Printronix P5000 Series User manual

Maintenance Manual
®
Printronix P5000 Line Matrix Printers

175455-001B
Maintenance Manual
P5000 Line Matrix Printers
®

Trademark Acknowledgements
Trademark Acknowledgements
ANSI is a registered trademark of American National Standards Institute, Inc.
Centronics is a registered trademark of Genicom Corporation.
Code V is a trademark of Quality Micro Systems.
Chatillon is a trademark of John Chatillon & Sons, Inc.
Dataproducts is a registered trademark of Dataproducts Corporation.
EIA is a registered service mark of Electronic Industries Association.
ENERGY STAR® is a registered trademark of the United States
Environmental Protection Agency. As an ENERGY STAR® Partner,
Printronix has determined that this product meets the ENERGY STAR®
guidelines for energy efficiency.
IBM is a registered trademark of International Business Machines
Corporation.
IEEE is a registered trademark of the Institute of Electrical and Electronics
Engineers.
IGP is a registered trademark of Printronix, Inc.
Intelligent Printer Data Stream and IPDS are trademarks of International
Business Machines Corporation.
LinePrinter Plus is a registered trademark of Printronix, Inc.
MS-DOS and Microsoft Windows (3.1x, 95, 98, Me, NT, 2000, and XP) are
trademarks of Microsoft Corporation.
PC-DOS is a trademark of International Business Machines Corporation.
PGL is a registered trademark of Printronix, Inc.
PrintNet is a registered trademark of Printronix, Inc.
Printronix is a registered trademark of Printronix, Inc.
PSA is a trademark of Printronix, Inc.
QMS is a registered trademark of Quality Micro Systems.
RibbonMinder is a trademark of Printronix, Inc.
SureStak is a trademark of Printronix, Inc.
Torx is a registered trademark of Camcar/Textron Inc.
Utica is a registered trademark of Cooper Power Tools.
Warranty And Copyright Information
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.

Communication Notices
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.
Copyright © 2002, 2003, Printronix, Inc.
Communication Notices
Federal Communications Commission (FCC) Statement: This equipment
has been tested and found to comply with the limits for a Class A digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to
provided reasonable protection against harmful interference when the
equipment is operated in a commercial environment. This equipment
generates, uses, and can radiate radio frequency energy and, if not installed
and used in accordance with the instruction manual, may cause harmful
interference to radio communications. Operation of this equipment in a
residential area is likely to cause harmful interference, in which case the user
will be required to correct the interference at his own expense.
Properly shielded and grounded cables and connectors must be used in order
to meet FCC emission limits. Printronix is not responsible for any radio or
television interference caused by using other than recommended cables and
connectors or by any unauthorized changes or modifications to this
equipment. Unauthorized changes or modifications could void the user’s
authority to operate the equipment.
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.
Canadian Department of Communications Compliance Statement: This
Class A digital apparatus complies with Canadian ICES-003.
Avis de conformite aux normes du ministere des Communcations du
Canada: Cet appareil numerique de la classe A est conform á norme NMB-
003 du Canada.
European Community (EC) Conformity Statement:
This product is in conformity with the protection requirements of EC Council
Directive 89/336/EEC on the approximation of the laws of the Member States
relating to electromagnetic compatibility. Printronix cannot accept
responsibility for any failure to satisfy the protection requirements resulting
from a non-recommended modification of the product, including the fitting of
non-Printronix option cards.
German Conformity Statement:
Zulassungsbescheinigung Gesetz über die elektromagnetische
Verträglichkeit von Geraten (EMVG) vom 30. August 1995
Dieses Gerät ist berechtigt in Übereinstimmung mit dem deutschen das EG-
Konformitätszelchen - CE - zu führen.

Communication Notices
Der Außteller der Konformitätserklärung ist die Printronix......(1)
Informationen in Hinsicht EMVG Paragraph 3 Abs. (2) 2:
EN 55022 Klasse A Geräte bedürfen folgender Hinweise:
Nach dem EMVG: “Geräte dürfen an Orten, für die sie nicht asreichend
entstört sind, nur mit besonderer Genehmigung des Bundesminesters für
Post und Telekommunikation oder des Bundesamtes für Post und
Telekommunikation betrieben werden. Die Genehmigung wird erteilt, wenn
keine elektromagnetischen Störungen zu erwarten sind.” (Auszug aus dem
EMVG, Paragraph 3, Abs. 4) Dieses Genehmigungsverfahren ist nach
Paragraph 9 EMVG in Verbindung mit der entsprechenden Kostenverordnung
(Amtsblatt 14/93) kostenpflichtig.
EN 55022: Dieses ist eine Kategorie A Vorrichtung. Betrieb in den
Wohnbereichen kann elektrische Störung verursachen. Es ist die
Verantwortlichkeit des Benutzers, passende Gegenmaßnahmen zu ergreifen.
EN 55024: Begrenzung Werte für Gebrauch in bevölkerten Bereiche,
kommerziellen und Industriegebieten sind innen Übereinstimmung mit den
spezifizierten Anforderungen Hinsichtlich Störfreiheit.
Anmerkung: Um die Einhaltung des EMVG sicherzustellen sind die Geräte,
wie in den Handbüchern angegeben, zu installieren und zu betreiben.
This product has been tested and found to comply with the limits for Class A
Information Technology Equipment according to European Standard EN
55022. The limits for Class A equipment were derived for commercial and
industrial environments to provide reasonable protection against interference
with licensed communication equipment.
Das Gerät erfüllt die Schutzanforderungen nach EN 55022 und
EN 55024 Klasse A.
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.
Warning

Communication Notices

Communication Notices

9
Table Of Contents
1 Maintenance Overview....................................... 15
About The Printer.................................................................................15
P5000 Printers..................................................................................... 15
H-Series Printers........................................................................... 15
Make Sure You Order The Correct Spares................................... 16
How To Identify A Printer .............................................................. 16
Important Maintenance Notes..............................................................19
About This Manual............................................................................... 19
How To Use This Manual.............................................................. 20
Notices .......................................................................................... 20
Safety Notices......................................................................................21
Hinweise zur Sicherheit.......................................................................21
Controls And Indicators .......................................................................22
Electrical Controls, Cabinet Models .............................................. 22
Electrical Controls, Pedestal Models............................................. 24
Mechanical Controls, All Models................................................... 26
Tools, Test Equipment, And Supplies..................................................28
Plugging In The Printer........................................................................ 29
Printronix Customer Support Center.................................................... 29
Maintenance Training Available For Printronix Products.....................29
2 Preventive Maintenance..................................... 31
Cleaning The Printer............................................................................ 31
Cleaning The Outside Surfaces........................................................... 31
Cleaning The Shuttle Frame Assembly............................................... 33
Cleaning The Card Cage Fan Assembly............................................. 34
3 Troubleshooting.................................................. 35
Introduction..........................................................................................35
Troubleshooting Aids...........................................................................35
Start Here... ......................................................................................... 36
Troubleshooting Display Messages.....................................................37
List Of Messages .......................................................................... 37
Troubleshooting Other Symptoms.......................................................89
General Symptom List................................................................... 90
Communications Failures .................................................................. 112

10
Table of Contents
Diagnostic Printer Tests..................................................................... 114
Selecting And Running Diagnostic Printer Tests ........................ 115
Boot Diagnostics Menu...................................................................... 118
Hex Code Printout ............................................................................. 121
How To Print A Hex Dump.......................................................... 122
ASCII Character Set.......................................................................... 123
Soft vs. Hard Reset............................................................................ 124
The Power On Sequence .................................................................. 125
Controller Board Handshake Sequences.................................... 125
DC Software Initialization And Power Up.................................... 129
4 Adjustment and Test Procedures .....................131
Introduction........................................................................................ 131
Adjustments and Tests................................................................ 131
Preparing The Printer For Maintenance ............................................ 132
Returning The Printer To Normal Operation...................................... 133
Belt, Paper Feed Timing, Adjustment................................................ 134
Belt, Platen Open, Adjustment........................................................... 136
Paper Scale Alignment...................................................................... 138
Platen Gap Adjustment...................................................................... 140
Ribbon Guide Alignment.................................................................... 142
Paper Out Adjustment ....................................................................... 144
Hammer Phasing Adjustment............................................................ 148
Loading Flash Memory...................................................................... 150
Loading Through The Serial Or Parallel Port.............................. 150
Loading Through the Network Interface Card (NIC) ................... 154
Coil Temperature Adjustment............................................................ 156
Dynamic Paper Tension Adjustment ................................................. 157
Tractor Belt Tension Adjustment ....................................................... 159
Shuttle Electrical Short Check........................................................... 160
Hammer Bank Power Cable Shorts Test........................................... 161
Cable Shorts Test.............................................................................. 162
Main Wire Harness Test Diagnostic .................................................. 164

Table of Contents
11
5 Replacement Procedures
And Illustrated Parts Lists...................................... 165
Organization Of This Chapter............................................................ 165
Section I: Replacement Procedures.................................................. 166
List Of Removal / Installation Procedures................................... 166
Belt, Paper Feed Timing ............................................................. 168
Belt, Platen Open........................................................................ 169
Circuit Breaker ............................................................................ 170
Connector Shells......................................................................... 171
Control Panel Assembly, Cabinet Models................................... 173
Control Panel Assembly, Pedestal Models ................................. 174
Controller Board (CMX And CFX) ............................................... 175
Cover Assembly, Hammer Bank / Ribbon Mask......................... 177
Cover Assembly, Shuttle............................................................. 178
Cover Assembly, Top, Pedestal Models ..................................... 179
Dashpot....................................................................................... 180
Expansion-CT ............................................................................. 181
Fan Assembly, Cabinet Exhaust................................................. 182
Fan Assembly, Card Cage.......................................................... 183
Fan Assembly, Hammer Bank..................................................... 184
Hammer Spring Assembly........................................................... 185
Magnetic Pickup (MPU) Assembly.............................................. 188
Memory And Security Modules ................................................... 189
NIC (Network Interface Card) Assembly..................................... 192
10/100Base-T LEDs And DIP Switches...................................... 193
Paper Feed Motor .......................................................................196
Paper Ironer ................................................................................ 198
Paper Path .................................................................................. 199
Platen..........................................................................................200
Platen Open Motor...................................................................... 204
Power Supply Board ................................................................... 206
Resistors, Terminating ................................................................ 207
Ribbon Drive Motor ..................................................................... 209
Ribbon Guide Assembly (L/R)..................................................... 210
Ribbon Hub ................................................................................. 211
Shaft, Splined.............................................................................. 212
Shaft, Support ............................................................................. 214
Shuttle Frame Assembly............................................................. 215
Spring, Extension, Hammer Bank ............................................... 217
Switch Assembly, Paper Detector............................................... 218
Switch Assembly, Platen Interlock .............................................. 219

12
Table of Contents
Tractor (L/R)................................................................................ 220
Section II: Illustrated Parts Lists ........................................................ 221
Illustrations of Printer Components............................................. 221
6 Principles Of Operation..................................... 253
Line Matrix Printing............................................................................ 253
Printing Rates.................................................................................... 256
Printing Mechanism........................................................................... 256
Shuttle Frame Assembly............................................................. 257
Paper Transport System ............................................................. 259
Ribbon Transport System ........................................................... 260
Logical Control Of The Printer........................................................... 261
Control Panel..................................................................................... 262
Controller Board................................................................................. 263
Data Controller............................................................................ 265
Engine Controller ........................................................................ 268
Power Supply Board.......................................................................... 269
AC Power.................................................................................... 269
DC Power.................................................................................... 269
Printer Interface................................................................................. 270
Graphics ............................................................................................ 270
A Wire Data ......................................................... 271
B Abbreviations And Signal Mnemonics..............319
C Metric Conversion Tables ................................327
D Noise Suppression Devices.............................329
E SureStak™ Power Stacker...............................331
Contents ............................................................................................ 331
Introduction........................................................................................ 332
Stacker Operation.............................................................................. 332
Removing The Power Stacker........................................................... 339
Installing The Power Stacker............................................................. 346
Replacing The Constant Force Spring............................................... 359
Replacing The Timing Belts............................................................... 361
Illustrated Parts Breakdown............................................................... 365
List of Illustrations ....................................................................... 365

Table of Contents
13
F Paper Specifications And Forms Design.......... 379
Introduction........................................................................................ 379
General Paper Specifications ............................................................ 380
Paper Guidelines ............................................................................... 381
Terms And Definitions................................................................. 381
Environmental Considerations .................................................... 383
Form Types................................................................................. 383
Form Weight................................................................................ 383
Form Thickness........................................................................... 383
Form Evenness........................................................................... 383
Tractor Pin Engagement ............................................................. 383
Methods Of Forms Attachment ................................................... 384
Chaff Content.............................................................................. 385
Form Design Checklist....................................................................... 386
Summary ........................................................................................... 389
Storage And Handling................................................................. 389
G Maintenance Information About Other P5000
Printers.................................................................. 391

14
Table of Contents

15
1Maintenance Overview
About The Printer
Printronix  P5000 line matrix printers use PSA  (Printronix System
Architecture), which puts all data control and printer control electronics on one
circuit board. The use of flash memory on this board permits rapid access to
stored printer emulations and very fast processing of print data. A variable-
speed shuttle and half-step paper feed control enable these printers to print a
wide variety of high-volume jobs with minimum maintenance and maximum
reliability.
The P5000 is an excellent graphics printer, with optional features that simplify
the creation of images. The IGP
 and Code V  Printronix emulations, for
example, are simple but versatile graphics programming languages that load
into flash memory.
A P5000 printer is easy to use. The operator can select every printer function
at the printer control panel or by sending control codes in the data stream
from the host computer to the printer. For greater security and to protect
special printer configurations, the operator can program which key
combination locks and unlocks the ENTER key on the control panel.
P5000 Printers
NOTE: Not all P5000 single hammer bank printers are covered in this
manual. Earlier models are covered in maintenance manual 164253-
001. P5000 single hammer bank printers using the PSA3 controller
board are covered in maintenance manual 176475-001. Dual
hammer bank printers are covered in maintenance manual
173843-001. (See page 391.)
The P5000 printer family consists of machines available in floor cabinet and
pedestal housings and which print at different speeds. (See Table 1.) These
printers use a redesigned shuttle frame assembly and a single hammer bank
that are not compatible with earlier P5000 printers.
The P5X05B, P5X10, and P5X15 models covered in this manual use the
CMX 040 controller board, which has a 40 MHz clock speed for the Data
Controller unit. The CMX 040 controller is not used in H-Series printers.

16
Chapter 1 P5000 Printers
H-Series Printers
The “H-Series” of Kanji/Hanzi/Hangul printers replaces the P5XKA printers
formerly used to print Asian character sets. The H-Series consists of four
models: P5006H, P5206H, P5003H, and P5203H. These printers use the
CFX controller board, a specially designed platen, and a unique single
hammer bank shuttle frame assembly. The new controller, platen, and shuttle
assembly are unique to the H-Series, and are not interchangeable with earlier
P5XKA models or any other P5000 series printers.
H-Series models print the character sets used in China, Hong Kong, South
Korea, and Taiwan, as shown below:
Make Sure You Order The Correct Spares
If you replace worn or damaged printer components, make sure you order the
correct spares for the model you are servicing. The next section explains how
to identify a P5000 series printer.
How To Identify A Printer
A P5000 printer is identified by its model number. The model number is coded
to indicate the printer type, family, maximum rated speed, housing, and
certain options. Figure 1 shows how to interpret a model number.
Table 1 lists the latest models the P5000 family. The speeds listed in Table 1
are the highest rated speeds attainable under controlled test conditions.
Actual printing speed is determined by the interaction of many variables and
varies from print job to print job. (For more information, see “Printing Rates”
on page 256.)
Character Set Where Used
GB China
BIG-5, with an additional 3000 Cantonese characters Hong Kong
BIG-5
TCA
DCI (1st and 2nd segments)
DCI (3rd segment)
CNS
Taiwan
KSC 5601 South Korea

How To Identify A Printer
17
Figure 1. How to Interpret Model Numbers
Printronix Line
Matrix Printer
P5000 Printer
P5005B-12-QA
Housing Code:
0 = Pedestal
1 = Table Top
2 = Floor Cabinet
Speed Rating:
05 = 475 lpm1
05A = 500 lpm1
05B = 500 lpm
08 = 800 lpm1
09 = 900 lpm1
10 = 1000 lpm
12 = 1200 lpm1
14 = 1400 lpm1
15 = 1500 lpm
20 = 2000 lpm2
24 = 2400 lpm2
KA = P5XKA printer1
06H = H-Series printer with 102-hammer shuttle
03H = H-Series printer with 60-hammer shuttle
1Model not covered in this manual. Refer to Maintenance Manual 164253-001.
2Model not covered in this manual. Refer to Maintenance Manual 173843-001.
Optional 12 MIL (0.012 inch) hammer tips.
Standard tips are 16 MIL (0.016 inch). This
option does not apply to H-Series printers,
which have unique hammer spring
assemblies.
QA = Pedestal model with optional Quick-Access cover
SS = Cabinet model with optional SureStak™ power
paper stacker.

18
Chapter 1 P5000 Printers
Table 1. P5000 Printers
Model Number Maximum Print
Speed Enclosure Hammer Bank Controller
Board1
P5003H  N/A Pedestal 60 Hammers 40 MHz CFX
P5005B
 500 lpm Pedestal 28 Hammers 40 MHz CMX
P5005B-QA  500 lpm Pedestal w/Quick-
Access Cover 28 Hammers 40 MHz CMX
P5005B-12
 500 lpm Pedestal 28 Hammers,
12 MIL tips 40 MHz CMX
P5005B-12-QA
 500 lpm Pedestal w/Quick-
Access Cover 28 Hammers, 12 MIL tips 40 MHz CMX
P5006H
 N/A Pedestal 102 Hammers 40 MH CFX
P5010  1000 lpm Pedestal 60 Hammers 40 MHz CMX
P5010-QA
 1000 lpm Pedestal w/Quick-
Access Cover 60 Hammers 40 MHz CMX
P5015
 1500 lpm Pedestal 102 Hammers 40 MHz CMX
P5015-QA  1500 lpm Pedestal w/Quick-
Access Cover 102 Hammers 40 MHz CMX
P5203H
 N/A Cabinet 60 Hammers 40 MHz CFX
P5205B
 500 lpm Cabinet 28 Hammers 40 MHz CMX
P5205B-12  500 lpm Cabinet 49 Hammers,
12 MIL tips 40 MHz CMX
P5206H
 N/A Cabinet 102 Hammers 40 MHz CFX
P5210
 1000 lpm Cabinet 60 Hammers 40 MHz CMX
P5215
 1500 lpm Cabinet 102 Hammers 40 MHz CMX
P5215-SS
 1500 lpm Cabinet
w/SureStak
Paper Stacker
102 Hammers 40 MHz CMX
1The 40 MHz CMX controller board is compatible with all PSA P5XXX printers except H-Series
printers. The 40 MHz CFX controller board is used in PSA models P5003H, P5203H, P5006H,
and P5206H.

How To Identify A Printer
19
Important Maintenance Notes
To ensure the best performance of the printer, remember these maintenance
principles when you service it. Failure to observe these guidelines can result
in damage to the equipment:
•Do not adjust the platen gap unless
1) the original shuttle frame assembly or platen has been replaced with a
new/rebuilt unit, or
2) you are instructed to do so in a troubleshooting procedure.
•Never bend or tweak hammer springs. Always handle hammer springs
by the thick mounting base. The hammer springs and hammer tips are
delicate and precisely aligned.
•Use only the ribbons specified in the User’s Manual.Use of incorrect
ribbons can lead to ink migration problems, degraded print quality, and
expensive damage to the printer.
•Do not close the forms thickness lever too tightly. Closing the forms
thickness lever too tightly can lead to smearing, degraded print quality,
paper jams, and damage to the platen and shuttle assembly.
About This Manual
This is a field service maintenance manual. It is designed so that you can
locate maintenance information quickly.
This manual does not explain how to install, operate, or configure the printer.
For that information, refer to the User’s Manual.
This manual does not explain how to program application software for
operation with the printer. Programming information for the protocols used by
the printer is in the appropriate programmer’s reference manual:
•LinePrinter Plus 
Programmer’s Reference Manual
Defines host control codes for the LinePrinter Plus emulations.
•Character Sets Reference Manual
Information about and examples of the character sets available in
Printronix line matrix printers.
•Network User’s Manual
Information about network protocols, configuration, and network
operation.
•Coax/Twinax Programmer’s Reference Manual
Defines host control codes and character sets for the optional coax/twinax
emulations.
•ANSI  Programmer’s Reference Manual
Defines host control codes and character sets for the ANSI emulation.
•IPDS  Twinax Emulation Programmer’s Reference Manual
An overview of Intelligent Printer Data Stream™ (IPDS) features,
commands, and diagnostics.
•IGP/PGL  Programmer’s Reference Manual
Describes the optional IGP Printronix emulation. The IGP Printronix

20
Chapter 1 About This Manual
emulation allows the user to create and store forms; generate logos, bar
codes, and expanded characters; create other graphics, and merge
graphics with alphanumeric data as a document is printed.
•IGP/VGL Programmer’s Manual
Describes the optional Code V Printronix emulation. The Code V
Printronix emulation allows the user to create and store forms; generate
logos, bar codes, and expanded characters; create other graphics, and
merge graphics with alphanumeric data as a document is printed.
How To Use This Manual
Taking a systematic approach to maintenance tasks will help you restore the
printer to operation as quickly as possible:
1. Locate the procedure or information you need in the Table of Contents or
Index.
2. Read the entire procedure before you do it.
3. Gather the parts and tools you will need.
4. Make sure you understand all notices before you start a task. Notices are
defined below.
Notices
For your safety and to protect valuable equipment, you must read and comply
with all information highlighted under notices.
The heading of a notice indicates the kind of information it contains:
WARNING Describes a condition that could hurt you.
CAUTION Describes a condition that could damage equipment.
IMPORTANT Information vital to proper operation and maintenance of the printer.
NOTE: Notes contain tips for efficient operation, maintenance, and
troubleshooting.
Printing Conventions In This Manual
Control panel keys and indicators are highlighted in UPPERCASE BOLD
PRINT.
Example: Press the CANCEL key, then press the ON LINE key.
LCD (Liquid Crystal Display) messages are set off by quotation marks (“ “).
Example: Press the ON LINE key. “OFF LINE” appears on the LCD.
Control panel key combinations are indicated by the + (plus) symbol.
Example: Press =+>.
means Press the =(UP) key and the >(DOWN) key at the same time.
IMPORTANT The Safety Notices on the next page apply at all times when you are
working on the printer. Please read them now.