Printronix P7000 Series Maintenance Manual
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Printronix P7000 Series Maintenance Manual

Line matrix printers
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Table of Contents

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Maintenance Manual
Printronix P7000 Series of Line Matrix Printers

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Table of Contents
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Summary of Contents for Printronix P7000 Series

  • Page 1 Maintenance Manual Printronix P7000 Series of Line Matrix Printers...
  • Page 3 P7000 Series of Line Matrix Printers Maintenance Manual 177705-001F...

  • Page 4: Trademark Acknowledgements

    Business Machines Corporation. Java is a trademark of Sun Microsystems. LinePrinter Plus is a registered trademark of Printronix, Inc. Linux is a registered trademark assigned to Linus Torvalds. MS-DOS and Microsoft Windows (3.1x, 95, 98, Me, NT, 2000, and XP) are trademarks of Microsoft Corporation.
  • Page 5 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 be held responsible for errors contained herein or any omissions from this...

  • Page 6: 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 unauthorized changes or modifications to this equipment.

  • Page 7: Industry Canada Compliance Statement

    TV communications and to other electrical or electronic equipment. Such cables and connectors are available from Printronix authorized dealers. Printronix cannot accept responsibility for any interference caused by using other than recommended cables and connectors.

  • Page 8: German Conformity Statement

    Dieses Gerät ist berechtigt in Übereinstimmung mit dem deutschen das EG- Konformitätszelchen - CE - zu führen. 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...
  • Page 9 Properly shielded and grounded cables and connectors must be used to reduce the potential for causing interference to radio and TV communication and to other electrical or electronic equipment. Printronix cannot be responsible for any interference caused by using other than recommended cables and connectors.
  • Page 10 Chapter Geräte dürfen an Orten, für die sie nicht ausreichend entstört sind, nur mit besonderer Genehmigung des Bundesminesters für Post und Telekommunikation oder des Bundesamtes für Post und Telekommunikation betrieben werden. Die Genehmigung wird erteilt, wenn keine elektromagnetischen Störungen zu erwarten sind. (Auszug aus dem EMVG vom 9.Nov.92, Para.3, Abs.4) Hinweis: Dieses Genehmigungsverfahren ist von der Deutschen Bundespost noch nicht veröffentlict worden.

  • Page 11: Table Of Contents

    Tools And Test Equipment ..............30 Plugging In The Printer ................31 Printronix Customer Support Center............32 Printronix Supplies Department............32 Maintenance Training For Printronix Products ........33 2 Preventive Maintenance ........35 Cleaning The Printer................35 Cleaning The Outside Surfaces..............35 Cleaning The Shuttle Frame Assembly ..........37...
  • Page 12 Table of Contents 3 Troubleshooting ............ 39 Introduction ..................... 39 Troubleshooting Aids ................39 Start Here....................40 Troubleshooting Display Messages............41 List Of Messages ................42 Troubleshooting Other Symptoms ............185 General Symptom List..............186 Communications Failures ..............209 Diagnostic Printer Tests................ 211 Selecting And Running Diagnostic Printer Tests ......
  • Page 13 Table of Contents Hammer Bank Power Cable Shorts Test..........260 Cable Shorts Test .................261 Main Wire Harness Test Diagnostic .............263 Power Supply Operational Check............264 5 Replacement Procedures ........269 Organization Of This Chapter ...............269 Replacement Procedures ..............269 List Of Removal / Installation Procedures ........269 Belt, Paper Feed Timing ..............271 Belt, Platen Open ................272 Circuit Breaker ................273...
  • Page 14 Table of Contents Shuttle Frame Assembly ..............321 Spring, Extension, Hammer Bank ..........323 Switch Assembly, Paper Detector..........324 Switch Assembly, Platen Interlock ..........325 Tractor (L/R) ................... 326 6 Illustrated Parts Breakdown ........ 327 Organization Of This Chapter ............... 327 Illustrations of Printer Components ..........327 7 Principles Of Operation........
  • Page 15 Table of Contents D SureStak™ Power Stacker ........ 457 Contents ....................457 Introduction ...................458 Stacker Operation.................458 Stacker Problems .................463 Stacker First Inspection..............463 Stacker Confidence Check.............464 Stacker Motor Check..............465 Removing The Power Stacker ..............468 Installing The Power Stacker ..............474 Replacing The Constant Force Spring..........486 Replacing The Timing Belts..............488 Replacing The Roller Drive Shaft ............491 Illustrated Parts Breakdown..............494...
  • Page 16 Chaff Content ................. 561 Form Design Checklist................562 Summary ....................565 Storage And Handling ..............565 G Maintenance Manuals For P5000 Printers..567 H Customer Support ..........573 Printronix Customer Support Center............. 573 Printronix Supplies Department ............573 Corporate Offices.................. 574...

  • Page 17: Maintenance Overview

    Maintenance Overview Printronix P7000 Printers P7000 printers are the latest line matrix printers to feature PSA3™ (Printronix System Architecture, third generation). This innovative printer architecture puts all data and printer control electronics one of two available “Hurricane” controller boards: V5 and V6. Up to 32 MB of flash memory on this board permits rapid access to stored printer control languages (emulations) and very fast processing of print data.

  • Page 18: Order The Correct Spares

    00 = 133 inches per minute (ipm) Figure 1. How to Interpret a Model Number Table 1 lists the models in the P7000 series. Remember that the speeds listed are the highest attainable under controlled test conditions. The speed of printing for “real world”...
  • Page 19 How To Identify A P7000 Printer Table 1. P7000 Printers Maximum Model Number Enclosure Hammer Bank Print Speed P7002H 200 lpm Pedestal 28 Hammers P7002HZT 200 lpm ZT Pedestal 28 Hammers P7202H 200 lpm Cabinet 28 Hammers P7003H 300 lpm Pedestal 60 Hammers P7003HZT...

  • Page 20: H-Series Printers

    H in the model number suffix. (See Figure 1 and Table 1.) H-Series printers have specially designed platens and unique shuttle assemblies which are only used in H-Series and HD Series printers. These assemblies are not interchangeable with any other Printronix printers. Table 2. H-Series Character Sets Character Set...

  • Page 21: Printer Configuration Code

    Printer Configuration Code Printer Configuration Code Every printer has a configuration code which specifies the printer’s cabinet type, controller board revision level, V8 ASIC revision level, and MECA ASIC revision level. The configuration code is included in the configuration printout. Figure 2 shows how to interpret the printer’s configuration code.

  • Page 22: Important Maintenance Notes

    Always handle hammer springs by the thick mounting base. • Use only the ribbons specified in the User’s Manual . Using ribbons not made by Printronix can lead to degraded print quality, expensive damage to the printer, and can void the owner’s warranty. •...

  • Page 23: About 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 24: How To Use This Manual

    Chapter About This Manual How To Use This Manual Taking a systematic approach to maintenance tasks will help you restore the printer to operation as quickly as possible: 1. Locate the procedure or information you need in the Table of Contents or Index.

  • Page 25: Safety Notices

    How To Use This Manual 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 26: Controls And Indicators

    Chapter Controls And Indicators Controls And Indicators Electrical Controls Switch or Active Active Function Indicator Online Offline 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 online, off when the printer is offline. Flashes to indicate a fault or warning.
  • Page 27 Electrical Controls Rotated 180 Degrees (Off) (On) Power Switch Arrow Keys Status Indicator SET TOF CONFIG VIEW/ ON LINE/ PAPER SELECT EJECT CANCEL CLEAR ADVANCE ENTER Figure 3. Electrical Controls...

  • Page 28: Mechanical Controls

    Chapter Controls And Indicators Mechanical Controls Control or Indicator Function Paper Supports Help prevent paper jams by supporting inner sections of paper. They are positioned manually by sliding them along the tractor shafts. Forms Thickness Lever Sets the platen for paper and forms of different thicknesses. This lever must be fully opened (raised) to load paper, unload paper, and move paper with the vertical position knob.
  • Page 29 Mechanical Controls Right Tractor Paper Supports Tractor Lock Left Tractor Tractor Lock Vertical Position Knob Forms Thickness Lever Platen Stop Assembly Ribbon Loading Path Diagram Figure 4. Mechanical Controls...

  • Page 30: Tools And Test Equipment

    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 31: Plugging In The Printer

    Mechanical Controls Plugging In The Printer Power Cord Requirements In compliance with international safety standards, a P7000 printer is equipped with a three-pronged electrical plug on the power cord. When this power cord is plugged into a correctly wired AC power outlet, the ground conductor ensures that the printer chassis is at ground (earth) electrical potential.

  • Page 32: Printronix Customer Support Center

    Chapter Printronix Customer Support Center Printronix Customer Support Center The Printronix Customer Support Center offers technical support with: • Installation • Configuration and setup • Loading supplies and operating the printer • Specifications of the proper ribbons, forms, and paper •...

  • Page 33: Maintenance Training For Printronix Products

    Hands-on work with the products • Diagnosis of equipment failures • Preventive and corrective maintenance requirements and procedures Customized classes designed to meet specific needs are also available upon request. Call Customer Training at (714) 368-2595 or visit the Printronix web page at www.printronix.com.
  • Page 34 Chapter Maintenance Training For Printronix Products...

  • Page 35: 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 necessary is periodic cleaning. Periodic cleaning, especially of the ribbon guides and ribbon path, contributes to increased printer life and reliability, and helps sustain superior print quality.
  • Page 36 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. 10. Using a cloth dampened (not wet) with alcohol, clean the ribbon guides. 11.

  • Page 37: Cleaning The Shuttle Frame Assembly

    Cleaning The Shuttle Frame Assembly 1. Remove the shuttle cover assembly (page 280). 2. Remove the shuttle frame assembly (page 321). 3. Remove the paper ironer(s) (page 302). 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 38: 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 303). Pedestal Models: Remove the top cover assembly (page 281). 2. Vacuum the card cage fan assembly and surrounding areas to remove paper particles, dust, and lint.

  • Page 39: Troubleshooting

    Troubleshooting Introduction This chapter lists fault messages and general symptoms, and provides procedures for troubleshooting printer malfunctions. NOTE: Because 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.

  • Page 40: Start Here

    Chapter Start Here... Start Here... Are you here because of an Go to Troubleshooting Display error message? Messages, page 41. Power on the printer and observe the control panel for the following sequence of events (retry as required): Did the status 1.

  • Page 41: Troubleshooting Display Messages

    Troubleshooting Display Messages WARNING Always disconnect the AC power cord from the printer before doing a maintenance procedure. Failure to do so 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 42: List Of Messages

    Chapter Troubleshooting Display Messages List Of Messages Find the message in the Message List below and follow the suggested procedure. After correcting an error, press the CLEAR key to clear the message and place the printer in the offline state. If an error is not cleared, the printer will try to print again but will display the error message until the error is cleared.
  • Page 43 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution 15 COMM CHECK Communication Check: a 1. Power off the printer. Reseat the message that appears in the twinax host data cable CT emulation meaning the connection and twinax I/O cable line is not active on a twinax connection at the CT board.
  • Page 44 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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.
  • Page 45 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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 247).
  • Page 46 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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.
  • Page 47 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution 32 PAPER JAM 9. 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 48 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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.
  • Page 49 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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 50 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution 48V CIRCUIT* Either the power supply is 1. Make sure the power supply See User Manual not generating a proper 48 board is correctly connected to Volts or the controller board the controller board.
  • Page 51 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution 426 BC READ ERR Bar code read error: The 1. Power down the printer. Remove See User Manual printer does not detect the the ribbon and wipe the two presence of the ribbon bar lenses of the ribbon bar code code sensor.
  • Page 52 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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 53 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution B02 STATUS: Status message informing No action required. SDRAM PASSED the operator that the printer finished testing SDRAM. B10 ERROR: Boot-up routines did not 1. Cycle power. If the message NO DRAM DETECTED* detect the presence of the appears again, power down and...
  • Page 54 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution B20 STATUS: 00% Status message informing No action required. DOWNLOAD MODE the operator that software is being downloaded through the printer’s parallel port using the three-key download activation (page 250).
  • Page 55 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution B35 STATUS: Status message: the DC on Cycle power. If the message appears WAITING FOR EC the controller board is again, replace the controller board. STATUS waiting for communication Record the message and return it...
  • Page 56 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution B43 ERROR: SDRAM Printer boot initialization 1. Cycle power. If the message TOO MANY BANKS* tests detect incorrect appears again, reseat the SDRAM. SDRAM DIMM. 2.
  • Page 57 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution B46 ERROR: SDRAM Printer boot initialization 1. Cycle power. If the message HAS MIXED SIZES* tests detect incorrect appears again, reseat the SDRAM. SDRAM DIMM. 2.
  • Page 58 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution B50 ERROR: SDRAM Printer boot initialization 1. Cycle power. If the message LOGIC COMB BANKS* tests detect incorrect appears again, reseat the SDRAM. SDRAM DIMM. 2.
  • Page 59 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution B54 ERROR: SDA The SDRAM or a PCI card is 1. Cycle power. If the message LINE STUCK LOW shorting out the serial data appears again, reseat the bus on the controller board.
  • Page 60 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution BC SENSOR ERR Bar code read error: The 1. Power down the printer. Remove See User Manual printer does not detect the the ribbon and wipe the two presence of the ribbon bar lenses of the ribbon bar code code sensor.
  • Page 61 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution CLEAR PAPER JAM Paper jam. 1. Inspect the paper path for jams. Clear jams. Load paper. 2. Press PAPER ADVANCE several times and check that forms feed without erratic motion, noise, or pin-hole damage.
  • Page 62 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution CLEAR PAPER JAM 10. Check the condition and tension (continued) of the paper feed belt. Adjust the paper feed belt. Replace the belt if it is damaged. 11.
  • Page 63 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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 64 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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.
  • Page 65 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution DP FIFO Busy* There is a timing problem in 1. Cycle Power. Run the print job the Engine Controller again. If the message appears, firmware. download the emulation software again (page 247).
  • Page 66 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution E01B TYPE 0x60 An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 67 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution E03C DSI BAT PL An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 68 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution E03G DSI ECXIWX An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 69 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution E04C ISI PROTEC An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 70 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution E12 SYSTEM CALL An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 71 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution E18 DSTORE MISS An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 72 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution E31A EVENT O BP An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 73 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution E31E EVENT 4 BP An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 74 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution E32A CND 0 BP An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 75 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution E32E CND 4 BP An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 76 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution E33 WRITE BP An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 77 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution ERROR: CPLD NOT The Complex Programmable Cycle power. If the message appears PROGRAMMED Logic Device (CPLD) on the again, replace the controller board. controller board is not Record the message and return it programmed.
  • Page 78 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution ERROR: EC STOPPED Where XXXX is a number 1. Power off the printer. Remove the AT STATE XXXX from 0000 to 0010. The flash memory SIMM and SDRAM Engine Controller has DIMM.
  • Page 79 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution ERROR: LOCKED SN= Where nnnnnnnnnnnnnnnn 1. Remove the SPX from the Debug nnnnnnnnnnnnnnnn is the serial number of the Port. printer’s security key. The 2. Cycle printer power. SPX gets “locked”...
  • Page 80 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution ERROR: SECURITY The security key is not 1. Check the security key at KEY NOT DETECTED present or has failed. connector J9 on the controller board.
  • Page 81 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution ETHERNET DETECTED Status message indicating No action required. that the PrintNet ethernet interface has established communication. Status message that No action required. ETHERNET INITIALIZING indicates that the internal Network Interface Card is processing the boot procedure.
  • Page 82 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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 NOTE: For cabinet models connector J307.
  • Page 83 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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 247).
  • Page 84 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution H00: PCI SLOT ? The controller board is not 1. Cycle power. If the message See User Manual communicating with a PCI appears, power down and reseat card.
  • Page 85 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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 samples the 2.
  • Page 86 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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 87 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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 88 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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 247).
  • Page 89 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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.
  • Page 90 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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 CT board.
  • Page 91 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution LOAD PAPER The 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 backing on the paper being used in printer.
  • Page 92 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution NEW SPX DETECTED The printer detects an SPX Press the ENTER key. The following PRESS ENTER in its debug port and the actions occur: SPX is valid for this printer.
  • Page 93 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution ONLINE Controller Unit Timed Out. Check cable connection and host CU TIMED OUT The printer was not enabled system. (Refer to line problem for one minute or more on a determination procedures, as coax interface.
  • Page 94 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution PAP FD DRVR CIR* Paper Feed Driver Circuit. 1. Cycle power. If the message See Manual The paper feed driver circuit appears, replace the controller on the controller board is board.
  • Page 95 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution PAP FIFO UNDRFL* Paper First In First Out 1. Cycle power. Run the print job Underflow. Firmware error again. If the message appears, on the controller board. download the emulation software again.
  • Page 96 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution PAP ILLGL ST* Paper Illegal State. Firmware 1. Cycle power. Run the print job error on the controller board. again. If the message appears, download the emulation software again.
  • Page 97 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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 98 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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.
  • Page 99 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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.
  • Page 100 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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 101 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution PRINTER HOT This message indicates 1. Controller board sensors report internal temperatures over high temperatures on the board. 60° Celsius (140° Inspect printer environment for Fahrenheit).
  • Page 102 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution PWR SUPP VOLT* Power Supply Voltage. The Replace the power supply board. power supply has failed. QUEUE OVERRUN In the CT twinax emulation, 1. If the message appears, replace the print buffer has the CT board.
  • Page 103 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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 104 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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).
  • Page 105 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution SHUT DRVR CIR* The shuttle driver circuit on 1. Power down the printer. Remove See User Manual the controller board is the paper path or top cover to drawing too much current.
  • Page 106 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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.
  • Page 107 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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 the defective board. 10.
  • Page 108 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution SPX FOUND, ERROR: The controller board does 1. Remove the SPX from the Debug KEY NOT DETECTED not have a security key. Port. 2. Power down the printer. 3.
  • Page 109 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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 110 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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 196.) If the limit switches are OK, go to the next step.
  • Page 111 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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.
  • Page 112 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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.
  • Page 113 List Of Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed 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.
  • Page 114 Chapter Troubleshooting Display Messages Table 4. P7000 ASCII (Spool) Error Messages List Displayed Message Explanation Solution WAITING FOR This status message No action required. ETHERNET ADAPTER appears when the printer is first powered on if the optional ethernet NIC is installed.
  • Page 115 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 000:SHUTTLE TYPE The shuttle type was not 1. Power down the printer. Remove NOT SUPPORTED* detected at power-up or the the paper path or top cover to shuttle installed in the printer gain access to the card cage.
  • Page 116 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 101:BARCODE FAIL Bar code error: The printer 1. Power down the printer. Remove SPECIFICATION does not detect the the ribbon and wipe the two presence of the ribbon bar lenses of the ribbon bar code code sensor.
  • Page 117 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 102:HAM.BANK HOT Hammer Bank Hot. 1. Cycle power. If the message LET PRINTER COOL appears, press CLEAR. If the message does not clear, go to step 2.
  • Page 118 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 104:POWER SUPPLY 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 119 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 105:PRINTER HOT This message indicates 1. Controller board sensors report internal temperatures over high temperatures on the board. 60° Celsius (140° Inspect printer environment for Fahrenheit).
  • Page 120 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 401:BUFFER The print buffer has 1. Verify that the printer matches the OVERRUN overflowed on a serial host serial interface configuration interface. The printed output settings for Data Protocol, Baud may contain random * Rate, Data Bits, Stop Bits, Parity,...
  • Page 121 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 402:CLEAR PAPER No paper motion. 1. Inspect the paper path for jams. Clear jams. Load paper. 2. Press PAPER ADVANCE several times and check that forms feed without erratic motion, noise, or pin-hole damage.
  • Page 122 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 402:CLEAR PAPER 10. Check the condition and tension JAM (continued) of the paper feed belt. Adjust the paper feed belt. Replace the belt if it is damaged. 11.
  • Page 123 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 403:CLOSE PLATEN The platen lever is open. 1. Load paper. Close the forms thickness lever. 2. Power off the printer. Remove the paper path or pedestal top cover. Disconnect connector P107 from the controller board.
  • Page 124 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 408:WRITE ERROR Hardware or software fault in 1. Replace flash memory. CHECK FLASH flash memory. 2. If message occurs with new memory, replace the controller board.
  • Page 125 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 410: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 backing on the paper being used in printer.
  • Page 126 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 411:PARITY ERROR The printed output may Verify that the printer matches contain a random ? host serial configuration settings (question mark) characters. for Data Protocol, Baud Rate, Data Bits, Stop Bits, Parity, Data Terminal Ready, and Request to Send.
  • Page 127 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 414: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 128 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 415: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.
  • Page 129 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 415:SHUTTLE JAM The shuttle is not moving or 9. Run a print test. If the message (continued) is moving at the wrong appears, replace the controller speed.
  • Page 130 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 417: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.
  • Page 131 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 419:RBN END PNT Integrated Print Install a new ribbon. Change Ribbon Management System software has determined that the ribbon is out of ink. 420:EXC RBN WEAR Status message that Install a new ribbon.
  • Page 132 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 424:UNKNOWN RBN1 The sensor detects a bar Install a new ribbon. Install New RBN code, but the ribbon model is not permitted on this printer. 425:UNKNOWN RBN2 The sensor detects a bar Install a new ribbon.
  • Page 133 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 600:15 VOLTS Controller Voltage Failure. 1. Cycle Power. Run the print job FAILED* 15 V failure on the controller again. If the message appears, board. download the emulation software again (page 247).
  • Page 134 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 602:23.5V 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.
  • Page 135 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 603:48 VOLTS 48 Volt Failed: an internal 1. Power off the printer. Remove the FAILED* 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 136 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 605:48V POWER 48 Volt Power Failed: an 1. Power off the printer. Remove the FAIL* internal power failure. paper path or pedestal top cover. Check that power supply connector P101 is fully seated in connector J101 on the controller...
  • Page 137 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 607:CTL VOLT Controller Voltage Failure. 1. Cycle Power. Run the print job FAIL* 15 V failure on the controller again. If the message appears, board. remove the hammer bank logic cable, inspect it for damage, and test it for continuity.
  • Page 138 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 608:DRIVER Driver Circuit Bad: the 1. Cycle power. If the message CIRCUIT BAD* hammer coil count test appears, press CLEAR. failed. 2. Power off the printer. Remove the shuttle cover.
  • Page 139 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 610:HAMMER COIL Hammer Coil Open. 1. Cycle power. If the message OPEN Electrical malfunction of one appears, replace the shuttle or more hammer coils. frame assembly. 2.
  • Page 140 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 614:HAMMER BANK Hammer Bank Not Installed. 1. Install the shuttle frame NOT INSTALLED* Self-test routines do not assembly. detect hammer coils at 2. Remove the paper path or printer start-up.
  • Page 141 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 616:INTAKE FAN Sensors cannot detect 1. Cycle power. If the message FAULT current in the card cage fan appears, press CLEAR. If the circuit. message does not clear, go to step 2.
  • Page 142 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 619:PAPER FEED Paper Feed Driver Circuit. 1. Cycle power. If the message DRIVER CIRCUIT* The paper feed driver circuit appears, replace the controller on the controller board is board.
  • Page 143 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 623:STACKER Two situations can trigger 1. Open the cabinet rear door and FAULT this message: check for obstructions preventing 1. The stacker elevator is elevator movement. Remove any obstructed while attempting obstructions.
  • Page 144 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 624:UPPER DRIVER Upper Driver Short. Hammer 1. Cycle power. If the message SHORT* driver circuits on the appears, press CLEAR. If the controller board are shorted message does not clear, replace to ground.
  • Page 145 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 702:FIRMWARE Application software tried to 1. Cycle power. Run the print job. If ERROR* perform an illegal printer the message appears, download function or damaged the emulation software again memory is detected on the (page 247).
  • Page 146 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 706:PAPER BAD Paper Bad Table. The paper 1. Cycle power. Run the print job TABLE* feed process on the again. If the message appears, controller board has a download the emulation software corrupted table.
  • Page 147 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 709:PAPER FIFO Paper First In First Out 1. Cycle power. Run the print job UNDERFLOW* Underflow. Firmware error again. If the message appears, on the controller board. download the emulation software again.
  • Page 148 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 710:PAP ILLGL 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.
  • Page 149 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 714:PAP NOT Paper Not Scheduled. The 1. Cycle power. Run the print job SCHED* 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 150 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 717: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.
  • Page 151 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 721:RIB INVLD Ribbon Invalid Command. 1. Cycle power. Run the print job CMD* Firmware error on the again. If the message appears, controller board. download the emulation software again.
  • Page 152 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 726:SHUTT. FAN Sensors cannot detect 1. Cycle power. If the message FAIL* current in the hammer bank appears, press CANCEL. fan circuit. 2. Power off and unplug the printer. Remove the paper guide assembly or pedestal top cover.
  • Page 153 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 727:SOFTWARE Application software tried to 1. Cycle power. If the message ERROR* perform an illegal printer appears, power off the printer. function or damaged logic 2.
  • Page 154 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution 731:UNDEFINED Undefined Interrupt. 1. Cycle power. Run the print job INTERRUPT* Firmware error on the again. If the message appears, controller board. download the emulation software again.
  • Page 155 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution B01 STATUS: 8245 Status message: printer No action required. SDRAM TEST 32MB boot-up routines are testing SDRAM. B10 ERROR: NO Boot-up routines did not 1. Cycle power. If the message DRAM DETECTED* detect the presence of the appears again, power down and...
  • Page 156 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution B21 STATUS: Status message informing No action is required. PRINTER RESET the operator that the printer is undergoing a system reset. B22 ERROR: Flash memory has not 1.
  • Page 157 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution B40 ERROR: SDRAM Flash memory has not 1. Cycle power. If the message EEPROM CKSUM passed boot initialization appears again, reseat the flash BAD* tests. SIMM.
  • Page 158 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution B43 ERROR: SDRAM Printer boot initialization 1. Cycle power. If the message TOO MANY BANKS* tests detect incorrect appears again, reseat the SDRAM. SDRAM DIMM. 2.
  • Page 159 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution B46 ERROR: SDRAM Printer boot initialization 1. Cycle power. If the message HAS MIXED SIZES* tests detect incorrect appears again, reseat the SDRAM. SDRAM DIMM. 2.
  • Page 160 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution B50 ERROR: SDRAM Printer boot initialization 1. Cycle power. If the message LOGIC COMB tests detect incorrect appears again, reseat the BANKS* SDRAM. SDRAM DIMM. 2.
  • Page 161 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution BC SENSOR ERR Bar code read error: The 1. Power down the printer. Remove See User Manual printer does not detect the the ribbon and wipe the two presence of the ribbon bar lenses of the ribbon bar code code sensor.
  • Page 162 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution D55 Status: Send Status message: The printer No action is required. Program to EC is loading the engine controller program into the engine controller (EC). DIAGNOSTIC Status message: the printer No action is required.
  • Page 163 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution E02 MACHINE CHK An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 164 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution E03D DSI BAT PS An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 165 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution E03H DSI ECXOWX An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 166 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution E06 NOT ALIGNED An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 167 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution E13 TRACE INT An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 168 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution E19 BREAKPOINT An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 169 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution E31B EVENT 1 BP An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 170 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution E31F EVENT 5 BP An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 171 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution E32B CND 1 BP An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 172 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution E32F CND 5 BP An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 173 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution E34 TRACE CMPLT An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 174 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution ERROR: EC The printer cannot find the 1. Download the program again PROGRAM NOT engine controller program or (page 247). If the message VALID the validation checksum is occurs again, replace all flash corrupt.
  • Page 175 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution ERROR: LOCKED Where nnnnnnnnnnnnnnnn 1. Remove the SPX from the Debug SN=nnnnnnnnnnnnnnn is the serial number of the Port. nnnnnn printer’s security key. The 2. Cycle printer power. SPX gets “locked”...
  • Page 176 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution ERROR: PROGRAM The printer does not see a There is no program in printer NOT VALID program in flash memory. memory. Download the emulation. ERROR: SECURITY The security key is not 1.
  • Page 177 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution ETHERNET ADAPTER Status message indicating No action is required. BEING INITIALIZED that the ethernet interface is processing the boot procedure. ETHERNET Status message indicating No action is required. DETECTED that the Network Interface Card has established...
  • Page 178 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution H02: PCI J13 The controller board is not 1. Cycle power. If the message See User Manual communicating with the PCI appears, power down and reseat card in PCI slot J13.
  • Page 179 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed 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 samples the 2.
  • Page 180 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed 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.
  • Page 181 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution NON VOLATILE Large emulations reduce the 1. If the message appears at power- MEMORY FAILED amount of space available up, replace the flash memory. for saving configurations, 2.
  • Page 182 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution SECURITY Security code of the security 1. Remove the paper path or VIOLATION* key at J9 on the controller pedestal top cover. Check that board does not match the the security key is correctly code of the firmware on the...
  • Page 183 List Of Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution TCP PORT BUSY Error message reported by 1. Power on the printer. the Printer Manager when 2. If the printer is online, press the ethernet interface option is ON LINE key to place the printer installed.
  • Page 184 Chapter Troubleshooting Display Messages Table 5. P7000 H-Series (Spool) Error Messages List Displayed Message Explanation Solution WAITING FOR This status message No action required. ETHERNET ADAPTER appears when the printer is first powered on if the optional ethernet NIC is installed.

  • Page 185: 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 do so 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 186: General Symptom List

    Chapter Troubleshooting Other Symptoms General Symptom List Table 6 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 6, troubleshoot using the Half-Split Method described on page 185.
  • Page 187 General Symptom List Table 6. General Symptom List Symptom Solution Jams CLEAR PAPER JAM 1. Power off the printer. Remove the paper path or pedestal message instead of LOAD top cover. Remove the barrier shield (cabinet model) or PAPER when printer is out of the barrier shield and paper guide (pedestal model).
  • Page 188 Chapter Troubleshooting Other Symptoms Table 6. General Symptom List Symptom Solution CLEAR PAPER JAM 1. Power off the printer. Remove the paper path or pedestal message will not clear but top cover. Check that connector P106/PMD is fully seated paper moves in connector J106 on the controller board.
  • Page 189 General Symptom List Table 6. 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 190 Chapter Troubleshooting Other Symptoms Table 6. 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 191 General Symptom List Table 6. 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 192 Chapter Troubleshooting Other Symptoms Table 6. General Symptom List Symptom Solution Printer does not initialize NOTE: Power-on initialization is explained on page 227. 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 193: Power Stacker

    General Symptom List Table 6. 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 194 Chapter Troubleshooting Other Symptoms Table 6. 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 195 General Symptom List Table 6. 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 196 Chapter Troubleshooting Other Symptoms Table 6. 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 197 General Symptom List Table 6. 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 198: Print Quality

    Chapter Troubleshooting Other Symptoms Table 6. 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 199 General Symptom List Table 6. General Symptom List Symptom Solution Characters or dots are 12. Power on the printer. If the problem still occurs, replace missing, smeared, too light, the controller board. or too dark. (continued.) Characters are compressed Adjust the tension of the tractor belts (page 258). on first line of a form Horizontal misalignment of 1.
  • Page 200 Chapter Troubleshooting Other Symptoms Table 6. 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 201 General Symptom List Table 6. 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 202: Printer Operation

    Chapter Troubleshooting Other Symptoms Table 6. 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 203 General Symptom List Table 6. 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 204 Chapter Troubleshooting Other Symptoms Table 6. General Symptom List Symptom Solution Paper feeds poorly 11. Load paper. Power on the printer. Press PAPER (continued) ADVANCE and VIEW several times and check that paper moves in both directions. Replace the paper feed motor if paper does not move in both directions.
  • Page 205 General Symptom List Table 6. General Symptom List Symptom Solution Printer does not print self 1. Power off the printer. Remove the paper path or pedestal tests top cover. Disconnect the control panel cable from connector J110 on the controller board. Disconnect the control panel cable from the control panel.
  • Page 206 Chapter Troubleshooting Other Symptoms Table 6. General Symptom List Symptom Solution TOF is lost repeatedly 1. Check that the customer is setting the forms length to match the size paper used. Set the forms length to match the length of paper being used. 2.
  • Page 207 General Symptom List Table 6. 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 ± 0.001 inch (0.254 ± 0.025 mm). Torque the 7/16 inch MPU clamp screw to 18 inch-pounds (2.03 N•m).
  • Page 208 Chapter Troubleshooting Other Symptoms Table 6. 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 209: Communications Failures

    General Symptom List 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 210 Chapter Communications Failures Table 7. 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 211: Diagnostic Printer Tests

    General Symptom List Diagnostic Printer Tests A set of printer tests is included in the DIAGNOSTICS configuration menu for use as diagnostic tools. Use these 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 212: Selecting And Running Diagnostic Printer Tests

    Chapter Diagnostic Printer Tests • Ethernet Test — Prints the ethernet statistics stored on the ethernet interface (if present). See page 215. • Acoustics — A test used by the manufacturer to measure acoustic properties of the printer. This test has no value as a maintenance tool. •...
  • Page 213 Selecting And Running Diagnostic Printer Tests Step Press LCD Result Notes DIAGNOSTICS Test Width UNTIL Test Width Full Width* Test Width Cycle through choices. X = Full Width or X = 80 columns. Test Width Test width is ENTER selected. DIAGNOSTICS Test Width DIAGNOSTICS...
  • Page 214 Chapter Diagnostic Printer Tests Step Press LCD Result Notes ENTER SWITCH Locks the ENTER LOCKED key and control panel. ONLINE Places the printer in ON LINE/CLEAR LinePrinter+ online mode. Examine print quality. Characters should be fully formed and of uniform density. Set TOF.
  • Page 215 Selecting And Running Diagnostic Printer Tests Printing The Ethernet Test NOTE: You must set TOF after printing the Ethernet 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 ON LINE/CLEAR...
  • Page 216 Chapter Diagnostic Printer Tests Step Press LCD Result Notes ENTER SWITCH Locks the ENTER LOCKED key and control panel. ONLINE Places the printer in ON LINE/CLEAR LinePrinter+ online mode. Set TOF. (Refer to the User’s Manual. )

  • Page 217: Boot Diagnostics Menu

    Selecting And Running Diagnostic Printer Tests 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 218 Chapter Boot Diagnostics Menu > = Down Arrow Key BOOT DIAGNOSTICS < = Next Arrow Key PRESS ENTER ENTER < DIAGNOSTICS MENU VERSION CONTROL > VERSION MENU VERSION MENU VERSION MENU < VERSION MENU < < < \SOFTWARE VERSION HARDWARE VERSION V8 ASIC VERSION BOOTCODE VERSION ENTER...
  • Page 219 Selecting And Running Diagnostic Printer Tests DIAGNOSTICS MENU DIAGNOSTICS MENU DIAGNOSTICS MENU < < MISC. TOOLS EXIT DIAGNOSTICS EXCEPTION VIEWER > From previous > ENTER page B30: STATUS > INITIALIZING... = Down Arrow Key < = Next Arrow Key MISC. TOOLS MENU MISC.

  • Page 220: Factory Menu

    Chapter Factory Menu Factory Menu Printer software contains a Factory menu that you can access by holding down the four arrow keys when the printer is in the offline state. This menu is not intended for the end user, but is used by manufacturing and maintenance personnel to set or change certain operational perameters.
  • Page 221 Selecting And Running Diagnostic Printer Tests > = Down Arrow Key < = Next Arrow Key Press ENTER to select or activate. Factory Factory Factory Factory < < < C/T Data Timeout Set Coil Temp PRINTER MGMT Demo Count > >...

  • Page 222: Exception Menu

    Chapter Exception Menu Exception Menu The exception menu is only accessible when certain faults occur. It provides additional troubleshooting information for some fault mesages. You will only use this menu when directed to by a troubleshooting procedure. When you come to this procedure, the printer will be powered on, with a specific fault message displayed which prevents further operation.

  • Page 223: 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-character hexadecimal code. (See Figure 10 below.) You can use hex dumps as an aid in troubleshooting data reception problems.

  • Page 224: 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/CLEAR QUICK SETUP ENTER SWITCH Unlocks the ENTER UNLOCKED key and control panel. OFFLINE QUICK SETUP OFFLINE...
  • Page 225 How To Print A Hex Dump Step Press LCD Result Notes ONLINE Places the printer in ON LINE/CLEAR LinePrinter+ online mode. Send a file from the host computer. the printer outputs a hex dump. Refer to the ASCII chart on page 226. When the hex dump is complete, take the printer offline and change the Hex Dump Mode back to Disable.

  • Page 226: Ascii Character Set

    Chapter ASCII Character Set 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 & 0 1 1 0 0 1 1 1 1 0 0 1 1 0 1 0...

  • Page 227: Soft Vs. Hard Reset

    How To Print A Hex Dump 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 228 Chapter Soft vs. Hard Reset...

  • Page 229: Adjustments And Tests

    Adjustments and Tests Introduction The printer is a durable, low-maintenance machine, but some components and systems require occasional adjustment and may need to be tested as part of a troubleshooting procedure. You usually will be referred to this chapter by a troubleshooting procedure, or as part of a removal/installation procedure.

  • Page 230: 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 231: Returning The Printer To Normal Operation

    Adjustments and Tests Returning The Printer To Normal Operation When you have finished servicing the printer, return it to service by doing the following steps: 1. Load paper. 2. Connect the data (signal) cable(s) to the printer interface. 3. Plug the AC power cord into the printer and the power source. 4.

  • Page 232: Belt, Paper Feed Timing, Adjustment

    Chapter Belt, Paper Feed Timing, Adjustment Belt, Paper Feed Timing, Adjustment 1. Prepare the printer for maintenance (page 230). 2. Cabinet Models: Remove the paper path (page 303). Pedestal Models: Remove the top cover assembly (page 281). 3. Remove the timing belt cover (1) by squeezing the front and back to release the plastic tabs from the slots in the side plate.
  • Page 233 Adjustments and Tests 1/8 inch Direction of Force Legend: Timing Belt Shield Motor Mount Bolt (2) Paper Feed Drive Motor Splined Shaft Figure 11. Paper Feed Timing Belt Adjustment...

  • Page 234: Belt, Platen Open, Adjustment

    Chapter Belt, Platen Open, Adjustment Belt, Platen Open, Adjustment 1. Prepare the printer for maintenance (page 230). 2. Cabinet Models: Remove the paper path (page 303). Pedestal Models: Remove the top cover assembly (page 281). 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 235 Adjustments and Tests 3/16 inch Legend: Belt Cover Motor Mount Screw (2) Platen Open Motor Shaft Figure 12. Platen Open Belt Adjustment...

  • Page 236: Paper Scale Alignment

    Chapter Paper Scale Alignment Paper Scale Alignment 1. Open the printer cover. 2. Load paper. 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 280). 6.
  • Page 237 Adjustments and Tests Legend: Shuttle Cover Screw, Button-Head, 5/64 inch hex (3) Paper Scale Figure 13. Paper Scale Alignment...

  • Page 238: Platen Gap Adjustment

    Chapter Platen Gap Adjustment Platen Gap Adjustment IMPORTANT Only do this procedure if the original equipment shuttle frame assembly or platen was replaced by a new or refurbished unit, or if you were instructed to in a troubleshooting procedure. 1. Prepare the printer for maintenance (page 230). 2.
  • Page 239 Adjustments and Tests NOTE: Left side adjustment shown. Right side is the same. Legend: Platen Stop Knob Forms Thickness Lever Feeler Gauge Hammer Bank Cover Ribbon Mask Setscrew, 3/32 inch hex (2) Figure 14. Platen Gap Adjustment...

  • Page 240: Ribbon Guide Alignment

    Chapter Ribbon Guide Alignment Ribbon Guide Alignment 1. Open the printer cover. 2. Load paper. 3. Install the ribbon. (Refer to the User’s Manual .) 4. Using the Shuttle Slow diagnostic printer test (page 211), wind the ribbon fully onto the ribbon spool on the side opposite the ribbon guide you want to adjust.
  • Page 241 Adjustments and Tests Left Ribbon Guide Right Ribbon Guide Legend: Screw, Skid (2) Ribbon Steel Washer Screw, Retaining (2) Figure 15. Ribbon Guide Alignment...

  • Page 242: 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 243 Adjustments and Tests 7. If the printer is online, press the ON LINE key to place the printer offline. “OFFLINE / QUICK SETUP.” displays. > 8. On the control panel, press the keys to unlock the ENTER key. “ENTER SWITCH UNLOCKED” briefly displays. (If “LOCKED” displays, >...
  • Page 244 Chapter Paper Out Adjustment < 20. Press until “Paper Out Dots” displays. > 21. Press . The top line of the display will show “Paper Out Dots” and the bottom line will show the current setting for the number of dots. >...

  • Page 245: Hammer Phasing Adjustment

    Adjustments and Tests 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 246 Chapter Hammer Phasing Adjustment > > 10. Press : The current phase index displays. Press again: An asterisk (*) appears next to the phase value. < 11. Press to increase or to decrease the phasing index value, then press ENTER to activate the value as it prints. Continue to increase or decrease the phasing index until the pattern of H’s is acceptable.

  • Page 247: Loading Flash Memory

    Adjustments and Tests Loading Flash Memory Flash memory is contained in a SIMM (single in-line memory module) 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 occasions when you may have to load this software: •...
  • Page 248 Chapter Loading Flash Memory 2. Set the printer power switch to O (Off). 3. Disconnect the data (signal) cable(s) from the I/O port(s) connectors on the printer interface. 4. Connect a printer data cable to the parallel, serial, or ethernet port of the computer you will use to download the software.

  • Page 249: Loading Through Parallel Port Using Dos

    Adjustments and Tests 19. Using the configuration printout(s) you made in step 1, restore the printer configurations. (Refer to the printer User’s Manual .) Loading Through Parallel Port Using DOS 1. Make a configuration printout of all saved configurations. (Refer to the User’s Manual.) 2.

  • Page 250: Loading Software If Flash Contains Only Boot Code

    Chapter Loading Flash Memory 14. At the command prompt type: C:<Enter> cd \download<Enter> 15. To load the file through the LPT1 parallel port on the computer, type the following at the command prompt on the computer: filename.exe -pb<Enter> where filename .exe is the file name you noted in step 11. 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.
  • Page 251 Adjustments and Tests 8. Wait until you see “B20: STATUS 00% / DOWNLOAD MODE” or “PROGRAM DOWNLOAD” on the LCD before doing the next step.This can take a few seconds to appear, depending on the emulations and interfaces installed in the printer. 9.

  • Page 252: Loading Software Through The Nic

    Chapter Loading Flash Memory Loading Software Through The NIC IMPORTANT To load software through the ethernet NIC (Network Interface Card) you need the IP Address of the printer and the flash memory must contain basic printer code. If the flash memory was replaced, or if a download was interrupted (for example, by a power outage), you must load software through the parallel port.

  • Page 253: Reprogramming The Security Key

    Adjustments and Tests 13. Start the FTP (file transfer protocol) program by typing: 123456 -n xxx.xxx.xxx.xxx<Enter> (where xxx.xxx.xxx.xxx is the IP Address of the printer.) IMPORTANT Do not interrupt the downloading process once it has started. Interrupting a download will leave the flash memory on the controller board and NIC incompletely loaded, and the printer may not boot up.
  • Page 254 Chapter Reprogramming the Security Key Debug Port Figure 17. Inserting the SPX into the Debug Port 4. Power on the printer. The printer will begin its boot-up sequence. 5. When the printer detects a valid SPX, the control panel displays: “NEW SPX DETECTED PRESS ENTER”...

  • Page 255: Coil Temperature Adjustment

    Adjustments and Tests Coil Temperature Adjustment IMPORTANT This procedure applies only to models P7000HD, P7X06H, P7X08H, P7X15, and P7220. Do this procedure only when the original controller board or shuttle frame assembly have been replaced or you are instructed to do so in a maintenance or troubleshooting procedure.

  • Page 256: Dynamic Paper Tension Adjustment

    Chapter Dynamic Paper Tension Adjustment 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 257 Adjustments and Tests 8. Use the scale to pull the paper slowly straight up through the print station for about six inches and note the maximum force exerted on the scale. Do not pull any page perforations through the print station. (Figure 19.) Scale Figure 19.

  • Page 258: Tractor Belt Tension Adjustment

    Chapter Tractor Belt Tension Adjustment Tractor Belt Tension Adjustment First line print compression can be reduced by adjusting the tension of the tractor belts. The procedure below removes the slack that can 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 256).

  • Page 259: Shuttle Electrical Short Check

    Adjustments and Tests 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 260: Hammer Bank Power Cable Shorts Test

    Chapter Hammer Bank Power Cable Shorts Test 13. Install the ribbon. (Refer to the User’s Manual .) 14. Return the printer to normal operation (page 231). Hammer Bank Power Cable Shorts Test This test determines if the hammer bank power cable is shorted. 1.

  • Page 261: Cable Shorts Test

    Adjustments and Tests 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 non- conductive shielding of the cable, exposing the conductor.
  • Page 262 Chapter Cable Shorts Test 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 263: Main Wire Harness Test Diagnostic

    Adjustments and Tests Main Wire Harness Test Diagnostic This is a procedure for extended testing of various printer components. 1. Prepare the printer for maintenance (page 230). 2. Cabinet Models: Remove the paper path (page 303). Pedestal Models: Remove the top cover assembly (page 281). 3.

  • Page 264: Power Supply Operational Check

    Chapter Power Supply Operational Check Power Supply Operational Check This procedure shows you how to use the Power Supply Tester (Field Kit, Tester, Power Supplies, Generic, P/N 178083-001), to quickly and safely monitor the output voltages of the printer power supply from outside the card cage.
  • Page 265 Adjustments and Tests Power Supply Tester Load Block — Can become warm when used continuously Pin 1 Power Supply Board Pin 1 Pin 1 Connector P101 Stacker Power Cable (Only on cabinet models with the power stacker) Controller Board Connector J101 Figure 21.
  • Page 266 Chapter Power Supply Operational Check 16. Measure the +48 V test point. It should be 46.0 to 49.6 volts. 17. Measure the+8.5 V test point. It should be 8.1 to 9.4 volts. 18. Release the Push Button. 19. If you must measure voltages again, for each minute you held the Push Button down, wait at least two minutes with the Push Button released This allows the Load Block to cool.
  • Page 267 Adjustments and Tests 22. Set the printer’s power switch to O (off). 23. Unplug power supply connector P101 from the 12-pin connector on the power supply tester Load Block. (Figure 21.) 24. Connect power supply cable connector P101 to either the power stacker power cable or connector J101 on the controller board.
  • Page 268 Chapter Power Supply Operational Check...

  • Page 269: Replacement Procedures

    Replacement Procedures Organization Of This Chapter This chapter contains 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 Chapter 6 on page 327. Replacement Procedures WARNING Unplug the printer power cord from the printer or power outlet before...
  • Page 270 Chapter Replacement Procedures Cover Assembly, Top, Pedestal Models ......... page 281 CT Board..................page 282 Dashpot................... page 283 Fan Assembly, Cabinet Exhaust ............. page 284 Fan Assembly, Card Cage .............. page 285 Fan Assembly, Hammer Bank ............page 286 Hammer Spring Assembly .............. page 287 Hammer Spring Assembly, Version 2 ..........

  • Page 271: Belt, Paper Feed Timing

    Belt, Paper Feed Timing Belt, Paper Feed Timing Removal 1. Prepare the printer for maintenance (page 230). 2. Cabinet Models: Remove the paper path (page 303). Pedestal Models: Remove the top cover assembly (page 281). 3. Remove the timing belt cover by squeezing the front and back to release the plastic tabs from the slots in the side plate.

  • Page 272: Belt, Platen Open

    Chapter Replacement Procedures Belt, Platen Open Removal 1. Prepare the printer for maintenance (page 230). 2. Cabinet Models: Remove the paper path (page 303). Pedestal Models: Remove the top cover assembly (page 281). 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 273: Circuit Breaker

    Circuit Breaker Circuit Breaker Removal 1. Prepare the printer for maintenance (page 230). 2. Remove the card cage fan (page 285). 3. Disconnect the four circuit breaker electrical leads. (Cabinet Models: See page 356. Pedestal Models: See page 340.) 4. Press in on the spring clips and remove the circuit breaker from the printer.

  • Page 274: Connector Coupling Shrouds

    Chapter Replacement Procedures Connector Coupling Shrouds Some of the cable connectors in the printer are grouped inside connector coupling shrouds designated P106 and P107. This procedure explains how to remove and install cable assemblies from these coupling shrouds. NOTE: There is also a diagram of the P106 / P107 connector coupling shrouds on the plastic protective barrier over the power supply.
  • Page 275 Connector Coupling Shrouds 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 the PLAT M EHF* PAPR M...

  • Page 276: Control Panel Assembly

    Chapter Replacement Procedures Control Panel Assembly NOTE: The procedure for removing and installing the control panel is the same for cabinet and pedestal model printers. Removal 1. Prepare the printer for maintenance (page 230). 2. Open the printer cover. 3. Disconnect the RJ-11 connector P310 from J2 on the back of the control panel.

  • Page 277: Controller Board

    Controller Board Controller Board Removal IMPORTANT There are two types of controller board, V5 and V6. They are not interchangeable. If you remove a V5 controller board, install a V5 controller board. If you remove a V6 controller board, install a V6 controller board.
  • Page 278 Chapter Replacement Procedures Installation CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle circuit boards. 1. If this is a replacement controller board, install the flash SIMM and security key on the new controller (page 297). 2.

  • Page 279: 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 230). 2. Remove the shuttle frame assembly (page 321). 3. Lift the thick plate of the hammer bank cover assembly at one end, and peel the cover away from hammer bank magnets.

  • Page 280: Cover Assembly, Shuttle

    Chapter Replacement Procedures Cover Assembly, Shuttle Removal 1. Prepare the printer for maintenance (page 230). 2. Remove the ribbon. (Refer to the User’s Manual .) 3. Loosen the shuttle cover screws (page 336, item 2). 4. Grasping the edges of the shuttle cover assembly, tilt the rear edge up and lift the shuttle cover assembly out of the printer.

  • Page 281: Cover Assembly, Top, Pedestal Models

    Cover Assembly, Top, Pedestal Models Cover Assembly, Top, Pedestal Models Removal 1. Prepare the printer for maintenance (page 230). 2. Remove the control panel assembly (page 276). 3. Loosen (do not remove) the two #2 Phillips hold-down screws on the rear of the printer.

  • Page 282: Ct Board

    Chapter Replacement Procedures CT Board Removal 1. Prepare the printer for maintenance (page 230). 2. Cabinet Models: Remove the paper path (page 303). Pedestal Models: Remove the top cover assembly (page 281). CAUTION To prevent electrostatic damage to electronic components, always wear a grounded static wrist strap when you handle circuit boards.

  • Page 283: Dashpot

    Dashpot 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 230). 2.

  • Page 284: Fan Assembly, Cabinet Exhaust

    Chapter Replacement Procedures Fan Assembly, Cabinet Exhaust NOTE: This procedure applies only to cabinet models. Removal 1. Prepare the printer for maintenance (page 230). 2. Open the front and rear cabinet doors and the printer cover. 3. Remove the paper fence/paper tray assembly. (See page 330.) 4.

  • Page 285: Fan Assembly, Card Cage

    Fan Assembly, Card Cage Fan Assembly, Card Cage Removal 1. Prepare the printer for maintenance (page 230). 2. Cabinet Models: Remove the paper path (page 303). Pedestal Models: Remove the top cover assembly (page 281). 3. Disconnect the card cage fan cable connector. (See page 354.) 4.

  • Page 286: Fan Assembly, Hammer Bank

    Chapter Replacement Procedures Fan Assembly, Hammer Bank Removal 1. Prepare the printer for maintenance (page 230). 2. Remove the ribbon. (Refer to the User’s Manual .) 3. Remove the shuttle cover assembly (page 280). 4. Cabinet Models: Remove the paper path (page 303). Pedestal Models: Remove the top cover assembly (page 281).

  • Page 287: Hammer Spring Assembly

    Hammer Spring Assembly, Version 1 Hammer Spring Assembly, Version 1 Removal 1. Prepare the printer for maintenance (page 230). 2. Remove the shuttle frame assembly (page 321). 3. Carefully vacuum the shuttle frame assembly. 4. Remove the hammer bank cover assembly (page 279). CAUTION Hammer springs and hammer tips are fragile.
  • Page 288 Chapter 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 289: Hammer Spring Assembly, Version 2

    Hammer Spring Assembly, Version 2 Hammer Spring Assembly, Version 2 Removal 1. Prepare the printer for maintenance (page 230). 2. Remove the shuttle frame assembly (page 321). 3. Carefully vacuum the shuttle frame assembly. 4. Remove the hammer bank cover assembly (page 279). CAUTION Hammer springs and hammer tips are fragile.
  • Page 290 Chapter Replacement Procedures Installation Using The Short Tip Alignment Tool This procedure is for installing one hammer spring assembly at a time, using short the tip alignment tool that comes with version 2 replacement hammer spring. To install more than one hammer spring assembly at a time, you must use the long tip alignment tool (page 292).
  • Page 291 Hammer Spring Assembly, Version 2 Torque Sequence • 14 inch-pounds (1.58 N Tip Alignment Tool Mounting Screw (3 or 4) Hammer Spring Assembly Figure 29. Installing the Mounting Screws in the Hammer Spring Assembly 5. Install the mounting screws in the hammer spring assembly. There will be three or four mounting screws, depending on the printer model.
  • Page 292 Chapter Replacement Procedures Installation Using The Long Tip Alignment Tool This procedure is for installing more than one version 2 hammer spring assembly at a time, using the long tip alignment tool. To install one hammer spring assembly at a time, use the short tip alignment tool (page 290). NOTE: If the hammer spring assemblies are being removed for cleaning, note their locations on the hammer bank and return them to the same locations when you reinstall them.
  • Page 293 Hammer Spring Assembly, Version 2 CAUTION In the next step, use ONLY the guide tool that comes with the alignment tool to align the version 2 hammer spring assemblies. To avoid damaging threads, never insert any metallic tool into the hammer spring mounting holes in the hammer bank.
  • Page 294 Chapter Replacement Procedures 6. Continue to apply a slight downward pressure on the tool and install the mounting screws in the hammer spring assemblies. Depending on the printer model, there will be three or four mounting screws per assembly. Torque the inner screw(s) to 14 in-lbs (1.58 N•m), then torque the outer screws to 14 in-lbs (1.58 N•m).

  • Page 295: Integrated Print Management Sensor

    Integrated Print Management Sensor Integrated Print Management Sensor Removal 1. Prepare the printer for maintenance (page 230). 2. Cabinet Models: Remove the paper path (page 303). Pedestal Models: Remove the top cover assembly (page 281). 3. Remove the screw securing the Integrated Print Management sensor to the base casting.

  • Page 296: Magnetic Pickup (Mpu) Assembly

    Chapter Replacement Procedures Magnetic Pickup (MPU) Assembly Removal 1. Prepare the printer for maintenance (page 230). 2. Remove the ribbon. (Refer to the User’s Manual .) 3. Remove the shuttle cover (page 280). 4. Disconnect the magnetic pickup (MPU) cable connector (page 346, item 5).

  • Page 297: Memory And Security Key

    The printer will not operate correctly without a security key. If you need to replace the security key, contact Printronix for a replacement. Installation 1. Put on a static wrist strap and ground the lead to an unpainted part of the printer frame.
  • Page 298 Chapter Replacement Procedures b. V5 controller only: Position the SDRAM DIMM in socket J14 with the component side upward. Press the DIMM gently into the socket until the edge connectors are seated, then press the DIMM downward until the side latches lock it in place. (NOTE: SDRAM is soldered on the V6 controller board and cannot be removed.) (See Figure 33 below.) 4.

  • Page 299: Nic (Network Interface Card) Assembly

    NIC (Network Interface Card) Assembly NIC (Network Interface Card) Assembly NOTE: This procedure only applies to printer with the V5 controller board. The ethernet interface is built onto the V6 controller board. Removal 1. Make a configuration printout of all saved configurations. (Refer to the User’s Manual.) 2.
  • Page 300 Chapter Replacement Procedures Testing NIC Operation You can test the NIC by starting a telnet session (telnet IP address) and sending start fox prn<Return> stop prn<Return> This command sequence sends consecutively numbered lines of text from the interface to the printer. The “fox” test is resident in the NIC and verifies that it can receive commands and can transfer data successfully to the printer.

  • Page 301: Paper Feed Motor

    Paper Feed Motor Paper Feed Motor Removal 1. Prepare the printer for maintenance (page 230). 2. Cabinet Models: Remove the paper path (page 303). Pedestal Models: Remove the top cover assembly (page 281). 3. Remove the timing belt cover by squeezing the front and back to release the plastic tabs from the slots in the side plate (page 336, item 7).

  • Page 302: Paper Ironer

    Chapter 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 230). 2. Remove the shuttle frame assembly (page 321). 3.

  • Page 303: Paper Path

    Paper Path Paper Path NOTE: This procedure applies only to cabinet models. Removal 1. Prepare the printer for maintenance (page 230). 2. Loosen—do not remove—the three screws that secure the paper path to the card cage. (See Figure 34.) 3. Slide the paper path to the left and lift it off the card cage. Installation 1.

  • Page 304: Platen

    Chapter Replacement Procedures Platen Removal 1. Prepare the printer for maintenance (page 230). 2. Remove the shuttle frame assembly (page 321). 3. Remove the paper ironer (page 302). 4. Remove the three 1/4 inch screws securing the paper ironer bracket assembly and remove the assembly.
  • Page 305 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 306 Chapter Replacement Procedures Platen Adjust Bracket Platen Washers Wear Saddle Mechanism Base Platen Seat Figure 36. 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 51 on page 354, items 7, 8, and 9.) 10.
  • Page 307 Platen 14. Install the paper ironer bracket. (See Figure 35.) a. With the flat part of the bracket facing the front of the printer, place the two hooks of the upper part of the paper ironer over the platen shafts. The left hook of the paper ironer bracket goes between the left platen adjustment bracket and the platen.

  • Page 308: Platen Open Motor

    Chapter Replacement Procedures Platen Open Motor Removal 1. Prepare the printer for maintenance (page 230). 2. Cabinet Models: Remove the paper path (page 303). Pedestal Models: Remove the top cover assembly (page 281). 3. Cabinet Models: Remove the card cage fan (page 285). 4.
  • Page 309 Platen Open Motor Installation 1. Position the platen open motor assembly with the wires toward the rear (page 354, 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, 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 310: Platen Stop Assembly (And Forms Thickness Lever)

    Chapter Replacement Procedures Platen Stop Assembly NOTE: The forms thickness lever is part of the platen stop assembly. Removal 1. Prepare the printer for maintenance (page 230). 2. Loosen—do not remove—the 7/64 inch clamp screw and pull the platen stop assembly off the platen shaft. (See page 350, items 12 through 15.) Installation 1.

  • Page 311: Power Supply Board

    Power Supply Board 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 on the board during removal or installation. Lift and handle the board only by the loops provided for this purpose.

  • Page 312: Resistors, Terminating, V5 Controller Board

    Chapter Replacement Procedures Resistors, Terminating, V5 Controller Board 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 37, page 313.) 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...
  • Page 313 Resistors, Terminating, V5 Controller Board V5 Controller Board Default: 1K Ohm Alt 1: 330 Ohm Alt 2: None Default: 470 Ohm Alt 1: 220 Ohm Alt 2: 1K Ohm Figure 37. Terminating Resistors, V5 Controller Board, Removal/Installation...

  • Page 314: Resistors, Terminating, V6 Controller Board

    Chapter Replacement Procedures Resistors, Terminating, V6 Controller Board For parallel interface configurations, the printer is equipped with 470 Ohm and and 1K Ohm terminating resistors on the controller board. These are suitable for most applications. (See Figure 38, page 315.) If the standard terminating resistor pack is not compatible with the particular interface driver requirements of the host computer, other RP1 and RP2 values may be required.
  • Page 315 Resistors, Terminating, V6 Controller Board V6 Controller Board RP1 and RP2 Default: 470/1K Ohm Alt: 220/330 Ohm Figure 38. Terminating Resistors, V6 Controller Board, Removal/Installation...

  • Page 316: Ribbon Drive Motor

    Chapter Replacement Procedures Ribbon Drive Motor Removal 1. Prepare the printer for maintenance (page 230). 2. Remove the ribbon. (Refer to the User’s Manual .) 3. Remove the screws and washers that secure the ribbon drive motor to the base casting at the lower right and upper left corners of the motor. (See page 354, items 13 and 14.) 4.

  • Page 317: Ribbon Guide Assembly (L/R)

    Ribbon Guide Assembly (L/R) Ribbon Guide Assembly (L/R) NOTE: The right ribbon guide is shown exploded in Figure 51 on page 354. The removal procedure is the same for both ribbon guides. Removal 1. Prepare the printer for maintenance (page 230). 2.

  • Page 318: Shaft, Splined

    Chapter Replacement Procedures Shaft, Splined IMPORTANT In order to preserve correct alignment of the side plates, the barrier panel must remain installed and fastened during this procedure. Removal 1. Prepare the printer for maintenance (page 230). 2. Remove the paper supports from the splined shaft and support shaft. (See page 348, item 4.) 3.
  • Page 319 Shaft, Splined Tractor NOTE: Align the marks on both tractors before inserting the splined shaft. Tolerance Alignment Marks Ring Splined Shaft Figure 39. Splined Shaft and Tractor Installation...

  • Page 320: Shaft, Support

    Chapter Replacement Procedures Shaft, Support IMPORTANT In order to preserve correct alignment of the side plates, make sure the barrier panel remains installed and fastened during this procedure. Removal 1. Prepare the printer for maintenance (page 230). 2. Unlock the tractors and slide them to the far right. 3.

  • Page 321: Shuttle Frame Assembly

    Shuttle Frame Assembly Shuttle Frame Assembly Removal 1. Prepare the printer for maintenance (page 230). 2. Remove the ribbon. (Refer to the User’s Manual .) 3. Remove the shuttle cover assembly (page 280). 4. Disconnect the MPU cable connector P03 and shuttle motor cable connector P02 (page 346, items 5 and 6).
  • Page 322 Chapter Replacement Procedures Installation 1. Install the hammer bank / ribbon mask cover assembly if it was removed (page 279). CAUTION To prevent electrostatic damage to electronic components, wear a properly grounded static wrist strap when you handle the shuttle frame assembly.

  • Page 323: 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 230). 2. Remove the ribbon. (Refer to the User’s Manual .) 3.

  • Page 324: Switch Assembly, Paper Detector

    Chapter Replacement Procedures Switch Assembly, Paper Detector Removal 1. Prepare the printer for maintenance (page 230). 2. Cabinet Models: Remove the paper path (page 303). Pedestal Models: Remove the top cover assembly (page 281). 3. Remove the two 1/4 inch screws securing the paper detector switch assembly.

  • Page 325: Switch Assembly, Platen Interlock

    Switch Assembly, Platen Interlock Switch Assembly, Platen Interlock Removal 1. Prepare the printer for maintenance (page 230). 2. Cabinet Models: Remove the paper path (page 303). Pedestal Models: Remove the top cover assembly (page 281). 3. Fully close the forms thickness lever (position ‘A’). 4.

  • Page 326: Tractor (L/R)

    Chapter Replacement Procedures Tractor (L/R) Removal 1. Prepare the printer for maintenance (page 230). 2. Remove the support shaft (page 320). 3. Remove the splined shaft (page 318). Installation 1. Using the replacement tractors, install the support shaft (page 320). 2.

  • Page 327: Illustrated Parts Breakdown

    Illustrated Parts Breakdown Organization Of This Chapter This chapter contains drawings of all electrical and mechanical assemblies in the printer. The table following each illustration lists the illustrated parts and their part numbers. Items marked “Ref” in the illustrations refer to parts that are not spared or are part of another assembly.
  • Page 328 Chapter Organization Of This Chapter Figure 40. Top Cover, Doors, and Casters...
  • Page 329 Illustrations of Printer Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 177505-901 177505-901 Top Cover Assembly, Stealth Black Includes items 2 and 3 179781-901 179781-901 Top Cover Assembly, Lt Gray Includes items 2 and 3 131803-901 131803-901...
  • Page 330 Chapter Organization Of This Chapter Figure 41. Paper Fence, Paper Chains, and Front Access Stacker...
  • Page 331 Illustrations of Printer Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 158179-901 158179-901 Passive Stacker Assembly Not used on printers with the power stacker; includes items 6, 7, and 8 153503-001 153503-001 Grommet Kit, Cabinet...
  • Page 332 Chapter Organization Of This Chapter Figure 42. Control Panel and Cabinet Details...
  • Page 333 Illustrations of Printer Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 177530-901 250483-001 Control Panel Assembly, Cab 152440-901 152440-901 Cable Assembly, Control Panel 107961-905 107961-905 Dashpot Kit Includes ball studs, spring clips, and mounting hardware Screw, w/Lock Washer (3)
  • Page 334 Chapter Organization Of This Chapter Figure 43. Pedestal Details...
  • Page 335 Illustrations of Printer Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 177530-902 250483-002 Control Panel Assembly, Ped Screw, Captive (2) 179163-001 179163-001 Field Kit, Lid Assembly, Ped, Blk Both kits also contain items 179845-001 179845-001 Field Kit, Lid Assembly, Ped, Gray...
  • Page 336 Chapter Organization Of This Chapter Figure 44. Inside Covers, Cabinet Models...
  • Page 337 Illustrations of Printer Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 179128-901 179128-901 Shuttle Cover Air Shroud Assembly 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 175188-901...
  • Page 338 Chapter Organization Of This Chapter See Figure 46, page 340. Figure 45. Inside Covers and Card Cage, Pedestal Models...
  • Page 339 Illustrations of Printer Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 179128-901 179128-901 Shuttle Cover Air Shroud Assembly 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 179276-001...
  • Page 340 Chapter Organization Of This Chapter From Figure 45, page 338. Rotated 180 degrees. To IEC 320 AC Power Input (Connector To Connector P1 J301, White (White Wire) Wire) To IEC 320 AC Power Input (Connector J301, Black Wire) To Connector P1 (Black Wire) Figure 46.
  • Page 341 Illustrations of Printer Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) Nut, 6-32 (1) Upper right fan corner only 150261-901 150261-901 Card Cage Fan Assembly Air flow is into card cage Fan Guard Screw, w/Lock Washer (4) 6-32x1.75...
  • Page 342 Chapter Organization Of This Chapter Two places: Exploded to show assembly. Do not remove the clamps and screws. To J02 (Shuttle To J03 Motor) (MPU) To the Terminator Board on the Shuttle Frame Figure 47. Print Mechanism and Circuit Boards...
  • Page 343 Illustrations of Printer Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 178311-901 178311-901 Ribbon Mask/HB Cover Assy P7X05, P7X02H 178310-901 178310-901 Ribbon Mask/HB Cover Assy P7X10, P7X03H 178309-901 178309-901 Ribbon Mask/HB Cover Assy P7X15, P7X06H 251665-901...
  • Page 344 Chapter Organization Of This Chapter Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 179074-901 250297-901 Power Supply, PFC, 5/10 P7X05, -10,- 02H, -03H 179074-991 250297-991 Power Supply, PFC, 5/10, Adv Exch P7X05, -10,- 02H, -03H 179075-901 250251-901...
  • Page 345 Illustrations of Printer Components (Parts lists continue on the next page.)
  • Page 346 Chapter Organization Of This Chapter 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. Figure 48.
  • Page 347 Illustrations of Printer Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 150281-901 150281-901 MPU Assembly Bracket, MPU Part of item 1 Screw, Socket Cap 6-32x.38 153537-901 153537-901 Spring, Hammer Bank MPU Cable Connector (P03) 176507-001 176507-001...
  • Page 348 Chapter Organization Of This Chapter IMPORTANT: In order to preserve correct alignment of the side plates, the barrier panel must remain installed and fastened if the splined or support shafts are removed or replaced. The barrier panel is shown in Figure 44 and Figure 45.
  • Page 349 Illustrations of Printer Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) Screw, Socket Cap, 6-32x.312 Trilob (Self- Tapping) (2) 173130-001 173130-001 Plate, Tractor Shaft, Left 151944-001 151944-001 Bearing, Ball, Sealed 178990-901 178990-901 Paper Support (2)
  • Page 350 Chapter Organization Of This Chapter NOTE: Black tape faces paper motion detector. NOTE: On P7000HD, P7X06H, P7X08H, P7X15, and P7220 models, install item 27 in front of item 3; that is, on the shuttle side. All others do not use item 27. Do NOT install Items 3 and 27 on ZTP printers.
  • Page 351 Illustrations of Printer Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) Setscrew (2) Part of item 25 Bracket, Platen (2) Part of item 25 150957-901 150957-901 Ironer Assembly, Reverse Paper Feed All except ZTP printers Screw, Thread-forming (3) 6-32x.25...
  • Page 352 Chapter Organization Of This Chapter Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 176630-901 176630-901 Paper Ironer, Auxiliary On P7X00HD, P7X06H, P7X08H, P7X15, and P7220 models install item 27 in front of item 3 (i.e., on the shuttle side).
  • Page 353 Illustrations of Printer Components (Parts lists continue on the next page.)
  • Page 354 Chapter Organization Of This Chapter Install screws here. Top View Route cable under Hammer Bank Fan base casting See detail above Figure 51. Motors, Fans, and Paper Detector Switch...
  • Page 355 Illustrations of Printer Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 150261-901 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 152415-901...
  • Page 356 Chapter Organization Of This Chapter 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) To Connector P1 (White Wire) (Card cage fan and power supply board Black Wire removed for clarity.)
  • Page 357 Illustrations of Printer Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 142013-901 142013-901 Circuit Breaker IEC 320 AC Power Connector Connector J301 Part of Field Kit, AC Assy 153502-001 Chassis Ground Stud Part of Field Kit, AC Assy 153502-001...
  • Page 358 Chapter Organization Of This Chapter IMPORTANT: Leave this slot empty if the printer has a power stacker with a V5 controller board. Coax/Twinax is not available on a V6 controller board with a power stacker. Figure 53. CT Board...
  • Page 359 Illustrations of Printer Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 177929-901 179913-901 Spare PCBA, PCI-CT, V3 177929-991 179913-991 Spare PCBA, PCI-CT, V3, Adv Exch 176257-001 176257-001 Plate, PCI Cover Card Cage Screw V5 Controller Board...
  • Page 360 Chapter Organization Of This Chapter NOTE: Twinax is not available on a V6 controller board with stacker. Figure 54. Twinax Extension Cable for Printers with PSA3 V5 Controller, Twinax I/O, and Power Stacker...
  • Page 361 Illustrations of Printer Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 140752-002 140752-002 Twinax Auto-Termination Cable (“Smart-T”) 204806-901 204806-901 Cable, Extension, Smart-T Required in printers with the power stacker so the twinax auto-termination cable will clear the stacker elevator.
  • Page 362 Chapter Organization Of This Chapter V5 Controller Board IMPORTANT: Leave this slot empty if the printer has a power stacker with a V5 Controller Board. V6 Controller Board Figure 55. The NIC (Network Interface Card) on the V5 and V6 Controller Board...
  • Page 363 Illustrations of Printer Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 250678-901 250678-901 Spare PCBA, PCI-Network These are used on the V5 250678-991 250678-991 Spare PCBA, PCI-Network, Adv Exch controller board.
  • Page 364 Chapter Organization Of This Chapter See detail at right Pin 10 Figure 56. RS-422 Interface...
  • Page 365 Illustrations of Printer Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 176287-901 179134-901 PCBA, RS422 ADAPTER, DB9/DB25 Part of Field Kit 176425-001 102922-001 102922-001 Screwlock Kit, Female (2) 176075-901 176075-901 Cable Assembly, RS-422, I/O Part of Field Kit...
  • Page 366 Chapter Organization Of This Chapter Cabinet Model Pedestal Model Figure 57. Dipole Antenna and Cable Used With the Optional Wireless NIC...
  • Page 367 Illustrations of Printer Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 179228-001 179228-001 Field Kit, Antenna, Fixed Point, Dipole 204479-001 204479-001 Cable, MMCX-BNC, 10 inch, S24...
  • Page 368 Chapter Organization Of This Chapter...

  • Page 369: Principles Of Operation

    Principles Of Operation Line Matrix Printing A line matrix printer creates characters and graphics by printing patterns of ink dots an entire line at a time. Every text character is stored in printer memory as a pattern of dots on a logical grid called the dot matrix.
  • Page 370 Chapter Line Matrix Printing When the shuttle reaches the end of a horizontal sweep, it reverses direction, the paper advances upward one dot row, and the hammer springs print the next row of dots as the shuttle moves in the opposite direction. When a line of text characters is completed, hammer action stops and the paper advances to the first dot row of the next print line.
  • Page 371 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 372: Printing Rates

    Chapter Printing Rates Printing Rates A line matrix printer prints entire lines sequentially, and measures the printing speed of text in lines per minute (lpm). This is faster than a moving-printhead printer, which prints single characters sequentially and measures its speed in characters per minute (cpm).

  • Page 373: Shuttle Frame Assembly

    Hammer Bank 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 61.) Hammer Bank Assembly Counterweight Connecting Rod Guide Shaft Shuttle Frame Assembly Shuttle Drive Motor...

  • Page 374: Shuttle Drive Motor

    Chapter Shuttle Frame Assembly Shuttle Drive Motor The shuttle drive motor is built into the shuttle assembly casting and spins a crankshaft, to which are attached the big ends of two connecting rods. (Figure 61.) The small end of one connecting rod attaches to the hammer bank;...

  • Page 375: Paper Transport System

    Shuttle Drive Motor While the hammer is in flight the coils are de-energized and their magnetic field collapses, restoring the magnetic attraction of the permanent magnet in the hammer bank. After striking the ribbon and paper, the hammer rebounds and is recaptured by the permanent magnet. When the shuttle reaches the end of a sweep, it reverses direction, the paper is micro-stepped upwards one dot row, and the hammer springs print the next row of dots as the shuttle sweeps in the opposite direction.

  • Page 376: Ribbon Transport System

    Chapter Ribbon Transport System Paper is positioned horizontally using the tractors. Each tractor is locked in position with a friction lock and engages the paper perforations with six sprocket pins. The vertical adjustment knob is used to position paper vertically by hand. Ribbon Transport System Ribbon Hub Left Ribbon Guide...

  • Page 377: Integrated Print Management System

    The bar code contains the following encoded information: • Identifies the ribbon as Printronix (or authorized OEM) • The thickness and length of the ribbon fabric to select the correct motor stepper tables •...

  • Page 378: Operation

    The default settings for the Integrated Print Management System are enabled at the factory, and the system functions without intervention as long as genuine Printronix ribbons are used and the Integrated Print Management options have been set. The user can change settings, as discussed later in this section.
  • Page 379 Operation For reference, the nominal starting density of a new black text ribbon is approximately 1.2, with a yield down to 0.5 density of approximately 16 million HS characters. Incrementing the Darker setting will raise the density end point, which decreases the ribbon yield. Each Darker increment will decrease the yield by a percentage from the expected 16 million.

  • Page 380: The Ribbon Log

    The Ribbon Log The printer identifies each ribbon by maker (Printronix or authorized OEM), type, and an identification code unique to that specific ribbon. The Integrated Print Management System recognizes the currently installed ribbon and previously used (but not depleted) ribbons, and resumes tracking the life of the ribbon from the value it had when it was removed from the printer.

  • Page 381: Logical Control Of The Printer

    The Ribbon Log OFFLINE DIAGNOSTICS DIAGNOSTICS Printer Tests Shift Recycle All Es E’s + TOF All H’s All Underlines All Black Shuttle Slow Shuttle Fast Ribbon Log Shuttle Only Installed Ribbon = PTX, Ribbon Name, 55%, Normal Phase Printer Ribbon History = PTX, Ribbon Name = 45 Paperout Adj.
  • Page 382 Chapter Logical Control Of The Printer Power Supply Controller Board Print Mechanism Control Panel Figure 65. Functional Elements of the Printer...

  • Page 383: Control Panel

    The Ribbon Log 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 384: Controller Board

    Chapter Controller Board Controller Board The heart of a P7000 printer is the “Hurricane” V5 or V6 controller board, which controls all printer functions and supports all P7000 models. The controller board receives and processes all data from the host computer, builds the printable images, controls all motors, and drives the hammer springs.
  • Page 385 The Ribbon Log Control Bus JTAP Data Bus System Reset SDRAM Motorola MPC8245 PCI Bus Buffer microprocessor FLASH Buffer Core Volt Regulator Non-Vol Port Control PCI Bus Logic RS-232 RS-232/422 Diagnostic Diagnostic Host I/O Port Port V8 ASIC Drivers IEEE-1284 (Parallel) Control Control...

  • Page 386: Data Controller

    Chapter Controller Board Data Controller The data controller (DC) consists of the following elements: • MPC8245 microprocessor • A 72-pin flash SIMM socket that holds up to 32MB of program memory • A 32MB SDRAM DIMM for data memory • 8K x 8 Non-Volatile Battery-Backed Static RAM (NVRAM) for storage of configuration and system statistical data •...
  • Page 387 Data Controller V8 ASIC The V8 is a multi-function custom gate array ASIC containing all the logic for the DC that is not contained in the MPC8245 processor. The V8 provides the following services: • Memory Access Controller • SDRAM Controller •...

  • Page 388: Engine Controller

    Chapter Controller Board “Cajun” Bus Interface The “Cajun” bus connects the DC and the EC. The EC uses this bus to access DC resources, including the semaphore registers. (The semaphore registers are the primary communications path between the EC and DC.) Ports The V8 ASIC controls the following I/O functions: •...
  • Page 389 Engine Controller 80C167 Microcontroller The Siemens SAB 80C167 is a high-integration microcontroller with many features that suit it extremely well to real-time control applications. This controller and the MECA ASIC provide the functionality of three separate processors used in earlier controller board architectures. In this manual, the 80C167 is referred to as the EC.

  • Page 390: Power Supply Board

    Chapter Power Supply Board The paper feed, ribbon drive, and shuttle motors are driven in control loops containing power MOSFETs, voltage and current sensors, the MECA ASIC, and the EC processor. The platen motor is driven by a stepping motor controller IC and the EC processor.

  • Page 391: 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 392 Chapter Graphics...

  • Page 393: A Wire Data

    Wire Data NOTE: Abbreviations, acronyms, and signal mnemonics are defined in Appendix B (page 447). Interconnection Diagram ..............page 395 Cable Routing, Cabinet Model ............page 396 Cable Routing, Pedestal Model............page 397 Main Wire Harness Test Tables ............page 398 Circuit Board Pinouts V5 Controller Board ..............
  • Page 394 Appendix A Ribbon Motor, Extension ............page 435 Shuttle Motor Drive ..............page 436 Power Stacker Cables Frame Cable, Power Stacker ..........page 437 Logic Cable, Power Stacker ..........page 438 Power Cable, Power Stacker ..........page 439 Rail Cable, Power Stacker ..........page 440 Elevator I/O Cable, Power Stacker ........

  • Page 395: Interconnection Diagram

    Interconnection Diagram...

  • Page 396: Cable Routing, Cabinet Model

    Appendix A Cable Routing, Cabinet Model NOTE: P7220 model uses a unique power supply. See page 416. Cabinet Exhaust Fan...

  • Page 397: Cable Routing, Pedestal Model

    Cable Routing, Pedestal Model...

  • Page 398: Main Wire Harness Test Tables

    Appendix A 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 when plugged into the 19 17 15 13 11 9 7 5 3 1 controller board.

  • Page 399: V5 Controller Board

    V5 Controller Board CAUTION: Do not try to remove or replace the NVRAM. The NVRAM contains a lithium battery that can explode if replaced incorrectly. NVRAM is replaced only at the factory. Power Supply J101 Motor Sensor Left N TEMP HI J106 N STDBY VCC1...
  • Page 400 Appendix A V5 Controller Board (continued) 0 Ohm 0.125W EC BOOT STRAP Hammer Bank Logic EC Diagnostics J108 J120 0.1W +10V SW C167 DB TXD HMR DAT COIL C167 DB RXD µ 50 MHz HMR DAT RET HMR CLK HMR CLK RET PPR TRIG CMD DAT PPR MOVING...
  • Page 401 V5 Controller Board (continued) Integrated Print Management System Sensor J122 BC DATA LED CTRL 2-Pin Jumpers VCC1 External Power 4.7 K EXT 5V 0.1 W J102 µ 1000 PF 4.7 K 0.1 W µ 1000 PF 500 Ohm LOGIC HIGH CHASSIS GND...
  • Page 402 Appendix A V5 Controller Board (continued) Host RS232 Diagnostic Port J201 DB TXD DB RXD 470PF On-Line Verifier Shuttle Drive J109 J116 EXT 5V SHUT A V TXC C SHUT B V RXD C SHUT C Control Panel J110 N FP DATA AVAIL Paper Stacker FP CLK J117...
  • Page 403 V5 Controller Board (continued) Host RS422 2.7K 0.1W Paper Feed Motor J103 SOFT ID DIFF TXD+ DIFF TXD- PF 4 PF 3 PF 2 DIFF RXD+ PF 1 1 2 3 DIFF RXD- Software Security Key VCC +48V Used Phase Driver Port J115 UD 1 UD 2...
  • Page 404 Appendix A V5 Controller Board (continued) PCI Connection VCC1 VCC1 NIRQ1 NINTA NINTB NINTC NINTB NINTC NINTD NINTD NPRSNT2 NPRSNT1 3.3V NPRSNT3 NPRSNT2 3.3VAUX PCI_NRST NRST CLK1 3.3V NGNT NGNT1 NREQ1 NREQ 3.3V NPME AD31 AD30 AD31 AD30 AD29 AD29 3.3V AD28 AD28...
  • Page 405 V5 Controller Board (continued) PCI Connection VCC1 VCC1 NIRQ2 NINTA NINTB NINTC NINTB NINTC NINTD NINTD NPRSNT0 NPRSNT1 3.3V NPRSNT1 NPRSNT2 3.3VAUX PCI_NRST NRST CLK2 3.3V NGNT NGNT2 NREQ2 NREQ 3.3V NPME AD31 AD30 AD31 AD30 AD29 AD29 3.3V AD28 AD28 AD26 AD27...
  • Page 406 Appendix A V5 Controller Board (continued) Centronics Connector J112 N STROBE N ACK BUSY PAPER EMPTY SELECT N INIT N AUTOFEED N FAULT VCC1 4.7K 0.1W NDPSEL EXT 5V N SELECT IN HOST LOGIC H NDPEN 0.1W CHASSIS GND...

  • Page 407: V6 Controller Board

    V6 Controller Board CAUTION: Do not try to remove or replace the NVRAM. The NVRAM contains a lithium battery that can explode if replaced incorrectly. NVRAM is replaced only at the factory. Power Supply J101 Motor Sensor Left N TEMP HI J106 N STDBY VCC1...
  • Page 408 Appendix A V6 Controller Board (continued) 0 Ohm 0.125W EC BOOT STRAP Hammer Bank Logic EC Diagnostics J108 J120 0.1W +10V SW C167 DB TXD HMR DAT COIL C167 DB RXD µ 50 MHz HMR DAT RET HMR CLK C167 NCS1 HMR CLK RET PPR TRIG CMD DAT...
  • Page 409 V6 Controller Board (continued) Integrated Print Management System Sensor J122 BC DATA COVER OPEN 2-Pin Jumpers External Power 4.7 K EXT 5V 0.1 W J102 µ 1000 PF 4.7 K 0.1 W µ 1000 PF 500 Ohm LOGIC HIGH CHASSIS GND...
  • Page 410 Appendix A V6 Controller Board (continued) RJ-45 LAN (Ethernet) Host RS232 J201 Diagnostic Port SHL1 DB TXD SHL2 DB RXD Shuttle Drive J116 SHUT A SHUT B SHUT C Control Panel J110 N FP DATA AVAIL Paper Stacker J117 FP CLK STK R NW 470 PF N FP LED WR...
  • Page 411 V6 Controller Board (continued) Host RS422 2.2K 0.062W Paper Feed Motor J103 SOFT ID DIFF TXD+ DIFF TXD- PF 4 PF 3 PF 2 DIFF RXD+ PF 1 1 2 3 DIFF RXD- Software Security Key Phase Driver Port J115 UD 1 UD 2 PH REF...
  • Page 412 Appendix A V6 Controller Board (continued) PCI Connection VCC1 VCC1 NIRQ1 NINTA NINTB NINTC NINTB NINTC NINTD NINTD NPRSNT2 NPRSNT1 3.3V NPRSNT3 NPRSNT2 3.3VAUX PCI_NRST NRST CLK1 3.3V NGNT NGNT1 NREQ1 NREQ 3.3V NPME AD31 AD30 AD31 AD30 AD29 AD29 3.3V AD28 AD28...
  • Page 413 V6 Controller Board (continued) Centronics Connector J112 N STROBE N ACK BUSY PAPER EMPTY SELECT N INIT N AUTOFEED N FAULT 4.7K 0.1W NDPSEL EXT 5V N SELECT IN HOST LOGIC H NDPEN 0.1W CHASSIS GND...

  • Page 414: Power Supply: P7X05, P7X10, P7X02H, And P7X03H

    Appendix A Power Supply: P7X05, P7X10, P7X02H, and P7X03H Cable Assembly AC In P101 Power Supply AC Common N TEMP HI White Chassis Ground N STDBY Orange LOAD +5V RTN Black = FAST-ON TERMINAL +5V RTN Black +48V / +8.5V RTN Brown LOAD = RING TERMINAL...

  • Page 415: Power Supply: P7X06H And P7X15

    Power Supply: P7X06H and P7X15 (Line Filter Area) AC Input AC COMMON CHASSIS GND P101 NACFAIL (Not AC Fail) Cable Assembly NSTBY (Not Standby) AC In +5 Volts Power Supply +5 Volts +5 Return / Logic GND LOAD +5 Return / Logic GND +48 / +8.5 Return = FAST-ON TERMINAL +48 / +8.5 Return...

  • Page 416: Power Supply: P7000Hd, P7X08H, And P7220

    Appendix A Power Supply: P7000HD, P7X08H, and P7220 (Phase Driver Control) UD 1 UD 2 +2.5V reference (Phase Driver Power) UD 3 UD 4 DIODE 1 DIODE 2 DIODE 3 DIODE 4 N COILTEST LDFB OPTO RET CABLE DET HD SENSE Chassis GND LDFB BUF Controller GND...

  • Page 417: Ct Board

    CT Board Twinax Connection TWINAX PHASE A TWINAX PHASE B Coax Connection COAX DATA 9400 pF, 1500 V Built-in COAX SHIELD capacitor coax shield to frame ground µ 500V...

  • Page 418: Surestak Power Stacker Pcba

    Appendix A SureStak Power Stacker PCBA...

  • Page 419: Cable Assemblies Centronics I/O

    Cable Assembly, Centronics I/O (P/N 152439-901) IMPORTANT To comply with Electromagnetic Compatibility (EMC) regulatory requirements, all interface cables must be of a minimal quality level, be the correct length, and be properly installed. RS-232 port and parallel port cables must meet the following specifications: 1) The cable design must be double shielded with a copper braid over an aluminum mylar foil...

  • Page 420: Dataproducts® Adapter

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

  • Page 421: 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 422: Cable Extension, Smart-T

    Appendix A Cable Extension, Smart-T (P/N 204806-901) Pin 1 Pin 1...

  • Page 423: 2-Pin Jumper, 0.1 Ctr

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

  • Page 424: Ac In, Power Supply

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

  • Page 425: Ac Power Input

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

  • Page 426: Ps I/O

    Appendix A Cable Assy, PS I/O (P/N 176601-901)

  • Page 427: Card Cage Fan

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

  • Page 428: Control Panel

    Appendix A Cable Assembly, Control Panel (P/N 152440-901) PIN 8 (Brown) PIN 1 (Gray) PIN 8 (Brown) PIN 1 (Gray)

  • Page 429: Exhaust Fan

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

  • Page 430: Hammer Bank Logic

    Appendix A Cable Assembly, Hammer Bank Logic (P/N 152421-901) To Shuttle To Controller Board...

  • Page 431: Hammer Bank Power

    Cable Assy, Hammer Bank Power (P/N 164805-901) IMPORTANT: Use this cable on any P7000 printer. P7220 also uses P/N 173215-901, shown on the next page. To Controller Board To Shuttle Wire Table P105...

  • Page 432: Hammer Bank Power

    Appendix A Cable Assy, Dual Hammer Bank Power (P/N 173215-901) IMPORTANT: Use this cable on the P7220 printer. To Power Supply To Shuttle Wire Table...

  • Page 433: Mpu

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

  • Page 434: Ribbon Guide

    Appendix A Cable Assembly, Ribbon Guide, P7000 Left: 178992-001 Right: 178992-002 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 435: Ribbon Motor, Extension

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

  • Page 436: Shuttle Motor Drive

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

  • Page 437: Frame Cable, Power Stacker

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

  • Page 438: Logic Cable, Power Stacker

    Appendix A Logic Cable, Power Stacker (P/N 176029-001)

  • Page 439: Power Cable, Power Stacker

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

  • Page 440: Rail Cable, Power Stacker

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

  • Page 441: Elevator I/O Cable, Power Stacker

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

  • Page 442: Fan Assembly, Hammer Bank

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

  • Page 443: Magnetic Pickup (Mpu) Assembly

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

  • Page 444: Switch Assembly, Paper Detector

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

  • Page 445: Switch Assembly, Platen Interlock

    Switch Assembly, Platen Interlock (P/N 152417-901)
  • Page 446 Appendix A...

  • Page 447: B Abbreviations

    Abbreviations NOTE: Signal abbreviations with first letter “N” are negative true. Abbreviation 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 Amplitude;...
  • Page 448 Appendix B Cathode Card Cage Card Cage Fan CHNG Change Circuit Clock Cover Open COLL Collector COMM Communication CONTLR Controller Command Connector, Connection Characters Per Inch CPLD Complex Programmable Logic Device Carriage Return Coaxial/Twinaxial (“Coax/Twinax”) Control Clear to Send Control Unit Current D0, D1, etc.
  • Page 449 Data Set Ready Data Terminal Ready Engine Controller (a functional unit of the controller board) EEPROM Electrically Erasable/Programmable Read-Only Memory Exhaust Fan Elevator motor (power stacker) EMEA Europe, Mideast, and Africa ElectroMagnetic Interference EMIT Emitter EPROM Electrically Programmable Read-Only Memory Error Electrostatic Discharge Exhaust, Extra...
  • Page 450 Appendix B Hammer Driver, High Definition HDIC Hammer Driver Integrated Circuit HDPH Hammer Driver Phase Hammer Bank Logic, Signals, and Power Hardware Integrated Circuit Identification Intelligent Graphics Printing INST Instruction Interrupt Input/Output Illustrated Parts Breakdown Inches Per Minute Interrupt Request Jack connector JEDEC Joint Electron Device Engineering Council.
  • Page 451 MOSFET Metal Oxide Semiconductor Field Effect Transistor Motor Magnetic Pick-Up (Unit) millisecond (10 second) Motor and Sensors, Left Motor and Sensors, Right Negative True; Newton (metric unit of force) Network Interface Card (ethernet interface) Not Connected Not Connected Near Letter Quality Number NOVRAM Nonvolatile Random Access Memory...
  • Page 452 Pin or Plug Part Number Paper Out Paper Out Detector Switch Paper PROM Programmable Read-Only Memory Power Supply Power Supply + 5 Volt PSA3 Printronix System Architecture, Third Generation Pointer, Printer Pulse Width Modulation Power Right Ribbon Read Ready Return Ribbon...
  • Page 453 RoHS Restriction of Hazardous Substances: In the illustrated parts sections part numbers listed in the column labeled Europe, Mideast, and Africa (EMEA) conform to requirements specified in DIRECTIVE 2002/95/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 27 January 2003 on the restriction of the use of certain hazardous substances in electrical and electronic equipment.
  • Page 454 Appendix B SYNC Synchronize Task Control Block TEMP Temperature; Temporary Top Of Form (first print line) Test Point Transistor-Transistor Logic Transmit Data UART Universal Asynchronous Receiver/Transmitter UDPH Upper Drive Phase UNDEF Undefined USART Universal Synchronous/Asynchronous Receiver/ Transmitter Volts Volts, Alternating Current Volts, Direct Current Voltage at Collector Voltage at Drain...

  • Page 455: 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 456 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 457: Contents

    SureStak Power Stacker ™ Contents Introduction ..................page 458 Stacker Operation ................page 458 Setting Up The Power Stacker ..........page 459 Loading And Starting The Power Stacker......... page 462 Stacker Problems ................page 463 Stacker First Inspection ............page 463 Stacker Confidence Check ............

  • Page 458: Introduction

    Appendix D 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 installed or up to 15.5 inches (39.5 cm) wide with the paper tent installed.

  • Page 459: Setting Up The Power Stacker

    Setting Up The Power Stacker 1. Set the printer power switch to | (On). 2. On the rear control panel, press the ON LINE key to take the printer offline. (Figure 69.) 3. Press the ELEVATOR UP key and wait for the elevator assembly to reach the top of its travel.
  • Page 460 Appendix D Stacker Operation 4. If the paper you will use is not wider than 15.5 inches (39.5 cm) pull out the paper tray and install the wireform paper tent. (Figure 70.) If the paper is wider than 15.5 inches (39.5 cm) leave the paper tent out of the printer. Paper Tent Paper Tray Note the positions of...
  • Page 461 5. Push or pull the paddle shaft toward 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 5 to 12 inches (12.7 to 30.5 cm) long.

  • Page 462: Loading And Starting The Power Stacker

    Appendix D Stacker Operation Loading And Starting The Power Stacker 1. Press the PAPER ADVANCE key and hand feed the paper down into the paper throat of the stacker. Continue to advance the paper until it reaches the paper tent (if installed) and feed three to five extra sheets into the stacker.

  • Page 463: Stacker Problems

    Stacker First Inspection 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. 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 464: Stacker Confidence Check

    Appendix D Stacker Problems c. With the elevator at its lowest position, run the Shuttle Slow test (page 211) from the front operator panel. While the test runs, interrupt both IR beams, one at a time, and verify that the elevator rises. d.

  • Page 465: Stacker Stacker Motor Check

    Stacker Motor Check 6. Using the rear operator panel, press the PAPER ADVANCE (down arrow) key until three or four pages feed through the stacker throat. a. Check the LCD on the front operator panel for faults. If there is a fault, the paper out detector is failing and needs to be checked and cleaned.
  • Page 466 Appendix D Stacker Problems 8. Check all four stacker motors for 15.2 ± 1.5 Ohms resistance per phase. All four motors are the same: Measure pin 1 to pin 2 for Phase A Measure pin 3 to pin 4 for Phase B pin 1 = red pin 2 = yellow pin 3 = orange...
  • Page 467 Stacker Motor Check Table 8. Power Stacker Problems Symptom Origin of Symptom Explanation Solution Stacker limit switch Other troubleshooting A procedure that tests the page 196 check procedures. motion limit switch at the top and bottom of the right vertical rail. You will usually be referred to this procedure from other troubleshooting procedures.

  • Page 468: Removing The Power Stacker

    Appendix D 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 Manual.) 4. Remove the paper tent (if present). (Figure 73.) Paper Tent Figure 73.
  • Page 469 Stacker Motor Check 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 75.) 7. Remove the two Torx T-10 screws securing the stacker base to the cabinet floor.
  • Page 470 Appendix D Removing The Power Stacker 9. Pull the paper tray out until the holes in the rails permit access to the M3 buttonhead screws. (Figure 76.) 10. Loosen one turn (do not remove) the M3x6 screws securing the vertical rails to the stacker base.
  • Page 471 Stacker Motor Check 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 472 Appendix D Removing The Power Stacker 13. Remove two screws, washers, and the standoff from the stacker control panel. (Figure 78.) Standoff Washer Washer Long Screw Short Screw Figure 78. Removing the Stacker Control Panel 14. Remove four cables from the stacker control panel, and remove the stacker control panel.
  • Page 473 Stacker Motor Check NOTE: It may be easier to wear gloves for the next step. 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.

  • Page 474: Installing The Power Stacker

    Appendix D Installing The Power Stacker Installing The Power Stacker NOTE: This section shows installation of the power stacker assembly, the stacker cable assemblies, and the stacker control panel. 1. Set the printer power switch to O (off). 2. Unplug the power cord. 3.
  • Page 475 Stacker Motor Check 5. Connect the power stacker logic cable P103 to connector J117 on the controller board. (Figure 82.) 6. Disconnect the power supply cable from connector J101 on the controller board. (Figure 82.) 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 476 Appendix D Installing The Power Stacker 10. Pull the paper tray out until the holes in the rails permit access to the M3 buttonhead screws. (Figure 83.) 11. Loosen one turn—do not remove—the M3 screws securing the vertical rails to the stacker base. Each rail is secured by two screws. (Figure 83.) M3x6 Buttonhead Screw (Two on each rail) Access Hole in...
  • Page 477 Stacker Motor Check 12. Position the elevator assembly at the bottom of the vertical rails. (Figure 84.) 13. 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 84. Vertical Rail Elevator Assembly Stacker I/O...
  • Page 478 Appendix D Installing The Power Stacker NOTE: It may be easier to wear gloves for the next step. 14. 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 479 Stacker Motor Check 17. Align the holes in the stacker base with the holes in the cabinet floor. (Figure 85c and Figure 86) 18. 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 86.) 19.
  • Page 480 Appendix D Installing The Power Stacker 21. Gather the stacker rail cable, elevator I/O cable, logic cable, and power cable. Route the cables outboard of the elevator assembly. (Figure 87.) Elevator I/O Cable Elevator Assembly Rail Cable Card Cage) Control Panel) Stacker Stacker...
  • Page 481 Stacker Motor Check 22. Connect the stacker cables to the rear of the stacker control panel assembly and make sure the ejector levers close over the connectors. (Figure 88.) 23. Press rail cable connector P107 into the control panel until the ejectors close, then tie wrap the ejectors to the connector.
  • Page 482 Appendix D Installing The Power Stacker 24. 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.
  • Page 483 Stacker Motor Check 27. 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 86.) 28. Move the elevator assembly up and down on the vertical rails until it travels smoothly with no binding.
  • Page 484 Appendix D Installing The Power Stacker Cutout Beneath Card Cage Fan Stacker Cables Wire Saddle Figure 90. Securing Stacker Cables 33. Install the paper fence. (Figure 91.) Stacker Base Paper Fence Figure 91. Paper Fence...
  • Page 485 Stacker Motor Check 34. If the paper you will use is not wider than 15.5 inches (39.5 cm), pull out the paper tray and install the paper tent. (Figure 92.) If the paper is wider than 15.5 inches (39.5 cm) leave the paper tent out of the printer Paper Tent Paper Tray Note the positions of...

  • Page 486: Constant Force Spring

    Appendix D Replacing The Constant Force Spring Replacing The Constant Force Spring 1. Remove the stacker assembly from the printer. (See page 468.) 2. Raise the elevator assembly to within about 1/4 inch of 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 487 Stacker Motor Check WARNING The constant force spring is powerful and under high tension. Protect your hands with gloves. To avoid pinching or cutting your fingers, grip the spring and drum firmly in the next two steps. Coil the spring slowly and carefully.

  • Page 488: Replacing The Timing Belts

    Appendix D Replacing The Timing Belts Replacing The Timing Belts 1. Remove the stacker assembly from the printer (page 468). 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 489 Stacker Motor Check 6. Remove the shoulder screw and large washer that secure the constant force spring to the vertical rail. (Figure 97.) NOTE: Left is shown. Right is the same. Constant Force Spring Large Washer Shoulder Screw Figure 97. Releasing the Constant Force Spring 7.
  • Page 490 Appendix D Replacing The Timing Belts 8. Remove the timing belt by working it around the vertical rail and constant force spring. (Figure 99.) 9. To install a timing belt, reverse the steps of this procedure. NOTE: Left timing belt is shown. Right is the same.

  • Page 491: Roller Drive Shaft

    Stacker Motor Check Replacing The Roller Drive Shaft 1. Remove the stacker assembly from the printer (page 468). 2. Unhook the right bearing pivot plate’s extension spring from the tab on the elevator. (Figure 100.) 3. Using an M-2 Allen wrench, remove the screw securing the right bearing pivot plate to the elevator.
  • Page 492 Appendix D Replacing The Roller Drive Shaft 4. Move the idler shaft enough to expose the lower mount screw of the power stacker stepper motor. (Figure 101.) 5. Cut and remove the upper tie wrap securing the stepper motor wires to the elevator.
  • Page 493 Stacker Motor Check 9. Remove the roller drive shaft, taking care to retain the bearing at the left end of the shaft and the collar at the right end of the shaft. (Figure 102.) 10. Remove the bearing and collar from the old roller drive shaft and retain these items for installation on the new roller drive shaft.

  • Page 494: Illustrated Parts Breakdown

    Appendix D Illustrated Parts Breakdown 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 495 List of Illustrations Parts Not Illustrated In This Section: • Extended Door Assembly, Stealth Black:177489-001 Extended Door Assembly, Lt Gray: 179792-001 • Reed Limit Switch Assembly: 204234-001 • Control Panel Assy, Pwr Stkr, Black, Americas and Asia/Pacific: 178911-901; EMEA (RoHS): :250676-901) (See Figure 89, page 482) Cont.

  • Page 496: Figure 103. Stacker Assembly

    Appendix D Illustrated Parts Breakdown See page 498. 3 4 5 Figure 103. Stacker Assembly...
  • Page 497 List of Illustrations Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 178908-001 178908-001 Stacker Assembly, Power, Black 179804-001 179804-001 Stacker Assembly, Power, Gray 204956-001 204956-001 Washer, 5/16 X .200 X .030, Stainless Steel Part of item 36 203251-001 203251-001...

  • Page 498: Figure 104. Elevator Detail: Motors, Rollers, And Paddles

    Appendix D Illustrated Parts Breakdown From page 496. See page 500. See page 504. 45 46 See page 502. See page 502. Figure 104. Elevator Detail: Motors, Rollers, and Paddles...
  • Page 499 List of Illustrations Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 158313-001 158313-001 Anti-Static Brush Shear Grommet Part of item 36 Cap Nut Part of item 36 158736-901 158736-901 Drive Shaft Assy (Roller Drive Shaft) Includes items 14, 70, and 156393-001 156393-001...

  • Page 500: Figure 105. Stacker Detail: Motor Bracket

    Appendix D Illustrated Parts Breakdown From page 498. Flag Connector Figure 105. Stacker Detail: Motor Bracket...
  • Page 501 List of Illustrations Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) Clip-On Bearing Part of item 36 158288-001 158288-001 Holder, LED, Round LED, IR, T-1, 3/4...

  • Page 502: Figure 106. Stacker Detail: Elevator Bracket

    Appendix D Illustrated Parts Breakdown From page 498. Flag Connector Figure 106. Stacker Detail: Elevator Bracket...
  • Page 503 List of Illustrations Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) Clip-On Bearing Part of item 36 158290-001 158290-001 Holder, LED, Flat Photodarlington, NPN, Rectifier...

  • Page 504: Figure 107. Stacker Detail: Paper Motion Detector

    Appendix D Illustrated Parts Breakdown From page 498. Rotated 180 Degrees Connector Figure 107. Stacker Detail: Paper Motion Detector...
  • Page 505 List of Illustrations Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 158290-001 158290-001 Holder, LED, Flat 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...
  • Page 506 Appendix D Illustrated Parts Breakdown...

  • Page 507: Contents

    Zero Tear Pedestal (ZTP) Printer Contents Overview ..................page 508 Operation ..................page 509 Load Paper And Set Up The Tractors ........page 509 Remove Paper................page 510 Adjust The Paper Guides............page 511 Position The Paper Out Sensor ..........page 513 Set The Tear Bar Distance ............

  • Page 508: Overview

    Appendix E Overview Tractor (L/R) ................page 537 Tractor Assembly Support Gate ..........page 537 Illustrated Parts Lists............... page 539 Figure 124. ZTP Details ..............page 540 Figure 125. ZTP Inside Covers, Barrier Shield, and Shuttle Assy .. page 542 Figure 126.

  • Page 509: Operation

    Load Paper And Set Up The Tractors Operation Load Paper And Set Up The Tractors Top Cover Paper Edge Paper Label Paper Paper Supply Box Figure 108. Aligning and Loading Paper onto the Printer 1. Align the paper supply box with the label on the bottom left side of the modesty panel.

  • Page 510: Remove Paper

    Appendix E Operation Outer Paper Guide Leaf (2) Front Paper Center Paper Guide Leaf (3) Guide Leaf Paper Tractor (2) Tractor Lock (2) Paper Out Sensor Figure 109. Adjusting the Horizontal Paper Tension 3. Unlock and open the tractor doors and slide the paper from below, through the black paper out sensor slot on the left side, and up between all front and rear paper guide leaves.

  • Page 511: Adjust The Paper Guides

    Adjust The Paper Guides Adjust The Paper Guides Outer Paper Guide Leaf (2) Center Paper Guide Leaf Front Paper Guide Leaf (3) Paper Guide Knob (3) Figure 110. Adjusting The Paper Guides NOTE: You must remove the paper before adjusting the paper guide leaves. Ensure that the paper guide leaves are not damaged.
  • Page 512 Appendix E Operation Center Paper Outer Paper Guide Leaf Guide Leaf (2) Paper Tractor (2) Outboard Mount Center Mount Block (2) Block Figure 111. Adjusting Paper Guide Leaves 4. Slide the left outboard mount block so that the left outer paper guide leaf is .5 inches from the left tractor.

  • Page 513: Position The Paper Out Sensor

    Position The Paper Out Sensor Position The Paper Out Sensor Extrusion Bar At least 2 inches Sensor Knob Paper Out Sensor Paper Figure 112. The Paper Out Sensor The paper out sensor indicates when the printer runs out of paper. (The sensor does not work with black backed forms.) Unlike the standard pedestal printer, the ZTP printer requires you to load the paper through the paper out sensor slot (Figure 109 and Figure 112).

  • Page 514: Set The Tear Bar Distance

    Appendix E Operation Set The Tear Bar Distance To set the tear bar distance, do the following steps: 1. Make sure the printer is offline. 2. Press the right arrow until “OFFLINE/ZTP SETTINGS” displays. 3. Press the down arrow . “ZTP DataTime” displays. 4.

  • Page 515: Set The Top Of Form

    Set The Top Of Form Set The Top Of Form Paper Tear Bar Form Advance Knob Figure 114. Setting The Tear Off Position The ZTP printer uses the tear bar as the reference point for setting the tear off position. To set the position of the forms perforation to the tear bar, use the SET TOF button as follows: 1.

  • Page 516: Control Panel Menus

    Appendix E Control Panel Menus Control Panel Menus The ZTP SETTINGS menu includes the ability to enable and disable features unique to the Zero Tear printer (ZTP), set the tear bar distance, set the auto present data time, and set the auto present wait time. This section defines these options.

  • Page 517: Performance Limitations

    Set The Top Of Form Performance Limitations Forms Type The paper feed tractors on the ZTP printer push the paper up through the print station instead of pulling it through, as in the standard pedestal printer. This limits the variety of forms the ZTP printer can use. If the forms do not fall within the range specified in Table 9, dot compression and line separation may occur.

  • Page 518: Paper Jams

    Appendix E Performance Limitations Paper Jams Printer jams can occur if you tear off the form incorrectly. If you experience two or more paper jams per box of forms, follow these guidelines to help reduce jams: • Position the lower paper guides properly •...

  • Page 519: Adjustments And Tests

    List of Adjustments and Tests Procedures Adjustments And Tests The printer is a durable, low-maintenance machine, but some components and systems require occasional adjustment and may need to be tested as part of a troubleshooting procedure. You usually will be referred to this chapter by a troubleshooting procedure, or as part of a removal/installation procedure.

  • Page 520: Preparing The Ztp Printer For Maintenance

    Appendix E Adjustments And Tests Preparing The ZTP 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 521: Barrier Panel

    Barrier Panel Barrier Panel 1. Prepare the printer for maintenance (page 520). 2. Loosen (do not remove) the two #2 Phillips hold-down screws on the rear of the printer. (See page 540, item 4.) 3. Remove the top cover assembly. (See page 527.) 4.

  • Page 522: Belt, Paper Feed Timing, Adjustment

    Appendix E Adjustments And Tests Belt, Paper Feed Timing, Adjustment 1. Prepare the printer for maintenance (page 520). 2. Remove the top cover assembly (page 527). 3. Remove the hex screws and right cover plate. (See page 523, items 1 and 2.) 4.
  • Page 523 Belt, Paper Feed Timing, Adjustment Direction of Force 1/8 inch Legend: Screw, Hex w/Lockwasher (4) Cover Plate, Right Extension Motor Mount Bolt (2) Paper Feed Drive Motor Splined Shaf Pulley Paper Feed Timing Belt Paper Feed Motor Pulley Figure 117. Paper Feed Timing Belt Adjustment...

  • Page 524: Paper Guide Leaf, Front, Center, Outer

    Appendix E Adjustments And Tests Paper Guide Leaf, Front, Center, Outer 1. Prepare the printer for maintenance (page 520). 2. Adjust the paper guides. (See page 511.) Paper Out Sensor, Adjustment 1. Prepare the printer for maintenance (page 520). 2. Adjust the paper out sensor. (See page 513.) Paper Tension, Horizontal 1.

  • Page 525: Replacement Procedures

    List of Removal / Installation Procedures 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 526: Belt, Paper Feed Timing

    Appendix E Replacement Procedures Belt, Paper Feed Timing Removal 1. Prepare the printer for maintenance (page 520). 2. Remove the hex screws and right cover plate. (See page 523, items 1 and 2.) 3. Loosen (do not remove) the two 5/16 inch paper feed motor mount screws.

  • Page 527: Control Panel Assembly

    Control Panel Assembly Control Panel Assembly Removal 1. Prepare the printer for maintenance (page 520). 2. Open the printer cover. 3. Disconnect the RJ-11 connector P310 from J2 on the back of the control panel. (See page 540, item 5.) 4.

  • Page 528: Paper Feed Motor

    Appendix E Replacement Procedures Paper Feed Motor Removal 1. Prepare the printer for maintenance (page 520). 2. Remove the top cover assembly. (See page 527.) 3. Remove the paper feed timing belt. (See page 526.) 4. Trace the paper feed motor cables back to the controller board, releasing it from tie wraps.

  • Page 529: Paper Guide Leaf, Center

    Paper Guide Leaf, Center Paper Guide Leaf, Center Removal 1. Prepare the printer for maintenance (page 520). 2. Remove the center paper guide knob and center paper guide leaf. (See page 533, Figure 121.) 3. Remove the top button head screw, bottom flat head screw, and center guide leaf.

  • Page 530: Paper Out Sensor

    Appendix E Replacement Procedures Paper Out Sensor Paper Out Screw (4) Sensor Cable Left Cover (See page 275, Figure 23 Plate for P106 connector configuration details.) Tie Wraps (5) Paper Out Sensor Sensor Wrap Knob Figure 119. Replacing the Paper Out Sensor Assembly Removal 1.
  • Page 531 Paper Out Sensor Installation 1. Install the sensor knob and paper out sensor. 2. Route the paper out sensor cable up along the left side of the printer. (See Figure 119 on page 530.) 3. Connect coupling shroud connector P106 to the controller board and install tie-wraps to secure the motor cable.

  • Page 532: Shaft, Splined

    Appendix E Replacement Procedures Shaft, Splined Back Cover Plate Screw (4) Right Cover Plate Screw (4) Motor Mount Screw (2) Paper Feed Timing Belt Figure 120. Removing the Right Cover Plate and Back Cover Plate...
  • Page 533 Shaft, Splined Removal 1. Prepare the printer for maintenance (page 520). 2. Remove the hex screws and right cover plate. (See Figure 120.) 3. Remove the screws and the back cover plate. 4. Loosen (do not remove) the two 5/16 inch paper feed motor mount screws.
  • Page 534 Appendix E Replacement Procedures Installation 1. Position the splined shaft so the alignment marks are at the bottom on both tractors. (See page 535, Figure 122.) 2. Slide the splined shaft through the right side plate, tractors, and block mounts. Make sure the same spline passes the marked groove on each tractor.
  • Page 535 Shaft, Splined 8. Install the paper feed timing belt (page 526). 9. Set the paper feed timing belt tension (page 522). 10. Install the back cover plate. (See page 532, Figure 120.) 11. Install right cover plate. (See page 532, Figure 120.) 12.

  • Page 536: Shaft, Support

    Appendix E Replacement Procedures Shaft, Support Removal 1. Prepare the printer for maintenance (page 520). 2. Remove the hex screws and right cover plate. (See page 544, items 24 and 25.) 3. Unlock the tractors and slide them to the far right. (See page 546, item 1.) 4.

  • Page 537: Tractor (L/R)

    Tractor (L/R) Tractor (L/R) Removal 1. Prepare the printer for maintenance (page 520). 2. Remove the support shaft (page 536). 3. Remove the splined shaft (page 532). Installation 1. Using the replacement tractors, install the support shaft (page 536). 2. Install the splined shaft (page 532). 3.
  • Page 538 Appendix E Replacement Procedures Support Shaft Splined Shaft Tractor Door (2) Tractor Lock (2) Left Side Plate Tractor Assembly Support Gate (2) Right Side Plate Figure 123. Removing and Installing the Tractor Assembly Support Gate...

  • Page 539: Illustrated Parts Lists

    Illustrations of ZTP Components Illustrated Parts Lists Only replaceable parts 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 540 Appendix E Illustrated Parts Lists Figure 124. ZTP Details...
  • Page 541 Illustrations of ZTP Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 177530-902 250483-002 Control Panel Assembly, Ped Screw, Captive (2) 250086-001 250086-001 Top Cover Assembly, Ped, Blk 250087-001 250087-001 Top Cover Assembly, Ped, Gray Screw (2) 152440-901...
  • Page 542 Appendix E Illustrated Parts Lists Two places: Exploded to show assembly. Do not remove the clamps and screws. To J02 (Shuttle Motor) To J03 (MPU) See Figure 46, page 340. Figure 125. ZTP Inside Covers, Barrier Shield, and Shuttle Assembly...
  • Page 543 Illustrations of ZTP Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 179128-901 Shuttle Cover Air Shroud Assembly Screw, Captive (2) 10-24x.62 with O-ring, .125x.250x.06 Screw, Thread-forming (2) 6-32x.25 and #6 flat washer 179396-001 179396-001...
  • Page 544 Appendix E Illustrated Parts Lists To the Terminator Board on the Shuttle Frame Figure 126. ZTP Circuit Boards and Paper Feed Assembly...
  • Page 545 Illustrations of ZTP Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 179074-901 250297-901 Power Supply, PFC, 5/10 P7005, -10,- 02H, -03H 179074-991 250297-991 Power Supply, PFC, 5/10, Adv Exch P7005, -10,- 02H, -03H 179075-901 250251-901...
  • Page 546 Appendix E Illustrated Parts Lists Figure 127. ZTP Tractor Shafts, Paper Guides, and Paper Feed Motor...
  • Page 547 Illustrations of ZTP Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 179065-901 179065-901 Tractor Set, Non-Roller, 05/10/15 (Blue) 177821-001 177821-001 Shaft, Spacer, Tractor, ZTP Part of item 24 178132-001 178132-001 Pad, Nylon, Mount Block, ZTP Part of item 24...
  • Page 548 Appendix E Illustrated Parts Lists Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 177806-001 177806-001 Left Side Plate 178137-001 178137-001 Support, Gate, Tractor, Assembly...
  • Page 549 Illustrations of ZTP Components (Parts list continues on the next page.)
  • Page 550 Appendix E Illustrated Parts Lists NOTE: Item 24: Platen Hardware Kit Figure 128. ZTP Platen and Integrated Print Management Sensor Assembly...
  • Page 551 Illustrations of ZTP Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) Setscrew (2) Part of item 24 Bracket, Platen (2) Part of item 24 Screw, Thread-forming (3) 6-32x.25 174968-001 174968-001 Ironer Bracket/Plate Field Kit Plate, Ironer...
  • Page 552 Appendix E Illustrated Parts Lists Install screws here. Top View Route cable under Hammer Bank Fan base casting See detail above Figure 129. ZTP Hammer Bank Fan, Motors, and Ribbon Guides...
  • Page 553 Illustrations of ZTP Components Europe, Mideast, Americas and Africa Item and Asia/ (EMEA) Description Notes Pacific Part No. Part No. (RoHS Compliant) 152415-901 152415-901 Switch Assembly, Paper Detector Optional switch used with 170172-001 170172-001 Field Kit, Slotted Black Back Form Switch black back forms Screw, Thread-forming, 6-32x.375 (2) Part of item 1...
  • Page 554 Appendix E Illustrated Parts Lists...

  • Page 555: Introduction

    Paper Specifications And Forms Design Introduction This appendix is divided into two sections. The first section lists general specifications for continuous form paper used in this printer. (Specific brands of paper are not recommended.) The second section goes into more detail, providing definitions, guidelines, and a checklist you can use to design forms that will run smoothly through the printer.

  • Page 556: General Paper Specifications

    Celsius (68 to 78 Fahrenheit) and 45% to 55% relative humidity. Printronix printers perform well with forms that meet the specifications listed in Table 10 and Table 11 below. NOTE: Printronix conforms to ANSI® Standard X3.96-1983, “American National Forms Information Systems for Continuous Business Forms,”...

  • Page 557: Paper Guidelines

    Terms And Definitions Test the paper first if it will be used in environments with greater than 80% or less than 20% humidity. Test paper that will be used at high humidity for satisfactory feeding and handling. Test paper that will be used at low humidity to determine if static buildup must be eliminated for proper paper stacking.
  • Page 558 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 130.

  • Page 559: 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 560: 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 561: Chaff Content

    Chaff Content Preferred Unacceptable Cut Point Tie Point Direction of Forms Movement Tie Point Cut Point Figure 131. Preferred vs. Unacceptable Form Staples 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 562: 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 563: Form Evenness

    Chaff Content Form Evenness The evenness of the form = ________ (Not to exceed 0.003 in. / 0.00762 cm) Tenting due to buildup of perforation thickness must be minimized. A perforation thickness measured at the major perforation that exceeds 1.25 times the forms thickness measured in the print area will result in an unreliable and unpredictable form.
  • Page 564 Appendix F Form Design Checklist ________ Staples should be placed in the margins so that they coincide with areas of the form where printing will not occur Cut-To-Tie Ratio ____:____ (Typical ratio is 4:1, or 80% cut to 20% tie) Thickness Buildup = ________ in.

  • Page 565: 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 566 Appendix F Summary...
  • Page 567 Maintenance Manuals For P5000 Printers This manual covers only P7000 printers. Information about Printronix P5000 line matrix printers is contained in the maintenance manuals summarized below. Type of Controller Type of Printer Model Maintenance Manual Board Hammer Bank P5000 - Early...
  • Page 568 Appendix G Table 12. Early P5000 Single Hammer Bank Printers: Maintenance Manual 164253-001 Controller Single Hammer Model Print Enclosure Bank Board Speed P5005-12-QA 475 lpm Pedestal w/ 28 Hammers, 25 MHz CMX ™ Quick-Access 12 MIL tips Cover P5005A 500 lpm Pedestal 28 Hammers 25 MHz CMX...
  • Page 569 Table 12. Early P5000 Single Hammer Bank Printers: Maintenance Manual 164253-001 Controller Single Hammer Model Print Enclosure Bank Board Speed P5015-QA 1500 lpm Pedestal w/ 102 Hammers 40 MHz CMX ™ Quick-Access Cover P51KA 585 lpm Table Top 91 Hammers 25 MHz CMX ™...
  • Page 570 Appendix G Table 13. Later P5000 Single Hammer Bank Printers (The “P5B/10/15” Line): Maintenance Manual 175455-001 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 571 Table 14. P5000 PSA3 Single Hammer Bank Printers: 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 Pedestal 102 Hammers PSA3...
  • Page 572 Appendix G...

  • Page 573: Printronix Customer Support Center

    Europe, Middle East, and Africa (31) 24 6489 311 Asia Pacific (65) 6548 4114 http://www.printronix.com/support.aspx Printronix Supplies Department Contact the Printronix Supplies Department for genuine Printronix supplies. Americas (800) 733-1900 Europe, Middle East, and Africa (33) 1 46 25 1900 Asia Pacific...

  • Page 574: Corporate Offices

    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) 6546 1588 Visit the Printronix web site at www.printronix.com...
  • Page 575 Index Numerics 414 RIBBON STALL message, 127 415 SHUTTLE JAM message, 128 000 SHUTTLE TYPE NOT SUPPORTED* 416 STACKER FULL message, 129 message, 115 417 STACKER JAM message, 130 001 TBL MISMATCH message, 115 418 RBN INK LOW message, 130 002 WRONG E-NET* message, 115 419 RBN END PNT message, 131 06 HOST REQUEST, 42...
  • Page 576 617 LOWER DRIVER SHORT* message, 141 732 UNDEFINED OPCODE* message, 154 618 MECHANICAL DRIVER LINK* message, 141 733 DP FIFO Busy*, 51 619 PAPER FEED DRIVER CIRCUIT* 733 DP FIFO BUSY* message, 154 message, 142 8.5V POWER FAIL*, 42 620 POWER SUPPLY VOLTAGE* message, 142 900 ERROR xxxx message, 154 621 RIBBON DRIVER CIRCUIT* message, 142 901 FLASH FULL message, 154...
  • Page 577 B02 STATUS: SDRAM PASSED, 53 B46 ERROR SDRAM HAS MIXED SIZES* B10 ERROR NO DRAM DETECTED* message, 159 message, 155 B46 ERROR: SDRAM HAS MIXED SIZES*, 57 B10 ERROR: NO DRAM DETECTED*, 53 B47 ERROR SDRAM LARGER THAN 256M* B11 ERROR RAM TEST FAILED* message, 155 message, 159 B11 ERROR: RAM TEST FAILED*, 53 B47 ERROR: SDRAM LARGER THAN 256M*, 57...
  • Page 578 Controls and indicators cabinet models, 26 Cable assembly mechanical, 28 coupling shroud and cable replacement, 274 printing conventions, 24 interconnections, 393 Conventions, printing, used in this manual, 24 part numbers, 393 Conversion, metric measurement, 455 routing diagrams, 393 Cord, power, requirements, 31 Cable shorts test, 261 Coupling shrouds, connector, replacement, 274 Cable, signal interface, requirements, 31...
  • Page 579 E16 ITRANS MISS - See User Manual, 70 E16 ITRANS MISS message, 167 E Net Test Unavailable, 76, 173 E17 DLOAD MISS - See User Manual, 70 E00 EXE @ ADDR0 - See User Manual, 65 E17 DLOAD MISS message, 167 E00 EXE @ ADDR0 message, 162 E18 DSTORE MISS - See User Manual, 71 E01A TYPE 0x40 - See User Manual, 65...
  • Page 580 E32H CND 7 BP message, 172 ERROR WRONG OEM message, 176 E33 WRITE BP - See User Manual, 76 ERROR WRONG PRINTER TYPE message, 176 E33 WRITE BP message, 172 ERROR: CPLD NOT PROGRAMMED, 77 E34 TRACE CMPLT - See User Manual, 76 ERROR: DC PROGRAM NOT VALID, 77 E34 TRACE CMPLT message, 173 ERROR: DRAM AT ADDRESS XXXXXXXX, 77...
  • Page 581 101 BARCODE FAIL SPECIFICATION, 116 613 HAM. COIL BAD, 139 102 HAM.BANK HOT, 117 614 HAMMER BANK NOT INSTALLED*, 140 104 POWERSUPPLY HOT, 118 615 HAMMER BANK FAN FAULT, 140 105 PRINTER HOT, 119 616 INTAKE FAN FAULT, 141 400 BUFFER OVERFLOW, 119 617 LOWER DRIVER SHORT*, 141 401 BUFFER OVERRUN, 120 618 MECHANICAL DRIVER LINK*, 141...
  • Page 582 730 TCB CORRUPTED*, 153 BC SENSOR ERR, 161 731 UNDEFINED INTERRUPT*, 154 CLEARING PROGRAM FROM FLASH, 161 732 UNDEFINED OPCODE*, 154 D50 STATUS%XX Clearing Flash, 161 733 DP FIFO BUSY*, 154 D51 STATUS%XX Programming, 161 900 ERROR xxxx, 154 D55 STATUS Send Program to EC, 162 901 FLASH FULL, 154 DIAGNOSTIC PASSED, 162 902 RAM FULL, 154...
  • Page 583 E32C CND 2 BP, 171 INCOMPAT E-NET, 179 E32D CND 3 BP, 171 INTERRUPT UNUSED VECTOR 00, 180 E32E CND 4 BP, 171 LOADING PROGRAM FROM PORT XX%, 180 E32F CND 5 BP, 172 LOADING PROGRAM INTO FLASH, 180 E32G CND 6 BP, 172 NEW SPX DETECTED, 180 E32H CND 7 BP, 172 NON VOLATILE MEMORY FAILED, 181...
  • Page 584 INCOMPAT E-NET message, 179 overview, 17, 567 Incompat WLAN - Remove NIC, 88 preventive, 35 Installation, 23 training for Printronix products, 33 INTAKE FAN FAULT, 88 Maintenance Preparation, ZTP, 520 Integrated Print Management System, 377 Manual control panel menus, 378...
  • Page 585 Menus PAP NOT SCHED*, 97 boot diagnostics menu, 217 PAP NT AT SPEED*, 97 diagnostic printer tests, 211 PAP UNEXP INT*, 97 exception menu, 222 Paper factory menu, 220 detector switch assembly, replacement, 324 Message List (troubleshooting), 42 dynamic paper tension adjustment, 256 Messages feed drive motor, replacement, 301 asterisk (*), what it means, 41...
  • Page 586 Printer cover assembly, top, pedestal models, 281 adjustments, 229 CT board, 282 cleaning, 35 dashpot, 283 configuration, 23 Ethernet interface, 299 diagnostic self-tests, 211 extension spring, hammer bank, 323 diagnostic tests, 211 hammer bank / ribbon mask cover grounding requirements, 31 assembly, 279 identification, 18 hammer bank fan assembly, 284, 286...
  • Page 587 top cover assembly, ZTP, 527 Shaft tractor assembly support gate, ZTP, 537 splined, replacement, 318 tractor, ZTP, 537 splined, skew adjustment, 242 Reset, soft vs. hard, 227 support, replacement, 320 Resistors, terminating Shorts location of, 313, 315 cable, checking for, 261 RESTORING BOOT CODE message, 181 hammer bank power cable, checking for, 260 RESTORING BOOT CODES, 102...
  • Page 588 468 Torque, conversion to or from metric, 455 replacing Tractor, replacement, 326 constant force spring, 486 Training, maintenance, for Printronix products, 33 timing belts, 488 TRNSPT INVL CMD* See User Manual, 102 Supplies Department, 32, 573 Troubleshooting, 39 Support shaft, replacement, 320...
  • Page 589 forms type, 517 ZTP TearDist, 516 front paper guide replacement, 529 ZTP WaitTime, 516 front, center, outer paper guide leaf adjustments, 524 horizontal paper tension adjustments, 524 illustrated parts lists, 539 load paper, 509 maintenance preparation, 520 operation, 509 outer paper guide replacement, 529 overview, 508 paper feed motor replacement, 528 paper feed timing belt adjustments, 522...
  • Page 592 *177705-001* 177705-001F...

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