User manual

Table of Contents
ProMaster 2500 User Manual vii
6. Troubleshooting
Messages...............................................................................................................................6-1
Troubleshooting Flow Charts.............................................................................................6-6
7. Repair and Replacement Procedures
Fuse Replacement ................................................................................................................7-2
Programming Electronics Assembly Replacement.........................................................7-3
Removing the PE ...........................................................................................................7-3
Installing the PE Assembly ..........................................................................................7-7
Motor Replacement..............................................................................................................7-7
Replacing the Input Orbital Motor .............................................................................7-7
Replacing the Output Orbital Motor ........................................................................7-10
Replacing the Print Drive Motor ...............................................................................7-11
Replacing the Dot Matrix Print Head .......................................................................7-12
Replacing the Thermal Print Head ...........................................................................7-13
Replacing the Beam Head Rotation Motor ..............................................................7-14
Replacing the Beam Traverse Motor ........................................................................7-14
Mechanical Assembly Removal.......................................................................................7-15
Replacing the Input Orbital Tube Clamp ................................................................7-15
Replacing the Output Orbital Tube Clamp .............................................................7-16
Replacing the Programming Module Clamp Air Cylinder ...................................7-17
Solenoid Replacement.......................................................................................................7-18
Replacing a Solenoid ...................................................................................................7-18
Power Supply Replacement..............................................................................................7-18
Replacing the PE Power Supply ................................................................................7-19
Replacing the Toroid Transformer ............................................................................7-19
Replacing the Toroid PCB ..........................................................................................7-19
Replacing the Controller Power Supply ..................................................................7-19
Replacing the Labeler Power Supply .......................................................................7-20
System Fan Replacement..................................................................................................7-20
Replacing the System Fan ..........................................................................................7-20
Controller Board Replacement.........................................................................................7-20
Replacing the Controller Board .................................................................................7-20
Beam Assembly Component Replacement....................................................................7-21
Replacing the Flex Coupler ........................................................................................7-21
Replacing the Right Lead Screw Bearing Assembly ..............................................7-22
Replacing the Left Lead Screw Bearing Assembly .................................................7-23
Replacing the Lead Screw ..........................................................................................7-23
Replacing the Anti-backlash Nut ..............................................................................7-24
Replacing the Beam Gasket ........................................................................................7-25
Disk Drive Replacement....................................................................................................7-27
Replacing the Disk Drive ............................................................................................7-27
Keyboard/Display Assembly Replacement...................................................................7-28
Replacing the Keyboard/Display Assembly ...........................................................7-28
Programming Module Components Replacement.......................................................7-28
Replacing Contacts on a DIP Module .......................................................................7-28
Replacing Contacts on a PLCC Module ...................................................................7-30
Replacing Pins on a SOIC Programming Module ..................................................7-33
Replacing the Pin Insulation Block ...........................................................................7-34
Replacing the Programming Block on a PLCC Module ........................................7-36
Assembly Drawings...........................................................................................................7-39
ProMaster 2500 Thermal Printer Standard Spares Kit..................................................7-64
ProMaster 2500 Advanced Spares Kit.............................................................................7-66