Printronix P6000 series User manual

P6000 Series Pedestal Model
Maintenance Manual
R
Volume 1 of 2
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P6000 Series Pedestal Model
Maintenance Manual, Vol. 1
R
P/N 108692–001, Rev B
V
olume 1 of 2
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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.
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 1986, 1996 PRINTRONIX, INC.
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iP6040/P6080 Maintenance
Table of Contents
VOLUME 1
Paragraph ăăăăăTitle Page
CHAPTER 1. MAINTENANCE O VERVIEW
1-1 Introduction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2 P
rinter Description 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1- Specifications 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4 Operation 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 2. PRINCIPLES OF OPER ATION
Section I. ENER
AL DESCRIPTION
2-1 Scope 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2 Purpose 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-
Matrix P rinting 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section II. PRINTER FUNCTION ELEMENTS
2-4 General 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5
Control P anel 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6 L
ogic C PCBA 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7
Hammer Driver PCBA 2-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8
Hammer Bank and Shuttle Mechanism/MPU 2-44. . . . . . . . . . . . . . . . . . . . . . . . .
2-9 P
ower Supply 2-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10
Ribbon Drive 2-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-11 P
aper F eed Control Circuits 2-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-12
Platen Open/P aper Out Switches 2-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
Safety Circuits, P6080 Only 2-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section III. OPER ATION
2-14
Normal Operation 2-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 3. PREVENTIVE MAINTENANCE
-1 General -1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-2 P
reventive Maintenance Checks And Service -1. . . . . . . . . . . . . . . . . . . . . . . . .
- Inspection -1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-4 Cleaning -2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-5 Lubrication -5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 4. TROUBLESHOOTIN
4-1 General 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2 Common Causes Of Malfunctions 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4- Testing 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4 F
ault Isolation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5 P
erformance T ests 4-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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P6040/P6080 Maintenanceii
Table of Contents
Paragraph ăăăăăTitle Page
CHAPTER 5. CORRECTIVE MAINTENANCE
Section I. ENER AL
5-1 Introduction 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2 Tools, T
est Equipment, and Supplies 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section II. ALI NMENTS AND ADJUSTMENTS
5- Ribbon Height A djustment 5-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4
Ribbon T racking Check And A djustment 5-. . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5
Shuttle Spring F orce A djustment 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6
Setting Shuttle and Counterweight P reload 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7
Hammer Spring R etensioning 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8
Hammer T ip Alignment 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9
Platen Gap 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10
Magnetic P ickup Gap 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11
Magnetic P ickup Phasing A djustment 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12 A
dapting Shuttle Motor to Line F requency 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
Shuttle Belt 5-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-14 P
aper F eed Belt 5-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-15 P
aper Motion Sensor 5-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-16 P
aper Out Detectors 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section III. REPLACEMENT
5-17 P rinter Cover 5-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-18
Control P anel 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-19
Ribbon Drive 5-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-20
Ribbon Control PCBA 5-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-21
Ribbon Drive Motor 5- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-22
Ribbon Drive Blower 5- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2
Shuttle Assembly 5- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-24
Hammer Spring 5-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-25
Hammer Coil 5-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-26
Counterweight Assembly 5-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-27
Flywheel Assembly 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-28
Cam W ick 5-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-29
Magnetic P ickup 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5- 0
Shuttle Motor 5-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5- 1
Shuttle Belt 5-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5- 2 P
aper Ironer 5-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5- P
aper F eed Belt 5-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5- 4 P
aper F eed Motor 5-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5- 5 Tractor 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5- 6 P
aper Motion Sensor 5-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5- 7 P
aper Out Mechanical Switch 5-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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iiiP6040/P6080 Maintenance
5- 8 P
aper Out Optical Sensor 5-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5- 9
Platen Open Switch 5-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents
Paragraph ăăăăăTitle Page
5-40 DC P
ower Supply F use 5-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-41 P
ower Supply PCBA 5-74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-42 P
ower Supply 5-74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4 R
ear F an 5-77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-44 L
ogic PCBA 5-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-45
Hammer Driver PCBA 5-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-46
Hammer Bank Cable Harness 5-82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VOLUME 2
APPENDICES
APPENDIX A. MNEMONIC TERMS A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
APPENDIX B. ELECTRONIC DRAWINGS B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
APPENDIX C. MECHANICAL DR A WINGS AND P AR TS LISTS C-1. . . . . . . . . . . . . . .
INDEX I-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Tables
Table ăăăăăăTitle Page
1-1 External Controls and Indicators 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
Internal Controls and Indicators 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
Host Interface Connector P in Assignments 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2 P
ower Supply Connector P in Assignments 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . .
2- F
ront P anel Connector P in Assignments 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4 F
our Phase Stepper Connector P in Assignments 2-20. . . . . . . . . . . . . . . . . . . . . .
2-5
Microprocessor Bus Expansion Connector P in Assignment 2-21. . . . . . . . . . . . .
2-6
DMA P arallel I/O Setup Parameters 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7 F
ront P anel and F ault Status Assignments 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8 L
ogic C Memory Map 2-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9 Logic C I/O A
ddress Map 2- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10 L
ogic C Interrupt V ectors 2- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-11 L
ogic C Unused Interrupt V ectors 2- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-12 L
ogic C Hardware Jumpers 2- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-1 P
reventive Maintenance Checks and Service -1. . . . . . . . . . . . . . . . . . . . . . . . .
-2
Physical Inspection -2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
Malfunction Symptom Index 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2
Supplemental T ests 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-
Malfunction Symptom Index 4-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1 Tools, T
est Equipment, and Supplies 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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P6040/P6080 Maintenanceiv
List of Illustrations
Figure ăăăăăTitle Page
1-1 P
rinter with P edestal 1-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
External Controls and Indicators 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-
Internal Controls and Indicators 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
Defining the Dot Matrix 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2 T
ypical Characters 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-
Elongated Characters 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4 P
ositioning and R elease of Odd and Even Hammers 2-4. . . . . . . . . . . . . . . . . . .
2-5
Hammer and Shuttle Arrangement (T ypical) 2-5. . . . . . . . . . . . . . . . . . . . . . . . .
2-6. P
rint Hammer A ction 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7
Standard Character F ormation 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8
Character F ormation by One Hammer 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9 P
rinter F unctional Elements 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10
System Block Diagram 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-11
Control P anel 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-12
Control P anel Block Diagram 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1 L
ogic C PCBA 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-14 L
ogic C PCBA Block Diagram 2-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-15
Hammer Driver PCBA 2-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-16
Hammer Driver Block Diagram 2-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-17
Hammer Driver Circuit T iming 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-18
Dot R ow T iming vs T iming Disk and Cam P osition 2-45. . . . . . . . . . . . . . . . . . . .
2-19
Operation of MPU Circuit 2-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-20 P
ower Supply 2-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-21 P
ower Supply Assembly, P6080 2-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-22 + 6 V and +70 V Supplies, P6080 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2 R
eference V oltage Circuit, P6080 2-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-24 +5 V and MOS Supplies, P6080 2-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-25 R
elay Switching Details, P6080 2-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-26
Motor R elay T rigger Circuit, P6080 2-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-27
Ribbon Drive Block Diagram 2-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-28
Ribbon Drive 2-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-29
Ribbon Control PCBA Simplified Schematic 2-61. . . . . . . . . . . . . . . . . . . . . . . . .
2- 0 P
aper F eed Control Circuits Block Diagram 2-62. . . . . . . . . . . . . . . . . . . . . . . . . .
2- 1 P
aper F eed Components 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2- 2
Platen Open Switch 2-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2- P
aper Out Switch 2-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2- 4
Safety Circuits 2-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2- 5
Operation Flow Diagram 2-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-1
Cleaning Interior of Cabinet -. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-2
Cleaning Hammer Bank Assembly-Ribbon Drive to Service P osition -6. . . .
-
Cleaning Hammer Bank Assembly-Hammer Bank to Service P osition -7. . .
-4
Lubrication, Counterweight and Cam W ick -10. . . . . . . . . . . . . . . . . . . . . . . . . .
-5
Lubrication, Self-Aligning Cam F ollowers, P6080 Only -11. . . . . . . . . . . . . . . .
-6
Lubrication, Antirotation Arm, P6040 Only -1. . . . . . . . . . . . . . . . . . . . . . . . . .
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vP6040/P6080 Maintenance
List of Illustrations
Figure ăăăăăTitle Page
4-1
Confidence Check 4-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2
New P rinter Does Not Operate 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-
POWER Indicator Not Illuminated 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4
Error Indication on Display Stays On 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5
Online Not Indicated on Display 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6
Shuttle Does Not A ccelerate to Speed When ON LINE Switch
is P ressed 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7
Ribbon Does Not A dvance 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8
Ribbon F olds Over 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9
Ribbon Not F eeding Smoothly 4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10
End of Ribbon Not Detected 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11
Not P rinting 4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12
Missing Characters 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
Missing Characters, Example of 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14
Missing Dots 4- 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15
Missing Dots, Example of 4- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-16
Light and/or Smeared Characters 4- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17
Light and/or Smeared Characters, Example of 4- 9. . . . . . . . . . . . . . . . . . . . . . . .
4-18
Misplaced Dots 4-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19 P
rint T oo Light or Dark 4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-20 P
rint T oo Light or Dark, Example of 4-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-21
Horizontal Misalignment 4-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-22
Horizontal Misalignment, Example of 4-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2 V
ertical Misalignment 4-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-24 V
ertically Misaligned Character P osition, Example of 4-5. . . . . . . . . . . . . . . . . .
4-25 V
ertically Deformed Characters, Example of 4-54. . . . . . . . . . . . . . . . . . . . . . . . .
4-26 V
ertical Compression of P rint 4-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-27
Garbled L etters and/or Incorrect F ont 4-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-28
No P aper F eed 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-29 P
aper F eeds Erratically 4-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4- 0 P
aper Drags 4-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4- 1 Top-of-F
orm Does Not Operate 4-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4- 2
Shift R ecycle T est - Sliding P attern 4-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-
Plot P attern T est 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4- 4
MPU Phasing T est - All H's 4-74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4- 5 R
ow Increment T est - Uppercase Characters 4-75. . . . . . . . . . . . . . . . . . . . . . . .
4- 6 Underline/V
ertical Hammer Alignment T est 4-76. . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
Ribbon Height A djustment 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2
Ribbon T racking Check and A djustment 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-
Shuttle Spring F orce A djustment 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4
Setting Shuttle and Counterweight P reload 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5
Hammer Spring R etensioning 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6
Hammer T ip Alignment 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7
Platen Gap A djustment 5-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8
Magnetic P ickup Gap and Phasing A djustment 5-16. . . . . . . . . . . . . . . . . . . . . . .
5-9
Shuttle Belt T ension Check and A djustment 5-19. . . . . . . . . . . . . . . . . . . . . . . . . .
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P6040/P6080 Maintenancevi
List of Illustrations
Figure ăăăăăTitle Page
5-10 P
aper F eed Belt T ension Check and A djustment 5-20. . . . . . . . . . . . . . . . . . . . . .
5-11 P
aper Motion Sensor Check and A djustment 5-22. . . . . . . . . . . . . . . . . . . . . . . . .
5-12 P
aper Out Detector A djustment 5-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1 Cover Removal/Installation 5-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-14
Control P anel R emoval/Installation 5-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-15
Ribbon Drive R emoval/Installation 5- 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-16
Ribbon Control PCBA R emoval/Installation 5- 1. . . . . . . . . . . . . . . . . . . . . . . . .
5-17
Ribbon Drive Motor R emoval/Installation 5-. . . . . . . . . . . . . . . . . . . . . . . . . . .
5-18
Ribbon Drive Blower R emoval/Installation 5- 4. . . . . . . . . . . . . . . . . . . . . . . . . .
5-19
Shuttle Assembly R emoval/Installation 5- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-20
Hammer Spring R emoval/Installation 5-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-21
Hammer Coil R emoval/Installation 5-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-22
Counterweight Assembly R emoval/Installation 5-47. . . . . . . . . . . . . . . . . . . . . . .
5-2
Flywheel Assembly R emoval/Installation 5-50. . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-24
Cam W ick R emoval/Installation 5-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-25
Magnetic P ickup R emoval/Installation 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-26
Shuttle Motor R emoval/Installation 5-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-27
Shuttle Belt R emoval/Installation 5-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-28 P
aper Ironer R emoval/Installation 5-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-29 P
aper F eed Belt R emoval/Installation 5-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5- 0 P
aper F eed Motor R emoval/Installation 5-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5- 1 T
ractor R emoval/Installation 5-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5- 2 P
aper Motion Sensor R emoval/Installation 5-66. . . . . . . . . . . . . . . . . . . . . . . . . . .
5- P
aper Out Mechanical Switch R emoval/Installation 5-68. . . . . . . . . . . . . . . . . . .
5- 4 P
aper Out Optical Sensor R emoval/Installation 5-70. . . . . . . . . . . . . . . . . . . . . . .
5- 5
Platen Open Switch R emoval/Installation 5-71. . . . . . . . . . . . . . . . . . . . . . . . . . . .
5- 6 DC P
ower Supply F uses R emoval/Installation 5-7. . . . . . . . . . . . . . . . . . . . . . . .
5- 7 P
ower Supply PCBA R emoval/Installation 5-75. . . . . . . . . . . . . . . . . . . . . . . . . . .
5- 8 P
ower Supply R emoval/Installation 5-76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5- 9 R
ear F an R emoval/Installation 5-78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-40 L
ogic PCBA R emoval/Installation 5-80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-41
Hammer Driver PCBA R emoval/Installation 5-81. . . . . . . . . . . . . . . . . . . . . . . . .
5-42
Hammer Bank Cable Harness R emoval/Installation 5-8. . . . . . . . . . . . . . . . . . .
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viiP6040/P6080 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 P6040/P6080 Maintenance Manual.
What This Manual Contains
This manual contains the following information. Consult your table of contents to locate this infor Ć
mation.
Introduction - P rovides 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 - P resents 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.
Mnemonic Terms - Lists and defines mnemonics.
Electronic Drawings - Electronic drawings and schematics required for field mainteĆ
nance
are included here.
Mechanical Drawings - Mechanical drawings and parts lists are included here.
Controls and Indicators
Throughout this manual controls and indicators are printed in text 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 operĆ
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. W arnings give
information about conditions that could lead to injury. Cautions provide information about condi Ć
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 R eference Manual will not be repeated
in the maintenance manual.
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P6040/P6080 Maintenanceviii
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1-1P6040/P6080 Maintenance Overview
CHAPTER 1
MAINTENANCE OVERVIEW
1-1. Introduction
This manual contains information required to maintain and repair the Printronix P6040 and
P6080 Printers (hereafter referred to as P6000 Series or simply, the printer). Print speed is the
basic
difference between printers.
The following documents provide detailed information which supplements this manual:
a. P6000 Series Multifunction Line Printer Pedestal Models Operator's Guide, P/N
108525-001
- Contains instructions for unpacking, installing, and operating the printer.
b. P6000
Series Multifunction Line P rinter P edestal Models User's R eference Manual, P/N
1085 4-001 - Describes functions and applications available for the printer.
1-2. Printer Description (Figure 1-1)
a. eneral
The P rintronix P6000 Series P rinter is a highly reliable, multi-function dot matrix line printer. In
addition to basic functions, the P6000 Series can produce correspondence quality print for near
letter quality (NLQ) printing requirements, draft print for higher speed, and character attributes
(dynamic
character generation) for wider application compatibility.
b. Standard Features
1. Quiet Operation
2. P-Series or Serial Matrix P rotocols
.
Plot and Bit Image Graphics
4. Dynamic Character Generation
-Selectable P itch
-Elongated Print
-Expanded P rint
-A
utomatic Underline
-Bold Character P rint
-Superscript P rinting
-Subscript P rinting
5.
Selectable F orms L ength
6.
Electronic V ertical F ormatting
-14 Channel Electronic V ertical F ormat Unit (EVFU)
-12 Channel Direct A ccess V ertical F ormat Unit (D AVFU)
7. R
esident International Character Sets
8. 5 Built-in Self-T ests and Diagnostics
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P6040/P6080 Maintenance Overview1-2
1-2. Printer Description-continued
b. Standard Features-continued
9. Configuration P rintout
10.
Datastream Hex Code P rintout
11. R
esident Serial and P arallel Interfaces
c. Optional Features. tbd
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1-P6040/P6080 Maintenance Overview
Figure 1-1. P rinter with P edestal
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P6040/P6080 Maintenance Overview1-4
1-3. Specifications
For a detailed list of printer specifications refer to the User's R eference Manual, P/N 1085 4-001.
1-4. Operation
a. Operating Procedures
For detailed operating procedures, refer to Operator's Guide, P/N 108525-001.
b. Controls and Indicators
a. External Controls and Indicators. External controls and indicators are illustrated in
Figure
1-2 and described in T able 1-1.
b. Internal Controls and Indicators. Internal controls and indicators are illustrated in
Figure
1- and described in T able 1-2.
Table 1-1. External Controls and Indicators
KEY
(FIG 1-2)
1
2
4
5
6
7
8
9
10
CONTROL OR
ON/POWER/OFF
1 0
POWER
ON LINE
TOP OF FORM
Display
SET
TOF
PRINT MODE
CONFIG
VALUE
CLEAR
FAULT
RUN/STOP
TEST
FUNCTION
Executes one of three basic functions:
1. Saves newly selected parameters or loads
default parameters.
2. Runs or stops configuration and self-tests.
. Runs or stops hex dump.
Sets AC power on or off.
Indicates power is applied to printer.
Places printer online or offline.
Advances paper one form length to top of next
form.
Displays printer status and error messages.
Establishes TOF (top of form) position.
Selects and displays current print mode.
Selects and displays individual parameters with-
in configuration menu.
When configuration values are displayed, this
switch selects and displays the next config-
uration menu. When fault message is dis-
played, resets printer after fault is corrected.
INDICATOR
continued
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1-5P6040/P6080 Maintenance Overview
Table 1-1. External Controls and Indicators-continued
11
12
1
14
CONFIG
MENU
FORMS
LENGTH
PAPER
ADVANCE
KEY
(FIG 1-2) CONTROL OR FUNCTION INDICATOR
Cycles through configuration menus.
Selects and causes display of current line spacing
in lines per inch.
Selects and causes display of current forms length
Advances paper one line when pressed momentarily
or continuously as long as it is pressed.
LINE
SPACING
Figure 1-2. External Controls and Indicators
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P6040/P6080 Maintenance Overview1-6
Table 1-2. Internal Controls and Indicators
KEY
(FIG 1- ) CONTROL OR FUNCTION INDICATOR
1
2
4
5
6
7
Forms Thickness
Adjustment Lever
Forms Thickness
Scale and Pointer
Tractors
Tractor Locks
Horizontal
Adjustment
Knob
Vertical Position
Knob
Vertical Position
Disk
Sets platen for different thickness forms or paper.
Opened (raised) fully for loading paper.
Indicates relative thickness of forms or paper.
Used to set left margin and paper width. Left
tractor moves about one inch. Right tractor moves
full range.
Lock tractors in position.
Allows fine positioning of left print margin. Moves
paper slightly to left or right.
Sets top of form or first line to be printed. Rotate
to move paper vertically.
Provides reference for setting top of form or first
line to be printed.
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1-7P6040/P6080 Maintenance Overview
Figure 1-3. Internal Controls and Indicators
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P6040/P6080 Maintenance Overview1-8
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