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Digital Equipment LG plus Series Maintenance Manual

Text and graphics printers
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LG
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Text and Graphics Printers
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Maintenance Manual
Order Number: EK–LGPLE–MM.A01
Digital Equipment Corporation

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Summary of Contents for Digital Equipment LG plus Series

  • Page 1 Series Text and Graphics Printers Maintenance Manual Order Number: EK–LGPLE–MM.A01 Digital Equipment Corporation...
  • Page 2 FCC Notice This equipment has been tested and found to comply with the limits of a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide a reasonable protection against harmful interference when the equipment is operated in a commercial environment.
  • Page 3 All Rights Reserved. December 1995. The information in this document is subject to change without notice and should not be construed as a commitment by Digital Equipment Corporation. Digital Equipment Corporation assumes no responsibility for any errors that may appear in this document.

  • Page 5: Table Of Contents

    Table of Contents Maintenance Overview About the Printer ..........1–2 Important Maintenance Notes .
  • Page 6 Printer Confidence Check ........3–34 Diagnostic Printer Tests .
  • Page 7 Control Panel Assembly ......... 5–14 Cover Assembly, Hammer Bank / Ribbon Mask .
  • Page 8 Figure 5–14. Platen ..........5–67 Figure 5–15.

  • Page 9: Maintenance Overview

    Maintenance Overview Chapter Contents About the Printer ........1–2 Important Maintenance Notes .

  • Page 10: About The Printer

    About the Printer plus plus The LG Series is a family of line matrix printers: The LG04 prints at a plus maximum rate of 475 lines per minute (lpm). The LG08 prints at a plus maximum rate of 800 lpm, and the LG12 has a maximum print rate of 1200 lpm.

  • Page 11: About This Manual

    About This Manual This is a field service maintenance manual. It is designed so that you can quickly locate maintenance information. How to Use This Manual 1. Locate the procedure or information you need: Use the Table of Contents at the front of the manual. Use the Chapter Contents listed at the front each chapter.

  • Page 12: Related Documents

    Related Documents This manual does not explain how to operate or configure the printer. For that information, refer to the following documents: plus Series Operator’s Guide (Order Number EK–LGPLE–OG.A01) plus Series Setup Guide (Order Number EK–LGPLS–SG.A01) plus Series Line Printer Plus Programmer’s Reference Manual (Order Number EK–LGPLE–RM.A01) plus Series (LG) Programmer’s Reference Manual...

  • Page 13: Printing Conventions In This Manual

    Printing Conventions in This Manual BOLD UPPERCASE print indicates control panel keys. Example: Press the CLEAR key, then press the ON LINE key. Quotation marks (“”) indicate messages you see on the Liquid Crystal Display (LCD). Example: Press the ON LINE key. “Off Line” appears on the LCD. The + (plus) symbol represents key combinations.

  • Page 14: Safety Notices

    Safety Notices WARNING To prevent serious personal injury from electrical shock when connecting or disconnecting the signal cable, set the printer power switch to the off position and unplug the power cable. WARNING Always disconnect the AC power cord from the power source before performing any maintenance procedure.

  • Page 15: Hinweise Zur Sicherheit

    Hinweise zur Sicherheit GERMAN VORSICHT Um ernstliche körperliche Verletzungen durch Stromschlag beim Anschließen oder Trennen des Signalton-Kabels zu vermeiden, muß der Drucker auf jeden Fall ausgeschaltet und der Netzstecker herausgezogen werden. VORSICHT Bevor Sie anfällige Wartungsarbeiten durchführen, müssen Sie zuerst immer das Netzkabel aus der Steckdose ziehen.

  • Page 16: Controls And Indicators

    Controls and Indicators Electrical Controls and Indicators (Figure 1–1) Switch or Active when printer is: Function Indicator Online Offline Power Switch Turns printer on and off: 1 = on, 0 = off. This switch is also a circuit breaker. Status Lamp On when the printer is online, off when printer is offline.
  • Page 17 (Off) (On) Power Switch Status Lamp CLEAR Liquid–Crystal Display PREV NEXT (LCD) SET TOF ON LINE VIEW ENTER DOWN RAISE PRINTER COVER TO USE THESE SWITCHES Figure 1–1. Electrical Controls and Indicators Maintenance Overview 1–9...

  • Page 18: Mechanical Controls And Indicators

    Mechanical Controls and Indicators Control or Function Indicator Sets the platen for paper and forms of different Forms Thickness Lever thicknesses. Lever must be fully opened (raised) to load or unload paper. Indicates relative thickness of forms/paper. Set this lever Forms Thickness at A for thin (single–part) forms, B for thicker forms, and Pointer and Scale...
  • Page 19 Paper Scale Left Tractor Right Tractor Horizontal Adjustment Tractor Knob Lock Vertical Position Knob Tractor Lock Ribbon Loading Path Diagram Forms Thickness Lever and Scale Forms Thickness Pointer Figure 1–2. Mechanical Controls and Indicators Maintenance Overview 1–11...

  • Page 20: Tools, Test Equipment, And Supplies

    Item Part No. Adapter, 1/4 in. hex to 1/4 in. square, Utica HW–18 29–24723–00 Alcohol Diagonal cutters Digital voltmeter ESD Wrist Strap Extension, 3 in., 3/8 in. drive Feeler gauge set Force Gauge, (Chatillon NY, Gauge–r, 0–20 lb.) CAT 719–20 Hex bit, 3/16 in., torque screwdriver...

  • Page 21: Scheduled Maintenance

    Scheduled Maintenance Chapter Contents Preventive Maintenance Checks and Services ....2–2 Inspecting the Printer ........2–3 Cleaning the Printer .

  • Page 22: Preventive Maintenance Checks And Services

    Preventive Maintenance Checks and Services Perform preventive maintenance checks and services at the intervals specified in Table 2–1. Do these checks more often if the printer is used for heavy–duty, continuous printing or is located in a dusty area. WARNING Always disconnect the AC power cord before performing scheduled maintenance.

  • Page 23: Inspecting The Printer

    Inspecting the Printer Correct any condition found during inspection that could affect printer performance or reliability. Table 2–2. Physical Inspection What to Inspect What to Look For Check for damage, cracks, breaks, dents, gouges, Cabinet, base, frame scratches, delamination, warping, corrosion, and proper finish.

  • Page 24: Cleaning The Printer

    Cleaning the Printer WARNING Always disconnect the ac power cord before cleaning the printer. CAUTION Do not use abrasive cleaners, particularly on the window. Do not drip water into the printer. Damage to the equipment will result. Do not spray directly onto the printer when using spray solutions (spray the cloth, then apply the dampened cloth to the printer).
  • Page 25 10. Vacuum up dust and residue from the lower cabinet. 11. Wipe the interior of the lower cabinet with a clean, lint–free cloth dampened with water and a mild detergent or window cleaning solution. 12. Dry the cabinet interior with a clean, lint–free cloth. Splined Tractor Shaft...

  • Page 26: Cleaning The Shuttle Frame Assembly

    Cleaning the Shuttle Frame Assembly 1. Remove the shuttle cover assembly (page 5–16). 2. Remove the shuttle frame assembly (page 5–42). 3. Remove the paper ironer (page 5–28). WARNING Over time, the upper edge of the paper ironer can become sharp. To avoid cutting yourself, handle the paper ironer on the sides.
  • Page 27 9. Install the hammer bank cover assembly (page 5–15). 10. Install the shuttle frame assembly (page 5–42). 11. Install the shuttle cover assembly (page 5–16). 12. Clean the card cage fan assembly (page 2–8). Ribbon Mask Hammer Bank Cover (Thin plate) (Thick plate) Hammer Bank Cover Assembly...

  • Page 28: Cleaning The Card Cage Fan Assembly

    Cleaning the Card Cage Fan Assembly 1. Remove the paper path (page 5–29). 2. Vacuum the card cage fan assembly and surrounding areas to remove paper particles, dust, and lint. (See Figure 2–3.) 3. Install the paper path (page 5–29). 4.

  • Page 29: Troubleshooting

    Troubleshooting Chapter Contents Introduction ..........3–2 Troubleshooting Aids .

  • Page 30: Introduction

    Introduction This chapter contains procedures for troubleshooting printer malfunctions. This manual does not cover printer operation or configuration, but you must operate the printer to check its performance, and sometimes you may have to reconfigure the printer. Therefore, have the Operator’s Guide and the Setup Guide handy when you troubleshoot the printer.

  • Page 31: Fault Messages

    LCD Messages WARNING Always disconnect the AC power cord from the power source before doing any maintenance procedure. Failure to remove power could result in injury to you or damage to equipment. If you must apply power during maintenance, you will be instructed to so in the maintenance procedure.
  • Page 32 Table 3–1. LCD Message Troubleshooting Table Displayed Message Explanation Solution Internal power failure. Cycle power. If message 8.5V PWR FAIL* recurs, replace one at a time until message clears: a) power supply board b) controller board Controller voltage failure. Cycle power. If message 15V CTL FAIL* recurs, replace one at a time until message clears:...
  • Page 33 Displayed Message Explanation Solution Controller voltage failure. Replace CMX controller CTL VOLT FAIL* board. Hammer coil count test Page 3–14 DRVR CIR BAD* failed. Sensors cannot detect Page 3–15 EXHAUST FAN FLT current in fan circuit. Application software tried to Page 3–16 FIRMWARE ERROR perform an illegal printer...
  • Page 34 Displayed Message Explanation Solution Printer is out of paper. Load paper. If message LOAD PAPER recurs, see page 3–20. Fatal firmware error on Cycle power and rerun print PAP BAD TABLE* CMX controller board. job. If message recurs, replace CMX controller board.
  • Page 35 Displayed Message Explanation Solution Fatal firmware error on Cycle power and rerun print PAP NT AT SPEED* CMX controller board. job. If message recurs, replace CMX controller board. Fatal firmware error on Cycle power and rerun print PAP UNEXP INT* CMX controller board.
  • Page 36 Displayed Message Explanation Solution Fatal firmware error on Cycle power and rerun print RIB INVLD CMD* CMX controller board. job. If message recurs, replace CMX controller board. Fatal firmware error on Cycle power and rerun print RIB INVLD STATE* CMX controller board. job.
  • Page 37 Displayed Message Explanation Solution Fatal firmware error on Cycle power and rerun print TCB CORRUPTED* CMX controller board. job. If message recurs, replace CMX controller board. Fatal firmware error on Cycle power and rerun print UNDEF INTERRUPT* CMX controller board. job.

  • Page 38: Clear Paper Jam

    CLEAR PAPER JAM Instruction Indication Forms feed without erratic Go to step 2. If pin holes are a) Load paper. motion, noise, or pin–hole damaged, go to damage. step 4. For erratic b) Press the FF key several motion or noise, times.
  • Page 39 CLOSE PLATEN Instruction Indication “CLOSE PLATEN” message. Go to step 2. Return printer to Load paper. Close the forms normal operation. thickness lever. Run an operator print test. Switch is bad. Replace platen Replace CMX Power off the printer. interlock switch controller board.
  • Page 40 COIL HOT NOTE: The printer has sensor circuits that sample the operating temperature of key print components. When higher than normal temperatures are sensed, print speed is automatically reduced. If the printer runs at reduced speed for an extended period of time, a (UNIT) HOT message is sent to the LCD and printing stops, allowing printer components to cool down.
  • Page 41 Instruction Indication Printer environment is OK. Go to step 9. Move printer to Examine printer environment cooler, cleaner for severity. (See NOTE location. above.) Print jobs are dense enough to Advise the user to Replace one at a Check the kinds of print jobs slow the printer.
  • Page 42 DRVR CIR BAD* Instruction Indication “DRVR CIR BAD*” message. Go to step 2. Return printer to Cycle power: Power off normal operation. printer. Wait 15 seconds. Power on printer. “DRVR CIR BAD*” message. Go to step 3. Return printer to Press the CLEAR key.
  • Page 43 (EXHAUST) (HMR BANK) (INTAKE) FAN FLT Instruction Indication “_____ FAN FLT” message. Go to step 2. Return printer to Cycle power: Power off normal operation. printer. Wait 15 seconds. Power on printer. Fan cable is properly Go to step 3. Connect the fan a) Power off the printer.
  • Page 44 FIRMWARE ERROR Instruction Indication “FIRMWARE ERROR” Replace the CMX Return printer to Cycle power: Power off message. controller board. normal operation. printer. Wait 15 seconds. Go to step 2. Power on printer. “FIRMWARE ERROR” Application Return printer to a) Power on the printer. message.
  • Page 45 HAM. COIL OPEN * Instruction Indication “HAM. COIL OPEN * ” Go to step 2. Return printer to Cycle power: Power off message. normal operation. printer. Wait 15 seconds. Power on printer. “HAM. COIL OPEN * ” Replace the Return printer to Press the CLEAR key.
  • Page 46 HB NOT INSTLD * Instruction Indication Shuttle frame assembly is Go to step 2. Install the shuttle a) Power off the printer. installed in the printer. frame assembly. b) Remove the shuttle cover. c) Verify that the shuttle frame assembly is installed. Hammer bank logic cable is Go to step 3.
  • Page 47 LO DRV. SHORT Instruction Indication “LO DRV. SHORT” message. Go to step 2. Return printer to Cycle power: Power off normal operation. printer. Wait 15 seconds. Power on printer. “LO DRV. SHORT” message. Replace the Return printer to Press the CLEAR key. shuttle frame normal operation.

  • Page 48: Load Paper

    LOAD PAPER Instruction Indication “LOAD PAPER” message. Replace paper Return printer to Load paper. Run a diagnostic detector switch normal operation. printer test. assembly. Go to step 2 “LOAD PAPER” message. Replace the CMX Return printer to Run a diagnostic printer test. controller board.
  • Page 49 POWER SUPPLY HOT NOTE: The printer has sensor circuits that sample the operating temperature of key print components. When higher than normal temperatures are sensed, print speed is automatically reduced. If the printer runs at reduced speed for an extended period of time, a (UNIT) HOT message is sent to the LCD and printing stops, allowing printer components to cool down.
  • Page 50 Instruction Indication Vents and airways are clear. Go to step 8. Remove Check for obstruction of obstructions. vents and fan airways. Make sure cabinet exhaust fan vents are not blocked. (Check for items beneath the printer blocking cabinet vents.) Printer environment is OK. Go to step 9.
  • Page 51 PRINTER HOT NOTE: This message indicates internal temperatures over 60 Celsius (140 Fahrenheit). Print jobs will not create such temperatures, so immediately determine that the fans are operating and that all air vents are unobstructed. It is crucial that the exhaust vents on the floor of the cabinet remain unblocked, since hot air from inside the printer is vented through the cabinet floor.

  • Page 52: Ribbon Drive

    RIBBON DRIVE Instruction Indication “RIBBON DRIVE” message. Go to step 2. Return printer to Cycle power: Power off normal operation. printer. Wait 15 seconds. Power on printer. Ribbon drive motor cables Go to step 3. Attach ribbon a) Power off printer. connected properly.
  • Page 53 Serial Interface Messages Instruction Indication Host and printer serial interface Go to step 2 Set printer serial a) Make a configuration parameters match. interface printout. (Ref.: Setup Guide ) parameters to match those of the b) Verify that host and printer host.

  • Page 54: Shuttle Jam

    SHUTTLE JAM Instruction Indication Forms thickness lever set Go to step 2. Set forms Check the forms thickness correctly. thickness lever for lever: if it is set too tightly, it thicker paper. Go can slow the shuttle enough to step 2. to trigger the fault message.

  • Page 55: Software Error

    SOFTWARE ERROR * Instruction Indication “SOFTWARE ERROR * ” Go to step 2 Return printer to Cycle power: Power off message. normal operation. printer. Wait 15 seconds. Power on printer. “SOFTWARE ERROR * ” Replace the CMX Not a printer Disconnect the input data line message.
  • Page 56 UP DRV. SHORT Instruction Indication “UP DRV. SHORT” message. Go to step 2. Return printer to Cycle power: Power off normal operation. printer. Wait 15 seconds. Power on printer. “UP DRV. SHORT” message. Replace the CMX Return printer to Press the CLEAR key. controller board.

  • Page 57: Symptoms Not Indicated By Fault Messages

    Symptoms Not Indicated by Fault Messages Use standard fault–isolation techniques to troubleshoot malfunctions not indicated by fault messages. These techniques are summarized below: 1. Ask the operator to describe the problem. 2. Verify the fault by running diagnostic tests or replicating conditions reported by the user.

  • Page 58: Troubleshooting Table

    Symptoms Not Indicated by Fault Messages Troubleshooting Table Symptom Instruction No power, control panel LCD and LEDs +5 volt distribution problem to the controller board. (See blank, card cage fan not running. Power Distribution Diagram, page A–3.) Power on hang condition. Replace one at a time until the problem is fixed: a) CMX controller board (page 5–10) b) power supply (page 5–12)
  • Page 59 Symptom Instruction Printer prints data sent from the host, but If the printer prints from the host, but occasionally loses occasionally prints double characters, blocks of data, the most likely cause is the host not random ! or * characters, or loses blocks responding to “send no more data”...
  • Page 60 Print Quality Problems Missing, light, or smeared characters or Check the forms thickness lever setting. dots: Check the ribbon for folds or tears. Clean the shuttle frame assembly (page 2–6). Check the platen gap adjustment (page 4–12). Replace one at a time until problem is fixed: a) shuttle frame assembly (page 5–42) b) controller board (page 5–10) All characters or dots are too light or too...
  • Page 61 Print Quality Problems Garbled print or paper slews a) Put the printer in hex dump mode and analyze the uncontrollably. binary data. One cause of garble is the host interface or cable not transmitting all 8 data bits. When this occurs, the Centronics interface receives a 1 on every unconnected data line.

  • Page 62: Printer Confidence Check

    Printer Confidence Check Instruction Indication Power cable installed correctly Power off printer. Power off the Check that printer is plugged to proper source. Go to step 2. printer. Connect into correct power source. printer to correct power source. Printer initializes correctly and Go to step 3 Troubleshoot the Power on the printer.

  • Page 63: Diagnostic Printer Tests

    Diagnostic Printer Tests A set of printer tests is included in the configuration menu structure for use as diagnostic and maintenance tools. You can use these printer tests to check the print quality and basic operation of the printer. In addition, you will use some of these tests in various troubleshooting and adjustment procedures.
  • Page 64 Phase Printer A hammer timing test that permits you to adjust the hammer phase value. The hammer phase value is a timing parameter that controls the vertical alignment of dots in character printing. The numerical units are relative; they do not represent a physical measurement or value.

  • Page 65: Selecting And Running Diagnostic Printer Tests

    Selecting and Running Diagnostic Printer Tests Step Result Notes a) Load paper. b) Install the ribbon. c) Set top–of–form. (Refer to the Operator’s Guide.) ON LINE Press: The printer must be offline OFFLINE to select diagnostic tests. CONFIG. CONTROL Allows you to make ENTER SWITCH configuration changes.
  • Page 66 Step Result Notes Printer Tests Shift Recycle* Cycle through the choices. Printer Tests Refer to page 3–35. All E’s To start The test runs. Printer Tests test: All E’s* To stop Stops tests. Printer Tests test: All E’s* Locks the configuration ENTER SWITCH LOCKED parameters.

  • Page 67: Hidden Diagnostic Menu

    Hidden Diagnostic Menu Printer boot–up software contains a hidden menu structure that you can access by holding down the (PREV) and (DOWN) keys while powering up the printer. These menus are not intended for the end user, but provide useful information for manufacturing and maintenance personnel. The hidden diagnostic menu is a multi–level menu that operates the same way as the user menus.
  • Page 68 BOOT DIAGNOSTICS PRESS ENTER (DOWN) (DOWN) (DOWN) BOOT DIAGNOSTICS VERSION CHECK BOOT/CMX V100H VERSION CHECK BOOT VERSION 12Sep95 #154669 VERSION CHECK 09/08/95 SOFTWARE VERSION 11:41:08 (NEXT) VERSION CHECK EC V1.00H EC VERSION 07Sep95 #154643 (NEXT) VERSION CHECK VX VERSION=F ASIC VERSIONS MECA VERSION=F (DOWN) (DOWN)

  • Page 69: Hex Code Printout

    Hex Code Printout A hex code printout (“hex dump”) lists each ASCII data character received from the host computer and lists its corresponding two-digit hexadecimal code. (See Figure 3–2.) Hex dumps can be used to troubleshoot some types of printer data reception problems. Every printable character prints both as its assigned symbol and as its hex equivalent.

  • Page 70: Making A Hex Code Printout

    Making a Hex Code Printout Step Result Notes Make sure the printer is on. Raise the printer cover. ON LINE Press: OFFLINE CONFIG. CONTROL Allows you to make ENTER SWITCH configuration changes. UNLOCKED OFFLINE CONFIG. CONTROL OFFLINE UNTIL MAINT / MISC MAINT / MISC Hex Dump Mode Hex Dump Mode...

  • Page 71: Ascii Character Set

    ASCII Character Set BITS OCTAL equivalent DECIMAL equivalent HEX equivalent ASCII Character BITS COLUMN (XON) ” 0 0 1 0 0 0 1 1 (XOFF) 0 1 0 0 0 1 0 1 & 0 1 1 0 ’ 0 1 1 1 1 0 0 1 1 0 1 0 1 0 1 1...
  • Page 72 3–44 Troubleshooting...

  • Page 73: Adjustment Procedures

    Adjustment Procedures Chapter Contents Preparing the Printer for Maintenance ......4–2 Returning the Printer to Normal Operation .

  • Page 74: Preparing The Printer For Maintenance

    Preparing the Printer for Maintenance WARNING Unplug the printer power cord from the power outlet before you do any maintenance procedure. Failure to remove power could result in injury to you or damage to equipment. If you must apply power during maintenance, you will be instructed to so in the maintenance procedure.

  • Page 75: Returning The Printer To Normal Operation

    Returning the Printer to Normal Operation When you have finished servicing the printer, restore it to operation by following the steps below: 1. Install the ribbon. 2. Plug the AC power cord into the printer and the power source. 3. Set the printer power switch to | (on). 4.

  • Page 76: Belt, Paper Feed Timing, Adjustment

    Belt, Paper Feed Timing, Adjustment (Figure 4–1) 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the paper path (page 5–29). 4. Loosen four screws and remove the barrier shield (page 5–59, Figure 5–10). 5.
  • Page 77 Direction of Force 1. Timing Belt Shield 2. Motor Mount Bolt (2) 3. Paper Feed Drive Motor 4. Splined Shaft Figure 4–1. Paper Feed Timing Belt Adjustment Adjustment Procedures 4–5...

  • Page 78: Belt, Platen Open, Adjustment

    Belt, Platen Open, Adjustment (Figure 4–2) 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the platen open belt cover (1) by squeezing the top and bottom to release the plastic tabs from the slots in the side plate. 4.
  • Page 79 1. Belt Cover 2. Motor Mount Screw 3. Platen Open Motor Shaft Direction of Force Figure 4–2. Platen Open Belt Adjustment Adjustment Procedures 4–7...

  • Page 80: Paper Drive Motor Pulley Alignment

    Paper Drive Motor Pulley Alignment (Figure 4–3) 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the timing belt cover (1) by squeezing the top and bottom to release the plastic tabs from the slots in the side plate. 4.
  • Page 81 1. Belt Shield 2. Cap Screw 3. Motor Pulley Collar 4. Motor Pulley 5. Splined Shaft Pulley Figure 4–3. Paper Drive Motor Pulley Alignment Adjustment Procedures 4–9...

  • Page 82: Paper Scale Alignment

    Paper Scale Alignment (Figure 4–4) 1. Load paper and ribbon. 2. Connect the power cord to the AC power source. 3. Set the printer power switch to 1 (on). 4. Open the printer cover. 5. Verify that the shuttle cover (1) is properly installed (page 5–16). 6.
  • Page 83 1. Shuttle Cover 2. Screw, Button–Head, 5/64 inch hex (3) 3. Paper Scale Figure 4–4. Paper Scale Alignment Adjustment Procedures 4–11...

  • Page 84: Platen Gap Adjustment

    Platen Gap Adjustment (Figure 4–5) IMPORTANT Only do this procedure if the original equipment shuttle frame assembly or platen has been replaced by a new or refurbished unit. 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3.
  • Page 85 9. Repeat steps 6 through 8 at the right end of the hammer bank. 10. After adjusting both sides, check the gap again at both ends. Readjust if necessary. 11. When the platen gap is correct at both ends of the platen, adjust the platen open belt (page 4–6).

  • Page 86: Platen Open Motor Pulley Alignment

    Platen Open Motor Pulley Alignment (Figure 4–6) 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the platen open belt cover (1) by squeezing the top and bottom to release the plastic tabs from the slots in the side plate. 4.
  • Page 87 1. Belt Cover 2. Set Screw 3. Platen Open Motor Pulley 4. Platen Shaft Pulley Figure 4–6. Platen Open Motor Pulley Alignment Adjustment Procedures 4–15...

  • Page 88: Ribbon Guide Alignment

    Ribbon Guide Alignment (Figure 4–7) 1. Open the printer cover. 2. Load paper and install the ribbon. To adjust the left ribbon guide, the ribbon should have a full spool on the right hub (1). 3. Run a ribbon and shuttle diagnostic self–test. (See Chapter 4.) 4.
  • Page 89 1. Right Hub 2. Screw, Left Ribbon Guide Skid (2) 3. Ribbon 4. Ribbon Guide, Left 5. Screw, Retaining (2) 6. Left Ribbon Spool 7. Ribbon Guide, Right Figure 4–7. Ribbon Guide Alignment Adjustment Procedures 4–17...

  • Page 90: Splined Shaft Skew Adjustment

    Splined Shaft Skew Adjustment (Figure 4–8) If lines of print are not parallel with the edge perforations on the paper, perform the following adjustment. 1. Prepare the printer for maintenance (page 4–2). 2. Loosen the screw (1) securing the adjusting link (2). 3.
  • Page 91 1. Screw 2. Adjusting Link 3. Horizontal Adjustment Knob Figure 4–8. Splined Shaft Skew Adjustment Adjustment Procedures 4–19...

  • Page 92: Adjusting The End Of Forms Distance

    Adjusting the End of Forms Distance This procedure tests and sets the distance from the page perforation at which a LOAD PAPER message is triggered. This adjustment prevents printing on the platen when the printer runs out of paper. The measurement units are dot rows. You will use the dot row patterns printed by the Paper Out Dots printer test to verify that this parameter is set correctly.
  • Page 93 Page Perforation Page Perforation 4 in. 4 in. Page Perforation Figure 4–9. Paper Preparation for Paper Out Adjustment Test Adjustment Procedures 4–21...
  • Page 94 5. Tear a four inch square in the manner described above, on every third sheet, until you have made 3 or 4 holes. 6. If the printer is online, press the ON LINE key to place the printer offline. 7. Raise the printer cover. 8.
  • Page 95 15. Measure how short or long the comb pattern printed by counting the number of dot rows needed to reach the perforation, or the number of dot rows that printed beyond the perforation. NOTE: You can use the long bars to count the dot rows quickly. There are three dot rows between each long bar, so each long bar increases the number of dot rows by four.
  • Page 96 29. Close the printer cover. 30. Press the ON LINE key to place the printer online. 4–24 Adjustment Procedures...

  • Page 97: Hammer Phasing Adjustment

    Hammer Phasing Adjustment You must check and adjust hammer phasing if the CMX controller board is replaced, the shuttle frame assembly is removed, or if the MPU is replaced. The hammer phase value is a timing parameter that permits you to adjust the vertical alignment of dots in character printing.
  • Page 98 10. Press . “Printer Tests / Shift Recycle” displays. 11. Press until “Printer Tests / Phase Printer” displays. 12. Press ENTER. The top line of the display will show “Phase Printer” and the bottom line will show the current phasing index value. 13.

  • Page 99: Installing Software

    Installing Software Flash memory is contained in one or two single in–line memory modules (SIMMs) located on the controller board. Printer emulation and operating system software are loaded into flash memory at the factory, but you will install software in the following situations: The customer needs to upgrade printer software The customer needs different emulation software You have replaced the controller board...
  • Page 100 8. Make the diskette drive the active drive by typing the following at the DOS prompt: A:<return> (If the diskette is in drive B, type B:<return>) 9. Get the name of the compressed file on the diskette by listing the contents of the diskette;...
  • Page 101 17. Power off the personal computer. 18. If you had to install a parallel data cable to the computer and printer in step 2, disconnect it from the computer and printer. 19. Reconnect the data input cable(s) to the printer. 20.
  • Page 102 Required Message Explanation Action ERROR: FLASH The printer could not find any flash Install flash memory memory. before attempting to NOT DETECTED download this program. ERROR: NO DRAM The printer could not find any Check DRAM on DRAM. CMX. If present, DETECTED reseat DRAM, If missing, install...
  • Page 103 Required Message Explanation Action ERROR: WRITING Hardware or software fault in flash Download the memory. program again. Go TO FLASH back to step 10. If the message occurs again, replace the flash memory. ERROR: WRONG The printer received the complete Download the program but the checksum did not program again:...
  • Page 104 4–32 Adjustment Procedures...

  • Page 105: Replacement Procedures And Illustrated Parts List

    Replacement Procedures and Illustrated Parts List Chapter Contents Organization of This Chapter ......5–4 Section I: Replacement Procedures .
  • Page 106 Paper Path ..........5–29 Platen .
  • Page 107 Section II: Illustrated Parts List ......5–51 Figure 5–7. Top Cover, Doors, and Casters .

  • Page 108: Organization Of This Chapter

    Organization of This Chapter This chapter is divided into two sections. Section I: Replacement Procedures This section consists of written procedures for removing and installing the components that are replaceable at the field service level of maintenance. Section I begins on this page. The removal/installation procedures in this section will refer you to the illustrations in Section II.

  • Page 109: Belt, Paper Feed Timing

    Belt, Paper Feed Timing Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the paper path (page 5–29). 4. Remove four screws, the barrier shield, and the anti–static brush (page 5–59, Figure 5–10). 5.
  • Page 110 Installation 1. Install the paper feed timing belt over the splined shaft pulley and the motor pulley. Slide the motor pulley onto the paper feed motor shaft. 2. Holding a 0.040 inch feeler gauge between the pulley collar and the motor body, torque the 7/64 inch collar screw to 25 2 inch–pounds (2.82...

  • Page 111: Belt, Platen Open

    Belt, Platen Open Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the platen open belt cover by squeezing the top and bottom to release the plastic tabs from the slots in the side plate (page 5–67, Figure 5–14).

  • Page 112: Cable Connectors And Connector Shells

    Cable Connectors and Connector Shells Some of the printer cable connectors are grouped inside connector shells. The procedure below explains how to remove and install cable assemblies from any connector shell in the printer. NOTE: There is also a diagram of the P106 / P107 connector shells on the plastic heat shield over the power supply.
  • Page 113 POD = Paper Out Detect (Switch) PMD = Paper Motion Detect (Switch) CCF = Card Cage Fan Typical LRP = Left Ribbon guide Typical 2–Wire 4–Wire PLAT M = Platen Open Motor Cable Cable LRIB M = Left Ribbon Motor Connector Connector P106 Connector...

  • Page 114: Circuit Board: Controller

    Circuit Board: CMX Controller CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle circuit boards. Removal 1. Make a configuration printout of all configurations. (Refer to the Operator’s Guide.) 2. Prepare the printer for maintenance (page 4–2). 3.
  • Page 115 Installation CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle circuit boards. 1. Position the controller board in the card cage, shield side down, component side up. Engage the screw on the bottom of the card cage in the keyway in the controller shield.

  • Page 116: Circuit Board: Power Supply

    Circuit Board: Power Supply WARNING To prevent injury from electric shock, wait at least one minute after shutting off power before removing the power supply board. Do not touch components or flex the board during removal/installation. Handle the board by the its sides. Always wear a properly grounded static wrist strap when handling the power supply board.

  • Page 117: Circuit Breaker

    Circuit Breaker Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the paper path (page 5–29). 4. Remove the card cage fan (page 5–17). 5. Disconnect the four circuit breaker electrical leads. (See page 5–71, Figure 5–16.) 6.

  • Page 118: Control Panel Assembly

    Control Panel Assembly Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Disconnect RJ11 connector P310 from connector J310 on the control panel. 4. Loosen the four screws securing the control panel to the control panel bracket.

  • Page 119: Cover Assembly, Hammer Bank / Ribbon Mask

    Cover Assembly, Hammer Bank / Ribbon Mask Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the shuttle frame assembly (page 5–42). 3. Lift the thick plate of the hammer bank cover assembly at one end, and peel the cover away from hammer bank magnets (page 5–61, Figure 5–11).

  • Page 120: Cover Assembly, Shuttle

    Cover Assembly, Shuttle Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the ribbon spools. 4. Loosen the shuttle cover screws (page 5–59, Figure 5–10). 5. Grasping the edges of the shuttle cover assembly, tilt the rear edge up and lift the shuttle cover assembly out of the printer.

  • Page 121: Fan Assembly, Card Cage

    Fan Assembly, Card Cage Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the paper path (page 5–29). 3. Disconnect the fan cable connector. (See Figure 5–15, page 5–69.) 4. Remove the mounting screws from the bottom of the fan. 5.

  • Page 122: Fan Assembly, Cabinet Exhaust

    Fan Assembly, Cabinet Exhaust Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the floor cabinet doors and the printer cover. 3. Remove the paper fence. (See Figure 5–8, page Figure 5–8.) 4. Remove the two 1/4 inch screws securing the bottom of the air exhaust duct.

  • Page 123: Fan Assembly, Hammer Bank

    Fan Assembly, Hammer Bank Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the shuttle cover assembly (page 5–16). 3. Remove the control panel bracket assembly (page 5–57, Figure 5–9). 4. Remove the paper path (page 5–29). 5. Trace the hammer bank fan cable assembly back to the controller board connector P107, releasing it from all cable constraints.

  • Page 124: Magnetic Pick-Up (Mpu) Assembly

    Magnetic Pick–up (MPU) Assembly Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the shuttle cover (page 5–16). 3. Disconnect the magnetic pick–up (MPU) cable connector (page 5–63, Figure 5–12). 4. Loosen the 7/64 inch hex MPU clamp screw (page 5–63, Figure 5–12). 5.

  • Page 125: Memory Modules And Security Pal

    Memory Modules and Security PAL Removal 1. Make a printout of all printer configurations. (Refer to the User’s Guide.) 2. Remove the paper path (page 5–29). CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle memory modules and circuit boards.

  • Page 126: Replacement Procedures And

    Security PAL CMX Controller Board Bank 1 Bank 0 Bank 1 Bank 0 IMPORTANT; Flash: SIMM notch DRAM: 80–pin SIMM at this end. 72–pin SIMM J11 = Bank 0 (must always be filled) J16 = Bank 0 (must always be filled) Notch J10 = Bank 1 Reserved for upgrades...

  • Page 127: Motor Assembly, Paper Feed

    Motor Assembly, Paper Feed Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the paper path (page 5–29). 4. Loosen four screws and remove the barrier shield (page 5–59, Figure 5–10). 5. Remove the timing belt cover by squeezing the top and bottom to release the plastic tabs from the slots in the side plate (page 5–59, Figure 5–10).
  • Page 128 Installation 1. Position the paper feed motor assembly on the right side plate and install the 5/16 inch motor mount bolts and nuts finger tight (page 5–69, Figure 5–15). 2. Connect the paper feed motor cable connector to connector shell P107 (page 5–8).

  • Page 129: Motor Assembly, Platen Open

    Motor Assembly, Platen Open Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the paper path (page 5–29). 3. Remove the card cage fan (page 5–17). 4. Remove the platen open belt cover by squeezing the top and bottom to release the plastic tabs from the slots in the side plate (page 5–67, Figure 5–14).
  • Page 130 Installation 1. Position the platen open motor assembly with the wires toward the rear (page 5–69, Figure 5–15). 2. Install the two 5/16 inch motor mount screws (and nuts, if present) finger tight. 3. Install the platen open belt and motor pulley. Bottom out the motor pulley on the motor shaft and tighten the setscrew to 9 2 inch–pounds (1.24...

  • Page 131: Motor Assembly, Ribbon Drive

    Motor Assembly, Ribbon Drive Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the ribbon. 3. Remove the ribbon hub (page 5–38). 4. Remove two screws and washers securing the ribbon drive motor to the base casting (page 5–61, Figure 5–11). 5.

  • Page 132: Paper Ironer

    Paper Ironer WARNING Over time, the upper edge of the paper ironer can become sharp. To avoid cutting yourself, handle the paper ironer on the sides. Removal 1. Remove the shuttle frame assembly (page 5–42). 2. Move the forms thickness lever to the open position. 3.

  • Page 133: Paper Path

    Paper Path WARNING Unless directed to do otherwise, always unplug the printer from the power source before performing a maintenance procedure. Failure to remove power could result in injury to persons or damage to equipment. Removal 1. Prepare the printer for maintenance (page 4–2). 2.

  • Page 134: Platen

    Platen Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the shuttle frame assembly (page 5–42). 3. Remove the paper ironer (page 5–28). 4. Remove the three 1/4 inch screws securing the paper ironer bracket assembly and remove the assembly. (See Figure 5–14, page 5–67, items 4 through 6.) 5.
  • Page 135 Installation IMPORTANT The dowel pins protruding from the ends of the platen are the platen shafts, and are not equal in length. The platen must be installed with the longer shaft on the right side. 1. Wipe the platen shafts clean of grease and debris. 2.
  • Page 136 Platen Installation (continued) Washer Platen Adjust Bracket Platen Adjust Bracket Bushing Platen Mechanism Base Platen Seat Wear Saddle Figure 5–4. Alignment of Platen Adjust Bracket Bushing 6. Apply a layer of bearing lubricant 1/4 inch high to the seat of each wear saddle, making the layer as wide as the saddle and touching the rear angled surface.
  • Page 137 Platen Installation (continued) 10. Slide the right ribbon guide assembly into the side plate and install the two 7/32 inch screws and washers. (See Figure 5–15, page 5–69, item 12, 14, and 15.) 11. Install the forms thickness indicator plate: a.
  • Page 138 Platen Installation (continued) 18. Install the platen shaft pulley with the 7/64 inch setscrew facing up and tighten the setscrew. Open and close the forms thickness lever and check that the platen pulley setscrew does not hit the left ribbon guide. 19.

  • Page 139: 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 5–5.) If the standard terminating resistor pack is not compatible with the particular interface driver requirements of the host computer, other values of pull–up and pull–down resistors may be required.
  • Page 140 Default: 470 ohm Alt 1: 220 ohm Alt 2: 1K ohm Controller Default: 1K ohm Board Alt 1: 330 ohm Alt 2: none Figure 5–5. Resistors, Terminating, Removal/Installation 5–36 Replacement Procedures and Illustrated Parts List...

  • Page 141: Ribbon Guide Assembly (L/R)

    Ribbon Guide Assembly (L/R) NOTE: The right ribbon guide is shown in Figure 5–15. The removal/installation procedure is the same for both ribbon guides. Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the printer ribbon. 3. Cut and remove the tie–wrap from the tie wrap hole to free the ribbon guide cable (page 5–69, Figure 5–15).

  • Page 142: Ribbon Hub

    Ribbon Hub Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the printer ribbon. 3. Loosen the #2 Phillips screw in the ribbon spool hub (page 5–69, Figure 5–15). 4. Remove the hub from the shaft of the ribbon drive motor. Installation 1.

  • Page 143: Shaft, Splined

    Shaft, Splined Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the paper feed timing belt (page 5–5). 3. Remove the 1/4 inch screw securing the ground clip, and remove the clip (page 5–65, Figure 5–13, items 10 and 11). 4.
  • Page 144 Installation 1. Open the doors on the left and right tractors. Position the tractor belts so the alignment marks are at the top on both tractors. (See Figure 5–6.) 2. Grasp the vertical adjustment knob and slide the splined shaft through the right side plate, the tractors, and the left side plate (page 5–65, Figure 5–13).

  • Page 145: Shaft, Support

    Shaft, Support Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Unlock the tractors and slide them to the far right. 4. Remove the E–ring (page 5–65, Figure 5–13, item 17). CAUTION Hold the tractors while removing the support shaft, and be careful not to lose the two curved spring washers.

  • Page 146: Shuttle Frame Assembly

    Shuttle Frame Assembly Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the shuttle cover assembly (page 5–16). 3. Disconnect the MPU cable connector J03 and shuttle motor cable connector J02 (page 5–63, Figure 5–12, items 5 and 6). CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle the shuttle frame...
  • Page 147 2. Open the forms thickness lever and move the tractors as far left and right as possible. 3. Holding the shuttle frame assembly by the support legs cast on both sides of the shuttle motor, set it into the base casting. Use both hands: the shuttle frame assembly is heavy (page 5–61, Figure 5–11).

  • Page 148: Spring Assembly, Gas

    Spring Assembly, Gas NOTE: Two persons may be required to perform this procedure. Prop or hold the printer cover securely while removing or installing the gas spring assembly. Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3.

  • Page 149: Spring, Extension, Hammer Bank

    Spring, Extension, Hammer Bank CAUTION Do not let the hammer bank rotate toward the platen during spring replacement. Removal 1. Prepare the printer for maintenance (page 4–2). 2. Open the printer cover. 3. Remove the shuttle cover assembly (page 5–16). 4.

  • Page 150: Switch Assembly, Paper Detector

    Switch Assembly, Paper Detector Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the paper path (page 5–29). 3. Loosen four screws and remove the barrier shield. (See page 5–59, Figure 5–10, items 3, 4, and 9.) 4. Remove the two 1/4 inch screws securing the paper detector switch assembly.
  • Page 151 Installation 1. Holding the slotted wheel against the PMD sensor, position the paper detector switch assembly and install the screws securing it to the printer base. (See Figure 5–15, page 5–69, item 4.) 2. Check PMD sensor arm range: make sure it travels freely and completely back into the sensing cavity.

  • Page 152: Switch Assembly, Platen Interlock

    Switch Assembly, Platen Interlock Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the paper path (page 5–29). 3. Fully close the forms thickness lever (position ‘A’). 4. Trace the platen interlock switch cable back to the controller board. Remove tie–wraps as necessary to free the cable.
  • Page 153 Installation 1. Fully close the forms thickness lever (position ‘A’). 2. Position the platen interlock switch assembly on the switch bracket and install the two #1 Phillips screws securing it to the bracket. (See Figure 5–14, page 5–67.) 3. Route the switch cable through the cutout in the right side plate and to the controller board.

  • Page 154: Tractor (L/R)

    Tractor (L/R) Removal 1. Prepare the printer for maintenance (page 4–2). 2. Remove the splined shaft (page 5–39). 3. Remove the support shaft (page 5–41). Installation 1. Using the replacement tractors, install the support shaft (page 5–41). 2. Install the splined shaft (page 5–40). 3.
  • Page 155 Section II: Illustrated Parts List List of Figures Figure 5–7. Top Cover, Doors, and Casters ....5–53 Figure 5–8. Paper Fence and Chains .
  • Page 156 Item Part No. Description Notes (Order No.) FD–51859–01 Top Cover Kit Includes cover, logo, and mounting hardware FD–51829–01 Window, Top Cover (Not visible in Figure 5–7) FD–51844–01 Wire Form Paper Path Includes mounting hardware FD–51860–01 Rear Door Kit Includes mounting hardware (Not visible in Figure 5–7) FD–51861–01...

  • Page 157: Figure 5-7. Top Cover, Doors, And Casters

    See Figure 5–9, page 5–57 Figure 5–7. Top Cover, Doors, and Casters Replacement Procedures and 5–53 Illustrated Parts List...
  • Page 158 Item Part No. Description Notes (Order No.) Paper Fence 475 lpm model only Paper Tray Assembly 800 and 1200 models only Grommet Kit, Cabinet FD–51830–01 Chain Assembly Kit AC Power Cord See Chart Below Grommet, Power Cord (2) Part of item 3 Rail, Stacker Part of item 2 Clip, Rail, Stacker...

  • Page 159: Figure 5-8. Paper Fence And Chains

    Figure 5–8. Paper Fence and Chains Replacement Procedures and 5–55 Illustrated Parts List...
  • Page 160 Item Part No. Description Notes (Order No.) FD–51863–01 Control Panel Assy Includes cable, mounting hardware, and all overlays FD–51856–01 Cable Assy, Control Panel Part of item 1. See also Appendix F. FD–51826–01 Gas Spring Kit Includes ball studs, spring clips, and mounting hardware w/Lock Washer (3) 6–32x.375...

  • Page 161: Figure 5-9. Control Panel And Cabinet Details

    Figure 5–9. Control Panel and Cabinet Details Replacement Procedures and 5–57 Illustrated Parts List...
  • Page 162 Item Part No. Description Notes (Order No.) FD–51836–01 Shuttle Cover (Shroud Assembly, Air) Screw, Captive (2), 10–24x.62 With O–ring, 125x.250x.06 (part of item 1) Screw (4), 6–32x.25 Thread forming Barrier Shield FD–51848–01 Paper Path Screw (3),Hex, w/Lock Washer, Part of item 5 6–32x.25, and #6 Flat Washer FD–51868–01 Platen/Paper Feed Cover Kit...

  • Page 163: Figure 5-10. Covers

    Figure 5–10. Covers Replacement Procedures and 5–59 Illustrated Parts List...
  • Page 164 Item Part No. Description Notes (Order No.) FD–51857–01 Ham Bank/Rbn Mask Cover Assy 475 lpm FD–M6654–01 Ham Bank/Rbn Mask Cover Assy 800 lpm FD–M6521–01 Ham Bank/Rbn Mask Cover Assy 1200 lpm FD–51846–01 Shuttle Frame Assembly 475 lpm FD–M6522–01 Shuttle Frame Assembly 800 lpm FD–M6523–01 Shuttle Frame Assembly...
  • Page 165 2 Places: Captive screws Exploded for clarity. 3 places Do not remove holddown clamps and screws. (MPU) (Shuttle Motor) Terminator Board on shuttle Frame Figure 5–11. Print Mechanisms and Card Cage Replacement Procedures and 5–61 Illustrated Parts List...
  • Page 166 Item Part No. Description Notes (Order No.) FD–51838–01 Magnetic Pickup Assy Bracket, MPU Part of item 1 Screw, socket cap 6–32x.38 FD–51858–01 Extension Spring MPU Cable Connector (J03) Shuttle Motor Cable (J02) 5–62 Replacement Procedures and Illustrated Parts List...

  • Page 167: Figure 5-12. Magnetic Pickup Unit (Mpu) And Extension Spring

    Spring Lug (Do not remove grease) Spring Lug (Do not remove grease) CAUTION Make sure the MPU cable does not touch the extension spring after cable connection. 0.010 .001 inch (0.254 .025mm) Figure 5–12. Magnetic Pickup Unit (MPU) and Extension Spring Replacement Procedures and 5–63 Illustrated Parts List...
  • Page 168 Item Part No. Description Notes (Order No.) Screw, Socket Cap, 4–40x.25 Part of item 15 Washer, Flat #4 Part of item 15 Knob, Tractor Adjust Part of item 15 Bushing, Tractor Adjust Part of item 15 Washer, Curved Spring Part of item 15 Ring, Grip Part of item 18 Bearing, Nylon .626...

  • Page 169: Figure 5-13. Tractor Shafts

    Figure 5–13. Tractor Shafts Replacement Procedures and 5–65 Illustrated Parts List...
  • Page 170 Item Part No. Description Notes (Order No.) setscrew Part of item 25 Bracket, Platen (2) Part of item 25 FD–51843–01 Ironer, Paper Screw, Thread Forming (3), 6–32x.25 Bracket, Ironer Plate, Ironer FD–51865–01 Platen Field Kit Washer, Flat Part of item 7 Screw (2) Part of item 11 10 Ref...

  • Page 171: Figure 5-14. Platen

    NOTE: Black tape faces paper motion detector. NOTE: Item 25: Platen Hardware Kit. 11 12 Figure 5–14. Platen Replacement Procedures and 5–67 Illustrated Parts List...
  • Page 172 Item Part No. Description Notes (Order No.) FD–51837–01 Fan Assy, Card Cage Air flow into card cage Screw, w/Lock Washer (3) 6–32x1.75 FD–51851–01 Switch Assy, Paper Detector Screw, Thread Forming (2) 6–32x.377, Part of item 3 FD–51849–01 Motor Assy, Platen FD–51869–01 Platen Pulley, Drive Motor With setscrew: 6–32x.25...

  • Page 173: Figure 5-15. Motors, Fans, And Paper Detector Switch

    Install screws here. Top View Route cable under Hammer Bank Fan base casting See detail above Figure 5–15. Motors, Fans, and Paper Detector Switch Replacement Procedures and 5–69 Illustrated Parts List...
  • Page 174 Item Part No. Description Notes (Order No.) FD–51834–01 Circuit Breaker IEC 320 AC Power Connector J301 Chassis Ground Stud Connector P1 To power supply board connector J1 AC Cable Assy, AC In, Power Supply 5–70 Replacement Procedures and Illustrated Parts List...

  • Page 175: Figure 5-16. Circuit Breaker

    Inside detail To IEC 320 AC Power Input (Connector J301) (Black Wire) To IEC 320 AC Power Input (Connector J301) (White Wire) To Connector P1 (Black Wire) To Connector P1 (White Wire) Card cage fan and power supply Black Wire board removed for clarity.
  • Page 176 5–72 Replacement Procedures and Illustrated Parts List...

  • Page 177: Principles Of Operation

    Principles of Operation Contents Line Matrix Printing ........6–2 Printing Mechanism .

  • Page 178: Line Matrix Printing

    Line Matrix Printing plus The LG Series printer creates characters and graphics by printing patterns of ink dots on paper, an entire line at a time. This technique is called line matrix printing. Every text character is stored in printer memory as a pattern of dots on a logical grid called the dot matrix.
  • Page 179 Direction of Shuttle Movement Start Paper Feed Text Direction Line Number of rows is determined by line spacing. This row is used only for lowercase descenders. This row is used for underlining and lowercase descenders. Figure 6–2. Standard Character Formation Elongated characters are made by printing all but the first and last dot rows twice, as shown in Figure 6–3.
  • Page 180 Figure 6–4 shows how each individual hammer spring forms characters as the shuttle scans horizontally. 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.

  • Page 181: Printing Mechanism

    Printing Mechanism While the principles of line matrix printing are easy to state, the act of printing dots accurately from a rapidly oscillating shuttle onto a vertically moving piece of paper requires precise timing and coordination between printer logic and the printing mechanism. The printing mechanism consists of the shuttle frame assembly, the ribbon transport system, and the paper transport system.
  • Page 182 Each hammer spring is a stiff leaf spring with a cylindrical, tungsten carbide tip on the free end. (See Figure 6–6.) A permanent magnet runs the length of the hammer bank and acts on the hammer springs through individual pole pieces.

  • Page 183: Paper Transport System

    Paper Transport System Tractors Horizontal Splined Adjustment Shaft Vertical Adjustment Knob Knob and Splined Shaft Pulley Tractor Support Shaft Shuttle Cover Assembly Paper Feed Timing Belt (Under the cover) Figure 6–7. Paper Transport System A two–phase DC stepper motor, directed by the PFC on the controller board, drives two tractor sprockets by means of a toothed belt and splined shaft pulley arrangement.

  • Page 184: Ribbon Transport System

    Ribbon Transport System Ribbon Hub Left Ribbon Guide (Not Shown) Hub Locking Latch Ribbon Spool Ribbon Motors Right Ribbon Guide Ribbon Figure 6–8. Ribbon Transport System An inked ribbon winds and unwinds continuously on a pair of spools latched to hubs that are driven by the ribbon motors. The left and right ribbon hubs are offset vertically to equalize ribbon wear and prolong ribbon life.

  • Page 185: Logical Control Of The Printer

    Logical Control of the Printer The printer is divided into four functional elements: the control panel, the controller board, the power supply, and the print mechanisms. See Figure 6–9. Control Panel POWER Input ON/OFF Circuit SWITCH Breaker Line 1 Power Supply Line 2 / Neutral Board J201...

  • Page 186: Control Panel

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

  • Page 187: Cmx Controller Board

    CMX Controller Board The heart of the printer is the CMX controller board, which monitors and directs all printer functions. The controller board receives and processes all data from the host computer, builds the printable images, controls all motors, and drives the hammer springs. Except for the power supply and final hammer drive circuits, all logic and drive circuitry for the printer are contained on the controller board.
  • Page 188 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 6–11. CMX Controller Board Block Diagram 6–12 Principles of Operation...

  • Page 189: Data Controller

    Data Controller The data controller (DC) consists of the following elements: 68EC030 microprocessor 1MB base flash memory, organized as 256K x 32 bits One flash SIMM socket, for up to 16MB of additional program memory 2MB base DRAM data memory, organized as 256K x 32 bits One DRAM SIMM socket, for 2, 3, 8, or 16MB of additional data memory 8K x 8 Non–Volatile Battery–Backed SRAM (NVRAM) for storage of...
  • Page 190 DRAM Memory DRAM is used for program variables, image buffers, and input buffers. All DRAM supports page mode operation and is addressable by individual byte. Two standard 72–pin DRAM SIMMs are used for expansion memory, addressable to 256MB, although 16MB is the practical upper DRAM limit. NVRAM A 8K x 8 bit Non–Volatile battery–backed static RAM (NVRAM) device provides for the storage of configuration and system statistical data.
  • Page 191 Control Panel Interface The VX operator panel interface consists of five lines: serial clock, serial data, and three select lines. It is the VX that handles all parallel–to–serial (and vice versa) conversion to and from the panel, as well as any special timing needed when toggling select lines, etc. “Dot Plucking”...

  • Page 192: Engine Controller

    Less than 0.02V common mode ripple, measured between chassis ground and the ground pins of the interface ICs. Less than 200V/ s slew rate for all outputs. Engine Controller The engine controller (EC) consists of four main elements: 80C166 Microcontroller Address Decode PAL 256KB 5.0V–only FLASH program memory, organized as 64K x 16 bits.
  • Page 193 peripherals are automatically reset. The timer interval is set through software and has a range of 25.6 sec to 419 ms; default setting is 6.55 ms. Analog Drive Circuitry The analog drive functions convert 48 and 8.5 volts into the power used to drive the motors and hammers in the printer.

  • Page 194: Power Supply Board

    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 195: Printer Interface

    Loss of + 48 V is seen by the RSP and reported as a fault. Printer Interface The printer interface is the point where the data line from the host computer plugs into the printer. The printer interface processes all signals and data to and from the host computer.
  • Page 196 6–20 Principles of Operation...

  • Page 197: A Wire Data

    Wire Data NOTE: Acronyms and Signal mnemonics are defined in Appendix E. plus Series Interconnection Diagram ..... . . A–2 plus Series Power Distribution Diagram .
  • Page 198 A–2 Wire Data...
  • Page 199 Wire Data A–3...
  • Page 200 A–4 Wire Data...
  • Page 201 Wire Data A–5...
  • Page 202 A–6 Wire Data...
  • Page 203 Wire Data A–7...
  • Page 204 A–8 Wire Data...
  • Page 205 Wire Data A–9...
  • Page 206 A–10 Wire Data...
  • Page 207 Wire Data A–11...
  • Page 208 A–12 Wire Data...
  • Page 209 Wire Data A–13...
  • Page 210 A–14 Wire Data...
  • Page 211 Wire Data A–15...
  • Page 212 A–16 Wire Data...
  • Page 213 Wire Data A–17...
  • Page 214 A–18 Wire Data...
  • Page 215 Wire Data A–19...
  • Page 216 A–20 Wire Data...
  • Page 217 Wire Data A–21...
  • Page 218 A–22 Wire Data...
  • Page 219 Wire Data A–23...
  • Page 220 A–24 Wire Data...

  • Page 221: Printer Specifications

    Printer Specifications Contents Duty Cycle ..........B–2 Ribbon Specifications .

  • Page 222: Duty Cycle

    Single–part (18 lb) paper Printer is installed in accordance with the Setup Guide Printer is maintained in accordance with this maintenance manual Ribbon Specifications NOTE: Use only the Digital Equipment Corporation ribbons listed below: Part Number Description LGxxR–SR Carton of 1 OCR Application ribbon (LG04 ribbon) Length: 60 yards (54.84 m)

  • Page 223: Paper Specifications

    Paper Specifications Paper Type: Edge–perforated, fan–fold, 3 to 16 inches (7.62 to 40.64 cm) wide, 1 to 12 inches (2.54 to 30.48 cm) long Thickness: Single–part: 15 to 100 pound (6.80 to 45.36 kg) stock; Multi–part: 1– to 6–part forms (maximum 12 lb [5.44 kg] ply of upper plies Sheet Thickness: 0.025 inch (0.0635 cm) maximum...

  • Page 224: Printer Dimensions

    Printer Dimensions Height: 41 inches (104.1 cm) Width: 27 inches (68.6 cm) Depth: 29 inches (73.7 cm) Weight: 225 lbs. (102.1 kg) unpackaged 285 lbs. (129.3 kg) packaged Environmental Characteristics Temperature Operating 41 to 104 F (5 to 40 C) up to 5000 feet (1524 meters) 41 to 90 F (5 to 32 C) up to 8000 feet (2438 meters) Storage –40 to 158 F (–...

  • Page 225: Electrical Characteristics

    Energy Star This printer complies with the requirements of the Energy Star Office Equipment Program of the U.S. Environmental Protection Agency. Electrical Characteristics Input Voltage Line Voltage Line RMS Current Design Range Frequency 475 LPM 800 LPM 1200 LPM 88–135 V RMS 47–63 Hz 6A @ 100 V 6A @ 100 V...
  • Page 226 Interfaces Type: Two resident parallel host interfaces: Centronics and Dataproducts; One resident serial host interface (RS–232/RS–422); One resident serial diagnostic port. Logic Levels: TTL/EIA–232–D Data Format: ASCII or EBCDIC Compatibility: Centronics parallel, Dataproducts parallel, Serial EIA RS–232–D and RS–422–A. Transfer Rates: Up to 200 Kilobytes on parallel interfaces Up to 38.4K baud on RS–232 serial interface Up to 115K baud on RS–422 serial interface...

  • Page 227: Printing Rates

    Printing Rates The printing speed of text is measured in lines per minute (lpm), and is a function of the selected font and the vertical dot density. Printing speed is independent of the number of characters configured in the character set repertoire.
  • Page 228 B–8 Printer Specifications...

  • Page 229: C Metric Conversion Tables

    Metric Conversion Tables Length Multiply To Obtain foot 0.3048* meter (m) foot 30.48* centimeter (cm) foot 304.8* millimeter (mm) inch 0.0254* meter (m) inch 2.54* centimeter (cm) inch 25.4* millimeter (mm) meter 3.280840 foot centimeter 0.03280840 foot millimeter 0.003280840 foot meter 39.37008 inch...
  • Page 230 Mass and Density Multiply To Obtain pound* 0.4535924 kilogram (kg) ounce* 28.34952 gram (g) kilogram 2.204622 pound* gram 0.03527397 ounce* * avoirdupois Temperature To Convert From Use Formula temperature Celsius (t temperature Fahrenheit (t = 1.8t + 32 temperature Fahrenheit (t temperature Celsius (t = (t –...

  • Page 231: D Torque Table

    Torque Table NOTE: The table below establishes the torque requirements for routine installation of threaded fasteners. These requirements apply to fasteners made of steel, at a minimum engagement of 3.5 threads, including chamfer and countersink. Fastener sizes are listed as Numbered Size –...
  • Page 232 Torque Table D–2...
  • Page 233 Abbreviations and Signal Mnemonics NOTE: Mnemonics with first letter “N” are negative true. ACRONYM/ DEFINITION MNEMONIC –6 ....microfarad (10 farad) –6 ....microsecond (10 second) –6...

  • Page 234: Controller

    ....Cathode ....Card Cage ....Card Cage Fan .

  • Page 235: Hammer Bank Logic

    ....Error ....Electrostatic Damage ....Exhaust, Extra .

  • Page 236: Mpu

    ....Lines Per Minute LRIB ... . . Left Ribbon ....Left Ribbon Guide .

  • Page 237: Ribbon Guide, L/R

    ....Paper Feed Controller ....Paper Feed Motor ....Paper Instruction PLAT .

  • Page 238: Shuttle Motor Drive

    ....SNA Character Stream ....Security (Key) ....Select .
  • Page 239 ....With ....Without ... . . Transmit Abbreviations and Signal Mnemonics E–7...
  • Page 240 E–8 Abbreviations and Signal Mnemonics...
  • Page 241 Noise Suppression Devices Ferrite noise suppressors are installed in the printer to reduce radio frequency interference (RFI) to and from electronic equipment located near the printer. Two kinds of ferrite noise suppressors are used: 1. Shielding Bead (P/N 141445–001)—Cylindrical core through and around which the control panel cable assembly is wound.
  • Page 242 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 right rear card cage wall. Connector J203 Figure F–1.
  • Page 243 Index Numbers Block diagram, operator panel, 6–10 Boards, controller (CMX), 5–10 15V PWR FAIL *, 3–4 Boards: layouts, connections, and pin–outs, 23.5V PWR FAIL *, 3–4 A–1 48V PWR FAIL *, 3–4 BUFFER OVERFLOW, 3–4 8.5V PWR FAIL *, 3–4 Cable assembly A TO D OVERUN *, 3–4 interconnections, A–1...
  • Page 244 CLOSE PLATEN, 3–4 DRVR CIR BAD *, 3–5 CMX controller board Duty cycle, B–2 data controller (DC), 6–13 engine controller (EC), 6–16 principles of operation, 6–11 EC (Engine Controller, CMX board), 6–16 COIL HOT, 3–4 Electrical characteristics, B–5 Control panel, replacement, 5–14 Elongated characters, 6–3 Controller board End of Forms Adjust, procedure, 4–20...
  • Page 245 PARITY ERROR, 3–7 PLAT INV CMD *, 3–7 Fan assembly PLAT INV PARM *, 3–7 card cage, replacement, 5–17 PLAT INV STATE *, 3–7 hammer bank, replacement, 5–18, 5–19 POWER SAVER ON, 3–7 Fault messages PROTECTED INSTR *, 3–7 15V PWR FAIL *, 3–4 RIB INVLD CMD *, 3–8 23.5V PWR FAIL *, 3–4 RIB INVLD STAT *, 3–8...
  • Page 246 ERROR: PROGRAM NEEDS MORE DRAM, 4–30 ILL EXT BUS ACC *, 3–5 ERROR: PROGRAM NEEDS MORE ILL INST ACCSS *, 3–5 FLASH, 4–30 ILLGL OPR ACCSS *, 3–5 ERROR: PROGRAM NOT COMPATIBLE, 4–30 Illustrations, replacement procedures, 5–51 ERROR: PROGRAM NOT VALID, 4–30 Inspection, printer, 2–3 ERROR: SHORT AT ADDRESS XXXX, Interconnection diagram, A–2...
  • Page 247 cleaning the printer, 2–4 Operation, principles of, 6–1 inspecting the printer, 2–3 Operator panel, block diagram, 6–10 overview, 1–1 preventive, 2–1 preventive maintenance checks and PAL, security, location, 5–22 services, 2–2 scheduled, 2–1 PAP BAD TABLE *, 3–6 Manual PAP BSY TOO LNG *, 3–6 how to use, 1–3 PAP FIFO OVERFL *, 3–6 notes and notices, 1–3...
  • Page 248 Physical Inspection, 2–3 preventive maintenance checks and services, 2–2 Pin–outs, A–1 principles of operation, 6–1 PLAT INV CMD *, 3–7 self–tests PLAT INV PARM *, 3–7 diagnostic print, 3–35 PLAT INV STATE *, 3–7 operator print, 3–35 Platen specifications, B–1 gap adjustment, 4–12 troubleshooting, 3–1 interlock switch assembly, replacement,...
  • Page 249 paper path, 5–29 SECURITY VIOLATION, 3–8 platen, 5–30 Self–tests platen interlock switch assembly, 5–48 diagnostic, printer, 3–35 platen open belt, 5–7 operator print, 3–35 platen open motor, 5–25 SENDING PROGRAM TO EC power supply circuit board, 5–12 PROCESSOR, 4–31 resistors, terminating, 5–35 Services.
  • Page 250 Spring fault messages, 3–3 extension, hammer bank, replacement, symptoms not indicated by fault messages, 5–45 3–29, 3–30 gas, assembly, replacement, 5–44 STACK OVERFLOW *, 3–8 STACK UNDERFLOW *, 3–8 UNDEF INTERRUPT *, 3–9 Status lamps, 1–8 UNDFNED OPCODE *, 3–9 Support shaft, replacement, 5–41 UP (arrow) key, 1–8 Switch...

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