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IBM
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6400
IBM 6400 Maintenance Information Manual
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Appendix
J
Illustrated Parts Breakdow
n
Item
No.
Part No.
D
escript
ion
Notes
36
24H9004
S
tacker Ha
rdware Kit
Kit
not illus
trated
75
24H8985
Com
pression S
pring
On
left end of
shaft o
n early
mode
ls
80
Ref
Fri
ction
W
asher
Part o
f item 3
6
85
Ref
Flan
ged Bu
shing
P
art of
item 36
90
24H8988
Dr
ive Roll
er
Five
on earl
y models
403
405
Table of Contents
Default Chapter
4
Default Chapter
4
Energy Star
4
Notices
5
Electrical Safety
5
Trademarks and Service Marks
6
Table of Contents
7
1 Maintenance Overview
13
About the Printer
13
The IBM 6400 Series Printer Family
13
Hanzi Printers
14
How to Identify the Printer
15
Printer Evolution
15
Important Maintenance Notes
16
About this Manual
16
How to Use this Manual
16
Notes and Notices
17
Printing Conventions in this Manual
18
Related Documents
18
Controls and Indicators
20
Electrical Controls, Cabinet Models
20
Electrical Controls, Pedestal Models
22
Mechanical Controls, All Models
24
Tools, Test Equipment, and Supplies
26
2 Installation
27
Installing and Configuring the IBM 6400 Printer
27
3 Preventive Maintenance
29
Cleaning the Printer
29
Cleaning the Exterior
29
Cleaning the Interior
30
Cleaning the Shuttle Frame Assembly
31
Cleaning the Card Cage Fan Assembly
33
4 Principles of Operation
35
Line Matrix Printing
35
Printing Rates
38
Printing Mechanism
38
Hammer Bank Assembly
39
Shuttle Drive Motor
39
Shuttle Frame Assembly
39
Paper Transport System
41
Ribbon Transport System
42
Logical Control of the Printer
43
Printer Electronics
43
Operator Panel
44
CMX Controller Board
45
Data Controller
47
Flash Memory
47
Engine Controller
49
Printer Interface
51
10Base2 and 10Base-T Leds and DIP Switches
52
10/100Base-T Leds and DIP Switches
54
Dip Switches
55
Power Supply Board
57
AC Power
57
DC Power
57
Graphics
58
5 Troubleshooting
59
Introduction
59
Troubleshooting Aids
59
Start of Call
60
Troubleshooting Display Messages
61
Message List
62
Troubleshooting Other Symptoms
109
General Symptom List
110
Communications Failures
131
Operator Print Tests
132
Selecting and Running Tests
133
Customer Engineer (CE) Tests
134
Shuttle Speed
136
Boot Diagnostics Menu
137
Hex Code Printout
140
ASCII Character Set
142
Printer Information Menu
143
Installed Memory
143
Print Strokes
143
Printing Time
143
Displaying Printer Information
144
Soft Vs. Hard Reset
145
Hard Reset ("Cycle Power")
145
Soft Reset
145
The Power on Sequence
146
CMX Controller Board Handshake Sequences
146
DC Software Initialization and Power up
150
6 Adjustment Procedures
151
Introduction
151
List of Adjustments
151
Preparing the Printer for Maintenance
152
Returning the Printer to Normal Operation
153
Belt, Paper Feed Timing, Adjustment
154
Belt, Platen Open, Adjustment
156
Paper Drive Motor Pulley Alignment
158
Paper Scale Alignment
160
Platen Gap Adjustment
162
Platen Open Motor Pulley Alignment
164
Ribbon Guide Alignment
166
Splined Shaft Skew Adjustment
168
Adjusting the End of Forms Distance
169
Hammer Phasing Adjustment
173
Downloading 6400 Microcode from the World Wide Web
175
Loading Flash Memory
176
Coil Temperature Adjustment
181
Set Shuttle Speed
182
Ethernet Initialization
183
7 Replacement Procedures and Illustrated Parts Lists
185
Organization of this Chapter
185
Section I: Replacement Procedures
186
List of Procedures
186
Belt, Paper Feed Timing
188
Belt, Platen Open
189
Circuit Board: Controller
190
Circuit Board: Power Supply
192
Circuit Breaker
193
Coax/Twinax Multi-Platform Interface
194
Connector Shells
195
Connector Stiffening Clips
198
Cover Assembly, Hammer Bank / Ribbon Mask
200
Cover Assembly, Shuttle
203
Cover Assembly, Top, Pedestal Model
204
Dashpot
205
Doors, Cabinet, Reversing
206
Ethernet Interface Assemblies
207
Fan Assembly, Cabinet Exhaust
208
Fan Assembly, Card Cage
209
Fan Assembly, Hammer Bank
210
Hammer Spring Assembly
211
IBM Coax/Twinax Expansion Board
215
Magnetic Pick-Up (MPU) Assembly
216
Memory and Security Modules
217
Security Module
217
Motor Assembly, Paper Feed
221
Motor Assembly, Platen Open
223
Motor Assembly, Ribbon Drive
225
Network Print Server
226
Operator Panel Assembly, Cabinet Model
227
Operator Panel Assembly, Pedestal Model
228
Paper Guide Assembly
229
Paper Ironer
230
Platen
231
Resistors, Terminating
235
Ribbon Guide Assembly (L/R)
237
Ribbon Hub
238
Shaft, Splined
239
Shaft, Support
241
Shuttle Frame Assembly
242
Spring, Extension
244
Switch Assembly, Cover Open
245
Switch Assembly, Paper Detector
246
Switch Assembly, Platen Interlock
247
Tractor (L/R)
248
Section II: Illustrated Parts Lists
249
Illustrations of Printer Components
249
A Wire Data
287
Circuit Board and Cable Pinouts
287
Appendix A: Wire Data
287
Interconnection Diagram
289
NOTE: Acronyms and Signal Mnemonics Are Defined in Appendix C.
289
Power Distribution Diagram
290
Main Wire Harness Test Tables
291
Controller, CMX
292
Power Supply
296
IBM Coax/Twinax Expansion Board
297
Surestak Power Stacker PCBA
298
Cabinet Model
299
Cabinet Model, Mechanism Base
300
Pedestal Model
301
Pedestal Model, Mechanism Base
302
Cable Assemblies Centronics I/O
303
Centronics/Dataproducts Adapter
304
Remote Power
305
Twinax Auto-Termination
306
AC-In, Power Supply
307
AC Power Input
308
Card Cage Fan
309
Control Panel
310
Exhaust Fan
311
Hammer Bank Logic
312
Hammer Bank Power
313
Mpu
314
Ribbon Guide Kit
315
Ribbon Motor, Extension
316
Appendix A Circuit Board and Cable Pinouts
317
Shuttle Motor Drive
317
Frame Cable, Power Stacker
318
Logic Cable, Power Stacker
319
Power Cable, Power Stacker
320
Vertical Rail Cable, Power Stacker
321
Fan Assembly, Hammer Bank
322
Magnetic Pickup (MPU) Assembly
323
Switch Assembly, Paper Detector
324
Switch Assembly, Platen Interlock
325
Switch Assembly, Cover Open
326
B Printer Specifications
327
Ribbon Specifications
327
Paper Specifications
328
Printer Dimensions
329
Environmental Characteristics
329
Relative Humidity
329
Electrical Characteristics
330
Interfaces
336
Duty Cycle
336
C Metric Conversion Tables
337
Length
337
Torque and Force
337
Mass and Density
338
Temperature
338
Power
338
D Torque Table
339
E Safety Inspection Guide
341
Safety Inspections
341
Preparation
341
Prepare the Printer for Inspection
342
Inspect Mechanical Parts
342
Print Mechanism
343
Inspect Electrical Parts
343
Power Cable
345
F Abbreviations and Signal Mnemonics
347
G Cords and Adapters
355
H Part Numbers
357
I Noise Suppression Devices
365
J Surestak Power Stacker
367
Contents
367
Introduction
368
Stacker Operation
368
Component Locations
368
Stacker Control Panel
370
Removing the Power Stacker
375
Installing the Power Stacker
380
Replacing the Constant Force Spring
391
Replacing the Timing Belts
394
Illustrated Parts Breakdown
398
Other manuals for IBM 6400
Operation Guide
110 pages
Programmer's Reference
242 pages
Setup Guide
370 pages
Owner's Manual
16 pages
Programmer's Reference Guide
450 pages
Safety Information
56 pages
4
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IBM 6400 Specifications
General
Brand
IBM
Model
6400
Category
Printer
Language
English
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