Printronix P4280 User manual

P4280 Line Matrix Printer
Maintenance Manual
R

P4280 Line Matrix Printer
Maintenance Manual
R
P/N 155064–001, Rev B

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 numérique de la classe A respecte toutes les exigences du Règlement sur le matériel 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 no representations or warranties of any kind regarding this material, including, but not
limited to, implied warranties of merchantability and fitness for a particular purpose. Printronix, Inc. shall not
be held responsible for errors contained herein or any omissions from this 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 B. January
, 1996.
Trademark Acknowledgements
IBM is a registered trademark of International Business Machines Corporation.
Intelligent Graphics Processor and IGP are trademarks of Printronix, Inc.
Printronix is a registered trademark of Printronix, Inc.

17500 Cartwright Road, P.O. Box 19559
Irvine, California 92713
Telephone [phone] FAX [phone]
Technical Support (714) 221–2686
COPYRIGHT
1992, 1996, PRINTRONIX, INC.

i
Table of Contents
1Maintenance Overview
About This Manual 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Documents 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Use This Manual 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings and Special Information 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Printing Conventions in This Manual 1–3. . . . . . . . . . . . . . . . . . . . . . . .
Controls and Indicators 1–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools, Test Equipment, and Supplies 1–10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
2Scheduled Maintenance
Preventive Maintenance Checks and Services (PMCS) 2–2. . . . . . . . . . . . . .
Inspecting the Printer 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the Printer 2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3Troubleshooting
Introduction 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Messages 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48 Volt Failed * 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dynamic RAM Fault 3–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ham. Bank Hot * 3–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ham. Coil Open * 3–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ham. Coil Short * 3–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ham. Drv. Short * 3–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mech Driver Hot * 3–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mech Driver Link * 3–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper Jam 3–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii
Paper Out 3–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platen Open 3–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ribbon Stall 3–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shttl Cover Open 3–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle Jam 3–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Error 3–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symptoms Not Indicated by Fault Messages 3–18. . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Aids 3–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Self–Tests 3–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Running the Diagnostic Self–Tests 3–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hex Code Printout 3–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4Adjustment Procedures
Preparing the Printer for Maintenance 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt, Paper Feed Timing, Adjustment 4–2. . . . . . . . . . . . . . . . . . . . . . . .
Belt, Platen Open, Adjustment 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer Phasing 4–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper Drive Motor Pulley Alignment 4–8. . . . . . . . . . . . . . . . . . . . . . . .
Paper Scale Alignment 4–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platen Angle Adjustment 4–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platen Gap Adjustment 4–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platen Open Motor Pulley Alignment 4–16. . . . . . . . . . . . . . . . . . . . . . . .
Ribbon Guide Alignment 4–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Splined Shaft Skew Adjustment 4–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5Replacement Procedures
Preparing the Printer for Maintenance 5–3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Procedures 5–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt, Paper Feed Timing 5–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt, Platen Open 5–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable Assembly W4, Hammer Bank 5–8. . . . . . . . . . . . . . . . . . . . . . . . .
Cable Assembly W5, Intermediate 5–10. . . . . . . . . . . . . . . . . . . . . . . . . .

iii
Cable Assembly, Multi I/O 5–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker 5–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel Assembly 5–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover Assembly, Hammer Bank 5–22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover Assembly, Shuttle 5–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Assembly, Card Cage 5–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Assembly, Cabinet Exhaust 5–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Assembly, Hammer Bank 5–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer Spring Assembly 5–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetic Pick–up (MPU) Assembly 5–34. . . . . . . . . . . . . . . . . . . . . . . . .
Motor Assembly, Ribbon Drive 5–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Assembly, Paper Feed 5–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Assembly, Platen Open 5–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper Guide Assembly 5–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper Ironer 5–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PCBA, Common Controller 5–46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PCBA, Mechanism Driver 5–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PCBA, Power Supply 5–50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platen 5–52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROMs, Chips, and ICs on the CCB 5–58. . . . . . . . . . . . . . . . . . . . . . . . .
PROMs, Chips, and ICs on the Mechanism Driver 5–60. . . . . . . . . . . . . .
Resistors, Terminating 5–62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ribbon Hub 5–64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ribbon Guide Assembly (L/R) 5–66. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft, Splined 5–68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft, Support 5–70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle Frame Assembly 5–72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring Assembly, Gas 5–76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring, Extension 5–78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch Assembly, Cover Open 5–80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch Assembly, Paper Detector 5–82. . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch Assembly, Platen Interlock 5–84. . . . . . . . . . . . . . . . . . . . . . . . . .
Tractor (L/R) 5–86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iv
6Optional Equipment
IGP–200/210 Option 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CT Option 6–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CT Installation 6–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CT Control Panels 6–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error Processing 6–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Messages 6–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symptoms Not Indicated by Fault Messages 6–28. . . . . . . . . . . . . . . . . . .
Printer Self Tests 6–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGP and CT Options Combined 6–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendices
A: Printer Configuration
B: Printer Specifications
C: Torque Table
D: Wire Data
E: Principles of Operation
F: Ferrite Noise Suppression Cores
G: Metric Conversion Tables
Index

1–1Maintenance Overview
1Maintenance Overview
Chapter Contents
About This Manual 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Documents 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Use This Manual 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings and Special Information 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printing Conventions in This Manual 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls and Indicators 1–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Controls and Indicators 1–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Controls and Indicators 1–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools, Test Equipment, and Supplies 1–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–2 Maintenance Overview
About This Manual
This manual explains how to maintain and repair the P4280 line matrix
printer at the field service level of maintenance. This manual covers
alignments and adjustments, preventive and corrective maintenance,
troubleshooting, and basic principles of operation.
Related Documents
Information about operating the P4280 printer is in the P4280 Operator’s
Guide. Installation and setup are covered in the P4280 Setup Guide.
How to Use This Manual
This manual is designed so you can quickly find the information you need to
maintain and repair the printer. You can locate maintenance information three
ways:
•Use the Table of Contents at the front of the manual.
•Use the Chapter Contents list on the first page of each chapter.
•Use the Index at the back of the manual.
Read the entire procedure before beginning any maintenance task. Gather all
required tools and make sure you understand all warnings, cautions, and
notes before you begin working on the printer.
Warnings and Special Information
Always read and comply with information highlighted by special headings.
The headings reveal the nature of the information:
WARNING
Conditions that could harm you as well as damage the equipment.
CAUTION
Conditions that could damage the printer or related equipment.
IMPORTANT
Information vital to proper operation of the printer.

1–3Maintenance Overview
NOTE: Information considered important enough to emphasize.
Printing Conventions in This Manual
Switches and indicators labeled on the printer are printed uppercase in this
manual. Example: “Press the ON LINE switch to take the printer off–line.”
If a control is not labeled on the printer, it is printed lowercase. Example:
“Set the forms thickness lever to the fully open position.”
Messages that appear on the control panel display are printed inside
quotation marks in lowercase with the first letter capitalized. Example: “Save
Config”appears on the message display.

1–4 Maintenance Overview
Controls and Indicators
The locations of the printer cover, cabinet doors, and operator control panel
are shown in Figure 1–1.
Electrical controls and indicators are described on page 1–6.
Mechanical controls and indicators are described on page 1–8.

1–5Maintenance Overview
Hinged on left.
Magnetic latch.
Open by pulling
right edge.
Lift to open
(Not shown)
Hinged on right.
Magnetic latch.
Open by pulling
left.
ON LINE FF VIEW
ENTER
CLEAR
R/S
SET
TOF LF
NEXTPREV
DOWN
UP
Operator Control Panel
Floor Cabinet
Front Door
Printer Cover
Rear Door
Operator
Control
Panel
See Detail
RAISE PRINTER
COVER TO ACCESS
THESE SWITCHES
Figure 1–1. Printer Cover, Doors, and Operator Control Panel

1–6 Maintenance Overview
Electrical Controls and Indicators (Figure 1–2)
Switch or
/O
ON LINE
Message display
LF
Function
= On O = Of f Turns printer on and off. Switch is
Toggles the printer on–line and off–line.
Displays printer status and error messages.
Indicator
Status lamps
FF Advances paper to top of form on next page.
VIEW
UP
DOWN
See above.
PREV
NEXT
Locks
and unlocks ENTER switch when pressed
simultaneously with DOWN switch. Also causes
display of configuration menus, submenus, and
diagnostic tests.
R/S
ENTER
Displays previous parameter in a configuration or
diagnostic test menu.
Illuminate when printer is on–line. Flash alternate-
ly to indicate fault. Off when printer is off–line.
Advances paper to top of next print line.
Runs and stops configuration and self tests. Runs
and stops hex dump. Resets printer when pressed
simultaneously with CLEAR switch.
Enters displayed parameter into printer nonvola-
tile memory
. Must be unlocked before using.
Clears printer after a fault is corrected. Returns
printer to off–line state from within a configura-
tion menu. Resets printer when pressed simulta -
neously with R/S switch.
Displays next parameter in a configuration or
diagnostic test menu.
Advances paper for viewing through cover win-
dow, then returns paper to print position.
CLEAR
SET TOF Sets location of first line of print on a page.
NOTE: Only the ON LINE switch operates when the printer is on–line.
All other switches operate only in the off–line state.
also a circuit breaker.

1–7Maintenance Overview
ON LINE FF VIEW
ENTER
CLEAR
R/S
SET
TOF LF
NEXTPREV
DOWN
UP
Status LampsMessage Display
(On) (Off)
Power Switch
RAISE PRINTER
COVER TO ACCESS
THESE SWITCHES
Figure 1–2. Electrical Controls and Indicators

1–8 Maintenance Overview
Mechanical Controls and Indicators (Figure 1–3)
Control or FunctionIndicator
Forms thickness
lever
Forms thickness
pointer and scale
Tractors (2)
Tractor locks (2)
Horizontal
adjustment knob
Vertical position
knob
Lock tractors in position.
Sets platen for paper and forms of different thick-
nesses. Must be fully opened (raised) to load paper .
Hold and feed paper
. Used to set side mar gin.
Allows fine positioning of left print mar
gins. Moves
paper left or right.
Used to set top of form or first line to be printed. Rotate
to move paper vertically.
(See Figure 1–3)
Indicates relative thickness of forms or paper. Set the
forms thickness lever at A for thin (single–part) forms,
B for thicker forms, and so on.

1–9Maintenance Overview
Vertical
Position
Knob
Tractor
Lock
Left Tractor Door
Right Tractor Door
Horizontal
Adjustment
Knob
Tractor
Lock
Forms Thickness Pointer
Forms Thickness
Lever and Scale
Figure 1–3. Mechanical Controls and Indicators

1–10 Maintenance Overview
Tools, Test Equipment, and Supplies
The tools and equipment required for field level maintenance of P4280
printers are listed below.
Item Part No.
RTV
silicone sealant
Adjustable wrench
Diagonal cutters
Digital voltmeter
Extension 3 in., 3/8 in. drive
Feeler gauge set
Alcohol, anhydrous (must contain no water)
Kimwipes
Nut driver set
Oscilloscope and probes (35 MHz or better)
Pliers, grip ring
Pliers, chain nose
Ratchet, 3/8 in. drive
Rule, steel, 6 in.
Screwdriver, torque, Utica TS–35
Adapter, 1/4 in. hex to 1/4 in. square, Utica HW–18
Hex bit, 3/32 in., torque screwdriver
Hex bit, 5/32 in., torque screwdriver
Screwdriver, Allen hex (set), w/extension
Screwdriver, Phillips
Screwdriver, flat tip
Small magnet
T
ie wraps
Socket, 7/16 in., 3/8 in. drive
101537–001
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–

Lubricant, bearing 101805–001
Force gauge CAT 719–20
Tweezers –
(Chatillon NY, Gauge–R, 0–20 lb)
(Lubriko M–3, Master Lubricant Co.)

Hex bit, 5/64 in., torque screwdriver –
Hex bit, 3/16 in., torque screwdriver

–
–
–
–
–
Platen Angle Adjustment Tool 996146–001

2–1Scheduled Maintenance
2Scheduled Maintenance
Chapter Contents
Preventive Maintenance Checks and Services (PMCS) 2–2. . . . . . . . . . . . . . . . . . . .
Inspecting the Printer 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the Printer 2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–2 Scheduled Maintenance
Preventive Maintenance Checks and Services (PMCS)
Perform preventive maintenance checks and services (PMCS) every six
months or after every 1000 hours of operation, whichever comes first.
Do these checks more often if the printer is used for heavy–duty, continuous
printing or is located in a dusty area.
PMCS are listed in Table 2–1.
WARNING
Disconnect the ac power cord before performing PMCS. Failure to do so
could result in injury to you or damage to equipment.
Table 2–1. Preventive Maintenance Checks and Services
Interval Procedure
Inspect the printer.
Clean the printer.
Check and adjust
platen gap.
Every 6 months or 1000
hours of operation,
whichever occurs first.
Page
2–3
2–4
4–14