TechNote TSB 40T-015A
4410 / 4440
490, 491, 492 and 493 Display
29 Feb 1996 Ed Palmer

Summary: A constant 490, 491, 492, or 493 display on power up.

Cause: The 49x error message in the display indicates the printer shuttle mechanism is not shuttling or shuttling at an improper frequency.

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Operator Level Troubleshooting

Paper Jam: If the printer display showed SDR before turning the power off, there may be a paper jam. Open print gap adjust knob to the load position and remove all paper. Turn on the printer power. If the printer powers up to SBO (striker bar open) and PO (paper out), visually check throat area for a paper jam. If labels were printed, check for stuck labels. Correct any paper jams, reset the print gap adjust to normal setting, and re-load the paper.

Print Modules and Ribbon Shield: Loose or missing print modules will affect the shuttle balance, as will a damaged or missing ribbon shield.

Shipping Hardware: Verify all shipping screws and blocks have been removed. Shipping hardware should have been removed when the printer was installed. If the shipping bolts were removed, but the blocks were left in the printer, the printer may run properly for some time. If the shipping blocks shift, they may jam the shuttle.

There are a total of 7 - 8mm yellow hexhead bolts. The locations of these bolts are 2 on the shuttle bar, 1 far left and 1 far right. 4 are inside the main cabinet, 2 mounted through black blocks in the front and 2 mounted through yellow blocks towards the rear behind the lower tractor assembly. 1 is under the print module access cover right side through a shipping bracket mounted to black cast iron plate. Remove this shipping bracket also. Refer to user's manual GEK-88440 (standard models) or GEK-88832 (XT models) "Removing the Shipping Blocks and Hardware" for more details.

Technician Level Troubleshooting

Non XT models: Remove left side door panel inspect that all red LED's are lit. This verifies all power supply voltages are present. If any LED's are not lit then replace that PWB card. Check for +42VDC on the SMMB at P3 pin 1.

XT models: Remove the back panel and check the green LED (all voltages normal) on the SPSC board. If not lit, replace the SPSC. If the red LED is lit (overvoltage on 42V bus) replace the SPSC [44C510004-G02S]. Check for +42VDC on the SMMB at P3 pin 1.

Shuttle Drive Test: Remove all the logic boards from the card cage in the right side of the printer. On the SMMC board, move the jumper on J7 to the J8 position. Re-install the SMMC card only. Turn on the printer power. The printer shuttle should swing constantly.

If the shuttle does not swing, the problem is probably in the SMMC, the shuttle motor, the LVT coil, or the cabling. If the shuttle does swing, the problem is probably in the SMIH [44C502577-G06S] (standard models), or the SMIS [44C510008-G01S] (XT models).

SMMC Board [44C502598-G10]: Check the jumpers: for the 4410- J1 should be in, for the 4440- J2 should be in. New SMMC boards are shipped with the jumper in the 4440 position (this should not be assumed).

Check F3 [44A417087-009] on the SMMC- this provides +42 volts to the shuttle motor drive circuit. F2 may be used as a spare fuse (F1 is for the paper and ribbon motors). If F3 repeatedly blows, check the shuttle motor resistance (see below). If the motor is not shorted, replace the SMMC board.

Shuttle Bar Assembly: [4410 - 44A507019-G01, 4440 - 44D416418-G02] The shuttle bar mus be replaced as a complete assemble (bar with leaf springs). The shuttle motor and shuttle bar leaf springs should be the same thickness. The 4410 has thinner leaf spring bars than the 4440. Components of the shuttle bar should never be dissassembled- the leaf springs are attached to the bar and tuned in the factory and cannot be reinstalled in the field.

Shuttle Motor: [4410 - 44A507020-G01, 4440 - 44A507020-G02] If the shuttle motor has just been replaced, visually compare the old and new motors. The shuttle motor and shuttle bar leaf springs should be the same thickness. The 4410 has thinner leaf spring bars than the 4440.

Motor resistance should read 22 ohms ± 20% measured at P3 (usually located to the lower right of the control panel) or the SMMB connector P1 pins 19 and 21 with the SMMC removed. The resistance from P1 pin 19 to ground should be open, and P1 pin 21 to ground should be open.

Components of the shuttle motor should never be dissassembled- the leaf springs are attached to the motor block and tuned in the factory and cannot be reinstalled in the field.

LVT Coil: [44B505572-G01]

If the shuttle moves very slowly, the fault is with the LVT circuit.

Coil resistance should read 220 ohms ± 20% measured at P7 or the SMMB connector P1 pins 1 and 2 with the SMMC removed. The resistance from P1 pin 1 to ground should be open, and P1 pin 2 to ground should be open.

SMIH Board: [44C502577-G06S] Check the jumpers (J2-J32)- they should be in the X (left) position for the 4410 or the Y (right) position) for the 4440.

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