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Maintenance Manual
1
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Trademark Acknowledgements
4
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Communication Notices
5
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Chapter Communication Notices
6
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Table of Contents
7
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5 Replacement Procedures
8
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1 Maintenance Overview
11
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Printer Evolution
12
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How to Identify the Printer
12
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Chapter 1 P5000 Printers
14
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Important Maintenance Notes
15
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About This Manual
15
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How to Use This Manual
16
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Notes and Notices
16
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Safety Notices
17
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Hinweise zur Sicherheit
17
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Controls and Indicators
18
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PRT CONFIG
19
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JOB SELECT
19
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Status Indicator
21
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Power Switch
21
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(Off) (On)
21
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0.1 inch
22
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2 Preventive Maintenance
25
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NOTE: P5005 hammer bank is
27
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NOTE: Cabinet model shown
28
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Procedure is the same for
28
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3 Troubleshooting
29
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Start Here
30
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How to Clear LCD Messages
31
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Table 2: Message List
32
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Table 3: General Symptom List
37
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Troubleshooting Procedures
38
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The Procedures
39
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15V CTL FAIL* Message
40
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22 INVALID ADDR Message
40
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23.5V CTL FAIL* Message
40
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31 PAPER OUT
41
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TIMEOUT Message
41
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32 PAPER JAM
41
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± 2 inch-pounds (1.02 ± 0.23
41
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33 PLATEN OPEN
42
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34 RIBBON STALL
42
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48V PWR FAIL* Message
43
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ACCESS NULL PTR* Message
43
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ACTIVATE LOST Message
44
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A TO D OVERRUN* Message
44
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BUFFER OVERRUN Message
45
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CLEAR PAPER JAM Message
46
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CLEARING PROGRAM
49
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FROM FLASH Message
49
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CLOSE PLATEN Message
49
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COIL HOT Message
49
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Control panel blank
50
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CTL VOLT FAIL* Message
51
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DIAGNOSTIC
51
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PASSED Message
51
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Downloads consistently fail
52
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DRVR CIR BAD* Message
52
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ERROR: DC PROGRAM
52
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NOT VALID Message
52
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EXHAUST FAN FLT Message
56
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FIRMWARE ERROR Message
56
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HAMMER COIL BAD
58
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#, #, #, #, ... etc. Message
58
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HB NOT INSTALLD* Message
58
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HMR BANK FAN FLT Message
58
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ILL EXT BUS ACC* Message
59
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ILL INST ACCSS* Message
60
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ILLGL OPR ACCSS* Message
60
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INTAKE FAN FAULT Message
60
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INVALID ACTIVATE Message
60
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INVALID COMMAND Message
61
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LO DRV. SHORT* Message
61
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PAP BSY TOO LNG* Message
64
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PAP FIFO OVERFL* Message
64
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PAP FIFO UNDRFL* Message
64
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PAP ILLGL ST* Message
65
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PAP INCMPL ENER* Message
65
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PAP INVLD CMD* Message
65
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PAP INVLD PARM* Message
65
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PAP NOT SCHED* Message
66
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PAP NT AT SPEED* Message
66
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PAP UNEXP INT* Message
66
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PARAMETER ERROR Message
66
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PARITY ERROR Message
67
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PLAT INV CMD* Message
67
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PLAT INV PARM* Message
67
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PLAT INV STATE* Message
67
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PLEASE WAIT
68
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RESET IN PROGRESS Message
68
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Paper feeds poorly
68
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Power on “hang” condition
69
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POWER SAVER MODE Message
69
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POWER SUPPLY HOT Message
69
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Stacker not operating
70
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Printer does not initialize
71
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PRINTER HOT Message
72
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Randomly misplaced dots
74
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RIB INVLD CMD* Message
75
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RIB INVLD STATE* Message
75
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RIBBON DRIVE Message
75
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RIBBON INK OUT
76
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CHANGE RIBBON Message
76
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SCS COMMAND ERROR Message
76
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SHUTTLE JAM Message
79
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± 1 inch-pounds (2.03
79
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± 0.11 N•m)
79
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Message
80
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Operator’s
81
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STACKER FAULT Message
82
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STACKER FULL Message
83
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STACKER JAM Message
83
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Stacker limit switch check
83
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Stacker motor check
84
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TABLE MISMATCH
85
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DOWNLOAD AGAIN Message
85
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TCB CORRUPTED* Message
85
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TOF is lost repeatedly
85
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Communications Failures
88
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Diagnostic Printer Tests
89
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Boot Diagnostics Menu
92
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BOOT DIAGNOSTICS
93
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PRESS ENTER
93
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Hex Code Printout
95
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How to Print a Hex Dump
96
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ASCII Character Set
97
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Soft vs. Hard Reset
98
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The Power On Sequence
104
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4 Adjustment Procedures
105
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IMPORTANT
106
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User’s Manual.)
107
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1) Timing Belt Shield
109
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2) Motor Mount Bolt (2)
109
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3) Paper Feed Drive Motor
109
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4) Splined Shaft
109
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± 0.23 N•m)
110
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Direction of Force
111
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1) Shuttle Cover
115
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3) Paper Scale
115
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1) Belt Cover
119
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2) Set Screw
119
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3) Platen Open Motor Pulley
119
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4) Platen Shaft Pulley
119
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1) Screw, Skid (2)
121
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2) Ribbon
121
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3) White Nylon Washer
121
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4) Screw, Retaining (2)
121
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1) Screw
123
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2) Adjusting Link
123
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Paper Out Adjustment
124
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< or ; key, adjust the XX
127
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Hammer Phasing Adjustment
128
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Adjustment
129
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User’s Manual
130
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FILENAME.ZIP
136
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FILENAME
136
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FILENAME.EXE
136
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Set Shuttle Speed
141
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Chapter 4 Set Shuttle Speed
142
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5 Replacement Procedures
143
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Belt, Paper Feed Timing
146
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Belt, Platen Open
147
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Circuit Breaker
148
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Connector Shells
149
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Connector Stiffening Clips
151
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Installation
153
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Controller Board (CMX)
155
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Removal
157
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Early Models
159
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Later Models
159
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Cover Assembly, Shuttle
160
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Expansion
162
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Fan Assembly, Cabinet Exhaust
163
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Fan Assembly, Card Cage
164
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Fan Assembly, Hammer Bank
165
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Hammer Spring Assembly
166
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Removal
171
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CMX Controller Board
173
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Paper Feed Motor
174
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Paper Ironer
176
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Paper Path
177
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± 2 inch-pounds (2.26 ± 0.23
181
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Platen Open Motor
182
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Power Supply Board
184
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(Default is all
186
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Run and Auto Reset Modes
188
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Dipswitches
189
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Resistors, Terminating
190
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Ribbon Drive Motor
192
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Ribbon Guide Assembly (L/R)
193
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Ribbon Hub
194
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Shaft, Splined
195
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Shaft, Support
197
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Shuttle Frame Assembly
198
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Spring Assembly, Gas
200
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Tractor (L/R)
204
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Part No. Description Notes
207
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Figure 32. Pedestal Details
212
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Figure 39. Tractor Shafts
226
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Figure 40. Platen
228
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Install screws here
230
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Route cable under
230
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Hammer Bank Fan
230
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Top View
230
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Figure 43. Expansion-CT Board
234
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6 Principles of Operation
239
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Printing Rates
242
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Printing Mechanism
242
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Chapter 6 Printing Mechanism
244
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Paper Transport System
245
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Ribbon Transport System
246
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Shuttle Assembly
247
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Control Panel
248
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Data Controller
251
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Engine Controller
254
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Printer Interface
256
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Graphics
257
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Chapter 6 Graphics
258
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A Wire Data
259
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Appendix A
260
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Interconnection Diagram
261
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Power Distribution Diagram
262
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Main Wire Harness Test Tables
263
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Controller, CMX
264
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PPR STK STAT0
265
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PPR STK STAT1
265
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PPR STK CTL0
265
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PPR STK CTL1
265
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Controller (continued)
266
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Cable Assembly
268
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Power Supply
268
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Expansion-CT
269
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SureStak Power Stacker PCBA
270
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Cable Routing, Cabinet Model
271
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Cable Routing, Pedestal Model
273
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If you replace the I/O cable
275
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See Appendix E
275
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DataproductsCentronics
276
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CentronicsDataproducts
276
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(P/N 154649-901)
277
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(AC Kit P/N 153502-901)
280
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To Circuit Breaker
281
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Input Power Connector
281
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Left Guide = P106 / LRP
288
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Right Guide = P107 / RRP
288
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P107 / HBF
295
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B Abbreviations &
299
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Appendix B
300
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C Metric Conversion Tables
307
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Appendix C
308
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D Noise Suppression Devices
309
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Control Panel Cable Assembly
310
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Parallel I/O Cable Assembly
310
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E SureStak™ Power Stacker
311
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Removing the Power Stacker
312
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2. Vertical Rail
315
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3. Stacker Base
315
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Installing the Power Stacker
317
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1. Screw, 6-32x1/4, Torx T-10
319
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1. Upper Frame Cross-Member
321
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2. Elevator Assembly
321
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4. Vertical Rail
321
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Figure 67. Stacker Fasteners
323
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Figure 68. Paper Fence
324
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1. Logic Cable (P104)
325
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2. Power Cable
325
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3. Frame Cable (P102)
325
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4. Rail Cable (P107)
325
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User’s Guide.)
327
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1. Tie Wrap
328
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1. Spring
330
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Replacing the Timing Belts
331
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1. Allen Screw
333
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2. Belt Clamp
333
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NOTE: Left timing
334
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Illustrated Parts Breakdown
335
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Figure 80. Stacker Assembly
336
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Numerics
349
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164253-001D
360
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