Printronix P5000 Maintenance Manual
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Printronix P5000 Maintenance Manual

Line matrix printers
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Table of Contents

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Maintenance Manual
Printronix P5000 Line Matrix Printers

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Summary of Contents for Printronix P5000

  • Page 1 ® Maintenance Manual Printronix P5000 Line Matrix Printers...
  • Page 3 P5000 Line Matrix Printers Maintenance Manual ® 175455-001B...

  • Page 4: Trademark Acknowledgements

    Utica is a registered trademark of Cooper Power Tools. Warranty And Copyright Information Printronix, Inc. makes no representations or warranties of any kind regarding this material, including, but not limited to, implied warranties of merchantability and fitness for a particular purpose. Printronix, Inc. shall not...

  • Page 5: Communication Notices

    Properly shielded and grounded cables and connectors must be used in order to meet FCC emission limits. Printronix is not responsible for any radio or television interference caused by using other than recommended cables and connectors or by any unauthorized changes or modifications to this equipment.
  • Page 6 Communication Notices Der Außteller der Konformitätserklärung ist die Printronix..(1) Informationen in Hinsicht EMVG Paragraph 3 Abs. (2) 2: Das Gerät erfüllt die Schutzanforderungen nach EN 55022 und EN 55024 Klasse A. EN 55022 Klasse A Geräte bedürfen folgender Hinweise: Nach dem EMVG: “Geräte dürfen an Orten, für die sie nicht asreichend entstört sind, nur mit besonderer Genehmigung des Bundesminesters für...
  • Page 7 Communication Notices...
  • Page 8 Communication Notices...

  • Page 9: Table Of Contents

    Mechanical Controls, All Models ........... 26 Tools, Test Equipment, And Supplies..........28 Plugging In The Printer ................ 29 Printronix Customer Support Center............ 29 Maintenance Training Available For Printronix Products..... 29 2 Preventive Maintenance ........31 Cleaning The Printer................31 Cleaning The Outside Surfaces............31 Cleaning The Shuttle Frame Assembly ..........
  • Page 10 Table of Contents Diagnostic Printer Tests..............114 Selecting And Running Diagnostic Printer Tests ......115 Boot Diagnostics Menu..............118 Hex Code Printout ................121 How To Print A Hex Dump ............122 ASCII Character Set ................123 Soft vs. Hard Reset................124 The Power On Sequence ..............
  • Page 11 Table of Contents 5 Replacement Procedures And Illustrated Parts Lists........165 Organization Of This Chapter ............165 Section I: Replacement Procedures ..........166 List Of Removal / Installation Procedures ........166 Belt, Paper Feed Timing ............. 168 Belt, Platen Open ................ 169 Circuit Breaker ................
  • Page 12 Table of Contents Tractor (L/R) ................220 Section II: Illustrated Parts Lists ............221 Illustrations of Printer Components ..........221 6 Principles Of Operation........253 Line Matrix Printing ................253 Printing Rates ..................256 Printing Mechanism ................256 Shuttle Frame Assembly ............. 257 Paper Transport System .............
  • Page 13 Form Evenness ................383 Tractor Pin Engagement ............. 383 Methods Of Forms Attachment ........... 384 Chaff Content ................385 Form Design Checklist............... 386 Summary ................... 389 Storage And Handling ..............389 G Maintenance Information About Other P5000 Printers ..............391...
  • Page 14 Table of Contents...

  • Page 15: Maintenance Overview

    A P5000 printer is easy to use. The operator can select every printer function at the printer control panel or by sending control codes in the data stream from the host computer to the printer.

  • Page 16: H-Series Printers

    Figure 1 shows how to interpret a model number. Table 1 lists the latest models the P5000 family. The speeds listed in Table 1 are the highest rated speeds attainable under controlled test conditions.
  • Page 17 2 = Floor Cabinet assemblies. Printronix Line Matrix Printer P5005B-12-QA P5000 Printer QA = Pedestal model with optional Quick-Access cover SS = Cabinet model with optional SureStak™ power paper stacker. Speed Rating: 05 = 475 lpm...
  • Page 18 Chapter P5000 Printers Table 1. P5000 Printers Maximum Controller Model Number Print Enclosure Hammer Bank Board Speed P5003H Pedestal 60 Hammers 40 MHz CFX ™ P5005B 500 lpm Pedestal 28 Hammers 40 MHz CMX ™ P5005B-QA 500 lpm Pedestal w/Quick-...

  • Page 19: Important Maintenance Notes

    Defines host control codes and character sets for the ANSI emulation. • IPDS Twinax Emulation Programmer’s Reference Manual ™ An overview of Intelligent Printer Data Stream™ (IPDS) features, commands, and diagnostics. • IGP/PGL Programmer’s Reference Manual ® Describes the optional IGP Printronix emulation. The IGP Printronix...

  • Page 20: How To Use This Manual

    IGP/VGL Programmer’s Manual Describes the optional Code V Printronix emulation. The Code V Printronix emulation allows the user to create and store forms; generate logos, bar codes, and expanded characters; create other graphics, and merge graphics with alphanumeric data as a document is printed.

  • Page 21: Safety Notices

    Notices Safety Notices WARNING Always disconnect the AC power cord from the printer or power source before performing any maintenance procedure. Failure to remove power could result in injury to persons or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure.

  • Page 22: Controls And Indicators

    Chapter Controls And Indicators Controls And Indicators Electrical Controls, Cabinet Models Switch or Active Active Function Indicator On-line Off-line Power Switch Turns printer on and off: 1 = on, 0 = off. This switch is also a circuit breaker. Status Indicator On when the printer is on-line, off when the printer is off-line.
  • Page 23 Electrical Controls, Cabinet Models (Off) (On) Power Switch Status Indicator PRT CONFIG SET TOF Arrow Keys ENTER CANCEL JOB SELECT VIEW/EJECT ON LINE/CLEAR PAPER ADVANCE Figure 2. Electrical Controls, Cabinet Models...

  • Page 24: Electrical Controls, Pedestal Models

    Chapter Controls And Indicators Electrical Controls, Pedestal Models Switch or Active Active Function Indicator On-line Off-line Power Switch Turns printer on and off: 1 = on, 0 = off. This switch is also a circuit breaker. Status Indicator On when the printer is on-line, off when the printer is off-line. Flashes to indicate a fault or warning.
  • Page 25 Electrical Controls, Pedestal Models (Rotated 180 Degrees) (Off) (On) Power Switch SELECT PREV DOWN CONFIG NEXT ENTER CLEAR PREV NEXT SELECT ENTER CONFIG DOWN VIEW EJECT ON-LINE PAPER Status Indicator CLEAR ADVANCE CANCEL ON-LINE PAPER VIEW CANCEL CLEAR ADVANCE EJECT Figure 3.

  • Page 26: Mechanical Controls, All Models

    Chapter Controls And Indicators Mechanical Controls, All Models Control or Indicator Function Forms Thickness Lever Sets the platen for paper and forms of different thicknesses. Lever must be fully opened (raised) to load or unload paper. Paper Supports Help prevent paper jams by supporting inner sections of paper. They are positioned manually by sliding them along the shafts.
  • Page 27 Mechanical Controls, All Models Paper Supports Left Tractor Right Tractor Tractor Lock Vertical Tractor Lock Position Knob Ribbon Loading Forms Thickness Path Diagrams Lever and Scale Forms Thickness Pointer Figure 4. Mechanical Controls, All Models...

  • Page 28: Tools, Test Equipment, And Supplies

    Hex bit, 3/16 in., torque screwdriver Hex bit, 3/32 in., torque screwdriver Hex bit, 5/32 in., torque screwdriver Hex bit, 5/64 in., torque screwdriver Lubricant, Bearing (Printronix P/N 101805-001) Nut Driver, 1/4 inch Nut Driver, 5/16 inch Nut Driver or Open End Wrench, 7/32 inch...

  • Page 29: Plugging In The Printer

    Specifications of the proper print media and ribbons • Answers to post-sales service support questions Call the Printronix Customer Support Center at (714) 368-2686 or visit the Printronix web page at www.printronix.com. Maintenance Training Available For Printronix Products Printronix offers Product Maintenance Training Classes designed to enhance the knowledge of your service personnel.
  • Page 30 Chapter Maintenance Training Available For Printronix Products...

  • Page 31: Preventive Maintenance

    Preventive Maintenance Cleaning The Printer The printer is designed to require very little maintenance. Aside from normal replenishment of paper and ribbons, the only preventive maintenance required is periodic cleaning. Because operating conditions vary widely, the user must determine how often to clean the printer.
  • Page 32 Chapter Cleaning The Outside Surfaces CAUTION To avoid corrosion damage, use only alcohol when cleaning printer mechanical elements, and make sure the cleaning solution contains no water. 9. Using a cloth dampened (not wet) with alcohol, clean the ribbon guides. 10.

  • Page 33: Cleaning The Shuttle Frame Assembly

    Cleaning The Shuttle Frame Assembly 1. Remove the shuttle cover assembly (page 178). 2. Remove the shuttle frame assembly (page 215). 3. Remove the paper ironer (page 198). WARNING Over time, the upper edge of the paper ironer can become sharp. To avoid cutting yourself, handle the paper ironer on the sides.

  • Page 34: Cleaning The Card Cage Fan Assembly

    Chapter Cleaning The Card Cage Fan Assembly Cleaning The Card Cage Fan Assembly 1. Cabinet Models: Remove the paper path (page 199). Pedestal Models: Remove the top cover assembly (page 179). 2. Vacuum the card cage fan assembly and surrounding areas to remove paper particles, dust, and lint.

  • Page 35: Troubleshooting

    Troubleshooting Introduction This chapter lists fault messages and general symptoms, and provides procedures for troubleshooting printer malfunctions. You must operate the printer to check its performance and sometimes you may have to reconfigure it. Always have the User’s Manual handy when you troubleshoot because this manual does not cover printer operation or configuration.

  • Page 36: Start Here

    Chapter Start Here... Start Here... Are you here because of an Go to Troubleshooting Display error message? Messages, page 37. Power on the printer and observe the control panel for the following sequence of events (retry as Did the status required): indicator lamp 1.

  • Page 37: Troubleshooting Display Messages

    List Of Messages Troubleshooting Display Messages WARNING Always disconnect the AC power cord from the printer before doing a maintenance procedure. Failure to remove power could result in injury to you or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure.
  • Page 38 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution 8.5V POWER FAIL * 8.5 Volt Power Failed. 1. Cycle power. If the message Internal power failure. appears, replace the power supply board. 2. Power on the printer. If the message appears, replace the controller board.
  • Page 39 List Of Messages Table 2. Message List Message Explanation Solution 15V CTL FAIL* Controller Voltage Failure. 1. Cycle Power. Run the print job again. If the message appears, remove the hammer bank logic cable, inspect it for damage, and test it for continuity. (See Appendix A.) Replace the hammer bank logic cable if it is damaged or fails continuity test.
  • Page 40 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution 23.5V CTL FAIL* 23.5 Volt Controller Failed: a 1. Cycle Power. Run the print job voltage failure on the again. If the message appears, controller board. download the emulation software again (page 150).
  • Page 41 List Of Messages Table 2. Message List Message Explanation Solution 32 PAPER JAM In the CT emulation with a 1. Clear the paper jam. Press TIMEOUT coax interface, a time-out CLEAR. message is sent to the host 2. Press PAPER ADVANCE if paper motion has not several times and check that occurred for 10 minutes after...
  • Page 42 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution 32 PAPER JAM 8. Inspect the tractors and tractor TIMEOUT (continued) door springs for damage, excessive wear, and equal door closing tension. If either tractor is worn, damaged, or exhibits uneven door closing tension, replace both tractor assemblies.
  • Page 43 List Of Messages Table 2. Message List Message Explanation Solution 33 PLATEN OPEN In the CT emulation with a 1. Load paper. Close the forms TIMEOUT coax interface, the forms thickness lever. Press CLEAR. thickness lever has been 2. Run a print test. If a platen open open for at least one minute.
  • Page 44 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution 34 RIBBON STALL In the CT emulation with a 1. Set the forms thickness lever to TIMEOUT coax interface, the ribbon match the thickness of the paper has not moved for 10 being used, but not too tightly.
  • Page 45 List Of Messages Table 2. Message List Message Explanation Solution 48V PWR FAIL* 48 Volt Power Failed: an 1. Power off the printer. Remove the internal power failure. paper path or pedestal top cover. Check that power supply connector P101 is fully seated in connector J101 on the controller board.
  • Page 46 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution ACCESS NULL PTR* Access Null Pointer: The 1. Cycle power. Run the print job processor tried to access a again. If the message appears, pointer that contains nothing download the emulation software (null).
  • Page 47 List Of Messages Table 2. Message List Message Explanation Solution BUFFER OVERRUN The print buffer has Verify that the printer matches overflowed on a serial the host serial interface interface. The printed output configuration settings for Data may contain random * Protocol, Baud Rate, Data Bits, (asterisk) characters.
  • Page 48 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution CLEAR PAPER JAM 8. Inspect the tractors and tractor (continued) door springs for damage, excessive wear, and equal door closing tension. If either tractor is worn, damaged, or exhibits uneven door closing tension, replace both tractor assemblies.
  • Page 49 List Of Messages Table 2. Message List Message Explanation Solution CLOSE PLATEN The forms thickness lever is 1. Load paper. Close the forms open. thickness lever. 2. Power off the printer. Remove the paper path or pedestal top cover. Disconnect connector P107 from the controller board.
  • Page 50 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution COIL HOT One or more hammer coils 1. Advise the user to move the are overheating. Inspect printer to cooler, cleaner location. printer environment for 2. Check the kinds of print jobs the severity.
  • Page 51 List Of Messages Table 2. Message List Message Explanation Solution CTL VOLT FAIL* Controller Voltage Failure. 1. Cycle Power. Run the print job 15 V failure on the controller again. If the message appears, board. download the emulation software again (page 150). 2.
  • Page 52 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution DRVR CIR BAD* Driver Circuit Bad: the 1. Cycle power. If the message hammer coil count test appears, press CLEAR. failed. 2. Power off the printer. Remove the shuttle cover. At the shuttle frame assembly, disconnect the hammer bank logic and power cables.
  • Page 53 List Of Messages Table 2. Message List Message Explanation Solution ERROR: EC STOPPED Where XXXX is a number 1. Power off the printer. Remove all AT STATE XXXX from 0000 to 0010. The flash memory and DRAM SIMMs. Engine Controller has Inspect the SIMM sockets on the stopped and is in the state controller board.
  • Page 54 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution ERROR: PROGRAM The printer is not compatible Use the correct emulation software NOT COMPATIBLE with the downloaded option(s) for this model printer. program. ERROR: PROGRAM The printer does not see a There is no program in printer NOT VALID program in flash memory.
  • Page 55 List Of Messages Table 2. Message List Message Explanation Solution ERROR OCCURRED An interim message that Wait. When the asterisk (*) stops FLUSHING QUEUES * displays while the printer rotating, a different fault message will discards host data it cannot appear: troubleshoot the final use because a fault message.
  • Page 56 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution EXHAUST FAN FLT Exhaust Fan Fault. Sensors 1. Cycle power. If the message cannot detect current in the appears, press CLEAR. fan circuit. 2. Check that the exhaust fan is connected to exhaust fan cable connector J307.
  • Page 57 List Of Messages Table 2. Message List Message Explanation Solution FIRMWARE ERROR Application software tried to 1. Cycle power. Run the print job. If perform an illegal printer the message appears, download function or damaged the emulation software again memory is detected on the (page 150).
  • Page 58 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution FREEFORM ON: OFF This message appears if the 1. Power off the printer. Hold any HOLD KEY @ PWRUP freeform feature is enabled. control panel key down and This feature is for power on the printer.
  • Page 59 List Of Messages Table 2. Message List Message Explanation Solution <Online, etc..> This is a status message, 1. Advise the user to move the Half Speed Mode not an operational state. The printer to cooler, cleaner location. controller periodically 2.
  • Page 60 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution HAMMER COIL BAD Hammer coil(s) number #, #, 1. Cycle power. If the message #, #, #, #, ... etc. etc. failed the current test at appears, replace the shuttle power-up.
  • Page 61 List Of Messages Table 2. Message List Message Explanation Solution HMR BANK FAN FLT Hammer Bank Fan Fault. 1. Cycle power. If the message Sensors cannot detect appears, press CLEAR. If the current in the fan circuit. message does not clear, go to step 2.
  • Page 62 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution ILLGL OPR ACCSS* Illegal Operand Accessed. 1. Cycle power. Run the print job Firmware error on the again. If the message appears, controller board. download the emulation software again (page 150). 2.
  • Page 63 List Of Messages Table 2. Message List Message Explanation Solution INTERRUPT UNUSED This message is generated 1. Cycle power. If this message VECTOR 00 when the controller board occurred once and never again, gets an interrupt it does not you can ignore it. If the message understand.
  • Page 64 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution INVALID COMMAND The printer detects a twinax 1. Reseat the twinax host data cable protocol communications connection and the twinax I/O error and reports the error. cable connection at the Power off the printer.
  • Page 65 List Of Messages Table 2. Message List Message Explanation Solution LOAD PAPER Printer is out of paper. 1. Load paper. Press CLEAR. If message does not clear, go to the next step. 2. Check for black or colored back on paper being used in printer. The paper out detector is optical and may not detect paper with a black or dark backing facing the...
  • Page 66 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution LOADING PROGRAM The printer has deleted the No action required. INTO FLASH previous program from flash memory and is loading the new program into flash memory. NON VOLATILE Large emulations reduce the 1.
  • Page 67 List Of Messages Table 2. Message List Message Explanation Solution PAP BAD TABLE* Paper Bad Table. The paper 1. Cycle power. Run the print job feed process on the again. If the message appears, controller board has a download the emulation software corrupted table.
  • Page 68 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution PAP FIFO OVERFL* Paper First In First Out 1. Cycle power. Run the print job Overflow. Firmware error on again. If the message appears, the controller board. download the emulation software again.
  • Page 69 List Of Messages Table 2. Message List Message Explanation Solution PAP ILLGL ST* Paper Illegal State. 1. Cycle power. Run the print job Firmware error on the again. If the message appears, controller board. download the emulation software again. 2. Cycle power. Run the print job again.
  • Page 70 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution PAP NOT SCHED* Paper Not Scheduled. The 1. Cycle power. Run the print job paper feed process is not again. If the message appears, scheduling on the controller download the emulation software board, and the printer cannot again.
  • Page 71 List Of Messages Table 2. Message List Message Explanation Solution PARAMETER ERROR Illegal parameter value 1. Press CLEAR then press ON received in a command code LINE. over a coax/twinax interface. 2. Run the print job that generated the error message. If the message appears, check the host data for invalid characters.
  • Page 72 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution PLAT INV CMD* Platen Invalid Command. 1. Cycle power. Run the print job Firmware error on the again. If the message appears, controller board. download the emulation software again. 2.
  • Page 73 List Of Messages Table 2. Message List Message Explanation Solution POWER SUPPLY HOT The printer has sensor 1. Inspect printer environment for circuits that sample the severity. Advise the user to move operating temperature of key the printer to cooler, cleaner components of the power location.
  • Page 74 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution PRINTER HOT This message indicates controller board sensors report internal temperatures over high temperatures on the board. 60° Celsius (140° Inspect printer environment for Fahrenheit). Print jobs will severity. Advise the user to move not create such the printer to cooler, cleaner temperatures, so...
  • Page 75 List Of Messages Table 2. Message List Message Explanation Solution QUEUE OVERRUN In the CT twinax emulation, 1. If the message appears, replace the print buffer has the expansion-CT board. Record overflowed. Send a print job the message and return it with to the printer.
  • Page 76 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution RIBBON DRIVE The controller board does 1. Cycle power. If the message not detect a ribbon drive appears, power off the printer. motor. Remove the paper path or pedestal top cover. Reseat the cable connections of both ribbon drive motors.
  • Page 77 List Of Messages Table 2. Message List Message Explanation Solution RIBBON STALL The controller board does 1. Cycle power. If the message not detect ribbon movement. appears, power off the printer. Check that both ribbon hubs are securely mounted on the ribbon motor shafts.
  • Page 78 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution SCS COMMAND In the CT emulation, the 1. The printer clears the error. ERROR printer received undefined 2. Run the print job that generated control character (hex 40). the error message. If the message appears, verify that there are no invalid control codes in the host data.
  • Page 79 List Of Messages Table 2. Message List Message Explanation Solution SF ERROR Structured Field Error. Not a printer problem. Have the Application software has system administrator correct violated structured data field applications data or configuration. parameters. SHUT DRVR CIR* The shuttle driver circuit on 1.
  • Page 80 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution SHUTTLE JAM The shuttle is not moving or 1. Set the forms thickness lever to is moving at the wrong match the thickness of paper, but speed. Check the forms not too tightly.
  • Page 81 List Of Messages Table 2. Message List Message Explanation Solution SHUTTLE JAM 9. Run a print test. If the message (continued) appears, replace the controller board. Record the message and return it with defective board. 10. Run a print test. If the message appears, replace the shuttle frame assembly.
  • Page 82 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution STACK OVERFLOW* Firmware error on the 1. Cycle power. Run the print job controller board. again. If the message appears, download the emulation software again. 2. Cycle power. Run the print job again.
  • Page 83 List Of Messages Table 2. Message List Message Explanation Solution STACKER FAULT Two situations can trigger 1. Open the cabinet rear door and this message: check for obstructions preventing 1. The stacker elevator is elevator movement. Remove any obstructed while attempting obstructions.
  • Page 84 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution STACKER FULL Status message: the power 1. Unload the stacker. paper stacker is full. 2. Check the stacker limit switches. (See page 99.) If the limit switches are OK, go to the next step.
  • Page 85 List Of Messages Table 2. Message List Message Explanation Solution STACKER JAM This message is triggered if 1. Open the cabinet rear door and there is paper inside the check for obstructions preventing throat of the stacker elevator movement. Remove any elevator, but the elevator is obstructions.
  • Page 86 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution TCB CORRUPTED* Task Control Block 1. Cycle power. Run the print job Corrupted. Firmware error again. If the message appears, on the controller board. download the emulation software again. 2.
  • Page 87 List Of Messages Table 2. Message List Message Explanation Solution UNDEF INTERRUPT* Undefined Interrupt. 1. Cycle power. Run the print job Firmware error on the again. If the message appears, controller board. download the emulation software again. 2. Cycle power. Run the print job again.
  • Page 88 Chapter Troubleshooting Display Messages Table 2. Message List Message Explanation Solution WAITING FOR This status message No action required. ETHERNET ADAPTER appears when the printer is first powered on if the optional PrintNet ethernet interface is installed. An ethernet adapter must be detected early in the power up sequence so the printer can tell the adapter it has...

  • Page 89: Troubleshooting Other Symptoms

    List Of Messages Troubleshooting Other Symptoms WARNING Always disconnect the AC power cord from the printer before doing a maintenance procedure. Failure to remove power could result in injury to you or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure.

  • Page 90: General Symptom List

    Chapter Troubleshooting Other Symptoms General Symptom List Table 3 is a list of possible printer problems that are not indicated by messages on the LCD. Troubleshooting procedures are included for each symptom. If you encounter a problem that is not listed in Table 3, troubleshoot using the Half-Split Method described on page 89.
  • Page 91 General Symptom List Table 3. General Symptom List Symptom Solution CLEAR PAPER JAM 1. Remove the paper path or pedestal top cover. Make sure message will not clear and connector P107/PAPR M is fully seated in connector J107 paper does not move on the controller board.
  • Page 92 Chapter Troubleshooting Other Symptoms Table 3. General Symptom List Symptom Solution Control Panel Black squares on control 1. Power off the printer. Remove the paper path or pedestal panel top cover. Disconnect the control panel cable from the panel and from J110 on the controller board. Check continuity of the cable.
  • Page 93 General Symptom List Table 3. General Symptom List Symptom Solution Control panel keys do not 1. Power on the printer. Check the operation of the control work panel keys. Replace the control panel assembly if the keys do not work. 2.
  • Page 94 Chapter Troubleshooting Other Symptoms Table 3. General Symptom List Symptom Solution Power Failures No power, and control panel 1. Check that the AC power outlet has power. Restore AC blank, and card cage fan not power if necessary. running 2. Unplug the printer AC power cord from the printer (leave it plugged into the power outlet) and check for AC power at the printer end of the cord.
  • Page 95 General Symptom List Table 3. General Symptom List Symptom Solution Printer does not initialize NOTE: Power-on initialization is explained on page 125. 1. Power off the printer. Remove the paper guide or pedestal top cover. Reseat all cable connectors on the controller board, especially connectors P106 and P107.
  • Page 96 Chapter Troubleshooting Other Symptoms Table 3. General Symptom List Symptom Solution Power Stacker Printer does not detect 1. Check that the power stacker is enabled under the Printer presence of power stacker Control menu. (Refer to the Setup Guide.) If the power stacker enable/disable option does not appear in the menu, go to the next step.
  • Page 97 General Symptom List Table 3. General Symptom List Symptom Solution Stacker “chatters” at upper or 1. Power off the printer. Unload paper. Open the rear cabinet lower limit door and check that stacker motion is not obstructed by the control panel cable or other obstruction. Remove obstruction or reroute the stacker control panel cable as necessary.
  • Page 98 Chapter Troubleshooting Other Symptoms Table 3. General Symptom List Symptom Solution Stacker does not stack 1. Check for and remove obstructions preventing elevator properly movement. 2. Check for misaligned stacker rails. Adjust the stacker rails if they are not vertical and parallel. 3.
  • Page 99 General Symptom List Table 3. General Symptom List Symptom Solution Stacker limit switch check NOTE: This procedure tests the upper and lower limit switches on the right vertical rail. These magnetic switches are normally closed. You can quickly check Right Vertical Rail their functionality with a small, powerful magnet.
  • Page 100 Chapter Troubleshooting Other Symptoms Table 3. General Symptom List Symptom Solution Stacker motor check NOTE: This procedure tests the four stacker motors and their cables. You will usually be referred to this procedure from other troubleshooting procedures. When you have completed this procedure, return to the procedure that sent you here.
  • Page 101 General Symptom List Table 3. General Symptom List Symptom Solution Print Quality Characters or dots are 1. Check the forms thickness lever: if it is set too loose or too missing, smeared, too light, tightly print quality can be affected. Set the forms or too dark.
  • Page 102 Chapter Troubleshooting Other Symptoms Table 3. General Symptom List Symptom Solution Characters are compressed Adjust the tension of the tractor belts (page 159). on first line of a form Horizontal misalignment of 1. Take the printer offline and print a test pattern of All H’s. If characters (Dots or characters shift left or right from line to line, there might be characters move left or right...
  • Page 103 General Symptom List Table 3. General Symptom List Symptom Solution Randomly misplaced dots 1. Power off the printer. Check the platen gap. Adjust the platen gap if necessary. 2. Remove the paper guide assembly or pedestal top cover. On the left rear wall of the card cage, make sure the nut which secures the line filter ground line and the AC In Power Supply cable lead to the ground stud is tight.
  • Page 104 Chapter Troubleshooting Other Symptoms Table 3. General Symptom List Symptom Solution Vertical misalignment of 1. Load paper. Press PAPER ADVANCE and check that characters: paper feeds smoothly. Press VIEW to verify that paper 1. Dots or characters move moves in both directions. Check the forms thickness lever: up or down from dot row to if it is set too loose or too tightly print quality can be dot row or line to line...
  • Page 105 General Symptom List Table 3. General Symptom List Symptom Solution Printer Operation Downloads consistently fail NOTE: Most download problems are detected by software during the procedure and communicated by LCD messages. If downloads fail consistently with no messages or with erratic messages, suspect a hardware failure.
  • Page 106 Chapter Troubleshooting Other Symptoms Table 3. General Symptom List Symptom Solution Paper feeds poorly 1. Check the forms thickness lever: if it is set too tightly paper feeding can be affected. Set the forms thickness lever to match the thickness of the paper being used. 2.
  • Page 107 General Symptom List Table 3. General Symptom List Symptom Solution Printer does not print from the 1. Check the host data cable connection at the rear of the host printer. Attach the data cable to the printer interface. 2. Make a configuration printout. Verify that the printer matches host interface settings.
  • Page 108 Chapter Troubleshooting Other Symptoms Table 3. General Symptom List Symptom Solution Reverse paper feed: platen 1. Raise the forms thickness lever and check that the platen does not open opens. If the platen opens with difficulty, inspect for and remove jams or obstructions. 2.
  • Page 109 General Symptom List Table 3. General Symptom List Symptom Solution Ribbon Ribbon folding or feed 1. Check that both ribbon spools are fully seated on the problems ribbon hubs and the ribbon runs between the ribbon mask and hammer bank cover. Install the ribbon correctly. 2.
  • Page 110 Chapter Troubleshooting Other Symptoms Table 3. General Symptom List Symptom Solution Shuttle Shuttle does not move 1. Power down the printer. Remove the shuttle cover. Check the MPU gap. Adjust the gap between the MPU assembly and the flywheel to 0.010 ± .001 inch (0.254 ± 0.025 mm). Torque the 7/16 inch MPU clamp screw to 18 ±...
  • Page 111 General Symptom List Table 3. General Symptom List Symptom Solution Shuttle is noisy 1. Check the bolts securing the mechanism base to the base pan. Tighten the mechanism base mounting bolts if they are loose enough to permit movement of the mechanism base.

  • Page 112: Communications Failures

    Chapter Communications Failures Communications Failures Many host-printer communications problems are complex. With the exception of a defective interface cable, most communications problems are not a result of a hardware failure. They usually result from an incompatible configuration of the host computer system, network (LAN, print server, controller, multiplexer, etc.), or the printer.
  • Page 113 General Symptom List Table 4. Communications Problems • Ethernet Interface cable defective • Host/Printer/Network configuration • Printer logic Ethernet PCBA responds Ethernet 1. Open a telnet session using the IP address of to “ping” and “telnet” the ethernet card. utilities, and can print from 2.

  • Page 114: Diagnostic Printer Tests

    Chapter Diagnostic Printer Tests Diagnostic Printer Tests A set of printer tests is included in the configuration menu structure for use as diagnostic tools. Use these printer tests to check the print quality and basic operation of the printer. You will also use some of the tests in some adjustment procedures.

  • Page 115: Selecting And Running Diagnostic Printer Tests

    Selecting And Running Diagnostic Printer Tests Selecting And Running Diagnostic Printer Tests NOTE: You must set TOF after running any diagnostic test. Step Press LCD Result Notes Make sure the printer is on. Raise the printer cover. Load paper. Set TOF. (Refer to the User’s Manual.) OFFLINE The printer must be off- ON LINE...
  • Page 116 Chapter Diagnostic Printer Tests Step Press LCD Result Notes Printer Tests Starts test. ENTER All E’s* Printer Tests Stops test. ENTER All E’s* ENTER SWITCH Locks the ENTER key LOCKED and control panel. ONLINE Places the printer in ON LINE LinePrinter+ on-line mode.
  • Page 117 Selecting And Running Diagnostic Printer Tests Printing The E-Net Test Page NOTE: You must set TOF after printing the E-Net Test Page Step Press LCD Result Notes Make sure the printer is on. Raise the printer cover. Load paper. Set TOF. (Refer to the User’s Guide.) OFFLINE The printer must be ON LINE...

  • Page 118: Boot Diagnostics Menu

    Chapter Boot Diagnostics Menu Boot Diagnostics Menu Printer boot-up software contains a “Boot Diagnostics” menu that you can access by holding down two keys while powering on the printer. This menu is not intended for the end user, but provides useful information for manufacturing and maintenance personnel.
  • Page 119 Selecting And Running Diagnostic Printer Tests NOTE: BOOT DIAGNOSTICS To exit this menu, cycle power. > PRESS ENTER = DOWN key < = NEXT key ENTER < BOOT DIAGNOSTICS VERSION CHECK > VERSION CHECK VERSION CHECK VERSION CHECK < VERSION CHECK <...
  • Page 120 Chapter Boot Diagnostics Menu NOTE: To exit this menu, cycle power. > BOOT DIAGNOSTICS = DOWN key MISC UTILITIES < = NEXT key From previous > page MISC UTILITIES MISC UTILITIES MISC UTILITIES < MISC UTILITIES < < < RESET PRINTER COPY FLASH SIMMS COPY BOOT SIMMS DISPLAY MEMORY...

  • Page 121: Hex Code Printout

    Selecting And Running Diagnostic Printer Tests Hex Code Printout A hex code printout (or “hex dump”) prints every ASCII data character received from the host computer, and lists its corresponding two-digit hexadecimal code. (See Figure 9 below.) You can use hex dumps as an aid in troubleshooting data reception problems.

  • Page 122: How To Print A Hex Dump

    Chapter Hex Code Printout How To Print A Hex Dump Step Press LCD Result Notes Make sure the printer is on. Raise the printer cover. OFFLINE ON LINE CONFIG. CONTROL ENTER SWITCH Unlocks the ENTER UNLOCKED key and control panel. OFFLINE CONFIG.

  • Page 123: Ascii Character Set

    How To Print A Hex Dump ASCII Character Set BITS OCTAL equivalent DECIMAL equivalent HEX equivalent ASCII Character Name BITS COLUMN (XON) " 0 0 1 0 0 0 1 1 (XOFF) 0 1 0 0 0 1 0 1 &...

  • Page 124: Soft Vs. Hard Reset

    Chapter Soft vs. Hard Reset Soft vs. Hard Reset Soft Reset A soft(ware) reset clears printer memory then loads the power-up configuration set by the user. (If no power-up configuration has been set by the user, the factory default configuration is loaded.) It is called a soft reset because no hardware is tested.

  • Page 125: The Power On Sequence

    Controller Board Handshake Sequences The Power On Sequence This section describes the normal sequence of events from the time the power switch is set to 1 until ONLINE (or OFFLINE, if so configured by the user) appears on the LCD. Use this sequence as a reference baseline to help you isolate problems that occur before the printer completes its boot and initialization routines.
  • Page 126 Chapter The Power On Sequence • Read Control Panel Keys — The control panel keys are read to determine if the user is requesting that the printer be placed in download mode, diagnostic mode, or debug SIMM disabled. If ON LINE and PAPER ADVANCE are pressed during start-up, the printer is placed in >...
  • Page 127 Controller Board Handshake Sequences • Check for Pedestal — Boot code uses the control panel to determine if the printer is a pedestal or floor cabinet model. Boot code needs to know the difference so the exhaust fan fault can be disabled on a pedestal model.
  • Page 128 Chapter The Power On Sequence detected, boot codes displays “ERROR: SECURITY PAL NOT DETECTED”. If a security PAL is detected, boot code checks for the presence of NVRAM. If NVRAM is not found, boot code displays “ERROR: NVRAM FAILURE”. • Test for Powerup File —...

  • Page 129: Dc Software Initialization And Power Up

    DC Software Initialization And Power Up • Jump to MTOS — Jump to start initialization of the MTOS (Multi-Tasking Operating System). DC Software Initialization And Power Up The final part of the power up sequence is initialization and startup of the DC software, which occurs in the following order: •...
  • Page 130 Chapter The Power On Sequence...

  • Page 131: Adjustment And Test Procedures

    Adjustment and Test Procedures Introduction The printer is a durable, low-maintenance machine, but some components and systems require occasional adjustment. Usually, you will be referred to this chapter by a troubleshooting procedure, or as part of a removal/installation procedure. Adjustments and Tests Preparing the Printer for Maintenance ..........

  • Page 132: Preparing The Printer For Maintenance

    Chapter Preparing The Printer For Maintenance Preparing The Printer For Maintenance WARNING Unplug the printer power cord from the printer or power outlet before you do any maintenance procedure. Failure to remove power could result in injury to you or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure.

  • Page 133: Returning The Printer To Normal Operation

    Adjustments and Tests Returning The Printer To Normal Operation When you are finished servicing the printer, test its operation and return it to service by doing the following steps: 1. Install the ribbon. 2. Load paper. 3. Connect the data (signal) cable to the printer interface. 4.

  • Page 134: Belt, Paper Feed Timing, Adjustment

    Chapter Belt, Paper Feed Timing, Adjustment Belt, Paper Feed Timing, Adjustment 1. Prepare the printer for maintenance (page 132). 2. Cabinet Models: Remove the paper path (page 199). Pedestal Models: Remove the top cover assembly (page 179). 3. Cabinet Models: Loosen four screws and remove the barrier shield. (See page 230, items 3, 4 and 9.) Pedestal Models: Loosen the four screws securing the paper guide and barrier shield and remove both.
  • Page 135 Adjustments and Tests 1/8 inch Direction of Force Legend: Timing Belt Shield Motor Mount Bolt (2) Paper Feed Drive Motor Splined Shaft Figure 10. Paper Feed Timing Belt Adjustment...

  • Page 136: Belt, Platen Open, Adjustment

    Chapter Belt, Platen Open, Adjustment Belt, Platen Open, Adjustment 1. Prepare the printer for maintenance (page 132). 2. Cabinet Models: Remove the paper path (page 199). Pedestal Models: Remove the top cover assembly (page 179). 3. Remove the platen open belt cover (1) by squeezing the top and bottom to release the plastic tabs from the slots in the side plate.
  • Page 137 Adjustments and Tests 3/16 inch Legend: Belt Cover Motor Mount Screw (2) Platen Open Motor Shaft Figure 11. Platen Open Belt Adjustment...

  • Page 138: Paper Scale Alignment

    Chapter Paper Scale Alignment Paper Scale Alignment 1. Open the printer cover. 2. Load paper and ribbon. 3. Connect the power cord to the AC power source. 4. Set the printer power switch to 1 (on). 5. Verify that the shuttle cover (1) is properly installed (page 178). 6.
  • Page 139 Adjustments and Tests Legend: Shuttle Cover Screw, Button-Head, 5/64 inch hex (3) Paper Scale Figure 12. Paper Scale Alignment...

  • Page 140: Platen Gap Adjustment

    Chapter Platen Gap Adjustment Platen Gap Adjustment IMPORTANT Only do this procedure if the original equipment shuttle frame assembly or platen has been replaced by a new or refurbished unit. 1. Prepare the printer for maintenance (page 132). 2. Remove the shuttle cover assembly (page 178). 3.
  • Page 141 Adjustments and Tests NOTE: Left side adjustment shown. Right side is the same. Legend: Forms Thickness Lever Feeler Gauge Hammer Bank Cover Ribbon Mask Setscrew, 3/32 inch hex (2) Figure 13. Platen Gap Adjustment...

  • Page 142: Ribbon Guide Alignment

    Chapter Ribbon Guide Alignment Ribbon Guide Alignment 1. Open the printer cover. 2. Load paper and install the ribbon. To align a ribbon guide, wind the ribbon fully onto the ribbon spool on the opposite side. For example, to align the left ribbon guide, wind the ribbon until the right ribbon spool is full.
  • Page 143 Adjustments and Tests Right Ribbon Guide Left Ribbon Guide Legend: Screw, Skid (2) Ribbon White Nylon Washer Screw, Retaining (2) Figure 14. Ribbon Guide Alignment...

  • Page 144: Paper Out Adjustment

    Chapter Paper Out Adjustment Paper Out Adjustment This procedure tests and sets the distance from the page perforation at which a LOAD PAPER fault message is triggered. This adjustment prevents printing on the platen when the printer runs out of paper. The measurement units are dot rows.
  • Page 145 Adjustments and Tests Page Perforation 4 in. 4 in. Cut out here Figure 15. Paper Preparation for Paper Out Adjustment Test...
  • Page 146 Chapter Paper Out Adjustment > 7. On the control panel, press the keys to unlock the ENTER key. “ENTER SWITCH UNLOCKED” briefly displays. (If “LOCKED” displays, > simply press again. This is the default key combination. The lock/ > unlock key combination can be programmed by the user. If does not unlock ENTER, get the combination from the user.) 8.
  • Page 147 Adjustments and Tests > 21. Press . The number of dots will move up to the top line of the display with an asterisk (*) next to it. < 22. Using the key, adjust the XX DOTS value up or down by the number of dots you counted in step 14.

  • Page 148: Hammer Phasing Adjustment

    Chapter Hammer Phasing Adjustment Hammer Phasing Adjustment You must check and adjust hammer phasing if the controller board is replaced, the shuttle frame assembly is removed, or if the MPU is replaced. The hammer phase value is a timing parameter that permits you to adjust the vertical alignment of dots in character printing.
  • Page 149 Adjustments and Tests Needs Needs Correct Adjustment Adjustment > > 12. Press : The current phase index displays. Press again: An asterisk (*) appears next to the phase value. < 13. Press to increase or to decrease the phasing index value, then press ENTER to activate the value as it prints.

  • Page 150: Loading Flash Memory

    Chapter Loading Flash Memory Loading Flash Memory Flash memory is contained in SIMMs (single in-line memory modules) located on the controller board. Printer control languages (the “emulations”) and printer operating system software are loaded into flash memory at the factory, but there are times when you may have to install software: •...
  • Page 151 17. Using Windows Explorer, navigate to the appropriate file on the CD based on the printer model number and desired emulation, e.g., P5000 PGL_VGL. (See Figure 16.) 18. Make note of the file name, which is a six digit number plus .exe, e.g., 123456.exe.
  • Page 152 Chapter Loading Flash Memory Figure 16. Navigating to the Appropriate Emulation File on the CD 19. Copy the file to the download directory. You may need to hold the Ctrl key to make sure a + appears to the right of the pointer. (See Figure 17.) Figure 17.
  • Page 153 Loading Through The Serial Or Parallel Port where filename.exe is the file name you noted in step 18. This command decompresses the file on the hard drive and copies it as a binary file into the flash memory on the printer controller board. NOTE: If you are loading the file using the LPT2 port on the computer, enter the following command: filename.exe -pb2 <Enter>...

  • Page 154: Loading Through The Network Interface Card (Nic)

    8. Using Windows Explorer, navigate to the appropriate file on the CD (using the Unzipped directory) based on the printer type, model number, and desired emulation, e.g., Unzipped P5000 PGL_VGL. (See Figure 18.) IMPORTANT You must use the Unzipped directory, since this contains the uncompressed files necessary for NIC download.
  • Page 155 Loading Through the Network Interface Card (NIC) 11. Start a command prompt session. (The Start Menu icon is usually labeled MS-DOS Prompt or Command Prompt.) 12. At the command prompt type: C:<Enter> cd \download<Enter> 13. Start the FTP protocol by typing: ftp xxx.xxx.xxx.xxx<Enter>...

  • Page 156: Coil Temperature Adjustment

    Chapter Coil Temperature Adjustment Coil Temperature Adjustment This procedure applies only to 1500 lpm printers. Do this procedure only when the original controller board, power supply board, or shuttle frame assembly have been replaced or you are instructed to do so in a troubleshooting procedure. Do not do this procedure if the original controller board, power supply board, or shuttle frame assembly were removed and reinstalled as part of other maintenance tasks.

  • Page 157: Dynamic Paper Tension Adjustment

    Loading Through the Network Interface Card (NIC) Dynamic Paper Tension Adjustment This procedure helps you identify and eliminate conditions that contribute to paper jams, excessive tension on the paper feed motor, and vertical dot compression or expansion. 1. Open the printer cover. 2.
  • Page 158 Chapter Dynamic Paper Tension Adjustment 6. Close the forms thickness lever all the way (pointer at ‘A’). 7. Attach the hook of a “fish scale” force gauge through the tape you installed in step 5. 8. Pull the paper slowly straight up through the print station for about six inches and note the maximum force exerted on the scale.

  • Page 159: Tractor Belt Tension Adjustment

    Loading Through the Network Interface Card (NIC) Tractor Belt Tension Adjustment Print compression can be reduced by adjusting the tension of the tractor belts. The procedure below removes the slack that might occur in some tractors. IMPORTANT Only do this procedure when the user reports that the first print line of forms is compressed and only after adjusting the dynamic paper tension (page 157).

  • Page 160: Shuttle Electrical Short Check

    Chapter Shuttle Electrical Short Check Shuttle Electrical Short Check This procedure checks for metallic debris and checks for hammer coils shorting to the shuttle frame. The hammer driver circuit board attached to the shuttle frame assembly can attract metal objects because of the magnets in the hammer bank. Such stray metal pieces can cause electrical shorting and damage to the shuttle assembly.

  • Page 161: Hammer Bank Power Cable Shorts Test

    Loading Through the Network Interface Card (NIC) Hammer Bank Power Cable Shorts Test This test determines if the hammer bank power cable is shorted. 1. Prepare the printer for maintenance (page 132). 2. Remove the paper path (page 199). 3. Disconnect hammer bank power cable connector P105 from J105 on the controller board.

  • Page 162: Cable Shorts Test

    Chapter Cable Shorts Test Cable Shorts Test This test determines if a cable has a short to ground or a pin-to-pin short (also called a wire-to-wire short). Such shorts can be caused by cables resting on or moving across sharp edges. The edges over time can wear away the plastic shielding of the cable, exposing the copper wire inside.
  • Page 163 Loading Through the Network Interface Card (NIC) 8. Check the pin for a short to ground, which is indicated by a meter reading of continuity (that is, a low resistance reading of less than 1 Ohm). 9. If you find a short to ground, replace the cable. If no short is detected, repeat steps 7 and 8 for the rest of the pins on the same end of the cable.

  • Page 164: Main Wire Harness Test Diagnostic

    Chapter Main Wire Harness Test Diagnostic Main Wire Harness Test Diagnostic This is a procedure for extended testing of various printer components. 1. Prepare the printer for maintenance (page 132). 2. Remove the paper path (page 199). 3. Disconnect cable connectors P106 and P107 from the controller board. 4.

  • Page 165: Replacement Procedures And Illustrated Parts Lists

    Replacement Procedures And Illustrated Parts Lists Organization Of This Chapter This chapter is divided into two sections. • Section I: Replacement Procedures Written procedures for removing and installing components that are replaceable at the field service level of maintenance. The replacement procedures refer you to the illustrations in Section II.

  • Page 166: Section I: Replacement Procedures

    Chapter Section I: Replacement Procedures Section I: Replacement Procedures WARNING Unplug the printer power cord from the printer or power outlet before doing any maintenance procedure. Failure to remove power could result in injury to you or damage to equipment. Only apply power during maintenance if you are instructed to do so in a maintenance procedure.
  • Page 167 List Of Removal / Installation Procedures Paper Ironer ..................page 198 Paper Path ..................page 199 Platen ....................page 200 Platen Open Motor ................page 204 Power Supply Board ............... page 206 Resistors, Terminating ..............page 207 Ribbon Drive Motor ................. page 209 Ribbon Guide Assembly (L/R)............

  • Page 168: Belt, Paper Feed Timing

    Chapter Section I: Replacement Procedures Belt, Paper Feed Timing Removal 1. Prepare the printer for maintenance (page 132). 2. Cabinet Models: Remove the paper path (page 199). Pedestal Models: Remove the top cover assembly (page 179). 3. Cabinet Models: Loosen four screws and remove the barrier shield. (See page 230, items 3, 4, and 9.) Pedestal Models: Loosen four screws and remove the paper guide and barrier shield.

  • Page 169: Belt, Platen Open

    Belt, Platen Open Belt, Platen Open Removal 1. Prepare the printer for maintenance (page 132). 2. Cabinet Models: Remove the paper path (page 199). Pedestal Models: Remove the top cover assembly (page 179). 3. Remove the platen open belt cover by squeezing the top and bottom to release the plastic tabs from the slots in the side plate.

  • Page 170: Circuit Breaker

    Chapter Section I: Replacement Procedures Circuit Breaker Removal 1. Prepare the printer for maintenance (page 132). 2. Remove the card cage fan (page 183). 3. Disconnect the four circuit breaker electrical leads. (Cabinet Models: See page 246. Pedestal Models: See page 234.) 4.

  • Page 171: Connector Shells

    Connector Coupling Shrouds Connector Coupling Shrouds Some of the cable connectors in the printer are grouped inside connector coupling shrouds. The procedure below explains how to remove and install cable assemblies from any connector coupling shroud. NOTE: There is also a diagram of the P106 / P107 connector coupling shrouds on the plastic cover over the power supply.
  • Page 172 Chapter Section I: Replacement Procedures P106 Connector Configuration P107 Connector Configuration Connectors are viewed 19 17 15 13 11 9 7 5 3 1 19 17 15 13 11 9 7 5 3 1 from the top, as seen when plugged into PLAT M PAPR M controller board.

  • Page 173: Control Panel Assembly, Cabinet Models

    Control Panel Assembly, Cabinet Models Control Panel Assembly, Cabinet Models Removal 1. Prepare the printer for maintenance (page 132). 2. Disconnect RJ11 connector P310 from connector J310 on the control panel. 3. Loosen four screws securing the control panel to the control panel bracket.

  • Page 174: Control Panel Assembly, Pedestal Models

    Chapter Section I: Replacement Procedures Control Panel Assembly, Pedestal Models Removal 1. Prepare the printer for maintenance (page 132). 2. Open the printer cover. 3. Loosen the four captive screws until the control panel is released from the printer top cover. (See page 228, item 2.) 4.

  • Page 175: Controller Board (Cmx And Cfx)

    Controller Board (CMX And CFX) Controller Board (CMX And CFX) Removal CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle circuit boards. 1. Make a configuration printout of all saved configurations. (Refer to the User’s Manual.) 2.
  • Page 176 Chapter Section I: Replacement Procedures Installation CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle circuit boards. IMPORTANT P5X05B, P5X10, and P5X15 printers take the 40 MHz CMX controller board. P5006H, P5206H, P5003H, and P5203H printers take the CFX controller board.

  • Page 177: Cover Assembly, Hammer Bank / Ribbon Mask

    Cover Assembly, Hammer Bank / Ribbon Mask Cover Assembly, Hammer Bank / Ribbon Mask Removal 1. Prepare the printer for maintenance (page 132). 2. Remove the shuttle frame assembly (page 215). 3. Lift the thick plate of the hammer bank cover assembly at one end, and peel the cover away from hammer bank magnets.

  • Page 178: Cover Assembly, Shuttle

    Chapter Section I: Replacement Procedures Cover Assembly, Shuttle Removal 1. Prepare the printer for maintenance (page 132). 2. Loosen the shuttle cover screws (page 230, item 2). 3. Grasping the edges of the shuttle cover assembly, tilt the rear edge up and lift the shuttle cover assembly out of the printer.

  • Page 179: Cover Assembly, Top, Pedestal Models

    Cover Assembly, Top, Pedestal Models Cover Assembly, Top, Pedestal Models Removal 1. Prepare the printer for maintenance (page 132). 2. Loosen—do not remove—the two #2 Phillips hold-down screws on the rear of the printer. (See page 228, item 5.) 3. Open the printer cover. 4.

  • Page 180: Dashpot

    Chapter Section I: Replacement Procedures Dashpot CAUTION Two persons may be required to do this procedure. Prop or hold the printer cover securely while disengaging the dashpot. NOTE: This procedure applies only to cabinet models. Removal 1. Prepare the printer for maintenance (page 132). 2.

  • Page 181: Expansion-Ct

    Expansion-CT Expansion Removal CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle circuit boards. 1. Prepare the printer for maintenance (page 132). 2. Cabinet Models: Remove the paper path (page 199). Pedestal Models: Remove the top cover assembly (page 179).

  • Page 182: Fan Assembly, Cabinet Exhaust

    Chapter Section I: Replacement Procedures Fan Assembly, Cabinet Exhaust NOTE: This procedure applies only to cabinet models. Removal 1. Prepare the printer for maintenance (page 132). 2. Open the front and rear cabinet doors and the printer cover. 3. Remove the paper fence/paper tray assembly. (See page 224.) 4.

  • Page 183: Fan Assembly, Card Cage

    Fan Assembly, Card Cage Fan Assembly, Card Cage Removal 1. Prepare the printer for maintenance (page 132). 2. Cabinet Models: Remove the paper path (page 199). Pedestal Models: Remove the top cover assembly (page 179). 3. Disconnect the card cage fan cable connector. (See page 244.) 4.

  • Page 184: Fan Assembly, Hammer Bank

    Chapter Section I: Replacement Procedures Fan Assembly, Hammer Bank Removal 1. Prepare the printer for maintenance (page 132). 2. Remove the shuttle cover assembly (page 178). 3. Cabinet Models: Remove the paper path (page 199). Pedestal Models: Remove the top cover assembly (page 179). 4.

  • Page 185: Hammer Spring Assembly

    Hammer Spring Assembly Hammer Spring Assembly Removal 1. Prepare the printer for maintenance (page 132). 2. Remove the shuttle frame assembly (page 215). 3. Carefully vacuum the shuttle frame assembly. 4. Remove the hammer bank cover assembly (page 177). CAUTION Hammer springs and hammer tips are fragile.
  • Page 186 Chapter Section I: Replacement Procedures Installation 1. Using a clean dry cloth, wipe the hammer spring mounting surface on the hammer bank. Make sure the cloth does not leave lint on the hammer bank. CAUTION Hammer springs and hammer tips are fragile. Do not touch the hammer springs or tips.
  • Page 187 Hammer Spring Assembly NOTE: The hammer spring assembly shown here is for a P5015 printer. Although hammer spring assemblies vary in appearance and number of mounting screws, removal and installation are the same for all models. Gently press down on the mounting base and hold the hammer spring in position as you install the screws.

  • Page 188: Magnetic Pickup (Mpu) Assembly

    Chapter Section I: Replacement Procedures Magnetic Pickup (MPU) Assembly Removal 1. Prepare the printer for maintenance (page 132). 2. Remove the shuttle cover (page 178). 3. Disconnect the magnetic pickup (MPU) cable connector (page 238, item 4. Loosen the 7/64 inch hex MPU clamp screw (page 238, item 3). 5.

  • Page 189: Memory And Security Modules

    Memory And Security Modules Memory And Security Modules CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle memory modules and circuit boards. Removal 1. Make a configuration printout of all saved configurations. (Refer to the User’s Manual.) 2.
  • Page 190 Chapter Section I: Replacement Procedures Security Module Number Emulation CT/VGL/LP+ CT/IPDS/LP+ CT/IPDS/PGL/LP+ CT/IPDS/VGL/LP+ Installation CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle memory modules and circuit boards. NOTE: Flash SIMMs from one controller board must be placed in the same slot on a replacement controller board.
  • Page 191 Memory And Security Modules Controller Board Bank 1 Bank 0 Bank 1 Bank 0 Notched End Notch Security Module Flash: DRAM: 80-pin SIMM 72-pin SIMM J11 = Bank 0 (must always J16 = Bank 0 (must always be filled) be filled) J10 = Bank 1 J15 = Bank 1 Reserved for upgrades...

  • Page 192: Nic (Network Interface Card) Assembly

    Chapter Section I: Replacement Procedures NIC (Network Interface Card) Assembly NOTE: The PrintNet LAN option is available in 10/100Base-T configuration. This option is available factory installed or as a field kit. The functions of the LEDs and DIP switches are described on page 193. To convert an ethernet-equipped printer to a parallel interface, remove the ethernet board assembly and install the Centronics connector in the slot the ethernet board occupied.

  • Page 193: 10/100Base-T Leds And Dip Switches

    10/100Base-T LEDs And DIP Switches 10/100Base-T LEDs And DIP Switches The 10/100Base-T ethernet interface has two indicator lights and two DIP switches, as shown below. DIP Switches Shown OFF (Default Position) STAT (System Status) (Data to Network) Inspect the two LEDs on the 10/100Base-T ethernet interface: 1.

  • Page 194: Dip Switches

    Chapter Section I: Replacement Procedures STAT (Status) Indicator In Run And Auto Reset Modes Run Mode is the normal operating state of this interface. Auto Reset mode is entered when the watchdog timer is triggered and the print server resets itself. In either mode, the STAT LED flashes at a varying rate, depending on whether the unit IP address is configured: STAT...
  • Page 195 10/100Base-T LEDs And DIP Switches Table 5. 10/100Base-T DIP Switch Settings DIP Switch Description Normal operation. With both DIP switches in the “OFF” (up) (up) position, the interface boots up using the settings in flash memory rather than the default settings. Factory default settings.

  • Page 196: Paper Feed Motor

    Chapter Section I: Replacement Procedures Paper Feed Motor Removal 1. Prepare the printer for maintenance (page 132). 2. Cabinet Models: Remove the paper path (page 199). Pedestal Models: Remove the top cover assembly (page 179). 3. Cabinet Models: Loosen four screws and remove the barrier shield. (See page 230, items 3, 4, and 9.) Pedestal Models: Loosen the four screws and remove the barrier shield and paper guide.
  • Page 197 Paper Feed Motor Installation 1. Position the paper feed motor assembly on the right side plate and install the motor mount bolts and nuts finger tight. (See page 244, items 10 and 23.) 2. Connect the paper feed motor cable connector to connector P107, then connect P107 to J107 on the controller board.

  • Page 198: Paper Ironer

    Chapter Section I: Replacement Procedures Paper Ironer WARNING Over time, the upper edge of the paper ironer can become sharp. To avoid cutting yourself, handle the paper ironer on the sides. Removal 1. Prepare the printer for maintenance (page 132). 2.

  • Page 199: Paper Path

    Paper Path Paper Path NOTE: This procedure applies only to cabinet models. Removal 1. Prepare the printer for maintenance (page 132). 2. Loosen the three screws that secure the paper path to the card cage. (See Figure 27.) 3. Slide the paper path to the left and lift it off the card cage. Installation 1.

  • Page 200: Platen

    Chapter Section I: Replacement Procedures Platen Removal 1. Prepare the printer for maintenance (page 132). 2. Remove the shuttle frame assembly (page 215). 3. Remove the paper ironer (page 198). 4. Remove the three 1/4 inch screws securing the paper ironer bracket assembly and remove the assembly.
  • Page 201 Platen Installation IMPORTANT Install the platen with the longer shaft on the right hand side of the printer. The dowel pins protruding from the ends of the platen are the platen shafts. The platen shafts are not of equal length. 1.
  • Page 202 Chapter Section I: Replacement Procedures Platen Adjust Bracket Platen Washers Wear Saddle Mechanism Base Platen Seat Figure 29. Positioning the Platen Adjust Brackets 9. Slide the right ribbon guide assembly into the side plate and install the two 7/32 inch screws and washers. (See Figure 43, items 7, 8, and 9.) 10.
  • Page 203 Platen b. Install and torque three screws to 20 ± 2 inch-pounds (2.26 ± 0.23 N•m). 15. Push the platen to the left. 16. Install the forms thickness lever on the right hand platen shaft, pressing the interlock switch out of the way as the lever slides past it. Tighten the 7/64 inch setscrew.

  • Page 204: Platen Open Motor

    Chapter Section I: Replacement Procedures Platen Open Motor Removal 1. Prepare the printer for maintenance (page 132). 2. Cabinet Models: Remove the paper path (page 199). Pedestal Models: Remove the top cover assembly (page 179). 3. Cabinet Models: Remove the card cage fan (page 183). 4.
  • Page 205 Platen Open Motor Installation 1. Position the platen open motor assembly with the wires toward the rear (page 244, item 5). 2. Install the 5/16 inch lower motor mount screw and torque it to 30 inch-pounds (3.39 N•m). 3. Install the 5/32 inch upper motor mount screw (page 244, item 10), platen spring post, and platen belt spring such that the screw is just loose enough to permit movement of the motor in the slotted side plate.

  • Page 206: Power Supply Board

    Chapter Section I: Replacement Procedures Power Supply Board WARNING To prevent injury from electric shock, wait at least one minute after shutting off power before removing the power supply board. Do not touch components or flex the board during removal or installation. Handle the board by its sides and always wear a properly grounded static wrist strap when handling the power supply board.

  • Page 207: Resistors, Terminating

    Resistors, Terminating Resistors, Terminating For parallel interface configurations, the printer is equipped with 470 Ohm pull-up terminating resistors and 1K Ohm pull-down terminating resistors on the controller board. These are suitable for most applications. (See Figure 30, page 208.) If the standard terminating resistor pack is not compatible with the particular interface driver requirements of the host computer, other values of pull-up and pull-down resistors may be required.
  • Page 208 Chapter Section I: Replacement Procedures Controller Board Default: 470 Ohm Alt 1: 220 Ohm Alt 2: 1K Ohm Default: 1K Ohm Alt 1: 330 Ohm Alt 2: None Figure 30. Terminating Resistors, Removal/Installation...

  • Page 209: Ribbon Drive Motor

    Ribbon Drive Motor Ribbon Drive Motor Removal 1. Prepare the printer for maintenance (page 132). 2. Remove the ribbon hub (page 211). 3. Remove two screws and washers securing the ribbon drive motor to the base casting. (See page 244, items 13 and 14.) 4.

  • Page 210: Ribbon Guide Assembly (L/R)

    Chapter Section I: Replacement Procedures Ribbon Guide Assembly (L/R) NOTE: The right ribbon guide is shown exploded in Figure 43 on page 244. The removal procedure is the same for both ribbon guides. Removal 1. Prepare the printer for maintenance (page 132). 2.

  • Page 211: Ribbon Hub

    Ribbon Hub Ribbon Hub Removal 1. Prepare the printer for maintenance (page 132). 2. Loosen the Torx T-15 screw in the ribbon spool hub (page 244, item 15). 3. Remove the hub from the shaft of the ribbon drive motor. Installation 1.

  • Page 212: Shaft, Splined

    Chapter Section I: Replacement Procedures Shaft, Splined NOTE: The barrier panel must remain installed and fastened during this procedure. Removal 1. Prepare the printer for maintenance (page 132). 2. Remove the paper supports from the splined shaft and support shaft. (See page 240, item 4.) 3.
  • Page 213 Shaft, Splined Installation 1. Open the doors on the left and right tractors. Position the tractor belts so the alignment marks are at the top on both tractors. (See Figure 31.) 2. Slide the splined shaft through the right side plate and tractors. Make sure the same spline passes the marked groove on each tractor.

  • Page 214: Shaft, Support

    Chapter Section I: Replacement Procedures Shaft, Support Removal 1. Prepare the printer for maintenance (page 132). 2. Unlock the tractors and slide them to the far right. 3. Remove the paper supports from the splined shaft and support shaft. (See page 240, item 4.) 4.

  • Page 215: Shuttle Frame Assembly

    Shuttle Frame Assembly Shuttle Frame Assembly Removal 1. Prepare the printer for maintenance (page 132). 2. Remove the shuttle cover assembly (page 178). 3. Disconnect the MPU cable connector P03 and shuttle motor cable connector P02 (page 238, items 5 and 6). CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle the shuttle...
  • Page 216 Chapter Section I: Replacement Procedures Installation 1. Install the hammer bank / ribbon mask cover assembly if it was removed (page 177). CAUTION To prevent electrostatic damage to electronic components, wear a properly grounded static wrist strap when you handle the shuttle frame assembly.

  • Page 217: Spring, Extension, Hammer Bank

    Spring, Extension, Hammer Bank Spring, Extension, Hammer Bank CAUTION Do not let the hammer bank rotate toward the platen during spring replacement. Removal 1. Prepare the printer for maintenance (page 132). 2. Remove the shuttle cover assembly (page 178). 3. Unhook the extension spring from the spring lugs on the hammer bank and shuttle frame.

  • Page 218: Switch Assembly, Paper Detector

    Chapter Section I: Replacement Procedures Switch Assembly, Paper Detector Removal 1. Prepare the printer for maintenance (page 132). 2. Cabinet Models: Remove the paper path (page 199). Pedestal Models: Remove the top cover assembly (page 179). 3. Cabinet Models: Loosen four screws and remove the barrier shield. (See page 230, items 3, 4, and 9.) Pedestal Models: Loosen the four screws and remove the paper guide and barrier shield.

  • Page 219: Switch Assembly, Platen Interlock

    Switch Assembly, Platen Interlock Switch Assembly, Platen Interlock Removal 1. Prepare the printer for maintenance (page 132). 2. Cabinet Models: Remove the paper path (page 199). Pedestal Models: Remove the top cover assembly (page 179). 3. Fully close the forms thickness lever (position ‘A’). 4.

  • Page 220: Tractor (L/R)

    Chapter Section I: Replacement Procedures Tractor (L/R) Removal 1. Prepare the printer for maintenance (page 132). 2. Remove the support shaft (page 214). 3. Remove the splined shaft (page 212). Installation 1. Using the replacement tractors, install the support shaft (page 214). 2.

  • Page 221: Section Ii: Illustrated Parts Lists

    Illustrations of Printer Components Section II: Illustrated Parts Lists NOTE: Only field-replaceable spares are given part numbers in the illustrated parts lists. Part numbers are not listed for common fasteners and attachment hardware. Items marked “Ref” in the illustrations refer to parts that are not spared or are part of another assembly.
  • Page 222 Chapter Section II: Illustrated Parts Lists Figure 32. Top Cover, Doors, and Casters...
  • Page 223 Illustrations of Printer Components Item Part No. Description Notes 164212-905 Top Cover Kit, Cabinet Includes mounting hardware 131803-901 Window, Top Cover Not visible in Figure 32 153640-901 Wireform Paper Path Includes mounting hardware (Part of 153997-001, Field Kit, Paper Path, Standard) 153084-902 Rear Door Kit Includes mounting hardware...
  • Page 224 Chapter Section II: Illustrated Parts Lists Figure 33. Paper Fence and Chains...
  • Page 225 Illustrations of Printer Components Item Part No. Description Notes 158179-901 Passive Stacker Assembly 1000 and 1500 lpm models. (Not on 500 lpm models or any printer with the power stacker.) 153503-001 Grommet Kit, Cabinet 153778-001 Chain Assembly Kit AC Power Cord Grommet, Power Cord (2) Included in item 2 Guide Rail, Stacker...
  • Page 226 Chapter Section II: Illustrated Parts Lists Figure 34. Control Panel and Cabinet Details...
  • Page 227 Illustrations of Printer Components Item Part No. Description Notes 175093-001 Control Panel Assembly Field Kit Includes mounting bracket 152440-901 Cable Assembly, Control Panel Installed with shielding beads: See Appendix E 107961-905 Dashpot Kit Includes ball studs, spring clips, and mounting hardware Screw, w/Lock Washer (3) 6-32x.375...
  • Page 228 Chapter Section II: Illustrated Parts Lists Figure 35. Pedestal Details...
  • Page 229 Illustrations of Printer Components Item Part No. Description Notes 153366-901 Control Panel Assembly Screw, Captive (4) Screw, Captive (2) Part of item 10 Lid, Pedestal Model Part of item 10 Screw (2) 152440-901 Cable Assembly, Control Panel 154288-002 Pedestal Kit w/Tray 158635-001 Caster w/Brake, Pedestal (4) Window, Top Cover...
  • Page 230 Chapter Section II: Illustrated Parts Lists Figure 36. Inside Covers, Cabinet Models...
  • Page 231 Illustrations of Printer Components Item Part No. Description Notes 164295-001 Shuttle Cover (Shroud Assembly, Air) Screw, Captive (2) 10-24x.62 with O-ring, .125x.250x.06 Screw, Thread-forming (2) 6-32x.25 and #6 flat washer Barrier Shield 152290-901 Paper Path Screw, w/Lock Washer (3) 6-32.25 and #6 flat washer 153488-001 Platen/Paper Feed Cover Kit Paper Feed Belt Cover...
  • Page 232 Chapter Section II: Illustrated Parts Lists See Figure 38, page 234. Figure 37. Inside Covers and Card Cage, Pedestal Models...
  • Page 233 Illustrations of Printer Components Item Part No. Description Notes 164295-001 Shuttle Cover (Shroud Assembly, Air) Screw, Captive (2) 10-24x.62 with O-ring, .125x.250x.06 Screw, Thread-forming (2) 6-32x.25 and #6 flat washer Barrier Shield 154286-001 Paper Path 152284-901 Anti-Static Brush Kit 154073-001 Power Supply Shield Taped to card cage along upper edge...
  • Page 234 Chapter Section II: Illustrated Parts Lists From Figure 37, page 232. Rotated 180 degrees. To IEC 320 AC Power Input (Connector To Connector P1 J301, White (White Wire) Wire) To Connector P1 (Black Wire) To IEC 320 AC Power Input (Connector J301, Black Wire) Figure 38.
  • Page 235 Illustrations of Printer Components Item Part No. Description Notes Nut, 6-32 (1) Upper right fan corner only 150261-901 Card Cage Fan Assembly Air flow is into card cage Fan Guard Screw, w/Lock Washer (4) 6-32x1.75 Card Cage, Pedestal 142013-901 Circuit Breaker...
  • Page 236 Chapter Section II: Illustrated Parts Lists Two places: Exploded to show assembly. Do not remove the holddown clamps and screws. To J02 (Shuttle Motor) To J03 (MPU) To Terminator Board on Shuttle Frame Figure 39. Print Mechanism and Circuit Boards...
  • Page 237 Illustrations of Printer Components Item Part No. Description Notes 174550-901 Hammer Bank Cover Assy, 500 P5X05B 174549-901 Hammer Bank Cover Assy, 1000 P5X10, P5X03H 174551-901 Hammer Bank Cover Assy, 1500 P5X15, P5X06H 174957-901 Shuttle Frame Assembly P5X05B 175863-901 Shuttle Frame Assembly P5X05B-12 174958-901 Shuttle Frame Assembly...
  • Page 238 Chapter Section II: Illustrated Parts Lists Spring Lug (Do not remove grease) Spring Lug (Do not remove grease) CAUTION: Make sure the MPU cable does not touch the extension spring 0.010 ± .001 inch (0.254 ± .025 mm) after cable connection.
  • Page 239 Illustrations of Printer Components Item Part No. Description Notes 150281-901 MPU Assembly Bracket, MPU Part of item 1 Screw, Socket Cap 6-32x.38 153537-901 Extension Spring MPU Cable Connector (P03) 176507-001 Anti-Rotation Spring Constraint Used only on model P5X08H and P5220S, which are not covered in this manual...
  • Page 240 Chapter Section II: Illustrated Parts Lists Figure 41. Tractor Shafts...
  • Page 241 Illustrations of Printer Components Item Part No. Description Notes Screw, Socket Cap, 6-32x.312 Trilob (Self-Tapping) (2) 173130-001 Plate, Tractor Shaft, Left 151944-001 Bearing, Ball, Sealed 155182-901 Paper Support (2) 204155-001 Tolerance Ring,.37X.25,.006 THK,SS 173272-001 Splined Shaft Assembly Screw, Socket Cap, 6-32x.312 Trilob (Self-Tapping) 173217-001 Plate, Tractor Shaft, Right...
  • Page 242 Chapter Section II: Illustrated Parts Lists NOTE: Black tape faces paper motion detector. NOTE: Item 25: Platen Hardware Kit Figure 42. Platen...
  • Page 243 Illustrations of Printer Components Item Part No. Description Notes Setscrew (2) Part of item 25 Bracket, Platen (2) Part of item 25 150957-901 Ironer, Paper Screw, Thread-forming (3) 6-32x.25 174968-001 Ironer Bracket/Plate Field Kit Plate, Ironer Part of item 5 112657-901 Platen Assembly 163080-001...
  • Page 244 Chapter Section II: Illustrated Parts Lists Install screws here. Top View Route cable under Hammer Bank Fan base casting (2 ea.) See detail above Figure 43. Motors, Fans, and Paper Detector Switch...
  • Page 245 Illustrations of Printer Components Item Part No. Description Notes 150261-901 Card Cage Fan Assembly Air flow is into card cage Screw, w/Lock Washer (3) Two 6-32x1.75 on bottom, One 6-32x0.50 on top left 152415-901 Switch Assembly, Paper Detector 170172-001 Field Kit, Slotted Black Back Form Optional switch assembly Switch used with black back forms...
  • Page 246 Chapter Section II: Illustrated Parts Lists See inside detail below. To IEC 320 AC Power Input (Connector J301, White Wire) To IEC 320 AC Power Input (Connector J301, Black Wire) To Connector P1 (Black Wire) Black Wire To Connector P1 (Card cage fan and (White Wire) power supply board...
  • Page 247 Illustrations of Printer Components Item Part No. Description Notes 142013-901 Circuit Breaker IEC 320 AC Power Connector Connector J301 Chassis Ground Stud Connector P1 To power supply board connector J1 AC Cable Assembly, AC-In, Power Supply Part of Field Kit, AC Assy 153502-901...
  • Page 248 Chapter Section II: Illustrated Parts Lists Figure 45. Expansion-CT Board...
  • Page 249 Illustrations of Printer Components Item Part No. Description Notes Screw (2) Card Cage 164427-001 Expansion-CT Subassembly CT V3 Screw, Captive Part of item 3 Standoff, Hex, 3/16 inch, M/F, .813 Lg Part of item 3 202485-001 Adapter, Expansion Connector, 60-pin Part of item 3 Controller Board Controller Board Connector J111...
  • Page 250 Chapter Section II: Illustrated Parts Lists Figure 46. PrintNet Ethernet Interface Assemblies...
  • Page 251 Illustrations of Printer Components Item Part No. Description Notes Screw, Connector Cover (2) 158295-001 Cover Plate, Centronics 202049-001 Ferrite Clamp See Appendix D 152439-901 Centronics I/O Cable Assembly 170593-001 Interface Kit, Dist, LAN 100Base-T PrintNet factory installed 170613-001 Interface Kit, Dist, LAN 100Base-T PrintNet field kit Rear of Card Cage Screw (2)
  • Page 252 Chapter Section II: Illustrated Parts Lists...

  • Page 253: Principles Of Operation

    Principles Of Operation Line Matrix Printing The printer creates characters and graphics by printing patterns of ink dots an entire line at a time. This technique is called line matrix printing. Every text character is stored in printer memory as a pattern of dots on a logical grid called the dot matrix.
  • Page 254 Chapter Line Matrix Printing When the shuttle reaches the end of a sweep, it reverses direction, the paper is advanced one dot row, and the hammer springs print the next row of dots as the shuttle sweeps in the opposite direction. After a line of characters is printed, hammer action stops and the paper advances to the first dot row of the next print line.
  • Page 255 Succesive Hammer Strokes Per Scan Shuttle 1 3 5 1 3 5 7 1 3 5 7 9 Scan Even column dot centers within the printed character area and character space hammer positions are not illustrated in this diagram. NOTE: = Hammer Released and Dot Printed = Hammer Not Released;...

  • Page 256: Printing Rates

    Chapter Printing Rates Printing Rates Because a line matrix printer prints entire lines sequentially, it is faster than a moving-printhead printer, which prints single characters sequentially. The printing speed of text is measured in lines per minute (lpm) rather than characters per minute (cpm).

  • Page 257: Shuttle Frame Assembly

    Shuttle Frame Assembly Shuttle Frame Assembly The central element of the printing mechanism is the shuttle frame assembly, which houses the hammer bank assembly and the shuttle drive motor. (Figure 50.) Hammer Bank Assembly Counterweight Assembly Connecting Rod Shuttle Frame Guide Shaft Assembly Shuttle Drive...
  • Page 258 Chapter Printing Mechanism length of the hammer bank and acts on the hammer springs through individual pole pieces. The pole pieces magnetically attract and hold the free end of the hammer spring under tension. This is called the retracted state. NOTE: P5015 hammer bank shown.

  • Page 259: Paper Transport System

    Paper Transport System Paper Transport System Paper Path Tractors Vertical Adjustment Splined Knob and Shaft Splined Shaft Pulley Tractor Support Shaft Shuttle Cover Assembly Paper Feed Timing Paper Supports Belt (under the cover) Figure 52. Paper Transport System A two-phase DC stepper motor, directed by the engine controller (EC), drives two tractor sprockets by means of a toothed belt and splined shaft pulley.

  • Page 260: Ribbon Transport System

    Chapter Printing Mechanism Ribbon Transport System Ribbon Hub Left Ribbon Guide Locking Latch Ribbon Spool Ribbon Motor Right Ribbon Guide Ribbon Figure 53. Ribbon Transport System An inked ribbon winds and unwinds continuously on a pair of spools latched to hubs that are driven by the ribbon motors.

  • Page 261: Logical Control Of The Printer

    Ribbon Transport System Logical Control Of The Printer The printer comprises four functional elements: the control panel, the controller board, the power supply board, and the print mechanism. (Figure 54.) Control Input Panel POWER ON/OFF Circuit SWITCH Breaker Power Line 1 Supply Line 2 / Neutral Board...

  • Page 262: Control Panel

    Chapter Control Panel Control Panel The user communicates with the printer by pressing keys on the control panel. The keys are momentary contact switches. The control panel processes and sends key closure information to the controller board and displays information from the controller on the LCD. A status indicator next to the LCD also conveys printer status information to the user.

  • Page 263: Controller Board

    Ribbon Transport System Controller Board The heart of the printer is the controller board, which monitors and directs all printer functions. ASCII and P5XKA printers use a controller designated the CMX controller board. H-Series printers use a controller designated the CFX controller board.
  • Page 264 Chapter Controller Board 25 or 40 MHz Expansion Port RS-232 RS-232/422 Diagnostic Port IEEE-1284 (Parallel) Control Panel Fault Sensors Paper Feed Ribbon Shuttle Platen Diagnostic Port Hammer Drive Figure 56. Controller Board Block Diagram...

  • Page 265: Data Controller

    DC unit on P5X05B, P5X10, and P5X15 printers. The controller board on these models is called the “CMX 040” board. The CMX 040 controller is backwards compatible with any earlier P5000 series printer except H-Series printers. The controller used in H-Series printers is called the “CFX controller board.”...
  • Page 266 Chapter Controller Board DRAM System DRAM is used for program variables, image buffers, and input buffers. All DRAM supports page mode operation and is addressable by individual byte. Two standard 72-pin DRAM SIMMs are used for expansion memory. The DC, through the VX ASIC, may address up to 32MB of DRAM in four banks.
  • Page 267 Data Controller Control Panel Interface The VX operator panel interface consists of five lines: serial clock, serial data, and three select lines. It is the VX that handles all parallel-to-serial (and vice versa) conversion to and from the panel, as well as any special timing needed when toggling select lines, etc.

  • Page 268: Engine Controller

    Chapter Controller Board Engine Controller The engine controller (EC) consists of four main elements: • 80C166 Microcontroller • 128KB 5.0V-only FLASH program memory, organized as 64K x 16 bits. This memory is not expandable. • MECA (Mechanism Engine Control ASIC) •...

  • Page 269: Power Supply Board

    AC Power The printer has five electric motors: two ribbon drive, one paper feed, one platen open, and one shuttle motor. The shuttle motor is a brushless DC motor driven by current control. The MPU encoder is used as feedback for motor commutations, hammer fire timing, and motor stall detection.

  • Page 270: Printer Interface

    The VGL Advanced Graphics programming language (a QMS graphics emulation) and the PGL Advanced Graphics programming language (a Printronix IGP emulation) are options that install in flash memory on the controller board. These programming languages simplify the job of creating forms, bar codes, logos, expanded characters, and other graphics.

  • Page 271: A Wire Data

    Wire Data NOTE: Acronyms and signal mnemonics are defined in Appendix B. Interconnection Diagram ..............page 273 Distribution Diagram................ page 274 Main Wire Harness Test Tables ............page 275 Circuit Board Pinouts CMX Controller Board............... page 276 CFX Controller Board ............... page 280 Power Supply................
  • Page 272 Appendix A Shuttle Motor Drive ..............page 309 Power Stacker Cables Frame Cable, Power Stacker ..........page 310 Logic Cable, Power Stacker ..........page 311 Power Cable, Power Stacker ..........page 312 Rail Cable, Power Stacker ..........page 313 Elevator I/O Cable, Power Stacker ........page 314 Fan Assembly, Hammer Bank ............

  • Page 273: Interconnection Diagram

    Interconnection Diagram...

  • Page 274: Distribution Diagram

    Appendix A Power Distribution Diagram...

  • Page 275: Main Wire Harness Test Tables

    Main Wire Harness Test Tables P106 Connector P107 Connector Connectors are viewed from the top, as seen 19 17 15 13 11 9 7 5 3 1 19 17 15 13 11 9 7 5 3 1 when plugged into CMX controller board.

  • Page 276: Cmx Controller Board

    Appendix A CMX Controller Board...
  • Page 277 CMX Controller Board (continued)
  • Page 278 Appendix A CMX Controller Board (continued)
  • Page 279 CMX Controller Board (continued)

  • Page 280: Cfx Controller Board

    Appendix A CFX Controller Board Power Supply Motor Sensor Left J101 J106 N TEMP HI N STDBY PLAT 1 RIB L1 PLAT 2 RIB L2 PLAT 3 RIB L3 +48V PLAT 4 +48V RIB L4 CC FAN + +48V µ L RBN POST + CC FAN - 470 PF...
  • Page 281 CFX Controller Board (continued) EC Diagnostics Hammer Bank Logic J120 0.1W Hammer Bank Power J108 EC DB TXD J105 +10V SW EC DB RXD HMR DAT COIL µ 50 MHz HMR DAT RET PPR TRIG HMR CLK PPR MOVING HMR CLK RET FT EVENT CMD DAT MPU OUT...
  • Page 282 Appendix A CFX Controller Board (continued) CAUTION: Do not remove or replace the NVRAM. The NVRAM contains a lithium battery that can explode if replaced incorrectly. NVRAM is replaced only at the factory. 2-Pin Jumpers External Power 4.7 K EXT 5V 0.1 W J102 µ...
  • Page 283 CFX Controller Board (continued) 470 PF J201 CAUTION: Do not remove or replace the HOST TXD NVRAM. The NVRAM contains a lithium HOST RXD2 battery that can explode if replaced HOST RTS incorrectly. NVRAM is replaced only at the HOST CTS factory.
  • Page 284 Appendix A CFX Controller Board (continued) Paper Feed Motor J103 PF 1 PF 2 Phase Driver Logic PF 3 J115 PF 4 UD 1 UD 2 PH REF Front Panel (FP) J110 Shuttle Drive UD 3 N FP DATA AVAIL J116 UD 4 SHUT A...
  • Page 285 CFX Controller Board (continued) CAUTION: Do not remove or replace the NVRAM. The NVRAM contains a lithium battery that can explode if replaced incorrectly. NVRAM is replaced only at the factory. Expansion Connector J111 4.7K 4.7K 0.1W 0.1W EXPD7 EXPD6 EXPD5 EXPD4 B1 EXPN ID SEL...
  • Page 286 Appendix A CFX Controller Board (continued) Centronics Connector J112 N STROBE N ACK BUSY PAPER EMPTY SELECT N INIT N AUTOFEED N FAULT 0.1W NDPSEL EXT 5V N SELECT IN HOST LOGIC H p2cfxort NDPEN August 17, 2001 0.1W CHASSIS GND...

  • Page 287: Power Supply

    Power Supply Board...

  • Page 288: Expansion-Ct

    Appendix A Expansion-CT...

  • Page 289: Surestak Power Stacker Pcba

    SureStak Power Stacker PCBA...

  • Page 290: Cabinet Model

    Appendix A Cable Routing, Cabinet Model...

  • Page 291: Cabinet Model, Mechanism Base

    Cable Routing, Mechanism Base, Cabinet Model...

  • Page 292: Pedestal Model

    Appendix A Cable Routing, Pedestal Model...

  • Page 293: Pedestal Model, Mechanism Base

    Cable Routing, Mechanism Base, Pedestal Model...

  • Page 294: Cable Assemblies Centronics I/O

    Appendix A Cable Assembly, Centronics I/O (P/N 152439-901) PIN 1 NOTE: If you replace this NOTE: cable assembly, you must If you replace the I/O cable install the ferrite clamp. assembly, you must install See Appendix D. the ferrite clamp. See Appendix E.

  • Page 295: Dataproducts Adapter

    Cable Assembly, Centronics-to-Dataproducts Adapter (P/N 154695-001)

  • Page 296: Dataproducts Long Lines I/O

    Appendix A Cable Assembly, Dataproducts Long Lines I/O (P/N 154649-901)

  • Page 297: Twinax Auto-Termination

    Cable Assembly, Twinax Auto-Termination (P/N 140752-002) Jack White Gray Shield Resistance Chart Ohms 1, 2, 3, 4 Shield Shield 1, 4 2, 3 Jack...

  • Page 298: 2-Pin Jumper, 0.1 Ctr

    Appendix A Cable Assembly, 2-Pin Jumper, 0.1 Ctr (P/N 154470-901)

  • Page 299: Ac In, Power Supply

    Cable Assembly, AC In, Power Supply (AC Kit P/N 153502-901) To Circuit Breaker To Power Supply J1...

  • Page 300: Ac Power Input

    Appendix A Cable Assembly, AC Power Input (AC Kit P/N 153502-901) To Circuit Breaker Input Power Connector...

  • Page 301: Card Cage Fan

    Cable Assembly, Card Cage Fan (P/N 152422-901) PIN 1 PIN 1...

  • Page 302: Control Panel

    Appendix A Cable Assembly, Control Panel (P/N 152440-901) NOTE: If you replace the control panel cable, you must install two ferrite shielding beads. See Appendix D. PIN 8 (Brown) PIN 1 (Gray) PIN 8 (Brown) PIN 1 (Gray)

  • Page 303: Exhaust Fan

    Cable Assembly, Exhaust Fan (P/N 152424-901) PIN 1 PIN 1...

  • Page 304: Hammer Bank Logic

    Appendix A Cable Assembly, Hammer Bank Logic (P/N 152421-901)

  • Page 305: Hammer Bank Power

    Cable Assembly, Hammer Bank Power (P/N 164805-901) Wire Table P105...

  • Page 306: Mpu

    Appendix A Cable Assembly, MPU (P/N 152425-901) PIN 2 PIN 3 PIN 1 PIN 1...

  • Page 307: Ribbon Guide Kit

    Cable Assembly, Ribbon Guide Kit (P/N 163597-901) NOTE: Left ribbon guide is shown. Right is mirror image. Pin Connection P106 (LRP) / P107 (RRP) Wire Color Pin 1 Black Pin 2 Black Left Guide = P106 / LRP Right Guide = P107 / RRP Pin 2 Pin 1...

  • Page 308: Ribbon Motor, Extension

    Appendix A Cable Assembly, Ribbon Motor, Extension (P/N 154067-901)

  • Page 309: Shuttle Motor Drive

    Cable Assembly, Shuttle Motor Drive (P/N 152420-001)

  • Page 310: Frame Cable, Power Stacker

    Appendix A Frame Cable, Power Stacker (P/N 173824-001)

  • Page 311: Logic Cable, Power Stacker

    Logic Cable, Power Stacker (P/N 158444-001)

  • Page 312: Power Cable, Power Stacker

    Appendix A Power Cable, Power Stacker (P/N 174414-001)

  • Page 313: Rail Cable, Power Stacker

    Rail Cable, Power Stacker (P/N 173823-001)

  • Page 314: Elevator I/O Cable, Power Stacker

    Appendix A Elevator I/O Cable, Power Stacker (P/N 174759-001)

  • Page 315: Fan Assembly, Hammer Bank

    Fan Assembly, Hammer Bank (P/N 152416-901) P107 / HBF...

  • Page 316: Magnetic Pickup (Mpu) Assembly

    Appendix A Magnetic Pickup (MPU) Assembly (P/N 150281-901)

  • Page 317: Switch Assembly, Paper Detector

    Switch Assembly, Paper Detector (P/N 152415-901)

  • Page 318: Switch Assembly, Platen Interlock

    Appendix A Switch Assembly, Platen Interlock (P/N 152417-901)

  • Page 319: B Abbreviations And Signal Mnemonics

    Abbreviations And Signal Mnemonics NOTE: Mnemonics with first letter “N” are negative true. Abbreviation or Mnemonic Definition KΩ 1,000 Ohms MegΩ 1,000,000 Ohms µF microfarad (10 farad) µs microsecond (10 second) µsec microsecond (10 second) A0, A1, etc. Address 0, Address 1, etc. Alternating Current Access Acknowledge...
  • Page 320 Appendix B British Thermal Unit Buffered Upper Driver Cathode Card Cage Card Cage Fan Customer Engineer The controller board used in H-Series printers. (CFX is the manufacturer’s designation; the letters are not an acronym or abbreviation.) CHNG Change Circuit Clock Cover Open COLL Collector...
  • Page 321 DPEN Dataproducts Enable DPMC Dot Plucker Memory Controller Data Processing Unit DRAM Dynamic Random-Access Memory Drive or Driver DRVR Driver Data Set Ready Data Terminal Ready Engine Controller (a functional unit of the CMX controller board) EEPROM Electrically Erasable/Programmable Read-Only Memory Exhaust Fan Elevator (stacker)
  • Page 322 Appendix B Hammer Bank Fan Hammer Bank, Left Hammer Bank Power Hammer Bank, Right Hammer Driver HDIC Hammer Driver Integrated Circuit HDPH Hammer Driver Phase Hammer Bank Logic, Signals, and Power Integrated Circuit Identification Intelligent Graphics Printing INST Instruction Interrupt Input/Output Interrupt Request Jack connector...
  • Page 323 Motor Magnetic Pick-Up (Unit) millisecond (10 second) Motor and Sensors, Left Motor and Sensors, Right Negative True Not Connected Not Connected Near Letter Quality Number NOVRAM Nonvolatile Random-Access Memory nanosecond (10 second) NVRAM Nonvolatile Random-Access Memory On Line Verify Operand + 5 V dc Pin connector P(1), P(2), etc.
  • Page 324 Pin or Plug Part Number Paper Out Paper Out Detect (Switch) Paper PROM Programmable Read-Only Memory Power Supply Power Supply + 5 Volt Printronix System Architecture Pointer, Printer, Printronix Pulse Width Modulation Power Right Ribbon Read Return Ribbon Ribbon Guide...
  • Page 325 Select Sense, Sensor Structured Field Signal Ground Shuttle Hall (Effect) Shuttle Motor SHUT Shuttle SHUTL Shuttle SIMM Single Inline Memory Module SLCT Select (On-line) Slew Rapid vertical paper movement Shuttle Motor Drive Systems Network Architecture Shuttle Processor Unit SRAM Static Random-Access Memory STAT Status or State STBY...
  • Page 326 Appendix B A special ASIC on the controller board containing circuits that help the DC controller operate. The initials VX do not signify words; they serve only to identify this ASIC. Write With Without Transmit...

  • Page 327: C Metric Conversion Tables

    Metric Conversion Tables Length Multiply To Obtain foot 0.3048* meter (m) foot 30.48* centimeter (cm) foot 304.8* millimeter (mm) inch 0.0254* meter (m) inch 2.54* centimeter (cm) inch 25.4* millimeter (mm) meter 3.280840 foot centimeter 0.03280840 foot millimeter 0.003280840 foot meter 39.37008 inch...
  • Page 328 Appendix C Mass and Density Multiply To Obtain pound* 0.4535924 kilogram (kg) ounce* 28.34952 gram (g) kilogram 2.204622 pound* gram 0.03527393 ounce* * avoirdupois Temperature To Convert Use Formula temperature Celsius (t temperature Fahreheit (t = 1.8 t + 32 temperature Fahreheit (t temperature Celsius (t = (t...

  • Page 329: D Noise Suppression Devices

    Noise Suppression Devices Ferrite noise suppressors are installed in the printer to reduce radio frequency interference (RFI) to and from electronic equipment located near the printer. Two kinds of ferrite noise suppressors are used: 1. Shielding Bead (P/N 141445-001) is a cylindrical core, through and around which the control panel cable assembly is wound.
  • Page 330 Appendix D Control Panel Cable Assembly Connector Connector P110 P310 Shielding Bead P/N 141445-001 NOTE: Two turns around each bead. Parallel I/O Cable Assembly Connector P112 Ferrite Core with Clamp and Adhesive Backing P/N 202049-001 NOTE: Attach the core to the right rear card cage wall.

  • Page 331: E Surestak™ Power Stacker

    SureStak Power Stacker ™ Contents Introduction ..................page 332 Stacker Operation ................page 332 Setting Up The Power Stacker ..........page 333 Loading And Starting The Power Stacker......... page 336 Stacker Problems ..............page 337 Removing The Power Stacker ............page 339 Installing The Power Stacker ............

  • Page 332: Introduction

    Appendix E Introduction Introduction The SureStak Power Stacker is a factory-installed option that augments the paper feed system of cabinet model printers. It is designed to work with forms 5 to 12 inches long (12.7 to 30.5 cm) and up to 16 inches (41 cm) wide without the paper tent or 15.5 inches (39.5 cm) wide with the paper tent installed.

  • Page 333: Setting Up The Power Stacker

    Setting Up The Power Stacker 1. Set the printer power switch to | (On). 2. Using the rear control panel, press the ON LINE key to take the printer offline. (Figure 59.) 3. Press the elevator disable switch, grasp the elevator lift handle, and raise the elevator to the top of its travel.
  • Page 334 Appendix E Stacker Operation 4. If the paper you will use is no wider than 15.5 inches (39.5 cm) install the wire paper tent in the pull out paper tray in the base of the stacker. If the paper is wider than 15.5 inches (39.5 cm) leave the paper tent out of the printer.
  • Page 335 5. Push or pull the paddle shaft towards the front or the rear of the printer to set the desired paper length. Align the indicator notch on the bearing bracket with the paper length indicator. The power stacker can handle paper or forms from five to 12 inches long.

  • Page 336: Loading And Starting The Power Stacker

    Appendix E Stacker Operation Loading And Starting The Power Stacker 1. Press the PAPER ADVANCE key and hand feed the paper into the paper throat. Continue to advance the paper until it reaches the wire tent and feed three to five extra sheets in the stacker. Make sure the paper passes through the paper stacker throat.

  • Page 337: Stacker Problems

    Stacker Problems The power stacker augments the paper feed system of the printer. The most frequently occurring problems in the paper feed system are paper jams. Because of the electromechanical nature of the system, other problems that can occur are worn or poor electrical connections and cabling, worn or defective feed motors, worn or damaged mechanical components, or incorrect installation of the stacker assembly.
  • Page 338 Appendix E Stacker Operation Table 6. Power Stacker Problems Symptom Origin of Symptom Explanation Solution Stacker motor check Other troubleshooting A procedure that tests the page 100 procedures. four stacker motors and their cables. You will usually be referred to this procedure from other troubleshooting procedures.

  • Page 339: Removing The Power Stacker

    Removing The Power Stacker 1. Set the printer power switch to O (off). 2. Unplug the power cord. 3. Unload paper from the stacker area. (Refer to the User’s Guide.) 4. Remove the paper tent. (Figure 63.) Paper Tent Figure 63. Removing the Paper Tent 5.
  • Page 340 Appendix E Removing The Power Stacker 6. Remove the two 10-32 x 5/32 inch buttonhead screws and washers securing the vertical rails to the upper frame cross-member at the rear of the cabinet. (Figure 65.) 7. Remove the two Torx T-10 screws securing the stacker base to the cabinet floor.
  • Page 341 9. Pull the paper tray out until the holes in the rails permit access to the M3 buttonhead screws. (Figure 66.) 10. Loosen one turn (do not remove) the M3x6 screws securing the vertical rails to the stacker base. Each rail is secured by two screws. (Figure 66.) M3x6 Buttonhead Screw (Two on each rail) Access Hole in...
  • Page 342 Appendix E Removing The Power Stacker 11. Lower the elevator assembly to its lowest position. Tilt the vertical rails towards the front of the printer to make room for removing the control panel. 12. Remove the two 4-40 x 1/4 inch screws securing the elevator I/O cable to the elevator assembly and disconnect the stacker I/O cable.
  • Page 343 13. Remove two screws, washers, and the standoff from the stacker control panel. (Figure 68.) Standoff Washer Long Screw Washer Short Screw Figure 68. Removing the Stacker Control Panel...
  • Page 344 Appendix E Removing The Power Stacker 14. Remove four cables from the stacker control panel, and remove the stacker control panel. (Figure 69.) Logic Cable (P104) Power Cable (P106) Frame Cable (P102) Rail Cable (P107) Remove the Tie Wrap Figure 69. Removing Cables from the Stacker Control Panel...
  • Page 345 15. Slide the stacker assembly slightly to the right to clear the air exhaust duct. Tilt the vertical rails toward the front of the printer until they clear the upper frame cross-member. Lift and slide the stacker assembly to the rear and angle it out of the cabinet, as shown in Figure 70.

  • Page 346: Installing The Power Stacker

    Appendix E Installing The Power Stacker Installing The Power Stacker NOTE: This section shows complete installation of the power stacker, including all cable assemblies and the stacker control panel. 1. Set the printer power switch to O (off). 2. Unplug the power cord. 3.
  • Page 347 5. Connect the power stacker logic cable P103 to connector J17 or J117 on the controller board. (Figure 72.) 6. Disconnect the power supply cable from connector J101 on the controller board. (Figure 72.) 7. Connect power supply cable connector P101 to the stacker power cable, then connect the stacker power cable to connector J101 on the controller board.
  • Page 348 Appendix E Installing The Power Stacker 10. Route the stacker logic cable straight through the cable routing guide, making sure that it is not twisted. (Figure 73.) 11. Position the cable routing guide so that the four chain hooks protrude through the holes in the guide.
  • Page 349 13. Insert the bent end of the retainer wire into the card cage notch. (Figure 75.) Card Cage Notch Figure 75. Locking the Cable Routing Guide Retainer Wire 14. Pull the paper tray out until the holes in the rails permit access to the M3 buttonhead screws.
  • Page 350 Appendix E Installing The Power Stacker 16. Position the elevator assembly at the bottom of the vertical rails. (Figure 77.) 17. Connect the elevator I/O cable to the elevator assembly and install the two 4-40 x 1/4 inch screws, as shown in Figure 77. Vertical Rail Elevator Assembly Stacker I/O...
  • Page 351 CAUTION The paper stacker assembly mounts to the rear upper frame cross- member and the cabinet floor. It is a snug fit. During installation, take care to avoid scratching painted surfaces or damaging the stacker. 18. Position the stacker assembly slightly to the right in order to clear the air exhaust duct, insert the vertical rails inside and under the upper frame cross-member, then slowly swing the base of the stacker assembly into the cabinet.
  • Page 352 Appendix E Installing The Power Stacker 22. Install finger tight the 10-32 x 5/32 inch buttonhead screw and washer securing the left vertical rail to the upper frame cross-member. (Do not install the right hand screw yet.) (Figure 79.) 23. Install and tighten the two Torx T-10 screws securing the stacker base to the cabinet floor.
  • Page 353 25. Gather the stacker rail cable, elevator I/O cable, logic cable, and power cable. Route the cables outboard of the elevator assembly. (Figure 80.) Elevator I/O Cable Elevator Assembly Rail Cable Card Cage) Control Panel) Stacker Stacker Logic Power Cable Cable Figure 80.
  • Page 354 Appendix E Installing The Power Stacker 26. Connect the stacker cables to the rear of the stacker control panel assembly and make sure the ejector levers close over the connectors. (Figure 81.) 27. Press rail cable connector P107 into the control panel until the ejectors close, then tie wrap the ejectors to the connector.
  • Page 355 28. Apply the double-sided tape to one end of the control panel standoff. Remove the paper backing and hold the standoff inside the cabinet while you insert the upper mounting screw and washer through the hole in the frame. Use the screw as a guide to align the standoff with the hole, then press the standoff against the inside wall and push the upper screw in as far as it will go.
  • Page 356 Appendix E Installing The Power Stacker 31. Install finger tight the 10-32 x 5/32 inch buttonhead screw and washer securing the right vertical rail to the upper frame cross-member. (Figure 79.) 32. Move the elevator assembly up and down on the vertical rails until it travels smoothly with no binding.
  • Page 357 37. Install the paper fence. (Figure 84.) Paper Fence Stacker Base Figure 84. Paper Fence...
  • Page 358 Appendix E Installing The Power Stacker 38. Pull out the paper tray and install the paper tent. (Figure 85.) Note the positions of alignment tab and the paper fence. Paper Tent Paper Tray Figure 85. Paper Tent 39. Install the paper path that you removed in step 4. 40.

  • Page 359: Replacing The Constant Force Spring

    Replacing The Constant Force Spring 1. Remove the stacker assembly from the printer. (See page 339.) 2. Raise the elevator assembly to its highest position and secure it to the vertical rails using tie wraps or string. Do not over-tighten the tie wraps or string;...
  • Page 360 Appendix E Replacing The Constant Force Spring WARNING The constant force spring is a high tension spring. To avoid pinching your fingers, coil the spring slowly and carefully. Do not let the spring twist or crimp. 3. Remove the shoulder screw and large washer from the constant force spring and drum.

  • Page 361: Replacing The Timing Belts

    Replacing The Timing Belts 1. Remove the stacker assembly from the printer (page 339). 2. Raise the elevator assembly to its highest position and secure it to the vertical rails using tie wraps or string. Do not over-tighten the tie wraps or string;...
  • Page 362 Appendix E Replacing The Timing Belts 5. Loosen the two setscrews on the motor pulley and remove the pulley. Unplug the motor cable, if necessary. (Figure 90.) Go to step 6. Timing Belt Motor Setscrew Pulley Setscrew Figure 90. Removing the Timing Belt Motor Pulley 6.
  • Page 363 7. Remove two Allen screws from the belt clamp that secures the timing belt to the stacker frame. (Figure 92.) Allen Screw Belt Clamp Allen Screw Belt Clamp Figure 92. Removing the Belt Clamps...
  • Page 364 Appendix E Replacing The Timing Belts 8. Remove the timing belt by working it around the vertical rail and constant force spring. (Figure 93.) 9. To install a timing belt, reverse the steps of this procedure. NOTE: Left timing belt is shown. Right is the same.

  • Page 365: Illustrated Parts Breakdown

    List of Illustrations Illustrated Parts Breakdown The Illustrated Parts Breakdown (IPB) consists of exploded drawings of the power stacker assembly and subassemblies. Parts are listed next to each drawing. IMPORTANT The Phase III (newest) power stacker is illustrated in this section. If the stacker you are working on does NOT look like the one illustrated here, order the part designated Phase II if the part has both a Phase II and Phase III listing.

  • Page 366: Figure 94. Stacker Assembly

    Appendix E Illustrated Parts Breakdown See page 368. 3 4 5 Figure 94. Stacker Assembly...
  • Page 367 List of Illustrations Item Part No. Description Notes 175273-991 Field Kit, Stacker Advance Exchange Replacement stacker; not illustrated 204476-001 Washer, Shim, 3/16 inch Bore X .016 inch Thick 203251-001 Screw, Hex Skt Btn Hd, Zinc M3X8mm 204458-001 Washer, Shim, .125 ID X .010 inch Thick 173818-001 Timing Belt Tensioner Assy, Pwr Stkr...

  • Page 368: Figure 95. Elevator Detail: Motors, Rollers, And Paddles

    Appendix E Illustrated Parts Breakdown From page 366. See page 370. See page 372. See page 376. 45 46 See page 374. See page 374. Figure 95. Elevator Detail: Motors, Rollers, and Paddles...
  • Page 369 List of Illustrations Item Part No. Description Notes 158313-001 Anti-Static Brush Shear Grommet Part of item 36 Cap Nut Part of item 36 156391-001 Shaft, Drive Roller 156393-001 Spacer, Drive Roller 202789-901 Bearing, Flanged Part of item 36 202824-901 Bearing Part of item 36 202708-901 Collar Clamp...

  • Page 370: Figure 96. Stacker Detail: Rollers

    Appendix E Illustrated Parts Breakdown From page 368. Figure 96. Stacker Detail: Rollers...
  • Page 371 List of Illustrations Item Part No. Description Notes 204255-001 Compression Spring 156392-901 Friction Washer Part of item 36 Flanged Bushing Part of item 36 157960-001 Drive Roller...

  • Page 372: Figure 97. Stacker Detail: Motor Bracket

    Appendix E Illustrated Parts Breakdown From page 368. Flag Connector Figure 97. Stacker Detail: Motor Bracket...
  • Page 373 List of Illustrations Item Part No. Description Notes Clip-On Bearing Part of item 36 158288-001 Holder, LED, Round 202727-001 LED, IR, T-1, 3/4...

  • Page 374: Figure 98. Stacker Detail: Elevator Bracket

    Appendix E Illustrated Parts Breakdown From page 368. Flag Connector Figure 98. Stacker Detail: Elevator Bracket...
  • Page 375 List of Illustrations Item Part No. Description Notes Clip-On Bearing Part of item 36 158290-001 Holder, LED, Flat 202728-001 Photodarlington, NPN, Rectifier...

  • Page 376: Figure 99. Stacker Detail: Paper Motion Detector

    Appendix E Illustrated Parts Breakdown From page 368. Rotated 180 Degrees Connector Figure 99. Stacker Detail: Paper Motion Detector...
  • Page 377 List of Illustrations Item Part No. Description Notes 158290-001 Holder, LED, Flat 202728-001 Photodarlington, NPN, Rectifier Retaining Ring, External, 0.093 inch Part of item 115 Screw, Panhead, Type B, 2 x 3/16 Part of item 36 Shaft, Paper Detector Switch, Long Part of item 115 202729-001 LED, IR, Rectangular...
  • Page 378 Appendix E Illustrated Parts Breakdown...

  • Page 379: F Paper Specifications And Forms Design

    Paper Specifications And Forms Design Introduction The dot matrix line printing technology used by this printer permits a high degree of printing flexibility. Dot matrix technology enables the user to print graphic images, line drawn characters, special characters, and multiple alphabets.

  • Page 380: General Paper Specifications

    The printer will perform well with forms that meet the specifications listed in Table 7 and Table 8 below. NOTE: Printronix conforms to ANSI® Standard X3.96-1983, “American National Forms Information Systems for Continuous Business Forms,” and ISO Recommendation No. 2784, which cover common form widths and depths, standards for sprocket feed holes and margins, and other basic tolerances.

  • Page 381: Paper Guidelines

    Terms And Definitions Paper Guidelines The terms below are used to describe and discuss continuous form paper. (See also Figure 100.) Terms And Definitions Chaff Residual bits of paper not completely removed after the punch process that creates tractor pin holes, major and minor perforations, etc.
  • Page 382 Appendix F Paper Guidelines The figure below illustrates the terms used in this appendix. Side Perforation Margin Area Tractor Pin Hole Page Perforation Cut Point Tie Point Print Area Form Span Side View of Form Printed Side of Form Outward Perforation Inward Perforation Figure 100.

  • Page 383: Environmental Considerations

    Environmental Considerations Environmental Considerations Before they are used, forms should be stored for at least 24 hours— preferably 48 hours—in the environment in which they will be used. This stabilizes the moisture content of the paper, resulting in better feeding and stacking.

  • Page 384: Methods Of Forms Attachment

    Appendix F Paper Guidelines Specification Inches Millimeters Hole centerline (CL) to edge of form 0.236 ± 0.028 6.0 ± 0.10 Hole Diameter (Serrations or any 0.156 ± 0.004 4.0 ± 0.10 occlusion due to incorrect registration of multipart forms cannot exceed this dimension.) Distance between centers of two 0.500 ±...

  • Page 385: Chaff Content

    Chaff Content Preferred Unacceptable Cut Point Tie Point Direction of Forms Movement Cut Point Tie Point Cut-To-Tie Ratio A common cut-to-tie ratio for bond forms is 4:1 (that is, 80% cut to 20% ties). This value is dictated chiefly by the application program that the form runs under.

  • Page 386: Form Design Checklist

    Appendix F Form Design Checklist Form Design Checklist Use this checklist to help you remember key areas of consideration when designing and ordering forms and paper stocks. Environment ________ Before they are used, forms are given at least 24 hours of condensing time in the environment in which they will be used.
  • Page 387 Chaff Content unreliable and unpredictable form. Perforation thickness must not exceed the maximum form thickness of 0.025 in. / 0.0635 cm. Tractor Pin Holes The holes which engage the tractor pins must conform to the following specifications: Specification Inches Millimeters Hole centerline (CL) to edge of form 0.236 ±...
  • Page 388 Appendix F Form Design Checklist Thickness Buildup = ________ in. / cm NOTE: A cut-to-tie ratio that causes a thickness buildup greater than 0.025 in. / 0.0635 cm, or that creates an evenness variation greater than 0.003 in. / 0.00762 cm, will result in an unreliable and unpredictable form.

  • Page 389: Summary

    Summary Because it is impossible to test all possible forms available for use in the printer, Printronix recommends that paper conform to the specifications outlined in this appendix for the best printer performance. But the guidelines in this appendix are not a substitute for actual testing.
  • Page 390 Appendix F Summary...

  • Page 391: G Maintenance Information About Other P5000

    Maintenance Information About Other P5000 Printers Table 9. Early P5000 Single Hammer Bank Printers: Use Maintenance Manual 164253-001 Controller Single Hammer Model Print Enclosure Bank Board Speed P50KA 585 lpm Pedestal 91 Hammers 25 MHz CMX ™ Kanji / Hanzi...
  • Page 392 Appendix G Table 9. Early P5000 Single Hammer Bank Printers: Use Maintenance Manual 164253-001 Controller Single Hammer Model Print Enclosure Bank Board Speed P5005B 500 lpm Pedestal 28 Hammers 40 MHz CMX ™ Pedestal w/ P5005B-QA 500 lpm Quick-Access 28 Hammers 40 MHz CMX ™...
  • Page 393 Table 9. Early P5000 Single Hammer Bank Printers: Use Maintenance Manual 164253-001 Controller Single Hammer Model Print Enclosure Bank Board Speed P5205A-12 500 lpm Cabinet 28 Hammers, 25 MHz CMX ™ 12 MIL tips P5205B 500 lpm Cabinet 28 Hammers 40 MHz CMX ™...
  • Page 394 Appendix G Table 10. Later P5000 Single Hammer Bank Printers (The “P5B/10/15” Line): Use This Maintenance Manual Maximum Controller Model Print Enclosure Hammer Bank Board Speed P5003H Pedestal 60 Hammers 40 MHz CFX ™ P5005B 500 lpm Pedestal 28 Hammers 40 MHz CMX ™...
  • Page 395 Table 11. P5000 PSA3 Single Hammer Bank Printers: Use Maintenance Manual 176475-001 Controller Maximum Printer Model Hammer Bank Print Speed Enclosure Board P5003H 340 lpm Pedestal 60 Hammers PSA3 ™ P5203H 340 lpm Cabinet 60 Hammers PSA3 ™ P5006H 600 lpm...
  • Page 396 Appendix G...
  • Page 397 Index Numerics platen open belt, 136 ribbon guide, 142 06 HOST REQUEST, 37 splined shaft skew adjustment, 144 08 HOLD PRINT / TIMEOUT, 37 tractor belt tension, 159 15 COMM CHECK, 38 ASCII Character Set chart, 122 15V POWER FAIL, 39 Asterisk (*), meaning on messages, 37 22 INVALID ADDR, 39 23.5V FAIL*, 40...
  • Page 398 cable shorts, 162 selection, 115 Checks, service Cores, Noise Suppression, 329 hammer bank power cable shorts, 161 Cover assembly shuttle electrical shorts, 160 hammer bank/ribbon mask, replacement, 177 Circuit board shuttle, replacement, 178 replacement top, pedestal models, 179 controller, 175 CT board, replacement, 181 power supply, 206 CTL VOLT FAIL*, 51...
  • Page 399 EC STOPPED AT STATE XXXX, 53 phasing adjustment, 148 FLASH DID NOT PROGRAM, 53 spring assembly, replacement, 185 FLASH NOT DETECTED, 53 Hammer bank NO DRAM DETECTED, 53 cover assembly, replacement, 177 NVRAM FAILURE, 53 fan assembly, replacement, 182, 184 power cable shorts test, 161 PROGRAM NEEDS MORE FLASH, 53 PROGRAM NEES MORE DRAM, 53...
  • Page 400 ONLINE / 8344 FAILED, 66 overview, 15, 391 ONLINE / CU TIMED OUT, 66 preventive, 31 Operation, principles of, 253 training for Printronix products, 29 Manual how to use, 20 PAP BAD TABLE*, 67 notes and notices, 20 PAP BSY TOO LNG*, 67...
  • Page 401 Phasing adjustment, 148 Printing Pinouts, 271 conventions is this manual, 20 PLAT INV CMD*, 72 line matrix printing explained, 253 PLAT INV PARM*, 72 problems, 35 PLAT INV STATE*, 72 Printouts hex code, 121 Platen gap adjustment, 140 Procedures interlock switch assembly, replacement, 219 adjustment, 131 platen open belt adjustment, 136 cleaning, 31...
  • Page 402 platen, 200 Self-tests platen interlock switch assembly, 219 diagnostic, printer, 114 platen open belt, 169 operator print, 114 platen open motor, 204 SENDING PROGRAM TO EC PROCESSOR, 78 power supply circuit board, 206 Setup, SureStak Power Paper Stacker, 333 resistors, terminating, 207 SF ERROR, 79 ribbon drive motor, 209 Shaft...
  • Page 403 SureStak Power Paper Stacker conversion to or from metric, 327 loading, 336 Tractor setup, 333 replacement, 220 starting, 336 Training, maintenance, for Printronix products, 29 Switch Troubleshooting, 35 paper detector switch assembly, replacement, aids, 35 communications failures, 112 platen interlock switch assembly, replacement,...
  • Page 406 Nederland BV P.O. Box 163, Nieuweweg 283 NL-6600 Ad Wijchen The Netherlands Phone: (31) 24 6489489 Fax: (31) 24 6489499 Printronix Schweiz GmbH 42 Changi South Street 1 Changi South Industrial Estate Singapore 486763 Phone: (65) 6542-0110 Fax: (65) 6543-0220...

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