® Maintenance Manual The Printronix P5000 series of Line Matrix Printers
The Printronix P5000 series of Line Matrix Printers Maintenance Manual ® 164253-001, Rev D
Trademark Acknowledgements Trademark Acknowledgements ANSI is a registered trademark of American National Standards Institute, Inc. Centronics is a registered trademark of Genicom Corporation. Code V is a trademark of Quality Micro Systems. Chatillon is a trademark of John Chatillon & Sons, Inc. Dataproducts is a registered trademark of Dataproducts Corporation. EIA is a registered service mark of Electronic Industries Association.
Warranty and Copyright Information Communication Notices Federal Communications Commission (FCC) Statement: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment.
Chapter Communication Notices Warning: This is a Class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures. Dieses Gerät erfüllt die Bedingungen der EN 55022 Klasse A.
Table of Contents 1 Maintenance Overview......................... 11 About the Printer................................................................. 11 P5000 Printers .................................................................... 11 Kanji/Hanzi Printers...................................................... 11 Printer Evolution ........................................................... 12 How to Identify the Printer ............................................ 12 Important Maintenance Notes.......
Table of Contents Hex Code Printout .............................................................. 95 How to Print a Hex Dump............................................. 96 ASCII Character Set ........................................................... 97 Soft vs. Hard Reset............................................................. 98 The Power On Sequence ................................................... 99 CMX Controller Board Handshake Sequences ............
Table of Contents Expansion-CT ............................................................ 162 Fan Assembly, Cabinet Exhaust ................................ 163 Fan Assembly, Card Cage ......................................... 164 Fan Assembly, Hammer Bank.................................... 165 Hammer Spring Assembly.......................................... 166 Magnetic Pickup (MPU) Assembly ............................. 170 Memory Modules and Security PAL ...........................
Table of Contents Engine Controller ....................................................... 254 Power Supply Board ......................................................... 255 AC Power ................................................................... 255 DC Power ................................................................... 256 Printer Interface ................................................................ 256 Graphics ...........................................................................
1 Maintenance Overview About the Printer Printronix P5000 series line matrix printers use PSA (Printronix System Architecture), which puts all data control and printer control logic on one circuit board. The use of flash memory on this board permits rapid access to stored printer emulations and fast processing of print data. A variable-speed shuttle and half-step paper control enable these printers to print a wide variety of high-volume jobs with minimum maintenance and maximum reliability.
Chapter 1 P5000 Printers Printer Evolution The newest models in the family are the P5X05B, P5X10, and P5X15, which are available both in pedestal and floor cabinet housings. These models have a redesigned shuttle frame assembly, hammer bank, and ribbon guides. The new shuttle and hammer bank assemblies are not compatible with earlier P5000 printers, but the new ribbon guides can be used on any model P5000 printer.
How to Identify the Printer Table 1.
Chapter 1 P5000 Printers Table 1.
How to Identify the Printer Important Maintenance Notes To ensure the best performance of the printer, remember these maintenance principles whenever you service the printer. CAUTION Failure to observe these guidelines can result in damage to the equipment. • Do not adjust the platen gap unless 1) the original shuttle frame assembly or platen has been replaced with a new or rebuilt unit, or 2) you are instructed to do so in a troubleshooting procedure. • Never bend or tweak hammer springs.
Chapter 1 About This Manual • IGP/PGL Programmer’s Reference Manual Describes the optional IGP Printronix emulation. The IGP 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. • IGP/VGL Programmer’s Manual Describes the optional Code V Printronix emulation.
Printing Conventions in 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. WARNING Always disconnect the AC power cord before cleaning the printer.
Chapter 1 Controls and Indicators Controls and Indicators Electrical Controls and Indicators, Cabinet Models (Figure 2) Switch or Indicator Active On-line Active Off-line On when the printer is on-line, off when the printer is off-line. Flashes to indicate a fault or warning. ä ä Liquid Crystal Display. Displays printer status messages, fault messages, and menus which permit user to set various configurations. ä ä ON LINE/ CLEAR Toggles the printer on-line and off-line.
Printing Conventions in This Manual (Off) (On) Power Switch Status Indicator Raise printer cover to use these keys. SET TOF UP PRT CONFIG LCD NEXT PREV JOB SELECT PAPER ON LINE ADVANCE DOWN VIEW CANCEL ENTER CLEAR EJECT Figure 2.
Chapter 1 Controls and Indicators Electrical Controls and Indicators, Pedestal Models (Figure 3) Switch or Indicator Active On-line Active Off-line On when the printer is on-line, off when the printer is off-line. Flashes to indicate a fault or warning. ä ä Liquid Crystal Display. Displays printer status messages, fault messages, and menus which permit user to set various configurations. ä ä ON-LINE CLEAR Toggles the printer on-line and off-line.
Printing Conventions in This Manual (Off) (On) Power Switch PREV LCD NEXT PREV UP DOWN SET TOF SET TOF NEXT UP PRT CONFIG JOB PRT CONFIG SELECT JOB SELECT ENTER ENTER DOWN Status Indicator ON-LINE CLEAR PAPER ADVANCE ON-LINE CLEAR PAPER ADVANCE VIEW EJECT VIEW EJECT CANCEL CANCEL Figure 3.
Chapter 1 Controls and Indicators Mechanical Controls and Indicators, All Models (Figure 6) Control or Indicator Function Forms Thickness Lever Sets the platen for paper and forms of different thicknesses. Lever must be fully opened (raised) to load or unload paper. Paper Supports Help prevent paper jams by supporting inner sections of paper. They are positioned manually by sliding them along the shafts. Forms Thickness Pointer and Scale Indicates relative thickness of forms and paper.
Printing Conventions in This Manual Paper Supports Left Tractor Horizontal Adjustment Knob Right Tractor Tractor Lock Tractor Lock Vertical Position Knob Ribbon Loading Path Diagrams Forms Thickness Lever and Scale Forms Thickness Pointer Figure 4.
Chapter 1 Tools, Test Equipment, and Supplies Tools, Test Equipment, and Supplies For field level maintenance of the printer, you will need these tools: Adapter, 1/4 in. hex to 1/4 in. square, Utica HW-18 Alcohol, anhydrous Allen Wrench, 1/16 inch Allen Wrench, 3/32 inch Allen Wrench, 7/64 inch Allen Wrench, 5/64 inch ESD Wrist Strap Feeler Gauge, .010 inch Feeler Gauge, .011 inch Feeler Gauge, .040 inch Force Gauge, (Chatillon NY, Gauge-r, 0-20 lb., CAT 719-20) Hex bit, 3/16 in.
2 Preventive Maintenance Cleaning the Printer The printer is designed to require very little maintenance. Aside from normal replenishment of paper and ribbons, the only preventive maintenance required is periodic cleaning. Because operating conditions vary widely, the user must determine how often to clean the printer. Since there is no guarantee that the user will clean the printer regularly, you should clean the printer whenever you are called to service it.
Chapter 2 Cleaning the Outside Surfaces 9. Using a cloth dampened (not wet) with alcohol, clean the ribbon guides. 10. Vacuum up dust and residue from the lower cabinet. 11. Wipe the interior of the lower cabinet with a clean, lint-free cloth dampened with water and a mild detergent or window cleaning solution. 12. Dry the cabinet interior with a clean, lint-free cloth. 13. Clean the shuttle frame assembly, as described in the next section. 4 3 2 1 NOTE: Cabinet model shown.
Cleaning the Shuttle Frame Assembly 1. Remove the shuttle cover assembly (page 160). 2. Remove the shuttle frame assembly (page 198). 3. Remove the paper ironer (page 176). WARNING Over time, the upper edge of the paper ironer can become sharp. To avoid cutting yourself, handle the paper ironer on the sides. 4. Moisten a clean, soft cloth with alcohol. Wipe the paper ironer to remove lint, ink, and paper residue. 5. Install the paper ironer (page 176). 6.
Chapter 2 Cleaning the Card Cage Fan Assembly 11. Install the shuttle cover assembly (page 160). 12. Clean the card cage fan assembly, as described in the next section. Cleaning the Card Cage Fan Assembly 1. Cabinet Models: Remove the paper path (page 177). Pedestal Models: Remove the top cover assembly (page 161). 2. Vacuum the card cage fan assembly and surrounding areas to remove paper particles, dust, and lint. (See Figure 7.) 3.
3 Troubleshooting Introduction This chapter lists fault messages and symptoms, and provides procedures for troubleshooting printer malfunctions. Always have the User’s Manual handy when you troubleshoot because this manual does not cover printer operation or configuration. You must operate the printer to check its performance, and sometimes you may have to reconfigure it. Troubleshooting Aids Troubleshooting is faster and more effective if you understand the equipment and make use of all available tools.
Chapter 3 Start Here... Start Here... Are you here because of an error message? YES NO Power on the printer and observe the control panel for the following sequence of events (retry as required): 1. All black squares appear on the display. 2. Display goes blank. YES 3. TESTING HARDWARE PLEASE WAIT appears on display. Power on the printer. Did steps 1, 2, and 3 occur? Go to Troubleshooting Display Messages, page 31.
How to Clear LCD Messages Troubleshooting Display Messages WARNING Always disconnect the AC power cord from the printer before doing a maintenance procedure. Failure to remove power could result in injury to you or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure.
Chapter 3 Troubleshooting Display Messages Table 2: Message List Symptom 32 Troubleshooting Procedure 31 PAPER OUT TIMEOUT page 41 32 PAPER JAM TIMEOUT page 41 33 PLATEN OPEN TIMEOUT page 42 34 RIBBON STALL TIMEOUT page 42 48V PWR FAIL* page 43 ACCESS NULL PTR* page 43 ACTIVATE LOST page 44 A TO D OVERRUN* page 44 BUFFER OVERRUN page 45 CLEAR PAPER JAM page 46 CLEARING PROGRAM FROM FLASH page 49 CLOSE PLATEN page 49 COIL HOT page 49 CTL VOLT FAIL* page 51 DIAGNOSTIC PASSED
How to Clear LCD Messages Table 2: Message List Symptom Troubleshooting Procedure ERROR: NVRAM FAILURE page 54 ERROR: PROGRAM NEEDS MORE DRAM page 54 ERROR: PROGRAM NEEDS MORE FLASH page 54 ERROR: PROGRAM NOT COMPATIBLE page 54 ERROR: PROGRAM NOT VALID page 55 ERROR: SECURITY PAL NOT DETECTED page 55 ERROR: SHORT AT ADDRESS XXXX page 55 ERROR: WRITING TO FLASH page 55 ERROR: WRONG CHECKSUM page 55 EXHAUST FAN FLT page 56 FIRMWARE ERROR page 56 FM HEADER ERROR page 57 FRAMING ERROR
Chapter 3 Troubleshooting Display Messages Table 2: Message List Symptom 34 Troubleshooting Procedure LO DRV.
How to Clear LCD Messages Table 2: Message List Symptom Troubleshooting Procedure PWR SUPP VOLT* page 73 QUEUE OVERRUN page 73 RESTORING BOOT CODE page 73 RIB INVLD CMD* page 75 RIB INVLD STATE* page 75 RIBBON DRIVE page 75 RIBBON INK OUT CHANGE RIBBON page 76 SCS COMMAND ERROR page 76 SECURITY CODE VIOLATION page 77 SECURITY PAL NOT DETECTED page 76 SENDING PROGRAM TO EC PROCESSOR page 77 SF ERROR page 77 SHUTL INV CMD* page 78 SHUTL INV PARM* page 78 SHUTTLE JAM page 79 SO
Chapter 3 Troubleshooting Other Symptoms Troubleshooting Other Symptoms WARNING Always disconnect the AC power cord from the printer before doing a maintenance procedure. Failure to remove power could result in injury to you or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure. Use standard fault isolation techniques to troubleshoot malfunctions not indicated by display messages. These techniques are summarized below: 1.
How to Clear LCD Messages Table 3: General Symptom List Symptom Troubleshooting Procedure Control Panel Black squares on control panel page 44 Control panel blank page 50 Control panel keys do not work page 51 Control panel display shows garbled, broken characters page 51 Power Failures No power, and control panel blank, and card cage fan not running page 62 Printer does not initialize page 71 Power Stacker Printer does not detect presence of power stacker page 70 Stacker “chatters” at uppe
Chapter 3 Troubleshooting Procedures Table 3: General Symptom List Troubleshooting Procedure Symptom Power on “hang” condition page 69 Printer does not print from the host page 71 Printer does not print self tests page 72 Reverse paper feed: platen does not open page 73 TOF is lost repeatedly page 85 Ribbon Ribbon folding or feed problems page 75 Shuttle Shuttle does not move page 77 Shuttle is noisy page 78 Troubleshooting Procedures Troubleshooting procedures are listed in this section
The Procedures The Procedures 06 HOST REQUEST Message 1. Status message: in CT emulation, the host computer or printer controller requires attention. Not a printer problem. 08 HOLD PRINT TIMEOUT Message 1. Status message: in CT emulation, the printer was off-line more than 10 minutes and the “Intervention Required” parameter is set to “Send to Host.” Press ON LINE. 8.5V PWR FAIL* Message 1. 8.5 Volt Power Failed. Internal power failure. Cycle power. If the message appears, replace the power supply board.
Chapter 3 Troubleshooting Procedures message still appears, replace the expansion-CT board. Record the message and return it with defective board. 15V CTL FAIL* Message 1. Controller Voltage Failure. Cycle Power. Run the print job again. If the message appears, download the emulation software again (page 130). 2. Cycle power. Run the print job again. If the message appears, replace the flash memory. 3. Power on the printer. Run the print job again.
The Procedures 31 PAPER OUT TIMEOUT Message 1. In the CT emulation with a coax interface, a time-out message is sent to the host if paper is not loaded within 10 minutes after CLEAR was pressed to clear a paper out fault. Load paper. Run a print test. If the message appears, replace the paper detector switch assembly. 2. Run a print test. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board. 32 PAPER JAM TIMEOUT Message 1.
Chapter 3 Troubleshooting Procedures 9. Inspect the tractors and tractor door springs for damage or excessive wear. If either tractor is worn or damaged, replace both tractor assemblies. 10. Check the condition and tension of the paper feed belt. Adjust the paper feed belt. Replace the belt if it is damaged. 11. Check the platen gap. Adjust the platen gap. 12. Clean the paper motion detector with a cotton swab and alcohol.
The Procedures Replace the hammer bank cover assembly if it is bent or damaged. 4. Check the platen gap. If the gap is too small, it can inhibit ribbon movement. Adjust the platen gap. 5. Power off the printer. Remove the paper path or pedestal top cover. Disconnect P106 and P107 from the CMX controller board. Check the resistance of LRIB M in P106 and RRIB M in P107. (Refer to the Main Wire Harness Test Tables in Appendix A.) If ribbon motor resistance is not correct, replace the motor.
Chapter 3 Troubleshooting Procedures Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130). 2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board. ACTIVATE LOST Message 1. The printer detects a twinax protocol communication error and reports the error. Power off the printer. Disconnect the AC power cord from the printer.
The Procedures Reseat flash memory. 4. Power on the printer. If black squares appear on the LCD, the flash memory could be blank. Replace the flash SIMM in J11 with a new flash SIMM with the boot program installed. 5. Power on the printer. If black squares appear on the LCD, replace the CMX controller board. Record the message and return it with defective CMX board. If the LCD displays characters correctly, download the emulation software again (page 130). BUFFER OVERRUN Message 1.
Chapter 3 Troubleshooting Procedures frame assembly for broken hammer springs, hammer tips, or contaminations. Replace any damaged hammer spring assemblies. Replace the hammer bank cover assembly if it is deformed or damaged. 6. Check the platen gap. Adjust the platen gap. 7. Remove the paper guide assembly or pedestal top cover. Make sure Connectors P105 and P108 have good connections on the CMX controller board. Make sure connectors P04 and P05 have good connections at the shuttle frame assembly.
The Procedures 8. Check the platen open pulley and the platen pulley for looseness. Bottom out the platen open motor pulley on the motor shaft and torque the 1/16 inch set screw to 9 ± 2 inch-pounds (1.02 ± 0.23 N•m). Tighten the 7/64 inch setscrew in the platen shaft pulley, then open and close the forms thickness lever and check that the platen pulley setscrew does not hit the left ribbon guide. 9. Inspect the tractors and tractor door springs for damage or excessive wear.
Chapter 3 Troubleshooting Procedures Connect P107/PAPR M to J107 on the CMX controller board. 2. Check the paper feed motor pulley for looseness. Hold the collar snug against the motor pulley and torque the 7/64 inch setscrew to 25 ± 2 inch-pounds (2.82 ± 0.23 N•m). 3. Check the condition and tension of the paper feed timing belt. Adjust the paper feed timing belt. Replace the belt if it is damaged. 4. Load paper. Power on the printer.
The Procedures CLEARING PROGRAM FROM FLASH Message 1. Status message: emulation software successfully loaded into printer RAM and the checksum matched. The old program is now being deleted from flash memory. No action required. CLOSE PLATEN Message 1. The forms thickness lever is open. 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 CMX controller board.
Chapter 3 Troubleshooting Procedures temperature at or above 40° Celsius (104° Fahrenheit) or that is dirty enough to create blockage of the cabinet fan vents. The printer must never be run at ambient temperatures greater than 40° Celsius (104° Fahrenheit). If the printer is located in such an environment, relocate it to a cooler, cleaner area. 1. One or more hammer coils are overheating. Inspect printer environment for severity. (See NOTE above.
The Procedures Control panel keys do not work 1. Power on the printer. Check the operation of the control panel keys. Replace the control panel assembly. 2. Power on the printer. Check the operation of the control panel keys. Replace the control panel cable assembly. 3. Power on the printer. Check the operation of the control panel keys. Replace the CMX controller board. Control panel display shows garbled, broken characters 1. Remove the paper path or pedestal top cover.
Chapter 3 Troubleshooting Procedures Downloads consistently fail NOTE: Most download problems are detected by software during the procedure and communicated by LCD messages. (See Table 5: on page 132.) If downloads fail consistently with no messages or with erratic messages, suspect a hardware failure. 1. Power off the printer. Remove the paper path or pedestal top cover. Check the I/O cable connections from the host to the printer. Check the parallel cable connection at J112 on the CMX controller board.
The Procedures ERROR: DRAM AT ADDRESS XXXXXXXX Message 1. The printer found a defective memory location. Replace the DRAM. 2. Power on the printer. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board. ERROR: EC PROGRAM NOT VALID Message 1. The printer cannot find the engine controller program or the validation checksum is corrupt. Download the program again (page 130). If the message occurs again, replace all flash memory SIMMs. 2.
Chapter 3 Troubleshooting Procedures Download the program again (page 130). If the message occurs again, replace the flash memory. ERROR: FLASH NOT DETECTED Message 1. The printer could not find flash memory. Check flash memory on the CMX controller board. If present, reseat the flash SIMMs; if missing, install flash SIMMs. ERROR: NO DRAM DETECTED Message 1. The printer could not find any DRAM. Check DRAM on the CMX controller board. If present, reseat DRAM; if missing, install DRAM.
The Procedures ERROR: PROGRAM NOT VALID Message 1. The printer does not see a program in flash memory. There is no program in printer memory. Download the emulation (page 130). ERROR: SECURITY PAL NOT DETECTED Message 1. The security PAL is not present or has failed. Check the security PAL at location U54 on the CMX controller board. If the PAL is absent, install the correct PAL. If a security PAL is present, replace it. 2. Power on the printer.
Chapter 3 Troubleshooting Procedures If the messages appears, replace the CMX controller board. Record the message and return it with defective CMX board. EXHAUST FAN FLT Message 1. Exhaust Fan Fault. Sensors cannot detect current in the fan circuit. Cycle power. If the message appears, press CLEAR. 2. Check that the exhaust fan is connected to exhaust fan cable connector J307. Connect the fan cable connector. 3. Power off the printer. Remove the paper path.
The Procedures Flash SIMM won’t copy 1. Power off the printer. Remove the flash SIMMs. Inspect the flash SIMM sockets on the CMX controller board. If any SIMM socket pins are bent or damaged, replace the CMX controller board. 2. Make sure the blank SIMM is the same size as the SIMM to be copied. Install the SIMMs, making sure they are fully and correctly seated. Power on the printer. From the Boot Diagnostics menu, select and run MISC UTILITIES / COPY FLASH SIMMS. (See page 92.
Chapter 3 Troubleshooting Procedures Cycle power. If the message appears, replace the shuttle frame assembly. 2. Power on the printer. Run a print test. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board. HAMMER COIL BAD #, #, #, #, ... etc. Message 1. Hammer coil(s) number #, #, etc. failed the current test at power-up. Check that the hammer bank cables are connected. Cycle power.
The Procedures connector P107/HBF for shorts or opens. (Refer to the Main Wire Harness Test Tables in Appendix A.) Replace components that fail test. 3. Make sure P107/HBF has a good connection at J107 on the CMX controller board. Connect P107 to the CMX controller board. 4. Inspect for obstructions of airways and vents. Remove obstructions. 5. Power on the printer. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.
Chapter 3 Troubleshooting Procedures If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board. ILL INST ACCSS* Message 1. Illegal Instruction Accessed. Firmware error on the CMX controller board. Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130). 2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board.
The Procedures Reseat the twinax host data cable connection and the twinax I/O cable connection at the expansion-CT board. 2. Disconnect the twinax auto-termination cable from the printer or from the last device on this twinax port. Test the cable for the resistances shown in the Main Wire Harness Test Tables in Appendix A. If resistances are not correct, replace the twinax auto-termination cable. 3. Connect the power cord to the printer. Power on the printer. Send a print job to the printer.
Chapter 3 Troubleshooting Procedures LOAD PAPER Message 1. Printer is out of paper. Load paper. Press CLEAR. If message does not clear, go to step 2. 2. Power off the printer. Remove the paper path or pedestal top cover. Remove the barrier shield (cabinet model) or the barrier shield and paper guide (pedestal model). Check that the paper detector switch assembly is securely mounted in its bracket. Install the paper detector switch assembly. 3.
The Procedures 5. Check that power supply cable connector P101 is connected to J101 on the CMX controller board. Connect power supply connector P101 to J101 on the CMX controller board. 6. Check all cable connections on the CMX controller board. Connect all cables. 7. If the printer has the expansion-CT board, check the CT cable connections and the adapter connection to the CMX controller board. Connect all cables.
Chapter 3 Troubleshooting Procedures 1. Paper Bad Table. The paper feed process on the CMX controller board has a corrupted table. Cycle power. Run the print job again. If the message appears, download the emulation software again. 2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board. PAP BSY TOO LNG* Message 1. Paper Busy Too Long. Firmware error on the CMX controller board. Cycle power.
The Procedures undamaged and have good connections. Replace as necessary. (Refer to Appendix A.) 3. Check hammer phasing. Try using a lower phasing value; sometimes this message indicates too high a hammer phase value. 4. Power on the printer. Run the print job again. If the message appears, replace the shuttle frame assembly. 5. Power on the printer. Run the print job again. If the message appears, replace the power supply board. 6. Power on the printer. Run the print job again.
Chapter 3 Troubleshooting Procedures Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130). 2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board. PAP NOT SCHED* Message 1. Paper Not Scheduled. The paper feed process is not scheduling on the CMX controller board, and the printer cannot feed paper. Cycle power. Run the print job again.
The Procedures 2. Run the print job that generated the error message. If the message appears, check the host data for invalid characters. 3. Ask the system operator to verify that the printer’s Device ID is set to the correct emulation with respect to the host configuration. Set printer Device ID to the correct emulation with respect to the host configuration. 4. Run the print job that generated the error message. If the message appears, go to Communications Failures, page 88. PARITY ERROR Message 1.
Chapter 3 Troubleshooting Procedures If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board. PLEASE WAIT... RESET IN PROGRESS Message 1. Status message: the printer finished loading the program into flash memory and is automatically resetting itself. No action required. Paper feeds poorly 1. Check the forms thickness lever: if it is set too tightly paper feeding can be affected.
The Procedures Power on “hang” condition 1. Remove the paper path or pedestal top cover. Check all cable connections to the CMX controller board and the power supply board. Connect cables. 2. Power up the printer. If the printer “hangs,” replace the CMX controller board. 3. Power up the printer. If the printer “hangs,” replace the power supply board. POWER SAVER MODE Message 1. This is a status message.
Chapter 3 Troubleshooting Procedures 5. Inspect vents and fan airways for obstructions. Look underneath cabinet models for items blocking the cabinet exhaust vents. Remove any obstructions from vents and airways. 6. Install paper path or pedestal top cover. Load paper. Power on the printer. Run the “All E’s” print test for 5-10 minutes. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.
The Procedures If the ON LINE indicator does not light, replace the stacker control panel. 6. Power on the printer. Check that the ON LINE indicator lights on the stacker control panel. If the ON LINE indicator does not light, replace the CMX controller board. Printer does not initialize NOTE: Power-on initialization is explained on page 99. 1. Power off the printer. Remove the paper guide or pedestal top cover. Check that all cables are connected to the CMX controller board.
Chapter 3 Troubleshooting Procedures If printer does not print and the interface is RS-232, interchange the wires to pins 2 and 3. (This is the most common cause of an inoperative RS-232 cable.) Verify that the host and printer have the same baud rate, number of data bits, number of stop bits, and parity. Configure the host for XON/XOFF if possible, since this requires the least complex cable. 4. Power up the printer. Send a print job from the host.
The Procedures 2. Power off the printer. Remove the paper path or pedestal top cover. Check that all fan cables are connected. Connect all fan cables. 3. Inspect vents and fan airways for obstructions. Look underneath cabinet models for items blocking the cabinet exhaust vents. Remove any obstructions from vents and airways. 4. Install paper path or pedestal top cover. Load paper. Power on the printer. Run the “All Black” print test for 1/4 page. If the message appears, replace the CMX controller board.
Chapter 3 Troubleshooting Procedures 2. Check the platen open pulley and the platen pulley for looseness. Bottom out the platen open motor pulley on the motor shaft and torque the 1/16 inch set screw to 9 ± 2 inch-pounds (1.02 ± 0.23 N•m). Tighten the 7/64 inch setscrew in the platen shaft pulley, then open and close the forms thickness lever and check that the platen pulley setscrew does not hit the left ribbon guide. 3. Check the condition and tension of the platen open belt.
The Procedures RIB INVLD CMD* Message 1. Ribbon Invalid Command. Firmware error on the CMX controller board. Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130). 2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board. RIB INVLD STATE* Message 1. Ribbon Invalid State. Firmware error on the CMX controller board. Cycle power. Run the print job again.
Chapter 3 Troubleshooting Procedures 5. Observe ribbon movement at both left and right ribbon posts as the metal end strip crosses each ribbon post. If the metal strip moves past either post without reversing the direction of the ribbon, power down the printer. Remove the paper path or pedestal top cover. Reseat connectors P106/LRP and P107/ RRP on the CMX controller board. 6.
The Procedures SECURITY CODE VIOLATION Message 1. Security code of the PAL on the CMX controller board does not match the code of the firmware on the CMX controller board. Remove the paper path or pedestal top cover. Check that the security PAL is correctly installed. Install correct PAL for the customer’s emulations with the notched end facing toward the flash and DRAM SIMM sockets. 2. Run a print test. If the message appears, replace the CMX controller board.
Chapter 3 Troubleshooting Procedures 6. Check continuity of the shuttle motor drive cable assembly. Replace shuttle motor drive cable assembly if it fails continuity test. 7. Power up the printer. Run a Shuttle Slow or Shuttle Fast test. If the shuttle does not move, replace the shuttle frame assembly. 8. Power up the printer. Run a Shuttle Slow or Shuttle Fast test. If the shuttle does not move, replace the power supply board. 9. Power up the printer. Run a Shuttle Slow or Shuttle Fast test.
The Procedures Clean the shuttle frame assembly and hammer bank cover assembly if you find debris. Replace the hammer bank cover assembly if you find any damage to the ribbon mask or hammer bank cover. 5. Power up the printer. Run a shuttle test. Replace the shuttle frame assembly if it is noisy or rattles. SHUTTLE JAM Message 1. The shuttle is not moving or is moving at the wrong speed. Check the forms thickness lever: if it is set too tightly, it can slow the shuttle enough to trigger the fault message.
Chapter 3 Troubleshooting Procedures If the message appears, replace the shuttle frame assembly. SOFTWARE ERROR* Cycle power Message 1. Application software tried to perform an illegal printer function or damaged logic circuits were detected on the CMX controller board. Cycle power. If the message appears, power off the printer. 2. Disconnect the input data line from the host computer. Power on the printer. If the message appears, download the emulation software again (page 130). 3. Cycle power.
The Procedures 3. Move the elevator up and down by hand and check that the limit switches are being tripped at the highest and lowest limits of elevator travel. Adjust the limit switches, if necessary, by gently bending the contact arms. Replace switches that cannot be adjusted. 4. Power on the printer. Operate the power stacker. (Refer to the Operator’s Guide.
Chapter 3 Troubleshooting Procedures Replace any cable that is damaged or fails continuity test. Reconnect all stacker cables to the CMX controller board, stacker, and stacker control panel. Stacker elevator moves by itself 1. Power off the printer. Inspect all stacker LEDs for dust, chaff, or dirt. (See Figure 81 through Figure 83, page 338 through page 342.) Clean the stacker LEDs and the sight tubes in the LED mounts. 2. Power on the printer.
The Procedures STACKER FULL Message 1. Status message: the power paper stacker is full. Unload the stacker. 2. Check the stacker limit switches. (See page 83.) If the limit switches are OK, go to the next step. 3. Power off the printer. Remove the paper path. Disconnect stacker cables from the CMX controller board, stacker assembly, and the stacker control panel (see Figure 59, page 313). Check cables for cuts, breaks, or damaged pins. Check continuity of cables. (See Appendix A.
Chapter 3 Troubleshooting Procedures other troubleshooting procedures. When you have completed this procedure, return to the procedure that sent you here. 1. Power off the printer. Open the rear cabinet door. Unload the power stacker. Move the elevator up and down by hand, checking that it moves smoothly and without chattering or shuddering. Eliminate causes of chattering or shuddering. (E.g., loose, damaged, or broken constant force springs, bent or misaligned rails, obstructions, etc.
The Procedures TABLE MISMATCH DOWNLOAD AGAIN Message 1. This message indicates that an EC software update is in process. Power off the printer. Download the program again from the beginning (page 130). TCB CORRUPTED* Message 1. Task Control Block Corrupted. Firmware error on the CMX controller board. Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130). 2. Cycle power. Run the print job again.
Chapter 3 Troubleshooting Procedures UNDEF INTERRUPT* Message 1. Undefined Interrupt. Firmware error on the CMX controller board. Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130). 2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board. UNDFNED OPCODE* Message 1. Undefined Opcode. Firmware error on the CMX controller board. Cycle power.
The Procedures Hold the collar snug against the motor pulley and torque the 7/64 inch setscrew to 25 ± 2 inch-pounds (2.82 ± 0.23 N•m). 3. Check the condition and tension of the paper feed timing belt. Adjust the paper feed timing belt. Replace the belt if it is damaged. 4. Check the platen gap. Adjust the platen gap. 5. Inspect the tractors and tractor door springs for damage or excessive wear. If either tractor is damaged or excessively worn, replace both tractor assemblies. 6.
Chapter 3 Communications Failures Communications Failures Many host-printer communications problems are complex. With the exception of a defective interface cable, most communications problems are not a result of a hardware failure. They usually result from an incompatible configuration of the host computer system, network (LAN, print server, controller, multiplexer, etc.), or the printer. Sometimes the print application program itself is at fault.
The Procedures Diagnostic Printer Tests A set of printer tests is included in the configuration menu structure for use as diagnostic tools. Use these printer tests to check the print quality and basic operation of the printer. You will also use some of the tests in some adjustment procedures. The diagnostic printer tests are summarized below: • Shift Recycle — A “sliding” alphanumeric pattern useful for identifying missing or malformed characters, improper vertical alignment, or vertical compression.
Chapter 3 Diagnostic Printer Tests Selecting and Running Diagnostic Printer Tests NOTE: You must set TOF after running any diagnostic test. Step Press LCD Result 1. Make sure the printer is on. Raise the printer cover. 2. Load paper. 3. Set TOF. (Refer to the User’s Manual.) 4. ON LINE 5. + Notes OFFLINE CONFIG. CONTROL The printer must be offline to run a print test. ENTER SWITCH UNLOCKED Unlocks ENTER key and control panel. OFFLINE CONFIG. CONTROL 6. UNTIL 7. 8.
Selecting and Running Diagnostic Printer Tests Step Press LCD Result Notes 16. ENTER Printer Tests All E’s* Starts test. 17. ENTER Printer Tests All E’s* Stops test. ENTER SWITCH LOCKED Locks the ENTER key and control panel. ONLINE LinePrinter+ Places the printer in on-line mode. 18. + 19. ON LINE 20. Examine print quality. Characters should be fully formed and of uniform density. 21. Set TOF. (Refer to the User’s Manual.
Chapter 3 Boot Diagnostics Menu Boot Diagnostics Menu Printer boot-up software contains a “Boot Diagnostics” menu that you can access by holding down two keys while powering on the printer. This menu is not intended for the end user, but provides useful information for manufacturing and maintenance personnel. The boot diagnostics menu is a multi-level menu that operates the same way as the user menus. The menu structure is shown in Figure 8 on page 93. Activating the Boot Diagnostics Menu 1.
Selecting and Running Diagnostic Printer Tests NOTE: To exit this menu, cycle power. BOOT DIAGNOSTICS PRESS ENTER >= DOWN key <= NEXT key ENTER < BOOT DIAGNOSTICS VERSION CHECK > VERSION CHECK BOOT VERSION < VERSION CHECK SOFTWARE VERSION ENTER < VERSION CHECK EC VERSION ENTER VERSION CHECK P.C. BOARD VERSION < VERSION CHECK SECURITY PART # ENTER ENTER VX VERSION=F MECA VERSION=F VERSION CHECK PROCESSOR SPEED ENTER P.C. BOARD VERSION 3.
Chapter 3 Boot Diagnostics Menu NOTE: To exit this menu, cycle power. A >= DOWN key <= NEXT key BOOT DIAGNOSTICS MISC UTILITIES From previous page > MISC UTILITIES DISPLAY MEMORY < MISC UTILITIES RESET PRINTER ENTER MISC UTILITIES COPY FLASH SIMMS ENTER RESETTING...
Selecting and Running Diagnostic Printer Tests Hex Code Printout A hex code printout (or “hex dump”) prints every ASCII data character received from the host computer, and lists its corresponding two-digit hexadecimal code. (See Figure 9 below.) You can use hex dumps as an aid in troubleshooting data reception problems. In a hex dump every printable character is printed both as its assigned symbol and as its hex equivalent. Every unprintable (ASCII control) character is printed out as a period (.
Chapter 3 Hex Code Printout How to Print a Hex Dump Step 1. 2. Press LCD Result Notes Make sure the printer is on. Raise the printer cover. ON LINE 3. + OFFLINE CONFIG. CONTROL ENTER SWITCH UNLOCKED Unlocks ENTER key and control panel. OFFLINE CONFIG. CONTROL 4. UNTIL 5. MAINT / MISC Hex Dump Mode 6. Hex Dump Mode Disable* Default Hex Dump Mode Enable Cycle through choices. Hex Dump Mode Enable* Asterisk (*) indicates choice is active.
How to Print a Hex Dump ASCII Character Set B7 0 B6 KEY B6 0 0 B5 BITS 0 0 1 B4 B3 B2 B1 1 0 B7 0 B5 BITS 0 1 0 1 1 OCTAL equivalent DECIMAL equivalent HEX equivalent ASCII Character Name 33 27 1B ESC 1 0 1 0 1 0 1 1 0 0 1 1 1 1 0 1 1 COLUMN 0 B4 B3 B2 B1 ROW 1 0 0 0 0 0 NUL 0 0 0 0 0 0 1 1 SOH 1 1 1 0 0 1 0 2 STX 2 2 2 DC2 0 0 1 1 3 ETX 3 3 3 0 1 0 0 4 EOT 0 1 0 1 5 0 1 1 0 DLE DC1 (XON) 2 20 16 10 21 17 11 SP ! 3 40 32 20 41 33 21 4
Chapter 3 Soft vs. Hard Reset Soft vs. Hard Reset Soft Reset A soft(ware) reset clears printer memory then loads the power-up configuration set by the user. (If no power-up configuration has been set by the user, the factory default configuration is loaded.) It is called a soft reset because no hardware is tested. All diagnostic and initialization tests are bypassed and memory is simply refreshed with the power-up printer configuration. The printer must be off-line to do a soft reset: 1.
CMX Controller Board Handshake Sequences The Power On Sequence This section describes the normal sequence of events from the time the power switch is set to 1 until ONLINE (or OFFLINE, if so configured by the user) appears on the LCD. Use this sequence as a reference baseline to help you isolate problems that occur before the printer completes its boot and initialization routines. The power on sequence consists of two sets of routines: 1.
Chapter 100 3 The Power On Sequence • Read Control Panel Keys — The control panel keys are read to determine if the user is requesting that the printer be placed in download mode, diagnostic mode, or debug SIMM disabled. If ON LINE and PAPER ADVANCE are pressed during start-up, the printer is placed in download mode. If ; (PREV) and > (DOWN) are pressed during start-up, the printer is placed in diagnostic mode. If any other combination of keys are pressed, the debug SIMM is disabled.
CMX Controller Board Handshake Sequences • Check for Pedestal — Boot code uses the control panel to determine if the printer is a pedestal or floor cabinet model. Boot code needs to know the difference so the exhaust fan fault can be disabled on a pedestal model. “FAN DISABLED” is printed out at the debug serial port of a pedestal model. • Check for Download Mode — Boot code checks whether the ON LINE and PAPER ADVANCE keys were pressed at power up. If so, the printer enters download mode.
Chapter 3 The Power On Sequence detected, boot codes displays “ERROR: SECURITY PAL NOT DETECTED”. If a security PAL is detected, boot code checks for the presence of NVRAM. If NVRAM is not found, boot code displays “ERROR: NVRAM FAILURE”. 102 • Test for Powerup File — Boot code checks for a DC executable file called powerup.sbr. If found, it executes the file, then returns to boot routines. If the file is not found, boot routines are resumed.
DC Software Initialization and Power Up • Jump to MTOS — Jump to start initialization of the MTOS (Multi–Tasking Operating System).
Chapter 104 3 The Power On Sequence
4 Adjustment Procedures Introduction The printer is a durable, low-maintenance machine, but some components and systems require occasional adjustment. Usually, you will be referred to this chapter by a troubleshooting procedure, or as part of a removal/installation procedure.
Chapter 4 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. IMPORTANT Do not attempt field repairs of electronic components or assemblies.
Returning the Printer to Normal Operation When you are finished servicing the printer, do the following steps: 1. Install the ribbon. 2. Load paper. 3. Connect the data (signal) cable to the printer interface. 4. Plug the AC power cord into the printer and the power source. 5. Close the cabinet doors. 6. Set the printer power switch to | (on). 7. Test printer operation by selecting and running one of the operator print tests. (See page 89.) 8. Select the emulation. (Refer to the User’s Manual.) 9.
Chapter 4 Belt, Paper Feed Timing, Adjustment (Figure 10) Belt, Paper Feed Timing, Adjustment (Figure 10) 1. Prepare the printer for maintenance (page 106). 2. Cabinet Models: Remove the paper path (page 177). Pedestal Models: Remove the top cover assembly (page 161). 3. Cabinet Models: Loosen four screws and remove the barrier shield. (See page 214, items 3, 4 and 9.) Pedestal Models: Loosen the four screws securing the paper guide and barrier shield and remove both. (See page 216, items 3, 4, and 5.
$ Direction of Force 4 2 1 $ 3 2 Legend: 1) 2) 3) 4) Timing Belt Shield Motor Mount Bolt (2) Paper Feed Drive Motor Splined Shaft Figure 10.
Chapter 4 Belt, Platen Open, Adjustment (Figure 11) Belt, Platen Open, Adjustment (Figure 11) 1. Prepare the printer for maintenance (page 106). 2. Cabinet Models: Remove the paper path (page 177). Pedestal Models: Remove the top cover assembly (page 161). 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. 4. Loosen the two 5/16 inch motor mount screws (2) enough to permit movement of the platen open motor.
$ 2 $ Direction of Force 1 3 2 Legend: 1) 2) 3) Belt Cover Motor Mount Screw (2) Platen Open Motor Shaft Figure 11.
Chapter 4 Paper Drive Motor Pulley Alignment (Figure 12) Paper Drive Motor Pulley Alignment (Figure 12) 1. Prepare the printer for maintenance (page 106). 2. Cabinet Models: Remove the paper path (page 177). Pedestal Models: Remove the top cover assembly (page 161). 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. 4. Loosen the 7/64 inch screw (2) in the motor pulley collar (3). 5.
$ 5 2 1 $ 3 Legend: 1) 2) 3) 4) 5) Belt Shield Cap Screw Motor Pulley Collar Motor Pulley Splined Shaft Pulley Figure 12.
Chapter 4 Paper Scale Alignment (Figure 13) Paper Scale Alignment (Figure 13) 1. Open the printer cover. 2. Load paper and ribbon. 3. Connect the power cord to the AC power source. 4. Set the printer power switch to 1 (on). 5. Verify that the shuttle cover (1) is properly installed (page 160). 6. Print a full 136 column line by selecting and running one of the diagnostic self-tests. (See page 89.) 7. Check alignment of the scale to the print at column positions 1 and 136. 8.
2 3 2 2 1 Legend: 1) 2) 3) Shuttle Cover Screw, Button-Head, 5/64 inch hex (3) Paper Scale Figure 13.
Chapter 4 Platen Gap Adjustment (Figure 14) Platen Gap Adjustment (Figure 14) IMPORTANT Only do this procedure if the original equipment shuttle frame assembly or platen has been replaced by a new or refurbished unit. 1. Prepare the printer for maintenance (page 106). 2. Remove the shuttle cover assembly (page 160). 3. Loosen the platen open belt (page 110, steps 2, 3, and 4). 4. Raise the forms thickness lever (1) to the fully open position.
$ 1 NOTE: Left side adjustment shown. Right side is the same. 5 2 3 4 $ Legend: 1) 2) 3) 4) 5) Forms Thickness Lever Feeler Gauge Hammer Bank Cover Ribbon Mask Set Screw, 3/32 inch hex (2) Figure 14.
Chapter 4 Platen Open Motor Pulley Alignment (Figure 15) Platen Open Motor Pulley Alignment (Figure 15) 1. Prepare the printer for maintenance (page 106). 2. Cabinet Models: Go to step 3. Pedestal Models: Remove the top cover assembly (page 161). 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. 4. Loosen the 1/16 inch set screw (2) in the motor pulley. 5.
$ 2 $ 1 3 4 Legend: 1) 2) 3) 4) Belt Cover Set Screw Platen Open Motor Pulley Platen Shaft Pulley Figure 15.
Chapter 4 Ribbon Guide Alignment (Figure 16) Ribbon Guide Alignment (Figure 16) 1. Open the printer cover. 2. Load paper and install the ribbon. To align a ribbon guide, wind the ribbon fully onto the ribbon spool on the opposite side. For example, to align the left ribbon guide, wind the ribbon until the right ribbon spool is full. 3. Check ribbon tracking by running a ribbon and shuttle diagnostic self-test. (See Chapter 3.) 4.
$ % $ Left Ribbon Guide Right Ribbon Guide % 1 2 Early Models 3 4 2 Later Models 3 4 1 Legend: 1) 2) 3) 4) Screw, Skid (2) Ribbon White Nylon Washer Screw, Retaining (2) Figure 16.
Chapter 4 Splined Shaft Skew Adjustment (Figure 17) Splined Shaft Skew Adjustment (Figure 17) If lines of print are not parallel with the perforations on the paper, perform the following adjustment. 1. Open the printer cover. 2. Loosen the screw (1) securing the adjusting link (2). 3. Adjust the link (2) by raising or lowering the horizontal adjustment knob (3) to obtain print parallel with paper perforations. Tighten the screw (1). 4. Return the printer to normal operation (page 107).
1 3 2 Legend: 1) 2) 3) Screw Adjusting Link Horizontal Adjustment Knob Figure 17.
Chapter 4 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. You will use the dot row patterns printed by the Paper Out Adjustment test to verify that this parameter is set correctly.
Page Perforation Page Perforation 4 in. Cut out here 4 in. Page Perforation Figure 18.
Chapter 4 Paper Out Adjustment 7. On the control panel, press the = + > keys to unlock the ENTER key. “ENTER SWITCH UNLOCKED” briefly displays. (If “LOCKED” displays, simply press = and > again. This is the default key combination. The lock/ unlock key combination can be programmed by the user. If = + > does not unlock ENTER, get the combination from the user.) 8. Press the ; key. “DIAGNOSTICS” displays. 9. Press >. “DIAGNOSTICS / Printer Tests” displays. 10. Press >. “SHIFT / RECYCLE” displays. 11.
21. Press >. The number of dots will move up to the top line of the display with an asterisk (*) next to it. 22. Using the < or ; key, adjust the XX DOTS value up or down by the number of dots you counted in step 14. (If the comb pattern stopped short of the perforation, increase the number of dots. If the comb pattern printed beyond the perforation, decrease the number of dots.) 23. Press ENTER to select the new number of dots as the active value.
Chapter 4 Hammer Phasing Adjustment Hammer Phasing Adjustment You must check and adjust hammer phasing if the CMX 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. The phase value numerical units are relative; they do not represent a physical measurement or value. Thus there is no “correct” value or range.
Needs Adjustment Correct Needs Adjustment 12. Press >: The current phase index displays. Press > again: An asterisk (*) appears next to the phase value. 13. Press < to increase or ; to decrease the phasing index value, then press ENTER to activate the value as it prints. Continue to increase or decrease the phasing index until the pattern of H’s is acceptable. 14. Press = twice: “Printer Tests / Phase Printer” displays. 15. Press ENTER to stop the test. 16. Press CLEAR. “OFFLINE / CONFIG.
Chapter 4 Loading Flash Memory from One Diskette Loading Flash Memory from One Diskette Flash memory is contained in SIMMs (single in-line memory modules) located on the controller board.
9. Power on the computer. 10. Insert the emulation or upgrade diskette into diskette drive A (or B) of the computer. 11. Make the diskette drive the active drive by typing the following at the DOS prompt: A: (If the diskette is in drive B, type B:) 12. Get the name of the compressed file on the diskette by listing the contents of the diskette; at the DOS prompt type: DIR The compressed file on the diskette takes the form FILENAME.
Chapter 4 Loading Flash Memory from One Diskette commands must match the selection you made in step 16. If you are loading the file through the printer serial port, enter the following DOS commands: MODE COM1:9600,N,8,1,P FILENAME.EXE -pbc1 19. While the file is copied into memory, the printer LCD informs you of the load process and status. (See Table 5: below.) 20.
Table 5: Flash Memory Message Guide Message Explanation Required Action ERROR: FLASH DID NOT PROGRAM The printer encountered an error trying to program flash memory. Download the program again: Power off the printer and start over at step 13. If the message occurs again, replace the flash memory. ERROR: FLASH NOT DETECTED The printer could not find any flash memory. Install flash memory before trying to download this program, or reseat the SIMMs if they are present.
Chapter 4 Loading Flash Memory from One Diskette Table 5: Flash Memory Message Guide Message Explanation Required Action ERROR: WRONG CHECKSUM The printer received the complete program but the checksum did not match. The data were corrupted during download. Download the program again: Power off the printer and start over at step 13. ERROR OCCURRED FLUSHING QUEUES * An interim message that displays while the printer discards host data it cannot use because a fault condition exists.
Loading Flash Memory from Multiple Diskettes Flash memory is contained in SIMMs (single in-line memory modules) located on the controller board.
Chapter 4 Loading Flash Memory from Multiple Diskettes 7. Connect the data cable to the appropriate I/O port of the printer. 8. Plug the AC power cord into the printer. 9. Power on the computer. 10. Create a directory on your computer hard drive where you will store the recombined files from the emulation diskettes by typing the following at the DOS prompt: MD DOWNLOAD 11. Make the newly created directory the “active” directory by typing the following at the DOS prompt: CD DOWNLOAD 12.
21. On the printer control panel, press and hold down the ON LINE + PAPER ADVANCE keys. Without releasing the keys, power the printer on. Continue holding the ON LINE and PAPER ADVANCE keys down. 22. When you see “WAITING FOR PROGRAM DOWNLOAD” on the LCD, release the ON LINE and PAPER ADVANCE keys. NOTE: The port default is CENTRONICS; this is the standard load through the parallel port. If you want to use the default, continue at step 18. 23.
Chapter 4 Loading Flash Memory from Multiple Diskettes 31. Power off the computer. 32. If you had to install a data cable to the computer and printer in step 6, disconnect it from the computer and printer. 33. Reconnect the customer’s data input cable(s) to the printer, if required. 34. Return the printer to normal operation (page 107). 35. Using the configuration printout(s) you made in step 1, reconfigure the printer. (Refer to the User’s Manual.
Table 6: Flash Memory Message Guide Message Explanation Required Action ERROR: NVRAM FAILURE The non-volatile memory has failed. Replace the CMX controller board. (Do NOT attempt to replace NVRAM.) ERROR: PROGRAM NEEDS MORE DRAM The printer requires more DRAM memory in order to run the downloaded program. Add DRAM or use a smaller emulation program. ERROR: PROGRAM NEEDS MORE FLASH The printer requires more flash memory in order to run the downloaded program.
Chapter 4 Loading Flash Memory from Multiple Diskettes Table 6: Flash Memory Message Guide Message Explanation Required Action LOADING PROGRAM INTO FLASH The printer has deleted the previous program from flash memory and is loading the new program into flash memory. None PLEASE WAIT... RESET IN PROGRESS The printer finished loading the program into flash memory and is automatically resetting itself. None RESTORING BOOT CODE Normal download initialization message.
Set Shuttle Speed IMPORTANT Do this procedure if you replaced the CMX controller board and/or the shuttle frame assembly in a 475 or 500 lpm printer. Do not do this procedure if you removed and reinstalled the original CMX board or shuttle frame assembly from a 475 or 500 lpm printer as part of other maintenance tasks. Do not do this procedure on 800, 900, 1000, 1200, 1400, or 1500 lpm printers. Do not do this procedure on Kanji/Hanzi printers. 1. Raise the printer cover. 2. Power on the printer. 3.
Chapter 142 4 Set Shuttle Speed
5 Replacement Procedures and Illustrated Parts Lists Organization of This Chapter This chapter is divided into two sections. • Section I: Replacement Procedures Written procedures for removing and installing components that are replaceable at the field service level of maintenance. The replacement procedures refer you to the illustrations in Section II. Section I begins on page 144. • Section II: Illustrated Parts Lists Drawings of all electrical and mechanical assemblies in the printer.
Chapter 5 Section I: Replacement Procedures Section I: Replacement Procedures WARNING Unplug the printer power cord from the printer or power outlet before doing any maintenance procedure. Failure to remove power could result in injury to you or damage to equipment. Only apply power during maintenance if you are instructed to do so in a maintenance procedure. IMPORTANT The components specified in this chapter are field replaceable units (FRUs). FRUs must be repaired at the factory.
List of Removal/Installation Procedures Paper Path page 177 Platen page 178 Platen Open Motor page 182 Power Supply Board page 184 PrintNet Ethernet Interface Assemblies page 185 Resistors, Terminating page 190 Ribbon Drive Motor page 192 Ribbon Guide Assembly (L/R) page 193 Ribbon Hub page 194 Shaft, Splined page 195 Shaft, Support page 197 Shuttle Frame Assembly page 198 Spring Assembly, Gas page 200 Spring, Extension, Hammer Bank page 201 Switch Assembly, Paper Detector page
Chapter 5 Section I: Replacement Procedures Belt, Paper Feed Timing Removal 1. Prepare the printer for maintenance (page 106). 2. Cabinet Models: Remove the paper path (page 177). Pedestal Models: Remove the top cover assembly (page 161). 3. Cabinet Models: Loosen four screws and remove the barrier shield. (See page 214, items 3, 4, and 9.) Pedestal Models: Loosen four screws and remove the paper guide and barrier shield. (See page 216, items 3, 4, and 5.) 4.
Belt, Platen Open Belt, Platen Open Removal 1. Prepare the printer for maintenance (page 106). 2. Cabinet Models: Remove the paper path (page 177). Pedestal Models: Remove the top cover assembly (page 161). 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 228, item 24). 4. Loosen (do not remove) the two 5/16 inch mounting screws of the platen open motor (page 230, item 15). 5.
Chapter 5 Section I: Replacement Procedures Circuit Breaker Removal 1. Prepare the printer for maintenance (page 106). 2. Remove the card cage fan (page 164). 3. Disconnect the four circuit breaker electrical leads. (Cabinet Models: See page 232. Pedestal Models: See page 218.) 4. Press in on the spring clips and remove the circuit breaker from the printer. Installation 1. Press the circuit breaker into the cutout until the spring clips snap into place. (Cabinet models: See page 232.
Connector Shells Connector Shells Some of the cable connectors in the printer are grouped inside connector shells. The procedure below explains how to remove and install cable assemblies from any connector shell in the printer. NOTE: There is also a diagram of the P106 and P107 connector shells on the plastic cover over the power supply. Removal 1. Prepare the printer for maintenance (page 106). 2. Cabinet Models: Remove the paper path (page 177). Pedestal Models: Remove the top cover assembly (page 161).
Chapter 5 Section I: Replacement Procedures P106 Connector Configuration 2 4 6 8 10 12 P107 Connector Configuration 14 16 18 20 LRIB M LRP PMD PLAT M CCF POD 1357 9 11 13 15 17 19 CCF = Card Cage Fan LRIB M = Left Ribbon Motor LRP = Left Ribbon Guide PLAT M = Platen Open Motor PMD = Paper Motion Detector (Switch) POD = Paper Out Detect (Switch) Pin No.
Connector Stiffening Clips Connector Stiffening Clips Later model printers have connector stiffening clips on CMX board connectors P106 and P107. The clips are also available in a field kit for installation on earlier models. The clips stiffen connectors P106 and P107 and help prevent accidental removal of wires when the connector shells are disconnected from the CMX board. Removal 1. Prepare the printer for maintenance (page 106). 2. Cabinet Models: Remove the paper path (page 177).
Chapter 5 Section I: Replacement Procedures P107 $ P106 $ Stiffening Clip Connector Shell Figure 20.
Control Panel Assembly, Cabinet Models Control Panel Assembly, Cabinet Models Removal 1. Prepare the printer for maintenance (page 106). 2. Disconnect RJ11 connector P310 from connector J310 on the control panel. 3. Loosen four screws securing the control panel to the control panel bracket. (See page 210, item 1.) 4. Remove the control panel assembly from the keyways in the control panel bracket. Installation 1.
Chapter 5 Section I: Replacement Procedures Control Panel Assembly, Pedestal Models Removal 1. Prepare the printer for maintenance (page 106). 2. Open the printer cover. 3. Loosen the four captive screws until the control panel is released from the printer top cover. (See page 212, item 2.) 4. Remove the two 5/16 inch screws securing the control panel ground straps. (See page 212, item 11.) 5. Lift the control panel and disconnect the RJ11 cable connector from the control panel assembly. 6.
Controller Board (CMX) Controller Board (CMX) Removal CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle circuit boards. 1. Make a configuration printout of all saved configurations. (Refer to the User’s Manual.) 2. Prepare the printer for maintenance (page 106). 3. Cabinet Models: Remove the paper path (page 177). Pedestal Models: Remove the top cover assembly (page 161). 4.
Chapter 5 Section I: Replacement Procedures 5. Install the expansion-CT board, if necessary (page 162). Install the PrintNet Ethernet interface assembly, if necessary (page 185). 6. Cabinet Models: Install the paper path (page 177). Pedestal Models: Install the top cover assembly (page 161). IMPORTANT If the original CMX board was replaced, you must download the emulation software again. Installing flash memory from the old board onto the new board does not transfer all operating system software. 7.
Cover Assembly, Hammer Bank / Ribbon Mask Cover Assembly, Hammer Bank / Ribbon Mask Removal 1. Prepare the printer for maintenance (page 106). 2. Remove the shuttle frame assembly (page 198). 3. Early models: Lift the thick plate of the hammer bank cover assembly at one end, and peel the cover away from hammer bank magnets. (See Figure 21.) 4. Later models: a. Using a Torx T-10 driver, remove the six screws and three ribbon mask clamp plates securing the ribbon mask to the hammer bank cover.
Chapter 5 Section I: Replacement Procedures Installation CAUTION The hammer bank contains a strong magnet. To prevent damage to the hammer tips, do not let the steel hammer bank cover assembly of early models snap into place as the hammer bank magnet attracts it. Any impact of the cover against the hammer bank can break hammer tips. 1. Early models: a. With the thick plate facing the hammer bank, engage the bottom edge of the hammer bank cover assembly on the alignment pins.
Cover Assembly, Hammer Bank / Ribbon Mask Early Models Hammer Bank Cover (Thick Plate) Ribbon Mask (Thick Plate) Hammer Bank Cover Assembly Later Models Ribbon Mask Torque Sequence 4 3 1 2 Ribbon Mask Clamp Plate (3) Hammer Bank Cover 5 6 Screw (6) Screw (12) Hammer Bank Cover Torque Sequence 9 5 1 3 7 11 10 6 2 4 8 12 Figure 21.
Chapter 5 Section I: Replacement Procedures Cover Assembly, Shuttle Removal 1. Prepare the printer for maintenance (page 106). 2. Loosen the shuttle cover screws (page 214, item 2). 3. Grasping the edges of the shuttle cover assembly, tilt the rear edge up and lift the shuttle cover assembly out of the printer. Installation 1. Place the shuttle cover assembly in the printer. Tilt the forward edge of the cover down slightly and work the cover into position.
Cover Assembly, Top, Pedestal Models Cover Assembly, Top, Pedestal Models Removal 1. Prepare the printer for maintenance (page 106). 2. Loosen, but do not remove, the two #2 Phillips hold-down screws on the rear of the printer. (See page 212, item 5.) 3. Open the printer cover. 4. Loosen the four captive #1 Phillips screws until the control panel is released from the printer top cover. (See page 212, items 1 and 2.) Set the control panel assembly on the shuttle cover assembly. 5.
Chapter 5 Section I: Replacement Procedures Expansion-CT Removal CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle circuit boards. 1. Prepare the printer for maintenance (page 106). 2. Cabinet Models: Remove the paper path (page 177). Pedestal Models: Remove the top cover assembly (page 161). 3. Loosen, but do not remove, the two screws securing the coax/twinax I/O plate to the rear of the card cage.
Fan Assembly, Cabinet Exhaust Fan Assembly, Cabinet Exhaust NOTE: This procedure applies only to cabinet models. Removal 1. Prepare the printer for maintenance (page 106). 2. Open the front and rear cabinet doors and the printer cover. 3. Remove the paper fence/paper tray assembly. (See page 208.) 4. Remove the two 1/4 inch screws securing bottom of the air exhaust duct. (See page 210, item 4). 5. Remove the 1/4 inch screw directly below the forms thickness lever. 6.
Chapter 5 Section I: Replacement Procedures Fan Assembly, Card Cage Removal 1. Prepare the printer for maintenance (page 106). 2. Cabinet Models: Remove the paper path (page 177). Pedestal Models: Remove the top cover assembly (page 161). 3. Disconnect the card cage fan cable connector. (See page 230.) 4. Cabinet Models: Remove the two fan mounting screws from the bottom of the fan. (See page 230, item 2.) Pedestal Models: Remove the four fan mounting screws and nut. (See page 218, items 1 through 4.) 5.
Fan Assembly, Hammer Bank Fan Assembly, Hammer Bank Removal 1. Prepare the printer for maintenance (page 106). 2. Remove the shuttle cover assembly (page 160). 3. Cabinet Models: Remove the paper path (page 177). Pedestal Models: Remove the top cover assembly (page 161). 4. Trace the hammer bank fan cable assembly back to the controller board connector P107, releasing it from all cable constraints. (See the cable routing diagrams in Appendix A.) 5.
Chapter 5 Section I: Replacement Procedures Hammer Spring Assembly Removal 1. Prepare the printer for maintenance (page 106). 2. Remove the shuttle frame assembly (page 198). 3. Carefully vacuum the shuttle frame assembly. 4. Remove the hammer bank cover assembly (page 157). CAUTION Hammer springs and hammer tips are fragile. Do not touch the hammer springs or tips. Handle hammer spring assemblies by the thick mounting base only. Apply pressure only to the mounting base. 5.
Hammer Spring Assembly Hammer Spring Assembly 7 NOTE: P5005 hammer bank and hammer spring assemblies are shown here. Although hammer spring assemblies vary, removal and installation are the same for all models. Hammer Spring Assembly 1 Discard old screws. Figure 22.
Chapter 5 Section I: Replacement Procedures Installation 1. Using a clean dry cloth, wipe the hammer spring mounting surface on the hammer bank. Make sure the cloth does not leave lint on the hammer bank. CAUTION Hammer springs and hammer tips are fragile. Do not touch the hammer springs or tips. Handle hammer springs by the thick mounting base only. Apply pressure only to the mounting base. 2.
Hammer Spring Assembly NOTE: P5005 hammer bank and hammer spring assemblies are shown here. Although hammer spring assemblies vary, removal and installation are the same for all models. Use new screws from the kit. Torque the screws to 14 inch-pounds (1.58 Newtonmeters). New Hammer Spring Assembly Figure 23.
Chapter 5 Section I: Replacement Procedures Magnetic Pickup (MPU) Assembly Removal 1. Prepare the printer for maintenance (page 106). 2. Remove the shuttle cover (page 160). 3. Disconnect the magnetic pickup (MPU) cable connector (page 224, item 5). 4. Loosen the 7/64 inch hex MPU clamp screw (page 224, item 3). 5. Unscrew the MPU assembly from the MPU bracket. Installation 1. Install the MPU assembly by screwing it into the MPU bracket. (See Figure 38, page 224). 2.
Memory Modules and Security PAL Memory Modules and Security PAL CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle memory modules and circuit boards. Removal 1. Make a configuration printout of all saved configurations. (Refer to the User’s Manual.) 2. Prepare the printer for maintenance (page 106). 3. Cabinet Models: Remove the paper path (page 177). Pedestal Models: Remove the top cover assembly (page 161). 4.
Chapter 5 Section I: Replacement Procedures Security PAL Number Emulation 1 2 3 4 CT/IPDS/PGL/LP+ ä CT/IPDS/VGL/LP+ ä 5 6 Installation CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle memory modules and circuit boards. NOTE: Flash SIMMs from one CMX controller board must be placed in the same slot on a replacement CMX controller board.
Memory Modules and Security PAL CMX Controller Board Bank 1 Bank 0 Bank 1 Bank 0 Notched End Notch 1 2 Latch Security PAL Flash: DRAM: 80-pin SIMM J11 = Bank 0 (must always be filled) 72-pin SIMM J16 = Bank 0 (must always be filled) J10 = Bank 1 Reserved for upgrades J15 = Bank 1 Reserved for upgrades If 1 Flash SIMM, use Bank 0 If 1 DRAM SIMM, use Bank 0 If 2 Flash SIMMs, use both If 2 DRAM SIMMs, use both banks but put pre-programmed banks (It does not matter which SIMMs in J11 SIMM goes
Chapter 5 Section I: Replacement Procedures Paper Feed Motor Removal 1. Prepare the printer for maintenance (page 106). 2. Cabinet Models: Remove the paper path (page 177). Pedestal Models: Remove the top cover assembly (page 161). 3. Cabinet Models: Loosen four screws and remove the barrier shield. (See page 214, items 3, 4, and 9.) Pedestal Models: Loosen the four screws and remove the barrier shield and paper guide. (See page 216, items 3, 4, and 5.) 4.
Paper Feed Motor Installation 1. Position the paper feed motor assembly on the right side plate and install the motor mount bolts and nuts finger tight. (See page 230, items 10 and 23.) 2. Connect the paper feed motor cable connector to connector P107, then connect P107 to J107 on the controller board. (See page 150.) 3. Install the collar, paper feed motor pulley, and timing belt. 4. Align the paper feed motor pulley with the splined shaft pulley. IMPORTANT Make sure there is at least 0.040 inches (1.
Chapter 5 Section I: Replacement Procedures Paper Ironer WARNING Over time, the upper edge of the paper ironer can become sharp. To avoid cutting yourself, handle the paper ironer on the sides. Removal 1. Prepare the printer for maintenance (page 106). 2. Remove the shuttle frame assembly (page 198). 3. Move the forms thickness lever to the open position. 4. Push the ends of the paper ironer toward the rear of the printer, disengage the tabs, then lift it up and out (page 228, item 3).
Paper Path Paper Path NOTE: This procedure applies only to cabinet models. Removal 1. Prepare the printer for maintenance (page 106). 2. Loosen the three paper path hold-down screws (page 214, item 6). 3. Slide the paper path to the left and lift it off the card cage. Installation 1. Position the paper path offset slightly to the left on the card cage with the keyway cutouts over the three loosened hold-down screws page 214, Figure 33). 2.
Chapter 5 Section I: Replacement Procedures Platen Removal 1. Prepare the printer for maintenance (page 106). 2. Remove the shuttle frame assembly (page 198). 3. Remove the paper ironer (page 176). 4. Remove the three 1/4 inch screws securing the paper ironer bracket assembly and remove the assembly. (See page 178, items 4, 5, and 6.) 5. Remove the platen open belt (page 147). 6. Remove the platen pulley (page 228, item 21), as follows: a. Loosen the 7/64 inch collar clamp screw. b.
Platen Installation IMPORTANT The dowel pins protruding from the ends of the platen are the platen shafts. The platen shafts are not of equal length. The platen must be installed with the longer shaft on the right side. 1. Wipe the platen shafts clean of grease and debris. 2. Install two washers on the longer (right) platen shaft. (See Figure 25 below.) 3. Apply bearing lubricant to both platen shafts. Platen Shaft (Right Side) Washer Ironer Bracket Washer Platen Adjust Bracket Figure 25.
Chapter 5 Section I: Replacement Procedures Washers Platen Adjust Bracket Platen Mechanism Base Platen Seat Wear Saddle Figure 26. 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 41, items 11, 13, and 14.) 10. Install the forms thickness indicator plate: a. Slide the indicator plate, with the interlock switch assembly attached, onto the platen shaft and up against the right side plate. b.
Platen b. Install and torque three screws to 20 ± 2 inch-pounds (2.26 ± 0.23 N•m). 15. Push the platen to the left. 16. Install the forms thickness lever onto the right side platen shaft, pressing the interlock switch out of the way as the lever slides past it. Tighten the 7/64 inch setscrew. (See page 228.) Open and close the forms thickness lever to make sure the setscrew does not touch the right ribbon guide. 17.
Chapter 5 Section I: Replacement Procedures Platen Open Motor Removal 1. Prepare the printer for maintenance (page 106). 2. Cabinet Models: Remove the paper path (page 177). Pedestal Models: Remove the top cover assembly (page 161). 3. Cabinet Models: Remove the card cage fan (page 164). 4. 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 228, item 24). 5. Loosen the two 5/16 inch motor mount screws (page 230, item 15).
Platen Open Motor Installation 1. Position the platen open motor assembly with the wires toward the rear (page 230, item 5). 2. Install the two 5/16 inch motor mount screws (and nuts, if present) finger tight. 3. Install the platen open belt and motor pulley. Bottom out the motor pulley on the motor shaft and torque the 1/16 inch setscrew to 11 ± 2 inch-pounds (1.24 ± 0.23 N•m). 4. Connect the platen motor cable connector to connector shell P106. 5.
Chapter 5 Section I: Replacement Procedures Power Supply Board WARNING To prevent injury from electric shock, wait at least one minute after shutting off power before removing the power supply board. Do not touch components or flex the board during removal or installation. Handle the board by its sides and always wear a properly grounded static wrist strap when handling the power supply board. Removal 1. Prepare the printer for maintenance (page 106). 2.
PrintNet Ethernet Interface Assemblies PrintNet Ethernet Interface Assemblies NOTE: The PrintNet LAN option is available in one of three configurations: 10Base-T, 10Base2, or 10/100Base-T. These options are available factory installed or as a field kit. Removal and installation is the same for all versions.The functions of the LEDs and DIP switches on the Ethernet Interface boards are described on page 186 and page 188.
Chapter 5 Section I: Replacement Procedures 10Base2 and 10Base-T LEDs and DIP Switches 10Base2 and 10Base-T PrintNet Ethernet interfaces have three LEDs and three DIP switches, as shown below. The indicators and switches are adjacent to the data line connectors. LED patterns are defined in the table below the illustration. Status Indicator LEDs and DIP Switches STAT ERR NET Status Indicators Grn Red Grn OFF DIP Switches 1 2 (Default is all switches OFF, as shown.) 3 Table 7.
10Base2 and 10Base-T LEDs and DIP Switches Run Mode and Auto Reset Mode: Run Mode is the normal operating state of the Ethernet Interface. Auto Reset mode is entered when the watchdog timer is triggered and the Print Server resets itself. In either mode, the STAT LED flashes differently, depending on whether the unit IP address is configured. The Run Mode and Auto Reset Mode indicator descriptions are shown below. Table 8.
Chapter 5 Section I: Replacement Procedures 10/100Base-T LEDs and Dipswitches The 10/100Base-T PrintNet Ethernet interface has two indicator lights, as shown below. STAT NET (System Status) (Data to Network) Run and Auto Reset Modes Run Mode is the normal operating state of this interface. Auto Reset mode is entered when the watchdog timer is triggered and the print server resets itself. In either mode, the STAT LED flashes at a varying rate, depending on whether the unit IP address is configured.
10/100Base-T LEDs and Dipswitches Dipswitches On the back of the 10/100Base-T PrintNet Ethernet interface (inside the printer) are two dipswitches labeled 1 and 2. The functions of these dipswitches are explained in Table 10. Table 10. 10/100Base-T Dipswitch Settings Dipswitch Description 1 2 OFF OFF Normal operation. With both dipswitches in the “OFF” position, the PrintNet interface boots up using the settings in flash memory rather than the default settings. ON OFF Factory default settings.
Chapter 5 Section I: Replacement Procedures Resistors, Terminating For parallel interface configurations, the printer is equipped with 470 ohm pullup terminating resistors and 1K ohm pull-down terminating resistors on the controller board. These are suitable for most applications. (See Figure 27, page 191.) If the standard terminating resistor pack is not compatible with the particular interface driver requirements of the host computer, other values of pull-up and pull-down resistors may be required.
Resistors, Terminating CMX Controller Board RP1 Default: 470 Ohm Alt 1: 220 Ohm Alt 2: 1K Ohm RP2 Default: 1K Ohm Alt 1: 330 Ohm Alt 2: None Figure 27.
Chapter 5 Section I: Replacement Procedures Ribbon Drive Motor Removal 1. Prepare the printer for maintenance (page 106). 2. Remove the ribbon hub (page 194). 3. Remove two screws and washers securing the ribbon drive motor to the base casting. (See page 230, items 18 and 19.) 4. Lift and rotate the ribbon drive motor until the motor cable is aligned with the slot on the base casting. 5. Disconnect the ribbon drive motor cable connector. 6. Remove the ribbon drive motor. Installation 1.
Ribbon Guide Assembly (L/R) Ribbon Guide Assembly (L/R) NOTE: The right ribbon guide is shown exploded in Figure 41 on page 230. The removal procedure is the same for both ribbon guides. Removal 1. Prepare the printer for maintenance (page 106). 2. Cut and remove the tie-wrap from the tie wrap hole to free the ribbon guide cable. (See page 230, item 11.) 3. Cabinet Models: Remove the paper path (page 177). Pedestal Models: Remove the top cover assembly (page 161). 4.
Chapter 5 Section I: Replacement Procedures Ribbon Hub Removal 1. Prepare the printer for maintenance (page 106). 2. Loosen the Torx T-10 screw in the ribbon spool hub (page 230, item 20). 3. Remove the hub from the shaft of the ribbon drive motor. Installation 1. Install the ribbon spool hub over the motor shaft (page 230, item 20). 2. Tighten the Torx T-10 hub screw so that it contacts the flat section of the motor shaft. 3. Return the printer to normal operation (page 107).
Shaft, Splined Shaft, Splined Removal 1. Prepare the printer for maintenance (page 106). 2. Remove the paper supports from the splined shaft and support shaft. (See page 226, item 20.) 3. Remove the paper feed timing belt (page 146). 4. Remove the 1/4 inch screw securing the ground clip, and remove the clip (page 226, items 10 and 11). 5. With grip ring pliers, remove the grip ring from left side of the splined shaft (page 226, item 6). 6.
Chapter 5 Section I: Replacement Procedures Installation 1. Open the doors on the left and right tractors. Position the tractor belts so the alignment marks are at the top on both tractors. (See Figure 28 below.) 2. Grasp the vertical adjustment knob and slide the splined shaft through the right side plate, the tractors, and the left side plate. (See page 226.) Make sure the same spline passes the marked groove on each tractor. 3. Install the bearing clamp and screw. 4.
Shaft, Support Shaft, Support Removal 1. Prepare the printer for maintenance (page 106). 2. Unlock the tractors and slide them to the far right. 3. Remove the paper supports from the splined shaft and support shaft. (See page 226, item 20.) 4. Remove the E-ring (page 226, item 17). NOTE: Hold the tractors while removing the support shaft. Be careful not to lose the curved spring washers. (See page 226, item 5.) 5.
Chapter 5 Section I: Replacement Procedures Shuttle Frame Assembly Removal 1. Prepare the printer for maintenance (page 106). 2. Remove the shuttle cover assembly (page 160). 3. Disconnect the MPU cable connector P03 and shuttle motor cable connector P02 (page 224, items 5 and 6). CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle the shuttle frame assembly. 4.
Shuttle Frame Assembly CAUTION Do not over-tighten the shuttle frame assembly clamp screws. 6. Slide the side clamps over the guide shaft and torque the 5/32 inch socket head clamp screws to 20 ± 2 inch-pounds (2.26 ± 0.23 N•m). 7. Torque the center captive 5/32 inch socket head screw to 20 ± 2 inch-pounds (2.26 ± 0.23 N•m). 8. Connect the hammer drive and hammer logic cable connectors to the terminator board on the shuttle frame assembly. 9. Connect the shuttle motor cable connector.
Chapter 5 Section I: Replacement Procedures Spring Assembly, Gas CAUTION Two persons may be required to do this procedure. Prop or hold the printer cover securely while disengaging the gas spring assembly. NOTE: This procedure applies only to cabinet models. Removal 1. Prepare the printer for maintenance (page 106). 2. Open the cabinet rear door. 3. Pry back the spring retaining clips. (See Figure 31, page 210.) 4. Remove the gas spring assembly from the ball studs.
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 106). 2. Remove the shuttle cover assembly (page 160). 3. Unhook the extension spring from the spring lugs on the hammer bank and shuttle frame. (See page 224, item 4.) Installation 1. Apply a dab of bearing lubricant to both spring lugs.
Chapter 5 Section I: Replacement Procedures Switch Assembly, Paper Detector Removal 1. Prepare the printer for maintenance (page 106). 2. Cabinet Models: Remove the paper path (page 177). Pedestal Models: Remove the top cover assembly (page 161). 3. Cabinet Models: Loosen four screws and remove the barrier shield. (See page 214, items 3, 4, and 9.) Pedestal Models: Loosen the four screws and remove the paper guide and barrier shield. (See page 216, items 3, 4, and 5.) 4.
Switch Assembly, Platen Interlock Switch Assembly, Platen Interlock Removal 1. Prepare the printer for maintenance (page 106). 2. Cabinet Models: Remove the paper path (page 177). Pedestal Models: Remove the top cover assembly (page 161). 3. Fully close the forms thickness lever (position ‘A’). 4. Trace the platen interlock switch cable back to the controller board. Remove tie-wraps as necessary to free the cable. (See cable routing diagrams in Appendix A.) 5.
Chapter 5 Section I: Replacement Procedures Tractor (L/R) Removal 1. Prepare the printer for maintenance (page 106). 2. Remove the support shaft (page 197). 3. Remove the splined shaft (page 195). Installation 1. Using the replacement tractors, install the support shaft (page 197). 2. Install the splined shaft (page 195). 3. Return the printer to normal operation (page 107).
Illustrations of Printer Components Section II: Illustrated Parts Lists NOTE: Only field-replaceable spares are given part numbers in the illustrated parts lists. Part numbers are not listed for common fasteners and attachment hardware. Items marked “Ref” in the illustrations refer to parts that are not spared or are part of another assembly. Illustrations of Printer Components Figure 29. Top Cover, Doors, and Casters (page 206) Figure 30. Paper Fence and Chains (page 208) Figure 31.
Chapter 5 Section II: Illustrated Parts Lists 1 2 8 3 5 4 7 6 Figure 29.
Illustrations of Printer Components Item No. Part No.
Chapter 5 Section II: Illustrated Parts Lists 4 1 9 8 3 5 2 6 7 Figure 30.
Illustrations of Printer Components Item No. Part No. 1 Ref Paper Fence 475 and 500 lpm models and models with power stacker 2 Ref Paper Tray Assembly 800, 900, 1000, 1200, 1400, and 1500 lpm models. (Not used on models with power stacker.
Chapter 5 Section II: Illustrated Parts Lists $ $ 4 1 3 2 5 6 7 4 Figure 31.
Illustrations of Printer Components Item No. Part No. 1 153700-901 Control Panel Assembly Includes mounting hardware 2 152440-901 Cable Assembly, Control Panel Installed with shielding beads: See Appendix E 3 107961-905 Gas Spring Kit Includes ball studs, spring clips, and mounting hardware 4 Ref Screw, w/Lock Washer (2) 6-32x.375 5 Ref Screw, w/Lock Washer (3) 6-32x2.
Chapter 5 Section II: Illustrated Parts Lists 4 10 2 9 1 11 5 6 7 12 13 8 Figure 32.
Illustrations of Printer Components Item No. Part No.
Chapter 5 Section II: Illustrated Parts Lists 5 6 9 4 3 10 12 11 2 1 8 7 Figure 33.
Illustrations of Printer Components Item No. Part No. 1 164295-001 2 Description Notes Shuttle Cover (Shroud Assembly, Air) Ref Screw, Captive (2) 10-24x.62 with O-ring, .125x.250x.06 3 Ref Screw, Thread-forming (2) 6-32x.25 and #6 flat washer 4 Ref Barrier Shield 5 152290-901 6 Ref 7 Paper Path Screw, w/Lock Washer (3) 6-32.25 and #6 flat washer 153488-001 Platen/Paper Feed Cover Kit Paper Feed Belt Cover shown 8 108664-903 Belt, Timing, .080 Pitch, 100 Teeth, .
Chapter 5 Section II: Illustrated Parts Lists 3 5 4 3 6 7 10 See Figure 35, page 218. 2 $ 1 8 7 Figure 34.
Illustrations of Printer Components Item No. Part No. 1 164295-001 2 Description Notes Shuttle Cover (Shroud Assembly, Air) Ref Screw, Captive (2) 10-24x.62 with O-ring, .125x.250x.06 3 Ref Screw, Thread-forming (2) 6-32x.25 and #6 flat washer 4 Ref Barrier Shield 5 154286-001 Paper Path 6 152284-901 Anti-Static Brush Kit 7 154073-001 Power Supply Shield Taped to card cage along upper edge 8 108664-903 Belt, Timing, .080 Pitch, 100 Teeth, .
Chapter 5 Section II: Illustrated Parts Lists $ 1 From Figure 34, page 216. Rotated 180 degrees. 2 3 4 5 To IEC 320 AC Power Input (Connector J301, White Wire) To Connector P1 (White Wire) To Connector P1 (Black Wire) 6 To IEC 320 AC Power Input (Connector J301, Black Wire) Figure 35.
Illustrations of Printer Components Item No. Part No. 1 Ref 2 150261-901 3 Ref Fan Guard 4 Ref Screw, w/Lock Washer (4) 5 Ref Card Cage, Pedestal 6 142013-901 Description Notes Nut, 6-32 (1) Upper right fan corner only Card Cage Fan Assembly Air flow is into card cage 6-32x1.
Chapter 5 Section II: Illustrated Parts Lists Two places: Exploded to show assembly. Do not remove holddown clamps and screws. 14 1 3 To J02 (Shuttle Motor) To J03 (MPU) 15 2 8 5 9 10 4 7 11 15 16 6 12 13 17 18 To Terminator Board on Shuttle Frame Figure 36.
Illustrations of Printer Components Item No. Part No.
Chapter 5 Section II: Illustrated Parts Lists Two places: Exploded to show assembly. Do not remove holddown clamps and screws. 2 14 1 3 4 4 6 To J02 (Shuttle Motor) To J03 (MPU) 18 5 11 8 12 13 7 10 14 18 19 9 15 16 20 21 To Terminator Board on Shuttle Frame Figure 37.
Illustrations of Printer Components Item No. Part No.
Chapter 5 Section II: Illustrated Parts Lists Spring Lug (Do not remove grease) 3 4 Spring Lug (Do not remove grease) CAUTION: Make sure the MPU cable does not touch the extension spring after cable connection. 1 2 6 5 0.010 " .001 inch (0.254 " .025 mm) Figure 38.
Illustrations of Printer Components Item No. Part No. 1 150281-901 2 Ref Bracket, MPU Part of item 1 3 Ref Screw, Socket Cap 6-32x.
Chapter 5 Section II: Illustrated Parts Lists 20 10 4 6 7 8 11 9 21 1 2 3 12 17 5 14 13 16 15 16 NOTE Item 18 (not shown): Tractor Shaft Hardware Kit, includes items 6, 7, 8, 9, 13, 14, and 21 Item 19 (not shown): Tractor Shaft Kit, includes items 1, 2, 3, 4, 5, 15, and 17 Figure 39.
Illustrations of Printer Components Item No. Part No. 1 Ref Screw, Socket Cap Part of item 19 2 Ref Washer, Flat #4 Part of item 19 3 Ref Knob, Tractor Adjust Part of item 19 4 Ref Bushing, Tractor Adjust Part of item 19 5 Ref Washer, Curved Spring (2) Part of item 19 6 Ref Ring, Grip Part of item 18 7 Ref Bearing, Nylon .626 Part of item 18 8 Ref Link, Spring Part of item 18 9 Ref Spring, Extension 1.00L Part of item 18 10 Ref Screw, Hex w/Lock Washer, 4-20x.
Chapter 5 Section II: Illustrated Parts Lists NOTE: Black tape faces paper motion detector. 1 3 2 4 NOTE: Item 25: Platen Hardware Kit 6 5 24 7 23 88 1 2 22 20 18 16 21 17 26 9 10 11 12 19 13 18 17 16 14 15 Figure 40.
Illustrations of Printer Components Item No. Part No. 1 Ref Setscrew (2) Part of item 25 2 Ref Bracket, Platen (2) Part of item 25 3 150957-901 4 Ref Screw, Thread-forming (3) 5 Ref Bracket, Ironer 6 Ref Plate, Ironer 7 112657-901 Platen Assembly 8 Ref Washer, Flat (2) Part of item 25 9 Ref Screw (2) Part of item 11 10 Ref Washer, Flat #4 (2) Part of item 11 11 152417-901 Platen Switch Kit Includes items 9, 10, 19 12 Ref Screw, Socket Cap, 6-32x.
Chapter 5 Section II: Illustrated Parts Lists 16 $ Install screws here. 2 1 Top View Hammer Bank Fan Route cable under base casting 4 3 4 6 5 20 18 19 15 2 (2 ea.) 23 17 12 8 21 9 22 10 14 13 11 $ See detail above Figure 41.
Illustrations of Printer Components Item No. Part No. 1 150261-901 Card Cage Fan Assembly Air flow is into card cage 2 Ref Screw, w/Lock Washer (3) Two 6-32x1.75 on bottom, One 6-32x0.50 on top left 3 152415-901 4 Ref 5 152299-901 Motor Assembly, Platen 6 155071-902 Platen Pulley, Drive Motor With setscrew: 6-32x.25 7 Ref Collar, Shaft Part of item 9 8 Ref Setscrew, 6-32x.
Chapter 5 Section II: Illustrated Parts Lists See inside detail below. % To IEC 320 AC Power Input (Connector J301, Black Wire) $ To IEC 320 AC Power Input (Connector J301, White Wire) $ To Connector P1 (Black Wire) To Connector P1 (White Wire) 1 % Card cage fan and power supply board removed for clarity. Black Wire Black Wire 2 White Wire 3 5 4 White Wire Figure 42.
Illustrations of Printer Components Item No. Part No.
Chapter 5 Section II: Illustrated Parts Lists 4 3 5 6 7 2 1 8 Figure 43.
Illustrations of Printer Components Item No. Part No. 1 Ref Screw (2) 2 Ref Card Cage 3 156075-001 4 Ref Screw, Captive Part of item 3 5 Ref Standoff, Hex, 3/16 inch, M/F, .
Chapter 5 Section II: Illustrated Parts Lists 5 2 3 4 1 6 7 10 9 8 Figure 44.
Illustrations of Printer Components Item No. Part No.
Chapter 238 5 Section II: Illustrated Parts Lists
6 Principles of Operation Line Matrix Printing The printer creates characters and graphics by printing patterns of ink dots an entire line at a time. This technique is called line matrix printing. Every text character is stored in printer memory as a pattern of dots on a logical grid called the dot matrix. (See Figure 45.) The ink dots are made by a row of small hammers mounted on a shuttle that sweeps rapidly back and forth. Logic circuits divide every line of incoming data into horizontal dot rows.
Chapter 6 Line Matrix Printing When the shuttle reaches the end of a sweep, it reverses direction, the paper is advanced one dot row, and the hammers print the next row of dots as the shuttle sweeps in the opposite direction. After a line of characters is printed, hammer action stops and the paper advances to the first dot row of the next print line. The number of dot rows allowed for line separation depends on the vertical line spacing the user selects.
Succesive Hammer Strokes Per Scan Shuttle Scan Dot Row 1 1 2 1 2 3 1 2 3 4 1 2 3 4 5 1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 5 6 7 * 1 * Even column dot centers within the printed character area and character space hammer positions are not illustrated in this diagram. NOTE: *1 3 * 1 3 5 *1 3 5 7 * 1 3 5 7 9 * = Hammer Released and Dot Printed = Hammer Not Released; No Dot Printed Figure 47.
Chapter 6 Printing Rates Printing Rates Because a line matrix printer prints entire lines sequentially, it is faster than a moving-printhead printer, which prints single characters sequentially. The printing speed of text is measured in lines per minute (lpm) rather than characters per minute (cpm). Many variables affect printing speed, the main ones being the selected font and the vertical dot density.
Shuttle Frame Assembly Shuttle Frame Assembly The central element of the printing mechanism is the shuttle frame assembly, which houses the hammer bank assembly and the shuttle drive motor. (See Figure 48.) Hammer Bank Assembly Counterweight Assembly Connecting Rod Shuttle Frame Assembly Shuttle Motor Guide Shaft Figure 48. Shuttle Frame Assembly Hammer Bank Assembly The hammer springs are grouped in comb-like assemblies mounted on a solid hammer bank.
Chapter 6 Printing Mechanism similar to that of a horizontally-opposed gasoline engine. Mechanically, this design achieves the same benefits as this type of engine: perfect primary balance, low vibration, and durability. Each hammer spring is a stiff leaf spring with a cylindrical tungsten carbide tip on the free end. (See Figure 49.) A permanent magnet is imbedded along the length of the hammer bank and acts on the hammer springs through individual pole pieces.
Paper Transport System Paper Transport System Paper Path Tractors Horizontal Adjustment Knob Splined Shaft Vertical Adjustment Knob and Splined Shaft Pulley Tractor Support Shaft Shuttle Cover Assembly Paper Feed Timing Belt (under the cover) Paper Supports Figure 50. Paper Transport System A two-phase DC stepper motor, directed by the engine controller (EC), drives two tractor sprockets by means of a toothed belt and splined shaft pulley.
Chapter 6 Printing Mechanism Ribbon Transport System Ribbon Hub Left Ribbon Guide (Not Shown) Hub Locking Latch Ribbon Spool Ribbon Motors Right Ribbon Guide Ribbon Figure 51. Ribbon Transport System An inked ribbon winds and unwinds continuously on a pair of spools latched to hubs that are driven by the ribbon motors. The hubs and spools are offset vertically to equalize ribbon wear and prolong ribbon life. The ribbon motors operate only when the shuttle assembly is moving.
Ribbon Transport System Logical Control of the Printer The printer comprises four functional elements: the control panel, the CMX controller board, the power supply board, and the print mechanism. See Figure 52.
Chapter 6 Control Panel Control Panel The user communicates with the printer by pressing keys on the control panel. The keys are momentary contact switches. The control panel processes and sends key closure information to the controller board and displays information from the controller on the LCD. A status indicator next to the LCD also conveys printer status information to the user. The LCD, status indicator, and keys are mounted on a printed circuit board assembly enclosed in a protective housing.
Ribbon Transport System CMX Controller Board The heart of the printer is the CMX controller board, which monitors and directs all printer functions. The controller board receives and processes all data from the host computer, builds the printable images, controls all motors, and drives the hammer springs. Except for the power supply and final hammer drive circuits, all logic and drive circuitry for the printer are contained on the controller board.
Chapter 6 CMX Controller Board 25 or 40 MHz Expansion Port RS-232 Diagnostic Port RS-232/422 IEEE-1284 (Parallel) Control Panel Fault Sensors Paper Feed Ribbon Shuttle Platen TTL Diagnostic Port Hammer Drive Figure 54.
Data Controller Data Controller The data controller (DC) consists of the following elements: • • • • 68EC030 microprocessor • • VX ASIC (Application-Specific Integrated Circuit) Two flash SIMM sockets, for up to 30MB of program memory Two DRAM SIMM sockets, for up to 32MB of data memory 8K x 8 Non-Volatile Battery-Backed static RAM (NVRAM) for storage of configuration and system statistical data Host I/O Drivers/Termination 68EC030 Microprocessor A Motorola 68EC030 microprocessor serves as the proces
Chapter 6 CMX Controller Board NVRAM An 8K x 8 bit Non-Volatile battery-backed static RAM (NVRAM) device provides for the storage of configuration and system statistical data. VX ASIC The VX is a multi-function custom gate array ASIC containing all the logic for the DC that is not contained in the 68EC030 processor.
Data Controller “Dot Plucking” and Adjacent Dot Checking “Dot Plucking” is a specialized DMA function that removes dot data from a dot image buffer in DRAM in a programmable manner, serializes it, and sends it to the hammer bank. This function is actually controlled by the EC (see page 254), which has access to the VX through the “Cajun” Bus Interface. “Cajun” Bus Interface The “Cajun” bus connects the DC, the EC, and the expansion port.
Chapter 6 CMX Controller Board Engine Controller The engine controller (EC) consists of four main elements: • • 80C166 Microcontroller • • MECA (Mechanism Engine Control ASIC) 128KB 5.0V-only FLASH program memory, organized as 64K x 16 bits. This memory is not expandable. Analog drive circuitry 80C166 Microprocessor The Siemens SAB 80C166 is a high-integration microcontroller. It has many features that suit it extremely well to real-time control applications.
AC Power The printer has five electric motors: two ribbon drive, one paper feed, one platen open, and one shuttle motor. The shuttle motor is a brushless DC motor driven by current control. The MPU encoder is used as feedback for motor commutations, hammer fire timing, and motor stall detection. The paper feed motor is a DC stepping motor driven by current control. The paper feed motor may be driven in full, half, or microsteps, depending on print requirements.
Chapter 6 Printer Interface DC Power The power supply board contains two DC power supply systems for the printer. The first is a +5 V bus for logic. The second consists of +48 V and +8.5 V buses for the hammer bank and all motors. The +5 V supply has an isolated return line that connects to the +48 V return at the printer load. Both returns are tied together in a one-point ground. The +5 V power supply has its own inverter, separate from the +48 V and +8.5 V outputs.
DC Power Graphics 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 CMX controller board. These programming languages simplify the job of creating forms, bar codes, logos, expanded characters, and other graphics.
Chapter 258 6 Graphics
A Wire Data NOTE: Acronyms and signal mnemonics are defined in Appendix C.
Appendix A Power Stacker Cables Frame Cable, Power Stacker page 291 Logic Cable, Power Stacker page 292 Power Cable, Power Stacker page 293 Vertical Rail Cable, Power Stacker page 294 Fan Assembly, Hammer Bank page 295 Magnetic Pickup (MPU) Assembly page 296 Switch Assemblies 260 Switch Assembly, Paper Detector page 297 Switch Assembly, Platen Interlock page 298
2 261 4 4 2 4 4 LRIB M LRP 12 10 PMD 20 18 16 14 J106 MSL P106 MSL PLAT M CCF POD Shuttle Assembly 8642 7531 11 9 19 17 15 13 J106 Configuration CMX Controller Board Print Mechanisms Left Ribbon Motor Left Ribbon Guide Paper Out Detector Paper Motion Detector Platen Motor P306 Card Cage Fan CHASSIS GND Line 1 Line 2 / Neutral AC to DC Power Supply Board Hammer Bank Fan 2 Hammer Bank Board Shuttle Motor Terminator Board P05 J05 10 P04 10 J105 HBP P105 HBP P101 J101 DC
+5V +5V +5V +48V Paper Out Detector Left Ribbon Guide Left Ribbon Motor +48V Shuttle Assembly Ret Ret P05 J05 +8.5/+48V Hammer Bank Fan +24V Ret Hammer Bank Board Shuttle Motor Terminator Board J04 P04 +8.
Main Wire Harness Test Tables P106 Connector 1357 9 11 P107 Connector 13 15 17 19 PLAT M CCF POD LRIB M LRP PMD 2 4 6 8 10 12 Pin No. 14 16 18 20 1357 9 11 PAPR M EHF PLO MPU RRIB M HBF RRP JMP 2468 10 12 14 16 18 20 Resistance Resistance Device P106 Pins LRIB M 2, 4 and 6,8 PLAT M 1, 3 and 5, 7 LRP 10, 12 CCF 9, 11 PMD 14, 16 18, 20 8 MegΩ Open POD 13, 15 17, 19 8 MegΩ Open Normal Device P106 Pins 7.2 - 8.8 Ω RRIB M 2, 4 and 6,8 7.2 - 8.8 Ω 1.35 - 1.
Appendix A 264 J201 RS232/RS422 J110 Front Panel J107 Motor Sensor Right VCC 1 2 3 4 5 26 6 7 8 9 10 11 12 13 14 15 16 27 17 18 19 20 21 22 23 24 25 HOST TXD HOST RXD HOST RTS HOST CTS HOST DSR HOST DCD NC NC NC NC NC NC DIFF RXDNC DIFF RXD+ NC DIFF TXDHOST DTR 470 PF 10% 50V 1 2 3 4 5 6 7 8 N FP DAT AVAIL FP CLK N FP LED WR FP DATA N FP LCD WR 470 PF 10% 50V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 NC NC NC NC DIFF TXD+ CAUTION: Do not remove or replace the NVRAM.
J6 Diagnostic Port CAUTION: Do not remove or replace the NVRAM. The NVRAM contains a lithium battery that can explode if it is replaced incorrectly. NVRAM is replaced only at the factory. 7 8 1 2 3 4 5 6 NC DB TXD DB RXD NC J9 Online Verifier 1 2 3 4 5 6 J17 Paper Stacker J102 External Power EXT 5V VCC J102 4.7K 0.1W 4.7K 0.1W L6 1 2 + U56 265 3 PER LOGIC 1 HIGH 2 1 2 3 4 GND IN1 IN2 EN 8 OUT1 7 OUT2 6 OUT3 5 OUT4 10 mF 10% 16V 1000 PF 10% 50V 500 OHM 0.
Appendix A 266 J111 Expansion Connector J105 Hammer Bank Power 1 2 3 4 5 6 7 8 9 10 J106 Motor Sensor Left 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 PLAT 1 RIB L1 PLAT 2 RIB L2 PLAT 3 +48V RIB L3 PLAT 4 RIB L4 CC FAN+ L RBN POST+ CC FANL RBN POSTPOD A PMD A POD K PMD K 0.01 mF 10% 100V PH1 4.7K 0.1W J101 Power Supply PH2 PH3 PH4 LDFB 1 2 3 4 5 6 7 8 9 10 11 12 N TEMP HI N STBY VCC NC EXP N ID SEL 12/10 V NC N DMA REQ0 N DMA REQ1 +8.
VCC 10K 1% 0.1W J2 EC Diagnostics 1 2 3 4 5 6 7 8 9 10 EC DB TXD EC DB RXD NC PPR TRIG PPR MOVING FT EVENT MPU OUT SHUT DIR Controller (continued) J1 2-PIN JUMPER +15V J108 Hammer Bank Logic 1 J116 Shuttle Motor 4.7V 3.0W 1 2 3 TOROID 50 MHz 267 2 HMR DAT 3 HMR DAT RET 4 HMR CLK 5 HMR CLK RET 6 CMD DAT 7 CMD DAT RET 8 CMD CLK 9 CMD CLK RET 10 TOROID 50 MHz SHUT A SHUT B SHUT C DRAM: 72-pin SIMM J15 = Bank 1 J16 = Bank 0 (See page 187.
1 2 P1 3 LOAD = FAST-ON TERMINAL = RING TERMINAL Cable Assembly able Assy, AC In, In AC Power Supply ower Supply GND LOAD J1 1 AC AC COMMON CHASSIS GND AC Input (Line Filter Area) +5V +5V N STBY N TEMP HI * +48V +48V +8.5V +8.5V +5V RET / LOGIC GND +5V RET / LOGIC GND +5V RET / LOGIC GND +5V RET / LOGIC GND * V3.5 BOARD PIN 1 = N TEMP HI V4 BOARD PIN 1 = N AC FAIL PIN 1 1 2 3 4 5 6 7 8 9 10 11 12 P101 470 mF 10% 50V VCC 470 mF 10% 50V P101 Controller Board 8.
17 16 1 2 J3 Coax Connector SHIELD 2 SHIELD 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 NC NC NC NC NC NC NC NC NC NC NC NC TWINAX PHASE A TWINAX PHASE B COAX SHIELD COAX DATA J2 Twinax Connector EXP D13 EXP D12 EXP D11 EXP D10 EXP D9 EXP D8 EXP NDSEL EXP D15 EXP D14 EXP NACK EXP NMSEL EXP NRESET EXP NWR NC EXP NINT N DMA REQ0 N DMA REQ1 12/10 V NC NC N CARD DETECT 1K 0.
+48V 11 22 33 44 J6 J6 Power ower Supply upply + + 10 mF 10% 10V 1 2 3 4 5 6 7 8 9 10 J7 Stacker Logic 10 mF 10% 10V + 1K 0.1W 10 mF 10% 10V + VCC VCC 100 PF 10% 50V 33 0.1W 10K 0.1W 10 mF 10% 10V +5 V 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 N RESET N 42V FAIL PMD SIG PAP IN SIG SW1 SW2 SW3 SW4 J2 Test J1 Test J5 100 PF 10% 50V 33 0.1W 10K 0.1W J7 LIMIT SIG FULL SIG BEAM SIG N PD FLT N EL FLT N PI FLT SKP DB TXD SKP DB RXD 100 PF 10% 50V 33 0.1W 10K 0.1W 33 0.
Cable Routing, Cabinet Model 271
Front of Printer Appendix A 272 Right Side of Printer Left Side of Printer Cable Routing, Mechanism Base, Cabinet Model To J106 on CMX board NOTE: This view shows the underside of the mechanism base.
Cable Routing, Pedestal Model 273
Left Side of Printer Right Side of Printer Cable Routing, Mechanism Base, Pedestal Model (Not connected on pedestal models) To J106 on CMX board on Controller (See page 166 for connector detail.) Appendix A 274 Front of Printer NOTE: This view shows the underside of the mechanism base. To J107 on CMX board on Controller (See page 166 for connector detail.
Cable Assembly, Centronics I/O (P/N 152439-901) PIN 1 NOTE: If you replace the I/O cable assembly, you must install the ferrite clamp. See Appendix E.
Appendix A Cable Assembly, Dataproducts Adapter (P/N 703316-001) Centronics Dataproducts Dataproducts Centronics PIN 1 PIN 1 276
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 PARITYERR RET NC IDENT1 IDENT0 VFU VERIF CABLE VERIF DATA4 RET DATA4 DATA6 RET DATA6 DATA8 RET NC (PARITY) PI BUFFER CLEAR IDENT0 RET VFU VERIF RET DATA5 DATA7 RET DATA7 STROBE RET STROBE R1 470 0.
Appendix A Cable Assembly, Twinax Auto-Termination (P/N 140752-002) 1 Jack 2 White 14 Gray 7 Shield 5 Resistance Chart 3 278 Jack 4 Pin Pin Ohms 1 2 110 3 4 110 1, 2, 3, 4 Shield 55 5 Shield 0 14 1, 4 0 7 2, 3 0
Cable Assembly, 2-Pin Jumper, 0.
Appendix A Cable Assembly, AC In, Power Supply (AC Kit P/N 153502-901) To Circuit Breaker To Power Supply J1 280
Cable Assembly, AC Power Input (AC Kit P/N 153502-901) To Circuit Breaker Input Power Connector 281
Appendix A Cable Assembly, Card Cage Fan (P/N 152422-901) PIN 1 PIN 1 282
Cable Assembly, Control Panel (P/N 152440-901) NOTE: If you replace the control panel cable, you must install two ferrite shielding beads. See Appendix E.
Appendix A Cable Assembly, Exhaust Fan (P/N 152424-901) PIN 1 PIN 1 284
Cable Assembly, Hammer Bank Logic (P/N 152421-901) 285
Appendix A Cable Assembly, Hammer Bank Power (P/N 152423-901) PIN 1 PIN 1 286
Cable Assembly, MPU (P/N 152425-901) PIN 2 PIN 3 PIN 1 PIN 1 287
Appendix A Cable Assembly, Ribbon Guide Kit (P/N 163597-901) NOTE: Left ribbon guide shown. Right is mirror image.
Cable Assembly, Ribbon Motor, Extension (P/N 154067-901) 289
Appendix A Cable Assembly, Shuttle Motor Drive (P/N 152420-001) 290
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 PMD C PMD E PMD A PMD K PID A PID K PID C PID E LD1 A LD1 K DT1 C DT1 E LD2 A LD2 K DT2 C DT2 E PI PHA 1 PI PHA 2 PI PHB 1 PI PHB 2 M1 A1 M1 A2 M1 B1 M1 B2 M2 A1 M2 A2 M2 B1 M2 B2 M1 = REAR PADDLE M1 = REAR PADDLE MOTOR MOTOR RESISTANCE = 15.2 ˙ 1.5 W Resistance = 15.2 ± 1.5 Ohm / / PHASE Phase M2 = FRONT PADDLE M2 = FRONT PADDLE MOTOR MOTOR RESISTANCE = 15.2 ˙ 1.5 W / Resistance = 15.2 ± 1.
Appendix A Logic Cable, Power Stacker (P/N 158444-001) 292
Power Cable, Power Stacker (P/N 158443-001) 293
Appendix A Vertical Rail Cable, Power Stacker (P/N 158442-001) 294
Fan Assembly, Hammer Bank (P/N 152416-901) P107/HBF P107 / HBF 295
Appendix A Magnetic Pickup (MPU) Assembly (P/N 150281-901) 296
Switch Assembly, Paper Detector (P/N 152415-901) 297
Appendix A P107/PLO Switch Assembly, Platen Interlock (P/N 152417-901) 298
B Abbreviations & Signal Mnemonics NOTE: Mnemonics with first letter “N” are negative true. Abbreviation or Mnemonic Definition KΩ 1,000 Ohms MegΩ 1,000,000 Ohms µF microfarad (10-6 farad) µs microsecond (10-6 second) µsec microsecond (10-6 second) A0, A1, etc. Address 0, Address 1, etc.
Appendix B BTU British Thermal Unit BUD Buffered Upper Driver CA Cathode CC Card Cage CCF Card Cage Fan CE Customer Engineer CHNG Change CIR Circuit CLK Clock CO Cover Open COLL Collector COMM Communication CONTLR Controller CMD Command CMX The controller board CNC Connector, Connection CPI Characters Per Inch CR Carriage Return CT Coaxial/Twinaxial CTL Control CTS Clear to Send CU Control Unit CUR Current D0, D1, etc. Data Bit 0, Data Bit 1, etc.
DRAM Dynamic Random-Access Memory DRV Drive or Driver DRVR Driver DSR Data Set Ready DTR Data Terminal Ready EC Engine Controller (a functional unit of the CMX controller board) EEPROM Electrically Erasable/Programmable Read-Only Memory EHF Exhaust Fan EL Elevator (stacker) EMI ElectroMagnetic Interference EMIT Emitter EPROM Electrically Programmable Read-Only Memory ERR Error ESD Electrostatic Discharge EX Exhaust, Extra EXH Exhaust EXF Exhaust Fan EXP Expansion EXPND E
Appendix B 302 HBR Hammer Bank, Right HD Hammer Driver HDIC Hammer Driver Integrated Circuit HDPH Hammer Driver Phase HLP Hammer Bank Logic, Signals, and Power IC Integrated Circuit ID Identification IGP Intelligent Graphics Printing INST Instruction INT Interrupt I/O Input/Output IRQ Interrupt Request (J) Jack connector L Left LAN Local Area Network LCD Liquid Crystal Display LED Light Emitting Diode LF Line Feed LO Low LPI Lines Per Inch LPM Lines Per Minute LRI
MSL Motor and Sensors, Left MSR Motor and Sensors, Right N Negative True N/C Not Connected NC Not Connected NLQ Near Letter Quality No. Number NOVRAM Nonvolatile Random-Access Memory ns nanosecond (10-9 second) NT Not NVRAM Nonvolatile Random-Access Memory OLV On Line Verify OP Operand P5 + 5 V dc (P) Pin connector P(1), P(2), etc. Parallel data 1, data 2, etc.
Appendix B 304 PN Pin or Plug P/N Part Number PO Paper Out POD Paper Out Detect (Switch) PPR Paper PROM Programmable Read-Only Memory PS Power Supply PS5 Power Supply + 5 Volt PSA Printronix System Architecture PTR Pointer, Printer, Printronix PWM Pulse Width Modulation PWR Power R Right RBN Ribbon RD Read RET Return RIB Ribbon RG Ribbon Guide RGL Ribbon Guide, Left RGR Ribbon Guide, Right RM Ribbon Motor RML Ribbon Motor, Left RMR Ribbon Motor, Right RQ Requ
SG Signal Ground SHH Shuttle Hall (Effect) SHM Shuttle Motor SHUT Shuttle SHUTL Shuttle SIMM Single Inline Memory Module SLCT Select (On-line) Slew Rapid vertical paper movement SMD Shuttle Motor Drive SNA Systems Network Architecture SPU Shuttle Processor Unit SRAM Static Random-Access Memory STAT Status or State STBY Standby STK Stacker SW Switch SYNC Synchronize TCB Task Control Block TEMP Temperature TOF Top of Form (first print line) TP Test Point TTL Transist
Appendix B 306 WR Write w/ With w/o Without XMT Transmit
C Metric Conversion Tables Length Multiply By 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 centimeter 0.3937008 inch millimeter 0.03937008 inch * Figure is exact. Torque and Force Multiply By To Obtain pound-inch 0.
Appendix C Mass and Density Multiply By To Obtain pound* 0.4535924 kilogram (kg) ounce* 28.34952 gram (g) kilogram 2.204622 pound* gram 0.03527393 ounce* * avoirdupois Temperature To Convert To Use Formula temperature Celsius (tc) temperature Fahreheit (tf) tf = 1.8 tc + 32 temperature Fahreheit (tf) temperature Celsius (tc) tc = (tf - 32) / 1.8 Power 308 Multiply By To Obtain Btu (International Table)/ hour 0.2930711 watt (W) watt (W) 3.
D Noise Suppression Devices Ferrite noise suppressors are installed in the printer to reduce radio frequency interference (RFI) to and from electronic equipment located near the printer. Two kinds of ferrite noise suppressors are used: 1. Shielding Bead (P/N 141445-001) is a cylindrical core, through and around which the control panel cable assembly is wound. Two are required. 2.
Appendix D Control Panel Cable Assembly Connector P110 Connector P310 Shielding Bead P/N 141445-001 NOTE: Two turns around each bead. Parallel I/O Cable Assembly Connector P112 Ferrite Core with Clamp and Adhesive Backing P/N 202049-001 NOTE: This core attaches to the right rear card cage wall. Connector J203 Figure 55.
E SureStak™ Power Stacker Contents Introduction: page 311 Removing the Power Stacker: page 312 Installing the Power Stacker: page 317 Replacement Procedures: Constant Force Spring: page 328 Timing Belts: page 331 Illustrated Parts Breakdown: page 335 Introduction The SureStak Power Stacker is a factory-installed option for cabinet model printers.
Appendix E Removing the Power Stacker Removing the Power Stacker 1. Set the printer power switch to O (off). 2. Unplug the power cord. 3. Unload paper from the stacker area. (Refer to the User’s Guide.) 4. Remove the paper tent. (See Figure 56.) 1 Legend: 1. Paper Tent Figure 56. Removing the Paper Tent 5. Cut the tie wrap and remove the paper fence. (See Figure 57.) 1 Legend: 1. 2. Paper Fence Stacker Base Figure 57.
6. Remove three screws and washers from the stacker control panel. (See Figure 58.) 2 1 3 2 Legend: 1. 2. 3. Long Screw Washer Short Screw Figure 58. Removing the Stacker Control Panel 7. Remove four cables from the stacker control panel, and remove the stacker control panel. (See Figure 59.) 1 2 3 4 Legend: 1. 2. 3. 4. Logic Cable (P104) Power Cable Frame Cable (P102) Rail Cable (P107) Figure 59.
Appendix E Removing the Power Stacker 8. Remove the two 5/32 x 3/4 inch screws and washers securing the vertical rails to the upper frame cross-member at the rear of the cabinet. (See Figure 60.) 9. Raise the elevator assembly. 1 2 3 1 4 5 6 Legend: 1. 2. 3. 4. 5. 6. Vertical Rail Washer (2) Screw, 5/32 x 3/4 inch (2) Screw, 7/64 x 1/2 inch or Torx T-10 (2) Washer (2) but no washers with Torx T-10 screws Stacker Base Figure 60.
10. Loosen one turn—do not remove—the Torx T-10 screws securing the vertical rails to the stacker base. Each rail is secured by two screws. (See Figure 61.) 2 1 1 3 Legend: 1. 2. 3. Screw, 6-32x1/4, Torx T-10: two at bottom of each rail Vertical Rail Stacker Base Figure 61. Loosening the Lower Screws in the Vertical Rails 11. Remove the 7/64 x 1/2 inch screws and washers (or Torx T-10 screws) securing the base plate to the cabinet floor. (See Figure 60.) 12.
Appendix E Removing the Power Stacker 1 4 2 3 Legend: 1. 2. 3. 4. Upper Frame Cross-Member Elevator Assembly Stacker Base Vertical Rail Figure 62.
Installing the Power Stacker NOTE: This procedure is for complete installation of the power stacker, including cable assemblies and the stacker control panel. 1. Set the printer power switch to O (off). 2. Unplug the power cord. 3. Remove paper. 4. Loosen the three paper path hold-down screws. Slide the paper path to the left and lift it off the card cage. (See Figure 63.) 1 2 Legend: 1. 2. Paper Path Hold-Down Screw (3) Figure 63.
Appendix E Installing the Power Stacker 5. Connect the power stacker logic cable P103 to connector J17 on the CMX controller board. (See Figure 64.) 6. Disconnect the power supply cable from connector J101 on the CMX controller board. (See Figure 64.) 7. Connect power supply cable connector P101 to the stacker power cable, then connect the stacker power cable to connector J101 on the CMX controller board. (See Figure 64.) 8.
CAUTION The paper stacker assembly mounts to the rear upper frame crossmember and the cabinet floor. It is a snug fit. During installation, take care to avoid scratching painted surfaces or damaging the stacker. 9. Loosen one turn—do not remove—the Torx T-10 screws securing the vertical rails to the stacker base. Each rail is secured by two screws. (See Figure 65.) 2 1 1 3 Legend: 1. 2. 3. Screw, 6-32x1/4, Torx T-10 Vertical Rail Stacker Base Figure 65.
Appendix E Installing the Power Stacker 10. Position the elevator assembly at the bottom of the vertical rails. (See Figure 66a.) 11. 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. (See Figure 66a.) 12. Work the stacker base rearward and engage the upper brackets of the vertical rails under the upper frame cross-member.
a b 1 4 2 3 c Legend: 1. 2. 3. 4. Upper Frame Cross-Member Elevator Assembly Stacker Base Vertical Rail Figure 66.
Appendix E Installing the Power Stacker 14. Align the holes in the stacker base with the holes in the cabinet floor. (See Figure 66c and Figure 67.) 15. Install finger tight the two 5/32 x 3/4 inch screws and washers securing the vertical rails to the upper frame cross-member. 16. Install and tighten the 7/64 x 1/2 inch screws and washers (or Torx T-10 screws) securing the stacker base to the cabinet floor. (See Figure 67.) 17.
NOTE: The stacker assembly is exploded to show mounting screws and locations. 1 2 7 6 4 5 3 Legend: 1. 2. 3. 4. 5. 6. 7. Washer (2) Screw, 5/32 x 3/4 inch (2) Stacker Base Screw, 7/64 x 1/2 inch or Torx T-10 (2) Washer (2) but no washers with Torx T-10 screws Vertical Rail Upper Frame Cross-Member Figure 67.
Appendix E Installing the Power Stacker 22. Install the paper fence. (See Figure 68.) 2 1 Legend: 1. 2. Paper Fence Stacker Base Figure 68.
23. Gather the rail cable, frame cable, logic cable, and power cable. Route the cables outboard of the elevator assembly. 24. Connect the stacker cables to the rear of the stacker control panel assembly, as shown in Figure 69. 1 2 3 4 Legend: 1. 2. 3. 4. Logic Cable (P104) Power Cable Frame Cable (P102) Rail Cable (P107) Figure 69.
Appendix E Installing the Power Stacker 25. Position the stacker control panel as shown in Figure 70, and install the mounting screws. 1 2 3 Legend: 1. 2. 3. Stacker Control Panel Long Screw Short Screw (2) Figure 70.
26. Bundle the stacker control panel cables in the wire harness clips located under the card cage. (See Figure 71.) Tie wrap the cables so they do not catch in the stacker mechanism as it moves up and down. Route the stacker rail and frame cables so they move without snagging as the elevator assembly moves up and down. 3 2 1 Legend: 1. 2. 3. Wire Saddle (2) Cutout Beneath Card Cage Fan Cable Bundle Figure 71. Securing Stacker Cables 27. Install the paper path that you removed in step 4. 28.
Appendix E Replacing the Constant Force Spring Replacing the Constant Force Spring 1. Remove the stacker assembly from the printer. (See page 312.) CAUTION In the next step, do not over-tighten the tie wraps or string. Tighten the tie wraps or string just enough to hold the elevator up. 2. Raise the elevator assembly to its highest position and secure it to the vertical rails using tie wraps or string. (See Figure 72.) 1 2 1 Legend: 1. 2. Tie Wrap Elevator Assembly Figure 72.
WARNING The constant force spring is a high tension spring. To avoid pinching your fingers, coil the spring slowly and carefully. Do not let the spring twist or crimp. 3. Remove the shoulder screw, washers, and spacer from the constant force spring and drum. Let the spring coil itself up until it reaches the screw that secures it to the vertical rail. (See Figure 73.) 4. Firmly gripping the spring and drum, remove the screw securing the spring to the vertical rail. (See Figure 73.
Appendix E Replacing the Constant Force Spring 5. Lift the loose end of the constant force spring and let it curl up on the outside of the remaining spring and drum. (See Figure 74.) 6. While holding the drum tightly, continue to curl the spring until it is completely unwound from the drum. (See Figure 74.) 7. To install a new constant force spring, reverse the steps of this procedure. 1 2 Legend: 1. 2. Spring Drum Figure 74.
Replacing the Timing Belts 1. Remove the stacker assembly from the printer. (See page 312.) 2. Raise the elevator assembly to its highest position and secure it to the vertical rails using tie wraps or string. (See Figure 72, page 328.) 3. If you are removing the left timing belt, remove the shoulder screw from the pulley at the bottom of the left vertical rail, and remove the pulley. (See Figure 75.) Go to step 6. 4.
Appendix E Replacing the Timing Belts 5. Loosen the two setscrews on the motor pulley and remove the pulley. Unplug the motor cable, if necessary. (See Figure 76.) Go to step 6. 1 2 2 3 Legend: 1. 2. 3. Timing Belt Motor Setscrew Pulley Figure 76. Removing the Timing Belt Motor Pulley 6. Remove the shoulder screw, washers, and spacer that secures the constant force spring to the vertical rail. (See Figure 77.) NOTE: Left is shown. Right is the same. 1 2 1 4 3 Legend: 1. 2. 3. 4.
7. Remove two Allen screws from the belt clamp that secures the timing belt to the stacker frame. (See Figure 78.) 1 2 1 2 Legend: 1. 2. Allen Screw Belt Clamp Figure 78.
Appendix E Replacing the Timing Belts 8. Remove the timing belt by working it around the vertical rail and constant force spring. (See Figure 79.) NOTE: Left timing belt is shown. Right is the same. 1 Legend: 1. Timing Belt Figure 79. Removing the Timing Belt 9. To install a timing belt, reverse the steps of this procedure.
Illustrated Parts Breakdown The Illustrated Parts Breakdown (IPB) consists of exploded drawings of the power stacker assembly and subassemblies. Each drawing also has a list of replaceable parts. Only replaceable parts are assigned part numbers. If a part or assembly is damaged but does not have a part number, replace the entire power stacker assembly. The IPB starts on the next page.
Appendix E Illustrated Parts Breakdown Detail: Figure 81, page 338. $ 38 10 14 12 6 38 7 35 20 30 9 12 11 10 7 20 38 25 13 9 8 8 37 5 12 Figure 80.
Item No. Part No. Description Notes 5 202706-904 Flanged Bearing Part of item 36 6 158342-001 Paper Deflector 7 202721-901 Clip-On Bearing Part of item 36 8 Ref Screw, Torx, 6-32 x .
Appendix E Illustrated Parts Breakdown Detail: Figure 83, 15 page 342. Detail: Figure 82, page 340. & 51 $ 15 Detail: Figure 83, page 342. % 15 & Detail: Figure 85, page 346. 48 47 ( 53 46 40 45 50 50 46 45 50 45 45 46 60 55 46 52 55 54 65 54 52 53 49 ' 65 Detail: Figure 84, page 344. ' Detail: Figure 84, page 344. Figure 81.
Item No. Part No.
Appendix E Illustrated Parts Breakdown From Figure 81, page 338. % 80 85 90 85 80 75 Figure 82.
Item No. Part No.
Appendix E Illustrated Parts Breakdown From Figure 81, page 338. & 95 95 96 96 Flat Side 100 Connector Flag Key Figure 83.
Item No. Part No.
Appendix E Illustrated Parts Breakdown From Figure 81, page 338. ' 105 Connector Flag Nib 95 Key 95 97 Figure 84.
Item No. Part No.
Appendix E Illustrated Parts Breakdown From Figure 81, page 338. ( Rotated 180 Degrees 105 Connector Flag Nib 105 97 Key 97 107 110 107 107 106 107 115 108 116 T5stk01x P5STK01Z Figure 85.
Item No. Part No. Description Notes 36 164405-001 Stacker Hardware Kit Kit not illustrated 97 158290-001 Holder, LED, Flat 105 202728-001 Photodarlington, NPN, Rectifier 106 202766-001 Retaining Ring, External, 0.
Appendix E 348 Illustrated Parts Breakdown
Index Numerics ribbon guide, 120 splined shaft skew adjustment, 122 06 HOST REQUEST, 39 Arrow keys 08 HOLD PRINT / TIMEOUT, 39 pedestal models, 20 15 COMM CHECK, 39 ASCII Character Set chart, 96 15V PWR FAIL *, 40 Asterisk (*), meaning on messages, 31 22 INVALID ADDR, 40 B 23.
Characters replacement, 155 misaligned horizontally, 59 Controls and indicators misaligned vertically, 86 blank, 62 or dots missing or smeared, 45 mechanical, 22 print smeared or missing, 45 pedestal models, 20 print too light or dark, 45 printing conventions, 16 randomly compressed and/or enlarged, 86 Circuit board Copy replacement cannot copy flash memory, 57 controller, 155 power supply, 184 Circuit breaker flash MISC UTILITIES Cover assembly hammer bank/ribbon mask, replacement, 157
randomly misplaced, 74 EXHAUST FAN FLT, 56 Expansion-CT board, replacement, 162 DOWN (arrow) key F pedestal models, 20 Downloading software from multiple diskettes, 135 from one diskette, 130 Downloads consistently fail, 52 Fan assembly card cage, replacement, 164 hammer bank, replacement, 163, 165 Fault messages, 31 DRVR CIR BAD *, 52 E EC (Engine Controller, CMX board), 254 Emulation software clearing, 31 FIRMWARE ERROR, 56 Flash messages CLEARING PROGRAM FROM FLASH, 49, loading from multiple dis
J Flash SIMM won’t copy, 57 FM HEADER ERROR, 57 Jams FRAMING ERROR, 57 G paper, 41 JOB SELECT key Gap, adjustment pedestal models, 20 K magnetic pick-up (MPU), 170 platen, 116 GRF CHK ERROR / PRESS STOP, 57 H HAM.
Memory 22 INVALID ADDR, 40 EC PROGRAM / NOT VALID, 53, 132, 138 EC STOPPED / AT STATE XXXX, 53, 132, 138 FLASH / DID NOT PROGRAM, 53, 133, 138 FLASH / NOT DETECTED, 54, 133, 138 NO DRAM / DETECTED, 54, 133, 138 NVRAM / FAILURE, 54, 133, 139 PROGRAM / NEEDS MORE DRAM, 54, 133, 139 PROGRAM / NEEDS MORE FLASH, 54, 133, 139 PROGRAM / NOT COMPATIBLE, 54, 133, 139 PROGRAM / NOT VALID, 55, 133, 139 SECURITY PAL NOT DETECTED, 55, 133, 139 SHORT AT / ADDRESS XXXX, 55, 133, 139 WRITING / TO FLASH, 55, 133, 139 WRON
PAP FIFO UNDRFL *, 64 STACKER FULL, 83 PAP ILLGL ST *, 65 STACKER JAM, 83 PAP INCMPL ENER *, 65 TABLE MISMATCH / DOWNLOAD AGAIN, 85, PAP INVLD CMD *, 65 134, 140 PAP INVLD PARM *, 65 TCB CORRUPTED *, 85 PAP NOT SCHED *, 66 UNDEF INTERRUPT *, 86 PAP NT AT SPEED *, 66 UNDFNED OPCODE *, 86 PAP UNEXP INT *, 66 UP DRV.
PAP INCMPL ENER *, 65 printer does not power up, 62 PAP INVLD CMD *, 65 start up sequence, 99 PAP INVLD PARM *, 65 Power on hang condition, 69 PAP NOT SCHED *, 66 Power on sequence, 99 PAP NT AT SPEED *, 66 POWER SAVER MODE, 69 PAP UNEXP INT *, 66 Power supply board Paper detector switch assembly, replacement, 202 principles of operation, 255 replacement, 184 drive motor pulley alignment, 112 POWER SUPPLY HOT, 69 feed drive motor, replacement, 174 Power switch feed timing belt replacement,
PRINTER HOT, 72 magnetic pick-up assembly, 170 Printing memory modules, 171 conventions is this manual, 16 paper detector switch assembly, 202 line matrix printing explained, 239 paper feed drive motor, 174 problems, 29 paper feed timing belt, 146 too light or too dark, 45 paper ironer, 176 PrintNet Ethernet interface assemblies, paper path, 177 replacement, 185 platen, 178 Printouts platen interlock switch assembly, 203 hex code, 95 platen open belt, 147 Procedures platen open motor
S skew adjustment, 122 Spring Safety, 17 notices, 17 notices, defined, 16 Safety Notices, 17 extension, hammer bank, replacement, 201 gas, assembly, replacement, 200 Squares, black, on control panel, 44 STACK SCS COMMAND ERROR, 76 OVERFLOW *, 80 SECURITY CODE VIOLATION, 77, 134, 140 UNDERFLOW *, 80 SECURITY PAL NOT DETECTED, 76 STACKER Security PAL, location, 173 elevator moves by itself, 82 Self Test FAULT, 82 10/100Base-T, 188 Self-tests diagnostic, printer, 89 operator print, 89 FULL, 83 J
TCB CORRUPTED *, 85 communications failures, 88 Tension adjustment fault messages, 31 paper feed timing belt, 108 message list, 31 platen open belt, 110 procedures, 38 Terminating resistors location of, 191 replacement, 190 start here...
Printronix, Inc. 14600 Myford Road Irvine, CA 92606-1005 Phone: 714 / 368-2300 Fax: 714 / 368-2600 Technical Support: 714 / 368-2686 Printronix Nederland BV P.O. Box 163, Nieuweweg 283 NL-6600 Ad Wijchen The Netherlands Phone: (31) 24 6489489 Fax: (31) 24 6489499 Printronix A.G. 42 Changi South Street 1 Changi South Industrial Estate Singapore 486763 Phone: (65) 542-0110 Fax: (65) 543-0220 Visit our Web site at: http://www.printronix.
