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EK-ELG06-MG-002

July 1992

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Document:	LG06 Text and Graphics Printer Maintenance Manual
Order Number:	EK-ELG06-MG
Revision:	002
Pages:	219
Original Filename:

OCR Text

LG06
Text and Graphics Printer

Maintenance Manual
digi tal 

Order Number: EK–ELG06–MG

LG06
Text and Graphics Printer

Maintenance Manual

Order Number: EK–ELG06–MG

Digital Equipment Corporation • Merrimack, NH 03054

2nd Edition, July 1992

 Digital Equipment Corporation 1991, 1992

The information in this document is subject to change without notice and should
not be construed as a commitment by Digital Equipment Corporation. Digital
Equipment Corporation assumes no responsibility for any errors that may appear
in this document.
Printed in U.S.A.

The following are trademarks of Digital Equipment Corporation:
DATATRIEVE
DEC
DECmate
DECset
DECsystem
DECUS
DECwriter
DECxpress
The DIGITAL logo

DIBOL
IVAX
MASSBUS
PDP
P/OS
Professional
Rainbow
RSTS

RSX
Scholar
ULTRIX
UNIBUS
VAX
VMS
VT
Work Processor

FCC USER STATEMENT
NOTICE:
This equipment generates, uses, and may emit radio frequency. The equipment has
been type tested and found to comply with the limits for a Class A computing device
pursuant to Subpart J of Part 15 of FCC rules, which are designed to provide reasonable
protection against such radio frequency interference. Operation of this equipment in a
residential area may cause interference in which case the user at his own expense will
be required to take whatever measures may be required to correct the interference.

Table of Contents
1

Maintenance Overview
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Warnings and Special Information . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Printing Conventions in This Manual . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Tools, Test Equipment, and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10

Scheduled Maintenance
Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . 2–2
Inspecting the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
Cleaning the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4

Troubleshooting
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
48 Volt Failed * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
Dynamic RAM Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
Ham. Bank Hot * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
Ham. Coil Open * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
Ham. Coil Short* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
Ham. Drv. Short * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8
Mech Driver Hot * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9
Mech Driver Link* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10
Paper Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11
Paper Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12
Platen Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–13

Ribbon Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–14
Shttl Cover Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15
Shuttle Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16
Software Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17
Symptoms Not Indicated by Fault Messages . . . . . . . . . . . . . . . . . . . . . . 3–18
Troubleshooting Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–19
Diagnostic Self–Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–26
Running the Diagnostic Self–Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–28
Hex Code Printout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29

Adjustment Procedures
Preparing for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Belt, Paper Feed Timing, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4–6
Belt, Platen Open, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
Hammer Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
Paper Drive Motor Pulley Alignment . . . . . . . . . . . . . . . . . . . . . . . . 4–10
Paper Scale Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Platen Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–16
Platen Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–18
Platen Open Motor Pulley Alignment . . . . . . . . . . . . . . . . . . . . . . . . 4–12
Ribbon Guide Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–20
Splined Shaft Skew Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–14

Replacement Procedures
Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
Preparing the Printer for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
Belt, Paper Feed Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
Belt, Platen Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6
Cable Assembly W4, Hammer Bank . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
Cable Assembly W5, Intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10
Cable Assembly, Multi I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14

Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–18
Control Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–20
Cover Assembly, Hammer Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–22
Cover Assembly, Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–24
Fan Assembly, Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–26
Fan Assembly, Cabinet Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–28
Fan Assembly, Hammer Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–30
Hammer Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–32
Magnetic Pick–up (MPU) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 5–34
Motor Assembly, Ribbon Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–36
Motor Assembly, Paper Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–38
Motor Assembly, Platen Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–40
Paper Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–42
Paper Ironer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–44
PCBA, Common Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–46
PCBA, Mechanism Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–48
PCBA, Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–50
PROMs, Chips, and ICs on the CCB . . . . . . . . . . . . . . . . . . . . . . . . . 5–52
PROMs, Chips, and ICs on the Mechanism Driver . . . . . . . . . . . . . . 5–54
Resistors, Terminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–56
Ribbon Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–58
Ribbon Guide Assembly (L/R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–60
Shaft, Splined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–62
Shaft, Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–64
Shuttle Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–66
Spring Assembly, Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–70
Spring, Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–72
Switch Assembly, Cover Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–74
Switch Assembly, Paper Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–76
Switch Assembly, Platen Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . 5–78
Tractor (L/R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–80
Returning the Printer to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . 5–80

iii

Appendices
A: Printer Configuration
B: Printer Specifications
C: Torque Table
D: Cable Interconnections and Hammer Bank Wiring
E: Principles of Operation
F: Ferrite Noise Suppression Cores

Index

Maintenance Overview

Chapter Contents
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Warnings and Special Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Printing Conventions in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Tools, Test Equipment, and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10

Maintenance Overview

1–1

About This Manual
This manual explains how to maintain and repair the LG06 printer at the field
service level of maintenance. This manual covers alignments and
adjustments, preventive and corrective maintenance, troubleshooting, and
basic principles of operation.

Related Documents
Information about operating the LG06 printer is in the User’s Manual.

How to Use This Manual
This manual is designed so you can quickly find the information you need to
maintain and repair the Encore printer. You can locate maintenance
information three ways:
•

Use the Table of Contents at the front of the manual.

•

Use the Chapter Contents list on the first page of each chapter.

•

Use the Index at the back of the manual.

Read the entire procedure before beginning any maintenance task. Gather all
required tools and make sure you understand all warnings, cautions, and
notes before you begin working on the printer.

Warnings and Special Information
Always read and comply with information highlighted by special headings.
The headings reveal the nature of the information:
WARNING

Conditions that could harm you as well as damage the equipment.
CAUTION

Conditions that could damage the printer or related equipment.
IMPORTANT

Information vital to proper operation of the printer.

NOTE: Information considered important enough to emphasize.

1–2

Maintenance Overview

Printing Conventions in This Manual
Switches and indicators labeled on the printer are printed uppercase in this
manual. Example: “Press the ON LINE switch to take the printer off–line.”
If a control is not labeled on the printer, it is printed lowercase. Example:
“Set the forms thickness lever to the fully open position.”
Messages that appear on the control panel display are printed inside
quotation marks in lowercase with the first letter capitalized. Example: “Save
Config” appears on the message display.

Maintenance Overview

1–3

Controls and Indicators
The locations of the printer cover, cabinet doors, and operator control panel
are shown in Figure 1–1.
Electrical controls and indicators are described in Table 1–1 and illustrated in
Figure 1–2.
Mechanical controls and indicators are described in Table 1–2 and illustrated
in Figure 1–3.

1–4

Maintenance Overview

Printer Cover
Lift to open
Operator
Control
Panel
Rear Door
(Not shown)

See Detail

Hinged on left.
Magnetic latch.
Open by pulling
right edge.
Floor Cabinet
Front Door
Hinged on left.
Magnetic latch.
Open by pulling
right edge.

Operator Control Panel

CLEAR
UP
R/S
PREV

NEXT
SET TOF
ON LINE

VIEW

ENTER
DOWN

Figure 1–1. Printer Cover, Door(s), and Operator Control Panel

Maintenance Overview

1–5

Table 1–1. Electrical Controls and Indicators
Function

Switch or
Indicator

NOTE: Only the ON LINE switch operates when the printer is on–line.
All other switches operate only in the off–line state.
/O
Status lamps

1–6

= On O = Off Turns printer on and off. Switch is
also a circuit breaker.
Illuminate when printer is on–line. Flash alternately to indicate fault. Off when printer is off–line.

Message display

Displays printer status and error messages.

ON LINE

Toggles the printer on–line and off–line.

Advances paper to top of form on next page.

Advances paper to top of next print line.

VIEW

Advances paper for viewing through cover window, then returns paper to print position.

Locks and unlocks ENTER switch when pressed
simultaneously with DOWN switch. Also causes
display of configuration menus, submenus, and
diagnostic tests.

DOWN

See above.

Displays previous parameter in a configuration or
diagnostic test menu.

Displays next parameter in a configuration or
diagnostic test menu.

CLEAR

Clears printer after a fault is corrected. Returns
printer to off–line state from within a configuration menu. Resets printer when pressed simultaneously with R/S switch.

R/S

Runs and stops configuration and self tests. Runs
and stops hex dump. Resets printer when pressed
simultaneously with CLEAR switch.

SET TOF

Sets location of first line of print on a page.

ENTER

Enters displayed parameter into printer nonvolatile
memory. Must be unlocked before using.

Maintenance Overview

(On)

(Off)

Power Switch

Message Display

Status Lamps

CLEAR
UP
R/S
PREV

NEXT
SET TOF
ON LINE

VIEW

ENTER
DOWN

Raise Printer Cover to
Access These Switches
CLEAR
UP
R/S
PREV

NEXT
SET TOF
ENTER

DOWN

Figure 1–2. Electrical Controls and Indicators

Maintenance Overview

1–7

Table 1–2. Mechanical Controls and Indicators

1–8

Control or
Indicator
(See Figure 1–3)

Function

Forms thickness
lever

Sets platen for paper and forms of different thicknesses. Must be fully opened (raised) to load paper.

Forms thickness
pointer and scale

Indicates relative thickness of forms or paper. Set the
forms thickness lever at A for thin (single–part) forms,
B for thicker forms, and so on.

Tractors (2)

Hold and feed paper. Used to set left margin. Left tractor moves about one inch. Right tractor moves full
range.

Tractor locks (2)

Lock tractors in position.

Horizontal
adjustment knob

Allows fine positioning of left print margins. Moves
paper left or right.

Vertical position
knob

Used to set top of form or first line to be printed. Rotate
to move paper vertically.

Maintenance Overview

Horizontal
Adjustment
Knob

Left Tractor Door
Right Tractor Door
Tractor
Lock
Vertical
Position
Knob

Tractor
Lock

Forms Thickness
Lever and Scale

Forms Thickness Pointer

Figure 1–3. Mechanical Controls and Indicators

Maintenance Overview

1–9

Tools, Test Equipment, and Supplies
The tools, test equipment, and supplies required for field level maintenance
of LG06 printers are listed in Table 1–3.
Table 1–3. Tools, Test Equipment, and Supplies

1–10

Item

Part No.

Adhesive, Loctite  (adhesive, methacryl)
Alcohol, anhydrous (must contain no water)
RTV silicone sealant
Adjustable wrench
Diagonal cutters
Digital voltmeter
Extension 3 in., 3/8 in. drive
Feeler gauge set
Force gauge (Chatillon  NY, Gauge–R, 0–20 lb)

101854–002
–
101537–001
–
–
–
–
–
CAT 719–20

Gauge, platen position

996083–200

Kimwipes 
Lubricant, bearing (Lubriko  M–3, Master Lubricant Co.)
Nut driver set

–
101805–001
–

Oscilloscope and probes (35 MHz or better)
Pliers, grip ring

–
–

Pliers, chain nose

–

Ratchet, 3/8 in. drive

–

Rule, steel, 6 in.

–

Screwdriver, torque, Utica TS–35

29–17381–00

Adapter, 1/4 in. hex to 1/4 in. square, Utica HW–18

29–24723–00

Hex bit, 3/16 in., torque screwdriver

29–20995–00

Hex bit, 3/32 in., torque screwdriver

29–18505–00

Hex bit, 5/32 in., torque screwdriver

24–18504–00

Hex bit, 5/64 in., torque screwdriver

–

Screwdriver, Allen hex (set), w/extension

–

Screwdriver, Phillips

–

Screwdriver, Phillips

–

Screwdriver, slot

–

Screwdriver, slot

–

Socket, 7/16 in., 3/8 in. drive
Tweezers

–
–

Maintenance Overview

Scheduled Maintenance

Chapter Contents
Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . . . . . . 2–2
Inspecting the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
Cleaning the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4

Scheduled Maintenance

2–1

Preventive Maintenance Checks and Services (PMCS)
Perform preventive maintenance checks and services (PMCS) every six
months or after every 1000 hours of operation, whichever comes first.
Do these checks more often if the printer is used for heavy–duty, continuous
printing or if is located in a dusty area.
PMCS are listed in Table 2–1.
WARNING

Disconnect the ac power cord before performing PMCS. Failure to do so
could result in injury to you or damage to equipment.

Table 2–1. Preventive Maintenance Checks and Services

Interval

Every 6 months or 1000
hours of operation,
whichever occurs first.

2–2

Procedure

Page

Inspect the printer.

2–3

Clean the printer.

2–4

Check and adjust
platen gap.

4–18

Scheduled Maintenance

Inspecting the Printer
Correct any condition found during inspection that could affect printer
performance or reliability.
Table 2–2. Physical Inspection
Item(s) to Inspect

What to Look For

Cabinet, base,
frame

Check for damage, cracks, breaks, dents, gouges, scratches,
delamination, warping, corrosion, and proper finish.

Attaching
hardware

Inspect fasteners for thread damage, corrosion.

Nameplates

Inspect for legibility and damage.

Printer cover,
cabinet door(s),
gas spring
assemblies

Inspect for damage and loose or missing hardware. Check
that door(s) open/close without binding and stay closed.
Check that printer cover opens/closes smoothly and the gas
spring assemblies hold the cover open.

Hinges

Inspect for damage and loose or missing hardware.

Electrical
connectors

Inspect for damage, bent or broken pins.

Controls and
indicators

Inspect for damage.

Windows

Inspect for breaks, cracks, or discoloration.

Ribbon cables

Inspect for broken wires, damaged insulation, pinched
wiring, etc.

Circuit boards

Inspect for breaks, warping, evidence of overheated
components.

Fans and motors

Inspect for obvious damage.

Scheduled Maintenance

2–3

Cleaning the Printer
CAUTION

Do not use abrasive cleaners, particularly on the window. Do not drip
water into the printer. Damage to the equipment will result. When using
spray solutions, do not spray directly onto the printer; spray the cloth,
then apply the dampened cloth to the printer.

Cleaning Outside the Cabinet
1.

Wipe the cabinet with a clean, lint–free cloth dampened (not wet) with
water and mild detergent or window cleaning solution.

Dry the cabinet with a clean, lint–free cloth.

Clean the inside of the cabinet. (See below.)

Cleaning Inside the Cabinet (Figure 2–1)
1.

Set the power switch to the O (off) position.

Disconnect the ac power cord from the printer.

Open the printer cover.

Move the forms thickness adjustment lever (1) to the fully–open
position.

Remove paper from the printer.

Squeeze the locking latch (2) and lift the ribbon spools (3) from the
ribbon hubs (4).

Using a soft–bristled brush, wipe off paper dust and ribbon lint. Vacuum
up the residue. Pay particular attention to the tractors (5), shuttle cover
assembly (6), and base casting (7).

Wipe the splined shaft (8) with a soft cloth.
CAUTION

To avoid corrosion damage, use only anhydrous alcohol when cleaning
printer mechanical elements. The cleaning solution must contain no
water.
9.

Using a cloth dampened with anhydrous alcohol, clean the ribbon guides
(9).

10. Vacuum up dust or residue that has accumulated inside the lower
cabinet.

2–4

Scheduled Maintenance

11. Wipe the lower cabinet interior with a clean, lint–free cloth dampened
with water and mild detergent or window cleaning solution.
12. Dry the cabinet interior with a clean, lint–free cloth.
13. Clean the shuttle assembly (page 2–6).

3
8

6
2

1
1. Forms Thickness Lever
2. Locking Latch (2)
3. Ribbon Spool (2)
4. Ribbon Hub (2)
5. Tractor (2)
6. Shuttle Cover Assembly
7. Base Casting
8. Splined Shaft
9. Ribbon Guide (2)

4
9
7

Figure 2–1. Cleaning Inside the Cabinet

Scheduled Maintenance

2–5

Cleaning the Shuttle Frame Assembly (Figure 2–2)
1.

Remove the shuttle cover assembly (page 5–24).

Remove the shuttle frame assembly (page 5–66).

Remove the paper ironer (page 5–44).
WARNING

Over time, the upper edge of the paper ironer can become sharp. To
avoid cutting yourself, handle the paper ironer on the sides.
4.

Moisten a clean, soft cloth with anhydrous alcohol. Wipe the paper
ironer to remove lint, ink, and paper residue.

Install the paper ironer (page 5–44).

Remove the hammer bank cover assembly (1).

Moisten a clean, soft cloth with anhydrous alcohol. Wipe the hammer
bank cover assembly to remove lint, ink, and paper residue. Clean the
holes in the cover strips.
CAUTION

Use of excessive force can chip hammer tips.
8.

Using a stiff, non–metallic brush (such as a toothbrush) and anhydrous
alcohol, carefully brush the hammer tips (2) to remove lint and ink
accumulations. Vacuum up any residue.
CAUTION

The hammer bank contains a strong magnet. To prevent damage to the
hammer tips, do not let the hammer bank cover assembly snap into
place as the hammer bank magnet attracts it. Any impact of the cover
against the hammer bank can break hammer tips.
9.

With the thick plate facing the hammer bank, engage the hammer bank
cover assembly (1) on the alignment pins (3).

10. Rotate the hammer bank cover assembly (1) until it lies flush on the
hammer bank.
11. Check that the hammer bank cover assembly is properly positioned over
the alignment pins (3) and hammer tips.
12. Install the shuttle frame assembly (page 5–66).
13. Install the shuttle cover assembly (page 5–24).
14. Clean the card cage fan assembly (page 2–8).

2–6

Scheduled Maintenance

Hammer Tip

Thin plate
Thick plate
Hammer Bank
Cover Assembly

Roll pin (2)
(Not shown)

Figure 2–2. Cleaning the Shuttle Frame Assembly

Scheduled Maintenance

2–7

Cleaning the Card Cage Fan Assembly (Figure 2–3)
1.

Open the printer cover.

Remove the paper guide assembly (page 5–42).

Vacuum the card cage fan assembly (1) and surrounding areas to remove
paper particles, dust, and lint.

Install the paper guide assembly (page 5–42).

Close the printer cover.

Connect the ac power cord to the printer.

Card Cage
Fan Assembly

Figure 2–3. Cleaning the Card Cage Fan Assembly

2–8

Scheduled Maintenance

Troubleshooting

Chapter Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
48 Volt Failed * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
Dynamic RAM Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
Ham. Bank Hot * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
Ham. Coil Open * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
Ham. Coil Short * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
Ham. Drv. Short * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8
Mech Driver Hot * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9
Mech Driver Link * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10
Paper Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11
Paper Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12
Platen Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–13
Ribbon Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–14
Shttl Cover Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15
Shuttle Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16
Software Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17
Symptoms Not Indicated by Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . 3–18
Troubleshooting Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–19
Diagnostic Self–Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–26
Running the Diagnostic Self–Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–28
Hex Code Printout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29

Troubleshooting

3–1

Introduction
This chapter contains procedures for troubleshooting printer malfunctions.
You must operate the printer to check printer performance, so have the User’s
Manual at the printer site. Although diagnostic test procedures are covered in
this chapter, basic printer operation is not covered.

Fault Messages
This section lists the fault messages that can appear on the control panel
display. The messages are listed in alphabetical order, followed by a
troubleshooting table.
If a fault condition occurs in the printer, the status lamps on the control panel
flash on and off and the first line of the display indicates “Fault Condition.”
The second line of the display indicates the specific fault.
There are two types of displayed faults:
•

Operator correctable

•

Field–service required, indicated by an asterisk (*) next to the fault
message
IMPORTANT

Test the printer after each corrective action. Stop maintenance when the
symptom disappears. Always press the CLEAR switch after correcting a
fault indicated by a fault message.

48 Volt Failed *
Instruction

1. Set power switch to O (off).

Indication

Yes

“48 Volt Failed * ” message.

Step 2.

Return printer to
normal operation.

“48 Volt Failed * ” message.

Step 3.

Return printer to
normal operation.

Step 4.

—

Wait 15 seconds. Set power
switch to 1 (on).

2. Press the CLEAR switch.
3. Remove paper guide

—

assembly (page 5–42).

3–2

Troubleshooting

Instruction

4. Disconnect cable assembly

Indication

—

Yes
Step 5.

—

W1, CCB/Mech Driver, from
connector J1 on the CCB and
connector J6 on the Mech
Driver board.

5. Power up the printer.

6. Pull the Mech Driver board

Card cage fan comes on.

Replace the
common controller
PCBA (page
5–46).

—

Step 7.

—

Step 8.

—

Step 9.

Reattach cable
assembly W1,
CCB/Mech Driver,
to connector J1 on
the CCB and
connector J6 on
the Mech Driver
board, and go to
step 6.

up so that it clears the bottom
edge connectors.

7. Disconnect +5Volt connector
PS5 (cable assembly W2)
from the power supply board
and put a 1K Ohm resistor
between pins 1 and 2.

8. Remove the Mech. Driver
board.

9. Power up the printer. Check

+ 48 Volts at pin 8.

Replace the
mechanism driver
PCBA (page
5–48) and go to
step 10.

Replace the
power supply
PCBA (page
5–50) and go to
step 10.

“48 Volt Failed * ” message.

Replace cable
assembly W2,
+5V. (See
Appendix D.) Go
to step 11.

Return printer to
normal operation.

“48 Volt Failed * ” message.

Replace cable
assembly W3, Hi
Voltage. (See
Appendix D.) Go
to step 12.

Return printer to
normal operation.

“48 Volt Failed * ” message.

Replace cable
assembly W6,
P4980A Main
Wire Harness.
(See Appendix D.)

Return printer to
normal operation.

for +48 V at power supply
cable W3 connector PS: pin 8
= +48 V, pin 15 = ground.
(See Appendix D for cable
interconnections.)

10. Cycle power and check for
the fault message.

11. Cycle power and check for
the fault message.

12. Cycle power and check for
the fault message.

Troubleshooting

3–3

Dynamic RAM Fault *
Instruction

1. Set power switch to O (off).
Wait 15 seconds. Set power
switch to 1 (on).

2. Disconnect the input data line
from the host computer. Set
power switch to O (off). Wait
15 seconds. Set power switch
to 1 (on).

3. Make a Diagnostic Check of

Indication

Yes

“Dynamic RAM Fault * ”
message.

Step 2.

Return printer to
normal operation.

“Dynamic RAM Fault * ”
message.

Step 3.

Return printer to
normal operation.

—

the Microprocessors (page
3–21).

3–4

Troubleshooting

Ham. Bank Hot *
Instruction

Indication

Yes

“Ham. Bank Hot * ” message.

Step 2.

Return printer to
normal operation.

2. Press the CLEAR switch.

“Ham. Bank Hot * ” message.

Step 3.

Return printer to
normal operation.

3. Run diagnostic self–test “All

“Ham. Bank Hot * ” message.

Step 4.

Return printer to
normal operation.

—

Step 5.

—

Step 6.

—

1. Set power switch to O (off).
Wait 15 seconds. Set power
switch to 1 (on).

Black” for 1/4 page (page
3–26).

4. Remove the shuttle cover
(page 5–24).

5. Install a magnet across the
hole in the base casting
where the cover open sensor
is mounted.

6. Run a diagnostic self–test
(page 3–26).

Troubleshooting

Hammer bank fan operates.

Replace shuttle
frame assembly
(page 5–66).

Replace hammer
bank fan
assembly (page
5–30).

3–5

Ham. Coil Open *
Instruction

Indication

Yes

“Ham. Coil Open * ” message.

Step 2.

Return printer to
normal operation.

2. Press the CLEAR switch.

“Ham. Coil Open * ” message.

Step 3.

Return printer to
normal operation.

3. Run a diagnostic self–test

“Ham. Coil Open * ” message.

Step 4.

Return printer to
normal operation.

—

Step 5.

—

Step 6.

—

Step 7.

—

Step 8.

—

1. Set power switch to O (off).
Wait 15 seconds. Set power
switch to 1 (on).

(page 3–26).

4. Remove the shuttle cover
(page 5–24).

5. Install a magnet across the
hole in the base casting
where the cover open sensor
is mounted.

6. Run a diagnostic self–test
(page 3–26) and observe
where the non–printing
hammer is located.

7. Reverse the hammer bank
flex circuit cables in the
connectors on the base
casting.

8. Run a diagnostic self–test
(page 3–26). Observe where
the non–printing hammer is
located. (NOTE: Hammer no.
48 is a permanently
non–printing hammer. Keep
this is mind when reversing
cables.)

9. Return the hammer bank flex
circuit cables to their correct
connectors on the base
casting. Run a diagnostic
self–test (page 3–26).

3–6

Position of the non–printing
hammer remains the same.

Replace the
shuttle frame
assembly (page
5–66) then go to
step 9.

If the non–printing
hammer is now on
the other side of
the hammer bank,
replace the
mechanism driver
PCBA (page
5–48) then go to
step 9.

“Ham. Coil Open * ” message.

Replace both
hammer bank
cable assemblies
(page 5–8).

Return printer to
normal operation.

Troubleshooting

Ham. Coil Short *
Instruction

Indication

Yes

“Ham. Coil Short * ” message.

Step 2.

Return printer to
normal operation.

2. Press the CLEAR switch.

“Ham. Coil Short * ” message.

Step 3.

Return printer to
normal operation.

3. Run a diagnostic self–test

“Ham. Coil Short * ” message.

Step 4.

Return printer to
normal operation.

—

Step 5.

—

Step 6.

—

Step 7.

—

1. Set power switch to O (off).
Wait 15 seconds. Set power
switch to 1 (on).

(page 3–26).

4. Remove the shuttle cover
(page 5–24).

5. Install a magnet across the
hole in the base casting
where the cover open sensor
is mounted.

6. Disconnect the hammer bank
flex circuit cables from the
connectors on the base
casting.

7. Run a diagnostic self–test

“Ham. Coil Short * ” message.

Replace the
mechanism driver
PCBA (page
5–48) then go to
step 8.

Replace the
shuttle frame
assembly (page
5–66).

“Ham. Coil Short * ” message.

Replace both
hammer bank
cable assemblies
(page 5–8).

Return printer to
normal operation.

(page 3–26).

8. Run a diagnostic self–test
(page 3–26).

Troubleshooting

3–7

Ham. Drv. Short *
Instruction

Indication

Yes

“Ham. Drv. Short * ” message.

Step 2.

Return printer to
normal operation.

2. Press the CLEAR switch.

“Ham. Drv. Short * ” message.

Step 3.

Return printer to
normal operation.

3. Run a diagnostic self–test

“Ham. Drv. Short * ” message.

Replace the
mechanism driver
PCBA (page
5–48).

Return printer to
normal operation.

1. Set power switch to O (off).
Wait 15 seconds. Set power
switch to 1 (on).

(page 3–26).

3–8

Troubleshooting

Mech Driver Hot *
Instruction

Indication

Yes

“Mech Driver Hot * ” message.

Step 2.

Return printer to
normal operation.

2. Press the CLEAR switch.

“Mech Driver Hot * ” message.

Step 3.

Return printer to
normal operation.

3. Run a diagnostic self–test

“Mech Driver Hot * ” message.

Step 4.

Return printer to
normal operation.

Card cage fan operates.

Replace
mechanism driver
PCBA (page
5–48).

Replace card
cage fan
assembly (page
5–26).

1. Set power switch to O (off).
Wait 15 seconds. Set power
switch to 1 (on).

(page 3–26).

4. Open printer cover and
observe card cage fan.

Troubleshooting

3–9

Mech Driver Link *
Instruction

Indication

Yes

“Mech Driver Link * ” message.

Step 2.

Return printer to
normal operation.

2. Press the CLEAR switch.

“Mech Driver Link * ” message.

Step 3.

Return printer to
normal operation.

3. Run a diagnostic self–test

“Mech Driver Link * ” message.

Step 4.

Return printer to
normal operation.

—

Step 5.

—

Connectors are attached
properly.

Step 6.

Connect and latch
ribbon connectors.
Go to step 6.

Boards are installed correctly.

Step 7.

Reseat CCB and
mechanism driver
boards in their
edge connectors
at bottom of card
cage. Go to step
7.

“Mech Driver Link * ” message.

Replace the
common controller
PCBA (page
5–46) then go to
step 8.

Return printer to
normal operation.

“Mech Driver Link * ” message.

Replace the
mechanism driver
PCBA (page
5–48) then go to
step 9.

Return printer to
normal operation.

“Mech Driver Link * ” message.

Replace cable
assembly W1,
CCB/Mech. Dr.
(See Appendix D.)

Return printer to
normal operation.

1. Set power switch to O (off).
Wait 15 seconds. Set power
switch to 1 (on).

(page 3–26).

4. Remove paper guide
assembly (page 5–42).

5. Check ribbon cable
connectors between common
controller board (CCB) and
mechanism driver board.

6. Check installation of common
controller board (CCB) (page
5–46) and mechanism driver
board (page 5–48).

7. Power up printer and check
for fault message.

8. Power up printer and check
for fault message.

9. Power up printer and check
for fault message.

3–10

Troubleshooting

Paper Jam
Instruction

Indication

1. Inspect paper path for

Paper path is clear.

Step 2.

Remove paper
and go to step 2.

Debris found.

Gently remove
paper or lint
particles with a
wooden stick or
pair of tweezers.
CAUTION: Do not
pry or apply force
to the hammer
tips. Go to step 3.

Step 3.

Ribbon mask damaged or bent.

Replace the
hammer bank
cover assembly
(page 5–22). Go
to step 5.

Step 5.

Yes

bunched, torn, folded paper
or labels.

2. Inspect the narrow
passageway between the
face of the platen and the
ribbon mask for bits of torn
paper or ribbon lint. Check
the holes in the ribbon mask
surrounding each hammer
tip.

3. Check that the ribbon mask
has not been deformed in
such a way as to block the
paper path.

4. Load paper.
5. Run a diagnostic self–test

—

Clean the paper
motion detector
with cotton swab.
Go to step 6.

Return printer to
normal operation.

“Paper Jam” message.

Replace paper
detector switch
assembly (page
5–76). Go to step
7.

Return printer to
normal operation.

“Paper Jam” message.

Replace the
intermediate cable
assembly (W5)
(page 5–10). Go
to step 8.

Return printer to
normal operation.

“Paper Jam” message.

Replace the
common controller
PCBA (page
5–46).

Return printer to
normal operation.

(page 3–26).

7. Run a diagnostic self–test
(page 3–26).

8. Run a diagnostic self–test
(page 3–26).

Troubleshooting

—

“Paper Jam” message.

(page 3–26).

6. Run a diagnostic self–test

Step 5.

3–11

Paper Out
Instruction

1. Load paper.
2. Run a diagnostic self–test

Indication

—

(page 3–26).

3–12

Step 2.

—

Replace paper
detector switch
assembly (page
5–76). Go to step
3.

Return printer to
normal operation.

“Paper Out” message.

Replace the
intermediate cable
assembly (W5)
(page 5–10). Go
to step 4.

Return printer to
normal operation.

“Paper Out” message.

Replace the
common controller
PCBA (page
5–46).

Return printer to
normal operation.

(page 3–26).

4. Run a diagnostic self–test

“Paper Out” message.

(page 3–26).

3. Run a diagnostic self–test

Yes

Troubleshooting

Platen Open
Instruction

Indication

Yes

1. Load paper.

—

Step 2.

—

2. Close forms thickness lever.

—

Step 3.

—

3. Run a diagnostic self–test
(page 3–26).

Troubleshooting

“Platen Open” message.

Replace platen
interlock switch
assembly (page
5–78).

Return printer to
normal operation.

3–13

Ribbon Stall
Instruction

1. Check that forms thickness
lever is not closed too tightly;
this can jam the ribbon and
shuttle.

2. Run a diagnostic self–test

Indication

Yes

Forms thickness lever is set
correctly.

Step 2.

Readjust the
setting of the
forms thickness
lever. Go to step
2.

“Ribbon Stall” message.

Step 3.

Return printer to
normal operation.

Ribbon path is clear

Step 5.

Remove
obstructions from
ribbon path and
go to step 5.

Ribbon is OK. (Folds are
permitted, if the ribbon is
otherwise undamaged.)

Rewind and
reinstall ribbon.
Go to step 6.

Replace ribbon, if
damaged. Unfold
and rewind ribbon
if it was folded. Go
to step 6.

Ribbon tracks OK.

Step 6.

Align ribbon
guides (page
4–20). Go to step
6.

Both motors wind the ribbon.

Replace the
mechanism driver
PCBA (page
5–48).

Replace the
defective ribbon
drive motor (page
5–36).

(page 3–26) and check for
shuttle obstruction.

3. Check ribbon path for
blockage or obstruction.

4. Wind ribbon by hand and
inspect for folds, tears, holes,
fraying.

5. Do a fast shuttle self–test
(page 3–26) and check the
alignment of the ribbon
guides and hubs if the ribbon
was folded.

6. Using a screwdriver, short
across the ribbon guide
screws to reverse ribbon hub
motion. Check for a ribbon
drive motor that will not wind
ribbon.

3–14

Troubleshooting

Shttl Cover Open
Instruction

1. Inspect shuttle cover for

Indication

Replace the
shuttle cover
assembly (page
5–24).

Step 2.

Shuttle cover installed correctly.

Step 3.

Install cover
correctly. Make
sure the cover lies
flat and the two
captive screws are
fully seated. Go to
step 3.

“Shttl Cover Open” message.

Replace the cover
open switch
assembly (page
5–74).

Return printer to
normal operation.

installation (page 5–24).

3. Run a diagnostic self–test
(page 3–26).

Troubleshooting

Shuttle cover damaged.

warping, damage, or missing
magnet. (The magnet covers
the sensor housing when the
cover is installed.)

2. Check shuttle cover

Yes

3–15

Shuttle Jam
Instruction

1. Check the forms thickness
lever: if it is set too tightly, it
can slow the shuttle enough
to trigger the fault message.

2. Run a diagnostic self–test

Indication

Yes

Forms thickness lever set
correctly.

Step 2.

Set forms
thickness lever for
thicker paper. Go
to step 2.

“Shuttle Jam” message.

Step 3.

Return printer to
normal operation.

Shuttle movement blocked.

Remove
obstruction. Go to
step 4.

Install shuttle
cover (page
5–24). Go to step
4.

“Shuttle Jam” message.

Replace the MPU
(page 5–34).

Return printer to
normal operation.

“Shuttle Jam” message.

Replace
mechanism driver
PCBA (page
5–48). Go to step
6.

Return printer to
normal operation.

“Shuttle Jam” message.

Replace shuttle
frame assembly
(page 5–66).

Return printer to
normal operation.

(page 3–26) and check for
shuttle obstruction.

3. Remove shuttle cover (page
5–24) and inspect shuttle
area and mechanism for
obstruction.

4. Run a diagnostic self–test
(page 3–26).

5. Run a diagnostic self–test
(page 3–26).

6. Run a diagnostic self–test
(page 3–26).

3–16

Troubleshooting

Software Error *
Instruction

1. Set power switch to O (off).

Indication

Yes

“Software Error * ” message.

Step 2.

Return printer to
normal operation.

“Software Error * ” message.

Step 3.

Problem is not in
the printer. Return
printer to normal
operation.

Wait 15 seconds. Set power
switch to 1 (on).

2. Disconnect the input data line
from the host computer. Set
power switch to O (off). Wait
15 seconds. Set power switch
to 1 (on).

3. Make a Diagnostic Check of

—

the Microprocessors (page
3–21).

Troubleshooting

3–17

Symptoms Not Indicated by Fault Messages
Troubleshoot malfunctions not indicated by fault messages using standard
fault–isolation techniques:
1.

Debrief the operator for a general description of the problem.

Verify the fault by running diagnostic self–tests or replicating conditions
reported by the user.

Locate the malfunction using the half–split method:
a. Isolate faults to half the remaining system at a time, until the
final half is a field–replaceable part or assembly.
•

Chapter 5 lists all field–replaceable assemblies.

•

Troubleshooting aids are listed on the next page.

b. Start at a general level and work down to details.
4.

Replace the defective part or assembly.
IMPORTANT

Do NOT attempt field repairs on electronic components or assemblies —
replace the entire assembly with an operational spare. Most electronic
problems are corrected by replacing the printed circuit board assembly
(PCBA), sensor, or cable that causes the fault indication. The same is
true of failures traced to the hammer bank: replace the entire shuttle
frame assembly; it is not field repairable.

3–18

Test printer operation after every corrective action.

Stop troubleshooting and return the printer to normal operation when the
reported symptoms disappear.

Troubleshooting

Troubleshooting Aids

Troubleshooting

•

Printer Confidence Check (page 3–20). This procedure
systematically checks basic printer operations and functions. Use it
to establish basic printer status or for troubleshooting imprecise or
intermittent symptoms.

•

Diagnostic Check of Microprocessors (page 3–21). This
procedure checks processor operations on the printed circuit board
assemblies (PCBAs).

•

Diagnostic Self–Tests (Page 3–26.)

•

Hex Code Printout (Page 3–29.)

•

Appendix D: Cable Interconnections and Hammer Bank
Wiring Diagram

3–19

Printer Confidence Check
Instruction

1. Check that printer is plugged
into correct power source.
(Ref.: User’s Manual)

2. Disconnect the interface

Indication

Yes

Power cable installed correctly
to proper source.

Step 2.

Connect printer to
correct power
source.

Printer operates correctly.

Fault is not in the
printer. Check
host computer,
applications
software, cabling,
etc.

Step 3

(data) cable from the host
computer to isolate the
printer, then run a diagnostic
self–test (page 3–26.)

Step 4

—

a) Configuration is correct for
the user’s application.
b) Host computer and printer
use the same protocol
(emulation).
c) Configuration has not been
inadvertently changed by the
user.

Step 5

Reconfigure the
printer. (Appendix
A.)

Assemblies and components
adjusted in accordance with
Chapter 4.

Step 6

Adjust all
assemblies that
are out of spec.

3. Connect the interface (data)

—

cable to host and printer.

4. Make a configuration printout.
(Appendix A.)

5. Check alignments and
adjustments. (Chapter 4.)

—

Step 7

—

Connections are clean and tight,
wires are not stripped, frayed, or
out of connectors.

Step 8.

Replace stripped,
frayed, or broken
wires.

PCBAs are firmly seated in
edge connectors.

Step 9.

Reseat PCBAs.

Metallic debris.

Remove debris.
Clean printer
(page 2–4).

Step 10.

6. Remove paper guide
assembly (page 5–42).

7. Check all electrical
connectors.

8. Check that PCBAs are
seated correctly in edge
connectors (bottom of card
cage).

9. Inspect for debris that could
cause short circuits (loose
fasteners, foil, etc.).

10. Install paper guide assembly

—

Step 11.

—

(page 5–42).

11. Set power switch to 1 (on).

3–20

Printer powers up and display
goes to “Off–line/Emulation”

Return printer to
normal operation.

Troubleshoot fault
message (page
3–2).

Troubleshooting

Diagnostic Check of Microprocessors
This procedure checks the operation of the microprocessors and IC chips on
the Common Controller (CCB) and Mechanism Driver boards. Do the steps
in the order presented.
1.

Set the power switch to O (off).

Remove the paper guide assembly (page 5–42).

Reseat the CCB and Mech Driver boards in the card cage.

Set the power switch to 1 (on). Wait at least 15 seconds; while you are
waiting watch the 68010 LED at location A2 on the CCB (some boards
may be silk–screened as “68000”) and watch the display on the control
panel. (NOTE: IC locations are shown on page 5–52.)
a. When the CCB is operating correctly, the control panel displays
“Diagnostic Tests in Progress,” and the 68010 LED turns on for
1 to15 seconds, then turns off. The 68010 LED turns off after the
68010 successfully tests itself, RAM, 68010 ROM, and
communication with the 64180 CPU. The more RAM or ROM
installed in the printer, the longer the LED is on, but it always
turns on then off when the CCB is functioning correctly. If the
printer turns on normally, the CCB is okay. Install the EMI shield
and return the printer to normal operation.
If the 68010 LED turns on and off as described above, but the
printer does work properly, or fails later, go to step 5.
(“Dynamic RAM Fault” on the display can mean the 64180 has
waited 15–20 seconds without getting its handshake from the
68010. The following substeps use the 68010 LED to fault
isolate this message.)

b. If the 68010 LED never turns on, it means the 68010 did not
execute the first software instruction in its ROM. Go to step 6.
c. If the 68010 LED stays on for 30 seconds but never blinks, it
means RAM and ROM for the 68010 are okay, but the 64180 is
not executing instructions. Go to step 7.
d. If the 68010 LED blinks steadily at 1 blink per second, it means
that the 68010 ROMs are bad. Turn off the printer, remove the

Troubleshooting

3–21

CCB (page 5–46), and check that all ROM chips are inserted in
the correct position and with all pins inserted correctly.
This check will catch out–of–order ROMs and all single and
multiple bit failures of floating–gate EPROMs (the type with the
window, that erase with ultraviolet light).
If a ROM chip was inserted backwards, discard it. Even if it
operates properly, a high current flowed through the
backwards–biased transistors, and its service life is probably
shortened due to thermal damage.
If ROMs appear correctly inserted, they may still be defective.
Sometimes bits “fade” to one when internal floating gates
discharge. This can occur from over–voltage programming,
radiation damage, too many EPROM erasures, etc. Install new
program PROMs.
e. If the 68010 LED blinks steadily 5 times per second, it means
CCB RAM has failed. The most common cause of this failure
during maintenance is turning off the printer too briefly for the
64180 to reset. The 64180 shares memory with the 68010, and
writes to RAM if it is not completely reset. Turn the printer off,
wait at least 15 seconds, then recycle power before accepting this
indication of CCB RAM failure.
The RAM chips are at board coordinates N9 and P9. The sockets
at N8 and P8 are normally empty; this will not cause a RAM
failure. Inspect the RAM chips, sockets and traces for shorts or
missing chips. Damaged traces or sockets call for replacement of
the CCB.
A remote possibility is failure of the 64180 in the start–up
handshake or in the code that programs the memory controller.
Try changing the 64180 PROM.
5.

The 68010 LED turns on, then off, but the printer doesn’t work. Look at
the control panel display:
a. If the display is blank, or has a single line of black squares across
the top, the connector to the control panel probably needs to be
plugged in or reseated. Turn off the printer, plug in the panel

3–22

Troubleshooting

cable to connector J3 on the CCB, and start over at step 1. If the
display is still blank, or has a black line, and the 68010 LED
lights and turns off, the control panel or its cable are defective.
b. If the display reads “Mech Driver Link,” the 8032 at location J12
on the CCB may have failed. Check the 8032 and its PROM at
location J10 for bent pins, misalignment, or backwards insertion.
Also, make sure the clock–test jumper E2 at location J14 is
installed. If everything appears okay, try reseating the PROM at
location J10, the 8032 at J12, the clock jumper at J14, and the
connector at J2—sometimes this message is caused by a failure to
communicate with the 8032 on the Mech Driver board. If the
problem persists, check the Mech Driver 8032, its clock jumper,
and the PROM. Look for backwards insertion, misalignment,
etc., and try reseating the parts. (NOTE: On some Mech Driver
boards, the 8032 PROM correct orientation may be upside down
in relation to the rest of the board. On these boards, the
silk–screen will show the correct orientation.) Always replace
PROMs and parts that were inserted backwards. If the problem
persists, replace the 8032 PROMs on the CCB and Mech Driver
boards. If the problem persists, replace the interconnect cable
W1. (See Appendix D.)
c. If the printer appears normal, but does not print from the host,
check the data cable to the host and reseat the cable that attaches
to J1 of the CCB and A12. Then make sure the correct interface
is selected and configured from the control panel. (See Appendix
A.) Save the configuration and reset the printer. If the printer is
running RS–232, interchange the wires to pins 2 and 3. This is
the most common cause of a completely inoperative RS–232
cable. Make sure the printer and host have the same baud rate
and parity. In RS–232, configure the host for XON/XOFF if
possible; this requires the least complex cable.
d. If the printer prints from the host, but occasionally loses blocks
of data, the most likely cause is the host not responding to “send
no more data” signals from the printer. With a Centronics
interface, this means the host is ignoring BUSY; in RS–232, the
host is ignoring the XOFF character or “Data Terminal Ready”
(pin 20). Sometimes the cable is not conveying the necessary
signals. Test this by using a serial line analyzer and software or
test equipment that displays the data and handshake lines of the

Troubleshooting

3–23

printer. A break–out box works, but will not debug XON/XOFF
or other RS–232 data protocols. If the printer is sending XOFF,
the host may not be receiving it if it requires 1.5 or 2 stop bits.
e. If the printer prints from the host, but occasionally prints double
characters, there is probably a noise problem at the interface or
the host computer is sending an inverted strobe. This problem
can occur on Centronics or Dataproducts interfaces, never on
RS–232. What happens is the strobe signal registers logic 1 more
than once for a certain character. To fix this, change the strobe to
trailing edge or invert the Dataproducts strobe polarity. Also
check that the terminating resistors are present at locations C12
and D12 on the CCB. You can correct noise problems by using a
shielded data cable or by changing the terminating resistors. (See
page 5–56.) The standard terminating resistors are optimized for
high speed data transfer for cables between 1 and 5 meters long;
you can change them to be slower and slightly more immune to
noise. Noise is caused by static, floating logic ground, unshielded
cable, changes in ground voltage from nearby equipment, or
capacitively– or magnetically–induced noise. On very long
cables, capacitively–induced noise from the other signals of the
cable (especially Centronics “ACK” or Dataproducts data
request “DRQ”) can cause false strobes. Unshielded and flat
ribbon cables are much more prone to problems due to increased
length. The best solution is to shorten cable, shield it, and reduce
local electromagnetic noise.
f.

3–24

If the printer prints garbled data or slews uncontrollably, put the
printer into hex dump mode and analyze the binary data. One
cause of garble is the host interface or cable is not transmitting
all the data. When this occurs, the Centronics or Dataproducts
interface receives a 1 on every unconnected data line.
Uncontrolled slewing is often caused by enabling PI (Paper
Instruction) when the host lacks a PI signal. (PI shows as “p” on
the hex dump.) Some DEC RS–232 and Dataproducts interfaces
only send 7 data bits. In this case, the eigth bit will be received as
one. In RS–232, a common cause of garble is to set the interface
to the wrong baud rate or parity. Sometimes the host sends 1.5 or
2 stop bits; in this case, the printer’s “1–stop–bit” setting will
accept both 1.5 and 2 stop bit data. Sometimes the data may
“fade” or “persist” from one character to the next. This reveals a
problem with Centronics or Dataproducts terminating resistors

Troubleshooting

on the CCB at C12 and D12, especially if they are absent. Garble
can also result from failed termination resistors or parallel logic,
but this is rare.
6.

The 68010 LED never lights. The 68010 has not run its first instruction.
a. The first two programs PROMs may be malfunctioning or
inserted wrong. Do the corrective actions listed in step 4.d.
b. Check the power supply voltages: look at the control panel
display. If it is not blank, the logic power supply is okay. If the
display is blank, turn off the printer. Reseat the power supply
cable on the Mech Driver board and the CCB/Mech. Driver cable
assembly W1. Turn the printer on. If that does not correct the
problem, check for logic supply voltage on the CCB board
between the positive end of C4 (location A5) and TP1 (location
A1).
c. On the CCB, inspect the PROM sockets, the 68010 socket (if
installed), and the oscillator module at location P6. Remove any
obvious dirt or conductive dust.
d. Test for voltage supplied to the 68010 LED. The LED may have
failed.
e. If the failure persists, replace the common controller board
(CCB).

The 68010 LED lights, but never turns off. Look at the control panel
display:
a. If the top line of the display is blank, the control panel is
probably unplugged or defective. Do the corrective actions listed
in step 5.a.
b. If the display has a single line of black squares on the top line,
the 64180 has failed. Turn off the printer, remove the CCB, and
check the 64180 PROM at location H8 for bent pins, pins not
inserted, or backwards insertion. Discard any PROMs that were
inserted backwards. Their transistors were reverse biased, and
even if they work their service life has been shortened by thermal
damage. Replace the 64180 PROM. Check that the 64180 is
correctly inserted and completely seated in its socket.

Troubleshooting

3–25

c. If the display reads “Diagnostic Tests in Progress” and 68010
LED has been on for 20 seconds or more but is not blinking, it
means the 64180 cannot communicate with the 8032 on the
Mech Driver board. Turn off the printer, reseat the cable in J2 of
the CCB and on the Mech Driver board. Check the 8032 on the
Mech Driver, its PROM, and its clock jumper (E1–E2) for
correct insertion, bent pins, etc. Reseat the jumper and socketed
parts. If the problem persists, replace the Mech Driver’s PROM
and the CCB/Mech. Driver cable assembly W1.

Diagnostic Self–Tests
Run diagnostic self–tests to check the print quality and operation of the
printer. The self–tests are listed below.
NOTE: Under the description of each diagnostic test is a list of items that
may require field replacement or adjustment if the test produces a
bad print pattern. Items are listed in the order they should be
checked: simplest items first, moving to more complex components.
•

ASCII Swirl A sliding alphanumeric pattern useful for identifying
missing or malformed characters, improper vertical alignment, or
vertical compression.
Hammer bank cover
Hammer spring
Shuttle frame assembly

•

All Es A pattern of all uppercase letter Es useful for identifying
missing characters, misplaced dots, smeared characters, improper
phasing, or light/dark character variations.
Ribbon
Hammer bank cover
MPU sensor
Hammer spring
Hammer coil (shuttle frame assembly)
Splined shaft skew adjustment

3–26

Troubleshooting

•

Es plus TOF A pattern of all Es followed by a form feed to the
next page top of form, useful for identifying paper motion or feeding
problems.
Hammer bank cover
Power supply PCBA
Mechanism Driver PCBA
Paper motion sensor or cable
Paper feed belt or motor
Splined shaft bearings
Tractors or tractor belts

•

All Hs A pattern of all uppercase letter Hs useful for detecting
missing characters or dots, smeared characters, or improper phasing.
Ribbon
Hammer bank cover
MPU sensor
Hammer spring
Hammer coil (shuttle frame assembly)

•

All Underlines An underline pattern useful for identifying
hammer bank misalignment.
Mechanism Driver PCBA
Hammer bank cover
Hammer tips
Paper feed belt or motor
Splined shaft bearings
Tractor bearings or belts

•

All Black All dot positions are printed, creating a solid black band.
Exercises shuttle and hammer bank at maximum capacity.
Mechanism Driver PCBA
Power Supply PCBA
Hammer bank cover
Hammer spring
Hammer coil (shuttle frame assembly)

Troubleshooting

•

Shuttle Slow Verifies proper operation by exercising shuttle
motion at low speed.

•

Shuttle Fast Verifies proper operation by exercising shuttle
motion at high speed.

3–27

•

Phasing A hammer timing parameter that permits you to adjust
the vertical alignment of dots in character printing. (See page 4–4.)

•

Test Width Permits you to run tests at all available print widths.

Running the Diagnostic Self–Tests
To run a diagnostic self–test:
1.

Press ON LINE to place the printer off–line. “Off–line/Emulation”
displays.

Press UP and DOWN simultaneously to unlock the ENTER switch.

Raise the printer cover.

Press DOWN. “Emulation/LG06” displays.

Press NEXT until “Emulation/Self–Test” displays.

Press ENTER to select self–test. “Emulation/Self–Test * ” displays.

To select one of the tests, press DOWN, then press NEXT or PREV until
the appropriate test displays.

Press R/S to begin the selected self–test. Press R/S again to stop the test.

Examine the print quality.

10. Press CLEAR to place the printer off–line. The display reads
“Off–line/Emulation”.
11. Press UP and DOWN simultaneously to lock the ENTER switch.
12. Close the printer cover.
13. Press ON LINE to place the printer on–line.

3–28

Troubleshooting

Hex Code Printout
Hex dumps list all ASCII character data received from the host computer
with their corresponding two–digit hexadecimal codes. You can use hex
dumps to troubleshoot printer data reception problems.
Printable characters print as the assigned symbol; nonprintable characters are
indicated by a period [.]. The letter [p] before a hex code indicates an active
Paper Instruction (PI) line. A blank space before a hex code indicates an
inactive PI line.
To make a hex printout:
1.

Press ON LINE to place the printer off–line. “Off–line/Emulation”
displays.

Raise the printer cover.

Simultaneously press the UP and DOWN switches to unlock the
ENTER switch. “Unlocked” displays briefly.

Press DOWN. “Emulation/LG06” displays.

Press NEXT until “Emulation/Hex Dump” displays.

Press ENTER. “Emulation/Hex Dump * ” displays.

Press on LINE. The display indicates that the printer is on–line in hex
dump mode (“On–line/Hex Dump”).

Send the data from the host — the data print in hex dump format. (Any
data remaining in the buffer print before the hex code printout starts.)

Press on–LINE again to stop the hex dump. The display reads
“Off–line/Emulation”.

10. Press DOWN. “Emulation/LG06” displays.
11. Press ENTER to reselect LG06 emulation. “Emulation/LG06 * ”
displays.
12. Simultaneously press the UP and DOWN switches to lock the ENTER
switch. “Locked” displays briefly.
13. Close the printer cover.
14. Press ON LINE to place the printer on–line.

Troubleshooting

3–29

3–30

Troubleshooting

Adjustment Procedures

Chapter Contents
Preparing the Printer for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Belt, Paper Feed Timing, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
Belt, Platen Open, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
Hammer Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
Paper Drive Motor Pulley Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10
Paper Scale Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Platen Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–16
Platen Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–18
Platen Open Motor Pulley Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12
Ribbon Guide Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–20
Splined Shaft Skew Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–14
Returning the Printer to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–22

Adjustment Procedures

4–1

Preparing the Printer for Maintenance
WARNING

Unless otherwise directed, do adjustment procedures with the printer
disconnected from the power source. Failure to remove power could
result in injury to personnel or damage to equipment.
The procedures in this chapter are written assuming the printer has been
prepared for maintenance. To prepare the printer for maintenance, do the
following before performing an adjustment or alignment:
1.

Set the printer power switch to O (off).

Disconnect the power cord from the ac power source.

Unload paper.

Read through the entire maintenance procedure before you begin
working on the printer.

Gather all necessary tools and parts before you begin working on the
printer.

Adjustments
This chapter contains the adjustment procedures done at the field service
maintenance level.

Paper Scale Adjustment (Figure 4–1 )

4–2

Connect the power cord to the ac power source.

Set the printer power switch to 1 (on).

Load paper.

Open the printer cover.

Verify that the shuttle cover (1) is properly installed (page 5–24).

Loosen the three button–head screws (2). (It may be necessary to
remove the shuttle cover to loosen the button–head screws.)

Position the scale (3) so that positions 1 and 132 are lined up with the
first and last characters on a 132 character printout.

Tighten the button–head screws (2).

Close the printer cover.

Adjustment Procedures

1. Shuttle Cover
2. Screw, Button–Head (3)
3. Paper Scale

Figure 4–1 . Paper Scale Adjustment

Adjustment Procedures

4–3

Hammer Phasing Adjustment (Figure 4–2 )
NOTE: Hammer phasing must be checked and adjusted when PROMs on
the common controller PCBA are replaced.
1.

Connect the power cord to the ac power source.

Set the printer power switch to 1 (on).

Load paper.

Press the ON LINE switch to take the printer off–line.
“Off–Line/Emulation” appears on the message display.

Open the printer cover.

Press the UP and DOWN switches simultaneously to unlock the ENTER
switch. “Unlocked” appears briefly on the display.

Press the DOWN switch. “Emulation/LG06” appears on the display.

Press NEXT (or PREV) until “Emulation/Self–Test” appears on the
display.

Press ENTER. “Emulation/Self–Test * ” appears on the display.

10. Press DOWN, then press NEXT (or PREV) until “Self Test/Phasing”
appears on the message display.
NOTE: Phasing adjustments should be made with the printer printing at full
paper width.
11. Press the R/S switch. “Phasing” and the current phasing index number
display. The printer begins printing all Hs in a data processing (DP) font,
each line preceded by the phasing index number.
12. Press the NEXT or PREV switches to increase or decrease the phasing
index until the pattern of Hs appears as shown in Figure 4–2 .
13. When the print pattern is acceptable, press the R/S switch. Printing
stops, and the current phasing value is entered into nonvolatile memory.
14. Press the CLEAR switch. “Off–Line/Emulation” appears on the message
display.
15. Press the UP and DOWN switches simultaneously to lock the ENTER
switch. “Locked” appears briefly on the display.
16. Close the printer cover.
17. Press the ON LINE switch to place the printer on–line.

4–4

Adjustment Procedures

NEEDS
ADJUSTMENT

CORRECT

NEEDS
ADJUSTMENT

Figure 4–2 . Hammer Phasing Adjustment

Adjustment Procedures

4–5

Paper Feed Timing Belt Adjustment (Figure 4–3 )
1.

Prepare the printer for maintenance (page 4–2).

Open the printer cover.

Remove the timing belt cover (1) by squeezing the top and bottom to
release the plastic tabs from the slots in the side plate.

Loosen the motor mount bolts (2).

Using a force gauge, apply 12 pounds of tension to the paper feed drive
motor (3).

Reduce tension to 9 pounds and torque the paper feed motor mount bolts
(2) to 18 ± 1 inch–pounds.

4–6

Snap the timing belt cover (1) into the slots in the side plate.

Return the printer to normal operation (page 4–22).

Adjustment Procedures

2
3

1. Timing Belt Shield
2. Motor Mount Bolt (2)
3. Paper Feed Drive Motor

Figure 4–3 . Paper Feed Timing Belt Adjustment

Adjustment Procedures

4–7

Platen Open Belt Adjustment (Figure 4–4 )
1.

Prepare the printer for maintenance (page 4–2).

Open the printer cover.

Remove the platen open belt cover (1) by squeezing the top and bottom
to release the plastic tabs from the slots in the side plate.

Loosen the motor mount screws (2).

Close the forms thickness lever all the way.

Make sure the collar of the platen open pulley (3) clears the left ribbon
guide (4) with the platen fully closed.
a. If not, rotate the platen open pulley (3) until the collar clears the
left ribbon guide and tighten the set screw (5). Go to step 7.
b. If the collar clears the ribbon guide with the forms thickness
lever closed, go to step 7.

Using a force gauge, apply 10 pounds of tension to the platen open
motor (6).

Reduce tension to 5 pounds and torque the motor mount screws (2) to
11 ± 1 inch–pounds.

Snap the platen open belt cover (1) into the slots in the side plate.

10. Return the printer to normal operation (page 4–22).

4–8

Adjustment Procedures

1. Belt Cover
2. Motor Mount Screw
3. Platen Open Pulley
4. Left Ribbon Guide
5. Set Screw
6. Platen Open Motor

2
5
4
6

1
3

Figure 4–4 . Platen Open Belt Adjustment

Adjustment Procedures

4–9

Paper Drive Motor Pulley Alignment (Figure 4–5 )

4–10

Prepare the printer for maintenance (page 4–2).

Open the printer cover.

Remove the timing belt cover (1) by squeezing the top and bottom to
release the plastic tabs from the slots in the side plate.

Loosen the set screw (2) in the motor pulley collar (3).

Align the paper drive motor pulley (4) with the splined shaft pulley (5).

Hold the collar (3) flush against the motor pulley (4) and tighten the set
screw (2).

Snap the timing belt cover (1) into the slots in the side plate.

Return the printer to normal operation (page 4–22).

Adjustment Procedures

1. Belt Shield
2. Set Screw
3. Motor Pulley Collar
4. Motor Pulley
5. Splined Shaft Pulley

Figure 4–5 . Paper Drive Motor Pulley Alignment

Adjustment Procedures

4–11

Platen Open Motor Pulley Alignment (Figure 4–6 )

4–12

Prepare the printer for maintenance (page 4–2).

Open the printer cover.

Remove the platen open belt cover (1) by squeezing the top and bottom
to release the plastic tabs from the slots in the side plate.

Loosen the set screw (2) in the motor pulley collar.

Align the platen open motor pulley (3) with the platen shaft pulley (4)
and tighten the set screw (2).

Snap the platen open belt cover (1) into the slots in the side plate.

Return the printer to normal operation (page 4–22).

Adjustment Procedures

2
1. Belt Cover
2. Set Screw
3. Platen Open Motor Pulley
4. Platen Shaft Pulley

1
3

Figure 4–6 . Platen Open Motor Pulley Alignment

Adjustment Procedures

4–13

Splined Shaft Skew Adjustment (Figure 4–7 )
If lines of print are not parallel with the edge perforations on the paper,
perform the following adjustment.

4–14

Prepare the printer for maintenance (page 4–2).

Loosen the screw (1) securing the adjusting link (2).

Adjust the link (2) to obtain print parallel with paper perforations.
Tighten the screw (1).

Return the printer to normal operation (page 4–22).

Adjustment Procedures

1. Screw
2. Adjusting Link

Figure 4–7 . Splined Shaft Skew Adjustment

Adjustment Procedures

4–15

Platen Angle Adjustment (Figure 4–8 )
1.

Prepare the printer for maintenance (page 4–2).

Remove the shuttle cover (page 5–24).

Close the forms thickness lever (1) all the way.

Install the platen position gauge (P/N 996083) (2) and check the angle
of the platen (3).
c. If the angle is correct, no adjustment is necessary. Go to step 8.
d. If the angle is incorrect, loosen the clamp screw (4) and set screw
(5).

Apply primer and loctite to the mating surfaces of the forms thickness
lever (1) and platen shaft.

Position the platen (3) at the correct angle.

Slide the platen (3) to the right and the forms thickness lever (1) to the
left to remove end play. Ensure that the forms thickness lever is fully
closed. Tighten the clamp screw (4), then tighten the setscrew (5).

Remove the platen position gauge (P/N 996083) (2).

Install the shuttle cover (page 5–24).

10. Return the printer to normal operation (page 4–22).

4–16

Adjustment Procedures

1. Forms Thickness Lever
2. Platen Position Gauge (P/N 996083)
3. Platen
4. Clamp Screw
5. Setscrew

3
2

Figure 4–8 . Platen Angle Adjustment

Adjustment Procedures

4–17

Platen Gap Adjustment (Figure 4–9 )
1.

Prepare the printer for maintenance (page 4–2).

Open the printer cover.

Remove the shuttle cover assembly (page 5–24).

Remove the ribbon.

Raise the forms thickness lever (1) to the fully open position.
CAUTION

Do not force the platen against the feeler gauge. Damage to the printer
will result.
6.

Insert a 0.010 inch flat feeler gauge (2) straight down between the platen
(3) and ribbon mask (4), within four hammer positions of the end of the
hammer bank.

Gently close the forms thickness lever (1) until the hammer tips and
platen contact the feeler gauge. With the forms thickness lever closed all
the way, the feeler gauge should contact both the tips and the platen and
move with light friction. Shift the gauge slightly to verify.

Adjust the gap as required by manipulating the set screw (5) located at
each end of the platen (3). Check the gap at both ends of the platen after
each adjustment of a set screw.

Repeat steps 4 through 7 at the other end of the hammer bank.

10. When the platen gap is correct at both ends of the platen, install the
ribbon.
11. Install the shuttle cover assembly (page 5–24).
12. Adjust the platen open belt (page 4–8).
13. Return the printer to normal operation (page 4–22).

4–18

Adjustment Procedures

1. Forms Thickness Lever
2. Feeler Gauge (0.010 inch)
3. Platen
4. Ribbon Mask
5. Set Screw (2)

4
3
5

NOTE: Left side adjustment
shown. Right side is
the same.

Figure 4–9 . Platen Gap Adjustment

Adjustment Procedures

4–19

Ribbon Guide Alignment (Figure 4–10 )
1.

Open the printer cover.

Load paper and install the ribbon. The ribbon should have a full spool
on the right hub (1).

Run a shuttle and ribbon diagnostic self–test (page 3–26).

Momentarily short between the left ribbon guide skid screws (2) to
assure right to left motion of the ribbon.

Observe how the ribbon (3) is passing around the left ribbon guide (4).
It should be centered.

If the ribbon is not centered, loosen the retaining screws (5) just enough
so that the ribbon guide (4) can be moved to new positions, but remains
in place once moved.

Reposition the ribbon guide (4) as necessary to center the ribbon (3).

Observe how the ribbon (3) is winding on the left spool (6). Reposition
the ribbon guide (4) as necessary to allow the ribbon to wind up without
interference.

Tighten the screws (5).

10. Allow most of the ribbon to accumulate on the left spool (6). Repeat
steps 3 through 9 for the right ribbon guide (7).

4–20

Adjustment Procedures

3
4

1. Right Hub
2. Screw, Left Ribbon Guide Skid (2)
3. Ribbon
4. Ribbon Guide, Left
5. Screw, Retaining (2)
6. Left Spool
7. Ribbon Guide, Right

Figure 4–10 . Ribbon Guide Alignment

Adjustment Procedures

4–21

Returning the Printer to Normal Operation

4–22

Load paper.

Install the ribbon.

Close floor cabinet doors and the printer cover.

Connect the ac power cord to the power source and the printer.

Set the power switch to 1 (on).

Test printer operation by selecting and running one of the diagnostic
self–tests (page 3–26).

Adjustment Procedures

Replacement Procedures

Chapter Contents
Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
Preparing the Printer for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
Belt, Paper Feed Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
Belt, Platen Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6
Cable Assembly W4, Hammer Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
Cable Assembly W5, Intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10
Cable Assembly, Multi I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–18
Control Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–20
Cover Assembly, Hammer Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–22
Cover Assembly, Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–24
Fan Assembly, Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–26
Fan Assembly, Cabinet Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–28
Fan Assembly, Hammer Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–30
Hammer Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–32
Magnetic Pick–up (MPU) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–34
Motor Assembly, Ribbon Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–36
Motor Assembly, Paper Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–38
Motor Assembly, Platen Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–40
Paper Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–42
Paper Ironer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–44
PCBA, Common Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–46

Replacement Procedures

5–1

PCBA, Mechanism Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–48
PCBA, Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–50
PROMs, Chips, and ICs on the CCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–52
PROMs, Chips, and ICs on the Mechanism Driver . . . . . . . . . . . . . . . . . . 5–54
Resistors, Terminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–56
Ribbon Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–58
Ribbon Guide Assembly (L/R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–60
Shaft, Splined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–62
Shaft, Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–64
Shuttle Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–66
Spring Assembly, Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–70
Spring, Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–72
Switch Assembly, Cover Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–74
Switch Assembly, Paper Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–76
Switch Assembly, Platen Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–78
Tractor (L/R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–80
Returning the Printer to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–80

5–2

Replacement Procedures

Replacement Procedures
CAUTION

The components specified in this chapter are replaced in the field, but
must be repaired at the factory. Do not attempt field repair of these
items.
This chapter contains illustrated removal/installation procedures for
components replaceable at the field service level of maintenance. The page
locations of all removal/installation tasks are listed on pages 5–1 and 5–2.

Part Numbers
Part numbers for assemblies on the manufacturer’s recommended spares list
are next to the name of the assembly on the removal/installation illustration.
(Procedures for gaining access to other assemblies do not include assembly
part numbers.) To order electronic parts, call 1–800–234–1998.

Preparing the Printer for Maintenance
Replacement procedures in this chapter are written assuming the printer has
been prepared for maintenance.
To prepare the printer for maintenance, do the following before performing a
replacement task:
1.

Set the printer power switch to O (off). (If power must be applied as part
of a maintenance procedure, you will be instructed to do so in the
procedure.)
WARNING

Unless otherwise specified, perform all replacement procedures with the
printer disconnected from the power source. Failure to remove power
could result in injury to persons or damage to equipment.
2.

Disconnect the power cord from the ac power source.

Unload paper.

Read the entire maintenance procedure before you begin working on the
printer.

Gather the necessary replacement parts before you begin working on the
printer.

Replacement Procedures

5–3

Belt, Paper Feed Timing (Figure 5–1 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Open the printer cover.

Remove the timing belt cover (1) by squeezing the top and bottom to
release the plastic tabs from the slots in the side plate.

Loosen the paper feed motor mount bolts (2).

Remove the paper feed timing belt (3) by working the side of the belt
onto the lip of the motor pulley (4) and rotating the pulleys until the belt
rolls off.

Installation
1.

Install the paper feed timing belt (3) over the splined shaft pulley (5) and
the lip of the motor pulley (4) and rotate the pulleys until the belt rolls
onto the motor pulley.

Using a force gauge, apply 12 pounds of tension to the paper feed drive
motor (6).

Reduce tension to 9 pounds and torque the paper feed motor mount bolts
(2) to 18 ± 1 inch–pounds.

5–4

Snap the timing belt cover (1) into the slots in the side plate.

Return the printer to normal operation (page 5–80).

Replacement Procedures

4
1

1. Timing Belt Shield
2. Motor Mount Bolt (2)
3. Paper Feed Timing Belt (P/N 29–29283–01)
4. Motor Pulley
5. Splined Shaft Pulley
6. Paper Feed Drive Motor

Figure 5–1 . Belt, Paper Feed Timing, Removal/Installation

Replacement Procedures

5–5

Belt, Platen Open (Figure 5–2 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Open the printer cover.

Remove the platen open belt cover (1) by squeezing the top and bottom
to release the plastic tabs from the slots in the side plate.

Loosen the motor mount screws (2).

Apply tension to the motor shaft to loosen the platen open belt (3).

Remove the platen open belt (3) from the motor pulley (4) and platen
pulley (5).

Installation
1.

Slide the platen open belt (3) over the motor pulley (4) and platen
pulley (5).

Close the forms thickness lever all the way.

Make sure the collar of the platen pulley (5) clears the left ribbon guide
with the platen fully closed.
a. If not, rotate the platen pulley (5) until the collar clears the left
ribbon guide and tighten the set screw (6). Go to step 4.
b. If the collar clears the ribbon guide with the forms thickness
lever closed, go to step 4.

5–6

Using a force gauge, apply 10 pounds of tension to the platen open
motor.

Reduce tension to 5 pounds and torque the motor mount screws (2) to
11 ± 1 inch–pounds.

Snap the platen open belt cover (1) into the slots in the side plate.

Return the printer to normal operation (page ).

Replacement Procedures

1. Belt Cover
2. Motor Mount Screw
3. Platen Open Belt (P/N 29–29284–01)
4. Motor Pulley
5. Platen Pulley
6. Set Screw

3
1

Figure 5–2 . Belt, Platen Open, Removal/Installation

Replacement Procedures

5–7

Cable Assembly, Hammer Bank (Figure 5–3 )

Removal
NOTE: This procedure removes the left hammer bank cable assembly. The
procedure for removing the right cable assembly is the same.
1.

Prepare the printer for maintenance (page 5–3).

Open the printer cover.

Remove the paper guide assembly (page ).

Remove the common controller PCBA (page 5–46).

Remove the mechanism driver PCBA (page 5–48).

Remove the power supply PCBA (page 5–50).

Remove two screws (1) securing the connector (2) to the bottom of the
card cage.

Remove two screws (3) securing the connector (4) to the base casting.

Note the location and number of tie wraps, then remove them.

10. Feed the hammer bank cable assembly (5) down through the base
casting, then out of the card cage.

Installation
NOTE: This procedure installs the left hammer bank cable assembly. The
procedure for installing the right cable assembly is the same.

5–8

Feed the hammer bank cable assembly (5) down through card cage,
around the printer, then up through the base casting.

Install two screws (3) securing the connector (4) to the base casting.

Install two screws (1) securing the connector (2) to the bottom of the
card cage.

Install tie wraps to join left and right hammer bank cable assemblies.

Install the power supply PCBA (page 5–50).

Install the mechanism driver PCBA (page 5–48).

Install the common controller PCBA (page 5–46).

Install the paper guide assembly (page 5–42).

Return the printer to normal operation (page 5–80).

Replacement Procedures

Printer viewed from above, PCBAs removed.
Right hammer bank
cable assembly

Left hammer bank
cable assembly

1
Card cage floor

Card
Cage
Fan

Platen
open
motor

Paper
feed
motor

Paper feed mechanisms
and barrier panel
Platen

Shuttle Frame Assembly

Base casting

Hammer Bank
Fan

3
4
Front

1. Screw (2)
2. Connector
3. Screw (2)
4. Connector
5. Hammer Bank Cable Assembly (P/N 29–29293–01)

Figure 5–3 . Cable Assembly, Hammer Bank, Removal/Installation

Replacement Procedures

5–9

Cable Assembly, Intermediate (Figure 5–4 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Open the printer cover.

Remove the paper guide assembly (page 5–42).

Remove the common controller PCBA (page 5–46).

Remove the mechanism driver PCBA (page 5–48).

Remove screws (1) securing the main wire harness connector (2) to the
bottom of the card cage. Move the main harness connector to one side.

Remove screws (3) securing the intermediate cable assembly connector
P1 (4) to the bottom of the card cage.

Disconnect connector P1(P) (5) from platen interlock switch assembly
(6).

Disconnect connector PMD (7) from paper detector switch assembly
connector PMD(J) (8).

10. Remove the cover open switch assembly (9) and disconnect connectors
CO+ and CO– (10 and 11).
11. Note the location of cable runs and restraints, cut tie wraps, and remove
the intermediate cable assembly (12) through the card cage.

5–10

Replacement Procedures

Printer viewed from above, PCBAs removed.
1

Card cage floor
(PCBAs removed)

Card
Cage
Fan

Paper
feed
motor

Platen
open
motor

Paper feed mechanisms
and barrier panel
Platen

6
Paper detector
switch assembly

Shuttle Frame Assembly

Base casting

Hammer Bank
Fan

10
1. Screw (2)
2. Main Wire Harness Connector
9
3. Screw (2)
4. Intermediate Cable Assy Connector P1
5. Connector P1(P)
Front
6. Platen Interlock Switch Assembly
7. Connector PMD
8. Connector PMD(J)
(Paper Detector Switch Assembly)
9. Cover Open Switch Assembly
10. Connector CO+
11. Connector CO–
12. Intermediate Cable Assembly (P/N 29–29292–01)

This section of cable runs
beneath the base casting.

Figure 5–4 . Cable Assembly, Intermediate, Removal/Installation

Replacement Procedures

5–11

Installation
1.

Feed the intermediate cable assembly (12) through the card cage
opening and install tie wraps and cable restraints.

Connect connectors CO+ and CO– (10 and 11) and install the cover
open switch assembly (9).

Connect connector PMD (7) to paper detector switch assembly
connector PMD(J) (8).

Connect connector P1(P) (5) to the platen interlock switch assembly (6).

Install the screws (3) securing the intermediate cable assembly
connector P1 (4) to the bottom of the card cage.

Move the main harness connector (2) back into position and install the
screws (1) securing the connector to the bottom of the card cage.

Install the mechanism driver PCBA (page 5–48).

Install the common controller PCBA (page 5–46).

Install the paper guide assembly (page 5–42).

10. Return the printer to normal operation (page 5–80).

5–12

Replacement Procedures

Printer viewed from above, PCBAs removed.
1

Card cage floor
(PCBAs removed)

Card
Cage
Fan

Paper
feed
motor

Platen
open
motor

Paper feed mechanisms
and barrier panel
Platen

6
Paper detector
switch assembly

Shuttle Frame Assembly

Base casting

Hammer Bank
Fan

This section of cable runs
beneath the base casting.

Figure 5–4. Cable Assembly, Intermediate, Removal/Installation

Replacement Procedures

5–13

Cable Assembly, Multi I/O (Figure 5–5 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Open the printer cover.

Remove the paper guide assembly (page 5–42).

Open the rear cabinet door.

Remove six screws (1) and move the fan duct (2) aside.

Open the ribbon cable restraints (3) on the upper rear and upper right
walls of the cabinet.

Open the latches (4) and disconnect the multi I/O ribbon cable connector
(5) from connector J1 (6) on the common controller PCBA.

Release the multi I/O ribbon cable from the holders on the rear wall of
the card cage.

Feed the multi I/O ribbon cable through the card cage and down into the
cabinet.

10. Remove four screws (7) securing the multi I/O cable assembly mounting
plate (8).
11. Remove the multi I/O cable assembly (9).

5–14

Replacement Procedures

1. Screw (6)
2. Fan Duct
3. Ribbon Cable Restraints
4. Latch (2)
5. Ribbon Cable Connector
6. Common Controller Connector J1
7. Screw (4)
8. Mounting Plate
9. Multi I/O Cable Assembly (P/N 29–29291–01)

4
3

7
2
1

Figure 5–5. Cable Assembly, Multi I/O, Removal/Installation

Replacement Procedures

5–15

Installation

5–16

Feed the multi I/O ribbon cable from the lower cabinet up into the
opening at the right rear of the card cage. Route the ribbon cable
outboard of the right gas spring assembly (the strut that holds the printer
cover open).

Install four screws (7) securing the multi I/O cable assembly mounting
plate (8).

Connect the multi I/O ribbon cable connector (5) to connector J1 (6) on
the common controller PCBA and close the latches (4).

Latch the multi I/O ribbon cable into the cable restraints (3) located on
the upper rear and upper right cabinet walls.

Engage the multi I/O ribbon cable in the holders on the rear wall of the
card cage.

Move the fan duct (2) into position and install the six screws (1).

Close the rear cabinet door.

Install the paper guide assembly (page 5–42).

Return the printer to normal operation (page 5–80).

Replacement Procedures

4
3

7
2
1

Figure 5–5 . Cable Assembly, Multi I/O, Removal/Installation

Replacement Procedures

5–17

Circuit Breaker (Figure 5–6 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Open the rear cabinet door.

Remove six screws (1) and move the fan duct (2) aside.

Tag and disconnect the four circuit breaker electrical leads (3).

Press in on the spring clips (4) and push the circuit breaker (5) out of the
mounting plate (6).

Installation
1.

Press the circuit breaker (5) into the mounting plate (6) until the spring
clips (4) snap into place.
CAUTION

Make sure the four leads are connected as shown in Figure 5–6 .

5–18

Connect the four circuit breaker electrical leads (3) as shown in
Figure 5–6 .

Move the fan duct (2) back into position and install the six screws (1).

Return the printer to normal operation (page 5–80).

Replacement Procedures

1. Screw (6)
2. Fan Duct
3. Circuit Breaker Electrical Lead (4)
4. Spring Clip (4)
5. Circuit Breaker (P/N 29–29329–01)
6. Mounting Plate

WHITE

BLACK

BROWN

BLUE

3
2
5

Figure 5–6 . Circuit Breaker Removal/Installation

Replacement Procedures

5–19

Control Panel Assembly (Figure 5–7 )
Removal
1.

Prepare the printer for maintenance (page 5–3).

Open the printer cover.

Remove the paper guide assembly (page 5–42).

Open the connector latches and disconnect the control panel ribbon
connector P1 (1) from connector J3 on the common controller PCBA
(2).

Remove the control panel ribbon cable from the wire saddles (3) on the
mechanism base pan.

Remove four screws (4) and washers (5).

Remove the control panel assembly (6) from the control panel bracket
(7).

Installation
IMPORTANT

You must install two ferrite cores on the control panel cable assembly.
Refer to Appendix F.

5–20

Feed ribbon connector (1) and the ribbon cable through the control
panel bracket (7) and position the control panel assembly (6) on the
bracket.

Install but do not tighten four washers (5) and screws (4).

Lower the printer cover and center the control panel assembly (6) in the
cutout of the printer cover.

Open the printer cover and tighten the four screws (4).

Route the control panel ribbon cable along the right side of the printer.
Feed the ribbon cable and ribbon connector (1) through the slot in the
card cage below the card cage fan.

Connect the control panel ribbon connector P1 (1) to connector J3 on
the common controller PCBA (2) and close the connector latches.

Insert the control panel ribbon cable into the wire saddles (3) on the
mechanism base pan.

Install the paper guide assembly (page 5–42).

Return the printer to normal operation (page 5–80).

Replacement Procedures

Install block–type
ferrite core here
and wind cable
around round
core.
Refer to Appendix F.

5
4

1. Control Panel Connector P1
2. Common Controller PCBA
3. Wire Saddles
4. Screw (4)
5. Washer (4)
6. Control Panel Assembly (P/N 29–29286–01)
7. Panel Bracket

Figure 5–7 . Control Panel Assembly Removal/Installation

Replacement Procedures

5–21

Cover Assembly, Hammer Bank (Figure 5–8 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Remove the shuttle frame assembly (page 5–66).

Rotate hammer bank cover assembly (1) away from hammer bank (2).

Remove hammer bank cover assembly (1) from alignment pins (3).

Installation
CAUTION

5–22

With the thick plate facing the hammer bank (2), engage the hammer
bank cover assembly (1) on the alignment pins (3).

Rotate the hammer bank cover assembly (1) until it lies flush on the
hammer bank (2). Check that the hammer bank cover assembly is
properly positioned over the alignment pins (3) and hammer tips.

Install the shuttle frame assembly (page 5–66).

Return the printer to normal operation (page 5–80).

Replacement Procedures

2
Thin plate

Thick plate

3
(Not shown)

1. Hammer Bank Cover Assembly (P/N 29–29280–01)
2. Hammer Bank
3. Alignment Pin (2)

Figure 5–8 . Cover Assembly, Hammer Bank, Removal/Installation

Replacement Procedures

5–23

Cover Assembly, Shuttle (Figure 5–9 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Open the printer cover.

Loosen the shuttle cover screws (1).

Grasping the edges of the shuttle cover assembly (2), tilt up the rear
edge and lift the shuttle cover assembly out of the printer.

Installation

5–24

Place the shuttle cover assembly (2) in the printer. Tilt the forward edge
of the cover down slightly and work the cover into position.

Tighten the shuttle cover screws (1).

Return the printer to normal operation (page 5–80).

Replacement Procedures

1. Screw, Captive, Shuttle Cover (2)
2. Shuttle Cover Assembly (Mfg. P/N 150123–011)

Figure 5–9 . Cover Assembly, Shuttle, Removal/Installation

Replacement Procedures

5–25

Fan Assembly, Card Cage (Figure 5–10 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Open the printer cover.

Remove the paper guide assembly (page 5–42).

Remove the power supply PCBA (page 5–50).

Remove the nut (1) and ground wire (2).

Remove four screws (3).

Disconnect the fan cable connector (4).

Remove the card cage fan assembly (5) and fan guard (6) from the card
cage (7).

Installation

5–26

Connect the fan cable connector (4).

Position the card cage fan assembly (5) and fan guard (6) in the card
cage (7).

Install four screws (3).

Install the ground wire (2) and nut (1).

Install the power supply PCBA (page 5–50).

Install the paper guide assembly (page 5–42).

Return the printer to normal operation (page 5–80).

Replacement Procedures

2
1

1. Nut
2. Ground Wire
3. Screw (4)
4. Fan Cable Connector
5. Card Cage Fan Assembly (P/N 29–29294–01)
6. Fan Guard
7. Card Cage

Figure 5–10 . Fan Assembly, Card Cage, Removal/Installation

Replacement Procedures

5–27

Fan Assembly, Cabinet Exhaust (Figure 5–11 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Open the floor cabinet rear door.

Remove six screws (1) and move the fan duct (2) aside.

Remove four screws (3) securing the cabinet exhaust fan assembly (4).

Disconnect the fan cable connector (5).

Remove the cabinet exhaust fan assembly (4) and fan guard (6).

Installation

5–28

Connect the fan cable connector (5).

Position the cabinet exhaust fan assembly (4) and fan guard (6) on the
cabinet floor.

Install six screws (3) securing the cabinet exhaust fan assembly (4).

Move the fan duct (2) back into position and install the four screws (1).

Return the printer to normal operation (page 5–80).

Replacement Procedures

1. Screw (6)
2. Fan Duct
3. Screw (4)
4. Cabinet Exhaust Fan Assembly (P/N 29–29294–01)
5. Fan Cable Connector
6. Fan Guard

2
1

5
3

4
6

Figure 5–11 . Fan Assembly, Cabinet Exhaust, Removal/Installation

Replacement Procedures

5–29

Fan Assembly, Hammer Bank (Figure 5–12 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Remove the shuttle cover assembly (page 5–24).

Remove three screws (1).

Reach under the base casting (2) and disconnect the hammer bank fan
cable connector (3).

NOTE: The hammer bank fan assembly is removed by angling it up and out
from beneath the shuttle motor.
5.

Remove the hammer bank fan assembly (4) from the base casting (2).

Installation
NOTE: The hammer bank fan assembly is installed by angling it down and
under the shuttle motor.

5–30

Feed the hammer bank fan cable connector (3) through the slot in the
fan well of the base casting (2).

Open the floor cabinet front door.

Reaching up under the base casting (2) from inside the cabinet, route the
fan cable to right and angle the hammer bank fan assembly (4) down
into the fan well.

Connect the hammer bank fan cable connector (5).

Close the floor cabinet front door.

Install three screws (1).

Install the shuttle cover assembly (page 5–24).

Return the printer to normal operation (page 5–80).

Replacement Procedures

2
4
Attach cable
connector here.

NOTE: Do not install
screw here.

Route cable under
base casting.

Hammer Bank

Fan

1. Screw (3)
2. Base Casting
3. Fan Cable Connector
4. Hammer Bank Fan Assembly (P/N 29–29295–01)

Front

Figure 5–12 . Fan Assembly, Hammer Bank, Removal/Installation

Replacement Procedures

5–31

Hammer Spring Assembly (Figure 5–13 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Remove the shuttle frame assembly (page 5–66).

Remove the hammer bank cover assembly (page 5–22).

Remove three 5/64 inch socket head screws from the old hammer fret.

Using the pointed end of the nylon stick supplied in the hammer spring
replacement kit, carefully pry the old hammer fret off its mounting pins
as shown in Figure 5–13 .

Discard the old hammer fret and mounting screws.

Installation
IMPORTANT

FRET ONE is on the RIGHT END of the hammer bank as you face the
hammer springs. FRET SEVEN is the LEFT END of the hammer bank.
If you accidently bend the wrong hammer, DO NOT attempt to rebend
the hammer and do not install that fret.

5–32

If you are replacing one of the inner frets, go to step 2.
If you are replacing fret seven, bend the left–most hammer spring as
shown in Figure 5–13 before removing it from the box. If you are
replacing fret one, bend the right–most hammer spring as shown in
Figure 5–13 before removing it from the box. Go to step 2.

Remove the new fret and mounting screws from the box.

Install the new fret on the hammer bank mounting pins and press it into
position with the flat end of the nylon stick supplied in the hammer
spring replacement kit.

Install the screws from the replacement kit in the order shown in
Figure 5–13 . Torque each screw to 8 in–lbs.

Install the hammer bank cover assembly (page 5–22).

Install the shuttle frame assembly (page 5–66).

Return the printer to normal operation (page 5–80).

Replacement Procedures

Preparation – Frets 1 and 7 only
NOTE:
If you replace fret 1 or 7, bend the end
hammer down BEFORE removing it from
the box, as shown below. Do this ONLY
for frets 1 and 7.

Right end

Hammer Bank
Left end

Bend this hammer if
replacing fret 7.

Bend this hammer if
replacing fret 1.

See NOTE.

Hammer
Fret 1
See
NOTE.

Hammer
Fret 7

Bend hammer down
until it touches the
mounting base in the
box.

Removal – Any Fret

Use these screws
to install new fret.

Installation – Any Fret
Tightening Sequence
(Torque to 8 in–lbs)

Discard
old screws.
8 in–lbs
Hammer Spring Replacement Kit: P/N 29–29281–01

Use new
screws.

Figure 5–13 . Hammer Spring Assembly Removal/Installation

Replacement Procedures

5–33

Magnetic Pick–up (MPU) Assembly (Figure 5–14 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Remove the shuttle cover (page 5–24).

Disconnect the magnetic pick–up (MPU) cable connector (1).

Loosen the MPU clamp screw (2).

Remove the MPU assembly (3) by unscrewing it from the MPU bracket
(4).

Installation
1.

Install the MPU assembly (3) by screwing it into the MPU bracket (4).

Using a feeler gauge, adjust the gap between the MPU assembly (3) and
the flywheel (5) to 0.010 ± .001 inch. Torque the MPU clamp screw (2)
to 19 ± 1 inch–pounds.

Check the gap between the MPU assembly (3) and the flywheel (5) with
a feeler gauge:
c. If the gap is 0.010 ± .001 inch, go to step 4.
d. If the gap is not 0.010 ± 0.001 inch, loosen the MPU clamp
screw (2) and go back to step 2.

5–34

Connect the magnetic pick–up (MPU) cable connector (1).

Install the shuttle cover (page 5–24).

Return the printer to normal operation (page 5–80).

Replacement Procedures

0.010 + .001INCH

Attach MPU
cable here.

1. MPU Cable Connector
2. MPU Clamp Screw
3. Magnetic Pick–Up (MPU) Assembly (P/N 29–29277–001)
4. MPU Bracket
5. Flywheel

Figure 5–14 . Magnetic Pick–up (MPU) Assembly Removal/Installation

Replacement Procedures

5–35

Motor Assembly, Ribbon Drive (Figure 5–15 )
Removal
NOTE: The procedure below is the same for the left and right ribbon drive
motor assemblies.
1.

Prepare the printer for maintenance (page 5–3).

Remove the ribbon.

Remove the ribbon hub (page 5–58).

Remove two screws (1) and washers (2).

Lift the ribbon drive motor (3) and its cable from base casting (4).

Disconnect the ribbon motor cable connector (5).

Loosen the set screw (6) and remove the collar (7) and shaft extension
(8).

Installation
IMPORTANT

You must install a ferrite core on the ribbon motor cable assembly. Refer
to Appendix F.

NOTE: The procedure below is the same for the left and right ribbon drive
motor assemblies.

5–36

Install the shaft extension (8) and collar (7), and tighten the set screw
(6).

Connect the ribbon motor cable connector (5) and position the ribbon
drive motor (3) in the base casting (4).

Install screws (1) and washers (2) to secure the upper right and lower
left corners of the ribbon drive motor assembly (3).

Install the ribbon hub (page 5–58).

Return the printer to normal operation (page 5–80).

Replacement Procedures

7
6
1
2

Install block–type
ferrite core here.
Refer to Appendix F.

5
4

1. Screw (2)
2. Washer (2)
3. Ribbon Drive Motor (P/N 29–29282–01)
4. Base Casting
5. Ribbon Motor Cable Connector
6. Set Screw
7. Collar
8. Shaft Extension

Figure 5–15 . Motor Assembly, Ribbon Drive, Removal/Installation

Replacement Procedures

5–37

Motor Assembly, Paper Feed (Figure 5–16 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Open the printer cover.

Remove the platen open belt cover (1) by squeezing the top and bottom
to release the plastic tabs from the slots in the side plate.

Loosen the set screw (2) and remove the paper feed motor pulley (3),
collar (4), and paper feed timing belt (5).

Disconnect the paper feed motor electrical connector (6).

Remove the motor mount bolts (7) and nuts (8).

Remove the paper feed motor assembly (9).

Installation
1.

Position the paper feed motor assembly (9) on the right side plate and
install the motor mount bolts (7) and nuts (8) finger tight.

Connect the paper feed motor electrical connector (6).

Install the paper feed motor pulley (3), collar (4), and timing belt (5).

Align the paper feed motor pulley (3) with the splined shaft pulley (10).

Hold the collar (4) snug against the motor pulley (3) and tighten the set
screw (2).

Using a force gauge, apply 12 pounds of tension to the paper feed motor
assembly (12).

Reduce tension to 9 pounds and torque the motor mount bolts (7) to
18 ± 1 inch–pounds.

5–38

Snap the platen open belt cover (1) into the slots in the side plate.

Return the printer to normal operation (page 5–80).

Replacement Procedures

6
10

3
5

7
1. Belt Cover
2. Set Screw
3. Paper Feed Motor Pulley
4. Collar
5. Paper Feed Timing Belt
6. Paper Feed Motor Connector
7. Bolt
8. Nut
9. Paper Feed Motor Assembly (P/N 29–29282–01)
10. Splined Shaft Pulley

Figure 5–16 . Motor Assembly, Paper Feed, Removal/Installation

Replacement Procedures

5–39

Motor Assembly, Platen Open (Figure 5–17 )
Removal
1.

Prepare the printer for maintenance (page 5–3).

Remove the card cage fan assembly (page 5–26).

Remove the platen open belt cover (1) by squeezing the top and bottom
to release the plastic tabs from the slots in the side plate.

Loosen the motor mount screws (2).

Remove the platen open belt (3).

Loosen the collar set screw (4) and remove the motor pulley (5).

Disconnect the platen motor cable connector (6).

Remove the motor mount screws (2) and nut ring (7).

Remove the platen open motor assembly (8).

Installation
1.

Position the platen open motor assembly (8) and nut ring (7) and install
the motor mount screws (2).

Install the motor pulley (5), align it with the platen pulley (9), and
tighten the collar set screw (4).

Connect the platen motor cable connector (6).

Install the platen open belt (3).

Close the forms thickness lever all the way.

Make sure the collar of the platen pulley (9) clears the left ribbon guide
with the platen fully closed.
a. If not, rotate the platen pulley (9) until the collar clears the left
ribbon guide and tighten the platen pulley set screw (10). Go to
step 7.
b. If the collar clears the ribbon guide with the forms thickness
lever closed, go to step 7.

Using a force gauge, apply 10 pounds of tension to the platen open
motor assembly (8), reduce tension to 5 pounds and torque the motor
mount screws (2) to 11 ± 1 inch–pounds.

Snap the platen open belt cover (1) into the slots in the side plate.

Install the card cage fan assembly (page 5–26).

10. Return the printer to normal operation (page 5–80).

5–40

Replacement Procedures

7
8

4
5

10
1. Cover, Platen Open Belt
2. Screw, Motor Mount
3. Platen Open Belt
4. Set Screw, Collar
5. Motor Pulley
6. Platen Motor Cable Connector
7. Nut Ring
8. Platen Open Motor Assembly (P/N 29–29282–01)
9. Platen Pulley
10. Set Screw, Platen Pulley

Figure 5–17 . Motor Assembly, Platen Open, Removal/Installation

Replacement Procedures

5–41

Paper Guide Assembly (Figure 5–18 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Open the printer cover.

Loosen—donotremove—thehold–downscrew(1).

Slide the paper guide assembly (2) to the left and lift it off the card cage
(3).

Installation

5–42

Position the paper guide assembly (2) offset slightly to the left on the
card cage (3).

Slide the paper guide assembly (2) to the right and engage the tabs on
the underside of the paper guide assembly with the left edge of the card
cage.

Slide the paper guide assembly (2) to the right as far as it will go.

Tighten the hold–down screw (1).

Return the printer to normal operation (page 5–80).

Replacement Procedures

NOTE: Loosen, do
not remove,
the hold–down
screw.

Clips on card
cage top.
(Not shown.)
2

Engage clips
here.

1. Hold–Down Screw
2. Paper Guide Assembly
3. Card Cage

Figure 5–18 . Paper Guide Assembly Removal/Installation

Replacement Procedures

5–43

Paper Ironer (Figure 5–19 )

Removal
1.

Remove the shuttle frame assembly (page 5–66).

Move the forms thickness lever (1) to the open position.
WARNING

Over time, the upper edge of the paper ironer can become sharp. To
avoid cutting yourself, grasp the paper ironer on the sides.
3.

Push back at the ends of the paper ironer (2) to disengage the tabs, then
lift it up and out.

Installation
WARNING

Over time, the upper edge of the paper ironer can become sharp. To
avoid cutting yourself, grasp the paper ironer on the sides.

5–44

Position the paper ironer (2) so that the lip on the upper edge faces the
front of the printer.

Push the paper ironer (2) down into the slots until the tabs engage.

Install the shuttle frame assembly (page 5–66).

Return the printer to normal operation (page 5–80).

Replacement Procedures

Push and Lift

Push and Lift
1

1. Forms Thickness Lever
2. Paper Ironer (Mfg. P/N 150724–001)

Figure 5–19 . Paper Ironer Removal/Installation

Replacement Procedures

5–45

PCBA, Common Controller (Figure 5–20 )
CAUTION

To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling PCBAs.

Removal
1.

Prepare the printer for maintenance (page 5–3).

Open the printer cover.

Remove the paper guide assembly (page 5–42).

Open the connector latches and disconnect the multi I/O ribbon cable (1)
from connector J1 (2).

Open the connector latches and disconnect the CCB/Mech. Driver cable
connector (3) from connector J2 (4).

Open the connector latches and disconnect the control panel ribbon
cable (5) from connector J3 (6).

Lift the ejection levers (7).

Grasp the common controller PCBA (8) by the ejection levers and pull it
up and out of the card cage (9).

Remove the program PROMs, font PROMs, memory paging PROM
(page 5–52), and host terminating resistors (page 5–56).

Installation

5–46

Install the program PROMs, font PROMs, memory paging PROM (page
5–52), and host terminating resistors (page 5–56) onto the replacement
PCBA.

Slide the common controller PCBA (8) down into the card cage (9).
Engage the card edge connectors in the connector at the bottom of the
card cage (9).

Lower the ejection levers (7) to the closed position.

Connect the control panel ribbon cable (5) to connector J3 (6).

Connect the CCB/Mech. Driver cable connector (3) to connector J2 (4).

Connect the multi I/O ribbon cable (1) to connector J1 (2).

Install the paper guide assembly (page 5–42).

If PROMs were replaced, adjust the hammer phasing (page 4–4).

Return the printer to normal operation (page 5–80).

Replacement Procedures

1. Multi I/O Ribbon Cable
2. Connector J1
3. CCB/Mech. Driver Cable
4. Connector J2
5. Control Panel Ribbon Cable
6. Connector J3
7. Ejection Lever (2)
8. Common Controller PCBA (CCB) (P/N 29–29288–01)
9. Card Cage

5
1

NOTE: Power Supply
and Mechanism Driver
boards shown for reference.
They are not removed in
this procedure.

4
6
2

Figure 5–20 . PCBA, Common Controller, Removal/Installation

Replacement Procedures

5–47

PCBA, Mechanism Driver (Figure 5–21 )
CAUTION

To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling PCBAs.
Do not flex the board or grasp components on the PCBA during
removal/installation. Damage to components may result. Handle the
board carefully by the ejections levers, sides, or the heat sink.

Removal
1.

Prepare the printer for maintenance (page 5–3).

Open the printer cover.

Remove the paper guide assembly (page 5–42).

Open the connector latches and disconnect the CCB/Mech. Driver
ribbon cable (1) from connector J6 (2).

Disconnect the power supply cable (3) from connector J7 (4).

Lift the ejection levers (5).

Grasp the mechanism driver PCBA (6) by the ejection levers and pull it
up and out of the card cage (7).

Installation

5–48

Slide the mechanism driver PCBA (6) down into the card cage (7).
Engage the card edge connectors in the connectors at the bottom of the
card cage.

Lower the ejection levers (5) to the closed position.

Connect the power supply cable (3) to connector J7 (4).

Connect the CCB/Mech. Driver ribbon cable (1) to connector J6 (2) and
close the connector latches.

Install the paper guide assembly (page 5–42).

Return the printer to normal operation (page 5–80).

Replacement Procedures

5
NOTE: Power Supply
and Common Controller
boards shown for reference.
They are not removed in
this procedure.

3
4

1. CCB/Mech. Driver Ribbon Cable
2. Connector J6
3. Power Supply Cable
4. Connector J7
5. Ejection Lever (2)
6. Mechanism Driver PCBA (P/N 29–29289–01)
7. Card Cage

Figure 5–21 . PCBA, Mechanism Driver, Removal/Installation

Replacement Procedures

5–49

PCBA, Power Supply (Figure 5–22 )
WARNING

To prevent injury from electric shock, wait at least one minute after
shutting off power before removing the power supply PCBA. Do not
touch components or flex the board during removal/installation. Handle
the board by the ejections levers and the sides. Wear a properly
grounded static wrist strap when handling the power supply PCBA.

Removal
1.

Prepare the printer for maintenance (page 5–3).

Open the printer cover.

Remove the paper guide assembly (page 5–42).

Disconnect the mechanism driver power supply cable (1) from
connector J102 (2).

Lift the ejection levers (3).

Grasp the power supply PCBA (4) by the ejection levers and pull it up
about four inches.

Disconnect the circuit breaker cable (5) from connector J1 (6).

Remove the power supply PCBA (4) from the card cage (7).

Installation

5–50

Slide the power supply PCBA (4) into the card cage (7) about two
inches.

Connect the circuit breaker cable (5) to connector J1 (6).

Slide the power supply PCBA (4) into the card cage (7), engaging the
ejection levers (3) under the lip of the card cage (7).

Slowly lower the ejection levers (3) to the closed position.

Connect the mechanism driver power supply cable (1) to connector J102
(2).

Install the paper guide assembly (page 5–42).

Return the printer to normal operation (page 5–80).

Replacement Procedures

NOTE: Mechanism Driver
and Common Controller
boards shown for reference.
They are not removed in
this procedure.

3
4

1
6

1. Mechanism Driver Power Supply Cable
2. Connector J102
3. Ejection Lever (2)
4. Power Supply PCBA (P/N 29–29290–01)
5. Circuit Breaker Cable
6. Connector J1
7. Card Cage

Figure 5–22 . PCBA, Power Supply, Removal/Installation

Replacement Procedures

5–51

PROMs, Chips, and ICs on the CCB (Figure 5–23 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Remove the common controller PCBA (page 5–46).
CAUTION

To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling PCBAs and
components.
3.

Using a chip puller, remove the defective chip(s). Locations are shown
in Figure 5–23 .

Installation
CAUTION

To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling PCBAs and
components.

5–52

Using a chip installation tool, install chip(s). Locations are shown in
Figure 5–23 .

Install the common controller PCBA (page 5–46).

If you changed DPU or font PROMs, adjust hammer phasing (page
4–4).

Return the printer to normal operation (page 5–80).

Replacement Procedures

LEGEND

PROM Kit: P/N 29–29287–01, Rev B01

DPMC = Dot Plucker Memory Controller
DPU = Data Processing Unit
FTIC = Fire Timer IC
LED = Light–Emitting Diode
MPU = Magnetic Pick–up
NOVRAM = Nonvolatile Random Access Memory
PAL = Programmable Array Logic
PFC = Paper Feed Controller
68010
Microprocessor

DPU RTPU
LED * LED

68010
Decode
PAL

68010
Controller
PAL

DPU –001

DPU –002

DPU –003

DPU –004

Font –001

Font –002

Font –003

Font –004

RTPU = Real Time Processing Unit

Shared
Bus
PAL

Bus
Arbiter
PAL

FTIC
64180
RTPU

MPU
PAL

64180
Decode
PAL DPMC
–001

DPU PROM
HI – 1

DPU PROM
LO – 1

–002

–003

DPU PROM
HI – 2

DPU PROM
LO – 2

–004

–001

Font PROM
HI – 1

Font PROM
LO – 1

–002

–003

Font PROM
HI – 2

Font PROM
LO – 2

–004

68010
&
64180
CLock

NOVRAM

Static
RAM

PFC
CLock

RTPU
PROM
68010
&
64180
Shared
Dynamic
RAM

PFC
PROM

E2
Jumper
(Must be
present
or board
will not
work.)

PFC

* DPU LED Indications at printer start–up:
ON for 2 sec., then OFF = DPU OK
FLASHING 5 times / second = DPU RAM failure
FLASHING 1 time / second = DPU ROM failure

Figure 5–23 . PROM, DIP, and IC Locations on the CCB

Replacement Procedures

5–53

PROMs, Chips, and ICs on the Mechanism Driver (Figure 5–24 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Remove the mechanism driver PCBA (page 5–48).
CAUTION

To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling PCBAs and
components.
3.

Using a chip puller, remove the defective chip(s). Locations are shown
in Figure 5–24 .

Installation
CAUTION

To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling PCBAs and
components.

5–54

Using a chip installation tool, install chip(s). Locations are shown in
Figure 5–24 .

Install the mechanism driver PCBA (page 5–48).

If you changed DPU or font PROMs, adjust hammer phasing (page
4–4).

Return the printer to normal operation (page 5–80).

Replacement Procedures

LEGEND
RSP = Ribbon/Shuttle Processor
ASIC = Application–Specific Integrated Circuit

Hammer Driver ASIC

RSP PROM
150846
8032
Microcontroller

Mech. Driver ASIC

Figure 5–24 . PROM, DIP, and IC Locations on the Mechanism Driver

Replacement Procedures

5–55

Resistors, Terminating (Figure 5–25 )
For parallel interface configurations, the LG06 printer is equipped with 1K
ohm pullup terminating resistors, located at coordinates 12C on the Common
Controller PCBA. The 1K ohm terminating resistors are suitable for most
applications.
If the standard terminating resistor pack is not compatible with the particular
interface driver requirements of the host computer, other values of
pullup/pulldown resistors may be required. Digital provides the 330 ohm
pullup and 220 ohm pulldown alternate terminating resistors. If the 330 ohm
pullup resistor is installed, also install the 220 ohm pulldown resistor.

Removal
1.

Prepare the printer for maintenance (page 5–3).

Remove the Common Controller PCBA (page 5–46).
CAUTION

To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling PCBAs and
components.
3.

Locate the terminating resistor pack (see Figure 5–25 ).

Using a chip puller, remove the pack.

Installation
CAUTION

To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling PCBAs and
components.

5–56

Using a chip installation tool, install the resistor pack in the correct
socket (see Figure 5–25 ).

Install the Common Controller PCBA (page 5–46).

Return the printer to normal operation (page 5–80).

Replacement Procedures

1K ohm DIP
or
330 ohm DIP
Pull up
(Location 12C)
220 ohm DIP
Pull down
(Location 12D)

13
C
D
E
F

Figure 5–25 . Resistors, Terminating, Removal/Installation

Replacement Procedures

5–57

Ribbon Hub (Figure 5–26 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Remove the printer ribbon.

Loosen the screw (1) in the ribbon spool hub (2).

Remove the hub (2) from the shaft adapter on the ribbon drive motor
(3).

Installation
1.

If the ribbon drive motor has a shaft extension and collar, go to step 2.
If the ribbon drive motor does not have an extension shaft and collar,
begin at step 4.

5–58

Loosen the collar screw (4).

Remove and discard the shaft extension (5) and collar (6).

Install the ribbon spool hub (2) over the motor shaft.

Tighten the hub screw (1) so that it contacts the flat section of the motor
shaft. Do not overtighten the hub screw.

Return the printer to normal operation (page 5–80).

Replacement Procedures

1. Hub Screw
2. Ribbon Spool Hub (Kit, P/N 29–29296–01)
3. Ribbon Drive Motor
4. Collar Screw
5. Shaft Extension
6. Collar

6
4

Figure 5–26 . Ribbon Hub Removal/Installation

Replacement Procedures

5–59

Ribbon Guide Assembly (L/R) (Figure 5–27 )

Removal
NOTE: Although the right ribbon guide is shown in Figure 5–27 , the
removal procedure is the same for the left ribbon guide.
1.

Prepare the printer for maintenance (page 5–3).

Open the printer cover.

Remove the printer ribbon.

Cut the tie–wrap and remove it from the spot tie (1) to free the ribbon
guide cable.

Disconnect the ribbon guide connector (2).

Remove the two screws (3) and washers (4).

Slide the ribbon guide assembly (5) out of the side plate (6).

Installation
NOTE: Although the right ribbon guide is shown in Figure 5–27 , the
installation procedure is the same for the left ribbon guide.

5–60

Slide the ribbon guide assembly (5) into the side plate (6).

Install two screws (3) and washers (4).

Connect the ribbon guide connector (2).

Tie–wrap the cable to the spot tie (1).

Align the ribbon guides (page 4–20).

Return the printer to normal operation (page 5–80).

Replacement Procedures

1. Spot Tie
2. Ribbon Guide Connector
3. Screw (2)
4. Washer (2)
5. Ribbon Guide Assembly, Right (P/N 29–29299–01)
Ribbon Guide Assembly, Left (P/N 29–29278–01)
6. Side Plate

Figure 5–27 . Ribbon Guide Assembly (L/R), Removal/Installation

Replacement Procedures

5–61

Shaft, Splined (Figure 5–28 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Open the printer cover.

Remove the paper feed timing belt (page 5–4).

With grip ring pliers, remove the grip ring (1) from the splined shaft (2).

Pull the bearing (3) and spring link (4) with the spring (5) off the splined
shaft (2).

Unlock the left and right tractors (6 and 7) and slide them to the center.

Remove the screw (8), washer (9), and bearing clamp (10).

Grasping the vertical adjustment knob (11), slide the splined shaft (2)
out of the left and right side plates (12 and 13).

Installation
1.

Open the doors on the left and right tractors (6 and 7). Position the
tractor belts so the alignment marks are at the top on both tractors.

Grasp the vertical adjustment knob (11) and slide the splined shaft (2)
through the right side plate (13), tractors (6 and 7), and the left side plate
(12). Make sure the same spline passes the marked groove on each
tractor.

Install the bearing clamp (10), washer (9), and screw (8).

Apply a thin film of M–3 grease to the bearing (3).

Slide the spring link (4) and bearing (3) onto the splined shaft (2).

Attach the spring (5) to the left side plate (11) and the spring link (4).

Install the grip ring (1) on the splined shaft (2) with 0.010 inches of
clearance between the grip ring and the left side plate (11).

Install the paper feed timing belt (page 5–4).

Set the paper feed timing belt tension (page 4–6, 5 through 7).

10. Adjust splined shaft skew (page 4–14).
11. Return the printer to normal operation (page 5–80).

5–62

Replacement Procedures

1
3

4
12

2
11

6
2

1. Grip Ring (Mfg. P/N 101551–002)
2. Splined Shaft Assembly (Mfg. P/N 150169–001)
3. Bearing (Mfg. P/N 101308–001)
4. Spring Link (Mfg. P/N 110280–001 or 150664–001)
5. Spring
6. Tractor, Left (Set, L/R, P/N 29–29285–01)
7. Tractor, Right
8. Screw
9. Washer
10.Bearing Clamp (Mfg. P/N 110281–001)
11.Vertical Adjustment Knob (Splined Shaft Pulley) (Mfg. P/N 150289–001)
12.Left Side Plate
13.Right Side Plate

10
9

Figure 5–28 . Shaft, Splined, Removal/Installation

Replacement Procedures

5–63

Shaft, Support (Figure 5–29 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Open the printer cover.

Unlock the tractors (1) and slide them to the far left.

Remove the E ring (2).

Slide the support shaft assembly — consisting of the support shaft (3), two
spring washers (4), bushing (5), horizontal adjustment knob (6), washer
(7) and screw (8) — to the left, out of the tractors (1) and the left side plate
(9).

Installation

5–64

Slide the support shaft assembly — consisting of the support shaft (3), two
spring washers (4), bushing (5), horizontal adjustment knob (6), washer
(7), and screw (8) — into the left side plate (9).

Slide the tractors (1) onto the support shaft (3).

Slide the support shaft assembly through the right side plate (10).

Install the E ring (2).

Return the printer to normal operation (page 5–80).

Replacement Procedures

9
5
4
2

1. Tractor (2) (Set, L/R, P/N 29–29285–01)
2. E Ring (Mfg. P/N 105678–003)
3. Support Shaft (Mfg. P/N 111685–001)
4. Spring Washer (2)
5. Bushing
6. Horizontal Adjustment Knob
7. Washer
8. Screw
9. Left Side Plate
10. Right Side Plate

Figure 5–29 . Shaft, Support, Removal/Installation

Replacement Procedures

5–65

Shuttle Frame Assembly (Figure 5–30 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Remove the shuttle cover assembly (page 5–24).

Disconnect the MPU cable connector (1).

Disconnect the shuttle motor cable connector (2).

Disconnect the shuttle cable assembly connector (3).
CAUTION

The hammer bank flex circuit ribbon cables can tear if handled roughly.
Do not pull on the cables; grasp the connectors to disconnect the flex
circuit ribbon cables. In the next step, disconnect the left and right flex
ribbon connectors gently, and do not bend the cables unnecessarily.
6.

Disconnect the left and right hammer bank flex circuit ribbon
connectors (4 and 5).

Loosen the side 5/32 inch socket head clamp screws (6) and pull the
clamps (7) back and off the guide shaft (8).

Loosen the center 5/32 inch socket head screw (9) enough to release the
shuttle frame assembly (10) from the base casting (11).

Slide the last three fingers of your hands under the outer beam standoffs
(12) and hold the ribbon mask in place with you index fingers.

10. Lift the shuttle frame assembly (10) out of the base casting (11). Lift
slowly and carefully: the shuttle frame assembly is heavy.
11. Remove the hammer bank cover (page 5–22).

5–66

Replacement Procedures

6
2 Places

9 NOTE:

NOTE:
Clamp hardware
exploded for
clarity. Do not
remove.

Center captive screw
exploded for clarity.
Do not remove it.

12
4

3
2

1. MPU Cable Connector
2. Shuttle Motor Cable Connector
3. Shuttle Cable Assembly Connector
4. Left Flex Circuit Ribbon Connector
5. Right Flex Circuit Ribbon Connector
6. Clamp Screw, Side (2)
7. Side Clamp (2)
8. Guide Shaft
9. Center Screw, Captive
10. Shuttle Frame Assembly
(P/N 29–29297–01)
11. Base Casting
12. Outer Beam Standoff (2)

1
10

Figure 5–30 . Shuttle Frame Assembly Removal/Installation

Replacement Procedures

5–67

Installation
1.

Install the hammer bank cover (page 5–22).

Holding the shuttle frame assembly (10) by the outer beam standoffs
(12), set it into the base casting (11). Use both hands: the shuttle frame
assembly is heavy.

Align the center 5/32 inch socket head screw (9) in the base casting (11)
and hand turn the screw until only two or three threads have started.

Pull the shuttle frame assembly (10) toward the front of the printer.

Slide the side clamps (7) over the guide shaft (8) and torque the
5/32 inch socket head clamp screws (6) to 20 ± 1 inch–pounds.

Lift up on the shuttle motor, then gently set it down to align the center
screw guide.

Torque the center captive 5/32 inch socket head screw (9) to
20 ± 1 inch–pounds.

Connect the left and right hammer bank flex circuit ribbon connectors (4
and 5).

Connect the shuttle cable assembly connector (3).

10. Connect the shuttle motor cable connector (2).
11. Connect the MPU cable connector (1).
12. Adjust the platen gap (page 4–18).
13. Install the shuttle cover assembly (page 5–24).
14. Adjust the platen open belt (page 4–8).
15. Return the printer to normal operation (page 5–80).

5–68

Replacement Procedures

6
2 Places

9 NOTE:

NOTE:
Clamp hardware
exploded for
clarity. Do not
remove.

Center captive screw
exploded for clarity.
Do not remove it.

12
4

3
2

1
10

Figure 5–30. Shuttle Frame Assembly Removal/Installation

Replacement Procedures

5–69

Spring Assembly, Gas (Figure 5–31 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Open the printer cover (1).

Open the floor cabinet rear door.

Remove two nuts (2) and washers (3).

Remove the gas spring assembly (4).

Installation

5–70

Position the gas spring assembly (4) on the upper and lower brackets (5
and 6).

Install two nuts (2) and washers (3).

Close the printer cover (1): make sure the cover closes all the way. If
necessary, adjust the position of the stud in the lower bracket to achieve
smooth and complete closure.

Return the printer to normal operation (page 5–80).

Replacement Procedures

1. Printer Cover
2. Nut
3. Washer
4. Gas Spring Assembly (P/N 29–29508–01)
5. Upper Bracket
6. Lower Bracket

2
3
5

2
4
3
6

Figure 5–31 . Spring Assembly, Gas, Removal/Installation

Replacement Procedures

5–71

Spring, Extension (Figure 5–32 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Open the printer cover.

Remove the shuttle cover assembly (page 5–24).

Unhook the extension spring (1) from the spring lugs (2) on the hammer
bank (3) and shuttle frame (4).

Installation

5–72

Apply a dab of M–3 lubricant to both spring lugs (2).

Hook the extension spring (1) over the spring lugs (2).

Install the shuttle cover assembly (page 5–24).

Return the printer to normal operation (page 5–80).

Replacement Procedures

3
1. Extension Spring (P/N 29–29279–01)
2. Spring Lug (2)
3. Hammer Bank
4. Shuttle Frame

Figure 5–32 . Spring, Extension, Removal/Installation

Replacement Procedures

5–73

Switch Assembly, Cover Open (Figure 5–33 )

Removal
1.

Prepare the printer for maintenance (page 5–3).

Open the printer cover.

Remove the shuttle cover assembly (page 5–24).

Remove two screws (1) and lift the cover open switch assembly (2) out
of the base casting.

Disconnect the switch connectors from intermediate cable assembly
connector CO+ (3) and CO– (4).

Installation

5–74

Connect the switch connectors to intermediate cable assembly connector
CO+ (3) and CO– (4).

Position the cover open switch assembly (2) in the base casting and
install two screws (1).

Install the shuttle cover assembly (page 5–24).

Return the printer to normal operation (page 5–80).

Replacement Procedures

Printer viewed from above.

Card
Cage
Fan

Card cage

Paper
feed
motor

Platen
open
motor

Paper feed mechanisms
and barrier panel
Platen

Shuttle Frame Assembly

Base casting

3
2

1
4

This section of cable runs
beneath the base casting.

Front

1. Screw (2)
2. Cover Open Switch Assembly (P/N 29–29274–01)
3. Connector CO+
4. Connector CO–

Figure 5–33 . Switch Assembly, Cover Open, Removal/Installation

Replacement Procedures

5–75

Switch Assembly, Paper Detector (Figure 5–34 )
Removal
1.

Prepare the printer for maintenance (page 5–3).

Remove the paper guide assembly (page 5–42).

Remove four screws (1) and the barrier shield (2).

Remove the shuttle frame assembly (page 5–66).

Remove the paper ironer (page 5–44).

Loosen the screws (3) securing the paper detector switch assembly (4).

Disconnect the paper detector switch cable connector (5) from the
intermediate cable assembly connector PMD.

Cut the tie wraps securing the switch assembly cable to the front of the
card cage and remove the paper detector switch assembly (4).

Installation

5–76

Position the paper detector switch assembly (4) and install the screw (3)
securing it to the printer base.

Connect the paper detector switch cable connector (5) to the
intermediate cable assembly connector PMD.

Install tie wraps securing the switch assembly cable to the front of the
card cage.

Install the paper ironer (page 5–44).

Install the shuttle frame assembly (page 5–66).

Install the barrier shield (2) and four screws (1).

Install the paper guide assembly (page 5–42).

Return the printer to normal operation (page 5–80).

Replacement Procedures

1. Screw (4)
2. Barrier Shield
3. Screw
4. Paper Detector Switch Assembly
(P/N 29–292976–01)
5. Paper Detector Switch Cable Connector

Figure 5–34 . Switch Assembly, Paper Detector, Removal/Installation

Replacement Procedures

5–77

Switch Assembly, Platen Interlock (Figure 5–35 )
Removal
1.

Prepare the printer for maintenance (page 5–3).

Open the printer cover.

Disconnect the platen interlock switch connector (1) from connector
P1(P) (2).

Fully close the forms thickness lever (3).

Remove two screws (4).

Remove the platen interlock switch assembly (5) from the forms
thickness indicator plate (6).

Installation

5–78

Fully close the forms thickness lever (3).

Position the platen interlock switch assembly (5) on the forms thickness
indicator plate (6).

Install two screws (4).

Connect the platen interlock switch connector (1) to connector P1(P)
(2).

Return the printer to normal operation (page 5–80).

Replacement Procedures

1
4
5

1. Platen Interlock Switch Connector
2. Connector P1(P)
3. Forms Thickness Lever
4. Screw
5. Platen Interlock Switch Assembly (P/N 29–29275–01)
6. Forms Thickness Indicator Plate

Figure 5–35 . Switch Assembly, Platen Interlock, Removal/Installation

Replacement Procedures

5–79

Tractor (L/R)

Removal
1.

Prepare the printer for maintenance (page 5–3).

Remove the splined shaft (page 5–62).

Remove the support shaft (page 5–64).

Remove the tractors from the support shaft.

Installation
1.

Using the replacement tractors, install the support shaft (page 5–64).

Install the splined shaft (page 5–62).

Return the printer to normal operation (see below).

Returning the Printer to Normal Operation

5–80

Load paper.

Install the ribbon.

Close floor cabinet doors and the printer cover.

Connect the ac power cord to the power source and the printer.

Set the power switch to 1 (on).

Test printer operation by selecting and running one of the diagnostic
self–tests (page 3–26).

Replacement Procedures

Printer Configuration

Contents
Printer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2
Configuration Printout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2
Configuration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–3
Saving Configuration Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–4
Loading Configuration Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–5
Changing Printer Emulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–6
Configuration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–7

Printer Configuration

A–1

Printer Configuration
IMPORTANT

Configuration directly affects printer operation. Do not change printer
configuration until you are thoroughly familiar with the procedures in
this appendix.
Configuration refers to the operating properties that define how the printer
responds to signals and commands received from the host computer. These
properties, called configuration parameters, are set to match the operating
characteristics of the host computer system.
You can set some configuration parameters either by a control code from the
host computer or at the operator control panel. In such cases, a command
from the host overrides the control panel selection. (If you save configuration
values after such an override, the data stream control code value is saved
instead of the value you selected at the control panel.)

Configuration Printout
The configuration printout lists the configuration parameters currently in use.
When you exit configuration printout mode, the printer restores the previous
font and line spacing (lpi) and all character attributes are canceled. All other
format parameters remain unaffected.
To obtain a configuration printout:

A–2

Press the ON LINE switch to place the printer off–line.

Open the printer cover.

Press NEXT until “Off–Line/Print Config” appears on the message
display.

Press the R/S (Run/Stop) switch. The configuration listing prints.

Press CLEAR and close the printer cover.

Press the ON LINE switch to place the printer on–line.

Printer Configuration

Configuration Procedure
Use the following procedure to configure the printer from the control panel:
1.

Obtain a configuration printout (page A–2).

Determine the parameter values that must be changed to meet your
requirements.

Take the printer off–line by pressing the ON LINE switch.

Open the printer cover.

NOTE: You must unlock the ENTER switch to change a configuration
value. If you leave the ENTER switch locked you can examine — but
not change — the current configuration.
5.

Press UP and DOWN simultaneously to unlock the ENTER switch.
“Unlocked” appears briefly on the message display.

Locate the desired menu by pressing DOWN and then NEXT or PREV
until the menu name appears on the display. Use the Configuration
Diagram (page A–7) as your “road map.”

Locate the desired value in a menu by pressing DOWN, then pressing
NEXT or PREV until the desired value appears on the display.

Press ENTER when the desired value is showing on the message
display.

Press UP, then NEXT or PREV to move to the next desired menu.
Repeat steps 7 and 8.

10. After you have made all required parameter changes, press CLEAR. The
display goes to “Off–Line/Emulation.” Press NEXT until
“Off–Line/Save Config” displays. Press ENTER. This saves the
parameter values as the power–up default values.
11. Lock the ENTER switch by pressing UP and DOWN simultaneously.
“Locked” appears briefly on the message display.
12. Close the printer cover. Place the printer on–line by pressing ON LINE.
Your selected values are now active.

Printer Configuration

A–3

Saving Configuration Values
When you save a set of configuration values they become active every time
the printer is turned on.
To save a set of configuration values:

A–4

Press the ON LINE switch to take the printer off–line.
“Off–Line/Emulation” appears on the message display.

Open the printer cover.

Press UP and DOWN simultaneously to unlock the ENTER switch.
“Unlocked” appears briefly on the message display.

Press NEXT (or PREV) until “Off–Line/Save Config” appears on the
display.

Press ENTER.
The printer saves the parameters in nonvolatile memory then displays
“Done.”

Press CLEAR to return to “Off–Line/Emulation” display.

Press UP and DOWN simultaneously to lock the ENTER switch.
“Locked” appears briefly on the message display.

Close the printer cover.

Press the ON LINE switch to place the printer on–line.

Printer Configuration

Loading Configuration Values
Configuration values saved using the “Save Config” menu (page A–4)
become the power–up default configuration. The set of factory values
remains permanently stored in printer memory, however.
The “Load Config” menu gives you the choice of loading either the saved or
the factory configuration values.
NOTE: If you have not saved a set of configuration values, this procedure
loads the factory value set.
To load a set of configuration values:
1.

Press the ON LINE switch to take the printer off–line.
“Off–Line/Emulation” appears on the message display.

Open the printer cover.

Press UP and DOWN simultaneously to unlock the ENTER switch.
“Unlocked” appears briefly on the message display.

Press NEXT or PREV until “Off–Line/Load” appears on the display.

Press DOWN, then press NEXT or PREV to select either “Load/Saved”
or “Load/Factory”.

Press ENTER when the desired selection displays.
The printer loads the parameters then displays “Done”.

Press CLEAR to return to “Off–Line/Emulation”.

Press UP and DOWN simultaneously to lock the ENTER switch.
“Locked” appears briefly on the message display.

Close the printer cover.

10. Press the ON LINE switch to place the printer on–line.

Printer Configuration

A–5

Changing Printer Emulations
Emulation refers to the ability of the LG06 to execute the commands of DEC
LG02/LG31/LN01 printers, an IBM Proprinter, or an Epson FX printer. (On
the LG06 printer, the self–test and hex printout modes are also considered
emulations.)
DEC emulation is the default mode, but you can select another emulation at
any time.
To change printer emualtions:
1.

Press ON LINE to place the printer in the off–line state.
“Off–Line/Emulation” appears on the message display.

Open the printer cover.

Press UP and DOWN simultaneously to unlock the ENTER switch.
“Unlocked” appears briefly on the message display.

Press DOWN.
The current emulation displays. (“Emulation/LG06” is default.)

Press NEXT (or PREV) until the desired emulation displays.

Press ENTER.
The printer sets all configuration values associated with that emulation.
The values are those previously saved when that emulation was selected.
If no values were altered, the factory default values are loaded.

Press CLEAR to return to “Off–Line/Emulation.”

Press UP and DOWN simultaneously to lock the ENTER switch.
“Locked” appears briefly on the message display.

Close the printer cover.

10. Press the ON LINE switch to place the printer on–line to the host computer.

A–6

Printer Configuration

Configuration Diagram
The Configuration Diagram is a series of block diagrams showing the
configuration menu structure and the parameter options available in each
menu. The Configuration Diagram begins on page A–8.

How to Read the Configuration Diagram
Boxes on the diagram represent the message display. Messages that appear
on the display are printed inside the boxes. The letters outside the boxes
represent control panel switches. When a switch is pressed, an arrow points
to the displayed result.
The symbols used in the Configuration Diagram are shown in Figure A–1.
UP

U =

P =

CLEAR

R/S

CL =

RS =

CLEAR
UP
R/S
PREV

NEXT
SET TOF
ON LINE

DOWN

VIEW

ENTER

ON LINE

E =

OL =

D =
NEXT

DOWN

N =

DISPLAYED
MESSAGE

+ = PRESS SWITCHES
SIMULTANEOUSLY
(DEFAULT)
* = FACTORY
SETTING

= ARROWS LEAD TO
THE DISPLAYED
RESULT AFTER
PRESSING A
SWITCH

= CONTINUED ON OR FROM
THIS SYMBOL AT THE
INDICATED PAGE

PAGE A–XX

Figure A–1. Configuration Diagram Symbol Key

Printer Configuration

A–7

CONFIGURATION DIAGRAM
IMPORTANT: To make configuration changes, unlock the ENTER
switch at “Off–Line Emulation” by simultaneously
pressing UP and DOWN.

On–Line

OL
P
P

Off–Line
Emulation

Off–Line
Print Engine

Off–Line
Interface

Off–Line
Panel Language

Off–Line
Statistics

Off–Line
Load

Configuration
Printing

PAGE A–16

PAGE A–13

Done

Lang. Affichage
Français

Load
Saved

U
P

Load
Factory

N
N

Idioma en Pant
Español

Emulation
LG06
D

Emulation
Proprinter XL

Emulation
Epson FX–1050

U
P

Done

Emulation
Self test

PAGE 4–10

PAGE A–11

PAGE A–14

(1)

Done

User defined
(1) Returns after 1 second

A–8

Emulation
Hex Dump

U
P

(1)

(3)

(2) Returns at completion (3) Returns after 1 second
of printout.

PAGE A–15

(2)

Anzeigesprache
Deutsch

Off–Line
Save Config

Panel Language
English

Off–Line
Print Config

D
PAGE A–19

E
PAGE A–20

Printer Configuration

FROM PAGE A–8

Emulation
LG06

Continued
on next page

D
U

LG06
Font
N
D

Font
Style

Font
Character Set

Style
P

U
P

A–9

Style

Character Set
DEC Multinat’l

(1)
(2)

DP 10 6*
DP 10 8
DP 12 6
DP 12 8
DP 15 6
DP 15 8
DP 15 10
HS 10 6
CORESPON 5 6
CORESPON 5 8
CORESPON 6 6
CORESPON 6 8
CORESPON 10 6
CORESPON 10 8
CORESPON 12 6
CORESPON 12 8
CORESPON 15 6
CORESPON 15 8
CORESPON 15 10
OCR A
OCR B
COMPRESS 6 6
COMPRESS 6 8
COMPRESS 8 6
COMPRESS 8 8
COMPRESS 13 6
COMPRESS 13 8
COMPRESS 13 10
COMPRESS 16 6
COMPRESS 16 8
COMPRESS 16 10
DP 5 6
DP 5 8
DP 6 6
DP 6 8
N

(1)
DP = Data Processing

Character Set
U.S. ASCII

CORESPON = Correspondence
COMPRESS = Compressed

OCR = Optical Character
Recognition
HS = High Speed

*
N

DEC Finland
France
DEC Fr. Can.
Germany
Italy
JIS Roman
DEC Nor./Den.
Spain
DEC Sweden
DEC Great Brit.
ISO Nor./Den.
DEC Dutch
DEC Swiss

(2)
First number is characters
per inch (cpi). Second number
is lines per inch (lpi).
For example, DP 10 6 is
Data Processing font at
10 cpi and 6 lpi.

P
N

Character Set
DEC Portuguese

N
U

P
U

Printer Configuration

Continued from
previous page

U
U

LG06
Vert. Forms

LG06
Horiz. Forms

(4)

N
D

LG06
Autowrap

LG06
CR

Horiz Forms
Left Mrg n

(1) (5)

Vert Forms
Top Mrg n

(2)

Autowrap
Yes

P
P
U

(1) (4)

Horiz Forms
Right Mrg n

LG06
(3)
Unsol. Reports?

Vert Forms
Bot. Frm n

LG06
LF

CR
= CR

LF
= CR + LF

N or P

Unsol. Reports?
No
N

N or P

(2)

Autowrap
No

CR
= CR + LF

LF
= LF

Unsol. Reports?
Small
N

Vert Forms
Bot Mrg n

P
U

(1) (4)
(1) n = 0 to 198.0 inch in increments of 1/6 inch.
(Press DOWN to change units:
NEXT increases, PREV decreases.)

Unsol. Reports?
Big

(2) n = 0 to 13.6 inch in increments of 0.1 inch.
(Press DOWN to change units:
NEXT increases, PREV decreases.)
(3) Status reports are only sent when
the RS–232 interface is selected.
(4) Margins will automatically adjust
so that left/right and top/bottom margins
cannot cross one another.
(5) Setting the Bot Frm n automatically
sets the top margin to zero and the
bottom margin to n. Setting Bot Mrg n
does not affect the top margin.

A–10

Printer Configuration

FROM PAGE A–8
B
Continued
on next page
Emulation
Proprinter XL
D

Proprinter XL
Font

Font
Draft at 10 CPI
P

D
U

Character Set
US 437

Compatibility
Slashed Zero
D

US 437
Graphic 1 (A)

Font
NLQ at 10 CPI

Compatibility
Compress 12 CPI

Character Set
Mult 850

U
U

Font
Draft at 12 CPI

N
D

Proprinter XL
Compatibility

N
D

Proprinter XL
Character Set

N or P

Mult 850
Graphic 1 (A)
N or P

Compress 12 CPI
20 CPI

N or P

Slashed Zero
Disable

N or P

US 437
Graphic 2 (B)

Mult 850
Graphic 2 (B)

Compress 12 CPI
12 CPI

Slashed Zero
Enable

Font
NLQ at 12 CPI

A–11

Printer Configuration

Continued from
previous page
U

Continued
on next page

U
P

Proprinter XL
Paper Format
N
D
U
P

Paper Format
Forms Length Set

Paper Format
Line Spacing

N
D

Line Spacing
Set at 6 LPI
P
P

In Inches
At 11.0 Inches

U
U

In Inches
At 11.0 Inches

In 6 LPI Lines
At 65 Lines
N

Define CR Code
CR = CR

N or P

Define LF Code
LF = LF + CR

Define CR Code
CR = CR + LF

N or P

Line Spacing
Set at 10.3 LPI

N
P

Define LF Code
LF = LF

Forms length range
is from 1 to 168 lines in
1 line increments.

N
P

Forms length range
is from 1 to 126 lines in 1
line increments.

In 8 LPI Lines
At 88 Lines

Forms length range
is from 1.0 to 21.0 inches
in 0.5 inch increments.

A–12

In Inches
At 10.5 Inches

In 6 LPI Lines
At 66 Lines

Line Spacing
Set at 8 LPI

D
U

In 8 LPI Lines
At 88 Lines

In 6 LPI Lines
At 66 Lines

Paper Format
Define CR Code

N
D

Paper Format
Define LF Code

P
U

In 8 LPI Lines
At 87 Lines

Printer Configuration

FROM PAGE A–8
J
Off–Line
Statistics
Continued from
previous page

D
P

Statistics
On: 0 Hrs
N

(1)

Paper Format
Form Feed at TOF

Statistics
Printed: 0 Hrs

Paper Format
Print Width

D
U

Form Feed at TOF
Enable

Print Width
13.6 Inches

Statistics
Print Lines: 0

N
N or P

Form Feed at TOF
Disable

U
P

(3)
P

Statistics
Print Strokes: 0 (4)

N
D

(2)

(5)
P

N or P

Statistics
11” Pages: 0

Print Width
8.0 Inches

N
N

Phase Value
XXX

(6)
U
P

(7)

(1) All set to zero after
factory burn–in.
(2) 0 to 30,000
(3) 0 to 30,000
(4) 0 to 4,000,000,000
(5) 0 to 4,000,000,000
(6) 0 to 4,000,000,000; total inches of paper movement /11
(7) Phase Value range is 0 to 315.

A–13

Printer Configuration

FROM PAGE A–8
C
Continued
on next page
Emulation
Epson FX–1050
D

Epson FX–1050
Font

Epson FX–1050
Condensed

N
D

Font
HS Draft 10
P

*
P

Font
HS Draft 15
N

P
U

Font
Draft 10
N

A–14

Font
NLQ 15

Draft Speed
Low

Character Set
Epson
N

P
U

Character Set
IBM Graphics

International Set
USA

P
U

France
Germany
UK
Denmark I
Sweden
Italy
Spain I
Japan
Norway
Denmark II
Spain II
International Set
Latin Am

N
U

P
U

Font
NLQ 12
N

Font
NLQ 10
N

Draft Speed
High

Epson FX–1050
International Set

Font
Draft 15
N

Condensed
Yes

Epson FX–1050
Character Set

Font
Draft 12

Condensed
No
N

Font
HS Draft 12

N
D

Epson FX–1050
Draft Speed

P
U

Printer Configuration

Continued from
previous page

Epson FX–1050
Slashed Zero

Epson FX–1050
CR =

Slashed Zero
Yes

Page Length
11 ”

N or P

Skip Over Perf
No

Page Width
13.2 ”

N or P

CR =
CR + LF

Epson FX–1050
Page Width

N or P

CR =
CR

Epson FX–1050
Skip Over Perf

Slashed Zero
No

Epson FX–1050
Page Length

N or P

Page Length
12 ”

*
P
U

Page Width
13.7”

Skip Over Perf
1”

Page Width
8”

P
U

FROM PAGE A–8
K

Off–Line
Print Engine
D
U
P
U

Print Engine
Unidirectional
N

Unidirectional
No

PMD Fault
Yes

N or P

Unidirectional
Yes

A–15

Print Engine
PMD Fault

*
N or P

PMD Fault
No

Printer Configuration

FROM PAGE A–8
F
Offline
Interface
D
U

Interface
Serial EIA–232

DATAPRODUCTS
PAGE A–19

H
(1)

CENTRONICS
PAGE A–18

Continued
on next page
U
N
P
U

Serial EIA–232
Data Rate

Serial EIA–232
Word Length 8

U
P

Serial EIA–232
Word Length 8
N
N or P

Serial EIA–232
Word Length 7

19200 Baud
150 Baud

Serial EIA–232
Stop Bits 1

Parity
None

Data Term Ready
On–Line and BNF

Parity
Odd

Serial EIA–232
Stop Bits 2

Date Term Ready
Off–Line or BF

Parity
Even

1200 Baud

2400 Baud

Parity
Mark
N

Data Term Ready
False
P

Data Rate
4800 Baud

A–16

N or P

600 Baud

Data Term Ready
True

300 Baud

U
P

Data Rate
9600 Baud

Serial EIA–232
Data Term Ready

Serial EIA–232
Parity

N
D

Serial EIA–232
Stop Bits 1

N
D

Parity
Sense

Printer Configuration

Continued from
previous page
U
N
P
U

Serial EIA–232
Request to Send
N

D
U

Reverse Channel
On–Line and BNF

A–17

Reverse Channel
False
P

Request to Send
True

Reverse Channel
Off–Line or BF

Request to Send
False

Request to Send
Off–Line or BF
P

Request to Send
On–Line and BNF

Serial EIA–232
Reverse Channel

Reverse Channel
True

Printer Configuration

FROM PAGE A–16
G
Interface
Centronics
D

P
P

Centronics
Data Bit 8

U
P

Centronics
Data Polarity

N
D

D
U

Data Bit 8
Yes

*
N or P

Data Bit 8
No

A–18

Centronics
Response Pol.

N or P

Data Polarity
Inverted

U
P

Centronics
Busy on Strobe

N or P

Response Pol.
Inverted

Centronics
Latch Data On

N or P

Busy on Strobe
No

Centronics
Prime Signal

N or P

Latch Data On
Trailing Edge

N
D

Latch Data On
Leading Edge

Centronics
TOF Action

N
D

Busy on Strobe
Yes

U
P

N
D

Response Pol.
Standard

U
P

Data Polarity
Standard

Prime Signal
Enable

N or P

Prime Signal
Disable

TOF Action
Reset

N or P

TOF Action
Do Nothing

Printer Configuration

FROM PAGE A–8

FROM PAGE A–16

Emulation
Hex Dump

Interface
Dataproducts
E

Emulation
Hex Dump

*
OL

On–Line
Hex Dump

P
OL

Off–Line
Emulation

Dataproducts
Data Bit 8

Dataproducts
PI Ignored

PI Ignored
Yes

N or P

Data Bit 8
No

Dataproducts
Data Polarity

N or P

PI Ignored
No

U
P

Dataproducts
Data Request Pol.

Data Polarity
Standard

N or P

Data Polarity
Inverted

Dataproducts
Strobe Polarity

U
P

Data Bit 8
Yes

A–19

Data Request Pol.
Standard

N or P

Data Request Pol.
Inverted

Strobe Polarity
Standard

N or P

Strobe Polarity
Inverted

Printer Configuration

FROM PAGE A–8
E
Emulation
Self Test
E

Emulation
Self Test

U
U

Self Test
ASCII Swirl

Self Test
All E’s
N

*
N or P

Self Test
Width: 8.0

A–20

PhaseValue
XXX

(1)

Running
Shuttle Fast

Running
All Underlines

Self Test
Shuttle Slow
P

Running
All H’s

Self Test
Shuttle Fast

Self Test
All Underlines
RS

Running
E’s + TOF

Self Test
Phase Value

N
RS

Running
All E’s

Self Test
Width: 13.2

Self Test
All H’s

Running
ASCII Swirl

Self Test
Width: 13.2

Self Test
E’s + TOF

Self Test
All Black
P

P
RS

Running
Shuttle Slow

Running
All Black

(1) Increase or decrease phase value
by pressing NEXT or PREV switch.
Range is 0 to 315.

Printer Configuration

Printer Specifications

Contents
Cleaning Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–2
Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–2
Paper Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–2
Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–2
Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–3
Printer Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–3
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–3
Environmental Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–4
Termperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–4
Relative Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–4
Accoustic Noise Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–4
Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–4
Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–4
Power Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–4
Data Input Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–5
Printing Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–6
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–8

Printer Specifications

B–1

Cleaning Interval
Clean the LG06 every 6 months or 1000 hours of operation, whichever
occurs first. (See page 2–4.)

Ribbon Specifications
NOTE: Use of ribbons that do meet digital specifications may void
warranty.
Part Number:

36–36692–01

Type:

OCR Application, carton of 1 ribbon

Dimensions:

Length: 60 yards (54.84 m)
Width: 1 inch (2.54 cm)
Thickness: 0.0039 inches (.009906 cm)

To order replacement ribbons, call 1–800–DIGITAL

Paper Specifications

Paper

B–2

Type:

Edge–perforated, fanfold, 7.62 to 40.64 cm (3 to 16
in) wide

Thickness:

Single–part: 6.80 to 45.36 kg (15 to 100 lb) stock;
Multi–part: 1– to 6–part forms (maximum 5.44 kg
[12 lb] ply of upper plies)

Sheet Thickness:

0.0635 cm (0.025 in) maximum

Drive:

Adjustable tractors (6–pin engagement)

Slew Rate:

40.64 cm/s (16 in/s) maximum

Printer Specifications

Labels
On Backing:

One–part continuous perforated fanfold back form.
Labels must be placed at least 0.42 cm (1/6 in) from
the fanfold perforation. Backing adhesive must not
be squeezed out during printing.

Sheet Size:

7.62 to 40.64 cm (3– to 16–in) wide, including the
two standard perforated tractor feed strips. A
maximum sheet size of 30.48 cm (12 in) between top
and bottom perforations.

Thickness:

Not to exceed 0.064 cm (0.025 in)
(including backing sheet)

Printer Dimensions
Height:

108 cm (42.5 in)

Width:

68.6 cm (27 in)

Depth:

72.9 cm (28.7 in)

Weight:

Approximately 102 kg (225 lb) – Unpackaged
Approximately 129 kg (285 lb) – Packaged for shipping

Interfaces
Type:

Two resident parallel, one resident serial

Logic Levels:

TTL/EIA–232D

Data Format:

ASCII

Compatibility:

Centronics, Dataproducts, EIA–232D

Buffer Size:

2 lines parallel, 1KB serial

Printer Specifications

B–3

Environmental Characteristics

Temperature
Operating 10° to 40° C (50° to 104° F)
Storage

– 40° to 70° C (–40° to 158° F)

Relative Humidity
Operating 10% to 90% (noncondensing)
Storage

5% to 95% (noncondensing)

Acoustic Noise Level
52 dBA (tested per ISO 7779)

Electrical Characteristics

Input Power
Voltage

120 Vac or 230 Vac (94 – 140 VRMS; 188 – 275
VRMS)

Phase

Single

Frequency

47 to 62 Hz

Max RMS Current

8A @ 120 V; 4A @ 230 V

Power Rating
Standby

165 VA 60 Hz (120 Watts)

Operating 480 VA 60 Hz (360 Watts)

B–4

Printer Specifications

Data Input Rate (maximum)
Dataproducts

Up to 30 000 characters per second

Centronics

Up to 30 000 characters per second

RS–232

Up to 19 200 baud

Radio Frequency Interference (RFI)
Radio Frequency Interference tested/certified to RFI standards FCC 15.J
Class A; VDE 0871 Class A; CISPR–22.

Printer Specifications

B–5

Printing Rates
Printing speed of text is measured in lines/minute, and is a function of the
selected font and dot density. Printing speed is independent of the number of
characters configured in the character set repertoire. Print rates for lines
containing attributes such as bold or emphasized printing, superscripts,
subscripts, or elongated attributes will decrease to not less than half the rates
of the font without such attributes. Typical printing rates for text are charted
in Table B–1.
Plotting speed of graphics is measured in inches/minute, and is calculated as
follows:

Shuttle Speed

1
x Vertical Density

60 000

Plotting speed in
inches/minute

Shuttle speed varies with the horizontal dot density:
Horizontal Density
(dots/inch)

Shuttle Speed
(milliseconds/stroke)

50
60
70
80
90
100
110
120
130
140
150
180
200

12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
13.5
14.5
15.6
18.75
20.8

Selectable by
graphics
control codes

To prevent damage from overheating when graphics plotting is done over
extended periods, the hammer bank contains a thermal sensing feature that
automatically reduces the print rate.

B–6

Printer Specifications

Table B–1. Text Printing Rates
Performance

Print Application

Uppercase
Only
(lines/minute)

Descenders
& Underline
(lines/minute)

Emulation, Font,
and Characters
/inch

Dot Density1

Dot Matrix2

LG06 DP 5

60 (120) x 66.6

10 (18) x 7 + 2

600

480

LG06 DP 6

60 (120) x 66.6

8 (14) x 7 + 2

600

480

LG06 DP 10

60 (120) x 66.6

5 (9) x 7 + 2

600

480

Pro DP 10

60 (120) x 75

5 (9) x 7 + 2

600

480

LG06 DP 12

60 (120) x 66.6

4 (7) x 7 + 2

600

480

Pro3 DP 12

60 (120) x 75

4 (7) x 7 + 2

600

480

LG06 DP 15

60 (120) x 100

3 (5) x 7 + 2

600

480

Pro DP 17

60 (120) x 75

3 (5) x 7 + 2

600

480

Pro DP 20

60 (120) x 75

3 (5) x 7 + 2

600

480

LG06 NLQ4 5

90 (180) x 85.7

14 (26) x 9 + 3

320

245

LG06 NLQ 6

90 (180) x 85.7

12 (22) x 9 + 3

320

245

LG06 NLQ 10

90 (180) x 85.7

7 (13) x 9 + 3

320

245

Pro NLQ 10

90 (180) x 100

7 (13) x 9 + 3

320

245

LG06 NLQ 12

90 (180) x 85.7

6 (11) x 9 + 3

320

245

Pro NLQ 12

90 (180) x 100

6 (11) x 9 + 3

320

245

LG06 NLQ 15

90 (180) x 85.7

5 (9) x 9 + 3

320

245

LG06 CMP 6.6

60 (120) x 85.7

4 (7) x 7 + 2

600

480

LG06 CMP 8.3

75 (150) x 85.7

4 (7) x 7 + 2

480

384

LG06 CMP 13.3

60 (120) x 85.7

4 (7) x 7 + 2

600

480

LG06 CMP 16.6

75 (150) x 85.7

4 (7) x 7 + 2

480

384

LG06 HS 10

60 (120) x 50

5 (9) x 5 + 1

800

685

LG06 OCR–A 10

120 (120) x 150

12 (12) x 15 + 1

300 (best)
155 (worst)

LG06 OCR–B 10

120 (120) x 150

12 (12) x 15 + 1

300 (best)
155 (worst)

1 A (B) x C where: A = maximum horizontal dot density; B = horizontal dot placement

density; C = vertical dot density.
2 D (E) x F + G where: D = maximum number of dots to be placed on horizontal dot positions;

E = horizontal dot positions; F = number of vertical dots for uppercase
symbols; G = number of dots available for descenders.
3 Pro = Proprinter emulation
4 NLQ = correspondence, CMP = compressed, HS = high speed

Printer Specifications

B–7

Duty Cycle
The LG06 text and graphics printer is capable of printing 75 000 pages per
month under the following conditions:

B–8

Uppercase only

6 lines/inch

10 characters/inch

63% character density or 83 characters/line

63% line density or 42 lines/11–inch page

Single part (18 lb) paper

Printer is maintained in accordance with the maintenance manual
(document number EK–ELG06–MG)

Printer is installed in accordance with Chapter 2, “Installation” of the
User’s Manual (document number EK–ELG06–UG).

Printer Specifications

Torque Table

IMPORTANT

Torque values specified in replacement procedures (Chapter 5) take
precedence over Table C–1.
Table C–1 establishes the torque requirements for routine installation of
threaded fasteners. The torque requirements in Table C–2 apply to fasteners
made of steel, at a minimum engagement of 3.5 threads, including chamfer
and countersink. Fastener sizes are listed as Numbered Size – Threads Per
Inch.
Table C–1. Torque Table
Carbon Steel Fasteners
(ANSI B18.6.3 – 1972)

Torque Table

Fastener
Size

Into Alum.
or Brass
25 000 psi
ultimate
tensile
strength

Into Steel
60 000 psi
ultimate
tensile
strength

Into
Weld/Press
Studs or
Nuts

Into Medium
Carbon Steel
Fasteners
105,000 psi
ultimate tensile
strength

2–56
4–40
6–32
8–32
10–24
10–32
1/4 – 20

25 ± 2 in oz
62 ± 4 in oz
122 ± 7 in oz
11 ± 1 in lb
20 ± 1 in lb
15 ± 1 in lb
40 ± 3 in lb

36 ± 2 in oz
75 ± 5 in oz
150 ± 10 in oz
18 ± 1 in lb
25 ± 1.5 in lb
29 ± 2 in lb
62 ± 4 in lb

30 ± 2 in oz
70 ± 5 in oz
135 ± 10 in oz
18 ± 1 in lb
21 ± 1 in lb
29 ± 1 in lb
62 ± 4 in lb

––
––
––
––
––
––
105 ± 5 in lb

Fastener Size

Torque for Routine Tightening of Threaded
Fasteners

4–40 UNC & 4–48 UNF
6–32 UNC & 6–40 UNF
8–32 UNC & 8–36 UNF
10–24 UNC & 10–32 UNF

4 ± 1 in lb
11 ± 1 in lb
19 ± 1 in lb
25 ± 1 in lb

C–1

C–2

Torque Table

Cable Interconnections and Hammer
Bank Wiring
Table D–1 lists the LG06 cable assemblies and their part numbers.
The LG06 Interconnection Diagram on page D–2 shows the electrical
interconnections in block diagram form. Use this diagram as a
troubleshooting aid.
The Hammer Bank Wiring Diagram on page D–3 is useful for tracing opens
or shorts.
Table D–1. Interconnection Cables
Cable No.

Part No.

150551–001

Cable Assembly, CCB/Mech. Dr.

150218–001

Cable Assembly, +5 V

150216–001

Cable Assembly, Hi Voltage

29–29293–01

Cable Assembly, Hammer Bank

29–29292–01

Cable Assembly, Intermediate

150376–001

Wire Harness, Main, P4980

150487–001

Cable Assembly, AC/Ground, P4980

Cable Interconnections and Hammer Bank Wiring

Description

D–1

PS5(P)

Cable Assy,
AC/Ground,
P4980

J101

J102

Power
Supply
PCBA

W2:
Cable Assy
+5V

PS(J)

PS5(J)

Mechanism
Driver
PCBA

CCB(J)

W1:
Cable Assy,
CCB/Mech. Dr.

Load

GND

W3:
Cable Assy,
High Voltage

GND

Circuit
Breaker

P/S Cond 2

P/S Cond 1

EXP(P)

Fan Assy,
P4000
(Cabinet)

W5:
Cable Assy
Intermediate

W6:
Wire Harness,
Main, P4980A

Common
Controller
PCBA

Control
Panel
Assy

HBL(J)

MH(J)

HD*(P)

HBR(J)

HD(J)

Not Used

Multi I/O
Cable
Assy

GND

CO–(P)

CO+(P)
PI(J)

PFM(P)

Filter, Power
Line, EMI

W4: (twice)
Cable Assy,
Hammer Bank

SHM(J) SHM(P)

SHH(J) SHH(P)

AC Input

Wire Assy,
Hammer Bank

Motor Assy,
Shuttle Driver

Fan Assy,
Hammer Bank

Motor Assy,
Paper Drive

HBF(P)

Motor Assy,
RIbbon
(Left)

Cable Assy,
Ribbon Guide,
Left

PMD(J) PMD(P)

PI(P)

RML(P)

J17

RGL(J) RGL(P)

Switch Assy,
Cover Open

HBL(J)

HBR(J)

D–2

Cable Interconnections and Hammer Bank Wiring

Magnetic
Pick–up Assy.

Motor Assy,
Platen Open

Fan Assy,
Card Cage

Motor Assy,
Ribbon
(Right)

Cable Assy,
Ribbon Guide,
Right

RM = Ribbon Motor

RG = Ribbon Guide

R = Right

PS = Power Supply

PMD = Paper Motion Detector

PLM = Platen Motor

PI = Platen Interlock

PF = Paper Feed

(P) = Pin connector

MPU = Magnetic Pick Up

MH = Main Harness

L = Left

(J) = Jack connector

HD = Hammer Driver

HB = Hammer Bank

GND = Ground

CO =Cover Open

CCF = Card Cage Fan

CCB = Common Controller Board

LG06 INTERCONNECTION DIAGRAM

MPU(J) MPU(P)

PLM(P)

CCF(P)

RMR(P)

RGR(J) RGR(P)

Switch Assy,
Paper Detector

Switch Assy,
Platen
Interlock

LEGEND

Key:
Unused hammer.
Hammer Coil.
Hammer Spring.
Ribbon Cable.

NOTES:
1. Coil 48 is wired, but not
used.
2. Hammer springs 1 and 49
are not used.
3. Hammer coil resistance =
4.7 Ohms.

Hammer Bank Wiring Diagram

Cable Interconnections and Hammer Bank Wiring

D–3

D–4

Cable Interconnections and Hammer Bank Wiring

Principles of Operation

Contents
Functional Elements of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–2
Common Controller PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–3
Mechanism Driver PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–11
Power Supply PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–14
Printing Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–15
Paper Transport System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–19
Ribbon Transport System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–20

Principles of Operation

E–1

Functional Elements of the Printer
The principal functional elements of the LG06 printer are the common
controller board (CCB), the mechanism driver board, the power supply
board, the operator control panel, and the components of the
electromechanical print mechanism.
These elements are depicted at their most basic level in Figure E–1. The
following sections of this appendix discuss these elements in more detail.

AC
POWER

ON / OFF
Switch / Circuit Brkr

PRINT MECHANISMS
EMI
FILTER
PAPER TRANSPORT

Data
HOST

AUTO–RANGING
POWER SUPPLY
PCBA *

Data
PRINTER
INTERFACE

RIBBON
TRANSPORT

Status
+9.5 Vdc

Status

+48 Vdc
+5 Vdc
Paper Feed
Platen Open
Motor Control

+5 Vdc
COMMON
CONTROLLER
PCBA *

Fault

DPU

Paper
Control

+5 Vdc
OPERATOR
CONTROL
PANEL

Ribbon Control
MECHANISM
DRIVER
PCBA *

Ribbon Status
Hammer Control
Shuttle Control
Shuttle Status

Shuttle
Timing

SHUTTLE
FRAME
ASSEMBLY

Keyboard
Message

SHARED
MEMORY

Indicator

Fan Control

HAMMER BANK
FAN

Hammer
Timing Data

Fan Control

CARD CAGE
FAN

Shuttle & Ribbon Control

Fan Control

CABINET
FAN

Hammer
Driver Data

RTPU

Sensors

PAPER
OUT

PLATEN
OPEN

PAPER
MOTION

COVER
OPEN

* Printed Circuit Board Assembly

Figure E–1. Functional Elements of the LG06 Printer

E–2

Principles of Operation

Common Controller PCBA
The heart of the LG06 Text and Graphics printer is the common controller
printed circuit board assembly (PCBA), also called the common controller
board (CCB). The CCB oversees and coordinates all printer functions.
The CCB is functionally two units, the data processing unit (DPU) and the
real–time processing unit (RTPU). The DPU converts all character data into
printable dot images. The DPU is the high–level logical controller of the
printer; it is not involved in real–time or hardware–dependent printer
operation. The RTPU operates the host interfaces, operator control panel, and
the print mechanism. The RTPU also monitors the fault circuitry in the
mechanism.
The DPU and RTPU communicate by means of shared memory. The DPU
gets host and operator input from buffers in memory which are filled by the
RTPU, and returns dot images and operator messages to buffers in memory
which the RTPU empties. Figure E–2 broadly summarizes the architecture of
the CCB.

CCB
DATA PROCESSING
UNIT

SHARED MEMORY

HOST
INTERFACE

REAL–TIME
PROCESSING
UNIT

OPERATOR
CONTROL
PANEL

PRINTING
MECHANISM
INTERFACE

Figure E–2. Architectural Overview of the Common Controller Board
(CCB)

Principles of Operation

E–3

Communicating with the Host Computer
The CCB processes three kinds of computer input: Centronics parallel,
DataProducts parallel, and RS–232 serial data. The RTPU operates all three
interfaces. The parallel interfaces are similar, and the RTPU contains
direct–memory–access (DMA) hardware which loads parallel data directly
into shared memory. The serial interface requires byte–by–byte intervention
by the processor, since ACK/NACK and XON/XOFF protocols require that
every byte be examined as it is received. The universal asynchronous
receiver/transmitter (UART) is internal to the RTPU, which processes any
protocol requirements then puts the data in shared memory, where the DPU
can read it. To the DPU, all input data looks the same, regardless of the
interface used to receive it.

Communicating with the Operator
All communication to and from the operator is done at the operator control
panel. The control panel processes three types of operation: keystroke input,
message display output, and indicator output. The RTPU handles the control
panel interface requirements of shifting, clocking, etc., but the DPU
processes all control panel data.

Printing
The RTPU coordinates printing of the dot images sent from the DPU.
Printing is a complex process requiring many control functions, but is
logically divided into two groups:
•

Hammer driver interface functions

•

Mechanical interface functions

Hammer Driver Interface
In order to print a dot image, two things must happen. First, the dots must get
to the hammers one dot row at a time and in the correct sequence. Second,
the hammers must be fired at the appropriate time in the stroke of the shuttle.
The RTPU microprocessor controls both of these functions, but each is
actually performed by an application–specific integrated circuit (ASIC)
containing hardware dedicated to the function. These ASICs are the Dot
Plucker Memory Controller (DPMC) and the Fire Timer IC (FTIC). The
hammer driver interface functions of the RTPU are summarized in
Figure E–3.

E–4

Principles of Operation

DATA PROCESSING
UNIT

SHARED MEMORY

DOT PLUCKER
ASIC

RTPU
64180
PROCESSOR

EPROM

Hammer
Driver
Data

DMA CONTROLLER

FIRE TIMER
ASIC

Hammer
Timing
Data

REAL–TIME PROCESSING UNIT

Figure E–3. Hammer Driver Interface Functions of the RTPU
Getting Dots to the Hammers Getting dots to the hammers consists of
going into the shared memory and pulling bits out in a given order and
shifting them to the hammer driver at the correct time. This process is called
dot plucking. The order in which dots are plucked from memory depends on
the dot density, the number of dots per hammer, the number of hammers on
the hammer bank, the number of phases, and other factors. These factors are
all considered by the RTPU processor as it programs the dot plucker for each
dot row.
Synchronizing Dot Plucking and Hammer Firing Transfer of dots to
the hammer driver must be synchronized with hammer firing. Dots are
transferred to the hammer driver in bursts, serial streams of dots that tell
which hammers will print when their phase is next fired. The bursts are timed
precisely; they must occur neither too early nor too late. Synchronization is
performed by having the FTIC request bursts from the dot plucker. The FTIC
reads the magnetic pick–up unit (MPU) to determine when to request a burst.
The time at which the burst request is made is contained in the fire timing
tables.

Principles of Operation

E–5

Mechanical Interface
Three mechanical operations are coordinated in printing: paper motion,
ribbon motion, and shuttle motion. Virtually all digital handling of paper
motion is contained in the RTPU. The ribbon and shuttle are controlled by
logic on the mechanism driver board, under the direction of the RTPU.
Figure E–4 shows the mechanical interface section of the RTPU.

DATA PROCESSING
UNIT

SHARED MEMORY

DOT PLUCKER

RTPU
64180
PROCESSOR

EPROM

UART

PAPER FEED
CONTROLLER

Shuttle
and
Ribbon
Control

Paper
Control

REAL–TIME PROCESSING UNIT

Figure E–4. Mechanism Driver Interface Functions of the RTPU
Paper Motion The DPU determines when paper must be moved and how
far to move it. It communicates this to the RTPU through the shared memory.
The RTPU processor performs some paper handling operations (such as
holdback on slews), but most RTPU paper handling is done by a dedicated
micro–controller called the paper feed controller (PFC).
The PFC moves paper by looking up motion profiles and driving a sequence
of motor positions to the mechanism driver board. If the motion is a dot row
or interline advance, it is synchronized to hammer firing by a signal from the
FTIC that tell the PFC when to move.
Ribbon and Shuttle Motion The ribbon and shuttle motors are controlled
by a micro–controller on the mechanism driver board. The RTPU interface to

E–6

Principles of Operation

the ribbon/shuttle processor (RSP) is a 2400 baud asynchronous serial line. A
message protocol is used to communicate ribbon and shuttle information.

Fault Monitoring
The RTPU also monitors the hammer driver, mechanism driver, and the
electro–mechanical sensors for fault conditions. Fault conditions are reported
to the DPU.

Hammer Bank and Hammer Driver Faults
The FTIC works with the hammer driver ASIC to monitor coil shorts, opens,
average upper driven phase current, and temperature conditions. The RTPU
reads the FTIC registers to determine out–of–range conditions, and these are
passed on to the DPU.

Paper Faults
Two kinds of paper faults can occur: paper out and paper jammed. Both of
these conditions are monitored through optical sensors. The paper feed
controller watches the paper out and paper motion sensors and reports errors
to the RTPU. The RTPU passes this information on to the DPU.

Ribbon and Shuttle Faults
The mechanism driver ribbon and shuttle controller monitors fault conditions
in the drive circuits and notifies the RTPU if it finds errors. The RTPU can
also use the FTIC to measure time between magnetic pick–up (MPU) pulses,
enabling it to monitor shuttle speed and thus detect some shuttle faults.

CCB Hardware Overview
A Motorola 68010 microprocessor performs the DPU functions, a 64180
microprocessor handles the RTPU functions, and an 8032 micro–controller
serves as the paper feed controller (PFC), which is part of the RTPU. Actual
implementation of this hardware blurs the distinctions between the DPU and
RTPU, since the 68010 has access to the parallel port and the real–time
functions of the dot plucker, which are RTPU resources, while the 64180 has
access to the nonvolatile memory (NVRAM), which is a resource of the
DPU. These possibilities exist because of efficiencies in the hardware design;
software maintains the functional differences between the DPU and RTPU.
The CCB has four data buses. The 68010 has a local sixteen bit bus. The
64180 uses a local bus eight bits wide. A third bus is shared by the DPU and

Principles of Operation

E–7

RTPU; it is sixteen bits wide and is arbitrated on a cycle–by–cycle basis. The
8032 chip has its own eight bit local bus. The manner in which the CCB
implements this hardware is depicted in Figure E–5.
The 64180 IC that oversees the RTPU processor contains a Z80
microprocessor with extended memory management, two DMA controllers,
two asynchronous and one synchronous serial port, two counter timers, and
an interrupt controller.

Communicating with the Host Computer
The 64180 processor runs both the parallel and serial interfaces.
Parallel Input Parallel input data is nine bits wide, and is transferred in one
cycle from the parallel port to shared memory over the shared sixteen bit bus.
Using the internal DMA controller of the 64180 to transfer parallel data
requires some manipulation. The eight bit DMA controller in the 64180
performs either eight or sixteen bit DMA cycles, while the eight bit processor
in the 64180 performs only eight bit memory access cycles. Sixteen bit DMA
is achieved by hardware shifting of the DMA addresses one bit (effectively
multiplying the address by two and changing the DMA auto–increment from
byte to word) and by manipulating the control strobe. Software adjusts the
addresses provided to the DMA controller when it is programmed for sixteen
bit DMA. This manipulation saves both the added cost of a sixteen bit DMA
controller and the second cycle that an eight bit transfer would require.
Serial Input One of the 64180 UARTs handles serial communication with
the host. Additional modem control lines are provided in the 64180 hardware
control register.

Communicating with the Operator
The synchronous serial port in the 64180 shifts data in and out of the operator
control panel. The control register in the 64180 contains three other control
panel bits: one samples the switches, one strobes the liquid–crystal display,
and one strobes a light–emitting diode (LED) holding register.

Printing
Hammer Driver Interface The 64180 programs the dot plucker ASIC
every dot row and programs the FTIC every stroke, after which the FTIC
uses a DMA request line to control the movement of tables from EPROM to
FTIC. The second DMA controller in the 64180 performs this transfer.
Mechanism Driver Interface The paper feed controller (PFC) directs all
paper motion. During printing, it usually moves paper in response to a trigger

E–8

Principles of Operation

from the FTIC, which synchronizes paper motion with shuttle motion. The
64180 programs the PFC 8032 at the beginning of each dot row, telling the
PFC how far to move when the trigger is received. The PFC sets up for the
move, waits, then moves when the trigger occurs. The other method of
starting paper motion is with a command passed through the inter–processor
port (an eight bit parallel port between the 8032 and the 64180). This results
in immediate movement. Other paper commands and status signals are also
passed through this port.
Ribbon and Shuttle Motion The 64180 interfaces through its second
UART to the ribbon / shuttle processor (RSP) on the mechanism driver
board. The 64180 begins all transactions on the serial interface; the RSP sets
a bit in the 64180 hardware status register when it needs service.

Fault Monitoring
The RTPU 64180, the PFC 8032, and the RSP monitor different functions for
faults. The 64180 looks for hammer driver faults, shuttle stalls, and an open
platen. The PFC 8032 monitors paper out and the paper motion detector. The
RSP watches for faults in the motor drive circuits. The PFC and RSP report
errors to the 64180, which collates fault status and passes it on to the DPU
68010 processor.
Hammer Bank and Hammer Driver Faults The 64180 and FTIC check
the hammer driver and hammer bank for faults on every shuttle stroke. Faults
are detected by circuits on the mechanism driver board and relayed to the
CCB. Fault circuitry can detect shorted coils and rising temperatures in the
coils. One coil is checked on every shuttle stroke; 48 shuttle strokes are
required to check all coils. When the RTPU is notified of a fault, it sends a
message to the 68010. If a coil shorts, the 64180 stops printing before firing
another dot row.
Paper Faults The PFC 8032 monitors paper faults and reports them to the
64180 through the eight bit parallel port they share. The PFC works with a
friction wheel paper motion detector and a reflective (optical) paper out
sensor. The sensors interface directly to the CCB; there are analog circuits on
the CCB to condition the sensor inputs.
Ribbon and Shuttle Faults The RSP monitors ribbon and shuttle faults
and reports them to the 64180 over the serial interface.

Principles of Operation

E–9

68010
MICROPROCESSOR

SHARED
BUS
INTERFACE

EPROM
512 KB

CONTROL
REGISTER

NVRAM
2 KB

DATA PROCESSING UNIT (DPU)

REAL–TIME PROCESSING UNIT
(RTPU)

PARALLEL
PORT

From
Host
Computer

DOT
PLUCKER
ASIC
Serial from
Host Computer
64180
PROCESSOR
Serial to Host,
Mech. Driver, and
Control Panel

SHARED
BUS
INTERFACE

DRAM
1 MB
To
Hammer
Driver

FIRE
TIMER IC

EPROM
32 KB

HARDWARE
CONTROL
REGISTER

SRAM
2 KB

HARDWARE
STATUS
REGISTER

COMM.
PORT

8032
PROCESSOR

PAPER FEED
CONTROLLER
(PFC)

EPROM
16 KB

To
Mech.
Driver

Figure E–5. Hardware Implementation of the CCB

E–10

Principles of Operation

Mechanism Driver PCBA
The mechanism driver board, acting on commands from the CCB, controls
real–time operation of the electromechanical printer systems. Functionally,
the board consists of nine subsystems:
•

An 8032 micro–controller that controls ribbon drive and
communication with the CCB.

•

The interface to the power supply board.

•

Pulse–width modulator (PWM) current mode / voltage mode
full–bridge power amplifiers connected directly to the shuttle,
ribbon, paper feed, and platen open motors. Current mode is used for
the paper feed motor, voltage mode is used for the ribbon and shuttle
motors.

•

The paper feed controller (PFC) accepts control codes from the CCB
for each motor phase to vector–control the paper feed motor.

•

The shuttle drive controller receives speed commands from the CCB
through the 8032 micro–controller and commands the speed of the
three–phase dc shuttle motor.

•

The ribbon drive controller, based around the 8032 micro–controller,
receives speed commands from the CCB and drives two dc stepper
motors, regulating the speed and tension of the ribbon and
monitoring the end of ribbon sensors.

•

The platen drive controller for reverse paper feed.

•

Fault detection circuitry samples and senses heat sink temperature,
ribbon speed, shuttle speed, hammer driver circuitry, hammer bank
coil temperatures, power supply voltages, and fault communication
with the CCB.

•

Circuitry that registers magnetic pick–up unit (MPU) output,
processes it for the logic interface, and sends it to the CCB for
timing hammer fire.

The Ribbon Drive System
The ribbon drive system is controlled by the 8032 micro–controller. The
CCB sends commands to the 8032 to start and stop the ribbon, set the ribbon
speed, and apply slack or tension to the ribbon. The real–time control
functions are done by the 8032, acting in accordance with firmware control
algorithms and look–up tables. The 8032 communicates with an ASIC to

Principles of Operation

E–11

provide direct digital PWM drive signals for the ribbon motor PWM
amplifier. The 8032 drives the ribbon motors through PWM generators in the
mechanism driver integrated circuit (MDIC). Nearly all mechanical control
functions are carried out through the MDIC ASIC. Digital I/O is done
through latches connected to the 8032 I/O ports and MDIC. Ribbon faults are
passed to the CCB.

Ribbon Velocity
Ribbon velocity is controlled by means of a closed–loop system that first
measures the speed of the two ribbon drive motors. One motor is driven; the
other motor is not driven and applies tension to the ribbon through its drag
circuitry. The velocity of the driven motor is known, while the velocity of the
tensioning motor is measured by converting the zero crossing of the
back–EMF signal to a digital pulse signal. This signal is processed by the
8032 to determine the radius of the ribbon on the take–up reel. The processor
monitors this information and adjusts the velocity of the driven motor to
maintain constant linear speed. The roles of the two motors reverse at the end
of ribbon travel, when a metallic strip crosses the ribbon guide of the
emptying reel and closes a circuit that causes the RSP to reverse motor
functions.
The four PWM amplifiers in the ribbon drive system are voltage mode to aid
in system damping (as opposed to current mode). The 8032 input to the
PWM amplifiers maintains a constant voltage/frequency ratio at the motor.
The ribbon drive is protected from over current.

Ribbon Tension
The 8032 processor regulates tension in three discrete steps by using
information gathered by the zero–crossing circuitry and ribbon information.
Tension is adjusted by controlling the load on the drag motor back emf. This
load generates drag torque on the ribbon hub that maintains tension.

Start / Stop Ribbon
The ribbon motors are started and stopped by a digital signal from the CCB.
After a stop signal is received, the ribbon is locked to maintain tension. If the
CCB sends a slack signal, the PWM amplifiers are tri–stated.

The Shuttle Drive System
The shuttle drive system is an analog closed–loop speed controller that
accepts commands from the CCB through the 8032 micro–controller and

E–12

Principles of Operation

MDIC ASIC. The CCB writes a word to the 8032, which writes a word to the
MDIC. The MDIC generates a clock signal based on this word.
The clock signal from the MDIC is the reference input to a phase detector.
The other input to the phase detector is a logical combination of the pulses
from three Hall–effect sensors in the brushless three–phase dc shuttle motor.
The Hall–effect sensors are mounted to the motor stator 120 electrical
degrees phase–shifted from each other. The phase detector is both a phase
and frequency detector. It operates as a frequency detector when out of lock,
and as a phase detector when the loop is phase–locked. During shuttle start,
the frequency error from the phase frequency detector drives the servo
system towards phase lock. At approximately 85% of final speed, the servo
integrator resets to prevent overshoot. When the correct speed is reached, the
system is in phase lock with the MDIC clock signal.
The shuttle is protected from overspeed, over current, missing hall–effect
sensors, and out–of–sync hall–effect sensors.

The Paper Feed System
Dot row advance and slew tables are stored in the CCB. The paper feed drive
circuit takes commands directly from the CCB to control the two–phase dc
paper feed stepper motor. A CCB paper feed command is a digital word
containing a value proportional to the desired current level in the paper feed
motor, enabling the motor to be quarter stepped in LG06 mode. Two PWM
current mode amplifiers, protected against overloads and short circuits, drive
the paper feed motor. The paper feed motor is energized whenever printer
power is on, unless the platen is open, in order to maintain tension and
position of the paper. The paper feed motor is disabled in a platen open fault
condition.

The Reverse Paper Feed System
To reverse paper motion, the printer must open the platen, move the paper
backwards vertically, close the platen, and remove the slack in the paper. A
platen open or close command is generated on the CCB and communicated
to the RSP 8032 processor. The RSP generates control and step clock signals
for the platen driver circuitry. The platen driver circuitry is connected to a
stepper motor that drives the platen through a toothed belt. The platen motor
is only energized during the open and close cycles. The platen driver is
protected from over current.

Principles of Operation

E–13

The Magnetic Pick–up Unit (MPU)
The magnetic pick–up unit (MPU) is mounted next to the shuttle motor
flywheel. It provides timing information to the hammer fire controller by way
of the CCB. The rotation of the flywheel generates a pulse signal in the
MPU. The output frequency is 100 times the shaft frequency of the shuttle
motor. The MPU pulse train has one missing pulse in every revolution of the
motor for indexing. The incoming signal from the MPU is processed with a
zero–crossing detecting circuit to produce a clean signal, compatible with
system logic. The clean signal is then sent directly to the CCB.

Power Supply PCBA
The printer power supply is contained on a printed circuit board assembly
(PCBA) mounted in the card cage. It senses and adjusts to any commercial
electrical system that provides ac mains potential in 50 or 60 Hertz systems.
AC input power is converted to dc power and sent to the mechanism driver
board for distribution to logic and electromechanical circuits.

AC Power
The power supply operates on ac voltages ranging from 86 to 264 V. It can
tolerate variations in frequency of 47 or 63 Hz. The power supply is designed
to withstand an ac input overvoltage of 300 Vac for one second with no
degradation of dc output voltage or damage to printer circuits.

DC Power
The power supply PCBA contains two dc power supply systems for the
printer. The first is a + 5 V bus for logic. The second consists of + 48 V and
+ 9.5 V buses for the electromechanical sections of the printer (that is, all
drive motors and the hammer bank).
The maximum total continuous average DC load is 346 W. The + 5 V supply
has a separate return line. Both returns are tied together in a single–point
ground.
There is an opto–isolated logic level input from the printer that can shut
down and latch off the + 48 V and + 9.5 V supplies while maintaining the
+ 5 V output. The return for this signal is the + 5 V return. In addition, this
shutdown circuit discharges and latches the + 48 V down to a level lower

E–14

Principles of Operation

than 15 V in less than 200 milliseconds and requires recycling of the circuit
breaker (ac input) to reset the latch.
The + 5 V power supply has its own inverter, separate from the + 48 V and
+ 9.5 V outputs.

Printing Mechanism
The printing mechanism consists of the shuttle frame assembly, which carries
the hammer bank assembly, the ribbon transport system, and the paper
transport system. Figure E–6 shows the shuttle frame assembly.

Counterweight
Assembly

Hammer Bank
Assembly

Connecting Rod
Shuttle Motor
Shuttle Frame
Assembly
Guide Shaft

Figure E–6. Shuttle Frame Assembly

Principles of Operation

E–15

Shuttle Frame and Hammer Bank Assemblies
Dots are printed by 47 hammer springs mounted on the hammer bank. The
hammers are arrayed in seven comb–like hammer spring assemblies, or frets.
Each fret contains 7 hammers. Using 49 hammers balances the magnetic field
characteristics of the hammer bank, while design parameters determine the
use of 47 hammers for printing. (The first and 49th hammers do not print.)
The frets mount to the hammer bank on alignment pins, eliminating the need
for individual hammer alignment.
Each print hammer is a stiff leaf spring with a cylindrical, tungsten carbide
tip on the free end. (See Figure E–7.) A permanent magnet runs the length of
the hammer bank and acts on the hammer springs through individual pole
pieces. The pole pieces magnetically attract and hold the free end of the
hammer spring under tension. This is called the retracted state.
Heat Sink

Tungsten Carbide
Hammer Tip

Hammer Bank:
Coils, Magnet,
and Pole Pieces

Hammer Spring
Assembly

Alignment Pin

Figure E–7. Hammer Springs and Hammer Bank (Detail)
A pair of electromagnetic coils is mounted behind each hammer and wound
around each pole piece. The coils are normally de–energized. When hammer
driver logic determines that the hammer must print a dot, a current pulse
energizes the coils. The polarity of the resulting magnetic field opposes the
field of the permanent magnet, cancelling its effect and releasing the hammer.

E–16

Principles of Operation

The hammer springs forward, strikes the ribbon and paper, and leaves a dot
impression of the hammer tip on the paper.
The coil is de–energized and its field collapses while the hammer is in flight.
After striking the ribbon and paper, the hammer rebounds and the permanent
magnet recaptures it.
A line of characters is created as the shuttle scans horizontally (See
Figure E–8). All the dots in a given row of the character dot matrix are
printed in a single scan as the shuttle moves through the character columns
from one side to the other. Figure E–9 shows how a hammer forms a
character as the shuttle scans horizontally.
Characters are formed inside dot matrices, the dimensions of which vary
according to the selected font. The dot printing process continues for the
number of dot matrix rows determined by the selected font. When an entire
character line is printed, the paper feed system advances the paper to the top
dot row of the next character line to be printed. During this line advance, the
hammer bank assembly continues the right/left oscillation, but the hammers
do not print.

Direction of Shuttle Movement
Dot
Row

Start

1
2
3
4
5
6
7
8*
9* *
10
Number of rows is determined by line spacing.
11
n
1
2

One
Text
Line

This row is used only for lowercase descenders.

This row is used for underlining and lowercase descenders.

Paper
Feed
Direction

Figure E–8. Standard Character Formation

Principles of Operation

E–17

Succesive Hammer Strokes Per Scan

Shuttle
Scan

Dot
Row

1
2

1
2
3

1
2
3
4

1
2
3
4
5

1
2
3
4
5
6

1
2
3
4
5
6
7

* 1

*1 3

*1 35

*1 3 5 7

*13 5 7 9 *

column dot centers within the printed character
* Even
area and character space hammer positions are not
illustrated in this diagram.
NOTE:

= Hammer Released and Dot Printed
= Hammer Not Released; No Dot Printed

Figure E–9. Typical Action of One Hammer in Text Printing

E–18

Principles of Operation

Paper Transport System
The paper transport system accepts continuous, fan–folded, edge–perforated
paper from three to 16 inches wide and from one to six sheets thick.
Horizontal positioning is provided by the horizontal adjustment knob and
two tractors. The tractors are laterally adjustable along the splined and
support shafts. Each tractor engages paper perforations with six pins and
locks in place with a friction lock. During printing, the tractors are driven by
the splined shaft, which is belt–driven by the paper feed drive motor. The
paper feed drive motor is a two–phase step motor controlled by the paper
feed sections of the mechanism driver board and the paper feed controller on
the common controller board.
Paper may be manually advanced vertically with the vertical adjustment
knob.

Left Tractor
Horizontal
Adjustment
Knob
Right Tractor
Vertical Adjustment
Knob And Splined Shaft
Pulley
Tractor
Support
Shaft

Shuttle Cover Assembly

Paper Feed Timing Belt
(Under the cover)
Splined Shaft

Figure E–10. Paper Transport System

Principles of Operation

E–19

Ribbon Transport System
The printer ribbon winds and unwinds continuously on a pair of spools
latched to hubs which are driven by the ribbon motors. The ribbon motors
operate only while the hammer bank assembly is running. Ribbon motion
reverses when the metal strip at either end of the ribbon crosses the left or
right ribbon guide, completing a circuit that causes both motors to reverse
direction.
Constant ribbon tension is maintained by controlling each motor with a drive
or drag circuit. While the hammer bank assembly is in motion, one motor
acts as a driving motor, drawing the ribbon against the resistance exerted by
the other motor—the drag motor. This system maintains a constant motor speed
and constant ribbon tension.

Ribbon Guide, Left
(Not Shown)
Ribbon Hub

Hub Locking Latch

Ribbon Spool

Ribbon Motors
(Not Shown):
Mounted In Base
Casting
Ribbon Guide, Right
Ribbon

Figure E–11. Ribbon Transport System

E–20

Principles of Operation

Ferrite Noise Suppression Cores

Ferrite cores reduce radio frequency interference (RFI) with electronic
equipment located near the printer.
Two kinds of ferrite cores are used in the printer:
1. Cylindrical cores—Cables pass through the core or are wound around it.
2. Block cores—The core is housed in a hinged plastic case. Cables are laid in a
groove in the core, and the plastic case is closed, securing the core to the
cable.
Figure F–1 shows the location of the ferrite cores in the LG06 printer.
IMPORTANT

When removing cables that pass through or around ferrite cores, note
the number of times the cable is wound around the core. You must
duplicate these windings when you replace the cable. Use Figure F–1 as
your guide.

Ferrite Noise Suppression Cores

F–1

Paper Feed
Motor cable
passes through
core (no wrap)
on its way to the
card cage.

Round ferrite cores are tie–
wrapped to the side of the
card cage. (See the
Maineance Tip below.)

Ribbon Motor
cable wraps once
around core before
it enters the card
cage.

Control Panel
cable wraps
4 times around
core before
it enters the
card cage.

Card Cage

Card
Cage
Fan

Maintenance TIp:
Route and wrap the cables
first. Tie wrap the round
ferrite cores to the card
cage last.

Platen
open
motor

Paper
feed
motor

Paper feed mechanisms
and barrier panel
Platen

Shuttle Frame Assembly

Ribbon motor cables
are routed under the base
casting.

Ribbon
Drive
Motor

Hammer Bank
Fan

Base casting

Cable
connector.

Round
ferrite core.

Hinged,
plastic wrapped
ferrite core.

Fold the ribbon cable
in half, then snap the ferrite
core shut over the cable.
Slide the core as close to
the control panel as
possible and flatten the
ribbon cable to prevent the
core from sliding down the
cable.

Figure F–1. Ferrite Core Locations

F–2

Ferrite Noise Suppression Cores

Index
Numbers
48 Volt Failed, 3–2

A
Adjustments, 4–1
hammer phasing, 4–4
paper drive motor pulley alignment, 4–10
paper feed timing belt tension, 4–6
paper scale, 4–2
platen angle, 4–16
platen gap, 4–18
platen open belt, 4–8
platen open motor pulley alignment, 4–12
ribbon guide, 4–20
splined shaft skew adjustment, 4–14
Appendices:
Ferrite Noise Suppression Cores, F–1
Interconnection Diagram and Cables, D–1
Principles of Operation, E–1
Printer Configuration, A–1
Printer Specifications, B–1
Torque Table, C–1

B
Belt
paper feed timing, replacement, 5–4
paper feed timing, tension adjustment, 4–6
platen open, replacement, 5–6
platen open, tension adjustment, 4–8

C
Cable assembly
hammer bank, replacement, 5–8

I/O, replacement, 5–14
interconnection diagram, D–1
intermediate, replacement, 5–10
part numbers, D–1
Card cage, fan assembly, replacement, 5–26
Cautions, 1–2
Checks. See Preventive Maintenance Checks
and Services
Checks and Service, 2–2
Preventive Maintenance, 2–2
Chips (PROMs, DIPs, ICs), location of, 5–53,
5–55
Circuit boards. See PCBA
Circuit breaker, replacement, 5–18
Cleaning the printer, 2–4
Commands, precedence, A–2
Configuration, A–1
diagram, A–7
how to read the configuration diagram, A–7
loading values, A–5
locking and unlocking the ENTER Switch,
A–3
printout, A–2
procedure, A–3
saving values, A–4
Control codes, override, A–2
Control panel
configuration diagram, A–7
replacement, 5–20
Controller PCBA, replacement, 5–46
Controls and indicators
locations and functions, 1–4

printing conventions, 1–3
Cores, noise suppression, F–1
Cover assembly
hammer bank, replacement, 5–22
shuttle, replacement, 5–24
Covers and doors, locations and operation,
1–4

D
Diagnostic self–tests, 3–26
Diagram
configuration, A–7
interconnection and cables, D–1
Dimensions, printer, B–3

48 Volt Failed, 3–2
Dynamic RAM Fault, 3–4
Ham. Bank Hot, 3–5
Ham. Coil Open, 3–6
Ham. Coil Short, 3–7
Ham. Drv. Short, 3–8
Mech Driver Hot, 3–9
Mech Driver Link, 3–10
Paper Jam, 3–11
Paper Out, 3–12
Platen Open, 3–13
Ribbon Stall, 3–14
Shttl Cover Open, 3–15
Shuttle Jam, 3–16
Software Error, 3–17
Ferrite cores, F–1

Display messages, printing conventions, 1–3
Documents related to this manual, 1–2
Doors and covers, locations and operation,
1–4
Duty cycle, B–8
Dynamic RAM Fault, 3–4

E
Electrical characteristics, B–4
Emulations, changing, A–6
Environmental characteristics, B–4
Error messages, 3–2

G
Gap, adjustment
magnetic pick–up (MPU), 5–34
platen, 4–18

H
Ham. Bank Hot, 3–5
Ham. Coil Open, 3–6
Ham. Coil Short, 3–7
Ham. Drv. Short, 3–8
Hammer
phasing adjustment, 4–4
spring assembly, replacement, 5–32

Fan assembly
card cage, replacement, 5–26
hammer bank, replacement, 5–28, 5–30

Hammer bank
cover assembly, replacement, 5–22
fan assembly, replacement, 5–28, 5–30
wiring diagram, D–1

Fault messages

Hammer phasing adjustment, 4–4

Hex code printout, 3–29

Mech Driver Link, 3–10

Hub, ribbon, replacement, 5–58

Mechanism driver PCBA, replacement, 5–48
Messages, fault, 3–2

I
ICs, location and replacement
CCB, 5–52
Mech. Driver, 5–54

Motor
paper feed drive, replacement, 5–38
platen open, replacement, 5–40
ribbon drive, replacement, 5–36

Important notes, 1–2

MPU. See Magnetic pick–up assembly

Information
how to locate, 1–2
special, 1–2

Noise suppression, F–1

Inspection, printer, 2–3

Notes, 1–2

Interface specifications, B–3

O
L
Loading configuration values, A–5

M
Magnetic pick–up assembly, replacement,
5–34
Maintenance
adjustments, 4–1
cleaning the printer, 2–4
inspecting the printer, 2–3
overview, 1–1
preparing the printer for, 5–3
preventive maintenance checks and services, 2–2
scheduled, 2–1
Manual
how to use this manual, 1–2
related documents, 1–2
warnings, cautions, and notes, 1–2

Operation, principles of, E–1
Override. See Control codes

P
Paper
detector switch assembly, replacement,
5–76
drive motor pulley alignment, 4–10
feed drive motor, replacement, 5–38
feed timing belt replacement, 5–4
feed timing belt tension adjustment, 4–6
guide assembly, removal/installation, 5–42
ironer, replacement, 5–44
scale adjustment, 4–2
specifications, B–2
tractor (L/R), replacement, 5–80
Paper detector switch, replacement, 5–76
Paper Jam, 3–11
Paper Out, 3–12

Mech Driver Hot, 3–9

Part Numbers, 5–3
PCBA, replacement
controller, 5–46
mechanism driver, 5–48
power supply, 5–50
Phasing adjustment, 4–4
Physical Inspection, 2–3
Platen
angle adjustment, 4–16
gap adjustment, 4–18
interlock switch assembly, replacement,
5–78
platen open belt adjustment, 4–8
platen open motor, replacement, 5–40
Platen Open, 3–13
Plot, rates, B–6
PMCS. See Preventive Maintenance Checks
and Services
Power supply, PCBA replacement, 5–50
Precedence, commands, A–2
Preventive Maintenance, Checks and Service,
2–2
Preventive Maintenance Checks and Services
(PMCS), 2–2
Principles of operation, E–1
Printed circuit board assembly. See PCBA
Printer
adjustments, 4–1
cleaning, 2–4
command precedence, A–2
configuration, A–1
dimensions, B–3
Duty cycle, B–8
emulations, changing, A–6
inspection, 2–3

maintenance overview, 1–1
preparing the printer for maintenance, 5–3
preventive maintenance checks and services, 2–2
principles of operation, E–1
self–tests, 3–26
specifications, B–1
troubleshooting, 3–1
Printing conventions in this manual, 1–3
Printouts
configuration, A–2
hex code, 3–29
Procedures
adjustment, 4–1
cleaning, 2–4
configuration, A–3
inspection, 2–3
replacement, 5–1
PROMs, location and replacement
CCB, 5–52
Mech. Driver, 5–54

R
Replacement
card cage fan assembly, 5–26
circuit breaker, 5–18
control panel assembly, 5–20
controller PCBA, 5–46
cover open switch assembly, 5–74
extension spring, 5–72
gas spring assembly, 5–70
hammer bank cable assembly, 5–8
hammer bank cover assembly, 5–22
hammer bank fan assembly, 5–28, 5–30
hammer spring, 5–32
intermediate cable assembly, 5–10
magnetic pick–up assembly, 5–34

mechanism driver PCBA, 5–48
multi I/O cable assembly, 5–14
paper detector switch assembly, 5–76
paper feed drive motor, 5–38
paper feed timing belt, 5–4
paper guide assembly, 5–42
paper ironer, 5–44
platen interlock switch assembly, 5–78
platen open belt, 5–6
platen open motor, 5–40
power supply PCBA, 5–50
PROMs
CCB, 5–52
Mech. Driver, 5–54
resistors, terminating, 5–56
ribbon drive motor, 5–36
ribbon guide assembly (L/R), 5–60
ribbon hub, 5–58
shuttle cover assembly, 5–24
shuttle frame assembly, 5–66
splined shaft, 5–62
support shaft, 5–64
tractor (L/R), 5–80
Resistors, terminating, location of, 5–57
Ribbon
drive motor, replacement, 5–36
guide assembly (L/R), replacement, 5–60
guide assembly, alignment, 4–20
hub, replacement, 5–58
specifications, B–2
Ribbon Stall, 3–14

Services. See Preventive Maintenance Checks
and Services
Shaft
splined, replacement, 5–62
splined, skew adjustment, 4–14
support, replacement, 5–64
Shttl Cover Open, 3–15
Shuttle
cover assembly, replacement, 5–24
frame assembly, replacement, 5–66
Shuttle Jam, 3–16
Software Error, 3–17
Specifications
cleaning, B–2
dimensions, printer, B–3
Duty cycle, B–8
electrical, B–4
environmental, B–4
interfaces, B–3
paper, B–2
printing rates, B–6
ribbon, B–2
Speed, printing, B–6
Splined shaft
replacement, 5–62
skew adjustment, 4–14
Spring
extension, replacement, 5–72
gas, assembly, replacement, 5–70
Support shaft, replacement, 5–64

S
Saving configuration values, A–4
Scheduled maintenance, 2–1
Self–tests, 3–26
running, 3–28

Switch
cover open switch assembly, replacement,
5–74
paper detector switch assembly, replacement, 5–76

platen interlock switch assembly, replacement, 5–78
Switch, power, replacement, 5–18
Switches, locations and operation, 1–6

T
Tension adjustment
paper feed timing belt, 4–6
platen open belt, 4–8
Terminating resistors
location of, 5–57
replacement, 5–56
Test
equipment, tools, and supplies, 1–10
printer performance, 3–26
Tools, test equipment, and supplies, 1–10
Torque table, C–1
Tractor, replacement, 5–80
Troubleshooting, 3–1
fault messages, 3–2

W
Warnings, 1–2
Wiring diagram, hammer bank, D–1