IBM 6400-I15 Maintenance Manual
IBM 6400-I15 Manual
 |
View all IBM 6400-I15 manuals
Add to My Manuals
Save this manual to your list of manuals |
IBM 6400-I15 manual content summary:
- IBM 6400-I15 | Maintenance Manual - Page 1
6400 Line Matrix Printers Maintenance Information Manual Cabinet and Pedestal Models Form Number S246-0117-06 ©Copyright IBM Corp., 1995, 1998 - IBM 6400-I15 | Maintenance Manual - Page 2
- IBM 6400-I15 | Maintenance Manual - Page 3
6400 Line Matrix Printers Maintenance Information Manual Cabinet and Pedestal Models S246-0117-06 - IBM 6400-I15 | Maintenance Manual - Page 4
Seventh Edition (October 1998) This edition applies to the 6400 Line Matrix Printer. The following paragraph does not apply to any other to 1-800-524-1519, by E-mail to [email protected], or by mail to: IBM Printing Systems Company Information Development Department H7FE, Building 003G P.O. - IBM 6400-I15 | Maintenance Manual - Page 5
Maintenance Overview About the Printer 13 The IBM 6400 Series Printer Family 13 Printer Evolution 15 How to Identify the Printer 15 Important Maintenance Notes 16 About This Manual 16 How to Use This Manual 16 Notes and Notices 16 Printing Conventions in This Manual 18 Related Documents 18 - IBM 6400-I15 | Maintenance Manual - Page 6
4 Principles of Operation Line Matrix Printing 35 Printing Mechanism 38 Shuttle Frame Assembly 38 Paper Transport System 41 Ribbon Transport System 42 Logical Control of the Printer 43 Operator Panel 44 CMX Controller Board 45 Data Controller 47 Engine Controller 50 Power Supply Board 51 - IBM 6400-I15 | Maintenance Manual - Page 7
158 Returning the Printer to Normal Operation 159 Belt, Paper Feed Timing, Adjustment 160 Belt, Platen Open, Adjustment 162 Paper Drive Motor Pulley Alignment 164 Paper Scale Alignment 166 Platen Gap Adjustment 168 Platen Open Motor Pulley Alignment 170 Ribbon Guide Alignment 172 Splined - IBM 6400-I15 | Maintenance Manual - Page 8
Fan Assembly, Hammer Bank 217 Hammer Spring Assembly 218 IBM Coax/Twinax Expansion Board 222 Magnetic Pick-up (MPU) Guide Assembly 235 Paper Ironer 236 Platen 237 Resistors, Terminating 242 Ribbon Guide Assembly (L/R 244 Ribbon Hub 245 Security Module 224 Shaft, Splined 246 Shaft, Support - IBM 6400-I15 | Maintenance Manual - Page 9
Assemblies 291 Appendices A Wire Data 293 B Printer Specifications 333 C Metric Conversion Tables 345 D Torque Table 347 E Safety Inspection Guide 349 F Abbreviations and Signal Mnemonics 357 G Cords and Adapters 365 H Part Numbers 367 I Noise Suppression Devices 375 - IBM 6400-I15 | Maintenance Manual - Page 10
by power generation. IBM participates in this program by introducing printers that reduce power consumption when they are not being used. This feature can cut energy use by up to 50 percent. Note: The ENERGY STAR emblem does not represent EPA endorsement of any product or service. Notices References - IBM 6400-I15 | Maintenance Manual - Page 11
generation, both of which are functionally necessary. Trademarks and Service Marks The following terms, denoted by an asterisk (*) in this publication, are trademarks of the IBM Corporation in the United States or other countries or both. IBM PC-DOS SCS Token-Ring The following terms, denoted - IBM 6400-I15 | Maintenance Manual - Page 12
to help you find the translated versions in the IBM 6400 Line Matrix Printer Safety Notices booklet. DANGER: Switch off printer power and unplug the printer power cord before cleaning the printer. Hazardous voltages are present in the printer with the power cord connected to the power source - IBM 6400-I15 | Maintenance Manual - Page 13
and Code V** Printronix** emulations are simple but versatile graphics programming languages that load into flash memory. The IBM 6400 Series Printer Family The IBM 6400 Line Matrix Printer family consists of pedestal mount and floor cabinet models that print at different speeds, as shown in Table - IBM 6400-I15 | Maintenance Manual - Page 14
1400, and 1500 lpm are available only in floor cabinets. Model Number 6400-004 6400-04P 6400-005 6400-05P 6400-050 6400-P50 6400-008 6400-08P 6400-009 6400-09P 6400-010 6400-P10 6400-012 6400-014 6400-015 Table 1. The IBM 6400 Series Printer Family Print Speed 475 lpm 475 lpm 500 lpm 500 lpm 500 - IBM 6400-I15 | Maintenance Manual - Page 15
Printer Evolution IBM 6400-050, -P50, -010, -P10, and -015 printers use a redesigned shuttle frame assembly, hammer bank, and ribbon guides which are not compatible with earlier *: P = Pedestal Model * No Code = Cabinet Model Figure 1. Interpreting the Printer Model Number Maintenance Overview 15 - IBM 6400-I15 | Maintenance Manual - Page 16
, remember these important maintenance concepts when you service the printer: ♦ Do not adjust the platen gap unless the original shuttle frame assembly or platen has been replaced with a new or rebuilt unit, or unless instructed to do so in the troubleshooting chapter. ♦ Never bend or "tweak" hammer - IBM 6400-I15 | Maintenance Manual - Page 17
of causing death or serious personal injury. Danger and Caution notices are numbered to help you find the translated versions in the IBM 6400 Line Matrix Printer Safety Notices booklet. CAUTION: The word Caution indicates the presence of a hazard that has the potential of causing moderate or minor - IBM 6400-I15 | Maintenance Manual - Page 18
manual does not explain how to operate or configure the printer. For that information, refer to the Operator's Guide and Setup Guide: ♦ IBM 6400 Line Matrix Printer Operator's Guide, Form No. S544-5641 Illustrated instructions on daily printer operation. ♦ IBM 6400 Line Matrix Printer Setup Guide - IBM 6400-I15 | Maintenance Manual - Page 19
with alphanumeric data as a document is printed. ♦ IBM 6400 IGP User's Manual: Form No. S544-5639 Provides information used with the troubleshooting of the Network Print Server are covered in the following documents: ♦ Print Server User's Guide, Part No. 30H4056 ♦ Ethernet** Interface User's Manual - IBM 6400-I15 | Maintenance Manual - Page 20
LCD The LCD (Liquid Crystal Display) displays printer status messages. Start Puts the printer in the READY (on-line) mode. This key also clears fault is configurable: refer to the Operator's Guide. Menu If in the NOT READY mode, this key puts the printer in the PROGRAM mode. If the - IBM 6400-I15 | Maintenance Manual - Page 21
(Off) (On) Power Switch Power Ready Processing Menu Scroll Enter Attention Printer Configuration Scroll Return LCD Micro Micro Line Feed Form Feed Start View Set Top Of Form Stop Cancel Eject/ Restore Figure 2. Electrical Controls and Indicators, Cabinet Models Maintenance - IBM 6400-I15 | Maintenance Manual - Page 22
LCD The LCD (Liquid Crystal Display) displays printer status messages. Start Puts the printer in the READY (on-line) mode. This key also clears fault is configurable: refer to the Operator's Guide. Menu If in the NOT READY mode, this key puts the printer in the PROGRAM mode. If the - IBM 6400-I15 | Maintenance Manual - Page 23
(Off) (On) Power Switch Power Ready Processing Menu Scroll Enter Attention Printer Configuration Scroll Return LCD Micro Line Feed Form Feed Start Micro View Set Top Of Form Stop Cancel Eject/ Restore Figure 3. Electrical Controls and Indicators, Pedestal Model Maintenance - IBM 6400-I15 | Maintenance Manual - Page 24
paper. Help prevent paper jams by supporting inner sections of paper. Positioned manually by sliding them along shafts. Forms form or first line to be printed. Rotate to move paper vertically. Works when Forms Thickness Lever is open. Instructions showing how to load the ribbon correctly. One - IBM 6400-I15 | Maintenance Manual - Page 25
Left Tractor Paper Scale Paper Supports Horizontal Adjustment Knob Tractor Lock Right Tractor Tractor Lock Vertical Position Knob Ribbon Loading Path Diagrams Forms Thickness Pointer Forms Thickness Lever and Scale Figure 4. Mechanical Controls and Indicators Maintenance Overview 25 - IBM 6400-I15 | Maintenance Manual - Page 26
are listed below. Item Part No. 6400 Line Matrix Printer Configuration Utility Disk 1-30 Inch-pound Torque Screwdriver ESD Wrist Strap Feeler Gauge, .010 inch Feeler Gauge, .011 inch Feeler Gauge, .040 inch Force Gauge, 20 lb Grip Ring Pliers Lubricant, Bearing, IBM #20 DIP Module Extracting - IBM 6400-I15 | Maintenance Manual - Page 27
2 Installation Installation and configuration of the printer are covered in the 6400 Line Matrix Printer Set-Up Guide, Form No. S544-5640 Installation, operation, and replacement parts for the optional coax/twinax interface are covered in the Coax/Twinax Multi-Platform Interface Option Installation - IBM 6400-I15 | Maintenance Manual - Page 28
28 Installation - IBM 6400-I15 | Maintenance Manual - Page 29
, so you should clean the printer whenever you are called to service it. DANGER: Switch off printer power and unplug the printer power cord before cleaning the printer. ATTENTION Do not use abrasive cleaners, particularly on the window. Do not drip water into the printer. Damage to the equipment - IBM 6400-I15 | Maintenance Manual - Page 30
cord from the power source. 3. Open the printer cover. 4. Remove paper from the printer. 5. Remove the ribbon. 6. Using a soft-bristled, non-metallic brush, wipe paper dust and ribbon lint off the tractors, shuttle cover assembly, base casting, and ribbon guides. Vacuum up the residue. 7. Wipe the - IBM 6400-I15 | Maintenance Manual - Page 31
Splined Shaft Shuttle Cover Assembly Base Casting Tractor NOTE: Cabinet model shown. Procedure is the same for pedestal model. Ribbon Guide (2) Forms Thickness Lever Figure 5. Cleaning Inside the Cabinet or Top Cover Cleaning the Shuttle Frame Assembly 1. Remove the shuttle cover assembly ( - IBM 6400-I15 | Maintenance Manual - Page 32
. (See Figure 6.) Vacuum up any residue. Hammer Tip NOTE: 6400-004/04P hammer bank shown. Procedure is the same for all hammer against the hammer bank can break hammer tips. 9. Install the hammer bank / ribbon mask cover assembly (page 206). 10. Install the shuttle frame assembly (page - IBM 6400-I15 | Maintenance Manual - Page 33
surrounding areas to remove paper particles, dust, and lint. 3. Cabinet Models: Install the paper guide assembly (page 235). Pedestal Model: Install the top cover assembly (page 210). 4. Close the printer cover. 5. Connect the AC power cord to the power source. NOTE: Cabinet model shown. Procedure - IBM 6400-I15 | Maintenance Manual - Page 34
34 Preventive Maintenance - IBM 6400-I15 | Maintenance Manual - Page 35
and graphics by printing patterns of ink dots on paper, an entire line at a time. This technique is called line matrix printing. Every text character is stored in printer memory as a pattern of dots on a logical grid called the dot matrix. (See Figure 8.) The ink dots are made by a row of small - IBM 6400-I15 | Maintenance Manual - Page 36
vary according to the font the user selects. For example, in the data processing (DP) font at a line spacing of six lines per inch (lpi), a dot matrix contains 12 dot rows from the top of one character line to the top of the next. (See Figure 8 and Figure 9.) At eight lpi there are nine - IBM 6400-I15 | Maintenance Manual - Page 37
Shuttle Dot Scan Row *1 1 1 1 2 2 1 2 3 3 1 2 3 4 4 1 2 3 4 5 5 1 2 3 4 5 6 6 1 2 3 4 5 6 7 7 Succesive Hammer Strokes Per Scan *1 3 *1 35 *1 3 5 7 * 1 3 5 7 9 * * Even column dot centers within the printed character area and character space hammer - IBM 6400-I15 | Maintenance Manual - Page 38
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 complex timing and coordination between printer logic and the printing mechanism. The printing - IBM 6400-I15 | Maintenance Manual - Page 39
hammer spring assembly and the number of hammer spring assemblies on the hammer bank vary according to printer model: ♦ 6400-004/-04P/-005/-05P/-050/-P50: seven 4-hammer assemblies, for a total of 28 hammer springs ♦ 6400-008/-08P/009/-09P: seven 7-hammer assemblies, for a total of 49 hammer springs - IBM 6400-I15 | Maintenance Manual - Page 40
Tungsten Carbide Hammer Tip NOTE: 6400-004/04P hammer bank shown. Hammer Bank Assembly: Coils, the permanent magnet, canceling its effect and releasing the hammer. The hammer springs forward, strikes the ribbon and paper, and leaves a dot impression of the hammer tip on the paper. While the hammer - IBM 6400-I15 | Maintenance Manual - Page 41
Shaft Tractors Paper Path Splined Shaft Vertical Adjustment Knob and Splined Shaft Pulley Shuttle Cover Assembly Paper Supports Paper Feed Timing Belt (Under the cover) Figure 13. Paper Transport System A two-phase DC stepper motor, directed by the EC on the controller board, - IBM 6400-I15 | Maintenance Manual - Page 42
Transport System Left Ribbon Guide (Not Shown) Hub Locking Latch Ribbon Spool Ribbon Hub Ribbon Motors Ribbon Right Ribbon Guide Figure 14. Ribbon Transport System An inked ribbon winds and unwinds continuously on a pair of spools latched to hubs that are driven by the ribbon motors. The hubs - IBM 6400-I15 | Maintenance Manual - Page 43
Motion Detector Paper Out Detector Left Ribbon Guide Left Ribbon Motor Print Mechanism Flex Circuits: Shuttle Assy Terminator Board Shuttle Motor Hammer Bank Board Shuttle Assembly MPU Hammer Bank Fan Figure 15. Functional Elements of the Printer Principles of Operation Cabinet Exhaust - IBM 6400-I15 | Maintenance Manual - Page 44
information to the controller board and displays information from the controller on the LCD. A status indicator next to the LCD also conveys printer status information to the user. The LCD, status indicator, and keys are mounted on a printed circuit board assembly enclosed in a protective housing - IBM 6400-I15 | Maintenance Manual - Page 45
and final hammer drive circuits, all logic and drive circuitry for the printer are contained on the controller board. The CMX controller board consists of processed, then sent to the hammer bank. The EC synchronizes paper, ribbon, platen, and shuttle motion as it feeds dot data to the hammer drivers - IBM 6400-I15 | Maintenance Manual - Page 46
RS-232 Diagnostic Port Control Panel 25 or 40 MHz Expansion Port RS-232/422 IEEE-1284 (Parallel) TTL Diagnostic Port 46 Fault Sensors Paper Feed Ribbon Shuttle Platen Hammer Drive Figure 17. CMX Controller Board Block Diagram Principles of Operation - IBM 6400-I15 | Maintenance Manual - Page 47
statistical data ♦ VX ASIC (Application-Specific Integrated Circuit) ♦ Host I/O Drivers any 6400 Series printer, but must be used in 6400-050, -P50, -010, -P10, and -015 printers. Although charge pump to make these voltages itself). This memory supports at least 100,000 write/erase cycles. The flash - IBM 6400-I15 | Maintenance Manual - Page 48
68EC030 processor. The VX provides the following services: ♦ Memory Access Controller ♦ DRAM Controller The VX supports up to four banks of page mode DRAM. FLASH Controller The VX supports up to four interface consists of five lines: serial clock, serial data, and three select lines. It is the VX - IBM 6400-I15 | Maintenance Manual - Page 49
for the drivers themselves, ESD protection, and terminations. Host I/O Drivers and Termination Beyond the 030 processor and VX ASIC, additional support circuitry completes the serial and parallel interfaces. These circuits include: ♦ RS-232 drivers and receivers. These circuits use internal charge - IBM 6400-I15 | Maintenance Manual - Page 50
of three separate processors used in earlier controller board architectures. In this manual, the 80C166 is referred to as either the EC or the 166. and FIFOs in the MECA to control many printer motor functions. The MECA is a custom gate array, specifically designed to drive this system. Analog Drive - IBM 6400-I15 | Maintenance Manual - Page 51
The printer uses five motors: two ribbon drive, one paper feed, one platen open, and one controller board and the hammer bank. Common circuits are located on the controller board, while hammer specific circuitry is contained on the hammer bank. The EC uses the MECA ASIC on the controller board - IBM 6400-I15 | Maintenance Manual - Page 52
V down to a level lower than 15 V in less than 200 milliseconds and Printer Interface The printer interface is the point where the data line from the host computer plugs into the printer. The printer interface processes all signals and data to and from the host computer. The printer supports supports - IBM 6400-I15 | Maintenance Manual - Page 53
board. These programming languages simplify the job of creating forms, bar codes, logos, expanded characters, and other graphics. These languages enable the printer to print sideways, upside down, and to make forms combining graphics, alphanumeric data, and bar codes-all in a single pass. Documents - IBM 6400-I15 | Maintenance Manual - Page 54
54 Principles of Operation - IBM 6400-I15 | Maintenance Manual - Page 55
and symptoms, and provides procedures for troubleshooting printer malfunctions. Always have the Operator's Guide and the Setup Guide handy when you troubleshoot because this manual does not cover printer operation or configuration. You must operate the printer to check its performance, and sometimes - IBM 6400-I15 | Maintenance Manual - Page 56
you here because of an error message? NO YES Go to Troubleshooting Display Messages, page 57. In the next step, you Table 3, page 67. The Operator Panel is not functioning (see Table 3, page 67) -OR- Printer does not complete IML, page 122. Did ANY of steps 1 thru 3 occur? YES NO Are - IBM 6400-I15 | Maintenance Manual - Page 57
the operator replenishes supplies, clears paper jams, corrects a problem of communication between the printer and host computer, etc. ♦ A Unit Check condition is a failure detected by self-test and fault circuitry. Unit check conditions are either recoverable or unrecoverable. Troubleshooting 57 - IBM 6400-I15 | Maintenance Manual - Page 58
to do in such cases is to power the printer off, wait 15 seconds, then power the printer back on. If the message reappears, classify the check and directs you to a troubleshooting procedure. After correcting an error, press the Stop key to clear the message and return the printer to the NOT READY - IBM 6400-I15 | Maintenance Manual - Page 59
RECEIVED CHECK PRINTER ADDRESS 024 SERIAL LINE PARITY ERROR VERIFY CONFIGURATION 025 SERIAL FRAMING ERROR VERIFY CONFIGURATION 026 HEX DUMP MODE 027 COMMUNICATIONS CHECK CALL SYSTEM OPERATOR 028 COMMUNICATIONS CHECK CALL SYSTEM OPERATOR 029 8344 DIAGNOSTIC TEST FAILED Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 60
057 CLOSE PLATEN 058 SHUTTLE JAM SEE USER'S GUIDE 059 CANCEL PRINT ACTIVE 060 PRINTER HOT 062 EXHAUST FAN FAULT 065 HAMMER BANK FAN FAULT 069 086 CONTROLLER 15V 087 PLATEN OPEN TIMEOUT CLOSE PLATEN 088 CONTROLLER 23.5V Troubleshooting Procedure Page 79 Page 80 Page 81 Page 82 Page 82 Page - IBM 6400-I15 | Maintenance Manual - Page 61
INSTRUCTION ACCESS SEE USER'S GUIDE 116 ILLEGAL EXTERNAL BUS ACCESS SEE USER'S GUIDE 117 A TO D OVERRUN SEE USER'S GUIDE 118 UNDEFINED INTERRUPT SEE USER'S GUIDE 119 TCB CORRUPTED SEE USER'S GUIDE 120 ACCESS NULL POINTER SEE USER'S GUIDE 121 PAPER NOT AT SPEED SEE USER'S GUIDE Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 62
INVALID COMMAND SEE USER'S GUIDE 133 RIBBON INVALID STATE SEE USER'S GUIDE 134 PLATEN INVALID COMMAND SEE USER'S GUIDE 135 PLATEN INVALID STATE SEE USER'S GUIDE 136 PLATEN INVALID PARAMETER SEE USER'S GUIDE 137 SHUTTLE INVALID COMMAND SEE USER'S GUIDE Troubleshooting Procedure Page 99 Page 99 - IBM 6400-I15 | Maintenance Manual - Page 63
138 SHUTTLE INVALID PARAMETER SEE USER'S GUIDE 139 SHUTTLE OVERSPEED SEE USER'S GUIDE 990 MACHINE CHECK 998 NON-VOLATILE LOADING PROGRAM INTO FLASH NOT READY OPERATOR MENU OPERATOR MENU LOCKED Troubleshooting Procedure Page 104 Page 104 Page 105 Page 105 Page 105 Page 105 Page 105 - IBM 6400-I15 | Maintenance Manual - Page 64
P68 ERROR: EC PROGRAM NOT VALID P69 ERROR: EC STOPPED AT STATE XXXX PLEASE WAIT... RESET IN PROGRESS READY RESETTING... PLEASE WAIT RESTORING BOOT CODE Troubleshooting Procedure Page 108 Page 109 Page 109 Page 109 Page 109 Page 109 Page 110 Page 110 Page 110 Page 110 Page 111 Page 111 - IBM 6400-I15 | Maintenance Manual - Page 65
Operator Panel Message RIBBON OUT OF INK CHANGE RIBBON SENDING PROGRAM TO EC PROCESSOR SERVICE SOFTWARE ERROR* Cycle power TABLE MISMATCH DOWNLOAD AGAIN TESTING HARDWARE PLEASE WAIT TOP OF FORM SET WAITING FOR PROGRAM DOWNLOAD Troubleshooting Procedure Page 112 Page 113 Page - IBM 6400-I15 | Maintenance Manual - Page 66
the problem. 2. Verify the fault by running a diagnostic printer test or by replicating conditions reported by the user. 3. Look for a match in the General Symptom List that begins on page 67. If you find a match, go to the troubleshooting procedure and follow the numbered instructions. 4. If - IBM 6400-I15 | Maintenance Manual - Page 67
. It is not field repairable. 5. Replace the defective part or assembly. 6. Test printer operation after every corrective action. 7. Reinstall any parts you replaced earlier that did not solve the problem. 8. Stop troubleshooting and return the printer to normal operation when the reported symptoms - IBM 6400-I15 | Maintenance Manual - Page 68
Troubleshooting Procedure Printer does not complete IML Power Stacker Printer line to line 2. Incorrect spacing from dot row to dot row or line to line 3. Characters randomly compressed and/or enlarged Printer Operation Downloads consistently fail Flash SIMM won't copy Paper feeds poorly Printer - IBM 6400-I15 | Maintenance Manual - Page 69
Symptom Reverse paper feed: platen does not open TOF is lost repeatedly Ribbon Ribbon folding or feed problems Shuttle Shuttle does not move Shuttle is noisy Troubleshooting Procedure Page 124 Page 131 Page 125 Page 126 Page 127 Troubleshooting 69 - IBM 6400-I15 | Maintenance Manual - Page 70
Troubleshooting Procedures MESSAGE / MALFUNCTION TEST / INSPECTION / EXPLANATION CORRECTIVE ACTION 001 END OF FORMS LOAD FORMS 1. Attention message: the printer is paper detector switch assembly. 3. Power off the printer. Remove the paper guide assembly or pedestal top cover. Remove the barrier - IBM 6400-I15 | Maintenance Manual - Page 71
and close the forms thickness lever and check that the platen pulley setscrew does not hit the left ribbon guide. 9. Inspect the tractors and tractor door springs for damage or excessive wear. If either tractor is it is damaged. 11. Check the platen gap. Adjust the platen gap. Troubleshooting 71 - IBM 6400-I15 | Maintenance Manual - Page 72
ATTENTION 2. Host attention message: the host computer or printer controller requires attention. Not a printer problem. 007 FM HEADER ERROR 3. Applications software has violated header format parameters. Not a printer problem. Have the system administrator correct applications data or configuration - IBM 6400-I15 | Maintenance Manual - Page 73
line. 2. Run the print job that generated the error message. If the message appears, check the host data for invalid characters. 3. Ask the system operator to verify that the printer Not a printer problem. Have the system administrator correct applications data or configuration. Troubleshooting 73 - IBM 6400-I15 | Maintenance Manual - Page 74
twinax auto-termination cable. 3. Connect the power cord to the printer. Power on the printer. Send a print job to the printer. If the message appears, replace the twinax cable. 4. Send a print job to the printer. If the message appears, go to Communications Failures, page 133. 74 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 75
auto-termination cable. 3. Connect the AC power cable to the printer. Power on the printer. Send a print job to the printer. Verify that all other devices on the twinax line are working properly. (Refer to line problem determination procedures, as recommended by the host system.) If the message - IBM 6400-I15 | Maintenance Manual - Page 76
the stacker. 2. Check the stacker limit switches. (See page 129.) If the limit switches are OK, go to the next step. 3. Power off the printer. Remove the paper guide assembly. Disconnect stacker cables from the CMX controller board, stacker assembly, and the stacker control 76 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 77
off the printer. Remove the paper guide assembly. Disconnect stacker cables from the CMX controller board, stacker assembly, and the stacker control panel (see Figure 61, page 380). Check cables for cuts, breaks, or damaged pins. Check continuity of cables. (See Appendix A.) Troubleshooting 77 - IBM 6400-I15 | Maintenance Manual - Page 78
address is not recognized by the printer. Have the system administrator make sure the printer address is correct. 024 SERIAL LINE PARITY ERROR VERIFY CONFIGURATION 1. The ) characters. Make a configuration printout. Verify that the printer matches host configuration settings 78 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 79
over a coax interface. Power off the printer. Disconnect the AC power cord from the printer. Check data cable connection and host system. (Refer to line problem determination procedures, as recommended by the host minutes after Stop was pressed to clear an end of forms fault. Troubleshooting 79 - IBM 6400-I15 | Maintenance Manual - Page 80
to step 3. 2. Power off the printer. Remove the paper guide assembly or pedestal top cover. Remove the barrier shield (cabinet model) or the barrier shield and paper guide (pedestal model). Check that the paper The right tractor should hold the paper under "slight" tension. 80 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 81
the platen pulley setscrew does not hit the left ribbon guide. 9. Inspect the tractors and tractor door springs for printer serial interface parameters to match those of the host. 2. Send a print job to the printer. If the message appears, go to Communications Failures, page 133. Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 82
SET FIRST 1. Printer configuration: custom set tried to perform an illegal printer function or damaged memory is printer. Run the print job again. If the message still appears, there is an application software error. Use your local support printer. Remove all flash memory and DRAM SIMMs. Inspect - IBM 6400-I15 | Maintenance Manual - Page 83
printer. Download the emulation. If the message appears, replace the flash SIMM(s). 3. Power on the printer . Download the emulation. If the message appears, replace the DRAM SIMM(s). 4. Power on the printer the printer. Remove the paper guide hit the left ribbon guide. 6. Disconnect connector - IBM 6400-I15 | Maintenance Manual - Page 84
platen gap. Adjust the platen gap. 3. Inspect the ribbon mask for bends or deformation that snag and interfere with shuttle the message appears, power off the printer. 5. Remove the shuttle cover. Remove the paper guide assembly or the pedestal top cover. 8. Run a print test. 84 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 85
CMX controller board sensors report high temperatures on the board. Inspect printer environment for severity. (See NOTE above.) Advise the user to move the printer to cooler, cleaner location. 2. Power off the printer. Remove the paper guide assembly or pedestal top cover. Check that all fan cables - IBM 6400-I15 | Maintenance Manual - Page 86
guide assembly or pedestal top cover. Power on the printer connector. 4. Power off the printer. Remove the paper guide assembly. Disconnect connector P107 from beneath the printer blocking cabinet vents. Remove obstructions. Make the exhaust fan. 8. Power on the printer. If the message appears, replace the - IBM 6400-I15 | Maintenance Manual - Page 87
Stop. 2. Power off the printer. Remove the paper guide assembly or pedestal top cover. printer is located in such an environment, relocate it to a cooler, cleaner area or reduce the size and duration of the print jobs. 1. Inspect printer environment for severity. (See NOTE above.) Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 88
3. Power off the printer. Remove the paper guide assembly or pedestal top paper guide assembly or pedestal top cover. Power on the printer. Load supply board. 2. Power on the printer. If the message appears, replace the power supply board. 2. Power on the printer. If the message appears, replace the - IBM 6400-I15 | Maintenance Manual - Page 89
2. Power off the printer. Remove the paper guide assembly or pedestal top obstructions. 5. Power on the printer. If the message appears, replace 1. Power off the printer. Remove the paper guide assembly or pedestal top expansion board. 3. Power on the printer. If the message appears, replace the - IBM 6400-I15 | Maintenance Manual - Page 90
board. Also check the resistance of connectors P106/LRIB M and P107/RRIB M. (Refer to the Main Wire Test Tables, page 297.) If ribbon motor resistance is not correct, replace the motor and/or the intermediate cable, if installed. 4. Power on the printer. Run the print job again. 90 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 91
or close platen message appears, power off the printer. Remove the paper guide assembly or pedestal top cover. Disconnect connector P107 check that the platen pulley setscrew does not hit the left ribbon guide. 6. Disconnect connector P106 from the CMX controller board. Check Troubleshooting 91 - IBM 6400-I15 | Maintenance Manual - Page 92
if it is bent or damaged. 4. Check the platen gap. If the gap is too small, it can inhibit ribbon movement. Adjust the platen gap. 5. Power off the printer. Remove the paper guide assembly or pedestal top cover. Check the resistance of connectors P106/LRIB M and P107/RRIB M. (Refer to the Main - IBM 6400-I15 | Maintenance Manual - Page 93
top cover. Reseat the cable connections of both ribbon drive motors. 2. Power on the printer. Using a screwdriver, short across the ribbon guide screws to reverse ribbon hub motion. Check for a ribbon drive motor that will not wind the ribbon. If the ribbon will not wind in one or both directions - IBM 6400-I15 | Maintenance Manual - Page 94
assemblies. 2. Power on the printer. If the message appears, replace defective board. 3. Power on the printer. If the message appears, replace printer. If the message appears, replace the shuttle frame assembly. 3. Power on the printer frame assembly. 2. Power on the printer. Run a print test. If the - IBM 6400-I15 | Maintenance Manual - Page 95
off the printer. Remove the paper guide assembly or pedestal top cover. Check all guide assembly or pedestal top cover. Load paper. Run the "All E's" print test for 5-10 minutes. If the message appears, replace the shuttle frame assembly. 7. Run the "All E's" print test for 5-10 minutes. Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 96
board. 110 STACK OVERFLOW SEE USER'S GUIDE 1. System stack has run out of 111 STACK UNDERFLOW SEE USER'S GUIDE 1. Firmware error on the CMX 112 UNDEFINED OPCODE SEE USER'S GUIDE 1. Firmware error on the CMX 113 PROTECTED INSTRUCTION SEE USER'S GUIDE 1. Protected Instruction. Firmware error - IBM 6400-I15 | Maintenance Manual - Page 97
ILLEGAL OPERAND ACCESS SEE USER'S GUIDE 1. Illegal Operand Accessed. Firmware ILLEGAL INSTRUCTION ACCESS SEE USER'S GUIDE 1. Illegal Instruction Accessed. EXTERNAL BUS ACCESS SEE USER'S GUIDE 1. Illegal External Bus Accessed. 117 A TO D OVERRUN SEE USER'S GUIDE 1. The analog-to-digital converter on - IBM 6400-I15 | Maintenance Manual - Page 98
. 118 UNDEFINED INTERRUPT SEE USER'S GUIDE 1. Firmware error on the CMX board. 119 TCB CORRUPTED SEE USER'S GUIDE 1. Task Control Block on the CMX 120 ACCESS NULL POINTER SEE USER'S GUIDE 1. The processor tried to access a PAPER NOT AT SPEED SEE USER'S GUIDE 1. Firmware error on the CMX controller - IBM 6400-I15 | Maintenance Manual - Page 99
job again. If the message appears, download the emulation software again. 2. Run the print job again. If the message appears, power off the printer. Remove the paper guide assembly or pedestal top cover. Make sure connectors P106 and P107 are fully seated on the CMX controller board. 3. Power on the - IBM 6400-I15 | Maintenance Manual - Page 100
the print job again. If the message appears, power off the printer. Remove the paper guide assembly or pedestal top cover. Make sure connectors P106 and P107 are A.) 5. Power on the printer. Run the print job again. If the message appears, replace the shuttle frame assembly. 100 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 101
printer. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board. 126 PAPER FEED BAD TABLE SEE USER'S GUIDE ILLEGAL STATE SEE USER'S GUIDE 1. Firmware error on INVALID COMMAND SEE USER'S GUIDE 1. Paper Invalid Command - IBM 6400-I15 | Maintenance Manual - Page 102
FEED INVALID PARAMETER SEE USER'S GUIDE 1. Paper Invalid Parameter. Firmware . 130 PAPER FEED PARTLY ENERGIZED SEE USER'S GUIDE 1. Firmware error on 131 PAPER FEED INTERRUPT SEE USER'S GUIDE 1. Unexpected interrupt in the paper CMX board. 132 RIBBON INVALID COMMAND SEE USER'S GUIDE 1. Firmware error - IBM 6400-I15 | Maintenance Manual - Page 103
defective CMX board. 133 RIBBON INVALID STATE SEE USER'S GUIDE 1. Firmware error on 134 PLATEN INVALID COMMAND SEE USER'S GUIDE 1. Firmware error on the CMX 135 PLATEN INVALID STATE SEE USER'S GUIDE 1. Firmware error on the CMX 136 PLATEN INVALID PARAMETER SEE USER'S GUIDE 1. Firmware error on the CMX - IBM 6400-I15 | Maintenance Manual - Page 104
controller board. Record the message and return it with defective CMX board. 139 SHUTTLE OVERSPEED SEE USER'S GUIDE 1. Firmware error on the CMX controller board. Cycle power. Run the print job again. If the board. Record the message and return it with defective CMX board. 104 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 105
PRESS STOP THEN START 1. The printer received a non-printable character successfully loaded into printer RAM and the checksum . 2. Power off the printer. Remove the shuttle cover. At the power cables. Power on the printer. If "HB NOT INSTALLD" the printer is in low-energy idle state, all fans - IBM 6400-I15 | Maintenance Manual - Page 106
1. The printer does not see a program in flash memory. There is no program in printer memory. Download the emulation. ERROR: SECURITY PAL NOT DETECTED 1. The security PAL is missing or has failed. Power off the printer. Remove the paper guide assembly or pedestal top cover. 106 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 107
Application software has violated header parameters. Not a printer problem. The system administrator should correct applications data or printer start-up. Power off the printer. Verify that the shuttle frame assembly is installed. Install the shuttle frame assembly. 2. Remove the paper guide - IBM 6400-I15 | Maintenance Manual - Page 108
: printer is offline, not in communication with host. No action required. OPERATOR MENU 1. Non-error status message. No action required. OPERATOR MENU LOCKED 1. Non-error status message. No action required. OPERATOR MENU UNLOCKED 1. Non-error status message. 108 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 109
board. Remove the paper guide assembly or pedestal top printer found a defective memory location. Replace the DRAM. (See Figure 34, page 226.) 2. Power on the printer. If the message appears, replace the CMX controller board. Record the message and return it with the defective board. Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 110
model printer. If the printer is an IBM 6404-B01, the controller is a CBO board. If the printer is an IBM 6400, the controller is a CMX board. P64 ERROR: CHECKSUM WRONG 1. The printer received the board. Record the message and return it with the defective board. 110 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 111
.) P66 ERROR: PROGRAM NEEDS MORE DRAM 1. The printer requires more DRAM memory in order to run the downloaded EC PROGRAM NOT VALID 1. The printer cannot find the engine controller program or at a process indicated by XXXX. Power off the printer. Remove all flash memory and DRAM SIMMs. Inspect the - IBM 6400-I15 | Maintenance Manual - Page 112
SIMM(s). (See Figure 34, page 226.) 4. Power on the printer. Download the emulation. If the message appears, replace the CMX RIBBON OUT OF INK CHANGE RIBBON 1. RibbonMindert software has determined that the ribbon is out of ink. Install a new ribbon and set ribbon life to 100%. 112 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 113
the message appears, power off the printer. 2. Disconnect the input data line from the host computer. Power on the printer. If the message appears, download the local support group. TABLE MISMATCH DOWNLOAD AGAIN 1. An Engine Controller software update is in process. Power off the printer. Download - IBM 6400-I15 | Maintenance Manual - Page 114
yet begun. No action required. Black squares on operator panel display 1. Power off the printer. Remove the paper guide assembly or pedestal top cover. Disconnect the operator panel cable from the panel and from J110 being used. 2. Check the paper tension between the tractors. 114 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 115
straight across them. Rewind or install new ribbon. If the ribbon does not track straight across the ribbon guides, adjust the ribbon guides. If the ribbon guides are loose, tighten them. If the ribbon guides are damaged, replace them. 5. Power off the printer. Remove the shuttle cover. Remove the - IBM 6400-I15 | Maintenance Manual - Page 116
printer. Load paper. Replace the paper detector switch assembly if either message appears. 4. Power on the printer is damaged. 4. Power on the printer. Load paper. Press Form Feed and . 5. Power on the printer. Press Form Feed and Power off the printer. Remove the paper guide assembly or pedestal top - IBM 6400-I15 | Maintenance Manual - Page 117
problems are detected by software during the procedure and communicated by LCD messages. If downloads fail consistently with no messages or with erratic messages, suspect a hardware failure. 1. Power off the printer. Remove the paper guide that support the emulation software. Troubleshooting 117 - IBM 6400-I15 | Maintenance Manual - Page 118
DESTINATION NOT DETECTED message appears, the blank SIMM is not a type supported by the boot code on the original SIMM. If SOURCE LARGER THAN or line to line) 1. If dots between alternate dot rows are misaligned, check the hammer phasing. Adjust hammer phasing. 2. If the printer is a model 6400-004, - IBM 6400-I15 | Maintenance Manual - Page 119
through the AC power cord, replace it. Plug the AC power cord into the printer and power outlet. 3. Remove the paper guide assembly or pedestal top cover. Verify that the AC-in power cable and the AC Check all cable connections on the CMX controller board. Connect all cables. Troubleshooting 119 - IBM 6400-I15 | Maintenance Manual - Page 120
power supply board. Operator panel blank 1. Power off the printer. Remove the paper guide assembly or pedestal top cover. Check all cable connections into 3. Power on the printer. Inspect the control panel display. If the control panel shows broken characters, replace the DRAM. 120 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 121
. 6. Check the platen gap. Adjust the platen gap. 7. Remove the paper guide assembly or pedestal top cover. Make sure connector P107/PAPR M is fully seated in on the printer. Load paper. Press Form Feed and View several times and check that paper moves in both directions. Troubleshooting 121 - IBM 6400-I15 | Maintenance Manual - Page 122
151. 1. Power off the printer. Remove the paper guide or pedestal top cover. printer. If the printer does not successfully complete IML, replace the power supply board. 7. Power up the printer. If the printer does not successfully complete IML, replace the CMX controller board. 122 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 123
stacker control panel. If the voltages are not correct, power off the printer, remove the paper guide assembly, and disconnect the stacker power cable from the CMX controller board. 5. Power on the printer. Check that the ONLINE indicators lights on the stacker control panel. Troubleshooting 123 - IBM 6400-I15 | Maintenance Manual - Page 124
Printer does not print self tests 1. Power off the printer. Remove the paper guide the printer. Load paper. Run a self . 3. Power on the printer. Run a self test. does not hit the left ribbon guide. 3. Check the condition and Power off the printer. Remove the paper guide assembly. Disconnect - IBM 6400-I15 | Maintenance Manual - Page 125
printer. Run a print test. If the problem occurs, replace the shuttle frame assembly. Ribbon folding or feed problems 1. Check that both ribbon spools are fully seated on the ribbon hubs and the ribbon runs between the ribbon mask and hammer bank cover. Install the ribbon correctly. Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 126
printer. Run a print test and observe ribbon movement across the left and right ribbon guides. Adjust the right and left ribbon guides. 5. Observe ribbon movement at both left and right ribbon the shuttle motor cables. 3. Remove the paper guide assembly or pedestal top cover. Check that the shuttle - IBM 6400-I15 | Maintenance Manual - Page 127
drive cable assembly if it fails continuity test. 7. Power up the printer. Run a Shuttle Slow or Shuttle Fast test. If the shuttle ribbon mask has not partially separated from the hammer bank cover. Check for debris trapped between the ribbon mask, hammer bank cover, and hammer bank. Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 128
bank cover assembly if you find any damage to the ribbon mask or hammer bank cover. 5. Power up the printer. Run a shuttle test. Replace the shuttle frame the printer. Operate the power stacker. (Refer to the Operator's Guide.) While the stacker is operating, check that: 128 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 129
OK, go to the next step. 6. Remove the paper guide assembly. Disconnect stacker cables from the CMX controller board, stacker sight tubes in the LED mounts. 2. Power on the printer. If the stacker elevator moves by itself, replace the stacker troubleshooting procedures. When you have completed this procedure, - IBM 6400-I15 | Maintenance Manual - Page 130
and their cables. You will usually be referred to this procedure from other troubleshooting procedures. When you have completed this procedure, return to the procedure that sent you here. 1. a) Power off the printer. b) Open the rear cabinet door. c) Unfasten the cable clamp holding the stacker - IBM 6400-I15 | Maintenance Manual - Page 131
15 If the customer is using multi-part forms, check that the forms thickness it is damaged. 5. Remove the paper guide assembly or pedestal top cover. Make sure CMX controller board. 6. Power on the printer. Load paper and set TOF. Press Form to TOF. 7. Power on the printer. Press Form Feed and View - IBM 6400-I15 | Maintenance Manual - Page 132
board. 7. Power on the printer. Load paper. Run a print test. If the problem occurs, replace the paper feed motor. 8. Run a print test. If the problem occurs, replace the CMX controller board. 9. Run a print test. If the problem occurs, replace the power supply board. 132 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 133
a copy of the Device Host Configuration if possible. 3. Call your support group for assistance in problem analysis. If you cannot obtain support, or you have previous experience solving host-printer communications problems, the following additional information is provided. You can quickly check the - IBM 6400-I15 | Maintenance Manual - Page 134
/Network configuration - Set DTR and RTS both True - Interface cable defective - Printer logic - Interface cable defective - Host-Printer definition - Controller/Network configuration - Printer logic - Interface cable defective - Controller/Network configuration - Printer logic 134 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 135
check the print quality and basic operation of the printer. The Operator Print Tests are summarized below. NOTE: Printer Demonstration Prints a sample page showing every print mode, font, and pitch available in the printer or light/dark character variations. Ribbon Splined shaft skew adjustment Hammer - IBM 6400-I15 | Maintenance Manual - Page 136
Ribbon Hammer bank cover MPU sensor Hammer springs Hammer coils (shuttle frame assembly) ♦ All E's + FF A pattern of all E's repeated for ten lines and followed by a form feed to the top of the next page. This test is useful for identifying paper motion or paper feed problems 136 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 137
Printer Demonstration, the first option in Operator Printer Tests menu. Cycles through the list of Printer Tests. Stop when the name of the test you wish to run displays. The printer test you have selected starts printing. 9. Press: Stop NOT READY The printer test stops printing. Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 138
troubleshooting and adjustment procedures. CE Tests NOTE: * = Default value SERVICE PRINTER MECHANISM TESTS SERVICE HAMMER PHASE VALUE SERVICE SERVICE CLEAR ERROR LOG Enter key activates SERVICE PRINT PARTIAL LINE ENABLE* DISABLE SERVICE TOP EXIT TEAR DISTANCE SERVICE SHUTTLE SPEED SERVICE - IBM 6400-I15 | Maintenance Manual - Page 139
by exercising the shuttle and ribbon mechanisms at low speed. You can also use this test to check ribbon tracking and reversing. ♦ of Forms Adjustment Value: This parameter determines where on the paper the printer will stop printing when an out of paper fault is detected. The Troubleshooting 139 - IBM 6400-I15 | Maintenance Manual - Page 140
6400-15 printers. See page 188. Selecting and Running CE Tests Step Key Displayed Result Notes 1. Make sure that the printer ribbon is installed in the printer and the printer is powered on and is loaded with paper. 2. Press: Stop 3. Press: Scroll + Scroll + Return + Enter NOT READY SERVICE - IBM 6400-I15 | Maintenance Manual - Page 141
instructions in the use of the Hammer Phasing and End of Forms Adjust tests. 8. Press: Stop -OR- Start (NOT) READY Stop halts the test, exits the menu, and puts the printer in the NOT READY state. Start halts the test, exits the menu, and puts the printer in the READY state. Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 142
Menu Method 1: Reset the printer from the Menu 1. Using the directional keys, move to the MISC UTILITIES / RESET PRINTER menu option. (See menu map on page 143.) 2. Press the ENTER key. Method 2: Cycle power 1. Power off the printer. 2. Wait 15 seconds. 3. Power on the printer. 142 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 143
P.C. BOARD VERSION ENTER P.C. BOARD VERSION 3.0 B VERSION CHECK SECURITY PART # ENTER SECURITY PART # 154143-001 B VERSION CHECK PROCESSOR SPEED ENTER PROCESSOR SPEED 68E030 STATUS USED = 0002048 B FLASHDISK STATUS DELETED = 0000000 Figure 19. Boot Diagnostics Menu Troubleshooting 143 - IBM 6400-I15 | Maintenance Manual - Page 144
key MISC UTILITIES DISPLAY MEMORY ENTER FLASH = 2 MBYTES DRAM = 2 MBYTES B MISC UTILITIES RESET PRINTER ENTER RESETTING... PLEASE WAIT B MISC UTILITIES COPY FLASH SIMMS ENTER LOADING PROGRAM INTO FLASH B MISC DATAPRODUCT Figure 19. Boot Diagnostics Menu (continued) 144 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 145
code. Hex dumps can be used to troubleshoot printer data reception problems by comparing the printed hex data to the printer is using a parallel interface, the letter p before a hex code indicates an active Paper Instruction (PI) line and a blank space before a hex code indicates an inactive PI line - IBM 6400-I15 | Maintenance Manual - Page 146
READY Notes Moves down to Disable, the active option. Moves down to Enable, the alternate option. Asterisk (*) indicates this choice is now active. Returns the printer to Not Ready mode. Press both keys at the same time to relock the Enter key. Puts the printer in READY mode. 146 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 147
0 0 11 0 1 11 1 0 11 1 1 12 10 LF 10 0 A 13 11 VT 11 0 B 14 12 FF 12 0 C 15 13 CR 13 0 D 16 14 SO 14 0 E 17 15 SI 15 0 F 0 0 1 1 20 DLE 16 10 DC1 (XON) 21 17 11 22 DC2 18 12 DC3 (XOFF) 23 19 13 24 DC4 20 7B 174 | 124 7C 175 } 125 7D ~ 176 126 7E 177 DEL 127 7F Troubleshooting 147 - IBM 6400-I15 | Maintenance Manual - Page 148
Strokes: The cumulative number of back-and-forth shuttle strokes the printer has printed during normal operation. The range is 0 to 4,000,000,000 shuttle strokes. 11 Inch Pages: The cumulative number of pages the printer has printed. The range is 0 to 363,000,000 pages. 148 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 149
] 9. Press: Stop NOT READY Advances to Installed Memory, the first of the Printer Information menus. Stop when you see the name of the menu you wish to display. The menu you selected displays accumulated statistics or printer information. Puts the printer in NOT READY mode. Troubleshooting 149 - IBM 6400-I15 | Maintenance Manual - Page 150
the printer power switch to O (off). 2. Wait 15 seconds. 3. Set the printer power switch to 1 (on). NOTE: A hard printer reset causes the +48V power supply (fans, motors, etc.) to shut down in 1 to 5 seconds, depending on the amount of memory installed on the controller board. 150 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 151
help you isolate problems that occur before the printer completes its boot processor received a valid reset vector and the first instructions to the processor are correct. This LED is all 32 data lines from the VX bus to the processor are connected. If a bad line is detected, Troubleshooting 151 - IBM 6400-I15 | Maintenance Manual - Page 152
problem printer is placed in diagnostic mode. If any other combination of keys are pressed, the debug SIMM is disabled. Key states are put in an internal register in the VX ASIC. ♦ Detect DRAM - The VX ASIC supports specific OEMs are stored in the DC code, not the boot code. 152 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 153
Flash - The boot code supports many different kinds of flash displays flash configuration, manufacturer's part number, size, and start printer continues boot routines. ♦ Check EC Program - The EC calculates a checksum of the program stored in its flash memory. If there is problem Troubleshooting 153 - IBM 6400-I15 | Maintenance Manual - Page 154
was not enabled, or if any key was held down during power up, automatic EC update is skipped and the boot sequence continues normally. 154 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 155
support the software, boot code displays "SECURITY CODE VIOLATION". ♦ Check Required DRAM - Boot code checks whether the amount of DRAM required to run the DC program is larger than the amount of DRAM in the printer this point, the ribbon motors engage. Boot will not think the printer has crashed. ♦ - IBM 6400-I15 | Maintenance Manual - Page 156
part of the power up sequence is initialization and startup of the DC software, which occurs in the following order: ♦ Clear Uninitialized RAM Variables ♦ Set Initialized RAM Variables ♦ Configure RAM (allocated based upon amount in the printer Display "READY" on operator panel 156 Troubleshooting - IBM 6400-I15 | Maintenance Manual - Page 157
6 Adjustment Procedures Introduction The printer is a durable, low-maintenance machine, but some components and systems require occasional adjustment. Usually, you will be referred to this chapter by a troubleshooting procedure, or as part of a removal/installation procedure. Adjustment - IBM 6400-I15 | Maintenance Manual - Page 158
from the AC power source. 3. Disconnect the host data cable from the printer interface. 4. Open the printer cover. 5. Unload paper. 6. Remove the ribbon. 7. Read the entire adjustment procedure before you begin working on the printer. 8. Gather the necessary parts before you begin working on the - IBM 6400-I15 | Maintenance Manual - Page 159
to Normal Operation When you are finished servicing the printer, restore it to operation by following these steps: 1. Connect the host data cable to the printer interface. 2. Install the ribbon. 3. Load paper. 4. Plug the AC power cord into the power source. 5. Close the cabinet doors. 6. Power - IBM 6400-I15 | Maintenance Manual - Page 160
(Figure 21) 1. Prepare the printer for maintenance (page 158). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: the motor mount bolts (2). 6. Using the straight end of a force gauge, apply 15 pounds (66.7 N) of pressure to the paper feed drive motor (3) near the mounting - IBM 6400-I15 | Maintenance Manual - Page 161
4 Direction of Force 5 1 3 2 2 1. Timing Belt Shield 2. Motor Mount Bolt (2) 3. Paper Feed Drive Motor 4. Splined Shaft 5. Paper Feed Timing Belt Figure 21. Paper Feed Timing Belt Adjustment Adjustment Procedures 161 - IBM 6400-I15 | Maintenance Manual - Page 162
mount screws (2). 8. Snap the platen open belt cover (1) into the slots in the side plate. 9. Cabinet Model: Install the paper guide assembly (page 235). Pedestal Model: Install the top cover assembly (page 210). 10. Return the printer to normal operation (page 159). 162 Adjustment Procedures - IBM 6400-I15 | Maintenance Manual - Page 163
1. Belt Cover 2. Motor Mount Screw (2) 3. Platen Open Motor Shaft 2 Direction of Force 1 3 2 Figure 22. Platen Open Belt Adjustment Adjustment Procedures 163 - IBM 6400-I15 | Maintenance Manual - Page 164
Paper Drive Motor Pulley Alignment (Figure 23) 1. Prepare the printer for maintenance (page 158). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: Remove the top cover assembly (page 210). 3. Remove the timing belt cover (1) by squeezing the front and back to release - IBM 6400-I15 | Maintenance Manual - Page 165
5 3 2 4 1 1. Belt Shield 2. Cap Screw 3. Motor Pulley Collar 4. Motor Pulley 5. Splined Shaft Pulley Figure 23. Paper Drive Motor Pulley Alignment Adjustment Procedures 165 - IBM 6400-I15 | Maintenance Manual - Page 166
(Figure 24) 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 209). 6. Print a full 136 column line by selecting and running one of the - IBM 6400-I15 | Maintenance Manual - Page 167
2 3 2 2 1 1. Shuttle Cover 2. Screw, Button-Head, 5/64 inch hex (3) 3. Paper Scale Figure 24. Paper Scale Alignment Adjustment Procedures 167 - IBM 6400-I15 | Maintenance Manual - Page 168
platen has been replaced by a new or refurbished unit. 1. Prepare the printer for maintenance (page 158). 2. Remove the shuttle cover assembly (page 209). the feeler gauge no more than 2 inches down from the top of the ribbon mask. 6. Gently close the forms thickness lever (1). As the platen is - IBM 6400-I15 | Maintenance Manual - Page 169
209). 11. Check the hammer phasing adjustment (page 179). 12. Return the printer to normal operation (page 159). 1. Forms Thickness Lever 2. Feeler Gauge (0.011 inch or 0.28 mm) 3. Hammer Bank Cover Plate 4. Ribbon Mask 5. Set Screw, 3/32 inch hex (2) 1 5 NOTE: Left side adjustment shown. Right - IBM 6400-I15 | Maintenance Manual - Page 170
Platen Open Motor Pulley Alignment (Figure 26) 1. Prepare the printer for maintenance (page 158). 2. Cabinet Model: Go to step 3. Pedestal Model: Remove step 9. Pedestal Model: Install the top cover assembly (page 210). 9. Return the printer to normal operation (page 159). 170 Adjustment Procedures - IBM 6400-I15 | Maintenance Manual - Page 171
1. Belt Cover 2. Set Screw 3. Platen Open Motor Pulley 4. Platen Shaft Pulley 1 2 3 4 Figure 26. Platen Open Motor Pulley Alignment Adjustment Procedures 171 - IBM 6400-I15 | Maintenance Manual - Page 172
paper and install the ribbon. To align a ribbon guide, wind the ribbon fully onto the ribbon spool on the opposite side. For example, to align the left ribbon guide, wind the ribbon until the right ribbon spool is full. 3. Check ribbon tracking by running the PRINTER MECHANISM TESTS : Shuttle Slow - IBM 6400-I15 | Maintenance Manual - Page 173
Left Ribbon Guide 4 2 Early Models Right Ribbon Guide 1 3 2 4 Later Models 1. Screw, Skid (2) 2. Ribbon 3. White Nylon Washer 4. Screw, Retaining (2) Figure 27. Ribbon Guide Alignment Adjustment Procedures 3 1 173 - IBM 6400-I15 | Maintenance Manual - Page 174
Splined Shaft Skew Adjustment (Figure 28) If lines of print are not parallel with the edge perforations on the paper, perform the following adjustment. 1. Open the printer cover. 2. Loosen the screw (1) securing the adjusting link (2). 3. Adjust the link (2) by raising or lowering the horizontal - IBM 6400-I15 | Maintenance Manual - Page 175
, although it is not required, it is advisable to test the End of Forms distance with 6-part paper, in order to verify correct printing with multi-part forms. The procedure below describes how to run the END OF FORMS ADJUST printer test and modify the END OF FORMS ADJUSTMENT VALUE. 1. Power on the - IBM 6400-I15 | Maintenance Manual - Page 176
Cut out here 4 in. 4 in. Page Perforation Page Perforation Page Perforation Figure 29. Paper Preparation for Paper Out Adjustment Test 176 Adjustment Procedures - IBM 6400-I15 | Maintenance Manual - Page 177
show "SERVICE / PRINTER MECHANISM TESTS", the first menu item. Press Enter to enter the mechanism tests menu. 9. Press Scroll" or Scroll# until "PRINTER MECHANISM rows off is too much.) Unless you wish to restart the procedure with 6-part paper, you may stop the test here, and skip to step 22. (See - IBM 6400-I15 | Maintenance Manual - Page 178
. (Press all four keys at the same time.) 15. The display will show "SERVICE / PRINTER MECHANISM TESTS," the first menu item. Press Scroll" or Scroll# until "SERVICE / END OF FORMS ADJUSTMENT VALUE" is on the display. 16. Press Enter. The top line of the display will show "END OF FORMS ADJUSTMENT - IBM 6400-I15 | Maintenance Manual - Page 179
not printing, the printer will return to its default phasing value when powered off then back on. 1. Power on the printer. 2. Install the ribbon. 3. Load keys at the same time.) 7. The display will show "SERVICE / PRINTER MECHANISM TESTS", the first menu item. Press Enter to enter the mechanism tests - IBM 6400-I15 | Maintenance Manual - Page 180
10. Press Return. The display will show "SERVICE / PRINTER MECHANISM TESTS". 11. Press Scroll" or Scroll" until "SERVICE / HAMMER PHASE VALUE" is on the display. 12. Press Enter. The top line of the display will show "HAMMER PHASE VALUE" and the bottom line will show the current phasing index number - IBM 6400-I15 | Maintenance Manual - Page 181
IBM-compatible computer using the PC-DOS* or MS-DOS** operating system, skip to step 8. If not, go to step 5. 5. Disconnect all data input cables from the printer interface. If the printer has an internal Ethernet interface card, do the following: a. Cabinet models: remove the paper guide assembly - IBM 6400-I15 | Maintenance Manual - Page 182
IBM-compatible personal computer using the PC-DOS or MS-DOS operating system. NOTE: You can connect the data cable to the LPT2 port if the LPT1 port is already in use. You can also download software through the printer serial port. The download commands are different if you use these ports - IBM 6400-I15 | Maintenance Manual - Page 183
15. Press the Scroll" key; "SELECT DOWNLOAD PORT=DATAPRODUCT" appears on the LCD. 16. Press Scroll" again to cycle through the download ports available in the printer: DATAPRODUCT (parallel) CENTRONICS* (parallel) (default port) RS232-9600 (RS-232 serial, 9600 baud) RS232-19.2K (RS-232 - IBM 6400-I15 | Maintenance Manual - Page 184
Using the configuration printout(s) you made in step 1, reconfigure the printer. (Refer to the Setup Guide.) Table 5. Flash Memory Message Guide NOTE: A continuous IML cycle indicates coax/twinax code is being loaded into a printer with a missing, defective, or improperly installed Coax/Twinax board - IBM 6400-I15 | Maintenance Manual - Page 185
FLASH NOT DETECTED ERROR: NO DRAM DETECTED ERROR: NVRAM FAILURE ERROR: PROGRAM NEEDS MORE DRAM ERROR: PROGRAM NEEDS MORE FLASH Explanation Printer cannot find the engine controller program or the validation checksum is corrupt. Hardware fault in the engine controller. Required Action Download the - IBM 6400-I15 | Maintenance Manual - Page 186
has loaded. Use the correct emulation software option(s) for this model. If the printer is an IBM 6404-B01, the controller is a CBO board. If the printer is an IBM 6400, the controller is a CMX board. There is no program in printer memory. Go to step 2. Check the security PAL at location U54 on the - IBM 6400-I15 | Maintenance Manual - Page 187
download initialization message. Required Action None None None The software running or being downloaded does not match the security PAL code. The printer is loading the engine controller program into the engine controller. EC software update in process. Install the correct PAL or program. (PAL - IBM 6400-I15 | Maintenance Manual - Page 188
Press Enter. The display tells you to "PLEASE WAIT" while the coil temperature is set by an automatic calibration sequence in printer software. 8. When the display again reads "SERVICE / SET COIL TEMPERATURE" press Scroll" + Scroll# to lock the Enter key. 9. Press Stop to exit the menu and put the - IBM 6400-I15 | Maintenance Manual - Page 189
value. 12. Install the ribbon and load full-width paper. 13. Select and run the Ripple Print printer test (page 135). 14. Examine the printout: if gaps or dark bars appear in the printout, go back to step 2 and set the shuttle speed to the other option. 15. When the printout is acceptable - IBM 6400-I15 | Maintenance Manual - Page 190
190 Adjustment Procedures - IBM 6400-I15 | Maintenance Manual - Page 191
and installing components that are replaceable at the field service level of maintenance. The procedures in this section refer Parts List This section contains drawings of all assemblies comprising the printer. On the page facing each illustration is a list of the illustrated parts and their part - IBM 6400-I15 | Maintenance Manual - Page 192
Assembly, Paper Feed 227 Motor Assembly, Platen Open 229 Motor Assembly, Ribbon Drive 231 Network Print Server 232 Operator Panel Assembly, Cabinet Model 233 Operator Panel Assembly, Pedestal Model 234 Paper Guide Assembly 235 Paper Ironer 236 192 Replacement Procedures and Illustrated - IBM 6400-I15 | Maintenance Manual - Page 193
Platen 237 Resistors, Terminating 242 Ribbon Guide Assembly (L/R 244 Ribbon Hub 245 Security Module 224 Shaft, Splined 246 Shaft, Support 248 Shuttle Frame Assembly 249 Spring Assembly, Gas 251 Spring, Extension 252 Switch Assembly, Cover Open 253 Switch Assembly, Paper Detector 254 - IBM 6400-I15 | Maintenance Manual - Page 194
the host data cable from the printer interface. 4. Open the printer cover. 5. Unload paper. 6. Remove the ribbon. 7. Read the entire adjustment procedure before you begin working on the printer. 8. Gather the necessary parts before you begin working on the printer. 194 Replacement Procedures and - IBM 6400-I15 | Maintenance Manual - Page 195
Belt, Paper Feed Timing Removal 1. Prepare the printer for maintenance (page 194). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: Remove the top cover assembly (page 210). 3. belt off the splined shaft pulley. Replacement Procedures and Illustrated Parts List 195 - IBM 6400-I15 | Maintenance Manual - Page 196
(2.82 ± 0.23 NSm). 3. Using the straight end of a force gauge, apply 15 pounds (66.7 N) of pressure to the paper feed drive motor near the mounting base Install the paper guide assembly (page 235). Pedestal Model: Install the top cover assembly (page 210). 8. Return the printer to normal operation - IBM 6400-I15 | Maintenance Manual - Page 197
printer for maintenance (page 194). 2. Cabinet Model: Remove the paper guide Figure 50). 5. Push the motor toward the front of the printer to loosen the platen open belt. 6. Loosen the setscrew guide assembly (page 235). Pedestal Model: Install the top cover assembly (page 210). 7. Return the printer - IBM 6400-I15 | Maintenance Manual - Page 198
plastic cover over the power supply. Removal 1. Prepare the printer for maintenance (page 194). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: Remove the top the cable connector shell to its printer connection. 198 Replacement Procedures and Illustrated Parts List - IBM 6400-I15 | Maintenance Manual - Page 199
printer to normal operation (page 159). POD = Paper Out Detect (Switch) PMD = Paper Motion Detect (Switch) CCF = Card Cage Fan LRP = Left Ribbon Guide PLAT M = Platen Open Motor LRIB M = Left Ribbon Motor P106 Connector Configuration 19 17 15 Replacement Procedures and Illustrated Parts List 199 - IBM 6400-I15 | Maintenance Manual - Page 200
electronic component. NOTE: 6400-050, -P50, -010, -P10, -014, and -015 printers must use the 40 Guide.) 2. Prepare the printer for maintenance (page 194). 3. Cabinet Model: Remove the paper guide the replacement controller board to ensure the printer functions correctly. NOTE: When Flash SIMMs - IBM 6400-I15 | Maintenance Manual - Page 201
board to right until the serial cable connector J201 on the board lines up with the cutout in the card cage. (See page 275, the Interconnection diagram on page 295 as your guide. 6. Cabinet Model: Install the paper guide assembly (page 235). Pedestal Model: Install and Illustrated Parts List 201 - IBM 6400-I15 | Maintenance Manual - Page 202
(page 179). 11. Adjust the end of forms distance (page 175). 12. Return the printer to normal operation (page 159). 13. Using the configuration printout you made as step 1 of the removal procedure, reset and save the printer configuration. 202 Replacement Procedures and Illustrated Parts List - IBM 6400-I15 | Maintenance Manual - Page 203
supply board. Removal 1. Prepare the printer for maintenance (page 194). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: : Install the paper guide assembly (page 235). Pedestal Model: Install the top cover assembly (page 210). 5. Return the printer to normal operation ( - IBM 6400-I15 | Maintenance Manual - Page 204
Prepare the printer for maintenance (page 194). 2. Open the printer cover. 3. on the spring clips and remove the circuit breaker from the printer. Installation 1. Press the circuit breaker into the cutout until the printer to normal operation (page 159). 204 Replacement Procedures and Illustrated - IBM 6400-I15 | Maintenance Manual - Page 205
parts for this optional feature are covered in detail in the Coax/Twinax Multi-Platform Interface Feature Installation and Operation Guide, 1. Prepare the printer for maintenance (page 158). 2. Refer to the Coax/Twinax Multi-Platform Interface Feature Installation and Operation Guide, Form Number - IBM 6400-I15 | Maintenance Manual - Page 206
Bank / Ribbon Mask Removal 1. Prepare the printer for ribbon mask off the alignment pins. b. Using a Torx T-10 driver, remove the 12 screws securing the hammer bank cover to the hammer bank. Remove the hammer bank cover. (See Figure 31, page 208.) 206 Replacement Procedures and Illustrated Parts - IBM 6400-I15 | Maintenance Manual - Page 207
ribbon mask facing inward (toward the hammer bank cover), position the ribbon mask on the allignment pins on the hammer bank cover. The ribbon mask is correctly installed when the angled ends of the ribbon 4. Return the printer to normal operation (page 159). Replacement Procedures and Illustrated - IBM 6400-I15 | Maintenance Manual - Page 208
Hammer Bank Cover Screw (12) Ribbon Mask Torque Sequence 43 12 56 Ribbon Mask Clamp Plate (3) Screw (6) Hammer Bank Cover Torque Sequence 9 5 1 3 7 11 10 6 2 4 8 12 Figure 31. Hammer Bank Cover Assembly / Ribbon Mask 208 Replacement Procedures and Illustrated Parts List - IBM 6400-I15 | Maintenance Manual - Page 209
Cover Assembly, Shuttle Removal 1. Prepare the printer for maintenance (page 194). 2. Open the printer cover. 3. Remove the ribbon spools. 4. Loosen the shuttle cover screws (page (page 269, Figure 43). 3. Return the printer to normal operation (page 159). Replacement Procedures and Illustrated - IBM 6400-I15 | Maintenance Manual - Page 210
Cover Assembly, Top, Pedestal Model Removal 1. Prepare the printer for maintenance (page 194). 2. Remove the operator panel ( hold-down screws on the rear of the printer. (See Figure 42, page 267, item 8.) 6. Lift the top cover assembly off the printer base. Installation To install the top cover - IBM 6400-I15 | Maintenance Manual - Page 211
the door closes squarely against the frame. 10. Move the original front door to the rear of the printer. With the marked top uppermost, slide the door hinges down onto the hinge pins. Adjust the position ropes to the doors and the cabinet frame. Replacement Procedures and Illustrated Parts List 211 - IBM 6400-I15 | Maintenance Manual - Page 212
boards, the shuttle frame assembly, and any other electronic component. 1. Prepare the printer for maintenance (page 158). 2. Cabinet Models: Remove the paper path (page 6 of the removal procedure. 2. Return the printer to normal operation (page 159). 212 Replacement Procedures and Illustrated - IBM 6400-I15 | Maintenance Manual - Page 213
and three DIP switches, as shown below. These indicators and switches are adjacent to the data line connectors. LED patterns are defined in the table below the illustration. Status Indicator LEDs and whether the unit IP address is configured. Replacement Procedures and Illustrated Parts List 213 - IBM 6400-I15 | Maintenance Manual - Page 214
both to the ON (down) position will clear all passwords, specifically passwords in the html webpage. DIP Switch 1 = EEPROM Enable up). Setting this switch to the ON (down) position and powering the printer off then on resets a previously configured IP address to the factory default setting Parts List - IBM 6400-I15 | Maintenance Manual - Page 215
Open the floor cabinet doors and the printer cover. 3. Remove the paper stacker. of the card cage, in front of the square air holes in the printer base plate.) (See page 265, Figure 41). 5. Disconnect the fan Return the printer to normal operation (page 159). Replacement Procedures and Illustrated - IBM 6400-I15 | Maintenance Manual - Page 216
Fan Assembly, Card Cage Removal 1. Prepare the printer for maintenance (page 194). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: Remove the label faces toward the inside of the printer. Air flow is INTO the card cage. 1. Reverse steps 2 through 6 of the removal - IBM 6400-I15 | Maintenance Manual - Page 217
Fan Assembly, Hammer Bank Removal 1. Prepare the printer for maintenance (page 194). 2. Remove the shuttle cover assembly (page 209). 3. (page 210). 5. Install the shuttle cover assembly (page 209). 6. Return the printer to normal operation (page 159). Replacement Procedures and Illustrated - IBM 6400-I15 | Maintenance Manual - Page 218
Hammer Spring Assembly Removal 1. Prepare the printer for maintenance (page 194). 2. Remove the shuttle frame mounting base. NOTE: Replace a hammer spring assembly only if there is visible damage or broken parts can be seen in the assembly. 5. Remove the mounting screws from the old hammer spring - IBM 6400-I15 | Maintenance Manual - Page 219
NOTE: The hammer spring assemblies shown below are for 6400-004, 04P, 005, 05P printers. The number of hammer springs and mounting screws varies among printer models, but hammer spring removal is the same. Hammer Spring Assembly 7 Hammer Spring Assembly 1 Discard old screws Figure 32. Hammer - IBM 6400-I15 | Maintenance Manual - Page 220
6400-050, -P50, -010, -P10, -014, and -015 printers hammer spring assembly only if there is visible damage or broken parts can be seen in the assembly. 2. Handling it by 6. Install the shuttle frame assembly (page 249). 7. Install the ribbon and load paper. ATTENTION Do not attempt to adjust or "tweak - IBM 6400-I15 | Maintenance Manual - Page 221
screws to 14 inch-pounds (1.58 NSm). NOTE: The hammer spring assemblies shown above are for 6400-004, 04P, 005, 05P printers. The number of hammer springs and mounting screws varies among printer models, but installation procedure and torque values are the same. Figure 33. Hammer Spring Assembly - IBM 6400-I15 | Maintenance Manual - Page 222
wrist strap when handling circuit boards, the shuttle frame assembly, and any other electronic component. 1. Prepare the printer for maintenance (page 194). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: Remove the top cover assembly (page 210). 3. Loosen, but do not - IBM 6400-I15 | Maintenance Manual - Page 223
Assembly Removal 1. Prepare the printer for maintenance (page 194). (0.254 ± 0.025 mm). Torque the MPU clamp screw to 19 ± 1 inch-pounds (2.15 ± 0.11 NSm). 3. Check the gap between the MPU assembly and the flywheel with a the printer to normal operation (page 159). Replacement Procedures and - IBM 6400-I15 | Maintenance Manual - Page 224
(Refer to the Setup Guide.) 2. Prepare the printer for maintenance (page 194). 3. Cabinet Model: Remove the paper guide assembly (page 235). 4. Gently pry the side locks open, angle the SIMM toward the front of the printer, and remove the SIMM from the socket. (See Figure 34, page 226 for the - IBM 6400-I15 | Maintenance Manual - Page 225
4. Download the emulation (page 181). 5. Return the printer to normal operation (page 159). 6. Using the configuration printouts you made as step 1 of the removal procedure, reset and save the printer configurations. (Refer to the Setup Guide.) Replacement Procedures and Illustrated Parts List 225 - IBM 6400-I15 | Maintenance Manual - Page 226
-002 154143-001 154143-002 154143-001 (14H5509) (14H5490) (14H5509) (14H5490) (14H5509) (14H5490) Figure 34. Memory Modules and Security PAL 226 Replacement Procedures and Illustrated Parts List - IBM 6400-I15 | Maintenance Manual - Page 227
Motor Assembly, Paper Feed Removal 1. Prepare the printer for maintenance (page 194). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: Remove the top cover assembly (page 10. Remove the paper feed motor assembly. Replacement Procedures and Illustrated Parts List 227 - IBM 6400-I15 | Maintenance Manual - Page 228
guide, and four screws. (See Figure 44, page 271, items 3, 4, and 5.) 10. Cabinet Model: Install the paper guide assembly (page 235). Pedestal Model: Install the top cover assembly (page 210). 11. Return the printer to normal operation (page 159). 228 Replacement Procedures and Illustrated Parts - IBM 6400-I15 | Maintenance Manual - Page 229
Motor Assembly, Platen Open Removal 1. Prepare the printer for maintenance (page 194). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: Remove the top cover assembly (page 210 . Remove the platen open motor assembly. Replacement Procedures and Illustrated Parts List 229 - IBM 6400-I15 | Maintenance Manual - Page 230
in the side plate. 9. Cabinet Model: Install the card cage fan (page 216). 10. Cabinet Model: Install the paper guide assembly (page 235). Pedestal Model: Install the top cover assembly (page 210). 11. Return the printer to normal operation (page 159). 230 Replacement Procedures and Illustrated - IBM 6400-I15 | Maintenance Manual - Page 231
Ribbon Drive Removal 1. Prepare the printer for maintenance (page 194). 2. Remove the ribbon. 3. Remove the ribbon hub (page 245). 4. Remove two screws and washers securing the ribbon drive motor to the base casting (page 285, Figure 50). 5. Lift and rotate the ribbon ribbon The ribbon drive motor should - IBM 6400-I15 | Maintenance Manual - Page 232
Guide, P/N 30H4056. This guide describes error messages and troubleshooting information. Also provided is a section that describes IBM service electronic component. 1. Prepare the printer for maintenance (page 158). 2. Refer to the Print Server User's Guide (P/N 30H4056) for information on - IBM 6400-I15 | Maintenance Manual - Page 233
Assembly, Cabinet Model Removal 1. Prepare the printer for maintenance (page 194). 2. Open the printer cover. 3. Remove the four screws securing the printer cover and align the operator panel in the cover cutout. Open the printer cover and tighten the panel plate screws. 5. Return the printer to - IBM 6400-I15 | Maintenance Manual - Page 234
printer for maintenance (page 194). 2. Open the printer cover. 3. Tilt the operator panel toward the front of the printer mounting plate toward the front of the printer. 2. Position the operator panel over the printer cover. 5. Return the printer to normal operation (page 159). 234 - IBM 6400-I15 | Maintenance Manual - Page 235
printer for maintenance (page 194). 2. Open the printer cover. 3. Loosen the three paper guide assembly hold-down screws (page 269, Figure 43, item 6). 4. Slide the paper guide paper guide assembly to the right, engaging the three hold-down screws in the keyway slots. Slide the paper guide assembly - IBM 6400-I15 | Maintenance Manual - Page 236
the open position. 3. Push the ends of the paper ironer toward the rear of the printer, disengage the tabs, then lift it up and out (page 283, Figure 49). Installation NOTE frame assembly (page 249). 4. Return the printer to normal operation (page 159). 236 Replacement Procedures and Illustrated - IBM 6400-I15 | Maintenance Manual - Page 237
1. Prepare the printer for maintenance (page platen shaft. (See Figure 49, page 283, item 15.) 9. Remove the right side platen support spring by repeating step 7 on the right side of ribbon guide assembly to the side plate. (See Figure 50, page 285, item 12, 14, and 15.) 13. Slide the ribbon guide - IBM 6400-I15 | Maintenance Manual - Page 238
14. Pull the right side of the platen toward the front of the printer and move the platen to the right and out of the left side plate. (Hold the black Ironer Bracket Washer Platen Adjust Bracket Figure 35. Installing the Platen Adjust Brackets 238 Replacement Procedures and Illustrated Parts List - IBM 6400-I15 | Maintenance Manual - Page 239
in Figure 36. Washers Platen Adjust Bracket Platen Wear Saddle Mechanism Base Platen Seat Figure 36. Installing the Platen Adjust Brackets Replacement Procedures and Illustrated Parts List 239 - IBM 6400-I15 | Maintenance Manual - Page 240
ribbon guide assembly into the side plate and install the two 7/32 inch screws and washers. (See Figure 50, page 285, item 12, 14, and 15.) Figure 35): a. With the flat part of the bracket facing the front of the printer, place the two hooks of the upper part of the paper ironer over the platen - IBM 6400-I15 | Maintenance Manual - Page 241
the left ribbon guide. 18. printer (page 236). 20. Install the shuttle frame assembly (page 249). 21. Adjust the platen gap (page 168). 22. Adjust the platen open belt (page 162). 23. Check ribbon guide alignment (page 172). 24. Check the hammer phasing (page 179). 25. Return the printer - IBM 6400-I15 | Maintenance Manual - Page 242
printer down alternate terminating resistors are provided with the printer. If you install the 220 ohm pull-up resistor Prepare the printer for maintenance (page 158). 2. Cabinet Model: Remove the paper guide assembly .) 2. Cabinet Model: Install the paper guide assembly (page 235). Pedestal Model: Install - IBM 6400-I15 | Maintenance Manual - Page 243
Return the printer to normal operation (page 159). CMX Controller Board RP1 Default: 470 ohm Alt 1: 220 ohm Alt 2: 1K ohm Resistor Kit: 14H5525 RP2 Default: 1K ohm Alt 1: 330 ohm Alt 2: none Figure 37. Resistors, Terminating, Removal/Installation Replacement Procedures and Illustrated Parts List - IBM 6400-I15 | Maintenance Manual - Page 244
guide is shown in Figure 50. The installation procedure is the same for the left ribbon guide. 1. Reverse steps 4 through 10 of the removal procedure above. 2. Align the ribbon guides (page 172). 3. Return the printer to normal operation (page 159). 244 Replacement Procedures and Illustrated Parts - IBM 6400-I15 | Maintenance Manual - Page 245
the ribbon drive motor. Installation 1. Install the ribbon spool hub over the motor shaft (page 285, Figure 50). 2. Tighten the hub screw so that it contacts the flat section of the motor shaft. 3. Return the printer to normal operation (page 159). Replacement Procedures and Illustrated Parts List - IBM 6400-I15 | Maintenance Manual - Page 246
Shaft, Splined Removal 1. Prepare the printer for maintenance (page 194). 2. Open the printer cover. 3. Remove the paper supports from the splined shaft and support shaft. (See Figure 48, page 281, item 21.) 4. Remove plates and the tractors. 246 Replacement Procedures and Illustrated Parts List - IBM 6400-I15 | Maintenance Manual - Page 247
belt tension (page 160). 11. Adjust splined shaft skew (page 174.) 12. Install the paper supports on the splined shaft and support shaft. (See Figure 48, page 281, item 21.) 13. Return the printer to normal operation (page 159). Tractor Alignment Mark NOTE: Align the marks on each tractor before - IBM 6400-I15 | Maintenance Manual - Page 248
Slide the support shaft assembly-consisting of the support shaft, the support shaft assembly-consisting of the support shaft tractors onto the support shaft. 3. Slide the support shaft assembly supports on the splined shaft and support shaft. (See Figure 48, page 281, item 21.) 6. Return the printer - IBM 6400-I15 | Maintenance Manual - Page 249
printer clamps back and off the guide shaft. Do not remove support legs cast on both sides of the shuttle motor, lift the shuttle frame assembly out of the base casting. Lift it slowly and carefully: the shuttle frame assembly is heavy. Installation 1. Install the hammer bank / ribbon Parts List 249 - IBM 6400-I15 | Maintenance Manual - Page 250
support shuttle frame assembly toward the front of the printer and hold it in this position while you -down screws. 5. Slide the side clamps over the guide shaft and torque the 5/32 inch socket head clamp screws 15. Return the printer to normal operation (page 159). 250 Replacement Procedures - IBM 6400-I15 | Maintenance Manual - Page 251
disengaging the gas spring assembly. 1. Prepare the printer for maintenance (page 194). 2. Open the printer cover. 3. Open the floor cabinet rear door. assembly onto the ball joints and install the spring clips. 3. Close the printer cover. If necessary, adjust the position of the ball joint stud in - IBM 6400-I15 | Maintenance Manual - Page 252
for maintenance (page 194). 2. Open the printer cover. 3. Remove the shuttle cover assembly (page 209). 4. Unhook the extension spring from the spring lugs on the hammer bank and shuttle frame. (See Figure 47, page 279.) Installation 1. Put a dab of IBM #20 bearing lubricant on both spring lugs - IBM 6400-I15 | Maintenance Manual - Page 253
Open Removal 1. Prepare the printer for maintenance (page 194). shell P107 (P7) from the controller board. 6. Trace the ribbon motor wires to the connector shell, and remove the cable connector from 209). 6. Return the printer to normal operation (page 159). Replacement Procedures and Illustrated - IBM 6400-I15 | Maintenance Manual - Page 254
Switch Assembly, Paper Detector Removal 1. Prepare the printer for maintenance (page 194). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: Remove the top cover assembly (page the paper detector switch assembly. 254 Replacement Procedures and Illustrated Parts List - IBM 6400-I15 | Maintenance Manual - Page 255
4, and 5.) 6. Cabinet Model: Install the paper guide assembly (page 235). Pedestal Model: Install the top cover assembly (page 210). 7. Check and adjust the End of Forms Distance (page 175). 8. Return the printer to normal operation (page 159). Replacement Procedures and Illustrated Parts List 255 - IBM 6400-I15 | Maintenance Manual - Page 256
Switch Assembly, Platen Interlock Removal 1. Prepare the printer for maintenance (page 194). 2. Cabinet Model: Remove the paper guide assembly (page 235). Pedestal Model: Remove the top cover assembly (page 210). cutout in the right side plate. 256 Replacement Procedures and Illustrated Parts List - IBM 6400-I15 | Maintenance Manual - Page 257
P107 (P7) (see page 198), then connect the connector shell to the controller board. 5. Cabinet Model: Install the paper guide assembly (page 235). Pedestal Model: Install the top cover assembly (page 210). 6. Return the printer to normal operation (page 159). Replacement Procedures and Illustrated - IBM 6400-I15 | Maintenance Manual - Page 258
3. Remove the support shaft (page 248). 4. Remove the tractors. Installation 1. Using the replacement tractors, install the support shaft (page 248). 2. Install the splined shaft (page 247). 3. Return the printer to normal operation (page 159). 258 Replacement Procedures and Illustrated Parts List - IBM 6400-I15 | Maintenance Manual - Page 259
Section II: Illustrated Parts List List of Figures Figure 39. Top Cover, Doors, and Casters, Cabinet Model 261 Figure 40. Paper 51. Circuit Breaker 287 Figure 52. Expansion Coax/Twinax Board 289 Figure 53. Ethernet Interface Assemblies 291 Replacement Procedures and Illustrated Parts List 259 - IBM 6400-I15 | Maintenance Manual - Page 260
Item Part No. No. (Order No.) 1 24H8961 2 57G1492 3 14H5567 4 24H8960 Description Top Cover Kit Window, Top Cover Wireform Paper Guide Assembly Rear Door Kit 5 24H8959 6 57G1485 7 57G1486 8 14H5603 9 30H4008 Front Door Kit Caster, with Brake Caster, without Brake Logo, 6400 Wire Rope, Front and - IBM 6400-I15 | Maintenance Manual - Page 261
NOTE: Item 10: Shipping Container Kit not shown Item 11: Hardware Kit not shown 1 13 12 5 9 2 8 3 4 7 6 Figure 39. Top Cover, Doors, and Casters, Cabinet Model Replacement Procedures and Illustrated Parts List 261 - IBM 6400-I15 | Maintenance Manual - Page 262
Item Part No. No. (Order No.) 1 57G7176 2 30H3981 3 04H4779 4 Ref 5 14H5296 6 14H5272 7 57G7260 9 Ref Description Stacker Runner, Stacker Riser, Stacker Cord, U.S. Grommet, Power Cord (2) Notes Kit contains eight chains Included in item 5 262 Replacement Procedures and Illustrated Parts List - IBM 6400-I15 | Maintenance Manual - Page 263
6 4 3 5 7 1 8 2 Figure 40. Paper Stacker and Chains Replacement Procedures and Illustrated Parts List 263 - IBM 6400-I15 | Maintenance Manual - Page 264
Item Part No. No. (Order No.) 1 14H5299 2 57G1598 57G1599 57G1600 57G1601 57G1602 57G1603 57G1604 3 Ref 4 14H5300 5 57G1481 Description Operator Panel, Cabinet 32x.375 Includes ball studs, spring clips, and mounting hardware 6-32x.375 6-32x.175 264 Replacement Procedures and Illustrated Parts List - IBM 6400-I15 | Maintenance Manual - Page 265
2 1 4 3 9 6 6 5 7 8 6 Figure 41. Control Panel and Cabinet Details Replacement Procedures and Illustrated Parts List 265 - IBM 6400-I15 | Maintenance Manual - Page 266
Item Part No. No. (Order No.) 1 63H5124 2 57G1598 57G1599 57G1600 57G1601 57G1602 57G1603 57G1604 3 Ref 4 63H5125 5 63H5121 6 14H5300 7 63H5119 8 Ref 9 63H5120 10 Ref 11 63H5118 12 63H7509 13 63H5117 14 Ref 15 24H8533 Description Operator Panel, Pedestal Operator Panel Overlay Operator Panel - IBM 6400-I15 | Maintenance Manual - Page 267
12 3 4 5 6 14 15 13 7 8 9 NOTE: Item 16: Lid Accessory Kit not shown Item 17: Pedestal Shipping Container not shown 11 10 12 Figure 42. Pedestal Details Replacement Procedures and Illustrated Parts List 267 - IBM 6400-I15 | Maintenance Manual - Page 268
Item Part No. No. (Order No.) 1 14H5235 2 Ref Description Shroud Assembly, Air Screw, Captive (2) 3 Ref 4 Ref 5 14H5271 Screw, Thread Forming (4) Barrier Shield Paper Guide Assembly 6 Ref 7 14H5174 Screw, w/Lock Washer (3) Platen/Paper Feed Cover Kit 8 57G1468 9 08H7954 10 Ref 11 14H5179 Belt - IBM 6400-I15 | Maintenance Manual - Page 269
5 6 4 3 9 3 1 11 10 2 8 7 Figure 43. Inside Covers, Cabinet Model Replacement Procedures and Illustrated Parts List 269 - IBM 6400-I15 | Maintenance Manual - Page 270
Item Part No. No. (Order No.) 1 14H5235 2 Ref Description Shroud Assembly, Air Screw, Captive (2) 3 Ref 4 Ref 5 63H5116 6 08H7954 7 Ref Screw, Thread Forming (4) feed belt cover shown in Figure 43. Platen open belt cover: item 24, page 283. 270 Replacement Procedures and Illustrated Parts List - IBM 6400-I15 | Maintenance Manual - Page 271
3 5 4 3 6 7 1 10 See Figure 44a, page 273. 2 8 9 Figure 44. Inside Covers and Card Cage, Pedestal Model Replacement Procedures and Illustrated Parts List 271 - IBM 6400-I15 | Maintenance Manual - Page 272
Item Part No. No. (Order No.) 1 Ref 2 57G1440 3 Ref 4 Ref 5 Ref 6 14H5571 Description Nut, 6-32 (1) Card Cage Fan Assembly Fan Guard Screw, w/Lock Washer Circuit Breaker Notes Upper right fan corner only Air flow is into card cage 6-32x.1.75 272 Replacement Procedures and Illustrated Parts List - IBM 6400-I15 | Maintenance Manual - Page 273
Connector P1, (Black Wire) To IEC 320 AC Power 6 Input (Connector J301, Black Wire) Figure 44a. Card Cage Detail, Pedestal Model Replacement Procedures and Illustrated Parts List 273 - IBM 6400-I15 | Maintenance Manual - Page 274
Ref 8 Ref 9 Ref 10 Ref 11 Ref 12 14H5287 14H5522 13 Ref 14 14H5211 15 Ref 16 Ref 17 Ref 18 14H5282 Controller Board, CMX, V5.5, 40 MHz Motor Sensor, 014 Models 004, 04P, 005, 05P, 008, 08P, 012 Models 009, 09P, 014 Part of Field Kit, AC Assy 14H5289 All models 004 and 04P. Models 008 and 012 with - IBM 6400-I15 | Maintenance Manual - Page 275
Exploded to show assembly. Do not remove holddown clamps and screws. 14 1 To To J02 J03 (Shuttle (MPU) Motor) 2 7 6 8 9 10 4 16 3 15 5 15 11 15 12 13 17 To Terminator Board on 18 Shuttle Frame Figure 45. Print Mechanism and Circuit Boards: Early Models Replacement Procedures - IBM 6400-I15 | Maintenance Manual - Page 276
, P10 Model 015 Models 050, P50 Models 010, P10 Model 015 12 for hammer bank cover 6 for ribbon mask Models 050, P50 Models 010, P10 Model 015 Models 050, P50 Models 010, P10 Model 015 Part of Field Kit AC Assy 14H5289 Models 050, P50, 010, P10, 014, 015 Housing Connector Kit - IBM 6400-I15 | Maintenance Manual - Page 277
. Do not remove holddown clamps and screws. 2 3 1 4 17 4 To J02 (Shuttle Motor) To J03 (MPU) 5 10 9 11 12 13 7 19 6 18 8 18 14 18 15 16 20 21 To Terminator Board on Shuttle Frame Figure 46. Print Mechanism and Circuit Boards: Later Models Replacement Procedures and Illustrated - IBM 6400-I15 | Maintenance Manual - Page 278
Item Part No. No. (Order No.) 1 57G1476 2 Ref 3 30H3985 4 14H5329 Description Magnetic Pickup Assy (MPU) Screw, Socket Cap, 6-32x.38 Extension Spring Cable Assembly, MPU Notes 278 Replacement Procedures and Illustrated Parts List - IBM 6400-I15 | Maintenance Manual - Page 279
not touch the MPU cable after installation. 1 4 0.010 ± .001 inch (0.254 ± .025mm) Figure 47. Magnetic Pickup Unit (MPU) and Extension Spring Replacement Procedures and Illustrated Parts List 279 - IBM 6400-I15 | Maintenance Manual - Page 280
Tractor Shaft Kit Bushing Paper Support (2) Link, Splined Shaft Skew Adjustment Part of item 19 Part of item 19 Part of item 19 Part of item 19 Part of item 19 Part of item 18 Part of item 18 Part of item 18 Part of item 18 Part of item 11 Part of item 18 Part of item 18 Part of item 19 Includes - IBM 6400-I15 | Maintenance Manual - Page 281
10 21 11 67 4 89 22 20 1 2 3 12 5 17 16 15 NOTE: Item 18: Tractor Shaft Hardware Kit not shown Item 19: Tractor Shaft Kit not shown 16 Figure 48. Tractor Shafts Replacement Procedures and Illustrated Parts List 14 13 281 - IBM 6400-I15 | Maintenance Manual - Page 282
Hardware Kit Platen Washer Notes Part of item 25 Part of item 25 Reverser Paper Feed 6-32x.25 Part of item 25 Part of item 11 Part of item 11 Part of item 15 Part of item 15 Part of item 15 Part of item 25 Part of item 25 Part of item 25 Part of item 11 Part of item 25 Part of item 21 Platen - IBM 6400-I15 | Maintenance Manual - Page 283
NOTE: Black tape faces paper motion detector. 1 2 NOTE: Item 25: Platen 6 Hardware Kit 24 23 22 21 17 20 26 18 16 3 4 5 7 8 1 2 9 10 Figure 49. Platen Replacement Procedures and Illustrated Parts List 11 12 13 19 18 17 16 15 14 283 - IBM 6400-I15 | Maintenance Manual - Page 284
8 Ref 9 57G1421 10 Ref 11 24H8894 12 14H5154 13 Ref 14 Ref 15 Ref 16 Ref 17 14H5521 18 Ref 19 Ref 20 57G1479 21 Ref 22 14H5159 7 through 9 Part of Platen Open Motor Assy 57G1509 and includes collar setscrew 6-32x.25 Part of item 9 10-32x.50 Includes left and right ribbon guides Includes item 6 - IBM 6400-I15 | Maintenance Manual - Page 285
16 6 20 18 15 19 17 23 11 2 1 Install screws here Top View Hammer Bank Fan Route cable under base casting 4 3 12 2 5 22 See detail above 8 7 21 13 14 10 9 11 Figure 50. Motors, Card Cage Fan, and Paper Detector Switch Replacement Procedures and Illustrated Parts List 285 - IBM 6400-I15 | Maintenance Manual - Page 286
AC Power Connector Chassis Ground Stud Connector P1 5 Ref Cable Assy, AC In, Power Supply Notes Connector J301 To power supply board connector J1 AC Part of Field Kit, AC Assy 14H5289 286 Replacement Procedures and Illustrated - IBM 6400-I15 | Maintenance Manual - Page 287
) Card cage fan and power supply board removed for clarity Black Wire Black Wire 2 WhiteWire 3 5 4 White Wire Figure 51. Circuit Breaker Replacement Procedures and Illustrated Parts List 287 - IBM 6400-I15 | Maintenance Manual - Page 288
Item Part No. No. (Order No.) 1 Ref 2 Ref 3 24H9011 4 Ref 5 Ref 6 24H8535 7 Ref 8 Ref Description Screw (2) Card Cage IBM Coax/Twinax Expansion Screw, Captive Standoff, Hex, 3/16 inch Adapter, Expansion Connector CMX Controller Board Controller Board Connector J111 Notes M/F, .813 Lg. 60-pin 288 - IBM 6400-I15 | Maintenance Manual - Page 289
4 3 5 6 7 2 1 8 1 Figure 52. IBM Coax/Twinax Expansion Board Replacement Procedures and Illustrated Parts List 289 - IBM 6400-I15 | Maintenance Manual - Page 290
Item Part No. No. (Order No.) 1 Ref 2 Ref 3 Ref 4 Ref 5 14H5287 6 24H8995 7 24H8994 8 Ref 9 Ref Description Screw, Connector Cover (2) Cover Plate, Base-T Ethernet LAN PCBA, 10-Base-2 Rear of Card Cage Screw (2) Notes See also Appendix I 290 Replacement Procedures and Illustrated Parts List - IBM 6400-I15 | Maintenance Manual - Page 291
2 5 3 4 1 6 7 9 8 Figure 53. Ethernet Interface Assemblies Replacement Procedures and Illustrated Parts List 291 - IBM 6400-I15 | Maintenance Manual - Page 292
292 Replacement Procedures and Illustrated Parts List - IBM 6400-I15 | Maintenance Manual - Page 293
A Wire Data NOTE: Acronyms and Signal mnemonics are defined in Appendix F. IBM 6400 Interconnection Diagram 295 IBM 6400 Power Distribution Diagram 296 IBM 6400 Main Wire Harness Test Tables 297 Circuit Board Pinouts Controller, CMX 298 Power Supply 302 Expansion Coax/Twinax 303 SureStak** - IBM 6400-I15 | Maintenance Manual - Page 294
Ribbon Guide Kit 318 Ribbon Motor, Extension 319 Shuttle Motor Drive 320 Twinax Auto-Termination 321 Centronics / DataProducts Adapter 322 +5V Remote Power 323 Power Stacker Cables Frame Cable, Power - IBM 6400-I15 | Maintenance Manual - Page 295
SWITCH Line 1 Line 2 / Neutral CHASSIS GND AC to DC Power Supply Board IBM 6400 INTERCONNECTION J101 DC POWER J111 EXP PORT J105 HBP P105 HBP J107 Configuration 19 17 15 13 11 9 7 5 3 1 MPU PLO EHF PAPR M CVO RRP Motion Detector Paper Out Detector Left Ribbon Guide 4 4 4 2 Flex Circuits - IBM 6400-I15 | Maintenance Manual - Page 296
CIRCUIT BREAKER Line 1 Line 2 / Neutral CHASSIS GND AC POWER AC to DC Power Supply Board Card Cage Fan CMX Controller Board P306 IBM 6400 POWER +5 V Ret +48V Platen Motor Paper Motion Detector Paper Out Detector Left Ribbon Guide Left Ribbon Motor J106 MSL P106 MSL +48V +5 V +5 V +5 V + - IBM 6400-I15 | Maintenance Manual - Page 297
15 13 11 9 7 5 3 1 POD PMD CCF PLAT M LRP LRIB M P106 20 18 16 14 12 10 8 6 4 2 CCF = Card Cage Fan LRIB M = Left Ribbon Motor LRP = Left Ribbon 18, 20 13, 15 17, 19 7.2 - 8.8 Ω 1.35 - 1.65 Ω Open across pins Short across post 4.6 KΩ 8 MegΩ Open 8 MegΩ Open IBM 6400 Main Wire Harness Test - IBM 6400-I15 | Maintenance Manual - Page 298
PF 10% 50V 4 5 6 N FP LCD WR 7 8 9 10 11 12 13 14 15 16 17 18 19 20 I/O CNC PN 25 14 PF 1 RIB R1 PF 2 RIB R2 PF 3 RIB R3 PF 4 + PN 14 27 R RBN POST+ 100V I/O CNC PN 32 28 PLAT OPEN RET I/O CNC PN 15 29 R RBN POST- I/O CNC PN 33 30 SLCT N INIT N AUTOFEED N FAULT PI MPU - IBM 6400-I15 | Maintenance Manual - Page 299
Wire Data CAUTION: Do not remove or replace the NVRAM. The NVRAM contains a lithium battery that can explode if it is replaced incorrectly. NVRAM is replaced only at the factory. J6 Diagnostic Port 1 NC 72 3 84 5 6 NC VX DB TXD VX DB RXD 470 PF 10% 50V Controller, CMX J9 Online - IBM 6400-I15 | Maintenance Manual - Page 300
10 11 12 L RBN POST+ CC FAN- L RBN POST- 0.01 mF 10% 100V 13 POD A 14 PMD A 15 16 POD K PMD K 17 POD C 18 PMD C 19 POD E 20 PMD E PH1 PH2 PH3 PH4 LDFB J101 Power 37 8 38 9 39 10 40 11 41 12 42 13 43 14 44 15 45 16 46 17 47 18 48 19 49 20 50 21 51 22 - IBM 6400-I15 | Maintenance Manual - Page 301
Wire Data 1 J2 2 EC Diagnostics 3 4 5 6 7 8 9 10 VCC 10K 1% 0.1W EC DB TXD EC DB RXD NC PPR TRIG PPR MOVING FT EVENT MPU OUT SHUT DIR Controller, CMX Terminating Resistors (See page 242.) J108 Hammer Bank Logic TOROID 1 50 MHz 2 HMR DAT 3 HMR DAT RET 4 HMR CLK 5 HMR CLK - IBM 6400-I15 | Maintenance Manual - Page 302
Power Supply 302 GND LOAD LOAD Cable Assy, AC In, Power Supply 1 2 P1 3 = RING TERMINAL = FAST-ON TERMINAL (Line Filter Area) 1 AC Input AC AC COMMON CHASSIS GND J1 PIN 1 P101 * V3.5 BOARD PIN 1 = N TEMP HI N TEMP HI * 1 V4 BOARD PIN 1 = N AC FAIL N STBY 2 + - IBM 6400-I15 | Maintenance Manual - Page 303
Data J2 Twinax Connector 1 2 3 16 4 SHIELD 1 5 6 7 8 17 9 SHIELD 2 10 11 12 13 14 15 NC NC NC NC NC TWINAX PHASE B NC NC NC NC NC NC TWINAX PHASE A NC J3 Coax Connector 1 COAX SHIELD 2 COAX DATA IBM Coax/TwinaxExpansion Board 1K 0.1W NC N CARD DETECT 12/10 V NC N DMA REQ0 - IBM 6400-I15 | Maintenance Manual - Page 304
SWT 5 LIMIT SWT RET 6 EL PHA 1 7 EL PHA 2 ELEVATOR MOTOR: 8 EL PHB 1 RESISTANCE = 15.2 1.5 Ω / PHASE 9 EL PHB 2 10 HW1 HW3 HW5 HW2 HW4 +48V J6 Power Supply 1 2 9 10 PI PHA 1 11 PI PHA 2 12 PI PHB 1 13 PI PHB 2 14 15 LD1 A 16 LD1 K 17 DT1 C 18 DT1 E 19 LD2 A 20 LD2 K 21 - IBM 6400-I15 | Maintenance Manual - Page 305
Cable Routing, Cabinet Model Wire Data 305 - IBM 6400-I15 | Maintenance Manual - Page 306
306 Left Side of Printer Front of Printer Right Side of Printer Wire Data To J106 on Controller (See page 199 for connector detail.) Cable Routing, Mechanism Base Cabinet Model (Looking up from below) P107 / CVO To J107 (See page 199 for on Controller connector detail.) - IBM 6400-I15 | Maintenance Manual - Page 307
Cable Routing, Pedestal Model Wire Data 307 - IBM 6400-I15 | Maintenance Manual - Page 308
Left Side of Printer Front of Printer Right Side of Printer 308 To J106 on Controller (See page 199 for connector detail.) (Unconnected on on pedestal models) Cable Routing, Mechanism Base, Pedestal Model (Looking up from - IBM 6400-I15 | Maintenance Manual - Page 309
Wire Data To Power Supply J1 To Circuit Breaker Part No. 14H5289 Description Cable Assembly, AC In, Power Supply 309 - IBM 6400-I15 | Maintenance Manual - Page 310
Wire Data 310 To Circuit Breaker Input Power Connector Part No. 14H5289 Description Cable Assembly, AC Power Input - IBM 6400-I15 | Maintenance Manual - Page 311
Wire Data PIN 1 PIN 1 Part No. 14H5285 Description Cable Assembly, Card Cage Fan 311 - IBM 6400-I15 | Maintenance Manual - Page 312
Wire Data 312 PIN 1 (Gray) PIN 8 (Brown) IMPORTANT: If you replace the control panel cable, you must install two ferrite shielding beads. See Appendix I. PIN 8 (Brown) PIN 1 (Gray) Part No. 14H5300 Description Cable Assembly, Operator Panel - IBM 6400-I15 | Maintenance Manual - Page 313
313 Wire Data Part No. 14H5286 Description Cable Assembly, Exhaust Fan - IBM 6400-I15 | Maintenance Manual - Page 314
Wire Data 314 Part No. 14H5279 Description Cable Assembly, Hammer Bank Logic - IBM 6400-I15 | Maintenance Manual - Page 315
Wire Data PIN 1 PIN 1 Part No. 14H5283 Description Cable Assembly, Hammer Bank Power 315 - IBM 6400-I15 | Maintenance Manual - Page 316
316 PIN 1 PIN 1 NOTE: If you replace the I/O cable assembly, you must install the ferrite clamp. See Appendix I. Part No. 14H5287 Description Cable Assembly, I/O, Centronics Wire Data - IBM 6400-I15 | Maintenance Manual - Page 317
Wire Data PIN 2 PIN 1 PIN 3 PIN 1 Part No. 14H5329 Description Cable Assembly, MPU 317 - IBM 6400-I15 | Maintenance Manual - Page 318
318 NOTE: Left ribbon guide shown. Right is mirror image. PIN 1 LEFT GUIDE = P106 / LRP RIGHT GUIDE = P107 / RRP PIN 2 Part No. 24H8894 Description Ribbon Guide Kit (Includes left and right guides) Wire Data - IBM 6400-I15 | Maintenance Manual - Page 319
319 Wire Data Part No. 63H7464 Description Cable Assembly, Ribbon Motor, Extension - IBM 6400-I15 | Maintenance Manual - Page 320
Wire Data 320 Part No. 14H5330 Description Cable Assembly, Shuttle Motor Drive - IBM 6400-I15 | Maintenance Manual - Page 321
Wire Data 15 position D-sub receptacle connector with EMI/RFI shield. Jack 1 2 White 14 Gray 7 Shield 5 3 4 Jack Resistance Chart Pin 1 3 1, 2, 3, 4 5 14 7 Pin 2 4 Shield Shield 1, 4 2, 3 Ohms 110 110 55 0 0 0 Part No. 38F8254 Description Cable Assembly, Twinax Auto-Termination 321 - IBM 6400-I15 | Maintenance Manual - Page 322
Wire Data 322 Part No. 14H5522 Description Cable Assembly, Centronics/DataProducts Adapter - IBM 6400-I15 | Maintenance Manual - Page 323
323 Wire Data Part No. 14H5589 Description Cable Assembly, +5V Remote Power - IBM 6400-I15 | Maintenance Manual - Page 324
.2 9 M2 B2 1.5 Ω / PHASE 10 11 12 PI PHA 1 PI PHA 2 PINCH ROLLER MOTOR 13 PI PHB 1 RESISTANCE = 15.2 14 PI PHB 2 1.5 Ω / PHASE 15 16 LD1 A 17 LD1 K 18 DT1 C 19 DT1 E 20 LD2 A 21 LD2 K 22 DT2 C 23 DT2 E 24 25 PID A 26 PID K 27 PID C 28 PID E - IBM 6400-I15 | Maintenance Manual - Page 325
325 Wire Data Part No. 24H8976 Description Cable, Logic, Power Stacker - IBM 6400-I15 | Maintenance Manual - Page 326
Wire Data 326 Part No. 24H8975 Description Cable, Power, Power Stacker - IBM 6400-I15 | Maintenance Manual - Page 327
327 Wire Data Part No. 24H8964 Description Cable, Vertical Rail, Power Stacker - IBM 6400-I15 | Maintenance Manual - Page 328
Wire Data 328 P107 / HBF P107/HBF Part No. 14H5159 Description Fan Assembly, Hammer Bank - IBM 6400-I15 | Maintenance Manual - Page 329
329 Wire Data Part No. 57G1476 Description Magnetic Pickup Assembly - IBM 6400-I15 | Maintenance Manual - Page 330
Wire Data 330 Part No. 14H5282 Description Switch Assembly, Cover Open - IBM 6400-I15 | Maintenance Manual - Page 331
331 Wire Data Part No. 14H5281 (63H5133) Description Switch Assembly, Paper Detector (Standard) (Black Back Forms Kit, 6400) - IBM 6400-I15 | Maintenance Manual - Page 332
Wire Data 332 P107/PLO Part No. 14H5280 Description Switch Assembly, Platen Interlock - IBM 6400-I15 | Maintenance Manual - Page 333
B Printer Specifications Ribbon Specifications NOTE: The ribbon life figures listed below are based on IBM tests conducted in accordance with ANSI Standard X3A.182. Actual ribbon life may vary, depending on the user's quality criteria, printer condition, machine settings, paper quality, and bar - IBM 6400-I15 | Maintenance Manual - Page 334
8 ips 8 ips 10 ips 10.4 ips 10.4 ips 10 ips 10 ips 10.4 ips Labels On Backing: One-part continuous perforated fan-fold back form. Labels must be placed at least 1/6 inch (0.42 cm) from the fan-fold perforation. Backing adhesive must not be squeezed out during printing. 334 Printer Specifications - IBM 6400-I15 | Maintenance Manual - Page 335
-40° to 158° F (-40° to 70° C) Relative Humidity Operating 15% to 80% (noncondensing) Storage 15% to 90% (noncondensing) ENERGY STAR IBM 6400 Series Printers comply with the requirements of the ENERGY STAR Computers Program of the U.S. Environmental Protection Agency. Printer Specifications 335 - IBM 6400-I15 | Maintenance Manual - Page 336
Design Range 88-135V RMS 178-270V RMS Line Frequency RMS Current 47-63 Hz -04, -04P -05 200 V 3A @ 178 V 4A @ 200 V 5A @ 200 V 5A @ 178 V Power Consumption 6400-004 6400-04P 120 VAC 60 Hz Watts BTU/Hour VA Operating DP Mode All H's Max Typical 200 165 680 560 350 Printer Specifications - IBM 6400-I15 | Maintenance Manual - Page 337
180 150 615 510 390 310 Standby Not Energy Star Energy Star 60 25 205 85 145 55 6400-050 6400-P50 120 VAC 60 Hz Watts BTU/Hour VA Operating DP Mode All H's Max Typical 210 180 Standby Not Energy Star Energy Star 80 22 275 75 130 41 Printer Specifications 337 - IBM 6400-I15 | Maintenance Manual - Page 338
Typical 210 180 720 615 435 360 Standby Not Energy Star Energy Star 60 25 205 85 145 55 6400-009 6400-09P 120 VAC 60 Hz Watts BTU/Hour VA Operating DP Mode All H's Max Typical 290 225 Standby Not Energy Star Energy Star 75 25 255 85 150 55 338 Printer Specifications - IBM 6400-I15 | Maintenance Manual - Page 339
Typical 290 230 990 790 600 450 Standby Not Energy Star Energy Star 80 25 275 85 150 55 6400-012 120 VAC 60 Hz Watts BTU/Hour VA Operating DP Mode All H's Max Typical 290 215 990 410 Standby Not Energy Star Energy Star 60 25 205 85 145 55 Printer Specifications 339 - IBM 6400-I15 | Maintenance Manual - Page 340
Typical 380 255 1300 870 710 485 Standby Not Energy Star Energy Star 75 25 255 85 150 55 6400-015 120 VAC 60 Hz Watts BTU/Hour VA Operating DP Mode All H's Max Typical 440 1500 740 Standby Not Energy Star Energy Star 90 27 310 92 170 58 340 Printer Specifications - IBM 6400-I15 | Maintenance Manual - Page 341
Cycle 6400-004, 04P 6400-005, 05P 6400-050, P50 6400-008, 08P 6400-009, 09P 6400-010, P10 6400-012 130, 000 pages per month 130, 000 pages per month 130, 000 pages per month 205, 000 pages per month 205, 000 pages per month 205, 000 pages per month 320, 000 pages per month Printer Specifications - IBM 6400-I15 | Maintenance Manual - Page 342
♦ 63% character density or 83 characters per line ♦ 63% line density or 42 lines per 11-inch page ♦ Single part (18 lb) paper ♦ Printer is installed in accordance with the Setup Guide ♦ Printer is maintained in accordance with this maintenance manual Printing Rates The printing speed of ASCII and - IBM 6400-I15 | Maintenance Manual - Page 343
PER INCH CORRESPONDENCE 90 (180) X 96 DATA PROCESSING 60 (120) X 72 10 12 15 10 12 13.3 15 17.1 DOT MATRIX NOTE UPPERCASE ONLY LPM PERFORMANCE DESCENDERS & UNDERLINE LPM PLOT MODE IPM MODEL 04 04P uppercase symbols G is number of dots available for descenders Printer Specifications 343 - IBM 6400-I15 | Maintenance Manual - Page 344
344 Printer Specifications - IBM 6400-I15 | Maintenance Manual - Page 345
C Metric Conversion Tables Multiply foot foot foot inch inch inch meter centimeter millimeter meter centimeter millimeter * Figure is exact Length By 0.3048* 30.48* 304.8* 0.0254* 2.54* 25.4* 3.280840 0.03280840 0.003280840 39.37008 0.3937008 0.03937008 Multiply pound-inch pound-foot Newton-meter - IBM 6400-I15 | Maintenance Manual - Page 346
Multiply pound* ounce* kilogram gram * avoirdupois Mass and Density By 0.4535924 28.34952 2.204622 0.03527397 To Obtain kilogram gram pound ounce Temperature From To temperature Celsius (tc) temperature Fahrenheit (tf) temperature Fahrenheit (tf) temperature Celsius (tc) Use Formula tf = 1. - IBM 6400-I15 | Maintenance Manual - Page 347
strength 2-56 4-40 6-32 8-32 10-24 10-32 1/4 - 20 25 + 2 in oz 62 + 4 in oz 122 + 7 in oz 11 + 1 in lb 20 + 1 in lb 15 + 1 in lb 40 + 3 in lb 36 + 2 in oz 75 + 5 in oz 150 + 10 in oz 18 + 1 in lb 25 + 1.5 in lb 29 + 2 in lb 62 - IBM 6400-I15 | Maintenance Manual - Page 348
348 Torque Table - IBM 6400-I15 | Maintenance Manual - Page 349
, and service personnel from injury. Use this inspection guide as an aid in identifying possible unsafe conditions in a 6400 series printer. Perform the inspection steps outlined in this guide before the normal inspection for Maintenance Agreement Qualification, or any time you are instructed to - IBM 6400-I15 | Maintenance Manual - Page 350
do the Safety Inspection. Have the following items available: 1. Electrical Safety for IBM Customer Engineers, Order No. S229-8124. 2. A Fluke** meter (P/N printer off-line. 2. Power off the printer. 3. Unplug the printer power cord from the customer's power outlet. 350 Safety Inspection Guide - IBM 6400-I15 | Maintenance Manual - Page 351
Parts Top Cover and Cabinet Doors 1. Inspect the top cover: a. Open the top cover. On cabinet models, make sure the gas spring assembly holds the cover up in the open position. b. Make sure the window path: a. Make sure the service panel permitting access to the 1. Open the printer top cover. 2. - IBM 6400-I15 | Maintenance Manual - Page 352
Inspect Electrical Parts Safety Ground Path 1. Make sure the printer power cord is unplugged. 2. Remove the paper guide assembly (page 235). 3. Make sure the ground cable from the circuit breaker power leads is undamaged and firmly attached to the ground lug on the - IBM 6400-I15 | Maintenance Manual - Page 353
printer frame: safety ground circuits should measure 0.1 Ohm or less. 5. Install the paper guide assembly (page 235). J301 IEC 320 AC POWER CIRCUIT BREAKER Line 1 Line +48V Platen Motor Paper Motion Detector Paper Out Detector Left Ribbon Guide Left Ribbon Motor J106 MSL P106 MSL +48V +5 V +5 V - IBM 6400-I15 | Maintenance Manual - Page 354
outlet. Follow the instructions supplied with the meter IBM Installation Planning Representative (IPR) of any problems with the customer's power source. Each branch circuit must be grounded for safety and correct operation of the printer. This ground must be connected either to the electrical service - IBM 6400-I15 | Maintenance Manual - Page 355
, depending on which power on state was selected when the printer was configured. 6. Power off the printer. Verify that the LCD goes completely blank and all fans stop. Print Interlock Service Check 1. Power on the printer. 2. Open the printer top cover. 3. Open the forms thickness lever. The LCD - IBM 6400-I15 | Maintenance Manual - Page 356
356 Safety Inspection Guide - IBM 6400-I15 | Maintenance Manual - Page 357
0, Address 1, etc. AC Alternating Current ACC Access ACK Acknowledge AMP Amplitude; Ampere AMPL Amplitude AN Anode ASIC Application-Specific Integrated Circuit ATTN Attention B Buffered BANK FAN Hammer Bank Fan BCOM Buffered Communication BCP Bi-phase Communications Processor BHSC - IBM 6400-I15 | Maintenance Manual - Page 358
BSY Busy BTU British Thermal Unit BUD Buffered Upper Driver CA Cathode CC Card Cage CCF Card Cage Fan CE Customer Engineer CHNG Change CIR Circuit CLK Clock CO Cover Open COLL Collector COMM Communication CONTLR Controller CMD Command CMX Manufacturer's designation of the controller - IBM 6400-I15 | Maintenance Manual - Page 359
DSR Data Set Ready DTR Data Terminal Ready EC Engine Controller (a functional unit of the CMX board) EEPROM Electrically Erasable/Programmable Read-Only Memory EHF Exhaust Fan EL Elevator (motor), Power Stacker EMI ElectroMagnetic Interference EMIT Emitter EPROM Electrically Programmable - IBM 6400-I15 | Maintenance Manual - Page 360
Initial Microcode Load INST Instruction INT Interrupt I/O Input/Output IRQ Interrupt Request (J Jack connector L Left LCD Liquid Crystal Display LED Light Emitting Diode LF Line Feed LO Low LPI Lines Per Inch LPM Lines Per Minute LRIB Left Ribbon LRP Left Ribbon Guide M1 Rear Paddle - IBM 6400-I15 | Maintenance Manual - Page 361
-volatile Random-Access Memory NT Not OLV On Line Verify OP Operand P5 5 V dc (P Board Assembly PCB Printed Circuit Board PE Printer Error, Paper Empty PER Peripheral Device Instruction PLAT Platen PLM Platen Motor PLO Platen Open (Switch) PMD Paper Motion Detect (Switch) PN Pin P/N Part - IBM 6400-I15 | Maintenance Manual - Page 362
Ribbon RD Read RET Return RIB Ribbon RG Ribbon Guide RGL Ribbon Guide, Left RGR Ribbon Guide, Right RM Ribbon Motor RML Ribbon Motor, Left RMR Ribbon Motor, Right RQ Request RRIB Right Ribbon RRP Right Ribbon Guide RSP Ribbon Module SLCT Select (On-line) Slew Rapid vertical paper - IBM 6400-I15 | Maintenance Manual - Page 363
STBY Standby STK Power Stacker SW Switch SYNC Synchronize TCB Task Control Block TEMP Temperature TOF Top of Form (first print line) TP Test Point TTL Transistor-Transistor Logic TXD Transmit Data UART Universal Asynchronous Receiver/Transmitter UDPH Upper Drive Phase UNDEF Undefined - IBM 6400-I15 | Maintenance Manual - Page 364
364 Abbreviations and Signal Mnemonics - IBM 6400-I15 | Maintenance Manual - Page 365
13F9998 1 Line Cord, IBM, Denmark 14F0016 1 Line Cord, IBM, Pakistan, South Africa 14F0034 1 Line Cord, IBM, India, United Kingdom 14F0052 1 Line Cord, IBM, Switzerland 14F0070 1 Line Cord, IBM, Chile, Italy 14F0088 1 Line Cord, 9 Feet, Israel 14H5301 1 Line Cord, 6400, 12 Foot - IBM 6400-I15 | Maintenance Manual - Page 366
Part Number Units Description 14H5311 1 Line Cord, 6400, Israel 14H5313 1 Line Cord, 6400, Chile, Italy 14H5315 1 Line Cord, 6400, Switzerland 14H5317 1 Line Cord, 6400, India, United Kingdom 14H5319 1 Line Cord, 6400, Europe (EMEA) 14H5321 1 Line Cord, 6400, Pakistan, South - IBM 6400-I15 | Maintenance Manual - Page 367
H Part Numbers Part Number Page 04H4779 08H7934 08H7936 08H7954 14H5154 14H5159 Scale Clamp, Shaft, Receiving Tractor Shaft Kit Tractor Shaft Hardware Kit Shroud Assembly, Air (Shuttle Cover) Paper Guide Assembly (Models 004, 005, 008, 009, 012, 014) Chain Assembly Kit Shuttle Frame Assy (Models - IBM 6400-I15 | Maintenance Manual - Page 368
Card Cage Fan Cable Assy, Exhaust Fan Centronics I/O Cable Assembly Housing, Connector Kit Cable Assy, AC In, Power Supply (Part of AC Field Kit) Cable Assy, AC Power Input (Part of AC Field Kit) Spares Kit, Grommet Operator Panel Assembly (Cabinet) Cable Assembly, Operator Panel Cable Assembly, MPU - IBM 6400-I15 | Maintenance Manual - Page 369
Part Paper Feed Motor Motor Assembly, Ribbon Cable Assy, Centronics/Dataproducts Coax/Twinax Multi-Platform Interface Logo, 6400 CMX Controller Board, V5.0 (All models 012) Input Tray (Optional) Adapter, Expansion Connector, 60-pin Paper Support CMX Controller Board, V5.5, 25 MHz (All models 005, 05P - IBM 6400-I15 | Maintenance Manual - Page 370
6400 Line Matrix Printer Setup Guide, Japanese Ribbon Mask, 500 (Models 050, P50) Ribbon Mask, 1000 (Models 010, 10P) Ribbon Mask, 1500 (Model 015) Hammer Bank Cover Assy, 500 (Models 050, P50) Hammer Bank Coverr Assy, 1000 (Models 010, 10P) 6400 ASCII Programmer's Reference 6400 IGP User's Manual - IBM 6400-I15 | Maintenance Manual - Page 371
279 261 261 19 321 Description 6400 Code V User's Manual 6400 CTA Programmer's Reference 6400 IPDS Programmer's Reference Ethernet Interface User's Manual Ribbon Guide Kit Hammer Bank Coverr Assy, 1500 Kit Wire Rope Print Server User's Guide Twinax Auto-Termination ("Smart T") Part Numbers 371 - IBM 6400-I15 | Maintenance Manual - Page 372
Ironer Assembly, Reverse Paper Feed Magnetic Pickup Assembly (MPU) Ribbon Hub Kit Gas Spring Kit Caster, with Brake Caster, without Brake Window, Top Cover Platen Pulley, Driven Ground Clip, Splined Shaft Panel Overlay, Dutch Operator Panel Overlay, Braz. Portuguese Stacker 372 Part Numbers - IBM 6400-I15 | Maintenance Manual - Page 373
Control Panel Paper Detector Switch Assy (Black Back) 6400 Line Matrix Printer Configuration Utility Disk Top Cover Seal Kit Cable Assembly, Ribbon Motor, Extension Platen Lever Kit Caster, Pedestal Pedestal Power Supply PCBA (Models 009, 09P, 014) Shuttle Frame Assy (Model 014) Part Numbers 373 - IBM 6400-I15 | Maintenance Manual - Page 374
Part Number Page 90H3271 275 S246-0149 18 Description CMX Controller Board, V5.5, 40 MHz (Models 050, P50, 010, P10, 014, 015) 6400 Coax/Twinax Multi-Platform Interface Option Installation and Operation Guide 374 Part Numbers - IBM 6400-I15 | Maintenance Manual - Page 375
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-Cylindrical core through and around which the control panel cable assembly is wound. Two are - IBM 6400-I15 | Maintenance Manual - Page 376
Connector P110 NOTE: Two turns around each bead. Control Panel Cable Assembly Shielding Bead Parallel I/O Cable Assembly Connector P310 Connector P112 Ferrite Core with Clamp and Adhesive Backing NOTE: This core attaches to right rear card cage wall. Connector J203 Figure 56. Ferrite Core - IBM 6400-I15 | Maintenance Manual - Page 377
model line matrix printers. Because all but a small portion of the stacker assembly is inside the cabinet, the stacker assembly must be removed from the printer in order to service the unit or replace most of its components. This appendix consists of two parts: ♦ Removal/installation instructions - IBM 6400-I15 | Maintenance Manual - Page 378
Removing the Power Stacker 1. Prepare the printer for maintenance (page 194). 2. Unload paper from the stacker area. (Refer to the User's Manual.) 3. Remove the paper tent. (See Figure 57.) Paper Tent Figure 57. Removing the Paper Tent 4. Remove the paper fence. (See Figure 58.) Paper Fence - IBM 6400-I15 | Maintenance Manual - Page 379
5. Remove the paper deflector. (See Figure 59.) Paper Deflector Figure 59. Removing the Paper Deflector 6. Remove three screws and washers from the stacker control panel. (See Figure 60.) Washer (2) Short Screw (2) Washer Long Screw Figure 60. Removing the Stacker Control Panel Power Stacker - IBM 6400-I15 | Maintenance Manual - Page 380
7. Close the top cover, remove four cables from the stacker control panel, and remove the stacker control panel. (See Figure 61.) Logic Cable (P104) Power Cable Frame Cable (P102) Rail Cable (P107) Figure 61. Removing Cables from the Stacker Control Panel 8. Remove the two 5/32 x 3/4 inch screws - IBM 6400-I15 | Maintenance Manual - Page 381
9. Raise the elevator assembly. 10. Loosen the screws securing the vertical rails to the stacker base one turn-do not remove the screws. Each rail is secured by two screws. (See Figure 63.) Elevator Assembly Vertical Rail Stacker Base Washer (2) Washer (2) Screw (2) Screw (2) NOTE: Hardware - IBM 6400-I15 | Maintenance Manual - Page 382
the cabinet floor. (See Figure 62.) 12. Lower the elevator assembly to its lowest position. 13. Tilt the vertical rails toward the front of the printer until they clear the upper frame cross-member. Slide the stacker assembly to rear and angle it out of the cabinet, as shown in Figure - IBM 6400-I15 | Maintenance Manual - Page 383
Power Stacker 1. Prepare the printer for maintenance (page 194). 2. Remove paper. 3. Loosen the three paper path hold-down screws. Slide the paper path to the left and lift it off the card cage. (See Figure 65.) Paper Path Hold-Down Screw (3) Figure 65. Remove the Paper Guide Power Stacker 383 - IBM 6400-I15 | Maintenance Manual - Page 384
4. Connect the power stacker logic cable P103 to connector J17 on the CMX controller board. (See Figure 66.) 5. Disconnect the power supply cable from connector J101 on the CMX controller board. (See Figure 66.) 6. Connect power supply cable connector P101 to the stacker power cable, then connect - IBM 6400-I15 | Maintenance Manual - Page 385
8. Loosen the screws at the bottom of each vertical rail one turn-do not remove the screws. Each rail is secured by two screws. (See Figure 67.) Vertical Rail Screw (2) Screw (2) Frame Cable Rail Cable Vertical Rail Figure 67. Stacker Rail and Frame Cables Power Stacker 385 - IBM 6400-I15 | Maintenance Manual - Page 386
ATTENTION The paper stacker assembly mounts to the rear upper frame cross-member and to the cabinet floor. It is a snug fit. During installation, take care to avoid scratching painted surfaces or damaging the stacker. 9. Position the elevator assembly at the bottom of the vertical rails. (See Figure - IBM 6400-I15 | Maintenance Manual - Page 387
a b Vertical Rail Upper Frame Cross-Member Elevator Assembly Stacker Base c Figure 68. Stacker Installation Power Stacker 387 - IBM 6400-I15 | Maintenance Manual - Page 388
. (See Figure 68c and Figure 69.) 14. Install two 5/32 x 3/4 inch screws and washers to secure the vertical rails to the upper frame cross-member. 15. Install four 7/64 x 1/2 inch screws and washers to secure the stacker base to the cabinet floor. (See Figure 69.) NOTE: Stacker assembly exploded to - IBM 6400-I15 | Maintenance Manual - Page 389
16. Tighten the four screws you loosened in step 8. When correctly installed, the stacker vertical rails are parallel and vertical, as shown in Figure 68c. 17. Install the paper fence. (See Figure 70.) Paper Fence Stacker Base Figure 70. Paper Fence Power Stacker 389 - IBM 6400-I15 | Maintenance Manual - Page 390
18. Gather the rail cable, frame cable, logic cable, and power cable. Make sure these cables are routed outboard of the elevator assembly. 19. Connect the stacker cables to the rear of the stacker control panel assembly, as shown in Figure 71. Logic Cable P104 Power Cable Frame Cable P102 Rail Cable - IBM 6400-I15 | Maintenance Manual - Page 391
stacker control panel as shown in Figure 72, and install the mounting screws. 21. Bundle and tie wrap the stacker control panel cables to the printer frame so they do not catch in the stacker mechanism as it moves up and down. Route the stacker rail and frame cables so they - IBM 6400-I15 | Maintenance Manual - Page 392
rails with the angled portion toward the front of the printer, as shown in Figure 73. 23. Install the paper path that you removed in step 3 (page 383). 24. Install paper and test stacker operation. (Refer to the User's Manual.) Paper Deflector Figure 73. Installing the Paper Deflector 392 Power - IBM 6400-I15 | Maintenance Manual - Page 393
Replacing the Constant Force Spring 1. Remove the stacker assembly from the printer. (See page 378.) ATTENTION In the next step, do not over-tighten the tie wraps or string. Tighten the tie wraps or string just enough - IBM 6400-I15 | Maintenance Manual - Page 394
CAUTION: The constant force spring is a high tension spring. To avoid pinching your fingers, coil the spring slowly and carefully. Do not let the spring twist or crimp. 3. Remove the shoulder screw, washers, and spacer from the constant force spring and drum. Let the spring coil itself up until it - IBM 6400-I15 | Maintenance Manual - Page 395
5. Lift the loose end of the constant force spring and let it curl up on the outside of the remaining spring and drum. (See Figure 76.) 6. While holding the drum tightly, continue to curl the spring until it is completely unwound from the drum. (See Figure 76.) 7. To install a new constant force - IBM 6400-I15 | Maintenance Manual - Page 396
Replacing the Timing Belts 1. Remove the stacker assembly from the printer. (See page 378.) 2. Raise the elevator assembly to its highest position and secure it to the vertical rails using tie wraps or string. (See Figure - IBM 6400-I15 | Maintenance Manual - Page 397
5. Loosen the two setscrews on the motor pulley and remove the pulley. (See Figure 78.) Go to step 6. Timing Belt Motor Pulley Setscrew Setscrew Figure 78. Removing the Timing Belt Motor Pulley 6. Remove the shoulder screw, washers, and spacer that secures the constant force spring to the - IBM 6400-I15 | Maintenance Manual - Page 398
7. Remove two Allen screws from the belt clamp that secures the timing belt to the stacker frame. (See Figure 80.) Allen Screw (2) Allen Screw (2) Belt Clamp Belt Clamp Figure 80. Removing the Belt Clamps 8. Remove the timing belt by working it around the vertical rail and constant force spring. - IBM 6400-I15 | Maintenance Manual - Page 399
. c. While holding downward pressure on the left side of the elevator assembly, tighten the timing belt pulley screw. Illustrated Parts Breakdown The Illustrated Parts Breakdown (IPB) consists of exploded drawings of the power stacker assembly and subassemblies. Each drawing also has a list of - IBM 6400-I15 | Maintenance Manual - Page 400
Detail: Figure 83, page 402 14 10 12 6 35 30 12 10 11 7 7 20 9 25 15 13 20 9 9A 5 12 8 8 Figure 82. Stacker Assembly 400 Power Stacker - IBM 6400-I15 | Maintenance Manual - Page 401
5 6 7 8 9 9A 10 11 12 13 14 15 20 25 30 35 36 Part No. (Order No.) Ref 24H8966 Ref Ref Ref Ref Power Stacker RE Ship Kit, Printer w/Power Stacker Notes Part of item 36 Part of item 36 Part of item 36 Part of item 36 Part of item 36 Mount chains outboard of shafts Part of item 36 Kit not illustrated - IBM 6400-I15 | Maintenance Manual - Page 402
48 47 40 Detail: Figure 87, page 410. 46 45 15 Detail: Figure 85, page 406. 53 15 50 50 46 45 45 46 55 50 60 45 46 52 55 54 65 54 52 49 53 Detail: Figure 86, page 408. 65 - IBM 6400-I15 | Maintenance Manual - Page 403
Item No. 15 36 40 45 46 47 48 49 50 51 52 53 54 55 60 65 Part No. (Order No.) 24H8969 24H9004 24H8978 Ref Screw Support Shaft Fence, Wireform Extension Spring Idler Roller Paddle, Power Stacker, P5XXX Notes Kit not illustrated Part of item 36 Part of item 36 Part of item 36 Part of item 36 Part of - IBM 6400-I15 | Maintenance Manual - Page 404
80 85 90 85 80 75 Figure 84. Stacker Detail: Rollers 404 Power Stacker - IBM 6400-I15 | Maintenance Manual - Page 405
Item No. 36 75 80 85 90 Part No. (Order No.) 24H9004 24H8985 Ref Ref 24H8988 Description Stacker Hardware Kit Compression Spring Friction Washer Flanged Bushing Drive Roller Notes Kit not illustrated Part of item 36 Part of item 36 Power Stacker 405 - IBM 6400-I15 | Maintenance Manual - Page 406
95 95 96 96 Flat Side Flag Connector 100 Key Figure 85. Stacker Detail: Motor Bracket 406 Power Stacker - IBM 6400-I15 | Maintenance Manual - Page 407
Item No. 36 95 96 100 Part No. (Order No.) 24H9004 Ref 24H8999 24H8989 Description Stacker Hardware Kit Clip-On Bearing Holder, LED, Round LED, IR, T-1, 3/4 Notes Kit not illustrated Part of item 36 Power Stacker 407 - IBM 6400-I15 | Maintenance Manual - Page 408
105 Flag 95 Connector Nib Key 95 97 Figure 86. Stacker Detail: Elevator Bracket 408 Power Stacker - IBM 6400-I15 | Maintenance Manual - Page 409
Item No. 36 95 97 105 Part No. (Order No.) 24H9004 Ref 24H9000 24H8990 Description Stacker Hardware Kit Clip-On Bearing Holder, LED, Flat Photodarlington, NPN, Rectifier Notes Kit not illustrated Part of item 36 Power Stacker 409 - IBM 6400-I15 | Maintenance Manual - Page 410
Connector Flag Nib Key 106 107 116 ROTATED 180_ 105 97 97 110 107 108 111 109 115 Figure 87. Stacker Detail: Paper Motion Detector 410 Power Stacker - IBM 6400-I15 | Maintenance Manual - Page 411
. 36 97 105 106 107 108 109 110 111 115 116 Part No. (Order No.) 24H9004 24H9000 24H8990 Ref Ref Ref Ref 24H8991 Lock Washer, #4 Wheel Assembly, PMD Sensor Assembly, PMD Notes Kit not illustrated Part of item 36 Part of item 36 Part of item 36 Part of item 36 Part of item 36 Power Stacker 411 - IBM 6400-I15 | Maintenance Manual - Page 412
412 Power Stacker - IBM 6400-I15 | Maintenance Manual - Page 413
CONFIGURATION, 78 022 UNIT ADDRESS NOT RECEIVED / CHECK PRINTER ADDRESS, 78 024 SERIAL LINE PARITY ERROR / VERIFY CONFIGURATION, 78 025 SERIAL FRAMING 057 CLOSE PLATEN, 83 058 SHUTTLE JAM / SEE USER'S GUIDE, 84 059 CANCEL PRINT ACTIVE, 85 060 PRINTER HOT, 85 062 EXHAUST FAN FAULT, 86 065 HAMMER BANK - IBM 6400-I15 | Maintenance Manual - Page 414
, 94 107 HAMMER COIL (number) HOT, 95 11 inch pages, Printer Information Menu, 148 110 STACK OVERFLOW / SEE USER'S GUIDE, 96 111 STACK UNDERFLOW / SEE USER'S GUIDE, 96 112 UNDEFINED OPCODE / SEE USER'S GUIDE, 96 113 PROTECTED INSTRUCTION / SEE USER'S GUIDE, 96 114 ILLEGAL OPERAND ACCESS / SEE USER - IBM 6400-I15 | Maintenance Manual - Page 415
162 platen open motor pulley alignment, 170 ribbon guide, 172 set shuttle speed, 189 software , 211 Cable assembly interconnections, 293 part numbers, 293 shell and cable replacement service customer's power source, 354 power on/off verification, 355 print interlock, 355 print mechanism, 351 printer - IBM 6400-I15 | Maintenance Manual - Page 416
Adapters, 365 Cores, ferrite (noise suppression), 375 Cover assembly hammer bank / ribbon mask, replacement, 206 shuttle, 209 top, pedestal model, 210 CT board, printer, 335 Display (LCD) cabinet model, 20 pedestal model, 22 Display messages, printing conventions, 18 Documents related to this manual - IBM 6400-I15 | Maintenance Manual - Page 417
Enter key cabinet model, 20 pedestal model, 22 Environmental characteristics, 335 Error log clear, 139 print, 135 Error messages, 57 ERROR: FLASH DID NOT PROGRAM, 106 PROGRAM NOT VALID, 106 SHORT AT ADDRESS XXXX, 107 ERROR: DC PROGRAM NOT VALID, 184 ERROR: DRAM AT ADDRESS (hex), 106 ERROR: DRAM AT - IBM 6400-I15 | Maintenance Manual - Page 418
IBM Coax/twinax expansion board, replacement, 222 Illustrations, replacement procedures, 259 IML, printer does not complete, 122 Information menu, printer, 148 Inspection, safety, guide, 349 Installation, 27 Installed memory, 148 Interface coax/twinax multi-platform, replacement, 205 specifications - IBM 6400-I15 | Maintenance Manual - Page 419
printer, 29 overview, 13 preparing the printer for, 194 preventive, 29 Manual ) cabinet model, 20 pedestal model, 22 Message List (troubleshooting), 58 Messages 001 END OF FORMS / LOAD FORMS, UNIT ADDRESS NOT RECEIVED / CHECK PRINTER ADDRESS, 78 024 SERIAL LINE PARITY ERROR / VERIFY CONFIGURATION, - IBM 6400-I15 | Maintenance Manual - Page 420
JAM / SEE USER'S GUIDE, 84 059 CANCEL PRINT ACTIVE, 85 060 PRINTER HOT, 85 062 EXHAUST GUIDE, 102 130 PAPER FEED PARTLY ENERGIZED / SEE USER'S GUIDE, 102 131 PAPER FEED INTERRUPT / SEE USER'S GUIDE, 102 132 RIBBON INVALID COMMAND / SEE USER'S GUIDE, 102 133 RIBBON INVALID STATE / SEE USER'S GUIDE - IBM 6400-I15 | Maintenance Manual - Page 421
/ SEE USER'S GUIDE, 104 990 MACHINE BOOT CODE, 112 RIBBON OUT OF INK / CHANGE RIBBON, 112 SENDING PROGRAM TO EC PROCESSOR, 113 SERVICE / (first service test), 113 SOFTWARE , 357 Models, printer, 13, 15 Motor paper feed drive, replacement, 227 platen open, replacement, 229 ribbon drive, replacement, - IBM 6400-I15 | Maintenance Manual - Page 422
ironer, replacement, 236 scale adjustment, 166 specifications, 334 stacker, power, 377 tractor (L/R), replacement, 258 Paper detector switch, replacement, 254 Paper guide assembly, removal, 235 Paper jams, 70 Parts illustrations, 259 replacement part numbers, 367 replacement procedures, 192 Phasing - IBM 6400-I15 | Maintenance Manual - Page 423
operator print, 135 specifications, 333 stacker motor check, 130 troubleshooting, 55 Printer information menu 11 inch pages, 148 installed memory, 148 power-on time, 148 print strokes, 148 printing time, 148 Printing conventions is this manual, 18 line matrix printing explained, 35 problems, 55 too - IBM 6400-I15 | Maintenance Manual - Page 424
, platen does not open, 124 Ribbon drive motor, replacement, 231 guide assembly (L/R), replacement, 244 guide assembly, alignment, 172 hub, replacement, 245 mask, replacement, 206 specifications, 333 RIBBON OUT OF INK / CHANGE RIBBON (message), 112 S Safety inspection guide, 349 notices, 12 notices - IBM 6400-I15 | Maintenance Manual - Page 425
Service checks customer's power source, 354 power on/off verification, 355 print interlock, 355 print mechanism, 351 printer problems, 132 Specifications dimensions, printer, 335 duty cycle, 341 electrical, 336 environmental, 335 interfaces, 341 paper, 334 printing rates, 342 ribbon 26 Support shaft, - IBM 6400-I15 | Maintenance Manual - Page 426
customer engineer (CE), 138 print, operator, 135 printer information menu, 148 Time power-on, 148 printing 345 table, 347 Tractor, replacement, 258 Troubleshooting, 55 aids, 55 communications failures, 133 66 Upgrading software, 181 V Vertical spacing problems, 132 View key cabinet model, 20 - IBM 6400-I15 | Maintenance Manual - Page 427
- IBM 6400-I15 | Maintenance Manual - Page 428
© Copyright IBM Corp., 1995, 1998 S246-0117-06 $$07S246011706:b7$$ 24H8887 $$0724H8887:b7$$ 163983-001A
-
1 -
2 -
3 -
4 -
5 -
6 -
7 -
8
-
9
-
10
-
11
-
12
-
13
-
14
-
15
-
16
-
17
-
18
-
19
-
20
-
21
-
22
-
23
-
24
-
25
-
26
-
27
-
28
-
29
-
30
-
31
-
32
-
33
-
34
-
35
-
36
-
37
-
38
-
39
-
40
-
41
-
42
-
43
-
44
-
45
-
46
-
47
-
48
-
49
-
50
-
51
-
52
-
53
-
54
-
55
-
56
-
57
-
58
-
59
-
60
-
61
-
62
-
63
-
64
-
65
-
66
-
67
-
68
-
69
-
70
-
71
-
72
-
73
-
74
-
75
-
76
-
77
-
78
-
79
-
80
-
81
-
82
-
83
-
84
-
85
-
86
-
87
-
88
-
89
-
90
-
91
-
92
-
93
-
94
-
95
-
96
-
97
-
98
-
99
-
100
-
101
-
102
-
103
-
104
-
105
-
106
-
107
-
108
-
109
-
110
-
111
-
112
-
113
-
114
-
115
-
116
-
117
-
118
-
119
-
120
-
121
-
122
-
123
-
124
-
125
-
126
-
127
-
128
-
129
-
130
-
131
-
132
-
133
-
134
-
135
-
136
-
137
-
138
-
139
-
140
-
141
-
142
-
143
-
144
-
145
-
146
-
147
-
148
-
149
-
150
-
151
-
152
-
153
-
154
-
155
-
156
-
157
-
158
-
159
-
160
-
161
-
162
-
163
-
164
-
165
-
166
-
167
-
168
-
169
-
170
-
171
-
172
-
173
-
174
-
175
-
176
-
177
-
178
-
179
-
180
-
181
-
182
-
183
-
184
-
185
-
186
-
187
-
188
-
189
-
190
-
191
-
192
-
193
-
194
-
195
-
196
-
197
-
198
-
199
-
200
-
201
-
202
-
203
-
204
-
205
-
206
-
207
-
208
-
209
-
210
-
211
-
212
-
213
-
214
-
215
-
216
-
217
-
218
-
219
-
220
-
221
-
222
-
223
-
224
-
225
-
226
-
227
-
228
-
229
-
230
-
231
-
232
-
233
-
234
-
235
-
236
-
237
-
238
-
239
-
240
-
241
-
242
-
243
-
244
-
245
-
246
-
247
-
248
-
249
-
250
-
251
-
252
-
253
-
254
-
255
-
256
-
257
-
258
-
259
-
260
-
261
-
262
-
263
-
264
-
265
-
266
-
267
-
268
-
269
-
270
-
271
-
272
-
273
-
274
-
275
-
276
-
277
-
278
-
279
-
280
-
281
-
282
-
283
-
284
-
285
-
286
-
287
-
288
-
289
-
290
-
291
-
292
-
293
-
294
-
295
-
296
-
297
-
298
-
299
-
300
-
301
-
302
-
303
-
304
-
305
-
306
-
307
-
308
-
309
-
310
-
311
-
312
-
313
-
314
-
315
-
316
-
317
-
318
-
319
-
320
-
321
-
322
-
323
-
324
-
325
-
326
-
327
-
328
-
329
-
330
-
331
-
332
-
333
-
334
-
335
-
336
-
337
-
338
-
339
-
340
-
341
-
342
-
343
-
344
-
345
-
346
-
347
-
348
-
349
-
350
-
351
-
352
-
353
-
354
-
355
-
356
-
357
-
358
-
359
-
360
-
361
-
362
-
363
-
364
-
365
-
366
-
367
-
368
-
369
-
370
-
371
-
372
-
373
-
374
-
375
-
376
-
377
-
378
-
379
-
380
-
381
-
382
-
383
-
384
-
385
-
386
-
387
-
388
-
389
-
390
-
391
-
392
-
393
-
394
-
395
-
396
-
397
-
398
-
399
-
400
-
401
-
402
-
403
-
404
-
405
-
406
-
407
-
408
-
409
-
410
-
411
-
412
-
413
-
414
-
415
-
416
-
417
-
418
-
419
-
420
-
421
-
422
-
423
-
424
-
425
-
426
-
427
-
428
 |
 |
6400 Line Matrix Printers
Maintenance Information Manual
Cabinet and Pedestal Models
Form Number S246–0117–06
©
Copyright IBM Corp., 1995, 1998