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Maintenance Manual

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7. EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE Figure 4 29 Characters Light or Smeared Example P3000 Troubleshooting 4 57 Character positions light or smeared dragging hammer Check and adjust platen gap per para 5 13 Apply power and check for symptom NO Symptom present YES Return to normal operation Check hammer bank for accumulation of dirt particularly back of hammer on or near pole pin NO Clean hammer bank assembly per para 3 4 YES Apply power and check for symptom NO Symptom present Return 1 normal operation Replace hammer spring If required per para 5 29 Apply power and check for symptom Symptom present NO Return to normal operation YES Rotate shuttle to Service position per para 3 4c 2 4 Check hammer coil s for visible damage or improper seating on pole pin NO YES Reposition on pole pin or replace per para 5 30 Apply power and check for symptom Symptom NO present Return to normal operation Continue to troubleshoot using standard techniques If problem remains contact authorized distributor Service representative Figure 4 30 Character Positions Light or Smeared Dragging Hammer
8. F m mimm m nii 1 1 TI FI TE IU H mam i rm Figure 4 26 Missing Dots Example Sheet 2 of 2 4 52 P3000 Troubleshooting Consistent dropout of dots Check forms thick ness lever setting NO Hammer bank clean NO Clean hammer bank per para 3 4 YES Reposition forms thickness lever as necessary Apply power and check for Apply power symptom and check for symptom Symptom NO present Symptom NO present Retension Return to hammer spring s normal operation Return to per para 5 5 normal operation Apply power Adjust platen gap per para 5 13 and check for symptom Apply power and check for symptom NO Symptom present NO YES Return to normal operation Return to hammer spring s Symptom present per para 5 29 Check hammer bank for accumulated dirt Return to normal operation Figure 4 27 Consistent Dropout of Dots P3000 Troubleshooting 4 53 Random dropout of dots Check forms thick ness lever setting NO YES Reposition forms thickness lever Ribbon NO as necessary OK YES Apply power Check for dirt and check for and obstruction symptom in ribbon path Remove obstructions Symptom NO Clean per
9. ein ale dara E ND uu EE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEFEEEEEEEEEEEEEEEEEFEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE Figure 4 26 Missing Dots Example Sheet 1 of 2 P3000 Troubleshooting 4 51 E E CEE E i im p m Hl m m m 1 Ti m m vm EEEEEEEE EEEEEEFEEEEE E E ECEEEEEFEEE EEE RE EEECEEECEEEC ss cus e e t EEUU
10. 5 20 5 14 Ribbon Guide Alignment 5 22 Section III REPLACEMENT 5 15 ME NER Re bana S T ie 5 24 5 16 Control Panel ua b eR ae 5 26 5 17 o c DR 5 28 5 18 Display Control Panel LL 5 30 5 19 Control Panel Cable uyu u aya sasa 5 32 5 20 Controller POBA LU u te 5 34 5 21 Mechanism Driver POBA Sissies wasis waww wasasapa 5 37 5 22 Power Supply POBA nestea nr e reme he uqata lea 5 38 5 23 au nde 5 40 5 24 Paper Scale u aww ia 5 42 5 25 Motherboard POBA eme e e 5 42 5 26 Cable Assembly 5 44 5 27 Shuttle Assembly iii ia 5 46 5 28 Hammer Bank Cable Assembly 5 48 5 29 Hammer Spring iii 5 50 5 30 Coll see cine Gon She fe ae ee wie a 5 52 5 31 lian Pm 5 54 5 32 Encoder PCBA esee toto i egre 5 56 5 33 ER oil eee E 5 58 5 34 Paper Feed Timing Belt 5 60 5 35 Paper Drive Motor e 5 62 5 36 Spline Shaft i Rhames 5 64 5 37 Support ae tea 5 66 5 38 ae liceo 5 6 5 39 Paper TONGE RE e 5 68 5 40 e etiope dai a 5 70 5
11. 4 38 4 19 Shuttle Moves Erratically eee 4 41 4 20 Shuttle Movement Produces Knocking Sound 4 43 4 21 Printer Does Not Print at 4 44 4 22 Printer Fails to Print Only When Controlled by Host Computer 4 45 4 23 Missing Characters Example 4 46 4 24 Characters Missing Consistently 4 47 4 25 Characters Missing Randomly 4 50 4 26 Missing Dots Example 8 4 51 4 27 Consistent Dropout of Dots 58 4 53 4 28 Random Dropout of Dots 4 54 4 29 Characters Light or Smeared Example 4 57 4 30 Character Positions Light or Smeared Dragging Hammer 4 58 4 31 Dots Misplac d ssania 4 59 4 32 Improper Print Density 1 4 61 4 33 Improper Print Density LL 4 62 4 34 Improper Horizontal Alignment Example 4 63 4 35 Improper Vertical Alignment Example 4 64 4 36 Improper Horizontal or Vertical Alignment 4 65 4 37 Characters Misformed Vertically Example 4 66 4 38 Characters Misformed 4 67
12. 5 75 5 36 Paper Detect Switch Removal Installation 5 77 5 37 Ribbon Drive Motor Removal Installation 5 79 5 38 Ribbon Guide Removal Installation 5 81 5 39 Blower Assembly Removal Installation 5 83 5 40 Fan Removal Installation 5 85 5 41 Circuit Breaker Removal Installation 5 87 5 42 AC Input Filter Removal Installation 5 89 5 43 Paper Feed Motor Pulley Removal Installation 5 91 vi P3000 Maintenance ABOUT THIS MANUAL This manual has been organized and written to make it easy to use The following information will help you use this P3000 Maintenance Manual What This Manual Contains This manual contains the following information Consult your table of contents to locate this infor mation Introduction Provides brief printer description Principles of Operation Describes functional operation of printer through the use of block diagrams and associated text Preventive Maintenance Lists detailed procedures required to maintain normal printer operation Troubleshooting Presents fault isolation procedures required to determine the source of common malfunctions Corrective Maintenance Presents procedures for printer adjustment and alignment and replacement of faulty hardware Electr
13. problem remains contact authorized distributor service representative Figure 4 38 Characters Misformed Vertically P3000 Troubleshooting 4 67 EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE
14. n a 6 SCREW 2 wicca cousin deae pe ee roh E PRX aa 102786 606 7 WASHER 2 101526 037 B SCREW pi aka 102786 606 9 TERMINAL TAB 101539 003 10 STAR WASHER 101527 003 11 SCREW pio ia ina 102786 604 12 MOUNTING PLATE 111423 001 13 FILTER aa 111564 001 Figure 5 43 Paper Feed Motor Pulley Removal Installation 1 SET SCREW 2 part of item 2 2 MOTOR PULLEY 105740 001 3 MOTOR iii 110353 003 P3000 Parts List A AC Input Filter Replacement 5 88 Figure 5 89 Adjustment Bumper Figure 5 9 Paper Scale Figure 5 4 Platen Gap 5 20 Figure 5 21 Spline Shaft Skew 5 16 5 17 Timing Belt Figure 5 13 Tension 5 12 Adjustments Alignments and Bumpers 5 8 Hammer Phasing 5 11 Hammer Spring Retensioning 5 6 Hammer Tips 5 3 Paper Drive Motor Pulley 5 14 Paper Scale 5 3 Platen Gap 5 20 Platen Angle 5 17 Figure 5 18 Ribbon Guide 5 22 Spline Shaft Skew 5 16 Stroke Timing 5 10 Timing Belt Tension 5 12 Alignment Hammer Tip Figure 5 5 Paper Drive Motor Pulley 5 14 Figure 5 15 Ribbon Guide 5 22 5 23 Alignments and Adjustments Bumpers 5 8 Hammer Phasing 5 11 Hammer Spring Retensioning 5 6 Ha
15. 102786 406 9 PCBA MOTHERBOARD 111499 001 10 INSULATOR 112010 001 11 CABLE ue ER EX EE queue 111540 001 12 BASE piloni 111365 003 112083 003 Figure 5 16 Controller and Mechanism DriverRemoval Installation 1 CONNECTOR n a 2 SCREW 3 102559 136 3 EMI SHIELD COVER 111430 01 4 PARALLEL CONTROLLER PCBA 111951 01 5 LATCH 2 he ie oe Ea boe a part of item 6 6 CONNECTOR P4 part of item 4 7 CONNECTOR J4 part of item 10 8 BASE silice rat qusa PE obe a os 111365 003 112083 003 9 MECHANISM DRIVER PCBA 111687 001 10 CABLE gt peni patoi Fe eds 11 CONNECTOR P16 of cable not shown Figure 5 17 P to o Controller PROM Locations DCU PROGRAM PROM 2 117178 001 13D 002 12D MCU PROGRAM PROM 117177 001 6D FONT PROM 2 117774 001 140 002 15D HOST TERMINATING RESISTORS varies with configuration MEMORY PAGING 140234 01 Figure 5 1 Power Supply PCBA Removal Installation P3000 Parts
16. 111779001 12 HAMMER BANK PCBA part of item 1 13 SCREW HEX 3 102786 604 14 HAMMER BANK 111392 001 amp 003 Figure 5 24 Hammer Spring Removal Installation 1 COVER 111702 001 2 SCREW 2 esed tx RR bea 140058 001 3 SHUTTLE COVER 111790 001 4 TRACTOR 2 105786 001 5 SHUTTLE LOCK KNOB 110257 001 6 SHUTTLE ASSEMBLY 111057 001 amp 003 7 HAMMER BANK COVER ASSY 111071 001 8 ROLL PIN 2 part of item 6 9 SCREW SOCKET HEAD 105575 001 10 HAMMER nn 105059 002 109004 001 11 SCREW ice segue tU xe pee mie 105575 001 15 CLAMP PLATE evened 111073 01 18 POLE PIN en vie part of item 6 Figure 5 25 Hammer Coil Removal Installation 1 HEAT SINK iori onire sss ERR eee tii part of item 7 2 OF COIL part of item 7 3 COIL WIRES part of item 7 4 BOBBIN SHAFT part of item 7 5 iei iaia part of hammer bank 6 HAMMER BANK CABLE ASSY 111070 001 7 COIL ASSEMBLY NEW 111703 001 Fig
17. Figure 4 24 Characters Missing Consistently Sheet 2 of 3 normal operation P3000 Troubleshooting FROM SHEET 2 Check coil s for visible signs of damage Continuity check s by 5 7 Q NO Replace coil s per para 5 30 YES Apply power and check for symptom NO Return to normal operation Replace mechanism driver per cable assembly per para 5 21 para 5 28 Apply power Apply power and check for Symptom and check for symptom NO Symptom NO E present f YES Return to YE Return to B normal operation Continue to troubleshoot using standard techniques If problem remains contact authorized distributor Service representative Figure 4 24 Characters Missing Consistently Sheet 3 of 3 P3000 Troubleshooting 4 49 Characters missing randomly Check ribbon for damage Ribbon NO OK YES Check for ribbon fold over Folding NO over YES Ribbon Folds Over Replace ribbon NO Return to normal operation Check Check for symptom hammer bank for accumulated dirt NO Hammer bank clean Clean hammer bank per para 3 4 Apply power and check for symptom Symptom NO Continue to present troubleshoot using standard techniques If problem remains contact Return to normal operation authorized distributor service representative Figure 4 25 Characters Missing
18. Pa di PB e Removal Disconnect I O connector 1 Remove cabinet per paragraph 5 15a Loosen three screws 2 and remove EMI shield cover 3 Grasp controller 4 and pull up to unseat connectors at base Open latches 5 on connector P4 6 Disconnect connector J4 7 Separate controller 4 from base 8 Installation NOTE When controller PCBA or DCU PROMSs are replaced check hammer phasing per paragraph 5 8 and adjust if necessary Install program PROM Figure 5 17 1 and 2 font PROMs 3 host terminating resistors 4 and memory paging prom 5 on replacement PCBA Use components from replaced board if appropriate Connect connector J4 7 On connector P4 6 close latches 5 Position controller Figure 5 16 4 in base 8 Install EMI shield cover 3 and tighten three screws 2 Install cabinet per paragraph 5 15b Connect I O cable 1 Apply power and run configuration test pattern to verify operation P3000 Corrective Maintenance CONNECTOR I O SCREW 3 EMI SHIELD COVER CONTROLLER PCBA LATCH 2 CONNECTOR CONNECTOR J4 BASE MECHANISM DRIVER PCBA CABLE CONNECTOR P16 AA Figure 5 16 Controller and Mechanism Driver Removal Installation P3000 Corrective Maintenance 5 35 N DCU PROGRAM PROM 2 MCU PROGRAM PROM FONT PROM 2 HOST TERMINATING RES MEMORY PAG
19. part of item 12 part of item 6 111499 001 105728 001 111381 001 105728 001 111338 001 111663 001 P3000 Parts List TABLE B 1 PARTS LIST continued FIGURE AND TITLE ITEM NO NAME PART NO COMMENTS Figure 5 37 Ribbon Drive Motor Removal Installation 1 FORMS THICKNESS LEVER 111724 001 2 CONNECTOR P28 part of item 6 3 MOTHERBOARD PCBA 111499 001 4 SCREW iii ina part of item 5 5 SPOOL HUB 102526 001 6 RIBBON DRIVE MOTOR 111460 001 Ift 002 rt SCREW 3 hn 102786 407 Ift 406 rt 8 WASHER 3 101526 005 9 BASE CASTING MECH 111663 001 Figure 5 38 Ribbon Guide Removal Installation 1 FORMS THICKNESS LEVER 111724 001 2 RIBBON set epe teda uds n a 3 CONNECTOR P24 part of item 7 4 MOTHERBOARD PCBA 111499 001 5 SCREW 2 102786 406 6 WASHER 2 orc a 101526 005 7 LEFT RIBBON GUIDE 111463 001 8 LEFT SIDE PLATE 110129 001 9 RIGHT RIBBON GUIDE
20. Figure 5 2 Bumper Removal Installation COVER SHUTTLE COVER LOCKSCREW LOCKSCREW Q N 1 CONNECTOR P21 2 MA 3 SPRING 4 SPRING 5 SCREW 2 6 PIVOT RETAINER 2 7 SCREW 4 8 9 SCREW 2 BUMPER FRONT BASE SHUTTLE BUMPER REAR PART NO COMMENTS part of item 18 111663 001 111980 001 111980 001 105728 004 110181 01 102786 614 111576 01 105728 004 101526 003 part of item 12 111057 001 amp 003 101514 053 111699 001 101514 011 part item 18 105728 006 111712 001 111702 001 140058 001 111790 001 101514 031 101514 031 110994 001 111326 001 110994 001 Figure 5 29 Paper Feed Timing Belt Removal Installation WASHER 2 BELT SHIELD BELT 4 9 m P N MOTOR PULLEY Figure 5 30 Paper Drive Motor Removal Installation SCREW 3 EMI SHIELD COVER CONNECTOR P16 MECHANISM DRIVER PCBA EMI SHIELD BASE SCREW 2 WASHER 2 BELT SHIELD 1 2 3 4 5 6 7 8 9 RIGHT SIDE
21. NI v IN L PITI ITP IW AJ KoA tT NLA 175 LINES MINUTE 13X9 NLQ i an HAR yI uu ZANNI NL 300 LINES MINUTE 9X7 DATA PROCESSING 400 LINES MINUTE 7X5 HIGH SPEED Figure 2 8 Typical Character Dot Patterns By Mode P3000 Principles of Operation 2 5 Controller PCBA Figure 2 9 The controller PCBA contains logic circuits for communicating with the host data source the operator control panels and the mechanism driver PCBA It is configured to accept any one of three data formats two parallel Centronics Data Products and one serial RS 232 Functionally the controller PCBA is divided into two sections the data control unit DCU and the mechanism control unit MCU The DCU and MCU each contain a Z80 CPU microprocessor to control their operation a Data Control Unit DCU The DCU microprocessor controls data operations between the host controller and the printer The DCU receives coded information from the host that determines characters to be printed font selection line spacing plotting EVFU selection elongated characters and paper movement In turn the DCU returns status data to the host Hammer Serial Data Multiplexer After data is received at the MCU RAM the MCU through the general purpose interface status register then informs the DCU that it is available for processing the next character The character from the MCU RAM bu
22. 3 10 4 1 All Indicators Come on and Stay at Power up 4 7 4 2 No Indicators Come on at 4 8 4 3 Indicators on Both Control Panels Operate Improperly 4 11 4 4 Switches or Indicators Operate Improperly on Front Control Panel Only ese reme eem alas 4 12 4 5 Digital Display Operates Improperly 4 13 4 6 CHECK Indicator Flashes Display Shows FAULT CONDITION PAPER OUT 4 14 4 7 CHECK Indicator Flashes Display Shows FAULT CONDITON PLATEN OPEN 4 16 4 8 CHECK Indicator on Continuously Display Shows FAULT CONDITION DCU RAM FONT PROM or MCU RAM 4 18 4 9 Paper Doesn t Feed at All 4 19 iv P3000 Maintenance List of Illustrations Figure Title Page 4 10 Paper Feeds 8 4 22 4 11 Paper EET 4 26 4 12 Set Top of Form Does not Operate 4 28 4 13 Ribbon Does not Move at 4 29 4 14 Ribbon Folds Over aa 4 31 4 15 Ribbon Does Not Run 4 32 4 16 Ribbon Does Not Change Direction at End 4 34 4 17 Shuttle Does Not Move at 4 36 4 18 Shuttle Jams or Moves too Slowly
23. Adjust per para 5 10 Pulley or replace pulley and belt per para 5 49 or replace belt per para 5 34 YES Apply power and check for symptom Symptom present Return to normal operation Inspect spline shaft for damage Adjust per para 5 11 or replace per para 5 36 Apply power and check for symptom Symptom present 2 Return to normal operation TO SHEET 4 Figure 4 10 Paper Feeds Erratically Sheet 3 of 4 4 24 P3000 Troubleshooting FROM SHEET 3 Replace mechanism driver PCBA per para 5 21 Apply power and check for symptom Return to normal operation Install original mechanism driver PCBA per para 5 21 Replace controller PCBA per para 5 20 Apply power and check for symptom Symptom present Return normal operation Continue to troubleshoot using standard techniques If problem remains contact authorized distributor service representative Figure 4 10 Paper Feeds Erratically Sheet 4 of 4 P3000 Troubleshooting Check forms thick ness lever setting Paper drags NO YES Check platen gap per para 5 13 NO YES Symptom present Adjust gap per para 5 13 Apply power and check for symptom Symptom present Reposition lever as required Apply power and check for symptom Inspect paper ironer and hammer bank NO Ret
24. Install screw 8 terminal tab 9 and star washer 10 Install screws 6 and washer 7 Install two terminal connectors 5 Install nut 1 terminal lug 2 and star washer 3 Install circuit breaker per paragraph 5 47b Install EMI shield per paragraph 5 20b7 Install cabinet per 5 15b P3000 Corrective Maintenance Li ad O O gt N N Fi ae 3 2 NUT TERMINAL LUG STAR WASHER EMI SHIELD TERMINAL CONNECTOR 2 SCREW 2 WASHER 2 SCREW TERMINAL TAB STAR WASHER SCREW MOUNTING PLATE FILTER Figure 5 42 AC Input Filter Removal Installation P3000 Corrective Maintenance 5 49 Paper Feed Motor Pulley Figure 5 43 a Removal 1 Remove timing belt per paragraph 5 34a 2 Loosen two set screws 1 on motor pulley 2 3 Slide motor pulley 2 off shaft of motor 3 b Installation 1 Slide motor pulley 2 onto shaft of motor 3 2 Tighten two set screws 1 on motor pulley 2 3 Install timing belt per paragraph 5 34b Align pulley during belt installation per paragraph 5 10 P3000 Corrective Maintenance 5 89 SET SCREW 2 2 MOTOR PULLEY 3 MOTOR 1 Figure 5 43 Paper Feed Motor Pulley Removal Installation P3000 Corrective Maintenance 5 90 APPENDIX A ELECTRONIC DRAWINGS In accordance with Printronix policy schematic drawings are no longer provided in the Mainte
25. c Ribbon Driver The ribbon driver circuits Figure 2 12 drive the ribbon from one reel to the other as it passes between the hammer bank and the platen The direction of ribbon travel is re versed automatically as the end of ribbon is detected by sensors on the ribbon guide A metal strip at each end of the ribbon provides the end of ribbon indication The ribbon is driven by two dc motors in a servo circuit For either direction of travel one motor is the driven motor drawing the ribbon against resistance exerted by the other mo tor This system maintains constant motor speed and ribbon tension When the end of ribbon is detected the two motors exchange roles The ribbon is in motion only while printing is taking place This activity is controlled by the ribbon RIB and ribbon park RIB PARK signals from the MCU on the controller PCBA Whenever an end of ribbon sensor SWR RIB SWL is activated it establishes the opposite state of the cross coupled latch at the input of the ribbon driver circuit to turn on the related FET If for example the left hand sensor RIB SWL resets the latch FET 1 is turned off and FET 2 is turned on With FET 2 turned on the output to the left ribbon motor driver is increased considerably by a voltage divider network This connects the left ribbon motor as the higher torque motor with the right ribbon motor providing drag for ribbon tension When right end of ribbon is detected the la
26. 111980 001 14 SPRING LEFT LOWER 106710 002 15 SCREW 2 105728 004 16 PIVOT RETAINER 110181 001 17 SCREW 4 102786 614 18 CASTING BRACE 111576 001 111057 003 19 SHUTTLE 2e RR uere dea 111057 003 20 WEAR SADDLE 2 111906 001 21 CAP SCREW 2 101514 042 22 SHUTTLE SHAFT part of item 19 23 BASE CASTING 111663 001 P3000 Parts List TABLE B 1 PARTS LIST continued FIGURE AND TITLE ITEM NO NAME PART NO COMMENTS Figure 5 23 Hammer Bank Cable Assembly Removal Installation 1 CABLE ASSEMBLY 111070 001 2 SCREW iii Ry 101514 001 8 TERMINAL LUG E1 part of item 1 4 TERMINAL LUG E2 part of item 1 5 TERMINAL LUG part of item 1 6 TERMINAL LUG E4 part of item 1 7 TERMINAL LUG E5 part of item 1 8 TIE WRAP 3 101480 001 9 GUIDE LINEAR MOTOR 111186 001 10 SCREW sese Sane Ede pa 102786 604 11 GUIDE CABLE
27. INDEX Improper Horizontal Alignment Example Figure 4 63 Improper Horizontal or Vertical Alignment Figure 4 65 Improper Print Density Figure 4 62 Improper Print Density Example Figure 4 61 Improper Vertical Alignment Example Fig ure 4 64 Indicators on Both Control Panels Operate Improperly 4 11 Indicators Controls and 1 2 External Figure 1 5 Table 1 4 for Options Figure 1 9 Table 1 8 Internal Table 1 6 Input Filter Replacement AC 5 88 Figure 5 89 Inspection 3 1 Physical Table 3 2 Figure 5 43 Interior of Cabinet Cleaning 3 3 Interlock Cable Assembly Replacement 5 74 Figure 5 75 Internal Controls and Indicators Figure 1 7 Table 1 6 Internal Testing 4 1 Introduction Maintenance Overview 1 1 Ironer Replacement Paper 5 68 Figure 5 69 Isolation Fault 4 1 M Maintenance Checks and Service Preventive 3 1 Table 3 1 Corrective Introduction 5 1 Maintenance Overview Introduction 1 1 Maintenance Preventive General 3 1 Malfunction Symptom Index Table 4 4 Malfunctions Common Causes of 4 1 Mechanism Driver Block Diagram Figure 2 14 2 13 Replacement 5 37 Figure 5 35 Mechanism Printing 2 4 Figure 2 5 Missing Characters Example Figure 4 46 Missing Dots Example Figure 4 51 Motherboard PCBA Replacement 5 42 Figure 5 43 Motor Pulley Replacement Paper Feed 5 9
28. Return hammer bank to operating position Remove shipping bolts 3 Proceed to b below Fine Adjustment J WARNING JJ Shuttle assembly will be moving forcefully against bumpers dur ing adjustment Do not put fingers between shuttle and bumper Take care to grip only edge of bumper pad while rotating bumper assembly during adjustment Do not touch linear motor cable guides Set printer power to on Place printer offline On display control panel press DOWN PREV DOWN PREV DOWN NEXT P3000 Corrective Maintenance SCREW 2 SHUTTLE COVER SHIPPING BOLT 2 LOCKSCREW FRONT BUMPER LOCKSCREW REAR BUMPER BUMPER ADJUSTING TOOL BUMPER FRONT REBOUND PAD BUMPER REAR HAMMER BANK 1 2 3 4 5 6 7 8 9 0 Figure 5 4 Bumper Adjustment P3000 Corrective Maintenance 5 9 5 6 Bumpers continued b 6 7 Fine Adjustment continued Press R S Printer motion will start and display will show HAMMERBANK INDEX XXX MOTORBAR INDEX XXX Observe display f HAMMERBANK INDEX is not 40 2 a Loosen clamp screw 5 b Reposition rear bumper 9 until HAMMERBANK INDEX is 40 2 c Tighten clamp screw 5 Observe display If MOTORBAR INDEX is not 40 2 a Loosen clamp screw 4 I N b Reposition front bumper 7 until MOTORBAR INDEX is 40 c Tighten clamp screw 4 Press R S then CLEAR Install shuttle cover 2 Tighten two screws 1
29. Symptom NO present YES Return to Return to normal operation normal operation Continue to troubleshoot using standard techniques If Replace mechanism driver PCBA per para 5 21 problem remains contact authorized distributor service representative Apply power and check for symptom Figure 4 12 Set Top of Form Does not Operate 4 28 P3000 Troubleshooting Ribbon doesn t move at all Manually rotate left ribbon spool so as to unwind ribbon Check that right spool takes up slack in ribbon NO Slack removed Replace right drive motor per para 5 43 Apply power and check for symptom Manually rotate right ribbon spool so as to unwind ribbon Symptom NO present Check that left spool takes up slack Return to in ribbon normal operation Slack removed NO Replace left drive motor per para 5 43 Apply power and check for symptom NO Return to normal operation Symptom present 2 SHEET 2 Figure 4 13 Ribbon Does not Move at All Sheet 1 of 2 P3000 Troubleshooting 4 29 FROM SHEET 1 Check that ribbon motor connectors are connected to motherboard PCBA Symptom present NO Return to normal operation YES dE Plug in connectors Install original controller PCBA per YES para 5 20 Replace mechanism driver Return to Replace PCBA per normal
30. 1 COVER 9 SLOTS FRONT 2 2 FORMS THICKNESS LEVER 10 SLOTS SIDE 2 3 SPOOL LATCH 2 11 TABS SIDE 2 4 SPOOL 2 12 SCREW BUTTON HEAD 6 5 SPOOL HUB 2 13 LOCKNUT 6 6 SCREW 2 14 PAPER SCALE 7 SHUTTLE COVER 8 TABS REAR 2 Figure 5 19 Shuttle Cover and Paper Scale Removal Installation P3000 Corrective Maintenance 5 41 5 24 Paper Scale Figure 5 19 a T9 Removal Remove shuttle cover per paragraph 5 23a Remove six button head screws 12 and locknuts 13 Separate paper scale 14 from shuttle cover 7 Installation Place paper scale 14 on shuttle cover 7 Install six button head screws 12 and locknuts 13 Install shuttle cover per paragraph 5 23b Adjust paper scale if required per paragraph 5 3 5 25 Motherboard PCBA Figure 5 20 Po o4 Removal Remove controller mechanism driver and power supply PCBAs per paragraphs 5 20a 21a and 22a Disconnect all connectors 1 from motherboard PCBA 2 Remove ten screws 3 and washers 4 Separate motherboard PCBA 2 and insulator 5 from base 6 Installation Place motherboard board 2 and insulator 5 in base 6 Install ten screws 3 and washers 4 Connect nine connectors 1 to motherboard PCBA 2 Install controller mechanism driver and power supply PCBAs per paragraphs 5 20b 21b and 22b P3000 Corrective Maintenance MOTHERBOARD PCBA CONNECT
31. 5 7 Stroke Timing NOTE Stroke timing should be checked and adjusted in conjunction with bumper adjustment 5 6 and hammer phasing 5 8 On display control panel press DOWN PREV DOWN PREV and DOWN Stroke timing is defined as half of period of shuttle movement When display indi cates STROKE TIME press R S once Shuttle motion will begin and STROKE TIME will be displayed Observe display a If it indicates 25 0 0 2 go to step 4 b If not readjust bumpers by selecting a new rebound rate Values less than 25 0 will decrease bumper adjustment and values greater will increase it Press R S switch Shuttle motion will stop P3000 Corrective Maintenance 5 8 Hammer Phasing NOTE Hammer phasing should be checked and adjusted in conjunction with bumper adjustment 5 6 and stroke timing 5 7 and must be repeated for each print mode It must be checked and adjusted if necessary when control ler or DCU PROMS are replaced or if display shows FACTORY PARAME TER LOADED 1 On display control panel Press DOWN PREV DOWN PREV DOWN and PREV 2 Press R S Printing of all H s will begin and current phasing index value will appear on the display Index range is between 99 and 99 3 Observe print quality Use NEXT or PREV to change phasing value printed at be ginning of each line When acceptable print is obtained press R S to stop the text and store the phasing value selected R S may a
32. Characters Missing Consistently Figure 4 47 Characters Missing Randomly Figure 4 50 Checks and Service Preventive Mainte nance 3 1 Table 3 1 Circuit Breaker Replacement 5 86 Figure 5 87 Cleaning 3 2 Exterior of Cabinet 3 2 Fan 3 6 Figure 3 8 Hammer Bank Assembly 3 4 Figure 3 5 Interior of Cabinet 3 3 Figure 3 3 Paper Ironer Figure 3 7 Coil Replacement Hammer 5 52 Figure 5 53 Common Causes of Malfunctions 4 1 Compacted Print Figure 4 69 Compacted Print Example Figure 4 68 Consistent Dropout of Dots Figure 4 53 Control Panel Cable Replacement Figure 5 33 Cable Replacement 5 32 Display Replacement 5 30 Replacement 5 26 5 27 Display Figure 5 31 Controller Block Diagram Figure 2 12 PCBA 2 11 Replacement 5 34 Figure 5 35 PROM Locations Figure 5 36 Controls and Indicators 1 2 External Figure 1 5 Table 1 4 for 3287 Option Figure 1 9 Table 1 8 Internal Figure 1 7 Table 1 6 Corrective Maintenance Introduction 5 1 Cover Replacement 5 28 Figure 5 29 Cover Replacement Shuttle 5 40 Figure 5 41 D Description Printer 1 1 Digital Display Operates Improperly Fig ure 4 13 Display Control Panel Replacement 5 30 Figure 5 31 Does Not Print Under Computer Control Figure 4 74 Dot Matrices vs Speed Density Table 2 9 Dot Patterns By Mode Typical
33. N Figure 5 12 Control Panel Removal Installation P3000 Corrective Maintenance 5 27 5 17 Cover Figure 5 13 a Removal Disconnect power cord 1 and open cover 2 Remove four Phillips head screws 3 and lockwashers 4 Separate cover 2 from hinges 5 Installation Position cover 2 on hinges 5 Install four Phillips head screws 3 and lockwashers 4 Close cover 2 to check alignment If misaligned loosen four screws 3 reposition cover 2 and tighten screws Connect power cord 1 P3000 Corrective Maintenance PHILLIPS HEAD SCREW 4 LOCKWASHER 4 POWER CORD HINGE 2 COVER 1 3 4 5 Figure 5 13 Cover Removal Installation 5 29 P3000 Corrective Maintenance 5 18 Display Control Panel Figure 5 14 a Removal 1 Disconnect power cord 1 Open cover 2 Loosen screw 3 Separate display control panel 4 from cabinet 5 gt d DD Disconnect connector P1 6 b Installation 1 Connect connector PI 6 Place display control panel 4 on cabinet 5 Tighten screw 3 gt H N Close cover 2 Connect power cord 1 Check operation 5 30 P3000 Corrective Maintenance POWER CORD COVER SCREW DISPLAY CONTROL PANEL CABINET CONNECTOR P1 Figure 5 14 Display Control Panel Removal Installation P3000 Corrective Maintenance 5 19 Control Panel Cable Figure 5 15 a O e J XA d
34. Return to normal operation YES Apply power and check for symptom Replace controller PCBA per para 5 20 Return to normal operation Apply power and check for symptom YES Continue to troubleshoot using standard techniques If problem remains contact authorized distributor Service representative Figure 4 7 CHECK Indicator Flashes Display Shows FAULT CONDITION PLATEN OPEN Sheet 2 of 2 P3000 Troubleshooting 4 17 CHECK Indicator on continuously display shows FAULT CONDITON DCU RAM FONT PROM or MCU RAM Replace controller PCBA per para 5 20 Apply power and check for symptom Symptom present Continue to troubleshoot using standard techniques If problem remains contact authorized distributor service representative Return to normal operation Figure 4 8 CHECK Indicator on Continuously Display Shows FAULT CONDITION DCU RAM FONT PROM or MCU RAM P3000 Troubleshooting Paper doesn t feed at all Check forms thick ness lever setting Check for paper jam NO Paper NO Clear jam YES Reposition forms x thickness lever as required YES Return to Inspect Paper normal operation feed timing Apply power belt and check for symptom Belt NO OK NO Adjust belt per YES para 5 9 Return to or replace per normal operation para 5 34 Apply power and check for symptom NO Re
35. 5 44 Figure 5 45 Interconnection PCBA 5 42 Figure 5 43 Interlock Switch 5 84 Figure 5 85 Mechanism Driver PCBA 5 37 Figure 5 35 Paper Scale 5 42 Paper Detect Switch 5 76 5 77 Paper Drive Motor 5 62 Figure 5 63 Paper Feed Motor Pulley 5 92 Figure 5 93 Paper Feed Timing Belt 5 60 Paper Ironer 5 68 Figure 5 69 Paper Scale Figure 5 41 Platen 5 70 Figure 5 71 Platen Open Switch 5 74 Figure 5 75 Power Supply PCBA 5 38 Figure 5 39 Ribbon Drive 5 78 Ribbon Drive Motor Figure 5 79 Ribbon Guide 5 80 Figure 5 81 Shuttle Assembly 5 46 Figure 5 47 Shuttle Cover 5 40 Figure 5 41 Spline Shaft 5 64 Figure 5 65 Support Shaft 5 66 Figure 5 67 Tractor 5 68 Retensioning Hammer Spring 5 6 Figure 5 7 Ribbon Does Not Change Direction at End Figure 4 34 Ribbon Does Not Run Smoothly Figure 4 32 Ribbon Does not Move at All Figure 4 29 Ribbon Drive Motor Replacement 5 78 Figure 5 79 Ribbon Driver Circuit 2 18 Ribbon Folds Over Figure 4 31 I 5 Ribbon Guide Alignment 5 22 Figure 5 23 Replacement 5 80 Figure 5 81 S Scale Replacement Paper 5 42 Figure 5 41 Service Checks and Preventive Mainte nance 3 1 Table 3 1 Shaft Replacement Spline 5 64 Figure 5 65 Support 5 66 Figure 5 67 Shuttle Replacement 5 46 Figure 5 47 Shuttle
36. HAMMER SERIAL DATA PAPER MOTION DETECTOR HOST N COMPUTER our HOST INTERFACE PAPER CIRCUITS STEPPER RIBBON SW GENERAL MECHANISM MOTION PANEL pisp PANEL INTERFACE DATA CONTROL PURPOSE CONTROL CONTROL CIRCUITS NIT INTERFACE NIT si FIRE SIGNAL OPEN INTERFACE PAPER CIRCUITS DIRECTION OUT 41 PDM POWER FAULT 44 DETECTION TIMING FENCE 4 9 MHZ SYSTEM CLOCK CLOCK GENERATOR 4 MHZ SYSTEM CLOCK Figure 2 9 Controller Block Diagram 2 12 P3000 Principles of Operation 2 5 Controller PCBA continuea c Mechanism Control Unit MCU The MCU controls the printing mechanism and the paper transport via the mechanism driver PCBA and monitors the shuttle direction and speed 1 Paper Advance Paper advance is controlled by paper feed pulses PF1 PF2 NRUNI and NRUN2 generated in the MCU then sent to the mechanism driver PCBA which supplies power to the paper feed motor Paper drive speed is controlled by three functions As each motion command in the printer buffer is encountered a counter is loaded with a count value proportional to the amount of paper motion identified by that command A particular modulus of count is used to determine the spacing between dot rows The spacing depends on the mode in effect Through the logical interaction of these functions paper is moved The motion is either intermittent or steady with appropriate response to any required change
37. P3000 Troubleshooting Dots misplaced Align hammers per para 5 4 Apply power and check for symptom NO Return to normal operation YES Adjust platen gap per para 5 13 Apply power and check for symptom Symptom present NO Return to normal operation YES Perform hammer phasing adjustment per para 5 8 Check for symptom Symptom present N Return to normal operation YES Replace encoder per para 5 31 Apply power and check for symptom Symptom present NO Return to normal operation YES TO SHEET 2 Figure 4 31 Dots Misplaced Sheet 1 of 2 P3000 Troubleshooting FROM SHEET 1 Refer to schematics in Appendix B using scope check for noise on power supply outputs from damaged or improper grounding Visually inspect ground points for damage NO Grounding OK YES Restore grounding Apply power and check for symptom Symptom NO present Replace controller PCBA per para 5 20 Return to normal operation Apply power and check for symptom Symptom present NO Return to normal operation YES Install original controller PCBA per para 5 20 Replace mechanism driver PCBA per para 5 21 Apply power and check for symptom NO Return to normal operation YES Continue to troubleshoot using standard techniq
38. RESTRAINT SPRING LEFT SIDE PLATE SPRING LINK LEFT BEARING LEFT ADJUSTMENT BRACKET RIGHT ADJUSTMENT BRACKET WASHER 2 WEAR SADDLE 2 PAPER IRONER HAMMER BANK COVER SHUTTLE COVER SCREW 2 O O QO N O O Db ON N PO PO IN HHA 2 O Q ON O O O NYO gt Figure 5 34 Platen Removal Installation P3000 Corrective Maintenance 5 71 5 40 Platen continuea b 10 11 12 13 14 15 16 17 18 Installation Slide left platen adjustment bracket 22 and right platen adjustment bracket 23 and two washers 24 onto shaft of platen 6 Insert left end of platen 6 into left side plate 19 Slide platen to left then rotate right side into slot in right side plate 8 Slide spring link 20 with bearing 21 onto shaft of platen 6 Attach spring 18 to left side plate 19 Slip restraint 17 onto shaft of platen 6 Install spacer 15 and screw 14 Tighten restraint screw 16 Slide platen open switch bracket 13 onto shaft of platen 6 Install screw 11 and washer 12 Slide spring link 9 with bearing 10 onto shaft of platen 6 Connect spring 7 to right side plate 8 Slip forms thickness lever 5 onto shaft of platen 6 Replace ironer mounting plate 2 Make sure hook over platen shaft is betwen two washers 24 Install three screws 1 Install paper ironer 26
39. UNDER COVER AC POWER CORD CABINET COVER FORMS THICKNESS LEVER LOCKING LATCH 2 RIBBON SPOOL 2 RIBBON HUB 2 TRACTOR 2 HAMMER BANK BASE PAN SPLINE SHAFT RIBBON GUIDE Figure 3 1 Cleaning Interior of Cabinet P3000 Preventive Maintenance 3 3 3 4 Cleaning continuea 10 11 Hammer Bank Assembly Figure 3 2 Loosen two captive screws 1 Grasp shuttle cover 2 at both ends Lift upward to free front tabs then remove Unlock tractors 3 and move outward to sides Lift up on shuttle lock knob 4 and pull toward front of printer When shuttle assembly 5 has rotated 90 degrees to service position release knob 4 Remove paper ironer Fig 3 3 1 by applying pressure at its edges toward rear of printer and lifting Wipe with alcohol dampened cloth Press ironer 1 back into place CAUTION J Shuttle 5 is magnetized This may cause some difficulty in performing the next step Be careful not to bend cover 6 Carefully lift ends of hammer bank cover Fig 3 2 6 from roll pins 7 Pivot cover 6 onto its rear edge to about 45 degrees then remove Moisten clean soft cloth with alcohol Wipe cover assembly to remove lint ink and paper residue Also clean holes between strips which make up cover 6 CAUTION J Use of excessive force could disturb alignment of hammers or chip them Using stiff non metallic brush such as a toothbrush and alcohol brush tips 8 to remove
40. by aligning with slots in mounting plate 2 and pushing down Remove hammer bank cover 27 Adjust platen angle per paragraph 5 12 Adjust platen gap per paragraph 5 13 4 through 11 Install shuttle cover 28 by engaging tabs then pressing down Tighten two screws 29 Install paper apply power and verify print quality by printing repeating patterns Install cabinet per paragraph 5 15b 5 41 Interlock Cable Assembly Figure 5 35 Removal Remove controller mechanism driver and power supply PCBAs per paragraphs 5 20a 21a and 22a Disconnect P22 1 from motherboard PCBA 2 Move forms thickness lever 3 to fully closed position Remove two screws 4 P3000 Corrective Maintenance Separate platen open switch 5 from mounting bracket 6 Loosen two screws 7 Grasp shuttle cover 8 at both ends Lift up and out Remove three nuts 9 washers 10 and shock mount spacers 11 Raise machined mechanics base 12 to gain access to interlock switch 13 I CON LA Remove hex screw 14 and lift switch 13 off pin 15 10 Remove spot ties as necessary and separate switches 5 and 13 and attached cable from mechanics base 12 b Installation Place switches 5 and 13 and attached cable in position in mechanics base 12 Position interlock switch 13 on underside of mechanics base 12 on pin 15 Install hex screw 14 Place switch 5 on mounting bracket 6 Insta
41. by sensing the presence of 5 Vdc when power is turned on initially The 5 Vdc charges an RC network which then turns the circuit off NMC high NMC is used to clear the microprocessors on the controller PCBA to establish the initial program load state f Encoder Circuit The encoder circuit accepts the analog output of the encoder preamplifier located on the shuttle The function of this circuit is to shape the analog input ENC to digital pulses FENCE at the output The output is applied to the controller PCBA for timing compu tations which are used to maintain shuttle and print control g Power Supplies The 12 Vdc and 12 Vdc power supplies are located on the mechanism driver PCBA The 12 Vdc supply is derived from the 30 Vdc input to and the 12 Vdc supply is derived from the 16 Vdc input to provide 12 Vdc at the output 2 7 Power Supply PCBA The power supply PCBA is a switching power supply Its regulated outputs are 5 Vdc 16 Vdc and 30 Vdc While all outputs are supplied to the mechanism driver PCBA only 5 Vdc is supplied to the controller PCBA the control panel PCBAs and the en coder PCBA P3000 Principles of Operation CHAPTER 3 PREVENTIVE MAINTENANCE General This chapter provides instructions necessary to maintain the printer in operating con dition Preventive Maintenance Checks and Service PMCS Printer PMCS are listed in Table 3 1 J WARNING J Remove power before per
42. controller PCBA per para 5 20 Replace encoder per para 5 31 Apply power and check for symptom Symptom present Return normal operation Replace shuttle assembly er 5 27 Apply power and check for symptom Return to normal operation Symptom present Continue to troubleshoot using standard techniques If problem remains contact authorized distributor Service representative Figure 4 19 Shuttle Moves Erratically Sheet 2 of 2 4 42 P3000 Troubleshooting Shuttle movement produces knocking sound Check and adjust platen gap per para 5 13 Apply power and check for symptom Symptom present Return to normal operation Check bumpers for damage Bumpers Replace OK umpers per para 5 33 YES Return to normal operation Adjust bumpers per para 5 6 Return normal operation Figure 4 20 Shuttle Movement Produces Knocking Sound P3000 Troubleshooting 4 43 Printer does not Apply power print at all and check for symptom Check and adjust platen gap per par 5 13 Symptom NO Return to Apply power present normal operation and check for symptom YES Symptom NO Return to Install original present normal operation controller PCBA per para 5 20 YES Replace mechanism driver PCBA per para 5 21 Replace power supply PCBA per Apply pow
43. with bearing 3 onto spline shaft 2 Attach spring 4 between left side plate 5 and spring link 6 Install grip ring 1 on spline shaft 2 Install belt 11 Set belt tension per paragraph 5 9 3 and 4 Position belt shield 9 on right side plate 10 Install two screws 7 and washers 8 Perform spline shaft skew adjustment per paragraph 5 11 Install cabinet per paragraph 5 15b P3000 Corrective Maintenance GRIP RING SPLINE SHAFT BEARING SPRING LEFT SIDE PLATE SPRING LINK SCREW 2 WASHER 2 BELT SHIELD 10 RIGHT SIDE PLATE 9 11 BELT 12 TRACTOR LEFT 13 TRACTOR RIGHT 14 SCREW 15 BEARING CLAMP 16 SPLINE SHAFT KNOB Q N Figure 5 31 Spline Shaft Removal Installation P3000 Corrective Maintenance 5 65 5 37 Support Shaft Figure 5 32 qe e Removal Remove cabinet per paragraph 5 15a Unlock tractors 1 Slide to far left Remove E ring 2 Slide assembly consisting of support shaft 3 two spring washers 4 bushing 5 adjusting knob 6 washer 7 and screw 8 to left out of tractors 1 and left side plate 9 Installation Slide assembly consisting of support shaft 3 two spring washers 4 bushing 5 adjust knob 6 washer 7 and screw 8 into left side plate 9 through tractors 1 and right side plate 10 Install E ring 2 Position tractors 1 as desired Install cabinet per
44. 1 Display Panel UP switch NEXT switch R S switch F L switch MODE switch ENTER switch PREV switch DOWN switch MECHANICAL 10 11 Tractors Vertical Alignment Knob Spline Shaft Knob Forms Thickness Platen Lever Top of Form Pointer indicator on tractor doors Forms Thickness Indicator Horizontal Vernier Adjustment Knob Displays message for print mode form length fault conditions test patterns or configuration options For details refer to User s Reference Manual Steps display up to next menu Used in conjunction with PREV switch to display in dividual configuration parameters and the current values from within various menus Starts or stops certain printer functions Used to select form length Selects type of character print or density of graphic plot For details on how to select mode refer to Operator s Guide Used to enter a displayed value into memory Used in conjunction with NEXT switch to display in dividual configuration parameters and the current values from within various menus Steps display down to next menu Provide horizontal positioning of forms Manually advances forms Opens paper path for insertion removal of Adjusts platen opening to allow for paper thickness or multiple copies Provides reference when setting top of form after reloading paper Indicates setting of platen lever Provides fine horizontal positionin
45. 111463 002 Figure 5 39 Blower Assembly Removal Installation 1 SCREW 2 140058 001 2 SHUTTLE COVER 111790 01 3 CONNECTOR P27 part of item 7 4 MOTHERBOARD PCBA 111499 001 5 BASE CASTING MECH 111663 001 6 SCREW 2 mm 105728 004 7 BLOWER ASSEMBLY 111464 01 Figure 5 40 Fan Removal Installation 1 SCREW 3 n 102786 614 2 FAN ASSEMBLY 110454 001 3 MOUNT part of 111428 001 Figure 5 41 Circuit Breaker Removal Installation 1 LEAD CONNECTORS n a 2 SPRING CLIP 4 part of item 3 3 CIRCUIT BREAKER 105705 001 4 MOUNTING PLATE 111423 001 P3000 Parts List TABLE B 1 PARTS LIST continued FIGURE AND TITLE PART NO COMMENTS ITEM NO NAME Figure 5 42 AC Input Filter Removal Installation cide sure n a 2 TERMINAL LUG part of item 13 3 STAR n a 4 EMI SHIELD BASE 111428 001 5 TERMINAL CONNECTOR 2
46. 5 70 Figure 5 71 Power Supply PCBA 2 20 Replacement 5 38 Figure 5 39 PROM Locations Controller 5 36 Preventive Maintenance Checks and Service 3 1 Table 3 1 General 3 1 Principles of Operation General 2 1 P3000 Index Print Hammer Action Figure 2 6 Printer Description 1 1 Printer Does Not Print at All Figure 4 44 Printer Fails to Print Only When Controlled by Host Computer Figure 4 45 Printer Functional Block Diagram 2 2 Printer with Pedestal 1 3 Printing Mechanism 2 4 Figure 2 5 Pulley Alignment Paper Drive Motor 5 14 Figure 5 15 Pulley Replacement Paper Feed Motor 5 90 Figure 5 91 R Random Dropout of Dots Figure 4 54 Recommended Tools Test Equipment and Supplies Table 5 2 Replacement AC Input Filter 5 90 Figure 5 91 Blower Assembly 5 82 Figure 5 83 Bumper 5 58 Figure 5 59 Cabinet 5 24 Cabinet Figure 5 25 Circuit Breaker 5 88 Figure 5 89 Control Panel 5 26 5 27 Cable Figure 5 33 Control Panel Cable 5 32 Controller PCBA Figure 5 35 Controller PCBA 5 34 Cover 5 28 Figure 5 29 Display Control Panel 5 30 Figure 5 31 Encoder 5 54 Figure 5 55 PCBA 5 56 Figure 5 57 Fan 5 86 Figure 5 87 Hammer Bank Cable Assembly 5 48 Figure 5 49 P3000 Index INDEX Hammer Coil 5 52 5 53 Hammer Spring 5 50 Figure 5 51 I O Cable
47. 5 20 Motherboard PCBA Removal Installation 1 CONNECTORS part of other assys 2 MOTHERBOARD PCBA 111499 001 3 SCREW 10 cu ee petro Aa 102786 406 4 WASHER 10 101526 001 5 INSULATOR iore ES 112010 001 6 BASE nbn erp emere epar 111365 003 112083 003 Figure 5 21 I O Cable Removal Installation 1 SCREW 2 ritorio Sta Ege dia 102786 604 2 MOUNTING PLATE part of item 3 3 CABLE 111486 001 Figure 5 22 Shuttle Assembly Removal Installation 1 SCREW 2 rela 140058 001 2 SHUTTLE COVER 111790 01 3 CONNECTOR P21 part of item 2 4 MOTHERBOARD PCBA 111499 001 5 SCREW HEX 2 102786 408 6 WASHER 2 101526 003 7 CONNECTOR J11 part of item 19 8 CONNECTOR J12 part of item 19 d ORAE NR DE UR mapa 111365 003 112083 003 10 SCREW 105728 004 11 CABLE ANCHOR BRACKET part of item 19 12 SPRING LEFT UPPER 111980 001 13 SPRING
48. 69 GA 6B OA 1 abcdefghijkl 5D 5E 5F 60 61 62 63 64 65 66 67 68 69 GA 6B 6C OA abcdefghijklm SF 60 61 62 63 64 65 66 67 68 69 GA GB 6C 6D OA _ abcdefghi jkimn 5F 60 61 62 63 64 65 66 67 68 69 GA 6 6D 6E OA abcdefghijkimno 60 61 62 63 64 65 66 67 68 69 6A 6B 6C 6D 6E 6F OA abcdefghi jk lmnop 61 62 63 64 65 66 67 68 69 GA 6B 6 60 6E 6F 70 0A bcderghijkImnopq 62 63 64 65 66 67 68 69 GA 6B 6C 6D GE 6F 70 71 OA cdefghi jk1mnopqr 63 64 65 66 67 68 69 6 6B 6C 6D GE GF 70 71 72 OA defghi jklmnopqrs 64 65 66 57 68 69 6A 6B 6C GD GE GF 70 71 72 73 OA efghijkimnopqrst 65 66 67 68 69 GA 6B 6C 6D GE GF 70 71 72 73 74 OA Fghijkimnoparstu 66 67 68 69 GA 6B 6C 6D GE 6F 70 71 72 73 74 75 OA ghijkilmnopqrstuv 67 68 69 6B 6C 60 GE 6F 70 71 72 73 74 75 76 OA hi jkImnopqrstuvw 68 69 6A 6B 6C 6D 6E 6F 70 71 72 73 74 75 76 77 0A i jKImnopqrstuvwx 69 6A 6B 6C 6D GE 6F 70 71 72 73 74 75 76 77 78 0A jkimnopqrstuvwxy 6B 6C 6D 6F 70 71 72 73 74 75 76 77 78 79 OA k1mnopqrstuvwxyz 6B 6C 6D 6E 6F 70 71 72 73 74 75 76 77 78 79 7A OA imnopqrstuvwxyz 6C 6D 6E 6F 70 71 72 73 74 75 76 77 78 79 7A 7B mnopqrstuvwxyzi 60 GE 6F 70 71 72 73 74 75 76 77 78 79 7A 7B 7 Figure 4 42 Expected Data Stream Printout P3000 Troubleshooting 4 73 Blower motor not operating Check to see if blower is rotating backward NO Rotating backward Replace blower motor per para 5 45 Apply power and check for
49. ASSY 111091 001 CONNECTOR P31 part of item 4 POWER CORD 102512 001 COVER 111702 001 PHILLIPS HEAD SCREW 4 103677 023 LOCKWASHER 4 101527 002 HINGE 2 111857 001 amp 002 Figure 5 14 Display Control Panel Removal Installation 1 2 3 4 5 6 POWER CORD 102512 001 COVER aaa Sa 111702 002 SCREW 140059 001 DISPLAY CONTROL PANEL 111485 001 CABINET suas wa paq awa nace R 111091 001 CONNECTOR P1 part of item 4 P3000 Parts List TABLE B 1 PARTS LIST continued FIGURE AND TITLE PART NO COMMENTS ITEM NO NAME Figure 5 15 Control Panel Cable Removal Installation 1 CONNECTOR P4 part item 2 2 DISPLAY CONTROL PANEL 111485 001 3 CONNECTOR P31 part of item 4 4 CONTROL PANEL 111421 001 5 SCREW HEX 2 102786 408 6 WASHER 2 101526 005 7 CONNECTOR J3 part of item 11 8 SCREW 10
50. Arrangement Cross Section Ham mer and Figure 2 6 Shuttle Cover Replacement 5 40 Figure 5 41 Shuttle Does Not Move at All Figure 4 36 Shuttle Jams or Moves too Slowly Figure 4 38 Shuttle Movement Produces Knocking Sound Figure 4 43 Shuttle Moves Erratically Figure 4 41 Skew Adjustment Spline Shaft 5 16 Figure 5 17 Speed Density Dot Matrices vs Table 2 9 Spline Shaft Replacement 5 64 Figure 5 65 Skew Adjustment Figure 5 16 Skew Adjustment 5 16 Standard Character Formation Figure 2 7 Standard Features 1 1 Stroke Timing Adjustment 5 10 Supplies Recommended Tools Test Equipment and Table 5 2 Tools Test Equipment and 5 2 Supplemental Tests Table 4 3 Support Shaft Replacement 5 66 Figure 5 67 Switches or Indicators Operate Improperly on Front Control Panel Only Figure 4 12 Symptom Index Malfunction Table 4 4 Tension Adjustment Timing Belt 5 12 Tension Check Paper Feed Belt 3 9 Figure 3 10 Test Equipment and Supplies Recom mended Tools Table 5 2 Test Equipment and Supplies Tools 5 2 Testing Internal 4 1 Tests Supplemental Table 4 3 Timing Stroke Adjustment 5 10 Timing Belt Adjustment Figure 5 13 Replacement Paper Feed 5 60 Timing Belt Replacement Paper Feed Fig ure 5 61 Tools Test Equipment and Supplies 5 2 Recommended Table 5 2 Top of
51. Character Figure 2 10 Dots Misplaced Figure 4 59 Drive Motor Replacement Paper Figure 5 63 Paper Feed 5 62 Ribbon 5 78 Figure 5 79 Driver PCBA Mechanism 2 13 E Elements Functional 2 1 Encoder PCBA Replacement 5 56 Figure 5 57 Replacement 5 54 Figure 5 55 Expected Data Stream Printout Figure 4 73 Exterior of Cabinet Cleaning 3 2 External Controls and Indicators 1 5 Table 1 4 F Fan Cleaning 3 6 Figure 3 8 Replacement 5 84 Figure 5 85 Fault Codes Table 4 2 P3000 Index Isolation 4 1 Features Optional 1 2 Standard 1 1 Feed Motor Pulley Replacement Paper Figure 5 91 Pulley Replacement Paper 5 90 Filter Replacement AC Input 5 88 Figure 5 89 Functional Elements 2 1 G Garbled Print and or Incorrect Font Figure 4 71 Guide Replacement Ribbon 5 80 Figure 5 81 H Hammer Action Print Figure 2 6 and Shuttle Arrangement Cross Section Figure 2 6 Phasing Adjustment 5 11 Hammer Bank Assembly Cleaning 3 4 Figure 3 5 Cable Assembly Replacement 5 48 Figure 5 49 Logic Drivers and Waveforms Figure 2 16 Hammer Coil Replacement 5 52 Figure 5 53 Hammer Spring Replacement 5 50 Figure 5 51 Retensioning 5 6 Figure 5 7 Hammer Tip Alignment Figure 5 5 Alignment and Adjustment 5 3 1 0 Cable Replacement 5 44 Figure 5 45 P3000 Index
52. Form Does not Operate Figure 4 28 Tractor Replacement 5 68 Transport Paper 2 1 Figure 2 3 Troubleshooting General 4 1 Typical Character Dot Patterns By Mode Figure 2 10 P3000 Index PRINTRONIX 17500 CARTWRIGHT ROAD P O Box 19559 IRVINE CA 92713 9559 PHONE 714 863 1900 Fax 714 660 8682 PRINTRONIX NEDERLAND BV P O Box 163 NIEUWEWEG 283 NL 6600 Ap 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 111839 001C
53. Open cover 2 Loosen screws 3 Set control panel 4 and display control panel 5 inside cabinet Loosen two Phillips head screws 6 Loosen two Phillips head screws 7 with finishing washers 8 Close cover 2 Lift cabinet 9 off base 10 Installation CAUTION J Take care during the following procedure to avoid pinching or creasing front panel ribbon cable Place cabinet 9 on base 10 Tighten two Phillips head screws 7 Tighten two phillips head screws 3 Install control panel 4 display control panel 5 and tighten two screws 3 Close cover 2 Connect power cord 1 P3000 Corrective Maintenance POWER CORD 6 SCREW PHILLIPS 2 COVER 7 SCREW PHILLIPS 2 SCREW 2 8 WASHER FINISHING 2 CONTROL PANEL 9 CABINET DISPLAY CONTROL PANEL 10 BASE Figure 5 11 Cabinet Removal Installation P3000 Corrective Maintenance 5 16 Control Panel Figure 5 12 a po m Removal Disconnect power cord 1 and open cover 2 Loosen screw 3 Separate control panel 4 from cabinet 5 Disconnect P31 6 inside right side of printer Installation Connect P31 6 Place control panel 4 in cabinet 5 Tighten screw 3 Close cover 2 Connect power cord 1 Check operation per Operator s Guide P3000 Corrective Maintenance POWER COVER SCREW CONTROL PANEL CABINET CONNECTOR P31 r
54. PLATE 10 SCREW 4 11 12 13 14 15 16 BARRIER PANEL LEFT SIDE PLATE SCREW 2 RIGHT SIDE PLATE SCREW 2 SPLINE PULLEY 105728 011 101526 037 110473 001 111824 001 102787 108 110353 003 105808 001 part of 111298 001 part of item 6 part of item 2 111430 001 part of item 16 111687 001 111428 001 105728 011 101526 037 110473 001 111824 001 105728 001 111381 001 110129 001 105728 011 102789 100 105808 001 110353 003 P3000 Parts List TABLE B 1 PARTS LIST continued FIGURE AND TITLE PART NO COMMENTS ITEM NO NAME Figure 5 31 Spline Shaft Removal Installation 1 GRIPRING 101551 002 2 SPLINE SHAFT ASSY 111298 01 3 BEARING n 101309 002 4 SPRING esee teenie names PER SEES part of item 6 5 LEFT SIDE PLATE 110129 01 6 SPRING LINK 105741 003 7 SCREW 2 dass 105728 011 8 WASHER 2 ele E EE 101526 036 9 SHIELD baku 110473 001 10
55. RIGHT SIDE PLATE 111824 001 11 BELT iii akan 105808 001 12 TRACTOR LEFT 105786 102 13 TRACTOR RIGHT 105786 101 14 SCREW Lco eere ege PUR REP I RAD e 105728 001 15 BEARING CLAMP 110281 001 16 SPLINE SHAFT KNOB part of item 2 Figure 5 32 Support Shaft Removal Installation 1 TRACTOR 105786 001 2 E RING igen ee ede nk one adha satu pas 105678 003 3 SUPPORT SHAFT 111685 001 4 SPRING WASHER 2 101552 004 5 BUSHING iii Mans 111684 001 6 ADJUST 111822 001 7 WASHER iina m 101526 005 8 SCREW MEME 101514 036 9 LEFT SIDE PLATE 110129 001 10 RIGHT SIDE PLATE 111824 001 Figure 5 33 Paper Ironer Removal Installation 1 COVER oerte deb Re e paged wees 111702 001 2 FORMS THICKNESS LEVER 111724 001 3 SCREW 2 Locis bed ran bep Temi ia 140058 001 4 SHUTTLE COVER 111790 001 5 SHUTTLE ASSY 111057 001 amp 003 6 PAPER IRONER 110408 001 Figure 5 34 Platen Removal Installation 1 SCREW 3 105
56. Ribbon Folds Over P3000 Troubleshooting Ribbon does not run smoothly Adjust platen gap per para 5 13 Apply power and check for symptom Symptom NO present YES Return to normal operation Check to see if printer needs cleaning NO YES Clean printer per para 3 4 Apply power E Check for symptom Symptom NO present Inspect hammer bank cover for damage and improper installation Return to X normal operation NO Replace cover per YES para 3 4c 10 amp 11 or install properly per para PPS Apply power and check for symptom Symptom NO present Return to normal operation Check for non retracting hammers TO SHEET 2 Figure 4 15 Ribbon Does Not Run Smoothly Sheet 1 of 2 P3000 Troubleshooting FROM SHEET 1 NO NO YES Replace guides per para 5 44 4 Apply power Check for non and check for retracting hammers symptom Symptom present NO Return to normal operation Run print sample and check for Check For Dragging Hammer non retraction Retension hammer toward pole pin per para 5 5 Replace hammer per para 5 29 Check for original symptom Symptom NO present R Return to normal operation Check ribbon guides for damage Figure 4 15 Ribbon Does Not Run Smoothly Sheet 2 of 2 P3000 Troubleshooting 4 33
57. at all Remove shuttle cover and check for retaining screws Replace mechanism driver PCBA per Screws NO para 5 21 removed Remove screws Apply power andi check for YES symptom Manually move Return to shuttle and check normal operation for binding S Symptom NO present Return to Determine Install original YES source of binding mechanism driver and repair PCBA per para 5 21 Apply power and check for Replace symptom controller PCBA per para 5 20 Symptom NO Apply power present and check for symptom Return 1 normal operation Symptom NO present Return to Install original controller NO Repair or reconnect PCBA per as required para 5 20 YES Return to normal operation TO SHEET 2 Inspect four wires to linear motor coils for damage or or incorrect connection Figure 4 17 Shuttle Does Not Move at All Sheet 1 of 2 4 36 P3000 Troubleshooting P3000 Troubleshooting FROM SHEET 1 Check linear motor coils for open circuit Replace shuttle assembly per para 5 27 Apply power and check for symptom Symptom present Return to X normal operation YES Continue to troubleshoot using standard techniques If problem remains contact authorized distributor Service representative Figure 4 17 Shuttle Does Not Move at All Sheet 2 of 2 Shuttle jams or moves too sl
58. bracket 15 Remove screw 16 from optical sensor 17 Remove two screws 18 from encoder PCBA 19 Separate encoder PCBA 19 and its attached hardware from shuttle 13 Installation Position encoder PCBA 19 and optical switch 17 on shuttle 13 Install two screws 18 Install optical sensor 17 onto bracket 15 with screw 16 Attach bracket 15 to shuttle 13 with screws 14 Carefully pick up shuttle assembly 13 and turn it right side up in base 2 Place cable anchor bracket 12 in position Install screw 10 and washers 11 Install casting brace 9 and four screws 8 Install pivot retainer 7 and two screws 6 Install three springs 3 4 and 5 using tool 995822 001 Feed connector P21 1 down through hole in center of base 2 Connect P21 1 Retie as necessary Install controller mechanism driver and power supply PCBAs per paragraphs 5 20a 21a and 22a P3000 Corrective Maintenance Q O Q N CONNECTOR P21 BASE SPRING SPRING SPRING SCREW 2 PIVOT RETAINER 2 SCREW 4 CASTING BRACE SCREW WASHER ANCHOR BRACKET SHUTTLE ASSEMBLY SCREW 2 ENCODER BRACKET SCREW OPTICAL SENSOR SCREW 2 ENCODER PCBA Figure 5 27 Encoder PCBA Removal Installation P3000 Corrective Maintenance 5 33 Bumper Figure 5 28 a Ut vbS Removal Open cover 1 Loosen two screws 2 Grasp shutt
59. motor 6 and its cable from base casting 9 b Installation NOTE Procedure below is for left drive motor Procedure for right drive motor is identical except connect P29 in step 6 1 Position motor 6 in base casting 9 Hold motor 6 while installing three screws 7 and washers 8 Place hub 5 over shaft of motor 6 Tighten screw 4 in spool hub 5 Make sure screw contacts flat of motor shaft Route cable of motor 6 to motherboard PCBA 3 Connect P28 2 to motherboard PCBA 3 Resecure cable as necessary Install PCBAs per paragraphs 5 20b 21b and 22b Sen UE Install cabinet per paragraph 5 15b and shuttle cover per paragraph 5 23b P3000 Corrective Maintenance 5 77 FORMS THICKNESS LEVER CONNECTOR P28 MOTHERBOARD PCBA SCREW SPOOL HUB RIBBON DRIVE MOTOR SCREW 3 WASHER 3 BASE CASTING OY O D OD N Figure 5 37 Ribbon Drive Motor Removal Installation 5 78 P3000 Corrective Maintenance 5 44 Ribbon Guide Figure 5 38 a momo X bx COM Removal NOTE The following procedure is for the left ribbon guide The procedure for the right guide is identical except disconnect P23 in step 5 Remove cabinet per paragraph 5 15a Raise forms thickness lever 1 to open position Remove ribbon 2 Remove major PCBAs per paragraphs 5 20 21a and 22 Disconnect connector P24 3 from motherboard PC
60. paragraph 5 15b P3000 Corrective Maintenance TRACTOR 2 E RING SUPPORT SHAFT SPRING WASHER 2 BUSHING ADJUST KNOB WASHER SCREW LEFT SIDE PLATE RIGHT SIDE PLATE Q N A Figure 5 32 Support Shaft Removal Installation P3000 Corrective Maintenance 5 67 5 38 Tractor a Removal Remove spline shaft per paragraph 5 36a Remove support shaft per paragraph 5 37a Remove tractors Installation Using replacement tractors install support shaft per paragraph 5 37b Install spline shaft per paragraph 5 36b 5 39 Paper Ironer Figure 5 33 Qv Removal Open cover 1 Move forms thickness lever 2 to open position Loosen two screws 3 Remove shuttle cover 4 by grasping edges with both hands then lifting up and disengaging tabs Rotate shuttle 5 to service position Push back at ends of paper ironer 6 to disengage tabs then lift up and out Installation Push paper ironer 6 into slots until tabs engage Return shuttle 5 to normal position Install shuttle cover 4 by engaging tabs then pushing down Tighten two screws 3 Close forms thickness lever 2 Close cover 1 P3000 Corrective Maintenance COVER FORMS THICKNESS LEVER SCREW 2 SHUTTLE COVER SHUTTLE PAPER IRONER Figure 5 33 Paper Ironer Removal Installation P3000 Corrective Maintenance 5 40 Platen Fig
61. paragraph 5 15a and EMI shield cover per paragraph 5 20a step 3 Disconnect four lead connectors 1 Press in on spring clips 2 and push circuit breaker 3 out of mounting plate 4 Installation Press circuit breaker 3 into mounting plate 4 until spring clips 2 snap into place Connect four lead connectors 1 Install EMI shield cover per paragraph 5 20b step 5 and cabinet per paragraph 5 155 P3000 Corrective Maintenance 5 85 BLUE WIRE FROM AC INPUT RECEPTACLE BROWN WIRE FROM AC INPUT RECEPTACLE BLUE WIRE FROM AC INPUT CABLE BROWN WIRE FROM AC INPUT CABLE 1 LEAD CONNECTORS 2 SPRING CLIP 4 3 CIRCUIT BREAKER 4 MOUNTING PLATE Figure 5 41 Circuit Breaker Removal Installation 5 86 P3000 Corrective Maintenance 5 48 AC Input Filter Figure 5 42 a So poe xo gw UA d 5 DD Me spe hoc Voie o Removal Remove cabinet per 5 15a Remove EMI shield per paragraph 5 20a3 Remove circuit breaker per paragraph 5 47a Remove nut 1 terminal lug 2 and star washer 3 from EMI shield 4 T g and remove two terminal connectors 5 Remove two screws 6 and washers 7 Remove screw 8 terminal tab 9 and star washer 10 Remove two screws 11 Remove mounting plate 12 and input filter 13 from printer Installation Place input filter 13 and mounting plate 12 in place in printer Install two screws 11
62. power and check for Adjust symptom laten gap per P para B 15 Apply power Symptom present Return normal operation and check for symptom Symptom present NO Return to normal operation TO SHEET 2 YES Check for proper paper ironer installation Figure 4 40 Compacted Print 1 of 2 P3000 Troubleshooting 4 69 Check paper drive motor belt tension per para 3 5 FROM SHEET 1 Set tension per para 5 9 Install original YES mech driver PCBA per para 5 21 Replace Apply power controller PCBA per and for para 5 20 symptom Apply power and check for NO symptom Symptom present Return normal operation Symptom present NO Return to normal operation Replace paper drive motor per YES para 5 35 son inal controller PCBA per Apply power para 5 20 and check for symptom Symptom present No Return to normal operation YES Continue to troubleshoot using standard techniques If problem remains contact authorized distributor service representative Figure 4 40 Compacted Print 2 of 2 4 70 P3000 Troubleshooting Garbled print and or incorrect font Look for message on digital display Shuttle jam Run data stream or shuttle stall code printout appear Compare results to Fig 4 42 Results same as Fig 4 42 NO Shuttle Jams or
63. screw 2 and terminal lug E1 3 Disconnect four slide on terminals E2 through ES 4 through 7 Remove three tie wraps 8 from linear motor guide 9 Remove screw 10 Separate cable guide 11 from hammer bank PCBA 12 Remove three hex screws 13 Separate hammer bank PCBA 12 and attached ca ble from hammer bank 14 Note that connectors at bottom rear must be slid away from hammers to disconnect Installation Place hammer bank PCBA 12 on hammer bank 14 Engage connectors at bot tom rear of PCBA with pins on hammer coils Install three hex screws 13 Place cable guide 11 on hammer bank PCBA 12 Install screw 10 Attach cable to linear motor guide 9 using three tie wraps 8 P3000 Corrective Maintenance AA AAA BON O O O Q gt Q N GUIDE CABLE HAMMER BANK PCBA SCREW HEX 3 HAMMER BANK 1 12 14 CABLE ASSEMBLY SCREW TERMINAL LUG E1 TERMINAL LUG E2 TERMINAL LUG E3 TERMINAL LUG E4 TERMINAL LUG E5 TIE WRAP 3 GUIDE LINEAR MOTOR SCREW Figure 5 23 Hammer Bank Cable Assembly Removal Installation P3000 Corrective Maintenance 5 28 Hammer Bank Cable Assembly continuea b Installation continued Connect four slide on terminals E2 through ES 4 through 7 Install terminal lug 3 and screw 2 Feed cable assembly 1 through hole in base Install cable anchor bracket connectors shuttle cover and PCBAs per par
64. symptom Symptom present Return to YES normal operation Check to see if blower is connected to motherboard NO Blower connected YES Replace Return to mechanism driver normal operation PCBA per para 5 21 Apply power and check for symptom Connect blower Symptom present NO Return to normal operation YES Install original mechanism driver PCBA per para 5 21 Replace blower motor per para 5 45 Apply power and check for symptom NO Return to normal operation YES Continue to troubleshoot using standard techniques If problem remains contact authorized distributor Service representative Figure 4 43 Blower Motor Not Operating P3000 Troubleshooting CHAPTER 5 CORRECTIVE MAINTENANCE Section L GENERAL 5 1 Introduction Corrective maintenance at field level consists of mechanical alignments adjustments and replacement of printer subassemblies a Alignments and Adjustments Those items that may require field alignment or adjustment are listed below 1 Shuttle Cover Assembly Paper Scale 2 Hammer Springs 3 Shuttle Bumpers 4 Timing Belt 5 Tractors 6 Paper Ironer 7 Platen Gap 8 Ribbon Guide Assembly b Replacement The following items are field replaceable No field repair should be attempted 1 Controller PCBA 2 Mechanism Driver PCBA 3 Linear Encoder 4 Power Supply PCBA 5
65. 0 Figure 5 91 Motor Replacement Paper Drive 5 62 Figure 5 63 Ribbon Drive 5 78 Figure 5 79 N No Indicators Come on at Power up Fig ure 4 8 O Operating Procedures 1 2 Operation 1 2 Optional Features 1 2 Options Controls and Indicators for 1 8 Figure 1 9 P Paper Detect Switch Replacement 5 76 Figure 5 77 Paper Doesn t Feed at All Figure 4 19 Paper Drags Figure 4 26 Paper Drive Motor Pulley Alignment Figure 5 15 Replacement 5 62 Figure 5 63 Paper Feed Belt Tension Check 3 9 Figure 3 10 1 4 Paper Feed Motor Pulley Replacement 5 90 Figure 5 91 Paper Feed Timing Belt Replacement 5 60 Figure 5 61 Paper Feeds Erratically Figure 4 22 Paper Ironer Cleaning Figure 3 7 Replacement 5 68 Figure 5 69 Paper Scale Adjustment Figure 5 4 Alignment and adjustment 5 3 Replacement 5 42 Figure 5 41 Paper Transport 2 1 Figure 2 3 PCBA Controller 2 11 Mechanism Driver 2 13 Power Supply 2 20 Replacement Controller 5 34 Encoder 5 56 Figure 5 57 Interconnection 5 42 Figure 5 43 Mechanism Driver 5 37 Figure 5 35 Power Supply 5 38 Figure 5 39 Replacement Controller Figure 5 35 Phasing Hammer Adjustment 5 11 Physical Inspection Table 3 2 Platen Angle Adjustment 5 17 Figure 5 18 Gap Adjustment Figure 5 21 Figure 5 75 Replacement
66. 0 Troubleshooting 4 61 Improper print density Check forms thick ness lever setting NO YES Reposition forms thickness lever as required Apply power and check for symptom NO Symptom present Adjust platen gap per para 5 13 and platen angle per para 5 12 Apply power and check for symptom YES Return to normal operation Return to normal operation Retension hammer spring s per para 5 5 Apply power and check for symptom YES Return to normal operation Replace coil s per para 5 30 Apply power and check for symptom Symptom present NO Return to normal operation YES Continue to troubleshoot using standard techniques If problem remains contact authorized distributor service representative Figure 4 33 Improper Print Density P3000 Troubleshooting EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEE
67. 2 1 A POWER POWER SUPPLY IN PCBA PRINT MECHANISM PAPER D PLATEN OPEN PAPER TRANSPORT INTERLOCK HAMMER ONTRO TO FROM HOST ONTRO MECHANISM iat lin COMPUTER DRIVER PCBA gt RIBBON TRANSPORT CONTROLLER PCBA SERIAL DATA OPERATOR CONTROLS AND INDICATORS Figure 2 1 Printer Functional Block Diagram 2 2 P3000 Principles of Operation SPLINE SHAFT LEFT TRACTOR SUPPORT SHAFT HORIZONTAL VERNIER ADJUST HAMMER BANK PAPER DRIVE MOTOR ADJUSTMENT KNOB AND SPLINE SHAFT VERTICAL FORMS PULLEY TIMING BELT NOTE CABINET EMI SHIELD COVER AND SHUTTLE COVER OMITTED COVER ASSEMBLY RIGHT TRACTOR Figure 2 2 Paper Transport P3000 Principles of Operation 2 4 Printing Mechanism Figure 2 3 The printing mechanism consists of the shuttle assembly on which the hammer bank as sembly is mounted and the ribbon transport a Shuttle Assembly The shuttle assembly consists of the linear motor assembly two bumper assemblies two drum assemblies the hammer bank assembly hammer bank cable assembly encoder PCBA and a linear encoder The linear motor is driven by the mechanism driver PCBA and sweeps the hammer bank assembly laterally across the 0 4 inch distance traveled by each hammer The bumpers rebound the hammer bank assembly s inertial energy when the shuttle reaches either end of its travel and reverses direction The drums in conjunc tio
68. 20 WEAR SADDLE 2 9 BASE 21 CAP SCREW 2 10 SCREW 22 SHUTTLE SHAFT CABLE ANCHOR BRACKET 23 BASE CASTING SPRING LEFT UPPER Na Figure 5 22 Shuttle Assembly Removal Installation P3000 Corrective Maintenance 5 27 Shuttle As sembly Continued b 10 11 12 13 14 Installation continued Place connector J12 7 in position on base 8 Install four screws 5 and washers 6 Connect connector P21 3 to motherboard PCBA 4 Check cable between shuttle 19 and anchor bracket 11 Make sure there are no sharp bends or creases Verify service loop is continuous and does not contact base when shuttle oscillates Reposition as necessary Check that shuttle assembly 19 rotates between normal and service positions and there is no slack in encoder cable underneath shuttle Install controller mechanism driver and power supply PCBAs per paragraphs 5 20b 21b and 22b Install shuttle cover 2 Tighten two screws 1 Verify print quality by printing repeating test patterns If print is not acceptable perform hammer alignment per paragraph 5 4 bumper adjustment per paragraph 5 6 or phasing adjustment per paragraph 5 8 5 28 Hammer Bank Cable Assembly Figure 5 23 M A Ut N Removal Remove PCBAs shuttle cover connectors and cable anchor bracket per paragraph 5 27a through 6 Feed cable assembly 1 up through hole in base Remove
69. 3000 Corrective Maintenance SCREW 3 EMI SHIELD COVER CONNECTOR P16 MECHANISM DRIVER PCBA EMI SHIELD SCREW 2 WASHER 2 BELT SHIELD RIGHT SIDE PLATE 10 SCREW 4 11 BARRIER PANEL 12 LEFT SIDE PLATE 13 SCREW 2 14 NUT 2 15 BELT 16 DRIVE MOTOR OO YO Q D Figure 5 30 Paper Drive Motor Removal Installation P3000 Corrective Maintenance 5 63 5 36 Spline Shaft Figure 5 31 a 11 12 ON t N 9p um UM FP e Removal Remove cabinet per paragraph 5 15a With grip ring pliers remove grip ring 1 from spline shaft 2 Pull bearing 3 and spring link 6 with spring 4 off spline shaft 2 Remove two screws 7 and washers 8 Separate belt shield 9 from right side plate 10 Remove belt 11 Unlock left tractor 12 and right tractor 13 and slide to center of printer Remove screw 14 and bearing clamp 15 Grasp spline shaft knob 16 and carefully slide spline shaft 2 to right and remove Installation Open covers on left tractor 12 and right tractor 13 Position tractor belts so tim ing marks are at top on both tractors Grasp spline shaft knob 16 and slip spline shaft 2 through right side plate 10 tractors 12 and 13 and left side plate 5 Make sure that the same spline passes the marked groove on each tractor Install bearing clamp 15 and screw 14 Slide spring link 6
70. 4 1 Table 4 1 Fault Codes Display Readout CHECK FAULT Operator Indicator CONDITION Correctable Description Flashing PAPER OUT Paper out Flashing PLATEN OPEN Platen open or shuttle cover off Flashing PAPER JAM No paper motion PMD option Flashing SHUTTLE JAM Shuttle jammed Flashing SHUTTLE STALL Shuttle not up to speed Steady DCU data RAM pattern check Steady FONT PROM Primary font PROM check sum Steady MCU data RAM pattern check Indicates Soft Fault 4 2 P3000 Troubleshooting Table 4 2 Supplimental Tests TEST COMMENTS PRINT TESTS Configuration i Configuration printout including part numbers of each installed PROM and font Printout of each installed character set in cluding font part number Repeating ests All E repeating E plus TOF All H repeating Shift recycle All underlines repeating Black plot Shuttle Ribbon Print sampler SERVICE AIDS Rebound Index Motor bar and hammer bank rebound index dis played Shuttle operates without printing Stroke Time Average stroke time displayed in xx x milliseconds Phasing Index Capability is provided to display an index number which represents the hammer phas ing index Continued P3000 Troubleshooting 4 3 Table 4 3 Malfunction Symptom Index Flowchart Malfunction Symptom L CONTROL PANEL INDICATORS SWITCHES AND DISPLAYS OPERATE IMPROPERLY Whenever power is app
71. 4 39 Compacted Print Example 4 68 4 40 Compacted Print uu s ur aus le i 4 69 4 41 Garbled Print and or Incorrect Font 4 71 4 42 Expected Data Stream 4 73 4 43 Blower Motor Not Operating 4 74 5 1 Paper Scale Adjustment 5 4 5 2 Hammer Tip Alignment LL 5 5 5 3 Hammer Spring Retensioning 5 7 5 4 Bumper Adjustment sessed dunen 5 9 P3000 Maintenance List of Illustrations Figure Title Page 5 5 Timing Belt Adjustment LL 5 13 5 6 Paper Drive Motor Pulley Alignment 5 15 5 7 Spline Shaft Skew Adjustment 5 16 5 8 Platen Angle 5 18 5 9 Platen Gap Adjustment 5 21 5 10 Ribbon Guide Alignment 5 23 5 11 Cabinet Removal Installation 5 25 5 12 Control Panel Removal Installation 5 27 5 13 Cover Removal Installation 5 29 5 14 Display Control Panel Removal Installation 5 31 5 15 Control Panel Cable Removal Installation 5 33 5 16 Controller and Mechanis
72. 41 Interlock Cable Assembly 5 74 5 42 Paper Detect Switch uu ayasa aaa 5 76 5 43 Ribbon Drive 5 78 5 44 Ribbon Guide e 5 80 5 45 Blower Assembly seas ead ues ce n 5 82 5 46 Falli enses eis vess 5 84 5 47 Circuit Breaker 5 86 5 48 AC Input Filter ea 5 88 5 49 Paper Feed Motor Pulley 5 90 ii P3000 Maintenance Paragraph Appendix A Appendix B Index Table Table of Contents Title Page APPENDICES A 1 Parts Liste ssa ea B 1 Q bal wa 1 1 List of Tables Title Page External Controls and Indicators ous oes 1 4 Internal Controls and Indicators aaa aa 1 6 Controls and Indicators for 3287 Option 1 8 Dot Matrices vs Speed Density 2 9 Preventive Maintenance Checks and Service 3 1 Physical Inspection 3 2 aan 4 2 Supplimental sfg Li 4 3 Malfunction Sympton 4 4 Recommended Tools Test Equipm
73. 728 011 2 IRONER MOUNTING PLATE 110548 001 3 SCREW CA ER We EROS 101514 037 4 SETSCREW ies eee eben adit part of item 5 5 FORMS THICKNESS LEVER 111724 01 6 PLATEN e 110592 001 P3000 Parts List TABLE B 1 PARTS LIST continued FIGURE AND TITLE PART NO COMMENTS ITEM NO NAME Figure 5 34 Platen Removal Installation continued Te SPRING me ve part of item 9 8 RIGHT SIDE PLATE 111824 001 9 SPRING LINK 105741 001 10 RIGHT BEARING 101309 002 11 SCREW ccc ric ae chp in 103677 001 12 WASHER ii 101526 005 13 SWITCH BRACKET 110144 001 105728 012 15 SPACER iii idea 102132 007 16 SCREW ii ae 101514 037 17 RESTRAINT e 111784 001 18 SPRING iii reali part of item 20 19 LEFT SIDE PLATE ipa 110129 001 20 SPRING 110280 001 21 101309 002 22 LEFT ADJUSTMENT BRACKET 110579 001 23 RIGHT ADJUSTMENT BRACKET 110579 001 24 WASHER 2 n a 25 WEAR SADDLE 2 110579 001 26 PAPER IRONER 11040
74. 8 001 27 HAMMER BANK COVER ASSY 111071 01 28 SHUTTLE COVER 111790 001 29 SCREW 2 140058 001 Figure 5 35 Interlock Shield Cable Assembly Removal Installation SHUTTLE COVER 10 WASHER 3 11 SHOCK MOUNT SPACER 3 12 MECHANICS BASE 13 INTERLOCK SWITCH 14 HEX SCREW 15 PIN zii ft ra mapa Figure 5 36 Paper Detect Switch Removal Installation 1 CONNECTOR P25 2 MOTHERBOARD PCBA 8 SCREW 4 4 BARRIER PANEL 5 SCREW 2 6 PAPER DETECT SWITCH 7 BASE CASTING MECH CONNECTOR P22 MOTHERBOARD PCBA FORMS THICKNESS LEVER SCREW 2 PLATEN OPEN SWITCH MOUNTING BRACKET SCREW 2 Maio part of 111453 001 111499 001 111724 001 103677 030 part of 111453 001 110144 001 140058 001 111790 001 101853 06 101526 028 111974 001 111663 001 part of 111453 001 105728 004
75. 8 P3000 Maintenance Overview ENABLE HOLD CLEAR 6 8 LPI PAPER ADV Figure 1 4 Controls and Indicators for 3287 Option P3000 Maintenance Overview 1 9 P3000 Maintenance Overview CHAPTER 2 PRINCIPLES OF OPERATION 2 1 General This chapter presents the principles of operation for the Printronix P3000 Series Line Printer Theory is presented at the functional block diagram level as an aid for perform ing field maintenance Refer to Appendix B for detailed schematic diagrams 2 2 Functional Elements Figure 2 1 Functional elements of the printer consist of the following a Paper Transport b Printing Mechanism c Controller PCBA d Mechanism Driver PCBA e Power Supply PCBA 2 3 Paper Transport Figure 2 2 The paper transport accepts one to six part continuous fan folded edge perforated pa per or forms from three to 16 inches wide The spline shaft knob is used to manually advance the paper supply vertically Horizontal positioning of the paper is provided by two tractors which can be adjusted laterally along the spline and support shafts and by a horizontal adjustment knob When properly positioned each tractor is then locked in place Each tractor provides five pin engagement of paper perforation During printing tractors are belt driven by the paper drive motor The paper drive motor is driven by sig nals from the two paper feed sections of the mechanism driver PCBA P3000 Principles of Operation
76. 89 lt gt ABCDEFGHI JKLMNOPGRSTUVWXYZINJ abcdefghijkl 0123456789 lt gt ABCDEF GHI JKLMNOPGRSTUVWXYZLIN1 abcdefghijkim 0123456789 lt gt BABCDEFGHI JKLMNOPGRSTUVWXYZEN1 abcdefghi jk1mn 7 0123456789 lt gt 7 ABCDEFGHI JKLMNOPQRSTUVWXYZE I _ abcdefghi jkimno 0123456789 lt gt ABCDEFGHI JKLMNOPQRSTUVWXYZLN1 abcdefghi jk1mnop 40123456789 lt gt JKLMNOPORSTUVWXYZIN1 abcdefghi jk1mnopq 0123456789 lt gt ABCDEFGHIJKLMNOPARSTUVWXYZC _ abcdefghi jkimnopqr 0123456789 lt gt JKLMNOPQGRSTUVWXYZLINJ abcdefghijklImnopqrs Figure 4 35 Improper Vertical Alignment Example 4 64 P3000 Troubleshooting P3000 Troubleshooting Improper horizontal or vertical alignment Align hammers per para 5 4 Return 1 normal operation Figure 4 36 Improper Horizontal or Vertical Alignment STUVWXYZULX1 HSA 0123455789 i Cap ABC DEFGHI JKLMNOPGRSTUV TUVWNXYZE I _ 20123435799 i C22 8ABCDEFGHI JKL MNDPGRSTUVW UVRXYTUX1 HEAL Chae 0123456789 i C22 ABCDEFGHI JKLMNOPGRSTUVWX VHXYZ X1 SESAR 10123452799 i C gt PRABC DEF GH I JKLMNGPGRSTUVWXY CEST ONG 019 24545 B9 C77 78ABCDEE GHI JKLMNOPGRSTUVWXYZ SEID O is3aa05EVE8S CUP PRABCDEFGHI JALMNOPGRSTUVWAYZE MESE ORG NUK TEA uae UPeARRCDEF GHI M
77. A gt Removal Remove cabinet per paragraph 5 15a Disconnect connector P1 1 from display control panel 2 and P31 3 from control panel 4 Remove all plug in PCBAs per paragraphs 5 20a 21a and 22a Remove two hex head screws 5 and washers 6 That secure connector J3 7 Remove ten screws 8 that secure motherboard PCBA 9 Lift motherboard PCBA 9 and insulator 10 and remove cable 11 that passes under it Installation Place cable 11 under motherboard PCBA 9 so that connector J3 7 is in position on base 12 Install two hex screws 5 and washers 6 Do not tighten fully Position insulator 10 and motherboard PCBA 9 on base 12 Install ten screws 8 Route cable 8 to front of printer and connect connector P1 1 to display control panel 2 and P31 3 to control panel 4 Install controller PCBA refer to para 5 20 to align J3 7 Remove controller PCBA and tighten screws 5 Install all plug in PCBAs per paragraphs 5 20b 21b and 22b Install cabinet per paragraph 5 15b P3000 Corrective Maintenance 2 lt Fa lt A 2602 SEE CEK lt x ox Op ot Woo Wb g FOF Ox O0 EO 2b bases 2212601204303 ATT RSET EEE 00000300020m NOTH G N Figure 5 15 Control Panel Cable Removal Installation P3000 Corrective Maintenance 5 20 Controller PCBA Figure 5 16 a Du 5 5
78. BA 4 Cut spot ties as required to free ribbon guide cable Remove two screws 5 and flat washers 6 Slide ribbon guide 7 out of left side plate 8 Remove guide 7 and its cable from printer Installation NOTE The following procedure is for the left ribbon guide The procedure for the right guide is identical except connect P23 in step 4 Slide ribbon guide 7 into left side plate 8 Install two screws 5 and flat washers 6 Route cable to motherboard PCBA 4 Connect P24 3 to motherboard PCBA 4 Retie cable as necessary Install PCBAs per paragraphs 5 20b 21b and 22b Align guides per paragraph 5 14 Install cabinet per paragraph 5 15b P3000 Corrective Maintenance 5 79 FORMS THICKNESS LEVER RIBBON CONNECTOR P24 MOTHERBOARD PCBA SCREW 2 WASHER 2 LEFT RIBBON GUIDE LEFT SIDE PLATE RIGHT RIBBON GUIDE N Figure 5 38 Ribbon Guide Removal Installation 5 0 P3000 Corrective Maintenance 5 45 Blower Assembly Figure 5 39 a Removal Remove cabinet per paragraph 5 15a Loosen two screws 1 Grasp shuttle cover 2 at both edges lift up to remove Disconnect connector P27 3 from motherboard PCBA 4 Feed cable around right side and up through hole in center of base casting 5 Remove two screws 6 Separate blower assembly 7 from base casting 5 Installation Place blower assemb
79. Control Panel Assemblies 6 Encoder PCBA 7 Shuttle Assembly 8 Ribbon Drive Motors P3000 Corrective Maintenance 5 1 5 1 Introduction continuea b Replacement continued 9 Paper Out Switch 10 Paper Motion Detector PMD 5 2 Tools Test Equipment and Supplies The items listed in Table 5 1 or their equivalents are required as a minimum to main tain the printer Table 5 1 Recommended Tools Test Equipment and Supplies Printronix Recommended Part No Item Adhesive Awl Bumper Adjustment Tool Adjustable Wrench Diagonal Cutters Digital Voltmeter Extension 3 in 3 8 Drive Feeler Gauge Set Hammer Tip Alignment Tool Long Hammer Tip Alignment Tool Short Isopropyl Alcohol Kimwipes Nut Driver Set Oscilloscope and Probes 35 MHz or better Platen Angle Adjustment Tool Optional Pliers Grip Ring Pliers Chain Nose Ratchet 3 8 in Drive Rule Steel 6 in Screwdriver Torque 12 36 in Ibs Adjustable Adapter Torque Screwdriver optional Hex Bit 3 16 in Torque Screwdriver Hex Bit 3 22 in Torque Screwdriver Hex Bit 5 32 in Torque Screwdriver Screwdriver Allen Hex Screwdriver Phillips Screwdriver Phillips Screwdriver Slot Screwdriver Slot Screwdriver Slot Spring Installation Tool Socket 7 16 in 3 8 in Drive X acto Knife and Blades 101537 001 995762 001 111339 001 111106 001 995641 001 995822 001 P3000 Corrective Maintenance Eastman 910 Utic
80. EEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE Figure 4 23 Missing Characters Example 4 46 P3000 Troubleshooting Characters missing consistently Check setting of forms thickness lever NO Set forms thickness lever correctly YES Check for symptom NO Return to normal operation Check and adjust platen gap per par 5 13 Apply power and check for symptom Symptom present NO Return to normal operation YES Check hammer bank for damaged hammers and accumulated dirt NO Replace hammer s per para 5 29 YES Return to normal operation Figure 4 24 Characters Missing Consistently Sheet 1 of 3 GO TO SHEET 2 P3000 Troubleshooting FROM SHEET 1 Clean hammer Hammer bank clean bank per para 3 4 Apply power and check for symptom Symptom present Return to Make sure coil terminals engage connectors on PCBA Terminals OK Repair terminals as necessary Return normal operation
81. EEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEFEEEEEEEEEEECEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEECEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEFEEECCEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEFECEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEFECEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEF E EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE
82. EEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHH UEUSUSSESTESUSSESITITISEREEESEEESESE TET ETTET R E REE 7 amp C 0123456788 lt gt 7 ABCDEFGH I JKLMNOP ORSTUVWXYZE VI Z amp amp X 0123456789 lt gt ABCDEFGHI JKLMNOPORSTUVW
83. EZEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EZCZEEEZEERZEEEZEEEZEEEZEEEZEEEZEEEEEEEEEEEECEEEEEEEEEEEC EEEZEEEZEEEZEEEZEEEZEEEZEEEZEEEZEEEEEEEEEEEEZEEEEZEEEEEEEE eee
84. Grasp power supply PCBA 8 with both hands and pull straight up away from base 9 Installation Place power supply PCBA 8 into position in base 9 and press down to seat con nector Connect connector J19 6 to J2 7 Connect connector J18 4 to J1 5 Fold down flap 3 Install EMI shield cover 2 and tighten three screws 1 Install cabinet per paragraph 5 15b P3000 Corrective Maintenance SCREW 3 EMI SHIELD COVER FLAP PROTECTIVE CONNECTOR J18 CONNECTOR CONNECTOR J19 CONNECTOR v2 POWER SUPPLY PCBA BASE 09 N Figure 5 1 Power Supply PCBA Removal Installation P3000 Corrective Maintenance 5 23 Shuttle Cover Figure 5 19 a gt p 1 Removal Open cover 1 Set forms thickness lever 2 fully open Squeeze latches 3 and remove ribbon spools 4 from hubs 5 Lift ribbon and spools out of printer Loosen two screws 6 Grasp edges of shuttle cover 7 and lift out Side of cover farthest from you will come free first Shuttle Cover Installation Place cover 7 in printer Tilt back of cover 8 down slightly and engage tabs 8 in slots 9 at front of printer Line up slots 10 at sides of cover 7 with tabs 11 in printer Push down firmly on rear of cover 7 Tighten two screws 6 Install ribbon spools 4 on hubs 5 and route ribbon properly Set forms thickness lever 2 closed Close cover 1 P3000 Corrective Maintenance
85. HHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHLHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH AAA OI Ai J 4 7 amp 0123456789 lt gt 7 ABCDEFGHI JKLMNOPQRSTUVWXYZE I _ g Z amp 0123456789 lt gt PABCDEFGHI JKLMNOPQRSTUVWXYZEC I _ a C 0123456789 lt gt ABCDEFGHIJKLMNOPORSTUVWXYZI _ 1 7 amp 0 0123456789 lt gt ABCDEFGHIJKLMNOPOARSTUVWXYZI _ 1 648 X 0123456789 lt gt ABCDEFGHIJKLMNOPORSTUVWXYZ I _ abcd 7 amp 00 0123456789 lt gt JKLMNOPGRSTUVWXYZLN 1 abcde 8 7 amp C 0123456789 lt gt PBABCDEFGHI JKLMNOPQRSTUVWXYZE I _ abcdef 7 amp OX 0123456788 lt gt GABCDEFGHIJKLMNOPQRSTUVWXYZLIN1 abcdefg 0123456789 lt gt ABCDEFGHI JKLMNOPQRSTUVWXYZEN 1 abcdefgh amp 01234567898 lt gt PABCDEFGHI JKLMNOPQRSTUVWXYZIN3 abcderghi t 0123456789 lt gt JKLMNOPQRSTUVWXYZIN1 abcdefghij X 0123456789 lt gt ABCDEFGHI JKLMNOPQRSTUVWXYZLINJ2 abcdef ghi jk 01234567
86. HHHHHHHHHHHHHHHHHHHHH HEHHUHHHHHHHE HHHH IHHBUIHHHEHHIHRIHHHB I HEHEHE IHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHH IHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHBHBTEBHHH HEHEHE SHHEHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HH HHH IHHHHHHHHHHHHHBH HH HHH HHH IHHHHHHHBI IHHRHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHH tH HHHHI tHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHA tHHHHHHHHHHHHHI tHHHHHHHHHHHHEHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHH HHHHHHHHI 4 IHHRHHHLHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH tHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HH IHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHH IHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH Figure 4 37 Characters Misformed Vertically Example 4 66 P3000 Troubleshooting Characters misformed vertically Check forms thick ness lever setting NO YES Reposition forms thickness lever as required Apply power and check for symptom Symptom NO present Return Adjust hammer normal operation phasing per para 5 8 Adjust platen gap per para 5 13 Apply power and check for symptom Apply power and check for symptom NO YES Return to normal operation YES Return to normal ration i al operatio Continue to troubleshoot using standard techniques If Symptom present
87. ING PROM es e de as ISTORS sila a J BE a a Figure 5 17 Controller PROM Locations P3000 Corrective Maintenance 5 21 Mechanism Driver PCBA Figure 5 16 a qu dI Removal Remove cabinet per paragraph 5 15a Loosen three screws 2 and remove EMI shield cover 3 Disconnect connector P16 11 CAUTION J Do not use heat sink on mechanism driver top edge as a handle Damage to board could result Grasp both sides of mechanism driver 9 and lift straight up Installation Position mechanism driver 9 in base 8 Make sure cable 10 is looped under board Push down driver 9 to seat connectors Connect connector P16 11 Install EMI shield cover 3 and tighten three screws 2 Install cabinet per paragraph 5 15b P3000 Corrective Maintenance 5 37 5 22 Power Supply PCBA Figure 5 18 ge ie gt P We de D NOTE Remove and install mech driver PCBA per paragraph 5 21 if neces sary to gain access to power supply PCBA Removal Remove cabinet per paragraph 5 15a Loosen three screws 1 and remove EMI shield cover 2 Lift flap 3 Disconnect connector J18 4 from 11 5 Disconnect connector J19 6 from J2 7 CAUTION J Do not grasp components on power supply PCBA during re moval installation Damage to soldered connections may result
88. If problem remains contact authorized distributor service representative Figure 4 3 Indicators on Both Control Panels Operate Improperly P3000 Troubleshooting 4 11 Switches or indicators operate improperly on front control panel only Replace control panel cable per para 5 19 Front panel side OK Check connectors 2 and ribbon cables for damage Apply power for symptom Connectors and cables ok NO Symptom present Return to normal operation YES Replace front control panel per para 5 16 Apply power and check for symptom NO Return to normal operation Replace controller PCBA per para 5 20 Apply power and check for symptom NO Return to normal operation YES Continue to troubleshoot using standard techniques If problem remains contact authorized distributor Service representative Figure 4 4 Switches or Indicators Operate Improperly on Front Control Panel Only 4 12 P3000 Troubleshooting Digital display operates improperly Inspect control panel cable for damage Cable NO OK Replace YES control panel cable Return to per para 5 19 YES normal operation Install original display control panel Apply power per para 5 18 and check for symptom Replace controller PCBA per para 5 20 Symptom NO present Return to Apply power YES normal operat
89. JKLMNOPQRSTUVWXYZLN1 abcdefghi jkImnopqrstuvwxyz GABCD kimnopqrstuvwxyz i GABCDEFGHIJKLMNOPQRSTUVWXYZLIN1 4 7 amp w Imnopqrstuvwxyzt GABCDEFGHIJKLMNOPQRSTUVWXYZIN1 7 mnopqrstuvwxyzt i GABCDEFGHIJKLMNOPQRSTUVWXYZLN1 48 K 70 nopqrstuvwxyzt GABCDEFGHI JKLMNOPQRSTUVWXYZL I _ S78 701 Opqrstuvwxyzti J CGABCDEFGHIJKLMNOFPGRSTUVWXYZLN1 II X 7012 pqarstuvwxyzt i1 CASCDEFGHIJKLMNOPGRSTUVWXYZLN1 ZS97Z amp Cot 70123 qrstuvwxyz GABCDEFGHI JKLMNOPQRSTUVWXYZIN1 Tee w 4 rstuvwxyzt ABCDEFGHI JKLMNOPGQRSTUVWXYZC 1 _ Z amp W 5 Stuvwxyz Y GABCDEFGHIJKLMNOPGRSTUVWXYZIN1 it 7 amp Cos 10123456 tuvwxyz ABCDEFGHI JKLMNOP RSTUVWXYZE _ IUBEUR H 701234567 UVWwxyz Y GABCDEFGHIJKLMNOPQGRSTUVWXYZLIN2 1 8 012345678 vwxyz i ABCDEFGHIJKLMNOPORSTUVWXYZC _ 4 amp X 0123456789 Figure 4 39 Compacted Print Example 4 68 P3000 Troubleshooting Compacted print Check forms thick ness lever setting NO Installation OK Reinstall ironer per para 5 39 Apply power and chock for symptom YES Reposition forms thickness lever as required Apply power and check for symptom Return to normal operation NO Replace mech driver Return normal operation Symptom present PCBA per para 5 21 Apply
90. LMNOPEGRSTUVWXYZEN I VARARCDEEGHIJKLANUPORSTUVWXYZUN 1 HABE DEF CH IKLHHOPORSTUVNXYZENX1 _ peace BCDEFROHIGUL CORSTUVKXYZINIJ a or ee CHI dii PEVUVAKY ZENE ab EFGHI URL MINOPONSTUVINXYZONI _ abc CEABGODEFCHIJKL MNOPORSTUVKNXYZCN 1 abcd iti MNDPORSTUVNKYZUN I abcde ree bey s YOEABCDEFGHIJKLHNOPORSTUVMXYZENI abcdef SLAC 44 10123455769 i Cr gt PARC DEF GHI JKL INDPGRETUVKWXYZLN 1 abcdefg 2 38 710123455789 i Cz GSABCDEFGHIJKLMNOPGRSTUVWXYZUN1 abcdefgh HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHUHHHHHHHH 4 t HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHUUHHHHHHHHHHHHHHHHHHHHHH iHHHHHHHHHHHHHHHHHH HHHHHHHHHHH HHHH IHHHHHEHHHHHHHPBHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HEHE HHHH HHHH THE EH HEHEHE Es HAAR Ht IHHHHHHHHHHHHHHHHHHHHHHHHHHH HE IHE HHHH HHEH HHE tH HE Ht iH tt IHHELULIHHHHHHHHLHHHEHHHHHHEHHHHHHHHHHHHH HEBR EM UBL HE SHE S IHHBHHHHHHHHH
91. List SCREW 3 nt a 102559 136 EMI SHIELD COVER 111430 001 FLAP PROTECTIVE part of item 8 CONNECTOR J18 n a CONNECTOR 1 part of item 8 CONNECTOR J19 CONNECTOR J2 part of item 8 POWER SUPPLY PCBA ASSY 111688 001 BASE cilea 111365 003 112083 003 TABLE B 1 PARTS LIST continued FIGURE AND TITLE ITEM NO NAME PART NO COMMENTS Figure 5 19 Shuttle Cover and Paper Scale Removal Installation 12 COVER sec seis bins ola dau e os 111702 001 2 FORMS THICKNESS LEVER 111724 001 3 SPOOL LATCH 2 part of item 5 4 SPOOL 2 iii iii i a n a 5 SPOOL HUB 2 102526 001 6 SCREW 9 ARR EY e Wa 140058 001 7 SHUTTLE COVER 111790 01 8 TABS REAR 2 n a 9 SLOTS FRONT 2 n a 10 SLOTS SIDE 2 n a 11 TABS SIDE 2 part of item 7 12 SCREW BUTTON HEAD 6 102288 003 13 LOCKNUT 6 score maa 101853 003 14 PAPER SCALE 110277 001 Figure
92. Moves Too Slowly Replace controller PCBA per para 5 20 Apply power and check for symptom Symptom present Return to normal operation Install original controller PCBA per para 5 20 TO SHEET 2 Figure 4 41 Garbled Print and or Incorrect Font Sheet 1 of 2 P3000 Troubleshooting 4 71 FROM SHEET 1 Replace hammer bank cable assembly per para 5 28 Apply power and check for symptom Symptom present Return to normal operation Replace encoder PCBA per para 5 32 Apply power and check for symptom Symptom present Return to normal operation Continue to troubleshoot using standard techniques If problem remains contact authorized distributor service representative Figure 4 41 Garbled Print and or Incorrect Font Sheet 2 of 2 4 72 P3000 Troubleshooting gt ABCDEFGHIUKLMNOPORSTUVWXYZ 1 _ abcdefghijkImnopgrstuvwxyz 8 JKLMNOPQRSTUVWXYZC I _ abcdefghijkimnopqrstuvwxyzi GA ABCDEFGHI JKLMNOPGRSTUVWXYZINJ abcdefghi jkiImnopqrstuvwxyzt GAB ABCDEFGHIJKLMNOPQRSTUVWXYZLIN1 abcdefghijkl1mnopqrstuvwxyzti BCDEFGHIJKLMNOPGRSTUVWXYZLN1 abcdefghijklImnopqrstuvwxyzti i ABCD CDEFGHIJKLMNOPGRSTUVWXYZUN1 abcdefghijkl1mnopqrstuvwxyzt i ABCDE DEFGHIJKLMNOPGRSTUVWXYZIN1 abcdefghijklmnopqrstuvwxyzt GABCDEF EFGHIJKLMNOPQRSTUVWXYZEN1 abcdefghijkiImnopqrstuvwxyzt GABCDEFG FGHIJKLMNOPQ
93. NE PULLEY MOTOR PULLEY SCREW Figure 5 29 Paper Feed Timing Belt Removal Installation P3000 Corrective Maintenance 5 35 Paper Drive Motor Figure 5 30 a p 9 wu gt p de D Removal Remove cabinet per paragraph 5 15a Loosen three screws 1 and remove EMI shield cover 2 Disconnect P16 3 from mechanism driver PCBA 4 and feed cable out of EMI shield 5 Remove two screws 6 and washers 7 Separate belt shield 8 from right side plate 9 Remove four screws 10 Separate barrier panel 11 from right side plate 9 and left side plate 12 Remove two screws 13 and nuts 14 Remove belt 15 Remove tie wraps as required and separate motor 16 from right side plate 9 Installation Position motor 16 on right side plate 9 Install two screws 13 and nuts 14 Align motor pulley per paragraph 5 10 steps 4 and 5 Loosen two screws 13 Install belt 15 Set belt tension per paragraph 5 9 steps 3 through 5 Retie cable as required Position barrier panel 11 on right side plate 9 and left side plate 12 Install four screws 10 Place belt shield 8 against right side plate 9 Install two screws 6 and washers 7 Feed connector P16 3 through EMI shield 5 and connect to mechanism driver PCBA 4 Install EMI shield cover 2 Tighten three screws 1 Install cabinet per paragraph 5 15b P
94. O Return to normal operation YES Continue to troubleshoot using standard techniques If Replace controller PCBA per para 5 20 problem remains contact authorized distributor service representative Figure 4 6 CHECK Indicator Flashes Display Shows FAULT CONDITION PAPER OUT Sheet 2 of 2 P3000 Troubleshooting 4 15 CHECK Indicator flashes display shows FAULT CONDITION PLATEN OPEN Check if forms thickness lever is closed Lever NO Return to closed Close lever normal operation YES Inspect shuttle cover for proper installation Shuttle cover installation OK NO Install cover Return to properly normal operation YES Remove shuttle cover and check for damaged tab on cover or inter lock switch Install new cover per Apply power para 5 23 or new and check for interlock shield cable symptom assy per para 5 41 Symptom present NO Return to normal operation TO SHEET 2 Figure 4 7 CHECK Indicator Flashes Display Shows FAULT CONDITION PLATEN OPEN Sheet 1 of 2 4 16 P3000 Troubleshooting FROM SHEET 1 Replace original cover per para 5 23 Symptom present no Return to normal operation YES Replace interlock cable 8 rpara 5 41 assy per para 5 Install original controller PCBA per para 5 20 Apply power and check for symptom Replace power supply PCBA per para 5 22
95. ORS SCREW 10 INSULATOR WASHER 10 BASE 1 2 3 4 5 6 Motherboard PCBA Removal Installation 20 Figure 5 P3000 Corrective Maintenance 5 26 I O Cable Assembly Figure 5 21 a Removal Remove controller PCBA per paragraph 5 20a Remove two screws 1 and mounting plate 2 Remove I O cable 3 and attached mounting plate 2 from printer Installation Place I O cable 3 and attached mounting plate 2 in printer Install mounting plate 2 and two screws 1 Install controller PCBA per paragraph 5 20b P3000 Corrective Maintenance SCREW 2 2 MOUNTING PLATE 3 CABLE 1 Figure 5 21 I O Cable Removal Installation 5 45 P3000 Corrective Maintenance 5 27 Shuttle Assembly Figure 5 22 a B dA Si t 10 pu We E Removal Remove controller mechanism driver and power supply PCBAs per paragraphs 5 20a 21a and 22a NOTE Cut cable ties as necessary to free cables during removal Loosen two screws 1 Remove shuttle cover 2 Disconnect connector P21 3 from motherboard PCBA 4 Remove four screws 5 and washers 6 Separate connector J11 7 and J12 8 from base 9 Feed connectors P21 3 and J11 7 around to left side of base 9 Remove screw 10 Separate cable anchor bracket 11 from base casting 23 Remove three springs 12 13 and 14 using tool 995822 001 Remove two screws 15 Remove right pivot re
96. POBA L ul utasa aa 2 6 Mechanism Driver PCBA eee eee eee 2 7 Power Supply PCBA CHAPTER 3 PREVENTIVE MAINTENANCE 3 1 General 3 2 Preventive Maintenance Checks and Service PMCS 3 3 Inspection cese ede utet std onere 3 4 Cleaning iiie esas ete o ei 3 5 Paper Feed Belt Tension Check 3 6 LUubrication siii ii a CHAPTER 4 TROUBLESHOOTING 4 1 General cits ben getti deere pelare 4 2 Common Causes of Malfunctions 4 3 Internal Testing i linear 4 4 Fault Isolation LL CHAPTER 5 CORRECTIVE MAINTENANCE Section L GENERAL 5 1 Introduction seen mb 5 2 Tools Test Equipment and Supplies Section II ALIGNMENTS AND ADJUSTMENTS 5 3 Pap f tee oes tine nee ey hanks 5 4 Hammer Tips 5 5 Hammer Spring Retensioning 5 6 BUDE iii qusa quas 5 7 Stroke Timing ila 5 8 Hammer Phasing saeteke gsi Aa P3000 Maintenance Page Table of Contents Paragraph Title Page 5 9 Timing Belt Tension Adjustment 5 12 5 10 Paper Drive Motor Pulley Alignment 5 14 5 11 Spline Shaft Skew Adjustment 5 16 5 12 Platen Angle Adjustment 5 17 5 13 Platen Gap Adjustment
97. PRINTRONIX Maintenance Manual P3000 Printer P3000 Printer Maintenance Manual PRINTRONDC P N 111839 001 Rev C US and CANADA Radio Interference Note Note This device complies with Part 15 of the FCC Rules Operation is subject to the following two conditions 1 this device may not cause harmful interference and 2 this device must accept any interference received including interference that may cause undesired operation Properly shielded and grounded cables and connectors must be used in order to meet FCC emission limits The manufacturer is not responsible for any radio or television interference caused by using other than recommended cables and connectors or by unauthorized changes or modifications to this equipment Unauthorized changes or modifications could void the user s authority to operate the equipment The input output I O cable must be shielded for the printer to comply with FCC rules and regulations Part 15 governing the radiation limits for Class A equipment This Class A digital apparatus meets all requirements of the Canadian Interference Causing Equipment Regulations Cet appareil num rique de la classe A respecte toutes les exigences du R glement sur le mat riel brouilleur du Canada WARNING This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures Printronix Inc makes n
98. RSTUVWXYZIN1 abcderfghijklImnopqrstuvwxyzi GABCDEFGH GHIJKLMNOPGRSTUVWXYZLNJ abcdefghijkl1mnopqrstuvwxyzti GABCDEFGHI HIJKLMNOPGRSTUVWXYZLN1 abcdefghi jkImnopqrstuvwxyzt GABCDEFGHI J IJKLMNOPGRSTUVWXYZLN1 abcdefghijkiImnopqrstuvwxyzt i GABCDEFGHIJK JKLMNOPGRSTUVWXYZE 1 _ abcdefghi jkI1mnopqrstuvwxyzt GABCDEFGHIJKL KLMNOP RSTUVWXYZC _ abcdefghi jkImnopgrstuvwxyz ABCDEFGHIJKLM LMNOPQRSTUVWXYZE I _ abcdefghi jkImnopqgrstuvwxyz Y GABCDEFGHI JKLMN MNOPQRSTUVWXYZENJ abcdefghijkiImnopqrstuvwxyzt GABCDEFGHIJKLMNO NOPQRSTUVUXYZLNJ abcdefghijkl1mnopqrstuvwxyzt GABCDEFGHI JKLMNOP OPQRSTUVWXYZLNJ abcdefghijkImnopqrstuvwxyzt GABCDEFGHI JKLMNOPG PORSTUVWXYZEN1 abcdefghi jkImnopqrstuvwxyz GABCDEFGHI JKLMNOPGR QRSTUVWXYZENX1 abcdefghijkl1mnopqrstuvwxyz GABCDEFGHI JKLMNOPQRS RSTUVWXYZEN1 abcdefghijkl1mnopqrstuvwxyz GABCDEFGHI JKLMNOPQRST STUVWXYZ 1 _ abcdefghijkImnopqgrstuvwxyz Y GABCDEFGHI JKLMNOPQRSTU TUVWXYZENI1 abcdefghijklImnopqrstuvwxyzt CABCDEFGHI JKLMNOPQRSTUV WXYZC I _ abcdef 57 58 59 5B 5C 5D 5E SF 60 61 62 63 64 65 66 OA XYZE I _ abcdefg 58 59 SA 5B 5 5D SF 60 61 62 63 64 65 66 67 YZLN1 abcdefgh 59 58 5C 5D SE 5F 60 61 62 63 64 65 66 67 68 ZCO I _ abcdefghi 5B 5C 5D SE 5F 60 61 62 63 64 65 66 67 68 69 OA C I _ abcdefghij SB 5C 5D 5E SF 60 61 62 63 64 65 66 67 68 69 GA OA 1 _ abcdefghi jk 5C 5D SE 5F 60 61 62 63 64 65 66 67 68
99. Randomly P3000 Troubleshooting EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE r s s sn FFUEEEELUUHUEEREKE EUER E E OFEEEESEE nu EEREEEFTEEEEEEEE thuat DEERE QUE O IL EEE RECLEREEE PEE EE ee EEE EEF ps EEEEEEFKEEEEEEEE EEKEEEEEFEEEEEEEEFEEEEREEFEKEEEE EET EEKEEEEEEECEKEEEEEEEEEVCEEEHEZELUEZUUEERREEEECECER SZEEEEEEEEEEEEEEEE C EEEEEEEESEF TES EEEEEECKEEEEEEEE i
100. Ribbon does not change direction at end Verify ribbon guide connectors not reversed at mother board PCBA NO Connect properly Guides connected see App B YES Momentarily short Return across guide terminals normal operation and check for direction change Fail to NO Check to see change direction if printer needs cleaning YES NO Replace mechanism driver YES Clean printer per para 3 4 para 5 21 Apply power and short across guide terminals Apply power and check for symptom NO Fail to change direction Symptom present Return to normal operation NO Return to normal operation SHEET 2 Figure 4 16 Ribbon Does Not Change Direction at End Sheet 1 of 2 P3000 Troubleshooting FROM SHEET 1 FROM SHEET 1 Install new ribbon Apply power and check for symptom Return to normal operation Symptom present Replace failed ribbon guide per para 5 44 Apply power momentarily short across guide and check for direction change Fail to change direction Return to normal operation Continue to troubleshoot using standard techniques If problem remains contact authorized distributor service representative Figure 4 16 Ribbon Does Not Change Direction at End Sheet 2 of 2 P3000 Troubleshooting Shuttle does not move
101. STATE Figure 2 5 Print Hammer Action 2 6 P3000 Principles of Operation INDICATES DIRECTION OF SHUTTLE MOVEMENT DOT PAPER ROW START ADVANCES 1 2 3 i PAPER ONE E FEED CHARACTER gt ROW 9 000000 1 PAPER 11 SPACE 12 0 ADVANCES 1 2 USED FOR LOWERCASE DESCENDER ONLY USED FOR UNDERLINE AND LOWERCASE DESCENDER NOTE P3000 SHUTTLE SWEEPS THROUGH FOUR IN 10 CPI CHARACTER POSITIONS Figure 2 6 Standard Character Formation P3000 Principles of Operation SHUTTLE DOT SCAN ROW 1 gt 1 1 2 2 e RON Q b OQ N akhond N O Q N SUCCESSIVE HAMMER STROKES PER SCAN A 1 1 3 135 1357 13579 x EVEN COLUMN DOT CENTERS WITHIN THE PRINTED CHARACTER AREA AND CHARACTER SPACE HAMMER POSITIONS ARE NOT ILLUSTRATED IN THIS DIAGRAM NOTE O NO DOT WHERE HAMMER HAS BEEN O HAMMER POSITION Figure 2 7 Character Formation by One Hammer P3000 Principles of Operation 2 4 Printing Mechanism continuea The shuttle moves in alternate directions as it prints each successive row of dots Charac ters are formed by various dot matrices Figure 2 8 according to the selected print mode as shown in Table 2 1 Table 2 1 Dot Matrices vs Speed Density Speed Dots Correspondence NLO 7 on 13 centers 9 plus 3 descenders Data Processing 5 on 9 centers 7 plus 2 descenders High Speed 5 9 centers 5 plus 1 descen
102. XYZEN 1 abcderghi 7 10123456789 lt gt ABCDEFGHI JKLMNOPQR STUVUXYZE V 1 abcdefghij 0123456789 lt gt ABCDEFGHI JKLMNOPQRS TUVWXYZIXJ abcdefghi jk 0123456789 lt gt ABCDEFGHI JKL MNOPORST UVWXYZENJ abcdefghijkl 0123456789 lt gt ABCDEFGHI JKLMNOPQRSTU VWXYZE V 1 abcdefghi jkim 7 10123456789 8ABCDEFGHIJKLMNOPQRSTUV WXYZLV1 abcdefghijkImn 7 0123456789 lt gt ABCDEFGHI JKLMNOPORSTUVWXYZINJ abcdefghijkImno 0123456789 AR gt ABCDEFGHI JKLMNOP QRSTUVWX 2 1 abcdefghi Jk1mnop 0123456789 lt gt ABCDEFGHIJKLMNOP RSTUVWXYZI 1 _ abcdefghijkImnopq 70123456789 lt gt ABCDEFGHI JKLMNOP RSTUVWXYZ 1 _ abcdefghi jk lmnopar 0123456789 lt gt ABCDEFGHI JKLMNOPQRSTUVWXYZE 1 _ abcdefghi jklmnopqrs 123456789 lt gt ABCDEFGHI JKLMNOPQRSTUVWXYZL J abcdefghijkimnopqrst 23456789 lt gt JKLMNOPQRSTUVWXYZE 1 _ abcdefghi jk lmnoparstu 3456789 lt gt ABCDEFGHI JKLMNOPORSTUVWXYZLNVJ abcdefghi Jk1mnopqrstuv 456789 lt gt ABCDEF GHI JKLMNOPORSTUVWXYZIV1 abcdefghiJkimnopqrstuvw 56789 a 8ABCDEFGHIJKLMNOPORSTUVWXYZEN 1 abcdef ghi jk Imnopqrstuvwx 6789 lt gt ABCDEFGHI JKLMNOPQRSTUVWXYZIN 1 abcderghijkImnopqrstuvwxy 789 i gt ABCDEFGHI JKLMNOPQRSTUVWXYZE I _ ab cdefghi jk lmnopqrstuvwxyz 89 lt gt ABCDEFGHI JKLMNOPORSTUVWXYZ J _ abcdefghi jkimnopq
103. a 5 20 Replace encoder PCBA per para 5 32 Apply power and check for Apply power symptom and check for symptom Symptom NO present Return to Install original controller Symptom NO present Return to YES normal operation PCBA per para 5 20 Continue to troubleshoot using standard techniques If problem remains contact authorized distributor service representative Figure 4 18 Shuttle Jams or Moves too Slowly Sheet 3 of 3 4 40 P3000 Troubleshooting Bumpers NO OK Shuttle moves erratically Check forms thick YES Adjust bumpers ness lever setting pari 5 6 Return to Ng Replace Reposition forms YES thickness lever mechanism as required 5 Apply power and check for Apply power symptom and check for symptom Symptom NO present Symptom NO present YES Return to YES Return to Install original mechanism driver PCBA per para 5 21 Check and adjust platen gap per par 5 13 Replace controller PCBA per Apply power para 5 20 and check for symptom Apply power and check for symptom NO YES Return to normal operation Check bumper YES Return to X adjustment per normal operation para 5 6 O TO SHEET 2 Symptom NO present Figure 4 19 Shuttle Moves Erratically Sheet 1 of 2 P3000 Troubleshooting 4 41 FROM SHEET 1 Install original
104. a 91 4C 91EH Proto 000AA Xcelite PS120 Truarc 1120 Erem 11DH General 616 Utica TS35 Utica HW 18 Utica W 8 Utica HW 4 Utica HW 6 Xcelite 99PS40 Xcelite X100 Xcelite X102 Xcelite A184 Xcelite R3164 Section II ALIGNMENTS AND ADJUSTMENTS 5 3 Paper Scale Figure 5 1 1 2 Open cabinet cover 1 Verify shuttle cover 2 is properly installed NOTE It may be necessary to remove shuttle cover 2 when loosening and tightening screws 3 Loosen six button head screws 3 slightly Position scale 4 so that positions 1 and 132 are lined up with first and last character on a 132 character printout Tighten button head screws 3 Close cabinet cover 1 5 4 Hammer Tips Figure 5 2 Gain access to hammers by performing the procedures of paragraph 3 4c steps 1 through 4 and 6 Check alignment of hammer tips 1 by using short alignment tool 2A Aligned tips will fit holes in tool which will lie flat When tool fails to lie flat take note of which hammers are misaligned and which direction they must be moved to bring them into alignment Loosen screw 3 securing misaligned hammer 4 Check that hammer can be repo sitioned If not loosen adjacent screw 5 on same clamp 6 Reposition hammer and recheck alignment as required until all hammers rest in holes in the tool and the tool rests flat With tool held in position against hammers torque screw s loosen
105. agraph 5 27b steps 6 through 14 5 29 Hammer Spring Figure 5 24 Removal Open cover 1 Loosen two screws 2 Grasp shuttle cover 3 at both ends Lift upward to free front tabs then remove Unlock tractors 4 and move outward to sides Lift up on shuttle lock knob 5 and pull toward front of printer When shuttle assembly 6 has rotated 90 degrees to service position release knob 5 CAUTION J Shuttle is magnetized This may cause some difficulty in per forming the next step Be careful not to bend cover Carefully lift ends of hammer bank cover 7 from roll pins 8 Pivot cover 7 onto its rear edge to about 45 degrees then remove Remove socket head screw 9 that secures hammer 10 Loosen other screw 11 on same clamp plate 12 Remove hammer 10 by sliding it forward over hammer coil pole pin 13 Installation Place hammer 10 under clamp plate 12 Install socket head screw 9 Do not tighten Align hammer and complete installation per paragraph 5 4 P3000 Corrective Maintenance 10 LEE S 2 2 HO u Y H OSOQmSO lt Su uw 2 f 22 gt na iu E GEES 55225 Pedqdde2 Ite ee gi OOICrILIXOOXO JO OooroormirtoiriooOn NA Figure 5 24 Hammer Spring Removal Installation P3000 Corrective Maintenance 5 30 Hammer Coil Figure 5 25 a SU wb d uS Removal Rem
106. and install two socket head screws 11 Place hammer bank assembly 9 on mounting bar 14 Install two screws 8 Install hammer bank cover 7 Rotate shuttle 6 to operating position Install two screws 5 Install shuttle cover 4 Tighten two screws 3 Install ribbon 2 Close cover 1 Check bumper timing per paragraph 5 6 and adjust if required P3000 Corrective Maintenance COVER RIBBON SCREW 2 SHUTTLE COVER SCREW 2 SHUTTLE HAMMER BANK COVER SCREW 2 HAMMER BANK ASSEMBLY ENCODER COVER SCREW 2 ENCODER SPACER HAMMER BANK MOUNTING BAR DON AAA ALA Figure 5 26 Encoder Removal Installation P3000 Corrective Maintenance 5 32 Encoder PCBA Figure 5 27 a S A WwW 11 12 10 11 12 9 I S A B o m Removal Remove controller mechanism driver and power supply PCBAs per paragraphs 5 20 21a and 22 Disconnect connector P21 1 Feed connector around to and up through hole in center of base 2 Cut ties as necessary to free cable Remove three springs 3 4 and 5 using tool 995822 001 Remove two screws 6 and pivot retainers 7 Remove four screws 8 and casting brace 9 Remove hex head screw 10 and washer 11 Move aside cable anchor bracket 12 Pick up shuttle assembly 13 and flip it over Carefully rest it in base 2 Remove two screws 14 from encoder
107. anel normal operation per para 5 18 Apply power and check for symptom YES Install original mechanism driver PCBA per para 5 21 Symptom present NO Return to Check control panel normal operation cable for visible damage YES Install original display control panel per Replace control nl panel cable para 5 18 per para 5 19 YES Continue to trouble Replace front shoot using standard control panel Dam to techniques If problem assembly Norma Sium remains contact auth para 5 16 orized distributor service representative Figure 4 2 No Indicators Come on at Power up Sheet 3 of 3 4 10 P3000 Troubleshooting Indicators on both control panels operate improperly Inspect control panel Replace controller PCBA per para 5 20 cable for damage Cable NO Apply power K and check for symptom YES Replace control panel cable per para 5 19 NO 2 Apply power and check for ES symptom Install original controller PCBA per NO para 5 20 Return to Replace mechanism normal operation driver PCBA per para 5 21 Symptom present Replace both control panels per para 5 16 and 18 Apply power and check for symptom Apply power and check for symptom NO Symptom present Return to YES Return to Continue to normal operation troubleshoot using standard techniques
108. ation procedures contained in this manual 4 2 Common Causes of Malfunctions Improper printer operation may be caused by electronic failures mechanical failures or interface problems Many problems can be corrected by replacing one of the PCBAs Other problems associated with poor print quality can be cleared up by adjusting ham mer alignment platen gap shuttle turnaround time or belt tension The remaining prob lems can be attributed to particular assemblies of the printing mechanism or occasion ally to cables or interconnecting PCBAs 4 3 Internal Testing a Self Test The printer continuously monitors some of its own functions When a problem develops fault indications appear on the indicators and digital display A summary of these indica tions is presented in Table 4 1 b Supplemental Tests The printer is capable of conducting additional tests which can be used to evaluate its performance These tests which are summarized in Table 4 2 are useful as an aid to troubleshooting For specific procedures refer to User s Reference Manual 4 4 Fault Isolation Failures are divided into catagories as listed in the malfunction symptom index Table 4 3 To fault isolate locate your symptom in the table The table will direct you to a flow chart which will guide you through the correct troubleshooting procedure Note that these flow charts do not take multiple failures into consideration P3000 Troubleshooting
109. d stay on at power up Remove and reseat major PCBAs per para 5 20 through 22 leave cabinet off Check that micro processors and PROMs show no signs of dam age and are properly seated in their sockets Replace controller PCBA per para 5 20 Apply power and check for NO Replace affected symptom Components 5 Symptom NO Return to present normal operation power and check for symptom YES Install original controller PCBA per para 5 20 Replace cover per 5 15 Replace mechanism YES driver PCBA per para 5 21 Replace power Return to supply PCBA per normal operation para 5 22 Apply power and check for Apply power symptom and check for symptom Symptom present NO Return to normal operation Symptom present normal operation YES YES Instal original power Continue to supply PCBA per to troubleshoot using para 5 22 standard techniques If problem remains contact authorized distributor service representative Figure 4 1 All Indicators Come on and Stay on at Power up P3000 Troubleshooting 4 7 No indicators come on at power up Check that control panel Replace circuit breaker per para 5 47 cables are properly connected Apply power and check for symptom NO Cables connected Connect cables NO Return nor
110. der In the correspondence NLO mode for example lower case characters are formed in 12 rows of a 13 by 12 dot matrix Seven overlapping dots are printed in the horizontal plane on 13 vertical centers for accurate character rendition The dot printing process continues for the number of dot matrix rows determined by the selected print mode When an entire character line has been printed the paper transport advances the paper to the top dot row of the next character line to be printed During the line advance the hammer bank assembly continues the right left sweeping motion at this time however the print hammers are disabled from printing c Ribbon Transport The printer ribbon advances continuously on spool hubs Ribbon motors are driven while the hammer bank assembly is running and stop when it stops Ribbon motion is reversed when the foil at either end of the ribbon is detected Constant ribbon tension is maintained by controlling the motors with a differential drive 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 This system oper ates to maintain a constant motor speed and constant ribbon tension When the end of the ribbon is detected the two motors reverse direction P3000 Principles of Operation 2 9 TAPSIN mE SC H TAUNTON JJM AI NI N SS N a Y
111. e of characters is cre ated by a scanning pattern Figure 2 6 AII dots in any row of the dot matrix are printed in a single scan as the shuttle moves from one side to the other through the character columns spaces Figure 2 7 shows the order in which a single character is formed by a single print ham mer P3000 Principles of Operation SHUTTLE ASSEMBLY SHUTTLE ASSEMBLY ROTATED TO SERVICE ENCODER COVER POSITION EXPOSING HAMMER BANK ASSEMBLY HAMMER BANK COVER ASSEMBLY LINEAR ENCODER LINEAR MOTOR BAR ASSEMBLY SHUTTLE LOCKING KNOB BUMPER ASSEMBLIES ENCODER PCBA l NA ENCODER CABLE i ASSEMBLY ENCODER OPTICAL SWITCH NOTE CABINET EMI SHIELD COVER AND SHUTTLE COVER OMITTED Figure 2 3 Printing Mechanism P3000 Principles of Operation 2 5 COIL ASSEMBLY WITH HEATSINK EL HAMMERBANK CABLE ASSEMBLY PLATEN ZI MOUNTING PAD HAMMER 4 POLE PIN RIVETED MAGNET TIT HAMMER SPRING BACK PLATE 177 NI ASSEMBLY DIA N FRONT OF PRINTER PAPER HAMMERBANK PLATE CLAMP HAMMER SPRING SCREW Figure 2 4 Hammer and Shuttle Arrangement Cross Section DE ENERGIZED ENERGIZED HAMMER TIP a HAMMER SPRING NOTE CURVATURE OF SPRING PERMANENT AND AMOUNT OF TRAVEL ARE EXAGGERATED PERMANENT MAGNET NORMAL RETRACTED STATE ACTIVATED RELEASED
112. ectors Controls and Indicators Window Ribbon Cables Circuit Boards Fan and Motors Bumpers Check for damage cracks breaks dents gouges scratches de lamination warpage rust corrosion and proper finish Inspect screws bolts nuts washers for thread damage rust or corrosion Inspect for legibility and damage Inspect for damage and loose or missing hardware Inspect for damage and loose or missing hardware Inspect for damage bent or broken pins Inspect for damage Inspect for breaks cracks or discoloration Inspect for broken wire or strands damaged insulation pinched wiring and possible shorting conditions Inspect for breaks warpage evidence of overheated components Inspect for obvious damage Inspect for unusual wear If cracked chipped or worn unevenly replace per paragraph 5 33 P3000 Preventive Maintenance 3 4 Cleaning continued b Interior of Cabinet Figure 3 1 1 Disconnect ac power cord 1 from printer Open cabinet cover 2 Move forms thickness lever 3 to full open Remove paper from printer Squeeze locking latch 4 and lift ribbon spools 5 from ribbon hubs 6 Dislodge paper dust and ribbon lint with a soft brush Vacuum up residue Pay particular attention to tractor 7 hammer bank 8 and base pan 9 6 Wipe spline shaft 10 with soft cloth 7 Using cloth dampened with alcohol clean ribbon guides 11 at each side of cabinet 8
113. ed in step 4 above to 12 in lbs Carefully remove hammer alignment tool Install hammer bank cover Place shuttle in operating position Install shuttle cover Load ribbon and paper Run underline test pattern per User s Reference Manual Repeat alignment as nec essary until all hammer tips are properly aligned P3000 Corrective Maintenance 5 3 3 SCREW BUTTON HEAD 6 1 CABINET COVER 4 PAPER SCALE 2 SHUTTLE COVER Figure 5 1 Paper Scale Adjustment P3000 Corrective Maintenance HAMMER TIP 2 ALIGNMENT TOOL LONG 1 2A ALTERNATE ALIGNMENT TOOL SHORT 4 HAMMER SPRING ASSEMBLY 5 SCREW 6 CLAMP PLATE 3 SCREW Figure 5 2 Hammer Tip Alignment P3000 Corrective Maintenance 5 5 Hammer Spring Retensioning Figure 5 3 If performance tests repeatedly show a hammer is printing too light or too dark reten sion it using following procedure CAUTION J Bending too far in either direction will produce light print a Print Too Light 1 Open cabinet cover Set forms thickness lever to fully open Remove ribbon Re move shuttle cover 2 Rotate shuttle to service position Carefully bend end of hammer 1 in direction indicated with tip of screwdriver 2 3 Check print Repeat b as necessary to achieve acceptable print 4 Return shuttle to operating position Replace shuttle cover Close cabinet cover Print Too Dark Open cabinet cover Remove shuttle c
114. ent and Supplies 5 2 P3000 Maintenance iii List of Illustrations Figure Title Page 1 1 Printer with Pedestal 1 3 1 2 External Controls and Indicators 1 5 1 3 Internal Controls and Indicators 1 7 1 4 Controls and Indicators for 3287 Option 1 9 2 1 Printer Functional Block Diagram 2 2 2 2 Paper i ps port xu ee HR re Ear ao S tek 2 3 2 3 Printing Mechanism iii 2 5 2 4 Hammer and Shuttle Arrangement Cross Section 2 6 2 5 Print Hammer Action ae 2 6 2 6 Standard Character Formation 2 7 2 7 Character Formation by One Hammer 2 8 2 8 Typical Character Dot Patterns By Mode 2 10 2 9 Controller Block Diagram 2 12 2 10 Mechanism Driver Block Diagram 2 14 2 11 Hammer Bank Logic Drivers and Waveforms 2 16 2 12 Ribbon Driver Circuit eee eee 2 18 3 1 Cleaning Interior of Cabinet 3 3 3 2 Cleaning Hammer Bank Assembly 3 5 3 3 Cleaning Paper Troner libri s t kasuwaq 3 7 3 4 Cleaning Fan Ses ara 3 8 3 5 Paper Feed Belt Tension Check
115. er para 5 22 and check for symptom Apply power NO Return 1 and check for normal operation symptom YES Symptom Install original present mechanism driver PCBA per para 5 21 YES NO Return to normal operation Continue to troubleshoot using standard techniques If Replace controller PCBA per para 5 20 problem remains contact authorized distributor service representative Figure 4 21 Printer Does Not Print at All 4 44 P3000 Troubleshooting Printer fails to print only when controlled by host computer Perform internal diagnostic tests per User s Reference Manual Correct any problems detected Check for original symptom Symptom NO present YES Return to normal operation Refer to User s Reference Manual Check configuration Configuration NO O YES Correct configuration Return to normal operation Check host computer interface cable for damage Cable NO OK YES Repair or replace cable Return to normal operation Check host computer cable for excessive length more than 12 ft Cable NO OK YES Add pullup and pulldown resistors to controller per User s Reference Manual Apply power and check for symptom NO Return 1 normal operation Symptom present Replace controller PCBA per para 5 20 Apply power and check for symptom NO YES Retu
116. ffer memory is loaded into the hammer serial data multiplexer The output of the hammer serial data multiplexer is applied serially to the input of the serial shift register on the mechanism driver PCBA This is accomplished via the com pare COM line b HostInterface Parallel When the printer is on line and ready to operate it sends ready READY and on line ONLINE output signals to the host controller via the host interface When the host controller is ready to transfer a byte of code it puts the byte on the host interface data lines DATA 1 through DATA 8 followed by a data strobe DATA STROBE pulse DATA STROBE loads the byte into the interface latches DATA STROBE also sets the data available DAV interrupt latch which is polled by the microprocessor Upon receiving DAV the CPU uses an input service subroutine in program memory The microprocessor sends addressing information to the DCU I O port decoding logic The decoder will generate a read host data NRDHDATA in response This action transfers the host s data byte or control byte onto the DCU data bus DD0 DD7 Next the CPU generates a write control NDWR signal which is used to store the byte of data in ran dom access memory RAM NWRCTRLI is applied to the host interface circuitry to generate NACK The NACK signal is sent to the host controller to indicate that the printer is ready to receive the next byte of data P3000 Principles of Operation 2 11
117. forming PMCS Failure to do so could result in injury or equipment damage NOTE Perform PMCS every six months or after 500 hours of operation whichever comes first Perform them more often when operating under se vere conditions Table 3 1 Preventive Maintenance Checks and Service Item 3 3 Entire Printer Perform overall physical inspection per paragraph 3 3 Do not disassemble for this inspection Entire Printer Clean per paragraph 3 4 Entire Printer Run print sample adjust hammers if as required Timing Belt Check tension per paragraph 3 5 Tractor Belts Check tension per paragraph 3 5 Inspection Visually inspect printer using Table 3 2 as a guide Perform no disassembly for this inspection Correct any condition that could affect performance or reliability P3000 Preventive Maintenance 3 1 3 4 Cleaning CAUTION 9 Do not use abrasive cleaners particularly on window Do not drip water into printer Damage to equipment will result a Exterior of Cabinet 1 Wipe cabinet with clean lint free cloth dampened not wet with water and mild detergent Alternate method spray exterior surfaces lightly with window cleaner 2 Wipe dry with clean lint free cloth 3 Vacuum ventilation slots at rear of cabinet Table 3 2 Physical Inspection Cabinet Base Structure Attaching Hardware Nameplates Latches and Catches cover and shuttle Hinges Electrical Conn
118. ft register parallel outputs by hammer clock NHCK which is sent from the controller PCBA Each output of the shift register latch is connected directly to the input of the corresponding hammer driver circuit Figure 2 11 1 Hammer Reset Overdrive Logic The hammer reset overdrive logic is used to gen erate the signals hammer reset NHRS and overdrive OD NHRS is used to en able disable the outputs of the shift register OD is used to speed generation of the electromagnetic field which results in hammer release by causing an initial extra high current to be applied NHRS causes the drivers to turn off NHRS and OD are derived from signals from the controller PCBA hammer clock NHCK which loads data into the hammer data latches and 1 2 MCLK the system clock 2 Hammer Bank Drivers The hammer bank drivers consist of identical drivers one for each hammer coil and three identical Darlington drivers Each Darlington driver energizes a portion of the hammer coils while the others energize the remain ing hammer coils When a hammer is to print its hammer driver is turned on by the data latch output and the return path to 16 Vdc for the associated hammer coil is completed Simultaneously the Darlington drivers are turned on by OD and 30 Vdc is applied to all the coils Each of the coils that has its hammer driver enabled by the data latch is energized When the coil is energized the hammer is released to print After a time dela
119. g when tractors are locked P3000 Maintenance Overview Figure 1 3 Internal Controls and Indicators P3000 Maintenance Overview Table 1 3 Controls and Indicators for 3287 Option NOTE Only those controls and indicators that are not present on the standard panel Figure 1 3 are discussed below Key Fig 1 4 Control or Indicator Function ELECTRONIC ENABLE HOLD Places printer in hold print mode following completion switch of line being printed When pressed a second time en ables normal operation HOLD Lights to indicate printer is in hold print mode indicator REPRINT PA1 Causes reprint of all data in interface buffer in non switch SCS modes In SCS modes sends intervention re quired message to host processor Active only in hold print mode When used in conjunction with ALT MODE switch causes program attention signal to be sent to host proc essor CANCEL PA2 No effect in non SCS modes In SCS modes causes switch printing to stop and SCS print data to be cleared from buffer Active only in hold print mode ALT MODE Causes alternate switch functions PA1 and PA2 to be switch come active Active only in hold print mode Pressing a second time deactivates PA1 and PA2 READY Lights to show that printer is ready to print not in indicator hold print mode ERROR Indicates error condition exists indicator ALT Indicates alternate mode selected PA1 and PA2 active indicator 1
120. gnment Figure 5 10 10 Open cover 1 Verify paper and ribbon are installed Ribbon should have full spool on right hub 2 Run a shuttle and ribbon test Momentarily short between left ribbon guide skid screws 3 to assure right to left motion of ribbon Observe how ribbon 4 is passing through left guide 5 It should be centered If ribbon is not centered loosen retaining screws 6 just enough that guide 5 can be forced to new positions but otherwise remains in place Reposition guide 5 as necessary to center ribbon 4 Observe how ribbon 4 is winding on left spool 7 Reposition guide 5 as neces sary to allow ribbon to wind up without interference Tighten screws 6 Allow most of ribbon to accumulate on left spool 7 Repeat 3 through 9 for right guide 8 P3000 Corrective Maintenance COVER RIGHT HUB SCREW LEFT RIBBON GUIDE SKID 2 RIBBON RIBBON GUIDE LEFT SCREW RETAINING 2 LEFT SPOOL RIBBON GUIDE RIGHT YJ O Q N Figure 5 10 Ribbon Guide Alignment P3000 Corrective Maintenance Section III REPLACEMENT J WARNING J Unless otherwise specified all replacement procedures are to be performed with power disconnected from the printer Failure to remove power could result in injury to personnel or damage to equipment 5 15 Cabinet Figure 5 11 a di gt des Removal Disconnect power cord 1
121. gure 4 9 Paper Doesn t Feed at All Sheet 3 of 3 P3000 Troubleshooting 4 21 Paper feeds erratically Check that paper is not too thick NO Load correct paper YES or reset Forms Thickness Adjustment Lever Apply power and check for symptom NO Symptom present Check platen gap per para 5 13 NO Adjust platen gap per para 5 13 YES Apply power and check for symptom NO Return to normal operation Return normal operation Check that paper is feeding into printer properly Paper feeding in OK NO Reload paper Apply power and check for symptom NO Return to normal operation TO SHEET 2 Figure 4 10 Paper Feeds Erratically Sheet 1 of 4 P3000 Troubleshooting FROM SHEET 1 Disengage paper from tractors and check tension and drag on paper for even feeding Analyze and correct Tension source of drag and drag OK Refer to Figure 4 11 YES Apply power and check for symptom Symptom present Return to normal operation Check tractors for damage Replace tractors per para 5 38 Apply power and check for symptom Symptom present Return normal operation TO SHEET 3 Figure 4 10 Paper Feeds Erratically Sheet 2 of 4 P3000 Troubleshooting FROM SHEET 2 Check paper feed timing belt and pulley for damage or improper adjustment
122. inter hereafter referred to as the P3000 Series or simply the printer The following documents provide detailed information which supplements this manual a P3000 Printer Operator s Guide P N 111837 001 Contains instructions for unpacking installing and operating the printer b P3000 Printer User s Reference Manual P N 111838 001 Describes functions and applications available for the P3000 Printer 1 2 Printer Description Figure 1 1 a General The Printronix P3000 Series Printer is a multi purpose dot matrix line printer designed to produce labels and characters as well as the standard data processing and compressed print character lines and graphics at various densities b Standard Features 1 Configurable for Printronix P Series matrix line printer or serial matrix printer con trol code protocols 2 Multi application character printing 3 Graphics plotting 4 Dynamic font selection a Selectable pitch expanded normal and compressed b Shadow printing c Bold printing d Auto underlining e Superscripts and subscripts Double high characters Selectable forms length Nonvolatile electronic vertical formatting go c Resident international character sets P3000 Maintenance Overview 1 1 Printer Description continuea b 10 11 12 13 14 15 4 Standard Features continued Self test and diagnostics Test pattern printing Configuration printou
123. ion and check for symptom Replace display control panel per para 5 18 Symptom present Return to YES normal operation Apply power and check for symptom Continue to troubleshoot using standard techniques If problem remains contact authorized distributor service representative Figure 4 5 Digital Display Operates Improperly P3000 Troubleshooting 4 13 CHECK Indicator flashes display shows FAULT CONDITION PAPER OUT Check that printer has paper and it is loaded properly Paper loaded properly Load paper YES Check for symptom Return to normal operation Replace paper detect switch per para 5 42 Apply power and check for symptom Symptom present Return normal operation TO SHEET 2 Figure 4 6 CHECK Indicator Flashes Display Shows FAULT CONDITION PAPER OUT Sheet 1 of 2 4 14 P3000 Troubleshooting FROM SHEET 1 Apply power and check for symptom Replace mechanism driver PCBA per para 5 21 Symptom NO Return to present normal operation Apply power and check for symptom YES Install original controller PCBA per para 5 20 Replace motherboard Symptom No Return to PCBA per prosent normal operation para 5 42 YES Apply power and check for symptom Install original mechanism driver PCBA per 5 21 Symptom present N
124. is derived from the 30 Vdc output of the power supply PCBA while the 12 Vdc is derived from the 16 Vdc output of the power supply PCBA P3000 Principles of Operation 2 13 CONTROLLER PCBA RIB RIB PARK PF1 PF2 1 2 MCLK MO gt FENCE MASTER RIBBON MOTOR DRIVER RIBBON GUIDES BLOWER MOTOR DRIVER PAPER FEED STEPPER MOTOR DRIVERS HAMMER DATA LATCHES HAMMER SERIAL DATA SHIFT REG LINEAR MOTOR DRIVER ENCODER PULSE SHAPER 12 V POWER SUPPLY 12V POWER SUPPLY POWER UP RESET 5V MECHANISM DRIVER PCBA LEFT RIBBON MOTOR RIGHT RIBBON MOTOR BLOWER MOTOR PAPER FEED MOTOR HAMMER BANK DRIVERS DARLINGTON SHUTTLE LINEAR MOTOR ENCODER PCBA 30V 16V Figure 2 10 Mechanism Driver Block Diagram P3000 Principles of Operation 2 6 Mechanism Driver continued The mechanism driver PCBA contains driver circuits for the printing mechanism as fol lows Figure 2 10 Hammer Bank Drivers and Logic Blower Driver Linear Motor Driver Optical Encoder Signal Conditioning Ribbon Motor Driver Paper Feed Motor Drivers a Hammer Bank Logic The hammer bank logic consists of a serial shift register The serial data output COM of the hammer serial data multiplexer on the controller PCBA is clocked into the shift register by the hammer shift clock NHSC After the data is shifted in serially it is strobed to the shi
125. le cover 3 at both ends Lift upward to free tabs then remove Loosen lockscrews 4 and 5 NOTE It may be necessary to screw one bumper all the way in to remove the other one Unscrew front bumper 6 from base 7 Unscrew rear bumper 8 from base 7 Installation Install rear bumper 8 in base 7 Install front bumper 6 in base 7 Perform bumper adjustment procedure per paragraph 5 6 Tighten lockscrews 4 and 5 Install shuttle cover 3 Engage tabs then push down Tighten two screws 2 Close cover 1 P3000 Corrective Maintenance COVER SCREW 2 SHUTTLE COVER LOCKSCREW LOCKSCREW BUMPER FRONT BASE BUMPER REAR G D Q N Figure 5 28 Bumper Removal Installation P3000 Corrective Maintenance 5 34 Paper Feed Timing Belt Figure 5 29 Ve wee di aes a d c Removal Remove cabinet per paragraph 5 15a Remove two screws 1 and washers 2 Separate belt shield 3 from side plate 4 Loosen two hex screws 5 that hold motor 6 Slide belt 7 off spline pulley 8 and motor pulley 9 Installation Slip belt 7 over spline pulley 8 and motor pulley 9 Set belt tension per paragraph 5 9 3 and 4 Position belt shield 3 on side plate 4 Install two screws 1 and washers 2 Install cabinet per paragraph 5 15b P3000 Corrective Maintenance 2 2 WASHER 2 RIGHT SIDE PLATE BELT SHIELD SPLI
126. lied to the printer all indicators on both panels should light for about two seconds while the printer runs self check then all indicators except ONLINE should extinguish ONLINE should flash offline or come on and stay on online a All indicators come on and stay on at power up b No indicators come on at power up c Indicators on both control panels operate improperly d Switches or indicators operate improperly on front panel only e Digital display operates improperly CHECK INDICATOR COMES ON When the CHK indicator lights an accompanying fault message can be expected on the digital display a CHECK Indicator Flashes Display Shows FAULT CONDITION PAPER OUT 4 6 PLATEN OPEN 4 7 PAPER JAM 4 9 4 10 SHUTILE JAM SHUTILE STALL b CHECK Indicator on Continuously Display shows FAULT CONDITION 1 DCU RAM FONT PROM or MCU RAM Continued 4 4 P3000 Troubleshooting Table 4 3 Malfunction Symptom Index continued Flowchart Malfunction Symptom III PAPER TRANSPORT NOT FEEDING PROPERLY Paper motion and EVFU tests shown below may be useful in ac cessing paper feed problems a Paper Doesn t Feed at All b Paper Feeds Erratically or Jams c Paper Drags d Set Top of Form Not Operating IV RIBBON TRANSPORT FEEDS IMPROPERIY Before proceeding verify ribbon is positioned correctly in hammer bank cover spools are pushed all the way down and latch has seated ab
127. lint and ink accumulations Vacuum up any residual debris CAUTION J When reinstalling hammer bank cover 6 position it care fully and try to prevent the magnets from snapping it into place Position hammer bank cover 6 horizontally slightly above hammer bank over alignment holes adjacent to roll pins 7 Gently lower cover 6 steering it into place P3000 Preventive Maintenance SHUTTLE LOCK KNOB SHUTTLE ASSEMBLY 6 HAMMER BANK COVER SCREW 2 SHUTTLE COVER TRACTOR 2 7 ROLL PIN 2 1 2 3 4 5 8 HAMMER TIP 9 SCREW 2 10 BLOWER 11 FAN WHEEL Figure 3 2 Cleaning Hammer Bank Assembly P3000 Preventive Maintenance 3 4 Cleaning continued 12 13 14 15 Hammer Bank Assembly continued Pull out shuttle lock knob 4 and rotate shuttle to operating position Release knob Remove two screws 9 Lift blower 10 to expose fan wheel 11 Brush wheel 11 to loosen dirt Vacuum up residue Return blower 10 to position Install two screws 9 Grasp shuttle cover 2 with both hands Slide tabs at front of cover into slots at front of printer Press down on cover 2 until it snaps into position Tighten two captive screws 1 Close cabinet cover Fan Figure 3 4 Remove cabinet per paragraph 5 15a Loosen three screws 1 and remove EMI shield cover 2 NOTE Now is a good time to check paper feed timing belt per paragraph 3 5 Vacuum fan 3 t
128. ll two screws 4 Connect P22 1 to motherboard PCBA 2 Retie cable as required Install three nuts 9 washers 10 and shock mount spacers 11 Engage tabs on shuttle cover 8 then press down Tighten two screws 7 sq A Install controller mechanism driver and power supply PCBAs per paragraphs 5 20b 21b and 22b P3000 Corrective Maintenance 5 73 CONNECTOR P22 SCREW 2 SHUTTLE COVER NUT 3 WASHER 3 SHOCK MOUNT SPACER 3 MECHANICS BASE INTERLOCK SWITCH HEX SCREW PIN Q N MOTHERBOARD PCBA FORMS THICKNESS LEVER SCREW 2 PLATEN OPEN SWITCH MOUNTING BRACKET Figure 5 35 Interlock Cable Assembly Removal Installation 5 74 P3000 Corrective Maintenance 5 42 Paper Detect Switch Figure 5 36 NOTE If necessary to gain working room remove front and left rear shock mount screw and screw on left braided strap then shift printer base forward a Removal 1 Remove cabinet per paragraph 5 15a 2 Remove controller mechanism driver and power supply PCBAs per paragraphs 5 20 21a and 22 Disconnect P25 1 from motherboard PCBA 2 Remove four screws 3 and barrier panel 4 Loosen two screws 5 gx Sec Separate paper detect switch 6 from base casting 7 Cut cable ties as necessary and remove from printer b Installation 1 Install paper detect switch 6 on base ca
129. lso be used to restart the test if re quired NOTE Each time NEXT is pressed the index value increases Each time PREV is pressed the index value decreases 4 Repeat 1 through 3 for each print mode P3000 Corrective Maintenance 5 11 5 9 Timing Belt Tension Adjustment Figure 5 5 1 Check tension per paragraph 3 5a 1 steps 1 through 4 Loosen two hex screws 1 holding motor 2 against side plate 3 Apply tension to motor shaft to tighten belt 4 While maintaining tension tighten two hex screws 1 to 32 2 in lbs Verify 1 16 inch deflection of belt 4 Repeat adjustment if necessary Install timing belt shield 5 two screws 6 and washers 7 Install cabinet per paragraph 5 15b 5 12 P3000 Corrective Maintenance 1 16 DEFLECTION MAXIMUM SCREW HEX 2 MOTOR SIDE PLATE RIGHT BELT BELT SHIELD SCREW 2 WASHER 2 gt N Figure 5 5 Timing Belt Adjustment P3000 Corrective Maintenance 5 13 5 10 Paper Drive Motor Pulley Alignment Figure 5 6 m Remove cabinet per paragraph 5 15a Remove two screws 1 and washers 2 Separate belt shield 3 from side plate 4 Loosen two set screws 5 on motor pulley 6 Align motor pulley 6 to spline shaft pulley 7 Tighten set screws 5 Check tracking by doing several top of form operations and observing belt action Place belt shield 3 on side plate 4 In
130. ly 7 in base casting 5 Install two screws 6 Feed connector P27 3 through hole in center of base casting 5 and over to motherboard PCBA 4 Connect connector P27 3 to motherboard PCBA 4 Engage tabs on shuttle cover 2 then press down to seat Tighten two screws 1 Install cabinet per paragraph 5 15b P3000 Corrective Maintenance 5 81 N SCREW 2 CONNECTOR P27 MOTHERBOARD PCBA SCREW 2 BLOWER ASSEMBLY SHUTTLE COVER BASE CASTING Figure 5 39 Blower Assembly Removal Installation P3000 Corrective Maintenance 5 46 Fan Figure 5 40 a D Removal Remove cabinet housing per paragraph 5 15a Remove controller and power supply PCBAs per paragraphs 5 20a and 22a Re move any optional PCBA Remove three screws 1 Cut tie wraps as necessary to free wires to fan assembly 2 Separate fan 2 from fan mount 3 Installation Place fan 2 against fan mount 3 Install three screws 1 Retie wires as necessary Install controller and power supply PCBAs per paragraphs 5 20b and 22b Install any optional PCBA P3000 Corrective Maintenance 5 83 FAN MOUNT SCREW 3 FAN ASSEMBLY 1 2 3 y P Ve D t A 4 IZ 5 o _ 4 2 a Figure 5 40 Fan Removal Installation P3000 Corrective Maintenance 5 84 5 47 Circuit Breaker Figure 5 41 a Removal Remove cabinet per
131. m Driver Removal Installation 5 35 5 17 Controller PROM Locations 5 36 5 18 Power Supply PCBA Removal Installation 5 39 5 19 Shuttle Cover and Paper Scale Removal Installation 5 41 5 20 Motherboard PCBA Removal Installation 5 43 5 21 Cable Removal Installation 5 45 5 22 Shuttle Assembly Removal Installation 5 47 5 23 Hammer Bank Cable Assembly Removal Installation 5 49 5 24 Hammer Spring Removal Installation 5 51 5 25 Hammer Coil Removal Installation 5 53 5 26 Encoder Removal Installation 5 55 5 27 Encoder PCBA Removal Installation 5 57 5 28 Bumper Removal Installation 5 59 5 29 Paper Feed Timing Belt 5 61 5 30 Paper Drive Motor Removal Installation 5 63 5 31 Spline Shaft Removal Installation 5 65 5 32 Support Shaft Removal Installation 5 67 5 33 Paper Ironer Removal Installation 5 69 5 34 Platen Removal Installation 5 71 5 35 Interlock Cable Assembly Removal Installation
132. mal operation Replace AC input filter assembly per para 5 48 Symptom present YES Return to normal operation Remove cabinet per para 5 15 Check fan Apply power and check for symptom Fan blades rotating NO Return normal operation YES Check AC power Restore power Return normal operation TO SHEET 2 Figure 4 2 No Indicators Come on at Power up Sheet 1 of 3 4 8 P3000 Troubleshooting FROM SHEET 1 Check that major PCBAs are seated in connectors NO Symptom Return to normal operation Apply power YES and check for symptom Replace power supply PCBA per para 5 22 Apply power and check for symptom No Return to normal operation YES Install original power supply PCBA per 5 22 Replace controller PCBA per para 5 20 Apply power and check for symptom NO Return to normal operation YES TO SHEET 3 Figure 4 2 No Indicators Come on at Power up Sheet 2 of 3 P3000 Troubleshooting 4 9 FROM SHEET 2 Apply power and check for symptom Install original controller PCBA per para 5 20 Symptom present Replace mechanism driver PCBA per para 5 21 YES NO Return to normal operation Install original Apply power front control panel and check for assembly per symptom para 5 16 Replace display NO Return to control p
133. mmer Tips 5 3 Paper Drive Motor Pulley Alignment 5 14 Paper Scale 5 3 Platen Gap 5 20 Platen Angle 5 18 Figure 5 19 Ribbon Guide 5 22 Spline Shaft Skew 5 16 Stroke Timing 5 10 Timing Belt Tension 5 12 All Indicators Come on and Stay on at Power up Figure 4 7 P3000 Index INDEX B Belt Tension Check Paper Feed 3 9 Figure 3 10 Belt Adjustment Timing Belt Figure 5 13 Belt Replacement Paper Feed Timing 5 60 Figure 5 61 Belt Tension Adjustment Timing 5 12 Block Diagram Controller Figure 2 12 Mechanism Driver 2 14 Printer Functional Figure 2 2 Blower Replacement 5 82 Figure 5 83 Blower Motor Not Operating Figure 4 74 Bumper Adjustment 5 8 Figure 5 9 Replacement 5 58 Figure 5 59 C Cabinet Interior of Cleaning Figure 3 3 Cabinet Exterior of Cleaning 3 2 Interior of Cleaning 3 3 Replacement 5 24 Figure 5 25 Cable Replacement Control Panel Figure 5 33 Cable Assembly Replacement Hammer Bank 5 48 Cable Assembly Replacement Hammer Bank Figure 5 49 Causes of Malfunctions Common 4 1 Character Formation by One Hammer Figure 2 8 Standard Figure 2 7 Character Positions Light or Smeared Fig ure 4 58 Characters Light or Smeared Example Fig ure 4 57 Characters Misformed Vertically Figure 4 67 Characters Misformed Vertically Example Figure 4 66
134. n with a stainless steel band provide a bearing action to the hammer bank assembly allowing it to move with low friction The optical linear encoder produces timing pulses that are used to determine hammer bank assembly position and speed to synchronize printing b Hammer Bank Assembly Printing is done by a row of 34 print hammers mounted on the hammer bank assembly Each hammer consists of a stiff leaf spring with a small cylindrical tip on one end It is held securely on the hammer bank by a screw passing through its other end A permanent magnet running the full length of the hammer bank and acting through individual pole pins holds all 34 hammer springs in the retracted tensioned state Each print hammer has associated with it a normally deenergized electromagnetic coil mounted on the pole pin Figure 2 4 The end of this pin magnetically attracts the free end of the hammer spring keeping it under tension When hammer driver logic deter mines that the hammer is to print a dot a current pulse energizes the coil The polarity of the resulting magnetic field opposes the field of the permanent magnet releasing the hammer which allows it to impact the ribbon and paper Figure 2 5 and leave a dot on the paper During flight time the coil is deenergized As the hammer rebounds after striking the permanent magnet recaptures the hammer and holds it ready for the next stroke In correspondence NLO and data processing DP modes a lin
135. nance Manual P3000 Electronic Drawings A 1 P3000 Electronic Drawings P3000 Parts List APPENDIX B PARTS LIST cross referenced to Chapter 5 Section III art B 1 The following table contains a parts listing for items that appear in the illustrations of Chapter 5 Section III Maintenance Replacement Please note the following 1 Parts not appearing in Chapter 5 will not be listed 2 Not all parts listed are available 3 Some parts listed may not be field replaceable TABLE B 1 PARTS LIST FIGURE AND TITLE PART NO COMMENTS ITEM NO NAME Figure 5 11 Cabinet Removal Installation 1 POWER CORD 101512 001 2 COVER iaia 111702 001 3 SCREW 2 iaia 140059 001 4 CONTROL PANEL 111421 01 5 DISPLAY CONTROL PANEL 111485 001 6 SCREW PHILLIPS 2 108732 001 7 SCREW PHILLIPS 2 105839 001 8 WASHER FINISHING 2 105838 001 9 CABINET ASSY 111091 001 10 BASE a ia 111365 003 112083 003 Figure 5 12 Control Panel Removal Installation 1 2 3 4 5 6 Figure 5 13 Cover Removal Installation 1 2 3 4 5 POWER CORD 102512 001 COVER 111702 001 usa 140059 001 CONTROL PANEL 111421 001 CABINET
136. o remove paper lint and chaff Install EMI shield cover 2 and tighten three screws 1 Install cabinet per paragraph 5 15b P3000 Preventive Maintenance PAPER IRONER 1 NOTE COVER CABINET AND EMI SHIELD COVER OMITTED FOR CLARITY MOVED SHUTTLE ASSEMBLY ROTATED TO SERVICE POSITION HAMMER BANK COVER RE Figure 3 3 Cleaning Paper Ironer P3000 Preventive Maintenance 1 SCR EW 3 2 EMI SHIELD COVER 3 FAN Figure 3 4 Cleaning Fan 3 8 P3000 Preventive Maintenance 3 5 Paper Feed Belt Tension Check Figure 3 5 1 Remove cabinet per paragraph 3 44 steps 1 through 3 2 Remove two screws 1 3 Separate belt shield 2 from right side plate 3 4 Depress center of upper span of belt 4 with finger Ideal deflection is 1 16 inch If tension is incorrect adjust per paragraph 5 9 5 Place belt shield 2 against right side plate 3 6 Install two screws 1 7 Replace cabinet per paragraph 5 15 a and b P3000 Preventive Maintenance 3 9 Q N SCREW 2 BELT SHIELD SIDE PLATE RIGHT BELT 1 16 INCH DEFLECTION MAXIMUM Figure 3 5 Paper Feed Belt Tension Check 3 10 P3000 Preventive Maintenance CHAPTER4 TROUBLESHOOTING 4 1 General This chapter provides procedures to fault isolate to field replaceable units A working knowledge of the P3000 Operator s Guide and the P3000 User s Reference Manual is required to perform fault isol
137. o 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 material or for any damages whether direct indirect incidental or consequential in connection with the furnishing distribution performance or use of this material The information in this manual is subject to change without notice This document contains proprietary information protected by copyright No part of this document may be reproduced copied translated or incorporated in any other material in any form or by any means whether manual graphic electronic mechanical or otherwise without the prior written consent of Printronix Inc All rights reserved Revision C January 1996 PRINTRONX 17500 Cartwright Road P O Box 19559 Irvine California 92713 Telephone 714 863 1900 FAX 714 660 8682 Technical Support 714 221 2686 COPYRIGHT 1988 1989 1996 PRINTRONIX INC Table of Contents Paragraph Title CHAPTERI MAINTENANCE OVERVIEW 1 1 ERE 1 2 Printer Description Li 1 3 Operation sip diede pa CHAPTER 2 PRINCIPLES OF OPERATION 2 1 General 2 2 Functional Elements Secs aa kas 2 3 Paper Transport erem athe e a 2 4 Printing Mechanism eee 2 5 Controller
138. of speed at any time during the paper feed cycle 2 Ribbon Motion Ribbon motion is controlled by the RIB PARK signal which causes equal tension to be applied to both ribbon motors causing ribbon motion to stop and by the RIB sig nal which allows the ribbon to move whenever the shuttle is in motion 3 Pulse Duration Modulator PDM Shuttle Drive Generator At the PDM shuttle drive generator a byte of motion data is presented to the shut tle drive generator latch and is loaded into it by NWRSTLMTR pulse Bit 0 is sent immediately to the mechanism driver PCBA where it determines the direction the hammer bank assembly is to take Bits 1 through 7 are applied to the generator s counter and are loaded into it when the 32 microsecond pulse is coincident to MSYSCLK The high order bit of the counter is set to a high or low state and re mains at that level until the counter count progresses far enough to change it The result is a pulse width modulated signal NLMD which is sent to the linear motor driver to control shuttle speed The width depends on the contents of the byte latched into the generator 2 6 Mechanism Driver PCBA The mechanism driver PCBA contains those circuits required to drive the printing mechanism These driver circuits are under control of the controller PCBA The mecha nism driver PCBA also produces by use of regulators the 12 Vdc and 12Vdc re quired by the controller PCBA for the serial interface The 12 Vdc
139. onic Drawings Electronic drawings and schematics required for field mainte nance are included here Parts List A parts lists cross referenced to Chapter 5 Section III is included here Controls and Indicators Throughout this manual in text controls and indicators are printed exactly as they appear on the printer with all capital letters Controls and indicators that do not have labeled names are given functional names that are printed with the first letter of each word capitalized For example the POWER switch has two settings ON and OFF The Forms Thickness Adjustment Lever is oper ated by raising and lowering Warnings Cautions and Notes In this manual extra information is given under the headings WARNING CAUTION AND NOTE They are set off from the text around them and appear in special typefaces Warnings give information about conditions that could lead to injury Cautions provide information about condi tions that could lead to equipment damage Both warnings and cautions are printed in bold type Notes provide extra information and are printed in italics What This Manual Does Not Contain Detailed specific information which appears in the User s Reference Manual will not be repeated in the maintenance manual P3000 Maintenance vii 3000 CHAPTER I MAINTENANCE OVERVIEW 1 1 Introduction This manual contains information required to maintain and repair the Printronix P3040 Pr
140. operation power supply para 5 21 PCBA per para 5 22 Apply power and check for Apply power symptom and check for symptom Symptom NO Return to present normal operation YES NO Return to normal operation YES Install original mechanism driver PST Continue to troubleshoot using standard techniques If Replace controller PCBA per para 5 20 problem remains contact authorized distributor Service representative Apply power and check for symptom Figure 4 13 Ribbon Does not Move at All Sheet 2 of 2 P3000 Troubleshooting Ribbon folds over Check ribbon for wear damage etc Ribbon NO OK Replace ribbon Apply power and check for symptom YES Symptom present Check to see if printer needs cleaning NO YES Clean printer per para 3 4 Apply power and check for symptom Symptom present NO Return to normal operation NO Return to normal operation Adjust ribbon guides per para 5 14 Apply power and check for symptom NO Return to YES normal operation Adjust spool hub height by loosening set screw and repositioning as required Apply power and check for symptom Symptom NO present Return to YES normal operation Continue to troubleshoot using standard techniques If problem remains contact authorized distributor Service representative Figure 4 14
141. or coils A constant current controller circuit is used to stabilize the induc tive current pulses smoothing paper drive operation and protecting circuit compo nents This controller circuit monitors current flow through the motor coils and controls the duration of the pulses applied to the push pull driver The effect of this circuit is to maintain motor coil current at a relatively constant value while still permitting the motor shaft to move at variable speeds The motor coil current is monitored across a 0 1 Ohm resistor connected to the ground side of the push pull driver The voltage drop across this resistor controls the limiting ac tion of the circuit and drives a low pass filter The filtered output signal is an error input signal to the controller circuit The stages of the controlled circuit are referenced to VREF and RAMP RAMP and VREF work together with NRUN1 and NRUN2 to set the pulse width of the signals sent to the paper feed motor The output of the controller is a pulse with a duration proportional to the input error signal This variable width pulse is used to gate the paper feed pulses to the push pull drivers and consequently vary the duration of the motor drive pulses to control the cur rent P3000 Principles of Operation 2 19 2 6 Mechanism Driver e Power up Reset Logic The power up reset logic is used to generate the master clear signal NMC This circuit is activated NMC is low
142. ove hammer per paragraph 5 29a CAUTION j Be careful not to damage pole pin when removing hammer coil Break off coil heat sink 1 Strip off top of coil 2 and wires 3 Split bobbin shaft 4 and peel away from pole pin 5 Clean pole pin 5 thoroughly Installation CAUTION j Be careful when installing hammer coil Damage to coil or pole pin is possible Do not tap into place using hammer Press new hammer coil assembly 7 down firmly so base is below pole pin surface Be sure to align and seat contact pins into hammer bank cable assembly 6 Install hammer per paragraph 5 28b P3000 Corrective Maintenance HAMMER BANK CABLE COIL ASSEMBLY NEW Figure 5 25 Hammer Coil Removal Installation P3000 Corrective Maintenance 5 31 Encoder Figure 5 26 a 9e BS gt 9 Removal Open cover 1 Remove ribbon 2 Loosen two captive screws 3 Grasp shuttle cover 4 at both ends Lift upward and remove Remove two screws 5 Rotate shuttle 6 to service position Remove hammer bank cover 7 Remove two screws 8 Move hammer bank assembly 9 aside to expose encoder cover 10 Remove two socket head screws 11 using ball end Allen wrench Using needlenose pliers remove encoder cover 10 Carefully lift out encoder 12 and spacer 13 Installation Position encoder 12 and spacer 13 on hammer bank mounting bar 14 Place encoder cover 10 in position
143. ove spool and that ribbon is tracking properly in guides a Ribbon Does Not Move at All b Ribbon Folds Over c Ribbon Does Not Run Smoothly d Ribbon Does Not Change Direction at End V SHUTTLE MOVEMENT NOT NORMAL a Shuttle Does Not Move at All b Shuttle Jams or Moves Too Slowly c Shuttle Moves Erratically d Shuttle Movement Produces Knocking Sound Continued P3000 Troubleshooting 4 5 Table 4 3 Malfunction Symptom Index continued Flowchart Malfunction Symptom VI PRINTER DOES NOT PRINT PROPERIY a Printer Does Not Print at All Printer Fails to Print Only When Controlled by Host Computer Characters Missing see Fig 4 23 for example 1 Characters Missing Consistently 2 Characters Missing Randomly Missing Dots see Fig 4 26 for example 1 Consistent Dropout of Dots 2 Random Dropout of Dots Character Positions Light or Smeared see Fig 4 29 for example Dots Misplaced g Improper Print Density see Fig 4 32 for example Improper Horizontal or Vertical Alignment see Fig 4 34 and 4 35 for examples i Characters Misformed Vertically see Fig 4 37 for example j Erratic Character Height See Paper Feeds Erratically k Compacted Print see Fig 4 39 for example See also Paper Feeds Erratically 1 Garbled Print and or Incorrect Font VII BLOWER MOTOR NOT OPERATING 4 6 P3000 Troubleshooting All indicators come on an
144. over Remove ribbon Rotate shuttle to service position Remove hammer spring per paragraph 5 29a Grip spring 1 with pliers 3 across mounting hole Bend tip back slightly Install spring per paragraph 5 29b Align hammer tips per paragraph 5 4 Rotate shuttle to operating position GE CES Install shuttle cover Close cabinet 5 6 P3000 Corrective Maintenance PRINT TOO LIGHT PRINT TOO DARK HAMMER SPRING ASSEMBLY 2 SCREW DRIVER 3 PLIERS 1 Figure 5 3 Hammer Spring Retensioning P3000 Corrective Maintenance 5 6 Bumpers Figure 5 4 T 0 N 10 11 12 1 2 NOTE Bumper adjustment should be performed in conjunction with a check and adjustment of stroke timing 5 7 and hammer phasing 5 8 Rough Adjustment Turn off power Loosen two screws 1 and remove shuttle cover 2 Install shipping bolts 3 Loosen clamp screws 4 and 5 Insert narrow end of bumper adjusting tool 6 between front bumper 7 and re bound pad 8 Adjust position of front bumper 7 until tool 6 can be removed with only slight resistance Tighten clamp screw 4 Rotate hammer bank to service position Insert wide end of tool 6 between rear bumper 9 and hammer bank 10 with notch on tool toward hammer bank Adjust position of rear bumper 9 so that tool 6 can be removed with only slight resistance Tighten clamp screw 5
145. owly Check forms thick ness lever setting NO Reposition lever YES Apply power and check for symptom Symptom present NO Return to normal operation Check for paper jam Paper NO Check for jam ribbon fold over s YE Clear paper jam NO Is it folding over Apply power Check adj just and check for YES platen gap per symptom para 5 13 NO Apply power Return to and check for normal operation symptom RIBBON FOLDS OVER YES TO SHEET 2 Figure 4 18 Shuttle Jams or Moves too Slowly Sheet 1 of 3 4 38 P3000 Troubleshooting FROM SHEET 1 NO Return to normal operation YES Manually move shuttle and check for binding Determine source of binding and repair YES Apply power and check for symptom Symptom NO present Return to normal operation Check bumper timing per Replace para 5 6 mechanism driver PCBA per para 5 21 NO ee per Apply power and check for symptom YES Return to normal operation 8 TO SHEET 3 Figure 4 18 Shuttle Jams or Moves too Slowly Sheet 2 of 3 P3000 Troubleshooting 4 39 FROM SHEET 2 Replace encoder per para 5 31 Apply power NO and check for symptom Symptom present Return to Install original mechanism driver PCBA per para 5 21 NO Return to YES normal operation Replace controller PCBA per par
146. per Gain access to shuttle and remove hammer bank cover per paragraph 5 29a steps 1 through 5 Remove paper ironer per paragraph 5 39a Rotate shuttle 3 to operating position Check platen angle per paragraph 5 12 CAUTION J Do not force platen against feeler gauge Damage to printer will result Insert 0 012 in flat feeler gauge 4 between platen 5 and hammer tips 6 within four hammer positions of end of hammer bank Carefully close forms thickness lever 2 until hammer tips and platen contact feeler gauge With lever closed gauge should contact both tips and platen and move with very little friction Shift gauge slightly to verify Repeat 5 through 7 at other end of hammer bank and four hammers in the mid dle two on each side of support pin Readjust gap as required by manipulating set screws 7 located at each end of platen 5 Check gap at both ends and center after each adjustment When adjustment is correct install paper ironer per paragraph 5 39b Install hammer bank cover per 3 4c steps 10 and 11 Install shuttle cover per paragraph 5 236 Install ribbon and paper Print repeating Hs to check print quality P3000 Corrective Maintenance P3000 Corrective Maintenance Figure 5 9 Platen Gap Adjustment COVER FORMS THICKNESS LEVER SHUTTLE ASSEMBLY FLAT FEELER GAUGE PLATEN HAMMER TIP SET SCREW 2 5 14 Ribbon Guide Ali
147. present para 3 4 Return to normal operation Replace ribbon Adjust platen gap per para check for symptom Apply power and check for symptom NO Return to normal operation NO Return to normal operation YES A Check condition TO SHEET 2 of ribbon Figure 4 28 Random Dropout of Dots Sheet 1 of 3 4 54 P3000 Troubleshooting FROM SHEET 1 Rotate shuttle to service position per para 3 4c 2 4 Check hammer coil s for visible damage and proper position on pole pin Continuity check sl 5 7 Reposition coil s per para 5 30 or replace per para 5 30 Apply power and check for symptom Return to normal operation Replace controller PCBA per para 5 20 Apply power and check for symptom Return to Symptom normal operation present TO SHEET 3 Figure 4 28 Random Dropout of Dots Sheet 2 of 3 P3000 Troubleshooting FROM SHEET 2 Install original controller PCBA per para 5 20 Replace mechanism driver PCBA per para 5 21 Apply power and check for symptom NO Return to normal operation Symptom present NO Return to normal operation YES YES Replace shuttle assembly Install original per mechanism driver ara 5 27 PCBA per E para 5 21 Apply power and check for Replace symptom power supply PCBA per para 5 22 Symptom presen
148. rn to normal operation Problem is most likely in host computer printer controller or application program Figure 4 22 Printer Fails to Print Only When Controlled by Host Computer P3000 Troubleshooting EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEE
149. rstuvwxyz 9 lt gt ABCDEFGHI JKLMNOPQRSTUVWXYZE 1 _Tabcd ef ghi jk Imnopqrstuvwxyz Figure 4 34 Improper Horizontal Alignment Example P3000 Troubleshooting 4 63 EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH
150. stall two screws 1 and washers 2 ies 55 oue Install cabinet per paragraph 5 15b 5 14 P3000 Corrective Maintenance SCREW 2 WASHER 2 BELT SHIELD SIDE PLATE RIGHT SET sCREWS MOTOR PULLEY SPLINE SHAFT PULLEY O Q N Figure 5 6 Paper Drive Motor Pulley Alignment P3000 Corrective Maintenance 5 15 5 11 Spline Shaft Skew Adjustment Figure 5 7 If lines of print are not parallel with perforations on paper perform the following adjust ment 1 Loosen screw 1 securing adjusting link 2 2 Adjust link 2 to obtain print parallel with perforations Tighten screw 1 Check results by printing Es ESTA ELE SI SN N S IS 1 SCREW 2 ADJUSTING LINK Figure 5 7 Spline Shaft Skew Adjustment P3000 Corrective Maintenance 5 12 Platen Angle Adjustment Figure 5 8 a e py EM dm cum Preferred Method with alignment tool Remove paper from printer Remove cabinet per paragraph 5 15 Loosen two captive screws 1 and remove shuttle cover 2 With Forms Thickness Adjustment Lever 3 fully closed check angle of platen 4 using 995641 001 platen angle tool 5 If angle is correct stop No adjustment is necessary If angle is incorrect loosen clamp screw 6 and setscrew 7 Reposition platen 4 to correct angle Slide platen 4 to right and forms thickness lever 3 to left to remove end pla
151. sting 7 Under two screws 5 Tighten two screws 5 Make sure switch 6 is parallel with paper ironer Install barrier panel 4 and four screws 3 Connect P25 1 to motherboard PCBA 2 Retie wire as necessary A ge d Install controller mechanism driver and power supply PCBAs per paragraphs 5 20b 21b and 22b 6 Install cabinet per paragraph 5 15b P3000 Corrective Maintenance 5 75 PAPER DETECT SWITCH MOTHERBOARD PCBA BASE CASTING CONNECTOR P25 SCREW 4 BARRIER PANEL SCREW 2 2 3 4 5 6 7 Figure 5 36 Paper Detect Switch Removal Installation P3000 Corrective Maintenance 5 76 5 43 Ribbon Drive Motor Figure 5 37 CAUTION j Mounting screws for left and right motors are of different lengths do not interchange screws damage to motor is pos sible a Removal NOTE Procedure below is for left drive motor Procedure for right drive motor is identical except disconnect P29 in step 4 m Remove cabinet per paragraph 5 15a and shuttle cover per paragraph 5 23a Remove PCBAs per paragraphs 5 20a 21a and 22a Raise forms thickness lever 1 to full open position Disconnect P28 2 from motherboard PCBA 3 Cut tie wraps as necessary and remove cable Loosen screw 4 in ribbon spool hub 5 Lift hub 5 from shaft of motor 6 Hold motor 6 and remove three screws 7 and washers 8 Hes dodo amp UE Separate
152. t Apply power NO Return to normal operation and check for symptom YES Continue to troubleshoot using standard techniques If problem remains contact authorized distributor service representative Figure 4 28 Random Dropout of Dots Sheet 3 of 3 4 56 P3000 Troubleshooting EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE
153. t Datastream HEX code printout Resident serial and parallel interfaces Selectable alternate horizontal and vertical dot densities Configurable for 13 2 or 13 6 inch print width Optional Features Intelligent Graphics Processor IGP a Forms generation b Bar code printing c Expanded character printing d Reverse image printing e Rotated character printing f Logo generation Optional character sets IBM interfaces a 3282 3287 b 5225 5224 Ribbon fault detector 1 3 Operation a Operating Procedures For detailed operating instructions refer to P3000 Printer Operators Guide P N 111837 001 b Controls and Indicators NOTE The following tables contain a brief summary of control and indicator functions For a detailed discussion refer to the User s Reference Manual For optional controls and indicators refer to the PI 3287 User s Reference Manual PIN 108174 001 External Controls and Indicators External controls and indicators are illustrated in Figure 1 2 and described in Table 1 1 Internal Controls and Indicators Internal controls and indicators are illustrated in Figure 1 3 and described in Table 1 2 Controls and Indicators for Options Printers configured to emulate an IBM 3287 will have external controls and indicators as shown in Figure 1 4 and described in Table 1 3 P3000 Maintenance Overview P3000 Maintenance Overview Figure 1 1 Printer with Pedes
154. tainer 16 Remove four screws 17 and casting brace 18 Lift shuttle 19 out of printer while feeding connectors P21 3 and J11 7 and J12 8 out through holes in base casting 23 NOTE Be careful that wear saddles at end of axles are not inadvertently dropped and lost during removal installation of shuttle Installation Feed connectors P21 3 J11 7 and J12 8 through holes in base casting 23 and position shuttle 19 in printer Verify wear saddles 20 are in place Install casting brace 18 and four screws 17 Remove shuttle end play a Loosen two cap screws 21 b Insert 0 005 inch flat feeler gauge between right end of shuttle shaft 22 and base casting 23 c Push shuttle assembly 19 to left while pushing right end of shaft 22 against feeler gauge and base casting 23 d Tighten two cap screws 21 Remove feeler gauge Install right pivot retainer 16 and two screws 15 Install three springs 12 13 and 14 using tool 995822 001 Place cable anchor bracket 11 on base casting 23 Install screw 10 Route connectors P21 3 J11 7 and J12 8 to their respective locations in base 9 P3000 Corrective Maintenance 1 SCREW 2 13 SPRING RIGHT 2 SHUTTLE COVER 14 SPRING LEFT LOWER 3 CONNECTOR P21 15 SCREW 2 4 MOTHERBOARD PCBA 16 PIVOT RETAINER 5 SCREW HEX 2 17 SCREW 4 6 WASHER 2 18 CASTING BRACE 7 CONNECTOR J11 19 SHUTTLE 8 CONNECTOR J12
155. tal Table 1 1 External Controls and Indicators Key Fig 1 2 Control or Indicator Function ON OFF Applies and removes ac power to printer ON LINE Sets printer online or offline switch ON LINE Illuminates steadily to indicate printer online indicator ready for computer messages Flashes to indicate printer offline not ready to accept messages CLEAR Resets check circuitry Used to clear check switch indicators after corrective action CHECK Illuminates to indicate printer problem Steady indicator light indicates service is required Flashing light indicates operator correctable problem Lighting of indicator is accompanied by display of message on internal display panel see Table 4 1 6 8LPI Selects line spacing of six or eight switch 8LPI Illuminates when alternate selected indicator PAPER ADV Moves paper one line when pressed momentarily switch Moves to top of form when pressed for than 0 5 second NOTE Top of form must be reset each time new paper is loaded see operator s guide VFU Illuminates when EVFU is loaded indicator 1 4 P3000 Maintenance Overview ON LINE CHECK Figure 1 2 External Controls and Indicators P3000 Maintenance Overview 1 5 Table 1 2 Internal Controls and Indicators NOTE The following electronic controls function only when the printer is of fline Key Fig 1 3 Control or Indicator Function ELECTRONIC
156. tch is set to the opposite state and control circuits and motors reverse roles When no printing is taking place RIB PARK is high and both FETS are turned off The motors then act in equal opposition to stop ribbon movement RIB PARK also is applied to the blower motor driver circuit There it is used to turn off the blower when printing is not in progress P3000 Principles of Operation 2 17 30 V 30 V 5V 5V N RIGHT LEFT RIB RIB MOTOR MOTOR RIGHT E LEFT RIBBON NS RIBBON MOTOR DRIVER mm MOTOR DRIVER COMMON FET 1 FET2 RIB PARK RIB SWR RIB SW L Figure 2 12 Ribbon Driver Circuit 2 18 P3000 Principles of Operation 2 6 Mechanism Driver PCBA continuea d Paper Drive Motor Drivers The paper drive motor is an incremental stepper motor containing two pairs of coils One pair of coils is driven by paper feed motor driver signals PFI NRUNI while the other pair is driven by PF2 NRUN2 The paper feed motor drivers are controlled by pa per feed pulses PF1 and PF2 NRUNI and NRUN2 are enable signals used conjunc tion with PF1 and PF2 to prevent spurious paper motion Paper feed pulses are under program control and require no manual intervention PF1 NRUN1 and PF2 NRUN2 pulses control the identical and essentially independent drive circuits Each drive circuit operates in like fashion The paper feed pulses are gated to a push pull amplifier to provide current through that pair of the mot
157. turn to normal operation Symptom present Inspect paper ironer TO SHEET 2 Figure 4 9 Paper Doesn t Feed at All Sheet 1 of 3 P3000 Troubleshooting FROM SHEET 1 NO Replace paper ironer Apply power and check for symptom YES Symptom present 2 NO Return to normal operation Check Replace tractor belts tractor s per 5 58 Apply power N and check for pud 9 symptom YES Inspect paper drive motor and cable N 2 Return to normal operation for signs of damage Check input to Motor and drive motor cable OK Voltage present during paper drive TO SHEET 3 TO SHEET 3 Figure 4 9 Paper Doesn t Feed at All Sheet 2 of 3 4 20 P3000 Troubleshooting FROM SHEET 2 FROM SHEET 2 Replace drive motor per para 5 35 Replace mechanism driver PCBA per para 5 21 Apply power and check for symptom Apply power and check for symptom Symptom present Symptom present NO Return to NO normal operation Return to normal operation YES YES Install original mechanism driver PCBA per para 5 21 Replace controller PCBA per para 5 20 Apply power and check for symptom Symptom present NO Return to normal operation YES Continue to troubleshoot using standard techniques If problem remains contact authorized distributor service representative Fi
158. ues If problem remains contact authorized distributor Service representative Figure 4 31 Dots Misplaced Sheet 2 of 2 P3000 Troubleshooting FTVUFEEEFVETYYEEETECEFVETEVUEYEVETVEUEEUYEEEEEEEEEETUEEEUUEEEEEEFEEEEEEE s STE t i La Ie CEP rE Le hd hi DI DISSE BERE E DE DE eB tt s DENEN GEA IS S TUM MM tees ae bal i ahha HORE ati ton a ag fa Ape LAE t E Ok DO HEEEEEEEELhnutos EEEEEEEEEEEEEE
159. ure 5 34 a e e e D Ul F WN CC oo X GS E Removal Remove cabinet per paragraph 5 15a Remove paper ironer per paragraph 5 39a 2 through 5 Remove three screws 1 Lift ironer mounting plate 2 from printer Loosen forms thickness lever retaining screw 3 and setscrew 4 Slip forms thickness lever 5 off shaft of platen 6 Disconnect spring 7 from right side plate 8 Slide spring link 9 with bearing 10 off shaft of platen 6 Remove screw 11 and washer 12 Slide platen open switch bracket 13 off of shaft of platen 6 Remove screw 14 and spacer 15 Loosen platen restraint screw 16 Slide restraint 17 off shaft of platen 6 Disconnect spring 18 from left side plate 19 Slide spring link 20 with bearing 21 off shaft of platen 6 Move right end of platen 6 forward until it clears right side plate 8 then move platen to right until it clears left side plate 19 Slide left platen adjustment bracket 22 and right platen adjustment bracket 23 and two washers 24 off shaft of platen 6 Do not reposition wear saddles 25 P3000 Corrective Maintenance gt 17 21 SCREW 3 1 MOUNTING SCREW SETSCREW FORMS THICKNESS LEVER PLATEN SPRING RIGHT SIDE PLATE SPRING LINK RIGHT BEARING SCREW WASHER SWITCH BRACKET SCREW SPACER SCREW
160. ure 5 26 Encoder Removal Installation 1 COVER 2 4 sense br aspa rale ASR as 111702 001 2 RIBBON lille UE n a 3 SCREW 2 140058 001 4 SHUTTLE COVER 111790 001 5 SCREW 2 102786 606 6 SHUTTLE ASSY 111057 001 amp 003 7 HAMMER BANK COVER ASSY 111071 001 SCREW 2 hasas e 102288 007 9 HAMMER BANK ASSEMBLY 111392 001 amp 003 10 ENCODER COVER 110618 001 11 SCREW 2 101514 053 12 ENCODER ey erem bere a 111063 001 13 SPACER Vis P tnb nama anan 111694 001 14 HAMMER BANK MOUNTING BAR part of item 6 P3000 Parts List B 5 TABLE B 1 PARTS LIST continued FIGURE AND TITLE ITEM NO NAME Figure 5 27 Encoder PCBA Removal Installation CONNECTOR P21 BASE CASTING MECH SPRING SPRING PIVOT RETAINER 2 SCREW 4 CASTING BRACE e SCREW jib ied ir e a 10 WASHER 11 ANCHOR BRACKET 12 SHUTTLE ASSEMBLY 13 SCREW 2 14 ENCODER BRACKET 15 SCREW ies sadan 16 OPTICAL SENSOR 17 SCREW 2 18 ENCODER PCBA
161. urn to normal operation cover for proper installation Installation OK Replace ironer per para 5 39 or cover per para TO SHEET 2 Return to normal operation Figure 4 11 Paper Drags Sheet 1 of 2 3 4 1 4 amp 6 Apply power and check for symptom NO Return normal operation P3000 Troubleshooting FROM SHEET 1 Check paper feed timing belt for wear or improper adjustment Adjust per para 5 9 or replace per para 5 34 Apply power and check for symptom Return to normal operation Symptom present Inspect tractors for damage or binding Replace tractors per para 5 38 Apply power and check for symptom Symptom present Return to normal operation Continue to troubleshoot using standard techniques If problem remains contact authorized distributor service representative Figure 4 11 Paper Drags Sheet 2 of 2 P3000 Troubleshooting 4 27 Set Top of Form does not operate Be sure you are pressing CLEAR and PAPER ADVANCE together Technique NO YES OK Correct technique Return to 2 normal operation YES Check tractors Install original for binding Return to mechanism driver normal operation PCBA per para 5 21 NO Replace controller PCBA per YES P Replace tractors para 5 20 per para 5 38 Apply power and check for symptom Apply power and check for symptom
162. y 30 V HB is disconnected from the coil when OD turns off the Dar lington drivers A constant 16 V is applied to the coils to sustain coil current and is turned off when NHRS clears the data latch b Linear Motor Driver The linear motor driver provides drive for the two linear motor coils on the shuttle and consists of two push pull drivers and control circuits The three inputs to the linear motor drivers NLMD DIR and NTA come from the MCU section on the controller PCBA The linear motor drive pulse NLMD is a pulse width modulated signal generated by the shuttle drive generator The shuttle speed is directly proportional to pulse width The longer the drivers are on the faster the shuttle is driven by the linear motors P3000 Principles of Operation 2 15 NHSC NHCK OD DATA COM NHRS 30V HB OVER DRIVE OD DARLINGTON PAIR SHIFT REGISTER LATCHES TYPICAL HAMMER BANK DRIVER 16 Figure 2 11 Hammer Bank Logic Drivers and Waveforms P3000 Principles of Operation Mechanism Driver continuea b Linear Motor Drive continued The direction DIR input also is generated by the shuttle drive generator on the control ler PCBA and is used to control the left and right shuttle direction by steering the polarity of the NLMD pulses to the linear motor drivers The remaining input signal to the linear motor drivers is the turnaround NTA signal which is sent from the controller PCBA
163. y Ensure Forms Thickness Lever is fully closed Tighten clamp screw 6 and then setscrew 7 Install shuttle cover 2 Tighten two captive screws 1 Install cabinet per paragraph 5 15b Alternate Method without alignment tool J CAUTION J This procedure exposes hammer tips to possible damage and is less accurate than the preferred method Exercise care when performing this procedure Perform steps 1 and 2 of a above With the Forms Thickness Lever 3 fully closed check distance from top of ham mer tip to top edge of platen using six inch steel rule see detail A Is dimension correct a If yes proceed to step 5 b If no loosen clamp screw 6 and setscrew 7 and reposition platen as neces sary Perform step 7 of a above Perform steps 8 and 9 above P3000 Corrective Maintenance 5 17 RULE HAMMER TIP PLATEN HAMMER TIP REAR VIEW DETAIL A CAPTIVE SCREW 2 SHUTTLE COVER FORMS THICKNESS ADJUSTMENT LEVER PLATEN PLATEN ANGLE TOOL CLAMP SCREW SETSCREW NOS N Figure 5 8 Platen Angle Adjustment 1 of 2 5 18 P3000 Corrective Maintenance AN lee s Figure 5 8 Platen Angle Adjustment 2 of 2 P3000 Corrective Maintenance 5 13 Platen Gap Adjustment Figure 5 9 10 11 12 13 NOTE Nominal setting for platen gap is 0 012 001 inch Open cover 1 Raise forms thickness lever 2 to open position and remove pa

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