Printronix P5214-SS, P52KA, P5214, P5215, P5210 User Manual

...

Maintenance Manual

The Printronix P5000 series of Line Matrix Printers

Maintenance Manual

164253-001, Rev D

Trademark Acknowledgements

T rade mark Ack nowledgemen ts

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.

ENERGY STAR® is a registered trademark of the United States

Environmental Protection Agency. As an Printronix has determined that this product meets the guidelines for energy efficiency. Ethernet is a trademark of Xerox Corporation. IBM is a registered trademark of International Business Machines Corporation. IEEE is a registered trademark of the Institute of Electrical and Electronics Engineers. IGP is a registered trademark of Printronix, Inc. Intelligent Printer Data Stream and IPDS are trademarks of International Business Machines Corporation. LinePrinter Plus is a registered trademark of Printronix, Inc. MS-DOS is a registered trademark of Microsoft Corporation. PC-DOS is a trademark of International Business Machines Corporation. PGL is a registered trademark of Printronix, Inc. PrintNet is a trademark of Printronix, Inc. Printronix is a registered trademark of Printronix, Inc. PSA is a trademark of Printronix, Inc. QMS is a registered trademark of Quality Micro Systems. RibbonMinder is a trademark of Printronix, Inc. SureStak is a trademark of Printronix, Inc. Torx is a registered trademark of Camcar/Textron Inc. Utica is a registered trademark of Cooper Power Tools.

ENERGY STAR® Partner,

ENERGY STAR®

War ranty and Copyrig ht Inform ation

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.

COPYRIGHT © 1996, 1999, PRINTRONIX, INC.

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. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his own expense.

Properly shielded and grounded cables and connectors must be used in order to meet FCC emission limits. Printronix is not responsible for any radio or television interference caused by using other than recommended cables and connectors or by unauthorized changes or modifications to this equipment.

Unauthorized changes or modifications could void the user’s authority to operate the equipment.

Warranty and Copyright Information

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 interferenc e that may cause unde si r ed operation.

Canadian Department of Communications Compliance Statement: This Class A digital apparatus meets all requirements of the Canadian

Interference-Causing Equipment Regulations. Avis de conformité aux normes du ministère des Communications du

Canada: Cet appareil numérique de la classe A respecte toutes les exigences du

Règlement sur le matériel brouilleur du Canada.

European Union (EC) Electromagnetic Compatibility Directives:

product is in conformity with the protection requirements of EC Council Directive 89/336/EEC on the approximation of the laws of the Member States relating to electromagnetic compatibility. Printronix cannot accept responsibility for any failure to satisfy the protection requirements resulting from a non-recommended modification of the product, including the fitting of non-Printronix option cards.

Dieses Gerät ist berechtigt in Übereinstimmung mit dem deutschen EMVG vom 9.Nov.92 das EG-Konformitätszeichen zu furhren.

Properly shielded and grounded cables and connectors must be used in order to reduce the potential for causing interference to radio and TV communication and to other electrical or electronic equipment.

This product has been tested and found to comply with limits for Class A Information Technology Equipment according to CISPR 22/European Standard EN 55022. The limits for Class A equipment were derived for commercial and industrial environments to provide reasonable protection against interference with licensed communication equipment.

This

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. Für diese Klasse von Geräten gilt folgende Bestimmung nach dem EMVG:

Geräte dürfen an Orten, für die sie nicht ausreichend entstört sind, nur mit besonderer Genehmigung des Bundesminesters für Post und Telekommunikation oder des Bundesamtes für Post und Telekommunikation betrieben werden. Die Genehmigung wird erteilt, wenn keine elektromagnetischen Störungen zu erwarten sind.

(Auszug aus dem EMVG vom 9.Nov.92, Para.3, Abs.4) Hinweis: Dieses Genehmigungsverfahren ist von der Deutschen Bundespost

noch nicht veröffentlict wor den .

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............................................. 15

About This Manual.............. ...... ...... ....... ...... ....... ...... ....... ... 15

How to Use This Manual .............................................. 16

Notes and Notices........................................................ 16

Printing Conventions in This Manual............................ 16

Safety Notices..................................................................... 17

Hinweise zur Sicherheit...................................................... 17

Controls and Indicators....................................................... 18

Tools, Test Equipment, and Supplies................................. 24

2 Preventive Maintenance....................... 25

Cleaning the Printer.................................................. ....... ... 25

Cleaning the Outside Surfaces................................. .......... 25

Cleaning the Shuttle Frame Assembly ............................ ... 27

Cleaning the Card Cage Fan Assembly ............................. 28

3 Troubleshooting ................................... 29

Introduction......................................................................... 29

Troubleshooting Aids.......................................................... 29

Start Here... ........................................................................ 30

Troubleshooting Display Messages.................................... 31

How to Clear LCD Messages....................................... 31

Troubleshooting Other Symptoms...................................... 36

Troubleshooting Procedures............................................... 38

How to Use the Troubleshooting Procedures............... 38

The Procedures............................................................ 39

Communications Failures ................................................... 88

Diagnostic Printer Tests...................................................... 89

Selecting and Running Diagnostic Printer Tests.......... 90

Boot Diagnostics Menu....................................................... 92

vii

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............ 99

DC Software Initialization and Power Up ................... 103

4 Adjustment Procedures ..................... 105

Introduction....................................................................... 105

Preparing the Printer for Maintenance.............................. 106

Returning the Printer to Normal Operation....................... 107

Belt, Paper Feed Timing, Adjustment (Figure 10) ............ 108

Belt, Platen Open, Adjustment (Figure 11)....................... 110

Paper Drive Motor Pulley Alignment (Figure 12) .............. 112

Paper Scale Alignment (Figure 13)................................... 114

Platen Gap Adjustment (Figure 14).................................. 116

Platen Open Motor Pulley Alignment (Figure 15) ............. 118

Ribbon Guide Alignment (Figure 16)................................ 120

Splined Shaft Skew Adjustment (Figure 17)..................... 122

Paper Out Adjustment ...................................................... 124

Hammer Phasing Adjustment........................................... 128

Loading Flash Memory from One Diskette....................... 130

Loading Flash Memory from Multiple Diskettes................ 135

Set Shuttle Speed............................................................. 141

viii

5 Replacement Procedures

and Illustrated Parts Lists....................... 143

Organization of This Chapter............................................ 143

Section I: Replacement Procedures................................. 144

List of Removal/Installation Procedures..................... 144

Belt, Paper Feed Timing ............................................ 146

Belt, Platen Open......................................... ...... ....... . 147

Circuit Breaker ........................................................... 148

Connector Shells........................................................ 149

Connector Stiffening Clips.......................................... 151

Control Panel Assembly, Cabinet Models.................. 153

Control Panel Assembly, Pedestal Models................ 154

Controller Board (CMX).............................................. 155

Cover Assembly, Hammer Bank / Ribbon Mask........ 157

Cover Assembly, Shuttle............................................ 160

Cover Assembly, Top, Pedestal Models .................... 161

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........................... 171

Paper Feed Motor ...................................................... 174

Paper Ironer ............................................................... 176

Paper Path ................................................................. 177

Platen......................................................................... 178

Platen Open Motor ..................................................... 182

Power Supply Board .................................................. 184

PrintNet Ethernet Interface Assemblies ..................... 185

10Base2 and 10Base-T LEDs and DIP Switches ...... 186

10/100Base-T LEDs and Dipswitches........................ 188

Resistors, Terminating ............................................... 190

Ribbon Drive Motor .................................................... 192

Ribbon Guide Assembly (L/R).................................... 193

Ribbon Hub ................................................................ 194

Shaft, Splined.. ...... ....... ...... ...... ....... ...... ..................... 195

Shaft, Support . ...... ....... ...... ...... ....... ...... ..................... 197

Shuttle Frame Assembly ............................................ 198

Spring Assembly, Gas................................................ 200

Spring, Extension, Hammer Bank.............................. 201

Switch Assembly, Paper Detector.............................. 202

Switch Assembly, Platen Interlock ............................. 203

Tractor (L/R)............................................................... 204

Section II: Illustrated Parts Lists ....................................... 205

Illustrations of Printer Components............................ 205

6 Principles of Operation...................... 239

Line Matrix Printing........................................................... 239

Printing Rates ................................................................... 242

Printing Mechanism .......................................................... 242

Shuttle Frame Assembly ............................................ 243

Paper Transport System ............................................ 245

Ribbon Transport System........................................... 246

Logical Control of the Printer............................................ 247

Control Panel.................................................................... 248

CMX Controller Board....................................................... 249

Data Controller........................................................... 251

Table of Contents

Engine Controller ....................................................... 254

Power Supply Board......................................................... 255

AC Power................................................................... 255

DC Power................................................................... 256

Printer Interface................................................................ 256

Graphics ........................................................................... 257

A Wire Data............................................. 259

B Abbreviations &

Signal Mnemonics ................................... 299

C Metric Conversion Tables ................. 307

D Noise Suppression Devices.............. 309

E SureStak™ Power Stacker ....... .........311

Contents ........................................................................... 311

Introduction....................................................................... 311

Removing the Power Stacker........................................... 312

Installing the Power Stacker ............................................. 317

Replacing the Constant Force Spring............................... 328

Replacing the Timing Belts............................................... 331

Illustrated Parts Breakdown.............................................. 335

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.

Although technologically advanced, the P5000 printer is easy to use. The

operator can select every printer function at the printer control panel or by

sending control codes in the data stream from the host computer to the

printer. For greater security and to protect special printer configurations, the

operator can program which key combination locks and unlocks the ENTER

key on the control panel.

This is also an excellent graphics printer, with optional features that simplify

the creation of images. The IGP and Code V Printronix emulations, for

example,

into flash memory.

are simple but versatile graphics programming languages that load

P5000 Printers

The P5000 family consists of machines that print at different speeds. (See

Table 1.) Many models are available in either a floor cabinet or pedestal

housing. P5XKA (Kanji/Hanzi) models are available in pedestal, cabinet, or

“table top” configuration. Despite its name, the table top P5XKA printer is not

intended for use on a table. It is really a pedestal model printer that has been

removed from the pedestal and packaged separately to facilitate shipping to

certain international markets. A “table top” printer is then installed on its

pedestal after it arrives at its destination.

Kanji/Hanzi Printers

P5XKA printers have shuttle assemblies, hammer springs, and software

modified to print the Kanji/Hanzi character sets used in Asia. These printers

support the GB Song and GB

Republic of China, Singapore, and Hong Kong, and the Big-5

set used in Hong Kong and Taiwan. P5XKA printers can mix ASCII and Kanji/

Hanzi characters on the same line, with ASCII characters occupying half the

width of Kanji/Hanzi character cells. Because of the density and complexity of

these character sets, these models print at lower speeds.

Kai character sets used in the People’s

Ming character

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.

The P5X05B, P5X10, and P5X15 models also use the CMX 040 controller board, which has a 40 MHz clock speed for the Data Controller unit. The CMX 040 can be used in any P5000 printer, but the P5X05B, P5X10, and P5X15 models cannot use earlier versions of the CMX board.

When you replace components, be careful to order the correct spares for the model you are servicing. The next section explains how to identify a P5000 series printer.

How to Identify the Printer

A P5000 printer is identified by its model number. The model number is a code that indicates the printer type, family, speed, and housing. Figure 1 shows how to interpret a model number.

Table 1 lists the models comprising the P5000 family. The speeds listed in Table 1 are the highest speeds attainable under controlled conditions. Actual printing speed is determined by the interaction of many variables. For more

information about printing speeds, refer to “Printing Rates” on page 242.

Optional 12 MIL (0.012 inch) hammer tips. Standard tips are 16 MIL (0.016 inch). This option does not apply to Kanji/ Hanzi printers, which have unique hammer spring assemblies.

Printronix Line Matrix Printer

Housing Code: 0 = Pedestal 1 = Table Top 2 = Floor Cabinet

P5005-12-QA

P5000 Printer

Speed Rating: 05 = 475 lpm 05A = 500 lpm 05B = 500 lpm (40 MHz CMX board) 08 = 800 lpm 09 = 900 lpm 10 = 1000 lpm 12 = 1200 lpm 14 = 1400 lpm 15 = 1500 lpm KA = Kanji/Hanzi printer

QA = Pedestal model with optional QuickAccess Cover

SS = Cabinet model with optional SureStak™ power paper stacker.

Figure 1. How to Interpret Model Numbers

Table 1. P5000 Printers

How to Identify the Printer

Model Number

Speed

Enclosure Hammer Bank

P50KA 585 lpm Pedestal 91 Hammers

Data

Controller

Clock Speed

25 MHz

Kanji / Hanzi P5005 475 lpm Pedestal 28 Hammers 25 MHz P5005-QA 475 lpm Pedestal w/Quick-

28 Hammers 25 MHz

Access Cover

P5005-12 475 lpm Pedestal 28 Hammers,

25 MHz

12 MIL tips

P5005-12-QA 475 lpm Pedestal w/Quick-

Access Cover

P51KA 585 lpm Table Top 91 Hammers

28 Hammers,

12 MIL tips

25 MHz

Kanji / Hanzi P5205 475 lpm Cabinet 28 Hammers 25 MHz P5205-12 475 lpm Cabinet 28 Hammers,

25 MHz

12 MIL tips

P5005A 500 lpm Pedestal 28 Hammers 25 MHz

P5005A-QA 500 lpm Pedestal w/Quick-

28 Hammers 25 MHz

Access Cover

P5005A-12 500 lpm Pedestal 28 Hammers,

25 MHz

12 MIL tips

P5005A-12-QA 500 lpm Pedestal w/Quick-

Access Cover

28 Hammers,

12 MIL tips

25 MHz

P5205A 500 lpm Cabinet 28 Hammers 25 MHz P5205A-12 500 lpm Cabinet 28 Hammers,

25 MHz

12 MIL tips P5005B 500 lpm Pedestal 28 Hammers 40 MHz P5005B-QA 500 lpm Pedestal w/Quick-

28 Hammers 40 MHz

Access Cover

P5005B-12 500 lpm Pedestal 28 Hammers,

40 MHz

12 MIL tips P5005B-12-QA 500 lpm Pedestal w/Quick-

Access Cover

28 Hammers,

12 MIL tips

40 MHz

P5205B 500 lpm Cabinet 28 Hammers 40 MHz

Chapter 1 P5000 Printers

Table 1. P5000 Printers

Model Number

Speed

Enclosure Hammer Bank

P5205B-12 500 lpm Cabinet 49 Hammers,

Data

Controller

Clock Speed

40 MHz

12 MIL tips P5008 800 lpm Pedestal 49 Hammers 25 MHz P5008-QA 800 lpm Pedestal w/Quick-

49 Hammers 25 MHz

Access Cover P5208 800 lpm Cabinet 49 Hammers 25 MHz P500 900 lpm Pedestal 49 Hammers 25 MHz P5009-QA 900 lpm Pedestal w/Quick-

49 Hammers 25 MHz

Access Cover P5209 900 lpm Cabinet 49 Hammers 25 MHz P5010 1000 lpm Pedestal 60 Hammers 40 MHz P5010-QA 1000 lpm Pedestal w/Quick-

60 Hammers 40 MHz

Access Cover P5210 1000 lpm Cabinet 60 Hammers 40 MHz

P5212 1200 lpm Cabinet 91 Hammers 25 MHz P5214 1400 lpm Cabinet 91 Hammers 40 MHz P5214-SS 1400 lpm Cabinet

91 Hammers 40 MHz

w/SureStak

Paper Stacker P5015 1500 lpm Pedestal 102 Hammers 40 MHz P5015-QA 1500 lpm Pedestal w/Quick-

102 Hammers 40 MHz

Access Cover P5215 1500 lpm Cabinet 102 Hammers 40 MHz P5215-SS 1500 lpm Cabinet

102 Hammers 40 MHz

w/SureStak

Paper Stacker

P52KA 585 lpm Cabinet 91 Hammers

40 MHz

Kanji / Hanzi

The microprocessor of the Data Controller unit on the CMX controller board runs at 25 MHz or 40 MHz, depending on printer model. This means there are two kinds of CMX controller board for these printers, used as indicated in Table 1. The 40 MHz controller board, however, is compatible with all models that use the 25 MHz board and should be used if the CMX board is replaced.

Important Maintenance Notes

To ensure the best performance of the printer, remember these maintenance principles whenever you service the printer.

How to Identify the Printer

CAUTION

Failure to observe these guidelines can result in damage to the equipment.

• Do not

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. Always handle hammer springs by

the thick mounting base. The hammer springs and hammer tips are delicate and precisely aligned.

• Use only

can lead to ink migration problems, degraded print quality, and expensive damage to the printer.

• Do not close the forms thickness lever too tightly. Closing the forms

thickness lever too tightly can lead to smearing, degraded print quality, paper jams, and damage to the platen and shuttle assembly.

About This Manual

This is a field service maintenance manual. It is designed so that you can locate maintenance information quickly.

This manual does not explain how to install, operate, or configure the printer. That information is in the

adjust the platen gap unless

the ribbons specified in Appendix B. Use of incorrect ribbons

User’s Manual.

This manual does not explain how to program application software for operation with the printer. Programming information for the protocols used by

the printer is in the appropriate programmer’s reference manual:

•

LinePrinter Plus

Defines host control codes for the LinePrinter Plus emulations.

•

Character Sets Reference Manual

Information about and examples of the character sets available in Printronix line matrix printers.

•

Network User’s Manual

Information about network protocols, configuration, and network operation.

•

Coax/Twinax Programmer’s Reference Manual

Defines host control codes and character sets for the optional coax/twinax emulations.

•

ANSI Programmer’s Reference Manual

Defines host control codes and character sets for the ANSI emulation.

•

IPDS Twinax Emulation Programmer’s Reference Manual

An overview of Intelligent Printer Data Stream™ (IPDS) features, commands, and diagnostics.



Programmer’s Reference Manual

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. The Code V Printronix emulation allows the user to create and store forms; generate logos, bar codes, and expanded characters; create other graphics, and merge graphics with alphanumeric data as a document is printed.

How to Use This Manual

1. Find the procedure or information you need in the Table of Contents or the Index.

2. Read the entire procedure before you work on the printer.

3. Gather the parts and tools you will need.

4. Make sure you understand all safety notices before you start a task. (See below.)

WARNING

CAUTION

IMPORTANT

Notes and Notices

For your safety and to protect valuable equipment, read and comply with all information highlighted under notes and notices. The heading of a notice indicates the kind of information it contains:

Conditions that could hurt you and damage equipment. Conditions that could damage equipment. Information vital to proper operation and maintenance of the printer.

NOTE: Notes contain tips for efficient operation, maintenance, and

troubleshooting.

The Safety Notices on page 17 apply at all times when you are working on the printer. Please read them now.

Printing Conventions in This Manual

Control panel keys and indicators are highlighted in UPPERCASE BOLD PRINT. Example: Press the CANCEL key, then press the ON LINE key.

LCD (Liquid Crystal Display) messages are set off by quotation marks (“ “). Example: Press the ON LINE key. “OFF LINE” appears on the LCD.

Control panel key combinations are indicated by the + (plus) symbol. Example: Press means Press the

= + >.

=(UP) key and the >(DOWN) key at the same time.

Safety Notices

Printing Conventions in This Manual

WARNING

WARNING WARNING

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.

Always disconnect the AC power cord before cleaning the printer. To prevent injury from electric shock, wait at least one minute after

shutting off power before removing the power supply circuit board. Wear a properly grounded static wrist strap when handling the power supply board. Handle the board by the sides. Do not touch components or flex the board during removal/installation.

Over time, the upper edge of the paper ironer can become sharp. To avoid cutting yourself, handle the paper ironer on the sides.

Hold the printer cover securely while disengaging the gas spring assembly.

Hinweise zur Sicherheit

Bevor Sie anfällige Wartungsarbeiten durchführen, müssen Sie zuerst immer das Netzkabel aus der Steckdose ziehen. Wird das Netzkabel nicht herausgezogen, können Verletzungen oder Geräteschäden entstehen. Falls die Wartungsarbeit Stromzufuhr erfordert, wird im Wartungsablauf darauf hingewiesen.

VORSICHT

Ziehen Sie das Netzkabel aus der Steckdose, bevor Sie den Drucker reinigen.

VORSICHT

Um Verletzungen durch Elektroschocks zu vermeiden, warten Sie mindestens eine Minute nach Stromausschaltung, bevor Sie die elektrische Schaltkarte entfernen. Bitte immer einen geerdeten, statischen Handgelenkriemen tragen, wenn Sie die elektrische Schaltkarte handhaben. Halten Sie die Karte nur an den seitlichen Auswurfshebeln. Während des Herausnehmens/Installierens dürfen die Komponenten der Karte nicht berührt oder gebogen werden.

VORSICHT

Die obere Kante der Papierschiene wird mit der Zeit scharf. Halten Sie die Schiene deshalb an den Seiten, damit Sie sich nicht schneiden.

VORSICHT

Behalten Sie die Druckerabdeckung sicher im Griff, wenn Sie das Gasfederpaket entfernen.

Chapter 1 Controls and Indicators

Controls and Indicators

Electrical Controls and Indicators, Cabinet Models (Figure 2)

Switch or

Indicator

Power Switch Turns printer on and off: 1 = on, 0 = off. This switch is also a circuit breaker.

Status

Indicator

LCD Liquid Crystal Display. Displays pri nter status messages, fault messages, and

ON LINE/

CLEAR PAPER

ADVANCE

VIEW / EJECT

CANCEL Clears all data from the print buffer (if enabled in the MAINT/MISC menu).

= (UP)

On when the print er is on -lin e, o f f w h en th e printer is off-line. Flashes to indicate a fault or warning.

menus which permit user to set various configurations. Toggles the printer on-line and off-line. Clears the printer after a fault is corrected

and returns the printer to off-line state. Prints any data in the buffer then moves paper up one line at the currently active

line spacing. If pressed longer than 1/2 second, moves paper to the next Top Of Form as defined by the currently active form length.

Moves the current print position to the tractor area for viewing. When paper is in

VIEW position, “Printer in View” displays and microstep adjustment feature is active. (See UP and DOWN keys.) Holding key down for more than 1/2 second invokes EJECT and paper is advanced two pages. (EJECT can be disabled via the menus.) Pressing key a second time moves paper back to the print position from either VIEW or EJECT position.

Displays next higher level of a configuration menu. In VIEW mode, moves paper up 1/72 inch. (See VIEW / EJECT key.)

Function

Active

On-line

Active

Off-line

ää

> (DOWN)

< (NEXT)

; (PREV)

SET TOF Moves paper downward from TOF alignment mark to the print station and sets this

PRT CONFIG Prints the current printer configuration. JOB SELECT Allows fast selection of any stored configuration. Repeated pressing scrolls

ENTER Enters an option disp layed on th e LCD into p rinter no n-volatile memory. Starts and

;+<

Displays next lower level of a configuration menu. In VIEW mode, moves paper down 1/72 inch. (See VIEW / EJECT key.)

Displays the next option in a configuration menu. Displays the previous option in a configuration menu.

as the first line of print on a page, independent of forms length. If there are data in the buffers, the printer slews to the page position where printing left off and prints the data.

through all saved configurations. Press ENTER to select the displayed configuration. (ENTER does not have to be unlocked for this function.)

stops printer tests, sets a value, or prints the configuration. This key is locked and unlocked by a user-selectable key combination. (Refer to the

Resets the printer by reloading the power-up configuration and resetting the internal state.

User’s Manual

ää

Printing Conventions in This Manual

(Off) (On)

Raise printer cover to use these keys.

DOWN

SET TOF

PRT CONFIG

JOB SELECT

ENTER

LCD

Power Switch

Status Indicator

ON LINE

CLEAR EJECT

PAPER

ADVANCE

VIEW

CANCEL

Figure 2. Electrical Controls, Cabinet Models

Chapter 1 Controls and Indicators

Electrical Controls and Indicators, Pedestal Models (Figure 3)

Switch or

Indicator

Power Switch Turns printer on and off: 1 = on, 0 = off. This switch is also a circuit breaker.

Status

Indicator

LCD Liquid Crystal Display. Displays pri nter status messages, fault messages, and

ON-LINE

CLEAR PAPER

ADVANCE

VIEW

EJECT

CANCEL Clears all data from the print buffer (if enabled in the MAINT/MISC menu).

↑

On when the printer is on -lin e, o f f w h en th e p rinte r is off-line. Flashes to indicate a fault or warning.

menus which permit user to set various configurations. Toggles the printer on-line and off-line. Clears the printer after a fault is corrected

and returns the printer to off-line state. Prints any data in the buffer then moves paper up one line at the currently active

line spacing. If pressed longer than 1/2 second, moves paper to the next Top Of Form as defined by the currently active form length.

Moves the current print position to the tractor area for viewing. When paper is in

Displays next higher level of a configuration menu. In VIEW mode, moves paper up 1/72 inch. (See VIEW / EJECT key.)

Function

Active

On-line

Active

Off-line

ää

↓

DOWN

→

←

SET

TOF

PRT

CONFIG

JOB

SELECT

ENTER Enters an option disp layed on th e LCD into p rinter non -volatile memory. Starts and

← + → Resets the printer by reloading the power-up configuration and resetting the

Displays next lower level of a configuration menu. In VIEW mode, moves paper down 1/72 inch. (See VIEW / EJECT key.)

Displays the next option in a configuration menu.

Displays the previous option in a configuration menu.

Moves paper downward from TO F ali gnment m ark to the p rint s tation and s ets this as the first line of print on a page, independent of forms length. If there are data in the buffers, the printer slews to the page position where printing left off and prints the data.

Prints the current printer configuration.

Allows fast selection of any stored configuration. Repeated pressing scrolls through all saved configurations. Press ENTER to select the displayed configuration. (ENTER does not have to be unlocked for this function.)

stops printer tests, sets a value, or prints the configuration. This key is locked and unlocked by a user-selectable key combination. (Refer to the

internal state.

User’s Manual

ää

Printing Conventions in This Manual

(Off) (On)

LCD

Power Switch

JOB

PRT

SET

DOWNUPNEXTPREV

TOF

SET

PRT

UP DOWN

TOF

CONFIG

Status Indicator

CONFIG

JOB

SELECT

ENTER

SELECT

ON-LINE

ENTER

CLEAR

PAPER

ADVANCE

ON-LINE PAPER VIEW CANCEL

CLEAR ADVANCE EJECT

VIEW

EJECT

CANCEL

Figure 3. Electrical Controls, Pedestal Models

Chapter 1 Controls and Indicators

Mechanical Controls and Indicators, All Models (Figure 6)

Control or

Indicator

Forms Thickness Lever

Sets the platen for paper and forms of different thicknesses. Lever must be fully opened (raised) to

Function

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. Set this lever at A for thin (single-part) forms, B for thicker forms, and so on.

Tractors (2) Hold and feed paper. Used to set side margin and

position paper horizontally. Tractor Locks (2) Lock tractors in position. Horizontal

Adjustment Knob Vertical Position

Knob

Allows fine positioning of left print margin. Moves

paper and tractors left or right.

Used to set top of form or first line to be printed.

Rotate this knob to move paper vertically. Works

when forms thickness lever is open. Ribbon Loading

Path Diagrams

Instructions showing how to load the ribbon correctly.

One diagram is cast in relief on the shuttle cover, and

another is printed on the paper scale. Paper Scale A horizontal scale graduated in tenths of an inch,

useful for setting paper margins counting text

columns. (See below.)

1 inch

110 20

0.1 inch

Column Number

Left Tractor

Printing Conventions in This Manual

Paper Supports

Tractor Lock

Horizontal Adjustment Knob

Ribbon Loading Path Diagrams

Right Tractor

Tractor Lock

Vertical Position Knob

Forms Thickness Lever and Scale

Forms Thickness Pointer

Figure 4. Mechanical Controls and Indicators, All Models

Chapter 1 Tools, Test Equipment, and Supplies

Tools, Test Equipment, and Supp lies

For field level maintenance of the printer, you will need these tools:

Adapter, 1/4 in. hex to 1/4 in. square, Utica 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)

HW-18

Hex bit, 3/16 in., torque screwdriver Hex bit, 3/32 in., torque screwdriver Hex bit, 5/32 in., torque screwdriver Hex bit, 5/64 in., torque screwdriver Lubricant, Bearing (Printronix P/N 101805-001) Nut Driver, 1/4 inch Nut Driver, 5/16 inch Nut Driver or Open End Wrench, 7/32 inch Open End Wrench, 5/16 inch Pliers, Grip Ring, External Screwdriver, flat tip Screwdriver, Phillips, #1 Screwdriver, Phillips, #2 Screwdriver, Torque, Utica TS-35 Tie Wraps, 4 inch Torx

T-10 Driver

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. The cleaning procedures in this chapter pertain to all models.

WARNING

CAUTION

Always disconnect the AC power cord before cleaning the printer. Do not use abrasive cleaners, particularly on the window.

Do not drip water into the printer. Damage to the equipment will result. Do not spray directly onto the printer when using spray solutions. Spray the cloth, then apply the dampened cloth to the printer. Do not vacuum the circuit boards.

Cleaning the Outside Surfaces

1. Power off the printer.

CAUTION

2. Disconnect the AC power cord from the printer or the power source.

3. Remove paper and the ribbon.

4. Dampen a clean, lint-free cloth with water and a mild detergent or with window cleaning solution. The cloth must be damp, not wet. Wipe down the outside surfaces of the printer.

5. Dry the outside surfaces with a clean, lint-free cloth.

6. Open the printer cover.

7. Using a soft-bristled, non-metallic brush (such as a toothbrush), brush paper dust and ribbon lint off the tractors, shuttle cover assembly, base casting, and ribbon guides. Vacuum up the residue. (See Figure 5.)

8. Wipe the splined shaft with a soft cloth.

To avoid corrosion damage, use only alcohol when cleaning printer mechanical elements, and make sure the cleaning solution contains no water.

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.

NOTE: Cabinet model shown. Procedure is the same for pedestal model.

Legend:

1) Base Casting

2) Shuttle Cover Assembly

3) Splined Shaft

4) Tractors

5) Forms Thickness Lever

6) Ribbon Guide

Figure 5. Cleaning Inside the Cabinet or Top Cover

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

CAUTION

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. Remove the hammer bank / ribbon mask cover assembly (page 157).

The ribbon mask is thin and easily bent. Be careful not to crease or kink the ribbon mask when handling and cleaning it.

7. Moisten a clean, soft cloth with alcohol. Wipe the hammer bank cover and ribbon mask to remove lint, ink, and paper residue. Clean the holes in the cover strips. Carefully wipe between the hammer bank cover and the ribbon mask (early models).

Do not use any solvents or liquids to clean the hammer tips. Clean the

hammer tips gently—too much pressure can chip them.

8. Using a stiff, non-metallic brush (such as a toothbrush), gently brush the hammer tips to remove lint and ink accumulations. (See Figure 6.) Vacuum up any residue.

NOTE: P5005 hammer bank is shown. Procedure is the same

for all hammer banks.

CAUTION

Legend:

1) Hammer Tip

Figure 6. Cleaning the Hammer Tips

The hammer bank contains a strong magnet. To prevent damage to the hammer tips, do not let the hammer bank cover assembly snap into place as the hammer bank magnet attracts it. Any impact of the cover against the hammer bank can break hammer tips.

9. Install the hammer bank / ribbon mask cover assembly (page 157).

10. Install the shuttle frame assembly (page 198).

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. Cabinet Models: Install the paper path (page 177) Pedestal Models: Install the top cover assembly (page 161).

4. Return the printer to normal operation (page 107).

NOTE: Cabinet model show n. Procedure is the same for pedestal model.

Legend:

1) Card Cage Fan Assemb.y

Figure 7. Cleaning the Card Cage Fan Assembly

3 Troubleshooting

Introduction

This chapter lists fault messages and symptoms, and provides procedures for troubleshooting printer malfunctions.

Always have the 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.

T roubleshooting Aids

Troubleshooting is faster and more effective if you understand the equipment and make use of all available tools.

This manual provides a number of troubleshooting aids to help you isolate printer malfunctions:

• “Start Here” Logic Tree page 30

• Troubleshooting Display Messages page 31

• Message List page 31

• Troubleshooting Other Symptoms page 36

• General Symptom List page 36

• Troubleshooting Procedures page 38

• Diagnostic Printer Tests page 92

• Hex Code Printout page 95

User’s Manual

handy when you troubleshoot because this

• ASCII Character Set page 97

• The Power On Sequence page 99

• Appendix A: Wire Data page 259

Chapter 3 Start Here...

Start Here...

Are you here because of an error message?

Power on the printer and observe the control panel for the following sequence of events (retry as required):

1. All blac k squares appear on the display.

2. Display goes blank.

3. TESTING HARDWARE PLEASE WAIT appears on display. Power on the printer. Did steps 1, 2, and 3 occur?

Did the fans come on after 10 seconds?

YES

Go to Troubleshooting Display Messages, page 31.

Did the status indicator lamp

After about 10 seconds did the fans come on?

Press ON LINE. Press PRT CONFIG. Press ENTER. Does machine configuration print?

YES

come on and ONLINE appear on the display? (If default is OFFLINE, status indicator will not come on.)

Go to Printer

does not initialize, page 71.

YES

Go to the Control Panel section of Table 3: page 36

Printer initialized successfully. Other symptoms are listed in Table 3: page

36.

Did ANY of steps 1 thru 3 occur?

Go to No power, and

control panel is blank, and card cage fan is not running, page 62.

YES

The Control Panel is not functioning (Table 3: page 36)

—OR—

Printer does not initialize, page 71.

Are there black squares on the control panel?

Go to Printer does not initialize, page 71.

YES

Go to Black squares

on control panel display, page 44.

+ 330 hidden pages