Page 3 6400 Line Matrix Printers S246-0117-08 Maintenance Information Manual Cabinet and Pedestal Models...
Page 4: Energy Star
Boulder, CO 80301-9191 When you send information to IBM or IBM Printing Systems Company, you grant a nonexclusive right to use or distribute the information in any way IBM or IBM Printing Systems Company believes appropriate without incurring any obligation to you.
Page 5: Notices
Notices References in this publication to IBM products, programs, or services do not imply that IBM intends to make these available in all countries in which IBM operates. Any reference to an IBM licensed product, program, or service is not intended to state or imply that only IBM’s product, program, or service may be used.
Page 6: Trademarks And Service Marks
Trademarks And Service Marks Trademarks And Service Marks The following terms, denoted by an asterisk (*) in this publication, are trademarks of IBM Corporation in the United States or other countries or both: AS/400 PC-DOS RISC System/6000 Token-Ring The following terms, denoted by a double asterisk (**) in this publication, are...
Page 7: Table Of Contents
Electrical Controls, Pedestal Models..........22 Mechanical Controls, All Models .............24 Tools, Test Equipment, And Supplies............26 2 Installation ............27 Installing And Configuring The IBM 6400 Printer........27 3 Preventive Maintenance ........29 Cleaning The Printer................29 Cleaning The Exterior ..............29 Cleaning The Interior...............30 Cleaning The Shuttle Frame Assembly...........31...
Page 8 Table of Contents Printing Mechanism ................38 Shuttle Frame Assembly ..............39 Paper Transport System ..............41 Ribbon Transport System ...............42 Logical Control Of The Printer ...............43 Printer Electronics ................43 Operator Panel ..................44 CMX Controller Board................45 Data Controller ................47 Engine Controller ................49 Printer Interface ..................51 10Base2 And 10Base-T LEDs And DIP Switches ......52 10/100Base-T LEDs And DIP Switches ..........54 Power Supply Board ................57...
Page 9 Ribbon Guide Alignment..............166 Splined Shaft Skew Adjustment............168 Adjusting The End Of Forms Distance ..........169 Hammer Phasing Adjustment ..............173 Downloading 6400 Microcode From The World Wide Web....175 Loading Flash Memory ................176 Coil Temperature Adjustment ..............181 Set Shuttle Speed................182 Ethernet Initialization ................183 7 Replacement Procedures And Illustrated Parts Lists........
Page 10 Table of Contents Fan Assembly, Hammer Bank ............210 Hammer Spring Assembly ............211 IBM Coax/Twinax Expansion Board..........215 Magnetic Pick-up (MPU) Assembly..........216 Memory and Security Modules............217 Motor Assembly, Paper Feed............221 Motor Assembly, Platen Open ............223 Motor Assembly, Ribbon Drive............225 Network Print Server ..............226 Operator Panel Assembly, Cabinet Model ........227...
Page 11 Table of Contents Mass and Density................338 Temperature..................338 Power ....................338 D Torque Table............. 339 E Safety Inspection Guide ........341 Safety Inspections ................341 Preparation ..................341 Prepare The Printer for Inspection............342 Inspect Mechanical Parts..............342 Inspect Electrical Parts ................343 F Abbreviations And Signal Mnemonics....347 G Cords And Adapters .........
Page 12 Table of Contents...
Page 13: Maintenance Overview
Maintenance Overview About The Printer The entire system architecture of an IBM* 6400 line matrix printer is contained on one circuit board. The use of DRAM and flash memory on this board permits rapid access to stored printer emulations and fast processing of print data.
Page 14: Hanzi Printers
25 MHz or 40 MHz, depending on printer model. This means there are two kinds of CMX controller board for IBM 6400 printers, used as shown in this table. The 40 MHz controller board, however, is backwards compatible in all models that use the 25 MHz board.
Page 15: Printer Evolution
Hanzi characters. The hammer springs have 10.5 MIL (0.0105 inch) tips and are unique to these printers. The 6400-C05 and -C5P printers also use the CMX 040 controller board, which has a 40 MHz clock speed on the Data Controller unit.
Page 16: Important Maintenance Notes
Chapter About This Manual Important Maintenance Notes To ensure the best performance of the printer, remember these important maintenance concepts when you service the printer. ATTENTION Failure to observe the guidelines below can result in damage to the equipment. • Do not adjust the platen gap unless the original shuttle frame assembly or platen has been replaced with a new or rebuilt unit, or unless instructed to do so in the troubleshooting chapter.
Page 17: Notes And Notices
The word Danger next to the lightning slash indicates the presence of a hazard that could cause death or serious personal injury. Danger and Caution notices are numbered to help you find the translated versions in the IBM 4400 Safety Notices booklet. CAUTION <#>...
Page 18: Printing Conventions In This Manual
To ensure complete understanding of important safety notices for technicians whose native language is not English, the notices have been translated into many languages in the IBM 6400 Line Matrix Printer Safety Notices: Form No. G544-5389 . This maintenance manual does not explain how to operate or configure the printer.
Page 19 Related Documents • IBM 6400 Code V User’s Manual: Form No. S544-5638 Provides information used with the optional Code V Printronix emulation enhancement feature. The Code V Printronix emulation allows the user to create and store forms, generate logos, bar codes, and expanded characters, create other graphics, and merge graphics with alphanumeric data as a document is printed.
Page 20: Controls And Indicators
Chapter Controls And Indicators Controls And Indicators Electrical Controls, Cabinet Models Key or Indicator Function Power Indicator Lit when the printer is on. Ready Indicator Lit when the printer is in READY mode (on-line), no errors are pending, and the printer is ready to process data.
Page 21 Electrical Controls, Cabinet Models (Off) (On) Power Switch Power Ready Processing Form Line Start Menu Scroll Enter Micro Cancel Feed Feed Set Top Eject/ Printer Con- Attention View Scroll Return Micro Stop figuration Of Form Restore Figure 2. Electrical Controls, Cabinet Models...
Page 22: Electrical Controls, Pedestal Models
Chapter Controls And Indicators Electrical Controls, Pedestal Models Key or Indicator Function Power Indicator Lit when the printer is on. Ready Indicator Lit when the printer is in READY mode (on-line), no errors are pending, and the printer is ready to process data. Off when the printer is in NOT READY mode (off-line). Processing Flashes when the printer is receiving data from the host.
Page 23 Electrical Controls, Pedestal Models (Off) (On) Power Switch Power Ready Processing Form Line Start Menu Scroll Enter Micro Cancel Feed Feed Set Top Eject/ Printer Con- Attention View Scroll Return Micro Stop figuration Of Form Restore Figure 3. Electrical Controls, Pedestal Models...
Page 24: Mechanical Controls, All Models
Chapter Controls And Indicators Mechanical Controls, All Models Control or Function Indicator Forms Thickness Sets the platen for paper and forms of different thicknesses. Lever must be Lever fully opened (raised) to load or unload paper. Paper Supports Help prevent paper jams by supporting inner sections of paper. They are positioned manually by sliding them along the tractor shafts.
Page 25 Mechanical Controls, All Models Paper Supports Left Tractor Horizontal Right Tractor Adjustment Knob Tractor Lock Tractor Lock Vertical Position Knob Ribbon Loading Path Diagrams Forms Thickness Lever and Scale Forms Thickness Pointer Figure 4. Mechanical Controls, All Models...
Page 26: Tools, Test Equipment, And Supplies
Tools, Test Equipment, And Supplies The tools and equipment required for field level maintenance of the printer are listed below. Item Part No. 6400 Line Matrix Printer Configuration Utility Disk 63H7379 1-30 Inch-pound Torque Screwdriver 16F1661 ESD Wrist Strap 6405959 Feeler Gauge, .010 inch...
Page 27: Installation
Installing And Configuring The IBM 6400 Printer Installation and configuration of the printer are covered in the 6400 Line Matrix Printer Set-Up Guide , Form No. S544-5640 Installation, operation, and replacement parts for the optional coax/twinax interface are covered in the Coax/Twinax Multi-Platform Interface Option Installation and Operation Guide , Form No.
Page 28 Chapter Installing And Configuring The IBM 6400 Printer...
Page 29: Preventive Maintenance
Preventive Maintenance Cleaning The Printer Aside from normal replenishment of paper and ribbons, the only preventive maintenance required for the printer is periodic cleaning. Because operating conditions vary widely, the user must determine how often to clean the printer. There is no guarantee that the user will clean the printer regularly, however, so you should clean the printer whenever you are called to service it.
Page 30: Cleaning The Interior
Chapter Cleaning The Printer Cleaning The Interior 1. Power off the printer. 2. Disconnect the AC power cord from the power source. 3. Open the printer cover. 4. Remove paper from the printer. 5. Remove the ribbon. 6. Using a soft-bristled, non-metallic brush, wipe paper dust and ribbon lint off the tractors, shuttle cover assembly, base casting, and ribbon guides.
Page 31: Cleaning The Shuttle Frame Assembly
Cleaning The Shuttle Frame Assembly Cleaning The Shuttle Frame Assembly 1. Remove the shuttle cover assembly (page 203). 2. Remove the shuttle frame assembly (page 242). 3. Remove the paper ironer (page 230). CAUTION <2> Over time the upper edge of the paper ironer can become sharp.
Page 32 Chapter Cleaning The Printer NOTE: 6400-004 hammer bank is shown. Procedure is the same for all hammer banks. Hammer Tip Figure 6. Cleaning the Hammer Tips ATTENTION The hammer bank contains a strong magnet. To prevent damage to the hammer tips, do not let the hammer bank cover assembly snap into place as the hammer bank magnet attracts it.
Page 33: Cleaning The Card Cage Fan Assembly
Cleaning The Card Cage Fan Assembly Cleaning The Card Cage Fan Assembly 1. Cabinet Models: Remove the paper guide assembly (page 229). Pedestal Model: Remove the top cover assembly (page 204). 2. Vacuum the card cage fan assembly and surrounding areas to remove paper particles, dust, and lint.
Page 34 Chapter Cleaning The Printer...
Page 35: Principles Of Operation
Principles Of Operation Line Matrix Printing The printer creates characters and graphics by printing patterns of ink dots on paper, an entire line at a time. This technique is called line matrix printing. Every text character is stored in printer memory as a pattern of dots on a logical grid called the dot matrix.
Page 36 Chapter Line Matrix Printing When the shuttle reaches the end of a sweep, it reverses direction, the paper is advanced one dot row, and the hammers print the next row of dots as the shuttle sweeps in the opposite direction. After a line of characters is printed, hammer action stops and the paper advances to the first dot row of the next print line.
Page 37 Succesive Hammer Strokes Per Scan Shuttle 1 3 5 1 3 5 7 1 3 5 7 9 Scan Even column dot centers within the printed character area and character space hammer positions are not illustrated in this diagram. NOTE: = Hammer Released and Dot Printed = Hammer Not Released;...
Page 38: Printing Rates
Chapter Printing Rates Printing Rates Because a line matrix printer prints entire lines sequentially, it is faster than a moving-printhead printer, which prints single characters sequentially. The printing speed of text is measured in lines per minute (lpm) rather than characters per minute (cpm).
Page 39: Shuttle Frame Assembly
28 hammer springs • 6400-008/-08P/-009/-09P: seven 7-hammer assemblies, for a total of 49 hammer springs • 6400-010 and -10P: six 10-hammer assemblies, for a total of 60 hammer springs • 6400-012/-014/-C05/-C5P: seven 13-hammer assemblies, for a total of 91 hammer springs •...
Page 40 The pole pieces magnetically attract and hold the free end of the hammer spring under tension. This is called the retracted state. NOTE: 6400-004 hammer bank shown. Hammer Bank Assembly: Coils, Magnet, Pole Pieces,...
Page 41: Paper Transport System
Paper Transport System Paper Transport System Paper Path Tractors Vertical Adjustment Horizontal Splined Knob and Adjustment Shaft Splined Shaft Knob Pulley Tractor Support Shaft Shuttle Cover Assembly Paper Feed Timing Belt (under the cover) Paper Supports Figure 13. Paper Transport System A two-phase DC stepper motor, directed by the EC on the controller board, drives two tractor sprockets by means of a toothed belt and splined shaft pulley arrangement.
Page 42: Ribbon Transport System
Chapter Printing Mechanism Ribbon Transport System Ribbon Hub Left Ribbon Guide (Not Shown) Locking Latch Ribbon Spool Ribbon Motors Right Ribbon Guide Ribbon Figure 14. Ribbon Transport System An inked ribbon winds and unwinds continuously on a pair of spools latched to hubs that are driven by the ribbon motors.
Page 43: Logical Control Of The Printer
Printer Electronics Logical Control Of The Printer The printer is divided into four functional elements: the operator panel, the CMX controller board, the power supply, and the print mechanism. Printer Electronics The functional elements of the printer are diagrammed in Figure 15. Operator Input Panel...
Page 44: Operator Panel
Chapter Operator Panel Operator Panel The operator communicates with the printer by pressing keys on the operator panel. The keys are momentary contact switches. The operator panel processes and sends key closure information to the controller board and displays information from the controller on the LCD. A status indicator next to the LCD also conveys printer status information to the user.
Page 45: Cmx Controller Board
Printer Electronics CMX Controller Board The heart of the printer is the CMX controller board, which monitors and directs all printer functions. The controller board receives and processes all data from the host computer, builds the printable images, controls all motors, and drives the hammer springs.
Page 46 Chapter CMX Controller Board 25 or 40 MHz Expansion Port RS-232 RS-232/422 Diagnostic Port IEEE-1284 (Parallel) Control Panel Fault Sensors Paper Feed Ribbon Shuttle Platen Diagnostic Port Hammer Drive Figure 17. CMX Controller Board Block Diagram...
Page 47: Data Controller
68EC030 Microprocessor A Motorola** 68EC030 microprocessor serves as the processor of the DC unit. This processor runs at 25 MHz on all models except the 6400-050, -P50, -010, -P10, -015, -C05, and -C5P. On 6400-050, -P50, -010, -P10, -015, -C05, and -C5P printers the 68EC030 processor runs at 40 MHz and the controller board on these models is called the “CMX 040.”...
Page 48 Chapter CMX Controller Board NVRAM A 8K x 8 bit Non-Volatile battery-backed static RAM (NVRAM) device provides for the storage of configuration and system statistical data. VX ASIC The VX is a multifunction custom gate array ASIC containing all the logic for the DC that is not contained in the 68EC030 processor.
Page 49: Engine Controller
Engine Controller “Cajun” Bus Interface The “Cajun” bus interfaces the DC, the EC, and the expansion port. The EC uses this bus to access DC resources, including the semaphore registers. (The semaphore registers are the primary communications path between the EC and DC.) Ports The VX ASIC controls the following I/O functions:...
Page 50 Chapter CMX Controller Board controller and the MECA ASIC provide the functionality of three separate processors used in earlier controller board architectures. In this manual, the 80C166 is referred to as either the EC or the 166. The 166 used on the CMX board runs at 20MHz and is housed in a 100-pin metric rectangular flat pack.
Page 51: Printer Interface
Engine Controller The paper feed, ribbon drive, and shuttle motors are driven in control loops containing power MOSFETs, voltage and current sensors, the MECA ASIC, and the EC processor. The platen open motor is driven by a stepping motor controller IC and the EC processor. Control of the hammer drive is split between the controller board and the hammer bank.
Page 52: 10Base2 And 10Base-T Leds And Dip Switches
Chapter Printer Interface 10Base2 And 10Base-T LEDs And DIP Switches 10Base2 and 10Base-T PrintNet Ethernet interfaces have three LEDs and three DIP switches, as shown below. The indicators and switches are adjacent to the data line connectors. LED patterns are defined in the table below the illustration.
Page 53 10Base2 And 10Base-T LEDs And DIP Switches Run Mode and Auto Reset Mode: Run Mode is the normal operating state of the Ethernet Interface. Auto Reset mode is entered when the watchdog timer is triggered and the Print Server resets itself. In either mode, the STAT LED flashes differently, depending on whether the unit IP address is configured: STAT Rate...
Page 54: 10/100Base-T Leds And Dip Switches
Chapter Printer Interface 10/100Base-T LEDs And DIP Switches The 10/100Base-T Ethernet interface has two indicator lights and two DIP switches, as shown below. DIP Switches Shown in OFF (default) position STAT (System Status) (Data to Network) Inspect the two LEDs on the 10/100Base-T Ethernet interface: 1.
Page 55: Dip Switches
10/100Base-T LEDs And DIP Switches STAT (Status) Indicator In Run And Auto Reset Modes Run Mode is the normal operating state of this interface. Auto Reset mode is entered when the watchdog timer is triggered and the print server resets itself. In either mode, the STAT LED flashes at a varying rate, depending on whether the unit IP address is configured: STAT...
Page 56 Chapter Printer Interface Table 3. 10/100Base-T DIP Switch Settings DIP Switch Description Normal operation. With both DIP switches in the “OFF” position, the interface boots up using the settings in flash memory rather than the default settings. Factory default settings. With the DIP switches in this configuration, the interface boots up and all settings stored in flash memory are erased except the Ethernet address and key value.
Page 57: Power Supply Board
AC Power Power Supply Board The printer power supply is contained on a printed circuit board mounted in the card cage. The power supply automatically senses and adjusts to any commercial electrical system that provides AC mains potential in 50 or 60 Hertz systems.
Page 58: Graphics
Chapter Graphics Graphics The Code V programming language (a QMS** graphics emulation) and the IGP programming language (a Printronix IGP emulation) are options that install in flash memory on the CMX controller board. These programming languages simplify the job of creating forms, bar codes, logos, expanded characters, and other graphics.
Page 59: Troubleshooting
Troubleshooting Introduction This chapter lists fault messages and symptoms, and provides procedures for troubleshooting printer malfunctions. Always have the Operator’s Guide and the Setup Guide handy when you troubleshoot because this manual does not cover printer operation or configuration. You must operate the printer to check its performance, and sometimes you may have to reconfigure it.
Page 60: Start Of Call
Chapter Start Of Call Start Of Call Are you here because of an Go to Troubleshooting Display error message? Messages, page 61. Power on the printer and observe the operator panel for the following sequence of IML was Did Power and events (retry as required): After about 10 successful.
Page 61: Troubleshooting Display Messages
Troubleshooting Display Messages DANGER <3> Hazardous voltages are present in the printer with the power cord connected to the power source. Switch off printer power and unplug the printer power cord before proceeding. <4> Do not connect or disconnect any communication port, teleport, attachment connector, or power cord during an electrical storm.
Page 62: Message List
Chapter Troubleshooting Display Messages the printer be powered off and the condition corrected before powering the printer back on. Message List Find the message in the Message List below and follow the suggested procedure. After correcting an error, press the Start key to clear the message. If an error is not cleared, the printer will try to print again but will display the error message until the error is cleared.
Page 63 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message 002 FORMS JAMMED Attention message: 1. Clear jams. Load paper. CLEAR JAM AND the printer cannot 2. Press Form Feed several times and RELOAD FORMS detect paper motion. check that forms feed without erratic Inspect the paper motion, noise, or pin-hole damage.
Page 64 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message 002 FORMS JAMMED 11. Check and adjust the platen gap. CLEAR JAM AND 12. Clean the paper motion detector with a RELOAD FORMS cotton swab and alcohol. At the control (continued) panel, set the paper motion detector (PMD) fault setting to DISABLE.
Page 65 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message 010 PARAMETER The printer received 1. Press Stop to clear fault. Press Start to ERROR an illegal parameter go on-line. value in the command 2. Run the print job that generated the error code.
Page 66 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message 013 ACTIVATE LOST The printer detects a 1. Power off the printer. Disconnect the AC twinax protocol power cord from the printer. Check the communication error twinax host data cable and twinax I/O and reports the error.
Page 67 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message The line is not active 1. Power off the printer. Disconnect the AC COMMUNICATIONS on a twinax interface. power cord from the printer. Check the CHECK twinax host data cable connection and CHECK CABLE twinax I/O cable connection at the CT board.
Page 68 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message 017 STACKER JAM This message is 1. Open the cabinet rear door and check for CHECK STACKER triggered if there is obstructions preventing elevator paper inside the movement.
Page 69 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message 018 STACKER FULL Status message: the 1. Unload the stacker. CHECK STACKER power paper stacker 2. Check the stacker limit switches. (See is full. page 119.) If the limit switches are OK, go to the next step.
Page 70 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message 019 STACKER FAULT Two situations can 1. Open the cabinet rear door and check for CHECK STACKER trigger this message: obstructions preventing elevator 1. The stacker movement.
Page 71 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message 021 RECEIVE BUFFER The print buffer has Make a configuration printout. Verify that OVERRUN overflowed on a serial the printer matches the host serial VERIFY interface. The printed interface configuration settings for Data CONFIGURATION output may contain...
Page 72 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message 025 SERIAL FRAMING The printed output 1. Make a configuration printout. Verify that ERROR may contain random ! the printer matches host configuration VERIFY (exclamation point) settings for Data Protocol, Baud Rate, CONFIGURATION characters.
Page 73 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message 031 END OF FORMS On a coax interface, a 1. Load paper. Press Stop. If message TIMEOUT timeout message is does not clear, go to the next step. LOAD FORMS sent to the host if 2.
Page 74 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message 032 FORMS JAMMED On a coax interface, a 1. Clear the paper jam. Press Stop. TIMEOUT timeout message is 2. Press Form Feed several times and CLEAR JAM AND sent to the host if check that forms feed without erratic...
Page 75 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message 032 FORMS JAMMED 11. Check and adjust the platen gap. TIMEOUT 12. Clean the paper motion detector with a CLEAR JAM AND cotton swab and alcohol. At the control RELOAD FORMS panel, set the paper motion detector (continued)
Page 76 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message 044 EC FIRMWARE/ Application software 1. Cycle power. Run the print job. If the HARDWARE ERROR tried to perform an message appears, download the illegal printer function emulation software again.
Page 77 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message 057 CLOSE PLATEN The forms thickness 1. Load paper. Close the forms thickness lever is open. lever. If message does not clear, go to the next step. 2. Power off the printer. Remove the paper guide assembly or pedestal top cover.
Page 78 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message 058 SHUTTLE JAM The shuttle is not Check the forms thickness lever: if it is SEE USER’S GUIDE moving or is moving set too tightly, it can slow the shuttle at the wrong speed.
Page 79 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message 058 SHUTTLE JAM 10. Run a print test. If the message appears, SEE USER’S GUIDE replace the shuttle frame assembly. (continued) 059 CANCEL PRINT Non-error status No action required. ACTIVE message.
Page 80 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message 060 PRINTER HOT CMX controller board 1. Inspect printer environment for severity. sensors report high Advise the user to move the printer to temperatures on the cooler, cleaner location.
Page 81 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message 062 EXHAUST FAN Sensors cannot 1. Cycle power. If the message appears, FAULT detect current in the press Stop. fan circuit. 2. If the message occurs on a pedestal model, check that the correct operator panel is installed.
Page 82 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message 065 HAMMER BANK Hammer Bank Fan 1. Cycle power. If the message appears, FAN FAULT Fault. Sensors cannot press Stop. detect current in the 2. Power off the printer. Remove the paper fan circuit.
Page 83 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message 080 POWER SUPPLY The printer has 1. Inspect printer environment for severity. sensor circuits that Advise the user to move the printer to sample the operating cooler, cleaner location. temperature of key 2.
Page 84 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message 081 POWER SUPPLY The power supply has 1. Replace the power supply board. VOLTAGE FAILURE failed. 2. Power on the printer. If the message appears, replace the CMX controller board.
Page 85 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message 084 POWER SUPPLY 48 Volt Power Failed. 1. Power off the printer. Remove the paper 48V FAILED Internal power failure. guide assembly or pedestal top cover. Check that power supply connector P101 is fully seated in connector J101 on the CMX controller board.
Page 86 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message 086 CONTROLLER 15V Controller Voltage 1. Cycle Power. Run the print job again. If Failure. the message appears, remove the hammer bank logic cable, inspect it for damage, and test it for continuity.
Page 87 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message 087 PLATEN OPEN On a coax interface, 1. Close the forms thickness lever. Press TIMEOUT the forms thickness Stop. CLOSE PLATEN lever has been open 2. Run a print test. If a platen open or close for at least one platen message appears, power off the minute.
Page 88 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message 088 CONTROLLER Controller Voltage 1. Cycle Power. Run the print job again. If 23.5V Failure. the message appears, download the emulation software again. 2. Cycle power. Run the print job again. If the message appears, replace the flash memory with pre-written flash.
Page 89 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message 089 RIBBON STALL This message occurs 1. Check the forms thickness lever: if it is when the ribbon fails set too tightly it can inhibit ribbon to move while movement.
Page 90 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message 090 SHUTTLE COVER The shuttle cover is 1. Inspect shuttle cover for warping, OPEN missing, damaged, or damage, or missing magnet. (The CLOSE SHUTTLE not correctly installed. magnet covers the sensor housing when COVER the cover is installed.) If the shuttle cover...
Page 91 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message 101 UPPER DRIVER Hammer driver 1. Cycle power. If the message appears, SHORT circuits on the CMX press Stop. If the message does not controller board are clear, replace the hammer bank logic shorted to ground.
Page 92 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message 107 HAMMER COIL One or more hammer 1. Inspect the printer environment for <number> HOT coils are overheating. severity. Advise the user to move the The printer has sensor printer to cooler, cleaner location.
Page 93 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message 110 STACK System stack has run 1. Cycle power. Run the print job again. If OVERFLOW out of room and the message appears, download the SEE USER’S GUIDE overflowed into other emulation software again.
Page 94 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message 116 ILLEGAL Illegal External Bus 1. Cycle power. Run the print job again. If EXTERNAL BUS Accessed. Firmware the message appears, download the ACCESS error on the CMX emulation software again.
Page 95 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message 122 PAPER NOT The paper feed 1. Cycle power. Run the print job again. If SCHEDULED process is not the message appears, download the SEE USER’S GUIDE scheduling on the emulation software again.
Page 96 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message 124 PAPER FIFO Paper First In First 1. Cycle power. Run the print job again. If OVERFLOW Out Overflow. the message appears, download the SEE USER’S GUIDE Firmware error on the emulation software again.
Page 97 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message 126 PAPER FEED BAD The paper feed 1. Cycle power. Run the print job again. If TABLE process on the CMX the message appears, download the SEE USER’S GUIDE controller board has a emulation software again.
Page 98 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message 131 PAPER FEED Unexpected interrupt 1. Cycle power. Run the print job again. If INTERRUPT in the paper feed the message appears, download the SEE USER’S GUIDE process on the CMX emulation software again.
Page 99 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message 137 SHUTTLE INVALID Firmware error on the 1. Cycle power. Run the print job again. If COMMAND CMX controller board. the message appears, download the SEE USER’S GUIDE emulation software again.
Page 100 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message BOOT DIAGNOSTICS Non-error status No action required. message. CLEARING PROGRAM Status message: No action required. FROM FLASH emulation software successfully loaded into printer RAM and the checksum matched.
Page 101 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message ERROR: FLASH DID The printer 1. Download the program again. NOT PROGRAM encountered an error 2. If the message occurs again, replace the trying to program flash memory with pre-written flash. (See flash memory.
Page 102 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message ETHERNET Status message that No action required. DETECTED indicates that the internal Network Interface Card has established communication. FM HEADER ERROR Frame Header Error. Not a printer problem. The system Application software administrator should correct applications data has violated header...
Page 103 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message HAMMER COIL BAD Hammer coil(s) 1. Cycle power. If the message appears, #, #, #, #, ... etc. number #, #, etc. replace the shuttle frame assembly. failed the current test Record the message and return it with at power-up.
Page 104 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message OPERATOR MENU Non-error status No action required, unless you want to lock UNLOCKED message. the Enter key. PA1 SELECTED Attach status No action required. message. PA2 SELECTED Attach status No action required.
Page 105 If the printer is an IBM COMPATIBLE downloaded 6404-B01, the controller is a CBO board. If program.(The user the printer is an IBM 6400, the controller is a may have tried to CMX board. load a CMX- compatible diskette in a CBO-controlled printer, or vice versa.)
Page 106 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message P68 ERROR: The printer cannot 1. Download the program again. If the EC PROGRAM NOT find the engine message occurs again, replace all flash VALID controller program or memory SIMMs with pre-written flash.
Page 107 Message List Table 4. Message List Operator Panel Explanation Corrective Action Message RESTORING BOOT Status message No action required. CODE when downloading boot code. Code is checked then saved in flash memory. RIBBON OUT OF INK RibbonMinder** Install a new ribbon and set ribbon life to CHANGE RIBBON software has 100%.
Page 108 Chapter Troubleshooting Display Messages Table 4. Message List Operator Panel Explanation Corrective Action Message WAITING FOR Status message that No action required. ETHERNET ADAPTER appears when printer is first powered on if the internal Network Interface Card is installed. An Ethernet adapter must be detected early in the power up sequence...
Page 109: Troubleshooting Other Symptoms
Message List Troubleshooting Other Symptoms DANGER <3> Hazardous voltages are present in the printer with the power cord connected to the power source. Switch off printer power and unplug the printer power cord before proceeding. <4> Do not connect or disconnect any communication port, teleport, attachment connector, or power cord during an electrical storm.
Page 110: General Symptom List
Chapter Troubleshooting Other Symptoms 8. Stop troubleshooting and return the printer to normal operation when the reported symptoms disappear. General Symptom List Table 5 is a list of possible printer problems that are not indicated by messages on the LCD. Troubleshooting procedures are included for each symptom.
Page 111 General Symptom List Table 5. General Symptom List Symptom Corrective Action CLEAR JAM message 1. Remove the paper guide assembly or pedestal top cover. Make will not clear and paper sure connector P107/PAPR M is fully seated in connector J107 does not move on the CMX controller board.
Page 112 Chapter Troubleshooting Other Symptoms Table 5. General Symptom List Symptom Corrective Action Operator Panel Black squares on 1. Power off the printer. Remove the paper guide assembly or operator panel display pedestal top cover. Disconnect the operator panel cable from the panel and from J110 on the CMX controller board.
Page 113 General Symptom List Table 5. General Symptom List Symptom Corrective Action Operator panel keys do 1. Power on the printer. Check the operation of the operator panel not work keys. Replace the operator panel if keys do not work. 2. Power on the printer. Check the operation of the operator panel keys.
Page 114 Chapter Troubleshooting Other Symptoms Table 5. General Symptom List Symptom Corrective Action Power / IML Failures No power, and the 1. Check that the AC power outlet has power. Restore AC power operator panel is blank, as required. and the card cage fan is 2.
Page 115 General Symptom List Table 5. General Symptom List Symptom Corrective Action Printer does not NOTE: Power-on initialization is explained on page 146. complete IML 1. Power off the printer. Remove the paper guide or pedestal top cover. Check that all cables are connected to the CMX controller board.
Page 116 Chapter Troubleshooting Other Symptoms Table 5. General Symptom List Symptom Corrective Action Power Stacker Printer does not detect 1. Check that the power stacker is enabled under the Printer Control menu. (Refer to the Setup Guide.) If the power stacker presence of power stacker enable/disable option does not appear in the menu, go to the...
Page 117 General Symptom List Table 5. General Symptom List Symptom Corrective Action Stacker chatters at 1. Check for and remove obstructions preventing elevator upper or lower limit movement. 2. Check for misaligned stacker rails Adjust the stacker rails if they are not vertical and parallel. 3.
Page 118 Chapter Troubleshooting Other Symptoms Table 5. General Symptom List Symptom Corrective Action Stacker does not stack 1. Check for and remove obstructions preventing elevator properly movement. 2. Check for misaligned stacker rails Adjust the stacker rails if they -or- are not vertical and parallel. 3.
Page 119 General Symptom List Table 5. General Symptom List Symptom Corrective Action Stacker limit switch NOTE: This procedure tests the motion limit switches at the top and check bottom of the vertical rails. You will usually be referred to this procedure from other troubleshooting procedures. When you have completed this procedure, return to the procedure that sent you here.
Page 120 Chapter Troubleshooting Other Symptoms Table 5. General Symptom List Symptom Corrective Action Stacker motor check NOTE: This procedure tests the four stacker motors and their cables. You will usually be referred to this procedure from other troubleshooting procedures. When you have completed this procedure, return to the procedure that sent you here.
Page 121 General Symptom List Table 5. General Symptom List Symptom Corrective Action Print Quality Characters or dots are 1. Check the forms thickness lever: if it is set too loose or too tightly missing, smeared, too print quality can be affected. Set the forms thickness lever to light, or too dark match the thickness of the paper being used.
Page 122 If the pattern of H’s did not print OK, go to the next step. 2. Check and adjust hammer phasing. 3. If the printer is a model 6400-004, -04P, -005, or -05P, check the shuttle speed setting (page 182). 4. Inspect the shuttle frame assembly area for ink residue, paper chaff, or debris.
Page 123 General Symptom List Table 5. General Symptom List Symptom Corrective Action Randomly misplaced 1. Power off the printer. Check and adjust the platen gap. dots 2. Remove the paper guide assembly or pedestal top cover. On the left rear wall of the card cage, make sure the nut which secures the line filter ground line and the AC-In Power Supply cable leads to the ground stud is tight.
Page 124 Chapter Troubleshooting Other Symptoms Table 5. General Symptom List Symptom Corrective Action Printer Operation Downloads consistently NOTE: Most download problems are detected by software during fail the procedure and communicated by LCD messages. If downloads fail consistently with no messages or with erratic messages, suspect a hardware failure.
Page 125 General Symptom List Table 5. General Symptom List Symptom Corrective Action Paper feeds poorly 1. Check the forms thickness lever: if it is set too tightly paper feeding can be affected. Set the forms thickness lever to match the thickness of the paper being used. 2.
Page 126 Chapter Troubleshooting Other Symptoms Table 5. General Symptom List Symptom Corrective Action Reverse paper feed: 1. Raise the forms thickness lever and check that the platen opens. platen does not open If the platen opens with difficulty, inspect for and remove jams or obstructions.
Page 127 General Symptom List Table 5. General Symptom List Symptom Corrective Action TOF is lost repeatedly 1. Check that the customer is setting the forms length to match the size paper used. Set the forms length to match the length of paper being used.
Page 128 Chapter Troubleshooting Other Symptoms Table 5. General Symptom List Symptom Corrective Action Ribbon Ribbon folding or feed 1. Check that both ribbon spools are fully seated on the ribbon problems hubs and the ribbon runs between the ribbon mask and hammer bank cover.
Page 129 General Symptom List Table 5. General Symptom List Symptom Corrective Action Shuttle Shuttle does not move 1. Power down the printer. Remove the shuttle cover. Adjust the gap between the MPU assembly and the flywheel to 0.010 ± .001 inch (0.254 ± 0.025 mm). Torque the 7/16 inch MPU clamp screw to 18 ±...
Page 130 Chapter Troubleshooting Other Symptoms Table 5. General Symptom List Symptom Corrective Action Shuttle is noisy 1. Check the bolts securing the mechanism base to the base pan. Tighten the mechanism base mounting bolts if they are loose enough to permit movement of the mechanism base. 2.
Page 131: Communications Failures
General Symptom List Communications Failures Many host-printer communications problems are complex. With the exception of a defective interface cable, most communications problems are not a result of a hardware failure. They usually result from an incompatible configuration of the host computer system, network (LAN, print server, controller, multiplexer, etc.), or the printer.
Page 132: Operator Print Tests
Chapter Operator Print Tests Operator Print Tests A set of print tests is included in the configuration menu structure for use as diagnostic tools. These are called the “Operator Print Tests” because they are available to the user. You can use these print tests to check the print quality and basic operation of the printer.
Page 133: Selecting And Running Tests
Selecting And Running Tests Splined shaft bearings Tractors or tractor belts • Underlines An underline pattern useful for identifying hammer bank misalignment. Hammer bank cover Hammer tips Paper feed belt or motor Splined shaft bearings Tractor bearings or belts Selecting And Running Tests To run Operator Print Tests you use the printer configuration menus, as shown below: Step...
Page 134: Customer Engineer (Ce) Tests
Chapter Customer Engineer (CE) Tests Customer Engineer (CE) Tests A set of printer tests is included in the configuration menu structure for use as maintenance tools. These are called “Customer Engineer Tests” (CE Tests) because they are for your use; they are not available to the user through his documentation.
Page 135 Selecting And Running Tests Hammer springs Hammer coils (the shuttle frame assembly) • Shuttle Only This test runs only the shuttle. • Shuttle Slow Verifies proper operation by exercising the shuttle and ribbon mechanisms at low speed. You can also use this test to check ribbon tracking and reversing.
Page 136: Shuttle Speed
This parameter allows adjustment in 0.01 inch increments of the final location of page perforations when top paper exit is used. Shuttle Speed: Sets shuttle speed in 6400-004, -04P, -005, and -05P printers. See page 182. Set Coil Temperature: An automatic sequence in printer software that recalibrates hammer coil temperature.
Page 137: Boot Diagnostics Menu
Boot Diagnostics Menu Step Press Displayed Result Notes NOT READY Stop halts the test, exits Stop Start -OR- the menu, and puts the printer in the NOT READY state. Start halts the test, exits the menu, and puts the printer in the READY state.
Page 138 Chapter Customer Engineer (CE) Tests NOTE: BOOT DIAGNOSTICS > PRESS ENTER = Scroll↓ key ENTER > BOOT DIAGNOSTICS VERSION CHECK ENTER VERSION CHECK VERSION CHECK VERSION CHECK > VERSION CHECK > > > SOFTWARE VERSION EC VERSION ASIC VERSIONS BOOT VERSION ENTER ENTER ENTER...
Page 139 Boot Diagnostics Menu NOTE: BOOT DIAGNOSTICS > MISC UTILITIES = Scroll↓ key From previous page ENTER MISC UTILITIES MISC UTILITIES MISC UTILITIES > MISC UTILITIES > > > RESET PRINTER COPY FLASH SIMMS COPY BOOT SIMMS DISPLAY MEMORY ENTER ENTER ENTER ENTER LOADING PROGRAM...
Page 140: Hex Code Printout
Chapter Hex Code Printout Hex Code Printout A hex code printout (“hex dump”) prints every ASCII character received from the host computer with its corresponding two-digit hexadecimal code. Hex dumps can be used to troubleshoot printer data reception problems by comparing the printed hex data to the data sent from the host.
Page 141 Boot Diagnostics Menu Step Press Displayed Result Notes OPERATOR MENU Relocks the ENTER key. UNLOCKED Scroll↑ Scroll↓ READY Puts printer in READY Start mode. Send a file from the host computer. The printer outputs a hex dump. Refer to the ASCII chart on page 142. When the hex dump is complete, take the printer offline and change the Hex Dump Mode back to Disable.
Page 142: Ascii Character Set
Chapter ASCII Character Set ASCII Character Set The ASCII character set is shown below in chart form. BITS OCTAL equivalent DECIMAL equivalent HEX equivalent ASCII Character Name BITS COLUMN (XON) " 0 0 1 0 0 0 1 1 (XOFF) 0 1 0 0 0 1 0 1 &...
Page 143: Printer Information Menu
Boot Diagnostics Menu Printer Information Menu You can view various printer statistics, such as hours of usage, and refer to these figures for preventive maintenance purposes. Printer statistics accumulate continuously; they do not reset when you power off the printer. All of the printer statistics are set to zero at the factory after burn-in testing.
Page 144: Displaying Printer Information
Chapter Printer Information Menu Displaying Printer Information You obtain printer information by using the configuration menus, as follows: Step Press Displayed Result Notes Install the ribbon, load paper, and power on the printer. NOT READY Puts printer in NOT Stop READY mode.
Page 145: Soft Vs. Hard Reset
Soft Reset Soft vs. Hard Reset Resetting the printer returns it to a previous configuration. There are two kinds of reset. Soft Reset A soft(ware) reset clears printer memory then loads the power-up configuration into memory. (The procedure for saving configurations is described in the Setup Guide .) It is called a soft reset because no hardware is tested.
Page 146: The Power On Sequence
Chapter The Power On Sequence The Power On Sequence This section describes the normal sequence of events from the time the power switch is set to 1 until READY (or NOT READY, if so configured by the user) appears on the LCD. Use this sequence as a reference baseline to help you isolate problems that occur before the printer completes its boot and initialization routines.
Page 147 CMX Controller Board Handshake Sequences with the I/O clock, the error blink code 4-3-4 is sent to the diagnostic LED on the CMX board. • Read Operator Panel Keys — The operator panel keys are read to determine if the user is requesting that the printer be placed in download mode, diagnostic mode, or debug SIMM disabled.
Page 148 Chapter The Power On Sequence • Display VX Registers — The boot code displays the values of the VX registers out of the debug serial port. • Check for Pedestal — Boot code uses the operator panel to determine if the printer is a pedestal or floor cabinet model.
Page 149 CMX Controller Board Handshake Sequences • Check Security PAL and NVRAM — The chip select for NVRAM comes from the security PAL. If the PAL is not installed, NVRAM cannot be accessed, so the PAL is tested before NVRAM. If the security PAL is not detected, boot codes displays “ERROR: SECURITY PAL NOT DETECTED”.
Page 150: Dc Software Initialization And Power Up
Chapter The Power On Sequence • Jump Back into Flash and Clear DRAM — Boot code jumps back into flash memory, then clears the DRAM that held the boot code. • Jump to MTOS — Jump to start initialization of the MTOS (Multi-Tasking Operating System).
Page 151: Adjustment Procedures
Adjustment Procedures Introduction The IBM 6400 series printer is a durable, low-maintenance machine, but some components and systems require occasional adjustment. Usually, you will be referred to this chapter by a troubleshooting procedure, or as part of a removal/installation procedure.
Page 152: Preparing The Printer For Maintenance
Chapter Preparing The Printer For Maintenance Preparing The Printer For Maintenance To prepare the printer for maintenance, always do the following steps before you do any maintenance procedure: DANGER <3> Hazardous voltages are present in the printer with the power cord connected to the power source. Switch off printer power and unplug the printer power cord before proceeding.
Page 153: Returning The Printer To Normal Operation
List Of Adjustments Returning The Printer To Normal Operation When you are finished servicing the printer, restore it to operation by following these steps: 1. Connect the host data cable to the printer interface. 2. Install the ribbon. 3. Load paper. 4.
Page 154: Belt, Paper Feed Timing, Adjustment
Chapter Belt, Paper Feed Timing, Adjustment Belt, Paper Feed Timing, Adjustment To make this adjustment, follow these steps: 1. Prepare the printer for maintenance (page 152). 2. Cabinet Model: Remove the paper guide assembly (page 229). Pedestal Model: Remove the top cover assembly (page 204). 3.
Page 155 List Of Adjustments Direction of Force Legend: Timing Belt Shield Motor Mount Bolt (2) Paper Feed Drive Motor Splined Shaft Figure 21. Paper Feed Timing Belt Adjustment...
Page 156: Belt, Platen Open, Adjustment
Chapter Belt, Platen Open, Adjustment Belt, Platen Open, Adjustment To make this adjustment, follow these steps: 1. Prepare the printer for maintenance (page 152). 2. Cabinet Model: Remove the paper guide assembly (page 229). Pedestal Model: Remove the top cover assembly (page 204). 3.
Page 157 List Of Adjustments Direction of Force Legend: Belt Cover Motor Mount Screw (2) Platen Open Motor Shaft Figure 22. Platen Open Belt Adjustment...
Page 158: Paper Drive Motor Pulley Alignment
Chapter Paper Drive Motor Pulley Alignment Paper Drive Motor Pulley Alignment To make this adjustment, follow these steps: 1. Prepare the printer for maintenance (page 152). 2. Cabinet Model: Remove the paper guide assembly (page 229). Pedestal Model: Remove the top cover assembly (page 204). 3.
Page 159 List Of Adjustments Legend: Belt Shield Cap Screw Motor Pulley Collar Motor Pulley Splined Shaft Pulley Figure 23. Paper Drive Motor Pulley Alignment...
Page 160: Paper Scale Alignment
Chapter Paper Scale Alignment Paper Scale Alignment To make this adjustment, follow these steps: 1. Open the printer cover. 2. Load paper and ribbon. 3. Connect the power cord to the AC power source. 4. Set the printer power switch to 1 (on). 5.
Page 161 List Of Adjustments Legend: Shuttle Cover Screw, Button-Head, 5/64 inch hex (3) Paper Scale Figure 24. Paper Scale Alignment...
Page 162: Platen Gap Adjustment
Chapter Platen Gap Adjustment Platen Gap Adjustment To make this adjustment, follow these steps: IMPORTANT Only do this procedure if the original equipment shuttle frame assembly or platen has been replaced by a new or refurbished unit. 1. Prepare the printer for maintenance (page 152). 2.
Page 163 List Of Adjustments NOTE: Left side adjustment shown. Right side is the same. ORF 0D\ Legend: Forms Thickness Lever Feeler Gauge (0.011 inch or 0.28 mm) Hammer Bank Cover Ribbon Mask Set Screw, 3/32 inch hex (2) Figure 25. Platen Gap Adjustment...
Page 164: Platen Open Motor Pulley Alignment
Chapter Platen Open Motor Pulley Alignment Platen Open Motor Pulley Alignment To make this adjustment, follow these steps: 1. Prepare the printer for maintenance (page 152). 2. Cabinet Model: Go to step 3. Pedestal Model: Remove the top cover assembly (page 204). 3.
Page 165 List Of Adjustments Legend: Belt Cover Set Screw Platen Open Motor Pulley Platen Shaft Pulley Figure 26. Platen Open Motor Pulley Alignment...
Page 166: Ribbon Guide Alignment
Chapter Ribbon Guide Alignment Ribbon Guide Alignment To make this adjustment, follow these steps: 1. Open the printer cover. 2. Load paper and install the ribbon. To align a ribbon guide, wind the ribbon fully onto the ribbon spool on the opposite side. For example, to align the left ribbon guide, wind the ribbon until the right ribbon spool is full.
Page 167 List Of Adjustments Left Ribbon Guide Right Ribbon Guide Early Models Later Models Legend: Screw, Skid (2) Ribbon White Nylon Washer Screw, Retaining (2) Figure 27. Ribbon Guide Alignment...
Page 168: Splined Shaft Skew Adjustment
Chapter Splined Shaft Skew Adjustment Splined Shaft Skew Adjustment If lines of print are not parallel with the edge perforations on the paper, perform the following adjustment. 1. Open the printer cover. 2. Loosen the screw (1) securing the adjusting link (2). 3.
Page 169: Adjusting The End Of Forms Distance
List Of Adjustments Adjusting The End Of Forms Distance This procedure tests and sets the distance from the page perforation at which an END OF FORMS fault message is triggered. This adjustment prevents printing on the platen when the printer runs out of paper. The measurement units are dot rows.
Page 170 Chapter Adjusting The End Of Forms Distance Page Perforation Page Perforation 4 in. Cut out here 4 in. Page Perforation Figure 29. Paper Preparation for Paper Out Adjustment Test...
Page 171 List Of Adjustments 8. The display will show “SERVICE / PRINTER MECHANISM TESTS”, the first menu item. Press Enter to enter the mechanism tests menu. 9. Press Scroll↑ or Scroll↓ until “PRINTER MECHANISM TESTS / END OF FORMS ADJUST” is on the display.
Page 172 Chapter Adjusting The End Of Forms Distance 17. Press Enter. The number of dots will move up to the top line of the display. 18. Using the Scroll↑ or Scroll↓ key, adjust the XX DOTS value up or down by the number of dots you counted in step 12. (If the comb pattern stopped short of the perforation, increase the number of dots.
Page 173: Hammer Phasing Adjustment
List Of Adjustments Hammer Phasing Adjustment You must check and adjust hammer phasing if the CMX controller board is replaced, the shuttle frame assembly is removed, or if the MPU is replaced. The hammer phase value is a timing parameter that permits you to adjust the horizontal alignment of dots in character printing.
Page 174 Chapter Hammer Phasing Adjustment 13. Press Enter. The phasing index (followed by an asterisk) will move up to the top line of the display. 14. Press Scroll↑ or Scroll↓ to increase or decrease the phasing index, then press Enter to activate the value as it prints. Continue to increase or decrease the phasing index until the pattern of Hs appears as shown below: Needs...
Page 175: Downloading 6400 Microcode From The World Wide Web
6400 printer. This process is done through Lotus Notes IBM First Service system. NOTE: It is helpful to create a directory named 6400 on the laptop to hold your 6400 code downloads. If you do not know how to create directories, see your ESPI or someone familiar with PCs.
Page 176: Loading Flash Memory
5. Unplug the AC power cord from the printer. 6. If the printer’s parallel data cable is connected to the parallel port of an IBM-compatible computer using the PC-DOS* or MS-DOS** operating system, skip to step 10. If not, go to step 7.
Page 177 List Of Adjustments 9. Connect the parallel data cable to the parallel port of the printer. 10. Plug the AC power cord into the printer. 11. Power on the computer. 12. On the printer control panel, press and hold down the Start + Cancel keys.
Page 178 Chapter Loading Flash Memory 22. If you had to install a parallel data cable to the computer and printer in step 8, disconnect it from the computer and printer. 23. Reconnect the customer’s data input cable(s) to the printer, if required. 24.
Page 179 CBO-controlled printer, or vice versa. IBM 6404-B01, the controller is a CBO board. If the printer is an IBM 6400, the controller is a CMX board. ERROR: PROGRAM The printer does not see a program in There is no program in NOT VALID flash memory.
Page 180 Chapter Loading Flash Memory Table 7. Flash Memory Message Guide Required Message Explanation Action ERROR: WRITING Hardware or software fault in flash Download the program TO FLASH memory. again: Power off the printer and start over at step 12. If the message occurs again, replace the flash memory.
Page 181: Coil Temperature Adjustment
List Of Adjustments Coil Temperature Adjustment This procedure applies only to models 6400-014 and 6400-015. Do this procedure only when the original CMX controller board or shuttle frame assembly have been replaced. Do not do this procedure if the original CMX board or shuttle frame assembly were removed and reinstalled as part of other maintenance tasks.
Page 182: Set Shuttle Speed
Set Shuttle Speed Set Shuttle Speed This procedure applies only to models 6400-004, -04P, -005, and -05P. Do this procedure only when the original CMX controller board or shuttle frame assembly have been replaced. Do not do this procedure if the original CMX board or shuttle frame assembly were removed and reinstalled as part of other maintenance tasks.
Page 183: Ethernet Initialization
List Of Adjustments Ethernet Initialization To initialize the Ethernet interface, do the following steps: 1. Power on the printer. 2. Wait for “READY / ETHERNET ADAPTER IS READY” to display on the LCD. 3. If the Ready indicator is on, press the Stop key. The printer must be in the NOT READY state to do this procedure.
Page 184 Chapter Ethernet Initialization...
Page 185: Replacement Procedures And Illustrated Parts Lists
Replacement Procedures And Illustrated Parts Lists Organization Of This Chapter This chapter is divided into two sections. • Section I: Replacement Procedures This section contains written procedures for removing and installing components that are replaceable at the field service level of maintenance. The procedures in this section refer you to the illustrations in Section II.
Page 186: Section I: Replacement Procedures
Fan Assembly, Card Cage .............. page 209 Fan Assembly, Hammer Bank ............page 210 Hammer Spring Assembly .............. page 211 IBM Coax/Twinax Expansion Board..........page 215 Magnetic Pick-up (MPU) Assembly..........page 216 Memory and Security Modules............page 217 Motor Assembly, Paper Feed............page 221...
Page 187 List Of Procedures Motor Assembly, Ribbon Drive............page 225 Network Print Server ............... page 226 Operator Panel Assembly, Cabinet Model ........page 227 Operator Panel Assembly, Pedestal Model ........page 228 Paper Guide Assembly ..............page 229 Paper Ironer ..................page 230 Platen ....................
Page 188: Belt, Paper Feed Timing
Chapter Section I: Replacement Procedures Belt, Paper Feed Timing Removal 1. Prepare the printer for maintenance (page 152). 2. Cabinet Model: Remove the paper guide assembly (page 229). Pedestal Model: Remove the top cover assembly (page 204). 3. Cabinet Model: Loosen four screws and remove the barrier shield. (See page 258, Figure 44, items 3 and 4.) Pedestal Model: Loosen the four screws securing the paper guide and barrier shield.
Page 189: Belt, Platen Open
Belt, Platen Open Belt, Platen Open Removal 1. Prepare the printer for maintenance (page 152). 2. Cabinet Model: Remove the paper guide assembly (page 229). Pedestal Model: Remove the top cover assembly (page 204). 3. Remove the platen open belt cover by squeezing the top and bottom to release the plastic tabs from the slots in the side plate.
Page 190: Circuit Board: Controller
Chapter Section I: Replacement Procedures Circuit Board: Controller NOTE: 6400-050, -P50, -010, -P10, -014, -015, -C05, and C5P printers must use the 40 MHz CMX controller board. ATTENTION To prevent electrostatic damage to electronic components, wear a properly grounded static wrist strap when handling circuit boards, the shuttle frame assembly, and any other electronic component.
Page 191 Circuit Board: Controller Installation ATTENTION To prevent electrostatic damage to electronic components, wear a properly grounded static wrist strap when handling circuit boards, the shuttle frame assembly, and any other electronic component. 1. Install the DRAM SIMM, Flash Memory, and Security PAL on the controller board (page 217).
Page 192: Circuit Board: Power Supply
Chapter Section I: Replacement Procedures Circuit Board: Power Supply CAUTION <4> To prevent injury from electric shock, wait at least one minute after powering off before removing the power supply board. ATTENTION Do not touch components or flex the board during removal/installation. Handle the board by the ejection levers and the sides.
Page 193: Circuit Breaker
Circuit Breaker Circuit Breaker Removal 1. Prepare the printer for maintenance (page 152). 2. Open the printer cover. 3. Remove the card cage fan (page 209). 4. Disconnect the four circuit breaker electrical leads. (Cabinet Model: See Figure 53, page 280. Pedestal Model: See Figure 46, page 262.) 5.
Page 194: Coax/Twinax Multi-Platform Interface
Chapter Section I: Replacement Procedures Coax/Twinax Multi-Platform Interface NOTE: Installation, operation, and replacement parts for this optional feature are covered in detail in the Coax/Twinax Multi-Platform Interface Feature Installation and Operation Guide, Form Number S246-0149. Removal ATTENTION To prevent electrostatic damage to electronic components, wear a properly grounded static wrist strap when handling circuit boards, the shuttle frame assembly, and any other electronic component.
Page 195: Connector Shells
Connector Shells Connector Shells Some of the printer cable connectors are grouped inside connector shells. The procedure below explains how to remove and install cable assemblies from any connector shell in the printer. NOTE: There is also a diagram of the P106 / P107 connector shells on the plastic cover over the power supply.
Page 196 Chapter Section I: Replacement Procedures Installation 1. Position the cable connector in the connector shell. Two-wire connectors are always grouped across from two-wire connectors in a connector shell. Four-wire connectors are always grouped across from four-wire connectors in a connector shell. (See Figure 30.) 2.
Page 197 Connector Shells P106 Connector Configuration P107 Connector Configuration (Top View: As seen 19 17 15 13 11 9 7 5 3 1 19 17 15 13 11 9 7 5 3 1 when plugged into the CMX controller board.) PLAT M PAPR M LRIB M RRIB M...
Page 198: Connector Stiffening Clips
Chapter Section I: Replacement Procedures Connector Stiffening Clips Later model printers have connector stiffening clips on CMX board connectors P106 and P107. For earlier models, the clips are available in a field kit. The clips stiffen connectors P106 and P107 and help prevent accidental removal of wires when the connector shells are disconnected from the CMX board.
Page 199 Connector Stiffening Clips P107 P106 Stiffening Clip Connector Shell Figure 31. Connector Stiffening Clips...
Page 200: Cover Assembly, Hammer Bank / Ribbon Mask
Chapter Section I: Replacement Procedures Cover Assembly, Hammer Bank / Ribbon Mask Removal 1. Prepare the printer for maintenance (page 152). 2. Remove the shuttle frame assembly (page 242). 3. Early models: Lift the thick plate of the hammer bank cover assembly at one end, and peel the cover away from hammer bank magnets.
Page 201 Cover Assembly, Hammer Bank / Ribbon Mask Installation ATTENTION The hammer bank contains a strong magnet. To prevent damage to the hammer tips, do not let the hammer bank cover assembly snap into place as the hammer bank magnet attracts it. Any impact of the cover against the hammer bank can break hammer tips.
Page 202 Chapter Section I: Replacement Procedures Hammer Bank Cover Early Models (Thick Plate) Ribbon Mask (Thin Plate) Hammer Bank Cover Assembly Later Models Ribbon Mask Torque Sequence Ribbon Mask Hammer Bank Cover Clamp Plate (3) Screw (6) Screw (12) Hammer Bank Cover Torque Sequence Figure 32.
Page 203: Cover Assembly, Shuttle
Cover Assembly, Shuttle Cover Assembly, Shuttle Removal 1. Prepare the printer for maintenance (page 152). 2. Loosen the shuttle cover screws (page 258, Figure 44, item 2). 3. Grasping the edges of the shuttle cover assembly, tilt up the rear edge and lift the shuttle cover assembly out of the printer.
Page 204: Cover Assembly, Top, Pedestal Model
Chapter Section I: Replacement Procedures Cover Assembly, Top, Pedestal Model Removal 1. Prepare the printer for maintenance (page 152). 2. Remove the operator panel (page 228). 3. Remove five screws and the control panel bracket. (See Figure 43, page 256, items 3 and 4.) 4.
Page 205: Dashpot
Dashpot Dashpot This procedure applies only to cabinet models. Removal CAUTION <3> Two persons may be required to do this procedure. Prop or hold the top cover securely open while disengaging the dashpot. 1. Prepare the printer for maintenance (page 152). 2.
Page 206: Doors, Cabinet, Reversing
Chapter Section I: Replacement Procedures Doors, Cabinet, Reversing NOTE: Floor cabinet printers are assembled with the front door hinged on the left side so that it opens at the right side. The rear door is hinged on the right side so that it opens on the left side. This procedure enables you to reverse this door configuration.
Page 207: Ethernet Interface Assemblies
Ethernet Interface Assemblies Ethernet Interface Assemblies NOTE: The Ethernet LAN option is available in one of three configurations: 10Base-T, 10Base2, or 10/100Base-T. These options are available factory installed or as field kits. Removal and installation is the same for all versions. The functions of the LEDs and DIP switches on the various Ethernet interface boards are described on page 52 and page To convert an Ethernet-equipped printer to a parallel interface, remove the Ethernet board assembly and install the Centronics...
Page 208: Fan Assembly, Cabinet Exhaust
Chapter Section I: Replacement Procedures Fan Assembly, Cabinet Exhaust Removal 1. Prepare the printer for maintenance (page 152). 2. Open the floor cabinet doors and the printer cover. 3. Remove the paper stacker. (See Figure 41, page 252.) 4. Remove the three screws securing the air exhaust duct. (The top screw is located near the right front of the card cage, in front of the square air holes in the printer base plate.) (See Figure 42, page 254.) 5.
Page 209: Fan Assembly, Card Cage
Fan Assembly, Card Cage Fan Assembly, Card Cage Removal 1. Prepare the printer for maintenance (page 152). 2. Cabinet Model: Remove the paper guide assembly (page 229). Pedestal Model: Remove the top cover assembly (page 204). 3. Disconnect the fan cable connector: Cabinet Model, Figure 52, page 278.
Page 210: Fan Assembly, Hammer Bank
Chapter Section I: Replacement Procedures Fan Assembly, Hammer Bank Removal 1. Prepare the printer for maintenance (page 152). 2. Remove the shuttle cover assembly (page 203). 3. Pedestal Model: Remove the top cover assembly (page 204). 4. Trace the hammer bank fan cable assembly back to the controller board connector J107, releasing it from all cable constraints.
Page 211: Hammer Spring Assembly
Hammer Spring Assembly Hammer Spring Assembly Removal 1. Prepare the printer for maintenance (page 152). 2. Remove the shuttle frame assembly (page 242). 3. Carefully vacuum the shuttle frame assembly. 4. Remove the hammer bank cover assembly (page 200). ATTENTION Hammer springs and hammer tips are fragile.
Page 212 Chapter Section I: Replacement Procedures NOTE: The hammer spring assemblies shown here are for 6400-004/-04P/-005/-05P printers. The number of hammer springs and mounting screws varies among printer models, but removal and installation are the same. Hammer Spring Assembly 7 Hammer Spring Assembly 1 Discard old screws.
Page 213 Hammer Spring Assembly Installation NOTE: 6400-050, -P50, -010, -P10, -014, -015, -C05, and -C5P printers must use the CMX 040 controller board. 1. Using a clean dry cloth, wipe the hammer spring mounting surface on the hammer bank. Make sure the cloth does not leave lint on the hammer bank.
Page 214 Chapter Section I: Replacement Procedures NOTE: The hammer spring assemblies shown here are for 6400-004/-04P/-005/-05P printers. The number of hammer springs and mounting screws varies among printer models, but removal and installation are the same. Use new screws from the New Hammer kit.
Page 215: Ibm Coax/Twinax Expansion Board
IBM Coax/Twinax Expansion Board IBM Coax/Twinax Expansion Board Removal ATTENTION To prevent electrostatic damage to electronic components, wear a properly grounded static wrist strap when handling circuit boards, the shuttle frame assembly, and any other electronic component. 1. Prepare the printer for maintenance (page 152).
Page 216: Magnetic Pick-Up (Mpu) Assembly
Chapter Section I: Replacement Procedures Magnetic Pick-up (MPU) Assembly Removal 1. Prepare the printer for maintenance (page 152). 2. Remove the shuttle cover (page 203). 3. Disconnect the shuttle cable assembly connector (page 272, Figure 49). 4. Disconnect the magnetic pick-up (MPU) cable connector (page 272, Figure 49).
Page 217: Memory And Security Modules
Memory and Security Modules Memory and Security Modules Removal 1. Make a configuration printout of all configurations. (Refer to the Setup Guide.) 2. Prepare the printer for maintenance (page 152). 3. Cabinet Model: Remove the paper guide assembly (page 229). Pedestal Model: Remove the top cover assembly (page 204).
Page 218 Chapter Section I: Replacement Procedures Installation ATTENTION To prevent electrostatic damage to electronic components, wear a properly grounded static wrist strap when handling circuit boards, the shuttle frame assembly, and any other electronic component. NOTE: Flash SIMMs from one CMX controller board must be placed in the same slot on a replacement CMX controller board.
Page 219 Table 8. Pre-Written Flash SIMMs and Security Modules: Early Models Pre-Written Flash for models Security Module Code Load Description 004, 04P, 005, 05P, 008, 08P, IBM P/N (Vendor P/N) 009, 09P, 012, 014, C05, C5P Base ASCII 24H9315 14H5509 (154143-002)
Page 220 Chapter Section I: Replacement Procedures CMX Controller Board CAUTION: <5> 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. Bank 1 Bank 0 Bank 1 Bank 0...
Page 221: Motor Assembly, Paper Feed
Motor Assembly, Paper Feed Motor Assembly, Paper Feed Removal 1. Prepare the printer for maintenance (page 152). 2. Cabinet Model: Remove the paper guide assembly (page 229). Pedestal Model: Remove the top cover assembly (page 204). 3. Cabinet Model: Loosen four screws and remove the barrier shield. (See Figure 44, page 258, items 3 and 4.) Pedestal Model: Remove the four screws, the barrier shield, and the paper guide.
Page 222 Chapter Section I: Replacement Procedures Installation 1. Position the paper feed motor assembly on the right side plate and install the motor mount bolts and nuts finger tight (page 278, Figure 52). 2. Connect the paper feed motor cable connector to connector P107, then connect P107 to J107 on the controller board.
Page 223: Motor Assembly, Platen Open
Motor Assembly, Platen Open Motor Assembly, Platen Open Removal 1. Prepare the printer for maintenance (page 152). 2. Cabinet Model: Remove the paper guide assembly (page 229). Pedestal Model: Remove the top cover assembly (page 204). 3. Cabinet Model: Remove the card cage fan (page 209). 4.
Page 224 Chapter Section I: Replacement Procedures Installation 1. Position the platen open motor assembly with the wires toward the rear (page 278, Figure 52). 2. Install the two 5/16 inch motor mount screws (and nuts, if present) finger tight. 3. Install the platen open belt and motor pulley. Bottom out the motor pulley ±...
Page 225: Motor Assembly, Ribbon Drive
Motor Assembly, Ribbon Drive Motor Assembly, Ribbon Drive Removal 1. Prepare the printer for maintenance (page 152). 2. Remove the ribbon hub (page 238). 3. Remove two screws and washers securing the ribbon drive motor to the base casting (page 278, Figure 52). 4.
Page 226: Network Print Server
Network Print Server Installation and operation of this optional feature are described in the Print Server User’s Guide , P/N 30H4056. This guide describes error messages and troubleshooting information. Also provided is a section that describes IBM service procedures. Removal...
Page 227: Operator Panel Assembly, Cabinet Model
Operator Panel Assembly, Cabinet Model Operator Panel Assembly, Cabinet Model Removal 1. Prepare the printer for maintenance (page 152). 2. Open the printer cover. 3. Remove the four screws securing the operator panel plate to the panel bracket. (See Figure 42, page 254.) 4.
Page 228: Operator Panel Assembly, Pedestal Model
Chapter Section I: Replacement Procedures Operator Panel Assembly, Pedestal Model Removal 1. Prepare the printer for maintenance (page 152). 2. Open the printer cover. 3. Tilt the operator panel toward the front of the printer. 4. Disconnect the phone-style cable connector at the rear of the operator panel.
Page 229: Paper Guide Assembly
Paper Guide Assembly Paper Guide Assembly This procedure applies only to cabinet models. Removal 1. Prepare the printer for maintenance (page 152). 2. Open the printer cover. 3. Loosen the three paper guide assembly hold-down screws (page 258, Figure 44, item 6). 4.
Page 230: Paper Ironer
Chapter Section I: Replacement Procedures Paper Ironer CAUTION <2> Over time the upper edge of the paper ironer can become sharp. To avoid cutting yourself, handle the paper ironer on the sides. Removal 1. Remove the shuttle frame assembly (page 242). 2.
Page 231: Platen
Platen Platen Removal 1. Prepare the printer for maintenance (page 152). 2. Remove the shuttle frame assembly (page 242). 3. Remove the paper ironer (page 230). 4. Remove the three 1/4 inch screws securing the paper ironer bracket assembly and remove the assembly. (See Figure 51, page 276, items 4 through 6.) 5.
Page 232 Chapter Section I: Replacement Procedures Installation IMPORTANT The dowel pins protruding from the ends of the platen are the platen shafts, and are not equal in length. The platen must be installed with the longer shaft on the right side. 1.
Page 233 Platen Washers Platen Adjust Bracket Platen Wear Saddle Mechanism Base Platen Seat Figure 37. Positioning the Platen Adjust Brackets 9. Slide the right ribbon guide assembly into the side plate and install the two 7/32 inch screws and washers. (See Figure 52, page 278, items 11, 13 and 14.) 10.
Page 234 Chapter Section I: Replacement Procedures For the right side of the platen, a washer goes on both sides of the paper ironer hook and the hook goes to the left of the right platen adjustment bracket. (See Figure 36, page 232.) ±...
Page 235: Resistors, Terminating
Resistors, Terminating Resistors, Terminating For parallel interface configurations, the printer is equipped with 470 ohm pull- up terminating resistors and 1K ohm pull-down terminating resistors on the controller board. These are suitable for most applications. (See Figure 38, page 236.) If the standard terminating resistor pack is not compatible with the interface driver requirements of the host computer, other values of pull-up and pull- down resistors may be required.
Page 236 Chapter Section I: Replacement Procedures CMX Controller Board Default: 470 Ohm Alt 1: 220 Ohm Alt 2: 1K Ohm Resistor Kit: 14H5525 Default: 1K Ohm Alt 1: 330 Ohm Alt 2: None Figure 38. Terminating Resistors, Removal/Installation...
Page 237: Ribbon Guide Assembly (L/R)
Ribbon Guide Assembly (L/R) Ribbon Guide Assembly (L/R) Removal 1. Prepare the printer for maintenance (page 152). NOTE: The right ribbon guide is shown in Figure 52. The removal procedure is the same for the left ribbon guide. 2. Cut and remove the tie wrap from the tie wrap hole to free the ribbon guide cable (page 278, Figure 52).
Page 238: Ribbon Hub
Chapter Section I: Replacement Procedures Ribbon Hub Removal 1. Prepare the printer for maintenance (page 152). 2. Loosen the Torx T-10 screw in the ribbon spool hub (page 278, Figure 52). 3. Remove the hub from the shaft of the ribbon drive motor. Installation 1.
Page 239: Shaft, Splined
Shaft, Splined Shaft, Splined Removal 1. Prepare the printer for maintenance (page 152). 2. Open the printer cover. 3. Remove the paper supports from the splined shaft and support shaft. (See Figure 50, page 274, item 21.) 4. Remove the paper feed timing belt (page 188). 5.
Page 240 Chapter Section I: Replacement Procedures Installation 1. Open the doors on the left and right tractors. Position the tractor belts so the alignment marks are at the top on both tractors. (See Figure 39.) 2. Grasp the vertical adjustment knob and slide the splined shaft through the right side plate, the tractors, and the left side plate (page 274, Figure 50).
Page 241: Shaft, Support
Shaft, Support Shaft, Support Removal 1. Prepare the printer for maintenance (page 152). 2. Open the printer cover. 3. Unlock the tractors and slide them to the far right. 4. Remove the paper supports from the splined shaft and support shaft. (See Figure 50, page 274, item 21.) 5.
Page 242: Shuttle Frame Assembly
Chapter Section I: Replacement Procedures Shuttle Frame Assembly Removal 1. Prepare the printer for maintenance (page 152). 2. Remove the shuttle cover assembly (page 203). 3. Disconnect the MPU cable connector (page 272, Figure 49). ATTENTION To prevent electrostatic damage to electronic components, wear a properly grounded static wrist strap when handling circuit boards, the shuttle frame assembly, and any other electronic component.
Page 243 Shuttle Frame Assembly Installation 1. Install the hammer bank / ribbon mask cover assembly (page 200), if it was removed. ATTENTION To prevent electrostatic damage to electronic components, wear a properly grounded static wrist strap when handling circuit boards, the shuttle frame assembly, and any other electronic component.
Page 244: Spring, Extension
4. Unhook the extension spring from the spring lugs on the hammer bank and shuttle frame. (See Figure 49, page 272.) Installation 1. Put a dab of IBM #20 bearing lubricant on both spring lugs. ATTENTION Make sure the extension spring does not touch the MPU cable after installation.
Page 245: Switch Assembly, Cover Open
Switch Assembly, Cover Open Switch Assembly, Cover Open Removal 1. Prepare the printer for maintenance (page 152). 2. Remove the shuttle cover assembly (page 203). 3. Carefully lift and pry the cover open switch assembly out of its well in the base casting to the right of the shuttle motor.
Page 246: Switch Assembly, Paper Detector
Chapter Section I: Replacement Procedures Switch Assembly, Paper Detector Removal 1. Prepare the printer for maintenance (page 152). 2. Cabinet Model: Remove the paper guide assembly (page 229). Pedestal Model: Remove the top cover assembly (page 204). 3. Cabinet Model: Loosen four screws and remove the barrier shield. (See page 258, Figure 44, items 3 and 4.) Pedestal Model: Remove the paper guide, barrier shield, and four screws.
Page 247: Switch Assembly, Platen Interlock
Switch Assembly, Platen Interlock Switch Assembly, Platen Interlock Removal 1. Prepare the printer for maintenance (page 152). 2. Cabinet Model: Remove the paper guide assembly (page 229). Pedestal Model: Remove the top cover assembly (page 204). 3. Fully close the forms thickness lever (position ‘A’). 4.
Page 248: Tractor (L/R)
Chapter Section I: Replacement Procedures Tractor (L/R) Removal 1. Prepare the printer for maintenance (page 152). 2. Remove the splined shaft (page 239). 3. Remove the support shaft (page 241). 4. Remove the tractors. Installation 1. Using the replacement tractors, install the support shaft (page 241). 2.
Page 249: Section Ii: Illustrated Parts Lists
Illustrations Of Printer Components Section II: Illustrated Parts Lists Only field-replaceable spares are given part numbers in the illustrated parts lists. Part numbers are not listed for common fasteners and attachment hardware. Items marked “Ref” in the illustrations refer to parts that are not spared or are part of another assembly.
Page 250 Chapter Section II: Illustrated Parts Lists Figure 40. Top Cover, Doors, and Casters, Cabinet Model...
Page 251 57G1485 Caster, with Brake Two at front 57G1486 Caster, without Brake Two at rear 14H5603 Logo, 6400 30H4008 Wire Rope, Front and Rear One on each door (Rear not shown in Figure 40) 30H3986 Shipping Container Kit Cabinet models only...
Page 252 Chapter Section II: Illustrated Parts Lists Figure 41. Paper Stacker and Chains...
Page 253 Illustrations Of Printer Components Item Part No. Description Notes (Order No.) 57G7176 Stacker 30H3981 Runner, Stacker 04H4779 Riser, Stacker Runner Screw (4) 14H5296 Spares Kit, Grommet 14H5272 Chain Assembly Kit Kit contains eight chains 57G7260 Power Cord, U.S. Grommet, Power Cord (2) Included in item 5...
Page 254 Chapter Section II: Illustrated Parts Lists Figure 42. Operator Panel and Cabinet Details...
Page 255 Illustrations Of Printer Components Item Part No. Description Notes (Order No.) 14H5299 Operator Panel, Cabinet Includes mounting hardware 57G1598 Operator Panel Overlay English 57G1599 Operator Panel Overlay Spanish 57G1600 Operator Panel Overlay French 57G1601 Operator Panel Overlay Italian 57G1602 Operator Panel Overlay German 57G1603 Operator Panel Overlay...
Page 256 Chapter Section II: Illustrated Parts Lists NOTE: Item 16: Lid Accessory Kit not shown Item 17: Pedestal Shipping Container not shown Figure 43. Pedestal Details...
Page 257 Illustrations Of Printer Components Item Part No. Description Notes (Order No.) 63H5124 Operator Panel, Pedestal Models 04P, 05P, 08P, 09P 57G1598 Operator Panel Overlay English 57G1599 Operator Panel Overlay Spanish 57G1600 Operator Panel Overlay French 57G1601 Operator Panel Overlay Italian 57G1602 Operator Panel Overlay German...
Page 258 Chapter Section II: Illustrated Parts Lists Figure 44. Inside Covers, Cabinet Model...
Page 259 Illustrations Of Printer Components Item Part No. Description Notes (Order No.) 14H5235 Shroud Assembly, Air Shuttle Cover Assembly Screw, Captive (2) 10-24x.62 with O-ring, .125x.250x.06 Screw, Thread Forming (4) 6-32x.25 Barrier Shield 14H5271 Paper Guide Assembly Models 004, 005, 008, 009, 012, 014 Screw, w/Lock Washer (3) 6-32x.25 and #6 Flat Washer...
Page 260 Chapter Section II: Illustrated Parts Lists See Figure 46, page 262. Figure 45. Inside Covers and Card Cage, Pedestal Model...
Page 261 Illustrations Of Printer Components Item Part No. Description Notes (Order No.) 14H5235 Shroud Assembly, Air Shuttle Cover Assembly Screw, Captive (2) 10-24x.62 with O-ring, .125x.250x.06 Screw, Thread Forming (4) 6-32x.25 Barrier Shield 63H5116 Paper Path Assembly Models 04P, 05P, 08P, 09P 08H7954 Anti-Static Brush Kit Power Supply Shield...
Page 262 Chapter Section II: Illustrated Parts Lists From Figure 45, page 260. Rotated 180 degrees. To IEC 320 AC Power Input (Connector J301, White To Connector P1 Wire) (White Wire) To Connector P1 (Black Wire) To IEC 320 AC Power Input (Connector J301, Black Wire) Figure 46.
Page 263 Illustrations Of Printer Components Item Part No. Description Notes (Order No.) Nut, 6-32 (1) Upper right fan corner only 57G1440 Card Cage Fan Assembly Air flow is into card cage Fan Guard Screw, w/Lock Washer (4) 6-32x.1.75 Card Cage, Pedestal 14H5571 Circuit Breaker...
Page 264 Chapter Section II: Illustrated Parts Lists Two places: Exploded to show assembly. Do not remove holddown clamps and screws. To J02 (Shuttle Motor) To J03 (MPU) To Terminator Board on Shuttle Frame Figure 47. Print Mechanism and Circuit Boards: Early Models...
Page 265 Illustrations Of Printer Components Item Part No. Description Notes (Order No.) 63H7518 Hammer Bank/Rbn Mask Cover Models 004, 04P, 005, 05P 63H7519 Hammer Bank/Rbn Mask Cover Models 008, 08P, 009, 09P 63H7520 Hammer Bank/Rbn Mask Cover Models 012, 014 14H5274 Shuttle Frame Assembly Models 004, 04P 24H8648...
Page 266 Chapter Section II: Illustrated Parts Lists Item Part No. Description Notes (Order No.) SIMM, Flash Memory See also page 217 SIMM, DRAM See also page 217 14H5282 Switch Assembly, Cover Open...
Page 267 Illustrations Of Printer Components (Illustrated parts lists continue on next page.)
Page 268 Chapter Section II: Illustrated Parts Lists Two places: Exploded to show assembly. Do not remove holddown clamps and screws. To J02 (Shuttle Motor) To J03 (MPU) To Terminator Board on Shuttle Frame Figure 48. Print Mechanism and Circuit Boards: Later Models...
Page 269 Illustrations Of Printer Components Item Part No. Description Notes (Order No.) 24H8872 Hammer Bank Cover Assy, 500 Models 050, P50 24H8886 Hammer Bank Cover Assy, 1000 Models 010, P10 24H8924 Hammer Bank Cover Assy, 1500 Model 015 63H7520 Hammer Bank Cover Assy, Hanzi Models C05, C5P 24H8828 Ribbon Mask, 500...
Page 270 Chapter Section II: Illustrated Parts Lists Item Part No. Description Notes (Order No.) SIMM, Flash Memory See also page 217 SIMM, DRAM See also page 217 14H5282 Switch Assembly, Cover Open 02N8261 Connector Clip...
Page 271 Illustrations Of Printer Components (Illustrated parts lists continue on next page.)
Page 272 Chapter Section II: Illustrated Parts Lists Spring Lug (Do not remove grease) Spring Lug (Do not remove grease) <21> Make sure the extension spring does not touch the MPU cable after installation. 0.010 .001 inch (0.254 .025mm) Figure 49. Magnetic Pickup Unit (MPU) and Extension Spring...
Page 273 Illustrations Of Printer Components Item Part No. Description Notes (Order No.) 57G1476 Magnetic Pickup Assy (MPU) Screw, Socket Cap, 6-32x.38 30H3985 Extension Spring 14H5329 Cable Assembly, MPU...
Page 274 Chapter Section II: Illustrated Parts Lists 14 13 NOTE Item 18: Tractor Shaft Hardware Kit not shown Item 19: Tractor Shaft Kit not shown Figure 50. Tractor Shafts...
Page 275 Illustrations Of Printer Components Item Part No. Description Notes (Order No.) Screw, Socket Cap, 4-40x.25 Part of item 19 Washer, Flat #4 Part of item 19 Knob, Tractor Adjust Part of item 19 Bushing, Tractor Adjust Part of item 19 Washer, Curved Spring (2) Part of item 19 Ring, Grip...
Page 276 Chapter Section II: Illustrated Parts Lists NOTE: Black tape faces paper motion detector. NOTE: Item 25: Platen Hardware Kit 18 17 Figure 51. Platen...
Page 277 Illustrations Of Printer Components Item Part No. Description Notes (Order No.) Setscrew Part of item 25 Bracket, Platen (2) Part of item 25 57G1469 Ironer Assembly Reverser Paper Feed Screw, Thread Forming (3) 6-32x.25 57G1571 Bracket, Ironer Plate, Ironer 08H7936 Platen Assembly Washer, Flat (2) Part of item 25...
Page 278 Chapter Section II: Illustrated Parts Lists Install screws here Top View Route cable under Hammer Bank Fan base casting See detail above Figure 52. Motors, Card Cage Fan, and Paper Detector Switch...
Page 279 Illustrations Of Printer Components Item Part No. Description Notes (Order No.) 57G1440 Fan Assembly Air flow is into card cage Screw, w/Lock Washer (3) Two 6-32x1.75 on botton One 6-32x0.50 on top left 14H5281 Paper Detector Switch Assy Standard 14H5570 Paper Detector Switch Assy Black Back forms Screw, Thread Forming, 6-32x.375...
Page 280 Chapter Section II: Illustrated Parts Lists See inside detail below. To IEC 320 AC Power Input (Connector J301, Black Wire) To IEC 320 AC Power Input (Connector J301, White Wire) To Connector P1 (Black Wire) To Connector P1 (White Wire) Black Wire Card cage fan and power supply board...
Page 281 Illustrations Of Printer Components Item Part No. Description Notes (Order No.) 14H5571 Circuit Breaker IEC 320 AC Power Connector Connector J301 Chassis Ground Stud Connector P1 To power supply board connector J1 AC Cable Assy, AC-In, Power Supply Part of Field Kit, AC Assy 14H5289...
Page 282 Chapter Section II: Illustrated Parts Lists Figure 54. IBM Coax/Twinax Expansion Board...
Page 283 Illustrations Of Printer Components Item Part No. Description Notes (Order No.) Screw (2) Card Cage 24H9011 IBM Coax/Twinax Expansion Screw, Captive Standoff, Hex, 3/16 inch M/F, .813 Lg. 24H8535 Adapter, Expansion Connector 60-pin CMX Controller Board Controller Board Connector J111...
Page 284 Chapter Section II: Illustrated Parts Lists Figure 55. Ethernet Interface Assemblies...
Page 285 Illustrations Of Printer Components Item Part No. Description Notes (Order No.) Screw, Connector Cover (2) Cover Plate, Centronics Ferrite Clamp See also Appendix I CMX Controller Board 14H5287 Centronics I/O Cable Assembly 24H8995 Ethernet LAN PCBA, 10Base-T 24H8994 Ethernet LAN PCBA, 10Base2 02N8315 Ethernet LAN PCBA, 10/100Base-T Rear of Card Cage...
Page 286 Chapter Section II: Illustrated Parts Lists...
Page 287: A Wire Data
Power Distribution Diagram ............page 290 Main Wire Harness Test Tables ............page 291 Circuit Board Pinouts Controller, CMX ................ page 292 Power Supply................page 296 IBM Coax/Twinax Expansion Board ......... page 297 ∗∗ SureStak Power Stacker PCBA ..........page 298 Cable Routing Cabinet Model................
Page 288 Appendix A Circuit Board And Cable Pinouts Shuttle Motor Drive ..............page 317 Power Stacker Cables Frame Cable, Power Stacker ..........page 318 Logic Cable, Power Stacker ..........page 319 Power Cable, Power Stacker ..........page 320 Vertical Rail Cable, Power Stacker ........page 321 Fan Assembly, Hammer Bank ............
Page 289: Interconnection Diagram
Interconnection Diagram...
Page 290: Power Distribution Diagram
Appendix A Circuit Board And Cable Pinouts Power Distribution Diagram...
Page 291: Main Wire Harness Test Tables
Main Wire Harness Test Tables P106 Connector P107 Connector Connectors are viewed from the top, as seen 19 17 15 13 11 9 7 5 3 1 19 17 15 13 11 9 7 5 3 1 when plugged into CMX controller board.
Page 292: Controller, Cmx
J112 Centronics I/O CNC PN 1 N STROBE I/O CNC PN 19 I/O CNC PN 2 I/O CNC PN 20 I/O CNC PN 3 I/O CNC PN 21 I/O CNC PN 4 I/O CNC PN 22 I/O CNC PN 5 J201 J110 I/O CNC PN 23...
Page 293 CAUTION: <5> Do not remove or replace Diagnostic Port the NVRAM. The NVRAM contains a lithium battery that can explode if it is replaced incorrectly. NVRAM is replaced DB TXD only at the factory. DB RXD 470 PF Online Verifier EXT 5V DB TXD DB RXD...
Page 294 J111 J105 Expansion Connector Hammer Bank Power 4.7K 4.7K J101 0.1W 0.1W J106 Power Supply EXP D7 Motor Sensor Left EXP D6 EXP D5 N TEMP HI EXP N ID SEL EXP D4 N STBY PLAT 1 RIB L1 12/10 V EXP D3 PLAT 2 EXP D2...
Page 295 0.1W EC DB TXD EC DB RXD EC Diagnostics PPR TRIG PPR MOVING FT EVENT MPU OUT SHUT DIR 2-PIN JUMPER Flash: Flash: 80-pin SIMM J108 J116 J10 = Bank 1 80-pin SIMM J11 = Bank 0 DRAM: Hammer Bank Logic Shuttle Motor J10 = Bank1 4.7V...
Page 296: Power Supply
Appendix A Circuit Board And Cable Pinouts Power Supply...
Page 297: Ibm Coax/Twinax Expansion Board
IBM Coax/Twinax Expansion Board...
Page 298: Surestak Power Stacker Pcba
Appendix A Circuit Board And Cable Pinouts SureStak Power Stacker PCBA...
Page 299: Cabinet Model
Cable Routing, Cabinet Model...
Page 300: Cabinet Model, Mechanism Base
Front of Printer Right Side of Printer Left Side of Printer L RBN M CABLE ASSY To J106 on CMX board NOTE: This view shows the underside of the To J107 on CMX board mechanism base.
Page 301: Pedestal Model
Cable Routing, Pedestal Model...
Page 302: Pedestal Model, Mechanism Base
Front of Printer Left Side of Printer Right Side of Printer P306 (Not connected TO CARD on pedestal models) CAGE FAN PLAT M P106/CCF P106/LRP To J106 on CMX board on Controller (See page 166 for To J107 on CMX board connector detail.) (See page 166 for NOTE: This view shows the underside of the...
Page 303: Cable Assemblies Centronics I/O
Cable Assembly, Centronics I/O 14H5287 PIN 1 NOTE: If you replace this cable, NOTE: you must also install a ferrite clamp. If you replace the I/O cable See Appendix I. assembly, you must install the ferrite clamp. See Appendix E. PIN 1...
Page 304: Centronics/Dataproducts Adapter
Appendix A Circuit Board And Cable Pinouts Cable Assembly, Centronics/Dataproducts Adapter 14H5522...
Page 305: Remote Power
Cable Assembly, +5V Remote Power 14H5589...
Page 306: Twinax Auto-Termination
Appendix A Circuit Board And Cable Pinouts Cable Assembly, Twinax Auto-Termination 38F8254 Jack White Gray Shield Resistance Chart Ohms 1, 2, 3, 4 Shield Shield 1, 4 2, 3 Jack...
Page 307: Ac-In, Power Supply
Cable Assembly, AC-In, Power Supply AC Kit: 14H5289 To Circuit Breaker To Power Supply J1...
Page 308: Ac Power Input
Appendix A Circuit Board And Cable Pinouts Cable Assembly, AC Power Input AC Kit: 14H5289 To Circuit Breaker Input Power Connector...
Page 309: Card Cage Fan
Cable Assembly, Card Cage Fan 14H5285 PIN 1 PIN 1...
Page 310: Control Panel
Appendix A Circuit Board And Cable Pinouts Cable Assembly, Operator Panel 14H5300 NOTE: If you replace the control panel cable, you must install two ferrite shielding beads. PIN 8 See Appendix I. (Brown) PIN 1 (Gray) PIN 8 (Brown) PIN 1 (Gray)
Page 311: Exhaust Fan
Cable Assembly, Exhaust Fan 14H5286 PIN 1 PIN 1...
Page 312: Hammer Bank Logic
Appendix A Circuit Board And Cable Pinouts Cable Assembly, Hammer Bank Logic 14H5279...
Page 313: Hammer Bank Power
Cable Assembly, Hammer Bank Power 02N6214 PIN 1 PIN 1...
Page 314: Mpu
Appendix A Circuit Board And Cable Pinouts Cable Assembly, MPU 14H5329 PIN 2 PIN 3 PIN 1 PIN 1...
Page 315: Ribbon Guide Kit
Cable Assembly, Ribbon Guide Kit 24H8894 NOTE: Left ribbon guide shown. Right is mirror image. Left Guide = P106 / LRP Right Guide = P107 / RRP Pin 2 Pin 1 Pin Connection P106 (LRP) / P107 (RRP) Wire Color Pin 1 Black Pin 2...
Page 316: Ribbon Motor, Extension
Appendix A Circuit Board And Cable Pinouts Cable Assembly, Ribbon Motor, Extension 63H7464...
Page 317: Shuttle Motor Drive
Cable Assembly, Shuttle Motor Drive 14H5330...
Page 318: Frame Cable, Power Stacker
Appendix A Circuit Board And Cable Pinouts Frame Cable, Power Stacker...
Page 319: Logic Cable, Power Stacker
Logic Cable, Power Stacker 24H8976...
Page 320: Power Cable, Power Stacker
Appendix A Circuit Board And Cable Pinouts Power Cable, Power Stacker 24H8975...
Page 321: Vertical Rail Cable, Power Stacker
Vertical Rail Cable, Power Stacker (Reference only: not spared.)
Page 322: Fan Assembly, Hammer Bank
Appendix A Circuit Board And Cable Pinouts Fan Assembly, Hammer Bank...
Page 323: Magnetic Pickup (Mpu) Assembly
Magnetic Pickup (MPU) Assembly 57G1476...
Page 324: Switch Assembly, Paper Detector
Appendix A Circuit Board And Cable Pinouts Switch Assembly, Paper Detector...
Page 325: Switch Assembly, Platen Interlock
Switch Assembly, Platen Interlock 14H5280...
Page 326: Switch Assembly, Cover Open
Appendix A Circuit Board And Cable Pinouts Switch Assembly, Cover Open 14H5282...
Page 327: B Printer Specifications
Printer Specifications Ribbon Specifications The ribbon life figures listed below are based on IBM tests conducted in accordance with ANSI Standard X3A.182. Actual ribbon life may vary, depending on the user’s quality criteria, printer condition, machine settings, paper quality, and bar code requirements. Label yield depends on label format, bar code symbology, and other parameters.
Page 328: Paper Specifications
Chapter Paper Specifications Ordering Ribbons Outside Of The U.S. Order supplies by contacting your local Lexmark International distributor or by writing to Lexmark International, Inc., P.O. Box 11427, Lexington, KY, 40575- 1427, USA Paper Specifications The paper specifications in this section are guidelines only. Always test paper stock with applications to determine print quality.
Page 329: Printer Dimensions
158 F (-40 to 70 Relative Humidity Operating: 15% to 80% (noncondensing) Storage: 15% to 90% (noncondensing) NERGY TAR** IBM 6400 Series Printers comply with the requirements of the NERGY TAR Computers Program of the U.S. Environmental Protection Agency.
Page 330: Electrical Characteristics
200 V 200 V 200 V 200 V 200 V 200 V 200 V 200 V 200 V 200 V Power Consumption 6400-004 6400-04P Operating HS Mode Standby 120 VAC 60 Hz Not Energy All H’s Max Typical Energy Star Star...
Page 331 6400-005 6400-05P Operating HS Mode Standby 120 VAC 60 Hz Not Energy All H’s Max Typical Energy Star Star Watts BTU/Hour Operating HS Mode Standby 240 VAC 50 Hz Not Energy All H’s Max Typical Energy Star Star Watts BTU/Hour...
Page 332 Chapter Electrical Characteristics Operating HS Mode Standby 240 VAC 50 Hz Not Energy All H’s Max Typical Energy Star Star 6400-008 6400-08P Operating HS Mode Standby 120 VAC 60 Hz Not Energy All H’s Max Typical Energy Star Star Watts...
Page 333 Operating HS Mode Standby 240 VAC 50 Hz Not Energy All H’s Max Typical Energy Star Star Watts BTU/Hour 1072 6400-010 6400-P10 Operating HS Mode Standby 120 VAC 60 Hz Not Energy All H’s Max Typical Energy Star Star Watts...
Page 334 Operating HS Mode Standby 240 VAC 50 Hz Not Energy All H’s Max Typical Energy Star Star Watts BTU/Hour 1365 1604 6400-014 Operating HS Mode Standby 120 VAC 60 Hz Not Energy All H’s Max Typical Energy Star Star Watts BTU/Hour 1399...
Page 335 Operating HS Mode Standby 240 VAC 50 Hz Not Energy All H’s Max Typical Energy Star Star Watts BTU/Hour 1447 1672 6400-C05 6400-C5P Standby 120 VAC Max Typical 60 Hz Not Energy Star Energy Star Watts BTU/Hour 1163 Standby 240 VAC...
Page 336: Interfaces
Up to 19.2K baud on RS-232 serial interface. Up to 115.2K baud on RS-422 serial interface Duty Cycle The duty cycles for IBM 6400 printers are listed below. These figures are averages, subject to the conditions specified following the list. 6400-004, 04P...
Page 337: C Metric Conversion Tables
Metric Conversion Tables Length Multiply To Obtain foot 0.3048* meter foot 30.48* centimeter foot 304.8* millimeter inch 0.0254* meter inch 2.54* centimeter inch 25.4* millimeter meter 3.280840 foot centimeter 0.03280840 foot millimeter 0.003280840 foot meter 39.37008 inch centimeter 0.3937008 inch millimeter 0.03937008 inch...
Page 338: Mass And Density
Appendix C Multiply To Obtain pound 4.4482 Newton inch 0.22481 pound Mass and Density Multiply To Obtain pound* 0.4535924 kilogram ounce* 28.34952 gram kilogram 2.204622 pound gram 0.03527397 ounce * avoirdupois Temperature From Use Formula temperature Celsius (tc) temperature Fahrenheit (tf) tf = 1.8tc + 32 temperature Fahrenheit temperature Celsius (tc)
Page 339: D Torque Table
Torque Table The table below establishes the torque requirements for routine installation of threaded fasteners. These requirements apply to fasteners made of steel, at a minimum engagement of 3.5 threads, including chamfer and countersink. For the most accurate torquing, apply anti-seize compound to fastener threads before you torque the fastener.
Page 340 Appendix D...
Page 341: E Safety Inspection Guide
Safety Inspections Safety devices to protect customers, operators, and service personnel from injury are installed in all IBM 6400 printers. Use this inspection guide as an aid in identifying possible unsafe conditions in a 6400 series printer. Perform the inspection steps outlined in this guide before the normal inspection for Maintenance Agreement Qualification, or any time you are instructed to make a safety inspection.
Page 342: Prepare The Printer For Inspection
Appendix E Prepare The Printer for Inspection Prepare The Printer for Inspection To prepare the printer for a safety inspection, read the safety notices below, then do the following steps. DANGER <3> Hazardous voltages are present in the printer with the power cord connected to the power source.
Page 343: Print Mechanism
b. Make sure the restraining cable is attached and unbroken. c. Make sure there are no exposed or sharp edges. d. Open the rear cabinet door and inspect the lower rear paper path: e. Make sure the service panel permitting access to the I/O plate and circuit breaker (on/off switch) is installed.
Page 344 Appendix E Inspect Electrical Parts 4. Set a Fluke meter (P/N 8496278) or similar device to the lowest resistance scale. Measure the resistance between the power cable ground pin and the printer frame: safety ground circuits should measure 0.1 Ohm or less. 5.
Page 345: Power Cable
Neutral impedance NOTE: The customer is responsible for correcting problems with the power source. Inform the IBM Installation Planning Representative (IPR) of any problems with the customer’s power source. Each branch circuit must be grounded for safety and correct operation of the printer.
Page 346 Appendix E Inspect Electrical Parts 4. Press Stop. The audible alarm should stop. 5. Close the forms thickness lever. The fault message should clear.
Page 347: F Abbreviations And Signal Mnemonics
Abbreviations And Signal Mnemonics NOTE: Mnemonics with the first letter “N” are negative true. Abbreviation or Mnemonic Definition KΩ 1,000 Ohms MegΩ 1,000,000 Ohms µF microfarad (10 farad) µs microsecond (10 second) µsec microsecond (10 second) A0, A1, etc. Address 0, Address 1, etc. Alternating Current Access Acknowledge...
Page 348 Appendix F Buffered Upper Driver Cathode Card Cage Card Cage Fan Customer Engineer CHNG Change Circuit Clock Cover Open COLL Collector COMM Communication CONTLR Controller Command Manufacturer’s designation of the controller board Connector, Connection Characters Per Inch Carriage Return Coaxial/Twinaxial Control Clear to Send Current...
Page 349 Data Set Ready Data Terminal Ready Engine Controller (a functional unit of the CMX board) EEPROM Electrically Erasable/Programmable Read-Only Memory Exhaust Fan Elevator (motor), Power Stacker ElectroMagnetic Interference EMIT Emitter EPROM Electrically Programmable Read-Only Memory Error Electrostatic Discharge Exhaust, Extra Exhaust Exhaust Fan Expansion...
Page 350 Appendix F Hammer Bank Logic, Signals and Power Integrated Circuit Identification Intelligent Graphics Processor Initial Microcode Load INST Instruction Interrupt Input/Output Interrupt Request Jack connector Left Liquid Crystal Display Light Emitting Diode Line Feed Lines Per Inch Lines Per Minute LRIB Left Ribbon Left Ribbon Guide...
Page 351 Negative True Not Connected Not Connected Network Interface Card (an optional Ethernet interface) Near Letter Quality Number NOVRAM Non-volatile Random-Access Memory nanosecond (10 second) NVRAM Non-volatile Random-Access Memory On Line Verify Operand + 5 V dc Pin connector P(1), P(2), etc. Parallel data 1, data 2, etc. Programmable Array Logic Paper PAPR...
Page 352 Appendix F Part Number Paper Out Paper Out Detect (Switch) Paper PROM Programmable Read-Only Memory Power Supply Power Supply + 5 Volt Pointer or Printer Pulse Width Modulation Power Right Ribbon Read Return Ribbon Ribbon Guide Ribbon Guide, Left Ribbon Guide, Right Ribbon Motor Ribbon Motor, Left Ribbon Motor, Right...
Page 353 Shuttle Hall (Effect) Shuttle Motor SHUT Shuttle SHUTL Shuttle SIMM Single Inline Memory Module SLCT Select (On-line) Slew Rapid vertical paper movement Shuttle Motor Drive Systems Network Architecture Shuttle Processor Unit SRAM Static Random-Access Memory STAT Status STBY Standby Power Stacker Switch SYNC Synchronize...
Page 354 Appendix F Write With Without Transmit...
Page 355: G Cords And Adapters
14F0070 Line Cord, IBM, Chile, Italy 14F0088 Line Cord, 9 Feet, Israel 14H5301 Line Cord, 6400, 12 Foot, United States, 125 Volt 14H5303 Line Cord, 6400, 8 Foot, Chicago 14H5305 Line Cord, 6400, 12 Foot, United States, 220 Volt 14H5309...
Page 356 Appendix G Part Number Description 14H5315 Line Cord, 6400, Switzerland 14H5317 Line Cord, 6400, India, United Kingdom 14H5319 Line Cord, 6400, Europe (EMEA) 14H5321 Line Cord, 6400, Pakistan, South Africa 14H5323 Line Cord, 6400, Australia 14H5325 Line Cord, 6400, Japan...
Page 357: H Part Numbers
Part Numbers Part Number Location Description 01P4611 page 274 Tractor Assembly, Power Stacker 01P4698 page 401 Fence, Wireform (Power Stacker) 01P4699 page 399 Field Kit, Power Stacker, Limit Switch 02N6214 page 313 Cable Assembly, Hammer Bank Power 02N8261 page 268 Connector Stiffening Clip 02N8315 page 284...
Page 358 Appendix H Part Number Location Description 14H5271 page 258 Paper Guide Assembly (Models 004, 005, 008, 009, 010, 012, 014, C05) 14H5272 page 252 Chain Assembly Kit 14H5274 page 264 Shuttle Frame Assy (Models 004, 04P) 14H5275 page 264 Hammer Spring Kit (Models 004, 04P, 005, 05P) 14H5279 page 312 Cable Assy, Hammer Bank Logic...
Page 359 Shuttle Frame Assy (Models 005, 05P) 24H8766 page 18 6400 Operator’s Guide, English 24H8767 page 18 6400 Operator’s Guide, Spanish 24H8768 page 18 6400 Line Matrix Printer Setup Guide, French 24H8769 page 18 6400 Operator’s Guide, Italian 24H8770 page 18 6400 Operator’s Guide, German...
Page 360 6400 Line Matrix Printer Setup Guide, German 24H8779 page 18 6400 Line Matrix Printer Setup Guide, Dutch 24H8780 page 18 6400 Line Matrix Printer Setup Guide, Brazilian Portuguese 24H8781 page 18 6400 Line Matrix Printer Setup Guide, Japanese 24H8828 page 268...
Page 361 Part Number Location Description 24H8959 page 250 Front Door Kit 24H8960 page 250 Rear Door Kit 24H8961 page 250 Top Cover Kit 24H8962 page 399 Rear Door, Extended, Power Stacker 24H8963 page 399 RE Ship Kit, Printer w/Power Stacker 24H8966 page 399 Paper Deflector (Power Stacker) 24H8968...
Page 362 Expansion-CT PCBA 24H9625 page 264 Shuttle Frame Assy (Models 009, 09P) 24L5203 page 18 6400 Line Matrix Printers Operator’s Guide, Hanzi 24L5204 page 18 6400 -C05/-C5P Line Matrix Printers Setup Guide 24L5205 page 18 6400 -C05/-C5P Line Matrix Printers Programmer’s Reference-...
Page 363 Part Number Location Description 57G1466 page 274 Tractor Set 57G1468 page 258 Belt, Timing, 050P, 100 Teeth (Paper Feed) 57G1467 page 276 Belt, Timing, 312W, 87 Teeth (Platen Open) 57G1469 page 276 Ironer Assembly, Reverse Paper Feed 57G1476 page 272 Magnetic Pickup Assembly (MPU) 57G1479 page 278...
Page 364 63H5124 page 256 Operator Panel (Pedestal) 63H5125 page 256 Bracket, Control Panel 63H7379 page 26 6400 Line Matrix Printer Configuration Utility Disk 63H7398 page 250 Top Cover Seal Kit 63H7464 page 316 Cable Assembly, Ribbon Motor, Extension 63H7478 page 276...
Page 365: I Noise Suppression Devices
Noise Suppression Devices Ferrite noise suppressors are installed in the printer to reduce radio frequency interference (RFI) to and from electronic equipment located near the printer. Two kinds of ferrite noise suppressors are used: 1. Shielding Bead: a cylindrical core, through and around which the control panel cable assembly is wound.
Page 366 Appendix I Control Panel Cable Assembly Connector Connector P110 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 the right rear card cage wall.
Page 367: J Surestak Power Stacker
SureStak Power Stacker Contents Introduction ..................page 368 Stacker Operation ................page 368 Component Locations............... page 368 Stacker Control Panel............... page 370 Using The Power Stacker ............page 371 Loading And Starting The Power Stacker......... page 372 Stacker Troubleshooting............page 374 Removing The Power Stacker ............
Page 368: Introduction
Appendix J Introduction Introduction The SureStak Power Stacker is an option available for cabinet model printers. Most of the stacker assembly is inside the cabinet, so usually you will have to remove the stacker assembly from the printer in order to service it or replace components.
Page 369 Legend: Pinch Rollers Paper Throat Stacker Control Panel Elevator Assembly Motor Bracket Wire Paper Tent Paddle Shaft Alignment Rod (2) Bearing Bracket 10) Paper Length Indicator Figure 59. Power Stacker Component Locations...
Page 370: Stacker Control Panel
Appendix J Stacker Operation Stacker Control Panel To gain access to the stacker control panel, open the rear door of the cabinet. The control panel has two indicator lamps and four keys. (See Figure 60.) Legend: ON/OFF Indicator Lamp On Line Indicator Lamp On Line Key Form Feed Key Stacker Elevator Up Key...
Page 371 Using The Power Stacker 1. Set the printer power switch to | (On). 2. Open the rear door of the cabinet. 3. On the stacker control panel, press ON LINE to take the printer to the NOT READY state. (See Figure 60.) 4.
Page 372 Appendix J Stacker Operation Legend: Paper Length Indicator Paddle Shaft Bearing Bracket Figure 62. Setting Paper Length Loading and Starting the Power Stacker 1. Press the FORM FEED key on the the stacker control panel and hand feed the paper down into the paper throat. Continue to advance the paper until it reaches the wire tent and there are 3 to 5 extra sheets in the stacker.
Page 373 3. Press the ON LINE key on the rear control panel or the Start key on the front control panel to put the printer in the READY state. The stacker elevator will descend to its lowest position. (See Figure 64.) Figure 64.
Page 374 Appendix J Stacker Operation Stacker Troubleshooting The power stacker augments the paper feed system of the printer. The most frequently occurring problems in the paper feed system are paper jams. Because of the electromechanical nature of the system, other problems that can occur are worn or poor electrical connections and cabling, worn or defective feed motors, worn or damaged mechanical components, or incorrect installation of the stacker assembly.
Page 375: Removing The Power Stacker
Removing The Power Stacker 1. Set the printer power switch to O (off). 2. Unplug the power cord. 3. Unload paper from the stacker area. (Refer to the Setup Guide.) 4. Remove the paper tent. (See Figure 65.) Legend: Paper Tent Figure 65.
Page 376 Appendix J Removing The Power Stacker 6. Remove three screws and washers from the stacker control panel. (See Figure 67.) Legend: Long Screw Washer Short Screw Figure 67. Removing the Stacker Control Panel 7. Remove four cables from the stacker control panel, and remove the stacker control panel.
Page 377 8. Remove the two 5/32 x 3/4 inch screws and washers securing the vertical rails to the upper frame cross-member at the rear of the cabinet. (See Figure 69.) 9. Raise the elevator assembly. Legend: Vertical Rail Washer (2) Screw, 5/32 x 3/4 inch (2) Screw, 7/64 x 1/2 inch or Torx T-10 (2) Washer (2) but no washers with Torx T-10 screws Stacker Base...
Page 378 Appendix J Removing The Power Stacker 10. Loosen one turn—DO NOT REMOVE—the Torx T-10 screws securing the vertical rails to the stacker base. Each rail is secured by two screws. (See Figure 70.) Legend: Screw, 6-32x1/4, Torx T-10: two at bottom of each rail Vertical Rail Stacker Base Figure 70.
Page 379 Legend: Upper Frame Cross-Member Elevator Assembly Stacker Base Vertical Rail Figure 71. Removing the Stacker Assembly...
Page 380: Installing The Power Stacker
Appendix J Installing The Power Stacker Installing The Power Stacker NOTE: This procedure is for complete installation of the power stacker, including cable assemblies and the stacker control panel. 1. Set the printer power switch to O (off). 2. Unplug the power cord. 3.
Page 381 5. Connect the power stacker logic cable P103 to connector J17 on the CMX controller board. (See Figure 73.) 6. Disconnect the power supply cable from connector J101 on the CMX controller board. (See Figure 73.) 7. Connect power supply cable connector P101 to the stacker power cable, then connect the stacker power cable to connector J101 on the CMX controller board.
Page 382 Appendix J Installing The Power Stacker ATTENTION The paper stacker assembly mounts to the rear upper frame cross- member and the cabinet floor. It is a snug fit. During installation, take care to avoid scratching painted surfaces or damaging the stacker. 9.
Page 383 10. Position the elevator assembly at the bottom of the vertical rails. (See Figure 75a.) 11. Position the stacker assembly slightly to the right in order to clear the air exhaust duct, insert the vertical rails inside and under the upper frame cross-member, then slowly swing the base of the stacker assembly into the cabinet.
Page 384 Appendix J Installing The Power Stacker Legend: Upper Frame Cross-Member Elevator Assembly Stacker Base Vertical Rail Figure 75. Stacker Installation...
Page 385 14. Align the holes in the stacker base with the holes in the cabinet floor. (See Figure 75c and Figure 76.) 15. Install finger tight the two 5/32 x 3/4 inch screws and washers securing the vertical rails to the upper frame cross-member. 16.
Page 386 Appendix J Installing The Power Stacker NOTE: The stacker assembly is exploded to show mounting screws and locations. Legend: Washer (2) Screw, 5/32 x 3/4 inch (2) Stacker Base Screw, 7/64 x 1/2 inch or Torx T-10 (2) Washer (2) but no washers with Torx T-10 screws Vertical Rail Upper Frame Cross-Member Figure 76.
Page 387 22. Install the paper fence. (See Figure 77.) Legend: Paper Fence Stacker Base Figure 77. Paper Fence...
Page 388 Appendix J Installing The Power Stacker 23. Gather the rail cable, frame cable, logic cable, and power cable. Route the cables outboard of the elevator assembly. 24. Connect the stacker cables to the rear of the stacker control panel assembly, as shown in Figure 78. Legend: Logic Cable (P104) Power Cable...
Page 389 25. Position the stacker control panel as shown in Figure 79, and install the mounting screws. Legend: Stacker Control Panel Long Screw Short Screw (2) Figure 79. Installing the Stacker Control Panel...
Page 390 Appendix J Installing The Power Stacker 26. Bundle the stacker control panel cables in the wire harness clips located under the card cage. (See Figure 80.) Tie wrap the cables so they do not catch in the stacker mechanism as it moves up and down. Route the stacker rail and frame cables so they move without snagging as the elevator assembly moves up and down.
Page 391: Replacing The Constant Force Spring
Replacing The Constant Force Spring 1. Remove the stacker assembly from the printer. (See page 375.) ATTENTION In the next step, do not over-tighten the tie wraps or string. Tighten the tie wraps or string just enough to hold the elevator up. 2.
Page 392 Appendix J Replacing The Constant Force Spring CAUTION The constant force spring is a high tension spring. To avoid pinching your fingers, coil the spring slowly and carefully. Do not let the spring twist or crimp. 3. Remove the shoulder screw, washers, and spacer from the constant force spring and drum.
Page 393 5. Lift the loose end of the constant force spring and let it curl up on the outside of the remaining spring and drum. (See Figure 83.) 6. While holding the drum tightly, continue to curl the spring until it is completely unwound from the drum.
Page 394: Replacing The Timing Belts
Appendix J Replacing The Timing Belts Replacing The Timing Belts 1. Remove the stacker assembly from the printer. (See page 375.) 2. Raise the elevator assembly to its highest position and secure it to the vertical rails using tie wraps or string. (See Figure 81, page 391.) 3.
Page 395 5. Loosen the two setscrews on the motor pulley and remove the pulley. Unplug the motor cable, if necessary. (See Figure 85.) Go to step 6. Legend: Timing Belt Motor Setscrew Pulley Figure 85. Removing the Timing Belt Motor Pulley 6.
Page 396 Appendix J Replacing The Timing Belts 7. Remove two Allen screws from the belt clamp that secures the timing belt to the stacker frame. (See Figure 87.) Legend: Allen Screw Belt Clamp Figure 87. Removing the Belt Clamps...
Page 397 8. Remove the timing belt by working it around the vertical rail and constant force spring. (See Figure 88.) NOTE: Left timing belt is shown. Right is the same. Legend: Timing Belt Figure 88. Removing the Timing Belt 9. To install a timing belt, reverse the steps of this procedure.
Page 398: Illustrated Parts Breakdown
Appendix J Illustrated Parts Breakdown Illustrated Parts Breakdown The Illustrated Parts Breakdown (IPB) consists of exploded drawings of the power stacker assembly and subassemblies. Parts are listed next to each drawing. Only replaceable parts are assigned part numbers. If a part or assembly is damaged but does not have a part number, replace the entire power stacker assembly.
Page 399 See page 401. Figure 89. Stacker Assembly...
Page 400 Appendix J Illustrated Parts Breakdown Item Part No. Description Notes Flanged Bearing Part of item 36 24H8966 Paper Deflector Clip-On Bearing Part of item 36 Screw, Torx, 6-32 x .25 Part of item 36 Screw, Shoulder, 10-32 Part of item 36 24H8968 Timing Belt 24H8996...
Page 401 From page 399. See page 403. See page 405. & See page 409. See page 407. See page 407. Figure 90. Stacker Detail: Motors, Rollers, and Paddles...
Page 402 Appendix J Illustrated Parts Breakdown Item Part No. Description Notes 24H8969 Motor 24H9004 Stacker Hardware Kit Kit not illustrated 24H8978 Anti-Static Brush Shear Grommet Part of item 36 Cap Nut Part of item 36 24H9005 Shaft, Drive Roller 24H9006 Spacer, Drive Roller Bearing, Flanged Part of item 36 Bearing...
Page 403 From page 401. Figure 91. Stacker Detail: Rollers...
Page 404 Appendix J Illustrated Parts Breakdown Item Part No. Description Notes 24H9004 Stacker Hardware Kit Kit not illustrated 24H8985 Compression Spring On left end of shaft on early models Friction Washer Part of item 36 Flanged Bushing Part of item 36 24H8988 Drive Roller Five on early models...
Page 405 From page 401. & Flat Side Flag Connector Figure 92. Stacker Detail: Motor Bracket...
Page 406 Appendix J Illustrated Parts Breakdown Item Part No. Description Notes 24H9004 Stacker Hardware Kit Kit not illustrated Clip-On Bearing Part of item 36 24H8999 Holder, LED, Round 24H8989 LED, IR, T-1, 3/4...
Page 407 From page 401. Flag Connector Figure 93. Stacker Detail: Elevator Bracket...
Page 408 Appendix J Illustrated Parts Breakdown Item Part No. Description Notes 24H9004 Stacker Hardware Kit Kit not illustrated Clip-On Bearing Part of item 36 24H9000 Holder, LED, Flat 24H8990 Photodarlington, NPN, Rectifier...
Page 409 From page 401. Rotated 180 Degrees Flag Connector T5stk01x P5STK01Z Figure 94. Stacker Detail: Paper Motion Detector...
Page 410 Appendix J Illustrated Parts Breakdown Item Part No. Description Notes 24H9004 Stacker Hardware Kit Kit not illustrated 24H9000 Holder, LED, Flat 24H8990 Photodarlington, NPN, Rectifier Retaining Ring, External, 0.093 inch Part of item 115 Screw, Panhead, Type B, 2 x 3/16 Part of item 36 Shaft, Paper Detector Switch, Long Part of item 115...
Page 411 Index Numerics OPERATOR, 72 029 8344 DIAGNOSTIC TEST FAILED, 72 001 END OF FORMS / LOAD FORMS, 62 031 END OF FORMS TIMEOUT / LOAD FORMS, 002 FORMS JAMMED / CLEAR JAM AND RELOAD FORMS, 63 032 FORMS JAMMED TIMEOUT / CLEAR JAM 003 FORMS EJECTED / PRESS EJECT/ AND RELOAD FORMS, 74 RESTORE, 64...
Page 412 101 UPPER DRIVER SHORT, 91 USER’S GUIDE, 97 102 LOWER DRIVER SHORT, 91 131 PAPER FEED INTERRUPT / SEE USER’S 105 HAMMER COIL OPEN, 91 GUIDE, 98 107 HAMMER COIL HOT, 92 132 RIBBON INVALID COMMAND / SEE USER’S 110 STACK OVERFLOW / SEE USER’S GUIDE, GUIDE, 98 133 RIBBON INVALID STATE / SEE USER’S 111 STACK UNDERFLOW / SEE USER’S GUIDE,...
Page 413 software upgrades, 176 Cleaning the printer, 29 splined shaft skew adjustment, 168 CLEARING PROGRAM FROM FLASH, 100, 178, ASCII Character Set chart, 142 Attention condition, 61 CMX controller board See Controller board, 45 Coax/twinax expansion board replacement, 215 Belt Coax/twinax multi-platform interface, replacement, paper feed timing, replacement, 188 paper feed timing, tension adjustment, 154 Coil temperature adjustment, 181...
Page 414 cable routing, 287 Error log ground path, 341 clear, 135 interconnection and cables, 287 print, 132 Dimensions Error messages, 61 printer, 329 Error messages, list of, 62 Dipswitches ERROR OCCURRED / FLUSHING QUEUES*, 10/100Base-T, 55 101, 180 Display (LCD) ETHERNET ADAPTER BEING INITIALIZED, 101 list of messages, 62 ETHERNET DETECTED, 102 Display messages, list of, 62...
Page 415 Hex code printout, 140 related documents, 18 Hub, ribbon, replacement, 238 Mechanical controls and indicators, 24 Memory modules, location and replacement, 217 IBM Coax/twinax expansion board, replacement, Memory, flash loading software, 176 Illustrations, replacement procedures, 249 Memory, installed, 143 Indicators...
Page 416 boot diagnostics, 137 P62 ERROR Customer Engineer (CE) tests, 134 DC PROGRAM NOT VALID, 104 Messages P63 ERROR list of, 62 PROGRAM NOT COMPATIBLE, 105 Metric measurement, conversion tables, 337 P64 ERROR Mnemonics, 347 CHECKSUM WRONG, 105 Mode P65 ERROR auto reset, 55 PROGRAM NEEDS MORE FLASH, 105 run, 55...
Page 417 367 principles of operation, 35 hammer bank fan assembly, 208, 210 reset, 145 hammer spring, 211 self-tests IBM Coax/twinax expansion board, 215 customer engineer (CE), 134 LAN interface assemblies, 207 operator print, 132 magnetic pick-up assembly, 216 specifications, 327...
Page 418 memory modules, 217 multi-platform interface, 194 Safety network print server, 226 inspection guide, 341 operator panel assembly notices, defined, 17 cabinet model, 227 SECURITY CODE VIOLATION, 180 pedestal model, 228 Security module, location, 220 paper detector switch assembly, 246 Self Test paper feed drive motor, 221 10/100Base-T, 54 paper feed timing belt, 188...
Page 419 paper, 328 Tension adjustment ribbon, 327 paper feed timing belt, 154 Speed platen open belt, 156 shuttle, set, 182 Terminating resistors Splined shaft location of, 236 replacement, 239 replacement, 235 skew adjustment, 168 Test Spring equipment, tools, and supplies, 26 extension, replacement, 244 TESTING HARDWARE / PLEASE WAIT, 107 Stacker, power, 367...
Page 421 Preliminary 1...

This manual is also suitable for:

6400-004 6400-04p 6400-005 6400-05p 6400-050 6400-p50 ... Show all

IBM 6400 Maintenance Information Manual

1 Maintenance Overview

2 Installation

3 Preventive Maintenance

4 Principles of Operation

5 Troubleshooting

6 Adjustment Procedures

7 Replacement Procedures and Illustrated Parts Lists

Appendix A: Wire Data

Appendix A Circuit Board and Cable Pinouts

Quick Links

Troubleshooting

Related Manuals for IBM 6400

Summary of Contents for IBM 6400