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Chapter 5 Section I: Replacement Procedures
Expansion
-
CT
Removal
CAUTION
To prevent electrostatic damage to electronic components, always wear
a properly grounded static wrist strap when you handle circuit boards.
1. Prepare the printer for maintenance (page 106).
2. Cabinet Models: Remove the paper path (page 177).
Pedestal Models: Remove the top cover assembly (page 161).
3. Loosen, but do not remove, the two screws securing the coax/twinax I/O
plate to the rear of the card cage. Loosen the thumbscrew on the
expansion-CT board until the screw is released from the standoff on the
controller board. (See page 234.)
4. Carefully lift the expansion-CT board out of the card cage cutout and off
the expansion connector adapter that attaches the CT to the CMX board.
5. Remove the expansion connector adapter from the CMX controller board
by carefully lifting it straight up and out of the controller connector.
Installation
1. Reverse steps 2 through 5 of the removal procedure.
2. Return the printer to normal operation (page 107).
- Maintenance Manual 1
- Trademark Acknowledgements 4
- Communication Notices 5
- Chapter Communication Notices 6
- Table of Contents 7
- 5 Replacement Procedures 8
- 1 Maintenance Overview 11
- Printer Evolution 12
- How to Identify the Printer 12
- Chapter 1 P5000 Printers 14
- Important Maintenance Notes 15
- About This Manual 15
- How to Use This Manual 16
- Notes and Notices 16
- Safety Notices 17
- Hinweise zur Sicherheit 17
- Controls and Indicators 18
- PRT CONFIG 19
- JOB SELECT 19
- Status Indicator 21
- Power Switch 21
- (Off) (On) 21
- 0.1 inch 22
- 2 Preventive Maintenance 25
- NOTE: P5005 hammer bank is 27
- NOTE: Cabinet model shown 28
- Procedure is the same for 28
- 3 Troubleshooting 29
- Start Here 30
- How to Clear LCD Messages 31
- Table 2: Message List 32
- Table 3: General Symptom List 37
- Troubleshooting Procedures 38
- The Procedures 39
- 15V CTL FAIL* Message 40
- 22 INVALID ADDR Message 40
- 23.5V CTL FAIL* Message 40
- 31 PAPER OUT 41
- TIMEOUT Message 41
- 32 PAPER JAM 41
- ± 2 inch-pounds (1.02 ± 0.23 41
- 33 PLATEN OPEN 42
- 34 RIBBON STALL 42
- 48V PWR FAIL* Message 43
- ACCESS NULL PTR* Message 43
- ACTIVATE LOST Message 44
- A TO D OVERRUN* Message 44
- BUFFER OVERRUN Message 45
- CLEAR PAPER JAM Message 46
- CLEARING PROGRAM 49
- FROM FLASH Message 49
- CLOSE PLATEN Message 49
- COIL HOT Message 49
- Control panel blank 50
- CTL VOLT FAIL* Message 51
- DIAGNOSTIC 51
- PASSED Message 51
- Downloads consistently fail 52
- DRVR CIR BAD* Message 52
- ERROR: DC PROGRAM 52
- NOT VALID Message 52
- EXHAUST FAN FLT Message 56
- FIRMWARE ERROR Message 56
- HAMMER COIL BAD 58
- #, #, #, #, ... etc. Message 58
- HB NOT INSTALLD* Message 58
- HMR BANK FAN FLT Message 58
- ILL EXT BUS ACC* Message 59
- ILL INST ACCSS* Message 60
- ILLGL OPR ACCSS* Message 60
- INTAKE FAN FAULT Message 60
- INVALID ACTIVATE Message 60
- INVALID COMMAND Message 61
- LO DRV. SHORT* Message 61
- PAP BSY TOO LNG* Message 64
- PAP FIFO OVERFL* Message 64
- PAP FIFO UNDRFL* Message 64
- PAP ILLGL ST* Message 65
- PAP INCMPL ENER* Message 65
- PAP INVLD CMD* Message 65
- PAP INVLD PARM* Message 65
- PAP NOT SCHED* Message 66
- PAP NT AT SPEED* Message 66
- PAP UNEXP INT* Message 66
- PARAMETER ERROR Message 66
- PARITY ERROR Message 67
- PLAT INV CMD* Message 67
- PLAT INV PARM* Message 67
- PLAT INV STATE* Message 67
- PLEASE WAIT 68
- RESET IN PROGRESS Message 68
- Paper feeds poorly 68
- Power on “hang” condition 69
- POWER SAVER MODE Message 69
- POWER SUPPLY HOT Message 69
- Stacker not operating 70
- Printer does not initialize 71
- PRINTER HOT Message 72
- Randomly misplaced dots 74
- RIB INVLD CMD* Message 75
- RIB INVLD STATE* Message 75
- RIBBON DRIVE Message 75
- RIBBON INK OUT 76
- CHANGE RIBBON Message 76
- SCS COMMAND ERROR Message 76
- SHUTTLE JAM Message 79
- ± 1 inch-pounds (2.03 79
- ± 0.11 N•m) 79
- Message 80
- Operator’s 81
- STACKER FAULT Message 82
- STACKER FULL Message 83
- STACKER JAM Message 83
- Stacker limit switch check 83
- Stacker motor check 84
- TABLE MISMATCH 85
- DOWNLOAD AGAIN Message 85
- TCB CORRUPTED* Message 85
- TOF is lost repeatedly 85
- Communications Failures 88
- Diagnostic Printer Tests 89
- Boot Diagnostics Menu 92
- BOOT DIAGNOSTICS 93
- PRESS ENTER 93
- Hex Code Printout 95
- How to Print a Hex Dump 96
- ASCII Character Set 97
- Soft vs. Hard Reset 98
- The Power On Sequence 104
- 4 Adjustment Procedures 105
- IMPORTANT 106
- User’s Manual.) 107
- 1) Timing Belt Shield 109
- 2) Motor Mount Bolt (2) 109
- 3) Paper Feed Drive Motor 109
- 4) Splined Shaft 109
- ± 0.23 N•m) 110
- Direction of Force 111
- 1) Shuttle Cover 115
- 3) Paper Scale 115
- 1) Belt Cover 119
- 2) Set Screw 119
- 3) Platen Open Motor Pulley 119
- 4) Platen Shaft Pulley 119
- 1) Screw, Skid (2) 121
- 2) Ribbon 121
- 3) White Nylon Washer 121
- 4) Screw, Retaining (2) 121
- 1) Screw 123
- 2) Adjusting Link 123
- Paper Out Adjustment 124
- < or ; key, adjust the XX 127
- Hammer Phasing Adjustment 128
- Adjustment 129
- User’s Manual 130
- FILENAME.ZIP 136
- FILENAME 136
- FILENAME.EXE 136
- Set Shuttle Speed 141
- Chapter 4 Set Shuttle Speed 142
- 5 Replacement Procedures 143
- Belt, Paper Feed Timing 146
- Belt, Platen Open 147
- Circuit Breaker 148
- Connector Shells 149
- Connector Stiffening Clips 151
- Installation 153
- Controller Board (CMX) 155
- Removal 157
- Early Models 159
- Later Models 159
- Cover Assembly, Shuttle 160
- Expansion 162
- Fan Assembly, Cabinet Exhaust 163
- Fan Assembly, Card Cage 164
- Fan Assembly, Hammer Bank 165
- Hammer Spring Assembly 166
- Removal 171
- CMX Controller Board 173
- Paper Feed Motor 174
- Paper Ironer 176
- Paper Path 177
- ± 2 inch-pounds (2.26 ± 0.23 181
- Platen Open Motor 182
- Power Supply Board 184
- (Default is all 186
- Run and Auto Reset Modes 188
- Dipswitches 189
- 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
- Tractor (L/R) 204
- Part No. Description Notes 207
- Figure 32. Pedestal Details 212
- Figure 39. Tractor Shafts 226
- Figure 40. Platen 228
- Install screws here 230
- Route cable under 230
- Hammer Bank Fan 230
- Top View 230
- Figure 43. Expansion-CT Board 234
- 6 Principles of Operation 239
- Printing Rates 242
- Printing Mechanism 242
- Chapter 6 Printing Mechanism 244
- Paper Transport System 245
- Ribbon Transport System 246
- Shuttle Assembly 247
- Control Panel 248
- Data Controller 251
- Engine Controller 254
- Printer Interface 256
- Graphics 257
- Chapter 6 Graphics 258
- A Wire Data 259
- Appendix A 260
- Interconnection Diagram 261
- Power Distribution Diagram 262
- Main Wire Harness Test Tables 263
- Controller, CMX 264
- PPR STK STAT0 265
- PPR STK STAT1 265
- PPR STK CTL0 265
- PPR STK CTL1 265
- Controller (continued) 266
- Cable Assembly 268
- Power Supply 268
- Expansion-CT 269
- SureStak Power Stacker PCBA 270
- Cable Routing, Cabinet Model 271
- Cable Routing, Pedestal Model 273
- If you replace the I/O cable 275
- See Appendix E 275
- DataproductsCentronics 276
- CentronicsDataproducts 276
- (P/N 154649-901) 277
- (AC Kit P/N 153502-901) 280
- To Circuit Breaker 281
- Input Power Connector 281
- Left Guide = P106 / LRP 288
- Right Guide = P107 / RRP 288
- P107 / HBF 295
- B Abbreviations & 299
- Appendix B 300
- C Metric Conversion Tables 307
- Appendix C 308
- D Noise Suppression Devices 309
- Control Panel Cable Assembly 310
- Parallel I/O Cable Assembly 310
- E SureStak™ Power Stacker 311
- Removing the Power Stacker 312
- 2. Vertical Rail 315
- 3. Stacker Base 315
- Installing the Power Stacker 317
- 1. Screw, 6-32x1/4, Torx T-10 319
- 1. Upper Frame Cross-Member 321
- 2. Elevator Assembly 321
- 4. Vertical Rail 321
- Figure 67. Stacker Fasteners 323
- Figure 68. Paper Fence 324
- 1. Logic Cable (P104) 325
- 2. Power Cable 325
- 3. Frame Cable (P102) 325
- 4. Rail Cable (P107) 325
- User’s Guide.) 327
- 1. Tie Wrap 328
- 1. Spring 330
- Replacing the Timing Belts 331
- 1. Allen Screw 333
- 2. Belt Clamp 333
- NOTE: Left timing 334
- Illustrated Parts Breakdown 335
- Figure 80. Stacker Assembly 336
- Numerics 349
- 164253-001D 360
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