Printronix P5000 Manual de Instruções

Maintenance Manual®The Printronix P5000 series of Line Matrix Printers

xTable of ContentsEngine Controller ... 254Power Supply Board...

100Chapter 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

CMX Controller Board Handshake Sequences 101• Check for Pedestal — Boot code uses the control panel to determine if the printer is a pedestal or floor

102Chapter 3 The Power On Sequencedetected, boot codes displays “ERROR: SECURITY PAL NOT DETECTED”. If a security PAL is detected, boot code checks f

DC Software Initialization and Power Up 103• Jump to MTOS — Jump to start initialization of the MTOS (Multi–Tasking Operating System).DC Software Init

104Chapter 3 The Power On Sequence

1054 Adjustment ProceduresIntroductionThe printer is a durable, low-maintenance machine, but some components and systems require occasional adjustmen

106Chapter 4 Preparing the Printer for MaintenancePreparing the Printer for Maintenance WARNINGUnplug the printer power cord from the printer or powe

107Returning the Printer to Normal Operation When you are finished servicing the printer, do the following steps:1. Install the ribbon.2. Load paper.

108Chapter 4 Belt, Paper Feed Timing, Adjustment (Figure 10)Belt, Paper Feed Timing, Adjustment (Figure 10) 1. Prepare the printer for maintenance (p

109Legend: 1) Timing Belt Shield 2) Motor Mount Bolt (2) 3) Paper Feed Drive Motor 4) Splined ShaftFigure 10. Paper Feed Timing Belt AdjustmentDirect

111 Maintenance OverviewAbout the PrinterPrintronix P5000 series line matrix printers use PSA (Printronix System Architecture), which puts all data

110Chapter 4 Belt, Platen Open, Adjustment (Figure 11)Belt, Platen Open, Adjustment (Figure 11) 1. Prepare the printer for maintenance (page 106).2.

111Legend: 1) Belt Cover 2) Motor Mount Screw (2) 3) Platen Open Motor ShaftFigure 11. Platen Open Belt Adjustment$Direction of Force1$232

112Chapter 4 Paper Drive Motor Pulley Alignment (Figure 12)Paper Drive Motor Pulley Alignment (Figure 12)1. Prepare the printer for maintenance (page

113Legend: 1) Belt Shield 2) Cap Screw 3) Motor Pulley Collar 4) Motor Pulley 5) Splined Shaft PulleyFigure 12. Paper Drive Motor Pulley Alignment$$1

114Chapter 4 Paper Scale Alignment (Figure 13)Paper Scale Alignment (Figure 13)1. Open the printer cover.2. Load paper and ribbon.3. Connect the powe

115Legend: 1) Shuttle Cover 2) Screw, Button-Head, 5/64 inch hex (3) 3) Paper ScaleFigure 13. Paper Scale Alignment12223

116Chapter 4 Platen Gap Adjustment (Figure 14)Platen Gap Adjustment (Figure 14)IMPORTANTOnly do this procedure if the original equipment shuttle fram

117Legend: 1) Forms Thickness Lever 2) Feeler Gauge 3) Hammer Bank Cover 4) Ribbon Mask 5) Set Screw, 3/32 inch hex (2)Figure 14. Platen Gap Adjustme

118Chapter 4 Platen Open Motor Pulley Alignment (Figure 15)Platen Open Motor Pulley Alignment (Figure 15) 1. Prepare the printer for maintenance (pag

119Legend: 1) Belt Cover 2) Set Screw 3) Platen Open Motor Pulley 4) Platen Shaft PulleyFigure 15. Platen Open Motor Pulley Alignment$$1432

12Chapter 1 P5000 PrintersPrinter EvolutionThe newest models in the family are the P5X05B, P5X10, and P5X15, which are available both in pedestal and

120Chapter 4 Ribbon Guide Alignment (Figure 16)Ribbon Guide Alignment (Figure 16)1. Open the printer cover.2. Load paper and install the ribbon. To a

121Legend: 1) Screw, Skid (2) 2) Ribbon 3) White Nylon Washer 4) Screw, Retaining (2)Figure 16. Ribbon Guide Alignment$$%Left Ribbon Guide Right Ribb

122Chapter 4 Splined Shaft Skew Adjustment (Figure 17)Splined Shaft Skew Adjustment (Figure 17)If lines of print are not parallel with the perforatio

123Legend: 1) Screw 2) Adjusting Link 3) Horizontal Adjustment KnobFigure 17. Splined Shaft Skew Adjustment213

124Chapter 4 Paper Out AdjustmentPaper Out AdjustmentThis procedure tests and sets the distance from the page perforation at which a LOAD PAPER fault

125Figure 18. Paper Preparation for Paper Out Adjustment TestPage PerforationPage PerforationPage PerforationCut out here4 in.4 in.

126Chapter 4 Paper Out Adjustment7. On the control panel, press the = + > keys to unlock the ENTER key. “ENTER SWITCH UNLOCKED” briefly displays.

12721. 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

128Chapter 4 Hammer Phasing AdjustmentHammer Phasing Adjustment You must check and adjust hammer phasing if the CMX controller board is replaced, the

12912. Press >: The current phase index displays. Press > again: An asterisk (*) appears next to the phase value.13. Press < to increase or

How to Identify the Printer 13Table 1. P5000 PrintersModel NumberPrint SpeedEnclosure Hammer BankData Controller Clock Speed1P50KA 585 lpm Pedestal 9

130Chapter 4 Loading Flash Memory from One DisketteLoading Flash Memory from One DisketteFlash memory is contained in SIMMs (single in-line memory mo

1319. 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

132Chapter 4 Loading Flash Memory from One Diskettecommands must match the selection you made in step 16.If you are loading the file through the prin

133ERROR: FLASHDID NOT PROGRAMThe printer encountered an error trying to program flash memory.Download the program again: Power off the printer and s

134Chapter 4 Loading Flash Memory from One DisketteERROR: WRONGCHECKSUMThe printer received the complete program but the checksum did not match. The

135Loading Flash Memory from Multiple DiskettesFlash memory is contained in SIMMs (single in-line memory modules) located on the controller board. Pr

136Chapter 4 Loading Flash Memory from Multiple Diskettes7. Connect the data cable to the appropriate I/O port of the printer.8. Plug the AC power co

13721. On the printer control panel, press and hold down the ON LINE + PAPER ADVANCE keys. Without releasing the keys, power the printer on. Continue

138Chapter 4 Loading Flash Memory from Multiple Diskettes31. Power off the computer.32. If you had to install a data cable to the computer and printe

139ERROR: NVRAMFAILUREThe non-volatile memory has failed. Replace the CMX controller board. (Do NOT attempt to replace NVRAM.)ERROR: PROGRAMNEEDS MOR

14Chapter 1 P5000 PrintersP5205B-12 500 lpm Cabinet 49 Hammers,12 MIL tips40 MHzP5008 800 lpm Pedestal 49 Hammers 25 MHzP5008-QA 800 lpm Pedestal

140Chapter 4 Loading Flash Memory from Multiple DiskettesLOADING PROGRAMINTO FLASHThe printer has deleted the previous program from flash memory and

141Set Shuttle Speed IMPORTANTDo this procedure if you replaced the CMX controller board and/or the shuttle frame assembly in a 475 or 500 lpm printe

142Chapter 4 Set Shuttle Speed

1435 Replacement Proceduresand Illustrated Parts ListsOrganization of This Chapter This chapter is divided into two sections.• Section I: Replacement

144Chapter 5 Section I: Replacement ProceduresSection I: Replacement ProceduresWARNINGUnplug the printer power cord from the printer or power outlet

List of Removal/Installation Procedures 145Paper Path page 177Platen page 178Platen Open Motor page 182Power Supply Board page 184PrintNet Ethernet In

146Chapter 5 Section I: Replacement ProceduresBelt, Paper Feed TimingRemoval1. Prepare the printer for maintenance (page 106).2. Cabinet Models: Remo

Belt, Platen Open 147Belt, Platen OpenRemoval1. Prepare the printer for maintenance (page 106).2. Cabinet Models: Remove the paper path (page 177).Ped

148Chapter 5 Section I: Replacement ProceduresCircuit BreakerRemoval1. Prepare the printer for maintenance (page 106).2. Remove the card cage fan (pa

Connector Shells 149Connector ShellsSome of the cable connectors in the printer are grouped inside connector shells. The procedure below explains how

How to Identify the Printer 15Important Maintenance NotesTo ensure the best performance of the printer, remember these maintenance principles whenever

150Chapter 5 Section I: Replacement ProceduresFigure 19. Cable Connector Shell, Disassembly/AssemblyTypical 4-Wire Cable ConnectorPull the side outwa

Connector Stiffening Clips 151Connector Stiffening ClipsLater model printers have connector stiffening clips on CMX board connectors P106 and P107. Th

152Chapter 5 Section I: Replacement ProceduresFigure 20. Connector Stiffening ClipsP107P106Stiffening Clip$$$Connector Shell

Control Panel Assembly, Cabinet Models 153Control Panel Assembly, Cabinet ModelsRemoval1. Prepare the printer for maintenance (page 106).2. Disconnect

154Chapter 5 Section I: Replacement ProceduresControl Panel Assembly, Pedestal ModelsRemoval1. Prepare the printer for maintenance (page 106).2. Open

Controller Board (CMX) 155Controller Board (CMX)Removal CAUTIONTo prevent electrostatic damage to electronic components, always wear a properly ground

156Chapter 5 Section I: Replacement Procedures5. Install the expansion-CT board, if necessary (page 162).Install the PrintNet Ethernet interface asse

Cover Assembly, Hammer Bank / Ribbon Mask 157Cover Assembly, Hammer Bank / Ribbon Mask Removal1. Prepare the printer for maintenance (page 106).2. Rem

158Chapter 5 Section I: Replacement ProceduresInstallationCAUTIONThe hammer bank contains a strong magnet. To prevent damage to the hammer tips, do n

Cover Assembly, Hammer Bank / Ribbon Mask 159Figure 21. Hammer Bank Cover Assembly / Ribbon Mask123456789101112123546Early ModelsLater ModelsHammer Ba

16Chapter 1 About This Manual•IGP/PGL Programmer’s Reference ManualDescribes the optional IGP Printronix emulation. The IGP Printronix emulation all

160Chapter 5 Section I: Replacement ProceduresCover Assembly, ShuttleRemoval1. Prepare the printer for maintenance (page 106).2. Loosen the shuttle c

Cover Assembly, Top, Pedestal Models 161Cover Assembly, Top, Pedestal ModelsRemoval1. Prepare the printer for maintenance (page 106).2. Loosen, but do

162Chapter 5 Section I: Replacement ProceduresExpansion-CTRemovalCAUTIONTo prevent electrostatic damage to electronic components, always wear a prope

Fan Assembly, Cabinet Exhaust 163Fan Assembly, Cabinet ExhaustNOTE: This procedure applies only to cabinet models.Removal1. Prepare the printer for ma

164Chapter 5 Section I: Replacement ProceduresFan Assembly, Card CageRemoval1. Prepare the printer for maintenance (page 106).2. Cabinet Models: Remo

Fan Assembly, Hammer Bank 165Fan Assembly, Hammer BankRemoval1. Prepare the printer for maintenance (page 106).2. Remove the shuttle cover assembly (p

166Chapter 5 Section I: Replacement ProceduresHammer Spring AssemblyRemoval1. Prepare the printer for maintenance (page 106).2. Remove the shuttle fr

Hammer Spring Assembly 167Figure 22. Hammer Spring Assembly, RemovalHammer Spring Assembly 7Hammer Spring Assembly 1NOTE: P5005 hammer bank and hammer

168Chapter 5 Section I: Replacement ProceduresInstallation1. Using a clean dry cloth, wipe the hammer spring mounting surface on the hammer bank. Mak

Hammer Spring Assembly 169Figure 23. Hammer Spring Assembly, InstallationNOTE: P5005 hammer bank and hammer spring assemblies are shown here. Although

Printing Conventions in This Manual 17Safety NoticesWARNINGAlways disconnect the AC power cord from the printer or power source before performing any

170Chapter 5 Section I: Replacement ProceduresMagnetic Pickup (MPU) AssemblyRemoval1. Prepare the printer for maintenance (page 106).2. Remove the sh

Memory Modules and Security PAL 171Memory Modules and Security PALCAUTIONTo prevent electrostatic damage to electronic components, always wear a prope

172Chapter 5 Section I: Replacement ProceduresInstallationCAUTIONTo prevent electrostatic damage to electronic components, always wear a properly gro

Memory Modules and Security PAL 173Figure 24. Memory Modules and Security PAL213Bank 0Bank 1Bank 0Bank 180-pin SIMMJ11 = Bank 0 (must alwaysbe filled)

174Chapter 5 Section I: Replacement ProceduresPaper Feed MotorRemoval1. Prepare the printer for maintenance (page 106).2. Cabinet Models: Remove the

Paper Feed Motor 175Installation1. Position the paper feed motor assembly on the right side plate and install the motor mount bolts and nuts finger ti

176Chapter 5 Section I: Replacement ProceduresPaper IronerWARNINGOver time, the upper edge of the paper ironer can become sharp. To avoid cutting you

Paper Path 177Paper PathNOTE: This procedure applies only to cabinet models.Removal1. Prepare the printer for maintenance (page 106).2. Loosen the thr

178Chapter 5 Section I: Replacement ProceduresPlatenRemoval1. Prepare the printer for maintenance (page 106).2. Remove the shuttle frame assembly (pa

Platen 179InstallationIMPORTANTThe dowel pins protruding from the ends of the platen are the platen shafts. The platen shafts are not of equal length.

18Chapter 1 Controls and IndicatorsControls and IndicatorsElectrical Controls and Indicators, Cabinet Models (Figure 2)Switch or IndicatorFunctionAct

180Chapter 5 Section I: Replacement ProceduresFigure 26. Positioning the Platen Adjust Brackets9. Slide the right ribbon guide assembly into the side

Platen 181b. 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 l

182Chapter 5 Section I: Replacement ProceduresPlaten Open MotorRemoval1. Prepare the printer for maintenance (page 106).2. Cabinet Models: Remove the

Platen Open Motor 183Installation1. Position the platen open motor assembly with the wires toward the rear (page 230, item 5).2. Install the two 5/16

184Chapter 5 Section I: Replacement ProceduresPower Supply BoardWARNINGTo prevent injury from electric shock, wait at least one minute after shutting

PrintNet Ethernet Interface Assemblies 185PrintNet Ethernet Interface AssembliesNOTE: The PrintNet LAN option is available in one of three configurati

186Chapter 5 Section I: Replacement Procedures10Base2 and 10Base-T LEDs and DIP Switches10Base2 and 10Base-T PrintNet Ethernet interfaces have three

10Base2 and 10Base-T LEDs and DIP Switches 187Run Mode and Auto Reset Mode: Run Mode is the normal operating state of the Ethernet Interface. Auto Res

188Chapter 5 Section I: Replacement Procedures10/100Base-T LEDs and DipswitchesThe 10/100Base-T PrintNet Ethernet interface has two indicator lights,

10/100Base-T LEDs and Dipswitches 189DipswitchesOn the back of the 10/100Base-T PrintNet Ethernet interface (inside the printer) are two dipswitches l

Printing Conventions in This Manual 19Figure 2. Electrical Controls, Cabinet ModelsON LINEPAPERVIEWUPDOWNPREVLCDENTERSET TOFPRT CONFIGJOB SELECTNEXTAD

190Chapter 5 Section I: Replacement ProceduresResistors, TerminatingFor parallel interface configurations, the printer is equipped with 470 ohm pull-

Resistors, Terminating 191Figure 27. Terminating Resistors, Removal/InstallationDefault: 470 OhmAlt 1: 220 OhmAlt 2: 1K OhmDefault: 1K OhmAlt 1: 330 O

192Chapter 5 Section I: Replacement ProceduresRibbon Drive MotorRemoval1. Prepare the printer for maintenance (page 106).2. Remove the ribbon hub (pa

Ribbon Guide Assembly (L/R) 193Ribbon Guide Assembly (L/R)NOTE: The right ribbon guide is shown exploded in Figure 41 on page 230. The removal procedu

194Chapter 5 Section I: Replacement ProceduresRibbon HubRemoval 1. Prepare the printer for maintenance (page 106).2. Loosen the Torx T-10 screw in th

Shaft, Splined 195Shaft, SplinedRemoval1. Prepare the printer for maintenance (page 106).2. Remove the paper supports from the splined shaft and suppo

196Chapter 5 Section I: Replacement ProceduresInstallation1. Open the doors on the left and right tractors. Position the tractor belts so the alignme

Shaft, Support 197Shaft, SupportRemoval1. Prepare the printer for maintenance (page 106).2. Unlock the tractors and slide them to the far right.3. Rem

198Chapter 5 Section I: Replacement ProceduresShuttle Frame AssemblyRemoval 1. Prepare the printer for maintenance (page 106).2. Remove the shuttle c

Shuttle Frame Assembly 199CAUTIONDo not over-tighten the shuttle frame assembly clamp screws.6. Slide the side clamps over the guide shaft and torque

20Chapter 1 Controls and IndicatorsElectrical Controls and Indicators, Pedestal Models (Figure 3)Switch or IndicatorFunctionActive On-lineActive Off-

200Chapter 5 Section I: Replacement ProceduresSpring Assembly, GasCAUTIONTwo persons may be required to do this procedure. Prop or hold the printer c

Spring, Extension, Hammer Bank 201Spring, Extension, Hammer Bank CAUTIONDo not let the hammer bank rotate toward the platen during spring replacement.

202Chapter 5 Section I: Replacement ProceduresSwitch Assembly, Paper DetectorRemoval1. Prepare the printer for maintenance (page 106).2. Cabinet Mode

Switch Assembly, Platen Interlock 203Switch Assembly, Platen InterlockRemoval1. Prepare the printer for maintenance (page 106).2. Cabinet Models: Remo

204Chapter 5 Section I: Replacement ProceduresTractor (L/R) Removal1. Prepare the printer for maintenance (page 106).2. Remove the support shaft (pag

Illustrations of Printer Components 205Section II: Illustrated Parts ListsNOTE: Only field-replaceable spares are given part numbers in the illustrate

206Chapter 5 Section II: Illustrated Parts ListsFigure 29. Top Cover, Doors, and Casters12345678

Illustrations of Printer Components 207Item No.Part No. Description Notes1 164212-905 Top Cover Kit, Cabinet Includes mounting hardware2 131803-901 Wi

208Chapter 5 Section II: Illustrated Parts ListsFigure 30. Paper Fence and Chains435126897

Illustrations of Printer Components 209Item No.Part No. Description Notes1 Ref Paper Fence 475 and 500 lpm models and models with power stacker2 Ref P

Printing Conventions in This Manual 21Figure 3. Electrical Controls, Pedestal ModelsPREVNEXTSETPRTENTERON-LINE PAPER VIEW CANCELJOBUP DOWNLCDSELECTCLE

210Chapter 5 Section II: Illustrated Parts ListsFigure 31. Control Panel and Cabinet Details$$124356447

Illustrations of Printer Components 211Item No.Part No. Description Notes1 153700-901 Control Panel Assembly Includes mounting hardware2 152440-901 Ca

212Chapter 5 Section II: Illustrated Parts ListsFigure 32. Pedestal Details1211104956713128

Illustrations of Printer Components 213Item No.Part No. Description Notes1 153366-901 Control Panel Assembly2 Ref Screw, Captive (4)3 Ref Screw, Capti

214Chapter 5 Section II: Illustrated Parts ListsFigure 33. Inside Covers, Cabinet Models121234101198765

Illustrations of Printer Components 215Item No.Part No. Description Notes1 164295-001 Shuttle Cover (Shroud Assembly, Air)2 Ref Screw, Captive (2) 10-

216Chapter 5 Section II: Illustrated Parts ListsFigure 34. Inside Covers and Card Cage, Pedestal ModelsSee Figure 35, page 218.1210$53436787

Illustrations of Printer Components 217Item No.Part No. Description Notes1 164295-001 Shuttle Cover (Shroud Assembly, Air)2 Ref Screw, Captive (2) 10-

218Chapter 5 Section II: Illustrated Parts ListsFigure 35. Card Cage Detail, Pedestal ModelsFrom Figure 34, page 216. Rotated 180 degrees.5$To IEC 32

Illustrations of Printer Components 219Item No.Part No. Description Notes1 Ref Nut, 6-32 (1) Upper right fan corner only2 150261-901 Card Cage Fan Ass

22Chapter 1 Controls and IndicatorsMechanical Controls and Indicators, All Models (Figure 6)Control or IndicatorFunctionForms Thickness LeverSets the

220Chapter 5 Section II: Illustrated Parts ListsFigure 36. Print Mechanism and Circuit Boards: Early Models1Two places: Exploded to show assembly. Do

Illustrations of Printer Components 221Item No.Part No. Description Notes1 159766-901159767-901159768-901Hammer Bank/Ribbon Mask Cover AssyHammer Bank

222Chapter 5 Section II: Illustrated Parts ListsFigure 37. Print Mechanism and Circuit Boards: Later ModelsTo J02 (Shuttle Motor) To J03 (MPU)To Term

Illustrations of Printer Components 223Item No.Part No. Description Notes1 163802-901163795-901164216-901Hammer Bank CoverHammer Bank CoverHammer Bank

224Chapter 5 Section II: Illustrated Parts ListsFigure 38. Magnetic Pickup (MPU) and Extension SpringCAUTION:Make sure the MPU cable does not touch t

Illustrations of Printer Components 225Item No.Part No. Description Notes1 150281-901 MPU Assembly2 Ref Bracket, MPU Part of item 13 Ref Screw, Socket

226Chapter 5 Section II: Illustrated Parts ListsFigure 39. Tractor ShaftsNOTEItem 18 (not shown): Tractor Shaft Hardware Kit, includes items 6, 7, 8,

Illustrations of Printer Components 227Item No.Part No. Description Notes1 Ref Screw, Socket Cap Part of item 192 Ref Washer, Flat #4 Part of item 193

228Chapter 5 Section II: Illustrated Parts ListsFigure 40. PlatenNOTE:Black tape faces paper motion detector.NOTE:Item 25: Platen Hardware Kit1243567

Illustrations of Printer Components 229Item No.Part No. Description Notes1 Ref Setscrew (2) Part of item 252 Ref Bracket, Platen (2) Part of item 253

Printing Conventions in This Manual 23Figure 4. Mechanical Controls and Indicators, All ModelsHorizontal Adjustment KnobTractor LockLeft TractorRight

230Chapter 5 Section II: Illustrated Parts ListsFigure 41. Motors, Fans, and Paper Detector SwitchInstall screws here.Route cable underbase castingHa

Illustrations of Printer Components 231Item No.Part No. Description Notes1 150261-901 Card Cage Fan Assembly Air flow is into card cage2 Ref Screw, w/

232Chapter 5 Section II: Illustrated Parts ListsFigure 42. Circuit Breaker, Cabinet ModelsTo IEC 320 AC Power Input (Connector J301, White Wire)To Co

Illustrations of Printer Components 233Item No.Part No. Description Notes1 142013-901 Circuit Breaker2 Ref IEC 320 AC Power Connector Connector J3013

234Chapter 5 Section II: Illustrated Parts ListsFigure 43. Expansion-CT Board12345687

Illustrations of Printer Components 235Item No.Part No. Description Notes1 Ref Screw (2)2 Ref Card Cage3 156075-001 Expansion-CT Subassembly4 Ref Scre

236Chapter 5 Section II: Illustrated Parts ListsFigure 44. PrintNet Ethernet Interface Assemblies12345679108

Illustrations of Printer Components 237Item No.Part No. Description Notes1 Ref Screw, Connector Cover (2)2 158295-001 Cover Plate, Centronics3 202049-

238Chapter 5 Section II: Illustrated Parts Lists

2396 Principles of OperationLine Matrix PrintingThe printer creates characters and graphics by printing patterns of ink dots an entire line at a time

24Chapter 1 Tools, Test Equipment, and SuppliesTools, Test Equipment, and SuppliesFor field level maintenance of the printer, you will need these too

240Chapter 6 Line Matrix PrintingWhen the shuttle reaches the end of a sweep, it reverses direction, the paper is advanced one dot row, and the hamme

241Figure 47. Action of One Hammer Spring in Text Printing= Hammer Released and Dot Printed******1 13 135 1 357 1357912345671234561234512341217653421

242Chapter 6 Printing RatesPrinting RatesBecause a line matrix printer prints entire lines sequentially, it is faster than a moving-printhead printer

Shuttle Frame Assembly 243Shuttle Frame AssemblyThe central element of the printing mechanism is the shuttle frame assembly, which houses the hammer b

244Chapter 6 Printing Mechanismsimilar to that of a horizontally-opposed gasoline engine. Mechanically, this design achieves the same benefits as thi

Paper Transport System 245Paper Transport SystemFigure 50. Paper Transport SystemA two-phase DC stepper motor, directed by the engine controller (EC),

246Chapter 6 Printing MechanismRibbon Transport SystemFigure 51. Ribbon Transport SystemAn inked ribbon winds and unwinds continuously on a pair of s

Ribbon Transport System 247Logical Control of the Printer The printer comprises four functional elements: the control panel, the CMX controller board,

248Chapter 6 Control PanelControl PanelThe user communicates with the printer by pressing keys on the control panel. The keys are momentary contact s

Ribbon Transport System 249CMX Controller BoardThe heart of the printer is the CMX controller board, which monitors and directs all printer functions.

252 Preventive MaintenanceCleaning the Printer The printer is designed to require very little maintenance. Aside from normal replenishment of paper a

250Chapter 6 CMX Controller BoardFigure 54. CMX Controller Board Block DiagramExpansionPortRS-232/422IEEE-1284(Parallel)FaultSensorsPaperFeedRibbonSh

Data Controller 251Data ControllerThe data controller (DC) consists of the following elements:• 68EC030 microprocessor• Two flash SIMM sockets, for up

252Chapter 6 CMX Controller BoardNVRAMAn 8K x 8 bit Non-Volatile battery-backed static RAM (NVRAM) device provides for the storage of configuration a

Data Controller 253“Dot Plucking” and Adjacent Dot Checking“Dot Plucking” is a specialized DMA function that removes dot data from a dot image buffer

254Chapter 6 CMX Controller BoardEngine ControllerThe engine controller (EC) consists of four main elements:• 80C166 Microcontroller• 128KB 5.0V-only

AC Power 255The printer has five electric motors: two ribbon drive, one paper feed, one platen open, and one shuttle motor. The shuttle motor is a bru

256Chapter 6 Printer InterfaceDC PowerThe power supply board contains two DC power supply systems for the printer. The first is a +5 V bus for logic.

DC Power 257GraphicsThe VGL Advanced Graphics programming language (a QMS graphics emulation) and the PGL Advanced Graphics programming language (a Pr

258Chapter 6 Graphics

259A Wire DataNOTE: Acronyms and signal mnemonics are defined in Appendix C.Interconnection Diagram page 261Distribution Diagram page 262Main Wire Ha

26Chapter 2 Cleaning the Outside Surfaces9. Using a cloth dampened (not wet) with alcohol, clean the ribbon guides.10. Vacuum up dust and residue fro

260Appendix APower Stacker CablesFrame Cable, Power Stacker page 291Logic Cable, Power Stacker page 292Power Cable, Power Stacker page 293Vertical Ra

261Interconnection Diagram122242444422421010322836J301AC INPUTCIRCUITBREAKERP1J1 ACLine 1Line 2 / NeutralCHASSISGNDIEC 320AC POWERCONNECTORAC to DCPo

262Appendix APower Distribution Diagram12345678910111212J301AC PowerCIRCUITBREAKERIEC 320AC POWERCONNECTOROn/Off SwitchP1J1 ACAC to DCPower Supply Bo

263Main Wire Harness Test TablesP106P107CCF = Card Cage FanLRIB M = Left Ribbon MotorLRP = Left Ribbon GuidePLAT M = Platen Open MotorPMD = Paper Mot

264Appendix AController, CMX12345678N STROBE910111213141516171819202122232425P1P2P3P4P5P6P7P8N ACKBUSYPAPER EMPTYSLCT262728293031323334353637383940NC

265Controller (continued)12345678PPR STK ST910PPR STK STPPR STK CTPPR STK CTPaper StackerJ17VCCNCNCNCNC470 PF10%50V470 PF10%50V470 PF10%50V470 PF10%5

266Appendix AController (continued)12345678PLAT 191011121314151617181920J106Motor Sensor LeftRIB L1PLAT 2RIB L2PLAT 3RIB L3PLAT 4RIB L4CC FAN+L RBN P

267Controller (continued)J1J13J12J14J52-PIN JUMPER2-PIN JUMPER2-PIN JUMPER2-PIN JUMPER2-PIN JUMPER12345678EC DB TXD910J2EC DB RXDFT EVENTMPU OUTSHUT

268Appendix APower SupplyP1011J1AC InputP1able Assy,AC In,ower SupplyACAC COMMONCHASSIS GND123LOADLOADGND= RING TERMINAL= FAST-ON TERMINAL(Line Filte

269Expansion-CTVCCJ4Expansion Connector12345678910111213141516171819202122232425262728293031323334353637383940414243444546474849505152535455565758596

27Cleaning the Shuttle Frame Assembly1. Remove the shuttle cover assembly (page 160).2. Remove the shuttle frame assembly (page 198).3. Remove the pa

270Appendix ASureStak Power Stacker PCBA1J6owerupply12345678SKP DB TXD910J2TestVCCSKP DB RXDLIMIT SIGFULL SIGBEAM SIGN PD FLTN EL FLTN PI FLT234+48V1

271Cable Routing, Cabinet Model

272Appendix ACable Routing, Mechanism Base, Cabinet ModelTo J107 on CMX boardTo J106 on CMX boardFront of PrinterLeft Side of PrinterRight Side of Pr

273Cable Routing, Pedestal Model

274Appendix ACable Routing, Mechanism Base, Pedestal Modelon Controlleron ControllerLeft SideRight SideFront of Printerof Printerof Printer(See page

275Cable Assembly, Centronics I/O (P/N 152439-901)PIN 1PIN 1NOTE:If you replace the I/O cableassembly, you must installthe ferrite clamp.See Appendix

276Appendix ACable Assembly, Dataproducts Adapter (P/N 703316-001)PIN 1PIN 1DataproductsCentronicsCentronicsDataproducts

277Cable Assembly, Dataproducts Long Lines I/(P/N 154649-901)J1J205DataproductsCHASSIS GND12345678910111213141516171819202122232425262728293031323334

278Appendix ACable Assembly, Twinax Auto-Termination (P/N 140752-002)WhiteGrayShield1475JackJack1234Resistance ChartPin Pin Ohms131, 2, 3, 4514724Shi

279Cable Assembly, 2-Pin Jumper, 0.1 Ctr (P/N 154470-901)

28Chapter 2 Cleaning the Card Cage Fan Assembly11. Install the shuttle cover assembly (page 160).12. Clean the card cage fan assembly, as described i

280Appendix ACable Assembly, AC In, Power Supply(AC Kit P/N 153502-901)To Power Supply J1To Circuit Breaker

281Cable Assembly, AC Power Input (AC Kit P/N 153502-901)To Circuit BreakerInput Power Connector

282Appendix ACable Assembly, Card Cage Fan (P/N 152422-901)PIN 1PIN 1

283Cable Assembly, Control Panel (P/N 152440-901)PIN 1PIN 1PIN 8PIN 8(Gray)(Brown)(Gray)(Brown)NOTE: If you replace the control panel cable, you must

284Appendix ACable Assembly, Exhaust Fan (P/N 152424-901)PIN 1PIN 1

285Cable Assembly, Hammer Bank Logic (P/N 152421-901)

286Appendix ACable Assembly, Hammer Bank Power (P/N 152423-901)PIN 1PIN 1

287Cable Assembly, MPU (P/N 152425-901)PIN 1PIN 3PIN 2PIN 1

288Appendix ACable Assembly, Ribbon Guide Kit (P/N 163597-901)NOTE: Left ribbon guide shown. Right is mirror image.Pin ConnectionP106 (LRP) / P107 (R

289Cable Assembly, Ribbon Motor, Extension (P/N 154067-901)

293 TroubleshootingIntroductionThis chapter lists fault messages and symptoms, and provides procedures for troubleshooting printer malfunctions.Alway

290Appendix ACable Assembly, Shuttle Motor Drive (P/N 152420-001)

291Frame Cable, Power Stacker (P/N 158445-001)12345678910111213141516171819202122232425262728293031323334PMD AM1 A1M1 A2M1 B1M1 B2M2 A1M2 A2M2 B1M2 B

292Appendix ALogic Cable, Power Stacker (P/N 158444-001)

293Power Cable, Power Stacker (P/N 158443-001)

294Appendix AVertical Rail Cable, Power Stacker (P/N 158442-001)

295Fan Assembly, Hammer Bank (P/N 152416-901)P107 / HBFP107/HBF

296Appendix AMagnetic Pickup (MPU) Assembly (P/N 150281-901)

297Switch Assembly, Paper Detector (P/N 152415-901)

298Appendix ASwitch Assembly, Platen Interlock (P/N 152417-901)P107/PLO

299B Abbreviations &Signal MnemonicsNOTE: Mnemonics with first letter “N” are negative true.Abbreviationor Mnemonic DefinitionKΩ 1,000 OhmsMegΩ 1

164253-001, Rev DMaintenance ManualThe Printronix P5000 series of Line Matrix Printers®

30Chapter 3 Start Here...Start Here...Are you here because of an error message?YESNOGo to Troubleshooting Display Messages, page 31.Power on the prin

300Appendix BBTU British Thermal UnitBUD Buffered Upper DriverCA CathodeCC Card CageCCF Card Cage FanCE Customer EngineerCHNG ChangeCIR CircuitCLK Cl

301DRAM Dynamic Random-Access MemoryDRV Drive or DriverDRVR DriverDSR Data Set ReadyDTR Data Terminal ReadyEC Engine Controller (a functional unit of

302Appendix BHBR Hammer Bank, RightHD Hammer DriverHDIC Hammer Driver Integrated CircuitHDPH Hammer Driver PhaseHLP Hammer Bank Logic, Signals, and P

303MSL Motor and Sensors, LeftMSR Motor and Sensors, RightN Negative TrueN/C Not ConnectedNC Not ConnectedNLQ Near Letter QualityNo. NumberNOVRAM Non

304Appendix BPN Pin or PlugP/N Part NumberPO Paper OutPOD Paper Out Detect (Switch)PPR PaperPROM Programmable Read-Only MemoryPS Power SupplyPS5 Powe

305SG Signal GroundSHH Shuttle Hall (Effect)SHM Shuttle MotorSHUT ShuttleSHUTL ShuttleSIMM Single Inline Memory ModuleSLCT Select (On-line)Slew Rapid

306Appendix BWR Writew/ Withw/o WithoutXMT Transmit

307C Metric Conversion TablesLengthTorque and ForceMultiply By To Obtainfoot 0.3048* meter (m)foot 30.48* centimeter (cm)foot 304.8* millimeter (mm)i

308Appendix CMass and DensityTemperaturePowerMultiply By To Obtainpound* 0.4535924 kilogram (kg)ounce* 28.34952 gram (g)kilogram 2.204622 pound*gram

309D Noise Suppression DevicesFerrite noise suppressors are installed in the printer to reduce radio frequency interference (RFI) to and from electro

How to Clear LCD Messages 31Troubleshooting Display MessagesWARNINGAlways disconnect the AC power cord from the printer before doing a maintenance pro

310Appendix DFigure 55. Ferrite Core InstallationNOTE: This core attaches to the right rear card cage wall.Ferrite Core with Clamp and Adhesive Backi

311E SureStak™ Power StackerContentsIntroduction: page 311Removing the Power Stacker: page 312Installing the Power Stacker: page 317Replacement Proce

312Appendix E Removing the Power StackerRemoving the Power Stacker1. Set the printer power switch to O (off).2. Unplug the power cord.3. Unload paper

3136. Remove three screws and washers from the stacker control panel. (See Figure 58.)Legend:1. Long Screw2. Washer3. Short ScrewFigure 58. Removing

314Appendix E Removing the Power Stacker8. Remove the two 5/32 x 3/4 inch screws and washers securing the vertical rails to the upper frame cross-mem

31510. 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 F

316Appendix E Removing the Power StackerLegend:1. Upper Frame Cross-Member2. Elevator Assembly3. Stacker Base4. Vertical RailFigure 62. Removing the

317Installing the Power StackerNOTE: This procedure is for complete installation of the power stacker, including cable assemblies and the stacker con

318Appendix E Installing the Power Stacker5. Connect the power stacker logic cable P103 to connector J17 on the CMX controller board. (See Figure 64.

319CAUTIONThe paper stacker assembly mounts to the rear upper frame cross-member and the cabinet floor. It is a snug fit. During installation, take c

32Chapter 3 Troubleshooting Display Messages31 PAPER OUTTIMEOUTpage 4132 PAPER JAMTIMEOUTpage 4133 PLATEN OPENTIMEOUTpage 4234 RIBBON STALLTIMEOUTpag

320Appendix E Installing the Power Stacker10. Position the elevator assembly at the bottom of the vertical rails. (See Figure 66a.)11. Position the s

321Legend:1. Upper Frame Cross-Member2. Elevator Assembly3. Stacker Base4. Vertical RailFigure 66. Stacker Installation1234abc

322Appendix E Installing the Power Stacker14. Align the holes in the stacker base with the holes in the cabinet floor. (See Figure 66c and Figure 67.

323Legend:1. Washer (2)2. Screw, 5/32 x 3/4 inch (2)3. Stacker Base4. Screw, 7/64 x 1/2 inch or Torx T-10 (2)5. Washer (2) but no washers with Torx T

324Appendix E Installing the Power Stacker22. Install the paper fence. (See Figure 68.)Legend:1. Paper Fence2. Stacker BaseFigure 68. Paper Fence12

32523. Gather the rail cable, frame cable, logic cable, and power cable. Route the cables outboard of the elevator assembly.24. Connect the stacker c

326Appendix E Installing the Power Stacker25. Position the stacker control panel as shown in Figure 70, and install the mounting screws.Legend:1. Sta

32726. 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

328Appendix E Replacing the Constant Force SpringReplacing the Constant Force Spring1. Remove the stacker assembly from the printer. (See page 312.)C

329WARNINGThe constant force spring is a high tension spring. To avoid pinching your fingers, coil the spring slowly and carefully. Do not let the sp

How to Clear LCD Messages 33ERROR: NVRAMFAILUREpage 54ERROR: PROGRAMNEEDS MORE DRAMpage 54ERROR: PROGRAMNEEDS MORE FLASHpage 54ERROR: PROGRAMNOT COMPA

330Appendix E Replacing the Constant Force Spring5. Lift the loose end of the constant force spring and let it curl up on the outside of the remainin

331Replacing the Timing Belts1. Remove the stacker assembly from the printer. (See page 312.)2. Raise the elevator assembly to its highest position a

332Appendix E Replacing the Timing Belts5. Loosen the two setscrews on the motor pulley and remove the pulley. Unplug the motor cable, if necessary.

3337. Remove two Allen screws from the belt clamp that secures the timing belt to the stacker frame. (See Figure 78.)Legend:1. Allen Screw2. Belt Cla

334Appendix E Replacing the Timing Belts8. Remove the timing belt by working it around the vertical rail and constant force spring. (See Figure 79.)L

335Illustrated Parts BreakdownThe Illustrated Parts Breakdown (IPB) consists of exploded drawings of the power stacker assembly and subassemblies. Ea

336Appendix E Illustrated Parts BreakdownFigure 80. Stacker AssemblyDetail: Figure 81, page 338.$14303510122093712588131525711209121067383838

337Item No.Part No. Description Notes5 202706-904 Flanged Bearing Part of item 366 158342-001 Paper Deflector7 202721-901 Clip-On Bearing Part of ite

338Appendix E Illustrated Parts BreakdownFigure 81. Elevator Detail: Motor, Roller, and Paddle AssembliesDetail: Figure 82, page 340.Detail: Figure 8

339Item No.Part No. Description Notes15 158446-001 Motor36 164405-001 Stacker Hardware Kit Kit not illustrated40 158313-001 Anti-Static Brush45 Ref S

34Chapter 3 Troubleshooting Display MessagesLO DRV. SHORT* page 61LOAD PAPER page 62LOADING PROGRAMFROM PORT XX%page 62ONLINE28 CU NOT ENABpage 63ON

340Appendix E Illustrated Parts BreakdownFigure 82. Stacker Detail: Rollers%758085908580From Figure 81, page 338.

341Item No.Part No. Description Notes36 164405-001 Stacker Hardware Kit Kit not illustrated75 159425-001 Compression Spring On left end of shaft on e

342Appendix E Illustrated Parts BreakdownFigure 83. Stacker Detail: Motor Bracket&95959696100ConnectorFlat SideFlagKeyFrom Figure 81, page 338.

343Item No.Part No. Description Notes36 164405-001 Stacker Hardware Kit Kit not illustrated95 Ref Clip-On Bearing Part of item 3696 158288-001 Holder

344Appendix E Illustrated Parts BreakdownFigure 84. Stacker Detail: Elevator Bracket9597ConnectorFlagKey'95Nib105From Figure 81, page 338.

345Item No.Part No. Description Notes36 164405-001 Stacker Hardware Kit Kit not illustrated95 Ref Clip-On Bearing Part of item 3697 158290-001 Holder

346Appendix E Illustrated Parts BreakdownFigure 85. Stacker Detail: Paper Motion DetectorP5STK01ZT5stk01x105ConnectorFlagKeyNib105(Rotated 180 Degree

347Item No.Part No. Description Notes36 164405-001 Stacker Hardware Kit Kit not illustrated97 158290-001 Holder, LED, Flat105 202728-001 Photodarling

348Appendix E Illustrated Parts Breakdown

349IndexNumerics06 HOST REQUEST, 3908 HOLD PRINT / TIMEOUT, 3915 COMM CHECK, 3915V PWR FAIL *, 4022 INVALID ADDR, 4023.5V PWR FAIL *, 4031 PAPER OUT

How to Clear LCD Messages 35PWR SUPP VOLT* page 73QUEUE OVERRUN page 73RESTORINGBOOT CODEpage 73RIB INVLD CMD* page 75RIB INVLD STATE* page 75RIBBON D

350Charactersmisaligned horizontally, 59misaligned vertically, 86or dots missing or smeared, 45print smeared or missing, 45print too light or dark, 4

351randomly misplaced, 74DOWN (arrow) keypedestal models, 20Downloading softwarefrom multiple diskettes, 135from one diskette, 130Downloads consisten

352Flash SIMM won’t copy, 57FM HEADER ERROR, 57FRAMING ERROR, 57GGap, adjustmentmagnetic pick-up (MPU), 170platen, 116GRF CHK ERROR / PRESS STOP, 57H

353Memoryflash will not copy, 57loading from multiple diskettes, 135loading from one diskette, 130Memory modules, location and replacement, 171Menusb

354PAP FIFO UNDRFL *, 64PAP ILLGL ST *, 65PAP INCMPL ENER *, 65PAP INVLD CMD *, 65PAP INVLD PARM *, 65PAP NOT SCHED *, 66PAP NT AT SPEED *, 66PAP UNE

355PAP INCMPL ENER *, 65PAP INVLD CMD *, 65PAP INVLD PARM *, 65PAP NOT SCHED *, 66PAP NT AT SPEED *, 66PAP UNEXP INT *, 66Paperdetector switch assemb

356PRINTER HOT, 72Printingconventions is this manual, 16line matrix printing explained, 239problems, 29too light or too dark, 45PrintNet Ethernet int

357SSafety, 17notices, 17notices, defined, 16Safety Notices, 17SCS COMMAND ERROR, 76SECURITY CODE VIOLATION, 77, 134, 140SECURITY PAL NOT DETECTED, 7

358TCB CORRUPTED *, 85Tension adjustmentpaper feed timing belt, 108platen open belt, 110Terminating resistorslocation of, 191replacement, 190Testequi

36Chapter 3 Troubleshooting Other SymptomsTroubleshooting Other SymptomsWARNINGAlways disconnect the AC power cord from the printer before doing a ma

Printronix, Inc.14600 Myford RoadIrvine, CA 92606-1005Phone: 714 / 368-2300Fax: 714 / 368-2600Technical Support: 714 / 368-2686164253-001DPrintronixNe

How to Clear LCD Messages 37Control PanelBlack squares on control panel page 44Control panel blank page 50Control panel keys do not work page 51Contro

38Chapter 3 Troubleshooting ProceduresTroubleshooting Procedures Troubleshooting procedures are listed in this section. Every troubleshooting procedu

The Procedures 39The Procedures06 HOST REQUEST Message1. Status message: in CT emulation, the host computer or printer controller requires attention.N

Trademark AcknowledgementsTrademark AcknowledgementsANSI is a registered trademark of American National Standards Institute, Inc.Centronics is a regis

40Chapter 3 Troubleshooting Proceduresmessage still appears, replace the expansion-CT board. Record the message and return it with defective board.15

The Procedures 4131 PAPER OUTTIMEOUT Message1. In the CT emulation with a coax interface, a time-out message is sent to the host if paper is not loade

42Chapter 3 Troubleshooting Procedures9. Inspect the tractors and tractor door springs for damage or excessive wear.If either tractor is worn or dama

The Procedures 43Replace 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 ribb

44Chapter 3 Troubleshooting ProceduresCycle power. Run the print job again. If the message appears, download the emulation software again (page 130).

The Procedures 45Reseat flash memory.4. Power on the printer.If black squares appear on the LCD, the flash memory could be blank. Replace the flash SI

46Chapter 3 Troubleshooting Proceduresframe assembly for broken hammer springs, hammer tips, or contaminations.Replace any damaged hammer spring asse

The Procedures 478. Check the platen open pulley and the platen pulley for looseness.Bottom out the platen open motor pulley on the motor shaft and to

48Chapter 3 Troubleshooting ProceduresConnect P107/PAPR M to J107 on the CMX controller board.2. Check the paper feed motor pulley for looseness.Hold

The Procedures 49CLEARING PROGRAMFROM FLASH Message1. Status message: emulation software successfully loaded into printer RAM and the checksum matched

Warranty and Copyright InformationCommunication NoticesFederal Communications Commission (FCC) Statement: This equipment has been tested and found to

50Chapter 3 Troubleshooting Procedurestemperature at or above 40° Celsius (104° Fahrenheit) or that is dirty enough to create blockage of the cabinet

The Procedures 51Control panel keys do not work1. Power on the printer. Check the operation of the control panel keys.Replace the control panel assemb

52Chapter 3 Troubleshooting ProceduresDownloads consistently failNOTE: Most download problems are detected by software during the procedure and commu

The Procedures 53ERROR: DRAM ATADDRESS XXXXXXXX Message1. The printer found a defective memory location.Replace the DRAM.2. Power on the printer.If th

54Chapter 3 Troubleshooting ProceduresDownload the program again (page 130). If the message occurs again, replace the flash memory.ERROR: FLASHNOT DE

The Procedures 55ERROR: PROGRAMNOT VALID Message1. The printer does not see a program in flash memory.There is no program in printer memory. Download

56Chapter 3 Troubleshooting ProceduresIf the messages appears, replace the CMX controller board. Record the message and return it with defective CMX

The Procedures 57Flash SIMM won’t copy1. Power off the printer. Remove the flash SIMMs. Inspect the flash SIMM sockets on the CMX controller board.If

58Chapter 3 Troubleshooting ProceduresCycle power. If the message appears, replace the shuttle frame assembly.2. Power on the printer. Run a print te

The Procedures 59connector P107/HBF for shorts or opens. (Refer to the Main Wire Harness Test Tables in Appendix A.)Replace components that fail test.

6Chapter Communication NoticesWarning: This is a Class A product. In a domestic environment this product may cause radio interference in which case t

60Chapter 3 Troubleshooting ProceduresIf the message appears, replace the CMX controller board. Record the message and return it with defective CMX b

The Procedures 61Reseat the twinax host data cable connection and the twinax I/O cable connection at the expansion-CT board.2. Disconnect the twinax a

62Chapter 3 Troubleshooting ProceduresLOAD PAPER Message1. Printer is out of paper.Load paper. Press CLEAR. If message does not clear, go to step 2.2

The Procedures 635. Check that power supply cable connector P101 is connected to J101 on the CMX controller board.Connect power supply connector P101

64Chapter 3 Troubleshooting Procedures1. Paper Bad Table. The paper feed process on the CMX controller board has a corrupted table.Cycle power. Run t

The Procedures 65undamaged and have good connections. Replace as necessary. (Refer to Appendix A.)3. Check hammer phasing.Try using a lower phasing va

66Chapter 3 Troubleshooting ProceduresCycle power. Run the print job again. If the message appears, download the emulation software again (page 130).

The Procedures 672. Run the print job that generated the error message.If the message appears, check the host data for invalid characters.3. Ask the s

68Chapter 3 Troubleshooting ProceduresIf the message appears, replace the CMX controller board. Record the message and return it with defective CMX b

The Procedures 69Power on “hang” condition1. Remove the paper path or pedestal top cover. Check all cable connections to the CMX controller board and

viiTable of Contents1 Maintenance Overview... 11About the Printer...

70Chapter 3 Troubleshooting Procedures5. Inspect vents and fan airways for obstructions. Look underneath cabinet models for items blocking the cabine

The Procedures 71If the ON LINE indicator does not light, replace the stacker control panel.6. Power on the printer. Check that the ON LINE indicator

72Chapter 3 Troubleshooting ProceduresIf printer does not print and the interface is RS-232, interchange the wires to pins 2 and 3. (This is the most

The Procedures 732. Power off the printer. Remove the paper path or pedestal top cover. Check that all fan cables are connected.Connect all fan cables

74Chapter 3 Troubleshooting Procedures2. Check the platen open pulley and the platen pulley for looseness.Bottom out the platen open motor pulley on

The Procedures 75RIB INVLD CMD* Message1. Ribbon Invalid Command. Firmware error on the CMX controller board.Cycle power. Run the print job again. If

76Chapter 3 Troubleshooting Procedures5. Observe ribbon movement at both left and right ribbon posts as the metal end strip crosses each ribbon post.

The Procedures 77SECURITY CODE VIOLATION Message1. Security code of the PAL on the CMX controller board does not match the code of the firmware on the

78Chapter 3 Troubleshooting Procedures6. Check continuity of the shuttle motor drive cable assembly.Replace shuttle motor drive cable assembly if it

The Procedures 79Clean the shuttle frame assembly and hammer bank cover assembly if you find debris. Replace the hammer bank cover assembly if you fin

viiiTable of ContentsHex Code Printout ... 95How to Print a Hex Dump...

80Chapter 3 Troubleshooting ProceduresIf the message appears, replace the shuttle frame assembly.SOFTWARE ERROR*Cycle power Message1. Application sof

The Procedures 813. Move the elevator up and down by hand and check that the limit switches are being tripped at the highest and lowest limits of elev

82Chapter 3 Troubleshooting ProceduresReplace any cable that is damaged or fails continuity test. Reconnect all stacker cables to the CMX controller

The Procedures 83STACKER FULL Message1. Status message: the power paper stacker is full.Unload the stacker.2. Check the stacker limit switches. (See p

84Chapter 3 Troubleshooting Proceduresother troubleshooting procedures. When you have completed this procedure, return to the procedure that sent you

The Procedures 85TABLE MISMATCHDOWNLOAD AGAIN Message1. This message indicates that an EC software update is in process.Power off the printer. Downloa

86Chapter 3 Troubleshooting ProceduresUNDEF INTERRUPT* Message1. Undefined Interrupt. Firmware error on the CMX controller board.Cycle power. Run the

The Procedures 87Hold 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

88Chapter 3 Communications FailuresCommunications FailuresMany host-printer communications problems are complex. With the exception of a defective in

The Procedures 89Diagnostic Printer TestsA set of printer tests is included in the configuration menu structure for use as diagnostic tools. Use these

Table of ContentsixExpansion-CT ... 162Fan Assembly, Cabinet Exhaust...

90Chapter 3 Diagnostic Printer TestsSelecting and Running Diagnostic Printer TestsNOTE: You must set TOF after running any diagnostic test.Step Press

Selecting and Running Diagnostic Printer Tests 9116. Printer TestsAll E’s*Starts test.17. Printer TestsAll E’s*Stops test.18. ENTER SWITCHLOCKEDLock

92Chapter 3 Boot Diagnostics MenuBoot Diagnostics MenuPrinter boot-up software contains a “Boot Diagnostics” menu that you can access by holding down

Selecting and Running Diagnostic Printer Tests 93Figure 8. Boot Diagnostics MenuBOOT DIAGNOSTICSPRESS ENTERBOOT DIAGNOSTICSVERSION CHECKVERSION CHECKB

94Chapter 3 Boot Diagnostics MenuFigure 10. Boot Diagnostics Menu (continued)AFrom previous pageBOOT DIAGNOSTICSMISC UTILITIESMISC UTILITIESDISPLAY M

Selecting and Running Diagnostic Printer Tests 95Hex Code PrintoutA hex code printout (or “hex dump”) prints every ASCII data character received from

96Chapter 3 Hex Code PrintoutHow to Print a Hex DumpStep Press LCD Result Notes1. Make sure the printer is on. Raise the printer cover.2. OFFLINECON

How to Print a Hex Dump 97ASCII Character Set KEYASCII Character NameESC33271BOCTAL equivalentDECIMAL equivalentHEX equivalentB70000111 1B6 0B5 001101

98Chapter 3 Soft vs. Hard ResetSoft vs. Hard ResetSoft ResetA soft(ware) reset clears printer memory then loads the power-up configuration set by the

CMX Controller Board Handshake Sequences 99The Power On SequenceThis section describes the normal sequence of events from the time the power switch is