IBM 5256-1, 5256-2, 5256-3 Maintenance Information Manual

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SY31

-0462-0

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IBM 5256 Printer Models

1,

2,

and 3

SY31-0462-0

Maintenance I nformation Manual

Preface

This maintenance manual is

IBM 5256 Printer. Customer engineers using this

manual are assumed

to

education course.

The maintenance

manual is in maintenance and theory. Maintenance includes locations, procedures, and diagnostic aids. Theory includes data

Setup instructions

flow, functional units, and features.

for

Appendix A.

to

be used

for

servicing the

have completed the 5256 Printer

two

major sections;

the 5256 Printer are in

•

IBM

5251 Display Station Model

r,

Information Manual, SY31-0461

• IBM

5256

(MAPs),

Printer Maintenance Analysis Procedures

SY31-0572

• IBM 5251 Display Station Operator's Guide,

GA21-9248

• IBM

5256

Printer

Operator's Guide,

Setup Procedures,

11

Maintenance

GA21-9260

GA21-9290

Definition common

of

terms and abbreviations

but

used

in

this manual are in the glossary and

that

are

not

abbreviations section.

Related information can be found in the following manuals:

• IBM

5250

Display Station Reference Card,

GX21-9429

IBM

5251 Display Station Model

11

Maintenance

Analysis Procedures (MAPs), SY31-0571

• IBM

5256

Printer

IR

ZY31-0505

Note: The following

and caution notices.

notices and

write

pages

If

desired, translate

your own words on the blank lines

provided on these pages:

1-10 1-16 1-24 1-32 1-36

1-37

1-44

1-46 1-58 1-62 1-63 1-64 1-67 4-23

Unit and Cause Code Guide,

of

the M I M

have

danger

these

First

Edition

The information in this manual is sometimes changed.

in

later editions.

Requests representative

A Reader's Comment Form is been removed. address Department 245. Rochester. Minnesota 55901. Comments become the property of

IBM.

for

(October

copies

or

the

1977)

of

IBM

publications should be made

IBM

branch

office

at

the

back

your

comments

Any

serving

your

locality.

of

this

publication.

to

IBM

Corporation. Publications.

changes will be given

to

your

IBM

If

the

form

has

The IBM 5256 Printer has the following specific dangers:

vi

Safety

• The print head becomes very

Primary Power switch.

• High voltage and current are present ferroresonant transformer.

Resistor 1 (in

while

power

is present

front

is on.

under

hot

during printing.

at

the

power

the

safety cover) is very

supply and the

at

the

hot

CE

SAFETY

All

Customer

precaution

tices while

1. You

should

or

around

advise

2. Remove all

bling

major power er

supplies,

3.

After Off

position

229-1266.

4.

When it having live electrical the

fol.lowing

a.

Another be in

b.

Do metal

c. Use

d.

Keep

e. When using

are capacity

f. Avoid

machine chased locally

5. Wear

6.

7.

8.

9.

10. Lift by

11.

12.

13. Place

14.

15. Always place CE tool kit away

safety a. Using a b.

Power c. Using spring d. Soldering, wire e. Cleaning

cals,

f.

Performing

your

Follow ized tasks such as handling high volta'ges.

and

the

Do

not

been

Avoid using proved Replace

this

takes

ment After

shields, signs,

Each no

action

customer

place Ensure machine

one

can

PRACTICES

Engineers are possible maintaining

not

equipment

your

manager if

power, components,

suppiies,

or

installing changes

turning

off

or

tag it

Pu

II

is

absolutely

exposed

circuitry

precautions:

person

immediate

not

wear

cuff

links.

only

insulated pliers

one

hand

set

or

maintenance,

Customer

removed

where

test

correctly

are

contacting

frames,

glasses

hammer

or

hand

parts

etc.

any

eyes. REMEMBER - THEY

special safety

These

safety

portion

use solvents, chemicals, greases,

approved

tools

by

IBM.

worn

or

standing

strain

parts

weighing

and

on

his

personnel

machine

no

that

all

machine

to

customer.

trip

over it;

expected

and

observe

IBM

work

ac

performing

wall

power

operating

familiar

vicinity.

rings,

in

instruments,

and

used.

if

necessary.

when:

to

drilling, reaming, grinding,

hooks,

cutting,

with

other

by

or

broken

or

pushing

off

back

restore

grounding

Engineer

part

one

can

the

equipment:

alone

under

with

dangerous

you

MUST

and

dc,

working

mechanical

box

power

with a "Do

supply

necessary

mechanical

anywhere

with

wrist

watches,

and

pocket.

that

insulated

ground

etc.).

to

potential

Use

drive pins, riveting, staking, etc.

attaching

removing steel

solvents, sprays, cleaners, chemi-

work

instructions

cathode

instructions

of

the

maintenance

IBM.

test

equipment

tools

up

muscles. Do

over

60

all

wires. -

is

responsible

renders

products

hazards.

covers in a safe out-of-the-way trip

over

covers are

for

example,

to

take

following

when

in

cord

to

screwdrivers.

be

suitable

that

and

with

pounds.

safety

from

every safety

safety

hazardous

voltage. Always

work

alone.

removing

in

immediate

inspection

machine

switch, lock it

Not

Operate"

whenever

work

on

equipment

parts

in

power

springs.

when

are

them.

under

or

the

machine,

off

controls

chains, bracelets,

certain

that

probes

(melal floor strips,'

rubber

bands.

may

be

ARE

performing

ray

tubes

outlined

manuals.

or

oils

that

have

test

equipment.

stronger

not

lift

devices, such as guards,

to

be

unsafe

in

place

before

walk areas

desk

prac·

conditions

or

assem·

areas

of

circuitry.

hazardous YOUR EYES.

pow-

in

the

tag,

Form

possible.

exposed

observe

must

or

controls

of

proper

mats,

pur-

etc.

to

special-

and

extremely

in

CEMs

that

have

not

been

leg muscles -

any

equip-

certain

that

or

exposes

returning

where

or

no

table.

ap-

16.

Avoid

touching

checking for

17. When using

18.

19.

20.

21.

be

may Avoid wearing loose

chinery. the

elbow.

Ties

must nonconductive) chains are

Before starting customer

Maintain forming

Knowing An unsafe Use

ARTIFICIAL

General

1.

2.

3.

4.

5.

6.

Rescue Breathing

1. Place

2. Clear

3. Tilt

4. Lift jaw

5.

6.

7.

8.

9.

Considerations

Start

Immediately -Seconds

Do

not from danger. Do loosen

clothing,

Check

Mouth

Remove foreign objects. Pull

Loosen

Take

care

self

or

when

Remain in Position

After

victim revives, be ready

necessary.

Call a

Doctor

Have

someone

Don't

Give Up Continue without

victim throat

head

Pinch nostrils Blow

until

Remove

Listen for snoring

tion.

Repeat

Continue

Thumb finger positions

moving mechanical

play,

stroboscope,

moving.

Shirt

sleeves

be

tucked

approximately

not

recommended.

equipment,

personnel are

good

housekeeping in area

and

after

safety

act

good

judgment·

RESPIRATION

move victim unless absolutely necessary

Clothing

help

up

your

mouth

and

not

warm

for

Obstructions

- Keep Victim Warm

of

these help

is

summon

without

or

is

for

on

his

of

water,

back

to

keep

to

prevent

you

see

lips

to

rescue

breathing

etc.

do

not

touch

clothing

in

completing

rules is

will inevitably lead

items

available.

interruption certainly

must

be left

shirt

or

make

not

in a hazardous

not

eliminate

wait

or

the

victim,

after

medical aid.

dead.

that

may be

have a tie clasp (preferably

3 inches from

certain

maintenance.

enough.

unsafe

Count

look

for

or

tongue

victim

to

resume respiration

until victim

Adults

back

immediately.

food,

or

foreign

open

air passage.

tongue

out

of

air passage.

air leakage

chest

rise.

and

allow lungs

and

gurglings - signs

mouth

breathing

until

to

victim

Final mouth

parts

when

ANYTHING - it

caught

buttoned

of

when

10-20

mouth~to

or

fellow CEs

position.

machine

to

an

accident.

acts.

help

or

apply

stimulants.

forward.

is

breathing

is

matter.

you

empty.

of

throat

times a minute.

breathes

position

end.

stop

breathing

lubricating,

in

mao

rolled above

Tie

and

while

per·

to

remove to

by

him-

if

blow.

obstruc-

for himself.

CE

Safety

Practices

5256

MIM

vii

viii

Contents

SAFETY

GLOSSARY

LEGEND

USING THE

MAINTENANCE SEQUENCE-AFFECTED LOCATIONS 100 101 102 103 Printer Mechanism

104 Printer Mechanism Base Locations. . . . . . . . . . .

105 106 107 108 Cabling Locations and

COVER . . . . . . . . . . .

110

111

SERVICE POSITIONS 115

116 PART 117

FORMS MOVING PARTS. . . . . . . . .

120

121

122

............................•.....

OF

TERMS AND ABBREVIATIONS

.................................

IBM

5256

MAINTENANCE INFORMATION

MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . xvii

Glossary

Maintenance. . . . . . .

Wiring Diagram Diagnostic Aids Preventive Maintenance Tools and Test Theory Features Appendix A . Index

Service Position) . . . . . . . . . . . . . . . . . . .

in

Motor Cables (EC2

Adjustment Top

Back Cover Removal Front

Control Panel Removal AC Cable Assembly Removal and Replacement

For

Removal and Replacement

Adjustment

Removal, Replacement,

of

Terms and Abbreviations

.......

Equipment.

..........

....

.....

Front Front Back Locations

Power Planar Board Power

Printer Covers . . . . . . . . . . . . . . . . 1-12

Cover Removal and

Control Panel and

Separating

Service

Moving

NUMBERS. . . . . . . . . . . . . . . . . . . . . . . 1-16

Boards, Card, I nterposers,

Platen

Platen Latches (Release Eccentrics and Springs)

Platen Gears and Bushing. . . . . . . . . . . . 1-18

.

..............

...........

and

Right Side Locations

and

Left Side

...........................

Supply

Board A 1 Locations and Jumpers. . . . . .1-7

Bl

Adapter

. . . . . . . . . . . . . . . . . . . . . . 1-12

Cover Removal and Replacement

the

Printer

Positions.

the

Power Supply for Printer Servicing

and

Paper Deflector

..........

..

.

PROCEDURES.

Locations.

Bottom

Locations

Board

to

AC

........................

and

Cl

Locations. . . . .

Station

TPBl

Replacement.

and

Replacement

Cable Assembly and

Replacement

From

. . . . . . . . . . . . . . . . . . . 1-14

and

...................

....................

and

....

... " .. . . .

.

"

.....

.

....

. . . . . . . . . . . . .

Locations (Print Mechanism

Jumpers.

Protector

and

TPB2)

...............

.............

the

Power

Jumpers.

" . . . . . . . . . . . . . 1-18

Adjustment. . . 1-18

.........

......

..........

..•........

. . . • . . . .

...........

. . . . .

............

...........

........

Supply

Board A 1

..... " ..

. . . 1-16

..

...

..

.1-12

.1-17

.......

xiii xvi

xvii

xvii xvii xvii xvii xvii xvii

xviii xviii xviii

1-1 1-1

.1-2

.1-3

1-4

.1-5 .1-6

.1-8

1-9 1-10 1-10 1-12

1-12 1-12 1-13 1-13 1-13 1-14

1-16

1-17 1-17 1-18

vi

Adjustment

124

Platen Gear Backlash (Play)

Adjustment

125

Forms Motor Gear Backlash (Play)

Adjustment

126

Forms

Removal

Disassembly

Assembly

127

Forms Feed

Adjustment

128

Forms Service Adjustment

129

A-Frame

Service

Alignment

130

End-of-Forms Switch Service Check Adjustment

Removal and Replacement. . . .

Forms

131

Removal Disassembly and Assembly

Left

132

Forms Service Check

Adjustment

133 Forms

Removal and Replacement

134

Forms

PRINTER EMITTER. . . . . . . . . . . . . . . . . . . . . . . 1-36

140

Print

Service Check Adjustment

Printer

Replacement

141 Print

Removal and Replacement. . . . . . . . 1-38

142

Print

Adjustment

143 Left Margin

Service

Adjustment CARRIER 150

Carrier Main

Service Check

Adjustment

151

Carrier

Removal and Replacement. .

Carrier and Main

152

Removal and Replacement

153

Belt Tensioner Assembly

Removal and

154

Carrier

Removal and Replacement

155

Carrier Leaf Spring and Bearing

Removal and Replacement

.........

.............

. . . . . . . . . .

Motor

and

Replacement

.........

...........

Emitter

.........

Motor

Check.

. .

...

Check.

...

..... ' ..

Tractor

and

Replacement

Tractor

Acljustment

Tractor

. . . . . . . . . . . . . . . . . . . . . . .

Tractor

Guide Rack

Emitter

. . . . . . . . . . . . . . . . . . . . . . . . · . 1-36

Emitter

............................

Emitter

.. ..

Check.

..

.....

and

.............

Support

Replacement

Motor

Platen Pressure Rolls

123

.............

.

...

. .

and

Emitter

to

Emitter

......

Unit

Unit Chain Cover

..............

Unit Chain

Board

......................

Pickup and Amplifier Removal and

Board.

Hold Down

Support

..........

Shaft

and

.

..

. .

Disk

..

.

Timing

..

. .

....

.

.....

.

.....

......

....................

Static

to

Pickup

. . . . . . . . . . 1-38

.......

...

Pulley

.

..

...................

Eliminator

and

Amplifier Card .

Bracket.

Shafts

..

.

. .

.. ..

. .. ..

. . . . . . . . . . . . . . . . 1-43

....

.

Replacement.

·

•......

·

.......

·

.......

·

.......

·

.......

.

.....

·

.......

. · . 1-36

·

...

·

...

·

...

·

...

·

...

·

...

·

...

·

...

·

...

·

...

·

...

·

...

·

...

·

...

·

... ...

·

...

·

...

·

•..

· . 1-19 1-19 1-20 1-20

1-21 1-21 1-23

· . 1-23 .1-24

·

.1-24

1-25 1-25

· . 1-26 1-26

· . 1-27 1-29 1-29 1-29 1-30 1-30 1-30

1-30 1-32 1-32 1-32 1-33 1-33 1-33 1-33 1-35 1-35

. . 1-35

·

.1-36

1-37

..

1-38

· . 1-38 . 1-38

·

.1-38

· . 1-38 .1-40

·

.1-40

·

.1-40

·

.1-40

· . 1-41

· . 1-42 1-42

1-43 1-43

·

.1-43

PRINT HEAD

...

160

Print Head . .

Service

Check.

Adjustment

. . . . . . . . . . . .

·

.1-44

·

.1-44

·

.1-44

·

.1-44

Removal and Replacement. . . • . . . . . . . . . . 1-44

161

Print Head Forms Guide

....................

1-45

Adjustment

. . . . . . . . . . . . . . . . . . . . . . . . . . 1-45

Removal

and

Replacement. . . . . . . . . . . . . . . . 1-45

162

Print Head Cable

(EC1).

. . . . . . . . .

.......

1-46

Removal.

. • . . . . • . . . • . . . . . . .

.........

1-46

Replacement. . . . . . . . . . • . . . . . . . . . . . . . . . . . 1-47

163

Oil

Felt

Service. . . . . . . • • • . . . . .

........•

1-48

164

Print Head Ribbon Lifter

..••..........••..••

1-48

Removal and Replacement

...•..........•....•

1-48

165

Print Head Ribbon Shield

...........••.....••

1-49

Service Check

..........••••..•.•......••

1-49

Removal, Replacement, and

Adjustment

.•••.•••...•

1-49

166

Copy Control Dial

.........•.•.•...•••.••.

1-51

Removal

and

Replacement

.....••...•..•....•.

1-51

167

Print Head

Retract

Ramp.

. . . . . . . .

.......

1·51

Adjustment.

. . .

..

. . . . . . • . . . .

.....

1·51

RIBBON DRIVE

.................•.........

1·52

170

Ribbon Drive

...........................

1-52

Removal and Replacement. . . . . . . . .

...

1-52

171 Ribbon Drive

Clutches.

. . . . . . . . 1-52

Removal and Replacement. . . . . . 1-52

172

Ribbon Drive

Shaft.

. . . . . . . . . . . . 1-52

Removal and Replacement. .

• . . . . . 1-52

173

Ribbon Drive

Lines.

. . . . • . . . . . . . 1-52

Removal and Replacement. . . . • . . . . . . . . . . . . . 1-52

174

Ribbon Feed Rolls. . . . . . . • . . . . . . . . .

.....

1-54

Service Check

..........

.

......

1-54

Adjustment

. . . . . . . . . . . .

......

1-54

Removal and Replacement. . . . . . . . . . . . 1-54

175

Ribbon Drive Gears . . . • . . . . . • . . . . . . . . . . . . . 1-54

Removal and Replacement

..•••....•••.•......

1-54

176

Ribbon

Box and Cover

..•.......•••.

~

......

1-54

Removal and Replacement. . . . . . . . . . . • . . . . . . . . 1-54

177

Ribbon Changing

.......•......•.•.......

1-55

. POWER AND ELECTRONICS

•.•.•.••••••.......

1-57

180

Power

Supply

.••..•.•.....•

_

•••....•...

1-57

Removal

and

Replacement. . • • . . . . . . . • • • • . _ . . . 1-57

Ripple Level Check

....••••.•..•.....

_ .

__

• _ 1-57

181

Power

Transformer

.••..••..........•.....

1-58

Removal

and

Replacement

__

• . . • . • • • . • . . . .

••••

1-58

182

Fans

...................•........•.••

1-60

Fan

B1

Removal

and

Replacement

........•...•••

1-60

Fan B2 Removal and Replacement

................

1-60

183

TB2

and Line Filter

.......................

1-60

TB2 Removal

and

Replacement

.................

1-60

Line Filter Removal and

Replacement. ~ ...........

1-60

184

Power

Adapter

Board

C1

and Capacitor Assembly

.....

1-62

Capacitor Service

Check.

. . . . . . . . .

.........

1-62

Removal and Replacement. . . . . . . . . . .

.......

1-62

185

AC Capacitor (C12) and Capacitor

C3

..........

1-63

C12 Removal and Replacement

.................

1-63

C3

Removal and Replacement. . . . . .

..

.

.......

1-63

186

Power

Supply

Board A 1 and Cable

..........

1-64

Removal and Replacement

.....................

1-64

187

Transistor (Q1).

.........................

1-65

Service

Check.

. . . . . . . . . . .

.........

1-65

Removal and Replacement. .

-.

.

188

Planar Board

B1

......

.

Removal and Replacement. .

189

Printer Wiring Diagram

...

·

.........

1-65

·

.........

1-67

·

.........

1-67

.

...........

1-68

DIAGNOSTIC

AIDS.

·

...

1-70

190

Power

on

Diagnostic

..............

.

·

...

1-70

191 Offline Tests

....

.

·

...

1-74

Print Test (PRT04)

...........

.

...........

1-74

Carrier Motor (PRT05)

.........

.

· . 1·75

Forms Motor (PRT06)

..

.........

1-75

Alignment (PRT07).

...

Print Character

Set

(PRT08).

..

Print Receive Buffers (PRT09) .

Left Margin Recognition

(PRT10) .

Printer Characteristics Display (PRT11)

....

Data Storage (PRT12)

.........

.

Address Switches

(PRT13).

......

.

Set

Transparent Mode (PRT14)

..

.

Print WireslTab (PRT15).

192

Online Tests

............

.

Online Tests Overview

.......

.

Matrix

Printer Verification

Test

(Online Exerciser)

•.

Matrix Printer Verification

Test

Printout

....••.

Matrix Printer Verification Test (Online Exerciser)

· . 1-75

· . 1-76

·

...

1-77

·

...

1-77

· . 1-77

· . 1-78

·

.1-78

· . 1-78

· . 1-79

·

.1-80

· . 1·81

·

.1-82

·

.1-86

Printout

in

Transparent Mode (Partial) . . . . . . . . . . 1.87

Fierd Definition

of

Error History Table (Sample Printout) . 1-88

193

Error Codes, Lights, Switches, and

Test

Points. . • . 1-89

Error Codes and Descriptions . . . . . . . . . . . . . . 1-89

Lights. . . .

• . . . . . • . . . . . • . . . . . . . . . . . 1-90

Control Panel Switches. . . . . . . . . . . . . . . .

..

1-93

Test Points. . . . . . . . . . . • . . . . . . . . . . . . . 1-93

195

Print Quality and Registration Problems

........•..

1·94

Print Quality Problem Examples

................

1-94

Registration Problem Examples

•................

1-95

196

Probe, Probing Information, and Interposer Check

.....

1-96

Probe

Setup

and Accessories. . . . . . . . . . . . . . . . . . . 1-96

Probe

Power.

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-96

Probe Test

.............•...............

1-96

Probe Light Conditions

..•.......•.....•.....

1-96

Probing EC1, EC2, and C1A 1

..................

1-96

Continuity Check

for

Interposers

................

1-97

Removing Wire

From

Plugs P2, P3, P4, and P5

......•.

1-97

PREVENTIVE MAINTENANCE

•••••••.•.•.•...•••

2·1

TOOLS AND

TEST

EQUIPMENT

••••••....••..••••

3-1

General Logic Probe

........................

3-1

Standard

CE

Tool Kit . . . . . . . . . . .

..........

3-1

Metric Tool Kit

...........................

3-1

Contents

5256

MIM

ix

x

THEORY INTRODUCTION

••••••••.•••••••••.•••••••••••••

................

Printer Operation Overview and Data Flow System Configuration Cable

Adapter.

Frame

Concept Transmission

Commands. . . . . .

Poll Response Frames Read Status Response Frame

. . . . . . . .

.......

Sequences

~

..

. . . .

..

. .

.....

Printer SCS Formatting Control Characters Set

Graphic Error Action Summary

Set

Horizontal Format Summary

Set

Vertical Interface Poll for Write Data

Format

...........

Status.

...

Summary

. . . . . . . .

..

....

.

Data Transfer .

Microprocessing Unit

...

Read/Write Storage. .

Internal Processing Queues

Control Panel

Sense

and

Latches.

CE Lights

. . . . . . . . . . .

Print Emitter Control and Print Timings Power and Signal Distribution Power On and Power Off Timings

Print Timings Printer

Functional Parts

Motors Print Head Carrier·

........

to

Adapter Interface.

..

. ..

.

.............•.......

..

.....

...

.

...

.

Print Emiiter and Print Emitter Pickup

Ribbon Drive . . . . .

Forms Feed

.......

Forms Tractor Unit

...

..

. . .

.

.....

...............

'.

............

.

..•.....

....

.

..

. .

. . .

.....

.

.....

.

· . .4-9

·

.4-10

·

.4-11

·

.4-12

·

.4-12

·

.4-13

·

.4-13·

·

.4-13

·

.4-13

•

.4-14

·

.4-15

·

.4-15

·

.4-15

·

.4-17

·

.4-17

·

.4-18

·

.4-20

·

.4-20

...

· .

·

.4-23

·

.4-23

·

.4-25

·

.4-33

·

.4-34

•

.4-36

·

.4-37

4-1 .4-1 .4-2 .4-5 .4-6 .4-6 .4-7 .4-8

4-19

4~22

4-41

FEATURES Cable Audible Alarm

APPENDIXA. SETTING SECTION 1. Standalone CABLE THRU FEATURE

.•••.•••••.••••••..•••.•••..•.•

Thru.

. . .5-1

..............................

UP

THE

IBM

Checkout.

......................

SECTION 2. CONNECTING TO THE

PROBLEM CHECK LIST

......................

5-1

5-2

5256

PRINTER

.••.

A-1

. . . . . . . . . . . . . . . . A-2

A-7

SYSTEM.

. A-8

A-11

Preventive Maintenance, Tools

and

Test

Equipment

Glossary,

Affected,

Seq.

0

Remove, Replace,

Adjust

Locations

Wiring Diagram, Diagnostic Aids

PM, Tools

xi

Theory, Features

o

Appendix, Index

xii

This page

is

intentionally

left

blank.

Glossary

of

Tenns

and

Abbreviations

This list includes

MAPs

as

well

A-frame:

words

as

those used in this manual.

The part

of

the printer

platen and pressure rolls.

ALU:

Arithmetic

amp:

Amplifier.

amplifier

of

size

AR:

a signal.

Amplifier.

AR-DF:

AR-MD:

ASCII:

(amp

Differential amplifier.

Amplifier

American National Standard Code

and logic unit.

and

AR):

for

driving magnets.

Information Interchange.

backiash:

belt

Gear play.

tensioner:

The part

belt.

and abbreviations used in the

that

supports the

A device used

to

increase the

for

that

gives tension

to

the drive

deflector:

detenting:

dr:

Drive.

EBCDIC:

A part

that

moves something away.

Locking.

Extended binary coded decimal interchange

code.

EC: Engineering change.

emitter:

EOM:

EOQ:

A device

End

of

message.

queue.

that

generates pulses

E1, E2, E3: Print emitter pulses.

FB

(fuse):

FF:

A fuse

Form-feed

that

switch.

opens the circuit

FL: Latch (flip latch).

frame: A 16-bit

group

that

carries information.

of

electricity.

with

no delay.

blows,

buffer:

blown

(fuse): Open

or

opens.

A small special storage device.

C: capacitor.

carrier:

The part

of

the printer

that

carries the print

head and ribbon box.

CE: Customer engineer.

chk: Check.

com: The common connection on a switch.

compression small space so

spring:

that

A spring that is pressed into a

it

can supply force.

CR: Diode.

crooked:

Skewed; not straight; sloping.

FRU: Field replaceable unit.

GLP: General logic probe.

gnd:

Ground.

10: Identification.

interposer:

A small connector

(see reference 196).

IRS:

Interchange record separator.

J:

Jack.

LF: Line feed switch.

line

turnaround:

See the System Theory Maintenance

Diagrams manual.

MAPs:

MHz:

Maintenance analysis procedures.

Megahertz.

with

pins on both sides

Glossary, Seq.

Affected,

Loc,;

Glossary

of

Terms

and

Abbreviations

5256

MIM

xiii

microprocessor:

MIM:

Maintenance information manual.

Microprocessing unit.

reinstall:

remove:

Put back the part

Take a part

off

that

was

the printer.

xiv

removed.

mini-MAPs:

miscellaneous MAP: A MAP

parts sequentially when locate the problem.

MPU:

Multi:

N:

Not

N/C:

Normally closed

N/O:

osc: Oscillator.

P:

Plug

pickup:

planar: character generator, cable adapter, control storage,

control panel adapter, printer adapter, data storage, and

the offline tests.

poll,

polled,

if

it

is ready

MAPs

0500

all other

Microprocessing unit.

A switch setting on

(inverter).

point

Normally open

A device

The electronic board

polling:

to

that

send

point

senses electrical pulses.

To

question a station

or

to

through 0516.

that

guides you in replacing

MAPs

have

the

general logic probe.

of

a switch.

of

a switch.

that

contains the MPU,

receive data.

failed

to

determine

replace, that

retract head away far

ribbon

the

is moved.

s:

S8

SCS:

SOLC: Synchronous data link control.

serv:

short:

sideframe: mechanism.

SL

SNA:

replaced:

was

removed.

ramp:

from

as possible

drive

ribbon drive clutches

Set

(fuse):

T:.

A fuse

SNA

character string.

Service voltage

Shorted

A plate on each side

Solid

logic

System

Put a

The metal blade

the

platen when the carrier is moved as

to

the

lines:

The material

that

or

grounded circuit.

technology.

network

new

part back in place

that

left

in the printer.

that

to

drive them

opens the circuit after a delay.

or

ground.

of

architecture.

of

one

moves the print

is wrapped around

when

the carrier

the printer

POR: Power on reset.

power indicate

pressure

the platen

prt:

pulsing:

conditions

pwr:

Q:

r: Reset.

reg:

on

transition

that

power

is on in the printer.

rolls:

Rubber rollers that press paper against

of

the

printer.

Print.

A distinct change between the on and

of

the lights on

Power.

A symbol

Register.

for

transistor.

bit: A bit

the

sent

to

the controller

off

general logic probe.

to

solid:

A continuous failure

SP:

Stop.

ST:

Start.

static

eliminator: attaches removes electrical move through the printer.

stepper

synchronization:

same

stuck:

TO:

TP:

to

the

motor: A motor

time.

Unable

Time delay.

Test point.

A printer part (reference 100

forms

rack. The static eliminator

c~arges

Two

or more events occurring at the

to

move.

or

indication.

that

build up when the

that

moves in regular steps.

II>

forms

that

TPB:

Taper pin block.

tractor

chains:

The parts on the tractor

that

protrude

through the forms.

transition:

Changing

from

active

to

inactive

or

from

inactive

to

active.

twinaxial:

A cable made

of

two

twisted wires inside a

shield.

Vac:

Volts alternating current.

Vdc:

Volts direct current.

Glossary, Seq.

Affected, Loc

..

Glossary

of

Terms and

Abbreviations

5256

MIM

xv

Legend

o

(--)

Decision Block

Information

Block

Note Block

On-Page

Connector

Off-Page Connector

Start

or

End

of

Flowchart

Display

Screen

xvi

Using

the

IBM

5256 Maintenance

InfonnationManual

The information in this manual is reference material when diagnosing machine failures. The maintenance information manual contains maintenance procedures, diagnostic aids, theory, and

level logics.

high that

is

not

the

5256 Printer (information such as setup procedures).

This

manual is engineering change controlled and revised possible

The section number, YYY is (although not

Reference methods used in the maintenance information manual are:

MAP drawings and maintenance procedures

the

emitter disk adjustment. section are information. For references are:

with

specific number

as

for

format

not

practical

MAP

3-digit

-Page-to-page On-page

3-digit

MAPs. For example, 127 indicates the

named

An

appendix gives general information

directly associated

needed

to

give you the latest information

diagnosing problems.

for

page numbering is

the

n.ormally used) is

to

give

new

numbers

reference numbers

reference numbers are assigned

Page-to-page

the

specific page containing the

example,

this

page,

see

or

numbered parts, the reference is

or

name

of

to

be used

with

the

maintenance

X-YVY.Z.

page number, and Z

for

expansion when

to

all pages.

to

reference

forms

references in a

see

page

4-15.

On-page

below, ·etc. For figures

the part.

as

X is

to

of

will

be

the

it

is

location

from

feed

to

the

Maintenance

This section contains location drawings and maintenance

procedures MAPs of

2 types: a reference drawing showing

functional units, and detail location drawings showing

the

FRUs in a functional unit. Maintenance procedures are service checks, adjustments. numbers assigned

Wiring

A wiring figure shows the

individual electrical FRUs in the printer.

Diagnostic

This section contains diagnostic program descriptions,

how

control. To aid in diagnosing machine failures in greater

detail, a list

Preventive

Parts needing regular service are described in this

section.

for

diagnosed

All procedures have

Diagram

Aids

to

use them, and

if

error conditions is included in this section.'

Maintenance

repairing

or

installing FRUs

as

failing. The location drawings are

the

removals, replacements, and

to

reference

point-to-point

what

3-digit

from

is available when they are in

reference

the MAPs.

wiring between

that

the

major

Glossary

This section contains definitions

abbreviations M

Glossary, Seq.

Affected, Loc

of

Terms and Abbreviations

that

I M and MAPs.

..

are

not

of

common,

terms and

but

are used in the

Tools

and

Test

Equipment

The tools needed this section.

to

service the printer are described in

Theory

The theory section contains descriptions functional units and features. These descriptions are preceded by a general idea function or feature

view

of

the system that gives you a

of

the complete operation and where each

fits

in.

Using the

MIM

of

5256

the

MIM

xvii

Features

The features section describes the operation

of

features

for

the printer.

Appendix A.

Appendix A contains the setup procedures.

Index

The index is a detailed list

of

all material in the

maintenance information

manual.

xviii

Sequence-Affected Procedures

Following is a list

of

sequence-affected procedures. Enter each list at any point, but perform all indicated operations from the entry point

to

the end

of

that list.

126 Forms

Motor

and Emitter Disassembly

125 Forms

Motor

Gear

Bac~lash

(Play)

plus

127 Forms

Feed

Emitter Disk Adjustment

128 Forms

Motor

to

Emitter Timing

124 Platen Gear Backlash

(Play)

End

121

Platen

Latches

(Release

Eccentrics

and

Springs)

Adjustment

or

129 A-Frame Alignment

(see

next list

also)

124 Platen Gear Backlash

(Play)

End

123 Platen Pressure Rolls Adjustment

or

129

A-frame

Alignment

(see

preceding list also)

130 End-Of-Forms Switch Adjustment

Glossary, Seq.

Affected,

Lac

..

End

Maintenance

140 Print Emitter Board and Print Emitter Board

to

Pickup and Amplifier Card Removal and

Replacement

or

141

Print Emitter Board Removal and Replacement

or

152 Carrier and Main Shaft Removal and Replacement 151

Carrier Support Shaft

Removal

and

Replacement or

162 Print Head Cable Removal and Replacement

or

140 Print Emitter Board and Print Emitter Board

to

Pickup and Amplifier Card Adjustment

143 Left Margin Adjustment

End

164 Print Head Ribbon Lifter Removal and

Replacement

or

166 Copy Control Dial Removal and Replacement

or

160 Print Head Removal and Replacement 160 Print Head Adjustment

End

Maintenance

5256

MIM

1-1

1-2

Locations

100

FRONT

AND

RIGHT SIDE LOCATIONS

II

Static Eliminator

III

Oscillator,

J3

II

Forms Tractor Unit Rack

II

Fine Adjustment Mounting Screw

II

Rollers

IE

Print Emitter Support

..

Right Tractor Release Knobs

1&

Carrier

Motor

and Pulley

II

Address Switches

II

Safety Lable

II

Cable Connectors

III

Safety Cover

II

Audible Alarm

'm

Guide (ribbon box)

II

Paper-Advance Knob

II

Print Head Retract Lever'

B

Forms Tractor Drive Gear

fI1

Paper-Advance Knob

m

TPB2

fIl

Ribbon-Advance Knob

III

TPB1

'til

Ribbon Release Lever (in operate position)

III

Horizontal Fine Adjustment Knob

m

Left Tractor

II

P3

101

FRONT

AND

LEFT SIDE LOCATIONS

..

End-of-

Forms

Switch

II

Platen- Release Lever (Latch)

(2)

D

A-Frame

II

Power Supply

II

Platen

II

Print Head Forms Guide

II

Planar Board

II

Paper Release Lever

II

Platen Gears

m

Idler Gear

III

Ribbon Box

IE

Print Head Cover

III

Control Panel

End-of-Forms Switch

COMO

N/O N/C

III

IE

m

II lID III

m

II

til til

fI

m

Copy Control Dial Connector

EC3

(under the cover) Oil Felt Carrier Ribbon Drive Lines

(2) Print Emitter Board Assembly Hold

Down

Bracket Retract Ramp Drive Belt Carrier Main Shaft Platen Pressure Rolls Connector

J 1

Connector

P1

-----m

~----im

Top

802

002

~

EC3

100,101

Glossary, Seq. Affected,

Loc

..

Maintenance

5256

MIM

1-3

1-4

102 BACK LOCATIONS

D

B1A1

II

B1B1

II

B1C1

..

B1D1

II

Fuse

F1

(3A, SB, part 2456618)

II

Fan

B2

II

TB2

(line filter on some

world

trade machines)

II

Line Cord

II

Terminal Block

TB1

IE

Transformer

T1

III

Power Adapter Board

C1

II

Capacitor C5 (+8.5V)

II

Capacitor C12 (AC)

III

Capacitor C4 (+5V)

II

Terminator Switch

m

Cable Connectors

II

Address Switches (shown in the 0 position)

IE]

Audible Alarm Volume Lever

DDII

II

103

PRINTER

MECHANISM

BOTTOM

LOCATIONS (PRINT

MECHANISM

IN

SERVICE POSITION)

..

Belt Tensioner Pulley

II

Printer Emitter Pickup and Amplifier

II

P2A

..

J2

II

P2B

II

Ribbon Drive Clutches and Gears

II

Carrier Drive Belt

II

Print Emitter Board

II

Carrier

Motor

102,103

Glossary, Seq.

Affected, Lac

..

III

J3

(See reference 100.)

III

P3

(See reference 100.)

III

Screw (to clamp printer in service position)

III

Print Emitter Flat Springs

II

Belt Clamp

IE

Print Head Cable

(EC1)

m

Compression Spring

II

Forms Feed

Motor

III

Forms Feed Emitter

Maintenance 5256

MIM

1-5

104

PRINTER

MECHANISM

BASE LOCATIONS

1-6

..

II

II II II

II

lID

Power Supply Board A 1 (See reference 105.)

J4

(See reference 105.)

A1Al

A1Bl Capacitor C3 (+24V) Capacitor C2 (+30V)

Resistor Rl

Fan Bl Transistor

Resistor

Ql

R2

III III

II II

IE

Capacitor TB3 A1A4 A183 A1A3

C1

(+10.8V)

105

POWER

SUPPLY BOARD

A1

LOCATIONS

AND

JUMPERS

The planar board has jumpers associated

with

character

set,

spee.d,

and cable type. (See reference 106.)

Planar Interface Cable

From

B1Al

Print

Head

Cable (EC1)

002

e

lA

5

802

A 8

CRl

Test Points

Toleranc&

Vl V2 V3 V4 V5

Wl

W2

LMl

LM2 FMA PMA G6;7 GS

+24

Vdc

24.6

Vdc

26.4

Vdc

+30

Vdc

24.0

Vdc

36.0

Vdc

+10.S

Vdc

S.l

Vdc

13.5

Vdc

+5

Vdc

4.6

Vdc

5.5

Vdc

+5

Vdc

4.6

Vdc

5.5

Vdc

-Wire on

Sets

wire

check

(to

adapter)

+Left

margin

Left

margin (to adapter)

+A

forms

drive

+A

carrier drive

Ground

from

A1A3

and

A1A4

Ground

from

A1A4

\

21 Wire Check

Jumper

(normal

position)

:

~~

S

~~.

•

V3

•

V4

1·

•

V5

J4

(white

dot

• G6 indicates

• G7

position

1)

•

GS

22

Left

Margin Jumper

15 (normal

position)

~

\23

R3 \

40

cps

has

resistor R3.

/

SO

and

120

cps have

jumper

23.

14

80ard

Al

CR30~

~

2e

EC2

e3

~C

,

013

To 40

~Cl

0

104,105

Glossary, Seq. Affected,

Loc,.

To6

813

ECl

Rl

ge~e

CR2

e

S

111111111111111111

CR4

6 I I

To

58

C2

,

\

T04E

013

Maintenance

5256

MIM

1-7

106 PLANAR BOARD

JUMPERS

B1

LOCATIONS

1-8

AND

Power supply board A 1 contains jumpers associated

with

speed and diagnostics. (See reference 105.)

CAUTION

When installing jumpers, they

can

cause a short circuit.

Language Group

o 4

00000

%1111

Plugged Canada (for other countries,

Speed

%~

~I

00 00

for

120

40

80

On

Off

cps

(1)

U.S.

(0)

and

see

chart) /

I

/

/ I

/ /

Cable

o

I Twinaxial

/

Type I

Unused

I

/

..

II II

II

Notes:

1.

Plugged only

2.

II

and

3.

This cable is polarity sensitive.

I Probe Points

I \

I \ 'J

I

(Seell',

I note 3) ,

.I

Termination ,

~

(See

CJ--e note

~

\

1)

To the address switches (Cable Thru feature

only).

To the control panel.

To the audible alarm, board A 1 A4, and board

C1

(see note

To board A1A3 and board

Internal system cable;

II

are part

2).

C1

if

the Cable Thru feature

of

the planar interface cable.

Language Group

Bit

01234

00000 00001 00010 00011 00100 00101 001

10

001

1 1 France 01000 01001 01010 010

1 1 01

100

01

101

o 1 1 1 0 o 1 1 1 1

10000 10001

I

1 1 1 1 0 1 1 1 1 1

(see note

Country

U.S. ASCII (international) Austria and Germany Belgium Brazil Denmark and Norway

Finland and Sweden

Italy

Japan

Portugal Spain Spanish Speaking

United Kingdom

Canada (French)

Unused

Katakana

Reserved

Defaults Canada

is

not

and Canada

to

2).

installed.

U.S.

and

,

Bottom

107

POWER

ADAPTER

BOARD

C1

LOCATIONS

..

II II

..

II

..

II

II II

Transformer

T1

Fuse

2,

4A

(5B-part

1143492) +30V (+24.0V

to

+36.0V)*

Fuse 3,

8A

(5B-part

1146953) +10.8V

(+8.1

V

to

+13.5V)*

Fuse 4,

6A

(FB-part 303679) +5V (+4.6V

to

+5.5V)

Fuse 5,

3A

(FB-part 855252) +8.5V (+7 .82V

to

+9.35V)

Fuse

6,

1A

(FB-part 855253)

-5V

(-4.6V

to

-5.5V)

Voltage

and

signal

connector

Cl

A 1

Probe power

E18

(+)

Probe power

E17

(-)

*

Fuses 2 and 3 are

in the return lines.

Connector C1A 1

Line

B02

Unused

002

-Power

good

B03 Power on

reset

003

+5V

B04

Ground

004

+5V

B05 Ground

005

+5V

B06

Ground

006

+5V

B07 Ground

007

+5V

BOB

Ground

OOB

+5V

B09 Ground

009

+5V

Bl0

Ground

010

+5V

Bll

Ground 011 +B.5V

B12

Unused

012

+B.SV

B13

-SV

013

Unused

Board

C1

Connections

Transformer

T1

Wires

C1

60

Hz

(U.S.)

El

-

E2

-

E3

-

E4

10

E5

11

E6

9

E7

19

EB

20

E9

lB

El0

16

Ell

I

17 E12 15 E13

7

E14

13 E15 E16

106,107

Glossary, Seq. Affected,

Lac.

60

Hz

(WT)

50

Hz

(WT)

-

14

16

15

17

13

15

23

25

24

26 22 24 20 22 21

23 19

21 11

13

17

19

J1

Other

+5Voutput Ground

1

5

Chassis

Ground

6

[J

E16

DJ

E15

DE14

1'"ItIlIl".,,1

'I

?

E3

(]

fJ 0 0

0ij

E5

[]

E13

[]

D[][]DfIll[]J[]

Rear-

E12

Ell

El0

E9

E8

E7 E6

0---·

Maintenance

5256

MIM

1-9

108

Motor

When the corresponding wire

CAUTioN Phasing is very important and the black-striped black dot, switch, and

to

CABLING PROTECTOR

Cables

installing this cable, always install the wires

new

cable one at a time

Cable Thru feature wiring. Always connect the

to

the planar.

LOCATIONS

(EC2

to

from

wire

to

the

right-hand

position 6

AND

TPB1

and TPB2)

as

you remove the

the old cable.

for

the internal system cable

the socket terminal beside the

side

of

the connector

STATION

the Terminator

that

attaches

1-10

from

Note: For cable quality checks, refer

documentation.

AC Cable Assembly

to

the controller

Part

of Secondary AC Cable (power

to

1 O.8V and

30V

supplies)

Address Switch

(Cable Thru feature

Cable

only)

Control

Panel

Cable

108 CABLING LOCATIONS AND STATION

PROTECTOR (CONTINUED)

See

IBM

5250

Information Display System Installation

for

Manual-Physical Planning, GA21-9277

informati on.

The station protector is owned and maintained by the customer. The following procedure can be used

check

an

IBM

supplied station

The cables

disconnected before the checks can be made. This will

disconnect the

DANGER

Never handle cables or connectors during

storm.

I

Typical Installation

to

the station protector must be

work

stations from the system.

pro~ector.

detailed

an

to

electrical

Only use scale.

1.

2.

CE

meter part 1749231. Use the R x 100

Check each diode the anode and the red lead connected cathode. The resistance should be less than

ohms.

Check each diode the cathode and the red lead connected

anode. The resistance should exceed ohms.

with

the black lead connected

with

the black lead connected

to

the

to

the

10,000

to

2,000

to

Work Station

System/ Controller

Building

Station Protector Board

1

----------1

I

Cathode

I

L

____

An

0

de---

__

<-

_

Outdoor Cable.

......

'Station

Protector

//

Work

Station

Work

",

Station

Building

Work

Station

2

108

Glossary, Seq. -

Affected,

Loc

..

Maintenance Procedures

5256

MIM

1-11

Covers

110 PRINTER COVERS

1-12

The covers are designed front,

or

back cover individually. Paper can remain in

the machine while removing covers.

Adjustment

1.

Center the platen knobs vertically and maintain a

of

gap inch) between the by adjusting the pads in back nuts in

2. Position the printer horizontally on the double pins slot .

. 3. Adjust the

each side

Top

Cover

1. cover

3.18 mm

front

II

to

center

front

of

Removal

For ribbon changing and observation, slide the

II

forward.

to

let you remove the top,

to

3.96 mm

top

(1/8

inch

to

cover and the forms tractor

II

and the double

II.

th~

Paper-Release

cover by moving the bracket on

the machine base.

and

Replacement

lever in the

5/32

nut

top

2.

To remove the up, and remove

Back

Cover

Removal

1.

Loosen the faste·ners

II

back

2. Lift the cover up and remove

Front

Cover

You can pull the remove the platen

1.

Move the back cover

2.

Pull

3. Press the release push buttons the off.'

Removal'and

off

the Horizontal Fine Adjustment knob

front

top

cover D slide

it

to

the front.

and

Replacement

II

and pull the back cover

to

free the

front

cover and slide the cover forward and

front

cover

Replacement

cover forward enough

without

removing the back cover.

II

back. (See above.)

it

II.

it

to

the rear.

II

on the sides

forward,

to

let you

lift

B.

it

of

'The

release

pushbuttons

are

not

on

all printers.

111

CONTROL

PANEL

AND

AC

CABLE·

ASSEMBLY

Control

Panel

Removal

and

Replacement

1.

Power

off.

2.

Disconnect the line cord

from

the

wall outlet.

3. Remove the printer covers (110).

4.

5.

Disconnect the control panel cable

at

the

planar

board socket

B1

C1

II.

.

Note

the

cable path and remove

the

cable

to

the

control panel

II.

6. Loosen

the

2 lower screws and remove the upper

screw

at

each end

of

the panel support brackets

7.

8.

9.

II·

Remove the back panel

II

from

the

front

panel

(6

screws)

II.

Remove

the

Power switch bracket B

from

the

control panel (2 screws).

Reinstall

the

control panel by reversing the

procedure.

110,

111

Remove, Replace,

Adjust

AC

Cable

Assembly

Removal

and

Replacement

The

AC

cable assembly includes

the

Power

switch

and

the fuse.

1.

Power

off.

2. Disconnect the line cord

from

the

wall outlet.

3.

4.

. 5.

Remove the printer covers (110).

At

the control panel, looserr

the

lower

screw

and

remove the upper

screw

at

each end

of

the

panel

support brackets

II.

Remove

the

Power switch shield

IE.

6. Remove

the

Power switch. •

7.

8.

9.

Remove the fuse case

II.

Note

the

position

of

and remove the leads

from

TB2

(or the line filter)

..

and TB 1

II.

Reinstall

the

cable

by

reversing this procedure.

Note:

Some

world

trade machines have a line filter

in place

of

the

terminal block.

Maintenance

5256

MIM

1-13

i"

Service Positions 115

SEPARATING THE PRINTER FROM THE POWER SUPPLY BOARD

A1

FOR

SERVICE

POSITIONS

1.

Power off.

2.

Remove the printer covers (110).

3.

Remove the 2 screws and the cable

clamp"

near

EC1

II.

4. Disconnect the cables

at

EC1

II

and

EC211.

For installation, ensure the print head cable is against the flat spring.

5.

Disconnect

J41J

(white

dot

indicates position 1).

6.

Remove the 2 screws

II

on the right end

of

the

printer.

7.

Loosen the 2 screws

II

on

the left end

of

the

printer.

8.

Lift the right end

of

the printer slightly and slide

the printer

to

the right

to

clear the screws II.

9.

Lift the printer from the power supply.

If

the

bottom

of

the printer is

to

be serviced, remove the paper deflector and set the printer into the service position

II

on

the base (so that the print emitter

II

points upward). Hold the printer in this position

with a base screw

II

on"

the left side and a base

screw

II

on the

right

side.

Note: Operate the Ribbon-Release lever

II

to open the ribbon feed rolls; ensure that the ribbon box cover remains closed.

10. To install the printer on the power supply, reverse this procedure.

1-14

. .

1m!

Service Position

Supply

Power

115

Remove, Replace.,

Adjust

Left End View

Maintenance

5256

MIM

1-15

116

1.

MOVING PRINTER SERVICING

Power

off.

THE

POWER

SUPPLY

FOR

Part

Numbers

117 , BOARDS, CARDS, INTERPOSERS,

JUMPERS

1-16

AND

2.

Loosen the shipping screws turns. You may shipping.

3.

Loosen the clamping screws D D

one-half

Pull the power supply back, at the place shown,

4. until

screws"

5.

To place the power supply in normal operating position, reverse this procedure.

leave them loose except

turn.

and II strike the stops II and

II

and

D

Stand-off for

Planar

Supply

Power

Pull

Here

II

I

seven

for

and IJ

TB2::f

rl

L

II·.

Fan

Boards

Planar Board

the caution.) Power Adapter Board Power Print Emitter

Cards

A1A1 5863340 A1B1 5863342 A1B3

Print Emitter (pickup)

Interposer

Jumper

CAUTION

The logic on planar board B 1 can be damaged by

electrostatic discharge. Do (metal) parts. Hold the planar by the plastic frame when moving it.

Before you take the planar from the bag, and touch the machine frame removes any static from you and the planar.

Ensure that the component side

when you put the planar on any surface.

B1

(See

Supply Board A 1 1638818

Part

Gi§~

C1

4176517

1638711

5863341

843202

2731011 1794401

not

touch any conducting

with

your hand. This

of

the planar is up

hold the bag

. Forms Moving Parts

120 PLATEN

Removal ,and

1.

Power off.

2.

Center the print head on the platen.

3. Tilt the forms tractor back.

4.

Pull

the

5.

To remove the platen, while pressing

AND

PAPER DEFLECTOR

Replacement

front

cover forward

down

lift

on the Platen-Release levers

D·

6.

Lift

out

the paper deflector II.

to

the stop (110).

up on the Platen knobs

7.

To install the platen:

a.

If

the Paper-Release lever ~ is back, pull

forward.

b. Ensure that the paper deflector

correctly

arms

engage the locating arms a

c.

Center the print head on the platen.

d. Align the groove

platen shaft down on both ends the gears engage correctly.

e.

Ensure that the Platen-Release levers are

. completely seated.

f. Turn the platen

8.

Close the

forward until the arms engage the platen shaft.

Note: The locating arms

ensure 0.51 deflector

the Copy Control dial is set

with

tabs ~ engaging the locating

lID

(both ends). Bend the tabs !II

if

a in the gear end

with

the side plate. Then, press

of

the platen. Ensure that

to

check

for

binds.

front

II

cover and

mm

(0.020 inch) between the paper

and the

tilt

the forms tractor

II

may need bending

tip

of

the print head when

to

O.

I!i is seated

to

needed.

of

the

it

to

«

D I

~

~.

i~

I

116-120

Remove. Replace.

Adjust

~~

____

--------m

Maintenance 5256

MIM

1-17

121

PLATEN LATCHES (RELEASE ECCENTRICS

AND

SPRINGS)

Adjustment

This procedure adjusts both the left and right eccentrics.

However, when adjusting the

left

eccentric, ensure that

the Platen Release lever does

not

touch the print head

forms

guide·

(1

01) when the carrier moves

to

the far left.

1.

2.

3.

4.

5.

6.

7.

8.

9.

Power off.

Remove the forms tractor (131).

Remove-the printer covers (110).

Loosen, until

it

is finger tight, the screw

II

that

locks the eccentric nut

II.

Note:

When

adjusting the right side, remove the

Platen knob and forms tractor drive gear.

When

installing, adjust gap

to

bushing

II.

Press the platen

bushing"

down

and turn the

eccentric nut so

that

when released, the lever

holds the bushing

tightly

against the frame.

Hold the eccentric

nut

in this position and tighten

the locking screw.

Check the platen gear backlash (play) adjustment (124).

Reinstall the printer cover (110).

Reinstall

the forms tractor (131).

Left

Side

Right Side

Lever Spring (small)

Make

sure

that

the

print

head

forms guide

does

not

strike

the paper

release

lever

here

when the

head

moves

to

the

extreme left.

Lever Spring (large)

1-18

122 PLATEN GEARS

AND

BUSHING

Removal,

Replacement,

and

Adjustment

1.

Power off.

2:

3.

4.

5.

6.

7.

Tilt the

forms

tractor back.

Pull the

front

cover forward

to

the stop and

remove the platen

(120).

Remove the knob

from

the gear end

of

the platen

(2 setscrews

lIP.

Loosen the clamp collar

II

on the

forms

tractor

drive gear.

For

installation, the bushing

II

must

turn freely

with

0.05 mm

to

0.13

mm

(0.002 inch

to

0.005

inch) gap

to

the gear collar.

Remove the gear

II

and bushing

II·

8. Remove the 2 screws

II

that

hold the platen gear.

9. Remove the gear

II.

10. To reinstall the gears, reverse this procedure.

,..-------0

,......-----m

,."

,

I

,..------0

,..-----IJ

/-0

I ,

~

O.05mmtoO.13mm

~

r (0.002 inch

to

0.005 inch)

123 PLATEN PRESSURE

ROllS

Adjustment

Adjust

the

paper-release shaft II

so

that

the

Paper-

Release

lever

II

gives a maximum pressure roll opening

when

the lever is forward.

If

the gap between the cam

follower

B and the cam II is 0.05

mm

to

0.51

mm

(0.002 inch

to

0.020 inch) when

the

lever is back,

the

adjustment is correct.

Adjust

the

pressure roll arms D

for

a strong hold and

no gap between the pressure rolls

II

and the platen,

when the

Paper-Release lever is back.

1.

2.

Power off.

Remove the printer covers

(110), platen (120),

tractor assembly (131), and

the

paper deflector.

3.

4.

5.

Adjust the paper release

shaft

II:

a.

Push the

Paper-Release

lever

II

back.

b. Loosen the 4 clamp

collars

II

along the paper

release shaft.

c.

Place a 0.38

mm

(0.015 inch) gauge on the cam

II

and hold

it

there

by

pressing

the

cam

follower

B on the gauge.

d.

Pivot the clamp collars so

that

the bell cranks

II

seat on the

bottom

of

the 4 openings; then

tighten the

4 clamp collars

II.

e.

Remove the gauge, check the adjustment, and adjust again

if

needed.

Install the platen and paper deflector (print head

centered on the platen).

Adjust the pressure

roll arms:

a.

Loosen the 2 nuts D

that

hold 1 set

of

pressure roll arms.

b.

Move the arms as needed

to

remove gap

between any

of

the pressure rolls and the

platen.

c.

Check the adjustment, adjust again

if

needed.

d. Check

the adjustment

of

pressure rolls

for

the

other half

of

the platen; adjust

if

needed, using

the preceding steps.

6. Check the adjustments

for

platen gear backlash

(play)

(124) and the

End-of-Forms

switch (130);

correct them

if

needed.

7. Reinstall the printer covers (110).

0.05 mm

to

0.51 mm

(0.002 inch

to

0.020 inch)

121-123

Remove, Replace,

Adjust

Maintenance 5256

MIM

1-19

124 PLATEN GEAR BACKLASH (PLAY)

Adjustment

The idler and platen gears should have slight backlash (play) throughout their rotation. Engaging the gears at a

high point,

II

' results in correct backlash (play) at other locations.

1.

2.

3.

such

as

that which occurs in line

Power off.

Remove the printer covers (110).

Loosen the 3 forms motor and emitter mounting

screws

II.

with

a hole

1-20

4. Turn the gears so that a hole is aligned with the gear shafts

5.

Position the motor up and back so that the gears

engage tightly.

6. Tighten the mounting screws.

7.

Check

for

no binds and adjust again

8.

Reinstall the printer covers (110).

II

in the idler gear

as

shown

II.

if

needed.

D---t-~-I

fJ-~~-'"

125

Adjustment

1. Power off.

2.

3. Remove the forms

FORMS

Separate the printer place the printer in the service position (115).

(126).

MOTOR

GEAR

from

motor

BACKLASH

the power supply and

and emitter assembly

(PLAY)

4. Loosen the 2 screws and the access through hole in the idler gear) that holds the emitter base

5.

Turn the gears idler gear is aligned

B on the motor.

as

needed so that a hole

with

nut

II

(bolt head

the gear shafts

II

as

in the

shown

II·

6.

Turn the emitter base B on the motor so

gears engage tightly.

7.

Tighten the 2 screws and the nut

8. Check

9. Reinstall the forms motor and emitter assembly.

10. Adjust the platen gear backlash (play) (124).

11. Assemble the printer and power supply (115).

for

binds and adjust again

II.

if

that

needed.

the

~,/

I

o I

II

124,125

Remove, Replace,

Adjust

Maintenance

5256

MIM

1-21

1-22

This page

is

intentionally

left

blank

126

FORMS

MOTOR

AND

EMITTER

Removal

and

Replacement

1.

Power

off.

2.

3.

4.

For installation,

if

the

motor

and emitter assembly

was. disassembled, perform the

forms

motor

to

emitter timing (128).

Disconnect

J4

on the power supply board A 1

(105).

Disconnect the

motor

leads

from

TPB2

II.

5.

Separate the printer

from

power

supply board A 1

and

place the printer in the service position (115).

126

Blue

1-+---

Fra

me

I I I

I

0--0-0

8

CBA

Remove. Replace.

Adjust

6.

7.

For installation only. adjust the platen gear backlash (play) (124) and return here.

While

holding the

forms

motor

and

emitter

assembly, remove the 3 mounting screws

from

the

right side frame

II.

8.

Remove the

motor

and emitter assembly. To

remove any parts

from

the

motor

and emitter

assembly

•.

disassemble

it

as

needed (126).

9.

To reinstall the

motor

and emitter assembly,

reverse this procedure.

D

Maintenance

5256

MIM

1-23

1-24

126

Disassembly

1.

2.

3.

4. Loosen the clamp collar

5.

6.

7.

FORMS (CONTINUED)

Power off.

Remove the forms side frame (126).

Remove the emitter outer cover

Remove the 2 adjusting screws D

of

the base.

Remove the screw assembly

CAUTION Do

not

or

scratch it.

MOTOR

AND

motor

that

ID and remove the photocell assembly.

use force on the disk; doing so will bend

EMITTER

and emitter from the

IEJ.

lB.

from

the back

holds the photocell

8. Remove the clip

and

lift

off

. 9. Remove the 3 screws

that

fasten the base

10.

To

put the

assembly procedure.

Assembly

1.

Install the 3 screws that

fasten the base

tighten the screws and

2.

Install the idler gear toward the

3. Install the inner cover screws

D finger tight.

II

that

the gear.

motor

and emitter together, use the

II

motor

and install the clip.

holds the idler gear

II

plus the

II

to

the

motor

plus the

II

to

bolt

with

lEI

bolt

the

motor

now.

the longest hub

with

the 2 adjusting

bolt

II.

and nut

II.

II

and nut

II

Do

II

not

Remove the inner cover assembly from the the

motor

gear as shown.

motor

lEI

and the disk and gear

shaft by using force on

4.

Place the photocell assembly

, gear assembly

shaft.

5.

Fasten the photocell assembly screw.

6.

Center the forms emitter disk not

scratch black paint A 0.76 mm (0.030 inch) thickness gauge should slide freely the gap

7.

Tighten the clamp collar

8. . Turn the gears so aligns

with

base

II

tightly.

9. Tighten the screws and nut, and check play several positions needed.

II

and slide

on the upper side

at

several points on the disk.

that

the gear shafts. Then turn the emitter

on the

motor

of

the idler gear. Adjust again

III

on the disk and

them

on the

with

its mounting

in

the opening. Do

from

around the disk holes.

of

the disk. Check

IE

and check the gap.

a hole

in

the idler gear

so

that

the gears engage

motor

in

if

Install the outer cover

10.

11. Install the printer

(126).

~.

motor

and emitter assembly in the

127

FORMS

FEED

EMITTER

DISK

Adjustment

The disk should be centered in the photocell assembly opening

for

all positions

of

the

disk.

1.

Remove the

forms

motor

and

emitter

assembly

(126).

2. Remove the outer cover

1m

.

3. Loosen the clamp collar m and center the disk in

the opening. Do

not

scratch the black paint

from

around the disk holes. A 0.76

mm

(0.030 inch)

thickness gauge should slide freely on the upper

si~e

of

the disk. Check

the

gap at several points

on the disk.

Forms Feed

Motor

(rotated

900 clockwise)

126,

127

Remove, Replace,

Adjust

4.

Tighten

the

clamp collar and check

the

gap.

5.

Reinstall the outer cover.

6.

Reinstall

the

motor

and emitter assembly (126).

~

0.63

mm

to

0.88

mm

I (0.025

inch

to

0.035

inch)

Ddl

Maintenance

5256

MIM

1-25

1-26

128

Service

1. Power off.

2.

3. Lock the

FORMS

Check

Remove. the printer cover (110).

between drive a.

Move the black

TP82-3C

b.

Move the red

A'

MOTOR

motor test

points

to

'ground').

II.

by

wire

II·

4. Connect the probe C1

E18 and the black

5.

Probe

8181007

point

test

6. Power on.

G8

with

II.

TO

EMITTER

connecting a

FMA

and

G7

wire

from

TP82-6C

from

TP82-58

power

wire

(red)

wire

to

C1

E17

the probe ground

TIMING

jumper

II

('forms

to

(196).

wire

motor

to

TP82-6C

test

point

wire

on

7.

Verify the adjustment a.

At

a Platen knob, use a small amount

in the direction

should remain at

probe

remove your hand from the

b.

At

a Platen knob, use a small amount

in the direction

should remain at a

probe

. .

8.

9. Remove the probe and the jumper wire.

remove your hand

If

the timing is procedure. Otherwise continue a.

Power

off.

b.

Move the red wire from

TP82-58

c.

Move the black

TP82-6C

II. II.

not

as

to

move the

to

move the

from

correct,

wire

follows:

forms

the

up level when you

Platen knob.

forms

down

level

the Platen knob .

go

to

the adjustment

as

follows:

TP82-6C

from

TP82-3C

of

force

up. The

of

force

down. The

when

you

back

to

back

to

Adjustment

1.

Do steps

1,

2,

and 3

of

the service check and

return

to

step 2 in this procedure.

2.

Loosen the photocell assembly

(2

screws

II

behind the motor) so

that

the assembly will slide

but

not

move

by

itself.

3. Connect the probe

power

wire (red)

to

test

point

C1

E18 and the black

wire

to

C1

E17

(196).

4. Probe

B1 B1

D07

with

the probe ground wire on

test point G8

B.

5.

Power on.

6.

Slide the photocell

down

as

far

as

possible.

7.

Slowly slide the assembly up until the probe up light comes on.

Note:

If

the up light is on

with

the photocell

down

as

far

as

possible, slide the assembly up until the

up

light goes

off

and then comes back on.

a.

Hold the photocell assembly tightly in place and

tighten the 2 screws

II.

b.

Verify the adjustment

as

follows:

At

a Platen knob, use a small amount

of

force in the direction

to

move the

forms

up.

The probe

should remain at the up level

when you remove your hand

from

the Platen

knob.

At

a Platen knob, use a small amount

of

force in the direction

to

move

the

forms

down. The probe should remain at a

down

'Ievel when you remove your hand

from

the

Platen knob.

c.

Adjust

again

if

needed.

d. Power

off.

e.

Move

the red

wire

from

TPB2-6C

back

to

TPB2-5B

II.

f. Move the black wire from

TPB2-3C

back

to

TPB2-6C

II.

8.

Remove the probe and the jumper wire.

9. Reinstall the printer covers and

forms

tractor unit.

128

Remove, Replace,

Adjust

Blue/White

Blue

Frame

I

__

.r--=-<"

I I

I

~8D

Maintenance 5256

MIM

1-27

1-28

This page

is

intentionally

left

blank

129 A-FRAME

A-frame and mounting screws are sealed

Alignment However, procedure:

Service

1.

2.

3.

alignment

should not be needed in normal printer use.

if

alignment is needed, use the

Check

Set the Copy Control dial

Run

PRT04 (191) and check

and density

Adjust

if

needed.

to

the platen is set at the factory

at

both ends

Alignment

1.

Power

off.

2.

Remove the printer cover (110).

with

Loctite'.

to

o.

for

uniform printing

of

the line.

following

6.

With

a brass punch and a hammer,

.

A-frame

7.

Tightly fasten the (Loctite is not needed), check the gap, and adjust again

8.

Check the step. (110), correct printing.

9.

If

the right end dimension is loosen side frame

left

side plate

if

needed.

the

gap

at

gap is

not

correct, continue on

If

the gap is correct, install the printer cover

power

on, and set

the 2 A-frame

to

obtain the specified gap.

A-frame

the right end

mounting screws

the

mounting screws in the right

O.

tap

of

the platen.

to

Copy Control dial

not

correct, slightly

on the

If

the next

for

3. Set the Copy Control dial

4.

Measure the gap between the platen and

head at both ends

0.30

mm

to

0.36 mm (0.012 inch

the

left

end dimension is not correct, go

5.

next step; go

to

If

the loosen the 2 side frame

if

the right end dimension is

step

"9.

left

end dimension is

A-frame

e.

to

of

the platen. Gap should be

mounting screws

o.

to

0.014 inch).

not

correct, slightly

to

not

in

the

the correct,

the

print

left

If

10.

With A-frame

gap.

11. Tightly fasten the (Loctite is again

Check

12. gap is correct, and set the

Check platen gear backlash (play) (124) and adjust,

13. if

needed.

Check the

14. correct

a brass punch and a hammer, tap on the

right side plate

not

needed), check the gap, and adjust

if

needed.

the

gap

at

not

correct, return

install the printer cover (110)'

Copy Control dial

End-of-Forms

it

if

needed.

A-frame

the

left

to

obtain the specified

mounting screws

end

of

the platen.

to

step

5.

If

the gap is

power

for

correct printing.

switch adjustment and

If

on,

the

'Trademark

129

of

the Loctite Corp"

Remove, Replace,

Adjust

Maintenance

5256

MIM

1-29

130

END-Of-fORMS

SWITCH

Service

Check

1.

Set your

CE

meter

to

the

R x 1 scale.

2.

3.

Connect the meter wires

to

the

normally open

(N/O)

and the common

(C)

terminals

of

the

switch

II.

Insert a 0.076

mm

(0.030 inch) thickness gauge

between the

top

of

the actuator lever and the

bottom

of

the platen groove. The meter should

show

that

the switch has operated.

Note: The gauge

must

be held horizontal and

not

inserted

too

far

or

the indication

will

not be

correct.

4.

Check (by operating the

Paper-Release

lever

several

times)

that

the override arm operates the

End-of-Forms switch.

5.

Adjust

if

needed.

Adjustment

1.

Power

off.

2. Remove the printer covers (110).

3. . Remove the

forms

tractor unit.

4. Remove the paper

deflector and install the platen.

5.

6.

7.

8.

9.

Pull the

Paper-Release

lever toward the platen and

leave

it

there.

Check

that

the switch actuator lever is centered in

the

platen groove

II.

If

it

is

not

centered, loosen

the switch assembly mounting screw

II

and place the switch assembly in position again. Fasten the screw

tightly.

Set

your

CE

meter

to

the R x 1 scale.

Connect

the

CE

meter leads

to

the normally open

(N

/0)

and the common

(C)

terminals

of

the

switch

II.

Loosen the 2 switch

mount

holding screws

0,

and move the switch

mount

II

toward

the

front

of

the printer.

1-30

10. Insert a 0.076

mm

(0.030 inch) thickness gauge

between the

top

of

the actuator lever and the

bottom

of

the platen groove.

Slowly

push the

switch

mount

toward

the rear until the meter

indicates

that

the switch has operated.

Note: The gauge

must

be held horizontal and

not

inserted

too

far

or

the adjustment will

not

be

correct.

11. Tighten the screws

0 and check the adjustment.

12. Remove the

platen.

13. Reinstall the paper deflector and the platen.

14. Operate the

Paper-Release

lever

several

times

to

check

that

the override arm operates the

End-of-

Forms switch.

If

the switch operates, skip

steps a

through~.

If

the switch does

not

operate:

a.

Move the

Paper-Release

lever backward.

b.

Place

0.30

mm

to

0.50

mm

(0.012 inch

to

0.020 inch)

of

paper between the platen and

actuator

lever

B.

c.

Loosen the setscrew

II

and move the override

arm

II

so

that

the end

of

the arm touches,

but

does "lOt. move,

the

End-of-Forms

switch

actuator

lever

B.

d. Tighten the setscrew. e.

Check the adjustment.

15.

Reinstall the printer covers (110).

Removal

and

Replacement

1.

Power

off.

2.

3.

4.

5.

6.

7.

Remove the printer covers (110).

Remove

the

End-of-Forms

switch assembly

by

removing the screw and

the

lockwasher

II.

Remove the switch

from

the assembly by

removing

the

2 screws

II.

Move the switch leads

from

the old switch

to

the

new

switch

(N/C

and

C)

II.

Install the

new

switch on the assembly and install

the

assembly on the printer.

Adjust

the switch.

C

N/O

'"

........

o

..........

N/C

........

~D

"

Top

View

........

..........

l

f!emove, Replace,

Adjust

Maintenance

5256

MIM

1-31

131

FORMS

TRACTOR

UNIT

Removal

and

Replacement

CAUTION

To prevent damage

to

the rear

of

the forms tractor unit,

do

not remove the tractor unit

by

lifting the front first.

1. Remove the unit by pulling up on the rear

extensions and letting the unit pivot on the platen shaft.

2. Install the unit by setting

it

on top

of

the printer

and pressing on the rear extensions

to

seat the rear legs on the pins. Then, seat the front legs over the platen shaft.

Note: When reinstalling, ensure that the gears 0

engage correctly and that the platen and the forms tractors turn.

D

1-32

Disassembly

and

Assembly

1.

Disassemble, as needed, as shown in the figure.

The end covers

are

removed by just pulling them

off.

2. When the chain gears are installed, slide the gears

together and ensure that the teeth on the gears line up

with

each other.

3. After assembling the forms tractor unit, check with

a

CE

meter

for

0 ohms between the rack and the

printer base.

End

Cover

Left

Tractor

With

the

D so the tractor

collar

(0.200 inch ± 0.010 inch).

Adjustment

left

tractor in the leftmost position, adjust the

can

move 5.08 mm ± 0.25 mm

132 FORMS TRACTOR

Service

Check

inch) between the chain guide II and the

Adjust

Adjustment

Check

for

0.63 mm

if

needed.

to

UNIT

CHAIN

1.13 mm (0.025 inch

COVER

to

0.045

cover.

D

5.08 mm ± 0.25 mm

l

(0.200 inch ± 0.010 inch)

Bend the cover chain guide (0.025 inch the hinge brackets gap.

stops.

II

and cover

to

0.045 inch).

so

that

II

is 0.63 mm

It

might

II

in another position

the gap between the

to

1.13 mm

be

necessary to

to

obtain this

put

131,132

Remove. Replace.

Adjust

o~a

~

0.63 mm tq 1.13 mm

(0.025 inch

Maintenance 5256

to

0.045 inch)

MIM

1-33

1-34

This

page is

intentionally

left

blank

133

FORMS

TRACTOR

UNIT

CHAIN

134

FORMS GUIDE RACK STATIC REPLACEMENT

ELIMINATOR

Removal

1.

2. Locate the pin

3. Slide the removable pin

4.

and

Replacement

Remove the forms tractor unit (131).

II

that

Move

the pin

clip.

tensioner

To

reinstall a chain, reverse the procedure.

to

..

and spring

the back side and remove the

holds the chain together.

from

the chain. The chain

might

fall out.

Install the static eliminator as shown in the below.

front

view

133,134

Remove, Replace,

Adjust

Left Tractor

Assembly

I~

D

Maintenance 5256

MIM

1-35

1-36

Print

140

The print emitter pickup contains

Service

1.

2.

3.

Emitter

PRINT AMPLIFIER

Check

Run or 2' s with sometimes a 1 is needed. or the left margin is not even), continue the service check adjusted correctly.

Check the emitter board adjustment a.

Turn the Horizontal Fine Adjustment knob counterclockwise as far board in the leftmost position).

b.

Move the carrier

c.

Insert a code plate aligning tool (part 460028)

into the left hole

d.

Check fo'r a gap inch ± 0.005 inch) between the left side frame and the aligning tool

e.

Perform the adjustment

correct.

Check the emitter pickup adjustment as follows:

a.

Use the Horizontal a gap

0.005 inch) between the aligning tool and the left side frame

b.

Remove the aligning tool from the left hole in the emitter board.

c.

Move the carrier frame.

d.

Try emitter pickup and board

e.

Perform the adjustment if,the 2 aligning tools cannot be inserted.

EMITTER BOARD TO PICKUP

CARD

an

amplifier.

PRT10 (191).

If

to

determine

If

the test runs OK (with all 2's,

or

a 3)' no adjustment

the test fails (prints mostly

what

part

of

the emitter is not

as

it

will go (emitter

to

the right.

II

in the emitter board.

of

2.46 mm ± 0.13 mm (0.097

II.

if

the gap is not

Fine

Adjustment knob

of

3.25 mm ± 0.13 mm (0.128 inch ±

II.

to

the left against the side

to

insert the 2 aligning tools through the

II.

as

AND

l' s or

follows:

IE

to

3'

set

Adjustment

1.

Adjust the print emitter board a.

Separate the printer from power supply board A1

(115).

b.

Turn the Horizontal Fine Adjustment knob fully counterclockwise (emitter position).

c.

Loosen the 2 setscrews

d. Slide the emitter board

s

2.

possible.

e.

Move the carrier

f.

Insert code plate aligning tool, part 460028, into

the left hole

g.

Slide the emitter board

between the left side frame and the aligning

tool is 2.46 mm ± 0.13 mm (0.097 inch ± 0.005

inch)

II.

h.

Tighten the 2 setscrews

Adjust the print emitter pickup board as follows: a.

Use the Horizontal Fine Adjustment knob a gap

of

3.25 mm ± 0.13 mm (0.128 inch ±

0.005 inch) between the aligning tool and the left side frame

b.

Remove the aligning tool.

c.

Loosen the pickup mounting screws

d. Move the carrier

frame.

e.

Insert the code plate aligning tools touch the Horizontal Fine Adjustment knob.

f.

CAUTION Do not pinch the wires

With

the carrier against the left side frame,

tighten the 2 pickup mounting screws.

g. Remove the aligning tools. h.

Reinstall the printer on power supply board A 1

(115).

i.

Perform the left margin adjustment (143).

II

to

in

II.

the right.

the emitter.

to

the left against the side

as

follows:

in

the leftmost

II.

as

far

to

the right

to

the left until the gap

II.

to

print emitter

II.

to

the emitter pickup.

IE

as

to

set

Do not

Printer

Emitter

Pickup

and

Amplifier

Removal

and

Replacement

1.

Separate the printer

from

power supply board A 1

(115) and place the printer in the service position.

2.

For installation, adjust the left margin (143).

3. Verify that P2A

II

and P28

II

are connected

as

shown on the safetY cover label;

if

they are not,

record the

way

they are connected.

4. Disconnect P2A and P28.

5. For installation, adjust the print emitter pickup and

amplifier card (140).

6.

CAUTION

The coil spring B is released when the pickup

mounting screws are removed.

Remove 2 screws

II that hold the pickup

to

the

carrier.

7. Reinstall the pickup by reversing this procedure.

140

Remove. Replace.

Adjust

DO

Underside View with Printer in Service Position

Maintenance

5256

MIM

1-37

141

PRINT

EMITTER BOARD

Removal

and

Replacement

1.

Power

off.

2.

Remove the printer covers (110).

. 3. Disconnect the connector

II

from

the

circuit card.

4.

5.

Remove the hold

down

bracket

1m

from

the

left

side frame.

Remove,

from

the

right end

of

the shaft, the

screw

II

that

holds

the

print emitter support shaft. (The

Horizontal Fine

Adjustment

shaft

II

will come

off

also.)

6.

Remove the emitter D

by

pulling the

left

end out.

7.

B.

9.

Reinstall the emitter

by

reversing this procedure.

Lubricate the emitter

as

shown in the section titled

Preventive Maintenance.

Adjust the print emitter pickup (140)'

left

margin

(143), and the print emitter

hold

down

bracket

(142).

142

PRINT

EMITTER HOLD

DOWN

BRACKET

Adjustment

Check the hold-down bracket

1m

for

2 conditions:

1.

2.

There

must

be no vertical movement

of

the print

emitter board

D.

The board must slide freely when the Horizontal

Fine Adjustment knob

II

is turned in both

directions.

3.

Adjust

if

needed.

1-38

143 LEFT

MARGIN

Service

Check

1.

Run PRT10 (191).

2.

Perform the adjustment

if

numbers other than

2,

or

a 2

with

sometimes a 1

or

a 3, appear on the

left

side

of

the form.

Adjustment

This adjustment is

to

ensure

that

the fall

of

the.

'left

margin' signal is centered between 2 ' print emitter

3'

signals.

1.

Power

off.

2.

Remove the printer covers (110).

3.

4.

5.

6.

7.

B.

Turn

the

Horizontal Fine Adjustment knob

II

to

the center

of

its movement.

Push the carrier against the

left

side frame.

Using the

CE

probe, observe

the'

-left

margin'

signal

by

connecting

the

probe

to

81 81

810.

Power on.

Slowly move the carrier

to

the right (by turning the

motor

pulley) until the up light turns on. (Use the

Horizontal Fine Adjustment knob

to

get

as near

to

the

shift

point

as

possible.)

Mark a point

on the knob

II.

9. Observe

the'

-print

emitter

3'

signal

by

connecting

the probe

to

8 J A 1 80B.

10. Check

that

the

down

light is not on

at

first

but

turns on when the

Horizontal Fine Adjustment

knob is turned 1

/4

turn

or

more in each direction

from

the mark.

11.

If

the

down

light does turn on,

go

to

the next

step.

If

the

down

light is on

at

first,

or

does

not

shift

as

indicated, move plug P28

II

to

another

position

D D or II (see the label on the safety

cover) and return

to

step 3.

12.

Mark

the last position

of

P28 on the

labelm.

13.

An

operating check

of

the

left

margin timing can

be made

by

running PRT10 (191).

The

white

Position

1.

c:::::Jc::JCJD

D

dot

J2

Bottom

indicates

0

View

II

Connect

Position 3

(See

the

location below'!

141-143

Remove, Replace,

Adjust

Maintenance

5256

MIM

1-39

Carrier

1-40

150

Service

1.

2.

Adjustment

Two

shaft is adjusted

the shaft. The carrier bracket support bearing is

adjusted

0.003 inch) gap

1.

2.

CARRIER

Check

The carrier support bearing should be 0.025 mm to

0.076 mm (0.001 inch

support shaft

Check the main shaft a.

Insert a strip (3/16

- between the bearing and shaft

b.

Push carbon paper.

c.

Check needed.

adjustments are needed

for

Remove the printer covers (110).

Adjust the carrier support shaft bearing a.

Separate the printer from power supply board

A1

(115).

b. Slightly loosen the socket head

end ribbon drive clutches

c.

Turn the eccentric mm bearing and shaft bottom

d.

Tighten the socket

bearing eccentric.

e.

Check the gap again and adjust

f. Assemble the printer and power supply.

MAIN

AND

SUPPORT SHAFTS

to

0.003 inch) from the

...

a_djustment

of

carbon paper about 4.7 mm

inch) wide and 127.0 mm

as

follows:

(5

inches) long

B.

the carrier so the bearlng rolls over the

for

a smooth, even mark; adjust

for

the carrier. The main

for

full contact

0.025 mm to

of

the bearing eccentric D Remove the

(0.001 inch

to

the support shaft.

to

of

the carrier as shown in the figure.

of

the carrier bearing on

0.076 mm (0.001 inch

as

screw.

for

access (171).

to

obtain 0.025 mm

0.003 inch) gap between the

..

while pushing on the

screw.

on the end

if

needed.

if

to

follows:

at

the

to

0.076

of

the

3.

Adjust the carrier main shaft a.

Loosen the screws

b.

Turn the shaft until the full

..

rolls on the flat part mark. be

c.

Hold the shaft in this position adjustable wrench (be careful not

the flat part screws

4. Check the adjustment a.

Insert a strip (3/16

between the bearing and shaft II.

b.

Push'the carrier so the bearing rolls over the carbon paper.

c.

Check needed.

Reinstall the printer covers (110).

5.

on the left end

up.

of

the shaft) and tighten the

in

the shaft ends.

of

carbon paper about 4.7 mm

inch) wide and 127.0

for

a smooth, even mark; adjust again

fJ

as

follows:

at

the shaft ends.

width

of

the shaft

of

the main shaft must

with

as

follows:

mm

of

the bearing

B.

The

an

to

damage

(5

inches) long

if

151

CARRIER

SUPPORT

SHAFT

Removal

and

Replacement

1. Power

off.

2. Separate the printer

from

the

power

supply (115).

3. Remove the print emitter (141).

4. Remove the carrier drive belt

from

the motor.

5.

Loosen the screws on the end

of

the carrier

hexagonal (main) shaft

II.

6. Remove the screw on each end

of

the carrier

support shaft

lEI.

7. Separate the side frames enough

to

free the

support shaft.

8. To reinstall the shaft, reverse this procedure.

9. Perform adjustments

for

the print emitter pickup

(140), the

left

margin (143), and the carrier main

shaft (150).

150-152

Remove, Replace,

Adjust

.

152

CARRIER

AND

MAIN

SHAFT

Removal

and

Replacement

1. Power off.

2.

Remove the covers (110).

3. Remove the print emitter (141).

4. Remove the print head

(160).

5. Separate the printer

from

power supply board

A1

(115).

6. Loosen the belt clamp

IE

and remove the belt

from

the motor. For installation, ensure the belt

alignment is correct (153).

7.

8.

9.

Remove the

print

emitter pickup (140).

Remove the ribbon drive lines (173).

Remove the screw

from

each end

of

the carrier

main shaft

II.

10. Pivot the carrier and main shaft around the carrier support

shaftEl

to

clear the

A-frame

II.

11. Lift the carrier

out

II.

For installation, ensure the

mark.

on the

left

end

of

the main shaft is up.

12. Remove the ribbon drive assembly

(170).

13. To reinstall the carrier, reverse this procedure. Always check the following items and adjust them if

needed:

a.

Carrier main shaft and carrier support shaft (150)

b. Print head (160)

c.

Print emitter pickup (140)

d. Left margin (143)

Maintenance

5256

MIM

1-41

153

BELT

TENSIONER

ASSEMBLY

Removal

and

Replacement

1.

Power

off.

2.

Remove the printer covers (110).

3.

Loosen the carrier

to

belt clamp

II

and slip the

belt

out

of

the clamp. For installation, ensure belt

alignment"

is correct before tightening

the

clamp

II

and the screw

D·

4. Remove the belt

from

the

motor

pulley.

5.

6.

Remove the screw

D.

Then, remove the tensioner

assembly.

When

reinstalling,

do

not

tighten the

screw

until alignment is completed.

To

reinstall, reverse this procedure.

Carrier Bracket

Belt

Clamp

80

cps

and

120

cps

Belt Tensioner Assembly

D Move

the

belt tensioner assembly

to

get

proper belt alignment as shown

at

e.

Underside View

of

Printer in

Service Position

Belt Clamp

Carrier Bracket

40

cps

1-42

154 CARRIER

MOTOR

AND

PULLEY

Removal

and

Replacement

1.

2.

3.

4.

5.

Power

off.

Separate the printer

from

power supply board

A 1 (115) and place the printer in the service

position.

Disconnect the

motor

leads

from

TPB 1

II.

Take the belt

off

the

motor

pulley

II.

Remove the 2 screws holding the

motor

II

to

the

motor

mount.

6.

To reinstall the motor, reverse this procedure.

Underside View

of

Printer

in Service Position

153-155

Remove, Replace,

Adjust

155

CARRIER LEAF

SPRING

AND

BEARING

Removal

and

Replacement

1.

2.

3.

4.

Power off.

Separate the printer

from

power

supply board A 1

and place the printer in the service position (115).

Remove the 2 screws

from

the leaf spring and

bearing

II.

Then, remove the assembly.

Reinstall the assembly by reversing this procedure. Ensure the bearing sides are parallel

to

the flat

part

of

the shaft. (Look through the holes in the

left

side frame

to

verify

that

the parts are parallel.)

A

B

___

.........Ie

White

Service

Position

(right

end

view)

Maintenance

5256

MIM

1-43

Print

Head

160

PRINT

HEAD

Service

Check

1.

Remove the printer covers (110).

2.

Center the print head on the platen.

3. Remove the print head cover

(2

screws) and place

the' cover and ribbon

to

the right.

4. Turn the platen so that the center point between the 2 setscrews that hold the right-hand Platen

knob points straight up.

5.

Set the Copy Control dial

II

to

O.

6.

Check that the ends

of

the print wires are 0.30

mm

to

0.35 mm (0.012 inch

to

0.014 inch)

II

from the platen; adjust

if

needed.

Adjustment

1.

Perform steps

1,

2,

3,

and 4

of

the service check;

then return

to

step 2

of

this procedure.

2.

Position the print head so that the ends

of

the

wires are

0.30 mm

to

0.35 mm (0.012 inch

to

0.014 inch) from the platen

as

follows:

a.

Loosen the

hold-down

IE

and screw II on the

right

of

the print head.

b.

Set the Copy Control dial

II

to

O.

c.

Place a 0.35 mm (0.014 inch) thickness gauge between the platen and print head wires

d.

Position the print head in the center

of

the platen and push the head lightly toward the platen.

e.

Tig~ten

the

hold-down

IE

and screw

II·

3. Check the adjustment and adjust again

if

needed.

4. Reinstall the print head cover and tighten the ribbon.

5.

Install the printer covers (110).

1-44

Removal 'and

Replacement

DANGER

The print head may

be

very hot after continued use.

Always let the head cool before removing it.

1.

Power off.

2.

Remove the printer cover (110).

3. For new print head installation, put IBM

No.6

oil on the 2 felt washers on the right bar, the bronze block, and rear slide points on the left bar.

4.

Push

the print head

to

the ramp position (far left).

5.

For installation, push the print head in and out

of

the ramp position

to

ensure that the head moves

back correctly.

Remove the ribbon from the print head and its covers, and place the ribbon

to

the right.

6.

Open the ribbon feed rolls II and remove the

print head cover

(2

screws).

7.

For installation, adjust the print head.

8. Disconnect the print head cable from

EC3

II.

9. To the right

of

the print head, remove the screw

II and

hold-down

IE

that hold the bronze tabs.

10. To the left

of

the print head, remove the screw

II

that holds the bronze block.

11. Remove the cover from the oil felt and pull the oil wick

from the felt

II.

For installation,

if

there is

no oil in the felt, add IBM

No.6

oil and check that

the

wick

touches all 8 print wires

II

or

lB.

12. For new print head installation, install the old

wick

in the new print head

III

or

lB.

13. Lift off· the print head.

14. For installation, tilt the tip

of

the head down so

that

it

will slide under the print head forms guide.

15. To reinstall the print head, reverse this procedure.

161

Adjustment

PRINT

HEAD

FORMS

GUIDE

0.30

mm

(0.012 inch

to

0.35

to

mm

0.014

inch)

The print head forms guide should from the platen and centered inside the limits mounting holes.

Removal

1.

2.

3.

4.

5.

6.

7.

and

Replacement

Power off.

Remove the platen and paper deflector (120).

Separate the pressure roll arms and move the end of

the left roll shaft

Remove the 2 guide mounting screws remove the guide.

Install the new guide with the screws loose.

Center the guide

toward the print head, and tighten the screws.

Complete the operation by reversing the first 4

steps.

..

in

the mounting holes, press

be

as

far

away from the platen area.

II

as

possible

of

and

the

it

40

cps

m

Oil

and

80

cps

Wick Installation

Print

~~--II

I=l-T+----lo=----II

Head Print Wires

\

\ \

\ \ \

o-fl

160, 161

\ \ \

\ \ \ \

The oil wick against

the

120

cps

if)

Oil

Wick Installation

must

be looped

print wires.

Install

the

oil wick

Maintenance

felt pad between

knot

and

the

5256

Print

Head

the

plastic tubing.

MIM

1-45

Remove, Replace,

Adjust

1-46

162

Removal

1.

2.

3. Remove the print head (160).

4. Separate the printer

5.

6.

PRINT

Power off.

Remove the printer covers (110).

head on

A 1 (115). Observe the

installing the cable.

Note P2BD·

CAUTION

When emitter

HEAD CABLE (EC1)

installation.

from

power supply board

cable path

how

P2B

is connected and remove P2A and

loosening the mounting screws

pickup, the coil spring

Adjust

to

II

is released.

the print

aid in

for

the print .

7.

Loosen the belt clamp

bracket

clamp.

8.

Work

the cable

and push the connector through the hole.

9. Remove assembly

the ends).

10. Remove the

the

2 screws

II

old cable.

II

(the long

II.

Remove the cable

(2 screws).

out

of

the holes in the casting

from

the cable clamp

flat

spring

with

II

plastic on .

Loosen the print Remove the clamp remove the wires

emitter

fI D

pickup cable clamp

screw

on the

from

under the clamp.

left

side and

II.

Underside View in Service Position

of

Printer

Replacement

1.

Fold the

new

cable on the mark

Da.

2.

Attach the cable clamp assembly and cable

to

the

bracket

III.

3.

Make a

90°

counterclockwise

twist

in the cable

and

fold

the cable at right angles

to

the long part

of

the cable.

4.

5.

Place the 2 small parts

of

the cable in the bracket

notch

II

and fold them back.

Push the

large connector through the hole in the

casting and fasten the

cable clamp bracket in

place (2 screws)

II.

6.

Work

the cable into

the

holes so

that

the locking

arms

IE

are at the left.

7.

Place the 2 small cables under the clamp

for

the

print emitter pickup and

install the screws loosely.

8.

Form the cable

to

the

flat

spring.

9. Form a

loop in the cable

II

at

the end

of

the

flat

spring.

10. Form the print head cable around the head mounting pin

II

before connecting the cable

to

EC3.

The loop

must

be large enough here so the

cable causes no interference

with

print head

movement.

11.

Install the print head (160).

12.

Install

the

printer on

the

power

supply (115).

13. Connect

P2A and

P28

D.

14. Adjust

the

print emitter

to

the

pickup (140).

15. Adjust

the

left

margin (143).

162

Remove, Replace,

Adjust

Maintenance

-l

I

,

5256

MIM

1-47

163

OIL

FELT SERVICE

1.

Power off.

2. Remove the top cover.

3. Remove the ribbon from its guides and place

it

on

top

of

the ribbon

in

the ribbon box. (If the ribbon

is worn badly, replace it.)

4.

Remove the print head cover

(2

screws)

II.

5.

Remove the plastic cover from the oil felt

II.

6. Soak the felt with IBM

No.6

oil.

7.

Complete the proc(;ldure by reversing the first 5 steps.

164

PRINT

HEAD

RIBBON LIFTER

Removal

and

Replacement

1.

Power

off

and remove the top cover (110).

2.

Remove the print head (160). Adjust the print

head during installation.

3. Remove the screw B and the ribbon lifter

II.

4. When installing, adjust the

tip

of

the lifter 0.00

mm

to

0.05 mm (0.000 inch

to

0.002 inch)

II

behind the tip

of

the print head

II

when the Copy

Control dial

II

is set

to

8.

5.

Complete the procedure by reversing the first four steps.

Use a small

ruler

to

. help align the ribbon lifter

II

to

the

print

head.

1-48

165

PRINT

HEAD

RIBBON

SHIELD

Service

Check

1.

Power off.

2.

3.

4.

5.

6.

7.

Open the

top

cover.

Remove the paper deflector

(120).

Remove the print head forms guide (161).

Open the ribbon feed rolls.

Check that the ribbon tracks below the bottom

of

the opening

in

the ribbon shield II; remove the

ribbon

from

in

front

of

the print head.

Check

for

a 0.18

mm

(0.007 inch) minimum

clearance"

between the ribbon shield and the

print head so the ribbon

can

be installed.

8.

Install the platen

without

the paper deflector.

9. Check

for

a 0.20 mm (0.008 inch) clearance

between the ribbon shield and the platen

II;

adjust

if

needed.

Removal,

Replacement,

and

Adjustment

1.

For removal, perform .steps 1 through 6

of

the

service check; then, return

to

step 2

of

this

procedure.

2.

Remove the 2 screws

II

and replace the ribbon'

shield. For adjustment only, loosen but do

not

remove the screws.

3.

Install the platen without the paper deflector.

4. Set the

Copy Control dial

II

to

O.

5.

Place 0.30 mm

to

0.50 mm (0.012 inch

to

0.020

inch)

of

paper

or

cards (2 or 3 cards) between the

ribbon shield and the platen.

6.

Push

the print head tightly against the paper or

cards and tighten the 2 screws

II. This is

to ensure correct parallel alignment between the ribbon shield and the platen.

163-165

Remove, Replace,

Adjust

7.

•

Remove the paper

or

cards. The result should be

a minimum

of

a 0.20

mm

(0.008 inch) gap

between the ribbon shield and the platen

II.

8.

Remove the platen.

9.

Assemble the machine by reversing the first 7 steps

of

the service check.

D

0.18 mm

-1

- (0.007 inch) Minimum

Print

Head

I

tr]

Platen

/

Ribbon Shield

II

Maintenance 5256

MIM

1-49

1-50

This page

is

intentionally

left

blank

•

166

COpy

CONTROL

DIAL

Removal

and

Replacement

1.

Remove the print head ribbon lifter (164).

2.

Tilt

the assembly away from the print head and

remove the screw

II

,that holds the dial.

3.

Complete the operation by reversing the preceding steps.

167

PRINT

HEAD

RETRACT

RAMP

Adjustment

1.

Power off.

2.

Remove the printer

front

cover (110).

3.

Loosen the 2 retract ramp mounting screws

II

slightly.

4.

Move

the carrier against the

left

side frame.

5.

Set the Copy Control dial

II

to

O.

6.

Position

the'

retrad

ramp

II

so

that

the Copy

Control dial

is 2.41

mm

± 0.13

mm

(0.095 inch ±

0.005 inch)

from

the print head housing. Use a

code

plate alignment tool (part 460028)

as

shown

II

to

measure this setting. Tighten the 2 screws.

7.

Complete the procedure by reversing steps 1

and

2.

o Print

Head

Retract Ramp

Underside

View

of

Printer in Service Position

166,167

Remove, Replace,

Adjust

2.41 mm ± 0.13 mm (0.095 inch ± 0.005 inch)

•

Print

Head

fI

Copy Control Dial

II

Code

Plate Alignment

Tool

(part 460028)

Maintenance 5256

MIM

1-51

Ribbon Drive

170 RIBBON DRIVE

Removal and

Replacement

1.

2.

3.

4.

5.

6.

7.

Power

off

and remove the printer covers (110).

Remove the print head (160). Adjust the print head during installation.

Separate the printer from power supply board A 1 and place the printer in the service position (115).

Remove the ribbon drive lines II (173).

Remove the screw from the inside

of

the ribbon

box II.

Remove the screw from the left side

of

the ribbon

box beside the feed rolls

II.

Lift out the ribbon drive.

8. To reinstall the assembly, reverse this procedure.

171 RIBBON DRIVE CLUTCHES

Removal

and

Replacement

1.

Separate the printer from power supply board A 1 and place

the

printer in the service position (115).

2.

Remove the ribbon drive lines II (173).

3.

4.

5.

6.

Remove the clip from the bottom

of

the ribbon

clutch shaft

II.

For installation, when the shaft is held, both clutches should turn clockwise (when seen from the clutch end

of

the shaft)

II

if

you turn them.

Remove the clutches and washers

II.

To reinstall the clutches, reverse this procedure. Put a little IBM No. 23 grease on the clutch end

of

the shaft before installing the clutches.

1-52

172 RIBBON DRIVE

SHAFT

Removal

and

Replacement

1.

Power

off

and remove the printer covers (110).

2.

Remove the ribbon (177).

3. Remove the clip at the Ribbon Advance knob II.

4.

Separate the printer from power supply board A 1 and place the printer in the service position (115).

5.

Remove the ribbon drive lines (173) and take the drive belt

off

the motor pulley.

6.

7.

Remove the shaft

II

with the clutches

II.

Remove the remaining clip

II

and slide the

clutches

II

off

the shaft.

8.

For installation, when the shaft

is

held, both clutches should turn clockwise (when seen from the clutch end

of

the shaft)

if

you turn them.

9. To reinstall the shaft, reverse this procedure.

173 RIBBON DRIVE LINES

Removal

and

Replacement

1.

Separate the printer from power supply board A 1 and place the printer in the service position (115).

2.

Remove the lines II from the clutches D but

leave the springs attached

to

the tabs on the right

and left brackets.

3.

To reinstall, thread the lines so they are parallel

to

each other and

to

the carrier main shaft. The line

crossovers must

be

as

shown

II.

4. Assemble power supply board A 1

to

the printer

(115).

Note: An aid, when installing the upper line is

to

use a

small amount

of

adhesive tape

to

hold the loop around

the clutch while attaching the ends ·to the side frame.

170-173

Remove, Replace,

Adjust

~

/

Underside View

of

Printer

in

the Service Position

•

Upper Clutch

Lower Clutch

~'..I---Clip

Maintenance 5256

MIM

1-53

174

RIBBON

FEED ROLLS

Service

Check

The right and left feed rolls should be aligned

with

each

other

\';'ithin 0.254 mm (0.010 inch)

II.

Adjustment

1.

Power off.

2.

Open the

top

cover.

3. Adjust the

feed· rolls

as

follows:

a.

Loosen the screw

II

that holds the right

fee,d

rolls.

b.,

Open the feed rolls by pushing the

,flat

spring

to

the right

II.

c.

Position the right feed rolls so

that

they align

with

the

left rolls

II.

, d. Tighten the screw.

Removal

and

Replacement

1.

Power

off

and remove' the ribbon (177).

2.

Remove the right feed rolls as

follows:

a.

Remove the screw

II.

b.

Hold the

flat

spring

II

to

the right and turn the

feed

rolls.

toward the platen area

to

free

them from

the· spring.

3. Remove the

left feed rolls

as

follows:

a.

For installation, install the platen and adjust the print head.

b.

Remove the print head (160).

c.

Remove the screw

II

from the

left

side

of

the

ribbon box.

d.

If

the

right feed rolls are in place, hold the

~Iat

spring II

to

the right and turn the left feed rolls

toward the platen.

4.

To reinstall the feed. rolls, reverse this procedure.

Align the right feed

rolls vertically

to

the

left

rolls

II·

1-54

175

RIBBON

DRIVE GEARS

Removal

and

Replacement

1.

Power off.

2.

Separate ,the printer

from

power supply board A 1

,(115).

3. Remove the· clips

III

and remove the gears from

the feed

roll shafts. .

4. Remove the drive shaft

II

(172).

'5. Remove the

dip

IE

and remove the idler gear:

6. Reinstall the gears by reversing this procedure. Put a little IBM No. 23 grease on the gear shafts

and on the

gear teeth.

176

RIBBON

BOX

AND

COVER

Removal

and

Replacement

The ribbon box cover can be separated

from

the box at

the hinge.

1.

Power off.

2.

Separate the printer from power supply board A 1 and place the printer in the service position (115).

3. Remove the ribbon drive assembly

(170).

4.

Remove the following parts:

a.

Ribbon feed rolls (174)

b.

Ribbon drive shaft (172)

c.

Ribbon Feed Roll Release knob

II

(it has a clip

on the bottom)

4. Assemble the ribbon box and cover by reversing

this procedure.

177 RIBBON

CHANGING

1.

Power

off.

2.

Open the

top

cover.

3.

Open the ribbon feed rolls II.

4. Remove and do

not

save the old ribbon (see the

label on the ribbon box cover).

5.

Eject a

new

ribbon into the box

by

pressing on the

disk in the case. Do

not

save the case and the

disk.

6.

Pull approximately

254

mm

(10 inches)

of

ribbon

from the

coil and

form

a loop.

7.

Thread the side

of

the loop nearest the platen as

shown on the ribbon box

label. Thread this end

just past the print head.

Close the feed rolls.

8.

9.

Thread the other end

of

the ribbon

as

shown. The

half

twist

should

now

be beside the horizontal

guides.

Tighten the ribbon by turning the knob

11.

Guide

the ribbon between the

horizontal guides so

that

1/4

turn counterclockwise

is

on each side

of

the

guide.

10. Close the cover and

power

on .

•

~I-D

t

II

174-177

- D

!--o

Remove, Replace, Adjust

m

....

_1

,

"

~,

/ \

I

r

\

\ /

, /

'--_/

Maintenance 5256

MIM

1-55

1-56

This page is

intentionally

left

blank

Power

al1d

Electronics

180 POWER SUPPLY

Removal

and

Replacement

1.

Power

off.

2. Disconnect the line cord.

3. Remove the printer back cover

(110).

4. Loosen the shipping screws

II

and

II

seven

turns. You may leave

t~em

loose except

for

shipping.

5.

Loosen the

front

clamping screws

II

and III

one-half

turn.

6. Loosen

the

rear clamping screws B and II

enough

to

clear

the

stops II and

II.

7. Disconnect

Jl

fJ.

8.

Remove the

TBl

wiresEJ.

9. Disconnect

C1A1D.

10. Remove the line cord

from

the terminal

blockD.

(if

a line

filter

is

present, remove

phase A from

A,

neutral

from

B (189).

11.

Support the

power

supply and remove

it

from

the

printer

by

pulling as shown in

the

drawing.

12. Reinstall the power supply by reversing this procedure.

Ripple

Level

Check

The

peak-to-peak

output

ripple level· should be less

than 3

%

of

the respective

DC

voltage

when

measured

with

an

oscilloscope.

180

Remove, Replace,

Adjust

•

Position 1

of

TB

1

Power Supply

(top view)

...

Pull Here

IJ

TB2~

L---=r

Fan

rl

L

Maintenance 5256

MIM

1-57

1-58

181

Removal

1.

2.

3. Remove the printer back cover (110).

4. Remove the wires from

5.

POWER

and

Power off.

Disconnect the line cord at the wall outlet.

DANGER This AC capacitor might contain enough power to Always discharge the capacitor by placing a screwdriver from each

TRANSFORMER

Replacement

TB1

II.

cause a lethal shock or a severe burn.

terminal

to

the case.

D

Transformer Wires

Transformer

C1

E4 E5 E6 E7 E8 E9

E10

E11

E12 E13 E14 13

60 Hz (U.S.)

to

Board

C1

A 1 (189)

T1

Wires

Hz (WT) 50

60

10 14 16 11

9 13

19

20 24

18 22 16 17 15

7

15

23 25

20 22 21 19 11 17

Hz

17 15

26 24

23 21

13 19

(WT)

Remove the transformer wires from

6. Remove the transformer wires through E14

7.

Disconnect J 1 on the right side

8.

Remove the transformer grounding lead present. Do

board

9. Remove the 4 transformer mounting screws. A grounding washer is under the

10. Lift the transformer

11. Reinstall the transformer by reversing this procedure.

C1

of

board

not

remove the wire

to

the

power

C1

D

supply base.

from

the

power

C1211.

from

terminals

II·

of

the printer

if

from

E15

left rear leg II.

supply.

one is

on

E4

II.

•

TB1

Connections

•

60

Hertz

(189)

Input Vac

100 6 115 200 4 208 220 230

Phase A (From

50 Hertz

Input

F1)

1

3 2

1

Neutral Fans

7

4

7

5

5 2

5

and and and and and and

8 3 8 8 8 8

Vac

100 110

123.5 200 220 235

(189)

Phase A

(From

7 9

6 9

4 9

3 9 2 1 9

F1)

Neutral

9

Fans

5

and

5

and

5

and

5

and

5

and

5

and

8 8 8 8 8 8

\

\0

2

Grounding Washer

Leg

181

Remove, Replace,

Adjust

Maintenance

5256

MIM

1-59

1-60

182 FANS

Fan

B1

Removal and Replacement.

1.

Power off.

Remove the printer covers (110).

2.

Remove the platen and paper deflector (120).

3.

4. Disconnect the cables from A 1 A3 and A 1

5.

Remove card A 1

6.

Remove the fan wires

7.

Remove the 2 screws

Slide the fan toward the front

8.

the fan backward, and remove the fan through the back

of

the printer.

9. Remove the fan from the bracket. When reinstalling the fan, ensure the air mark on the fan points toward the bracket.

B3

II.

fro~

II.

TB3

.

of

II.

the printer,

flow

di~ection

A4

II.

tilt

183 TB2

The line filter is not used on all machines.

TB2 Removal and Replacement

1.

Power off.

Remove the printer back cover (110).

2.

3.

Remove the shield from TB2 II.

4.

Remove the line cord wires from TB2 (phase A from

5.

Remove the 2 mounting screws and

6.

Move the remaining leads

block.

7.

Complete the operation by reversing this procedure.

Line Filter

AND

LINE FILTER

2,

and neutral from 1 III (189).

to

the new terminal

Removal and Replacement

lift

out TB2.

10. Reinstall the fan

Fan

B2

Removal and Replacement

1.

Power off.

Remove the printer back cover

2.

Remove the fan wires from TB 1 on the

3.

transformer II.

Remove the fan II. When reinstalling the fan,

4.

ensure

5.

that

from the bracket.

Reinstall the fan

by

the air

by

reversing this procedure.

(2

flow

direction mark points away

reversing this procedure.

screws).

1. Power off.

2.

Remove the printer back cover (110).

3. Remove the

4. Remove the line cord wires from the line filter (phase A from A, neutral from B

5.·

Remove the 2 mounting screws and filter.

6. Move the remaining leads

7.

Complete the operation by reversing this procedure.

shi~ld

from the line filter II.

to

II

(189).

lift

out the

the new filter.

Line Filter (used on

World Trade

some

machines)

ACB

Brown

Blue---l,a,..

........

--.,.

182,183

Remove, Replace,

Adjust

Position 1 of

TB1

..

Maintenance

5256

MIM

1-61

184 POWER ADAPTER

BOARD

C1

AND

CAPACITOR

ASSEMBLY

Capacitor

Service

Check

CAUTION To avoid damage

to

the

CE

meter, always discharge the

capacitor before connecting the meter wires.

1.

Power off.

2.

Remove the capacitor from the circuit.

3.

Set a

CE

meter

to

the R x 100 scale.

4. Place a screwdriver across the capacitor terminals.

5.

Connect the meter wires to the capacitor and watch the meter.

6.

Reverse the meter

wires

at

thecapacitor

terminals

and watch the meter.

7.

If

the meter needle moves quickly toward 0 ohms

and then slowly toward infinity (

00

) each

time the meter is connected, or the wires are reversed, the capacitor is

OK.

If

not, the capacitor

should be replaced

..

1-62

Removal

and

Replacement

1.

Power off.

2.

Remove the printer back cover (110).

3.

Disconnect

C1

A 1

II.

4.

Disconnect the wires from

E3

through

E1611.

5.

Loosen the clamp

II

that holds capacitors C4 and

C511·

6.

Lift the board and capacitors out

of

the power .

supply.

7.

Reinstall the assembly by reversing this procedure.

'C1

Tranformer

T1

Wires

J1

60

Hz

U.S.

60

Hz WT

50 Hz WT

E3

1

E4

10

14 16

E5

11

15

17

E6

9

13 15

E7

19

23

25

E8

20 24

26

E9

18

22

24

E10

16 20

22

E11

17

21

23

E12

15.

19

21

E13

7

11

13

E14 13

17

19

E15

5

E16

6

\

D

•

185

AC

CAPACITOR

(C12)

AND

CAPACITOR

C3

See 184

for

a capacitor check.

C12

Removal

and

Replacement

1. Power off.

2.

Disconnect the line cord from the wall outlet.

3. Remove the back cover (110).

DANGER

This AC capacitor

might

contain enough power

to

cause a lethal shock or a severe burn.

Always discharge the capacitor by placing a

screwdriver from each

terminal

to

the case

D.

4.

After

discharging the capacitor, remove the leads.

5.

Loosen the capacitor clamp

II

and remove the

capacitor.

6.

Reinstall the capacitor by reversing this procedure.

184,185

Remove, Replace,

Adjust

C3

Removal

and

Replacement

See 184

for

a capacitor check.

1.

Remove the power supply board A 1 (186).

2.

3.

Note the polarity connections. Then, remove the 2 capacitor connecting screws

II

on the bottom

of

power supply board A

1.

To

replace the capacitor, reverse this procedure.

Position the capacitor

as

far

to

the rear

as

possible.

Maintenance

5256

MIM

1-63

1-64

186 POWER SUPPLY

Removal

1.

2.

3.

4.

and

Replacement

Power off.

Separate the printer from power (115).

If

the cable is disconnect the transformer wires from the board: a.

Black from points 4B, and 4C b. Blue from points 3 and 9 c.

Red

If

the cable is being installed

a.

Disconnect

(seen from the rear). b. Disconnect the positive

not

from points 2 and 8

P1

BOARD

being installed

A1

B.

II.

with

at the right end

lead from capacitor

AND

supply board A 1

with

II.

the board:

of

III·

5.

Disconnect and label the capacitor cable leads

as

shown.

CABLE

the board,

the printer

C2

II

7.

Remove the screw and stud from capacitor

8.

Remove the 2 screws

side.

9. Remove the 2

out.

1

O.

For installation, locate

board

as

the rear

11. To reinstall the board, reverse this procedure. Ensure

that

CAUTION

When installing leads from the capacitors B

polarity must be correct.

screws"

possible and locate the board

of

the printer

R3

or Z3

III

and move the fan

and

II

.

C3

as

far

as

possible.

is

installed

1&.

and

to

the rear

lift

the board

as

far

C3

to

of

II.

the

to

6.

Disconnect the cables from A 1

D D

Fan

B1

A3

and A 1

Power Supply Board A 1

A411.

W1

W2 e V2

LM1 e V3

~V1

LM2 e V4

e

FMA

e V5

e FEA e

G6

e LM e

G7

eE3

1

eG8

8~

1W

J4

(_~m

R1

(+) •

C2

TOP1m

-

187

TRANSISTOR

(Q1)

Service

Check

1.

2.

3.

4.

5.

6.

Power off.

Separate the printer from power supply board A 1

(115).

Remove the gray safety cover.

Disconnect the 3 transistor leads from the pins on board A 1 (189).

Set up a

CE

meter

to

the R x 1000 scale.

Measure the resistance in both directions on each pair

of

leads (collector and base, collector and

emitter, and emitter and base).

7.

A good transistor has at least

10

times the

resistance in one direction

as

in the other direction

for

all 3 pairs

of

leads. (Change the resistance

scale

if

needed

to

verify the readings.)

8.

Reconnect the transistor leads

to

the pins on

board A 1 (189).

9.

Complete the procedure by replacing the transistor (see below) or by reversing this procedure.

186,187

Remove, Replace,

Adjust

•

Removal

and

Replacement

1.

2.

3.

4.

5.

Separate the printer from power supply board A 1 (115).

Remove the gray safety cover.

Remove the 2

screws"

from

the transistor.

Pull the transistor from the socket. An insulating

washer will fall out also.

Replace the transistor by reversing this procedure.

Always install a new insulating washer

with

the

new transistor.

Maintenance

5256

MIM

1-65

1-66

This

page

is

intentionally

left

blank

•

-.

188

Removal

CAUTION

The logic on planar board electrostatic discharge. Do

(metal) parts. Hold the planar by the plastic frame when moving it.

Before you take the bag and touch the machine frame removes any static from you and the

Ensure when you

PLANAR

and

that

put

BOARD

Replacement

new

the component side

the planar on any surface.

B1

can be damaged

not

touch any conducting

planar from the bag, hold the

with

your hand. This

planar.

of

the planar

is

by

up

1.

Power off.

Remove the rear cover

2.

3.

Disconnect the cables

Remove the interposers.

4.

Slide the

5.

(116).

Remove the

6.

supply.

7. Remove the plastic pins to

power

planar and

its frame.

8. Remove the planar

9. Ensure

type, speed, and cable termination on the

planar are the same as those on the old planar. (Jumpers are shown on 106.)

that

jumpers

supply

boardll·

for

(110).

II.

to

the service position

Its

-frame D

fJ

that

hold the planar board

language group, cable

from

the

new

power

10.

Reverse steps 1 through 8 B1.

D

fJ

to

reinstall planar board

II

188

Remove. Replace,

Adjust

Maintenance 5256

MIM

1-67

1-68

189

AClnput

PRINTER

A Blue

C

--of--

Brownj

On

Black

or Blue (phase

A)

/Ground

~

Whiteor-

Brown (neutral I

\

See 181

World Trade

Some

for

WIRING

Ll

.........

World

Trade

TB2

connections

DIAGRAM

o

Machines

------

Transfornw

Jl

60

2

3 8

9

r-+---------f----.,H

6

....

Wir.

Hz

1M)

60

Hz

10

16

12 18

1M)

12 18 14 20

.-----------4--H9

----"I

Jl

+

4

7

8

Al·5B

PI

+POR

-Power

Good

AI·

(Voltages

see

chart

below.)

A3011

A4011 A3008 A3009 A400S A4012 A4009

to

planar

on

page

and Power Good

L-'--'~"------..'A3012

'-------

i5Vdc

'------4--

L.....---------<t-

.....

(A1A1J03)

Al·l3A

TP·V5

Al·15B

TP-G8

......

(AlAI

(AI81G05) (A1B3004)

~----------------------------------------------------~

- ...... - (AI

t--

DOS)

......

(A

J::*P

-?

Bl

005,006,007,

183

DOS,

006,

007,P03,

B05 P

EC2

004

>--t---<

~~)~

____

~~~

)~

__ I .. A __

~OS,

J05, J06, J07, J05,

33

31

P2A2 J2·1

~P2~A~3~(:.~J~2.~2

TPB2 Comm TPBl

l.:

________

J06, J07,

Print Emitter Board

JOS) JOB)

Print Emitter Pickup

-:

____

~

~r-TN/C

AR J2-3

t---~~

J24

J;!·5

J2-6

J2-8

8:

P2A4

P ECI

'J

B04

<E:(~---4cr-u>------::...---

P

J

ECI

P2B·l

8:

<

-Print

D03 (

-Print

(

B03 )

-Print

Note:

Refer

front

of

the mechanism

Reference 143

P EC2 J +End-of.Forms J A1A3 P r:-'\..

007

-E(:----~-)~

Z2 +Left Margin

TP·LMI Tp·LM2

Emitter 1

Emitter 2

Emitter 3

to

the

decal

on

for

in

this manual.

J

A1A3

)

the

safety cover

the

plug position.

BIO

BOO

BOS

013

P

)

> >

)>------<U

[0

A

[0

V

[0

at

the

11

•

189

PRINTER

~

______________________________________

~-----i0

P J

Volt

+S

+8.5

-S

Gnd

Control

Panal

Part

of

r70;;;;"sFee'd

I Emitter

4-4 G07 G12

GIl

4-8

-Power

Good

+POR B1B13

-Print

Emitter 1

-Print

Emitter 2

-Print

Emitter 3

+End-of·Forms

Cl

Bl

AI

006

B1D03

AlDOS

81012

A1Dl0

A1D12

AI

009

A1Bll

A1D12

AlDll

B1Bl1

A1BI3

AI

BOO

AIBll

AI

DOS

AIBIO

AI

009

A1B05

BIOOS

BID09

AIB04

-Power

On

-Attention

-Sys

Available Light

-Line

Check

-I

nternal Check Light

-Unit

Check Light

-Line

Sync Light

-Graphic

-Storage

Check Light

-Transparent

-Data

Cleared

-Forms

Light

-Ready

Light

-StopSw

-Line

Feed Sw

-Form

Feed

-Line

Space Sw

-TestSw

-Cancel

Sw

-StartSw

+5 Vdc

Ground

Twinaxial Signal (wh/blue)

Twinaxial Ground

~

WIRING

AlAI

--,

Amp

I J

G13

+5 Vdc

+8.S Vdc

-5Vdc

Ground

Li

ht

Light

Li

ht

Check Light

Mode Light

Li

ht

Sw

(wh/red)

DIAGRAM

(CONTINUED)

1

A1A4

-Forms

Emitter A

P

D07~----------------~

-Forms

812~----------------~

4-2

4-1~

4-5

4-8

l

...

4-7 A

Emitter 8

LED 8

".B..

81007 81812

B1D13

A1Bl0 A1B09

AIBOS A1D13

CIBOO

Planar Board

CIB07 CIB08 CIB09

CIBIO ClD02 ClD07 CIDIO CID09

C1Dl1

C1Bll

CIB05

CIOOS

C1B02

C1B04

CIB03 CID12

C1BI2

CI813

CID04

ClD03

Cl00S

J5·3 JS-6 JS·I

LEDA

'.

'·""w,""

A1812

B1B09 A1D02 A1A3 B1Bl0

A1B03

A1D04 A1B04 AIDOS AIBOS AI

006

A1B07

AID07

DIBIO DIB09

BI

DIBOS

BI

D02+8.S Vdc

A1B02

Audible Alarm

BIB07 BIBOS BIB05

BIDOO

81004

81B03

81005

81B04

<b

+Left

~Ma~rg~in

+10.8 Vdc

A1A3 B12

____

A1A4 B09

002 A1A4 Bl0

A1A3

B03

004 B04 DOS

BOS 006 B07 007

(p;r;;;;-A-;-;'

~~~~I

J04I

J

-Print

.

-Print

Address Switches

Audible Alarm

I

AIA4

J

P

-Not

B07

-A

BOS BOS ( -Not

-B

DOS

P A1A4 J

-8

004

-Not

B03

-A

DOS

-Not

804

__________

L

-Wire

Carrier

Forms

- - - - -

~N~

______________________________

______________

On

Print Wire Drive Card

B07

Wire

1

BOS

Wire

2

B09

Wire 3

Bl0

Wire

4

Wire

S G07

Wire 6

GOS Wire 7 G09 Wire 8

Gl0

Motor Drive Card

r----,

I

A Carrier Dr G09

Carrier

B Carrier

B Forms

FormsDr

A Forms

+10.8 Vdc

I

Dr

GIO

Dr

G07 G08

Dr

BOS

Dr

B07 810

Dr

B09

V$g;Reg:;;;:S;;;;;;m-;;iiii;c..~

ECI

010

B13

Bl0 OIl

DOS

B07 BOS DOS

AIBI

I

JIO

~&9-----~Uft~~Ma~~~·n--~

Note: A Not Ready condition will result

from any

of

tha

following:

+24 Vdc

is

less

than

is

greater is

less

missing

+21.S Vdc

than

+2S.4 Vdc

+S

•

• +24 Vdc +10.8 Vdc +S

Vdc

J

Collector

Base

Emitter

+24 Vdc

ECI Print Head

P PEC3J- -

.>------------1------<

.>-

____

~--~~-----<DOS

~-----t-------<810

L-----1----C809

1--

______

EC2

P

B05 DOS BOO 006

B07

BII 010 810

~

B09

012><D04~

BI2><BOS~

,

~+_----~CI804

811><800UJ

L--t-------<807

DOO><OIO~

L-----,1-

__

D09~D07~

800><811~

809><8OS~

D07><D09~

TPBI

3BRed

3A 4A

48

RedlWhitel I

SA

SB

Blue I I

SAl

7A

78

Black

TP82

2A 3A 4A SA

SA

Forms Feed Stepper Motor

28

BluelWhite ---

38

81ue

48

RedlWhite

58

Red

S8

+Printer Ready

(See

note)

Vdc

--,

I CAl Ll

DOS

I

CA~L2

I CA3

I

I CA4

-<005

I CAS L5

L3

.

L4

I

I CAS L6

I

I CA7

I

I CR8

<

012-

Carrier Stepper Motor

r---,

___

L7

L8

__

--1

.J

-l

___

-.J

I

I I

I

189

Wiring

Diagram,

Diagnostic

Aids

Maintenance

5256

MIM

1-69

Diagnostic Aids

190 POWER ON DIAGNOSTIC

The

power

on diagnostic checks the basic internal functions the sequence

switch is pressed.

POR

turning on

Page 1-71

of

the printer. The following

of

events

that

occur when the Power

is

not

part

of

the diagnostic

power

to

the printer.

Press the Power switch

8

but

flowchart

results

shows

from

Degates

receiver

Initializes ware 0000

the

all

and

sets the IAR

driver

and

logic hard-

1-70

to

Turns on

all

lights

__

1

__

-1

__

T_es_t_a_"_L_E_D_S

...

_E_x_ce_p_t_p_o_we_r_o_n

____

___

_

..

A Page

--

1-68

--

-

Diagnostic

Microcode ---

--

----

Halt No

__

Halt

N,.;..'

Performs

o.;;......,~

the

micro-

Checks

the

cessor,

data registers in read/write read

only

Checks

read/write

with

patterns

If

the

Cable

is

installed address to

7,

the

test

fails

invalid

address

micropro-

paths,

the

storage

Thru

and

switches

cable

because

MPU,

and

storage

feature

the

are

set

adapter

of

an

190

Wiring Diagram,

Diagnostic

Aids

Maintenance

5256 MIM 1-71

Halt No

No

--

- Normal Microcode -

--

-

--

Sets

the

'power

on

tran-

sition'

bit

in

the

status

register

The carrier

is

moved in

and

out

of

the

left

margin

If

the

Unit Check

and

Attention lights are

on,

the

printer

hardware

failed.

If

the

2 lights are

off,

the

planar failed.

Sends poll response frame

1 (basic status)

to

the controller

--

- Controller and System ----

-

--

----

--

- -

Power on diagnostics

will

end

here if

the

con-

troller

is

not

polling

or

if

the

printer

is

not

connected

to

the

controller

Indicates line activity

Indicates

that

the

printer

is

being polled

1-72

190

..

-

Page

1-72

Controller

acknowledges

power

on transition

status response

to a poll

command

Acknowledgement is

in

the

command

Successful host system communications

is

establ ished

The

5256

Printer

is

now

online and

is

available

for

printing

Wiring

Diagram,

Diagnostic

Aids

Maintenance

5256

MIM

1-73

1-74

191

The offline tests are tests

The offline tests are selected and run control panel by using combinations (LF), To put the printer in offline mode, set the Status switch to Feed and Line the tests, press the operation and lets you select a specific offline diagnostic test. The Ready light will be on during a remains on also pulses when you press the Start .switch while selecting a test.) Pressing the Stop switch while a is running causes the printer on. These should be ignored because the MAPs use these light conditions. The Stop switch must be pressed after the Status to Stop switch and then the Start switch. The following chart shows the switch combinations tests:

OFFLINE TESTS

of

the basic printer functions.

from

of

the Line Feed

Form Feed

Test. This inhibits the normal function

end a test. A test can be repeated

if

(FF),

Start (ST), and

Feed

switches. Before selectin'g any

Stop

switch. This stops all machine

the

test

runs correctly. (The Ready light

to

stop

switch· is set

Stop

with

to

by

for

the printer

(SP)

switches.

of

the Form

of

test

and

test

various lights

do

not

Normal in order

pressing the

selecting

the

Print

Test

(PRT04)

The print

across a

the same character in the opposite direction. This

process continues until the Pressing the print head printed. (5 cannot be restarted until the

The

available

test

prints the alignment character repeatedly

132-character

Stop

to

the

If

the

test

minutes on the 120 cps model), the test. is ended and

'printer

reset' line (A 1

as

a probe

line, line spaces once, and prints

Stop

switch is pressed.

switch causes' the carrier

left

margin

is allowed

point

at

the end

to

continue

test

is selected again.

A38

12

or

B 1 A 1 B 12) is

during the test.

of

for

to

move the

the

line being

256 lines

Test

Number

PRT04 PRT05 PRT06 PRT07 PRTOS

PRT09

PRT10

PRT11

PRT12 PRT13

Name

Print Carrier Forms Alignment Print character

set Print receive

buffers Left margin

recognition Printer

characteristics display

Data storage

Address

switches

motor

Switch'

SP

FF FF

SP SP

FF

SP

FF

SP

LF

SP

LF

S P

LF

SP

FF

SP

FF

ST ST ST

FF

ST

LF

ST

FF

ST ST

ST

FF

ST

LF

ST

FF

LF

ST ST

LF

ST

ST ST

LF

ST

LF

FF

ST

~~~~t~§§lj~JI313r

§

fU;J

§

~H;U.=I

~I

.:

@

f~1

rj

~~

~nu~

I3lj

fJ

[~t~

/;I§

~l

~113

§

t:l

§

~~

~l§

~I

1]t:l§~~§~~nt~rjtl~ll]

~1::

,

PRT14

PRT15

Set transparent mode

Print

wire/tab

SP

ST

FF

LF

ST

LF

FF

ST

LF

Carrier

The carrier at of speed.

The long pulses motor phases move the motor motor correct position.

The

is pressed For either action, the operating speed, through the From the ramp, the

and then back

out press the

The complete

pressing the Stop switch and then the Start switch.

The available

Motor

low

speed and then moves the head

the

left

motor

slowly forward in equal steps. Failing

might

to

motor

of

left

'printer

(PRTOS)

motor

test checks the carrier

margin, and back

phases are tested by generating a series

with a 50%

motor

also move backward.

step backward

continues in

or

until the

head is moved

to

the ramp. This movement (from ramp,

margin, and back

Stop switch.

test

can be repeated

reset' line (A1A3B12 or B1A1B12) is

as

a probe point during this test.

to

the ramp at normal

duty

cycle. These move the

in steps that are not equal. The

for

the first step

slow

speed until the start switch

motor

has advanced 256 steps.

motor

returns the head, at normal

left

margin

to

ramp) continues until you

to

It

is normal

out

of

from

motor

phases

the ramp,

motor

for

to

locate

to

the ramp.

left

margin

the start

the

by

out

of

Note: Light 8 PRT06. When the is running, various lights test

status when the switch

should be ignored

test

The pressing the Stop Switch and then the Start switch.

The 'printer reset' line (A1A3B12

available

Alignment

The alignment test prints the alignment character across

a 132-character line and then prints the same character

while

returning until you press the line in which the returned

If

the

test minutes on cannot be restarted until the

'printer

The available

might

turn on while you are running

Stop switch is pressed while the

will

turn on depending on the

was

pressed. The lights

for

MAP

purposes.

can be repeated

as

a probe point during this test.

(PRT07)

without

Stop switch

to

the

left

is allowed

120 cps models) the

reset' line (A 1A3B12

as

a probe point during this test.

from

the start at any time

a line space. The

Stop switch.

was

margin.

to

continue

test

or

At

for

test

is selected again.

or

test

by

B1A1 B12) is

test

continues

the end

pressed, the head is

256 lines (5

B1

is

ended and

A 1 B12) is

of

the print

Forms

This test checks the and then operates the to

The

long pulses

the

forward in equal steps. Failing motor move backward. backward

Too much platen

cause steps

The

switch. Pressing the Start switch causes the motor normal operating speed (high speed

The

forward direction. The operation continues until you press the

Motor

check

motor

in steps

low

and emitter operation

forms

(PRTOS)

forms

feed and

phases are tested by generating a series

with

a 50 %

slowly

(at

that

It

for

the first step

or

that

are

speed

test

motor

operates smoothly at this speed in a

Stop switch.

forms

motor

phases at

motor

at normal operating speed

forms

emitter operation.

duty

cycle. These pulses move

part

of

a space per increment)

motor

are

not

equal. The

is normal

motor

not

continues until you press the Start

for

the

to

locate correct position.

gear backlash (play)

equal (124, 125).

to

be tested

forms

slow

speed

phases move the

motor

might

motor

to

step

might

forms

by

running at

movement).

of

also

~§§§§§~§~§§~

~~§§§§§B~§§§§§§§§§§~

•

•••

• •

••••

• •

••••

• •

••••

\

191

Wiring Diagram, Diagnostic Aids

Maintenance

5256

MIM

1-75

1-76

191

OFFLINE

Print Character

The print character set test prints each character of the print character set sequentially. the figure. Hyphens are printed for EBCDIC characters

U.

S.

and

Canada

---------¢.c(+I&---------!S*>1~-I--------I,X_>?----~----':~@'="-abcdefghi-------jkLMnop~r-----I--stuvWxyZ---------------------

(ABCDEFGHI------)JKLMNOPQR------\-STUVWXYZ------0123456789------

ASCII

(I nternational)

---------[.C(+!&---------lS*);A-/--------I,X_>?---------':~@'="-abcdefghi-------jkLMnop~r-----I--stuvWXyZ---------------------

(ABCDEFGHI------)JKLMNOPQR------\-STUVWXYZ------0123456789------

Austria

aABCDEFGHI------ijJKLMNOPQR------~-STUVWXYZ------0123456789------

and

----~----~.C(+!&---------U$*>IA-l--------ti,x_>?---------':~§'="-abcdefghi-------jkLMnop~r-----I-BstuvwxyZ---------------------

TESTS

Set

Germany

(CONTINUED)

(PRT08)

All

sets are shown

in

that are not defined. (Some machines might substitute a blank for undefined EBCDIC characters.) The test be

run

in

transparent mode

mode (PRT14) and then

jumpers

are

shown

on

by

first selecting transparent

selecting PRT08. Character set

reference 106.

can

Belgium

---------[.C(+!&---------lS*>;A-I--------b,X_)?---------':~~'="-abcdefghi-------jkLMnop~r-----I-··stuvWXyZ---------------------

~ABCDEFGHI------eJKLMNOPQR------~-STUVWXYZ~~----0123456789------

Brazil

---------t.C(+!&---------$C*>:A-I--------~,X_)?---------~:6~'="-abcdefghi-------jkLMnop~r-----I--stuvWXyZ---------------------

oABCDEFGHI------~JKLMNOPQR------\-STUVWXYZ------0123456789------

Denmark

---------~.«+!&---------~A*>:A-/--------~,X_)?---------':~~'="-abcdefghi-------jkLMnop.r-----I-ijstuvwXyZ---------------------

~ABCDEFGHI------~JKLMNOPQR------\-STUVWXYZ------0123456789------

Finland

---------§.C(+!&---------UA*>:A-I--------ti,X_)?---------~:~O'="-abcdefghi-------jkLMnop.r-----I-listuvwxyZ---------------------

aABCDEFGHI------~JKLMNOPQR------t-STUVWXYZ------0123456789------

and

Norway

Sweden

France

---------o.«+!&---------§S*>;A-I--------b,X_>?---------'

~ABCDEFGHI------eJKLMNOPQR------~-STUVWXYZ------0123456789------

:t~'="-abcdefghi-------jkLMnop.r-----I--stuvWXyZ---------------------

Italy

---------o.«+!L---------6S*)'A-I--------b,I_)?--------~b:£§I="-abcdefghi-------jkLffinop.r-----I-lstuvwxyZ---------------------

~ABCDEFGHI------eJKLMNOPQR------~-STUVWXYZ------0123456789------

Japan

(English)

---------t.C(+I&---------!¥*';~-I--------I,X_)?---------':I@'="-abcdefghi-------jkLMnOpqr-----I--stuvWxyZ---------------------

(ABCDEFGHI------)JKLMNOPQR------$-STUVWXYZ------0123456789------

Portugal

---------[.C(+!&---------lS*>;A-I--------o,X_}?---------'

~ABCDEFGHI------'JKLMNOPQR------C-STUVWXYZ------0123456789------

:~6'="-abcdefghi-------jkLMnOpqr-----I-~stuvWxyZ---------------------

Spain

---------[.«+I&---------l~*);~-I--------H,X_)?---------':~@I="-abcdefghi-------jklMnOpqr-----I-··stuvWXyZ---------------------

(ABCDEFGHI------)JKLMNOPQR------\-STUVWXYZ------0123456789------

Spanish

(ABCDEFGHI------)JKLMNOPQR------\-STUVWXYZ------0123456789------

United

(ABCDEFGHI------)JKLMNOPQR------\-STUVWXYZ------0123456789------

Speaking

---------[.«+I&---------]S*>:~-I--------H,X_)?---------':~@'="-abcdefghi-------jklMnOpqr-----I--stuvwxyZ---------------------

Kingdom

---------S.C(+I&---------!£*>:~-I--------I,X_>?---------':~@'=n-abcdefghi-------jklMnOpqr-----I--stuvwxyZ---------------------

Canada

---------~.«+!&---------'$*>;A-I--------b,X_)?---------':~@I="-abcdefghi-------jkLMnOpqr-----I--stuvWXyZ---------------------

~ABCDEFGHI------eJKLMNOPQR------J-STUVWXYZ------0123456789------

Japan

.rJ.

-ABCDEFGHI-------JKLMNOPQR------$-STUVWXYZ------0123456789------

(French)

(Katakana)

·'?i'£.«+I&I~t13'---!¥*>;~-I---------,X_)?----------:~@'="-1~~I~n"!J-'~lt~9'~j.,=it)--~bJ--~~~~~j~'1-35~~----------~D?)"·

i.

______ --__

191 OFFLINE TESTS (CONTINUED

Print

Receive

The print receive buffers test, usually run

mode, formats and prints the contents buffers until the test is stopped by pressing the Stop switch.

The purpose received, including data and formatting information, so that you can compare system.

run

To transparent mode (PRT14) and then select PRT09.

Left

The left margin recognition test senses the location the left margin pulse relative

Left margin recognition testing occurs while the carrier is moving left margin signal after each print emitter pulse. When

the left margin signal is sensed, the printer starts

counting print emitter pulses. The count, which is reset by the

Count

the test

Margin

E3

Left Margin

The location at which the left margin signal is sensed is indicated by the count

3 Between 2 Between

Between

Buffers

of

the test is

in

Recognition

to

the right. The microcode checks

pulse, is printed at the left side

---rC""""""

Location

E3 E1 E2

(PRT09)

to

see

what

it

with

what

was sent by the

transparent mode, first select

(PRT10)

to

the print emitter pulses.

Count Starts

LJ

.~

as

follows:

and

E1

and

E2

and

E3

in

transparent

of

the receive·

the printer has

for

the

of

the form.

This timing would

}

a count

of

cause

of

To obtain the best location, move plug this test. Details the gray safety cover at the front mechanism.

Printer

The printer characteristics are displayed in control panel lights 1 through 8. The lights compare jumpering that selects the language group and printer speed.

Lights 1 through 5 identify the language group plugged on planar jumper pins a through 4

Language A 1 indicates no jumper; a a indicates a jumper.

Lights 12345

00000 00001 00010 00011 00100

Characteristics

a a 1 a 1 a a 1 1 a

of

P2B

plugging are on the label on

Display

Group

Country

U.S. and Canada ASCII (International) Austria and Germany Belgium Brazil Denmark and Norway Finland and Sweden

P2B

of

the printer

(PRT11)

to

the planar

a a 1 1 1 France

01000

Italy

a 1 a a 1 Japan (English)

00

1 l

1 a

·1

1

. Portugal

Spain Spanish-Speaking United Kingdom Canada (French) Reserved

Japan (Katakana)

Reserved

Defaults

to

U.S. and Canada

be

plugged.

a 1 a 1 a

2.

a 1

011

a 1 1 a 1 1 a 1

01110

a 1

111

10000

1

000

to 111 1 1 1

Note: All jumpers must

and repeat

as

(see

106).

The best position is indicated by a count combination shows that the left margin pulse is active possible from the print emitter 3 pulses (between emitter pulses 1 and 2 is best, during a 1 or 2 pulse is acceptable).

191

of

2 with sometimes a 1

of

or a 3.

as

2 or a

This

far

Wiring Dia

nostic

as

Maintenance 5256 MIM 1-77

Diagram,

Aids

191

Printer

A 1 indicates no jumper; a 0 indicates a jumper.

Lights

OFFLINE

Speed

TESTS (CONTINUED)

Characters

per

Second

78

Set

Transparent

The set transparent mode or the customer application programs.

Mode

wish

to

(PRT14)

test

should be used when you

locate problems

or

1-78

debug

o 0 Undefined o 1 120

1 0 1 1

Light 6 is

Data

A thorough data storage combinations in all storage positions. The

until the Stop switch is pressed. The Storage Check

light

Address

The address switches test is used feature not

change switch settings while the test is running.

The following the address switches are set

Switch---4

5 6

O

40 80

not

Storage

(4)

is on

Switches

to

check operation

Internal Check

used.

(PRT12)

test

writes and reads all bit

test

continues

if

an

error occurs.

(PRT13)

with

the Cable Thru

of

the address switches. Do

example shows the control panel when

to

6:

2

I

Graphic Check

I

7

• Data . Cleared

Line

Spacing

~~~'

••

/~<.~

.

8

~

6

~

I

8

Transparent

Mode

O

Status

Cancel

·~

..

'1s:"",.~~..

Normal

,~~~

Test

When

operating in this mode, all data (characters and formatting with To aid counting and identification, a hexadecimal count

is printed above every 16th character and a

above every 8th character starting from the 2nd

character on the indicates the print out

codes are not executed default character is printed below the hexadecimal code for

the formatting control codes and other unprintable

characters.

The selected.

However, the printer remains in transparent mode and the returned

be active

Normal. This allows PRT08 and PRT09 transparent mode. then transparent mode

Normal

A

sample transparent mode printout is

Buffer Number 16th Character

06

control codes) is printed in hexadecimal code

the character repre-senting the code printed below.

vertical bar

left. The 2nd digit on the

buffer

used. One line

as 4 lines in transparent mode. Formatting control

but

are treated

Transpa~ent

light comes back on when the Status switch

to

whether

select PRT08

to

Mode

light is turned on when PRT14 is

It

turns

off

when the Stop switch is pressed.

the Normal position. Transparent mode can

the Status switch is set

(Select transparent mode first and

or

PRT09.) The 5256 remains in

until the Status

Test position.

8th Character

swit~h

from

Buffer Number

from

left

column

of

data prints

as

data. The

is

to

Test or

to

be printed in

is moved

as

follows:

Buffer Number

from

I

CC1C4CC2CCCCDDDDOD 1253045567891234D5

AB

C

DEIFGHIJKLMIN

Address 7 (all 3 switches on) is invalid. 'The

fail

with

lights

5,

diagnostics will the

cable adapter part,

Note: Do

disconnected when servicing a printer that has the Cable Thru feature. Other series when the

7362230) is available when should be protected against accidental grounding connection.

not

leave the external system cable

it

is necessary

if

the address is

work

cable is disconnected. An adapter (part

for

connecting 2 cables together

to

bypass a printer. The adapter

6,

stations are released

power

on

7, and 8 on during

7.

from

the

of

the

Line

Feed

Space

Character

New Line

In Normal mode,

executed, the above

with

AB

C

DE

N

FGHIJKLM

A part

of

the verification

mode (192).

Carrier Return

the SCS control characters

would

print as:

test

is printed in transparent

191

OFFLINE

TESTS (CONTINUED)

Print

Wires/Tab

(PRT15)

The print

wire/tab

test

performs a

high-speed

tab1 to

the

right

for

15

spaces, prints 15 alignment characters

to

the right, line spaces,

high-speed

tabs

to

the

left

for

15

spaces, and then prints 15 alignment characters

to

the

left.

____

Left

Margin I

I • 15

Spaces

----.'-

15 Characters

-t

I I I

I

B§§§§§§~B§§~B§B

I

tl

tH~

~I§

~~

tl

§ §

~113

§ §

rJ~]

The print

wire

drivers are

off

during

the

line spacing and

tabbing operations. This allows

the

probe

to

be used in

checking

for

correct

print

wire

operation.

1The 120

cps

printer

does

not

tab

at

high

speed.

191

Wiring Diagram, Diagnostic Aids

--

:;...-,

Maintenance 5256

MIM

1-79

192

ON

II

NE

TESTS

Online tests include

work

station exerciser routines

that

are in

the

system. A prime

option

menu

is

dis-

played

that

allows

you

to

select display verification, matrix printer verification (online exerciser), configuration

data,

and

error recovery analysis procedures

(ERAP).

Online tests can be run

on

the

work

station

while

other

jobs are being run on

the

system. How-

ever,

the

work

station

must

be

in

a signed

off

state

Check with

the

system operator before pressing the

Load key

. ~ __

. -

._r-

Yes

before

the

online tests can be run

on

'that

work

station~-80

Various ways can be used

to

end

or

sign

off

a job.

Not

a"

methods wi" be described here because

they

are system operating procedures.

If

you

do

not

under-

stand

the

system, use

the

procedure

in

the

flowchart

below.

If

the

test

is

to

be printed, set

up

the

printer

for

normal operation.

Ensure

that

the

Status

switch

is

in

the

Normal

position

No

Contact

the

system

operator

for assistance

(MSIPL, msg waiting, etc)

Prime

option

menu

displayed

If

any message

or

error

code

is

displayed, verify

that

you

have

followed

the

steps correctly.

If

you

have,

contact

the

system

operator

for assistance.

Some

of

the

reasons you may

not

get

to

the

online tests are:

•

The

system

is

not

powered

on.

•

The

MSIPL has

not

been successfullY

completed.

• This station

is

not

configured

in

the

system.

• A message

is

waiting

on

the

system console for this

station

and

the

operator

has

taken

no

action

.

192

ONLINE

TESTS

Online Test Overview

(CONTINUED)

Prime Option

1

See

the

IBM

5251

11

Model

Display Station Mainrenance Information Manual,

SY31-0461

ERAP

Option

1

Prime Option

2

ERAP

Option

7

Prime Option

3

ERAP

Option

8

Prime Option

4

Prime Option

5

See

the

maintenance documentation the

controller

ERAP

Option

9

for

192

See

the

maintenance

documentation

the

controller

Wiring Diagram,

Diagnostic

Aids

for

See

the

IBM

5251

Model

11

Display Station Maintenance Information Manual,

SY31-0461

Maintenance

5256

MIM

1-81

1-82

192

Matrix

This

including the standard character string (SCS) control

characters. The controlling program is in the controller.

Successful completion system, correctly. All more

• Ability

• Suppression

•

• Graphic error option

'ONLINE

TESTS

(CONTINUED)

Printer Verification Test (Online Exerciser)

test

exercises the printer by using all characters

of

the

test

verifies

controller, cabling, and the printer operate

of

the

following

times:

to

print all valid characters in a ripple pattern

of

nulls

Automatic

Formatting

Setting Setting vertical Absolute horizontal position Absolute vertical position Relative horizontal position Relative vertical position New Interchange Carrier return Line feed ForlT!s

new

line

horizontal

format

line

record separator (IRS)

feed

functions are tested 1

format

that

the

or

The following testing the printer

flowchart

along

shows

the

procedures used in

with

the available options.

Online Test Displays

To obtain the matrix printer verification (online exerciser)

I D select menu:

A

sample printout

flowchart.

of

the

test

is at the end

of

the

1.

Press the 2 key.

2.

Press the Enter key.

192 ONLINE TESTS (CONTINUED)

1.

To obtain the matrix 'printer verification (online exerciser) menu: a.

Enter the identification number

of

the printer

(a

letter and a number).

b.

Press the Enter key.

2.

To select the number

of

times

to

run the test:

a.

Enter,

from

the menu, the number

that

corresponds

to

the desired number

of

times

to

run the test.

b.

Press the Enter key.

The

display will

show

when

the

test

is executing,

when

it

is complete, and when a hard error occurs.

3. To repeat the test, press the Enter key.

192

Wiring Diagram, Diagnostic Aids

To select Configuration Data:

1.

Press the 3 key.

2.

Press the Enter key.

The descriptions

for

configuration data are:

1. Device

Addr

is the address

of

the controller.

2.

Unit

Addr

is the address

of

station(s) assigned

to

the

controller. The

first

digit

is the

port

number

and the second

digit

is the station address.

3.

Logical I D is the name the system uses

to

address

this station.

4. To return

to

the prime option menu:

a.

Press the C key.

b.

Press the Enter key.

1.

To select the Error Recording Analysis Procedure

(ERAP) men.u: a.

Press the 4 key.

b.

Press the Enter key.

2.

To select the serial matrix printer:

a.

Press the 9 key.

b.

Press the Field Exit key.

Maintenance

5256

MIM

1-83