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Maintenance Information Manual Cabinet and Pedestal

1. 7201 15 00 1 O a 20 S o 1 a 3 x E 98 1 n Ed 5 1 le PRINTRONIX Uo V5 5 4 Ct of J112 zz 5 5 P Centronics Pcs 136298 001 ev _ oO uU mg 5 O 0 CNC PN 1 1 NSTROBE Na s8 2 CNC PN 19 2 A VOCNCPN2 3 1 i n OCNCPN20 4 m om gH r OW VOCNCPN3 5 P2 VOCNCPN21 6 9 VOCNCPN4 7 P3 22 8 9 5 9 P4 J201 J110 PN23 10 gt 4107 VOCNC PN6 11 m p5 RS232 RS422 Front Panel PN 24 12 vec Motor Sensor Right VOCNCPN7 13 P6 1 DAT AVAIL lO PN25 14 9 2 1 L 1 VOCNC PN8 15 P7 1 10 yo
2. po O B 4 an Of VES 0 00 0 6 Oe ae Ls PRINTRONIX ES o m 0 BE 11 ag m a nt x LI H T MOT ME n 3L 8 BANK vec J111 109 Expansion Connector Hammer Bank Power J101 Motor Sensor Left 3 L 2 4 e 1 N TEMP HI NC E sue 1 L 5 Lu e 2 STBY EXP N ID SEL E 34 2 RB 6 PHA 3 1210 V 6 36 EXP D3 3 2 i M NC 7 SO sh 02 2 DATA 48V 9 LDFB 6 DMA 8 38 _ _ a D1 LL 10 7 DMA 1 9 RIB L3 a 8 E 10 40 EXP AS 8 RIBL4 cc FAN 9 m 11 9 7 10 EXP NINT 12 42 9 10 L RBN POST 0 01 mF 11 48V 13 43 ES CCFAN 10 12 EXP NWR EXP A12 11 LReNPosr 100 EXP NRESET 12 E EXP 11 12 13 POD CAJ 16 46 10 14 PMD A 470PF 470 PF 470 PF 470 PF EXP NMSEL 17 47 15 PODK pup Ww CT SV SV 50V 18 48 EXP AD 19 4 9 17 PODC EXPNDS 20 50 L 18 EMD C EXP 015 1 9 4 21 51 EXP 6 PODE 19 EXP D14 22 52 EXP A5 20 PMDE
3. Avet JOJO _ 2 5 d alo JOON uoga 8 o o ASSY 9 9 8Y uoqqu Ast uedo ASt AS ye peog yueg s 8 abi uedo AS 1012818 pueog Jojeuiuue AS gt JOlOJA pee Asr quiessy JOJO ayn 20 m 8 died led zor je 8 i A8v G 8 49 YSN 7014 awseua ISIN 9014 c YSN 2017 CWS 9010 801 ISN 9017 as el 8 A8vt 1 Eun AS 9 oL d Od AS8 6 prep AS 9I9O1 13H AS 8 9I901 13H 9 Z 5 QNO 13H AS 9 preog Jojou05 yeuigeo QN52I5O1 13HAS S XINO QNO AS v SISSVHO leu AS 6 sneux3 16 2 T T OLen IH c LOLd a 5 eur a eur Ajddng OV N Uld IH N 1 90 YAMS JOJuO K quiessy jeueg YOLOANNOO H3MOd OV oze 991 OV c Y 290 Main Wire Harness Test Tables
4. Legend 1 2 3 4 Upper Frame Cross Member Elevator Assembly Stacker Base Vertical Rail Figure 75 Stacker Installation 20 21 Align the holes in the stacker base with the holes in the cabinet floor See Figure 75c and Figure 76 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 four 7 64 x 1 2 inch screws and washers or Torx T 10 screws securing the stacker base to the cabinet floor See Figure 76 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 74 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 385 Appendix J Installing The Power Stacker NOTE
5. 10K 1 1 ENS EC DB TXD J2 E RN UR EC DB RXD EC Diagnostics 4 2 PPR MOVING 2 FT EVENT 8 MPUOUT 9 SHUT DIR 10 PA 00 2 Loe Ee m AE EN er 3n e d o U fle F4 ery ERINTRONIKT ERUN ES LE 9 9 E A n 1 7 8 0 00 on E Q 4 Flash J J108 J116 80 pin SIMM Hammer Bank Logic 47 Soules J10 Bank1 i J11 1 SHUT A See page 217 1 So wie 2 6 Banko T See page 217 3 HMRDATRET 4 L HMRCLK 5 RET 0 01 mF 6 DAT ie 7 C MD DAT RET IDEE CAUTION 5 Do not remove or replace 8 the NVRAM The NVRAM contains a 9 CMDCLKRET lithium battery that can explode if it is 10 replaced incorrectly NVRAM is replaced m only at the factory TOROID J1 2 PIN JUMPER J13 Eo E 2 PIN JUMPER J12 2 PIN JUMPER J14 No E 2 PIN JUMPER J5 2 PIN JUMPER 4 penunuoo Appendix A Circuit Board And Cable Pinouts Power Supply IBM Coax Twinax Expansion Board Appendix A Circuit Board And Cable Pinouts SureStak Power Stacker PCBA V Gld 3130 ul AOS 02 ro 0 13d ul
6. Step Press Displayed Result Notes 1 Install the ribbon load paper and power on the printer 2 NOT READY Puts printer in NOT Stop READY mode 3 OPERATOR MENU Unlocking ENTER key Scroll Scroll UNLOCKED gives you access to the configuration menus 4 OPERATOR MENU First of series of Menu PRINTER CONTROL configuration menus 5 OPERATOR MENU Advances to the Printer Scroll UNTIL PRINTER INFORMATION Information menu 6 PRINTER INFORMATION Advances to the first of Ener NSTALLED MEMORY the Printer Information menus 7 PRINTER INFORMATION Stop when the menu you Scroll MENU NAME want is displayed 8 MENU NAME Your selection displays Enter STATISTICS OR INFO the information 9 NOT READY Returns printer to NOT Stop READY mode Soft Reset Soft vs Hard Reset Resetting the printer returns it to a previous configuration There are two kinds of reset Soft Reset A soft ware reset clears printer memory then loads the power up configuration into memory The procedure for saving configurations is described in the Setup Guide It is called a soft reset because no hardware is tested All diagnostic and initialization tests are bypassed and memory is simply refreshed with the power up printer configuration Put the printer the NOT READY state to do a soft reset 1 Press the Stop key to put the printer the NOT READY state 2 Press the Sto
7. Length Multiply By To Obtain foot 0 3048 meter foot 30 48 centimeter foot 304 8 millimeter inch 0 0254 meter inch 2 54 centimeter inch 25 4 millimeter meter 3 280840 foot centimeter 0 03280840 foot millimeter 0 003280840 foot meter 39 37008 inch centimeter 0 3937008 inch millimeter 0 03937008 inch Figure is exact Torque and Force Multiply By To Obtain inch pound 0 11298 Newton meter foot pound 1 3558 Newton meter Newton meter 8 8511 inch pound Newton meter 0 7376 foot pound 337 Appendix C 338 Multiply By To Obtain pound 4 4482 Newton inch 0 22481 pound Mass and Density Multiply By To Obtain pound 0 4535924 kilogram ounce 28 34952 gram kilogram 2 204622 pound gram 0 03527397 ounce avoirdupois Temperature From To Use Formula temperature Celsius tc temperature Fahrenheit tf tf 1 8tc 32 temperature Fahrenheit tf temperature Celsius tc tc tf 32 1 8 Power Multiply By To Obtain Btu International Table 0 2930711 Watt hour Watt 3 412141 Btu International Table hour Watt 0 001359621 horsepower metric horsepower metric 735 499 Watt D Torque Table The table below establishes the torque requirements for routine installation of threaded fasteners These re
8. o 5985 OD eCOCOSCOCO CO nO E fo PRINTRONIX V5 5 CAUTION 5 Do not FS or replace r the NVRAM The NVRAM contains a 1 __lithium battery that can explode if it is replaced incorrectly NVRAM is replaced only at the factory Bank 1 Bank 0 Bank 1 2 P Bank 0 9 Notch Notched End 1 Flash pram Security PAL 80 pin SIMM 72 pin SIMM J11 Bank 0 must always J16 Bank 0 must always be filled be filled J10 Bank 1 J15 Bank 1 Reserved for upgrades Reserved for upgrades If 1 Flash SIMM use Bank 0 If 1 DRAM SIMM use Bank 0 If 2 Flash SIMMs use both If 2 DRAM SIMMS use bo
9. B Legend 1 Vertical Rail 2 Paper Tent 3 Alignment Rod Figure 61 Positioning the Paper Tent Push or pull the paddle shaft toward the front or the rear of the printer and set the paper length by aligning indicator notch on the bearing bracket with the paper length indicator Length range 5 to 12 inches See Figure 62 371 Appendix J _ Stacker Operation Legend 1 Paper Length Indicator 2 Paddle Shaft 3 Bearing Bracket Figure 62 Setting Paper Length Loading and Starting the Power Stacker 1 Press the FORM FEED key on the the stacker control panel and hand feed the paper down into the paper throat Continue to advance the paper until it reaches the wire tent and there are 3 to 5 extra sheets in the stacker Make sure the paper passes through the throat of the paper stacker See Figure 63 Figure 63 Paper Path the Power Stacker 2 Stackthe 3 to 5 sheets of paper on top of the wire paper tent making sure the paper lies with the natural fold 372 3 Press the ON LINE key on the rear control panel or the Start key on the front control panel to put the printer in the READY state The stacker elevator will descend to its lowest position See Figure 64 Figure 64 Power Stacker in Print Position 4 Checkthat the paper is still centered between the paper guides 5 Close the cabinet rear door 6
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11. NOTE You must cycle power to exit the file download menu SELECT DOWNLOAD PORT CENTRONIC w SELECT DOWNLOAD PORT RS232 9600 SELECT DOWNLOAD w PORT RS232 19 2K PORT RS232 38 4K SELECT DOWNLOAD v SELECT DOWNLOAD PORT RS232 115K w 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 v SELECT DOWNLOAD PORT RS422 19 2K SELECT DOWNLOAD w PORT RS422 38 4K SELECT DOWNLOAD w PORT RS422 115K SELECT DOWNLOAD 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 19 Boot Diagnostics Menu continued 139 Hex Code Printout Chapter 5 Hex Code Printout A hex code printout hex dump prints every ASCII character received from the host computer with its corresponding two digit hexadecimal code Hex dumps can be used to troubleshoot printer data reception problems by comparing the
12. page 227 Operator Panel Assembly Pedestal Model page 228 Paper Guide page 229 Paper IrOner ud pt bean page 230 Platon eie nnn page 231 Resistors 235 Ribbon Guide Assembly page 237 Fubborn Flub siue Et et eie EE etes page 238 Security Module page 217 Shaft Splined 5c c pe e pata ne eee page 239 Shaft SUppott uisu e tene rt n rr e DO nte Pe rite page 241 Shuttle Frame page 242 Spring Extension a a aaa a page 244 Switch Assembly Cover page 245 Switch Assembly Paper page 246 Switch Assembly Platen Interlock page 247 Tractor LAR iiri seen Mee eee eee dp eens page 248 187 Chapter 7 Section Replacement Procedures Belt Paper Feed Timing Removal 1 Prepare the printer for maintenance page 152 2 Cabinet Model Remove the paper guide assembly page 229 Pedestal Model Remove the top cover assembly page 204 3 Cabinet Model Loosen four screws and remove the barrier shield See page 258 Figure 44 items 3 and 4 Pedestal Model Loosen the four screws securing the paper guide and barrier sh
13. Input Voltage Line RMS Current Voltage Line Design Frequency 04 05 50 08 09 010 05 04 05 P50 08P o9p P40 O12 14 015 csp 88 47 63 Hz 6 6 6 6 6 6 6 8 6 135V 100V 100V 100V 100V 100V 100V 100V 100V 100V 100V RMS 178 47 63 Hz 3AQ Q9 5A 5 270V 200 V 200 V 200 V 200 V 200 V 200 V 200 V 200 V 200 V 200 V RMS Power Consumption 6400 004 6400 04P Operating HS Mode Standby 120 VAC oo AllH s Max Typical o hd Energy Star Watts 212 232 80 20 BTU Hour 723 791 273 71 VA 321 348 133 34 Operating HS Mode Standby 240 VAC 2005 AllH s Max Typical iere Energy Star Watts 212 227 82 21 BTU Hour 723 775 279 71 VA 390 426 164 39 6400 005 6400 05P Operating HS Mode Standby 120 VAC pu Fiz AllH s Max Typical Energy Star Watts 223 244 84 21 BTU Hour 761 833 287 75 VA 338 366 140 36 Operating HS Mode Standby 240 VAC 90 AllH s Max Typical d Energy Star Watts 223 239 86 22 BTU Hour 761 816 294 75 VA 410 449 173 41 6400 050 6400 P50 Operating HS Mode Standby 120 VAC ere AllH s Max Typical ilH Energy Star Watts 223 244 84 21 BTU Hour 761 833 287 75 VA 338 366 140 36 Operating HS Mode Standby 240 VAC SURE
14. Make sure the service panel permitting access to the I O plate and circuit breaker on off switch is installed Make sure the paper stacker tray assembly or optional power stacker is in place and undamaged Print Mechanism 1 Open the printer top cover 2 Make sure the shuttle cover is correctly installed and undamaged See page 203 3 Make sure the paper guide assembly is correctly installed and undamaged See page 229 Inspect Electrical Parts Safety Ground Path 1 Make sure the printer power cord is unplugged Remove the paper guide assembly page 229 Make sure the ground cable from the circuit breaker power leads is undamaged and firmly attached to the ground lug on the wall of the card cage as shown in Figure 56 NOTE Ground paths for the entire printer are summarized in Figure 57 Figure 56 Circuit Breaker Ground Cabinet Models 343 Appendix E _ Inspect Electrical Parts 4 Seta Fluke meter P N 8496278 or similar device to the lowest resistance scale Measure the resistance between the power cable ground pin and the printer frame safety ground circuits should measure 0 1 Ohm or less 5 Install the paper guide assembly page 229 POWER IEC 320 AC POWER CIRCUIT BREAKER AG ta DC Power Supply Board eutral D 2 CHASSIS GND V3 5 BOARD PIN 1 N TEMP V4 BOARD PIN
15. Figure 45 Inside Covers and Card Cage Pedestal Model 260 Illustrations Of Printer Components Item Part No ae No Order No Description Notes 1 14H5235 Shroud Assembly Air Shuttle Cover Assembly 2 Ref Screw Captive 2 10 24x 62 with O ring 125x 250x 06 3 Ref Screw Thread Forming 4 6 32x 25 4 Ref Barrier Shield 5 63H5116 Paper Path Assembly Models 04P 05P 08P 09P 6 08H7954 Anti Static Brush Kit 7 Ref Power Supply Shield Taped to card cage along upper edge 8 5781468 Belt Timing 050P 100 Teeth Paper Feed Belt 9 14H5174 Platen Paper Feed Cover Kit Paper feed belt cover shown in Figure 45 Platen open belt cover item 24 page 276 10 14H5179 Paper Scale 261 Chapter 7 Section Il Illustrated Parts Lists From Figure 45 page 260 Rotated 180 degrees Power Input Connector J301 White Wire To Connector P1 White Wire To Connector P1 Black Wire 6 To IEC 320 AC Power Input Connector J301 Black Wire Figure 46 Card Cage Detail Pedestal Model 262 Illustrations Of Printer Components bon o der Na Description Notes 1 Ref Nut 6 32 1 Upper right fan corner only 2 5761440 Card Cage Fan Assembly Air flow is into card cage 3 Ref Fan Guard 4 Ref Screw w Lock Washer 4 6 32x 1 75 5 Ref Card Cage Pedestal 6 14H5571 Circuit Breaker 263 Chapter 7 Section Il Illustrated Parts Lists Two places Exploded to show a
16. P106 Connector Connectors are viewed P107 Connector from the top as seen 19171513 119 7531 when pluggedinto 1917 1513 119 7531 POD CCF PLATM contro ser poard MPU PLO EHF PAPR M PMD LRP LRIB M CVO HBF RRIBM in No 20181614 1210 2018 1614 1210 8642 Resistance Resistance Device P106 Pins Normal Device P107 Pins Normal LRIBM 2 4and6 8 72 880 RRIBM 2 4and68 72 880 PLATM 1 5 7 1 35 1 65 Q PAPRM 1 3and5 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 CCF 9 11 4 6 RRP 14 16 Open across pins PMD 14 16 8 Meg Q Short across post 18 20 Open Ka PLO 13 15 Continuity switch closed POD 13 15 8 Meg Q Open switch open 17 19 Open a CVO 18 20 Continuity switch closed CCF Card Cage Fan open LRIB M Left Ribbon Motor LRP Left Ribbon Guide TAI eOe 291 c6c
17. 391 Replacing The Timing 394 Illustrated Parts 398 Table of Contents l Maintenance Overview About The Printer The entire system architecture of an IBM 6400 line matrix printer is contained on one circuit board The use of DRAM and flash memory on this board permits rapid access to stored printer emulations and fast processing of print data A variable speed shuttle and half step paper control enables the printer to print a wide variety of high volume jobs with minimum maintenance and maximum reliability Although technologically advanced the 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 This is also an excellent graphics printer with optional features that simplify the creation of dot images The IGP and Code V Printronix emulations are simple but versatile graphics programming languages that load into flash memory The IBM 6400 Series Printer Family The IBM 6400 Line Matrix Printer family consists of pedestal mount and floor cabinet models that print at different speeds as shown in Table 1 Some models are available in either floor cabinet or pedestal housings while other models are available only in floor cabinets The print speeds listed in Table 1 are the ma
18. you downloaded from the World Wide Web This command expands the file and copies it as a binary file into the flash memory on the CMX controller board NOTE If you are downloading the file using the LPT2 port on the computer enter the following DOS command FILENAME EXE pb 2 lt Return gt If you are downloading the file into 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 18 While the file is copied into memory the printer LCD informs you of the load process and status See Table 7 below 19 When the file has successfully loaded into memory and the printer has reset itself set the printer power switch to O off 20 Unplug the AC power cord from the printer 21 Power off the personal computer 177 Chapter 6 Loading Flash Memory 22 If you had to install a parallel data cable to the computer and printer in step 8 disconnect it from the computer and printer 23 Reconnect the customer s data input cable s to the printer if required 24 Return the printer to normal operation page 153 25 Using the configuration printout s you made in step 3 reconfigure the printer Refer to the Setup Guide NOTE A continuous IML cycle indicates coax twinax code is being loaded into a printer with a missing defective or improperly installed Coax Twinax board If the printer is supposed to have this feature reseat the Coa
19. 4 3 2 EON os Ts 5 N FP LED WR 4 RIBR2 VO CNC PN 27 6 DATA E 5 dev VO CNC PN 10 19 5 7 6 js BUSY 26 6 HOST DSR AA lO CNC PN29 22 7 9 VOCNC PN 12 23 PAPER EMPTY 5 HOST DCD 10 lO PN30 24 e 53 VOCNC PN 13 25 L SLCT 10 NC m BAN 0 01 mF VO CNC PN31 26 1 NINIT 11 13 BLAT OPENS 10 VOCNCPN14 27 NAUTOFEED 12 Nc 100V VOCNCPN32 28 NFAULT 13 11 Be eee VOCNC PN 15 29 14 15 PLAT OPEN RET PI 16 6 RRBNPOST l OCNCPN33 30 15 DIFESRAD 17 Med CNC PN 16 31 vec 16 Nc 18 COVER OPEN SW PN34 32 H NC 4 7K e 27 17 DIEF RXD 19 MPU VO CNC PN 17 33 0 1W 18 20 PN35 34 N DP SEL 19 DIFF TXD COVER OPEN RET VOCNC PN 18 35 EXT 5V 20 HOST DTR 7 vO CNC PN36 36 NSELECT IN 21 7 NC 37 Host Loaic H 77 22 Ne 38 N DP EN 23 39 1 9 lt iok 24 NC 40 0 1W 25 DIFF TXD CAUTION 5 Do not remove or replace 470 PE the NVRAM The NVRAM contains a H7 50V lithium battery that can explode if it is replaced incorrectly NVRAM is replaced CHASSIS OND only at the factory sinouid 1 puy y xipueddy 6c
20. Figure 68 Removing Cables from the Stacker Control Panel 376 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 69 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 69 Preparing the Stacker for Removal gre em re 377 Appendix J _ Removing The Power Stacker 10 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 70 Legend 1 Screw 6 32x1 4 Torx T 10 two at bottom of each rail 2 Vertical Rail 3 Stacker Base Figure 70 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 69 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 shown in Figure 71 378 RA
21. Pin Connection P106 LRP P107 RRP Wire Color Pin 1 Black Pin 2 Black 315 Appendix A Circuit Board And Cable Pinouts Cable Assembly Ribbon Motor Extension 63H7464 316 Cable Assembly Shuttle Motor Drive 14H5330 PIN 1 ll me FIIS PIN 3 WIRE TABLE 5 P416 Joz WIRE COLOR 1 1 BLACK 2 2 BLACK IL 5 3 BLACK RESI SECTION A A 317 Frame Cable Power Stacker Appendix A Circuit Board And Cable Pinouts HH HH HH HH 7 ui T HH HH 5 Nid k aNd 26 LE 4 05 Ud 6c 8c k 22 9c V Gld Sc ve c ke 0c 61 8L 11 vigi 9L 2 Z 8Hd Id vl d Id l eseud WYO 912 2791 eoueisised 2 yhd Id 21 HOLOW f Y31104 LL Ol 6 WYO gi F Z S 18 21 8 HOLOIN 2 2W 9 28 IW 9 18 UN v eseug WYO 91 F Z S eoueisised ZY IW WHOlOW iyin 2 qnaava uvau LN jou A uo e2uo19J8u 318 Logic Cable Power Stacker 2
22. 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 88 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action 089 RIBBON STALL This message occurs when the ribbon fails to move while printing Check the forms thickness lever if it is set too tightly it can inhibit ribbon movement Set the forms thickness lever to match the thickness of the paper being used but not too tightly Inspect the ribbon guides for ink buildup which can inhibit ribbon movement Clean the printer Inspect the hammer bank cover ribbon mask for bending or damage which can inhibit ribbon movement Replace the hammer bank cover assembly if it is bent or damaged Check the platen gap If the gap is too small it can inhibit ribbon movement Adjust the platen gap Power off the printer Remove the paper guide assembly or pedestal top cover Check the resistance of connectors P106 LRIB M and P107 RRIB M Refer to the Main Wire Harness Test Tables page 291 If ribbon motor resistance is not correct replace the motor and or the intermediate cable if installed Power on the printer Run an Operator Print Test See page 132 If the 089 RIBBON STALL message appears replace the CMX controller board Record the message and return it w
23. 3810821 220 Security Module Hanzi 57G1421 page 278 Motor Pulley Paper Feed 57G1440 page 278 Fan Assembly 57G1453 page 278 Paper Detector Switch Assy page 324 57G1460 page 274 Splined Shaft 362 Part Number Location Description 5761466 274 Tractor Set 5791468 258 Belt Timing 050P 100 Teeth Paper Feed 5791467 276 Belt Timing 312W 87 Teeth Platen Open 5761469 276 lroner Assembly Reverse Paper Feed 57G1476 page 272 Magnetic Pickup Assembly MPU 57G1479 page 278 Ribbon Hub Kit 57G1481 page 254 Dashpot Kit 57G1484 page 250 Hinge Plate Bottom 57G1485 page 250 Caster with Brake 57G1486 page 250 Caster without Brake 57G1492 page 250 Window Top Cover 57G1514 page 276 Platen Pulley Driven 57G1521 page 274 Ground Clip Splined Shaft and or Power Stacker page 399 57G1571 page 276 Bracket 57G1598 page 254 Operator Panel Overlay English 57G1599 page 254 Operator Panel Overlay Spanish 57G1600 page 254 Operator Panel Overlay French 57G1601 page 254 Operator Panel Overlay Italian 57G1602 page 254 Operator Panel Overlay German 57G1603 page 254 Operator Panel Overlay Dutch 57G1604 page 254 Operator Panel Overlay Braz Portuguese 57G7176 page 252 Stacker 57G7260 page 252 Power Cord U S See also Appendix
24. NOTE Left timing belt is shown Right is the same ROT em Legend 1 Timing Belt Figure 88 Removing the Timing Belt 9 Toinstall a timing belt reverse the steps of this procedure 397 Appendix J _ Illustrated Parts Breakdown 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 are assigned part numbers If a part or assembly is damaged but does not have a part number replace the entire power stacker assembly The IPB starts on the next page 398 See page 401 Figure 89 Stacker Assembly 399 Appendix J Illustrated Parts Breakdown jo Part No Description Notes 5 Ref Flanged Bearing Part of item 36 6 24H8966 Paper Deflector 7 Ref 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 24H8968 Timing Belt 11 24H8996 Shaft Lift 12 24H9002 Pulley Timing Belt 13 24H9001 Pulley Motor 14 5791521 Clip Grounding 15 24H8969 Motor 20 24H8970 Constant Force Spring 25 24H8971 Chain Mount chains outboard of shafts 30 Ref Nylon Plug 35 24 8973 Cable 36 24H9004 Stacker Hardware Kit Kit not illustrated 37 Ref Screw Shoulder 8 32 Part of item 36 38 01P4699 Power Stacker Limit Switch Kit Replac
25. 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 an IEEE 1284 Level 2 host e Interface to RS 232E serial host e Interface to RS 422 serial host All the circuitry required for these host types is provided on the CMX board except for the drivers themselves ESD protection and terminations Host I O Drivers And Termination Beyond the 030 processor and VX ASIC additional support circuitry completes the serial and parallel interfaces These circuits include 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 are DIP socketed 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 measured 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 Engine Controller The engine controller EC consists of four main elements e 80C166 Microcontroller e 128KB 5 0V only FLASH program memory organized as 64K x 16 bits This memory is not expandable e Mecha
26. VERSION CHECK VERSION CHECK VERSION CHECK P C BOARD VERSION W SECURITY PART PROCESSOR SPEED ENTER ENTER ENTER P C BOARD VERSION SECURITY PART PROCESSOR SPEED 3 0 154143 001 68E030 AT 25 MHZ BOOT DIAGNOSTICS FILE UTILITIES p Continued on ENTER next page FILE UTILITIES v FILE UTILITIES FILE UTILITIES VIEW FILES FILE SYSTEM STATUS W OPTIMIZE FILES ENTER ENTER OPTIMIZING FLASH FILES VIEW FILES VIEW FILES VERSION FILENAME FLASHDISK STATUS FREE 0012473 FLASHDISK STATUS w ERASES 000073 w FLASHDISK STATUS OF FILES 000 v FLASHDISK STATUS USED 0002048 v FLASHDISK STATUS DELETED 0000000 138 Figure 19 Boot Diagnostics Menu Boot Diagnostics Menu NOTE BOOT DIAGNOSTICS A P MISC UTILITIES Scroll key From previous page ENTER MISC UTILITIES MISC UTILITIES MISC UTILITIES MISC UTILITIES DISPLAY MEMORY PRINTER W COPY FLASH SIMMS COPY BOOT SIMMS v 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 RUN MEMORY TESTS W FILE DOWNLOAD CLEAR NVRAM ENTER ENTER ENTER ENTER ERASE ALL FLASH TESTING FOR CLEAR NVRAM COMPLETED ADDRESS SHORTS COMPLETED
27. 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 CMX controller where XX is the data line plus 1 For example a bad data line 8 would blink as 4 1 1 9 Initialize VX ASIC The boot code detects the processor type and sets up the internal registers of the VX ASIC e initialize Debug Serial 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 e Turn On Instruction Cache The instruction cache is turned on to help speed up memory tests and the entire boot process e 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 sta
28. etc failed the current test at power up Check that the hammer bank cables are connected 1 Cycle power If the message appears replace the shuttle frame assembly Record the message and return it with the defective assembly 2 Power on the printer If the message appears replace CMX controller board Record the message and return it with the defective board INTERRUPT UNUSED VECTOR 00 This message is generated when the CMX controller board gets an interrupt that it does not understand This problem can be created by electrical noise a software problem or by a hardware problem 1 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 2 Power on the printer Cycle power If the message appears suspect an application software error Request assistance from your local support group Install the original CMX controller board LOADING PROGRAM FROM PORT XX 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 emulation program from flash memory and is loading the new program into flash memory No action required NOT READY Printer state message printer is o
29. 23 53 L EXP A4 77 EXP D13 24 54 9 EXP D12 m 25 55 EXP D11 r 26 56 EXP 2 CAUTION 5 Do not remove or replace E purs the NVRAM The NVRAM contains a T5 59 lithium battery that can explode if it is 30 60 IT replaced incorrectly NVRAM is replaced only at the factory vcc 77 penunuoo puy pjeog y xipueddy 660
30. P107 RRP R RBN M P107 HBF To J107 on CMX board JOPOW 1oeuiqe jqeg S NOUld ejqe puy pjeog y xipueddy Cable Routing Pedestal Model 301 206 Front of Printer o Left Side of Printer Right Side H of Printer ZZ Pos 9 16 LO LO R RBN M CABLE ASSY L RBN M s 5 CABLE ASSY m J06 SIDE PLATE 5 22 view L P307 EXHAUST TN s Hs 5H Not connected BE on pedestal models BEADED P306 TO CARD CAGE FAN P108 P105 P116 Pa gt TE WRAP 2 Fo P406 PMD P407 EHF P407 PLO PLATM P106 P0D prosiccr L RBN M P106 LRP E TDZZMBU P107 RRP P107 JMP WIRE R M 106 board Poz Her PPR M To J107 on CMX board NOTE This view shows the underside of the mechanism base sjnould ejqe
31. appears replace the operator panel FREEFORM ON OFF This message 1 Power off the printer Hold any control HOLD KEY PWRUP appears if the panel key down and power on the printer freeform feature is Hold the key down until the printer enabled This feature powers up and the message FREEFORM is for manufacturing OFF appears on the LCD use only and is never 5 Ifthe message reappears after doing step used by the customer 1 replace the CMX controller board or field maintenance Record the message and return it with personnel defective CMX board HAMMER BANK NOT Self test routines do 1 Power off the printer Verify that the INSTALLED not detect hammer shuttle frame assembly is installed Install coils at printer start the shuttle frame assembly up 2 Remove the paper guide assembly or pedestal top cover Verify that the hammer bank logic cable is connected to connector J108 on the CMX controller board and to the shuttle frame assembly 3 Power on the printer If the message appears replace the hammer bank logic cable 4 Power on the printer If the message appears replace the shuttle frame assembly 5 Power on the printer If the message appears replace the CMX controller board Record the message and return it with the defective board 102 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action HAMMER COIL BAD etc Hammer coil s number
32. 01P4699 page 399 Field Kit Power Stacker Limit Switch 02N6214 page 313 Cable Assembly Hammer Bank Power 02N8261 page 268 Connector Stiffening Clip 02N8315 page 284 Ethernet LAN PCBA 100Base T 02N8327 page 409 Field Kit Power Stacker PMD 02N8329 page 399 Pivot Arm Block 04H4779 page 252 Riser Stacker Runner 08H7934 page 278 Platen Open Motor Pulley 08H7936 page 276 Platen Assembly 08H7954 page 258 Anti Static Brush Kit 14H5154 page 278 Platen Open Motor Assembly 14H5159 page 278 Hammer Bank Fan Assembly page 322 14H5169 page 276 Platen Hardware Kit 14H5174 page 258 Platen Paper Feed Cover Kit 14H5179 page 258 Paper Scale 14H5211 page 264 Clamp Shaft Receiving 14H5214 page 274 Tractor Shaft Kit 14H5217 page 274 Tractor Shaft Hardware Kit 14H5235 258 Shroud Assembly Air Shuttle Cover 357 Appendix H Part Number Location Description 14H5271 258 Paper Guide Assembly Models 004 005 008 009 010 012 014 C05 14H5272 252 Chain Assembly Kit 14H5274 264 Shuttle Frame Assy Models 004 04 14H5275 page 264 Hammer Spring Kit Models 004 04P 005 05 14H5279 page 312 Cable Assy Hammer Bank Logic 14H5280 page 276 Platen Switch Kit page 325 63H5133 page 278 Paper Detector Switch Assembly Standard page 324 14H5282 page 264 Switch Asse
33. 244 Stacker power 367 control panel 370 installation 380 398 loading and starting 372 operation 368 replacing constant force spring 391 timing belts 394 Start of call 60 Start up sequence 146 Supplies tools and test equipment 26 Support shaft replacement 241 Switch cover open switch assembly replacement 245 paper detector switch assembly replacement 246 platen interlock switch assembly replacement 247 power replacement 193 Symptom list troubleshooting 110 Symptoms from LCD messages 62 not from messages 110 T TABLE MISMATCH DOWNLOAD AGAIN 107 180 Temperature coil adjustment 181 Tension adjustment paper feed timing belt 154 platen open belt 156 Terminating resistors location of 236 replacement 235 Test equipment tools and supplies 26 TESTING HARDWARE PLEASE WAIT 107 Tests boot diagnostics menu 137 customer engineer CE 134 print operator 132 printer information menu 143 Time poweron 143 printing 143 Tools test equipment and supplies 26 TOP OF FORM SET 107 Torque conversion to or from metric 337 table 339 Tractor replacement 248 Troubleshooting 59 aids 59 communications failures 131 fault messages 61 symptoms not indicated by messages 62 U Unit check condition 61 Upgrading software 176 WAITING FOR ETHERNET ADAPTER 108 WAITING FOR PROGRAM DOWNLOAD 108 Wiring diagrams 287 419 420 Copyright IBM Corp
34. 29 Cleaning Th Printer retain ae aana Cete Een petis 29 Cleaning The 29 Cleaning The 30 Cleaning The Shuttle Frame 31 Cleaning The Card Cage Fan 33 Principles Of Operation 35 Line Matrix Printing aci rte cete cct teu ree teet 35 Pintong at on 38 Table of Contents Printing Mechanism 38 Shuttle Frame 39 Paper Transport 41 Ribbon Transport System 42 Logical Control Of The 2 43 Printer Electronics nie ret e 43 Operator Panel 2 ide icu v fee HE ve 44 Controller Board sse 45 Data 2 47 Engine Controller eere e cete eri ER ea Te Re Rudd 49 Printer cnc m 51 10Base2 And 10Base T LEDs And DIP Switches 52 10 100Base T LEDs And DIP Switches 54 Power Supply 57 AG e de ae 57 DC POWOL utet eaeque E 57 rt 58 b Trouble
35. 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 47 Chapter 4 48 CMX Controller Board NVRAM A 8K x 8 bit Non Volatile battery backed static RAM NVRAM device provides for the storage of configuration and system statistical data VX ASIC The VX is a multifunction custom gate array ASIC containing all the logic for the DC that is not contained in the 68ECO030 processor The VX provides the following services e Memory Access Controller e DRAM Controller e Flash Controller e Two DMA Channels e Operator Panel Interface e
36. CAUTION lt 5 gt Do not remove or replace the NVRAM The NVRAM contains a J6 Diagnostic Port 1000 PF 10 50V 500 OHM lithium battery that can explode if it is pem NE replaced incorrectly NVRAM is replaced 2 DEJXD only at the factory 8 4 5 DB RXD 6 470 PF 1096 50V 0
37. Hex w Lock Washer 2 10 32x 50 11 24H8894 Ribbon Guide Kit Includes left and right ribbon guides 12 14H5154 Platen Open Motor Assembly Includes item 6 13 Ref Washer Flat 4 2 14 Ref Screw Hex w Lock Washer 2 4 40x 38 15 Ref Screw Hex w Lock Washer 2 10 32x 50 16 Ref Shield Card Cage Fan 17 14H5521 Motor Assembly Ribbon 18 Ref Screw Hex w Lock Washer 2 6 32x 50 19 Ref Washer Flat 6 2 20 57G1479 Ribbon Hub Kit 21 Ref Screw w Lock Washer 2 6 32x1 25 22 14H5159 Hammer Bank Fan Assembly Air flow is up 23 Ref Boot Cabinet models only 279 Chapter 7 Section Il Illustrated Parts Lists See inside detail below To IEC 320 AC Power Input Connector J301 Black Wire To IEC 320 AC Power Input Connector J301 White Wire To Connector P1 Black Wire To Connector P1 White Wire Black Wire Card cage fan and gu tS power supply board removed for clarity Black Wire J White Wire White Wire Figure 53 Circuit Breaker 280 Illustrations Of Printer Components Item Part No No Order No Description Notes 1 14H5571 Circuit Breaker 2 Ref IEC 320 AC Power Connector Connector J301 3 Ref Chassis Ground Stud 4 Ref Connector P1 To power supply board connector J1 AC 5 Ref Cable Assy AC In Power Supply Part of Field Kit AC Assy 14H5289 281 Section II Illustrated Parts Lists 7 Chapter N m Fi
38. Install the paper guide barrier shield and four screws See page 260 Figure 45 items 3 4 and 5 6 Cabinet Model Install the paper guide assembly page 229 Pedestal Model Install the top cover assembly page 204 Check and adjust the End of Forms Distance page 169 Return the printer to normal operation page 153 246 Switch Assembly Platen Interlock Switch Assembly Platen Interlock Removal 1 2 Prepare the printer for maintenance page 152 Cabinet Model Remove the paper guide assembly page 229 Pedestal Model Remove the top cover assembly page 204 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 on page 300 and page 302 Disconnect connector shell P107 P7 from the controller board Remove the platen interlock cable connector from the connector shell page 195 Remove two screws securing the platen interlock switch assembly See Figure 51 page 276 Remove the platen interlock switch assembly from the switch bracket Remove the switch cable from the cutout in the right side plate Installation 1 2 Fully close the forms thickness lever position A Position the platen interlock switch assembly on the switch bracket and install the two screws securing it to the bracket See Figure 51 page 276 Route the
39. MHz 015 7 Ref Motor Sensor Left Cable Assy Housing Connector Kit 14H5288 8 Ref Hammer Bank Logic Cable Assy 9 Ref Shuttle Motor Cable Assy 10 Ref Hammer Bank Power Cable Assy 11 Ref Motor Sensor Right Cable Assy Housing Connector Kit 14H5288 12 14H5287 Centronics I O Cable Assy 14H5522 Centronics Dataproducts Adapter Optional cable assembly 13 Ref Control Panel Cable Assy 14 14H5211 Clamp Shaft Receiving 15 Ref Screw Captive Power Supply 3 265 Chapter 7 Section Il Illustrated Parts Lists io Description Notes 16 Ref SIMM Flash Memory See also page 217 17 Ref SIMM DRAM See also page 217 18 14H5282 Switch Assembly Cover Open 266 Illustrations Of Printer Components Illustrated parts lists continue on next page 267 Chapter 7 Section Il Illustrated Parts Lists Two places Exploded to show assembly Do not remove holddown clamps and Screws Shuttle Motor To J03 MPU To Terminator Board on Shuttle Frame Figure 48 Print Mechanism and Circuit Boards Later Models 268 Illustrations Of Printer Components Item Part No Order Description Notes 1 24H8872 Hammer Bank Cover Assy 500 Models 050 P50 24H8886 Hammer Bank Cover Assy 1000 Models 010 P10 24H8924 Hammer Bank Cover Assy 1500 Model 015 63H7520 Hammer Bank Cover Assy Hanzi Models C05 2 24H8828 Ribbon Mask 500 Models 050 P50 24H8844 Ribbon M
40. Message Explanation Corrective Action 131 PAPER FEED INTERRUPT SEE USER S GUIDE Unexpected interrupt in the paper feed process 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 132 RIBBON INVALID COMMAND SEE USER S GUIDE 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 133 RIBBON INVALID STATE SEE USER S GUIDE 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 134 PLATEN INVALID COMMAND SEE USER S GUIDE 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
41. Table 7 Flash Memory Message Guide List Of Adjustments Message Explanation Required Action ERROR FLASH NOT DETECTED The printer could not find any flash memory Install flash memory before attempting to download this program ERROR NO DRAM DETECTED The printer could not find any DRAM Check DRAM on 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 ERROR PROGRAM NEEDS MORE DRAM The printer requires more DRAM memory in order to run the downloaded program Add DRAM or use a smaller emulation program 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 User tried to load CMX compatible diskette in CBO controlled printer or vice versa Use the correct emulation software option s for this model If the printer is an IBM 6404 B01 the controller is a CBO board If the printer is an IBM 6400 the controller is a CMX board ERROR PROGRAM NOT VALID The printer does not see a program in flash memory There is no program in printer memory Go to step 4 ERROR SECURITY PAL NOT DETECTED The security PAL is
42. The ECOS tester will trip ground fault detector protected outlets This is a good test of the ground fault detector Reset the outlet as needed Plug the ECOS meter into the customer s outlet Follow the instructions supplied with the meter to test for the following Wiring errors Low voltage e Neutral to ground short e Ground path impedance e Neutral impedance NOTE The customer is responsible for correcting problems with the power source Inform the IBM Installation Planning Representative IPR of any problems with the customer s power source Each branch circuit must be grounded for safety and correct operation of the printer This ground must be connected either to the electrical service ground or to a suitable building ground The printer power cable has a green or green yellow insulated grounding conductor This is not a neutral line Power Cable 1 Make sure the power cable is not damaged 2 Make sure the power plug is the correct type Power On Off Verification Make sure all covers are installed Plug the power cable into the customer s power outlet Power on the printer and watch the LCD Rom c Verify that the power on diagnostic tests and initialization routines are successful 5 After successful initialization the printer should cycle automatically to either the READY or NOT READY mode depending on which power on state was selected when the printer was configured 6 Power off the printer Ver
43. The printer received an illegal parameter value in the command code 1 Press Stop to clear fault Press Start to go on line 2 Run the print job that generated the error message If the message appears check the host data for invalid characters 3 Askthe system operator to verify that the printer s Device ID is set to the correct emulation with respect to the host configuration 4 Runthe print job that generated the error message If the message appears go to Communications Failures page 131 011 SCS COMMAND ERROR The printer received an undefined control character hex 40 through the coax twinax interface 1 The printer clears the error 2 Run the print job that generated the error message If the message appears verify that there are no invalid control codes in the host data 3 Askthe system operator to verify that the printer s Device ID is set to the correct emulation with respect to the host configuration 4 Run the print job that generated the error message If the message appears go to Communications Failures page 131 012 STRUCTURED FIELD ERROR Application software has violated structured data field parameters Not a printer problem Have the system administrator correct applications data or configuration 65 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel Message Explanation Corrective Action 013 AC
44. There are 13 14 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 Reload the paper and set the top of form Press Scroll Scroll Return Enter to enter the CE Tests menu Press all four keys at the same time The display will show SERVICE PRINTER MECHANISM TESTS the first menu item Press Scroll or Scroll until SERVICE END OF FORMS ADJUSTMENT VALUE is on the display Press Enter The top line of the display will show END OF FORMS ADJUSTMENT VALUE and the bottom line will show the current setting for the number of dots 171 Chapter 6 Adjusting End Of Forms Distance 17 Press Enter The number of dots will move up to the top line of the display 18 Using the ScrollT or Scroll key adjust the XX DOTS value up or down by the number of dots you counted in step 12 If the comb pattern stopped short of the perforation increase the number of dots If the comb pattern printed beyond the perforation decrease the number of dots 19 Press Enter to select the new number of dots as the active value The asterisk that appears tells you that it is now the active value 20 Press Stop to put the printer into NOT READY mode 21 Run the END
45. an environment relocate it to a cooler cleaner area or reduce the size and duration of the print jobs Inspect the printer environment for severity 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 guide assembly or pedestal top cover Check all fan cable connections 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 guide assembly 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 the defective board 92 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action 110 STACK System stack has run Cycle power Run the print job again If OVERFLOW out of room and the message appears download the SEE USER S GUIDE overflowed into other memory emulation software again Cycle power Run the print job ag
46. go to step 3 If the ON OFF indicator is lit press the ONLINE key and check that the ONLINE indicator lights If the ONLINE indicator comes on the stacker is detected by the printer If the ONLINE 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 c Disconnect the stacker power cable from the back of the stacker control panel See Figure 68 page 376 d Locate pin 1 of connector P106 See the cable assembly drawing in Appendix A page 320 e Power on the printer f At connector P106 check for 48 volts DC between pins 1 and 2 and 5 volts DC between pins 3 and 4 If the voltages are correct replace the stacker control panel If the voltages are not correct power off the printer remove the paper guide assembly and disconnect the stacker power cable from the CMX controller board See Figure 73 page 381 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 guide assembly Disconnect stacker cables from the CMX controller board stacker assembly and the stacker control panel see Figure 68 page 376 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 ca
47. message occurs again replace all flash memory SIMMs with pre written flash See Table 8 and Table 9 on page 219 and Figure 35 on page 220 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 P69 ERROR Where XXXX is a Power off the printer Remove all flash EC STOPPED AT number from 0000 to memory and DRAM SIMMs Inspect the STATE XXXX 0010 The Engine SIMM sockets on the CMX controller Controller hung at a board See Figure 35 page 220 If any process indicated by socket pins are bent or damaged replace XXXX the CMX controller board If the state is 0000 Install the flash and DRAM SIMMs replace the CMX making sure they are fully and correctly controller board seated Power on the printer Download the emulation If the message appears replace the flash memory with pre written flash See Table 8 and Table 9 on page 219 and Figure 35 on page 220 Power on the printer Download the emulation If the message appears replace the DRAM SIMM s See Figure 35 page 220 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 PLEASE WAIT Status message the No action required RESET IN PROGRESS printer finished loading the program into flash memory and is automatically resetting itself
48. page 242 213 Chapter 7 Section Replacement Procedures NOTE The hammer spring assemblies shown here are for 6400 004 04P 005 05P printers The number of hammer springs and mounting screws varies among printer models but removal and installation are the same Use new screws from the New Hammer kit Torque the screws to i 14 inch pounds 1 58 Newton meters Figure 34 Hammer Spring Assembly Installation 214 IBM Coax Twinax Expansion Board IBM Coax Twinax Expansion Board Removal ATTENTION To prevent electrostatic damage to electronic components wear a properly grounded static wrist strap when handling circuit boards the shuttle frame assembly and any other electronic component 1 Prepare the printer for maintenance page 152 2 Cabinet Model Remove the paper guide assembly page 229 Pedestal Model Remove the top cover assembly page 204 3 Loosen but do not remove the two screws securing the coax twinax I O plate to the rear of the card cage Loosen the thumbscrew on the CT board until the screw is released from the standoff on the controller board See Figure 54 page 282 4 Carefully lift the expansion CT board out of the card cage cutout and off the expansion connector adapter that attaches the CT to the CMX board 5 Remove the expansion connector adapter from the CMX controller board by carefully lifting it straight up and out of the controller connector Installation 1
49. 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 wind 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 the defective board 90 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action 101 UPPER DRIVER SHORT Hammer driver circuits on the CMX controller board are shorted to ground Cycle power If the message appears press Stop If the message does not clear replace the hammer bank logic cable and the hammer bank power cable assemblies Power on the printer If the message appears replace the CMX controller board Record the message and return it with the defective board Power on the printer If the message appears replace the shuttle frame assembly 102 LOWER DRIVER SHORT Circuit s on the hammer bank or in the hammer bank power cable are shorted to ground Cycle power If the message appears press Stop If the message does not clear replace the hammer bank logic cable and the hammer bank 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 w
50. 18 6400 Coax Twinax Multi Platform Interface Option Installation and Operation Guide 364 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 a cylindrical core through and around which the control panel cable assembly is wound Two are required 2 Ferrite Clamp a noise suppression core in a 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 58 shows how these devices are installed IMPORTANT Duplicate the number of turns around the shielding beads when installing or replacing the control panel cable See Figure 58 365 Appendix Control Panel Cable Assembly Connector Connector P P110 ESE 310 Shielding Bead 2 P N 141445 001 NOTE Two turns around each bead Parallel I O Cable Assembly Connector P112 Ferrite Core with Clamp and Adhesive Backing P N 202049 001 NOTE This core a
51. 1995 2000 5246 0117 08 01 4612 164636 001
52. 219 and Figure 35 on page 220 Load 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 Vertical misalignment of characters 1 Dots or characters move up or down from dot row to dot row or line to line 2 Incorrect spacing from dot row to dot row or line to line 3 Characters randomly compressed and or enlarged Load paper Press Form Feed and check that paper feeds smoothly Press View to verify that paper moves in both directions 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 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 Check and adjust the paper feed timing belt Replace the belt if it is damaged Check and adjust the platen gap Inspect the tractors and tractor door springs for damage or excessive wear If either tractor is damaged or excessively worn replace both tractor assemblies Remove the paper guide assembly or pedestal top cover Make sure connector P107 PAPR M is fu
53. 24H8933 page 268 Hammer Spring Field Kit 1500 Model 015 360 Part Number Location Description 24H8959 page 250 Front Door Kit 24H8960 page 250 Rear Door Kit 24H8961 250 Top Cover Kit 24H8962 page 399 Rear Door Extended Power Stacker 24H8963 page 399 RE Ship Kit Printer w Power Stacker 24H8966 page 399 Paper Deflector Power Stacker 24H8968 page 399 Timing Belt Power Stacker 24H8969 page 399 Motor Power Stacker page 401 24H8970 page 399 Constant Force Spring Power Stacker 24H8971 page 399 Chain Power Stacker 24H8973 page 399 Cable Power Stacker 24H8974 page 399 Control Panel Assembly Power Stacker 24H8975 page 320 Power Cable Power Stacker 24H8976 page 319 Logic Cable Power Stacker 24H8978 page 401 Anti Static Brush Power Stacker 24H8981 page 401 Extension Spring Power Stacker 24H8982 page 401 Idler Roller Power Stacker 24H8983 page 401 Paddle Power Stacker 24H8985 page 403 Compression Spring Power Stacker 24H8988 page 403 Drive Roller Power Stacker 24H8989 page 405 LED IR T 1 3 4 Power Stacker 24H8990 page 407 Photodarlington NPN Rectifier Power Stacker page 409 24H8991 page 409 LED IR Rectangular Power Stacker 24H8994 page 284 Ethernet LAN PCBA 10Base2 24H8995 page 284 Ethernet LAN PCBA 10Base T 24H8996 page 399 Shaft Lift Power Stacke
54. 4 and 5 Cabinet Model Install the paper guide assembly page 229 Pedestal Model Install the top cover assembly page 204 Return the printer to normal operation page 153 List Of Adjustments Direction of Force Legend B gt Sao 282 2 0 5 on 2 g gozo esses gt Figure 21 Paper Feed Timing Belt Adjustment 155 Chapter 6 _ Belt Platen Open Adjustment Belt Platen Open Adjustment To make this adjustment follow these steps 1 Prepare the printer for maintenance page 152 2 Cabinet Model Remove the paper guide assembly page 229 Pedestal Model Remove the top cover assembly page 204 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 motor mount screws 2 Close the forms thickness lever all the way ATTENTION Too much tension on the platen open belt can cause the platen gap to change which can lead to premature wear of the platen damaged hammer tips and poor print quality 6 Using a force gauge apply 10 1 pounds 44 48 4 45 of tension to the shank of the platen drive pulley 3 pushing away from the large platen pulley 7 Reduce tension to 5 1 pounds 22 24 4 45 N and tighten the motor mount screws 2 Snap the platen open belt cover 1 into the slots in the side plate Cab
55. 6 Using the straight end of a force gauge apply 12 pounds 53 4 N of pressure to the paper feed motor Use the splined shaft to steady the gauge 7 Reduce pressure to 9 pounds 40 0 N and torque the motor mount screws to 18 2 inch pounds 1 36 0 23 Nem Snap the timing belt cover into the slots in the side plate Cabinet Model Install the barrier shield and four screws See Figure 44 page 258 items 3and 4 Pedestal Model Install the barrier shield paper guide and four screws See Figure 45 page 260 items 3 4 and 5 10 Cabinet Model Install the paper guide assembly page 229 Pedestal Model Install the top cover assembly page 204 11 Return the printer to normal operation page 153 222 Motor Assembly Platen Open Motor Assembly Platen Open Removal 1 2 Prepare the printer for maintenance page 152 Cabinet Model Remove the paper guide assembly page 229 Pedestal Model Remove the top cover assembly page 204 Cabinet Model Remove the card cage fan page 209 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 276 Figure 51 Loosen the two 5 16 inch motor mount screws page 278 Figure 52 Loosen the 1 16 hex pulley setscrew and remove the motor pulley and platen open belt Trace the platen open motor cables back to the controller board releasing the cables from the tie wraps See cab
56. Angle the hammer bank fan assembly up and out of the base casting and feed the motor wires and cable connector out from between the base casting and the base pan See Figure 52 page 278 Installation ATTENTION Make sure to install the fan so the label faces up Air flow is UP NOTE The hammer bank fan assembly is installed by angling it down and under the shuttle motor 1 Feed the hammer bank fan cable connector HBF and motor wires between the fan well of the base casting and the base pan Reach up under the base casting and route the fan cable to the right and angle the hammer bank fan assembly under the shuttle motor and down into the fan well See Figure 52 page 278 2 Route the fan motor wires as shown on page 300 connect fan cable connector HBF to P107 then connect P107 to J107 on the controller board See page 197 Install two screws in the locations shown in Figure 52 page 278 Pedestal Model Install the top cover assembly page 204 Install the shuttle cover assembly page 203 gud o Return the printer to normal operation page 153 210 Hammer Spring Assembly Hammer Spring Assembly Removal 1 Prepare the printer for maintenance page 152 2 Remove the shuttle frame assembly page 242 3 Carefully vacuum the shuttle frame assembly 4 Remove the hammer bank cover assembly page 200 ATTENTION Hammer springs and hammer tips are fragile Do not touch the hammer springs or t
57. C9 s eI Return the printer to normal operation page 153 216 Memory and Security Modules Memory and Security Modules Removal 1 Make a configuration printout of all configurations Refer to the Setup Guide Prepare the printer for maintenance page 152 Cabinet Model Remove the paper guide assembly page 229 Pedestal Model Remove the top cover assembly page 204 ATTENTION To prevent electrostatic damage to electronic components wear a properly grounded static wrist strap when handling circuit boards the shuttle frame assembly and any other electronic component NOTE If flash SIMMs are removed from one controller board and placed on another controller board the SIMMs must be placed on the new board in the same order and location as on the original board 4 Gently pry the side locks open angle the SIMM toward the front of the printer and remove the SIMM from the socket See Figure 35 page 220 for the locations of memory modules 5 Using a module extraction tool remove the security module See Figure 35 page 220 217 Chapter 7 Section Replacement Procedures Installation ATTENTION To prevent electrostatic damage to electronic components wear a properly grounded static wrist strap when handling circuit boards the shuttle frame assembly and any other electronic component NOTE Flash SIMMs from one CMX controller board must be placed in the same slot on a replacement CMX con
58. Card Cage Fan Figure 73 Stacker Power and Logic Connections on the CMX Controller Board nog One OO Nes 381 Appendix J Installing The Power Stacker 382 ATTENTION 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 74 Legend 1 Screw 6 32x1 4 Torx T 10 two at bottom of each rail 2 Vertical Rail 3 Stacker Base Figure 74 Loosening the Lower Screws in the Vertical Rails Position the elevator assembly at the bottom of the vertical rails See Figure 75a 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 75a Work the stacker base rearward and engage the upper brackets of the vertical rails under the upper frame cross member See Figure 75b Align the holes in the vertical rail brackets with the holes in the upper frame cross member See Figure 75c and Figure 76 383 Appendix J Installing The Power Stacker 384
59. Dot Plucking and Adjacent Dot Checking e Cajun Bus Interface Host I O and Diagnostic Port Memory Access Controller All 030 addresses go through the VX ASIC The VX handles all address decoding chip selects DTACKs and so on DRAM Controller The VX supports up to four banks of page mode DRAM FLASH Controller The VX supports up to four banks of flash memory DMA Channels The VX provides two channels for direct memory access These channels move data from the host interface or expansion bus to the DRAM and vice versa One address is an I O address the other is a memory address with auto increment Operator Panel Interface The VX operator panel interface consists of five lines serial clock serial data and three select lines It is the VX that handles all parallel to serial and vice versa conversion to and from the panel as well as any special timing needed when toggling select lines etc Dot Plucking And Adjacent Dot Checking Dot Plucking is a specialized DMA function that removes dot data from a dot image buffer in DRAM in a programmable manner serializes it and sends it to the hammer bank This function is actually controlled by the EC see page 49 which has access to the VX through the Cajun Bus Interface Engine Controller Cajun Bus Interface The Cajun bus interfaces the DC the EC and the expansion port The EC uses this bus to access DC resources including the semaphore registers
60. E 5 A403 Q ce asa gi O DLL 221 Ors KS gt n o LJ mE 9 N 50 Eu 1 J PRINTRONIX J CMX V5 5 5 e T 2 2 156298 00 REV _ Jit noc off au E E IJ sB o 9 zi o 1 B BANK 0 2 E J17 Paper Stacker yes J102 EXT 5V 1 2 External Power 3 4 5 6 7 L6 8 1000PF NM 9 10 10 50V J9 Online Verifier SII EXT 5V DB TXD DB RXD OLV SYNC OLV IRQ penunuoo J102 PPR STK STATO PPR STK STAT1 PPR STK CTLO PPR STK CTL1 470 PF 10 50V v6c
61. For that information refer to the Operator s Guide and Setup Guide e 6400 Line Matrix Printer Operator s Guide Form No 5544 5641 Illustrated instructions on daily printer operation e IBM 6400 Line Matrix Printer Setup Guide Form No 5544 5640 Explains how to install and configure the printer e 6400 CO5 C5P Line Matrix Printer Setup Guide Form No 8544 5684 Explains how to install and configure the Hanzi printer e Coax Twinax Multi Platform Interface Option Installation and Operation Guide Form Number S246 0149 Information pertaining to printer control languages emulations and control codes is in the applicable Programmer s Reference manual e 6400 ASCII Programmer s Reference Form No 5544 5635 e 6400 CTA Programmer s Reference Form No 5544 5636 e 6400 IPDS Programmer s Reference Form 5544 5637 e IBM 6400 C05 C5P Programmer s Reference LQ1600K Form No 5544 5683 Information pertaining to graphics programming is in the applicable User s Manual Related Documents IBM 6400 Code V User s Manual Form No 5544 5638 Provides information used with the optional Code V Printronix emulation enhancement feature The Code V Printronix emulation allows the user to create and store forms generate logos bar codes and expanded characters create other graphics and merge graphics with alphanumeric data as a document is printed IBM 6400 IGP User s Manual Form No S544 5639
62. Hammer Driver Integrated Circuit Hammer Driver Phase 349 Appendix F 350 LPI LPM LRIB LRP M1 M2 MAIN MECA MECH MF MH MOSFET MOT MPU ms MSL MSR Hammer Bank Logic Signals and Power Integrated Circuit Identification Intelligent Graphics Processor Initial Microcode Load Instruction Interrupt Input Output Interrupt Request Jack connector Left Liquid Crystal Display Light Emitting Diode Line Feed Low Lines Per Inch Lines Per Minute Left Ribbon Left Ribbon Guide Rear Paddle Motor Power Stacker Front Paddle Motor Power Stacker Motor Maintenance Jack RS 232 Optional Mechanism Engine Control ASIC Mechanism microfarad 10 6 farad Mounting Hole Metal Oxide Semiconductor Field Effect Transistor Motor Magnetic Pickup Unit millisecond 10 second Motor and Sensors Left Motor and Sensors Right N N C NC NIC NLQ No NOVRAM ns NVRAM NT OLV OP P5 P Negative True Not Connected Not Connected Network Interface Card an optional Ethernet interface Near Letter Quality Number Non volatile Random Access Memory nanosecond 1 09 second Non volatile Random Access Memory Not On Line Verify Operand 45V dc Pin connector P 1 P 2 etc Parallel data 1 data 2 etc PAL PAP PAPR PARM PCBA PCB PE PER PF PFC PFM PHA PHB P PLAT PLM PLO PMD PN Programmable Array Logic Paper Paper Parameter Printed Circuit Board Asse
63. Hanzi printing requirements Ordering Ribbons In The U S Ribbons can be purchased from Lexmark Authorized IBM Supplies Dealers or directly from Lexmark by calling 1 800 438 2468 Send fax orders to 1 800 522 3422 Send mail orders to Lexmark International Inc 1221 Alverser Drive Midlothian VA 23113 327 Chapter Paper Specifications Ordering Ribbons Outside Of The U S Order supplies by contacting your local Lexmark International distributor or by writing to Lexmark International Inc P O Box 11427 Lexington KY 40575 1427 USA Paper Specifications 328 The paper specifications in this section are guidelines only Always test paper stock with applications to determine print quality Paper Type Edge perforated fan fold 3 to 17 inches 7 62 to 43 18 cm wide 2 to 24 inches 5 08 to 60 96 cm long Single part 15 pound 57 g m to 100 pound 377 g m stock e Multi part carbon 1 to 6 part forms maximum 12 pound 45 g m ply of upper plies e Multti part carbonless Verify readability of greater than 4 part Thickness 0 025 inches 0 064 cm maximum Drive Adjustable tractors 6 pin engagement Labels On Backing One part continuous perforated fan fold back form Labels must be placed at least 1 6 inch 0 42 cm from the fan fold perforation Backing adhesive must not be squeezed out during printing Sheet Size 3 to 17 inches 7 62 to 43 18 cm wide including the two standa
64. MODE Asterisk indicates this mE ENABLE choice is now active 10 NOT READY Returns printer to NOT Stop READY mode Boot Diagnostics Menu Step Press Displayed Result Notes 11 OPERATOR MENU Relocks the ENTER key Scrollf Scroll UNLOCKED 12 READY Puts printer in READY Start mode 13 Send a file from the host computer The printer outputs a hex dump Refer to the ASCII chart on page 142 14 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 141 Chapter 5 ASCII Character Set ASCII Character Set The ASCII character set is shown below in chart form KEY B2 ROW B7 B BITS 85 B4 B3 B2 B1 OCTAL equivalent DECIMAL equivalent HEX equivalent ASCII Character Name m m of A m m j IN ON o aw Jo ou oo 0 0 0 1 1 1 2 2 2 3 3 3 4 4 4 5 5 5 7 7 7 10 8 8 11 9 9 12 10 0A 13 11 0B 14 12 oc 15 13 oD 16 14 17 15 OF 142 o amp R a wo Jo Boot Diagnostics Menu Printer Information Menu You can view various printer statistics such as hours of usage and refer to these figures for preventive maintenance purp
65. Message List Operator Panel Message Explanation Corrective Action BOOT DIAGNOSTICS Non error status message No action required CLEARING PROGRAM FROM FLASH Status message emulation software successfully loaded into printer RAM and the checksum matched The old program is now being deleted from flash memory No action required DRIVER CIRCUIT BAD The hammer coil count test failed 1 Cycle power If the message appears press Stop 2 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 ENERGY SAVER MODE ACTIVE 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 ERROR DRAM AT ADDRESS hex The printer found a defective memory location 1 Replace the DRAM 2 Power on the printer If the message appears replace the CMX controller board Record the message and return it with the defective board ERROR DRAM NOT DETECTED DRAM is defective or missing 1 Check DRAM on the CMX controller board If present reseat DRAM if missing install DRAM 2 Power on the printer If the messa
66. Microcontroller TTL Nu EC I Platen Diagnostic Diagnostic Port Port Hammer Drive Figure 17 CMX Controller Board Block Diagram 46 Data Controller Data Controller The data controller DC consists of the following elements e 68bECO030 microprocessor e Two flash SIMM sockets used for up to 30MB of program memory 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 Drivers Termination 68EC030 Microprocessor A Motorola 68EC030 microprocessor serves as the processor of the DC unit This processor runs at 25 MHz on all models except the 6400 050 P50 010 P10 015 05 and 5 On 6400 050 P50 010 P10 015 C05 and C5P printers the 68EC030 processor runs at 40 MHz and the controller board on these models is called the CMX 040 The CMX 040 controller is backward compatible with any 6400 Series printer but must be used in 6400 050 P50 010 P10 015 C05 and C5P printers Although this chapter refers to the DC microprocessor as simply the 030 remember that two different clock speeds are available 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
67. N 13S3HN 2 1591 Ir TON C TS A8v Kjddns 9 298 Cable Routing Cabinet Model 299 00 Left Side of Printer LRBNM CABLE ASS J06 Front of Printer Right Side of Printer R RBN M CABLE ASSY P306 TO CARD CAGE PLAT M P106 CCF P106 P106 LRP To J106 on CMX board P106 PMD P106 POD L RBN M P108 P4105 P116 NOTE This view shows the underside of the mechanism base WP det TIE WRAP P RIBBON GUIDE PLATEN LEVER SIDE PLATE view BOTH SIDE PLATES P107 EHF Et P107 MPU P107 JMP WIRE PPR M
68. Not Released No Dot Printed Figure 10 Action of One Hammer Spring in Text Printing 37 Chapter 4 Printing Rates Printing Rates Because a line matrix printer prints entire lines sequentially it is faster than a moving printhead printer which prints single characters sequentially The printing speed of text is measured in lines per minute lpm rather than characters per minute cpm Many variables affect printing speed the main ones being the selected font and the vertical dot density Lines containing attributes such as bold or emphasized print superscripts subscripts or elongated characters also reduce print speed to never less than half the rates of lines without such attributes The actual print rate of lines containing these attributes depends on the specific print job but software maximizes the throughput by dynamically determining which dot rows contain adjacent dots and must be printed in two strokes Printing speed is not affected by the number of characters in a character set The printing speed of graphics plot mode is expressed in inches per minute ipm The ability of the printer to feed paper downwards as well as upwards allows the printing of multiple densities on a single line This is useful for printing forms and text together or for mixing fonts on the same print line Use of multiple densities and reverse paper feed also affects throughput Printing Mechanism 38 While the principles of
69. OF FORMS ADJUST and the END OF FORMS ADJUSTMENT VALUE tests until the comb pattern prints at an acceptable distance from the page perforation Return to step 7 22 When the End of Forms Adjustment is acceptable reload the paper feed it past any remaining unused holes that you tore in it and set the top of form 23 Press ScrollT Scroll to lock the Enter key 24 Press Start to put the printer into READY mode 172 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 horizontal alignment of dots in character printing The phase value numerical units are relative they do not represent a physical measurement or value Thus there is no correct value or range 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 124 PAPER FIFO UNDERFLOW 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 horizontal alignment When alignment is acceptable write the new phasing value on the shuttle Phasing should be adjusted wit
70. Panel 389 Appendix J Installing The Power Stacker 26 Bundle the stacker control panel cables in the wire harness clips located under the card cage See Figure 80 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 assembly moves up and down IA 0 Legend 1 Wire Saddle 2 places 2 Cutout Beneath Card Cage Fan 3 Cable Bundle Figure 80 Securing Stacker Cables 27 Install the paper path that you removed in step 4 28 Install paper and test stacker operation Refer to the Setup Guide 390 Replacing The Constant Force Spring 1 Remove the stacker assembly from the printer See page 375 ATTENTION 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 2 Raise the elevator assembly to its highest position and secure it to the vertical rails using tie wraps or string See Figure 81 Legend 1 Tie Wrap 2 Elevator Assembly Figure 81 Securing the Elevator Assembly 391 Appendix J Replacing The Constant Force Sprin CAUTION 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 3 Remove the shoulder scr
71. 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 tractor 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 shuttle cover and another is printed on the paper scale A horizontal scale graduated in tenths of an inch useful for setting paper margins counting text columns See below 24 Mechanical Controls All Models Paper Supports Left Tractor Horizontal Adjustment JN Right Tractor Knob Tractor Lock Tractor Lock Vertical 5 Position e Knob Ribbon Loading Path Diagrams Pd Thickness Lever and Scal
72. Power on the printer Run the print job again If the message appears power off the printer 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 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 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 96 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action 126 PAPER FEED BAD TABLE SEE USER S GUIDE The paper feed process on the CMX controller board has a corrupted table If this message appears during a software download do the download again If the message appears on the second try replace 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 127 PAPER FEED ILLEGAL STATE SEE USER S GUIDE Firmware error on the CMX controller board Cycle power Run the print job again If the message
73. READY Printer state No action required message the printer is online RESETTING Status message the No action required PLEASE WAIT printer is resetting itself 106 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action RESTORING BOOT CODE Status message when downloading boot code Code is checked then saved in flash memory No action required RIBBON OUT OF INK CHANGE RIBBON RibbonMinder software has determined that the ribbon is out of ink Install a new ribbon and set ribbon life to 100 SENDING PROGRAM TO EC PROCESSOR Status message the printer is loading the engine controller program into the engine controller No action required SERVICE lt service test gt Non error status message No action required SOFTWARE ERROR Cycle power Application software tried to perform an illegal printer function or damaged logic circuits were detected on the CMX controller board 1 Cycle power If the message appears power off the printer 2 Disconnect the input data line from the host computer Power on the printer If the message appears download the emulation software again 3 Cycle power Run the print job again If the message appears replace the CMX controller board If the message is gone there is an application software error Request assistance from your local support group TABLE
74. Ref Spring Torsion Part of item 115 410 Index Numerics 001 END OF FORMS LOAD FORMS 62 002 FORMS JAMMED CLEAR JAM AND RELOAD FORMS 63 003 FORMS EJECTED PRESS EJECT RESTORE 64 006 HOST SYSTEM REQUEST ATTENTION 64 007 FM HEADER ERROR 64 008 HOLD PRINT TIMEOUT PRESS START 64 009 INVALID KEY PRESS 64 010 PARAMETER ERROR 65 011 SCS COMMAND ERROR 65 012 STRUCTURED FIELD ERROR 65 013 ACTIVATE LOST 66 014 INVALID ACTIVATE 66 015 COMMUNICATIONS CHECK CHECK CABLE 67 016 INVALID COMMAND 67 017 STACKER JAM CHECK STACKER 68 018 STACKER FULL CHECK STACKER 69 019 STACKER FAULT CHECK STACKER 70 021 RECEIVE BUFFER OVERRUN VERIFY CONFIGURATION 71 022 UNIT ADDRESS NOT RECEIVED CHECK PRINTER ADDRESS 71 024 SERIAL LINE PARITY ERROR VERIFY CONFIGURATION 71 025 SERIAL FRAMING ERROR VERIFY CONFIGURATION 72 026 EXHAUST FAN FAULT 81 026 HEX DUMP MODE 72 027 COMMUNICATIONS CHECK CALL SYSTEM OPERATOR 72 028 COMMUNICATIONS CHECK CALL SYSTEM OPERATOR 72 029 8344 DIAGNOSTIC TEST FAILED 72 031 END OF FORMS TIMEOUT LOAD FORMS 73 032 FORMS JAMMED TIMEOUT CLEAR JAM AND RELOAD FORMS 74 04 VIEW FORMS PRESS VIEW KEY 64 041 BUFFER OVERFLOW 75 042 CUSTOM SET DOES NOT EXIST SAVE FIRST 75 043 CUSTOM SET ALREADY EXISTS DELETE EXISTING SET FIRST 75 044 EC FIRMWARE HARDWARE ERROR 76 046 EC STOPPED AT STATE 76 057 CLOSE PLATEN 77 058 SHUTTLE JAM SEE
75. Reverse steps 2 through 5 of the removal procedure 2 Return the printer to normal operation page 153 215 Chapter 7 Section Replacement Procedures Magnetic Pick up MPU Assembly Removal Prepare the printer for maintenance page 152 Remove the shuttle cover page 203 Disconnect the shuttle cable assembly connector page 272 Figure 49 c Disconnect the magnetic pick up MPU cable connector page 272 Figure 49 Loosen the 7 64 inch hex MPU clamp screw page 272 Figure 49 6 Unscrew the MPU assembly from the MPU bracket Installation 1 Install the MPU assembly by screwing it into the MPU bracket page 272 Figure 49 2 Using a feeler gauge adjust the gap between the MPU assembly and the flywheel to 0 010 001 inch 0 254 0 025 mm Torque the MPU clamp screw to 19 1 inch pounds 2 15 0 11 Nem 3 Check the gap between the MPU assembly and the flywheel with a feeler gauge a Ifthe gap is 0 010 001 inch 0 254 0 025 mm go 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 ATTENTION Make sure the MPU cable is below the extension spring and does not touch the spring after the cable is connected 4 Connect the magnetic pick up MPU cable connector Connect the shuttle cable assembly connector page 272 Figure 49 Install the shuttle cover page 203 Adjust the hammer phasing page 173
76. Screw 2 9 63H5120 Top Cover Models 04 08 09 10 Ref Screw 4 10 32x 625 11 63H5118 Paper Basket Models 05 08 09 12 63H7509 Caster Pedestal Models 04P 05P 08P 09P 13 63H5117 Pedestal Kit Models 04P 05P 08P 09P 14 Ref Screw Captive 2 15 24H8533 Input Tray Optional item on models 04P 08 09 16 63H5122 Lid Accessory Kit Replacement acoustic seals Not shown in Figure 13 17 64H5123 Shipping Container Pedestal Models 04P 05 08 09 Not shown in Figure 13 257 Chapter 7 Section Il Illustrated Parts Lists Figure 44 Inside Covers Cabinet Model 258 Illustrations Of Printer Components Item Part No ae No Order No Description Notes 1 14H5235 Shroud Assembly Air Shuttle Cover Assembly 2 Ref Screw Captive 2 10 24x 62 with O ring 125x 250x 06 3 Ref Screw Thread Forming 4 6 32x 25 4 Ref Barrier Shield 5 14H5271 Paper Guide Assembly Models 004 005 008 009 012 014 6 Ref Screw w Lock Washer 3 6 32x 25 and 6 Flat Washer 7 14H5174 Platen Paper Feed Cover Kit Paper feed belt cover shown in Figure 44 Platen open belt cover item 24 page 276 8 5781468 Belt Timing 050P 100 Teeth Paper Feed Belt 9 08H7954 Anti Static Brush Kit 10 Ref Power Supply Shield Taped to card cage along upper edge 11 14H5179 Paper Scale 259 Illustrated Parts Lists Section 7 Chapter Do GN iL DD
77. Section Replacement Procedures Fan Assembly Cabinet Exhaust Removal 1 Prepare the printer for maintenance page 152 2 Open the floor cabinet doors and the printer cover 3 Remove the paper stacker See Figure 41 page 252 4 Remove the three screws securing the air exhaust duct The top screw is located near the right front of the card cage in front of the square air holes in the printer base plate See Figure 42 page 254 5 Disconnect the fan cable connector from connector P307 and remove the air exhaust duct 6 Remove the fan cable connector from the cutout in the side of the air exhaust duct 7 Remove the two fan mounting screws and the cabinet exhaust fan assembly Installation ATTENTION Make sure to install the fan so that air flow is down 1 Position the cabinet exhaust fan assembly in the air exhaust duct so that air flow is down and install the two screws securing the fan to the duct See Figure 42 page 254 2 Snapthe fan cable connector into the cutout in the side of the air exhaust duct Move the air exhaust duct back into position and install the three screws Connect the cabinet exhaust fan cable connector to connector P307 Install the paper stacker See Figure 41 page 252 CD QU reo Return the printer to normal operation page 153 208 Fan Assembly Card Cage Fan Assembly Card Cage Removal 1 2 Prepare the printer for maintenance page 152 Ca
78. again 2 Oycle power Run the print job again If the message appears replace the coax twinax expansion board Record the message and return it with defective board 72 Message List Table 4 Message List Operator Panel Explanation Corrective Action Message 031 END OF FORMS Onacoaxinterface a 1 Load paper Press Stop If message TIMEOUT timeout message is does not clear go to the next step LOAD FORMS sent to the host if 2 Power off the printer Remove the paper guide assembly 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 paper is not loaded within 10 minutes after Stop was pressed to clear an end of forms fault 4 Poweron the printer Load paper Replace the paper detector switch assembly if the message appears 5 Power on the printer Load paper Replace the CMX controller board if the message appears Record the message and return it with the defective board 73 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel Message Explanation Corrective Action 032 FORMS JAMMED TIMEOUT CLEAR JAM AND RELOAD FORMS coax interface a timeout message is sent to the h
79. alignment pins and hammer tips and lies flat on the hammer bank Install all 12 hold down screws finger tight Using a Torx T 10 driver torque the 12 hold screws to 14 inch pounds 1 58 Nem in the sequence shown in Figure 32 on page 202 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 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 torque the six screws to 14 inch pounds 1 58 N m in the sequence shown in Figure 32 on page 202 Install the shuttle frame assembly page 242 Return the printer to normal operation page 153 201 Chapter 7 Section Replacement Procedures Hammer Bank Cover Early Models Unless Plate Ribbon Mask Thin Plate Hammer Bank Cover Assembly Later Models Ribbon Mask Torque Sequence 4 3 1 2 5 6 Hammer Bank Cover Ribbon Mask Clamp Plate 3 Screw 12 Screw 6 Figure 32 Hammer Bank Cover Assembly Ribbon Mask 202 Cover Assembly Shuttle Cover Assembly Shuttle Removal 1 Prepare the printer for maintenance page 152 Loosen the shuttle cover screws page 258 Figure 44 item 2 Grasping the edges of the shuttle cover assembly tilt up the rear ed
80. and paper guide pedestal model Check that the paper 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 Power on the printer Load paper Replace the paper detector switch assembly if the message appears Power on the printer Load paper Replace the CMX controller board if the message appears Record the message and return it with the defective board 111 Chapter 5 Troubleshooting Other Symptoms Table 5 General Symptom List Symptom Corrective Action Operator Panel Black squares on operator panel display Power off the printer Remove the paper guide assembly or pedestal top cover Disconnect the operator panel cable from the panel and from J110 on the CMX controller board Check continuity of the cable See Appendix A Replace the operator panel cable if it fails continuity test Connect the cable Power on the printer If the symptom appears replace the operator panel If the printer has the coax twinax expansion board check the adapter connection to the CMX controller board Make sure the 60 pin expansion adapter is correctly seated in the CMX controller board connector J111 and the coax twinax
81. 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 128 PAPER FEED INVALID COMMAND SEE USER S GUIDE Paper Invalid Command 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 129 PAPER FEED INVALID PARAMETER SEE USER S GUIDE Paper Invalid Parameter 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 130 PAPER FEED PARTLY ENERGIZED SEE USER S GUIDE 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 97 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel
82. 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 Power on the printer Load paper 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 125 Chapter 5 Troubleshooting Other Symptoms Table 5 General Symptom List Symptom Corrective Action 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 and adjust the platen open belt Replace the belt if it is damaged Check and adjust the platen gap Power off the printer Remove the paper guide assembly Disconnect connector P10
83. can lead to ink migration problems degraded print quality and expensive damage to the printer Do not close the forms thickness lever too tightly Closing the forms thickness lever too tightly can lead to smearing degraded print quality paper jams and damage to the platen and shuttle assembly About This Manual 16 This is a field service maintenance manual It is designed so that you can quickly locate maintenance information How To Use This Manual Find the procedure or information you need in 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 safety notices before you start a task Notes and notices are defined below Notes And Notices Notes And Notices For your safety and to protect valuable equipment it is very important that you read and comply with all information highlighted under notes and notices DANGER gt lt gt The word Danger next to the lightning slash indicates the presence of a hazard that could cause death or serious personal injury Danger and Caution notices are numbered to help you find the translated versions in the 4400 Safety Notices booklet CAUTION gt lt gt The word Caution next to the exclamation point indicates the presence of a hazard that could cause moderate or minor personal injury CAUTION gt lt gt The word Cauti
84. conditions of high electrical potentials and heat generation both of which are functionally necessary Trademarks And Service Marks Trademarks And Service Marks The following terms denoted by an asterisk in this publication are trademarks of IBM Corporation in the United States or other countries or both AS 400 IBM PC DOS RISC System 6000 SCS Token Ring The following terms denoted by a double asterisk in this publication are trademarks of other companies Acrobat Adobe AMD Centronics Code V CSA Dataproducts ECOS EIA Energy Star Epson Ethernet Fluke FX IEEE IGP Motorola MS DOS MTOS PrintNet Printronix QMS RibbonMinder Siemens SureStak Torx UL Adobe Systems Incorporated Adobe Systems Incorporated Advanced Micro Devices Inc Genicom Corporation Quality Micro Systems Canadian Standards Association Dataproducts Corporation ECOS Electronics Corp Inc Oak Park Ill Electronic Industries Association United States Environmental Protection Agency Seiko Epson Corporation Xerox Corporation John Fluke Manufacturing Co Inc Seiko Epson Corporation Institute of Electrical and Electronics Engineers Inc Printronix Inc Motorola Inc Microsoft Corporation Industrial Programming Inc Printronix Inc Printronix Inc Quality Micro Systems Inc Printronix Inc Fujitsu Siemens Corporation Printronix Inc Camcar Textron Inc Underwriters Laboratories
85. expansion board Power off the printer Make sure the flash memory is seated properly in J10 and J11 Regardless of memory configuration J11 must be used Reseat flash memory 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 pre written flash SIMM See Table 8 and Table 9 on page 219 and Figure 35 on page 220 Power on the printer If black squares appear on the LCD replace the CMX controller board Operator panel blank Power off the printer Remove the paper guide assembly 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 If the printer has the coax twinax expansion board check the adapter connection to the CMX controller board Make sure the 60 pin expansion adapter is correctly seated in the CMX controller board and the coax twinax expansion board Power on the printer Inspect the operator panel display and cooling fans If the operator panel is blank and the cooling fans come on replace the operator panel cable assembly and or the operator panel as required Power on the printer If the operator panel is blank and the fans do not come on replace the CMX controller board Operator panel display shows garbled broken characters Remove the paper guide assembly or pedestal top cover Check cable connections int
86. feed platen does not open page 126 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 ribbon mask for bends or deformation that block the paper path or prevent paper from exiting the pedestal top cover Replace a damaged hammer bank cover assembly Check and adjust the platen open belt Replace the belt if it is damaged 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 Inspect the tractors and tractor door springs for damage or excessive wear If either tractor is worn or damaged replace both tractor assemblies Check and adjust the paper feed belt Replace the belt if it is damaged 63 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel Message Explanation Corrective Action 002 FORMS JAMMED CLEAR JAM AND RELOAD FORMS continued 11 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 m
87. 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 Start of Gall page 60 e Troubleshooting Display page 61 Message List a eere de nett page 62 e Troubleshooting Other page 109 General Symptom 00 110 e Communications page 131 e Operator Print 2 0 440 page 132 e Customer Engineer CE page 134 Hex Gode Printout eot ere page 140 ASCII Character page 142 Power On Sequence sse page 146 Appendix A Wire Data page 287 59 Chapter 5 Start Of Call Start Of Call Are you here because of an error message NO Power the printer and observe the operator panel for the following sequence of events retry as required 1 All LEDs on and
88. 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 8 and Figure 9 At eight Ipi there are nine dot rows per character line at nine eight dot rows per character line and so on Each individual hammer spring forms more than one character as the shuttle moves horizontally This principle is illustrated in Figure 10 Direction of Shuttle Movement a Dot Row 1 2 3 4 5 Paper One 6 Feed Text Direction Line 7 8 9 ee0000 10 11 Number of rows determined by line spacing n epee epee 2 e gt This row is used only for lowercase descenders This row is used for underlining and lowercase descenders Figure 9 Standard Character Formation Shuttle Scan 1 gt Dot Succesive Hammer Strokes Per Scan Row x 1 x13 1 35 x1357 135729 x 1 RON gt N TEN a A P Even column dot centers within the printed character area and character space hammer positions are not illustrated in this diagram NOTE o Hammer Released and Dot Printed Q Hammer
89. menus as shown below ScrollT Scroll Return Enter PRINTER MECHANISM TESTS PRINTER MECHANISM TESTS Burn In Test PRINTER MECHANISM TESTS Plot Test 4 Enter 5 Scroll UNTIL 6 ScrollT Scroll 7 Enter OPERATOR MENU UNLOCKED Plot Test Running Step Press Displayed Result Notes 1 Install the ribbon load paper and power on the printer 2 NOT READY Printer must be in NOT Stop READY mode to access the tests 3 SERVICE Press all four keys at the same time Press Enter to view the different mechanism tests Cycles through list of tests Stop when your test displays Unlocking ENTER key allows you to test the printer The test you selected starts printing See Chapter 6 for instructions in the use of the Hammer Phasing and End of Forms Adjust tests Boot Diagnostics Menu Step Press Displayed Result Notes 8 NOT READY Stop halts the test exits Stop OR Start the menu and puts the printer in the NOT READY state Start halts the test exits the menu and puts the printer in the READY state Boot Diagnostics Menu Printer boot up software contains a menu structure that you can access by holding down the Eject Restore and Stop keys while powering up the printer These menus are not intended for the e
90. page 204 3 Cabinet Model Loosen four screws and remove the barrier shield See page 258 Figure 44 items 3 and 4 Pedestal Model Remove the paper guide barrier shield and four screws See page 260 Figure 45 items 3 4 and 5 4 Remove the two screws securing the paper detector switch assembly See Figure 52 page 278 5 Trace the paper detector switch cables back to the controller board releasing the cables from the restraints under the base casting See cable routing diagrams on page 300 and page 302 Disconnect connector shell P106 from the controller board Remove switch cable connectors PMD and POD from connector P106 page 195 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 screws securing it to the printer base See Figure 52 page 278 2 Checkthe PMD sensor arm range make sure it travels freely and completely back into the sensing cavity 3 Route switch cables PMD and POD back to the controller board installing the cables in the restraints under the base casting See cable routing diagrams on page 300 and page 302 4 Connect switch cables PMD and POD to the connector P106 page 195 then connect P106 to controller board connector J106 5 Cabinet Model Install the barrier shield and tighten the four screws See page 258 Figure 44 items 3 and 4 Pedestal Model
91. power cord before cleaning the printer ATTENTION Do not use abrasive cleaners particularly on the window Do not drip water into the printer Damage to the equipment will result Do not spray directly onto the printer when using spray solutions spray the cloth then apply the dampened cloth to the printer Do not vacuum circuit boards Cleaning The Exterior 1 Power off the printer Disconnect the AC power cord from the power source Wipe the outside of the enclosure with a clean lint free cloth dampened not wet with water and a mild detergent or window cleaning solution Dry the enclosure with a clean lint free cloth Clean the inside of the printer as described below 29 Chapter 3 Cleaning The Printer Cleaning The Interior Power off the printer Disconnect the AC power cord from the power source Open the printer cover Remove paper from the printer Remove the ribbon BOT GO Using a soft bristled non metallic brush wipe paper dust and ribbon lint off the tractors shuttle cover assembly base casting and ribbon guides Vacuum up the residue See Figure 5 Wipe the splined shaft and the ribbon guides with a soft cloth Vacuum up dust or residue that has accumulated inside the lower cabinet 9 Wipe the interior of the lower cabinet with a clean lint free cloth dampened with water and a mild detergent or window cleaning solution 10 Dry the cabinet interior wit
92. pushing away from the large platen pulley reduce tension to 5 pounds 22 24 N and torque the motor mount screws to 11 2 inch pounds 1 24 0 23 Nem Snap the platen open belt cover into the slots in the side plate Cabinet Model Install the card cage fan page 209 10 Cabinet Model Install the paper guide assembly page 229 Pedestal Model Install the top cover assembly page 204 11 Return the printer to normal operation page 153 224 Motor Assembly Ribbon Drive Motor Assembly Ribbon Drive Removal 1 Prepare the printer for maintenance page 152 Remove the ribbon hub page 238 Remove two screws and washers securing the ribbon drive motor to the base casting page 278 Figure 52 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 Cabinet models remove the heat boot from the motor You will install the boot on the replacement motor Installation 1 Reverse steps 2 through 6 of the removal procedure above NOTE The ribbon drive motor should be secured at the right front and left rear corners See page 278 Figure 52 2 Return the printer to normal operation page 153 225 Chapter 7 Section Replacement Procedures Network Print Server Installation and operation of this optional feature are described in the Print Server User s Guide P N 30H4056 This guide describes erro
93. 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 displays 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 XXXX to the LCD where XXXX 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 000A Start running normal EC firmware CMX Controller Board Handshake Sequences Check Security PAL and NVRAM The chip select for NVRAM com
94. series 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 152 Returning the Printer to Normal page 153 Belt Paper Feed Timing Adjustment page 154 Belt Platen Open page 156 Paper Drive Motor Pulley Alignment page 158 Paper Scale Alignment page 160 Platen Gap page 162 Platen Open Motor Pulley page 164 Ribbon Guide Alignment sse page 166 Splined Shaft Skew 0 page 168 Adjusting the End of Forms page 169 Hammer Phasing Adjustment sse page 173 Downloading 6400 Microcode from the World Wide Web page 175 Loading Flash page 176 Coil Temperature page 181 Set Shuttle Speed is eaves Aaa e edes page 182 Ether
95. switch cable through the cutout in the right side plate and to the controller board See cable routing diagrams on page 300 and page 302 Connect the platen interlock switch cable to the connector shell P107 P7 see page 195 then connect the connector shell to the controller board Cabinet Model Install the paper guide assembly page 229 Pedestal Model Install the top cover assembly page 204 Return the printer to normal operation page 153 247 Chapter 7 Section Replacement Procedures Tractor L R Removal Prepare the printer for maintenance page 152 Remove the splined shaft page 239 Remove the support shaft page 241 peo dm um Remove the tractors Installation 1 Using the replacement tractors install the support shaft page 241 2 Install the splined shaft page 239 3 Return the printer to normal operation page 153 248 Illustrations Of Printer Components Section Illustrated Parts Lists 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 40 Top Cover Doors and Casters Cabinet Model page 250 Figure 41 Paper Stacker and page 252 Fi
96. that the AC in power cable and the AC power input cables are connected to the on off switch circuit breaker See Figure 46 page 262 or Figure 53 page 280 Connect the AC in power supply cable and AC power input cables to the on off switch circuit breaker 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 Check that power supply cable connector P101 is connected to J101 on the CMX controller board Check all cable connections on the CMX controller board Reseat all cables If the printer has the coax twinax expansion board make sure the 60 pin expansion adapter is correctly seated in the CMX controller board and the coax twinax expansion 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 114 General Symptom List Table 5 General Symptom List Symptom Corrective Action Printer does not complete IML NOTE Power on initialization is explained on page 146 1 Power off the printer Remove the paper guide or pedestal top cover Check that all cables are connected to the CMX controller board Reseat all cable connectors on the CMX controller board especially connectors P106 and P107 If the printer has the coax twinax ex
97. to J107 on the CMX controller board Power on the printer Load paper and set TOF Press Form Feed 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 Form Feed and View several times and check that paper returns to TOF Replace the CMX controller board if paper does not return to TOF 127 Chapter 5 Troubleshooting Other Symptoms Table 5 General Symptom List Symptom Corrective Action 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 and 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 guide assembly or pedestal top cover Reseat connectors P106
98. ull 6400 Line Matrix Printers Maintenance Information Manual Cabinet and Pedestal Models Form Number S246 0117 08 Copyright IBM Corp 1995 2000 6400 Line Matrix Printers 5246 0117 08 Maintenance Information Manual Cabinet and Pedestal Models ENERGY STAR NOTE Before using the information and the product it works with make sure that you read the general information under Notices below Ninth Edition August 2000 This edition applies to the IBM 6400 Line Matrix Printer The following paragraph does not apply to any other country where such provisions are inconsistent with local law INTERNATIONAL BUSINESS MACHINES CORPORATION PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND EITHER EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow disclaimer of express or implied warranties in certain transactions therefore this statement may not apply to you Requests for IBM publications should be made to your IBM representative or to the IBM branch office serving your locality Publications are not stocked at the address given below You may send your comments by facsimile to 1 800 524 1519 by E mail to print_pubs vnet ibm com or by mail to IBM Printing Systems Company Information Development Department H7FE Building 003G P O Box 1900 Boulder CO 80301 9191 USA When you send information to IBM or IB
99. use as maintenance tools These are called Customer Engineer Tests CE Tests because they are for your use they are not available to the user through his documentation You will use these tests in various troubleshooting and adjustment procedures NOTE Default Value CE Tests SERVICE SERVICE SERVICE SERVICE PRINTER MECHANISM TESTS HAMMER PHASE VALUE END OF FORMS ADJUST VALUE CLEAR ERROR LOG Burn In Test 1 1000 4 76 40 Enter key activates Plot Test NOTE Value is numeric Unit of dot measurement Shuttle Only unit only Test defined on is dot rows Procedure on Shuttle Slow page 135 Procedure on page 169 Shuttle Fast page 173 Hammer Phasing End of Forms Adjust SERVICE SERVICE SERVICE SERVICE PRINT PARTIAL LINE TOP EXIT TEAR DISTANCE SHUTTLE SPEED __ SET TEMPERATURE _ ENABLE 5 25 to 5 75 inches in 475 Procedure on page 181 DISABLE increments of 0 01 500 inch Procedure on page 182 5 50 SERVICE SERVICE UPGRADE NETWORK ADAPTER PRINTER MGMT Procedure on page Procedure on page 207 183 Figure 18 CE Tests Menu The CE Tests shown in Figure 18 are summarized below Printer Mechanism Tests e Burnin Test Use of this test is not recommended This test is used by the manufacturer to burn in the printer prior to shipment and has no value as a maintenance tool e Plot Test Prints a
100. with defective CMX board 94 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action 122 PAPER NOT SCHEDULED SEE USER S GUIDE The paper feed process is not scheduling on the CMX controller board and the printer cannot advance 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 123 PAPER BUSY TOO LONG SEE USER S GUIDE Firmware error on the CMX controller board 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 guide assembly or pedestal top cover Make sure connectors P106 and P107 are fully seated on the CMX controller 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
101. 0 14H5572 page 250 Hardware Kit 14H5592 page 194 Cable Data Coax Twinax Multi Platform Interface 14H5593 page 194 I O Bracket Assembly Coax Twinax Multi Platform Interface 14H5595 page 194 PROM Coax Twinax Multi Platform Interface 14H5603 page 250 Logo 6400 14H5643 page 264 CMX Controller Board V5 0 All models 004 and 04P Models 008 and 012 with Serial Nos 01AXXXX 01BXXXX and 01CXXXX 14H5644 page 264 Power Supply PCBA Models 004 04P 005 05P 008 08P 012 24H8533 page 256 Input Tray Optional 24H8535 page 282 Adapter Expansion Connector 60 pin 24H8593 274 Paper Support 24H8647 page 264 CMX Controller Board V5 5 25 MHz All models 005 05P and 08 Models 008 and 012 with Ser Nos 01DXXXX 01EXXXX and higher All models 009 and 09P 24H8648 264 Shuttle Frame Assy Models 005 05 24H8766 page 18 6400 Operator s Guide English 24H8767 page 18 6400 Operator s Guide Spanish 24H8768 page 18 6400 Line Matrix Printer Setup Guide French 24H8769 page 18 6400 Operator s Guide Italian 24H8770 page 18 6400 Operator s Guide German 359 Appendix H Part Number Location Description 24H8771 page 18 6400 Operator s Guide Dutch 24H8772 page 18 6400 Operator s Guide Brazilian Portuguese 24H8773 page 18 6400 Line Matrix Printer Operator s Guide Japanese 24H8774 page 18 6
102. 1 FAIL N TEMP HI NSTBY 5V 5V LOGIC GND 5V LOGIC GND 5 LOGIC GND 5 LOGIC GND 8 5V 8 5V OPERATOR PANEL 000 48V EIA 232 E 48V Serial CMX Controller Board Parallel Card Cage Vo Fan SHIELD GND 5 V Remote Point Power of J101 DC POWER Common Ground Exhaust Fan Ret J106 MSL J108 HBL J105 HBP J116 SMD J107 MSR Cabinet PIOS NISL PIOS HE only 8 5V 8 5 48V 48 Ret Ret R Flaten s Shuttle Mato Assy Paper Feed Paper Moti Terminator Board Motor aper Motion erminator Boar Detector 5 Platen Open Paper Out Shuttle Motor 48 5 Switch Detector 5 1 Hammer Bank Board Left Ribbon Right Ribbon Guide 45V o Guide Left Ribbon Right Ribl Motor 48 Ret 9 Mor 344 Hammer Bank Fan 24 AA Figure 57 Ground Path Diagram Customer Power Source Service Check Use an ECOS Electrical Safety Tester P N 6339695 in the United States or a similar safety tester in other countries NOTE
103. 154143 001 ASCII with Code V 24H9329 14H5490 154143 001 Base CTA 24H9332 14H5509 154143 002 CTA with IGP 24H9330 14H5490 154143 001 CTA with Code V 24H9331 14H5490 154143 001 IPDS Twinax 24H9333 14H5509 154143 002 IPDS Twinax with IGP 24H9334 14H5490 154143 001 IPDS Twinax with Code V 24H9335 14H5490 154143 001 IPDS Coax 24H9336 14H5509 154143 002 IPDS Coax with IGP 24H9337 14H5490 154143 001 IPDS Coax with Code V 24H9338 14H5490 154143 001 LQ 1600K Hanzi 24L5211 38L0821 154143 005 Table 9 Pre Written Flash SIMMs and Security Modules Later Models Code Load Description Pre Written Flash for models 050 P50 010 P10 015 Security Module IBM P N Vendor P N Base ASCII 02N8319 14H5509 154143 002 ASCII CV IGP 02N8320 14H5490 154143 001 Ethernet IPDS for ASCII 02N8321 14H5509 154143 002 Ethernet IPDS CV IGP 02N8322 14H5490 154143 001 for ASCII Base CTA 02N8323 14H5509 154143 002 Base CV IGP 02N8324 14H5490 154143 001 Coax Twinax Ethernet 02N8325 14H5509 154143 002 IPDS Coax Twinax Ethernet 02N8326 14H5490 154143 001 IPDS CV IGP 219 Chapter 7 Section I Replacement Procedures CMX Controller Board Oo 8 E om PS
104. 195 Chapter 7 Section Replacement Procedures 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 30 2 Pullthe side of the connector shell outward and gently push the cable connector down into the connector shell 3 Engage the tabs on the cable connector in the slots in the side of the connector shell Press the sides of the connector shell inward to make sure all cable connector tabs are engaged in the shell slots NOTE Later models have stiffening clips on connectors P106 and P107 4 On later model printers install the stiffening clip page 198 5 Connect the cable connector shell to its printer connection 6 Cabinet Model Install the paper guide assembly page 229 Pedestal Model Install the top cover assembly page 204 7 Return the printer to normal operation page 153 196 Connector Shells P106 Connector Configuration P107 Connector Configuration 19171513 119 7531 Top View As seen 19171513 119 7531 when plugged into the POD CCF PLATM CMX controller board MPU PLO EHF PAPRM PMD LRP M CVO HBF RRIBM DA Pin No 20181614 1210 8642 20181614 1210 8642 CCF Card Cage Fan CVO Cover Open Switch LRIB M Left Ribbon Moto
105. 2 otherwise skip to step 11 11 Install the shuttle cover assembly page 203 12 Models 014 and 015 only adjust the coil temperature if the original shuttle frame assembly was replaced page 181 13 Models 004 04P 005 and 05P only set shuttle speed if the original shuttle frame assembly was replaced page 182 14 Adjust the hammer phasing page 173 15 Return the printer to normal operation page 153 243 Chapter 7 Section Replacement Procedures Spring Extension ATTENTION Do not let the hammer bank rotate toward the platen during spring replacement Removal 1 Prepare the printer for maintenance page 152 2 Open the printer cover 3 Remove the shuttle cover assembly page 203 4 Unhook the extension spring from the spring lugs on the hammer bank and shuttle frame See Figure 49 page 272 Installation 1 Puta dab of IBM 20 bearing lubricant on both spring lugs ATTENTION Make sure the extension spring does not touch the MPU cable after installation 2 Hookthe extension spring over the spring lugs See Figure 49 page 272 Install the shuttle cover assembly page 203 Return the printer to normal operation page 153 244 Switch Assembly Cover Open Switch Assembly Cover Open Removal 1 Prepare the printer for maintenance page 152 Remove the shuttle cover assembly page 203 Carefully lift and pry the cover open switch assembly out of its well i
106. 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 5791514 Platen Pulley Driven 22 Ref Screw Socket Cap 6 32x 44 Part of item 21 23 5761467 Belt Timing 312W 87 Teeth Platen Open Belt 24 14H5174 Platen Paper Feed Cover Kit Platen open belt cover shown in Figure 51 Paper feed belt cover page 258 item 7 25 14H5169 Platen Hardware Kit 26 Ref Platen Washer Part of item 25 277 Section II Illustrated Parts Lists 7 Chapter Install screws here Route cable under base casting c x c m o E E I 8 E _ Lh 8 2 Ne See detail above Figure 52 Motors Card Cage Fan and Paper Detector Switch 278 Illustrations Of Printer Components Eni o d Na Description Notes 1 5791440 Fan Assembly Air flow is into card cage 2 Ref Screw w Lock Washer 3 Two 6 32x1 75 on botton One 6 32x0 50 on top left 3 14H5281 Paper Detector Switch Assy Standard 14H5570 Paper Detector Switch Assy Black Back forms 4 Ref Screw Thread Forming 6 32x 375 5 14H5520 Paper Feed Motor Assy Includes items 7 through 9 6 08H7934 Motor Pulley Platen Open Part of Platen Open Motor Assy 57601509 and includes collar setscrew 6 32x 25 7 Ref Collar Part of item 9 8 Ref Screw Socket Head 6 32x 51 9 57G1421 Motor Pulley Paper Feed 10 Ref Screw
107. 3 158 List Of Adjustments Legend 1 BeltShield 2 CapScrew 3 Motor Pulley Collar 4 Motor Pulley 5 Splined Shaft Pulley Figure 23 Paper Drive Motor Pulley Alignment 159 Chapter 6 Paper Scale Alignment Paper Scale Alignment To make this adjustment follow these steps Open the printer cover Load paper and ribbon Connect the power cord to the AC power source Set the printer power switch to 1 on Verify that the shuttle cover 1 is properly installed page 203 OGL coo Nee Print a full 136 column line by selecting and running one of the diagnostic self tests See Chapter 5 Check alignment of the scale to the print at column positions 1 and 136 If adjustment is necessary loosen the three button head 5 64 inch hex screws 2 9 Position the scale 3 so that column positions 1 and 136 line up with the first and last characters on the 136 character printout 10 Tighten the 5 64 inch button head screws 2 11 Close the printer cover 160 List Of Adjustments Legend 1 Shuttle Cover 2 Screw Button Head 5 64 inch hex 3 3 Paper Scale Figure 24 Paper Scale Alignment 161 Chapter 6 Platen Gap Adjustment Platen Gap Adjustment 162 To make this adjustment follow these steps IMPORTANT Only do this procedure if the original equipment shuttle frame assembly or platen has been replaced by a new or refurbished unit Prepare the printer fo
108. 4 f 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 84 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 84 Removing the Timing Belt Pulley and Motor 394 5 Loosen the two setscrews on the motor pulley and remove the pulley Unplug the motor cable if necessary See Figure 85 Go to step 6 Legend 1 Timing Belt Motor 2 Setscrew 3 Pulley Figure 85 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 86 7 5 NOTE Left is shown ERG 2 Right is the same 1 A Is gt l EN d 2 1 WP _ FON CAT N 2 4 74 3 Legend 1 Large Washer 2 Spacer 3 Constant Force Spring 4 Shoulder Screw Figure 86 Releasing the Constant Force Spring 395 Appendix J _ Replacing The Timing Belts 7 Remove two Allen screws from the belt clamp that secures the timing belt to the stacker frame See Figure 87 Legend 1 Allen Screw 2 Belt Clamp Figure 87 Removing the Belt Clamps 396 8 Remove the timing belt by working it around the vertical rail and constant force spring See Figure 88
109. 4 Stacker Hardware Kit Kit not illustrated 75 24H8985 Compression Spring On left end of shaft on early models 80 Ref Friction Washer Part of item 36 85 Ref Flanged Bushing Part of item 36 90 24H8988 Drive Roller Five on early models 404 Figure 92 Stacker Detail Motor Bracket Appendix J Illustrated Parts Breakdown jo Part No Description Notes 36 24H9004 Stacker Hardware Kit Kit not illustrated 95 Ref Clip On Bearing Part of item 36 96 24H8999 Holder LED Round 100 24 8989 LED IR T 1 3 4 406 Figure 93 Stacker Detail Elevator Bracket Appendix J Illustrated Parts Breakdown jo Part No Description Notes 36 24H9004 Stacker Hardware Kit Kit not illustrated 95 Ref Clip On Bearing Part of item 36 97 24H9000 Holder LED Flat 105 24 8990 Photodarlington NPN Rectifier 408 From page 401 Rotated 180 Degrees Connector ag Figure 94 Stacker Detail Paper Motion Detector 409 Appendix J Illustrated Parts Breakdown Item No Part No Description Notes 36 24H9004 Stacker Hardware Kit Kit not illustrated 97 24 9000 Holder LED Flat 105 24 8990 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 24H8991 LED IR Rectangular 115 02 8327 Field Kit Power Stacker PMD 116
110. 400 012 Operating HS Mode Standby 120 VAC SUE AllH s Max Typical je Energy Star Watts 410 480 81 25 BTU Hour 1399 1638 276 85 VA 540 624 170 48 333 Chapter 334 Electrical Characteristics Operating HS Mode Standby 240 VAC PORE AllH s Max Typical Energy Star Watts 400 470 81 25 BTU Hour 1365 1604 276 85 VA 660 780 170 55 6400 014 Operating HS Mode Standby 120 VAC AllH s Max Typical Energy Star Watts 410 430 84 25 BTU Hour 1399 1468 287 85 VA 540 564 139 48 Operating HS Mode Standby 240 VAC 22 06 AllH s Max Typical ME Energy Star Watts 410 420 81 25 BTU Hour 1399 1433 276 85 VA 540 768 170 55 6400 015 Operating HS Mode Standby 120 VAC Mina AllH s Max Typical iie Energy Star Watts 426 513 84 27 BTU Hour 1453 1751 287 92 VA 587 727 139 50 Operating HS Mode Standby 240 VAC 90Hz AllH s Max Typical ia Energy Star Watts 424 490 79 27 BTU Hour 1447 1672 270 92 VA 722 857 163 58 6400 C05 6400 C5P 120 VAC standby 60 Hz Max Typical Not Energy Star Energy Star Watts 341 49 25 BTU Hour 1163 167 85 VA 475 79 48 240 VAC Standby 50 Hz Max Typical Not Energy Star Energy Star Watts 310 59 25 BTU Hour 1058 201 85 V
111. 400 Line Matrix Printer Setup Guide English 24H8775 page 18 6400 Line Matrix Printer Setup Guide Spanish 24H8776 page 18 6400 Operator s Guide French 24H8777 page 18 6400 Line Matrix Printer Setup Guide Italian 24H8778 page 18 6400 Line Matrix Printer Setup Guide German 24H8779 page 18 6400 Line Matrix Printer Setup Guide Dutch 24H8780 page 18 6400 Line Matrix Printer Setup Guide Brazilian Portuguese 24H8781 page 18 6400 Line Matrix Printer Setup Guide Japanese 24H8828 page 268 Ribbon Mask 500 Models 050 P50 24H8844 page 268 Ribbon Mask 1000 Models 010 10 24H8858 page 268 Ribbon Mask 1500 Model 015 24H8872 page 268 Hammer Bank Cover Assy 500 Models 050 P50 24H8886 page 268 Hammer Bank Cover Assy 1000 Models 010 10P 24H8888 page 18 6400 ASCII Programmer s Reference 24H8889 page 18 6400 IGP User s Manual 24H8890 page 18 6400 Code V User s Manual 24H8891 page 18 6400 CTA Programmer s Reference 24H8892 page 18 6400 IPDS Programmer s Reference 24H8893 page 18 Ethernet Interface User s Manual 24H8894 page 278 Ribbon Guide Kit page 315 24H8924 page 268 Hammer Bank Cover Assy 1500 Model 015 24H8925 page 268 Shuttle Frame Assembly 500 Models 050 P50 24H8927 page 268 Shuttle Frame Assembly 1000 Models 010 10 24H8929 page 268 Shuttle Frame Assembly 1500 Model 015 24H8931 page 268 Hammer Spring Field Kit 500 Models 050 P50 24H8932 page 268 Hammer Spring Field Kit 1000 Models 010 10P
112. 4H8976 319 Appendix A Circuit Board And Cable Pinouts Power Cable Power Stacker 24H8975 320 Vertical Rail Cable Power Stacker Reference only not spared 321 Appendix A Circuit Board And Cable Pinouts Fan Assembly Hammer Bank X Es 4 Mons 8 T ul Ke tr T ae uo ge Ed 2014 Lu I n ns v T PIN 1 322 Magnetic Pickup MPU Assembly 57G1476 323 Appendix A Circuit Board And Cable Pinouts Switch Assembly Paper Detector b NId 3HI 009 901 V V NOTLOAS NOILVLNSTHO HOS 10 31IHM lt 5 W 0 il Wi Q0d 901d 0 99 21 104 xoeg xoelg L8ZGHY 4 prepueis joies 324 Switch Assembly Platen Interlock 14H5280 COM PINGE Leu H 7 1 _ mE je PINGI P107 PLO i M VN N WIRE TABLE PIN NO INTERLOCK SWITCH COLOR PIN 1 COM BLA
113. 5 problems 59 Printing time 143 Printouts hex code 140 Procedures adjustment 151 cleaning 29 safety inspection 341 R READY 106 Replacement card cage fan assembly 209 circuit breaker 193 Coax twinax expansion board 215 Coax twinax multi platform interface 194 connector shells 195 connector stiffening clips 198 controller circuit board 190 cover assembly shuttle 203 cover assembly top pedestal model 204 cover open switch assembly 245 dashpot 205 doors cabinet reversing 206 Ethernet interface assemblies 207 extension spring 244 hammer bank ribbon mask cover assembly 200 hammer bank fan assembly 208 210 hammer spring 211 IBM Coax twinax expansion board 215 LAN interface assemblies 207 magnetic pick up assembly 216 417 memory modules 217 multi platform interface 194 network print server 226 operator panel assembly cabinet model 227 pedestal model 228 paper detector switch assembly 246 paper feed drive motor 221 paper feed timing belt 188 paper guide assembly 229 paper ironer 230 platen 231 platen interlock switch assembly 247 platen open belt 189 platen open motor 223 power supply circuit board 192 print server network 226 resistors terminating 235 ribbon drive motor 225 ribbon guide assembly L R 237 ribbon hub 238 shuttle frame assembly 242 splined shaft 239 support shaft 241 tractor L R 248 Reset Mode 55 Reset soft vs ha
114. 6 from the CMX controller board Check the resistance of connector P106 PLAT M Refer to the Main Wire Harness Test Tables on page 291 Replace the platen open motor if it fails the resistance test Power on the printer Press Form Feed and View several times and check that paper moves in both directions Replace the CMX controller board if the platen does not open during paper reverse 126 General Symptom List Table 5 General Symptom List Symptom Corrective Action 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 that 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 and adjust the paper feed timing belt Replace the belt if it is damaged Remove the paper guide assembly or pedestal top cover Make sure connector P107 PAPR M is fully seated in connector J107 on the CMX controller board Connect P107 PAPR M
115. 7 Mnemonics 347 Mode auto reset 55 run 55 Models printer 13 15 Module security location 220 Motor paper feed drive replacement 221 platen open replacement 223 ribbon drive replacement 225 MPU See Magnetic pick up assembly 216 Multi platform interface replacement 194 N Network print server replacement 226 Noise Suppression 365 NOT READY 103 Notes and notices 17 Numbers replacement parts 357 Operation principles of 35 OPERATOR MENU 103 OPERATOR MENU LOCKED 103 OPERATOR MENU UNLOCKED 104 Operator panel block diagram 44 replacement cabinet model 227 pedestal model 228 P P05 DIAGNOSTIC TEST PASSED 104 P17 SECURITY VIOLATION 104 P60 ERROR DRAM AT ADDRESS 104 P61 ERROR FLASH NOT DETECTED 104 416 P62 ERROR DC PROGRAM NOT VALID 104 P63 ERROR PROGRAM NOT COMPATIBLE 105 P64 ERROR CHECKSUM WRONG 105 P65 ERROR PROGRAM NEEDS MORE FLASH 105 P66 ERROR PROGRAM NEEDS MORE DRAM 105 P67 ERROR WRITING TO FLASH 105 P68 ERROR EC PROGRAM NOT VALID 106 P69 ERROR EC STOPPED AT STATE XXXX 106 PA1 SELECTED 104 PA2 SELECTED 104 Panel control See Operator panel 227 Paper detector switch assembly replacement 246 drive motor pulley alignment 158 feed drive motor replacement 221 feed timing belt replacement 188 feed timing belt tension adjustment 154 ironer replacement 230 scale adjustment 160 specifications 328 stacker power 367 tractor L R replace
116. 9 and Figure 35 on page 220 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 Also check the resistance of connectors P106 LRIB M and P107 RRIB M Refer to the Main Wire Test Tables page 291 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 86 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action 087 PLATEN OPEN TIMEOUT CLOSE PLATEN On a coax interface the forms thickness lever has been open for at least one minute Load paper Close the forms thickness lever Press Stop Run a print test If a platen open or close platen message appears power off the printer Remove the paper guide assembly or pedestal top cover Disconnect connector P107 from the CMX controller board Check continuity of the platen interlock switch cable from P107 to the switch Replace the platen interlock switch assembly if it fails continuity test Refer to Appendix A Switch Assembly Platen Interlock Check that the platen interlock switch is not loose Check and adjust the platen open belt Replace the be
117. A 624 130 55 335 Chapter Interfaces Interfaces Standard PC Parallel RS 232 serial RS 422 serial Optional Coax Twinax Ethernet 10Base T Ethernet 10Base2 Ethernet 10 100Base T Logic Levels EIA 232E EIA 422B Data Format ASCII Compatibility Parallel EIA 232E EIA 422B Transfer Up to 200 Kilobytes on parallel interface Rates Up to 19 2K baud on RS 232 serial interface Up to 115 2K baud on RS 422 serial interface Duty Cycle 336 The duty cycles for IBM 6400 printers are listed below These figures are averages subject to the conditions specified following the list 6400 004 04P 6400 005 05 6400 050 P50 6400 008 08P 6400 009 09 6400 010 P10 6400 012 6400 014 6400 015 6400 C05 C5P 130 000 pages per month 130 000 pages per month 130 000 pages per month 205 000 pages per month 205 000 pages per month 205 000 pages per month 320 000 pages per month 376 000 pages per month 376 000 pages per month 130 000 pages per month Under the following conditions e Uppercase text characters only no graphics e 6 lines per inch e 10 characters per inch e 63 character density or 83 characters per line e 63 line density or 42 lines per 11 inch page e Single part 18 Ib paper e Printer is installed in accordance with the Setup Guide e Printer is maintained in accordance with this maintenance manual Metric Conversion Tables
118. Adjust the platen gap page 162 22 Adjust the platen open belt page 156 23 Check ribbon guide alignment page 166 24 Check the hammer phasing page 173 25 Return the printer to normal operation page 153 234 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 These are suitable for most applications See Figure 38 page 236 If the standard terminating resistor pack is not compatible with the 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 ATTENTION To prevent electrostatic damage to electronic components wear a properly grounded static wrist strap when handling circuit boards the shuttle frame assembly and any other electronic component 1 Prepare the printer for maintenance page 152 2 Cabinet Model Remove the paper guide assembly page 229 Pedestal Model R
119. AllH s Max Typical Energy Star Watts 223 239 86 22 BTU Hour 761 816 294 75 331 Chapter 332 Electrical Characteristics Operating HS Mode Standby 240 VAC AllH s Max Typical ced Energy Star VA 410 449 173 41 6400 008 6400 08P Operating HS Mode Standby 120 VAC 502 AllH s Max Typical Energy Star Watts 330 370 84 25 BTU Hour 1126 1263 287 85 VA 450 492 140 48 Operating HS Mode Standby 240 VAC AllH s Max Typical Energy Star Watts 320 360 86 25 BTU Hour 1092 1228 294 85 VA 528 600 173 55 6400 009 6400 09P Operating HS Mode Standby 120 VAC po Hiz AllH s Max Typical A Energy Star Watts 287 327 80 25 BTU Hour 980 1116 273 85 VA 425 475 132 48 Operating HS Mode Standby 240 VAC 9095 AllH s Max Typical Energy Star Watts 281 314 86 25 BTU Hour 959 1072 294 85 VA 497 569 173 55 6400 010 6400 P10 Operating HS Mode Standby 120 VAC 60 kiz AllH s Max Typical d Energy Star Watts 332 360 86 25 BTU Hour 1133 1229 294 85 VA 457 527 143 48 Operating HS Mode Standby 240 VAC SURE AllH s Max Typical ied Energy Star Watts 306 360 81 25 BTU Hour 1044 1229 276 85 VA 554 662 170 55 6
120. Alt 1 220 Ohm Alt 2 1K Ohm Resistor Kit 14H5525 IW RP2 Default 1K Ohm Alt 1 330 Ohm Alt 2 None Figure 38 Terminating Resistors Removal Installation 236 Ribbon Guide Assembly L R Ribbon Guide Assembly L R Removal 1 Prepare the printer for maintenance page 152 NOTE The right ribbon guide is shown in Figure 52 The removal procedure is the same for the left ribbon guide 2 Cutand remove the tie wrap from the tie wrap hole to free the ribbon guide cable page 278 Figure 52 3 Cabinet Model Remove the paper guide assembly page 229 Pedestal Model Remove the top cover assembly page 204 4 Trace the ribbon guide cable back to the controller board releasing it from the cable restraints See cable routing diagrams on page 300 and page 302 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 195 7 Remove the two screws and washers securing the ribbon guide assembly to the side plate 8 Slide the ribbon guide assembly out of the side plate Installation NOTE The right ribbon guide is shown in Figure 52 The installation 1 2 3 procedure is the same for the left ribbon guide Reverse steps 2 through 8 of the removal procedure above A
121. BM s intellectual property rights may be used instead of the IBM product Evaluation and verification of operation in conjunction with other products except those expressly designated by IBM is the user s responsibility Any performance data contained in this document was obtained in a controlled environment based on the use of specific data The results that may be obtained in other operating environments may vary significantly Users of this document should verify the applicable data in their specific environment Therefore such data does not constitute a performance guarantee or warranty IBM may have patents or pending patent applications covering subject matter in this document The furnishing of this document does not give you any license to these patents You can send license inquiries in writing to the IBM Corporation IBM Director of Licensing 208 Harbor Drive Stamford Connecticut United States 06904 Electrical Safety This printer is inspected and listed by recognized national testing laboratories such as Underwriters Laboratories Inc UL in the U S A and Canadian Standards Association CSA in Canada Listing of a product by a national testing laboratory indicates that the product is designed and manufactured in accordance with national requirements intended to minimize safety hazards IBM equipment meets a very high standard of safety in design and manufacture Remember however that this product operates under
122. CK NO EN GRAY 325 Appendix A Circuit Board And Cable Pinouts Switch Assembly Cover Open 14H5282 326 B Printer Specifications Ribbon Specifications The ribbon life figures listed below are based on IBM tests conducted in accordance with ANSI Standard X3A 182 Actual ribbon life may vary depending on the user s quality criteria printer condition machine settings paper quality and bar code requirements Label yield depends on label format bar code symbology and other parameters Label yield with high performance scanning equipment may exceed these yields Use only the ribbons listed below e General Purpose Ribbon P N 1040990 Used for general text printing such as data and word processing Average yield 20 million DP characters e General Purpose Ribbon P N 1040995 Average yield 30 million DP characters e High Contrast Ribbon P N 1040993 Used for general text printing as well as OCR graphics and bar code printing Average yield 20 million DP characters 2500 AIAG B3 labels with visible light source scanning equipment or 1300 AIAG B3 labels with infrared light source scanning equipment e High Contrast Ribbon P N 1040998 Average yield 30 million DP characters 3600 AIAG B3 labels with visible light source scanning equipment or 1800 AIAG B3 labels with infrared light source scanning equipment Hanzi Ribbon P N 1402739 100 Yard Hi Resolution ribbon for all
123. COLOR PIN 4 FIN 5 BLACK EIN Z PIN Z GRAY PIN 1 N C PIN 1 309 Appendix A Circuit Board And Cable Pinouts Cable Assembly Operator Panel 14H5300 NOTE If you replace the control panel cable you must install two ferrite shielding beads PING See Appendix 1 Brown 25 119 PNG E a P Gray Lf a 220 LT PIN8 PIN 1 Brown Gray 310 Cable Assembly Exhaust Fan 14H5286 311 Appendix A Circuit Board And Cable Pinouts Cable Assembly Hammer Bank Logic 14H5279 312 Cable Assembly Hammer Bank Power 02N6214 POS P105 PIN 1 Nom UM WIRE TABLE 205 WIRE COLOR 22 1 GRAY 1 2 BLACK 4 5 GRAY Ei 4 BLACK 6 5 GRAY 5 6 BLACK 8 7 GRAY 7 8 BLACK 10 9 GRAY 9 10 BLACK 313 Appendix A Circuit Board And Cable Pinouts Cable Assembly MPU PIN 2 4 EE M S rZ 3 NS 5 L Em MPU 2 05 IN 1 WIRE TABLE MPU JOS WIRE COLOR 4 1 BLACK e 2 GRAY 5 N C 314 Cable Assembly Ribbon Guide Kit 24H8894 NOTE Left ribbon guide shown Right is mirror image Left Guide P106 LRP Right Guide P107 RRP
124. Coax Twinax Multi Platform Interface 194 Connector ree tutis 195 Connector Stiffening Clips seen 198 Cover Assembly Hammer Bank Ribbon Mask 200 Cover Assembly Shuttle essere 203 Cover Assembly Top Pedestal Model 204 c ecce 205 Doors Cabinet 206 Ethernet Interface Assemblies 207 Fan Assembly Cabinet 208 Fan Assembly Card 209 Table of Contents Fan Assembly Hammer Bank 210 Hammer Spring Assembly 211 Coax Twinax Expansion 215 Magnetic Pick up MPU 216 Memory and Security 217 Motor Assembly Paper 221 Motor Assembly Platen Open 223 Motor Assembly Ribbon 225 Network Print 226 Operator Panel Assembly Cabinet 227 Oper
125. Enter Press all four keys at the same time SERVICE PRINTER MECHANISM TESTS appears on the display Press ScrollT Scroll to unlock the Enter key Press the ScrollT or Scroll key until SERVICE SET COIL TEMPERATURE appears on the display Press Enter The display tells you to PLEASE WAIT while the coil temperature is set by an automatic calibration sequence in printer software When the display again reads SERVICE SET COIL TEMPERATURE press ScrollT Scroll to lock the Enter key Press Stop to exit the menu and put the printer in the NOT READY state Press Start to exit the menu and put the printer the READY state Coil temperature is now set Power off the printer and close the printer cover 181 Chapter 6 SetShuttle Speed Set Shuttle Speed This procedure applies only to models 6400 004 04P 005 and 05P Do this procedure only when the original CMX controller board or shuttle frame assembly have been replaced Do not do this procedure if the original CMX board or shuttle frame assembly were removed and reinstalled as part of other maintenance tasks 1 Install the ribbon and load full width paper 2 Poweron the printer 3 Ifthe Ready indicator is on press the Stop key The printer must be in the NOT READY state to do this procedure 4 Press ScrollT Scroll Return Enter Press all four keys at the same time SERVICE PRINTER MECHANISM TESTS appears on the di
126. Figure 44 Loosen the paper feed motor mount screws page 278 Figure 52 item 10 Loosen the shaft collar setscrew and remove the paper feed motor pulley shaft collar and paper feed timing belt page 278 Figure 52 Trace the paper feed motor cables back to the controller board releasing it from tie wraps See the cable routing diagrams on page 300 and page 302 Disconnect connector P107 from the controller board and remove the paper feed motor connector from connector P107 See page 195 NOTE Some paper feed motors are mounted with nuts and bolts other 9 motors have threaded flanges eliminating the need for nuts Remove the motor mount bolts and nuts if present 10 Remove the paper feed motor assembly 221 Chapter 7 Section Replacement Procedures Installation 1 Position the paper feed motor assembly on the right side plate and install the motor mount bolts and nuts finger tight page 278 Figure 52 2 Connect the paper feed motor cable connector to connector P107 then connect P107 to J107 on the controller board See page 195 Install the collar paper feed motor pulley and timing belt Align the paper feed motor pulley with the splined shaft pulley ATTENTION Make sure there is at least 0 040 inches 1 016 mm of clearance between the collar pulley and the motor face plate 5 Hold the collar snug against the motor pulley and torque the setscrew to 25 2 inch pounds 2 82 0 23 N m
127. G 63H5116 page 260 Paper Path Assembly Models 04P 05P 08P 09P C5P 63H5118 page 256 Paper Basket 63H5119 256 Lid Pedestal Model 63H5120 page 256 Top Cover Complete Pedestal Model 63H5121 page 256 Hinge Lid Kit Pedestal Model 63H5122 256 Lid Accessory Kit Pedestal Model 63H5123 256 Shipping Container Pedestal 363 Appendix H Part Number Location Description 63H5124 256 Operator Panel Pedestal 63H5125 page 256 Bracket Control Panel 63H7379 page 26 6400 Line Matrix Printer Configuration Utility Disk 63H7398 page 250 Top Cover Seal Kit 63H7464 page 316 Cable Assembly Ribbon Motor Extension 63H7478 page 276 Platen Lever Kit 63H7509 page 256 Caster Pedestal 63H5117 page 256 Pedestal Kit 63H7510 page 250 Door Seal Kit 63H7518 page 264 Hmr Bank Rbn Mask Cov Assy Models 004 04P 005 05P 63H7519 264 Hmr Bank Rbn Mask Cov Assy Models 008 009 09 63H7520 page 264 Hmr Bank Rbn Mask Cov Assy Models 012 014 C05 C5P 83F2834 page 26 Torx T 10 Bit 90H3268 page 264 Power Supply PCBA Models 050 P50 009 O9P 010 P10 014 015 C05 C5P 90H3269 page 264 Shuttle Frame Assy Model 014 90H3271 page 268 CMX Controller Board V5 5 40 MHz Models 050 P50 010 P10 014 015 C05 C5P 93F7037 page 250 Hinge Plate Top 5246 0149
128. If necessary set Top Of Form 373 Appendix J _ Stacker Operation Stacker Troubleshooting The power stacker augments the paper feed system of the printer The most frequently occurring problems in the paper feed system are paper jams Because of the electromechanical nature of the system other problems that can occur are worn or poor electrical connections and cabling worn or defective feed motors worn or damaged mechanical components or incorrect installation of the stacker assembly Table 10 shows some of the problems that may occur with the power stacker and the page where you can find the troubleshooting procedure Table 10 Power Stacker Troubleshooting does not detect presence of power stacker Symptom Origin of Symptom Explanation Solution Printer does not detect Reported by customer Various causes possible page 116 presence of power stacker 017 STACKER JAM Message on control Paper is bunching above the page 68 CHECK STACKER panel LCD elevator or the paper motion detector is not working properly 018 STACKER FULL Message on control Status message the power page 69 CHECK STACKER panel LCD paper stacker is full 019 STACKER FAULT Message on control This message is triggered page 70 CHECK STACKER panel LCD when the elevator cannot reach the top or bottom limit switch before timing out Stacker chatters at Reported by customer Various causes possible pa
129. If the message appears power off the printer 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 again If the message appears replace the CMX controller board Record the message and return it with defective CMX board 95 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel Message Explanation Corrective Action 124 PAPER FIFO OVERFLOW SEE USER S GUIDE Paper First In First Out Overflow 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 125 PAPER FIFO UNDERFLOW SEE USER S GUIDE Paper First In First Out 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 guide assembly or pedestal top cover Make sure connectors P106 and P107 are fully seated on the CMX controller board Check hammer phasing Try using a lower phasing value sometimes this message indicates too high a hammer phase value
130. Inc Table of Contents ENERGY STAR eie ev deve aetna aped 4 i on r cU 5 ex iudei iere 5 Trademarks And Service 6 Maintenance 13 About Th Printer es ete et ete be 13 The IBM 6400 Series Printer 13 Hanzi ilic PH 14 Printer Evolutions idee reed 15 How To Identify The 0 4440 15 Important Maintenance 8 16 About This 16 How Use This 16 Notes And tet ert Pe 17 Printing Conventions In This 2 18 Related 18 Controls And Indicators 20 Electrical Controls Cabinet Models 20 Electrical Controls Pedestal 22 Mechanical Controls All Models 24 Tools Test Equipment And 26 Installation 27 Installing And Configuring 6400 27 Preventive Maintenance
131. LINE a VE Legend 1 ON OFF Indicator Lamp On Line Indicator Lamp Line Key Form Feed Key Stacker Elevator Up Key Stacker Elevator Down Key QUOI E OI Figure 60 Power Stacker Control Panel e ON OFF Indicator Lamp Lit when printer power is on Unlit when printer power is off e ON LINE Indicator Lamp Lit when printer is online to host computer READY Unlit when printer is offline NOT READY e ONLINE Key Toggles the printer between the READY and NOT READY operational states FORM FEED Key Moves paper one form length as defined by the currently active form length This key is active only when the printer is in the NOT READY state e ELEVATOR UP Key Moves the elevator to its highest position This key is active only when the printer is in the NOT READY state e ELEVATOR DOWN Key Moves the elevator to its lowest position This key is active only when the printer is in the NOT READY state 370 Using The Power Stacker 1 Set the printer power switch to On Open the rear door of the cabinet On the stacker control panel press ON LINE to take the printer to the NOT READY state See Figure 60 Press the ELEVATOR UP key and wait for the stacker to reach the top of its travel See Figure 60 Make sure the wire paper tent is in the base of the stacker with the alignment rods against the vertical rails See Figure 61
132. LLEGAL STATE USER S GUIDE 97 128 PAPER FEED INVALID COMMAND SEE USER S GUIDE 97 129 PAPER FEED INVALID PARAMETER SEE USER S GUIDE 97 130 PAPER FEED PARTLY ENERGIZED SEE 412 USER S GUIDE 97 131 PAPER FEED INTERRUPT SEE USER S GUIDE 98 132 RIBBON INVALID COMMAND SEE USER S GUIDE 98 133 RIBBON INVALID STATE SEE USER S GUIDE 98 134 PLATEN INVALID COMMAND SEE USER S GUIDE 98 135 PLATEN INVALID STATE SEE USER S GUIDE 98 136 PLATEN INVALID PARAMETER SEE USER S GUIDE 98 137 SHUTTLE INVALID COMMAND SEE USER S GUIDE 99 138 SHUTTLE INVALID PARAMETER SEE USER S GUIDE 99 139 SHUTTLE OVERSPEED SEE USER S GUIDE 99 990 MACHINE CHECK 99 998 NON VOLATILE MEMORY FAILED 99 A A97 GRAPHIC CHECK ERROR PRESS STOP THEN START 99 Abbreviations 347 About the printer 13 Acronyms 347 Adapters and Cords 355 Adjustments 151 coil temperature 181 end of forms distance 169 Ethernet initialization 183 hammer phasing 173 loading flash memory 176 paper drive motor pulley alignment 158 paper feed timing belt tension 154 paper scale 160 platen gap 162 platen open belt 156 platen open motor pulley alignment 164 ribbon guide 166 set shuttle speed 182 software upgrades 176 splined shaft skew adjustment 168 ASCII Character Set chart 142 Attention condition 61 B Belt paper feed timing replacement 188 paper feed timing tension adjustment 154 platen open r
133. LRP and P107 RRP on the CMX 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 on page 291 Replace a ribbon post that fails the continuity test Check and adjust the platen gap 128 General Symptom List Table 5 General Symptom List Symptom Corrective Action Shuttle Shuttle does not move Power down the printer Remove the shuttle cover 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 N m 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 Remove the paper guide assembly or pedestal top cover Check that the shuttle motor drive cable is connected to J116 on the CMX controller board Check and adjust the platen gap 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 Check continuity of the shuttle motor drive cable assembly Replace shuttle motor drive cable ass
134. M Printing Systems Company you grant a nonexclusive right to use or distribute the information in any way IBM or IBM Printing Systems Company believes appropriate without incurring any obligation to you Copyright International Business Machines Corporation 1995 2000 All rights reserved Note to U S Government Users Documentation related to restricted rights Use duplication or disclosure is subject to restrictions set forth in GSA ADP Schedule Contract with IBM Corp ENERGY STAR The EPA ENERGY STAR Computers program is a partnership effort with manufacturers of data processing equipment to promote the introduction of energy efficient personal computers monitors and printers and to reduce air pollution caused by power generation IBM participates in this program by introducing printers that reduce power consumption when they are not being used This feature can cut energy use by up to 50 percent Notices Note The ENERGY STAR emblem does not represent EPA endorsement of any product or service Notices References in this publication to IBM products programs or services do not imply that IBM intends to make these available in all countries in which IBM operates Any reference to an IBM licensed product program or service is not intended to state or imply that only IBM s product program or service may be used Any functionally equivalent product program or service that does not infringe any of I
135. MISMATCH DOWNLOAD AGAIN An Engine Controller software update is in process Power off the printer Download the program again from the beginning TESTING HARDWARE PLEASE WAIT Status message when printer runs self tests and initialization routines No action required TOP OF FORM SET Non error status message No action required 107 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel Message Explanation Corrective Action WAITING FOR ETHERNET ADAPTER Status message that appears when printer is first powered on if the internal Network Interface Card 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 No action required WAITING FOR PROGRAM DOWNLOAD Emulation download mode has been activated but program download has not yet begun No action required 108 Message List Troubleshooting Other Symptoms DANGER 3 Hazardous voltages are present in the printer with the power cord connected to the power source Switch off printer power
136. OADING PROGRAM The printer has deleted the previous None INTO FLASH program from flash memory and is loading the new program into flash memory RESETTING The printer finished loading the None PLEASE WAIT program into flash memory and is automatically resetting itself RESTORING Normal download initialization None BOOT CODE message SECURITY CODE The software running or being Install the correct PAL or VIOLATION downloaded does not match the program PAL and program must match SENDING PROGRAM TO EC PROCESSOR The printer is loading the engine controller program into the engine controller None TABLE MISMATCH DOWNLOAD AGAIN EC software update in process Download the program again Power off the printer and start over at step 12 180 List Of Adjustments Coil Temperature Adjustment This procedure applies only to models 6400 014 and 6400 015 Do this procedure only when the original CMX controller board or shuttle frame assembly have been replaced Do not do this procedure if the original CMX board or shuttle frame assembly were removed and reinstalled as part of other maintenance tasks The shuttle frame assembly must be at room temperature to do this procedure 1 2 3 10 11 Raise the printer cover Power on the printer If the Ready indicator is on press the Stop key The printer must be in the NOT READY state to do this procedure Press Scroll Scroll Return
137. Open the printer cover Open the floor cabinet rear door Pry back the spring retaining clips page 254 Figure 42 Qv sm US o Remove the dashpot from the ball studs Installation ATTENTION The dashpot must be installed with the large cylinder uppermost 1 Position the dashpot against the ball studs on the upper and lower brackets page 254 Figure 42 The large cylinder must be uppermost Push the dashpot onto the ball joints and install the spring clips Close the printer cover If necessary adjust the position of the ball joint stud in the lower bracket to achieve smooth and complete closure 4 Return the printer to normal operation page 153 205 Chapter 7 Section Replacement Procedures Doors Cabinet Reversing NOTE Floor cabinet printers are assembled with the front door hinged on the left side so that it opens at the right side The rear door is hinged on the right side so that it opens on the left side This procedure enables you to reverse this door configuration 1 Open the front and rear cabinet doors Mark the top of each door Remove the screws and wire ropes from the doors and cabinet frame See Figure 40 page 250 item 9 4 Lift each door up and off the hinge pins of the upper and lower cabinet hinge plates Do not remove the hinge plates from the doors Remove two screws and the paper fence from the original rear door Remove the screws securing the hinge pin plates to the fr
138. Provides information used with the optional IGP Printronix emulation enhancement feature The IGP Printronix emulation allows the user to create and store forms generate logos bar codes and expanded characters create other graphics and merge graphics with alphanumeric data as a document is printed Installation configuration and troubleshooting of the Network Print Server and internal Network Interface Card NIC are covered in the following documents Print Server User s Guide Part No 30H4056 Ethernet Interface User s Manual Form No S246 0153 10Base2 and 10Base T cards Ethernet Interface User s Manual Form No S246 0154 10 100Base T card Chapter 1 Controls And Indicators Controls And Indicators Electrical Controls Cabinet Models Key or Indicator Function Power Indicator Ready Indicator Processing Indicator Attention Indicator Power Switch LCD Start Stop Form Feed Set Top Of Form Line Feed View Cancel Eject Restore Menu Enter Return Micro T Micro J Scroll T Scroll J Printer Configuration Stop Enter Scroll T Scroll Lit when the printer is on Lit when the printer is in READY mode on line no errors are pending and the printer is ready to process data Off when the printer is in NOT READY mode off line Flashes when the printer is receiving data from the host Flashes when an error occurs After correcting the error press Stop to turn
139. R OCCURRED FLUSHING QUEUES 101 180 ETHERNET ADAPTER BEING INITIALIZED 101 ETHERNET DETECTED 102 Ethernet interface assemblies initialization procedure 183 LEDs and DIP switches 52 replacement 207 F Fan assembly card cage replacement 209 hammer bank replacement 208 210 Fault messages 61 list of 62 Fault symptoms not from messages 110 Flash memory pre written part numbers for early models 219 pre written part numbers for later models 219 Flash memory loading 176 Flash messages CLEARING PROGRAM FROM FLASH 178 DIAGNOSTICS PASSED 178 ERROR DC PROGRAM NOT VALID 178 DRAM AT ADDRESS XXXXXXXX 178 EC PROGRAM NOT VALID 178 EC STOPPED AT STATE XXXX 178 FLASH NOT DETECTED 179 NO DRAM DETECTED 179 NVRAM FAILURE 179 PROGRAM NEEDS MORE DRAM 179 PROGRAM NEEDS MORE FLASH 179 PROGRAM NOT COMPATIBLE 179 PROGRAM NOT VALID 179 SECURITY PAL NOT DETECTED 179 SHORT AT ADDRESS XXXX 179 WRITING TO FLASH 178 180 WRONG CHECKSUM 180 ERROR OCCURRED FLUSHING QUEUES 180 LOADING PROGRAM FROM PORT 180 LOADING PROGRAM INTO FLASH 180 RESETTING PLEASE WAIT 180 RESTORING BOOT CODE 180 SECURITY CODE VIOLATION 180 SENDING PROGRAM TO EC PROCESSOR 180 TABLE MISMATCH DOWNLOAD AGAIN 180 FM HEADER ERROR 102 FREEFORM OFF 102 OFF HOLD KEY PWRUP 102 G Gap adjustment magnetic pick up MPU 216 platen 162 Ground path diagram 341 H Hammer phasing adjustment 173 spring assembly
140. RAM 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 147 Chapter 5 148 The Power On Sequence Display VX Registers The boot code displays the values of the VX registers out of the debug serial port Check for Pedestal Boot code uses the operator 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 Cancel and Start 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 Eject Restore and Stop keys were pressed at power up If so the printer enters the Boot Diagnostics menu If not the printer continues the boot
141. See also page 217 21 14H5282 Switch Assembly Cover Open 22 02N8261 Connector Clip 270 Illustrations Of Printer Components Illustrated parts lists continue on next page 271 Chapter 7 Section Il Illustrated Parts Lists Spring Lug Do not remove grease Spring Lug Do not remove grease 22 22 21 Make sure the extension spring does not touch the MPU cable after installation 0 010 001 inch 0 254 025mm Figure 49 Magnetic Pickup Unit MPU and Extension Spring 272 Illustrations Of Printer Components us x deri Description Notes 1 5791476 Magnetic Pickup Assy MPU 2 Ref Screw Socket Cap 6 32x 38 3 30H3985 Extension Spring 4 14H5329 Cable Assembly MPU 273 Chapter 7 Section Il Illustrated Parts Lists NOTE Item 18 Tractor Shaft Hardware Kit not shown Item 19 Tractor Shaft Kit not shown Figure 50 Tractor Shafts 274 Illustrations Of Printer Components bon o Description Notes 1 Ref Screw Socket Cap 4 40x 25 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 i
142. TIVATE LOST The printer detects a twinax protocol communication error and reports the error Power off the printer Disconnect the AC power cord from the printer Check the twinax host data cable and twinax I O cable connection at the CT board Reseat the twinax host data cable connection and the twinax cable connection at the CT board Disconnect the twinax auto termination cable from the printer Test the cable for the resistances shown on page 306 If resistances are not correct replace the twinax auto termination cable Connect the power cord to the printer Power on the printer Send a print job to the printer If the message appears replace the twinax cable Send a print job to the printer If the message appears go to Communications Failures page 131 014 INVALID ACTIVATE The printer detects a twinax protocol communications error and reports the error Power off the printer Disconnect the AC power cord from the printer Check the twinax host data cable and twinax I O cable connection at the CT board Reseat the twinax host data cable connection and the twinax cable connection at the CT board Disconnect the twinax auto termination cable from the printer or from the last device on this twinax port Test the cable for the resistances shown on page 306 If resistances are not correct replace the twinax auto termination cable Connect the power cord to the printer Power on the prin
143. The stacker assembly is exploded to show mounting screws and locations 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 76 Stacker Fasteners S 386 22 Install the paper fence See Figure 77 Legend 1 Paper Fence 2 Stacker Base Figure 77 Paper Fence 387 Appendix J Installing The Power Stacker 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 78 QU OOO0OOOOCOOO OO OOOOOo0O00000057 amp 20 CQ OU 0C 0 eo0cO000000000000p V at Legend 1 Logic Cable P104 2 Power Cable 3 Frame Cable P102 4 Rail Cable P107 Figure 78 Stacker Control Panel Cables 388 25 Position the stacker control panel as shown in Figure 79 and install the mounting screws Legend 1 Stacker Control Panel 2 LongScrew 3 Short Screw 2 Figure 79 Installing the Stacker Control
144. USER S GUIDE 78 059 CANCEL PRINT ACTIVE 79 060 PRINTER HOT 80 065 HAMMER BANK FAN FAULT 82 069 DATA CLEARED 82 080 POWER SUPPLY HOT 83 081 POWER SUPPLY VOLTAGE FAILURE 84 082 POWER SUPPLY 8 5V FAILED 84 083 INTAKE FAN FAULT 84 084 POWER SUPPLY 48V FAILED 85 085 CONTROLLER VOLTAGE 85 086 CONTROLLER 15V 86 087 PLATEN OPEN TIMEOUT CLOSE PLATEN 87 088 CONTROLLER 23 5V 88 089 RIBBON STALL 89 090 SHUTTLE COVER OPEN CLOSE SHUTTLE COVER 90 092 RIBBON DRIVER CIRCUIT 90 411 101 UPPER DRIVER SHORT 91 102 LOWER DRIVER SHORT 91 105 HAMMER COIL OPEN 91 107 HAMMER COIL HOT 92 110 STACK OVERFLOW SEE USER S GUIDE 93 111 STACK UNDERFLOW SEE USER S GUIDE 93 112 UNDEFINED OPCODE SEE USER S GUIDE 93 113 PROTECTED INSTRUCTION SEE USER S GUIDE 93 114 ILLEGAL OPERAND ACCESS SEE USER S GUIDE 93 115 ILLEGAL INSTRUCTION ACCESS SEE USER S GUIDE 93 116 ILLEGAL EXTERNAL BUS ACCESS SEE USER S GUIDE 94 117 A TO D OVERRUN SEE USER S GUIDE 94 118 UNDEFINED INTERRUPT SEE USER S GUIDE 94 119 TCB CORRUPTED SEE USER S GUIDE 94 120 ACCESS NULL POINTER SEE USER S GUIDE 94 121 PAPER NOT AT SPEED SEE USER S GUIDE 94 122 PAPER NOT SCHEDULED SEE USER S GUIDE 95 123 PAPER BUSY TOO LONG SEE USER S GUIDE 95 124 PAPER FIFO OVERFLOW SEE USER S GUIDE 96 125 PAPER FIFO UNDERFLOW SEE USER S GUIDE 96 126 PAPER FEED BAD TABLE SEE USER S GUIDE 97 127 PAPER FEED I
145. X board 118 UNDEFINED INTERRUPT SEE USER S GUIDE 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 119 TCB CORRUPTED SEE USER S GUIDE Task Control Block on the CMX controller board has been corrupted 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 120 ACCESS NULL POINTER SEE USER S GUIDE The 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 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 121 PAPER NOT AT SPEED SEE USER S GUIDE 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
146. Y Ss SCI J B p gt ef Legend 1 Upper Frame Cross Member 2 Elevator Assembly 3 Stacker Base 4 Vertical Rail Figure 71 Removing the Stacker Assembly 379 Appendix J Installing The Power Stacker 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 Bos mm Loosen the three paper guide hold down screws Slide the paper guide to the left and lift it off the card cage See Figure 72 Legend 1 Paper Guide 2 MHold Down Screw 3 Figure 72 Remove the Paper Guide 380 5 Connectthe power stacker logic cable P103 to connector J17 on the CMX controller board See Figure 73 6 Disconnect the power supply cable from connector J101 on the CMX controller board See Figure 73 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 73 8 Route the stacker power cable and the stacker logic cable in front of the CMX board and through the cutout beneath the card cage fan as shown in Figure 73 Legend Power Supply Connector P101 CMX Board Connector J101 Connector P103 CMX Board Connector J17 Stacker Logic Cable Stacker Power Cable Cutout Beneath
147. accessed through the Cajun bus MECA ASIC The 166 uses numerous counters PWM generators and FIFOs in the MECA to control many printer motor functions The MECA is a custom gate array specifically designed to drive this system Analog Drive Circuitry The analog drive functions convert 48 and 8 5 volts into the power used to drive the motors and hammers in the printer Sensors are used to monitor the operation and status of critical components within the printer 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 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 Engine Controller The paper feed ribbon drive and shuttle motors are driven in control loops containing power MOSFETs voltage and current sen
148. ace 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 130 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 Sometimes the print application program itself is at fault If you have limited communications background experience and the cause of the problem is not readily apparent do the following 1 Print out the printer configuration 2 Obtain a copy of the Device Host Configuration if possible 3 Call your support group for assistance in problem analysis If you cannot obtain support or you have previous 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 Setup Guide Table 6 Common Communications Problems Or Drops characters Prints extra characters Problem Interfa
149. adjustment brackets 14 Install the paper ironer bracket See Figure 36 page 232 a With the flat part of the bracket facing the front of the printer place the two hooks of the upper part of the paper ironer over the platen shafts The left hook of the paper ironer goes between the left platen adjustment bracket and the platen 233 Chapter 7 Section Replacement Procedures For the right side of the platen a washer goes on both sides of the paper ironer hook and the hook goes to the left of the right platen adjustment bracket See Figure 36 page 232 b Install and torque three screws to 20 2 inch pounds 2 26 0 23 Nem 15 Push the platen to the left 16 Install the forms thickness lever onto the right side platen shaft pressing the interlock switch out of the way as the lever slides past it Tighten the 7 64 inch setscrew See Figure 51 page 276 Open and close the forms thickness lever to make sure the setscrew does not touch the right ribbon guide 17 Install the platen shaft pulley with the 7 64 inch setscrew facing up and tighten the setscrew Open and close the forms thickness lever and check that the platen pulley setscrew does not hit the left ribbon guide 18 Install but do not adjust the platen open belt and platen open motor pulley page 189 19 Install the paper ironer with the black tape towards the rear of the printer page 230 20 Install the shuttle frame assembly page 242 21
150. ads PSC Machine Microcode scroll down to the 6400 machine type and click on ICON Netscape will open the Code download site Find the code you need in the list move your mouse pointer so it points to the icon of the needed file and double click with the left mouse button At the prompt Unknown File Type click once on the Save File button At the Save As window point to the down arrow just to the right of the Save In pane and select the folder the directory for example the 6400 folder in which to save the file After you select the folder to receive the file verify that the File name window has the the correct name then click on the Save button The file will download to the directory you requested You can now load flash memory page 176 175 Chapter 6 Loading Flash Memory Loading Flash Memory Emulation and operating system software are loaded into flash memory at the factory but you will install software in the following situations The customer needs to upgrade printer software The customer needs different emulation software You have replaced the controller board You have added or replaced a flash memory SIMM Emulation and operating system software are stored as a compressed file The file is executable you will expand it and copy it into printer flash memory with a single command DANGER 4 Do not connect or disconnect any communications port teleport attach
151. ain If the message appears replace the CMX controller board Record the message and return it with defective CMX board 111 STACK UNDERFLOW SEE USER S GUIDE 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 112 UNDEFINED OPCODE SEE USER S GUIDE 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 113 PROTECTED INSTRUCTION SEE USER S GUIDE Protected Instruction 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 114 ILLEGAL OPERAND ACCESS SEE USER S GUIDE Illegal Operand Accessed 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 t
152. and unplug the printer power cord before proceeding lt 4 gt Do not connect or disconnect any communication port teleport attachment connector or power cord during an electrical storm lt 5 gt Power off the printer and disconnect the power cord before connecting or disconnecting any communication port teleport or attachment cable connector Use standard fault isolation techniques to troubleshoot malfunctions that are not indicated by display messages These techniques are summarized below 1 Ask the operator to describe the problem 2 Verify the fault by running a diagnostic printer test or by replicating conditions reported by the user 3 Look for a match in the General Symptom List that begins on page 110 If you find a match go to the troubleshooting procedure and follow the numbered instructions 4 Ifyou do not find the symptom in 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 59 IMPORTANT Do not attempt field repairs of electronic components or assemblies Replace a malfunctioning electronic assembly with an operational spare Most electronic problems are corrected by replacing the printed circuit board assembly sensor or cable that causes the fault indicat
153. ansion Board page 297 SureStak Power Stacker PCBA Cable Routing Cabinet 299 Cabinet Model Mechanism page 300 Pedestal Model tette TTA E AR page 301 Pedestal Model Mechanism Base Cable Assemblies Gentronics i e eee dui veg page 303 Centronics Dataproducts 5V Remote page 305 Twinax page 306 AC In Power page 307 AG Power 308 Card Cage page 309 Control Panel eant venas page 310 Exhaust Fare ete ete A teretes tetas page 311 Hammer Bank page 312 Hammer Bank page 313 La peepee page 314 Ribbon Guide 315 Ribbon Motor Extension page 316 287 page 289 page 290 page 291 page 292 page 296 page 298 page 302 page 304 Appendix A Circuit Board And Cable Pinouts Shuttle Motor Drive page 317 Power Stacker Cables Frame Cable Pow
154. are the printer for maintenance page 152 2 Cabinet Model Remove the paper guide assembly page 229 Pedestal Model Remove the top cover assembly page 204 3 Disconnect output connector P101 from the controller board and AC input connector P1 from the power supply board 4 Loosen three captive screws securing the power supply board to the rear wall of the card cage See page 264 Figure 47 item 15 5 Carefully disengage the power supply board from the three standoffs on the rear wall of the card cage 6 Remove the power supply board from the card cage Installation 1 Position the power supply board over the three standoffs on the rear wall of the card cage and gently push the board until it engages fully on the standoffs 2 Install three screws securing the power supply board to the rear wall of the card cage See page 264 Figure 47 item 15 3 Connect output connector P101 to the controller board and AC input connector P1 to the power supply board 4 Cabinet Model Install the paper guide assembly page 229 Pedestal Model Install the top cover assembly page 204 5 Return the printer to normal operation page 153 192 Circuit Breaker Circuit Breaker Removal 1 Prepare the printer for maintenance page 152 2 Open the printer cover 3 Remove the card cage fan page 209 4 Disconnect the four circuit breaker electrical leads Cabinet Model See Figure 53 page 280 Pedestal M
155. ask 1000 Models 010 P10 24H8858 Ribbon Mask 1500 Model 015 3 Ref Ribbon Mask Clamp Plate 3 4 Ref Screw Torx T 10 18 12 for hammer bank cover 6 for ribbon mask 5 24H8925 Shuttle Frame Assembly 500 Models 050 P50 24H8927 Shuttle Frame Assembly 1000 Models 010 P10 24H8929 Shuttle Frame Assembly 1500 Model 015 24L5207 Shuttle Frame Assembly Hanzi Models C05 C5P 24H8931 Hammer Spring Field Kit 500 Models 050 P50 24H8932 Hammer Spring Field Kit 1000 Models 010 P10 24H8933 Hammer Spring Field Kit 1500 Model 015 24L5209 Hammer Spring Field Kit Hanzi Models C05 C5P 6 90H3268 Power Supply PCBA 7 Ref P101 Cable Connector 8 Ref Cable Assy AC In Power Supply Part of Field Kit AC Assy 14H5289 9 90H3271 Controller Board V5 5 40 MHz Models 050 P50 010 P10 014 015 C05 C5P 10 Ref Motor Sensor Left Cable Assembly Housing Connector Kit 14H5288 11 Ref Hammer Bank Logic Cable Assembly 12 Ref Shuttle Motor Cable Assembly 13 Ref Hammer Bank Power Cable Assy 14 Ref Motor Sensor Right Cable Assembly Housing Connector Kit 14H5288 15 14H5287 Centronics Cable Assembly 14H5522 Centronics Dataproducts Adapter Optional cable assembly 16 Ref Control Panel Cable Assembly 17 14H5211 Clamp Shaft Receiving 18 Ref Screw Captive Power Supply 3 269 Chapter 7 Section II Illustrated Parts Lists nem Description Notes No Order No 19 Ref SIMM Flash Memory See also page 217 20 Ref SIMM DRAM
156. at will shut down and latch off the 48 V and 8 5 V supplies unless it is pulled up to 5V with a 1KQ resistor This resistor is mounted on the controller board and may be pulled down or disconnected by software or internal cable interlocks The 5 V output will remain stable for reporting and latching the fault condition The return for this signal is the 5 V return In addition this shutdown circuit discharges and latches the 48 V down to a level lower than 15 V in less than 200 milliseconds and requires recycling of the circuit breaker On Off switch to reset the latch Loss of 48 V is seen by the EC and reported as a fault 57 Chapter 4 Graphics Graphics The Code V programming language a QMS graphics emulation and the IGP programming language a Printronix IGP emulation are options that install in flash memory on the CMX controller board These programming languages simplify the job of creating forms bar codes logos expanded characters and other graphics These languages enable the printer to print sideways upside down and to make forms combining graphics alphanumeric data and bar codes all in a single pass Documents explaining configuration operation and programming are included with each option 58 5 Troubleshooting Introduction This chapter lists fault messages and symptoms and provides procedures for troubleshooting printer malfunctions Always have the Operator s Guide and the Setup Guide
157. aten Flex Circuits Motor Shuttle t Assy Paper Motion Paper Feed Detector Terminator Board Motor Shuttle Motor Platen Open Paper Out Detector MPU Switch Hammer Bank Board Left Ribbon Guide Shuttle Assembly Left Ribbon 1 Ripbon Figure 15 Functional Elements of the Printer 43 Chapter 4 Operator Panel Operator Panel The operator communicates with the printer by pressing keys on the operator panel The keys are momentary contact switches The operator panel processes and sends key closure information to the controller board and displays information from the controller on the LCD A status indicator next to the LCD also conveys printer status information to the user The LCD status indicator and keys are mounted on a printed circuit board assembly enclosed in a protective housing Figure 16 Operator Panel Functional Overview 44 Printer Electronics CMX Controller Board The heart of the printer is the CMX controller board which monitors and directs all printer functions The controller board receives and processes all data from the host computer builds the printable images controls all motors and drives the hammer springs Except for the power supply and final hammer drive circuits all logic and drive circuitry for the printer are contained on the controller board The CMX controller board consists of two functional units the Data Cont
158. ator Panel Assembly Pedestal Model 228 Paper Guide 2 229 ER d E T 230 Paten scene ote enn cu 231 Resistors 235 Ribbon Guide Assembly L R sse 237 RIDDOn3idubz E eee ht eM 238 Shalt Spline deed 239 Shaft SUDpott intente ee La eee EP ado 241 Shuttle Frame 242 Spring EXtENSION Petre tied 244 Switch Assembly Cover 245 Switch Assembly Paper 246 Switch Assembly Platen Interlock 247 Tractor CR ti Si PE IPIE CR ied ates 248 Section 11 Illustrated Parts 0 8 249 Illustrations Of Printer Components 249 Ac Wire Dio eco AUI AANA a 287 Circuit Board And Cable 287 B Printer 327 Ribbon Specifications 1 327 Paper SpecificatiOris n etie pe ef e eie etes 328 Printer Dimensions 329 Environmental Characterist
159. ax interface are covered in the Coax Twinax Multi Platform Interface Option Installation and Operation Guide Form No S246 0149 Installation configuration and troubleshooting of the Network Print Server are covered in the following documents Network Print Server Ethernet Administrator s Guide Form No S246 01 1 1 Network Print Server Token Ring Administrator s Guide Form No S246 0112 e Network Print Server Technical Reference Manual is included on diskette that comes with the Network Print Server This softcopy document is in Adobe Acrobat Reader format Installation configuration and troubleshooting of the internal Network Interface Card are covered in two manuals e 10Base2 and 10Base T cards Ethernet Interface User s Manual Form No S246 0153 e 10 100Base T card Ethernet Interface User s Manual Form No S246 0154 27 Chapter 2 Installing And Configuring The IBM 6400 Printer 28 3 Preventive Maintenance Cleaning The Printer Aside from normal replenishment of paper and ribbons the only preventive maintenance required for the printer is periodic cleaning Because operating conditions vary widely the user must determine how often to clean the printer There is no guarantee that the user will clean the printer regularly however so you should clean the printer whenever you are called to service it DANGER 2 Switch off printer power and unplug the printer
160. binet Model Remove the paper guide assembly page 229 Pedestal Model Remove the top cover assembly page 204 Disconnect the fan cable connector Cabinet Model Figure 52 page 278 Pedestal Model Figure 46 page 262 Cabinet Model Remove the two fan mounting screws from the bottom of the fan See Figure 52 page 278 item 2 Pedestal Model Remove the four fan mounting screws and nut See Figure 46 page 262 items 1 through 4 Remove the card cage fan assembly from the card cage Remove the screw securing the shield to the card cage fan Installation ATTENTION Make sure to install the fan so the label faces toward the inside of the printer Air flow is INTO the card cage 1 2 Reverse steps 2 through 6 of the removal procedure Return the printer to normal operation page 153 209 Chapter 7 Section Replacement Procedures Fan Assembly Hammer Bank Removal 1 Prepare the printer for maintenance page 152 2 Remove the shuttle cover assembly page 203 3 Pedestal Model Remove the top cover assembly page 204 4 Trace the hammer bank fan cable assembly back to the controller board connector J107 releasing it from all cable constraints See the cable routing diagrams on page 299 and page 301 5 Disconnect connector P107 from the controller board and remove the fan connector HBF from on the controller board See page 197 6 Remove the two screws securing the fan to the base casting
161. black squares on the display 2 All LEDs off and display blank 3 TESTING HARDWARE PLEASE WAIT appears on display 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 and operator panel is blank and card cage fan is not running page 114 60 Go to Troubleshooting Display YE P Messages page 61 After about 10 Did Power and IML was YES gt seconds did the YES gt Ready LEDs YES successful come after 10 Other fans come on NO NO listed in Table 5 page 110 Go to Printer does not complete IML page 115 Press Stop Press Print YES Configuration YES Go to the Operator Panel Press Start section of Table 5 page Does machine 110 configuration print NO v The Operator Panel is not functioning Table 5 page 110 QOR Printer does not complete IML page 115 Are there black Go to Black squares on YES gt squares onthe YES 5 operator panel display operator panel page 112 NO wv Go to Printer does not complete IML page 115 Troubleshooting Display Messages DANGER 3 Hazardous voltages are present in the printer with the power cord connected to the power source Switch off printer power and unplug the printer power cord before proceeding lt 4 gt Do not connect or disconnect any communication port teleport attachment connector o
162. bles to the CMX controller board stacker and stacker control panel Power on the printer Check that the ONLINE indicator lights on the stacker control panel If the ONLINE indicator does not light replace the stacker control panel Power on the printer Check that the ONLINE indicator lights on the stacker control panel If the ONLINE indicator does not light replace the CMX controller board 116 General Symptom List Table 5 General Symptom List Symptom Corrective Action Stacker chatters at upper or lower limit Check for and remove obstructions preventing elevator movement Check for misaligned stacker rails Adjust the stacker rails if they are not vertical and parallel Move the elevator up and down by hand Check that the limit switches are tripped when elevator reaches top and bottom of travel If necessary gently bend contact arms to adjust limit switches If you cannot adjust a switch that requires adjustment replace it Power on the printer Operate the power stacker Refer to the Operator s Guide While the stacker is operating check that 8 all motors are operating b the paddles are rotating 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 mo
163. bon 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 Legend 1 Screw Skid 2 Ribbon 3 White Nylon Washer 4 Screw Retaining 2 Figure 27 Ribbon Guide Alignment 167 Chapter 6 Splined Shaft Skew Adjustment Splined Shaft Skew Adjustment If lines of print are not parallel with the edge perforations on the paper perform the following adjustment 1 2 3 168 Open the printer cover Loosen the screw 1 securing the adjusting link 2 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 153 C ge Legend 1 Screw 2 Adjusting Link 3 Horizontal Adjustment Knob Figure 28 Splined Shaft Skew Adjustment List Of Adjustments Adjusting The End Of Forms Distance This procedure tests and sets the distance from the page perforation at which an END OF FORMS fault message is triggered This adjustment prevents printing on the platen when the printer runs out of paper The measurement units are dot rows You will use the dot row patterns printed by the END OF FORMS ADJUST self test to verify that this parameter is set correctly NOTE Do this procedure only if a new paper detector switch assembly has been installed or if you are sure that the end of forms a
164. 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 adapter 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 D
165. ce Common Causes Fails to print from host parallel Interface cable defective Or Host Network configuration Prints incorrect characters Printer logic or Terminating Resistors serial Host Printer interface cable pinouts incompatible Host Printer Network configuration Set DTR and RTS both True Interface cable defective Printer logic twinax Interface cable defective Host Printer definition Controller Network configuration Printer logic coax Interface cable defective Controller Network configuration Printer logic Ethernet Interface cable defective Host Printer Network configuration Printer logic 131 Chapter 5 Operator Print Tests Operator Print Tests A set of print tests is included in the configuration menu structure for use as diagnostic tools These are called the Operator Print Tests because they are available to the user You can use these print tests to check the print quality and basic operation of the printer The Operator Print Tests are summarized below NOTE Under the description of some tests is a list of items that may need to 132 be adjusted or replaced if the test produces a bad print pattern The items are listed in the order you should check them simplest items first complex items last Printer Demonstration Prints a sample page showing every print mode font and pitch available in the printer Print Error Log Prints th
166. cedures Shuttle Frame Assembly Removal 1 Prepare the printer for maintenance page 152 2 Remove the shuttle cover assembly page 203 3 Disconnect the MPU cable connector page 272 Figure 49 ATTENTION To prevent electrostatic damage to electronic components wear a properly grounded static wrist strap when handling circuit boards the shuttle frame assembly and any other electronic component 4 Disconnect the shuttle motor cable connector page 272 Figure 49 5 Disconnect the hammer drive and hammer logic cables connectors from the terminator board on the shuttle frame assembly 6 Loosen the side 5 32 inch socket head clamp screws and pull the clamps back and off the guide shaft Do not remove the clamps 7 Loosen the center 5 32 inch socket head screw enough to release the shuttle frame assembly from the base casting 8 Unlock and slide the tractors outward as far as they will go on the tractor support shaft 9 Grasping the support legs cast on both sides of the shuttle motor lift the shuttle frame assembly out of the base casting Lift it slowly and carefully the shuttle frame assembly is heavy 242 Shuttle Frame Assembly Installation 1 Install the hammer bank ribbon mask cover assembly page 200 if it was removed ATTENTION To prevent electrostatic damage to electronic components wear a properly grounded static wrist strap when handling circuit boards the shuttle frame assembly an
167. cessary 9 When the platen gap is correct at both ends of the platen adjust the platen open belt page 156 10 Install the shuttle cover assembly page 203 11 Check the hammer phasing adjustment page 173 12 Return the printer to normal operation page 153 List Of Adjustments NOTE Left side adjustment shown Right side is the same b A gt lt e NL Legend 1 Forms Thickness Lever Feeler Gauge 0 011 inch or 0 28 mm Hammer Bank Cover Ribbon Mask Set Screw 3 32 inch hex 2 SHE Figure 25 Platen Gap Adjustment 163 Chapter 6 Platen Open Motor Pulley Alignment Platen Open Motor Pulley Alignment To make this adjustment follow these steps 1 Prepare the printer for maintenance page 152 2 Cabinet Model Go to step 3 Pedestal Model Remove the top cover assembly page 204 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 torque the 1 16 inch set screw 2 to 9 2 inch pounds 1 02 0 23 Nem Check the platen open belt tension page 156 Adjust if necessary Snap the platen open belt cover 1 into the slots in the side plate Cabinet Model Go to step 9 Pedestal Model Install the top cover assembly page 204 9 Return the printer to normal o
168. cing each illustration is a list of the illustrated parts and their part numbers Section II begins on page 249 IMPORTANT The components specified in this chapter are field replaceable units FRUs FRUs must be repaired at the factory Do not attempt field repair of these items 185 Chapter 7 Section I Replacement Procedures Section I Replacement Procedures 186 This section contains removal installation procedures for components that are replaceable at the field service maintenance level These procedures are listed below IMPORTANT Do not attempt field repairs of electronic components or assemblies Replace a malfunctioning electronic assembly with an operational spare Most electronic problems are corrected by replacing the circuit board sensor or cable that causes the fault indication The same is true of failures traced to the hammer bank coils and electronics you must replace the entire shuttle frame assembly It is not field repairable Hammer spring assemblies are the only replaceable components of the shuttle frame assembly List Of Procedures Belt Paper Feed 0 page 188 Belt POR at page 189 Circuit Board Controller sse page 190 Circuit Board Power Supply page 192 Circuit Breaker irn sete doe dede es page 193 Coax Twinax Multi Pla
169. cloth wipe the hammer spring mounting surface on the hammer bank Make sure the cloth does not leave lint on the hammer bank ATTENTION Hammer springs and hammer tips are fragile Do not touch the hammer springs or tips Handle hammer springs by the thick mounting base only Apply pressure only to the mounting base NOTE Replace a hammer spring assembly only if there is visible damage or you see broken parts in the assembly 2 Handling it by the mounting base only remove the new hammer spring assembly and mounting screws from the box 3 Handling the hammer spring assembly by the mounting base only carefully position the new hammer spring assembly onto the hammer bank mounting pins and press it into position with the flat end of the stick supplied in the hammer spring replacement kit See Figure 34 page 214 4 Install the mounting screws from the replacement kit Using a Torx T 10 bit adapter torque each screw to 14 inch pounds 1 58 Nem Tighten the center screw s first See Figure 34 page 214 Install the hammer bank cover assembly page 200 Install the shuttle frame assembly page 242 Install the ribbon and load paper ATTENTION Do not attempt to adjust or tweak hammer springs 8 Run a Customer Engineer Test and check print quality page 134 a If print quality is acceptable return the printer to normal operation page 153 b If print quality is still degraded replace the shuttle frame assembly
170. ctor P107 from the CMX controller board Check continuity of the platen interlock switch cable from P107 PLO to the switch Replace the platen interlock switch assembly if it fails the continuity test Refer to Appendix A Switch Assembly Platen Interlock Check that the platen interlock switch is not loose Check and adjust the platen open belt Replace the belt if it is damaged 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 Disconnect connector P106 from the CMX controller board Check the resistance of connector P106 PLAT M Refer to the Main Wire Harness Test Tables on page 306 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 77 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel Message Explanation Corrective Action 058 SHUTTLE JAM SEE USER S GUIDE The shuttle is not moving or is moving at the wrong speed 1 Check the forms thickness lever if it is set too tight
171. d any other electronic component Do not remove the grease from the shaft of the replacement shuttle frame assembly The shuttle shaft is aluminum and the clamped ends of the shaft must be greased to prevent galling 2 Holding the shuttle frame assembly by the support legs cast on both sides of the shuttle motor set it into the base casting Use both hands the shuttle frame assembly is heavy page 264 Figure 47 3 Align the center 5 32 inch socket head screw in the base casting and hand turn the screw until only two or three threads have started 4 Pullthe shuttle frame assembly toward the front of the printer and hold it in this position while you do step the next step IMPORTANT Do not over tighten the shuttle frame assembly hold down screws 5 Slide the side clamps over the guide shaft and torque the 5 32 inch socket head clamp screws to 20 2 inch pounds 2 26 0 23 Nem 6 Torque the center captive 5 32 inch socket head screw to 20 2 inch pounds 2 26 0 23 Nem 7 Connect the hammer drive and hammer logic cable connectors to the terminator board on the shuttle frame assembly Connect the shuttle motor cable connector Route the MPU cable under the extension spring and connect the MPU cable connector See Figure 49 page 272 item 4 Make sure the MPU cable does not touch the extension spring after it is connected 10 If the shuttle frame assembly is a new or refurbished unit adjust the platen gap page 16
172. d out of printer after Cancel key has been pressed No action required 82 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action 080 POWER SUPPLY HOT The printer has sensor circuits that sample the operating temperature of key components of the power supply When higher than normal temperatures are sensed print speed is automatically reduced If the printer runs at reduced speed for an extended period of time the POWER SUPPLY HOT message is sent to the LCD and printing stops allowing printer components to cool down Pressing the Start key resumes the print task Check the operating environment A severe environment is one with an ambient temperature at or above above 40 Celsius 104 Fahrenheit or is dirty enough to create blockage of the cabinet fan vents The printer must never be run at ambienttemperatures greater than 40 Celsius 104 Fahrenheit If the printer is located in such an 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 running look for very dense graphics and layouts Advise the user to run jobs in smaller batches Power off the printer Remove the paper guide assembly or pedestal top cover Check that the power supply guard air deflector is correctly posi
173. de Run Mode is the normal operating state of the Ethernet 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 differently depending on whether the unit IP address is configured STAT Rate Indicates Flashes On once per second Normal Mode IP address configured Flashes On 2 5 times per second Monitor Mode IP address not configured Flashes Off 2 5 times per second Monitor Mode or Download Mode IP address not configured Flashes Off once per 2 seconds Download Mode IP address configured Setting both DIP Switch 1 and DIP Switch 2 to the ON down position will clear ALL passwords specifically passwords in the html webpage DIP Switch 1 EEPROM Enable Default position is OFF up Setting this switch to the ON down position and powering the printer off then on resets the Ethernet Interface to the factory default settings This also erases any previously configured IP address Before reconfiguring the unit DIP switch 1 must be set back to the OFF up position otherwise it will lose its configuration through another power on off cycle DIP Switch 2 Default IP Default position is OFF up Setting this switch to the ON down position and powering the printer off then on resets a previously configured IP address to the factory default setting no IP address However this does not cause the unit to lo
174. djustment is incorrect An END OF FORMS triggering distance of 1 or 2 dot rows from the perforation is acceptable 5 to 7 dot rows off indicates adjustment is required Also although it is not required it is advisable to test the End of Forms distance with 6 part paper in order to verify correct printing with multi part forms The procedure below describes how to run the END OF FORMS ADJUST printer test and modify the END OF FORMS ADJUSTMENT VALUE 1 2 Power on the printer Load paper and set the top of form Make sure the forms thickness lever is closed Open the cabinet front door On the sheet of paper just below the paper entrance slot tear a four inch square on the left side immediately below the perforation See Figure 29 This creates a hole that will trigger an END OF FORMS condition but allows printing to the right of the hole which would normally be on the platen Tear a four inch square in the manner described above on every third sheet until you have made 3 or 4 holes If the printer is in READY mode press Stop to put it into NOT READY mode Press Scroll Scroll to unlock the Enter key Press Scroll Scroll Return Enter to enter the CE Tests menu Press all four keys at the same time 169 Chapter 6 Adjusting End Of Forms Distance Figure 29 Paper Preparation for Paper Out Adjustment Test List Of Adjustments The display will show SERVICE PRINTER MECHANISM TESTS th
175. ds poorly 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 Power off the printer Remove paper Inspect the paper feed path for obstructions that could snag paper Clear paper feed path of any obstructions Inspect the tractors and tractor door springs for damage or excessive wear If either tractor is damaged or excessively worn replace both tractor assemblies 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 Check and adjust the paper feed timing belt Replace the belt if it is damaged Check and adjust the platen gap Remove the paper guide assembly or pedestal top cover Make sure connector P107 PAPR M is fully seated in connector J107 on the CMX controller board Power on the printer Load paper Press Form Feed 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 Power on the printer Press Form Feed 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 Printer does not print self tests Power off the printer Remove the paper guide assembly or pedestal top cover Disconnect the control panel
176. e Forms Thickness Pointer Figure 4 Mechanical Controls All Models 25 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 Item Part No 6400 Line Matrix Printer Configuration Utility Disk 63H7379 1 30 Inch pound Torque Screwdriver 16F1661 ESD Wrist Strap 6405959 Feeler Gauge 010 inch Feeler Gauge 011 inch Feeler Gauge 040 inch Force Gauge 20 Ib 25F9687 Grip Ring Pliers 9900317 Lubricant Bearing IBM 20 117397 DIP Module Extracting Tool 9900764 Nut Driver 1 4 inch Nut Driver 5 16 inch Open End Wrench 7 32 inch 1650843 Open End Wrench 5 16 inch 9900005 PLCC Module Pick Extraction Tool 73G5523 PLCC Module Plier Extraction Tool 10G3902 Screwdriver Phillips 1 73G5362 Screwdriver Phillips 2 73G5363 Spring Hook Heavy Duty Tie Wraps 75X5972 Torque Screwdriver Adapter 39F 8449 Torque Screwdriver Hex Adapter 3 32 inch 39F8451 Torque Screwdriver Hex Adapter 5 32 inch 39F8450 Torque Screwdriver Hex Adapter 3 16 inch 39F8455 Torque Screwdriver Hex Adapter 5 64 inch 16F1663 Torx T 10 Bit 83F2834 26 p Installation Installing And Configuring The IBM 6400 Printer Installation and configuration of the printer are covered in the 6400 Line Matrix Printer Set Up Guide Form 5544 5640 Installation operation and replacement parts for the optional coax twin
177. e first menu item Press Enter to enter the mechanism tests menu Press Scroll or Scroll until PRINTER MECHANISM TESTS END OF FORMS ADJUST is on the display This test will print a vertical comb pattern at around column 70 each long bar separated by three shorter bars An enlarged example of the comb pattern is shown below Press Enter until the END OF FORMS ADJUST test starts The comb pattern will print until the display shows 001 END OF FORMS LOAD FORMS and if enabled the audible alarm sounds If the alarm sounds press Stop to silence it Remove the paper from the tractors and examine the area of the page perforation If the alarm sounds when you open the platen press Stop to silence it If a bar from the comb pattern just meets the perforation the end of forms adjustment distance is correct A bar exactly on perforation is ideal 1 or 2 dot rows off is OK 5 to 7 dot rows off is too much Unless you wish to restart the procedure with 6 part paper you may stop the test here and skip to step 22 See the note at the beginning of this procedure If the comb pattern stopped short of the perforation or printed beyond the perforation go to step 12 Measure how short or long the comb pattern printed by counting the number of dot rows needed to reach the perforation or the number of dot rows that printed beyond the perforation NOTE You can use the long bars to count the dot rows quickly
178. e 119 If the limit switches are OK go to the next step Disable the power stacker unit under the Printer Control menu Refer to the User s Guide If the message occurs replace the CMX controller board and download new function code 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 70 page 348 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 If the cables are okay replace the stacker motors 70 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action 021 RECEIVE BUFFER OVERRUN VERIFY CONFIGURATION The print buffer has overflowed on a serial interface The printed output may contain random asterisk characters 1 a configuration printout Verify that the printer matches the host serial interface configuration settings for Data Protocol Baud Rate Data Bits Stop Bits Parity Data Terminal Ready and Request to Send Set printer serial interface parameters to match those of the host Send a print job to the printer If the message appears go to Communications Failures page 131 022 UNIT ADDRESS NOT RECEIVED CHECK PRINTER ADDRESS Poll timeout on the twinax interface indicating the unit address is not recogni
179. e 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 31 Repeat step 3 for the P106 connector 5 Cabinet Model Install the paper guide assembly page 229 Pedestal Model Install the top cover assembly page 204 6 Return the printer to normal operation page 153 Installation 1 Prepare the printer for maintenance page 152 2 Cabinet Model Remove the paper guide assembly page 229 Pedestal Model Remove the top cover assembly page 204 3 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 31 Repeat step 3 for the P106 connector Cabinet Model Install the paper guide assembly page 229 Pedestal Model Install the top cover assembly page 204 6 Return the printer to normal operation page 153 198 Connector Stiffening Clips Stiffening Clip Connector Shell Figure 31 Connector Stiffening Clips 199 Chapter 7 Section Replacement Procedures Cover Assembly Hammer Bank Ribbon Mask Removal 1 Prepare the printer for maintenance page 152 Remove the shuttle frame assembly page 242 Early models Lift the thick plate of the hammer bank cover assembly at one end and peel the cover away from hammer bank magnets See Fi
180. e contents of the error log The error log automatically records certain unit check conditions in a buffer in NVRAM that stores up to 50 messages The most recent message is stored at the top of the list the oldest message at the bottom of the list If more than 50 messages occur before the log is cleared the oldest messages are deleted so that the log never contains more than 50 messages Ripple Print A sliding alphanumeric pattern useful for identifying missing or malformed characters improper vertical alignment or vertical compression Hammer bank cover Hammer spring Shuttle frame assembly All E s A pattern of all uppercase letter E s useful for identifying missing characters misplaced dots smeared characters improper phasing or light dark character variations Ribbon Splined shaft skew adjustment Hammer bank cover MPU sensor Hammer springs Hammer coils shuttle frame assembly All H s A pattern of all uppercase letter H s useful for detecting missing characters or dots smeared characters or improper phasing Ribbon Hammer bank cover MPU sensor Hammer springs Hammer coils shuttle frame assembly All E s FF 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 Hammer bank cover Power supply board Paper motion sensor or cable Paper feed belt or motor Splined shaft bearing
181. e to six sheets thick For reverse paper feeding the platen open motor opens and closes the platen via a toothed belt Opening the platen prevents paper jams when paper direction is reversed that is paper is moved downwards in order to view the print area set top of form or allow applications to overprint forms Paper is positioned horizontally using the tractors and the horizontal adjustment knob Each tractor engages paper perforations with six sprocket pins and locks in place with a friction lock The horizontal adjustment knob allows vernier positioning of the left print margin Paper can be positioned vertically by hand with the vertical adjustment knob 41 Chapter 4 Printing Mechanism Ribbon Transport System m Hub e 2 Left Ribbon Guide 2 2 Not Shown Hub Locking Latch lt lt Ribbon Spool Ribbon Motors 7 Right Ribbon Guide Ribbon Figure 14 Ribbon Transport System An inked ribbon winds and unwinds continuously on a pair of spools latched to hubs that are driven by the ribbon motors The hubs and spools are offset vertically to equalize ribbon wear and prolong ribbon life The ribbon motors operate only when the shuttle assembly is moving Ribbon motion reverses when a metal strip at either end of the ribbon crosses the left or right ribbon guide completing a circuit that causes both motors to reverse direction Constant ribbon tension is maintained by controlling each motor with a dr
182. efore proceeding lt 4 gt Do not connect or disconnect any communication port teleport attachment connector or power cord during an electrical storm lt 5 gt Power off the printer and disconnect the power cord before connecting or disconnecting a communication port teleport or attachment cable connector 1 Have the operator take the printer off line 2 Power off the printer 3 Unplug the printer power cord from the customer s power outlet Inspect Mechanical Parts Top Cover And Cabinet Doors 1 Inspect the top cover a Open the top cover On cabinet models make sure the gas spring assembly holds the cover up in the open position Make sure the window is not cracked or broken Make sure the seal around the top cover is not cracked or broken Make sure there are no exposed or sharp edges Make sure the wireform paper path is undamaged 5 Make sure the electrostatic discharge ESD fingers are not loose or damaged Make sure they touch the contact strips on the frame when the cover is closed g Close the top cover Make sure the operator panel is centered in the opening of the cover 2 Oncabinet models inspect the front and rear cabinet doors a Make sure the seals and magnetic strips are not loose or damaged 342 Make sure the restraining cable is attached and unbroken Make sure there are no exposed or sharp edges Open the rear cabinet door and inspect the lower rear paper path
183. el upward until the plastic tab at the upper rear of the panel locks into the mounting plate 3 Position the operator panel and plate on the bracket and install the four screws finger tight See Figure 42 page 254 4 Slowly lower the printer cover and align the operator panel in the cover cutout Open the printer cover and tighten the panel plate screws 5 Return the printer to normal operation page 153 227 Chapter 7 Section Replacement Procedures Operator Panel Assembly Pedestal Model Removal 1 Prepare the printer for maintenance page 152 2 Open the printer cover 3 Tilt the operator panel toward the front of the printer 4 Disconnect the phone style cable connector at the rear of the operator panel 5 Press down on the plastic tab at the upper rear of the panel and slide the operator panel downward on the mounting plate until the tabs on the panel housing slide out of the cutouts Installation 1 Tilt the operator panel mounting plate toward the front of the printer 2 Position the operator panel over the cutouts in the mounting plate and slide the panel upward until the plastic tab at the upper rear of the panel locks into the mounting plate 3 Connect the phone style operator panel cable to the bottom of the operator panel Close the printer cover Return the printer to normal operation page 153 228 Paper Guide Assembly Paper Guide Assembly This procedure applies only to cabinet
184. embly if it fails continuity test Power up the printer Run a Shuttle Slow or Shuttle Fast test If the shuttle does not move replace the shuttle frame assembly Power up the printer Run a Shuttle Slow or Shuttle Fast test If the shuttle does not move replace the power supply board Power up the printer Run a Shuttle Slow or Shuttle Fast test If the shuttle does not move replace the CMX controller board 129 Chapter 5 Troubleshooting Other Symptoms Table 5 General Symptom List Symptom Corrective Action Shuttle is noisy Check the bolts securing the mechanism 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 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 Repl
185. emove the top cover assembly page 204 Locate the terminating resistor packs See Figure 38 page 236 Using a chip puller remove the packs Installation ATTENTION To prevent electrostatic damage to electronic components wear a properly grounded static wrist strap when handling circuit boards the shuttle frame assembly and any other electronic component 1 Using a chip installation tool install the resistor packs in the correct Socket See Figure 38 page 236 2 Cabinet Model Install the paper guide assembly page 229 Pedestal Model Install the top cover assembly page 204 3 Return the printer to normal operation page 153 235 Chapter 7 Section Replacement Procedures CMX Controller Board 7 4201 O 0 Dl 15 7 25 Su O 000 4 D NER 00000 0 00 0000 p iH ooo 0 n un D 1 n m L EDS 00 J110 n 0 Loss 4102 is J17 009 00 oo nn oA 0 U 224107 1 RP1 Default 470 Ohm
186. eplacement 189 platen open tension adjustment 156 Block diagram operator panel 44 Boards layouts connections and pinouts 287 BOOT DIAGNOSTICS 100 Cabinet doors reversing 206 Cable assembly interconnections 287 part numbers 287 routing diagrams 287 shell and cable replacement 195 198 Cable connectors and shells replacement 195 198 Call start of 60 Card cage fan assembly replacement 209 CE tests 134 Character Set U S ASCII 142 Checks service customer s power source 345 power on off verification 345 print interlock 345 print mechanism 343 printer power cable 345 Circuit board replacement controller 190 power supply 192 Circuit breaker replacement 193 Cleaning the printer 29 CLEARING PROGRAM FROM FLASH 100 178 180 CMX controller board See Controller board 45 Coax twinax expansion board replacement 215 Coax twinax multi platform interface replacement 194 Coil temperature adjustment 181 Communications failures 131 Configuration 27 Control panel See Operator panel 227 Controller board principles of operation 45 Controller circuit board replacement 190 Controls and indicators 20 mechanical all models 24 printing conventions 18 Conversion metric measurement 337 Cords and Adapters 355 Cores Noise Suppression 365 Cover assembly hammer bank ribbon mask replacement 200 shuttle 203 top pedestal model 204 Customer Engineer CE tests 134 C
187. epping 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 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 P05 DIAGNOSTIC TEST 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 p
188. er page 318 Logic Cable Power page 319 Power Cable Power Stacker page 320 Vertical Rail Cable Power Stacker page 321 Fan Assembly Hammer Bank page 322 Magnetic Pickup MPU Assembly een page 323 Switch Assemblies Switch Assembly Paper Detector page 324 Switch Assembly Platen page 325 Switch Assembly Cover Open page 326 288 Interconnection Diagram Std amd gt s J102 uodx3 Jewod OC 10 tc e gt N 5 a gt 72 gt n a T wo e 5 n I e 5 J106 MSL Appendix A Circuit Board And Cable Pinouts Power Distribution Diagram uey yueg
189. er Cathode Card Cage Card Cage Fan Customer Engineer Change Circuit Clock Cover Open Collector Communication Controller Command Manufacturer s designation of the controller board Connector Connection Characters Per Inch Carriage Return Coaxial Twinaxial Control Clear to Send Current Cover Open Switch 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 Dot Plucker Memory Controller Data Processing Unit Dynamic Random Access Memory Drive or Driver Driver DSR DTR EC EEPROM EHF EL EMI EMIT EPROM ERR ESD EX EXH EXF EXP EXPND FD FF FIFO FLT FLTR FP FTIC GND HB HBA HBF HBL HBP HBR HD HDIC HDPH Data Set Ready Data Terminal Ready Engine Controller a functional unit of the CMX board Electrically Erasable Programmable Read Only Memory Exhaust Fan Elevator motor Power 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 Operator 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
190. er If the message appears press Stop Power off the printer Remove the paper guide assembly 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 on page 291 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 Power on the printer If the message appears replace the CMX controller board Record the message and return it with the defective board 84 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action 084 POWER SUPPLY 48V FAILED 48 Volt Power Failed Internal power failure 1 Power off the printer Remove the paper guide assembly or pedestal top cover Check that power supply connector P101 is fully seated in connector J101 on the CMX controller board If the printer has the coax twinax expansion board check the adapter connection to the CMX controller board Make sure the 60 pin expansion adapter is correctly seated between the CMX controller board and the coax twinax expansion 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 Po
191. error and reports the error Power off the printer Disconnect the AC power cord from the printer Check the twinax host data cable and twinax cable connection at the CT board Reseat the twinax host data cable connection and the twinax I O cable connection at the CT board Disconnect the twinax auto termination cable from the printer Test the cable for the resistances shown on page 306 If resistances are not correct replace the twinax auto termination cable Connect the power cord to the printer Power on the printer Send a print job to the printer If the message appears replace the twinax cable Send a print job to the printer If the message appears go to Communications Failures page 131 67 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel Message Explanation Corrective Action 017 STACKER JAM CHECK STACKER This message is triggered if there is paper inside the throat of the stacker elevator but the elevator is not moving Open the cabinet rear door and check for obstructions preventing elevator movement Remove any obstructions 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 detec
192. es 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 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 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 and single st
193. es earlier limit switches 40 170870 901 Limit Switch Assembly Replacement switch if item 38 is installed 24H8974 Control Panel Assembly Figure 78 page 388 Ref Rail Cable Power Stacker See page 321 24H8975 Power Cable Power Stacker See page 320 24H8976 Logic Cable Power Stacker See page 319 Ref Frame Cable Power Stacker See page 318 24H8962 Rear Door Extended Power Stacker Not illustrated 24H8963 RE Ship Kit Printer w Power Stacker Not illustrated 400 From page 399 15 15 See page 403 9d 2 47 4 405 407 Figure 90 Stacker Detail Motors Rollers and Paddles 401 Appendix J Illustrated Parts Breakdown jo Part No Description Notes 15 24H8969 Motor 36 24H9004 Stacker Hardware Kit Kit not illustrated 40 24H8978 Anti Static Brush 45 Ref Shear Grommet Part of item 36 46 Ref Cap Nut Part of item 36 47 24H9005 Shaft Drive Roller 48 24H9006 Spacer Drive Roller 49 Ref Bearing Flanged Part of item 36 50 Ref Bearing Part of item 36 51 24H9003 Collar Clamp 52 Ref Collar Setscrew Part of item 36 53 24H8997 Support Shaft 54 01P4698 Fence Wireform 55 24H8981 Extension Spring 60 24H8982 Idler Roller Five on early models 65 24H8983 Paddle Power Stacker 402 From page 401 PS 85 JD N 75 Figure 91 Stacker Detail Rollers 403 Appendix J Illustrated Parts Breakdown jo Part No Description Notes 36 24H900
194. ew 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 82 4 Firmly gripping the spring and drum remove the screw securing the spring to the vertical rail See Figure 82 1 E i pee s E 2 4 6 Legend 1 Screw 2 Washer 3 Constant Force Spring 4 Large Washer 5 Spacer 6 Drum 7 Shoulder Screw 0 Figure 82 Removing the Constant Force Spring 392 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 83 6 While holding the drum tightly continue to curl the spring until it is completely unwound from the drum See Figure 83 7 Toinstall a new constant force spring reverse the steps of this procedure Legend 1 Spring 2 Drum Figure 83 Removing the Constant Force Spring from the Drum 393 Appendix J Replacing The Timing Belts Replacing The Timing Belts 1 Remove the stacker assembly from the printer See page 375 2 Raise the elevator assembly to its highest position and secure it to the vertical rails using tie wraps or string See Figure 81 page 391 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 84 Go to step 6
195. ffline not in communication with host No action required OPERATOR MENU lt menu item gt Non error status message No action required OPERATOR MENU LOCKED Non error status message No action required unless you want to unlock the Enter key 103 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel Message Explanation Corrective Action OPERATOR MENU UNLOCKED Non error status message No action required unless you want to lock the Enter key PA1 SELECTED Attach status message No action required PA2 SELECTED Attach status message No action required P05 DIAGNOSTIC TEST PASSED Non error status message the printer passed its memory and hardware initialization tests No action required P17 SECURITY Security code of the 1 Remove the paper guide assembly or DRAM AT ADDRESS hex defective memory location VIOLATION PAL on the CMX pedestal top cover Check that the controller board does security PAL is correctly installed See not match the code of Figure 35 page 220 Install correct PAL the firmware on the for the customer s emulations with the CMX controller board notched end toward the flash and DRAM SIMM sockets 2 Run a print test If the message appears replace the CMX controller board Record the message and return it with the defective board P60 ERROR The printe
196. ge and lift the shuttle cover assembly out of the printer Installation 1 Place the shuttle cover assembly in the printer Tilt the forward edge of the cover down slightly and work the cover into position page 258 Figure 44 NOTE Make sure the holes in the cover are over the locating pins 2 Tighten the shuttle cover screws page 258 Figure 44 item 2 3 Return the printer to normal operation page 153 203 Chapter 7 Section Replacement Procedures Cover Assembly Top Pedestal Model Removal 1 Prepare the printer for maintenance page 152 Remove the operator panel page 228 Remove five screws and the control panel bracket See Figure 43 page 256 items 3 and 4 4 Loosen the two captive 2 Phillips screws in the lower front corners of the top cover See Figure 43 page 256 item 14 5 Loosen but do not remove the two 2 Phillips hold down screws on the rear of the printer See Figure 43 page 256 item 8 6 Liftthe top cover assembly off the printer base Installation 1 To install the top cover assembly reverse steps 2 through 6 of the removal procedure 2 Return the printer to normal operation page 153 204 Dashpot Dashpot This procedure applies only to cabinet models Removal CAUTION 3 Two persons may be required to do this procedure Prop or hold the top cover securely open while disengaging the dashpot Prepare the printer for maintenance page 152
197. ge appears replace the DRAM 3 Power on the printer If the message appears replace the CMX controller board Record the message and return it with the defective board 100 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action ERROR FLASH DID NOT PROGRAM The printer encountered an error trying to program flash memory 1 Download the program again 2 Ifthe message occurs again replace the flash memory with pre written flash See Table 8 and Table 9 on page 219 and Figure 35 on page 220 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 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 missing or has failed Power off the printer Remove the paper guide assembly or pedestal top cover 1 Check the security PAL at location 054 on the CMX controller board If the PAL is absent install the correct PAL Ifa security PAL is present replace it 2 Power on the printer If the message appears replace the CMX control
198. ge 117 upper or lower limit Stacker does not stack Reported by customer Various causes possible page 118 properly Stacker elevator does Reported by customer Various causes possible page 118 not move Stacker elevator moves Reported by customer Various causes possible page 118 by itself Stacker not operating Reported by customer Same symptom as Printer page 116 374 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 Setup Guide Remove the paper tent See Figure 65 PORN gt Legend 1 Paper Tent Figure 65 Removing the Paper Tent 5 Cut the tie wrap and remove the paper fence See Figure 66 Legend 1 Paper Fence 2 Stacker Base Figure 66 Removing the Paper Fence 375 Appendix J _ Removing The Power Stacker 6 Remove three screws and washers from the stacker control panel See Figure 67 Legend 1 Long Screw 2 Washer 3 Short Screw Figure 67 Removing the Stacker Control Panel 7 Remove four cables from the stacker control panel and remove the stacker control panel See Figure 68 oooooooooooooo ooooooooooooooO 2200000000000 oooooooooooo oooooooooooooo ocooooooooooooo 2 1 Logic Cable P104 2 Power Cable 3 Frame Cable P102 4 Rail Cable P107
199. gure 32 page 202 4 Later models a Using a Torx T 10 driver remove the six screws and three ribbon mask clamp plates securing the ribbon mask to the hammer bank cover Remove the ribbon mask See Figure 32 page 202 NOTE If you are replacing just the ribbon mask simply loosen the six screws until you can slip the ribbon mask off the alignment pins b Usinga Torx T 10 driver remove the 12 screws securing the hammer bank cover to the hammer bank Remove the hammer bank cover See Figure 32 page 202 200 Cover Assembly Hammer Bank Ribbon Mask Installation ATTENTION The hammer bank contains a strong magnet To prevent damage to the hammer tips do not let the hammer bank cover assembly snap into place as the hammer bank magnet attracts it Any impact of the cover against the hammer bank can break hammer tips 1 Early models a With the thick plate facing the hammer bank engage the bottom edge of the hammer bank cover assembly on the alignment pins Engage the round hole first then the oblong hole to ensure that the cover lies flat on the hammer bank Gently lower the hammer bank cover assembly until it lies flush on the hammer bank Check that the hammer bank cover assembly is properly positioned over the alignment pins and hammer tips 2 Later models a Position the hammer bank cover on the alignment pins on the hammer bank Make sure the hammer bank cover is properly positioned over the
200. gure 42 Control Panel and Cabinet Details page 254 Figure 43 Pedestal page 256 Figure 44 Inside Covers Cabinet page 258 Figure 45 Inside Covers and Card Cage Pedestal Model page 260 Figure 46 Card Cage Detail Pedestal page 262 Figure 47 Print Mechanism and Circuit Boards Early Models page 264 Figure 48 Print Mechanism and Circuit Boards Later Models page 268 Figure 49 Magnetic Pickup Unit MPU and Extension Spring page 272 Figure 50 Tractor Shafts page 274 Figure 51 Platen sede ite page 276 Figure 52 Motors Card Cage Fan and Paper Detector Switch page 278 Figure 53 Circuit 2 page 280 Figure 54 Expansion Coax Twinax page 282 Figure 55 Ethernet Interface Assemblies page 284 249 Chapter 7 Section Il Illustrated Parts Lists Figure 40 Top Cover Doors and Casters Cabinet Model 250 Illustrations Of Printer Components bon o Description Notes 1 24H8961 Top Cover Kit Includes mounting hardware 2 5791492 Window Top Cover Not visible in Figure 40 3 14H5567 Wireform Paper Guide Assembly Incl
201. gure 54 IBM Coax Twinax Expansion Board 282 Illustrations Of Printer Components em Description Notes No Order No 1 Ref Screw 2 2 Ref Card Cage 3 24H9011 IBM Coax Twinax Expansion 4 Ref Screw Captive 5 Ref Standoff Hex 3 16 inch M F 813 Lg 6 24H8535 Adapter Expansion Connector 60 pin 7 Ref CMX Controller Board 8 Ref Controller Board Connector J111 283 Chapter 7 Section Il Illustrated Parts Lists Figure 55 Ethernet Interface Assemblies 284 Illustrations Of Printer Components Eni o Description Notes 1 Ref Screw Connector Cover 2 2 Ref Cover Plate Centronics 3 Ref Ferrite Clamp See also Appendix I 4 Ref CMX Controller Board 5 14H5287 Centronics I O Cable Assembly 6 24H8995 Ethernet LAN PCBA 10Base T 7 24H8994 Ethernet LAN PCBA 10Base2 8 02N8315 Ethernet LAN PCBA 10 100Base T 9 Ref Rear of Card Cage 10 Ref Screw 2 285 Chapter 7 _ Section Il Illustrated Parts Lists 286 A Wire Data Circuit Board And Cable Pinouts NOTE Acronyms and signal mnemonics are defined in Appendix C Interconnection Power Distribution Main Wire Harness Test Circuit Board Pinouts Controller CMX arrie vale n Power tere a ee des es tpe ni dg ens Coax Twinax Exp
202. h a clean lint free cloth 11 Clean the shuttle frame assembly as described below Tractors Shuttle Cover Assembly Base Casting Forms Thickness Ribbon Lever Guide 2 NOTE Cabinet model shown Procedure is the same for pedestal model Figure 5 Cleaning Inside the Cabinet or Top Cover 30 Cleaning The Shuttle Frame Assembly Cleaning The Shuttle Frame Assembly 1 Remove the shuttle cover assembly page 203 2 Remove the shuttle frame assembly page 242 3 Remove the paper ironer page 230 CAUTION 2 Over time the upper edge of the paper ironer can become sharp To avoid cutting yourself handle the paper ironer on the sides 4 Wipe the paper ironer with a soft cloth to remove lint ink and paper residue Install the paper ironer page 230 Remove the hammer bank ribbon mask cover assembly page 200 ATTENTION The thin plate ribbon mask of the hammer bank cover assembly is fragile Be careful not to over bend or kink the ribbon mask when handling and cleaning the hammer bank cover assembly 7 Using aclean soft cloth 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 early models ATTENTION Do not use solvents or liquids to clean the hammer tips Clean the hammer tips gently too much pressure can chip hammer tips 8 Using a stiff non
203. h the paper ironer down into the slots until the tabs engage Install the shuttle frame assembly page 242 Return the printer to normal operation page 153 230 Platen Platen Removal 1 Prepare the printer for maintenance page 152 2 Remove the shuttle frame assembly page 242 3 Remove the paper ironer page 230 4 Remove the three 1 4 inch screws securing the paper ironer bracket e 13 14 assembly and remove the assembly See Figure 51 page 276 items 4 through 6 Remove the platen open belt page 189 Remove the platen pulley page 276 Figure 51 item 21 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 Figure 51 page 276 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 Figure 51 page 276 item 15 Remove the right side platen support spring by repeating step 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 Figure 51 page 276 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 ribbo
204. h the printer printing at full paper width IMPORTANT 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 NVRAM If the value is changed when not printing the printer will return to its default phasing value when powered off then back on Install the ribbon Load full width 136 column paper Power on the printer and set top of form Press Stop to put the printer into NOT READY mode Press ScrollT Scroll to unlock the Enter key Oo ur m om Press ScrollT Scroll Return Enter to enter the CE Tests menu Press all four keys at the same time 7 The display will show SERVICE PRINTER MECHANISM TESTS the first menu item Press Enter to enter the mechanism tests menu 8 Press Scroll or Scroll until PRINTER MECHANISM TESTS HAMMER PHASING is on the display 9 Press Enter The printer begins printing all Hs each line preceded by the phasing index number 10 Press Return The display will show SERVICE PRINTER MECHANISM TESTS 11 Press ScrollT or Scroll until SERVICE HAMMER PHASE VALUE is on the display 12 Press Enter The top line of the display will show HAMMER PHASE VALUE and the bottom line will show the current phasing index number 173 Chapter 6 _ Hammer Phasing Adjustment 13 Press Enter The phasing index followed by an asterisk will move up to the top line of the displa
205. he CMX controller board if either message appears Record the message and return it with the defective board 110 General Symptom List Table 5 General Symptom List Symptom Corrective Action CLEAR JAM message will not clear and paper does not move Remove the paper guide assembly or pedestal top cover Make sure connector P107 PAPR M is fully seated in connector J107 on the CMX controller board 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 Check and adjust the paper feed timing belt Replace the belt if it is damaged Power on the printer Load paper Press Form Feed 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 Power on the printer Press Form Feed 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 the defective board CLEAR JAM message will not clear but paper moves Power off the printer Remove the paper guide assembly 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
206. he card cage 5 Connect all cable connectors to the controller board using the Interconnection diagram on page 289 as your guide 6 Cabinet Model Install the paper guide assembly page 229 Pedestal Model Install the top cover assembly page 204 IMPORTANT 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 7 Load flash memory page 176 8 Models 014 and 015 only adjust the coil temperature if the original CMX board was replaced page 181 9 Models 004 04P 005 and 05P only set shuttle speed if the original CMX board was replaced page 182 10 Adjust the hammer phasing page 173 11 Adjust the end of forms distance page 169 12 Return the printer to normal operation page 153 13 Using the configuration printout you made as step 1 of the removal procedure reset and save the printer configuration 191 Chapter 7 Section Replacement Procedures Circuit Board Power Supply CAUTION 4 To prevent injury from electric shock wait at least one minute after powering off before removing the power supply board ATTENTION Do not touch components or flex the board during removal installation Handle the board by the ejection levers and the sides Wear a properly grounded static wrist strap when handling the power supply board Removal 1 Prep
207. he print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board 115 ILLEGAL INSTRUCTION ACCESS SEE USER S GUIDE Illegal Instruction Accessed 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 93 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel SEE USER S GUIDE controller board Message Explanation Corrective Action 116 ILLEGAL Illegal External Bus 1 Cycle power Run the print job again If EXTERNAL BUS Accessed Firmware the message appears download the ACCESS error on the CMX 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 117 A TO D OVERRUN SEE USER S GUIDE The analog to digital converter on the CMX controller board has overflowed 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 CM
208. hronize Task Control Block Temperature Top of Form first print line Test Point Transistor Transistor Logic Transmit Data Universal Asynchronous Receiver Transmitter Upper Drive Phase Undefined Universal Synchronous Asynchronous Receiver Transmitter Volts Voltage at Collector Voltage at Drain Voltage at Source A special ASIC containing circuits that help the DC controller operate The letters VX do not stand for anything they simply designate this ASIC 353 Appendix F 354 WR w w o XMT Write With Without Transmit G Cords And Adapters Part Number Description 1332167 Line Cord IBM Japan 1838573 Line Cord IBM 12 Feet United States 220 Volt 1838574 Line Cord 220V 6 Feet Non Lock United States Canada 6952299 Power Cord 110V 12 Feet Non Lock United States Canada Brazil Cayman Islands Costa Rica Dominican Republic El Salvador Guatemala Mexico Liberia Panama Saudi Arabia Phillipines Honduras Peru Columbia Nicaragua Bermuda Bahamas Barbados Bolivia Guyana Ecuador Haiti Jamaica Venezuela Netherlands Antilles Trinidad Suriname Taiwan Tobago Saint Lucia Indonesia 8509386 Cable PC RS 232 IBM 08H7968 Coax Adapter Cable for use with Multi Platform Interface 13F9941 Line Cord IBM Australia 13F9980 Line Cord IBM Europe EMEA 13F9998 Line Cord IBM Denmark 14F0016 Line Cord IBM Pakis
209. ht side of the splined shaft Hold the tractors so they do not fall grasp the vertical adjustment knob and slide the splined shaft to the right out of the side plates and the tractors 239 Chapter 7 Section Replacement Procedures Installation 1 Open the doors on the left and right tractors Position the tractor belts so the alignment marks are at the top on both tractors See Figure 39 2 Grasp the vertical adjustment knob and slide the splined shaft through the right side plate the tractors and the left side plate page 274 Figure 50 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 8 Install the ground clip and screw 9 Install the paper feed timing belt page 188 10 Set the paper feed timing belt tension page 154 11 Adjust splined shaft skew page 168 12 Install the paper supports on the splined shaft and support shaft See Figure 50 page 274 item 21 13 Return the printer to normal operation page 153 NOTE Align the marks on each tractor before inserting T
210. hten the four screws See page 260 Figure 45 items 3 4 and 5 7 Cabinet Model Install the paper guide assembly page 229 Pedestal Model Install the top cover assembly page 204 8 Return the printer to normal operation page 153 188 Belt Platen Open Belt Platen Open Removal 1 Prepare the printer for maintenance page 152 2 Cabinet Model Remove the paper guide assembly page 229 Pedestal Model Remove the top cover assembly page 204 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 See page 276 Figure 51 item 24 4 Loosen do not remove the two motor mount screws page 278 Figure 52 item 15 5 Push the motor toward the front of the printer to loosen the platen open belt Loosen the setscrew in the platen open motor pulley Remove the platen open belt by sliding the platen motor pulley off the motor shaft and the belt off the platen open pulley Installation 1 Slide the platen open timing belt over the platen open pulley and the motor pulley and tighten the 1 16 inch setscrew 2 Slide the motor pulley onto the platen open motor shaft and tighten the pulley setscrew ATTENTION Too much tension on the platen open belt can cause the platen gap to change which can lead to premature wear of the platen damaged hammer tips and poor print quality 3 Using a force gauge apply 10 pounds 44 48 N
211. icates the operator panel is locked Selects the option displayed on the LCD This action either sets a value moves to the next lower level of configuration or starts a self test Stop Enter resets the printer Returns to the next higher level of a configuration menu In the NOT READY mode moves the paper upward 1 72 inch micro step function In the NOT READY mode moves the paper downward 1 72 inch micro step function In the PROGRAM mode this key moves to the next menu Scroll function In the PROGRAM mode this key moves to the previous menu Scroll function Prints the current configuration Soft reset load power on configuration in memory Printer must be in NOT READY mode Toggles the lock on the configuration menus 22 Electrical Controls Pedestal Models Power Switch Power LCD Ready mm Processing Line Form Menu Scroll 1 Enter Micro T Feed Feed Start Cancel um Set Eject Pri Attention figuration Scroll J Return Micro Y View OfForm Stop Figure 3 Electrical Controls Pedestal Models 23 Chapter 1 Controls And Indicators Mechanical Controls All Models Control or Indicator Function Forms Thickness Lever
212. ics esses 329 Electrical Characteristics sss 330 IHE EINE PEE 336 Duty Cycle otc Eee ate a eua 336 C Metric Conversion Tables 337 337 D E lI o Table of Contents Mass and Density nennen 338 Temperature tee e ete eris 338 sj M 338 Torque Table vote 339 Safety Inspection 341 Safety Inspections eren 341 Preparation ee ee ee d Lee eu 341 Prepare The Printer for 08 342 Inspect Mechanical 342 Inspect Electrical Parts 343 Abbreviations And Signal Mnemonics 347 Cords And Adapters 355 NUITIDBIS 357 Noise Suppression 365 SureStak Power 367 Contents is ro a tee ED NI a anu ient 367 Introduction Lact caet eee Lue cep de eret de nee e eat 368 Stacker Operation jase oe rer hie drea 368 Removing The Power Stacker sse 375 Installing The Power 1 380 Replacing The Constant Force
213. ictable behavior of the stacker This appendix consists of three parts e overview of stacker operation e Removal installation instructions for the power stacker assembly and components that require the most frequent replacement e illustrated parts breakdown IPB showing how the entire power stacker unit is assembled The IPB also lists the part numbers for replaceable parts NOTE 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 ration 368 The power stacker mechanically directs the paper from the printer to the paper stack It is mounted in the rear of the cabinet and has its own control panel This section explains briefly how to use the power stacker Component Locations Figure 59 shows the names and locations of the major components of the paper stacker Legend 1 Pinch Rollers 2 Paper Throat 3 Stacker Control Panel 4 Elevator Assembly 5 Motor Bracket 6 Wire Paper Tent 7 Paddle Shaft 8 Alignment Rod 2 9 Bearing Bracket 10 Paper Length Indicator Figure 59 Power Stacker Component Locations 369 Appendix J _ Stacker Operation Stacker Control Panel To gain access to the stacker control panel open the rear door of the cabinet The control panel has two indicator lamps and four keys See Figure 60 O on OFF A ON
214. ield Remove the paper guide and barrier shield See page 260 Figure 45 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 258 Figure 44 5 Loosen do not remove the paper feed motor mount screws page 278 Figure 52 item 10 Loosen the setscrew in the paper feed motor pulley collar Remove the paper feed timing belt by sliding the paper feed motor pulley off the motor shaft and the belt off the splined shaft pulley Installation 1 Install the paper feed timing belt over the splined shaft pulley and the motor pulley Slide the motor pulley onto the paper feed motor shaft page 278 Figure 52 2 Holding a 0 040 inch feeler gauge between the pulley collar and the motor body torque the 7 64 inch collar screw to 25 2 inch pounds 2 82 0 23 Nem 3 Using the straight end of a force gauge apply 15 pounds 66 7 N of pressure to the paper feed drive motor near the mounting base of the motor Use the splined shaft to steady the gauge 4 Reduce tension to 12 pounds 53 4 N and torque the paper feed motor mount bolts to 18 2 inch pounds 2 03 0 23 Nem 5 Snap the timing belt cover into the slots in the side plate page 258 Figure 44 6 Cabinet Model Install the barrier shield and tighten the four screws See page 258 Figure 44 items 3 and 4 Pedestal Model Install the barrier shield and paper guide and tig
215. ify that the LCD goes completely blank and all fans stop Print Interlock Service Check 1 Power on the printer Open the printer top cover Open the forms thickness lever The LCD should display 057 CLOSE PLATEN and the audible alarm should sound if it is enabled 345 Appendix E _ Inspect Electrical Parts 4 Press Stop The audible alarm should stop 5 Close the forms thickness lever The fault message should clear 346 F Abbreviations And Signal Mnemonics NOTE Mnemonics with the first letter N are negative true Abbreviation or Mnemonic Definition KQ MegQ uF us usec 0 A1 etc AC ACC ACK AMP AMPL AN ASIC ATTN B BANK FAN BCOM BCP BHSC BN BNLD BPS BSY BTU 1 000 Ohms 1 000 000 Ohms microfarad 10 6 farad microsecond 10 6 second microsecond 1 p second 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 347 Appendix F 348 BUD CA CC CCF CE CHNG CIR CLK CO COLL COMM CONTLR CMD CMX CNC CPI CR CT CTL CTS CUR CVO DO D1 etc DAT DC DCD DIAG DIFF DMA DP DPMC DPU DRAM DRV DRVR Buffered Upper Driv
216. inet Model Install the paper guide assembly page 229 Pedestal Model Install the top cover assembly page 204 10 Return the printer to normal operation page 153 156 List Of Adjustments Direction of Force Legend 1 Belt Cover 2 Motor Mount Screw 2 3 Platen Open Motor Shaft Figure 22 Platen Open Belt Adjustment 157 Chapter 6 Paper Drive Motor Pulley Alignment Paper Drive Motor Pulley Alignment To make this adjustment follow these steps 1 Prepare the printer for maintenance page 152 2 Cabinet Model Remove the paper guide assembly page 229 Pedestal Model Remove the top cover assembly page 204 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 screw 2 in the motor pulley collar 3 Align the paper drive motor pulley 4 with the splined shaft pulley 5 ATTENTION Make sure there is at least 0 040 inches 1 016 mm of clearance between the collar 3 and the motor face plate 6 Hold the collar 3 flush against the motor pulley 4 and tighten the screw 2 7 Check for correct tension on the paper feed timing belt page 154 Adjust if necessary Snap the timing belt cover 1 into the slots in the side plate Cabinet Model Install the paper guide assembly page 229 Pedestal Model Install the top cover assembly page 204 10 Return the printer to normal operation page 15
217. ion The same is true of failures traced to the hammer bank replace the entire shuttle frame assembly It is not field repairable 5 Replace the defective part or assembly 6 Test printer operation after every corrective action 7 Reinstall any parts you replaced earlier that did not solve the problem 109 Chapter 5 Troubleshooting Other Symptoms 8 Stop troubleshooting and return the printer to normal operation when the reported symptoms disappear General Symptom List Table 5 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 5 troubleshoot using the Half Split Method described on page 109 Table 5 General Symptom List Symptom Corrective Action Communications page 131 Failures Jams CLEAR JAM message 1 Power off the printer Remove the paper guide assembly or instead of LOAD pedestal top cover Remove the barrier shield cabinet model or FORMS when printer is the barrier shield and paper guide pedestal model Check that out of paper the paper detector switch assembly is securely mounted in its bracket 2 Checkthat connector P106 PMD is fully seated in connector J106 on the CMX controller board 3 Power on the printer Load paper Replace the paper detector Switch assembly if either message appears 4 Poweron the printer Load paper Replace t
218. ips Handle hammer springs by the thick mounting base only Apply pressure only to the mounting base NOTE Replace a hammer spring assembly only if there is visible damage or broken parts can be seen in the assembly 5 Remove the mounting screws from the old hammer spring assembly See Figure 33 page 212 6 Handling the hammer spring assembly by the mounting base only gently pry the old hammer spring assembly off its mounting pins See Figure 33 page 212 7 Inspect the hammer bank and the old hammer spring assembly a If there is ink on the hammer bank mounting surface the hammer spring assembly mounting surface or the hammer spring neck or tines reinstall the old hammer spring assembly and replace the shuttle frame assembly page 242 b Ifthe old hammer spring assembly and the hammer bank are free of ink install the new hammer spring assembly page 213 211 Chapter 7 Section Replacement Procedures NOTE The hammer spring assemblies shown here are for 6400 004 04P 005 05P printers The number of hammer springs and mounting screws varies among printer models but removal and installation are the same Hammer Sp Assembly 7 Hammer Spring Assembly 1 Discard old screws Figure 33 Hammer Spring Assembly Removal 212 Hammer Spring Assembly Installation NOTE 6400 050 P50 010 P10 014 015 C05 and C5P printers must use the CMX 040 controller board 1 Usinga clean dry
219. ith the defective board 89 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel Message Explanation Corrective Action 090 SHUTTLE COVER OPEN CLOSE SHUTTLE COVER The shuttle cover is missing damaged or not correctly installed 1 Inspect shuttle cover for warping damage or missing magnet The magnet covers the sensor housing when the cover is installed If the shuttle cover is warped damaged or the magnet is missing replace the shuttle cover assembly Check shuttle cover installation Make sure the cover lies flat and the two captive screws are fully seated Power on the printer If the message appears power off the printer Remove the paper guide assembly or pedestal top cover Disconnect P107 on the CMX controller board and check the CVO Switch by testing for continuity across pins 18 and 20 Refer to the Main Wire Harness Test Tables page 291 Replace the cover open switch assembly as required Power on the printer If the message appears replace the CMX controller board Record the message and return it with the defective board 092 RIBBON DRIVER CIRCUIT The CMX controller board does not detect a ribbon drive motor Cycle power If the message appears power off the printer Remove the paper guide assembly or pedestal top cover Reseat the cable connections of both ribbon drive motors Power on the printer Using a
220. ith the defective board 105 HAMMER COIL number OPEN Electrical 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 CMX controller board Record the message and return it with the defective board 91 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel Message Explanation Corrective Action 107 HAMMER COIL number HOT One or more hammer coils are overheating The printer has sensor circuits that sample the operating temperature of key components of the print mechanism When higher than normal temperatures are sensed print speed is automatically reduced by 50 and a COIL HOT message is sent to the LCD to inform the operator When the coil s cool down print speed automatically returns to 10096 and the message clears from the LCD This message is normal for extremely dense print jobs such as the Plot Test If the printer often prints at half speed it may be operating in a severe environment A severe environment is one with an ambient temperature at or above above 40 Celsius 104 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
221. ive or drag circuit While the shuttle assembly is in motion one motor acts as a drive motor pulling the ribbon against the resistance exerted by the other motor the drag motor This system maintains a constant motor speed and ribbon tension 42 Printer Electronics Logical Control Of The Printer The printer is divided into four functional elements the operator panel the CMX controller board the power supply and the print mechanism Printer Electronics The functional elements of the printer are diagrammed in Figure 15 AC Operator POWER anel sas ON OFF Circuit SWITCH Breaker Line 1 Power Supply Board Line 2 Neutral CHASSIS GND Ho EIA 232 E Serial 4 Card Cage CMX Controller Board Fan Parallel Vo Shield GND 5 V Remote Power Hammer Bank aK Print Mechanism Fan C JL J Cabinet Exhaust Fan Cabinet models only ee Se ee es a ae Pl
222. lamation point characters i Make a configuration printout Verify that the printer matches host configuration settings for Data Protocol Baud Rate Data Bits Stop Bits Parity Data Terminal Ready and Request to Send Set printer serial interface parameters to match those of the host 2 Send a print job to the printer If the message appears go to Communications Failures page 131 026 HEX DUMP MODE Printer attach status message No action required 027 Enable poll timeout Power off the printer Disconnect the AC COMMUNICATIONS The printer was not power cord from the printer Check data cable CHECK enabled for one connection and host system Refer to line CALL SYSTEM minute over a coax problem determination procedures as OPERATOR interface recommended by the host system 028 Poll timeout error Power off the printer Disconnect the AC COMMUNICATIONS The printer was not power cord from the printer Check data cable CHECK polled for one minute connection and host system Refer to line CALL SYSTEM over a coax interface problem determination procedures as OPERATOR recommended by the host system 029 8344 DIAGNOSTIC TEST FAILED Link level code test detects a hardware failure on the coax twinax expansion board This message can also occur if the software in flash memory is corrupted 1 Cycle power Run the print job again If the message appears download the emulation software
223. le routing diagrams on page 300 and page 302 Disconnect connector P106 from the controller board Trace the platen open motor cables to the connector shell and remove the platen open cable connector from the connector shell page 195 NOTE Some platen open motors are mounted with nuts and bolts other motors have threaded flanges eliminating the need for nuts 10 Remove the two 5 16 inch motor mount screws and nuts if present 11 Remove the platen open motor assembly 223 Chapter 7 Section Replacement Procedures Installation 1 Position the platen open motor assembly with the wires toward the rear page 278 Figure 52 2 Install the two 5 16 inch motor mount screws and nuts if present finger tight 3 Install the platen open belt and motor pulley Bottom out the motor pulley on the motor shaft and tighten the setscrew to 9 2 inch pounds 1 24 0 23 Nem Connect the platen motor cable connector to connector shell P106 Connect shell connector P106 to J106 on the controller board Install tie wraps to secure the motor cable See cable routing diagrams on page 300 and page 302 6 Close the forms thickness lever all the way ATTENTION Too much tension on the platen open belt can cause the platen gap to change which can lead to premature wear of the platen damaged hammer tips and poor print quality 7 Using a force gauge apply 10 pounds 44 48 of tension to the platen open motor shaft by
224. ler board Record the message and return it with the defective board ERROR SHORT AT Hardware failure in 1 Download the program again ADDRESS UR DRAM or CMX 2 Ifthe message appears again replace controller circuitry the DRAM If message occurs with new memory replace the CMX controller board Record the message and return it with defective CMX board ETHERNET ADAPTER Status message that No action required BEING INITIALIZED indicates that the internal Network Interface Card is processing the boot procedure May occur with older versions of microcode 101 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel internal Network Interface Card has established communication Explanation Corrective Action Message ETHERNET Status message that No action required DETECTED indicates that the FM HEADER ERROR Frame Header Error Application software has violated header parameters Not a printer problem The system administrator should correct applications data or configuration FREEFORM OFF This message can appear if an operator panel key is stuck in Release any stuck keys Determine and correct what made the key s stick Ur 2 Cycle power power off the printer wait the down position 15 seconds power on the printer The Check the operator message should be gone If the message panel for stuck key s
225. lide the controller board to left until the keyway clears the screw securing the controller board to the bottom of the card cage Remove the controller board Remove the DRAM SIMM FLASH SIMM and Security PAL from the controller board page 217 These will be installed on the replacement controller board The Security PAL must be installed on the replacement controller board to ensure the printer functions correctly NOTE When Flash SIMMs are removed from one controller board and placed on another controller board the SIMMs must be placed on the new board in the same order and location as on the original board 190 Circuit Board Controller Installation ATTENTION To prevent electrostatic damage to electronic components wear a properly grounded static wrist strap when handling circuit boards the shuttle frame assembly and any other electronic component 1 Install the DRAM SIMM Flash Memory and Security PAL on the controller board page 217 2 Position the controller board assembly in the card cage shield side down component side up Engage the screw on the bottom of the card cage in the keyway in the controller shield Slide the board to right until the serial cable connector J201 on the board lines up with the cutout in the card cage See page 264 Figure 47 3 Tighten the screw securing the controller shield near serial cable connector J201 4 Tighten the screw securing the controller shield to the bottom of t
226. lign the ribbon guides page 166 Return the printer to normal operation page 153 237 Chapter 7 Section Replacement Procedures Ribbon Hub Removal 1 Prepare the printer for maintenance page 152 2 Loosen the Torx T 10 screw in the ribbon spool hub page 278 Figure 52 3 Remove the hub from the shaft of the ribbon drive motor Installation 1 Install the ribbon spool hub over the motor shaft page 278 Figure 52 ATTENTION Tightening the hub screw too much can crack the ribbon hub Be careful not to over tighten the hub screw 2 Tighten the Torx T 10 hub screw so that it contacts the flat section of the motor shaft Make sure the ribbon hub is securely fastened to the motor shaft and there are no cracks in the ribbon hub around the hub screw 3 Return the printer to normal operation page 153 238 Shaft Splined Shaft Splined Removal 1 Prepare the printer for maintenance page 152 Open the printer cover Remove the paper supports from the splined shaft and support shaft See Figure 50 page 274 item 21 Remove the paper feed timing belt page 188 Remove the ground clip page 274 Figure 50 With grip ring pliers remove the grip ring from left side of the splined shaft Pull the bearing and spring link with the spring off the left side of the splined shaft Unlock the left and right tractors and slide them to the center of the shaft Remove the bearing clamp on the rig
227. line matrix printing are easy to state the act of printing dots accurately from a rapidly oscillating shuttle onto a piece of paper moving vertically requires complex timing and coordination between printer logic and the printing mechanism The printing mechanism consists of three integrated subassemblies e Shuttle Frame Assembly Ribbon Transport System e Paper Transport System Shuttle Frame Assembly 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 11 Hammer Bank Assembly Counterweight Assembly Shuttle Frame Assembly Figure 11 Shuttle Frame Assembly Hammer Bank Assembly The hammer springs are grouped in comb like assemblies mounted on a solid hammer bank See Figure 12 Both the number of hammer springs per hammer assembly and the number of hammer spring assemblies on the hammer bank vary according to printer model e 6400 004 04P 005 05P 050 P50 seven 4 hammer assemblies for a total of 28 hammer springs e 6400 008 08P 009 09P seven 7 hammer assemblies for a total of 49 hammer springs e 6400 010 and 10P six 10 hammer assemblies for total of 60 hammer springs e 6400 012 014 C05 C5P seven 13 hammer assemblies for a total of 91 hammer springs e 6400 015 six 17 hammer assemblies for a total of 102 hammer springs Shuttle Drive Motor The shut
228. lish 5781599 Operator Panel Overlay Spanish 5781600 Operator Panel Overlay French 5791601 Operator Panel Overlay Italian 5791602 Operator Panel Overlay German 5761603 Operator Panel Overlay Dutch 5761604 Operator Panel Overlay Brazilian Portuguese 3 Ref Screw Hex w Lock Washer 4 6 32x 375 4 14H5300 Cable Assy Operator Panel 5 5701481 Dashpot Kit Includes ball studs spring clips and mounting hardware 6 Ref Screw w Lock Washer 3 6 32x 375 7 Ref Screw w Lock Washer 2 6 32x 175 8 5781440 Fan Assembly 9 Ref Duct Air Exhaust 255 Chapter 7 Section II Illustrated Parts Lists m 2 a Item 16 Lid Accessory Kit not shown Item 17 Pedestal Shipping Container not shown Figure 43 Pedestal Details 256 Illustrations Of Printer Components Item Part No No Order No Description Notes 1 63H5124 Operator Panel Pedestal Models 05 08 09 2 5701598 Operator Panel Overlay English 5781599 Operator Panel Overlay Spanish 5781600 Operator Panel Overlay French 5791601 Operator Panel Overlay Italian 5791602 Operator Panel Overlay German 5761603 Operator Panel Overlay Dutch 5761604 Operator Panel Overlay Brazilian Portuguese 3 Ref Screw 5 6 32x 50 4 63H5125 Bracket Operator Panel Models 08 09 5 63 5121 Hinge Lid Kit Models 04P 05P 08P 09P 6 14H5300 Cable Assy Operator Panel 7 63H5119 Lid Pedestal Model Models 04P 05P 08P 09P 8 Ref
229. ll dot positions creating a solid black band Exercises the shuttle and hammer bank at maximum capacity Power Supply board Hammer bank cover 134 Selecting And Running Tests Hammer springs Hammer coils the shuttle frame assembly e Shuttle Only This test runs only the shuttle Shuttle Slow Verifies proper operation by exercising the shuttle and ribbon mechanisms at low speed You can also use this test to check ribbon tracking and reversing e Shuttle Fast Verifies proper operation by exercising the shuttle and ribbon mechanisms at high speed You can also use this test to check ribbon tracking and reversing e Hammer Phasing A hammer timing parameter that permits you to adjust the vertical alignment of dots in character printing End of Forms Adjust A vertical comb pattern used to determine the number of dot rows from the completion of a paper out fault to the end of the paper Hammer Phase Value The hammer phase value is a timing parameter that permits you to adjust the vertical alignment of dots in character printing The numerical units are relative they do not represent a physical measurement or value There is no correct value or range The factory prints the initial phase value on the aluminum casting of the shuttle assembly next to the motor housing Use this value as your starting point when adjusting hammer phasing End of Forms Adjustment Value This parameter determines where on the paper the prin
230. ller board stacker and stacker control panel 69 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel Message Explanation Corrective Action 019 STACKER FAULT CHECK STACKER Two situations can trigger this message 1 The stacker elevator is obstructed while attempting to move up or down The message will always occur if the user presses the ELEVATOR UP key on the stacker control panel to move the elevator and the elevator is blocked so that it cannot move to the top of its travel 2 Controller hardware tells firmware that an over current condition exists This will only occur if the controller board or the stacker motors are bad Open the cabinet rear door and check for obstructions preventing elevator movement Remove any obstructions Power on the printer Operate the power stacker and check that 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 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 pag
231. lly seated in connector J107 on the CMX controller board Power on the printer Load paper Run a print test If the problem occurs replace the paper feed motor Run a print test If the problem occurs replace the CMX controller board Run a print test If the problem occurs replace the power supply board 123 Chapter 5 Troubleshooting Other Symptoms Table 5 General Symptom List Symptom Corrective Action 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 Power off the printer Remove the paper guide assembly or pedestal top cover Check the I O cable connections from 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 Remove the flash SIMMs Inspect the flash SIMM sockets on the CMX controller board If any socket pins are bent or damaged replace the CMX controller board Check that customer has the right size SIMMs for the emulation See Figure 35 page 220 Install SIMMs that support the emulation software Power up the printer Download the emulation If the download fails activa
232. ls that use the 25 MHz board Hanzi Printers 6400 05 and 6400 C5P printers have shuttle assemblies hammer springs and software specially designed to print the GB character set and Song typeface used in the People s Republic of China These printers can mix ASCII and Hanzi characters on the same line with ASCII characters occupying half the width of Hanzi character cells Because of the density and 14 Printer Evolution complexity of Hanzi characters the highest rated speed for these models is 585 Ipm Printer Evolution IBM 6400 050 P50 010 P10 and 015 printers use a redesigned shuttle frame assembly hammer bank and ribbon guides These models use the CMX 040 controller board which has a 40 MHz clock speed on the Data Controller unit These models use standard hammer springs which have 16 MIL 0 016 inch tips 6400 05 and C5P printers use a shuttle frame assembly hammer spring assemblies and software specially designed to print complex Hanzi characters The hammer springs have 10 5 MIL 0 0105 inch tips and are unique to these printers The 6400 05 and C5P printers also use the CMX 040 controller board which has a 40 MHz clock speed on the Data Controller unit Except for the CMX 040 controller board and ribbon guides which are backwards compatible with all 6400 printers the redesigned components of these newer models are not compatible with earlier models When replacing c
233. lt if it is damaged 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 Disconnect connector P106 from the CMX controller board Check the resistance of connector P106 PLAT M Refer to the Main Wire Harness Test Tables on page 291 Replace the platen open motor if it fails the resistance test Run a print test If a platen open or close platen message appears replace the CMX controller board Record the message and return it with the defective board 87 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel Message Explanation Corrective Action 088 CONTROLLER 23 5V Controller Voltage Failure 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 flash memory with pre written flash See Table 8 and Table 9 on page 219 and Figure 35 on page 220 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
234. ly 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 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 Inspect the paper ironer If the paper ironer has slipped up into the print line reposition the paper ironer Check and adjust the platen gap Remove the paper guide assembly or pedestal top cover Make sure connectors P105 and P108 have good connections on the CMX controller board Make sure connectors P04 and P05 have good connections at the shuttle frame assembly Print out the configuration Refer to the User s Manual Call support to confirm the correct microcode levels especially the DC and EC levels If the code levels are incorrect download the correct microcode page 175 and reload the flash memory page 176 On 475 lpm and 500 Ipm
235. ly 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 cables b Disconnect stacker rail cable connector P107 from connector on the back of the stacker control panel See Figure 68 page 376 C Locate pin 1 of connector P107 See the cable assembly drawing in Appendix A page 321 d Check the stacker rail cable and limit switches for continuity and shorts Check continuity of the switch when open and closed See the power stacker control panel PCBA pinout drawing on page 298 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 119 Chapter 5 Troubleshooting Other Symptoms Table 5 General Symptom List Symptom Corrective Action 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 h
236. ly it can slow the shuttle enough to trigger the fault message Set the forms thickness lever to match the thickness of paper and provide satisfactory print quality but not too tightly Check and adjust the platen gap 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 Run a print test If the message appears power off the printer Remove the shuttle cover Remove the paper guide assembly 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 Appendix A Interconnection Diagram page 289 Remove obstructions and reseat all cables Check the resistance of MPU in P107 Refer to the Main Wire Harness Test Tables page 289 Replace the MPU if it fails the test Run a 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 Run a print test If the message appears replace the MPU and the MPU cable assembly Run a print test If the message appears replace the CMX controller board Record the message and return it with the defective board Run a p
237. m again from the beginning If the message appears replace the DRAM See Figure 35 page 220 2 Download the program If the message appears replace the flash memory with pre written flash See Table 8 and Table 9 on page 219 and Figure 35 on page 220 3 Download the program If the message appears replace the CMX controller board Record the message and return it with the defective board P65 ERROR The printer requires Add flash memory or use a smaller emulation PROGRAM NEEDS more flash memory in program See Figure 35 on page 220 MORE FLASH order to run the downloaded program P66 ERROR The printer requires Add DRAM or use a smaller emulation PROGRAM NEEDS more DRAM memory program See Figure 35 on page 220 MORE DRAM in order to run the downloaded program P67 ERROR Hardware or software 1 Replace flash memory with pre written WRITING TO FLASH fault in flash memory flash See Table 8 and Table 9 on page 219 and Figure 35 on page 220 2 f message occurs with new memory replace the CMX controller board Record the message and return it with the defective board 105 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel Message Explanation Corrective Action P68 ERROR EC PROGRAM NOT VALID The printer cannot find the engine controller program or the validation checksum is corrupt Download the program again If the
238. mbly Cover Open page 326 14H5285 page 309 Cable Assy Card Cage Fan 14H5286 page 311 Cable Assy Exhaust Fan 14H5287 page 264 Centronics I O Cable Assembly page 284 page 303 14H5288 page 197 Housing Connector Kit 14H5289 page 307 Cable Assy AC In Power Supply Part of AC Field Kit 14H5289 page 308 Cable Assy AC Power Input Part of AC Field Kit 14H5296 page 252 Spares Kit Grommet 14H5299 page 254 Operator Panel Assembly Cabinet 14H5300 page 254 Cable Assembly Operator Panel page 256 page 310 14H5329 page 272 Cable Assembly MPU page 314 14H5330 page 317 Cable Assembly Shuttle Motor Drive 14H5490 page 220 Security Module Graphics 14H5509 page 220 Security Module Base 14H5512 page 264 Hammer Spring Kit Models 008 08P 009 09P 14H5513 page 264 Hammer Spring Kit Models 012 014 14H5516 page 264 Shuttle Frame Assy Models 008 08P 14H5517 page 264 Shuttle Frame Assy Model 012 358 Part Number Location Description 14H5520 page 278 Paper Feed Motor 14H5521 page 278 Motor Assembly Ribbon 14H5522 page 264 Cable Assy Centronics Dataproducts Adapter page 304 14H5525 page 236 Resistor Kit 14H5589 page 305 Cable Assy 5V Remote Power 14H5567 page 250 Wireform Paper Path 14H5570 page 278 Paper Detector Switch Assembly Black Back Forms page 324 14H5571 page 262 Circuit Breaker page 28
239. mbly Printed Circuit Board Printer Error Paper Empty Peripheral Device picofarad 1071 farad Paper Feed Controller Paper Feed Motor Phase A Phase B Paper Instruction Platen Platen Motor Platen Open Switch Paper Motion Detect Switch Pin 351 Appendix F 352 P N PO POD PPR PROM PS PS5 PTR PWM PWR RBN RD RET RIB RG RGL RGR RM RML RMR RQ RRIB RRP RSP RST RTPU RTS RXD SCS SEC SEL SEN SF SG Part Number Paper Out Paper Out Detect Switch Paper Programmable Read Only Memory Power Supply Power Supply 5 Volt Pointer or Printer Pulse Width Modulation Power Right Ribbon Read Return Ribbon 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 Real Time Processing Unit Request to Send Receive Data SNA Character Stream Security Key Select Sense Sensor Structured Field Signal Ground SHH SHM SHUT SHUTL SIMM SLCT Slew SMD SNA SPU SRAM STAT STBY STK SW SYNC TCB TEMP TOF TP TTL TXD UART UDPH UNDEF USART Shuttle Hall Effect Shuttle Motor Shuttle Shuttle Single Inline Memory Module Select On line Rapid vertical paper movement Shuttle Motor Drive Systems Network Architecture Shuttle Processor Unit Static Random Access Memory Status Standby Power Stacker Switch Sync
240. ment 248 Paper detector switch replacement 246 Paper guide assembly removal 229 Parts illustrations 249 replacement part numbers 357 replacement procedures 186 Phasing adjustment 173 Pinouts 287 Platen gap adjustment 162 interlock switch assembly replacement 247 platen open belt adjustment 156 platen open motor replacement 223 Platen replacement 231 PLEASE WAIT RESET IN PROGRESS 106 Power cycle how to 145 on off verification 345 start up sequence 146 Power consumption 330 Power on sequence 146 Power Paper Stacker component locations 368 loading and starting 372 setting up 371 Power supply circuit board replacement 192 Power supply board principles of operation 57 Poweron time 143 Principles of operation 35 Print server network 226 Print strokes 143 Printer adjustments 151 boot diagnostics menu 137 cleaning 29 configuration 27 description 13 dimensions 329 duty cycle 336 installation 27 logical control of 43 maintenance overview 13 models 13 evolution 15 Hanzi 14 how to identify 15 power paper stacker 367 principles of operation 35 reset 145 self tests customer engineer CE 134 operator print 132 specifications 327 troubleshooting 59 Printer information menu 11 inch pages 143 installed memory 143 poweron time 143 print strokes 143 printing time 143 Printing conventions is this manual 18 line matrix printing explained 3
241. ment connector or power cord during an electrical storm 5 Power off the printer and disconnect the power cord before connecting or disconnecting a communication port teleport or attachment cable connector Download the correct level of microcode from the World Wide Web page 175 If the printer has an internal Ethernet interface card refer to the Ethernet User s Manual for download instructions If you loading flash memory through the parallel or serial port continue with this procedure Make a printout of a saved configurations Refer to the Setup 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 Unplug the AC power cord from the printer If the printer s parallel data cable is connected to the parallel port of an IBM compatible computer using the PC DOS or MS DOS operating system skip to step 10 If not go to step 7 Disconnect all data input cables from the printer interface Connect the parallel data cable to the default parallel port LPT1 of an IBM compatible computer using the PC DOS or MS DOS operating system NOTE You can connect the data cable to the LPT2 port if the LPT1 port is 176 already in use You can also download software through the printer serial port The download commands are different if you use these ports as described in the note after step 17 List Of Adjus
242. metallic brush such as a toothbrush gently brush the hammer tips to remove lint and ink accumulations See Figure 6 Vacuum up any residue 31 Chapter 3 32 Cleaning The Printer NOTE 6400 004 hammer bank is shown Procedure is the same for all hammer banks Hammer Tip Figure 6 Cleaning the Hammer Tips ATTENTION 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 200 10 Install the shuttle frame assembly page 242 11 Install the shuttle cover assembly page 203 12 Clean the card cage fan assembly as described on the next page Cleaning The Card Cage Fan Assembly Cleaning The Card Cage Fan Assembly 1 Cabinet Models Remove the paper guide assembly page 229 Pedestal Model Remove the top cover assembly page 204 2 Vacuum the card cage fan assembly and surrounding areas to remove paper particles dust and lint See Figure 7 3 Cabinet Models Install the paper guide assembly page 229 Pedestal Model Install the top cover assembly page 204 Close the printer cover Connect the AC power cord to the power source NOTE Cabinet model shown Procedure is the same for pedestal model Figure 7 Cleaning the Card Cage Fan A
243. models Removal 1 Prepare the printer for maintenance page 152 Open the printer cover Loosen the three paper guide assembly hold down screws page 258 Figure 44 item 6 4 Slide the paper guide assembly to the left and lift it off the card cage Installation 1 Position the paper guide assembly offset slightly to the left on the card cage with the keyway cutouts over the three loosened hold down screws page 258 Figure 44 item 6 2 Slide the paper guide assembly to the right engaging the three hold down screws in the keyway slots Slide the paper guide assembly to the right as far as it will go Tighten the three hold down screws page 258 Figure 44 item 6 Return the printer to normal operation page 153 229 Chapter 7 Section Replacement Procedures Paper CAUTION 2 Over time the upper edge of the paper ironer can become sharp To avoid cutting yourself handle the paper ironer on the sides Removal 1 Remove the shuttle frame assembly page 242 Move the forms thickness lever to the open position Push the ends of the paper ironer toward the rear of the printer disengage the tabs then lift it up and out page 276 Figure 51 Installation NOTE The black tape on the paper ironer faces the paper detector switch assembly 1 Position the paper ironer so that the black tape is on the side that faces the paper detector switch assembly See page 276 Figure 51 Pus
244. move the barrier shield cabinet model or the barrier shield and paper guide pedestal model see Figure 45 page 260 Make sure the sensors are securely snapped into the bracket the mounting screws hold the paper detector Switch assembly securely and clean the sensors if they are dirty Check that connector P106 PMD is fully seated in connector J106 on the CMX controller board Power on the printer Load paper Replace the paper detector switch assembly if the message appears Power on the printer Load paper Replace the CMX controller board if the message appears Record the message and return it with the defective board 62 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action 002 FORMS JAMMED CLEAR JAM AND RELOAD FORMS Attention message the printer cannot detect paper motion Inspect the paper path for jams 10 Clear jams Load paper Press Form Feed 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 125 If forms feed go to the next step Press View once and check that forms move up Make sure the forms thickness lever is not set too tightly 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
245. n guide assembly to the side plate See Figure 52 page 278 item 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 shaft as you remove the platen Make sure the copper wear saddles in the platen seat of the mechanism base stay in place 231 Chapter 7 Section Replacement Procedures Installation IMPORTANT The dowel pins protruding from the ends of the platen are the platen shafts and are not equal in length The platen must be installed with the longer shaft on the right side 1 Wipe the platen shafts clean of grease and debris 2 Install two washers on the longer right platen shaft See Figure 36 3 Apply bearing lubricant to both platen shafts BJ Ironer Bracket C gt attire Platen Shaft Right Side Washer Platen Adjust fA ER X 9 9 Figure 36 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 37 5 Apply a layer of bearing lubricant 1 4 inch high to the seat of each wear saddle making the layer as wide as the saddle and touching the rear angled surface 6 Install one platen adjust bracket onto the longer platen shaft with the screw at the
246. n the base casting to the right of the shuttle motor See Figure 47 page 264 item 18 Trace the cover open switch cable back to the controller board releasing the cable from the restraints under the base casting See cable routing diagrams on page 300 and page 302 Disconnect connector shell P107 P7 from the controller board Trace the ribbon motor wires to the connector shell and remove the cable connector from the connector shell page 195 Installation 1 Remove the protective covering from the adhesive backing on the cover open switch assembly Feed the switch cable down into the cover open switch well to the right of the shuttle motor Position the cover open switch assembly in the base casting and press it into place See Figure 47 page 264 item 18 Route the cover open switch cable back to the controller board installing the cable in the restraints under the base casting See cable routing diagrams on page 300 and page 302 Connect the cover open cable to the connector shell page 195 then connect the connector shell P107 P7 to the controller board Install the shuttle cover assembly page 203 Return the printer to normal operation page 153 245 Chapter 7 Section Replacement Procedures Switch Assembly Paper Detector Removal 1 Prepare the printer for maintenance page 152 2 Cabinet Model Remove the paper guide assembly page 229 Pedestal Model Remove the top cover assembly
247. nd user but provide useful information for manufacturing and maintenance personnel The boot diagnostic menu structure is depicted in Figure 19 Activating The Boot Diagnostic Menu 1 Setthe printer power switch to O off Press and hold down the Eject Restore and Stop keys While holding the Eject Restore and Stop keys set the printer power switch to 1 on 4 When DIAGNOSTICS PRESS ENTER appears on the LCD release the Eject Restore and Stop keys 5 Press the Enter key Menu options are shown in Figure 19 Exiting The Boot Diagnostic Menu Method 1 Reset the printer from the Menu 1 Using the directional keys move to the MISC UTILITIES RESET PRINTER menu option See menu map on page 138 2 Press the ENTER key Method 2 Cycle power 1 Power off the printer 2 Wait 15 seconds 3 Poweron the printer 137 Chapter 5 Customer Engineer CE Tests NOTE BOOT DIAGNOSTICS PRESS ENTER Scroll key ENTER BOOT DIAGNOSTICS v VERSION CHECK ENTER VERSION CHECK VERSION CHECK VERSION CHECK VERSION CHECK BOOT VERSION V SOFTWARE VERSION W EC VERSION Y ASIC VERSIONS ENTER ENTER ENTER ENTER BOOT CMX V10B 09 08 95 EC V1 00H VX VERSION F 1 550098 158945 11 41 08 07Sep95 154643 MECA VERSION F
248. net Initialization 183 151 Chapter 6 Preparing The Printer For Maintenance Preparing The Printer For Maintenance To prepare the printer for maintenance always do the following steps before you do any maintenance procedure DANGER 3 Hazardous voltages are present in the printer with the power cord connected to the power source Switch off printer power and unplug the printer power cord before proceeding Power off the printer Unplug the printer power cord from the AC power source Disconnect the host data cable from the printer interface Open the printer cover Unload paper Remove the ribbon DUIS 709 i Read the entire adjustment procedure before you begin working on the printer 8 Gather the necessary parts before you begin working on the printer 152 List Of Adjustments Returning The Printer To Normal Operation When you are finished servicing the printer restore it to operation by following these steps 1 5002 OF ON N Connect the host data cable to the printer interface Install the ribbon Load paper Plug the AC power cord into the power source Close the cabinet doors Power on the printer Set the top of form Refer to the Operator s Guide Select the emulation Refer to the Operator s Guide Test printer operation by selecting and running one of the operator print test
249. nism 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 49 Chapter 4 50 CMX Controller Board controller and the MECA ASIC provide the functionality of three separate processors used in earlier controller board architectures In this manual the 80C166 is referred to as either the EC or the 166 The 166 used on the CMX board runs at 20MHz and is housed in a 100 pin metric rectangular flat pack Bus Configuration The 166 bus is configured for 18 bit address 16 bit data non multiplexed and segmented operation The flash memory runs with zero wait states An external PAL is used for address decoding Power Reduction The 166 chip has two power reduction modes idle and Energy Star Idle mode is not used In Energy Star mode 48 and all motors are de energized but the 166 operates as normal EC Flash Memory The EC stores all boot code program code and tables in its own local flash memory This flash is organized as 64K x16 bits and uses the same technology as the DC flash it is 5 0V only and is rated for a minimum of 100 000 write erase cycles EC memory is fixed it is soldered to the controller board Its contents can be updated through the DC through the serial or parallel ports At run time the EC also stores tables in shared DRAM which is
250. not present or has failed Check the security PAL at location U54 on the CMX controller If the PAL is absent install the correct PAL If security PAL is present replace the CMX controller board ERROR SHORT AT ADDRESS XXXX Hardware failure in DRAM or CMX controller circuitry Replace DRAM If message occurs with new DRAM replace CMX controller board 179 Chapter 6 Loading Flash Memory Table 7 Flash Memory Message Guide Message Explanation Required Action ERROR WRITING TO FLASH Hardware or software fault in flash memory Download the program again Power off the printer and start over at step 12 If the message occurs again replace the flash memory ERROR WRONG CHECKSUM The printer received the complete program but the checksum did not match The data were corrupted during download Download the program again Power off the printer and start over at step 12 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 security PAL code LOADING PROGRAM The new program is loading into None FROM PORT printer RAM XX indicates how much of the program has loaded L
251. ns 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 moves 1 Power off the printer Inspect all stacker LEDs for dust chaff or by itself dirt See Figure 92 through Figure 94 page 405 through page 409 Clean the stacker LEDs and the sight tubes in the LED mounts 2 Poweron the printer If the stacker elevator moves by itself replace the stacker LEDs See Figure 92 through Figure 94 page 405 through page 409 118 General Symptom List Table 5 General Symptom List Symptom Corrective Action Stacker limit switch check 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 If the elevator assembly or the rails are bent or damaged 2 you must replace the entire power stacker assemb
252. nter to normal operation page 153 194 Connector Shells Connector Shells Some of the printer cable connectors are grouped inside connector shells The procedure below explains how to remove and install cable assemblies from any connector shell in the printer NOTE There is also a diagram of the P106 P107 connector shells on the plastic cover over the power supply Additionally later model printers have stiffening clips attached to connectors P106 and P107 See page 198 Removal 1 Prepare the printer for maintenance page 152 2 Cabinet Model Remove the paper guide assembly page 229 Pedestal Model Remove the top cover assembly page 204 NOTE Later models have stiffening clips on connectors P106 and P107 3 On later model printers remove the stiffening clip page 198 4 Disconnect the cable connector shell containing the cable assembly that will be replaced 5 Pull the side of the connector shell outward and gently pull the cable connector upward See Figure 30 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 lock 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 rest in the shell
253. o a cooler cleaner area Inspect printer environment for severity Advise the user to move the printer to cooler cleaner location Power off the printer Remove the paper guide assembly or pedestal top cover 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 Remove any obstructions from vents and airways Install the paper guide assembly or pedestal top cover Power on the printer Load paper Run the Plot Test for 1 4 page If the message appears replace the CMX controller board Record the message and return it with the defective board 80 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action 062 EXHAUST FAN FAULT Sensors cannot detect current in the fan circuit Cycle power If the message appears press Stop If the message occurs on a pedestal model check that the correct operator panel is installed The operator panel for a pedestal model has resistors R18 and R19 next to the operator panel cable connector Check that the exhaust fan is connected to exhaust fan cable connector J307 Power off the printer Remove the paper guide assembly Disconnect connector P107 from the CMX controller board Test connector P107 EHF for shorts or opens Refer to the Main Wire Harness Test Tables on page 291 Replace components tha
254. o the CMX controller board Make sure the control panel cable is seated 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 If the control panel shows broken characters replace the DRAM 112 General Symptom List Table 5 General Symptom List Symptom Corrective Action Operator panel keys do Power on the printer Check the operation of the operator panel not work keys Replace the operator panel if keys do not work 2 Poweron the printer Check the operation of the operator panel keys Replace the operator panel cable assembly if keys do not work 3 Poweron the printer Check the operation of the operator panel keys Replace the CMX controller board if the keys do not work 113 Chapter 5 Troubleshooting Other Symptoms Table 5 General Symptom List Symptom Corrective Action Power IML Failures No power and the operator panel is blank and the card cage fan is not running Check that the AC power outlet has power Restore AC power as required 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 guide assembly or pedestal top cover Verify
255. odel See Figure 46 page 262 5 Press on the spring clips and remove the circuit breaker from the printer Installation 6 Press the circuit breaker into the cutout until the spring clips snap into place Cabinet Model See Figure 53 page 280 Pedestal Model See Figure 46 page 262 ATTENTION Make sure the four leads are connected as shown on page 280 and page 262 7 Connect the four circuit breaker electrical leads Cabinet Model See Figure 53 page 280 Pedestal Model See Figure 46 page 262 Install the card cage fan page 209 Return the printer to normal operation page 153 193 Chapter 7 Section Replacement Procedures Coax Twinax Multi Platform Interface NOTE Installation operation and replacement parts for this optional feature are covered in detail in the Coax Twinax Multi Platform Interface Feature Installation and Operation Guide Form Number S246 0149 Removal ATTENTION To prevent electrostatic damage to electronic components wear a properly grounded static wrist strap when handling circuit boards the shuttle frame assembly and any other electronic component 1 Prepare the printer for maintenance page 152 2 Refertothe Coax Twinax Multi Platform Interface Feature Installation and Operation Guide Form Number S246 0149 Installation 1 Refer to the Coax Twinax Multi Platform Interface Feature Installation and Operation Guide Form Number S246 0149 2 Return the pri
256. of tension to the motor shaft by pushing in the direction away from the large platen pulley Reduce tension to 5 pounds 22 24 N and torque the motor mount screws to 11 2 inch pounds 1 24 0 23 Nem Snap the platen open belt cover into the slots in the side plate Cabinet Model Install the paper guide assembly page 229 Pedestal Model Install the top cover assembly page 204 Return the printer to normal operation page 153 189 Chapter 7 Section Replacement Procedures Circuit Board Controller NOTE 6400 050 P50 010 P10 014 015 C05 and C5P printers must use the 40 MHz CMX controller board ATTENTION To prevent electrostatic damage to electronic components wear a properly grounded static wrist strap when handling circuit boards the shuttle frame assembly and any other electronic component Removal 1 Make a configuration printout of all configurations Refer to the Operator s Guide Prepare the printer for maintenance page 152 Cabinet Model Remove the paper guide assembly page 229 Pedestal Model Remove the top cover assembly page 204 4 Disconnect all cable connectors from the controller board See page 264 Figure 47 5 Loosen but do not remove the screws securing the controller shield near serial cable connector J201 6 Loosen but do not remove the screw securing the controller shield to the bottom of the card cage on the left side near the card cage fan 7 S
257. off this LED Applies AC power to the printer 1 on 0 off This switch is also a circuit breaker The LCD Liquid Crystal Display displays printer status messages Puts the printer in the READY on line mode This key also clears fault conditions exits program mode menus moves paper back to print position after View is pressed and restores print position after an eject Puts the printer in the NOT READY off line mode This key also silences the audible alarm stops a Printer Test and restores after an eject Stop Enter resets the printer Advances paper to next Top Of Form as defined by the current page length Sets TOF and moves paper downward from the tractor alignment notches to the print position Moves paper up one line as determined by current line spacing Press to move the current print position up to the tractor area for viewing Press again to return paper to original print position Cancels a print job Moves paper for viewing or tear off This key is configurable refer to the Operator s Guide If in the NOT READY mode this key puts the printer in the PROGRAM mode If the configuration menus are locked the LCD indicates the operator panel is locked Selects the option displayed on the LCD This action either sets a value moves to the next lower level of configuration or starts a self test Stop Enter resets the printer Returns to the next higher level of a configuration menu In the NOT READY mode m
258. olding 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 68 page 376 e Disconnect stacker frame cable connector P102 from connector J4 on the rear of the stacker control panel See Figure 68 page 376 f Locate pin 1 of connector P102 and connector P107 See the cable assembly drawings in Appendix A page 318 and page 321 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 298 Replace any cable that is damaged or fails continuity test Replace any motor that fails the resistance test 120 General Symptom List Table 5 General Symptom List Symptom Corrective Action Print Quality Characters or dots are missing smeared too light or too dark 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 assemb
259. omponents be careful to order the correct spares for the model you are servicing The next section explains how to identify an IBM 6400 printer How To Identify The Printer The model number of the printer indicates the printer family speed and type of enclosure See Figure 1 Maximum Speed Rating 004 475 005 500 25 MHz controller 050 500 40 MHz controller C05 585 lpm Hanzi 008 800 Ipm IBM 6400 Printer Family 005 F 012 1200 Ipm 014 1400 Ipm 015 1500 Ipm 6400 04P Uses hammer springs with 10 5 MIL 0 0105 inch tips Standard hammer Enclosure Code tips are 16 MIL 0 016 inch P Pedestal Model No Code Cabinet Model Figure 1 How to Interpret Model Numbers Chapter 1 About This Manual Important Maintenance Notes To ensure the best performance of the printer remember these important maintenance concepts when you service the printer ATTENTION Failure to observe the guidelines below can result in damage to the equipment Do not adjust the platen gap unless the original shuttle frame assembly or platen has been replaced with a new or rebuilt unit or unless instructed to do so in the troubleshooting chapter Never bend or tweak hammer springs Always handle the hammer springs by the thick mounting base The hammer springs and hammer tips are delicate and precisely aligned Use only the ribbons specified in Appendix B Use of incorrect ribbons
260. on next to this symbol indicates a heavy assembly that requires two or more persons to lift or hold CAUTION E lt gt The word Caution next to this symbol indicates a part or assembly that is sharp enough to cut you ATTENTION The word Attention indicates the possibility of damage to a program device system or data Chapter 1 18 About This Manual IMPORTANT The word Important indicates information vital to proper operation of the printer NOTE A note gives you helpful tips about printer operation and maintenance Printing Conventions In This Manual Operator panel keys and LCD messages are set off from regular text in this manual e Operator panel keys and indicators are printed boldface Example Press the Cancel key then press the Start key e Liquid Crystal Display LCD messages are printed in capital letters inside quotation marks Example Press the Stop key NOT READY appears on the LCD e Key combinations are denoted by the plus symbol Example Press ScrollT Scroll means Press the Scroll key and the Scroll key at the same time Related Documents To ensure complete understanding of important safety notices for technicians whose native language is not English the notices have been translated into many languages in the BM 6400 Line Matrix Printer Safety Notices Form No 9544 5389 This maintenance manual does explain how to operate or configure the printer
261. ond every time a Second data packet is transmitted OFF Constantly Network connection has been severed 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 3 55 Chapter 4 Printer Interface Table 3 10 100Base T DIP Switch Settings DIP Switch Description 1 2 OFF OFF Normal operation With both DIP switches in the OFF position the interface boots up using the settings in flash memory 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 connected to a network it will print a test page For More Information For more information about the 10 100Base T Ethernet interface refer to Ethernet Interface U
262. ont and rear of the cabinet Remove the hinge plates and the pads beneath the plates 7 Install pads and hinge pin plates to the right front side of the frame with the hinge pins up and toward the outside edge of the printer frame 8 Install pads and hinge pin plates to the left rear side of the frame with the hinge pins up and toward the outside edge of the printer frame 9 Move the original rear door to the front of the printer With the marked top uppermost slide the door hinges down onto the hinge pins Adjust the position of the hinge pin plates as necessary so the door closes squarely against the frame 10 Move the original front door to the rear of the printer With the marked top uppermost slide the door hinges down onto the hinge pins Adjust the position of the hinge pin plates as necessary so the door closes squarely against the frame 11 Install the paper fence to the new rear door with the two screws 12 Install the wire ropes to the doors and the cabinet frame 206 Ethernet Interface Assemblies Ethernet Interface Assemblies NOTE The Ethernet LAN option is available in one of three configurations 10Base T 10Base2 or 10 100Base T These options are available factory installed or as field kits Removal and installation is the same for all versions The functions of the LEDs and DIP switches on the various Ethernet interface boards are described on page 52 and page 54 To convert an Ethernet equipped
263. 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 122 General Symptom List Table 5 General Symptom List Symptom Corrective Action Randomly misplaced dots k Power off the printer Check and adjust the platen gap Remove the paper guide assembly or pedestal top cover On the left rear wall of the card cage make sure the nut which secures the line filter ground line and the AC In Power Supply cable leads to the ground stud is tight See Figure 53 page 280 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 with pre written flash and replace the DRAM See Table 8 and Table 9 on page
264. oses Printer statistics accumulate continuously they do not reset when you power off the printer All of the printer statistics are set to zero at the factory after burn in testing Printer Information Installed Memory Power On Time Printing Time 11 Inch Pages To view options press Scroll Scroll Enter Return To select an option press Enter To exit the configuration menus and return to READY press Start Factory Default Figure 20 Printer Information Menu Installed Memory Displays the amount of RAM in Megabytes installed in the printer Power on Time The cumulative time in hours that the printer has been powered on The range is 0 to 30 000 hours Printing Time The cumulative time in hours that the printer has actually been printing The range is 0 to 30 000 hours Print Strokes The cumulative number of back and forth shuttle strokes the printer has made during normal operation The range is 0 to 4 000 000 000 shuttle strokes 11 Inch Pages The cumulative number of pages the printer has printed The range is 0 to 363 000 000 pages 143 Chapter 5 144 Printer Information Menu Displaying Printer Information You obtain printer information by using the configuration menus as follows
265. ost if paper motion has not occurred for 10 minutes after Stop was pressed to clear a paper jam fault Clear the paper jam Press Stop Press Form Feed 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 125 If forms feed go to step 3 Press View once and check that forms move up Make sure the forms thickness lever is not set too tightly 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 126 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 ribbon mask for bends or deformation that block the paper path or prevent paper from exiting the pedestal top cover Replace a damaged hammer bank cover assembly Check and adjust the platen open belt Replace the belt if it is damaged 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 tha
266. otion 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 the defective board If the message does not appear replace the paper detector switch assembly and set the paper motion detector PMD to ENABLE 003 FORMS EJECTED PRESS EJECT RESTORE Non error status message Press Eject Restore key to return paper to print position 004 VIEW FORMS PRESS VIEW KEYO Non error status message Press View key to return paper to print position 006 HOST SYSTEM REQUEST ATTENTION Host attention message the host computer or printer controller requires attention Not a printer problem 007 FM HEADER ERROR Applications software has violated header format parameters Not a printer problem Have the system administrator correct applications data or configuration 008 HOLD PRINT TIMEOUT PRESS START Status message the printer was offline more than 10 minutes and the Intervention Required parameter is set to Send to Host Press Start to put the printer in the READY state 009 INVALID KEY PRESS Attention message informing the operator that the wrong key was pressed No action required 64 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action 010 PARAMETER ERROR
267. oves the paper upward 1 72 inch micro step function In the NOT READY mode moves the paper downward 1 72 inch micro step function In the PROGRAM mode this key moves to the next menu Scroll function In the PROGRAM mode this key moves to the previous menu Scroll function Prints the current configuration Soft reset load power on configuration in memory Printer must be in NOT READY mode Toggles the lock on the configuration menus 20 Electrical Controls Cabinet Models Off On Power Switch E Processing Attention LCD Li Form Menu Scroll Enter Micro Feed Feed Start Cancel o ee Printer Con Set To Eject figuration Scroll d Return Micro View Of Form Stop Beste Figure 2 Electrical Controls Cabinet Models 21 Chapter 1 Controls And Indicators Electrical Controls Pedestal Models Key or Indicator Function Power Indicator Ready Indicator Processing Indicator Attention Indicator Power Switch LCD Start Stop Form Feed Set Top Of Form Line Feed View Cancel Eject Restore Menu Enter Return Micro Micro 4 Scroll T Scroll J Printer Configuration Stop Enter Scroll T Scroll Lit when the printer is on Lit when
268. p Enter keys The LCD displays 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 NOTE A hard printer reset causes the 48V power supply fans motors etc to shut down in 1 to 5 seconds depending on the amount of memory installed on the controller board 145 Chapter 5 ThePower On Sequence The Power On Sequence This section describes the normal sequence of events from the time the power switch is set to 1 until READY or NOT READY 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 The first power up routines are the handshaking sequences which sample and test the condition of the CMX controller board The sequences occur as follows e Processor Alive The green LED marked 1 on the
269. pansion board verify that the correct microcode is loaded in the machine If the printer does not have the coax twinax expansion board go to step 6 Download CT emulation software Power off the printer Check that the user has enough flash memory installed to handle his emulation software See Figure 35 on page 220 and the Boot Diagnostics Menu on page 137 Install flash memory and download emulation software Check the coax twinax adapter connection to the CMX controller board Make sure that J111 is correctly seated between the CMX controller board and the coax twinax expansion board Power up the printer If the printer does not successfully complete IML replace the coax twinax expansion board Power up the printer If the printer does not successfully complete IML replace the power supply board Power up the printer If the printer does not successfully complete IML replace the CMX controller board 115 Chapter 5 Troubleshooting Other Symptoms Table 5 General Symptom List Symptom Corrective Action Power Stacker Printer does not detect presence of power stacker Or Stacker not working 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
270. peration page 153 164 List Of Adjustments Legend 1 Belt Cover 2 SetScrew 3 Platen Open Motor Pulley 4 Platen Shaft Pulley Figure 26 Platen Open Motor Pulley Alignment 165 Chapter 6 Ribbon Guide Alignment Ribbon Guide Alignment 166 To make this adjustment follow these steps 1 2 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 Check ribbon tracking by running the PRINTER MECHANISM TESTS Shuttle Slow page 134 On the ribbon quide 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 rib
271. physically connect more than one interface but only one interface at a time can be used electrically 51 Chapter 4 52 Printer Interface 10Base2 And 10Base T LEDs And DIP Switches 10Base2 and 10Base T PrintNet Ethernet interfaces have three LEDs and three DIP switches as shown below The indicators and switches are adjacent to the data line connectors LED patterns are defined in the table below the illustration Status Indicator LEDs And DIP Switches STAT ERR NET Status Indicators Grn sei fed fee Default is all DIP Switches OFF Switches as shown Table 2 LED Pattern Indications STAT ERR NET System System Data to Mode Status Error Network ON OFF ON RAM Test ON OFF OFF ROM Test ON ON OFF EEPROM Test OFF ON ON Network Interface Test OFF OFF ON PRN1 Test FLASH OFF FLASH Run Mode FLASH ON FLASH Auto Reset Mode FLASH FLASH OFF Firmware Panic ON FLASH ON Hardware Exception The PrintNet Ethernet assembly has a self test and two internally controlled modes Power on Self Test A seven stage power on self test performs diagnostics on the Ethernet Interface processor RAM ROM EEPROM parallel port and network interface The STAT ERR and NET LEDs indicate which test is currently in progress IMPORTANT 10Base2 And 10Base T LEDs And DIP Switches Run Mode and Auto Reset Mo
272. ppears go to Communications Failures page 131 042 CUSTOM SET DOES NOT EXIST SAVE FIRST Printer configuration the custom configuration set does not exist Save the custom configuration set 043 CUSTOM SET ALREADY EXISTS DELETE EXISTING SET FIRST Printer configuration custom set is write protected Delete the existing custom configuration set then save the new set 75 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel Message Explanation Corrective Action 044 EC FIRMWARE HARDWARE ERROR Application software tried to perform an illegal printer function or damaged memory Cycle power Run the print job If the message appears download the emulation software again 2 Cycle power Run the print job again If is detected on the the message appears replace the flash CMX controller board memory with pre written flash memory If the message See Table 8 and Table 9 on page 219 appears at power up and Figure 35 on page 220 replace the CMX mE controller board 3 Cycle power Run the print job again If Record the message the message appears replace the CMX and return it with controller board Record the message defective CMX and return it with defective CMX board board 4 Poweron the printer Run the print job again If the message still appears there is an application software error Use your local support p
273. printed hex data to the data sent from the host In a hex dump every character is printed as its assigned ASCII symbol and as the hexadecimal value of the character A character that does not have a printed symbol for example a control character is printed as a period and 140 the hex value of the control character If the printer is using a parallel interface the letter p before a hex code indicates an active Paper Instruction PI line and a blank space before a hex code indicates an inactive line To convert an ASCII character to its corresponding hex code or vice versa refer to the ASCII code chart on page 142 Step Press Displayed Result Notes 1 Install the ribbon load paper and power on the printer 2 NOT READY Puts printer in NOT Stop READY mode 3 OPERATOR MENU Unlocking ENTER key ScrollT Scroll UNLOCKED gives you access to the configuration menus 4 OPERATOR MENU First of series of Menu PRINTER CONTROL configuration menus 5 PRINTER CONTROL Moves down to Interface Enter INTERFACE SELECTION Selection option 6 PRINTER CONTROL Moves down to the Hex Scroll UNTIL HEX PRINT MODE Print Mode option 7 ER HEX PRINT MODE Moves down to Disable mer DISABLE the active option 8 HEX PRINT MODE Moves to Enable the Scroll ENABLE alternate option 9 HEX PRINT
274. 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 ATTENTION To prevent electrostatic damage to electronic components wear a properly grounded static wrist strap when handling circuit boards the shuttle frame assembly and any other electronic component 1 Prepare the printer for maintenance page 152 2 Cabinet Model Remove the paper guide assembly page 229 Pedestal Model Remove the top cover assembly page 204 3 Disconnect Centronics cable connector P112 from connector J112 on the CMX controller board See Figure 47 page 264 4 Open the ferrite clamp and lift the Centronics cable out of the ferrite clamp 5 Loosen the two screws securing the Ethernet interface assembly to the cutout at the rear of the card cage 6 Slide the Ethernet interface assembly out of the cutout in the card cage and lift the assembly out of the card cage Installation ATTENTION To prevent electrostatic damage to electronic components wear a properly grounded static wrist strap when handling circuit boards the shuttle frame assembly and any other electronic component 1 2 3 Reverse steps 2 through 6 of the removal procedure Initialize the Ethernet interface page 183 Return the printer to normal operation page 153 207 Chapter 7
275. printer tries a number of times to correct the condition before posting the message to the operator panel The first thing to do in such cases is to power the printer off wait 15 seconds then power the printer back on If the message reappears classify the check condition unrecoverable Unrecoverable unit check conditions are hard failures such as overcurrent component failure or microcode failures that prevent printing until the conditions are corrected Unrecoverable conditions require that 61 Chapter 5 Troubleshooting Display Messages Message List the printer be powered off and the condition corrected before powering the printer back on Find the message in the Message List below and follow the suggested procedure After correcting an error press the Start key to clear the message If an error is not cleared the printer will try to print again but will display the error message until the error is cleared Table 4 Message List Operator Panel Message Explanation Corrective Action 001 END OF FORMS LOAD FORMS Attention message the printer is out of paper Load paper Press Stop If message does not clear go to the next step Check forms for dark backs or holes perforations large enough to cause false End Of Forms messages Consider ordering the black back paper detector Switch assembly Power off the printer Remove the paper guide assembly or pedestal top cover Re
276. printers check the shuttle speed page 182 Adjust the shuttle speed as necessary to match the printer s rated speed 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 121 Chapter 5 Troubleshooting Other Symptoms Table 5 General Symptom List Symptom Corrective Action Characters or dots are missing smeared too light or too dark continued 13 14 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 Horizontal misalignment of characters Dots or characters move left or right from dot row 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 i e 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 and adjust hammer phasing If the printer is a model 6400 004 04P 005 or 05P check the shuttle speed setting page 182 Inspect the shuttle frame assembly area for ink residue paper chaff
277. puy pjeog y xipueddy je1sepag uisiueuoojy qeg Cable Assembly Centronics 14H5287 replace tnis yo e you must also install a ferrite clamp See Appendix l 303 Appendix A Circuit Board And Cable Pinouts Cable Assembly Centronics Dataproducts Adapter 14H5522 304 Cable Assembly 5V Remote Power 14H5589 ce ME li N ee Y o N gt 3202 LL PIN 2 E TABLE P102 DESCRIPTION Jeo2 TERMINAL GRAY PIN TERMINAI EIN Z BLACK SLEEVE TERMINA PIN DA CU OFF SLEEVE SHUNT TERMINA PIN TERMINA 305 Appendix A Circuit Board And Cable Pinouts Cable Assembly Twinax Auto Termination 38F8254 306 Cable Assembly AC In Power Supply PIN ME AC Kit 14H5289 PIN 4 7 E To Power Supply J1 To Circuit Breaker PIN WIRE COLOR BLACK 2 WHITE 5 GREEN YELLOW 307 Appendix A Circuit Board And Cable Pinouts Cable Assembly AC Power Input AC Kit 14H5289 308 Cable Assembly Card Cage Fan E a Z F 2 GEF PIN 1 14H5285 fel WIRE TABLE GCE P306 WIRE
278. quirements apply to fasteners made of steel at a minimum engagement of 3 5 threads including chamfer and countersink For the most accurate torquing apply anti seize compound to fastener threads before you torque the fastener Fastener sizes are listed as Numbered Size Threads Per Inch For example 2 56 represents No 2 Screw 56 Threads Per Inch Carbon Steel Fasteners ANSI B18 6 3 1972 Into Medium i riu Into Steel Carbon 60 000 psi Into Weld Steel ultimate Press Studs Fasteners tensile or Nuts 100 000 psi strenath strength ultimate 9 tensile strength 2 56 25 21 oz 36 2 in oz 30 2 in oz Y 4 40 62 41 oz 75 5 07 70 5inoz i 6 32 122 7 in oz 150 10 135 10inoz 8 32 11 in Ib 18 1 in Ib 18 1inlb id 10 24 20 1 lb 25 1 5 in Ib 21 1inlb 10 32 15 1 in lb 29 2 16 29 1 lb x 1 4 20 40 3 Ib 62 4 in lb 62 4 in Ib 105 5inlb Fastener Sizes Torque for Routine Tightening of Threaded Fasteners 4 40 UNC amp 4 48 UNF 4 1 inlb 6 32 UNC amp 6 40 UNF 11 1 in Ib 8 32 UNC amp 8 36 UNF 19 1 in Ib 10 24 UNC amp 10 32 UNF 25 1inlb 339 Appendix D 340 E Safety Inspection Guide Safety Inspections Safety devices to protect customers operators and service personnel from injury are installed in all IBM 6400 printers Use this inspection guide as an aid in identifying possible un
279. r 24H8997 page 401 Support Shaft Power Stacker 24H8999 405 Holder LED Round Power Stacker 361 Appendix H Part Number Location Description 24H9000 page 407 Holder LED Flat Power Stacker page 409 24H9001 page 399 Pulley Motor Power Stacker 24H9002 page 399 Pulley Timing Belt Power Stacker 24H9003 page 401 Collar Clamp Power Stacker 24H9004 page 399 Stacker Hardware Kit Power Stacker 24H9005 page 401 Shaft Drive Roller Power Stacker 24H9006 page 401 Spacer Drive Roller Power Stacker 24H9007 page 409 Sensor Assembly PMD Power Stacker 24H9009 page 220 SIMM Flash Blank 4 MB 24H9010 page 220 SIMM DRAM Blank 8MB 24H9011 282 Expansion CT PCBA 24H9625 264 Shuttle Frame Assy Models 009 09 24L5203 page 18 6400 Line Matrix Printers Operator s Guide Hanzi 24L5204 page 18 6400 C05 C5P Line Matrix Printers Setup Guide 24L5205 page 18 6400 C05 C5P Line Matrix Printers Programmer s Reference LQ1600K 24L5207 page 268 Shuttle Frame Assembly Models C05 24L5209 page 268 Hammer Spring Field Kit Models C05 C5P 30H3981 252 Runner Stacker 30H3985 page 272 Extension Spring 30H3986 page 250 Shipping Container Kit 30H4008 page 250 Wire Rope 30H4056 page 18 Print Server User s Guide 38F8254 page 306 Twinax Auto Termination Smart T
280. r EHF Exhaust Fan LRP Left Ribbon Guide HBF Hammer Bank Fan 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 RRIB M Right Ribbon Motor RRP Right Ribbon Guide JMP on pedestal models used as a spacer Later models have stiffening clips on connectors P106 and P107 See page 198 Key Tab Typical 4 Wire Typical 2 Wire UL Cable Connector Cable Connector Pull the sides outward just enough to release the connector lock tab from the slot in the connector shell Connector shell P106 P107 Key Tab Slot P N 202362 901 Push here to we remove the shell from the controller board J106 or J107 on CMX Controller Board Figure 30 Cable Connector Shell Disassembly Assembly 197 Chapter 7 Section Replacement Procedures Connector Stiffening Clips Later model printers have connector stiffening clips on CMX board connectors P106 and P107 For earlier models the clips are available in a field kit The clips stiffen connectors P106 and P107 and help prevent accidental removal of wires when the connector shells are disconnected from the CMX board Removal 1 Prepare the printer for maintenance page 152 2 Cabinet Model Remove the paper guide assembly page 229 Pedestal Model Remove the top cover assembly page 204 3 Unsnap the front open side of th
281. r found a 1 Replace the DRAM Figure 35 page 220 2 Power on the printer If the message appears replace the CMX controller board Record the message and return it with the defective board DC PROGRAM NOT VALID find the data controller program or the validation checksum is corrupt P61 ERROR The printer could not Check flash memory on the CMX controller FLASH NOT find flash memory board If present reseat the flash SIMMs if DETECTED missing install flash SIMMs Figure 35 page 220 P62 ERROR The printer cannot 1 Download the program again 2 Ifthe message appears replace flash memory SIMMs with pre written flash See Table 8 and Table 9 on page 219 and Figure 35 on page 220 104 Message List Table 4 Message List Operator Panel Explanation Corrective Action Message P63 ERROR The printer is not Use the correct emulation software option s PROGRAM NOT compatible with the for this model printer If the printer is an IBM COMPATIBLE downloaded 6404 B01 the controller is a CBO board If program The user the printer is an IBM 6400 the controller is a may have tried to CMX board load a CMX compatible diskette in a CBO controlled printer or vice versa P64 ERROR The printer received 1 Power off the printer Download the CHECKSUM WRONG hex the complete program but the checksum did not match The data may have been corrupted during download progra
282. r maintenance page 152 Remove the shuttle cover assembly page 203 Loosen the platen open belt page 156 steps 2 3 and 4 Togo or eee Raise the forms thickness lever 1 to the fully open position ATTENTION Do not force the platen against the feeler gauge Damage to the hammer tips will result 5 Insert a 0 011 inch 0 28 mm flat feeler gauge 2 straight down between the hammer bank cover plate 3 and ribbon mask 4 within four hammer positions of the left end of the hammer bank ATTENTION 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 ne
283. r messages and troubleshooting information Also provided is a section that describes IBM service procedures Removal ATTENTION To prevent electrostatic damage to electronic components wear a properly grounded static wrist strap when handling circuit boards the shuttle frame assembly and any other electronic component 1 Prepare the printer for maintenance page 152 2 Refer to the Print Server User s Guide P N 30H4056 for information on determining if the print server is operating correctly Installation 1 Referto the Print Server User s Guide P N 30H4056 for information on installing and testing the feature 2 Return the printer to normal operation page 153 226 Operator Panel Assembly Cabinet Model Operator Panel Assembly Cabinet Model Removal 1 Prepare the printer for maintenance page 152 Open the printer cover Remove the four screws securing the operator panel plate to the panel bracket See Figure 42 page 254 4 Press down on the plastic tab at the upper rear of the panel and slide the operator panel downward on the mounting plate until the tabs on the panel housing slide out of the cutouts 5 Lift the operator panel assembly and disconnect the phone style cable connector Installation 1 Connect the phone style operator panel cable to the bottom of the operator panel See Figure 42 page 254 2 Position the operator panel over the cutouts in the panel plate Slide the pan
284. r power cord during an electrical storm lt 5 gt Power off the printer and disconnect the power cord before connecting or disconnecting any communication port teleport or attachment cable connector If a fault condition occurs in the printer four things happen The Attention indicator on the operator panel flashes on and off If enabled the audible alarm sounds Press Stop to silence the alarm A message describing the fault condition appears on the LCD Certain Unit Check conditions see below are automatically recorded in the error log The error log is a buffer in NVRAM that stores up to 50 messages as a list The most recent message is stored at the top of the list the oldest message at the bottom of the list If more than 50 messages occur before the log is cleared the oldest messages are deleted so the log never contains more than 50 messages You can print the error log and clear it See page 135 The LCD displays two kinds of printer conditions An Attention condition halts printing until the operator replenishes supplies clears paper jams corrects a problem of communication between the printer and host computer etc A Unit Check condition is a failure detected by self test and fault circuitry Unit check conditions are either recoverable or unrecoverable Recoverable unit check conditions are errors detected in the electromechanical print mechanism that may be temporary and correctable by cycling power The
285. ractor the splined shaft lt gt Alignment Mark re Splined Shaft Figure 39 Splined Shaft and Tractor Installation 240 Shaft Support Shaft Support Removal 1 Prepare the printer for maintenance page 152 2 Open the printer cover 3 Unlock the tractors and slide them to the far right 4 Remove the paper supports from the splined shaft and support shaft See Figure 50 page 274 item 21 Remove the E ring page 274 Figure 50 ATTENTION Hold the tractors while removing the support shaft and be careful not to lose the curved spring washers See Figure 50 page 274 item 5 6 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 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 Figure 50 page 274 Slide the tractors onto the support shaft Slide the support shaft assembly through the right side plate While pushing on the knob to compress the curved washers install the E ring in the groove on the bushing Install the paper supports on the splined shaft and support shaft See Figure 50 page 274 item 21 Return the printer to normal operation page 153 241 Chapter 7 Section Replacement Pro
286. rd 145 RESETTING PLEASE WAIT 106 RESETTING PLEASE WAIT 180 Resistors terminating location of 236 RESTORING BOOT CODE 107 RESTORING BOOT CODE message 180 Ribbon drive motor replacement 225 guide assembly L R replacement 237 guide assembly alignment 166 hub replacement 238 mask replacement 200 specifications 327 RIBBON OUT OF INK CHANGE RIBBON 107 Run Mode 55 418 S Safety inspection guide 341 notices defined 17 SECURITY CODE VIOLATION 180 Security module location 220 Self Test 10 100Base T 54 Self tests customer engineer CE 134 operator print 132 printer information menu 143 SENDING PROGRAM TO EC PROCESSOR 107 180 SERVICE 107 Service checks customer s power source 345 power on off verification 345 print interlock 345 print mechanism 343 printer power cable 345 Set shuttle speed 182 Shaft splined replacement 239 splined skew adjustment 168 support replacement 241 Shuttle cover assembly replacement 203 frame assembly replacement 242 speed setting 182 Signal mnemonics 347 SIMMs location and replacement 217 Soft reset 145 Software loading into flash memory 176 SOFTWARE ERROR Cycle power 107 Specifications dimensions printer 329 duty cycle 336 electrical 330 environmental 329 interfaces 336 paper 328 ribbon 327 Speed shuttle set 182 Splined shaft replacement 239 skew adjustment 168 Spring extension replacement
287. rd perforated tractor feed strips A maximum sheet length of 16 inches 40 64 cm between top and bottom perforations Thickness Not to exceed 0 025 inch 0 064 cm including backing sheet On pedestal models when using the rear paper exit the maximum width is 16 inches 40 64 cm On cabinet models forms longer than 12 inches 30 48 cm can be printed by opening the front and rear printer doors Printer Dimensions Cabinet Model Pedestal Model Height 42 5 inches 108 cm 35 5 inches 90 2 cm Width 27 inches 68 6 cm 24 6 inches 62 5 cm Depth 29 inches 73 7 cm 30 inches 76 2 cm 32 5 inches 82 6 cm with power stacker Weight 225 lbs 102 1 kg 120 Ibs 54 4 kg 285 Ibs 129 3 kg packaged 160 Ibs 72 6 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 IBM 6400 Series Printers comply with the requirements of the ENERGY STAR Computers Program of the U S Environmental Protection Agency 329 Chapter Electrical Characteristics Electrical Characteristics 330
288. re met you should be able to ping the printer from a network host You can test by starting a telnet session telnet IP address and sending start fox prn lt Return gt stop prn lt Return gt This command sequence sends consecutively numbered lines of text from the interface to the printer The fox test is resident in the network interface and verifies that it can receive commands and can transfer data successfully to the printer If no network cable is connected or the cable is defective and the IP address is configured from the control panel the top LED will be off and the bottom LED will blink on off 54 10 100Base T LEDs And DIP Switches 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 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 NET Network Indicator The NET LED displays the status of the network link NET Rate Indication ON Constantly Indicates link integrity ON Flashes OFF 1 3 Flashes off 1 3 sec
289. replacement 211 Hammer bank cover assembly replacement 200 fan assembly replacement 208 210 wiring diagram 287 HAMMER BANK NOT INSTALLED 102 HAMMER COIL BAD etc 103 Hammer phasing adjustment 173 Hanzi models 14 Hard reset 145 Hex code printout 140 Hub ribbon replacement 238 IBM Coax twinax expansion board replacement 215 Illustrations replacement procedures 249 Indicators 10 100Base T 54 Information menu printer 143 Inspection safety guide 341 Installation 27 Installed memory 143 Interface coax twinax multi platform replacement 194 specifications 336 INTERRUPT UNUSED VECTOR 00 103 K Keys operator panel cabinet models 20 pedestal models 22 L Labels specifications 328 LAN interface assemblies replacement 207 Levers and knobs 24 Line matrix printing explained 35 LOADING PROGRAM FROM PORT 103 180 LOADING PROGRAM INTO FLASH 103 Magnetic pick up assembly gap adjustment 216 replacement 216 Maintenance adjustments 151 cleaning the printer 29 overview 13 preventive 29 Manual how to use 16 notes and notices 17 printing conventions 18 related documents 18 Mechanical controls and indicators 24 Memory modules location and replacement 217 Memory flash loading software 176 Memory installed 143 Menus 415 boot diagnostics 137 Customer Engineer CE tests 134 Messages list of 62 Metric measurement conversion tables 33
290. rint test If the message appears replace the power supply board 78 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action 058 SHUTTLE JAM SEE USER S GUIDE continued 10 Run a print test If the message appears replace the shuttle frame assembly 059 CANCEL PRINT ACTIVE Non error status message No action required 79 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel Message Explanation Corrective Action 060 PRINTER HOT CMX controller board sensors report high temperatures on the board This message indicates internal temperatures over 60 Celsius 140 Fahrenheit Print jobs do 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 environment is one with an ambient temperature at or above above 40 Celsius 104 Fahrenheit or is dirty enough to create blockage of the cabinet fan vents The printer must never be run at ambienttemperatures greater than 40 Celsius 104 Fahrenheit If the printer is located in such an environment relocate it t
291. rinter has crashed 149 Chapter 5 150 The Power On Sequence Jump Back into Flash and Clear DRAM Boot code jumps back into flash memory then clears the DRAM that held the boot code 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 Clear Uninitialized RAM Variables Set Initialized RAM Variables Configure RAM allocated based upon amount in the printer Jump to MTOS Multi Tasking Operating System Initialize the Processor cache vector table etc Partition RAM for Tasks Allocate Peripheral Interfaces console driver etc Start Main Task supervisor Verify and Initialize NVRAM statistics are cleared if NVRAM is not valid Initialize Libraries fault system emulation Load Front Panel Menus from ROM 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 PGL or VGL Base Emulation Task Initialize Fonts Initialize Graphics Library Complete Emulation Library Initialization Wait for all emulation tasks to initialize Front Panel Task Display READY on operator panel 6 Introduction Adjustment Procedures The IBM 6400
292. rmally de energized When hammer driver logic determines that the hammer must print a dot a current pulse energizes the coils The polarity of the resulting magnetic field opposes the field of the permanent magnet canceling its effect and releasing the hammer The hammer springs forward strikes the ribbon and paper and leaves a dot impression of the hammer tip on the paper While the hammer is in flight the coil is de energized and its field collapses After striking the ribbon and paper the hammer rebounds and the permanent magnet recaptures it When the shuttle reaches the end of a sweep it reverses direction the paper is moved up one dot row and the hammer springs print the next row of dots as the shuttle sweeps in the opposite direction Paper Transport System Paper Transport System Paper Path Pd Il Tractors Vertical Horizontal 2 d 24 Splined iment Ko en MEE AP LLL Splined Shaft A fa 2 Pulley 2 Tractor 4 j Support Shaft Shuttle Cover Assembly Z Paper Feed Timing Belt under the cover Paper Supports Figure 13 Paper Transport System A two phase DC stepper motor directed by the EC on the controller board drives two tractor sprockets by means of a toothed belt and splined shaft pulley arrangement The stepper motor permits extremely accurate incremental vertical paper movement This drive configuration is designed for continuous fan folded paper three to 17 inches wide and on
293. rocedure to request assistance 046 EC STOPPED AT Where state is a 1 Power off the printer Remove all flash STATE lt state gt number from 0000 to memory and DRAM SIMMSs Inspect the 0010 The Engine SIMM sockets on the CMX controller Controller processor board If any socket pins are bent or has stopped and is in damaged replace the CMX controller the state identified by board the number 2 Install the flash and DRAM SIMMs displayed making sure they are fully and correctly If the EC stops at seated Power on the printer Download state 0000 at power the emulation If the message appears up replace the CMX replace the flash memory with pre written controller board flash See Table 8 and Table 9 on page Record the message 219 and Figure 35 on page 220 and return it with the defective board 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 the defective board 76 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action 057 CLOSE PLATEN The forms thickness lever is open Load paper Close the forms thickness lever If message does not clear go to the next step Power off the printer Remove the paper guide assembly or pedestal top cover Disconnect conne
294. roller DC and the Engine Controller EC The DC is responsible for e Host I O 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 17 summarizes this architecture 45 Chapter 4 Controller Board Non Volatile 25 or 40 MHz Memory DC FLASH Motorola 8kx8 Up to 30Mb 68EC030 2 SIMM Sockets Microprocessor DC Expansion Port Expansion Interface Port DC DRAM Up to 32Mb in 2 SIMM Sockets RS 232 DC ASIC Diagnostic Diagnostic diced gt RS 232 422 Port Port Dri IEEE 1284 Parallel Control Control Panel Panel Interface Data Controller DC Engine Controller EC UM Fault Sensors gt ASIC Feed I Ribbon EC 64k x 16 Analog Drive Circuitry gt Shuttle FLASH 20MHz Memory Siemens 80C166
295. rt After sending the message the refresh rate is set to the proper rate and DRAM is ready to be tested e 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 operator panel and to get the time for DRAM refreshes If the boot code detects a problem 146 CMX Controller Board Handshake Sequences with the I O clock the error blink code 4 3 4 is sent to the diagnostic LED on the CMX board Read Operator Panel Keys The operator panel keys are read to determine if the user is requesting that the printer be placed in download mode diagnostic mode or debug SIMM disabled If Cancel and Start are pressed during start up the printer is placed in download mode If Eject Restore and Stop 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
296. s 10 Close the printer cover 153 Chapter 6 Belt Paper Feed Timing Adjustment Belt Paper Feed Timing Adjustment 154 To make this adjustment follow these steps 1 2 10 11 Prepare the printer for maintenance page 152 Cabinet Model Remove the paper guide assembly page 229 Pedestal Model Remove the top cover assembly page 204 Cabinet Model Loosen four screws and remove the barrier shield See page 258 Figure 44 items 3 and 4 Pedestal Model Remove the four screws securing the paper guide and barrier shield Remove the paper guide and barrier shield See page 260 Figure 45 items 3 4 and 5 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 motor mount bolts 2 Using the straight end of a force gauge apply 15 pounds 66 7 N of pressure to the paper feed drive motor 3 near the mounting base of the motor Use the splined shaft 4 to steady the gauge Reduce tension to 12 pounds 53 4 N and torque the paper feed motor mount bolts 2 to 18 2 inch pounds 2 03 0 23 Nem Snap the timing belt cover 1 into the slots in the side plate Cabinet Model Install the barrier shield and tighten the four screws See page 258 Figure 44 items 3 and 4 Pedestal Model Install the paper guide and barrier shield and tighten the four screws See page 260 Figure 45 items 3
297. s Tractors or tractor belts Selecting And Running Tests e Underlines An underline pattern useful for identifying hammer bank misalignment Hammer bank cover Hammer tips Paper feed belt or motor Splined shaft bearings Tractor bearings or belts Selecting And Running Tests To run Operator Print Tests you use the printer configuration menus as shown below Step Press Displayed Result Notes 1 Install the ribbon load paper and power on the printer 2 NOT READY Printer must be in NOT Stop READY mode to access the tests 3 OPERATOR MENU Unlocking ENTER key ScrollT Scroll UNLOCKED allows you to test the printer 4 OPERATOR MENU First of series of Menu PRINTER CONTROL configuration menus 5 OPERATOR MENU Advances to the Operator Scrollf UNTIL OPERATOR PRINT TESTS Printer Tests menu 6 OPERATOR PRINT TESTS Advances to first option in Enter PRINTER DEMONSTRATION Operator Printer Tests menu 7 OPERATOR PRINT TESTS Cycles through list of Scroll UNTIL TEST NAME tests Stop when your test displays 8 OPERATOR PRINT TESTS The test you selected a TEST NAME starts printing 9 NOT READY The printer test stops Stop printing 133 Chapter 5 Customer Engineer CE Tests Customer Engineer CE Tests A set of printer tests is included in the configuration menu structure for
298. safe conditions in a 6400 series printer Perform the inspection steps outlined in this guide before the normal inspection for Maintenance Agreement Qualification or any time you are instructed to make a safety inspection If you find any unsafe conditions determine the severity of the hazard and whether or not you can continue the inspection without first correcting the problem NOTE The correction of any unsafe condition is the customer s responsibility Preparation You must have completed the Electrical Safety Training Course for IBM Customer Engineers self study course 77170 or existing level to do the Safety Inspection Have the following items available e Electrical Safety for Customer Engineers Order No 5229 8124 e AFluke meter P N 8496278 or similar device for resistance and voltage measurements e ECOS Electrical Safety Tester P N 6339695 in the United States or a similar safety tester in other countries For each safety check on the following pages do the steps in the order presented Do not omit any steps 341 Appendix E Prepare The Printer for Inspection Prepare The Printer for Inspection To prepare the printer for a safety inspection read the safety notices below then do the following steps DANGER 3 Hazardous voltages are present in the printer with the power cord connected to the power source Switch off printer power and unplug the printer power cord b
299. same time SERVICE PRINTER MECHANISM TESTS appears on the display Press Scroll Scroll to unlock the Enter key Press the ScrollT or Scroll key until SERVICE PRINTER MGMT appears on the display Press Enter PRINTER MGMT DIAGNOSTIC PORT appears on the display Press Enter DIAGNOSTIC PORT and the current diagnostic port setting appears on the display If the current setting is DEBUG ETHERNET go to step 11 Press Scroll until DIAGNOSTIC PORT DEBUG ETHERNET appears on the display Press Enter An asterisk appears next to the selection indicating it is now the diagnostic port Press ScrollT Scroll to lock the Enter key Press Stop to exit the menu and put the printer in the NOT READY state Power off the printer wait a few seconds then power on the printer to activate the new diagnostic port 183 Chapter 6 _ Ethernet Initialization 184 Replacement Procedures And Illustrated Parts Lists Organization Of This Chapter This chapter is divided into two sections e Section I Replacement Procedures This section contains written procedures for removing and installing components that are replaceable at the field service level of maintenance The procedures in this section refer you to the illustrations in Section Il Section begins on page 186 e Section Illustrated Parts Lists This section contains drawings of all assemblies comprising the printer On the page fa
300. se its other stored configuration settings as happens with DIP switch 1 Before reconfiguring the unit with an IP address DIP switch 2 must be set back to the OFF up position otherwise it will lose its IP address through another power on off cycle DIP Switch 3 z Link Integrity Disable Default position is OFF up which means link integrity is enabled This DIP switch determines whether link integrity is turned on or off in the Ethernet interface It may be necessary to turn link integrity off if the unit is connected to an older hub etc Link integrity only applies to the 10Base T interface option For more information For more information about the 10Base2 or 10Base T Ethernet interface refer to Ethernet Interface User s Manual Form No S246 0153 53 Chapter 4 Printer Interface 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 AN 1 Shown in OFF 2 default position STAT System ur Status pe 2 d e NET Data to sE x Network a Inspect the two LEDs on the 10 100Base T Ethernet interface 1 When an IP address is configured into the printer via the control panel the bottom LED should be blinking on and off at the same rate 2 When a working network cable is installed the top LED should be on steadily and will blink off for 1 3 second when data are received When these two conditions a
301. ser s Manual Form No S246 0154 56 AC Power Power Supply Board The printer power supply is contained on a printed circuit board mounted in the card cage The power supply automatically senses and adjusts to any commercial electrical system that provides AC mains potential in 50 or 60 Hertz systems In other words the printer is fully operational from available commercial power anywhere in the world The power supply converts alternating current AC to direct current DC at three voltage levels and sends the DC voltages to the controller board The controller board distributes all DC power to the logic and electromechanical circuits AC Power The power supply operates on AC voltages ranging from 88 to 270 V It can tolerate variations in frequency of 47 to 63 Hz The power supply is designed to withstand an AC input overvoltage of 300 VAC for one second with no degradation of DC output voltage or damage to printer circuits DC Power The power supply board contains two DC power supply systems for the printer The first is a 5 V bus for logic The second consists of 48 V and 8 5 V buses for the hammer bank and all motors The 5 V supply has an isolated return line that connects to the 48 V return at the printer load Both returns are tied together in a single point ground The 5 V power supply has its own inverter separate from the 48 V and 8 5 V outputs There is an opto isolated input on the power supply th
302. shooting doge nS Ma 59 En 59 Troubleshooting 59 exceed 60 Troubleshooting Display Messages eee 61 Message List uii ed eau E eres PER 62 Troubleshooting Other Symptoms sse 109 General Symptom List 110 Communications 131 Operator Print 132 Selecting And Running 133 Customer Engineer CE 4 134 Boot Diagnostics 137 Hex Gode PrintOUt 5 oed e 140 ASCII Character 142 Printer Information 143 Soft vs Hard 145 Soft Reset iino Aad eA ee ed ee 145 Hard Reset Cycle 145 The Power On 146 Controller Board Handshake Sequences 146 DC Software Initialization And Power 150 Table of Contents 6 Adjustment Procedures 151 Introduction cuc ene De tu Dn Deo ee Deed pe an 151 List Of Adjustments en te nre tete erre 151 Preparing The Printer For Maintenance 152 Returning The Printer To Normal 153 Bel
303. sors the MECA ASIC and the EC processor The platen open motor is driven by a stepping motor controller IC and the EC processor Control of 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 Printer Interface The printer interface is the point where the data line from the host computer plugs into the printer The printer interface processes all signals and data to and from the host computer The printer supports supports a number of standard and optional interfaces to the host e Centronics parallel standard e 1284 parallel standard e EIA 232 E serial standard e EIA 422 B serial standard e Coaxial twinaxial Expansion CT optional e Ethernet 10Base2 10Base T or 10 100Base T adapter optional Selection of the input output interface is controlled by configuration menus accessed at the operator panel It is possible to
304. splay Press ScrollT Scroll to unlock the Enter key Press the Scroll or Scroll key until SERVICE SHUTTLE SPEED appears on the display 7 Press Enter SHUTTLE SPEED 475 or SHUTTLE SPEED 500 appears on the display The asterisk indicates which shuttle speed is currently active Press Scroll until the shuttle speed you want appears on the display Press the Enter An asterisk appears next to the selection indicating it is now the active shuttle speed 10 Press ScrollT Scroll to lock the Enter key 11 Press Stop to exit the menu and put the printer in the NOT READY state 12 Power off the printer wait a few seconds then power on the printer to activate the new shuttle speed value 13 Select and run the Ripple Print printer test page 132 14 Examine the printout if gaps or dark bars appear in the printout go back to step 3 and set the shuttle speed to the other option 15 When the printout is acceptable power off the printer and close the printer cover 182 List Of Adjustments Ethernet Initialization To initialize the Ethernet interface do the following steps 1 2 11 12 13 Power on the printer Wait for READY ETHERNET ADAPTER IS READY to display on the LCD If the Ready indicator is on press the Stop key The printer must be in the NOT READY state to do this procedure Press Scroll Scroll Return Enter Press all four keys at the
305. ssembly 33 Chapter 3 Cleaning The Printer 34 A Principles Of Operation Line Matrix Printing The printer creates characters and graphics by printing patterns of ink dots on paper an entire line at a time This technique is called line matrix printing Every text character is stored in printer memory as a pattern of dots ona logical grid called the dot matrix See Figure 8 The ink dots are made by a row of small hammers mounted on a shuttle that sweeps rapidly back and forth Printer logic circuits divide every line of incoming data into horizontal dot rows The hammers put dots at the required positions for the entire line by striking an inked ribbon and the paper 1 lt Column No 12 0 10 inch 0 00835 inch 0 01389 inch First row and column of next character line at 6 0 02 inch es 4 Figure 8 A Dot Matrix First row and column of next character column at 10 cpi Lowest descender dot line 35 Chapter 4 36 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
306. ssembly Do not remove holddown clamps and Screws To Terminator Board on Shuttle Frame 18 Figure 47 Print Mechanism and Circuit Boards Early Models 264 Illustrations Of Printer Components Item Part No 2222 Order No Description Notes 1 63H7518 Hammer Bank Rbn Mask Cover Models 004 04P 005 05 63H7519 Hammer Bank Rbn Mask Cover Models 008 08P 009 09P 63H7520 Hammer Bank Rbn Mask Cover Models 012 014 2 14H5274 Shuttle Frame Assembly Models 004 04P 24H8648 Shuttle Frame Assembly Models 005 05P 14H5516 Shuttle Frame Assembly Models 008 08P 24H9625 Shuttle Frame Assembly Models 009 09P 14H5517 Shuttle Frame Assembly Model 012 90H3269 Shuttle Frame Assembly Model 014 14H5275 Hammer Spring Assembly Models 004 04P 005 05P 14H5512 Hammer Spring Assembly Models 008 08P 009 09P 14H5513 Hammer Spring Assembly Models 012 014 3 14H5644 Power Supply PCBA Models 004 04P 005 05 008 08P 012 90H3268 Power Supply PCBA Models 009 09P 014 4 Ref P101 Cable Connector 5 Ref Cable Assy AC In Power Supply Part of Field Kit AC Assy 14H5289 6 14H5643 Controller Board CMX V5 0 All models 004 and 04P Models 008 and 012 with Ser Nos 01AXXXX 01BXXXX and 01CXXXX 24H8647 Controller Board CMX V5 5 25 All models 005 08P MHz Models 008 and 012 with Ser Nos 01DXXXX 01EXXX and higher All models 009 O9P 90H3271 Controller Board CMX V5 5 40 Model 014 050 P50 010 P10
307. t Paper Feed Timing 154 Belt Platen Open Adjustment see 156 Paper Drive Motor Pulley Alignment eene 158 Paper Scale Alignment sssssssssseeeeeen nnns 160 Platen Gap Adjustment 162 Platen Open Motor Pulley Alignment eene 164 Ribbon Guide Alignment sse 166 Splined Shaft Skew Adjustment see 168 Adjusting The End Of Forms Distance 169 Hammer Phasing Adjustment eene 173 Downloading 6400 Microcode From The World Wide Web 175 Loading Flash 176 Coil Temperature 181 Set Shuttle Speed edt ae ei is 182 Ethernet Initialization seen 183 7 Replacement Procedures And Illustrated Parts Lists 185 Organization Of This Chapter 185 Section Replacement Procedures 186 List Of Procedures 186 Belt Paper Feed 0 188 Platen OPEN ae EE 189 Circuit Board 000 220 190 Circuit Board Power 192 Circuit Breaker 42 2 193
308. t 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 tractors Check and adjust the paper feed belt Replace the belt if it is damaged 74 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action 032 FORMS JAMMED TIMEOUT CLEAR JAM AND RELOAD FORMS continued 11 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 the defective board If the message does not appear replace the paper detector switch assembly and set the paper motion detector PMD to ENABLE S 041 BUFFER OVERFLOW The print buffer has overflowed on a serial interface The printed output may contain random asterisk characters 1 Make a configuration printout Verify that the printer matches the host serial interface configuration settings for Data Protocol Baud Rate Data Bits Stop Bits Parity 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 a
309. t fail test Make sure connector P107 EHF has a good connection at J107 on the CMX controller board Inspect for obstructions of airways and vents Check for items beneath the printer blocking cabinet vents Make sure cabinet exhaust fan vents are not blocked Power on the printer Check for fan operation If the message appears or the fan doesn t work replace the exhaust fan Power on the printer If the message appears replace the CMX controller board Record the message and return it with the defective board 81 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel Message Explanation Corrective Action 065 HAMMER BANK FAN FAULT Hammer Bank Fan Fault Sensors cannot detect current in the fan circuit i Cycle power If the message appears press Stop Power off the printer Remove the paper guide assembly or pedestal top cover Disconnect connector P107 from the CMX controller board Test connector P107 HBF for shorts or opens Refer to the Main Wire Harness Test Tables on page 291 Replace components that fail test Make sure P107 HBF has a good connection at J107 on the CMX controller board Inspect airways and vents for obstructions Power on the printer If the message appears replace the CMX controller board Record the message and return it with the defective board 069 DATA CLEARED This message appears when data are cleare
310. tan South Africa 14F0034 Line Cord IBM India United Kingdom 14F0052 Line Cord IBM Switzerland 14F0070 Line Cord IBM Chile Italy 14F0088 Line Cord 9 Feet Israel 14H5301 Line Cord 6400 12 Foot United States 125 Volt 14H5303 Line Cord 6400 8 Foot Chicago 14H5305 Line Cord 6400 12 Foot United States 220 Volt 14H5309 Line Cord 6400 Denmark 14H5311 Line Cord 6400 Israel 14H5313 Line Cord 6400 Chile Italy 355 Appendix G Part Number Description 14H5315 Line Cord 6400 Switzerland 14H5317 Line Cord 6400 India United Kingdom 14H5319 Line Cord 6400 Europe EMEA 14H5321 Line Cord 6400 Pakistan South Africa 14H5323 Line Cord 6400 Australia 14H5325 Line Cord 6400 Japan 14H5335 Twinax Auto Termination Cable 47 Inches 14H5541 DP Adapter 6400 21F4342 Cable AS 400 RS 232 IBM 38F8254 Twinax Auto Termination Cable 57G7261 Power Cord 6 Feet Non Lock United States Canada 110 Volt 58F2861 Conn Cable RISC System 6000 IBM 63H7362 Cable RISC System 6000 63H7364 Cable AS 400 RS 232 63H7366 Cable PC Parallel 63H7368 Cable PC RS 232 63H7456 LAN Power Coupling 92F3176 Cable PC Parallel IBM 356 H Part Numbers Part Number Location Description 01P4611 page 274 Tractor Assembly Power Stacker 01P4698 page 401 Fence Wireform Power Stacker
311. te the Boot Diagnostics Menu page 137 and run MISC UTILITIES RUN MEMORY TESTS If memory fails test replace the DRAM If memory tests OK replace the flash memory with pre written flash See Table 8 and Table 9 on page 219 and Figure 35 on page 220 Power up the printer Download the emulation If the download fails replace the CMX controller board Flash SIMM won t copy 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 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 137 If the DESTINATION NOT DETECTED message appears the blank SIMM is not a type supported by the boot code on the original SIMM If SOURCE LARGER THAN DESTINATION appears the blank 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 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 124 General Symptom List Table 5 General Symptom List Symptom Corrective Action Paper fee
312. tem 11 11 5761521 Ground Clip Splined Shaft 12 5761460 Splined Shaft Assembly 13 Ref Screw Thread Forming 6 32x 25 Part of item 18 14 Ref Clamp Bearing Part of item 18 15 Ref Tractor Support Shaft Part of item 19 16 5791466 Includes L and R tractors 17 Ref E Ring Part of item 19 18 14H5217 Tractor Shaft Hardware Kit 19 14H5214 Tractor Shaft Kit 20 Ref Bushing Part of item 18 21 24H8593 Paper Support 2 22 Ref Link Splined Shaft Skew Adjustment 23 01P4611 Tractor Assembly Power Stacker Installed at factory on models with power stacker 275 Section II Illustrated Parts Lists 7 Chapter Figure 51 Platen NOTE Black tape faces paper motion detector NOTE Item 25 Platen Hardware Kit 276 Illustrations Of Printer Components bon o Description Notes 1 Ref Setscrew Part of item 25 2 Ref Bracket Platen 2 Part of item 25 3 5791469 Ironer Assembly Reverser Paper Feed 4 Ref Screw Thread Forming 3 6 32x 25 5 5791571 Bracket 6 Ref Plate Ironer 7 08H7936 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 14H5280 Platen Switch Kit Platen Interlock Switch 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 63H7478 Platen Lever Kit 16 Ref Spring Extension 1 12L Part of item
313. ter Send a print job to the printer If the message appears replace the twinax cable Send a print job to the printer If the message appears go to Communications Failures page 131 66 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action 015 COMMUNICATIONS CHECK CHECK CABLE The line is not active on a twinax interface Power off the printer Disconnect the AC power cord from the printer Check the twinax host data cable connection and twinax I O cable connection at the CT board Reseat the twinax host data cable connection and the twinax cable connection at the CT board Disconnect the twinax auto termination cable from the printer Test the cable for the resistances shown on page 306 If resistances are not correct replace the twinax auto termination cable Connect the AC power cable to the printer Power on the printer Send a print job to the printer Verify that all other devices on the twinax line are working properly Refer to line problem determination procedures as recommended by the host system If the message is gone the host has reestablished communication with the printer If all other twinax devices work properly and the message still appears replace the coax twinax expansion board Record the message and return it with defective board 016 INVALID COMMAND The printer detects a twinax protocol communications
314. ter will stop printing when an out of paper fault is detected The unit of measurement is dot rows The number of dot rows may be adjusted up or down 1 2 inch from the factory default of 40 dots Clear Error Log This menu selection enables you to delete the stored contents of the error log The error log automatically records certain unit check conditions in a buffer in NVRAM that stores up to 50 messages The most recent message is stored at the top of the list the oldest message at the bottom of the list If more than 50 messages occur before the log is cleared the oldest messages are deleted so that the log never contains more than 50 messages Print Partial Line If the final line of a data stream has no line feed or carriage return character it is retained in the buffer DISABLE holds the line in the buffer ENABLE permits the line to be printed after a timeout 135 Customer Engineer CE Tests Chapter 5 Top Exit Tear Distance This parameter allows adjustment in 0 01 inch increments of the final location of page perforations when top paper exit is used Shuttle Speed Sets shuttle speed in 6400 004 04P 005 and 05P printers See page 182 Set Coil Temperature 136 An automatic sequence in printer software that recalibrates hammer coil temperature This procedure applies only to 6400 014 and 6400 15 printers See page 181 Selecting And Running CE Tests To run CE Tests you use the printer configuration
315. tform Interface page 194 Connector Shells sssssssssssseeeeeen nenne page 195 Connector Stiffening page 198 Cover Assembly Hammer Bank Ribbon Mask page 200 Cover Assembly Shuttle esses page 203 Cover Assembly Top Pedestal page 204 Daspols E page 205 Doors Cabinet page 206 Ethernet Interface Assemblies see page 207 Fan Assembly Cabinet page 208 Fan Assembly Card page 209 Fan Assembly Hammer Bank page 210 Hammer Spring page 211 Coax Twinax Expansion page 215 Magnetic Pick up MPU page 216 Memory and Security page 217 Motor Assembly Paper page 221 Motor Assembly Platen page 223 List Of Procedures Motor Assembly Ribbon 8 page 225 Network Print page 226 Operator Panel Assembly Cabinet
316. th banks but put pre programmed banks It does not matter which Latch SIMMs in J11 SIMM goes into which bank 3 IMPORTANT J11 and J16 must always be filled no matter what combination of SIMMs is used The CMX board does not support EDO RAM Blank SIMMs 4 MB Flash 24H9009 4 DOM 3 HORNO Security Module Base 14H5509 Security Module Graphics 14H5490 IPDS ASCII CTA Datastream ASCII IGP CTA IGP On pis Code V Code V Code V Flash 8 MB 8 MB 8 8 8 MB 8 4MB Memory DRAM 8 MB 8 MB 8 8 MB 8 MB 8 8 CT Installed No No Yes Yes Yes Yes No Security PAL 154143 002 154143 001 154143 002 154143 001 154143 002 154143 001 154143 005 Vendor P N 14H5509 14H5490 14H5509 14H5490 14H5509 14H5490 38L0821 220 Figure 35 Memory and Security Modules Motor Assembly Paper Feed Motor Assembly Paper Feed Removal 1 2 Prepare the printer for maintenance page 152 Cabinet Model Remove the paper guide assembly page 229 Pedestal Model Remove the top cover assembly page 204 Cabinet Model Loosen four screws and remove the barrier shield See Figure 44 page 258 items 3 and 4 Pedestal Model Remove the four screws the barrier shield and the paper guide See Figure 45 page 260 items 3 4 and 5 Remove the timing belt cover by squeezing the top and bottom to release the plastic tabs from the slots in the side plate page 258
317. the message and return it with defective CMX board 135 PLATEN INVALID STATE SEE USER S GUIDE 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 136 PLATEN INVALID PARAMETER SEE USER S GUIDE 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 98 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action 137 SHUTTLE INVALID COMMAND SEE USER S GUIDE 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 Oycle 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 138 SHUTTLE INVALID PARAMETER SEE USER S GUIDE Firmware error on the CMX controller board 1 Cycle power Run the print job again If the message appears download the emulation soft
318. the printer is in READY mode on line no errors are pending and the printer is ready to process data Off when the printer is in NOT READY mode off line Flashes when the printer is receiving data from the host Flashes when an error occurs After correcting the error press Stop to turn off this LED Applies AC power to the printer 1 on 0 off This switch is also a circuit breaker The LCD Liquid Crystal Display displays printer status messages Puts the printer in the READY on line mode This key also clears fault conditions exits program mode menus moves paper back to print position after View is pressed and restores print position after an eject Puts the printer in the NOT READY off line mode This key also silences the audible alarm stops a Printer Test and restores after an eject Stop Enter resets the printer Advances paper to next Top Of Form as defined by the current page length Sets TOF and moves paper downward from the tractor alignment notches to the print position Moves paper up one line as determined by current line spacing Press to move the current print position up to the tractor area for viewing Press again to return paper to original print position Cancels a print job Moves paper for viewing or tear off This key is configurable refer to the Operator s Guide If in the NOT READY mode this key puts the printer in the PROGRAM mode If the configuration menus are locked the LCD ind
319. tioned over the power supply board CAUTION 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 guide assembly or pedestal top cover Power on the printer Load paper 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 the defective board 83 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel Explanation Corrective Action Message 081 POWER SUPPLY The power supply has Replace the power supply board VOLTAGE FAILURE failed Power on the printer If the message appears replace the CMX controller board 082 POWER SUPPLY 8 5V FAILED 8 5 Volt Power Failed Internal 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 the defective board Power on the printer If the message appears replace the shuttle frame assembly 083 INTAKE FAN FAULT Sensors cannot detect current in the card cage fan circuit Cycle pow
320. tle drive motor is built into the shuttle assembly casting and drives two connecting rods on a crankshaft See Figure 11 The small end of one connecting rod attaches to the hammer bank the small end of the other 39 Chapter 4 40 Printing Mechanism 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 12 A permanent magnet is imbedded along the length of the hammer bank and acts on the hammer springs through individual pole pieces The pole pieces magnetically attract and hold the free end of the hammer spring under tension This is called the retracted state NOTE 6400 004 hammer bank shown Hammer Bank Assembly Coils Magnet Pole Pieces Hammer Spring Assemblies Tungsten Carbide Hammer Tip Hammer Spring Assembly Figure 12 Hammer Springs and Hammer Bank Detail Two electromagnetic coils are mounted behind each hammer and wound around each pole piece The coils are no
321. tments 9 Connect the parallel data cable to the parallel port of the printer 10 Plug the AC power cord into the printer 11 Power on the computer 12 On the printer control panel press and hold down the Start Cancel keys Without releasing the keys power the printer on Continue holding the Start and Cancel keys down for five seconds then release them NOTE The port default is CENTRONICS this is the standard download through the parallel port If you want to use the default continue at step 17 13 When you see WAITING FOR PROGRAM DOWNLOAD on the LCD press the Scroll key SELECT DOWNLOAD PORT DATAPRODUCT appears on the LCD 14 Press ScrollT again to cycle through the download ports available in the RS422 19 2K RS 422 serial 19200 baud RS422 38 4K RS 422 serial 38400 baud RS422 115K RS 422 serial 115000 baud 15 Press Scroll Scroll to unlock the Enter key 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 16 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 17 At the DOS prompt on the computer type FILENAME EXE pb lt return gt where FILENAME EXE is the
322. 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 36 232 Platen Washers Platen Adjust lt Q a Bracket Mechanism Base Platen Seat 29 U Figure 37 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 Figure 52 page 278 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 Figure 51 page 276 item 26 12 Apply bearing lubricant to the nylon bearings in the two spring links slide the spring links onto the two platen shafts and connect the springs to the spring hooks in the side plates See Figure 51 page 276 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
323. tor Power on the printer Operate the power stacker and check that 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 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 Check continuity of cables See Appendix A Replace any cable that is damaged or fails continuity test 68 Message List Table 4 Message List Operator Panel Message Explanation Corrective Action 018 STACKER FULL CHECK STACKER Status message the power paper stacker is full Unload the stacker Check the stacker limit switches See page 119 If the limit switches are OK go to the next step Power off the printer Remove the paper guide assembly Disconnect stacker cables from the CMX controller board stacker assembly and the stacker control panel see Figure 68 page 376 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 contro
324. troller board Installing flash memory from one controller board to another does not transfer all operating system software so you must download the emulation again NOTE Part numbers for pre written flash memory and security modules are listed in Table 8 and Table 9 1 Insert the memory module into the correct socket on the CMX controller board a Position the SIMM so the notched end is toward the right hand side of board See Figure 35 page 220 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 Install the security module See Figure 35 page 220 Cabinet Model Install the paper guide assembly page 229 Pedestal Model Install the top cover assembly page 204 Download the emulation page 176 Return the printer to normal operation page 153 Using the configuration printouts you made as step 1 of the removal procedure reset and save the printer configurations Refer to the Setup Guide 218 Memory and Security Modules Table 8 Pre Written Flash SIMMs and Security Modules Early Models Code Load Description Pre Written Flash for models 004 04P 005 05P 008 08P 009 09P 012 014 C05 C5P Security Module IBM P N Vendor P N Base ASCII 24H9315 14H5509 154143 002 ASCII with IGP 24H9317 14H5490
325. ttaches to the right rear card cage wall Cet pow Figure 58 Ferrite Core Installation 366 J Contents SureStak Power Stacker Introduction oie pee pet ete atto page 368 Stacker Operation page 368 Component 368 Stacker Control 370 Using Power 22 2 page 371 Loading And Starting The Power page 372 Stacker Troubleshooting ssssseeeeeeee page 374 Removing The Power Stacker sse page 375 Installing The Power page 380 Replacement Procedures Constant Force page 391 TIMING Belts rib t eene page 394 Illustrated Parts Breakdown sm page 398 367 Appendix J Introduction Introduction Stacker Ope The SureStak Power Stacker is an option available for cabinet model printers Most of the stacker assembly is inside the cabinet so usually you will have to remove the stacker assembly from the printer in order to service it or replace 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 unpred
326. udes mounting hardware 4 24H8960 Rear Door Kit Includes item 14 5 24H8959 Front Door Kit Includes item 14 6 5791485 Caster with Brake Two at front 7 5791486 Caster without Brake Two at rear 8 14H5603 Logo 6400 9 30H4008 Wire Rope Front and Rear One on each door Rear not shown in Figure 40 10 30H3986 Shipping Container Kit Cabinet models only Not shown in Figure 40 11 14H5572 Hardware Kit Not shown in Figure 40 12 63H7510 Door Seal Kit 13 63H7398 Top Cover Seal Kit 14 93F7037 Hinge Plate Top Included in items 4 and 5 15 5761484 Hinge Plate Bottom 251 Chapter 7 Section Il Illustrated Parts Lists Figure 41 Paper Stacker and Chains 252 Illustrations Of Printer Components bon o der Ni Description Notes 1 57G7176 Stacker 2 30H3981 Runner Stacker 3 04H4779 Riser Stacker Runner 4 Ref Screw 4 5 14H5296 Spares Kit Grommet 6 14H5272 Chain Assembly Kit Kit contains eight chains 7 5797260 Power Cord U S 9 Ref Grommet Power Cord 2 Included in item 5 253 Chapter 7 Section Il Illustrated Parts Lists Figure 42 Operator Panel and Cabinet Details 254 Illustrations Of Printer Components em Description Notes No Order No 1 14 5299 Operator Panel Cabinet Includes mounting hardware 2 5781598 Operator Panel Overlay Eng
327. unted and undamaged Tighten pulley setscrews and or replace damaged components as necessary 117 Chapter 5 Troubleshooting Other Symptoms Table 5 General Symptom List Symptom Corrective Action Stacker does not stack properly Check for and remove obstructions preventing elevator movement 2 Checkfor misaligned stacker rails Adjust the stacker rails if they RES are not vertical and parallel Stacker elevator does 3 Poweron the printer Operate the power stacker Refer to the not move Operator s Guide While the stacker is operating check that all motors are operating b the paddles are rotating the elevator moves smoothly and without obstruction d the timing belts are undamaged and the belt pulleys are not slipping 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 4 Checkthe stacker limit switches See page 119 If the limit switches are OK go to the next step 5 Checkthe stacker motors See page 120 If the stacker motors are OK go to the next step 6 Remove the paper guide assembly Disconnect stacker cables from the CMX controller board stacker assembly and the stacker control panel see Figure 68 page 376 Check cables for cuts breaks or damaged pi
328. ware again 2 Oycle power Run the print job again If the message appears replace the CMX controller board Record the message and return it with defective CMX board 139 SHUTTLE OVERSPEED SEE USER S GUIDE 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 Remove the shuttle cover Remove the paper guide assembly or the pedestal top cover Make sure the MPU cable P N 14H5329 is not pinched Check both the section of MPU cable coming from the sensor and the intermediate cable extension that runs to the controller board Refer to Appendix A Interconnection Diagram page 289 Check the resistance of the MPU at connector P107 Refer to the Main Wire Harness Test Tables page 291 Replace the MPU if it fails the test 3 Oycle 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 990 MACHINE CHECK Host status message No action required 998 NON VOLATILE MEMORY FAILED The non volatile memory has failed Replace the CMX controller board Do NOT attempt to replace NVRAM A97 GRAPHIC CHECK ERROR PRESS STOP THEN START The printer received a non printable character over a twinax interface Press Stop then Start 99 Chapter 5 Troubleshooting Display Messages Table 4
329. wer on the printer If the message appears replace the CMX controller board Record the message and return it with the defective board Power on the printer If the message appears replace shuttle frame assembly 085 CONTROLLER VOLTAGE Controller Voltage Failure 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 flash memory with pre written flash See Table 8 and Table 9 on page 219 and Figure 35 on page 220 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 85 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel Message Explanation Corrective Action 086 CONTROLLER 15V Controller Voltage Failure 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 replace the flash memory with pre written flash See Table 8 and Table 9 on page 21
330. x Twinax board If the printer is not supposed to have this feature install new emulation code without the Coax Twinax feature Table 7 Flash Memory Message Guide Required Message Explanation Action CLEARING PROGRAM The program successfully loaded into None FROM FLASH printer RAM and the checksum matched The old program is now being deleted from flash memory DIAGNOSTIC The printer passed its memory and None PASSED hardware initialization tests ERROR DC PROGRAM Printer cannot find the data controller Download the program NOT VALID program or the validation checksum is again Power off the corrupted printer and start over at step 12 If the message occurs again replace the flash memory ERROR DRAM AT The printer found a defective memory Replace the DRAM ADDRESS XXXXXXXX location ERROR EC PROGRAM Printer cannot find the engine Download the program NOT VALID controller program or the validation again Power off the checksum is corrupt printer and start over at step 12 If the message occurs again replace the flash memory ERROR EC STOPPED Hardware fault in the engine Replace the CMX AT STATE XXXX controller controller board ERROR FLASH The printer encountered an error Download the program DID NOT PROGRAM trying to program flash memory again Power off the printer and start over at step 12 If the message occurs again replace the flash memory 178
331. ximum speeds attainable under controlled conditions Actual print speed is determined by the interaction of many variables For more information refer to the discussion of Printing Rates on page 38 Chapter 1 ThelBM 6400 Series Printer Family Table 1 The IBM 6400 Series Printer Family Mod DiM enclosure Hammer Conroll Clock 6400 004 475 lpm Cabinet 28 Hammers 25 MHz 6400 04P 475 lpm Pedestal 28 Hammers 25 MHz 6400 005 500 Ipm Cabinet 28 Hammers 25 MHz 6400 05P 5001 Pedestal 28 Hammers 25 MHz 6400 050 500 Ipm Cabinet 28 Hammers 40 MHz 6400 P50 500 Pedestal 28 Hammers 40 MHz 6400 008 800 Ipm Cabinet 49 Hammers 25 MHz 6400 08P 800 Pedestal 49 Hammers 25 MHz 6400 009 900 Cabinet 49 Hammers 25 MHz 6400 09P 900 Pedestal 49 Hammers 25 MHz 6400 010 1000 Ipm Cabinet 60 Hammers 40 MHz 6400 P10 1000 Ipm Pedestal 60 Hammers 40 MHz 6400 012 1200 Ipm Cabinet 91 Hammers 25 MHz 6400 014 1400 lpm Cabinet 91 Hammers 40 MHz 6400 015 1500 Ipm Cabinet 102 Hammers 40 MHz 6400 C05 585 Ipm Cabinet 91 Hammers 40 MHz 6400 C5P 585 lpm Pedestal 91 Hammers 40 MHz 1 The microprocessor of the Data Controller unit on the CMX controller board runs at 25 MHz or 40 MHz depending on printer model This means there are two kinds of CMX controller board for IBM 6400 printers used as shown in this table The 40 MHz controller board however is backwards compatible in all mode
332. y 14 Press Scroll or Scroll to increase or decrease the phasing index then press Enter to activate the value as it prints Continue to increase or decrease the phasing index until the pattern of Hs appears as shown below 15 When the print pattern is acceptable press Stop Printing stops and the printer automatically enters the current phase index value into NVRAM The display shows NOT READY 16 Press Scroll Scroll to lock the Enter key 17 Close the printer cover Press Start to put the printer into READY mode NOTE If you changed the phasing value power down the printer remove the shuttle cover and write the new phase value on the aluminum shuttle casting 174 List Of Adjustments Downloading 6400 Microcode From The World Wide Web This section describes the procedure for obtaining microcode for all models of the 6400 printer This process is done through Lotus Notes IBM First Service system NOTE It is helpful to create a directory named 6400 on the laptop to hold OV m your 6400 code downloads If you do not know how to create directories see your ESPI or someone familiar with PCs Open Lotus Notes Open the IBM First Service System data base Click on the button at the left of your screen that says uCode PSC machine and RIM Notes Code Microcode should now be showing Highlight Machine Records via the WEB Primary Site click on the OK button When the next screen re
333. ycle power 145 D Dashpot replacement 205 Data controller DC 47 DC Data Controller CMX board 47 Diagnostic menus boot 137 Diagnostic self tests customer engineer CE 134 operator print 132 printer information menu 143 Diagnostics 10 100Base T 54 DIAGNOSTICS PASSED 178 Diagrams 413 cable routing 287 ground path 341 interconnection and cables 287 Dimensions printer 329 Dipswitches 10 100Base T 55 Display LCD list of messages 62 Display messages list of 62 Display messages printing conventions 18 Documents related to this manual 18 Doors cabinet reversing 206 DRIVER CIRCUIT BAD 100 Duty cycle 336 E EC Engine Controller CMX board 49 Electrical characteristics 330 End of Forms Adjust procedure 169 ENERGY SAVER ACTIVE 100 Energy Star compliance 329 Engine controller EC 49 Environmental characteristics 329 ERROR DC PROGRAM NOT VALID 178 DRAM AT ADDRESS 100 DRAM AT ADDRESS XXXXXXXX 178 DRAM NOT DETECTED 100 EC PROGRAM NOT VALID 178 EC STOPPED AT STATE XXXX 178 FLASH DID NOT PROGRAM 101 FLASH NOT DETECTED 179 NO DRAM DETECTED 179 NVRAM FAILURE 179 PROGRAM NEEDS MORE DRAM 179 PROGRAM NEEDS MORE FLASH 179 PROGRAM NOT COMPATIBLE 179 PROGRAM NOT VALID 101 179 SECURITY PAL NOT DETECTED 101 179 SHORT AT ADDRESS XXXX 101 179 WRITING TO FLASH 178 180 414 Error log clear 135 print 132 Error messages 61 Error messages list of 62 ERRO
334. zed by the printer Have the system administrator make sure the printer address is correct 024 SERIAL LINE PARITY ERROR VERIFY CONFIGURATION The printed output may contain random question mark characters Make a configuration printout 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 Set printer serial interface parameters to match those of the host Send a print job to the printer If the message appears replace the serial data cable Send a print job to the printer If the message appears go to Communications Failures page 131 If the printer is in a twinax environment check the error log for 024 errors and inspect the customer s cable hook ups Connect all communications cables correctly Send a print job to the printer If the message appears replace the twinax auto termination cable T connector Send a print job to the printer If the message appears replace the coax twinax multi platform interface Refer to the Coax Twinax Multi Platform Interface Feature Installation and Operation Guide Form Number S246 0149 71 Chapter 5 Troubleshooting Display Messages Table 4 Message List Operator Panel Message Explanation Corrective Action 025 SERIAL FRAMING ERROR VERIFY CONFIGURATION The printed output may contain random exc

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