On Thu, 16 May 2002, Garry wrote:

> Constant,
>
> There is a clue here.
>
> By indicating that you were able to print something
> normally after the switch was removed, you have a
> good probability that it's your cable or connectors.
>
> Check your connectors *carefully* for bent pins,
> dirt, loose pins, or any damage to the cable itself.

Having removed the data switch, you should have two "spare" cables.
Try them instead of the present cable.  If that doesn't fix it, but
swapping the I/O card does, look at the I/O card pins.  The solder around
a pin where it goes through the board sometimes stress-cracks from
flexing, causing an intermittent connection.  The best way to find a crack
is to hook up a solid connection to the pin using a single socket from a
mating connector.  Use a "beeper", test light, or VOM to check for
continuity.  Use a clip or probe to make a good connection to the trace,
either at a lead or another solder joint, or at least back from the joint
in question.  If gently wiggling the pin, or pressing on it with a small
stick, etc. breaks continuity, you will find a microscopic crack around
the pin - but you will need a bright light and a strong magnifying glass
to see it.

The same test could be used on the printer board connector - but that is
probably a real pain to inspect.  If you find a bad joint, resolder it,
making sure to get a good clean joint.

My sympathies - intermittent faults are the worst kind of problem to find.
:-(

Boyd Ramsay

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