Digital LG plus Series Bedienerhandbuch

LGplus SeriesText and Graphics PrintersMaintenance ManualOrder Number: EK–LGPLE–MM.A01Digital Equipment CorporationTM

1–2 Maintenance OverviewAbout the PrinterThe LGplus Series is a family of line matrix printers: The LG04plus prints at amaximum rate of 475 lines per

4–28Adjustment Procedures8. Make the diskette drive the active drive by typing the following at theDOS prompt:A:<return>(If the diskette is in d

4–29Adjustment Procedures17. Power off the personal computer.18. If you had to install a parallel data cable to the computer and printer instep 2, dis

4–30Adjustment ProceduresMessageRequiredActionExplanationERROR: FLASHNOT DETECTEDThe printer could not find any flashmemory.Install flash memorybefore

4–31Adjustment ProceduresMessageRequiredActionExplanationERROR: WRITINGTO FLASHHardware or software fault in flashmemory.Download theprogram again. Go

4–32Adjustment Procedures

5–1Replacement Procedures andIllustrated Parts List5Replacement Proceduresand Illustrated Parts ListChapter ContentsOrganization of This Chapter 5–4.

5–2Replacement Procedures andIllustrated Parts ListPaper Path 5–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5–3Replacement Procedures andIllustrated Parts ListSection II: Illustrated Parts List 5–51. . . . . . . . . . . . . . . . . . . . . . . . . . . . Figu

5–4Replacement Procedures andIllustrated Parts ListOrganization of This Chapter This chapter is divided into two sections.♦ Section I: Replacement Pro

5–5Replacement Procedures andIllustrated Parts ListBelt, Paper Feed TimingRemoval1. Prepare the printer for maintenance (page 4–2).2. Open the printer

1–3Maintenance OverviewAbout This Manual This is a field service maintenance manual. It is designed so that you canquickly locate maintenance informat

5–6Replacement Procedures andIllustrated Parts ListInstallation1. Install the paper feed timing belt over the splined shaft pulley and themotor pulley

5–7Replacement Procedures andIllustrated Parts ListBelt, Platen Open Removal1. Prepare the printer for maintenance (page 4–2).2. Open the printer cove

5–8Replacement Procedures andIllustrated Parts ListCable Connectors and Connector Shells Some of the printer cable connectors are grouped inside conne

5–9Replacement Procedures andIllustrated Parts ListConnectorShell P106 / P107Typical2–WireCableTypical4–WireCableKeyTabKeyTabSlotConnectorConnectorTyp

5–10Replacement Procedures andIllustrated Parts ListCircuit Board: CMX ControllerCAUTIONTo prevent electrostatic damage to electronic components, alwa

5–11Replacement Procedures andIllustrated Parts ListInstallationCAUTIONTo prevent electrostatic damage to electronic components, always wear aproperly

5–12Replacement Procedures andIllustrated Parts ListCircuit Board: Power SupplyWARNINGTo prevent injury from electric shock, wait at least one minute

5–13Replacement Procedures andIllustrated Parts ListCircuit BreakerRemoval1. Prepare the printer for maintenance (page 4–2).2. Open the printer cover.

5–14Replacement Procedures andIllustrated Parts ListControl Panel Assembly Removal1. Prepare the printer for maintenance (page 4–2).2. Open the printe

5–15Replacement Procedures andIllustrated Parts ListCover Assembly, Hammer Bank / Ribbon Mask Removal1. Prepare the printer for maintenance (page 4–2)

1–4 Maintenance OverviewRelated DocumentsThis manual does not explain how to operate or configure the printer. Forthat information, refer to the follo

5–16Replacement Procedures andIllustrated Parts ListCover Assembly, ShuttleRemoval1. Prepare the printer for maintenance (page 4–2).2. Open the printe

5–17Replacement Procedures andIllustrated Parts ListFan Assembly, Card CageRemoval1. Prepare the printer for maintenance (page 4–2).2. Remove the pape

5–18Replacement Procedures andIllustrated Parts ListFan Assembly, Cabinet ExhaustRemoval1. Prepare the printer for maintenance (page 4–2).2. Open the

5–19Replacement Procedures andIllustrated Parts ListFan Assembly, Hammer BankRemoval1. Prepare the printer for maintenance (page 4–2).2. Remove the sh

5–20Replacement Procedures andIllustrated Parts ListMagnetic Pick–up (MPU) AssemblyRemoval1. Prepare the printer for maintenance (page 4–2).2. Remove

5–21Replacement Procedures andIllustrated Parts ListMemory Modules and Security PALRemoval1. Make a printout of all printer configurations. (Refer to

5–22Replacement Procedures andIllustrated Parts ListCMX Controller BoardFlash:80–pin SIMMJ10 = Bank 1Reserved for upgradesJ11 = Bank 0 (must always be

5–23Replacement Procedures andIllustrated Parts ListMotor Assembly, Paper FeedRemoval1. Prepare the printer for maintenance (page 4–2).2. Open the pri

5–24Replacement Procedures andIllustrated Parts ListInstallation1. Position the paper feed motor assembly on the right side plate and installthe 5/16

5–25Replacement Procedures andIllustrated Parts ListMotor Assembly, Platen OpenRemoval1. Prepare the printer for maintenance (page 4–2).2. Remove the

1–5Maintenance OverviewPrinting Conventions in This ManualBOLD UPPERCASE print indicates control panel keys.Example: Press the CLEAR key, then press t

5–26Replacement Procedures andIllustrated Parts ListInstallation1. Position the platen open motor assembly with the wires toward the rear(page 5–69, F

5–27Replacement Procedures andIllustrated Parts ListMotor Assembly, Ribbon DriveRemoval1. Prepare the printer for maintenance (page 4–2).2. Remove the

5–28Replacement Procedures andIllustrated Parts ListPaper IronerWARNINGOver time, the upper edge of the paper ironer can become sharp. Toavoid cutting

5–29Replacement Procedures andIllustrated Parts ListPaper PathWARNINGUnless directed to do otherwise, always unplug the printer from thepower source b

5–30Replacement Procedures andIllustrated Parts ListPlatenRemoval1. Prepare the printer for maintenance (page 4–2).2. Remove the shuttle frame assembl

5–31Replacement Procedures andIllustrated Parts ListInstallationIMPORTANTThe dowel pins protruding from the ends of the platen are the platenshafts, a

5–32Replacement Procedures andIllustrated Parts ListPlaten Installation (continued)PlatenWasherPlaten Adjust BracketPlaten Adjust Bracket BushingWear

5–33Replacement Procedures andIllustrated Parts ListPlaten Installation (continued)10. Slide the right ribbon guide assembly into the side plate and i

5–34Replacement Procedures andIllustrated Parts ListPlaten Installation (continued)18. Install the platen shaft pulley with the 7/64 inch setscrew fac

5–35Replacement Procedures andIllustrated Parts ListResistors, TerminatingFor parallel interface configurations, the printer is equipped with 470 ohmp

1–6 Maintenance OverviewSafety NoticesWARNINGTo prevent serious personal injury from electrical shock whenconnecting or disconnecting the signal cable

5–36Replacement Procedures andIllustrated Parts ListCMXRP1RP2Default: 470 ohmAlt 1: 220 ohmAlt 2: 1K ohmDefault: 1K ohmAlt 1: 330 ohmAlt 2: noneContro

5–37Replacement Procedures andIllustrated Parts ListRibbon Guide Assembly (L/R)NOTE: The right ribbon guide is shown in Figure 5–15. Theremoval/instal

5–38Replacement Procedures andIllustrated Parts ListRibbon HubRemoval 1. Prepare the printer for maintenance (page 4–2).2. Remove the printer ribbon.3

5–39Replacement Procedures andIllustrated Parts ListShaft, SplinedRemoval1. Prepare the printer for maintenance (page 4–2).2. Remove the paper feed ti

5–40Replacement Procedures andIllustrated Parts ListInstallation1. Open the doors on the left and right tractors. Position the tractor belts sothe ali

5–41Replacement Procedures andIllustrated Parts ListShaft, SupportRemoval1. Prepare the printer for maintenance (page 4–2).2. Open the printer cover.3

5–42Replacement Procedures andIllustrated Parts ListShuttle Frame AssemblyRemoval 1. Prepare the printer for maintenance (page 4–2).2. Remove the shut

5–43Replacement Procedures andIllustrated Parts List2. Open the forms thickness lever and move the tractors as far left and rightas possible.3. Holdin

5–44Replacement Procedures andIllustrated Parts ListSpring Assembly, GasNOTE: Two persons may be required to perform this procedure. Prop orhold the p

5–45Replacement Procedures andIllustrated Parts ListSpring, Extension, Hammer BankCAUTIONDo not let the hammer bank rotate toward the platen during sp

1–7Maintenance OverviewHinweise zur SicherheitGERMANVORSICHTUm ernstliche körperliche Verletzungen durch Stromschlag beimAnschließen oder Trennen des

5–46Replacement Procedures andIllustrated Parts ListSwitch Assembly, Paper DetectorRemoval1. Prepare the printer for maintenance (page 4–2).2. Remove

5–47Replacement Procedures andIllustrated Parts ListInstallation1. Holding the slotted wheel against the PMD sensor, position the paperdetector switch

5–48Replacement Procedures andIllustrated Parts ListSwitch Assembly, Platen InterlockRemoval1. Prepare the printer for maintenance (page 4–2).2. Remov

5–49Replacement Procedures andIllustrated Parts ListInstallation1. Fully close the forms thickness lever (position ‘A’).2. Position the platen interlo

5–50Replacement Procedures andIllustrated Parts ListTractor (L/R) Removal1. Prepare the printer for maintenance (page 4–2).2. Remove the splined shaft

5–51Replacement Procedures andIllustrated Parts ListSection II: Illustrated Parts ListList of FiguresFigure 5–7. Top Cover, Doors, and Casters 5–53. .

5–52Replacement Procedures andIllustrated Parts List1 FD–51859–01 Top Cover Kit Includes cover, logo, andmounting hardware2 FD–51829–01 Window, Top Co

5–53Replacement Procedures andIllustrated Parts List145673See Figure 5–9,page 5–572Figure 5–7. Top Cover, Doors, and Casters

5–54Replacement Procedures andIllustrated Parts List1 Ref Paper Fence 475 lpm model only2 Ref Paper Tray Assembly 800 and 1200 models only3 Ref Gromme

5–55Replacement Procedures andIllustrated Parts List153462987Figure 5–8. Paper Fence and Chains

1–8 Maintenance OverviewControls and IndicatorsElectrical Controls and Indicators (Figure 1–1)Switch orON LINELCDLFFunctionIndicatorStatus LampFFVIEWO

5–56Replacement Procedures andIllustrated Parts List1 FD–51863–01 Control Panel Assy Includes cable,mounting hardware, andall overlays2 FD–51856–01 Ca

5–57Replacement Procedures andIllustrated Parts List134567442Figure 5–9. Control Panel and Cabinet Details

5–58Replacement Procedures andIllustrated Parts List1 FD–51836–01 Shuttle Cover (Shroud Assembly, Air)2 Ref Screw, Captive (2), 10–24x.62 With O–ring,

5–59Replacement Procedures andIllustrated Parts List178235649103Figure 5–10. Covers

5–60Replacement Procedures andIllustrated Parts List1 FD–51857–01 Ham Bank/Rbn Mask Cover Assy 475 lpmFD–M6654–01 Ham Bank/Rbn Mask Cover Assy 800 lpm

5–61Replacement Procedures andIllustrated Parts List12356ToToJ02(ShuttleMotor)J03Exploded for clarity.Do not remove holddownclamps and screws.(MPU)2 P

5–62Replacement Procedures andIllustrated Parts List1 FD–51838–01 Magnetic Pickup Assy2 Ref Bracket, MPU Part of item 13 Ref Screw, socket cap 6–32x.3

5–63Replacement Procedures andIllustrated Parts List0.010±.001 inch12(0.254 ± .025mm)CAUTIONMake sure the MPU cable doesnot touch the extension spring

5–64Replacement Procedures andIllustrated Parts List1 Ref Screw, Socket Cap, 4–40x.25 Part of item 152 Ref Washer, Flat #4 Part of item 153 Ref Knob,

5–65Replacement Procedures andIllustrated Parts List1112151612546789101314173Figure 5–13. Tractor Shafts

1–9Maintenance OverviewON LINE FF VIEWENTERCLEARR/SSET TOFLFNEXTPREVDOWNUP(On)(Off)Power SwitchLiquid–Crystal Display(LCD)RAISE PRINTERCOVER TO USETHE

5–66Replacement Procedures andIllustrated Parts List1 Ref setscrew Part of item 252 Ref Bracket, Platen (2) Part of item 253 FD–51843–01 Ironer, Paper

5–67Replacement Procedures andIllustrated Parts List12457811121415242322212031319161718691012NOTE:Black tape facespaper motiondetector.NOTE:Item 25: P

5–68Replacement Procedures andIllustrated Parts List1 FD–51837–01 Fan Assy, Card Cage Air flow into card cage2 Ref Screw, w/Lock Washer (3) 6–32x1.753

5–69Replacement Procedures andIllustrated Parts ListInstall screws here.Route cable underbase castingHammer Bank FanTop View221720191821See detailabov

5–70Replacement Procedures andIllustrated Parts List1 FD–51834–01 Circuit Breaker2 Ref IEC 320 AC Power Connector J3013 Ref Chassis Ground Stud4 Ref C

5–71Replacement Procedures andIllustrated Parts List1234To Connector P1To IEC 320AC Power Input(Connector J301)Inside detailCard cage fanand power sup

5–72Replacement Procedures andIllustrated Parts List

6–1Principles of Operation6Principles of OperationContentsLine Matrix Printing 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6–2Principles of OperationLine Matrix PrintingThe LGplus Series printer creates characters and graphics by printing patternsof ink dots on paper, an e

6–3Principles of OperationDotRow StartPaperFeedNumber of rows is determined by line spacing.1234567891011n12***This row is used only for lowercase des

1–10 Maintenance OverviewMechanical Controls and IndicatorsControl orFunctionIndicatorForms ThicknessLeverForms ThicknessPointer and ScaleTractors (2)

6–4Principles of OperationFigure 6–4 shows how each individual hammer spring forms characters asthe shuttle scans horizontally.******1 13 135 1 357 13

6–5Principles of OperationPrinting Mechanism While the principles of line matrix printing are easy to state, the act ofprinting dots accurately from a

6–6Principles of OperationEach hammer spring is a stiff leaf spring with a cylindrical, tungsten carbidetip on the free end. (See Figure 6–6.) A perma

6–7Principles of OperationPaper Transport System TractorsVertical AdjustmentKnob and SplinedShaft PulleyPaper Feed TimingBelt (Under the cover)Splined

6–8Principles of OperationRibbon Transport System Right Ribbon GuideHub LockingLatchLeft Ribbon Guide(Not Shown)RibbonSpoolRibbon MotorsRibbonRibbon H

6–9Principles of OperationLogical Control of the Printer The printer is divided into four functional elements: the control panel, thecontroller board,

6–10Principles of OperationControl PanelThe user communicates with the printer by pressing keys on the controlpanel. The keys are momentary contact sw

6–11Principles of OperationCMX Controller BoardThe heart of the printer is the CMX controller board, which monitors anddirects all printer functions.

6–12Principles of OperationExpansionPortRS–232/422IEEE–1284(Parallel)FaultSensorsPaperFeedRibbonShuttlePlatenHammerDriveTTLDiagnosticPortControlPanelR

6–13Principles of OperationData ControllerThe data controller (DC) consists of the following elements:♦ 68EC030 microprocessor♦ 1MB base flash memory,

1–11Maintenance OverviewLeft TractorRight TractorForms ThicknessLever and ScalePaper ScaleRibbon Loading PathDiagramVerticalPositionKnobHorizontalAdju

6–14Principles of OperationDRAM MemoryDRAM is used for program variables, image buffers, and input buffers. AllDRAM supports page mode operation and i

6–15Principles of OperationControl Panel Interface The VX operator panel interface consists of fivelines: serial clock, serial data, and three select

6–16Principles of Operation♦ Less than 0.02V common mode ripple, measured between chassis groundand the ground pins of the interface ICs.♦ Less than 2

6–17Principles of Operationperipherals are automatically reset. The timer interval is set through softwareand has a range of 25.6 sec to 419 ms; defa

6–18Principles of OperationPower Supply Board The printer power supply is contained on a printed circuit board mounted inthe card cage. The power supp

6–19Principles of OperationLoss of + 48 V is seen by the RSP and reported as a fault.Printer InterfaceThe printer interface is the point where the dat

6–20Principles of Operation

A–1Wire DataAWire DataNOTE: Acronyms and Signal mnemonics are defined in Appendix E.LGplus Series Interconnection Diagram A–2. . . . . . . . . . . . .

Wire DataA–2Flex CircuitsJ1J310P310J301AC INPUTCIRCUITBREAKERIEC 320AC POWERCONNECTORON/OFFSWITCHP1J1 ACAC to DCPower SupplyBoardLine 1Line 2 / Neutra

A–3Wire Data+5 VLGplus POWER DISTRIBUTION DIAGRAM ACPOWERFlex CircuitsControl Panel AssemblyJ310P310J301CIRCUITBREAKERIEC 320AC POWERCONNECTORON/OFFSW

FCC NoticeThis equipment has been tested and found to comply with the limits of a Class A digital device, pursuant to Part 15 of the FCCRules. These l

1–12 Maintenance OverviewTools, Test Equipment, and SuppliesListed below are the tools and equipment required for field levelmaintenance of the printe

Wire DataA–4Controller, CMX12345678N STROBE910111213141516171819202122232425P1P2P3P4P5P6P7P8N ACKBUSYPAPER EMPTYSLCT262728293031323334353637383940NCN

A–5Wire Data12345678PPR STK STAT0910PPR STK STAT1PPR STK CTL0PPR STK CTL1Paper StackerJ17VCCNCNCNCNC470 PF10%50V470 PF10%50V470 PF10%50V470 PF10%50V47

Wire DataA–612345678PLAT 191011121314151617181920J106Motor Sensor LeftRIB L1PLAT 2RIB L2PLAT 3RIB L3PLAT 4RIB L4CC FAN+L RBN POST+POD APMD APOD KPMD K

A–7Wire DataJ1J13J12J14J52–PIN JUMPER2–PIN JUMPER2–PIN JUMPER2–PIN JUMPER2–PIN JUMPER12345678EC DB TXD910J2EC DB RXDFT EVENTMPU OUTSHUT DIRNCNCEC Diag

Wire DataA–8Power SupplyP1011J1AC InputP1Cable Assy,AC In,Power SupplyACAC COMMONCHASSIS GND123LOADLOADGND= RING TERMINAL= FAST–ON TERMINAL(Line Filte

A–9Wire DataCHASSIS GNDCable Assembly,Centronics/Dataproducts I/ODescriptionPart No.153364–90112345678910111213141516171819202122232425262728293031323

Wire DataA–10Cable Routing, Mechanism BaseP108 P105 P116A – AViewTie wrapboth sideplates.AAP307To exhaustfanP306To cardcage fanRibbonGuidePlatenLeverS

A–11Wire DataCable Assembly, 2–Pin Jumper, 0.1 CtrDescriptionPart No.154470–901P107 / JMPWIRE

Wire DataA–12Cable Assembly, AC In, Power SupplyDescriptionPart No.152625–901

A–13Wire DataCable Assembly, AC Power ConnectorDescriptionPart No.152624–901

2–1Scheduled Maintenance2Scheduled MaintenanceChapter ContentsPreventive Maintenance Checks and Services 2–2. . . . . . . . . . . . . . . . . Inspecti

Wire DataA–14Cable Assembly, Card Cage FanDescriptionPart No.152422–901PIN 1PIN 1

A–15Wire DataCable Assembly, Control PanelDescriptionPart No.152440–901PIN 1PIN 1PIN 8PIN 8(Gray)(Brown)(Brown)(Gray)NOTE:If you replace the controlpa

Wire DataA–16Cable Assembly, Exhaust FanDescriptionPart No.152424–901PIN 1PIN 1

A–17Wire DataCable Assembly, Hammer Bank LogicDescriptionPart No.152421–901

Wire DataA–18Cable Assembly, Hammer Bank PowerDescriptionPart No.152423–901PIN 1PIN 1

A–19Wire DataCable Assembly, MPUDescriptionPart No.152425–901PIN 1PIN 3PIN 2PIN 1

Wire DataA–20Kit, Ribbon Guide** includes left and right guidesDescriptionPart No.FD–51855–01PIN 1PIN 2NOTE: Left ribbonguide shown. Right ismirror im

A–21Wire DataCable Assembly, Shuttle Motor DriveDescriptionPart No.152420–901

Wire DataA–22Fan Assembly, Hammer BankDescriptionPart No.FD–51852–01

A–23Wire DataSwitch Assembly, Paper DetectorDescriptionPart No.FD–51851–01SECTION A–AWIRE TABLEPOD RCPT PMD RCPT PODPIN 1 BLACKPMD CABLEPIN 2PIN 3PIN

2–2Scheduled MaintenancePreventive Maintenance Checks and ServicesPerform preventive maintenance checks and services at the intervalsspecified in Tabl

Wire DataA–24Switch Assembly, Platen InterlockDescriptionPart No.FD–51853–01P107/PLO

B–1Printer SpecificationsBPrinter Specifications ContentsDuty Cycle B–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B–2 Printer SpecificationsDuty CycleLG04plus prints 130, 000 pages per monthLG08plus prints 205, 000 pages per monthLG12plus prints 320, 000 pages per

B–3Printer SpecificationsPaper SpecificationsPaperType: Edge–perforated, fan–fold, 3 to 16 inches (7.62 to40.64 cm) wide, 1 to 12 inches (2.54 to 30.4

B–4 Printer SpecificationsPrinter DimensionsHeight: 41 inches (104.1 cm)Width: 27 inches (68.6 cm)Depth: 29 inches (73.7 cm)Weight: 225 lbs. (102.1 kg

B–5Printer SpecificationsEnergy StarThis printer complies with the requirements of the Energy Star OfficeEquipment Program of the U.S. Environmental P

B–6 Printer SpecificationsInterfacesType: Two resident parallel host interfaces: Centronics and Dataproducts; One resident serial host interface (RS–2

B–7Printer SpecificationsPrinting RatesThe printing speed of text is measured in lines per minute (lpm), and is afunction of the selected font and the

B–8 Printer Specifications

C–1Metric Conversion TablesCMetric Conversion TablesLengthMultiplyfoot 0.3048*By To Obtainmeter (m)* Figure is exact.foot 30.48* centimeter (cm)foot 3

2–3Scheduled MaintenanceInspecting the PrinterCorrect any condition found during inspection that could affect printerperformance or reliability.Table

C–2Metric Conversion TablesMass and DensityMultiplypound* 0.4535924By To Obtainkilogram (kg)* avoirdupoisounce* 28.34952 gram (g)kilogram 2.204622 pou

D–1Torque TableDTorque TableNOTE: The table below establishes the torque requirements for routineinstallation of threaded fasteners. These requirement

D–2Torque Table

E–1Abbreviations and Signal MnemonicsEAbbreviations and Signal MnemonicsNOTE: Mnemonics with first letter “N” are negative true.ACRONYM/ DEFINITIONMNE

E–2Abbreviations and Signal MnemonicsCA Cathode. . . . . . . . . . . . . . . CC Card Cage. . . . . . . . . . . . . . . CCF Card Cage Fan. . . . . . .

E–3Abbreviations and Signal MnemonicsERR Error. . . . . . . . . . . . . . ESD Electrostatic Damage. . . . . . . . . . . . . . EX Exhaust, Extra. . . .

E–4Abbreviations and Signal MnemonicsLPM Lines Per Minute. . . . . . . . . . . . . . LRIB Left Ribbon. . . . . . . . . . . . . LRP Left Ribbon Guide.

E–5Abbreviations and Signal MnemonicsPFC Paper Feed Controller. . . . . . . . . . . . . . PFM Paper Feed Motor. . . . . . . . . . . . . . PI Paper Ins

E–6Abbreviations and Signal MnemonicsSCS SNA Character Stream. . . . . . . . . . . . . . SEC Security (Key). . . . . . . . . . . . . . SEL Select. . .

E–7Abbreviations and Signal Mnemonicsw/ With. . . . . . . . . . . . . . . . w/o Without. . . . . . . . . . . . . . . XMT Transmit. . . . . . . . . . .

2–4Scheduled MaintenanceCleaning the Printer WARNINGAlways disconnect the ac power cord before cleaning the printer.CAUTIONDo not use abrasive cleaner

E–8Abbreviations and Signal Mnemonics

F–1Noise Suppression DevicesFNoise Suppression DevicesFerrite noise suppressors are installed in the printer to reduce radio frequencyinterference (RF

F–2 Noise Suppression DevicesFerrite CoreControl Panel Cable AssemblyParallel I/O Cable AssemblyConnectorShielding BeadP110ConnectorP310ConnectorJ203C

1IndexIndexNumbers15V PWR FAIL *, 3–423.5V PWR FAIL *, 3–448V PWR FAIL *, 3–48.5V PWR FAIL *, 3–4AA TO D OVERUN *, 3–4Abbreviations, E–1About the prin

2 IndexCLOSE PLATEN, 3–4CMX controller boarddata controller (DC), 6–13engine controller (EC), 6–16principles of operation, 6–11COIL HOT, 3–4Control pa

3IndexFFan assemblycard cage, replacement, 5–17hammer bank, replacement, 5–18, 5–19Fault messages15V PWR FAIL *, 3–423.5V PWR FAIL *, 3–448V PWR FAIL

4 IndexERROR: PROGRAM NEEDS MOREDRAM, 4–30ERROR: PROGRAM NEEDS MOREFLASH, 4–30ERROR: PROGRAM NOTCOMPATIBLE, 4–30ERROR: PROGRAM NOT VALID, 4–30ERROR: S

5Indexcleaning the printer, 2–4inspecting the printer, 2–3overview, 1–1preventive, 2–1preventive maintenance checks andservices, 2–2scheduled, 2–1Manu

6 IndexPhysical Inspection, 2–3Pin–outs, A–1PLAT INV CMD *, 3–7PLAT INV PARM *, 3–7PLAT INV STATE *, 3–7Platengap adjustment, 4–12interlock switch ass

7Indexpaper path, 5–29platen, 5–30platen interlock switch assembly, 5–48platen open belt, 5–7platen open motor, 5–25power supply circuit board, 5–12re

2–5Scheduled Maintenance10. Vacuum up dust and residue from the lower cabinet.11. Wipe the interior of the lower cabinet with a clean, lint–free cloth

8 IndexSpringextension, hammer bank, replacement,5–45gas, assembly, replacement, 5–44STACK OVERFLOW *, 3–8STACK UNDERFLOW *, 3–8Status lamps, 1–8Suppo

2–6Scheduled MaintenanceCleaning the Shuttle Frame Assembly1. Remove the shuttle cover assembly (page 5–16).2. Remove the shuttle frame assembly (page

2–7Scheduled Maintenance9. Install the hammer bank cover assembly (page 5–15).10. Install the shuttle frame assembly (page 5–42).11. Install the shutt

2–8Scheduled MaintenanceCleaning the Card Cage Fan Assembly1. Remove the paper path (page 5–29).2. Vacuum the card cage fan assembly and surrounding a

3–1Troubleshooting3TroubleshootingChapter ContentsIntroduction 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

All Rights Reserved. December 1995.The information in this document is subject to change without notice and should not be construed as a commitment b

3–2 TroubleshootingIntroduction This chapter contains procedures for troubleshooting printer malfunctions.This manual does not cover printer operation

3–3TroubleshootingLCD MessagesWARNINGAlways disconnect the AC power cord from the power source beforedoing any maintenance procedure. Failure to remov

3–4 TroubleshootingTable 3–1. LCD Message Troubleshooting TableDisplayed Message ExplanationSolution8.5V PWR FAIL*Internal power failure. Cycle power.

3–5TroubleshootingDisplayed MessageSolutionExplanationCTL VOLT FAIL*Controller voltage failure. Replace CMX controllerboard.DRVR CIR BAD*Hammer coil c

3–6 TroubleshootingDisplayed MessageSolutionExplanationLOAD PAPERPrinter is out of paper. Load paper. If messagerecurs, see page 3–20.PAP BAD TABLE*Fa

3–7TroubleshootingDisplayed MessageSolutionExplanationPAP NT AT SPEED*Fatal firmware error onCMX controller board.Cycle power and rerun printjob. If m

3–8 TroubleshootingDisplayed MessageSolutionExplanationRIB INVLD CMD*Fatal firmware error onCMX controller board.Cycle power and rerun printjob. If me

3–9TroubleshootingDisplayed MessageSolutionExplanationTCB CORRUPTED*Fatal firmware error onCMX controller board.Cycle power and rerun printjob. If mes

3–10 TroubleshootingCLEAR PAPER JAMInstruction Indication Yes No1. a) Load paper.b) Press the FF key severaltimes.Forms feed without erraticmotion, no

3–11TroubleshootingCLOSE PLATENInstruction Indication Yes No1. Load paper. Close the formsthickness lever. Run anoperator print test.“CLOSE PLATEN” me

3–12 TroubleshootingCOIL HOTNOTE: The printer has sensor circuits that sample the operating temperatureof key print components. When higher than norma

3–13TroubleshootingInstruction NoYesIndication7. Examine printer environmentfor severity. (See NOTEabove.)Printer environment is OK. Go to step 9. Mov

3–14 TroubleshootingDRVR CIR BAD*Instruction Indication Yes No1. Cycle power: Power offprinter. Wait 15 seconds.Power on printer.“DRVR CIR BAD*” messa

3–15Troubleshooting(EXHAUST) (HMR BANK) (INTAKE) FAN FLTInstruction Indication Yes No1. Cycle power: Power offprinter. Wait 15 seconds.Power on printe

3–16 TroubleshootingFIRMWARE ERRORInstruction Indication Yes No1. Cycle power: Power offprinter. Wait 15 seconds.Power on printer.“FIRMWARE ERROR”mess

3–17TroubleshootingHAM. COIL OPEN *Instruction Indication Yes No1. Cycle power: Power offprinter. Wait 15 seconds.Power on printer.“HAM. COIL OPEN * ”

3–18 TroubleshootingHB NOT INSTLD *Instruction Indication Yes No1. a) Power off the printer.b) Remove the shuttle cover.c) Verify that the shuttlefram

3–19TroubleshootingLO DRV. SHORTInstruction Indication Yes No1. Cycle power: Power offprinter. Wait 15 seconds.Power on printer.“LO DRV. SHORT” messag

3–20 TroubleshootingLOAD PAPERInstruction Indication Yes No1. Load paper. Run a diagnosticprinter test.“LOAD PAPER” message. Replace paperdetector swi

3–21TroubleshootingPOWER SUPPLY HOTNOTE: The printer has sensor circuits that sample the operating temperatureof key print components. When higher tha

iTable of Contents1Maintenance OverviewAbout the Printer 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3–22 TroubleshootingInstruction NoYesIndication7. Check for obstruction ofvents and fan airways.Vents and airways are clear. Go to step 8. Removeobstr

3–23TroubleshootingPRINTER HOTNOTE: This message indicates internal temperatures over 60° Celsius (140°Fahrenheit). Print jobs will not create such te

3–24 TroubleshootingRIBBON DRIVEInstruction Indication Yes No1. Cycle power: Power offprinter. Wait 15 seconds.Power on printer.“RIBBON DRIVE” message

3–25TroubleshootingSerial Interface MessagesInstruction Indication Yes No1. a) Make a configurationprintout. (Ref.: Setup Guide)b) Verify that host an

3–26 TroubleshootingSHUTTLE JAMInstruction Indication Yes No1. Check the forms thicknesslever: if it is set too tightly, itcan slow the shuttle enough

3–27TroubleshootingSOFTWARE ERROR *Instruction Indication Yes No1. Cycle power: Power offprinter. Wait 15 seconds.Power on printer.“SOFTWARE ERROR * ”

3–28 TroubleshootingUP DRV. SHORTInstruction Indication Yes No1. Cycle power: Power offprinter. Wait 15 seconds.Power on printer.“UP DRV. SHORT” messa

3–29TroubleshootingSymptoms Not Indicated by Fault MessagesUse standard fault–isolation techniques to troubleshoot malfunctions notindicated by fault

3–30 TroubleshootingSymptoms Not Indicated by Fault MessagesTroubleshooting Table Symptom InstructionNo power, control panel LCD and LEDsblank, card c

3–31TroubleshootingSymptom InstructionPrinter prints data sent from the host, butoccasionally prints double characters,random ! or * characters, or lo

iiPrinter Confidence Check 3–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Printer Tests 3–35. . . . .

3–32 TroubleshootingPrint Quality ProblemsMissing, light, or smeared characters ordots:1. Check the forms thickness lever setting.2. Check the ribbon

3–33TroubleshootingPrint Quality ProblemsGarbled print or paper slewsuncontrollably.1. a) Put the printer in hex dump mode and analyze thebinary data.

3–34 TroubleshootingPrinter Confidence Check Instruction Indication Yes No1. Check that printer is pluggedinto correct power source.Power cable instal

3–35TroubleshootingDiagnostic Printer TestsA set of printer tests is included in the configuration menu structure for useas diagnostic and maintenance

3–36 Troubleshooting♦ Phase Printer A hammer timing test that permits you to adjust thehammer phase value. The hammer phase value is a timing paramet

3–37TroubleshootingSelecting and Running Diagnostic Printer TestsStep Key Result Notes1. a) Load paper.b) Install the ribbon.c) Set top–of–form. (Refe

3–38 TroubleshootingStep NotesResultKey12.Printer TestsShift Recycle*13.ORPrinter TestsAll E’sCycle through the choices.Refer to page 3–35.14. To star

3–39TroubleshootingHidden Diagnostic MenuPrinter boot–up software contains a hidden menu structure that you canaccess by holding down the A (PREV) and

3–40 TroubleshootingB (DOWN)" (NEXT)BOOT DIAGNOSTICSBOOT DIAGNOSTICSVERSION CHECKPRESS ENTERVERSION CHECKBOOT VERSIONVERSION CHECKSOFTWARE VERSIO

3–41TroubleshootingHex Code Printout A hex code printout (“hex dump”) lists each ASCII data character receivedfrom the host computer and lists its cor

iiiControl Panel Assembly 5–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover Assembly, Hammer Bank / Ribbon M

3–42 TroubleshootingMaking a Hex Code PrintoutStep Key Result Notes1. Make sure the printer is on. Raise the printer cover.2. Press:ON LINEOFFLINECONF

3–43TroubleshootingASCII Character SetKEYASCII CharacterESC33271BOCTAL equivalentDECIMAL equivalentHEX equivalentB7 0 0 0 0 1 1 1 1B6 0B5 001101100011

3–44 Troubleshooting

4–1Adjustment Procedures4Adjustment Procedures Chapter ContentsPreparing the Printer for Maintenance 4–2. . . . . . . . . . . . . . . . . . . . . . .

4–2Adjustment ProceduresPreparing the Printer for Maintenance WARNINGUnplug the printer power cord from the power outlet before you do anymaintenance

4–3Adjustment ProceduresReturning the Printer to Normal Operation When you have finished servicing the printer, restore it to operation byfollowing th

4–4Adjustment ProceduresBelt, Paper Feed Timing, Adjustment (Figure 4–1) 1. Prepare the printer for maintenance (page 4–2).2. Open the printer cover.3

4–5Adjustment Procedures1. Timing Belt Shield2. Motor Mount Bolt (2)3. Paper Feed Drive Motor4. Splined Shaft2132Direction of Force4Figure 4–1. Paper

4–6Adjustment ProceduresBelt, Platen Open, Adjustment (Figure 4–2) 1. Prepare the printer for maintenance (page 4–2).2. Open the printer cover.3. Remo

4–7Adjustment Procedures1. Belt Cover2. Motor Mount Screw3. Platen Open Motor Shaft232Direction of Force1Figure 4–2. Platen Open Belt Adjustment

ivFigure 5–14. Platen 5–67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5–15. Motors, Fans, and Pap

4–8Adjustment ProceduresPaper Drive Motor Pulley Alignment (Figure 4–3)1. Prepare the printer for maintenance (page 4–2).2. Open the printer cover.3.

4–9Adjustment Procedures1. Belt Shield2. Cap Screw3. Motor Pulley Collar4. Motor Pulley5. Splined Shaft Pulley41235Figure 4–3. Paper Drive Motor Pulle

4–10Adjustment ProceduresPaper Scale Alignment (Figure 4–4)1. Load paper and ribbon.2. Connect the power cord to the AC power source.3. Set the printe

4–11Adjustment Procedures1. Shuttle Cover2. Screw, Button–Head, 5/64 inch hex (3)3. Paper Scale2312Figure 4–4. Paper Scale Alignment

4–12Adjustment ProceduresPlaten Gap Adjustment (Figure 4–5)IMPORTANTOnly do this procedure if the original equipment shuttle frame assemblyor platen h

4–13Adjustment Procedures9. Repeat steps 6 through 8 at the right end of the hammer bank.10. After adjusting both sides, check the gap again at both e

4–14Adjustment ProceduresPlaten Open Motor Pulley Alignment (Figure 4–6) 1. Prepare the printer for maintenance (page 4–2).2. Open the printer cover.3

4–15Adjustment Procedures1. Belt Cover2. Set Screw3. Platen Open Motor Pulley4. Platen Shaft Pulley2341Figure 4–6. Platen Open Motor Pulley Alignment

4–16Adjustment ProceduresRibbon Guide Alignment (Figure 4–7)1. Open the printer cover.2. Load paper and install the ribbon. To adjust the left ribbon

4–17Adjustment Procedures1. Right Hub2. Screw, Left Ribbon Guide Skid (2)3. Ribbon4. Ribbon Guide, Left5. Screw, Retaining (2)6. Left Ribbon Spool7. R

1–1Maintenance Overview1Maintenance OverviewChapter ContentsAbout the Printer 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4–18Adjustment ProceduresSplined Shaft Skew Adjustment (Figure 4–8)If lines of print are not parallel with the edge perforations on the paper,perform

4–19Adjustment Procedures1. Screw 2. Adjusting Link3. Horizontal Adjustment Knob123Figure 4–8. Splined Shaft Skew Adjustment

4–20Adjustment ProceduresAdjusting the End of Forms DistanceThis procedure tests and sets the distance from the page perforation at whicha LOAD PAPER

4–21Adjustment Procedures4 in.4 in.Page PerforationPage PerforationPage PerforationFigure 4–9. Paper Preparation for Paper Out Adjustment Test

4–22Adjustment Procedures5. Tear a four inch square in the manner described above, on every thirdsheet, until you have made 3 or 4 holes.6. If the pri

4–23Adjustment Procedures15. Measure how short or long the comb pattern printed by counting thenumber of dot rows needed to reach the perforation, or

4–24Adjustment Procedures29. Close the printer cover.30. Press the ON LINE key to place the printer online.

4–25Adjustment ProceduresHammer Phasing Adjustment You must check and adjust hammer phasing if the CMX controller board isreplaced, the shuttle frame

4–26Adjustment Procedures10. Press B. “Printer Tests / Shift Recycle” displays.11. Press A until “Printer Tests / Phase Printer” displays.12. Press EN

4–27Adjustment ProceduresInstalling SoftwareFlash memory is contained in one or two single in–line memory modules(SIMMs) located on the controller boa