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vii
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
- 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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