LG06 Text and Graphics Printer Maintenance Manual digi tal Order Number: EK–ELG06–MG
LG06 Text and Graphics Printer Maintenance Manual Order Number: EK–ELG06–MG Digital Equipment Corporation • Merrimack, NH 03054
2nd Edition, July 1992 Digital Equipment Corporation 1991, 1992 All Rights Reserved The information in this document is subject to change without notice and should not be construed as a commitment by Digital Equipment Corporation. Digital Equipment Corporation assumes no responsibility for any errors that may appear in this document. Printed in U.S.A.
Table of Contents 1 Maintenance Overview About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 Warnings and Special Information . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 Printing Conventions in This Manual . . . . . . . . . . . . . . . . . . . . . . . .
Ribbon Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–14 Shttl Cover Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15 Shuttle Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16 Software Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17 Symptoms Not Indicated by Fault Messages . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–18 Control Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–20 Cover Assembly, Hammer Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–22 Cover Assembly, Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–24 Fan Assembly, Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–26 Fan Assembly, Cabinet Exhaust .
Appendices A: Printer Configuration B: Printer Specifications C: Torque Table D: Cable Interconnections and Hammer Bank Wiring E: Principles of Operation F: Ferrite Noise Suppression Cores Index iv
1 Maintenance Overview Chapter Contents About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 Warnings and Special Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 Printing Conventions in This Manual . . . . .
About This Manual This manual explains how to maintain and repair the LG06 printer at the field service level of maintenance. This manual covers alignments and adjustments, preventive and corrective maintenance, troubleshooting, and basic principles of operation. Related Documents Information about operating the LG06 printer is in the User’s Manual. How to Use This Manual This manual is designed so you can quickly find the information you need to maintain and repair the Encore printer.
Printing Conventions in This Manual Switches and indicators labeled on the printer are printed uppercase in this manual. Example: “Press the ON LINE switch to take the printer off–line.” If a control is not labeled on the printer, it is printed lowercase. Example: “Set the forms thickness lever to the fully open position.” Messages that appear on the control panel display are printed inside quotation marks in lowercase with the first letter capitalized. Example: “Save Config” appears on the message display.
Controls and Indicators The locations of the printer cover, cabinet doors, and operator control panel are shown in Figure 1–1. Electrical controls and indicators are described in Table 1–1 and illustrated in Figure 1–2. Mechanical controls and indicators are described in Table 1–2 and illustrated in Figure 1–3.
Printer Cover Lift to open Operator Control Panel Rear Door (Not shown) See Detail Hinged on left. Magnetic latch. Open by pulling right edge. Floor Cabinet Front Door Hinged on left. Magnetic latch. Open by pulling right edge. Operator Control Panel CLEAR UP R/S PREV NEXT SET TOF ON LINE FF LF VIEW ENTER DOWN Figure 1–1.
Table 1–1. Electrical Controls and Indicators Switch or Indicator Function NOTE: Only the ON LINE switch operates when the printer is on–line. All other switches operate only in the off–line state. /O Status lamps Message display ON LINE Displays printer status and error messages. Toggles the printer on–line and off–line. FF Advances paper to top of form on next page. LF Advances paper to top of next print line.
(On) (Off) Power Switch Message Display Status Lamps CLEAR UP R/S PREV NEXT SET TOF ON LINE FF LF VIEW ENTER DOWN Raise Printer Cover to Access These Switches CLEAR UP R/S PREV NEXT SET TOF ENTER DOWN Figure 1–2.
Table 1–2. Mechanical Controls and Indicators 1–8 Control or Indicator (See Figure 1–3) Function Forms thickness lever Sets platen for paper and forms of different thicknesses. Must be fully opened (raised) to load paper. Forms thickness pointer and scale Indicates relative thickness of forms or paper. Set the forms thickness lever at A for thin (single–part) forms, B for thicker forms, and so on. Tractors (2) Hold and feed paper. Used to set left margin. Left tractor moves about one inch.
Horizontal Adjustment Knob Left Tractor Door Right Tractor Door Tractor Lock Vertical Position Knob Tractor Lock Forms Thickness Lever and Scale Forms Thickness Pointer Figure 1–3.
Tools, Test Equipment, and Supplies The tools, test equipment, and supplies required for field level maintenance of LG06 printers are listed in Table 1–3. Table 1–3. Tools, Test Equipment, and Supplies Item 1–10 Part No. Adhesive, Loctite (adhesive, methacryl) Alcohol, anhydrous (must contain no water) RTV silicone sealant Adjustable wrench Diagonal cutters Digital voltmeter Extension 3 in., 3/8 in.
2 Scheduled Maintenance Chapter Contents Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . . . . . . 2–2 Inspecting the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3 Cleaning the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventive Maintenance Checks and Services (PMCS) Perform preventive maintenance checks and services (PMCS) every six months or after every 1000 hours of operation, whichever comes first. Do these checks more often if the printer is used for heavy–duty, continuous printing or if is located in a dusty area. PMCS are listed in Table 2–1. WARNING Disconnect the ac power cord before performing PMCS. Failure to do so could result in injury to you or damage to equipment. Table 2–1.
Inspecting the Printer Correct any condition found during inspection that could affect printer performance or reliability. Table 2–2. Physical Inspection Item(s) to Inspect What to Look For Cabinet, base, frame Check for damage, cracks, breaks, dents, gouges, scratches, delamination, warping, corrosion, and proper finish. Attaching hardware Inspect fasteners for thread damage, corrosion. Nameplates Inspect for legibility and damage.
Cleaning the Printer CAUTION Do not use abrasive cleaners, particularly on the window. Do not drip water into the printer. Damage to the equipment will result. When using spray solutions, do not spray directly onto the printer; spray the cloth, then apply the dampened cloth to the printer. Cleaning Outside the Cabinet 1. Wipe the cabinet with a clean, lint–free cloth dampened (not wet) with water and mild detergent or window cleaning solution. 2. Dry the cabinet with a clean, lint–free cloth. 3.
11. Wipe the lower cabinet interior with a clean, lint–free cloth dampened with water and mild detergent or window cleaning solution. 12. Dry the cabinet interior with a clean, lint–free cloth. 13. Clean the shuttle assembly (page 2–6). 3 3 8 5 5 6 2 4 1 1. 2. 3. 4. 5. 6. 7. 8. 9. Forms Thickness Lever Locking Latch (2) Ribbon Spool (2) Ribbon Hub (2) Tractor (2) Shuttle Cover Assembly Base Casting Splined Shaft Ribbon Guide (2) 4 9 7 2 Figure 2–1.
Cleaning the Shuttle Frame Assembly (Figure 2–2) 1. Remove the shuttle cover assembly (page 5–24). 2. Remove the shuttle frame assembly (page 5–66). 3. Remove the paper ironer (page 5–44). WARNING Over time, the upper edge of the paper ironer can become sharp. To avoid cutting yourself, handle the paper ironer on the sides. 4. Moisten a clean, soft cloth with anhydrous alcohol. Wipe the paper ironer to remove lint, ink, and paper residue. 5. Install the paper ironer (page 5–44). 6.
Hammer Tip Thin plate Thick plate Hammer Bank Cover Assembly Roll pin (2) (Not shown) Figure 2–2.
Cleaning the Card Cage Fan Assembly (Figure 2–3) 1. Open the printer cover. 2. Remove the paper guide assembly (page 5–42). 3. Vacuum the card cage fan assembly (1) and surrounding areas to remove paper particles, dust, and lint. 4. Install the paper guide assembly (page 5–42). 5. Close the printer cover. 6. Connect the ac power cord to the printer. Card Cage Fan Assembly Figure 2–3.
3 Troubleshooting Chapter Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 48 Volt Failed * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 Dynamic RAM Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4 Ham. Bank Hot * .
Introduction This chapter contains procedures for troubleshooting printer malfunctions. You must operate the printer to check printer performance, so have the User’s Manual at the printer site. Although diagnostic test procedures are covered in this chapter, basic printer operation is not covered. Fault Messages This section lists the fault messages that can appear on the control panel display. The messages are listed in alphabetical order, followed by a troubleshooting table.
Instruction 4. Disconnect cable assembly Indication — Yes Step 5. No — W1, CCB/Mech Driver, from connector J1 on the CCB and connector J6 on the Mech Driver board. 5. Power up the printer. 6. Pull the Mech Driver board Card cage fan comes on. Replace the common controller PCBA (page 5–46). — Step 7. — Step 8. — Step 9. Reattach cable assembly W1, CCB/Mech Driver, to connector J1 on the CCB and connector J6 on the Mech Driver board, and go to step 6.
Dynamic RAM Fault * Instruction 1. Set power switch to O (off). Wait 15 seconds. Set power switch to 1 (on). 2. Disconnect the input data line from the host computer. Set power switch to O (off). Wait 15 seconds. Set power switch to 1 (on). 3. Make a Diagnostic Check of Indication Yes No “Dynamic RAM Fault * ” message. Step 2. Return printer to normal operation. “Dynamic RAM Fault * ” message. Step 3. Return printer to normal operation. — — — the Microprocessors (page 3–21).
Ham. Bank Hot * Instruction Indication Yes No “Ham. Bank Hot * ” message. Step 2. Return printer to normal operation. 2. Press the CLEAR switch. “Ham. Bank Hot * ” message. Step 3. Return printer to normal operation. 3. Run diagnostic self–test “All “Ham. Bank Hot * ” message. Step 4. Return printer to normal operation. 1. Set power switch to O (off). Wait 15 seconds. Set power switch to 1 (on). Black” for 1/4 page (page 3–26). 4. Remove the shuttle cover — Step 5. — — Step 6.
Ham. Coil Open * Instruction Indication Yes No “Ham. Coil Open * ” message. Step 2. Return printer to normal operation. 2. Press the CLEAR switch. “Ham. Coil Open * ” message. Step 3. Return printer to normal operation. 3. Run a diagnostic self–test “Ham. Coil Open * ” message. Step 4. Return printer to normal operation. 1. Set power switch to O (off). Wait 15 seconds. Set power switch to 1 (on). (page 3–26). 4. Remove the shuttle cover — Step 5. — — Step 6. — — Step 7.
Ham. Coil Short * Instruction Indication Yes No “Ham. Coil Short * ” message. Step 2. Return printer to normal operation. 2. Press the CLEAR switch. “Ham. Coil Short * ” message. Step 3. Return printer to normal operation. 3. Run a diagnostic self–test “Ham. Coil Short * ” message. Step 4. Return printer to normal operation. 1. Set power switch to O (off). Wait 15 seconds. Set power switch to 1 (on). (page 3–26). 4. Remove the shuttle cover — Step 5. — — Step 6. — — Step 7.
Ham. Drv. Short * Instruction Indication Yes No “Ham. Drv. Short * ” message. Step 2. Return printer to normal operation. 2. Press the CLEAR switch. “Ham. Drv. Short * ” message. Step 3. Return printer to normal operation. 3. Run a diagnostic self–test “Ham. Drv. Short * ” message. Replace the mechanism driver PCBA (page 5–48). Return printer to normal operation. 1. Set power switch to O (off). Wait 15 seconds. Set power switch to 1 (on). (page 3–26).
Mech Driver Hot * Instruction Indication Yes No “Mech Driver Hot * ” message. Step 2. Return printer to normal operation. 2. Press the CLEAR switch. “Mech Driver Hot * ” message. Step 3. Return printer to normal operation. 3. Run a diagnostic self–test “Mech Driver Hot * ” message. Step 4. Return printer to normal operation. Card cage fan operates. Replace mechanism driver PCBA (page 5–48). Replace card cage fan assembly (page 5–26). 1. Set power switch to O (off). Wait 15 seconds.
Mech Driver Link * Instruction Indication Yes No “Mech Driver Link * ” message. Step 2. Return printer to normal operation. 2. Press the CLEAR switch. “Mech Driver Link * ” message. Step 3. Return printer to normal operation. 3. Run a diagnostic self–test “Mech Driver Link * ” message. Step 4. Return printer to normal operation. 1. Set power switch to O (off). Wait 15 seconds. Set power switch to 1 (on). (page 3–26). 4. Remove paper guide Step 5. — Connectors are attached properly.
Paper Jam Instruction 1. Inspect paper path for Indication Yes Paper path is clear. Step 2. Remove paper and go to step 2. Debris found. Gently remove paper or lint particles with a wooden stick or pair of tweezers. CAUTION: Do not pry or apply force to the hammer tips. Go to step 3. Step 3. Ribbon mask damaged or bent. Replace the hammer bank cover assembly (page 5–22). Go to step 5. Step 5. bunched, torn, folded paper or labels. 2.
Paper Out Instruction 1. Load paper. 2. Run a diagnostic self–test Indication — (page 3–26). 3–12 Step 2. — Replace paper detector switch assembly (page 5–76). Go to step 3. Return printer to normal operation. “Paper Out” message. Replace the intermediate cable assembly (W5) (page 5–10). Go to step 4. Return printer to normal operation. “Paper Out” message. Replace the common controller PCBA (page 5–46). Return printer to normal operation. (page 3–26). 4.
Platen Open Instruction Indication Yes No 1. Load paper. — Step 2. — 2. Close forms thickness lever. — Step 3. — 3. Run a diagnostic self–test (page 3–26). Troubleshooting “Platen Open” message. Replace platen interlock switch assembly (page 5–78). Return printer to normal operation.
Ribbon Stall Instruction 1. Check that forms thickness lever is not closed too tightly; this can jam the ribbon and shuttle. 2. Run a diagnostic self–test Indication Yes No Forms thickness lever is set correctly. Step 2. Readjust the setting of the forms thickness lever. Go to step 2. “Ribbon Stall” message. Step 3. Return printer to normal operation. Ribbon path is clear Step 5. Remove obstructions from ribbon path and go to step 5. Ribbon is OK.
Shttl Cover Open Instruction 1. Inspect shuttle cover for Indication Replace the shuttle cover assembly (page 5–24). Step 2. Shuttle cover installed correctly. Step 3. Install cover correctly. Make sure the cover lies flat and the two captive screws are fully seated. Go to step 3. “Shttl Cover Open” message. Replace the cover open switch assembly (page 5–74). Return printer to normal operation. installation (page 5–24). 3. Run a diagnostic self–test (page 3–26).
Shuttle Jam Instruction 1. Check the forms thickness lever: if it is set too tightly, it can slow the shuttle enough to trigger the fault message. 2. Run a diagnostic self–test Indication Yes No Forms thickness lever set correctly. Step 2. Set forms thickness lever for thicker paper. Go to step 2. “Shuttle Jam” message. Step 3. Return printer to normal operation. Shuttle movement blocked. Remove obstruction. Go to step 4. Install shuttle cover (page 5–24). Go to step 4. “Shuttle Jam” message.
Software Error * Instruction 1. Set power switch to O (off). Indication Yes “Software Error * ” message. Step 2. Return printer to normal operation. “Software Error * ” message. Step 3. Problem is not in the printer. Return printer to normal operation. Wait 15 seconds. Set power switch to 1 (on). 2. Disconnect the input data line from the host computer. Set power switch to O (off). Wait 15 seconds. Set power switch to 1 (on). 3.
Symptoms Not Indicated by Fault Messages Troubleshoot malfunctions not indicated by fault messages using standard fault–isolation techniques: 1. Debrief the operator for a general description of the problem. 2. Verify the fault by running diagnostic self–tests or replicating conditions reported by the user. 3. Locate the malfunction using the half–split method: a. Isolate faults to half the remaining system at a time, until the final half is a field–replaceable part or assembly.
Troubleshooting Aids Troubleshooting • Printer Confidence Check (page 3–20). This procedure systematically checks basic printer operations and functions. Use it to establish basic printer status or for troubleshooting imprecise or intermittent symptoms. • Diagnostic Check of Microprocessors (page 3–21). This procedure checks processor operations on the printed circuit board assemblies (PCBAs). • Diagnostic Self–Tests (Page 3–26.) • Hex Code Printout (Page 3–29.
Printer Confidence Check Instruction 1. Check that printer is plugged into correct power source. (Ref.: User’s Manual) 2. Disconnect the interface Indication Yes No Power cable installed correctly to proper source. Step 2. Connect printer to correct power source. Printer operates correctly. Fault is not in the printer. Check host computer, applications software, cabling, etc. Step 3 (data) cable from the host computer to isolate the printer, then run a diagnostic self–test (page 3–26.) 3.
Diagnostic Check of Microprocessors This procedure checks the operation of the microprocessors and IC chips on the Common Controller (CCB) and Mechanism Driver boards. Do the steps in the order presented. 1. Set the power switch to O (off). 2. Remove the paper guide assembly (page 5–42). 3. Reseat the CCB and Mech Driver boards in the card cage. 4. Set the power switch to 1 (on).
CCB (page 5–46), and check that all ROM chips are inserted in the correct position and with all pins inserted correctly. This check will catch out–of–order ROMs and all single and multiple bit failures of floating–gate EPROMs (the type with the window, that erase with ultraviolet light). If a ROM chip was inserted backwards, discard it. Even if it operates properly, a high current flowed through the backwards–biased transistors, and its service life is probably shortened due to thermal damage.
cable to connector J3 on the CCB, and start over at step 1. If the display is still blank, or has a black line, and the 68010 LED lights and turns off, the control panel or its cable are defective. b. If the display reads “Mech Driver Link,” the 8032 at location J12 on the CCB may have failed. Check the 8032 and its PROM at location J10 for bent pins, misalignment, or backwards insertion. Also, make sure the clock–test jumper E2 at location J14 is installed.
printer. A break–out box works, but will not debug XON/XOFF or other RS–232 data protocols. If the printer is sending XOFF, the host may not be receiving it if it requires 1.5 or 2 stop bits. e. If the printer prints from the host, but occasionally prints double characters, there is probably a noise problem at the interface or the host computer is sending an inverted strobe. This problem can occur on Centronics or Dataproducts interfaces, never on RS–232.
on the CCB at C12 and D12, especially if they are absent. Garble can also result from failed termination resistors or parallel logic, but this is rare. 6. The 68010 LED never lights. The 68010 has not run its first instruction. a. The first two programs PROMs may be malfunctioning or inserted wrong. Do the corrective actions listed in step 4.d. b. Check the power supply voltages: look at the control panel display. If it is not blank, the logic power supply is okay.
c. If the display reads “Diagnostic Tests in Progress” and 68010 LED has been on for 20 seconds or more but is not blinking, it means the 64180 cannot communicate with the 8032 on the Mech Driver board. Turn off the printer, reseat the cable in J2 of the CCB and on the Mech Driver board. Check the 8032 on the Mech Driver, its PROM, and its clock jumper (E1–E2) for correct insertion, bent pins, etc. Reseat the jumper and socketed parts.
• Es plus TOF A pattern of all Es followed by a form feed to the next page top of form, useful for identifying paper motion or feeding problems. Hammer bank cover Power supply PCBA Mechanism Driver PCBA Paper motion sensor or cable Paper feed belt or motor Splined shaft bearings Tractors or tractor belts • All Hs A pattern of all uppercase letter Hs useful for detecting missing characters or dots, smeared characters, or improper phasing.
• Phasing A hammer timing parameter that permits you to adjust the vertical alignment of dots in character printing. (See page 4–4.) • Test Width Permits you to run tests at all available print widths. Running the Diagnostic Self–Tests To run a diagnostic self–test: 1. Press ON LINE to place the printer off–line. “Off–line/Emulation” displays. 2. Press UP and DOWN simultaneously to unlock the ENTER switch. 3. Raise the printer cover. 4. Press DOWN. “Emulation/LG06” displays. 5.
Hex Code Printout Hex dumps list all ASCII character data received from the host computer with their corresponding two–digit hexadecimal codes. You can use hex dumps to troubleshoot printer data reception problems. Printable characters print as the assigned symbol; nonprintable characters are indicated by a period [.]. The letter [p] before a hex code indicates an active Paper Instruction (PI) line. A blank space before a hex code indicates an inactive PI line. To make a hex printout: 1.
3–30 Troubleshooting
4 Adjustment Procedures Chapter Contents Preparing the Printer for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2 Belt, Paper Feed Timing, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6 Belt, Platen Open, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8 Hammer Phasing . . . . . . . . . . . . . . .
Preparing the Printer for Maintenance WARNING Unless otherwise directed, do adjustment procedures with the printer disconnected from the power source. Failure to remove power could result in injury to personnel or damage to equipment. The procedures in this chapter are written assuming the printer has been prepared for maintenance. To prepare the printer for maintenance, do the following before performing an adjustment or alignment: 1. Set the printer power switch to O (off). 2.
2 3 1 1. Shuttle Cover 2. Screw, Button–Head (3) 3. Paper Scale Figure 4–1 .
Hammer Phasing Adjustment (Figure 4–2 ) NOTE: Hammer phasing must be checked and adjusted when PROMs on the common controller PCBA are replaced. 1. Connect the power cord to the ac power source. 2. Set the printer power switch to 1 (on). 3. Load paper. 4. Press the ON LINE switch to take the printer off–line. “Off–Line/Emulation” appears on the message display. 5. Open the printer cover. 6. Press the UP and DOWN switches simultaneously to unlock the ENTER switch.
NEEDS ADJUSTMENT CORRECT NEEDS ADJUSTMENT Figure 4–2 .
Paper Feed Timing Belt Adjustment (Figure 4–3 ) 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the timing belt cover (1) by squeezing the top and bottom to release the plastic tabs from the slots in the side plate. 4. Loosen the motor mount bolts (2). 5. Using a force gauge, apply 12 pounds of tension to the paper feed drive motor (3). 6. Reduce tension to 9 pounds and torque the paper feed motor mount bolts (2) to 18 ± 1 inch–pounds. 4–6 7.
1 2 3 2 1. Timing Belt Shield 2. Motor Mount Bolt (2) 3. Paper Feed Drive Motor Figure 4–3 .
Platen Open Belt Adjustment (Figure 4–4 ) 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the platen open belt cover (1) by squeezing the top and bottom to release the plastic tabs from the slots in the side plate. 4. Loosen the motor mount screws (2). 5. Close the forms thickness lever all the way. 6. Make sure the collar of the platen open pulley (3) clears the left ribbon guide (4) with the platen fully closed. a.
1. 2. 3. 4. 5. 6. Belt Cover Motor Mount Screw Platen Open Pulley Left Ribbon Guide Set Screw Platen Open Motor 2 5 4 6 1 3 2 Figure 4–4 .
Paper Drive Motor Pulley Alignment (Figure 4–5 ) 4–10 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the timing belt cover (1) by squeezing the top and bottom to release the plastic tabs from the slots in the side plate. 4. Loosen the set screw (2) in the motor pulley collar (3). 5. Align the paper drive motor pulley (4) with the splined shaft pulley (5). 6. Hold the collar (3) flush against the motor pulley (4) and tighten the set screw (2). 7.
5 2 4 1 3 1. Belt Shield 2. Set Screw 3. Motor Pulley Collar 4. Motor Pulley 5. Splined Shaft Pulley Figure 4–5 .
Platen Open Motor Pulley Alignment (Figure 4–6 ) 4–12 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the platen open belt cover (1) by squeezing the top and bottom to release the plastic tabs from the slots in the side plate. 4. Loosen the set screw (2) in the motor pulley collar. 5. Align the platen open motor pulley (3) with the platen shaft pulley (4) and tighten the set screw (2). 6.
2 1. 2. 3. 4. Belt Cover Set Screw Platen Open Motor Pulley Platen Shaft Pulley 1 3 4 Figure 4–6 .
Splined Shaft Skew Adjustment (Figure 4–7 ) If lines of print are not parallel with the edge perforations on the paper, perform the following adjustment. 4–14 1. Prepare the printer for maintenance (page 4–2). 2. Loosen the screw (1) securing the adjusting link (2). 3. Adjust the link (2) to obtain print parallel with paper perforations. Tighten the screw (1). 4. Return the printer to normal operation (page 4–22).
1 2 1. Screw 2. Adjusting Link Figure 4–7 .
Platen Angle Adjustment (Figure 4–8 ) 1. Prepare the printer for maintenance (page 4–2). 2. Remove the shuttle cover (page 5–24). 3. Close the forms thickness lever (1) all the way. 4. Install the platen position gauge (P/N 996083) (2) and check the angle of the platen (3). c. If the angle is correct, no adjustment is necessary. Go to step 8. d. If the angle is incorrect, loosen the clamp screw (4) and set screw (5). 5.
1. 2. 3. 4. 5. Forms Thickness Lever Platen Position Gauge (P/N 996083) Platen Clamp Screw Setscrew 3 2 4 1 5 Figure 4–8 .
Platen Gap Adjustment (Figure 4–9 ) 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the shuttle cover assembly (page 5–24). 4. Remove the ribbon. 5. Raise the forms thickness lever (1) to the fully open position. CAUTION Do not force the platen against the feeler gauge. Damage to the printer will result. 6. Insert a 0.
1. 2. 3. 4. 5. Forms Thickness Lever Feeler Gauge (0.010 inch) Platen Ribbon Mask Set Screw (2) 1 2 4 3 5 NOTE: Left side adjustment shown. Right side is the same. Figure 4–9 .
Ribbon Guide Alignment (Figure 4–10 ) 1. Open the printer cover. 2. Load paper and install the ribbon. The ribbon should have a full spool on the right hub (1). 3. Run a shuttle and ribbon diagnostic self–test (page 3–26). 4. Momentarily short between the left ribbon guide skid screws (2) to assure right to left motion of the ribbon. 5. Observe how the ribbon (3) is passing around the left ribbon guide (4). It should be centered. 6.
2 3 4 5 6 1 7 3 1. 2. 3. 4. 5. 6. 7. Right Hub Screw, Left Ribbon Guide Skid (2) Ribbon Ribbon Guide, Left Screw, Retaining (2) Left Spool Ribbon Guide, Right Figure 4–10 .
Returning the Printer to Normal Operation 4–22 1. Load paper. 2. Install the ribbon. 3. Close floor cabinet doors and the printer cover. 4. Connect the ac power cord to the power source and the printer. 5. Set the power switch to 1 (on). 6. Test printer operation by selecting and running one of the diagnostic self–tests (page 3–26).
5 Replacement Procedures Chapter Contents Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3 Preparing the Printer for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3 Belt, Paper Feed Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4 Belt, Platen Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6 Cable Assembly W4, Hammer Bank . . .
PCBA, Mechanism Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–48 PCBA, Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–50 PROMs, Chips, and ICs on the CCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–52 PROMs, Chips, and ICs on the Mechanism Driver . . . . . . . . . . . . . . . . . . 5–54 Resistors, Terminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–56 Ribbon Hub .
Replacement Procedures CAUTION The components specified in this chapter are replaced in the field, but must be repaired at the factory. Do not attempt field repair of these items. This chapter contains illustrated removal/installation procedures for components replaceable at the field service level of maintenance. The page locations of all removal/installation tasks are listed on pages 5–1 and 5–2.
Belt, Paper Feed Timing (Figure 5–1 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Open the printer cover. 3. Remove the timing belt cover (1) by squeezing the top and bottom to release the plastic tabs from the slots in the side plate. 4. Loosen the paper feed motor mount bolts (2). 5. Remove the paper feed timing belt (3) by working the side of the belt onto the lip of the motor pulley (4) and rotating the pulleys until the belt rolls off. Installation 1.
6 5 4 1 3 1. 2. 3. 4. 5. 6. Timing Belt Shield Motor Mount Bolt (2) Paper Feed Timing Belt (P/N 29–29283–01) Motor Pulley Splined Shaft Pulley Paper Feed Drive Motor Figure 5–1 .
Belt, Platen Open (Figure 5–2 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Open the printer cover. 3. Remove the platen open belt cover (1) by squeezing the top and bottom to release the plastic tabs from the slots in the side plate. 4. Loosen the motor mount screws (2). 5. Apply tension to the motor shaft to loosen the platen open belt (3). 6. Remove the platen open belt (3) from the motor pulley (4) and platen pulley (5). Installation 1.
2 1. 2. 3. 4. 5. 6. Belt Cover Motor Mount Screw Platen Open Belt (P/N 29–29284–01) Motor Pulley Platen Pulley Set Screw 6 4 3 1 2 5 Figure 5–2 .
Cable Assembly, Hammer Bank (Figure 5–3 ) Removal NOTE: This procedure removes the left hammer bank cable assembly. The procedure for removing the right cable assembly is the same. 1. Prepare the printer for maintenance (page 5–3). 2. Open the printer cover. 3. Remove the paper guide assembly (page ). 4. Remove the common controller PCBA (page 5–46). 5. Remove the mechanism driver PCBA (page 5–48). 6. Remove the power supply PCBA (page 5–50). 7.
Printer viewed from above, PCBAs removed. Right hammer bank cable assembly Left hammer bank cable assembly 2 1 Card cage floor Card Cage Fan 5 Platen open motor Paper feed motor Paper feed mechanisms and barrier panel Platen Shuttle Frame Assembly Base casting Hammer Bank Fan 3 4 Front 1. 2. 3. 4. 5. Screw (2) Connector Screw (2) Connector Hammer Bank Cable Assembly (P/N 29–29293–01) Figure 5–3 .
Cable Assembly, Intermediate (Figure 5–4 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Open the printer cover. 3. Remove the paper guide assembly (page 5–42). 4. Remove the common controller PCBA (page 5–46). 5. Remove the mechanism driver PCBA (page 5–48). 6. Remove screws (1) securing the main wire harness connector (2) to the bottom of the card cage. Move the main harness connector to one side. 7.
Printer viewed from above, PCBAs removed. 1 2 3 4 Card cage floor (PCBAs removed) 12 Card Cage Fan 7 5 Paper feed motor 8 Platen open motor Paper feed mechanisms and barrier panel Platen 6 Paper detector switch assembly Shuttle Frame Assembly Base casting Hammer Bank Fan 10 1. Screw (2) 2. Main Wire Harness Connector 9 3. Screw (2) 4. Intermediate Cable Assy Connector P1 5. Connector P1(P) Front 6. Platen Interlock Switch Assembly 7. Connector PMD 8.
Installation 1. Feed the intermediate cable assembly (12) through the card cage opening and install tie wraps and cable restraints. 2. Connect connectors CO+ and CO– (10 and 11) and install the cover open switch assembly (9). 3. Connect connector PMD (7) to paper detector switch assembly connector PMD(J) (8). 4. Connect connector P1(P) (5) to the platen interlock switch assembly (6). 5. Install the screws (3) securing the intermediate cable assembly connector P1 (4) to the bottom of the card cage.
Printer viewed from above, PCBAs removed. 1 2 3 4 Card cage floor (PCBAs removed) 12 Card Cage Fan 7 5 Paper feed motor 8 Platen open motor Paper feed mechanisms and barrier panel Platen 6 Paper detector switch assembly Shuttle Frame Assembly Base casting Hammer Bank Fan 10 1. Screw (2) 2. Main Wire Harness Connector 9 3. Screw (2) 4. Intermediate Cable Assy Connector P1 5. Connector P1(P) Front 6. Platen Interlock Switch Assembly 7. Connector PMD 8.
Cable Assembly, Multi I/O (Figure 5–5 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Open the printer cover. 3. Remove the paper guide assembly (page 5–42). 4. Open the rear cabinet door. 5. Remove six screws (1) and move the fan duct (2) aside. 6. Open the ribbon cable restraints (3) on the upper rear and upper right walls of the cabinet. 7. Open the latches (4) and disconnect the multi I/O ribbon cable connector (5) from connector J1 (6) on the common controller PCBA. 8.
1. 2. 3. 4. 5. 6. 7. 8. 9. Screw (6) Fan Duct Ribbon Cable Restraints Latch (2) Ribbon Cable Connector Common Controller Connector J1 Screw (4) Mounting Plate Multi I/O Cable Assembly (P/N 29–29291–01) 5 4 3 9 6 7 2 1 8 Figure 5–5.
Installation 5–16 1. Feed the multi I/O ribbon cable from the lower cabinet up into the opening at the right rear of the card cage. Route the ribbon cable outboard of the right gas spring assembly (the strut that holds the printer cover open). 2. Install four screws (7) securing the multi I/O cable assembly mounting plate (8). 3. Connect the multi I/O ribbon cable connector (5) to connector J1 (6) on the common controller PCBA and close the latches (4). 4.
1. 2. 3. 4. 5. 6. 7. 8. 9. Screw (6) Fan Duct Ribbon Cable Restraints Latch (2) Ribbon Cable Connector Common Controller Connector J1 Screw (4) Mounting Plate Multi I/O Cable Assembly (P/N 29–29291–01) 5 4 3 9 6 7 2 1 8 Figure 5–5 .
Circuit Breaker (Figure 5–6 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Open the rear cabinet door. 3. Remove six screws (1) and move the fan duct (2) aside. 4. Tag and disconnect the four circuit breaker electrical leads (3). 5. Press in on the spring clips (4) and push the circuit breaker (5) out of the mounting plate (6). Installation 1. Press the circuit breaker (5) into the mounting plate (6) until the spring clips (4) snap into place.
1. 2. 3. 4. 5. 6. Screw (6) Fan Duct Circuit Breaker Electrical Lead (4) Spring Clip (4) Circuit Breaker (P/N 29–29329–01) Mounting Plate WHITE BLACK BROWN BLUE 6 1 3 2 5 1 4 1 Figure 5–6 .
Control Panel Assembly (Figure 5–7 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Open the printer cover. 3. Remove the paper guide assembly (page 5–42). 4. Open the connector latches and disconnect the control panel ribbon connector P1 (1) from connector J3 on the common controller PCBA (2). 5. Remove the control panel ribbon cable from the wire saddles (3) on the mechanism base pan. 6. Remove four screws (4) and washers (5). 7.
1 2 6 7 Install block–type ferrite core here and wind cable around round core. Refer to Appendix F. 5 4 1. 2. 3. 4. 5. 6. 7. Control Panel Connector P1 Common Controller PCBA Wire Saddles Screw (4) Washer (4) Control Panel Assembly (P/N 29–29286–01) Panel Bracket 3 Figure 5–7 .
Cover Assembly, Hammer Bank (Figure 5–8 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Remove the shuttle frame assembly (page 5–66). 3. Rotate hammer bank cover assembly (1) away from hammer bank (2). 4. Remove hammer bank cover assembly (1) from alignment pins (3). Installation CAUTION 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.
2 Thin plate Thick plate 1 3 (Not shown) 1. Hammer Bank Cover Assembly (P/N 29–29280–01) 2. Hammer Bank 3. Alignment Pin (2) Figure 5–8 .
Cover Assembly, Shuttle (Figure 5–9 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Open the printer cover. 3. Loosen the shuttle cover screws (1). 4. Grasping the edges of the shuttle cover assembly (2), tilt up the rear edge and lift the shuttle cover assembly out of the printer. Installation 5–24 1. Place the shuttle cover assembly (2) in the printer. Tilt the forward edge of the cover down slightly and work the cover into position. 2. Tighten the shuttle cover screws (1).
1 2 1. Screw, Captive, Shuttle Cover (2) 2. Shuttle Cover Assembly (Mfg. P/N 150123–011) Figure 5–9 .
Fan Assembly, Card Cage (Figure 5–10 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Open the printer cover. 3. Remove the paper guide assembly (page 5–42). 4. Remove the power supply PCBA (page 5–50). 5. Remove the nut (1) and ground wire (2). 6. Remove four screws (3). 7. Disconnect the fan cable connector (4). 8. Remove the card cage fan assembly (5) and fan guard (6) from the card cage (7). Installation 5–26 1. Connect the fan cable connector (4). 2.
6 3 5 7 4 2 1 1. 2. 3. 4. 5. 6. 7. Nut Ground Wire Screw (4) Fan Cable Connector Card Cage Fan Assembly (P/N 29–29294–01) Fan Guard Card Cage Figure 5–10 .
Fan Assembly, Cabinet Exhaust (Figure 5–11 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Open the floor cabinet rear door. 3. Remove six screws (1) and move the fan duct (2) aside. 4. Remove four screws (3) securing the cabinet exhaust fan assembly (4). 5. Disconnect the fan cable connector (5). 6. Remove the cabinet exhaust fan assembly (4) and fan guard (6). Installation 5–28 1. Connect the fan cable connector (5). 2.
1. 2. 3. 4. 5. 6. Screw (6) Fan Duct Screw (4) Cabinet Exhaust Fan Assembly (P/N 29–29294–01) Fan Cable Connector Fan Guard 2 1 5 3 4 6 Figure 5–11 .
Fan Assembly, Hammer Bank (Figure 5–12 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Remove the shuttle cover assembly (page 5–24). 3. Remove three screws (1). 4. Reach under the base casting (2) and disconnect the hammer bank fan cable connector (3). NOTE: The hammer bank fan assembly is removed by angling it up and out from beneath the shuttle motor. 5. Remove the hammer bank fan assembly (4) from the base casting (2).
3 1 2 4 Attach cable connector here. NOTE: Do not install screw here. Route cable under base casting. Hammer Bank Fan 2 1. 2. 3. 4. Screw (3) Base Casting Fan Cable Connector Hammer Bank Fan Assembly (P/N 29–29295–01) 4 1 3 Front Figure 5–12 .
Hammer Spring Assembly (Figure 5–13 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Remove the shuttle frame assembly (page 5–66). 3. Remove the hammer bank cover assembly (page 5–22). 4. Remove three 5/64 inch socket head screws from the old hammer fret. 5. Using the pointed end of the nylon stick supplied in the hammer spring replacement kit, carefully pry the old hammer fret off its mounting pins as shown in Figure 5–13 . 6. Discard the old hammer fret and mounting screws.
Preparation – Frets 1 and 7 only NOTE: If you replace fret 1 or 7, bend the end hammer down BEFORE removing it from the box, as shown below. Do this ONLY for frets 1 and 7. Right end Hammer Bank Left end Bend this hammer if replacing fret 7. Bend this hammer if replacing fret 1. See NOTE. Hammer Fret 1 See NOTE. Hammer Fret 7 Bend hammer down until it touches the mounting base in the box. Removal – Any Fret Use these screws to install new fret.
Magnetic Pick–up (MPU) Assembly (Figure 5–14 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Remove the shuttle cover (page 5–24). 3. Disconnect the magnetic pick–up (MPU) cable connector (1). 4. Loosen the MPU clamp screw (2). 5. Remove the MPU assembly (3) by unscrewing it from the MPU bracket (4). Installation 1. Install the MPU assembly (3) by screwing it into the MPU bracket (4). 2.
0.010 + .001INCH 2 5 4 3 Attach MPU cable here. 1 1. 2. 3. 4. 5. MPU Cable Connector MPU Clamp Screw Magnetic Pick–Up (MPU) Assembly (P/N 29–29277–001) MPU Bracket Flywheel Figure 5–14 .
Motor Assembly, Ribbon Drive (Figure 5–15 ) Removal NOTE: The procedure below is the same for the left and right ribbon drive motor assemblies. 1. Prepare the printer for maintenance (page 5–3). 2. Remove the ribbon. 3. Remove the ribbon hub (page 5–58). 4. Remove two screws (1) and washers (2). 5. Lift the ribbon drive motor (3) and its cable from base casting (4). 6. Disconnect the ribbon motor cable connector (5). 7. Loosen the set screw (6) and remove the collar (7) and shaft extension (8).
8 7 6 1 2 3 Install block–type ferrite core here. Refer to Appendix F. 5 4 1. 2. 3. 4. 5. 6. 7. 8. Screw (2) Washer (2) Ribbon Drive Motor (P/N 29–29282–01) Base Casting Ribbon Motor Cable Connector Set Screw Collar Shaft Extension Figure 5–15 .
Motor Assembly, Paper Feed (Figure 5–16 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Open the printer cover. 3. Remove the platen open belt cover (1) by squeezing the top and bottom to release the plastic tabs from the slots in the side plate. 4. Loosen the set screw (2) and remove the paper feed motor pulley (3), collar (4), and paper feed timing belt (5). 5. Disconnect the paper feed motor electrical connector (6). 6. Remove the motor mount bolts (7) and nuts (8). 7.
8 9 6 10 2 7 4 3 5 1 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Belt Cover Set Screw Paper Feed Motor Pulley Collar Paper Feed Timing Belt Paper Feed Motor Connector Bolt Nut Paper Feed Motor Assembly (P/N 29–29282–01) Splined Shaft Pulley Figure 5–16 .
Motor Assembly, Platen Open (Figure 5–17 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Remove the card cage fan assembly (page 5–26). 3. Remove the platen open belt cover (1) by squeezing the top and bottom to release the plastic tabs from the slots in the side plate. 4. Loosen the motor mount screws (2). 5. Remove the platen open belt (3). 6. Loosen the collar set screw (4) and remove the motor pulley (5). 7. Disconnect the platen motor cable connector (6). 8.
7 8 4 5 6 10 1. Cover, Platen Open Belt 2. Screw, Motor Mount 3. Platen Open Belt 4. Set Screw, Collar 5. Motor Pulley 6. Platen Motor Cable Connector 7. Nut Ring 8. Platen Open Motor Assembly (P/N 29–29282–01) 9. Platen Pulley 10. Set Screw, Platen Pulley 1 3 2 9 Figure 5–17 .
Paper Guide Assembly (Figure 5–18 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Open the printer cover. 3. Loosen—donotremove—thehold–downscrew(1). 4. Slide the paper guide assembly (2) to the left and lift it off the card cage (3). Installation 5–42 1. Position the paper guide assembly (2) offset slightly to the left on the card cage (3). 2.
1 NOTE: Loosen, do not remove, the hold–down screw. Clips on card cage top. (Not shown.) 2 3 Engage clips here. 1. Hold–Down Screw 2. Paper Guide Assembly 3. Card Cage Figure 5–18 .
Paper Ironer (Figure 5–19 ) Removal 1. Remove the shuttle frame assembly (page 5–66). 2. Move the forms thickness lever (1) to the open position. WARNING Over time, the upper edge of the paper ironer can become sharp. To avoid cutting yourself, grasp the paper ironer on the sides. 3. Push back at the ends of the paper ironer (2) to disengage the tabs, then lift it up and out. Installation WARNING Over time, the upper edge of the paper ironer can become sharp.
2 Push and Lift Push and Lift 1 1. Forms Thickness Lever 2. Paper Ironer (Mfg. P/N 150724–001) Figure 5–19 .
PCBA, Common Controller (Figure 5–20 ) CAUTION To prevent electrostatic damage to electronic components, wear a properly grounded static wrist strap when handling PCBAs. Removal 1. Prepare the printer for maintenance (page 5–3). 2. Open the printer cover. 3. Remove the paper guide assembly (page 5–42). 4. Open the connector latches and disconnect the multi I/O ribbon cable (1) from connector J1 (2). 5. Open the connector latches and disconnect the CCB/Mech.
1. 2. 3. 4. 5. 6. 7. 8. 9. Multi I/O Ribbon Cable Connector J1 CCB/Mech. Driver Cable Connector J2 Control Panel Ribbon Cable Connector J3 Ejection Lever (2) Common Controller PCBA (CCB) (P/N 29–29288–01) Card Cage 3 7 5 1 8 NOTE: Power Supply and Mechanism Driver boards shown for reference. They are not removed in this procedure. 4 6 2 9 Figure 5–20 .
PCBA, Mechanism Driver (Figure 5–21 ) CAUTION To prevent electrostatic damage to electronic components, wear a properly grounded static wrist strap when handling PCBAs. Do not flex the board or grasp components on the PCBA during removal/installation. Damage to components may result. Handle the board carefully by the ejections levers, sides, or the heat sink. Removal 1. Prepare the printer for maintenance (page 5–3). 2. Open the printer cover. 3. Remove the paper guide assembly (page 5–42). 4.
1 5 NOTE: Power Supply and Common Controller boards shown for reference. They are not removed in this procedure. 6 2 3 4 7 1. 2. 3. 4. 5. 6. 7. CCB/Mech. Driver Ribbon Cable Connector J6 Power Supply Cable Connector J7 Ejection Lever (2) Mechanism Driver PCBA (P/N 29–29289–01) Card Cage Figure 5–21 .
PCBA, Power Supply (Figure 5–22 ) WARNING To prevent injury from electric shock, wait at least one minute after shutting off power before removing the power supply PCBA. Do not touch components or flex the board during removal/installation. Handle the board by the ejections levers and the sides. Wear a properly grounded static wrist strap when handling the power supply PCBA. Removal 1. Prepare the printer for maintenance (page 5–3). 2. Open the printer cover. 3.
NOTE: Mechanism Driver and Common Controller boards shown for reference. They are not removed in this procedure. 3 4 1 6 5 2 7 1. 2. 3. 4. 5. 6. 7. Mechanism Driver Power Supply Cable Connector J102 Ejection Lever (2) Power Supply PCBA (P/N 29–29290–01) Circuit Breaker Cable Connector J1 Card Cage Figure 5–22 .
PROMs, Chips, and ICs on the CCB (Figure 5–23 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Remove the common controller PCBA (page 5–46). CAUTION To prevent electrostatic damage to electronic components, wear a properly grounded static wrist strap when handling PCBAs and components. 3. Using a chip puller, remove the defective chip(s). Locations are shown in Figure 5–23 .
LEGEND PROM Kit: P/N 29–29287–01, Rev B01 DPMC = Dot Plucker Memory Controller DPU = Data Processing Unit FTIC = Fire Timer IC LED = Light–Emitting Diode MPU = Magnetic Pick–up NOVRAM = Nonvolatile Random Access Memory PAL = Programmable Array Logic PFC = Paper Feed Controller 68010 Microprocessor DPU RTPU LED * LED 68010 Decode PAL 68010 Controller PAL DPU –001 DPU –002 DPU –003 DPU –004 Font –001 Font –002 Font –003 Font –004 RTPU = Real Time Processing Unit Shared Bus PAL Bus Arbiter PAL
PROMs, Chips, and ICs on the Mechanism Driver (Figure 5–24 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Remove the mechanism driver PCBA (page 5–48). CAUTION To prevent electrostatic damage to electronic components, wear a properly grounded static wrist strap when handling PCBAs and components. 3. Using a chip puller, remove the defective chip(s). Locations are shown in Figure 5–24 .
LEGEND RSP = Ribbon/Shuttle Processor ASIC = Application–Specific Integrated Circuit Hammer Driver ASIC RSP PROM 150846 8032 Microcontroller Mech. Driver ASIC Figure 5–24 .
Resistors, Terminating (Figure 5–25 ) For parallel interface configurations, the LG06 printer is equipped with 1K ohm pullup terminating resistors, located at coordinates 12C on the Common Controller PCBA. The 1K ohm terminating resistors are suitable for most applications. If the standard terminating resistor pack is not compatible with the particular interface driver requirements of the host computer, other values of pullup/pulldown resistors may be required.
1K ohm DIP or 330 ohm DIP Pull up (Location 12C) 220 ohm DIP Pull down (Location 12D) 11 12 13 C D E F Figure 5–25 .
Ribbon Hub (Figure 5–26 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Remove the printer ribbon. 3. Loosen the screw (1) in the ribbon spool hub (2). 4. Remove the hub (2) from the shaft adapter on the ribbon drive motor (3). Installation 1. If the ribbon drive motor has a shaft extension and collar, go to step 2. If the ribbon drive motor does not have an extension shaft and collar, begin at step 4. 5–58 2. Loosen the collar screw (4). 3.
1. 2. 3. 4. 5. 6. Hub Screw Ribbon Spool Hub (Kit, P/N 29–29296–01) Ribbon Drive Motor Collar Screw Shaft Extension Collar 2 1 5 6 4 3 Figure 5–26 .
Ribbon Guide Assembly (L/R) (Figure 5–27 ) Removal NOTE: Although the right ribbon guide is shown in Figure 5–27 , the removal procedure is the same for the left ribbon guide. 1. Prepare the printer for maintenance (page 5–3). 2. Open the printer cover. 3. Remove the printer ribbon. 4. Cut the tie–wrap and remove it from the spot tie (1) to free the ribbon guide cable. 5. Disconnect the ribbon guide connector (2). 6. Remove the two screws (3) and washers (4). 7.
5 6 4 3 1 2 1. 2. 3. 4. 5. Spot Tie Ribbon Guide Connector Screw (2) Washer (2) Ribbon Guide Assembly, Right (P/N 29–29299–01) Ribbon Guide Assembly, Left (P/N 29–29278–01) 6. Side Plate Figure 5–27 .
Shaft, Splined (Figure 5–28 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Open the printer cover. 3. Remove the paper feed timing belt (page 5–4). 4. With grip ring pliers, remove the grip ring (1) from the splined shaft (2). 5. Pull the bearing (3) and spring link (4) with the spring (5) off the splined shaft (2). 6. Unlock the left and right tractors (6 and 7) and slide them to the center. 7. Remove the screw (8), washer (9), and bearing clamp (10). 8.
1 3 4 12 5 13 2 11 6 2 7 1. Grip Ring (Mfg. P/N 101551–002) 2. Splined Shaft Assembly (Mfg. P/N 150169–001) 3. Bearing (Mfg. P/N 101308–001) 4. Spring Link (Mfg. P/N 110280–001 or 150664–001) 5. Spring 6. Tractor, Left (Set, L/R, P/N 29–29285–01) 7. Tractor, Right 8. Screw 9. Washer 10.Bearing Clamp (Mfg. P/N 110281–001) 11.Vertical Adjustment Knob (Splined Shaft Pulley) (Mfg. P/N 150289–001) 12.Left Side Plate 13.Right Side Plate 10 9 8 Figure 5–28 .
Shaft, Support (Figure 5–29 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Open the printer cover. 3. Unlock the tractors (1) and slide them to the far left. 4. Remove the E ring (2). 5. Slide the support shaft assembly — consisting of the support shaft (3), two spring washers (4), bushing (5), horizontal adjustment knob (6), washer (7) and screw (8) — to the left, out of the tractors (1) and the left side plate (9). Installation 5–64 1.
8 7 6 9 5 4 2 1 10 3 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Tractor (2) (Set, L/R, P/N 29–29285–01) E Ring (Mfg. P/N 105678–003) Support Shaft (Mfg. P/N 111685–001) Spring Washer (2) Bushing Horizontal Adjustment Knob Washer Screw Left Side Plate Right Side Plate Figure 5–29 .
Shuttle Frame Assembly (Figure 5–30 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Remove the shuttle cover assembly (page 5–24). 3. Disconnect the MPU cable connector (1). 4. Disconnect the shuttle motor cable connector (2). 5. Disconnect the shuttle cable assembly connector (3). CAUTION The hammer bank flex circuit ribbon cables can tear if handled roughly. Do not pull on the cables; grasp the connectors to disconnect the flex circuit ribbon cables.
6 2 Places 9 NOTE: NOTE: Clamp hardware exploded for clarity. Do not remove. Center captive screw exploded for clarity. Do not remove it. 7 12 4 5 3 2 1. MPU Cable Connector 2. Shuttle Motor Cable Connector 3. Shuttle Cable Assembly Connector 4. Left Flex Circuit Ribbon Connector 5. Right Flex Circuit Ribbon Connector 6. Clamp Screw, Side (2) 7. Side Clamp (2) 8. Guide Shaft 9. Center Screw, Captive 10. Shuttle Frame Assembly (P/N 29–29297–01) 11. Base Casting 12.
Installation 1. Install the hammer bank cover (page 5–22). 2. Holding the shuttle frame assembly (10) by the outer beam standoffs (12), set it into the base casting (11). Use both hands: the shuttle frame assembly is heavy. 3. Align the center 5/32 inch socket head screw (9) in the base casting (11) and hand turn the screw until only two or three threads have started. 4. Pull the shuttle frame assembly (10) toward the front of the printer. 5.
6 2 Places 9 NOTE: NOTE: Clamp hardware exploded for clarity. Do not remove. Center captive screw exploded for clarity. Do not remove it. 7 12 4 5 3 2 1. MPU Cable Connector 2. Shuttle Motor Cable Connector 3. Shuttle Cable Assembly Connector 4. Left Flex Circuit Ribbon Connector 5. Right Flex Circuit Ribbon Connector 6. Clamp Screw, Side (2) 7. Side Clamp (2) 8. Guide Shaft 9. Center Screw, Captive 10. Shuttle Frame Assembly (P/N 29–29297–01) 11. Base Casting 12.
Spring Assembly, Gas (Figure 5–31 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Open the printer cover (1). 3. Open the floor cabinet rear door. 4. Remove two nuts (2) and washers (3). 5. Remove the gas spring assembly (4). Installation 5–70 1. Position the gas spring assembly (4) on the upper and lower brackets (5 and 6). 2. Install two nuts (2) and washers (3). 3. Close the printer cover (1): make sure the cover closes all the way.
1. 2. 3. 4. 5. 6. Printer Cover Nut Washer Gas Spring Assembly (P/N 29–29508–01) Upper Bracket Lower Bracket 1 2 3 5 2 4 3 6 Figure 5–31 .
Spring, Extension (Figure 5–32 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Open the printer cover. 3. Remove the shuttle cover assembly (page 5–24). 4. Unhook the extension spring (1) from the spring lugs (2) on the hammer bank (3) and shuttle frame (4). Installation 5–72 1. Apply a dab of M–3 lubricant to both spring lugs (2). 2. Hook the extension spring (1) over the spring lugs (2). 3. Install the shuttle cover assembly (page 5–24). 4.
3 1. 2. 3. 4. Extension Spring (P/N 29–29279–01) Spring Lug (2) Hammer Bank Shuttle Frame 1 2 4 Figure 5–32 .
Switch Assembly, Cover Open (Figure 5–33 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Open the printer cover. 3. Remove the shuttle cover assembly (page 5–24). 4. Remove two screws (1) and lift the cover open switch assembly (2) out of the base casting. 5. Disconnect the switch connectors from intermediate cable assembly connector CO+ (3) and CO– (4). Installation 5–74 1. Connect the switch connectors to intermediate cable assembly connector CO+ (3) and CO– (4). 2.
Printer viewed from above. Card Cage Fan Card cage Paper feed motor Platen open motor Paper feed mechanisms and barrier panel Platen Shuttle Frame Assembly Base casting 3 2 1 4 This section of cable runs beneath the base casting. Front 1. Screw (2) 2. Cover Open Switch Assembly (P/N 29–29274–01) 3. Connector CO+ 4. Connector CO– Figure 5–33 .
Switch Assembly, Paper Detector (Figure 5–34 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Remove the paper guide assembly (page 5–42). 3. Remove four screws (1) and the barrier shield (2). 4. Remove the shuttle frame assembly (page 5–66). 5. Remove the paper ironer (page 5–44). 6. Loosen the screws (3) securing the paper detector switch assembly (4). 7. Disconnect the paper detector switch cable connector (5) from the intermediate cable assembly connector PMD. 8.
1. Screw (4) 2. Barrier Shield 3. Screw 4. Paper Detector Switch Assembly (P/N 29–292976–01) 5. Paper Detector Switch Cable Connector 2 1 3 5 4 Figure 5–34 .
Switch Assembly, Platen Interlock (Figure 5–35 ) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Open the printer cover. 3. Disconnect the platen interlock switch connector (1) from connector P1(P) (2). 4. Fully close the forms thickness lever (3). 5. Remove two screws (4). 6. Remove the platen interlock switch assembly (5) from the forms thickness indicator plate (6). Installation 5–78 1. Fully close the forms thickness lever (3). 2.
6 1 4 5 2 3 1. Platen Interlock Switch Connector 2. Connector P1(P) 3. Forms Thickness Lever 4. Screw 5. Platen Interlock Switch Assembly (P/N 29–29275–01) 6. Forms Thickness Indicator Plate Figure 5–35 .
Tractor (L/R) Removal 1. Prepare the printer for maintenance (page 5–3). 2. Remove the splined shaft (page 5–62). 3. Remove the support shaft (page 5–64). 4. Remove the tractors from the support shaft. Installation 1. Using the replacement tractors, install the support shaft (page 5–64). 2. Install the splined shaft (page 5–62). 3. Return the printer to normal operation (see below). Returning the Printer to Normal Operation 5–80 1. Load paper. 2. Install the ribbon. 3.
A Printer Configuration Contents Printer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2 Configuration Printout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2 Configuration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–3 Saving Configuration Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printer Configuration IMPORTANT Configuration directly affects printer operation. Do not change printer configuration until you are thoroughly familiar with the procedures in this appendix. Configuration refers to the operating properties that define how the printer responds to signals and commands received from the host computer. These properties, called configuration parameters, are set to match the operating characteristics of the host computer system.
Configuration Procedure Use the following procedure to configure the printer from the control panel: 1. Obtain a configuration printout (page A–2). 2. Determine the parameter values that must be changed to meet your requirements. 3. Take the printer off–line by pressing the ON LINE switch. 4. Open the printer cover. NOTE: You must unlock the ENTER switch to change a configuration value. If you leave the ENTER switch locked you can examine — but not change — the current configuration. 5.
Saving Configuration Values When you save a set of configuration values they become active every time the printer is turned on. To save a set of configuration values: A–4 1. Press the ON LINE switch to take the printer off–line. “Off–Line/Emulation” appears on the message display. 2. Open the printer cover. 3. Press UP and DOWN simultaneously to unlock the ENTER switch. “Unlocked” appears briefly on the message display. 4. Press NEXT (or PREV) until “Off–Line/Save Config” appears on the display.
Loading Configuration Values Configuration values saved using the “Save Config” menu (page A–4) become the power–up default configuration. The set of factory values remains permanently stored in printer memory, however. The “Load Config” menu gives you the choice of loading either the saved or the factory configuration values. NOTE: If you have not saved a set of configuration values, this procedure loads the factory value set. To load a set of configuration values: 1.
Changing Printer Emulations Emulation refers to the ability of the LG06 to execute the commands of DEC LG02/LG31/LN01 printers, an IBM Proprinter, or an Epson FX printer. (On the LG06 printer, the self–test and hex printout modes are also considered emulations.) DEC emulation is the default mode, but you can select another emulation at any time. To change printer emualtions: 1. Press ON LINE to place the printer in the off–line state. “Off–Line/Emulation” appears on the message display. 2.
Configuration Diagram The Configuration Diagram is a series of block diagrams showing the configuration menu structure and the parameter options available in each menu. The Configuration Diagram begins on page A–8. How to Read the Configuration Diagram Boxes on the diagram represent the message display. Messages that appear on the display are printed inside the boxes. The letters outside the boxes represent control panel switches. When a switch is pressed, an arrow points to the displayed result.
On–Line OL P U Off–Line Emulation D D Emulation LG06 * P N P N D U OL Off–Line Print Engine K U PAGE A–15 D Emulation Proprinter XL P N P N D Off–Line Interface F CONFIGURATION DIAGRAM P P N N P N OL U Off–Line Panel Language D * P Panel Language English N N P P Anzeigesprache Deutsch Lang.
FROM PAGE A–8 A–9 N A P D Emulation LG06 D LG06 Font D Font Style N Style U U DP 10 6* DP 10 8 DP 12 6 DP 12 8 DP 15 6 DP 15 8 DP 15 10 HS 10 6 CORESPON 5 6 CORESPON 5 8 CORESPON 6 6 CORESPON 6 8 CORESPON 10 6 CORESPON 10 8 CORESPON 12 6 CORESPON 12 8 CORESPON 15 6 CORESPON 15 8 CORESPON 15 10 OCR A OCR B COMPRESS 6 6 COMPRESS 6 8 COMPRESS 8 6 COMPRESS 8 8 COMPRESS 13 6 COMPRESS 13 8 COMPRESS 13 10 COMPRESS 16 6 COMPRESS 16 8 COMPRESS 16 10 DP 5 6 DP 5 8 DP 6 6 DP 6 8 N Style P P U (1) (2)
P U Vert Forms Bot Mrg n N Vert Forms Top Mrg n N Vert Forms Bot. Frm n D LG06 Vert. Forms U Continued from previous page N N A–10 U (1) (5) P (1) (4) P (1) (4) N U U U N P P U LG06 Horiz. Forms D Horiz Forms Left Mrg n N Horiz Forms Right Mrg n U (4) (2) P (2) U N U P U LG06 Autowrap D N or P * Autowrap Yes Autowrap No U N P LG06 CR CR = CR U * CR = CR + LF D U N or P (1) n = 0 to 198.0 inch in increments of 1/6 inch.
A–11 N P P P P * U FROM PAGE A–8 B U Emulation Proprinter XL D Proprinter XL Font D Font Draft at 10 CPI N Font Draft at 12 CPI N Font NLQ at 10 CPI N Font NLQ at 12 CPI N U U U U P U U Proprinter XL Character Set D Character Set US 437 D US 437 Graphic 1 (A) N or P US 437 Graphic 2 (B) * U N N P U Character Set Mult 850 D Mult 850 Graphic 1 (A) N or P Mult 850 Graphic 2 (B) U P U U Proprinter XL Compatibility D D Compatibility Compress 12 CPI * Compress 12 CPI 2
U Continued from previous page U D U P P U * Paper Format Forms Length Set U Proprinter XL Paper Format N D In Inches At 11.0 Inches D In Inches At 11.0 Inches N N In Inches At 10.5 Inches P Forms length range is from 1.0 to 21.0 inches in 0.5 inch increments. P P N N A–12 N N U U N P P U In 6 LPI Lines At 66 Lines D In 6 LPI Lines At 66 Lines N P P U * N U U Forms length range is from 1 to 126 lines in 1 line increments.
P U D Form Feed at TOF Disable N or P Form Feed at TOF Enable * Paper Format Form Feed at TOF Continued from previous page N A–13 U N P U Paper Format Print Width D Print Width 13.6 Inches * N or P Print Width 8.
N A–14 P U FROM PAGE A–8 C Emulation Epson FX–1050 D U P P P P P P P P * Epson FX–1050 Font D Font HS Draft 10 N Font HS Draft 12 N Font HS Draft 15 N Font Draft 10 N N Font Draft 12 Font Draft 15 N Font NLQ 10 N N Font NLQ 12 Font NLQ 15 N U U U U U U U U U P U U Epson FX–1050 Condensed D Condensed No N Condensed Yes * P N U U P U U Epson FX–1050 Draft Speed D Draft Speed High N Draft Speed Low * P N U U P U U Epson FX–1050 Character Set D Charac
P U D Slashed Zero No Slashed Zero Yes N or P * Epson FX–1050 Slashed Zero Continued from previous page N A–15 U N P U D N or P * Epson FX–1050 CR = CR = CR CR = CR + LF U N P FROM PAGE A–8 K U * Epson FX–1050 Page Length D Page Length 11 ” * P N or P Page Length 12 ” Off–Line Print Engine D U D Print Engine Unidirectional Unidirectional No N or P Unidirectional Yes U U N N P U * Epson FX–1050 Skip Over Perf D Skip Over Perf No N or P Skip Over Perf 1” P U
A–16 P P N F N P * FROM PAGE A–8 D Offline Interface U Interface Serial EIA–232 D U Serial EIA–232 Data Rate D Data Rate 9600 Baud * P N 19200 Baud 150 Baud 300 Baud 600 Baud 1200 Baud 2400 Baud P Data Rate 4800 Baud U N U N P P U G N CENTRONICS PAGE A–18 U (1) Serial EIA–232 Word Length 8 D Serial EIA–232 Word Length 8 N or P Serial EIA–232 Word Length 7 U * P N P U H N U N DATAPRODUCTS PAGE A–19 U Serial EIA–232 Stop Bits 1 D Serial EIA–232 Stop Bits 1 * N o
A–17 P Continued from previous page U N P N P N U D Serial EIA–232 Request to Send Request to Send N U On–Line and BNF * P N Request to Send Off–Line or BF P N Request to Send False P Request to Send True N P N P U D Serial EIA–232 Reverse Channel N Reverse Channel On–Line and BNF P N Reverse Channel Off–Line or BF P N Reverse Channel False P Reverse Channel True U * N P Printer Configuration
G P N or P * U P N FROM PAGE A–16 D U Interface Centronics D Centronics Data Bit 8 Data Bit 8 Yes Data Bit 8 No A–18 D U Centronics Data Polarity Data Polarity Standard * N or P Data Polarity Inverted P N U D U Centronics Response Pol. * Response Pol. Standard N or P Response Pol.
A–19 OL OL * E FROM PAGE A–8 D Emulation Hex Dump Emulation Hex Dump On–Line Hex Dump Off–Line Emulation P U FROM PAGE A–16 H U Interface Dataproducts D D N or P Dataproducts Data Bit 8 * Data Bit 8 Yes Data Bit 8 No P N U D Dataproducts PI Ignored N or P * PI Ignored Yes PI Ignored No U P N U D Dataproducts Data Polarity U N P U D Dataproducts Data Request Pol. * Data Request Pol. Standard N or P Data Polarity Standard * Data Request Pol.
A–20 P N E * U FROM PAGE A–8 E Emulation Self Test D Emulation Self Test Self Test ASCII Swirl U * N or P RS Running ASCII Swirl Self Test Width: 13.2 D Self Test Width: 13.2 Self Test Width: 8.0 P N P U U N U Self Test All E’s Running All E’s U RS Self Test Phase Value RS PhaseValue XXX (1) P N N P U Self Test E’s + TOF Running E’s + TOF U Self Test Shuttle Fast RS RS Running Shuttle Fast (1) Increase or decrease phase value by pressing NEXT or PREV switch.
B Printer Specifications Contents Cleaning Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–2 Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–2 Paper Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–2 Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–2 Labels . .
Cleaning Interval Clean the LG06 every 6 months or 1000 hours of operation, whichever occurs first. (See page 2–4.) Ribbon Specifications NOTE: Use of ribbons that do meet digital specifications may void warranty. Part Number: 36–36692–01 Type: OCR Application, carton of 1 ribbon Dimensions: Length: 60 yards (54.84 m) Width: 1 inch (2.54 cm) Thickness: 0.0039 inches (.009906 cm) To order replacement ribbons, call 1–800–DIGITAL Paper Specifications Paper B–2 Type: Edge–perforated, fanfold, 7.
Labels On Backing: One–part continuous perforated fanfold back form. Labels must be placed at least 0.42 cm (1/6 in) from the fanfold perforation. Backing adhesive must not be squeezed out during printing. Sheet Size: 7.62 to 40.64 cm (3– to 16–in) wide, including the two standard perforated tractor feed strips. A maximum sheet size of 30.48 cm (12 in) between top and bottom perforations. Thickness: Not to exceed 0.064 cm (0.025 in) (including backing sheet) Printer Dimensions Height: 108 cm (42.
Environmental Characteristics Temperature Operating 10° to 40° C (50° to 104° F) Storage – 40° to 70° C (–40° to 158° F) Relative Humidity Operating 10% to 90% (noncondensing) Storage 5% to 95% (noncondensing) Acoustic Noise Level 52 dBA (tested per ISO 7779) Electrical Characteristics Input Power Voltage 120 Vac or 230 Vac (94 – 140 VRMS; 188 – 275 VRMS) Phase Single Frequency 47 to 62 Hz Max RMS Current 8A @ 120 V; 4A @ 230 V Power Rating Standby 165 VA 60 Hz (120 Watts) Operating 480 VA
Data Input Rate (maximum) Dataproducts Up to 30 000 characters per second Centronics Up to 30 000 characters per second RS–232 Up to 19 200 baud Radio Frequency Interference (RFI) Radio Frequency Interference tested/certified to RFI standards FCC 15.J Class A; VDE 0871 Class A; CISPR–22.
Printing Rates Printing speed of text is measured in lines/minute, and is a function of the selected font and dot density. Printing speed is independent of the number of characters configured in the character set repertoire. Print rates for lines containing attributes such as bold or emphasized printing, superscripts, subscripts, or elongated attributes will decrease to not less than half the rates of the font without such attributes. Typical printing rates for text are charted in Table B–1.
Table B–1. Text Printing Rates Print Application Emulation, Font, and Characters /inch Performance Uppercase Only (lines/minute) Descenders & Underline (lines/minute) Dot Density1 Dot Matrix2 LG06 DP 5 60 (120) x 66.6 10 (18) x 7 + 2 600 480 LG06 DP 6 60 (120) x 66.6 8 (14) x 7 + 2 600 480 LG06 DP 10 60 (120) x 66.6 5 (9) x 7 + 2 600 480 Pro DP 10 60 (120) x 75 5 (9) x 7 + 2 600 480 LG06 DP 12 60 (120) x 66.
Duty Cycle The LG06 text and graphics printer is capable of printing 75 000 pages per month under the following conditions: B–8 1. Uppercase only 2. 6 lines/inch 3. 10 characters/inch 4. 63% character density or 83 characters/line 5. 63% line density or 42 lines/11–inch page 6. Single part (18 lb) paper 7. Printer is maintained in accordance with the maintenance manual (document number EK–ELG06–MG) 8.
C Torque Table IMPORTANT Torque values specified in replacement procedures (Chapter 5) take precedence over Table C–1. Table C–1 establishes the torque requirements for routine installation of threaded fasteners. The torque requirements in Table C–2 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. Table C–1. Torque Table Carbon Steel Fasteners (ANSI B18.6.
C–2 Torque Table
D Cable Interconnections and Hammer Bank Wiring Table D–1 lists the LG06 cable assemblies and their part numbers. The LG06 Interconnection Diagram on page D–2 shows the electrical interconnections in block diagram form. Use this diagram as a troubleshooting aid. The Hammer Bank Wiring Diagram on page D–3 is useful for tracing opens or shorts. Table D–1. Interconnection Cables Cable No. Part No. W1 150551–001 Cable Assembly, CCB/Mech. Dr.
PS PS5(P) Cable Assy, AC/Ground, P4980 P1 J1 J101 J102 Power Supply PCBA P2 P1 W2: Cable Assy +5V PS(J) PS5(J) Mechanism Driver PCBA CCB(J) W1: Cable Assy, CCB/Mech. Dr.
Key: Unused hammer. Hammer Coil. Hammer Spring. Ribbon Cable. NOTES: 1. Coil 48 is wired, but not used. 2. Hammer springs 1 and 49 are not used. 3. Hammer coil resistance = 4.7 Ohms.
D–4 Cable Interconnections and Hammer Bank Wiring
E Principles of Operation Contents Functional Elements of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–2 Common Controller PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–3 Mechanism Driver PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–11 Power Supply PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–14 Printing Mechanism . . . . . . . . . .
Functional Elements of the Printer The principal functional elements of the LG06 printer are the common controller board (CCB), the mechanism driver board, the power supply board, the operator control panel, and the components of the electromechanical print mechanism. These elements are depicted at their most basic level in Figure E–1. The following sections of this appendix discuss these elements in more detail.
Common Controller PCBA The heart of the LG06 Text and Graphics printer is the common controller printed circuit board assembly (PCBA), also called the common controller board (CCB). The CCB oversees and coordinates all printer functions. The CCB is functionally two units, the data processing unit (DPU) and the real–time processing unit (RTPU). The DPU converts all character data into printable dot images.
Communicating with the Host Computer The CCB processes three kinds of computer input: Centronics parallel, DataProducts parallel, and RS–232 serial data. The RTPU operates all three interfaces. The parallel interfaces are similar, and the RTPU contains direct–memory–access (DMA) hardware which loads parallel data directly into shared memory. The serial interface requires byte–by–byte intervention by the processor, since ACK/NACK and XON/XOFF protocols require that every byte be examined as it is received.
DATA PROCESSING UNIT SHARED MEMORY DOT PLUCKER ASIC RTPU 64180 PROCESSOR EPROM Hammer Driver Data DMA CONTROLLER FIRE TIMER ASIC Hammer Timing Data REAL–TIME PROCESSING UNIT Figure E–3. Hammer Driver Interface Functions of the RTPU Getting Dots to the Hammers Getting dots to the hammers consists of going into the shared memory and pulling bits out in a given order and shifting them to the hammer driver at the correct time. This process is called dot plucking.
Mechanical Interface Three mechanical operations are coordinated in printing: paper motion, ribbon motion, and shuttle motion. Virtually all digital handling of paper motion is contained in the RTPU. The ribbon and shuttle are controlled by logic on the mechanism driver board, under the direction of the RTPU. Figure E–4 shows the mechanical interface section of the RTPU.
the ribbon/shuttle processor (RSP) is a 2400 baud asynchronous serial line. A message protocol is used to communicate ribbon and shuttle information. Fault Monitoring The RTPU also monitors the hammer driver, mechanism driver, and the electro–mechanical sensors for fault conditions. Fault conditions are reported to the DPU. Hammer Bank and Hammer Driver Faults The FTIC works with the hammer driver ASIC to monitor coil shorts, opens, average upper driven phase current, and temperature conditions.
RTPU; it is sixteen bits wide and is arbitrated on a cycle–by–cycle basis. The 8032 chip has its own eight bit local bus. The manner in which the CCB implements this hardware is depicted in Figure E–5. The 64180 IC that oversees the RTPU processor contains a Z80 microprocessor with extended memory management, two DMA controllers, two asynchronous and one synchronous serial port, two counter timers, and an interrupt controller.
from the FTIC, which synchronizes paper motion with shuttle motion. The 64180 programs the PFC 8032 at the beginning of each dot row, telling the PFC how far to move when the trigger is received. The PFC sets up for the move, waits, then moves when the trigger occurs. The other method of starting paper motion is with a command passed through the inter–processor port (an eight bit parallel port between the 8032 and the 64180). This results in immediate movement.
68010 MICROPROCESSOR SHARED BUS INTERFACE EPROM 512 KB CONTROL REGISTER NVRAM 2 KB DATA PROCESSING UNIT (DPU) REAL–TIME PROCESSING UNIT (RTPU) PARALLEL PORT From Host Computer DOT PLUCKER ASIC Serial from Host Computer 64180 PROCESSOR Serial to Host, Mech. Driver, and Control Panel SHARED BUS INTERFACE DRAM 1 MB To Hammer Driver FIRE TIMER IC EPROM 32 KB HARDWARE CONTROL REGISTER SRAM 2 KB HARDWARE STATUS REGISTER COMM.
Mechanism Driver PCBA The mechanism driver board, acting on commands from the CCB, controls real–time operation of the electromechanical printer systems. Functionally, the board consists of nine subsystems: • An 8032 micro–controller that controls ribbon drive and communication with the CCB. • The interface to the power supply board. • Pulse–width modulator (PWM) current mode / voltage mode full–bridge power amplifiers connected directly to the shuttle, ribbon, paper feed, and platen open motors.
provide direct digital PWM drive signals for the ribbon motor PWM amplifier. The 8032 drives the ribbon motors through PWM generators in the mechanism driver integrated circuit (MDIC). Nearly all mechanical control functions are carried out through the MDIC ASIC. Digital I/O is done through latches connected to the 8032 I/O ports and MDIC. Ribbon faults are passed to the CCB.
MDIC ASIC. The CCB writes a word to the 8032, which writes a word to the MDIC. The MDIC generates a clock signal based on this word. The clock signal from the MDIC is the reference input to a phase detector. The other input to the phase detector is a logical combination of the pulses from three Hall–effect sensors in the brushless three–phase dc shuttle motor. The Hall–effect sensors are mounted to the motor stator 120 electrical degrees phase–shifted from each other.
The Magnetic Pick–up Unit (MPU) The magnetic pick–up unit (MPU) is mounted next to the shuttle motor flywheel. It provides timing information to the hammer fire controller by way of the CCB. The rotation of the flywheel generates a pulse signal in the MPU. The output frequency is 100 times the shaft frequency of the shuttle motor. The MPU pulse train has one missing pulse in every revolution of the motor for indexing.
than 15 V in less than 200 milliseconds and requires recycling of the circuit breaker (ac input) to reset the latch. The + 5 V power supply has its own inverter, separate from the + 48 V and + 9.5 V outputs. Printing Mechanism The printing mechanism consists of the shuttle frame assembly, which carries the hammer bank assembly, the ribbon transport system, and the paper transport system. Figure E–6 shows the shuttle frame assembly.
Shuttle Frame and Hammer Bank Assemblies Dots are printed by 47 hammer springs mounted on the hammer bank. The hammers are arrayed in seven comb–like hammer spring assemblies, or frets. Each fret contains 7 hammers. Using 49 hammers balances the magnetic field characteristics of the hammer bank, while design parameters determine the use of 47 hammers for printing. (The first and 49th hammers do not print.
The hammer springs forward, strikes the ribbon and paper, and leaves a dot impression of the hammer tip on the paper. The coil is de–energized and its field collapses while the hammer is in flight. After striking the ribbon and paper, the hammer rebounds and the permanent magnet recaptures it. A line of characters is created as the shuttle scans horizontally (See Figure E–8).
Succesive Hammer Strokes Per Scan Shuttle Scan Dot Row 1 1 2 1 2 3 1 2 3 4 1 2 3 4 5 1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 5 6 7 * 1 *1 * Even column dot centers within the printed character area and character space hammer positions are not illustrated in this diagram. NOTE: 3 * 1 3 5 *1 3 5 7 * 1 3 5 7 9 * = Hammer Released and Dot Printed = Hammer Not Released; No Dot Printed Figure E–9.
Paper Transport System The paper transport system accepts continuous, fan–folded, edge–perforated paper from three to 16 inches wide and from one to six sheets thick. Horizontal positioning is provided by the horizontal adjustment knob and two tractors. The tractors are laterally adjustable along the splined and support shafts. Each tractor engages paper perforations with six pins and locks in place with a friction lock.
Ribbon Transport System The printer ribbon winds and unwinds continuously on a pair of spools latched to hubs which are driven by the ribbon motors. The ribbon motors operate only while the hammer bank assembly is running. Ribbon motion reverses when the metal strip at either end of the ribbon crosses the left or right ribbon guide, completing a circuit that causes both motors to reverse direction. Constant ribbon tension is maintained by controlling each motor with a drive or drag circuit.
F Ferrite Noise Suppression Cores Ferrite cores reduce radio frequency interference (RFI) with electronic equipment located near the printer. Two kinds of ferrite cores are used in the printer: 1. Cylindrical cores—Cables pass through the core or are wound around it. 2. Block cores—The core is housed in a hinged plastic case. Cables are laid in a groove in the core, and the plastic case is closed, securing the core to the cable. Figure F–1 shows the location of the ferrite cores in the LG06 printer.
Paper Feed Motor cable passes through core (no wrap) on its way to the card cage. Round ferrite cores are tie– wrapped to the side of the card cage. (See the Maineance Tip below.) Ribbon Motor cable wraps once around core before it enters the card cage. Control Panel cable wraps 4 times around core before it enters the card cage. Card Cage Card Cage Fan Maintenance TIp: Route and wrap the cables first. Tie wrap the round ferrite cores to the card cage last.
Index Numbers 48 Volt Failed, 3–2 A Adjustments, 4–1 hammer phasing, 4–4 paper drive motor pulley alignment, 4–10 paper feed timing belt tension, 4–6 paper scale, 4–2 platen angle, 4–16 platen gap, 4–18 platen open belt, 4–8 platen open motor pulley alignment, 4–12 ribbon guide, 4–20 splined shaft skew adjustment, 4–14 Appendices: Ferrite Noise Suppression Cores, F–1 Interconnection Diagram and Cables, D–1 Principles of Operation, E–1 Printer Configuration, A–1 Printer Specifications, B–1 Torque Table, C–1
printing conventions, 1–3 Cores, noise suppression, F–1 Cover assembly hammer bank, replacement, 5–22 shuttle, replacement, 5–24 Covers and doors, locations and operation, 1–4 D Diagnostic self–tests, 3–26 Diagram configuration, A–7 interconnection and cables, D–1 Dimensions, printer, B–3 48 Volt Failed, 3–2 Dynamic RAM Fault, 3–4 Ham. Bank Hot, 3–5 Ham. Coil Open, 3–6 Ham. Coil Short, 3–7 Ham. Drv.
Hex code printout, 3–29 Mech Driver Link, 3–10 Hub, ribbon, replacement, 5–58 Mechanism driver PCBA, replacement, 5–48 Messages, fault, 3–2 I ICs, location and replacement CCB, 5–52 Mech. Driver, 5–54 Motor paper feed drive, replacement, 5–38 platen open, replacement, 5–40 ribbon drive, replacement, 5–36 Important notes, 1–2 MPU.
Part Numbers, 5–3 PCBA, replacement controller, 5–46 mechanism driver, 5–48 power supply, 5–50 Phasing adjustment, 4–4 Physical Inspection, 2–3 Platen angle adjustment, 4–16 gap adjustment, 4–18 interlock switch assembly, replacement, 5–78 platen open belt adjustment, 4–8 platen open motor, replacement, 5–40 Platen Open, 3–13 Plot, rates, B–6 PMCS.
mechanism driver PCBA, 5–48 multi I/O cable assembly, 5–14 paper detector switch assembly, 5–76 paper feed drive motor, 5–38 paper feed timing belt, 5–4 paper guide assembly, 5–42 paper ironer, 5–44 platen interlock switch assembly, 5–78 platen open belt, 5–6 platen open motor, 5–40 power supply PCBA, 5–50 PROMs CCB, 5–52 Mech.
platen interlock switch assembly, replacement, 5–78 Switch, power, replacement, 5–18 Switches, locations and operation, 1–6 T Tension adjustment paper feed timing belt, 4–6 platen open belt, 4–8 Terminating resistors location of, 5–57 replacement, 5–56 Test equipment, tools, and supplies, 1–10 printer performance, 3–26 Tools, test equipment, and supplies, 1–10 Torque table, C–1 Tractor, replacement, 5–80 Troubleshooting, 3–1 fault messages, 3–2 W Warnings, 1–2 Wiring diagram, hammer bank, D–1 6
