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6. Inspect the ribbon mask for bends or deformation that block the paper path or prevent paper from exiting the pedestal top cover. Replace a damaged hammer bank cover assembly. 7. Check the condition and tension of the platen open belt. Adjust the platen open belt. Replace the belt if it is damaged. 8. Check the platen open pulley and the platen pulley for looseness. Bottom out the platen open motor pulley on the motor shaft and torque the 1/16 inch set screw to 9 ± 2 inch-pounds (1.02 ± 0.23 NSm). Tighten the 7/64 inch setscrew in the platen shaft pulley, then open 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 worn or damaged, replace both tractor assemblies. 10. Check the condition and tension of the paper feed belt. Adjust the paper feed belt. Replace the belt if it is damaged. 11. Check the platen gap. Adjust the platen gap. 12. Clean the paper motion detector with a cotton swab and alcohol. At the control panel, set the paper motion detector (PMD) fault setting to DISABLE. Load paper. Run a print test and observe how the paper feeds. If the message appears, replace the CMX controller board. Record the message and return it with the defective board. If the message does not appear, replace the paper detector switch assembly and set the paper motion detector (PMD) to ENABLE. 041 BUFFER OVERFLOW 1. The print buffer has overflowed on a serial interface. The printed output may contain random * (asterisk) characters. Make a configuration printout. Verify that the printer matches the host serial interface configuration settings for Data Protocol, Baud Rate, Data Bits, Stop Bits, Parity, Data Terminal Ready, and Request to Send. Set 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 81

Section	Page
Edition Notice	4
Table Of Contents	5
Energy Notice	10
Electrical Safety	10
Trademarks & Service Marks	11
Safety Notices	12
Chapt 1 Maintenance Overview	13
About the Printer	13
The IBM 6400 Series Printer Family	13
Table 1 6400 Printer Family	14
Printer Evolution	15
How to Identify the Printer	15
Important Maintenance Notes	16
About this Manual	16
How to Use this Manual	16
Notes & Notices	17
Printing Conventions in this manual	18
Related Documents	18
Controls & Indicators	20
Figure 2 Electrical Controls & Indicators Cabinet Manuals	20
Figure 3 Electrical Controls & Indicators, Pedastal models	22
Figure 4 Mechanical Controls & Indicators, All Models	24
Tools & test Equiptment	26
Chapt 2 Installation	27
Chapt 3 Preventative Maintenance	29
Cleaning the Printer	29
Cleaning the Exterior	30
Cleaning the Interior	30
Cleaning the Shuttle	31
Cleaning the Card Cage Fan	33
Chapt 4 Principles of Operation	35
Line Matrix Printing	35
Printing Mechanism	38
Shuttle Frame Asm	38
Hammer Bank Asm	39
Shuttle Drive Motor	39
Paper Transport Asm	41
Ribbon Transport System	42
Logic Control	43
Operator Panel	44
CMX Controller	45
Data Controller	47
68E030 Microprocessor	47
Flash Memory	47
DRAM	48
NVRAM	48
VX ASIC	48
Memory Access Controller	48
DRAM Controller	48
DMA Channels	48
Operator Panel Interface	48
DOT Plucking	49
Cajun Bus Interface	49
Ports	49
Host I/O Drivers & Termination	49
Engine Controller	50
80C166 Micropressor	50
Bus cofig	50
Power Reduction	50
EC Flash Memory	50
MECA ASIC	50
Analog Drive Circuitry	50
Power Supply Board	51
AC Power	51
CD Power	52
Printer Interface	52
Graphics	53
Chapt 5 Troubleshooting	55
Introduction	55
Troubleshooting Aids	55
Start of Call	56
Troubleshooting Display Messages	57
Clearing Error Messages	58
Table 2 Message List	58
Troubleshooting Other Systems	66
Table 3 General Symptom List	67
Jams	67
Operator Panel	67
Power/IML Failures	67
Power Stacker	68
Print Quality	68
Printer Operation	68
Ribbon	69
Shuttle	69
Troubleshooting Procedures	70
001	70
002	70
003 - 009	72
010	73
011	73
012	73
013	74
014	74
015	75
016	75
017	76
018	76
019	77
021	78
022	78
024	78
025	78
026	79
027	79
028	79
029	79
031	79
032	80
041	81
042	82
043	82
044	82
046	82
057	83
058	84
059	85
060	85
062	86
065	86
069	87
080	87
081	88
082	88
083	89
084	89
085	90
086	90
087	91
088	92
089	92
090	93
092	93
101	94
102	94
105	94
107	95
110	96
111	96
112	96
113	96
114	97
115	97
116	97
117	97
118	98
119	98
120	98
121	98
122	99
123	99
124	100
125	100
126	101
127	101
128	101
129	102
130	102
131	102
132	102
133	103
134	103
135	103
136	103
137	104
138	104
139	104
990	105
998	105
A97	105
Boot Diagnostics	105
Clearing Program from Flash	105
Driver Bad Circuit Bad	105
Energy Saver Mode Active	105
Dram At Address<>	106
DRAM Not detected	106
Flash did not program	106
Program not Valid	106
Security Pal not detected	106
Short at address XXXX	107
FM Header Error	107
Hammer Bank not installed	107
Hammer Coil Bad	108
Loading Program From Port XXXX	108
Loading Program into flash	108
Not Ready	108
Operator Menu	108
Operator Menu Locked	108
Operator Menu Unlocked	108
PA1 Selected	109
PA2 Selected	109
P05 Diagnostic test passed	109
P17 Security Violation	109
P60	109
P61	110
P62	110
P63	110
P64	110
P65	111
P66	111
P67	111
P68	111
P69	111
Please Wait	112
Ready	112
Resetting	112
Restoring Boot Code	112
Ribbon out of Ink	112
Sending to EC processor	113
Service	113
Software Error	113
Table Mismatch	113
Testing Hardware	113
Top of Form set	113
Waiting for program download	114
Black Squares on Op-Panel	114
Clear Jam instead of LOAD Forms	115
Clear Jam won't clear	116
Downloads constantly fail	117
Flash SIMM Won't copy	118
Horizontal misalignment of characters	118
No Power Op-Panel Blank	119
Op-Panel Blank	120
Op-Panel garbled	120
Op-Panel keys won't work	121
Paper Feeds poorly	121
IML won't complete	122
Power Stacker Not detected	123
Stacker not operating	123
Self Tests won't print	124
Platen won't open during reverse feed	124
Random;y misplaced dots	125
Ribbon fold/feed problems	125
Shuttle won't move	126
Shuttle noisy	127
Stacker chatters at limits	128
Stacker not stacking correctly	128
Stacker doesn't move	128
Stacker elevator does not move	129
Stacker elevator moves by itself	129
Stacker limit switch check	129
Stacker motor check	130
TOF lost	131
Vertical alignment problems	132
Communications Failures	133
Table 4 Common Comm Problems	134
Operator Print Tests	135
Printer Demonstration	135
Print Errror Log	135
Ripple Print	135
All E's	135
All H's	135
All E's + FF	136
Underlines	136
Selecting & Running Operator Tests	137
Customer Engineering Tests	138
Burn in Test	138
Plot Test	138
Shuttle Only	139
Shuttle Slow	139
Shuttle Fast	139
Hammer Phasing	139
End of Forms Adjust	139
Hammer Phase Value	139
EOF Value	139
Clear Error Log	139
Print Partial Line	140
Top Exit Trar Distance	140
Shuttle Speed	140
Set Coil Temperature	140
Selecting & Running CE Test	140
Boot Diagnostics Menu	142
Activating the boot diagnostic menu	142
Exiting the boot diagnostic menu	142
Fig 19 cBoot diagnostic Menu	143
Hex Code Printout	145
ASCII Character Set	147
Printer Information Menu	148
Displaying Printer Information	149
Soft vs Hard Reset	150
Soft Reset	150
Hard Reset	150
Power On Sequence	151
CMX board handshake sequence	151
DC Software Initialization & Power Up	156
Chapt 6 Adjustment Procedures	157
Introduction	157
Preparing printer for maintenance	158
Return to Normal	159
Paper Feed Timing Belt adjustment	160
Platen Open Belt 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 Shaft Skew adjustment	174
End Of Forms distance adj.	175
Hammer Phasing	179
Flash Memory Loading	181
Table 5 Flash Mem Messagee Guide	184
Coil Temp	188
Set Shuttle Speed	189
Chapt 7 Replacement Proceedures	191
Organization of this chapter	191
TOC	192
Preparing Printer for Maintenance	194
Paper Feed Timing Belt	195
Platen Open Belt	197
Cable connector and Shells	198
Fig 30 Connectors Shell Asm	199
Circuit Board controller	200
Circuit Board Power Supply	203
Circuit Breaker	204
Coax/Twinax interface	205
Hammer Bank Ribbon cover	206
Shuttle cover asm	209
Top Cover - pedestal	210
Cabinet doors	211
Ethernet Interface	212
Exhaust Fan - cabinet models	215
Card Cage fan	216
Hammer Bank Fan	217
Hammer Spring Asm	218
Coax/Twinax Expansion Board	222
MPU Asm	223
Memory Mod & Security PAL	224
Fig 34 MeM Mods & Security PAL	226
Paper Feed Motor	227
Platen open Motor	229
Ribbon Drive Motor	231
Network Print Server	232
Op-Panel - Cabinet Model	233
Op-Panel -Pedestal Model	234
Paper Guide Asm	235
Paper Ironer	236
Platen	237
Terminating Resistors	242
Ribbon Guide Asm	244
Ribbon Hub	245
Splined Shaft	246
Support Shaft	248
Shuttle Frame Asm	249
Gas Spring Asm	251
Extension Spring	252
Cover open Switch	253
Paper Detector Switch	254
Platen interlock Switch	256
Tractor	258
Chapt 7 Parts List	259
TOC	259
Covers & Door list	260
Fig 39 Top covers & Door	261
Paper Stacker & Chains list	262
Fig 40 Paper Stacker & chains	263
Control cabinet - list	264
Fig 41 ControlPanel & cabinet	265
Pedestal Detail list	266
Fig 42 Pedestal Details	267
Inside covers - cab list	268
Fig 43 Inside covers -cab model	269
Inside Covers Ped list	270
Fig 44 Inside Covers & Card Cage - ped model	271
Card Cage - Ped list	272
Fig 44a card Cage detail -Ped Model	273
Print Mech -early list	274
Fig 45 Print Mech & circuit boards earlt models	275
Print Mech 7 circuit Boards - late	276
Fig 46 Print Mech & Circuit Boards - late	277
MPU list	278
Fig 47 MPU	279
Tractor Shaft list	280
Fig 48 Tractor Shafts	281
Platen list	282
Fig 49 Platen	283
Motors 7 card cage list	284
Fig 50 Motors, Card Cage Fan	285
Circuit Breaker list	286
Fig 51 Circuit Breaker	287
IBM coax/Twinax board list	288
Fig 52 IBM Coax Twinax Expansion Board	289
Ethernet Interface list	290
Fig 53 Ethernet Interface	291
Appendix A Wire Data	293
TOC	293
Interconnection diag	295
Power Distribution	296
Main Wire Harness	297
CMX Controller	298
CMX Controller (2)	299
CMX Controller (3)	300
CMX Controller (4)	301
Power Supply	302
Coax/Twinax Expansion	303
SureStak Stacker	304
Cable Routing Cabinet Model	305
Cable Routing Mech Base (cabinte model)	306
Cable Routing (pedestal Model)	307
Cable Routing Base Mech (Pedestal Mod)	308
AC Power Cable	309
CabAC Power Input Cable	310
Card Cage Fan cable asm	311
Op-Panel Cable	312
Exhaust Fan Cable	313
Hammer bank logic Cable	314
Hammer Banl Power cable	315
Centronics I/O cable	316
MPU Cable	317
Ribbon Guide kit	318
Ribbon Motor Extension Cable	319
Shuttle Motor Drive Cable	320
Twinax Auto-Termination Cable	321
Centronics/Data Products Adapter Cable	322
+5V Remoter Power Cable	323
Power Stacker Cable Frame	324
Power Stacker Logic Cable	325
Power Stacker Power cable	326
Power Stacker Vertical Rail cable	327
Hammer Banks Fan Asm	328
MPU	329
Cover Open Switch Asm	330
Paper Detector Switch	331
Black Back Forms Kit	331
Platen Interlock Switch Asm	332
Appendix B Printer Specifications	333
Printer Dimensions	335
Environmental Characteristics	335
Temperature	335
Relative Humidity	335
Energy Star	335
Electrical Characteristics	336
Power consumption	336
Interfaces	341
Duty cycle	341
Printing Rates	342
Table 6 Printing Rates	343
Appendix C Metric Conversion Tables	345
Appendix D Torque Table	347
Appendix E Safety Inspection guide	349
Safety inspections	349
Preperation	350
Prepare the Printer for Inspection	350
Inspect Mechanical Parts	351
Top Cover & Cabinet doors	351
Print Mechanism	351
Inspect Electrical Parts	352
Safety Ground Path	352
Customer Power Source Service Check	354
Power Cable	354
Power On/Off Verification	355
Printer Interlock Service Check	355
Appendix F Abbreviations and Signal Mnemonics	357
Appendix G Cords And Adapters	365
Appendix H Part Numbers	367
Appendix I Noise Suppression Devices	375
Appendix J SureStak Power stacker	377
TOC	377
Introduction	377
Removing the Power Stacker	378
Installing the Power Stacker	383
Replacing the Constant Force Spring	393
Replacing the Timing Belts	396
Illustrated Parts Breakdown	399
Fig 82 Stacker Assembly	400
Fig 83 Motor, Roller, & Paddle Asm.	402
Figure 84 Rollers	404
Figure 85 Motor Bracket	406
Figure 86 Elevator Bracket	408
Figure 87 Paper Motion Detector	410
Index	413
Numbers	413
A	414
B & C	415
D & E	416
F	417
G, H I, J, K & L	418
M	419
N, O, & P	422
R	423
S	424