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INDEX

I-5

P6040/P6080 Index

ăParagraph,

Figure, Table

Page

ăăNumber

Jumpers, Logic C3 Hardware

T2-12

2-39

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . .

Light and/or Smeared Characters

F4-16

4-37

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . .

Light and/or Smeared Characters, Example of

F4-17

4-39

. . . . . . . . . . . . . . . .

. . . . . . .

Logic C3

Hardware Jumpers

T2-12

2-39

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

Interrupt Vectors

T2-10

2-37

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

I/O Address Map

T2-9

2-34

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . .

Memory Map

T2-8

2-33

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . .

PCBA

2-6, F2-132-15,2-16

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PCBA Block Diagram

F2-14

2-17

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

Unused Interrupt Vectors

T2-11

2-37

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

Logic PCBA Replacement

5-44, F5-40

5-79,5-80

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .

Lubrication

3-5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

Mnemonic Terms

App A

A-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . .

Magnetic Pickup

Gap Adjustment

5-10, F5-8

5-15,5-16

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . .

Phasing Adjustment

5-11, F5-8

5-17,5-16

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . .

Replacement

5-29, F5-25

5-49,5-53

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

Malfunctions, Common Causes of

4-2

4-1

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

Malfunction Symptom Index

T4-1

4-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . .

Matrix Printing, General Description

2-32-1

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

Mechanical Drawings and Parts Lists

App C

C-1

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . .

Memory Map, Logic C3T2-8

2-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . .

Microprocessor Bus Expansion Connector Pin Assignments

T2-5

2-21

. . . . .

. . . . . . . .

Misplaced Dots

F4-18

4-40

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . .

Missing Characters

F4-12

4-25

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . .

Missing Characters, Example of

F4-134-29

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . .

Missing Dots

F4-14

4-30

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . .

Missing Dots, Example of

F4-15

4-36

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . .

MOS Supplies, P6080, +5 V and MOS

F2-24

2-55

. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . .

Motor Relay Trigger Circuit, P6080

F2-26

2-58

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . .

Motor Replacement

Paper Feed

5-34, F5-30

5-61,5-62

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

Shuttle

5-30, F5-26

5-54,5-55

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

MPU Circuit, Operation of

F2-19

2-46

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . .

MPU, Hammer Bank, and Shuttle Mechanism

2-8

2-44

. . . . . . . . . . . . . . . .

. . . . . . . . . .

MPU Phasing Test - All Hs

F4-34

4-71

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . .

All manuals and user guides at all-guides.com

Summary of Contents for 108525-001

Page 1: ...P6000 Series Pedestal Model Maintenance Manual R Volume 1 of 2 All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 2: ...All manuals and user guides at all guides com...

Page 3: ...P6000 Series Pedestal Model Maintenance Manual Vol 1 R P N 108692 001 Rev B Volume 1 of 2 All manuals and user guides at all guides com...

Page 4: ...ent this product may cause radio interference in which case the user may be required to take adequate measures Printronix Inc makes no representations or warranties of any kind regarding this material...

Page 5: ...Driver PCBA 2 40 2 8 Hammer Bank and Shuttle Mechanism MPU 2 44 2 9 Power Supply 2 47 2 10 Ribbon Drive 2 59 2 11 Paper Feed Control Circuits 2 62 2 12 Platen Open Paper Out Switches 2 64 2 13 Safety...

Page 6: ...to Line Frequency 5 17 5 13 Shuttle Belt 5 18 5 14 Paper Feed Belt 5 18 5 15 Paper Motion Sensor 5 21 5 16 Paper Out Detectors 5 23 Section III REPLACEMENT 5 17 Printer Cover 5 25 5 18 Control Panel...

Page 7: ...Interface Connector Pin Assignments 2 18 2 2 Power Supply Connector Pin Assignments 2 19 2 3 Front Panel Connector Pin Assignments 2 20 2 4 Four Phase Stepper Connector Pin Assignments 2 20 2 5 Microp...

Page 8: ...and Cam Position 2 45 2 19 Operation of MPU Circuit 2 46 2 20 Power Supply 2 48 2 21 Power Supply Assembly P6080 2 50 2 22 36 V and 70 V Supplies P6080 2 53 2 23 Reference Voltage Circuit P6080 2 54 2...

Page 9: ...lignment 4 47 4 22 Horizontal Misalignment Example of 4 48 4 23 Vertical Misalignment 4 49 4 24 Vertically Misaligned Character Position Example of 4 53 4 25 Vertically Deformed Characters Example of...

Page 10: ...ick Removal Installation 5 52 5 25 Magnetic Pickup Removal Installation 5 53 5 26 Shuttle Motor Removal Installation 5 55 5 27 Shuttle Belt Removal Installation 5 57 5 28 Paper Ironer Removal Installa...

Page 11: ...rawings Mechanical drawings and parts lists are included here Controls and Indicators Throughout this manual controls and indicators are printed in text exactly as they appear on the printer with all...

Page 12: ...P6040 P6080 Maintenance viii All manuals and user guides at all guides com...

Page 13: ...ion Figure 1 1 a General The Printronix P6000 Series Printer is a highly reliable multi function dot matrix line printer In addition to basic functions the P6000 Series can produce correspondence qual...

Page 14: ...2 1 2 Printer Description continued b Standard Features continued 9 Configuration Printout 10 Datastream Hex Code Printout 11 Resident Serial and Parallel Interfaces c Optional Features tbd All manual...

Page 15: ...1 3 P6040 P6080 Maintenance Overview Figure 1 1 Printer with Pedestal All manuals and user guides at all guides com...

Page 16: ...TOP OF FORM Display SET TOF PRINT MODE CONFIG VALUE CLEAR FAULT RUN STOP TEST FUNCTION Executes one of three basic functions 1 Saves newly selected parameters or loads default parameters 2 Runs or st...

Page 17: ...UNCTION INDICATOR Cycles through configuration menus Selects and causes display of current line spacing in lines per inch Selects and causes display of current forms length Advances paper one line whe...

Page 18: ...ent thickness forms or paper Opened raised fully for loading paper Indicates relative thickness of forms or paper Used to set left margin and paper width Left tractor moves about one inch Right tracto...

Page 19: ...1 7 P6040 P6080 Maintenance Overview Figure 1 3 Internal Controls and Indicators All manuals and user guides at all guides com...

Page 20: ...P6040 P6080 Maintenance Overview 1 8 All manuals and user guides at all guides com...

Page 21: ...Printing a The Dot Matrix In order to generate characters from dots the dots must be arranged properly The imaginary grid on which the dots are positioned is referred to as the matrix In normal six l...

Page 22: ...CASE WITH DESCENDER Figure 2 2 Typical Characters DOT COLUMN DOT ROW WITH UNDERLINE 1 3 5 7 9 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 PRINTED UNDERLINE WITH UNDERLINES WITHOUT UNDERLINES DOT COLUMN DOT ROW 1...

Page 23: ...re 2 4 Each hammer consists of a stiff leaf spring attached at one end to the hammer bank with a screw Figure 2 5 The end opposite the screw has a pointed tip attached A permanent magnet keeps all the...

Page 24: ...2 4 P6040 P6080 Principles of Operation Figure 2 4 Positioning and Release of Odd and Even Hammers P6080 All manuals and user guides at all guides com...

Page 25: ...2 5 P6040 P6080 Principles of Operation A P6040 B P6080 Figure 2 5 Hammer and Shuttle Arrangement Typical All manuals and user guides at all guides com...

Page 26: ...2 6 P6040 P6080 Principles of Operation A P6040 B P6080 Figure 2 6 Print Hammer Action All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 27: ...2 7 P6040 P6080 Principles of Operation A P6040 B P6080 Figure 2 7 Standard Character Formation All manuals and user guides at all guides com...

Page 28: ...2 8 P6040 P6080 Principles of Operation Figure 2 8 Character Formation by One Hammer All manuals and user guides at all guides com...

Page 29: ...up of the following functional elements n Control Panel n Logic C3 PCBA n Hammer Driver PCBA n Hammer Bank and Shuttle Mechanics Magnetic Pickup MPU n Power Supply n Ribbon Drive n Paper Transport n...

Page 30: ...2 10 P6040 P6080 Principles of Operation Figure 2 9 Printer Functional Elements All manuals and user guides at all guides com...

Page 31: ...2 11 P6040 P6080 Principles of Operation Figure 2 10 System Block Diagram All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 32: ...munication scheme that does not require the direct use of the data or address bus This minimizes RFI EMI problems due to the high fre quency content and sensitivity of these signals The control panel...

Page 33: ...2 13 P6040 P6080 Principles of Operation Figure 2 11 Control Panel All manuals and user guides at all guides com...

Page 34: ...2 14 P6040 P6080 Principles of Operation Figure 2 12 Control Panel Block Diagram All manuals and user guides at all guides com...

Page 35: ...the control panel to display and monitor fault information Major functions on the board are under control of a 68000 CPU A replaceable PROM contains font and program information a Connectors There are...

Page 36: ...2 16 P6040 P6080 Principles of Operation Figure 2 13 Logic C3 PCBA All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 37: ...2 17 P6040 P6080 Principles of Operation Figure 2 14 Logic C3 PCBA Block Diagram All manuals and user guides at all guides com...

Page 38: ...Input Data Bit 6 SERIAL Receive clock PARALLEL Input Data Bit 7 SERIAL External clock PARALLEL Input Data Bit 8 PARALLEL Paper Instruction PARALLEL Dataproducts data strobe PARALLEL Data request SERIA...

Page 39: ...Enable Power 30V Magnetic Pickup from Codewheel Paper Drive Enable Paper Motion Detect Paper Feed 1 Hammer Master Clear Paper Feed 2 Hammer Data Fault Status Hammer Shift Clock 2MHz Signal Hammer Clo...

Page 40: ...REGSEL NENABLE NSWITCH NOT USED PDATA NPLOAD NOT USED NPCLK 5V GND Paper Feed 2 Shuttle Drive Enable Paper Drive Enable Color Expansion Color Expansion Front Panel Switch Depressed Ribbon Direction C...

Page 41: ...from CPU Buffered Data Bus Line 13 Bus Error Input to CPU Segment Line 4 Buffered Address Bus Line 5 Buffered Data Bus Line 8 Buffered Data Bus Line 10 Buffered Address Bus Line 2 Buffered Address Bus...

Page 42: ...s Grant from CPU Buffered Data Bus Line 5 Bus Grant Acknowledge to CPU Signal Ground 8A 9A 10A 11A 12A 13A 14A 15A 16A 17A 18A 19A 20A 21A 22A 23A 24A 25A 26A 27A 28A 29A 30A 31A 32A BSN3 NBAS BA7 BD1...

Page 43: ...ud rate configuration is available The timer B input pin TBI is tied to the receive data RXD line so that in an auto configuration mode the software driving the 68901 could determine the baud rate of...

Page 44: ...not online condi tion All of the signals described below initialize in the reset or low condition The signals change state by writing to addresses as described below ONL On Line 040144 ONL RESET 0 04...

Page 45: ...a match character The signal must be reset for at least 25 ns to clear the ICBUSY signal to the host and reset the flip flop OPS Output Polarity Select 040158 OPS RESET 0 04015A OPS SET 1 When reset...

Page 46: ...ng OPS output polarity select The interface follows the Dataproducts protocols defined in 900197 Note that the activation of the Dataproducts interface requires that the proper cable kits are installe...

Page 47: ...alled NRESYNC is treated as an interrupt to the processor handled through the 68901 MFP l Hammer Load Circuit The hammer load circuit unloads the dot image buffer after the software writes to an addre...

Page 48: ...0C4 RESET 400C6 SET NPDE 400D4 RESET 400D6 SET PF1 and PF2 are used in conjunction with each other to move the paper If NPDE is not set paper will not move when PF1 and PF2 are switched To move paper...

Page 49: ...Clear Fault Config Value Form Length Print Mode Set TOF Form Feed On Line Run Stop Lock Key Config Menu Line Spacing N C Paper Out Platen Open Ribbon Fault 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 8000 4...

Page 50: ...dress bus is used for access of the DRAMS on the C3 card The 68B44 direct memory access DMA device resides on the upper data bus D8 D15 while the 68901 multi function peripheral MFP resides on the low...

Page 51: ...device on the C3 card that asserts the bus request NBR and grant acknowledge NBGACK signals The bus arbitration signals are available at the expansion connector Note that the PAL decode logic takes th...

Page 52: ...the refresh circuit the processor DRAM addresses and the hammer load circuit addresses u Data Bus There is one data bus on the card divided into two groups of eight the upper and lower data byte The...

Page 53: ...030000 03FFFF 040000 04FFFF 050000 05FFFF 060000 067FFF 068000 06FFFF 070000 FDFFFF FE0000 FEFFFF FF0000 FFFFFF EPROM1 EPROM2 NO DECODE I O SPACE EEPROM RAM0 RAM1 Not Assigned FONT0 FONT1 32Kx16 2725...

Page 54: ...F4 SET SD RESET SD SET PDE RESET PD SET 270 N120 RES 270 N120 SET SWHRS RES SWHRS SET REGSEL RES REGSEL SET ENABLE RES ENABLE SET PCLK RESET PLCK SET PLOAD RESET PLOAD SET CLR E ND RES CLR E ND SET St...

Page 55: ...es for the printer The addressing of the EEPROM starts from 050000 and extends to 05FFFF Presently a 512 x 8 device is called out but larger devices 2K x 8 are available if required The 512 bytes are...

Page 56: ...e hammer load circuit also accesses the DRAM starting at an address specified by the software then skips 64 locations and accesses the next word of data for 44 or 66 cycles for P6040 or P6080 respecti...

Page 57: ...Table 2 11 Logic C3 Unused Interrupt Vectors Vector Hex Definition Function 48 Timer B GPIB 1 is configured as an I O output GPIB 0 is configured as an I O output 45 44 41 Timer C Timer D GPIB1 port D...

Page 58: ...in the fundamental mode and divided by 2 4 and 8 by a 74HC161 CLK2 is derived from the 20MHz signal and has the high est loading since this signal is used for many functions it also drives circuits on...

Page 59: ...ts strobe polarity P6040 P6080 Select P6080 NRESYNC timer Not Used Not Used Not Used Not Used Phase Fire select 27256 addressing EPROM0 Clock 20 MHz 3 33MHz hammer load 1MHz hammer load N N N N N N N...

Page 60: ...pulses loading from the COM DATA line into the hammer driver shift register Every odd bit on the COM line is clocked into the shift regis ter by the rising edge of NSC selecting dot information for th...

Page 61: ...2 41 P6040 P6080 Principles of Operation Figure 2 15 Hammer Driver PCBA All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 62: ...2 42 P6040 P6080 Principles of Operation A P6040 B P6080 Figure 2 16 Hammer Driver Block Diagram All manuals and user guides at all guides com...

Page 63: ...2 43 P6040 P6080 Principles of Operation A P6040 B P6080 Figure 2 17 Hammer Driver Circuit Timing All manuals and user guides at all guides com...

Page 64: ...inches and no printing occurs During each of the four printing periods each hammer covers an area three characters wide for P6040 and two characters wide for P6080 An entire dot row is printed in 36 S...

Page 65: ...2 45 P6040 P6080 Principles of Operation A P6040 B P6080 Figure 2 18 Dot Row Timing vs Timing Disk and Cam Position All manuals and user guides at all guides com...

Page 66: ...2 46 P6040 P6080 Principles of Operation Figure 2 19 Operation of MPU Circuit All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 67: ...voltage in use Secondary windings of the transformer provide power to rectifiers regulators and filters that gen erate the following voltages to the PCBA 18 V unfiltered regulated on the PCBA to prov...

Page 68: ...2 48 P6040 P6080 Principles of Operation P6080 Shown Figure 2 20 Power Supply All manuals and user guides at all guides com...

Page 69: ...ovide the following voltage to the PCBA 36 Vac used to produce unfiltered 36 Vdc and 70 Vdc for the paper feed drive circuits 9 5 Vdc applied to the reference voltage circuit the 5 Vdc supply for the...

Page 70: ...2 50 P6040 P6080 Principles of Operation Figure 2 21 Power Supply Assembly P6080 All manuals and user guides at all guides com...

Page 71: ...ve voltage reference source 9 5 V for the fault detection circuitry The 9 5 V is fused and applied to the 2 6 V regulator The 2 6 V regulator provides the bias for the 5 V regulator and is the input t...

Page 72: ...2 52 P6040 P6080 Principles of Operation Figure 2 22 36 V and 70 V Supplies P6080 All manuals and user guides at all guides com...

Page 73: ...2 53 P6040 P6080 Principles of Operation Figure 2 23 Reference Voltage Circuit P6080 All manuals and user guides at all guides com...

Page 74: ...2 54 P6040 P6080 Principles of Operation Figure 2 24 5 V and MOS Supplies P6080 All manuals and user guides at all guides com...

Page 75: ...ich is further divided by stages of the clock counter to produce a 119 4 millisecond pulse and a 238 8 millisecond pulse Then 238 8 milliseconds after NSD goes low the 238 8 millisecond pulse sets the...

Page 76: ...2 56 P6040 P6080 Principles of Operation Figure 2 25 Relay Switching Details P6080 All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 77: ...2 57 P6040 P6080 Principles of Operation Figure 2 26 Motor Relay Trigger Circuit P6080 All manuals and user guides at all guides com...

Page 78: ...control logic from the ac power circuit The zero crossing detector prevents an excessive transient by switching the triac only when the ac voltage passes through zero volts The NSD signal enables gate...

Page 79: ...2 59 P6040 P6080 Principles of Operation Figure 2 28 Ribbon Drive All manuals and user guides at all guides com...

Page 80: ...2 60 P6040 P6080 Principles of Operation Figure 2 29 Ribbon Control PCBA Simplified Schematic All manuals and user guides at all guides com...

Page 81: ...the top of form to a selected vertical tab or by being put under EVFU control the corresponding profile of paper movement velocity is selected from the velocity profile to obtain precise paper contro...

Page 82: ...2 62 P6040 P6080 Principles of Operation Figure 2 31 Paper Feed Components All manuals and user guides at all guides com...

Page 83: ...These switches signal the control panel that the printer is out of paper or the platen has been left open When either signal is detected paper transport is disabled The signal faults are reported to t...

Page 84: ...2 64 P6040 P6080 Principles of Operation Figure 2 32 Platen Open Switch All manuals and user guides at all guides com...

Page 85: ...2 65 P6040 P6080 Principles of Operation Figure 2 33 Paper Out Switch All manuals and user guides at all guides com...

Page 86: ...bling the tri state buffers under control of the OE signal For each of the following three conditions OE is held low Initial power on the OE flip flop is held reset until 9 5 V rises to a value within...

Page 87: ...r HMC or the loss of the hammer reset pulse HRS When HMC is low the output of the one millisecond one shot U16 is normally kept high while being triggered by HRS pulses Whenever HRS pulses stop or HMC...

Page 88: ...the dot image buffer Information from the dot image buffer is synchronized with printer requirements using magnetic pickup signal then shifted out to hammer drivers The selected hammers are fired When...

Page 89: ...2 69 P6040 P6080 Principles of Operation Figure 2 35 Operation Flow Diagram All manuals and user guides at all guides com...

Page 90: ...2 70 P6040 P6080 Principles of Operation All manuals and user guides at all guides com...

Page 91: ...3 1 Preventive Maintenance Checks and Service Item No 1 2 3 4 5 6 Name Entire Printer Entire Printer Shuttle Belt Paper Feed Belt Cam Wick and Procedure Perform overall physical inspection per paragra...

Page 92: ...tion Check for damage cracks breaks dents gouges scratches de lamination warpage rust corrosion and proper finish Inspect screws bolts nuts washers for thread damage rust or corrosion Inspect for legi...

Page 93: ...3 3 P6040 P6080 Preventive Maintenance Figure 3 1 Cleaning Interior of Cabinet All manuals and user guides at all guides com...

Page 94: ...spools 5 from ribbon hubs 6 b Remove two socket head screws 7 c Raise ribbon drive assembly 8 slightly and lift it off retaining clips 9 d Mount ribbon drive assembly 8 on vertical cover support pin...

Page 95: ...i Check platen to hammer tip gap and adjust per paragraph 5 9 if necessary NOTE Placing a piece of paper between the hammer tips and paper ironer makes it easier to install the hammer bank cover Pape...

Page 96: ...BBON LOCKS 5 RIBBON SPOOLS 6 RIBBON HUBS 7 SCREW SOCKET HD 2 8 RIBBON DRIVE ASSEMBLY 9 RETAINNG CLIP 2 10 SUPPORT PIN VERTICAL COVER 11 SHOULDER SCREW Figure 3 2 Cleaning Hammer Bank Assembly Ribbon D...

Page 97: ...2 4 ANTIROTATION ARM 5 HAMMER BANK 6 RIGHT TRACTOR 7 HAMMER BANK COVER 8 ROLL PINS 9 HAMMER SPRINGS 10 HAMMER TIPS 11 FILTER 12 BEARING BLOCK SCREW 2 Figure 3 3 Cleaning Hammer Bank Assembly Hammer B...

Page 98: ...P6040 P6080 Preventive Maintenance 3 8 B P6040 NOTE See Sheet 1 for Legend Figure 3 3 Cleaning Hammer Bank Assembly Hammer Bank to Service Position 2 of 2 All manuals and user guides at all guides com...

Page 99: ...nspect If damaged or worn replace it Install original or re placement per paragraph 5 26b 4 Restore printer to normal operating configuration by performing steps 10 through 13 of paragraph 5 26b b Sel...

Page 100: ...P6040 P6080 Preventive Maintenance 3 10 1 OIL PORT PLUG 2 2 CAM WICK 3 LEAF SPRING 4 CAM Figure 3 4 Lubrication Counterweight and Cam Wick All manuals and user guides at all guides com...

Page 101: ...ventive Maintenance 1 CAM 2 MAGNET BLOCK 3 RIGHT BEARING BLOCK 4 CAM FOLLOWER YOKE 5 PIN Figure 3 5 Lubrication Self Aligning Cam Followers P6080 Only All manuals and user guides at all guides com a l...

Page 102: ...on arm 4 upward until tip clears spring 5 Rotate arm 4 forward and remove from printer 4 Wipe flat surfaces of antirotation arm 4 that fit behind spring 5 Apply a light coating of medium bearing greas...

Page 103: ...3 13 P6040 P6080 Preventive Maintenance 1 POWER CORD 2 COVER 3 SCREW 2 4 ANTIROTATION ARM 5 SPRING Figure 3 6 Lubrication Antirotation Arm P6040 Only All manuals and user guides at all guides com...

Page 104: ...P6040 P6080 Preventive Maintenance 3 14 All manuals and user guides at all guides com...

Page 105: ...uttle turnaround time or belt tension The remaining problems can be attributed to particular assem blies of the printing mechanism or occasionally to cables or interconnecting PCBAs 4 3 Testing a Self...

Page 106: ...n Not Detected VI PRINTER NOT PRINTING PROPERL Y Not Printing Missing Characters See Fig 4 13 for example Missing Dots See Fig 4 15 for example Light and or Smeared Characters See Fig 4 17 for Misplac...

Page 107: ...4 3 P6040 P6080 Troubleshooting Figure 4 1 Confidence Check 1 of 5 All manuals and user guides at all guides com...

Page 108: ...P6040 P6080 Troubleshooting 4 4 Figure 4 1 Confidence Check 2 of 5 All manuals and user guides at all guides com...

Page 109: ...4 5 P6040 P6080 Troubleshooting Figure 4 1 Confidence Check 3 of 5 All manuals and user guides at all guides com...

Page 110: ...P6040 P6080 Troubleshooting 4 6 Figure 4 1 Confidence Check 4 of 5 All manuals and user guides at all guides com...

Page 111: ...4 7 P6040 P6080 Troubleshooting Figure 4 1 Confidence Check 5 of 5 All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 112: ...P6040 P6080 Troubleshooting 4 8 Figure 4 2 New Printer Does Not Operate All manuals and user guides at all guides com...

Page 113: ...4 9 P6040 P6080 Troubleshooting Figure 4 3 POWER Indicator Not Illuminated 1 of 2 All manuals and user guides at all guides com...

Page 114: ...P6040 P6080 Troubleshooting 4 10 Figure 4 3 POWER Indicator Not Illuminated 2 of 2 All manuals and user guides at all guides com...

Page 115: ...4 11 P6040 P6080 Troubleshooting Figure 4 4 Error Indication on Display Stays On 1 of 2 All manuals and user guides at all guides com...

Page 116: ...P6040 P6080 Troubleshooting 4 12 Figure 4 4 Error Indication on Display Stays On 2 of 2 All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 117: ...4 13 P6040 P6080 Troubleshooting Figure 4 5 Online Not Indicated on Display 1 of 2 All manuals and user guides at all guides com...

Page 118: ...P6040 P6080 Troubleshooting 4 14 Figure 4 5 Online Not Indicated on Display 2 of 2 All manuals and user guides at all guides com...

Page 119: ...4 15 P6040 P6080 Troubleshooting Figure 4 6 Shuttle Does Not Accelerate to Speed When ON LINE Switch is Pressed All manuals and user guides at all guides com...

Page 120: ...P6040 P6080 Troubleshooting 4 16 Figure 4 7 Ribbon Does Not Advance 1 of 2 All manuals and user guides at all guides com...

Page 121: ...4 17 P6040 P6080 Troubleshooting Figure 4 7 Ribbon Does Not Advance 2 of 2 All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 122: ...P6040 P6080 Troubleshooting 4 18 Figure 4 8 Ribbon Folds Over All manuals and user guides at all guides com...

Page 123: ...4 19 P6040 P6080 Troubleshooting Figure 4 9 Ribbon Not Feeding Smoothly 1 of 2 All manuals and user guides at all guides com...

Page 124: ...P6040 P6080 Troubleshooting 4 20 Figure 4 9 Ribbon Not Feeding Smoothly 2 of 2 All manuals and user guides at all guides com...

Page 125: ...4 21 P6040 P6080 Troubleshooting Figure 4 10 End of Ribbon Not Detected All manuals and user guides at all guides com...

Page 126: ...P6040 P6080 Troubleshooting 4 22 Figure 4 11 Not Printing 1 of 3 All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 127: ...4 23 P6040 P6080 Troubleshooting Figure 4 11 Not Printing 2 of 3 All manuals and user guides at all guides com...

Page 128: ...P6040 P6080 Troubleshooting 4 24 Figure 4 11 Not Printing 3 of 3 All manuals and user guides at all guides com...

Page 129: ...4 25 P6040 P6080 Troubleshooting Figure 4 12 Missing Characters 1 of 4 All manuals and user guides at all guides com...

Page 130: ...P6040 P6080 Troubleshooting 4 26 Figure 4 12 Missing Characters 2 of 4 All manuals and user guides at all guides com...

Page 131: ...4 27 P6040 P6080 Troubleshooting Figure 4 12 Missing Characters 3 of 4 All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 132: ...P6040 P6080 Troubleshooting 4 28 Figure 4 12 Missing Characters 4 of 4 All manuals and user guides at all guides com...

Page 133: ...4 29 P6040 P6080 Troubleshooting Figure 4 13 Missing Characters Example of All manuals and user guides at all guides com...

Page 134: ...P6040 P6080 Troubleshooting 4 30 Figure 4 14 Missing Dots 1 of 6 All manuals and user guides at all guides com...

Page 135: ...4 31 P6040 P6080 Troubleshooting Figure 4 14 Missing Dots 2 of 6 All manuals and user guides at all guides com...

Page 136: ...P6040 P6080 Troubleshooting 4 32 Figure 4 14 Missing Dots 3 of 6 All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 137: ...4 33 P6040 P6080 Troubleshooting Figure 4 14 Missing Dots 4 of 6 All manuals and user guides at all guides com...

Page 138: ...P6040 P6080 Troubleshooting 4 34 Figure 4 14 Missing Dots 5 of 6 All manuals and user guides at all guides com...

Page 139: ...4 35 P6040 P6080 Troubleshooting Figure 4 14 Missing Dots 6 of 6 All manuals and user guides at all guides com...

Page 140: ...P6040 P6080 Troubleshooting 4 36 Figure 4 15 Missing Dots Example of All manuals and user guides at all guides com...

Page 141: ...4 37 P6040 P6080 Troubleshooting Figure 4 16 Light and or Smeared Characters 1 of 2 All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 142: ...P6040 P6080 Troubleshooting 4 38 Figure 4 16 Light and or Smeared Characters 2 of 2 All manuals and user guides at all guides com...

Page 143: ...4 39 P6040 P6080 Troubleshooting Figure 4 17 Light and or Smeared Characters Example of All manuals and user guides at all guides com...

Page 144: ...P6040 P6080 Troubleshooting 4 40 Figure 4 18 Misplaced Dots 1 of 4 All manuals and user guides at all guides com...

Page 145: ...4 41 P6040 P6080 Troubleshooting Figure 4 18 Misplaced Dots 2 of 4 All manuals and user guides at all guides com...

Page 146: ...P6040 P6080 Troubleshooting 4 42 Figure 4 18 Misplaced Dots 3 of 4 All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 147: ...4 43 P6040 P6080 Troubleshooting Figure 4 18 Misplaced Dots 4 of 4 All manuals and user guides at all guides com...

Page 148: ...P6040 P6080 Troubleshooting 4 44 Figure 4 19 Print Too Light or Dark 1 of 2 All manuals and user guides at all guides com...

Page 149: ...4 45 P6040 P6080 Troubleshooting Figure 4 19 Print Too Light or Dark 2 of 2 All manuals and user guides at all guides com...

Page 150: ...P6040 P6080 Troubleshooting 4 46 Figure 4 20 Print Too Light or Dark Example of All manuals and user guides at all guides com...

Page 151: ...4 47 P6040 P6080 Troubleshooting Figure 4 21 Horizontal Misalignment All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 152: ...P6040 P6080 Troubleshooting 4 48 Figure 4 22 Horizontal Misalignment Example of All manuals and user guides at all guides com...

Page 153: ...4 49 P6040 P6080 Troubleshooting Figure 4 23 Vertical Misalignment 1 of 4 All manuals and user guides at all guides com...

Page 154: ...P6040 P6080 Troubleshooting 4 50 Figure 4 23 Vertical Misalignment 2 of 4 All manuals and user guides at all guides com...

Page 155: ...4 51 P6040 P6080 Troubleshooting Figure 4 23 Vertical Misalignment 3 of 4 All manuals and user guides at all guides com...

Page 156: ...P6040 P6080 Troubleshooting 4 52 Figure 4 23 Vertical Misalignment 4 of 4 All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 157: ...4 53 P6040 P6080 Troubleshooting Figure 4 24 Vertically Misaligned Character Position Example of All manuals and user guides at all guides com...

Page 158: ...P6040 P6080 Troubleshooting 4 54 Figure 4 25 Vertically Deformed Characters Example of All manuals and user guides at all guides com...

Page 159: ...4 55 P6040 P6080 Troubleshooting Figure 4 26 Vertical Compression of Print All manuals and user guides at all guides com...

Page 160: ...P6040 P6080 Troubleshooting 4 56 Figure 4 27 Garbled Letters and or Wrong Font 1 of 2 All manuals and user guides at all guides com...

Page 161: ...4 57 P6040 P6080 Troubleshooting Figure 4 27 Garbled Letters and or Wrong Font 2 of 2 All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 162: ...P6040 P6080 Troubleshooting 4 58 Figure 4 28 No Paper Feed 1 of 4 All manuals and user guides at all guides com...

Page 163: ...4 59 P6040 P6080 Troubleshooting Figure 4 28 No Paper Feed 2 of 4 All manuals and user guides at all guides com...

Page 164: ...P6040 P6080 Troubleshooting 4 60 Figure 4 28 No Paper Feed 3 of 4 All manuals and user guides at all guides com...

Page 165: ...4 61 P6040 P6080 Troubleshooting Figure 4 28 No Paper Feed 4 of 4 All manuals and user guides at all guides com...

Page 166: ...P6040 P6080 Troubleshooting 4 62 Figure 4 29 Paper Feeds Erratically 1 of 5 All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 167: ...4 63 P6040 P6080 Troubleshooting Figure 4 29 Paper Feeds Erratically 2 of 5 All manuals and user guides at all guides com...

Page 168: ...P6040 P6080 Troubleshooting 4 64 Figure 4 29 Paper Feeds Erratically 3 of 5 All manuals and user guides at all guides com...

Page 169: ...4 65 P6040 P6080 Troubleshooting Figure 4 29 Paper Feeds Erratically 4 of 5 All manuals and user guides at all guides com...

Page 170: ...P6040 P6080 Troubleshooting 4 66 Figure 4 29 Paper Feeds Erratically 5 of 5 All manuals and user guides at all guides com...

Page 171: ...4 67 P6040 P6080 Troubleshooting Figure 4 30 Paper Drags 1 of 3 All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 172: ...P6040 P6080 Troubleshooting 4 68 Figure 4 30 Paper Drags 2 of 3 All manuals and user guides at all guides com...

Page 173: ...4 69 P6040 P6080 Troubleshooting Figure 4 30 Paper Drags 3 of 3 All manuals and user guides at all guides com...

Page 174: ...P6040 P6080 Troubleshooting 4 70 Figure 4 31 Top of Form Does Not Operate 1 of 2 All manuals and user guides at all guides com...

Page 175: ...4 71 P6040 P6080 Troubleshooting Figure 4 31 Top of Form Does Not Operate 2 of 2 All manuals and user guides at all guides com...

Page 176: ...Figure 4 32 1 Load printer with full width single part paper 2 Set Exerciser controls as follows LINE LENGTH 132 CHARACTER SRO 96 if lowercase character set is installed SRO 64 if uppercase character...

Page 177: ...width single part paper 2 Set Exerciser controls as follows LINE LENGTH 132 CHARACTER DELETE SPECIAL PLOT MODE FUNCTION LINE FEED 3 Place printer online Print one half page and take printer offline 4...

Page 178: ...E LENGTH 132 CHARACTER H SPECIAL NONE FUNCTION LINE FEED 3 Place printer online Print one half page of the letter H and take printer offline 4 Examine printout for vertical alignment of dots in altern...

Page 179: ...single part paper 2 Set Exerciser controls as follows LINE LENGTH 132 CHARACTER SR0 64 SPECIAL ROW INC FUNCTION LINE FEED 3 Place printer online Print one page and take printer offline 4 Examine print...

Page 180: ...H 132 CHARACTER SPACE or DELETE SPECIAL UNDERLINE FUNCTION LINE FEED 3 Place printer online Print one half page of underlines and take printer offline 4 Examine printout Check for straight underlines...

Page 181: ...2 Ribbon Guides 3 Shuttle Spring 4 Counterweight 5 Hammer Springs 6 Hammer Tips 7 Platen Gap 8 Magnetic Pickup Gap 9 Shuttle Belt 10 Paper Feed Belt 11 Paper Motion Sensor 12 Paper Out Detector b Rep...

Page 182: ...orque Screwdriver Hex Bit 3 32 in Torque Screwdriver Hex Bit 5 32 in Torque Screwdriver Screwdriver Allen Hex Screwdriver Phillips Screwdriver Phillips Screwdriver Slot Screwdriver Slot Socket 7 16 in...

Page 183: ...re no error indications appear 5 With shuttle motor running swing out card cage 4 and disconnect J4 5 on power supply PCBA 6 CAUTION J4 must be connected any time printer power is turned on If it is n...

Page 184: ...P6040 P6080 Corrective Maintenance 5 4 Figure 5 1 Ribbon Height Adjustment All manuals and user guides at all guides com...

Page 185: ...5 5 P6040 P6080 Corrective Maintenance Figure 5 2 Ribbon Tracking Check and Adjustment All manuals and user guides at all guides com...

Page 186: ...screws 2 3 Remove cam cover 3 and attached gasket 4 4 Inspect area around shuttle spring 5 and counterweight spring 6 for shims that may have broken or come loose Replace any loose shims per steps 7 a...

Page 187: ...5 7 P6040 P6080 Corrective Maintenance Figure 5 3 Shuttle Spring Force Adjustment All manuals and user guides at all guides com...

Page 188: ...ree more shims 4 Perform steps 9 through 11 of paragraph 5 5 b Setting Preload Using Force Gauge Figure 5 4 1 Remove ribbon drive per paragraph 5 19a Perform steps 1 through 6 of paragraph 5 16a to ga...

Page 189: ...5 9 P6040 P6080 Corrective Maintenance Figure 5 4 Setting Shuttle and Counterweight Preload All manuals and user guides at all guides com...

Page 190: ...9 Tip front edge of shuttle yoke 8 down 10 Cycle ON LINE until left cam follower 6 lines up with cam 4 11 Tip front edge of shuttle yoke 8 up 12 Cycle ON LINE until left cam follower 6 lines up with...

Page 191: ...5 11 P6040 P6080 Corrective Maintenance Figure 5 5 Hammer Spring Retensioning All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 192: ...UTION Hammer tips are susceptible to damage when subjected to a sideways force 4 Remove hammer bank cover a Force top edge of hammer bank cover 3 away from hammer bank 4 b While maintaining the hammer...

Page 193: ...5 13 P6040 P6080 Corrective Maintenance Figure 5 6 Hammer Tip Alignment All manuals and user guides at all guides com...

Page 194: ...P6040 P6080 Corrective Maintenance 5 14 Figure 5 7 Platen Gap Adjustment All manuals and user guides at all guides com...

Page 195: ...rected gap adjustment should be followed by phasing adjustment paragraph 5 11 1 Gain access to MPU by performing steps 1 through 4 of paragraph 5 26 2 Remove covers per paragraph 5 17a 3 Loosen screw...

Page 196: ...P6040 P6080 Corrective Maintenance 5 16 Figure 5 8 Magnetic Pickup Gap and Phasing Adjustment All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 197: ...te all Hs 5 Press ON LINE switch and observe printout NOTE To precisely set MPU phase a long shanked screwdriver or Allen wrench shaft may be used as a pry bar with the bracket arms as a fulcrum 6 Pos...

Page 198: ...per paragraph 5 17b 6 Replace cam cover by performing steps 10 through 13 of paragraph 5 26b 5 14 Paper Feed Belt Figure 5 10 a Tension Check 1 Open front cover 1 2 Press down at center of paper feed...

Page 199: ...5 19 P6040 P6080 Corrective Maintenance Figure 5 9 Shuttle Belt Tension Check and Adjustment All manuals and user guides at all guides com...

Page 200: ...P6040 P6080 Corrective Maintenance 5 20 Figure 5 10 Paper Feed Belt Tension Check and Adjustment All manuals and user guides at all guides com...

Page 201: ...eep speed at about 10 mSec division c Rotate vertical position knob while observing scope for a maximum signal level of not less than 150 mV peak to peak If amplitude is less than 150 mV loosen mount...

Page 202: ...P6040 P6080 Corrective Maintenance 5 22 Figure 5 11 Paper Motion Sensor Check and Adjustment All manuals and user guides at all guides com...

Page 203: ...Load paper and apply power 2 Set Forms Thickness Lever 1 to position 1 3 Gain access to equipment by performing steps 1 through 6 of paragraph 5 17a Do not disconnect power cord 4 Rotate shaft 2 unti...

Page 204: ...P6040 P6080 Corrective Maintenance 5 24 Figure 5 12 Paper Out Detector Adjustment All manuals and user guides at all guides com...

Page 205: ...Slide cover 11 forward slightly 6 Lift rear cover 14 and set on front cover 11 7 Swing out card cage 15 Remove two screws 16 8 Disconnect connector LBP1 17 Cut cable ties as necessary to free covers...

Page 206: ...P6040 P6080 Corrective Maintenance 5 26 Figure 5 13 Cover Removal Installation All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 207: ...Separate connector LBP1 14 from card cage 12 12 Lift control panel 6 and attached cable from printer 15 b Installation 1 Place control panel 6 and attached cable into printer 15 2 Route cable with co...

Page 208: ...P6040 P6080 Corrective Maintenance 5 28 Figure 5 14 Control Panel Removal Installation All manuals and user guides at all guides com...

Page 209: ...d ground wire 4 through grommet 5 Retie wires as neces sary 3 Install ground wire 4 and connectors at J1 1 J2 2 and J3 3 4 Return ribbon drive to operating position per paragraph 3 4c 9 and 10 5 20 Ri...

Page 210: ...P6040 P6080 Corrective Maintenance 5 30 Figure 5 15 Ribbon Drive Removal Installation All manuals and user guides at all guides com...

Page 211: ...5 31 P6040 P6080 Corrective Maintenance Figure 5 16 Ribbon Control PCBA Removal Installation All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 212: ...motor is being installed replace ribbon control PCBA per paragraph 5 20b 3 Install four nuts 6 4 Connect motor cable connector 4 to ribbon control PCBA 5 Install new tie wraps as required 5 Install h...

Page 213: ...5 33 P6040 P6080 Corrective Maintenance Figure 5 17 Ribbon Drive Motor Removal Installation All manuals and user guides at all guides com...

Page 214: ...P6040 P6080 Corrective Maintenance 5 34 Figure 5 18 Ribbon Drive Blower Removal Installation All manuals and user guides at all guides com...

Page 215: ...6080 1 Remove printer cover per paragraph 5 17a 2 Set Forms Thickness Lever 1 to open 3 Loosen two captive screws 2 with washers 3 and 4 4 Separate cam cover 5 and attached gasket 6 from cam housing 7...

Page 216: ...P6040 P6080 Corrective Maintenance 5 36 A P6080 Figure 5 19 Shuttle Assembly Removal Installation 1 of 2 All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 217: ...5 37 P6040 P6080 Corrective Maintenance B P6040 Figure 5 19 Shuttle Assembly Removal Installation 2 of 2 All manuals and user guides at all guides com...

Page 218: ...not show at either side 9 Put comb brackets 20 back in place Tighten two screws 9 10 Torque screw 8 to 12 in lbs 11 Torque bearing block screws CAUTION Torquing to incorrect value or without operatin...

Page 219: ...t pinched un der bearing block 2 Install terminal lug 4 star washer 5 and screw 3 Allow sufficient slack for service loop in ground wire 22 3 Route hammer bank cable 20 to card cage 9 CAUTION When con...

Page 220: ...quire only one additional screw to be loosened 5 Slide hammer spring 4 forward past clamp plate 5 and remove b Installation CAUTION Transport new hammer springs flat and unstressed Handle carefully to...

Page 221: ...5 41 P6040 P6080 Corrective Maintenance Figure 5 20 Hammer Spring Removal Installation All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 222: ...sary to remove leads Damage to connector will result a Using X acto knife or other small tool gently pry up releasing tab 9 b Withdraw coil lead 4 and its terminal 10 8 Separate coil 11 from hammer ba...

Page 223: ...tion per paragraph 3 4c 9 and 10 c Removal P6040 1 Remove hammer spring per paragraph 5 24a NOTE Each hammer coil is integral with its mounting base The hammer coil is held in place on the pole pin wi...

Page 224: ...P6040 P6080 Corrective Maintenance 5 44 A P6080 Figure 5 21 Hammer Coil Removal Installation 1 of 2 All manuals and user guides at all guides com...

Page 225: ...5 45 P6040 P6080 Corrective Maintenance B P6040 Figure 5 21 Hammer Coil Removal Installation 2 of 2 All manuals and user guides at all guides com...

Page 226: ...upper counterbalance 20 will come free 12 Remove two screws 21 13 Separate cam follower 22 and gasket 23 from counterweight 15 b Installation 1 Position cam follower 22 and gasket 23 on counterweight...

Page 227: ...5 47 P6040 P6080 Corrective Maintenance Figure 5 22 Counterweight Assembly Removal Installation 1 of 2 All manuals and user guides at all guides com...

Page 228: ...P6040 P6080 Corrective Maintenance 5 48 Figure 5 22 Counterweight Assembly Removal Installation 2 of 2 All manuals and user guides at all guides com...

Page 229: ...s relative to vertical Position cam 10 with lobes at top and bottom Make sure belt 7 engages grooves in pulley 11 on flywheel 3 4 Install two screws 5 and star washers 6 5 Rotate flywheel 3 a few time...

Page 230: ...P6040 P6080 Corrective Maintenance 5 50 Figure 5 23 Flywheel Assembly Removal Installation All manuals and user guides at all guides com...

Page 231: ...to MPU by performing procedures of paragraph 5 26a 1 through 4 2 Loosen two fasteners 1 and open rear door 2 3 Working through rear door disconnect MPU leads 3 from terminal strip 4 by remov ing two...

Page 232: ...P6040 P6080 Corrective Maintenance 5 52 Figure 5 24 Cam Wick Removal Installation All manuals and user guides at all guides com...

Page 233: ...5 53 P6040 P6080 Corrective Maintenance Figure 5 25 Magnetic Pickup Removal Installation All manuals and user guides at all guides com...

Page 234: ...move two nuts 9 and star washers 10 7 Remove cover 11 from terminal board 12 8 Tag motor leads 13 9 Remove screws 14 and terminal lugs 15 to free up leads 13 10 Disconnect ground lead 16 11 Support mo...

Page 235: ...5 55 P6040 P6080 Corrective Maintenance Figure 5 26 Shuttle Motor Removal Installation All manuals and user guides at all guides com...

Page 236: ...15 6 Place cover 11 over terminal board 12 7 Install two nuts 9 and star washers 10 8 Slip belt 7 over motor pulley 8 9 Adjust belt tension per paragraph 5 13 10 Position cam cover 2 with attached ga...

Page 237: ...5 57 P6040 P6080 Corrective Maintenance Figure 5 27 Shuttle Belt Removal Installation All manuals and user guides at all guides com...

Page 238: ...y in operating position per paragraph 3 4c8 but do not in stall comb clamp 3 Tighten two middle then two outer screws 3 4 Slip comb clamp 2 under screws 1 5 Tighten two screws 1 6 Place ribbon drive i...

Page 239: ...5 59 P6040 P6080 Corrective Maintenance Figure 5 28 Paper Ironer Removal Installation All manuals and user guides at all guides com...

Page 240: ...P6040 P6080 Corrective Maintenance 5 60 Figure 5 29 Paper Feed Belt Removal Installation All manuals and user guides at all guides com...

Page 241: ...haft 5 9 Check belt tension per paragraph 5 14a Adjust if necessary per paragraph 5 14b 10 Close cover 2 Connect power cord 1 5 34 Paper Feed Motor Figure 5 30 a Removal 1 Remove printer cover per par...

Page 242: ...P6040 P6080 Corrective Maintenance 5 62 Figure 5 30 Paper Feed Motor Removal Installation All manuals and user guides at all guides com...

Page 243: ...nd 4 d Slide right tractor 3 to right and off support shaft 10 9 To remove left tractor a Remove paper motion sensor per paragraph 5 36a b Slide spline shaft 7 to right until it clears tractor 4 Slip...

Page 244: ...P6040 P6080 Corrective Maintenance 5 64 Figure 5 31 Tractor Removal Installation All manuals and user guides at all guides com...

Page 245: ...rew 8 and washer 9 5 Install bushing 6 on spline shaft 7 6 Tighten setscrew 5 7 Adjust belt tension if required per paragraph 5 14 8 Verify tractors 3 and 4 are parallel on shafts Adjust if necessary...

Page 246: ...P6040 P6080 Corrective Maintenance 5 66 Figure 5 32 Paper Motion Sensor Removal Installation All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 247: ...er per paragraph 5 17a 2 Swing out card cage 1 3 Remove two screws 2 and star washers 3 4 Slide power supply 4 toward rear of printer to gain access to paper out switch assembly 5 5 Disconnect connect...

Page 248: ...P6040 P6080 Corrective Maintenance 5 68 Figure 5 33 Paper Out Mechanical Switch Removal Installation All manuals and user guides at all guides com...

Page 249: ...4 9 Lift prism 15 off belt cover 13 b Installation 1 Place prism 15 on belt cover 13 2 Install two nuts 14 3 Place sensor PCBA 10 sensor support 11 and cover 12 on belt cover 13 4 Install two nuts 8 a...

Page 250: ...P6040 P6080 Corrective Maintenance 5 70 Figure 5 34 Paper Out Optical Sensor Removal Installation All manuals and user guides at all guides com...

Page 251: ...5 71 P6040 P6080 Corrective Maintenance Figure 5 35 Platen Open Switch Removal Installation All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 252: ...re severe injury or death is possible 1 Disconnect power cord 1 Wait five minutes before continuing 2 Loosen two fasteners 2 and allow rear door 3 to swing open 3 Swing out card cage 4 4 On capacitor...

Page 253: ...5 73 P6040 P6080 Corrective Maintenance Figure 5 36 DC Power Supply Fuses Removal Installation All manuals and user guides at all guides com...

Page 254: ...crews 5 and terminal lug 6 3 Connect connectors 1 connector 2 and terminals 3 to PCBA 4 according to labels 4 Perform steps 2 through 5 of paragraph 5 40b 5 42 Power Supply Figure 5 38 a Removal 1 Loo...

Page 255: ...5 75 P6040 P6080 Corrective Maintenance Figure 5 37 Power Supply PCBA Removal Installation All manuals and user guides at all guides com...

Page 256: ...P6040 P6080 Corrective Maintenance 5 76 Figure 5 38 Power Supply Removal Installation All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 257: ...card cage 3 back into place 10 Close rear door 2 and tighten two fasteners 1 5 43 Rear Fan Figure 5 39 a Removal 1 Remove cover per paragraph 5 17a 2 Remove two nuts 1 and star washers 2 3 Lift up tra...

Page 258: ...P6040 P6080 Corrective Maintenance 5 78 Figure 5 39 Rear Fan Removal Installation All manuals and user guides at all guides com...

Page 259: ...alling a PCBA in the wrong slot or backwards in the correct slot will damage PCBA and connector 2 Slide PCBA 5 into correct slot of card cage 5 with component side toward rear of printer 3 Engage ejec...

Page 260: ...P6040 P6080 Corrective Maintenance 5 80 Figure 5 40 Logic PCBA Removal Installation All manuals and user guides at all guides com...

Page 261: ...5 81 P6040 P6080 Corrective Maintenance Figure 5 41 Hammer Driver PCBA Removal Installation All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 262: ...teps 1 through 6 of paragraph 5 45a 4 Remove two screws 1 5 Separate connector J1 2 from card cage 3 6 Remove two screws 4 7 Separate connector J3 5 from card cage 3 8 Remove two screws 6 and washers...

Page 263: ...5 83 P6040 P6080 Corrective Maintenance Figure 5 42 Hammer Bank Cable Harness Removal Installation P6080 Only 1 of 2 All manuals and user guides at all guides com...

Page 264: ...P6040 P6080 Corrective Maintenance 5 84 Figure 5 42 Hammer Bank Cable Harness Removal Installation P6080 Only 2 of 2 All manuals and user guides at all guides com...

Page 265: ...nal of capacitor C2 17 8 Install screw 13 and star washer 14 9 Place terminal bank C 8 on positive terminal of capacitor C1 12 10 Place terminal bank C 9 connector COM 1 10 and connector COM 2 11 on n...

Page 266: ...P6040 P6080 Corrective Maintenance 5 86 All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 267: ...14 Ribbon Height 5 3 F5 1 5 3 5 4 Ribbon Tracking 5 4 F5 2 5 3 5 5 Shuttle Belt Tension 5 13 F5 9 5 18 5 19 Shuttle Spring Force 5 5 F5 3 5 6 5 7 Hammer Tip 5 8 F5 6 5 12 5 13 B Belt Replacement Paper...

Page 268: ...k to Service Position F3 3 3 7 Hammer Bank Assembly Ribbon Drive to Service Position F3 2 3 6 Interior of Cabinet F3 1 3 3 Coil Replacement Hammer 5 25 F5 21 5 42 5 44 Common Causes of Malfunctions 4...

Page 269: ...onic Drawings App B B 1 Elongated Characters F2 3 2 2 End of Ribbon Not Detected F4 10 4 21 Error Indication on Display Stays On F4 4 4 11 External Controls and Indicators F1 2 T1 1 1 5 1 4 F Fan Repl...

Page 270: ...F5 41 5 79 5 81 Hammers Positioning and Release of Odd and Even F2 4 2 4 Hammer Spring Replacement 5 24 F5 20 5 40 5 41 Hammer Spring Retensioning 5 7 F5 5 5 10 5 11 Hammer Tip Alignment 5 8 F5 6 5 12...

Page 271: ...ment 5 29 F5 25 5 49 5 53 Malfunctions Common Causes of 4 2 4 1 Malfunction Symptom Index T4 1 4 2 Matrix Printing General Description 2 3 2 1 Mechanical Drawings and Parts Lists App C C 1 Memory Map...

Page 272: ...31 2 36 Control Circuits 2 11 2 62 Control Circuits Block Diagram F2 30 2 62 Paper Feed Belt Adjustment 5 14 F5 10 5 18 5 20 Replacement 5 33 F5 29 5 58 5 60 Paper Feed Motor Replacement 5 34 F5 30 5...

Page 273: ...9 Power Supply 2 9 F2 20 2 47 2 48 Assembly P6080 F2 21 2 50 Connector Pin Assignments T2 2 2 19 Fuse Replacement DC 5 40 F5 36 5 72 5 73 PCBA Replacement 5 41 F5 37 5 74 5 75 Replacement 5 42 F5 38 5...

Page 274: ...Paper Motion Sensor 5 36 F5 32 5 65 5 66 Paper Out Mechanical Switch 5 37 F5 33 5 67 5 68 Paper Out Optical Sensor 5 38 F5 34 5 69 5 70 Platen Open Switch 5 39 F5 35 5 69 5 71 Power Supply 5 42 F5 38...

Page 275: ...placement 5 23 F5 19 5 35 5 36 Shuttle Belt Adjustment 5 13 F5 9 5 18 5 19 Replacement 5 31 F5 27 5 56 5 57 Shuttle Does Not Accelerate to Speed When ONLINE Switch is Pressed F4 6 4 15 Shuttle Motor R...

Page 276: ...ng Ribbon Check and Adjustment 5 4 F5 2 5 3 5 5 Tractor Replacement 5 35 F5 31 5 63 5 64 Trigger Circuit Motor Relay P6080 F2 26 2 58 Troubleshooting General 4 1 4 1 Typical Characters F2 2 2 2 U Unde...

Page 277: ...All manuals and user guides at all guides com...

Page 278: ...PRINTRONIX NEDERLAND BV P O BOX 163 NIEUWEWEG 283 NL 6600 AD WIJCHEN THE NETHERLANDS PHONE 31 8894 90111 FAX 31 246 419768 PRINTRONIX A G 512 CHAI CHEE LANE HEX 02 15 BEDOK INDUSTRIAL ESTATE SINGAPORE...

Page 279: ...P6000 Series Pedestal Model Maintenance Manual R Volume 2 of 2 All manuals and user guides at all guides com...

Page 280: ...All manuals and user guides at all guides com...

Page 281: ...P6000 Series Pedestal Model Maintenance Manual Vol 2 R P N 108692 001 Rev B Volume 2 of 2 All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 282: ...ent this product may cause radio interference in which case the user may be required to take adequate measures Printronix Inc makes no representations or warranties of any kind regarding this material...

Page 283: ...Driver PCBA 2 40 2 8 Hammer Bank and Shuttle Mechanism MPU 2 44 2 9 Power Supply 2 47 2 10 Ribbon Drive 2 59 2 11 Paper Feed Control Circuits 2 62 2 12 Platen Open Paper Out Switches 2 64 2 13 Safety...

Page 284: ...huttle Motor to Line Frequency 5 17 5 13 Shuttle Belt 5 18 5 14 Paper Feed Belt 5 18 5 15 Paper Motion Sensor 5 21 5 16 Paper Out Detectors 5 23 Section III REPLACEMENT 5 17 Printer Cover 5 25 5 18 Co...

Page 285: ...Interface Connector Pin Assignments 2 18 2 2 Power Supply Connector Pin Assignments 2 19 2 3 Front Panel Connector Pin Assignments 2 20 2 4 Four Phase Stepper Connector Pin Assignments 2 20 2 5 Microp...

Page 286: ...tion 2 45 2 19 Operation of MPU Circuit 2 46 2 20 Power Supply 2 48 2 21 Power Supply Assembly P6080 2 50 2 22 36 V and 70 V Supplies P6080 2 53 2 23 Reference Voltage Circuit P6080 2 54 2 24 5 V and...

Page 287: ...lignment 4 47 4 22 Horizontal Misalignment Example of 4 48 4 23 Vertical Misalignment 4 49 4 24 Vertically Misaligned Character Position Example of 4 53 4 25 Vertically Deformed Characters Example of...

Page 288: ...ick Removal Installation 5 52 5 25 Magnetic Pickup Removal Installation 5 53 5 26 Shuttle Motor Removal Installation 5 55 5 27 Shuttle Belt Removal Installation 5 57 5 28 Paper Ironer Removal Installa...

Page 289: ...Mechanical Drawings Mechanical drawings and parts lists are included here Controls and Indicators Throughout this manual controls and indicators are printed in text exactly as they appear on the print...

Page 290: ...P6040 P6080 Maintenance viii All manuals and user guides at all guides com...

Page 291: ...A 1 P6040 P6080 Mnemonic Terms APPENDIX A MNEMONIC TERMS All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 292: ...ledge interface ICBY Busy interface ICPE Printer enable ready for Centronics interface ICSTB IDSTB Data strobes for Centronics and Dataproducts interface IDR Data request interface IONL Online interfa...

Page 293: ...ttle is beginning a left to right excursion NSD Shuttle drive activates the shuttle drive motor and the ribbon motors OE Output enable hammer drive interlock or timing ONL Online PF1 PF2 Paper feed pu...

Page 294: ...P6040 P6080 Mnemonic Terms A 4 All manuals and user guides at all guides com...

Page 295: ...A 5 P6040 P6080 Mnemonic Terms All manuals and user guides at all guides com...

Page 296: ...P6040 P6080 Mnemonic Terms A 6 All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 297: ...B 1 P6040 P6080 Electronic Drawings APPENDIX B ELECTRONIC DRAWINGS All manuals and user guides at all guides com...

Page 298: ...P6040 P6080 Electronic Drawings B 2 All manuals and user guides at all guides com...

Page 299: ...B 3 P6040 P6080 Electronic Drawings All manuals and user guides at all guides com...

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Page 339: ...C 1 P6040 P6080 Drawings and Parts Lists APPENDIX C MECHANICAL DRAWINGS AND PARTS LISTS All manuals and user guides at all guides com...

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Page 445: ...14 Ribbon Height 5 3 F5 1 5 3 5 4 Ribbon Tracking 5 4 F5 2 5 3 5 5 Shuttle Belt Tension 5 13 F5 9 5 18 5 19 Shuttle Spring Force 5 5 F5 3 5 6 5 7 Hammer Tip 5 8 F5 6 5 12 5 13 B Belt Replacement Paper...

Page 446: ...Position F3 3 3 7 Hammer Bank Assembly Ribbon Drive to Service Position F3 2 3 6 Interior of Cabinet F3 1 3 3 Coil Replacement Hammer 5 25 F5 21 5 42 5 44 Common Causes of Malfunctions 4 2 4 1 Confid...

Page 447: ...onic Drawings App B B 1 Elongated Characters F2 3 2 2 End of Ribbon Not Detected F4 10 4 21 Error Indication on Display Stays On F4 4 4 11 External Controls and Indicators F1 2 T1 1 1 5 1 4 F Fan Repl...

Page 448: ...F5 41 5 79 5 81 Hammers Positioning and Release of Odd and Even F2 4 2 4 Hammer Spring Replacement 5 24 F5 20 5 40 5 41 Hammer Spring Retensioning 5 7 F5 5 5 10 5 11 Hammer Tip Alignment 5 8 F5 6 5 12...

Page 449: ...5 16 Replacement 5 29 F5 25 5 49 5 53 Malfunctions Common Causes of 4 2 4 1 Malfunction Symptom Index T4 1 4 2 Matrix Printing General Description 2 3 2 1 Mechanical Drawings and Parts Lists App C C 1...

Page 450: ...31 2 36 Control Circuits 2 11 2 62 Control Circuits Block Diagram F2 30 2 62 Paper Feed Belt Adjustment 5 14 F5 10 5 18 5 20 Replacement 5 33 F5 29 5 58 5 60 Paper Feed Motor Replacement 5 34 F5 30 5...

Page 451: ...ly 2 9 F2 20 2 47 2 48 Assembly P6080 F2 21 2 50 Connector Pin Assignments T2 2 2 19 Fuse Replacement DC 5 40 F5 36 5 72 5 73 PCBA Replacement 5 41 F5 37 5 74 5 75 Replacement 5 42 F5 38 5 74 5 76 Pre...

Page 452: ...Paper Motion Sensor 5 36 F5 32 5 65 5 66 Paper Out Mechanical Switch 5 37 F5 33 5 67 5 68 Paper Out Optical Sensor 5 38 F5 34 5 69 5 70 Platen Open Switch 5 39 F5 35 5 69 5 71 Power Supply 5 42 F5 38...

Page 453: ...placement 5 23 F5 19 5 35 5 36 Shuttle Belt Adjustment 5 13 F5 9 5 18 5 19 Replacement 5 31 F5 27 5 56 5 57 Shuttle Does Not Accelerate to Speed When ONLINE Switch is Pressed F4 6 4 15 Shuttle Motor R...

Page 454: ...4 70 Tracking Ribbon Check and Adjustment 5 4 F5 2 5 3 5 5 Tractor Replacement 5 35 F5 31 5 63 5 64 Trigger Circuit Motor Relay P6080 F2 26 2 58 Troubleshooting General 4 1 4 1 Typical Characters F2...

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Page 456: ...EDERLAND BV P O BOX 163 NIEUWEWEG 283 NL 6600 AD WIJCHEN THE NETHERLANDS PHONE 31 8894 90111 FAX 31 246 419768 PRINTRONIX A G 512 CHAI CHEE LANE HEX 02 15 BEDOK INDUSTRIAL ESTATE SINGAPORE 1646 PHONE...

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