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Printronix P4280, Maintenance Manual

Looking for the Maintenance Manual for your Printronix P4280 printer? Look no further! Download the comprehensive manual for free from manualshive.com. This user-friendly guide provides step-by-step instructions for optimal printer maintenance, ensuring maximum performance and longevity for your Printronix P4280.

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3–4

Troubleshooting

Dynamic RAM Fault *

Instruction

Indication

Yes

No

1.

Set power switch to O (off).
Wait 15 seconds. Set power
switch to 1 (on).

“Dynamic RAM Fault * ”
message.

Step 2.

Return printer to
normal operation.

2.

Disconnect the input data line
from the host computer. Set
power switch to O (off). Wait
15 seconds. Set power
switch to 1 (on).

“Dynamic RAM Fault * ”
message.

Step 3.

Return printer to
normal operation.

3.

Make a Diagnostic Check of
the Microprocessors (page
3–21).

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—

Summary of Contents for P4280

Page 1: ...P4280 Line Matrix Printer Maintenance Manual R ...

Page 2: ......

Page 3: ...P4280 Line Matrix Printer Maintenance Manual R P N 155064 001 Rev B ...

Page 4: ...duct 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 including but not limited to implied warranties of merchantability and fitness for a particular purpose Printronix Inc shall not be held responsible for errors contained herein or any omissions from this materia...

Page 5: ...Indicators 1 4 Tools Test Equipment and Supplies 1 10 2 Scheduled Maintenance Preventive Maintenance Checks and Services PMCS 2 2 Inspecting the Printer 2 3 Cleaning the Printer 2 4 3 Troubleshooting Introduction 3 2 Fault Messages 3 2 48 Volt Failed 3 2 Dynamic RAM Fault 3 4 Ham Bank Hot 3 5 Ham Coil Open 3 6 Ham Coil Short 3 7 Ham Drv Short 3 8 Mech Driver Hot 3 9 Mech Driver Link 3 10 Paper Jam...

Page 6: ...nce 4 2 Belt Paper Feed Timing Adjustment 4 2 Belt Platen Open Adjustment 4 4 Hammer Phasing 4 6 Paper Drive Motor Pulley Alignment 4 8 Paper Scale Alignment 4 10 Platen Angle Adjustment 4 12 Platen Gap Adjustment 4 14 Platen Open Motor Pulley Alignment 4 16 Ribbon Guide Alignment 4 18 Splined Shaft Skew Adjustment 4 20 5 Replacement Procedures Preparing the Printer for Maintenance 5 3 Replacement...

Page 7: ...8 Motor Assembly Platen Open 5 40 Paper Guide Assembly 5 42 Paper Ironer 5 44 PCBA Common Controller 5 46 PCBA Mechanism Driver 5 48 PCBA Power Supply 5 50 Platen 5 52 PROMs Chips and ICs on the CCB 5 58 PROMs Chips and ICs on the Mechanism Driver 5 60 Resistors Terminating 5 62 Ribbon Hub 5 64 Ribbon Guide Assembly L R 5 66 Shaft Splined 5 68 Shaft Support 5 70 Shuttle Frame Assembly 5 72 Spring ...

Page 8: ...cessing 6 19 Fault Messages 6 20 Symptoms Not Indicated by Fault Messages 6 28 Printer Self Tests 6 30 IGP and CT Options Combined 6 38 Appendices A Printer Configuration B Printer Specifications C Torque Table D Wire Data E Principles of Operation F Ferrite Noise Suppression Cores G Metric Conversion Tables Index ...

Page 9: ...nual 1 2 Related Documents 1 2 How to Use This Manual 1 2 Warnings and Special Information 1 2 Printing Conventions in This Manual 1 3 Controls and Indicators 1 4 Electrical Controls and Indicators 1 6 Mechanical Controls and Indicators 1 8 Tools Test Equipment and Supplies 1 10 ...

Page 10: ...ir the printer You can locate maintenance information three ways Use the Table of Contents at the front of the manual Use the Chapter Contents list on the first page of each chapter Use the Index at the back of the manual Read the entire procedure before beginning any maintenance task Gather all required tools and make sure you understand all warnings cautions and notes before you begin working on...

Page 11: ...n this manual Example Press the ON LINE switch to take the printer off line If a control is not labeled on the printer it is printed lowercase Example Set the forms thickness lever to the fully open position Messages that appear on the control panel display are printed inside quotation marks in lowercase with the first letter capitalized Example Save Config appears on the message display ...

Page 12: ...and Indicators The locations of the printer cover cabinet doors and operator control panel are shown in Figure 1 1 Electrical controls and indicators are described on page 1 6 Mechanical controls and indicators are described on page 1 8 ...

Page 13: ...on right Magnetic latch Open by pulling left ON LINE FF VIEW ENTER CLEAR R S SET TOF LF NEXT PREV DOWN UP Operator Control Panel Floor Cabinet Front Door Printer Cover Rear Door Operator Control Panel See Detail RAISE PRINTER COVER TO ACCESS THESE SWITCHES Figure 1 1 Printer Cover Doors and Operator Control Panel ...

Page 14: ... to indicate fault Off when printer is off line Advances paper to top of next print line Runs and stops configuration and self tests Runs and stops hex dump Resets printer when pressed simultaneously with CLEAR switch Enters displayed parameter into printer nonvola tile memory Must be unlocked before using Clears printer after a fault is corrected Returns printer to off line state from within a co...

Page 15: ...nce Overview ON LINE FF VIEW ENTER CLEAR R S SET TOF LF NEXT PREV DOWN UP Status Lamps Message Display On Off Power Switch RAISE PRINTER COVER TO ACCESS THESE SWITCHES Figure 1 2 Electrical Controls and Indicators ...

Page 16: ...ion Sets platen for paper and forms of different thick nesses Must be fully opened raised to load paper Hold and feed paper Used to set side margin Allows fine positioning of left print margins Moves paper left or right Used to set top of form or first line to be printed Rotate to move paper vertically See Figure 1 3 Indicates relative thickness of forms or paper Set the forms thickness lever at A...

Page 17: ...rview Vertical Position Knob Tractor Lock Left Tractor Door Right Tractor Door Horizontal Adjustment Knob Tractor Lock Forms Thickness Pointer Forms Thickness Lever and Scale Figure 1 3 Mechanical Controls and Indicators ...

Page 18: ...Pliers grip ring Pliers chain nose Ratchet 3 8 in drive Rule steel 6 in Screwdriver torque Utica TS 35 Adapter 1 4 in hex to 1 4 in square Utica HW 18 Hex bit 3 32 in torque screwdriver Hex bit 5 32 in torque screwdriver Screwdriver Allen hex set w extension Screwdriver Phillips Screwdriver flat tip Small magnet Tie wraps Socket 7 16 in 3 8 in drive 101537 001 Lubricant bearing 101805 001 Force ga...

Page 19: ...2 1 Scheduled Maintenance 2 Scheduled Maintenance Chapter Contents Preventive Maintenance Checks and Services PMCS 2 2 Inspecting the Printer 2 3 Cleaning the Printer 2 4 ...

Page 20: ...is used for heavy duty continuous printing or is located in a dusty area PMCS are listed in Table 2 1 WARNING Disconnect the ac power cord before performing PMCS Failure to do so could result in injury to you or damage to equipment Table 2 1 Preventive Maintenance Checks and Services Interval Procedure Inspect the printer Clean the printer Check and adjust platen gap Every 6 months or 1000 hours o...

Page 21: ...atches delamination warping corrosion and proper finish Inspect fasteners for thread damage corrosion Inspect for legibility and damage Inspect for damage and loose or missing hardware Check that door s open close without binding and stay closed Check that printer cover opens closes smoothly and the gas spring assemblies hold the cover open Inspect for damage and loose or missing hardware Inspect ...

Page 22: ...1 1 Set the power switch to O off 2 Disconnect the ac power cord from the printer 3 Open the printer cover 4 Move the forms thickness adjustment lever to the fully open position 5 Remove paper from the printer 6 Squeeze the locking latch and lift the ribbon spools from the ribbon hubs 7 Using a soft bristled brush wipe off paper dust and ribbon lint Vacuum up the residue Pay particular attention t...

Page 23: ...ndow cleaning solution 12 Dry the cabinet interior with a clean lint free cloth 13 Clean the shuttle assembly page 2 6 Splined Base Tractor Ribbon Hub Shuttle Tractor Ribbon Forms Thickness Lever Ribbon Guide 2 Locking Latch Locking Latch Spool Ribbon Spool Ribbon Hub Shaft Casting Cover Assembly Figure 2 1 Cleaning Inside the Cabinet ...

Page 24: ...cohol Wipe the hammer bank cover assembly to remove lint ink and paper residue Clean the holes in the cover strips CAUTION Use of excessive force can chip hammer tips 8 Using a stiff non metallic brush such as a toothbrush and anhydrous alcohol carefully brush the hammer tips to remove lint and ink accumulations Vacuum up any residue CAUTION The hammer bank contains a strong magnet To prevent dama...

Page 25: ...2 7 Scheduled Maintenance Hammer Tip Hammer Bank Thin plate Thick plate Cover Assembly Alignment Pin 2 Not shown Figure 2 2 Cleaning the Shuttle Frame Assembly ...

Page 26: ...paper guide assembly page 5 42 3 Vacuum the card cage fan assembly and surrounding areas to remove paper particles dust and lint 4 Install the paper guide assembly page 5 42 5 Close the printer cover 6 Connect the ac power cord to the printer Card Cage Fan Assembly Figure 2 3 Cleaning the Card Cage Fan Assembly ...

Page 27: ...r Hot 3 9 Mech Driver Link 3 10 Paper Jam 3 11 Paper Out 3 12 Platen Open 3 13 Ribbon Stall 3 14 Shttl Cover Open 3 15 Shuttle Jam 3 16 Software Error 3 17 Symptoms Not Indicated by Fault Messages 3 18 Troubleshooting Aids 3 19 Printer Confidence Check 3 20 Diagnostic Check of Micorprocessors 3 21 Diagnostic Self Tests 3 27 Running the Diagnostic Self Tests 3 29 Hex Code Printout 3 30 Hidden Diagn...

Page 28: ... flash on and off and the first line of the display indicates Fault Condition The second line of the display indicates the specific fault There are two types of displayed faults Operator correctable Field service required indicated by an asterisk next to the fault message IMPORTANT Test the printer after each corrective action Stop maintenance when the symptom disappears Always press the CLEAR swi...

Page 29: ...ove the Mech Driver board Step 9 9 Power up the printer Check for 48 V at power supply cable W3 connector PS pin 8 48 V pin 15 ground See Appendix D for cable interconnections 48 Volts at pin 8 Replace the mechanism driver PCBA page 5 48 and go to step 10 Replace the power supply PCBA page 5 50 and go to step 10 10 Cycle power and check for the fault message 48 Volt Failed message Replace cable as...

Page 30: ...ch to 1 on Dynamic RAM Fault message Step 2 Return printer to normal operation 2 Disconnect the input data line from the host computer Set power switch to O off Wait 15 seconds Set power switch to 1 on Dynamic RAM Fault message Step 3 Return printer to normal operation 3 Make a Diagnostic Check of the Microprocessors page 3 21 ...

Page 31: ...Return printer to normal operation 3 Run diagnostic self test All Black for 1 4 page page 3 27 Ham Bank Hot message Step 4 Return printer to normal operation 4 Remove the shuttle cover page 5 24 Step 5 5 Install a magnet across the hole in the base casting where the cover open sensor is mounted Step 6 6 Run a diagnostic self test page 3 27 Hammer bank fan operates Replace shuttle frame assembly pa...

Page 32: ...on printing hammer is located Step 7 7 Reverse the hammer bank flex circuit cables in the connectors on the base casting Step 8 8 Run a diagnostic self test page 3 27 Observe where the non printing hammer is located NOTE Hammer no 48 is a permanently non printing hammer Keep this is mind when reversing cables Position of the non printing hammer remains the same Replace the shuttle frame assembly p...

Page 33: ...o normal operation 4 Remove the shuttle cover page 5 24 Step 5 5 Install a magnet across the hole in the base casting where the cover open sensor is mounted Step 6 6 Disconnect the hammer bank flex circuit cables from the connectors on the base casting Step 7 7 Run a diagnostic self test page 3 27 Ham Coil Short message Replace the mechanism driver PCBA page 5 48 then go to step 8 Replace the shut...

Page 34: ...power switch to 1 on Ham Drv Short message Step 2 Return printer to normal operation 2 Press the CLEAR switch Ham Drv Short message Step 3 Return printer to normal operation 3 Run a diagnostic self test page 3 27 Ham Drv Short message Replace the mechanism driver PCBA page 5 48 Return printer to normal operation ...

Page 35: ...printer to normal operation 2 Press the CLEAR switch Mech Driver Hot message Step 3 Return printer to normal operation 3 Run a diagnostic self test page 3 27 Mech Driver Hot message Step 4 Return printer to normal operation 4 Open printer cover and observe card cage fan Card cage fan operates Replace mechanism driver PCBA page 5 48 Replace card cage fan assembly page 5 26 ...

Page 36: ... Connect and latch ribbon connectors Go to step 6 6 Check installation of common controller board CCB page 5 46 and mechanism driver board page 5 48 Boards are installed correctly Step 7 Reseat CCB and mechanism driver boards in their edge connectors at bottom of card cage Go to step 7 7 Power up printer and check for fault message Mech Driver Link message Replace the common controller PCBA page 5...

Page 37: ... deformed in such a way as to block the paper path Ribbon mask damaged or bent Replace the hammer bank cover assembly page 5 22 Go to step 5 Step 5 4 Load paper Step 5 5 Run a diagnostic self test page 3 27 Paper Jam message Clean the paper motion detector with cotton swab Go to step 6 Return printer to normal operation 6 Run a diagnostic self test page 3 27 Paper Jam message Replace paper detecto...

Page 38: ...tch assembly page 5 82 Go to step 3 Return printer to normal operation 3 Run a diagnostic self test page 3 27 Paper Out message Replace the intermediate cable assembly W5 page 5 10 Go to step 4 Return printer to normal operation 4 Run a diagnostic self test page 3 27 Paper Out message Replace the common controller PCBA page 5 46 Return printer to normal operation ...

Page 39: ...n Instruction Indication Yes No 1 Load paper Step 2 2 Close forms thickness lever Step 3 3 Run a diagnostic self test page 3 27 Platen Open message Replace platen interlock switch assembly page 5 84 Return printer to normal operation ...

Page 40: ... go to step 5 4 Wind ribbon by hand and inspect for folds tears holes fraying Ribbon is OK Folds are permitted if the ribbon is otherwise undamaged Rewind and reinstall ribbon Go to step 6 Replace ribbon if damaged Unfold and rewind ribbon if it was folded Go to step 6 5 Do a fast shuttle self test page 3 27 and check the alignment of the ribbon guides and hubs if the ribbon was folded Ribbon trac...

Page 41: ...er damaged Replace the shuttle cover assembly page 5 24 Step 2 2 Check shuttle cover installation page 5 24 Shuttle cover installed correctly Step 3 Install cover correctly Make sure the cover lies flat and the two captive screws are fully seated Go to step 3 3 Run a diagnostic self test page 3 27 Shttl Cover Open message Replace the cover open switch assembly page 5 80 Return printer to normal op...

Page 42: ...mal operation 3 Remove shuttle cover page 5 24 and inspect shuttle area and mechanism for obstruction Shuttle movement blocked Remove obstruction Go to step 4 Install shuttle cover page 5 24 Go to step 4 4 Run a diagnostic self test page 3 27 Shuttle Jam message Replace the MPU page 5 34 Return printer to normal operation 5 Run a diagnostic self test page 3 27 Shuttle Jam message Replace mechanism...

Page 43: ...ftware Error message Step 2 Return printer to normal operation 2 Disconnect the input data line from the host computer Set power switch to O off Wait 15 seconds Set power switch to 1 on Software Error message Step 3 Problem is not in the printer Return printer to normal operation 3 Make a Diagnostic Check of the Microprocessors page 3 21 ...

Page 44: ...replaceable assemblies Troubleshooting aids are listed on the next page b Start at a general level and work down to details 4 Replace the defective part or assembly IMPORTANT Do NOT attempt field repairs on electronic components or assemblies replace the entire assembly with an operational spare Most electronic problems are corrected by replacing the printed circuit board assembly PCBA sensor or c...

Page 45: ...tions and functions Use it to establish basic printer status or for troubleshooting imprecise or intermittent symptoms Diagnostic Check of Microprocessors page 3 21 This procedure checks processor operations on the printed circuit board assemblies PCBAs Diagnostic Self Tests Page 3 27 Hex Code Printout Page 3 30 Appendix D Wire Data ...

Page 46: ...een inadvertently changed by the user Step 5 Reconfigure the printer Appendix A 5 Check alignments and adjustments Chapter 4 Assemblies and components adjusted in accordance with Chapter 4 Step 6 Adjust all assemblies that are out of spec 6 Remove paper guide assembly page 5 42 Step 7 7 Check all electrical connectors Connections are clean and tight wires are not stripped frayed or out of connecto...

Page 47: ...the 68010 LED turns on for 1 to15 seconds then turns off The 68010 LED turns off after the 68010 successfully tests itself RAM 68010 ROM and communication with the 64180 CPU The more RAM or ROM installed in the printer the longer the LED is on but it always turns on then off when the CCB is functioning correctly If the printer turns on normally the CCB is okay Turn power off Install the paper guid...

Page 48: ...bits fade to one when internal floating gates discharge This can occur from over voltage programming radiation damage too many EPROM erasures etc Install new program PROMs page 5 58 e If the 68010 LED blinks steadily 5 times per second it means CCB RAM has failed The most common cause of this failure during maintenance is turning off the printer too briefly for the 64180 to reset The 64180 shares ...

Page 49: ...nicate with the 8032 on the Mech Driver board If the problem persists check the Mech Driver 8032 its clock jumper and the PROM Look for backwards insertion misalignment etc and try reseating the parts NOTE On some Mech Driver boards the 8032 PROM correct orientation may be upside down in relation to the rest of the board On these boards the silk screen will show the correct orientation Always repl...

Page 50: ...is problem can occur on Centronics or Dataproducts interfaces never on RS 232 What happens is the strobe signal registers logic 1 more than once for a certain character To fix this change the strobe to trailing edge or invert the Dataproducts strobe polarity Also check that the terminating resistors are present at locations C12 and D12 on the CCB You can correct noise problems by using a shielded ...

Page 51: ...e next This reveals a problem with Centronics or Dataproducts terminating resistors on the CCB at C12 and D12 especially if they are absent Garble can also result from failed termination resistors or parallel logic but this is rare 6 The 68010 LED never lights The 68010 has not run its first instruction a The first two programs PROMs may be malfunctioning or inserted wrong Do the corrective action...

Page 52: ...backwards Their transistors were reverse biased and even if they work their service life has been shortened by thermal damage Replace the 64180 RTPU PROM Check that the 64180 is correctly inserted and completely seated in its socket c If the display reads Diagnostic Test in Progress and 68010 LED has been on for 20 seconds or more but is not blinking it means the 64180 cannot communicate with the ...

Page 53: ... Hammer bank cover Hammer spring Shuttle frame assembly All Es A pattern of all uppercase letter Es useful for identifying missing characters misplaced dots smeared characters improper phasing or light dark character variations Ribbon Splined shaft skew adjustment Hammer bank cover MPU sensor Hammer spring Hammer coil shuttle frame assembly Es plus TOF A pattern of all Es followed by a form feed t...

Page 54: ...rinted creating a solid black band Exercises shuttle and hammer bank at maximum capacity Mechanism Driver PCBA Power Supply PCBA Hammer bank cover Hammer spring Hammer coil shuttle frame assembly Shuttle Slow Verifies proper operation by exercising shuttle motion at low speed Shuttle Fast Verifies proper operation by exercising shuttle motion at high speed Phasing A hammer timing parameter that pe...

Page 55: ...est 8 Inch Width or Printer Test Full Width displays Do not select Full Width unless you have 132 column paper loaded in the printer 8 Press DOWN Printer Test Shift Recycle displays 9 Decide which of the tests listed on page 3 27 you want to run Press NEXT or PREV until that test displays 10 Press R S to start the self test Press R S again to stop the test 11 Examine the print quality Characters s...

Page 56: ...ne Off line Ready displays 2 Raise the printer cover 3 On the control panel press the UP and DOWN switches simultaneously ENTER Switch Not Locked briefly displays If Locked displays simply press UP and DOWN again 4 Press the DOWN switch Ribbon Life displays 5 Press the PREV switch Diagnostics displays 6 Press DOWN Configuration Print Out displays 7 Press NEXT until Printer Data Stream in Hex Code ...

Page 57: ...42 2A 53 43 2B 54 44 2C 55 45 2D 56 46 2E 57 47 2F 0 1 2 3 4 5 6 7 8 9 60 48 30 61 49 31 62 50 32 63 51 33 64 52 34 65 53 35 66 54 36 67 55 37 70 56 38 71 57 39 72 58 3A 73 59 3B 74 60 3C 75 61 3D 76 62 3E 77 63 3F A B C D E F G H I J K L M N O 100 64 40 101 65 41 102 66 42 103 67 43 104 68 44 105 69 45 106 70 46 107 71 47 110 72 48 111 73 49 112 74 4A 113 75 4B 114 76 4C 115 77 4D 116 78 4E 117 7...

Page 58: ...Hidden Diagnostics Menu diagram page 3 34 The diagram shows the menu structure and summarizes the switch sequences used to select the various tests Hidden Diagnostics Menu options Burn In A special test pattern that exercises the hammer bank to a high degree Burn in tests will not overheat the printer but they do stress the equipment Use these tests sparingly and carefully You can run the burn in ...

Page 59: ...When you activate this option the printer performs all calculations stores the data and informs you when it is done The procedure must only be run when the coils are at room temperature If the printer was operating just prior to running this program wait at least two hours more if possible before calibrating coils Sig Analysis Read the CAUTION statement below When the signature analysis state is s...

Page 60: ... press UP and DOWN then simultaneously press NEXT and PREV N P P N Burn In U Always On RS 7 sec cycle Printing Idle RS 20 min cycle Printing Idle RS Always On Printing RS Error Print Printing 1 Returns at completion of printout 1 Done E 2 Clear NVM 2 Returns after 1 second Done Calibrate Coils calculting and storing On Line OL Font 3 Returns after ambient temperature data E 3 N Symbol Key DISPLAYE...

Page 61: ...justment 4 2 Belt Platen Open Adjustment 4 4 Hammer Phasing 4 6 Paper Drive Motor Pulley Alignment 4 8 Paper Scale Alignment 4 10 Platen Angle Adjustment 4 12 Platen Gap Adjustment 4 14 Platen Open Motor Pulley Alignment 4 16 Ribbon Guide Alignment 4 18 Splined Shaft Skew Adjustment 4 20 Returning the Printer to Normal Operation 4 22 ...

Page 62: ...you begin working on the printer Belt Paper Feed Timing Adjustment Figure 4 1 1 Prepare the printer for maintenance page 4 2 2 Open the printer cover 3 Remove the paper guide assembly page 5 42 4 Remove four screws and the barrier shield Refer to Figure 5 35 5 Remove the timing belt cover 1 by squeezing the top and bottom to release the plastic tabs from the slots in the side plate 6 Loosen do not...

Page 63: ...4 3 Adjustment Procedures 1 Timing Belt Shield 2 Motor Mount Bolt 2 3 Paper Feed Drive Motor 2 1 3 2 Direction of Force 4 Figure 4 1 Paper Feed Timing Belt Adjustment ...

Page 64: ...sion on the platen open belt can cause the platen gap to change which can lead to premature wear of the platen damaged hammer tips and poor print quality 6 Using a force gauge apply 10 1 pounds of tension to the platen open motor shaft 3 pulling away from the large platen pulley 7 Reduce tension to 5 1 pounds and torque the motor mount screws 2 to 11 2 inch pounds 8 Check the platen gap page 4 14 ...

Page 65: ...4 5 Adjustment Procedures 1 Belt Cover 2 Motor Mount Screw 3 Platen Open Motor Shaft 1 2 3 2 Direction of Force Figure 4 2 Platen Open Belt Adjustment ...

Page 66: ...WN Configuration Print Out appears on the display 10 Press NEXT until Printer Test Full Width appears on the display 11 Press DOWN then press PREV until Printer Test Phase Index appears on the message display 12 Press the R S switch Phase Index and the current phasing index number display The printer begins printing all Hs in a data processing DP font each line preceded by the phasing index number...

Page 67: ...4 7 Adjustment Procedures CORRECT NEEDS ADJUSTMENT NEEDS ADJUSTMENT Figure 4 3 Hammer Phasing Adjustment ...

Page 68: ...e splined shaft pulley 5 CAUTION Make sure there is at least 0 010 inches of clearance between the collar pulley and the motor face plate 6 Hold the collar 3 flush against the motor pulley 4 and tighten the set screw 2 a If the pulley 4 is black aluminum torque the set screw to 11 2 inch pounds b If the pulley 4 is silver steel torque the set screw to 25 2 inch pounds 7 Check for correct tension o...

Page 69: ...4 9 Adjustment Procedures 1 Belt Shield 2 Set Screw 3 Motor Pulley Collar 4 Motor Pulley 5 Splined Shaft Pulley 4 1 2 3 5 Figure 4 4 Paper Drive Motor Pulley Alignment ...

Page 70: ... 5 24 6 Print a full 132 column line by selecting and running one of the diagnostic self tests See page 3 27 7 Check alignment of the scale to the print at column positions 1 and 132 8 If adjustment is necessary loosen the three button head 5 64 inch hex screws 2 9 Position the scale 3 so that column positions 1 and 132 line up with the first and last characters on the 132 character printout 10 Ti...

Page 71: ...4 11 Adjustment Procedures 1 Shuttle Cover 2 Screw Button Head 5 64 inch hex 3 3 Paper Scale 2 3 1 2 2 Figure 4 5 Paper Scale Alignment ...

Page 72: ... the angle is incorrect loosen the clamp screw 4 and set screw 5 5 Apply primer and Loctite to the mating surfaces of the forms thickness lever 1 and platen shaft 6 Position the platen 3 at the correct angle 7 Slide the platen 3 to the right and the forms thickness lever 1 to the left to remove end play Ensure that the forms thickness lever is fully closed Tighten the clamp screw 4 then tighten th...

Page 73: ...4 13 Adjustment Procedures 1 Forms Thickness Lever 2 Platen Angle Adjustment Tool P N 996146 001 3 Platen 4 Clamp Screw 5 Setscrew 2 5 4 1 3 Figure 4 6 Platen Angle Adjustment ...

Page 74: ... 1 As the platen is closing gently slide the feeler gauge up and down keeping it between the hammer tip and ribbon mask If the feel is too tight when the platen is being closed adjust the set screw 5 at the end of the platen counterclockwise If the feel is too loose adjust the set screw clockwise With the forms thickness lever closed all the way the feeler gauge should contact both the tips and th...

Page 75: ...1 1 Forms Thickness Lever 2 Feeler Gauge 0 010 inch 3 Hammer Bank Cover Plate 4 Ribbon Mask 5 Set Screw 3 32 inch hex 2 3 4 2 NOTE Left side adjustment shown Right side is the same 5 3 32 inch hex Figure 4 7 Platen Gap Adjustment ...

Page 76: ...tom to release the plastic tabs from the slots in the side plate 4 Loosen the set screw 2 in the motor pulley 5 Align the platen open motor pulley 3 with the platen shaft pulley 4 and tighten the set screw 2 to 9 2 inch pounds 6 Check the platen open belt tension page 4 4 Adjust if necessary 7 Snap the platen open belt cover 1 into the slots in the side plate 8 Return the printer to normal operati...

Page 77: ...4 17 Adjustment Procedures 1 Belt Cover 2 Set Screw 3 Platen Open Motor Pulley 4 Platen Shaft Pulley 1 2 3 4 Figure 4 8 Platen Open Motor Pulley Alignment ...

Page 78: ...he left ribbon guide 4 It should be centered and not folding against either of the two white nylon washers 6 If the ribbon is not centered loosen the retaining screws 5 just enough so that the ribbon guide 4 can be rotated to new positions but remains in place once moved 7 Rotate the ribbon guide 4 as necessary to center the ribbon 3 8 Observe how the ribbon 3 is winding on the left spool 6 Reposi...

Page 79: ... 19 Adjustment Procedures 1 Right Hub 2 Screw Left Ribbon Guide Skid 2 3 Ribbon 4 Ribbon Guide Left 5 Screw Retaining 2 6 Left Spool 7 Ribbon Guide Right 6 2 3 3 4 5 7 1 Figure 4 9 Ribbon Guide Alignment ...

Page 80: ...the paper perform the following adjustment 1 Prepare the printer for maintenance page 4 2 2 Loosen the screw 1 securing the adjusting link 2 3 Adjust the link 2 by raising or lowering the horizontal adjustment knob 5 to obtain print parallel with paper perforations Tighten the screw 1 4 Return the printer to normal operation page 4 22 ...

Page 81: ...4 21 Adjustment Procedures 1 Screw 2 Adjusting Link 3 Horizontal Adjustment Knob 1 2 3 Figure 4 10 Splined Shaft Skew Adjustment ...

Page 82: ...the ribbon 3 Close floor cabinet doors and the printer cover 4 Connect the ac power cord to the power source and the printer 5 Set the power switch to 1 on 6 Test printer operation by selecting and running one of the diagnostic self tests page 3 27 7 Select the desired emulation See Appendix A ...

Page 83: ...8 Control Panel Assembly 5 20 Cover Assembly Hammer Bank 5 22 Cover Assembly Shuttle 5 24 Fan Assembly Card Cage 5 26 Fan Assembly Cabinet Exhaust 5 28 Fan Assembly Hammer Bank 5 30 Hammer Spring Assembly 5 32 Magnetic Pick up MPU Assembly 5 34 Motor Assembly Ribbon Drive 5 36 Motor Assembly Paper Feed 5 38 Motor Assembly Platen Open 5 40 Paper Guide Assembly 5 42 Paper Ironer 5 44 PCBA Common Con...

Page 84: ...4 Ribbon Guide Assembly L R 5 66 Shaft Splined 5 68 Shaft Support 5 70 Shuttle Frame Assembly 5 72 Spring Assembly Gas 5 76 Spring Extension 5 78 Switch Assembly Cover Open 5 80 Switch Assembly Paper Detector 5 82 Switch Assembly Platen Interlock 5 84 Tractor L R 5 86 Returning the Printer to Normal Operation 5 86 ...

Page 85: ...7 or FAX 714 474 9218 Preparing the Printer for Maintenance WARNING Unless directed to do otherwise always unplug the printer from the power source before performing a maintenance procedure Failure to remove power could result in injury to persons or damage to equipment The procedures in this chapter are written assuming the printer is prepared for maintenance To prepare the printer for maintenanc...

Page 86: ...ip of the motor pulley 4 and rotating the pulleys until the belt rolls off Installation 1 Install the paper feed timing belt 3 over the splined shaft pulley 5 and the lip of the motor pulley 4 and rotate the pulleys until the belt rolls onto the motor pulley 2 Using the straight end of a force gauge apply 12 pounds of pressure to the paper feed drive motor 6 Use the splined shaft 7 to steady the g...

Page 87: ... 108664 003 4 Motor Pulley p o item 6 5 Splined Shaft Pulley P N 150289 001 p o item 7 6 Paper Feed Drive Motor P N 150452 001 Paper Feed Drive Motor Assembly P N 155005 001 7 Splined Shaft Assy w Pulley P N 150491 001 includes item 5 5 4 1 3 6 2 2 Direction of Force 7 Figure 5 1 Belt Paper Feed Timing Removal Installation ...

Page 88: ...clears the left ribbon guide with the platen fully closed a If not rotate the platen pulley 5 until the collar clears the left ribbon guide and tighten the set screw 6 to 11 2 inch pounds Go to step 4 b If the collar clears the ribbon guide with the forms thickness lever closed go to step 4 CAUTION Too much tension on the platen open belt can cause the platen gap to change which can lead to premat...

Page 89: ...69 001 2 Screw 2 Scr Hex w LW 10 32x 50 3 Platen Open Belt P N 105808 003 4 Motor Pulley P N 155071 001 5 Platen Pulley P N 150703 001 6 Set Screw Scr Skt cap 6 32x 44 1 6 5 2 2 4 3 Direction of Force Figure 5 2 Belt Platen Open Removal Installation ...

Page 90: ...g then out of the card cage Installation CAUTION Be careful not to damage the ribbon cable on the card cage or base casting Make sure the protective barrier is on top of the ribbon cables at the card cage bottom NOTE This procedure installs the left hammer bank cable assembly The procedure for installing the right cable assembly is the same 1 Feed the hammer bank cable assembly 5 down through card...

Page 91: ...or Paper feed motor 1 Screw 2 Scr w LW 4 40x 75 and 4 flat washer 2 Connector p o item 5 3 Screw 2 Same as item 1 4 Connector p o item 5 5 Hammer Bank Cable Assembly P N 150215 001 6 Protective Barrier Ref 2 1 Right hammer bank cable assembly Left hammer bank cable assembly 3 4 5 NOTE Connector locating key is on the right side of each connector Tie wraps 6 Figure 5 3 Cable Assembly Hammer Bank Re...

Page 92: ...ediate cable assembly connector P1 2 to the bottom of the card cage Loosen the screw securing the ground lug and remove the ground lug 7 Disconnect connector P1 P 3 from platen interlock switch assembly 4 8 Disconnect connector PMD 5 from paper detector switch assembly connector PMD P 6 9 Remove the cover open switch assembly 7 and disconnect connectors CO and CO 8 and 9 See page 5 80 10 Note the ...

Page 93: ...tem 10 4 Platen Interlock Switch Assembly P N 150284 001 5 Connector PMD J p o item 10 6 Connector PMD P p o Paper Detector Switch Assembly 7 Cover Open Switch Assembly P N 150296 001 8 Connector CO p o item 10 9 Connector CO p o item 10 10 Intermediate Cable Assembly P N 150286 001 1 2 3 4 5 6 8 9 7 This section of cable runs beneath the base casting Paper detector switch assembly Printer viewed ...

Page 94: ...to paper detector switch assembly connector PMD P 6 4 Connect connector P1 P 3 to the platen interlock switch assembly 4 5 Install the screws 1 securing the intermediate cable assembly connector P1 2 to the bottom of the card cage 6 Insert the ground lug under the screw and tighten the screw 7 Install the mechanism driver PCBA page 5 48 8 Install the common controller PCBA page 5 46 9 Install the ...

Page 95: ...tem 10 4 Platen Interlock Switch Assembly P N 150284 001 5 Connector PMD J p o item 10 6 Connector PMD P p o Paper Detector Switch Assembly 7 Cover Open Switch Assembly P N 150296 001 8 Connector CO p o item 10 9 Connector CO p o item 10 10 Intermediate Cable Assembly P N 150286 001 1 2 3 4 5 6 8 9 7 This section of cable runs beneath the base casting Paper detector switch assembly Printer viewed ...

Page 96: ...ght 6 Remove six screws 1 and move the service panel 2 aside 7 Remove the ribbon cable from the restraints 3 on the upper rear and upper right walls of the cabinet 8 Open the latches 4 and disconnect the multi I O ribbon cable connector 5 from connector J1 6 on the common controller PCBA 9 Release the multi I O ribbon cable from the holders on the rear wall of the card cage Remove the common contr...

Page 97: ...le Restraints P N 107953 002 or 109822 002 4 Latch 2 Ref 5 Ribbon Cable Connector p o item 9 6 Common Controller Connector J1 Ref 7 Screw 4 Scr Hex w LW 10 24x 38 8 Mounting Plate P N 112430 001 9 Multi I O Cable Assembly P N 150310 002 3 2 5 4 6 7 8 9 1 Figure 5 5 Cable Assembly Multi I O Removal Installation ...

Page 98: ... rear wall of the card cage Remove the common controller PCBA if necessary page 5 46 5 Connect the multi I O ribbon cable connector 5 to connector J1 6 on the common controller PCBA and close the latches 4 6 Move the service panel 2 into position and install the six screws 1 7 Install the paper fence through the front door a Tilt and install the paper fence in the top right hole in the service pan...

Page 99: ...le Restraints P N 107953 002 or 109822 002 4 Latch 2 Ref 5 Ribbon Cable Connector p o item 9 6 Common Controller Connector J1 Ref 7 Screw 4 Scr Hex w LW 10 24x 38 8 Mounting Plate P N 112430 001 9 Multi I O Cable Assembly P N 150310 002 3 2 5 4 6 7 8 9 1 Figure 5 5 Cable Assembly Multi I O Removal Installation ...

Page 100: ...clips 4 and push the circuit breaker 5 out of the cabinet Installation 1 Press the circuit breaker 5 into the cabinet until the spring clips 4 snap into place CAUTION Make sure the four leads are connected as shown in Figure 5 6 2 Connect the four circuit breaker electrical leads 3 as shown in Figure 5 6 3 Move the service panel 2 back into position and install the six screws 1 4 Install the paper...

Page 101: ...cr Hex Wshr SEMS 10 24x 50 2 Service Panel P N 150538 004 3 Circuit Breaker Electrical Lead 4 Ref 4 Spring Clip 4 p o item 5 5 Circuit Breaker P N 141286 001 BROWN BLUE BROWN BLUE 3 4 5 2 1 1 1 Figure 5 6 Circuit Breaker Removal Installation ...

Page 102: ...panel bracket 7 Installation IMPORTANT You must install two ferrite cores on the control panel cable assembly Refer to Appendix F 1 Feed ribbon connector 1 and the ribbon cable through the control panel bracket 7 and position the control panel assembly 6 on the bracket 2 Hand tighten four screws 4 3 Lower the printer cover and center the control panel assembly 6 in the cutout of the printer cover ...

Page 103: ... Control Panel Connector P1 p o item 7 2 Common Controller PCBA P N 150404 901 3 Wire Saddles P N 141359 001 4 Screw 4 Scr Hex w LW 6 32x 375 5 Washer 4 6 6 Control Panel Assembly P N 150377 901 7 Panel Bracket P N 150811 001 4 5 6 7 3 Install block type ferrite core here Refer to Appendix F and wind cable around round core after routing 1 2 cable through bracket Figure 5 7 Control Panel Assembly ...

Page 104: ... not let the hammer bank cover assembly snap into place as the hammer bank magnet attracts it Any impact of the cover against the hammer bank can break hammer tips 1 With the thick plate facing the hammer bank 2 engage the bottom edge of the hammer bank cover assembly 1 on the alignment pins 3 2 Gently lower the hammer bank cover assembly 1 until it lies flush on the hammer bank 2 Check that the h...

Page 105: ...over Assembly P N 150207 001 2 Hammer Bank p o 150181 901 Shuttle Frame Assy 3 Alignment Pin 2 p o 150181 901 Shuttle Frame Assy 1 2 3 Not shown Thin plate Thick plate Alignment Pin Hole Figure 5 8 Cover Assembly Hammer Bank Removal Installation ...

Page 106: ...the edges of the shuttle cover assembly 2 tilt up the rear edge and lift the shuttle cover assembly out of the printer Installation 1 Place the shuttle cover assembly 2 in the printer Tilt the forward edge of the cover down slightly and work the cover into position NOTE Make sure the holes in the cover are over the locating pins 2 Tighten the shuttle cover screws 1 3 Return the printer to normal o...

Page 107: ...5 25 Replacement Procedures 1 Screw Captive Shuttle Cover 2 Scr 10 24x 62 O Ring 0 125x0 250x0 06 2 Shuttle Cover Assembly P N 150808 001 1 2 1 Figure 5 9 Cover Assembly Shuttle Removal Installation ...

Page 108: ... connector 2 6 Remove the card cage fan assembly 3 and fan guard 4 from the card cage 5 Installation CAUTION Make sure to install the fan so the label is against the card cage Air flow is INTO the card cage 1 Connect the fan cable connector 4 2 Position the card cage fan assembly 3 and fan guard 4 in the card cage 5 3 Install two screws 1 4 Install the paper guide assembly page 5 42 5 Return the p...

Page 109: ...4 Scr w LW 6 32x2 00 2 Fan Cable Connector p o item 3 3 Card Cage Fan Assembly P N 150261 001 4 Fan Guard P N 130025 001 5 Card Cage p o Frame Base P N 150803 001 1 2 3 4 Air Flow 5 Figure 5 10 Fan Assembly Card Cage Removal Installation ...

Page 110: ...the cabinet exhaust fan assembly 4 and fan guard 6 Installation CAUTION Make sure to install the fan so the label is down facing the cabinet floor Air flow is down 1 Connect the fan cable connector 5 2 Position the cabinet exhaust fan assembly 4 and fan guard 6 on the cabinet floor 3 Install two screws 3 securing the cabinet exhaust fan assembly 4 4 Move the service panel 2 back into position and ...

Page 111: ...0 24x 50 2 Service Panel P N 150538 004 3 Screw 4 Scr w LW 6 32x2 00 4 Cabinet Exhaust Fan Assembly P N 150261 001 5 Fan Cable Connector p o item 4 6 Fan Guard P N 130025 001 3 1 6 5 4 2 Air Flow 3 Figure 5 11 Fan Assembly Cabinet Exhaust Removal Installation ...

Page 112: ...nstall the fan so the label faces up Air flow is up NOTE The hammer bank fan assembly is installed by angling it down and under the shuttle motor 1 Feed the hammer bank fan cable connector 3 through the slot in the fan well of the base casting 2 and over the foam air shroud 2 Open the floor cabinet front door 3 Reaching up under the base casting 2 from inside the cabinet route the fan cable to the...

Page 113: ...n Cable Connector p o item 4 4 Hammer Bank Fan Assembly P N 150183 001 Front Hammer Bank Fan 3 Route cable under base casting 2 1 NOTE Do not install screw here 1 NOTE Do not install screw here 1 4 3 2 Attach cable connector here Air Flow Figure 5 12 Fan Assembly Hammer Bank Removal Installation ...

Page 114: ...r bank surface under the fret is clean before installing a new fret Dirt or debris between the fret and hammer bank can cause misalignment degraded performance or damage to hammers 1 If you are replacing one of the inner frets go to step 2 If you are replacing fret seven bend the left most hammer spring as shown in Figure 5 13 before removing it from the box If you are replacing fret one bend the ...

Page 115: ...FORE removing it from the box as shown below Do this ONLY for frets 1 and 7 Use these screws to install new fret Removal Any Fret Discard old screws Installation Any Fret 1 2 3 8 in lbs Tightening Sequence Torque to 8 in lbs Use new screws Bend hammer down until it touches the mounting base in the box Left end Right end Btn Hd Cap 6 32x 25 Steel Zinc P N 102288 019 Bend this hammer if replacing fr...

Page 116: ...gap between the MPU assembly 3 and the flywheel 5 to 0 010 001 inch Torque the MPU clamp screw 2 to 19 1 inch pounds 3 Check the gap between the MPU assembly 3 and the flywheel 5 with a feeler gauge a If the gap is 0 010 001 inch go to step 4 b If the gap is not 0 010 0 001 inch loosen the MPU clamp screw 2 and go back to step 2 CAUTION In the next step route the MPU cable under the extension spri...

Page 117: ...Bracket P N 150827 001 5 Flywheel p o 150181 901 Shuttle Frame Assy 0 010 001INCH 1 2 3 4 Attach MPU cable here 5 CAUTION Make sure the MPU cable does not touch extension spring P N 106710 006 after cable connection NOTE For clarity in showing this assembly the extension spring is not shown Figure 5 14 Magnetic Pick up MPU Assembly Removal Installation ...

Page 118: ...re below is the same for the left and right ribbon drive motor assemblies IMPORTANT You must install a ferrite core on the ribbon motor cable assembly Refer to Appendix F CAUTION Make sure the ferrite core does not pinch the ribbon motor cable wires and take care not to damage the cable wires when inserting the motor into the base casting 1 Install the snap on ferrite core to the motor cable 2 Con...

Page 119: ...0 2 Washer 2 Flat 6 3 Ribbon Drive Motor P N 150452 001 4 Base Casting P N 150727 001 5 Ribbon Motor Cable Connector p o item 3 3 2 5 4 1 Install block type ferrite core here Refer to Appendix F 2 1 Figure 5 15 Motor Assembly Ribbon Drive Removal Installation ...

Page 120: ...ht side plate and install the motor mount bolts 7 and nut plate 8 finger tight 2 Connect the paper feed motor electrical connector 6 3 Install the paper feed motor pulley 3 collar 4 and timing belt 5 4 Align the paper feed motor pulley 3 with the splined shaft pulley 10 CAUTION Make sure there is at least 0 010 inches of clearance between the collar pulley and the motor face plate 5 Hold the colla...

Page 121: ... 001 4 Collar P N 140763 002 5 Paper Feed Timing Belt P N 108664 003 6 Paper Feed Motor Connector p o item 9 7 Screw 2 Scr Hex w LW 10 32x 50 8 Nut plate P N150707 001 9 Paper Feed Motor Motor only P N 150452 001 Paper Feed Motor Assembly P N 155005 001 includes items 2 4 10 Splined Shaft Pulley P N 150289 001 1 2 3 4 7 7 10 6 8 5 Direction of Force 9 Figure 5 16 Motor Assembly Paper Feed Removal ...

Page 122: ... with the platen pulley 9 and tighten the set screw 4 to 9 2 inch pounds 3 Connect the platen motor cable connector 6 4 Install the platen open belt 3 5 Close the forms thickness lever all the way 6 Make sure the collar of the platen pulley 9 clears the left ribbon guide with the platen fully closed a If not rotate the platen pulley 9 until the collar clears the left ribbon guide and tighten the p...

Page 123: ...Motor Pulley P N 155071 001 6 Platen Motor Cable Connector p o item 8 7 Nut Plate P N 150707 001 8 Platen Open Motor motor only 150452 001 Platen Open Motor Assembly P N 150452 001 includes items 4 5 9 Platen Pulley P N 150703 001 10 Set Screw Platen Pulley Scr skt cap 6 32x 44 1 3 4 8 6 5 9 10 2 7 Direction of Force Figure 5 17 Motor Assembly Platen Open Removal Installation ...

Page 124: ... 3 Installation 1 Position the paper guide assembly 2 offset slightly to the left on the card cage 3 2 While holding the right end slightly elevated slide the paper guide assembly 2 to the right and engage the tabs on the underside of the paper guide assembly with the left edge of the card cage 3 Slide the paper guide assembly 2 to the right as far as it will go 4 Lower the right end of the paper ...

Page 125: ... 25 and Washer flat 6 2 Paper Guide Assembly Ref 3 Card Cage p o frame base P N 150803 001 1 2 3 Clips on card cage top Not shown Engage clips here NOTE Remove screw and lift this end before sliding the cover Figure 5 18 Paper Guide Assembly Removal Installation ...

Page 126: ...paper ironer can become sharp To avoid cutting yourself grasp the paper ironer on the sides 1 Position the paper ironer 2 so that the lip on the upper edge faces the front of the printer NOTE Newer models do not have a lip on the upper edge of the paper ironer These models also have a rectangular black label near one end This label must be on the left rear side of the paper ironer so that it faces...

Page 127: ...acement Procedures 1 Forms Thickness Lever P N 111724 001 2 Paper Ironer P N 150434 001 2 Push and Lift Push and Lift 1 NOTE Black label on back side of newer models Figure 5 19 Paper Ironer Removal Installation ...

Page 128: ...er PCBA 8 by the ejection levers and pull it up and out of the card cage 9 10 Remove the DPU PROMs font PROMs RTPU and PFC PROMs page 5 58 and host terminating resistors page 5 62 Installation 1 Install the DPU PROMs font PROMs RTPU and PFC PROM page 5 58 and host terminating resistors page 5 62 onto the replacement PCBA 2 Slide the common controller PCBA 8 down into the card cage 9 Engage the car...

Page 129: ...2 Connector J1 p o item 8 3 CCB Mech Driver Cable P N 150551 001 4 Connector J2 p o item 8 5 Control Panel Ribbon Cable p o item 8 6 Connector J3 p o item 8 7 Ejection Lever 2 p o item 8 8 Common Controller PCBA CCB P N 150404 901 9 Card Cage p o frame base P N 150803 001 Power Supply and Mechanism Driver boards shown for reference They are not removed in this procedure NOTE 1 3 5 7 8 9 2 4 6 Figu...

Page 130: ...e power supply cable 3 from connector J7 4 6 Lift the ejection levers 5 7 Grasp the mechanism driver PCBA 6 by the ejection levers and pull it up and out of the card cage 7 8 Remove the RSP PROM page 5 60 Installation 1 Install the RSP PROM page 5 60 onto the replacement PCBA 2 Slide the mechanism driver PCBA 6 down into the card cage 7 Engage the card edge connectors in the connectors at the bott...

Page 131: ...N 150218 001 4 Connector J7 p o item 6 5 Ejection Lever 2 p o item 6 6 Mechanism Driver PCBA P N 150468 901 7 Card Cage p o frame base P N 150803 001 Power Supply and Common Controller boards shown for reference They are not removed in this procedure NOTE 4 2 3 7 5 6 1 Figure 5 21 PCBA Mechanism Driver Removal Installation ...

Page 132: ... cable 1 from connector J102 2 5 Lift the ejection levers 3 6 Grasp the power supply PCBA 4 by the ejection levers and pull it up about four inches 7 Disconnect the circuit breaker cable 5 from connector J1 6 8 Remove the power supply PCBA 4 from the card cage 7 Installation 1 Connect the circuit breaker cable 5 to connector J1 6 2 Slide the power supply PCBA 4 into the card cage 7 engaging the ca...

Page 133: ... Lever 2 p o item 4 4 Power Supply PCBA P N 150316 901 5 Circuit Breaker Cable P N 150649 001 6 Connector J1 p o item 4 7 Card Cage P N 150803 001 Mechanism Driver and Common Controller boards shown for reference They are not removed in this procedure NOTE 2 7 3 4 1 6 5 Figure 5 22 PCBA Power Supply Removal Installation ...

Page 134: ...e spring hook on the side plate b Pull the spring link 6 and left platen support spring 5 off the platen shaft 8 Remove the forms thickness lever a Loosen the set screw 7 and clamp screw 8 b Pull the forms thickness lever 9 off platen shaft 9 Remove the right side platen support spring by repeating step 7 on the right side of the platen 10 Remove the forms thickness indicator plate a Disconnect th...

Page 135: ... 125 8 Screw Clamp Skt Cap 6 32x 75 9 Lever Forms Thickness P N 111724 001 10 Connector Platen Interlock Switch Ref 11 Screw 2 P N 103677 001 12 Washer 4 P N 101526 005 13 Indicator Plate P N 110144 001 14 Platen P N 110592 002 15 Washer Flat 2 P N 101526 048 16 Bracket Platen Adjust 2 P N 110245 001 17 Wear Saddle P N 150253 001 18 Platen seat Ref 19 Bearing Nylon P N 101309 002 2 3 4 6 7 8 9 1 1...

Page 136: ...in the left side plate Rotate the shaft into the opening in the right side plate and position the adjustment brackets 16 so the mechanism base platen seats are between the flanges of the brackets 7 Install the forms thickness indicator plate a Slide the indicator plate 13 with the interlock switch assembly attached onto the platen shaft and up against the right side plate b Install the washer 12 a...

Page 137: ... 125 8 Screw Clamp Skt Cap 6 32x 75 9 Lever Forms Thickness P N 111724 001 10 Connector Platen Interlock Switch Ref 11 Screw 2 P N 103677 001 12 Washer 4 P N 101526 005 13 Indicator Plate P N 110144 001 14 Platen P N 110592 002 15 Washer Flat 2 P N 101526 048 16 Bracket Platen Adjust 2 P N 110245 001 17 Wear Saddle P N 150253 001 18 Platen seat Ref 19 Bearing Nylon P N 101309 002 2 3 4 6 7 8 9 1 1...

Page 138: ...nter place the two hooks of the upper piece over the platen shafts The left hook goes between the left platen adjustment bracket and the platen The right hook goes between the two washers to the left of the right platen adjustment bracket b Install and torque three screws 1 to 20 2 inch pounds 14 Install the paper ironer page 5 44 15 Install the shuttle frame assembly page 5 72 16 Adjust the plate...

Page 139: ... 125 8 Screw Clamp Skt Cap 6 32x 75 9 Lever Forms Thickness P N 111724 001 10 Connector Platen Interlock Switch Ref 11 Screw 2 P N 103677 001 12 Washer 4 P N 101526 005 13 Indicator Plate P N 110144 001 14 Platen P N 110592 002 15 Washer Flat 2 P N 101526 048 16 Bracket Platen Adjust 2 P N 110245 001 17 Wear Saddle P N 150253 001 18 Platen seat Ref 19 Bearing Nylon P N 101309 002 2 3 4 6 7 8 9 1 1...

Page 140: ...e defective chip s Locations are shown in Figure 5 24 Installation CAUTION To prevent electrostatic damage to electronic components wear a properly grounded static wrist strap when handling PCBAs and components 1 Using a chip installation tool install chip s Locations are shown in Figure 5 24 2 Install the common controller PCBA page 5 46 3 If you changed DPU or font PROMs adjust hammer phasing pa...

Page 141: ...y Controller FTIC Fire Timer IC NOVRAM Nonvolatile Random Access Memory PAL Programmable Array Logic PFC Paper Feed Controller RTPU Real Time Processing Unit LEGEND DPU LED DPU LED Indications at printer start up RTPU ON for 2 sec then OFF DPU OK FLASHING 5 times second DPU RAM failure FLASHING 1 time second DPU ROM failure DPU Data Processing Unit MPU Magnetic Pick up LED Light Emitting Diode RTP...

Page 142: ...BAs and components 3 Using a chip puller remove the defective chip s Locations are shown in Figure 5 25 Installation CAUTION To prevent electrostatic damage to electronic components wear a properly grounded static wrist strap when handling PCBAs and components 1 Using a chip installation tool install chip s Locations are shown in Figure 5 25 2 Install the mechanism driver PCBA page 5 48 3 If you c...

Page 143: ...ocedures 8032 Microcontroller RSP Ribbon Shuttle Processor LEGEND ASIC Application Specific Integrated Circuit RSP PROM 150846 Hammer Driver ASIC Mech Driver ASIC J5 J6 Figure 5 25 PROMs and Chips on the Mechanism Driver ...

Page 144: ...stall the 330 ohm pull down resistor Possible terminating resistor combinations are shown below Pull up at 12C Pull down at 12D 470 ohm 1K ohm 220 ohm 330 ohm 1K ohm none Removal CAUTION To prevent electrostatic damage to electronic components wear a properly grounded static wrist strap when handling PCBAs and components 1 Prepare the printer for maintenance page 5 3 2 Remove the Common Controller...

Page 145: ... Procedures C D E F 12 13 11 Location 12D Pull down Standard 1K ohm DIP Alternate 330 ohm DIP or Location 12C Pull up Standard 470 ohm DIP Alternate 220 ohm DIP or Figure 5 26 Resistors Terminating Removal Installation ...

Page 146: ...oosen the screw 1 in the ribbon spool hub 2 4 Remove the hub 2 from the shaft of the ribbon drive motor 3 Installation 1 Install the ribbon spool hub 2 over the motor shaft 2 Tighten the hub screw 1 so that it contacts the flat section of the motor shaft Do not overtighten the hub screw 3 Return the printer to normal operation page 5 86 ...

Page 147: ...5 65 Replacement Procedures 1 Hub Screw 6 19x 50 2 Ribbon Spool Hub Kit P N 150868 001 3 Ribbon Drive Motor P N 150452 001 2 1 3 Figure 5 27 Ribbon Hub Removal Installation ...

Page 148: ... ribbon guide cable 5 Disconnect the ribbon guide connector 2 6 Remove the two screws 3 and washers 4 7 Slide the ribbon guide assembly 5 out of the side plate 6 Installation NOTE Although the right ribbon guide is shown in Figure 5 28 the installation procedure is the same for the left ribbon guide 1 Slide the ribbon guide assembly 5 into the side plate 6 2 Install two screws 3 and washers 4 3 Co...

Page 149: ...onnector p o item 5 3 Screw 2 Hex w LW 4 40x 38 4 Washer 2 Flat 4 5 Ribbon Guide Assembly Right P N 150222 002 Ribbon Guide Assembly Left P N 150222 001 6 Side Plate R P N 150772 001 Side Plate L P N 150771 001 5 6 4 3 1 2 Figure 5 28 Ribbon Guide Assembly L R Removal Installation ...

Page 150: ...rs 8 and 9 Position the tractor belts so the alignment marks are at the top on both tractors 2 Grasp the vertical adjustment knob 12 and slide the splined shaft 4 through the right side plate 14 tractors 8 and 9 and the left side plate 13 Make sure the same spline passes the marked groove on each tractor 3 Install the bearing clamp 11 and screw 10 4 Apply a thin film of M 3 grease to the bearing 5...

Page 151: ... P N 110280 001 7 Spring Extension P N 105741 003 8 Tractor Left Set L R P N 140716 003 9 Tractor Right Set L R P N 140716 003 10 Screw Thread Forming 6 32x 25 11 Bearing Clamp P N 110281 001 12 Vertical Adjustment Knob Splined Shaft Pulley P N 150289 001 13 Left Side Plate P N 150771 001 14 Right Side Plate P N 150772 001 10 11 14 12 3 5 6 4 13 9 7 8 1 2 Figure 5 29 Shaft Splined Removal Installa...

Page 152: ...sher 7 and screw 8 to the left out of the tractors 1 and the left side plate 9 Installation 1 Slide the support shaft assembly consisting of the support shaft 3 two curved washers 4 bushing 5 horizontal adjustment knob 6 washer 7 and screw 8 into the left side plate 9 2 Slide the tractors 1 onto the support shaft 3 3 Slide the support shaft assembly through the right side plate 10 4 While pushing ...

Page 153: ...haft P N 111685 001 4 Curved Washer 2 P N 101552 004 5 Bushing P N 111684 001 6 Horizontal Adjustment Knob P N 111822 001 7 Washer Flat 4 8 Screw Skt cap 4 40x 25 9 Left Side Plate P N 150771 001 10 Right Side Plate P N 150772 001 3 1 2 4 5 6 7 8 9 10 1 Figure 5 30 Shaft Support Removal Installation ...

Page 154: ...nnect the left and right flex ribbon connectors gently and do not bend the cables unnecessarily 6 Disconnect the left and right hammer bank flex circuit ribbon connectors 4 and 5 7 Loosen the side 5 32 inch socket head clamp screws 6 and pull the clamps 7 back and off the guide shaft 8 Do not remove the clamps 8 Loosen the center 5 32 inch socket head screw 9 enough to release the shuttle frame as...

Page 155: ...r Ref 4 Left Flex Circuit Ribbon Connector Ref 5 Right Flex Circuit Ribbon Connector Ref 6 Clamp Screw Side 2 Skt cap 10 24x 50 7 Side Clamp 2 P N 150399 001 8 Guide Shaft p o item 10 9 Center Screw Captive p o item 10 10 Shuttle Frame Assembly P N 150181 901 11 Base Casting P N 150727 001 12 Outer Beam Standoff 2 p o item 10 13 Tractor 2 Set L R P N 140716 003 14 Tractor Support Shaft P N 111685 ...

Page 156: ...s 6 to 20 2 inch pounds 6 Lift up on the shuttle motor then gently set it down to align the center screw guide 7 Torque the center captive 5 32 inch socket head screw 9 to 20 2 inch pounds 8 Connect the left and right hammer bank flex circuit ribbon connectors 4 and 5 9 Connect the shuttle cable assembly connector 3 10 Connect the shuttle motor cable connector 2 CAUTION Make sure the MPU cable is ...

Page 157: ...ctor Ref 4 Left Flex Circuit Ribbon Connector Ref 5 Right Flex Circuit Ribbon Connector Ref 6 Clamp Screw Side 2 Skt cap 10 24x 50 7 Side Clamp 2 P N 150399 001 8 Guide Shaft p o item 10 9 Center Screw Captive p o item 10 10 Shuttle Frame Assembly P N 150181 901 11 Base Casting P N 150727 001 12 Outer Beam Standoff 2 p o item 10 13 Tractor 2 Set L R P N 140716 003 14 Tractor Support Shaft P N 1116...

Page 158: ...4 Pry back the spring retaining clips 5 Remove the gas spring assembly 4 from the ball studs 7 Installation 1 Position the gas spring assembly 4 against the ball studs 7 on the upper and lower brackets 5 and 6 2 Push the gas spring assembly 4 onto the ball joints 7 3 Close the printer cover 1 If necessary adjust the position of the ball joint stud in the lower bracket to achieve smooth and complet...

Page 159: ...r P N 150814 001 2 Nut Hex 312 18 3 Washer Split lock 5 16 4 Gas Spring Assembly P N 107961 005 5 Upper Bracket p o item 1 6 Lower Bracket Ref 7 Ball Stud 2 P N 107962 001 2 1 4 3 2 3 5 6 7 7 Figure 5 32 Spring Assembly Gas Removal Installation ...

Page 160: ...r 3 Remove the shuttle cover assembly page 5 24 4 Unhook the extension spring 1 from the spring lugs 2 on the hammer bank 3 and shuttle frame 4 Installation 1 Apply a dab of M 3 lubricant to both spring lugs 2 CAUTION Make sure the extension spring does not touch the MPU cable 2 Hook the extension spring 1 over the spring lugs 2 3 Install the shuttle cover assembly page 5 24 4 Return the printer t...

Page 161: ...5 79 Replacement Procedures 1 Extension Spring P N 106710 006 2 Spring Lug 2 p o item 4 3 Hammer Bank p o item 4 4 Shuttle Frame Ref 1 3 2 4 Figure 5 33 Spring Extension Removal Installation ...

Page 162: ...en switch assembly 2 out of the base casting 5 Disconnect the switch connectors from intermediate cable assembly connector CO 3 and CO 4 Installation 1 Connect the switch connectors to intermediate cable assembly connector CO 3 and CO 4 2 Position the cover open switch assembly 2 in the base casting and install two screws 1 Refer to the NOTE on Figure 5 34 3 Install the shuttle cover assembly page...

Page 163: ...models that use adhesive backing on the switch 2 Cover Open Switch Assembly P N 150296 001 3 Connector CO Ref 4 Connector CO Ref 3 4 2 This section of cable runs beneath the base casting 1 Printer viewed from above NOTE Newer models use pressure sensitive adhesive backing on the switch Discard screws if installing switch with adhesive backing Figure 5 34 Switch Assembly Cover Open Removal Installa...

Page 164: ...s securing the switch assembly cable to the front of the card cage and remove the paper detector switch assembly 4 Installation 1 Holding the slotted wheel against the PMD sensor position the paper detector switch assembly 4 and install the screws 3 securing it to the printer base 2 Connect the paper detector switch cable connector 5 to the intermediate cable assembly connector PMD 3 Install tie w...

Page 165: ...g 6 32x 25 2 Barrier Shield P N 150303 001 3 Screw 2 Thread finding 6 32x 375 4 Paper Detector Switch Assembly P N 150834 001 5 Paper Detector Switch Cable Connector p o item 4 1 2 4 3 5 3 Figure 5 35 Switch Assembly Paper Detector Removal Installation ...

Page 166: ...ews 4 6 Remove the platen interlock switch assembly 5 from the forms thickness indicator plate 6 7 Remove the connector 1 from the right side plate Installation 1 Fully close the forms thickness lever 3 2 Position the platen interlock switch assembly 5 on the forms thickness indicator plate 6 3 Install two screws 4 4 Install the connector 1 to the right side plate 5 Connect the platen interlock sw...

Page 167: ... item 5 2 Connector P1 P Ref 3 Forms Thickness Lever P N 111724 001 4 Screw 2 CRCFM 2 28x 63 5 Platen Interlock Switch Assembly P N 150284 001 6 Forms Thickness Indicator Plate P N 110144 001 2 3 4 5 6 1 Figure 5 36 Switch Assembly Platen Interlock Removal Installation ...

Page 168: ...e 5 70 2 Install the splined shaft page 5 68 3 Return the printer to normal operation see below Returning the Printer to Normal Operation 1 Load paper 2 Install the ribbon 3 Close floor cabinet doors and the printer cover 4 Connect the ac power cord to the power source and the printer 5 Set the power switch to 1 on 6 Test printer operation by selecting and running one of the diagnostic self tests ...

Page 169: ...pment Contents IGP 200 210 Option 6 2 CT Option 6 8 CT Installation 6 8 CT Control Panels 6 16 Error Processing 6 19 Fault Messages 6 20 Symptoms Not Indicated by Fault Messages 6 28 Printer Self Tests 6 30 IGP and CT Options Combined 6 38 ...

Page 170: ...ency interference RFI some ribbon cables are wound around ferrite cores You must duplicate these windings when reassembling the printer Refer to Appendix G NOTE To remove the IGP reverse the steps of this procedure 1 Prepare the printer for IGP installation a Remove the paper guide assembly page 5 42 b Remove the common controller board page 5 46 c Remove the mechanism driver board page 5 48 d Rem...

Page 171: ...e front edge of the card cage remove the slack in the cable and install two tie wraps Make sure the part of the cable covered by the heat shrink tubing is under the tie wraps Mounting Stud Tie Wrap Card Cage CT IGP 2X0 Power Board P N 155018 001 Tie Wrap Heat Shrink Tubing Figure 6 1 Installing the CT IGP 2X0 Power Board ...

Page 172: ...he opening at the rear of the card cage 7 Slide the IGP board half way down the rear most card slot in the card cage a Loop the printer multi I O ribbon cable over the top of the IGP board and b connect the multi I O cable connector to connector J61 on the IGP board CAUTION In the next step make sure the cables under the IGP board are not pinched or crushed 8 Slide the IGP board down into the card...

Page 173: ...CT IGP 2X0 Power Cable P N 155054 001 Power Supply Mech Driver CCB IGP Printer Control Panel Cable IGP Control Panel Cable Multi I O Cable P N 150310 002 Power Supply Cable P1 Interconnect Cable P N 155026 001 Figure 6 2 Installing the Circuit Boards and Cables ...

Page 174: ...racket 14 Install the shuttle cover and tighten the captive screws 15 Connect the IGP control panel connector J11 to IGP ribbon cable connector P11 16 Stow cable slack in the wire saddles on the right side of the printer base plate 17 Install the paper guide assembly page 5 42 18 Configure the printer for Dataproducts interface Refer to the P4280 Setup Guide 19 For information about IGP operation ...

Page 175: ...Panel Support Bracket IGP Control Panel IGP Ribbon Cable Connector J11 IGP Control Panel Connector J11 Wire Saddle Screw 2 Hex w LW 6x 25 Captive Screw Captive Screw Not Shown Shuttle Cover Figure 6 3 Installing the IGP Control Panel ...

Page 176: ... frequency interference RFI some ribbon cables are wound around ferrite cores You must duplicate these windings when reassembling the printer Refer to Appendix G NOTE To remove the IGP reverse the steps of this procedure 1 Prepare the printer for CT installation a Remove the paper guide assembly page 5 42 b Remove the common controller printed circuit board assembly PCBA page 5 46 c Remove the mec...

Page 177: ...ctor plate P N 112435 001 Screw 4 Cable Restraints Coax twinax I O Cable Assembly NOTE To prevent crushing install cables at bottom of restraints Route cables into the card cage Screw 6 Service Panel Figure 6 4 Installing the Coax Twinax I O Cable Assembly ...

Page 178: ...ink tubing runs straight up the front wall of the card cage b Install tie wraps securing the power cable to the front wall of the card cage Make sure the part of the cable covered by the heat shrink tubing is under the tie wraps on the front wall c Pull the the power cable straight across the bottom of the card cage remove the slack and install a tie wrap this will leave enough slack at both ends ...

Page 179: ...6 11 Optional Equipment Tie Wrap CT Power Cable P N 155029 001 Tie Wrap Figure 6 5 Installing the CT Power Cable ...

Page 180: ... bracket See Figure 6 6 5 Install the CT bracket on the rear wall of the card cage with two screws Screw 2 SEMS Hex wshr 10 24x 375 Card Cage CT Bracket P N 150801 001 PCBA Guide 2 P N 108599 006 NOTE Notch must be at top of bracket Card Cage Fan Figure 6 6 Installing the CT Card Bracket ...

Page 181: ...ller board replace the DCU PROMs at locations H1 and H2 with the PROMs included in this kit See Figure 6 7 Remove these DPU PROMs and install the ones in the CT kit Font 002 Font 001 DPU 002 DPU 001 Common Controller Board CCB Figure 6 7 Installing New DPU PROMs on the CCB ...

Page 182: ... to crush the CT cables 12 Insert the common controller board in its guides in the card cage and seat it in the bottom connector 13 Connect the CT interconnect cable to connector J1 on the common controller board 14 Connect the printer control panel cable connector to connector J3 on the common controller board 15 Install the mechanism driver PCBA page 5 48 16 Connect the CCB Mech Driver interconn...

Page 183: ...ail Grey CT I O Cable Orange CT I O Cable Connector P2 Beveled edge rests on board CT Power Cable P N 155029 001 Power Supply Cable P1 CCB Mech Driver Cable P N 150551 001 Printer Control Panel Cable CT Power Cable Connect as shown 1 Note location of pin 1 Figure 6 8 Installing the Circuit Boards and Cables ...

Page 184: ...panels RAISE PRINTER COVER TO ACCESS THESE SWITCHES Coax Control Panel Twinax Control Panel CU SCS ALT CHECK ENABLE HOLD FORM FEED SETUP INDEX 0 1 2 3 FUNC TEST BUFRP CANCEL ALT PGM 5 4 ENTER PA1 8 9 6 7 INSPC ADJUST PA2 LINE SYNC SYS AVAIL BUFFER PRINT ATTN ENABLE HOLD FORM FEED SETUP INDEX 0 1 2 3 FUNC TEST INSPC CANCL PRT 1 PGM 5 4 ENTER ADJUST 8 9 6 7 Figure 6 9 CT Control Panels ...

Page 185: ... to the User s Manual for information In the PROGRAM state this key functions as a left arrow Provides a second function for the following keys INSPC Y ADJUST B BUFRP PA1 and CANCL PA2 The ALT LED lights when ALTERNATE functions are active In the PROGRAM state this key functions as a right arrow TEST ENTER Prints an 80 column sliding pattern of all characters in the present character set Press the...

Page 186: ... data on the page This key functions as an up arrow in the HOLD and PROGRAM States Cancels a print job Permits entry into the PROGRAM State from which you may change printer parameters Refer to the User s Manual for information In the PROGRAM State this key functions as a left arrow Prints one line of data In the PROGRAM State this key functions as a right arrow TEST ENTER Prints an 80 column slid...

Page 187: ...to on Note the error message before pressing the CANCL or ENABLE HOLD switch to turn off the alarm The error log buffer automatically logs the error The control panel displays a message indicating which fault has occurred Error Types The printer can detect four kinds of errors Fatal Errors problems detected in the inner workings of the printer When fatal errors occur printing stops and the printer...

Page 188: ...an correct are self explanatory and appear on the second line of the liquid crystal display PAPER JAM PLATEN OPEN OUT OF FORMS RIBBON FAULT RIBBON OUT After correcting an operator correctable fault press the ENABLE HOLD switch before placing the printer on line IMPORTANT If NVRAM ERROR displays every time printer power is cycled non volatile memory must be replaced Non volatile memory can be tempo...

Page 189: ... ERROR message Replace one at at time until message is gone inoperative fan s mech driver PCBA CCB PCBA GRAPHIC CHECK Instruction Indication Yes No 1 Run a buffer print and refer to the user s manual Run the same job that generated the error message GRAPHIC CHECK message Verify host data are correct and there are no invalid characters Verify printer s World Trade Language is correct 2 Run the Tran...

Page 190: ...ge Replace the mech driver PCBA and check for error message Go to step 4 Return printer to normal operation 4 Run a diagnostic self test page 6 30 HAMMER DRV ERROR message Replace one at a time until message is gone power supply PCBA shuttle frame assembly Return printer to normal operation INTERNAL ERROR Instruction Indication Yes No 1 Record the error code of the internal error type from the err...

Page 191: ... OFF Wait 5 seconds Set power switch to 1 ON NVRAM ERROR message Replace the NOVRAM chip on the CCB PCBA Return printer to normal operation OUT OF FORMS Instruction Indication Yes No 1 Load paper Press ENABLE HOLD twice Step 2 2 Run a diagnostic self test page 6 30 OUT OF FORMS message Replace paper detector switch assembly Return printer to normal operation 3 Check for inoperative mech driver PCB...

Page 192: ...ge Clean the paper detector with cotton swab Go to step 6 Return printer to normal operation 5 Set the paper motion detector fault setting to DISABLE PAPER JAM message Return printer to normal operation 6 Check paper feeding as the printer prints PAPER JAM message Check the tractors and spring behind the tractor door Replace the mech driver PCBA Return printer to normal operation 7 Run a diagnosti...

Page 193: ... connection to PCBA Error message displays Reseat cable 4 Check coax twinax cable for interconnect and length specifications being met Cable doesn t meet specifications Replace cable 5 Check CCB and CT PCBAs Check coax and twinax cables Error message displays Replace one at a time until message is gone CCB PCBA CT PCBA coax or twinax cable PLATEN OPEN Instruction Indication Yes No 1 Load paper Ste...

Page 194: ...operation RIBBON OUT Instruction Indication Yes No 1 This message displays when using the RibbonMinder feature RIBBON OUT message Change the ribbon SCS CODE ERROR or SCS PARAM ERROR Instruction Indication Yes No 1 Run a buffer print Run the same job that generated the error message SCS CODE or SCS PARAM ERROR message Verify host data are correct and there are no invalid characters 2 Verify printer...

Page 195: ...SHUTTLE STALL message Remove the obstruction and go to step 3 Return printer to normal operation 3 Readjust the MPU Check the MPU sensor for proper gap broken or loose connector SHUTTLE STALL message Replace MPU Go to step 4 Return printer to normal operation 4 Run a shuttle ribbon test SHUTTLE STALL message Replace one at a time until message is gone mech driver PCBA CCB PCBA Go to step 5 Return ...

Page 196: ...tle frame assembly or the hammer bank Replace the entire assemblies they are not field repairable NO DISPLAY Instruction Indication Yes No 1 Inspect control panel ribbon cable connector for bent or broken pins Pins are damaged Straighten bent pins If broken replace control panel assembly Step 2 2 Power up printer and check display and card cage fan operation Display comes on Resume printing Replac...

Page 197: ...lication b Host computer and printer use the same protocol emulation c Configuration has not been inadvertently changed by the user Step 5 Reconfigure the printer 6 Turn off the power and remove the paper guide assemby Step 7 7 Check all electrical connectors Connections are clean tight and oriented correctly Wires are not stripped frayed or out of connectors Step 8 Replace stripped frayed or brok...

Page 198: ...AM STATE FORMAT PARAMETER Select the DCU or CTPC Tests from the Internal Tests Options 1 Press the switch to advance through the PROGRAM state Level I options until you come to INTERNAL TESTS 2 When INTERNAL TESTS appears on the second line of the LCD press the switch to enter the Level II options The display shows the following message options INTERNAL TESTS 3 Press the switch to view the Level I...

Page 199: ...the Test 1 Press the TEST ENTER switch to activate the test If the test has its own display it will appear on the LCD and the message shown here may only flash on RUNNING DCU CTPC TEST 2 Press the TEST ENTER switch to stop the test the display shows the following message DCU CTPC TEST STOPPED The test may be rerun or another test selected 3 Press the switch several times to exit to Level I of the ...

Page 200: ... diagnostic self tests to check the print quality and operation of the printer Some of the self tests described below include a list of items that may require field replacement or adjustment if the test produces a bad pattern print DCU Hex Dump This test places the print engine controller in the hex dump mode It is used to determine what data is being sent from the CT controller PCBA to the print ...

Page 201: ...c pattern useful for identifying missing or malformed characters improper vertical alignment or vertical compression Hammer bank cover Hammer spring Shuttle assembly E s plus TOF A pattern of all E s followed by a form feed to the next page top of form useful for identifying paper motion or feeding problems e g paper path obstruction improper forms Hammer bank cover Power supply PCBA Mechanism dri...

Page 202: ... motors at the fastest possible speed Use for identifying spooling and ribbon guide misalignment CT Tests Test Function NVRAM Print Out Print Error Log Demo Print Burn In Test Prints out the parameters set in all four NVRAM blocks Prints a log of errors that have occurred in the printer To clear the log hold down the FUNC switch and press the CANCL switch To end the test press the TEST ENTER switc...

Page 203: ...Press the FUNC switch and the CANCL switch to clear the Error Log 2 The LCD shows the following message for one to two seconds PRINT ERROR LOG STOPPED This ends the test To exit the Print Error Log test without clearing the error log press TEST ENTER NOTE The values of the POWER ON HOURS and LINES PRINTED in the Error Log printout will not be cleared The Clear Error Log feature only clears the Err...

Page 204: ...echanism Error Internal Error NVRAM Error Paper Jam Error Ribbon Error Shuttle Stall Paper Out Platen Open Error Type Priority Level CU Time Out coax Bell twinax Level 6 Twinax Errors Error Log The CT Test called Print Error Log produces a record of the number of times each error occurred in the printer since the last time the Error Log was cleared The errors are stored in the Error Log as a two d...

Page 205: ...Platen Open Error End of Form INTERNAL ERROR Message Displayed MECHANISM ERROR PLATEN OPEN OUT OF FORMS SHUTTLE STALL NVRAM ERROR PAPER JAM Internal Error 22 Ribbon Error RIBBON ERROR 16 18 34 36 37 38 39 40 41 42 Hammer Driver Error Cooling Error Failure TWINAX ERROR Parity Error Activate Lost Invalid Activate Invalid Command Input Queue Overrun Graphic Check Error SCS Code Error SCS Parameter Er...

Page 206: ...the printer for CT installation a Remove the paper guide assembly page 5 42 b Remove the common controller printed circuit board assembly PCBA page 5 46 c Remove the mechanism driver PCBA page 5 48 d Remove the power supply PCBA page 5 50 e Remove the multi I O cable assembly page 5 14 2 Install the coax twinax I O cable assembly See Figure 6 10 a Position the coax twinax I O interface connector p...

Page 207: ...plate P N 112435 001 Screw 4 Cable Restraints Coax twinax I O Cable Assembly NOTE To prevent crushing install cables at bottom of restraints as shown Route cables into the card cage Screw 6 Service Panel Figure 6 10 Installing the Coax Twinax I O Cable Assembly ...

Page 208: ... 3 and change jumper E12 to 2 3 5 If the printer does not yet have the CT option go to step 6 If the printer already has a CT option installed remove the CT board the board bracket and the CT power cable that runs along the bottom and front of the card cage Remove these DPU PROMs and install the ones in the CT kit Common Controller Board CCB Font 002 Font 001 DPU 002 DPU 001 Figure 6 11 Installing...

Page 209: ... power board to the bottom of the card cage 7 Tie wrap the cable from the CT IGP 2X0 power board snugly into position a Route the cable straight across the bottom of the card cage and remove the slack b Hold the cable vertical against the front edge of the card cage remove the slack in the cable and install two tie wraps Make sure the part of the cable covered by the heat shrink tubing is under th...

Page 210: ...P and CT Options continued 8 Using the nylon nuts bolts and spacers provided in the kit install the CT board on the IGP board See Figure 6 13 9 Connect the CT IGP interconnect cable to P1 on the CT board and J61 on the IGP board ...

Page 211: ...ard Nylon Nut 4 Hex 6 32 P N 102952 002 CT IGP Interconnect Cable P N 155028 002 Nylon Bolt 4 Pan head 6x 50 P N 109862 001 Nylon Spacer 4 171 ID x 187 LG P N 106520 001 CT Board Figure 6 13 Installing the CT Board on the IGP Board ...

Page 212: ... CT board Pin 1 on the cable connector faces up 15 Connect the power jumper cable to the power connector on the CT board 16 Route the printer control panel cable under the IGP board 17 Connect the IGP CCB interconnect cable to connector J60 on the IGP board CAUTION In the next two steps make sure the cables under the IGP board are not pinched or crushed 18 Slide the IGP board down into the card ca...

Page 213: ... 001 Power Supply Mech Driver CCB Printer Control Panel Cable IGP Control Panel Cable Power Supply Cable P1 See Detail Detail Grey CT I O Cable Orange CT I O Cable Connector P2 Beveled edge rests on board CT IGP Power Cable Assy P N 155029 002 Connect as shown 1 Note location of pin 1 Figure 6 14 Installing the Circuit Boards and Cables ...

Page 214: ...in the wire saddles on the right side of the printer base plate 27 Install the paper guide assembly page 5 42 28 Set the coax twinax switch on the I O plate to the type that will be used 29 Install the appropriate overlay on the printer control panel Control Panel Support Bracket IGP Control Panel IGP Ribbon Cable Connector J11 IGP Control Panel Connector J11 Wire Saddle Screw hex w LW 6x 25 2 Cap...

Page 215: ...ion Contents Printer Configuration A 2 Configuration Printout A 3 Factory Default Configuration Values A 4 Configuration Procedure A 6 Loading Configuration Values A 7 Resetting the Printer to Default or Saved Parameters A 8 Configuration Diagram A 9 ...

Page 216: ...ost computer Configuration is the process of matching the printer s operating characteristics to those of the host computer The characteristics that define the printer s response to signals and commands received from the host computer are called configuration parameters You can configure the printer with the control panel or by sending control codes from the host computer This appendix shows you h...

Page 217: ...nd DOWN simultaneously ENTER Switch Not Locked displays briefly If ENTER Switch Locked displays press UP and DOWN again 4 Press DOWN Ribbon Life xxx displays 5 Press PREV Diagnostics displays 6 Press DOWN Configuration Print Out displays 7 Press ENTER Configuration Printing displays and the configuration listing prints Wait until the printer stops printing the configuration list 8 Press CLEAR Off ...

Page 218: ...configuration parameters as required but the factory default values are permanently stored in ROM and easily reloaded To load the factory default values use the Load Parameters menu page A 7 or reset the printer page A 8 On the Configuration Diagram beginning on page A 9 factory configuration values are indicated by an asterisk in the message display box ...

Page 219: ... Disable Reverse Channel Define LF Code LF CR LF Alarm On Fault Enable Unidirectional Disable Configuration Factory Default Parameter Value Select Subset Select Set ASCII IBM PC Select Language IBM PC GRAPHICS Select SFCC 01 SOH Control Code 08 Double High 80 9F Hex Control Codes Overstrike Enable Print Width 13 2 Inches Centronics On Line and BNF On Line and BNF Fast Busy Enable Shuttle Timeout 4...

Page 220: ...e Configuration Diagram page A 9 as a road map 6 Press DOWN to enter a menu then press NEXT or PREV until the value you want is on the display 7 Press ENTER An asterisk appears next to the value indicating this parameter is now the active value 8 Press CLEAR to move out of the configuration menus and to the Off Line Ready state 9 Repeat steps 5 through 8 to make all required parameter changes 10 P...

Page 221: ...s UP and DOWN simultaneously ENTER Switch Not Locked displays briefly 4 Press DOWN then press NEXT or PREV until Load Parameters appears on the display 5 Press DOWN then press NEXT or PREV to display either the Load Saved Parameters or Load Factory Parameters menu If an IGP IBM 3287 or IBM 5225 board is installed in your printer display the appropriate parameter menu 6 Press ENTER The printer load...

Page 222: ...n reset the printer any time the power is on while it is on line off line even while it is printing However to prevent losing data it is recommended that you reset only when the printer is off line and no data are in the buffer 1 Press the ON LINE switch to take the printer off line 2 Open the printer cover IMPORTANT In the next step make sure you press and release CLEAR and ENTER together If you ...

Page 223: ...ure the printer NOTE The availability of some menus depends on the the protocol or host interface option you choose How to Read the Configuration Diagram The Configuration Diagram shows the configuration menus and parameters in the order they appear on the display The boxes represent the control panel display Capital letters N D etc represent the control panel switches you press to move through th...

Page 224: ...AT 12 9 CPI NLQ AT 15 CPI OCR A AT 10 CPI OCR B AT 10 CPI HS AT 10 CPI HS AT 12 CPI HS AT 15 CPI HS AT 13 CPI HS AT 17 CPI HSB AT 10 CPI HSB AT 12 CPI HSB AT 15 CPI HSB AT 13 CPI HSB AT 17 CPI HSC AT 10 CPI HSC AT 12 CPI HSC AT 15 CPI HSC AT 13 CPI HSC AT 17 CPI N D DP AT 12 CPI P P P P P P P P P P N U U U U U U U U U U U U U U U U Press CLEAR to go to Off Line Ready Press UP to move up a level Pr...

Page 225: ...fe xxx Ribbon Life xxx Ribbon Life xxx Ribbon Life xxx Ribbon Life xxx When Worn Action When Worn Action When Worn Action Ribbon Life xxx Ribbon Life xxx P P P P P U U U U Press NEXT or PREV to increase or decrease New Size by 10 Press NEXT or PREV to increase or decrease New Rate by 1 Press ENTER to reset ribbon life to 100 A new ribbon must be installed in order to reset ribbon life to 100 Press...

Page 226: ...nguage N D N FRENCH CANADIAN JAPANESE 1 1 1 1 JAPANESE DOWNLOADED is displayed when a downloaded substitution table is active FRENCH CANADIAN MULTINAT DP10 MULTINAT DP12 MULTINAT NLQ10 GREEK DP10 GREEK DP12 CREEK NLQ10 GRAPHICS DP10 GRAPHICS NLQ10 SCIENT DP10 SCIENT DP12 Character Set FROM PAGE A 10 Select Subset Select Subset Primary Extended D D N D IBM PC GRAPHICS Select Subset CODE PAGE 850 Se...

Page 227: ...tle Timeout Shuttle Timeout 4 Shuttle TImeout 10 TImeouts range from 10 to 300 in increments of 5 seconds Shuttle TImeout 300 Unidirectional Unidirectional Disable Unidirectional P Series Plot Unidirectional Enable Select SFCC 4 Select SFCC 01 SOH 4 Only in P Series protocol 03 ETX 1B ESC 5E Circumflex 7E Tilde 80 9F Hex 80 9F Control Codes 80 9F Printable Control Code 06 5 Control Code 06 8 0 LPI...

Page 228: ...t Select 0E Elongated 08 Font Select 08 Elongated 0E Display Language Display Language English Overstrike Disable Compress Print 09 HT Draft Print 02 STX Draft Print 03 ETX Draft Print 09 HT Display Language Deutsch Display Language Français Display Language Español N P N P Press CLEAR to go to Off Line Ready Press UP to move up a level Press ENTER to select N P N P N P N P D U D U D U D U D U N P...

Page 229: ...Forms Length Set at 66 Lines Option range is from 1 to 192 lines in 1 line increments Forms Length Set at 88 Lines Option range is from 1 to 192 lines in 1 line increments Auto Line Feed Auto Line Feed After Full Line Auto Line Feed Disable Define CR Code Define CR Code CR CR Define CR Code CR CR LF Define LF Code Define LF Code LF CR LF Define LF Code LF LF Continued on next page N P D U N P Pres...

Page 230: ...elative 0 to 15 Print Width Print Width 13 2 Inches Print Width 13 7 Inches Print Width 8 0 Inches N P N P D U Press CLEAR to go to Off Line Ready Press UP to move up a level Press ENTER to select N P N P N P N P N P N P D U D U D U D U D U D U N P N P N P N P N P N P N P N P N P N P N P N P N P EVFU DVFU NVFU CVFU Disable 3 Pressing ENTER removes the loaded VFU data 4 Pressing ENTER saves the cur...

Page 231: ...usy Disable Strobe Polarity Strobe Polarity Standard Strobe Polarity Inverted Latch Data On Latch Data On Leading Edge Latch Data On Trailing Edge Press CLEAR to go to Off Line Ready Press UP to move up a level Press ENTER to select D U N P N P N P U U U U D U D U D U D U D U D U D U N P N P N P N P N P N P N P N P N P N P N P N P U U U 2 When disabled the paper instruction PI line is always read ...

Page 232: ...y Strobe Polarity Standard Strobe Polarity Inverted Latch Data On Latch Data On Leading Edge Latch Data On Trailing Edge D U N P U U U U D U D U D U D U D U D U N P N P N P N P N P N P N P N P N P N P U Press CLEAR to go to Off Line Ready Press UP to move up a level Press ENTER to select 2 When disabled the paper instruction PI line is always read as not a paper instruction 1 When disabled bit 8 i...

Page 233: ...Ready On Line and BNF Data Term Ready Off Line or BF Data Term Ready False Data Term Ready True Request to Send Request to Send On Line and BNF Request to Send Off Line or BF Request to Send False Request to Send True Reverse Channel Reverse Channel On Line and BNF Reverse Channel Off Line or BF Reverse Channel False Reverse Channel True 2 CAUTION When RS 232 protocol is set to ETX NAK ETX is cons...

Page 234: ... Same as IBM 3287 parameters PI Line Enabled Factory settings are indicated by asterisks in the menu boxes throughout this diagram 80 9F HEX Printable SFCC 01 SOH except 80 9F printable Character Set Multinational 1 Returns after 1 second Strobe Polarity Standard Latch Data On Leading Edge FROM PAGE A 10 Load Parameters Load IGP Load IBM 3287 Laod IBM 5225 Load Factory Completed Completed Complete...

Page 235: ...g Test Running Test Shift Recycle All E s E Plus TOF All H s Underline Only Black Plot Shuttle Ribbon Slow E Phase Index XX Printer Test Phase Index 99999 9 Hrs 99999 9 Hrs 2 147 483 648 Power On Time Print Time Shuttle Strokes Print Lines Print Pages 1 All set to zero after factory burn in 2 3 4 5 6 2 0 to 30 000 3 0 to 30 000 4 0 to 2 147 483 648 5 0 to 2 147 483 648 6 0 to 2 147 483 648 1 2 147...

Page 236: ...A 22 Configuring the Printer ...

Page 237: ... B 2 Paper Specifications B 2 Paper B 2 Labels B 3 Printer Dimensions B 3 Interfaces B 3 Environmental Characteristics B 4 Termperature B 4 Relative Humidity B 4 Accoustic Noise Level B 4 Electrical Characteristics B 4 Input Power B 4 Power Rating B 4 Data Input Rate B 5 Printing Rates B 6 Duty Cycle B 8 ...

Page 238: ...ibbons Extended Life Text Ribbon Kit P N 107675 001 Bar Code Ribbon Kit P N 107675 005 Paper Specifications Paper Type Edge perforated fanfold 7 62 to 40 64 cm 3 to 16 in wide Thickness Single part 6 80 to 45 36 kg 15 to 100 lb stock Multi part 1 to 6 part forms maximum 5 44 kg 12 lb ply of upper plies Sheet Thickness 0 0635 cm 0 025 in maximum Drive Adjustable tractors 6 pin engagement Slew Rate ...

Page 239: ...eed strips A maximum sheet size of 30 48 cm 12 in between top and bottom perforations Thickness Not to exceed 0 064 cm 0 025 in including backing sheet Printer Dimensions Height 108 cm 42 5 in Width 68 6 cm 27 in Depth 72 9 cm 28 7 in Weight Approximately 102 kg 225 lb Unpackaged Approximately 129 kg 285 lb Packaged for shipping Interfaces Type Two resident parallel one resident serial Logic Level...

Page 240: ...ty Operating 10 to 90 noncondensing Storage 5 to 95 noncondensing Acoustic Noise Level 52 dBA tested per ISO 7779 Electrical Characteristics Input Power Voltage 120 Vac or 230 Vac 94 140 VRMS 188 275 VRMS Phase Single Frequency 47 to 62 Hz Max RMS Current 8A 120 V 4A 230 V Power Rating Standby 165 VA 60 Hz 120 Watts Operating 480 VA 60 Hz 360 Watts ...

Page 241: ...taproducts Up to 30 000 characters per second Centronics Up to 30 000 characters per second RS 232 Up to 19 200 baud Radio Frequency Interference RFI Radio Frequency Interference tested certified to RFI standards FCC 15 J Class A VDE 0871 Class B CISPR 22 ...

Page 242: ...pical printing rates are charted in Table B 1 Plotting speed of graphics is measured in inches minute and is calculated as follows Shuttle Speed x Vertical Density 60 000 Plotting speed in 1 x inches minute Shuttle speed varies with the horizontal dot density Shuttle Speed Horizontal Density milliseconds stroke 12 5 12 5 12 5 12 5 12 5 12 5 12 5 12 5 13 5 14 5 15 6 18 75 20 8 50 60 70 80 90 100 11...

Page 243: ...A B X C where A is maximum horizontal dot density B is horizontal placement resolution C is vertical dot density NOTE 2 D E X F G where D is maximum number of dots that may be placed on E horizontal dot positions F is number of vertical dots for uppercase symbols G is number of dots available for descenders LPM Lines Per Minute IPM Inches Per Minute Mode CPI OCR 90 180 X 144 10 9 17 X 14 2 110 96 ...

Page 244: ... following conditions 1 Uppercase only 2 6 lines inch 3 10 characters inch 4 63 character density or 83 characters line 5 63 line density or 42 lines 11 inch page 6 Single part 18 lb paper 7 Printer is maintained in accordance with this maintenance manual 8 Printer is installed in accordance with the Setup Guide ...

Page 245: ...te tensile strength Into Weld Press Studs or Nuts Into Medium Carbon Steel Fasteners 105 000 psi ultimate tensile strength Into Steel 60 000 psi ultimate tensile strength Carbon Steel Fasteners ANSI B18 6 3 1972 2 56 4 40 6 32 8 32 10 24 10 32 1 4 20 25 2 in oz 62 4 in oz 122 7 in oz 11 1 in lb 20 1 in lb 15 1 in lb 40 3 in lb 36 2 in oz 75 5 in oz 150 10 in oz 18 1 in lb 25 1 5 in lb 29 2 in lb 6...

Page 246: ...C 2 Torque Table ...

Page 247: ...r Supply D 8 Test Points CCB and Mech Driver D 9 Interface Connectors D 10 Cable Assemblies D 11 W1 Cable Assembly CCB Mech Dr D 11 W2 Cable Assembly 5 V D 12 W3 Cable Assembly Hi Voltage D 13 W4 Cable Assembly Hammer Bank D 14 W5 Cable Assembly Intermediate D 15 W6 Wire Harness Main D 16 W7 Cable Assembly AC Ground D 17 Hammer Bank Wiring Diagram D 18 ...

Page 248: ...C Input Load Load GND GND GND Cable Assy AC Ground P4280 P2 P1 P S Cond 1 P S Cond 2 W3 Cable Assy High Voltage W2 Cable Assy 5V Cable Assy CCB Mech Dr W6 Wire Harness Main P4980A EXF P HBL J HBR J W4 twice Cable Assy Hammer Bank CO P CO P PMD P PMD J PI J PI P W5 Cable Assy Intermediate RGL P RGL J RML P PFM P J17 HBF P SHH P SHH J RGR P RGR J RMR P CCF P PLM P MPU P MPU J SHM P SHM J Right Left ...

Page 249: ...E N MECH DRVR TXD N MECH DRVR ATTN N MECH DRVR RXD 31 32 33 34 35 36 37 38 N MECH RESET 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 VCC P5 N CROWBAR N C N C N C MOTOR ID SENSOR ID N C N C N C N C N C N C MECH ID N C Pin1 J2 J2 To Control Panel 1 2 3 4 5 6 7 8 9 10 J3 Pin1 NFP SWITCH RD FP CLOCK VCC P5 NFP LCD WR FP DATA VCC P5 NFP LED WR GND GND GND LEGEND FP FRONT PANEL CONT...

Page 250: ...NACK RET PRIME NACK N C SPARE 3 SPARE 4 SPARE5 PE REV CHNL TX DATA RX DATA RTS CTS DTR DSR DCD TX CLK RCV CLK EXT CLK SPARE 2 Multi I O Cable Assy 150310 002 Intermediate Cable Assy W5 29 29292 01 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 A B C D E F H J K L M N P R S N C N C N C N C N C N C N C COVER OPEN SWITCH PLATEN OPEN SWITCH PPR OUT LED CATHODE PPR OUT SENS COLL GND PMD SENS COLL N C N C N C N C ...

Page 251: ...33 34 35 36 37 38 N RESET 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 VCC P5 N CROWBAR N C N C N C MOTOR ID J4 P SENSOR ID J5 5 N C N C N C N C N C N C MECH ID J5 35 N C J6 J6 GND GND P6 To CCB J2 Pin1 CCB Mech Drver Cable Assy W1 150551 001 VCC R82 10K R24 1K R74 1K Cable Assy 5V W2 150218 001 Pin1 PS J 1 1 1 3 PS5 J To Power Supply J102 48 V 9 5 V Input 1 2 3 4 5 6 7 8 J7 N...

Page 252: ...34N COIL 35 MDCOIL 35N COIL 36 COIL 33 COIL 34 MDCOIL 30N MDCOIL 36N 1 2 3 4 5 6 7 8 N C 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 UDPH1A MDCOIL 13N UDPH2A MDCOIL 14N UDPH 3A MDCOIL 15N UDPH 4A MDCOIL 16N COIL 17 MDCOIL 17N COIL 18 MDCOIL 18N 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 J2 J2 COIL 1 MDCOIL 1N COIL 2 MDCOIL 2N MDCOIL 3N MDCOIL 4N COIL 5 MDCOIL ...

Page 253: ...OT 1P RIB MOT 3P SHUT PHASE A CC FAN EX FAN A B C D E F H J K L M N P R S T U V W X Y Z J4 J4 GND RIB MOT 2P RIB MOT 4P SHUT PHASE B BANK FAN PS5 PS5 PLAT MOT 1P R RBN FAULT R RBN HALL B MPU PLAT MOT 2P R RBN POST HALL A HALL PFM 2 PFM 4 RIB MOT 1N RIB MOT 3N SHUT PHASE C HB FAN MOTOR ID GND RIB MOT 2N RIB MOT 4N 48 V CC FAN EX FAN PLAT MOT 1N L RBN FAULT L RBN 15 V MPU PLAT MOT 2N L RBN POST HALL...

Page 254: ...1 AC Input P1 Cable Assy AC Ground P4980 150649 001 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 A B C D E F H J K L M N P R S 9 5 V J101 J101 48 V P2 P2 48 V 9 5 V P2 A 1 S 15 To Mech Driver J3 High Voltage Cable Assy W3 150216 001 AC AC COMMON CHASSIS GND 1 2 3 LOAD LOAD GND GND GND RING TERMINAL FAST ON TERMINAL 0 V CHASSIS GND 0 V J102 1 Power Supply ...

Page 255: ...P7 TP8 TP9 TP10 TP11 TP12 TP13 TP14 TP15 TP16 TP17 TP18 TP19 TP20 TP21 TP22 TP23 TP24 TP25 TP26 TP27 TP28 TP29 PAPER B AMPLITUDE PAPER A AMPLITUDE PAPER B CURRENT PAPER A CURRENT N MPU PULSE VCC 5V GND 5V RET SHUT CLK SHUT SPEED SHUT ERR HALL CLK GND PAPER FEED N COIL TEST N SHORT GND HAMMER PWR COIL TEMP 58V N FAIL SAFE GND SHUTTLE PFM1 PFM2 PFM3 PFM4 48V 9 5V 15V 42V N CROWBAR N MD RESET TP30 N ...

Page 256: ...1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 RD CTS GND N C N C N C TX CLK RCV CLK N C N C N C EXT CLK J4 TD RTS DSR DCD N C N C REV CHNL N C N C DTR N C N C Serial RS232 VFU READY N C DB8 PI N C DB5 DB7 DATA STROBE DB4 RET DB6 RET DB8 RET N C N C PAR ERROR N C PARITY N C BUF CLR N C N C DB7 RET DS RET GND DB4 DB6 CABLE VER N C N C 1 2 3 4 5 6 7 8 DATA STROBE 9 10 11 12 13 14 15 16 17 18 DB2 DB4 DB...

Page 257: ...D 11 Wire Data Cable No Part No Description W1 150551 001 Cable Assembly CCB Mech Dr PIN 1 PIN 1 ...

Page 258: ...D 12 Wire Data W2 150218 001 Cable Assembly 5 V Cable No Part No Description PIN 1 NOTE PIN 5 NOT CONNECTED P1 PS5 PIN 1 ...

Page 259: ...D 13 Wire Data Cable No W3 150216 001 Part No Description Cable Assembly Hi Voltage PIN A PIN 1 PIN A PIN 1 PIN 15 PIN S PIN 15 PIN S TO MECH DRIVER TO POWER SUPPLY P2 PS ...

Page 260: ...D 14 Wire Data Cable No W4 150215 001 Part No Description Cable Assembly Hammer Bank PIN 1 HD P HB J PIN 50 HD P KEYWAY R or L Cable is same ...

Page 261: ...IN S TO PIN 15 PIN A PIN C PIN J PIN S CO P CO P PI P PMD J PIN 1 PIN 1 PIN 9 FROM P1 TO PIN 2 PIN B CO CO FROM P1 TO PIN 3 PIN C PIN 1 PIN 3 FROM P1 TO PIN J PIN 9 PIN 1 PIN 2 PIN K PIN 10 PIN L PIN 11 PIN M PIN 12 PIN N PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PAPER OUT DETECT POD PAPER MOTION DETECT PMD ...

Page 262: ... Cable No Part No Description W6 150376 001 Wire Harness Main P4280 PFM P RGR J RMR P RML P SHM J RGL J PLM P CCF P EXF P SHH J MPU J HBF P 9 PIN 9 PIN 9 PIN 9 PIN 3 PIN 9 PIN 9 PIN 3 PIN 3 PIN 3 PIN 3 PIN 3 PIN M H ...

Page 263: ...D 17 Wire Data Cable No Part No Description W7 150649 001 Cable Assembly AC Ground PIN 1 ...

Page 264: ...ut not used 2 Hammer springs 0 and 48 are not used 3 Hammer coil resistance 4 7 Ohms Unused hammer Hammer Coil Hammer Spring Ribbon Cable Key 4 8 4 7 4 6 Hammer No 0 1 2 3 Top Bot Top Bot Top Bot Top Bot Top Bot Top Bot Top Bot Top Bot Key Key Pin 50 Pin 50 Pin 1 Pin 1 ...

Page 265: ... Principles of Operation Contents Functional Elements of the Printer E 2 Common Controller PCBA E 3 Mechanism Driver PCBA E 11 Power Supply PCBA E 14 Printing Mechanism E 15 Paper Transport System E 19 Ribbon Transport System E 20 ...

Page 266: ... DRIVER PCBA PRINT MECHANISMS SHUTTLE FRAME ASSEMBLY RIBBON TRANSPORT Paper Feed Platen Open Motor Control Shuttle Control Ribbon Control Fan Control Shuttle Status Hammer Control Ribbon Status 5 Vdc Data Status 5 Vdc AC POWER PRINTER INTERFACE COMMON FILTER EMI Fault Hammer Driver Data Hammer Timing Data Shuttle Ribbon Control Paper Control DPU RTPU SHARED MEMORY Keyboard Indicator Message ON OFF...

Page 267: ...lved in real time or hardware dependent printer operation The RTPU operates the host interfaces operator control panel and the print mechanism The RTPU also monitors the fault circuitry in the mechanism The DPU and RTPU communicate by means of shared memory The DPU gets host and operator input from buffers in memory which are filled by the RTPU and returns dot images and operator messages to buffe...

Page 268: ... control panel The control panel processes three types of operation keystroke input message display output and indicator output The RTPU handles the control panel interface requirements of shifting clocking etc but the DPU processes all control panel data Printing The RTPU coordinates printing of the dot images sent from the DPU Printing is a complex process requiring many control functions but is...

Page 269: ...per hammer the number of hammers on the hammer bank the number of phases and other factors These factors are all considered by the RTPU processor as it programs the dot plucker for each dot row Synchronizing Dot Plucking and Hammer Firing Transfer of dots to the hammer driver must be synchronized with hammer firing Dots are transferred to the hammer driver in bursts serial streams of dots that tel...

Page 270: ... Mechanism Driver Interface Functions of the RTPU Paper Motion The DPU determines when paper must be moved and how far to move it It communicates this to the RTPU through the shared memory The RTPU processor performs some paper handling operations such as holdback on slews but most RTPU paper handling is done by a dedicated micro controller called the paper feed controller PFC The PFC moves paper ...

Page 271: ...rts errors to the RTPU The RTPU passes this information on to the DPU Ribbon and Shuttle Faults The mechanism driver ribbon and shuttle controller monitors fault conditions in the drive circuits and notifies the RTPU if it finds errors The RTPU can also use the FTIC to measure time between magnetic pick up MPU pulses enabling it to monitor shuttle speed and thus detect some shuttle faults CCB Hard...

Page 272: ... the 64180 performs only eight bit memory access cycles Sixteen bit DMA is achieved by hardware shifting of the DMA addresses one bit effectively multiplying the address by two and changing the DMA auto increment from byte to word and by manipulating the control strobe Software adjusts the addresses provided to the DMA controller when it is programmed for sixteen bit DMA This manipulation saves bo...

Page 273: ...ooks for hammer driver faults shuttle stalls and an open platen The PFC 8032 monitors paper out and the paper motion detector The RSP watches for faults in the motor drive circuits The PFC and RSP report errors to the 64180 which collates fault status and passes it on to the DPU 68010 processor Hammer Bank and Hammer Driver Faults The 64180 and FTIC check the hammer driver and hammer bank for faul...

Page 274: ...river Serial to Host Mech Driver and Control Panel PARALLEL PORT DOT PLUCKER DRAM 1 MB BUS INTERFACE FIRE TIMER IC HARDWARE CONTROL HARDWARE STATUS REGISTER REGISTER COMM PORT 8032 PROCESSOR EPROM 16 KB EPROM 32 KB SRAM 2 KB 64180 PROCESSOR BUS INTERFACE CONTROL REGISTER NVRAM 2 KB RTPU PFC SHARED SHARED ASIC Serial from Host Computer Figure E 5 Hardware Implementation of the CCB ...

Page 275: ...the speed of the three phase dc shuttle motor The ribbon drive controller based around the 8032 micro controller receives speed commands from the CCB and drives two dc stepper motors regulating the speed and tension of the ribbon and monitoring the end of ribbon sensors The platen drive controller for reverse paper feed Fault detection circuitry samples and senses heat sink temperature ribbon spee...

Page 276: ... motor to maintain constant linear speed The roles of the two motors reverse at the end of ribbon travel when a metallic strip crosses the ribbon guide of the emptying reel and closes a circuit that causes the RSP to reverse motor functions The four PWM amplifiers in the ribbon drive system are voltage mode to aid in system damping as opposed to current mode The 8032 input to the PWM amplifiers ma...

Page 277: ...The Paper Feed System Dot row advance and slew tables are stored in the CCB The paper feed drive circuit takes commands directly from the CCB to control the two phase dc paper feed stepper motor A CCB paper feed command is a digital word containing a value proportional to the desired current level in the paper feed motor enabling the motor to be quarter stepped in P4280 mode Two PWM current mode a...

Page 278: ... dc power and sent to the mechanism driver board for distribution to logic and electromechanical circuits AC Power The power supply operates on ac voltages ranging from 86 to 264 V It can tolerate variations in frequency of 47 or 63 Hz The power supply is designed to withstand an ac input overvoltage of 300 Vac for one second with no degradation of dc output voltage or damage to printer circuits D...

Page 279: ...from the 48 V and 9 5 V outputs Printing Mechanism The printing mechanism consists of the shuttle frame assembly which carries the hammer bank assembly the ribbon transport system and the paper transport system Figure E 6 shows the shuttle frame assembly Shuttle Motor Hammer Bank Assembly Counterweight Assembly Shuttle Frame Assembly Guide Shaft Connecting Rod Figure E 6 Shuttle Frame Assembly ...

Page 280: ...ide tip on the free end See Figure E 7 A permanent magnet runs the length of the hammer bank and acts on the hammer springs through individual pole pieces The pole pieces magnetically attract and hold the free end of the hammer spring under tension This is called the retracted state Hammer Bank Coils Magnet and Pole Pieces Alignment Pin Hammer Spring Assembly Tungsten Carbide Hammer Tip Heat Sink ...

Page 281: ... a character as the shuttle scans horizontally Characters are formed inside dot matrices the dimensions of which vary according to the selected font The dot printing process continues for the number of dot matrix rows determined by the selected font When an entire character line is printed the paper feed system advances the paper to the top dot row of the next character line to be printed During t...

Page 282: ...1 1 2 3 NOTE Hammer Released and Dot Printed Hammer Not Released No Dot Printed Shuttle Scan Dot Row Succesive Hammer Strokes Per Scan Even column dot centers within the printed character area and character space hammer positions are not illustrated in this diagram Figure E 9 Typical Action of One Hammer in Text Printing ...

Page 283: ...cks in place with a friction lock During printing the tractors are driven by the splined shaft which is belt driven by the paper feed drive motor The paper feed drive motor is a two phase step motor controlled by the paper feed sections of the mechanism driver board and the paper feed controller on the common controller board Paper may be manually advanced with the vertical adjustment knob Right T...

Page 284: ...eting a circuit that causes both motors to reverse direction Constant ribbon tension is maintained by controlling each motor with a drive or drag circuit While the hammer bank assembly is in motion one motor acts as a driving motor drawing the ribbon against the resistance exerted by the other motor the drag motor This system maintains a constant motor speed and constant ribbon tension Ribbon Guid...

Page 285: ...or are wound around it 2 Block cores The core is housed in a hinged plastic case Cables are laid in a groove in the core and the plastic case is closed securing the core to the cable Figure F 1 shows the location of the ferrite cores in the P4280 printer IMPORTANT When removing cables that pass through or around ferrite cores note the number of times the cable is wound around the core You must dup...

Page 286: ...ore Cable connector Ribbon Motor cable wraps once around core before it enters the card cage Maintenance TIp Route and wrap the cables first Tie wrap the round ferrite cores to the card cage last Fold the ribbon cable in half then snap the ferrite core shut over the cable Slide the core as close to the control panel as possible and flatten the ribbon cable to prevent the core from sliding down the...

Page 287: ...meter m inch 2 54 centimeter cm inch 25 4 millimeter mm meter 3 280840 foot centimeter 0 03280840 foot millimeter 0 003280840 foot meter 39 37008 inch centimeter 0 3937008 inch millimeter 0 03937008 inch Torque Multiply pound inch 175 1268 By To Obtain newton meter NSm pound foot 14 59390 newton meter NSm newton meter NSm 0 005710148 pound inch 0 06852178 pound foot newton meter NSm ...

Page 288: ...27397 ounce Temperature To Convert From temperature Celsius tC To Use Formula tF 1 8tC 32 temperature Fahrenheit tF temperature Fahrenheit tF tC tF 32 1 8 temperature Celsius tC Power 735 499 Multiply Btu International Table hour By To Obtain watt W 0 2930711 watt W Btu International Table hour 3 412141 watt W horsepower metric 0 001359621 horsepower metric watt W ...

Page 289: ... I O replacement 5 14 interconnections D 1 intermediate replacement 5 10 part numbers D 1 Card cage fan assembly replacement 5 26 Cautions 1 2 Character Set U S ASCII 3 31 Checks See Preventive Maintenance Checks and Services Checks and Service 2 2 Preventive Maintenance 2 2 Chips PROMs DIPs ICs location of 5 59 5 61 Circuit boards See PCBA Circuit breaker replacement 5 18 Cleaning the printer 2 4...

Page 290: ... 8 Dynamic RAM Fault 3 4 E Electrical characteristics B 4 Environmental characteristics B 4 Equipment Optional 6 1 Error Log Print 6 35 Error log 6 36 Error Messages See Fault Messages 6 19 Error messages 3 2 error log 6 36 Error ranking 6 36 Error types 6 19 F Fan assembly card cage replacement 5 26 hammer bank replacement 5 28 5 30 Fatal errors 6 19 Fault Processing 6 19 Fault Messages Clearing ...

Page 291: ...ank cover assembly replacement 5 22 fan assembly replacement 5 28 5 30 wiring diagram D 1 HAMMER DRV ERROR message 6 22 Hammer phasing adjustment 4 6 Hex code printout 3 30 Hidden diagnostics menu 3 32 Hub ribbon replacement 5 64 I ICs location and replacement CCB 5 58 Mech Driver 5 60 Important notes 1 2 Information how to locate 1 2 special 1 2 Initializing the printer A 8 INPUT QUEUE OVER messa...

Page 292: ... 23 overrideable errors 6 19 P Paper detector switch assembly replacement 5 82 drive motor pulley alignment 4 8 feed drive motor replacement 5 38 feed timing belt replacement 5 4 feed timing belt tension adjustment 4 2 guide assembly removal installation 5 42 ironer replacement 5 44 scale adjustment 4 10 specifications B 2 tractor L R replacement 5 86 Paper detector switch replacement 5 82 Paper J...

Page 293: ...nventions in this manual 1 3 Printouts Configuration A 3 hex code 3 30 Procedures adjustment 4 1 cleaning 2 4 inspection 2 3 replacement 5 1 PROMs location and replacement CCB 5 58 Mech Driver 5 60 R Ranking of errors 6 36 Replacement card cage fan assembly 5 26 circuit breaker 5 18 control panel assembly 5 20 controller PCBA 5 46 cover open switch assembly 5 80 extension spring 5 78 gas spring as...

Page 294: ...Tests 6 30 Self tests 3 27 running 3 29 Services See Preventive Maintenance Checks and Services Shaft splined replacement 5 68 splined skew adjustment 4 20 support replacement 5 70 Shttl Cover Open 3 15 Shuttle cover assembly replacement 5 24 frame assembly replacement 5 72 Shuttle Jam 3 16 SHUTTLE STALL fault message 6 27 Software Error 3 17 Specifications cleaning B 2 dimensions printer B 3 Duty...

Page 295: ...ors location of 5 63 replacement 5 62 Test equipment tools and supplies 1 10 printer performance 3 27 Tests Printer Self Tests 6 30 Tools test equipment and supplies 1 10 Torque conversion to metric G 1 table C 1 Tractor replacement 5 86 Troubleshooting 3 1 fault messages 3 2 Troubleshooting techniques 6 28 Types of errors 6 19 W Warnings 1 2 Wiring diagrams D 1 ...

Page 296: ...8 Index Notes ...

Page 297: ......

Page 298: ... 863 1900 FAX 714 660 8682 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 1646 PHONE 65 449 7555 FAX 65 449 7553 155064 001B ...

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