LG12 Text and Graphics Printer Maintenance Manual digi tal Order Number: FW–LGMA1–A8 Digital Equipment Corporation • Merrimack, NH 03054
nd Edition, May 1993 Digital Equipment Corporation, 1993 All Rights Reserved The information in this document is subject to change without notice and should not be construed as a commitment by Digital Equipment Corporation. Digital Equipment Corporation assumes no responsibility for any errors that may appear in this document. Printed in U.S.A.
Table of Contents 1 Overview About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 Warnings and Special Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 Printing Conventions in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Preventive Maintenance Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 Cleaning the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 4 Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3 Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments Hammer Bank Service Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 Hammer Spring Retensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8 Hammer Tip Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10 Magnetic Pickup Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12 Magnetic Pickup Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper Motion/Out Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–28 Platen Open Motor and Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–29 Platen Open Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–30 Printed Circuit Board Assemblies (PCBAs) . . . . . . . . . . . . . . . . . . . . . . . . . . 6–32 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendices A Wire Data B Abbreviations, Acronyms, and Signal Mnemonics C PROM and Chip Locations D Torque Table E Metric Conversion Tables F Printer Specifications Table of Contents v
vi Table of Contents
1 Overview Chapter Contents About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 Warnings and Special Information . . . . . . . . . . . . . . . . . . . . . . . 1–2 Printing Conventions in this Manual . . . . . . . . . . . . . . . . . . . . . 1–3 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About This Manual This is a field service maintenance manual for the LG12 Text and Graphics printer. This manual does not explain how to operate or configure the printer. For that information, refer to the User’s Manual. How to Use This Manual This manual is designed so that you can quickly find the information you need to service the printer. You can locate maintenance information three ways: ♦ Use the Table of Contents at the front of the manual.
Printing Conventions in This Manual Switches, indicators, and switch positions that are labeled on the printer are printed in uppercase letters. Example: Press the CLEAR switch. Messages that appear on the liquid crystal display of the control panel are printed in quotation marks. Example: Press the CLEAR switch. “Off–Line Emulation” appears on the LCD.
Controls and Indicators Electrical Controls and Indicators (Figure 1–1) Switch or Indicator NOTE: ON LINE is the only switch that operates when the printer is on–line. All other switches operate only in the off–line state. Power Switch Turns printer on and off. Is also a circuit breaker. Status lamps Illuminate when printer is on–line. Flash alternately to indicate fault or warning. Off when printer is off–line. LCD Liquid Crystal Display. Shows printer status and error messages.
Printer Cover On Power Switch Off Status Lamps Liquid Crystal Display (LCD) CLEAR UP R/S PREV NEXT SET TOF ON LINE FF LF VIEW ENTER DOWN RAISE PRINTER COVER TO ACCESS THESE SWITCHES Figure 1–1.
Mechanical Controls (Figure 1–2) Control or Indicator 1–6 Function Forms thickness lever Sets platen for paper and forms of different thicknesses. Must be raised to load paper. Forms thickness pointer and scale Indicates relative thickness of paper. Set the forms thickness lever at A for thin (single–part) forms, B for thicker forms, and so on. Tractors (2) Hold and feed paper. Also used to set left side margin. Tractor locks (2) Lock tractors in position.
Tractor Lock Tractor Lock Horizontal Adjustment Knob Vertical Adjustment Knob Forms Thickness Pointer and Scale Forms Thickness Lever Tractor Figure 1–2.
Tools, Test Equipment, and Supplies The tools, test equipment, and supplies required for field level maintenance of LG12 printers are listed below. Item Part Number Recommended Item Adjustable Wrench — Utica 91–4C Alcohol, Anhydrous — — 29–26246–01 — Diagonal Cutters — Erem 91EH Digital Voltmeter — — Extension, 3 in.
Item Part Number Recommended Item Screwdriver, Slot — Xcelite A184 Screwdriver, Slot — Xcelite R3164 Screwdriver, Stubby, 1.5 in shank, 0.25 in tip–width — — Shim, Antirotation (0.010 in.) 29–30943–01 — Shim, Antirotation (0.005 in.) 29–30944–01 — Shims, Counterweight 29–24417–00 — Shims, Shuttle Spring 29–24420–00 — Socket, 7/16 in., 3/8 in.
1–10 Overview
2 Principles of Operation Chapter Contents Line Matrix Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2 Functional Elements of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11 Common Controller Board (CCB) . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12 CCB Hardware Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Matrix Printing The LG12 creates characters and graphics by a printing technique called line matrix printing. Line matrix printing consists of printing patterns of ink dots on paper, an entire line at a time. Each text character is stored in memory as a pattern of dots on a logical grid called the dot matrix. (See Figure 2–1.) The actual ink dots are made by a row of hammer springs mounted on a shuttle that sweeps rapidly back and forth.
The dot patterns of characters vary according to the font selected. For example, in the data processing (DP) font at a line spacing of six lines per inch (lpi), the dot matrix contains 12 dot rows from the top of one character line to the top of the next. (See Figure 2–1 and Figure 2–2.) At eight lpi there are nine dot rows per character line, at nine lpi eight dot rows per character line, and so on. Uppercase (Reference) Underline Lowercase with Descender Figure 2–2.
The Hammer Bank The LG12 uses a hammer bank to print dots. The hammer bank consists of 88 hammer springs mounted on a shuttle that moves horizontally back and forth. The hammer bank prints one horizontal line of dots during each horizontal sweep of the shuttle. A hammer spring is a stiff leaf spring with a hardened steel tip at the upper end, and is attached to the hammer bank at the lower end. (See Figure 2–3.) A permanent magnet keeps the hammer springs retracted and under tension.
Ribbon Ribbon Mask Hammer Bank Cover Paper Hammer Tip Magnet Coil Coil Platen Shuttle Shaft Hammer Spring Hammer Spring Mounting Screw Paper Ironer Figure 2–3. Hammer Spring and Shuttle Arrangement Normal (retracted) State Coils de–energized Activated (released) State Coils energized Permanent Magnet Coil Coil Coil Hammer Tip Coil Hammer Spring Figure 2–4.
Character Generation Paper advances one dot row after each horizontal sweep of the shuttle. (See Figure 2–5 and Figure 2–6.) Direction of Shuttle Movement Dot Row Character Row 1 2 3 4 5 6 7 8* 9** 10 11 12 1 2 Paper Advances Start Paper Feed Paper Advances Space 1 Hammer Print Span The LG12 shuttle sweeps through 1.5 character positions at 10 cpi. 1 Hammer Print Span * Used for lowercase descender only. ** Used for underline and lowercase descender. Figure 2–5.
Successive Hammer Strokes Per Scan Dot Column Shuttle Scan Dot Row 1 1 2 1 2 3 1 2 3 4 1 2 3 4 5 1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 5 6 7 * 1 * NOTE: * 1 3 * 1 3 5 * 1 3 5 7 * 1 3 5 7 9 * Even column dot centers within the printed character area and character space hammer positions are not illustrated in this diagram. = Dot =No dot where hammer has already been = Hammer Position Figure 2–6.
Normal Operation In normal operation, the user presses a switch on the control panel to put the printer on–line. Host computer data are then read into the input buffer as ASCII data. The data in the input buffer are compared to tables stored in memory to determine the matrix and location of each character The characters are then built in the dot image buffer. Information from the dot image buffer is synchronized with printer requirements using the magnetic pickup signal, then shifted to the hammer drivers.
Functional Elements of the Printer The printer consists of six functional elements: ♦ Control panel ♦ Common controller board (CCB) ♦ Mechanism driver board ♦ Hammer driver board ♦ Auto–ranging power supply ♦ Print mechanism Figure 2–8 is a block diagram of these elements. The rest of this chapter discusses these systems in more detail.
+12.5Vdc ON / OFF Switch AUTO–RANGING POWER SUPPLY EMI FILTER Circuit Brkr AC POWER HAMMER DRIVER BOARD POWER SUPPLY FAN HOST COMPUTER Data PRINT MECHANISMS +48 Vdc HMR DRV 1–40 +12.
Control Panel The control panel consists of indicator lamps, LEDs, contact switches, and a liquid crystal display (LCD). The control panel processes and sends switch closure information to the controller board and receives status information. Control Panel Assembly Switch Closures Status Control Panel Circuit Board Assembly Control Data Switch Closures Common Controller Board (CCB) Figure 2–9.
Common Controller Board (CCB) The Common Controller Board (CCB) oversees and coordinates all printer functions. It is functionally two units: the data processing unit (DPU) and the real–time processing unit (RTPU). The DPU converts all character data into printable dot images. The DPU is the high–level logical controller of the printer; it is not involved in real–time or hardware–dependent printer operation. The RTPU operates the host interfaces, operator control panel, and the print mechanism.
Controller Communication with the Host Computer and Operator The controller board processes three kinds of computer input: Centronics parallel, DataProducts parallel, and RS–232 serial data. The RTPU operates all three interfaces. The parallel interfaces are similar, and the RTPU contains direct–memory–access (DMA) hardware which loads parallel data directly into shared memory.
DATA PROCESSING UNIT (DPU) SHARED MEMORY DOT PLUCKER ASIC Hammer Driver Data RTPU PROCESSOR EPROM DMA CONTROLLER FIRE TIMER ASIC Hammer Timing Data REAL–TIME PROCESSING UNIT Figure 2–11. Hammer Driver Interface Functions of the RTPU Getting Dots to the Hammers Getting dots to the hammers consists of going into the shared memory and pulling bits out in a given order and shifting them to the hammer driver at the correct time. This process is called “dot plucking.
Mechanical Interface Functions Three mechanical operations are coordinated in printing: paper motion, ribbon motion, and shuttle motion. Virtually all digital handling of paper motion is contained in the RTPU. The ribbon and shuttle are controlled by logic on the mechanism driver board, under the direction of the RTPU. Figure 2–12 shows the mechanical interface section of the RTPU.
the ribbon/shuttle processor (RSP) is a 2400 baud asynchronous serial line. A message protocol is used to communicate ribbon and shuttle information. Fault Monitoring The RTPU also monitors the hammer driver, mechanism driver, and the electro–mechanical sensors for fault conditions. Fault conditions are reported to the DPU. Hammer Bank and Hammer Driver Faults The FTIC works with the hammer driver ASIC to monitor coil shorts, opens, average upper driven phase current, and temperature conditions.
CCB Hardware Summary A Motorola 68010 microprocessor performs the DPU functions, a 64180 microprocessor handles the RTPU functions, and an 8032 microcontroller serves as the paper feed controller (PFC), which is part of the RTPU.
68010 MICROPROCESSOR SHARED BUS INTERFACE EPROM 512 KB CONTROL REGISTER NVRAM 2 KB DATA PROCESSING UNIT (DPU) REAL–TIME PROCESSING UNIT (RTPU) PARALLEL PORT From Host Computer DOT PLUCKER ASIC Serial from Host Computer 64180 PROCESSOR Serial to Host, Mech. Driver, and Control Panel SHARED BUS INTERFACE SHARED MEMORY DRAM 512 KB To Hammer Driver FIRE TIMER IC (FTIC) EPROM 64 KB HARDWARE CONTROL REGISTER SRAM 2 KB HARDWARE STATUS REGISTER COMM.
Communicating with the Host Computer The 64180 processor runs both the parallel and serial interfaces. Parallel Input Parallel input data is nine bits wide, and is transferred in one cycle from the parallel port to shared memory over the shared sixteen bit bus. Using the internal DMA controller of the 64180 to transfer parallel data requires some manipulation.
results in immediate movement. Other paper commands and status signals are also passed through this port. Ribbon and Shuttle Motion The 64180 interfaces through its second UART to the ribbon / shuttle processor (RSP) on the mechanism driver board. The 64180 begins all transactions on the serial interface. Fault Monitoring The RTPU 64180, the PFC 8032, and the RSP monitor different functions for faults. The 64180 looks for hammer driver faults, shuttle stalls, and an open platen.
Mechanism Driver Board The mechanism driver board, acting on timing and control signals from the CCB, controls real–time operation of the electromechanical printer systems. Functionally, the board consists of the following subsystems: • An 8032 microcontroller controls ribbon, shuttle, and platen drives, and communication with the controller board. This 8032 is called the RSP (Ribbon/Shuttle/Platen) controller. • The interface to the power supply.
MECHANISM DRIVER BOARD HAMMER DRIVERS 41–88 FAULT CIRCUITS To Coils 41–88 HAMMER DRIVE BOARD LOGIC To CCB 8032 RIBBON & SHUTTLE DRIVE PAPER TRANSPORT DRIVE HAMMER DRIVER LOGIC HAMMER DRIVERS 1–40 To Coils 1–40 PAPER FEED CONTROL PLATEN OPEN CONTROL RIBBON CONTROL & STATUS SHUTTLE DRIVE & MPU Figure 2–14.
The Ribbon Drive System The ribbon drive system is controlled by the 8032 microcontroller. The controller board sends commands to the 8032 to start and stop the ribbon, set the ribbon speed, and apply slack or tension to the ribbon. The real–time control functions are done by the 8032, acting in accordance with firmware control algorithms and look–up tables. The 8032 communicates with an ASIC to provide direct digital PWM drive signals for the ribbon motor PWM amplifier.
Start / Stop Ribbon The ribbon motors are started and stopped by a digital signal from the controller board. After a stop signal is received, the ribbon is locked to maintain tension. If the controller board sends a slack signal, the PWM amplifiers are tri–stated. The Shuttle Drive System The shuttle drive system is an analog closed–loop speed controller that accepts commands from the controller board through the 8032 microcontroller and MDIC ASIC.
Hammer Driver Board The hammer driver board consists of three functional elements: hammer driver logic and control circuits, blower drive and monitoring circuits, and filter capacitors for the +48 V and +12.5 V power supplies. Hammer Driver Logic and Control Each hammer spring is controlled by two electromagnetic coils, a driver, and a logic circuit. The hammer logic circuits perform the following functions: ♦ Convert serial data bits on the COM line into parallel data bits.
Test Mode 12.5 V V ramp +48 V Coil Temp. & Open Detect +24 V bootstrap Level Shift 12.5 VSUS HD Coil Temp. Flyback Diodes 12.5 1% Boot Strap Window Compare & Fault Detect HD Short Hammer Coil LD FET COM CLK FIRE Shift Register Latch NLD_RST Figure 2–15. Hammer Driver Logic Power Filtering The power supply is housed in a protected and independently cooled steel module separate from the card cage containing the hammer driver and mechanism driver boards.
Hammer Bank Cooling The hammer driver board also powers a blower fan that cools the hammer bank. A fixed 60/40 signal (PWM) is provided to the hammer driver board to run the blower fan. The hammer driver board demodulates this signal to a binary (on/off) logic signal, then drives a MOSFET that powers the blower. A current monitoring circuit tells the RTPU when the blower is running. If the blower is stalled or not connected, the RTPU declares a fault. (See Figure 2–17.
Auto–Ranging Power Supply The power supply board, AC input connector, power switch/circuit breaker, and a cooling fan are contained in a removable steel module at the rear of the printer. The power supply senses and adjusts to any commercial electrical system that provides AC mains potential in 50 or 60 Hertz systems. AC input power is converted to +48 volt and +12.5 volt DC power and sent to the hammer driver board for bulk filtering. The hammer driver board then passes the filtered +48 and +12.
Print Mechanisms Hammer Bank, Shuttle, and MPU Printing is synchronized with shuttle movement by signals from the magnetic pickup unit (MPU). The MPU, located next to the flywheel timing disk, is so oriented that timing signals relate precisely to the shuttle position. (See Figure 2–18.) Variations in magnetic reluctance are sensed by the MPU from apertures on the timing disk as it rotates, generating SYNC pulses.
Hammer Bank and Shuttle Assembly Shuttle Motor (Shuttle Mechanics) MPU Figure 2–18.
Ribbon Deck The printer ribbon winds and unwinds continuously on a pair of spools latched to hubs driven by the ribbon motors. The ribbon motors operate only while the hammer bank assembly is running. Ribbon motion reverses when the metal strip at either end of the ribbon crosses the left or right ribbon guide, completing a circuit that causes both motors to reverse direction. Constant ribbon tension is maintained by controlling each motor with a drive or drag circuit.
Paper Feed Control The paper transport system accepts continuous, fan–folded, edge–perforated paper from three to 16 inches wide and from one to six sheets thick. (See Appendix F for precise paper specifications.) Horizontal positioning is provided by the horizontal adjustment knob and two tractors. The tractors are laterally adjustable along the splined and support shafts. Each tractor engages paper perforations with eight pins and locks in place with a friction lock.
3 Preventive Maintenance Chapter Contents Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 Cleaning the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventive Maintenance The LG12 printer requires no preventive maintenance beyond normal replenishment of paper and ribbons and periodic cleaning. Since operating conditions vary widely, the user must determine how often to clean the printer. Cleaning the Printer CAUTION Do not use abrasive cleaners, particularly on the window. Do not drip water into the printer; damage to equipment will result. When using spray solutions, do not spray directly onto the printer; spray the cloth. 1. Turn the printer off.
Ribbon Spools Left Tractor Splined Shaft Support Shaft Right Tractor Platen Forms Thickness Lever Lock Tab (2) Ribbon Hub (2) Ribbon Deck Ribbon Guide (2) Figure 3–1.
12. Wipe the platen with a cloth dampened with anhydrous alcohol. 13. Unlock the right tractor and slide it all the way to the right. (See Figure 3–2.) 14. Remove the ribbon deck to gain access to the hammer bank. 15. Push the top edge of the ribbon mask on the hammer bank cover assembly toward the platen and hold it in that position as you do step16. NOTE: Handle the ribbon mask carefully. A damaged ribbon mask can degrade print quality. 16.
Right Tractor Forms Thickness Lever Lock Tab (2) Platen Ribbon Hub (2) Screw (3) Ribbon Deck Ribbon Mask Hammer Spring Hammer Bank Cover Hammer TIp Figure 3–2.
3–6 Preventive Maintenance
4 Troubleshooting Chapter Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3 Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3 48 Volt Failed * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3 Dynamic RAM Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5 Ham. Bank Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Self–Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–27 Running the Diagnostic Self–Tests . . . . . . . . . . . . . . . . . . . . . . . . . . 4–29 Hex Code Printout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–30 Clearing Nonvolatile Memory (NVRAM) . . . . . . . . . . . . . . . . . . . .
Introduction This chapter contains procedures for troubleshooting printer malfunctions. Diagnostic test procedures are covered in this chapter, but basic printer operation is not. Since you must operate the printer to check its performance, have the Operator‘s Guide or User‘s Manual at the printer site. Fault Messages This section contains troubleshooting tables for fault messages that can appear on the Liquid Crystal Display (LCD).
Instruction 5. Turn printer on and observe Indication power supply fan. 7. Cycle power and observe the power supply fan. 8. Cycle power and observe the power supply fan above the on/off switch. 9. Cycle power and check for Replace the controller board. Reattach CCB/Mech Driver cable to connector J2 on the controller and connector J6 on the mech driver board, and go to step 6. Power supply fan runs, then stops. Replace the mech. driver board. Go to step 7.
Dynamic RAM Fault * Instruction 1. Cycle power: Turn printer off. Wait 15 seconds. Turn printer on. 2. Disconnect the input data line from the host computer. Set power switch to off. Wait 15 seconds. Set power switch to on. 3. Make a Diagnostic Check of Indication Yes No “Dynamic RAM Fault * ” message. Go to step 2. Return printer to normal operation. “Dynamic RAM Fault * ” message. Go to step 3. Return printer to normal operation. — — — the CCB (page 4–21).
Ham. Bank Hot NOTE: The printer has protective circuits that sense conditions which can lead to overheating. When such conditions are sensed, print speed is reduced 50%. If the printer consistently prints at half speed, it may be printing long jobs of very dense graphics or operating in a severe environment. A severe environment is consistently above 90° Fahrenheit (32° Celsius) or is dirty enough to create blockage of the blower ducts.
Ham. Coil Open * Instruction Indication Yes No “Ham. Coil Open * ” message. Go to step 2. Return printer to normal operation. 2. Press the CLEAR switch. “Ham. Coil Open * ” message. Go to step 3. Return printer to normal operation. 3. Run a diagnostic self–test “Ham. Coil Open * ” message. Go to step 4. Return printer to normal operation. Observe where the non–printing hammer is located. Go to step 5. — Go to step 6. — 1. Cycle power: Turn printer off. Wait 15 seconds. Turn printer on.
Ham. Coil Short * Instruction 1. Cycle power: Turn the printer Indication Yes No “Ham. Coil Short * ” message. Go to step 2. Return the printer to normal operation. Resistance is 4–8 Ohms for all coils. Go to step 4. For coils less than 4 Ohms, go to step 3. Coil resistance still less than 4 Ohms. Replace the coil. Go to step 4. Cable resistance is more than 1K Ohm. For hammers 1 – 40, replace the hammer driver board. For hammers 41 – 88, replace the mechanism driver board.
Ham. Drv. Short * Instruction Indication Yes No “Ham. Drv. Short * ” message. Go to step 2. Return printer to normal operation. 2. Press the CLEAR switch. “Ham. Drv. Short * ” message. Go to step 3. Return printer to normal operation. 3. Disconnect connectors J4, “Ham. Drv. Short * ” message. Replace the mechanism driver board. Go to step 4. “Ham. Drv. Short * ” message. Replace the hammer driver board. Return printer to normal operation. “Ham. Drv. Short * ” message.
Mech Driver Hot * Instruction Indication Yes No “Mech Driver Hot * ” message. Go to step 2. Return printer to normal operation. Card cage fan operates. Go to step 3. Replace the card cage fan. Cabinet exhaust fan operates. Go to step 4. Replace the cabinet exhaust fan. Power supply fan operates. Go to step 5. Replace power supply. 5. Press the CLEAR switch. “Mech Driver Hot * ” message. Go to step 6. Return printer to normal operation. 6.
Mech Driver Link * Instruction Indication Yes No “Mech Driver Link * ” message. Go to step 2. Return printer to normal operation. 2. Press the CLEAR switch. “Mech Driver Link * ” message. Go to step 3. Return printer to normal operation. 3. Run a diagnostic self–test “Mech Driver Link * ” message. Go to step 4. Return printer to normal operation. — Go to step 5. — 1. Cycle power: Turn printer off. Wait 15 seconds. Turn printer on. (page 4–27). 4. Remove the card cage cover. 5.
Paper Jam Instruction 1. Inspect paper path for Indication Yes No Paper path is clear. Go to step 2. Remove paper and go to step 2. Debris found. Gently remove paper or lint particles with a wooden stick or pair of tweezers. CAUTION: Do not pry or apply force to the hammer tips. Go to step 3. Go to step 3. Ribbon mask damaged or bent. Replace the hammer bank cover assembly. Go to step 4. Go to step 4. Paper moves correctly but “Paper Jam” message still appears.
Paper Out Instruction 1. Load paper. 2. Run a diagnostic self–test Indication — (page 4–27). Troubleshooting — Replace paper detector switch assembly. Adjust the new paper motion switch assembly (Chapter 4). Go to step 3. Return printer to normal operation. “Paper Out” message. Replace the sensor harness assembly. Go to step 4. Return printer to normal operation. “Paper Out” message. Replace the controller board. Return printer to normal operation. (page 4–27). 4.
Platen Open Instruction 1. Load paper and close the Indication — Yes No Go to step 2. — forms thickness lever. 2. Run a diagnostic self–test “Platen Open” message. Replace platen interlock switch assembly. Go to step 3. Return printer to normal operation. “Platen Open” message. Replace sensor harness assembly. Go to step 4. Return printer to normal operation. “Platen Open” message. Replace the controller board. Return printer to normal operation. (page 4–27). 3.
Ribbon Stall Instruction 1. Check that forms thickness lever is not closed too tightly; this can jam the ribbon and shuttle. 2. Run a diagnostic self–test Indication Yes Forms thickness lever is set correctly. Go to step 2. Readjust the setting of the forms thickness lever. Go to step 2. “Ribbon Stall” message. Go to step 3. Return printer to normal operation. Ribbon path is clear. Go to step 4. Remove obstructions from ribbon path and go to step 4. Ribbon is OK.
Shuttle Fan * Instruction 1. Cycle power: Turn printer off. Indication Yes No “Shuttle Fan” message. Go to step 2. Return printer to normal operation. Blower starts and runs, but “Shuttle Fan” message displays. Go to step 3. Go to step 4. Cables are connected and undamaged. Replace the controller and hammer driver boards. Replace the defective cable assembly. “Shuttle Fan” message displays and blower does not run. Replace the blower. Go to step 5. Return printer to normal operation.
Shuttle Jam Instruction 1. Check the forms thickness lever: if it is set too tightly, it can slow the shuttle enough to trigger the fault message. 2. Run a diagnostic self–test Indication Yes Forms thickness lever set correctly. Go to step 2. Set forms thickness lever for thicker paper. Go to step 2. “Shuttle Jam” message. Go to step 3. Return printer to normal operation. Shuttle movement blocked. Remove obstruction. Go to step 4. Install ribbon deck. Go to step 4.
Software Error * Instruction 1. Cycle power: Turn printer off. Indication Yes “Software Error * ” message. Go to step 2. Return printer to normal operation. “Software Error * ” message. Go to step 3. Problem is not in the printer. Return printer to normal operation. Wait 15 seconds. Turn printer on. 2. Disconnect the input data line from the host computer. Cycle power. 3. Make a Diagnostic Check of No — — — the CCB (page 4–21). If any problems are found on the CCB, replace the board.
Troubleshooting Symptoms Not Indicated by Fault Messages Use standard fault–isolation techniques to troubleshoot malfunctions not indicated by fault messages: 1. Ask the user to describe the problem. 2. Verify the fault by running diagnostic self–tests or replicating conditions reported by the user. 3. Locate the malfunction using the half–split method: a. Isolate faults to half the remaining system at a time, until the final half is a field–replaceable part or assembly. b.
Printer Confidence Check Instruction 1. Check that printer is plugged into correct power source. (Refer to User’s Manual.) 2. Disconnect the interface Indication No Power cable installed correctly to proper source. Go to step 2. Connect printer to correct power source. Printer operates correctly. Fault is not in the printer. Check host computer, applications software, cabling, etc. Go to step 3 (data) cable from the host computer to isolate the printer, then run a diagnostic self–test (page 4–27.
CCB Diagnostic Checks This procedure checks the operation of the microprocessors and IC chips on the Common Controller (CCB) and Mechanism Driver boards. Do the steps in the order presented. 1. Turn the printer off. 2. Open the card cage and reseat the CCB and Mech Driver boards. 3. Turn the printer on. Wait at least 15 seconds; while you are waiting watch the DPU LED at location A2 on the CCB and watch the display on the control panel. (NOTE: IC locations are shown in Appendix C.
d. If the DPU LED blinks steadily at 1 blink per second, it means that the 68010 ROMs are bad. Turn off the printer, remove the CCB, and check that all ROM chips are inserted in the correct position and with all pins inserted correctly. This check will catch out–of–order ROMs and all single and multiple bit failures of floating–gate EPROMs (the type with the window, that erase with ultraviolet light). If a ROM chip was inserted backwards, discard it.
a. If the display is blank, or has a single line of black squares across the top, the connector to the control panel probably needs to be plugged in or reseated. Turn off the printer, plug in the panel cable to connector J3 on the CCB, and start over at step 1. If the display is still blank, or has a black line, and the DPU LED lights and turns off, the control panel or its cable are defective. b. If the display reads “Mech Driver Link,” the 8032 at location J12 on the CCB may have failed.
d. If the printer prints from the host, but occasionally loses blocks of data, the most likely cause is the host not responding to “send no more data” signals from the printer. With a Centronics interface, this means the host is ignoring BUSY; in RS–232, the host is ignoring the XOFF character or “Data Terminal Ready” (pin 20). Sometimes the cable is not conveying the necessary signals.
f. If the printer prints garbled data or slews uncontrollably, put the printer into hex dump mode and analyze the binary data. One cause of garble is the host interface or cable is not transmitting all the data. When this occurs, the Centronics or Dataproducts interface receives a 1 on every unconnected data line. Uncontrolled slewing is often caused by enabling PI (Paper Instruction) when the host lacks a PI signal. (PI shows as “p” on the hex dump.
6. The DPU LED lights, but never turns off. Look at the control panel display: a. If the top line of the display is blank, the control panel is probably unplugged or defective. Do the corrective actions listed in step 4.a. b. If the display has a single line of black squares on the top line, the 64180 has failed. Turn off the printer, remove the CCB, and check the 64180 RTPU PROM at location H8 for bent pins, pins not inserted, or backwards insertion. Discard any PROMs that were inserted backwards.
Diagnostic Self–Tests Run diagnostic self–tests to check the print quality and operation of the printer. The self–tests are listed below; the procedure for running the tests is explained on page 4–29. NOTE: Under the description of each diagnostic test is a list of items that may require adjustment or replacement if the test produces a bad print pattern. Items are listed in the order they should be checked: simplest items first, moving to more complex components.
Ribbon MPU sensor Hammer spring Hammer coil All Underlines An underline pattern useful for identifying hammer bank misalignment. Mechanism Driver board Hammer tips Paper feed belt or motor Splined shaft bearings Tractor bearings or belts All Black All odd dot positions are printed, creating a solid black band. Exercises shuttle and hammer bank at maximum capacity.
Running the Diagnostic Self–Tests To run a diagnostic self–test: 1. On the control panel, press the ON LINE switch to place the printer off–line. “Off–line Emulation” displays. 2. Raise the printer cover. 3. On the control panel, press the and switches at the same time. “ENTER Switch Not Locked” briefly displays. (If “Locked” displays, press and again.) 4. Press the switch. The current emulation displays. 5. Press the or switch until “Emulation Self Test” displays. 6. Press ENTER.
Hex Code Printout Hex dumps list all ASCII character data received from the host computer with their corresponding two–digit hexadecimal codes. (The ASCII character set is on page 4–31.) You can use hex dumps to troubleshoot printer data reception problems. Printable characters print as the assigned symbol; nonprintable characters are indicated by the period symbol (.). The letter p before a hex code indicates an active Paper Instruction (PI) line.
ASCII Character Set B7 0 B6 KEY B7 B6 0 B5 0 0 0 1 B4 B3 B2 B1 1 0 BITS 0 B5 BITS 0 1 0 1 1 OCTAL equivalent DECIMAL equivalent HEX equivalent ASCII Character 33 27 1B ESC 1 0 1 0 1 0 1 1 0 0 1 1 1 1 0 1 1 COLUMN 0 B4 B3 B2 B1 ROW 1 0 0 0 0 0 NUL 0 0 0 0 0 0 1 1 SOH 1 1 1 0 0 1 0 2 STX 2 2 2 DC2 0 0 1 1 3 ETX 3 3 3 0 1 0 0 4 EOT 0 1 0 1 5 0 1 1 0 DLE DC1 (XON) 2 20 16 10 21 17 11 3 SP 40 32 20 ! 41 33 21 4 0 60 48 30 1 61 49 31 5
Clearing Nonvolatile Memory (NVRAM) Clearing nonvolatile memory (NVRAM) erases all configuration values stored in NVRAM. These values include the saved configuration under all emulations, the print statistics, and the phasing index. IMPORTANT The printer must be rephased if NVRAM is cleared. To clear NVRAM, hold down the CLEAR switch while the printer is turned on and powers up.
5 Adjustments Chapter Contents Special Procedures Hammer Bank Service Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 Adjustments Hammer Spring Retensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8 Hammer Tip Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10 Magnetic Pickup Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12 Magnetic Pickup Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer Bank Service Position Putting the Hammer Bank in the Service Position 1. Remove the printer’s power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap (29–26246–01) be worn, especially while servicing logic components. 2. Remove the paper supply from the print station and tractors. 3. Disconnect four connectors (1) from the bottom of the ribbon deck assembly (2). (See Figure 5–1.
1. 2. 3. 4. 5. 6. 7. Connector (4) Ribbon Deck Assembly Lock Tab (2) Ribbon Spool (2) Ribbon Hub (2) Screw (3) Retaining Clip (2) 4 6 7 2 5 3 1 Figure 5–1.
7. Place the hammer bank assembly in the service position, as follows: a. Raise the forms thickness lever (1) all the way. (See Figure 5–2) b. Remove the velcro pad (2) holding the coil wires. c. Disconnect the coil connectors (3). d. Remove four screws (4), eight washers (23, 24), and two coil lead brackets (5). e. Remove two screws (6), lockwashers (7), and washers (8). f. Remove two screws (9) and washers (10) from the shroud (11). g. Separate the shroud from the shuttle assembly (12).
1. Forms Thickness Lever 2. Velcro Pad 3. Coil Connector 4. Screw (4) 5. Coil Lead Bracket (2) 6. Screw (2) 7. Lockwasher (2) 8. Washer (2) 9. Screw (2) 10. Washer (2) 11. Shroud 12. Shuttle Assembly 13. Screw (2) 14. Antirotation Block 15. Shim 16. Hammer Bank 17. Hammer Bank Cover 9 10 8 3 6 7 11 1 15 14 5 12 17 24 25 23 4 19 2 20 22 13 16 21 18. Holding Pin (2) 19. Screw 20. Screw 21. Hammer Spring 22. Clamp Plate 23. Washer (4) 24. Washer (4) 25. Set Screw (2) 26. Coil Clamp 27.
Returning the Hammer Bank to the Operating Position 1. Install the hammer bank cover. Check for engagement with the holding pins. 2. Rotate the hammer bank as far as it will go toward the rear of the printer. CAUTION Do not lubricate the bearing block assemblies or hammer bank shaft. 3. Apply a 1/4 inch dab of bearing lubricant (see page 1–8) to both sides of the plate of the hammer bank where the plate contacts the bearing surfaces of the antirotation block. 4.
1. Forms Thickness Lever 2. Velcro Pad 3. Coil Connector 4. Screw (4) 5. Coil Lead Bracket (2) 6. Screw (2) 7. Lockwasher (2) 8. Washer (2) 9. Screw (2) 10. Washer (2) 11. Shroud 12. Shuttle Assembly 13. Screw (2) 14. Antirotation Block 15. Shim 16. Hammer Bank 17. Hammer Bank Cover 9 10 8 3 6 7 11 1 15 14 5 12 17 24 25 13 23 4 19 20 22 16 21 2 18 18. Holding Pin (2) 19. Screw 20. Screw 21. Hammer Spring 22. Clamp Plate 23. Washer (4) 24. Washer (4) 25. Set Screw (2) Figure 5–2.
Hammer Spring Retensioning (Figure 5–3) NOTE: Tensioning hammer springs is a trial–and–error process. Adjust and test until print quality is satisfactory. If Print is Too Light: 1. Put the hammer bank in the service position. (See page 5–2.) CAUTION The hammer tip is fragile. Take care not to damage the hammer tip with the screwdriver when flexing the spring. 2. Using the tip of a screwdriver, carefully flex the tip of the hammer spring away from the pole pin under the spring. 3.
PRINT TOO LIGHT PRINT TOO DARK Figure 5–3.
Hammer Tip Alignment (Figure 5–4) IMPORTANT You must use the alignment tool to correctly align the hammer tips. This procedure cannot be done accurately by hand. 1. Put the hammer bank in the service position. (See page 5–2.) 2. Loosen the screw (1) of the hammer spring (2) to be aligned. 3. Place the hammer alignment tool (3) (P/N FD–28262–01) over the hammer tips. Move the hammer spring until the tip is in an appropriate hole in the alignment tool. 4. Torque the screw (1) to 6 to 9 in–lbs. 5.
1. Screw 2. Hammer Spring 3. Hammer Alignment Tool (P/N FD–28262–01) 3 1 2 Figure 5–4.
Magnetic Pickup Gap (Figure 5–5) NOTE: Unless otherwise directed, do the MPU phasing adjustment (page 5–14) immediately after this procedure. 1. Loosen the two captive screws and remove the cam cover (1). 2. Loosen the clamping screw (2) enough to allow the MPU (3) to be rotated. 3. Set the gap between the MPU and the flywheel (4) using a flat feeler gauge (5): a. If a blue mark is on the flywheel, use a 0.002 inch feeler gauge and set the gap in line with the blue mark. b.
1. 2. 3. 4. 5. Cam Cover Screw MPU Flywheel (Sync Windows) Flat Feeler Gauge 1 4 5 2 3 Figure 5–5.
Magnetic Pickup Phasing Adjustment (Figure 5–6) NOTE: Unless otherwise directed, adjust the MPU gap (page 5–12) before doing this procedure. 1. Open the printer cover. 2. Loosen the screw (1) until the MPU arm (2) can be pivoted, but only with some effort. Push the MPU arm (2) all the way down. 3. Load full width (132 column) paper and ribbon. 4. Turn the printer on. 5. Press ON LINE to take the printer off–line. 6. Press and at the same time to unlock the ENTER switch. 7. Press .
1. Screw 2. MPU Arm 1 2 Figure 5–6.
Paper Feed Belt Tension (Figure 5–7) Tension Check 1. Open the printer cover. 2. Remove two screws (1) and the belt guard (2). 3. Press the middle of the paper feed belt (3) down with the force gauge, using 2 to 5 pounds of force. 4. If the belt deflects more or less than .06 inch (1.6 mm), adjust the tension as described below. 5. Install the belt guard and two screws. 6. Close the printer cover. Adjustment 1. Remove the lower paper guide. (See page 6–40.) 2.
1. 2. 3. 4. 5. Screw (2) Belt Guard Paper Feed Belt Nut (4) Paper Feed Motor 4 5 0.0625 in. DEFLECTION 2 3 1 Figure 5–7.
Paper Out Switch Adjustment This procedure is required only if a new paper out switch has been installed or if the paper out distance is set incorrectly. Although not mandatory, it is advisable to test the Paper Out distance with 6–part paper, in order to verify printing with multi–part forms. 1. Turn the printer on and load full width (132 column) paper. 2. Make sure the printer is not in a fault condition and the forms thickness lever is closed. 3. Press ON LINE to take the printer off–line.
Page Perforation 4 in. 4 in. Figure 5–8. Paper Preparation for Paper Out Adjustment Test NOTE: You will use paper prepared this way a number of times during this procedure. Cut or tear 8 to 10 pages, every third sheet. b. Press . the current emulation appears on the LCD. c. Press until the display reads “Emulation Self Test.” Press ENTER to select this “emulation.” d. Press , then press repeatedly until the display reads “Self Test Paperout Adjust.
f. Press R/S or ENTER to start the test. When the Paper Out condition occurs, remove the paper from the tractors, and determine the distance to the edge of the paper by counting the number of dot rows from the end of the comb to the perforation (if short), or the dot rows beyond the perforation (if long). NOTE: Use the long bars for counting the dot rows quickly. The distance between long bars is 4 dot rows.
o. Repeat Step 12. to print the comb pattern. If the pattern does not stop just at the perforation, repeat the steps to increase or decrease the Paper Out Adjust value as necessary. Otherwise, go to Step 13. 13. Press CLEAR to exit the configuration menus. 14. Press , then press until the emulation you want to print with is displayed. 15. Press ENTER to select this emulation. An asterisk (*) appears next to it on the display. 16. Press and at the same time to lock the ENTER switch. 17.
Platen Gap (Figure 5–9) 1. Disconnect the power cord from the rear of the printer. Open the printer cover. Remove paper from the printer. 2. Remove the ribbon deck assembly. (See page 5–2.) 3. Remove the RPF belt cover. Loosen the platen open motor screws to loosen the platen open belt. (See page 6–44.) 4. Raise the forms thickness lever (1) all the way. 5. Measure the platen gap, as follows: CAUTION Take care not to damage the hammer bank cover or the hammer tips with the feeler gauge. a.
3 6 1 6 6 2 5 4 (hidden) 1. 2. 3. 4. 5. 6. Figure 5–9.
Platen Open Belt Adjustment (Figure 5–10) 1. Open the printer cover and the rear door. 2. Remove the RPF belt cover (1) by squeezing the top and bottom to release the plastic tabs from the slots in the side plate. 3. Loosen the platen open motor mount screws (2). 4. Place a reusable tie–wrap (3) around the platen open motor (4), leaving enough slack to insert the force gauge. 5. Close the forms thickness lever all the way.
2 1 2 3 5 1. 2. 3. 4. 5. 4 Figure 5–10.
Ribbon Tracking Check and Adjustment (Figure 5–11) 1. Make sure ribbon and paper are loaded and that the ribbon is fully wound on one of the spools. 2. Turn the printer on and open the printer cover. 3. Set the forms thickness lever (1) to any position between “A” and “B.” Make sure no error indications appear. 4. Run a shuttle fast self–test (page 4–27). Shuttle action and ribbon motion should begin. 5. On either the left or right ribbon guide (2), momentarily short across the skids (3) with a screwdriver.
1. 2. 3. 4. 5. 6. Forms Thickness Lever Right Ribbon Guide Right Guide Skid (2) Screw (2) Washer (2) Guide Post 1 Short across here with a screwdriver. 2 3 6 5 4 Figure 5–11.
Shuttle and Counterweight Preload (Figure 5–12) NOTE: Set shuttle and counterweight preload when improper shuttling action or excessive rattle is detected, or whenever shuttle drive components have been replaced. 1. Disconnect the AC power cord from the rear of the printer. Open the printer cover. 2. Remove the ribbon deck assembly. (See page 5–2.) 3. Loosen two captive screws (1) and remove the cam cover (2). (Figure 5–12, detail A.) 4. Remove six screws (3) and the cam front cover plate (4). 5.
2 1 7 5 3 4 12 6 11 9 10 1. Captive Screw (2) 2. Cam Cover 3. Screw (6) 4. Cam Cover Plate 5. Dust Barrier 6. Force Gauge 7. Counterweight 8. Feeler Gauge 9. Cam 10. Right Cam Follower 11. Left Cam Follower 12. Cam Follower Yoke 8 Figure 5–12.
11. Push the force gauge horizontally to the left. Note the gauge indication when the feeler gauge comes loose. NOTE: If springs have been replaced, set the preload at the high end of range, otherwise set it at the low end. a. If the indication is between 12 and 17 pounds, go to Step 12. b. If the indication is less than 12 pounds, install a shuttle spring shim as described on page 5–32 and repeat Steps 9. through 11. c.
2 1 7 3 4 5 12 6 11 9 10 1. Captive Screw (2) 2. Cam Cover 3. Screw (6) 4. Cam Cover Plate 5. Dust Barrier 6. Force Gauge 7. Counterweight 8. Feeler Gauge 9. Cam 10. Right Cam Follower 11. Left Cam Follower 12. Cam Follower Yoke 8 Figure 5–12.
Shuttle and Counterweight Spring Adjustment (Figure 5–13) NOTE: You can make force adjustments with or without a force gauge. The procedure on page 5–28 describes the use of a force gauge and is the preferred method. Although the procedure below is not recommended, you can do it if excessive rattle is detected under the cam cover and you are unable to do the procedure on page 5–28. (Rattle under the cam cover indicates incorrect spring force, which can effect print quality.) 1. Open the printer cover. 2.
1. Captive Screw (2) 2. Cam Cover 3. Shuttle Spring 4. Counterweight Spring 5. Counterweight 6. Yoke 7. Shim, Shuttle Spring 8. Screw 9. Shim, Counterweight Spring 10. Base Support 2 1 7 3 5 4 9 (Hidden) 6 8 10 Figure 5–13.
7. Install a counterweight spring shim as follows: NOTE: More than one shim may be required to obtain the desired effect. a. Loosen screw (8) about three turns. b. With the screwdriver, press in on the loosened screw to create space for a shim (9). c. Install a shim between the spring spacer and the base support (10). d. Tighten the screw. 8. Operate the printer. a. Run a shuttle/ribbon fast test for 10 minutes. Check for rattle and increase the preload if necessary. b. Run a shuttle/ribbon slow test.
1. Captive Screw (2) 2. Cam Cover 3. Shuttle Spring 4. Counterweight Spring 5. Counterweight 6. Yoke 7. Shim, Shuttle Spring 8. Screw 9. Shim, Counterweight Spring 10. Base Support 2 1 7 3 5 4 9 (Hidden) 6 8 10 Figure 5–13.
Shuttle Belt Tension (Figure 5–14) Tension Check 1. Open the printer cover. 2. Loosen the two captive screws and remove the cam cover (1). 3. Press down with your finger in the middle of the shuttle belt (2) using about 2 ounces of force. 4. If the belt deflection is more or less than 0.21 inches (5.3 mm), do the adjustment procedure below. Adjustment 1. Loosen the four motor mount nuts (3). 2. Position the motor (4) to obtain the proper belt tension. Do not allow the motor to tilt. 3.
1. 2. 3. 4. Cam Cover Shuttle Belt Nut (4) Motor 0.21 in. DEFLECTION 1 2 3 4 2 Figure 5–14.
5–38 Adjustments
6 Replacement Procedures and Parts Chapter Contents Replacement Procedures Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4 Cabinet Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5 Card Cage Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7 Counterweight Assembly . . . .
Ribbon Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–33 Ribbon Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–34 Shuttle Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–35 Shuttle Motor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–36 Tractor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Illustrated Parts Lists Printer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–38 Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–40 Ribbon Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–42 Tractor Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–44 Paper Feed and Platen Open Motors, Paper Out and Platen Open Switches . . .
Replacement Procedures Blower Assembly (29–30891–01) 1. Unplug the printer power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap (29–26246–01) be worn, especially while servicing logic components. 2. Remove the paper supply from the print station and tractors. Remove the paper chains, paper tent, and wire paper guide. 3.
Cabinet Cooling Fan (29–29294–01) 1. Unplug the printer power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap (29–26246–01) be worn, especially while servicing logic components. 2. Open the printer cover to gain access to the upper cooling fan, located at the right rear of the printer. (See Figure 6–6, page 6–38). 3. Disconnect the power mate–n–lock connector from the fan.
Card Cage Fan (29–29294–01) 1. Unplug the printer power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap (29–26246–01) be worn, especially while servicing logic components. 2. Remove the front panel (Figure 6–6, page 6–38, item #1), from the cabinet to gain access to the card cage and fan.
Control Panel (29–29286–01) 1. Unplug the printer power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap (29–26246–01) be worn, especially while servicing logic components. 2. Using a 5/16” wrench or nut driver, loosen the 4 screws which hold the control panel in place. (See Figure 6–15, page 6–56.) 3.
Counterweight Assembly (29–30892–01) 1. Unplug the printer power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap(29–26246–01) be worn, especially while servicing logic components. 2. Remove the cam cover (Figure 6–7, page 6–40, item #4), and the cam cover plate (item #12), to gain access to the counterweight assembly. 3.
(Shuttle) Cam and Flywheel (FD–38890–01) 1. Unplug the printer power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap(29–26246–01) be worn, especially while servicing logic components. 2. Remove the paper supply from the print station and tractors. 3.
8. Re–install the counterweight assembly: e. To install the counterweight assembly first remove the rear base plate allen screw which was loosened during the removal procedure. Position this screw into the base plate rear slot, and with the allen wrench inserted into the screw, slide the counter weight assembly into place, starting the screw into the printer deck threads. Do not tighten this screw at this time. f. Next replace the the counterweight allen screw which secures the right spring seat.
Gas Shock (107961–005) 1. Unplug the printer power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap (29–26246–01) be worn, especially while servicing logic components. 2. Remove the paper supply from the print station and tractors. Remove the paper chains, paper tent, and wire paper guide. 3.
Hammer Bank Removal 1. Turn the printer off and unplug the ac power cord. 2. Remove the ribbon and unload paper. 3. Disconnect the two ribbon motor cables (1) on each side of the ribbon deck. (See Figure 6–1.) 4. Remove the ribbon deck assembly (2) by removing one screw on the right side of the ribbon deck, and two screws on the left side. 5. Remove the cam cover (3). 6. Remove the cam cover plate (4). 7. Remove the dust barrier block (5). 8. Disconnect the six hammer bank cables (6). 9.
3 17 18 19 8 6 14 10 8 16 9 21 7 13 20 14 14 15 5 1 2 12 11 1 4 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
13. Remove the hammer bank (17): (See Figure 6–2.) a. Note the U–shaped shims (18) installed at the end of the shuttle spring (22). Do not lose these shims while removing the hammer bank. b. Firmly gripping the right and left shuttle shroud screws (24) with your right and left thumbs, slowly lift the hammer bank while keeping the shuttle shroud, hammer bank cables, and antirotation pad in place. c.
17. 18. 22. 23. 24. 25. 26. 24 23 Hammer Bank Shuttle Spring Shims Shuttle Spring Linear Bearing Sleeve (2) Shuttle Shroud Screws Antirotation Pad Right Linear Bearing Slot 17 24 18 23 26 22 25 Correct Location for Anti–Rotation Pad Figure 6–2.
Installation CAUTION To prevent excessive noise, bearing failure, and poor print quality, carefully perform every step in this procedure. Do not skip or omit any steps. 1. Clean oil, dirt, and paper dust from the base casting in the hammer bank area, the bearing seats, and the anti–rotation block. IMPORTANT The antirotation pad (Figure 6–3, item 25) must be kept in place inside the shuttle shroud (Figure 6–3A) to ensure good print quality.
17. 18. 22. 23. 24. 25. 26. 24 23 Hammer Bank Shuttle Spring Shims Shuttle Spring Linear Bearing Sleeve (2) Shuttle Shroud Screws Antirotation Pad Right Linear Bearing Slot 17 24 18 23 26 22 25 Correct Location for Anti–Rotation Pad Figure 6–3.
4. Rotate the bearing sleeves (23) so that the slots (Figure 6–3, item 26) are facing the front of the printer. Make sure that the front edge of the shuttle shroud (Figure 6–4, item 26) fits behind the machined edge of the casting, and that the foam air seal (27) makes a tight seal against the casting. 5.
8. 9. 10. 13. 14. 15. 16. 22. 25. 26. 27. 28. 14 (3) 14 (2) 14 (1) 16 Screw (2) Anti–Rotation Block Screw (2) Anti–Rotation Shims (3) Bearing Cap Screw (1) Bearing Cap Screw (5) Right Bearing Cap Left Bearing Cap Linear Bearing Sleeve (2) Shuttle Spring Shoulder Washer Shuttle Shroud Foam Air Seal 1/16–Inch Allen Wrench 14 (2) 13 22 14 (3) 15 26 22 8 10 27 9 28 25 8 Casting Line Up Line Up Screw Hole Cam Follower Yoke Oil Wick Bearing Sleeve Cam Follower Bearing Thrust Shims 131256–001=.
11. Torque the right and left bearing set screws (Figure 6–5A, item 12) to 10 in–lb. 12. Wedge the shank of a large screwdriver between the yoke and the flywheel shank (29) such that the cam follower bearing and cam are not in contact. Remove the cam follower bearing screw (Figure 6–5B, item 30), holding a finger under the bearing to keep it in place. Remove the two washers from the screw. Reinstall the screw with the antirotation tool (Figure 6–5B, item 32).
11. 12. 28. 29. 30. 31. 32. 33. Jam Nut (2) Bearing Set Screw (2) 1/16–inch Allen Wrench Screwdriver Cam Follower Bearing Screw Cam Follower Yoke Tool, Antirotation (29–30905–01) .004–inch Feeler Gauge 29 12 11 28 30 32 33 32 30 31 30 31 32 30 33 SIDE VIEW TOP VIEW Figure 6–5.
19. Adjust the right bearing set screw using the shuttle/ribbon fast diagnostic test. Place a 1/16–inch allen wrench through the cutout in the ribbon deck and into the slot of the right bearing sleeve to keep the slot forward, then run the shuttle/ribbon fast diagnostic test. As the printer is shuttling, loosen the right bearing set screw two turns and retighten it with a torque driver, torquing it to 10 in–lb.
Hammer Cover Assembly (FD–38422–01) 1. Put the hammer bank in the service position (page 5–2). From the service position, the hammer cover, which is magnetic, can be lifted clear of the hammer bank face and the two lower tabs which hold it in place. 2. Install the new hammer cover assembly by reversing the removal procedure. Return the hammer bank to the operating position (page 5–6).
Hammer Spring (FD–15794–01) and Hammer Coil (FD–15793–01) Spring Removal: 1. Put the hammer bank in the service position (page 5–2). 2. To remove a defective hammer spring, remove the two (2) allen screws which secure the hammer retaining clamp. Each clamp supports 2 hammer springs. (See Figure 6–12, page 6–50.) 3. After reassembling the hammer bank, adjust the hammer tips (page 5–10). Coil Removal: 1. Remove the corresponding hammer spring to expose the defective coil.
I/O Panel and Cable Assembly (29–30893–01) 1. Unplug the printer power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap (29–26246–01) be worn, especially while servicing logic components. 2. Remove the paper supply from the print station and tractors. Remove the paper chains, paper tent, and wire paper guide. 3.
Magnetic Pickup Assembly (MPU) (FD–15800–01) 1. Unplug the printer power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap(29–26246–01) be worn, especially while servicing logic components. 2. Loosen the MPU locking screw (Figure 5–5, page 5–13, item #2). 3. Remove the MPU guide bracket (Figure 6–14, page 6–54, item #3). 4. Disconnect the MPU cable connector P35. 5.
Paper Feed Motor and Belt (FD–30894–01) (FD–13861–01) 1. Unplug the printer power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap (29–26246–01) be worn, especially while servicing logic components. 2. Remove the paper supply from the print station and tractors. 3. Remove the lower paper guide (Figure 6–7, page 6–40, item #16), four (4) 1/4” screws.
Paper Motion/Out Detector (29–30805–01) 1. Unplug the printer power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap (29–26246–01) be worn, especially while servicing logic components. 2. Remove the paper supply from the print station and tractors. Remove the paper chains, paper tent, and wire paper guide. 3.
Platen Open Motor and Belt (29–29282–01) (29–30899–01) 1. Unplug the printer power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap (29–26246–01) be worn, especially while servicing logic components. 2. Remove the platen belt cover by depressing down to release the top tab, then tip the cover out while pulling upward. 3.
Platen Open Switch (FD–15791–01) 1. Unplug the printer power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap (29–26246–01) be worn, especially while servicing logic components. 2. Remove the platen belt cover by depressing down to release the top tab, then tip the cover out while pulling upward. 3. Remove the lower paper guide (Figure 6–7, page 6–40, item #16), four (4) 1/4” screws.
Power Supply (29–30895–01) 1. Unplug the printer power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap (29–26246–01) be worn, especially while servicing logic components. 2. Remove the paper supply from the print station and tractors. Remove the paper chains, paper tent, and wire paper guide. 3.
Printed Circuit Board Assemblies (PCBAs): (CCB DX 29–30901–01) (Mech Driver 29–30903–01) (Hammer Driver 29–30902–01) 1. Unplug the printer power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap (29–26246–01) be worn, especially while servicing logic components. 2. Remove the front panel (Figure 6–6, page 6–38), from the cabinet to gain access to the card cage.
Ribbon Hub (29–29296–01) 1. Unplug the printer power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap (29–26246–01) be worn, especially while servicing logic components. 2. Squeeze the lock tabs and remove the ribbon spools from the ribbon hubs. (See Figure 5–1, page 5–3.) 3. As shown in Figure 6–8 (page 6–42, item #2), loosen the ribbon hub set screw and remove the hub. 4.
Ribbon Motor (29–30897–01) 1. Unplug the printer power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap (29–26246–01) be worn, especially while servicing logic components. 2. Squeeze the lock tabs and remove the ribbon spools from the ribbon hubs. (See Figure 5–1, page 5–3.) 3. Disconnect four connectors from the bottom of the ribbon deck assembly. 4.
Shuttle Motor (FD–32538–01) 1. Unplug the printer power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap (29–26246–01) be worn, especially while servicing logic components. 2. Remove the paper supply from the print station and tractors. 3. Remove the lower paper guide (Figure 6–7, page 6–40, item #16), this will allow access to the shuttle motor. 4.
Shuttle Motor Belt (FD–34554–01) 1. Unplug the printer power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap (29–26246–01) be worn, especially while servicing logic components. 2. Remove the paper supply from the print station and tractors. 3. Remove the lower paper guide (Figure 6–7, page 6–40, item #16), this will allow access to the shuttle motor. 4.
Tractor Assemblies (Left – 29–30906–01) (Right – 29–30907–01) 1. Unplug the printer power cord from the AC receptacle to insure that there are no hazardous voltages present while servicing this equipment. It is also recommended that an anti–static wrist strap (29–26246–01) be worn, especially while servicing logic components. 2. Remove the paper supply from the print station and tractors. 3.
Illustrated Parts Lists 3 5 See Page 6–40. 2 See Page 6–60. 4 (Not Shown.) 1 See Page 6–56. Figure 6–6. 6–38 See Page 6–58.
Item No.
From Page 6–38. 17 1 3 2 16 4 5 See Page 6–44. 7 8 9 10 15 11 12 See Page 6–42. 14 13 Figure 6–7.
Item No. Part Number Description Notes 1 102786–605 Screw, Hex w/LW, 6x.31 (4) 2 101526–002 Washer, Flat #6 (4) 3 133519–001 Ground Clip (2) 4 140269–001 Cam Cover 5 106963–001 Gasket 6 103258–001 Captive Screw (2) 7 131152–001 Rear Paper Guide 8 108740–001 Paper Guide Retainer (2) 9 101526–001 Washer, Flat #6 (2) 10 102786–605 Screw, Hex w/LW, 6x.
1 2 From Page 6–40. 5 11 10 3 4 6 9 7 8 Figure 6–8.
Item No. Part Number Description 1 29–29296–01 Assembly, Ribbon Hub (2) 2 103677–009 Screw, Cruciform, 6–19x.50 (2) 3 102288–001 Screw, Btn Hd, Hex Dr, 6–32x.
From Page 6–40. 18 19 15 20 21 1 See Page 6–46. 2 16 17 6 14 13 12 5 4 See Page 6–48. 3 11 8 7 9 10 Figure 6–9.
Item No. Part Number Description 1 131152–001 Rear Paper Guide 2 150521–001 Pulley, Paper Feed 3 102786–610 Screw, Hex w/LW, 6x.62 (2) 4 132312–001 Belt Guard 5 FD–13861–01 Belt, Paper Feed 6 108653–001 Splined Shaft Assy 7 102786–605 Screw, Hex w/LW, 6x.
From Page 6–44. 27 5 13 29 3 4 26 7 28 8 6 10 11 31 12 25 30 21 15 14 17 16 18 22 19 32 20 23 2 1 24 Figure 6–10.
Item No. Part Number Description Notes 1 134647–001 Guide, Paper, Machined 2 134646–001 Guide, Paper, Front 3 102559–420 Screw, w/LW 4–40x1.00 (2) 4 101526–009 Washer, Flat #4 (2) 5 Ref Red and White leads 6 FD–15791–01 Switch, Platen Open 1.0A, 125 VAC 7 102132–013 Spacer, Round (2) .115/.375x.
21 (3 places) 1 From Page 6–44. 2 20 21 (2 places) 22 3 4 19 18 17 5 6 7 8 See Page 6–50. 23 9 13 11 10 12 See Page 6–52. 14 16 15 Figure 6–11.
Item No. Part Number Description Notes 1 101514–025 Screw, Skt Cap, 6x.31 (2) 2 102158–005 Washer, Split Lock, #6 (2) 3 131998–001 Shroud, Shuttle 4 140540–001 Cap, Bearing, Right 5 101526–003 Washer, Flat #10 (2) 6 102158–002 Washer, Split Lock #10 (2) 7 101514–017 Screw, Skt Cap, 10x.38 (2) Torque: 10 in–lb 8 101514–057 Screw, Skt Cap, 4x1.
From Page 6–48. 1 15 16 14 13 2 3 4 11 5 12 10 6 7 8 9 Figure 6–12.
Item No. Part Number Description 1 FD–38422–01 Assembly, Hammer Cover 2 29–30898–01 Assembly, Shuttle 3 101514–055 Screw, Skt Cap–U (88) 4 131173–001 Plate, Clamp, Hmr Spring (44) 5 FD–15794–01 Assembly, Hammer Spring (88) 6 FD–15793–01 Assembly, Hammer Coil (88) 7 101514–056 Screw, Skt Cap–U (22) 8 101526–039 Washer, Flat #2 (22) 9 132001–001 Clamp, Coil (11) 10 FD–28262–01 Tool, Short Alignment 11 105947–001 Screw, Philips, Self–Lock (12) 6,4x.
From Page 6–48. See Page 6–54. 24 21 22 23 1 2 19 18 3 20 7 6 5 4 15 17 16 11 14 13 12 Figure 6–13.
Item No. Part Number Description Notes 1 101526–003 Washer, Flat #10 2 102158–002 Washer, Split Lock #10 3 101514–041 Screw, Counterweight, 10x.75 4 101564–001 Shim, Counterweight, Spring Guide 5 131960–001 Seat, Spring 6 131053–001 Spring, Shuttle 7 131960–001 Seat, Spring 8 101514–002 Screw, Skt Cap, 4x.
From Page 6–52. 11 10 1 8 9 7 6 2 3 4 5 Figure 6–14.
Item No. Part Number Description 1 FD–34554–01 Belt, Shuttle 2 101514–041 Screw, Skt Cap, 10x.75 3 102633–001 Bracket, Guide, Mag Pickup 4 101240–001 Magnetic Pickup Arm 5 133673–001 Base Support, Machined 6 29–30900–01 Oil Wick 7 140133–001 Screw, w/LW (2) 8 Part of item 9 Cam 9 FD–38890–01 Assembly, Flywheel 10 102158–002 Washer, Split Lock #10 (2) 11 101514–042 Screw, Skt Cap, 10x1.
1 From Page 6–38. 21 2 3 4 20 19 5 18 6 13 7 8 17 12 9 16 14 10 11 15 Figure 6–15.
Item No. Part Number Description 1 29–29286–01 Assembly, Control Panel 2 134287–001 Bracket, Control Panel, P9212 3 101526–002 Washer, Flat #6 4 102786–606 Screw, Hex w/LW, 6–32x.
1 2 From Page 6–38. 3 4 5 6 7 8 10 11 13 12 9 Figure 6–16.
Item No. Part Number Description 1 102786–682 Screw, w/LW, 6x1.75 (2) 2 130025–001 Guard, Finger 3 29–29294–01 Assembly, 48VDC Fan 4 102998–001 Screw, Skt Cap, 10–32x.
From Page 6–38. 10 9 1 2 8 11 3 5 NOTE: Remove this panel 7 4 6 Figure 6–17.
Item No. Part Number Description Notes 1 29–30893–01 Assembly, I/O Cable 2 Ref Access Panel 3 140113–001 Screw, Hex, Washer (7) 4 Part of item 10 #6 Stud 5 102788–600 Nut, Hex, w/LW, 6–32 Torque: 8 in–lb 6 Part of item 7 18 AWG wire, w/ring terminal Green with yellow stripe.
6–62 Replacement Procedures and Parts
A Wire Data NOTE: Signal mnemonics and acronyms are defined in Appendix B. Interconnection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2 PCBAs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–3 Common Controller PCBA (CCB DX) . . . . . . . . . . . . . . . . . . . A–3 Mechanism Driver PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–5 Hammer Driver PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . .
J104 J102 J102 Power Supply 29–30895–01 A–2 Cable Assy: Hmr Dr / Mech Dr 133749–001 NCB(J) J101 J101 NCB(P) J7 Cable Assy: CCB / Mech Dr 150551–001 J5 Mechanism Driver PCBA 29–30903–01 Hammer Driver PCBA 29–30902–01 P1 ..
Common Controller PCBA Wire Data VCC P5 J2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 (CCB DX) 29–30901–01 VCC P5 J2 N HAMMER SHIFT CLK N HAMMER DATA N HDIC DATA N HDIC CLK N HDIC LATCH N HDIC MODE N HDIC STATUS N PAPER DATA N PAPER CLK N PAPER LATCH NC N MPU PULSE N MECH DRVR RXD N MECH DRVR TXD N MECH DRVR ATTN 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 N MECH RESET N CROWBAR NC J3 NC 1 2 3 4 5 6 7 8 9 10 NC MO
J1 Common Controller PCBA A–4 (CCB DX) To Multi29–30901–01 I/O Interface A B 3 1 TP1 Triple I/O Cable Assy.
VCC P5 VCC P5 J6 Wire Data 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 J6 N HAMMER SHIFT CLK N HAMMER DATA N HDIC DATA N HDIC CLK N HDIC LATCH N HDIC MODE N HDIC STATUS N PAPER DATA N PAPER CLK N PAPER LATCH NC N MPU PULSE N MECH DRVR RXD N MECH DRVR TXD N MECH DRVR ATTN 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Mechanism Driver PCBA N RESET J7 29–30903–01 N CROWBAR 1 2 3 4 5 6 7 8 VCC NC NC R74 R82 NC 1K R2
A–6 Mechanism Driver PCBA 29–30903–01 To Hammer Driver J7 J5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Hmr Dr / Mech Dr Cable Assy (133750–001) J4 J5 BCOM1 BCOM2 SENSOR ID BCOM3 BCOM4 BHSC1 VCC BHSC2 BHSC3 BHSC4 +24V BNLD RST1 BNLD RST2 BNLD RST3 +15V BNLD RST4 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 BUD1 BUD2 1 J5 BUD3 J6 BUD4 BN COIL TEST MECH ID BNVRAMP HDCOIL TEMP VCC HDPH CVR N HD SHORT HD LOOPBACK NC BCOM OUT BANK FAN PWM J1 J2
Mechanism Driver PCBA 29–30903–01 1 J5 Wire Data HD P1 (HBR) J1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 N/C N/C UDPH 1B (COIL 25) MDCOIL 37N MDCOIL 25N UDPH2B (COIL 26) MDCOIL 38N MDCOIL 26N UDPH 3B (COIL 27) MDCOIL 39N MDCOIL 27N UDPH 4B (COIL 28) MDCOIL 40N MDCOIL 28N (COIL 41) (COIL 29) MDCOIL 41N MDCOIL 29N (COIL 42) (COIL 30) MDCOIL 42N HD P1 HD P2 J1 J2 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 MDCOIL 30N (COIL 43) (COIL 31) MDCOI
Hammer Driver PCBA A–8 29–30902–01 1 TP1 TP2 TP3 GND VSUS +48V 33 1 Hammer 1 J1 33 1 Hammer 2 J2 33 1 Hammer 3 J3 33 Hammer 4 J4 1 33 Hammer 5 J5 1 33 Hammer 6 J6 GND NHDSHORT TP7 Wire Data 48V FAN – BLOWER + BLOWER + 48V FAN + BANK BLOWER N CROWBAR LOOP A BLOWER FAULT N CROWBAR LOOP B TP8 TP9 NSHORT C42 C43 C44 GND C45 C49 C47 NC 1 22 P1 Power Connector (From PWR Supply) 1 15 P2 Power Connector (to Mech Drvr) VSUS +48V 2 S 15 R 14 P 13 N 12 M 11 L 10 K 9 J 8 H
Hammer Driver PCBA 29–30902–01 Wire Data 1 TP1 TP2 TP3 GND VSUS +48V 33 1 Hammer 1 J1 33 Hammer 2 J2 1 33 1 Hammer 3 J3 33 Hammer 4 J4 1 33 Hammer 5 J5 1 33 Hammer 6 J6 TP4 TP5 TP6 (To Mech Driver logic) GND NHDSHORT TP7 TP111 +15V TP112 +24V TP10 VCC COIL TEMP J7 Mech Driver BLOWER FAULT TP8 TP9 NSHORT C43 C44 1 C45 C47 22 P1 Power Connector (From PWR Supply) C49 15 P2 Power Connector (to Mech Drvr) 2 50 P3 Coil Connector 2 (Mech Drvr Coils 1–24) 25 24 23 22 21
Hammer Driver PCBA 29–30902–01.A01 A–10 1 J1 33 Hammer 1 1 J2 33 Hammer 2 1 J3 33 Hammer 3 1 J4 33 Hammer 4 1 J5 33 Hammer 5 1 J6 33 Hammer 6 NOTE: Hammer drive circuits 1–48 are transposed by the hammer driver board to drive hammer coils 41–88.
Hammer Driver PCBA 29–30902–01.A01 Wire Data 1 TP1 TP2 TP3 GND VSUS +48V 33 1 Hammer 1 J1 33 1 Hammer 2 J2 33 1 Hammer 3 J3 33 Hammer 4 J4 1 33 Hammer 5 J5 1 33 Hammer 6 J6 GND NHDSHORT TP7 TP111 +15V TP112 +24V TP10 VCC COIL TEMP J7 Mech Driver BLOWER FAULT TP8 TP9 NSHORT C42 C43 C44 1 GND C45 22 C47 1 (To Mech Driver logic) TP4 TP5 TP6 NOTE: Hammer drive circuits 1–48 are transposed to drive hammer coils 41–88 by the hammer driver board.
J102 +5V / 0V Logic Connector Power Supply Assembly A–12 29–30895–01 POWER FACTOR CHOKE 1 2 3 4 5 6 7 8 9 10 J6 1 2 J5 AC Input CHASSIS GND LINE NEUTRAL BUS DISABLE +5V +5V +5V CHASSIS GND 5V RET (0V) 5V RET (0V) 5V RET (0V) 5V SENSE RET +5V SENSE J102 1 2 3 J101 Main High Voltage Power Connector J6 J5 J101 J103 J104 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 +12.8V SENSE RET +12.8V SENSE +12.8V +12.8V +12.8V +12.8V 48V / +12.8V RET (0V) 48V / +12.8V RET (0V) 48V / +12.8V RET (0V) 48V / +12.
J2 Parallel Parallel J3 Dataproducts Centronics J1 I/O Cable Assembly 29–30893–01 Wire Data J2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 J3 A–13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Parallel Centronics DATA STROBE DB1 DB2 DB3 DB4 DB5 DB6 DB7 DB8 NACK BUSY PE ONLINE GND PI PE RET CHASSIS GND NC Parallel Dataproducts DB3 DB3 RET DB1 RET DB2 RET OL RET READY RET DEMAND RET NC NC VFU RET (N/C) PAR ERR RET (N/C) NC PARITY RET (N/C) PI RET BUF CLR (N/C) NC NC DB5 RET DB1
A–14 P2 PIN S PIN A P3 PIN 1 PIN 15 PIN 15 PIN 1 Wire Data Part No.
Wire Data PIN 1 PIN 1 PIN 2 J4 PIN 2 J7 A–15 Part No.
A–16 P1/P2 P3/P4 PIN 2 PIN 1 PIN 1 PIN 2 Wire Data Part No.
Wire Data Connector Keys: farside 33 1 34 2 J1 – J6 J6 P5 P4 P3 P2 A–17 33 1 34 2 34 J4 J3 J2 1 33 P6 J5 Connector Keys: farside 2 P1 Part No.
A–18 (Red) NCL COM (White) CCB J1 / LMI J4 PMD(J) PIN 1 J19 P43 PIN 1 Termination Table Wire Data CONN J1/J4 TO CCB / LMI J19 PAPER STACKER P43 BLOWER FAULT PMD(J) Part No. Description 133871–001 Sensor Harness Assembly (Continued on next page.
PAPEROUT LED CATHODE PAPEROUT LED AN Wire Data PAPEROUT SEN COLL PAPEROUT SEN EMIT AN CHASSIS GND PMD ANODE PMD SEN EMIT VCC P5 N STACKER FAULT A–19 Part No. 133871–001 Description Sensor Harness Assembly (Continued from previous page.
Termination Table TO CONN PIN 1 A–20 PIN 1 PIN 3 PIN 3 P32 P4 MECH DRIVER J32 PAPER FEED MOTOR J35 MAGNETIC PICKUP J40 SHUTTLE MOTOR J34 ENCODER P45 P46 P30 P33 PLM RT RIBBON GUIDE LT RIBBON GUIDE RT RIBBON MOTOR LT RIBBON MOTOR PLATEN MOTOR P30 PIN A PIN 1 PIN 3 P4 PIN 1 P33 P45 PIN 1 P46 J40 PIN 1 PIN 3 PIN 1 J35 PIN 1 PLM Wire Data PIN 1 J34 Part No. Description 133872–001 Wire Harness, Main (Continued on next page.
Wire Data A–21 Part No. 133872–001 Description Wire Harness, Main (Continued from previous page.
A–22 J101 NCB(P) J43 J1 P1 P18 P1 Wire Data Part No. Description 134481–001 Cable Assembly, High Voltage, Power Supply (Continued on next page.
Wire Data Description 134481–001 Cable Assembly, High Voltage, Power Supply (Continued from previous page.) A–23 Part No.
A–24 NCB(J) J102 P7 Wire Data Part No.
Wire Data PIN 1 PIN 1 A–25 Part No. Description 150551–001 Cable Assembly, CCB/Mech. Dr.
A–26 Wire Data
B Abbreviations, Acronyms, and Signal Mnemonics Signal mnemonics with initial letter “N” are negative true, all others are positive true. ACRONYM/ MNEMONIC DEFINITION +5VHL . . . . . . . . . . . . Isolated +5V from –12V ACK . . . . . . . . . . . . . . Acknowledge AIRFLT . . . . . . . . . . . Cooling Fan Fault ASIC . . . . . . . . . . . . . Application–Specific Integrated Circuit Assy . . . . . . . . . . . . . . Assembly BA0–15 . . . . . . . . . . . Buffered Address 0 to 15 BD0–7 . . . . . . . . . . . .
COLL . . . . . . . . . . . . . Collector COM . . . . . . . . . . . . . Communication to Hammer Drivers COM1 . . . . . . . . . . . . COM Data Line Optically Isolated COMOUT . . . . . . . . . COM Data Output to Next H.D. CTS . . . . . . . . . . . . . . Clear to Send DB1, 2, etc. . . . . . . . . Data Bit 1, 2, etc. DBA1–23 . . . . . . . . . . Buffered Address 1–23 DBD0–15 . . . . . . . . . . Buffered Data 0–15 DCD . . . . . . . . . . . . . . Data Carrier Detect DCMOD . . . . . . . . . .
GND . . . . . . . . . . . . . . Ground HD . . . . . . . . . . . . . . . Hammer Driver Hd . . . . . . . . . . . . . . . Head HESA,B,C . . . . . . . . . Hall Sense A,B,C HESPWR . . . . . . . . . . Hall Sense Power HRS . . . . . . . . . . . . . . Hammer Reset HSC . . . . . . . . . . . . . . Shift Clock for communication to Hammer Drivers IC . . . . . . . . . . . . . . . . Integrated Circuit IL . . . . . . . . . . . . . . . . Interlock Switch INT . . . . . . . . . . . . . . . Interface, Interrupt INTPOL . . . .
NBUDS . . . . . . . . . . . Upper Data Strobe NBUFCLR . . . . . . . . . Buffer Clear NBRDBWR . . . . . . . . Read or Write NBRKRTRP . . . . . . . Breaker Trip NC, N/C . . . . . . . . . . . Not Connected NCASOL . . . . . . . . . . Column Address Strobe Lower NCASOU . . . . . . . . . . Column Address Strobe Upper NCIACK . . . . . . . . . . Interrupt Acknowledge NCNTCLR . . . . . . . . . Dot Count Clear NCTC0–2 . . . . . . . . . . Counter/Timer Chip 0–2 Select NCTRO . . . . . . . . . . . Dot Count Read NDAV .
NMFPE . . . . . . . . . . . Multi Function Peripheral (68901) Device Enable NOHSTWR . . . . . . . . No Host Writes Allowed NOVRAM . . . . . . . . . Nonvolatile Random–Access Memory NPAPO . . . . . . . . . . . . Paper Out Switch NPAPOSW . . . . . . . . . Paper Out Switch NPCLOCK . . . . . . . . . Serial Shift Clock for Front Panel NPE . . . . . . . . . . . . . . No Paper Empty NPLAO . . . . . . . . . . . Platen Open Switch NPLOAD . . . . . . . . . . Load Switch Data into Shift Register NPLAOSW . . . . . . .
PB . . . . . . . . . . . . . . . Parity Bit PBE . . . . . . . . . . . . . . Parity Bit Error PCBA . . . . . . . . . . . . . Printed Circuit Board Assembly PDATA . . . . . . . . . . . . Front Panel Data PE . . . . . . . . . . . . . . . . Printer Error, Paper Empty PF1,2 . . . . . . . . . . . . . Paper Feed 1, 2 PFC . . . . . . . . . . . . . . Paper Feed Controller PFM . . . . . . . . . . . . . . Paper Feed Motor PI . . . . . . . . . . . . . . . . Paper Instruction PIEN . . . . . . . . . . . . .
SEN . . . . . . . . . . . . . . Sensor SENS . . . . . . . . . . . . . Sensor SERXFER . . . . . . . . . Serial I/O DMA Data Transfer SHT PROP . . . . . . . . . Proportional Speed Error SHT INTEG . . . . . . . . Integral Speed Error SHUT . . . . . . . . . . . . . Shuttle Skt . . . . . . . . . . . . . . . Socket SLCT . . . . . . . . . . . . . Select (On–line) SPARE . . . . . . . . . . . . Spare circuit or chip location SPSHAM . . . . . . . . . . Spare Sense Hammer Driver 0, 1, 2 SRAM . . . . . . . . . . . .
B–8 Abbreviations, Acronyms, and Signal Mnemonics
C PROM and Chip Locations Contents PROM Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–2 Mechanism Driver Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–3 Common Controller Board (CCB) . . . . . . . . . . . . . . . . . . . . . . . . . .
PROM Kit The PROM Kit (P/N 29–3094–01) for the LG12 printer contains the following items: PROM DPU Font RTPU Part No. 151043–001 (Hi–1) 151029–001 (Hi–1) 134610 PFC RSP 151006 150916 151043–002 (Lo–1) 151029–002 (Lo–1) 151043–003 (Hi–2) 151029–003 (Hi–2) 151043–004 (Lo–2) 151029–004 (Lo–2) NOTE: PROMs are shaded on the location drawings.
LEGEND RSP = Ribbon/Shuttle Processor ASIC = Application–Specific Integrated Circuit Hammer Driver ASIC 8032 Microcontroller RSP PROM* 150846 Mech. Driver ASIC * RSP oriented 180 degrees opposite other ICs. Figure C–1.
LEGEND PROM Kit: P/N 29–3094–01 DPMC = Dot Plucker Memory Controller Terminating Resistor: Pull–down (Location 12D) Standard: 1K ohm DIP or Alternate: 330 ohm DIP DPU = Data Processing Unit FTIC = Fire Timer IC LED = Light–Emitting Diode MPU = Magnetic Pick–up NOVRAM = Nonvolatile Random Access Memory Terminating Resistor: Pull–up (Location 12C) Standard: 470 ohm DIP or Alternate: 220 ohm DIP PAL = Programmable Array Logic 68010 Microprocessor DPU RTPU LED * LED 68010 Decode PAL 68010 Controller PA
D Torque Table Table C–1 establishes the torque requirements for routine installation of threaded fasteners. These requirements apply to fasteners made of steel, at a minimum engagement of 3.5 threads, including chamfer and countersink. Fastener sizes are listed as Numbered Size – Threads Per Inch. Torque Table Carbon Steel Fasteners (ANSI B18.6.3 – 1972) Fastener Size 2–56 4–40 6–32 8–32 10–24 10–32 1/4 – 20 Torque Table Into Alum.
D–2 Torque Table
E Metric Conversion Tables Length Multiply By To Obtain foot foot foot 0.3048* 30.48* 304.8* meter (m) centimeter (cm) millimeter (mm) inch inch inch 0.0254* 2.54* 25.4* meter (m) centimeter (cm) millimeter (mm) meter centimeter millimeter 3.280840 0.03280840 0.003280840 foot foot foot meter centimeter millimeter 39.37008 0.3937008 0.03937008 inch inch inch * Figure is exact. Torque Multiply By pound/inch pound/foot newton/meter (N m) newton/meter (N m) 175.1268 14.59390 0.005710148 0.
Mass and Density Multiply By To Obtain pound* ounce* 0.4535924 28.34952 kilogram (kg) gram (g) kilogram gram 2.204622 0.03527397 pound* ounce* * avoirdupois Temperature To Convert From To Use Formula temperature Celsius (tC) temperature Fahrenheit (tF) tF = 1.8tC + 32 temperature Fahrenheit (tF) temperature Celsius (tC) tC = (tF – 32)/1.8 Power Multiply E–2 By To Obtain Btu (International Table)/hour watt (W) 0.2930711 3.
F Printer Specifications Contents Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–2 Paper Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–2 Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–2 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–2 Printer Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ribbon Specifications Carbon Black, OCR: Fabric: LG12R–BC Nylon, 1 inch x 100 yards spool–to–spool; metal reversing tabs on each end NOTE: For best print quality, only use ribbons that meet these specifications. Use of ribbons that do meet Digital specifications may void your printer warranty. Paper Specifications Paper Type: Edge–perforated, fan–folded, 3 to 16 inches wide Thickness: Single–part, 15 to 100 pound stock; Multi–part, 1– to 6–part forms, carbon and carbonless Sheet Thickness: 0.
Printer Dimensions Height: 105.9 cm (42 inches) Width: 86.4 cm (34 inches) Depth: 72.4 cm (29 inches) Weight: Approximately 150 kg (330 lbs.) – Unpacked Approximately 201 kg (450 lbs.
Electrical Characteristics Input Power Voltage 100–120 / 200–240 Vac Phase Single Frequency 50 Hz or 60 Hz (47 Hz to 62 Hz) Power Rating Standby 330 VA 60 Hz (200 Watts) Operating 830 VA 60 Hz (520 Watts) Data Input Rate (maximum) Dataproducts Up to 500,000 characters per second Centronics Up to 200,000 characters per second RS–232 Up to 19.2K Baud Radio Frequency Interference (RFI) Radio Frequency Interference tested/certified to RFI standards FCC 15.B Class A; VDE 0871 Class B; CISPR–22.
Print Rates The printing speed of text characters is a function of the selected font and dot density, and is measured in lines per minute (LPM). Print speed is independent of the number of characters configured in the character set. Text attributes such as bold or emphasized printing, superscripts, subscripts, or elongated characters cause print rates to decrease to not less than half the rates of the font without such attributes. Table F–1 charts typical LG12 printing rates.
Table F–1. Printing Rates Print Application Emulation, Font, and Characters /inch (cpi) Dot Density1 Dot Matrix2 Uppercase Only (lines/minute) Descenders & Underline (lines/minute) LG06 DP 5 60 (120) x 66.6 10 (18) x 7 + 2 900 720 LG06 DP 6 60 (120) x 66.6 8 (14) x 7 + 2 900 720 LG06 DP 10 60 (120) x 66.6 5 (9) x 7 + 2 900 720 60 (120) x 75 5 (9) x 7 + 2 900 720 LG06 DP 12 60 (120) x 66.
Duty Cycle The LG12 can print 150,000 pages per month under the following conditions: 1. Uppercase only 2. 6 lines per inch (lpi) 3. 10 characters per inch (cpi) 4. 50% character density, or 66 characters per line 5. 50% line density, or 33 lines per 11–inch page 6. Single part (18 lb) paper 7. Printer is maintained in good operating condition. 8. Printer is installed as directed in the User’s Manual.
F–8 Printer Specifications
Index Numbers 48 Volt Failed, 4–3 A CCB diagnostic checks, 4–21 functional overview, 2–12 hardware summary, 2–17 replacement, 6–32 Adjusting counterweight preload, 5–28 counterweight spring, 5–32 hammer spring, 5–8 magnetic pickup gap, 5–12 magnetic pickup phasing, 5–14 paper feed belt, 5–16 paper out switch, 5–18 platen gap, 5–22 platen open belt, 5–24 ribbon tracking, 5–26 shuttle belt, 5–36 shuttle preload, 5–28 shuttle spring, 5–32 Character formation by one hammer, 2–7 standard, 2–6 Aligning, hamm
G Display messages, printing conventions, 1–3 Display, liquid crystal, 1–4 Gas shock, replacement, 6–11 Duty cycle, F–7 Dynamic RAM Fault, 4–5 H Ham. Bank Hot, 4–6 E Ham. Coil Open, 4–7 Electrical Characteristics, F–4 Ham. Coil Short, 4–8 ENTER switch, 1–4 Ham. Drv.
L O Labels, Specifications, F–2 Oil wick, replacement, 6–26 LCD, 1–4 ON LINE switch, 1–4 LMI, functional overview, 2–12 Operation control panel, 2–11 hammer bank and shuttle, 2–29 hammer driver, 2–25 magnetic pickup, 2–29 paper feed control, 2–32 ribbon transport, 2–31 M Magnetic pickup gap, adjusting, 5–12 operation, 2–29 phasing, adjusting, 5–14 Magnetic pickup assembly (MPU), replacement, 6–26 P Maintenance, preventive, 3–2 Paper, specifications, F–2 Manual how to use, 1–2 printing convention
shuttle counterweight assembly, 6–52 switches, 6–46 tractor shafts, 6–44 Parts, replacement, 6–1 PCBAs, replacement, 6–32 Platen gap, adjusting, 5–22 Platen Open, 4–14 Platen open belt, replacement, 6–29 motor, replacement, 6–29 switch, replacement, 6–30 Platen open belt, adjusting, 5–24 Plot, rates, F–5 Power supply, replacement, 6–31 Preload counterweight, 5–28 shuttle, 5–28 Preventive maintenance, 3–2 Print quality too dark, 5–8 too light, 5–8 Print rates, F–5 Printer cleaning, 3–2 dimensions, F–3 functi
Ribbon tracking, adjusting, 5–26 S Self–tests, 4–27 running, 4–29 SET TOF switch, 1–4 Shuttle belt, adjusting, 5–36 motor belt, replacement, 6–36 motor, replacement, 6–35 preload, 5–28 spring, adjusting, 5–32 Torque conversion to or from metric, E–1 table, D–1 Tractor assemblies, replacement, 6–37 Troubleshooting, 4–1 aids, 4–19 fault messages, 4–3 printer confidence check, 4–20 symptoms not indicated by fault messages, 4–19 Typical characters, 2–3 V Shuttle cam and flywheel, replacement, 6–9 VIEW switc
Index–6
