TallyGenicom 6600 Series, 6605Q, 6610Q, 6615Q, 6620Q Maintenance Manual
Maintenance Manual
Approved Final
May 19, 2011
6600 Series Printers
6600 Series Printers
Maintenance Manual
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Communication Notices
This is a Class A product. In a domestic environment this product may
cause radio interference in which case the user may be required to
take adequate measures.
WARNING
Federal Communications Com m ission (FCC) Statement
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to Part 15 of the FCC Fules. These limits are
designed to provide reasonable protection against harmful interference when
the equipment is operated in a commercial environment. This equipment
generates, uses, and can radiate radio frequency energy and, if not installed
and used in accordance with the instructions, may cause harmful interference
to radio communications. Operation of this equipment in a residential area is
likely to cause harmful interference in which case the user will be required to
correct the interference at his own expense.
Properly shielded and grounded cables and connectors must be used in order
to meet FCC emission limits. Printronix is not responsible for any radio or
television interference caused by using other than recommended cables and
connectors or by unauthorized changes or modifications to this equipment.
Unauthorized changes or modifications could void the user’s authority to
operate the equipment.
This device complies with Part 15 of the FCC Fules. Operation is subject to
the following two conditions: (1) this device may not cause harmful
interference, and (2) this device must accept any interference received,
including interference that may cause undesired operation.
European Union (EU) Co nformity Statement
Printronix cannot accept responsibility for any failure to satisfy the protection
requirements resulting from a non-recommended modification of the product,
including the fitting of option cards not authorized by Printronix.
This product has been tested and found to comply with the limits for Class A
Information Technology Equipment according to European standard EN
55022. The limits for Class A equipment were derived for commercial and
industrial environments to provide reasonable protection against interference
with licensed communication devices.
Properly shielded and grounded cables and connectors must be used in order
to reduce the potential for causing interference to radio and TV
communications and to other electrical or electronic equipment. Such cables
and connectors are available from Printronix authorized dealers. Printronix
cannot accept responsibility for any interference caused by using other than
recommended cables and connectors.
Industry Canada Compliance St atem ent
This Class A digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la classe A conform á la norme NMB-003 du
Canada.
Statement of CISPR 22 Compliance
Attention: This is a Class A Product. In a domestic environment this product
may cause radio interference in which case the user may be required to take
adequate measures.
Japanese VCCI Class A
Taiwan
Warning: This is a Class A product. In a domestic environment this product
may cause radio interference in which case the user will be required to take
adequate measures.
Australia/New Zealand
Attention: This is a Class A Product. In a domestic enviroment this product
may cause radio interference in which case the user may be required to take
adequate measures.
China
Declaration: This is a Case A Product. In a domestic environment this
product may cause radio interference, in which case the user may be required
to take practical actions.
German Conformity St ateme nt
Zulassungsbescheinigung Gesetz über die elektromagnetische
Verträglichkeit von Geraten (EMVG) vom 30. August 1995
Dieses Gerät ist berechtigt in Übereinstimmung mit dem deutschen das EGKonformitätszelchen - CE - zu führen.
Der Außteller der Konformitätserklärung ist die Printronix......(1)
Informationen in Hinsicht EMVG Paragraph 3 Abs. (2) 2:
Das Gerät erfüllt die Schutzanforderungen nach EN 55022 und
EN 55024 Klasse A.
EN 55022 Klasse A Geräte bedürfen folgender Hinweise:
Nach dem EMVG: “Geräte dürfen an Orten, für die sie nicht asreichend
entstört sind, nur mit besonderer Genehmigung des Bundesminesters für
Post und Telekommunikation oder des Bundesamtes für Post und
Telekommunikation betrieben werden. Die Genehmigung wird erteilt, wenn
keine elektromagnetischen Störungen zu erwarten sind.” (Auszug aus dem
EMVG, Paragraph 3, Abs. 4) Dieses Genehmigungsverfahren ist nach
Paragraph 9 EMVG in Verbindung mit der entsprechenden Kostenverordnung
(Amtsblatt 14/93) kostenpflichtig.
EN 55022: Dieses ist eine Kategorie A Vorrichtung. Betrieb in den
Wohnbereichen kann elektrische Störung verursachen. Es ist die
Verantwortlichkeit des Benutzers, passende Gegenmaßnahmen zu ergreifen.
EN 55024: Begrenzung Werte für Gebrauch in bevölkerten Bereiche,
kommerziellen und Industriegebieten sind innen Übereinstimmung mit den
spezifizierten Anforderungen Hinsichtlich Störfreiheit.
Anmerkung: Um die Einhaltung des EMVG sicherzustellen sind die Geräte,
wie in den Handbüchern angegeben, zu installieren und zu betreiben.
European Union (EC) Electromagnetic Compatibility
Directives
This product conforms to the protection requirements of EC Council Directive
89/336/EEC on the approximation of the laws of the Member States relating
to electromagnetic compatibility. Printronix cannot accept responsibility for
any failure to satisfy the protection requirements resulting from a nonrecommended modification of the product, including the fitting of option cards
not authorized by Printronix.
Dieses Gerät ist berechtigt in Übereinstimmung mit dem deutschen EMVG
vom 9.Nov.92 das EG-Konformitätszeichen zu furhren.
Properly shielded and grounded cables and connectors must be used to
reduce the potential for causing interference to radio and TV communication
and to other electrical or electronic equipment. Printronix cannot be
responsible for any interference caused by using other than recommended
cables and connectors.
This product has been tested and found to comply with limits for Class A
Information Technology Equipment according to CISPR 22/European
Standard EN 55022. The limits for Class A equipment were derived for
commercial and industrial environments to provide reasonable protection
against interference with licensed communication equipment.
Warning: This is a Class A product. In a domestic environment this product
may cause radio interference in which case the user may be required to take
adequate measures.
Dieses Gerät erfüllt die Bedingungen der EN 55022 Klasse A. Für diese
Klasse von Geräten gilt folgende Bestimmung nach dem EMVG:
Geräte dürfen an Orten, für die sie nicht ausreichend entstört sind, nur mit
besonderer Genehmigung des Bundesminesters für Post und
Telekommunikation oder des Bundesamtes für Post und Telekommunikation
betrieben werden. Die Genehmigung wird erteilt, wenn keine
elektromagnetischen Störungen zu erwarten sind.
(Auszug aus dem EMVG vom 9.Nov.92, Para.3, Abs.4)
Hinweis: Dieses Genehmigungsverfahren ist von der Deutschen Bundespost
noch nicht veröffentlict worden.
Table of Contents
1 Maintenance Overview......................................... 17
TallyGenicom® 6600 Cartridge Ribbon Printer (CRP) Series ................ 17
Order the Correct Spares ................................................................. 18
How to Identify a 6600 Cartridge Ribbon Printer..............................19
Zero Tear Pedestal (ZTP) Printers................................................... 19
Printer Configuration Code...............................................................20
Forms Handling ................................................................................ 20
Important Maintenance Notes................................................................. 21
Notices ............................................................................................. 21
About this Manual ...................................................................................22
How to Use this Manual ................................................................... 22
Printing Conventions in this Manual .................................................23
Safety Notices.........................................................................................23
Hinweise zur Sicherheit ..........................................................................24
Controls and Indicators ........................................................................... 25
Electrical Controls ............................................................................25
Mechanical Controls.........................................................................28
Tools and Test Equipment......................................................................30
Plugging in the Printer ............................................................................31
TallyGenicom Customer Support Center................................................32
TallyGenicom Supplies Department .......................................................32
Corporate Offices.................................................................................... 33
Maintenance Training for TallyGenicom Products..................................33
2 Preventive Maintenance....................................... 35
Cleaning the Printer ................................................................................35
Cleaning the Exterior........................................................................35
Cleaning the Interior ......................................................................... 36
Cleaning the Shuttle Frame Assembly ...................................................38
Cleaning the Card Cage Fan Assembly .................................................41
Table of Contents
3 Troubleshooting ....................................................43
Introduction .............................................................................................43
Troubleshooting Aids ..............................................................................43
Start Here... ............................................................................................44
Troubleshooting Display Messages........................................................45
List of Messages ..............................................................................46
Troubleshooting Other Symptoms........................................................111
General Symptom List....................................................................112
Communications Failures .....................................................................134
Diagnostic Printer Tests........................................................................ 136
Selecting And Running Diagnostic Printer Tests ........................... 137
Boot Diagnostics Menu......................................................................... 141
Factory Menu........................................................................................144
Exception Menu ....................................................................................146
Firmware Diagnostic Port .....................................................................147
Diagnostic Cable ............................................................................147
Capturing Information.....................................................................148
Hex Code Printout ................................................................................149
How To Print A Hex Dump ............................................................. 149
ASCII Character Set ............................................................................. 151
Hard Reset (Cycle Power) ....................................................................152
4 Adjustments and Tests ....................................... 153
Introduction ...........................................................................................153
Adjustments and Tests...................................................................153
Preparing the Printer for Maintenance.................................................. 154
Returning the Printer to Normal Operation ........................................... 155
Belt, Paper Feed Timing, Adjustment...................................................156
Belt, Platen Open, Adjustment.............................................................. 158
Paper Scale Alignment .........................................................................160
Platen Gap Adjustment......................................................................... 162
Paper Out Adjustment ..........................................................................164
Hammer Phasing Adjustment...............................................................167
Loading Flash Memory .........................................................................169
Loading Software with the Firmware Download Utility ...................170
Loading through Parallel Port using DOS ...................................... 171
Loading Software if Flash Contains Only Boot Code .....................173
Loading Software through the NIC................................................. 174
Reprogramming the Security Key......................................................... 176
How to Reprogram the Security Key.............................................. 176
Coil Temperature Adjustment ...............................................................178
Dynamic Paper Tension Adjustment ....................................................179
Table of Contents
Tractor Belt Tension Adjustment ..........................................................181
Shuttle Electrical Short Check ..............................................................182
Hammer Bank Power Cable Shorts Test..............................................183
Cable Shorts Test .................................................................................184
Main Wire Harness Test Diagnostic .....................................................186
Power Supply Operational Check......................................................... 187
5 Replacement Procedures ................................... 191
Organization of this Chapter .................................................................191
Replacement Procedures .....................................................................191
List of Removal / Installation Procedures .......................................191
Belt, Paper Feed Timing ................................................................193
Belt, Platen Open ...........................................................................194
Cartridge Interface Board (CIB)......................................................195
Circuit Breaker ...............................................................................196
Connector Coupling Shrouds ......................................................... 197
Control Panel Assembly .................................................................199
Controller Board ............................................................................. 200
Cover Assembly, Hammer Bank / Ribbon Mask ............................202
Cover Assembly, Shuttle ................................................................ 203
Cover Assembly, Top, Pedestal Models ........................................ 204
Dashpot.......................................................................................... 205
Fan Assembly, Cabinet Exhaust ....................................................206
Fan Assembly, Card Cage .............................................................207
Fan Assembly, Hammer Bank........................................................208
Hammer Spring Assembly, Version 1 ............................................ 209
Hammer Spring Assembly, Version 2 ............................................ 211
Magnetic Pickup (MPU) Assembly.................................................217
Memory (Flash, Expansion) ........................................................... 218
Motor Bracket Assembly ................................................................ 219
Paper Feed Motor .......................................................................... 220
Paper Ironer ................................................................................... 221
Paper Guide Assembly ..................................................................222
Platen ............................................................................................. 223
Platen Open Motor .........................................................................227
Platen Stop Assembly ....................................................................229
Power Supply Board ......................................................................230
Resistors, Terminating, V6 Controller Board..................................231
Ribbon Drive Motor ........................................................................ 233
Security Key ................................................................................... 234
Shaft, Splined................................................................................. 236
Shaft, Support ................................................................................238
Table of Contents
Shuttle Frame Assembly ................................................................ 239
Spring, Extension, Hammer Bank .................................................. 241
Switch Assembly, Paper Detector.................................................. 242
Switch Assembly, Platen Interlock ................................................. 243
Tractor (L/R)................................................................................... 244
Weld Sensor...................................................................................244
6 Illustrated Parts Breakdown................................ 245
Organization of this Chapter .................................................................245
Illustrations of Printer Components ................................................ 245
7 Principles Of Operation....................................... 279
Line Matrix Printing ...............................................................................279
Printing Rates .......................................................................................282
Printing Mechanism ..............................................................................282
Shuttle Frame Assembly....................................................................... 283
Hammer Bank Assembly................................................................ 283
Shuttle Drive Motor ........................................................................284
Paper Transport System....................................................................... 285
Ribbon Transport System .....................................................................286
Integrated Print Management System .................................................. 287
Operation .......................................................................................287
Logical Control of the Printer ................................................................290
Control Panel ........................................................................................291
Controller Board.................................................................................... 292
Data Controller ............................................................................... 294
Engine Controller ...........................................................................296
Power Supply Board .............................................................................298
AC Power ....................................................................................... 298
DC Power....................................................................................... 298
Printer Interface ....................................................................................299
A Wire Data ........................................................... 301
B Abbreviations...................................................... 343
C Metric Conversion Tables .................................. 351
Table of Contents
D SureStak™ Power Stacker ................................ 353
Contents ...............................................................................................353
Introduction ...........................................................................................354
Stacker Operation.................................................................................354
Stacker Problems .................................................................................359
Stacker First Inspection..................................................................359
Stacker Confidence Check.............................................................360
Stacker Motor Check......................................................................361
Removing the Power Stacker ...............................................................364
Installing the Power Stacker .................................................................370
Replacing the Constant Force Spring...................................................382
Replacing the Timing Belts ...................................................................384
Replacing the Roller Drive Shaft...........................................................387
Illustrated Parts Breakdown.................................................................. 390
List of Illustrations ..........................................................................390
E Zero Tear Pedestal (ZTP) Printer....................... 403
Contents ...............................................................................................403
Overview...............................................................................................404
Operation ..............................................................................................405
Load Paper and Set Up the Tractors .............................................405
Remove Paper ............................................................................... 406
Adjust The Paper Guides ...............................................................407
Position the Paper Out Sensor.......................................................409
Set the Tear Bar Distance .............................................................. 410
Set the Top Of Form ......................................................................411
Control Panel Menus ............................................................................412
Performance Limitations .......................................................................413
Adjustments and Tests .........................................................................415
List of Adjustments and Tests Procedures.....................................415
Preparing the ZTP Printer for Maintenance.................................... 416
Returning the Printer to Normal Operation.....................................416
Barrier Panel .................................................................................. 417
Belt, Paper Feed Timing, Adjustment.............................................418
Paper Guide Leaf, Front, Center, Outer......................................... 420
Paper Out Sensor, Adjustment ......................................................420
Paper Tension, Horizontal..............................................................420
Table of Contents
Replacement Procedures .....................................................................421
List of Removal / Installation Procedures ....................................... 421
Belt, Paper Feed Timing ................................................................422
Control Panel Assembly ................................................................. 423
Cover Assembly, Top, Pedestal Models ........................................ 423
Paper Feed Motor .......................................................................... 424
Paper Guide Leaf, Center .............................................................. 425
Paper Guide Leaf, Front.................................................................425
Paper Guide Leaf, Outer................................................................425
Paper Out Sensor ..........................................................................426
Shaft, Splined................................................................................. 428
Shaft, Support ................................................................................431
Tractor (L/R)................................................................................... 432
Tractor Assembly Support Gate..................................................... 433
Illustrated Parts Lists ............................................................................435
Illustrations of ZTP Components.................................................... 435
F Paper Specifications And Forms Design ............ 449
Introduction ...........................................................................................449
General Paper Specifications ...............................................................450
Paper Guidelines ..................................................................................451
Terms and Definitions .................................................................... 451
Environmental Considerations ....................................................... 453
Form Types ....................................................................................453
Form Weight...................................................................................453
Form Thickness.............................................................................. 453
Form Evenness ..............................................................................453
Tractor Pin Engagement ................................................................ 453
Methods of Forms Attachment ....................................................... 454
Chaff Content .................................................................................455
Form Design Checklist.......................................................................... 456
Summary ..............................................................................................459
Storage and Handling ....................................................................459
G Customer Support.............................................. 461
TallyGenicom Customer Support Center..............................................461
TallyGenicom Supplies Department ..................................................... 462
Corporate Offices.................................................................................. 462
1
Maintenance Overview
TallyGenicom® 6600 Cartridge Ribbon Printer (CRP) Series
TallyGenicom® has been the global leader in industrial printing solutions for
over 30 years, earning a reputation for designing and manufacturing leading
edge products and delivering them to market with unsurpassed service and
support.
The TallyGenicom 6600™ Line Matrix Printing Platform extends the series of
technology innovations that cement TallyGenicom’s leadership position. Line
matrix printing is TallyGenicom’s flagship technology, and it remains the
workhorse solution for supply-chain and back-office printing applications
because of its reliability, lower cost of ownership and flexibility of printing
applications.
•
Most reliable printer ever – provides more up time and lower operating
costs
•
Ultra capacity ribbons – deliver darker image, last longer, and costs less
to operate than other print technologies
•
Integrated print management system – provides precise control over print
quality, print costs, and job planning
•
Cabinet or Pedestal styles – best user access and forms handling
flexibility
•
Unsurpassed ease of use – simplifies operation and enhances
productivity
There are four printer configurations:
Enclosed Cabinet
•
The enclosed cabinet models provide for near silent operation, making
these printers perfectly suitable for use in the quietest of office
environments.
•
Provides the best paper handling for large print runs. All paper input and
output is contained inside the cabinet and protected from bumping and
contamination.
•
Highly effective combination of moveable fences and chains allows for
precise stacking all the way up to a full box of paper.
•
For tougher forms that tend not to refold well, a SureStak power stacker
option is available for the enclosed cabinet models.
•
Available in four print speeds – 500 line per minute (lpm), 1000 lpm,
1500 lpm, and 2000 lpm models.
17
Chapter 1
TallyGenicom® 6600 Cartridge Ribbon Printer (CRP) Series
Pedestal
•
The pedestal model has a clamshell design that allows easy access to all
controls, providing faster ribbon replacements and easier paper loading.
•
Oversized casters are standard making movement easy.
•
Versatility to configure the paper path for either top or rear exit.
•
Using the top paper exit, this printer is ideal for short print runs and easy
access to output.
•
Available in three print speeds – 500 line per minute (lpm), 1000 lpm, and
1500 lpm models.
Quiet Pedestal
•
This printer configuration is the same as the above Pedestal configuration
but with an enclosed input paper area with a front door, side panels, and
bottom panel to seal the input paper path.
•
Provides a reduction in acoustic noise.
Zero Tear Pedestal
•
Special push tractor configuration enables printing from the very first to
the very last line of a form and then tear-off with no forms lost.
•
The elimination of wasted forms between jobs can yield significant
savings.
•
An ideal solution for supply-chain and back-office applications.
•
Available in three print speeds – 500 line per minute (lpm), 1000 lpm, and
1500 lpm models.
Order the Correct S p are s
When you replace worn or damaged printer components, make sure you
order the correct spares for the model you are servicing. The next section
shows you how to identify a 6600 Cartridge Ribbon Printer.
18
How to Identify a 6600 Cartridge Ribbon Printer
6600 CRP Printer
6605QZ
Housing Code:
Without Q = Pedestal
Q = Floor Cabinet
Speed Rating:
05 = 500 lines per minute (lpm)
10 = 1000 lpm
15 = 1500 lpm
20 = 2000 lpm
Z = Zero Tear printer
How to Identify a 6600 Cartridge Ribbon Printe r
A 6600 printer has a model number logo and ribbon cartridge logo on the
printer front cover. The model number is an alphanumeric code that identifies
the printer type, its housing, and its maximum rated print speed. The serial
number “C” indicates that this is a cartridge equipped printer. The model
number and serial number of the printer are on the identification label next to
the input/output ports at the rear of the printer.
interpret a model number.
Figure 1 shows how to
The speed of printing for “real world” print jobs is affected by the interaction of
many variables and varies from print job to print job. For more information,
see “Printing Rates” on
Zero Tear Pedestal (ZTP) Printers
Zero Tear Pedestal (ZTP) printers are models equipped with special
hardware and software that permits them to print small jobs or single sheets
without losing a sheet between print jobs. A ZTP printer automatically
presents the current print line to a tear bar when it finishes printing and
presents the perforation of the last form printed to the tear bar. When it
receives more data from the host computer, the printer pulls the form down to
the print station and resumes printing.
ZTP printers are covered in Appendix E (page 403).
Figure 1. How to Interpret a Model Number
page 282.
19
Chapter 1
FH06AA
Cabinet Type:
F = Floor Cabinet
P = Pedestal Model
Controller Board Revision Level.
H = PSA3 board
V8 ASIC Revision Level
MECA ASIC
Revision Level
TallyGenicom® 6600 Cartridge Ribbon Printer (CRP) Series
Printer Configuration Code
Every printer has a configuration code which specifies the printer’s cabinet
type, controller board revision level, V8 ASIC revision level, and MECA ASIC
revision level. The configuration code is included in the configuration printout.
Figure 2 shows how to interpret the printer’s configuration code.
Figure 2. How to Interpret the Printer’s Configuration Code
Forms Handling
Pedestal Models
Pedestal models provide access to printed forms from the top cover with a
tear-at-perforation edge for ejected forms or a paper exit at the rear of the top
cover. Pedestal printers also have a wireform paper tray attached to the front
of the pedestal and a wireform catch basket attached either to the back of the
pedestal or to the back of the printer top cover.
Cabinet Models
Cabinet models can be equipped with four kinds of paper stacking devices:
•
The fixed paper fence is a wireform divider that separates the source
paper stack from the printed output stack, and is used in combination with
hanging chains that guide printed forms downward.
•
For improved performance at higher print speeds, the chains are used
with a moveable fence called the “passive paper stacker,” which can be
positioned to match the form’s length.
•
The front access paper stacker consists of a shelf that holds the input
paper and a sliding tray that receives the printed forms. The sliding tray
pulls forward, permitting the user to both load and unload paper from the
front of the printer. This option is helpful in locations where access to the
rear of the printer is limited or impossible.
•
For more demanding applications, an optional power stacker is available.
(The power stacker is covered in Appendix D on
page 353.)
These devices are summarized in Table 1.
20
Table 1. Paper Stackers Used On Cabinet Models
Notices
Printer
6605Q Standard Option Option Option
6610Q Not Used Standard Option Option
6615Q Not Used Standard Option Option
6620Q Not Used Standard Option Option
Fixed Paper
Fence
Important Maintenance Notes
To ensure the best performance of the printer, remember these maintenance
principles when you service it. Failure to observe these guidelines can result
in damage to the equipment:
•
Do not adjust the platen gap unless
1) the original shuttle assembly or platen has been replaced with a new or
rebuilt unit, or
2) you are instructed to do so in a troubleshooting procedure.
•
Never bend or try to adjust (“tweak”) the hammer springs. The
hammer springs are precisely aligned and the hammer tips are delicate.
Always handle hammer springs by the thick mounting base.
•
Use only the ribbon cartridges specified in the User’s Manual. Using
ribbon cartridges not made by TallyGenicom can lead to degraded print
quality, expensive damage to the printer, and can void the owner’s
warranty.
Passive
Paper
Stacker
Front
Access
Stacker
Power
Paper
Stacker
WARNING
CAUTION
IMPORTANT
•
Never close the forms thickness lever (platen lever) too tightly.
Closing the forms thickness lever too tightly can lead to smeared print,
degraded print quality, paper jams, and damage to the platen and shuttle
assembly.
Notices
For your safety and to protect valuable equipment, always read and comply
with all information highlighted under notices.
The heading of a notice indicates the kind of information it contains, as
explained below:
Describes a condition that could hur t you.
Describes a condition that coul d damage equipment or data.
Information vital to proper operation and maintenance of the printer.
NOTE: Tips for efficient operation, maintenance, and troubleshooting.
21
Chapter 1
About this Manual
About this Manual
This is a field service maintenance manual, intended for use by trained
service personnel. It is designed so that you can quickly locate the
maintenance information you need to restore the printer to operation.
This manual does not explain how to install, operate, or configure the printer.
For that information, refer to the Quick Reference Guide and the User’s
Manual.
This manual does not explain how to program application software for
operation with the printer. Programming information for the printer languages
used by the printer is in the appropriate programmer’s reference manual:
•
Integrated Network Interface Card User’s Manual
Information about network protocols, configuration, and network
operation.
•
6600 Series Printers Emulations Applications Manual, Volume 1
Defines printer emulations.
•
6600 Series Printers Fonts and Character Sets Applications Manual,
Volume 3
Defines printer fonts and character sets.
•
6600 Series Printers Graphics Languages Applications Manual, Volume 4
Defines Code V, PGL, and MT660 IG printer graphics languages.
How to Use this Manual
Taking a systematic approach to maintenance tasks will help you restore the
printer to operation as quickly as possible:
1. Locate the procedure or information you need in the Table of Contents or
Index.
2. Read the entire procedure before you do it.
3. Gather the parts and tools you will need.
4. Make sure you understand all notices before you start a task. (Notices are
defined on
page 21.)
22
Printing Conventions in this Manual
Printing Conventions in this Manual
Control panel keys and indicators are highlighted in UPPERCASE BOLD
PRINT.
Example: Press the CLEAR key, then press the ONLINE key.
Messages that appear on the LCD (Liquid Crystal Display) are set off by
quotation marks (“ ”).
Example: Press the ONLINE key. “OFFLINE” appears on the LCD.
Control panel key combinations are indicated by the + (plus) symbol.
Example: Press U + V.
means press the key and the key at the same time.
IMPORTANT
The Safety Notices on page 23 apply at all times when you are working
on the printer. Please read them now.
Safety Notices
WARNING
WARNING
WARNING
WARNING
WARNING
Always disconnect the AC power cord from the printer or power source
before performing any maintenance procedure. Failure to remove power
could result in injury to persons or damage to equipment. If you must
apply power during maintenance, you will be instructed to do so in the
maintenance procedure.
Always disconnect the AC power cord before cleaning the printer.
To prevent injury from electric shock, wait at least one minute after
shutting off power before removing the power supply circuit board.
Wear a properly grounded static wrist strap when handling the power
supply board. Handle the board by the sides. Do not touch components
or flex the board during removal/installation.
Over time, the upper edge of the paper ironer can become sharp. To
avoid cutting yourself, handle the paper ironer on the sides.
Hold the printer cover securely while disengaging the dashpot.
23
Chapter 1
Hinweise zur Sicherheit
Hinweise zur Sicherheit
VORSICHT
VORSICHT
VORSICHT
VORSICHT
VORSICHT
Bevor Sie anfällige Wartungsarbeiten durchführen, müssen Sie zuerst
immer das Netzkabel aus der Steckdose ziehen. Wird das Netzkabel
nicht herausgezogen, können Verletzungen oder Geräteschäden
entstehen. Falls die Wartungsarbeit Stromzufuhr erfordert, wird im
Wartungsablauf darauf hingewiesen.
Ziehen Sie das Netzkabel aus der Steckdose, bevor Sie den Drucker
reinigen.
Um Verletzungen durch Elektroschocks zu vermeiden, warten Sie
mindestens eine Minute nach Stromausschaltung, bevor Sie die
elektrische Schaltkarte entfernen. Bitte immer einen geerdeten,
statischen Handgelenkriemen tragen, wenn Sie die elektrische
Schaltkarte handhaben. Halten Sie die Karte nur an den seitlichen
Auswurfshebeln. Während des Herausnehmens/Installierens dürfen die
Komponenten der Karte nicht berührt oder gebogen werden.
Die obere Kante der Papierschiene wird mit der Zeit scharf. Halten Sie
die Schiene deshalb an den Seiten, damit Sie sich nicht schneiden.
Behalten Sie die Druckerabdeckung sicher im Griff, wenn Sie das
Gasfederpaket entfernen .
24
Controls and Indicators
Electrical Contro ls
Electrical Controls
Switch or
Indicator
Power Switch Turns printer on and off: 1 = on, 0 = off. This switch is also a circuit
breaker.
Status Indicator On when the printer is online, off when the printer is offline. Flashes to
indicate a fault or warning.
LCD Liquid Crystal Display. Displays printer status messages, fault messages,
and menus which permit user to set various configurations.
ONLINE Toggles the printer online and offline. Clears the printer after a fault is
corrected and returns the printer to offline state. Pressing CLEAR silences
the audible alarm (if enabled).
LF Performs a line feed (LF - line feed). A single press of the LF key causes a
line advance.
FF Performs a form feed paper advance (FF - form feed) . A single press of
the FF key causes a form advance to the top of the next form.
CLEAR In a fault state this key attempts to clear the fault. When the fault is cleared
the printer returns to the offline mode.
When the printer is in offline mode and no fault is present, this key allows
entry into the Clear menu..
TOF Moves paper downward from TOF (Top Of Form) alignment mark to the
print station and sets this as the first line of print on a page, independent of
forms length. If there are data in the buffers, the printer slews to the page
position where printing left off and prints the data.
Function
Active
Online
9 9
9 9
9 9
9 9
9 9
Active
Offline
9
9
VIEW When the printer is online or offline, pressing this key executes the view or
eject function. A short press of the View key performs the view function. If
the key is held down for more than one second, the key eject function is
performed.
If online with data in the printer buffer, the data prints and the key functions
as described below.
For cabinet models, pressing the VIEW key moves the last data printed to
the tractor area for viewing. While in the view state, the message "Printer
in View" displays, and pressing the UP or DOWN arrow keys moves the
paper up or down in 1/72 inch increments. Pressing VIEW a second time
moves the paper back to the adjusted print position.
If in a fault state, this key will be ignored.
CONFIG In offline mode, this key allows for fast selection of any of the previously
stored configurations. Pressing this key causes the printer to cycle through
the following messages: Load Config., Factory Config, Load Config 1,
Load Config 2, Load Config 3,...,Load Config 8.
9 9
9
25
Chapter 1
Controls and Indicators
Switch or
Indicator
MENU/ENTER While in offline mode, this key allows entry into the configuration menus.
When navigating the configuration menus, MENU/ENTER selects the
currently displayed option value as the active value. An asterisk (*)
appears next to the active value on the display. MENU/ENTER is also
used for starting and stopping printer tests and generating a configuration
printout.
Moves up between levels in the configuration menus. When in offline
mode, makes vertical forms adjust.
In VIEW mode, moves paper up 1/72 inch. (See VIEW key.)
Moves down between levels in the configuration menus. When in offline
mode, makes vertical forms adjust.
In VIEW mode, moves paper down 1/72 inch. (See VIEW key.)
Moves between the options on the current level of configuration.
Moves between the options on the current level of configuraiton.
+
Press up and down arrow keys together unlocks or locks the MENU/
ENTER key.
Function
Active
Online
Active
Offline
9
9
9
9
9
9
26
Electrical Controls
184071b
184071 REV B
(Off) (On)
A
A
Rotated 180 Degrees
B
C
Power Switch
C
A
184136b
FF
LF
ONLINE
TOF
VIEW
CONFIG
MENU/ENTER
CLEAR
TOF
VIEW
CONFIG
MENU/ENTER
ONLINE
LF
FF
CLEAR
Circular Pad
ONLINE
Message
Display
Status
Indicator
B
C
B
Figure 3. Electrical Controls
27
Chapter 1
110 20
1 inch
0.1 inch
Column
Number
Controls and Indicators
Mechanical Controls
Control or Indicator Function
Paper Supports Help prevent paper jams by supporting inner sections of paper. They
are positioned manually by sliding them along the tractor shafts.
Forms Thickness Lever Sets the platen for paper and forms of different thicknesses. This
lever must be fully opened (raised) to load paper, unload paper, and
move paper with the vertical position knob.
Forms Thickness
Pointer and Scale
Forms Thickness Lever
and Platen Stop
Assembly
Indicates the relative thickness of forms and paper. Align pointer with
A for thin (single-part) forms, B for thicker forms, and so on.
The forms thickness lever closes the platen to the relative thickness
of the paper. The platen stop assembly returns the platen to the lever
adjustment made by the user.
Tractors (2) Hold and feed paper. Used to set side margins and position the paper
horizontally.
Tractor Locks (2) Lock tractors in position.
Vertical Position Knob Used to set top of form or the first line to be printed. Open the forms
thickness lever and rotate this knob to move paper vertically.
Paper Scale A horizontal scale graduated in tenths of an inch, useful for setting
paper margins and counting text columns. (See below.)
28
Mechanical Controls
TOF
TOF
TOF
T
OF
183871 REV A
183871a
Ribbon
Ribbon
Cartridge
Ribbon
Tension Knob
Air Shroud
Assembly
Tab (2)
Tab
Slot (2)
Blue Tractor
Lock (2)
Paper
Support (2)
Tractor (2)
Vertical
Position Knob
Platen Lever
Splined Shaft
Platen Stop
Hammer Bank
Cover and
Ribbon Mask
Ribbon Cartridge
Interface
Figure 4. Mechanical Controls
29
Chapter 1
Tools and Test Equipment
Tools and Test Equipment
For field level maintenance of the printer, you will need these tools:
Adapter, 1/4 in. hex to 1/4 in. square, Utica® HW-18
Alcohol, anhydrous
Allen Wrench, 1/16 inch
Allen Wrench, 3/32 inch
Allen Wrench, 5/32 inch
Allen Wrench, 7/64 inch
Allen Wrench, 5/64 inch
ESD Wrist Strap
Feeler Gauge, Flat, 0.010 inch
Feeler Gauge, Flat, 0.011 inch
Feeler Gauge, Flat, 0.012 inch
Feeler Gauge, Flat, 0.013 inch
Feeler Gauge, Flat, 0.040 inch
Field Kit, Tester, P5 Power Supplies, Generic, (P/N 178083-001)
Force Gauge, (Chatillon™ NY, Gauge-r, 0-20 lb., CAT 719-20)
Force Gauge, “Fish Scale” type, 0-16 oz.
Hardware Kit, P5XXX Mech, ZTP (P/N 178573-001)
Hex bit, 3/16 in., torque screwdriver
Hex bit, 3/32 in., torque screwdriver
Hex bit, 5/32 in., torque screwdriver
Hex bit, 5/64 in., torque screwdriver
Lubricant, Bearing (P/N 101805-001)
Nut Driver, 1/4 inch
Nut Driver, 5/16 inch
Nut Driver or Open End Wrench, 7/32 inch
Open End Wrench, 5/16 inch
Pliers, Grip Ring, External
Screwdriver, flat tip
Screwdriver, Phillips, #1
Screwdriver, Phillips, #2
Screwdriver, Torque, Utica TS-35
Shuttle Stabilizer Tool (P/N 255447-001)
Tie Wraps, 4 inch and 8 inch
Torx® T-10, T-15 Driver
30
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