genicom 3460 maint manual

8/13/2019 Genicom 3460 Maint Manual

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GENICOM

MODEL 3460/3480/3480+

MAINTENANCE MANUAL

GEK-89537


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Maintenance Manual

Contents

GENICOM 3460 / 3480 / 3480+ ii.1 GEK-89537

Table of Contents

CHAPTER 1 GENERAL OVERVIEW Page

1.1 Introduction 1.21.1.1 Scope of the Products 1.21.1.2 Printer Features Summary 1.2

1.2 General Description 1.31.2.1 Physical Overview 1.41.2.2 Physical Dimension 1.61.2.3 Printer Structure 1.6

1.2.3.1 Mechanical Assy 1.61.2.3.1.1 Tractor Unit Assy 1.7

1.2.3.2 Print Head 1.71.2.3.3 Cabinet 1.71.2.3.4 Electronic Hardware 1.81.2.3.5 Inked Ribbon Cartridge 1.81.2.3.6 Mechanical Options 1.8

1.3 Product Components 1.91.3.1 Basic Printer 1.111.3.2 Options 1.11

1.3.2.1 Inked Ribbons 1.111.3.2.2 Automatic Sheet Feeder 1.111.3.2.3 Optional Tractor 1.111.3.2.4 Color Kit 1.111.3.2.5 Pedestal 1.11

1.4 Prnters Technical Specifications 1.12

CHAPTER 2PAPER HANDLING OVERVIEW

2.1 Introduction 2.22.1.1 Paper Handling Architecture 2.22.1.2 Paper Feeder Movements 2.52.1.3 Paper Path Configurations 2.8

2.1.3.1 Basic Configurations 2.82.1.3.2 Dual Fanfold Configurations 2.102.1.3.3 ASF Configuration 2.11

2.2 Actions to put Rear Tractor in Pull Mode 2.13


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Table of Contents cont'd

CHAPTER 3 REMOVAL AND REPLACEMENT PageFOR 3460 (A3) / 3480 (A3) / 3480+

3.1 Overview 3.23.2 Recommended Hand Tools and Equipment 3.23.3 O.R.U.Order of Access 3.3

3.3.1 Front Push-Pull Tractor Group 3.43.3.2 Operator Panel Boards 3.53.3.3 Print Head 3.73.3.4 Front Cover Parts 3.83.3.5 Rear Cover Parts 3.93.3.6 Serial Interface 3.103.3.7 Main Board 3.113.3.8 Power Supply Board 3.123.3.9 Ribbon Motor 3.133.3.10 AGA Motor 3.143.3.11 AGA Support and T/F Lever 3.153.3.12 Carriage Motor 3.163.3.13 Bail Assy 3.173.3.14 Cut Sheet Assy 3.183.3.15 Upper Feeder Assy 3.193.3.16 Platen Assy 3.203.3.17 Lower Feeder Assy 3.213.3.18 Carriage Assy 3.23

3.3.19 Sensor Assy 3.243.3.20 Mechanical Assy 3.263.3.21 Paper Motor Assy 3.273.3.22 Friction Bar Assy 3.28


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CHAPTER 4 REMOVAL AND REPLACEMENT PageFOR 3460 (A2) / 3480 (A2)

4.1 Overview 4.24.2 Recommended Hand Tools and Equipment 4.24.3 O.R.U.Order of Access 4.2

4.3.1 Front Push-Pull Tractor Group 4.24.3.2 Operator Panel Boards 4.24.3.3 Print Head 4.24.3.4 Front Cover Parts 4.24.3.5 Rear Cover Parts 4.24.3.6 Main Board 4.44.3.7 Power Supply Board 4.54.3.8 Ribbon Motor 4.54.3.9 AGA Motor 4.54.3.10 AGA Support and T/F Lever 4.54.3.11 Carriage Motor 4.54.3.12 Bail Assy 4.54.3.13 Cut Sheet Assy 4.54.3.14 Upper Feeder Assy 4.54.3.15 Platen Assy 4.54.3.16 Carriage Assy 4.74.3.17 Lower Feeder Assy 4.94.3.18 Sensor Assy 4.9

4.3.19 Mechanical Assy 4.94.3.20 Paper Motor 4.94.3.21 Friction Bar Assy 4.94.3.22 Ribbon Mask 4.94.3.23 Lower Mylar 4.10

CHAPTER 5ADJUSTMENTS

5.1 Overview 5.25.1.1 Carriage Belt 5.2

5.1.2 Paper Belt 5.35.1.3 Print Head Gap 5.45.1.4 AGA Calibrate 5.85.1.5 First Printing Line 5.105.1.6 Vertical (bidirectional printing) 5.115.1.7 Tear-off Line 5.135.1.8 Sensor Tuning 5.14


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CHAPTER 6SERVICE MAINTENANCE Page

6.1 Overview 6.2

6.2 Initial Ispection 6.26.2.1 Set-Up 6.26.2.2 Cleaning 6.36.2.3 Paper Specifications 6.36.2.4 Consumables 6.3

6.3 Troubleshooting Guide 6.46.3.1 Initializing Phase 6.46.3.2 Printer Errors 6.4

6.3.2.1 Status Errors 6.46.3.2.2 Recoverable Errors 6.56.3.2.3 Unrecoverable Errors 6.7

6.3.3 Power Malfunctions 6.96.3.3.1 P.S. Troubleshooting Guide 6.10

6.3.4 Self-Test 6.126.3.5 Hex-Dump 6.136.3.6 Faulty Probability Guide 6.14

6.4 Test & Diagnostic 6.186.4.1 Introduction 6.186.4.2 T&D Structure 6.186.4.3 T&D Kit 6.186.4.4 Execution of USER T&D 6.196.4.5 Loop-Back Connectors 6.20

6.4.5.1 Loop-Back Connector Diagrams 6.206.4.6 Diagnostic Program Management 6.22

6.4.6.1 Diagnostic Flow Chart 6.23

6.4.6.2 Diagnostic Error Management 6.266.4.7 T&D Tests List 6.276.4.8 ORU List 6.276.4.9 Diagnostic Errors Table 6.286.4.10 Tests Description 6.296.4.11 Analisys of Standard Modules 6.34

6.4.10.1 Fanfold Printout 6.346.4.10.2 Single Sheet Printout 6.37


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CHAPTER 7 ELECTROMECHANICAL DEVICES Page

7.1 Overview 7.2

7.1.1 Print Head 7.27.1.2 Motors 7.5

7.1.2.1 Carriage Motor 7.57.1.2.2 Paper Motor 7.67.1.2.3 AGA Motor 7.77.1.2.4 Ribbon Motor 7.87.1.2.5 Alternance Motor 7.97.1.2.6 ASF Motor 7.97.1.2.7 Color Motor 7.107.1.2.8 Stacker Motor 7.11

7.1.3 Cables 7.127.1.3.1 Sensors Cable 7.127.1.3.2 Alternance Cable 7.137.1.3.3 Paper Stacker Cable 7.137.1.3.4 Operator Panel Cable 7.14

CHAPTER 8INTERFACES

8.1 Overview 8.28.1.1 Hot Interfaces 8.2

8.2 IEEE 1284 Parallel Interface 8.28.2.1 Communication Modes 8.38.2.2 Operating Phases 8.38.2.3 Negotiation 8.4

8.2.4 Parallel Interface Signals 8.58.2.4.1 Parallel Interface Signals Behaviour 8.6

8.2.5 Electrical and Physical Characteristics 8.98.2.6 Interface Timing 8.10

8.3 Serial Interface 8.118.3.1 RS232/C Full Duplex Connection 8.11

8.3.1.1 Serial Interface RS232/C Signals 8.118.3.1.2 RS232/C Signals Behaviour 8.128.3.1.3 RS232/C Electrical and Physical Characteristics 8.14

8.3.2 RS422/A Interface 8.148.3.2.1 RS422/A Interface Signals 8.148.3.2.2 RS422/A Signals Behaviour 8.158.3.2.3 RS422/A Electrical and Physical Characteristics 8.16

8.3.3 Other characterisitcs of RS232/C & RS422/A 8.168.4 Link Protocols 8.17

8.4.1 DTR & 2nd RTS Data Flow Control 8.178.4.2 Xon/Xoff Data Flow Control 8.188.4.3 Buffer Management 8.19

CHAPTER 9OPTIONS Page

9.1 Overview 9.29.1.1 Automatic Sheet Feeder 9.29.1.2 Color Motor 9.6


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Figures

Page

1.1 Basic Printer Parts Location (front view) 1.31.2 Basic Printer Parts Location (rear view) 1.41.3 Printer Internal Architecture 1.51.4 Operator Panel Overview 1.17

2.1 Paper Handling Architecture 2.42.2 Paper Feeder Parts on Right Side 2.62.3 Paper Feeder Parts on Left Side 2.62.4 Automatic Movement of Friction Rollers 2.72.5 Front Load Push-Mode 2.82.6 Rear Load Push-Mode 2.92.7 Rear (bottom) Load Push-Mode 2.92.8 Front Load Push-mode and Rear Front Push-mode

with two tractors 2.102.9 Front Load Push-Pull with two tractors 2.112.10 Automatic Sheet Feeder 2.122.11 Actions to do to put Rear Tractor in Pull-mode 2.13

3.1 Front Push-Pull Tractor Group 3.4

3.2 Operator Panel Boards 3.53.3 Print Head 3.63.4 Front Cover Parts 3.73.5 Rear Cover Parts 3.83.6 Serial Interface Board 3.93.7 Main Board 3.103.8 Power Supply Board 3.113.9 Ribbon Motor 3.123.10 AGA Motor 3.133.11 AGA Support and T/F Lever 3.143.12 Carriage Motor 3.153.13 Bail Assy 3.163.14 Cut Sheet Assy 3.17

3.15 Upper Feeder Assy 3.183.16 Platen Assy 3.193.17 Lower Feeder Assy 3.213.18 Carriage Assy 3.223.19 Sensor Assy 3.233.20 Mechanical Assy 3.243.21 Paper Motor 3.25

3.22 Friction Bar Assy


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Figures cont'd

Page

4.1 Front Push-Pull Tractor Group 4.44.2 Operator Panel Boards 4.54.3 Print Head 4.64.4 Front Cover Parts 4.74.5 Rear Cover Parts 4.84.6 Serial Interface Board 4.94.7 Main Board 4.104.8 Power Supply Board 4.114.9 Ribbon Motor 4.124.10 AGA Motor 4.134.11 AGA Support and T/F Lever 4.144.12 Carriage Motor 4.154.13 Bail Assy 4.164.14 Cut Sheet Assy 4.174.15 Upper Feeder Assy 4.184.16 Platen Assy 4.194.17 Lower Feeder Assy 4.214.18 Carriage Assy 4.224.19 Sensor Assy 4.234.20 Mechanical Assy 4.244.21 Paper Motor 4.254.22 Friction Bar Assy 4.26

5.1 Carriage Assy Belt Adjustment 5.25.2 Paper Belt Adjustment 5.35.3 Print Head Adjustment 5.75.4 AGA Marker Adjustment 5.75.5 Vertical Adjustment Test 5.12

6.1 Power Supply Cover Tool Installation 6.96.2 Power Supply Test Points 6.116.3 Self-Test Printout 6.126.4 Hex-Dump Printout 6.136.5A 232/C Serial Interface Loop-back Diagram 6.206.5b 422/A Serial Interface Loop-back Diagram 6.20

6.6 Parallel Interface Loop-back Diagram 6.216.7 Mechanical Option Loop-back Diagram 6.216.8 Friction Bar Assy Position 6.316.9 3460 T&D Standard Fanfold Printout 6.356.10 3480 T&D Standard Fanfold Printout 6.366.11 T&D Standard Single Sheet Printout 6.38


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Figures cont'd

Page

7.1 9 Needles Print Head Pinout 7.37.2 24 Needles Print Head Pinout 7.47.3 Carriage Motor 7.57.4 Paper Motor 7.67.5 AGA Motor 7.77.6 Ribbon Motor 7.87.7 Color Motor 7.107.8 Stacker Motor 7.117.9 Sensors Cable 7.127.10 Alternance Cable 7.137.11 Paper Stacker Cable 7.137.12 Operator Panel Cable 7.14

8.1 Compatibility, Nibble and Byte Modephases Transitions 8.8

8.2 Centronics Timing 8.108.3 IEEE 1284 Timing 8.108.4 DTR & 2nd RTS Timing 8.178.5 XON-XOFF Timing 8.188.6 Buffer Management 8.19

9.1 First ASF Components 9.29.2 ASF and Stacker Blocks Diagrams 9.39.3 ASF Installation (rear view) 9.49.4 Second Bin ASF Installation 9.5

9.5 Color Motor Installation 9.69.6 Color Ribbon Installation 9.7


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Tables

Page

2.1 Paper Path Configurations 2.43.1 Printer Connections Table 3.44.1 ORU Order of Access 4.36.1A Unrecoverable Error Display Messages

(Bootstrap Phase) 6.76.1B Unrecoverable Error Display Messages 6.8

(Normal Phase)6.2 T&D USER Flow Chart 6.236.3 T&D Tests List 6.276.4 T&D ORU List 6.276.5 T&D Error Codes 6.287.1 Print Head Resistance/Temperature Characterist ics 7.17.2 9 Needles Print Head Pin assignment 7.37.3 24 Needles Print Head Pin assignment 7.48.1 Parallel Interface Pin Assignent 8.58.2 RS-232/C Serial Interface Pin Assignment 8.118.3 RS-422/A Serial Interface Pin Assignment 8.15


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GENICOM 3460 3480 i.1 GEK-89537

September 1998 Rev. 002

This Maintenance Manual focuses over the bare printer plus their specific options.

All defects originated by incorrect paper insertion, wrong menu setting or mistakencontrols commands, are not covered by this document to avoid duplications of information

available on the USER MANUAL forwarded to each end user within printer package, andavailable in five local languages.

When the malfunction eludes all the solutions proposed in the USER MANUAL ordeducible from it, a severe failure within the printer hardware, firmware or mechanismsshould be suspected.

Then follow the troubleshooting sequence advised in this manual together with defectivepart removal replacement.

The information in this document is subject to change without notice.

For every evolution regarding the maintainability aspects refers also to the specific technicalbulletin issued by the Product Support.

All efforts have been made to ensure the accuracy of the contents of this manual.

However, GENICOM Corporation cannot assume responsability for any errors that mayappear in this document or their consequences.

TRADEMARK ACKNOWLEDGEMENTS

- IBM Proprinter XLIII, IBM Proprinter XL, IBM Proprinter XLAGM are trademarks ofInternational Business Machines Co.

- EPSON LQ 1050 and EPSON FX1000 are registered trademarks of EpsonCorporation.

- Centronics is a registered trademarks of Genicom Corporation.

COPYRIGHT 1998 - GENICOM CORPORATION

Printed in ItalyAll Rights Reserved


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GENICOM 3460 3480 i.2 GEK-89537

FCC Regulations

Note:This equipment has been tested and found to comply with the limits for a Class Bdigital device, pursuant to Part 15 of the FCC Rules. These limits are designed to providereasonable protection against harmful interference in a residential installation. Thisequipment generates, uses and can radiate radio frequency energy and, if not installed andused in accordance with the instructions, may cause harmful interference to radiocommunications. However, there is no guarantee that interference will not occur in a

particular installation. If this equipment does cause harmful interference to radio ortelevision reception, which can be determined by turning the equipment off and on, the useris encouraged to try to correct the interference by one or more of the following measures:

### Reorient or relocate the receiving antenna.### Increase the separation between the equipment and receiver.### Connect the equipment and the receiver to outlets on different circuits.### Consult the dealer or an experienced radio/TV technician for help.

Changes or modifications not expressly approved by the party esponsible for compliancecould void the user's authority to operate the equipment.

The use of a non-shielded interface cable with the referenced device is prohibited. Thelength of the parallel interface cable must be 3 meters (10 feet) or less. The length of theserial interface cable must be 15 meters (50 feet) or less.

Canadian D.O.C. Radio Interference Regulation

This digital apparatus does not exceed the Class B limits for radio noise emission fromdigital apparatus as set out in the radio interference regulations of the Canadian Departmentof Communications.

Le prsent appareil numrique n'met pas de bruits radiolectriques dpassant les limites

applicables aux appareils numriques de classe B prescrites dans le rglement sur lebrouillage radiolectrique dict par le ministre des communications du Canada.

EEC Regulations

This equipment conforms to the EEC Directive 89/392 (the sound pressure, measuredaccording to ISO 7779, does not exceed 70 dBA).


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Maintenance Manual General

Overview

GENICOM 3460 / 3480 / 3480+ 1.1 GEK-89537

Chapter 1

General Overview


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1.1 Introduction

This Manual describes the features and the maintenance procedures for the SerialImpact Dot Matrix printers3460, 3480, 3480+ and their options.

These printers are part of the GENICOM Corporation Product Line.

Difference about 3460/3480 (A2), 3460/3480 (A3) and

3480+

The main difference between these three differents profile are the following:

Compuprint P/N DESCRIPTION 3460/3480 (A2) 3460/3480 (A3) 3480+

78399160-001 Kit P.H. mask x78399636-003 Carriage Assy x78399638-002 Support Spring Assy x

78407242-001 P.H. mask x x78399661-001 Carriage Assy x x78399660-002 Lower Mylar Assy x x78399639-002 Support spring Assy new x x x78403364-003 Fan Carriage Assy x78402198-001 Carriage motor x78407658-001 Print Head x78406948-001 Pwa 2V4C24 x

Pratically, the (A3) profile introduce the following difference respect the (A2) profile.-The support sring with the removable lower mylar.-A new carriage assy with a new print head mask.

-A new main board and related firmware for electronic AGA.-The serial interface is integrated in the main board.

The 3480+ is a more speedy model of the 3480 (A3). Its printing speed is 450 cps at 10 cpiin draft mode.For this reason, a new pwa/fw, a new print head, a new carriage motor and a fan carriagehas been introduced in this model.

1.1.1 Scope of the Products

These printers are advanced impact printers which give real and efficient solutions to the

actual and future printer needs.

They are designed to be extremely flexible in paper handling and capable to managedifferent paper types and formats, able to print on thick and multipart forms, specializedon dual fanfold management in non-attended mode.

In the same time, these printers are intended to support EDP, Office and"Administrative" environments applications requiring very high throughput, high level printquality and graphic capabilities, either in black or in colors, in order to print listing,invoicing & billing, spread sheets, diagrams, business or technical graphics andmachine readable texts.


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These printers enter in the top segment of the SIDM pinter market and can be a valideand convenient alternative to the low end line-printers.

1.1.2 Printers Features Summary

9 (3460) or 24 (3480) wire print head. Draft print at 400 cps and LQ print at 120/133 cps (3460/3480) Draft print at 450 cps and LQ print at 120/133 cps (3480+) High resolution Graphics Printing at 240x144 dpi for 3460 model,

360x180 dpi for 3480/3480+ models. IBM Proprinter XLIII and EPSON FX1000 resident emulation for 3460 model.

IBM Proprinter X24 and XL24 and EPSON LQ1050 resident emulationfor 3480/3480+ models. (ANSI emulation also available).

Paper path switching selected by operator panel or SW commands. Easy print function selection and printer configuration via the operator panel or with

SW commands. Centronics parallel and RS-232-C and RS-422-A serial interfaces.

Font styles in multiple international character sets. Optional second tractor assembly for dual fanfold operation. Optional Automatic Sheet Feeder that handles cut sheets, multicopies & envelopes. Optional color motor for color feature printing.


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1.2 General Description

1.2.1 Physical Overview

A sketch of the resulting appearance is reported on figures 1.1 and 1.2.

1. Top Cover 4. Single Sheet Support2. Operator Panel 5. Paper Knob3. Power Switch 6. Front Tractor Unit Cover

Fig. 1.1 Basic Printer Parts Location (front view)


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1. Interface Cover 4. ASF Location Cover 2. Rear Tractor Unit Cover 5. AC Power Inlet3. Paper Stacker Covers 6. Paper Deflector


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Fig. 1.2 Basic Printer Parts Location (rear view)


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1.2.2 Physical Dimension

Basic printer without options

Dimensions

- HEIGHT 12.1" (310 mm)- WIDTH 26.2" (665 mm)- DEPTH 13.3" (390 mm)- WEIGHT (unpacked) 38 lbs (18 Kg)

1.2.3 Printer Structure

The printer can be described as the complex of the following parts.In the next figure it is possible to see the internal printer architecture and where themajor blocks described below are located.

### MECHANICAL ASSY### PRINT HEAD

### CABINET

### ELECTRONIC HARDWARE

### INKED RIBBON

Fig. 1.3 Printer Internal Architecture


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1.2.3.1 Mechanical Assy

This block is composed of a rubber platen roller with a carriage carrying a print headwith 9 needles (3460 model) or 24 needles (3480/3480+ models) in front of theplaten.This movement is obtained via a step-motor (providing 1/120" movement per step)and a minipitch belt.

The movement of the rubber drum for paper traslation is obtained via a specific stepmotor providing a minimum movement of 1/144" for 9 needle model or 1/180" for 24needles model and a couple of minipitch belts.

The motion of the ribbon cartridge is obtained through a specific step-motorindipendently from the actual carriage speed, movement, direction and width.In this way in front of the print head there is a continuously renewing well inkedribbon. The ribbon speed is optimized to reduce conflicts with ribbon and graphicprintout appearance when ribbon and print head are moving in the same direction.

The color ribbon and the extended life black cartridges are moved up and down

through a linear actuator (step motor) with a plastic coupler that transmits the axialmovement to the plastic print head mask installed on the color ribbon cartridge.

Another step motors is used for the A.G.A. (automatic gap adjustment) of the printhead movement to have the best perfomance on the paper in use.The printer is able to increase/decrease the strength of the needle stroke via MENU(selectable by User) to allow a high impact force also for multi-part forms (up to 7copies).

1.2.3.1.1 Tractor Unit Assy

A removable push-pull tractor unit is installed on the printer.

Inside of it, a DC motor switches to engage/disengage the gear to allow the fanfoldor the single sheet to be fed.The tractor unit can be installed in two different positions depending on the type offanfold management (front - rear - both).In the next chapter all the paper handling possibilities of this mechanism aredetailed.

1.2.3.2 Print Head

The core of the printer is the print head, which is for both models an electromagneticnon- ballistic type with a life of 400 MChrs.

There are three different print heads: 9 needles for 3460.24 needles for 3480.24 needles for 3480+.

1.2.3.3 Cabinet

The cabinet allows safety-proof lifting of frontal part for ribbon substitution and paperpath check.It is composed of various parts to allow an easy access to all the printer internalparts.


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1.2.3.4 Electronic Hardware

This section is composed of the following boards:

MAIN BOARD located in the bottom right side of the printer which controls themotors movement, the various input sensors, the parallel interface and the print head

needles.It also provides the management of the asynchronous host serial interface, externalsynchronous serial interface for mechanical options and fonts cartridge.

POWER SUPPLY BOARD located in the bottom left side of the printer whichprovides specific voltages for logical area, printhead needles and drive motors.There are two power supply boards: 120 and 220/240 Vac respectively.

OPERATOR PANEL BOARD placed on the front side of the printer driving 9 pushbuttons and 8 leds (3 for printer status and 5 for paper path selection).This board also drives a 16 Digit LCD Alphanumeric display to easily interact withparameters setting for menu operation.

SERIAL INTERFACE board located on the rear right side and plugged to the mainboard which drives the proper drivers for serial interface.

1.2.3.5 Inked Ribbon Cartridge

The ribbon cartridge is installed in different ways according to the ribbon types.In case of the black ribbon, the cartridge is fixed on both sides on four points.Its position is obliquous to the print line to automatically show the complete height ofthe ribbon in front of print head while printing on the full print line.

The inked ribbon inside of these cartridges is a continuous loop.

In case a color ribbon or an extended life black ribbon installed, the cartridge is fixedon both sides only on the two rear points, so that is is free to move its frontal partupward and downward.Its installation is parallel to the print line to assure the correct color band selection.A specific step motor is used to move the ribbon band up and down for colorselection.

1.2.3.6 Mechanical Options

This printer can provide some mechanical options :

AUTOMATIC SHEET FEEDER (up to 3 bins).Each bin has a DC motor inside it to automatically load the single sheet paper.Internally on the bin a series of gears takes the movement of the motor to the rubberroller shaft.Together with the first bin a PAPER STACKER is provided to collect the outputprinted paper.Also this part has an internal step motor to select the path where the paper shouldbe output.


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1.3 Product Components

1.3.1 Basic Printers

Product Name: 3460Marketing Identifier: 3P3461A1 or 3P3461A2 or3P3461A1A

The product is composed of: - 9 needles Basic Printer - 9 MC Black Ribbon Cartridge - 120 Vac Power Cable - Push/Pull Tractor Unit

- Parallel & Serial Interfaces - User Manual

Product Name: 3460Marketing Identifier: 3P3462A1 or 3P3462A2The product is composed of: - 9 needles Basic Printer - 9 MC Black Ribbon Cartridge - 220/240 Vac Power Cable

- Push/Pull Tractor Unit- Parallel & Serial Interfaces

- User Manual

Product Name: 3460Marketing Identifier: 3P3461A3The product is composed of: - 9 needles Basic Printer

- new mech. profile and 400 cps speed - 9 MC Black Ribbon Cartridge - 120 60Hz Vac Power Cable - Push/Pull Tractor Unit



- new mech. profile and 400 cps speed- 9 MC Black Ribbon Cartridge

- 220/240 Vac 50Hz Power Cable - Push/Pull Tractor Unit


Product Name: 3480Marketing Identifier: 3P3481A1 or 3P3481A2 or3P3481A1AThe product is composed of: - 24 needles Basic Printer - 9 MC Black Ribbon Cartridge - 120 Vac Power Cable - Push/Pull Tractor Unit



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Product Name: 3480Marketing Identifier: 3P3482A1 or 3P3482A2

The product is composed of: - 24 needles Basic Printer - 9 MC Black Ribbon Cartridge - 220/240 Vac Power Cable - Push/Pull Tractor Unit



- new mech. profile and 400 cps speed - 9 MC Black Ribbon Cartridge

- 120 Vac 60Hz Power Cable - Push/Pull Tractor Unit



- new mech. profile and 400 cps speed - 9 MC Black Ribbon Cartridge - 220/240 50Hz Vac Power Cable - Push/Pull Tractor Unit


Product Name: 3480+Marketing Identifier: 3P3481A4The product is composed of: - 24 needles Basic Printer

- new mech. profile and 450 cps speed - 9 MC Black Ribbon Cartridge - 120 Vac 60Hz Power Cable - Push/Pull Tractor Unit

- Parallel & Serial Interfaces

- User Manual

Product Name: 3480+Marketing Identifier: 3P3482A4The product is composed of: - 24 needles Basic Printer

- new mech. profile and 450 cps speed - 9 MC Black Ribbon Cartridge - 220/240 50Hz Vac Power Cable - Push/Pull Tractor Unit



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Note: printers whose marketing identifiers ends with A1A or A2, have theGENICOM ANSI emulation installed.


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1.3.2 Options

1.3.2.1 Inked Ribbons

Marketing Identifier: 1A3000B01The product is composed of: 1 Black Ribbon Cartridge

Marketing Identifier: 1A3000B02The product is composed of: 1 Color Ribbon Cartridge (4 band)

Marketing Identifier: 1A3000B03The product is composed of: 1 Black/Red Color Ribbon Cartridge

Marketing Identifier: 1A3000B04The product is composed of: 1 Extended Life Black Ribbon Cartridge

1.3.2.2 Automatic Sheet FeederMarketing Identifier: 1A3003B01The product is composed of: - ASF 1st Bin Unit (up to 120 sheets) - Paper Stacker (up to 150 sheets) - User Manual

Marketing Identifier: 1A3003B02The product is composed of: - ASF 2nd Bin Unit (up to 120 sheets) - User Manual

1.3.2.3 Optional Tractor

Marketing Identifier: 1A3003B03The product is composed of: - Push/Pull Tractor Unit - Installation Manual

1.3.2.4 Color Kit

Marketing Identifier: 1A3003B04

The product is composed of: - Color motor - User Manual

1.3.2.5 Pedestal

Marketing Identifier: 1A3003B05The product is composed of: - Inclinable two levels floor pedestal (for document on demand application) - Installation Manual


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Marketing Identifier: 1A3003B06The product is composed of: - Three levels floor pedestal (for dual fanfold application) - Installation Manual

1.4 Printers Technical Specifications

The following features refer mainly to intrinsic characteristics and can change without notice.

### PRINT HEAD Model 3460 Model 3480/80+

N. of Needles 9 24Life (MChrs draft) 400 400V. Pitch 1/72" 1/120"V. Pitch n.a. 1/180"Needle Diameter 0.3 mm (0.0118") 0.2 mm (0.0078")

###PRINT SPEED Model 3460 Model 3480/80+

CPI= characters per inchDPI= dots per inchCPS= characters per secondDPS= dots per second

CPI DPI CPS DPS CPI DPI CPS DPS

Draft mode: 10 60 400 10 60 40012 60 480 12 60 48015 75 480 15 60 60017 103 400 17 120 343

20 120 400 20 120 400- - - 24 120 400

Letter Quality mode: 10 100 120 10 180 13312 120 120 12 180 16015 150 120 15 180 20017 102 200 17 180 22920 120 200 20 180 267- - - 24 180 320

Dot Graphic Mode: - 60 - 2100 - 60 - 2100- 72 - 2100 - 80 - 1660- 72 - 2100 - 90 - 1245

- 120 - 2100 - 120 - 2100- 144 - 2100 - 180 - 2100- 240 - 2100 - 240 - 2100- 288 - 2100 - 360 - 2100

### THROUGHPUT PPH ECMA 132

PPH= pages per hour Model 3460 Model 3480/80+

PPH Fanfold ASF Fanfold ASF


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Letter Draft: 405 330 402 330Letter Quality: 132 106 208 150Graphic: 244 135 75 95Spread 17: 235 78 226 170Spead 10: 247 - 246 -


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### CHARACTER PITCH

Basic: 10, 12, 15Compressed: 16.7, 17.14, 20, 24Double-Wide: 5, 6, 7.5, 8.33, 8.5Other: Proportional

Model 3460 Model 3480/80+

Intercharacter spacing n/60 n/120n/72 n/180n/120 n/360n/144 n/720n/216n/720

### CHARACTER FORMATION

DPC= dots per character

Model 3460 Model 3480/80+H S H Res (V) H S H Res (V)

Draft (text 10 cpi): 5 2 1/72" (9) 9 3 1/120" (24)Draft (text 12 cpi): 5 1 1/72" (9) 7 3 1/120" (24)Draft (text 15 cpi): 5 1 1/72" (9) 7 1 1/120" (16)Draft (graphic char): 7 0 1/72" (9) 12 0 1/120" (30)LQ (text 10 cpi): 12 2 1/144" (18) 31 5 1/360" (24)LQ (text 12 cpi): 12 1 1/144" (18) 27 3 1/360" (24)LQ (text 15 cpi): 12 1 1/144" (18) 21 3 1/360" (24)LQ (proportional): 18 0 1/144" (18) 42 0 1/360" (24)LQ (graphic char): 14 0 1/144" (18) 36 0 1/360" (30)

### VERTICAL SPACING

LPI= lines per inch

Basic: 2, 3, 4, 6, 8, 12


Incremental n/72 n/60n/144 n/72

n/216 n/180n/720 n/216n/360

### BIT IMAGE (DOT GRAPHICS)


Horizontal: 60, 72, 120, 144 60, 80, 90, 120,216, 240, 288 180, 240, 360

Vertical: 60, 72, 144, 216 60, 72, 144, 180


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### CHARACTER SETS

- CS1, CS2, EPSON Italic.- EPSON National Character Sets.- ANSI National Character Sets.- ISO Character Sets with all national variations.- PC437, PC850, PC851, PC852, PC853, PC855, PC860, PC863, PC864, PC865,

PC866, PC867, Mazowia, Turkish, Greek

RESIDENT FONTS

Draft, Courier, OCRA-Ext, OCRB-Ext., Gothic, Prestige, Script, Orator

OPTIONAL FONTS

Possibility to add other fonts through optional Fonts cartridge up to 256 KBsupport according to PCMCIA Standard.

PRINTING ATTRIBUTES

CompressedDouble HeightDouble WidthSub/SuperscriptSlantedDouble StrikeEmphasizedUnderline

BAR-CODES

12 BAR-CODE types: UPC-A, UPC-E, EAN8, EAN 13, 2/5 INTERLEAVEDCODE 3 of 9, CODE 93, CODABAR, CODE 128,POSTNET, CODE 11, MSI

Height, Check Digit, Horizontal Print density programmable.Human Readable Characters available.


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### MEDIA HANDLING

BACKWARD PAPER MOVEMENT

The reverse paper movement is always allowed with the following limitations:

- Fanfold Form Until the paper is parked (max. 20").

- Cut Sheet Form up to 76.2 mm, (3").

### MEDIA CHARACTERISTIC

The basic printers can manage a manual single sheet front insertion and up to3 fanfold modules formats in 4 different paths.

SINGLE SHEET

Front insertion and straight path

The printer can accept these formats:###A5, A4, A3, portrait and landscape

###A2 portraitLETTER, LEGAL and EXECUTIVE

WIDTH minimum 114.3mm 4.5"maximum 444.5 mm 17.5"

LENGTH minimum 101.6 mm 4"maximum 558.8 mm 22"

THICKNESS maximum 0.635 mm 0.025"COPIES 1 + 7

WEIGHT (original) minimum 50 gr/M 12.5 lbs maximum 120 gr/M 30.0 lbs

WEIGHT (Multicopy)first sheet minimum 55 gr/M

maximum 75 gr/M 18.75 lbsother minimum 45 gr/M 11.25 lbs

maximum 75 gr/M 18.75 lbscarbon minimum 14 gr/M 3.5 lbs

maximum 35 gr/M 8.75 lbs

FRONT PUSH FANFOLD

Frontal push fanfold feeding and straigh path

WIDTH minimum 76.2 mm 3.0"maximum 431.8 mm 17.0"

LENGTH minimum 76.2 mm 3.0" maximum 609.6 mm 24"THICKNESS maximum 0.635mm 0.025"COPIES 1 + 7

WEIGHT (original) minimum 55 gr/M 13.75 lbsmaximum 150 gr/M 37.5 lbs

WEIGHT (Multicopy)copies minimum 45 gr/M 11.25 lbs

maximum 75 gr/M 18.75 lbscarbon maximum 35 gr/M 8.75 lbs


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REAR PULL FANFOLD

Frontal pull fanfold feeding and straight pathSame as Front Push Fanfold


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REAR PULL FANFOLD

Bottom pull fanfold feeding and straight pathSame as Front Push Fanfold, except for the maximum WIDTH up to 381 mm (15") .

REAR PUSH FANFOLD

Rear push fanfold feeding

WIDTH minimum 76.2 mm 3.0"maximum 431.8 mm 17.0"

LENGTH minimum 76.2 mm 3.0" maximum 609.6 mm 24"THICKNESS maximum 0.35mm 0.0138"COPIES 1 + 3

WEIGHT (original) minimum 55 gr/M 13.75 lbsmaximum 80 gr/M 20 lbs

WEIGHT (Multicopy)copies minimum 45 gr/M 11.25 lbs

maximum 75 gr/M 18.75 lbs

carbon maximum 35 gr/M 8.75 lbs

The printer can accept also the Automatic Sheet Feeder option with these paper limitations:

ASF ALL BINS

Capacity Bin of 120 sheetsLENGTH maximum 355 mm 14"THICKNESS maximum 0.35mm 0.0138"COPIES 1 + 2WIDTH minimum 88.9 mm 6"

maximum 304.8 mm 12"

WEIGHT (original) minimum 60 gr/M 15 lbsmaximum 150 gr/M 37.5 lbs

WEIGHT (Multicopy with carbon)first/last sheet minimum 70 gr/M 17.5 lbs

maximum 80 gr/M 20.0 lbsother minimum 35 gr/M 8.75 lbs

maximum 40 gr/M 10.0 lbscarbon approx. 25 gr/M 6.25 lbs

WEIGHT (Multicopy sensitive)

first/last sheet minimum 70 gr/M 17.5 lbsmaximum 80 gr/M 20.0 lbs

other minimum 40 gr/M 10.0 lbsmaximum 60 gr/M 15.0 lbs

ENVELOPES

Capacity of 30 envelopes max., Size US 6, US 10

ASF 1 BIN

LENGTH minimum 114 mm 4.5"

ASF 2 BIN


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LENGTH minimum 216 mm 8.5"

ASF 3 BIN

LENGTH minimum 267 mm 10.5"### INTERFACES

There are two interfaces with automatic protocol and I/F switching on SW commands.

- Parallel interface IBM-EPSON and CENTRONICS compatible MENU SELECTABLE 7/8 DATA BITS

Transfer speed up to 200 KB Buffer up to 64 KB

- Serial interface RS232/C for remote and local connection, RS422A for local connection 300/600/1200/2400/4800/9600/19200/38400 BAUD 7/8 DATA BITS DTR / XON - XOFF flow control

Break function

Buffer up to 64 KB

### DEVICE PROTOCOLS


Emulation: Printer Names

EPSON FX1000 LQ1050IBM Proprinter XLIII Proprinter X24/XL24ANSI GENICOM 3410, 3840 GENICOM 1220

### ELECTRICAL CHARACTERISTICS

JA/US Specification : 120 V +10% -15%, 50/60Hz 2Hz

EU/UK Specification : 220/240 V +10% -15%, 50/60Hz 2Hz

AC Consumption : Idle less than 80 VAPrinting less than 200 VA

### ENVIRONMENTAL CONDITIONS

The storage and transit environment (1 year) of the device and the relatedexpansion module and supplies is:

Temperature Range - 20 C to + 60 C (-4 F to 140 F) Humidity Range 5% RH to 90% RH (not condensing)

The operating environment is :

Temperature Range + 10 C to + 40 C (41 F to 104 F) Humidity Range 20% RH to 80% RH (not condensing)


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Additional resctrictions are introduced by the paper.The ECMA standard suggestions are :

Temperature Range + 16 C to + 24 CHumidity Range 40% RH to 60% RH (not condensing)


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### NOISE

Sound Pressure level bystander position according to ISO 7779:

58 dBA in Draft mode (without A.S.F.) 53 dBA in Quiet mode (without A.S.F.)

### CONFORMITY TO STANDARDS

The product technical approach, materials and implementation will beconsistent with the latest issue of the following requirements herafterdistinguished by market area:

For mains voltage 115 V :

Electromagnetic Compatibility FCC Class B Safety Regulations UL1950,CSA 950

For mains voltage 220 - 240 V :

Electromagnetic Compatibility GS SIGN Cispr 22 Class B

Safety Regulations EN60950 IEC 801-2, 3, 4

### MAINTAINING PARAMETERS

Next maintaining parameters are valid under the following conditions:

Standard temperature and humidity (23 2 C, 50 5 RH)

MTTR

The MTTR is the estimated time to repair the printer at OptimumReplaceable Unit (ORU) level is 15 minutes.

It includes:

- Identifying the faulty ORU - Changing the ORU - Cleaning paper paths - Testing locally

MTBF/RELIABILITY

MTBF depends on duty cycle rate (D.C.). For these printers it is 10.000 HRS @ 25 % D.C. (excluding print head).

Duty cycle rate estimated for this printer is calculated as follows:

Paper Movement & Print Time Duty Cycle = ---------------------------------------------------- = 25 %

Power-on Time


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Reference usage of 25% duty-cycle is assumed on the basis of thefollowing parameters : 60% column density, 50% line density, 40%character density, 40 hours/week.


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LIFE

- UNIT 5 years

- RIBBON 9 Mcharacters Draft (standard black type)15 MCharacters Draft (extended black type)2 MCharacters Draft each band (color type)

- PRINT HEAD 400 M Characters Draft

### USER INTERFACE

The Operator Panel of this printer has the overall appearance of a plane surfaceas shown in the next figure 1.4 with the following:

- 1 LCD Display with 16 alpha-numeric digit - 9 Push Buttons

- 8 LED indicators (3 for status and 5 for paper paths)

Fig. 1.4 Operator Panel Overview


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Maintenance Manual Paper Handling

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Chapter 2

Paper Handling Overview


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2.1 Introduction

These printers are designed to be extremely flexible in paper handling.

Moreover, the mechanism has been designed to be, first of all, ergonomic for a betterand easier end-user operation.

2.1.1 Paper Handling Architecture

All the paper paths described below can co-exist and can be selectable via MENUand SW commands.

The printer automatically switches from one path to the other except for the rear pulltractor positions.

Via operator panel menu it is possible to select one format per each path (up to 6) ora single format (equal for all paths).

The basic configuration provides these ways to manage the paper formats:(In the next figure the paths for continuous modules are indicated as ,while the paths for single sheet forms are indicated as --->; each path is identifiedwith a number).

### SINGLE SHEET

A semi-automatic frontal single sheet insertion (PATH 1).

The single sheet forms are manually loaded in this path.When a sheet is inserted, the sensors detect its presence and the printerloads the paper automatically without any other action.

### CONTINUOUS MODULE (FANFOLD)

Through a user installable/removable tractor unit the fanfold module canbe fed through the following positions:

FRONT PUSH mode (PATH 2) with tractor group in position A, alsooverlapped with single sheet (PATH 1).

REAR PUSH mode (PATH 3) with tractor group in position B, alsooverlapped with single sheet (PATH 1).

REAR PULL mode with frontal insertion (PATH 4) with tractor group inposition C, also overlapped with single sheet (PATH 1), exclusive with fanfoldin PATH 3.

REAR PULL mode (PATH 4) with tractor group in position C, with inputfrom the bottom (PATH 5), also overlapped with single sheet (PATH 1)exclusive with fanfold in PATH 3.

For the first two paths, the continuous module exits from PATH 10.


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### DOUBLE FANFOLDS

Through the optional second user installable/removable tractor unit the

following feeding positions for continuous module are available :

DUAL PUSH fanfolds mode.The first fanfold from the front in push mode with basic tractor group inposition A (PATH 2), the second from the rear in push mode with optionaltractor group in position B (PATH 3), both overlapped with a single sheet(PATH 1).

For this path, the fanfolds exit (once at a time) from PATH 10.

PUSH&PULL fanfolds mode in which the fanfold can be fed from the frontin push mode with the basic tractor group in position A (PATH 2) and at thesame time is pulled from the second tractor group in position C (PATH 4).

Also this configuration can be overlapped with a single sheet (PATH 1).

### AUTOMATIC SHEET FEEDER (ASF)

Through the optional Automatic Sheet Feeder the following feedingpositions for single sheets are available :

REAR in the first bin (PATH 6).REAR in the second bin (PATH 7).REAR in the third bin (PATH 8).

Inside the paper output stacker, a mechanical switch allows the alternancebetween the output single sheets, which are collected to the output stacker(PATH 9), and the fanfold using this exit (PATH 10).

On the next figure 2.1 it is possible to see the internal architecture of this printer inwhich the different paper paths handled by the new design of the mechanicalassembly are put in evidence.

On the table 2.1 it is possible to find the Paper Path Types that can be selectedaccording to the printer Path Configurations.


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Fig. 2.1 Paper Handling Architecture

PAPER PATH TYPES PAPER PATH CONFIGURATIONS

A B - - - - - FRONT PUSH PATH

- B C - - - - REAR PUSH PATH

- B - D - - - REAR PULL PATH

A B C - - - - FRONT+REAR PUSH

A B - - E - - PUSH PULL PATH

A B - - - F - FRONT PUSH+ASF1

A B - - - F G FRONT PUSH+ASF2

A B C - - F G FRONT PUSH+ASF3

A B C - - F - FRONT & REAR PUSH+ASF1A B C - - F G FRONT & REAR PUSH+ASF2

A B C - - F G FRONT & REAR PUSH+ASF3

A= FRONT PUSH PATHB= MANUAL PUSH PATHC= REAR PUSH PATHD= REAR PULL PATHE= PUSH-PULL PATHF= ASF 1G= ASF 2&3


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Figure 2.2 Paper Feeder Parts on Right Side


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Figure 2.3 Paper Feeder Parts on Left SideThe figure below shows the mechanical parts related to the automatical movement ofthe friction rollers.

Carriage assy (1) Friction Lever assy (2) Friction Bar assy (3) with Sector gear (4)

Open Gear (5) Friction Rollers (6)

At manufacturing site, the mechanical assy is mounted and the tests and diagnosticare done to store the proper rear fanfold sensor values in the NVM according to theproper friction rollers position (the rear fanfold sensor tuning values stored in NVM aredifferent if the friction rollers are opened or closed).

It is important not to move the carriage and paper advance knob manually to changethe friction bar position because this would cause the loss of the correspondancebetween mechanism position and the sensor tuning .

If any intervention of this kind has been done, it is indispensable to run the T&D to

assure the correct correspondance.

Figure 2.4 Automatic Movement of Friction Rollers


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2.1.3 Paper Path Configurations

2.1.3.1 Basic Configuration

The next figures 2.5, 2.6 and 2.7 show the alternative positions of the standard push-pull tractor unit, and related paper paths.

The figure 2.5 shows the Front Load Push-Mode of the fanfold.

The figure 2.6 shows the Rear Load Push-Mode of the fanfold.

The figure 2.7 shows the Rear Load Pull-Mode of the fanfold (alternatively the papercan enter in the bottom feed slot).

For all these paper paths, it is possible to overlap a single sheet.

IMPORTANT REMARK

### For the REAR PUSH mode, the fanfold must have a maximum thickness of 0.35mm instead of 0.635 mm of the other paths.

### For the REAR PULL mode, a manual intervention is necessary.The bail assy must be lifted (upper position) and the selection slider located onthe left side of the printer must be in its up position to assure the correct rotation of

the rear tractor (see chapter 2.2.5 or user manual for major details).


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Figure 2.5 Front Load Push-Mode

Figure 2.6 Rear Load Push-Mode


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Figure 2.7 Rear (Bottom) Load Pull-Mode

2.1.3.2 Dual Fanfold Configurations

The next figures 2.8, 2.9 show the dual tractor units configuration allowing the alternancebetween two fanfolds, and related paper paths.

The figure 2.8 shows the Front Load Push-Mode and the Rear Load Push-Mode of thefanfolds.The figure 2.9 shows the Front Load Push-Pull Mode of the fanfold.For all these paper paths, it is possible to overlap a single sheet.

IMPORTANT REMARK

### For the REAR PUSH mode, the fanfold must have a maximum thickness of 0.35mm instead of 0.635 mm of the other paths.

### For the REAR PULL mode, a manual intervention is necessary.The bail assy must be lifted (upper position) and the selection slider located onthe left side of the printer must be in its up position to assure the correct rotation of

the rear tractor.


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Figure 2.8 Front Load Push-Mode and Rear Load Push-Mode with two tractors


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Figure 2.9 Front Load Push-Pull Mode with two tractors


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2.1.3.3 ASF Configuration

The figure 2.10 on next page shows the positions of the Automatic Sheet Feeder andrelated paper paths.The ASF can co-exists with both the push-pull tractor units (front and rear) installed.The 1st BIN can accept also envelopes.

Figure 2.10 Automatic Sheet Feeder


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2.2 Actions to put the Rear Tractor in Pull Mode

The figure 2.11 shows the manual actions that must be done to put the rear tractor unitin PULL mode instead of push.

### Check that the plastic slider is in "PULL" mode selection (up position).

### Open the top cover and gently lift the paper bail assy.


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Figure 2.11 Actions to do to put the Rear Tractor in Pull mode


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Maintenance Manual Removal and

Replacement

GENICOM 3460 / 3480 / 3480+ 3.1 GEK-89537

Chapter 3

Removal and Replacement

for 3460 (A2) / 3480 (A2)


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3.1 Overview

This section describes the removal and replacement procedures for the basic printer.

Before starting any of these procedures, turn the power switch OFF, and take off the plugfrom the wall socket.

Before disassembling the printer, remove the paper in the printer and the inked ribboncartridge.After the covers removal, the power supply cover tool must be installed to prevent anyaccidental contact of technician hand with the main heat-sink of the power supply itself ifthe printer is powered-on without covers.

REMARKCautionand Warningin this section highlight specific information.

A CAUTIONprovides information intended to prevent equipment damage.

AWARNINGprovides information intended to prevent personal injury.

You must observe anti-static precautions when maintaining this printer.Disassembly procedure must to be executed from the front side of the printer.

3.2 Recommended Hand Tools and Equipment

The following items should be available for the technicians performing correctivemaintenance on printers:

###Assortment of Philips head and common screwdrivers###Set of spanners for M3 and M5 nut

###Extractor for chip###Pliers###Soldering iron (and soldering wire with flux core)###A Multimeter for resistance and voltage measurements###Feeler gauge for print head gap adjustment###Dynamometer for carriage and motor belts adjustment###Slender spring hook###Set of fastener loop self-lock

### Power Supply cover tool P.N. 78399165-001

### Test & Diagnostic ToolsT&D Card P.N. 78399178-001

Serial 232 Loop-Back Connector P.N. 78403675-001 Serial 422 Loop-Back Connector P.N. 78403676-001 Parallel Loop-Back Connector P.N. 78401829-001 Mechanical Option Loop-Back Connector P.N. 78403674-001

### Antistatic Tools (on-site) P.N. 76166990-209 Antistatic Tools (repair bech) P.N. 76957474-002


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3.3 O.R.U. ORDER OF ACCESS

Table 4.1 shows the accessibility of EACH ORU (Optimum Replaceable Unit), and theprocedure necessary to access to each one.

Remove ORU: Requires these procedures in the order shown:

1) Push-Pull Tractor Group 1 (section 3.3.1)2) Operator Panel Boards 2 (section 3.3.2)3) Print Head 3 (section 3.3.3)4) Front Cover Parts 1,2,4 (section 3.3.4)5) Rear Cover Parts 5 (section 3.3.5)6) Serial Interface Board 5,6 (section 3.3.6)7) Main Board 5,6,7 (section 3.3.7)8) Power Supply Board 5,6,8 (section 3.3.8)9) Ribbon Motor 1,2,4,5,9 (section 3.3.9)10) AGA Motor 1,2,4,5,10 (section 3.3.10)

11) AGA Support and T/F lever 1,2,4,5,11 (section 3.3.11)12) Carriage Motor and Fan 1,2,4,5,12 (section 3.3.12) (*)13) Bail Assy 13 (section 3.3.13)14) Cut Sheet Assy 1,2,4,14 (section 3.3.14)15) Upper Feeder Assy 1,2,4,5,15 (section 3.3.15)16) Platen Assy 1,2,4,5,16 (section 3.3.16) (*)17) Lower Feeder Assy 1,2,4,5,17 (section 3.3.17) (*)18) Carriage Assy 1,2,4,5,18 (section 3.3.18) (*)19) Sensor Cable Assy 1,2,4,5,19 (section 3.3.19) (*)20) Mechanical Assy 1,2,4,5,20 (section 3.3.20)21) Paper Motor 1,2,4,5,20,21 (section 3.3.21) (*)22) Friction Bar Assy 1,2,4,5,20,22 (section 3.3.22)

Table 3-1 ORU ORDER OF ACCESS

NOTE : Procedure with an asterisk require ADJUSTMENT PROCEDURE (see chapter 5)

All the spare parts available on logistic are reported in the specific Illustrated Parts Catalog at chapter11.


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3.3.1 Push-Pull Front Tractor Group

CAUTION

Do not remove and install the push-pull tractor group with the printer at power-on.

1) Open the front antinoise cover.

2) Close the single sheet support cover, if open, by pulling it upward until it is fastened withthe magnetic lock.

3) Disengage the tractor group from the mechanical assy by acting on the two small levers(located on plastic tractor sides) that block the tractor group on it.

4) Remove the push-pull tractor unit by pulling it downward.

Replace the tractor group following the above instructions in reverse order.

The same operations are required for the optional rear push-pull tractor group.


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Figure 3.1 Push-Pull Front Tractor Group removal


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3.3.2 Operator Panel Boards

CAUTION

Don't attempt this operation without taking all recommended anti-static precautions.

1) Open the operator panel group by acting on its middle top side to disengage it from thecover.

2) Open the top cover group by acting on the two push-buttons (located on the front side ofthe cover).

3) Unscrew the screw securing the operator panel shield to the mechanical assy (in newprinters this action will be not necessary anymore).

4) Unplug the operator panel connector from the operator panel board.

5) Rotate the operator panel group of 90 and at the same time extract it from the frontcover.

6) Unscrew the six screws securing the operator panel boards to the cover and removethem.

7) Remove the operator panel board from the LCD display board by acting on the twoplastic spacers catches that retain the boards together.

Replace the operator panel boards group following the above instructions in reverse order.


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Figure 3.2 Operator Panel Parts removal


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3.3.3 Print Head

WARNING

The print head may have hot surface after a certain time of printing.Wait for it to cool down.

1) Open the top cover group by acting on the two push-buttons (located on the front side of

the cover).

2) Place the print head to the rightmost carriage position and remove the inked ribboncartridge and bail assy.

3) Unscrew the screw securing the print head cable to the carriage assy.

4) Unscrew the two screws securing the print head.

5) Open the printhead cable zif-connectors and unplug these connectors and the colormotor connector (if present) by manually acting on their bends.

6) Remove the printhead.

Replace the Print Head following the above instructions in reverse order.

NOTICE: Before securing the screw, push the P.H. to its inside stop position. No adjustment is required.


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Figure 3.3 Printhead Removal


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3.3.4 Front Cover Parts

1) Remove the front tractor group (refer to chapter 3.3.1)

2) Remove the operator panel group (refer to chapter 3.3.2)

3) Unscrew the four screws securing the main front group (two on left and right printer side,

the other two on the front side).

4) Remove the main front cover by extracting it and, at the same time, rotating it towards itsfront side.

5) Open the top cover and extract it from the main front cover by acting on its pins (locatedon both sides).

6) Extract the magnet interlock from the front cover by simply pulling it out of the cover.

Replace the Main Front Cover Parts following the above instructions in reverse order.

Figure 3.4 Main Front Cover Parts


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3.3.5 Rear Cover Parts

1) Remove the ASF cover by simply extracting it from the main rear cover.

2) Unscrew the four screws securing the main rear group (two on left and right printer side,the other two on the rear side under the ASF cover).

3) Remove the main rear cover by extracting it from the rear side.

4) Extract the rear tractor cover with the interlock board by simply extracting them from themain rear cover.

5) Remove the paper deflector cover by simply unhooking it from the cover.

6) Extract the paper stacker covers by simply unhooking them from the main rear cover.

7) Extract the interface cover by simply unhooking them from the main rear cover.

8) Extract the paper knob by simply pulling it out from the platen axis.

Replace the Main Rear Cover Parts following the above instructions in reverse order.

Figure 3.5 Main Rear Cover Parts


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3.3.6 Serial Interface Board

CAUTION

Do not attempt this operation without taking all recommended anti-static precautions.

1) Remove the rear cover group (refer chapter 3.3.5)

2) Unscrew the two screws securing the serial interface board to the base assy.

3) Remove the the Serial Interface Board by simply extracting it from the main boardconnector.

Figure 3.6 Serial Interface Board


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3.3.7 Main Board

CAUTION

Do not attempt this operation without taking all recommended anti- static precautions.Remember to remove the eproms from the main board and install them on the new one inthe corresponding position.

1) Remove the main rear cover (refer to chapter 3.3.5)

2) Unscrew the six screws securing the main board to the base unit.

3) Unscrew the three screws securing the interface connector metal support to the lowershield (two are located on the rear side, one is located on the left side of the printer).

4) Unplug all the connectors from the main board by acting on their bends.

Note: Open the print head cable zif-connector before extracting the cable.Open the metal retaining clip with a screwdriver (installed only on the flat

cables)

5) Unhook the upper part of the rear connector bracket from the base assy.

6) Extract the main board from the printer.

7) Unscrew the two screws fixing the metal plate on the parallel connector and remove it.

Replace the Main Rear Cover Parts following the above instructions in reverse order payingattention to the rear horizontal guides and to its bottom shield.


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Figure 3.7 Main Board


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3.3.8 Power Supply Board

CAUTION

Do not attempt this operation without taking all recommended anti-static precautions.

1) Remove the main rear cover (refer to chapter 3.3.5)

2) Unscrew the screw securing the inlet bracket and remove it.

3) Unscrew the screw securing the ground cable on the metal shield.

4) Unscrew the screws securing the power supply cover to the lower shield and remove it.

5) Unscrew the six screws securing the power supply board to the base unit.

6) Unplug the connector from the main board and gently extract the power supply boardfrom the printer.

Replace the power supply board following the above instructions in reverse order payingattention to the rear horizontal guides.


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Figure 3.8 Power Supply Board


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3.3.9 Ribbon Motor

1) Remove the Main Rear and Front Covers (refer to chapter 3.3.4 and 3.3.5)

2) Remove the circlip retains the pivot assy to the left ribbon cartridge support.

3) Unscrew the four screws securing the left ribbon cartridge support on the left side of the

mechanical assy.

4) Extract the ribbon motor from the plastic support.

5) Remove the plastic support and the pivot assy from the mechanical assy.

6) Unplug the ribbon motor connector from the main board and extract the cable from itscable retainers located in the rear part of the mechanical assy.

7) Remove the pivot assy.

Replace the ribbon motor assy and the left support parts following above instructions inreverse order.


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3.3.10 AGA Motor


2) Unscrew the two screws securing the AGA motor on the mechanical assy.

3) Unplug the AGA motor connector from the main board and extract the cable from itscable retainers located on the rear part of the mechanical assy.

4) Remove the AGA motor assy.

Replace the AGA motor following the above instructions in reverse order.

NOTICE : Before tighteing the motor screws, verify the correct and free movement of the AGA gears. Run the AGA calibration procedure to verify the correct AGA marker

position.


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Figure 3.10 AGA Motor


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3.3.11 AGA Support and T/F Lever

1) Remove the Main Rear and Front Covers (refer chapter 3.3.4 and 3.3.5)

2) Unscrew the two screws securing the AGA support on the left side of the mechanicalassy and remove it.

3) Remove the AGA support.

4) Remove the retainer circlip by a proper tool from the platen axis.

5) Remove the friction washer, the open gear and the spring by simply extracting them fromthe platen axis.

6) Remove the tractor friction lever by simply extracting upward from the left side of themechanism.

Replace the AGA support and T/F lever following the above instructions in reverse order.

NOTICE: Put the AGA marker position in the same previous position. Run the AGA calibration procedure to verify the correct AGA marker

position.


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Figure 3.11 Aga Support and T/F Lever


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3.3.12 Carriage Motor


2) Cut the self-lock plastic strips retaining the cables on the carriage motor bracket.

3) Unscrew the two screws securing the motor bracket on the right side of the mechanical

assy and to the ground shield.

4) Remove the M3 nut securing the motor bracket on the front tractor connector support.

5) Remove the rear motor bracket by extracting it from the rear.

6) Unplug the carriage motor connector from the main board and extract the cable from itscable retainers located in the rear part of the mechanical assy.

7) Unscrew the four screws securing the front carriage motor bracket to the mechanism.

8) Remove the front carriage motor bracket.

9) Unscrew the two screws securing the carriage motor assy to the mechanism.

10) Drive off the carriage belt from the carriage motor gear.

11) Unscrews the three studs securing the carriage motor to its support.

12) Remove the carriage motor assy.

Replace the carriage motor assy following the above instructions in reverse order.

NOTICE: The carriage motor replacement requires an appropriate carriage beltadjustment (refer to chapter 5).


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Figure 3.12 Carriage Motor


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3.3.15 Upper Feeder Assy


2) Remove the bail assy (refer to chapter 3.3.16).

3) Remove the circlip retaining the upper feeder axis on the left side of the mechanical assyand shift the bushing on the the feeder assy axis right.

4) Remove the right bushing.

5) Drive off the platen belt from the upper feeder assy gear.

6) Put the rear tractor plastic slider push-pull selector in its rear position.

7) Remove the upper feeder assy by extracting it from the left side of the mechanicalassy rotating the feeder assy on the left side slightly to the front.

Replace the upper feeder assy following the above instructions in reverse order.

Figure 3.15 Upper Feeder Assy


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3.3.16 Platen Assy

1) Remove the Main Rear and Front Covers (refer chapter to 3.3.4 and 3.3.5).

2) Remove the upper feeder assy (refer to chapter 3.3.15).

3) Remove the Aga support and the T/F lever (refer to chapter 3.3.13).

4) Remove the circlip retaining the platen assy to the pulley gear.

5) Unscrew the two screws securing the bearing bracket to the left side of the mechanismand remove it.

6) Remove the bearing and the special washer from the platen axis.

7) Put the print head to its maximum distance from the platen assy.

8) Gently shift the platen assy left from its position and then extract it from the left side ofthe mechanical assy.

Replace the platen assy following the above instructions in reverse order.

NOTICE: the platen assy replacement requires an appropriate print head gap adjustmentprocedure (refer to chapter 5).


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Figure 3.16 Platen Assy


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3.3.17 Lower Feeder Assy

1) Remove the Main Rear and Front Covers (refer chapter to 3.3.4 and 3.3.5).

2) Remove the AGA motor (refer to chapter 3.3.13).

3) Remove the AGA support (refer to chapter 3.3.14).

4) Remove the cut sheet assy (refer to chapter 3.3.17)

5) Remove the circlip retaining the AGA gear to its pivot and remove the gear.

6) Unscrew the screw securing the AGA sector to the main shaft and remove it.

7) Remove the carriage motor assy (refer to chapter 3.3.15).

8) Loosen the paper belt tensioning lever screw and remove the paper belt from the lowerfeeder assy gear and the gear from its axis.

9) Remove the circlip retaining the lower feeder gear to the axis.

10) Unscrew the four screws securing the cut sheet profile to the mechanical assy.

11) Remove the cut sheet profile by simply extracting it from the front.

12) Remove the circlip retaining the lower feeder axis on the right side of the mechanicalassy and shift the feeder assy from its location.

13) Remove the lower feeder assy by simply extracting it from the mechanism.

Replace the lower feeder assy following the above instructions in reverse order.

NOTICE: the lower feeder assy replacement requires an appropriate carriage and paperbelts adjustment procedure (refer to chapter 5).


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Figure 3.17 Lower Feeder Assy


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3.3.18 Carriage Assy

CAUTION: Before starting with this procedure, put the carriage assy in the maximumdistance from the platen assy to avoid any print head mask damage.

1) Remove the Main Rear and Front Covers (refer to chapter 3.3.4 and 3.3.5).

2) Remove the print head (refer to chapter 3.3.3).

3) Remove the carriage motor assy (refer to chapter 3.4.15).

4) Remove the AGA support and the AGA sector on the left side part.

5) Unscrew the screw securing the carriage belt to the carriage assy.

6) Unscrew the two screws securing the main shaft retainer to the left side of themechanism.

7) Unscrew the two screws securing the main shaft retainer to the right side of the

mechanism.

8) Gently rotate the carriage assy with the front bar upward and extract it from the rear bar.

Replace the carriage assy following the above instructions in reverse order.

NOTICE: the carriage assy replacement requires the appropriate print head gap andcarriage belt adjustment procedures (refer to chapter 5). Slowly

introduce the front bar into the carriage holes paying attention to the oil-feltinside it.

Figure 3.18 Carriage Assy


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3.3.19 Sensor Assy


2) Remove the AGA support and the T/F lever on the left side part (refer to chapter 3.3.14).

3) Remove the ribbon motor and support (refer to chapter 3.4.12).

4) Remove the platen assy (refer to chapter 3.3.19).

5) Remove the two left-most friction assemblies.

6) Unscrew the screw securing the rear fanfold sensor support to the frame and remove itby simply extracting it from the left side.

7) Unscrew the screw securing the front fanfold sensor to its support.

8) Unscrew the screws securing the ribbon fault and home position sensors to the plasticsupport.

9) Unscrew the single sheet sensor from its metal support and extract it from the left side ofthe mechanical assy.

10) Unplug the connector from the main board and extract the cable from its cable retainerslocated in the rear part of the mechanical assy.

Replace the sensor assy following the above instructions in reverse order.


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Figure 3.19 Sensor Assy


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3.3.20 Mechanical Assy


2) Unscrew the screws securing the ground strips on the lower shield on both sides of theprinter.

3) Unplug all the connector from the main board.

4) Unscrew the two screws retaining the mechanical block to the base assy.

5) Cut the two plastic self-locked strips retaining the mechanical blocks on the base assyand remove the mechanical assy.

6) Pay attention to the paper position mylar on the base assy.

Replace the mechanical assy following the above instructions in reverse order.


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Figure 3.20 Mechanical Assy


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3.3.21 Paper Motor


2) Remove the mechanical assy (refer to chapter 3.3.23).

3) Loose the paper belt tensioning lever screw and remove the paper belt from the papermotor gear.

4) Unscrew the three screws securing the paper motor to the right side of the mechanicalassy and remove it.

Replace the paper motor following the above instructions in reverse order.

NOTICE: the paper motor replacement requires an appropriate paper belt adjustmentprocedure (refer to chapter 5).

Figure 3.21 Paper Motor


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3.3.22 Friction Bar Assy

1) Before proceeding, assure that the friction rollers are open; the flat part of the friction barassy must be upward (see chapter 2 for more details).


3) Remove the platen assy (refer to chapter 3.3.20).

4) Extract the friction supports by simply pulling them upward from their location.

5) Remove the mechanical assy (refer to chapter 3.3.23).

6) Remove the circlip retaining the friction bar assy to the mechanism.

7) Remove the friction bar assy by simply extracting it from the left side.

Replace the friction bar assy following the above instructions in reverse order.

NOTICE: the friction bar assy must have a proper position coherently with the sensortuning values stored in NVM.See chapter 6.4 for more details.

Figure 3.22 Friction Bar Assy


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Chapter 4

Removal and Replacement

for 3460 (A3) / 3480 (A3) / 3480+


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4.1 OverviewSee the same section of the chapter 3.

4.2 Recommended Hand Tools and EquipmentSee the same section of the chapter 3.

4.3 O.R.U. ORDER OF ACCESS

Table 4.1 shows the accessibility of EACH ORU (Optimum Replaceable Unit), and theprocedure necessary to access to each one.

Remove ORU: Requires these procedures in the order shown:

1) Push-Pull Tractor Group 1 (section 4.3.1)2) Operator Panel Boards 2 (section 4.3.2)3) Print Head 3 (section 4.3.3)4) Front Cover Parts 1,2,4 (section 4.3.4)5) Rear Cover Parts 5 (section 4.3.5)6) Main Board 5,6 (section 4.3.6)7) Power Supply Board 5,6,7 (section 4.3.7)8) Ribbon Motor 1,2,4,5,8 (section 4.3.8)9) AGA Motor 1,2,4,5,9 (section 4.3.9)10) AGA Support and T/F lever 1,2,4,5,10 (section 4.3.10)11) Carriage Motor and Fan 1,2,4,5,11 (section 4.3.11) (*)12) Bail Assy 12 (section 4.3.12)13) Cut Sheet Assy 1,2,4,13 (section 4.3.13)14) Upper Feeder Assy 1,2,4,5,14 (section 4.3.14)15) Platen Assy 1,2,4,5,15 (section 4.3.15) (*)

16) Lower Feeder Assy 1,2,4,5,16 (section 4.3.16) (*)17) Carriage Assy 1,2,4,5,17 (section 4.3.17) (*)18) Sensor Cable Assy 1,2,4,5,18 (section 4.3.18) (*)19) Mechanical Assy 1,2,4,5,19 (section 4.3.19)20) Paper Motor 1,2,4,5,19,20 (section 4.3.20) (*)21) Friction Bar Assy 1,2,4,5,19,21 (section 4.3.21)22) Ribbon Mask 22 (section 4.3.22)23) Lower Mylar 23 (section 4.3.23)

Table 4-1 ORU ORDER OF ACCESS

NOTE : Procedure with an asterisk require ADJUSTMENT PROCEDURE (see next chapter)

All the spare parts available on logistic are reported in the specific Illustrated Parts Catalog.


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4.3.1 Push-Pull Front Tractor GroupSee the same section of the chapter 3.

4.3.2 Operator Panel BoardSee the same section of the chapter 3.

4.3.3 Print HeadTo remove the print head please refere to the same section of chapter 3.

NOTICE: Before securing the screw, push the P.H. to its inside stop position. Securing the right screw and then the left one with a force = 25Kg. Run the AGA calibration procedure (T&D 12) to verify a correct AGA

value.

4.3.4 Front Cover PartsSee the same section of the chapter 3.

4.3.5 Rear Cover PartsSee the same section of the chapter 3.


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4.3.6 Main BoardSee the related sectiont of the chapter 3.

MAIN BOARD

J28 J22 J24

) S1

) S2

) S3

Figure 4.2 Main board and firmware location

PWA 2V4C24 / 2V4C09

J22= Serial interface connector (to plug serial inerface board).J24= Serial interface connector for cable.J28= Parallel interface connector.S1= Controller firmware location.S2= T&D firmware location.S3= Generator firmware location.

MODEL RELEASE CODE I.C. TYPE LOCATION CHECKSUM

TBD XXXX (controller) S1

3480+ TBD XXXX (T&D) S2

TBD XXXX (generator) S3


3480 (A3) TBD XXXX (T&D) S2



3460 (A3) TBD XXXX (T&D) S2



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4.3.7 Power Supply BoardSee the related section of the chapter 3.

NOTICE

On 3480+ unplug also the fan connector cable before removal and replacement thepower supply.

4.3.8 Ribbon MotorSee the related section of the chapter 3.

4.3.9 AGA MotorSee the related section of the chapter 3.

4.3.10 AGA Support and T/F LeverSee the related section of the chapter 3.

4.3.11 Carriage MotorSee the related section of the chapter 3.

4.3.12 Bail AssySee the related section of the chapter 3.

4.3.13 Cut Sheet AssySee the related section of the chapter 3.

4.3.14 Upper Feeder Assy

See the related section of the chapter 3.

4.3.15 Platen AssySee the related section of the chapter 3.


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Figure 4.3 Force for fixing platen and main shaft of carriage assy


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4.3.16 Carriage Assy

CAUTION: Before starting with this procedure, put the carriage assy in the maximumdistance from the platen assy.


2) Remove the print head (refer to chapter 4.3.3).

3) Unscrew the two screws securing the ribbon mask and remove it.

4) Remove the AGA support and the AGA sector on the left side part.

5) Unscrew the screw securing the carriage belt to the carriage assy.

6) Unscrew the two screws securing the main shaft retainer to the left side of themechanism.

7) Gently pull-up a little the front bar in its right side and in the meantime moves it left in

order to exctract it from the right side.Be carefull to do not damage the little spring (item 137 of fig.4.16B) located in each sidebetween the front bar and the frame.Before reassembly of the printer it is mandatory to apply in this point a silicon grease(molikote type).

8) Gently rotate the carriage assy with the front bar upward and extract it from the rear bar.

Replace the carriage assy.a- Insert the black flange on the main bar.b- Insert the carriage on the main bar.c- Insert the other black flange on the main bar and assembly the carriage with its flanges.d- Gently insert oil felt in proper locate under the periferal area of the flanges.

Continue the reassembly of the printer following the above instructions in reverse order.

ATTENTION: before tight the front bar retainer screws, push-down the retainers indicatein figure 4.15B (force F2), then secure in sequence the screws C

and D. Check for the correct tighten of the belt clamp screw securing the

carriage belt.

NOTICE: the carriage assy replacement requires the appropriate print head gap andcarriage belt adjustment procedures.


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Figure 4.4 Carriage Assy


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Figure 4.5 Particular of little spring and main shaft

4.3.17 Lower Feeder AssySee the related section of the chapter 3.

4.3.18 Sensor AssySee the related section of the chapter 3.

4.3.19 Mechanical AssySee the related section of the chapter 3.

4.3.20 Paper MotorSee the related section of the chapter 3.

4.3.21 Friction Bar Assy

Se

genicom 3460 maint manual

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