Printronix P3000 User Manual
R
Maintenance Manual
P3000 Printer
P3000 Printer
Maintenance Manual
P/N 111839–001, Rev C
R
US and CANADA Radio Interference Note
Note: This device complies with Part 15 of the FCC Rules. Operation is subject to the following two
conditions: (1) this device may not cause harmful interference, and (2) this device must accept any
interference received, including interference that may cause undesired operation.
Properly shielded and grounded cables and connectors must be used in order to meet FCC emission limits.
The manufacturer is not responsible for any radio or television interference caused by using other than
recommended cables and connectors or by unauthorized changes or modifications to this equipment.
Unauthorized changes or modifications could void the user’s authority to operate the equipment.
The
input/output (I/O) cable must be shielded for the printer
to comply with FCC rules and regulations Part 15
governing the radiation limits for Class “A” equipment.
This Class A digital apparatus meets all requirements of the Canadian Interference–Causing Equipment
Regulations.
Cet appareil numérique de la classe A respecte toutes les exigences du Règlement sur le matériel brouilleur
du Canada.
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.
Printronix, Inc. makes no representations or warranties of any kind regarding this material, including, but not
limited to, implied warranties of merchantability and fitness for a particular purpose. Printronix, Inc. shall not
be held responsible for errors contained herein or any omissions from this material or for any damages,
whether direct, indirect, incidental or consequential, in connection with the furnishing, distribution,
performance or use of this material. The information in this manual is subject to change without notice.
This document contains proprietary information protected by copyright. No part of this document may be
reproduced, copied, translated or incorporated in any other material in any form or by any means, whether
manual, graphic, electronic, mechanical or otherwise, without the prior written consent of Printronix, Inc.
All rights reserved. Revision C. January 1996.
17500 Cartwright Road, P.O. Box 19559
Irvine, California 92713
Telephone (714) 863–1900 FAX (714) 660–8682
Technical Support (714) 221–2686
COPYRIGHT 1988, 1989, 1996, PRINTRONIX, INC.
Table of Contents
Paragraph Title Page
MAINTENANCE O
1-1 Introduction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2 P
1-3 Operation 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1 General 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2 F
2-3 P
2-4 P
2-5
2-6
2-7 P
3-1 General 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2 P
3-3 Inspection 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4 Cleaning 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5 P
3-6 Lubrication 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rinter Description
PRINCIPLES OF OPER
unctional Elements
aper T
ransport 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rinting Mechanism
Controller PCBA
Mechanism Driver PCBA
ower Supply PCBA
PREVENTIVE MAINTENANCE
reventive Maintenance Checks and Service (PMCS)
aper F
eed Belt T
ension Check
CHAPTER l
VERVIEW
CHAPTER 2
ATION
CHAPTER 3
1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. . . . . . . . . . . . . .
3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 4
TROUBLESHOOTING
4-1 General 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2 Common Causes of Malfunctions 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3
4-4 F
5-1 Introduction 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2 Tools, T
5-3 P
5-4
5-5
5-6 Bumpers 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7
5-8
Internal T
ault Isolation
aper Scale
Hammer T
Hammer Spring R
Stroke T
Hammer Phasing
esting 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CORRECTIVE MAINTENANCE
est Equipment, and Supplies
Section II. ALIGNMENTS AND ADJUSTMENTS
ips 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iming 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 5
Section I. GENER
etensioning 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AL
4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iP3000 Maintenance
Table of Contents
Paragraph Title Page
5-9 T
5-10 P
5-11
5-12
5-13
5-14
5-15 Cabinet 5-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-16
5-17 Cover 5-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-18
5-19
5-20
5-21
5-22 P
5-23
5-24 P
5-25
5-26
5-27
5-28
5-29
5-30
5-31 Encoder 5-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-32
5-33 Bumper 5-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-34 P
5-35 P
5-36
5-37
5-38 Tractor 5-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-39 P
5-40
5-41
5-42 P
5-43
5-44
5-45
5-46 Fan 5-84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-47
5-48 A
5-49 P
iming Belt T
aper Drive Motor Pulley Alignment
Spline Shaft Skew A
Platen Angle A
Platen Gap A
Ribbon Guide Alignment
Control P
Display Control P
Control P
Controller PCBA
Mechanism Driver PCBA
ower Supply PCBA
Shuttle Cover
aper Scale
Motherboard PCBA
I/O Cable Assembly
Shuttle Assembly
Hammer Bank Cable Assembly
Hammer Spring
Hammer Coil
Encoder PCBA
aper F
aper Drive Motor
Spline Shaft
Support Shaft
aper Ironer
Platen
Interlock Cable Assembly
aper Detect Switch
Ribbon Drive Motor
Ribbon Guide
Blower Assembly
Circuit Breaker
C Input Filter
aper F
ension A
djustment 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
djustment 5-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
anel 5-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
anel Cable 5-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
eed T
iming Belt
eed Motor Pulley
djustment 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
djustment 5-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section III. REPLA
anel 5-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CEMENT
5-14. . . . . . . . . . . . . . . . . . . . . . . . . .
5-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P3000 Maintenanceii
Table of Contents
Paragraph Title Page
APPENDICES
Appendix A
Appendix B
Index I-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Drawings
P
arts List
A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Tables
Table Title Page
1-1
1-2
1-3
2-1
3-1 P
3-2
4-1 Fault Codes 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2
4-3
External Controls and Indicators
Internal Controls and Indicators
Controls and Indicators for 3287 Option
Dot Matrices vs Speed/Density
reventive Maintenance Checks and Service
Physical Inspection
Supplimental T
Malfunction Sympton Index
ests 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8. . . . . . . . . . . . . . . . . . . . . . . . .
2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. . . . . . . . . . . . . . . . . . . . . .
3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1 R
ecommended T
ools, T
est Equipment, and Supplies
5-2. . . . . . . . . . . . . . .
iiiP3000 Maintenance
List of Illustrations
Figure Title Page
1-1 P
1-2
1-3
1-4
2-1 P
2-2 P
2-3 P
2-4
2-5 P
2-6
2-7
2-8 T
2-9
2-10
2-11
2-12
3-1
3-2
3-3
3-4
3-5 P
rinter with P
External Controls and Indicators
Internal Controls and Indicators
Controls and Indicators for 3287 Option
rinter F
aper T
rinting Mechanism
Hammer and Shuttle Arrangement, Cross Section
rint Hammer A
Standard Character F
Character F
ypical Character Dot P
Controller Block Diagram
Mechanism Driver Block Diagram
Hammer Bank L
Ribbon Driver Circuit
Cleaning Interior of Cabinet
Cleaning Hammer Bank Assembly
Cleaning P
Cleaning F
aper F
edestal 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
unctional Block Diagram
ransport 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ction 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ormation 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ormation by One Hammer
atterns, By Mode
ogic, Drivers, and W
aper Ironer
an 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
eed Belt T
ension Check
aveforms 2-16. . . . . . . . . . . . . . . . . . .
1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-9. . . . . . . . . . . . . . . . . . . . . . . . .
2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. . . . . . . . . . . . . . . . .
2-8. . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10. . . . . . . . . . . . . . . . . . . . .
2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9 P
All Indicators Come on and Stay on at P
No Indicators Come on at P
Indicators on Both Control P
Switches or Indicators Operate Improperly on F
Control P
Digital Display Operates Improperly
CHECK Indicator Flashes--Display Shows
FAULT CONDITION P
CHECK Indicator Flashes--Display Shows
FAULT CONDITON PLATEN OPEN 4-16. . . . . . . . . . . . . . . . . . . . . . . . .
CHECK Indicator on Continuously--Display Shows
FAULT CONDITION DCU RAM, FONT PROM or MCU RAM 4-18. .
aper Doesn't F
anel Only
eed at All
ower-up 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
anels Operate Improperly
APER OUT
ower-up 4-7. . . . . . . . . . . . . . . . .
ront
4-11. . . . . . . . . . . .
4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P3000 Maintenanceiv
List of Illustrations
Figure Title Page
4-10 P
4-11 P
4-12
4-13
4-14
4-15
4-16
4-17
4-18
4-19
4-20
4-21 P
4-22 P
4-23
4-24
4-25
4-26
4-27
4-28 R
4-29
4-30
4-31
4-32
4-33
4-34
4-35
4-36
4-37
4-38
4-39
4-40
4-41
4-42
4-43
aper F
eeds Erratically
aper Drags
Set T
op-of-F
Ribbon Does not Move at All
Ribbon F
Ribbon Does Not R
Ribbon Does Not Change Direction at End
Shuttle Does Not Move at All
Shuttle Jams or Moves too Slowly
Shuttle Moves Erratically
Shuttle Movement P
rinter Does Not P
rinter F
Missing Characters Example
Characters Missing Consistently
Characters Missing R
Missing Dots Example
Consistent Dropout of Dots
andom Dropout of Dots
Characters Light or Smeared Example
Character P
Dots Misplaced
Improper P
Improper P
Improper Horizontal Alignment Example
Improper V
Improper Horizontal or V
Characters Misformed V
Characters Misformed V
Compacted P
Compacted P
Garbled P
Expected Data Stream P
Blower Motor Not Operating
orm Does not Operate
olds Over 4-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
un Smoothly
roduces Knocking Sound
rint at All
ails to P
rint Only When Controlled by Host Computer
andomly 4-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ositions Light or Smeared (Dragging Hammer)
rint Density Example
rint Density
ertical Alignment Example
ertical Alignment
ertically Example
ertically 4-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rint Example
rint 4-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rint and/or Incorrect F
rintout 4-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ont 4-71. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-28. . . . . . . . . . . . . . . . . . . . . . . . . .
4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-34. . . . . . . . . . . . . . . . . . . . .
4-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-43. . . . . . . . . . . . . . . . . . . .
4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-45. . . . .
4-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-57. . . . . . . . . . . . . . . . . . . . . . . . .
4-58. . . . . . . .
4-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-63. . . . . . . . . . . . . . . . . . . . . . .
4-64. . . . . . . . . . . . . . . . . . . . . . . . .
4-65. . . . . . . . . . . . . . . . . . . . . .
4-66. . . . . . . . . . . . . . . . . . . . . . .
4-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1 P
5-2
5-3
5-4
aper Scale A
Hammer T
Hammer Spring R
Bumper A
djustment 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ip Alignment
djustment 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
etensioning 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vP3000 Maintenance
List of Illustrations
Figure Title Page
5-5 T
5-6 P
5-7
5-8
5-9
5-10
5-11
5-12
5-13 Cover Removal/Installation 5-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-14
5-15
5-16
5-17
5-18 P
5-19
5-20
5-21 I/O Cable Removal/Installation 5-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-22
5-23
5-24
5-25
5-26
5-27
5-28
5-29 P
5-30 P
5-31
5-32
5-33 P
5-34
5-35
5-36 P
5-37
5-38
5-39
5-40 F
5-41
5-42 A
5-43 P
iming Belt A
aper Drive Motor Pulley Alignment
Spline Shaft Skew A
Platen Angle A
Platen Gap A
Ribbon Guide Alignment
Cabinet R
Control P
Display Control P
Control P
Controller and Mechanism Driver R
Controller PROM L
ower Supply PCBA R
Shuttle Cover and P
Motherboard PCBA R
Shuttle Assembly R
Hammer Bank Cable Assembly R
Hammer Spring R
Hammer Coil R
Encoder R
Encoder PCBA R
Bumper R
aper F
aper Drive Motor R
Spline Shaft R
Support Shaft R
aper Ironer R
Platen R
Interlock Cable Assembly R
aper Detect Switch R
Ribbon Drive Motor R
Ribbon Guide R
Blower Assembly R
an R
emoval/Installation 5-85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker R
C Input Filter R
aper F
djustment 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
djustment 5-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
djustment 5-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
djustment 5-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
emoval/Installation 5-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
anel R
emoval/Installation 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . .
anel R
emoval/Installation 5-31. . . . . . . . . . . . . . . . . . . . .
anel Cable Removal/Installation 5-33. . . . . . . . . . . . . . . . . . . . . . .
emoval/Installation 5-35. . . . . . . . . . .
ocations 5-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
emoval/Installation 5-39. . . . . . . . . . . . . . . . . . . . . . .
aper Scale R
emoval/Installation 5-43. . . . . . . . . . . . . . . . . . . . . . .
emoval/Installation 5-47. . . . . . . . . . . . . . . . . . . . . . . . .
emoval/Installation 5-51. . . . . . . . . . . . . . . . . . . . . . . . . .
emoval/Installation 5-53. . . . . . . . . . . . . . . . . . . . . . . . . . . .
emoval/Installation 5-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
emoval/Installation 5-57. . . . . . . . . . . . . . . . . . . . . . . . . . .
emoval/Installation 5-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
eed T
iming Belt R
emoval/Installation 5-63. . . . . . . . . . . . . . . . . . . . . . . .
emoval/Installation 5-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
emoval/Installation 5-67. . . . . . . . . . . . . . . . . . . . . . . . . . . .
emoval/Installation 5-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
emoval/Installation 5-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
emoval/Installation 5-77. . . . . . . . . . . . . . . . . . . . . . .
emoval/Installation 5-79. . . . . . . . . . . . . . . . . . . . . .
emoval/Installation 5-81. . . . . . . . . . . . . . . . . . . . . . . . . . . .
emoval/Installation 5-83. . . . . . . . . . . . . . . . . . . . . . . . .
emoval/Installation 5-87. . . . . . . . . . . . . . . . . . . . . . . . . . .
emoval/Installation 5-89. . . . . . . . . . . . . . . . . . . . . . . . . . .
eed Motor Pulley R
emoval/Installation 5-41. . . . . . . . . . . . . .
emoval/Installation 5-49. . . . . . . . . . . . .
emoval/Installation 5-61. . . . . . . . . . . . . . . . . . . .
emoval/Installation 5-75. . . . . . . . . . . . . . . . . .
emoval/Installation 5-91. . . . . . . . . . . . . . . . . . .
5-15. . . . . . . . . . . . . . . . . . . . . . . . . . .
5-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P3000 Maintenancevi
ABOUT THIS MANUAL
This
manual has been organized and written to make it easy to use. The following information will
help
you use this P3000 Maintenance Manual.
What This Manual Contains
This
manual contains the following information. Consult your table of contents to locate this infor
mation.
Ć
Introduction -
P
rovides brief printer description.
Principles of Operation - Describes functional operation of printer through the use of
block
diagrams and associated text.
Preventive
operation.
Troubleshooting
common
Maintenance
- Presents fault isolation procedures required to determine the source
malfunctions.
-
Lists
detailed procedures required to maintain normal printer
of
Corrective Maintenance - Presents procedures for printer adjustment and alignment
replacement of faulty hardware.
and
Electronic Drawings - Electronic drawings and schematics required for field mainteĆ
nance
are included here.
Parts List -
A parts lists, cross referenced to Chapter 5, Section III, is included here.
Controls and Indicators
Throughout
printer, with all capital letters. Controls and indicators that do not have labeled names are given
functional names that are printed with the first letter of each word capitalized. For example, the
POWER switch has two settings, ON and OFF. The Forms Thickness Adjustment Lever is operĆ
by raising and lowering.
ated
this manual, in text, controls and
indicators are printed exactly as they appear on the
Warnings, Cautions, and Notes
In this manual, extra information is given under the headings WARNING, CAUTION, AND
NOTE.
information about conditions that could lead to injury. Cautions provide information about condi
tions that could lead to equipment damage. Both warnings and cautions are printed in bold type.
Notes
They are set off from the text around
provide extra information and are printed in
them and appear in special typefaces. W
italics.
arnings give
What This Manual Does Not Contain
Detailed,
in
the maintenance manual.
specific information which appears in the User's R
eference Manual will not be repeated
viiP3000 Maintenance
Ć
P3000 Maintenanceviii
CHAPTER l
MAINTENANCE OVERVIEW
1-1. Introduction
This
manual contains information required to maintain and repair the
rinter (hereafter referred to as the P3000 Series, or simply, the printer).
P
The following documents provide detailed information which supplements this manual.
a.
P3000 P
Contains instructions for unpacking, installing, and operating the printer.
b.
P3000 P
Describes functions and applications available for the P3000 P
rinter Operator's Guide, P/N 111837-001.
rinter User's R
eference Manual, P/N 111838-001.
1-2. Printer Description (Figure 1-1)
Printronix P3040
rinter.
a. General
The Printronix
to
produce labels and characters, as well as the standard data processing and compressed
print
character lines and graphics at various densities.
b.
Standard F
l. Configurable
trol
2.
Multi-application character printing
3.
Graphics plotting
4.
Dynamic font selection:
5.
Double high characters
P3000 Series P
eatures
for P
code protocols
(a)
Selectable pitch - expanded, normal, and compressed
(b)
Shadow printing
(c)
Bold printing
(d) A
uto underlining
(e)
Superscripts and subscripts
rinter is a multi-purpose, dot matrix line printer designed
rintronix P Series matrix line printer or serial matrix printer con
Ć
6.
Selectable forms length
7.
Nonvolatile electronic vertical formatting
8. R
esident international character sets
1-1P3000 Maintenance Overview
1-2. Printer Description-continued
b. Standard Features-continued
ă9.
Self-test and diagnostics
10. T
est pattern printing
11.
Configuration printout
12.
Datastream HEX code printout
13. R
esident serial and parallel interfaces
14.
Selectable alternate horizontal and vertical dot densities
15.
Configurable for 13.2 or 13.6 inch print width
c. Optional Features
ă1.
Intelligent Graphics P
(a) F
orms generation
(b)
Bar code printing
(c)
Expanded character printing
(d) R
everse image printing
(e) R
otated character printing
(f) L
ogo generation
ă2.
Optional character sets
rocessor (IGP)
ă3.
IBM interfaces
Ribbon fault detector
ă4.
1-3. Operation
a. Operating Procedures
For detailed operating instructions refer to P3000 Printer Operator's Guide, P/N
111837-001.
b. Controls and Indicators
NOTE:
functions. For a detailed discussion, refer to the User's R
optional controls and indicators refer to the PI 3287 User's R
(P/N 108174-001).
1. External
Figure
Internal Controls and
2.
Figure
(a) 3282/3287
(b) 5225/5224
The following tables contain a brief
Controls and Indicators. External controls and indicators
1-2 and described in T
Indicators. Internal controls and indicators are illustrated in
1-3 and described in T
able 1-1.
able 1-2.
summary of control and indicator
eference Manual. F
or
eference Manual
are illustrated in
3. Controls and Indicators for Options. Printers configured to emulate an IBM 3287
will have external controls and indicators as shown in Figure 1-4 and described in
Table 1-3.
P3000 Maintenance Overview1-2
Figure 1-1. P
rinter with P
edestal
1-3P3000 Maintenance Overview
Table 1-1. External Controls and Indicators
Key
(Fig 1-2) Control or Indicator Function
1
2
3
4
5
ON/OFF
ON LINE
switch
ON LINE
indicator
CLEAR
switch
CHECK
indicator
6
7
8
6/8LPI
switch
8LPI
indicator
PAPER ADV
switch
Applies and removes ac power to printer
Sets printer online or offline.
Illuminates steadily to indicate printer online
(ready for computer messages).
Flashes to indicate printer offline (not ready
to accept messages).
Resets check circuitry. Used to clear check
indicators after corrective action.
Illuminates to indicate printer problem. Steady
light indicates service is required. Flashing light
indicates operator correctable problem. Lighting
of indicator is accompanied by display of message
on internal display panel (see Table 4-1)
Selects line spacing of six lpi or eight lpi.
Illuminates when alternate lpi selected
Moves paper one line when pressed momentarily.
Moves paper to top of form when pressed for more
than 0.5 second.
NOTE:
Top of form must be reset each time new paper
is loaded (see operator's guide).
9
VFU
indicator
Illuminates when EVFU is loaded.
P3000 Maintenance Overview1-4
357 9
ON LINE CHECK 8 LPI VFU
Figure 1-2. External Controls and Indicators
ON LINE
CLEAR
6/8 LPI PAPER ADV
2468
1-5P3000 Maintenance Overview
Table 1-2. Internal Controls and Indicators
: The following electronic controls function only when the printer is of
NOTE
fline.
Key
(Fig 1-3) Control or Indicator Function
ELECTRONIC
1
2
3
4
5
6
7
Display
Panel
UP
switch
NEXT
switch
R/S
switch
F/L
switch
MODE
switch
ENTER
switch
Displays message for print mode, form length,
fault conditions, test patterns, or configuration options.
For details, refer to User's Reference Manual.
Steps display up to next menu
Used in conjunction with PREV switch to display individual configuration parameters and the current values
from within various menus.
Starts or stops certain printer functions.
Used to select form length.
Selects type of character print or density of graphic plot.
F
or details on how to select mode, refer to Operator's
Guide.
Used to enter a displayed value into memory.
Ć
8
9
MECHANICAL
10
11
12
13
14 Forms Thickness
15
PREV
switch
DOWN
switch
Tractors
Vertical Alignment
Knob (Spline Shaft
Knob)
Forms Thickness
(Platen) Lever
Top of Form
Pointer (indicator
on tractor doors)
Indicator
Horizontal Vernier
Adjustment Knob
Used in conjunction with NEXT switch to display individual configuration parameters and the current values
from within various menus.
Steps display down to next menu.
Provide horizontal positioning of forms.
Manually advances forms.
Opens paper path for insertion/removal of paper.
Adjusts platen opening to allow for paper thickness
A
or multiple copies.
Provides reference when setting top of form after
P
reloading paper.
Indicates setting of platen lever.
Provides fine horizontal positioning when tractors are
locked.
P3000 Maintenance Overview1-6
Figure 1-3. Internal Controls and Indicators
1-7P3000 Maintenance Overview
Table 1-3. Controls and Indicators for 3287 Option
NOTE:
panel
Key
(Fig 1-4) Control or Indicator Function
ELECTRONIC
1
2
3
4
Only those controls and indicators
(F
igure 1-3) are discussed below
ENABLE/HOLD
switch
HOLD
indicator
REPRINT/PA1
switch
CANCEL/PA2
switch
Places printer in hold print mode following completion
of line being printed. When pressed a second time, en
ables normal operation.
Lights to indicate printer is in hold print mode.
Causes reprint of all data in interface buffer in nonSCS modes. In SCS modes, sends intervention re
quired message to host processor. A
print mode.
When used in conjunction with AL
causes program attention signal to be sent to host proc
essor.
No effect in non-SCS modes. In SCS modes, causes
printing to stop and SCS print data to be cleared from
buffer. A
ctive only in hold print mode.
that are not present on the standard
.
Ć
Ć
ctive only in hold
T MODE switch,
Ć
5
6
7
8
ALT MODE
switch
READY
indicator
ERROR
indicator
ALT
indicator
Causes alternate switch functions P
come active. A
second time deactivates P
Lights to show that printer is ready to print (not in
hold print mode).
Indicates error condition exists.
Indicates alternate mode selected (P
ctive only in hold print mode. P
A1 and P
A1 and P
A2.
A1 and P
A2 to be-
ressing a
A2 active).
P3000 Maintenance Overview1-8
ON LINE CHECK 8 LPI VFU
ENABLE/HOLD 6/8 LPI PAPER ADV
CLEAR
PA1
PA2
ALT MODE
HOLD READY ERROR ALT
2
67 8
REPRINT
1
CANCEL
345
Figure 1-4. Controls and Indicators for 3287 Option
1-9P3000 Maintenance Overview
P3000 Maintenance Overview1-10
CHAPTER 2
PRINCIPLES OF OPERATION
2-1. General
This chapter presents the principles of operation for the Printronix P3000 Series Line
Printer.
ing field maintenance. R
Theory is presented at the functional block diagram level as an aid for perform
efer to Appendix B for detailed schematic diagrams.
2-2. Functional Elements (Figure 2-1)
Ć
Functional
a. P
b. Printing Mechanism
c.
d.
e. P
elements of the printer consist of the following:
aper T
ransport
Controller PCBA
Mechanism Driver PCBA
ower Supply PCBA
2-3. Paper Transport (Figure 2-2)
The paper transport accepts one to six part, continuous fan folded, edge perforated paĆ
per (or forms) from three to 16-inches wide. The spline shaft knob is used to manually
advance the paper supply vertically. Horizontal positioning of the paper is provided by
tractors which can be adjusted laterally along the spline and support shafts and by a
two
horizontal adjustment knob. When properly positioned, each tractor is then locked in
place. Each tractor provides five
tractors
nals
are belt driven by the paper drive motor. The paper drive motor is
from the two paper feed sections of the mechanism driver PCBA.
pin engagement of paper perforation. During printing,
driven by sig
Ć
2-1P3000 Principles of Operation
+30V
AC
POWER
IN
TO/FROM
HOST
COMPUTER
DATA
CONTROL
STATUS
POWER SUPPLY
PCBA
CONTROLLER
PCBA
-16V
+5V
+12 V
-12 V
CONTROL
TIMING
SERIAL DATA
MECHANISM
DRIVER
PCBA
PAPER FEED
PLATEN OPEN/
INTERLOCK
HAMMER CONTROL
SHUTTLE CONTROL
SHUTTLE STALL
RIBBON CONTROL
RIBBON FAULT
BLOWER CONTROL
PRINT MECHANISM
PAPER TRANSPORT
HAMMERBANK/
SHUTTLE
RIBBON
TRANSPORT
BLOWER MOTOR
+5V
OPERATOR
CONTROLS
AND
INDICATORS
Figure 2-1.
P
rinter F
unctional Block Diagram
P3000 Principles of Operation2-2
Figure 2-2. P
aper T
ransport
2-3P3000 Principles of Operation
2-4. Printing Mechanism (Figure 2-3)
The
printing mechanism consists of the shuttle assembly on which the
sembly is mounted, and the ribbon transport.
a. Shuttle Assembly
The
shuttle assembly consists of the linear motor assembly, two bumper assemblies, two
drum assemblies, the hammer bank assembly, hammer bank cable assembly, encoder
and a linear
PCBA,
and
sweeps the hammer
each hammer. The bumpers rebound the hammer bank assembly's inertial energy
the
shuttle reaches either end of its travel and reverses direction. The drums, in conjunc
tion with a stainless steel band, provide a bearing action to the hammer bank assembly,
allowing it to move with low friction. The optical linear encoder produces timing pulses
that are used to determine hammer bank assembly position and speed to synchronize
printing.
Hammer Bank Assembly
b.
Printing is done by a row of 34 print hammers mounted on the hammer bank assembly.
Each hammer consists of a stiff leaf spring with a small, cylindrical tip on one end. It is
securely on the hammer bank by a screw passing through its other end. A permanent
held
magnet running the full length of the hammer bank and acting through individual pole
holds all 34 hammer springs in the retracted (tensioned) state.
pins
encoder. The linear motor is driven by the mechanism driver PCBA
bank assembly laterally across the 0.4-inch distance traveled by
hammer bank as
when
Ć
Ć
Each print hammer has associated with it a normally deenergized electromagnetic coil
mounted
end of the hammer spring keeping it under tension. When hammer driver logic deterĆ
mines
the resulting magnetic field opposes the field of the permanent magnet, releasing the
hammer
the
During flight time, the coil is deenergized. As the hammer rebounds after striking, the
permanent
In correspondence (NLQ) and data processing (DP) modes, a line of characters is creĆ
ated
in a single scan as the shuttle moves from one side to the other through the character
columns
Figure 2-7 shows the order in which a single character is formed by a single print hamĆ
mer.
on the pole pin (Figure 2-4).
that the hammer is to print a dot, a current pulse energizes the coil. The polarity of
which allows it to impact the ribbon and paper (Figure 2-5) and leave a dot on
paper.
magnet recaptures the hammer and holds it ready for the next stroke.
by a scanning pattern (Figure 2-6). All dots in any row of the dot
(spaces).
The end of this pin magnetically attracts the free
matrix are printed
P3000 Principles of Operation2-4
Figure 2-3. Printing Mechanism
2-5P3000 Principles of Operation
Figure 2-4. Hammer and Shuttle Arrangement, Cross Section
Figure 2-5. P
rint Hammer Action
P3000 Principles of Operation2-6
INDICATES DIRECTION OF SHUTTLE MOVEMENT
DOT
ROW START
PAPER
ADVANCES
1
2
3
ONE
CHARACTER
ROW
10
11
12
4
5
6
7
8
*
9
**
SPACE
0
PAPER
FEED
PAPER
ADVANCES
1
2
USED FOR LOWERCASE DESCENDER ONLY
*
USED FOR UNDERLINE AND LOWERCASE DESCENDER
**
NOTE: P3000 SHUTTLE SWEEPS THROUGH FOUR (IN 10 CPI) CHARACTER POSITIONS
Figure 2-6. Standard Character F
ormation
2-7P3000 Principles of Operation
SUCCESSIVE HAMMER STROKES PER SCAN
SHUTTLE
SCAN
1
2
3
4
5
6
7
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
113135135713579
******
EVEN COLUMN DOT CENTERS WITHIN THE PRINTED CHARACTER
*
AREA AND CHARACTER SPACE HAMMER POSITIONS ARE NOT
ILLUSTRATED IN THIS DIAGRAM.
NOTE: = DOT
= NO DOT WHERE HAMMER HAS BEEN
= HAMMER POSITION
Figure 2-7. Character Formation by One Hammer
P3000 Principles of Operation2-8
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