chapter 1 Safety Notices Safety Notices The following notices apply at all times when you are working on the printer To prevent serious personal injury from electrical shock when connecting or disconnecting the signal cable set the power switch to the off position and unplug the power cable 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 prevent injury from electric shock wait at least one minute after shutting off power before removing the power supply circuit boa
143. d connect the springs to the spring hooks in the side plates See page 206 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 24 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 bracket goes between the left platen adjustment bracket and the platen On the right side of the platen position a washer on both sides of the paper ironer bracket hook and position the hook to the left of the right platen adjustment bracket See Figure 24 15 16 20 21 22 23 24 25 Platen b Install and tighten the three screws Push the platen to the left 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 page 206 item 15 Open and close the forms thickness lever to make sure the setscrew does not touch the right ribbon guide 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 Install but do not adjust the platen open belt and platen open motor
144. d in one or both directions replace the defective ribbon drive motor s If the ribbon winds in both directions replace the CMX controller board Record the message and return it with defective CMX board RIBBON INK OUT CHANGE RIBBON RibbonMinder software has determined that the ribbon is out of ink Install a new ribbon and set ribbon life to 100 SECURITY CODE VIOLATION Security code of the PAL on the controller board does not match the code of the firmware on the CMX controller board 1 Remove the paper path or pedestal top cover Check that the security PAL is correctly installed 2 Install correct PAL for the customer s emulations with the notched end facing toward the flash and DRAM SIMM sockets 3 Run a print test If the message appears replace the CMX controller board Record the message and return it with defective CMX board SECURITY PAL NOT DETECTED The security PAL is missing or has failed Power off the printer Remove the paper path or pedestal top cover Check the security PAL at location U54 on the CMX controller board If the PAL is absent install the correct PAL If security PAL is present replace the CMX controller board Record the message and return it with defective CMX board 56 List of Messages Table 2 Message List Message Explanation Solution SENDING PROGRAM TO EC PROCESSOR Status message the printer is loading
145. d motor pulley off the motor shaft and the belt off the splined shaft pulley Installation 1 Install the paper feed timing belt over the splined shaft pulley and the motor pulley and collar Slide the motor pulley and retaining collar onto the paper feed motor shaft Align the belt so that it will run straight on both pulleys Tighten the two 5 16 inch bolts to secure the paper feed motor so that there is 1 8 inch deflection in the belt midway between the pulleys Holding a 0 040 inch feeler gauge between the pulley collar and the motor body tighten the 7 64 inch collar screw Snap the timing belt cover into the slots in the side plate See page 192 item 7 Cabinet Models Install the barrier shield and tighten the four screws See page 192 items 3 4 and 9 Pedestal Models Install the barrier shield and paper guide and tighten the four screws See page 194 items 3 4 and 5 Cabinet Models Install the paper path page 161 Pedestal Models Install the top cover assembly page 142 Return the printer to normal operation page 101 Belt Platen Open Belt Platen Open Removal 1 Prepare the printer for maintenance page 100 2 Cabinet Models Remove the paper path page 161 Pedestal Models Remove the top cover assembly page 142 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 206 item 24 4 Loosen do
146. digit number e g 123456 exe you noted above This is the file you will download into the printer 21 On the printer control panel press and hold down the ON LINE FF keys Without releasing the keys power the printer on Continue holding the ON LINE and FF keys down 22 When you see WAITING FOR PROGRAM DOWNLOAD on the LCD release the ON LINE and FF keys The port default is CENTRONICS this is the standard load through the parallel port If you want to use the default continue at step 18 23 Press the NEXT key SELECT DOWNLOAD PORT DATAPRODUCT appears on the LCD 24 Press NEXT again to cycle through the download ports available in the printer DATAPRODUCT parallel CENTRONICS parallel default port RS232 9600 RS 232 serial 9600 baud RS232 19 2K RS 232 serial 19200 baud RS232 38 4K RS 232 serial 38400 baud RS232 115K RS 232 serial 115000 baud RS422 9600 RS 422 serial 9600 baud RS422 19 2 RS 422 serial 19200 baud RS422 38 4K RS 422 serial 38400 baud RS422 115K RS 422 serial 115000 baud 25 When the printer download port you want to use is displayed on the LCD press ENTER WAITING DOWNLOAD PORT lt your selection gt appears on the display 26 At the DOS prompt on the computer type FILENAME EXE pb lt Return gt where FILENAME EXE is the compressed file you noted in step 20 This command decompresses the file on the hard drive and copies it as a
147. djust the platen open belt Replace the belt if it is damaged 36 Table 2 Message List List of Messages Message Explanation Solution CLEAR PAPER JAM continued 10 11 Bottom out the platen open motor pulley on the motor shaft and torque the 1 16 inch set screw to 9 2 inch pounds 1 02 0 23 Nem Tighten the 7 64 inch setscrew in the platen shaft pulley then open and close the forms thickness lever and check that the platen pulley setscrew does not hit the left ribbon guide Inspect the tractors and tractor door springs for damage or excessive wear If either tractor is worn or damaged replace both tractor assemblies Check the condition and tension of the paper feed belt Adjust the paper feed belt Replace the belt if it is damaged Check and adjust the platen gap 12 Clean the paper motion detector with a cotton swab and alcohol At the control panel set the paper motion detector PMD fault setting to DISABLE Load paper Run a print test and observe how the paper feeds If the message appears replace the CMX controller board Record the message and return it with defective CMX board If the message does not appear replace the paper detector switch assembly and set the paper motion detector PMD to ENABLE CLEARING PROGRAM FROM FLASH Status message emulation software successfully loaded into printer RAM and the checksum matched The old program
148. e status indicator on the control panel flashes on and off e audible alarm beeps if it is enabled Press CLEAR to silence the alarm e control panel LCD displays a fault message List of Messages Find the message in the Message List below and follow the suggested procedure After correcting an error press the CLEAR key to clear the message and place the printer in the off line state If an error is not cleared the printer will try to print again but will display the error message until the error is cleared 33 Chapter 4 Troubleshooting Display Messages Table 2 Message List Message Explanation Solution 8 5V POWER FAIL 8 5 Volt Power Failed Internal 1 power failure Cycle power If the message appears replace the power supply board Power on the printer If the message appears replace the CMX controller board Record the message and return it with defective CMX board Power on the printer If the message appears replace the shuttle frame assembly 15V CTL FAIL Controller Voltage Failure 1 Cycle Power Run the print job again If the message appears remove the hammer bank logic cable inspect it for damage and test it for continuity See Appendix A Replace the hammer bank logic cable if it is damaged or fails continuity test Cycle Power Run the print job again If the message appears download the emulation software again Cycle p
149. e Shel Splined Shaft 74 Fe 2 2 Pulley Tractor Support Shaft Shuttle Cover Assembly 22 Paper Feed Timing Belt under the cover Paper Supports gt Figure 47 Paper Transport System A two phase DC stepper motor directed by the engine controller EC drives two tractor sprockets by means of a toothed belt and splined shaft pulley The stepper motor permits extremely accurate incremental vertical paper movement This drive configuration is designed for continuous fan folded paper three to 17 inches wide and one to six sheets thick For reverse paper feeding the platen motor opens and closes the platen via a toothed belt Opening the platen prevents paper jams when paper direction is reversed moved downwards after viewing the print area setting top of form or allowing applications to overprint forms Paper is positioned horizontally using the tractors and the horizontal adjustment knob Each tractor is locked in position with a friction lock and engages the paper perforations with six sprocket pins The horizontal adjustment knob allows vernier positioning of the left print margin The vertical adjustment knob is used to position paper vertically by hand 220 Ribbon Transport System Ribbon Transport System pS Hub e 2 Left Ribbon Guide 2 2 Not Shown Locking Latch lt lt Ribbon Spool Ribbon Motors Right Ribbon Guide Ribbon Figure 48 Ribbon Transport Sys
150. e assigned part numbers If a part or assembly is damaged but does not have a part number replace the entire power stacker assembly To replace the entire stacker assembly order Field Kit Stacker Advance Exchange Kit 170690 991 The IPB starts on the next page 335 Appendix Illustrated Parts Breakdown See page 338 Figure 80 Stacker Assembly 336 Item No Part No Description Notes 1 170690 991 Field Kit Stacker Advance Exchange Replacement stacker not Kit illustrated 5 202706 904PX Flanged Bearing Part of item 36 6 158342 001PX Paper Deflector Early model stacker 170719 001PX Paper Deflector Later model stacker 7 202721 901PX Clip On Bearing Part of item 36 8 Ref Screw Torx 6 32 x 25 Part of item 36 9 Ref Screw Shoulder 10 32 Part of item 36 10 202716 001PX Timing Belt 11 156388 001PX Shaft Lift 12 163992 001PX Pulley Timing Belt 13 159398 001PX Pulley Motor 14 150784 901PX Grounding 15 158446 001PX Motor 20 202713 001PX Constant Force Spring 25 151527 905PX Chain Mount chains outboard of shafts 30 202705 901PX Nylon Plug 35 202720 901 Cable 36 164405 001PX Stacker Hardware Kit Kit not illustrated 37 Ref Screw Shoulder 8 32 Part of item 36 38 170285 001PX Power Stacker Limit Switch Field Kit 158732 901PX 158442 001PX 158443 001PX 158444 001PX Ref Control Panel Assembly Rail Cable Power Stacker Power Cable Power Stacker Logic Cable
151. e blank SIMM is not a type supported by the boot code on the original SIMM If SOURCE LARGER THAN DESTINATION appears the blank SIMM is not large enough to contain the code on the original SIMM If the SIMM does not copy or the ERROR WRITING TO FLASH message appears replace the blank SIMM 3 Power on the printer From the Boot Diagnostics menu select and run MISC UTILITIES COPY FLASH SIMMS If the new SIMM does not copy replace the CMX controller board 76 General Symptom List Table 3 General Symptom List Symptom Solution Paper feeds poorly 1 Check the forms thickness lever if it is set too tightly paper feeding can be affected Set the forms thickness lever to match the thickness of the paper being used 2 Power off the printer Remove paper Inspect the paper feed path for obstructions that could snag paper Clear paper feed path of any obstructions 3 Inspect the tractors and tractor door springs for damage or excessive wear If either tractor is damaged or visibly worn replace both tractor assemblies 4 Check the paper feed motor pulley for looseness Hold the collar snug against the motor pulley and torque the 7 64 inch setscrew to 25 2 inch pounds 2 82 0 23 Nem 5 Check the condition and tension of the paper feed timing belt Adjust the paper feed timing belt Replace the belt if it is damaged 6 Check the platen gap Adjust the platen gap 7 Remove the paper path or pedestal top
152. e perforation the paper out adjustment distance is correct skip to step 26 1 or 2 dot rows above the perforation is OK 5 to 7 dot rows above or any dots below the perforation mean adjustment of the Paper Out Dots value is required If the comb pattern stopped short of the perforation or printed beyond the perforation go to step 14 14 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 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 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 15 Close the platen 16 Press CLEAR to remove the fault condition OFFLINE CONFIG CONTROL displays 17 Press the 4 key DIAGNOSTICS displays 18 Press V DIAGNOSTICS Printer Tests displays 19 Press gt until Paper Out Dots displays 20 Press V The top line of the display will show Paper Out Dots and the bottom line will show the current setting for the number of dots 119 Chapter 5 120 Paper Out Adjustment 21 22 23 24 25 26 27 28 29 Press The number of dots will move up to th
153. e top line of the display with an asterisk next to it Using the gt or 4 key adjust the XX DOTS value up or down by the number of dots you counted in step 14 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 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 Press CLEAR to place the printer offline OFFLINE CONFIG CONTROL displays Run the Paper Out Dots and the Paper Out Adjustment tests until the comb pattern prints at an acceptable distance from the page perforation Return to step 9 When the paper out triggering distance is acceptable reload the paper feed it past any remaining unused holes that you tore in it and set the top of form Press ENTER SWITCH LOCKED briefly displays Close the printer cover Press the ON LINE key to place the printer on line List of Adjustments 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 vertical 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 c
154. ear 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 25 163 Chapter 6 164 Section Replacement Procedures Washers Platen Adjust N Q a Bracket D LN Platen 4 f Mechanism Base Platen Seat y A LZ Figure 25 Positioning the Platen Adjust Brackets 9 Slide the right ribbon guide assembly into the side plate and install the two 7 32 inch screws and washers See page 208 items 11 13 and 14 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 page 206 item 26 12 Apply bearing lubricant to the nylon bearings in the two spring links slide the spring links onto the two platen shafts an
155. echanism with no ribbon movement e Phase Printer A hammer timing test that permits you to adjust the hammer phase value The hammer phase value is a timing parameter that controls 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 casting of the shuttle assembly next to the motor housing Use this value as your starting point when adjusting hammer phasing e Paperout Adj Prints a vertical comb pattern You use this pattern when you do the end of forms paper out adjustment procedure The comb pattern lets you measure the number of dot rows from the completion of a paper out fault to the end of the paper Burnin Test Do not use This test is used by the printer manufacturer to burn in the printer prior to shipment and has no value as a maintenance tool 84 Selecting and Running Diagnostic Printer Tests Selecting and Running Diagnostic Printer Tests You must set TOF after running any diagnostic test Step Press LCD Result Notes 1 Make sure the printer is on Raise the printer cover Load paper 2 3 Set TOF Refer to the User s Guide 4 ON LINE OFFLINE The printer must be CONFIG CONTROL offline to run a print test 5 ENTER SWITCH Unlocks ENTER key T Ww UNLOCKED and control pan
156. ed NET Network Indicator The NET LED displays the status of the network link When the NET LED is on this confirms link integrity The NET LED flashes off for 1 3 second when a data packet is being transferred When the NET LED is off the network connection has been severed 145 Chapter 6 Section Replacement Procedures DIP Switches On the back of the 10 100Base T interface inside the printer there are two DIP switches labeled 1 and 2 The functions of the DIP switches are explained in Table 6 Table 6 10 100Base T DIP Switch Settings DIP Switch Description 1 2 OFF OFF Normal operation With both DIP switches in the OFF posi tion the interface boots up using the settings in flash mem ory rather than the default settings ON OFF Factory default settings With the DIP switches in this configuration the interface boots up and all settings stored in flash memory are erased except the Ethernet address and key value OFF ON Default IP With the DIP switches in this configuration the interface boots up with factory default settings but the stored settings in flash memory remain intact Setting DIP switch 2 to ON does not clear any settings stored in flash memory it boots the unit in a different state with the settings in flash memory temporarily ignored ON ON If the interface is connected to a network with link integrity and then reset to MOS a download will be forced If the unit is not c
157. ed in connector J110 on the controller board Make sure the DRAM SIMM s is are seated properly in J15 J16 Reseat DRAM SIMM s Power on the printer Inspect the control panel display If the control panel shows broken characters replace the DRAM Power Failures No power and control panel blank and card cage fan not running Check that the AC power outlet has power Restore AC power if necessary Unplug the printer AC power cord from the printer leave it plugged into the power outlet and check for AC power at the printer end of the cord If there is no power through the AC power cord replace it Plug the AC power cord into the printer and power outlet Remove the paper path or pedestal top cover Verify that the AC In power cable and the AC power input cables are connected to the on off switch circuit breaker See Figure 42 page 226 Make sure all ground connections are clean and tight Check that AC in power cable connector P1 is connected to J1 on the power supply board Reseat the connector Check that power supply cable connector P101 is connected to J101 on the CMX controller board Reseat the connector Check all cable connections on the CMX controller board Disconnect AC in power supply cable connector P1 Set the circuit breaker to 1 on Measure AC voltage at pins 1 and 2 of connector P1 If no voltage replace the circuit breaker If there is voltage replace the power supply board Printer
158. el OFFLINE CONFIG CONTROL 6 s OFFLINE E DIAGNOSTICS 7 DIAGNOSTICS NA Printer Tests 8 DIAGNOSTICS J UNTIL Test Width 9 Test Width S Full Width 10 Test Width Cycle through choices 2 X X Full Width or X 80 columns 11 ENTER Test Width Test width is selected x 12 DIAGNOSTICS a Test Width 13 DIAGNOSTICS UNTIL Printer Tests 85 Chapter 4 Diagnostic Printer Tests Step Press LCD Result Notes 14 MK Printer Tests Shift Recycle 15 Printer Tests Cycle through the lt oR 2 All E s choices 16 ENTER Printer Tests Starts test All E s 17 ENTER Printer Tests Stops test All E s 18 ENTER SWITCH Locks the ENTER key a LOCKED and control panel 19 ON LINE ONLINE Places the printer in LinePrinter online mode 20 Examine print quality Characters should be fully formed and of uniform density 21 Set TOF Refer to the User s Guide 86 Selecting and Running Diagnostic Printer Tests Boot Diagnostics Menu Printer boot up software contains a Boot Diagnostics menu that you can access by holding down two keys while powering on the printer This menu is not intended for the end user but provides useful information for manufacturing and maintenance personnel The boot diagnostics menu is a multi level menu t
159. embly page 172 RIDDOMIFIUBD goes 173 Shaft SPINEA t re eee ep y ease page 174 Shaft Support s aa ue page 176 Shuttle Frame page 177 Spring Extension Hammer page 179 Switch Assembly Paper page 180 Switch Assembly Platen Interlock page 181 actor O RY A page 182 127 Chapter 6 128 Section I Replacement Procedures Belt Paper Feed Timing Removal 1 2 Prepare the printer for maintenance page 100 Cabinet Models Remove the paper path page 161 Pedestal Models Remove the top cover assembly page 142 Cabinet Models Loosen four screws and remove the barrier shield See page 192 items 3 4 and 9 Pedestal Models Loosen four screws and remove the paper guide and barrier shield See page 194 items 3 4 and 5 Remove the timing belt cover by squeezing the front and back to release the plastic tabs from the slots in the side plate See page 192 item 7 Loosen the 7 64 inch setscrew in the paper feed motor pulley collar See page 208 item 8 Loosen do not remove the two 5 16 inch paper feed motor mount screws See page 208 item 10 Remove the paper feed timing belt by sliding the paper fee
160. embly Pedestal Models page 136 Controller Board sse page 137 Cover Assembly Hammer Bank Ribbon Mask page 139 Cover Assembly Shuttle essere page 141 Cover Assembly Top Pedestal Models page 142 EE page 143 Ethernet Interface page 144 Fan Assembly Cabinet page 147 Fan Assembly Card page 148 Fan Assembly Hammer Bank page 149 List of Removal Installation Procedures Hammer Spring Assembly sse page 150 Magnetic Pickup MPU page 154 Memory Modules and Security PAL page 155 Paper Feed 2 4440 2 0 page 158 Paper tonels page 160 atio iari page 161 Platon ESadue nS nai page 162 Platen Open 10 102021 enne nnne page 166 Power Supply Board eene page 168 Resistors Terminating sss tiiri ee eea E page 169 Ribbon Drive Motor na A page 171 Ribbon Guide Ass
161. er is online press the ON LINE key to place the printer offline OFFLINE CONFIG CONTROL displays Print out the printer configuration Refer to the User s Guide Verify that the configuration printout shows the correct SHUTTLE TYPE If the shuttle type is incorrect return to step 3 and do this procedure again Return the printer to normal operation page 101 123 Chapter 5 SetShuttle Speed 124 6 Organization Replacement Procedures and Illustrated Parts Lists 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 The replacement procedures refer you to the illustrations in Section Il Section begins on page 126 Section II Illustrated Parts Lists Drawings of all electrical and mechanical assemblies in the printer On the page facing each illustration is a list of the illustrated parts and their part numbers Only field replaceable spares are given part numbers in the illustrated parts lists Part numbers are not listed for common fasteners and attachment hardware Items marked Ref in the illustrations refer to parts that are not spared or are part of another assembly Section Il begins on page 183 125 Chapter 6 Section I Replacement Procedures Section I Replacement Procedures Unplug the printer
162. ercial power 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 volts to 270 volts 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 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 one 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 Q 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
163. erial Port The boot code checks the validity of the debug serial parameters in NVRAM if they are valid it sets the baud rate data type and which messages should be sent out the debug port If the values in NVRAM are not valid boot code initializes NVRAM to 9600 baud 8 data bits one stop bit no parity bit and standard messages Turn On Instruction Cache The instruction cache is turned on to help speed up memory tests and the entire boot process Enable DRAM Controller A DRAM controller is built into the VX ASIC DRAM must be refreshed a few times to operate correctly To speed the boot process the refresh rate is temporarily increased The message TESTING HARDWARE PLEASE WAIT is sent to the LCD during which time the refreshes run and finish At this point the fans start After sending the message the refresh rate is set to the proper rate and DRAM is ready to be tested Test I O Clock The VX ASIC has two clocks for internal timing a processor clock and an I O clock The processor clock cannot be checked because the processor will not run without it but the I O clock can be checked The I O clock is used for sending data to the control panel and to get the time for DRAM refreshes If the boot code detects a problem with the I O clock the error blink code 4 3 4 is sent to the diagnostic LED on the CMX board Controller Board Handshake Sequences Read Control Panel Keys The control panel keys are read t
164. ers out of the debug serial port 95 Chapter 4 96 The Power On Sequence Check for Pedestal Boot code uses the control panel to determine if the printer is a pedestal or floor cabinet model Boot code needs to know the difference so the exhaust fan fault can be disabled on a pedestal model FAN DISABLED is printed out at the debug serial port of a pedestal model Check for Download Mode Boot code checks whether the ON LINE and FF keys were pressed at power up If so the printer enters download mode If not the printer continues the boot routines Check for Diagnostics Mode Boot code checks whether the 4 PREV and DOWN keys were pressed at power up If so the printer enters the Boot Diagnostics menu If not the printer continues the boot routines Check for Remote Download Mode Boot code checks if the user remotely requested the printer to enter download mode If so the printer enters download mode If not the printer continues boot routines Check for Flash Optimize Boot code checks if the user requested the flash file system to be optimized at power up If so flash memory is optimized at this time If not the printer continues boot routines Check EC Program The EC calculates a checksum of the program stored in its flash memory If there is problem with its program the EC puts the message in the ECDC communications register If the boot code detects this message it dis
165. es the same technology as the DC flash it is 5 0V only and is rated for a minimum of 100 000 write erase cycles EC memory is fixed it is soldered to the controller board Its contents can be updated through the DC through the serial or parallel ports At run time the EC also stores tables in shared DRAM which is accessed through the Cajun bus MECA ASIC The 166 uses numerous counters PWM generators and FIFOs in the MECA to control many printer motor functions The MECA is a custom gate array specifically designed to drive this system Analog Drive Circuitry The analog drive circuits convert 48 volts 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 229 Chapter 7 Power Supply Board The printer uses five motors two ribbon drive one paper feed one platen open and one shuttle motor 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 turnaround The drive ribbon motor is microstepped in voltage mode while
166. for maintenance page 100 Unlock the tractors and slide them to the far right Remove the paper supports from the splined shaft and support shaft See page 204 item 20 4 Remove the E ring page 204 item 17 Hold the tractors while removing the support shaft Be careful not to lose the curved spring washers See page 204 item 5 5 Slide the support shaft assembly consisting of the support shaft two curved washers bushing horizontal adjustment knob washer and screw to the left out of the tractors and the left side plate See page 204 items 1 through 5 and 15 Installation 1 Slide the support shaft assembly consisting of the support shaft two curved washers bushing horizontal adjustment knob washer and screw into the left side plate See page 204 items 1 through 5 and 15 Slide the tractors onto the support shaft Slide the support shaft assembly through the right side plate Push the horizontal adjustment knob to compress the curved washers and install the E ring in the groove on the support shaft 5 Install the paper supports to the splined shaft and support shaft See page 204 item 20 6 Return the printer to normal operation page 101 176 Shuttle Frame Assembly Shuttle Frame Assembly Removal 1 Prepare the printer for maintenance page 100 Remove the shuttle cover assembly page 141 Disconnect the MPU cable connector and shuttle motor cable connector
167. g Belt Pulley and Motor 331 Appendix H _ Replacing the Timing Belts 5 Loosen the two setscrews on the motor pulley and remove the pulley Unplug the motor cable if necessary See Figure 76 Go to step 6 Legend 1 Timing Belt Motor 2 Setscrew 3 Pulley Figure 76 Removing the Timing Belt Motor Pulley 6 Remove the shoulder screw washers and spacer that secures the constant force spring to the vertical rail See Figure 77 Legend 1 Large Washer 2 Spacer 3 Constant Force Spring 4 Shoulder Screw Figure 77 Releasing the Constant Force Spring 332 7 Remove two Allen screws from the belt clamp that secures the timing belt to the stacker frame See Figure 78 Legend 1 Allen Screw 2 Belt Clamp Figure 78 Removing the Belt Clamps 333 Appendix H _ Replacing the Timing Belts 8 Remove the timing belt by working it around the vertical rail and constant force spring See Figure 79 NOTE Left timing belt is shown Right is the same 5 555 KKK Legend 1 Timing Belt Figure 79 Removing the Timing Belt To install a timing belt reverse the steps of this procedure 334 Illustrated Parts Breakdown The Illustrated Parts Breakdown IPB consists of exploded drawings of the power stacker assembly and subassemblies Parts are listed next to each drawing Only replaceable parts ar
168. ge 161 Pedestal Models Remove the top cover assembly page 142 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 two 5 16 inch motor mount screws 2 enough to permit movement of the platen open motor Some motors are mounted with nuts and bolts other motors have threaded flanges eliminating the need for nuts 5 Close the forms thickness lever all the way 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 Push the platen open motor toward the rear of the printer until there is 1 8 inch belt deflection midway between the pulleys then tighten the upper motor mount screw with a 5 16 inch nutdriver Tighten the lower motor mount screw with a 5 16 inch open end wrench Check belt deflection after both motor mounts have been tightened Snap the platen open belt cover 1 into the slots in the side plate Cabinet Models Install the paper path page 161 Pedestal Models Install the top cover assembly page 142 9 Return the printer to normal operation page 101 104 List of Adjustments Direction of Force Legend 1 Belt Cover 2 Motor Mount Screw 2 3 Platen Open Motor Shaft Figure 10 Platen Open Belt Adjustment 105 Chapter 5 Paper Drive Motor Pulley Al
169. guides are loose tighten them If the ribbon guides are damaged replace them Power off the printer Remove the shuttle cover Remove the shuttle frame assembly Inspect the ribbon mask for bends or deformation that adversely affect paper feeding Make sure the hammer bank cover assembly is correctly installed on its mounting pegs Check the shuttle frame assembly for broken hammer springs hammer tips or contaminations Replace any damaged hammer spring assemblies Replace the hammer bank cover assembly if it is deformed or damaged Check the platen gap Adjust the platen gap if necessary Remove the paper guide assembly or pedestal top cover Make sure Connectors P105 and P108 have good connections on the controller board Make sure connectors P04 and P05 have good connections at the shuttle frame assembly Reseat connectors P04 P05 P105 and P108 Power on the printer If the problem still occurs replace the hammer bank logic cable and the hammer bank power cable Power on the printer If the problem still occurs replace the shuttle frame assembly Power on the printer If the problem still occurs replace the power supply board Power on the printer If the problem still occurs replace the CMX controller board 73 Chapter 4 Troubleshooting Other Symptoms Table 3 General Symptom List Symptom Solution Horizontal misalignment of characters Dots or characters move left or right from dot row
170. h defective CMX board driver circuits on the CMX controller board are shorted to ground UP DRV SHORT Upper Driver Short Hammer 1 Cycle power If the message appears press CLEAR If the message does not clear replace the hammer bank logic cable and the hammer bank power cable assemblies Power on the printer If the message appears replace the CMX controller board Record the message and return it with defective CMX board Power on the printer If the message appears replace the shuttle frame assembly 62 List of Messages Table 2 Message List Message Explanation Solution WAITING FOR This status message appears No action required ETHERNET ADAPTER when the printer is first powered on if the optional PrintNet Ethernet interface is installed An Ethernet adapter must be detected early in the power up sequence so the printer can tell the adapter it has been detected and continue with its own power up sequence Compared to the printer the Ethernet adapter takes a long time to complete its internal diagnostic tests so the boot code allows the adapter to power up in parallel with the printer to reduce its effect on overall boot time 63 Chapter 4 Troubleshooting Other Symptoms Troubleshooting Other Symptoms Always disconnect the AC power cord from the printer before doing a maintenance procedure Failure to remove power could result in injury to you or da
171. hammer spring replacement kit See Figure 22 page 153 4 Install the mounting screws from the replacement kit Using a Torx T 10 bit adapter tighten the center screw s then the outer screws See Figure 22 page 153 Install the hammer bank cover assembly page 139 Install the shuttle frame assembly page 177 Install the ribbon and load paper Do not attempt to adjust or tweak hammer springs 8 Run a Diagnostic Printer Test and check print quality page 84 a If print quality is acceptable return the printer to normal operation page 101 b If print quality is still degraded replace the shuttle frame assembly page 177 152 Hammer Spring Assembly NOTE LineJet 500Q hammer bank and hammer spring assemblies shown here Although hammer spring assemblies vary removal and installation are the same for all models Use new screws from the kit and the Torx T 10 bit adapter to install them ew Hammer Spring Assembly Figure 22 Hammer Spring Assembly Installation 153 Chapter 6 Section Replacement Procedures Magnetic Pickup MPU Assembly Removal 1 Prepare the printer for maintenance page 100 Remove the shuttle cover page 141 Disconnect the magnetic pickup MPU cable connector page 202 item 5 Loosen the 7 64 inch hex MPU clamp screw page 202 item 3 Unscrew the MPU assembly from the MPU bracket Installation 1 Install the MPU
172. hat operates the same way as the user menus The menu structure is shown in Figure 7 on page 88 Activating the Boot Diagnostics Menu Set the printer power switch to O off On cabinet models raise the printer cover On the control panel press and hold down 4 PREV DOWN While holding 4 PREV DOWN set the printer power switch to 1 on 5 When BOOT DIAGNOSTICS PRESS ENTER appears on the LCD release the 4 PREV DOWN keys 6 Press the ENTER key Menu options are shown in Figure 7 dE UE Exiting the Boot Diagnostics Menu Method 1 Resetting the printer from the Boot Diagnostics Menu 1 Using the directional keys move to the MISC UTILITIES RESET PRINTER menu option Refer to the menu map on page 88 2 Press the ENTER key Method 2 Cycling power 1 Power off the printer 2 Wait 15 seconds 3 Poweron the printer 87 Chapter 4 Boot Diagnostics Menu NOTE BOOT DIAGNOSTICS PRESS ENTER DOWN key gt NEXT key ENTER BOOT DIAGNOSTICS gt VERSION CHECK v VERSION CHECK VERSION CHECK VERSION CHECK VERSION CHECK BOOT VERSION SOFTWARE VERSION gt EC VERSION gt ASIC VERSIONS 09 08 95 1 00 VX VERSION F 11 41 08 07Sep95 154643 VERSION F VERSION CHECK BOARD VERSION VERSION CH
173. hat the forms thickness lever is not being set too tightly Set the forms thickness lever to match the thickness of paper and provide satisfactory print quality but not too tightly Check the paper feed motor pulley for looseness Make sure the correct pulley is being used it should have 25 teeth Hold the collar snug against the motor pulley and torque the 7 64 inch setscrew to 25 2 inch pounds 2 82 0 23 Nem Replace the paper feed pulley if it does not have 25 teeth Check the condition and tension of the paper feed timing belt Adjust the paper feed timing belt Replace the belt if it is damaged Remove the paper path or pedestal top cover Make sure connector P107 PAPR M is fully seated in connector J107 on the controller board Connect P107 PAPR to J107 on the controller board Power on the printer Load paper and set TOF Press PAPER ADVANCE and VIEW several times and check that paper returns to TOF Replace the paper feed motor if paper does not return to TOF Power on the printer Press PAPER ADVANCE and VIEW several times and check that paper returns to TOF Replace the controller board if paper does not return to TOF 79 Chapter 4 Troubleshooting Other Symptoms Table 3 General Symptom List Symptom Solution Ribbon Ribbon folding or feed problems Check that both ribbon spools are fully seated on the ribbon hubs and the ribbon runs between the ribbon mask a
174. he defective board ERROR SHORT AT ADDRESS XXXX Hardware failure in DRAM or CMX controller circuitry Download the program again If the message occurs again replace the DRAM If message occurs with new memory replace the CMX controller board Record the message and return it with defective CMX board ERROR WRITING TO FLASH Hardware or software fault in flash memory Replace flash memory If message occurs with new memory replace the CMX controller board Record the message and return it with defective CMX board ERROR WRONG CHECKSUM The printer received the complete program but the checksum did not match The data may have been corrupted during download 1 Power off the printer Download the program again from the beginning If the messages appears replace the DRAM 2 Download the program using a new software diskette If the messages appears replace the flash memory 3 Download the program If the messages appears replace the CMX controller board Record the message and return it with defective CMX board ERROR OCCURRED FLUSHING QUEUES An interim message that displays while the printer discards host data it cannot use because a fault condition exists While this message displays the asterisk rotates Wait When the asterisk stops rotating a different fault message will appear troubleshoot the final message 42 List of Messages Table 2 Mes
175. hese are suitable for most applications See Figure 26 page 170 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 RP1 Pull Up RP2 Pull Down Factory Default 470 Ohm 1K Ohm Alternate 1 220 Ohm 330 Ohm Alternate 2 1K Ohm None Removal To prevent electrostatic damage to electronic components always wear a properly grounded static wrist strap when you handle circuit boards 1 Prepare the printer for maintenance page 100 2 Cabinet Models Remove the paper path page 161 Pedestal Models Remove the top cover assembly page 142 3 Locate the terminating resistor packs See Figure 26 page 170 Using chip puller remove the resistor packs Installation To prevent electrostatic damage to electronic components always wear a properly grounded static wrist strap when you handle circuit boards 1 Using a chip installation tool install the resistor packs in the correct socket See Figure 26 page 170 169 Chapter 6 Section Replacement Procedures 2 Cabinet Models Ins
176. iation ENERGY STAR is a registered trademark of the United States Environmental Protection Agency Ethernet is a trademark of Xerox Corporation IBM is a registered trademark of International Business Machines Corporation IEEE is a registered service mark of the Institute of Electrical and Electronics Engineers IGP PGL and Printronix are registered trademarks of Printronix Inc Lubriko is a registered trademark of Master Lubricants Company Motorola is a registered trademark of Motorola Inc MS DOS is a registered trademark of Microsoft Corporation MTOS is a registered trademark of Industrial Programming Inc PC DOS is a trademark of International Business Machines Corporation PCL is a registered trademark of Hewlett Packard Company PKZIP is a registered trademark of PKWARE Inc QMS is a registered trademark of Quality Micro Systems Inc Siemens is a registered trademark of Siemens Corporation SureStak is a trademark of Printronix Inc Torx is a registered trademark of Camcar Textron Inc Copyright 1995 2000 Hewlett Packard Company Table of Contents Maintenance 9 About the Printer RI EE fedens 9 Important Maintenance Notes 2 10 About This Manu al 2 tet iR ERR kh ERR ee RE 11 Notes and Notices eter teet Ire rt eqs 11 Printing Conventions in This
177. ich secures the line filter ground line and the AC In Power Supply cable lead to the ground stud is tight See Figure 42 page 226 Disconnect the AC power cord and check the ground leads for continuity Replace the AC power cord if it fails continuity test Make sure the printer is plugged in to a grounded power outlet Power up the printer Run a print test If the problem occurs replace the hammer bank logic cable Power up the printer Run a print test If the problem occurs replace the flash memory and DRAM Download the emulation software again Power up the printer Run a print test If the problem occurs replace the CMX controller board Power up the printer Run a print test If the problem occurs replace the power supply board Power up the printer Run a print test If the problem occurs replace the shuttle frame assembly 74 General Symptom List Table 3 General Symptom List Symptom Solution Vertical misalignment of 1 Load paper Press PAPER ADVANCE and check that paper characters feeds smoothly Press VIEW to verify that paper moves in both 1 Dots or characters move up or directions Check the forms thickness lever if it is set too loose or down from dot row to dot row or too tightly print quality can be affected Set the forms thickness line to line lever to match the thickness of the paper being used 2 Incorrect spacing from dot row 2 Check the paper feed motor pulley for looseness H
178. ight Form weight Minimum 15 Ib 6 8 kg Maximum 100 Ib 45 36 kg Form Thickness Form thickness 0 025 inches 0 0635 cm maximum measured at the thickest point of the form which includes perforations compressed staples glue lines etc Form Evenness The evenness of the form Not to exceed 0 003 in 0 0635 cm Tenting due to buildup of perforation thickness must be minimized A perforation thickness measured at the major perforation that exceeds 1 25 times the forms thickness measured in the print area will result in an Chaff Content unreliable and unpredictable form Perforation thickness must not exceed the maximum form thickness of 0 025 in 0 0635 cm Tractor Pin Holes The holes which engage the tractor pins must conform to the following specifications hole CL to righthand hole CL Specification Inches Millimeters Hole centerline CL to edge of form 0 236 0 028 6 0 0 1 Hole Diameter Serrations or any 0 156 0 004 4 0 0 1 occlusion due to incorrect registration of multipart forms cannot exceed this dimension Distance between centers of two 0 500 0 002 12 7 0 05 consecutive holes Maximum deviation of holes from their 0 004 0 1 centerline Maximum deviation of lefthand hole to 0 006 0 15 adjacent righthand hole CL to CL Maximum parallel deviation of lefthand 0 006 0 15 Methods of Forms Attachment Must not allow air entrapment between copies
179. ign the ribbon guides page 114 3 Return the printer to normal operation page 101 172 Ribbon Hub Ribbon Hub Removal 1 Prepare the printer for maintenance page 100 2 Loosen the Torx T 10 screw in the ribbon spool hub page 208 item 20 3 Remove the hub from the shaft of the ribbon drive motor Installation 1 Install the ribbon spool hub over the motor shaft page 208 item 20 2 Tighten the Torx T 10 hub screw so that it contacts the flat section of the motor shaft 3 Return the printer to normal operation page 101 173 Chapter 6 Section Replacement Procedures Shaft Splined Removal 1 Prepare the printer for maintenance page 100 2 Remove the paper supports from the splined shaft and support shaft See page 204 item 20 Remove the paper feed timing belt page 128 Remove the 1 4 inch screw securing the ground clip and remove the clip page 204 items 10 and 11 5 With grip ring pliers remove the grip ring from left side of the splined shaft page 204 item 6 6 Pull the bearing and spring link with the spring off the left side of the splined shaft page 204 items 7 8 and 9 Unlock the left and right tractors and slide them to the center of the shaft Remove the 1 4 inch screw securing the bearing clamp on the right side of the splined shaft and remove the clamp page 204 items 13 and 14 9 Hold the tractors so they do not fall grasp the vertical adjustment
180. ignment Paper Drive Motor Pulley Alignment 1 Prepare the printer for maintenance page 100 2 Cabinet Models go to step 3 Pedestal Models Remove the top cover assembly page 142 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 Loosen the 7 64 inch screw 2 in the motor pulley collar 3 5 Align the paper drive motor pulley 4 with the splined shaft pulley 5 Make sure there is at least 0 040 inches 1 016 mm of clearance between the collar pulley and the motor face plate h d 6 Hold the collar 3 flush against the motor pulley 4 and tighten the 7 64 inch screw 2 7 Check for correct tension on the paper feed timing belt page 102 Adjust if necessary Snap the timing belt cover 1 into the slots in the side plate Cabinet Models go to step 10 Pedestal Models Install the top cover assembly page 142 10 Return the printer to normal operation page 101 106 List of Adjustments Legend 1 Belt Shield 2 Cap Screw 3 Motor Pulley Collar 4 Motor Pulley 5 Splined Shaft Pulley Figure 11 Paper Drive Motor Pulley Alignment 107 Chapter 5 Paper Scale Alignment Paper Scale Alignment 1 Open the printer cover 2 Load paper and ribbon 3 Connect the power cord to the AC power source 4 Set the printer power switch to 1 on 5 Verify that the shuttle cover 1 is properly installed
181. igure 8 below You can use hex dumps as an aid in troubleshooting data reception problems In a hex dump every printable character is printed both as its assigned symbol and as its hex equivalent Every unprintable ASCII control character is printed out as a period and its hex equivalent 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 92 To make a hex code printout refer 90 to the procedure on page 91 IDREXALO0G 20 21 228 24 25 26 27 28 29 2A 2B 2E 0123456789 gt 32 22 24 35 36 37 38 39 3E 3C 3D eABCDEFGHIJALMNO 40 41 42 43 44 45 45 47 48 49 4 4B 4C 4D 4E PGRSTUVWXYZLNIT 50 51 52 53 54 55 56 57 58 59 SB SC SD SE SF abcdefghijklmno 60 61 62 64 65 66 67 68 99 B 6 6D 6E OF parstuvwxyz i 70 71 72 73 74 75 76 77 78 79 7A 7B 7C 7D Cet 0 21 22 23 24 25 26 27 98 29 2 2B 2D 2E 2F 30 122455789 lt gt 31 32 33 34 35 37 38 39 3D 40 ABCDEFGH 4 amp Z amp 41 42 43 44 45 47 48 OD OA 21 22 23 24 25 26 0123456 27 BB 29 24 2B 2 20 2E 2F 30 31 32 33 34 35 36 789 4 27G0ABCDEF 27 38 39 3B 3D 40 41 42 43 44 4
182. ile on the diskette and copies it as a binary file into the flash memory on the printer controller board If you are loading the file using the LPT2 port on the computer enter the following DOS command FILENAME EXE pb 2 lt Return gt The 9600 baud rate is the only selection older versions of DOS can use The baud rate information entered in the following DOS commands must match the selection you made in step 16 If you are loading the file through the printer serial port enter the following DOS commands MODE COM1 9600 N 8 1 P lt Return gt FILENAME EXE pbc1 lt Return gt 19 While the file is copied into memory the printer LCD informs you of the load process and status See Table 2 page 34 20 When the new program 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 computer and store it with the printer 23 Power off the computer 24 If you had to install data cable to the computer and printer in step 6 disconnect it from the computer and printer 25 Reconnect the customer s data input cable s to the printer if required 26 Return the printer to normal operation page 101 27 Using the configuration printout s you made in step 1 reconfigure the printer Refer to the User s Guide 287 Appendix D Loading Flash Memory from Multiple Diskettes Loading Fl
183. imum Right Margin 1 to 13 6 inches 2 54 to 34 54 cm Maximum Left Margin 0 to 13 5 inches 0 to 34 29 cm Maximum Form Length 16 inches 40 64 cm Minimum Form Length 2 inches 5 08 cm Table 8 Paper Weights Single Part Forms Standard 15 to 100 pound 57 to 380 gm meter Best Print Quality 18 to 60 pound 68 to 227 gm meter Multipart Forms Carbon Paper 12 pounds 46 gm meter up to 6 total pages Carbons 8 pounds 30 gm meter up to 6 total pages Pack Thickness Maximum 0 025 inch 0 0635 mm total Carbonless Up to 4 part forms Terms and Definitions Test the paper first if it will be used in environments with greater than 80 or less than 20 humidity Test paper that will be used at high humidity for satisfactory feeding and handling Test paper that will be used at low humidity to determine if static buildup must be eliminated for proper paper stacking Paper Guidelines The terms below are used to describe and discuss continuous form paper Terms and Definitions Chaff Cut Point Cut to Tie Evenness Residual bits of paper not completely removed after the punch process that creates tractor pin holes major and minor perforations etc The area along a perforation where a cut has been made that extends through the entire form The ratio of cut points to tie points occurring along a perforation The amount of variation between the thickest and thinnest
184. in the correct what made the key s stick down position Check the 2 Cycle power power off the printer control panel for stuck key s wait 15 seconds power on the printer If the message appears replace the control panel FREEFORM ON OFF This message appears if the 1 Power off the printer Hold any HOLD KEY PWRUP freeform feature is enabled control panel key down and power on This feature is for the printer Hold the key down until manufacturing use only and is the printer powers up and the never used by the customer or message FREEFORM OFF appears field maintenance personnel on the LCD 2 Ifthe message reappears after doing step 1 replace the CMX controller board Record the message and return it with defective CMX board 44 Table 2 Message List List of Messages Message Explanation Solution HAM COIL OPEN Hammer Coil Open Electrical 1 malfunction of one or more hammer coils Cycle power If the message appears replace the shuttle frame assembly Power on the printer Run a print test If the message appears replace the controller board Record the message and return it with defective board HAMMER COIL BAD etc Hammer coil s number 1 etc failed the current test at power up Check that the hammer bank cables are connected 2 Cycle power If the message appears replace the shuttle frame assembly Record the message and retu
185. individual hammer spring forms more than one character as the shuttle moves horizontally This principle is illustrated in Figure 44 Figure 43 Standard Character Formation Shuttle Scan 1 Dot Row 1 Succesive Hammer Strokes Per Scan x13 1 35 x1 357 x13579 x 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 O Hammer Not Released No Dot Printed Figure 44 Action of One Hammer Spring in Text Printing 217 Chapter 7 Printing Mechanism Printing Mechanism 218 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 hammer bank assembly and the shuttle drive motor See Figure 45 22 Hammer Bank Assembly 2 ounterweight Assembly onnecting Rod uttle Frame Assembly utile Guide Shaft 2 Figure 45 Shut
186. ing clips over the top bottom of the ball joint into the retaining grooves Close the printer cover Return the printer to normal operation page 101 143 Chapter 6 CAUTION 144 CAUTION Section I Replacement Procedures Ethernet Interface Assembly NOTE The LineJet network board is an optional 10 100Base T Ethernet adapter This option is available factory installed or as a field kit The functions of the LEDs and DIP switches on the Ethernet interface board are described on page 145 To convert an Ethernet equipped printer to a parallel interface remove the Ethernet board assembly and install the Centronics connector in the slot the Ethernet board occupied The Centronics cable joins the back of the Ethernet board to the controller board Removal To prevent electrostatic damage to electronic components always wear a properly grounded static wrist strap when you handle circuit boards 1 Prepare the printer for maintenance page 106 2 Cabinet Models Remove the paper path page 161 Pedestal Models Remove the top cover assembly page 142 3 Disconnect Centronics cable connector P112 from connector J112 on the CMX controller board See page 212 item 5 4 Open the ferrite clamp and lift the Centronics cable out of the ferrite clamp 5 Loosen the two screws securing the LineJet Ethernet interface assembly to the cutout at the rear of the card cage 6 Slide the Ethernet interface assembly out
187. ining graphics alphanumeric data and bar codes all in a single pass Documents explaining configuration operation and programming are included with each option 232 Wire Data NOTE Acronyms and signal mnemonics are defined in Appendix C Interconnection 8 235 Distribution 1 236 Main Wire Harness Test page 237 Circuit Board Pinouts Controller GMX ro tete ce etiaai page 238 Power 4 enne 242 SureStak Power Stacker page 243 Cable Routing Gabinet M del 2 2 degrade ed ee reae pieta page 244 Cabinet Model Mechanism page 245 Pedestal een page 246 Pedestal Model Mechanism Base page 247 Cable Assemblies Centronics page 248 2 Pin Jumper 249 In Power 250 AG Power ce e e e aber bete bens page 251 Gard Cage ete Ee ra tid esit den page 252 Control Pari l tete e P fa e ted page 253 Exhaust Eandem edt page 254 Hammer Bank
188. inter to normal operation when the reported symptoms disappear 64 General Symptom List General Symptom List Table 3 is a list of possible printer problems that are not indicated by messages on the LCD Troubleshooting procedures are included for each symptom If you encounter a problem that is not listed in Table 3 troubleshoot using the Half Split Method described on page 64 Table 3 General Symptom List Symptom Solution Communications Failures See page 83 Jams CLEAR PAPER JAM message instead of LOAD PAPER when printer is out of paper 1 On 475 Ipm and 500 Ipm printers check the shuttle speed page 136 Adjust the shuttle speed to match the printer s rated speed 2 Power off the printer Remove the paper path or pedestal top cover Remove the barrier shield cabinet model or the barrier shield and paper guide pedestal model Check that the paper detector switch assembly is securely mounted in its bracket 3 Check that connector P106 PMD is fully seated in connector J106 on the CMX controller board 4 Load paper Power on the printer Replace the paper detector switch assembly if either message appears 5 Inspect the paper ironer If the paper ironer has slipped up into the print line reposition the paper ironer 6 Load paper Power on the printer Replace the CMX controller board if either message appears Record the message and return it with defective CMX board CL
189. inting patterns of ink dots 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 ona logical grid called the dot matrix See Figure 42 The ink dots are made by a row of small hammers mounted on a shuttle that sweeps rapidly back and forth 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 Figure 42 A Dot Matrix 215 Chapter 7 216 Line Matrix Printing 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 a dot matrix contains 12 dot rows from the top of one character line to the top of the next See Figure 42 and Figure 43 At eight Ipi there are nine dot rows per character line at nine there are eight dot rows per character line and so on Each
190. ips Connector stiffening clips are used on connectors P106 and P107 to help prevent accidental removal of wires when the connector shells are disconnected from the CMX board Removal 1 2 6 Prepare the printer for maintenance page 100 Cabinet Models Remove the paper path page 161 Pedestal Models Remove the top cover assembly page 142 Unsnap the front open side of the clip from the connector shell release the back of the clip from the lip of connector shell P107 and work the stiffening clip off the cable bundle See Figure 19 Repeat step 3 for the P106 connector Cabinet Models Install the paper path page 161 Pedestal Models Install the top cover assembly page 142 Return the printer to normal operation page 101 Installation 1 2 Prepare the printer for maintenance page 100 Cabinet Models Remove the paper path page 161 Pedestal Models Remove the top cover assembly page 142 Work the stiffening clip over the cable bundle engage the back of the clip under the lip of connector shell P107 then snap the front open side of the clip down over the connector shell See Figure 19 Repeat step 3 for the P106 connector Cabinet Models Install the paper path page 161 Pedestal Models Install the top cover assembly page 142 Return the printer to normal operation page 101 133 Chapter 6 Section Replacement Procedures Stiffening Clip Connector Shell
191. istance from your local support group Install the original CMX controller board LO DRV SHORT Lower Driver Short Circuit s on 1 the hammer bank or in the hammer bank power cable are shorted to ground Cycle power If the message appears press CLEAR If message does not clear replace the hammer bank logic cable and the hammer bank power cable Power on the printer If the message appears replace the shuttle frame assembly Power on the printer If the message appears replace the CMX controller board Record the message and return it with defective CMX board 47 Chapter 4 Troubleshooting Display Messages Table 2 Message List Message Explanation Solution LOAD PAPER Printer is out of paper 1 Load paper Press CLEAR If message does not clear go to step 2 Power off the printer Remove the paper path or pedestal top cover Remove the barrier shield cabinet model or the barrier shield and paper guide pedestal model Check that the paper detector switch assembly is securely mounted in its bracket Check that connector P106 PMD is fully seated in connector J106 on the controller board Load paper Power on the printer Replace the paper detector switch assembly if message appears Load paper Power on the printer Replace the CMX controller board if message appears Record the message and return it with defective board LOADING PROGR
192. k ribbon tracking by running a ribbon and shuttle diagnostic self test See Chapter 3 On the ribbon guide to be adjusted momentarily short between the ribbon guide skid screws 1 to verify that the ribbon reverses Observe how the ribbon 2 passes around and across the ribbon guide It should be centered and not folding against either of the two white nylon washers 3 If the ribbon is not centered loosen the retaining screws 4 just enough so that you can rotate the ribbon guide to new positions but it remains in place once moved Rotate the ribbon guide as required to center the ribbon 2 Observe how the ribbon 2 winds onto the ribbon spool of the side you adjusted If the ribbon is interfering with the flange of the spool make sure the ribbon hub and spool are mounted correctly Tighten the retaining screws 4 Allow most of the ribbon to wind onto the ribbon spool on the side you adjusted then repeat steps 3 through 9 for the other ribbon guide List of Adjustments Early Models Later Models Legend 1 Screw Skid 2 2 Ribbon 3 White Nylon Washer 4 Screw Retaining 2 Figure 15 Ribbon Guide Alignment 115 Chapter 5 Splined Shaft Skew Adjustment Splined Shaft Skew Adjustment If lines of print are not parallel with the perforations on the paper perform the following adjustment 1 2 3 116 Open the printer cover Loosen the screw 1 securing the adjusting link 2
193. knob and slide the splined shaft to the right out of the side plates and the tractors 174 Shaft Splined Installation 1 10 11 12 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 27 below Grasp the vertical adjustment knob and slide the splined shaft through the right side plate the tractors and the left side plate See page 204 Make sure the same spline passes the marked groove on each tractor Install the bearing clamp and screw Apply a thin film of bearing lubricant to the bearing 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 Attach the spring to the left side plate and the spring link Install the grip ring on the splined shaft with 0 010 inches of clearance between the grip ring and the nylon bearing Install the ground clip and screw Install the paper feed timing belt page 128 Set the paper feed timing belt tension page 102 Adjust splined shaft skew page 116 Install the paper supports on the splined shaft and support shaft See page 204 item 20 Return the printer to normal operation page 101 NOTE Align the marks on a Figure 27 Splined Shaft and Tractor Installation 175 Chapter 6 Section Replacement Procedures Shaft Support Removal 1 Prepare the printer
194. l Mnemonics 277 Firmware Download Procedure 285 Loading Flash Memory from One Diskette 285 Loading Flash Memory from Multiple Diskettes 288 E Host Configurations and Drivers 293 Pa b ERE He ese 293 000 MPE XL nnn 294 HP9900 FIPSUXQ iiit dta teet en ret npe bnt Der ee at 295 F Paper Specifications and Forms Design 297 INTOAUICION cx 2 oA eet RAI 297 General Paper Specifications 298 Paper P eR Pede 299 Terms and Definitions 004 0 171 4 4 4 299 Environmental Considerations 0040 0 301 Form Types ist eee reete re e 301 Form Weight ie EG e ERO 301 Form ThBiekness ai ds 301 Form WR 301 Tractor Pin 301 Methods of Forms 302 hat s o oe 303 Form Design 304 SUMMA ER 307 Storage and Handling 307 Noise Suppression Devices 309
195. ld and paper guide and tighten the four screws See page 194 items 3 4 and 5 9 Cabinet Models Install the paper path page 161 Pedestal Models Install the top cover assembly page 142 10 Return the printer to normal operation page 101 159 Chapter 6 Section Replacement Procedures Paper lroner 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 Prepare the printer for maintenance page 100 2 Remove the shuttle frame assembly page 177 3 Move the forms thickness lever to the open position 4 Push the ends of the paper ironer toward the rear of the printer disengage the tabs then lift it up and out page 206 item 3 Installation The black tape on the paper ironer faces toward the rear of the printer and the paper detector switch assembly 1 Position the paper ironer so the black tape is on the side that faces the rear of the printer towards the paper detector switch assembly See page 206 item 3 Push the paper ironer down into the slots until the tabs engage Install the shuttle frame assembly page 177 Return the printer to normal operation page 101 160 This procedure applies only to cabinet models Removal 1 Prepare the printer for maintenance page 100 2 Loosen the three paper path hold down screws page 1
196. les b Disconnect stacker rail cable connector P107 from connector J3 on the back of the stacker control panel See Figure 59 page 307 C Locate pin 1 of connector P107 See the cable assembly drawing in Appendix A page 257 d Check the stacker rail cable and limit switches for continuity and shorts Check continuity of the switch when open and closed See the power stacker control panel PCBA pinout drawing on in Appendix A page 264 STK FULL is the upper limit switch STK LIMIT is the bottom switch Replace the stacker rail cable if it is damaged or fails continuity test Replace any switch that fails continuity test 71 Chapter 4 Troubleshooting Other Symptoms Table 3 General Symptom List Symptom Solution Stacker motor check NOTE This procedure tests the four stacker motors and their cables You will usually be referred to this procedure from other troubleshooting procedures When you have completed this procedure return to the procedure that sent you here a Power off the printer b Open the rear cabinet door c Unfasten the cable clamp holding the stacker control panel cables d Disconnect stacker rail cable connector P107 from connector J3 on the back of the stacker control panel See Figure 59 page 307 e Disconnect stacker frame cable connector P102 from connector J4 on the rear of the stacker control panel See Figure 59 page 307 f Locate pin 1 of connector P102 and co
197. ligned stacker rails Adjust the stacker rails if they are not vertical and parallel Power on the printer Operate the power stacker Refer to the User s Guide While the stacker is operating check that a all motors are operating b the paddles are rotating c the elevator moves smoothly and without obstruction d the timing belts are undamaged and the belt pulleys are not slipping e the extension springs are attached and undamaged not bent or stretched f the drive rollers are not damaged g the constant force springs are tightly mounted and undamaged Tighten pulley setscrews and or replace damaged components as necessary Check the stacker limit switches See page 71 If the limit switches are OK go to the next step Check the stacker motors See page 72 If the stacker motors are OK go to the next step Remove the paper path Disconnect stacker cables from the CMX controller board stacker assembly and the stacker control panel see Figure 59 page 307 Check cables for cuts breaks or damaged pins Check continuity of cables See Appendix A Replace any cable that is damaged or fails continuity test Reconnect all stacker cables to the CMX controller board stacker and stacker control panel Stacker elevator does not move See Stacker does not stack properly Stacker elevator moves by itself Power off the printer Inspect all stacker LEDs for dust chaff or dirt See Figure 81 thr
198. ll the top cover assembly page 142 Return the printer to normal operation page 101 167 Chapter 6 Section Replacement Procedures Power Supply Board 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 or installation Handle the board by its sides and always wear a properly grounded static wrist strap when handling the power supply board Removal 1 Prepare the printer for maintenance page 100 2 Cabinet Models Remove the paper path page 161 Pedestal Models Remove the top cover assembly page 142 3 Disconnect output connector P101 from the controller board and AC input connector P1 from the power supply board See page 198 items 7 and 8 4 Loosen the three captive screws securing the power supply board to the rear wall of the card cage See page 198 item 18 5 Carefully pry the power supply board off the three studs on the rear wall of the card cage 6 Remove the power supply board from the card cage Installation 1 Reverse steps 2 through 6 of the removal procedure 2 Return the printer to normal operation page 101 168 Resistors Terminating 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 T
199. ller board Record the message and return it with defective board 51 Chapter 4 Troubleshooting Display Messages Table 2 Message List Message Explanation Solution Firmware error on the CMX controller board PAP UNEXP INT Paper Unexpected Interrupt 1 Cycle power Run the print job again If the message appears download the emulation software again Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board coax twinax interface PARAMETER ERROR Illegal parameter value received 1 in a command code over a 2 Press CLEAR then press ON LINE Run the print job that generated the error message If the message appears check the host data for invalid characters Ask the system operator to verify that the printer s Device ID is set to the correct emulation with respect to the host configuration Run the print job that generated the error message If the message appears go to Communications Failures page 83 random question mark characters Make a configuration printout PARITY ERROR The printed output may contain 1 Verify that the printer matches host serial configuration settings for Data Protocol Baud Rate Data Bits Stop Bits Parity Data Terminal Ready and Request to Send Send a print job to the printer If the message appears replace the serial data cable
200. ller board Record the message and return it with defective CMX board If the LCD displays characters correctly download the emulation software again page 129 Control panel blank Power off the printer Remove the paper path or pedestal top cover Check all cable connections into the CMX controller board make sure the control panel cable is seated in connector J110 on the controller board Power on the printer Inspect the control panel display and cooling fans If the control panel is blank and the cooling fans come on replace the control panel cable assembly and or the control panel as required Power on the printer If the control panel is blank and the fans do not come on replace the CMX controller board 66 General Symptom List Table 3 General Symptom List Symptom Solution Control panel keys do not work Power on the printer Check the operation of the control panel keys Replace the control panel assembly if the keys do not work Power on the printer Check the operation of the control panel keys Replace the control panel cable assembly if the keys do not work Power on the printer Check the operation of the control panel keys Replace the CMX controller board if the keys do not work Control panel display shows garbled broken characters Remove the paper path or pedestal top cover Check cable connections into the CMX controller board Make sure the control panel cable is seat
201. mage buffer in DRAM in a programmable manner serializes it and sends it to the hammer bank This function is actually controlled by the EC see page 229 which has access to the VX through the Cajun Bus Interface 227 Chapter 7 Controller Board Cajun Bus Interface The Cajun bus connects 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 e Interface to IEEE 1284 Level 2 host e Interface to RS 232 E serial host e Interface to RS 422 B serial host All the circuitry required for these types of hosts 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 e RS 232 drivers and receivers These circuits use internal charge pumps to eliminate the need for 12V power e RS 422 differential drivers and receivers e Parallel port pull up and pull down terminating resistors DIP configuration for easy removal and installation All interface ICs and terminations have the following characteristics e Provide ESD protection to 15KV for all inputs e Less than 0 05V common mode ripple me
202. mage to equipment If you must apply power during maintenance you will be instructed to do so in the maintenance procedure Use standard fault isolation techniques to troubleshoot malfunctions not indicated by display messages These techniques are summarized below 1 Askthe operator to describe the problem 2 Verify the fault by running a diagnostic printer test or by replicating conditions reported by the user 3 Look for a match in the General Symptom List below If you find a match go to the troubleshooting procedure and follow the numbered instructions 4 If you cannot find the symptom the General Symptom List use the Half Split Method to find the malfunction a Start at a general level and work down to details b Isolate faults to half the remaining system at a time until the final half is a field replaceable part or assembly Troubleshooting aids are listed on page 31 5 Replace the defective part or assembly Do not attempt field repairs of electronic components or assemblies Most electronic problems are corrected by replacing the printed circuit board assembly sensor or cable that causes the fault indication The same is true of failures traced to the hammer bank replace the entire shuttle frame assembly It is not field repairable Test printer operation after every corrective action Reinstall any parts you replaced earlier that did not solve the problem Stop troubleshooting and return the pr
203. ment is one with an ambient temperature at or above 40 Celsius 104 Fahrenheit or is dirty enough to create blockage of the cabinet fan vents The printer must never be run at ambient temperatures greater than 40 Celsius 104 Fahrenheit If the printer is located in such an environment relocate it to a cooler cleaner area 1 CMX controller board sensors report high temperatures on the board Inspect printer environment for severity Advise the user to move the printer to cooler cleaner location 2 Power off the printer Remove the paper path or pedestal top cover Check that all fan cables are connected 3 Inspect vents and fan airways for obstructions Look underneath cabinet models for items blocking the cabinet exhaust vents Remove any obstructions from vents and airways 4 Install paper path or pedestal top cover Load paper Power on the printer Run the All Black print test for 1 4 page If the message appears replace the CMX controller board Record the message and return it with defective CMX board PROTECTED INSTR Protected Instruction Firmware error on the CMX controller board 1 Oycle power Run the print job again If the message appears download the emulation software again 2 Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board PWR SUPP VOLT Power Supply Voltage
204. mode 11 Send a file from the host computer The printer outputs a hex dump Refer to the ASCII chart on page 92 12 When the hex dump is complete take the printer offline and change the Hex Dump Mode back to Disable Follow the steps outlined above and select Disable 91 Chapter 4 _ ASCII Character Set ASCII Character Set How to Print a Hex Dump Soft vs Hard Reset Soft Reset A soft ware reset clears printer memory then loads the power up configuration set by the user If no power up configuration has been set by the user the factory default configuration is loaded 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 The printer must be offline to do a soft reset 1 Press the ON LINE key to put the printer in the offline state 2 Press the PREV gt NEXT keys simultaneously The LCD will display Standby Soft Reset while the printer loads the power up configuration Hard Reset Cycle Power A hard ware reset is a power shutdown and restart that runs all initialization and diagnostic routines This is also called cycling power 1 Setthe printer power switch to O off 2 Wait 15 seconds 3 Setthe printer power switch to 1 on A hard printer reset causes the 48V power supply fans motors etc to shut down in 1 to 5 seconds depending
205. n it with defective CMX board 46 Table 2 Message List List of Messages Message Explanation Solution INTAKE FAN FAULT Sensors cannot detect current 1 in the card cage fan circuit Cycle power If the message appears press CLEAR If the message does not clear go to step 2 Power off the printer Remove the paper path or pedestal top cover Disconnect connector P106 from the CMX controller board Test connector P106 CCF for shorts or opens Refer to the Main Wire Harness Test Tables in Appendix A Replace components that fail test Make sure P106 CCF has a good connection at J106 on the CMX controller board Inspect for obstructions of airways and vents Remove obstructions Power on the printer If the message appears replace the CMX controller board Record the message and return it with defective CMX board INTERRUPT UNUSED VECTOR 00 This message is generated 1 when the CMX controller board gets an interrupt it does not understand The problem can be created by electrical noise by a software problem or by a hardware problem Cycle power If this message occurred once and never again you can ignore it If the message reappears or appears consistantly check the grounding of the printer If the machine is correctly grounded replace the CMX controller board Power on the printer Cycle power If the message appears suspect an application software error Request ass
206. nd hammer bank cover Install the ribbon correctly Check that the ribbon spools are not rubbing against the shuttle cover assembly Install the shuttle cover assembly correctly so that the ribbon spools do not rub against it Inspect the paper print path for paper chaff ink residue and debris Clean the shuttle frame assembly Power on the printer Run a print test and observe ribbon movement across the left and right ribbon guides Adjust the right and left ribbon guides Observe ribbon movement at both left and right ribbon posts as the metal end strip crosses each ribbon post If the metal strip moves past either post without reversing the direction of the ribbon power down the printer Remove the paper path or pedestal top cover Reseat connectors P106 LRP and P107 RRP the controller board While shorting across each ribbon post with the ribbon metal strip or a screwdriver check for continuity in connector P106 LRP pins 10 and 12 and connector P107 RRP pins 14 and 16 Refer to the Main Wire Harness Test Tables in Appendix A Replace a ribbon post that fails the continuity test Check the platen gap Adjust the platen gap 80 General Symptom List Table 3 General Symptom List Symptom Solution Shuttle Shuttle does not move 1 Power down the printer Remove the shuttle cover Check the MPU gap Adjust the gap between the MPU assembly and the flywheel to 0 010 001 inch 0 254 0 02
207. ng look for very dense graphics and layouts Advise the user to run jobs in smaller batches Power off the printer Remove the paper path or pedestal top cover Check that the power supply guard air deflector is correctly positioned over the power supply board WARNING DO NOT TOUCH THE POWER SUPPLY but hold your hand close enough to check for heat radiating off the power supply board If the power supply is noticeably hot replace it Check that all fan cables are connected Inspect vents and fan airways for obstructions Look underneath cabinet models for items blocking the cabinet exhaust vents Install paper path or pedestal top cover Load paper Power on the printer Run the All E s print test for 5 10 minutes If the message appears replace the CMX controller board Record the message and return it with defective CMX board 54 List of Messages Table 2 Message List Message Explanation Solution PRINTER HOT 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 must be stored under the printer Then check the operating environment A severe environ
208. nment page 106 Paper Scale Alignment page 108 Platen Gap page 110 Platen Open Motor Pulley page 112 Ribbon Guide 114 Splined Shaft Skew Adjustment 2 116 Paper Out 2 2 400 page 117 Hammer Phasing 121 Set Shuttle Speed eee caedere page 123 99 Chapter 5 Preparing the Printer for Maintenance Preparing the Printer for Maintenance To prepare the printer for maintenance do the following steps before you make any adjustments Unplug the printer power cord from the printer or power outlet before you do any maintenance procedure Failure to remove power could result in injury to you or damage to equipment If you must apply power during maintenance you will be instructed to do so in the maintenance procedure Do not attempt field repairs of electronic components or assemblies Do not de solder any circuit board components Replace a malfunctioning electronic assembly with an operational spare Most electronic problems are corrected by replacing the printed circuit board assembly sensor or cable that causes the fault indication The same is true of failures traced to the hammer bank you must repl
209. nnector P107 See the cable assembly drawings in Appendix A page 285 and page 288 g Check both cables for pin damage continuity and shorts Check all motors for 15 2 1 5 Ohms on both phases Refer to the power stacker control panel PCBA pinout drawing on page 264 Replace any cable that is damaged or fails continuity test Replace any motor that fails the resistance test Stacker not operating See Printer does not detect presence of power stacker 72 General Symptom List Table 3 General Symptom List Symptom Solution Print Quality Characters or dots are missing smeared too light or too dark 10 11 Check the forms thickness lever if it is set too loose or too tightly print quality can be affected Set the forms thickness lever to match the thickness of the paper being used Check the paper tension between the tractors Adjust the right tractor so that it does not pull paper too tightly or leave it too loose The right tractor should hold the paper under slight tension Inspect the shuttle frame assembly for print chaff debris or ink residue that could be causing the problem Clean the shuttle frame assembly Check the ribbon for folds or tears Check that the ribbon guides are tight and the ribbon tracks straight across them Rewind or install new ribbon If the ribbon does not track straight across the ribbon guides adjust the ribbon guides If the ribbon
210. ntaining circuits that help the DC controller operate The initials VX do not signify words they serve only to identify this ASIC WR Write w With w o Without XMT Transmit 283 Appendix 284 D Firmware Download Procedure Loading Flash Memory from One Diskette Flash memory is contained in SIMMs single in line memory modules located on the controller board Printer emulation and operating system software are loaded into flash memory at the factory but you will install software in some situations e The customer buys the PGL or Code V graphics option after the printer is installed customer needs to upgrade printer software e customer needs different emulation software e You have replaced the controller board e You have added or replaced the flash memory SIMM Emulation and operating system software are stored as a compressed file on a 3 5 inch floppy diskette This file is executable You will expand it and copy it into printer flash memory You can load software through the serial parallel or Ethernet ports of the printer The following procedure is for loading software through the serial or parallel port To download software through the Ethernet interface refer to the LineJet Print Server User s Guide 170989 001 The load commands are different depending on the printer port you use These differences are explained in the note following step 18 1 Make a print
211. nts 99 hammer phasing 121 loading flash memory from multiple diskettes 288 loading flash memory from one diskette 285 paper drive motor pulley alignment 106 paper feed timing belt tension 102 paper out 117 paper scale 108 platen gap 110 platen open belt 104 platen open motor pulley alignment 112 ribbon guide 114 splined shaft skew adjustment 116 Arrow keys pedestal models 18 ASCII Character Set chart 91 Asterisk meaning on messages 33 B paper feed timing replacement 128 tension adjustment 102 platen open replacement 129 tension adjustment 104 Block diagram control panel 223 Boards controller CMX 137 layouts connections and pinouts 233 power supply 168 BTU 271 BUFFER OVERRUN 36 Cable assembly interconnections 233 part numbers 233 routing diagrams 233 shell and cable replacement 131 133 Cable connectors and shells replacement 133 Card cage fan assembly replacement 148 Character Set U S ASCII 91 Circuit board replacement controller 137 power supply 168 Circuit breaker replacement 130 Cleaning card cage fan assembly 30 printer 26 349 shuttle frame assembly 28 CLEAR key pedestal models 18 CLEAR PAPER JAM 36 CLEARING PROGRAM FROM FLASH 37 CLOSE PLATEN 38 controller board See Controller board 224 COIL HOT 39 Communications failures 83 Configuration 23 Control panel block diagram 223 replacement cabinet models 135
212. o determine if the user is requesting that the printer be placed in download mode diagnostic mode or debug SIMM disabled If ON LINE and FF are pressed during start up the printer is placed in download mode If lt PREV and DOWN are pressed during start up the printer is placed in diagnostic mode If any other combination of keys are pressed the debug SIMM is disabled Key states are put in an internal register in the VX ASIC Detect DRAM The VX ASIC supports up to four banks of DRAM totalling up to 32 Megabytes Boot code detects how much DRAM is located in each bank and relocates the banks to create one contiguous block of DRAM The size and location of each bank is then displayed on the debug terminal through the debug serial port Test DRAM DRAM is tested by writing a pseudo random number sequence to all the DRAM then reading the pattern back to verify it against what was originally written If an error is detected the message ERROR DRAM AT ADDRESS is displayed on the LCD When finished the DRAM test sets all memory to zero Inform the EC Processor The first 8 Kilobytes of DRAM are reserved for the EC processor which must be notified when DRAM is ready to be used This is done by putting the message DCS1 in the ECDC communications register in the VX ASIC Detect Ethernet Adapter An Ethernet adapter must be detected early in the power up sequence so the printer can tell the adap
213. oard 43 Chapter 4 Troubleshooting Display Messages Table 2 Message List Message Explanation Solution FIRMWARE ERROR Application software tried to 1 Cycle power Run the print job If the perform an illegal printer message appears download the function or damaged memory is emulation software again page 129 detected on the CMX controller 2 Cycle power Run the print job again board If the message appears If the message appears replace the at power up replace the CMX flash memory controller board Record the message and return it with 3 Cycle power Run the print job again defective CMX board If the message appears replace the controller board Record the message and return it with defective board 4 Power on the printer Run the print job again If the message still appears there is an application software error Use your local support procedure to request assistance FRAMING ERROR The printed output may contain 1 Make configuration printout Set random exclamation point printer serial interface parameters to characters match host configuration settings for Data Protocol Baud Rate Data Bits Stop Bits Parity Data Terminal Ready and Request to Send 2 Senda print job to the printer If the message appears go to Communications Failures page 83 FREEFORM OFF This message can appear if a 1 Release stuck keys Determine and control panel key is stuck
214. of the cutout in the card cage and lift the assembly out of the card cage Installation To prevent electrostatic damage to electronic components always wear a properly grounded static wrist strap when you handle circuit boards 1 2 Reverse steps 2 through 6 of the removal procedure Return the printer to normal operation page 107 10 100Base T LEDs and DIP Switches 10 100Base T LEDs and DIP Switches The 10 100Base T Ethernet interface has two indicator lights and two DIP switches as shown below DIP Switches STAT System Status LE EN NET Data to L Network eee NS STAT Status Indicator in Run and Auto Reset Modes Run Mode is the normal operating state of this interface Auto Reset mode is entered when the watchdog timer is triggered and the print server resets itself In either mode the STAT LED flashes at a varying rate depending on whether the unit IP address is configured The Run Mode and Auto Reset Mode indicator descriptions are shown in Table 5 Table 5 Run Mode and Auto Reset Mode Indicator Descriptions STAT Rate Indication OFF Flashes ON Normal Mode IP address once per second configured OFF Flashes ON 2 IP address not configured times per second ON Flashes OFF Download MOS once per second ON Flashes OFF Error twice per second ON Constantly Indicates link integrity ON Flashes OFF 1 3 Flashes off 1 3 second evry time Second packet is transmitt
215. oggles the printer online and offline Clears the printer after Y Y a fault is corrected and returns the printer to offline state FF Prints any data in the buffer then moves paper to top of form Y Y as defined by the currently active form length LF Prints any data in the buffer then moves one line feed as v v defined by the currently active line spacing Repeats if held down View Moves the current print position to the tractor area for Y Y viewing Press again to move paper back to the print position T Up Displays next higher level of a configuration menu After v View is pressed moves paper up 1 72 inch Down Displays next lower level of a configuration menu After View Y is pressed moves paper down 1 72 inch Next Displays the next option in a configuration menu Y lt Prev Displays the previous option in a configuration menu Y Clear Clears the printer after a fault is corrected and returns the Y printer to the offline state Shift L P I Adj Selects new line spacing Y Shift Clear Resets PCL II emulation v Shift Page L Adj Selects new form length in inches which is then selected v with Page L Adj key Set TOF Sets the location of the first line of print on a page Y independent of form length Enter Enters an option displayed on the LCD into printer non v volatile memory Starts and stops printer tests Must be unlocked before using See below Tal Locks and unlocks the ENTER key v 18 Related Documents
216. old the collar to dot row or line to line snug against the motor pulley and torque the 7 64 inch setscrew 3 Characters randomly to 25 2 inch pounds 2 82 0 23 Nem compressed and or enlarged 3 Check the condition and tension of the paper feed timing belt Adjust the paper feed timing belt Replace the belt if it is damaged 4 Check the platen gap Adjust the platen gap 5 Inspect the tractors and tractor door springs for damage or excessive wear If either tractor is damaged or visibly worn replace both tractor assemblies 6 Remove the paper guide assembly or pedestal top cover Make sure connector P107 PAPR M is fully seated in connector J107 the controller board 7 Load paper Power on the printer Run a print test If the problem occurs replace the paper feed motor 8 Runa print test If the problem occurs replace the CMX controller board 9 Run a print test If the problem occurs replace the power supply board 75 Chapter 4 Troubleshooting Other Symptoms Table 3 General Symptom List Symptom Solution Printer Operation Downloads consistently fail NOTE Most download problems are detected by software during the procedure and communicated by LCD messages If downloads fail consistently with no messages or with erratic messages suspect a hardware failure 1 Power off the printer Remove the paper path or pedestal top cover Check the I O cable connections from
217. on tests DIAGNOSTIC Status message the printer No action required coil count test failed DRVR CIR BAD Driver Circuit Bad the hammer 1 Cycle power If the message appears press CLEAR Power off the printer Remove the shuttle cover At the shuttle frame assembly disconnect the hammer bank logic and power cables Power on the printer If HB NOT INSTALLD appears on the LCD replace the shuttle frame assembly If HB NOT INSTALLD does not appear on the LCD replace the CMX controller board ERROR DC PROGRAM The printer cannot find the data Download the program again If the NOT VALID controller program or the message appears replace all flash validation checksum is corrupt memory SIMMs ERROR DRAM AT The printer found a defective 1 ADDRESS XXXXXXXX memory location 2 Replace the DRAM Power on the printer If the message appears replace the CMX controller board Record the message and return it with defective CMX board 40 List of Messages Table 2 Message List Message Explanation Solution ERROR EC PROGRAM NOT VALID The printer cannot find the engine controller program or the validation checksum is corrupt 1 Download the program again page 129 If the message occurs again replace all flash memory SIMMs 2 Power on the printer Download the emulation If the message appears replace the CMX controller board Record the message and return it
218. on the amount of memory installed on the controller board 93 Chapter 4 The Power On Sequence The Power On Sequence 94 This section describes the normal sequence of events from the time the power switch is set to 1 until ONLINE or OFFLINE if so configured by the user appears on the LCD Use this sequence as a reference baseline to help you isolate problems that occur before the printer completes its boot and initialization routines The power on sequence consists of two sets of routines 1 CMX controller board handshake sequences DC hardware initialization 2 DC software initialization and power up The routines are listed below in order of occurrence CMX Controller Board Handshake Sequences Processor Alive The green LED marked 1 on the CMX controller board is turned on to indicate that the processor received a valid reset vector and the first instructions to the processor are correct This LED is used to report all DC errors and states Test VX Data Bus A walking zero and one test verifies that all 32 data lines from the VX bus to the processor are connected If a bad line is detected a 4 1 1 XX blink code is sent to the LED on the controller where XX is the data line plus 1 For example a bad data line 8 would blink as 4 1 1 9 Initialize VX ASIC The boot code detects the processor type and sets up the internal registers of the VX ASIC Initialize Debug S
219. onnected to a network it will print a test page 146 Fan Assembly Cabinet Exhaust Fan Assembly Cabinet Exhaust This procedure applies only to cabinet models Removal 1 Prepare the printer for maintenance page 100 2 Open the front and rear cabinet doors and the printer cover 3 Remove the paper fence paper tray assembly See page 186 4 Remove the two 1 4 inch screws securing bottom of the air exhaust duct See page 188 item 4 e Remove the 1 4 inch screw directly below the forms thickness lever 6 Disconnect the fan cable connector from connector P307 and remove the air exhaust duct Disconnect the fan cable connector from the side of the air exhaust duct Remove the two 1 4 inch fan mounting screws and the cabinet exhaust fan assembly Installation Air flow is DOWN Install the cabinet exhaust fan so the label on the fan faces down h d 1 Reverse steps 2 through 8 of the removal procedure 2 Return the printer to normal operation page 101 147 Chapter 6 Section Replacement Procedures Fan Assembly Card Cage Removal 1 Prepare the printer for maintenance page 100 2 Cabinet Models Remove the paper path page 161 Pedestal Models Remove the top cover assembly page 142 Disconnect the card cage fan cable connector See page 208 Cabinet Models Remove the two fan mounting screws from the bottom of the fan See page 208 item 2
220. onnector J17 Stacker Logic Cable Stacker Power Cable 7 Cutout Beneath Card Cage Fan Figure 64 Stacker Power and Logic Connections on the CMX Controller Board 318 The paper stacker assembly mounts to the rear upper frame cross member and the cabinet floor It is a snug fit During installation take care to avoid scratching painted surfaces or damaging the stacker 9 Loosen one turn DO NOT REMOVE the Torx T 10 screws securing the vertical rails to the stacker base Each rail is secured by two screws See Figure 65 Legend 1 Screw 6 32x1 4 Torx 10 2 Vertical Rail 3 Stacker Base Figure 65 Loosening the Lower Screws in the Vertical Rails 319 Appendix Installing the Power Stacker 320 10 11 12 13 Position the elevator assembly at the bottom of the vertical rails See Figure 66a Position the stacker assembly slightly to the right in order to clear the air exhaust duct insert the vertical rails inside and under the upper frame cross member then slowly swing the base of the stacker assembly into the cabinet See Figure 66a Work the stacker base rearward and engage the upper brackets of the vertical rails under the upper frame cross member See Figure 66b Align the holes in the vertical rail brackets with the holes in the upper frame cross member See Figure 66c and Figure 67
221. or cache vector table etc e Partition RAM for Tasks e Allocate Peripheral Interfaces console driver etc e Start Main Task supervisor e Verify and Initialize NVRAM statistics are cleared if NVRAM is not valid e Initialize Libraries fault system emulation e Load Front Panel Menus from ROM e initialize these tasks then start them after all have initialized Print Engine Driver Task CT Driver Task sends 8344 code to the CT expansion board Serial Driver Task Parallel Driver Task CT Emulation Task IGP Task VGL Base Emulation Task Initialize Fonts Initialize Graphics Library Complete Emulation Library Initialization Wait for all emulation tasks to initialize Front Panel Task e Display ONLINE on control panel 98 5 Introduction Adjustment Procedures The printer is a durable low maintenance machine but some components and systems require occasional adjustment Usually you will be referred to this chapter by a troubleshooting procedure or as part of a removal installation procedure List of Adjustments Preparing the Printer for Maintenance page 100 Returning the Printer to Normal page 101 Belt Paper Feed Timing Adjustment page 102 Belt Platen Open page 104 Paper Drive Motor Pulley Alig
222. orrect value or range But if the phasing value is far enough from the theoretical ideal value on a particular printer errors can occur If for example you are adjusting phasing and an error such as PAP FIFO UNDRFL occurs the phase value may be too high Try a lower value 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 vertical alignment When vertical alignment is acceptable write the new phasing value on the shuttle Phasing should be adjusted with the printer printing at full paper width The printer must be printing the Phase pattern of H s when the Phasing Value is changed or the New Phasing Value will not be written into If the value is changed when not printing the printer will return to its default phasing value when powered off then back on Raise the printer cover Install the ribbon Load full width 136 column paper and set the top of form Power on the printer mo If the printer is online press the ON LINE key to place the printer offline OFFLINE CONFIG CONTROL displays 6 the control panel press the keys to unlock the ENTER key ENTER SWITCH UNLOCKED briefly displays If LOCKED displays simply press and again 7 Press the 4 key OFFLINE DIAGNOSTICS displays 8 Press DIAGNOSTICS Printe
223. ort shaft replacement 176 Switch paper detector switch assembly replacement 180 platen interlock switch assembly replacement 181 power replacement 130 Switch power location pedestal models 18 T TABLE MISMATCH DOWNLOAD AGAIN 61 TCB CORRUPTED 62 Tension adjustment paper feed timing belt 102 platen open belt 104 Terminating resistors location of 170 replacement 169 Test equipment tools and supplies 22 Tests print operator 84 printer diagnostic 84 Tools test equipment and supplies 22 Tractor replacement 182 Troubleshooting 31 aids 31 communications failures 83 fault messages 33 message list 33 start here 32 symptoms not indicated by messages 64 U UNDEF INTERRUPT 62 UNDFNED OPCODE 62 UP arrow key pedestal models 18 UP DRV SHORT 62 V VIEW key pedestal models 18 WAITING FOR ETHERNET ADAPTER 63 Wattage printer 271 Wiring diagrams 233 355 356
224. ough Figure 83 page 332 through page 336 Clean the stacker LEDs and the sight tubes in the LED mounts Power on the printer If the stacker elevator moves by itself replace the stacker LEDs See Figure 81 through Figure 83 page 332 through page 336 70 General Symptom List Table 3 General Symptom List Symptom Solution Stacker limit switch check 2 NOTE This procedure tests the motion limit switches at the top and bottom of the vertical rails You will usually be referred to this procedure from other troubleshooting procedures When you have completed this procedure return to the procedure that sent you here Power off the printer Open the rear cabinet door Unload the power stacker Move the elevator up and down by hand checking that it moves smoothly and without chattering or shuddering Eliminate causes of chattering or shuddering E g loose damaged or broken constant force springs bent or misaligned rails obstructions etc NOTE lf the elevator assembly or the rails are bent or damaged you must replace the entire power stacker assembly Move the elevator up and down by hand Check that the limit switches are physically tripped when elevator reaches top and bottom of travel If necessary gently bend the contact arms to adjust limit switches If you cannot adjust a switch that requires adjustment replace it a Unfasten the cable clamp holding the stacker control panel cab
225. out of a saved configurations Refer to the User s Guide Installing new software erases all saved configurations You will use the printouts to restore printer configuration Set the printer power switch to O off If the printer is already connected to the serial or parallel port of a computer capable of running an MS DOS based PKZIP self extracting file go to step 10 If not go to step 4 4 Unplug the AC power cord from the printer 285 Appendix D _ Loading Flash Memory from One Diskette Disconnect all data input cables from the printer interface Connect a parallel data cable to the LPT1 port or a serial data cable to the COM port of an IBM compatible computer that is using the PC DOS or MS DOS operating system You can connect the cable to the LPT2 port if the LPT1 port is already in use The load commands are different if you use this port as described in the note after step 18 Connect the data cable to the appropriate I O port of the printer Plug the AC power cord into the printer Power on the computer 10 Insert the emulation or upgrade diskette into diskette drive A or B of the computer 11 Make the diskette drive the active drive by typing the following at the DOS prompt A lt Return gt If the diskette is in drive B type lt Return gt 12 Get the name of the compressed file on the diskette by listing the contents of the diskette at the DOS prompt type DIR lt Return g
226. over Assembly Hammer Bank Ribbon Mask Removal 1 Prepare the printer for maintenance page 100 Remove the shuttle frame assembly page 177 Using a Torx T 10 driver remove the six screws and three ribbon mask clamp plates securing the ribbon mask to the hammer bank cover Remove the ribbon mask See Figure 20 If you are replacing just the ribbon mask simply loosen the six screws until you can slip the ribbon mask off the alignment pins 4 Using a Torx T 10 driver remove the 12 screws securing the hammer bank cover to the hammer bank Remove the hammer bank cover See Figure 20 Installation The hammer bank contains a strong magnet To prevent damage to the hammer tips do not let the steel hammer bank cover assembly of early models snap into place as the hammer bank magnet attracts it Any impact of the cover against the hammer bank can break hammer tips 1 Position the hammer bank cover on the alignment pins on the hammer bank Make sure the hammer bank cover is properly positioned over the alignment pins and hammer tips and lies flat on the hammer bank 2 Install all 12 hold down screws finger tight Using a Torx T 10 driver tighten the hold down screws in the sequence shown in Figure 20 3 With the seam of the folded lower edge of the ribbon mask facing inward toward the hammer bank cover position the ribbon mask on the alignment pins on the hammer bank cover The ribbon mask is correctly
227. ovides for the storage of configuration and system statistical data Data Controller 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 e Memory Access Controller e DRAM Controller e Flash Controller Two DMA Channels e Operator Panel Interface Dot Plucking and Adjacent Dot Checking e Cajun Bus Interface e 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 Control 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 i
228. ower Run the print job again If the message appears replace the flash memory Power on the printer Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board Check the resistance of connectors P106 LRIB M and P107 RRIB M Refer to the Main Wire Harness Test Tables in Appendix A If ribbon motor resistance is not correct replace the motor and or the intermediate cable if installed Power on the printer Run the print job again If the message appears replace the power supply board Power on the printer If the message appears replace the shuttle frame assembly 34 Table 2 Message List List of Messages Message Explanation Solution 23 5V CTL FAIL 23 5 Volt Controller Failed a 1 voltage failure on the controller board Cycle Power Run the print job again If the message appears download the emulation software again page 129 Cycle power Run the print job again If the message appears replace the flash memory Power on the printer Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board Power on the printer Run the print job again If the message appears replace the power supply board Power on the printer If the message appears replace the shuttle frame assembly 48V PWR FAIL 48
229. ower level of a configuration menu After v VIEW is pressed moves paper down 1 72 inch gt NEXT Displays the next option in a configuration menu v 4 PREV Displays the previous option in a configuration menu v CLEAR Clears the printer after a fault is corrected and returns the Y printer to the offline state SHIFT ADJ Selects new line spacing Y SHIFT CLEAR Resets PCL II emulation v SHIFT PAGE L ADJ Selects new form length in inches which is then selected Y with PAGE L ADJ key SET TOF Sets the location of the first line of print on a page Y independent of form length ENTER Enters an option displayed on the LCD into printer non Y volatile memory Starts and stops printer tests Must be unlocked before using See below Locks and unlocks the ENTER key v 16 Raise poe fuse er cover to use these Figure 1 Electrical Controls Cabinet Models Related Documents Chapter 1 Controls and Indicators Electrical Controls and Indicators Pedestal Models Figure 2 Switch or A Active Active Indicator PuncHon Online Offline Power Switch Turns printer on and off 1 on 0 off This switch is also a circuit breaker On Line LED On when the printer is online off when the printer is offline v Flashes to indicate a fault or warning LCD Liquid Crystal Display Displays printer status messages Y Y fault messages and menus which permit user to set various configurations OnLine T
230. own in Figure 62 315 Appendix _ Removing the Power Stacker Legend 1 Upper Frame Cross Member 2 Elevator Assembly 3 Stacker Base 4 Vertical Rail Figure 62 Removing the Stacker Assembly 316 Installing the Power Stacker NOTE This procedure is for complete installation of the power stacker including cable assemblies and the stacker control panel Set the printer power switch to O off Unplug the power cord Remove paper Po Loosen the three paper path hold down screws Slide the paper path to the left and lift it off the card cage See Figure 63 Legend 1 Paper Path 2 _Hold Down Screw 3 Figure 63 Remove the Paper Path 317 Appendix Installing the Power Stacker 5 Connect the power stacker logic cable P103 to connector J17 on the controller board See Figure 64 6 Disconnect the power supply cable from connector J101 on the CMX controller board See Figure 64 7 Connect power supply cable connector P101 to the stacker power cable then connect the stacker power cable to connector J101 on the CMX controller board See Figure 64 8 Route the stacker power cable and the stacker logic cable in front of the board and through the cutout beneath the card cage fan as shown in Figure 64 Legend 1 2 3 4 5 6 Power Supply Connector P101 Board Connector J101 Connector P103 Board C
231. p 7 on the right side of the platen Remove the Phillips 1 screw and washer securing the forms thickness indicator plate from the inside of the right side bracket See page 206 items 9 and 10 Pull the indicator plate with the interlock switch assembly attached off the platen shaft Remove the two 7 32 inch screws and washers securing the right ribbon guide assembly to the side plate See page 208 items 11 13 and 14 Slide the ribbon guide assembly out of the side plate 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 of the shaft as you remove the platen Make sure the copper wear saddles in the platen seat of the mechanism base stay in place Installation The dowel pins protruding from the ends of the platen are the platen shafts The platen shafts are not of equal 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 24 below 3 Apply bearing lubricant to both platen shafts Figure 24 Installing the Platen Adjust Bracket 4 Make sure the two wear saddles are set flush into the corners of the mechanism base platen seat See Figure 25 5 Apply a layer of bearing lubricant 1 4 inch high to the seat of each w
232. p come Printer initialized successfully YES b Other symptoms are listed in Table 3 page 65 display If default is OFFLINE status NO indicator will not come on NO Go to Printer does not initialize page 67 fans come on Make a configuration Go to the Control YES gt Panel section of Does machine Table 3 page 65 configuration print NO The Control Panel is not functioning Table 3 page 65 QOR Printer does not initialize page 67 Go to Black squares control YES p on control panel pane display page 66 NO Go to Printer does initialize page 67 List of Messages Troubleshooting Display Messages Always disconnect the AC power cord from the printer before doing a maintenance procedure Failure to remove power could result in injury to you or damage to equipment If you must apply power during maintenance you will be instructed to do so in the maintenance procedure Three kinds of messages appear on the Liquid Crystal Display LCD e Status messages e Configuration menus and menu options e Fault messages Most fault messages are cleared from the LCD by first correcting the fault condition then pressing the CLEAR key Fault messages that can only be cleared by shutting down and restarting the printer are indicated by an asterisk appended to the message If printer logic detects a fault condition three things happen
233. plays ERROR EC PROGRAM NOT VALID on the LCD If the EC processor does not respond within three seconds the boot code sends EC STOPPED AT STATE to the LCD where is one of these states State Description 0000 Power up 0001 Enter checksum calculation 0002 Enter copy download code from FLASH into shared DRAM 0003 Enter programming FLASH mode 0004 Erase EC FLASH 0005 Program FLASH 0006 Finish programming FLASH 0007 Enter initialization of EC serial debug 0008 Enter EC firmware task initializations 0009 Enter power up coil diagnostic 000 Start running normal EC firmware Check Security PAL and NVRAM The chip select for NVRAM comes from the security PAL If the PAL is not installed NVRAM cannot be accessed so the PAL is tested before NVRAM If the security PAL is not Controller Board Handshake Sequences detected boot codes displays ERROR SECURITY PAL NOT DETECTED If a security PAL is detected boot code checks for the presence of NVRAM If NVRAM is not found boot code displays ERROR NVRAM FAILURE Test for Powerup File Boot code checks for a DC executable file called powerup sbr If found it executes the file then returns to boot routines If the file is not found boot routines are resumed If any key was held down during power up boot code does not look for the powerup file and continues
234. power cord from the printer or power outlet before doing any maintenance procedure Failure to remove power could result in injury to you or damage to equipment Only apply power during maintenance if you are instructed to do so in a maintenance procedure The components specified in this chapter are field replaceable units FRUs FRUs must be repaired at the factory Do not repair these items in the field Do not attempt field repairs of electronic components or assemblies Do not de solder any circuit board components Replace a malfunctioning electronic assembly with an operational spare Most electronic problems are corrected by replacing the printed circuit board assembly sensor or cable that causes the fault indication The same is true of failures traced to the hammer bank it is not field repairable so you must replace the entire shuttle frame assembly Hammer spring assemblies the hammer bank cover and the ribbon mask are the only replaceable components of the shuttle frame assembly 126 List of Removal Installation Procedures Belt Paper Feed 0 page 128 Belt Platen page 129 Circuit Breaker eniti ice fe ELE de e oe page 130 Connector Shells hene oett a ertet eres page 131 Connector Stiffening Clips seen page 133 Control Panel Assembly Cabinet page 135 Control Panel Ass
235. quired POWER SAVER MODE This is a status message The printer is in low energy idle state all fans and higher voltages are off only 5Vdc logic circuits are active No action required but you can press the PAPER ADVANCE key to revive the printer from power saver mode 53 Chapter 4 Troubleshooting Display Messages Table 2 Message List Message Explanation Solution POWER SUPPLY HOT The printer has sensor circuits 1 that sample the operating temperature of key components of the power supply When 2 higher than normal temperatures are sensed print speed is automatically reduced If the printer runs at reduced speed for an extended period of 3 time the POWER SUPPLY HOT message is sent to the LCD and printing stops allowing printer components to cool down Pressing the CLEAR key resumes the print task Check the operating environment A severe environment is one with an ambient temperature at or above 40 Celsius 104 4 Fahrenheit or is dirty enough to create blockage of the cabinet 5 fan vents The printer must never be run at ambient temperatures greater than 40 Celsius 104 Fahrenheit If the printer is located in such an 6 environment relocate it to a cooler cleaner area Inspect printer environment for severity Advise the user to move the printer to cooler cleaner location Check the kinds of print jobs the user is runni
236. r Tests displays 9 Press Printer Tests Shift Recycle displays 10 Press 4 until Printer Tests Phase Printer displays 11 Press ENTER The display shows Printer Tests Phase Printer and the test begins The current phasing value is printed on the left of the printed pattern of all H s As the pattern prints compare the H s to the figure below If the phasing needs adjustment go to step 12 If the phasing is OK go to step 15 121 Chapter 5 Hammer Phasing Adjustment 12 Press V The current phase index displays Press again An asterisk appears next to the phase value 13 Press to increase or 4 to decrease the phasing index value then press ENTER to activate the value as it prints Continue to increase or decrease the phasing index until the pattern of H s is acceptable 14 Press A twice Printer Tests Phase Printer displays 15 Press ENTER to stop the test 16 Press CLEAR OFFLINE CONFIG CONTROL displays 17 Press A ENTER SWITCH LOCKED briefly displays 18 Close the printer cover 19 Press the ON LINE key to place the printer on line 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 122 List of Adjustments Set Shuttle Speed Do this procedure if you replaced the CMX controller board or the shuttle frame assembly in a LineJet 500 o
237. r if you were instructed to do so ina troubleshooting procedure Do not do this procedure if you removed and reinstalled the original CMX board or shuttle frame assembly from a 500 lpm printer as part of other maintenance tasks 12 13 14 Raise the printer cover Power on the printer If the printer is online press the ON LINE key to place the printer offline OFFLINE CONFIG CONTROL displays On the control panel press the keys to unlock the ENTER key ENTER SWITCH UNLOCKED briefly displays If LOCKED displays simply press and Y again Press the 4 gt keys simultaneously to enter the Factory Menu Factory Shuttle Speed appears on the display Press the Y key Shuttle Speed 500 or Shuttle Speed 475 appears on the display The asterisk indicates which shuttle speed is currently active Press the key until the shuttle speed you want appears on the display Press the ENTER key An asterisk appears next to the selection indicating it is now the active shuttle speed Press the ON LINE or CLEAR key to exit the Factory Menu Press the A Y keys to lock the ENTER key ENTER SWITCH LOCKED briefly displays Cycle printer power to activate the shuttle speed setting set the power switch to O wait 15 seconds then set the power Switch to 1 Adjust the hammer phasing page 121 Adjust the paper out distance page 117 If the print
238. rT 2 PIN JUMPER 45 2 PIN JUMPER 4 penunuoo Appendix A8v 4 915 dWALN Power Supply 01 0 pieog 9 LOld E 99 CO s A8v A8v AS 8 AS 8 QNO 21901 13H AS 21901 199 AS 21907 L3H AS 21901 13H AS ASISN OV L Nid QHVOS tA IH dWAL N Nid QHVOS WNIWYAL NO LSV SISSVHO NOWNOO eeuy eur 1 9NIH7 bod A ddng 160g Ul OW Assy 2 242 VV VV mana HH GE GLFOGL eoueisiseH uuo GLa eouelsiseg lt a o x o gt Appendix Cable Routing Cabinet Model 244 Sve Left Side of Printer L RBN M A CABLE ASSY JO6 Front of Printer Right Side of Printer 6 R_RBN CABLE ASSY o6 NR
239. rd 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 Over time the upper edge of the paper ironer can become sharp To avoid cutting yourself handle the paper ironer on the sides Hold the printer cover securely while disengaging the gas spring assembly 4 Related Documents Hinweise zur Sicherheit Um erstliche k rperliche Verletzungen durch Stromschlag beim Anschlie en oder Trennen des Signalton Kabels zu vermeiden mu der Drucker auf jeden Fall ausgeschaltet und der Netzstecker herausgezogen werden Vorsicht Bevor Sie anf llige Wartungsarbeiten durchf hren m ssen Sie zuerst immer das Netzkabel aus der Steckdose ziehen Wird das Netzkabel nicht herausgezogen k nne Verletzungen oder Ger tesch den entstehen Falls die Wartungsarbeit Stromzufuhr erfordert wird im Wartungsablauf darauf hingewiesen Um Verletzungen durch Elektroschocks zu vermeiden warten Sie mindestens eine Minute nach Stromausschaltung bevor Sie die elektrische Schaltkarte entfernen Bitte immer einen geerdeten statischen Handgelenkriemen tragen wenn Sie die elektrische Schaltkarte handhaben Halten Sie die Karte nur an den seitlichen Auswurfshebeln W hrend des Herausnehmens Installierens d rfen die Komponenten der Karte nicht ber hrt oder gebogen werden
240. re 52 Basic Forms Terminology Side View of Form neus Printed Side of Form Outward Perforation Inward Perforation lt Figure 53 Inward and Outward Perforations Perforation X Cut Point Tie Point Figure 54 Cut Points and Tie Points Environmental Considerations Environmental Considerations Before they are used forms should be stored for at least 24 hours preferably 48 hours in the environment in which they will be used This stabilizes the moisture content of the paper resulting in better feeding and stacking But forms should never be stored in environments that result in damage such as delamination of glues creasing folding etc Form Types Three kinds of continuous form paper are specified for use with the printer e Edge perforated fanfolded single part forms e 2 10 6 part multipart carbon forms e 2 10 4 part multipart carbonless forms For all forms the width range is 3 to 16 inches the length range is 3 to 12 inches Form Weight Use 15 to 100 pound 6 80 to 45 36 kg stock Light weight and recycled forms must be strong enough to assure that tractor holes and perforations do not tear or detach during form feed skipping and ejecting operations Form Thickness Forms must be no thicker than 0 025 inches 0 0635 cm This figure is for the thickest point of the form including glue lines staples perforations etc and is not restricted to just the
241. rn it with the defective assembly Power on the printer If the message appears replace CMX controller board Record the message and return it with the defective assembly HB NOT INSTALLD Hammer Bank Not Installed 1 Self test routines do not detect 2 hammer coils at printer start up Power off the printer Verify that the shuttle frame assembly is installed Install the shuttle frame assembly Remove the paper path or pedestal top cover Verify that the hammer bank logic cable is connected to connector J108 on the controller board and to the shuttle frame assembly Power on the printer If the message appears replace the hammer bank logic cable Power on the printer If the message appears replace the shuttle frame assembly Power on the printer If the message appears replace the CMX controller board Record the message and return it with defective CMX board 45 Chapter 4 Troubleshooting Display Messages Table 2 Message List Message Explanation Solution HMR BANK FAN FLT Hammer Bank Fan Fault 1 Sensors cannot detect current in the fan circuit Cycle power If the message appears press CLEAR If the message does not clear go to step 2 Power off the printer Remove the paper path or pedestal top cover Disconnect connector P107 from the controller board Test connector P107 HBF for shorts or opens Refer to the Main Wire Harness Test Ta
242. routing diagrams in Appendix A 8 Disconnect connector P107 from the controller board and remove the paper feed motor connector from connector P107 See page 132 Some paper feed motors are mounted with nuts and bolts other motors have threaded flanges eliminating the need for nuts 158 9 Remove the motor mount screws and nuts if present 10 Remove the paper feed motor assembly Paper Feed Motor Installation 1 Position the paper feed motor assembly on the right side plate and install the motor mount bolts and nuts finger tight See page 208 items 10 and 23 2 Connect the paper feed motor cable connector to connector P107 then connect P107 to J107 on the controller board See page 132 Install the collar paper feed motor pulley and timing belt Align the paper feed motor pulley with the splined shaft pulley 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 tighten the 7 64 inch setscrew 6 While pushing the motor toward the rear of the printer tighten the two 5 16 inch mounting bolts so there is 1 8 inch of belt deflection midway between the pulleys Snap the timing belt cover into the slots in the side plate Cabinet Models Install the barrier shield and tighten the four screws See page 192 items 3 4 and 9 Pedestal Models Install the barrier shie
243. rungen zu erwarten sind Auszug aus dem EMVG vom 9 Nov 92 Para 3 Abs 4 Hinweis Dieses Genehmigungsverfahren ist von der Deutschen Bundespost noch nicht ver ffentlict worden Japanese EMI TOREJ VCCI ORB lt CORE CHAT oU BSesleHOFTCEMNHBVES 5 KIBRENSCEMHBVET 275 Appendix _ Communication Notices 276 Abbreviations amp Signal Mnemonics NOTE Mnemonics with first letter N are negative true Abbreviation or Mnemonic Definition Meg Q us usec AO A1 etc AMPL AN ASIC ATTN B BANK FAN BCOM BCP 5 BN BNLD BPS BSY BTU 1 000 Ohms 1 000 000 Ohms microfarad 10 farad microsecond 1 0 8 second microsecond 1 0 Address 0 Address 1 etc Alternating Current Access Acknowledge Amplitude Ampere Amplitude Anode Application Specific Integrated Circuit Attention Buffered Hammer Bank Fan Buffered Communication Bi phase Communications Processor Buffered Hammer Shift Clock Buffered Low True Buffered Low True Lower Driver Bits Per Second Busy British Thermal Unit 277 Appendix 278 BUD CA CCF CHNG CIR CLK COLL COMM CONTLR CMD CMX CNC CR CTL CTS CU CUR DO D1 etc DAT DC DCD DIAG DIFF DMA DP DPEN DPMC DPU DRAM DRV DRVR DSR DTR Buffered Upper Driver Cathode Card Cage
244. s diagnostic tools Use these printer tests to check the print quality and basic operation of the printer You will also use some of the tests in some adjustment procedures The diagnostic printer tests are summarized below e Shift Recycle A sliding alphanumeric pattern useful for identifying missing or malformed characters improper vertical alignment or vertical compression A pattern of all uppercase letter E s useful for identifying missing characters misplaced dots smeared characters improper phasing or light dark character variations e TOF A pattern of all E s 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 All H s A pattern of all uppercase letter H s useful for detecting missing characters or dots smeared characters or improper phasing e Underline Only An underline pattern useful for identifying hammer bank misalignment All Black Prints all dot positions creating a solid black band Exercises the shuttle and hammer bank at maximum capacity e Shuttle Slow Exercises the shuttle and ribbon mechanisms at low speed You can also use this test to check ribbon tracking and reversing e Shuttle Fast Exercises the shuttle and ribbon mechanisms at high speed You can also use this test to check ribbon tracking and reversing e Shuttle Only Runs the shuttle m
245. s special characters and multiple alphabets The first section of this appendix lists general specifications for continuous form paper Specific brands or types of paper are not recommended Adherence to these specifications will ensure the best print quality and reliable operation The second section goes into more detail providing definitions guidelines and a checklist to use for designing forms that will run smoothly through the print station of the HP LineJet printer 297 Appendix F _ General Paper Specifications General Paper Specifications This section describes the minimum paper specifications that must be met to ensure the best printer performance Always test paper and forms before buying large quantities Make all measurements at 20 to 26 Celsius 68 to 78 Fahrenheit and 45 to 55 relative humidity LineJet printers perform well with forms that meet the specifications listed in Table 7 and Table 8 below Hewlett Packard conforms to ANSI Standard X3 96 1983 American National Forms Information Systems for Continuous Business Forms and ISO Recommendation No 2784 which cover common form widths and depths standards for sprocket feed holes and margins and other basic tolerances 298 Table 7 Paper Sizes Maximum form width 17 0 inches 43 18 cm edge to edge Minimum form width 3 0 inches 7 62 cm edge to edge Maximum Printing Width 13 6 inches 34 54 cm Max
246. s the print application program itself is at fault If you have limited communications experience and the cause of the problem is not readily apparent do the following 1 Print out the printer configuration 2 Obtain a copy of the Device Host Configuration if possible 3 Call your support group for assistance in problem analysis If you cannot obtain support or you have experience solving host printer communications problems the following additional information is provided You can quickly check the ASCII portion of the printer logic by sending a plain text file from a PC to the printer via the parallel or serial port For a description of each of the ASCII interfaces refer to the User s Guide Table 4 Common Communications Problems Problems Interface Common Causes Fails to print from host parallel Interface cable defective or Host Network configuration Prints incorrect characters Printer logic or Terminating Resistors Prints extra characters Or Drops characters serial Host Printer interface cable pinouts incompatible Host Printer Network configuration Set DTR and RTS both True Interface cable defective Printer logic Ethernet Interface cable defective Host Printer Network configuration Printer logic 83 Chapter 4 Diagnostic Printer Tests Diagnostic Printer Tests A set of printer tests is included in the configuration menu structure for use a
247. sage List Message Explanation Solution ETHERNET ADAPTER BEING INITIALIZED Status message indicating that the Ethernet interface is processing the boot procedure May occur with older versions of microcode No action required ETHERNET DETECTED Status message indicating that the PrintNet Ethernet interface has established communication No action required EXHAUST FAN FLT Exhaust Fan Fault Sensors cannot detect current in the fan circuit 1 Cycle power If the message appears press CLEAR 2 Check that the exhaust fan is connected to exhaust fan cable connector J307 Connect the fan cable connector 3 Power off the printer Remove the paper path Disconnect connector P107 from the CMX controller board Test connector P107 EHF for shorts or opens See the Main Wire Harness Test Tables in Appendix A Replace components that fail test 4 Make sure connector P107 EHF has a good connection at J107 on the controller board 5 Inspect for obstructions of airways and vents Check for items beneath the printer blocking cabinet vents Remove obstructions Make sure cabinet exhaust fan vents are not blocked 6 Power on the printer Check for fan operation If the message appears or the fan doesn t work replace the exhaust fan 7 Power on the printer If the message appears replace the CMX controller board Record the message and return it with defective CMX b
248. sembly as described in the next section 29 Chapter 3 Cleaning the Card Cage Fan Assembly Cleaning the Card Cage Fan Assembly 1 Cabinet Models Remove the paper path page 161 Pedestal Models Remove the top cover assembly page 142 2 Vacuum the card cage fan assembly and surrounding areas to remove paper particles dust and lint See Figure 6 3 Cabinet Models Install the paper path page 161 Pedestal Models Install the top cover assembly page 142 4 Return the printer to normal operation page 101 NOTE Cabinet model shown Procedure is the same for pedestal model Legend 1 Card Cage Fan Assembly Figure 6 Cleaning the Card Cage Fan Assembly 30 4 Troubleshooting Introduction This chapter lists fault messages and symptoms and provides procedures for troubleshooting printer malfunctions Always have the User s Guide handy when you troubleshoot because this manual does not cover printer operation or configuration You must operate the printer to check its performance and sometimes you may have to reconfigure it 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 e Start Here Logic page 32 e Troubleshooting Display
249. soft cloth with alcohol Wipe the paper ironer to remove lint ink and paper residue 5 Install the paper ironer page 160 6 Remove the hammer bank ribbon mask cover assembly page 139 The ribbon mask is thin and easily bent Be careful not to crease or kink the ribbon mask when handling and cleaning it 7 Moisten a clean soft cloth with alcohol Wipe the hammer bank cover and ribbon mask to remove lint ink and paper residue Clean the holes in the cover strips Carefully wipe between the hammer bank cover and the ribbon mask Do not use any solvents or liquids to clean the hammer tips Clean the hammer tips gently too much pressure can chip them 8 Using a stiff non metallic brush such as a toothbrush gently brush the hammer tips to remove lint and ink accumulations See Figure 5 Vacuum up any residue 28 NOTE LineJet 500Q hammer bank is shown but the procedure is the Legend 1 Hammer Tip Figure 5 Cleaning the Hammer Tips 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 ribbon mask cover assembly page 139 10 Install the shuttle frame assembly page 177 11 Install the shuttle cover assembly page 141 12 Clean the card cage fan as
250. ssembly See page 208 item 4 5 Trace the paper detector switch cables back to controller board connector P106 removing all tie wraps See the cable routing diagrams in Appendix A Disconnect connector shell P106 from the controller board page 132 Trace the paper detector switch cables to the connector shell and remove the PMD and POD cable connector from the connector shell page 131 8 Remove the paper detector switch assembly Installation 1 Holding the slotted wheel against the PMD sensor position the paper detector switch assembly and install the two 1 4 inch screws securing it to the printer base See page 208 item 4 2 Check PMD sensor arm range make sure it travels freely and completely back into the sensing cavity 3 Route the switch cables back to the controller board connector P106 See the cable routing diagrams in Appendix A 4 Connect switch cables PMD and POD to the connector shell page 132 then connect P106 to controller board connector J106 5 Cabinet Models Install the barrier shield and tighten the four screws See page 192 items 3 4 and 9 Pedestal Models Install the barrier shield and paper guide and tighten the four screws See page 194 items 3 4 and 5 6 Cabinet Models Install the paper path page 161 Pedestal Models Install the top cover assembly page 142 Check the paper out adjustment page 117 Return the printer to normal operation page 101 180
251. t See Figure 23 page 157 5 Ifthe security PAL must be replaced remove the old PAL See Figure 23 page 157 The printer uses security PAL P N 154141 007PX 155 Chapter 6 Section Replacement Procedures Installation To prevent electrostatic damage to electronic components always wear a properly grounded static wrist strap when you handle memory modules and circuit boards Flash SIMMs from one CMX controller board must be placed in the same slot on a replacement CMX controller board Installing flash memory from one controller board to another does not transfer all operating system software so you must download the emulation again 1 If you are replacing the security PAL observe the correct pin orientation see page 157 and install P N 154141 007PX 2 Insert the memory module into the correct socket on the CMX controller board a Position the SIMM with the notched end toward the right side of the CMX controller board See Figure 23 page 157 b Pressthe 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 3 Cabinet Models Install the paper path page 161 Pedestal Models Install the top cover assembly page 142 Download the emulation page 285 Return the printer to normal operation page 101 Using the configuration printout s you made in step
252. t The compressed file on the diskette takes the form FILENAME EXE Now write down the complete name of the file with the EXE extension 13 On the printer control panel press and hold down the ON LINE FF keys Without releasing the keys power the printer on Continue holding the ON LINE and FF keys down 14 When you see WAITING FOR PROGRAM DOWNLOAD on the LCD release the ON LINE and FF keys The port default is CENTRONICS this is the standard load through the parallel port If you want to use the default continue at step 18 15 Press the NEXT key SELECT DOWNLOAD PORT DATAPRODUCT appears on the LCD 16 Press NEXT again to cycle through the download ports available in the printer DATAPRODUCT parallel CENTRONICS parallel default port RS232 9600 RS 232 serial 9600 baud RS232 19 2K RS 232 serial 19200 baud RS232 38 4K RS 232 serial 38400 baud RS232 115K RS 232 serial 115000 baud 286 RS422 9600 RS 422 serial 9600 baud RS422 19 2 RS 422 serial 19200 baud RS422 38 4K RS 422 serial 38400 baud RS422 115K RS 422 serial 115000 baud 17 When the printer download port you want to use is displayed on the LCD press ENTER WAITING DOWNLOAD PORT lt your selection gt appears on the display 18 At the DOS prompt on the computer type FILENAME EXE pb lt Return gt where FILENAME EXE is the compressed file you noted in step 12 This command decompresses the f
253. tall the paper path page 161 Pedestal Models Install the top cover assembly page 142 3 Return the printer to normal operation page 101 CMX Controller Board RP1 Default 470 Ohm 0 cen O 4 2 0 E rn 7 Alt 1 220 Ohm T Alt 2 1K Ohm oo o O 0 00000 D 00 PER RP2 Default 1K Ohm 000 Alt 1 330 Ohm 34 Alt 2 None 00 0 0 1 E oo nn 0 0 0 E J102 000 SE 000 ol 0 L J107 on O Figure 26 Terminating Resistors Removal Installation 170 Ribbon Drive Motor Ribbon Drive Motor Removal 1 Prepare the printer for maintenance page 100 Remove the ribbon hub page 173 Remove two screws and washers securing the ribbon drive motor to the base casting See page 208 items 18 and 19 4 Lift and rotate the ribbon drive motor until the motor cable is aligned with the slot on the base casting Disconnect the ribbon drive motor cable connector Remove the ribbon drive motor Installation 1
254. tem 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 and a 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 motor the drag motor This system maintains constant motor speed and ribbon tension 221 Chapter 7 Logical Control of the Printer Logical Control of the Printer The printer comprises four functional elements the control panel the CMX controller board the power supply board and the print mechanism See Figure 49 Figure 49 Functional Elements of the Printer 222 Ribbon Transport System Control Panel The user communicates with the printer by pressing keys on the control panel The keys are momentary contact switches The control 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
255. ter it has been detected and continue with its own power up sequence An Ethernet adapter takes a long time to complete its internal diagnostic tests so the boot code allows the adapter to power up in parallel with the printer to reduce its effect on overall boot time Load Boot Messages The boot code scans flash memory for OEM boot messages and loads them into DRAM The manufacturer s boot code is the same for all OEMs and contains a set of default messages Boot messages for specific OEMs are stored in the DC code not the boot code Load Boot Code into DRAM Flash memory cannot be accessed while flash is being detected cleared or programmed This prevents boot code from running in flash because the opcodes cannot be fetched This is solved by copying the program into DRAM and executing the program out of DRAM The boot code is position independent in order for the program to operate at a different address The interrupt vector table is also move to DRAM and the vectors are changed to reflect the new address Detect Flash The boot code supports many different kinds of flash memory permitting any mixture of flash in the four memory banks The only requirement is that flash must exist in bank 0 and have boot code programmed on it The boot code displays flash configuration manufacturer s part number size and start address out the debug serial port Display VX Registers The boot code displays the values of the VX regist
256. the engine controller program into the engine controller No action required SHUTL INV CMD Shuttle Invalid Command Firmware error on the CMX controller board 1 Cycle power Run the print job again If the message appears download the emulation software again 2 Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board SHUTL INV PARM Shuttle Invalid Parameter Firmware error on the CMX controller board 1 Oycle power Run the print job again If the message appears download the emulation software again 2 Cycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board 57 Chapter 4 Troubleshooting Display Messages Table 2 Message List Message Explanation Solution SHUTTLE JAM The shuttle is not moving or is 1 Set the forms thickness lever to moving at the wrong speed match the thickness of paper but not Check the forms thickness too tightly lever if it is set too tightly itcan 5 slow the shuttle enough to trigger the fault message 3 Inspect the ribbon mask for deformation that snags and interferes with shuttle movement Correctly install the hammer bank cover assembly or replace a deformed cover assembly Check adjust the platen gap 4 Run a print test If the mess
257. ting 31 PRINTER HOT 55 Printing conventions in this manual 12 line matrix printing explained 215 problems 31 Printouts hex code 90 Procedures adjustment 99 cleaning 25 PROTECTED INSTR 55 PWR SUPP 55 R Regulatory information 269 Replacement card cage fan assembly 148 circuit breaker 130 connector shells 131 connector stiffening clips 133 control panel assembly cabinet models 135 pedestal models 136 controller circuit board 137 cover assembly top pedestal models 142 CT board 147 dashpot 143 Ethernet interface assemblies 144 Ethernet interface assembly 144 expansion CT board 147 extension spring hammer bank 179 hammer bank ribbon mask cover assembly 139 hammer bank fan assembly 147 149 hammer spring 150 LAN interface assemblies 144 magnetic pick up assembly 154 memory modules 155 paper detector switch assembly 180 paper feed drive motor 158 paper feed timing belt 128 paper ironer 160 paper path 161 platen 162 platen interlock switch assembly 181 platen open belt 129 platen open motor 166 power supply circuit board 168 resistors terminating 169 ribbon drive motor 171 ribbon guide assembly L R 172 ribbon hub 173 shuttle cover assembly 141 shuttle frame assembly 177 splined shaft 174 support shaft 176 tractor L R 182 Reset Mode 145 Reset soft vs hard 93 Resistors terminating location of 170 RESTORING BOOT CODE 55 353 RIB INVLD CMD 5
258. tion Reverse paper feed platen does not open Raise the forms thickness lever and check that the platen opens If the platen opens with difficulty inspect for and remove jams or obstructions Check the platen open pulley and the platen pulley for looseness Bottom out the platen open motor pulley on the motor shaft and torque the 1 16 inch set screw to 9 2 inch pounds 1 02 0 23 Nem Tighten the 7 64 inch setscrew in the platen shaft pulley then open and close the forms thickness lever and check that the platen pulley setscrew does not hit the left ribbon guide Check the condition and tension of the platen open belt Adjust the platen open belt Replace the belt if it is damaged Check the platen gap Adjust the platen gap Power off the printer Remove the paper guide assembly Disconnect connector P106 from the CMX controller board Check the resistance of connector P106 PLAT M Refer to the Main Wire Harness Test Tables in Appendix A Replace the platen open motor if it fails the resistance test Power on the printer Press PAPER ADVANCE and VIEW several times and check that paper moves in both directions Replace the controller board if the platen does not open during paper reverse TOF is lost repeatedly Check that the customer is setting the forms length to match the size paper used Set the forms length to match the length of paper being used If the customer is using multi part forms check t
259. tle Frame Assembly Hammer Bank Assembly The hammer springs are grouped in comb like assemblies mounted on a solid hammer bank The number of hammer springs per hammer spring assembly and the number of hammer spring assemblies on the hammer bank vary according to printer model e LineJet 5000 and LineJet 500P seven 4 hammer assemblies for a total of 28 hammer springs e LineJet 10000 six 10 hammer assemblies for a total of 60 hammer springs e LineJet 15000 six 17 hammer assemblies for a total of 102 hammer springs Shuttle Drive Motor The shuttle drive motor is built into the shuttle assembly casting and drives two connecting rods on a crankshaft The small end of one connecting rod Shuttle Frame Assembly attaches to the hammer bank the small end of 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 this type of engine perfect primary balance low vibration and durability Each hammer spring is a stiff leaf spring with a cylindrical tungsten carbide tip on the free end See Figure 46 A permanent magnet is imbedded along the length of the hammer bank
260. to the user The LCD status indicator and keys are mounted on a printed circuit board assembly enclosed in a protective housing Figure 50 Control Panel Functional Overview 223 Chapter 7 CMX Controller Board CMX Controller Board 224 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 DC Data Controller and the EC Engine Controller The DC is responsible for e Host I O Input Output e Operator I O e Security Interface e Print Image Generation e Overall High Level Logical Control The EC is responsible for e Print Mechanism Operation e Print Mechanism Fault Monitoring e 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 51 summarizes this architecture
261. trol panel assembly Installation 1 Reverse steps 2 through 6 of the removal procedure 2 Return the printer to normal operation page 101 136 Controller Board CMX Controller Board CMX Removal To prevent electrostatic damage to electronic components always wear a properly grounded static wrist strap when you handle circuit boards 1 Make configuration printout of all saved configurations Refer to the User s Guide Prepare the printer for maintenance page 100 Cabinet Models Remove the paper path page 161 Pedestal Models Remove the top cover assembly page 142 4 Disconnect all cable connectors from the controller board See page 198 5 Loosen but do not remove the two 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 Do not separate the CMX controller board from the controller shield The shield serves as a stiffener and ground plane and is an integral part of the CMX controller board assembly 7 Slide the controller board assembly to the left until the keyway clears the screw securing the controller board to the bottom of the card cage Lift the controller board out of the printer 137 Chapter 6 Section Replacement Procedures Installation To prevent electrostatic damage to electronic components
262. ts e Removal installation instructions for the power stacker assembly and components that require the most frequent replacement e An illustrated parts breakdown IPB showing how the entire power stacker unit is assembled The IPB also lists the part numbers for replaceable parts Only replaceable parts have part numbers in the IPB If you need to replace a part for which no part number is shown replace the entire power stacker assembly 311 Appendix _ Removing the Power Stacker Removing the Power Stacker Set the printer power switch to O off Unplug the power cord Unload paper from the stacker area Refer to the User s Guide pe ges Remove the paper tent See Figure 56 Legend 1 Paper Tent Figure 56 Removing the Paper Tent 5 Cut the tie wrap and remove the paper fence See Figure 57 Legend 1 Paper Fence 2 Stacker Base Figure 57 Removing the Paper Fence 312 6 Remove three screws and washers from the stacker control panel See Figure 58 Legend 1 Long Screw 2 Washer 3 Short Screw Figure 58 Removing the Stacker Control Panel 7 Remove four cables from the stacker control panel and remove the stacker control panel See Figure 59 T d NN N ES oooooooooooooo n NN 2200000000000 Legend
263. ual testing Always test forms including special single part paper multipart forms forms with glue strips carbonless forms card stock and labels for satisfactory feeding registration and print quality prior to purchase For best results in selecting standard or specialty forms consult a forms vendor who can ensure conformance to the guidelines in this appendix and who can recommend cost effective purchases Storage and Handling The performance of the printer depends to a large degree on the condition of the paper used therefore the following principles for packaging handling and storage are recommended Packaging To avoid damage during handling use top and bottom fillers in continuous form cartons to hold the paper stack firmly in place Proper packaging ensures that the paper remains flat and is not damaged along the edges Storage Do not store cartons directly on the floor and do not stack them more than six high Set each carton upright and squarely on the one underneath Do not place anything else on the stack of paper as this can damage the paper Preconditioning Forms Protect paper from temperature and humidity extremes Store paper in the same environment as the printer for 24 to 48 hours before using the paper This allows the moisture content of the paper to stabilize LineJet printers are used at temperatures from 5 to 40 C 41 to 104 F up to 1524 meters 5000 feet from 5 to 32 C 41 to 90 F
264. ve RS 232 cable Verify that the host and printer have the same baud rate number of data bits number of stop bits and parity Configure the host for XON XOFF if possible since this requires the least complex cable Power up the printer Send a print job from the host If the printer does not print from the host replace the data and interface cable assemblies Remove the paper path or pedestal top cover Check all cable connections on the CMX controller board Reseat all cable connectors on the CMX controller board Power up the printer Send a print job from the host If the printer still does not print from the host replace the CMX controller board Printer does not print self tests Power off the printer Remove the paper path or pedestal top cover Disconnect the control panel cable from connector J110 on the CMX controller board Disconnect the control panel cable from the control panel Check continuity of the control panel cable assembly Replace the control panel cable assembly if it fails continuity test Connect the control panel cable assembly to J110 on the CMX controller board and to the control panel Load paper Power on the printer Run a self test If the self test does not run replace the control panel assembly Power on the printer Run a self test If the self test does not run replace the CMX controller board 78 General Symptom List Table 3 General Symptom List Symptom Solu
265. vers HP3000 MPE V MPE V Typical Configuration LOGICAL DEVICE Provided by CE DEVICE NAME HPPCLATPFor use with ATP HPPCLADCCFor use with ADCC HPLPATPFor use with ATP HPLPADCCFor use with ADCC DRT Provided by CE UNIT Provided by CE SOFTWARE CHANNEL 0 TYPE 32 SUB TYPE 14 ENTER TERM TYPE DESCRIPTOR FILENAME 19 SPEED IN CHARACTERS PER SECOND 240 RECORD WIDTH 66 OUTPUT DEVICE 0 ACCEPT JOB SESSIONS N ACCEPT DATA INTERACTIVE N DUPLICATIVE N INITIALLY SPOOLED Y AUTO REPLY DRIVER NAME HIOASLPOFor use with ATP HIOASLP2For use with ADCC DEVICE CLASSES LP User s choice 293 Appendix 3000 MPE XL MPE iX HP3000 MPE XL MPE iX MPE XL MPE iX Typical Configuration Within NMMGR follow the menu Open Config DTS Go to Profiles Add or Modify Printer Type 18 18 21 22 or 26 or Printer Type File Name Line Speed 9600 300 through 38400 Record Width 132 1 2048 bytes Modem Type 0 0 1 US 2 Europe Parity NONE None Even Odd 0 s 1 s Initially Spooled Y Y N Device Class user s choice Save Data Prior Screen twice Go to DTC Config Card Assign Profile to LDEV Save Data Validate Link DTX After successful Validation run SYSGEN to cross validate the DTS configuration with the system configuration In order for any TIO changes to take effect you must reboot the s
266. vers Termination 68EC030 Microprocessor A Motorola 68EC030 microprocessor serves as the processor of the DC unit This processor runs at 40 MHz and is called the CMX 040 This chapter refers to the DC microprocessor as the 030 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 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 An 8K x 8 bit Non Volatile battery backed static RAM NVRAM device pr
267. y DRAM Check DRAM on the CMX controller board If present reseat DRAM if missing install DRAM ERROR NVRAM FAILURE The non volatile memory has failed Replace the CMX controller board Do NOT attempt to replace NVRAM Record the message and return it with defective CMX board ERROR PROGRAM NEEDS MORE DRAM The printer requires more DRAM in order to run the downloaded program Add DRAM or use a smaller emulation program 41 Chapter 4 Troubleshooting Display Messages Table 2 Message List Message Explanation Solution ERROR PROGRAM NEEDS MORE FLASH The printer requires more flash memory in order to run the downloaded program Add flash memory or use a smaller emulation program ERROR PROGRAM NOT COMPATIBLE The printer is not compatible with the downloaded program Use the correct emulation software option s for this model printer ERROR PROGRAM NOT VALID The printer does not see a program in flash memory There is no program in printer memory Download the emulation ERROR SECURITY PAL NOT DETECTED The security PAL is not present or has failed 1 Check the security PAL at location U54 on the CMX controller board If the PAL is absent install the correct PAL If a security PAL is present replace it 2 Power on the printer If the message appears replace the CMX controller board Record the message and return it with t
268. y Shuttle Motor Cable Assembly Hammer Bank Power Cable Assembly Connector Kit P106 P107 Centronics I O Cable Assembly Control Panel Cable Assembly Clamp Shaft Receiving 500 lpm models 1000 lpm models 1500 lpm models 500 lpm models 1000 lpm models 1500 lpm models 12 for hammer bank cover 6 for ribbon mask 500 lpm models 1000 lpm models 1500 lpm models Part of Field Kit AC Assy 153502 901PX P106 Motor Sensor Left See also Appendix A See also Appendix A See also Appendix A P107 Motor Sensor Right See also Appendix A 199 Chapter 6 Section II Illustrated Parts Lists 19 202417 001PX SIMM Socket Flash Memory 4 20 202412 001PX SIMM Socket DRAM 4 21 154141 007PX Security Module Base 22 163211 901PX Connector Clip Field Kit Description Notes 18 Ref Screw Captive Power Supply 3 See page 155 See page 155 See page 155 200 Illustrations of Printer Components 201 Chapter 6 Section II Illustrated Parts Lists Spring Lug Do not 3 remove grease Spring Lug Do not remove grease s Make sure the MPU cable does not touch the extension spring after cable connection 1 5 0 010 001 inch 0 254 025 mm E Figure 36 Magnetic Pickup MPU and Extension Spring 202 Illustrations of Printer Components Item No Part No Description Notes 1 150281 901PX MPU Assembly
269. y moves up and down SO 5555555 55 945555454 Legend 1 Wire Saddle 2 2 Cutout Beneath Card Cage Fan 3 Cable Bundle Figure 71 Securing Stacker Cables 27 Install the paper path that you removed in step 4 28 Install paper and test stacker operation Refer to the User s Guide 327 Appendix _ Replacing the Constant Force Spring Replacing the Constant Force Spring 1 Remove the stacker assembly from the printer See page 312 In the next step do not over tighten the tie wraps or string Tighten the tie wraps or string just enough to hold the elevator up h d 2 Raise the elevator assembly to its highest position and secure it to the vertical rails using tie wraps or string See Figure 72 Legend 1 Tie Wrap 2 Elevator Assembly Figure 72 Securing the Elevator Assembly 328 The constant force spring is a high tension spring To avoid pinching your fingers coil the spring slowly and carefully Do not let the spring twist or crimp Remove the shoulder screw washers and spacer from the constant force spring and drum Let the spring coil itself up until it reaches the screw that secures it to the vertical rail See Figure 73 Firmly gripping the spring and drum remove the screw securing the spring to the vertical rail See Figure 73 Legend 1 2 3 4 5 6 7 Figure
270. ystem Within SYSGEN sysgen gt io io gt LD io gt HO sysgen gt Keep configuration 294 HP9000 HP UX amp HP UX Typical Configuration Printers set up on HP PB amp CIO computers Drivers Required Interface HP PB CIO 6 CHANNEL CIO 16 MUX CHANNEL MUX Serial mux2 cio 0 muxO 16 cio 0 Parallel Ipr2 N A N A The Drivers shown in this table should be installed in the Kernel Configuration Configuration Guidelines Within SAM follow the menu Printers and Plotters Printers Plotters Printer Plotter Manager menu select Actions Add Local Printer Plotter Add parallel Printer Plotter or Add serial Printer Plotter If parallel printer is selected Printer Nameuser s choice Printer Model Interfaceuser s choice Printer Device File NameSAM creates a special file Printer Classuser s choice If serial printer is selected The system displays the Serial Interface Hardware Paths Portselect a valid port Printer Nameuser s choice Printer Model Interfaceuser s choice Printer Device File NameSAM creates a special file Printer Classuser s choice 295 Appendix 9000 HP UX 296 F Paper Specifications and Forms Design Introduction LineJet printers use dot matrix line printing technology which permits a high degree of printing flexibility Dot matrix technology enables the user to print graphic images line drawn character

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