IBM 6400 series Maintenance Manual
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IBM 6400 series Maintenance Manual

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Table of Contents

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Download this manual See also: Owner's Manual, Operator's Manual
6400 Line Matrix Printers
Maintenance Information Manual
Cabinet and Pedestal Models
Form Number S246–0117–06
Copyright IBM Corp., 1995, 1998

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  • Page 1 6400 Line Matrix Printers Maintenance Information Manual Cabinet and Pedestal Models Form Number S246–0117–06 Copyright IBM Corp., 1995, 1998...
  • Page 3 6400 Line Matrix Printers S246–0117–06 Maintenance Information Manual Cabinet and Pedestal Models...
  • Page 4 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.

  • Page 5: Table Of Contents

    ........... . The IBM 6400 Series Printer Family .
  • Page 6 Principles of Operation Line Matrix Printing ..........Printing Mechanism .
  • Page 7 Adjustment Procedures Introduction ............Preparing the Printer for Maintenance .
  • Page 8 ..........IBM Coax/Twinax Expansion Board .
  • Page 9 ..........Figure 52. IBM Coax/Twinax Expansion Board .

  • Page 10: Electrical Safety

    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.

  • Page 11: Trademarks And Service Marks

    Trademarks and Service Marks The following terms, denoted by an asterisk (*) in this publication, are trademarks of the IBM Corporation in the United States or other countries or both. PC-DOS...

  • Page 12: Safety Notices

    Safety Notices Danger and Caution notices are numbered to help you find the translated versions in the IBM 6400 Line Matrix Printer Safety Notices booklet. DANGER: <2> Switch off printer power and unplug the printer power cord before cleaning the printer.

  • Page 13: Maintenance Overview

    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. The print speeds listed in Table 1 are the maximum speeds attainable under certain conditions.
  • Page 14 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 Table 1. The 40 MHz controller board, however, is backwards compatible in all models that use the 25 MHz board.

  • Page 15: Printer Evolution

    Printer Evolution IBM 6400–050, –P50, –010, –P10, and –015 printers use a redesigned shuttle frame assembly, hammer bank, and ribbon guides which are not compatible with earlier models. These models use the CMX 040 controller board, which has a 40 MHz clock speed on the Data Controller unit.

  • Page 16: Important Maintenance Notes

    Important Maintenance Notes ATTENTION Failure to observe the following guidelines can result in damage to the equipment. To ensure the best performance of the printer, remember these important maintenance concepts when you service the printer: Do not adjust the platen gap unless the original shuttle frame assembly or platen has been replaced with a new or rebuilt unit, or unless instructed to do so in the troubleshooting chapter.
  • Page 17 Danger and Caution notices are numbered to help you find the translated versions in the IBM 6400 Line Matrix Printer Safety Notices booklet. CAUTION: The word Caution indicates the presence of a hazard that has the potential of causing moderate or minor personal injury.

  • Page 18: Printing Conventions In This Manual

    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 IBM 6400 Line Matrix Printer Safety Notices : Form No. G544–5389. This maintenance manual does not explain how to operate or configure the printer.
  • Page 19 IBM 6400 Code V User’s Manual: Form No. S544–5638 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.

  • Page 20: Controls And Indicators

    Controls and Indicators Electrical Controls and Indicators, Cabinet Models (Figure 2) Key or Indicator Function Power Indicator Lit when the printer is on. Ready Indicator Lit when the printer is in READY mode (on-line), no errors are pending, and the printer is ready to process data.
  • Page 21 (Off) (On) Power Switch Power Ready Processing Form Line Start Menu Scroll Enter Micro Cancel Feed Feed Set Top Eject/ Printer Con- Attention View Stop Scroll Return Micro Of Form figuration Restore Figure 2. Electrical Controls and Indicators, Cabinet Models Maintenance Overview...
  • Page 22 Electrical Controls and Indicators, Pedestal Models (Figure 3) Key or Indicator Function Power Indicator Lit when the printer is on. Ready Indicator 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). Processing Indicator Flashes when the printer is receiving data from the host.
  • Page 23 (Off) (On) Power Switch Power Ready Processing Form Line Start Menu Scroll Enter Micro Cancel Feed Feed Set Top Eject/ Printer Con- Attention View Scroll Return Micro Stop Of Form figuration Restore Figure 3. Electrical Controls and Indicators, Pedestal Model Maintenance Overview...

  • Page 24: Mechanical Controls And Indicators

    Mechanical Controls and Indicators, All Models (Figure 4) Control or Function Indicator Sets the platen for paper and forms of different Forms Thickness thicknesses. Lever must be fully opened (raised) to load Lever or unload paper. Help prevent paper jams by supporting inner sections of Paper Supports paper.
  • Page 25 Paper Scale Paper Left Tractor Supports Horizontal Right Tractor Adjustment Knob Tractor Vertical Lock Position Knob Tractor Lock Ribbon Loading Path Diagrams Forms Thickness Lever and Scale Forms Thickness Pointer Figure 4. Mechanical Controls and Indicators Maintenance Overview...

  • Page 26: Tools, Test Equipment, And Supplies

    Feeler Gauge, .011 inch Feeler Gauge, .040 inch Force Gauge, 20 lb 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...

  • Page 27: Installation

    Installation and Operation Guide , Form No. S246–0149. Installation, configuration, and troubleshooting of the Network Print Server are covered in the following documents: IBM Network Print Server Ethernet Administrator’s Guide , Form No. S246–0111 IBM Network Print Server Token-Ring Administrator’s Guide , Form No.
  • Page 28 Installation...

  • Page 29: Preventive Maintenance

    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.

  • Page 30: Cleaning The Exterior

    Cleaning the Exterior 1. Power off the printer. 2. Disconnect the AC power cord from the power source. 3. Wipe the outside of the enclosure with a clean, lint-free cloth dampened (not wet) with water and a mild detergent or window cleaning solution. 4.

  • Page 31: Cleaning The Shuttle Frame Assembly

    Splined Tractor Shaft NOTE: Cabinet model shown. Procedure is the same for Shuttle pedestal model. Cover Assembly Base Casting Forms Thickness Lever Ribbon Guide (2) Figure 5. Cleaning Inside the Cabinet or Top Cover Cleaning the Shuttle Frame Assembly 1. Remove the shuttle cover assembly (page 209). 2.
  • Page 32 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 a clean soft cloth, wipe the hammer bank cover and ribbon mask to remove lint, ink, and paper residue.

  • Page 33: Cleaning The Card Cage Fan Assembly

    Cleaning the Card Cage Fan Assembly 1. Cabinet Models: Remove the paper guide assembly (page 235). Pedestal Model: Remove the top cover assembly (page 210). 2. Vacuum the card cage fan assembly and surrounding areas to remove paper particles, dust, and lint. 3.
  • Page 34 Preventive Maintenance...

  • Page 35: Principles Of Operation

    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 on a logical grid called the dot matrix.
  • Page 36 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.
  • Page 37 Succesive Hammer Strokes Per Scan Shuttle 1 3 5 1 3 5 7 1 3 5 7 9 Scan Even column dot centers within the printed character area and character space hammer positions are not illustrated in this diagram. NOTE: = Hammer Released and Dot Printed = Hammer Not Released;...

  • Page 38: Printing Mechanism

    Printing Mechanism While the principles of line matrix printing are easy to state, the act of printing dots accurately from a rapidly oscillating shuttle onto a vertically moving piece of paper requires complex timing and coordination between printer logic and the printing mechanism. The printing mechanism consists of the shuttle frame assembly, the ribbon transport system, and the paper transport system.
  • Page 39 Hammer Bank Assembly The hammer springs are grouped in comb-like assemblies mounted on a solid hammer bank. Both the number of hammer springs per hammer spring assembly and the number of hammer spring assemblies on the hammer bank vary according to printer model: 6400–004/–04P/–005/–05P/–050/–P50: seven 4-hammer assemblies, for a total of 28 hammer springs 6400–008/–08P/009/–09P: seven 7-hammer assemblies, for a total of 49...
  • Page 40 NOTE: 6400–004/04P hammer bank shown. Hammer Bank Assembly: Coils, Magnet, Pole Pieces, Hammer Spring Assemblies Tungsten Carbide Hammer Tip Hammer Spring Assembly Alignment Pin Figure 12. Hammer Springs and Hammer Bank (Detail) Two electromagnetic coils are mounted behind each hammer and wound around each pole piece.

  • Page 41: Paper Transport System

    Paper Transport System Paper Path Tractors Horizontal Splined Adjustment Vertical Adjustment Shaft Knob Knob and Splined Shaft Pulley Tractor Support Shaft Shuttle Cover Assembly Paper Feed Timing Paper Belt (Under the cover) 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.

  • Page 42: Ribbon Transport System

    Ribbon Transport System Ribbon Hub Left Ribbon Guide (Not Shown) Hub Locking Latch Ribbon Spool Ribbon Motors 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.

  • Page 43: Logical Control Of The Printer

    Logical Control of the Printer The printer is divided into four functional elements: the operator panel, the CMX controller board, the power supply, and the print mechanism. See Figure 15. Operator Input Panel POWER ON/OFF Circuit SWITCH Breaker Line 1 Power Supply Line 2 / Neutral Board...

  • Page 44: Operator Panel

    Operator Panel The user communicates with the printer by pressing keys on the operator panel. The keys are momentary contact switches. The operator panel processes and sends key closure information to the controller board and displays information from the controller on the LCD. A status indicator next to the LCD also conveys printer status information to the user.

  • Page 45: Cmx Controller Board

    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.
  • Page 46 25 or 40 MHz Expansion Port RS–232 RS–232/422 Diagnostic Port IEEE–1284 (Parallel) Control Panel Fault Sensors Paper Feed Ribbon Shuttle Platen Diagnostic Port Hammer Drive Figure 17. CMX Controller Board Block Diagram Principles of Operation...

  • Page 47: Data Controller

    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, and –015 printers.
  • Page 48 DRAM System DRAM is used for program variables, image buffers, and input buffers. All DRAM supports page mode operation and is addressable by individual byte. Two standard 72-pin DRAM SIMMs are used for expansion memory. The DC, through the VX ASIC, may address up to 32MB of DRAM in four banks. NVRAM A 8K x 8 bit Non-Volatile battery-backed static RAM (NVRAM) device provides for the storage of configuration and system statistical data.
  • Page 49 “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 50), which has access to the VX through the “Cajun”...

  • Page 50: Engine Controller

    Engine Controller The engine controller (EC) consists of four main elements: 80C166 Microcontroller 128KB 5.0V-only FLASH program memory, organized as 64K x 16 bits. This memory is not expandable. MECA (Mechanism Engine Control ASIC) Analog drive circuitry 80C166 Microprocessor The Siemens SAB 80C166 is a high-integration microcontroller. It has many features that suit it extremely well to real-time control applications.

  • Page 51: Power Supply Board

    The printer uses five motors: two ribbon drive, one paper feed, one platen open, and one shuttle motor. The shuttle motor is a brushless DC motor driven by current control. The MPU encoder is used as feedback for motor commutations, hammer fire timing, and motor stall detection. The paper feed motor is a DC stepping motor driven by current control.

  • Page 52: Printer Interface

    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.

  • Page 53: Graphics

    Selection of the input/output interface is controlled by configuration menus accessed at the operator panel. It is possible to physically connect more than one interface, but only one interface at a time can be used electrically. Graphics The Code V programming language (a QMS graphics emulation) and the IGP programming language (a Printronix IGP emulation) are options that install in flash memory on the CMX controller board.
  • Page 54 Principles of Operation...

  • Page 55: Troubleshooting

    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 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.

  • Page 56: Start Of Call

    Start of Call Are you here because of an error message? Go to Troubleshooting Display Messages, page 57. In the next step, you will observe the operator panel for the following sequence of events (retry as required): 1. All LEDs on and black squares on display.

  • Page 57: Troubleshooting Display Messages

    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. <4> Do not connect or disconnect any communication port, teleport, attachment connector, or power cord during an electrical storm.

  • Page 58: Message List

    a. Recoverable unit check conditions are errors detected in the electromechanical print mechanism that may be temporary and correctable by cycling power. The printer tries a number of times to correct the condition before posting the message to the operator panel.
  • Page 59 Troubleshooting Operator Panel Message Procedure 008 HOLD PRINT TIMEOUT Page 72 PRESS START 009 INVALID KEY PRESS Page 72 010 PARAMETER ERROR Page 73 011 SCS COMMAND ERROR Page 73 012 STRUCTURED FIELD ERROR Page 73 013 ACTIVATE LOST Page 74 014 INVALID ACTIVATE Page 74 015 COMMUNICATION CHECK...
  • Page 60 Troubleshooting Operator Panel Message Procedure 031 END OF FORMS TIMEOUT Page 79 LOAD FORMS 032 FORMS JAMMED TIMEOUT Page 80 CLEAR JAM AND RELOAD FORMS 041 BUFFER OVERFLOW Page 81 042 CUSTOM SET DOES NOT EXIST Page 82 SAVE FIRST 043 CUSTOM SET ALREADY EXISTS Page 82 DELETE EXISTING SET FIRST...
  • Page 61 Troubleshooting Operator Panel Message Procedure 089 RIBBON STALL Page 92 090 SHUTTLE COVER OPEN Page 93 CLOSE SHUTTLE COVER 092 RIBBON DRIVER CIRCUIT Page 93 101 UPPER DRIVER SHORT Page 94 102 LOWER DRIVER SHORT Page 94 105 HAMMER COIL <number> OPEN Page 94 107 HAMMER COIL <number>...
  • Page 62 Troubleshooting Operator Panel Message Procedure 122 PAPER NOT SCHEDULED Page 99 SEE USER’S GUIDE 123 PAPER BUSY TOO LONG Page 99 SEE USER’S GUIDE 124 PAPER FIFO OVERFLOW Page 100 SEE USER’S GUIDE 125 PAPER FIFO UNDERFLOW Page 100 SEE USER’S GUIDE 126 PAPER FEED BAD TABLE Page 101 SEE USER’S GUIDE...
  • Page 63 Troubleshooting Operator Panel Message Procedure 138 SHUTTLE INVALID PARAMETER Page 104 SEE USER’S GUIDE 139 SHUTTLE OVERSPEED Page 104 SEE USER’S GUIDE 990 MACHINE CHECK Page 105 998 NON-VOLATILE MEMORY FAILED Page 105 A97 GRAPHIC CHECK ERROR Page 105 PRESS STOP THEN START BOOT DIAGNOSTICS Page 105 CLEARING PROGRAM FROM FLASH...
  • Page 64 Troubleshooting Operator Panel Message Procedure OPERATOR MENU UNLOCKED Page 108 PA1 SELECTED Page 109 PA2 SELECTED Page 109 P05 DIAGNOSTIC TEST PASSED Page 109 P17 SECURITY VIOLATION Page 109 P60 ERROR: Page 109 DRAM AT ADDRESS <hex> P61 ERROR: Page 110 FLASH NOT DETECTED P62 ERROR: Page 110...
  • Page 65 Troubleshooting Operator Panel Message Procedure RIBBON OUT OF INK Page 112 CHANGE RIBBON SENDING PROGRAM TO EC PROCESSOR Page 113 SERVICE Page 113 <first service test> SOFTWARE ERROR* Page 113 Cycle power TABLE MISMATCH Page 113 DOWNLOAD AGAIN TESTING HARDWARE Page 113 PLEASE WAIT TOP OF FORM SET...

  • Page 66: Troubleshooting Other Symptoms

    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 and unplug the printer power cord before proceeding. <4> Do not connect or disconnect any communication port, teleport, attachment connector, or power cord during an electrical storm.

  • Page 67: General Symptom List

    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 indication. The same is true of failures traced to the hammer bank: replace the entire shuttle frame assembly.
  • Page 68 Troubleshooting Symptom Procedure Printer does not complete IML Page 122 Power Stacker Printer does not detect presence of power Page 123 stacker Stacker chatters at upper or lower limit Page 128 Stacker does not stack properly Page 128 Stacker elevator does not move Page 128 Stacker elevator moves by itself Page 129...
  • Page 69 Troubleshooting Symptom Procedure Reverse paper feed: platen does not open Page 124 TOF is lost repeatedly Page 131 Ribbon Ribbon folding or feed problems Page 125 Shuttle Shuttle does not move Page 126 Shuttle is noisy Page 127 Troubleshooting...

  • Page 70: Troubleshooting Procedures

    Troubleshooting Procedures MESSAGE / MALFUNCTION TEST / INSPECTION / EXPLANATION CORRECTIVE ACTION 001 END OF FORMS LOAD FORMS 1. Attention message: the printer is out of paper. Load paper. Press Stop. If message does not clear, go to step 2. 2.
  • Page 71 2. 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 121. If forms feed, go to step 3. 3. Press View once and check that forms move up. Make sure the forms thickness lever is not set too tightly.
  • Page 72 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.
  • Page 73 010 PARAMETER ERROR 1. The printer received an illegal parameter value in the command code. 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.
  • Page 74 013 ACTIVATE LOST 1. 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 I/O cable connection at the CT board.
  • Page 75 015 COMMUNICATION CHECK CHECK CABLE 1. 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 I/O cable connection at the CT board.
  • Page 76 017 STACKER JAM CHECK STACKER Message 1. Paper is bunching above the elevator or the paper motion detector is not working properly. Remove the paper jam. 2. Power off the printer. Check that the wheel of the stacker paper motion detector rests against the rear brace of the paper throat.
  • Page 77 panel (see Figure 61, page 380). Check cables for cuts, breaks, or damaged pins. Check continuity of cables. (See Appendix A.) Replace any cable that is damaged or fails continuity test. Reconnect all stacker cables to the CMX controller board, stacker, and stacker control panel.
  • Page 78 Replace any cable that is damaged or fails continuity test. Reconnect all stacker cables to the CMX controller board, stacker, and stacker control panel. 021 RECEIVE BUFFER OVERRUN VERIFY CONFIGURATION 1. The print buffer has overflowed on a serial interface. The printed output may contain random * (asterisk) characters.
  • Page 79 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 133. 026 HEX DUMP MODE 1.
  • Page 80 Load paper. Press Stop. If message does not clear, go to step 3. 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).
  • Page 81 6. 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. 7. Check the condition and tension of the platen open belt. Adjust the platen open belt.
  • Page 82 042 CUSTOM SET DOES NOT EXIST SAVE FIRST 1. Printer configuration: the custom configuration set does not exist. Save the custom configuration set. 043 CUSTOM SET ALREADY EXISTS DELETE EXISTING SET FIRST 1. Printer configuration: custom set is write-protected. Delete the existing custom configuration set, then save the new set. 044 EC FIRMWARE/HARDWARE ERROR 1.
  • Page 83 If any socket pins are bent or damaged, replace the CMX controller board. 2. Install the flash and DRAM SIMMs, making sure they are fully and correctly seated. Power on the printer. Download the emulation. If the message appears, replace the flash SIMM(s). 3.
  • Page 84 7. Run a print test. If the message appears, replace the CMX controller board. Record the message and return it with the defective board. 058 SHUTTLE JAM SEE USER’S GUIDE 1. The shuttle is not moving or is moving at the wrong speed. Check the forms thickness lever: if it is set too tightly, it can slow the shuttle enough to trigger the fault message.
  • Page 85 If the message appears, replace the CMX controller board. Record the message and return it with the defective board. 9. Run a print test. If the message appears, replace the power supply board. 10. Run a print test. If the message appears, replace the shuttle frame assembly. 059 CANCEL PRINT ACTIVE 1.
  • Page 86 4. 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. 062 EXHAUST FAN FAULT 1.
  • Page 87 Cycle power. If the message appears, press Stop. 2. 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 297.) Replace components that fail test.
  • Page 88 Advise the user to move the printer to cooler, cleaner location. 2. 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. 3. Power off the printer. Remove the paper guide assembly or pedestal top cover. Check that the power supply guard/air deflector is correctly positioned over the power supply board.
  • Page 89 If the message appears, replace the shuttle frame assembly. 083 INTAKE FAN FAULT 1. Sensors cannot detect current in the card cage fan circuit. Cycle power. If the message appears, press Stop. 2. Power off the printer. Remove the paper guide assembly or pedestal top cover. Disconnect connector P106 from the CMX controller board.
  • Page 90 If the message appears, replace the power supply board. 5. Power on the printer. If the message appears, replace the CMX controller board. Record the message and return it with the defective board. 6. Power on the printer. If the message appears, replace shuttle frame assembly. 085 CONTROLLER VOLTAGE 1.
  • Page 91 If the message appears, replace the power supply board. 5. Power on the printer. If the message appears, replace the shuttle frame assembly. 087 PLATEN OPEN TIMEOUT CLOSE PLATEN 1. On a coax interface, the forms thickness lever has been open for at least one minute.
  • Page 92 088 CONTROLLER 23.5V 1. Controller Voltage Failure. Cycle Power. Run the print job again. If the message appears, download the emulation software again. 2. Cycle power. Run the print job again. If the message appears, replace the flash memory. 3. Power on the printer. Run the print job again. If the message appears, replace the CMX controller board.
  • Page 93 6. Power on the printer. Run an Operator Print Test. (See page 135.) If the ribbon a RIBBON STALL message appears, replace the CMX controller board. Record the message and return it with the defective board. 090 SHUTTLE COVER OPEN CLOSE SHUTTLE COVER 1.
  • Page 94 101 UPPER DRIVER SHORT 1. 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.
  • Page 95 107 HAMMER COIL <number> HOT NOTE: 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.
  • Page 96 If the message appears, replace the CMX controller board. Record the message and return it with the defective board. 110 STACK OVERFLOW SEE USER’S GUIDE 1. System stack has run out of room and overflowed into other memory. Cycle power. Run the print job again. If the message appears, download the emulation software again.
  • Page 97 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 1. 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.
  • Page 98 If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board. 118 UNDEFINED INTERRUPT SEE USER’S GUIDE 1. Firmware error on the CMX controller board. Cycle power. Run the print job again. If the message appears, download the emulation software again.
  • Page 99 If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board. 122 PAPER NOT SCHEDULED SEE USER’S GUIDE 1. The paper feed process is not scheduling on the CMX controller board, and the printer cannot advance paper.
  • Page 100 undamaged and have good connections. Replace as necessary. (Refer to Appendix A.) 5. Power on the printer. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board. 124 PAPER FIFO OVERFLOW SEE USER’S GUIDE 1.
  • Page 101 6. Power on the printer. Run the print job again. If the message appears, replace the power supply board. 7. 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.
  • Page 102 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 1. 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.
  • Page 103 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 1. Firmware error on the CMX controller board. Cycle power. Run the print job again. If the message appears, download the emulation software again.
  • Page 104 If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board. 137 SHUTTLE INVALID COMMAND SEE USER’S GUIDE 1. Firmware error on the CMX controller board. Cycle power. Run the print job again. If the message appears, download the emulation software again.
  • Page 105 990 MACHINE CHECK 1. Host status message. No action required. 998 NON-VOLATILE MEMORY FAILED 1. 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 1. The printer received a non-printable character over a twinax interface. Press Stop then Start.
  • Page 106 No action required, but you can press the Form Feed key to revive the printer from energy saver mode. ERROR: DRAM AT ADDRESS <hex> 1. The printer found a defective memory location. Replace the DRAM. 2. Power on the printer. If the message appears, replace the CMX controller board.
  • Page 107 Check the security PAL at location U54 on the CMX controller board. If the PAL is absent, install the correct PAL. If a security PAL is present, replace it. 2. Power on the printer. If the message appears, replace the replace the CMX controller board. Record the message and return it with the defective board.
  • Page 108 HAMMER COIL BAD #, #, #, #, ... etc. 1. Hammer coil(s) number #, #, etc. failed the current test at power-up. Check that the hammer bank cables are connected. Cycle power. If the message appears, replace the shuttle frame assembly.
  • Page 109 No action required. PA1 SELECTED 1. Attach status message. No action required. PA2 SELECTED 1. Attach status message. No action required. P05 DIAGNOSTIC TEST PASSED 1. Non-error status message: the printer passed its memory and hardware initialization tests. No action required. P17 SECURITY VIOLATION 1.
  • Page 110 CMX-compatible diskette in a CBO-controlled printer, or vice versa.) Use the correct emulation software option(s) for this model printer. If the printer is an IBM 6404–B01, the controller is a CBO board. If the printer is an IBM 6400, the controller is a CMX board. P64 ERROR: CHECKSUM WRONG <hex>...
  • Page 111 P65 ERROR: PROGRAM NEEDS MORE FLASH 1. The printer requires more flash memory in order to run the downloaded program. Add flash memory or use a smaller emulation program. (See Figure 34, page 226.) P66 ERROR: PROGRAM NEEDS MORE DRAM 1.
  • Page 112 2. Install the flash and DRAM SIMMs, making sure they are fully and correctly seated. Power on the printer. Download the emulation. If the message appears, replace the flash SIMM(s). (See Figure 34, page 226.) 3. Power on the printer. Download the emulation. If the message appears, replace the DRAM SIMM(s).
  • Page 113 SENDING PROGRAM TO EC PROCESSOR 1. Status message: the printer is loading the engine controller program into the engine controller. No action required. SERVICE <first service test> 1. Non-error status message. No action required. SOFTWARE ERROR RECYCLE POWER 1. Application software tried to perform an illegal printer function or damaged logic circuits were detected on the CMX controller board.
  • Page 114 No action required. WAITING FOR PROGRAM DOWNLOAD 1. Emulation download mode has been activated, but program download has not yet begun. No action required. Black squares on operator panel display 1. 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.
  • Page 115 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. 3. Inspect the shuttle frame assembly for print chaff, debris, or ink residue that could be causing the problem.
  • Page 116 Install the paper detector switch assembly. 2. Check that connector P106/PMD is fully seated in connector J106 on the CMX controller board. Connect P106/PMD to J106 on the CMX controller board. 3. Power on the printer. Load paper. Replace the paper detector switch assembly if either message appears. 4.
  • Page 117 2. 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. Install the paper detector switch assembly. 3. Check that the paper detector switch assembly is securely mounted to the mechanism base.
  • Page 118 4. Power up the printer. Download the emulation. If the download fails, activate the Boot Diagnostics Menu (page 142) and run MISC UTILITIES / RUN MEMORY TESTS. If memory fails test, replace the DRAM. If memory tests OK, replace the flash SIMM(s). 5.
  • Page 119 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 N m). 5. Power up the printer. Run a print test. If the symptom is not gone, replace the MPU.
  • Page 120 7. 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. 8. Disconnect AC-in power supply cable connector P1. Set the circuit breaker to 1 (on).
  • Page 121 Operator panel keys do not work 1. Power on the printer. Check the operation of the control panel keys. Replace the control panel assembly. 2. Power on the printer. Check the operation of the control panel keys. Replace the control panel cable assembly. 3.
  • Page 122 Replace the paper feed motor if paper does not move in both directions. 9. 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.
  • Page 123 Printer does not detect presence of power stacker —or— Stacker not operating 1. Check that the power stacker is enabled under the Printer Control menu. (Refer to the Setup Guide .) Enable the power stacker under the Printer Control menu. If the power stacker enable/disable option does not appear in the menu, go to the next step.
  • Page 124 If the ONLINE indicator does not light, replace the stacker control panel. 6. Power on the printer. Check that the ONLINE indicators lights on the stacker control panel. If the ONLINE indicator does not light, replace the CMX controller board. Printer does not print self tests 1.
  • Page 125 Replace the platen open motor if it fails the resistance test. 6. 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.
  • Page 126 2. 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. 3. Inspect the paper print path for paper chaff, ink residue, and debris. Clean the shuttle frame assembly.
  • Page 127 4. Check the platen gap. Adjust the platen gap. 5. Inspect the ribbon mask for bends or deformation that snag and interfere with shuttle movement. Make sure the hammer bank cover assembly is correctly installed on its mounting pegs. Reinstall the hammer bank cover assembly. Replace a damaged or deformed hammer bank cover assembly.
  • Page 128 Clean the shuttle frame assembly and hammer bank cover assembly if you find debris. Replace the hammer bank cover assembly if you find any damage to the ribbon mask or hammer bank cover. 5. Power up the printer. Run a shuttle test. Replace the shuttle frame assembly if it is noisy or rattles.
  • Page 129 a) all motors are operating b) the paddles are rotating c) the elevator moves smoothly and without obstruction d) the timing belts are undamaged and the belt pulleys are not slipping e) the extension springs are attached and undamaged (not bent or stretched) f) the drive rollers are not damaged g) the constant force springs are tightly mounted and undamaged Tighten pulley setscrews and/or replace damaged components as...
  • Page 130 1. 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, you must replace the entire power stacker assembly.
  • Page 131 15.2 1.5 Ohms on both phases. (Refer to the power stacker control panel PCBA pinout drawing on page 304.) Replace any cable that is damaged or fails continuity test. Replace any motor that fails the resistance test. TOF is lost repeatedly 1.
  • Page 132 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 1.

  • Page 133: Communications Failures

    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.
  • Page 134 Table 4. Common Communications Problems Problem Interface Common Causes Fails to print from host parallel – Interface cable defective –OR– – Host/Network configuration Prints incorrect characters – Printer logic –OR– – Terminating Resistors Prints extra characters –OR– Drops characters serial –...

  • Page 135: 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.
  • Page 136 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.

  • Page 137: Selecting And Running Operator Print Tests

    Selecting and Running Operator Print Tests Step Displayed Result Notes Make sure that the printer ribbon is installed in the printer and the printer is powered on and is loaded with paper. Press: Places the printer in Not NOT READY Ready mode.

  • Page 138: Customer Engineer (Ce) Tests

    Customer Engineer (CE) Tests A set of printer tests is included in the configuration menu structure for use as maintenance tools. These are called “Customer Engineer Tests” (CE Tests) because they are for your use—they are not available to the user through his documentation.
  • Page 139 Power Supply board Hammer bank cover Hammer springs Hammer coils (the shuttle frame assembly) Shuttle Only This test runs only the shuttle. Shuttle Slow Verifies proper operation by exercising the shuttle and ribbon mechanisms at low speed. You can also use this test to check ribbon tracking and reversing.

  • Page 140: Selecting And Running Customer Engineer Tests

    Print Partial Line: If the final line of a data stream has no line feed or carriage return character it is retained in the buffer. DISABLE holds the line in the buffer; ENABLE permits the line to be printed after a timeout. Top Exit Tear Distance: This parameter allows adjustment in 0.01 inch increments of the final location of page perforations when top paper exit is used.
  • Page 141 Step Displayed Result Notes Press: Cycles through the list PRINTER MECHANISM TESTS Scroll of mechanism tests. UNTIL Plot Test Stop when the name of the test you wish to run displays. Press: Press both keys at the OPERATOR MENU Scroll Scroll same time.

  • Page 142: Boot Diagnostics Menu

    Boot Diagnostics Menu Printer boot-up software contains a menu structure that you can access by holding down the Eject/Restore and Stop keys while powering up the printer. These menus are not intended for the end user, but provide useful information for manufacturing and maintenance personnel. The boot diagnostic menu structure is depicted in Figure 19.
  • Page 143 BOOT DIAGNOSTICS NOTE: To exit this PRESS ENTER menu, cycle power. B = Scroll ENTER BOOT DIAGNOSTICS VERSION CHECK ENTER VERSION CHECK VERSION CHECK VERSION CHECK VERSION CHECK BOOT VERSION SOFTWARE VERSION EC VERSION ASIC VERSIONS ENTER ENTER ENTER ENTER BOOT/CMX V10B 09/08/95 EC V1.00H...
  • Page 144 NOTE: To exit this menu, cycle power. = Scroll BOOT DIAGNOSTICS MISC UTILITIES From Previous ENTER Page MISC UTILITIES MISC UTILITIES MISC UTILITIES MISC UTILITIES DISPLAY MEMORY RESET PRINTER COPY FLASH SIMMS COPY BOOT SIMMS ENTER ENTER ENTER ENTER FLASH = 2 MBYTES RESETTING...

  • Page 145: Hex Code Printout

    Hex Code Printout A hex code printout (“hex dump”) prints every ASCII character received from the host computer with its corresponding two-digit hexadecimal code. Hex dumps can be used to troubleshoot printer data reception problems by comparing the printed hex data to the data sent from the host. In a hex dump, every character is printed as its assigned ASCII symbol and as the hexadecimal value of the character.
  • Page 146 Step Displayed Result Notes Press: Moves down to Disable, HEX PRINT MODE Enter DISABLE* the active option. Press: Moves down to Enable, HEX PRINT MODE Scroll the alternate option. ENABLE Press: Asterisk (*) indicates HEX PRINT MODE Enter this choice is now ENABLE* active.

  • Page 147: Ascii Character Set

    ASCII Character Set BITS OCTAL equivalent DECIMAL equivalent HEX equivalent ASCII Character BITS COLUMN (XON) ” 0 0 1 0 0 0 1 1 (XOFF) 0 1 0 0 0 1 0 1 & 0 1 1 0 ’ 0 1 1 1 1 0 0 1 1 0 1 0 1 0 1 1...

  • Page 148: Printer Information Menu

    Printer Information Menu PRINTER INFORMATION Installed Power On Time Printing Time Print Strokes 11 Inch Pages Memory To view options, press: Scroll Scroll Enter Return Enter To select an option, press: To exit the configuration menus To exit the configuration menus Start and return to READY, press: * = Factory Default...

  • Page 149: Displaying Printer Information

    Displaying Printer Information Step Displayed Result Notes Power on the printer. Press: Places the printer in Not NOT READY Ready mode. Stop Press: Press both keys at the OPERATOR MENU Scroll Scroll same time. Unlocking UNLOCKED the Enter key gives access to configuration menus.

  • Page 150: Soft Vs. Hard Reset

    Soft vs. Hard Reset Soft Reset A soft(ware) reset clears printer memory then loads the power-up configuration into memory. (The procedure for saving configurations is described in the Setup Guide .) It is called a soft reset because no hardware is tested.

  • Page 151: The Power 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.
  • Page 152 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.
  • Page 153 Load Boot Code into DRAM — Flash memory cannot be accessed while flash is being detected, cleared, or programmed. This prevents boot code from running in flash because the opcodes cannot be fetched. This is solved by copying the program into DRAM and executing the program out of DRAM.
  • Page 154 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...
  • Page 155 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-stepping from the MTOS debugger.
  • Page 156 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...

  • Page 157: Adjustment Procedures

    Adjustment Procedures Introduction The printer is a durable, low-maintenance machine, but some components and systems require occasional adjustment. Usually, you will be referred to this chapter by a troubleshooting procedure, or as part of a removal/installation procedure. Adjustment Procedures...

  • Page 158: Preparing The Printer For Maintenance

    Preparing the Printer for Maintenance 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. To prepare the printer for maintenance, do the following steps before making an adjustment: 1.

  • Page 159: Returning The Printer To Normal Operation

    Returning the Printer to Normal Operation When you are finished servicing the printer, restore it to operation by following these steps: 1. Connect the host data cable to the printer interface. 2. Install the ribbon. 3. Load paper. 4. Plug the AC power cord into the power source. 5.

  • Page 160: Belt, Paper Feed Timing, Adjustment

    Belt, Paper Feed Timing, Adjustment (Figure 21) 1. Prepare the printer for maintenance (page 158). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: Remove the top cover assembly (page 210). 3. Cabinet Model: Loosen four screws and remove the barrier shield. (See page 269, Figure 43, items 3 and 4.) Pedestal Model: Remove the four screws securing the paper guide and barrier shield.
  • Page 161 Direction of Force 1. Timing Belt Shield 2. Motor Mount Bolt (2) 3. Paper Feed Drive Motor 4. Splined Shaft 5. Paper Feed Timing Belt Figure 21. Paper Feed Timing Belt Adjustment Adjustment Procedures...

  • Page 162: Belt, Platen Open, Adjustment

    Belt, Platen Open, Adjustment (Figure 22) 1. Prepare the printer for maintenance (page 158). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: Remove the top cover assembly (page 210). 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.
  • Page 163 1. Belt Cover 2. Motor Mount Screw (2) 3. Platen Open Motor Shaft Direction of Force Figure 22. Platen Open Belt Adjustment Adjustment Procedures...

  • Page 164: Paper Drive Motor Pulley Alignment

    Paper Drive Motor Pulley Alignment (Figure 23) 1. Prepare the printer for maintenance (page 158). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: Remove the top cover assembly (page 210). 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.
  • Page 165 1. Belt Shield 2. Cap Screw 3. Motor Pulley Collar 4. Motor Pulley 5. Splined Shaft Pulley Figure 23. Paper Drive Motor Pulley Alignment Adjustment Procedures...

  • Page 166: Paper Scale Alignment

    Paper Scale Alignment (Figure 24) 1. Load paper and ribbon. 2. Connect the power cord to the AC power source. 3. Set the printer power switch to 1 (on). 4. Open the printer cover. 5. Verify that the shuttle cover (1) is properly installed (page 209). 6.
  • Page 167 1. Shuttle Cover 2. Screw, Button-Head, 5/64 inch hex (3) 3. Paper Scale Figure 24. Paper Scale Alignment Adjustment Procedures...

  • Page 168: Platen Gap Adjustment

    Platen Gap Adjustment (Figure 25) IMPORTANT Only do this procedure if the original equipment shuttle frame assembly or platen has been replaced by a new or refurbished unit. 1. Prepare the printer for maintenance (page 158). 2. Remove the shuttle cover assembly (page 209). 3.
  • Page 169 10. Install the shuttle cover assembly (page 209). 11. Check the hammer phasing adjustment (page 179). 12. Return the printer to normal operation (page 159). 1. Forms Thickness Lever 2. Feeler Gauge (0.011 inch or 0.28 mm) 3. Hammer Bank Cover Plate 4.

  • Page 170: Platen Open Motor Pulley Alignment

    Platen Open Motor Pulley Alignment (Figure 26) 1. Prepare the printer for maintenance (page 158). 2. Cabinet Model: Go to step 3. Pedestal Model: Remove the top cover assembly (page 210). 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.
  • Page 171 1. Belt Cover 2. Set Screw 3. Platen Open Motor Pulley 4. Platen Shaft Pulley Figure 26. Platen Open Motor Pulley Alignment Adjustment Procedures...

  • Page 172: Ribbon Guide Alignment

    Ribbon Guide Alignment (Figure 27) 1. Open the printer cover. 2. 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.
  • Page 173 Left Ribbon Guide Right Ribbon Guide Early Models Later Models 1. Screw, Skid (2) 2. Ribbon 3. White Nylon Washer 4. Screw, Retaining (2) Figure 27. Ribbon Guide Alignment Adjustment Procedures...

  • Page 174: Splined Shaft Skew Adjustment

    Splined Shaft Skew Adjustment (Figure 28) If lines of print are not parallel with the edge perforations on the paper, perform the following adjustment. 1. Open the printer cover. 2. Loosen the screw (1) securing the adjusting link (2). 3. Adjust the link (2) by raising or lowering the horizontal adjustment knob (3) to obtain print parallel with paper perforations.

  • Page 175: Adjusting The End Of Forms Distance

    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.
  • Page 176 Page Perforation Page Perforation 4 in. 4 in. Cut out here Page Perforation Figure 29. Paper Preparation for Paper Out Adjustment Test Adjustment Procedures...
  • Page 177 8. The display will show “SERVICE / PRINTER MECHANISM TESTS”, the first menu item. Press Enter to enter the mechanism tests menu. 9. Press Scroll" or Scroll# until “PRINTER MECHANISM TESTS / END OF FORMS ADJUST” is on the display. This test will print a vertical “comb”...
  • Page 178 13. Reload the paper and set the top of form. 14. Press Scroll" + Scroll# + Return + Enter to enter the CE Tests menu. (Press all four keys at the same time.) 15. The display will show “SERVICE / PRINTER MECHANISM TESTS,” the first menu item.

  • Page 179: Hammer Phasing

    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.
  • Page 180 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 Scroll or Scroll" until “SERVICE / HAMMER PHASE VALUE” is on the display.

  • Page 181: Loading Flash Memory

    3. Unplug the AC power cord from the printer. 4. If the printer’s parallel data cable is connected to the parallel port of an IBM or IBM-compatible computer using the PC-DOS* or MS-DOS** operating system, skip to step 8. If not, go to step 5.
  • Page 182 Centronics I/O connector. 6. Connect the parallel data cable to the default parallel port (LPT1) of an IBM or IBM-compatible personal computer using the PC-DOS or MS-DOS operating system. NOTE: You can connect the data cable to the LPT2 port if the LPT1 port is already in use.
  • Page 183 15. Press the Scroll key; “SELECT DOWNLOAD PORT=DATAPRODUCT” appears on the LCD. 16. Press Scroll again to cycle through the download ports available in the printer: DATAPRODUCT (parallel) CENTRONICS* (parallel) (default port) 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...
  • Page 184 24. Power off the personal computer. 25. If you had to install a parallel data cable to the computer and printer in step 6, disconnect it from the computer and printer. 26. Reconnect the customer’s data input cable(s) to the printer, if required. 27.
  • Page 185 Required Message Explanation Action ERROR: EC PROGRAM Printer cannot find the engine Download the controller program or the validation program again: NOT VALID checksum is corrupt. Power off the printer and start over at step 13. If the message occurs again, replace the flash memory.
  • Page 186 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 The printer does not see a program There is no program in flash memory.
  • Page 187 Required Message Explanation Action LOADING PROGRAM The printer has deleted the previous None program from flash memory and is INTO FLASH loading the new program into flash memory. RESETTING . . . The printer finished loading the None program into flash memory and is PLEASE WAIT automatically resetting itself.

  • Page 188: Coil Temperature Adjustment

    Coil Temperature Adjustment IMPORTANT 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.

  • Page 189: Set Shuttle Speed

    Set Shuttle Speed IMPORTANT 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.
  • Page 190 Adjustment Procedures...

  • Page 191: Replacement Procedures And Illustrated Parts List

    Replacement Procedures and Illustrated Parts List Organization of This Chapter 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. This chapter is divided into two sections. Section I: Replacement Procedures This section contains written procedures for removing and installing components that are replaceable at the field service level of...

  • Page 192: Section I: Replacement Procedures

    ........IBM Coax/Twinax Expansion Board .
  • Page 193 Platen ............Resistors, Terminating .

  • Page 194: Preparing The Printer For Maintenance

    Preparing the Printer for Maintenance 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.

  • Page 195: Belt, Paper Feed Timing

    Belt, Paper Feed Timing Removal 1. Prepare the printer for maintenance (page 194). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: Remove the top cover assembly (page 210). 3. Cabinet Model: Loosen four screws and remove the barrier shield. (See page 269, Figure 43, items 3 and 4.) Pedestal Model: Loosen the four screws securing the paper guide and barrier shield.
  • Page 196 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 285, Figure 50). 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...

  • Page 197: Belt, Platen Open

    Belt, Platen Open Removal 1. Prepare the printer for maintenance (page 194). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: Remove the top cover assembly (page 210). 3. Remove the platen open belt cover by squeezing the top and bottom to release the plastic tabs from the slots in the side plate (page 283, Figure 49).

  • Page 198: Cable Connectors And Connector Shells

    Cable Connectors and Connector Shells Some of the printer cable connectors are grouped inside connector shells. The procedure below explains how to remove and install cable assemblies from any connector shell in the printer. NOTE: There is also a diagram of the P106 / P107 connector shells on the plastic cover over the power supply.
  • Page 199 5. Cabinet Model: Install the paper path (page 235). Pedestal Model: Install the top cover assembly (page 210). 6. Return the printer to normal operation (page 159). POD = Paper Out Detect (Switch) PMD = Paper Motion Detect (Switch) CCF = Card Cage Fan LRP = Left Ribbon Guide PLAT M = Platen Open Motor Typical...

  • Page 200: Circuit Board: Controller

    Circuit Board: Controller 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: 6400–050, –P50, –010, –P10, –014, and –015 printers must use the 40 MHz CMX controller board.
  • Page 201 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: 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.
  • Page 202 10. Adjust the hammer phasing (page 179). 11. Adjust the end of forms distance (page 175). 12. Return the printer to normal operation (page 159). 13. Using the configuration printout you made as step 1 of the removal procedure, reset and save the printer configuration. Replacement Procedures and Illustrated Parts List...

  • Page 203: Circuit Board: Power Supply

    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.

  • Page 204: Circuit Breaker

    Circuit Breaker Removal 1. Prepare the printer for maintenance (page 194). 2. Open the printer cover. 3. Remove the card cage fan (page 216). 4. Disconnect the four circuit breaker electrical leads. (Cabinet Model: See Figure 51, page 287. Pedestal Model: See Figure 44a, page 273.) 5.

  • Page 205: Coax/Twinax Multi-Platform Interface

    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.

  • Page 206: Cover Assembly, Hammer Bank / Ribbon Mask

    Cover Assembly, Hammer Bank / Ribbon Mask Removal 1. Prepare the printer for maintenance (page 194). 2. Remove the shuttle frame assembly (page 249). 3. Early models: Lift the thick plate of the hammer bank cover assembly at one end, and peel the cover away from hammer bank magnets.
  • Page 207 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.
  • Page 208 Early Models Hammer Bank Cover Ribbon Mask (Thick Plate) (Thin Plate) Hammer Bank Cover Assembly Later Models Ribbon Mask Torque Sequence Ribbon Mask Clamp Plate (3) Screw (12) Hammer Bank Screw (6) Cover Hammer Bank Cover Torque Sequence Figure 31. Hammer Bank Cover Assembly / Ribbon Mask Replacement Procedures and Illustrated Parts List...

  • Page 209: Cover Assembly, Shuttle

    Cover Assembly, Shuttle Removal 1. Prepare the printer for maintenance (page 194). 2. Open the printer cover. 3. Remove the ribbon spools. 4. Loosen the shuttle cover screws (page 269, Figure 43). 5. Grasping the edges of the shuttle cover assembly, tilt up the rear edge and lift the shuttle cover assembly out of the printer.

  • Page 210: Cover Assembly, Top, Pedestal Model

    Cover Assembly, Top, Pedestal Model Removal 1. Prepare the printer for maintenance (page 194). 2. Remove the operator panel (page 234). 3. Remove five screws and the control panel bracket. (See Figure 42, page 267, items 3 and 4.) 4. Loosen the two captive #2 Phillips screws in the lower front corners of the top cover.

  • Page 211: Doors, Cabinet, Reversal

    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.

  • Page 212: Ethernet Interface Assemblies

    Ethernet Interface Assemblies NOTE: The Ethernet LAN option is available in 10-Base-T or 10-Base-2 configuration, and is available factory installed or in a field kit. Removal and installation is the same for all versions. The LEDs and DIP switches on the Ethernet Interface board are described on page 213.
  • Page 213 Ethernet Interface LEDs and DIP Switches The Ethernet Interface has three LEDs and three DIP switches, as shown below. These 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...
  • Page 214 The Run Mode and Auto Reset Mode indicator descriptions are shown below. Run Mode and Auto Reset Mode Indicator Descriptions 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...

  • Page 215: Fan Assembly, Cabinet Exhaust

    Fan Assembly, Cabinet Exhaust Removal 1. Prepare the printer for maintenance (page 194). 2. Open the floor cabinet doors and the printer cover. 3. Remove the paper stacker. (See Figure 40, page 263.) 4. Remove the three screws securing the air exhaust duct. (The top screw is located near the right front of the card cage, in front of the square air holes in the printer base plate.) (See page 265, Figure 41).

  • Page 216: Fan Assembly, Card Cage

    Fan Assembly, Card Cage Removal 1. Prepare the printer for maintenance (page 194). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: Remove the top cover assembly (page 210). 3. Disconnect the fan cable connector: Cabinet Model, Figure 50, page 285. Pedestal Model, Figure 44a, page 271.

  • Page 217: Fan Assembly, Hammer Bank

    Fan Assembly, Hammer Bank Removal 1. Prepare the printer for maintenance (page 194). 2. Remove the shuttle cover assembly (page 209). 3. Pedestal Model: Remove the top cover assembly (page 210). 4. Trace the hammer bank fan cable assembly back to the controller board connector J107, releasing it from all cable constraints.

  • Page 218: Hammer Spring Assembly

    Hammer Spring Assembly Removal 1. Prepare the printer for maintenance (page 194). 2. Remove the shuttle frame assembly (page 249). 3. Carefully vacuum the shuttle frame assembly. 4. Remove the hammer bank cover assembly (page 206). ATTENTION Hammer springs and hammer tips are fragile. Do not touch the hammer springs or tips.
  • Page 219 NOTE: The hammer spring assemblies shown below are for 6400–004, 04P, 005, 05P printers. The number of hammer springs and mounting screws varies among printer models, but hammer spring removal is the same. Hammer Spring Assembly 7 Hammer Spring Assembly 1 Discard old screws Figure 32.
  • Page 220 Installation NOTE: 6400–050, –P50, –010, –P10, –014, and –015 printers must use the CMX 040 controller board. 1. Using a clean dry cloth, wipe the hammer spring mounting surface on the hammer bank. Make sure the cloth does not leave lint on the hammer bank.
  • Page 221 New Hammer Spring Assembly Use new screws from the kit. Torque screws to 14 inch-pounds (1.58 N m). NOTE: The hammer spring assemblies shown above are for 6400–004, 04P, 005, 05P printers. The number of hammer springs and mounting screws varies among printer models, but installation procedure and torque values are the same.

  • Page 222: 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 194).

  • Page 223: Magnetic Pick-Up (Mpu) Assembly

    Magnetic Pick-up (MPU) Assembly Removal 1. Prepare the printer for maintenance (page 194). 2. Remove the shuttle cover (page 209). 3. Disconnect the shuttle cable assembly connector (page 275, Figure 45). 4. Disconnect the magnetic pick-up (MPU) cable connector (page 279, Figure 47).

  • Page 224: Memory Modules And Security Pal

    Memory Modules and Security PAL Removal 1. Make a configuration printout of all configurations. (Refer to the Setup Guide .) 2. Prepare the printer for maintenance (page 194). 3. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: Remove the top cover assembly (page 210). ATTENTION To prevent electrostatic damage to electronic components, wear a properly grounded static wrist strap when handling circuit boards, the...
  • Page 225 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 controller board.
  • Page 226 CAUTION: <5> Do not remove or CMX Controller Board replace the NVRAM. The NVRAM contains a lithium battery that can explode if it is replaced incorrectly. NVRAM is replaced only at the factory. Bank 1 Bank 0 Bank 1 Bank 0 Security PAL* Flash Memory: DRAM:...

  • Page 227: Motor Assembly, Paper Feed

    Motor Assembly, Paper Feed Removal 1. Prepare the printer for maintenance (page 194). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: Remove the top cover assembly (page 210). 3. Cabinet Model: Loosen four screws and remove the barrier shield. (See Figure 43, page 269, items 3, 4, and 9.) Pedestal Model: Remove the four screws, the barrier shield, and the paper guide.
  • Page 228 Installation 1. Position the paper feed motor assembly on the right side plate and install the motor mount bolts and nuts finger tight (page 285, Figure 50). 2. Connect the paper feed motor cable connector to connector P107, then connect P107 to J107 on the controller board. (See page 198.) 3.

  • Page 229: Motor Assembly, Platen Open

    Motor Assembly, Platen Open Removal 1. Prepare the printer for maintenance (page 194). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: Remove the top cover assembly (page 210). 3. Cabinet Model: Remove the card cage fan (page 216). 4.
  • Page 230 Installation 1. Position the platen open motor assembly with the wires toward the rear (page 285, Figure 50). 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 N m).

  • Page 231: Motor Assembly, Ribbon Drive

    Motor Assembly, Ribbon Drive Removal 1. Prepare the printer for maintenance (page 194). 2. Remove the ribbon. 3. Remove the ribbon hub (page 245). 4. Remove two screws and washers securing the ribbon drive motor to the base casting (page 285, Figure 50). 5.

  • Page 232: Network Print Server

    NOTE: Installation and operation of this optional feature are described in the Print Server User’s Guide , P/N 30H4056. This guide describes error 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.

  • Page 233: Operator Panel Assembly, Cabinet Model

    Operator Panel Assembly, Cabinet Model Removal 1. Prepare the printer for maintenance (page 194). 2. Open the printer cover. 3. Remove the four screws securing the operator panel plate to the panel bracket. (See Figure 41, page 265.) 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.

  • Page 234: Operator Panel Assembly, Pedestal Model

    Operator Panel Assembly, Pedestal Model Removal 1. Prepare the printer for maintenance (page 194). 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.

  • Page 235: Paper Guide Assembly

    Paper Guide Assembly NOTE: This procedure applies only to cabinet models. Removal 1. Prepare the printer for maintenance (page 194). 2. Open the printer cover. 3. Loosen the three paper guide assembly hold-down screws (page 269, Figure 43, item 6). 4.

  • Page 236: Paper Ironer

    Paper Ironer 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 249). 2. Move the forms thickness lever to the open position. 3.

  • Page 237: Platen

    Platen Removal 1. Prepare the printer for maintenance (page 194). 2. Remove the shuttle frame assembly (page 249). 3. Remove the paper ironer (page 236). 4. Remove the three 1/4 inch screws securing the paper ironer bracket assembly and remove the assembly. (See Figure 49, page 283, items 4 through 6.) 5.
  • Page 238 14. Pull the right side of the platen toward the front of the printer and move the platen to the right and out of the left side plate. (Hold the black metal washer on the left side shaft as you remove the platen. Make sure the copper wear saddles in the platen seat of the mechanism base stay in place.) Installation...
  • Page 239 Platen Installation (continued) 4. Make sure the two wear saddles are set flush into the corners of the mechanism base platen seat. (See Figure 36.) 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.
  • Page 240 Platen Installation (continued) 9. Slide the right ribbon guide assembly into the side plate and install the two 7/32 inch screws and washers. (See Figure 50, page 285, item 12, 14, and 15.) 10. Install the forms thickness indicator plate: a.
  • Page 241 Platen Installation (continued) 17. Install the platen shaft pulley with the 7/64 inch setscrew facing up and tighten the setscrew. Open and close the forms thickness lever and check that the platen pulley setscrew does not hit the left ribbon guide. 18.

  • Page 242: 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 37, page 243.) If the standard terminating resistor pack is not compatible with the particular interface driver requirements of the host computer, other values of pull-up and pull-down resistors may be required.
  • Page 243 3. Return the printer to normal operation (page 159). CMX Controller Board Default: 470 ohm Alt 1: 220 ohm Alt 2: 1K ohm Resistor Kit: 14H5525 Default: 1K ohm Alt 1: 330 ohm Alt 2: none Figure 37. Resistors, Terminating, Removal/Installation Replacement Procedures and Illustrated Parts List...

  • Page 244: Ribbon Guide Assembly (L/R)

    Ribbon Guide Assembly (L/R) Removal 1. Prepare the printer for maintenance (page 194). 2. Open the printer cover. 3. Remove the printer ribbon. NOTE: The right ribbon guide is shown in Figure 50. The removal procedure is the same for the left ribbon guide. 4.

  • Page 245: Ribbon Hub

    Ribbon Hub Removal 1. Prepare the printer for maintenance (page 194). 2. Remove the printer ribbon. 3. Loosen the Torx T-10 screw in the ribbon spool hub (page 285, Figure 50). 4. Remove the hub from the shaft of the ribbon drive motor. Installation 1.

  • Page 246: Shaft, Splined

    Shaft, Splined Removal 1. Prepare the printer for maintenance (page 194). 2. Open the printer cover. 3. Remove the paper supports from the splined shaft and support shaft. (See Figure 48, page 281, item 21.) 4. Remove the paper feed timing belt (page 195). 5.
  • Page 247 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 38.) 2. Grasp the vertical adjustment knob and slide the splined shaft through the right side plate, the tractors, and the left side plate (page 281, Figure 48).

  • Page 248: Shaft, Support

    Shaft, Support Removal 1. Prepare the printer for maintenance (page 194). 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 48, page 281, item 21.) 5.

  • Page 249: Shuttle Frame Assembly

    Shuttle Frame Assembly Removal 1. Prepare the printer for maintenance (page 194). 2. Remove the shuttle cover assembly (page 209). 3. Disconnect the MPU cable connector (page 279, Figure 47). 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.
  • Page 250 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 275, Figure 45). 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.

  • Page 251: Spring Assembly, Gas

    Spring Assembly, Gas NOTE: This procedure applies only to cabinet models. Removal CAUTION: <3> Two persons may be required to perform this procedure. Prop or hold the top cover securely open while disengaging the gas spring assembly. 1. Prepare the printer for maintenance (page 194). 2.

  • Page 252: Spring, Extension

    4. Unhook the extension spring from the spring lugs on the hammer bank and shuttle frame. (See Figure 47, page 279.) Installation 1. Put a dab of IBM #20 bearing lubricant on both spring lugs. ATTENTION Make sure the extension spring does not touch the MPU cable after installation.

  • Page 253: Switch Assembly, Cover Open

    Switch Assembly, Cover Open Removal 1. Prepare the printer for maintenance (page 194). 2. Remove the shuttle cover assembly (page 209). 3. Carefully lift and pry the cover open switch assembly out its well in the base casting to the right of the shuttle motor. (See Figure 45, page 275.) 4.

  • Page 254: Switch Assembly, Paper Detector

    Switch Assembly, Paper Detector Removal 1. Prepare the printer for maintenance (page 194). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: Remove the top cover assembly (page 210). 3. Cabinet Model: Loosen four screws and remove the barrier shield. (See page 269, Figure 43, items 3, 4, and 9.) Pedestal Model: Remove the paper guide, barrier shield, and four screws.
  • Page 255 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 50, page 285.) 2. Check the PMD sensor arm range: make sure it travels freely and completely back into the sensing cavity.

  • Page 256: Switch Assembly, Platen Interlock

    Switch Assembly, Platen Interlock Removal 1. Prepare the printer for maintenance (page 194). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: Remove the top cover assembly (page 210). 3. Fully close the forms thickness lever (position ‘A’). 4.
  • Page 257 Installation 1. Fully close the forms thickness lever (position ‘A’). 2. Position the platen interlock switch assembly on the switch bracket and install the two screws securing it to the bracket. (See Figure 49, page 283.) 3. Route the switch cable through the cutout in the right side plate and to the controller board.

  • Page 258: Tractor (L/R)

    Tractor (L/R) Removal 1. Prepare the printer for maintenance (page 194). 2. Remove the splined shaft (page 246). 3. Remove the support shaft (page 248). 4. Remove the tractors. Installation 1. Using the replacement tractors, install the support shaft (page 248). 2.

  • Page 259: Section Ii: Illustrated Parts List

    Section II: Illustrated Parts List List of Figures Figure 39. Top Cover, Doors, and Casters, Cabinet Model ..Figure 40. Paper Stacker and Chains ......Figure 41.
  • Page 260 Item Part No. Description Notes (Order No.) 24H8961 Top Cover Kit Includes mounting hardware 57G1492 Window, Top Cover Not visible in Figure 39 14H5567 Wireform Paper Guide Assembly Includes mounting hardware 24H8960 Rear Door Kit Includes mounting hardware (Not visible in Figure 39) 24H8959 Front Door Kit Includes mounting hardware...

  • Page 261: Figure 39. Top Cover, Doors, And Casters, Cabinet Model

    NOTE: Item 10: Shipping Container Kit not shown Item 11: Hardware Kit not shown Figure 39. Top Cover, Doors, and Casters, Cabinet Model Replacement Procedures and Illustrated Parts List...
  • Page 262 Item Part No. Description Notes (Order No.) 57G7176 Stacker 30H3981 Runner, Stacker 04H4779 Riser, Stacker Runner Screw (4) 14H5296 Spares Kit, Grommet 14H5272 Chain Assembly Kit Kit contains eight chains 57G7260 Power Cord, U.S. Grommet, Power Cord (2) Included in item 5 Replacement Procedures and Illustrated Parts List...

  • Page 263: Figure 40. Paper Stacker And Chains

    Figure 40. Paper Stacker and Chains Replacement Procedures and Illustrated Parts List...
  • Page 264 Item Part No. Description Notes (Order No.) 14H5299 Operator Panel, Cabinet Includes mounting hardware 57G1598 Operator Panel Overlay English 57G1599 Operator Panel Overlay Spanish 57G1600 Operator Panel Overlay French 57G1601 Operator Panel Overlay Italian 57G1602 Operator Panel Overlay German 57G1603 Operator Panel Overlay Dutch 57G1604...

  • Page 265: Figure 41. Control Panel And Cabinet Details

    Figure 41. Control Panel and Cabinet Details Replacement Procedures and Illustrated Parts List...
  • Page 266 Item Part No. Description Notes (Order No.) 63H5124 Operator Panel, Pedestal Models 04P, 05P, 08P, 09P 57G1598 Operator Panel Overlay English 57G1599 Operator Panel Overlay Spanish 57G1600 Operator Panel Overlay French 57G1601 Operator Panel Overlay Italian 57G1602 Operator Panel Overlay German 57G1603 Operator Panel Overlay...

  • Page 267: Figure 42. Pedestal Details

    NOTE: Item 16: Lid Accessory Kit not shown Item 17: Pedestal Shipping Container not shown Figure 42. Pedestal Details Replacement Procedures and Illustrated Parts List...
  • Page 268 Item Part No. Description Notes (Order No.) 14H5235 Shroud Assembly, Air Shuttle Cover Assembly Screw, Captive (2) 10–24x.62 with O-ring, .125x.250x.06 Screw, Thread Forming (4) 6–32x.25 Barrier Shield 14H5271 Paper Guide Assembly Models 004, 005, 008, 009, 012, 014 Screw, w/Lock Washer (3) 6–32x.25 and #6 Flat Washer 14H5174 Platen/Paper Feed Cover Kit...

  • Page 269: Figure 43. Inside Covers, Cabinet Model

    Figure 43. Inside Covers, Cabinet Model Replacement Procedures and Illustrated Parts List...
  • Page 270 Item Part No. Description Notes (Order No.) 14H5235 Shroud Assembly, Air Shuttle Cover Assembly Screw, Captive (2) 10–24x.62 with O-ring, .125x.250x.06 Screw, Thread Forming (4) 6–32x.25 Barrier Shield 63H5116 Paper Path Assembly Models 04P, 05P, 08P, 09P 08H7954 Anti-Static Brush Kit Power Supply Shield Taped to card cage along upper edge...

  • Page 271: Figure 44. Inside Covers And Card Cage, Pedestal Model

    See Figure 44a, page 273. Figure 44. Inside Covers and Card Cage, Pedestal Model Replacement Procedures and Illustrated Parts List...
  • Page 272 Item Part No. Description Notes (Order No.) Nut, 6–32 (1) Upper right fan corner only 57G1440 Card Cage Fan Assembly Air flow is into card cage Fan Guard Screw, w/Lock Washer (4) 6–32x.1.75 Card Cage, Pedestal 14H5571 Circuit Breaker Replacement Procedures and Illustrated Parts List...

  • Page 273: Figure 44A. Card Cage Detail, Pedestal Model

    From Figure 44, page 271. (Rotated 180 degrees.) To IEC 320 AC Power Input (Connector J301, White Wire) To Connector P1, (White Wire) To Connector P1, (Black Wire) To IEC 320 AC Power Input (Connector J301, Black Wire) Figure 44a. Card Cage Detail, Pedestal Model Replacement Procedures and Illustrated Parts List...
  • Page 274 Item Part No. Description Notes (Order No.) 63H7518 Hammer Bank/Rbn Mask Cover Models 004, 04P, 005, 05P 63H7519 Hammer Bank/Rbn Mask Cover Models 008, 08P, 009, 09P 63H7520 Hammer Bank/Rbn Mask Cover Models 012, 014 14H5274 Shuttle Frame Assembly Models 004, 04P Shuttle Frame Assembly Models 005, 05P 24H8648...

  • Page 275: Figure 45. Print Mechanism And Circuit Boards: Early Models

    2 Places: Exploded to show assembly. Do not remove holddown clamps and screws. (MPU) (Shuttle Motor) Terminator Board on Shuttle Frame Figure 45. Print Mechanism and Circuit Boards: Early Models Replacement Procedures and Illustrated Parts List...
  • Page 276 Item Part No. Description Notes (Order No.) 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 24H8828 Ribbon Mask, 500 Models 050, P50 24H8844 Ribbon Mask, 1000 Models 010, P10...

  • Page 277: Figure 46. Print Mechanism And Circuit Boards: Later Models

    2 Places: Exploded to show assembly. Do not remove holddown clamps and screws. (Shuttle (MPU) Motor) Terminator Board on Shuttle Frame Figure 46. Print Mechanism and Circuit Boards: Later Models Replacement Procedures and Illustrated Parts List...
  • Page 278 Item Part No. Description Notes (Order No.) 57G1476 Magnetic Pickup Assy (MPU) Screw, Socket Cap, 6–32x.38 30H3985 Extension Spring 14H5329 Cable Assembly, MPU Replacement Procedures and Illustrated Parts List...

  • Page 279: Figure 47. Magnetic Pickup Unit (Mpu) And Extension Spring

    Spring Lug (Do not remove grease) Spring Lug (Do not remove grease) <21> Make sure the extension spring does not touch the MPU cable after installation. 0.010 .001 inch (0.254 .025mm) Figure 47. Magnetic Pickup Unit (MPU) and Extension Spring Replacement Procedures and Illustrated Parts List...
  • Page 280 Item Part No. Description Notes (Order No.) Screw, Socket Cap, 4–40x.25 Part of item 19 Washer, Flat #4 Part of item 19 Knob, Tractor Adjust Part of item 19 Bushing, Tractor Adjust Part of item 19 Washer, Curved Spring (2) Part of item 19 Ring, Grip Part of item 18...

  • Page 281: Figure 48. Tractor Shafts

    NOTE: Item 18: Tractor Shaft Hardware Kit not shown Item 19: Tractor Shaft Kit not shown Figure 48. Tractor Shafts Replacement Procedures and Illustrated Parts List...
  • Page 282 Item Part No. Description Notes (Order No.) Setscrew Part of item 25 Bracket, Platen (2) Part of item 25 57G1469 Ironer Assembly Reverser Paper Feed Screw, Thread Forming (3) 6–32x.25 57G1571 Bracket, Ironer Plate, Ironer 08H7936 Platen Assembly Washer, Flat (2) Part of item 25 Screw (2) Part of item 11...

  • Page 283: Figure 49. Platen

    NOTE: Black tape faces paper motion detector. NOTE: Item 25: Platen Hardware Kit Figure 49. Platen Replacement Procedures and Illustrated Parts List...
  • Page 284 Item Part No. Description Notes (Order No.) 57G1440 Fan Assembly Air flow is into card cage Screw, w/Lock Washer (3) Two 6–32x1.75 on botton One 6–32x0.50 on top left 14H5281 Paper Detector Switch Assy Standard 63H5133 Paper Detector Switch Assy Black Back forms Screw, Thread Forming, 6–32x.375 14H5520...

  • Page 285: Figure 50. Motors, Card Cage Fan, And Paper Detector Switch

    Install screws here Top View Route cable under Hammer Bank Fan base casting See detail above Figure 50. Motors, Card Cage Fan, and Paper Detector Switch Replacement Procedures and Illustrated Parts List...
  • Page 286 Item Part No. Description Notes (Order No.) 14H5571 Circuit Breaker IEC 320 AC Power Connector Connector J301 Chassis Ground Stud Connector P1 To power supply board connector J1 AC Cable Assy, AC In, Power Supply Part of Field Kit, AC Assy 14H5289 Replacement Procedures and Illustrated Parts List...

  • Page 287: Figure 51. Circuit Breaker

    Inside detail 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) Card cage fan and power supply board removed for clarity Black Wire Black Wire...
  • Page 288 Item Part No. Description Notes (Order No.) Screw (2) Card Cage 24H9011 IBM Coax/Twinax Expansion Screw, Captive Standoff, Hex, 3/16 inch M/F, .813 Lg. 24H8535 Adapter, Expansion Connector 60-pin CMX Controller Board Controller Board Connector J111 Replacement Procedures and Illustrated Parts List...

  • Page 289: Figure 52. Expansion Coax/Twinax Board

    Figure 52. IBM Coax/Twinax Expansion Board Replacement Procedures and Illustrated Parts List...
  • Page 290 Item Part No. Description Notes (Order No.) Screw, Connector Cover (2) Cover Plate, Centronics Ferrite Clamp See also Appendix I CMX Controller Board 14H5287 Centronics I/O Cable Assembly 24H8995 Ethernet LAN PCBA, 10-Base-T 24H8994 Ethernet LAN PCBA, 10-Base-2 Rear of Card Cage Screw (2) Replacement Procedures and Illustrated Parts List...

  • Page 291: Figure 53. Ethernet Interface Assemblies

    Figure 53. Ethernet Interface Assemblies Replacement Procedures and Illustrated Parts List...
  • Page 292 Replacement Procedures and Illustrated Parts List...

  • Page 293: Appendix A: Wire Data

    ......IBM 6400 Main Wire Harness Test Tables ..... . .
  • Page 294 Ribbon Guide Kit ......... Ribbon Motor, Extension .

  • Page 295: Ibm 6400 Interconnection Diagram

    IBM 6400 INTERCONNECTION DIAGRAM J301 IEC 320 AC POWER AC INPUT CONNECTOR Operator Panel Legend: = Number of conductors CIRCUIT in cable assembly ON/OFF AC to DC BREAKER SWITCH Power Supply =Chassis/ Board Line 1 frame/ Line 2 / Neutral...

  • Page 296: Ibm 6400 Power Distribution Diagram

    IBM 6400 POWER DISTRIBUTION DIAGRAM POWER IEC 320 J301 AC POWER CONNECTOR Operator Panel ON/OFF SWITCH CIRCUIT AC to DC BREAKER Power Supply Board Line 1 P101 Line 2 / Neutral J310 N TEMP HI * * V3.5 BOARD PIN 1 = N TEMP HI...

  • Page 297: Ibm 6400 Main Wire Harness Test Tables

    IBM 6400 Main Wire Harness Test Tables Top view; as seen when plugged PIN NO. into the CMX board. PLAT M P106 LRIB M NOTE: For cable shell connector assembly/disassembly, see Figure 30 on page 199. CCF = Card Cage Fan LRIB M = Left Ribbon Motor Top view;...

  • Page 298: Controller, Cmx

    Controller, CMX J112 Centronics I/O CNC PN 1 N STROBE I/O CNC PN 19 I/O CNC PN 2 I/O CNC PN 20 I/O CNC PN 3 I/O CNC PN 21 I/O CNC PN 4 I/O CNC PN 22 I/O CNC PN 5 J201 J110 I/O CNC PN 23...
  • Page 299 Diagnostic Port Controller, CMX CAUTION: <5> Do not remove or replace VX DB TXD the NVRAM. The NVRAM contains a lithium battery that can explode if it is VX DB RXD replaced incorrectly. NVRAM is replaced only at the factory. Online Verifier 470 PF EXT 5V...
  • Page 300 Controller, CMX J111 J105 Expansion Connector Hammer Bank Power 4.7K 4.7K J101 0.1W 0.1W J106 Power Supply + Stacker Power EXP D7 Motor Sensor Left EXP D6 EXP D5 N TEMP HI EXP N ID SEL EXP D4 N STBY PLAT 1 RIB L1 12/10 V...
  • Page 301 Controller, CMX 0.1W EC DB TXD EC DB RXD EC Diagnostics PPR TRIG PPR MOVING FT EVENT MPU OUT SHUT DIR Terminating Resistors (See page 242.) 2–PIN JUMPER +15V Flash: 80–pin SIMM J108 J116 J10 = Bank 1 J11 = Bank 0 Hammer Bank Logic Shuttle Motor DRAM: 72–pin SIMM...

  • Page 302: Power Supply

    Power Supply LOAD LOAD (Line Filter Area) Cable Assy, AC Input AC In, Power Supply AC COMMON CHASSIS GND = RING TERMINAL P101 = FAST–ON TERMINAL P101 PIN 1 Controller Board * V3.5 BOARD PIN 1 = N TEMP HI N TEMP HI * N TEMP HI V4 BOARD PIN 1 = N AC FAIL...

  • Page 303: Expansion Coax/Twinax

    Twinax IBM Coax/TwinaxExpansion Board Connector SHIELD 1 TWINAX PHASE B SHIELD 2 TWINAX PHASE A Expansion Connector 0.1W EXP D7 EXP D6 EXP D5 N CARD DETECT EXP D4 12/10 V EXP D3 EXP D2 EXP D1 N DMA REQ0...

  • Page 304: Surestak Power Stacker Control Panel Pcba

    Limit Switches and SureStak Power Stacker Test Test Elevator Motor Control Panel PCBA SKP DB TXD N RESET SKP DB RXD STK FULL SWT N 42V FAIL FULL SWT RET PMD SIG LIMIT SIG STK LIMIT SWT PAP IN SIG FULL SIG LIMIT SWT RET BEAM SIG...

  • Page 305: Cable Routing

    Cable Routing, Cabinet Model...

  • Page 306: Cabinet Model, Mechanism Base

    Front of Printer Left Side of Printer Right Side of Printer Cable Routing, Mechanism Base P107 / CVO Cabinet Model To J106 on Controller (See page 199 for (Looking up from below) (See page 199 for connector detail.) To J107 connector detail.) on Controller...

  • Page 307: Pedestal Model

    Cable Routing, Pedestal Model...

  • Page 308: Pedestal Model, Mechanism Base

    Front of Printer Left Side of Printer Right Side of Printer (Unconnected on on pedestal models) Cable Routing, Mechanism Base, Pedestal Model (Looking up from Below) P107/CVO To J106 on Controller (See page 199 for (See page 199 for connector detail.) To J107 on Controller connector detail.)

  • Page 309: Ac In, Power Supply

    To Circuit Breaker To Power Supply J1 Part No. Description 14H5289 Cable Assembly, AC In, Power Supply...

  • Page 310: Ac Power Input

    To Circuit Breaker Input Power Connector Part No. Description 14H5289 Cable Assembly, AC Power Input...

  • Page 311: Card Cage Fan

    PIN 1 PIN 1 Part No. Description 14H5285 Cable Assembly, Card Cage Fan...

  • Page 312: Operator Panel

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

  • Page 313: Exhaust Fan

    Part No. Description 14H5286 Cable Assembly, Exhaust Fan...

  • Page 314: Hammer Bank Logic

    Part No. Description 14H5279 Cable Assembly, Hammer Bank Logic...

  • Page 315: Hammer Bank Power

    PIN 1 PIN 1 Part No. Description 14H5283 Cable Assembly, Hammer Bank Power...

  • Page 316: I/O, Centronics

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

  • Page 317: Mpu

    PIN 2 PIN 3 PIN 1 PIN 1 Part No. Description 14H5329 Cable Assembly, MPU...
  • Page 318 NOTE: Left ribbon guide shown. Right is mirror image. PIN 1 PIN 2 LEFT GUIDE = P106 / LRP RIGHT GUIDE = P107 / RRP Part No. Description 24H8894 Ribbon Guide Kit (Includes left and right guides)
  • Page 319 Part No. Description 63H7464 Cable Assembly, Ribbon Motor, Extension...
  • Page 320 Part No. Description 14H5330 Cable Assembly, Shuttle Motor Drive...
  • Page 321 15 position D–sub receptacle connector with EMI/RFI shield. Jack White Gray Shield Resistance Chart Ohms 1, 2, 3, 4 Shield Shield 1, 4 2, 3 Jack Part No. Description 38F8254 Cable Assembly, Twinax Auto–Termination...
  • Page 322 Part No. Description 14H5522 Cable Assembly, Centronics/DataProducts Adapter...
  • Page 323 Part No. Description 14H5589 Cable Assembly, +5V Remote Power...
  • Page 324 M1 = REAR PADDLE M1 A1 MOTOR M1 A2 RESISTANCE = 15.2 M1 B1 1.5 Ω / PHASE M1 B2 M2 A1 M2 = FRONT PADDLE M2 A2 MOTOR RESISTANCE = 15.2 M2 B1 1.5 Ω / PHASE M2 B2 PI PHA 1 PINCH ROLLER PI PHA 2...
  • Page 325 Part No. Description 24H8976 Cable, Logic, Power Stacker...
  • Page 326 Part No. Description 24H8975 Cable, Power, Power Stacker...
  • Page 327 Part No. Description 24H8964 Cable, Vertical Rail, Power Stacker...
  • Page 328 P107 / HBF Part No. Description 14H5159 Fan Assembly, Hammer Bank...
  • Page 329 Part No. Description 57G1476 Magnetic Pickup Assembly...
  • Page 330 Part No. Description 14H5282 Switch Assembly, Cover Open...
  • Page 331 Part No. Description 14H5281 Switch Assembly, Paper Detector (Standard) (63H5133) (Black Back Forms Kit, 6400)
  • Page 332 Part No. Description 14H5280 Switch Assembly, Platen Interlock...

  • Page 333: B Printer Specifications

    Printer Specifications Ribbon Specifications NOTE: The ribbon life figures listed below are based on IBM tests conducted in accordance with ANSI Standard X3A.182. Actual ribbon life may vary, depending 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.

  • Page 334: Paper Specifications

    Fax orders may be sent to: 1–800–522–3422 Mail orders may be sent to: Lexmark International, Inc., 1221 Alverser Drive, Midlothian, VA 23113. Ordering Ribbons (Outside of U.S.) Order supplies by contacting your local Lexmark International distributor or by writing to Lexmark International, Inc. Lexmark International, Inc.

  • Page 335: Printer Dimensions

    –40 to 158 F (–40 to 70 C) Relative Humidity Operating 15% to 80% (noncondensing) Storage 15% to 90% (noncondensing) NERGY IBM 6400 Series Printers comply with the requirements of the NERGY TAR Computers Program of the U.S. Environmental Protection Agency. Printer Specifications...

  • Page 336: Electrical Characteristics

    Electrical Characteristics Input Voltage Line Line Current Voltage Frequency Design Range –04, –05, –50, –08, –09, –010, –012 –014 –015 –04P –05P –P50 –08P –09P –P10 88–135V 47–63 Hz 6A @ 100 V 6A @ 100 V 6A @ 88 V 6A @ 100 V 6A @ 100 V 6A @ 88 V...
  • Page 337 6400–005 6400–05P Operating DP Mode Standby 120 VAC Not Energy All H’s Max Typical 60 Hz Star Energy Star Watts BTU/Hour Operating DP Mode Standby 230 VAC Not Energy All H’s Max Typical 50 Hz Star Energy Star Watts BTU/Hour 6400–050 6400–P50 Operating DP Mode...
  • Page 338 6400–008 6400–08P Operating DP Mode Standby 120 VAC Not Energy All H’s Max Typical 60 Hz Star Energy Star Watts BTU/Hour Operating DP Mode Standby 230 VAC Not Energy All H’s Max Typical 50 Hz Star Energy Star Watts BTU/Hour 6400–009 6400–09P Operating DP Mode...
  • Page 339 6400–010 6400–P10 Operating DP Mode Standby 120 VAC Not Energy All H’s Max Typical 60 Hz Star Energy Star Watts BTU/Hour 1025 Operating DP Mode Standby 230 VAC Not Energy All H’s Max Typical 50 Hz Star Energy Star Watts BTU/Hour 6400–012 Operating DP Mode...
  • Page 340 6400–014 Operating DP Mode Standby 120 VAC Not Energy All H’s Max Typical 60 Hz Star Energy Star Watts BTU/Hour 1260 Operating DP Mode Standby 230 VAC Not Energy All H’s Max Typical 50 Hz Star Energy Star Watts BTU/Hour 1300 6400–015 Operating DP Mode...

  • Page 341: Duty Cycle

    6400–XXK Operating DP Mode Standby 120 VAC Not Energy All H’s Max Typical 60 Hz Star Energy Star Watts BTU/Hour 1260 Operating DP Mode Standby 230 VAC Not Energy All H’s Max Typical 50 Hz Star Energy Star Watts BTU/Hour 1300 Interfaces Type:...

  • Page 342: Printing Rates

    6400–014 376, 000 pages per month 6400–015 376, 000 pages per month —under the following conditions: Uppercase text characters only (no graphics) 6 lines per inch 10 characters per inch 63% character density or 83 characters per line 63% line density or 42 lines per 11-inch page Single part (18 lb) paper Printer is installed in accordance with the Setup Guide Printer is maintained in accordance with this maintenance manual...

  • Page 343: Printer Specifications

    Table 6. Printing Rates PERFORMANCE PRINT QUALITY UPPERCASE DESCENDERS PLOT MODE MATRIX CHARACTERS ONLY & UNDERLINE DENSITY NOTE INCH (DPI) NOTE MODEL 7 (13) X 9 + 3 CORRESPONDENCE 6 (11) X 9 + 3 36.5 90 (180) X 96 5 (9) X 9 + 3 5 (9) X 7 + 2 DATA...
  • Page 344 Printer Specifications...

  • Page 345: C Metric Conversion Tables

    Metric Conversion Tables Length Multiply 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...
  • Page 346 Mass and Density Multiply To Obtain pound* 0.4535924 kilogram ounce* 28.34952 gram kilogram 2.204622 pound gram 0.03527397 ounce * avoirdupois Temperature From 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...

  • Page 347: D Torque Table

    Torque Table The table below establishes the torque requirements for routine installation of threaded fasteners. These requirements apply to fasteners made of steel, at a minimum engagement of 3.5 threads, including chamfer and countersink. Fastener sizes are listed as Numbered Size – Threads Per Inch. Torque Table Carbon Steel Fasteners (ANSI B18.6.3 –...
  • Page 348 Torque Table...

  • Page 349: E Safety Inspection Guide

    IBM 6400 printers incorporate safety items installed to protect customers, operators, and service personnel from injury. Use this inspection guide as an aid in identifying possible unsafe conditions in a 6400 series printer. Perform the inspection steps outlined in this guide before the normal inspection for Maintenance Agreement Qualification, or any time you are instructed to make a safety inspection.

  • Page 350: Prepare The Printer For Inspection

    Preparation You must have completed the “Electrical Safety Training Course for IBM Customer Engineers” (self-study course 77170 or existing level) to do the Safety Inspection. Have the following items available: 1. Electrical Safety for IBM Customer Engineers , Order No. S229–8124.

  • Page 351: Inspect Mechanical Parts

    Inspect Mechanical Parts Top Cover and Cabinet Doors 1. Inspect the top cover: a. Open the top cover. On cabinet models, make sure the gas spring assembly holds the cover up in the open position. b. Make sure the window is not cracked or broken. c.

  • Page 352: Inspect Electrical Parts

    Inspect Electrical Parts Safety Ground Path 1. Make sure the printer power cord is unplugged. 2. Remove the paper guide assembly (page 235). 3. Make sure the ground cable from the circuit breaker power leads is undamaged and firmly attached to the ground lug on the wall of the card cage, as shown in Figure 54.

  • Page 353: Safety Inspection Guide

    4. Set a Fluke meter (P/N 8496278) or similar device to the lowest resistance scale. Measure the resistance between the power cable ground pin and the printer frame: safety ground circuits should measure 0.1 Ohm or less. 5. Install the paper guide assembly (page 235). POWER * V3.5 BOARD PIN 1 = N TEMP HI V4 BOARD PIN 1 = N AC FAIL...
  • Page 354 5. Neutral impedance NOTE: The customer is responsible for correcting problems with the power source. Inform the IBM Installation Planning Representative (IPR) of any problems with the customer’s power source. Each branch circuit must be grounded for safety and correct operation of the printer.
  • Page 355 Power On/Off Verification 1. Make sure all covers are installed. 2. Plug the power cable into the customer’s power outlet. 3. Power on the printer and watch the LCD. 4. Verify that the power on diagnostic tests and initialization routines are successful.
  • Page 356 Safety Inspection Guide...

  • Page 357: F Abbreviations And Signal Mnemonics

    Abbreviations and Signal Mnemonics NOTE: Mnemonics with the first letter “N” are negative true. Abbreviation/ Definition Mnemonic –6 ....microfarad (10 farad) –6 .
  • Page 358 ....Busy ....British Thermal Unit ....Buffered Upper Driver .
  • Page 359 ....Data Set Ready ....Data Terminal Ready ....Engine Controller (a functional unit of the CMX board) EEPROM .
  • Page 360 ....Integrated Circuit ....Identification .
  • Page 361 ....Number NOVRAM ... . Non-volatile Random-Access Memory –9 ....nanosecond (10 second) NVRAM...
  • Page 362 ....Power ....Right ....Ribbon .
  • Page 363 STBY ....Standby ....Power Stacker ....Switch SYNC .
  • Page 364 Abbreviations and Signal Mnemonics...

  • Page 365: G Cords And Adapters

    Units 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,...
  • Page 366 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 6000, IBM...

  • Page 367: H Part Numbers

    Part Numbers Part Number Page Description 04H4779 Riser, Stacker Runner 08H7934 Platen Open Motor Pulley 08H7936 Platen Assembly 08H7954 Anti-Static Brush Kit 14H5154 Platen Open Motor Assembly 14H5159 285,328 Hammer Bank Fan Assembly 14H5169 Platen Hardware Kit 14H5174 Platen/Paper Feed Cover Kit 14H5179 Paper Scale 14H5211...
  • Page 368 Part Number Page Description 14H5280 283,332 Platen Switch Kit 14H5281 285,331 Paper Detector Switch Assembly (Standard) 14H5282 275,330 Switch Assembly, Cover Open 14H5283 Cable Assy, Hammer Bank Power 14H5285 Cable Assy, Card Cage Fan 14H5286 Cable Assy, Exhaust Fan 14H5287 275, 291, Centronics I/O Cable Assembly 14H5288...
  • Page 369 Part Number Page Description 14H5520 Paper Feed Motor 14H5521 Motor Assembly, Ribbon 14H5522 275, Cable Assy, Centronics/Dataproducts Adapter 14H5525 Resistor Kit 14H5589 Cable Assy, +5V Remote Power 14H5539 SIMM, Flash, Blank, 1MB 14H5540 SIMM, Flash, Blank, 2MB 14H5567 Wireform Paper Path 14H5571 Circuit Breaker 14H5572...
  • Page 370 Part Number Page Description 24H8648 Shuttle Frame Assy (Models 005, 05P) 24H8766 6400 Operator’s Guide, English 24H8767 6400 Operator’s Guide, Spanish 24H8768 6400 Line Matrix Printer Setup Guide, French 24H8769 6400 Operator’s Guide, Italian 24H8770 6400 Operator’s Guide, German 24H8771 6400 Operator’s Guide, Dutch 24H8772 6400 Operator’s Guide, Brazilian Portuguese...
  • Page 371 Part Number Page Description 24H8890 6400 Code V User’s Manual 24H8891 6400 CTA Programmer’s Reference 24H8892 6400 IPDS Programmer’s Reference 24H8893 Ethernet Interface User’s Manual 24H8894 285,318 Ribbon Guide Kit 24H8924 Hammer Bank Coverr Assy, 1500 (Model 015) 24H8925 Shuttle Frame Assembly, 500 (Models 050, P50) 24H8927 Shuttle Frame Assembly, 1000 (Models 010, 10P) 24H8929...
  • Page 372 Part Number Page Description 57G1421 Motor Pulley, Paper Feed 57G1440 Fan Assembly 57G1453 Paper Detector Switch Assy 57G1460 Splined Shaft 57G1466 Tractor Set 57G1468 Belt, Timing, 050P, 100 Teeth (Paper Feed) 57G1467 Belt, Timing, 312W, 87 Teeth (Platen Open) 57G1469 Ironer Assembly, Reverse Paper Feed 57G1476 279,329...
  • Page 373 Part Number Page Description 57G7260 Power Cord, U.S. (See also Appendix G.) 63H5116 Paper Path Assembly (Models 04P, 05P, 08P, 09P) 63H5118 Paper Basket 63H5119 Lid, Pedestal Model 63H5120 Top Cover, Complete (Pedestal Model) 63H5121 Hinge Lid Kit (Pedestal Model) 63H5122 Lid Accessory Kit (Pedestal Model) 63H5123...
  • Page 374 Part Number Page Description 90H3271 CMX Controller Board, V5.5, 40 MHz (Models 050, P50, 010, P10, 014, 015) S246–0149 6400 Coax/Twinax Multi-Platform Interface Option Installation and Operation Guide Part Numbers...

  • Page 375: I Noise Suppression Devices

    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—Cylindrical core through and around which the control panel cable assembly is wound.
  • Page 376 Control Panel Cable Assembly Connector Connector P110 P310 Shielding Bead NOTE: Two turns around each bead. Parallel I/O Cable Assembly Connector P112 Ferrite Core with Clamp and Adhesive Backing NOTE: This core attaches to right rear card cage wall. Connector J203 Figure 56.

  • Page 377: Introduction

    SureStak** Power Stacker Contents of This Appendix Introduction ..........Removing the Power Stacker .

  • Page 378: Removing The Power Stacker

    Removing the Power Stacker 1. Prepare the printer for maintenance (page 194). 2. Unload paper from the stacker area. (Refer to the User’s Manual .) 3. Remove the paper tent. (See Figure 57.) Paper Tent Figure 57. Removing the Paper Tent 4.
  • Page 379 5. Remove the paper deflector. (See Figure 59.) Paper Deflector Figure 59. Removing the Paper Deflector 6. Remove three screws and washers from the stacker control panel. (See Figure 60.) Washer Long Screw Washer (2) Short Screw (2) Figure 60. Removing the Stacker Control Panel Power Stacker...
  • Page 380 7. Close the top cover, remove four cables from the stacker control panel, and remove the stacker control panel. (See Figure 61.) Logic Cable (P104) Power Cable Frame Cable (P102) Rail Cable (P107) Figure 61. Removing Cables from the Stacker Control Panel 8.
  • Page 381 9. Raise the elevator assembly. 10. Loosen the screws securing the vertical rails to the stacker base one turn—do not remove the screws. Each rail is secured by two screws. (See Figure 63.) Elevator Assembly Stacker Base Washer (2) Vertical Rail Screw (2) NOTE: Hardware exploded to show location.
  • Page 382 11. Remove the four 7/64 x 1/2 inch screws and washers securing the base plate to the cabinet floor. (See Figure 62.) 12. Lower the elevator assembly to its lowest position. 13. Tilt the vertical rails toward the front of the printer until they clear the upper frame cross-member.

  • Page 383: Installing The Power Stacker

    Installing the Power Stacker 1. Prepare the printer for maintenance (page 194). 2. Remove paper. 3. Loosen the three paper path hold-down screws. Slide the paper path to the left and lift it off the card cage. (See Figure 65.) Paper Path Hold-Down Screw (3)
  • Page 384 4. Connect the power stacker logic cable P103 to connector J17 on the CMX controller board. (See Figure 66.) 5. Disconnect the power supply cable from connector J101 on the CMX controller board. (See Figure 66.) 6. 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.
  • Page 385 8. Loosen the screws at the bottom of each vertical rail one turn—do not remove the screws. Each rail is secured by two screws. (See Figure 67.) Frame Cable Vertical Rail Rail Cable Vertical Rail Screw (2) Screw (2) Figure 67. Stacker Rail and Frame Cables Power Stacker...
  • Page 386 ATTENTION The paper stacker assembly mounts to the rear upper frame cross-member and to the cabinet floor. It is a snug fit. During installation, take care to avoid scratching painted surfaces or damaging the stacker. 9. Position the elevator assembly at the bottom of the vertical rails. (See Figure 68a.) 10.
  • Page 387 Upper Frame Cross-Member Elevator Vertical Assembly Rail Stacker Base Figure 68. Stacker Installation Power Stacker...
  • Page 388 13. Align the holes in the stacker base with the holes in the cabinet floor. (See Figure 68c and Figure 69.) 14. Install two 5/32 x 3/4 inch screws and washers to secure the vertical rails to the upper frame cross-member. 15.
  • Page 389 16. Tighten the four screws you loosened in step 8. When correctly installed, the stacker vertical rails are parallel and vertical, as shown in Figure 68c. 17. Install the paper fence. (See Figure 70.) Paper Fence Stacker Base Figure 70. Paper Fence Power Stacker...
  • Page 390 18. Gather the rail cable, frame cable, logic cable, and power cable. Make sure these cables are routed outboard of the elevator assembly. 19. Connect the stacker cables to the rear of the stacker control panel assembly, as shown in Figure 71. Logic Cable P104...
  • Page 391 20. Close the top cover, position the stacker control panel as shown in Figure 72, and install the mounting screws. 21. Bundle and tie wrap the stacker control panel cables to the printer frame so they do not catch in the stacker mechanism as it moves up and down. Route the stacker rail and frame cables so they move without snagging as the elevator assembly moves up and down.
  • Page 392 22. Install the paper deflector on the vertical rails with the angled portion toward the front of the printer, as shown in Figure 73. 23. Install the paper path that you removed in step 3 (page 383). 24. Install paper and test stacker operation. (Refer to the User’s Manual .) Paper Deflector Figure 73.

  • Page 393: Constant Force Spring

    Replacing the Constant Force Spring 1. Remove the stacker assembly from the printer. (See page 378.) 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.
  • Page 394 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 screw, washers, and spacer from the constant force spring and drum.
  • Page 395 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 76.) 6. While holding the drum tightly, continue to curl the spring until it is completely unwound from the drum.

  • Page 396: Timing Belts

    Replacing the Timing Belts 1. Remove the stacker assembly from the printer. (See page 378.) 2. Raise the elevator assembly to its highest position and secure it to the vertical rails using tie wraps or string. (See Figure 74.) 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.
  • Page 397 5. Loosen the two setscrews on the motor pulley and remove the pulley. (See Figure 78.) Go to step 6. Timing Belt Motor Setscrew Pulley Setscrew Figure 78. Removing the Timing Belt Motor Pulley 6. Remove the shoulder screw, washers, and spacer that secures the constant force spring to the vertical rail.
  • Page 398 7. Remove two Allen screws from the belt clamp that secures the timing belt to the stacker frame. (See Figure 80.) Allen Screw (2) Belt Clamp Allen Screw (2) Belt Clamp Figure 80. Removing the Belt Clamps 8. Remove the timing belt by working it around the vertical rail and constant force spring.

  • Page 399: Illustrated Parts Breakdown

    10. After you have installed a timing belt, make the following final adjustments: a. Loosen the left timing belt pulley screw. b. Position the elevator assembly at its lowest point of travel, and apply downward pressure on the left side of the elevator assembly. c.
  • Page 400 Detail: Figure 83, page 402 Figure 82. Stacker Assembly Power Stacker...
  • Page 401 Item Part No. Description Notes (Order No.) Flanged Bearing Part of item 36 24H8966 Paper Deflector Clip-On Bearing Part of item 36 Screw, Torx, 6–32x.25 Part of item 36 Screw, Shoulder, 10–32 Part of item 36 Screw, Shoulder, 8–32 Part of item 36 24H8968 Timing Belt 24H8996...
  • Page 402 Detail: Figure 84, page 404. Detail: Figure 85, page 406. Detail: Figure 87, page 410. Detail: Figure 86, page 408. Detail: Figure 86, page 408. Figure 83. Stacker Detail: Motor, Roller, and Paddle Assemblies Power Stacker...
  • Page 403 Item Part No. Description Notes (Order No.) 24H8969 Motor 24H9004 Stacker Hardware Kit Kit not illustrated 24H8978 Anti-Static Brush Shear Grommet Part of item 36 Cap Nut Part of item 36 24H9005 Shaft, Drive Roller 24H9006 Spacer, Drive Roller Bearing, Flanged Part of item 36 Bearing Part of item 36...
  • Page 404 Figure 84. Stacker Detail: Rollers Power Stacker...
  • Page 405 Item Part No. Description Notes (Order No.) 24H9004 Stacker Hardware Kit Kit not illustrated 24H8985 Compression Spring Friction Washer Part of item 36 Flanged Bushing Part of item 36 24H8988 Drive Roller Power Stacker...
  • Page 406 Flat Side Flag Connector Figure 85. Stacker Detail: Motor Bracket Power Stacker...
  • Page 407 Item Part No. Description Notes (Order No.) 24H9004 Stacker Hardware Kit Kit not illustrated Clip-On Bearing Part of item 36 24H8999 Holder, LED, Round 24H8989 LED, IR, T-1, 3/4 Power Stacker...
  • Page 408 Flag Connector Figure 86. Stacker Detail: Elevator Bracket Power Stacker...
  • Page 409 Item Part No. Description Notes (Order No.) 24H9004 Stacker Hardware Kit Kit not illustrated Clip-On Bearing Part of item 36 24H9000 Holder, LED, Flat 24H8990 Photodarlington, NPN, Rectifier Power Stacker...
  • Page 410 Flag ROTATED 180 Connector Figure 87. Stacker Detail: Paper Motion Detector Power Stacker...
  • Page 411 Item Part No. Description Notes (Order No.) 24H9004 Stacker Hardware Kit Kit not illustrated 24H9000 Holder, LED, Flat 24H8990 Photodarlington, NPN, Rectifier Screw, Socket Cap, 4x.25 Part of item 36 Screw, Panhead, Type B, 2x3/16 Part of item 36 Retaining Ring, .093 Part of item 36 Nut, Hex, 4–40 Part of item 36...
  • Page 412 Power Stacker...

  • Page 413: Index

    Index Numbers 027 COMMUNICATIONS CHECK / CALL SYSTEM OPERATOR, 79 001 END OF FORMS / LOAD FORMS, 70 028 COMMUNICATIONS CHECK / CALL 002 FORMS JAMMED / CLEAR JAM AND SYSTEM OPERATOR, 79 RELOAD FORMS, 70 029 8344 DIAGNOSTIC TEST FAILED, 79 003 FORMS EJECTED / PRESS 031 END OF FORMS TIMEOUT / LOAD EJECT/RESTORE, 72...
  • Page 414 089 RIBBON STALL, 92 125 PAPER FIFO UNDERFLOW / SEE USER’S GUIDE, 100 090 SHUTTLE COVER OPEN / CLOSE SHUTTLE COVER, 93 126 PAPER FEED BAD TABLE / SEE USER’S GUIDE, 101 092 RIBBON DRIVER CIRCUIT, 93 127 PAPER FEED ILLEGAL STATE / SEE 101 UPPER DRIVER SHORT, 94 USER’S GUIDE, 101 102 LOWER DRIVER SHORT, 94...
  • Page 415 Adapters and Cords, 365 shell and cable replacement, 198 Adjustments, 157 Cable connectors and shells, replacement, coil temperature, 188 end of forms distance, 175 Cable routing, mechanism base, 306 hammer phasing, 179 Call, start of, 56 loading flash memory, 181 Cancel key paper drive motor pulley alignment, 164 cabinet model, 20...
  • Page 416 CLEARING PROGRAM FROM FLASH, 105, Data controller (DC), 47 184, 187 DC (Data Controller, CMX board), 47 CMX controller board. See Controller board Diagnostic menus, boot, 142 Coax/twinax expansion board Diagnostic self–tests pinouts, 303 customer engineer (CE), 138 replacement, 222 operator print, 135 Coax/twinax multi–platform interface, printer information menu, 148...
  • Page 417 Enter key cabinet model, 20 Fan assembly pedestal model, 22 card cage, replacement, 216 Environmental characteristics, 335 hammer bank, replacement, 215, 217 Error log Fault messages, 57 clear, 139 Ferrite cores (noise suppression), 375 print, 135 Flash memory, loading, 181 Error messages, 57 Flash messages ERROR:...
  • Page 418 Hex code printout, 145 cabinet model, 20 Hub, ribbon, replacement, 245 pedestal model, 22 Levers and knobs, 24 Light characters or dots, 114 IBM Coax/twinax expansion board, Line Feed key replacement, 222 cabinet model, 20 Illustrations, replacement procedures, 259 pedestal model, 22...
  • Page 419 006 HOST SYSTEM REQUEST ATTENTION, 72 Magnetic pick–up assembly 007 FM HEADER ERROR, 72 gap adjustment, 223 008 HOLD PRINT TIMEOUT / PRESS replacement, 223 START, 72 Maintenance 009 INVALID KEY PRESS, 72 adjustments, 157 010 PARAMETER ERROR, 73 cleaning the printer, 29 011 SCS COMMAND ERROR, 73 overview, 13 012 STRUCTURE FIELD ERROR, 73...
  • Page 420 044 EC FIRMWARE/HARDWARE 117 A TO D OVERRUN / SEE USER’S ERROR, 82 GUIDE, 97 046 EC STOPPED AT STATE (state), 82 118 UNDEFINED INTERRUPT / SEE USER’S GUIDE, 98 057 CLOSE PLATEN, 83 119 TCB CORRUPTED / SEE USER’S 058 SHUTTLE JAM / SEE USER’S GUIDE, 98 GUIDE, 84...
  • Page 421 139 SHUTTLE OVERSPEED / SEE P65 ERROR: PROGRAM NEEDS MORE USER’S GUIDE, 104 FLASH, 111 990 MACHINE CHECK, 105 P66 ERROR: PROGRAM NEEDS MORE DRAM, 111 998 NON–VOLATILE MEMORY FAILED, P67 ERROR: WRITING TO FLASH, 111 A97 GRAPHIC CHECK ERROR / PRESS P68 ERROR: EC PROGRAM NOT VALID, STOP THEN START, 105 BOOT DIAGNOSTICS, 105...
  • Page 422 P66 ERROR: PROGRAM NEEDS MORE DRAM, 111 Network print server, replacement, 232 P67 ERROR: WRITING TO FLASH, 111 Noise Suppression, 375 P68 ERROR: EC PROGRAM NOT VALID, NOT READY, 108 Notes and notices, 17 P69 ERROR: EC STOPPED AT STATE Numbers, replacement parts, 367 XXXX, 111 PA1 SELECTED, 109...
  • Page 423 PLEASE WAIT... RESET IN PROGRESS, models, 13 evolution, 15 how to identify, 15 Plot, rates, 342 power paper stacker, 377 Power power stacker not operating, 123 cycle, how to, 150 preparing the printer for maintenance, 194 input voltage, 336 principles of operation, 35 on/off verification, 355 reset, 150 printer does not power up, 119...
  • Page 424 231 hammer bank fan assembly, 215, 217 guide assembly (L/R), replacement, 244 hammer spring, 218 guide assembly, alignment, 172 IBM Coax/twinax expansion board, 222 hub, replacement, 245 LAN interface assemblies, 212 mask, replacement, 206 magnetic pick–up assembly, 223...
  • Page 425 Service checks shuttle, set, 189 customer’s power source, 354 Splined shaft power on/off verification, 355 replacement, 246 print interlock, 355 skew adjustment, 174 print mechanism, 351 Spring printer power cable, 354 extension, replacement, 252 safety ground path, 352 gas, assembly, replacement, 251 top cover and doors, 351 Squares, black, on operator panel, 114 Set shuttle speed, 189...
  • Page 426 Upgrading software, 181 TABLE MISMATCH / DOWNLOAD AGAIN, 113, 187 Temperature, coil, adjustment, 188 Vertical spacing problems, 132 Tension adjustment View key paper feed timing belt, 160 cabinet model, 20 platen open belt, 162 pedestal model, 22 Terminating resistors location of, 243 replacement, 242 WAITING FOR PROGRAM DOWNLOAD, Test, equipment, tools, and supplies, 26...
  • Page 428 Copyright IBM Corp., 1995, 1998 S246–0117–06 $$07S246011706:b7$$ 24H8887 $$0724H8887:b7$$ 163983–001A...

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