IBM Infoprint 6500-v05 User manual

Infoprint 6500 Line Matrix Printers
Models 6500-v05, -v5P, -v10, -v1P, -v15, and -v20
Maintenance Information Manual
Form No. G544-5978-00

First Edition (July 2005)
This edition applies to the IBM Infoprint 6500 Line Matrix Printer.
The following paragraph does not apply to any other country where such provisions are inconsistent with local law:
INTERNATIONAL BUSINESS MACHINES CORPORATION PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY
OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
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Copyright International Business Machines Corporation, 2005. All rights reserved.
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Note!
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3
Table Of Contents
ENERGY STAR .......................................................................................................................................................... 10
Notices............................................................................................................................................................................... 10
Communication Statements ........................................................................................................................................ 12
European Union (EC) Electromagnetic Compatibility Directives............................................................................... 16
Electrical Safety .......................................................................................................................................................... 17
Lightning Safety .......................................................................................................................................................... 17
Safety And Notices...................................................................................................................................................... 17
Trademarks and Service Marks ..................................................................................................................................19
Safety Inspection ............................................................................................................................................................... 21
Preparation.................................................................................................................................................................. 21
Prepare The Printer For Inspection.............................................................................................................................21
Inspect Mechanical Parts ............................................................................................................................................ 22
Inspect Electrical Parts................................................................................................................................................ 23
Preface .............................................................................................................................................................................. 26
About This Manual ...................................................................................................................................................... 26
Printing Conventions In This Manual .......................................................................................................................... 27
Related Documents..................................................................................................................................................... 28
About The Printer............................................................................................................................................................... 29
The IBM Infoprint 6500 Printer Family............................................................................................................................... 29
How To Identify The Printer ........................................................................................................................................ 30
Printer Configuration Code.......................................................................................................................................... 31
Forms Handling........................................................................................................................................................... 32
Important Maintenance Notes ..................................................................................................................................... 33
Controls And Indicators ..................................................................................................................................................... 34
Electrical Controls: Figure 5 ........................................................................................................................................ 34
Mechanical Controls: Figure 6 .................................................................................................................................... 37

Table of Contents
4
1 Diagnosing Problems..................................................................................................39
Introduction........................................................................................................................................................................ 39
Troubleshooting At A Glance ............................................................................................................................................ 39
Start Of Call ....................................................................................................................................................................... 40
How To Troubleshoot ........................................................................................................................................................ 41
Troubleshooting Display Messages................................................................................................................................... 42
Display Messages ....................................................................................................................................................... 42
Troubleshooting Other Symptoms................................................................................................................................... 170
Communication Problems ......................................................................................................................................... 171
General Symptom List............................................................................................................................................... 176
2 Diagnostics ...............................................................................................................212
Contents .......................................................................................................................................................................... 212
Operator Print Tests ........................................................................................................................................................ 213
Selecting And Running Tests.................................................................................................................................... 215
Customer Engineer (CE) Tests........................................................................................................................................ 216
Boot Diagnostics Menu.................................................................................................................................................... 221
Hex Code Printout ........................................................................................................................................................... 224
Printer Information Menu ................................................................................................................................................. 226
Soft vs. Hard Reset.......................................................................................................................................................... 228
Soft Reset ................................................................................................................................................................. 228
Hard Reset (“Cycle Power”) ...................................................................................................................................... 228
Controller Board Status LEDs At Power Up .................................................................................................................... 229
Troubleshooting A New Installation ................................................................................................................................. 230
Printer Configuration ................................................................................................................................................. 230
Documentation .......................................................................................................................................................... 230
RibbonMinder**................................................................................................................................................................ 231
RibbonMinder Operation ........................................................................................................................................... 231
The Ribbon Log......................................................................................................................................................... 235
Downloading Microcode From IBM First.......................................................................................................................... 236
Clear NVRAM .................................................................................................................................................................. 237

Table of Contents
5
Loading Flash Memory .................................................................................................................................................... 238
Loading Through The Serial Or Parallel Port ............................................................................................................ 239
Loading Through the Network Interface Card (NIC) ................................................................................................. 248
Reprogramming the Security Key.................................................................................................................................... 250
Shuttle Electrical Shorts Test........................................................................................................................................... 252
Hammer Bank Power Cable Shorts Test......................................................................................................................... 253
Cable Shorts Test............................................................................................................................................................ 254
Main Wire Harness Test Diagnostic ................................................................................................................................ 256
Power Supply Operational Check.................................................................................................................................... 258
3 Locations ..................................................................................................................262
Locations Of Components And Assemblies .................................................................................................................... 262
4 Circuit Diagrams, Circuit Boards, Cables, and Switches ..........................................264
Contents .......................................................................................................................................................................... 264
5 Removals and Adjustments ......................................................................................311
About This Chapter.......................................................................................................................................................... 311
Tools And Materials .................................................................................................................................................. 311
Preparing The Printer For Maintenance.................................................................................................................... 313
Restoring The Printer To Operation .......................................................................................................................... 314
Removal And Replacement Procedures.......................................................................................................................... 315
List Of Procedures .................................................................................................................................................... 315
Belt, Paper Feed Timing ........................................................................................................................................... 317
Belt, Platen Open ...................................................................................................................................................... 318
Circuit Board: PSA3 Controller.................................................................................................................................. 319
Circuit Board: Power Supply ..................................................................................................................................... 321
Circuit Breaker .......................................................................................................................................................... 322
Connector Shells....................................................................................................................................................... 323
Cover Assembly, Hammer Bank / Ribbon Mask ....................................................................................................... 325
Cover Assembly, Shuttle........................................................................................................................................... 326

Table of Contents
6
Cover Assembly, Top, Pedestal Model ..................................................................................................................... 327
Dashpot..................................................................................................................................................................... 328
Ethernet Interface Assembly ..................................................................................................................................... 329
Fan Assembly, Cabinet Exhaust ............................................................................................................................... 330
Fan Assembly, Card Cage ........................................................................................................................................ 331
Fan Assembly, Hammer Bank .................................................................................................................................. 332
Hammer Spring Assembly ........................................................................................................................................ 333
IBM Coax/Twinax Expansion Board.......................................................................................................................... 337
Magnetic Pick-up (MPU) Assembly........................................................................................................................... 338
Memory Modules and Security Key .......................................................................................................................... 339
Motor Assembly, Paper Feed.................................................................................................................................... 342
Motor Assembly, Platen Open .................................................................................................................................. 344
Motor Assembly, Ribbon Drive.................................................................................................................................. 346
Operator Panel Assembly ......................................................................................................................................... 347
Paper Guide Assembly ............................................................................................................................................. 348
Paper Ironer .............................................................................................................................................................. 349
Platen ........................................................................................................................................................................ 350
Platen Stop Assembly ............................................................................................................................................... 354
Resistors, Terminating .............................................................................................................................................. 355
Ribbon Guide Assembly (L/R)................................................................................................................................... 357
RibbonMinder** Sensor............................................................................................................................................. 358
Shaft, Splined............................................................................................................................................................ 359
Shaft, Support ........................................................................................................................................................... 361
Shuttle Frame Assembly ........................................................................................................................................... 362
Spring, Extension, Hammer Bank ............................................................................................................................. 364
Switch Assembly, Paper Detector............................................................................................................................. 365
Switch Assembly, Platen Interlock ............................................................................................................................ 366
Tractor (L/R).............................................................................................................................................................. 367
Adjustment Procedures ................................................................................................................................................... 368
List Of Adjustments ................................................................................................................................................... 368
Belt, Paper Feed Timing, Adjustment (Figure 24)..................................................................................................... 369

Table of Contents
7
Belt, Platen Open, Adjustment (Figure 25) ............................................................................................................... 371
Paper Scale Alignment (Figure 26) ........................................................................................................................... 373
Platen Gap Adjustment (Figure 27)........................................................................................................................... 374
Ribbon Guide Alignment (Figure 28)......................................................................................................................... 376
Adjusting The End Of Forms Distance...................................................................................................................... 378
Hammer Phasing Adjustment ................................................................................................................................... 381
Coil Temperature Adjustment ................................................................................................................................... 383
Dynamic Paper Tension Adjustment......................................................................................................................... 384
Tractor Belt Tension Adjustment............................................................................................................................... 387
Ethernet Initialization................................................................................................................................................. 389
6 Parts Catalog ............................................................................................................390
Organization Of This Chapter .......................................................................................................................................... 390
Illustrated Parts Breakdown............................................................................................................................................. 390
7 Preventive Maintenance ...........................................................................................431
Contents .......................................................................................................................................................................... 431
Cleaning The Printer........................................................................................................................................................ 432
Cleaning The Exterior...................................................................................................................................................... 432
Cleaning The Interior ....................................................................................................................................................... 433
Cleaning The Shuttle Frame Assembly ........................................................................................................................... 434
Cleaning The Card Cage Fan Assembly ......................................................................................................................... 436
A Installing And Relocating The Printer .......................................................................437
Installing And Configuring The Infoprint 6500 Printer...................................................................................................... 437
Relocating The Infoprint 6500 Printer.............................................................................................................................. 437
B Communication Adapters .........................................................................................438
Contents .......................................................................................................................................................................... 438
Ethernet Interface Assembly............................................................................................................................................ 439
Ethernet Troubleshooting Tips......................................................................................................................................... 439
IBM Coax/Twinax Expansion Board ................................................................................................................................ 444

Table of Contents
8
C Power Cords And Adapters......................................................................................445
D ASCII Codes ............................................................................................................447
E SureStak** Power Stacker .......................................................................................451
Contents .......................................................................................................................................................................... 451
Introduction...................................................................................................................................................................... 452
How To Operate The Power Stacker............................................................................................................................... 453
Stacker Problems ............................................................................................................................................................ 459
Removing The Power Stacker......................................................................................................................................... 465
Installing The Power Stacker........................................................................................................................................... 473
Replacing The Constant Force Spring............................................................................................................................. 485
Replacing The Timing Belts............................................................................................................................................. 487
Replacing The Roller Drive Shaft .................................................................................................................................... 491
Illustrated Parts Breakdown............................................................................................................................................. 494
List of Illustrations ..................................................................................................................................................... 494
F Printer Specifications................................................................................................504
Contents .......................................................................................................................................................................... 504
Ribbon Specifications ...................................................................................................................................................... 505
Ordering Ribbons............................................................................................................................................................. 505
6500-v Models........................................................................................................................................................... 505
Paper Specifications........................................................................................................................................................ 507
Labels........................................................................................................................................................................ 508
Printer Dimensions and Weight ....................................................................................................................................... 508
Environmental Characteristics......................................................................................................................................... 509
Temperature.............................................................................................................................................................. 509
Relative Humidity ...................................................................................................................................................... 509
Noise Levels.............................................................................................................................................................. 509
Electrical Characteristics ................................................................................................................................................. 510
Interfaces ......................................................................................................................................................................... 511

Table of Contents
9
Cables.............................................................................................................................................................................. 511
Printing Rates .................................................................................................................................................................. 512
G Metric Conversion Tables ........................................................................................515
Length ....................................................................................................................................................................... 515
Torque and Force...................................................................................................................................................... 516
Mass and Density...................................................................................................................................................... 516
Temperature.............................................................................................................................................................. 517
Power ........................................................................................................................................................................ 517
H Torque Table............................................................................................................518
I Abbreviations .............................................................................................................520

ENERGY STAR
10
E NERGY S TAR
The Environmental Protection Agency ENERGY STAR ® Computers program is a partnership effort with manufacturers of data
processing equipment to promote the introduction of energy-efficient personal computers, monitors, printers, fax machines, and
copiers to help reduce air pollution and global warming caused by electricity generation.
IBM* Printing Systems Company participates in this program by introducing printers that reduce power consumption when they
are not being used. As an ENERGY STAR
® Partner, IBM Printing Systems Company has determined that this product meets the
ENERGY STAR
® guidelines for energy efficiency.
NOTE: The ENERGY STAR
® emblem does not represent EPA endorsement of any product or service.
Notices
This information was developed for products and services offered in the U.S.A.
IBM may not offer the products, services, or features discussed in this document in other countries. Consult your IBM
representative for information on the products and services currently available in your area. Any reference to an IBM product,
program, or service is not intended to state or imply that only that IBM product, program, or service may be used. Any
functionally equivalent product, program, or service that does not infringe any IBM intellectual property rights may be used
instead. However, it is the user’s responsibility to evaluate and verify the operation of any non-IBM product, program, or
service.
IBM may have patents or pending patent applications covering subject matter described in this document. The furnishing of this
document does not give you any license to these patents. You can send license inquires, in writing, to:
IBM Director of Licensing
IBM Corporation
North Castle Drive
Armonk, NY 10504-1785 U.S.A.

ENERGY STAR
11
The following paragraph does not apply to the United Kingdom or any other country where such provisions are
inconsistent with local law:
INTERNATIONAL BUSINESS MACHINES CORPORATION PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY
OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
NON-INFRINGEMENT, MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow
disclaimer of express or implied warranties in certain transactions, therefore, this statement may not apply to you.
This information could include technical inaccuracies or typographical errors. Changes are periodically made to the information
herein; these changes will be incorporated in new editions of the publication. IBM may make improvements and/or changes in
the product(s) described in this publication at any time without notice.
Any references in this information to non-IBM Web sites are provided for convenience only and do not in any manner serve as
an endorsement of those Web sites. The materials at those Web sites are not part of the materials for this IBM product and use
of those Web sites is at your own risk.
IBM may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation
to you.
Any performance data contained herein was determined in a controlled environment. Therefore, the results obtained in other
operating environments may vary significantly. Some measurements may have been made on development-level systems and
there is no guarantee that these measurements will be the same on generally available systems. Furthermore, some
measurement may have been estimated through extrapolation. Actual results may vary. Users of this document should verify
the applicable data for their specific environment.
Information concerning non-IBM products was obtained from the suppliers of those products, their published announcements
or other publicly available sources. IBM has not tested those products and cannot confirm the accuracy of performance,
compatibility or any other claims related to non-IBM products. Questions on the capabilities of non-IBM products should be
addressed to the suppliers of those products.
This information contains examples of data and reports used in daily business operations. To illustrate them as completely as
possible, the examples include the names of individuals, companies, brands, and products. All of these names are fictitious and
any similarity to the names and addresses used by an actual business enterprise is entirely coincidental.
If you are viewing this information softcopy, the photographs and color illustrations may not appear.
For online versions of this book, we authorize you to:
•Copy, modify, and print the documentation contained on the media, for use within your enterprise, provided you reproduce
the copyright notice, all warning statements, and other required statements on each copy or partial copy.

Communication Statements
12
•Transfer the original unaltered copy of the documentation when you transfer the related IBM product (which may be either
machines you own, or programs, if the program’s license terms permit a transfer). You must, at the same time, destroy all
other copies of the documentation.
You are responsible for payment of any taxes, including personal property taxes, resulting from this authorization.
Your failure to comply with the terms above terminates this authorization. Upon termination, you must destroy your machine
readable documentation.
Communication Statements
Federal Communications Commission (FCC) Statement
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC
Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated
in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and
used in accordance with the instructions, may cause harmful interference to radio communications. Operation of this equipment
in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at
his own expense.
Properly shielded and grounded cables and connectors must be used in order to meet FCC emission limits. IBM is not
responsible for any radio or television interference caused by using other than recommended cables and connectors or by
unauthorized changes or modifications to this equipment. Unauthorized changes or modifications could void the user’s
authority to operate the equipment.
This device complies with Part 15 of the FCC Fules. Operation is subject to the following two conditions: (1) this device may not
cause harmful interference, and (2) this device must accept any interference received, including interference that may cause
undesired operation.
European Union (EU) Conformity Statement
IBM cannot accept responsibility for any failure to satisfy the protection requirements resulting from a non-recommended
modification of the product, including the fitting of non-IBM option cards.
Hereby, IBM declares that this product is in complicance with the essential requirements and other relevent
provisions of Directive 1999/5/EC.

Communication Statements
13
This product has been tested and found to comply with the limits for Class A Information Technology Equipment according to
European standard EN 55022. The limits for Class A equipment were derived for commercial and industrial environments to
provide reasonable protection against interference with licensed communication devices.
Properly shielded and grounded cables and connectors must be used in order to reduce the potential for causing interference
to radio and TV communications and to other electrical or electronic equipment. Such cables and connectors are available from
IBM authorized dealers. IBM cannot accept responsibility for any interference caused by using other than recommended cables
and connectors.
Industry Canada Compliance Statement
This Class A digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la classe A conform á la norme NMB-003 du Canada.
Statement of CISPR 22 Edition 2 Compliance
Attention: This is a Class A Product. In a domestic environment this product may cause radio interference in which case the
user may be required to take adequate measures.
Japanese VCCI Class A
This is a Class A product. In a domestic environment this product may cause radio interference in which case the user may
be required to take adequate measures.
WARNING

Communication Statements
14
Japanese JEITA Statement
Taiwan
Warning: This is a Class A product. In a domestic environment this product may cause radio interference in which case the
user will be required to take adequate measures.
Australia/New Zealand
Attention: This is a Class A Product. In a domestic enviroment this product may cause radio interference in which case the
user may be required to take adequate measures.

Communication Statements
15
Korea
China
Declaration: This is a Case A Product. In a domestic environment this product may cause radio interference in which case the
user may be required to take practical actions.
German Conformity Statement
Handbuchtexte: FCC class A entspricht: EMVG Klasse A
Text für alle in Deutschland vertriebenen EN 55022 Klasse A Geräte:
Zulassungsbescheinigung laut dem Deutschen Gesetz über die elektromagnetische Verträglichket von Geräten (EMVG) vom
18. September 1998 (bzw. der EMC EG Richtlinie 89/336):
Dieses Gerät ist berechtigt in Übereinstimmung mit dem deutschen das EG-Konformitätszeichen - CE - zu führen.
Verantwortlich für die Konformitätserklärung nach Paragraph 5 des EMVG ist die IBM Deutschland Informationssysteme
GmbH, 70548 Stuttgart.

European Union (EC) Electromagnetic Compatibility Directives
16
Informationen in Hinsicht EMVG Paragraph 3 Abs. (2) 2:
Das Gerät erfüllt die Schutzanforderungen nach EN 55022 Klasse A und EN 50024.
EN 55022 Klasse A Gerdte müssen mit folgendem Warnhinweis versehen werden: Warnung: dies ist eine Einrichtung der
Klasse A. Diese Einrichtung kann im Wohnbereich Funkstörungen öerursachen; in diesem Fall kann vom Betreiber verlangt
werden, angemessene Maßnahmen durchzuführen und dafür aufzukommen.
EN 55024 Hinweis:
Wird dieses Gerät in einer industriellen Umgebung betrieben (wie in EN 55024 festgelegt), dann kann es dabei eventuell
gestört werden. In solch einem Fall ist der Abstand bzw. die Abschirmung zu der industriellen Störquelle zu öergrvßern.
Anmerkung:
Um die Einhaltung des EMVG sicherzustellen sind die Geräte, wie in den Handbüchern angegeben, zu installieren und zu
betreiben.
European Union (EC) Electromagnetic Compatibility Directives
This product conforms to the protection requirements of EC Council Directive 89/336/EEC on the approximation of the laws of
the Member States relating to electromagnetic compatibility. IBM cannot accept responsibility for any failure to satisfy the
protection requirements resulting from a non-recommended modification of the product, including the fitting of non-IBM option
cards.
Dieses Gerät ist berechtigt in Übereinstimmung mit dem deutschen EMVG vom 9.Nov.92 das EG-Konformitätszeichen zu
furhren.
Properly shielded and grounded cables and connectors must be used to reduce the potential for causing interference to radio
and TV communication and to other electrical or electronic equipment. IBM cannot be responsible for any interference caused
by using other than recommended cables and connectors.
This product has been tested and found to comply with limits for Class A Information Technology Equipment according to
CISPR 22/European Standard EN 55022. The limits for Class A equipment were derived for commercial and industrial
environments to provide reasonable protection against interference with licensed communication equipment.
Warning: This is a Class A product. In a domestic environment this product may cause radio interference in which case the user
may be required to take adequate measures.
Dieses Gerät erfüllt die Bedingungen der EN 55022 Klasse A. Für diese Klasse von Geräten gilt folgende Bestimmung nach
dem EMVG:
Geräte dürfen an Orten, für die sie nicht ausreichend entstört sind, nur mit besonderer Genehmigung des Bundesminesters für
Post und Telekommunikation oder des Bundesamtes für Post und Telekommunikation betrieben werden. Die Genehmigung
wird erteilt, wenn keine elektromagnetischen Störungen zu erwarten sind.

Electrical Safety
17
(Auszug aus dem EMVG vom 9.Nov.92, Para.3, Abs.4)
Hinweis: Dieses Genehmigungsverfahren ist von der Deutschen Bundespost noch nicht veröffentlict worden.
Electrical Safety
The printers are inspected and listed by recognized national testing laboratories: Underwriters Laboratories, Inc. (UL**) in the
U.S.A., Canadian Standards Association (CSA**) in Canada, and TUV Rheinland. Listing of a product by a national testing
laboratory indicates that the product is designed and manufactured in accordance with national requirements intended to
minimize safety hazards. Remember, however, that this product operates under conditions of high electrical potentials and heat
generation, both of which are functionally necessary.
Lightning Safety
To avoid personal risk, do not install or reconfigure a communication port or a teleport during a lightning storm.
Safety And Notices
For your safety and to protect valuable equipment, always read and comply with all information highlighted under notes and
notices:
<#> This symbol indicates the presence of a hazard that could cause death or serious injury. Danger and
Caution notices are numbered to help you find the translated versions in the
IBM 6500 Safety Notices
booklet.
<#> This symbol indicates the presence of a hazard that could cause moderate or minor injury.
<#> This symbol indicates a heavy assembly that requires two or more persons to lift or hold.
DANGER
CAUTION
CAUTION

Safety And Notices
18
ATTENTION Attention indicates the possibility of damage to a device, program, system, or data.
IMPORTANT Important indicates information vital to proper operation of the printer.
NOTE: A note gives you helpful information and tips about printer operation and maintenance.
<#> This symbol indicates a part or assembly that is hot enough to burn you.
<#> This symbol indicates a part or assembly that is sharp enough to cut you.
CAUTION
CAUTION

Trademarks and Service Marks
19
Trademarks and Service Marks
The following terms are trademarks of IBM Corporation in the United States or other countries or both, and are designated by
one asterisk ( * ) in this manual:
AS/400
IBM
Infoprint
Intelligent Printer Data Stream
IPDS
PC-DOS
RISC System/6000
SCS
Token-Ring
The following terms are trademarks of other companies, and are designated by two asterisks ( ** ) in this manual:
Acrobat Adobe Systems Incorporated
Adobe Adobe Systems Incorporated
Auto Label Mapping Printronix, Inc.
Centronics Genicom Corporation
Code V Quality Micro Systems
CSA Canadian Standards Association
Dataproducts Dataproducts Corporation
ECOS ECOS Electronics Corp., Inc., Oak Park, Ill.
EIA Electronic Industries Association
Energy Star United States Environmental Protection Agency
Fluke John Fluke Manufacturing Co., Inc.
IEEE Institute of Electrical and Electronics Engineers, Inc.
IGP Printronix, Inc.

Trademarks and Service Marks
20
LinePrinter Plus, LP+ Printronix, Inc.
MS-DOS Microsoft Corporation
MTOS Industrial Programming, Inc.
PGL Printronix, Inc.
PKZIP PKWARE, Inc.
Printronix Printronix, Inc.
PSA3 Printronix, Inc.
QMS Quality Micro Systems, Inc.
RibbonMinder Printronix, Inc.
SureStak Printronix, Inc.
Torx Camcar/Textron Inc.
UL Underwriter’s Laboratories, Inc.
Windows 3.1x, 95, 98, Me, NT, 2000, and XP Microsoft Corporation