LG plus Series Text and Graphics Printers TM Maintenance Manual Order Number: EK–LGPLE–MM.
FCC Notice This equipment has been tested and found to comply with the limits of a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide a reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications.
All Rights Reserved. December 1995. 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.
Table of Contents 1 Maintenance Overview About the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 Important Maintenance Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 Notes and Notices . . . . . . . . . . . .
Printer Confidence Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–34 Diagnostic Printer Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–35 Selecting and Running Diagnostic Printer Tests . . . . . . . . . . . . . . . . . . . 3–37 Hidden Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–39 Hex Code Printout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14 Cover Assembly, Hammer Bank / Ribbon Mask . . . . . . . . . . . . . . . . . . . . . . 5–15 Cover Assembly, Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16 Fan Assembly, Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–17 Fan Assembly, Cabinet Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–14. Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–67 Figure 5–15. Motors, Fans, and Paper Detector Switch . . . . . . . . . . . . . . . . . 5–69 Figure 5–16. Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–71 6 Principles of Operation Line Matrix Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2 Printing Mechanism . . . . . . . . . . . . . . . . . . .
1 Maintenance Overview Chapter Contents About the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 Important Maintenance Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 Notes and Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About the Printer The LG plus Series is a family of line matrix printers: The LG04 plus prints at a maximum rate of 475 lines per minute (lpm). The LG08 plus prints at a maximum rate of 800 lpm, and the LG12 plus has a maximum print rate of 1200 lpm. Each model is housed in a quiet floor cabinet. These rugged and reliable line printers represent the state of the art in line matrix printing technology.
About This Manual This is a field service maintenance manual. It is designed so that you can quickly locate maintenance information. How to Use This Manual 1. Locate the procedure or information you need: ♦ Use the Table of Contents at the front of the manual. ♦ Use the Chapter Contents listed at the front each chapter. ♦ Use the Index at the back of the manual. 2. Read the entire procedure before you do it. 3. Gather the parts and tools you will need. 4. Read the Safety Notices on page 1–6.
Related Documents This manual does not explain how to operate or configure the printer. For that information, refer to the following documents: 1–4 ♦ LGplus Series Operator’s Guide (Order Number EK–LGPLE–OG.A01) ♦ LGplus Series Setup Guide (Order Number EK–LGPLS–SG.A01) ♦ LGplus Series Line Printer Plus Programmer’s Reference Manual (Order Number EK–LGPLE–RM.A01) ♦ LGplus Series (LG) Programmer’s Reference Manual (Order Number EK–LGPLP–RM.
Printing Conventions in This Manual BOLD UPPERCASE print indicates control panel keys. Example: Press the CLEAR key, then press the ON LINE key. Quotation marks (“”) indicate messages you see on the Liquid Crystal Display (LCD). Example: Press the ON LINE key. “Off Line” appears on the LCD. The + (plus) symbol represents key combinations. Example: “Press Y + B ” means press the Y (UP) key and the B (DOWN) key at the same time. Some printer controls have no label on the printer.
Safety Notices WARNING To prevent serious personal injury from electrical shock when connecting or disconnecting the signal cable, set the printer power switch to the off position and unplug the power cable. WARNING Always disconnect the AC power cord from the power source before performing any maintenance procedure. Failure to remove power could result in injury to persons or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure.
Hinweise zur Sicherheit GERMAN VORSICHT Um ernstliche körperliche Verletzungen durch Stromschlag beim Anschließen oder Trennen des Signalton-Kabels zu vermeiden, muß der Drucker auf jeden Fall ausgeschaltet und der Netzstecker herausgezogen werden. VORSICHT Bevor Sie anfällige Wartungsarbeiten durchführen, müssen Sie zuerst immer das Netzkabel aus der Steckdose ziehen. Wird das Netzkabel nicht herausgezogen, können Verletzungen oder Geräteschäden entstehen.
Controls and Indicators Electrical Controls and Indicators (Figure 1–1) Switch or Indicator Active when printer is: Online Offline Toggles the printer online and offline. n n FF Advances paper to top of form on next page. n n LF Advances paper to top of next print line. Power Switch Turns printer on and off: 1 = on, 0 = off. This switch is also a circuit breaker. Status Lamp On when the printer is online, off when printer is offline. Flashes to indicate a fault or warning.
(Off) (On) Power Switch Status Lamp CLEAR UP R/S PREV NEXT Liquid–Crystal Display (LCD) SET TOF ON LINE FF LF VIEW ENTER DOWN RAISE PRINTER COVER TO USE THESE SWITCHES Figure 1–1.
Mechanical Controls and Indicators Control or Indicator Function Forms Thickness Lever Sets the platen for paper and forms of different thicknesses. Lever must be fully opened (raised) to load or unload paper. Forms Thickness Pointer and Scale Indicates relative thickness of forms/paper. Set this lever at A for thin (single–part) forms, B for thicker forms, and so on. Tractors (2) Hold and feed paper. Used to set side margin and position paper horizontally.
Paper Scale Left Tractor Right Tractor Horizontal Adjustment Knob Tractor Lock Vertical Position Knob Tractor Lock Ribbon Loading Path Diagram Forms Thickness Lever and Scale Forms Thickness Pointer Figure 1–2.
Tools, Test Equipment, and Supplies Listed below are the tools and equipment required for field level maintenance of the printer. Item Adapter, 1/4 in. hex to 1/4 in. square, Utica HW–18 Part No. 29–24723–00 Alcohol Diagonal cutters Digital voltmeter ESD Wrist Strap Extension, 3 in., 3/8 in. drive Feeler gauge set Force Gauge, (ChatillonT NY, Gauge–r, 0–20 lb.) CAT 719–20 Hex bit, 3/16 in., torque screwdriver 29–20995–00 Hex bit, 3/32 in., torque screwdriver 29–18505–00 Hex bit, 5/32 in.
2 Scheduled Maintenance Chapter Contents Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . . 2–2 Inspecting the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3 Cleaning the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4 Cleaning the Cabinet and Print Mechanism . . . . . . . . . . . . . . . . 2–4 Cleaning the Shuttle Frame Assembly . . . . . . . . . . . . . . . . . . . .
Preventive Maintenance Checks and Services Perform preventive maintenance checks and services at the intervals specified in Table 2–1. Do these checks more often if the printer is used for heavy–duty, continuous printing or is located in a dusty area. WARNING Always disconnect the AC power cord before performing scheduled maintenance. 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 What 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 WARNING Always disconnect the ac power cord before 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. Do not spray directly onto the printer when using spray solutions (spray the cloth, then apply the dampened cloth to the printer). Do not vacuum the circuit boards. NOTE: The cleaning procedures in this chapter are the same for all models.
10. Vacuum up dust and residue from the lower cabinet. 11. Wipe the interior of the lower cabinet with a clean, lint–free cloth dampened with water and a mild detergent or window cleaning solution. 12. Dry the cabinet interior with a clean, lint–free cloth. Splined Shaft Tractor Shuttle Cover Assembly Base Casting Forms Thickness Lever Ribbon Guide (2) Figure 2–1.
Cleaning the Shuttle Frame Assembly 1. Remove the shuttle cover assembly (page 5–16). 2. Remove the shuttle frame assembly (page 5–42). 3. Remove the paper ironer (page 5–28). 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 alcohol. Wipe the paper ironer to remove lint, ink, and paper residue. 5. Install the paper ironer (page 5–28). 6.
9. Install the hammer bank cover assembly (page 5–15). 10. Install the shuttle frame assembly (page 5–42). 11. Install the shuttle cover assembly (page 5–16). 12. Clean the card cage fan assembly (page 2–8). Hammer Bank Cover (Thick plate) Ribbon Mask (Thin plate) Hammer Bank Cover Assembly Alignment Pin (2) (See below) Hammer Tip NOTE: 475 LPM Hammer Bank shown Hammer Bank Cover Alignment Pin Figure 2–2.
Cleaning the Card Cage Fan Assembly 1. Remove the paper path (page 5–29). 2. Vacuum the card cage fan assembly and surrounding areas to remove paper particles, dust, and lint. (See Figure 2–3.) 3. Install the paper path (page 5–29). 4. Close the printer cover. 5. Connect the ac power cord to the printer and the power source. Card Cage Fan Assembly Figure 2–3.
3 Troubleshooting Chapter Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 Troubleshooting Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 LCD Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3 Symptoms Not Indicated by Fault Messages . . . . . . . . . . . . . . . . . . 3–29 Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction This chapter contains procedures for troubleshooting printer malfunctions. This manual does not cover printer operation or configuration, but you must operate the printer to check its performance, and sometimes you may have to reconfigure the printer. Therefore, have the Operator’s Guide and the Setup Guide handy when you troubleshoot the printer. Troubleshooting Aids Troubleshooting is faster and more effective if you understand the equipment and make use of all available tools.
LCD Messages WARNING Always disconnect the AC power cord from the power source before doing any maintenance procedure. Failure to remove power could result in injury to you or damage to equipment. If you must apply power during maintenance, you will be instructed to so in the maintenance procedure.
Table 3–1. LCD Message Troubleshooting Table Displayed Message Explanation Solution 8.5V PWR FAIL* Internal power failure. Cycle power. If message recurs, replace one at a time until message clears: a) power supply board b) controller board 15V CTL FAIL* Controller voltage failure. Cycle power. If message recurs, replace one at a time until message clears: a) controller board b) power supply board 23.5V CTL FAIL* Controller voltage failure. Cycle power.
Displayed Message Explanation Solution CTL VOLT FAIL* Controller voltage failure. Replace CMX controller board. DRVR CIR BAD* Hammer coil count test failed. Page 3–14 EXHAUST FAN FLT Sensors cannot detect current in fan circuit. Page 3–15 FIRMWARE ERROR Application software tried to perform an illegal printer function or damaged memory detected on CMX board. Page 3–16 FRAMING ERROR Serial framing error. (Serial interface.) Page 3–25 HAM.
Displayed Message Explanation Solution LOAD PAPER Printer is out of paper. Load paper. If message recurs, see page 3–20. PAP BAD TABLE* Fatal firmware error on CMX controller board. Cycle power and rerun print job. If message recurs, replace CMX controller board. PAP BSY TOO LNG* Fatal firmware error on CMX controller board. Cycle power and rerun print job. If message recurs, replace CMX controller board. PAP FIFO OVERFL* Fatal firmware error on CMX controller board.
Displayed Message Explanation Solution PAP NT AT SPEED* Fatal firmware error on CMX controller board. Cycle power and rerun print job. If message recurs, replace CMX controller board. PAP UNEXP INT* Fatal firmware error on CMX controller board. Cycle power and rerun print job. If message recurs, replace CMX controller board. PARITY ERROR Parity error. (Serial interface.) Page 3–25 PLAT INV CMD* Fatal firmware error on CMX controller board. Cycle power and rerun print job.
Displayed Message Explanation Solution RIB INVLD CMD* Fatal firmware error on CMX controller board. Cycle power and rerun print job. If message recurs, replace CMX controller board. RIB INVLD STATE* Fatal firmware error on CMX controller board. Cycle power and rerun print job. If message recurs, replace CMX controller board. RIBBON DRIVE CMX controller does not detect ribbon drive motor.
Displayed Message Explanation Solution TCB CORRUPTED* Fatal firmware error on CMX controller board. Cycle power and rerun print job. If message recurs, replace CMX controller board. UNDEF INTERRUPT* Fatal firmware error on CMX controller board. Cycle power and rerun print job. If message recurs, replace CMX controller board. UNDFNED OPCODE* Fatal firmware error on CMX controller board. Cycle power and rerun print job. If message recurs, replace CMX controller board. UP DRV.
CLEAR PAPER JAM Instruction 1. a) Load paper. b) Press the FF key several times. Indication Yes No Forms feed without erratic motion, noise, or pin–hole damage. Go to step 2. If pin holes are damaged, go to step 4. For erratic motion or noise, go to step 6. 2. Press the VIEW key twice. Forms move correctly in both directions, without jamming, tearing, or folding. Suspect a false indication. Go to step 9. Go to step 3. 3. Check the platen open belt. Platen open belt OK.
CLOSE PLATEN Instruction Indication Yes No 1. Load paper. Close the forms thickness lever. Run an operator print test. “CLOSE PLATEN” message. Go to step 2. Return printer to normal operation. 2. Power off the printer. Disconnect the platen interlock switch connector. Check the switch with a meter. Switch is bad. Replace platen interlock switch assembly. Replace CMX controller board.
COIL HOT NOTE: The printer has sensor circuits that sample the operating temperature of key print components. When higher than normal temperatures are sensed, print speed is automatically reduced. If the printer runs at reduced speed for an extended period of time, a (UNIT) HOT message is sent to the LCD and printing stops, allowing printer components to cool down. Pressing the CLEAR key resumes the print task. If the printer often prints at half speed, it may be operating in a severe environment.
Instruction Indication Yes No 7. Examine printer environment for severity. (See NOTE above.) Printer environment is OK. Go to step 9. Move printer to cooler, cleaner location. 8. Check the kinds of print jobs the user is running: look for very dense graphics and layouts. Print jobs are dense enough to slow the printer. Advise the user to run jobs in smaller batches.
DRVR CIR BAD* Instruction Indication Yes No 1. Cycle power: Power off printer. Wait 15 seconds. Power on printer. “DRVR CIR BAD*” message. Go to step 2. Return printer to normal operation. 2. Press the CLEAR key. “DRVR CIR BAD*” message. Go to step 3. Return printer to normal operation. 3. a) Power off the printer. b) Remove the shuttle cover. c) At the shuttle frame assembly, disconnect the hammer bank logic and power cables. d) Power on the printer. “HB NOT INSTALLD*” message.
(EXHAUST) (HMR BANK) (INTAKE) FAN FLT Instruction Indication Yes No 1. Cycle power: Power off printer. Wait 15 seconds. Power on printer. “_____ FAN FLT” message. Go to step 2. Return printer to normal operation. 2. a) Power off the printer. b) Remove the paper path. c) Check that the fan cable connector is connected. (See Appendix A, Interconnect Diagram.) Fan cable is properly connected. Go to step 3. Connect the fan cable connector. 3. Check for obstruction of vents and fan airway.
FIRMWARE ERROR Instruction Indication Yes No 1. Cycle power: Power off printer. Wait 15 seconds. Power on printer. “FIRMWARE ERROR” message. Replace the CMX controller board. Go to step 2. Return printer to normal operation. 2. a) Power on the printer. b) Run the print job that was active when the fault message first occurred. “FIRMWARE ERROR” message. Application software error. Use your local support procedure to request assistance. Return printer to normal operation.
HAM. COIL OPEN * Instruction Indication Yes No 1. Cycle power: Power off printer. Wait 15 seconds. Power on printer. “HAM. COIL OPEN * ” message. Go to step 2. Return printer to normal operation. 2. Press the CLEAR key. “HAM. COIL OPEN * ” message. Replace the shuttle frame assembly. Go to step 3. Return printer to normal operation. 3. a) Power on the printer. b) Run a diagnostic printer test. “HAM. COIL OPEN * ” message. Replace the CMX controller board.
HB NOT INSTLD * Instruction Indication Yes No 1. a) Power off the printer. b) Remove the shuttle cover. c) Verify that the shuttle frame assembly is installed. Shuttle frame assembly is installed in the printer. Go to step 2. Install the shuttle frame assembly. 2. a) Remove the paper path. b) Verify that the hammer bank logic cable is connected to connector J108 on the CMX controller board and to its connector on the shuttle frame assembly.
LO DRV. SHORT Instruction Indication Yes No 1. Cycle power: Power off printer. Wait 15 seconds. Power on printer. “LO DRV. SHORT” message. Go to step 2. Return printer to normal operation. 2. Press the CLEAR key. “LO DRV. SHORT” message. Replace the shuttle frame assembly. Go to step 3. Return printer to normal operation. 3. Power on the printer. “LO DRV. SHORT” message. Replace the CMX controller board. Go to step 4. Return printer to normal operation. 4. Power on the printer. “LO DRV.
LOAD PAPER Instruction Indication Yes No 1. Load paper. Run a diagnostic printer test. “LOAD PAPER” message. Replace paper detector switch assembly. Go to step 2 Return printer to normal operation. 2. Run a diagnostic printer test. “LOAD PAPER” message. Replace the CMX controller board. Return printer to normal operation.
POWER SUPPLY HOT NOTE: The printer has sensor circuits that sample the operating temperature of key print components. When higher than normal temperatures are sensed, print speed is automatically reduced. If the printer runs at reduced speed for an extended period of time, a (UNIT) HOT message is sent to the LCD and printing stops, allowing printer components to cool down. Pressing the CLEAR key resumes the print task. Check the operating environment.
Instruction Indication Yes No 7. Check for obstruction of vents and fan airways. Vents and airways are clear. Go to step 8. Remove obstructions. Make sure cabinet exhaust fan vents are not blocked. (Check for items beneath the printer blocking cabinet vents.) 8. Examine printer environment for severity. (See NOTE above.) Printer environment is OK. Go to step 9. Move printer to cooler, cleaner location. 9.
PRINTER HOT NOTE: This message indicates internal temperatures over 60° Celsius (140° Fahrenheit). Print jobs will not create such temperatures, so immediately determine that the fans are operating and that all air vents are unobstructed. It is crucial that the exhaust vents on the floor of the cabinet remain unblocked, since hot air from inside the printer is vented through the cabinet floor. Nothing should be stored under the printer. Then check the operating environment.
RIBBON DRIVE Instruction Indication Yes No 1. Cycle power: Power off printer. Wait 15 seconds. Power on printer. “RIBBON DRIVE” message. Go to step 2. Return printer to normal operation. 2. a) Power off printer. b) Check cable connections of both ribbon driver motors. (Refer to Appendix A.) Ribbon drive motor cables connected properly. Go to step 3. Attach ribbon drive motor cables. Go to step 3. 3. a) Power on the printer.
Serial Interface Messages Instruction 1. a) Make a configuration printout. (Ref.: Setup Guide) Indication Yes Host and printer serial interface parameters match. Go to step 2 Set printer serial interface parameters to match those of the host. (Ref.: Setup Guide) Job prints OK and no serial interface fault messages appear. Return printer to normal operation. Replace the CMX controller board.
SHUTTLE JAM Instruction Indication Yes No 1. Check the forms thickness lever: if it is set too tightly, it can slow the shuttle enough to trigger the fault message. Forms thickness lever set correctly. Go to step 2. Set forms thickness lever for thicker paper. Go to step 2. 2. Run a diagnostic printer test and check for shuttle obstruction. “SHUTTLE JAM” message. Go to step 3. Return printer to normal operation. 3. a) Remove shuttle cover and paper path.
SOFTWARE ERROR * Instruction Indication Yes No 1. Cycle power: Power off printer. Wait 15 seconds. Power on printer. “SOFTWARE ERROR * ” message. Go to step 2 Return printer to normal operation. 2. Disconnect the input data line from the host computer. Cycle power: Power off printer. Wait 15 seconds. Power on printer. “SOFTWARE ERROR * ” message. Replace the CMX controller board. Not a printer problem. Application software error. Request assistance from your local support group.
UP DRV. SHORT Instruction Indication Yes No 1. Cycle power: Power off printer. Wait 15 seconds. Power on printer. “UP DRV. SHORT” message. Go to step 2. Return printer to normal operation. 2. Press the CLEAR key. “UP DRV. SHORT” message. Replace the CMX controller board. Go to step 3. Return printer to normal operation. 3. Power on the printer. “UP DRV. SHORT” message. Replace the shuttle frame assembly. Go to step 4. Return printer to normal operation. 4. Power on the printer. “UP DRV.
Symptoms Not Indicated by Fault Messages Use standard fault–isolation techniques to troubleshoot malfunctions not indicated by fault messages. These techniques are summarized below: 1. Ask the operator to describe the problem. 2. Verify the fault by running diagnostic tests or replicating conditions reported by the user. 3. Look for a match in the “Symptoms Not Indicated by Fault Messages Troubleshooting Table” on page 3–30, and follow the instructions given. 4.
Symptoms Not Indicated by Fault Messages Troubleshooting Table Symptom Instruction No power, control panel LCD and LEDs blank, card cage fan not running. 1. +5 volt distribution problem to the controller board. (See Power Distribution Diagram, page A–3.) Power on hang condition. 1. Replace one at a time until the problem is fixed: a) CMX controller board (page 5–10) b) power supply (page 5–12) Blank or single line of black squares across top row of control panel LCD. 1. Power off printer.
Symptom Printer prints data sent from the host, but occasionally prints double characters, random ! or * characters, or loses blocks of data. Instruction 1. If the printer prints from the host, but occasionally loses blocks of data, the most likely cause is the host not responding to “send no more data” signals from the printer. With a Centronics interface, this means the host is ignoring BUSY; in RS–232, the host is ignoring the XOFF character or “Data Terminal Ready” signal (pin 20).
Print Quality Problems Missing, light, or smeared characters or dots: All characters or dots are too light or too dark. 1. Check the forms thickness lever setting. 2. Check the ribbon for folds or tears. 3. Clean the shuttle frame assembly (page 2–6). 4. Check the platen gap adjustment (page 4–12). 5. Replace one at a time until problem is fixed: a) shuttle frame assembly (page 5–42) b) controller board (page 5–10) 1. Check the forms thickness lever setting. 2.
Print Quality Problems Garbled print or paper slews uncontrollably. 1. a) Put the printer in hex dump mode and analyze the binary data. One cause of garble is the host interface or cable not transmitting all 8 data bits. When this occurs, the Centronics interface receives a 1 on every unconnected data line. Uncontrolled slewing is often caused by enabling PI (Paper Instruction) in the printer when the host lacks a PI signal. (PI shows as “p” on the hex dump printout.
Printer Confidence Check Instruction Indication Yes No 1. Check that printer is plugged into correct power source. Power cable installed correctly to proper source. Power off printer. Go to step 2. Power off the printer. Connect printer to correct power source. 2. Power on the printer. Printer initializes correctly and goes to online or offline state, depending on power–up configuration. Go to step 3 Troubleshoot the fault message (page 3–3). 3. Run an operator print test (page 3–35).
Diagnostic Printer Tests A set of printer tests is included in the configuration menu structure for use as diagnostic and maintenance tools. You can use these printer tests to check the print quality and basic operation of the printer. In addition, you will use some of these tests in various troubleshooting and adjustment procedures.
3–36 ♦ Phase Printer A hammer timing test that permits you to adjust the hammer phase value. The hammer phase value is a timing parameter that controls the vertical alignment of dots in character printing. The numerical units are relative; they do not represent a physical measurement or value. There is no “correct” value or range. The factory prints the initial phase value on the aluminum casting of the shuttle assembly, next to the motor housing.
Selecting and Running Diagnostic Printer Tests Step Key Result 1. a) Load paper. b) Install the ribbon. c) Set top–of–form. (Refer to the Operator’s Guide.) 2. Press: ON LINE 3. + Notes OFFLINE CONFIG. CONTROL The printer must be offline to select diagnostic tests. ENTER SWITCH UNLOCKED Allows you to make configuration changes. OFFLINE CONFIG. CONTROL 4. UNTIL 5. DIAGNOSTICS Printer Tests 6. UNTIL 7. 10. 11. Troubleshooting DIAGNOSTICS Test Width Test Width Full Width* 8. 9.
Step Key Result 12. Printer Tests Shift Recycle* 13. OR 14. To start test: R/S 15. To stop test: R/S 16. 17. Notes Printer Tests All E’s* Printer Tests All E’s* + CLEAR Printer Tests All E’s Cycle through the choices. Refer to page 3–35. The test runs. Stops tests. ENTER SWITCH LOCKED Locks the configuration parameters. OFFLINE CONFIG. CONTROL Moves the printer out of the menus to offline. 18. Examine the print quality.
Hidden Diagnostic Menu Printer boot–up software contains a hidden menu structure that you can access by holding down the A (PREV) and B (DOWN) keys while powering up the printer. These menus are not intended for the end user, but provide useful information for manufacturing and maintenance personnel. The hidden diagnostic menu is a multi–level menu that operates the same way as the user menus. The hidden diagnostic menu is depicted in Figure 3–1. To exit the hidden diagnostic menu, you must recycle power.
BOOT DIAGNOSTICS PRESS ENTER B (DOWN) BOOT DIAGNOSTICS VERSION CHECK B (DOWN) VERSION CHECK BOOT VERSION B (DOWN) BOOT/CMX V100H 12Sep95 #154669 VERSION CHECK SOFTWARE VERSION 09/08/95 11:41:08 VERSION CHECK EC VERSION EC V1.
Hex Code Printout A hex code printout (“hex dump”) lists each ASCII data character received from the host computer and lists its corresponding two-digit hexadecimal code. (See Figure 3–2.) Hex dumps can be used to troubleshoot some types of printer data reception problems. Every printable character prints both as its assigned symbol and as its hex equivalent. Every nonprintable (ASCII control) character prints both as a period (.) and as its hex equivalent.
Making a Hex Code Printout Step Key Result 1. Make sure the printer is on. Raise the printer cover. 2. Press: ON LINE 3. Notes OFFLINE CONFIG. CONTROL + ENTER SWITCH UNLOCKED Allows you to make configuration changes. OFFLINE CONFIG. CONTROL 4. UNTIL 5. MAINT / MISC Hex Dump Mode 6. Hex Dump Mode Disable 7. 8. OR ENTER 9. 10. OFFLINE MAINT / MISC + ON LINE Hex Dump Mode Enable Cycle through the choices. Hex Dump Mode Enable * Asterisk (*) indicates this choice is active.
ASCII Character Set B7 0 B6 KEY B6 0 0 B5 BITS 0 0 1 B4 B3 B2 B1 1 0 B7 0 B5 BITS 0 1 0 1 1 OCTAL equivalent DECIMAL equivalent HEX equivalent ASCII Character 33 27 1B ESC 1 0 1 0 1 0 1 1 0 0 1 1 1 1 0 1 1 COLUMN 0 B4 B3 B2 B1 ROW 1 0 0 0 0 0 NUL 0 0 0 0 0 0 1 1 SOH 1 1 1 0 0 1 0 2 STX 2 2 2 DC2 0 0 1 1 3 ETX 3 3 3 0 1 0 0 4 EOT 0 1 0 1 5 0 1 1 0 DLE DC1 (XON) 2 20 16 10 21 17 11 SP ! 3 40 32 20 41 33 21 4 0 60 48 30 1 61 49 31 5
3–44 Troubleshooting
4 Adjustment Procedures Chapter Contents Preparing the Printer for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 4–2 Returning the Printer to Normal Operation . . . . . . . . . . . . . . . . . . . . 4–3 Belt, Paper Feed Timing, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4–4 Belt, Platen Open, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6 Paper Drive Motor Pulley Alignment . . . . . . . . . . . . . . . . . . . . . . . . 4–8 Paper Scale Alignment . .
Preparing the Printer for Maintenance WARNING Unplug the printer power cord from the power outlet before you do any maintenance procedure. Failure to remove power could result in injury to you or damage to equipment. If you must apply power during maintenance, you will be instructed to so in the maintenance procedure. Always do the following before performing any maintenance: 1. Set the printer power switch to O (off). 2. Unplug the printer power cord from the AC power source. 3. Unload paper. 4.
Returning the Printer to Normal Operation When you have finished servicing the printer, restore it to operation by following the steps below: 1. Install the ribbon. 2. Plug the AC power cord into the printer and the power source. 3. Set the printer power switch to | (on). 4. Load paper. 5. Close the cabinet doors and the printer cover. 6. Test printer operation by selecting and running one of the diagnostic print tests. (See Chapter 3.) 7. Select the emulation.
Belt, Paper Feed Timing, Adjustment (Figure 4–1) 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the paper path (page 5–29). 4. Loosen four screws and remove the barrier shield (page 5–59, Figure 5–10). 5. Remove the timing belt cover (1) by squeezing the top and bottom to release the plastic tabs from the slots in the side plate. 6. Loosen (do not remove) the motor mount bolts (2). 7. Using the straight end of a force gauge, apply 15 pounds (66.
Direction of Force 4 1 2 3 2 1. 2. 3. 4. Timing Belt Shield Motor Mount Bolt (2) Paper Feed Drive Motor Splined Shaft Figure 4–1.
Belt, Platen Open, Adjustment (Figure 4–2) 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.
1. Belt Cover 2. Motor Mount Screw 3. Platen Open Motor Shaft 2 Direction of Force 1 3 2 Figure 4–2.
Paper Drive Motor Pulley Alignment (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 screw (2) in the motor pulley collar (3). 5. Align the paper drive motor pulley (4) with the splined shaft pulley (5). CAUTION Make sure there is at least 0.040 inches (1.016 mm) of clearance between the collar (3) and the motor face plate.
5 2 4 1 3 1. 2. 3. 4. 5. Belt Shield Cap Screw Motor Pulley Collar Motor Pulley Splined Shaft Pulley Figure 4–3.
Paper Scale Alignment (Figure 4–4) 1. Load paper and ribbon. 2. Connect the power cord to the AC power source. 3. Set the printer power switch to 1 (on). 4. Open the printer cover. 5. Verify that the shuttle cover (1) is properly installed (page 5–16). 6. Print a full 132 column line by selecting and running one of the diagnostic self–tests. (See Chapter 4.) 7. Check alignment of the scale to the print at column positions 1 and 132. 8.
3 2 2 1 1. Shuttle Cover 2. Screw, Button–Head, 5/64 inch hex (3) 3. Paper Scale Figure 4–4.
Platen Gap Adjustment (Figure 4–5) IMPORTANT Only do this procedure if the original equipment shuttle frame assembly or platen has been replaced by a new or refurbished unit. 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the shuttle cover assembly (page 5–16). 4. Remove the ribbon. 5. Loosen the platen open belt (page 4–6, steps 3 and 4). 6. Raise the forms thickness lever (1) to the fully open position. CAUTION Do not force the platen against the feeler gauge.
9. Repeat steps 6 through 8 at the right end of the hammer bank. 10. After adjusting both sides, check the gap again at both ends. Readjust if necessary. 11. When the platen gap is correct at both ends of the platen, adjust the platen open belt (page 4–6). 12. Install the shuttle cover assembly (page 5–16). 13. Check the hammer phasing adjustment (page 4–25). 14. Return the printer to normal operation (page 4–3). 1. 2. 3. 4. 5. Forms Thickness Lever Feeler Gauge (0.011 inch or 0.
Platen Open Motor Pulley Alignment (Figure 4–6) 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. 5. Bottom out the platen open motor pulley (3) on the motor shaft and torque the set screw (2) to 9 ± 2 inch–pounds (1.02 ± 0.23 NSm). 6. Check the platen open belt tension (page 4–6).
1. 2. 3. 4. Belt Cover Set Screw Platen Open Motor Pulley Platen Shaft Pulley 2 1 3 4 Figure 4–6.
Ribbon Guide Alignment (Figure 4–7) 1. Open the printer cover. 2. Load paper and install the ribbon. To adjust the left ribbon guide, the ribbon should have a full spool on the right hub (1). 3. Run a ribbon and shuttle diagnostic self–test. (See Chapter 4.) 4. To adjust the left ribbon guide, 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).
6 1 2 4 3 7 5 3 1. 2. 3. 4. 5. 6. 7. Right Hub Screw, Left Ribbon Guide Skid (2) Ribbon Ribbon Guide, Left Screw, Retaining (2) Left Ribbon Spool Ribbon Guide, Right Figure 4–7.
Splined Shaft Skew Adjustment (Figure 4–8) If lines of print are not parallel with the edge perforations on the paper, perform the following adjustment. 1. Prepare the printer for maintenance (page 4–2). 2. Loosen the screw (1) securing the adjusting link (2). 3. Adjust the link (2) by raising or lowering the horizontal adjustment knob (3) to obtain print parallel with paper perforations. Tighten the screw (1). 4. Return the printer to normal operation (page 4–3).
1 3 2 1. Screw 2. Adjusting Link 3. Horizontal Adjustment Knob Figure 4–8.
Adjusting the End of Forms Distance This procedure tests and sets the distance from the page perforation at which a LOAD PAPER message is triggered. This adjustment prevents printing on the platen when the printer runs out of paper. The measurement units are dot rows. You will use the dot row patterns printed by the Paper Out Dots printer test to verify that this parameter is set correctly.
Page Perforation Page Perforation 4 in. 4 in. Page Perforation Figure 4–9.
5. Tear a four inch square in the manner described above, on every third sheet, until you have made 3 or 4 holes. 6. If the printer is online, press the ON LINE key to place the printer offline. 7. Raise the printer cover. 8. On the control panel, press the Y + B keys to unlock the ENTER key. “ENTER SWITCH UNLOCKED” briefly displays. (If “LOCKED” displays, simply press Y + B again.) 9. Press the B key. “CONFIG CONTROL” displays. 10. Press the A key. “DIAGNOSTICS” displays. 11. Press B.
15. Measure how short or long the comb pattern printed by counting the number of dot rows needed to reach the perforation, or the number of dot rows that printed beyond the perforation. NOTE: You can use the long bars to count the dot rows quickly. There are three dot rows between each long bar, so each long bar increases the number of dot rows by four.
29. Close the printer cover. 30. Press the ON LINE key to place the printer online.
Hammer Phasing Adjustment You must check and adjust hammer phasing if the CMX controller board is replaced, the shuttle frame assembly is removed, or if the MPU is replaced. The hammer phase value is a timing parameter that permits you to adjust the vertical alignment of dots in character printing. The phase value numerical units are relative; they do not represent a physical measurement or value. Thus there is no “correct” value or range.
10. Press B. “Printer Tests / Shift Recycle” displays. 11. Press A until “Printer Tests / Phase Printer” displays. 12. Press ENTER. The top line of the display will show “Phase Printer” and the bottom line will show the current phasing index value. 13. Press ENTER. The phasing index value (followed by an asterisk) will move up to the top line of the display. The printer begins printing all Hs, each line preceded by the phasing index value. 14.
Installing Software Flash memory is contained in one or two single in–line memory modules (SIMMs) located on the controller board.
8. Make the diskette drive the active drive by typing the following at the DOS prompt: A: (If the diskette is in drive B, type B:) 9. Get the name of the compressed file on the diskette by listing the contents of the diskette; at the DOS prompt type: DIR The compressed file on the diskette takes the form FILENAME.EXE Write down the complete name of the file with the .EXE extension. 10. On the printer operator panel, press and hold down the ONLINE + FF keys.
17. Power off the personal computer. 18. If you had to install a parallel data cable to the computer and printer in step 2, disconnect it from the computer and printer. 19. Reconnect the data input cable(s) to the printer. 20. Return the printer to normal operation (page4–3). 21. Using the configuration printout(s) you made in step 1, reconfigure the printer. (Refer to the Setup Guide.) Table 1.
Message ERROR: FLASH NOT DETECTED ERROR: NO DRAM DETECTED ERROR: NVRAM FAILURE ERROR: PROGRAM NEEDS MORE DRAM ERROR: PROGRAM NEEDS MORE FLASH ERROR: PROGRAM NOT COMPATIBLE ERROR: PROGRAM NOT VALID ERROR: SHORT AT ADDRESS XXXX 4–30 Required Action Explanation The printer could not find any flash memory. Install flash memory before attempting to download this program. The printer could not find any DRAM. Check DRAM on CMX. If present, reseat DRAM, If missing, install DRAM.
Message ERROR: WRITING TO FLASH ERROR: WRONG CHECKSUM LOADING PROGRAM FROM PORT XX% LOADING PROGRAM INTO FLASH RESETTING . . . PLEASE WAIT RESTORING BOOT CODE SECURITY CODE VIOLATION SENDING PROGRAM TO EC PROCESSOR Adjustment Procedures Explanation Required Action Hardware or software fault in flash memory. Download the program again. Go back to step 10. If the message occurs again, replace the flash memory. The printer received the complete program but the checksum did not match.
4–32 Adjustment Procedures
5 Replacement Procedures and Illustrated Parts List Chapter Contents Organization of This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4 Section I: Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . 5–4 Belt, Paper Feed Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5 Belt, Platen Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7 Cable Connectors and Connector Shells . . . . . . . . . . . . .
Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–29 Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–30 Resistors, Terminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–35 Ribbon Guide Assembly (L/R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–37 Ribbon Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section II: Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–51 Figure 5–7. Top Cover, Doors, and Casters . . . . . . . . . . . . . . . . . . . . 5–53 Figure 5–8. Paper Fence and Chains . . . . . . . . . . . . . . . . . . . . . . . . . 5–55 Figure 5–9. Operator Panel and Cabinet Details . . . . . . . . . . . . . . . . 5–57 Figure 5–10. Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–59 Figure 5–11. Print Mechanisms and Circuit Boards . . . .
Organization of This Chapter This chapter is divided into two sections. ♦ Section I: Replacement Procedures This section consists of written procedures for removing and installing the components that are replaceable at the field service level of maintenance. Section I begins on this page. The removal/installation procedures in this section will refer you to the illustrations in Section II. ♦ Section II: Illustrated Parts List This section consists of drawings of all the assemblies comprising the printer.
Belt, Paper Feed Timing Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the paper path (page 5–29). 4. Remove four screws, the barrier shield, and the anti–static brush (page 5–59, Figure 5–10). 5. Remove the timing belt cover by squeezing the top and bottom to release the plastic tabs from the slots in the side plate (page 5–59, Figure 5–10). 6. Loosen (do not remove) the 7/64 inch setscrew in the paper feed motor pulley collar. 7.
Installation 1. Install the paper feed timing belt over the splined shaft pulley and the motor pulley. Slide the motor pulley onto the paper feed motor shaft. 2. Holding a 0.040 inch feeler gauge between the pulley collar and the motor body, torque the 7/64 inch collar screw to 25 ± 2 inch–pounds (2.82 ± 0.23 NSm). 3. Using the straight end of a force gauge, apply 12 pounds (53.38 N) of pressure to the paper feed drive motor. Use the splined shaft to steady the gauge. 4. Reduce pressure to 9 pounds (40.
Belt, Platen Open Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the platen open belt cover by squeezing the top and bottom to release the plastic tabs from the slots in the side plate (page 5–67, Figure 5–14). 4. Loosen (do not remove) the two 5/16 inch mounting screws of the platen open motor (page 5–69, Figure 5–15). 5. Push the motor toward the front of the printer to loosen the platen open belt. 6.
Cable Connectors and Connector Shells Some of the printer cable connectors are grouped inside connector shells. The procedure below explains how to remove and install cable assemblies from any connector shell in the printer. NOTE: There is also a diagram of the P106 / P107 connector shells on the plastic heat shield over the power supply. Removal 1. Remove the paper path (page 5–29). 2. Disconnect the cable connector shell containing the cable assembly that will be replaced. 3.
POD = Paper Out Detect (Switch) PMD = Paper Motion Detect (Switch) CCF = Card Cage Fan LRP = Left Ribbon guide PLAT M = Platen Open Motor LRIB M = Left Ribbon Motor P106 Connector Configuration Key Tab Typical 2–Wire Cable Connector Typical 4–Wire Cable Connector PIN NO. 2 4 6 8 10 12 14 16 18 20 LRIB M LRP PMD PLAT M CCF POD 1 3 5 7 9 11 13 15 17 19 Pull the side outward just enough to release the connector lock tab from the slot in the connector shell. (See also page A–10.
Circuit Board: CMX Controller CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle circuit boards. Removal 1. Make a configuration printout of all configurations. (Refer to the Operator’s Guide.) 2. Prepare the printer for maintenance (page 4–2). 3. Remove the paper path (page 5–29). 4. Disconnect all cable connectors from the controller board. (See page 5–61, Figure 5–11.) 5.
Installation CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle circuit boards. 1. Position the controller board in the card cage, shield side down, component side up. Engage the screw on the bottom of the card cage in the keyway in the controller shield. Slide the board to the right until the hole in the side of the controller shield lines up with the hole in the card cage. (See page 5–61, Figure 5–11, item 13.) 2.
Circuit Board: Power Supply WARNING To prevent injury from electric shock, wait at least one minute after shutting off power before removing the power supply board. Do not touch components or flex the board during removal/installation. Handle the board by the its sides. Always wear a properly grounded static wrist strap when handling the power supply board. Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the paper path (page 5–29). 3.
Circuit Breaker Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the paper path (page 5–29). 4. Remove the card cage fan (page 5–17). 5. Disconnect the four circuit breaker electrical leads. (See page 5–71, Figure 5–16.) 6. Press in on the spring clips and remove the circuit breaker from the printer. Installation 1. Press the circuit breaker into the cabinet wall until the spring clips snap into place. (See Figure 5–16, page 5–71.
Control Panel Assembly Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Disconnect RJ11 connector P310 from connector J310 on the control panel. 4. Loosen the four screws securing the control panel to the control panel bracket. (See Figure 5–9, page 5–57.) 5. Remove the control panel assembly from the keyways in the control panel bracket. Installation 1.
Cover Assembly, Hammer Bank / Ribbon Mask Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the shuttle frame assembly (page 5–42). 3. Lift the thick plate of the hammer bank cover assembly at one end, and peel the cover away from hammer bank magnets (page 5–61, Figure 5–11). 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.
Cover Assembly, Shuttle Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the ribbon spools. 4. Loosen the shuttle cover screws (page 5–59, Figure 5–10). 5. Grasping the edges of the shuttle cover assembly, tilt the rear edge up and lift the shuttle cover assembly out of the printer. Installation 1. Place the shuttle cover assembly in the printer. Tilt the forward edge of the cover down slightly and work the cover into position (page 5–59, Figure 5–10).
Fan Assembly, Card Cage Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the paper path (page 5–29). 3. Disconnect the fan cable connector. (See Figure 5–15, page 5–69.) 4. Remove the mounting screws from the bottom of the fan. 5. Remove the card cage fan assembly from the card cage. Installation CAUTION Air flow is INTO the card cage. Make sure to install the fan so the label faces toward the inside of the printer and the cable faces the front of the printer. 1.
Fan Assembly, Cabinet Exhaust Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the floor cabinet doors and the printer cover. 3. Remove the paper fence. (See Figure 5–8, page Figure 5–8.) 4. Remove the two 1/4 inch screws securing the bottom of the air exhaust duct. (See page 5–57, Figure 5–9). 5. Remove the 1/4 inch screw directly below the forms thickness lever. (The screw is located near the right front of the card cage, in front of the square air holes in the printer base plate.) 6.
Fan Assembly, Hammer Bank Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the shuttle cover assembly (page 5–16). 3. Remove the control panel bracket assembly (page 5–57, Figure 5–9). 4. Remove the paper path (page 5–29). 5. Trace the hammer bank fan cable assembly back to the controller board connector P107, releasing it from all cable constraints. (See the cable routing diagram on page A–10.) 6. Disconnect the fan connector from connector shell J107 on the controller board. 7.
Magnetic Pick–up (MPU) Assembly Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the shuttle cover (page 5–16). 3. Disconnect the magnetic pick–up (MPU) cable connector (page 5–63, Figure 5–12). 4. Loosen the 7/64 inch hex MPU clamp screw (page 5–63, Figure 5–12). 5. Unscrew the MPU assembly from the MPU bracket. Installation 1. Install the MPU assembly by screwing it into the MPU bracket (page 5–63, Figure 5–12). 2.
Memory Modules and Security PAL Removal 1. Make a printout of all printer configurations. (Refer to the User’s Guide.) 2. Remove the paper path (page 5–29). CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle memory modules and circuit boards. 3. Gently pry the side locks open, allow the SIMM to angle 45 degrees toward the front of the printer, and remove the SIMM from the socket.
Security PAL CMX Controller Board Bank 1 Bank 0 Bank 1 Bank 0 Flash: 80–pin SIMM 1 DRAM: 72–pin SIMM J11 = Bank 0 (must always be filled) Notch IMPORTANT; SIMM notch at this end. J16 = Bank 0 (must always be filled) J10 = Bank 1 Reserved for upgrades J15 = Bank 1 Reserved for upgrades IMPORTANT: No matter what combination of SIMMs is used, J11 and J16 must always be filled.
Motor Assembly, Paper Feed Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the paper path (page 5–29). 4. Loosen four screws and remove the barrier shield (page 5–59, Figure 5–10). 5. Remove the timing belt cover by squeezing the top and bottom to release the plastic tabs from the slots in the side plate (page 5–59, Figure 5–10). 6. Loosen, but do not remove, the two 5/16 inch paper feed motor mounting bolts (page 5–69, Figure 5–15). 7.
Installation 1. Position the paper feed motor assembly on the right side plate and install the 5/16 inch motor mount bolts and nuts finger tight (page 5–69, Figure 5–15). 2. Connect the paper feed motor cable connector to connector shell P107 (page 5–8). 3. Connect shell connector P107 to J107 on the controller board. (See cable routing diagram on page A–10.) 4. Install the collar, paper feed motor pulley, and timing belt. 5. Align the paper feed motor pulley with the splined shaft pulley.
Motor Assembly, Platen Open Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the paper path (page 5–29). 3. Remove the card cage fan (page 5–17). 4. Remove the platen open belt cover by squeezing the top and bottom to release the plastic tabs from the slots in the side plate (page 5–67, Figure 5–14). 5. Loosen the two 5/16 inch motor mount screws (page 5–69, Figure 5–15). 6. Loosen the 1/16 inch hex pulley setscrew and remove the motor pulley and platen open belt. 7.
Installation 1. Position the platen open motor assembly with the wires toward the rear (page 5–69, Figure 5–15). 2. Install the two 5/16 inch motor mount screws (and nuts, if present) finger tight. 3. Install the platen open belt and motor pulley. Bottom out the motor pulley on the motor shaft and tighten the setscrew to 9 ± 2 inch–pounds (1.24 ± 0.23 NSm). 4. Connect the platen motor cable connector to connector shell P106 (page 5–8). 5. Connect shell connector P106 to J106 on the controller board.
Motor Assembly, Ribbon Drive Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the ribbon. 3. Remove the ribbon hub (page 5–38). 4. Remove two screws and washers securing the ribbon drive motor to the base casting (page 5–61, Figure 5–11). 5. Lift and rotate the ribbon drive motor until the motor cable is aligned with the slot on the base casting. 6. Disconnect the ribbon drive motor cable connector. Installation 1. Reverse steps 3 through 6 of the removal procedure above.
Paper Ironer WARNING Over time, the upper edge of the paper ironer can become sharp. To avoid cutting yourself, handle the paper ironer on the sides. Removal 1. Remove the shuttle frame assembly (page 5–42). 2. Move the forms thickness lever to the open position. 3. Push the ends of the paper ironer toward the rear of the printer, disengage the tabs, then lift it up and out (page 5–67, Figure 5–14). Installation NOTE: The black tape on the paper ironer faces the paper detector switch assembly. 1.
Paper Path WARNING Unless directed to do otherwise, always unplug the printer from the power source before performing a maintenance procedure. Failure to remove power could result in injury to persons or damage to equipment. Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Loosen the three paper path hold–down screws (page 5–59, Figure 5–10, item 6). 4. Slide the paper path to the left and lift it off the card cage. Installation 1.
Platen Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the shuttle frame assembly (page 5–42). 3. Remove the paper ironer (page 5–28). 4. Remove the three 1/4 inch screws securing the paper ironer bracket assembly and remove the assembly. (See Figure 5–14, page 5–67, items 4 through 6.) 5. Remove the platen open belt (page 5–7). 6. Remove the platen pulley (page 5–67, Figure 5–14, item 21): a. Loosen the 7/64 inch collar clamp screw. b. Pull the platen pulley off the platen shaft. 7.
Installation IMPORTANT The dowel pins protruding from the ends of the platen are the platen shafts, and are not equal in length. The platen must be installed with the longer shaft on the right side. 1. Wipe the platen shafts clean of grease and debris. 2. Install the washer on the longer platen shaft. (See Figure 5–3.) Platen Shaft (Right Side) Washer Ironer Bracket Platen Adjust Bracket Platen Bracket Bushing Figure 5–3. Installation of Platen Adjust Bracket Bushing 3.
Platen Installation (continued) Washer Platen Adjust Bracket Platen Adjust Bracket Bushing Platen Mechanism Base Platen Seat Wear Saddle Figure 5–4. Alignment of Platen Adjust Bracket Bushing 6. Apply a layer of bearing lubricant 1/4 inch high to the seat of each wear saddle, making the layer as wide as the saddle and touching the rear angled surface. 7. Install one platen adjust bracket and platen adjust bracket bushing together onto the longer platen shaft, with the screw at the top of the bracket.
Platen Installation (continued) 10. Slide the right ribbon guide assembly into the side plate and install the two 7/32 inch screws and washers. (See Figure 5–15, page 5–69, item 12, 14, and 15.) 11. Install the forms thickness indicator plate: a. Slide the indicator plate, with the interlock switch assembly attached, onto the platen shaft and up against the right side plate. b. Install the Phillips #1 screw and washer securing the indicator plate. 12.
Platen Installation (continued) 18. Install the platen shaft pulley with the 7/64 inch setscrew facing up and tighten the setscrew. Open and close the forms thickness lever and check that the platen pulley setscrew does not hit the left ribbon guide. 19. Install, but do not adjust, the platen open belt and platen open motor pulley (page 5–7). 20. Install the paper ironer with the black tape towards the rear of the printer (page 5–28). 21. Install the shuttle frame assembly (page 5–42). 22.
Resistors, Terminating For parallel interface configurations, the printer is equipped with 470 ohm pull–up terminating resistors and 1K ohm pull–down terminating resistors on the controller board. These are suitable for most applications. (See Figure 5–5.) If the standard terminating resistor pack is not compatible with the particular interface driver requirements of the host computer, other values of pull–up and pull–down resistors may be required.
RP1 Default: 470 ohm Alt 1: 220 ohm Alt 2: 1K ohm CMX Controller Board RP2 Default: 1K ohm Alt 1: 330 ohm Alt 2: none Figure 5–5.
Ribbon Guide Assembly (L/R) NOTE: The right ribbon guide is shown in Figure 5–15. The removal/installation procedure is the same for both ribbon guides. Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the printer ribbon. 3. Cut and remove the tie–wrap from the tie wrap hole to free the ribbon guide cable (page 5–69, Figure 5–15). 4. Remove the paper path (page 5–29). 5. Trace the ribbon guide cable back to the controller board, releasing it from the cable restraints.
Ribbon Hub Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the printer ribbon. 3. Loosen the #2 Phillips screw in the ribbon spool hub (page 5–69, Figure 5–15). 4. Remove the hub from the shaft of the ribbon drive motor. Installation 1. Install the ribbon spool hub over the motor shaft (page 5–61, Figure 5–11). 2. Tighten the hub screw so that it contacts the flat section of the motor shaft. 3. Return the printer to normal operation (page 4–3).
Shaft, Splined Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the paper feed timing belt (page 5–5). 3. Remove the 1/4 inch screw securing the ground clip, and remove the clip (page 5–65, Figure 5–13, items 10 and 11). 4. With grip ring pliers, remove the grip ring from left side of the splined shaft (page 5–65, Figure 5–13, item 6). 5. Pull the bearing and spring link with the spring off the left side of the splined shaft (page 5–65, Figure 5–13, items 7, 8, and 9). 6.
Installation 1. Open the doors on the left and right tractors. Position the tractor belts so the alignment marks are at the top on both tractors. (See Figure 5–6.) 2. Grasp the vertical adjustment knob and slide the splined shaft through the right side plate, the tractors, and the left side plate (page 5–65, Figure 5–13). Make sure the same spline passes the marked groove on each tractor. 3. Install the bearing clamp and screw. 4. Apply a thin film of bearing lubricant to the bearing. 5.
Shaft, Support Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Unlock the tractors and slide them to the far right. 4. Remove the E–ring (page 5–65, Figure 5–13, item 17). CAUTION Hold the tractors while removing the support shaft, and be careful not to lose the two curved spring washers. (See Figure 5–13, page 5–65, item 5.) 5.
Shuttle Frame Assembly Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the shuttle cover assembly (page 5–16). 3. Disconnect the MPU cable connector J03 and shuttle motor cable connector J02 (page 5–63, Figure 5–12, items 5 and 6). CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle the shuttle frame assembly. 4.
2. Open the forms thickness lever and move the tractors as far left and right as possible. 3. Holding the shuttle frame assembly by the support legs cast on both sides of the shuttle motor, set it into the base casting. Use both hands: the shuttle frame assembly is heavy (page 5–61, Figure 5–11). 4. Align the center 5/32 inch socket head screw in the base casting and hand turn the screw until only two or three threads have started. 5.
Spring Assembly, Gas NOTE: Two persons may be required to perform this procedure. Prop or hold the printer cover securely while removing or installing the gas spring assembly. Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Open the floor cabinet rear door. 4. Pry back the spring retaining clips (page 5–57, Figure 5–9). 5. Remove the gas spring assembly from the ball studs.
Spring, Extension, Hammer Bank CAUTION Do not let the hammer bank rotate toward the platen during spring replacement. Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the shuttle cover assembly (page 5–16). 4. Unhook the extension spring from the spring lugs on the hammer bank and shuttle frame. (See Figure 5–12, page 5–63.) Installation 1. Apply a dab of bearing lubricant to both spring lugs.
Switch Assembly, Paper Detector Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the paper path (page 5–29). 3. Loosen four screws and remove the barrier shield. (See page 5–59, Figure 5–10, items 3, 4, and 9.) 4. Remove the two 1/4 inch screws securing the paper detector switch assembly. (See Figure 5–15, page 5–69.) 5. Trace the paper detector switch cable back to the controller board, releasing the cable from the restraints under the base casting.
Installation 1. Holding the slotted wheel against the PMD sensor, position the paper detector switch assembly and install the screws securing it to the printer base. (See Figure 5–15, page 5–69, item 4.) 2. Check PMD sensor arm range: make sure it travels freely and completely back into the sensing cavity. 3. Route the switch cable back to the controller board, installing the cable in the restraints under the base casting. (See cable routing diagram on page A–10.) 4.
Switch Assembly, Platen Interlock Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the paper path (page 5–29). 3. Fully close the forms thickness lever (position ‘A’). 4. Trace the platen interlock switch cable back to the controller board. Remove tie–wraps as necessary to free the cable. (See cable routing diagram on page A–10.) 5. Disconnect connector shell P107 from the controller board. 6. Remove the platen interlock cable connector from the connector shell (page 5–8). 7.
Installation 1. Fully close the forms thickness lever (position ‘A’). 2. Position the platen interlock switch assembly on the switch bracket and install the two #1 Phillips screws securing it to the bracket. (See Figure 5–14, page 5–67.) 3. Route the switch cable through the cutout in the right side plate and to the controller board. (See cable routing diagram on page A–10.) 4.
Tractor (L/R) Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the splined shaft (page 5–39). 3. Remove the support shaft (page 5–41). Installation 1. Using the replacement tractors, install the support shaft (page 5–41). 2. Install the splined shaft (page 5–40). 3. Return the printer to normal operation. (See page 4–3.
Section II: Illustrated Parts List List of Figures Figure 5–7. Top Cover, Doors, and Casters . . . . . . . . . . . . . . . . . . . . 5–53 Figure 5–8. Paper Fence and Chains . . . . . . . . . . . . . . . . . . . . . . . . . 5–55 Figure 5–9. Control Panel and Cabinet Details . . . . . . . . . . . . . . . . . 5–57 Figure 5–10. Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–59 Figure 5–11. Print Mechanisms and Circuit Boards . . . . . . . . . . . . . 5–61 Figure 5–12.
Item No. Part No. (Order No.
1 2 See Figure 5–9, page 5–57 3 5 4 7 6 Figure 5–7.
Item No. Part No. (Order No.) Description Notes 1 Ref Paper Fence 475 lpm model only 2 Ref Paper Tray Assembly 800 and 1200 models only 3 Ref Grommet Kit, Cabinet 4 FD–51830–01 Chain Assembly Kit 5 Ref AC Power Cord See Chart Below 6 Ref Grommet, Power Cord (2) Part of item 3 7 Ref Rail, Stacker Part of item 2 8 Ref Clip, Rail, Stacker Part of item 2 9 Ref Screw (4) Power Cords Part No. 5–54 Country Voltage 17–00606–10 U.S.A.
4 9 1 8 3 5 2 6 7 Figure 5–8.
Item No. Part No. (Order No.) 1 FD–51863–01 Control Panel Assy Includes cable, mounting hardware, and all overlays 2 FD–51856–01 Cable Assy, Control Panel Part of item 1. See also Appendix F. 3 FD–51826–01 Gas Spring Kit Includes ball studs, spring clips, and mounting hardware 4 Ref w/Lock Washer (3) 6–32x.375 5 Ref Screw, w/Lock Washer (2) 6–32x2.
4 1 3 2 5 7 6 4 4 Figure 5–9.
Item No. Part No. (Order No.) 1 FD–51836–01 Shuttle Cover (Shroud Assembly, Air) 2 Ref Screw, Captive (2), 10–24x.62 With O–ring, 125x.250x.06 (part of item 1) 3 Ref Screw (4), 6–32x.25 Thread forming 4 Ref Barrier Shield 5 FD–51848–01 Paper Path 6 Ref Screw (3),Hex, w/Lock Washer, 6–32x.
5 6 9 4 3 3 1 10 2 8 7 Figure 5–10.
Item No. Part No. (Order No.
2 Places: Exploded for clarity. Do not remove holddown clamps and screws. Captive screws 3 places 14 1 3 To J02 (Shuttle Motor) To J03 (MPU) 15 2 8 5 9 10 7 4 15 11 15 6 12 13 To Terminator Board on shuttle Frame Figure 5–11.
Item No. Part No. (Order No.) 1 FD–51838–01 Magnetic Pickup Assy 2 Ref Bracket, MPU Part of item 1 3 Ref Screw, socket cap 6–32x.
Spring Lug (Do not remove grease) 3 4 Spring Lug (Do not remove grease) CAUTION Make sure the MPU cable does not touch the extension spring after cable connection. 1 6 2 5 0.010 ± .001 inch (0.254 ± .025mm) Figure 5–12.
Item No. Part No. (Order No.) Description Notes 1 Ref Screw, Socket Cap, 4–40x.25 Part of item 15 2 Ref Washer, Flat #4 Part of item 15 3 Ref Knob, Tractor Adjust Part of item 15 4 Ref Bushing, Tractor Adjust Part of item 15 5 Ref Washer, Curved Spring Part of item 15 6 Ref Ring, Grip Part of item 18 7 Ref Bearing, Nylon .626 Part of item 18 8 Ref Link Spring Part of item 18 9 FD–51825–01 Spring, Extension 1.00L 10 Ref Screw, Hex w/Lock Washer, 4–20x.
10 11 6 7 8 9 1 2 3 12 4 5 14 13 16 17 15 Figure 5–13.
Item No. Part No. (Order No.) Description Notes 1 Ref setscrew Part of item 25 2 Ref Bracket, Platen (2) 3 FD–51843–01 Ironer, Paper 4 Ref Screw, Thread Forming (3), 6–32x.25 5 Ref Bracket, Ironer 6 Ref Plate, Ironer 7 FD–51865–01 Platen Field Kit 8 Ref Washer, Flat Part of item 7 9 Ref Screw (2) Part of item 11 10 Ref Washer, Flat #4 (2) Part of item 11 11 Platen Switch Kit FD–51853–01 Part of item 25 12 Ref Screw, Socket Cap, 6–32x.
NOTE: Black tape faces paper motion detector. 3 26 1 2 4 NOTE: Item 25: Platen Hardware Kit. 5 6 24 7 23 8 1 22 21 2 20 17 26 25 18 9 16 10 11 12 13 19 18 17 16 14 15 Figure 5–14.
Item No. Part No. (Order No.) 1 FD–51837–01 Fan Assy, Card Cage Air flow into card cage 2 Ref Screw, w/Lock Washer (3) 6–32x1.75 3 FD–51851–01 Switch Assy, Paper Detector 4 Ref Screw, Thread Forming (2) 5 FD–51849–01 Motor Assy, Platen 6 FD–51869–01 Platen Pulley, Drive Motor With setscrew: 6–32x.25 7 Ref Collar, Shaft Part of item 10 8 Ref setscrew, 6–32x.51 Part of item 8 9 FD–51839–01 Pulley, Paper Feed Description Notes 6–32x.
2 Install screws here. 16 1 Top View Hammer Bank Fan Route cable under base casting 5 4 3 6 20 18 15 19 23 2 17 12 8 7 22 21 10 14 13 11 See detail above Figure 5–15.
Item No. Part No. (Order No.
Inside detail To IEC 320 AC Power Input (Connector J301) (Black Wire) To IEC 320 AC Power Input (Connector J301) (White Wire) 1 To Connector P1 (Black Wire) To Connector P1 (White Wire) Card cage fan and power supply board removed for clarity. Black Wire 2 Black Wire White Wire 3 5 4 White Wire Figure 5–16.
5–72 Replacement Procedures and Illustrated Parts List
6 Principles of Operation Contents Line Matrix Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2 Printing Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5 Shuttle Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5 Paper Transport System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7 Ribbon Transport System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Matrix Printing The LG plus Series printer creates characters and graphics by printing patterns of ink dots on paper, an entire line at a time. This technique is called line matrix printing. Every text character is stored in printer memory as a pattern of dots on a logical grid called the dot matrix. (See Figure 6–1.) The ink dots are made by a row of small hammers mounted on a shuttle that sweeps rapidly back and forth.
Direction of Shuttle Movement Dot Row Start 1 2 3 4 5 6 7 8* 9* * 10 Number of rows is determined by line spacing. 11 n 1 2 One Text Line * ** Paper Feed Direction This row is used only for lowercase descenders. This row is used for underlining and lowercase descenders. Figure 6–2. Standard Character Formation Elongated characters are made by printing all but the first and last dot rows twice, as shown in Figure 6–3.
Figure 6–4 shows how each individual hammer spring forms characters as the shuttle scans horizontally. 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.
Printing Mechanism While the principles of line matrix printing are easy to state, the act of printing dots accurately from a rapidly oscillating shuttle onto a vertically moving piece of paper requires precise timing and coordination between printer logic and the printing mechanism. The printing mechanism consists of the shuttle frame assembly, the ribbon transport system, and the paper transport system.
Each hammer spring is a stiff leaf spring with a cylindrical, tungsten carbide tip on the free end. (See Figure 6–6.) A permanent magnet runs the length of the hammer bank and acts on the hammer springs through individual pole pieces. The pole pieces magnetically attract and hold the free end of the hammer spring under tension. This is called the retracted state. NOTE: LG04 hammer bank shown.
Paper Transport System Tractors Horizontal Adjustment Knob Splined Shaft Vertical Adjustment Knob and Splined Shaft Pulley Tractor Support Shaft Shuttle Cover Assembly Paper Feed Timing Belt (Under the cover) Figure 6–7. Paper Transport System A two–phase DC stepper motor, directed by the PFC on the controller board, drives two tractor sprockets by means of a toothed belt and splined shaft pulley arrangement. The stepper motor permits extremely accurate incremental vertical paper movement.
Ribbon Transport System Ribbon Hub Left Ribbon Guide (Not Shown) Hub Locking Latch Ribbon Spool Ribbon Motors Right Ribbon Guide Ribbon Figure 6–8. Ribbon Transport System An inked ribbon winds and unwinds continuously on a pair of spools latched to hubs that are driven by the ribbon motors. The left and right ribbon hubs are offset vertically to equalize ribbon wear and prolong ribbon life. The ribbon motors operate only when the shuttle assembly is moving.
Logical Control of the Printer The printer is divided into four functional elements: the control panel, the controller board, the power supply, and the print mechanisms. See Figure 6–9.
Control Panel The user communicates with the printer by pressing keys on the control panel. The keys are momentary contact switches. The control panel processes and sends key closure information to the controller board and displays information from the controller on the LCD. A status lamp next to the LCD also conveys printer status information to the user. The LCD, status lamp, and keys are mounted on a printed circuit board assembly enclosed in a protective housing.
CMX Controller Board The heart of the printer is the CMX controller board, which monitors and directs all printer functions. The controller board receives and processes all data from the host computer, builds the printable images, controls all motors, and drives the hammer springs. Except for the power supply and final hammer drive circuits, all logic and drive circuitry for the printer are contained on the controller board.
Expansion Port RS–232 Diagnostic Port RS–232/422 IEEE–1284 (Parallel) Control Panel Fault Sensors Paper Feed Ribbon Shuttle Platen TTL Diagnostic Port Hammer Drive Figure 6–11.
Data Controller The data controller (DC) consists of the following elements: ♦ 68EC030 microprocessor ♦ 1MB base flash memory, organized as 256K x 32 bits ♦ One flash SIMM socket, for up to 16MB of additional program memory ♦ 2MB base DRAM data memory, organized as 256K x 32 bits ♦ One DRAM SIMM socket, for 2, 3, 8, or 16MB of additional data memory ♦ 8K x 8 Non–Volatile Battery–Backed SRAM (NVRAM) for storage of configuration and system statistical data ♦ VX ASIC ♦ Host I/O Drivers/Terminati
DRAM Memory DRAM is used for program variables, image buffers, and input buffers. All DRAM supports page mode operation and is addressable by individual byte. Two standard 72–pin DRAM SIMMs are used for expansion memory, addressable to 256MB, although 16MB is the practical upper DRAM limit. NVRAM A 8K x 8 bit Non–Volatile battery–backed static RAM (NVRAM) device provides for the storage of configuration and system statistical data.
Control Panel Interface The VX operator panel interface consists of five lines: serial clock, serial data, and three select lines. It is the VX that handles all parallel–to–serial (and vice versa) conversion to and from the panel, as well as any special timing needed when toggling select lines, etc.
♦ Less than 0.02V common mode ripple, measured between chassis ground and the ground pins of the interface ICs. ♦ Less than 200V/ s slew rate for all outputs. Engine Controller The engine controller (EC) consists of four main elements: ♦ 80C166 Microcontroller ♦ Address Decode PAL ♦ 256KB 5.0V–only FLASH program memory, organized as 64K x 16 bits. This memory is not expandable. ♦ MECA ASIC 80C166 Microprocessor The Siemens SAB 80C166 is a high–integration microcontroller.
peripherals are automatically reset. The timer interval is set through software and has a range of 25.6 sec to 419 ms; default setting is 6.55 ms. Analog Drive Circuitry The analog drive functions convert 48 and 8.5 volts into the power used to drive the motors and hammers in the printer. Sensors are used to monitor the operation and status of critical components within the printer. Five motors are used on the printer: paper feed, two ribbon drive, shuttle, and platen open.
Power Supply Board The printer power supply is contained on a printed circuit board mounted in the card cage. The power supply automatically senses and adjusts to any commercial electrical system that provides AC mains potential in 50 or 60 Hertz systems. In other words, the printer is fully operational from available commercial power anywhere in the world. The power supply converts alternating current (AC) to direct current (DC) at three voltage levels and sends the DC voltages to the controller board.
Loss of + 48 V is seen by the RSP and reported as a fault. Printer Interface The printer interface is the point where the data line from the host computer plugs into the printer. The printer interface processes all signals and data to and from the host computer. The printer is equipped with buffered IEEE 1284 parallel, EIA–232–D serial, and EIA–422–A interfaces mounted on the CMX controller board. The interface cable connectors are accessible through a cutout at the rear of the card cage.
6–20 Principles of Operation
A Wire Data NOTE: Acronyms and Signal mnemonics are defined in Appendix E. LG plus Series Interconnection Diagram . . . . . . . . . . . . . . . . . . . . . . . A–2 LG plus Series Power Distribution Diagram . . . . . . . . . . . . . . . . . . . . A–3 Circuit Board Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–4 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–4 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON/OFF SWITCH 2 Wire Data P1 4 4 2 4 4 AC to DC Power Supply Board 7 5 3 1 Shuttle Assy J05 2 Hammer Bank Board Shuttle Motor Terminator Board Hammer Bank Fan J04 P05 10 10 P04 P105 HBP J105 HBP 8 J108 HLP Flex Circuits 7 P108 HLP 8 6 4 2 6 J106 MSL 12 10 LRP LRIB M CCF PLAT M 11 9 Point of Common Ground 5 J101 DC POWER P101 12 P106 MSL 20 18 16 14 PMD POD 19 17 15 13 P106 Configuration CMX Controller Board J1 AC Print Mechanisms Left Ribbon Motor Left Rib
Line 1 Line 2 / Neutral +5 V +5 V +5 V +48V Paper Motion Detector Paper Out Detector Left Ribbon Guide Left Ribbon Motor P1 +48V P106 MSL 5 P105 HBP J105 HBP 8 +24V Ret Ret J05 P05 Shuttle Motor Terminator Board Shuttle Assy +8.5/+48V 7 Hammer Bank Board J04 6 J101 DC POWER P101 Return +48V +48V +5 V +5 V +8.5V +8.5V Ret P04 +8.
A–4 Wire Data 1 2 3 4 5 26 6 7 8 9 10 11 12 13 14 15 16 27 17 18 19 20 21 22 23 24 25 NC NC NC NC NC NC NC NC NC NC NC NC DIFF TXD+ DIFF TXD– HOST DTR DIFF RXD+ DIFF RXD– HOST DCD HOST TXD HOST RXD2 HOST RTS HOST CTS HOST DSR J201 RS232/RS422 470 PF 10% 50V N FP LCD WR N FP LED WR FP DATA FP CLK N FP DAT AVAIL VCC 470 PF 10% 50V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Motor CAUTION: Do not remove or replace the NVRAM.
Wire Data A–5 1 2 1000 PF 10% 50V + 10 F 10% 16V J102 External Power 1000 PF 10% 50V CAUTION: Do not remove or replace the NVRAM. The NVRAM contains a lithium battery that can explode if it is replaced incorrectly. NVRAM is replaced only at the factory.
A–6 Wire Data 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 POD C PMD C POD E PMD E POD A PMD A POD K PMD K L RBN POST+ CC FAN– L RBN POST– PLAT 1 RIB L1 PLAT 2 RIB L2 PLAT 3 +48V RIB L3 PLAT 4 RIB L4 CC FAN+ J106 Motor Sensor Left 0.01 F 10% 100V LDFB PH4 PH3 PH2 PH1 1 2 3 4 5 6 7 8 9 10 11 12 +48V 8.5V VCC N TEMP HI N STBY J101 Power Supply CAUTION: Do not remove or replace the NVRAM. The NVRAM contains a lithium battery that can explode if it is replaced incorrectly.
Wire Data A–7 HMR CLK HMR CLK RET CMD DAT CMD DAT RET CMD CLK CMD CLK RET 4 5 6 7 8 9 TOROID 50 MHz HMR DAT RET 3 10 HMR DAT TOROID 50 MHz 2 1 J108 Hammer Bank Logic 4.7V 1.0W 0.01 F 10% 50V 15V 1 2 3 SHUT A SHUT B SHUT C J116 Shuttle Motor J2 EC Diagnostics NC NC PPR MOVING FT EVENT MPU OUT SHUT DIR EC DB TXD EC DB RXD Flash: 80–pin SIMM J10 = Bank 1 J11 = Bank 0 (See page 5–21.) CAUTION: Do not remove or replace the NVRAM.
A–8 Wire Data 1 2 P1 3 LOAD = FAST–ON TERMINAL = RING TERMINAL Cable Assy, AC In, Power Supply GND LOAD J1 1 AC AC COMMON CHASSIS GND AC Input (Line Filter Area) Power Supply P101 Controller Board PIN 1 1 2 3 4 5 6 7 8 9 10 11 12 P101 470 F 10% 50V VCC 470 F 10% 50V 8.
Wire Data A–9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 PARITYERR RET DATA3 DAT3 RET DATA1 RET DATA2 RET ONLINE RET RDY RET DRQ RET PARITYERR NC NC NC NC CABLE VERIF DATA4 RET DATA4 DATA6 RET DATA6 DATA8 RET DATA8 NC (PARITY) DATAPI NC (BUFF CLR) NC NC DATA5 DATA7 RET DATA7 STROBE RET STROBE GND NC NC NC NC NC (PARITY RET) DATAPI RET NC (BUFF CLR RET) NC NC DATA5 RET DATA1 DATA2 ONLINE RDY DRQ NC N
P106/LRP P106/CCF PLAT M Ribbon Guide P306 To card cage fan A–10 Wire Data P106 To J106 on Controller (See page 5–9 for connector detail.) Left Side of Printer LRIB M P106/POD P106/PMD P05 P04 P108 P105 P116 (Looking up from below.
Wire Data A–11 154470–901 Part No. Cable Assembly, 2–Pin Jumper, 0.
A–12 Wire Data Description Cable Assembly, AC In, Power Supply Part No.
Wire Data A–13 Description Cable Assembly, AC Power Connector Part No.
A–14 Wire Data PIN 1 Description Cable Assembly, Card Cage Fan Part No.
Wire Data A–15 PIN 1 (Gray) PIN 8 (Brown) Description Cable Assembly, Control Panel 152440–901 PIN 8 (Brown) Part No. NOTE: If you replace the control panel cable, you must install two ferrite shielding beads. See Appendix F.
A–16 Wire Data PIN 1 152424–901 Part No.
Wire Data A–17 Description Cable Assembly, Hammer Bank Logic Part No.
A–18 Wire Data PIN 1 Description Cable Assembly, Hammer Bank Power Part No.
Wire Data A–19 PIN 1 PIN 2 152425–901 Part No.
A–20 Wire Data FD–51855–01 Part No. NOTE: Left ribbon guide shown. Right is mirror image.
Wire Data A–21 Description Cable Assembly, Shuttle Motor Drive Part No.
A–22 Wire Data FD–51852–01 Part No.
Wire Data A–23 POD PIN C PIN E PIN A PIN 4 PIN 3 PIN 4 PIN K PIN 3 PIN A PIN K PIN C PIN 2 PMD PIN 1 PIN 2 PIN E POD WIRE TABLE PIN 1 POD RCPT PMD RCPT ORANGE RED BROWN BLACK RED WHITE GRAY BLACK CABLE FD–51851–01 Part No.
A–24 Wire Data P107/PLO FD–51853–01 Part No.
B Printer Specifications Contents Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–2 Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–2 Paper Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–3 Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–3 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duty Cycle LG04 plus prints 130, 000 pages per month LG08 plus prints 205, 000 pages per month LG12 plus prints 320, 000 pages per month —under the following conditions: ♦ Uppercase text only ♦ 6 lines per inch (lpi) ♦ 10 characters per inch (cpi) ♦ 63% character density or 83 characters per line ♦ 63% line density or 42 lines per 11–inch page ♦ Single–part (18 lb) paper ♦ Printer is installed in accordance with the Setup Guide ♦ Printer is maintained in accordance with this maintenance manua
Paper Specifications Paper Type: Edge–perforated, fan–fold, 3 to 16 inches (7.62 to 40.64 cm) wide, 1 to 12 inches (2.54 to 30.48 cm) long Thickness: Single–part: 15 to 100 pound (6.80 to 45.36 kg) stock; Multi–part: 1– to 6–part forms (maximum 12 lb [5.44 kg] ply of upper plies) Sheet Thickness: 0.025 inch (0.
Printer Dimensions Height: 41 inches (104.1 cm) Width: 27 inches (68.6 cm) Depth: 29 inches (73.7 cm) Weight: 225 lbs. (102.1 kg) unpackaged 285 lbs. (129.
Energy Star This printer complies with the requirements of the Energy Star Office Equipment Program of the U.S. Environmental Protection Agency.
Interfaces B–6 Type: Two resident parallel host interfaces: Centronics and Dataproducts; One resident serial host interface (RS–232/RS–422); One resident serial diagnostic port. Logic Levels: TTL/EIA–232–D Data Format: ASCII or EBCDIC Compatibility: Centronics parallel, Dataproducts parallel, Serial EIA RS–232–D and RS–422–A. Transfer Rates: Up to 200 Kilobytes on parallel interfaces Up to 38.
Printing Rates The printing speed of text is measured in lines per minute (lpm), and is a function of the selected font and the vertical 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.
B–8 Printer Specifications
C Metric Conversion Tables Length Multiply By To Obtain foot foot foot 0.3048* 30.48* 304.8* meter (m) centimeter (cm) millimeter (mm) inch inch inch 0.0254* 2.54* 25.4* meter (m) centimeter (cm) millimeter (mm) meter centimeter millimeter 3.280840 0.03280840 0.003280840 foot foot foot meter centimeter millimeter 39.37008 0.3937008 0.03937008 inch inch inch * Figure is exact. Torque and Force Multiply By To Obtain pound–inch pound–foot Newton–meter (NSm) Newton–meter (NSm) 0.11298 1.
Mass and Density Multiply By To Obtain pound* ounce* 0.4535924 28.34952 kilogram (kg) gram (g) kilogram gram 2.204622 0.03527397 pound* ounce* * avoirdupois Temperature To Convert From To Use Formula temperature Celsius (tC) temperature Fahrenheit (tF) tF = 1.8tC + 32 temperature Fahrenheit (tF) temperature Celsius (tC) tC = (tF – 32)/1.8 Power Multiply C–2 By To Obtain Btu (International Table)/hour watt (W) 0.2930711 3.
D Torque Table NOTE: The table below establishes the torque requirements for routine installation of threaded fasteners. These requirements apply to fasteners made of steel, at a minimum engagement of 3.5 threads, including chamfer and countersink. Fastener sizes are listed as Numbered Size – Threads Per Inch. Torque Table Carbon Steel Fasteners (ANSI B18.6.3 – 1972) Into Steel 60,000 psi ultimate tensile strength Into Weld/Press Studs or Nuts Fastener Size Into Alum.
D–2 Torque Table
E Abbreviations and Signal Mnemonics NOTE: Mnemonics with first letter “N” are negative true. ACRONYM/ MNEMONIC DEFINITION F . . . . . . . . . . . . . . . . microfarad (10–6 farad) s . . . . . . . . . . . . . . . . microsecond (10–6 second) sec . . . . . . . . . . . . . . microsecond (10–6 second) A0, A1, etc. . . . . . . . . Address 0, Address 1, etc. AC . . . . . . . . . . . . . . . Alternating Current ACK . . . . . . . . . . . . . . Acknowledge AMP . . . . . . . . . . . . . .
CA . . . . . . . . . . . . . . . Cathode CC . . . . . . . . . . . . . . . Card Cage CCF . . . . . . . . . . . . . . Card Cage Fan CE . . . . . . . . . . . . . . . Customer Engineer CHNG . . . . . . . . . . . . Change CLK . . . . . . . . . . . . . . Clock COLL . . . . . . . . . . . . . Collector CONTLR . . . . . . . . . . Controller CMD . . . . . . . . . . . . . Command CMX . . . . . . . . . . . . . Manufacturer’s designation of the controller board CNC . . . . . . . . . . . . . . Connector, Connection CPI .
ERR . . . . . . . . . . . . . . Error ESD . . . . . . . . . . . . . . Electrostatic Damage EX . . . . . . . . . . . . . . . Exhaust, Extra EXH . . . . . . . . . . . . . . Exhaust EXF . . . . . . . . . . . . . . Exhaust Fan EXP . . . . . . . . . . . . . . Expansion FD . . . . . . . . . . . . . . . Feed FF . . . . . . . . . . . . . . . . Form Feed FLT . . . . . . . . . . . . . . . Fault FLTR . . . . . . . . . . . . . Filter FP . . . . . . . . . . . . . . . . Front Panel (Operator Panel) FTIC . . . . . . . . .
LPM . . . . . . . . . . . . . . Lines Per Minute LRIB . . . . . . . . . . . . . Left Ribbon LRP . . . . . . . . . . . . . . Left Ribbon Guide M . . . . . . . . . . . . . . . . Motor MAIN . . . . . . . . . . . . . Maintenance Jack, RS–232 MECA . . . . . . . . . . . . Mechanism Engine Control ASIC MECH . . . . . . . . . . . . Mechanism MF . . . . . . . . . . . . . . . microfarad (10–6 farad) MH . . . . . . . . . . . . . . . Mounting Hole, Main Harness MOSFET . . . . . . . . . .
PFC . . . . . . . . . . . . . . Paper Feed Controller PFM . . . . . . . . . . . . . . Paper Feed Motor PI . . . . . . . . . . . . . . . . Paper Instruction PLAT . . . . . . . . . . . . . Platen PLM . . . . . . . . . . . . . . Platen Motor PLO . . . . . . . . . . . . . . Platen Open (Switch) PMD . . . . . . . . . . . . . . Paper Motion Detect PN . . . . . . . . . . . . . . . Pin P/N . . . . . . . . . . . . . . . Part Number PO . . . . . . . . . . . . . . . Paper Out POD . . . . . . . . . . . . . .
SCS . . . . . . . . . . . . . . SNA Character Stream SEC . . . . . . . . . . . . . . Security (Key) SEL . . . . . . . . . . . . . . Select SEN . . . . . . . . . . . . . . Sense, Sensor SHH . . . . . . . . . . . . . . Shuttle Hall (Effect) SHM . . . . . . . . . . . . . . Shuttle Motor SHUT . . . . . . . . . . . . . Shuttle SIMM . . . . . . . . . . . . . Single Inline Memory Module SLCT . . . . . . . . . . . . . Select (On–line) SMD . . . . . . . . . . . . . . Shuttle Motor Drive SNA . . . . . . . . . . . . .
w/ . . . . . . . . . . . . . . . . With w/o . . . . . . . . . . . . . . . Without XMT . . . . . . . . . . . . .
E–8 Abbreviations and Signal Mnemonics
F Noise Suppression Devices Ferrite noise suppressors are installed in the printer to reduce radio frequency interference (RFI) to and from electronic equipment located near the printer. Two kinds of ferrite noise suppressors are used: 1. Shielding Bead (P/N 141445–001)—Cylindrical core through and around which the control panel cable assembly is wound. Two are required. 2.
Control Panel Cable Assembly Connector P110 Connector P310 Shielding Bead P/N 141445–001 NOTE: Two turns around each bead. Parallel I/O Cable Assembly Connector P112 Ferrite Core with Clamp and Adhesive Backing P/N 202049–001 NOTE: This core attaches to right rear card cage wall. Connector J203 Figure F–1.
Index Numbers Block diagram, operator panel, 6–10 15V PWR FAIL *, 3–4 Boards, controller (CMX), 5–10 23.5V PWR FAIL *, 3–4 Boards: layouts, connections, and pin–outs, A–1 48V PWR FAIL *, 3–4 8.
CLOSE PLATEN, 3–4 DRVR CIR BAD *, 3–5 CMX controller board data controller (DC), 6–13 engine controller (EC), 6–16 principles of operation, 6–11 Duty cycle, B–2 COIL HOT, 3–4 Control panel, replacement, 5–14 Controller board pinouts, A–4 principles of operation, 6–11 replacement, 5–10 Controls and indicators, 1–8 mechanical, 1–10 printing conventions, 1–5 Conversion, metric measurement, C–1 Cores, Noise Suppression, F–1 Cover assembly hammer bank / ribbon mask, replacement, 5–15 shuttle, replacement, 5–
F Fan assembly card cage, replacement, 5–17 hammer bank, replacement, 5–18, 5–19 Fault messages 15V PWR FAIL *, 3–4 23.5V PWR FAIL *, 3–4 48V PWR FAIL *, 3–4 8.5V PWR FAIL *, 3–4 A TO D OVERUN *, 3–4 ACCESS NULL PTR *, 3–4 BUFFER OVERFLOW, 3–4 CLEAR PAPER JAM, 3–4 CLOSE PLATEN, 3–4 COIL HOT, 3–4 CTL VOLT FAIL *, 3–5 DRVR CIR BAD *, 3–5 EXHAUST FAN FLT, 3–5 FIRMWARE ERROR, 3–5 FRAMING ERROR, 3–5 HAM.
ERROR: PROGRAM NEEDS MORE DRAM, 4–30 ERROR: PROGRAM NEEDS MORE FLASH, 4–30 ERROR: PROGRAM NOT COMPATIBLE, 4–30 ERROR: PROGRAM NOT VALID, 4–30 ERROR: SHORT AT ADDRESS XXXX, 4–30 ERROR: WRITING TO FLASH, 4–29, 4–30 ERROR: WRONG CHECKSUM, 4–30 LOADING PROGRAM FROM PORT XX%, 4–31 RESETTING . . .
cleaning the printer, 2–4 inspecting the printer, 2–3 overview, 1–1 preventive, 2–1 preventive maintenance checks and services, 2–2 scheduled, 2–1 Operation, principles of, 6–1 Operator panel, block diagram, 6–10 P PAL, security, location, 5–22 PAP BAD TABLE *, 3–6 Manual how to use, 1–3 notes and notices, 1–3 printing conventions, 1–5 related documents, 1–4 PAP BSY TOO LNG *, 3–6 Mechanical controls and indicators, 1–10 PAP INCMPL ENER *, 3–6 Memory modules, location and replacement, 5–21 PAP INVLD
Physical Inspection, 2–3 Pin–outs, A–1 PLAT INV CMD *, 3–7 PLAT INV PARM *, 3–7 PLAT INV STATE *, 3–7 Platen gap adjustment, 4–12 interlock switch assembly, replacement, 5–48 platen open belt adjustment, 4–6 platen open motor, replacement, 5–25 Platen replacement, 5–30 preventive maintenance checks and services, 2–2 principles of operation, 6–1 self–tests diagnostic print, 3–35 operator print, 3–35 specifications, B–1 troubleshooting, 3–1 Printing conventions is this manual, 1–5 line matrix printing explai
paper path, 5–29 platen, 5–30 platen interlock switch assembly, 5–48 platen open belt, 5–7 platen open motor, 5–25 power supply circuit board, 5–12 resistors, terminating, 5–35 ribbon drive motor, 5–27 ribbon guide assembly (L/R), 5–37 ribbon hub, 5–38 shuttle cover assembly, 5–16 shuttle frame assembly, 5–42 splined shaft, 5–39 support shaft, 5–41 tractor (L/R), 5–50 SECURITY VIOLATION, 3–8 Self–tests diagnostic, printer, 3–35 operator print, 3–35 SENDING PROGRAM TO EC PROCESSOR, 4–31 Services.
Spring extension, hammer bank, replacement, 5–45 gas, assembly, replacement, 5–44 fault messages, 3–3 symptoms not indicated by fault messages, 3–29, 3–30 STACK OVERFLOW *, 3–8 STACK UNDERFLOW *, 3–8 Status lamps, 1–8 Support shaft, replacement, 5–41 Switch paper detector switch assembly, replacement, 5–46 platen interlock switch assembly, replacement, 5–48 power, replacement, 5–13 U UNDEF INTERRUPT *, 3–9 UNDFNED OPCODE *, 3–9 UP (arrow) key, 1–8 UP DRV.
